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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
Henan Province
P. R. China
Tel: +86-371-67988888/67981888
+86-371-67991553/67992951/67992952
+86-371-67981000(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.
Smartgen Technology reserves the right to change the contents of this document
without prior notice.
Software Version
Date
Version
2011-07-06
1.0
2012-03-15
1.1

Note
Original release.
Modify typical application.

HGM400 Series Automatic Control Module

This manual is suitable for HGM400 series controller only.


Clarification of notation used within this publication.
SYMBOL

INSTRUCTION
Highlights an essential element of a procedure to ensure
NOTE
correctness.
Indicates a procedure or practice, which, if not strictly observed,
CAUTION! could result in damage or destruction of equipment.

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


WARNING! personnel or loss of life if not followed correctly.

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HGM400 Series Automatic Control Module

Table of Contents
1

SUMMARY....................................................................................5

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

SPECIFICATION ..........................................................................6

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

PROTECTION ............................................................................10
5.1 WARNINGS ............................................................................................ 10
5.2 SHUTDOWN ALARM...............................................................................11

CONNECTIONS .........................................................................12

DEFINITION AND RANGE OF PARAMETERS .........................14


7.1 PARAMETER CONTENTS AND RANGE (TABLE 1) ............................. 14
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) ................................................................ 21
7.5 CONDITIONS OF CRANK DISCONNECT (TABLE 5) ........................... 22

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

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

10 COMMISSIONING ......................................................................25
11 TYPICAL APPLICATION.............................................................26
12 INSTALLATION ...........................................................................27
12.1 FIXING CLIPS ......................................................................................... 27
12.2 OVERALL DIMENSION AND PANEL CUTOUT ..................................... 28

13 FAULT FINDING .........................................................................29


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HGM400 Series Automatic Control Module

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
Line Voltage (Uab, Ubc, Uca)
Phase Voltage (Ua, Ub, Uc)
Frequency (HZ)

Generator
Line Voltage (Uab, Ubc, Uca)
Phase Voltage (Ua, Ub, Uc)
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,
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HGM400 Series Automatic Control Module

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

<3W(Standby mode: 2W)

AC voltage Input:
3 Phase 4 Wire
2 Phase 3 Wire
Single phase 2 Wire
3 Phase 3 Wire

15V AC - 360 VAC (ph-N)


15V AC - 360 VAC (ph-N)
15V AC - 360 VAC (ph-N)
30V AC - 620 VAC (ph-ph)

Alternator Frequency

50Hz/60 Hz

Speed Sensor Voltage

1.0V to 24V (effective value)

Speed Sensor Frequency

10,000 Hz (max)

Start Relay Output

5A DC28V power supply

Programmable Relay Output 1

5A DC28V power supply

Programmable Relay Output 2

5A DC28V power supply

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HGM400 Series Automatic Control Module

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;

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

Humidity: (20~93)%RH

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.


Pressing this key will set the module into manual mode.

Manual
Pressing this and up key
Automatic
Set/Confirm
Up/Increase
Down/Decrease

HGM400 Series Genset Controller

can adjust LCD contrast.

Pressing this key will set the module into auto mode.
Enter into Set menu after pressing this key;
Shift cursor to confirm.
Turning pages up;
In parameter setting, shift cursor and increase values.
Turning pages down;
In parameter setting, shift cursor and decrease values.
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HGM400 Series Automatic Control Module

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.


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HGM400 Series Automatic Control Module

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.
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HGM400 Series Automatic Control Module

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


Press

and its indicator illuminates.

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
Then press

key and its indicator illuminates.

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
Loss Of Speed When controller detected engine speed is 0 (the delay is 0),
1
Signal
a warning alarm signal will be sent and displayed in LCD.
When controller detected gens current above the pre-set
Gens
Over
2
value (the delay is 0), a warning alarm initiates and displayed
Current
in LCD.
3 Fail To Stop
When generator cannot stop after the stop delay, controller
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HGM400 Series Automatic Control Module

No

Items

Low Fuel Level

Charge Failure

Battery
Voltage

Under

Battery
Voltage

Over

Low
Level

Liquid

Temp.
Open

Sensor

10

Oil
Press
Sensor Open

Description
will send warning alarm signal and it will be displayed in
LCD.
When controller detected the fuel level is lower than
threshold, controller will send warning alarm signal and it will
be displayed in LCD.
When controller detected the charger voltage is lower than
threshold, controller will send warning alarm signal and it will
be displayed in LCD.
When controller detected the battery voltage is lower than
threshold, controller will send warning alarm signal and it will
be displayed in LCD.
When controller detected the battery voltage is higher than
threshold, controller will send warning alarm signal and it will
be displayed in LCD.
When controller detected low water level input is active,
controller will send warning alarm signal and it will be
displayed in LCD.
When temperature sensor opens circuit and the warning
input is active, controller will send a warning alarm signal and
it will be displayed in LCD.
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
When controller detected emergency stop signal, it will send
1 Emergency Stop
a stop alarm signal and it will be displayed in LCD.
When controller detected the temperature of water/cylinder
High
2
is higher than preset, it will send a stop alarm signal and it
Temperature
will be displayed in LCD.
When controller detected oil pressure is lower than the
Low
Oil
3
preset, it will send a stop alarm signal and it will be displayed
Pressure
in LCD.
When controller detected genset speed is over the preset, it
4 Over Speed
will send a stop alarm signal and it will be displayed in LCD.
When controller detected genset speed is under the preset, it
5 Under Speed
will send a stop alarm signal and it will be displayed in LCD.
Loss Of Speed When controller detected genset speed is 0 (the delay is not
6
Signal
0), it will send a stop alarm signal and it will be displayed in
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HGM400 Series Automatic Control Module

No

Items

Description

Gens
Voltage

Over

Gens
Voltage

Under

Gens
Current

Over

10

Fail To Start

11

Over Frequency

12

Under
Frequency

13

Genset Failed

14

Low Fuel Level

15

Low
Level

Liquid

16

Temp.
Open

Sensor

17

Oil
Pressure
Sensor Open

LCD.
When controller detected genset voltage is over the preset, it
will send a stop alarm signal and it will be displayed in LCD.
When controller detected genset voltage is under the preset,
it will send a stop alarm signal and it will be displayed in
LCD.
When controller detected genset current is over the preset
and delay is not 0, it will send a stop alarm signal and it will
be displayed in LCD.
During the start attempt times, if genset start failed, it will
send a stop alarm signal and it will be displayed in LCD.
When controller detected genset frequency is over the
preset, it will send a stop alarm signal and it will be displayed
in LCD.
When controller detected genset frequency is under the
preset, it will send a stop alarm signal and it will be displayed
in LCD.
When controller detected genset frequency is 0, it will send a
stop alarm signal and it will be displayed in LCD
When controller detected genset fuel level low input is active,
it will send a stop alarm signal and it will be displayed in
LCD.
When controller detected genset water level low input is
active, it will send a stop alarm signal and it will be displayed
in LCD.
When temperature sensor opens circuit and the input is
active, controller will send a stop alarm signal and it will be
displayed in LCD.
When oil pressure sensor opens circuit and the input is
active, controller will send a stop alarm signal and it will be
displayed in LCD.

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.

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HGM400 Series Automatic Control Module

Description of terminal connections:


Cable
Pin
Function
Size
1
DC Power Supply B1.5mm2

Description
Connect battery negative.
Connect battery positive. If longer than
30m, parallel connection with 2 cables.
Recommend using maximum 20A fuse.
Plant Supply B+ from pin 2, 5 A rated.

DC Power Supply B+

1.5mm2

Programmable
Output 1

1.0mm2

Start Relay Output

1.0mm2

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


Connect starting coil.

Programmable Relay
Output 2
Programmable Relay
Output 3
Auxiliary Input 1
Auxiliary Input 2
Auxiliary Input 3
Auxiliary Input 4
Temperature
Sensor
Input

1.0mm2

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

1.0mm2

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

1.0mm2
1.0mm2
1.0mm2
1.0mm2

12

Oil Press Sensor Input

1.0mm2

13

CT A Phase Sensing

1.5mm2

Connect to GND (B-)


Connect to GND (B-)
See Table 3
Connect to GND (B-)
Connect to GND (B-)
Connect a temperature
resistance sensor.
See Table 4
Connect to a pressure
resistance sensor.
Connect current transformer secondary
coil (rated 5A)

5
6
7
8
9
10
11

Relay

HGM400 Series Genset Controller

1.0mm2

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HGM400 Series Automatic Control Module

Pin

Cable
Size

Function

Description

14

CT B Phase Sensing

1.5mm2

15

CT C Phase Sensing

1.5mm2

16

CT Common

1.5mm2
2

17

Speed Sensor Input

0.5mm

18

Charger D+ Input

1.0mm2

19
20
21
22
23
24
25
26
27
28
29

Programmable
Output 4
Programmable
Output 5

Relay

1.0mm2

Relay

1.0mm2

Common Port

1.5mm2

Generator U Phase
Sensing
Generator V Phase
Sensing
Generator W Phase
Sensing
Generator N2 Output
Mains
R
Phase
Sensing
Mains
S
Phase
Sensing
Mains
T
Phase
Sensing

1.0mm2

Mains N1 Sensing

1.0mm2

1.0mm2
1.0mm2
1.0mm2
1.0mm2
1.0mm2
1.0mm2

Connect current transformer secondary


coil (rated 5A)
Connect current transformer secondary
coil (rated 5A)
See INSTALLATION in the manual.
Connect magnetic pickup.
Recommend using screen.
Connect battery negative at one end.
Connect D+ terminal. If there is no, this
input remains Not Connect.
Terminal 19 and 21 are relay N/O contact,
rated 5A.
Terminal 20 and 21 are relay N/O contact,
rated 5A.
Common port of programmable relay
output 4 and 5.
Connect U phase of generator
Recommend 2A fuse
Connect V phase of generator
Recommend 2A fuse
Connect W phase of generator
Recommend 2A fuse
Connect neutral output of generator.
Connect R phase of mains
Recommend 2A fuse (HGM410 without)
Connect S phase of mains
Recommend 2A fuse (HGM410 without)
Connect T phase of mains
Recommend 2A fuse (HGM410 without)
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)

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HGM400 Series Automatic Control Module

No
1

Items
Mains
Delay
Mains
Delay

Range

Normal

Abnormal

Mains
Voltage

Under

Mains
Voltage

Over

Transfer
Time

Rest

(0-3600)s

Default
10

Mains transient delay, suitable for


ATS (automatic transfer switch).
(0-3600)s

(30-620)V

184

(30-620)V

276

(0-99.9)s

1.0

Start Delay

(0-3600)s

Stop Delay

(0-3600)s

Start Times

(1-10)times

Preheat Time

(0-300)s

10

Crank Time

(3-60)s

11

Crank Rest Time

(3-60)s

10

12

Safety
Time

(1-60)s

10

13

Start Idle Time

(0-3600)s

14

Warm Up Time

(0-3600)s

10

Run

On

Description

HGM400 Series Genset Controller

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When mains voltage is under the


point, Mains Under Voltage is
active. When the point is 30V, not
detect low voltage signal.
When mains voltage is over the
point, Mains Over Voltage is
active. When the point is 620V,
not detect high voltage signal.
Its the delay from mains is open
to gens closing or from gene
open to mains closing.
Its the delay from remote start
signal is active or mains
abnormal, to start generator.
Its the delay from remote start
signal is inactive or mains
normal, to stop generator.
Maximum start times, if failed to
start within the specified times,
controller will send Fail To Start
signal.
Time to power the glow plug
before cranking.
The starter adds the time of the
electricity each time.
Delay of waiting for another
cranking.
During this period, Low Oil
Pressure, High Temperature,
Under Speed, Under Frequency
and Charge Failure alarms are
inactive.
Idle running time when starting.
Delay for warming up before
closing.
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HGM400 Series Automatic Control Module

No

Items

Range

Default

15

Cooling Time

(3-3600)s

10

16

Stop Idle
ETS
Solenoid
Hold

(0-3600)s

(0-120)s

20

18

Over Stop Delay

(0-120)s

19

Switching On

(0-10)s

5.0

20

Flywheel Teeth

(10-300)

118

21

Generator
Abnormal Delay

(0-20.0)s

10.0

22

Generator
Voltage

(30-620)V

264

23

Generator Under
Voltage

(30-620)V

196

24

Under Speed

(0-6000)RPM

1200

25

Over Speed

(0-6000)RPM

1710

26

Under Frequency

(0-75.0)Hz

45.0

27

Over Frequency

(0-75.0)Hz

57.0

17

Over

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Description
Delay of cooling time before
stopping.
Idle running time when stopping.
Its the delay for energizing to
stop.
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.
Pulse width of mains or closing
gens. When it is 0s, output is
continuous.
Used
for
judging
crank
disconnect and detecting rotating
speed. See INSTALLATION in
this manual.
Gens high voltage and low
voltage alarm delay.
When voltage is over the point,
Gens Over Voltage is active.
When the point is 620V, Gens
Over Voltage is disabled.
When voltage is under the point,
Gens Under Voltage is active.
When the point is 30V, Gens
Under Voltage is disabled.
When engine speed is under the
point and holds for 10s, Gens
Under Speed is active.
When engine speed is over the
point and holds for 2s, Gens
Over Speed is active.
When generator frequency is
lower than the point and holds for
10s, Gens Under Frequency is
active.
When generator frequency is
over the point and holds for 2s,
Gens Over Frequency is active.

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HGM400 Series Automatic Control Module

No

Items

Range

Default

28

High Temperature

(80-140)C

98

29

Low Oil Pressure

(0-400)kPa

103

30

Loss of
Signal

(0-20.0)s

5.0

31

Charge Failure

(0-30)V

6.0

32

Battery
Voltage

Over

(12-40)V

33.0

33

Battery
Voltage

Under

(4-30)V

8.0

34

CT Rate

(5-6000)/5

500

35

Full Load Current

(5-6000)A

500

36

Over
Current
Percentage

(50-130)%

120

37

Over
Delay

(0-3600)s

1296

38

Digital Output 1

(0-17)

14

39

Digital Output 2

(0-17)

Speed

Current

HGM400 Series Genset Controller

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Description
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)
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)
If set the delay as 0, only warn
not to stop the generator.
During generator is running,
when alternator WL/D+ voltage is
under this point and remains for
5s, generator will send shutdown
alarm.
When battery voltage is over the
point and holds for 20s, Battery
Over Voltage is active. Its a
warning alarm.
When generator battery voltage
is under the point and holds for
20s, Battery Under Voltage is
active. Its a warning alarm.
Current transformer rate
Maximum rated current, used for
calculating over current.
When the load current is over the
point, over current delay begins.
When load current is over the
pre-set value, over current is
initiated. When set delay timer as
0, only warning no shutdown,
Factory default: Fuel Relay
Output
Factory default: Energized To
Stop
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HGM400 Series Automatic Control Module

No

Items

Range

Default

Description

40
41
42

Digital Output 3
Digital Output 4
Digital Output 5

(0-17)
(0-17)
(0-17)

3
5
6

43

Auxiliary Input 1

(0-15)

(0-1)

(0-20.0)s

2.0

(0-15)

Factory default: Low Oil Pressure


Alarm

(0-1)

Factory default: Closed

(0-20.0)s

2.0

(0-15)

10

Factory default: Remote Start

(0-1)

Factory default: Closed

(0-20.0)s

2.0

(0-15)

11

Factory default: Low Fuel Level


Warn

(0-1)

Factory default: Closed

(0-20.0)s

2.0

44
45
46
47
48
49
50
51
52
53
54

Auxiliary Input 1
Active
Auxiliary Input 1
Delay
Auxiliary Input 2
Auxiliary Input
Active
Auxiliary Input
Delay
Auxiliary Input 3
Auxiliary Input
Active
Auxiliary Input
Delay

2
2

3
3

Auxiliary Input 4
Auxiliary Input 4
Active
Auxiliary Input 4
Delay

55

Module Mode

(0-2)

56

Module Address

(1-254)

57

Passwords

(0-9999)

1234

58

Crank Disconnect

(0-5)

59

Engine Speed

(0-3000)RPM

360

HGM400 Series Genset Controller

ISSUE 2012-03-15

Factory default: Idle Control


Factory default: Gens Closed
Factory default: Mains Closed
Factory
default:
High
Temperature Alarm
Factory default: Closed

0: Stop Mode
1: Manual Mode
2: Auto Mode
Communication
controller.

address

of

Conditions of crank disconnect


includes gens, magnetic pickup
and oil pressure which make
starter separate with engine.
See Table 5
When engine speed is over this
point, starter will disconnect.

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HGM400 Series Automatic Control Module

No

Items

Range

Default

Description
When generator frequency is
over this point, starter will
disconnect.
When engine oil pressure is over
this point, starter will disconnect.
Factory default: when the
temperature is too high, alarm to
shutdown. Note 1.
Factory
default:
when
oil
pressure is lower, alarm to
shutdown. Note 2
0: 3P4W; 1:2P3W
2:1P2W; 3: 3P3W Note 3

60

Engine
Frequency

(10.0-30.0)Hz 14.0

61

Engine Oil Press

(0-400)kPa

200

62

High Temp. Inhibit

(0-1)

63

Low OP Inhibit

(0-1)

64

Voltage Input

(0-3)

(0-9)

08

SGX

(0-9)

08

SGX

(2-32)

65
66
67

Temp.
Sensor
Select
Pressure Sensor
Select
Number Of Poles

68

Temperature
Sensor Open

(0-2)

69

Oil
Pressure
Sensor Open

(0-2)

70

Defined
Curve

(0-1)

Sensor

0: Indication (temperature sensor


will show +++);
1:Warning; 2:Shutdown
0: Indication (oil pressure sensor
will show +++);
1:Warning; 2:Shutdown
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.

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HGM400 Series Automatic Control Module

7.2 PROGRAMMABLE OUTPUT 1-5 (TABLE 2)


No
0

Items
Not Used

Common Alarm

ETS Solenoid Hold

Idle Control

Preheat Control

Close Generator

Close Mains

Switching Off

Acceleration Control

Deceleration Control

10

Genset Run

11

Fuel Pump Control

12

High Speed Control

13
14
15
16
17

Description
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.
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.
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.
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.
When closing time is 0, its continuous output.
When closing time is 0, its continuous output.
(HGM410 without)
When closing time is 0, its disabled.
Pull-in during warm-up delay. Open when auxiliary
acceleration input is active.
Pull-in when entering stop idle or ETS solenoid
process, (alarm to shutdown). Open when auxiliary
deceleration input is active.
Outputting when genset in normal running and
disconnect when rotating speed is under engine speed
after started.
Close when fuel level is lower than the set threshold;
open when low fuel level warning input is inactive.
Outputting when entering into Warming Up and
disconnect when Cooling Down is over.

System
In
Auto
The controller work in automatic mode.
Mode
Fuel Relay Output
To control fuel relay output.
Reserved
Reserved
Reserved

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HGM400 Series Automatic Control Module

7.3 PROGRAMMABLE INPUT 1-4


CONNECT GND (B-) (TABLE 3)
No
0
1

Items
Not Used
High Temp. Alarm

TABLE

(ACTIVE

WHEN

Description

Low OP Alarm

When safety on run delay is over, if the signal is active,


generator will immediately alarm to shutdown.

Auxiliary Alarm

If the input is active, only warning, no shutdown.

Auxiliary Shutdown

Coolant To Stop

If the input is active, stop the genset immediately.


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
7

Generator Closed
Mains Closed
High Temp. Stop
Inhibit
Low Oil Pressure
Stop Inhibit

HGM410 without
When it is active, prohibit stopping when high
temperature occurs. Note 1
When it is active, prohibit stopping when oil low
pressure occurs. Note 2

Remote Start Input

HGM420 without

8
9
10

Low
Fuel
Warn
Low Liquid
Warn
Low
Fuel
Shutdown
Low Liquid
Shutdown

11
12
13
14

15

Level
Level
Level
Level

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

Temperature
Sensor

HGM400 Series Genset Controller

Content
0 Not used
1 Defined Res. Type
2 VDO
3 SGH(Huanghe sensor)
4 SGD(Dongkang sensor)
ISSUE 2012-03-15

Description
Defined input resistance
range
is
(0~6000).
Factory default is SGX.

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HGM400 Series Automatic Control Module

No

Content

Pressure
Sensor

Description

5 CURTIS
6 DATCON
7 VOLVO-EC
8 SGX
9 Reserved
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

Magnetic pickup

Generator

Magnetic pickup + Generator

Magnetic pickup + Oil pressure

Generator + Oil pressure

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.
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HGM400 Series Automatic Control Module

8 PARAMETERS SETTING
After controller powered on, press

to enter into the parameters setting menu, see fig 1

below:
Fig1

1
2
3
4

Set Parameters
Information
Set Language
Mode Select

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
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.

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HGM400 Series Automatic Control Module

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:

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HGM400 Series Automatic Control Module

Common unit conversion table

1Pa
1kgf/cm2
1bar
1psi

1N/m2 (pa)

1kgf/cm2

1bar

1
9.8x104
1x105
6.89x103

1.02x10 5
1
1.02

7.03x10 2

1x10 5
0.98
1

6.89x10 2

(1b/in2) psi
1.45x10
14.2
14.5
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) Emergence stop input must be connected to positive of starting battery via normally
close contact of emergency stop.
4) 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.
5) 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.
6) 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.
7) 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.
8) 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.
9) If there are any other questions, please contact our technical personnel.

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HGM400 Series Automatic Control Module

11 TYPICAL APPLICATION
HGM410 Typical wiring diagram

HGM420 Typical wiring diagram

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HGM400 Series Automatic Control Module

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.

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.

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HGM400 Series Automatic Control Module

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
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HGM400 Series Automatic Control Module

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
Controller inoperative

Genset stops

Emergency shutdown

Possible Remedy
Check starting battery;
Check connections of the controller;
Check the DC fuse.
Check if water/cylinder temperature too high.
Check alternator voltage.
Check the DC fuse.
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


Check oil pressure sensor and connections.
(after crank success)
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HGM400 Series Automatic Control Module

Symptom
Possible Remedy
High Temp. alarm (after
Check temperature sensor and connections.
crank success)
Check switch and connections according to information
Shutdown Alarm During
on LCD.
Running
Check configuration inputs.
Check connections of fuel solenoid.
Check starting battery.
Crank Not Disconnect
Check speed sensor and its connections.
Refer to engine manual.
Check connections of starter;
Starter Inoperative
Check starting battery.
Genset Running but ATS Check ATS;
Not Transfer
Check connections between ATS and controller.

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