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User Manual: HGM9510 Genset Parallel (With Genset) Unit
User Manual: HGM9510 Genset Parallel (With Genset) Unit
USER MANUAL
Smartgen Technology
CONTENTS
1 OVERVIEW ....................................................................................................... 5
4 SPECIFICATION ............................................................................................... 9
5 OPERATION ................................................................................................... 10
5.1 INDICATOR LIGHT........................................................................................................ 10
5.2 PUSHBUTTONS ........................................................................................................... 10
5.3 LCD DISPLAY ............................................................................................................... 11
5.3.1 MAIN DISPLAY .......................................................................................................... 11
5.3.2 USER MENU AND PARAMETERS SETTING MENU ............................................... 13
5.4 AUTO START/STOP OPERATION ............................................................................... 16
5.5 MANUAL START/STOP OPERATION .......................................................................... 17
5.6 SWITCH CONTROL PROCEDURES ............................................................................ 17
5.6.1 MANUAL TRANSFER PROCEDURES...................................................................... 17
5.6.2 AUTOMATIC CONTROL PROCEDURE.................................................................... 18
6 PROTECTIONS ............................................................................................... 19
6.1 WARNING ALARMS ...................................................................................................... 19
6.2 SHUTDOWN ALARMS .................................................................................................. 21
6.3 TRIP AND STOP ALARMS ............................................................................................ 23
6.4 TRIP ALARM ................................................................................................................. 24
10 SENSORS SETTING....................................................................................... 48
11 COMMISSIONING ........................................................................................... 49
11.1 STEP 1. SINGLE UNIT DEBUGGING ............................................................................ 49
11.2 STEP 2: MANUAL PARALLEL OPERATION OFF-LOAD .............................................. 49
11.3 STEP 3: MANUAL PARALLEL OPERATION ON-LOAD ................................................ 49
11.4 STEP 4: AUTOMATIC PARALLEL OPERATION ........................................................... 50
13 INSTALLATION .............................................................................................. 55
15 USB ................................................................................................................. 64
HGM9510 controller is designed for manual/auto parallel system generators with similar or
different capacity. Additionally, it is suitable for single unit constant power output and mains
paralleling. It allows automatic start/stop, parallel running, data measurement, alarm protection as
well as remote control, remote measurement and remote communication function. It fit with LCD
display, optional Chinese, English and other languages interface, and it is reliable and easy to
use.
Utilizing the GOV (Engine Speed Governor) and AVR (Automatic Voltage Regulator) control
function, the controller is able to synchronize and share load automatically; it can be used to
parallel with other HGM9510 controller.
HGM9510 controller also monitors the engine, indicating the operational status and fault
conditions accurately. When abnormal condition occurs, it splits bus and shuts down the genset,
simultaneously the exact failure mode information is indicated by the LCD display on the front
panel. SAE J1939 interface enables the controller to communicate with various ECU (ENGINE
CONTROL UNIT) which fitted with J1939 interface.
The powerful 32-bit Microprocessor contained within the module allows for precision parameters
measuring, fixed value adjustment, time setting and set value adjusting and etc..Majority
parameters can be configured from front panel, and all parameters can be configured by USB
interface (or RS485) to adjust via PC. It can be widely used in all types of automatic gen-set
control system with compact structure, advanced circuits, simple connections and high reliability.
2 MODULES COMPARISON
HGM HGM HGM HGM HGM HGM HGM HGM HGM HGM
9210 9220 9310 9320 9410 9420 9610 9620 9510 9520
Dimension 3.7” 4.3”
LCD
pixel 132 x 64 480 x 272
AMF ● ● ● ● ●
BUS Monitoring ●
Parallel connection ● ●
Expansion module ● ●
Input Port 7 7 7 7 7 7 8 8 7 7
Output Port 8 8 8 8 8 8 8 8 8 8
Sensor Number 5 5 5 5 5 5 5 5 5 5
Neutral (Earth)
● ●
current
Schedule function ● ● ● ● ● ● ● ● ● ●
ETHERNET ● ●
RS485 ● ● ● ● ● ● ● ●
GSM ● ● ● ● ● ●
J1939 ● ● ● ● ● ●
USB ● ● ● ● ● ● ● ● ● ●
LINK ● ●
Real-time clock ● ● ● ● ● ● ● ● ● ●
Event log ● ● ● ● ● ● ● ● ● ●
Micro SD card ● ●
NOTE:
(1) Two of the outputs are fixed: start output and fuel output.
(2)HGM9510’s analog sensors are composed by 3 fixed sensors (temperature, pressure, level)
and 2 configurable sensors.
NOTE: The features of HGM9210/HGM9220/HGM9310/HGM9320/HGM9410/
HGM9420/HGM9520/HGM9610/HGM9620 controllers mentioned in this document may change,
please check the corresponding user manual for accurate information.
3 PERFORMANCE AND CHARACTERISTICS
With ARM-based 32-bit SCM, high integration of hardware and more reliable;
480x272 LCD with backlight, multilingual interface (including English, Chinese or other
languages) which can be chosen at the site, making commissioning convenient for factory
personnel;
Improved LCD wear-resistance and scratch resistance due to hard screen acrylic;
Silicon panel and pushbuttons for better operation in high/low temperature environment;
RS485 communication port enable remote control, remote measuring, remote communication
via ModBus protocol.
Fitted with CANBUS port and can communicate with J1939 genset. Not only can you
monitoring frequently-used data (such as water temperature, oil pressure, engine speed, fuel
consumption and so on) of ECU machine, but also control start, stop, raising speed and
speed droop via CANBUS port.
Suitable for 3-phase 4-wire, 3-phase 3-wire, single phase 2-wire, and 2-phase 3-wire systems
with voltage 120/240V and frequency 50/60Hz;
Collects and shows 3-phase voltage, current, power parameter and frequency of Bus/mains.
For Bus, controller has loss of phase and phase sequence wrong detection functions; For
generator, controller has over voltage, under voltage, over frequency, under frequency, over
current, over power, reverse power, loss of phase, phase sequence wrong detection
functions;
Synchronization parameters : Voltage Difference Between Bus and Mains, Frequency
Difference Between Bus and Mains, Phase Difference Between Bus and mains;
Multiple running modes in auto state: with load running, off load running, demand parallel
running;
Ramp on and ramp off function;
3 fixed sensors (temperature, oil pressure and liquid level);
2 configurable sensors can be set as sensor of temperature, oil pressure or fuel level;
More kinds of curves of temperature, oil pressure, fuel level can be used directly and users
can define the sensor curves by themselves;
Precision measure and display parameters about Engine,
Temp. (WT) °C/°F both be displayed
Oil pressure (OP) kPa/Psi/Bar all be displayed
Fuel level (FL) %(unit)
Speed (SPD) r/min(unit)
Battery Voltage (VB) V (unit)
Charger Voltage (VD) V (unit)
Hour count (HC) can accumulate Max. 65535 hours.
Start times can accumulate Max. 65535 times
Protection: automatic start/stop of the gen-set, ATS(Auto Transfer Switch) control with perfect
fault indication and protection function;
All output ports are relay output;
Parameter setting: parameters can be modified and stored in internal EEPROM memory and
cannot be lost even in case of power outage; most of them can be adjusted using front panel
of the controller and all of them can be modified using PC via USB or RS485 ports;
Multiple crank disconnect conditions (speed sensor, oil pressure, generator frequency) are
optional;
Widely power supply range DC(8~35)V, suitable to different starting battery voltage
environment;
Event log, real-time clock, scheduled start & stop generator (can be set as start genset once a
day/week/month whether with load or not);
Accumulative total run time and total electric energy of A and B. Users can reset it as 0 and
re-accumulative the value which make convenience to users to count the total value as their
wish.
Can control engine heater, cooler and fuel pump.
With maintenance function. Actions (warning, trip and stop, shutdown) can be set when
maintenance time out;
All parameters used digital adjustment, instead of conventional analog modulation with
normal potentiometer, more reliability and stability;
IP55 waterproofness level can be achieved with the help of rubber-ring gasket between shell
and control panel.
Metal fixing clips enable perfect in high temperature environment;
Modular design, anti-flaming ABS plastic shell, pluggable terminal, built-in mounting,compact
structure with easy installation;
4 SPECIFICATION
Parameter Details
Working Voltage DC8. 0V to 35. 0V, uninterruptible power supply
Overall Consumption <4W (Standby mode: ≤2W)
AC Input:
3 Phase 4 Wire AC 15V - 360V (ph-N)
3 Phase 3 Wire AC 30V - 620V (ph- ph)
Single Phase 2 Wire AC 15V - 360V (ph-N)
2 Phase 3 Wire AC 15V - 360V (ph-N)
Alternator Frequency 50Hz/60Hz
Speed Sensor Voltage 1. 0 V to 24 V (RMS)
Speed Sensor Frequency Maximum 10,000 Hz
Start Relay Output 16A DC28V power supply output
Fuel Relay Output 16A DC28V power supply output
Flexible Relay Output 1 7A DC28V power supply output
Flexible Relay Output 2 7A DC28V power supply output
Flexible Relay Output 3 7A DC28V power supply output
Flexible Relay Output 4 7A 250VAC passive output
Flexible Relay Output 5 7A 250VAC passive output
Flexible Relay Output 6 7A 250VAC passive output
Case Dimensions 266mm x 182mm x 45mm
Panel Cutout 214mm x 160mm
CT Secondary Current Rated 5A
Working Conditions Temperature: (-25~+70)°C Humidity: (20~93)%RH
Storage Conditions Temperature:(-30~+80)°C
Protection Level IP55 Gasket
Apply AC2.2kV voltage between high voltage terminal and low
Insulation Intensity voltage terminal;
The leakage current is not more than 3mA within 1min.
Weight 0.95kg
5 OPERATION
5.2 PUSHBUTTONS
Stop running generator in Auto/Manual mode; Lamp test
(press at least 3 seconds); Reset alarm in stop mode;
Stop
During stopping process, press this button again to stop
generator immediately.
Manual Mode Press this key and controller enters in Manual mode.
Auto Mode Press this key and controller enters in Auto mode.
Mute/Reset Alarming sound off; If trip alarm occurs, pressing the button
Alarm at least 3 seconds can reset this alarm.
1) Screen scroll;
Up/Increase
2) Up cursor and increase value in setting menu.
1) Screen scroll;
Down/Decrease
2) Down cursor and decrease value in setting menu.
1) Screen scroll;
Left
2) Left move cursor in setting menu.
1) Screen scroll;
Right
2) Right move cursor in setting menu.
WARNING: Default password is 00318, user can change it in case of others change the
advanced parameters setting. Please clearly remember the password after changing. If you forget
it, please contact Smartgen services and send all information in the controller page of “ABOUT” to
us.
Main screen show pages; use to scroll the pages and to scroll the screen.
★Main Screen, including as below,
Gen: voltage, frequency, current, active power, reactive power
Bus: voltage, frequency
Engine: speed, temperature, oil pressure
Some status
★Status, including as below,
Status of genset and ATS
★Engine, including as below,
Engine speed, engine temperature, engine oil pressure, fuel level, flexible sensor 1, flexible
sensor 2, battery voltage, charger voltage, engine accumulated run, accumulated start times.
NOTE: If connected with J1939 engine via CANBUS port, this page also includes: coolant
pressure, coolant level, fuel temperature, fuel pressure, inlet temperature, exhaust temperature,
turbo pressure, total fuel consumption and so on. (Different engine with different parameters)
★Generator, including as below,
Phase voltage, line voltage, frequency, phase sequence, current, Active Power(positive and
negative), total active power (positive and negative), Reactive Power(positive and negative), total
reactive power (positive and negative), Apparent Power, total apparent power, Power
Factor(positive and negative), average power factor (positive and negative), accumulated
energy (kWh, kVarh, kVAh), multi power, earth current, negative sequence current.
NOTE: Power factor shows as following,
Remark:
P stands for active power
Q stands for inactive power
Note:
1. Input active power, generator send active power to load.
2. Output active power, load supply electricity to generator.
3. Input reactive power, generator send reactive power to load.
4. Output reactive power, load send reactive power to generator.
★Bus, including as below,
Phase voltage, line voltage, frequency, phase sequence
★SNYC, including as below,
Volt difference, freq difference, angle difference, active power percentage, target active power
percentage, reactive power percentage, target reactive power percentage, GOV percentage, AVR
percentage and MSC status
★Alarm:
NOTE: For ECU alarms and shutdown alarms, if the alarm information is displayed, check
engine according to it, otherwise, please check the generator manual according to SPN alarm
code.
★Event log
Make records about all start/stop events (shutdown alarm, trip and stop alarm, manual /auto start
or stop) and the real time when alarm occurs.
★Others, including,
Time and Date, maintenance due, input/output ports status.
★About, including,
Issue time of software and hardware version, product PD number.
5.3.2 USER MENU AND PARAMETERS SETTING MENU
Auto mode is selected by pressing the button; a LED besides the button will illuminate to
confirm the operation.
Automatic Start Sequence:
1. When “Remote Start” is active, “Start Delay” timer is initiated;
2. “Start Delay” countdown will be displayed on LCD;
3. When start delay is over, preheat relay energizes (if configured), “preheat delay XX s”
information will be displayed on LCD;
4. After the above delay, the Fuel Relay (if configured) is energized, and then one second later,
the Start Relay is engaged. The engine is cranked for a pre-set time. If the engine fails to fire
during this cranking attempt then the fuel relay and start relay are disengaged for the pre-set
rest period; “crank rest time” begins and wait for the next crank attempt.
5. Should this start sequence continue beyond the set number of attempts, the start sequence
will be terminated, the first line of LCD display will be highlighted with black and Fail to Start
fault will be displayed.
6. In case of successful crank attempt, the “Safety On” timer is activated, allowing Low Oil
Pressure, High Temperature, Under speed and Charge Alternator Failure inputs to stabilise
without triggering the fault. As soon as this delay is over, “start idle” delay is initiated (if
configured).
7. During “start idle” delay, under speed, under frequency, under voltage alarms are inhibited.
When this delay is over, “warming up” delay is initiated (if configured).
8. In the case of a single generator system, after the “warming up” delay, if generator status is
normal, its indicator will be illuminated. If generator voltage and frequency have reached
on-load requirements, then the generator close relay will be energized; genset will take load;
generator power indicator will illuminate and generator will enter into Normal Running status.
If voltage or frequency is abnormal, the controller will initiate shutdown alarm (alarm
information will be displayed on LCD).
9. In case of running in parallel, after the warming up delay:
a) If bus has no voltage, then the controller will send a closing signal to other waiting parallel
gensets and generator close relay will activate, this prevents other sets in the system from
attempting to close their own breakers at the same time.
b) If bus has voltage or other gensets are already closed, the controller will adjust speed and
voltage through GOV and AVR to synchronize the gensets to the bus; when synchronism
requirements has been achieved, breaker close signal will be initiated and the genset will be
paralleled with the bus. Once they are paralleled, the controller will control the generator to
gradually accelerate and share load with other paralleled gensets.
Note: When started via “Remote Start (off Load)” input, same procedures as above but
generator close relay deactivated, moreover, genset off load. When started via “Remote Start
(Demand)” input,the genset will start, synchronization, parallel and load sharing automatically
according to the pre-set priority order.
Automatic Stop Sequence,
1) When the “Remote Start” signal is removed, the Stop Delay is initiated.
2) Once this “stop delay” has expired, the module will ramp the load from the generator to
remaining set. The Generator Breaker will open and the “Cooling Delay” is then initiated.
Should the Remote Start signal be re-activated during the cooling down period, the set will
return parallel status. Once the “Cooling Delay” expires, the “Stop Idle” delay is initiated.
3) During “Stop Idle” Delay (if configured), idle relay is energized.
4) “ETS Solenoid Hold” begins, ETS relay is energized while fuel relay is de-energized, complete
stop is detected automatically.
5) "Fail to Stop Delay" begins, complete stop is detected automatically.
6) When generator is stop completely, “After stop” delay will be initiated. Otherwise, fail to stop
alarm is initiated and the corresponding alarm information is displayed on LCD. ( If generator
is stop successfully after “fail to stop” alarm has initiated, “After stop” delay will be initiated and
the alarm will be removed)
7) Generator is placed into its standby mode after its “After stop” delay.
1. Manual mode is selected by pressing the button; a LED besides the button will illuminate
to confirm the operation; then press button to start the gen-set; can detect crank
disconnect condition and generator accelerates to high-speed running automatically. With
high temperature, low oil pressure, over speed and abnormal voltage during generator
running, controller can protect genset to stop quickly (please refer to No.3~9 of Automatic
Start Sequence for detail procedures).
2. MANUAL STOP: Press can shuts down the running generators. (Please refer to
No.2~7 of Automatic Start Sequence for detail procedures).
NOTE: In “manual mode”, the procedures of ATS please refer to Switch Control Procedure of
generator in this manual.
Opening operation:Press ,
1) In case of single unit running, the controller sends open breaker signal.
2) During parallel operation, if button is pressed, first of all, the controller will transfer load
to other generators, and only then send an opening signal.
5.6.2 AUTOMATIC CONTROL PROCEDURE
When controller is in auto mode, the switch control procedure is automatic control procedure.
Note: The auxiliary close input should be configured necessarily and make sure the
connection is correct.
6 PROTECTIONS
Timer Setting
Time from mains abnormal or remote
1 Start Delay (0~3600)s 5
start signal is active to start genset.
Time from mains normal or remote start
2 Stop Delay (0~3600)s 30
signal is inactive to stop genset.
Time of pre-powering heat plug before
3 Preheat Delay (0~3600)s 0
starter is powered up.
4 Cranking Time (3~60)s 8 Time of starter power on
The waiting time before second power
5 Crank Rest Time (3~60)s 10
up when engine start fail.
Alarms for low oil pressure, high
temperature, under speed, under
6 Safety On Delay (0-3600)s 10
frequency /voltage, charge fail are
inactive.
Idle running time of genset when
7 Start Idle Time (0~3600)s 10
starting.
Warming up time between genset switch
8 Warming Up Time (0~3600)s 30
on and high speed running.
Radiating time before genset stop, after
9 Cooling Time (0~3600)s 60
it unloads.
10 Stop Idle Time (0~3600)s 10 Idle running time when genset stop.
Stop electromagnet’s power on time
11 ETS Solenoid Hold (0~3600)s 20
when genset is stopping.
Time between over of genset idle delay
and stopped when “ETS time” is set as
0;
12 Fail to Stop Delay (0~3600)s 0
Time between over of ETS hold delay
and stopped when “ETS Hold output
time” is not 0.
Time between genset stopped and
13 After Stop Time (0~3600)s 0
standby
Engine Setting
Default: Conventional Engine(not
J1939)
1 Engine Type (0~39) 0
When connected to J1939 engine,
choose the corresponding type.
2 Flywheel Teeth (10~300) 118 Tooth number of the engine, for judging
NOTE:
a. There are 3 conditions to make starter disconnected with engine, that is, speed sensor,
generator frequency and engine oil pressure. They all can be used separately. We
recommend that engine oil pressure should be using with speed sensor and generator
frequency together, in order to make the starter motor is separated with engine immediately
and can check crank disconnect exactly.
b. Speed sensor is the magnetic equipment which be installed in starter for detecting flywheel
teeth.
c. When set as speed 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.
d. If genset without speed sensor, please don’t select corresponding items, otherwise, “start fail”
or “loss speed signal” maybe caused.
e. If genset without oil pressure sensor, please don’t select corresponding items.
f. If not select generator frequency in crank disconnect setting, controller will not collect and
display the relative power quantity (can be used in water pump set); if not select speed sensor
in crank disconnect setting, the rotating speed displayed in controller is calculated by
generator frequency and number of poles.
9 PARAMETERS SETTING
CAUTION: Please change the controller parameters when generator is in standby mode
only (e. g. Start conditions selection, configurable input, configurable output, various delay),
otherwise, alarming to stop and other abnormal conditions may happen.
NOTE: Maximum set value must over minimum set value in case that the condition of too
high as well as 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 maximum value, the return value must less
than setting; when setting the minimum value, the return value must over setting.
NOTE: Please set the generator frequency value as low as possible when cranking, in
order to make the starter be separated quickly as soon as crank disconnect.
NOTE: Configurable input could not be set as same items; otherwise, there are abnormal
functions. However, the configurable output can be set as same items.
10 SENSORS SETTING
10.1 When reselect sensors, the sensor curve will be transferred into the standard value.
For example, if temperature sensor is SGX (120°C 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.
10.2 When there is difference between standard sensor curves and using sensor, user can
adjust it in “curve type”.
10.3 When input the sensor curve, X value (resistor) must be input from small to large,
otherwise, mistake occurs.
10.4 If select sensor type as “None”, sensor curve is not working.
10.5 If corresponding sensor has alarm switch only, user must set this sensor as “None”,
otherwise, maybe there is shutdown or warning.
10.6 The headmost or backmost values in the vertical coordinates can be set as same as
below,
Note: Fuse F1:min. 2A; max. 20A. Fuse F2:max. 32A. Users should select suitable
fuse depend on practical application.
3 Phase 3 Wire
2 Phase 3 Wire
Note: Mains parallel function for HGM9510 controller can be selected via configurable
input port. In mains parallel mode, generator will run in parallel with mains and it will only be
able to output a fixed amount of power. (Set load mode as Gen control mode).
13 POWER MANAGEMENT MODE
14 LOAD SHEDDING
Manual Trip
If NEL manual trip input is active (earthed failing edge is active), NEL1 will trip without delay; If
NEL manual trip input is active again, NEL2 will trip; If NEL manual trip input is active the third
time, NEL3 will trip. During this process, the controller do not detect if the genset power has
exceed the NEL trip value or not.
If NEL manual reconnection input is active (earthed failing edge is active), NEL3 will reconnect
without delay; If NEL manual reconnection input is active again, NEL2 will reconnect; If NEL
manual reconnection input is active the third time, NEL1 will reconnect. During this process, the
controller detects the genset power: if the genset power has fallen below the NEL reconnection
value, then the input is active; if it doesn’t, the input is deactivated.
Note: When auto trip and auto reconnection are enabled, manual trip is still active.
15 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,
16.14 PERKINS
It is suitable for ADEM3/ ADEM4 engine control module. Engine type is 2306, 2506, 1106, and
2806.
Terminals of controller Connector Remark
Fuel relay output 1,10,15,33,34
Start relay output - Connect to starter coil directly
CAN communication shielding
CAN GND - line(connect with controller’s terminal
only)
CAN(H) 31 Using impedance 120Ω connecting line
CAN(L) 32 Using impedance 120Ω connecting line
16.15 SCANIA
It is suitable for S6 engine control module. Engine type is DC9, DC12, and DC16.
Terminals of controller B1 connector Remark
Fuel relay output 3
Start relay output - Connect to starter coil directly
CAN communication shielding
CAN GND - line(connect with controller’s terminal
only)
CAN(H) 9 Using impedance 120Ω connecting line
CAN(L) 10 Using impedance 120Ω connecting line
Engine type: Scania
16.19 YUCHAI
It is suitable for BOSCH common rail pump engine.
Terminals of controller Engine 42 pins port Remark
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 with controller’s this terminal
only)
CAN(H) 1.35 Using impedance 120Ω connecting line
CAN(L) 1.34 Using impedance 120Ω connecting line
16.20 WEICHAI
It is suitable for Weichai BOSCH common rail pump engine.
Terminals of controller Engine port Remark
Fuel relay output 1.40 Connect to engine ignition lock
Start relay output 1.61
CAN communication shielding
CAN GND - line(connect to the controller at this end
only)
CAN(H) 1.35 Using impedance 120Ω connecting line
CAN(L) 1.34 Using impedance 120Ω connecting line
Engine type: GTSC1
NOTE: If there is any question of connection between controller and ECU communication,
please feel free to contact Smartgen’s service.
17 USB
Users can set the controller’s parameters and monitor the controller’s status via the test software
which provided by Smatgen company. The connection way between PC and controller as
following:
18 FAULT FINDING