Smartgen HGM8151 User Manual
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Smartgen HGM8151 User Manual

Genset parallel controller
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HGM8151
GENSET PARALLEL CONTROLLER
USER MANUAL

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Summary of Contents for Smartgen HGM8151

  • Page 1 HGM8151 GENSET PARALLEL CONTROLLER USER MANUAL...

  • Page 2: Table Of Contents

    STEP 3: MANUAL PARALLEL OPERATION ON-LOAD ..............46 10.4 STEP 4: AUTOMATIC PARALLEL OPERATION ................47 11 TYPICAL APPLICATION ......................... 48 12 POWER MANAGEMENT MODE ......................50 13 NEL TRIP ILLUSTRATION ........................51 14 INSTALLATION ............................52 HGM8151 Genset Parallel Controller User Manual Page 2 of 66...
  • Page 3 17.3.1 ILLUSTRATION .......................... 64 17.3.2 CONTROLLER CONNECT WITH PC WITH A LINE OF CABLE ..........64 17.3.3 CONTROLLER AND PC CONNECTION VIA SWITCHBOARD (OR ROUTER)......64 18 FAULT FINDING ............................65 HGM8151 Genset Parallel Controller User Manual Page 3 of 66...
  • Page 4 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 5 This user manual only suits for HGM8151 controller. Table 2 Notation Clarification Symbol 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 6: Overview

    AVR (Automatic Voltage Regulator) control function, the controller is able to synchronize and share load automatically; it can be used to parallel with other HGM8151 controller. It also monitors the engine, indicating the operational status and fault conditions accurately. When abnormal condition occurs, it splits bus and shuts down the genset, simultaneously the exact failure mode information is indicated by the LCD display on the front panel.

  • Page 7: Performance And Characteristics

    Hour count (HC) can accumulate Max. 65535 hours. Start times can accumulate Max. 65535 times ─ Protection: automatic start/stop of the gen-set, ATS (Auto Transfer Switch) control with perfect fault indication and protection function. HGM8151 Genset Parallel Controller User Manual Page 7 of 66...
  • Page 8 Accumulative total run time and total electric energy of A and B. Users can reset it as 0 and re-accumulative the value which make convenience to users to count the total value as their wish. HGM8151 Genset Parallel Controller User Manual Page 8 of 66...

  • Page 9: Specification

    (-40~+70)°C Protection Level IP55 Gasket Apply AC2.2kV voltage between high voltage terminal and low voltage Insulation Intensity terminal. The leakage current is not more than 3mA within 1min. Weight 0.85kg HGM8151 Genset Parallel Controller User Manual Page 9 of 66...

  • Page 10: Operation

    2) Up cursor and increase value in setting menu. 1) Screen scroll; Down/Decrease 2) Down cursor and decrease value in setting menu. 1) Screen scroll; Left 2) Left move cursor in setting menu. HGM8151 Genset Parallel Controller User Manual Page 10 of 66...

  • Page 11: 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 all information in the controller page of “ABOUT” to us.
  • Page 12 ⚫ Others, including, Time and Date, maintenance due, input/output ports status, network settings and etc. ⚫ About, including, Issue time of software and hardware version, product PD number. HGM8151 Genset Parallel Controller User Manual Page 12 of 66...

  • Page 13: Pararmeters Setting Manual

    Switch input port settings ⚫ output port settings Module settings ⚫ ⚫ Scheduling and maintenance settings ⚫ GSM settings Synchronization settings ⚫ Expansion module settings ⚫ NOTE: Press can exist parameter setting directly. HGM8151 Genset Parallel Controller User Manual Page 13 of 66...

  • Page 14: Auto Start/Stop Operation

    When generator is stop completely, “after stop” delay will be initiated. Otherwise, fail to stop alarm is initiated (If generator is stop successfully after “fail to stop” alarm has initiated, “after stop” delay will be initiated and the alarm will be removed). HGM8151 Genset Parallel Controller User Manual Page 14 of 66...

  • Page 15: Manual Start/Stop Operation

    During parallel operation, the controller will transfer load to other generators, and then send an opening signal. 4.6.2 AUTO CONTROL PROCEDURES When controller is in auto mode, the switch control procedure is automatic control procedure. HGM8151 Genset Parallel Controller User Manual Page 15 of 66...

  • Page 16: Protections

    (power is positive) has exceeded the pre-set value and the action select “Warn”, it will initiate a warning alarm. ECU Warn If an error message is received from ECU via J1939, it will initiate a HGM8151 Genset Parallel Controller User Manual Page 16 of 66...
  • Page 17 “Warn”, it will initiate a warning alarm. When the controller does not detect synchronization signal within the Fail to sync pre-set synchronization time, it will initiate a warning alarm. HGM8151 Genset Parallel Controller User Manual Page 17 of 66...

  • Page 18: Shutdown Alarms

    If an error message is received from ECU via J1939, it will initiate a ECU Shutdown shutdown alarm. If the module does not detect the ECU data via J1939, it will initiate a ECU Fail shutdown alarm. HGM8151 Genset Parallel Controller User Manual Page 18 of 66...
  • Page 19 MSC Too Few Sets alarm. There are 2 possible reasons: a) Communication line between the controllers disconnects, which interrupts communication. b) Other parallel gen-sets controllers have not been powered on. HGM8151 Genset Parallel Controller User Manual Page 19 of 66...

  • Page 20: Trip And Stop Alarms

    If loss of excitation fault detection is enabled, when the controller Loss of Excitation detects that the genset negative reactive power has exceeded the pre-set value, it will initiate a trip and stop alarm. HGM8151 Genset Parallel Controller User Manual Page 20 of 66...

  • Page 21: Trip Alarm

    If loss of excitation fault detection is enabled, when the controller Loss of Excitation detects that the genset negative reactive power has exceeded the pre-set value, it will initiate a trip alarm. HGM8151 Genset Parallel Controller User Manual Page 21 of 66...

  • Page 22: Wiring Connection

    WIRING CONNECTION HGM8151 controller’s back panel as following: Fig.1 Controller Back Panel Table 11 Description of Terminal Connection Functions Cable Size Remark 2.5mm Connected with negative of starter battery Connected with positive of starter battery. If wire length 2.5mm is over 30m, better to double wires in parallel. Max. 20A...
  • Page 23 Gen-set B-phase Connected to B-phase of gen-set (2A fuse is 1.0mm voltage input recommended) Gen-set C-phase Connected to C-phase of gen-set (2A fuse is 1.0mm voltage input recommended) HGM8151 Genset Parallel Controller User Manual Page 23 of 66...
  • Page 24 NOTE: USB ports in controller rear panel are configurable parameter ports, user can directly program controller via NOTE: ETHERNET ports in controller rear panel are network monitoring ports, user can directly monitor controller via HGM8151 Genset Parallel Controller User Manual Page 24 of 66...

  • Page 25: Scopes And Definitions Of Programmable Parameters

    Flywheel Teeth (10~300) inspecting of engine speed. See the installation instructions. Offer standard to judge over/under/loading Rated Speed (0~6000)r/min 1500 speed. Loading Speed (0~100)% Setting value is percentage of rated speed. HGM8151 Genset Parallel Controller User Manual Page 25 of 66...
  • Page 26 Engine When generator speed is higher than the (0~200)% Speed set value, starter will be disconnected. See the installation instruction. Disconnect Oil (0~1000)kPa When generator oil pressure higher than the HGM8151 Genset Parallel Controller User Manual Page 26 of 66...
  • Page 27 Delay value (default: 5s) and return value (over frequency default: 108 and under frequency default: 86) also can be Under Freq. Warn (0~200)% set. Generator Load Setting Current Trans. (5~6000)/5 The ratio of external CT HGM8151 Genset Parallel Controller User Manual Page 27 of 66...
  • Page 28 0: Disable; 1: Enable Enable Date and Time Set the module’s date and time. 0: Disable; 1: Enable Ethernet Enable (0~1) All Ethernet setting changes (e.g. IP address, Subnet mask) are active after HGM8151 Genset Parallel Controller User Manual Page 28 of 66...
  • Page 29 0: Warn; 1: Alarm Shutdown; 2: No Action When liquid level value of the external liquid Low Fuel Level Warn (0~300)% level sensor is lower than the set value, low HGM8151 Genset Parallel Controller User Manual Page 29 of 66...
  • Page 30 Time from detecting input port is active to Delay (0~20.0)s confirm. LCD display detailed contents when the Description input is active. Digital Input Port 6 Contents Setting (0~55) First priority. Active Type (0~1) 0: Closed to active HGM8151 Genset Parallel Controller User Manual Page 30 of 66...
  • Page 31 Gen Open Output. 0: Normally open; Output Type (0~1) 1: Normally close Relay Output Port 6 Contents Setting (0~299) Close Gen Output. 0: Normally open; Output Type (0~1) 1: Normally close HGM8151 Genset Parallel Controller User Manual Page 31 of 66...
  • Page 32 0: No Action; 1: Warn; 2: Trip. Type When the input is active, the controller will Balance Engine (1-1000)hours Disable start/stop genset automatically Hours according to the running time and the HGM8151 Genset Parallel Controller User Manual Page 32 of 66...
  • Page 33 Default volt. range: (-1.5~+1.5)V. Sync Control Gain (0-500) Adjust and control before paralleling. Sync Control (0-2000) Adjust and control before paralleling. Stability Load Control Gain (0-500) Adjust and control after paralleling. HGM8151 Genset Parallel Controller User Manual Page 33 of 66...
  • Page 34 Setting value is phase angle’s change rate of mains voltage waveform, and alarm Vector Shift (0-20.0)° action (default: trip and stop) and delay value (default: 0.1s) also can be set. HGM8151 Genset Parallel Controller User Manual Page 34 of 66...

  • Page 35: Defined Contents Of Programmable Output Ports

    This port is controlled by communication (PC). It is used for supply power for GSM module (power off and GSM Power Supply reset GSM module when GSM fail to communication) HGM8151 Genset Parallel Controller User Manual Page 35 of 66...
  • Page 36 Action when charge failure warning alarms. Reserved Reserved Reserved ECU Warning Indicate ECU sends a warning signal. ECU Shutdown Indicate ECU sends a shutdown signal. ECU Communication Failure Indicate controller not communicates with ECU. HGM8151 Genset Parallel Controller User Manual Page 36 of 66...
  • Page 37 Gen Loss of Phase Action when generator loss phase. Gen Phase Sequence Wrong Action when generator reverse phase. Reserved Over Power Alarm Action when controller detects generator have over power. HGM8151 Genset Parallel Controller User Manual Page 37 of 66...
  • Page 38 166_201 Expand 1 Sensor 16-24 202~229 Reserved Stop Mode Action when system in Stop mode. Manual Mode Action when system in Manual mode. Reserved Auto Mode Action when system in Auto mode. HGM8151 Genset Parallel Controller User Manual Page 38 of 66...

  • Page 39: Defined Period Output

    When input port 1 active or input port 2 active, if input port 3 is active, Defined combination output is outputting; If input port 3 inactive, Defined combination output is not outputting; HGM8151 Genset Parallel Controller User Manual Page 39 of 66...

  • Page 40: Defined Contents Of Programmable Input Ports (All Gnd (B-) Active)

    When input is active, controller won’t work under Auto mode key Auto Mode Inhibit and simulate auto key input does not work. Static Parallel HGM8151 Genset Parallel Controller User Manual Page 40 of 66...
  • Page 41 Reserved Reserved Configuration 1 Users can set different parameters to make it easy to select Configuration 2 current configuration via input port. Configuration 3 Balance Test Speed Raise Speed Drop HGM8151 Genset Parallel Controller User Manual Page 41 of 66...

  • Page 42: Selection Of Sensors

    7 SGX Defined resistance’s range Pressure Sensor 8 SGD (0~6)kΩ, default is SGX sensor. 9 SGH 10 VDO 5Bar 11 DATCON 5Bar 12 DATCON 7Bar 13 SUSUKI 14 PRO 15 Reserved HGM8151 Genset Parallel Controller User Manual Page 42 of 66...

  • Page 43: Conditions Of Crank Disconnect Selection

    (can be used in water pump set); if not select speed sensor in crank disconnect setting, the rotating speed displayed in controller is calculated by generator frequency and number of poles. HGM8151 Genset Parallel Controller User Manual Page 43 of 66...

  • Page 44: Parameters Setting

    Configurable input could not be set as same items; otherwise, there are abnormal functions. However, the configurable output can be set as same items. HGM8151 Genset Parallel Controller User Manual Page 44 of 66...

  • Page 45: Sensors Setting

    Fig.2 Curve Setting Table 17 Normal Pressure Unit Conversion Unit kgf/cm － － － 1.02x10 1x10 1.45x10 1kgf/cm 9.8x10 0.98 14.2 1bar 1x10 1.02 14.5 1psi 6.89x10 － － 7.03x10 6.89x10 HGM8151 Genset Parallel Controller User Manual Page 45 of 66...

  • Page 46: Commissioning

    HGM8151 controller, or adjust engine GOV or generator AVR gain and stability potentiometer to avoid active and reactive power oscillation; output close to 0.

  • Page 47: Step 4: Automatic Parallel Operation

    Opening breaker, unloading and stop is performed automatically. All the gen-sets are repeatedly started and stopped according to their total run time. HGM8151 Genset Parallel Controller User Manual Page 47 of 66...

  • Page 48: Typical Application

    11 TYPICAL APPLICATION Fig.3 HGM8151 3P4W Typical Application Diagram NOTE: Fuse F1: min. 2A; max. 20A. Fuse F2: max. 32A. Users should select suitable fuse depend on practical application. Fig.4 3 Phase 3 Wire Typical Application Diagram Fig.5 2 Phase 3 Wire Typical Application Diagram...
  • Page 49 Fig.7 HGM8151 Multi-genset Parallel Application NOTE: Mains parallel function for HGM8151 controller can be selected via configurable input port. In mains parallel mode, generator will run in parallel with mains and it will only be able to output a fixed amount of power. (Set load mode as Gen control mode).

  • Page 50: Power Management Mode

    12 POWER MANAGEMENT MODE Power management mode can be selected via configurable input ports. Fig.9 Power Management Mode Flowchart HGM8151 Genset Parallel Controller User Manual Page 50 of 66...

  • Page 51: Nel Trip Illustration

    NEL reconnection value, then the input is active; if it doesn’t, the input is deactivated. NOTE: When auto trip and auto reconnection are enabled, manual trip is still active. HGM8151 Genset Parallel Controller User Manual Page 51 of 66...

  • Page 52: Installation

    Fig.11 Overall Dimension and Cutout 14.2 BATTERY VOLTAGE INPUT HGM8151 controller can suit for widely range of battery voltage (8~35) VDC. Negative of battery must be connected to the shell of starter stable. The wire’s diameter must be over 2.5mm and which is connected to B+ and B- of controller power.

  • Page 53: Withstand Voltage Test

    SMS STOP MODE SMS STOP OK Set as stop mode SMS MANUAL MODE SMS MANUAL MODE OK Set as manual mode SMS AUTO MODE SMS AUTO MODE OK Set as auto mode HGM8151 Genset Parallel Controller User Manual Page 53 of 66...
  • Page 54 D+ voltage, water temperature, oil pressure, oil level, engine speed, total running time, genset status, and alarm status. HGM8151 Genset Parallel Controller User Manual Page 54 of 66...

  • Page 55: Connections Of Controller With J1939 Engine

    CAN GND SAE J1939 shield-E (connect with ECU terminal only) CAN(H) SAE J1939 signal-C Using impedance 120Ω connecting line CAN(L) SAE J1939 return-D Using impedance 120Ω connecting line Engine type: Cummins-CM850. HGM8151 Genset Parallel Controller User Manual Page 55 of 66...

  • Page 56: Cummins Qsm11 (Import)

    SAE J1939 shield-E (connect with ECU terminal only) CAN(H) SAE J1939 signal-C Using impedance 120Ω connecting line CAN(L) SAE J1939 return-D Using impedance 120Ω connecting line Engine type: Cummins QSX15-CM570. HGM8151 Genset Parallel Controller User Manual Page 56 of 66...

  • Page 57: Cummins Gcs-Modbus

    Connect with starter coil directly CAN GND communication shielding line (connect with controller’s this terminal only) CAN(H) Using impedance 120Ω connecting line CAN(L) Using impedance 120Ω connecting line Engine type: common J1939. HGM8151 Genset Parallel Controller User Manual Page 57 of 66...

  • Page 58: Cummins Qsz13

    Connect to starter coil directly communication shielding line CAN GND (connect with controller’s terminal only) CAN(H) CAN(H) Using impedance 120Ω connecting line CAN(L) CAN(L) Using impedance 120Ω connecting line Engine type: Common J1939. HGM8151 Genset Parallel Controller User Manual Page 58 of 66...

  • Page 59: Deutz Emr2

    Fuel relay output Start relay output communication shielding line CAN GND (connect with one terminal only) CAN(H) Using impedance 120Ω connecting line CAN(L) Using impedance 120Ω connecting line Engine type: MTU-MDEC-303. HGM8151 Genset Parallel Controller User Manual Page 59 of 66...

  • Page 60: Mtu Adec (Smart Module)

    CAN GND X23 3 (connect with controller’s this terminal only) CAN(H) X23 2 Using impedance 120Ω connecting line CAN(L) X23 1 Using impedance 120Ω connecting line Engine type: Common J1939. HGM8151 Genset Parallel Controller User Manual Page 60 of 66...

  • Page 61: Perkins

    Terminals of controller “Data bus” connector Remark communication shielding line CAN GND (connect with controller’s terminal only) CAN(H) Using impedance 120Ω connecting line CAN(L) Using impedance 120Ω connecting line Engine type: Volvo. HGM8151 Genset Parallel Controller User Manual Page 61 of 66...

  • Page 62: Volvo Edc4

    Using impedance 120Ω connecting line CAN(L) 2(Lo) Using impedance 120Ω connecting line Engine type: Volvo-EMS2. NOTE: When this engine type is selected, preheating time should be set to at least 3 seconds. HGM8151 Genset Parallel Controller User Manual Page 62 of 66...

  • Page 63: Yuchai

    CAN(L) 1.34 Using impedance 120Ω connecting line Engine type: GTSC1. NOTE: If there is any question of connection between controller and ECU communication, please feel free to contact SmartGen’s service. HGM8151 Genset Parallel Controller User Manual Page 63 of 66...

  • Page 64: 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 17.3 CONTROLLER AND NETWORK CABLE CONNECTION...

  • Page 65: Fault Finding

    Check connections of CAN high and low polarity; Check if correctly connected of 120Ω resister; ECU communication failed Check if type of engine correct; Check if connections from controller to engine and setting of outputs correct. HGM8151 Genset Parallel Controller User Manual Page 65 of 66...
  • Page 66 Get information from LCD of alarm page; ECU warning or stop If there is detailed alarm, check engine according to description. If not, please refer to engine manual according to SPN alarm code. _________________________________ HGM8151 Genset Parallel Controller User Manual Page 66 of 66...

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