Smartgen HGM7110DC User Manual
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Smartgen HGM7110DC User Manual

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HGM7110DC DC Genset Controller
USER MANUAL
ZHENGZHOU SMARTGEN TECHNOLOGY CO.,LTD

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Summary of Contents for Smartgen HGM7110DC

  • Page 1 HGM7110DC DC Genset Controller USER MANUAL ZHENGZHOU SMARTGEN TECHNOLOGY CO.,LTD...
  • Page 2 All rights reserved. No part of this publication may be reproduced in any material form (including photocopying or storing in any medium by electronic means or other) without the written permission of the copyright holder. Smartgen Technology reserves the right to change the contents of this document without prior notice. Version history...
  • Page 3 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. 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

    HGM7110DC Genset Controller Contents OVERVIEW ........................6 PERFORMANCE AND CHARACTERISTICS ..............7 SPECIFICATION ......................10 OPERATION ........................11 4.1. PUSHBUTTONS ....................11 4.2. LCD DISPLAY ....................12 4.2.1. MAIN DISPLAY .................... 12 4.2.2. PARAMETERS SETTING MENU ..............12 4.3. AUTO START/STOP OPERATION ..............15 4.4.
  • Page 5 HGM7110DC Genset Controller 14.4 CUMMINS QSX15-CM570 ................61 14.5 CUMMINS GCS-MODBUS ................62 14.6 DETROIT DIESEL DDEC III / IV ................ 62 14.7 DEUTZ EMR2 ....................63 14.8 JOHN DEERE ....................63 14.9 MTU MDEC ....................... 64 14.10 PERKINS ......................64 14.11...

  • Page 6: Overview

    HGM7110DC Genset Controller 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.

  • Page 7: Performance And Characteristics

    HGM7110DC Genset Controller 2 PERFORMANCE AND CHARACTERISTICS HGM7110DC： Control the genset to start/stop by detecting the accumulator voltage or charger current.  With ARM-based 32-bit SCM, highly integrated hardware, new reliability level;  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;...
  • Page 8 HGM7110DC Genset Controller  Collects and shows parameters: Accumulator Accumulator Voltage (after the compensation) Accumulator Temperature Accumulator Charge Current Accumulator Discharge Current Load Current Generator Current  Accumulator over voltage, under voltage protection functions;  3 fixed analog sensors (temperature, oil pressure and liquid level);...
  • Page 9 HGM7110DC Genset Controller once a day/week/month);  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;  All parameters used digital adjustment, instead of conventional analog modulation with normal potentiometer, more reliability and stability;...

  • Page 10: Specification

    HGM7110DC Genset Controller 3 SPECIFICATION Parameter Details Working Voltage DC8. 0V to 35. 0V, continuous power supply <3W (Standby mode: ≤2W) Overall Consumption Speed Sensor Voltage 1. 0 V to 24 V (RMS) Speed Sensor Frequency Maximum 10,000 Hz Start Relay Output...

  • Page 11: Operation

    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 12: Lcd Display

    HGM7110DC Genset Controller 4.2. LCD DISPLAY 4.2.1. MAIN DISPLAY Main screen show pages; use 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，...
  • Page 13 HGM7110DC Genset Controller ★ Timer settings ★ Engine settings ★ Load settings ★ ATS settings ★ Analog sensor settings ★ Input port settings ★ Output port settings ★ Module settings ★ Scheduling and maintenance settings ★ GSM settings Example: Advanced Parameters Form 1: >...
  • Page 14 HGM7110DC Genset Controller Form 5: Charge OC Sel：Disable to scroll settings (form 6), to enter settings Set Value： 00110% Return Value： 00108% (form 7), to exit settings menu. (form 4) Delay： 00005 Form 6: Charge OC Sel：Disable to scroll settings (form 5), to enter settings Set Value：...

  • Page 15: Auto Start/Stop Operation

    HGM7110DC Genset Controller 4.3. AUTO START/STOP OPERATION Auto mode is selected by pressing the button; a 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)”...
  • Page 16 HGM7110DC Genset Controller 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.

  • Page 17: Manual Start/Stop Operation

    HGM7110DC Genset Controller 4.4. MANUAL START/STOP OPERATION Manual mode is selected by pressing the button; a LED besides the button will illuminate to confirm the operation; Then press button to start the generator, it can automatically judge crank success and accelerate to high speed running. If high...

  • Page 18: Switch Control Procedures

    HGM7110DC Genset Controller 5 SWITCH CONTROL PROCEDURES 5.1 ACCUMULATOR/GENSET PRIORITY SYSTEM: Charging： Igen = Iacc + Iload； Non-charging：Igen = 0，Iacc = -Iload； Charging： Iacc = Igen - Iload； Non-charging：Iacc = -Iload； HGM7110DC Genset Controller Version: 1.0 2014-09-27 Page 18 of 68...
  • Page 19 HGM7110DC Genset Controller Charging： Iload = Igen - Iacc； Non-charging：Iacc = xxx，Iload = xxx，Igen = 0； Accumulator Priority System: In Auto mode, K2 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.

  • Page 20: Two Accumulator Priority System

    HGM7110DC Genset Controller 5.2 TWO ACCUMULATOR PRIORITY SYSTEM 1# Acc Charging：Iacc1 = Igen; 1# Acc on-load：Iacc1 = -Iload; 2# Acc Charging：Iacc2 = Igen; 2# Acc on-load：Iacc2 = -Iload; 1. Accumulator Switching Mode: Gap 1# Accumulator 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).
  • Page 21 HGM7110DC Genset Controller 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.

  • Page 22: Protections

    HGM7110DC Genset Controller 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: Type Description When the controller detects that the genset speed has Over Speed exceeded the pre-set value, it will initiate a warning alarm.
  • Page 23 HGM7110DC Genset Controller Type Description When the controller detects that the oil pressure has fallen Low Oil Pressure below the pre-set value, it will initiate a warning alarm. When the controller detects that the level sensor is open Level Sensor Open circuit and the action select “Warn”, it will initiate a warning...

  • Page 24: Shutdown Alarm

    HGM7110DC Genset Controller 6.2 SHUTDOWN ALARM When controller detects shutdown alarm, it will send signal to open breaker and shuts down generator. Shutdown alarms as following: Type Description When the controller detects an emergency stop alarm signal, Emergency Stop it will initiate a shutdown alarm.
  • Page 25 HGM7110DC Genset Controller Type Description When the controller detects that the level sensor is open Level Sensor Open circuit and the action select “Shutdown”, it will initiate a Circuit shutdown alarm. When the controller detects that the flexible sensor 1 is open...

  • Page 26: Trip And Stop Alarm

    HGM7110DC Genset Controller 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.

  • Page 27: Trip Alarm

    HGM7110DC Genset Controller 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, Type Description When the controller detects that the genset current has exceeded the pre-set value and the action select “Trip”, it will Gen Over Current initiate a trip alarm.

  • Page 28: Wiring Connection

    HGM7110DC Genset Controller 7 WIRING CONNECTION HGM7110DC controller’s rear as following: Description of terminal connection: Cable Functions Remark Size DC Input -Ve 2.5mm Connected with negative of starter battery. Connected with positive of starter battery. If wire DC Input +Ve 2.5mm...
  • Page 29 HGM7110DC Genset Controller Cable Functions Remark Size Normally open outputs, rated 7A Aux. Output 3 2.5mm Normally open outputs; volts free; rated 16A Aux. Output 4 2.5mm Reserved B(+) 1.5mm Connect to GOV or AVR. A(-) 1.5mm User IDC 1+ 1.0mm...
  • Page 30 HGM7110DC Genset Controller Cable Functions Remark Size A common terminal of input port, (-Ve) has Aux. Input COM 1.0mm already connected internal. shielding wire CANBUS SCR 0.5mm Impedance-120Ω CAN- 0.5mm recommended, single-end earthed. CANBUS, no these terminals) CAN+ 0.5mm shielding...

  • Page 31: Scopes And Definitions Of Programmable Parameters

    HGM7110DC Genset Controller 8 SCOPES AND DEFINITIONS OF PROGRAMMABLE PARAMETERS 8.1 CONTENTS AND SCOPES OF PARAMETERS Form 1 Items Parameters Defaults Description Charge Setting Acc. 1# Rated (0-75) V The rated voltage of 1#accumulator. Voltage 1# Cell Count (1-50) The battery number of 1#accumulator.
  • Page 32 HGM7110DC Genset Controller Items Parameters Defaults Description (0-3600) s Delay (0-1) 0: Disable; 1: Enable Under (0-1000) % Set Value Voltage Stop (0-3600) s Delay (0-1) 0: Disable; 1: Enable Over (0-1000) % Set Value Voltage Stop (0-3600) s Delay...
  • Page 33 HGM7110DC Genset Controller Items Parameters Defaults Description Mode”. If the genset enters into the “Constant Voltage mode”, 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...
  • Page 34 HGM7110DC Genset Controller Items Parameters Defaults Description Volt. (0-10.0)V GOV output maximum voltage Max. GOV Interface (0-1) 0: Normal Output；1:Reversed Output Type GOV Gain (0-500%) GOV Control GOV Stability (0-2000%) GOV Control GOV Kd (0-2000) GOV Control AVR Volt. Min.
  • Page 35 HGM7110DC Genset Controller Items Parameters Defaults Description Fail Stop Time between ending of cooling delay (0-3600)s Delay and stopped. After Stop Time between genset stopped and (0-3600)s Time standby. Engine Setting Default: Conventional Engine(not J1939) Engine Type (0-39) When connected to J1939 engine, choose the corresponding type.
  • Page 36 HGM7110DC Genset Controller Items Parameters Defaults Description D+(WL) voltage under this value, charge failure alarm will be initiated. Max. Crank times of crank attempts. Start Attempts (1-10) Times When reach this number, failure alarm will be initiated. See form 5...
  • Page 37 HGM7110DC Genset Controller Items Parameters Defaults Description Current 0: 4-20mA (0-1) Curve Type 1: 0-5V Current X(0-32762)mA/V 0 Curve Custom (x0,y0),(x1,y1) Y(0-32767)A Contents Switch Setting Close Time (0-20.0)s Open Time (0-20.0)s Check Time (0-20.0)s Open Check (0-1) 0: Disable ;1: Enable...
  • Page 38 HGM7110DC Genset Controller Items Parameters Defaults Description Open Circuit 0: Warn; 1: Shutdown; (0-2) Action 2: No action Shutdown when sensor temperature High Temp. higher than this value. Detecting only (-50-+300)º C Shutdown after safety delay is over. The delay value can be set.
  • Page 39 HGM7110DC Genset Controller Items Parameters Defaults Description Configure Input Ports Configure Input 1 Contents (0-50) Remote start (on load). See form 3 Setting 0: Closed to active Active Type (0-1) 1: Open to active Configure Input 2 Contents High temperature shutdown...
  • Page 40 HGM7110DC Genset Controller Items Parameters Defaults Description LCD display detailed contents when Description the input is active. Configure Input 6 Contents (0-50) User defined .See form 3 Setting 0: Closed to active Active Type (0-1) 1: Open to active 0: From safety on 1: From starting...
  • Page 41 HGM7110DC Genset Controller Items Parameters Defaults Description Contents (0-239) Reserved See Form 4 Setting 0:Normally open; Active Type (0-1) 1:Normally close Configure Output 6 Contents (0-239) Common alarm. See Form 4 Setting 0:Normally open; Active Type (0-1) 1:Normally close HGM7110DC Genset Controller Version: 1.0...

  • Page 42: Programmable Output Ports

    HGM7110DC Genset Controller 8.2 PROGRAMMABLE OUTPUT PORTS Form 2 Type Description Not Used Reserved Reserved Reserved Reserved Reserved Reserved Details of function description please see the following. Custom Combined 1 Custom Combined 2 Custom Combined 3 Custom Combined 4 Custom Combined 5...
  • Page 43 HGM7110DC Genset Controller Open Gen Output Control generator to off load. 1#Acc Load Close Two Accs：Control 1# accumulator to take load. 1#Acc Load Open Two Accs：Control 1# accumulator to off load. Start Relay Action when genset start and disconnect when Fuel Relay genset stop completely.
  • Page 44 HGM7110DC Genset Controller Warn 1# Acc. Over Voltage Shutdown 1# Acc. Under Voltage Shutdown 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...

  • Page 45: Defined Combination Output

    HGM7110DC Genset Controller Reserved Reserved Config1 High Warn Config1 Low Warn Config1 High Shutdown Config1 Low Shutdown Config2 High Warn Config2 Low Warn Config2 High Shutdown Config2 Low Shutdown 158~229 Reserved Stop Mode Action in stop mode. Manual Mode Action in Manual mode.
  • Page 46 HGM7110DC Genset Controller 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);...

  • Page 47: Programmable Input Ports

    HGM7110DC Genset Controller 8.3 PROGRAMMABLE 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 Trip and stop: alarm, generator unloads and shutdown...
  • Page 48 HGM7110DC Genset Controller Accumulator. When input is active, controller enters into Auto Mode; Auto Mode Lock all the keys except are inactive and there is in the right of first row in LCD. When input is active, controller won’t work under Auto Auto Mode Invalid Mode.
  • Page 49 HGM7110DC Genset Controller Simulate Drop Key button. Reserved Reserved Reserved Reserved Reserved Reserved HGM7110DC Genset Controller Version: 1.0 2014-09-27 Page 49 of 68...

  • Page 50: Selection Of Sensors

    HGM7110DC Genset Controller 8.4 SELECTION OF SENSORS Form4 Items Description Remark 0 Not used 1 Custom Res Curve 2 Custom 4-20mA curve 3 VDO 4 CURTIS 5 VOLVO-EC Defined resistance’s range Temperature 6 DATCON (0~6)KΩ, default is SGX sensor. Sensor...

  • Page 51: Conditions Of Crank Dinsconnect Selection

    HGM7110DC Genset Controller 8.5 CONDITIONS OF CRANK DINSCONNECT SELECTION Setting Description Engine Speed Oil pressure Oil pressure + Engine Speed NOTE: 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.

  • Page 52: Sensors Setting

    HGM7110DC Genset Controller 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° 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 53: Commissioning

    (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. If there is any other question, please contact Smartgen’s service. HGM7110DC Genset Controller Version: 1.0...

  • Page 54: Typical Application

    HGM7110DC Genset Controller TYPICAL APPLICATION HGM7110DC Genset Controller Version: 1.0 2014-09-27 Page 54 of 68...

  • Page 55: Installation

    Battery Voltage Input NOTE: 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 2.5mm...
  • Page 56 HGM7110DC Genset Controller CAUTION! 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. HGM7110DC Genset Controller Version: 1.0...

  • Page 57: Gsm Short Message Alarm And Remote Control

    HGM7110DC Genset Controller 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. NOTE: All alarms about shutdown, trip and stop and trip will be sent to the pre-set phone.

  • Page 58: Gsm Short Message Remote Control

    HGM7110DC Genset Controller 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 execute the orders by pre-set. Detail orders as following:...
  • Page 59 HGM7110DC Genset Controller Pass back information SMS DETAIL can be set via controller Gets details information of genset. software. SMS INHIBIT INHIBIT START OK Generator start will be inhibited. START SMS PERMIT PERMIT START OK Discharge the inhibit start signal.

  • Page 60: Connections Of Controller With J1939 Engine

    HGM7110DC Genset Controller CONNECTIONS OF CONTROLLER WITH J1939 ENGINE 14.1 CUMMINS ISB/ISBE Terminals of controller Connector B Remark Fuel relay output Start relay output Connect with starter coil directly Expand 30A relay, battery ECU power Set Auxiliary output 1 as “ECU...

  • Page 61: Cummins Qsm11 (Import)

    HGM7110DC Genset Controller 14.3 CUMMINS QSM11 (IMPORT) It is suitable for CM570 engine control module. Engine type is QSM11 G1, QSM11 G2. Terminals of controller C1 connector Remark Outside expand relay, when fuel Fuel relay output 5&8 output, making port 5 and port 8 of...

  • Page 62: Cummins Gcs-Modbus

    HGM7110DC Genset Controller 14.5 CUMMINS GCS-MODBUS It is suitable for GCS engine control module. Use RS485-MODBUS to read information of engine. Engine types are QSX15, QST30, QSK23 / 45/60/78 and so on. Terminals of controller D-SUB connector 06 Remark Outside expand relay, when fuel Fuel relay output 5&8...

  • Page 63: Deutz Emr2

    HGM7110DC Genset Controller 14.7 DEUTZ EMR2 Terminals of controller F connector Remark Expand 30A relay; battery voltage of terminal 14 is Fuel relay output supplied by relay. Fuse is 16A. Start relay output Connect to starter coil directly Connect to battery negative pole...

  • Page 64: Mtu Mdec

    HGM7110DC Genset Controller 14.9 MTU MDEC Suitable for MTU engines, 2000 series, 4000series Terminals of controller X1 connector Remark Fuel relay output Start relay output communication shielding CAN GND line(connect with terminal only) Impedance 120Ω connecting line is CAN(H) recommended.

  • Page 65: Scania

    HGM7110DC Genset Controller 14.11 SCANIA It is suitable for S6 engine control module. Engine type is DC9, DC12, and DC16. Terminals of controller B1 connector Remark Fuel relay output Start relay output Connect to starter coil directly communication shielding line(connect with controller’s terminal...

  • Page 66: Volvo Edc4

    HGM7110DC Genset Controller 14.13 VOLVO EDC4 Suitable engine types are TD520, TAD520 (optional), TD720, TAD720 (optional), TAD721, TAD722, and TAD732. Terminals of controller Connector Remark Expand 30A relay; battery voltage of terminal 14 is Fuel relay output supplied by relay. Fuse is 16A.

  • Page 67: Bosch

    Wire diameter 2.5mm Battery positive Wire diameter 2.5mm Engine type: BOSCH NOTE: If there is any question of connection between controller and ECU communication, please feel free to contact Smartgen’s service. HGM7110DC Genset Controller Version: 1.0 2014-09-27 Page 67 of 68...

  • Page 68: Fault Finding

    HGM7110DC Genset Controller 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; Check DC fuse.

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