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Smartgen HGM8100A User Manual
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Smartgen HGM8100A User Manual

Genset controller
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HGM8100A GENSET CONTROLLER
(HGM8110A/HGM8120A)
(VFD DISPLAY)
USER MANUAL
SMARTGEN (ZHENGZHOU) TECHNOLOGY CO., LTD.

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Summary of Contents for Smartgen HGM8100A

  • Page 1 HGM8100A GENSET CONTROLLER (HGM8110A/HGM8120A) (VFD DISPLAY) 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 This manual is suitable for HGM8110A/HGM8120A controller only. Clarification of notation used within this publication. 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 CONTENT OVERVIEW ............................... 6 PERFORMANCE AND CHARACTERISTICS ................... 7 SPECIFICATION ............................ 10 OPERATION ............................11 4.1 KEY FUNCTION ..........................11 4.2 INDICATOR LIGHT .......................... 12 4.3 LCD DISPLAY ..........................13 4.3.1 MAIN DISPLAY ........................13 4.3.2 BASIC PARAMETER SETTING MENU ................14 4.3.3 ADVANCED PARAMETERS SETTING ................
  • Page 5 7.5 CONDITIONS OF CRANK DISCONNECT SELECTION ..............48 PARAMETER EDITING .......................... 49 SENSORS SETTING ..........................51 10 COMMISSIONING ..........................52 11 TYPICAL APPLICATION ........................53 12 INSTALLATION ............................. 55 12.1 BATTERY VOLTAGE INPUT ......................55 12.2 SPEED SENSOR INPUT ........................55 12.3 OUTPUT AND EXPAND RELAYS ....................
  • Page 6 1 OVERVIEW HGM8110A/8120A genset controllers are especially designed for extremely high/low temperature environment (-40~+70)°C. The controllers can operate reliably in extreme temperature conditions with the help of VFD display and the components that resist extreme temperature. All display information is Chinese (English is optional). Operation information, status information and faults information are all displayed which make commissioning convenience for factory personnel.
  • Page 7 2 PERFORMANCE AND CHARACTERISTICS ♦ HGM8100A series controller has two types: HGM8110A: ASM (Automatic Start Module), used for single automation systems; HGM8120A: AMF (Auto Mains Failure), updates based on HGM8110A, moreover, has mains electric quantity monitoring and mains/generator automatic transfer control function, especially for automatic system composed by generator and mains;...
  • Page 8 ♦ 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 Speed (RPM) Voltage of Battery (VB) V (unit) Voltage of Charger (VD) V (unit)
  • Page 9 ♦ Real time clock and run time accumulation function. 99 pieces of event logs can be circularly stored and inquired on the spot; also can be print or be inquired via PC; ♦ Scheduled start & stop generator (can be set as start genset once a week/month); ♦...
  • Page 10 3 SPECIFICATION Table 3 Technical Parameters Item Content Operating Voltage DC8. 0V to 35. 0V, Continuous Power Supply Power Consumption <6W (Standby mode: ≤3W) Alternator Input Range 3-Phase 4 Wire AC20V - AC360V (ph-N) 3-Phase 3 Wire AC30V - AC600V (ph-ph) Single-Phase 2 Wire AC20V - AC360V (ph-N) 2-Phase 3 Wire...
  • Page 11 CAUTION: 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. HGM8110A/8120A Genset Controller User Manual...
  • Page 12 4.2 INDICATOR LIGHT Table 5 Alarm Indicator Alarm Type Alarm Indicator Warning Slow flashing (1 time per sec) Trip Alarm Slow flashing (1 time per sec) Shutdown Alarm Fast flashing (5 times per sec) Trip and Stop Alarm Fast flashing (5 times per sec) Generator normal light: It is light on when generator is normal;...
  • Page 13 4.3 LCD DISPLAY 4.3.1 MAIN DISPLAY Main screen is used to display real time data of all parameters, use to scroll the screen and view parameters. ★Status, including as below, Status of genset, mains (HGM8120A), and ATS. ★Mains, including as below Phase voltage, Line voltage, frequency.
  • Page 14 Table 6 Power Factor Power Factor Conditions Active Power Reactive Power Remark COS>0L P>0, Q>0 Input Input Load is inductive resistance. COS>0C P>0, Q<0 Input Output Load is capacitance resistance. Load equal under COS<0L P<0, Q>0 Output Input excitation generator Load equal to one over excitation COS<0C P<0, Q<0...
  • Page 15 ★Rated Speed ★Gen Rated Voltage ★Gen Rated Frequency ★CT Ratio ★Rated Current ★Rated Power ★Battery Voltage ★Date and Time ★Start Delay ★Stop Delay ★Pre-heat Delay ★Cranking Time ★Crank Rest Time ★Safety On Delay ★Start Idle Time ★Warming Up Time ★Cooling Time ★Stop Idle Time ★ETS Solenoid Hold ★Fail to Stop Delay...
  • Page 16 4.3.3 ADVANCED PARAMETERS SETTING Advanced parameter setting including as following, ★Mains settings ★Timer settings ★Engine settings ★Generator settings ★Load settings ★ATS settings ★Analog sensor settings ★Input port settings ★Output port settings ★Module settings ★Scheduling and maintenance settings Example, Advanced Parameters Setting Form 1: are used for changing the setting >Mains...
  • Page 17 Gen Overvolt Warn Form 5: are used for changing the setting contents Sel: Disable (form 6). Confirm setting (form 7), return to Set Value: 00110% Return Value: 00108% previous menu (form 4) Delay: 00005 Gen Overvolt Warn Form 6: are used for changing the setting contents Sel: Disable (form 5).
  • Page 18 4.4 AUTOMATIC START/STOP OPERATION Press , its indicator lights, and controller enters Auto mode. Starting Sequence, HGM8120A: When Mains is abnormal (over and under voltage, over and under frequency), it enters into mains “abnormal delay” and VFD displays count down time. When mains abnormal delay is over, it enters into “start delay”;...
  • Page 19 power supply indicator is extinguishing, and mains power supply indicator is illuminated; Idle relay is output when the controller enters “stop idle delay”; Enter into “ETS delay” and ETS relay is active. Fuel relay output is disconnected; Genset can automatically judge if it is steady when the controller enters “Genset after stop time”; After genset stops steadily, enter generator standby status;...
  • Page 20 4.6 GENSET CONTROLLER ATS CONTROL PROCEDURES 1. HGM8120A ATS CONTROL PROCEDURES 1) If input port is configured as Closed Auxiliary A. If “Open breaker detect” is “Enable” When transferring load from mains to generator, controller begins detecting “fail to transfer”, then the open delay and transfer rest delay will begin.
  • Page 21 (shutdown, trip and stop, manual/auto start/stop) and corresponding time. Press key to view records backward. Again press key to return real time display status of the controller. HGM8100A controller can save recent 99-piece event log records. HGM8110A/8120A Genset Controller User Manual Page 21 of 57...
  • Page 22 5 PROTECTION 5.1 WARNING When controller detects the warning signal, it sends alarm only and doesn’t stop the genset, besides, the VFD displays the warning information. Table 7 Warning Alarm Type Description When controller detects the speed is higher than the set value, it Over Speed Warn will send warn signal.
  • Page 23 Type Description When controller detects the generator loss phase, it will send Gen Loss of Phase warn signal. Gen Reverse Phase When controller detects the reverse phase, it will send warn Sequence signal. When controller detects the switch on and off fail, and the Switch Fail Warn action is selected enable, it will send warn signal.
  • Page 24 5.2 SHUTDOWN ALARM When controller detects shutdown alarm, it will send generator close signal and stop the generator immediately. Table 8 Shutdown Alarm Type Description When controller detects emergency stop signal, it will send stop Emergency Stop signal. When controller detects the speed value is higher than the set Over Speed value, it will send stop signal.
  • Page 25 Type Description value, it will send stop signal. When controller detects sensor is open circuit, and the action OP Sensor Open selects “Shutdown”, it will send stop signal. When controller detects oil pressure is lower than the set value, Low OP Shutdown it will send stop signal.
  • Page 26 5.3 TRIP AND STOP ALARM When controller detects trip and stop alarm signal, it will break generator close signal quickly and stop the genset after high speed cooling. Table 9 Trip and Stop Alarm Type Description When controller detects the value is higher than the set value, Over Current and the action selects “Trip and Stop”, it will send trip and stop signal.
  • Page 27 6 WIRING CONNECTION Compared with HGM8120A, HGM8110A has no 3-phase mains voltage input terminal. The back panel of HGM8110A and HGM8120A controller is shown as follows: Fig.1 HGM8110A/HGM8120A Back Panel Table 11 Terminal Wiring Connection Description Cable Size Function Remarks DC input B- Connected with negative of starter battery.
  • Page 28 Cable Size Function Remarks active (B-) Ground connected is Aux. Input 4 active (B-) Ground connected is Aux. Input 5 active (B-) Ground connected is Aux. Input 6 active (B-) Common grounded; Connected with Magnetic Pickup enclosure or negative of starter battery. Magnetic Pickup + Connected to speed sensor Magnetic Pickup -...
  • Page 29 Cable Size Function Remarks Genset N-wire input Connected to N-wire of genset. A-phase sensing Outside connected to secondary coil of input current transformer (rated 5A). B-phase sensing Outside connected to secondary coil of input current transformer (rated 5A). C-phase sensing Outside connected to secondary coil of input current transformer (rated 5A).
  • Page 30 SCOPES AND DEFINITIONS OF CONFIGURABLE PARAMETERS HGM8110A/8120A genset controllers can set the following parameters, (HGM8110A has no mains items) 7.1 CONTENTS AND SCOPES OF PARAMETERS Table 12 Parameter Setting Contents and Scopes Items Parameters Defaults Description Mains Setting 0: 3P4W; 1: 3P3W; AC System (0~3) 2: 2P3W;...
  • Page 31 Items Parameters Defaults Description Start Idle Time (0~3600)s Idle running time of genset when starting. Warming Up Warming time between genset switch on (0~3600)s Time and high speed running. Radiating time before genset stop, after it Cooling Time (0~3600)s unloads. Stop Idle Time (0~3600)s Idle running time when genset stop.
  • Page 32 Items Parameters Defaults Description Battery Rated Standard for detecting over/under voltage (0~60.0)V 24.0 Voltage of battery. Battery Over (0~200)% Setting value is percentage of rated Volts voltage of battery. Delay value & return Battery Under value also can be set. (0~200)% Volts In normal running, when charger D+(WL)
  • Page 33 Items Parameters Defaults Description under load voltage, genset won’t enter into normally running. Rated To offer standards for detecting of (10.0~600.0) Hz 50.0 Frequency over/under/load frequency. Setting value is percentage of generator Loading rated frequency. When generator (0~200)% Frequency frequency under load frequency, it won’t enter into normal running.
  • Page 34 Items Parameters Defaults Description generator switch on; or from generator switch off to mains switch on. Pulse width of mains/generator switch on. Close Time (0~20.0)s When it is 0, means output constantly. Pulse width of mains/generator switch Open Time (0~20.0)s off.
  • Page 35 Items Parameters Defaults Description Temp. (0~1) 0: Disable; 1: Enable Warn Oil Pressure Sensor Curve Type (0~15) SGX. See table 15. Open Circuit (0~2) 0: Warn 1: Shutdown 2: No action Action Shutdown when oil pressure lower than this value. Detecting only after safety (0~1000)kPa Shutdown delay is over.
  • Page 36 Items Parameters Defaults Description 0: Closed to active Active Type (0~1) 1: Open to active Flexible Input Port 4 Contents (0~50) User defined. See table 14. Setting 0: Closed to active Active Type (0~1) 1: Open to active 0: From safety on 1: From starting Active Range (0~3) Always 3: Never...
  • Page 37 Items Parameters Defaults Description Contents (0~239) Common alarm. See table 13. Setting Active Type (0~1) 0: Normally open; 1: Normally close Flexible Output Port 3 Contents (0~239) ETS solenoid hold. See table 13. Setting Active Type (0~1) 0: Normally open; 1: Normally close Flexible Output Port 4 Contents (0~239)
  • Page 38 7.2 ENABLE DEFINITION OF PROGRAMMABLE OUTPUT PORTS 1-6 7.2.1 DEFINED CONTENTS OF PROGRAMMABLE OUTPUT PORTS 1-6 Table 13 Defined Contents of Programmable Output Ports 1-6 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 39 Type Description Reserved Reserved Close Generator Control generator to take load. Open Breaker Control breaker to off load. Close Mains Control mains to take load. Reserved Crank Relay Action when genset is starting and disconnect when Fuel Relay stop is completed. Used for machine which has idles.
  • Page 40 Type Description Reserved Reserved Reserved Reserved Reserved 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 Aux Input 4 Active Action when input port 4 is active Aux Input 5 Active...
  • Page 41 Type Description power. Reserved Action when controller detects generator have reverse Reverse Power power. Over Current Action when over current. Reserved Mains Inactive Mains Over Freq Mains Over Volt Mains Under Freq Mains Under Volt Mains Reverse Phase Mains Loss of Phase 132~138 Reserved High Temp Warn...
  • Page 42 Type Description Reserved Reserved Reserved 7.2.2 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. 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 43 Example, Contents of OR condition output S1: output port 1 is active; Close when OR condition output S1 is active/inactive: close when active (disconnect when inactive); Contents of OR condition output S2, output port 2 is active; Close when OR condition output S2 is active/inactive: close when active (disconnect when inactive); Contents of AND condition output S3: output port 3 is active;...
  • Page 44 7.3 DEFINED CONTENTS OF CONFIGURABLE INPUT PORTS 1-6 Table 14 Defined Contents of Configurable Input Ports (All GND Connected (B-) Active) 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 shuts down Users Configured after high-speed cooling...
  • Page 45 Type Description mode. key and simulate auto key input does not work. Reserved Reserved All shutdown alarms are prohibited except emergence Inhibit Alarm Stop stop. (Means battle mode or override mode) Aux Instrument Mode All outputs are prohibited in this mode. Reserved Controller will set maintenance time and date as default Reset Maintenance...
  • Page 46 Type Description (HGM8120A). Alternative Config1 When input is active, alternative configuration is active. It Alternative Config2 can set different parameters, which makes it easy to select current configuration via input port. Alternative Config3 Reserved HGM8110A/8120A Genset Controller User Manual Page 46 of 57...
  • Page 47 7.4 SELECTION OF SENSORS Table 15 Sensors Selection Description Remark 0 Not used 1 Custom Res Curve 2 Custom 4-20mA curve 3 VDO 4 CURTIS Defined resistance’s 5 VOLVO-EC Temperature Sensor range is 0~6KΩ, default 6 DATCON is SGX sensor. 7 SGX 8 SGD 9 SGH...
  • Page 48 7.5 CONDITIONS OF CRANK DISCONNECT SELECTION Table 16 Crank Disconnect Conditions Selection Setting description Gen frequency Speed sensor Speed sensor + Gen frequency Oil pressure Oil pressure + Gen frequency Oil pressure + Speed sensor Oil pressure + Speed sensor + Gen frequency NOTE: There are 3 conditions to make starter disconnected with engine, that is, speed sensor, generator frequency and engine oil pressure.
  • Page 49 8 PARAMETER EDITING 1) Advanced Parameters Setting: After controller start, Input Password press advanced parameter password 0**** confirmation interface (picture on the right). Press “+” and “-” to increase or decrease values and input the corresponding password; press “√” key to right move the bit, in fourth bit press “√” key to check password. If password is correct, enter into advanced parameter setting interface, otherwise, exit directly.
  • Page 50 NOTE: Maximum set value must over minimum set value in case that the condition of too high as well as too low will happen. NOTE: When setting the warning alarm, please set the correct return value; otherwise, maybe there is abnormal alarm. When setting the maximum value, the return value must less than set value;...
  • Page 51 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. 2.
  • Page 52 ATS as generator load. If not like this, please check ATS’ wires connection of control part according to this manual; If there is any other question, please contact Smartgen’s service. HGM8110A/8120A Genset Controller User Manual...
  • Page 53 11 TYPICAL APPLICATION Fig.3 HGM8110A Typical Application Diagram Fig.4 HGM8120A Typical Application Diagram NOTE: If the engine starting battery voltage is 24V, starting output, fuel output and stop output (according to user’s configuration) should not be less than 2Ω for battery cathode resistance, if less than 2Ω, please expand relays with more than 30A current in corresponding output.
  • Page 54 Fig.5 3 Phase 3 Wire Connection Diagram (take HGM8120A for example) Single Phase 2 Wire (take HGM8120A for example) Fig.6 Single Phase 2 Wire Connection Diagram (take HGM8120A for example) Fig.7 2 Phase 3 Wire Connection Diagram (take HGM8120A for example) HGM8110A/8120A Genset Controller User Manual Page 54 of 57...
  • Page 55 12 INSTALLATION The installation dimension of HGM8110A is just the same with HGM8120A. 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, Fig.8 Overall and Cutout Dimensions 12.1 BATTERY VOLTAGE INPUT NOTE: HGM8110A/8120A controller can suit for widely range of battery voltage DC (8~35)V.
  • Page 56 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. NOTE: ICOM port must be connected to negative pole of battery. WARNING! When there is load current, transformer’s secondary side is prohibited open circuit.
  • Page 57 13 FAULT FINDING Here are the common faults and troubleshooting. If there is any other problem, please feel free to contact Smartgen’s service. Table 18 Fault Finding Symptoms Possible Solutions Check starting batteries; Controller response with Check controller connection wirings;...

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Hgm8120a