SmartGen HGM501 Genset Controller User Manual

SmartGen HGM501 Genset Controller

OVERVIEW

HGM501 gen-set controller is smart digital controller for control and protection of single gen-set. It can carry out start/stop, data measurement, alarm indication, shutdown protection and other functions. The controller is fitted with LED indicators; it is reliable and easy to use.
HGM501 gen-set controller contains the microprocessor allows precise measurement of multiple parameters, which can be configured using controller front panel. With simple wiring, compact structure and high reliability, HGM501 can be widely used for data display and fault protection of a large number of diesel and petrol generator sets.

PERFORMANCE AND CHARACTERISTICS

1. Nixie tube displays: single phase voltage display and total active power voltage display (calculated using single phase power, taking load as balanced);
2. Multifunction nixie tube display that can be switched between single phase frequency, single phase current, battery voltage, total running time (max 999 hours), engine and generator temperature;
3. Under voltage, over voltage, under frequency, over frequency, over load, over temperature protection, starting with flashing lights alarm and followed by shutdown protection after alarm delay;
4.  Low oil pressure digital input that immediately shuts down the generator in case of low oil pressure;
5. Displayed parameters can be selected using touch-buttons;
6. Wide selection of temperature sensor types in settings;
7. All the parameters can be set via front panel for easy and convenient operation;
8. Modular design, anti-flaming ABS plastic enclosure, compact structure, convenient embedded installation.

TECHNICAL DATA

used

Overall consumption| <2W (Standby mode ≤1W)
Alternator voltage inputs: Single phase 2-wire (L and N only)

2-  phase 3-wire (L and N only)

3-  phase 4-wire (L and N only)

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AC 30V – 360V (ph-N) AC 30V – 360V (ph-N) AC 30V – 360V (ph-N)

Alternator frequency| 50/60Hz
Start relay output| 7A    DC12V power supply output
Fuel relay output| 7A    DC12V power supply output
Case dimensions| 118 mm x 128 mm x 36 mm
CT Secondary current| Rated 62.5mA
Operating conditions| Temperature: (-25~+70)°C            Humidity: (20~90)%
Storage conditions| Temperature: (-30~+80)°C
Protection level| IP42

Insulation strength

| Apply AC1.5kV voltage between high voltage terminal and low voltage terminal;

The leakage current is not more than 3mA within 1min.

Weight| 0.216kg

OPERATION

BUTTON DESCRIPTION

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FUNCTION

| 1.     In configuration menu, pressing this button enters setting or confirms;

2.     During normal operation, press this button to switch to frequency display;

3.     In case of alarm shutdown, pressing and holding the

button for 1 second will reset the alarm.

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UP/SCROLL

| 1.     During parameter configuration, pressing this button increases the set value;

2.     During normal operation press this button to switch to

the upper LED.

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DOWN/SCROLL

| 1.     During parameter configuration pressing the button decreases the set value;

2.     During normal operation the button switches to the

lower LED.

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LEFT

| 1.     During parameter configuration pressing this button will return to the previous menu;

2.     During normal operation press this button to switch to

the next (upper) LED.

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RIGHT

| 1.     During parameter configuration press this button to enter the next menu.

2.     During normal operation the button switches to the

lower LED.

START/STOP OPERATION

STARTING PROCEDURE
In stop mode turn the starter key from OFF to ON position to power on the controller, then change the starter key position to START to begin cranking; after the engine fires, release the starter key(crank disconnect condition is gen frequency>14.0Hz), then voltage, power and frequency windows will show the real measured values. Press or button to switchover between indicators 1#-6# and multifunctional window will show corresponding  settings. Press  button to return to the frequency window.
LED indicators state:

1. Frequency (Hz)
2. Current (A)
3. Battery voltage (V)
4. Run time (H)
5. Engine temp.(℃)
6.  Generator temp.(℃)
7. Auto protection If on, auto protection is enabled; if not, it is disabled.
8.  Run on indicator Fuel relay output indicator
9. Crank indicator Start output indicator
10. Engine oil warning Low oil pressure indicator

NOTE: Before starting the engine please make sure that all the parameter settings are correct.
NOTE “Engine oil warning” indicator operates according to the oil pressure switch. Before the start of the gen-set, the light must be on; if it is not, it means that oil pressure switch or its return circuit is faulty; in this case please do not proceed before clearing up the problem.

STOPPING PROCEDURE

1. Auto stop
   If auto protection condition occurs, the system will be stopped automatically; During normal running of the gen-set, if low oil pressure signal is detected an last for  over 2s, the set will be stopped.

2. Manual stop
   Under any circumstances, if starter key is turned from ON to OFF position, it will lead to shutdown.

AUTO PROTECTION

In auto protection mode, except for low oil pressure protection, all the other protections (voltage, frequency, overload, temperature) are active.

1. Voltage protection
   When the limits of rated voltage are exceeded by ±10%, Voltage LED starts flashing; after 7 seconds delay in case of under voltage or 3 seconds delay in case of over voltage, alarm shutdown is initiated. After that voltage LED continues to flash and shows pre-alarm value.

2. Frequency protection
   50Hz：(45~55)Hz
   60Hz：(55~65)Hz
   When the set value is exceeded, frequency LED starts flashing; after 7 seconds delay in case of under frequency and 3 seconds delay in case of over frequency, alarm shutdown is initiated. After that frequency LED continues to flash and shows pre-alarm value.

3. Overload protection
   If the set value is exceeded by 5% or less, alarm will not be initiated;
   If the set value is exceeded by more than 5%, power LED will start flashing;
   If the set value is exceeded by 5%-7.5% and continuous for more than 3 hours, then alarm shutdown will be initiated;
   If the set value is exceeded by 7.5%-10% and continues for more than 1 hour, alarm shutdown will be initiated;
   If the set value is exceeded by more than 10%, and continues for more than pre-set over power delay value, alarm shutdown will be initiated (defult: 30s);
   After alarm shutdown is initiated power LED continues to flash and shows pre- alarm value.

4. Low oil pressure protection
   Irrespective of whether auto protection mode is enabled or not, genset will shutdown if low oil pressure occurs and last for more than 2s.

5. High engine temperature protection
   If engine temperature exceeds pre-set high temperature threshold, LED window starts flashing; after 7 seconds delay, protection begins; LED window continues to flash and shows pre-protection value (for air-cooled engine);

6. High generator temperature protection
   When generator temperature exceeds 95℃, LED window starts flashing; after 7 second delay, protection begins; LED window continues to flash and shows pre- protection value;

7. Battery voltage protection
   Battery voltage protection is enabled irrespective of whether auto protection mode is enabled or not and whether gen-set is running. If battery voltage value is lower than 8V or higher than 16.5V, Nixie tube or LED display starts flashing, but shutdown protection is not initiated.

TERMINAL

HGM501 controller back panel is shown below:

max current    62.5mA

4| Load CT Secondary I* (in)| 1.0mm2

5

| Aux. Input1| | Can be configured as programmable digital input port(active connect to B-); Also  can  be  configured  as generator temp. sensor.
6| Engine Temperature Sensor Input| |

7

|

Low Oil Pressure Input

| | Low oil pressure digital or sensor signal      input     port;    must be connected to B-
8| Battery Negative Input B-| 1.5mm2| Controller power supply input     B-
9| Electric Lock ON Signal Input B+| 1.5mm2| Controller power supply input B+ and fuel relay output (activates when Electric key is turned to ON position)

NOTE: Controller within the LINK port, which connect to SmartGen’s SG72 adapter. It is can be set or check genset’s real time data via PC software.

CONFIGURABLE PARAMETERS

CONFIGURABLE PARAMETERS TABLE

1

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AC system

| 1P

2P

3P

4P

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1P

| 1P：1P2W

2P：2P3W

3P：3P4W

4P：Double Rated Volts

2

| ****

Rated voltage

| 110 V

115 V

120 V

130 V

220 V

230 V

240V

| ****

220

| ****

Generator rated    voltage     value selection

3| Rated

frequency

| 50Hz

60Hz

| 50| Generator       rated        frequency

selection

4| Rated power| (0.0-99.9)kw| 5.0| Generator rated Active power
5| Enable       Auto

protection

| Enable

Disable

| Enable| Irrespective of whether gen-set

auto protection is enabled

6

| ****

CT Ratio

| ****

(0-999)/62.5

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50/62.5

| Unit: A/62.5mA

(Must correspond to the used current transformer)

7

| ****

Engine temperature sensor type

| L-0

L-1

L-2

L-3

L-4

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L-4

| L-0：Not used

L-1：TE1(SGX Sensor) L-2：TE2(SGD Sensor)

L-3：TE3(PT100 Sensor)

L-4：TE4 (See TE4/TG4 Sensor Curve)

Remark:

1. Parts of parameters only can be configured via PC software, e.g. digital input port1, engine high temp. threshold.
2. AC system selected “Double Rated Volts” means generator can output two kinds of rated voltage.

TE4/TG4 sensor curve as bellow,

PARAMETER CONFIGURATION

Before using controller for the first time, parameters must be configured: rated voltage, rated frequency, rated power set values must comply with the used generator, set C.T. ratio value should comply to the used current transformer.

1. When the controller is disconnected, press button, then change start key position from OFF to ON; after the controller is powered on release button and all the three windows (voltage window, frequency window and multifunctional window will show set parameters; at the same time voltage window will start flashing showing four choices (1P/2P/3P/4P) which mean 1P2W, 2P3W, 3P4W and Double Rated Volts respectively. Use and to choose AC wire type and to confirm and automatically enter the next menu item;
2. Rated voltage value settings: there are 7 possible variants of voltage (110/115/120/130/220/230/240V), use and to switchover between them (each pressing will increase/decrease the value for one step). When the screen shows the needed value, press to confirm and enter the next menu item;
3. Rated power settings: power LED window first digit will start flashing; use and to choose a value from 0 to 9, then press to confirm and enter next settings; power window second digit will start flashing, use and to choose a value from 0 to 9 and to confirm; power window third digit will start flashing, use and to choose a value from 0 to 9 and to confirm and enter the next menu item;
4. Rated frequency setting: frequency LED indicator illuminates, multifunctional window starts flashing; press and to choose frequency value (there are 2 choices: 50 and 60Hz), every time you press the button the value will change; when the needed value is displayed, press to confirm and automatically enter the next setting;
5. Auto protection setting: when auto protection light indicator is on, press to confirm and auto protection will continue to be enabled; use or to make indicator flashing and press to disable auto protection. When the light indicator is off, it means that auto protection is disabled. Enabling this function is recommended;
6. C.T setting: current LED indicator illuminates; multifunctional window first digit will start flashing; use and to choose a value from 0 to 9, then press to confirm and enter next settings; power window second digit will start flashing, use and to choose a value from 0 to 9 and to confirm; power window third digit will start flashing, use and to choose a value from 0 to 9 and to confirm and enter the next menu item;
7. Engine temperature sensor type setting: when engine temperature indicator is on, multifunctional window will start flashing: use and to select temperature sensor type (there are five choices: L-0，L-1，L-2，L-3，L-4. L-0 stands for ‘no temperature sensor used’). Every time you press the button, the temperature sensor type will change; when the needed type is displayed, press button to confirm and automatically enter the next setting;
8. Generator temperature sensor type setting: the same as 7.
9. Turn the start key from ON to OFF position to finish configuration.

NOTE: during configuration use button to enter the next menu item and to return to the previous.
CAUTION: Please change inner controller parameters (rated generator voltage, generator frequency etc.) only in standby mode, otherwise in can lead to shutdown or other abnormal condition.

 COMMISSIONING

It is recommended that the following checks are made before starting the system:

1. Check that all the connections are correct and wire sizes are suitable.
2. Ensure all parameters are configured correctly and oil pressure light is on.
3. Ensure the controller DC power supply is fused and correctly connected to the positive and negative of starter battery.
4. Take proper measures to prevent the engine from starting (e. g. unplug fuel valve wire). After checking that there are no faults, connect the starter battery, change start key position from OFF to ON, and the controller will carry out the procedure.
5. Then change start key position to START to start cranking. After the engine is fired, remove start key; voltage, frequency and power windows will show true collected values.
6. For further information please contact SmartGen services.

TYPICAL WIRING DIAGRAM

Typical wiring diagram is shown below:

INSTALLATION

The controller is designed for panel mounting, it is held with the help of fixing clips. Overall and cutout dimensions can be seen below (unit: mm)

1.  Battery Voltage Input
   NOTE: HGM501 controller is suitable for 9-18 VDC battery voltage. Battery negative must be reliably connected to the enclosure of the engine. The controller power supply B+ and B- must be connected to battery positive and negative, and the wire size must not be less then 1.5mm2. In case of floating charger connect charger output to battery positive and negative directly, then, connect battery positive and negative poles to controller positive and negative power supply input port using single lines to prevent charger interference into normal operation of the controller.

2. AC input
   Current transformer with rated secondary current 62.5mA must be externally connected to the controller current input.

3. Withstanding voltage test
   CAUTION: If withstanding voltage test is conducted after the controller has already been installed onto the control panel, please unplug all controller terminal connections in order to prevent high voltage from damaging it.

TROUBLESHOOTING

the controller Check DC fuse
Low  oil  pressure  alarm  after crank disconnect| Check oil pressure sensor and its wiring.
Alarm shutdown during running| Check corresponding switch and wiring in accordance with the information on the display

Fail to start

| Check fuel return circuit and wiring Check start battery Consult engine manual
Starter motor does not respond| Check the wiring to the starter Check start battery

References

• 众智科技
• smartgen.cn/
• 众智科技
• smartgen.com.cn/

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