Smartgen HGM6510 User Manual
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Smartgen HGM6510 User Manual

Genset parallel unit
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HGM6510 Genset Parallel Unit
USER MANUAL
Smartgen Technology

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Summary of Contents for Smartgen HGM6510

  • Page 1 HGM6510 Genset Parallel Unit USER MANUAL Smartgen Technology...

  • Page 2: Table Of Contents

    HGM6510 GENSET PARALLEL UNIT CONTENTS 1 OVERVIEW ................... 6 2 PERFORMANCE AND CHARACTERISTICS ........7 3 SPECIFICATION ..................10 4 FRONT PANEL ..................11 4.1 INDICATOR LIGHT ..................... 11 PUSHBUTTONS ....................12 5 OPERATION ................... 13 AUTOMATIC OPERATION (MULTIPLE SETS) ..........13 MANUAL OPERATION (MULTIPLE SETS) ............
  • Page 3 13 POWER MANAGEMENT MODE ............48 14 TROUBLESHOOTING ................. 49 15 TYPICAL WIRING DIAGRAMS ............50 15.1 HGM6510 TYPICAL WIRING DIAGRAM ............50 15.2 HGM6510 MAINS PARALLEL APPLICATION ............50 15.3 HGM6510 MULTI-SET PARALLEL APPLICATION ..........51 16 COMMUNICATION INTERFACE ............52 17 CASE DIMENSIONS AND PANEL CUTOUT .........

  • Page 4: Overview

    HGM6510 GENSET PARALLEL UNIT 1 OVERVIEW HGM6510 controller is designed for manual/auto parallel systems of up to 20 generators with similar or different capacity. Additionally, it is suitable for single unit constant power output and mains paralleling. It allows automatic start/stop, data measurement, alarm protection as well as remote control, remote measurement and remote communication function.

  • Page 5: Performance And Characteristics

    HGM6510 GENSET PARALLEL UNIT 2 PERFORMANCE AND CHARACTERISTICS  2 application modes: Multi-set parallel operation; Single unit (constant power output) parallel with mains.  32-bit ARM microprocessor, LCD display with backlight, optional languages interface, push-button operation;  Complete monitoring functions: almost all generator electric/non-electric parameters...
  • Page 6 HGM6510 GENSET PARALLEL UNIT Generator abnormal conditions: Over Voltage Under Voltage Over Frequency Under Frequency Loss of Phase Phase Sequence Wrong No power Fault display and alarm: High temperature warn High temperature shutdown Low oil pressure warn Low oil pressure shutdown...
  • Page 7 HGM6510 GENSET PARALLEL UNIT  Accurately measure and display the electric parameters as well as water temperature, oil pressure, fuel level and others;  Control protection: Genset automatic start/stop/parallel operation, synchronization detection, load sharing and alarm protection;  Maintenance function, maintenance due warning/shutdown alarm;...

  • Page 8: Specification

    HGM6510 GENSET PARALLEL UNIT 3 SPECIFICATION Parameter Details Working Voltage DC8. 0V to 35. 0V, Continuous Power Supply. <3W (Standby mode: ≤2W) Overall Consumption Alternator Voltage Input: 3 Phase 4 Wire AC15V - AC360V (ph-N) 3 Phase 3 Wire AC30V - AC600V (ph-ph)

  • Page 9: Front Panel

    HGM6510 GENSET PARALLEL UNIT Parameter Details Storage Conditions Temperature:(-40~+85)°C Protection Level IP55 Gasket Apply AC2.2kV voltage between high voltage terminal and low voltage terminal Insulation Intensity The leakage current is not more than 3mA within 1min. Weight 0.90kg 4 FRONT PANEL 4.1 INDICATOR LIGHT...

  • Page 10: Pushbuttons

    HGM6510 GENSET PARALLEL UNIT 4.2 PUSHBUTTONS When the genset is running, pressing this button will ramp off and stop running the generator; In case of alarm condition, pressing the button will reset alarm; Stop/Reset In stop mode, pressing and holding the button for 3 seconds will test indicator lights (lamp test);...

  • Page 11: Operation

    HGM6510 GENSET PARALLEL UNIT 5 OPERATION 5.1 AUTOMATIC OPERATION (MULTIPLE SETS) Auto mode is selected by pressing the button; a LED besides the button will illuminate to confirm the operation. Automatic Start Sequence: Configure one of the 9 configurable input ports as “Remote Start on Load Demand” using PC software.

  • Page 12: Manual Operation (Multiple Sets)

    HGM6510 GENSET PARALLEL UNIT 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).
  • Page 13 HGM6510 GENSET PARALLEL UNIT NOTE: If the unit has been configured for CAN Bus, compatible ECU‟s will receive the start command via CAN Bus. Should this start sequence continue beyond the set number of attempts, the start sequence will be terminated, the first line of LCD display will be highlighted with black and Fail to Start fault will be displayed.

  • Page 14: Protections

    HGM6510 GENSET PARALLEL UNIT 6 PROTECTIONS When an alarm is present, the Common Alarm LED (if configured) will illuminate and alarm information will be displayed on LCD. 6.1 WARNING ALARMS Warnings are not shutdown alarms and do not affect the operation of the genset. Warning does not lead to shutdown, and when warning condition is no longer present, warning alarm will be cleared automatically.
  • Page 15 HGM6510 GENSET PARALLEL UNIT Type Active Range Description If reverse power detection is enabled, when the controller detects that the reverse power Reverse value (power is negative) has fallen below Always active Power the pre-set value it will initiate a warning...
  • Page 16 HGM6510 GENSET PARALLEL UNIT Type Active Range Description When the controller detects an imbalance in Negative the load current of each phase above a pre- When generator Sequence set level, it will initiate a warning alarm and is closed Current the corresponding alarm information will be displayed on LCD.

  • Page 17: Shutdown Alarms

    HGM6510 GENSET PARALLEL UNIT Type Active Range Description When the controller detects that the genset From “Waiting for voltage has fallen below the pre-set value, it Genset Under load” delay will initiate a warning alarm and the Voltage “Cooling” delay corresponding alarm information will be displayed on LCD.
  • Page 18 HGM6510 GENSET PARALLEL UNIT latching and stop the Generator. Type Range Description When the controller detects an emergency Emergency stop alarm signal, it will initiate a shutdown Always active Stop alarm corresponding alarm information will be displayed on LCD. When...
  • Page 19 HGM6510 GENSET PARALLEL UNIT Type Range Description When the controller detects that the genset From “Waiting for voltage has fallen below the pre-set value, it Under load” delay will initiate a shutdown alarm and the Voltage “Cooling” delay corresponding alarm information will be displayed on LCD.
  • Page 20 HGM6510 GENSET PARALLEL UNIT Type Range Description If the open signal was not be detected within the generator breaker open timer, it will Fail Always active initiate shutdown alarm Open corresponding alarm information will be displayed on LCD. maintenance enabled,...

  • Page 21: Trip And Stop Alarms

    HGM6510 GENSET PARALLEL UNIT Type Range Description If “earth fault” detection is enabled, when the controller detects a generator earth fault Earth Fault current has exceeded the pre-set value and Always active the action select “Shutdown”, it will initiate a...
  • Page 22 HGM6510 GENSET PARALLEL UNIT When the controller detects that the mains When mains frequency has exceeded the pre-set value, it Mains Over parallel operation will initiate a trip and stop alarm and the Frequency is enabled corresponding alarm information will be displayed on LCD.
  • Page 23 HGM6510 GENSET PARALLEL UNIT When controller does detect When synchronization signal within the pre-set Fail to sync synchronization is synchronization time, it will initiate a trip and enabled stop alarm and the corresponding alarm information will be displayed on LCD.

  • Page 24: Panel Configuration

    HGM6510 GENSET PARALLEL UNIT 7 PANEL CONFIGURATION 7.1 LCD DISPLAY 7.1.1 STATUS DISPLAY STATUS First Status Screen Controller Modes: STOP/MANUAL/AUTO Mode STOP MODE GENSET AT REST Genset Working Status GENSET OPEN Generator Breaker Status STATUS Second Status Screen Generator Average Phase Voltage/Current UL-N 0.0 A...

  • Page 25: Engine Display

    HGM6510 GENSET PARALLEL UNIT 7.1.2 ENGINE DISPLAY ENGINE First Engine Screen SPEED 0 RPM Engine Speed BATTERY 0.0 V Generator Start Battery Voltage CHARGE D+ 0.0 V AC Charger D+ Voltage ENGINE Second Engine Screen OIL PRESSURE 0 kPa Engine Oil Pressure 0.0 Bar...

  • Page 26: Bus Display

    HGM6510 GENSET PARALLEL UNIT GENERATOR Fifth Generator Screen 0.0 0.0 0.0 3-phase Apparent Power L1 L2 L3 TkVA Total Apparent Power GOV Output Percentage, AVR Output Percentage GOV% 0.0 AVR% 0.0 GENERATOR Sixth Generator Screen 0000000.0 Total kW Energy kVAh 0000000.0...

  • Page 27: Event Log

    HGM6510 GENSET PARALLEL UNIT 7.1.7 EVENT LOG EVENTS First Event Log Screen RECORDS: (01/02) Total Records OVER POWER TRIP Fault Type 2010-12-18 21:31:55 Record Time EVENTS Second Event Log Screen RECORDS: (02/02) Total Records GEN FAIL TO CLOSE Fault Type...
  • Page 28 HGM6510 GENSET PARALLEL UNIT Parameters list: Parameter Range Default Notes 01 Low Oil Pressure Return value: (1-999)kPa 124kPa/18.0PSI (Warn) 138kPa/20.0PSI Setting standard: 02 Low Oil Pressure (0-997)kPa 103kPa/14.9PSI Shutdown value<Warn (Shutdown) value<Return value High Temperature (81-139)ºC 90ºC/194ºF Return value: 88°C/190°F...
  • Page 29 HGM6510 GENSET PARALLEL UNIT Parameter Range Default Notes value>Return value On-load value: 45.0Hz Generator Under Setting standard: (0.1-74.9)Hz 42.0Hz Frequency (Warn) Shutdown value<Warn value<On-load value Generator Under Generator under frequency (0-74.8)Hz 40.0Hz Frequency (Shutdown) shutdown value Generator Over (0.1-74.9)Hz 55.0Hz Return value: 52.0Hz...
  • Page 30 HGM6510 GENSET PARALLEL UNIT Parameter Range Default Notes 48 Load Ramp Rate (0-100)% Load/unload speed %/s Schedule other gen-sets’ 49 Full Power (0-100)% start load percentage Power Schedule other gen-sets’ (0-99)% Shutdown stop load percentage Positive Freq Frequency difference (0-2)Hz 0.2Hz...
  • Page 31 HGM6510 GENSET PARALLEL UNIT Other parameters configuration (can only be configured via PC software) Parameter Default Value Module Address Alternator Selection Poles Magnetic Pickup Quick On-load Mode Start Times Voltage Transformer Fuel Pump Control Input 1 Remote start on-load demand; close to activate Low oil pressure;...

  • Page 32: Date/Time Setting

    HGM6510 GENSET PARALLEL UNIT Synch Frequency PID Settings Synch Voltage PID Settings Configured via HGM6500 PC software. Active Power PID Settings Reactive Power PID Settings 7.3 DATE/TIME SETTING Press simultaneously to enter into date/time setting interface. The first digit of the fourth row will be highlighted with black. Press increase/decrease the value and input the corresponding password 0~9;...

  • Page 33: Ecu Display

    HGM6510 GENSET PARALLEL UNIT Generator 3-phase Total Reactive Power Generator Total Active/Reactive/Apparent Energy Generator Phase Sequence Bus Phase Voltage (L1-N, L2-N, L3-N) Bus Line Voltage (L1-L2, L2-L3, L3-L1) Bus Frequency Bus Phase Sequence 7.4.2 ECU DISPLAY Engine Oil Temperature Coolant Pressure...

  • Page 34: Input And Output Ports Configuration

    HGM6510 GENSET PARALLEL UNIT 8 INPUT AND OUTPUT PORTS CONFIGURATION 8.1 CONFIGURABLE INPUT PORTS 1~9 No. Type Description 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...
  • Page 35 HGM6510 GENSET PARALLEL UNIT input is inactive, the gen-set will automatically open and stop. In Auto mode, when the input is active, all the parallel Remote Start On Load units are started in the order of priority; then according Demand to the load, the number of units is automatically increased or decreased.

  • Page 36: Configurable Output Ports 1-5

    HGM6510 GENSET PARALLEL UNIT simultaneously activated to control the breaker closed. Used in case of transformer load to avoid over current shutdown when the generator is closed. When the input is active, the controller is in auto mode Auto Mode Input and other modes are disabled.
  • Page 37 HGM6510 GENSET PARALLEL UNIT No. Type Description Close Generator Generator impulse close output; output time depends on Pulse impulse time. 014 Close Mains Control mains to take load. ( Continuous active) Close Mains Pulse Mains impulse close output; output time depends on impulse time.
  • Page 38 HGM6510 GENSET PARALLEL UNIT No. Type Description Generator High Action when generator over voltage warning alarm. Voltage Pre-alarm Generator High Action when generator over voltage shutdown alarm. Voltage Shutdown Generator Low Freq. Action when generator under frequency warning alarm. Pre-alarm Generator Low Freq.
  • Page 39 HGM6510 GENSET PARALLEL UNIT No. Type Description Preheat (during Action from preheat delay till the start of cranking. pre-heat timer) Preheat (until end of Action from preheat delay till the end of cranking. crank) Preheat (until end of Action from preheat delay till the end of warming up.

  • Page 40: Event Log

    HGM6510 GENSET PARALLEL UNIT 9 EVENT LOG HGM6510 controller can save a maximum of 99 event logs, including shutdown type, date and time (warning alarms are not recorded). Once the log is full (99 records), any subsequent shutdown entry will overwrite the oldest entry in the log, so the log will always contain the 99 most recent abnormal events.
  • Page 41 HGM6510 GENSET PARALLEL UNIT Cable Pin Function Description Size Aux. Output 1 2.5mm B+ output，rated 16A 2.5mm B+ output，rated 16A Aux. Output 2 2.5mm B+ output，rated 16A Aux. Output 3 starter’s Connected with charger Charger(D+) 1.0mm terminal. Ground connected is not allowed.
  • Page 42 HGM6510 GENSET PARALLEL UNIT Cable Pin Function Description Size Bus C Phase Voltage Connected to C-phase of bus (2A fuse is 1.0mm Sensing Input recommended) 1.0mm Bus N-wire input Connected to N-wire of bus Genset A Phase Voltage Connected to A-phase of genset (2A fuse is 1.0mm...

  • Page 43: Ecu Interface

    HGM6510 GENSET PARALLEL UNIT 11 ECU INTERFACE HGM6510 controller is fitted with ECU interface. As different manufactories use different ports and communication protocols, please check if the controller is suitable for your engine. This controller can monitor and control some parameters of the engine, such as engine speed, oil pressure, temperature.

  • Page 44: Step 2: Manual Parallel Operation Off-Load

    0; if it is not, then check if there is power oscillation; if there is, adjust the gain and stability values of HGM6510 controller, or adjust engine GOV or generator AVR gain and stability potentiometer to avoid active and reactive power oscillation;...
  • Page 45 HGM6510 GENSET PARALLEL UNIT below module pre-set shutdown minimum percentage, the module with lowest priority enters stop delay and then cools down and stops. If load exceeds the preset start maximum percentage, the generators that are at rest will all start again.

  • Page 46: Power Management Mode

    HGM6510 GENSET PARALLEL UNIT 13 POWER MANAGEMENT MODE Power management mode can be selected via configurable input ports. HGM6510 Genset Parallel Unit ISSUE 2013-07-15 Version 1.7 Page 48 of 52...

  • Page 47: Troubleshooting

    Check the DC fuse. respond to power on Check that HGM6510 controller DIP switch on back panel is in the right position: Dial up for normal use; Dial down for upgrading program. Check that water/cylinder temperature is not too high;...

  • Page 48: Typical Wiring Diagrams

    HGM6510 GENSET PARALLEL UNIT 15 TYPICAL WIRING DIAGRAMS 15.1 HGM6510 TYPICAL WIRING DIAGRAM NOTE: Expansion high-capacity relays for start and fuel output ports are recommended. 15.2 HGM6510 MAINS PARALLEL APPLICATION HGM6510 Genset Parallel Unit ISSUE 2013-07-15 Version 1.7 Page 50 of 52...

  • Page 49: Hgm6510 Multi-Set Parallel Application

    HGM6510 GENSET PARALLEL UNIT 15.3 HGM6510 MULTI-SET PARALLEL APPLICATION HGM6510 Genset Parallel Unit ISSUE 2013-07-15 Version 1.7 Page 51 of 52...

  • Page 50: Communication Interface

    HGM6510 GENSET PARALLEL UNIT 16 COMMUNICATION INTERFACE The controller is fitted with both standard RS232 and RS485 communication interfaces, so computer can directly (or through a modem) communicate with controller and perform remote start/stop, data monitoring and other functions. RS232/485 interface uses MODBUS communication protocol. MODBUS is a master- slave protocol, and the controller acts as a slave.

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