Smartgen HGM6110N-4G/HGM6120N-4G GPS Auto Start AMF Generator Controller Instruction Manual

1. Introduction

The Smartgen HGM6110N-4G and HGM6120N-4G are advanced generator controllers designed for automatic start and automatic mains failure (AMF) applications, respectively. These controllers integrate digital, intelligent, and network communication technologies, offering comprehensive control and monitoring of your generator set. They feature an LCD display for clear parameter viewing, alarm indications, and remote control capabilities via cloud server (app/PC) using GPS and 4G/GPRS connectivity. The HGM6110N-4G is an auto start module, while the HGM6120N-4G is an AMF module, capable of automatically starting and stopping the generator based on mains power status.

This manual provides essential information for the proper installation, operation, and maintenance of your Smartgen HGM6110N-4G/HGM6120N-4G controller.

Figure 1: Smartgen HGM6110N-4G/HGM6120N-4G Controller and Included Accessories

2. Setup and Installation

2.1 Unboxing and Components

Before installation, ensure all components are present:

• Smartgen HGM6110N-4G or HGM6120N-4G Controller
• Mounting hardware (screws/clips)
• Connection cables
• GPS antenna
• GPRS/4G antenna
• User Manual (this document)

2.2 Physical Installation

The controller is designed for panel mounting. Ensure adequate space for wiring and ventilation. Secure the controller using the provided mounting hardware.

2.3 Wiring Connections

Refer to the detailed inner diagram for all electrical connections. Proper wiring is crucial for safe and correct operation.

Figure 2: Rear View with Inner Wiring Diagram and Ports

Key Connection Points:

• Terminals 1-14 (Control Outputs):
  • 1: B+ (Battery Positive)
  • 2: B- (Battery Negative)
  • 3: EM. STOP (Emergency Stop)
  • 4: FUEL (16A)
  • 5: CRANK (16A)
  • 6: AUX. OUTPUT 1 (7A/250VAC)
  • 7: AUX. OUTPUT 2 (7A/250VAC)
  • 8: AUX. OUTPUT 3 (16A/250VAC)
  • 9: AUX. OUTPUT 4 (16A/250VAC)
  • 10: CHARGER (D+)
• Terminals 15-26 (Inputs & Current):
  • 15-16: MAGNETIC PICKUP
  • 17: ENGINE TEMP
  • 18: OIL PRESSURE
  • 19: FUEL LEVEL
  • 20-24: AUX. INPUT 1-5
  • 25-26: CURRENT (RATED 5A) IA, IB, IC, ICOM
• Terminals 27-34 (Voltage Inputs):
  • 27-30: GENS VOLTAGE U, V, W, N2
  • 31-34: MAINS VOLTAGE R, S, T, N1
• Terminals 35-45 (Communication & ECU):
  • 35-37: RS485 (ISOLATION) A(-), B(+)
  • 41-45: ECU (J1939) SCR, CAN L, CAN H, NULL

2.4 Antenna and SIM Card Installation

For network communication and GPS functionality, install the provided antennas and a SIM card.

1. Locate the SIM card slot on the rear of the controller (refer to Figure 2). Insert a compatible SIM card.
2. Connect the GPS antenna to the blue port labeled 'GPS'.
3. Connect the GPRS/4G antenna to the pink port labeled 'GPRS/4G'.

Figure 3: GPS and GPRS/4G Antennas

2.5 USB Connection

A USB port is available for local configuration and firmware updates. Connect a standard USB cable from the controller to a PC for these operations.

3. Operating Instructions

3.1 Control Panel Overview

The front panel features an LCD display and various buttons for control and navigation:

Figure 4: Front Panel Controls

• LCD Display: Shows generator parameters, alarms, and status.
• Alarm Indicator: Lights up when an alarm condition is detected.
• Status Indicator: Shows the current operating status.
• Navigation Buttons (Up, Down, Left/Return, Set/OK): Used to navigate menus and adjust settings.
• Load/Genset/Open/Close Buttons: Control the load and generator breakers.
• Mode Buttons (Auto, Manual): Select the operating mode.
• Start/Stop Buttons: Manually start or stop the generator.

3.2 Operating Modes

• Auto Mode: The controller automatically manages the generator based on pre-configured settings and external signals (e.g., mains failure for HGM6120N-4G).
• Manual Mode: Allows for direct manual control of the generator start/stop and breaker operations via the front panel buttons.

3.3 Basic Operation (Manual Start/Stop)

1. Ensure all connections are secure and the generator is ready for operation.
2. Press the 'Manual' button to enter manual mode.
3. Press the 'Start' button to initiate the generator start sequence.
4. To stop the generator, press the 'Stop' button.

3.4 Network Communication and Remote Monitoring

The HGM6110N-4G/HGM6120N-4G controllers support network communication via 4G/GPRS and GPS for remote monitoring and control. Once configured, the controller can upload data to a cloud server, allowing users to monitor generator status, receive alarms, and perform remote operations through a dedicated application or PC software.

4. Maintenance

Regular maintenance ensures the longevity and reliable operation of your Smartgen controller:

• Cleaning: Keep the controller's front panel and enclosure clean. Use a soft, dry cloth. Avoid abrasive cleaners or solvents.
• Connection Checks: Periodically inspect all wiring connections for tightness and signs of corrosion. Ensure all terminals are securely fastened.
• Firmware Updates: Check the manufacturer's website for available firmware updates to ensure optimal performance and access to new features. Updates can typically be performed via the USB port.
• Gasket Integrity: For IP65 protection, ensure the waterproof gasket between the control panel and enclosure is intact and properly seated.

5. Troubleshooting

This section addresses common issues you might encounter:

• Controller Not Powering On:
  • Check the DC power supply (B+ and B- terminals) for correct voltage (DC8.0V to DC35.0V) and secure connections.
  • Verify the battery is charged and functional.
• Generator Fails to Start:
  • Ensure the 'EM. STOP' circuit is not active.
  • Check fuel and crank relay outputs (Terminals 4 and 5) and their connections to the generator.
  • Verify fuel level and engine oil pressure sensors are functioning correctly.
  • Check for any active alarms displayed on the LCD.
• No Network Connection/GPS Signal:
  • Ensure the SIM card is correctly inserted and active with a data plan.
  • Verify GPS and GPRS/4G antennas are securely connected and positioned for optimal signal reception.
  • Check network settings within the controller's configuration (if accessible).
• Incorrect Readings on Display:
  • Verify sensor connections (e.g., engine temp, oil pressure, fuel level) are correct and secure.
  • Check voltage and current transformer (CT) connections for proper polarity and rating.
• Alarms Triggering Unexpectedly:
  • Consult the controller's specific alarm codes (usually found in the full technical manual) to identify the cause.
  • Check the associated sensors or circuits for faults.

For complex issues, it is recommended to contact qualified technical support.

6. Specifications

The following table outlines the technical specifications for the Smartgen HGM6110N-4G/HGM6120N-4G controller:

Figure 5: Product Specifications

7. User Tips

• Regular System Checks: Periodically test your generator's auto-start function (for AMF models) to ensure it activates correctly during a power outage.
• Understand Alarms: Familiarize yourself with the common alarm codes and their meanings to quickly diagnose and address issues.
• Secure Wiring: Always double-check all wiring connections, especially after any maintenance or relocation, to prevent intermittent faults.
• Environmental Considerations: While the controller has an IP65 rating, ensure it is installed in an environment that minimizes exposure to extreme conditions to prolong its lifespan.
• Data Plan for Connectivity: For remote monitoring, ensure your SIM card has an active data plan with sufficient allowance for continuous data transmission.

8. Warranty and Support

For warranty information, specific technical support, or service inquiries, please refer to the documentation provided with your purchase or contact the seller/manufacturer directly. Ensure you have your product model and serial number ready when seeking support.