1. Overview
The SMARTGEN HGM6100U series automatic controller integrates digital, intelligent, and network techniques for comprehensive genset automatic control and monitoring. It supports automatic start/stop, data measurement, alarm protection, and three remote functions: remote control, remote measurement, and remote communication.
This controller features an LCD display with optional language interfaces including Chinese, English, Spanish, and Russian, ensuring easy and reliable operation. Utilizing micro-processing technology, it achieves precise measurement, value adjustment, timing, and threshold settings. All parameters can be configured from the front panel or via a programmable interface (or RS485 interface) using a PC. Its compact structure, simple connections, and high reliability make it suitable for various automatic control systems.
Figure 1: Front view of the HGM6120U controller, showing the LCD screen and control buttons.
2. Performance and Characteristics
The HGM6100U controller series offers several variants, with the HGM6120U/6120UC model specifically designed for Automatic Mains Failure (AMF) systems. This model includes mains AC monitoring and automatic switching control between mains and generator, making it ideal for automation systems involving both power sources.
Key Features:
- Display: 132x64 LCD with backlight, supporting multiple language interfaces (Chinese, English, Spanish, Russian) and push-button operation.
- Durability: Acrylic screen for improved wear and scratch resistance; silica-gel panel and keys for adaptability to varying temperatures.
- Communication: RS485 communication port for 'three remote' functions (remote control, remote measure, remote communication) via MODBUS protocol.
- Power System Compatibility: Adaptable to 3P4W, 3P3W, 1P2W, and 2P3W (120V/240V) AC power systems at 50Hz/60Hz.
- Measurement & Display: Capable of measuring and displaying 3-phase voltage, 3-phase current, frequency, and power parameters for both mains and generator.
- Protection: Automatic start/stop of genset, load transfer (ATS control), and comprehensive failure display and protection.
- Control Functions: ETS, idle speed control, pre-heat control, speed droop/raising control, all with relay output.
- Parameter Setting: Allows user to modify and store settings in internal FLASH memory. Parameters can be configured via the front panel or PC (using PS485 interface).
- Sensor Inputs: Multi-sensor support for temperature, pressure, and fuel level.
- Crank Disconnect: Multiple conditions for crank disconnect (speed sensor, oil pressure, generator).
- Power Supply: Wide power supply range (8-35VDC).
- Installation: Controller is fixed by metal fixing clips; modular design with flame-retardant ABS shell for embedded mounting.
- Waterproofing: Rubber gasket between shell and controller screen ensures IP55 waterproof rating.
3. Specifications
| Item | Contents |
|---|---|
| Working Voltage | DC8.0V to DC35.0V, continuous |
| Power Consumption | <3W (Standby mode: ≤2W) |
| AC System | 3P4W, 3P3W, 1P2W, 2P3W (120V/240V) |
| AC Alternator Frequency | 50Hz/60Hz |
| Rotate Speed Sensor Voltage | 1.0V to 24V (RMS) |
| Rotate Speed Sensor Frequency | 10,000 Hz (max.) |
| Start Relay Output | 16 A DC28V at supply voltage |
| Fuel Relay Output | 16 A DC28V at supply voltage |
| Programmable Relay Output 1 | 7 A DC28V at supply voltage |
| Programmable Relay Output 2 | 7 A 250VAC volt-free output |
| Programmable Relay Output 3 | 16 A Amp 250VAC volt-free output |
| Programmable Relay Output 4 | 16 A 250VAC volt-free output |
| Overall Dimensions | 197 mm x 152 mm x 47 mm (7.76 x 5.98 x 1.85 inches) |
| Panel Cutout | 186 mm x 141 mm |
| C.T. Secondary Current | 5A (rated) |
| Working Condition | Temperature: (-25~70)°C; Humidity: (20~93)% |
| Storage Condition | Temperature: (-25~70)°C |
| Protection Level | IP55 Gasket |
| Insulation Intensity | Apply AC2.2kV voltage between high voltage terminal and low voltage terminal; The leakage current is not more than 3mA within 1min. |
| Weight | 0.56kg (1.23 pounds) |
| Material | Acrylic |
| Display Type | LCD |
4. Installation and Wiring
Proper installation and wiring are crucial for the safe and effective operation of the HGM6120U controller. Refer to the wiring diagram and the back panel layout for correct connections.
Figure 2: Rear view of the HGM6120U controller, detailing the various wiring terminals for power, sensors, and outputs.
Figure 3: Typical application diagram for the HGM6120UC, illustrating connections for genset, mains, load, and control signals. This diagram is representative for the HGM6120U model.
Wiring Guidelines:
- Ensure all power connections are made with appropriate gauge wiring to prevent overheating.
- Connect the mains voltage and genset voltage to the designated terminals as shown in the diagram.
- Properly connect all auxiliary inputs and outputs according to your specific application requirements.
- For RS485 communication, ensure correct polarity and termination.
- Always disconnect power before performing any wiring or maintenance.
5. Operation
The HGM6120U controller features an intuitive interface with dedicated buttons for various functions. Understanding these keys is essential for proper operation.
Key Descriptions:
| Key | Description |
|---|---|
| Stop/Reset | Stops the generator under Manual/Auto mode. Resets shutdown alarms. Press for at least 3 seconds to test panel indicators. During stopping, press again to immediately stop the generator. |
| Start | Starts the genset under Manual or Manual Test mode. |
| Manual | Sets the module to Manual mode. |
| Auto | Sets the module to Auto mode. |
| Test/on load | Controller is under manual testing mode. Under this mode, the genset will run automatically with load when mains are normal. |
| Gens Close/Open | Controls the genset to switch on or off in Manual mode. |
| OK (Set/Confirm) | Shifts cursor to confirm in parameter setting menu. |
| Up/Increase | Screen scroll up; Increases value in setting menu. |
| Down/Decrease | Screen scroll down; Decreases value in setting menu. |
| Menu | Pressing this key sets the menu; Pressing again returns to the main interface. |
6. Maintenance
Regular maintenance ensures the longevity and reliable performance of your SMARTGEN HGM6120U controller.
- Cleaning: Periodically clean the controller's display and panel with a soft, dry cloth. Avoid abrasive cleaners or solvents.
- Connections: Annually inspect all wiring connections for tightness and corrosion. Loose connections can lead to intermittent operation or damage.
- Environment: Ensure the operating environment remains within the specified temperature and humidity ranges to prevent component degradation.
- Firmware Updates: Check the manufacturer's website for any available firmware updates that may improve performance or add features.
7. Troubleshooting
This section provides basic troubleshooting steps for common issues. For complex problems, contact technical support.
- Controller Not Powering On: Check the DC power supply connections and ensure the voltage is within the specified range (8-35VDC). Verify fuses if applicable.
- Genset Fails to Start: Confirm the controller is in Manual or Auto mode. Check fuel level, battery voltage, and engine fault indicators. Verify start relay output.
- Alarm Indication: Refer to the controller's display for specific alarm codes or messages. Consult the full manual (if available) for detailed alarm explanations and corrective actions.
- Communication Issues (RS485): Check wiring for correct polarity and secure connections. Ensure MODBUS parameters are correctly configured on both the controller and the PC.
8. Product Video
Watch this video for an unboxing and overview of a SMARTGEN AMF controller, demonstrating its physical components and general appearance. Please note that the video features model MGC320, which is part of a similar product series to the HGM6120U.
Video: Unboxing and overview of a SMARTGEN AMF controller (MGC320 model shown).
9. Warranty and Support
For warranty information, technical support, or service inquiries, please contact your authorized SMARTGEN dealer or visit the official SMARTGEN website. Keep your purchase receipt and product serial number handy for faster service.
