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Smartgen HGM8110DC-2 User Manual

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HGM8110DC-2
GENSET CONTROLLER
USER MANUAL
SMARTGEN (ZHENGZHOU) TECHNOLOGY CO., LTD.

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  • Page 1 HGM8110DC-2 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 This manual is suitable for HGM8110DC-2 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

    5.4 AUTO START/STOP OPERATION ....................16 5.5 MANUAL START/STOP OPERATION ................... 17 5.6 GENSET CONTROLLER SWITCH CONTROL PROCEDURES ..........18 5.6.1 HGM8110DC-2 SWITCH CONTROL PROCEDURES ............18 6 PROTECTION ............................19 6.1 WARNINGS ............................ 19 6.2 SHUTDOWN ALARM ........................22 6.3 TRIP AND STOP ALARM .......................
  • Page 5 HGM8110DC-2 GENSET CONTROLLER USER MANUAL 13.1 OVERALL DIMENSION ........................ 58 13.2 BATTERY VOLTAGE INPUT ......................58 13.3 SPEED SENSOR INPUT ......................58 13.4 OUTPUT AND EXPAND RELAYS ....................58 13.5 AC INPUT ............................. 58 13.6 WITHSTAND VOLTAGE TEST ..................... 59 14 CONNECTIONS OF CONTROLLER WITH J1939 ENGINE ..............

  • Page 6: Overview

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL 1 OVERVIEW HGM8110DC-2 Genset Controller is especially designed for single unit system in DC and AC applications, which can adapt to extremely high/low temperature environments (-40~+70)° C. Controller applies self-luminous vacuum fluorescent graphic display (VFD) and electronic components which bear extreme high and low temperatures, so that it can work reliably under extreme temperatures.

  • Page 7: Models Comparison

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL 2 MODELS COMPARISON HGM8100DC series controllers include HGM8110DC and HGM8110DC-2. HGM8110DC-2 is the upgraded version of HGM8110DC. Model comparison of HGM8110DC and HGM8110DC-2 is as Table Table 3 - Models Comparison Models HGM8110DC HGM8110DC-2 Display ●...

  • Page 8: Performance And Characteristics

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL 3 PERFORMANCE AND CHARACTERISTICS HGM8110DC-2: It is DC genset controller and used for single automation systems to control genset start/stop through remote signal control; It is especially suitable for single unit automation system made up of 1-way DC and 1-way AC.
  • Page 9 HGM8110DC-2 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 counter (HC) accumulative to max. 65535 hours. Start times accumulative to max. 65535 times.

  • Page 10: Specification Operation

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL 4 SPECIFICATION OPERATION Table 4 - Technical Parameters Items Contents Operating Voltage DC8.0V to DC35.0V, Continuous Power Supply. <8W (standby ≤3W) Power Consumption Alternator Input Range 3Phase 4Wire AC15V-AC 360V (ph-N) 3Phase 3Wire AC30V - AC620V (ph-ph)
  • Page 11 HGM8110DC-2 GENSET CONTROLLER USER MANUAL Items Contents pollution class 2, altitude 3000m; Case Dimension 242mm x186mm x53mm Panel Cutout 214mm x160mm CT Secondary Current 5A rated Working Conditions Temperature: (-40~+70)° C; Relative Humidity: (20~93)%RH Storage Condition Temperature: (-45~+80)° C IP65: when rubber seal installed between the controller enclosure Protection Level and panel fascia.

  • Page 12: Operation

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL 5 OPERATION 5.1 KEY FUNCTION Table 5 - Key Description Icon Description Stop running generator in Auto/Manual mode; Reset alarms in stop mode; Press for over 3s to test whether panel indicators are normal Stop/Reset (lamp test);...

  • Page 13: Controller Panel

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL Icon Description Confirm In settings menu, confirm the set value. 1. Return to the first screen; Exit 2. In settings menu return to previous level menu. NOTE: In manual mode, press simultaneously and genset can be forced to start. At this time, controller won't judge whether genset has been started according to crank disconnect conditions, but starter separation is controlled by operator.

  • Page 14: Lcd Display

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL 5.3 LCD DISPLAY 5.3.1 MAIN DISPLAY Main screen show pages; use to scroll the pages and to scroll the screens. ★Main Screen includes following contents: Partial status display; AC Gens: voltage, frequency, AC Load: current, active power, reactive power, power factor;...

  • Page 15: Pararmeters Setting Manual

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL Table 7 - Power Factor Descriptions Power factor Conditions Active power Inactive 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 equals to one under excitation COS<0L...

  • Page 16: Auto Start/Stop Operation

    , its indicator light is on, which means controller enters Auto mode. Auto Starting Sequence: HGM8110DC-2: Generator enters into ―Start Delay‖ as soon as ―Remote Start on Load‖ input 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 17: Manual Start/Stop Operation

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL Enter ―After Stop Time‖ (if configured) as soon as generator stops. Otherwise, controller enters stop failure and sends ―Fail to Stop‖ warning alarm at the same time. (If gen-set stops successfully after warning of ―Failed to Stop‖, it will enter ―After Stop Time‖ and removes alarm automatically.) Enter ―Generator at Rest‖...

  • Page 18: Genset Controller Switch Control Procedures

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL 5.6 GENSET CONTROLLER SWITCH CONTROL PROCEDURES 5.6.1 HGM8110DC-2 SWITCH CONTROL PROCEDURES 5.6.1.1 MANUAL TRANSFER PROCEDURES When controller is in manual mode, manual control procedure is conducted for switch control. Users can control switch on or off by pressing close/open key.

  • Page 19: Protection

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL 6 PROTECTION 6.1 WARNINGS When controllers detect the warning signals, it is alarm only and not stop the genset. Table 8 - Warning Alarms Type Action Range Description Always active When controller detects the speed is higher Over Speed than the set value, it will send warn signals.
  • Page 20 HGM8110DC-2 GENSET CONTROLLER USER MANUAL Type Action Range Description select ―Warn‖, it will send warn signals. time is due Active always When controller detects the reverse power value (power is negative) is higher than the AC Reverse Power set value and the action select ―Warn‖, it will send warn signals.
  • Page 21 HGM8110DC-2 GENSET CONTROLLER USER MANUAL Type Action Range Description stop idle lower than the set value, it will send warn signals. Active Always When controller detects the sensor is open circuit, and the action select ―warn‖, it will Level Sensor Open send warn signals.

  • Page 22: Shutdown Alarm

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL 6.2 SHUTDOWN ALARM When controller detects shutdown alarm, it will disconnect Gens close signal and stop the generator immediately. Table 9 - Shutdown Alarms Type Action Range Description Active always When controller detects emergency stop Emergency Stop signals, it will send stop signals.
  • Page 23 HGM8110DC-2 GENSET CONTROLLER USER MANUAL Type Action Range Description than the set value, and the reverse power action select ―shutdown‖, it will send stop signals. Active always When controller detects reverse power value of AC genset (power is positive) is higher...
  • Page 24 HGM8110DC-2 GENSET CONTROLLER USER MANUAL Type Action Range Description stop signals. Active always When controller detects sensor is open Flexible Sensor 2 circuit, and the action select ―shutdown‖, it Open will send stop signals. Active from start idle to When controller detects the sensor value is...

  • Page 25: Trip And Stop Alarm

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL 6.3 TRIP AND STOP ALARM When controller detects trip and stop alarm signals, it will disconnect Gens close signal and stop the generator after cooling. Table 10 - Trip and Stop Alarms Type Action Range...

  • Page 26: Trip Alarm

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL 6.4 TRIP ALARM When controller detects trip alarm, it will disconnect Gens close signal immediately but genset won't stop. Table 11 - Trip Alarms Type Action Range Description Active always When controller detects the current value of...

  • Page 27: Wirings Connection

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL 7 WIRINGS CONNECTION HGM8110DC-2 controller‘s back panel is as below: Fig.2 - Controller 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 28 HGM8110DC-2 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 29 HGM8110DC-2 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 30: Scopes And Definitions Of Programmable Parameters

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL 8 SCOPES AND DEFINITIONS OF PROGRAMMABLE PARAMETERS 8.1 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;...
  • Page 31 HGM8110DC-2 GENSET CONTROLLER USER MANUAL Items Parameters Defaults Description set value. Set value is DC generator rated voltage‘s percentage; when alarm is active, and (0-200)% voltage is below the return value, alarm can be cleared automatically. Alarm starts when voltage gets up to the (0-3600)s alarm value and this delay is expired.
  • Page 32 HGM8110DC-2 GENSET CONTROLLER USER MANUAL Items Parameters Defaults Description Timers Time from mains abnormal or remote start Start Delay (0~3600)s signal is active to start genset. Time from mains normal or remote start Stop Delay (0~3600)s signal is deactivated to genset stop.
  • Page 33 HGM8110DC-2 GENSET CONTROLLER USER MANUAL Items Parameters Defaults Description 0: Disable Start to detect alarms when it is enabled; 1: Enable not detect alarms when disabled; Set value is percentage of rated speed; Over Speed (0~200)% start alarm handle when it is above this Shutdown value.
  • Page 34 HGM8110DC-2 GENSET CONTROLLER USER MANUAL Items Parameters Defaults Description voltage; when alarm is active and battery voltage is below return value, alarm can be cleared automatically. Alarm starts when voltage reaches alarm (0~3600)s value and this delay time is expired.
  • Page 35 HGM8110DC-2 GENSET CONTROLLER USER MANUAL Items Parameters Defaults Description than the set value, starter will be disconnected. See the installation instruction. When generator oil pressure higher than Disconnect Oil (0~1000)kPa the set value, starter will be disconnected. Pressure See the installation instruction.
  • Page 36 HGM8110DC-2 GENSET CONTROLLER USER MANUAL Items Parameters Defaults Description voltage; start alarm handle when it is below this value. Alarm starts when voltage reaches alarm (0-3600)s value and this delay time is expired. 0: Disable Start to detect alarms when it is enabled;...
  • Page 37 HGM8110DC-2 GENSET CONTROLLER USER MANUAL Items Parameters Defaults Description this value. Set value is percentage of AC Gen rated freq. when alarm is active, and freq. is (0~200)% below return value, alarm can be cleared automatically. Alarm starts when freq. reaches alarm (0-3600)s value and this delay time is expired.
  • Page 38 HGM8110DC-2 GENSET CONTROLLER USER MANUAL Items Parameters Defaults Description After IDMT is active, realize alarm delay by (1-36) setting this multiplier. 0: Disable Start to detect alarms when it is enabled; 1: Enable not detect alarms when disabled; Set value is percentage of AC Gen rated (0-200)% power;...
  • Page 39 HGM8110DC-2 GENSET CONTROLLER USER MANUAL Items Parameters Defaults Description 0: Disable 1: Enable All the settings about Ethernet (such as IP IP Set (0-1) address and subnet mask) will active after the next time power on. Scheduling And Maintenance Setting...
  • Page 40 HGM8110DC-2 GENSET CONTROLLER USER MANUAL Items Parameters Defaults Description value and this delay time is expired. Users can configure it according to Custom Curve sensor‘s performance. Oil Pressure Sensor Curve Type (0~15) SGD. See Table 16. Open Circuit 0: Warning 1: Shutdown...
  • Page 41 HGM8110DC-2 GENSET CONTROLLER USER MANUAL Items Parameters Defaults Description 0: Not Used Flexible Sensor 1 1: Temp. Sensor (0~3) Setting 2: Pressure Sensor 3: Level Sensor Flexible Sensor 2 0: Not Used Flexible Sensor 2 1: Temp. Sensor (0~3) Setting...
  • Page 42 HGM8110DC-2 GENSET CONTROLLER USER MANUAL Items Parameters Defaults Description LCD display detailed contents when the Description input is active. Digital Input Port 6 Contents Setting (0~55) User defined .See Table 15 0: Closed to Activate Active Type (0~1) 1: Open to Activate...

  • Page 43: Enable Definition Of Programmable Output Ports

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL Items Parameters Defaults Description 1: Output(N/C) Relay Output Port 5 Contents Setting (0~299) Energise to Stop. See Table 14 0: Output(N/O) Active Type (0~1) 1: Output(N/C) Relay Output Port 6 Contents Setting (0~299) Common Alarm. See Table 14...
  • Page 44 HGM8110DC-2 GENSET CONTROLLER USER MANUAL Type Description the upper and lower limits. Fuel Pre-supply Act in the period from crank to safety on time. Output in the crank process; output for 2s again if Gen Generator Excite frequency is lost in high speed period.
  • Page 45 HGM8110DC-2 GENSET CONTROLLER USER MANUAL Type Description Charge Alternator Failure Act when charge failure warning alarm occurs. Reserved Reserved Reserved ECU Warning Indicate ECU sends a warning signal. ECU Shutdown Indicate ECU sends a shutdown signal. Communication Indicate controller not communicates with ECU.
  • Page 46 HGM8110DC-2 GENSET CONTROLLER USER MANUAL Type Description AC Under Voltage Warn Act when generator low voltage warning occurs. Under Voltage Act when generator low voltage shutdown occurs. Shutdown AC Loss of Phase Act when generator loss phase. AC Phase Rotation Act when generator reverse phase.
  • Page 47 HGM8110DC-2 GENSET CONTROLLER USER MANUAL Type Description 158~161 Reserved Exp1 Ch15 High Shut 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...
  • Page 48 HGM8110DC-2 GENSET CONTROLLER USER MANUAL Type Description At Manual Mode Act when system is in Manual mode. Reserved At Auto Mode Act when system is in Auto mode. Generator Load Reserved 236~239 Reserved 240~279 PLC Flag 1-40 Act when PLC flag is 1.

  • Page 49: Custom Period Output

    HGM8110DC-2 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 50: Defined Contents Of Configurable Input Ports (All Active When Connect To Ground (B-))

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL 8.3 DEFINED CONTENTS OF CONFIGURABLE INPUT PORTS (All Active when connect to Ground (B-)) Table 15 - Defined Contents of Programmable Inputs Type Description Including following functions, Indication: indicate only, not warning or shutdown. Warning: warn only, not shutdown.
  • Page 51 HGM8110DC-2 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 52: Selection Of Sensors

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL 8.4 SELECTION OF SENSORS Table 16 - Sensors Selection Description Remark 0 Not Used 1 User Configured (Resistance) 2 User Config((4-20)mA) Curve 3 User Config.( 0-5V) Curve 4 VDO 5 CURTIS Defined resistance‘s 6 VOLVO-EC range is (0~6)KΩ, default...
  • Page 53 HGM8110DC-2 GENSET CONTROLLER USER MANUAL 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 There are three kinds of separation conditions for starter and eninge, speed, frequency, and oil pressure, all of which can be used separately.

  • Page 54: Parameters Setting

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL 9 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 or other abnormal conditions may happen.

  • Page 55: Sensors Setting

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL 10 SENSORS SETTING — At reselecting 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°...
  • Page 56 During this time, please observe engine‘s running situations, AC generator‘s voltage and frequency and DC generator voltage. If something abnormal occurs, stop genset running and check all wires connection according to this manual. — If there is any other question, please contact SmartGen‘s service. HGM8110DC-2 Genset Controller 2020-02-20 Version 1.0...

  • Page 57: Typical Application

    Fig.4 - HGM8110DC-2 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.5 - HGM8110DC-2 Expand Module Typical Application Diagram HGM8110DC-2 Genset Controller 2020-02-20 Version 1.0...

  • Page 58: Installation

    Fig.6 - Overall Dimensions 13.2 BATTERY VOLTAGE INPUT HGM8110DC-2 controller can suit for wide 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 B+ and B- to battery positive and negative must be over 2.5mm...

  • Page 59: Withstand Voltage Test

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL WARNING! When there is load current, transformer‘s secondary side is prohibited to have open circuit. 13.6 WITHSTAND VOLTAGE TEST CAUTION! When controller has been installed in control window, if it needs voltage withstand test, please disconnect controller‘s all terminal connections, in order to prevent high voltage entering controller and damaging it.

  • Page 60: Connections Of Controller With J1939 Engine

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL 14 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 61: Cummins Qsm11 (Import)

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL 14.3 CUMMINS QSM11 (import) It is suitable for CM570 engine control module. Engine type is QSM11 G1, QSM11 G2. Table 23 - C1 Pin Connector Terminals of controller C1 connector Remark Externally extend relay, when fuel is Fuel relay output 5&8...

  • Page 62: Cummins Gcs-Modbus

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL 14.5 CUMMINS GCS-MODBUS It is suitable for GCS engine control module. RS485-MODBUS is used to read information of engine. Engine types are QSX15, QST30, QSK23 / 45/60/78 and so on. Table 27 - D-SUB Connector 06...

  • Page 63: Detroit Diesel Ddec Iii / Iv

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL Engine type: Common J1939 14.8 DETROIT DIESEL DDEC III / IV Table 31 - Engine CAN Connector Terminals of controller CAN port of engine Remark Expand 30A relay, battery Fuel relay output voltage of ECU is supplied by relay.

  • Page 64: Mtu Mdec

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL 14.11 MTU MDEC Suitable for MTU engines, 2000 series, 4000series Table 34 - X1 Pin Connector Terminals of controller X1 connector Remark Fuel relay output Start relay output CAN communication shielding line (connect CAN GND with one terminal only).

  • Page 65: Perkins

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL 14.14 PERKINS It is suitable for ADEM3/ ADEM4 engine control module. Engine type is 2306, 2506, 1106, and 2806. Table 39 - Connector Terminals of controller Connector Remark Fuel relay output 1,10,15,33,34 Start relay output Connect to starter coil directly.

  • Page 66: Volvo Edc4

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL 14.17 VOLVO EDC4 Suitable engine types: TD520, TAD520 (optional), TD720, TAD720 (optional), TAD721, TAD722, and TAD732. Table 43 - Connector Terminals of controller Connector Remark Expand 30A relay, and relay Fuel relay output offers battery voltage for terminal14.

  • Page 67: Yuchai

    HGM8110DC-2 GENSET CONTROLLER USER MANUAL 14.19 YUCHAI It is suitable for BOSCH common rail pump engine. Table 45 - Engine 42-Pin Connector Terminals of controller Engine 42 pins port Remark Fuel relay output 1.40 Connect to engine ignition lock. Start relay output Connect to starter coil directly.

  • Page 68: Ethernet Interface

    — The communication between the controller and monitoring equipment is carried out by 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 69: Fault Finding

    HGM8110DC-2 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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