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HGM6200K Series Automatic Generator Module

OPERATING MANUAL

Smartgen Electronics

Smartgen Electronic Equipment Co., Ltd No. 28 Jinsuo Road Zhengzhou Henan Province P.R.China Tel: 0086-371-67988888/67981888 0086-371-67991553/67992951/67992952 0086-371-67981000(overseas) Fax: (0086)-371-67992952/67981000 Web: http://www.smartgen.com.cn http://www.smartgen.cn Email: sales@smartgen.com.cn All rights reserved. No part of this publication may be reproduced in any material form (including photocopying or storing in any medium by electronic means or other) without the written permission of the copyright holder. Applications for the copyright holders written permission to reproduce any part of this publication should be addressed to Smartgen Electronics at the address above. Any reference to trademarked product names used within this publication is owned by their respective companies. Smartgen Electronics reserves the right to change the contents of this document without prior notice. Software Version Version Date Note 1.0 2009-7-17 Original release. 1.1 2009-12-31 Amend the typical applications. Increased function: historical records, real-time clock, scheduler run, Spanish. Also increased function: output port 1.2 2010-04-21 function15, over current output; Input port function 25, low Fuel level warns; Input port function 26, low Fuel level shutdown. Amend products appearance picture, panel cutout size long 1.3 2010-06-21 wide all increase 2, controller applicable working temperature. 1.4 2010-08-17 Optimize some detail parts of the operator Manual. 1.5 2011-06-20 Modify single-phase/three phase input of parameter range.

HGM6200K Series Automatic Generator Module

CONTENT
1 2 3 4 SUMMARY .................................................................................................. 4 PERFORMANCE AND CHARACTERISTICS .............................................. 4 SPECIFICATION ......................................................................................... 6 OPERATION ................................................................................................ 7 4.1 KEY FUNCTION ..................................................................................... 7 4.2 AUTOMATIC OPERATION...................................................................... 7 4.3 MANUAL OPERATION............................................................................ 8 5 PROTECTION ............................................................................................. 9 5.1 WARN ..................................................................................................... 9 5.2 SHUTDOWN ALARM ............................................................................ 11 6 7 CONNECTING TERMINAL ........................................................................ 12 PARAMETER RANGE AND DEFINE ......................................................... 14 7.1 PARAMETERS TABLE (TABLE 1)......................................................... 14 7.2 DIGIT OUTPUT 1-6 TABLE (TABLE 2) .................................................. 20 7.3 DIGIT INPUT 1-7 TABLE (TABLE 3)...................................................... 23 7.4 SENSOR (TABLE 4) ............................................................................. 24 7.5 CONDITION OF CRANK SUCCEED (TABLE 5) ................................... 25 8 9 10 11 12 13 14 SETTING PARAMETER ............................................................................ 25 SENSOR SETTINGS................................................................................. 27 TEST RUN................................................................................................. 28 TYPICAL WIRING DIAGRAM .................................................................... 29 INSTALLATION.......................................................................................... 30 FACTORY DEFAULT VALUES................................................................... 31 FAULT FINDING ........................................................................................ 34

HGM6200K Series Automatic Generator Module

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Version 1.5

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HGM6200K Series Automatic Generator Module

1 SUMMARY
HGM6200K 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/shutdown, data measure and alarming. The controller uses LCD display, optional Chinese, English, and Spanish, display interface with operation easy and reliable. HGM6200K series Genset controller uses micro-processing technique which can carry out precision measure, constant value adjustment, timing and threshold setting and etc. function, but most widely controller parameters can be adjusted from controller front panel, or use the PC through programming interface, also can use a PC via RS485 interface and monitoring. Its compact structure, simple wiring and high reliability, can be widely applied to various types of generating units automation system.

2 PERFORMANCE AND CHARACTERISTICS


HGM6200K series controller has four types: HGM6210K/6210KC: Automatic Start Module, it controls generator to start/stop by remote start signal; HGM6220K/6220KC: Based on HGM6110K/6110KC and add mains AC monitoring, Mains/Generator Automatic Mains Failure functions (AMF), especially suitable for the automation control system composed by Mains and Generator.
Note1: HGM6210KC/6220KC with RS485 interface, HGM6210K/6220K without RS485 interface. Note2: The following section takes HGM6210KC/6220KC as an example to describe.

Using microprocessor as a core, graphics LCD with big screen and backlight, display between Chinese, English, and Spanish, key touch for operation; Have a RS485 port, can used for communicate with PC; Measure and display 3 phase voltage, 3 phase current, frequency, power etc. parameter; Measure and display 3 phase voltage, 3 phase current, frequency, power etc. parameter; Precision measure and display of Mains voltage Mains frequency (Hz) Mains current Generator voltage
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HGM6200K Series Automatic Generator Module

Generator current Generator frequency (Hz) Generator active power (kW) Generator inactive power (kVar) Generator apparent power (kVA) Generator power factor (Cos) Generator starts count Generator hours count Generator cumulate electric energy (kWh) Generator temperature Generator pressure Generator fuel level Start battery voltage Mains have over voltage, under voltage, loss phase function; Generators have over voltage, under voltage, over frequency, under frequency, over current function; Power on mode can select: Shutdown mode, Manual mode, Automatic mode; Double temperature double oil pressure sensor input; Control protection: Automatic start/stop, load transfer and alarming of generator; With ETS solenoid hold, idle control, pre-heat control, raise speed control function, and equal to relay output; Controllers have the historical records, real-time clock, and scheduler run (PC) function. Parameters setting: Allow user to modify setting and store them inside internal FLASH memory, the parameters can not be lost even with power down. Most of parameters can be set from the front panel, or be set by PC used SG72; Three channel analog inputs, may joint with Resistive-type temperature/ pressure/ fuel level sensors, several temperature and pressure sensors can be used directly (ie. VDO, DATCON, CUMMINS), also may select user defined sensor via entering 8 point curves; Display of generator cumulated electric energy; Security password-protected programming levels; Several crank success conditions are optional; Built-in speed/frequency detecting units can accurately judge the states such as crank success and over speed; Power supply range is wide, accommodating to different starting battery voltage environments; All parameters use digital modulation, abandoning analog modulation using
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HGM6200K Series Automatic Generator Module

conventional electronic potentiometer, reliability and stability are increased; Modular configuration design, Flame Retardant ABS plastic shell, inserted type connection terminals, flush type installation, compact structure, easy installation.

3 SPECIFICATION
Operating voltage Power consumption AC voltage Input Range 3-Phase 4 Wire 2-Phase 3 Wire Single phase 2 Wire Frequency Magnetic AC voltage Magnetic AC Frequency Start Relay Output Fuel Relay Output Auxiliary Relay Output (1-6) DC8. 0V to 35. 0V, continuous power supply. <3W(Waiting mode: 2W) 15VAC - 360VAC (ph-N) 15VAC - 360VAC (ph-N) 15VAC - 360VAC (ph-N) 50Hz - 60 Hz at rated engine speed. 1.0V to 24V (RMS) 10,000 Hz (max) at rated engine speed. 16 Amp DC28V at supply voltage. 16 Amp DC28V at supply voltage. (1-3)7 Amp DC28V at supply voltage, (4)7A 250VAC free voltage contact, (5, 6)16A 250VAC free voltage contact. 209mm x 153mm x 55mm 186mm x 141mm Temperature: (-25~70) Humidity: (20~90)% C; Temperature: (-30~80) C IP55: Front of module when module is installed into the control panel with the optional sealing gasket. IP42: Front of module when module is installed into the control panel without being sealed to the panel. Object: between input and output power supply. Quote from standard: IEC688-1992. Test method: AC1.5kV/1min with current 3mA. 5A 0.73kg

Dimensions Panel cutout Operating Temp. range Storage condition

Protection rank

Dielectric strength C. T. Secondary Weight

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HGM6200K Series Automatic Generator Module

4 OPERATION
4.1 KEY FUNCTION
This button places the module into its Shutdown/reset mode. When engine is running, pressing this key will shutdown the engine. When a shutdown alarm occurs, Shutdown/Reset key pressing this key will reset alarm. In shutdown mode, pressing this key over 3 seconds will test LED mounted on the panel. During shutdown, again pressing the key, can fast shutdown. In manual or manual test mode, pressing this Start key key will start engine. Pressing this key will set the module into manual Manual mode key mode. Pressing this key will set the module into Auto key automatic mode. Pressing this key will set the module into manual test mode, when generate electricity is normal, Manual test mode the generator will on-load (HGM6210KC have not this key). Set/enter Page up /increase Page down /decrease Enter the set menu, or validate the setting. Page up, or in setting parameter status, pressing this key will increase setting value. Page down, or in setting parameter status, pressing this key will decrease setting value.

4.2 AUTOMATIC OPERATION


The following description details the sequences followed by a module containing the standard factory configuration. Always refer to your configuration source for the exact sequences and timers observed by any particular module in the field. This mode is activated by pressing the pushbutton. An LED indicator beside

the button confirms this action. When a Remote Start signal is applied to the remote start input (HGM6210KC) or when mains voltage occur over-voltage, under-voltage, miss phasic (HGM6220KC), the following sequence is initiated: To allow for false signals the mains abnormal timer is initiated (only HGM6220KC), then the Start Delay timer is initiated. After this delay, if the pre-heat output option is selected then the pre-heat timer is initiated, and the corresponding auxiliary output (if configured) will energize.
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HGM6200K Series Automatic Generator Module

NOTE: If the Remote Start signal is removed (HGM6210KC) during the Start Delay timer, or if mains voltage is normal (HGM6220KC) during the mains abnormal timer, the unit will return to a stand-by state. After the above delays the Fuel Solenoid is energized, the one second later, the Starter Motor is engaged. The engine is cranked for a pre-set time period. If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the pre-set rest period. Should this sequence continue beyond the set number of attempts, the start sequence will be terminated and failed to start alarm will be displayed on the LCD screen. When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency from the Alternator output. Alternatively a Magnetic Pickup mounted on the flywheel housing can be used for speed detection (This is selected by PC using the 6200K series configuration software or form from the front panel). Rising oil pressure can also be used to disconnect the starter motor. After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure, High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilize without triggering the fault. Once the engine is running, the Warm Up timer, if selected is initiated, allowing the engine to stabilize before accepting the load. If an auxiliary output has been selected to give a load transfer signal, this would then activate. NOTE: A load transfer will not be initiated until the Oil Pressure has risen. Thus prevent excessive wear on the engine. On removal of the Remote start signal, the Shutdown delay timer is initiated, once it has timed out, the load Transfer signal is de-energized, removing the load. The Cooling timer is then initiated, allowing the engine a cooling down period off load before shutting down. Once the Cooling timer expires the Fuel Solenoid is de-energized, bringing the generator to a shutdown.

4.3 MANUAL OPERATION


HGM6220KC: This manual mode is activated by pressing the This manual test mode is activated by pressing the pushbutton.

pushbutton. An LED

indicator beside the button confirms this action. In any of the two modes, pressing the pushbutton will initiate the start sequence.

If the pre-heat output option is selected this timer is then initiated, and the auxiliary output selected is energized.
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HGM6200K Series Automatic Generator Module

After the above delay the Fuel Solenoid is energized, and then the Starter Motor is engaged. The engine is cranked for a pre-set time period. If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the pre-set rest period. Should this sequence continue beyond the set number of attempts, the start sequence will be terminated and failed to start alarm will be displayed on the LCD screen. When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency from the Alternator output. Alternatively a Magnetic Pickup mounted on the flywheel housing can be used for speed detection (This is selected by PC using the 6200K series configuration software, or form from the front panel). Rising oil pressure can also be used to disconnect the starter motor. After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure, High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilize without triggering the fault. Once the engine is running, the Warm Up timer, if selected is initiated, allowing the engine to stabilize before it can be loaded. In manual mode, generator take load or no load depend on mains supply, if mains is normal, it will not take load, otherwise it will take load. In manual test mode, generator will take load regardless of mains supply normal or abnormal. HGM6210KC: This manual mode is activated by pressing the pushbutton.

An LED indicator beside the button confirms this action. In any of the two modes, pressing the pushbutton will initiate the start sequence.

The start sequence is similar as the above. In above process, when the Warm Up timer has expired, if the remote start signal is active, generator will take load, if inactive, generator will not take load. In above process, pressing key will bring the generator to a shutdown.

5 PROTECTION
5.1 WARN
Warns are non-critical alarm conditions and do not affect the operation of the generator system; they serve to draw the operators attention to an undesirable condition. In the event of warn, the module will display at the last screen of LCD.

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HGM6200K Series Automatic Generator Module

Warn is shown as the below: HIGH ENGINE TEMPERATURE 1,if the module detects that the engine coolant temperature 1 has exceeded the high engine temperature setting level after the Safety On timer has expired and the input of Inhibit WTH shutdown is activated, a warn will occur. LOW OIL PRESSURE 1, if the module detects that the engine oil pressure 1 has fallen below the low oil pressure setting level after the Safety On timer has expired and the input of Inhibit OPL shutdown is activated, a warn will occur. HIGH ENGINE TEMPERATURE 2, if the module detects that the engine coolant temperature 2 has exceeded the high engine temperature setting level after the Safety On timer has expired and the input of Inhibit WTH shutdown is activated, a warn will occur. LOW OIL PRESSURE 2, if the module detects that the engine oil pressure 2 has fallen below the low oil pressure setting level after the Safety On timer has expired and the input of Inhibit OPL shutdown is activated, a warn will occur. LOSS OF SPEED SIGNAL, if the speed sensing signal is lost, a warn will occur and the Lost speed delay set to zero, warns will occur. GENERATOR OVER CURRENT, if the module detects a generator output current in excess of the setting and the over current delay set to zero, warns is initiated. OVERSPEED, if the engine speed exceeds the setting value, warns will occur. UNDERSPEED, if the engine speed falls below the setting value after the Safety on timer has expired, warns will occur. GENERATOR OVER FREQUENCY, if the module detects a generator output frequency in excess of the setting value, warns will occur. GENERATOR UNDER FREQUENCY, if the module detects a generator output frequency below the setting value after the Safety On timer has expired, warns will occur. GENERATOR OVER VOLTAGE, if the module detects a generator output voltage in excess of the setting value, warns will occur. GENERATOR UNDER VOLTAGE, if the module detects a generator output voltage below the setting value after the Safety On timer has expired, warns will occur. FAIL TO SHUTDOWN, if the module detects the engine is still running when the Fail to shutdown timer expires, warns is initiated. BATTERY HIGH VOLTAGE, if the module detects that the plant DC supply has risen above the high volts setting level, warns is initiated. BATTERY LOW VOLTAGE, if the module detects that the plant DC supply has fallen below the low volts setting level, warns is initiated. AUXILIARY INPUTS, if an auxiliary input has been configured as warn the appropriate information will be displayed. LOW LEVEL WARN, if the module detects that the engine oil level has fallen below the low level setting level has expired, a warn will occur. FAILED TO CHARGE WARN, if the module detects that the charge of volts has fallen below the setting level has expired, a warn will occur.
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HGM6200K Series Automatic Generator Module

5.2 SHUTDOWN ALARM


Shutdowns are latching and shutdown the generator. The alarm must be cleared, and the fault removed to reset the module. NOTE: The alarm condition must be rectified before a reset will take place. If 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 SHUTDOWN, removal of the +ve DC supply from the Emergency Shutdown input initiates the following sequence, firstly it will initiate a controlled shutdown of the generator and prevent any attempt to restart the generator until the Emergency shutdown push-button has been reset. Secondly it removes the +ve DC supply from both the Fuel Solenoid and Starter Solenoid. HIGH ENGINE TEMPERATURE 1, if the module detects that the engine coolant temperature 1 has exceeded the high engine temperature setting level after the Safety On timer has expired, a shutdown will occur. LOW OIL PRESSURE 1, if the module detects that the engine oil pressure 1 has fallen below the low oil pressure setting level after the Safety On timer has expired, a shutdown will occur. HIGH ENGINE TEMPERATURE 2, if the module detects that the engine coolant temperature 2 has exceeded the high engine temperature setting level after the Safety On timer has expired, a shutdown will occur. LOW OIL PRESSURE 2, if the module detects that the engine oil pressure 2 has fallen below the low oil pressure setting level after the Safety On timer has expired, a shutdown will occur. LOSS OF SPEED SIGNAL, if the speed sensing signal is lost, a shutdown is initiated. OVERSPEED, if the engine speed exceeds the setting value a shutdown is initiated. UNDERSPEED, if the engine speed falls below the setting value after the Safety On timer has expired, a shutdown is initiated. GENERATOR OVER FREQUENCY, if the module detects a generator output frequency in excess of the setting value a shutdown is initiated. GENERATOR UNDER FREQUENCY, if the module detects a generator output frequency below the setting value after the Safety On timer has expired, a shutdown is initiated. GENERATOR OVER VOLTAGE, if the module detects a generator output voltage in excess of the setting value a shutdown is initiated. GENERATOR UNDER VOLTAGE, if the module detects a generator output voltage below the setting value after the Safety On timer has expired, a shutdown is initiated. NO GENERATOR, when the controller detects to generator frequency equals to zero, the controller sends out the shutdown alarm signal. GENERATOR OVER CURRENT, if the module detects a generator output current in excess of the setting value is initiated, a shutdown is initiated.
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HGM6200K Series Automatic Generator Module

FAIL TO START, if the engine does not fire after the pre-set number of attempts has been made a shutdown will be initiated. AUXILIARY INPUTS, if an auxiliary input has been configured as a shutdown the appropriate information will be displayed. TEMPERATURE 1 OPEN CIRCUIT, if the module detects temperature sensor 1 open circuits, a shutdown is initiated. PRESSURE 1 OPEN CIRCUIT, if the module detects pressure sensor 1 open circuits, a shutdown is initiated. TEMPERATURE 2 OPEN CIRCUIT, if the module detects temperature sensor 2 open circuits, a shutdown is initiated. PRESSURE 2 OPEN CIRCUIT, if the module detects pressure sensor 2 open circuits, a shutdown is initiated.

6 CONNECTING TERMINAL
HGM6210KC compared with HGM6220KC is less than a Mains three phase AC input terminals. HGM6210KC and HGM6220KC the backplane of controller show as following.

Pin 1

Function DC plant supply input (-ve) DC plant (+ve) supply input

Dim 2.5mm

2.5mm

3 4

Emergency shutdown input Fuel relay output

2.5mm 1.5mm

Description System DC negative input. (Battery Negative). System DC positive input. (Battery Positive).(Recommended Maximum Fuse 20A) Plant Supply +ve. Also supplies fuel & start outputs. Plant Supply +ve from pin 3.
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Pin

Function

Dim

Crank relay output

1.5mm

Aux. output relay 1

1.5mm

Aux. output relay 2

1.5mm

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

Aux. output relay 3

1.5mm

Description 16 Amp rated. Plant Supply +ve from pin 3. 16 Amp rated. Plant Supply +ve from pin 2. 7 Amp rated. Plant Supply +ve from pin 2. 7 Amp rated. Plant Supply +ve from pin 2. Reference 7 Amp rated. table 2 Free voltage contacts. 7 Amp rated

Aux. output relay 4

1.5mm

Aux. output relay 5 Aux. output relay 6 Charge failure/ excite Aux. input 1 Aux. input 2 Aux. input 3 Aux. input 4 Aux. input 5 Aux. input 6 Aux. input 7 Aux. input common Magnetic pickup screen Magnetic pickup +ve Magnetic pickup -ve Temp. sensor 1 Input Oil pressure1 Input Fuel level sensor input Temp. sensor 2 input Oil pressure 2 input Sensor common CT Secondary for A CT Secondary for B

2.5mm 2.5mm 1.0mm

Free voltage contacts. 16 Amp rated

Do not connect to ground (battery ve) 1.0mm Switch to -ve 1.0mm Switch to -ve 1.0mm Switch to -ve Reference 1.0mm Switch to -ve table 3 1.0mm Switch to -ve 1.0mm Switch to -ve 1.0mm Switch to -ve Aux. input common Connect to Magnetic Pickup device Connect to Temperature sensor Connect to Oil pressure sensor Reference Connect to Fuel Level sensor table 4 Connect to Temperature sensor Connect to Oil pressure sensor Sensor common Connect to secondary of A 1.5mm monitoring CT Connect to secondary of B 1.5mm monitoring CT
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HGM6200K Series Automatic Generator Module

HGM6200K Series Automatic Generator Module

Pin 36 37 38 39 40 41 42 43 44 45 46 47 48

Function CT Secondary for C CT secondary common Generator A voltage monitoring Generator B voltage monitoring Generator C voltage monitoring Generator Neutral input Mains A voltage monitoring Mains B voltage monitoring Mains C voltage monitoring Mains Neutral input RS485 port Common RS485 port A(-) RS485 port B(+)

Dim 1.5mm 1.5mm 1.0mm 1.0mm 1.0mm 1.0mm 1.0mm 1.0mm 1.0mm 1.0mm 0.5mm 0.5mm 0.5mm

Description Connect to secondary of C monitoring CT Connect to secondary of all monitoring CTs Connect to generator A output (Recommend 2A fuse) Connect to generator B output (Recommend 2A fuse) Connect to generator C output (Recommend 2A fuse) Connect to generator Neutral terminal (AC) Connect to mains A output (Recommend 2A fuse) Connect to mains B output (Recommend 2A fuse) Connect to mains C output (Recommend 2A fuse) Connect to mains Neutral terminal Use only 120 RS485 approved cable

Note: 1. These terminals of 42, 43, 44, and 45 are not used for HGM6210KC module. 2. The terminal of LINK on the rear panel is an interface for upgrading module software. 3. Sensor sensing input. Connect to resistive type sensor.

7 PARAMETER RANGE AND DEFINE


All parameters of HGM6200KC as follows:

7.1 PARAMETERS TABLE (TABLE 1)


Num Parameter Range Default Remark

Mains volt normal delay Mains volt abnormal delay Mains under volt

(0-3600)s

10

(0-3600)s

Mains transient delay, suited for ATS(automatic transfer switch) When mains voltage is under than the point, mains under voltage are active.
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(30-360)V

184

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HGM6200K Series Automatic Generator Module Num Parameter Range Default Remark

Mains over volt (30-360)V

276

Transfer switch (0-99.9)s interval

1.0

Start delay

(0-3600)s

Shutdown delay Number of crank Preheat time Cranking time Crank rest time Safe run time Start idle time Warming up time Cooling time Shutdown idle time ETS solenoid hold Fail to shutdown delay

(0-3600)s

When the point is zero, mains under voltage are disabled. When mains voltage is over than the point, mains over voltage are active. When the point is 360V, mains over voltage are disabled. Its the delay from mains is opened to generator closing or from generator is opened to mains closing. Its the delay from remote start signal is active or mains is failure, to start generator. Its the delay from remote start signal is inactive or mains is normal, to shutdown generator. Numbers of crank cycles.

8 9 10 11 12 13 14 15 16 17

(1-10) times (0-300)s (3-60)s (3-60)s (1-60)s (0-3600)s (3-3600)s (3-3600)s (0-3600)s (0-120)s

3 0 8 10 10 0 10 10 0 20

Its the delay for energizing to shutdown.

18

(0-120)s

0 Mains or Generator switch closing pulse width, when it is zero, output is continuous.

19

ATS close time

(0-10)s

5.0

20

Flywheel teeth

(10-300)

118
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HGM6200K Series Automatic Generator Module

HGM6200K Series Automatic Generator Module Num Parameter Range Default Remark

21

Gens volt abnormal time

(0-20.0)s

10.0 When generator voltage is over than the point, generator over voltage is active. When the point is 360V, generator over voltage is disabled. When generator voltage is under than the point, generator under voltage is active. When the point is 30V, generator under voltage is disabled. When the engine speed is under than the point and hold great than 10 seconds, generator under speed is active. When the engine speed is over than the point and hold over than 2 seconds, generator over speed is active. When generator frequency is low than the point, generator low frequency and hold over than 10 seconds is active. When generator frequency is over than the point and hold over than 2 seconds, generator over frequency is active. When engine temperature sensor value is over than this point and remain for 2 seconds, send out shutdown alarm. When engine oil pressure sensor value is under than this point and remain for 2
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22

Gens over volt (30-360)V (shutdown)

264

23

Gens under (30-360)V volt (shutdown)

196

24

Under speed (shutdown)

(0-6000)RPM

1200

25

Over speed (shutdown)

(0-6000)RPM

1710

26

Gens under freq (0-75.0)Hz (shutdown)

45.0

27

Gens over freq (0-75.0)Hz (shutdown)

57.0

28

High temp. 1 (80-300) C (shutdown)

98

29

Low oil pressure 1 (shutdown)

(0-400)kPa

103

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HGM6200K Series Automatic Generator Module Num Parameter Range Default Remark

30

High temp. 2 (80-300) C (shutdown)

98

31

Low oil pressure 2 (shutdown)

(0-400)kPa

103

32

Low fuel oil level

(0-100)%

10

33

Lose speed delay

(0-20.0)s

5.0

34

Gens over volt (30-360)V (warn)

256

35

Gens under volt (warn)

(30-360)V

205

36

Under speed (warn)

(0-6000)RPM

1200

37

Over speed (warn) Gens under

(0-6000)RPM

1650

38

(0-75.0)Hz

47.0

seconds, send out shutdown alarm. When engine temperature sensor value is over than this point and remain for 2 seconds, send out shutdown alarm. When engine oil pressure sensor value is under than this point and remain for 2 seconds, send out shutdown alarm. When fuel level sensor value is under than this point and remain for 10 seconds, send out warn alarm. When speed is zero and remain for the delay, send out shutdown alarm. When the delay is zero, send out warn alarm. When generator voltage is over than the point, generator over voltage is active. When the point is 360V, generator over voltage is disabled. When generator voltage is under than the point, generator under voltage is active. When the point is 30V, generator under voltage is disabled. When the engine speed is under than the point, generator under speed is active. When the engine speed is over than the point, generator over speed is active. When generator frequency
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HGM6200K Series Automatic Generator Module Num Parameter Range Default Remark

freq (warn)

39

Gens over freq (warn)

(0-75.0)Hz

55.0

40

Charge fail volt (0-30)V

6.0

41

Battery over volt

(12-40)V

33.0

42

Battery under volt

(4-30)V

8.0

43

High temp. 1 (80-300) C (warn)

95

44

Low oil pressure 1 (warn)

(0-400)kPa

124

45

High temp. 2 (80-300) C (warn)

95

46

Low oil pressure 2 (warn) CT rate Full load

(0-400)kPa

124

47 48

(5-6000)/5 (5-6000)A

500 500

is low than the point, generator low frequency is active. When generator frequency is over than the point, generator over frequency is active. During generator is running, when charge alternator WL/D+ voltage is low than this point and remain for 5 seconds, generator will warn alarm. When generator battery voltage is over than the point and hold for 20 seconds, battery over voltage signal is active. Its a warn alarm. When generator battery voltage is under than the point and hold for 20 seconds, battery under voltage signal is active. Its a warn alarm. When engine temperature sensor value is over than this point, send out warn alarm. When engine oil pressure sensor value is under than this point, send out warn alarm. When engine temperature sensor value is over than this point, send out warn alarm. When engine oil pressure sensor value is under than this point, send out warn alarm. Current transformer rate Mains or generator set
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HGM6200K Series Automatic Generator Module Num Parameter Range Default Remark

current 49 Over current (shutdown) (50-130)% 120

50

Over current delay

(0-3600)s

1296

51

Over current (warn) Output1 set Output2 set Output3 set Output4 set Output5 set Output6 set Digit input1 set Digit input1 delay Digit input2 set Digit input2 delay Digit input3 set Digit input3 delay Digit input4 set Digit input4 delay Digit input5 set Digit input5 delay Digit input6 set Digit input6 delay Digit input7 set

(50-130)%

110

52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70

(0-34) (0-34) (0-34) (0-34) (0-34) (0-34) (0-26) (0-20.0)s (0-26) (0-20.0)s (0-26) (0-20.0)s (0-26) (0-20.0)s (0-26) (0-20.0)s (0-26) (0-20.0)s (0-26)

16 1 10 7 21 22 8 2.0 1 2.0 2 2.0 3 2.0 4 2.0 19 2.0 21

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 shutdown is disabled. When the load current is over than the point, send out warn alarm. Preheat(during pre-heat timer) Common alarm Energized to shutdown Idle control Close gens Close mains Remote start input(Only 6210KC)

High Temp alarm input

Low Oil Pressure alarm input

Warn input

Shutdown input

Fuel level low warn

LED test
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HGM6200K Series Automatic Generator Module Num Parameter Range Default Remark

71 72 73 74 75

Digit input7 delay Module power on Module address Password set Crank success condition select Speed disconnect Freq disconnect

(0-20.0)s (0-2) (1-254) (0-9999) (0-5)

2.0 0 1 1234 2 Setting item is given in Table 5. When engine speed is over than this point, starter will disconnect. When generator frequency is over than this point, starter will disconnect. When engine oil pressure is over than this point, starter will disconnect. 3P4L(3 phase 4 wire) Shutdown mode

76

(0-3000)RPM

360

77

(10-30)Hz

14

78

OP disconnect

(0-400)kPa 0 3P4L 1 2P3L 2 1P2L (0-10) (0-10)

200

79

Select system

AC

80 81 82 83 84

Select temp 1 sensor Select press 1 sensor Select Fuel level sensor Select temp 2 sensor Select press 2 sensor

08 08 03 00 00

SGX(120 C) SGX(10Bar) SGD Not used Not used

(0-5) (0-10) (0-10)

7.2 DIGIT OUTPUT 1-6 TABLE (TABLE 2)


Num 0 1 Content Not used Common alarm The designated programmable output relay will energize when any warn or shutdown fault circuit has been activated. The output indicates that a shutdown alarm has been activated. This output can only be reset by removal of the fault and by then
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Description

Common shutdown alarm

HGM6200K Series Automatic Generator Module

HGM6200K Series Automatic Generator Module

Num

Content

Common warn alarm

Description pressing the Shutdown reset button or by using an external Alarm Reset Input. The output indicates that a warn alarm has been activated. This output is normally self-resetting on removal of the fault. However, it is possible to configure the module such that the warn alarms are.

4 5

Reserved The output mimics the operation of the start Start relay output relay. Can be used to control external logic circuitry. The output mimics the operation of the fuel Fuel relay output relay. Can be used to control external logic circuitry. This output is active from cranking, continues to be active until the start idle timer has elapsed; Also this output is active Idle control during the period of the shutdown idle timer, continues to be active until the engine has shutdown. This output is active during the warming up Raise speed timer. This output is available during the period of Drop speed the Shutdown idle timer, and remain until the engine has shutdown. The designated programmable output relay will energize when a shutdown signal has ETS Solenoid to been activated. The output will remain shutdown energized for pre-set timer once the engine has come to a complete shutdown, then de-energizes. This output is available for the period of the crank timer. This output will energize for 2 Charge excitation control seconds during the period of the safety on timer if generator has no voltage. The output is used to control a fuel transfer pump. Once the Fuel warn level has been Fuel pump control reached the module will activate the fuel pump control output. This output will remain active until the 85% level is reached. The output controls the closing of the Air flap control air-flaps in an Emergency Shutdown or
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10

11

12

13

HGM6200K Series Automatic Generator Module

HGM6200K Series Automatic Generator Module

Num

14 15

16

17

18

19

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

Description Over-speed situation. The output controls the opening of the Louver control louvers on engine starting and closure when engine has shutdown. Over current output The load exceeds warn current threshold. The output controls the pre-heater. Pre-heat Pre-heat (during preheat output is available for the duration of the timer) pre-heat timer, which terminates prior to cranking. The output controls the pre-heater. As Pre-heat (until end of Pre-heat (during preheat timer) mode but cranking) pre-heat is also available during cranking. The output controls the pre-heater. As Pre-heat (until end of Pre-heat (until safety on) but pre-heat warming) continues to be available until the warm-up timer has elapsed. The output controls the pre-heater. As Pre-heat (until end of cranking) but Pre-heat (until safety on) pre-heat is also available while waiting for the delayed alarms to become active. Reserved Close Gens Switch generator breaker on. Close Mains Switch mains breaker on.(HGM6220KC) Switch breaker off. The output delay is 3 Open ATS seconds. Reserved Crank succeed output Engine normal run Generator normal output Reserved System in Manual test This output indicates that the module is in Mode the test mode. The output indicates that the module is in System in Auto Mode the Auto mode. This output indicates that the module is in System in Manual Mode the manual mode. System in Shutdown The output indicates that the module is in Mode the Shutdown mode. Reserved Mains over voltage, under voltage, loss Mains abnormal phase when is active. (Only 6220KC) Reserved
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Content

HGM6200K Series Automatic Generator Module

HGM6200K Series Automatic Generator Module

7.3 DIGIT INPUT 1-7 TABLE (TABLE 3)


Num 0 1 2 3 4 Content Not used High Temp. alarm Low OP alarm Auxiliary warn Auxiliary shutdown alarm Description High engine temperature digital input Low oil pressure digit input Auxiliary warn alarm digital input. When power on, if active, generator will shutdown immediately. During engine running, if the engine occur high temperature shutdown, when the input is active, the engine will first initiate cooling delay and then shutdown, else will shutdown immediately. The input state of generator closed. The input state of mains closed. If this input is active, the engine will operate thus: To use this function the engine should be placed in the AUTO mode. The module will perform the start sequence as described earlier in this manual. When it is active, during engine running, if the engine occurs high temperature, the engine will only send out high temperature warn alarm, not shutdown. When it is active, during engine running, if the engine occurs low oil pressure, the engine will only send out low oil pressure warn alarm, not shutdown.

Shutdown after cooled

6 7

Gen closed state input Mains closed state input

Remote Start

Inhibit WTH shutdown

10

Inhibit OPL shutdown

11 12 13 14 15

Analog manual key Analog auto key Analog start key Analog shutdown key Analog manual test key This input is used to provide security to the installation. If the Panel lock input is active, the module will not respond to operation of the Mode select or start buttons. When active, the icon will display on line 4 of the LCD display. When it is active at auto mode, not have shutdown will not shutdown. When it is active at auto mode, will not start.
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16

Inhibit keys

17 18

Auto shutdown Inhibit Auto start Inhibit

HGM6200K Series Automatic Generator Module

HGM6200K Series Automatic Generator Module

Num 19 20 21 22 23 24 25 26

Content Low fuel level warn Reset alarm LED test Reserved Raise speed auxiliary input Drop speed auxiliary input

Description Auxiliary Low fuel level digital input. When an alarm is active, it will be cleared. When it is active, all LED will lighten.

When it is active, raise speed output will not output. When it is active, drop speed output will not output. When it is active, display low Fuel level Low Fuel Level Warn warn. Low Fuel Level When it is active, display low Fuel level shutdown alarm and shutdown.

7.4 SENSOR (TABLE 4)


Num Content 0 Not used 1 Defined Res. Type 2 VDO 3 SGH(Hunghe sensor) 4 SGD(Dongkang sensor) 5 CURTIS 6 DATCON 7 VOLVO-EC 8 SGX 9 Reserved 10 Reserved 0 Not used 1 Defined Res. Type 2 VDO 10Bar 3 SGH(Hanghe sensor) 4 SGD(Dongkang sensor) 5 CURTIS 6 DATCON 10Bar 7 VOLVO-EC 8 SGX 9 Reserved 10 Reserved 0 Not used 1 Defined Res. Type 2 SGH 3 SGD 4 Reserved
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Remark

Temp. sensor

Defined curve input resistance range is 0-999.9 ohm, factory default is SGX

Pressure sensor

Defined curve input resistance range is 0-999.9 ohm, factory default is SGX

Fuel level sensor

Defined curve input resistance range is 0-999.9 ohm, factory default is no sensor.

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HGM6200K Series Automatic Generator Module

Num

Content 5 Reserved

Remark

7.5 CONDITION OF CRANK SUCCEED (TABLE 5)


Num 0 1 2 3 4 5 Magnetic pickup sensor Generator Magnetic pickup sensor + Generator Magnetic pickup sensor + Oil pressure Generator + Oil pressure Generator + Magnetic pickup sensor + Oil pressure Content

a) The crank disconnect condition has three kinds, the magnetic pickup sensor and the generator voltage can be used alone, the oil pressure must be used with the magnetic pickup sensor and the generator voltage, the purpose is to make the starter and the engine to disconnect as soon as possible. b) Magnetic pickup sensor is installed in the engine block number of magnetic device testing flywheel. c) When choosing magnetic pickup sensor, ensure engine flywheel teeth setting, otherwise may appear over speeding shutdown or loss speed shutdown. d) If the generator is not magnetic pickup sensors, please don't choose corresponding, otherwise this will occur fail to start or loss of speed alarm and shutdown. e) If the generator has no oil pressure sensor, please don't choose corresponding. f) If the generator 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.

8 SETTING PARAMETER
After powered up, press the key 1 Set Parameters 2 Information 3 Set Languages Set parameters to enter into the setting interface:

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HGM6200K Series Automatic Generator Module

The default password is 1234 when it leaves factory. The senior setting password is fixed as 0318. When setting each item, after selecting this item, press the key to enter the setting interface, then press the key or

to adjust the numerical value, press the key the key NOTE: to confirm the set parameter.

to move the cursor, finally press

a When the controller type is HGM6210KC, you will not have a table with a 1-5; the programmable output 1-6 will have no power of some mains switch output. b Please modify the standby controller parameters (such as starting a successful conditions select, programmable input and output configuration, various delay, etc.); otherwise it might alarm shutdown or other abnormal behavior. cThe over-voltage threshold value 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 when crank success. f Programmable input port 1-7 cannot set for the same items, otherwise cannot appear correct function, programmable output 1-6 export can be set for the same item. g If need to high temperature after shutdown, please input in a programmable port settings "high temperature stop when this option", then connect this input with GND. Information LCD will display the controller software version, issue date. Note: Press the key output port state. Set language User may set display interface language as Chinese, English and Spanish. *Note: Press the key will exit setting interface at any time. will display the states of configurable input port and

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HGM6200K Series Automatic Generator Module

9 SENSOR SETTINGS
1 When the choice sensor, the sensor to standard curve will call. If factory set temperature sensor for SGD (120 degrees resistance-type), sensor curve for SGD (120 degrees resistance-type), 120 degrees Celsius (elected SGH type), resistively curve for temperature sensor SGH 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 curve no affection, LCD display temperature or pressure for---. 5 If there is no pressure sensor, only low pressure switch, it must be alarm settings for pressure sensor "nothing", otherwise may appear oil pressure low alarm shutdown. 6 Can set up several point of forehand or some several point of backmost ordinate the same. The following picture:

Common units conversion table 1N/m2 (pa) 1Pa 1kgf/cm2 1bar 1psi 1 9.8104 1105 6.89103 1kgf/cm2 1.0210-5 1 1.02 7.03010-2 1bar 110-5 0.98 1 6.8910-2 (1b/in2) psi 1.4510-4 14.2 14.5 1

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HGM6200K Series Automatic Generator Module

10 TEST RUN
Before operation, inspections that are recommended as follows should be carried out: a. Check and assure that all connections are correct, and that diameter of wire is suitable; b. The DC power supply of controller is equipped with fuse, and the positive supply (+Ve) and negative supply (-Ve) connected with battery are connected correctly; c. The emergency shutdown input is connected with the positive supply (+Ve) of the battery through the NC terminal and fuse of emergency shutdown button; d. 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; e. 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 Shutdown/Reset key to make the controller resetting; f. 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 generator 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 generator. If there is abnormal, shutdown the generator, then check connections of each part according to this handbook; g. 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 to go into standby state until the mains is abnormal again; h. After the mains is abnormal again, the generator will automatically crank into normal operation state, and then close generator relay, control the ATS to switch transfer to generator on load. If the situation is not same as described above, check the connection of control part of the ATS according to this handbook; i. If there are other questions, please contact the technical personnel of our company in time.

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11 TYPICAL WIRING DIAGRAM


HGM6210KC Typical wiring diagram

HGM6220KC Typical wiring diagram

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Single phase 2 wires (HGM6220KC)

2-phase 3 wires (HGM6220KC)

Note: Recommend that the output of crank and Fuel expand high capacity relay.

12 INSTALLATION
The controller is designed to panel installation mode, and it is fixed by clamps when it is installed. The overall case dimension and panel cutout dimension are given as follows:

1 Battery voltage input HGM6200K series controller can be applicable to (8-35)VDC battery voltage environment, battery anode must be reliable connect engine shell B + and Bcontroller power battery anode and cathode connections is not less than 2.5, if there was the float electrical, please put the charger output line directly to battery is negative, and from the battery is connected to the anode separately
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HGM6200K Series Automatic Generator Module

on the power input, positive controller to prevent the normal operation of the controller battery charger interference. 2 Speed sensor input Speed sensor is installed in the engine block of magnetic device testing flywheel teeth, it should be used with the controller of attachment 2 core shielding wire, shielding layer on the 25th pin controller, the other end terminal, the other two are respectively in signal controller, and meet the terminals26th and 27th 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. 3 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 extended relay coil links AC), in order to prevent interference controller or other equipment. 4 Alternating current input HGM6200K 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 of power controllers. B. When the load current, the transformer secondary side is strictly open circuit. 5 Pressure test When the controller has been installed in the control panel, if you will, please put pressure test controller terminals all disconnected, lest high-pressured into and damaged controller.

13 FACTORY DEFAULT VALUES


Num 1 2 3 4 5 Program Mains volt normal delay Mains volt abnormal delay Mains over volt Mains under volt Transfer switch interval Range (0-3600)s (0-3600)s (30-360)V (30-360)V (0-99.9)s Default 10 5 276 184 1.0
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Num 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

Program Start delay Shutdown delay Close delay Gens over volt (shutdown) Gens under volt (shutdown) CT rate Full load current Over current(shutdown) percentage Over current (shutdown)delay Over current (warn) percentage Number of Crank Cranking time Crank rest time Safe run time Start idle time Warming up time Cooling time Shutdown idle time ETS solenoid hold Fail to shutdown delay Preheat time Crank success condition select Flywheel teeth Over speed shutdown Under speed shutdown Over freq. shutdown Under freq. shutdown Over speed warn Under speed warn Over frequency warn Under frequency warn Gens over volt warn

Range (0-3600)s (0-3600)s (0-10)s (30-360)V (30-360)V (5-6000)/5 (5-6000)A (50-130)% (0-3600)s (50-130)% (1-9)times (3-60)s (3-60)s (1-60)s (0-3600)s (3-3600)s (3-3600)s (0-3600)s (0-120)s (0-120)s (0-300)s (0-5) (10-300)

Default 1 1 5.0 264 196 500 500 120 1296 110 3 8 10 10 0 10 10 0 20 0 0 Magnetic pickup sensor + Generator 118

(0-6000)RPM 1710 (0-6000)RPM 1200 (0-75.0)Hz (0-75.0)Hz 57.0 45.0

(0-6000)RPM 1650 (0-6000)RPM 1350 (0-75.0)Hz (0-75.0)Hz (30-360)V 55.0 47.0 256
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Num 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

Program Gens under volt warn Crank success Gens frequency Crank success Gens speed Crank success Gens oil pressure Low oil pressure 1 (shutdown) Temp. 1 over(shutdown) Low oil pressure 2 (shutdown) High Temperature 2 (shutdown) Low Fuel level Battery over volt Battery under volt Charge fail volt Low oil pressure 1 (warn) High temperature 1 (warn) Low oil pressure 2 (warn) High temperature 2 (warn) Aux. input1 set Aux. input 2 set Aux. input 3 set Aux. input 4 set Aux. input 5 set Aux. input 6 set Aux. input 7 set Switch output 1 set Switch output 2 set Switch output 3 set

Range (30-360)V (14-30)Hz

Default 205 14

(0-3000)RPM 360 (0-400)kPa (0-400)kPa (80-300) C (0-400)kPa (80-300) C (0-100)% (12-40)V (4-30)V (0-30)V (0-400)kPa (80-140) C (0-400)kPa (80-300) C (0-26) (0-26) (0-26) (0-26) (0-26) (0-26) (0-26) (0-34) (0-34) (0-34) 200 103 98 103 98 10 33.0 8.0 6.0 124 95 124 95 Remote start input High Temp alarm input Low oil pressure input Warn input Shutdown input Low fuel level warn input LED test Preheat(during timer) Common alarm Energized to stop
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pre-heat

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Num 64 65 66 67 68 69 70 71 72 73 74

Program Switch output 4 set Switch output 5 set Switch output 6 set Temp. 1 sensor select Fuel level sensor select Temp. 2 sensor select

Range (0-34) (0-34) (0-34) (0-8) (0-5) (0-8)

Default Idle control Close Gens Mains closed SGX SGX SGD Not used Not used 3P4L 1 0:Shutdown

Pressure1 sensor select (0-8)

Pressure 2 sensor (0-8) select Select AC system (0-2) Communication address (1-254) Module power on (0-2)

14 FAULT FINDING
Possible Remedy Check the battery and wiring to the unit. Generator inoperative Check the DC supply. Check the DC fuse. Check DC supply voltage is not above 35 Volts or below 8 Volts. Generator shutdown Check the operating temperature is not above 70 C. Check the DC fuse. If an Emergency Shutdown switch is not fitted, ensure that a positive is connected to the Emergency shutdown input. Emergency shutdown 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. High Temp. alarm (after Check switch/sensor and wiring. crank success) Check configured polarity (if applicable) is correct. Check relevant switch and wiring of fault indicated Shutdown fault operates on LCD display. Check configuration of input.
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Symptom

HGM6200K Series Automatic Generator Module

Symptom

Crank no success

Starter motor inoperative

Unit operation but ATS

RS485 communication abnormal

Possible Remedy Check wiring of fuel solenoid. Check battery supply. Check wiring of the speed sensing signal. Refer to engine manual. Check wiring to starter solenoid. Check battery supply. Check ATS. Check the connection between the ATS and the controller. Check wiring. Check COM ports set correctly. Check the A and B RS485 line is reversed. Check of RS485 conversion 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 120 resistor.

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