Smartgen HGM8140Z User Manual
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Smartgen HGM8140Z User Manual

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HGM8140Z
GENSET CONTROLLER
USER MANUAL

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Summary of Contents for Smartgen HGM8140Z

  • Page 1 HGM8140Z GENSET CONTROLLER USER MANUAL...
  • 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 Indicates a procedure or practice, which, if not strictly observed, could result in CAUTION! damage or destruction of equipment. Indicates error operation may cause death, serious injury and significant property WARNING! damage. HGM8140Z Genset Controller User Manual Page 3 of 56...

  • Page 4: Table Of Contents

    13.9 DEUTZ EMR2 ............................50 13.10 JOHN DEERE ............................ 50 13.11 MTU MDEC ............................50 13.12 MTU ADEC (SMART MODULE) ......................51 13.13 MTU ADEC (SAM MODULE) ......................51 13.14 PERKINS ............................52 HGM8140Z Genset Controller User Manual Page 4 of 56...
  • Page 5 13.20 WEICHAI ............................54 14 ETHERNET PORT ............................55 14.1 ILLUSTRATION ........................... 55 14.2 NETWORK CLIENT CONNECTION MODE ..................55 14.3 CONTROLLER AND NETWORK CABLE CONNECTION..............55 15 TROUBLESHOOTING ..........................56 HGM8140Z Genset Controller User Manual Page 5 of 56...

  • Page 6: Overview

    1 OVERVIEW HGM8140Z genset controller, integrating digital, intelligent and network technology, adopts “Main Control and Display” separated type mode. It is suitable for single unit automation and monitoring system to achieve automatic start/stop, data measurement, alarm protection as well as remote control, remote measurement and remote communication functions.

  • Page 7: Performance And Characteristics

    2 PERFORMANCE AND CHARACTERISTICS HGM8140Z controller is used for single unit automation, which can control genset to start/stop by detecting DC input voltages or remote start signals. HGM8140Z controller contains two modules: HGM8140ZM (main control module) and HGM8140ZD (display module). Two modules can communicate with each other by RS232 or CAN BUS communication.
  • Page 8 Waterproof security level IP65 due to rubber seal installed between the controller enclosure  and panel fascia;  Modular design, anti-flaming ABS plastic enclosure, pluggable connection terminals and embedded installation way; compact structure with easy mounting. HGM8140Z Genset Controller User Manual Page 8 of 56...

  • Page 9: Specification Operation

    Protection Level panel fascia. Apply AC2.2kV voltage between high voltage terminal and low voltage Insulation Intensity terminal. The leakage current is not more than 3mA within 1min. HGM8140ZD: 0.28kg Weight HGM8140ZM: 0.43kg HGM8140Z Genset Controller User Manual Page 9 of 56...

  • Page 10: Operation

    Please keep the password in your mind after change it. If forget, please to contact with SmartGen service personnel, and send all the information in the page of “Controller Information”. NOTE: press any key can mute alarms.

  • Page 11: Controller Panel

    Speed, temperature of engine, engine oil pressure, liquid (fuel) level, battery voltage, charger voltage and etc. ★Alarm, including as below, All warning alarms and shutdown alarms are displayed. Fig.2 Gen Page Example Fig.3 Load Page Example HGM8140Z Genset Controller User Manual Page 11 of 56...

  • Page 12: Auto Start/Stop Operation

    , its indicator lights, and controller enters Auto mode. Starting Sequence, HGM8140Z: Generator enters into “start delay” as soon as “Remote Start” input is active or DC input volt is below pre-set start volt. Start Delay timer is shown on LCD.

  • Page 13: Emergency Start

    HGM8140Z Genset Controller User Manual Page 13 of 56...

  • Page 14: Protection

    LCD. High Temperature When it is enabled and the controller detects that config. sensor HGM8140Z Genset Controller User Manual Page 14 of 56...
  • Page 15 When it is enabled and low oil pressure shutdown is prohibited or low oil Low Oil Pressure pressure of input port shutdown is prohibited, controller will initiate a Warning Input warning alarm and the corresponding alarm information will be HGM8140Z Genset Controller User Manual Page 15 of 56...

  • Page 16: Trip Alarm

    “Trip”, it will initiate a trip alarm. When digit input port is selected as user-defined and it is set as “Trip” Digital Input and the alarm is active, it will initiate a trip alarm. HGM8140Z Genset Controller User Manual Page 16 of 56...

  • Page 17: Trip And Stop Alarms

    (action selects “Shutdown”), it will send stop signals and the corresponding alarm information will be displayed on LCD. Gen Over Voltage When controller detects the voltage value is higher than the set value, it HGM8140Z Genset Controller User Manual Page 17 of 56...
  • Page 18 “shutdown”, it will send stop signals. When controller detects the reverse power value (power is negative) is Reverse Power higher than the max. set value and the action select “shutdown”, it will HGM8140Z Genset Controller User Manual Page 18 of 56...
  • Page 19 NOTE: ECU warns and shutdown alarms illustration, if there are detailed alarms display, controller will check engine based on the content. Otherwise, please look up engine Manuel to get the information based on the SPN code. HGM8140Z Genset Controller User Manual Page 19 of 56...

  • Page 20: Wirings Connection

    Grounding is active (B-). Aux. Input 5 1.0mm Grounding is active (B-). Aux. Input 6 1.0mm Grounding is active (B-). Speed Sensor Input 0.5mm Connect with speed sensor, shielded wire is HGM8140Z Genset Controller User Manual Page 20 of 56...
  • Page 21 CT B-phase monitoring 1.5mm secondary coil of CT (5A input rated). Outside connected CT C-phase monitoring 1.5mm secondary coil of CT (5A input rated). Installation Details to see CT Common Ground 1.5mm Instructions. HGM8140Z Genset Controller User Manual Page 21 of 56...
  • Page 22 Aux. Sensor 1 Input 1.0mm resistor type sensor. Sensor Common 1.0mm Internally disconnected with B-. NOTE: USB ports in controller rear panel are programmable parameter ports, user can directly configure controller via PC. HGM8140Z Genset Controller User Manual Page 22 of 56...

  • Page 23: Hgm8140Zd Rear Panel

    30m, better to double wires in parallel. Max. 20A fuse is recommended. 0.5mm RS232 0.5mm Connected with HGM8140ZM module. 0.5mm CANL 1.0mm Connected with HGM8140ZM module. CANH 1.0mm HGM8140Z Genset Controller User Manual Page 23 of 56...

  • Page 24: Scops And Definitions Of Programmable Parameters

    118.0 of engine speed. See the installation instructions. Alarm delay of generator over voltage and Gen Abnormal Delay (0-20.0)s 10.0 under voltage. Over Volt (30-620)V When generator voltage has exceeded the HGM8140Z Genset Controller User Manual Page 24 of 56...
  • Page 25 10s, “Low Fuel Level” signal is initiated. (it is warning only). If the set value is 0, only warning and not to Loss of Speed Signal (0-20.0)s shut down the generator. HGM8140Z Genset Controller User Manual Page 25 of 56...
  • Page 26 Input, details to see Table 13. Digital Input 1 Delay (0-20.0)s Factory default: Low Oil Pressure Warning Digital Input 2 (0-31) Input, details to see Table 13. Digital Input 2 Delay (0-20.0)s HGM8140Z Genset Controller User Manual Page 26 of 56...
  • Page 27 Note 2 Low OP Shut Inhibit Factory default: when low oil pressure (0-1) Enabled occurs, shutdown alarm is initiated. Note 3 AC System (0-3) 0: 3P4W; 1: 2P3W HGM8140Z Genset Controller User Manual Page 27 of 56...
  • Page 28 Password to enter into the maintenance (0-9999) Password setting page. Date Setting Controller’s date setting. 0 Not used 1 Custom temperature sensor Custom Sensor Curve (0-3) 2 Custom pressure sensor 3 Custom level sensor HGM8140Z Genset Controller User Manual Page 28 of 56...
  • Page 29 When gen freq. is lower than this, but not 0 Under Freq. (0-75.0)Hz 42.0 and lasts for 5s, under freq. is considered Warning and under freq. alarm is initiated. HGM8140Z Genset Controller User Manual Page 29 of 56...
  • Page 30 PC software, it need to input password in password window. NOTE4: Between input correct password and LCD back light haven’t got dark, input parameter numbers can enter parameter setting interface when enters “Password Input” again. HGM8140Z Genset Controller User Manual Page 30 of 56...
  • Page 31 It is indicate that ECU has sent a warning alarm signal. ECU Shutdown It is indicate that ECU has sent a shutdown alarm signal. ECU Comm. Failure It is indicate that controller cannot communicate with ECU. HGM8140Z Genset Controller User Manual Page 31 of 56...
  • Page 32 Action when generator over frequency shutdown alarm. Shutdown Gen Over Volt Shutdown Action when generator over voltage shutdown. Gen Under Freq. Shutdown Action when generator low frequency shutdown. Under Volt. Shutdown Action when generator low voltage shutdown. HGM8140Z Genset Controller User Manual Page 32 of 56...
  • Page 33 Aux Input 4 Active Action when input port 4 is active. Aux Input 5 Active Action when input port 5 is active. Aux Input 6 Active Action when input port 6 is active. Reserved HGM8140Z Genset Controller User Manual Page 33 of 56...

  • Page 34: User-Defined Period Output

    If input port 3 inactive, defined combination output is not outputting; When input port 1 inactive and input port 2 inactive, whatever input port 3 is active or not, defined combination output is not outputting. HGM8140Z Genset Controller User Manual Page 34 of 56...
  • Page 35 When input is active, all keys except for on the Remote Control Mode panel of HGM8140Z are inactive and remote control mode will display on the LCD. HGM8140Z Genset Controller User Manual Page 35 of 56...
  • Page 36 When it is active, hose control function can be realized by the Enable displayed HGM8140ZD module on CAN-2 port. CAN-3 Display Control When it is active, hose control function can be realized by the Enable displayed HGM8140ZD module on CAN-3 port. HGM8140Z Genset Controller User Manual Page 36 of 56...
  • Page 37 1 Custom Resistance Curve 2 SGH 3 SGD Defined resistance’s range Fuel Level Sensor 4 Reserved 0Ω-6000Ω, default is SGD sensor. 5 Reserved 6 Digital Low Input Active 7 Digital High Input Active HGM8140Z Genset Controller User Manual Page 37 of 56...
  • Page 38 If not select generator frequency in crank disconnect setting, controller will not collect and display the relative power quantity (can be used in water pump set); if not select speed in crank disconnect setting, the engine speed displayed in controller is calculated by generator signal. HGM8140Z Genset Controller User Manual Page 38 of 56...

  • Page 39: Parameters Setting

    2) Language selection Chinese, English and Spanish can be optional. 3) LCD contrast control Press simultaneously to adjust LCD contrast ratio and make LCD character display more clearly. Contrast ratio adjustment range: 0-7. HGM8140Z Genset Controller User Manual Page 39 of 56...

  • Page 40: Sensor Setting

    6) The headmost or backmost values in the vertical coordinates can be set as same as below. Fig.6 Pressure Sensor Curve Table 16 Common Unit Conversion Table kgf/cm － － － 1.02x10 1x10 1.45x10 1kgf/cm 9.8x10 0.98 14.2 1bar 1x10 14.5 － － 1psi 6.89x10 7.03x10 6.89x10 HGM8140Z Genset Controller User Manual Page 40 of 56...

  • Page 41: Commissioning

    ATS transfers to genset on load. If not, please check ATS controlling wiring connection according to this user manual; If there is any other question, please contact our service personnel. HGM8140Z Genset Controller User Manual Page 41 of 56...

  • Page 42: Typical Application Diagram

    11 TYPICAL APPLICATION DIAGRAM Fig.7 HGM8140ZM Typical Application Diagram Fig.8 HGM8140Z Connection Diagram HGM8140Z Genset Controller User Manual Page 42 of 56...
  • Page 43 Fig.9 Single Phase 2-Wire Wiring Connection Fig.10 2-Phase 3-Wire Connection NOTE: Expand relay with high capacity in start and fuel output is recommended. HGM8140Z Genset Controller User Manual Page 43 of 56...

  • Page 44: Installation

    NOTE: Care should be taken not to over tighten the screws of fixing clips. 12.2 OVERALL DIMENSIONS Fig.11 HGM8140ZD Overall and Cutout Dimensions (Unit: mm) Fig.12 HGM8140ZM Overall and Installation Dimensions (Unit: mm) HGM8140Z Genset Controller User Manual Page 44 of 56...
  • Page 45 HGM8140Z genset controller can suit for widely range of battery voltage (8~35) VDC. Negative of battery must be connected with the engine shell. Diameter of wire that connects from power supply to battery must be over 2.5mm . If floating charge is configured, please firstly connect output wires of charger to battery’s positive and negative directly, then, connect wires from battery’s positive and...

  • Page 46: Connections Of Controller With J1939 Engine

    CAN_SCR 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. HGM8140Z Genset Controller User Manual Page 46 of 56...

  • Page 47: Cummins Qsm11 (Import)

    CAN communication shielding line (Connect CAN_SCR SAE J1939 shield-E 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. HGM8140Z Genset Controller User Manual Page 47 of 56...

  • Page 48: Cummins Gcs-Modbus

    Set relay output 1 as “Fuel Output”. Start relay output Connect with starter coil directly. CAN_SCR CAN communication shielding line. CAN(H) Using impedance 120Ω connecting line. CAN(L) Using impedance 120Ω connecting line. Engine Type: Common J1939. HGM8140Z Genset Controller User Manual Page 48 of 56...

  • Page 49: Cummins Qsz13

    Start relay output Connect to starter coil directly. CAN_SCR CAN communication shielding line. CAN(H) CAN(H) Using impedance 120Ω connecting line. CAN(L) CAN(L) Using impedance 120Ω connecting line. Engine type: Common J1939. HGM8140Z Genset Controller User Manual Page 49 of 56...

  • Page 50: Deutz Emr2

    Set relay output 1 as “Fuel Output”. Start relay output communication shielding line CAN_SCR (connect with one terminal only). CAN(H) Using impedance 120Ω connecting line. CAN(L) Using impedance 120Ω connecting line. Engine type: MTU-MDEC-303 HGM8140Z Genset Controller User Manual Page 50 of 56...

  • Page 51: Mtu Adec (Smart Module)

    SAM (X23 port) Remark CAN_SCR X23 3 CAN communication shielding line. CAN(H) X23 2 Using impedance 120Ω connecting line. CAN(L) X23 1 Using impedance 120Ω connecting line. Engine type: Common J1939. HGM8140Z Genset Controller User Manual Page 51 of 56...

  • Page 52: Perkins

    Using impedance 120Ω connecting line. CAN(L) Using impedance 120Ω connecting line. Engine type: Volvo. NOTE: When this engine type is selected, preheating time should be set to at least 3 seconds. HGM8140Z Genset Controller User Manual Page 52 of 56...

  • Page 53: 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. HGM8140Z Genset Controller User Manual Page 53 of 56...

  • Page 54: Yuchai

    Using impedance 120Ω connecting line. 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. HGM8140Z Genset Controller User Manual Page 54 of 56...

  • Page 55: Ethernet Port

    Parallel cable: EIA/TIA 568A standard on both ends or EIA/TIA 568B standard on both ends. NOTE: If switchboard (or router) network port has Auto MDI/MDIX function, crossover cable can also be used. HGM8140Z Genset Controller User Manual Page 55 of 56...

  • Page 56: Troubleshooting

    Check RS485’s connections of A and B is reverse connect or not; abnormal Check communication port of PC is damaged or not. Put 120Ω between A and B of controller RS485 port is recommended. _________________________________ HGM8140Z Genset Controller User Manual Page 56 of 56...

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