Smartgen HGM9120 User Manual
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Smartgen HGM9120 User Manual

Genset amf controller
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HGM9120 Genset AMF Controller
USER MANUAL
Smartgen Technology

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Summary of Contents for Smartgen HGM9120

  • Page 1 HGM9120 Genset AMF Controller USER MANUAL Smartgen Technology...
  • 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.
  • Page 3 Software Version Date Version Note 2014-04-14 Original release This manual is suitable for HGM9120 controller only. Clarification of notation used within this publication. SIGN INSTRUCTION Highlights an essential element of a procedure to ensure correctness. NOTE Indicates a procedure or practice, which, if not strictly observed, could CAUTION! result in damage or destruction of equipment.

  • Page 4: Table Of Contents

    4.4 AUTO START/STOP OPERATION ....................18 4.5 MANUAL START/STOP OPERATION ....................19 4.6 SWITCH CONTROL PROCEDURES ....................20 4.6.1 HGM9120 Switch Control Procedures .................. 20 PROTECTION ......................22 5.1 WARNINGS ............................22 5.2 SHUTDOWN ALARM ........................24 5.3 TRIP AND STOP ALARM ........................26 5.4 TRIP ALARM .............................
  • Page 5 HGM9120 Genset Controller PARAMETERS SETTING .................... 50 SENSORS SETTING ....................51 10 COMMISSIONING ......................52 11 TYPICAL APPLICATION ..................... 53 12 INSTALLATION ......................54 13 GSM SHORT MESSAGE ALARM AND REMOTE CONTROL ........56 13.1 GSM SHORT MESSAGE ALARM ....................56 13.2...

  • Page 6: Overview

    HGM9120 Genset Controller 1 OVERVIEW HGM9120 genset controller is used for genset automation and monitor control system of single unit to achieve automatic start/stop, data measure, alarm protection and “three remote” (remote control, remote measuring and remote communication); especially for auto mains failure (AMF) system composed by generator and mains.

  • Page 7: Performance And Characteristics

    GSM port (GSM MODEM must be fitted, SG361 module produced by Smartgen is recommended.) When genset is alarming, controller can send short messages via SMS automatically to max. 5 telephone numbers.
  • Page 8 HGM9120 Genset Controller phase and phase sequence wrong detection functions; For generator, controller has over and under voltage, over and under frequency, loss of phase, phase sequence wrong, over and reverse power, over current functions; ♦ Earth current detection function (earth fault protection);...
  • Page 9 HGM9120 Genset Controller 50/60Hz units, but also in 400Hz units. ♦ Widely power supply range DC(8~35)V, suitable to different starting battery voltage environment; ♦ 100 pieces event logs; real-time clock; scheduled start & stop generator (can be set as start genset once a day/week/month whether with load or not); scheduled not start (this function can be set in the evening to prevent disturbing the residents);...

  • Page 10: Specification

    HGM9120 Genset Controller 3 SPECIFICATION Items Contents Operating Voltage DC8.0V to DC35.0V, Continuous Power Supply. <3W (standby ≤0.9W) Power Consumption Alternator Input Range 3-Phase 4-Wire AC15V - AC 360V (ph-N) 3-Phase 3-Wire AC30V - AC620V (ph-ph) Single-Phase 2-Wire AC15V - AC360V (ph-N)

  • Page 11: Operation

    HGM9120 Genset Controller 4 OPERATION 4.1 INDICATOR LIGHT HGM9120 HGM9120 Genset Controller Version: 1.0 2014-04-14 Page 11 of 58...

  • Page 12: Key Functions

    HGM9120 Genset Controller 4.2 KEY FUNCTIONS Stop running generator in Auto/Manual mode; Lamp test (press at least 3 seconds); Reset alarm Stop in stop mode; During stopping process, press this button again to stop generator immediately. Start Start genset in Manual/Test mode.
  • Page 13 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 all information in the controller page of “ABOUT” to us.

  • Page 14: Lcd Display

    HGM9120 Genset Controller 4.3 LCD DISPLAY 4.3.1 MAIN DISPLAY Main screen shows pages; use to scroll the pages and to scroll the screen. ★Status, including as below, Genset status, mains status, and switch close/open status ★Engine, including as below, Speed, engine temperature, engine oil pressure, liquid (fuel) level, canopy temperature, oil temperature, Configure Sensor 1, Configure Sensor 2, battery voltage, charger voltage, accumulated run time, accumulated start times.
  • Page 15 HGM9120 Genset Controller Power Active Inactive Conditions Remark Factor Power Power Load is inductive resistance. COS>0L P>0,Q>0 Input Input Load is capacitance resistance. COS>0C P>0,Q<0 Input Output Load equal to one under excitation COS<0L P<0,Q>0 Output Input generator Load equal to one over excitation COS<0C...

  • Page 16: Parameters Setting Menu

    HGM9120 Genset Controller 4.3.2 PARAMETERS SETTING MENU Parameter setting Including as following, ★Mains settings ★Timer settings ★Engine settings ★Generator settings ★Load settings ★Switch settings ★Analog sensor settings ★Input port settings ★Output port settings ★Module settings ★Scheduling and maintenance settings ★GSM settings...
  • Page 17 HGM9120 Genset Controller Over Voltage Warn Form 4: Enable choice: Disable Enter setting menu (Form 5)‚ Set value: 00110% back to previous Return value: 00108% menu (Form 3). Delay: 00005 Over Voltage Warn Form 5: Enable choice: Disable to scroll settings (Form 6)‚...

  • Page 18: Auto Start/Stop Operation

    Starting Sequence, 1. HGM9120: When Mains is abnormal (over and under voltage, over and under frequency, loss of phase, phase sequence wrong), it enters into mains “abnormal delay” and LCD display count down time. When mains abnormal delay is over, it enters into “start delay”;...

  • Page 19: Manual Start/Stop Operation

    HGM9120 Genset Controller into this mode when “remote start on load” is inactive. When stop delay is over, close generator relay is un-energized; generator enters into “cooling down time”. After “transfer rest time”, close mains relay is energized; mains will accept load;...

  • Page 20: Switch Control Procedures

    HGM9120 Genset Controller 4.6 SWITCH CONTROL PROCEDURES 4.6.1 HGM9120 SWITCH CONTROL PROCEDURES Manual transfer procedures When controller is in Manual mode, the switch control procedures will start through manual transfer procedures. Users can control the loading transfer of ATS via pressing button.
  • Page 21 HGM9120 Genset Controller Mains load is transferred into generator load, after the delay of switch off and transfer interval, generator switch on. Detecting transfer fail while generator switch on. After detecting time out, if switch on fail, then wait for generator switch on. If transfer fail and warning “SELECT Enable”, there is alarming signal.

  • Page 22: Protection

    HGM9120 Genset Controller 5 PROTECTION 5.1 WARNINGS When controller detects the warning signal, alarm only and not stop genset. Warnings as following, Type Description When controller detects the speed is higher than the set Over Speed Warn value, it will send warn signal.
  • Page 23 HGM9120 Genset Controller Type Description When controller detects the temperature is higher than the High Temp. Warn set value, it will send warn signal. When controller detects the temperature is lower than the set Low Temp. Warn value, it will send warn signal.

  • Page 24: Shutdown Alarm

    HGM9120 Genset Controller 5.2 SHUTDOWN ALARM When controller detects shutdown alarm, it will send signal to stop the generator. Shutdown alarms as following, Type Description When controller detects emergency stop signal, it will send a Emergency Stop stop signal. When controller detects the speed value is higher than the Over Speed set value, it will send a stop signal.
  • Page 25 HGM9120 Genset Controller Type Description When controller detects the temperature is higher than the High Oil Temp. Warn set value, it will send warn signal. Canopy Temperature When controller detects the sensor is open circuit, and the action select “warn”, it will send warn signal.

  • Page 26: Trip And Stop Alarm

    HGM9120 Genset Controller 5.3 TRIP AND STOP ALARM When controller detects trip and stop alarm signal, it will shutdown generator quickly and stop after high speed cooling. Trip and stop alarm as following, Type Description When controller detects the value is higher than the set value, and the action select “trip and stop”, it will send trip...

  • Page 27: Trip Alarm

    HGM9120 Genset Controller 5.4 TRIP ALARM When controller detects trip alarm, it will break close generator signal quickly, but genset not stop. Trip alarm as following, Type Description When controller detects the value is higher than the set Over Current value, and the action select “trip”, it will send trip signal.

  • Page 28: Wirings Connection

    HGM9120 Genset Controller 6 WIRINGS CONNECTION HGM9120 controller‟s rear as following: Description of terminal connection: Cable Function Remarks Size DC input B- 2.5mm Connected with negative of starter battery Connected with positive of starter battery. If DC input B+ 2.5mm wire length is over 30m, better to double wires in parallel.
  • Page 29 HGM9120 Genset Controller Cable Function Remarks Size Ground connected High Temp. 1.0mm active (B-) Ground connected Low Oil Temperature 1.0mm active (B-) Ground connected Low Fuel Level 1.0mm active (B-) Details see form Ground connected Remote Start 1.0mm active (B-)
  • Page 30 HGM9120 Genset Controller Cable Function Remarks Size Genset N-wire input 1.0mm Connected to N-wire of gen-set CT A-phase sensing Outside connected to secondary coil of current 1.5mm input transformer(rated 5A) CT B-phase sensing Outside connected to secondary coil of current 1.5mm...

  • Page 31: Scopes And Definitions Of Programmable Parameters

    HGM9120 Genset Controller 7 SCOPES AND DEFINITIONS OF PROGRAMMABLE PARAMETERS 7.1 CONTENTS AND SCOPES OF PARAMETERS Form 1 Items Parameters Defaults Description Mains Setting 0: 3P4W; 1: 3P3W; 2: 2P3W; 3: 1P2W. AC System (0~4) 4: Mains inactive (Do not detect and...
  • Page 32 HGM9120 Genset Controller Items Parameters Defaults Description Alarms for low oil pressure, high Safety temperature, under speed, under (0~3600)s Delay frequency/voltage, charge fail inactive. Start Idle Idle running time of genset when (0~3600)s Time starting. Warming Up Warming time between genset switch...
  • Page 33 HGM9120 Genset Controller Items Parameters Defaults Description Under Speed can be set. (0~200)% Warn Battery Rated Standard detecting over/under (0~60.0)V 24.0 Voltage voltage of battery. Battery Over (0~200)% Setting value is percentage of rated Volts voltage of battery; delay value and Battery Under return values can be set.
  • Page 34 HGM9120 Genset Controller Items Parameters Defaults Description Setting value percentage generator rated voltage. Controller Loading (0~200)% detects when it is ready to load. When Voltage generator voltage under load voltage, won‟t enter into normally running. Rated To offer standards for detecting of (10.0~600.0)Hz 50.0...
  • Page 35 HGM9120 Genset Controller Items Parameters Defaults Description value can be set as definite time and inverse definite minimum time. Over Power (0~1) 0: Disable 1: Enable. Reverse (0~1) 0: Disable 1: Enable. Power Earth Current (5~6000)/5 The ratio of external earth CT.
  • Page 36 HGM9120 Genset Controller Items Parameters Defaults Description be added.) Scheduling And Maintenance Setting Scheduled (0~1) 0: Disable; 1: Enable Scheduled (0~1) 0: Disable; 1: Enable Not Run Maintenance (0~1) 0: Disable; 1: Enable Analog Sensors Setting Temperature Sensor Curve Types (0~15) SGX.
  • Page 37 HGM9120 Genset Controller Items Parameters Defaults Description Curve Types (0~15) SGX. See form 4 Open Circuit (0~2) 0: Warn; 1: Shutdown; 2: No action Action Shutdown when sensor temperature High Temp. higher than this value. Detecting only (0~300)º C Shutdown after safety delay is over.
  • Page 38 HGM9120 Genset Controller Items Parameters Defaults Description LCD display detailed contents when Description the input is active. Low Oil Pressure Input Active Type (0~1) 0: Closed to active 1: Open to active 0: From safety on 1: From starting Arming...
  • Page 39 HGM9120 Genset Controller Items Parameters Defaults Description Active Delay (0~20.0)s Time from detecting active to confirm LCD display detailed contents when Description the input is active. Flexible Input Port 3 Contents (0~50) User defined. See form 3 Setting Active Type...

  • Page 40: Enable Definition Of Programmable Output Ports

    HGM9120 Genset Controller 7.2 ENABLE DEFINITION OF PROGRAMMABLE OUTPUT PORTS Form 2 Type Description Not Used Custom Period 1 Custom Period 2 Custom Period 3 Custom Period 4 Custom Period 5 Custom Period 6 Details of function description please see the following.
  • Page 41 HGM9120 Genset Controller Close Generator Control generator to take load. Open Breaker Control generator to off load. Close Mains Control mains to take load. Reserved Start Relay Action when genset cranking Fuel Relay disconnect when stopped completely. Used for engine which has idles. Close before starting and open in warming up delay;...
  • Page 42 HGM9120 Genset Controller Reserved Reserved Reserved Reserved Reserved Reserved Aux Input 1 Active Action when input port 1 is active Aux Input 2 Active Action when input port 2 is active Aux Input 3 Active Action when input port 3 is active...
  • Page 43 HGM9120 Genset Controller Mains Under Volt Mains Reverse Phase Mains Loss of Phase 132~138 Reserved High Temp Warn Action when hi-temperature warning. Low Temp Warn Action when low temperature warning. High Temp Shutdown Action when hi-temperature shutdown alarm. Reserved Low OP Warn Action when low oil pressure warning.

  • Page 44: Custom Period Output

    HGM9120 Genset Controller Reserved 7.2.1 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. Period output S1, can set generator‟s one or more period output freely, can set the delayed time and output time after enter into period.
  • Page 45 HGM9120 Genset Controller include themselves. Example, Contents of probably condition output S1: output port 1 is active; Close when probably condition output S1 is active /inactive: close when active (disconnect when inactive); Contents of probably condition output S2, output port 2 is active;...

  • Page 46: Grand (B-))

    HGM9120 Genset Controller 7.3 DEFINED CONTENTS OF CONFIGURABLE INPUT PORTS (ALL ACTIVE WHEN CONNECT TO GRAND (B-)) Form 3 Type Description Including following functions, Indication: indicate only, not warning or shutdown. Warning: warn only, not shutdown. Shutdown: alarm and shutdown immediately...
  • Page 47 HGM9120 Genset Controller mode; keys except are inactive, and will show in the first line of LCD display. When input is active, controller won‟t work under Auto Mode Invalid Auto mode. key and simulate auto key input does not work.

  • Page 48: Selection Of Sensors

    HGM9120 Genset Controller Reserved Reserved In Auto mode, mains are normal when input is Aux Mains OK active. In Auto mode, mains are abnormal when input is Aux Mains Fail active. Alternative Config1 Users can set different parameters to make it easy Alternative Config2 to select current configuration via input port.

  • Page 49: Conditions Of Crank Dinsconnect Selection

    HGM9120 Genset Controller Description Remark 0 Not used Defined resistance‟s 1 Custom Res Curve 0~6KΩ, 2 Custom 4-20mA curve range Fuel Level Sensor 3 SGD default 4 SGH sensor. 5~15 Reserved NOTE: User should make special declare when order controller if your genset equip with sensor of 4~20mA.

  • Page 50: Parameters Setting

    HGM9120 Genset Controller 8 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. NOTE: Maximum set value must over minimum set value in case that the condition of too high as well as too low will happen.

  • Page 51: Sensors Setting

    HGM9120 Genset Controller 9 SENSORS SETTING 1. 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); if select the SGD (120° C resistor type), the temperature sensor curve is SGD curve.

  • Page 52: Commissioning

    ATS as generator load. If not like this, please check ATS‟ wires connection of control part according to this manual. 9. If there is any other question, please contact Smartgen‟s service. HGM9120 Genset Controller Version: 1.0...

  • Page 53: Typical Application

    HGM9120 Genset Controller 11 TYPICAL APPLICATION HGM9120 typical application diagram Note: Fuse F1：min. 2A; max. 20A. Fuse F2：max. 32A. Users should select suitable fuse depend on practical application. HGM9120 Genset Controller Version: 1.0 2014-04-14 Page 53 of 58...

  • Page 54: Installation

    Battery Voltage Input NOTE: HGM9120 controller can suit for widely range of battery voltage DC(8~35)V. Negative of battery must be connected with the engine shell. The diameter of wire which from power supply to battery must be over 2.5mm...
  • Page 55 HGM9120 Genset Controller current), in order to prevent disturbance to controller or others equipment. 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.

  • Page 56: Gsm Short Message Alarm And Remote Control

    Warnings are sent to the phone according to the pre-set. 13.2 GSM SHORT MESSAGE REMOTE CONTROL Users send order message to GSM MODEM (SG361 module produced by Smartgen is recommended), then controller will make actions according to this SMS order and pass back corresponding operations information.
  • Page 57 HGM9120 Genset Controller MANUAL SMS MANUAL MODE OK Set as manual mode MODE SMS AUTO SMS AUTO MODE OK Set as auto mode MODE Pass back information can controller Gets details information of genset. DETAIL software. INHIBIT INHIBIT START OK Generator start will be inhibited.

  • Page 58: Fault Finding

    HGM9120 Genset Controller 14 FAULT FINDING Symptoms Possible Solutions Check starting batteries; Controller no response with Check controller connection wirings; power. Check DC fuse. Check the water/cylinder temperature is too high or not; Genset shutdown Check the genset AC voltage;...

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