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HGM 6120U User Manual

1. Mains Under Voltage 30 620 V 30 620 V R Transfer est 0 99 9 s controller send start fail signal Time of pre powering heat plug before starter is powered up Time of starter power up each time The second waiting time before power up when engine Start fail When engine start failure it s Start Times 1 10 times the maximum cranking times Preheat Time 0 300 s When setting crank times out Crank Time 3 60 s Crank Rest Time 3 60 s AN Alarm for low oil pressure high temp under speed under frequency voltage charge fail are all inactive Idle running time of genset when starting Safe Running 1 60 s Start Idle Time 0 3600 s HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 16 of 32 HGM6100U Series Automatic Control Module items Default Warming time between Warming Up Time 0 3600 s 10 genset switch on and high speed running Coolant Time 3 3600 s HA for cooling before stopping Stop Idle Time 0 3600 s e run time when genset Stop electromagnet s power ETS Time 0 120 s on time when genset is Over Stop Delay 0 120 s stopping If ETS output time set as 0 it is the time from end of idle delay to gen set at rest if not 0 it is from end of ETS solenoid delay to gen set at rest Mains or generator s switch 0 10 s closing pulse width when it is 0 output is continuous Number of flywheel teeth it 10 30
2. High cart When the temperature of water cylinder is higher than set Shutdown threshold controller will send a stop alarm signal and it will be displayed in LCD Shutdown send a stop alarm signal and it will be displayed in LCD shutdown will send a stop alarm signal and it willbe displayed in LCD shutdown will send a stop alarm signal and it will be displayed in LCD Loss Of Speed When rotate speed is and delay is not 0 controller will Signal Shutdown send a stop alarm signal ana it will be displayed in LCD Genset Over Voltage Shutdown Genset Under Voltage Shutdown Genset Over When genset voltage is higher than threshold controller will send a stop alarm signal and it will be displayed in LCD When genset voltage is under set threshold controller will send a stop alarm signal and it will be displayed in LCD When genset current is higher than set threshold and delay Current is not O it will send a stop alarm signal and it will be Shutdown displayed in LCD Within set start times if failed to start controller will send a 2 stop alarm signal and it will be displayed in LCD When genset frequency is higher than set threshold controller will send a stop alarm signal and it will be displayed in LCD When genset frequency is lower than set threshold controller will send a stop alarm signal and it will be displayed in LCD When genset frequency is O controller will send a stop stop alarm signal and it will
3. 2 32 Temp Sensor Open Circuit 0 2 Action 0 Indication 1 Warning Oil Pressure 2 Shutdown sensor Open 0 2 Circuit Action It is used for settin enset 76 Maintenance time 0 5000 h 30 S TH Y maintenance interval N O1 O Not used 1 Warning 2 Shutdown When maintenance action type is set as Not used maintenance alarm reset Maintenance time out action 0 Defined temperature sensor 1 Defined pressure sensor 2 Defined liquid level sensor Select the sensor input corresponding 8 values Defined Sensor Curve N 00 N N N Note1 if select high temperature inhibit or set programmable input as High Temperature Inhibit this input is active when temperature is higher than pre setting threshold or high temperature alarm is activated controller sends warning signal only and not shutdown HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 21 of 32 HGM6100U Series Automatic Control Module Note2 if select low oil pressure inhibit or set programmable input as Low Oil Pressure Inhibit this input is active when low oil pressure is lower than pre setting threshold or low oil pressure alarm is activated controller sends warning signal only and not shutdown 7 2 PROGRAMMABLE OUTPUT 1 4 TABLE TABLE 2 Not Used Output is disabled when this item is selected Including all shutdown alarm and warning alarm When a warning alarm occurs the alarm won
4. Aux Input 5 0 15 actory default Low coolant level warn Aux Input 0 1 Factory default close Active Aux Input 0 20 0 s Delay Power Mode 0 Stop Mode Manual Select Mode 2 Auto a 1 Module Address 1 254 4 The address of controller Conditions of disconnecting 2 0 9989 starter generator magnetic Crank pickup sensor oil pressure Disconnect Each condition can be used Condition alone and simultaneously to separating the start motor and genset as soon as possible When engine speed is over Engine Speed 0 3000 RPM 360 this point starter will disconnect When generator frequency is 10 30 Hz over this point starter will disconnect Factory default close al gt W W W lidi JOE O oO N O O A Engine Frequency O VI O O When engine oil pressure is 0 400 kPa over this point starter will disconnect Engine Pressure HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 20 of 32 HGM6100U Series Automatic Control Module High Temp Inhibit Default when temperature is Select 0 1 overheat the genset alarm and shutdown Note1 Low OP Inhibit Default nen oil pressure is Select 0 1 too low it alarm and shutdown is Voltage Input eo e fe 0 3P4W 2P3W Select 1P2W 3 3P3W Select ANN Seleci Sensor Select Number of magnetic poles used for calculating rotating speed of generator without speed sensor O N N O Poles Number
5. When input is disabled genset will automatically start or stop judging by mains normal or not 7 4SENSOR SELECTION TABLE 4 0 Not used 1 Defined Resistance Type 2 VDO 3 SGH Huanghe sensor Temperature 4SGD DongKang sensor Sensor 5 CURTIS 6 DATCON 7 VOLVO EC 8 SGX 9 Reserved O Not used 1 Defined Resistance Type 2 VDO 10Bar 3 SGH Huanghe sensor Pressure 4 SGD DongKang sensor Sensor 5 CURTIS 6 DATCON 10Bar 7 VOLVO EC 8 SGX 9 Reserved 0 Not used 1 Defined Resistance Type Fuel Level 2 SGH Sensor 3 SGD 4 Reserved 1 5 Reserved 2 7 5 CONDITIONS OF CRANK DISCONNECT TABLE 5 HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 24 of 32 Defined input resistance range is 00 60000 factory default is SGX sensor Defined input resistance range is 0060000 factory default is SGX sensor Defined input resistance range is 0 6000Q factory default is SGD sensor HGM6100U Series Automatic Control Module nu Magnetic pickup sensor Magnetic pickup sensor Generator Magnetic pickup sensor Oil pressure Generator Oil pressure Generator Magnetic pickup sensor Oil pressure 1 There are 3 kinds of crank disconnect conditions Magnetic pickup sensor and generator can be used alone Oil pressure must be used with magnetic pickup sensor and the generator in order to make the starter and the engine disconnect as soon as possible 2 Magnetic pickup sensor is ins
6. g Remove the connections of fuel value If checking is OK connect start battery select Manual Mode controller will execute the program Set controller as Manual Mode press start button to start genset If failed within the setting crank times controller will send Failed to Start signal then press stop to reset controller Recover actions of preventing engine to disconnect crank e g Connect wire of fuel value press start button again genset will start If everything goes well genset will normal run after idle running if configured Duringrthis period watch for engine s running situations and voltage and frequency of alternator lf there is abnormal stop genset and check all connections according to this manual Select the Auto Mode from front panel Connect Io mains signal After the mains normal delay controller will transfer ATS if configured into mains load After cooling controller will stop genset and into standby state until mains abnormal again When mains abnormal again genset will start automatically and into normal running send signal to makergens close transfer ATS and make genset take load If it not likes this please check connections of ATS according to this manual lf there are any other questions please contact Smartgen s service HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 28 of 32 HGM6100U Series Automatic Control Module 11TYPICAL APPLICATION
7. is sending out When the Low Oil Pressure 0 400 kPa value is 0 warning alarm shutdown won t be sent only suited for oil pressure sensor except for low oil pressure alarm signal inputted by programmable Under Frequency shutdown van Over Frequency Hz shutdown ER High Temperature shutdown aS A input port When fuel level sensor value under this point and remains for 10s genset send out warning alarm only warn but not shutdown it only warn but not EN During generator is running when charge alternator WL D voltage is under this Low Fuel Level 0 100 Loss Of Speed 2 Signal Delay nee Charge Failure 0 30 V point and remain for 5s generator will warning alarm and shutdown HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 18 of 32 HGM6100U Series Automatic Control Module o Range Zz Default When generator battery voltage is over the point and 12 40 V 33 0 remains for 20s battery over voltage signal is active it only warn but not shutdown Battery Over Voltage When generator battery voltage is under the point and remains for 20s battery under voltage signal is active it only warn but not shutdown Voltage 5 CT Rate 5 6000 5 500 Current transformer rate Rated current of generator Full Load Current 5 6000 A 500 used for calculating over load current When load current is over the 50 130 120 point the over current dela
8. be displayed in LCD send a stop alarm signal and it will be displayed in LCD HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 12 of 32 Over Frequency Shutdown zech Under Frequency Shutdown a al HGM6100U Series Automatic Control Module When sensor hasnt connected to corresponding port controller will send shutdown alarm signal and it will be displayed in LCD Oil Pressure When sensor hasn t connected to corresponding port Sensor Open controller will send shutdown alarm signal and it will be Temp Sensor Open Circuit Circuit displayed in LCD When genset running is longer than maintenance time of user setting and maintenance action is set as shutdown controller send shutdown alarm signal ong H will be displayed in LCD When maintenance action type ls set as Not used maintenance alarm reset Maintenance time out shutdown 6 CONNECTIONS Compared with HGM6120UC HGM6110UC doesn t have 3 phase input terminal of mains voltage The back panel of HGM6110UC and HGM6120UC is as below EEEEELELELEER ENE EEN B ul N m a U V W N2 R S T NI GENS VOLTAGE MAINS VOLTAGE CRANK 16A AUX OUTPUT 7A250VAC AUX OUTPUT 16A250VAC AUX OUTPUT 4 16A 250VAC CHARGER D C RS485 ISOLATION ez CURRENT RATED 5A IA IB IC ICOM NPUT u H z FUEL LEVEL ZU16 1110 AUX AE ee D 5 16 17 16 9 20 21 22 26 020 EEE ee
9. cece cee 12 6 CONNECTIONS EE 13 7 PARAMETER RANGE AND DEFINITION amp Ben 15 7 1 PARAMETER CONTENT AND RANGE TABLE TABLE 1 15 7 2 PROGRAMMABLE OUTPUT 1 4TABLE TABLE Zi 22 7 3 PROGRAMMABLE INPUT 1 5 TABLE ALL IS ACTIVE WHEN CONNECT TO GROUND B TABLE 3 ae WA ontevreden 23 7 4 SENSOR SELECTION TA GBR MD eenen RRE NK 24 7 5 CONDITIONS OF CRANK DISCONNECT TABLE 5 nee 24 8 PARAMETER SETTING ten 25 9 SENSOR SETTING nnen 26 10 COMMISSIONING en 27 11 FYPICAL APPLICATION enn 29 12 INSTALLATION en 30 A On AAA 30 12 2 OVERALL DIMENSION AND PANEL CUTOUT cece cece ec ceceeeeeeeeees 31 13 FAQ DO NO iii 32 HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 3 of 32 HGM6100U Series Automatic Control Module 1 SUMMARY HGM6100U series automatic controller integrating digital intelligent and network techniques is used for automatic control and monitoring system of genset It can carry out functions of automatic start stop data measurement alarm protection and three remote remote control remote measure and remote communication The controller uses LCD display optional display interface including Chinese English Spanish and Russian with easy and reliable operation HGM6100U series automatic controller uses micro processing technique which can achieve precision measurement value adjustment timing and threshold setting etc All the parameters can be configured from front panel or use pro
10. of low oil pressure hightemperature under speed charge failure and Aux input be configured are disabled As soon as this delay is over genset will enter into Start Idle Delay if configured During start idle delay alarms of under speed under frequency under voltage are disabled As soon as this delay is over genset will enter into Warming up Delay if configured When Warming up Delay is over the indicator is illuminating if gens normal li voltage and frequency of engine reach the load requirement close relay outputs genset is taking load and indicator illuminates if engine voltage or frequency is abnormal controller will alarm and shutdown LCD displays the alarm information Stopping Sequence 1 4 HGM6120UC during normal running if mains normal genset will enter into Mains Normal Delay when mains indicator illuminates Stop Delay begins HGM6110UC genset enters into Stop Delay as soon as Remote Start is inactive When Stop Delay is over genset enters into Cooling Delay Closing relay is disconnected After switch Transfer Rest Delay closing relay is outputting mains is taking load generator indicator eliminates while mains indicator illuminates When entering Stop Idle Delay idle relay is energized to output If configured HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 9 of 32 HGM6100U Series Automatic Control
11. quickly detail procedures please refer to No 4 9 of Auto start operation After genset runs well in high speed ares Band gens take load 3 Manual stop oressing D can shut down the running genset detail procedures please refer to No 3 7 of Auto stop operation 5 PROTECTION 5 1 WARNINGS When controller detects the warning signal the genset only alarm and not stop The HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 10 of 32 HGM6100U Series Automatic Control Module alarms are displayed in LCD Warnings as following When the speed of genset is 0 and speed loss delay is 0 controller will send warning alarm signal and it will be displayed in LCD Loss Of Speed Signal When the current of genset is higher than threshold and setting over current delay is 0 controller will send warning alarm signal and it will be displayed in LCD Genset Over Current When genset cannot stop after the stop delay is over Fail To Stop controller will send warning alarm signal and it will De displayed in LCD When the fuel level of genset is lower than threshold or low Low Fuel Level fuel level warning is active controller will send warning alarm signal and it will be displayed in LGD When the voltage of genset charger is lower than threshold Charge Failure controller will send warning alarm signal and it will be displayed in LCD e Battery When the battery voltage of genset is lo
12. 0 can detect disconnection conditions and engine speed 0 20 0 s Hoo E or under volt alarm When genset voltage is over the point generator over 30 620 V voltage is active When the point is 620V generator over voltage is disabled When generator voltage is under the point generator 30 620 V under voltage is active When Switch Close Genset Over Voltage shutdown Genset Under Voltage the point is 30V generator under voltage is disabled When the engine speed is under the point for 10s shutdown alarm signal is sent Under Speed shutdown 0 6000 RPM When the engine speed is 0 6000 RPM over the point for 2s shutdown shutdown alarm signal is sent HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 17 of 32 PO HGM6100U Series Automatic Control Module in OOU Series Automatic Control Module Range Default When generator frequency is lower than the point not equal to 0 for 10s shutdown alarm signal is sent When generator s frequency is over the point and continues for 2s generator over frequency is active When engine temperature sensor value is over this point it sends out high temp alarm When the value is 140 warning alarm won t be sent only suited for temperature sensor except for high temp pressure alarm signal inputted by programmable input port No When engine oil pressure sensor value is under this point Low Oil Pressure alarm
13. C without 34 Mains N1 Input at Connect to mains N wire HGM6110UC without RS485 Common Ground Impedance 1200 shielding wire is RS485 recommended its single end connect RS485 with ground Ground connected is fi le 4 1 2 ongure active B Reference 39 Configurable Input 5 1 0mm Ground connected is table 3 active B Ani LINK ports in controller rear panel are programmable parameter ports user can directlyprogram SG72 via PC 1 0mm NO NO NO W 00 7 PARAMETER RANGE AND DEFINITION 7 1 PARAMETER CONTENT AND RANGE TABLE TABLE 1 Default Mains Normal Delay 0 3600 s The delay from abnormal to HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 15 of 32 HGM6100U Series Automatic Control Module No Range Default normal or from normal to abnormal It used for ATS automatic transfer switch control When mains voltage is under the point mains under voltage active When the value is 30 mains under voltage disabled When mains voltage is greater than the point mains over voltage active When the point ds 620V mains over voltage disabled It s the delay from mains open to generator closed or from Time generator open to mains closed Time from mains abnormal or remote start signal is active to No e o ou K start genset Time from mains normal or 0 3600 s a remote start signal is inactive to genset stop Mains Abnormal 3600 s Delay a
14. HGM6110UC Typical Application Diagram u U 0 0 2 L1 mou mmm Q a V di ME medi L2 el Gi W sis mp L3 O a pen TI N oe N _ 10 AUX OUTPUT2 O AUX OUTPUT 4 8 9 as be H 12 13 30 29 28 Sg 23 24 25 26 e 4 14 17 18 19 1516 20 21 23 35 39 an al el ela sen gt ul 3 2 gt 2 gt gt wr IL Yl kr Ma W a a a a a O zc ii u Z 2 5 el e sl lt gt O TI lt st lt lt x 5 op HI lt SEE HGM6120UC Typical Application Diagram LOAD WAS SWITCH 1 SWITCH2 WON en U ee R a l wg a z V SCH amm S Z ETT s a y T je N _ KC m N 5 l lt L a O o ke AUX OUTPUT 2 2 ET C 3S a 23 24 25 26 30 28 SE Ba ET 32 33 34 5 u LA 37 o 14 17 18 19 1516 20 21 22 38 39 Ao em a wl a I da SL un E W A 5 Y LLI gt E gt f E a a il rye op OD ao ar al a a Ol 2 Lu i O 5 5 5131 3 3 3 Dy Fiol lt x z lt x x ol Of 5 lt O MAGNETIC PICKUP HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 29 of 32 HGM6100U Series Automatic Control Module Single Phase 2 Wire 34 31 30 single Phase 2 Wire 2 Phase 3 Wire 27 28 30 34 32 31 Phase 3 Wire Note Recommend that the output of crank and Fuel expand high capacity relay 12INSTALLATION 12 1 FIXING CLIPS The module is held into the panel fascia using the supplied fixing clips 1 Withdraw the fixin
15. Module When entering ETS Delay ETS relay is energized to output fuel relay output is disconnected When entering Genset at Rest genset will automatically judge if it has stopped When genset has stopped enter into standby mode if genset failed to stop controller will alarm Fail to Stop alarm will be displayed in LCD 4 4MANUAL START STOP OPERATION 1 HGM6120UC Auto Mode is active when press anc its indicator illuminates press then controller enters into Manual Test Mode and its indicator is illuminating Under both of the modes res Do start genset It can automatically detect crank disconnect and accelerate to high speed running lf there is high temperature low oil pressure over speed and abnormal voltage during genset running controller can protect genset to stop detail procedures please refer to No 4 9 of Auto start operation Under Manual Mode switch wont transfer automatically it is necessary to pres Bo transfer load Under Manual Test Mode after genset runs well in high speed no matter mains is normal or not loading switch will be transferred to gens HGM6110UC Auto Mode is active when oressing W and its indicator is 2 illuminating Then ress Di start genset it can automatically detect crank disconnect and accelerate to high speed running If there is high temperature low oil pressure over speed and abnormal voltage during running controller can protect genset to stop
16. Smartgen HGM6100U Series Automatic Control Controllers HGM6110U 6110UC 6120U 6120UC USER MANUAL Genset Controller Smartgen Technology Ak E HH Chinese trademark Smartgen Smartgen make your generator smart English trademark Smartgen Technology Co Ltd No 28 Jinsuo Road Zhengzhou Henan Province P R China Tel 86 371 67988888 86 371 67981888 86 371 67991553 86 371 67992951 67992952 86 371 67981000 overseas Fax 0086 371 67992952 Web http www smartgen com en http www smartgen cn Email sales smartgenicom 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 Smartgen Technology reserves the right to change the contents of this document without prior notice Software Version 2011 09 15 Original release 2012 06 04 some parameters are optimized HGM6100U Series Automatic Control Module Contents 1 SUMMARY eeen A 2 PERFORMANCE AND CHARACTERISTICS ne A 3 SPECIFICATION nennen 6 A OPERATION 7 AA KEYS DSCRIPRIONE EE 7 4 2 CONTROLLER PANEL eeens enn enennersnvsnnsnersersnvenven 8 4 3 AUTOMATIC START STOP OPERATION ENNEN 8 4 4 MANUAL START STOP OPERATION NENNEN 10 5 PROTECTION nn NM 10 5 1 WARNINGS aaneen enennernernnennn W Do 10 5 2 SHUTDOWN ALARMG MAR AMO MB
17. ed gt Power supply range 8 35 VDC accommodating to different starting battery volts HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 5 of 32 HGM6100U Series Automatic Control Module gt All parameters use digital modulation instead of analog modulation using conventional potentiometer having improved reliability and stability gt Add rubber gasket between shell and controller screen the waterproof can reach IP55 gt Controller is fixed by metal fixing clips gt Modular design flame retardant ABS shell embedded mounting compact structure and easy installation 3 SPECIFICATION Working Voltage DC8 0V to DC35 0V continuous Power Consumption lt 3W Standby mode lt 2W AC Voltage Input Range 3P4W 15V AC 360 V AC ph N 3P3W 30V AC 620V AC ph ph 1P2W 15V AC 360 V AC ph N 2P3W 15V AC 360 V AC ph N 16 Amp 250VAC volt free output sa ated Temperature 25 70 C Humidity 20 90 Storage Condition Temperature 30 80 C IP55 when waterproof rubber gasket added Protection Level between controller and its panel IP42 when waterproof rubber gasket not added HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 6 of 32 HGM6100U Series Automatic Control Module Object among in input output power Insulation Intensity Quote standard IEC688 1992 Test way AC1 5 kV 1min 3mA leakage current 4 OPERATION 4 1KEYS DSCRIPTION Can s
18. g clip screw4turn anticlockwise until it reaches proper position 2 Pull the fixing clip backwards towards the back of the module ensuring four clips are inside their allotted slots 3 Turn the fixing clip screws clockwise until they make contact with the panel Note Care should be taken not to over tighten the screws of fixing clips Fixing clip Fitted to Module HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 30 of 32 HGM6100U Series Automatic Control Module 12 2 OVERALL DIMENSION AND PANEL CUTOUT CUT OFF 186mm 141mm 1 Battery Voltage Input HGM6100U series controller can be applicable to 8 35 VDC battery voltage Battery negative must be reliably connected to engine shell The connection between controller power and battery should not be Jess than 2 5mm If a float charger is fitted please connect output line of the charger with battery directly and then connect battery positive and negative to power input of controller separately in case that charger will interfere with the normal running of controller 2 Speed Sensor Input speed sensor is installed in the engine for testing flywheel teeth The connection with controller uses 2 core screen shield layer should be connected to terminal16 of controller and the other end vacant The other two signal lines are respectively connected to terminal15 and terminal16 At full speed output voltage range is 1 24 VAG RMS 12VAC is recomme
19. ge Uab Ubc and Uca Phase voltage Ua Ub and Uc Phase voltage Ua Ub and Uc Frequency HZ Frequency HZ Load Current IA IB IC Active power KW Reactive power KVar Apparent power KVA Power factor PF Generator accumulated energy kWh gt Mains have functions of over under voltage and Jack ot phase Gens have functions of over under voltage over under frequency and over current gt Precision measure and display of parameters about engine Temp WT C F both are displayed Oil pressure OP kPa Psi Bar are all displayed Fuel level FL Speed SPD RPM Battery Voltage VB V Charger Voltage VD V Hours counter HC camaccumulate Max 999999 hours Start times can accumulate Max 999999 times gt Control protection Automatic start stop of genset load transfer ATS control and perfect failure display and protection gt With ETS idle speed control pre heat control speed droop raising control all of them are relay output gt Parameter setting Allow user to modify setting and store them in internal FLASH memory The parameters cannot be lost even when power off All of parameters can be set not only from the front panel but also use programmable interface or PS485 interface to adjust them via PC gt Multi sensors of temperature pressure and fuel level can be used directly parameters can be defined by user gt Multi conditions of crank disconnect speed sensor oil pressure generator can be select
20. grammable interface or RS485 interface to adjust via PC It can be widely used in all types of automatic control system for its compact structure simple connections and high reliability 2 PERFORMANCE AND CHARACTERISTICS HGM6100U controller has four variants HGM6110U 6110UC Automatic Start Module it controls generator to start stop by remote start signal HGM6120U 6120UC Based on HGM6110U 6110UC it adds mains AC monitoring and mains generator automatic switching control AMF especially suitable for the automation system composed by mains and genset Note1 HGM6110UC 6120UC has RS485 port HGM6110U 6120U without Note2 HGM6110UC 6120UC is taken as an example to describe in this manual gt 132 64 LCD display with backlight optional language interface Chinese English Spanish and Russian push button operation gt Acrylic screen improved wearable and scratch resistance property gt Silica gel panel and keys can well adapt to higher and lower temperature gt With RS485 communication port can achieve three remote functions via MODBUS protocol gt Adapt to 3P4W 3P3W 1P2W and 2P3W 120V 240V 50Hz 60Hz AC power system gt Can measure and display 3 phase voltage 3 phase current frequency power parameter of mains gens HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 4 of 32 HGM6100U Series Automatic Control Module Mains Generator Line voltage Uab Ubc and Uca Line volta
21. itive is connected to the emergency stop input Check if connection is open circuit Genset Stops Emergency Stop Low Oil Pressure Alarm After Crank Disconnect High Temp Alarm After Crank Disconnect Check oil pressure sensor and connections Check temperature sensor and connections Check switch and connections according to Information on LCD Check configurable inputs Check connections of fuel solenoid Check starting battery Check speed sensor and its connections Refer to engine manual Check connections of starter Check starting battery Genset Running While ATS Check ATS Not Transfer Check connections between ATS and controller Check connections Check if COM port is correct Check if A and B of RS485 is connected reversely Shutdown Alarm During Running Crank Disconnect Failed Starter Inoperative RS485 Failure Check if PC COM port is damaged 1200 resistance between PR485 and AB is Recommended HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 32 of 32
22. n standard sensor curve and chosen sensor curve HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 26 of 32 HGM6100U Series Automatic Control Module select defined sensor and then input defined sensor curve 3 When sensor curve is inputted X value resistance must be in accordance with the order of higher to lower otherwise errors will occur 4 When sensor is selected as Not used temperature pressure and fuel level will be display as in LCD 5 If there is no pressure sensor but only has low pressure alarm switch then you must set pressure sensor as Not used otherwise oil pressure low alarm shutdown may appear 6 Can set several points of forehand or backmost as the same ordinate as the following picture 32 64 96128160192 224 2 omh Conventional pressure unit conversion table 6 89x10 7 03x10 6 89x10 10COMMISSIONING Before operation the following checking should be carried out 1 Check and ensure all the connections are correct and wires diameter is suitable 2 Ensure that the controller DC power has fuse battery positive and negative have correctly connected 3 Emergence stop input must be connected to positive of starting battery via normally HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 27 of 32 HGM6100U Series Automatic Control Module close contact of emergency stop Take proper actions to prevent engine to disconnect crank e
23. nded rated speed During installing make the speed sensor contact the flywheel firstly then pour out 1 3 laps finally lock nut on the sensor 3 Output And Expansion Relay All the outputs of controller are relay output If need to expand relay please add freewheeling diode in both ends of relay coil when expansion relay coil links DC or add RC loop when expansion relay coil links AC in case controller or other equipments are interfered 4 AC Input HGM6100U series controller must externally connect to current transformer CT secondary current must be 5A Besides the phase of CT and input voltage must be correct or the sampling current and active power may be incorrect HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 31 of 32 HGM6100U Series Automatic Control Module Note A ICOM must connect to battery cathode of the controller B When there is load current open circuit is inhibited in the CT secondary side 5 Dielectric Strength test When the controller has been installed in the control panel during the test please disconnect all the terminals in case high voltage damages the controller 13FAULT FINDING Symptoms Possible Solutions Check starting battery Check connections of controller Check the DC fuse Controller Inoperative Check if water cylinder temperature too high Check alternator voltage Check the DC fuse Check if an emergency stop button is fitted Ensure battery pos
24. nter into warming up time and 12 High Speed Control disconnect after cooling System In Auto Mode The controller is in Auto Mode KL 1 e Reseed AA KOUL CO ooo gO 7 3PROGRAMMABLE INPUT 1 5 TABLE ALL IS ACTIVE WHEN CONNECT TO GROUND B TABLE 3 0 Not Used AN D High Temp Alarm Ifthe signal is active after safety run on delay over 2 Low OP Alarm gensebwill immediately alarm to shutdown Auxiliary Alarm Only warn not shutdown lf the signal is active genset will immediately 4 Aux Shutdown Alarm alarm to shutdown During engine running and the input is active if high temperature occurs controller will stop after 5 Goolant To Stop high speed cooling when the input is disabled controller will stop immediately Gens Closed Input MS 7 Mains Closed Input When it is active high oil temperature stop is High Temp Inhibit un inhibited See Note1 for more information a _ When it is active low oil pressure stop is inhibited Low Oil Pressure Inhibit See Note2 for more information Low Fuel Level Wam Low Water Level Warn Fuel Level HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 23 of 32 HGM6100U Series Automatic Control Module Shutdown 14 Low Water A Shutdown In Auto Mode when the input is active no matter mains normal or not genset won t start If genset is in normal running stop process wont be Auto Start Inhibit on executed
25. pen Norma gt gt en eh Mains Normal Stop Mode Stop Man f Auto KE Menu RESCHT oo Maine On load Stop Reset 1 O Start Key Manual Manual Gens Auto Auto Test Test Menu Key Mode Key On load Mode Key Mode On load Key 4 3 AUTOMATIC START STOP OPERATION Auto mode is activated by pressing the LED indicator beside the button is illuminating which confirms this action HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 8 of 32 HGM6100U Series Automatic Control Module Starting Sequence 1 HGM6120UC When mains is abnormal over under voltage lack of phase enter into Mains Abnormal Delay and LCD displays count down time When delay is over Start Delay begins HGM6110UC when remote start input is active enter into Start Delay Count down of start delay is displayed in LCD When start delay is over preheat relay is outputting if configured Preheat Delay XX s is displayed in LCD When preheat delay is over fuel relay is outputting for 1s and then start relay outputs if genset failed to start during Crank Time the fuel and start relay stop outputting and enter into Crank Rest Time and wait for next cranking If genset failed to start within set start times the fourth line of LED will turn black and Fail to Start alarm will be displayed Any time to start genset successfully it will enter into Safe Running During this period alarms
26. put 3 3 3 3 Oil Pressure Sensor o 3 Gegen Input resistance type sensor Liquid Level Sensor Lonn Input resistance type sensor gt Ground connected is gt Ground connected is Reference Configurable Input 2 Configurable Input 3 1 CT A Phase Sensing De Input CT B Phase Sensing 1 5mm Input HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 14 of 32 table 3 active B Ground connected is active B 0mm 0mm Omm 20 21 22 23 Connect secondary coil rated 5A 4 2 Connect secondary coil rated 5A HGM6100U Series Automatic Control Module T Ph 25 gie eee SARSIN 1 5mm Connect secondary coil rated 5A 6 CT Common Port 1 5mm Refer to INSTALLATION description Generator Connect to U phase output 2A fuse is 27 1 0mm Voltage Sensing Input Generator V phase Voltage sensing Input recommended recommended 2 Connect to V phase output 2A fuse is O 3 3 Generator W phase Connect to W phase output 2A fuse is Voltage Sensing Input recommended 30 Generator N2 Input 1 0mm Connect to generator N wire 31 Mains R phase Voltage 1 Omm Connect to mains R phase 2A fuse is Sensing Input recommended HGM6110UC without 30 Mains S phase Voltage Lomm Connect to mains S phase 2A fuse is Sensing Input recommended HGM6110UC without 33 Mains T phase Voltage 1 0mm Connect to mains T phase 2A fuse is Sensing Input recommended HGM6110U
27. r AS oo Descriptions of terminal connection as following Cable No Function cross sect Description ional area 1 DC input B Connected to negative of starter battery Connected to positive of starter battery 2 DC input B 2 5mm D aks S lf wire length is over 30m better to HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 13 of 32 HGM6100U Series Automatic Control Module W Emeraency Sto gt Emm Connected to B via emergency stop button Fuel Relay Output 1 5mm B is supplied by 3 points rated 16A Start Relay Output 1 5mm B is supplied by 3 points rated 16A we Connect to starter coil B is supplied by 2 points rated 7A Normal close output A rated 1 5mm Relayeommon port Normal open output 7 A rated Aux Relay Output 3 2 5mm volt free contact output Aux Relay Output 4 2 5mm 16A rated Charging Generator D fin gt Conneet to D WL terminal If without Input the terminal is not connected Speed sensor input Speed sensor input B 0 5mmf is connected 1 0mm double wires in parallel Max 20A fuse is recommended IN A m m ma Lech J W 00 O A A WIN OO O1 3 3 Aux Relay Output 1 Aux Relay Output 2 y p Reference table 2 Relay normal open a Connected to Speed sensor shielding line is recommended Connect to water cylinder temp resistance type sensor 17 Temp Sensor In
28. t Common Alarm self lock When a shutdown alarm occurs the alarm will self lock until alarm is reset Used for the genset with stop solenoid Pick up ETS Control when idle speed is over while disconnect when ETS delay is over Used for the genset with idle speed Pick up when crank while disconnect when enter into warming Idle Control l up Pick up when stop idle while disconnect when genset stop completely Close before started and disconnect before Preheat Control powered on When close time is set as 0 it is continuous Gens Close closing HGM6110UC without When close time is set as 0 Open Breaker is Open Breaker disabled Pick up when enter into warming up time N O 2 3 4 9 D Accelerate Control Disconnect when raise speed auxiliary input active Pick up when enter into stop idle or ETS solenoid Decelerate Control stop shutdown alarm Disconnect when droop Speed auxiliary input active Output when genset is in normal running Genset Run Output disconnect when rotating speed is lower than engine speed after fired HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 22 of 32 HGM6100U Series Automatic Control Module Pick up when the fuel level lower than the open threshold or low fuel level warning is active 11 Fuel Pump Control disconnect when the fuel level over the close threshold and the low fuel level warning input is disabled Output when it e
29. talled in the engine for testing flywheel teeth 3 When choosing magnetic pickup sensor ensure the number of flywheel teeth is same as the pre set otherwise over or under speed shutdown may appear 4 If generator has no magnetic pickup sensor don t choose corresponding item otherwise Fail to Start or Loss of Speed Signal shutdown will occur 5 If the generator has no oil pressure sensor don t choose corresponding item 6 If generator has not been selected controller will not measure and display the relative parameters can be applied to the pump set if magnetic pickup sensor has not been selected the rotating speed will calculated by the generating AC signal 8 PARAMETER SETTING After controller powered on press o enter into the parameters setting menu 1 Parameters Setting 2 Information 3 Language 1 Parameters Setting 1234 can set the part of the items in Table 1 during inputting password 0318 can set all items in Table 1 lf more parameter items need to be set such as voltage and current calibration please contact with the factory NOTE HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 25 of 32 HGM6100U Series Automatic Control Module HGM6110UC there are not items 1 5 in table1 programmable output 1 4 have no digital outputs about mains Please modify the parameters in standby mode crank conditions auxiliary input and output configuration multi delays etc otherwise shu
30. tdown alarm or other abnormal conditions may appear The over voltage threshold must be greater than the under voltage threshold otherwise over voltage and under voltage will occur at the same time The over speed threshold must be greater than under speed threshold otherwise over speed and under speed will occur at the same time Set frequency value after crank disconnect as low as possible in order to disconnect starter quickly Programmable input 1 5 cannot be set as the same items otherwise it cannot realize correct function programmable output 1 4 can be set as the same item lf need to shut down after cooling please set any input as stop after cooling then connect this input to ground 2 Information LCD will display some information of controller such as software version issue date note Pressing WB wil display the status of digital inputs and outputs 3 Language User may select display language as Chinese English Spanish and Russian 4 LCD contract press and Y 0 can adjust LCD contract Adjustment range is 0 7 A vote pres key at any time will exit the editor and back to main interface 9 SENSOR SETTING 1 2 When choosing sensor standard of sensor curve will be needed If temperature sensor is set as SGH 120 C resistor type sensor curve should be SGH 120 C resistor type If it is set as SGD 120 C resistor type sensor curve should be SGD curve lf there is difference betwee
31. top generator under Manual Auto mode Can reset shutdown alarm Press this key atdeast 3 seconds to test Stop Reset panel indicators are OK or not lamp test During stopping process press this key again can stop generator immediately CI O TN wenn Pressing this key will setthe module as Manual mode AUTO Pressing this key will set the module as Auto mode Controller is under manual testing mode Running with load Under this mode gen set will run automatically with load when gens normal HGM6110UC without o Gens Close Open Can control gens to switch on or off in Manual mode O Set Confirm Shift cursor to confirm In parameters setting menu Screen scroll Up Increase l Up cursor and increase value in setting menu Scroll screen Down Decrease Down cursor and decrease value in setting menu Menu Pressing this key will set menu Again pressing this key can return main interface HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 7 of 32 HGM6100U Series Automatic Control Module 4 2 CONTROLLER PANEL HGM6110UC Panel Indicators Genset Controller Alarm Up Running Set Confirm Running 8 Down Gens er Close Open Normal Stop Mode Gens On load Stop L Auto Menu Start P Man Stop Reset O Manual Manual Auto Auto Menu Key Start Key Mode Key Mode Key HGM6120UC Panel Indicators Genset Controller Alarm vi Akan On Set Confirm Running 28 Ve Down _ Close O
32. wer than threshold DH t controller will send warning alarm signal and it will be Voltage displayed in LCD When the battery voltage of genset is higher than threshold controller will send warning alarm signal and it will be displayed in LCD When low water level input is active controller will send Low Water Level e A e l warning alarm signal and it will be displayed in LCD When sensor hasnt connected to corresponding port controller will send warning alarm signal and it will be displayed in LCD Oil Pressure When sensor hasn t connected to corresponding port Sensor Open controller will send warning alarm signal and it will be Battery Voltage Temp Sensor Open Circuit Circuit displayed in LCD When genset running time is longer than maintenance time of user setting and the maintenance action is set as warning controller send warning alarm signal and it will be displayed in LCD When maintenance action type is set as Not used maintenance alarm reset Maintenance time out warn HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 11 of 32 HGM6100U Series Automatic Control Module 5 2SHUTDOWN ALARMS When controller detects shutdown alarm it will send signal to open switch and stop genset The alarms are displayed in LCD Shutdown alarms as following pe When controller detects emergency stop signal it will send STI TR a stop alarm signal and it will be displayed in LCD
33. y is initiated When load current is over the point over current signal is sent When the delay is O only warn but not shutdown When the fuel level lower than the set value for 10s send a signal to open fuel pump When the fuel level higher than the set value for 10s send a signal to close fuel pump Factory default Energized to stop Factory default Idle control Factory default Gens closed Factory default Mains closed Factory default High Battery Under 4 30 V Over Current Percentage W N Over Current 12 Delay 0 3600 s 96 W co Fuel Pump Open 0 100 NO Fuel Pump Close 0 100 41 Aux Output 1 0 17 Aux Output 2 0 17 Aux Output 3 0 17 Aux Output 4 0 17 ee 9 15 temperature alarm Aux Input 1 Active 0 Factory default close Aux Input 1 20 2 0 F fault L il 48 Aux Input 2 0 15 actory default ow Ol pressure alarm HGM6100U Automatic Genset Controller ISSUE 2012 06 04 Version 1 1 Page 19 of 32 2 3 5 A gt E 0 gt gt gt gt W W W W W N O No O SS O E W C O HGM6100U Series Automatic Control Module Default Aux Input Active Aux Input 2 20 2 0 F fault R Aux Input 3 0 15 actory default Remote start Input 0 1 0 1 Factory default close NO Aux Input Active AURS ME nis 2 0 Delay fault Low fuel level warn AS pl ln on Factory default close Active oe ul 0 20 0 s 2 0 Delay F fault L

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