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HGM7200_HGM7100 INSTRUCTION

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1. 5 5 1 HGM7X20 Switch control procedures sse esse 21 5 5 2 HGM7X10 Switch control procedures sse eee eee 22 6 PROTECTION D DN WE 24 6 1 WARNINGS ff W 24 Gr SHUTDOWN ALARM esse eee 26 6 3 TRIP AND SHUTDOWN UI EE 28 GA TRIPAND NOT SHUTDOWN ALARM see eee eee 29 7 WIRINGS CONNECTION ee ees 30 8 SCOPES AND DEFINITIONS OF PROGRAMMABLE PARAMETERS 33 8 1 CONTENTS AND SCOPES OF PARAMETERS eee 33 8 2 ENABLE DEFINITION OF PROGRAMMABLE OUTPUT PORTS sse eee eee 42 8 2 1 Defined period output sese essen 46 8 2 2 Defined combination output eee 47 8 3 DEFINED CONTENTS OF PROGRAMMABLE INPUT PORTS ALL ACTIVE WHEN GONNER 48 HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 4 of 69 HGM7200 HGM7100 Series Gen set Controller 8 4 SELECTION OF SENSORS e 50 8 5 CONDITIONS OF CRANK DINSCONNECT SELECTION eee ee 51 H PARAMETERS SET UND raaa Eaa aaa aaan aaa aaa aaa aam aah irawan ahaaa Wasaa 52 10 SENSORS SETTING ees 52 11 ee el e 53 12 TYPICAL APPLICATION e eeerge egeeueegegeeuge egeeugegereeuge esegugegezeguge eregugegereeeg 55 13 INSTALLATION wtiecececteccscectiwsweweceecwcectencwececewewewecowewewcceesweusceecseweteesneeccewewee 56 14 GSM SHORT MESSAGE ALARM AND REMOTE CONTROL sssssssss 58 14 1 GSM SHORT MESSAGE ALAPM eene all D 58 14 2GSM SHORT MESSAGE REMOTE CONTROL A celine ER 58 15 CONNECTIONS OF CONTROLLER WITH J1939 ENGINE 0 60 15 1 CUMMINS ISB ISBE ce 0 A Oooo 60 1
2. Engine type is QSX15 Terminals of 50 pins Remark controller connector Fuel relay output 38 Oil injection switch Start relay output Connect to starter coil directly Terminals of 9 pins Remark controller connector CAN communication shielding CAN GND aE te line connect to ECU terminal shield E only CAN H SAE J1939 Using impedance 1200 signal C connecting line CAN L SAE J1939 Using impedance 1200 return D connecting line Engine type Cummins QSX15 CM570 15 5CUMMINS GCS MODBUS It is suitable for GCS engine control mode Use RS485 MODBUS to read information of engine Engine types are QSX15 QST30 QSK23 45 60 78 and so on Terminals of D SUB Remark controller connector 06 Outside expand relay when oil Fuel relay output 5 amp 8 output connect port 06 and08 of the connector Start relay output Connect to starter coil directly Terminals of D SUB Remark controller connector 06 CAN communication shielding RS485 GND 20 line connect to ECU terminal only RS4854 24 Using impedance 1200 connecting line RS485 18 Using impedance 1200 connecting line HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 62 of 69 HGM7200 HGM7100 Series Gen set Controller Engine type Cummins QSK MODBUS Cummins QST MODBUS Cummins QSX MODBUS 15 6DETROIT DIESEL DDEC Ill IV Terminals of CAN p
3. HGM7200 HGM7100 Series Gen set Controller 16 FAULT FINDING Check starting batteries Check controller connection wirings Check DC fuse Check the water cylinder temperature is high Check the genset AC voltage Check DC fuse Check emergence stop button isscorrect or not Controller emergency stop Check whether the starting battery positive be connected to the emergency stop input Check whether the circuit is open Low oil pressure alarm after Check the ol pressure sensor and its Controller no response with power Genset shutdown crank disconnect connections High water temp alarm after Check the temperature sensor and its crank disconnect connections Check related Switch and its connections Shutdown Alarm in running according to the information on LCD Check programmable inputs Check fuel oil circuit and its connections Check starting batteries Check speed sensor and its connections Refer to engine manual Check starter connections Check starting batteries Crank not disconnect Starter no response A Check ATS ernn hile ATS not Check the connections between ATS and transfer controllers Check connections Check setting of COM port is correct or not Check RS485 s connections of A and B is RS485 communication is reverse connect or not abnormal Check whether damage RS485transfer model Check whether damage communication port of PC HGM7200 7100 Series Gen set Con
4. Low Level Warning over the threshold of setting Programmable l When controller detects the sensor is open 27 Sensori ae E Ge ae circuit and select warning of open circuit Open Circuit HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 25 of 69 HGM7200 HGM7100 Series Gen set Controller No Type Description op Programmable When controller detects the sensor value is over Sensor 1 High the maximum threshold of setting 29 Programmable When controller detects the sensor value is Sensor 1 Low under the minimum threshold of setting Programmable When controller detects the sensor is open 30 Sensor 2 va l SN Open Circi circuit and select warning of open circuit 31 Programmable When controller detects the sensor value is over Sensor 2 High the maximum threshold of setting 40 Programmable When controller detects the sensor value is Sensor 2 Low under the minimum threshold of setting When digit input port is set as warning and 33 Aux Input Warning active controller sends corresponding warning signal When select GSM enable and can t detect GSM 34 GSM Com Fail model controller sends corresponding warning signal 6 2SHUTDOWN ALARM When controller detects shutdown alarm it will send signal to switch off gens and shutdown Shutdown alarms as following No Type Description l Emergency When controller detects emergency sto
5. Version A 2012 6 15 Page 45 of 69 HGM7200 HGM7100 Series Gen set Controller 139 High Temp Warning Action in hi temperature warning alarm 140 Low Temp Warning Action in low temperature warning alarm 141 High Temp Shutdown Action in hi temp Shutdown alarm 142 Reserved 143 Low OP Warning Action in low oil pressure warning alarm 144 Low OP Shutdown Action in low oil pressure shutdown 145 OP Sensor Open Action when oil pressure sensor are open circuit 146 Reserved 147 Low Level Warning Action when controller has low oil level alarm 148 Reserved 149 Reserved 150 Configi High Warning 151 Configi Low Warning 152 Configi High Shut 153 Configi Low Shut 154 Config2 High Warning 155 Config2 Low Warning 156 Config2 High Shut 157 Config2 Low Shut oo Reserved 230 In Stop Mode Action in stop mode 231 In Manual Mode Action in Manual mode 232 In Test Mode Action in Manual test mode 233 In Auto Mode Action in Auto mode 234 Generator On boad 235 Mains On Load 2364 Reserved 237 Reserved 238 Reserved 239 Reserved 8 2 1 DEFINED PERIOD OUTPUT Defined Period output is made of 3 parts period output S1 and condition output S2 S1 S2 Je While S1 and S2 are TRUE synchronously OUTPUT While S1 or S2 is FALSE NOT OUTPUT Period output S1
6. power each phase and average power factor positive and negative accumulated energy kWh kVarh kVAh Note When only mains switch on and indicator lights count active and inactive power apparent power not accumulate electric energy Counting the gens active and inactive power apparent power power factor and accumulate electric energy under other conditions ANOTE Power factor shows as following Q COS lt UL COS gt 0L Remark P stands for active power COS lt DC COS gt 0C Q stands for inactive power HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 14 of 69 HGM7200 HGM7100 Series Gen set Controller Powet papgiiisns E Inactive Reeg factor power power COSS0L P gt 0 Q gt 0 Input Input Load is inductive resistance COS gt 0C P gt 0 Q lt 0 Input Output e resistance COS lt OL P lt 0 Q gt 0 Output Input Load as one under excitation generator COS lt 0C P lt 0 Q lt 0 Output Output Load as one over excitation generator Note 1 Input active power gens or mains on load 2 Output active power load send active power to gens or mains 3 Input reactive power gens or mains send reactive power toload 4 Output reactive power load send reactive power to gens or mains Alarm NOTE Instruction about ECU warning and alarming if there is definite alarm and LCD will show details please check The generator according to it otherw
7. 0 Disable 1 Enable can be set as temperature pressure Joud lever sensor Programmable Sensor 2 Programmable 0 Disable 1 Enable can be set as 1 Sensor 2 0 1 0 ae temperature pressure liquid Setting lever sensor HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 39 of 69 HGM7200 HGM7100 Series Gen set Controller No Items Parameters Defaults Description Programmable Input Ports Programmable Input Port 1 Contents 1 Setting 0 50 28 Remote start with load 2 Active Type 0 1 0 0 closed active 1 open active Programmable Input Port 2 r Contents 0 50 26 Hi temperature shutdown Setting input 0 closed active 1 open 2 Active Type 0 1 0 e active Programmable Input Port 3 Contents 0 50 27 Low oil pressure shutdown Setting input 2 Active Type 0 1 0 0 closed active 1 open active Programmable Input Port 4 Contents 1 Setting 0 50 0 User defined 2 Active Type 0 1 0 0 closed active 1 open active 0 after safety on delay 1 3 Active Range 0 3 2 cranking 2 always active 3 inactive O warn 1 warn and shutdown 2 trip and 4 Active Actions 0 4 0 shutdown 3 trip and not shutdown 4 indicating only 5 Active Delay 0 20 0 s ag je Wem ER put active to confirm 6 Description Programmable Input Port 5 Contents t 1 Setting 0 50 0
8. Reserved 99 Emergency Stop Action in emergency stop alarm 100 Fail To Start Action in failed start alarm 101 Fail To Stop Action in failed stop 102 Under Speed Warning Action in under speed warning 103 Under Speed Shutdown Action in under speed shutdown 104 Over Speed Warning Action in over speed warning 105 Over Speed Shutdown Action in over speed shutdown alarm 106 Reserved 107 Reserved 108 Reserved 109 Gens Of Warning Action in gens over frequency warning 410 Gens Of Shutdown Action in gens over frequency shutdown alarm 111 Over Volt Warning Action ingens over voltage warning 112 Over Volt Shutdown Action in gens over voltage shutdown 113 Low Freq Warning Action in gens low frequency warning 114 Low Freq Shutdown Action in gens low frequency shutdown 115 Low Volt Warning Action in gens low voltage warning 116 Low Volt Shutdown Action in gens low voltage shutdown 117 Loss of Phase Action in gens loss phase 118 Gens Reverse Phase Action in gens reverse phase 119 Reserved 1204 Over Power 121 Reserved 122 Reverse Power Action in controller detects gens have reverse power 123 Over Current Action in over current 124 Reserved 125 Mains Inactive 126 Mains Over Freq 127 Mains Over Volt 128 Mains Under Freq 129 Mains Under Volt 130 Mains Reverse Phase 131 Mains Loss of Phase FE Reserved HGM7200 7100 Series Gen set Controller
9. Sensor 1 Open this alarm is set it will send a shutdown alarm signal Circuit When controller detects sensor value is over upper Programmable D l o 22 limit alarm and this alarm is set it will send a Sensor 1 High shutdown alarm signal When controller detects sensor value is under lower Programmable S ZEN 22 limit alarm and this alarm is set it will send a Sensor 1 Low shutdown alarm signal Programmable When controller detects sensor is open circuit and 24 Sensor 2 Open this alarm is set it will send a shutdown alarm signal Circuit When controller detects sensor value is over upper Programmable Se f 25 l limit alarm and this alarm is setit will send a Sensor 2 High shutdown alarm signal When controller detects sensor value is under t lower Programmable KC er 26 limit alarm and this alarm is set it will send a Sensor 2 Low shutdown alarm signal When switch value port is set as shutdown alarm Aux Input x Ee 27 and Ine alarm isactive it will send a shutdown alarm Shutdown signal 6 3TRIP AND SHUTDOWN ALARM When controller detects shutdown alarm signal it will shutdown gens quickly and after high speed cooling to stop Trips shutdown alarm as following No Type Description When controller detects current is over setting and 1 Over Current over current trip stop is set it will send a trip stop alarm signal Maintenance When count down time is 0 and the Maintenance S Time Up Time
10. Up is set it will send a trip stop alarm signal When controller detects reverse power value power is negative is over value of setting and the reverse 3 Reverse Power power action trip alarm is set it will send a trip stop alarm signal HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 28 of 69 HGM7200 HGM7100 Series Gen set Controller No Type Description When controller detects reverse power value power is positive is greater than value of setting and the 4 Over Power l See e reverse power action trip alarm is set it will send a trip stop alarm signal When input port is set as trip stop alarm and the 5 Aux Input Ports alarm is active it will send a trip stop alarm signal 6 4TRIP AND NOT SHUTDOWN ALARM When controller detects stop alarm it wills breaker signal of gens switch on quickly but genset not stop Trip but not stop alarm as following No Type Description When controller detects current is over setting and 1 Over Current over current trip and not stop is set it will send a trip and not stop alarm signal When controller detects reverse power value power is negative is over value of setting and the reverse 2 Reverse Power i l Po SC power action trip alarm is set it will send a trip and not stop alarm signal When controller detects reverse power value power is positive is greater
11. User defined 2 Active Type 0 1 0 0 closed active 1 open active 0 after safety on delay 1 3 Active Range 0 3 2 cranking 2 always active 3 inactive 4 Active Actions 0 4 1 Oana Pwan and shutdown 2 trip and HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 40 of 69 HGM7200 HGM7100 Series Gen set Controller No Items Parameters Defaults Description shutdown 3 trip and not shutdown 4 indicating only 5 Active Delay 0 20 0 s Boe ne nen eee rane input active to confirm 6 Description Programmable Input Port 6 Contents l 1 Setting 0 50 0 User defined 2 Active Type 0 1 0 0 closed active 1 open active 0 after safety on delay 1 3 Active Range 0 3 2 cranking 2 always active 3 inactive O warn warn and sh tdown 2 trip and 4 Active Actions 0 4 2 shutdown 3 trip and not shutdown 4 indicating only 5 Active Delay 0 20 0 s time trom aetecing input active to confirm 6 Description Programmable Input Port 7 Contents 1 Setting 0 50 5 Lamp test 2 Active Typ 0 1 0 0 closed active 1 open active Programmable Output Ports Programmable Output Port 1 User defined period output i ee 0 239 1 default is output in Setting preheating O normally open EE SE WH S 1 normally close Programmable Output Port 2 Contents 1 Setting 0 239 35 Idle control output O normally open
12. condition output S1 is active inactive close when active disconnect when inactive Contents of probably condition output S2 output port 2 is active Close when probably condition output S2 is active inactive close when active disconnect when inactive Contents of probably condition output S3 output port 3 is active Close when probably condition output S3 is active inactive close when active HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 47 of 69 HGM7200 HGM7100 Series Gen set Controller disconnect when inactive When input port 1 active or input port 2 active if input port 3 is active Defined combination output is outputting If input port 3 inactive Defined combination output is not outputting When input port 1 inactive and input port 2 inactive whatever input port 3 is active or not Defined combination output is not outputting 8 3DEFINED CONTENTS OF PROGRAMMABLE INPUT PORTS ALL ACTIVE WHEN CONNECT TO GRAND B Form 3 No Type Description Including following functions Indicator indicate only not warning or shutdown Warning warn only not shutdown Shutdown alarm and shutdown immediately Trip and shutdown alarm generator uninstalls shutdown after hi speed cooling trip and not 0 Users Defined shutdown alarm generator uninstalls not shutdown Inactive input inactive Always active input is active all the time Start active detecting as soon as start Safet
13. e Relves IYPS e E 1 normally close Programmable Output Port 3 Contents 1 Setting 0 239 29 Gens closed output HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 41 of 69 HGM7200 HGM7100 Series Gen set Controller No Items Parameters Defaults Description O normally open EECHER CH E 1 normally close Programmable Output Port 4 Contents 1 Setting 0 239 31 Mains closed output O normally open 2 neve TBE e S 1 normally close Programmable Output Port 5 Contents 1 Setting 0 239 38 ETS hold O normally open S Reve TYPE a 9 1 normally close Programmable Output Port 6 1 SEH 0 239 48 Common alarm Setting O normally open ACUE TYDE oy g normally close 8 2 ENABLE DEFINITION OF PROGRAMMABLE OUTPUT PORTS Form 2 No Type Description 0 Not Used 1 Custom Period 1 Output 2 Custom Period 2 Output 3 Custom Period 3 Output 4 Gustom Period 4 Output 54 Custom Period 5 Output 6 Custom Period 6 Output Details of function description please see 7 Custom Combined 1 the following 8 Gustom Combined 2 9 Custom Combined 3 10 Custom Combined 4 11 Custom Combined 5 12 Custom Combined 6 13 Reserved 14 Reserved 15 Reserved 16 Reserved 17 Air Flap Action in over speed alarm stop and emergence stop It also can close the air HGM7200 7100
14. of mains 8 When mains issabnormal again genset will be started auto and into normal running then controller send signal to make gens switch on and control the ATS as gens load If not like this please check ATS wires connection of control part according to this manual 9 If have any other questions please contact Smartgen s service HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 54 of 69 HGM7200 HGM7100 Series Gen set Controller 12 TYPICAL APPLICATION HGM7210 typical application diagram Pel ell PEFR L ER Ee we LOAD EER To S vie BERG e ll l aux AUX AUX A AUX 10 vu OUTPUT1 OUTPUTS OUTPUTS lt sl OUTPUT2 Com GIRRES i 35 GENS 2 S E W N 19 20 21 30 31 27 1718 N J AUX INPUT1 AUX INPUT AUX INPUT3 AUX INPUT6 ENGINE TEM OIL PRESSURE SWITCH1 SWITCH2 40 41 4243 7 KEE re U ee H R pa an VM U 1 su Z w sts Koup e ae Corrs 111 a S z AUX AUX aux N SZ OO CO S N m LS loton OUTPUTS aire BN HI AUX 10 Kess 12 OUTPUT2 ee 11 T E OUTPUT2 14 19 20 21 30 31 27 1718 2829 47 4849 JN B El ef 2 z s 2 s L gt ES el el Sl ale A gt aa l l EN a Z Tn MAGNETIC ISS PICKUP CS HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 55 of 69 HGM7200 HGM7100 Series Gen set Controller HGM7
15. sensor curve will be transferred into the stand HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 52 of 69 HGM7200 HGM7100 Series Gen set Controller value For example if temperature sensor is SGX 120 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 When there is difference between standard sensor curves and using sensor user can adjust it in curve type input When input the sensor curve X value resistor must be input from small to large otherwise there is mistake If don t select sensor sensor curve is not working If corresponding sensor has alarm switch only user must set this sensor as NO otherwise maybe there is alarming stop or warning The headmost or backmost values in the vertical coordinates can be set as same as below kPa 800 700 600 500 400 300 200 100 32 64 96 128 160192 224 2 omh Normal Pressure Unit Conversion Form pa kgf cm bar psi 1Pa 1 1 02x10 1x10 1 45x10 4 1kgf cm 9 8x104 1 0 98 14 2 1bar 1x10 1 02 1 14 5 1psi 6 89x10 7 03x10 6 89x10 1 11 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 control
16. starter with engine Each condition can be used alone and simultaneously 17 Frequency 0 200 24 When gens freq Over pre setting starter will be disconnected 18 Speed 0 200 24 When gens rotate speed over pre setting starter will be disconnected 19 Oil Pressure 0 1000 kPa Not used When oil pressure over pre setting starter will be disconnected Generat or Setting Gens AC Supply System 0 3 0 0 3P4W 1 3P38W 2 2P3W 3 4P2W Number Of Poles 2 32 Numbers of generator pole used for calculating starter rotate speed when without speed sensor Gens Rated Volt 30480000 y 230 To offer standards for detecting of gens over under voltage and loading voltage If using voltage transformer this value is first voltage of transformer Load Volt 0 200 85 Setting value is percentage of gens rated voltage When gens voltage under load voltage won t enter into normally running during the period of when controller ready to detect loading Gens Rated Freq 10 0 600 0 Hz 50 0 To offer standards Tor detecting of over under load frequency Load Freq 0 200 85 Setting value is percentage of gens rated frequency When gens frequency under load frequency won t enter into normal running during the period of when HGM7200 7100 Series Gen set Control
17. 110CAN typical application diagram poom el RARA L1 We dy ZE RES Rm e GENS Za S E ES EE e GIE i g 12 1414 OUTPUT1 j ajo o OUTPUT3 T sm dl N 25 26 47 4849 44 45 46 ei AUX INPUTL AUX_INPUT3 AUX INPUT4 ENGINE TEMP AUX INPUT AUX INP sot MAGNETIC soul HGM7120CAN typical application diagram LOAD 3 9 9 SS SWITCH1 SWITCH2 E T U Sg Sg R v Lage ste s Ben sts KS TZ 1 1 SN L lt e L w L M l AU saag gg j L E iwin RJY r 1 AUX WE Serer errr reer rrr rere rrr rrr 13 12 OUTPUT2 40 41 42 43 d i 2 2 am a mi al oof s ite B SI el S S Lp Bl gt Sal S 0 el m e a af al a S A z 2 z z 2 LO K j j ra 4 el w Kal j lel zi a e Bl E lt j lt lt a lt ga LO e ki MAGNETIC 13 INSTALLATION 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 HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 56 of 69 HGM7200 HGM7100 Series Gen set Controller E z E E E 186mm Del wm SA wn wm bel Esc E SS E z E S GR 39 mm 8 mm 184mm 197mm 1 Battery Voltage Input NOTE HGM7200 7100 series controller can suit for widelyrange of battery voltage 8 35 VDC Negative of battery must be connected
18. 2000 series 4000series Terminals of X1 connector Remark controller Fuel relay output BE1 Start relay output BE9 CAN communication shielding CAN GND E line connect to ECU terminal only CAN H G Using impedance 1200 connecting line CANIL F Using impedance 1200 connecting line Engine type MTU MDEC 303 15 10PERKINS It is suitable for ADEM3 ADEM4 engine control mode Engine type is 2306 2506 1106 and 2806 Tani Suna al Connector Remark controller Fuel relay output 1 10 15 33 34 Start relay output Connect to starter coil directly CAN GND CAN communication shielding line connect to ECU terminal HGM7200 7100 Series Gen set Controller Version1 4 2012 6 15 Page 64 of 69 HGM7200 HGM7100 Series Gen set Controller only CAN H 31 Using impedance 1200 connecting line CAN L 39 Using impedance 1200 connecting line Engine type Perkins 15 11SCANIA It is suitable for S6 engine control mode Engine type is DC9 DC 12 and DC16 Terminals of B1 connector Remark controller Fuel relay output 3 Start relay output Connect to starter coil directly CAN communication shielding CAN GND line connect to ECU terminal only CAN H 9 Using impedance 1200 connecting line CAN L 10 Using impedance 1200 connecting line Engine type Scania 15 1
19. 2VOLVO EDC3 Suitable engine contro mode is TAD1240 TAD1241 and TAD1242 Terminals of Stand alone Remark controller connector Fuel relay output H Gart relay output E ECU power Configurable output 1 P Configurable output 1 ECU power Terminals of controller Data bus Remark connector CAN communication shielding CAN GND line connect in ECU this terminal only CAN H Using impedance 1200 connecting line CAN L 2 Using impedance 1200 HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 65 of 69 HGM7200 HGM7100 Series Gen set Controller connecting line Engine type Volvo AANOTE When select this engine type the preheat time should be set more than 3 seconds 15 13VOLVO EDC4 Suitable engine types are TD520 TAD520 optional TD720 TAD720 optional TAD721 TAD722 and TAD732 ee Connector Remark controller Expanded 30A relay and relay offers battery Fuel relay output voltage id terminal 1 Fuse is 16A Start relay output Connect to starter coil directly Connected to negative of battery CAN communication shielding CAN GND line connect to ECU terminal only CAN H 12 Using impedance 1200 connecting line CAN L 13 Using impedance 1200 connecting line Engine type VolvoEDC4 15 14VOLVO EMS2 Volvo Engine types are TAD734 TAD940 TAD941 TAD1640 TAD1641 and TAD1642 Terminals of Engine s Rema
20. 5 2CUMMINS QSLSY sss 61 15 3CUMMINS QSM11 RE inai 61 15 4CUMMINS OGv1b CMD 62 15 5CUMMINS GCS MODBUSG Sp cccsccsssecsstessstesseressetessenessenesserersanes 62 15 6DETROIT DIESEL DDEC WW eee 63 15 7DELUTZ EMR2 a a 63 15 8JOHN DB inr WEN WEN 64 15 9MTU MDEC My nenn n ennnen nrnna nennen ennenen nennen 64 E 82 len EE 64 TT Ltr WEE 65 15 12 A ADe EE 65 TSO WW OLV OED GA EE 66 el ON 66 T5ASBOSC EE 67 16 FAULT FINDING esesegeeseregeeseregeheseregehegeregeheseuegeh eseu Ee eseu EReeReV ggn 68 HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 5 of 69 HGM7200 HGM7100 Series Gen set Controller 1 SUMMARY HGM7200 7100 series generator controllers are used in automatic and monitor control system of genset to achieve automatic start stop data measure alarm protection and three remote remote control remote measuring remote communication The controller adopts large liquid crystal display LCD and selectable Chinese and English interface with easy and reliable operation HGM7200 7100 gen set automatic controllers use microprocessor technique with precision parameters measuring fixed value adjustment time setting and threshold adjusting and etc It can be widely used in all types of automatic genset control system with compact structure advanced circuits simple connections and high reliability 2 ORDER INFORMATION AND MODULES COMPARISON 2 1ORDER INFORMATION HGM7120CAN Ge
21. Add custom start per weekly 2012 6 15 1 4 Add selectivity configuration Add part of the engine wiring instructions This manual is suitable for HGM7200 and HGM7100 series controller only Clarification of notation used within this publication SIGN INSTRUCTION Bence Highlights an essential element of a procedure to ensure correctness Amen Indicates a procedure or practice which if not strictly observed could result in damage or destruction of equipment GL Indicates a procedure or practice which could result in injury to personnel or loss of life if not followed correctly HGM7200 HGM7100 Series Gen set Controller CONTENTS 1 SUMMARY es sscsrerceuaicneiscas snanacasnacecnujunvguasavassoaudunadead suacceuvdeacauancencsuasavasieatass 6 2 ORDER INFORMATION AND MODULES COMPARISON cs se0 6 2 1 ORDER INFORMATION EE 6 2 2 REENEN EE 6 2 3 MODULES ABBREVIATION sees eee 7 3 PERFORMANCE AND CHARACTERISTICS ccccsssseeeeesseeeeeeeesesseeees 7 4 SPECIFICATION sccsssscesssserensserssssserenssessssesersrsssesesenersrsees ee 10 5 OPERATION MEN WEEN aai 11 BI KEY FUNCTIONS essea A 12 5 2 LCD DISPLAY eene EE ME n 13 5 2 1 Main display eene EE En 13 5 2 2 Basic parameters setting menu 7 Reen 16 5 2 3 Advanced parameters Setting men 17 5 3 AUTO START STOP OPERATION dh Tee 18 5 4 MANUAL START STOP OPERATION E 20 5 5 SWITCH CONTROL PROCEDURES 2 EE 21
22. ECUAlarm aa J1939 it will send a stop ajarm signal 13 ECU Com Fail When controller not gets data from engine via J1939 Shutdown it will send a stop alam signal When controller detects reverse power value power 14 Reverse Power is negative is over value of setting and the reverse Shutdown power action alarm is set it will send a stop alarm signal When controller detects reverse power value power 45 Over Power is positive is over value of setting and the reverse Shutdown power action alarm is set it will send a stop alarm signal id Temp Sensor When controller detects sensor is open circuit and Open Circuit this alarm is set it will send a shutdown alarm signal 47 High Temp When controller detects temperature is higher than Shutdown set for alarming it will send a shutdown alarm signal 18 Pres Sensor When controller detects sensor is open circuit and Open Circuit this alarm is set it will send a shutdown alarm signal T Low OP When controller detects oil pressure is under than set Shutdown for alarming it will send a shutdown alarm signal 20 Level Sensor When controller detects sensor is open circuit and Open Circuit this alarm is set it will send a shutdown alarm signal 21 Programmable When controller detects sensor is open circuit and HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 27 of 69 HGM7200 HGM7100 Series Gen set Controller No Type Description
23. GM7200 7100 Series Gen set Controller Version1 4 2012 6 15 Page 59 of 69 HGM7200 HGM7100 Series Gen set Controller SMS 9 PERMIT PERMIT START OK Set as start permit START NOTE Area code should be added to setting number e g Chinese number should be set as 8613666666666 NOTE When sending orders user need to follow SMS orders in above form and all the letters must be capital ANOTE Detailed information of re back information including working mode mains voltage gens voltage load current mains frequency gens frequency active power apparent power power factor battery voltage D voltage water temperature oil pressure oil level rotate speed total running time genset status and alarm status 15 CONNECTIONS OF CONTROLLER WITH J1939 ENGINE 15 1CUMMINS ISB ISBE Terminals of controller Connector B Remark Fuel relay output 39 Connect to starter coil Start relay output directly battery votage of ECU Power Auxiliary outputport 1 y g Set configurable output 1 as 01 07 12 13 is i R ECU power supplied by relay Terminals of controller S SS Remark connector CAN communication shielding CAN GND Gas gie line connect to ECU terminal shield only CAN H SAE J1939 Using impedance 1200 signal connecting line CAN L SAE J1939 Using impedance 1200 return connecting line Engine type Cummins ISB HGM7200 7100 Series G
24. S D HD99 and Se inactive and Riil show In he right of first line in LCD display Kite Mode When input is active Controller wont work under 18 ae Auto mode key and analog auto key do not Invalidation work 19 Reserved 20 Reserved inhibit Shutdown All shutdown alarms are prohibited except 21 emergence stop Means battle mode or over Alarm control mode 22 Pa INSUB All outputs are prohibited in this mode Mode 23 Reserved Reset Controller will set maintenance time and date as 24 l Maintenance default when input is active 25 Reserved 26 AuxHigh Temp 27 Aux Low OP In Auto mode when input active genset can be 28 S ie Start On started and with load after genset is OK when Load l e input inactive can be stopped In Auto mode when input is active genset can 29 REESEN be started and without load after genset is OK Load a when input is inactive can be stopped 30 AcM 6 In ALIO mode when input active genset can be started when input inactive can be shutdown 31 Reserved 32 Reserved 33 Analog Stop An external button can be connected and Key pressed as simulate panel HGM7200 7100 Series Gen set Controller Version1 4 2012 6 15 Page 49 of 69 HGM7200 HGM7100 Series Gen set Controller Analog Manual 34 Key 35 Analog Test Key 36 Analog Auto Key 37 Analog Start Key 38 Analog G Load Key 39 Analog M Load Key 40 Reserved 41 Reserved 42 Rese
25. Series Gen set Controller Version1 4 2012 6 15 Page 42 of 69 HGM7200 HGM7100 Series Gen set Controller inflow the engine Action in warning shutdown trips Can be connected outside alarm When 18 Audible Alarm bk programmable input port is active of alarm mute can prohibit its output 463 eege Conta Action in genset starting and disconnect when genset stopped completely 20 Fuel Pump Control It is controlled by fuel pump of level sensor s limited threshold It is controlled by heating of temperature 21 Heater Control sensor s setting bound 22 Cooler Control It is Ge by cooler oi temperature sensor s setting bound 23 Pre Oil Supply Output Action from crank on to safety on Output in start period If there is no gens 24 Excite Generator frequency during hi speed running output 2 seconds again 25 Pre Lubricate Output ae in period of pre heating to safety 26 Remote PC Output TA port is controlled by communication Power for GSM module GSM module is 27 GSM Power power off reset when GSM communication failed 28 Reserved 29 Close Generator Control switch of gens is load 30 Open Breaker Control switch is uninstalling 31 Close Mains Control switch of mains is load 32 Reserved 33 Crank Relay Action when genset is starting and a T as disconnect when shutdown co
26. Smartden HGM7200 HGM7100 Series Automatic Genset Control Module User Manual Genset Controller Smartgen Technology Smartgen Smartgen Technology Co Ltd No 28 Jinsuo Road Zhengzhou Henan Province P R China Tel 0086 37 1 67988888 6798 1888 0086 37 1 67991553 67992951 67992952 0086 37 1 67981000 overseas Fax 0086 37 1 67992952 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 Note 2010 10 15 1 0 Original release Add note about some engine type Add functions of inputs giai i 1 Change factory default of liquid level sensor Correct some errors in selection table of sensors 2011 08 24 1 2 Add the function of start inhibit 2011 10 27 13 Add input function Auto Mode Lock and Auto Mode Invalidation
27. When detecting time up if switch on failed to wait for switch on Otherwise switch on is completed If transfer failed and warning SEL Enable there is alarming signal whatever switch on or off failure B If Open breaker detect is SELECT Enable Gens load is transferred into gens unload after the delay of switch off switch off is completed Gens unload is transferred into gens load after the delay of switch on detecting transfer failure while switch on outputting When detecting time up if switch on failed to wait for switch on Otherwise switch on is completed If transfer failure warning is SEL Enable there is warning signal that switch on fail 2 lf configurable input port is connected with closing breaker signal Gens un load is transferred into gens load gens switch on and output HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 23 of 69 HGM7200 HGM7100 Series Gen set Controller Gens load is transferred into gens un load gens switch off and output ANOTE When using ATS of no interposition switch off detecting is SELECT Disable When using ATS of having interposition switch off SELECT Disable or SELECT Enable are both OK If choose SELECT Enable switch off output should be configured When using AC contactor switch off SELECT Disable recommended 6 PROTECTION 6 1WARNINGS When controller detects the warning signal alarm only
28. X10 Auto Start Module controls genset to start or stop automatically by remote start signal HGM7X20 Auto Main Failure updates based on HGM7X10 especially for automatic system composed by gens and mains HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 7 of 69 HGM7200 HGM7100 Series Gen set Controller Main characteristics With ARM based 32 bit CPU high integration of hardware and more reliable 132x64 LCD with backlit Chinese English or other languages display gentle push button for operation Acrylic materials used for protecting LCD screen wearable performance is better Rubber panel and push buttons more adaptable to high or low temperature RS485 communication port and remote control remote measuring remote communication by the ModBus protocol controller with RS485 port only With SMS Short Message Service function When genset is alarming controller can send SMS automatic to max 5 telephone numbers User can control or check genets by sending Short Message controller with GSM port only CANBUS port and can communicate with J1939 genset controller with CAN Bus port only Suitable for various system of 3 phase 4 wire 3 phase 3 wire 1 phase 2 wire and 2 phase 3 wire 120 240V power 50 60HZz Senses and shows 3 phase Voltage current and power frequency of gens or mains Parameters Mains Gens Line voltage Uab Ube and Uca Line voltage Uab Ubc an
29. and not stop genset Warnings as following No Type Description When controller detects the speed is over the 1 Over Speed threshold of over speed setting When controller detects the speed is under the 2 Under Speed threshold of under speed setting When controller detects the speed is 0 and 3 Loss of Speed speed signal lost type When controller detects that the frequency is 4 Over Frequency over the threshold of over frequency setting When controller detects that the frequency is 5 Under Frequency under the threshold of under frequency setting When controller detects that the voltage is over 6 Over Voltage the threshold of over voltage setting When controller detects that the voltage is under 7 Under Voltage the threshold of under voltage setting When controller detects the current is over the 8 Over Current threshold of over current setting When generator not stops after the stop relay 9 Fail to Stop is over When controller detects the charge voltage is 10 Charge Fail under the threshold of setting HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 24 of 69 HGM7200 HGM7100 Series Gen set Controller No Type Description When controller detects the battery voltage is 11 Battery High Voltage over the threshold of setting When controller detects the battery volta
30. can set generator s one or more period output freely can set the delayed time and output time after into period HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 46 of 69 HGM7200 HGM7100 Series Gen set Controller Condition output S2 can set as any conditions in output ports NOTE when delay time and output time both are 0 in period output S1 it is TRUE in this period Example Output period start Delay output time 2s Output time 3s Condition output contents output port 1 is active Close when condition output active inactive close when active disconnect when inactive Output port 1 active after enter starts time and delay 2s this defined period output is outputting after 3s stop outputting Output port 1 inactive defined output period is not outputting 8 2 2 DEFINED COMBINATION OUTPUT Defined combination output is made of 3 parts condition output S1 or S2 and condition output S3 S1 LZ Weg i i S2 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 ANOTE S1 2 S3 cambe set as any contents except for defined combination output in the output setting ANOTE 3 parts of defined combination output S1 S2 S3 couldn t include or recursively include themselves Example Contents of probably condition output S1 output port 1 is active Close when probably
31. d Uca Phase voltage Ua Ub and Uc Phase voltage Ua Ub and Uc Phase sequence Phase sequence Frequency F1 Frequency F2 Load Current IA IB IC Each phase and total active power KW Each phase and total reactive power KVar Each phase and total apparent power KVA Each phase and average power factor PF Accumulate total gens power kWh kVarh kVAh For Mains controller has over and under voltage over and under frequency HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 8 of 69 HGM7200 HGM7100 Series Gen set Controller loss and anti phase functions For gens has over and under voltage over and under frequency loss and anti phase over and anti power over current functions 3 fixed sensors temperature oil pressure and liquid level 2 configurable sensors can be set as sensor of temperature or fuel level HGM72xX0 only Precision measure and display parameters about Engine Temp WT C F both be display Oil pressure OP kPa Psi Bar all be display Fuel level FL Speed SPD RPM unit Voltage of Battery VB Y unit Voltage of Charger VD Y unit Hour count HC can accumulate Max 65535 hours Start times can accumulate Max 65535 times Control protection Start amp Stop genset ATS Auto Transfer Switch control with complete failure protection function All output ports are relay out User can modify and store parameters into internal FLASH memory the parameters
32. d is 00318 user can change it in event of others change the senior parameters setting Please closely remember it after changing If you forget it please contact Smartgen services and send all information in the controller page of ABOUT 5 3LCD DISPLAY 5 3 1 MAIN DISPLAY Main display screen pages for turning pages while OV for turning screen HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 13 of 69 HGM7200 HGM7100 Series Gen set Controller Status including as below Status of genset mains and ATS Engine including as below Speed temperature of engine engine oil pressure liquid fuel level programmable analog 1 programmable analog 2 battery voltage charger voltage accumulated run time accumulated start times ANOTE If connected with J1939 engine via CANBUS port this page also includes coolant pressure coolant level fuel temperature oil pressure niet and outlet port temperature turbo pressure total fuel consumption and so on different engine with different parameters Gens including as below Phase voltage Line voltage frequency phase sequence Mains including as below Phase voltage Line voltage frequency phase sequence NOTE HGM7X10 don t have this page Load including as below Current each phase and total active power positive and negative each phase and total inactive power positive and negative each phase and total apparent
33. delay B J enter ETS hold delay ETS relay is energized Fuel relay s output is broken 6 Then enter gen set Fail to stop timer auto decides whether generator is stopped or not 7 Enter over stop time if configured as soon as generator stops Otherwise controller will send Fail to stop alarm If genset stopped successfully after warning of Failed to Stop will erter over stop time and remove alarm 8 Enter generator at rest as soon as over stop time is over 5 5MANUAL START STOP OPERATION 1 HGM7X20 0 controller enters into Manual starts mode and its indicator lights Press then controller enters into Manual Test Mode and its indicator lights In the both mode press aD to start generator can automatically detect crank disconnected and generator accelerates to high speed running With high temperature low oil pressure and abnormal voltage during generator running controller can protect genset to stop quickly please refer to No 4 9 of Auto start operation for detail procedures In Manual Test Mode generator runs well whether mains normal or not HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 20 of 69 HGM7200 HGM7100 Series Gen set Controller loading switch must be transferred to generator side In manual model the procedures of ATS please refer to ATS procedure of generator in this manual 2 HGM7X10 Press controller enters
34. ed 0 6000 Offer standard to judge E Mared aas RPM aag over under loading speed Setting value is percentage of rated speed Controller 5 detects when will load 4 Load Speed 0 100 90 Won t uc when speed is under loading speed 5 Loss Of Speed 0 3600 s 5 Time fromsdetecting speed Delay is 0 to confirm the action 6 Loss Of Speed 0 1 0 O alarm 1 shutdown Action alarm 7 EE 0 200 114 Setting value is percentage Shutdown Under Space of rated speed and delay 8 H 0 200 80 value also can be set Shutdown Over Speed S Setting value is percentage 3 Warning e db ITU of rated speed and delay amp l l 10 Under Speed 0 200 86 return values also can be Warning set Standard for detecting of 11 pag WW 0 60 0 V 24 0 over under voltage of Battery battery 12 Wm Pigh 0 200 120 Setting value is percentage Volt Warning of rated voltage of battery ier Low and delay amp return values 13 Voltage 0 200 85 7 l also can be set Warning In normal running when 14 EE Falga 0 60 0 V 8 0 charger voltage under this Warning e value charge fail alarms Max Crank times of crank 15 Start Times 1 10 times 3 EE awa We number controller will send start failure signal 16 Crank 0 6 2 Conditions of disconnecting HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 35 of 69 HGM7200 HGM7100 Series Gen set Controller No Items Parameters Defaults Description Disconnect
35. en controller and its panel IP42 when waterproof rubber ring not have between controller and its panel Protection Level Object among in input output power Insulation Intensity Quote standard IEC688 1992 Test way AC1 5kV 1min 3mA leakage current Net Weight 0 75kg 5 OPERATION 5 1INDICATOR LIGHT HGM7X20 Genset Controller Alar A Gens Mains Normal Normal Stop ains Mode Close Manual Gens Test AUTO Mute Mode Close Mode Mode HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 11 of 69 HGM7200 HGM7100 Series Gen set Controller HGM7X10 Genset Controller Alarm A Running Gens Normal Stop Mode Manual AUTO Mute NOTE The instruction of part of the indicator light Alarm light Alarm Type Status Warning Twinkle slowly 1 time per sec Trip and Not Shutdown Twinkle slowly 1 time per sec Shutdown Twinkle fast 5 times per sec Trip and Shutdown Twinkle fast 5 times per sec Running light Its light on from crank disconnect to ETS while extinguishing in other period Gens normal light It is light on when gens is normal It is twinkling when gens is abnormal lt is extinguishing when there is no power Mamme normal light It is light on when mains is normal It is twinkling when mains is abnormal It is extinguishing when there is no power 5 2KEY FUNCTIONS Stop generator and reset alarms Lamp test Stop Res
36. en set Controller Version A 2012 6 15 Page 21 of 69 HGM7200 HGM7100 Series Gen set Controller B If Open breaker detect is SELECT Enable To transfer load from mains to gens need to press mains switch off key D firstly After switch off delay press gens switch on key and gens will take load there is no action when pressing switch on key directly The way to transfer from gens to mains is as the same as above Auto transfer procedures When controller is in Manual Test Auto or Stop mode switch control procedures will start through automatic transfer 1 If configurable input port is connected with closing breaker signal A If Open breaker detect is SELECT Disable When transferring load from mains to gens controller begins detecting fail to transfer then the open delay and transfer rest delay will begin When detecting time up if switch open failed the gens will not switch on otherwise gens switch on Detecting transfer failure while gens switcheon When detecting time up if switch on fail it is need to wait Tor gens to switch on If transfer failed and warning SELECT Enable there is alarming signal whatever switch on or off failure The way to transfer from gens load to mains load is as same as above B If Open breaker detect is SELECT Disable Mains load is transferred into gens load after the delay of switch off and transfer interval gens switch on Detecting transfer fail
37. en set Controller Version A 2012 6 15 Page 60 of 69 15 2CUMMINS QSL9 Suitable for CM850 engine control mode HGM7200 HGM7100 Series Gen set Controller Terminals of 50 pins Remark controller connector Fuel relay output 39 Start relay output Connect to starter coil directly Controller terminals S SS Remark connector CAN communication shielding CAN GND Ge aina line connect to ECU terminal shield E only CAN H SAE J1939 Using impedance 1200 signal C connecting line CAN L SAE J1939 Using impedance 1200 return D connecting line Engine type Cummins CM850 15 3CUMMINS QSM11 It is suitable for CM570 engine Control mode Engine type is QSM11 G1 QSM11 G2 Terminals of controller CA connector Remark Fuel relay output 5 amp 8 Outside expand relay when oil output using make port 5 and port 8 of C1 be connected Start relay output Connect to starter coil directly Terminals of 3 pins data link Remark controller connector CAN communication shielding CAN GND C line connect to ECU terminal only CAN H A Using impedance 1200 connecting line CAN L B Using impedance 1200 connecting line Engine type Cummins ISB HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 61 of 69 15 4CUMMINS QSX15 CM570 HGM7200 HGM7100 Series Gen set Controller It is suitable for CM570 engine control mode
38. ens in crank disconnect setting controller will not collect and display the relative power quantity can be used in water pump set if not select of magnetic sensor in crank disconnect setting the rotating speed displayed in controller is calculated by gens frequency and number of poles 9 PARAMETERS SETTING In HGM7x10 series controller there are no items of mains n setting and also no mains items in configurable ports of input output ACAUTION Please change the controller parameters when generator is in stand by mode only e g Start conditions selection configurable input programmable output various delay otherwise alarming to stop and other abnormal conditions may happen NOTE Maximum threshold must over minimum threshold in case that the condition of too high or too low will happen NOTE When setting the warning alarm please set the correct return value otherwise maybe there is abnormal alarm When setting the overtop warning the return value must less than setting When setting the over low warning the return value must over setting ANOTE Please set the generator frequency value as low as possible when crank disconnect in order to make the starter be separated quickly as soon as crank disconnect ANOTE Configurable input couldn t be set as same items otherwise there are abnormal functions But the configurable output can be set as same items 10 SENSORS SETTING 1 When reselect sensors the
39. eries Gen set Controller Version A 2012 6 15 Page 57 of 69 HGM7200 HGM7100 Series Gen set Controller order to prevent disturbance to controller or others equipment 4 AC Input Current input of 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 A NOTE COM port must be connected to negative pole of battery controller power E WARNING When there is load current transformers secondary side prohibit from open circuit 5 Withstand Voltage Test Acaution When controller had been installed in control panel if need the high voltage test please disconnect controller s all terminal connections in order to prevent high voltage into controller and damage it 14 GSM SHORT MESSAGE ALARM AND REMOTE CONTROL 14 1GSM SHORT MESSAGE ALARM When controller detects alarm it will send short message to phone number which be setautomatic A NOTE Al alarmes about stop trip stop and trip not stop will be sent to the set phone number Warning alarms are sent to the phone number according to the set 14 2GSM SHORT MESSAGE REMOTE CONTROL Users send order message to GSM mode then controller will make actions according to this SMS order and re back operations information Controllers only execute the orders by s
40. et Detail orders as following HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 58 of 69 HGM7200 HGM7100 Series Gen set Controller SMS No Re back Information Description Orders GENSET ALARM oat Ooi ie stopping to alarm SYSTEM IN STOP MODE Standby in stop GENSET AT standby mode Sew IN MANUAL Standby in manual MODE mode GENSET AT REST SYSTEM IN TEST MODE Standby in trial test GENSET AT REST mode SMS SYSTEM IN AUTO MODE Standby in Auto Status 1 GeNseT GENSET AT REST mode of SYSTEM IN STOP MODE Start status in genset GENSET IS RUNNING stop mode SYSTEM IN MANUAL Start Statusi in MODE manual mode GENSET IS RUNNING SYSTEM IN TEST MODE Start status in trial GENSET IS RUNNING testmode SYSTEM IN AUTO MODE Start status in GENSET AT RYNNING Auto mode GENSET AU ADM Genset is stop to alarm or trip alarm Cannot start in v SMS STOP MODE NOT START slaptos Sm START SMS START OK Start in manual or genset auto mode AUTO MODENOT START Cae start in auto mode 3 ET SMS STOP OK Set as stop mode SMS 4 MANUAL SMS MANUAL MODE OK Set as manual mode MODE 5 sue TEST SMS TEST MODE OK Set as trial test mode MODE 6 OM AU tO SMS AUTO MODE OK Set as auto mode MODE 7 SMS Re back information can be Gets details information of DETAIL set via controller software genset SMS 8 INHIBIT INHIBIT START OK Set as start inhibit START H
41. et press at least 3 seconds During stopping process stop generator immediately Start genset in Manual mode or Manual Oo Start Testing mode Manual Mode Press and controller to enter Manual mode HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 12 of 69 HGM7200 HGM7100 Series Gen set Controller Press this key and controller enters Auto Auto Mode mode Running With Load Press to enter Manual Testing mode Alarming sound off If trip and no shutdown Mute Reset Alarm alarm pressing 3 seconds can reset this alarm C5 9 Can control gens to switch on or off in Up Increase e d increase value in setting menu 1 Screen scroll 2 Down cursor and Down Decrease decrease value in setting menu D Gens Closed Open manual mode D Mains Can control mains to switch on_or off in Closed Open manual mode HGM7X10 without x Page Scroll 1 Page turning 21 Shift cursor to confirm Confirm in parameters setting menu O 1 Screen scroll 2 Up cursor and A NOTE Press over 3 seconds go into basic parameters setting menu A NOTE Press anO simultaneously enter into senior parameters setting menu if password is correct A NOTE Press DA A simultaneously increase contrast of LCD press G simultaneously decrease it And the contrast of LCD will back to default setting when controller have power again after lost GI WARNING default passwor
42. ety On Timer 0 3600 s 10 Alarm ms for low oil pressure high temp under speed under frequency voltage charge fail are inactive Start Idle Timer 0 3600 s 0 Idle running time of genset when starting Warm Up Timer 0 3600 s 0 Warming time before genset switch on after it into high speed running Coolant Timer 0 8600 s 10 Radiating time before genset stop after it unloads 10 Stop Idle Timer 0 3600 s 0 Idle running time when genset stop Energized To Stop ETS 0 3600 s 20 Stop electromagnet s power on time when genset is stopping 12 Fail Timer To Stop 0 3600 s 0 Time from over of idle delay to stopped when ETS time is set as 0 Time from over of ETS hold delay to stopped when ETS Hold output time is not 0 13 Over Stop Timer 0 3600 s 0 Time from genset stopped to standby Engine Setting Engine Type 0 39 0 Default common genset not J1939 When connected to J1939 HGM7200 7100 Series Gen set Controller Version1 4 2012 6 15 Page 34 of 69 HGM7200 HGM7100 Series Gen set Controller No Items Parameters Defaults Description engine choose the correspond type Tooth number of the engine Number Of for judging of starter S Flywheel Teeth SE WE separation conditions and inspecting of engine spe
43. ge is 12 Battery Low Voltage under the threshold of setting 43 Maintenance Over When count down time is 0 and select the Time Maintenance Over Time setting When controller detects the value reverse power 14 Reverse Power ee e power is minus is over the threshold of setting When controller detects the value reverse power 15 Over Power power is positive is over the threshold of setting When controller gets the alarm signal from 16 ECU Warning engine via J1939 17 Gens Loss of Phase When controller detects the gens loss phase Gens Reverse 18 When controller detects the gens reverse phase Phase Sequence 19 Switch Transfer Fail When controller detects the switch on and off Warning fail and Switch transfer select enable om Temperature Sensor When controller detects the sensor is open Open Circuit circuit and select warning of open circuit e High Temperature When controller detects the temperature is over Warning the threshold of setting go Low Temperature When controller detects the temperature is Warning under the threshold of setting ol Pressure Sensor When controller detects the sensor is open Open Circuit circuit and select warning of open circuit When controller detects the oil pressure is under 24 Low OP Warning the threshold of setting op Level Sensor Open When controller detects the oil lever sensor is Circuit under the threshold of setting When controller detects the oil lever sensor is 26
44. ial declare when order controller if your genset equip for sensor of 4 20mA 8 5CONDITIONS OF CRANK DINSCONNECT SELECTION No Setting description 0 Gens frequency 1 Speed sensor 2 Speed sensor Gens frequency 3 Oil pressure 4 Oil pressure Gens frequency 5 Oil pressure Speed sensor 6 Oil pressure Speed sensor Gens frequency ANOTE 1 There are 3 conditions to make starter disconnected with engine that is magnetic sensor gens frequency and engine oil pressure They all can be used separately We recommend that engine oil pressure should be using with magnetic sensor and gens frequency together in order to make the starter motor is separated with engine immediately and can check crank disconnect or not exactly 2 Magnetic sensor is the magnetic equipment which be installed in starter for HGM7200 7100 Series Gen set Controller Version1 4 2012 6 15 Page 51 of 69 HGM7200 HGM7100 Series Gen set Controller detecting flywheel teeth 3 When set as magnetic sensor must ensure that the number of flywheel teeth is as same as Setting otherwise over speed stop or under speed stop may be caused AH genset without Magnetic sensor please don t select corresponding items otherwise stop fail or loss speed signal and alarming maybe caused 5 If genset without oil pressure sensor please don t select corresponding items 6 If not select of g
45. into Manual starts mode and its indicator lights Then press L to start generator can automatically detect crank disconnected and generator accelerates to high speed running With high temperature low oil pressure and abnormal voltage dung generator running controller can protect genset to stop quickly please refer to No 4 9 of Auto start operation for detail procedures After generator runs well if remote start signal is active controller will send closing gens signal if the remote signal is inactive controller won t send closing signal 3 Manual stop press can shutdown the running generator please refer to No 3 8 of Auto stop operation for detail procedures 5 6SWITCH CONTROL PROCEDURES 5 5 1 HGM7X20 SWITCH CONTROL PROCEDURES Manual transfer procedures When controller As in Manual mode the switch control procedures will start through manual transfer Users Can control the loading transfer of ATS via pressing button to switch on or off A If Open breaker detect is SELECT Disable Press gens switch on or off key if gens has taken load will send unload signal if taken no load gens will send load signal if mains has taken load mains will unload and then gens will take load Press mains switch on or off key if mains has taken load will send unload signal if taken no load mains will send load signal if gens has taken load gens will unload and then mains will take load HGM7200 7100 Series G
46. ise please check the manual of generator according to SPN alarm code Event log Make records about all start stop events shutdown alarm trip and shutdown alarm manual auto start or stop and the real time when alarm occurs NOTE HGM71X0 without this page Others including Time and Date count down time for maintenance input output ports status About Issue time of software and hardware version Example Voltage of gens Speed of engine HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 15 of 69 HGM7200 HGM7100 Series Gen set Controller 5 3 2BASIC PARAMETERS SETTING MENU Including as following S Conditions of crank disconnect Number of engine flywheel teeth Rated speed Rated voltage of gens Rated frequency of gens Rated voltage of mains Rated frequency of mains Changing ratio of current transformer Rated current Rated power Voltage of battery Time and date Start delay Stop delay Preheat timer Crank on timer Crank Rest Timer Safety on timer Start idle timer Warm up timer Cooling timer Stop idle timer ETS Energize to Stop hold time Fail to stop time Example Form 1 OQchange the items enter into setting form2 and CB setting Conditions of start Form 2 Genter into setting Form3 press O Q to back HGM7200 7100 Series Gen set Controller Version1 4 2012 6 15 Page 16 of 69 HGM7200 HGM7100 Series Gen set Controlle
47. its indicator lights and controller enters Auto mode Starting Sequence 1 HGM7X20 When Mains is abnormal over and under voltage over and under HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 18 of 69 HGM7200 HGM7100 Series Gen set Controller frequency miss phase anti phase enter into mains abnormal delay and LCD display count down time When mains abnormal are over enter into start delay also can be into this mode when remote start on load is active HGM7X10 Generator enters into start delay as soon as Remote Start on Load is active Count down of start delay is shown in LCD When start delay is over preheat relay outputs if this be configured oreheat start delay XX s is shown in LCD When preheat delay is over fuel relay outputs 1s and hen start relay output if engine crank fail during cranking time the fuel relay and start relay stop outputs and enter into crank rest time and wait for next crank If generator crank fails within setting times controller will send Fail to start Whatever ways to start generator successfully lt it will enter into safety on timer During this period alarms of low oihpressure high temperature under speed charge fails are inactive As soon as this delay is over generator will enter into start idle delay if configured During start idlesdelay alarms of under speed under frequency under v
48. ler Version1 4 2012 6 15 Page 36 of 69 HGM7200 HGM7100 Series Gen set Controller No Items Parameters Defaults Description controller ready to detect loading Volt f 7 0 1 0 0 Disable 1 Enable Transformer 8 SH ZER 0 200 120 Setting value is percentage Shutdown KS SS of gens rated volt Delay nder olt anne value also can be set 9 ehutdewa 0 200 80 10 vel ZER 0 200 114 Setting value is percentage Shutdown Under Fre of gens rated freq Delay 11 K 0 200 80 value also can be set Shutdown Over Volt A Setting value is percentage P Warning WEE na of gens rated volt Delay l l 13 Under Volt 0 1000 g and return value also can Warning b set Over Freq o Setting value is percentage L Warning 10006 TS of gens rated freq Delay E l l 15 Under Freq 0 1000 84 and return value also can Warning be set We ge Ge Oat 0 Disable 1 Enable 17 Anti Phase 04 1 Monitor Load Setting Current The change of outside T Transtager EE 00 l connected CT Rated Full Generator s rated current S Current een 200 standard of load current 3 Rated Power 0 6000 kw 276 Generators rated power standard of load current Setting value is percentage 4 ae 0 200 120 of gens rated volt Delay Current value also can be set B Over Power 0 1 0 0 Disable 1 Enable 0 Disable 6 Anti Power 0 1 0 is Enable Switch Se
49. ler s positive and negative connected to start battery are correct HGM7200 7100 Series Gen set Controller Version1 4 2012 6 15 Page 53 of 69 HGM7200 HGM7100 Series Gen set Controller 3 Scram button s normal close point is connected with input of emergence stop and insurance must be connected with positive and negative of start battery 4 Take proper action to prevent engine to crank disconnect e g Remove the connection wire of fuel value If checking is OK make the start battery power on choose manual mode and controller will executive routine 5 Set controller under manual mode press start button genset will start After the setting times as setting controller will send signal of Start Fail then press stop to make controller as reset 6 Recover the action of stop engine start e g Connect wire of fuel value press start button again genset will start H everything goes well genset will normal run after idle running if idle run be set During this time please watch for engine s running situations and AC generator s voltage and frequency If abnormal stop genset running and check all wires connection according to this manual 7 Select the AUTO mode from controller s panel connect mains signal After the mains normal delay controller will transfer ATS if fitted and into mains load After cooling time controller will stop genset and make it in to stand by time until there is abnormal
50. mains over under voltage 2 230 e l Volt V This Value is primary voltage of transformer Mains Rated 10 0 75 0 Gel ey eee 3 50 0 mains over under Freq Hz frequency 4 Mains Normal 0 3600 10 The delay from abnormal to Delay normal Mains 5 aa 0 3600 s 5 The delay from normal to abnormal Delay e ie T Tao 0 0 Disable 1 Enable Transformer 7 Mains Over 0 1000 120 FENM VANE is mains rated Volt voltage s percentage and 8 Mans Under 0 1000 80 return and delay values Volt also can be set 9 Mains Over 0 1000 Disable Setting valle is mains rated Freq frequency s percentage 10 Mains Under 0 1000 Disable return and delay values Freq also can be set Miss Phase 11 Monitor et 0 Disable Anti Phase 1 Enable t Monitor WH i Timer Setting Time from mains abnormal 1 Start Delay 0 3600 s 1 or remote start signal is active to start genset HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 33 of 69 HGM7200 HGM7100 Series Gen set Controller No Items Parameters Defaults Description Stop Delay 0 3600 s 1 Time from mains normal or remote start signal is inactive to genset stop Preheat Timer 0 3600 s 0 Time of pre powering heat plug before starter is powered up Crank Timer 3 60 s 8 Time of starter power up each time Crank Rest Timer 3 60 s 10 The second waiting time before Dower Op when engine start fail Saf
51. mpleted Used for engine which has idles Pull in before starting and pull out after into 35 Idle Control hi speed warming Pull in during stopping idle mode and pull out after shutdown completed 36 Raise Speed Action in hi speed warming run 37 Drop Speed Action in period of stop idle mode to time of wait for stopping completely Used for engines with ETS electromagnet 38 ETS Control Pull in when stop idle is over and pull out when set ETS delay is over 39 Pulse droop output The genset act for 0 1s when it enters into HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 43 of 69 HGM7200 HGM7100 Series Gen set Controller speed idle mode It is used to control part of ECU droop to idle 40 ECU Stop Used for ECU engine and control its stop 41 ECU Power Used for ECU engine and control its power The genset act for 0 1s when it enters into 42 Pulse acceleration high speed warming mode It is used to output control part of ECU accelerate to normal speed 45 Crank Disconnect Pull in when detects a successful start signal 44 Generator OK Action when gens are normal Palen eee Men Action in period of gens ok jo hi speed cooling 46 Mains OK Action when mains normal 47 Reserved ae Hee Action in gens common warning common shutdown common trips alarm 49 Common Electrical T
52. nerator l Oooo Series Function 7100Series ASM RS485 Port 7200Series AMF CAN Bus Port Note 1 It is basic model if without postfix 2 Please contact with our qualified personnel for more information about the postfix descriptions 2 2MODULES COMPARISON HGM HGM HGM HGM HGM HGM HGM HGM es 7220 7210 7120 7110 7120C 7110C 7120CAN 7110CAN Number of digit input 7 7 5 5 5 5 5 5 port HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 6 of 69 HGM7200 HGM7100 Series Gen set Controller Number of relay 8 8 6 6 6 6 6 6 output 1 Number of sensors 5 5 3 3 3 3 3 3 2 AMF e 6 RS485 6 e e GSM L L SMS CAN J J1939 USB e e e e e e e Real time L L clock Event log e e Note 1 Including two fixed output ports start output and fuel output 2 HGM7220 7210 s analog sensors are composed by 3 fixed sensors temperature pressure fuel level and 2 configurable sensors Other controllers are composed by 3 fixed sensors temperature pressure liquid level only 2 3MODELS ABBREVIATION Abbreviation Description HGM72xX0 All HGM7200 series controllers HGM71X0 All HGM7100 series controllers HGM7X20 All HGM7200 7100 series AMF controllers HGM7X10 All HGM7200 7100 series ASM controllers 3 PERFORMANCE AND CHARACTERISTICS HGM7
53. oltage are inactive As soon as this delay is over generator will enter into warming up time delay generator indicator is light if generator s voltage frequency is normal When warming up time delay is over if generator s voltage frequency is normal close gens relay will output Generator will enter into normal running with load and gens close indicator is light if generator s voltage and frequency is abnormal controller will alarm and stop engine gens alarm is shown in controller s alarm page NOTE When started via Remote Start off Load input same procedures as above except for gens switch on relay not output and generator without load in NO 9 HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 19 of 69 HGM7200 HGM7100 Series Gen set Controller Stopping Sequence 1 HGM7X20 when mains return during genset running enters into mains voltage Abnormal delay When mains abnormal delay are over enter into stop delay also can be into this mode when remote start on load is inactive 2 HGM7X10 generator enters into stop delay as soon as Remote Start on Load is inactive 3 When stop delay is over close generator relay is un energized _ generator enters into cooling time relay After transfer rest time close mains relay is energized Gens indicator dark while mains indicator lights 4 ldle relay is energized as soon as entering stop idle
54. ort of Remark controller engine Expand 30A relay battery voltage of Fuel relay output 01 07 12 13 is supplied by relay Start relay output Connect to starter coil directly CAN communication shielding CAN GND line connect po ECU terminal only CAN H CAN H Using impedance 1200 connecting line CAN L CAN L Using impedance 1200 connecting line Engine type J1939 common used 15 7DEUTZ EMR2 Terminals of controller F connector Remark Fuel relay output Expand 30A relay battery voltage of 01 07 12 13 is supplied by relay Fuse is 16A Start relay output Connect to starter coil directly 1 Connect to battery negative pole CAN communication shielding CAN GND line connect to ECU terminal only CAN H 12 Using impedance 1200 connecting line CAN L 13 Using impedance 1200 connecting line HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 63 of 69 HGM7200 HGM7100 Series Gen set Controller Engine type VolvoEDC4 15 8JOHN DEERE connecting line Terminals of 21 pins Remark controller connector Fuel relay output GJ Start relay output D CAN communication shielding CAN GND line connect to ECU terminal only CAN H v Using impedance 1200 connecting line CAN L U Using impedance 1200 Engine type John Deere 15 9MTU MDEC Suitable for MTU engines
55. p signal it will Shutdown send a stop alarm signal 5 Over Speed When controller detects over speed value it will send Shutdown a stop alarm signal 4 Under Speed When controller detects under speed value it will shutdown send a stop alarm signal Voss ofpe When EE oe speed value ER 0 and speed signal is lost it will send a stop alarm signal When controller detects frequency is over value of 5 Gens Over Freq eee setting it will send a stop alarm signal e Gens Under When controller detects frequency is under value of Freq setting it will send a stop alarm signal HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 26 of 69 HGM7200 HGM7100 Series Gen set Controller No Type Description When controller detects voltage is over value of 7 Gens Over Volt ee l setting it will send a stop alarm signal 8 Gens Under When controller detects voltage is under value of Volt setting it will send a stop alarm signal If genset start fail within setting of start times 9 Fail To Start l l controller will send a stop alarm signal When controller detects current is under value of 10 Over Current setting and over current alarm is set it will send a stop alarm signal When count down time is 0 and select the 11 ES Maintenance Over Time is set it will send a stop Over Time l alarm signal When controller gets stop alarm from engine via 12
56. pe connection terminals and built in mounting Structure compact with easy mounting 4 SPECIFICATION Items Contents Operating Voltage DC8 0V to 35 0V Continuous Power Supply Power Consumption lt 3W standby lt 2W Alternator Input Range 15VAC 360VAC ph N 3 Phase 4 Wire 30VAC 620VAC ph ph 3 Phase 3 Wire 15VAC 860VAC ph N Single Phase 2 Wire 15VAG gt 360VAC ph N 2 Phase 3 Wire Alternator Input Frequency 50 60Hz Magnetic Input Range 1 0V to 24 0V RMS Magnetic Input Frequency 10 000 Hz max Start Relay Output 16 Amp DC28V at supply output Fuel Relay Output 16 Amp DC28V at supply output Auxiliary Relay Output 1 7 Amp DC28V at supply output Auxiliary Relay Output 2 7 Amp 250VAC voltage free output Auxiliary Relay Output 3 16 Amp 250VAC voltage free output Auxiliary Relay Output 4 16 Amp 250VAC voltage free output Auxiliary Relay Output 5 7 Amp DC28V at supply output HGM72xX0 only Auxiliary Relay Output 6 7 Amp DC28V at supply output HGM72X0 only Mounting Dimensions 197mm x152mm x47mm Panel Cutout 186mm x141mm C T Secondary 5A rated Working Conditions Temperature 25 70 C Humidity 20 90 HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 10 of 69 HGM7200 HGM7100 Series Gen set Controller Storage Condition Temperature 30 80 C IP55 when waterproof rubber ring added betwe
57. r D previous menu cress back to previous menu form 1 Form 3 1 frequency speed S OQchange items 6 setting form2 G setting form2 5 3 3 ADVANCED PARAMETERS SETTING MENU Including S Mains Timers Engine Generator Load ATS Analog Sensor Inputs Outputs Module Scheduled and maintenance GSM SMS Example Formi OO change items enters setting form2 exits setting Form 2 D Change items form3 select return and press back to previous menu fom back to previous menu form 1 Form 3 AY Change tems confirm setting form Wo back to previous menu form 1 HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 17 of 69 HGM7200 HGM7100 Series Gen set Controller Form 4 Oa into setting form5 press O Y back to previous menu forms back to previous menu form 3 Form 5 D Change setting items form 6 confirm setting form 7 and exit setting form4 Form 6 DU Change setting items tiom Z confirm setting form 79 and exit setting form4 Form 7 DU nue setting items form5 confirm setting and exit setting form4 Form 8 OQchange setting items confirm setting form 4 and exit setting form4 ANOTE Long time pressing can exit setting directly during setting 5 4AUTO START STOP OPERATION Press
58. rip Action in common trips shutdown alarm 50 Common Shutdown Action in common shutdown alarm 51 Common Trip Alarm Action in commonstrips and not shutdown alarm 52 Common Warning Alarm Action in common warning alarm 53 Reserved 54 Battery High Volts An action in battery s over voltage warning alarm 55 Battery Low Vg Action in battery s low voltage warning alarm 56 Charge Fail Action in charge alt fail warning alarm 57 Reserved 58 Reserved 59 Reserved 60 ECU Warning Indicate ECU sends a warning alarm signal 61 EGU Shutdown Indicate ECU sends a shutdown alarm signal 62 ECU Com Fail Indicate controller not communicates with ECU 63 Reserved 64 Reserved 65 Reserved 66 Reserved 67 Reserved 68 Reserved 69 Aux Input 1 Active Action when input port 1 is active 70 Aux Input 2 Active Action when input port 2 is active HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 44 of 69 HGM7200 HGM7100 Series Gen set Controller 71 Aux Input 3 Active Action when input port 3 is active 72 Aux Input 4 Active Action when input port 4 is active 73 Aux Input 5 Active Action when input port 5 is active 74 Aux Input 6 Active Action when input port 6 is active 75 Aux Input 7 Active Action when input port 7 is active a
59. rk controller CAN port ECU stop Configurable output 1 6 Configurable output 1 ECU stop ECU power SHEET g Configurable output 2 ECU HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 66 of 69 HGM7200 HGM7100 Series Gen set Controller power Negative power Positive power CAN GND CAN communication shielding line connect to ECU terminal only CAN H 1 Hi Using impedance 1200 connecting line CAN L 2 Lo Using impedance 1200 connecting line Engine type Volvo EMS2 A NOTE When select this engine type the preheat time should be set more than 3 seconds 15 15BOSCH It is suitable for BOSCH common rail pump engine Terminals of Engine A2 ons Remark controller Fuel relay output 1 40 Connect to engine ignition lock Start relay output Connect to starter coil directly CAN communication shielding CAN GND line connect to ECU terminal only CAN H 1 35 Using impedance 1200 connecting line CAN L 1 34 Using impedance 1200 connecting line Battery Engine 2 pins Remark Battery negative 1 Wire diameter 2 5mm Battery positive 2 Wire diameter 2 5mm Engine type BOSCH A NOTE If there is any question of connection between controller and ECU communication please feel free to contact Smartgen service HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 67 of 69
60. rs Setting Temperature Sensor 1 Type Of Curve 0 15 7 SGH Open Circuit 0 warn 1 shutdown 2 Action 0 2 S 2 no action High Temp S Warn when temperature S Shutdown aa 2 ee over this value Detecting HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 38 of 69 HGM7200 HGM7100 Series Gen set Controller No Items Parameters Defaults Description only after safety delay is over The delay value also can be set Warn when temperature is High Temp over this value Detecting 4 Warning 0 300 C 95 only after safety delay is over The delay and return value also can be set p ow MP ga 0 0 Disable 1 Enable Warning Oil Pressure Sensor 1 Type Of Curve 0 15 7 SGH 2 Open Circuit 0 2 0 0 warn 1 gt shutdown 2 Action no action Warn wen pressure over our Pressue this value Detecting only 3 0 1000 kPa 103 after safety delay is over Shutdown The delay value also can be set Warn when pressure over R EE this value Detecting only 4 0 1000 kPa 124 after safety delay is over Warning The delay and return value also can be set Liquid Level Sensor 1 Type Of Curve 0 15 4 SGH Open Circuit O warn 1 shutdown 2 Action We S 2 no action Warn when level under this Low Level o value Detecting all the S Warning e 1 time The delay and return value also can be set Programmable Sensors1 Programmable Sensor 1 Setting 0 1
61. rved 43 Reserved 44 Reserved 45 Aux Mains Ok In Auto mode mains are normal when input is active Ap Aux Mains Fail In Auto mode mains are abnormal when input is active Selectivity Selectivity configuration act when the input is 47 Configuration 1 valid Selectivity configuration can set different Active parameters and users can choose present Selectivity configuration by input port 48 Configuration 2 Active Selectivity 49 Configuration 3 Active 50 Reserved 8 4SELECTION OF SENSORS Form4 No Description Remark Temperature Sensor 0 Not used 1 Defined resistance curve 2 Defined 4 20ma curve 3 VDO Defined resistance s 4 CURTIS scope is O 6KQ 5 VOLVO EC default is SGX kind 6 DATCON sensor 7 SGX 8 SGD 9 SGH HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 50 of 69 HGM7200 HGM7100 Series Gen set Controller No Description Remark 10 PT100 11 15 Reserved Pressure Sensor 0 Not used 1 Defined resistance curve 2 Defined 4 20mA curve 3 VDO 10Bar 4 CURTIS 5 VOLVO EC 6 DATCON 10Bar 7 SGX 8 SGD 9 SGH 10 15 Reserved Defined resistance s scope is O 6KQ default is SGX kind sensor Oil Level Sensor 0 Not used 1 Defined resistance curve 2 Defined 4 20mA curve 3 SGD 4 SGH 5 15 Reserved Defined resistance s scope is O 6KQ default is SGH kind sensor NOTE User should make spec
62. s 2A 41 voltage sensing 1 0mm fuse is recommended HGM7X10 input without Mains C phase Connected to C phase of mains 2A 42 voltage sensing 1 0mm fuse is recommended HGM7X10 input without DEE Connected to output N wire of mains 43 Mains N wire input 1 0mm HGM7X10 without 44 CAN screen Impedance 1200 shielding wire is 45 CAN L 0 5mm recommended its single end earthed 46 CAN H bh gi EE without CANBUS function don t have this terminal 47 RS485 screen Impedance 1200 shielding wire is 48 RS485 0 5mm_ recommended its single end earthed 49 RS485 Ace aah controllers without RS485 don t have this terminal RS232 GND 2 EN oom Connected to GSM module e E E HGM7100 series without 52 RS232 TX 0 5mm NOTE USB ports in controller rear panel are programmable parameter ports user can directly program controller via PC NOTE Please refer to the model comparison in this manual for more products functions HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 32 of 69 HGM7200 HGM7100 Series Gen set Controller 8 SCOPES AND DEFINITIONS OF PROGRAMMABLE PARAMETERS 8 1 CONTENTS AND SCOPES OF PARAMETERS Form 1 No Items Parameters Defaults Description Mains Setting Mains AC 0 3 0 0 3P4W 1 3P3W Supply System 2 2P3W 3 1P2W Standard lt for checking Mains Rated 30 30000
63. setting cannot be lost even without power most parameters can be set via panel oL controller and all parameters can be set via PC which connected with USB or RS485 More kinds of curves of temperature pressure fuel level can be used directly and users can define the sensor curves by themselves More conditions of crank disconnect speed sensor oil pressure generator frequency are optional Widely power supply range 8 35 VDC accommodating to different starting battery voltage environment Event log and real time clock Timing start amp stop generator can be set as start genset once a day weekly monthly whether with load or not also can be set as custom weekly Selectivity configuration Users can choose different configuration by input port Can be used as an supervisory instrument indicate and alarm are enable HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 9 of 69 HGM7200 HGM7100 Series Gen set Controller only output is inhibited With timing maintenance function Actions warning only or shutdown alarm can be set when maintenance time up All parameters used digital adjustment instead of conventional analog modulation with normal potentiometer more reliability and stability Seal ring between controller and shell excellent waterproof ability Metal fixing clips enable perfect high temperature resistance Modular design anti flaming ABS plastic shell inserted ty
64. ted 7A 10 Programmable Normal open passive 2 5mm 11 relay output 3 contacts of relay rated 12 Programmable 16A output of passive 2 5mm 13 relay output 4 contacts HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 30 of 69 HGM7200 HGM7100 Series Gen set Controller No Functions Diameter Remark Charge nerio Connected to charging starters D 14 g g 1 0mm WL terminals If there is no this D port input l terminal and be hung up 15 Programmable Homm Ve supplied by 2 relay output 5 points rated Details see Programmable 7A HGM7100 series form 2 16 1 5mm relay output 6 without Magnetic pickup 17 Input Magnetic pickup Connected to Magnetic Pickup shielding line is 18 input and controller recommended inner be connected to battery negative 19 EES sensor Connected to temp Sensor input Setting Oil pressure sensor 20 SEH Connected to oil pressure sensor items see z level nsor aiia 2 ARA R Connected to oil level sensor input 22 Auxiliary input 1 1 0mm 23 Auxiliary i 2 1 i E E E Omg Ground connected is meng 24 Auxiliary input 3 1 0mm active Ve items see 25 Auxiliary input 4 1 0mm form 3 26 Auxiliary input 5 1 0mm 97 Public terminals_of Public terminals of sensor controller inner are sensor connected to battery negative 28 Auxiliary input 6 4 0mm Ground connected is Set
65. than value of setting and the 3 Over Power l ee reverse power action trip alarm is set it will send a trip and not stop alarm signal When input port is set as trip stop alarm and the 4 Input Port alarm is active it will send a trip and not stop alarm signal HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 29 of 69 HGM7200 HGM7100 Series Gen set Controller 7 WIRINGS CONNECTION HGM7200 7100 series controller rear Description of terminal connection EE EE Eo Ee EES U V W N2 R S T M p GENS AC VOLTAGE MAINS AC VOLTAGE CURRENT RATED 5A CANBUS RS485 ISOLATION ISOLATION e bsiadeteig No Functions Diameter Remark 1 DC input ve 2 Rmn Connected to negative of starter battery Connected to positive of starter battery If wire length is over 30m dL anas uy better to double wires in parallel Max 20A fuse recommended 3 Emergency stop fone Connected to Ve via emergency stop Input button 4 Fuel relay output 1 5mm_ Ve is supplied by 3 points rated 16A Connected 5 eStart relay output 1 5mm ae Upped Py 2 to coil of points rated 16A starter 6 Programmable SE Ve is supplied by 2 relay output 1 points rated 7A 7 Normal close outputs rated 7A Programmable S s 8 1 5mm_ Public points of relay relay output 2 Details see 9 Normal open outputs Form 2 ra
66. ting active Ve ieme 629 29 Auxiliary input 7 1 0mm HGM7100series form 3 without 30 Ai i Connected to temperature oil Setting Gg mabic Pressure or fuel level sensors items see 31 9 HGM7100 series without form 4 sensor 2 Curran ees Outside connected to secondary coil of 32 A phase sensing 1 5mm current transformer rated 5A input ER DEE Outside connected to secondary coil of 33 B phase sensing 1 5mm x current transformer rated 5A input cure WER Outside connected to secondary coil of 34 C phase sensing 1 5mm input current transformer rated 5A HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 31 of 69 HGM7200 HGM7100 Series Gen set Controller No Functions Diameter Remark 35 ee eee 1 5mm See following installation instruction current transformer Gelee SES Connected to A phase output of 36 Voltage sensing 1 0mm l input genset 2A fuse is recommended See Aphase Connected to B phase output of 37 voltage sensing 1 0mm input genset 2A fuse is recommended Gensel C plese Connected to C phase output of 38 voltage sensing 1 0mm l input genset 2A fuse is recommended 39 Genset N wire input 1 0mm Connected to output N wire of genset Mains A phase Connected to A phase of mains 2A 40 voltage sensing 1 0mm fuse is recommended HGM7X10 input without Mains B phase Connected to B phase of main
67. troller Version A 2012 6 15 Page 68 of 69 HGM7200 HGM7100 Series Gen set Controller ECU communication failed ECU warning or stop Check connections of CAN high and low polarity Check if correctly connected of 1200 resister Check if type of engine correct Check if connections from controller to engine and setting of inputs correct Get information from LCD of alarm page If there is detailed alarm check engine according to description If not please refer to engine manual according to SPN alarm code HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 69 of 69
68. tting l Interval time from mains 1 eo ee 0 7200 s 5 switch off to gens switch on Rest Timer or from gens switch off to HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 37 of 69 HGM7200 HGM7100 Series Gen set Controller No Items Parameters Defaults Description mains switch on Pulse width of mains gens 2 wien CN 0 20 0 s 5 0 switch on When it is 0 Delay means output constantly 3 Switch Off 0 20 0 s 3 0 Pulse width of mains gens Delay switch off Time of detecting switch 4 ven Manet 0 20 0 s 5 0 auxiliary contacts after Delay transferred Transfer Failed 5 Warning 0 1 0 Enable SE Switch Off 0 Disable 1 Enable 6 Detecting 0 1 0 Enable Module Setting i Working 0 2 0 O Stop mode 1 Manual Mode mode 2 Auto mode 2 Communication 1 254 Controller s address during Address remote sensing Number Of 0 2 stop bits 1 1 stop Stop Bits st bit Language 0 simplified Chinese 1 select 104 9 English 2 others 5 Password Ki 318 To entering advanced parameters setting GSM Setting 1 GSM Enable 0 1 0 0 Disable 1 Enable off Gm cl Max 20 Must be acco its national digits and area s cods Timing And Maintenance Setting 1 Scheduled Start 0 1 0 0 Disable 1 Enable See to 0 0 Disable 1 Enable Start 3 Maintenance 0 1 0 0 Disable 1 Enable Analog Senso
69. while gens switch on After detecting time up if switch on fail then wait for gens switch on If transfer fail and warning SEL Enable there is alarming signal 2 If input port is not connected with closing breaker input Mains load be transferred into gens load after switch off and transfer interval delay gens switch on The way to transfer gens load to mains load is as same as above 5 5 2 HGM7X10 SWITCH CONTROL PROCEDURES Manual transfer procedures HGM7200 7100 Series Gen set Controller Version A 2012 6 15 Page 22 of 69 HGM7200 HGM7100 Series Gen set Controller When controller is in Manual mode manual transfer will be executive Users can control switch on or off by pressing key Press gens switch on or off key if gens have taken load will output unload signal if taken no load gens will output load signal Auto control procedures When controller is in manual test auto or stop mode switch control procedures will start auto transfer 1 If configurable input port is connected with closing breaker signal Al Open breaker detect is SELECT Disable Gens load is transferred into gens un load after the delay of switch off detecting transfer failure while switch off output When detecting time up if switch off failed to wait for switch off Otherwise switch off is completed Gens unload is transferred into gens load after the delay of switch on detecting transfer failure while switch on outputting
70. with the shell of starter stable The wire s diameter must be over 2 5mm and which is connected to B and B of controller power If floatingycharge configured please firstly connect output wires of charger to battery s positive and negative directly then connect wires from batter a positive and negative to controllers positive and negative lt input ports in order to prevent charge disturbing the controllers normal working 2 Speed Sensor Input NOTE speed sensor is the magnetic equipment which be installed in starter and for detecting eet oT flywheel Its connection wires to controller should apply for 2 cores shielding line The shielding layer should connect with No 18 terminal in controller while another side is hanging in air The else two signal wires are connected with No 17 and No 18 terminals in controller The Output voltage of speed sensor should be within 1 24 VAC effective value during the full speed 12VAC is recommended in rated speed When install the speed sensor let the sensor is spun to contacting flywheel first then port out 1 3 lap and lock the nuts of sensor at last 3 Output And Expand Relays Acaution all outputs of controller are relay contact output type If need to expand the relays please add freewheel diode to both ends of expand relay s coils when coils of relay has DC current or increase resistance capacitance return circuit when coils of relay has AC current in HGM7200 7100 S
71. y run active detecting after safety on run delay 1 Reserved 2 Alarm Miia Can prohibit output of Audible Alarm when is active 3 Reset Alarm Can reset shutdown alarm and trip alarm when is active 4 6OHZ Select Use for CANBUS engine and it is 60HZ when is active 5 Lamp Test All LED indicators are illuminating when input is active All buttons in panel is inactive except OOG and 6 Panel Lock there is in the right of first row in LCD when input is active 7 Reserved 8 Slow Control Protection less voltage frequency and speed is Mode inactive 9 Inhibit Auto Stop In Auto mode when input is active prohibit gens HGM7200 7100 Series Gen set Controller Version1 4 2012 6 15 Page 48 of 69 HGM7200 HGM7100 Series Gen set Controller shutdown auto after gens is OK In Auto mode prohibit gens start auto when 10 Inhibit Auto Start h input is active 11 Inhibit Scheduled In Auto mode prohibit fixed timing start genset when input is active 12 Reserved 13 Aux Gens Closed Connect gens loading switch s Aux Point 14 Inhibit Gens Load Prohibit genset switch on when input is active 15 EE Connect mains loading switch s Aux Point Closed 16 GC mains Prohibit mains switch on when input isvactive When input is active controller enters into Auto CG 17 Auto Mode Input mage alme KBY

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