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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.
  • Page 3 HGM8110A/8120A Genset Controller Software Version Date Version Note 2013-01-29 Original release. 2013-04-12 Modify some details. Modify case dimension; Modify the contents of “Oil Pressure 2013-06-17 Sensor” Add “Loss of Speed Signal Shutdown” in output port 2013-11-20 settings. Add function: Long pressing “ ”...
  • Page 4 HGM8110A/8120A Genset Controller CONTENT OVERVIEW ........................ 6 PERFORMANCE AND CHARACTERISTICS ............7 SPECIFICATION ..................... 10 OPERATION ......................11 .................. 11 4.1 KEY FUNCTION ................12 4.2 INDICATOR LIGHT ..................13 4.3 LCD DISPLAY 4.3.1 MAIN DISPLAY ..................13 4.3.2 BASIC PARAMETER ................14 4.3.3 ADVANCED PARAMETERS SETTING ..........
  • Page 5 HGM8110A/8120A Genset Controller ..............61 12.1 BATTERY VOLTAGE INPUT ...............61 12.2 SPEED SENSOR INPUT ............61 12.3 OUTPUT AND EXPAND RELAYS ...................62 12.4 AC INPUT ..............62 12.5 WITHSTAND VOLTAGE TEST FACTORY DEFAULT VALUES ................63 HGM8110A/8120A Genset Controller ISSUE2016-9-28 Version1.6 Page 5 of 63...
  • Page 6 HGM8110A/8120A Genset Controller 1 OVERVIEW HGM8110A/8120A genset controllers are especially designed for extremely high/low temperature environment (-40~+70)°C. The controllers can operate reliability 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 HGM8110A/8120A Genset Controller 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 HGM8110A/8120A Genset Controller wrong, over and reverse power, over current detection functions; ♦ 3 fixed analog sensors (temperature, oil pressure and liquid level); ♦ 2 configurable sensors can be set as sensor of temperature, oil pressure or fuel level; ♦ Precision measure and display parameters about Engine, Temp.
  • Page 9 HGM8110A/8120A Genset Controller users can define the sensor curves by themselves; ♦ Multiple crank disconnect conditions (speed sensor, oil pressure, generator frequency) are optional; ♦ Real time clock and run time accumulation function. 99 pieces of event logs can be circularly stored and inquired on the spot;...
  • Page 10 HGM8110A/8120A Genset Controller 3 SPECIFICATION ITEM CONTENT Operating voltage DC8. 0V to 35. 0V, Continuous Power Supply <6W(Standby mode: ≤3W) Power consumption 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 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. HGM8110A/8120A Genset Controller ISSUE2016-9-28 Version1.6...
  • Page 12 HGM8110A/8120A Genset Controller INDICATOR LIGHT 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) Genenerator normal light：It is light on when generator is normal;...
  • Page 13 HGM8110A/8120A Genset Controller LCD DISPLAY MAIN DISPLAY 4.3.1 Main screen is used to display real time data of all parameters, use to scroll the screen. ★Status, including as below, Status of genset, mains (HGM8120A), and ATS ★Mains, including as below Phase voltage, Line voltage, frequency NOTE: HGM8110A has no mains status screen.
  • Page 14 HGM8110A/8120A Genset Controller Power Active Conditions Inactive power Remark factor 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 P<0,Q<0 Output...
  • Page 15 HGM8110A/8120A Genset Controller Flywheel Teeth Gen 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...
  • Page 16 HGM8110A/8120A Genset Controller ADVANCED PARAMETERS SETTING 4.3.3 Advanced 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 Example, Advanced Parameters Setting Form1:...
  • Page 17 HGM8110A/8120A Genset Controller Overvolt Warn Form 5: are used for changing the setting Sel: Disable contents ( form 6). Confirm setting (form 7), Set Value： 00110% Return Value： 00108% return to previous menu (form 4) Delay： 00005 Overvolt Warn Form 6: are used for changing the setting Sel: Disable contents ( form 5).
  • Page 18 HGM8110A/8120A Genset Controller AUTOMATIC OPERATION Press , its indicator lights, and controller enters Auto mode. Starting Sequence, 1. HGM8120A: When Mains is abnormal (over and under voltage, over and under frequency), it enters into mains “abnormal delay” and VFD display count down time. When mains abnormal delay is over, it enters into “start delay”;...
  • Page 19 HGM8110A/8120A Genset Controller inactive. 3) HGM8120A： After stop delay ends, enter “cooling time”, and generator close relay is disconnected, after “switch transfer delay”, mains close relay output, mains is on-load, generator power supply indicator is extinguishing, and mains power supply indicator is illuminates.
  • Page 20 HGM8110A/8120A Genset Controller MANUAL OPERATION 1) HGM8120A: “Manual Mode” is active when press key and its indicator illuminates. Press key, then controller enters “Test Mode” and indicator illuminates. Under the both modes, press key to start genset, and it automatically detects if it starts successfully and accelerate high speed running.
  • Page 21 HGM8110A/8120A Genset Controller GENSET CONTROLLER ATS CONTROL PROCEDURES 1. HGM8120A ATS CONTROL PROCEDURES 1) If input port is configured as Closed Auxiliary (Mains Closed Auxiliary/ Gen Closed Auxiliary) A. If “Open breaker detect” is “SELECT 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 22 HGM8110A/8120A Genset Controller Generator load is transferred into generator unload, after the delay of switch off, switch off is completed. Generator unload is transferred into generator load, after the delay of switch on, detecting transfer failure while switch on outputting. When detecting time out, if switch on failed, to wait for switch on.
  • Page 23 (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 pieces event log records. HGM8110A/8120A Genset Controller ISSUE2016-9-28 Version1.6...
  • Page 24 HGM8110A/8120A Genset Controller 5 PROTECTION WARNINGS When controllers detects the warning signal, alarm only and not stop the genset, besides, the VFD displays the warning information. 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 25 HGM8110A/8120A Genset Controller Type Description signal. When controller detects the generator loss phase, it will Gen Loss of Phase send warn signal. Gen Phase When controller detects the reverse phase, it will send Sequence Wrong warn signal. When controller detects the switch on and off fail, and Switch Fail Warn the action select enable, it will send warn signal.
  • Page 26 HGM8110A/8120A Genset Controller 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 Emergency Stop send stop signal. When controller detects the speed value is higher than Over Speed the set value, it will send stop signal.
  • Page 27 HGM8110A/8120A Genset Controller Type Description Pressure Sensor When controller detects sensor is open circuit, and the Open action select “shutdown”, it will send stop signal. When controller detects oil pressure is lower than the Low OP Shutdown set value, it will send stop signal. Level Sensor When controller detects sensor is open circuit, and the Open...
  • Page 28 HGM8110A/8120A Genset Controller 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 Over Current value, and the action select “trip and stop”, it will send trip and stop signal.
  • Page 29 HGM8110A/8120A Genset Controller 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. When controller detects reverse power value (power is Reverse Power negative) is lower than the set value, and the action...
  • Page 30 HGM8110A/8120A Genset Controller 6 CONNECTING Compared with HGM8120A, HGM8110A has no 31~34 terminals. The back panel of HGM8110A and HGM8120A controller is shown as follows: Cable Size Function Remarks Connected with negative of starter DC input B- battery. Connected with positive of starter DC input B+ battery.
  • Page 31 HGM8110A/8120A Genset Controller Cable Size Function Remarks is active (B-) Details see form 3 Ground connected Aux. Input 2 is active (B-) Ground connected Aux. Input 3 is active (B-) Ground connected Aux. Input 4 is active (B-) Ground connected Aux.
  • Page 32 HGM8110A/8120A Genset Controller Cable Size Function Remarks Connected N-wire mains Mains N-wire input (HGM8110A without) Genset A-phase Connected to A-phase of gen-set (2A voltage sensing input fuse is recommended) Genset B-phase Connected to B-phase of gen-set (2A voltage sensing input fuse is recommended) Genset C-phase...
  • Page 33 HGM8110A/8120A Genset Controller 7 SCOPES AND DEFINITIONS OF CONFIGURABLE PARAMETERS HGM8110A/8120A generator controllers can set the following parameters, (HGM8110 has no mains items) CONTENTS AND SCOPES OF PARAMETERS FORM 1 Items Parameters Defaults Description Mains Setting 0: 3P4W; 1: 3P3W; AC System (0~3) 2: 2P3W;...
  • Page 34 HGM8110A/8120A Genset Controller Items Parameters Defaults Description Timer Setting Time from mains abnormal or remote Start Delay (0~3600)s start signal is active to start genset. Time from mains normal or remote Stop Delay (0~3600)s start signal is deactivated to genset stop.
  • Page 35 HGM8110A/8120A Genset Controller Items Parameters Defaults Description Offer standard judge Rated Speed (0~6000)r/min 1500 over/under/loading speed. Setting value is percentage of rated Speed speed. Controller detects when it is (0~100)% Load ready to load. It won’t switch on when speed is under loading speed. Loss Time from detecting speed is 0 to (0~3600)s...
  • Page 36 HGM8110A/8120A Genset Controller Items Parameters Defaults Description start motor and genset as soon as possible. When generator frequency higher Disconnect than the set value, starter will be Generator (0~200)% disconnected. See the installation Freq instruction. Setting value is percentage of rated speed.
  • Page 37 HGM8110A/8120A Genset Controller Items Parameters Defaults Description Under Volt. be set. (0~200)% Shutdown Setting value percentage Over Freq. (0~200)% 114% generator rated freq. Delay value Shutdown also can be set. Setting value percentage Under Freq. (0~200)% generator rated frequency. Delay Shutdown value can be set.
  • Page 38 HGM8110A/8120A Genset Controller Items Parameters Defaults Description generator switch from generator switch off to mains switch Pulse width mains/generator Close Time (0~20.0)s switch on. When it is 0, means output constantly. Pulse width mains/generator Open Time (0~20.0)s switch off. Time of detecting switch auxiliary Check Time (0~20.0)s contacts after transferred.
  • Page 39 HGM8110A/8120A Genset Controller Items Parameters Defaults Description Warn when sensor temperature higher than this value. Detecting High Temp. (0~300) ºC only after safety delay is over. The Warn delay value and return value also can be set. Temp. (0~1) 0: Disable; 1: Enable Warn Oil Pressure Sensor Curve Type...
  • Page 40 HGM8110A/8120A Genset Controller Items Parameters Defaults Description Flexible Input Port 2 Contents High temperature shutdown (0~50) Setting See form 3 0: Closed to active Active Type (0~1) 1: Open to active Flexible Input Port 3 Contents Low oil pressure shutdown (0~50) Setting See form 3...
  • Page 41 HGM8110A/8120A Genset Controller Items Parameters Defaults Description Active Delay (0~20.0)s Time from detecting active to confirm Description User defined. Flexible Output Ports Flexible Output Port 1 Contents User defined period output (default (0~239) Setting output is in preheating) See Form 2 Active Type (0~1) 0:Normally open;...
  • Page 42 HGM8110A/8120A Genset Controller t：Timing multiplier ratio IA：Current max. load current（L1/L2/L3） IT：Overcurrent setting value Example： t = 36 IA = 550A IT =500A Conclusion: T = 3600s(1hour) HGM8110A/8120A Genset Controller ISSUE2016-9-28 Version1.6 Page 42 of 63...
  • Page 43 HGM8110A/8120A Genset Controller 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 Custom Combined 1 following.
  • Page 44 HGM8110A/8120A Genset Controller sensor’s setting bound. It is controlled by cooler of temperature Cooler Control sensor’s setting bound. Oil Pre-supply Actions in period of cranking to safety run. Output in start period. If there is no generator Excite Generator frequency during hi-speed running, output for 2 seconds again.
  • Page 45 HGM8110A/8120A Genset Controller Active 0.1s when controller enter into warming Pulse raise speed up delay; used for control part of ECU raising to normal speed (temporary reserved). Crank Success Close when detects a successful start signal. Generator OK Action when generator are normal. Action in period of generator ok to hi-speed Generator Available cooling.
  • Page 46 HGM8110A/8120A Genset Controller 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 Action when input port 5 is active...
  • Page 47 HGM8110A/8120A Genset Controller over power. Reserved Action when controller detects generator have Reverse Power reverse 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...
  • Page 48 HGM8110A/8120A Genset Controller Config2 Low Shut 158~229 Reserved Stop Mode Action in stop mode. Manual Mode Action in Manual mode. Test Mode Action in Test mode. (HGM8110A without) Auto Mode Action in Auto mode. Generator On Load Mains On Load Reserved Reserved Reserved...
  • Page 49 HGM8110A/8120A Genset Controller Custom Combined Output 7.2.2 Defined combination output is composed by 3 parts, condition output S1 or S2 and condition output S3. S1 or S2 is TRUE, while S3 is TRUE, Defined combination output is outputting; S1 and S2 are FALSE, or S3 is FALSE, Defined combination output is not outputting. NOTE: S1, S2, S3 can be set as any contents except for “defined combination output”...
  • Page 50 HGM8110A/8120A Genset Controller DEFINED CONTENTS OF CONFIGURABLE INPUT PORTS (All active when connect to grand (B-)) Form 3 Type Description Including following functions, Indication: indicate only, warning shutdown. Warning: warn only, not shutdown. Shutdown: alarm and shutdown immediately Trip and stop: alarm, generator unloads and Users Configured shutdown after hi-speed cooling Trip: alarm, generator unloads but not shutdown.
  • Page 51 HGM8110A/8120A Genset Controller Aux Gen Closed Connect generator loading switch’s Aux. Point. Inhibit Gen Load Prohibit genset switch on when input is active. Aux Mains Closed Connect mains loading switch’s Aux. Point. Inhibit Mains Load Prohibit mains switch on when input is active. When input is active, controller enters into Auto Auto Mode Lock mode;...
  • Page 52 HGM8110A/8120A Genset Controller Simulate Start key Reserved Reserved Reserved Reserved Reserved Reserved Reserved In Auto mode, mains are normal when input is Aux Mains OK active (HGM8120A). In Auto mode, mains are abnormal when input is Aux Mains Fail active (HGM8120A). Alternative Config1 Users can set different parameters to make it easy to select current configuration via input...
  • Page 53 HGM8110A/8120A Genset Controller SELECTION OF SENSORS Form4 Description Remark 0 Not used 1 Custom Res Curve 2 Custom 4-20mA curve 3 VDO 4 CURTIS Defined resistance’s Temperature 5 VOLVO-EC 0~6KΩ, range Sensor 6 DATCON default is SGX sensor. 7 SGX 8 SGD 9 SGH 10 PT100...
  • Page 54 HGM8110A/8120A Genset Controller CONDITIONS OF CRANK DINSCONNECT 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: 1.
  • Page 55 HGM8110A/8120A Genset Controller 8 PARAMETER EDITING 1) Advanced Parameters Setting：After controller start, Input Password press to 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.
  • Page 56 HGM8110A/8120A Genset Controller 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 57 HGM8110A/8120A 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 58 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. HGM8110A/8120A Genset Controller ISSUE2016-9-28 Version1.6...
  • Page 59 HGM8110A/8120A Genset Controller TYPICAL WIRING DIAGRAMS HGM8110A Typical wiring diagram HGM8120A Typical wiring 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 2 ohms for battery cathode resistance, if less than 2 ohms, please expand relays with more than 30A current in corresponding output.
  • Page 60 HGM8110A/8120A Genset Controller for battery cathode resistance; if less than 1 ohm， please expand relays with more than 30A current in corresponding output. 3 Phase 3 Wire (take HGM8120A for example) Single Phase 2 Wire (take HGM8120A for example) 2 Phase 3 Wire (take HGM8120A for example) HGM8110A/8120A Genset Controller ISSUE2016-9-28 Version1.6...
  • Page 61 HGM8110A/8120A Genset Controller 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, 12.1 BATTERY VOLTAGE INPUT NOTE: HGM8110A/8120A controller can suit for widely range of battery voltage DC(8~35)V.
  • Page 62 HGM8110A/8120A Genset Controller 12.4 AC INPUT Current input of HGM8110A/8120A 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. Otherwise, the current of collecting and active power maybe not correct.
  • Page 63 HGM8110A/8120A Genset Controller FACTORY DEFAULT VALUES Here are the common faults and troubleshooting. If there is any other problem, please feel free to contact Smartgen’s service. Symptoms Possible Solutions Check starting batteries; Controller no response with Check controller connection wirings;...

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