HGM6000K Series Automatic Generator Module USER MANUAL
Contents
1. aaa 37 13 FAULT FINDING c c ooo aaa 39 HGM6000K Series Automatic Generator Module 1 SUMMARY HGM6000K series Genset controller integrating digital intelligent and network techniques is used for automatic control system of diesel generator It can carry out functions including automatic start stop data measure and alarm protective The controller uses LCD display with operation easy and reliable HGM6000K series Genset controller uses micro processing technique which can carry out precision measure constant value adjustment timing and threshold setting and etc functions It can be widely used in all types of generator automatic control system for compact structure advanced circuits simple connections and high reliability can be widely applied to various types of generating units automation system HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 5 of 40 HGM6000K Series Automatic Generator Module 2 PERFORMANCE AND CHARACTERISTICS HGM6000K controller has four types HGM6010K 6010KC Automatic Start Module it controls genset to start stop by remote start signal HGM6020K 6020KC Based on HGM6010K 6010KC and add mains AC monitoring Mains Genset automatic switching control functions AMF especially suitable for the automation system composed by Mains and Genset Note1 HGM6010KC 6020KC with RS485 interface HGM6010K 6020K without RS485 interface Note2 And then2. Connect to starter Start relay 1 5mm from pin 3 starting coil 16 Amp rated PI Auxiliary output AAPP teed asad 1 5mm from pin 2 y 7 Amp rated 7 Closed NAA R 7 NAA R rated Reference table 2 s Auxiliary output Lo Relay common relay 2 point Erol rc O output 7 Erol rc O rated HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 19 of 40 HGM6000K Series Automatic Generator Module O Auxiliary output 0 5mm relay 3 Free volt contacts Auxiliary output 16 Amp rated relay 4 h fail P al aN Do not connect to ground battery ve excite Magnetic pickup L LS Connect to Magnetic Pickup device Magnetic pickup 9 p VE Connecting water cylinder temperature resistance type sensor Reference Oil pressure Connect to oil pressure table 4 input sensor 9 Liquid level input Connect to liquid level sensor O Auxiliary input 1 Switch to ve 1 Auxiliary input 2 Switch to ve R j enor a Switch to ve input CT secondar a for A y Connect to secondary of A monitoring CT CT secondar maan for B y Connect to secondary of B monitoring CT CT secondary s Connect to secondary of C monitoring 1 for C CT T s Wi See also back install instructions common 07 Gens A voltage 4 Ga 2 Connect to Genset A output monitoring E Recommend 2A fuse 28 Gens B voltage 1 Omm Connect to Genset B output monitoring en Recommend 2A fuse 2 2 2 2 2 h N _ b gt gt b
3. Smartgen HGM6000K Series Automatic Generator Module USER MANUAL Lae AGE Z pras CHARG ate L2 3N evar BHB 93 cae BOSSE oan PATNO No reper GHARG 4 LEVELPF I E E NY F Bar v L3 1N VASkVar Line fp ollo lo lo lole Smartgen Technology tk E F F Chinese trademark Smartgen Smartgen make your generator smart English trademark Smartgen Technology Co Ltd No 28 Jinsuo Road Zhengzhou city Henan Province P R China Tel 86 37 1 67988888 67981 888 86 371 67991553 67992951 86 371 67981000 overseas Fax 0086 371 67992952 Web http www smartgen com cn http www smartgen cn Email sales smartgen cn All rights reserved No part of this publication may be reproduced in any material form including photocopying or storing in any medium by electronic means or other without the written permission of the copyright holder Smartgen Technology reserves the right to change the contents of this document without prior notice Software Version Version Date ne __ 2009 07 18 Original release aa 2009 09 01 Add oil pressure sensor SGX temperature sensor SGX and power on mode select 2009 11 01 Add edition display function 2009 12 25 Amend sensor curve function Add output port high speed output function Add input port 4 and 5 function 1 4 2010 06 17 Amend products appearance picture panel cutout size long wide all increase 2 controller applicable worki
4. delay Gens Over one volt 30 360 V shutdown Gens under e volt 30 360 V shutdown a Under speed Dar 0 6000 RPM A A Over speed abutan 0 6000 RPM P 26 Gens undef P21 freq 0 75 0 H shutdown Gens Over j 4 freq 0 75 0 H shutdown High Kas temperature 80 140 P23 shutdown Too high or too low voltage genset alarm delay When genset voltage is over than the point genset over shutdown voltage is active When the point is 360V genset over voltage is disabled When genset voltage is under than the point genset under shutdown voltage is active When the point is 30V genset under voltage is disabled When the engine speed is under than the point and hold great than 10 seconds genset under shutdown speed is active When the engine speed is over than the point and hold great than 2 seconds genset over shutdown speed is active When genset frequency is low than the point genset low frequency shutdown and hold great than 10 seconds is active When genset frequency is over than the point and hold great than 2 seconds genset over shutdown frequency is active When engine temperature sensor value is large than this point and remain for 2 seconds send out shutdown alarm When the value is 140 send out warning alarm Its suited for engine temperature sensor only HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 24 of 40 SS HGM6000K Series Automati
5. 1 9 Page 15 of 40 HGM6000K Series Automatic Generator Module FAILED TO CHARGE WARN if the module detects that the charge of volts has fallen below the setting level has expired a warning will occur At the same time LCD screen E1 icon lighten GENSET OVER VOLTAGE WARN if the module detects a genset output voltage in excess of the setting a warning Is initiated At the same time LCD screen vi icon lighten GENSET UNDER VOLTAGE WARN if the module detects a genset output voltage below the setting a warning is initiated At the same time LCD screenV icon lighten OVER SPEED WARN if the engine speed exceeds the setting value a warning is initiated At the same time LCD screen E icon lighten UNDER SPEED WARN if the engine speed falls below the setting value after the Safety On timer has expired a warning Is initiated Atthe same time LCD screen lt icon lighten GENSET OVER FREQUENCY WARN if the module detects a genset output frequency in excess of the setting value a warn in is initiated At the same time LCD screen Hz icon lighten GENSET UNDER FREQUENCY WARN if the module detects a genset output frequency below the setting value after the Safety On timer has expired a warning is initiated At the same time LCD screen Hz icon lighten 5 2 SHUTDOWN ALARM Shutdowns are latching and stop the genset The alarm must be cleared and the fault removed to reset the module NOTE The alarm condition must be rectified before a res
6. PP flicker LOSS OF SPEED SIGNAL if the speed sensing signakis lost a shutdown is initiated At the same time LCD screen PF flicker GENSET OVER FREQUENCY if the module detects a genset output frequency in excess of the setting value a shutdown is initiated At the same time LCD screen Hz flicker GENSET UNDER FREQUENCY if the module detects a genset output frequency below the setting value after the Safety On timer has expired a shutdown is initiated At the same time LCD screen Hz flicker GENSET OVER VOLTAGE if the module detects a genset output voltage in excess of the setting value a shutdown is initiated At the same time LCD screen V t flicker GENSET UNDER VOLTAGE if the module detects a genset output voltage below the setting value after the Safety On timer has expired a shutdown is initiated Atihe same time LCD screen V flicker GENSET OVER CURRENT if the module detects a genset output current in excess of the setting value is initiated a shutdown is initiated At the same time LCD screen At flicker FAIL TO START if the engine does not fire after the pre set number of attempts has been made a shutdown will be initiated At the same time LCD screen af flicker AUXILIARY INPUTS if an auxiliary input has been configured as a shutdown the appropriate information will be displayed At the same time LCD screen Ip flicker HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 17 of 40 HGM60
7. is illuminating Then press D to start genset it can automatic detect start successfully and genset automatic accelerates to Hi speed running If there is Hi temperature low oil level and voltage abnormal during diesel genset running HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 13 of 40 HGM6000K Series Automatic Generator Module controller can protect genset to stop quickly detail procedures please refer to No 4 9 of Auto start operation After genset runs well in High speed controller will send signal of gens close 3 Manual stop press can shutdown the running genset detail procedures please refer to No 3 7 of Auto stop operation HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 14 of 40 HGM6000K Series Automatic Generator Module 5 PROTECTION 5 1WARN Warns are non critical alarm conditions and do not affect the operation of the genset system they serve to draw the operators attention to an undesirable condition In the event of a warning the module will display at the last screen of LCD Warn is shown as the below HIGH ENGINE TEMPERATURE WARN if the module detects that the engine coolant temperature has exceeded the high engine temperature setting level after the Safety On timer has expired and the input of Inhibit WTH stop is activated a warn will occur At the same time LCD screen 3s icon lighten LOW OIL PRESSURE WARN if the module detects th
8. ook FH h ook anb mb da N O O1 Temp sensor Input N eference table 3 O1 2 5mm 29 Gens C voltage 10 Connect to Genset C output monitoring SULU Recommend 2A fuse Gens neutral input a Connect to Genset neutral terminal 31 Mains A voltage 10 Connect to mains A output monitoring ALL Recommend 2A fuse 1 0mm Omm 30 Mains B voltage Connect to mains B output monitoring Recommend 2A fuse 33 Mains C voltage Connect to mains C output monitoring Recommend 2A fuse HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 20 of 40 N N NO N N IN O O gt N HGM6000K Series Automatic Generator Module Mai Connect to mains neutral terminal paa Use only 1200 RS485 approved cable 1 These terminals of 31 32 33 and 34 are not used for HGM6010KC module 2 Back LINK interface as a parameter programming interface used by SG72 adapter PC controller programming HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 21 of 40 HGM6000K Series Automatic Generator Module 7 PARAMETER RANGE AND DEFINE All parameters of HGM6000K series as follows Note small brackets set item number 6010KC 7 1 PARAMETERS TABLE TABLE 1 Num Parameter Range poy Mains volt 9 3600 s 10 normal delay Mains volt Mains transient delay suited for AlLS automatic transfer switch abnormal 0 3600 s delay lt When mains volt
9. power on 0 2 1 Manual mode P 2 Auto mode P 63 Module pae ares 0 _ 1 P 64 Passwords Aa Crank P 65 success 0 5 o Setting item is given in P60 condition Table 5 select HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 27 of 40 HGM6000K Series Automatic Generator Module Parameter Range Default Remark When engine speed is large Speed disconnect 0 3000 RPM H Freq 14 disconnect ne OP disconnect Select AC system P65 sensor P66 Sensor P67 level sensor P73 P68 P74 P69 P75 P70 HGM6000K Series Automatic Generator Module O 8 0 8 0 5 Temperature sensor custom curve setting Oil pressure sensor custom curve setting Liquid level sensor custom curve setting ISSUE 2013 08 13 than this point starter will disconnect When genset frequency is large than this point starter will disconnect When engine oil pressure is large than this point starter will disconnect 3P4L 3 phase 4 wire Need to set up eight first acts of the current data set the number of items the second act to set the resistance value of the third act to set the resistance value of the temperature corresponding to the value of Need to set up eight first acts of the current data set the number of items the second act to set the resistance value the third act to set the resistance va
10. to go into standby state until the mains is abnormal again After the mains is abnormal again the Genset will automatically crank into normal operation state and then close genset relay control the ATS to switch transfer to genset on load If the situation is not same as described above check the connection of control part of the ATS according to this handbook lf there are other questions please contact the technical personnel of Smartgen immediately HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 34 of 40 HGM6000K Series Automatic Generator Module 11 TYPICAL WIRING DIAGRAM GENS Ss lt GENS HGM6010KC Typical wiring diagram 30 29 28 27 ea al a 14 17 18 19 1516 20 21 22 38 39 40 6 B aj wal u r lt t x 5 2 E z z 3 a rar PPIK LI HGM6020KC Typical wiring diagram LOAD o AA 9 SWITCH1 SWITCH2 arang _ _ U o e o v mi V 1 bi CTs sell si aa so lll lt a O 3 AUX OUTPUT2 M TAYAAN 12 Pamm 11 7 8 9 13 Fx 23 24 25 26 30 29 28 27 PF 31 32 33 34 5 4 14 17 18 19 1516 20 21 22 38 39 40 2 3 1 B LEVEL R FUEL OOLANT TEMP AUX INPUT AUX INPUT2 AUX INPUT3 AUX INPUT5 C fr a N Nn fr ce O 7 oe oC Na HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 AUX OUTPUT 1 AUX OUTPUT Li l L2 LOAD AUX OUTPUT4 12 13 35 5
11. 00K Series Automatic Generator Module NO GENSET ALARM SHUTDOWN when the controller detects to genset frequency equals to zero the controller sends out the shutdown alarm signal At the same time LCD screen Hz flicker TEMPERATURE SENSOR OPEN CIRCUIT when the controller detects to temperature sensor open circuit the controller sends out the shutdown alarm signal At the same time LCD screen Na flicker OIL PRESSURE SENSOR OPEN CIRCUIT when the controller detects to oil pressure sensor open circuit the controller sends out the shutdown alarm signal At the same time LCD screen Y flicker HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 18 of 40 HGM6000K Series Automatic Generator Module 6 CONNECTING TERMINAL HGM6010KC compared with HGM6020KC is less a Mains three phase AC input terminal The HGM6010KC and HGM6020KC backplane is as following GENS VOLTAGE MAINS VOLTAGE 7A 7A250VAC U V W N2 R S T N1 27 26 29 30 gt gt o1 22 20 24 CONTROLLER rad e PROGRAM shee AST PORT ADJUST IA IB IC ICOM EEE AUX OUTPUT1 AUX OUTPUT2 AUX OUTPUT3 16A250VAC AUX OUTPUT4 16A 250VAC CHA CURRENT RATED 5A a ENGINE TEM AUX INPU AUX INPU AUX INPU PICKUP Y A DC ne Supp System DC negative input input Battery Negative System DC positive input a T a Battery Positive Recommended Maximum ue 20A pau gaan input Start outputs Plant mania ve
12. 672 Module 36 LA 3 5485 USB sr OC FEY MAINS Z 1G A 35 A SG72 Module Page 35 of 40 HGM6000K Series Automatic Generator Module Single phase 2 wires HGM6020KC R GENSET MAINS INPUT N 34 31 27 Single phase 2 wires R N MAINS INPUT 34 32 31 27 28 30 2 phase 3 wires Note Recommend that the output of crank and Fuel expand high capacity relay HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 36 of 40 HGM6000K Series Automatic Generator Module 12 INSTALLATION The controller is designed to panel installation mode and it is fixed by clamps when it is installed The overall dimension and panel tapping dimension are given as follows 2 3 CUT OFF E o ra Battery voltage input HGM6000K series controller can be applicable to 8 35VDC battery voltage environment battery anode must be reliable connect engine shell B and B controller power battery anode and cathode connections is not less than 2 5 if there was the float electrical please put the charger output wire directly to battery is negative and from the battery is connected to the anode separately on the power input positive controller to prevent the normal operation of the controller battery chargerinterference Speed sensor input Speed sensor is installed in the engine block of magnetic device testing flywheel teeth itsshould be used with the control
13. E 2013 08 13 Version 1 9 Page 12 of 40 HGM6000K Series Automatic Generator Module At the first line NO 4 is the Start interval state 3s is the countdown to remain time intervals of Start interval Gens Status List 0 Genset Waiting 1 Start preheat 2 Fuel output 3 Start 4 Start Interval 5 Safety run 6 Start Idling 7 Start warm up 8 Wait for the Load 9 Normal Run 10 Stop for cooling 11 Stop idling 12 ETS stop 13 Wait for stop steady 14 Shutdown failures 4 4 MANUAL OPERATION 1 HGM6020KC Auto starts mode is active when press Q and its indicator is illuminating press then controller under Manual Test Mode and its indicator is illuminating Under the both modes press O to start genset and it can automatic detect start successfully and accelerate to Hi speed running If there is Hi temperature low oil level and voltage abnormal during diesel genset running controller can protect genset to stop quickly detail procedures please refer to No 4 9 of Auto start operation Under Manual Test mod OD genset with load is decided by Mains is normal or not If mains are normal loading switch is never transferred while mains are abnormal loading switch is transferred into gens side Under Manual Test Mode GD after genset runs well in high speed no matter mains is normal or not loading switch must be transferred into gens side 2 HGM6010KC Auto starts mode is active when rose and its indicator
14. age is under than the point mains under voltage are active When the point is zero mains under voltage are disabled When mains voltage is over than the point mains over 30 360 V 276 voltage are active When the point is 360V mains over voltage are disabled It s the delay from mains is opened to genset closing or from genset is opened to mains closing It s the delay from remote start signal is active Or mains is failure to start genset It s the delay from remote start signal is inactive or mains is normal to stop genset When engine start no success most of cranking numbers When reach setting crank numbers controller send out start fail signal Before the starter adds the electricity preheat plug add one Preheat time 0 300 s to the electricity in advance P10 be ae The starter adds the time of P05 SIGNKIng ume 42H60 the electricity each time HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 22 of 40 Mains under cai 30 360 V 184 Mains over volt Transfer switch 0 99 9 s interval P 06 PO start delay 0 3600 s P 07 P02 Stop delay 0 3600 s Number of 1 10 Times Crank ook HGM6000K Series Automatic Generator Module Num Parameter Range Default Remark When the engine start not P 11 Crank interval 3 60 s successful in the second P06 time plus electric before the start of the waiting time At this time low o
15. ase 4 Wire AC15V AC360V ph N 2 Phase 3 Wire AC15V AC360V ph N Single phase 2 Wire AC15V AC360V ph N ing 1 7Amp DC28V atsupply voltage Helay Quip Ul 2 7Amp AC250V free voltage contact 3 4 16Amp AC250V free voltage contact Overall Dimensions 209mm x 153mm x 55mm Panel cutoff 186mm x 141mm Operating Temp Range Temperature 25 70 C Humidity 20 90 RH Storage Condition Temperature 30 80 C IP55 when waterproof rubber ring added between controller and its panel IP42 when waterproof rubber ring not have between controller and its panel Protective Level Object among in input output power Insulation Intensity Quote standard IEC688 1992 Test way AC1 5 kV 1min 3mA leakage current C T Secondary 5A rated HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 8 of 40 HGM6000K Series Automatic Generator Module 4 OPERATION 4 1 KEY FUNCTION Can stop genset under mode of Manual Auto Can reset alarming under Stop Stop Reset To test panel indicators are OK or not pressing this key at least 3 seconds During stopping process press this again can stop genset immediately To start genset under Manual or Auto mode Manual Pressing this key will set the module into manual Manual mode Pressing this k ill he modale in mati ere g this key will set the module into automatic Pressing and controller is under manual testing Running with mode load Un
16. at the engine oil pressure has fallen below the low oil pressure setting level after the Safety On timer has expired and the input of Inhibit OPL stop is activated a warning will occur At the same time LCD screen amp icon lighten LOSS OF SPEED SIGNAL WARN if the speed sensing signal is lost a warning will occur and the lost speed delay set to Zero a warning will occur At the same time LCD screen icon lighten GENSET OVER CURRENT WARN if the module detects a genset output current in excess of the setting and the over current delay set to zero a warning is initiated At the same time LCD screen Al icon lighten FAIL TO STOP WARN if the module detects the engine is still running when the Fail to stop timer expires a warning is initiated At the same time LCD screen pao icon lighten START BATTERY OVER VOLTAGE WARN if the module detects that the plant DC supply has risen above the high volts setting level a warning is initiated At the same time LCD screen VI icon lighten START BATTERY UNDER VOLTAGE WARN if the module detects that the plant DC supply has fallen below the low volts setting level a warning is initiated At the same time LCD screen V icon lighten LOW FUEL LEVEL WARN if the module detects that the engine oil level has fallen below the low level setting level has expired a warning will occur At the same time LCD screen NIN icon lighten HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version
17. c Generator Module KC Series Automatic Generator Module Num Parameter Range _ Default Remark When engine oil pressure sensor value is less than this point and remain for 2 p 29 Low oil seconds send out pressure 0 400 kPa shutdown alarm When the P24 shutdown value is zero send out warning alarm It s suited for oil pressure sensor only When low Fuel level sensor P 30 Low Fuel 0 100 value is less than this point P25 level and remain for 10 seconds send out warning alarm When speed is zero and remain for the delay send eat levee Pee 0 20 0 s out shutdown alarm When P26 delay the delay is zero send out warning alarm When genset voltage is over than the point genset P32 Gens over 30 360 V over warning voltage is P27 volt warn active When the point is 360V genset over voltage is disabled When genset voltage is under than the point genset P33 Gens under 30360 V under warning voltage is P28 volt warn active When the point is 30V genset under voltage is disabled When the engine speed is P 34 Under speed 0 6000 RPM under than the point genset P29 warn under warning speed is active When the engine speed is P35 Over speed 0 6000 RPM over than the point genset P30 warn over warning speed is active E pang When genset frequency is P36 Gens under low than the point genset 0 75 0 H P31 freq warn under warning frequency is active Fa pang When genset freq
18. d curve will call If factory set temperature sensor for SGX resistance type sensor curve for SGX resistance type 120 degrees Celsius elected SGD type resistively curve for temperature sensor SGD curve 2 If use standard sensor with the curve can differ option Item sensor curve input after adjusting adjustment can be determined according to save 3 When the input sensor curve X resistance must be in accordance with the order of big from small otherwise will enter errors 4 When the sensor is choosing nothing the sensor curves no affection LCD display temperature or pressure for 5 If there is no pressure sensor only low pressure alarm switch it must be alarm settings for pressure sensor nothing otherwise may appear oll pressure low alarm shutdown 6 Can set up several point of forehand or several point of backmost ordinate the same The following picture VY AA f E _ L 32 64 96 128160192 224 2 omh Common unit s conversion table 1 psi 6 89x10 7 03x10 6 89x10 HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 33 of 40 HGM6000K Series Automatic Generator Module 10 COMMISSIONING Before operation inspections that are recommended as follows should be carried Out 1 2 9 Check and assure that all connections are correct and that diameter of line is Suitable The DC power supply of controller is equipped with fuse and the po
19. der this mode genset will run with load automatic when gens are normal HGM6010KC without Enters into Set menu after pressing this and can Set Confirm shift cursor to confirm Page up Screen pages turning increase Shift cursor and increase its position no in setting Page down Screen pages turning decrease Shift cursor and decrease its position no in setting HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 9 of 40 HGM6000K Series Automatic Generator Module 4 2 DISPLAY DESCRIBE Mains line voltage Uab Ubc Uca Mains phase voltage Ua Ub Uc Mains frequency Hz F1 Genset line voltage Uab Ubc Uca Load current IA IB IC Load active power kW inactive power kVar apparent power kVA Accumulate total gens power kWh Battery voltage BAT Charger Power factor voltage CHARG Liquid level CHARG m no y LEVEL 7 HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 10 of 40 HGM6000K Series Automatic Generator Module Water temperature Gens oil pressure Gens hours count Gens starts count Ejs 4 3 AUTOMATIC OPERATION This mode is activated by pressing the LED indicator is illuminating beside the button confirms this action Sequence of Auto Start 1 HGM6020KC When Mains is abnormal over and under voltage or miss phase enters into mains abnormal delay and LCD display count down time When mains abnor
20. e Gens When closing time set to zero time off to continue this function when the feeder namely for continues when closed on does not have this function In the process of warm up when he entered the suction suck time for high speed warm up delay time Raise speed auxiliary input effective disconnect Enter into stop idling process or to ETS solenoid stop when alarm stop sucked and suck time to stop idling delay time Drop speed when the auxiliary valid disconnect 0 Pre supply oil control SSS High speed warm up ready to on load normal L G operating output after high speed cooling HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 29 of 40 Preheat control 7 Open ATS Raise speed control Drop speed control HGM6000K Series Automatic Generator Module 7 3 DIGIT INPUT 1 5 TABLE TABLE 3 KO Notused High Temp input After the end of the delay in the safe operation if the signal is active genset will immediately alarm shutdown Auxiliary warn input Auxiliary warn alarm digital input 4 Auxiliary shutdown When power on if active genset will shut down alarm input immediately During engine running if the engine occur high temperature shutdown when the input is 5 Stop after cooled ka sic an a P active the engine will first initiate cooling delay 2 Low OP alarm input and then stop else will stop immediately Gens closed input The input state of
21. e modify the parameters such as crank disconnect input and output configuration various time etc in standby mode otherwise gt it might alarm shutdown or other abnormal behavior c The over voltage threshold must be greater than the under voltage threshold otherwise both will occur at the same time over voltage and under voltage situation d The over speed threshold must be greater than under speed threshold otherwise you will receive both the over speed and under speed e As far as possible set the frequency crank disconnect to lower numerical in order to quickly crank disconnect whemcrank success Configurable input port 1 5 cannot set for the same items otherwise cannot appear correct function configurable output 1 4 can be set for the same item g If need to shutdown after cooling please set any one configurable input as stop after cooling then connect this input with GND Information LCD will display the controller software version issue date Note Press the key will display the states of configurable input port and output port state Set language User may set display interface language as Chinese English and Spanish Remark Press the key will exit setting interface at any time HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 32 of 40 HGM6000K Series Automatic Generator Module 9 SENSOR SETTINGS h When the choice sensor the sensor to standar
22. et will take place lf the alarm condition remains it will not be possible to reset the unit The exception to this is the Low Oil Pressure alarm as the oil pressure will be low with the engine at rest EMERGENCY STOP removal of the ve DC Supply from the Emergency Stop input initiates the following sequence firstly it will initiate a controlled shutdown of the genset and prevent any attempt to restart the genset until the Emergency stop push button has been reset Secondly it removes the ve DC supply from both the Fuel Solenoid and Starter Solenoid At the same time LCD screen X flicker HIGH ENGINE TEMPERATURE if the module detects that the engine coolant temperature has exceeded the high engine temperature setting level after the HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 16 of 40 HGM6000K Series Automatic Generator Module Safety On timer has expired a shutdown will occur At the same time LCD screen zh flicker LOW OIL PRESSURE if the module detects that the engine oil pressure has fallen below the low oil pressure setting level after the Safety On timer has expired a shutdown will occur At the same time LCD screent flicker OVERSPEED if the engine speed exceeds the setting value a shutdown is initiated At the same time LCD screen flicker UNDERSPEED if the engine speed falls below the setting value after the Safety On timer has expired a shutdown is initiated At the same time LCD screen
23. genset closed 7 Mains closed input The input state of Mains closed When it is active during engine running if the engine appears high temperature the engine will only send out high temperature warning alarm not stop a When it is active during engine running if the Inhibit high temp stop engine appears low oil pressure the engine will only send out low oil pressure warning alarm not stop In automatic state controller remote starts the 10 Remote start input signal effectively when starting 7 4 SENSOR TABLE 4 N Inhibit OPL STOP O Not used Pressure 1 Defined Res Type Sensor 2 VDO 10Bar 3 SGH Huanghe sensor Defined input resistance range is 0 999 9 ohm factory default is SGX Num O Not used 1 Defined Res Type 2 VDO 3 SGH Huanghe sensor Temperature ASGD in si Defined input resistance 1 range is 0 999 9 ohm mene cali factory default is SGX 5 CURTIS 6 DATCON 7 VOLVO EC 8 SGX HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 30 of 40 1 HGM6000K Series Automatic Generator Module SGD DongKang sensor 5 CURTIS 6 DATCON 10Bar 7 VOLVO EC 8 SGX O Not used 1 Defined RT Fuel level 2 SGH Sensor 3 SGD 4 Reserved 1 5 Reserved 2 Defined input resistance range is 0 999 9 ohm factory default is SGD The crank disconnect condition has three kinds the magnetic pickup sensor and the genset voltage can be used alone the oil pre
24. ing alarm It s suited for oil pressure sensor only Current transformer rate Mains or genset set maximum rated current When the load current is over than the point the over current delay is initiated When load current is over than the point and hold great than the timer send out over current signal When the delay is zero over current is disabled HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 26 of 40 HGM6000K Series Automatic Generator Module Parameter Range Default Remark Over current corso no When the load current is warn 50 130 110 over than the point over percentage current warn icon illume Switching value output1 0 11 2 ETS solenoid to stop set Switching value output 2 0 11 3 ldle control set Switching value output 3 0 11 5 Close Gens set P 51 nips AB 0 11 Close mains 6010KC has P46 sai no function P47 set switch Input 4 2 0 P53 Aux input 1 P48 delay paran A4 N P 54 Aux input 2 P49 set 0 10 Low oil pressure input P55 Aux input 2 P50 delay paa EN SAM P 56 Aux input 3 ma P51 set 0 10 Auxiliary warning input P57 Aux input 3 psn aey gt YO J 20T P 58 Aux input 4 P53 set 0 10 6 Oil engine closed state input P 59 Aux input 4 Paca L 2o P 60 Auxs input 5 P55 set 0 10 Remote start input P61 Aux input 5 P 62 Module Na Stop mode P57
25. ler of attachment 2 core shielding line shielding layer on the 16th pin controller the other end terminal the other two are respectively in signal controller and meet the terminals 15th and 16th pin At full speed sensor output voltage range should be in 1 24VAC RMS recommend voltage for 12VAC in the rated speed When the velocity sensor can be installed to contact the flywheel spinning sensor first then pour out 1 3 laps finally will lock nut on the sensor Output and relays Controller for all output relay contacts output if need to expand relays please will expand relay coil free wheeling diode increased ends when extended relay coil links DC or increase resistance and capacitance loop when HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 37 of 40 HGM6000K Series Automatic Generator Module extended relay coil links AC in order to prevent interference controller or other equipment 4 Alternating current input HGM6000K series controller to external input current transformer electric current transformer side must be 5A while the current transformers for phases and the phase of the input voltage must be correct otherwise the current and sampling the active power may be incorrect Note A ICOM must connect battery anode power controllers B When the load current the transformer secondary side is strictly open circuit 5 Withstand Voltage test When controller had been installed in control
26. ll pressure high water temperature under speed P12 under frequency under P07 Sale URONG es voltage and charging failure and auxiliary input configured alarm is void volume P13 Start idle time 0 9600 s o Sen genset idle running P08 Lo Genset entered high speed operation in the warm up before closed for time P14 Warming up P09 time P 15 P10 Cooling time 3 3600 s ih Stop idle time 0 3600 s P11 running time P17 ETS solenoid 0 120 s It s the delay for energizing P12 hold to stop ETS solenoid shutdown output time for zero idle time delay stop steady to time and when kaa Pari lo AG ETS solenoid hold output y time is not equal to zero from ETS solenoid shutdown delay end to stop steady need of time Mains or Genset switch P19 ATS closing pulse width when it P14 time IS Zero output IS 3 3600 s After unloading in genset the time needed to cool before shutdown When stop idling genset continuous The flywheel teeth on engine starter teeth used P 20 Flywheel for _ Starters separation condition judgment and P15 teeth engine speed detection see behind the installation instructions HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 23 of 40 HGM6000K Series Automatic Generator Module CC Series Automatic Generator Module Num Parameter Range Gens KA abnormal 0 20 0 s P16
27. lue of the pressure corresponding to the value of Need to set up eight first acts of the current data set the number of items the second act to set the resistance value the third act to set the resistance value of the value of the corresponding level Version 1 9 Page 28 of 40 HGM6000K Series Automatic Generator Module Num Parameter Range Default Remark Number of magnetic poles P76 Number of 2 32 04 used for calculating rotating P71 speed of generator without speed sensor 7 2 OUTPUT 1 4 TABLE TABLE 2 Description 0 Notused Output is no use when select this The designated programmable output relay will 1 Common alarm energize when any warning or shutdown fault circuit has been activated The designated programmable output relay will energize when a stop signal has been ETS solenoid hold activated The output will remain ETS solenoid for pre set timer once the engine has come to a complete stop then de energizes The designated programmable output relay will energize when the idle delay is not zero The 3 ldle control output contact would typically be connected to the idle run input control of an electronic governor The designated programmable output relay will energize during the preheat delay timer period and also energize until the engine receive a crank success signal The preheat output is typically used for an engine starting aid such as glow plugs 5 Clos
28. mal delay is over enter into start delay HGM6010KC entries into start delay as soon as Remote Start is input valid Count down of start delay is displayed in LCD When start delay is over preheat relay is outputting if be equipped preheat start delay XX s is displayed in LCD When preheat relay is over oil relay is outputting 1s and then start relay output if genset fails in starting during cranking time the oil and start relays stop outputting and enters into crank rest time and wait for next attempt If genset fails in starting within setting attempt times LCD start up failure alarming icon a flash HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 11 of 40 T HGM6000K Series Automatic Generator Module Whatever times to start genset successfully it will enter into safety on time During this period alarms of low oil pressure hi temperature under speed charge fail and Aux input been configured are inactive As soon as this delay is over genset will enter into start idle delay if this be configured During start idle delay alarms of under speed under frequency under voltage are inactive As soon as this delay is over genset will enter into warming up time delay if this be configured When warming up time delay is over gens status indicator is light if gens normal If alternator s voltage frequency meets to requi
29. ng temperature 2010 07 07 Optimize some detail parts of the operator Manual 2010 12 03 Gens speed and frequency was changed to a screen 2011 06 20 Modify single phase three phase input of parameter range 2012 8 14 Modify parameters 2013 8 13 Add Number of poles item HGM6000K Series Automatic Generator Module HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 4 of 40 CONTENT t SUMMARY ak mana EE 5 2 PERFORMANCE AND CHARACTERISTICS ccc eee 6 3 SPECIFICATION esner nrar iraia aieiai 8 4 OPERATION 000 cee aaa 9 4 1 KEY FUNCTION cccccccccc cccccccccciiccicii2 9 4 2 DISPLAY DESCRIBE 10 4 3 AUTOMATIC OPERATION cccccccssessssessesesseseesesesseseesesesssstsseseesesveseeeees 11 4 4 MANUAL OPERATION Mhan 13 5 PROTECTION 1 2 ah 15 5 1 WARN Luma aai AW 15 5 2 SHUTDOWN ALARM Meee ae MP 16 6 CONNECTING TERMINAL c ccc i AA aa 19 7 PARAMETER RANGE AND DEFINE jm maa 22 7 1 PARAMETERS TABLE TABLES 2 2 0 0 anan baa 22 7 2 OUTPUT 1 4 TABLE TABLE 2 12mm esaad aaa 29 7 3 DIGIT INPUT 1 5 TABLE TABLE 3 oiana aaa 30 7 4 SENSOR TABLE 4 QU Op WP 30 7 5 CONDITION OF CRANK SUCCEED TABLE 5 aaa 31 8 SETTING PARAMETER Aicil ala 32 9 SENSOR SETTINGS M BOL aaa 33 10 COMMISSIONING del aa 34 11 TYPICAL WIRING DIAGRAM 7 7 7 7 7m aaa 35 12 INSTALOQBEMONWA
30. ngine manual Unit operation but ATS Check ATS Check the connection between the ATS and the controller Check wiring RS485 communication Check COM ports set correctly abnormal Check the A and B RS485 line is reversed Check of RS485 conversion module Genset shutdown Emergency shutdown High Temp alarm after crank success Crank no success HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 39 of 40 HGM6000K Series Automatic Generator Module Check the PC communications port is damaged Suggest that the A and B lines of the 485 network should be terminated at each end with a 1200 resistor HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 40 of 40
31. 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 HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 38 of 40 HGM6000K Series Automatic Generator Module 13 FAULT FINDING Check the battery and wiring to the unit Check Genset inoperative the DC supply Check the DC fuse Check water cylinder temperature whether or not too high Check AC genset voltage Check the DC fuse lf an Emergency Shutdown switch is not fitted ensure that a positive is connected tothe Emergency shutdown input Check emergency shutdown switch is functioning correctly Check wiring is not open circuit Check engine oil pressure Low oil Pressure alarm after Check oil pressure switch sensor and wiring crank success Check configured polarity if applicable is correct Check engine temperature Check switch sensor and wiring Check configured polarity is correct Check relevant switch and wiring of fault indicated shutdown fault operates on LCD display Check configuration of input Check wiring of fuel solenoid Check battery supply Check wiring of the speed sensing signal Refer to engine manual Check wiring of fuel solenoid Check fuel Check battery supply Crank failure Check battery supply is present on the Fuel output of the module Check the speed sensing signal is present on the 6000K series inputs Refer to e
32. rement of load gens will close and relay is outputting then genset will enter into normal running with load and gens indicator is light if genset voltage and frequency Is abnormal controller will alarm and stop engine gens alarming is displayed LCD Sequence of Auto Stop 1 HGM6020KC when Mains recovery during genset running enters into mains voltage normal delay and its indicator light after Mains normal be confirmed Start delay is beginning HGM6010KC genset enters into stop delay as soon as Remote Start putting is inactive As soon as stop delay is over genset enters into High Speed cooling delay Mains are close and breaker is disconnected After switch rest time delay mains are close and relay is output as well as with loading Gens indicator is dark while mains light ldle relay has power and outputs as soon as entering stop idle relay If this been configured When enters ETS relay ETS relay has power and outputs Oil relay s output is disconnected When genset enters stop time automatic to decide whether genset is stopped or not When genset will enter into over stop time as soon as genset is stopped If genset failed to stop and controller will alarm stop failed will be displayed in LCD Note This page is nonce genset status genset status delay countdown display for example HGM6000K Series Automatic Generator Module ISSU
33. s m Control protection Automatic crank stop of diesel engine load transfer ATS control and completely faults display protection With ETS idle control pre heat control raises speed control functions and all types of them are belong to relay output Parameters setting Allow user to modify setting and store them by inside internal FLASH memory the parameters cannot be losteven with power off All of parameters can be set not only from the front panel but by PC via SG72 an adaptor USB LINK RS485 module or through RS485 port via PC Most of temperature pressure oil level sensor can be directly used and also user can define sensor curve by themselves Multiple crank disconnection conditions can be selected Speed sensor oil pressure gens m Power supply range is wide 8 35 VDC accommodating to different starting battery voltage environments All parameters use digital modulation abandoning analog modulation using conventional electronic potentiometer more reliability and stability Modular configuration design Flame Retardant ABS plastic shell inserted type connection terminals flush type installation compact structure easy installation HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 7 of 40 HGM6000K Series Automatic Generator Module 3 SPECIFICATION Operating Voltage DC8 0V to 35 0V Continuous Power Consumption lt 3W Standby mode s2W Alternator Input Range 3 Ph
34. sitive supply Ve and negative supply Ve connected with battery are connected correctly The emergency stop input is connected with the positive supply Ve of the battery through the NC terminal and fuse of emergency stop button The suitable operation should be taken to prevent the engine from crank success such as dismantling the connection of fuel check and assure that it is correct then connect with battery select manual mode the controller will execute program Press down the starting button on the panel of controller the engine will crank after starts have been carried out according to setting crank numbers the controller sends the signal that indicates crank failure Press the Stop Reset key to make the controller resetting Restore the measure that prevents the engine from crank success such as restoring the connection of fuel press down the starting button again the engine will crank if crank is normal the genset will operate from idle operation if idle has been set to normal operation In the meantime observe the operation situation of engine and the voltage and frequency of the AC genset li there is abnormal stop the genset then check connections of each part according to this handbook select automatic state through front panel then switch on the mains voltage the controller switches over ATS if it exist to mains on load after pass through the mains normal delay after cooling time and then shut down
35. ssure must be used with the magnetic pickup sensor and the genset voltage the purpose is to make the starter and the engine to disconnect as soon as possible Magnetic pickup sensor is installed in the engine block number of magnetic device testing flywheel When choosing magnetic pickup sensor ensure engine flywheel teeth setting otherwise may appear over speeding shutdown or loss speed shutdown lf the genset is not magnetic pickup sensors please don t choose corresponding otherwise this will occur fail to start or loss of speed alarm and shutdown If the genset has no oil pressure sensor please don t choose corresponding If the genset starting conditions has not be selected the controller will not measure and display the relative parameters This can be applied to the pump set if not choose magnetic pickup sensor the speed signal will come from the generating AC signal HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 31 of 40 HGM6000K Series Automatic Generator Module 8 SETTING PARAMETER After controller powered on press to enter into the parameters setting menu Set parameters When entering password entering 1234 can set the item 1 to 47in the table parameters table Table 1 entering 0318 can set all items NOTE a When the controller type is HGM6010KC you will not have a tablewith a 1 5 the programmable output 1 4 will have no power of some mains switch output b Pleas
36. take HGM6010KC 6020KC with text as an example to describe Using microprocessor as a core graphics LCD with big screen and backlight display between character and icon display key touch for operation m Have a RS485 port with Modus communication protocol Adapt to 3phase 4wires single phase 2wires or 2phase 3 wires 120 240V 50 60Hz AC power system Measure and display 3 phase voltage 3 phase current frequency power etc parameter of Mains and Gens m Precision measure and display of Mains Gens Line voltage Uab Ubc and Uca Line voltage Uab Ubc and Uca Phase voltage Ua Ub and Uc Phase voltage Ua Ub and Uc Frequency HZ Frequency HZ Load Power Current IA IB IC Active power KW Inactive power KVar Apparent power KVA Power factor Cos Accumulate total gens power kWh m Mains have over voltage under voltage loss phase function Gens have over voltage under voltage over frequency under frequency over current function m Precision measure and display parameters about Engine HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 6 of 40 HGM6000K Series Automatic Generator Module Temp WT C F both are display Oil pressure OP kPa Psi Bar all be display Fuel oil level FL unit Speed SPD RPM unit Voltage of Battery VB V unit Voltage of Charger VD V unit Hour count HC can accumulate Max 999999 hours Starting up can accumulate Max 999999 time
37. uency is P 37 Gens over over than the point genset 0 75 0 P32 freq warn over warning frequency is active HGM6000K Series Automatic Generator Module ISSUE 2013 08 13 Version 1 9 Page 25 of 40 HGM6000K Series Automatic Generator Module Num Parameter Range P38 Charge fall P33 P 39 Battery over P34 volt PEO P40 Battery under P35 volt pa Mak erature 80 140 C P36 oP warn Low oil P 42 P37 pressure 0 400 kPa warn P 43 P38 CT rate 5 6000 5 P 44 Full load P39 current 7990A P 45 Over current shutdown 50 130 P40 percentage Over current shutdown 0 3600 s delay O GO O 0 30 V C O V P 46 P41 500 During genset is running when charge alternator WL D voltage is low than this point and remain for 5 seconds genset will warning alarm When genset battery voltage is over than the point and hold for 20 seconds battery over voltage signal 4s active It s a warning alarm When genset battery voltage is less than the point and hold for 20 seconds battery under voltage signal is active Its a warning alarm When engine temperature sensor value is large than this point send out warning alarm When the value is 140 send out warning alarm It s suited for engine temperature sensor only When engine oil pressure sensor value is less than this point send out warning alarm When the value is zero send out warn
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