SMARTGEN HGM1791 Genset Controller User Manual

1. Product Overview

The SMARTGEN HGM1791 Genset Controller is designed for single unit automation and monitoring control of gensets. It facilitates both manual and automatic start/stop operations based on remote signals. The controller continuously monitors and protects genset operation by collecting and analyzing critical data such as generation voltage, current, water temperature, and oil pressure. It provides fault indications and supports timely maintenance actions. The user interface features an LCD display with Chinese and English language options and intuitive touch-button operation. Parameters and delay values can be adjusted via the front panel or through PC software connected via a USB port.

Figure 1: Front panel of the SMARTGEN HGM1791 Genset Controller. It features a central LCD screen displaying various parameters like voltage, frequency, current, power, and engine status. Below the screen are three distinct buttons: a red 'Stop' button, a central 'Auto' button with a fan icon, and a green 'Start' button. The text 'AUTO START MODULE' is visible at the bottom.

2. Key Features

• Display: 128x64 LCD with backlight, supporting Chinese and English interfaces.
• Durability: Hard screen acrylic material for screen protection; silicone panel and buttons for enhanced temperature adaptation.
• Power Supply: DC (8~35)V range, compatible with 12V or 24V starting batteries.
• Generator Monitoring: Measures and displays single-phase voltage, current, frequency, power, and load percentage.
• Engine Monitoring: Precision measurement and display of oil pressure, temperature, fuel level, total running time, battery voltage, engine speed, and accumulated start times.
• Protection: Integrated genset fault protection and display functions.
• Operating Modes: Three distinct modes: Manual, Auto, and Stop.
• Sensor Compatibility: Compatible with multiple user-defined temperature, pressure, and fuel level sensors.
• Crank Disconnection: Multiple configurable crank disconnection conditions (engine speed sensor, oil pressure, generator frequency).
• Input/Output Ports: 3 configurable input ports (digital or sensor); 2 fixed relay outputs (fuel, start); 3 configurable output ports (common alarm, preheat, idle control).
• Parameter Configuration: Parameters can be set and modified via the front panel or PC software (Type-C USB port), with settings retained upon power loss.
• Design: Modular design, self-extinguishing ABS plastic enclosure, pluggable terminal blocks, embedded installation, compact size.

3. Setup

3.1 Installation

The HGM1791 controller is designed for embedded installation. Ensure adequate space for mounting and access to the rear connections. The modular design with pluggable terminal blocks simplifies wiring.

3.2 Wiring Connections

1. Power Supply: Connect the DC (8~35)V power supply to the designated terminals. Ensure correct polarity.
2. Engine Sensors: Connect engine sensors (oil pressure, water temperature, fuel level, speed sensor) to the appropriate input ports. The controller supports various sensor types, which can be user-defined.
3. Generator Connections: Connect the generator voltage, current, and frequency inputs as per the wiring diagram.
4. Control Outputs: Connect the fuel relay, start relay, and configurable output ports (e.g., common alarm, preheat, idle control) to the respective genset components.
5. Remote Start/Stop: If using remote start functionality, connect the remote start signal to the designated input.

3.3 Initial Configuration

After wiring, power on the controller. Use the front panel buttons or connect to a PC via the Type-C USB port and use the provided software to configure parameters such as sensor types, alarm thresholds, and operational delays. Refer to the detailed wiring diagram and software manual for specific parameter settings.

4. Operating Instructions

The HGM1791 controller features three primary operating modes: Manual, Auto, and Stop. These modes are selected using the dedicated buttons on the front panel.

4.1 Stop Mode

Press the Stop button (red circle icon) to place the controller in Stop mode. In this mode, the genset will shut down if running, and will not start automatically or manually. This mode is typically used for maintenance or when the genset is not required.

4.2 Manual Mode

Press the Start button (green 'I' icon) to initiate a manual start sequence. The genset will attempt to start and run continuously until manually stopped or a fault occurs. This mode is useful for testing or specific operational requirements.

4.3 Auto Mode

Press the Auto button (fan icon) to activate Auto mode. In this mode, the controller will automatically start and stop the genset based on a remote start signal or other configured conditions. The controller will also monitor the genset and initiate protective shutdowns if faults are detected. This is the typical operating mode for unattended operation.

4.4 Display Navigation

The LCD display shows various genset parameters and status information. Use the navigation buttons (if present, typically arrow keys or similar) to scroll through different screens and view detailed data such as voltage, current, frequency, engine speed, oil pressure, and temperature.

5. Maintenance

Regular maintenance ensures the longevity and reliable operation of your HGM1791 Genset Controller and the connected genset.

• Cleaning: Keep the controller's front panel clean and free from dust and debris. Use a soft, dry cloth. Avoid abrasive cleaners or solvents.
• Connections: Periodically check all wiring connections for tightness and signs of corrosion. Loose connections can lead to intermittent operation or faults.
• Firmware Updates: Check the manufacturer's website for any available firmware updates for the controller. Updates can improve performance or add new features.
• Environmental Conditions: Ensure the operating environment remains within the specified temperature and humidity ranges to prevent damage to the electronic components.
• Battery Check: Verify the health of the genset's starting batteries, as the controller relies on a stable power supply.

6. Troubleshooting

This section provides guidance for common issues. For complex problems, contact qualified service personnel.

6.1 Controller Not Powering On

• Check Power Supply: Verify that the DC power supply (8~35V) is connected correctly and providing the specified voltage.
• Fuse Check: Inspect any inline fuses on the power supply line for continuity.
• Wiring: Ensure all power wiring connections are secure.

6.2 Genset Fails to Start

• Operating Mode: Confirm the controller is in Manual or Auto mode.
• Remote Start Signal: In Auto mode, verify that the remote start signal is active.
• Engine Faults: Check the controller display for any active fault codes (e.g., low oil pressure, high temperature, overspeed). Address the underlying engine issue.
• Fuel/Battery: Ensure adequate fuel supply and a charged starting battery for the genset.
• Crank Disconnection: Verify crank disconnection conditions are correctly configured and not preventing start.

6.3 Inaccurate Readings

• Sensor Calibration: Check if sensors are correctly calibrated and configured in the controller's parameters.
• Sensor Connections: Inspect sensor wiring for damage or loose connections.
• Sensor Type: Ensure the correct sensor type is selected in the controller's settings for each input.

7. Specifications

8. Warranty and Support

Specific warranty details for the SMARTGEN HGM1791 Genset Controller are not provided within the product information. For warranty claims, technical support, or service inquiries, please contact SMARTGEN directly or refer to the documentation included with your purchase. It is recommended to retain your proof of purchase for warranty purposes.