HGM410-420

HGM400 Automatic Genset Controller

(HGM410/HGM420)

USER MANUAL

Smartgen Technology

Chinese trademark

English trademark

Smartgen make your generator smart

Smartgen Technology Co., Ltd.

No. 28 Jinsuo Road

Zhengzhou City

Henan Province

P. R. China

Tel: +86-371-67988888/67981888

+86-371-67991553/67992951

+86-371-67981000(overseas)

Fax: 0086-371-67992952

Web: http://www.smartgen.com.cn

http://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.

Smartgen Technology reserves the right to change the contents of this document

without prior notice.

Software Version

Date Version Note

2011-07-06 1.0 Original release.

2012-03-15 1.1 Modify typical application.

2012-10-30 1.2 Modify some details.

HGM400 Series Automatic Control Module

HGM400 Series Genset Controller ISSUE 2012-10-30 Version 1.2 Page 3 of 30

This manual is suitable for HGM400 series controller only.

Clarification of notation used within this publication.

SYMBOL INSTRUCTION

NOTE

Highlights an essential element of a procedure to ensure

correctness.

CAUTION!

Indicates a procedure or practice, which, if not strictly observed,

could result in damage or destruction of equipment.

WARNING!

Indicates a procedure or practice, which could result in injury to

personnel or loss of life if not followed correctly.



Table of Contents

1 SUMMARY.................................................................................. 5

2 PERFORMANCE AND CHARACTERISTICS ............................. 5

3 SPECIFICATION ......................................................................... 6

4 OPERATION ............................................................................... 7

4.1 PANEL KEYS ........................................................................................... 7

4.2 PANEL DESCRIPTION ............................................................................ 8

4.3 AUTOMATIC START/STOP OPERATION ............................................... 8

4.4 MANUAL START/STOP OPERATION ................................................... 10

5 PROTECTION .......................................................................... 10

5.1 WARNINGS ........................................................................................... 10

5.2 SHUTDOWN ALARM ............................................................................. 11

6 CONNECTIONS ....................................................................... 13

7 DEFINITION AND RANGE OF PARAMETERS ......................... 15

7.1 PARAMETER CONTENTS AND RANGE (TABLE 1) ............................. 15

7.2 PROGRAMMABLE OUTPUT 1-5 (TABLE 2) ......................................... 20

7.3 PROGRAMMABLE INPUT 1-4 TABLE (ACTIVE WHEN CONNECT GND (B-)

(TABLE 3) ...................................................................................................... 21

7.4 SENSOR SELECT (TABLE 4) ............................................................... 22

7.5 CONDITIONS OF CRANK DISCONNECT (TABLE 5) ........................... 22

8 PARAMETERS SETTING ......................................................... 23

9 SENSOR SELECT .................................................................... 24

10 COMMISSIONING .................................................................... 25

11 TYPICAL APPLICATION ........................................................... 26

12 INSTALLATION ......................................................................... 28

12.1 FIXING CLIPS ....................................................................................... 28

12.2 OVERALL DIMENSION AND PANEL CUTOUT ..................................... 29

13 FAULT FINDING ....................................................................... 30



1 SUMMARY

HGM400 series automatic controller, integrating digital, intelligent and network

techniques, is used for automatic control system of generator. It can achieve automatic

start/stop, data measuring and three remote functions (SG485 module is needed).

The controller uses LCD display, optional Chinese, English, Spanish and Russian

display interface with easy and reliable operation.

HGM400 series automatic controller uses micro-processing technique which can carry

out precision measuring, constant value adjustment, timing and threshold setting and

etc.. All the parameters can be adjusted from front panel or through programmable

interface (USB to LINK, can use SG72 adaptor) via PC. It can be widely used in all

types of generator automatic control system for compact structure, simple connections

and high reliability.

2 PERFORMANCE AND CHARACTERISTICS

HGM400 series controller has two variants:

HGM410: Automatic Start Module, it controls generator to start/stop by remote start

signal;

HGM420: Based on HGM410, add mains AC monitoring, mains/generator automatic

switching control (AMF), especially suitable for automatic control system composed by

mains and generator.

132x64 LCD with backlight, optional language interface (Chinese, English, Spanish

and Russian), push-button operation;

Adapt to 3 phase 4 wire, single phase 2 wire, 3 phase 3 wire and 2 phase 3 wire

(120/240V), 50/60Hz power supply;

Can measure and display 3-phase voltage, 3-phase current, frequency, and power;

Mains Generator

Line Voltage (Uab, Ubc, Uca) Line Voltage (Uab, Ubc, Uca)

Phase Voltage (Ua, Ub, Uc) Phase Voltage (Ua, Ub, Uc)

Frequency (HZ) Frequency (HZ)

Load

Current (IA, IB, IC)

Active Power (KW)

Reactive Power (KVar)

Apparent Power (KVA)

Power Factor (PF)

Accumulated Energy (kWh)

For mains: Over/under voltage, lack of phase; for generator: over/under voltage,

over/under frequency, over current;

Precision measure and display engine parameters,



Temperature (WT), C/ F both are display

Oil pressure (OP), kPa/Psi/Bar all be display

Speed (SPD), RPM (unit)

Voltage of Battery (VB) V (unit)

Voltage of Charger (VD) V (unit)

Hours counter (HC): Max. 999999 hours.

Start times: Max.999999 times.

Control protection: Automatic start/stop, switch on/off (ATS control) and fault

display;

With ETS, idle control, pre-heat control, acceleration and deceleration control, all

are relay output;

Parameters setting: Allow user to modify parameters and store them in internal

FLASH, which cannot be lost even when power off. All the parameters can be

adjusted from the front panel, or by PC via an SG72 adaptor;

Types of temperature and pressure sensor can be directly used and user defined;

Conditions of crank disconnect can be selected.(magnetic pickup, oil pressure,

generator);

Power supply range is (8~35)VDC, accommodating to different starting voltage;

All parameters use digital modulation, abandoning analog modulation of

conventional potentiometer, more reliability and stability;

Modular design, flame retardant ABS shell, plug-in terminals, embedded mounting,

compact structure, easy installation.

3 SPECIFICATION

Items Contents

Working Voltage DC8.0V to 35.0V, continuous

Power Consumption



Programmable Relay Output 3 5A DC28V power supply

Programmable Relay Output 4 5A AC250V voltage-free output

Programmable Relay Output 5 5A AC250V voltage-free output

Overall Dimensions 130mm x 112mm x 39mm

Panel Cutout 110mm x 90mm

CT Secondary Current 5A (rated )

Working Condition Temperature: (-25~70)C;

Humidity: (20~93)%RH

Storage Condition Temperature: (-30~+80)C

Protection Level

IP55: when waterproof rubber gasket added

between controller and its panel.

IP42: when waterproof rubber gasket not added

between controller and its panel.

Insulation Intensity

Object: among in input/output/power

Quote standard: IEC688-1992

Test way: AC1.5 kV/1min 3mA leakage current

Weight 0.26kg

4 OPERATION

4.1 PANEL KEYS

Stop/ Reset

Can stop generator under Manual/Auto mode;

Can reset shutdown alarm;

Pressing this key at least 3 seconds can test panel

indicators (Lamp Test),;

During stopping process, pressing this again can stop

generator immediately.

Start To start genset under Manual or Manual Test mode.

Manual

Pressing this key will set the module into manual mode.

Pressing this and up key can adjust LCD contrast.

Automatic Pressing this key will set the module into auto mode.

Set/Confirm

Enter into Set menu after pressing this key;

Shift cursor to confirm.

Up/Increase

Turning pages up;

In parameter setting, shift cursor and increase values.



Down/Decrease

Turning pages down;

In parameter setting, shift cursor and decrease values.

4.2 PANEL DESCRIPTION

HGM410 Panel Indicators

HGM420 Panel Indicators

4.3 AUTOMATIC START/STOP OPERATION

This mode is activated by pressing . LED indicator beside the key is illuminating



which confirms this action.

Start Sequence,

1) HGM420: when mains is abnormal (over/under voltage, lack of phase), enter into

Mains Abnormal Delay and LCD displays count-down timer. When the delay is

over, Start Delay begins.

2) HGM410: genset enters into Start Delay when Remote Start is active.

3) Count- down timer of Start Delay is displayed in LCD.

4) When start delay is over, preheat relay is outputting (if configured), Preheat Delay

XX s is displayed in LCD.

5) When preheat delay is over, fuel relay is outputting 1s and then start relay outputs; if

genset failed to start during Start Time, fuel and start relays stop outputting and

enter into Crank Rest Time and wait for next cranking.

6) If genset failed to start within specified start times, the fourth line of LED will turn

black and Fail to Start alarm will be displayed.

7) Whatever time to start successfully, genset will enter into Safety on Run Time.

During this period, alarms of low oil pressure, hi-temperature, under speed, charge

failure and auxiliary input (be configured) are disabled. As soon as this delay is over,

genset will enter into Start Idle Delay (if configured).

8) During start idle delay, alarms of under speed, under frequency, under voltage are

disabled. As soon as this delay is over, genset will enter into Warming Up Delay (if

configured).

9) When Warming Up Delay is over, the indicator is illuminating if gens normal. If

engine voltage and frequency reach the load demand, closing relay outputs, genset

takes load and indicator illuminates; if engine voltage and frequency appear

abnormal, controller will alarm to shutdown (alarm is displayed in LCD).

Stop Sequence,

1) HGM420: during genset running, if mains normal, enters into Mains Normal Delay.

When mains indicator illuminates, Stop Delay begins.

2) HGM410: genset enters into Stop Delay when Remote Start is inactive.

3) When stop delay is over, genset enters into Cooling Delay. Gens closing relay is

open. After switch Transfer Rest Delay, mains closing relay outputs, mains will take

load, power indicator of gens eliminates while indicator of gens illuminates.

4) When entering Stop Idle Delay (if configured), Idle relay is energized to output.

5) When entering ETS delay, ETS relay is energized to output, fuel relay is open.

6) When entering Genset at Rest, automatically judge whether genset is stopped or



not.

7) When genset has stopped, enters into standby mode; if failed to stop, controller will

alarm (Fail to Stop alarm will be displayed in LCD).

4.4 MANUAL START/STOP OPERATION

1) HGM420: Manual Mode is activated when press and its indicator illuminates.

Press key, choose Manual Test Mode. Under the two modes, press key to

start genset, it can automatically judge crank disconnect and accelerate to hi-speed

running. If high temperature, low oil pressure, over speed and abnormal voltage

occur during genset running, controller can effectively protect genset to stop (detail

procedures please refer to No.4~9 of Auto start operation). Under Manual Mode ,

if mains normal, load switch wont transfer; if mains abnormal, load switch will transfer

to gens. Under Manual Test Mode, after genset normally runs in high speed, no

matter mains normal or not, load will be transferred to gens.

2) HGM410: Manual Mode is activated when press key and its indicator illuminates.

Then press key to start generator, it can automatically judge crank disconnect and

accelerate to hi-speed running. If hi-temperature, low oil pressure, over speed and

abnormal voltage occur during genset running, controller can effectively protect

genset to stop (detail procedures please refer to No.4~9 of Auto start operation).

Controller will send closing signal when genset runs in high speed.

3) Manual stop: pressing key can shut down the running genset. (detail procedures

please refer to No.3~7 of Auto stop operation)

5 PROTECTION

5.1 WARNINGS

When controller detects the warning signal, only alarm and not stop genset. The alarms

are displayed in LCD.

Warnings as following,

No. Items Description

1 High

Temperature

When controller detected the temperature is higher than

preset and shutdown is prohibited, it will send a stop alarm

signal and it will be displayed in LCD.



2 Low Oil

Pressure

When controller detected oil pressure is lower than the

preset and shutdown is prohibited, it will send a stop alarm


3 Gens Over

Current

When controller detected genset current is over the preset

and delay value is more than preset, it will send a stop alarm


4 Fail To Stop

When generator cannot stop after the stop delay/ETS

delay, controller will send warning alarm signal and it will be

displayed in LCD.

5 Low Fuel Level

When controller detected the Low Fuel Level input is active,

controller will send warning alarm signal and it will be

displayed in LCD.

6 Charge Failure

When controller detected the charger voltage is lower than

threshold, controller will send warning alarm signal and it will

be displayed in LCD.

7 Battery Low

Voltage

When controller detected the battery voltage is lower than



8 Battery Over

Voltage

When controller detected the battery voltage is higher than



9 Auxiliary

Warning

When controller detected the input port external warning is

active, controller will send warning alarm signal and it will be

displayed in LCD.

10 Loss Of Speed

Signal

When controller detected engine speed is 0 (the delay is 0),

a warning alarm signal will be sent and displayed in LCD.

11 Low Coolant

Level

When controller detected the low coolant level input is active,

controller will send warning alarm signal and it will be

displayed in LCD.

12 Temp. Sensor

Open

When temperature sensor opens circuit and the input is

active, controller will send a stop alarm signal and it will be

displayed in LCD.

13 Oil Pressure

Sensor Open

When oil pressure sensor opens circuit and the warning

input is active, controller will send warning alarm signal and it

will be displayed in LCD.

5.2 SHUTDOWN ALARM

When controller detected shutdown alarm, it will send signal to open switch and stop the

unit. The alarms are displayed in LCD.

No Items Description

1 Auxiliary

Shutdown

When controller detected the input port external warning is

active, controller will send shutdown alarm signal and it will





2 High

Temperature

When controller detected the temperature of water/cylinder

is higher than preset, it will send a stop alarm signal and it

will be displayed in LCD.

3 Low Oil

Pressure

When controller detected oil pressure is lower than the

preset, it will send a stop alarm signal and it will be displayed

in LCD.

4 Over Speed When controller detected genset speed is over the preset, it

will send a stop alarm signal and it will be displayed in LCD.

5 Under Speed When controller detected genset speed is under the preset, it


6 Loss Of Speed

Signal

When controller detected genset speed is 0 (the delay is not

0), it will send a stop alarm signal and it will be displayed in

LCD.

7 Gens Over

Voltage

When controller detected genset voltage is over the preset, it


8 Gens Under

Voltage

When controller detected genset voltage is under the preset,

it will send a stop alarm signal and it will be displayed in

LCD.

9 Gens Over

Current

When controller detected genset current is over the preset

and delay is not 0, it will send a stop alarm signal and it will


10 Fail To Start During the start attempt times, if genset start failed, it will

send a stop alarm signal and it will be displayed in LCD.

11 Over Frequency

When controller detected genset frequency is over the


in LCD.

12 Under

Frequency

When controller detected genset frequency is under the


in LCD.

13 Genset Failed When controller detected genset frequency is 0, it will send a

stop alarm signal and it will be displayed in LCD

14 Low Fuel Level

When controller detected genset fuel level low input is active,

it will send a stop alarm signal and it will be displayed in

LCD.

15 Low Liquid

Level

When controller detected genset water level low input is

active, it will send a stop alarm signal and it will be displayed

in LCD.

16 Temp. Sensor

Open

When temperature sensor opens circuit and the input is

active, controller will send a stop alarm signal and it will be

displayed in LCD.

17 Oil Pressure When oil pressure sensor opens circuit and the input is




Sensor Open active, controller will send a stop alarm signal and it will be

displayed in LCD.

6 CONNECTIONS

Compared with HGM420, HGM410 is lack of a 3 phase AC input terminal of mains.

The rear panel of HGM410 and HGM420 is as below.

Description of terminal connections:

Pin Function Cable Size

Description

1 DC Power Supply B- 1.5mm2 Connect battery negative.

2 DC Power Supply B+ 1.5mm2

Connect battery positive. If longer than

30m, parallel connection with 2 cables.

Recommend using maximum 20A fuse.

3 Programmable Relay

Output 1 1.0mm2

Plant Supply B+ from pin 2, 5 A rated.

4 Start Relay Output 1.0mm2 Plant Supply B+ from pin 2, 5 A rated.

Connect starting coil.


Output 2 1.0mm2 Plant supply B+ from pin 2, 5 A rated.


Output 3 1.0mm2 Plant supply B+ from pin 2, 5 A rated.

7 Auxiliary Input 1 1.0mm2 Connect to GND (B-) See Table 3

8 Auxiliary Input 2 1.0mm2 Connect to GND (B-)



Pin Function Cable Size

Description



11 Temperature Sensor

Input 1.0mm2

Connect a temperature

resistance sensor. See Table 4

12 Oil Press Sensor Input 1.0mm2 Connect to a pressure

resistance sensor.

13 CT A Phase Sensing 1.5mm2 Connect current transformer secondary

coil (rated 5A)

14 CT B Phase Sensing 1.5mm2 Connect current transformer secondary

coil (rated 5A)

15 CT C Phase Sensing 1.5mm2 Connect current transformer secondary

coil (rated 5A)

16 CT Common 1.5mm2 See INSTALLATION in the manual.

17 Speed Sensor Input 0.5mm2

Connect magnetic pickup.

Recommend using screen.

Connect battery negative at one end.

18 Charger D+ Input 1.0mm2 Connect D+ terminal. If there is no, this

input remains Not Connect.


Output 4 1.0mm2

Terminal 19 and 21 are relay N/O contact,

rated 5A.


Output 5 1.0mm2

Terminal 20 and 21 are relay N/O contact,

rated 5A.

21 Common Port 1.5mm2 Common port of programmable relay

output 4 and 5.

22 Generator U Phase

Sensing 1.0mm2

Connect U phase of generator

Recommend 2A fuse

23 Generator V Phase

Sensing 1.0mm2

Connect V phase of generator

Recommend 2A fuse

24 Generator W Phase

Sensing 1.0mm2

Connect W phase of generator

Recommend 2A fuse

25 Generator N2 Output 1.0mm2 Connect neutral output of generator.

26 Mains R Phase

Sensing 1.0mm2

Connect R phase of mains

Recommend 2A fuse (HGM410 without)

27 Mains S Phase

Sensing 1.0mm2

Connect S phase of mains


28 Mains T Phase

Sensing 1.0mm2

Connect T phase of mains


29 Mains N1 Sensing 1.0mm2 Connect neutral line of mains

(HGM410 without)

NOTE: LINK interface is programmable interface for parameters that can be



programmed by PC via an SG72 adapter. If there is need to remote start the genset,

please use the SG485 module.

7 DEFINITION AND RANGE OF PARAMETERS

7.1 PARAMETER CONTENTS AND RANGE (TABLE 1)

No Items Range Default Description

1 Mains Normal

Delay (0-3600)s 10

Mains transient delay, suitable for

ATS (automatic transfer switch).

2 Mains Abnormal

Delay (0-3600)s 5

3 Mains Under

Voltage (30-620)V 184

When mains voltage is under the

point, Mains Under Voltage is

active. When the point is 30V, not

detect low voltage signal.

4 Mains Over

Voltage (30-620)V 276

When mains voltage is over the

point, Mains Over Voltage is

active. When the point is 620V,

not detect high voltage signal.

5 Transfer Rest

Time (0-99.9)s 1.0

Its the delay from mains is open

to gens closing or from gene

open to mains closing.

6 Start Delay (0-3600)s 1

Its the delay from remote start

signal is active or mains

abnormal, to start generator.

7 Stop Delay (0-3600)s 1

Its the delay from remote start

signal is inactive or mains

normal, to stop generator.

8 Start Times (1-10)times 3

Maximum start times, if failed to

start within the specified times,

controller will send Fail To Start

signal.

9 Preheat Time (0-300)s 0 Time to power the glow plug

before cranking.

10 Crank Time (3-60)s 8 The starter adds the time of the

electricity each time.

11 Crank Rest Time (3-60)s 10 Delay of waiting for another

cranking.




12 Safety Run On

Time (1-60)s 10

During this period, Low Oil

Pressure, High Temperature,

Under Speed, Under Frequency

and Charge Failure alarms are

inactive.

13 Start Idle Time (0-3600)s 0 Idle running time when starting.

14 Warm Up Time (0-3600)s 10 Delay for warming up before

closing.

15 Cooling Time (3-3600)s 10 Delay of cooling time before

stopping.

16 Stop Idle (0-3600)s 0 Idle running time when stopping.

17 ETS Solenoid

Hold (0-120)s 20

Its the delay for energizing to

stop.

18 Over Stop Delay (0-120)s 0

When set ETS solenoid hold as

0s, from idle delay over to over

stop timer; if not 0s, its from ETS

delay over to genset at rest.

19 Switching On (0-10)s 5.0

Pulse width of mains or closing

gens. When it is 0s, output is

continuous.

20 Flywheel Teeth (10-300) 118

Used for judging crank

disconnect and detecting rotating

speed. See INSTALLATION in

this manual.

21 Generator

Abnormal Delay (0-20.0)s 10.0

Gens high voltage and low

voltage alarm delay.

22 Generator Over

Voltage (30-620)V 264

When voltage is over the point,

Gens Over Voltage is active.

When the point is 620V, Gens

Over Voltage is disabled.

23 Generator Under

Voltage (30-620)V 196

When voltage is under the point,

Gens Under Voltage is active.

When the point is 30V, Gens

Under Voltage is disabled.

24 Under Speed (0-6000)RPM 1200

When engine speed is under the

point and holds for 10s, Gens

Under Speed is active.

25 Over Speed (0-6000)RPM 1710

When engine speed is over the

point and holds for 2s, Gens

Over Speed is active.




26 Under Frequency (0-75.0)Hz 45.0

When generator frequency is

lower than the point and holds for

10s, Gens Under Frequency is

active.

27 Over Frequency (0-75.0)Hz 57.0


over the point and holds for 2s,

Gens Over Frequency is active.

28 High Temperature (80-140)C 98

When engine temperature sensor

value is over this point, send

alarm signal. Active from end of

safety run on timer. When the

value is 140, high temperature

alarm is disabled. (only suitable

for temperature sensor)

29 Low Oil Pressure (0-400)kPa 103

When engine oil pressure sensor

value is under this point, send

alarm signal. Active from end of

safety run on timer. Low oil

pressure alarm is disabled. (only

suitable for oil pressure sensor)

30 Loss of Speed

Signal (0-20.0)s 5.0

If set the delay as 0, only warn

not to stop the generator.

31 Charge Failure (0-30)V 6.0

During generator is running,

when alternator WL/D+ voltage is

under this point and remains for

5s, generator will send shutdown

alarm.

32 Battery Over

Voltage (12-40)V 33.0

When battery voltage is over the

point and holds for 20s, Battery

Over Voltage is active. Its a

warning alarm.

33 Battery Under

Voltage (4-30)V 8.0

When generator battery voltage

is under the point and holds for

20s, Battery Under Voltage is

active. Its a warning alarm.

34 CT Rate (5-6000)/5 500 Current transformer rate

35 Full Load Current (5-6000)A 500 Maximum rated current, used for

calculating over current.

36 Over Current

Percentage (50-130)% 120

When the load current is over the

point, over current delay begins.




37 Over Current

Delay (0-3600)s 1296

When load current is over the

pre-set value, over current is

initiated. When set delay timer as

0, only warning no shutdown,

38 Digital Output 1 (0-17) 14 Factory default: Fuel Relay

Output

39 Digital Output 2 (0-17) 2 Factory default: Energized To

Stop

40 Digital Output 3 (0-17) 3 Factory default: Idle Control

41 Digital Output 4 (0-17) 5 Factory default: Gens Closed

42 Digital Output 5 (0-17) 6 Factory default: Mains Closed

43 Auxiliary Input 1 (0-15) 1 Factory default: High

Temperature Alarm

44 Auxiliary Input 1

Active (0-1) 0 Factory default: Closed


Delay (0-20.0)s 2.0

46 Auxiliary Input 2 (0-15) 2 Factory default: Low Oil Pressure

Alarm




Delay (0-20.0)s 2.0

49 Auxiliary Input 3 (0-15) 10 Factory default: Remote Start




Delay (0-20.0)s 2.0

52 Auxiliary Input 4 (0-15) 11 Factory default: Low Fuel Level

Warn




Delay (0-20.0)s 2.0

55 Module Mode (0-2) 0

0: Stop Mode

1: Manual Mode

2: Auto Mode

56 Module Address (1-254) 1 Communication address of

controller.

57 Passwords (0-9999) 1234




58 Crank Disconnect (0-5) 2

Conditions of crank disconnect

includes gens, magnetic pickup

and oil pressure which make

starter separate with engine.

See Table 5

59 Engine Speed (0-3000)RPM 360 When engine speed is over this

point, starter will disconnect.

60 Engine

Frequency (10.0-30.0)Hz 14.0


over this point, starter will

disconnect.

61 Engine Oil Press (0-400)kPa 200 When engine oil pressure is over

this point, starter will disconnect.

62 High Temp. Inhibit (0-1) 0

Factory default: when the

temperature is too high, alarm to

shutdown. Note 1.

63 Low OP Inhibit (0-1) 0

Factory default: when oil

pressure is lower, alarm to

shutdown. Note 2

64 Voltage Input (0-3) 0 0: 3P4W; 1:2P3W

2:1P2W; 3: 3P3W Note 3

65 Temp. Sensor

Select (0-9) 08 SGX

66 Pressure Sensor

Select (0-9) 08 SGX

67 Number Of Poles (2-32) 4

68 Temperature

Sensor Open (0-2) 1

0: Indication (temperature sensor

will show +++);

1:Warning; 2:Shutdown

69 Oil Pressure

Sensor Open (0-2) 1

0: Indication (oil pressure sensor

will show +++);

1:Warning; 2:Shutdown

70 Defined Sensor

Curve (0-1) 0

Temperature and oil pressure

sensor curve can be defined.

Note 1, if high temperature stop inhibit is configured, or set programmable input

as high temperature stop inhibit and this input is active, when temperature is higher

than preset, or high temperature alarm input is active, controller will send warning

signal only and not stop unit.

Note 2, if low oil press stop inhibit is configured, or set programmable input as

low oil press stop inhibit and this input is active, when oil pressure is lower than



preset, or low oil pressure alarm input is active, controller will send warning signal only

and not stop unit.

Note 3, if 3P3W is selected, maximum shutdown threshold of Mains Over

Voltage and Gens Over Voltage can be 620V; when select others, maximum

shutdown threshold can be 360V. .

7.2 PROGRAMMABLE OUTPUT 1-5 (TABLE 2)


0 Not Used

1 Common Alarm

Including all shutdown alarms and warning alarms.

When there is warning alarm only, it is not self-lock;

when a shutdown alarm occurs, it is self locking until

the alarm is reset.

2 ETS Solenoid Hold

Suitable for genset with electromagnet and will pick up

after stop idle delay. The output will remain energized

until engine has come to a complete stop, then

de-energizes.

3 Idle Control

The designated programmable output relay will

energize when the idle delay is not zero. The output

contact would typically be connected to the idle/run

input control of an electronic governor.

4 Preheat Control

The designated programmable output relay will

energize until the engine receive a crank success

signal. The preheat output is typically used for an

engine starting aid such as glow plugs.

5 Close Generator When closing time is 0, its continuous output.

6 Close Mains When closing time is 0, its continuous output.

(HGM410 without)

7 Switching Off When closing time is 0, its disabled.

8 Acceleration Control Pull-in during warm-up delay. Open when auxiliary

acceleration input is active.

9 Deceleration Control

Pull-in when entering stop idle or ETS solenoid

process, (alarm to shutdown). Open when auxiliary

deceleration input is active.

10 Genset Run

Outputting when genset in normal running and

disconnect when rotating speed is under engine speed

after started.

11 Fuel Pump Control Close when fuel level is lower than the set threshold;

open when low fuel level warning input is inactive.

12 High Speed Control Outputting when entering into Warming Up and

disconnect when Cooling Down is over.




13 System In Auto

Mode The controller work in automatic mode.

14 Fuel Relay Output To control fuel relay output.

15 Reserved

16 Reserved

17 Reserved

7.3 PROGRAMMABLE INPUT 1-4 TABLE (ACTIVE WHEN CONNECT GND (B-) (TABLE 3)


0 Not Used

1 High Temp. Alarm When safety on run delay is over, if the signal is active,

generator will immediately alarm to shutdown. 2 Low OP Alarm

3 Auxiliary Alarm If the input is active, only warning, no shutdown.

4 Auxiliary Shutdown If the input is active, stop the genset immediately.

5 Coolant To Stop

During engine running, if the engine temperature is too

high, the controller will stop the unit after cooling delay;

when the input is inactive, controller will stop the unit

immediately.

6 Generator Closed

7 Mains Closed HGM410 without

8 High Temp. Stop

Inhibit

When it is active, prohibit stopping when high

temperature occurs. Note 1

9 Low Oil Pressure

Stop Inhibit

When it is active, prohibit stopping when oil low

pressure occurs. Note 2

10 Remote Start Input HGM420 without

11 Low Fuel Level

Warn

12 Low Liquid Level

Warn

13 Low Fuel Level

Shutdown

14 Low Liquid Level

Shutdown

15 Auto Start Inhibit

In Auto mode, if this input is active, when mains failure

(HGM420) or a remote start signal occurs (HGM410),

the controller will not give a start command to the

generator. If generator is running, stop command wont

be executed. When this input is inactive, genset will

automatically start or stop according to the mains

normal or abnormal.



7.4 SENSOR SELECT (TABLE 4)

No Content Description

1 Temperature

Sensor

0 Not used

1 Defined Res. Type

2 VDO

3 SGH(Huanghe sensor)

4 SGD(Dongkang sensor)

5 CURTIS

6 DATCON

7 VOLVO-EC

8 SGX

9 Reserved

Defined input resistance

range is (0~6000).

Factory default is SGX.

2 Pressure

Sensor

0 Not used

1 Defined Res. Type

2 VDO 10Bar

3 SGH(Huanghe sensor)

4 SGD(Dongkang sensor)

5 CURTIS

6 DATCON

7 VOLVO-EC

8 SGX

Defined input resistance

range is (0~6000).

Factory default is SGX.

7.5 CONDITIONS OF CRANK DISCONNECT (TABLE 5)

No Content

0 Magnetic pickup

1 Generator

2 Magnetic pickup + Generator

3 Magnetic pickup + Oil pressure

4 Generator + Oil pressure

5 Generator + Magnetic pickup + Oil pressure

1) The crank disconnect condition has three kinds, the magnetic pickup and the

generator voltage can be used alone, oil pressure must be used with the magnetic

pickup and the generator voltage, in order to make the starter disconnect as soon

as possible.

2) Magnetic pickup is installed in the engine for testing flywheel.

3) When choosing magnetic pickup, ensure the number of flywheel teeth is same as

the set, otherwise over speed or under speed shutdown may appear.

4) If the generator is not installed with magnetic pickup, please don't select



corresponding item.

5) If the generator has no oil pressure sensor, please don't choose corresponding.

6) If the generator is not selected, controller will not measure and display relative

parameters (This can be applied to the pump set), if not choose magnetic pickup,

the speed signal will come from the generating AC signal.

8 PARAMETERS SETTING

After controller powered on, press to enter into the parameters setting menu, see fig 1

below:

Set Parameters

When entering password interface, inputting 1234 can set part of the parameter

items in table 1; inputting 0318 can set all the items. (Table 1) If there is need to

set more parameters, please contact the factory.

NOTES:

1. For HGM410, there are no items from 1 to 5 in table 1; there are no digital outputs

about mains in auxiliary output 1-5.

2. Please modify the parameters (such as crank disconnection, auxiliary input/output

and various timers) in standby mode, otherwise alarm to shutdown or other

abnormal conditions may happen.

3. The over-voltage threshold must be greater than the under-voltage threshold;

otherwise over-voltage and under-voltage will occur at the same time.

4. The over-speed threshold must be greater than under-speed threshold, otherwise

over speed and under speed will occur at the same time.

5. Set the frequency (crank disconnect) as low as possible, in order to separate the

starter quickly when crank disconnect.

6. Auxiliary input 1-4 cannot be set as the same item, or will cause incorrect functions.

But auxiliary output 1-5 can be set as the same item.

7. If need to shut down after cooling, please set any auxiliary input as Coolant To

1 Set Parameters

2 Information

3 Set Language

4 Mode Select

Fig1



Stop, then connect this input to GND.

Information

LCD will display software version, issue date of the controller.

Note: Pressing will display the states of digital inputs and outputs.

Set Language

Chinese, English, Spanish and Russian interface can be selected.

Mode Select

The controller can be set as Manual Test Mode, Manual Mode or Auto Mode.

Note: Pressing key at any time will quit the setting and return to the previous

setting menu.

9 SENSOR SELECT

1) When choosing sensor, standard of sensor curve will be needed. If set

temperature sensor as SGH (120C resistance type), sensor curve should be SGH

(120oC resistance type); If set as SGD (120C resistance type), sensor curve

should be SGD curve.

2) If there is difference between standard sensor curve and chosen sensor, select

"defined sensor", and then input defined sensor curve.

3) When inputting sensor curve, X value (resistance) must be in accordance with the

order of higher to lower, otherwise errors will occur.

4) When select sensor "Not used", temperature, pressure and fuel level will be

display as" - - -" in LCD.

5) If there is no pressure sensor, but only has low pressure alarm switch, then you

must set pressure sensor as "Not used", otherwise oil pressure low alarm

shutdown may appear.

6) Can set several points of forehand or backmost as the same ordinate, like the

following picture:



Common unit conversion table

1N/m2 (pa) 1kgf/cm2 1bar (1b/in2) psi

1Pa 1 1.02x105 1x10

5 1.45x104

1kgf/cm2 9.8x104 1 0.98 14.2

1bar 1x105 1.02 1 14.5

1psi 6.89x103 7.03x102 6.89x10

2 1

10 COMMISSIONING

Before operation, the following checking should be carried out:

1) Check and ensure all the connections are correct and wires diameter is suitable.

2) Ensure that the controller DC power has insurance; battery positive and negative

have correctly connected.

3) Take proper actions to prevent engine to disconnect crank (for example, to remove

the connections of fuel value). If checking is OK, connect start battery, select Manual

Mode, controller will execute the program.

4) Set controller as Manual Mode, press start button to start genset. If failed within the

setting crank times, controller will send Failed to Start signal; then press Reset to

reset controller.

5) Recover actions of preventing engine to disconnect crank (e. g. Connect wire of fuel

value), press start button again, genset will start. If everything goes well, genset will

normal run after idle running (if configured). During this period, watch for engines

running situations and voltage and frequency of alternator. If abnormal, stop genset

and check all connections according to this manual.

6) Select the Auto Mode from front panel, connect to mains signal. After the mains



normal delay, controller will transfer ATS (if configured) and into mains load. After

cooling, controller will stop genset and into standby state until mains abnormal again.

7) When mains abnormal again, genset will start automatically and into normal running,

send signal to make gens close, transfer ATS and make genset take load. If not like

this, please check connections of ATS according to this manual.

8) If there are any other questions, please contact our technical personnel.

11 TYPICAL APPLICATION

HGM410 Typical wiring diagram



HGM420 Typical wiring diagram

Single Phase 2 Wire (HGM420)

2 Phase 3 Wire (HGM420)

CAUTION! Recommend expanding relay with high capacity in start and fuel

output.



CAUTION! Use expansion relay in mains/gens closing outputs.

CAUTION! Let its normally closed contact series connect between fuel relay

output port and electromagnetic valve when you connect emergency stop button on

the controller. Emergency stop alarm can be displayed if you configure a input port as

external stop input (one end connect to normally open contact, the other end connect

to ground).

12 INSTALLATION

12.1 FIXING CLIPS

The module is held into the panel fascia using the supplied fixing clips.

1) Withdraw the fixing clip screw (turn anticlockwise) until it reaches proper position.

2) Pull the fixing clip backwards (towards the back of the module) ensuring four clips

are inside their allotted slots.

3) Turn the fixing clip screws clockwise until they make contact with the panel.

Note: Care should be taken not to over tighten the screws of fixing clips.



12.2 OVERALL DIMENSION AND PANEL CUTOUT

1) Battery Voltage Input

HGM400 series controller can be applicable to (8-35) VDC battery voltage. Battery

negative must be reliably connected engine shell. The connection between

controller power and battery should not be less than 1.5mm2, if a float charger is

fitted, please directly connect output line of the charger with battery, then from

battery positive and negative separately connect power input, in case that charger

will interfere with the normal running of controller.

2) Speed Sensor Input

Speed sensor is installed in the engine for testing flywheel teeth. The connection

with controller uses 2-core screen, shield layer should connect terminal1 of

controller with the other end vacant. The other two signal lines are respectively

connected to terminal 1 and terminal 17. At full speed, output voltage range is

1-24VAC (RMS). Recommend using 12VAC (rated speed) voltage. During

installing, make the speed sensor contact the flywheel firstly, then pour out 1/3

laps, finally lock nut on the sensor.

3) Output And Expansion Relay

All outputs of the controller are relay contact outputs, if expansion relay is needed,

please add free-wheeling diode at both ends of the relay coil (expansion relay coil

links DC) or increase RC loop (expansion relay coil links AC) in order to prevent

from interfering controller or other equipment.

4) AC Input

HGM400 series controller must externally connect current transformer, CT



secondary current must be 5A. Besides, the phase of CT and input voltage must

be correct, or the sampling current and active power may be incorrect.

CAUTIONICOM must connect battery anode of the controller.

WARNING! When there is load current; the CT secondary side cannot open

circuit.

5) Withdraw Voltage Test

When the controller has been installed in the control panel, during the test please

disconnect all the terminals, lest high voltage damages the controller.

13 FAULT FINDING

Symptom Possible Remedy

Controller inoperative

Check starting battery;

Check connections of the controller;

Check the DC fuse.

Genset stops

Check if water/cylinder temperature too high.

Check alternator voltage.

Check the DC fuse.

Emergency shutdown

Check if an emergency stop button is fitted; Ensure

battery positive is connected to the emergency stop

input.

Check if connection is open circuit.

Low oil Pressure alarm

(after crank success) Check oil pressure sensor and connections.

High Temp. alarm (after

crank success) Check temperature sensor and connections.

Shutdown Alarm During

Running

Check switch and connections according to information

on LCD.

Check configuration inputs.

Crank Not Disconnect

Check connections of fuel solenoid.

Check starting battery.

Check speed sensor and its connections.

Refer to engine manual.

Starter Inoperative Check connections of starter;

Check starting battery.

Genset Running but ATS

Not Transfer

Check ATS;

Check connections between ATS and controller.

Date post:	25-Nov-2015
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HGM410-420

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