User Manual
Contents
1. Smartgen HGM190 190HC Generator Control Module User Manual Smartgen Technology HGM190 190HC Generator Control Module Smartgen Smartgen Technology Co Ltd No 28 Jinsuo Road Zhengzhou Henan Province P R China Tel 0086 37 1 67988888 67981888 0086 37 1 67991553 67992951 67992952 0086 371 67981000 overseas National Free Tel 4000318139 Fax 0086 371 67992952 67981000 Web http www smartgen com cn http www smartgen cn Email sales smartgen com cn 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 Applications for the copyright holder s written permission to reproduce any part of this publication should be addressed to 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 Software Version Date Version Notes o 2007 11 01 Original release 2010 08 12 Change over speed time from 3s to 1 55 2011 0643 13 Change ne name of the pompany Smartgen electronics to Smartgen Technology 2011 12 22 Modify Typical Application HGM190 190HC Generator Controller ISSUE 2011 12 22 Version 1 4 Page 2 of 11 HGM190 190HC Generator Co2. 1m 3mA leakage current Weight 0 25kg 4 PANEL OPERATION 4 1 Keys and Indicators Protection Level gt keys BEN De In Stop Mode or Auto Mode this key is inactive JO Va PE siop voae or Auto Moe ne key is racie In Stop Mode or Auto Mode this key is inactive Pressing this key can set parameters gt Indicators E Q High Temperature When engine stops for high temperature it illuminates When engine stops for low oil pressure it By Low Oil Pressure A en p p illuminates Over Speed When engine over speed it illuminates HGM190 190HC Generator Controller ISSUE 2011 12 22 Version 1 4 Page 5 of 11 HGM190 190HC Generator Control Module charge Failure When engine failed to charge it illuminates When over speed temperature high oil pressure low auxiliary shutdown alarm Saa O Somone fail to start and fail to stop alarms occur it illuminates Hours Connie Genset accumulated run hours Max 99999 9 hours 4 2 Description of Working Modes The module has 3 positions stop position O manual position O and auto position fars including 3 keys pre heat key start key O and set key G 1 Stop Position O During genset normal running turn the key to stop position enter into idle process and idle high speed relay disconnect When idle delay is over fuel relay disconnects ETS outputs and genset stops When genset fault alarm occurs turn the key to stop position a
3. engine shell The connection of controller power supply B and B to battery poles should not be less than 2 5mm if float charger is fitted please directly connect the charger output wire to battery poles HGM190 190HC Generator Controller ISSUE 2011 12 22 Version 1 4 Page 10 of 11 2 3 HGM190 190HC Generator Control Module and then separately connect the wirings from the battery poles to the power supply output of the controller in case that the charger will interfere with the normal operation of the controller Output and Expansion Relay All output of the controller is relay contacts output if there is need to expand output relays please expand follow current diode in both ends of the relay coil when extended relay coil links DC or increase resistance and capacitance loop when extended relay coil links AC in order to prevent interference with the controller or other equipments Withstand Voltage Test When the controller has been installed in the control panel if you want to have withstand voltage test please disconnect all terminals in the controller lest high voltage damages the controller 11 FAULT FINDING Check starting batteries Controller no response with u Check controller connection wirings power Check DC fuse Check if the engine temperature is too high Genset shutdown Check the genset AC voltage Check DC fuse Low oil pressure alarm after Check the oil pressure sensor and its crank disc
4. running situations and AC generator s voltage and frequency If abnormal stop genset running and check all connections according to this manual 7 Set controller into Auto mode enable remote start input and start the engine If there is any wrong during engine running stop to check the connections according to the manual 8 If there are any other questions please contact Smartgen s service gt AN ANN AN HGM190 190HC Generator Controller ISSUE 2011 12 22 Version 1 4 Page 9 of 11 HGM190 190HC Generator Control Module 9 TYPICAL APPLICATION MAGNETIC PICKUP Uns Remote Start Aux snutaown High Engine Temp Low Ol Pressure 3 4 Jean free Fr 2A i E Alt 74 Crank ii m motor Battery negative should be grounded 10 INSTALLATION The controller is built in design which fixed by fixing clips The overall dimensions and cutout is as following 2 Stop Output Config Output Preheat Output WL D WL EJ High Engine Temp Input E Low Oil Pressure Input 7 Alternate Charger WL D E Aux Shutdown Input 5 cen MP A Start Output MP 3 Fuel Output Config Output 2 ES Stop Output 65mm 72mm S5 S N N 5 S5 S gY Sales O B Remote Start Input 2091 0902 N A 77mm 84mm 1 Battery Voltage Input HGM190 190HC can be applicable to range of 8 35 VDC battery voltage battery negative must be reliability connected to
5. time HGM190 190HC Generator Controller ISSUE 2011 12 22 Version 1 4 Page 7 of 11 HGM190 190HC Generator Control Module O Q O Reserved Q Reserved Reserved Note O means light is illuminating while O means not 2 Setting procedures of rated speed Turn the key to Auto position O long pressing at least 5 seconds to enter into setting status Press to preheat and to crank When reaching rated speed press to set the speed See the below table After setting turn the key to stop position O to exit the setting status and genset stops Result Successful Note a During setting rated speed over speed is not protected If rotating speed is O the setting is invalid Rated speed can be repeatedly set under programming mode If there is no need to set rated speed turn the key to Auto position without starting the engine and go to the stop position directly If programmable output is set as common alarm output idle delay is 0 6 ALARM AND PROTECTION Low Oil Pressure After crank disconnect detecting begins after delay 10s Low OP lasts for 2s alarm to shutdown High Temperature After crank disconnect detecting begins after delay 10s High temperature lasts for 2s alarm to shutdown Over Speed Detect when crank disconnect Over speed lasts for 1 5s alarm to shutdown Charge Faily Detect when high speed running When D WL voltage under 3V and lasts for 3s war
6. isconnect and enter into 10s idle delay When idle delay is over idle high speed relay close and the genset run in high speed Note During crank interval delay fuel relay disconnects 3s delay begins Once delay is over ETS energize to stop disconnect fuel outputs and preheat output disconnect before cranking When remote start input inactive enter into idle process after 10s delay During this period idle high speed output disconnects Once idle delay over fuel disconnects ETS output genset will stop automatically When genset at rest ETS and idle output disconnect Under this mode preheat key start key and set key Y are disable 5 SETTING Setting contents Idle time rotating speed when crank disconnect and rated speed 1 Setting procedures of idle time and rotating speed Turn the key to stop position O pressing set key SD for at least 5 seconds can enter into editing status Idle time and rotating speed when crank disconnect can be set Press preheat key to choose items withzfsand indicating then press to choose the value of setting item with and indicating see the below table tm ke amp a Value Q JQ Q Bseconds Q0 6 10seconds Default Q O t5secons OQ OO 20secons _ Q JQ 30seconds Q O 60secons QO 120seconds _ 180seconds QIQ le Rotating speed OQOJQO i8 FF percentage of rated O Q 24 Default pa ee A _ O O 38 o Idle
7. larm can be removed In genset normal standby turn key to stop position controller will be in low power consumption standby mode 9 In this mode preheat and start key are inactive 2 Manual Position O Turn the key to manual position Press key preheat outputs and disconnects before starter is powered After crank disconnect preheat output is disabled Turn the key to manual position Press amp key after preheat outputs 1s starter is powered to output and genset starts When gens frequency is over 15Hz or OP sensor disabled OP sensor is enabled before cranking or press Oey starter power off and crank disconnect After 10s safety delay enter into idle delay When delay is over idle high speed relay closes and genset enters into high speed running 3 Auto Position AT HGM190 190HC Generator Controller ISSUE 2011 12 22 Version 1 4 Page 6 of 11 HGM190 190HC Generator Control Module Turn the key to Auto position When remote start signal active connect to B after 2s delay genset will start automatically preheat delay begin outputting When the delay is over fuel outputs and preheat output disconnects after 1s crank begins Maximum 3 times to start 8 seconds for cranking and 10 seconds interval If crank disconnect within 3 times module is started if fail to disconnect every time common alarm annunciator illuminates and relay outputs When engine speed exceeds crank speed can be set crank d
8. n not shutdown Auxiliary Stop Alarm Detect in Auto mode and Manual mode do not detect in stop mode Fail to Start Under normal condition fail to start within 3 times Fail to stop When fuel signal has disconnected for 30s but genset not stop then the input is active Lose of Speed Signal After crank disconnect detect when delay 10s If lasting for 5 seconds alarm to shutdown Common Alarm when over speed high temperature low oil pressure auxiliary shutdown alarm lose of speed signal fail to start and fail to stop happen alarm HGM190 190HC Generator Controller ISSUE 2011 12 22 Version 1 4 Page 8 of 11 HGM190 190HC Generator Control Module annunciator illuminates and common alarm outputs 7 CONNECTIONS Terminals description 9 Terminal 1 B Connected to plant battery negative Terminal 2 B Connected to plant battery positive Terminal 3 Fuel Output Fuel Output B Connected to fuel relay Terminal 4 Start Output Start Output B Connected to start relay Terminal 5 Pre heat Output Pre heat Output B Terminal 6 Aux Shutdown Input auxiliary shutdown alarm input connect to B active Terminal 7 D Connect to alternator WL or D terminal When charging fails D voltage lt 3V annunciator on the panel illuminates indication only not shutdown Terminal 8 Low Oil Pressure Input Low Oil Pressure Input port connect B active Terminal 9 High Engine Temp in
9. ntrol Module CONTENTS SUMMARY ee ee 4 2 PERFORMANCE AND GHARAGTERISTICSen 22522 een 4 O ze ee ee Rs tg 4 A PANE OPERATION ns iii oil deans laico 5 AA Keys and MICA a 5 4 2 Description of Working Modes ccooccccccccccccoccncnoncnconoconononcncnnanononannnonnanono ernennen 6 Soe fi Cit ee hr ie nee 7 6 ALARM AND PROTECTION 22222222222222000000000000000000 nennen EEE ar 0 ccoo 8 CONNECTIONS cup ea Zi Be 9 8 COMMISSION Nissan II ee en 9 9 TYPICAL APPLICATION een Mean on on on on N ee 10 F ANS TALLATION se rea or n ste een 10 11 FAULT FINDING ze IE ia 11 HGM190 190HC Generator Controller ISSUE 2011 12 22 Version 1 4 Page 3 of 11 HGM190 190HC Generator Control Module 1 SUMMARY HGM190 190HC is a generator control module designed to start and stop the engine via a key switch and pushbuttons on the front panel or remote start signal When detecting faults low oil pressure high water cylinder temperature auxiliary alarm over speed it will disconnect fuel relay and energize to stop LED annunciator displays the faults which can offer real and effective alarm information HGM190HC adds hours counter based on HGM190 other functions are as the same 2 PERFORMANCE AND CHARACTERISTICS 9410090900 9 Wide range of DC supply can adapt to 12V or 24V starting battery Low oil pressure high water cylinder temperature over speed protection and indication With charge failure indication warn n
10. onnect connections High water cylinder temp Check the temperature sensor and its alarm after crank disconnect connections Check fuel circuit and its connections Check starting battery Check speed sensor and its connections Refer to engine manual Check starter connections Starter no response Check starting battery Crank not disconnect HGM190 190HC Generator Controller ISSUE 2011 12 22 Version 1 4 Page 11 of 11
11. ot shutdown An auxiliary shutdown alarm signal Speed signal comes from generator frequnecy LED displays various alarm states Hours counter LCD display Rated rotating speed over speed threshold can be set With fuel output start output pre heat stop output and common alarm idle output All are relay output Idle speed control Output can be set as idle high speed output by dialing the switch or the port is common alarm output See the picture Idle delay is programmable Modular structure design ABS plastic case plug in installation compact structure with small volume advanced SCU control stable performance and convenient operation 3 SPECIFICATION Contents Working Voltage DC8 0V to 35 0V continuous Standby 12V 0 12W 24V 0 24W Power Consumption Working 12V 0 5W 24V 1W Speed Signal Input 1 24 V RMS lt 10kHz Engine Speed Over Speed 114 of rated Disconnect Charge Failure Volt 4 Digital Inputs Connect to B active HGM190 190HC Generator Controller ISSUE 2011 12 22 Version 1 4 Page 4 of 11 HGM190 190HC Generator Control Module 1Amp DC28V relay output Temperature 30 70 2C Humidity 20 90 Temperature 40 80 C IP55 when waterproof rubber gasket added between controller and its panel IP42 when waterproof rubber gasket not added between controller and its panel Object among input output power Insulation Intensity Quote standard IEC688 1992 Test way AC1 5kV
12. put High water cylinder temperature input port connect to B active Terminal 10 L 11 N Connect to AC voltage signal for detecting crank disconnect and over speed protection Terminal 12 Config Output Config Output B can be set as idle high speed output or common alarm via dial switch of the controller Terminal 13 Stop Output Energize to stop ETS B Terminal 14 Remote Start Input Remote start input port connect to B active 8 COMMISSIONING Please make the under procedures checking before commissioning 1 Check all the connections are correct and wires diameter is suitable 2 Ensure that the controller DC power has insurance controller s positive and negative connected to start battery are correct 3 Auxiliary alarm input is connected to start battery negative via normal close contact of emergency stop button and insurance 4 Take proper action to prevent engine to crank disconnect e g Remove the connection wire of fuel valve If checking is OK energize start battery 5 Set controller into Manual mode press start button genset will start After the setting times controller will send fail to start signal press stop key to reset the controller 6 Recover the action of stop engine start e g Connect wire of fuel valve press start button again genset will start If everything goes well genset will enter into normal running During this period please watch for engine s
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