HGM7110DC DC Genset Controller USER MANUAL
Contents
1. No Items Parameters Defaults Description Current 2 0 4 20mA 2 1 Curve Type st 1 0 5V 27 Current 2 X 0 32762 mA V 0 C 1 y1l 42 urve 0 32767 0 Custom 0 0 1 1 Contents Switch Setting 1 Close Time 0 20 0 s 5 0 2 Open Time 0 20 0 s 3 0 3 Check Time 0 20 0 s 5 0 Check 4 RAN Oa 0 0 Disable 1 Enable Enable heck Fail al 0 1 0 0 Disable 1 Enable Warn Module Setting 1 0 2 0 0 Stop mode 1 Manual mode Mode 2 Auto mode Modul i 2 odule 1 254 1 address during remote Address sensing 3 Stop Bits 0 1 0 0 2 stop bits 1 1 stop bit 0 Simplified Chinese 1 English 4 L 2 ee 2 Others For entering advanced parameters 5 Password 0 65535 00318 setting GSM Setting 1 GSM Enable 0 1 0 0 Disable 1 Enable Phone Its national and area s cods must be 2 Max 20 digit Number ga added e g China 8613666666666 Scheduling And Maintenance Setting Schedul 1 0 1 0 0 Disable 1 Enable Run Scheduled Not 2 0 1 0 0 Disable 1 Enable Run 3 Maintenance 0 1 0 0 Disable 1 Enable Analog Sensors Setting Temperature Sensor 1 Curve Type 0 15 7 SGX See form 5 No Items Parameters Defaults Description Open Circuit 0 Warn2. 14 Normally open outputs rated 7A 15 16 Output 3 2 5mm Normally open 17 outputs volts free in Aux Output 4 2 5mm rated 16 19 NC Reserved 20 B 1 5mm 21 rn 1 5mm Connect to GOV or AVR 22 User IDC 1 1 0mm Confi T Connect to 4 20 mA 0 5 current 23 Hh IDC 1 1 0mm transformer 24 U IDC 2 1 0mm a T Connect to 4 20 mA or 0 5 current 25 5 IDC 2 1 0mm transformer 26 Al 1 0mm 27 a came 1 Accumulator Voltage Input 0 75V 28 Bi 1 0mm If Acc priority or Gen priority is selected generator voltage will be input If Two accs is 29 B1 iome selected generator voltage or 2 accumulator voltage 0 75V will be input depends on generator voltage status 30 MP1 MP2 has Connected with Speed sensor shielding line is 31 already connected recommended internal Ground connected is 2 Aux 1 1 2 E m active Ve 33 Aux Input 2 Ground connected is E active Ve 34 Aux Input 3 Jomm Ground connected is MT active Ve 35 Aux Input 4 1 0mm around connected 15 Details see form 3 active Ve Ground connected is Aux 1 2 uu active Ve 37 Aux Input 6 tomm Ground connected is hii active Ve 38 Aux Input 7 iimm Ground connected is 2 active Ve
3. 39 Aux Input COM enue A common of input port Ve has already connected internal 40 CANBUS SCR 0 5mm Impedance 1200 shielding wire is 41 CAN 0 5mm recommended its single end earthed 42 CAN 0 5mm CANBUS no these terminals 43 RS485 SCR 0 5mm Impedance 1200 shielding wire is 44 RS485 0 5mm recommended its single end earthed 45 RS485 0 5mm RS485 no these terminals 46 GND 47 Engine Temp Connect to temperature Sensor 48 Oil Pressure Connect to oil pressure sensor 49 Fuel Level Connect to fuel level sensor 50 Config Sensor 1 Connect to temperature sensor 54 Config Sensor 2 oil pressure sensor or fuel level Details see form 4 sensor 50 Sensor COM A common terminal of sensor Ve has NOT connected internal 53 RS232 GND 0 5mm 54 RS232 TX 0 5mm Connected to GSM module 55 RS232 RX 0 5mm A NOTE USB ports in controller rear panel are configurable parameter ports user can directly program controller via PC A NOTE If 1 accumulator 2 accumulator temperatures need to be detected Configured sensor 1 sensor 2 should be set as Temperature Sensor 8 SCOPES AND DEFINITIONS OF PROGRAMMABLE PARAMETERS 8 1 CONTENTS AND SCOPES OF PARAMETERS Form 1 No Items Parameters Defaults Description Charge Setting Acc 1 Rated 1 0 75 V 48 The rated voltage
4. Stop it will initiate a trip and stop alarm If the charging is not finished within the preset time and the 5 Charge Over Time action select Trip and Stop it will initiate a trip and stop alarm 3 Digital Input 6 4 TRIP ALARM On initiation of the trip condition the controller will de energize the Close Generator Output without stop the generator Trip alarm as following 7 When the controller detects that the genset current has 1 Gen Over Current exceeded the pre set value and the action select Trip it will initiate a trip alarm When digit input port is set as Trip and the alarm is active it will initiate a trip alarm When the controller detects that the accumulator current has 3 Charge Over Current exceeded the pre set value and the action select Trip it will initiate a trip alarm If the charging is not finished within the preset time and the action select Trip it will initiate a trip alarm 2 Digital Input 4 Charge Over Time 7 WIRING CONNECTION HGM7110DC controller s rear as following B 12 FUEL 16A CRANK 16A MAGNETIC PICKUP NPUT 2 NPUT3 AUX AUX ET ENED ES EES EE EDIE Description of terminal connection AUX OUTPUT 1 7A NPUT 4 AUX AUX OUTPUT 5 7A NPUT5 AUX AUX OUTPUT 6 7A NPUT6 AUX 2 C NPUT 7 AUX IF
5. CHARGER D AUX OUTPUT 2 7A250VAC mE 9 z AUX OUTPUT 3 16 250 AUX OUTPUT 4 16A250VAC RS232 GSM CANBUS 485 ISOLATION ISOLATION 7 porani USER DEFINED 4 20 0 5 al af lt a ACCU1 ACCU2 URRENT ACCUMULATOR VOLTAGE 0 75 V GND ZDC17 1502 ENGINE TEMP OIL PRESSURE FUEL LEVEL SENSOR COM SENSOR 1 pts SENSOR 2 EIL ai N Cable NO Functions IS Remark 1 DC Input Ve 2 5mm Connected with negative of starter battery Connected with positive of starter battery If wire 2 DC Input Ve 2 5mm length is over 30m better to double wires in parallel Max 20A fuse is recommended 3 Emergency Stop 2 5mm Connected with 4 Ve via emergency stop button 4 Fuel 16A 1 5mm Ve is supplied by terminal 3 rated 16A is supplied by 16A 1 5mm 5 Crank 16A 5mm tenias rated 18 Connected to starter coi 6 Aux Output 1 1 5mm Ve 1 li 7 Aux Output 5 1 5mm 9 18 SUPP E Details see form 2 8 Aux Output 1 terminal 2 rated 7A 9 GND 1 5mm 10 PWMOUT 11 Charger D Connected with charger s WL terminals Be 9 hanging in the air If there is no this terminal 12 Normally close Aux Output 2 1 5mm outputs rated 7A Details see form 2 13 Public points of relay
6. P action select Warn it will initiate a warning alarm 6 2 SHUTDOWN ALARM When controller detects shutdown alarm it will send signal to open breaker and shuts down generator Shutdown alarms as following When the controller detects an emergency stop alarm signal 198 it will initiate a shutdown alarm When the controller detects that the generator speed has 2 Over Speed DCN exceeded the pre set value it will initiate a shutdown alarm When the controller detects that the generator speed has 3 Under Speed dup die fallen below the pre set value it will initiate a shutdown alarm Lesser enced When the controller detects that the generator speed is 0 and P 9 the action select Shutdown it will initiate a shutdown alarm If the engine does not fire after the pre set number of 5 Fail To Start attempts it will initiate a shutdown alarm When the controller detects that the genset current has 6 Gen Over Current exceeded the pre set value and the action select Shutdown it will initiate a shutdown alarm When count down time is 0 and the action select Shutdown 7 Maintenance Due MN it will initiate a shutdown alarm If an error message is received from ECU via J1939 it will 8 ECU Shutdown e X initiate a shutdown alarm If an error message is NOT received from ECU via J1939 it 9 ECU Com Fail ee will initiate
7. 7 Battery Over Volt 8 Battery Under Volt 9 Maintenance Due 10 ECU Warn Temperature Sensor 12 Open Circuit 13 High Temperature 14 Low Temperature Oil Pressure Open 15 Circuit When the controller detects that the oil pressure has fallen 16 Low Oil Pressure ES 7 below the pre set value it will initiate warning alarm When the controller detects that the level sensor is open Level Sensor Open MO 17 Circuit circuit and the action select Warn it will initiate a warning alarm When the controller detects that the fuel level has fallen below 18 Low Fuel Level MEER the pre set value it will initiate a warning alarm When the controller detects that the flexible sensor 1 is open Flexible Sensor 1 19 circuit and the action select Warn it will initiate a warning Open Circuit alarm 20 Flexible Sensor 1 When the controller detects that the sensor 1 value has High exceeded the pre set value it will initiate a warning alarm 21 Flexible Sensor 1 When the controller detects that the sensor 1 value has fallen Low below the pre set value it will initiate a warning alarm When the controller detects that the flexible sensor 2 is open Flexible Sensor 2 i p 22 T circuit and the action select Warn it will initiate a warning Open Circuit alarm 23 Flexible Senso
8. CAN communication shielding CAN GND line connect with controller s terminal only CAN H 1 Impedance 1200 connecting line is recommended CAN L 2 Impedance 1200 connecting line is recommended Engine type Volvo ANOTE When this engine type is selected preheating time should be set to at least 3 seconds 14 13 VOLVO EDC4 Suitable engine types are TD520 TAD520 optional TD720 TAD720 optional TAD721 Fuel relay output TAD722 and TAD732 Expand 30A relay battery voltage of terminal 14 is supplied by relay Fuse is 16A Start relay output Connect to starter coil directly 1 Connected to negative of battery CAN communication shielding CAN GND line connect with controller s terminal only CAN H 12 Impedance 1200 connecting line is recommended CAN L 13 Impedance 1200 connecting line is recommended Engine type VolvoEDC4 14 14 VOLVO EMS2 Volvo Engine types are TAD734 TAD940 TAD941 TAD1640 TAD1641 and TAD1642 Terminals of controller Engine s port Remark Auxiliary output 1 6 ECU stop Set Auxiliary output 1 ECU Stop Auxiliary output 2 ECU power Set Auxiliary output 2 as ECU power Negative power Positive power CAN GND CAN communication line connect with terminal only shielding controller s CAN H 1 Hi Impedance 1200 connecting line is reco
9. 51 SENSORS SETTING teo rs rte bee dent 52 OIA ONIN as 5 TYPIGAL APPLIGATIOD 54 INSTALLATION oda Med cran ol 55 GSM SHORT MESSAGE ALARM AND REMOTE 57 13 1 GSM SHORT MESSAGE 8 57 13 2 GSM SHORT MESSAGE REMOTE eene 58 CONNECTIONS OF CONTROLLER WITH J1939 60 14 1 CUMMINS ISB ISBE a ein edet vor te ruebant erii Eu Rh atn ribi c tas 60 14 2 CUMMINS QSL O eaan ea eh duc act aduecne Le dm Qin LRQ a Ee EAE AG AENEA NENT 60 14 87 CUMMINS OSM TI import 61 14 4 CUMMINS tede o eben tubi rir iode edu 61 TAS 2 05 iter te dat rhe eei dba reti ria nb Ra ea 62 14 6 DETROIT DIESEL DDEC IW IV addita nti noc ud adis hc dude cali dit 62 14 7 DEUTZ EMEO2 iinir ni a DUK RE AR ER ERR ima RR ES ERA 63 14 0 ou cao caca ad 63 MT MDEG acd ea sci cha qub ador dee Vertu fa nes 64 CEA t Lecco 64 14 11 SORANIA uiris kr na o ra a ek Eta KR eae
10. 1 Shutdown 2 2 Action 2 No action Shutdown when sensor temperature High Temp higher than thi lue D i 3 9 50 300 98 igher than this valle etecting only Shutdown after safety delay is over The delay value can be set Warn when sensor temperature higher High Temp than this value Detecting only after 4 50 300 C 95 Warn 90800 safety delay is over The delay value and return value can be set L Temp B 55 SEU ass 0 0 Disable 1 Enable Warn Oil Pressure Sensor 1 Curve Type 0 15 7 5 See form 5 2 Open Circuit 0 2 0 0 Warn 1 Shutdown Action 2 No action Shutdown when oil pressure lower Low OP than this value Detecting only after 3 0 1000 kPa 103 Shutdown safety delay is over The delay value can be set Warn when oil pressure higher than hi lue D i ly af 4 Low OP Warn 0 1000 kPa 124 this vane etecting only after safety delay is over The delay value and return value can be set Liquid Level Sensor 1 Curve Type 0 15 4 SGH See form 5 Open Circuit 0 Warn 1 Shutdown 2 2 Action P 2 No action Warn when level lower than this value Low Level 3 Warn 0 300 96 10 It is detecting all the time The delay value and return value can be set Configure Sensor 1 Configure 0 Disable 1 Enable can be set as 1 Sensor 1 0 1 0 temperature pressure liquid lever Setting sensor Configure Sensor 2 Configure 0 Disable 1 Enable can be set as 1 Sensor 2 0 1 0 temperat
11. 8 dE PERMIT START OK Discharge the inhibit start signal When sending orders users need to follow SMS orders in above form and all the letters must be capital Pass back information from SMS DETAIL including working mode 14 CONNECTIONS OF CONTROLLER WITH J1939 ENGINE 14 14 CUMMINS ISB ISBE Fuel relay output 39 Start relay output Connect with starter coil directly Expand 30A relay battery ECU power Auxiliary output port 1 voltage of 01 07 12 13 is Set Auxiliary output 1 as ECU supplied by relay power CAN communication shielding CAN GND SAE J1939 shield line connect with terminal only 1200 ting line i CAN H SAE J1939 signal mpedance connecting line is recommended 1200 ting line i CAN L SAE J1939 retum Impedance 1200 connecting line is recommended Engine type Cummins ISB 14 2 CUMMINS QSL9 Suitable for CM850 engine control module Fuel relay output 39 Start relay output Connect to starter coil directly CAN communication shielding CAN GND SAE J1939 shield E line connect with terminal only 1200 ting line i CAN H SAE J1939 signal C mpedance 1200 connecting line is recommended 1200 ting line i CAN L SAE J1939 retum D mpedance 1200 connecting line is recommended Engine type Cummins CM850 14 3 CUMMINS 05 11 IMPORT It is suitable for CM570 engine control
12. 0 1 0 Disable 1 Enable 0 200 120 Charging Over Current Percentage 0 3 0 Warn 1 Shutdown 2 Trip and Stop 3 Trip 0 3600 s Charging Over Current Delay 24 Charge increment 0 10 A Adjust the charge increment manually in Manual mode 25 Charge Rest Time 0 1 0 Enable 1 Disable 0 300 h In Auto mode it is the waiting time before second charging 26 Charge Limit Time 0 1 0 Enable 1 Disable 0 3 0 Warn 1 Shutdown 2 Trip and Stop 3 Trip 0 300 h After the module is start successfully if the charging is not finished after the set delay has expired Charge Limit Time alarm will be initiatd 27 System Mode 0 Accumulator Priority 1 Gen Priority 2 Double Accumulator Priority 28 Two Accumulators Transfer Mode 0 Gap Power Supply 1 Uninterrupted Power Supply 29 Control Mode 0 GOV 1 PWM 2 AVR 30 GOV Volt Min GOV output minimum voltage No Items Parameters Defaults Description GOV Volt 31 Max 9 0 10 0 2 0 GOV output maximum voltage GOV Interf 32 5 0 1 0 0 Normal Output 1 Reversed Output Type 33 GOV Gain 0 500956 20 GOV Control 34 GOV Stability 0 200096 20 GOV Control 35 GOV Kd 0 2000 0 GOV Control 36 AVR Volt Min 0 10 0 V 0 AVR ou
13. Breaker will open and the Cooling Delay is then initiated 2 After the Cooling Delay Fail to Stop Delay begins fuel relay is de energized complete stop is detected automatically 3 When generator is stop completely After stop delay will be initiated Otherwise fail to stop alarm is initiated and the corresponding alarm information is displayed on LCD display If generator is stop successfully after fail to stop alarm has initiated After stop delay will be initiated and the alarm will be removed 4 Generator is placed into its standby mode after its After stop delay 4 4 MANUAL START STOP OPERATION 1 Manual mode is selected by pressing the button a LED besides the button will illuminate to confirm the operation Then press 0 button to start the generator it can automatically judge crank success and accelerate to high speed running If high temperature low oil pressure over speed and abnormal voltage occur during genset running controller can effectively protect genset to stop detail procedures please refer to No 2 6 of Auto Start Sequence If generator is normal users can energize Close Relay manually via D button or adjust engine speed manually via o button in order to let the accumulator is charged 2 Manual stop pressing Okey can shut down the running genset detail procedures please refer to No 2 4 of Auto Stop Sequence A NOTE Manual start stop operations are used for Test only 5
14. Connect generator loading switch s auxiliary point 14 Inhibit Gen Load Prohibit genset switch on when input is active 15 1h New ead Connect to the load switch s auxiliary point of 1 Accumulator 16 2 Acc Load Closed Connect to the load switch s auxiliary point of 2 Accumulator When input is active controller enters into Auto Mode 17 Auto Mode Lock all the keys except 009 inactive and there is in the right of first row in LCD When input is active controller won t work under Auto 18 Auto Mode Invalid Mode Okey and simulate auto key input does not work 19 Reserved 20 Reserved 21 Inhibit Alarm Stop alarms are ponies except emergence stop i e battle mode or override mode 22 Aux Instrument Mode All outputs are prohibited in this mode 23 Reserved Controller will set maintenance time and date as default 24 Reset Maintenance when input is active 25 Reserved Connect to sensor digital input 27 Aux Low OP Connect to sensor digital input In Auto mode when input is active can start genset og Remote Start automatically and with load when genset is normal On Load running when input is inactive can stop genset automatically 29 Reserved In Manual mode when input is active can start genset 30 Aux Manual Start automatically when input is inactive can stop genset automatica
15. dri 1 Normally close Configure Output 5 Content 1 eas 0 239 38 Reserved See Form 4 Setting 0 Normally open 2 A T ENDS vn i 1 Normally close Configure Output 6 C 1 o is 0 239 48 Common alarm See Form 4 Setting 0 Normally open 2 A Wee Oe i 1 Normally close 8 2 PROGRAMMABLE OUTPUT PORTS 0 Not Used 1 Reserved 2 Reserved 3 Reserved 4 Reserved 5 Reserved 6 Reserved Details of function description please see the y Custom Combined 1 following 8 Custom Combined 2 9 Custom Combined 3 10 Custom Combined 4 11 Custom Combined 5 12 Custom Combined 6 13 Reserved 14 Reserved 15 Reserved 16 Reserved Action when over speed shutdown and emergence 17 Air Flap Control stop It can close the air inflow to stop the engine as soon as possible Action when warning shutdown trips Can be 18 Audible Alarm externally when alarm mute configurable input port is active it can remove the alarm Action when genset start and disconnect when 19 Louver Control genset stopped completely 20 Fuel Pump Control It is controlled by limited threshold of fuel pump 21 Heater Control It is controlled by limited threshold of heater 22 Cooler Control It is controlled by limited threshold of cooler 23 Oil Pre supply Output Act
16. module Engine type is 05 11 G1 QSM11 G2 Outside expand relay when fuel Fuel relay output 5 amp 8 output making port 5 and port 8 of C1 be connected Start relay output Connect to starter coil directly CAN communication shielding CAN GND C line connect with ECU terminal only CAN H A Impedance 120Q connecting line is recommended CAN L B Impedance 1200 connecting line is recommended Engine type Cummins ISB 14 4 CUMMINS QSX15 CM570 It is suitable for CM570 engine control module Engine type is QSX15 Fuel relay output 38 Oil spout switch Start relay output Connect to starter coil directly CAN communication shielding CAN GND SAE J1939 shield E line connect with ECU terminal only CAN H SAE J1939 signal C Impedance 1200 connecting line is recommended 1200 ing line i CAN L SAE J1939 retum D mpedance 1200 connecting line is recommended Engine type Cummins QSX15 CM570 14 5 CUMMINS GCS MODBUS It is suitable for GCS engine control module Use RS485 MODBUS to read information of engine Engine types are 05 15 QST30 QSK23 45 60 78 and so on Outside expand relay when fuel Fuel relay output 5 amp 8 output making port 05 and 08 of the connector 06 be connected Connect to starter coil directly Start relay output CAN communication shielding RS485 GND 20 line connect with terminal
17. of 1 accumulator Voltage 2 1 Cell Count 1 50 24 The battery number of 1 accumulator 0 1 0 0 Disable 1 Enable 3 Voltage Warn 0 1000 98 Return Value 0 3600 s 5 Delay 0 1 0 0 Disable 1 Enable 1 Over 0 1000 115 Set Value Voltage Warn 0 1000 26 112 Return Value 0 3600 s 5 Delay T Und 0 1 0 0 Disable 1 Enable 5 nee 0 1000 96 92 Set Value Voltage Stop 0 3600 s 5 Delay 0 1 0 0 Disable 1 Enable 1 Over 6 0 1000 118 Set Value Voltage Stop 0 3600 s 5 Delay Acc 2 Rated 7 0 75 V 48 The rated voltage of 2 accumulator Voltage 8 1 Cell Count 1 50 24 The battery number of 2 accumulator 0 1 0 0 Disable 1 Enable 28 Under 0 1000 95 Set Value 9 Voltage Warn 0 1000 98 Return Value 0 3600 s 5 Delay 0 1 0 0 Disable 1 Enable 2 Over 1 1 11 0 Voltage Warn 0 1000 5 Set Value 0 1000 96 112 Return Value No Items Parameters Defaults Description 0 3600 s 5 Delay 0 1 0 0 Disable 1 Enable 2 1 2 Under 5 1000 92 Set Value Voltage Stop 0 3600 s 5 Delay 0 1 0 0 Disable 1 Enable 2 Over 12 0 1000 118 Set Val Voltage Stop os 0 3600 s 5 Delay Used for calculating the accumulator voltage after the compensation Vtc Vn Tc N T 20 Vtc Accumulator voltage after the Temperature compensation 1 2 5b mV C 4 Coeffic
18. only RS4854 21 Impedance 1200 connecting line is recommended RS485 18 Impedance 1200 connecting line is recommended Engine type Cummins QSK MODBUS Cummins QST MODBUS Cummins QSX MODBUS 14 6 DETROIT DIESEL DDEC III IV Expand 30A relay battery Fuel relay output voltage of ECU is supplied by relay Start relay output Connect to starter coil directly CAN communication shielding CAN GND line connect with controller s terminal only Impedance 1200 connecting line is H E recommended CAN L CAN L Impedance 1200 connecting line is recommended Engine type Common J1939 14 7 DEUTZ EMR2 Expand 304A relay battery Fusl r l v voltage of terminal 14 is supplied by relay Fuse is 16A Start relay output Connect to starter coil directly 1 Connect to battery negative pole CAN communication shielding CAN GND line connect with controller s terminal only CAN H 12 Impedance 1200 connecting line is recommended CAN L 13 Impedance 1200 connecting line is recommended Engine type VolvoEDC4 14 8 JOHN DEERE Fuel relay output GJ Start relay output D CAN communication shielding CAN GND line connect with controller s terminal only Impedance 1200 connecting line is recommended Impedance 1200 connecting line is recommended CAN H V U Engine type John Deere 14 9 MTU MDE
19. running when charger No Items Parameters Defaults Description D WL voltage under this value charge failure alarm will be initiated Max Crank times of crank attempts 15 Start Attempts 1 10 Times 3 When reach this number failure alarm will be initiated See form 5 There 2 conditions of 16 Crank 0 2 0 disconnecting starter with engine Disconnect Each condition can be used alone and simultaneously to separating the start motor and genset as soon as possible Setting value is percentage of rated speed When generator speed 18 Engine Speed 0 200 24 than the set value starter will be disconnected See the installation instruction When generator oil pressure higher 19 Disconnect Oil 0 1000 kPa 200 inan the set value Slater will me Pressure disconnected See the installation instruction Load Setting 1 Rated Current 5 6000 A 500 Rated load current Over Current 0 Disable Enable ig 1 Enable 3 Over Current 0 200 96 120 4 Current 0 3 0 0 1 Action 2 Trip and Stop 3 Trip Over Current 5 Tyne 0 1 0 6 Type 1 Delay 0 3600 5 10 Type 2 7 Multiply 1 36 36 Current Input 0 1 2 lload 8 0 2 0 1 1 lgen 2 Mode 2 1 lgen 2 lacc 9 Current 1 0 1 0 0 4 20mA Curve Type 1 0 5V ji Current 1 X 0 32762 m V 0 25 Curve Y 0 32767 A 0 Custom 0 0 1 1 Contents
20. start stop of the genset perfect fault indication and protection function NI output ports are relay out Parameter setting parameters can be modified and stored in internal FLASH memory and cannot be lost even in case of power outage most of them can be adjusted using front panel of the controller and all of them can be modified using PC via USB or RS485 ports More kinds of curves of temperature oil pressure fuel level can be used directly and users can define the sensor curves by themselves Multiple crank disconnect conditions speed sensor oil pressure are optional gt Widely power supply range DC 8 35 V suitable to different starting battery voltage environment gt Event log real time clock and Scheduled start amp stop function can be set as start genset once a day week month gt Can be used as an indicating instrument indicate and alarm are enable only relay is inhibited With maintenance function Actions warning shutdown can be set when maintenance time out gt All parameters used digital adjustment instead of conventional analog modulation with normal potentiometer more reliability and stability Waterproof security level IP55 due to rubber seal installed between the controller enclosure and panel fascia gt Metal fixing clips enable perfect in high temperature environment Modular design self extinguishing ABS plastic enclosure pluggable connection terminals and embedde
21. 33 Auto Mode Action in Auto mode 234 Generator On Load 235 Reserved 236 Reserved 237 Reserved 238 Reserved 239 Reserved 8 2 1 DEFINED COMBINATION OUTPUT Defined combination output is composed by 3 parts condition output S1 or S2 and condition output S3 S1 A S2 51 or S2 is TRUE while 53 is TRUE Defined combination output is outputting 51 and S2 are FALSE or S3 is FALSE Defined combination output is not outputting 51 S2 S3 can set as any item except for defined combination output which is given in the section entitled Programmable Output Ports elsewhere in this manual Anote 3 parts of defined combination output S1 S2 S3 couldn t include or recursively include themselves Example Contents of condition output S1 output port 1 is active Close when condition output S1 is active inactive close when active disconnect when inactive Contents of condition output S2 output port 2 is active Close when condition output S2 is active inactive close when active disconnect when inactive Contents of condition output S3 output port 3 is active Close when condition output S3 is active inactive close when active disconnect when inactive When input port 1 active or input port 2 active if input port 3 is active Defined Combination Output is outputting If input port 3 inactive Defined Combination Output is not outputting When input port 1 inactive and moreover i
22. C Suitable for MTU engines 2000 series 4000series Fuel relay output BE1 Start relay output BE9 CAN communication shielding CAN GND E line connect with terminal only CAN H G Impedance 1200 connecting line is recommended CAN L F Impedance 1200 connecting line is recommended Engine type MTU MDEC 303 14 10 PERKINS It is suitable for ADEM3 ADEM4 engine control module Engine type is 2306 2506 1106 and 2806 Fuel relay output 1 10 15 33 34 Start relay output Connect to starter coil directly CAN communication shielding CAN GND line connect with controller s terminal only CAN H 31 Impedance 1200 connecting line is recommended CAN L 32 Impedance 1200 connecting line is recommended Engine type Perkins 14 11 SCANIA It is suitable for 56 engine control module Engine type is DC9 DC12 and DC16 Fuel relay output 3 Start relay output Connect to starter coil directly CAN communication shielding CAN GND line connect with controller s terminal only CAN H 9 Impedance 1200 connecting line is recommended CAN L 10 Impedance 1200 connecting line is recommended Engine type Scania 14 12 VOLVO EDC3 Suitable engine control mode is TAD1240 TAD1241 and TAD1242 Fuel relay output H Start relay output E ECU power Auxiliary output 1 Set Auxiliary output 1 as ECU power
23. QD FRA NULL FERES RUE R Mand ea aed awed 65 14 12 MOEN EG a 65 14 19 VOLVOU EDDA Lens enn e edic tn 66 14 14 VOVO EM S EN E OUR 66 ILLE So a 67 15 ai Mc nC TR 68 1 OVERVIEW HGM7110DC genset controller is used for genset automation and monitor control system of single unit to achieve automatic start stop data measurement alarm protection and three remote remote control remote measuring and remote communication The controller adopts large liquid crystal display LCD and selectable Chinese English or other languages interface with easy and reliable operation HGM7110DC controller adopts 32 bits micro processor technology with precision parameters measuring fixed value adjustment time setting and threshold adjusting and etc The majority of parameters can be set using front panel and all the parameters can be set using PC via USB port and can be adjusted and monitored with the help of RS485 ports It can be widely used in all types of automatic genset control system with compact structure advanced circuits simple connections and high reliability 2 PERFORMANCE AND CHARACTERISTICS HGM7110DC Control the genset to start stop by detecting the accumulator voltage or charger current gt With ARM based 32 bit SCM highly integrated hardware new relia
24. SHENZHEN GRAIGAR MACHINERY CO LTD Xinfu Building Center Road Shajing Street Baoan District Shenzhen CN Tel 86 755 27541660 Fax 0086 755 23728063 Email sales graigar com Http www gensetspart com Graigar HGM7110DC DC Genset Controller USER MANUAL Genset Controller RAISE SPEED DROP SPEED Stop Auto Mute Start Breaker OMCOMCOMCEL EO ZHENGZHOU SMARTGEN TECHNOLOGY CO LTD This manual is suitable for HGM7110DC controller only Clarification of notation used within this publication SIGN INSTRUCTION Highlights an essential element of a procedure to ensure correctness Indicates a procedure or practice which if not strictly observed could Caution result in damage or destruction of equipment 2 Indicates error operation may cause death serious injury and arning significant property damage WD 10 11 12 13 Contents OVERVIEW t Aaah cu a Lect tan seas 6 PERFORMANCE AND 6 7 SPECIFICATION ea a 10 OPERATION T ot ch 11 4 1 PU SB GONG denen coute 11 4 2 12 lo MAIN DISPLAY cra s
25. SWITCH CONTROL PROCEDURES 5 1 ACCUMULATOR GENSET PRIORITY SYSTEM Igen 4 20 load gt T N e 3i i K2 K3 Charging Igen lacc lload Non charging Igen 0 lacc lload Igen 4 4 20mA 4 20mA 9 Acc Load Charging lacc Igen lload Non charging lacc lload Igen 1 4 20mA 2 3 O gt K3 Charging Igen lacc Non charging lacc xxx lload lgen 0 Accumulator Priority System Auto mode K2 and are always close When the accumulator voltage has fallen below the Charge Start Volt the genset will be started according to the preset sequence If the on load requirements have been reached K1 Close relay will activate to charge the accumulator Genset Priority System In Auto mode K1 and K3 are always close When the accumulator voltage has fallen below the Charge Start Volt the genset will be started according to the preset sequence If the on load requirements have been reached K2 Close relay will activate to charge the accumulator If Genset failure occurs K2 Close relay will activate and the Accumulator will take load 5 2 TWO ACCUMULATOR PRIORITY SYSTEM Igen K1 K4 1 Acc Charging lacc1 Igen 1 Acc on load lacc1 lload 2 Acc Charging lacc2 Igen 2 Acc on load lacc2 lload 1 Accumulator Switching Mode Gap 1 Accu
26. a shutdown alarm The controller will initiate a shutdown alarm if the input is 10 Aux High Temp P active controller will initiate shutdown alarm if the input is active When the controller detects that the temperature sensor is Temperature Sensor M 12 mE open circuit and the action select Shutdown it will initiate a Open Circuit shutdown alarm When the controller detects that engine temperature has 13 Temperature exceeded the pre set value it will initiate a shutdown alarm When the controller detects that the oil pressure sensor is Oil Pressure Open p MM LEE 14 A open circuit and the action select Shutdown it will initiate a Circuit shutdown alarm When the controller detects that the oil pressure has fallen 15 Low Oil Pressure below the pre set value it will initiate a shutdown alarm Level Sensor Open When the controller detects that the level sensor is open 16 ua circuit and the action select Shutdown it will initiate a Circuit shutdown alarm When the controller detects that the flexible sensor 1 is open Flexible Sensor 1 NEFAS 17 UN circuit and the action select Shutdown it will initiate a Open Circuit shutdown alarm 18 Flexible Sensor 1 When the controller detects that the sensor 1 value has High exceeded the pre set value it will initiate a shu
27. bility level gt 132x64 LCD with backlight multilingual interface including English Chinese or other languages which can be chosen at the site making commissioning convenient for factory personnel gt Improved LCD wear resistance and scratch resistance due to hard screen acrylic gt Silicon rubber panel and pushbuttons for better operation in high low temperature environment RS485 communication port enables remote control remote measuring remote communication via ModBus protocol gt Equipped with SMS Short Message Service function When genset is alarming controller can send short messages via SMS automatically to max 5 telephone numbers Besides generator status can be controlled and checked using SMS gt Equipped with CANBUS port and can communicate with J1939 genset Not only can you monitoring frequently used data such as water temperature oil pressure speed fuel consumption and so on of ECU machine but also control starting up shutdown raising speed and speed droop via CANBUS port gt Suitable for Accumulator Priority System Generator Priority System Or Double Accumulator System gt Accumulator Priority System The accumulator supplies the power for load continuously In Auto mode the genset will start automatically to charger the accumulator if the accumulator voltage has fallen below the Charge Start Voltage gt Generator Priority System The generator supplies the power for load continuousl
28. ceeded the pre set value and the action select Warn it will initiate a warning alarm After fail to stop delay if gen set does not stop completely it will initiate a warning alarm Charge X Alternator When the controller detects that charger voltage has fallen Failure below the pre set value it will initiate a warning alarm When the controller detects that genset battery voltage has exceeded the pre set value it will initiate a warning alarm When the controller detects that genset battery voltage has fallen below the pre set value it will initiate a warning alarm When count down time is 0 and the action select Warn it will initiate a warning alarm If an error message is received from ECU 1939 it will initiate a warning alarm When the controller detects that the breaker close or open 11 Switch Fail Warn failure occurs and the action select Warn it will initiate a warning alarm When the controller detects that the temperature sensor is open circuit and the action select Warn it will initiate a warning alarm When the controller detects that engine temperature has exceeded the pre set value it will initiate a warning alarm When the controller detects that engine temperature has fallen below the pre set value it will initiate a warning alarm When the controller detects that the oil pressure sensor is open circuit and the action select Warn it will initiate a warning alarm 5 Fail To Stop
29. d installation way compact structure with easy mounting 3 SPECIFICATION Parameter Details Working Voltage DC8 to 35 continuous power supply Overall Consumption 3W Standby mode x2W Speed Sensor Voltage 1 0 V to 24 V RMS Speed Sensor Frequency Maximum 10 000 Hz Start Relay Output 16A DC28V power supply output Fuel Relay Output 16A DC28V power supply output Configurable Relay Output 1 DC28V power supply output Configurable Relay Output 2 AC250V passive output Configurable Relay Output 3 16A AC250V passive output Configurable Relay Output 4 16A AC250V passive output Configurable Relay Output 5 DC28V power supply output Configurable Relay Output 6 DC28V power supply output Case Dimensions 197mm x 152mm x 47mm Panel Cutout 186mm x 141mm Working Conditions Temperature 25 70 Humidity 20 93 RH Storage Conditions Temperature 25 70 C Protection Level IP55 Gasket Insulation Intensity Apply AC2 2kV voltage between high voltage terminal and low voltage terminal The leakage current is not more than 3mA within 1min Weight 0 75kg 4 OPERATION 4 1 PUSHBUTTONS Stop running generator in Auto Manual mode Lamp test press at Stop least 3 seconds Reset alarm in stop mode During stopping process press this butt
30. ient Vn Accumulator voltage before the compensation Tc Compensation Coefficient N Cell Count T Temperature Value Charge Start 0 1000 96 97 Set Value 14 Volt 0 3600 s 5 Delay Charge Stop 0 1000 96 112 Set Value 15 Volt 0 3600 s 5 Delay 16 Charge Stop 0 2 0 Current Volt 1 Charge Mode Delay The accumulator charging mode is 17 Constant 0 1000 110 Constant Voltage if the charging Charge Volt voltage after the compensation has reached the set value SE The charging current during Constant 18 Charge 0 200 A 50 amg g Current Mode Current In Auto mode choose Charge Delay as its Charge Stop Mode If the Constant 19 0 300 8 genset enters into the Constant 9 Voltage mode it will stop after the charge delay has expired Charge Sto In Auto mode choose Charge 20 9 P 0 1000 96 40 Current Current Voltage as its Charge Stop No Items Parameters Defaults Description Mode If the genset enters into the Constant Voltage mode the accumulator charges the genset with its set value as soon as the charge current has fallen below the set value The charging is finished if the charging voltage has reached the Charge Stop Voltage 21 Float Voltage 0 1000 96 80 Reserved 22 Nominal Voltage 0 1000 96 100 Its the load voltage if the Gen Priority is selected 23 Charge OC
31. ime of software and hardware version Time and Date Event Log including as below Records all start stop events shutdown alarm trip and stop alarm manual auto start or stop and the real time when alarm occurs 4 2 2 PARAMETERS SETTING MENU Parameters setting including as following Charge Settings Timer settings Engine settings x Load settings settings Analog sensor settings Input port settings Output port settings Module settings Scheduling and maintenance settings GSM settings Example Form 1 use CQ to scroll settings to enter settings form 2 to exit settings menu Form 2 sO to scroll settings form 3 select return and press to return to previous menu form 1 or press to return to previous menu form 1 Form 3 use 99 scroll settings confirm settings form 4 9 to return to previous menu form 1 Form 4 Use to enter settings form 5 OOQ scroll settings to return to previous menu form 3 Form 5 use scroll settings form 6 enter settings form 7 to exit settings menu form 4 Form 6 use scroll settings form 5 enter settings form 7 to exit settings menu form 4 Form 7 use scroll settings form 5 enter settings to exit settings menu form 4 Form 8 e OOQ scroll settings enter sett
32. ings form 4 7 to exit settings menu form 4 Anote Long time pressing can exit setting directly during setting 4 3 AUTO START STOP OPERATION Auto mode is selected by pressing the button LED besides the button will illuminate to confirm the operation Starting Sequence 1 When the accumulator voltage has fallen below the Charge Start Voltage or when Remote Start with load is active Start Delay timer is initiated Start Delay countdown will be displayed on LCD display 2 When start delay is over preheat relay energizes if configured preheat delay XXs information will be displayed on LCD display 3 After the above delay the Fuel Relay if configured is energized and then one second later 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 4 Should this start sequence continue beyond the set number of attempts the start sequence will be terminated and Fail to Start fault will be displayed on LCD display 5 case of successful crank attempt the Safety On timer is activated allowing Low Oil Pressure High Temperature Under speed and Charge Alternator Failure inputs to stabilise without triggering the fault As soon as this delay is over Waiting For Load delay i
33. 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 31 terminal in controller while another side is hanging in air The else two signal wires are connected to No 30 and No 31 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 spun the sensor until only the pointed end is protruding from the flywheel then withdraw 1 3 lap and lock the nuts of the sensor at last 3 Output And Expand Relays Acaution All outputs of controller are relay contact output If need to expand the relays please add freewheel diode to both ends of expand relay s coils when relay coils has DC current or increase resistance capacitance return circuit when relay coils has AC current in order to prevent disturbance to controller or others equipment 4 Withstand Voltage Test Acaution 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 13 GSM SHORT MESSAGE ALARM AND REMOTE CONTROL 13 1 GSM SHORT MESSAGE ALARM When controller detects alarm it will send short message to phone automatically Anote All alarms about shutdown trip and stop and trip
34. ion 5 Active Delay 0 20 0 s 2 0 Time from detecting active to confirm No Items Parameters Defaults Description LCD displ il h 6 Description C ed contents when the input is active Configure Input 6 Content 1 bd 0 50 0 User defined See form 3 Setting Cl i 2 Active 0 1 0 0 Closed to 1006 1 Open to active 0 From safety on 1 From starting 3 A 2 oe oo 2 Always 3 Never Warn 1 Sh 2 Tri 4 Active Actions 0 4 2 5 one 3 Trip 4 Indication 5 Active Delay 0 20 0 s 2 0 Time from detecting active to confirm 6 Description E contents when the input is active Configure Input 7 Contents 1 L Setting 0 50 5 amp test See form 3 0 Closed to active 2 Active Type 0 1 0 Vt 1 Open to active Configure Output Ports Configure Output 1 Content p 0 239 1 Reserved See Form 4 Setting 0 Normally open 2 Active T 0 1 Mp eO i 1 Normally close Configure Output 2 Contents 1 0 239 35 Reserved See Form 4 Setting 0 Normally open 2 A 1 Mu 1 Normally close Configure Output 3 Contents 1 0 239 29 Generator closed output See Form 4 Setting 0 Normally open 2 Active T 0 1 0 T PS un 1 Normally close Configure Output 4 Contents 1 0 239 31 Reserved See Form 4 Setting 0 Normall 2 ActiveType 0 1 0
35. ion from crank to safety 24 Reserved 25 Pre Lubricate Actions in period of pre heating to safety run 26 Remote Control Output This port is controlled by communication PC Power for GSM module GSM module is reset i when GSM communication failed 28 Reserved 29 Close Gen Output Control generator to take load 30 Open Gen Output Control generator to off load 31 1 Acc Load Close Two Accs Control 1 accumulator to take load 32 1 Acc Load Open Two Accs Control 1 accumulator to off load 33 Start Relay 34 Fuel Relay Action when genset start and disconnect when genset stop completely 35 36 37 Reserved 38 39 40 ECU Stop Used for ECU engine and control its stop 41 ECU Power Used for ECU engine and control its power 42 Reserved 43 Crank Success Close when detects a successful start signal 44 Reserved 45 Reserved 47 48 omman Aat Action when JENSEN common warning common shutdown common trips alarm 49 Common Trip and Stop Action when common trip and stop alarm 50 Common Shutdown Action when common shutdown alarm 51 Common Trip Alarm Action when common trips alarm 52 Common Warn Alarm Action in common warning alarm 53 Reserved 54 Battery High Volts Action when battery s over voltage warning alarm 55 Battery Low Volts Action
36. l K1 Close Generator Priority K1 and K3 are always close Press e button if Accumulator have taken load K2 Close will output unload signal K2 Open if taken no load K2 Open accumulator will output load signal K2 Close Two accumulators Priority In Manual mode only genset will be started and the ATS will not act AUTO TRANSFER PROCEDURES 1 If input port is configured as Close Generator Auxiliary If Open breaker detect is SELECT Enable Generator load is transferred into generator un load or accumulator load is transferred into accumulator un load or accumulator is full charged after the open delay switch off signal will be output while fail to transfer delay will be initiated Once the delay has expired if switch off failed it will wait for switch off Otherwise switch off is completed Generator unload is transferred into generator load or accumulator unload is transferred into accumulator load or accumulator charge is beginning after the close delay switch on signal will be output while fail to transfer delay will be initiated Once the delay has expired if switch on failed it will wait for switch on Otherwise switch on is completed If fail to transfer warn is Enable alarm signal will be initiated whatever switch on or off failure If Open breaker detect is SELECT Disable Generator load is transferred into generator unload or accumulator load is transferred into accumulato
37. led stop alarm 102 Under Speed Warn Action when under speed alarm 103 Under Speed Shutdown Action when under speed shuts down 104 Over Speed Warn Action when over speed warn 105 Over Speed Shutdown Action when over speed shutdown alarm 106 2 Load Close Two Accs Control 2 accumulator to take load 107 2 Load Open Two Accs Control 2 accumulator to off load 108 122 Reserved 123 Over Current Action when over current 124 133 Reserved 134 2 Overvolts Warn 135 2 UndervoltsWarn 136 2 Overvolts Shutdown 137 2 Undervolts Shutdown 138 Reserved 139 High Temp Warn Action when hi temperature warning 140 Low Temp Warn Action when low temperature warning 141 High Temp Shutdown Action when hi temperature shutdown alarm 142 Reserved 143 Low OP Warn Action when low oil pressure warning 144 Low OP Shutdown Action when low oil pressure shutdown 145 OP Sensor Open Action when oil pressure sensor is open circuit 146 Reserved 147 Low Level Warn Action when controller has low oil level alarm 148 Reserved 149 Reserved 150 Config1 High Warn 151 Config1 Low Warn 152 Config1 High Shutdown 153 Config1 Low Shutdown 154 Config2 High Warn 155 Config2 Low Warn 156 Config2 High Shutdown 157 Config2 Low Shutdown 158 229 Reserved 230 Stop Mode Action in stop mode 231 Manual Mode Action in Manual mode 232 Reserved 2
38. ller page of ABOUT to us 4 2 LCD DISPLAY 4 2 1 MAIN DISPLAY Main screen show pages use OOQ to scroll the screen Main Screen including as below Genset status ATS status Accumulator voltage Accumulator temperature Generator Current Accumulator Charge Current Accumulator Discharge Current Load current Engine speed Accumulator Charging Curve Screen including as below Charge Start Voltage Const Charge Voltage Charge Stop Voltage Accumulator Voltage Accumulator Current Charging Status Engine 1 including as below Engine Speed GOV AVR Engine Temperature Engine Oil Pressure Engine 1 including as below Liquid Fuel Level Controller Voltage Charger Voltage Configure Analog 1 A NOTE If connected with J1939 engine via CANBUS port this page also includes coolant pressure coolant level fuel temperature oil pressure inlet temperature exhaust temperature turbo pressure total fuel consumption and so on different engine with different parameters Information including as below Total Running Time Total Start Times Maintenance Due Alarm Display all of alarm information A NOTE For ECU alarms and shutdown alarms if the alarm information is displayed check engine according to it otherwise please check the manual of generator according to SPN alarm code Press can enter into menu interface to viewing the following items event log input output ports status Issue t
39. lly 31 1 Acc Charge Closed Connect to the auxiliary point of 1 accumulator 32 2 Closed Connect to the auxiliary point of 24 accumulator 33 Simulate Stop key 34 Simulate Manual key 35 Reserved An external button can be connected to simulate panel 36 Simulate Auto key button 37 Simulate Start key 38 Simulate Load key 39 Reserved 40 Reserved 41 Reserved 42 Reserved 43 Simulate Raise Key An external button can be connected to simulate panel 44 Simulate Drop Key button 45 Reserved 46 Reserved 47 Reserved 48 Reserved 49 Reserved 50 Reserved 8 4 SELECTION OF SENSORS Form4 No Description Remark 2 0 Not used 1 Custom Res Curve 2 Custom 4 20mA curve 3 VDO 4 CURTIS Temperature Defined resistance s range is Sensor 7 SGX 0 6 default is SGX sensor 8 SGD 9 SGH 10 PT100 11 14 Reserved 15 Custom 0 5V Curve 0 Not used 1 Custom Res Curve 2 Custom 4 20mA curve 3 VDO 10Bar 4 CURTIS Pressure 5 VOLVO EC Defined resistance s range is Sensor 6 DATCON 10Bar 0 6 default is SGX sensor 7 SGX 8 SGD 9 SGH 10 14 Reserved 15 Custom 0 5V Curve 0 Not used 1 Custom Res Curve 3 Fuel Level 5 Defined resistance s range is Sensor 4 SGH 0 6 default is SGH sensor 5 14 Reserved 15 Custom 0 5V Curve Anote User should make special declare when order controller if you
40. m pa kgf cm bar psi 1Pa 1 1 02 10 5 1x10 1 45x10 4 1kgf cm 9 8x10 1 0 98 14 2 1bar 1x10 1 02 1 14 5 1 6 89x10 7 03 10 2 6 89x10 2 1 10 COMMISSIONING Please make the under procedures checking before commissioning 1 Ensure all the connections are correct and wires diameter is suitable 2 Ensure that the controller DC power has fuse controller s positive and negative connected to start battery are correct 3 Emergence stop must be connected with positive of start battery via scram button s normal close point and fuse 4 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 5 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 6 Recover the action of stop engine start e g Connect wire of fuel valve press start button again genset will start If everything goes well genset will normal run after idle running if idle run be set During this time please watch for engine s running situations and AC generator s voltage and frequency If abnormal stop genset running and check all wires connection according to this manual 7 is any other question please contact Smartge
41. may occur When setting the warning alarm please set the correct return value otherwise maybe abnormal alarm occurs When setting the maximum value the return value must less than set value When setting the minimum value the return value must greater than set value Anote Configurable input ports could not be set as same items otherwise abnormal functions occur However the configurable output ports can be set as same items 9 SENSORS SETTING 1 When reselect sensors the sensor curve will be transferred into the standard value For example if default temperature sensor is SGX 120 resistor type its sensor curve is SGX 120 C resistor type if select the SGD 120 C resistor type the temperature sensor curve is SGD curve 2 When there is difference between standard sensor curves and using one user can adjust in curve type 3 When input the sensor curve X value resistor must be input from small to large otherwise mistake occurs 4 If select sensor type as None sensor curve is not working 5 If corresponding sensor has alarm switch only user must set this sensor as None otherwise shutdown or warning alarm occurs 6 The headmost or backmost values in the vertical coordinates can be set as the same one as shown below kPa 800 700 600 500 400 300 200 100 32 64 96 128160192 224 omh Normal Pressure Unit Conversion For
42. mmended CAN L 2 Lo Impedance 1200 connecting line is recommended Engine type Volvo EMS2 NOTE When this engine type is selected preheating time should be set to at least 3 seconds 14 15 BOSCH It is suitable for BOSCH common rail pump engine Fuel relay output 1 40 Connect to engine ignition lock Start relay output Connect to starter coil directly CAN communication shielding CAN GND line connect with controllers this terminal only Impedance 1200 connecting line is CAN H 1 35 CAN L 1 34 mpedance 1200 connecting line is recommended Battery negative 1 Wire diameter 2 5mm Battery positive 2 Wire diameter 2 5mm Engine type BOSCH A NOTE If there is any question of connection between controller and ECU communication please feel free to contact Smartgen s service 15 FAULT FINDING Controller no response with power Genset shutdown Controller emergency stop Low oil pressure alarm after crank disconnect High water temp alarm after crank disconnect Shutdown Alarm in running Crank not disconnect Starter no response Genset running while ATS not transfer RS485 communication is abnormal ECU communication failed ECU warning or shutdown Check starting batteries Check controller connection wirings Check DC fuse Check the water cylinder temperature is too high or no
43. mulator take load K4 is closed When the 1 accumulator voltage has fallen below the Charge Start Volt K4 open relay will active after 10s delay 2 Accumulator take load K5 is closed During the above transfer process the load is disconnect The genset will be started according to the preset sequence to charge the 1 Accumulator K1 is closed Same procedures as above when 2 Accumulator transfer to 1 Accumulator 2 Two Accumulator Switching Mode Continuous 1 Accumulator take load K4 is closed When the 1 accumulator voltage has fallen below the Charge Volt 2 accumulator voltage will be recorded and the genset voltage detection begins The genset will be started according to the preset sequence When the genset voltage rise to 1 accumulator voltage K2 close relay will active and genset takes load After 1s delay K4 open relay will active Adjust the genset voltage to reach to 2 accumulator voltage then 2 accumulator takes load K5 is closed K2 open relay active After 1s delay K1 close relay active to charge the 1 accumulator Same procedures as above when 2 Accumulator transfer to 1 Accumulator All above switch actions can be implemented when the controller is Auto mode MANUAL TRANSFER PROCEDURES Accumulator Priority K2 and K3 are always close Press e button if generator have taken load K1 Close will output unload signal K1 Open if taken no load K1 Open generator will output load signa
44. n s service 11 TYPICAL APPLICATION CURRENT1 CURRENT2 Accu Volt 4 20 4 20 0 75V SG72MODULE 0 5V 0 5V AUX AUX AUX AUX AUX AUX OUTPUT1 OUTPUTS OUTPUT6 OUTPUT2 OUTPUT3 OUTPUT4 12 13 14 15 16 1718 147 48 49 50 5152 3031 1 x gt dv N Q 5 S 3 5 2 aj g 2 2 2 2 z z zz x x x x x 5 5 3535 lt 8 a 4 lt lt Lj PICKUP 12 INSTALLATION Controller is panel built in design it is fixed by clips when installed The controller s overall dimensions and cutout dimensions for panel please refers to as following CUT OUT E E 5 186mm 2 E u 39 mm 8mm 184mm 197mm 1 Battery Voltage Input HGM7110DC controller can suit for widely range of battery voltage DC 8 35 V Negative of battery must be connected with the shell of starter The wire s diameter connect controller and battery must be over 2 5 2 If floating charger 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 corresponding ports in order to prevent the charger interfere with the normal operation of the controller 2 Speed Sensor Input Anote Speed sensor is the magnetic equipment which be
45. nput port 2 inactive whatever input port 3 is active or not Defined Combination Output is not outputting 8 3 PROGRAMMABLE INPUT PORTS ALL ACTIVE WHEN CONNECT TO GRAND B Form 3 Including following functions Indication indicate only not warning or shutdown Warning warn only not shutdown Shutdown alarm and shutdown immediately Trip and stop alarm generator unloads and shutdown 0 Users Configured after hi speed cooling Trip alarm generator unloads but not shutdown Never input inactive Always input is active all the time From crank detecting from generator start From safety on detecting after safety on delay 1 Reserved 2 Alarm Mute Can prohibit Audible Alarm output when input is active Can reset shutdown alarm and trip alarm when input is 3 Reset Alarm active 4 Reserved 5 Lamp Test All LED indicators are illuminating when input is active All buttons in panel is inactive except 6 Panel Lock there is amp in the right of first row in LCD when input is active 7 8 Reserved In Auto mode during generator normal running when 9 Inhibit Auto Stop input is active prohibit generator shutdown automatically 10 inhibit Auto Start In Aa mode generator start automatically when input is active inhibit Scheduled nh ue prohibit fixed timing start genset when input is active 12 Reserved 13 Aux Gen Closed
46. nset stopped and TM bd 0 3600 s 0 9 Time standby Engine Setting Default Conventional Engine not J1939 ee 9 When connected to J1939 engine choose the corresponding type Tooth number of the engine for uy Flywheel judging separation 2 10 300 118 conditions and inspecting of engine Teeth speed See the installation instructions Offer standard to judge 3 RatedSpeed 0 6000 RPM 1500 i over under loading speed Setting value is percentage of rated speed Controller detects when it is Loading 4 Sua 0 100 96 90 ready to load It won t enter into Constant Charging Mode when speed is under loading speed L f Speed Time from detecting speed is O to 5 id 0 3600 s 5 Signal confirm the action L f d 6 Pei 27 0 1 0 0 Warn 1 Shutdown Signal Action Over Speed 7 0 200 114 Shutdown Setting value is percentage of rated speed and delay value can be set 3 Under Speed 0 200 80 p y valu Shutdown Over Speed 9 Wd P 0 200 96 110 Setting value is percentage of rated Under speed delay value and return value 10 peed 0 200 86 can be set Warn Battery Rated 0 60 0 V 240 Standard for detecting of over under Voltage voltage of battery Batt 12 a 0 200 120 Setting value is percentage of rated EX Unda voltage of battery delay value and 13 y 0 200 85 return value be set Volts 14 Charge Alt Fail 0 60 0 V 8 0 normal
47. o uet ra do iab oval ate frc va Mec 12 4 2 2 PARAMETERS SETTING MENU ertet nnda 12 4 3 AUTO START STOP 15 4 4 MANUAL START STOP 17 SWITCH CONTROL PROCEDURES beta adea ve debis atra estin deckut 18 5 1 ACCUMULATOR GENSET PRIORITY 18 5 2 TWO ACCUMULATOR PRIORITY SYSTEM enn 20 lm 22 6 1 WARNING ALARM S cinnara carotte e Does 22 6 2 SHUTDOWN ALARM 20 a cuu ERE RE 24 6 3 TEIPARINBESTOPALARFItistectic iu Ete abies 26 6 4 TRIPAAEARMI S cidit ei kr ark era KV UR RE RED S BM RR ER EY RA VELA 27 WIRING CONNEC THO INS 242 T 28 SCOPES AND DEFINITIONS OF PROGRAMMABLE 31 8 1 CONTENTS AND SCOPES OF PARAMETERS eee 31 8 2 PROGRAMMABLE OUTPUT PORTS nitrate kr d ena bao 42 8 2 1 ee eb tg cds e ub 45 8 3 PROGRAMMABLE INPUT PORTS ALL ACTIVE WHEN CONNECT TO GRAND B 47 8 4 SELECTION OF SENSORS rk di e Rate EE E 50 8 5 CONDITIONS OF CRANK DINSCONNECT
48. on again to stop generator immediately Start Start genset in Manual mode Manual Mode Press this key and controller enters in Manual mode Auto Mode Press this key and controller enters in Auto mode Close Open Can control generator to switch on or off in Manual mode Mute Reset Alarming sound off If there is trip alarm pressing the button at Alarm least 3 seconds can reset this alarm Raise Speed Control the genset accelerate in Manual mode Drop Speed Control the genset decelerate in Manual mode Menu Confirm 1 Enter into Menu interface 2 Shift cursor and confirm the set information Up Increase 2 Up cursor and increase value in setting menu Down Decrea 1 Screen scroll 1 Screen scroll se 2 Down cursor and decrease value in setting menu Pressing to enter into Menu interface select Parameters and input correct passwords allows the users to set parameters Anote Pressing Bana simultaneously will increase LCD contrast Pressing 9 simultaneously will decrease LCD contrast When controller is powered on after outage LCD contrast will return factory default WARNING Default password is 00318 user can change it case of others change the advanced parameters setting Please clearly remember the password after changing If you forget it please contact Smartgen services and send all information in the contro
49. r 2 When the controller detects that the sensor 2 value has High exceeded the pre set value it will initiate a warning alarm 24 Flexible Sensor 2 When the controller detects that the sensor 2 value has fallen Low below the pre set value it will initiate a warning alarm When digit input port is set as warning and the alarm is active 25 Digital Input p iid a it will initiate a warning alarm When GSM is enable but the controller couldn t detect GSM 26 GSM COM Failure Hp module it will initiate a warning alarm When the controller detects that the 1 accumulator battery 1 Acc Over Voltage ea 27 Warn voltage has exceeded the pre set value it will initiate a warning alarm 28 1 Under When the controller detects that 1 accumulator voltage has Voltage Warn fallen below the pre set value it will initiate a warning alarm When the controller detects that the 22 accumulator battery 2 Over Voltage se oa ee pce 29 Warn voltage has exceeded the pre set value it will initiate a warning alarm 30 2 Under When the controller detects that 2 accumulator voltage has Voltage Warn fallen below the pre set value it will initiate a warning alarm When the controller detects that the accumulator current has 31 Charge Over Current exceeded the pre set value and the action select Warn it will initiate a warning alarm If the charging is not finished within the preset time and the 32 Charge Over Time
50. r genset equip with 4 20mA sensor or 0 5V sensor 8 5 CONDITIONS OF CRANK DINSCONNECT SELECTION 1 Engine Speed 2 Cil pressure 3 Oil pressure Engine Speed Anote 1 There are 2conditions to make starter disconnected with engine that is engine speed and oil pressure Both of them can be used separately We recommend that oil pressure should be using with speed sensor together in order to make the starter separate with engine as soon as possible and can check start exactly 2 Speed sensor is the magnetic equipment which be installed in starter for detecting flywheel teeth 3 When set as engine speed must ensure that the number of flywheel teeth is as same as setting otherwise over speed stop or under speed stop may be caused 4 If genset without speed sensor please don t select corresponding items which include engine speed otherwise start fail or loss of speed signal maybe caused 5 If genset without oil pressure sensor please don t select corresponding items which include oil pressure ACAUTION Please change the controller parameters when generator is in standby mode only e g Crank disconnect conditions selection configurable input configurable output various delay otherwise shutdown alarm or other abnormal conditions may occur Maximum set value must greater than minimum set value in case that the condition of too high as well as too low
51. r un load or accumulator is full charged after the open delay switch off is completed Generator unload is transferred into generator load or accumulator unload is transferred into accumulator load or accumulator charge is beginning after the close delay switch on signal will be output while fail to transfer delay will be initiated Once the delay has expired if switch on failed it will wait for switch on Otherwise switch on is completed If fail to transfer warn is Enable alarm signal will be initiated f switch on failure 2 If input port is NOT configured as Close Generator Auxiliary Generator un load is transferred into generator load close generator output Generator load is transferred into generator un load open generator output 6 PROTECTIONS 6 1 WARNING ALARMS Warnings are not shutdown alarms and do not affect the operation of the gen set Warning alarms does not lead to shutdown Warning alarms types are as follows When the controller detects that the genset speed has exceeded the pre set value it will initiate a warning alarm When the controller detects that the genset speed has fallen below the pre set value it will initiate a warning alarm Loss of Speed When the controller detects that the genset speed is 0 and the 1 Over Speed 2 Under Speed Signal action select Warn it will initiate a warning alarm When the controller detects that the genset current has 4 Gen Over Current ex
52. rge current has fallen 28 Charge Fault below the rated charge current it will initiate a shutdown alarm In Two Accumulator mode if both accumulator are satisfy the 29 Two Acc Fault DANCE start requirement it will initiate a shutdown alarm When the controller detects that the 22 accumulator battery 30 2 Acc Over Voltage voltage has exceeded the pre set value it will initiate shutdown alarm 41 2 Under When the controller detects that 2 accumulator voltage has Voltage fallen below the pre set value it will initiate a shutdown alarm 6 3 TRIP AND STOP ALARM On initiation of the trip and stop condition the controller will de energize the Close Generator Output to remove the load from the generator Once this has occurred the controller will start the Cooling delay and allow the engine to cool before shutting down the engine When the controller detects that the genset current has 1 Gen Over Current exceeded the pre set value and the action select Trip and Stop it will initiate a trip and stop alarm When count down time is O and the action select Trip and Stop it will initiate a trip and stop alarm 2 Maintenance Due When digit input port is set as Trip and Stop and the alarm is active it will initiate a trip and stop alarm When the controller detects that the accumulator current has 4 Charge Over Current exceeded the pre set value and the action select Trip
53. s initiated 6 If the on load requirements have been reached then the generator close relay will be energized and the constant current charge status is settled The generator will regulate GOV AVR voltage automatically according to the charging current If the GOV AVR voltage has reached its maximum value while the charging current is lower than the Rated Charge Current Charge Fault alarm will be initiated Charge Stop Mode Charge Current Volt The accumulator charges the genset with the preset rated charging current charge type constant current When the accumulator voltage has exceeded the constant voltage value enter into the Constant Voltage Charge status During the Constant Voltage Charge status the accumulator charges the genset with its minimum charging current as soon as the minimum value is reached After the accumulator voltage has reached the Charge Stop Voltage the charging is finished and the genset is enter into Stop Mode Charge Stop Mode Charge Delay The accumulator charges the genset with the preset rated charging current charge type constant current When the accumulator voltage has exceeded the constant voltage value enter into the Constant Voltage Charge status and this status will last for preset time Automatic Stop Sequence 1 When the genset is charged or when the Remote Start signal is removed the Stop Delay is initiated Once this stop delay has expired the Generator
54. t Check the genset AC voltage Check DC fuse Check emergence stop button is correct or not Check whether the starting battery positive is connected with the emergency stop input Check whether the circuit is open Check the oil pressure sensor and its connections Check the temperature sensor and its connections Check related switch and its connections according to the information on LCD Check programmable inputs Check fuel oil circuit and its connections Check starting batteries Check speed sensor and its connections Refer to engine manual Check starter connections Check starting batteries Check ATS Check the connections between ATS and controllers Check connections Check setting of COM port is correct or not Check RS485 s connections of A and B is reverse connect or not Check RS485 transfer model whether damage or not Check communication port of PC whether damage Check connections of CAN high and low polarity Check if correctly connected of 1200 resister Check if type of engine correct Check if connections from controller to engine and output ports setting are correct Get information from LCD of alarm page If there is detailed alarm check engine according to description If not please refer to engine manual according to SPN alarm code
55. tdown alarm 19 Flexible Sensor 1 When the controller detects that the sensor 1 value has fallen Low below the pre set value it will initiate a shutdown alarm When the controller detects that the flexible sensor 2 is open Flexible Sensor 2 a KNEE 20 a circuit and the action select Shutdown it will initiate a Open Circuit shutdown alarm 24 Flexible Sensor 2 When the controller detects that the sensor 2 value has High exceeded the pre set value it will initiate a shutdown alarm 20 Flexible Sensor 2 When controller detects that the sensor 2 value has fallen Low below the pre set value it will initiate a shutdown alarm M When digit input port is set as shutdown and the alarm is 23 Digital Input Vp Cs active it will initiate a shutdown alarm When the controller detects that the 1 accumulator battery 24 1 Acc Over Voltage voltage has exceeded the pre set value it will initiate shutdown alarm 25 1 Under When the controller detects that 1 accumulator voltage has Voltage fallen below the pre set value it will initiate a shutdown alarm When the controller detects that the accumulator current has 26 Charge Over Current exceeded the pre set value and the action select Shutdown it will initiate a shutdown alarm If the charging is not finished within the preset time and the 27 Charge Over Time i action select Shutdown it will initiate a shutdown alarm If GOV output is 100 and the cha
56. tput minimum voltage 37 AVR Volt Max 0 10 0 V 2 0 AVR output maximum voltage AVR Interf 38 0 1 0 0 Normal Output 1 Reversed Output Type 39 AVR Gain 0 500956 20 AVR Control 40 AVR Stability 0 200096 20 AVR Control 41 AVR Kd 0 2000 0 AVR Control 42 PWM Gain 0 100926 20 PWM Control 43 PWM Stability 0 100946 20 PWM Control 44 PWM Kd 0 100 0 PWM Control Timer Setting Time from accumulator voltage has fall low the Ch Start Voltage 1 StartDelay 0 3600 s 1 or remote start signal is active to start genset Time from accumulator charging is 2 Stop Delay 0 3600 s 1 finished or remote start signal is inactive to stop genset Ti f pre ing heat plug bef 3 Preheat Delay 0 3600 s 0 Mi T P uM incre starter is powered up 4 Cranking Time 3 60 s 8 Time of starter power on Crank Rest The waiting time before second power g 8 60 s 10 Mg do d Time up when engine start fail Alarms for low oil pressure high 6 Safety On 1 60 s 10 temperature under speed Delay frequency voltage charge fail are inactive Radiating ti bef t stop 9 Cooling Time 0 3600 s 10 adiating time before genset stop after it unloads No Items Parameters Defaults Description to St Time between ending of cooling dela 12 9 9 SOP 0 3600 s 20 i ng Tuner Delay and stopped Aft St Time between ge
57. ure pressure liquid lever Setting sensor No Items Parameters Defaults Description Configure Input Ports Configure Input 1 Contents 1 0 50 28 Remote start on load See form 3 Setting CI i 2 Activa Tube 0 1 0 0 Closed to 1 Open to active Configure Input 2 1 Contents 0 50 26 High temperature shutdown Setting See form 3 CI i 2 Active Type 0 1 0 0 Closed to Hone 1 Open to active Configure Input 3 1 Solent 0 50 27 Low oil pressure shutdown Setting See form 3 0 Closed to active 2 Active Type 0 1 0 99 1 Open to active Configure Input 4 Contents 1 0 50 0 User defined See form 3 Setting 0 Closed to active 2 Active 0 1 0 idis a 1 Open to active a i 3 Armina 0 3 2 0 From safety 1 From starting 2 Always 3 Never Warn 1 Sh 2 Tri Active Actions 0 4 0 0 5 HEN 2 Trip and stop 3 Trip 4 Indication 5 Active Delay 0 20 0 s 2 0 Time from detecting active to confirm 6 nis display contents when the input is active Configure Input 5 Content 1 P 0 50 0 User defined See form 3 Setting Cl i 2 Active Type 0 1 0 0 Closed to 1 Open to active 0 From safety 1 From starting A 2 i Mi 9 2 Always 3 Never 0 Warn 1 Sh 2 Tri 4 Active Actions 0 4 1 3 Trip 4 Indicat
58. when battery s low voltage warning alarm 56 Charge Alt Fail Action when charge failure warning alarms 57 1 Acc Charge Close Control 1 accumulator charge switch to close 58 1 Acc Charge Open Control 1 accumulator charge switch to open 59 Measuring Gen Volts Two accumulator system detect the Gen voltage or 2 Accumulator Voltage effectively 60 ECU Warn Indicate ECU sends a warning signal 61 ECU Shutdown Indicate ECU sends a shutdown signal 62 ECU Com Fail Indicate controller not communicates with ECU 63 2 Charge Close Control 2 accumulator charge switch to close 64 2 Charge Open Control 2 accumulator charge switch to open 1 Acc Over Voltage 65 Warn 66 1 Acc Under Voltage Warn 67 1 Acc Over Voltage Shutdown 68 1 Acc Under Voltage Shutdown 69 Aux Input 1 Active Action when input port 1 is active 70 Aux Input 2 Active Action when input port 2 is active 71 Aux Input 3 Active Action when input port 3 is active 72 Aux Input 4 Active Action when input port 4 is active 73 Aux Input 5 Active Action when input port 5 is active 74 Aux Input 6 Active Action when input port 6 is active 75 Aux Input 7 Active Action when input port 7 is active 76 98 Reserved 99 Emergency Stop Action when emergency stop alarm 100 Failed To Start Action when failed start alarm 101 Failed To Stop Action when fai
59. will be sent to the pre set phone Warnings are sent to the phone according to the pre set 13 2 GSM SHORT MESSAGE REMOTE CONTROL Users send order message to GSM module then controller will make actions according to this SMS order and pass back corresponding operations information Controllers only execut e the orders by pre set Detail orders as following When is MODE GENSET ALARM stopping alarm M RISE At rest status in stop mode GENSET AT REST SYSTEM IN MANUAL MODE At rest status in manual GENSET AT REST ua At rest status in Auto 1 SMS MODE Get status of GENSET GENSET AT REST genset bis Running status in stop mode GENSET IS RUNNING DEM sie Running status MODE GENSET IS RUNNING 9792 mode 2 M AU n status in Auto GENSET AT RUNNING GENSET ALARM shutdown alarm or trip alarm STOP MODE Cannot start in stop 2 sMssrART START eoe Start genset SMS START OK Start in manual mode AUTO MODE NOT Cannot start in auto START mode 3 E SMS STOP Set as stop mode SMS 4 MANUAL Bin Set as manual mode MODE 5 ML SMS AUTO MODE OK Set as auto mode Pass back information 6 SMS DETAIL can be set via controller Gets details information of genset software SMS INHIBIT m 7 START INHIBIT START OK Generator start will be inhibited
60. y If there is shutdown alarm occurs by either engine or generator the accumulator will supply the power for load In Auto mode the genset will charge the accumulator if the accumulator voltage has fallen below the Charge Start Voltage When the accumulator voltage has fallen below the Nominal Voltage in addition the generator abnormal condition occurs Shutdown alarm will be initiated gt Double Accumulator System Firstly the accumulator 1 supplies the power for load if the accumulator 1 satisfies the charger requirement then it will charged by the genset and the accumulator 2 supplies the power for load gt Collects and shows parameters Accumulator Accumulator Voltage after the compensation Accumulator Temperature Accumulator Charge Current Accumulator Discharge Current Load Current Generator Current gt Accumulator over voltage under voltage protection functions gt 3 fixed analog sensors temperature oil pressure and liquid level gt 2 configurable sensors can be set as sensor of temperature oil pressure or fuel level Precision measure and display parameters about Engine Temp WT C F both be displayed Oil pressure OP kPa Psi Bar all be displayed Fuel level FL unit Speed SPD r min unit Voltage of Battery VB V unit Voltage of Charger VD V unit Hour count HC can accumulate to max 65535 hours Start times can accumulate to max 65535 times gt Protection automatic
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