Smartgen HGM8110DC User Manual
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Smartgen HGM8110DC User Manual

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HGM8110DC
GENSET CONTROLLER
USER MANUAL
SMARTGEN (ZHENGZHOU) TECHNOLOGY CO., LTD.

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  • Page 1 HGM8110DC GENSET CONTROLLER USER MANUAL SMARTGEN (ZHENGZHOU) TECHNOLOGY CO., LTD.
  • Page 2 SmartGen Technology at the address above. Any reference to trademarked product names used within this publication is owned by their respective companies. SmartGen Technology reserves the right to change the contents of this document without prior notice. Table 1 - Software Version Date...
  • Page 3 HGM8110DC GENSET CONTROLLER USER MANUAL This manual is suitable for HGM8110DC controller only. Table 2 - Notation Clarification Sign Instruction Highlights an essential element of a procedure to ensure correctness. NOTE Indicates a procedure or practice, which, if not strictly observed, could result in CAUTION! damage or destruction of equipment.

  • Page 4: Table Of Contents

    HGM8110DC GENSET CONTROLLER USER MANUAL CONTENTS 1 OVERVIEW .............................. 6 2 MOUDLES COMPARISON ........................7 3 PERFORMANCE AND CHARACTERISTICS ..................8 4 SPECIFICATION OPERATION ......................10 5 OPERATION ............................11 5.1 INDICATORS ..........................11 5.2 KEY FUNCTION ........................... 11 5.3 LCD DISPLAY ..........................12 5.3.1.
  • Page 5 HGM8110DC GENSET CONTROLLER USER MANUAL 13.6 WITHSTAND VOLTAGE TEST ....................51 14 CONNECTIONS OF CONTROLLER WITH J1939 ENGINE ..............52 14.1 CUMMINS ISB/ISBE ........................52 14.2 CUMMINS QSL9.......................... 52 14.3 CUMMINS QSM11(import) ......................52 14.4 CUMMINS QSX15-CM570 ......................53 14.5 CUMMINS GCS-MODBUS ......................53 14.6 CUMMINS QSM11 ........................

  • Page 6: Overview

    HGM8110DC GENSET CONTROLLER USER MANUAL OVERVIEW HGM8110DC genset controller is especially designed for single unit system in DC and AC applications, which can adapt extremely high/low temperature environment (-40~+70)° C. The controllers can operate reliability in extreme temperature conditions with the help of VFD display and the components that resist extreme temperature.

  • Page 7: Moudles Comparison

    HGM8100N series controller include HGM8110V， HGM8120V， HGM8110CAN， HGM8120CAN. HGM8110N been collectively named of HGM8110V and HGM8110CAN. HGM8120N been collectively named of HGM8120V and HGM8120CAN. HGM8110DC is the optimize version for HGM8110CAN. HGM8110DC and HGM8100N modules comparison is as below, Table 3 - Moudles Comparison Modules HGM8110DC...

  • Page 8: Performance And Characteristics

    HGM8110DC GENSET CONTROLLER USER MANUAL PERFORMANCE AND CHARACTERISTICS HGM8110DC: It is DC genset controller and used for single automation systems. Control genset start/stop through remote signals control; Compared with HGM8110CAN, HGM8110DC added generator DC electric quantity monitoring and alarming functions, which is especially suit for single unit automatic system composed by 1-way DC and 1-way AC circuits.
  • Page 9 HGM8110DC GENSET CONTROLLER USER MANUAL 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.

  • Page 10: Specification Operation

    HGM8110DC GENSET CONTROLLER USER MANUAL SPECIFICATION OPERATION Table 4 - Technical Parameters Items Contents Operating Voltage DC8.0V to DC35.0V, Continuous Power Supply. <4W (standby ≤2W) Power Consumption Alternator Input Range 3Phase 4Wire AC15V-AC 360V (ph-N) 3Phase 3Wire AC30V - AC620V (ph-ph)

  • Page 11: Operation

    HGM8110DC GENSET CONTROLLER USER MANUAL OPERATION INDICATORS Table 5 - Alarm Indicators Alarm Type Alarm Indicator No Alarm Indicator off Warning Slow flashing(1time/s) Trip Alarm Slow flashing(1time/s) Shutdown Alarm Fast flashing(5 times/s) Trip and Stop Alarm Fast flashing(5 times/s) NOTE: Partial indicators description, Status indicator: illuminated from crank disconnect to ETS while off during other periods.

  • Page 12: Lcd Display

    WARNING: Default password is ―00318‖, user can change it in 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 PD information in the controller page of ―ABOUT‖ to us. LCD DISPLAY 5.3.1.
  • Page 13 HGM8110DC GENSET CONTROLLER USER MANUAL consumption, total fuel consumption and so on. (Different engine with different parameters) ★AC Gen, including as below, Phase voltage, Line voltage, frequency, phase sequence. ★AC Load, including as below Current of each phase, each phase and total active power (positive and negative), each phase and total...

  • Page 14: Pararmeters Setting Manual

    HGM8110DC GENSET CONTROLLER USER MANUAL 5.3.2. PARARMETERS SETTING MANUAL Press and hold for more than 3 seconds to enter user menu; Parameter：After entering the correct password (factory default password is 00318) you can enter parameter settings screen. Language：Selectable Chinese, English and others (default: Espanol) Commissioning：On load, off load and custom commissioning are optional.

  • Page 15: Auto Start/Stop Operation

    , its indicator lights, and controller enters Auto mode. Starting Sequence, HGM8110DC: Generator enters into ―Start Delay‖ as soon as ―Remote Start on Load‖ is active. Start delay timer is shown on LCD. When start delay is over, preheat relay outputs (if this be configured), ―Preheat Start Delay XX s‖...

  • Page 16: Manual Start/Stop Operation

    HGM8110DC GENSET CONTROLLER USER MANUAL MANUAL START/STOP OPERATION MANUAL START: Press , controller enters into manual mode and its indicator lights. Press to start generator, can automatically detect crank disconnected, and generator accelerates to high-speed running automatically. With high temperature, low oil pressure, over speed and abnormal voltage during generator running, controller can protect genset to stop quickly.

  • Page 17: Genset Controller Switch Control Procedures

    HGM8110DC GENSET CONTROLLER USER MANUAL GENSET CONTROLLER SWITCH CONTROL PROCEDURES 5.6.1. HGM8110DC SWITCH CONTROL PROCEDURES 5.6.1.1 MANUAL TRANSFER PROCEDURES When controller is in manual mode, manual control will be executive. Users can control switch on or off by pressing key.

  • Page 18: Protection

    HGM8110DC GENSET CONTROLLER USER MANUAL PROTECTION WARNINGS When controllers detects the warning signals, alarm only and not stop the genset. Table 8 - Warning Alarms Type Description When controller detects the speed is higher than the set value, it will Over Speed send warn signals.
  • Page 19 HGM8110DC GENSET CONTROLLER USER MANUAL Type Description When controller detects the AC generator loss phase, it will send warn AC Loss of Phase signals. AC Phase Sequence When controller detects the AC generator phase rotation, it will send Wrong warn signals.

  • Page 20: Shutdown Alarm

    HGM8110DC GENSET CONTROLLER USER MANUAL Type Description value, it will send warn signals. When controller detects the sensor value is lower than the min. set Flexible Sensor 2 Low value, it will send warn signals. When digit input port is set as warning and active, controller sends Digital Input Warn corresponding warning signals.
  • Page 21 HGM8110DC GENSET CONTROLLER USER MANUAL Type Description When controller detects reverse power value of AC genset (power AC Reverse Power is negative) is higher than the set value, and the reverse power Shutdown action select ―shutdown‖, it will send stop signals.

  • Page 22: Trip And Stop Alarm

    HGM8110DC GENSET CONTROLLER USER MANUAL Type Description Shutdown it will send stop signals. When controller detects the earth current of genset exceeds preset earth fault threshold and the earth fault action select ―shutdown‖ it Earth Fault will send stop signals.

  • Page 23: Trip Alarm

    HGM8110DC GENSET CONTROLLER USER MANUAL TRIP ALARM When controller detects trip alarm, it will break close generator signals quickly, but genset not stop. Table 11 - Trip Alarms Type Description When controller detects the current value of AC genset is higher than the set value, and the action select ―trip‖, it will send trip...

  • Page 24: Wirings Connection

    HGM8110DC GENSET CONTROLLER USER MANUAL WIRINGS CONNECTION HGM8110DC series controller‘s back as following: Fig.1 - HGM8110DC Back Panel Table 12 - Terminal Wiring Connection Function Cable Size Remarks 2.5mm Connected with negative of starter battery Connected with positive of starter battery. If wire length 2.5mm...
  • Page 25 HGM8110DC GENSET CONTROLLER USER MANUAL Function Cable Size Remarks Connected with charger starter‘s D+ (WL) terminals. Charger(D+) 1.0mm Being hang up If there is no this terminal. Aux. Input 1 1.0mm Ground connected is active (B-) Aux. Input 2 1.0mm Ground connected is active (B-) Aux.
  • Page 26 HGM8110DC GENSET CONTROLLER USER MANUAL Function Cable Size Remarks AC Gen A-Phase Volt Connected to A-phase of AC gen-set (2A fuse is 1.0mm Input recommended) AC Gen B-Phase Volt Connected to B-phase of AC gen-set (2A fuse is 1.0mm Input...

  • Page 27: Scopes And Definitions Of Programmable Parameters

    HGM8110DC GENSET CONTROLLER USER MANUAL SCOPES AND DEFINITIONS OF PROGRAMMABLE PARAMETERS CONTENTS AND SCOPES OF PARAMETERS Table 13 - Parameters Contents and Scopes Items Parameters Defaults Description DC Generator 0: DC; Work Mode (0~2) 1: AC 2: DC+AC Standard for checking DC generator...
  • Page 28 HGM8110DC GENSET CONTROLLER USER MANUAL Items Parameters Defaults Description signal is active to start genset. Time from mains normal or remote start Stop Delay (0~3600)s signal is deactivated to genset stop. Time of pre-powering heat plug before Preheat Delay (0~3600)s starter is powered up.
  • Page 29 HGM8110DC GENSET CONTROLLER USER MANUAL Items Parameters Defaults Description Shutdown and delay value (over speed default: 2s; under speed default:3s) also can be set. Under Speed (0~200)% Shutdown Over Speed Warn (0~200)% Setting value is percentage of rated speed and delay value (default: 5s) and return...
  • Page 30 HGM8110DC GENSET CONTROLLER USER MANUAL Items Parameters Defaults Description without speed sensor. To offer standards for detecting of generator‘ over/under voltage and loading Rated Voltage (30~30000)V voltage. It is primary voltage when using voltage transformer. Setting value is AC generator rated voltage‘s percentage.
  • Page 31 HGM8110DC GENSET CONTROLLER USER MANUAL Items Parameters Defaults Description current. Generator‘s rated power, standard of load Rated Power (0~6000)kW power. Setting value is percentage of AC generator rated full load current. Delay Over Current (0~200)% value also can be set as fixed time lag or inverse time lag.
  • Page 32 HGM8110DC GENSET CONTROLLER USER MANUAL Items Parameters Defaults Description 2: No action Shutdown when sensor temperature is higher than this value. Detecting only after High Shutdown (0~300)º C safety delay is over. The delay value (default: 3s) also can be set.
  • Page 33 HGM8110DC GENSET CONTROLLER USER MANUAL Items Parameters Defaults Description Digital Input Port 1 Contents Setting (0~55) Remote start On Load. See Table 15 0: Closed to Activate Active Type (0~1) 1: Open to Activate Digital Input Port 2 High Temperature Shutdown...
  • Page 34 HGM8110DC GENSET CONTROLLER USER MANUAL Items Parameters Defaults Description 3: Trip 4: Indication Active Delay (0~20.0)s Time from detecting active to confirm LCD display detailed contents when the Description input is active. Digital Input Port 7 Contents Setting (0~55) Lamp Test. See Table 15...

  • Page 35: Enable Definition Of Programmable Output Ports

    HGM8110DC GENSET CONTROLLER USER MANUAL Items Parameters Defaults Description 0: Output(N/O) Active Type (0~1) 1: Output(N/C) ENABLE DEFINITION OF PROGRAMMABLE OUTPUT PORTS 8.2.1. ENABLE DEFINITION OF PROGRAMMABLE OUTPUT PORTS FORM Table 14 – Definition Content of Programmable Output Ports Type...
  • Page 36 HGM8110DC GENSET CONTROLLER USER MANUAL Type Description Reserved Reserved Close Generator Control generator to take load. Open Breaker Control generator to off load. Reserved Reserved Start Relay Action when genset is cranking and disconnect when Fuel Relay stopped completely. Used for engine which has idles. Close before starting and open when enter into warming up;...
  • Page 37 HGM8110DC GENSET CONTROLLER USER MANUAL Type Description Reserved ECU Warning Indicate ECU sends a warning signal. ECU Shutdown Indicate ECU sends a shutdown signal. Communication Indicate controller not communicates with ECU. Failure Reserved Reserved Reserved Reserved Reserved Reserved Digital Input 1 Active...
  • Page 38 HGM8110DC GENSET CONTROLLER USER MANUAL Type Description Action when controller detects AC generator has over AC Over Power power. Reserved Action when controller detects AC generator has AC Reverse Power reverse power. Action when controller detects AC generator over AC Over Current current.
  • Page 39 HGM8110DC GENSET CONTROLLER USER MANUAL Type Description Exp1 Ch15 High Warn Exp1 Ch15 Low Shut Exp1 Ch15 Low Warn Exp1 Ch16 High Shut Exp1 Ch16 High Warn Exp1 Ch16 Low Shut Exp1 Ch16 Low Warn Exp1 Ch17 High Shut Exp1 Ch17 High Warn...
  • Page 40 HGM8110DC GENSET CONTROLLER USER MANUAL Type Description Reserved 236~239 Reserved 240~279 PLC Flag 1-40 Action when PLC flag is 1. 280~299 Reserved HGM8110DC Genset Controller 2018-12-27 Version 1.1 Page 40 of 60...

  • Page 41: Custom Period Output

    HGM8110DC GENSET CONTROLLER USER MANUAL 8.2.2. CUSTOM PERIOD OUTPUT Defined Period output is composed by 2 parts, period output S1 and condition output S2. While S1 and S2 are TRUE synchronously, OUTPUT; While S1 or S2 is FALSE, NOT OUTPUT.

  • Page 42: Defined Contents Of Configurable Input Ports

    HGM8110DC GENSET CONTROLLER USER MANUAL DEFINED CONTENTS OF CONFIGURABLE INPUT PORTS All active when connect to grand (B-) Table 15 - Enable Programmable Inputs Type Description Including following functions, Indication: indicate only, not warning or shutdown. Warning: warn only, not shutdown.
  • Page 43 HGM8110DC GENSET CONTROLLER USER MANUAL Type Description All shutdown alarms are prohibited except emergence Alarm Stop Inhibit stop.(Means battle mode or override mode) Instrument Mode All outputs are prohibited in this mode. Reserved Controller will set maintenance time and date as default when Reset Maintenance Alarm input is active.

  • Page 44: Selection Of Sensors

    HGM8110DC GENSET CONTROLLER USER MANUAL SELECTION OF SENSORS Table 16 - Sensors Selection Description Remark 0 Not Used 1 User Configured (Resistance) 2 User Config((4-20)mA) 3 User Config.(Voltage) 4 VDO 5 CURTIS Defined resistance‘s 6 VOLVO-EC range is (0~6)KΩ, default...

  • Page 45: Conditions Of Crank Disconnect Selection

    HGM8110DC GENSET CONTROLLER USER MANUAL CONDITIONS OF CRANK DISCONNECT SELECTION Table 17 - Crank Disconnect Conditions Selection Setting description Gen frequency Speed Speed + Gen frequency Oil pressure Oil pressure + Gen frequency Oil pressure + Speed Oil pressure + Speed + Gen frequency...

  • Page 46: Parameters Setting

    HGM8110DC GENSET CONTROLLER USER MANUAL PARAMETERS SETTING CAUTION: 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 and other abnormal conditions may happen.

  • Page 47: Sensors Setting

    HGM8110DC GENSET CONTROLLER USER MANUAL 10 SENSORS SETTING — When reselect sensors, the sensor curve will be transferred into the standard value. For example, if temperature sensor is SGX (120° C resistor type), its sensor curve is SGX (120° C resistor type);...

  • Page 48: Commissioning

    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. — If there is any other question, please contact SmartGen‘s service. HGM8110DC Genset Controller 2018-12-27 Version 1.1...

  • Page 49: Typical Application

    Fig.3 - HGM8110DC Typical Application Diagram NOTE: B+ fuse: minimum 2A, and maximum 20A. Emergency fuse: maximum 32A. customers should select appropriate fuse based on the local situation. Fig.4 - HGM8110DC Expend Module Typical Application Diagram HGM8110DC Genset Controller 2018-12-27 Version 1.1...

  • Page 50: Installation

    Fig.5 - Overall Dimensions 13.2 BATTERY VOLTAGE INPUT HGM8110DC controller can suit for widely range of battery voltage DC(8~35)V. Negative of battery must be connected with the engine shell. Diameter of wire that connects from power supply to battery must be over 2.5mm .

  • Page 51: Ac Input

    HGM8110DC GENSET CONTROLLER USER MANUAL 13.5 AC INPUT Current input of controller must be connected to outside current transformer. And the current transformer‘s secondary side current must be 5A. At the same time, the phases of current transformer and input voltage must correct. Otherwise, the current of collecting and active power maybe not correct.

  • Page 52: Connections Of Controller With J1939 Engine

    HGM8110DC GENSET CONTROLLER USER MANUAL CONNECTIONS OF CONTROLLER WITH J1939 ENGINE 14.1 CUMMINS ISB/ISBE Table 19 - Connector B Terminals of controller Connector B Remark Fuel relay output Start relay output Connect with starter coil directly. Expand 30A relay, battery...

  • Page 53: Cummins Qsx15-Cm570

    HGM8110DC GENSET CONTROLLER USER MANUAL Table 24 – 3 Pins Data Link Connector Terminals of controller 3 pins data link connector Remark CAN communication shielding line CAN GND (connect with ECU terminal only). Using impedance 120Ω connecting line. CAN(H) Using impedance 120Ω connecting line.

  • Page 54: Cummins Qsm11

    HGM8110DC GENSET CONTROLLER USER MANUAL 14.6 CUMMINS QSM11 Table 29 - Engine OEM Connector Terminals of controller OEM connector of engine Remark Fuel relay output Start relay output Connect with starter coil directly CAN communication shielding line (connect CAN GND with controller‘s this terminal only).

  • Page 55: Deutz Emr2

    HGM8110DC GENSET CONTROLLER USER MANUAL 14.9 DEUTZ EMR2 Table 32 - F Connector Terminals of controller F connector Remark Expand 30A relay, battery Fuel relay output voltage of 14 is supplied by relay. Fuse is 16A. Start relay output Connect to starter coil directly.

  • Page 56: Mtu Adec(Smart Module)

    HGM8110DC GENSET CONTROLLER USER MANUAL 14.12 MTU ADEC(SMART MODULE) It is suitable for MTU engine with ADEC (ECU8) and SMART module. Table 35 - ADEC(X1 Connector) Terminals of controller ADEC (X1port) Remark X1 Terminal 9 Connected to negative of Fuel relay output...

  • Page 57: Scania

    HGM8110DC GENSET CONTROLLER USER MANUAL 14.15 SCANIA It is suitable for S6 engine control module. Engine type is DC9, DC12, and DC16. Table 40 - B1 Connector Terminals of controller B1 connector Remark Fuel relay output Start relay output Connect to starter coil directly.

  • Page 58: Volvo-Ems2

    HGM8110DC GENSET CONTROLLER USER MANUAL 14.18 VOLVO-EMS2 Volvo Engine types are TAD734, TAD940, TAD941, TAD1640, TAD1641, and TAD1642. Table 44 - Engine CAN Connector Terminals of controller Engine‘s CAN port Remark ECU stop Auxiliary output 1 Configurable output 1 ―ECU stop‖.

  • Page 59: Ethernet Interface

    — The communication between the controller and monitoring equipment is carried out using TCP ModBus protocol. NOTE: In this connection mode controller parameters can be set. SmartGen provides testing software for this connection mode. Communication protocol can be obtained from the SmartGen service.

  • Page 60: Fault Finding

    HGM8110DC GENSET CONTROLLER USER MANUAL 16 FAULT FINDING Table 49 - Troubleshooting Symptoms Possible Solutions Check starting batteries; Controller no response with power. Check controller connection wirings; Check DC fuse. Check the water/cylinder temperature is too high or not; Genset shutdown Check the genset AC voltage;...

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