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HGM4100LT en
HGM4100LT en
GENSET CONTROLLER
USER MANUAL
Chinese trademark
English trademark
SmartGen — make your generator smart
SmartGen Technology Co., Ltd.
No.28 Jinsuo Road
Zhengzhou
Henan Province
P. R. China
Tel: +86-371-67988888/67981888/67992951
+86-371-67981000(overseas)
Fax: +86-371-67992952
Web: www.smartgen.com.cn/
www.smartgen.cn/
Email: [email protected]
All rights reserved. No part of this publication may be reproduced in any material form (including
photocopying or storing in any medium by electronic means or other) without the written permission
of the copyright holder.
Applications for the copyright holder’s written permission to reproduce any part of this publication
should be addressed to SmartGen Technology at the address above.
Any reference to trademarked product names used within this publication is owned by their
respective companies.
SmartGen Technology reserves the right to change the contents of this document without prior notice.
HGM4100LT: it is used for single unit automation and genset auto start/stop control by remote
start signals.
Main characteristics:
— LCD display with backlight, 132x64 size, and eight language display (Chinese, English,
Spanish, Russian, Turkish, French, Portugal, and Polish), push-button operation;
— Hard acrylic screen material with great wear-resisting and scratch-resisting performance,
which are used to protect the screen;
— Silicone panel and pushbuttons which can better adapt extreme temperature environment;
— RS485 communication interface, which enables “Three remote” (remote control, remote
measuring and remote communication) functions by MODBUS protocol;
— CANBUS port, which can connect with J1939-equipped electronic injection engine. Not only
can it monitor frequently-used data (such as water temperature, oil pressure, speed, fuel
consumption and so on) of ECU machine, but also control start-up, shutdown, speed raising and
speed dropping etc. (the controller with CANBUS interface is needed);
— 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;
— Collecting and displaying 3-phase voltage, 3-phase current, frequency, and power
parameters;
Generator
Line voltage (Uab, Ubc, Uca)
Phase voltage (Ua, Ub, Uc)
Frequency (Hz)
Phase sequence
Load
Current Ia, Ib, Ic A (unit)
Each phase and total active power P kW (unit)
Reactive power Q kvar (unit)
Apparent power S kVA (unit)
Power factor PF
Accumulated total generator power W kWh, kvarh, kVAh (unit)
Items Contents
Operating Voltage DC8.0V to DC35.0V, Continuous Power Supply.
Power Consumption <3W (standby ≤2W)
AC Gen Voltage Input:
3Phase 4Wire 15V AC - 360 V AC (ph-N)
3Phase 3Wire 30V AC - 620 V AC (ph-ph)
Single Phase 2Wire 15V AC - 360 V AC (ph-N)
2Phase 3Wire 15V AC - 360 V AC (ph-N)
AC Gen Frequency 50Hz/60Hz
Speed Sensor Voltage 1.0V to 24.0V (RMS)
Speed Sensor Frequency 10,000Hz (max.)
Starter Relay Output 5A DC28V power supply output
Fuel Relay Output 5A DC28V power supply output
Programmable Relay Output 1 1A DC28V power supply output
Programmable Relay Output 2 1A DC28V power supply output
Programmable Relay Output 3 1A DC28V power supply output
Programmable Relay Output 4 1A DC28V power supply output
Case Dimension 135mm x 110mm x 44mm
Panel Cutout 116mm x 90mm
CT Secondary Current 5A rated
Temperature: (-40~+70)°C
When reaches -40°C, the controller is powered on for 50
Working Temperature
seconds, but there is double image, and the display can be
normal after 1.5 minutes.
Working Humidity (20~93)%RH
Storage Temperature (-45~+80)°C
IP65: rubber seal installed between the controller enclosure and
Protection Level
panel window.
Apply AC2.2kV voltage between high voltage terminal and low
Insulation Intensity voltage terminal and the leakage current is not more than 3mA
within 1min.
Weight 0.32kg
Manual Press this key and the controller shall be in manual mode.
Auto Press this key and the controller shall be in auto mode.
The switchover key for breaker close and open; press this key and the
C/O page and main page shall display alternately; When C/O page
C/O
displays and the controller is in manual mode, press Up/Down keys
and breaker open and close can be controlled.
Press this key and it shall enter Menu List;
Set/Confirm During parameter setting, it is used to move the cursor and confirm
setting information.
Scrolls the screen up; during parameter setting, it is used to move
the cursor up and add the value of the place where the cursor is;
Up/Increase
When the C/O page displays and the controller is in manual mode, it
can control Gen breaker close.
Scrolls the screen down; during parameter setting, it is used to
move the cursor down and reduce the value where the cursor is;
Down/Decrease
When the C/O page displays and the controller is in manual mode, it
can control Gen breaker open.
Press , and the indicator besides is on, which means the genset is in auto start mode.
Auto Start Sequence:
1) When the remote start input is active, LCD displays countdown and it enters “Start Delay”;
2) LCD displays “Start Delay” countdown;
3) When start delay is over, preheating relay outputs (if configured), LCD displays “preheat start
delay XX s”;
4) When preheating delay is over, fuel relay outputs for 1s and then starter relay outputs; during the
start time if the genset does not start successfully, the fuel relay and starter relay stop outputting
and enter “crank rest time” for waiting for next start;
5) During the set starting attempts, if the genset does not start successfully, the fifth line of LCD
display window turns black, and at the same time it displays start failure alarm;
6) If the genset starts successfully in any of the start attempts, “safety on delay” starts. During this
period, low oil pressure, high water temperature, under speed, charging failure and auxiliary inputs (if
configured) alarm types are disabled. As soon as this delay is over, “start idle delay” is initiated (if
configured);
7) During the process of “start idle delay”, under speed, under frequency, under voltage alarms are
inhibited. When this delay is over, “warming up delay” starts (if configured);
8) When “warming up delay” is over, if generator state normal, the indicator will be illuminated. If
genset voltage and frequency has reached loading requirements, the Gen close relay will be
energized, generator will work with loading, generator power indicator will turn on, and generator will
enter Normal Running state; if the voltage and frequency are abnormal, the controller will initiate
shutdown alarm (Gen alarm type will be displayed on LCD).
Auto Stop Sequence:
1) When the remote start input is invalid, “Stop Delay” starts;
2) When the stop delay is over, high-speed cooling delay starts, Gen close relay is disconnected, and
Gen power indicator is off;
3) When stop idling speed delay (if configured) starts, idling speed relay is energized and outputs;
4) When “ETS hold delay” starts, ETS relay is energized and outputs, and the fuel relay output is
disconnected;
5) When genset “Fail to stop time” starts, it shall judge whether it stops completely automatically;
6) When the genset stops completely, it enters standby status; if the genset cannot stop, the controller
shall alarm (LCD displays stop failure warning.).
1) Press , and the controller shall enter “Manual mode”. The manual mode indicator is on. Then
press and start the genset. It can automatically judge whether crank disconnection is
successful and it can accelerate to high speed running automatically. It can effectively protect and
stop if high water temperature, low oil pressure, over speed, abnormal voltage etc. circumstances
occur in the diesel genset running process (for details please refer to the auto start process 4~8).
When genset high-speed running goes normal, press and it comes the C/O interface. By
2) Manual stop: press key and it can stop the running genset (for detail procedures please refer
to No.3~7 of Auto stop sequence).
Under manual mode, simultaneously press and , and the genset can be started
forcibly. At this time, the controller shall not judge whether the genset has started by crank
disconnection conditions. The starter disconnection is controlled by the operator. When the operator
observes the genset has started, let go of the buttons and start output is stopped. The controller
enters safe running delay.
5.1 WARNINGS
When the controller detects the warning signals, it shall only give alarm and not stop the genset.
Besides, LCD displays the warning information.
Table 4 Warnings
When the controller detects shutdown alarm, it will open the breaker immediately and stop. At the
same time alarm type shall be displayed.
Start the controller, and then press to enter the parameter setting menu. Menu items are
as follows:
1 Set Parameters
2 Information
3 Set Language
4 Event Log
5 Maintenance
When password “0318” is inputted, all parameter setting items can be set. When default
password (0318) is changed, it needs to input the same password as controller for parameter setting
via PC software. If more parameter items are needed to set (such as voltage and current calibration)
or password is forgotten, please contact with the factory.
NOTES:
a) Please change the controller parameters when generator is in standby mode only (e. g. Crank disconnection
condition selection, auxiliary input, auxiliary output, various delays), otherwise, shutdown and other abnormal
conditions may occur.
b) Over voltage set value must be higher than under voltage set value, otherwise over voltage and under voltage
conditions may occur simultaneously.
c) Over speed set value must be higher than under speed set value, otherwise over speed and under speed conditions
may occur simultaneously.
d) Please set the generator frequency value as low as possible at the moment of cranking. It is supposed to make the
starter be separated quickly as soon as possible.
e) Auxiliary inputs 1~5 could not be set as the same item; otherwise, there are abnormal functions. However, the
auxiliary outputs 1~5 can be set as the same item.
f) Auxiliary sensor 1 input port can be set as fuel level sensor or digital input port 4; programmable sensor 2 input
port can be set as temperature sensor, pressure sensor, coolant level sensor or digital input port 5. Either the
sensor or the digital input port is Ok, and if digital input port is selected, the corresponding set parameters shall be
functional and sensor parameters are inactive and reserved; otherwise, if the sensor is selected, the corresponding
sensor parameters shall be functional and digital input port parameters are deactive and reserved.
g) If it is needed to shut down after cooling, please set any auxiliary input as “High Temperature Stop Input”, then
connect this input port to GND or set “High Temperature Stop Input” action as “Cooling Stop”.
a) This item shall display information about software version, hardware version, release date.
NOTE: In this interface, press and it shall display the digital inputs and outputs status.
Press and ( and ) simultaneously and adjust LCD contrast ratio to make LCD
character display clearer. Contrast ratio adjustment range: 0-7.
This item can set display languages: Chinese, English, Spanish, Russian, Turkish, French,
Portuguese and Polish.
Through this item event log information can be checked, including start/stop information and
shutdown alarm information log. The maximum is up to 99 pieces for records and logs.
8.5. MAINTENANCE
─ If a sensor is needed to be changed again, the sensor curve will be transferred into the standard
value. For example, if the default temperature sensor is SGH (120°C resistor type), the sensor
curve is SGH curve (120°C resistor type); if it is set SGD (120°C resistor type), the temperature
sensor curve is SGD curve.
─ If there is difference between standard sensor curve and the used sensor, users can choose
“defined sensor”, and input “defined sensor curve”.
─ At the time of inputting the sensor curve, X value (resistor) must be inputted from small to large,
otherwise, any mistake may occur.
─ If there is not an oil pressure sensor, and there is only a low oil pressure alarm switch, then the
pressure sensor must be set “None”, otherwise, low oil pressure shutdown alarm may occur.
─ It is applicable to set the headmost and backmost values in the vertical coordinate as the same
as the Figure 3.
Please make sure the following checks are made before commissioning:
— Check and make sure that all connections are correct and wire diameter is suitable.
— Check and make sure that the controller DC power has fuse, and controller’s positive and negative
connections with the start battery are correct.
— Check and make sure that emergency stop input is connected to the positive pole of starter battery
via emergency stop button’s normally closed point and fuse.
— Take proper action to prevent engine to crank successfully (e. g. remove the connecting wire of the
fuel valve). If everything is correct, connect power with the start battery; choose manual mode and the
controller will executive the routine.
— Set the controller under manual mode; press “start” button, and the genset will start. After the set
cranking times, the controller will send Start Failure signal, and then press “stop” to reset the controller.
— Recover the action to prevent engine to crank successfully (e. g. connect the wire of the fuel valve).
Press start button again, the genset will start. If everything goes well, the genset will go to normally
running after idling speed running (if configured). During this time, please observe engine’s running
situation and AC generator’s voltage and frequency. If there is something abnormal, stop the genset and
check all wire connections according to this manual.
— Select the AUTO mode on controller’s panel, and make the remote start input active. The engine
shall enter normal running status automatically and then sends Gen close signal to control ATS to
transfer to genset loading. If this is not the case, please refer to this manual and check ATS control wire
connections.
— If there is any other question, please contact SmartGen’s service as soon as possible.
NOTE: Expansion relays with high capacity in start and fuel outputs are recommended.
1) The controller is panel built-in design; and it is fixed by clips for installation.
2) Withdraw the fixing clip screws (anticlockwise) until they reach proper position.
3) Pull the fixing clips backwards (towards the back of the module) and ensure two clips are inside
their allotted slots.
4) Turn the fixing clip screws clockwise steady until they are fixed on the panel.
NOTE: Care should be taken not to over tighten the screws of the fixing clips.
HGM4100LT controller can suit wide range of battery voltage DC(8~35)V. Negative of battery must
be connected with the engine shell. Diameter of wire which connects power supply with battery must be
over 2.5mm2. If floating charger is configured, please firstly connect output wires of the charger to
battery’s positive and negative directly, then connect wires from battery’s positive and negative to
controller’s positive and negative input ports in order to prevent charger disturbing the controller’s normal
working.
— SPEED SENSOR INPUT
Speed sensor is the magnetic equipment which is installed on the engine for detecting flywheel
teeth. The connection wires with controller should apply 2-core shielding line. The shielding layer should
be connected to No. 15 terminal in the controller and another side is hanging in the air. The else two
signal wires are connected to No.16 and No.17 terminals. The output voltage of speed sensor should be
within AC (1~24)V (RMS) during the full speed range. AC12V is recommended (at rated speed). When
speed sensor is installed, let the sensor spun to contacting flywheel first, then, port out 1/3 lap, and lock
the nuts of sensor at last.
— OUTPUT AND EXPAND RELAYS
All controller outputs are relay contact output type. If expansion relay is needed, please add
freewheel diode to both ends of expansion relay’s coils (when relay coils have DC current) or, increase
resistance-capacitance circuit (when relay coils have AC current), in order to prevent disturbance to the
controller or other equipment.
— AC INPUT
Current input of HGM4100LT controller must be connected to external current transformer. And the
current transformer’s secondary side current must be 5A. At the same time, the phases of current
transformer and input voltage must be correct. Otherwise, the collected current and active power may be
Table 13 Connector B
It is suitable for CM570 engine control module. Engine type is QSM11 G1, QSM11 G2.
Table 17 C1 Connector
It is suitable for GCS engine control module. Read engine information by using RS485-MODBUS.
Engine types are QSX15, QST30, QSK23 / 45/60/78 and so on.
Table 26 F Connector
Table 28 X1 Connector
It is suitable for MTU engine with ADEC (ECU8) and SMART module.
It is suitable for MTU engine with ADEC (ECU7) and SAM module.
13.14. PERKINS
It is suitable for ADEM3/ ADEM4 engine control module. Engine type is 2306, 2506, 1106, and 2806.
Table 33 Connector
13.15. SCANIA
It is suitable for S6 engine control module. Engine type is DC9, DC12, and DC16.
Table 34 B1 Connector
It is suitable for engine types TD520, TAD520 (optional), TD720, TAD720 (optional), TAD721,
TAD722, and TAD732.
Table 37 Connector
It is suitable for Volvo Engine types: TAD734, TAD940, TAD941, TAD1640, TAD1641, and TAD1642.
13.19. YUCHAI
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