SmartGen HGM6100N Series Genset Controller User Manual

1 Overview

The HGM6100N series automatic controller integrates digital, intelligent, and network techniques for automatic control and monitoring of gensets. It supports automatic start/stop, data measurement, alarm protection, and three "remote" functions (remote control, remote measure, and remote communication). The controller features an LCD display with optional language interfaces including Chinese, English, Spanish, Russian, Portuguese, Turkish, Polish, and French, ensuring easy and reliable operation. It utilizes micro-processing techniques for precise measurement, value adjustment, and threshold setting. All parameters can be configured via the front panel or a PC using a USB or RS485 interface. Its compact structure, simple connections, and high reliability make it suitable for various automatic control systems.

2 Performance and Characteristics

The HGM6100N controller has six variants:

• HGM6110N/6110NC/6110CAN: Automatic Start Module, controls generator start/stop via remote start signal.
• HGM6120N/6120NC/6120CAN: Builds upon the HGM6110N series by adding mains AC monitoring and mains/generator automatic switching control (AMF), ideal for systems with both mains and gensets.

Note 1: HGM6110NC/6120NC feature an RS485 port, while HGM6110N/6120N do not. HGM6110CAN/6120CAN have a CAN port, absent in HGM6110N/6120N and HGM6110NC/6120NC.

Note 2: HGM6110/6120 are used as examples throughout this manual.

Key features include:

• 132x64 LCD display with backlight and multilingual support (Chinese, English, Spanish, Russian, Portuguese, Turkish, Polish, French).
• Acrylic screen for enhanced wear and scratch resistance.
• Silica-gel panel and keys for adaptability to varying temperatures.
• RS485 communication port for "three remote" functions via MODBUS protocol.
• CANBUS port for connection with J1939 electronic injection systems, enabling monitoring of engine data (water temperature, oil pressure, speed, fuel consumption) and control of start, stop, high speed, and low speed.
• Compatibility with 3P4W, 3P3W, 1P2W, and 2P3W (120V/240V), 50Hz/60Hz AC power systems.
• Measurement and display of 3-phase voltage, 3-phase current, frequency, and power parameters for mains and gensets.
• Mains Parameters: Line voltage (Uab, Ubc, Uca), Phase voltage (Ua, Ub, Uc), Frequency (Hz).
• Generator Parameters: Line voltage (Uab, Ubc, Uca), Phase voltage (Ua, Ub, Uc), Frequency (Hz).
• Load Parameters: Current (IA, IB, IC), Active power (kW), Reactive power (kvar), Apparent power (kVA), Power factor (PF).
• Generator accumulated energy (kWh) and output percentage with load (%).
• Mains protection: over/under voltage, phase loss. Genset protection: over/under voltage, over/under frequency, over current, over power.
• Precision measurement and display of engine parameters: Temperature (WT), Oil pressure (OP), Fuel level (FL), Speed (SPD), Battery Voltage (VB), Charger Voltage (VD).
• Accumulative running hours and start times.
• Control Protection: Automatic start/stop, load transfer (ATS control), and failure display/protection.
• Supports ETS, idle speed control, pre-heat control, speed droop/raising control (relay output).
• Parameter Setting: User-configurable parameters stored in internal FLASH memory, accessible via front panel or PC (USB/RS485).
• Supports multi-sensors for temperature, pressure, and fuel level.
• Configurable crank disconnect conditions (speed, oil pressure, frequency).
• Emergency start function.
• Automatic flywheel teeth identification.
• Power supply range: (8~35)VDC.
• Digital modulation for improved reliability and stability.
• Maintenance function with configurable warning or shutdown actions based on date or running time.
• Event log, real-time clock, scheduled start & stop.
• IP65 protection level with rubber gasket.
• Modular design with flame-retardant ABS shell.

3 Specification

Table 2 - Technical Parameters

4 Operation

4.1 Keys Description

Table 3 - Keys Description

4.2 Controller Panel

Fig.1 - HGM6110N/ HGM6110NC/HGM6110CAN Front Panel Indication

(Image description: Front panel of HGM6110N/HGM6110NC/HGM6110CAN controller showing display, buttons like Alarm Lamp, Status Lamp, Close, Open, Start, Stop, Auto, Manual, and indicators like Gen Normal, Manual Mode, Stop/Reset, Auto Mode Indicator, Stop Mode Indicator.)

Fig.2 - HGM6120N/ HGM6120NC/HGM6120CAN Front Panel Indication

(Image description: Front panel of HGM6120N/HGM6120NC/HGM6120CAN controller showing display, buttons like Alarm Lamp, Status Lamp, Mains Close/Open, Load, Genset Close/Open, Start, Stop, Auto, Manual, and indicators like Gen Normal, Manual Mode, Stop/Reset, Auto Mode Indicator, Stop Mode Indicator.)

Note: Partial indicator states:

• Alarm Lamp: Slowly blinks for warning alarms; fast blinks for shutdown alarms; does not illuminate when there is no alarm.
• Status Lamp: Does not illuminate when genset is on standby; blinks once per second during start or stop process; always illuminates when running normally. For HGM6100CAN, pressing the start key in auto or manual mode results in ECU power output and the status lamp always illuminating.

4.3 Automatic Start/Stop Operation

Auto mode is activated by pressing the @ button, confirmed by its illuminating LED indicator.

Starting Sequence

1. HGM6120: When mains is abnormal (over/under voltage, phase loss), the controller enters "Mains Abnormal Delay" with a countdown displayed on the LCD. Upon delay completion, "Start Delay" begins.
2. HGM6110: When "remote start" input is active, "Start Delay" commences.
3. The "Count-down" of start delay is displayed on the LCD.
4. Upon start delay completion, the preheat relay outputs (if configured), and "Preheat Delay XX s" is displayed on the LCD.
5. After preheat delay, the fuel relay outputs for 1s, followed by the start relay output. If the genset fails to start within "Crank Time", the fuel and start relays stop outputting, and the controller enters "Crank Rest Time" before the next cranking attempt.
6. If the genset fails to start within the set number of attempts, the fifth line of the LED will turn black, and a "Fail to Start" alarm will be displayed.
7. Upon successful start, the controller enters "Safe Running". During this period, alarms for low oil pressure, high temperature, under speed, failed to charge, and configured auxiliary inputs are disabled. After this delay, the controller enters "Start Idle Delay" (if configured).
8. During "Start Idle Delay", alarms for under speed, under frequency, and under voltage are disabled. Upon completion, the controller enters "Warming up Delay" (if configured).
9. When "Warming up Delay" is over, the indicator illuminates if the genset is normal. If the engine voltage and frequency meet load requirements, the close relay outputs, the genset takes load, and the indicator illuminates. If engine voltage or frequency is abnormal, the controller will alarm and shut down, displaying the alarm information on the LCD.

Stopping Sequence

1. HGM6120: During normal running, if mains are normal, the genset enters "Mains Normal Delay". When the mains indicator illuminates, "Stop Delay" begins.
2. HGM6110: The genset enters "Stop Delay" as soon as "Remote Start" becomes inactive.
3. Upon "Stop Delay" completion, the genset enters "Cooling Delay". The closing relay disconnects. After the "Transfer Rest Delay", the closing relay outputs, mains take load, the generator indicator extinguishes, and the mains indicator illuminates.
4. When entering "Stop Idle Delay", the idle relay energizes and outputs (if configured).
5. When entering "ETS Delay", the ETS relay energizes and outputs, and the fuel relay output disconnects.
6. When entering "Genset at Rest", the genset automatically determines if it has stopped.
7. If the genset has stopped, it enters standby mode. If the genset fails to stop, the controller will alarm with a "Fail to Stop" message on the LCD.

4.4 Manual Start/Stop Operation

1. HGM6120: Manual Mode is active when the Manual button is pressed, and its indicator illuminates. In this mode, pressing the I button starts the genset, automatically detecting crank disconnect and accelerating to high speed. If high temperature, low oil pressure, over speed, or abnormal voltage occurs during running, the controller protects the genset by stopping it (refer to sections 4~9 of Auto start operation for details). In Manual Mode, automatic load transfer does not occur; pressing the Close button is required to transfer the load.
2. HGM6110: Manual Mode is active when the Manual button is pressed, and its indicator illuminates. Pressing the I button starts the genset, automatically detecting crank disconnect and accelerating to high speed. If high temperature, low oil pressure, over speed, or abnormal voltage occurs during running, the controller protects the genset by stopping it quickly (refer to sections 4~9 of Auto start operation for details). After the genset runs normally at high speed, pressing the Close button allows the genset to take load.
3. Manual stop is performed by pressing the O button, which shuts down the running genset (refer to sections 3~7 of Auto stop operation for details).

4.5 Emergency Start

In manual mode, pressing the O and I buttons together compels the genset to start. The controller does not automatically verify successful start based on disconnect conditions or starter disengagement. Operators must observe the genset's start and then release the buttons. The controller then enters a safety delay before outputting start stops.

5 Protection

5.1 Warnings

When the controller detects a warning signal, the genset will alarm but not stop. Alarms are displayed on the LCD.

Table 4 - Controller Warning Alarms

5.2 Shutdown Alarms

When the controller detects a shutdown alarm, it signals to open the switch and stop the genset. Alarms are displayed on the LCD.

Table 5 - Shutdown Alarms

Note: ECU warning and Shutdown alarm explanations require checking the genset according to displayed alarm contents. Otherwise, consult the engine user manual for SPN alarm codes.

6 Connections

Compared to HGM6120, HGM6110 lacks a 3-phase input terminal for mains voltage. The back panel of HGM6120 is shown below.

(Image description: Diagram showing the back panel of the HGM6120 controller with numbered terminals and their functions like DC input, Emergency Stop, Fuel, Crank, Aux Outputs, Charger, Magnetic Pickup, Engine Temp, Oil Pressure, Fuel Level, Aux Inputs, CAN, RS485, USB, etc.)

Fig.3 - Controller Rear Panel Drawing

Table 6 - Terminal Connection Description

Note: USB ports in the controller's rear panel are programmable parameter ports; users can directly program via PC.

7 Parameter Range and Definition

7.1 Parameter Content and Range Table

Table 7 - Parameter Content and Range

Note 1: The value in the first line of "Number" column is for HGM6120CAN and the value in brackets is for HGM6110CAN. If HGM6100N and HGM6100CAN parameter numbers are inconsistent, the second line of "Number" column is for HGM6120N, and the value in brackets is for HGM6110N.

Note 2: If high temperature inhibit is selected, or programmable input is set as High Temperature Inhibit (this input is active), when temperature is higher than pre-setting threshold, the controller sends a warning signal only and does not shut down.

Note 3: If low oil pressure inhibit is selected, or programmable input is set as Low Oil Pressure Inhibit (this input is active), when low oil pressure is lower than pre-setting threshold, the controller sends a warning signal only and does not shut down.

Note 4: If the default password (0318) is not changed, it is not necessary to input it when configuring parameters via PC software. If the password is changed for the first time via PC software, it needs to be entered in the password window.

Note 5: After entering the correct password and before the LCD backlight darkens, inputting parameter numbers allows entry into the parameter setting interface when "Password Input" is entered again.

Note 6: In the teeth configuration interface, if in teeth configuration status and frequency is larger than 20Hz, press the start key for auto calculation of teeth numbers and press the confirm key for changing teeth numbers.

7.2 Programmable Output 1-4 Table

Table 8 – Definition Content of Programmable Output 1-4

7.3 Programmable Input 1-5 Table

Table 9 - Definition Content of Programmable Input 1-5 (Active When Connect To Ground (B-)

7.4 Sensor Selection

Table 10 - Sensor Selection

Note: Special instructions are required for ordering when the genset uses 4-20mA or 0-5V sensors.

7.5 Conditions of Crank Disconnect

Table 11 - Crank Disconnect Conditions

1. There are 3 types of crank disconnect conditions: Speed, Generator frequency, and Oil pressure, which can be used alone. Oil pressure is recommended with speed and generator frequency for prompt starter and engine disconnect.
2. Speed is measured by a magnetic sensor installed in the engine for testing flywheel teeth.
3. When selecting speed, ensure the number of flywheel teeth matches the pre-set value; otherwise, over or under speed shutdown may occur.
4. If the generator lacks a magnetic pickup sensor, do not choose the speed item; otherwise, "Fail to Start" or "Loss of Speed Signal" shutdown may occur.
5. If the generator lacks an oil pressure sensor, do not choose the corresponding item.
6. If generator frequency is not selected, the controller will not measure or display relative parameters (applicable to pump sets). If speed is not selected, rotating speed will be calculated by the generating AC signal.

8 Parameter Setting

After the controller is powered on, press /OK to enter the parameters setting menu:

1. Parameters Setting
2. Information
3. Language
4. Event Log
5. Maintenance Setting

Parameters Setting

The default password "0318" allows setting all items in Table 7. If the default password is changed, the same password must be used for parameter setting via PC software. For more parameter items or forgotten passwords (e.g., voltage and current calibration), contact the factory.

Notes:

1. HGM6110 has no items 1-5 in Table 7; programmable outputs 1-4 have no digital outputs for mains.
2. Modify parameters in standby mode (crank conditions, auxiliary input/output configuration, multi-delays, etc.) to avoid shutdown alarms or other abnormal conditions.
3. The over-voltage threshold must be greater than the under-voltage threshold; otherwise, over-voltage and under-voltage may occur simultaneously.
4. The over-speed threshold must be greater than the under-speed threshold; otherwise, over speed and under speed may occur simultaneously.
5. Set frequency value (after crank disconnect) as low as possible to quickly disconnect the starter.
6. Programmable inputs 1-5 cannot be set to the same items to ensure correct function; programmable outputs 1-4 can be set to the same item.
7. To shut down after cooling, set any input as "stop after cooling" and connect it to ground, or set the high temperature stop action as "cooling stop".

Information

1. LCD displays controller information, such as software version and issue date. Note: Pressing ▲ or ▼ displays the status of digital inputs and outputs.
2. Language: User can select display language from Chinese, English, Spanish, Russian, Portuguese, Turkish, Polish, and French.
3. LCD contrast ratio adjustment: Press ▲ and ▼ to adjust LCD contrast ratio for clearer characters. Adjustment range is 0-9.

9 Sensor Setting

When selecting a sensor, the standard sensor curve is required. If the temperature sensor is set as SGH (120°C resistor type), the sensor curve should be SGH (120°C resistor type). If set as SGD (120°C resistor type), the sensor curve should be SGD. If there's a difference between the standard sensor curve and the chosen sensor curve, select "defined sensor" and input the defined sensor curve. When inputting the sensor curve, the X value (resistance) must be in ascending order; otherwise, errors will occur. When a sensor is selected as "Not used", temperature, pressure, and fuel level will display as "- - -" on the LCD. If there is no pressure sensor but only a low pressure alarm switch, set the pressure sensor as "Not used"; otherwise, oil pressure low alarm shutdown may occur. Several points can be set with the same ordinate value.

(Image description: A sensor curve diagram showing kPa on the y-axis and Ω (ohm) on the x-axis, with plotted points.)

Fig.4 Sensor Curve Diagram

Table 12 - Conventional pressure unit conversion table

10 Commissioning

Before operation, perform the following checks:

• Ensure all connections are correct and wire diameters are suitable.
• Verify the controller has a DC power fuse and that the battery positive and negative are correctly connected.
• The emergency stop input must be connected to the positive of the starting battery via a normally closed contact of the emergency stop button.
• Take precautions to prevent engine crank disconnect (e.g., remove fuel connections). If checks are satisfactory, connect the start battery, select Manual Mode, and the controller will execute the program.
• Set the controller to Manual Mode, press the "start" button to start the genset. If it fails within the set crank times, the controller will send a "Failed to Start" signal; then press "stop" to reset the controller.
• Reconnect the prevented engine connections (e.g., fuel connections). Press the "start" button again; the genset will start. If successful, the genset will run normally after idle running (if configured). Monitor engine running status, alternator voltage, and frequency. If abnormal, stop the genset and check all connections as per this manual.
• Select Auto Mode from the front panel and connect to the mains signal. After the mains normal delay, the controller will transfer ATS (if configured) to the mains load. After cooling, the controller will stop the genset and enter standby until mains become abnormal again.
• When mains become abnormal again, the genset will start automatically and run normally, sending a signal to close the mains, transfer ATS, and make the genset take load. If this does not occur, check ATS connections as per this manual.
• For any further questions, please contact SmartGen service.

11 Typical Application

(Image description: Wiring diagrams for HGM6110NC, HGM6120NC, HGM6110CAN, and HGM6120CAN typical application, showing connections for GENS, MAINS, LOAD, AUX OUTPUTS, sensors, and communication ports.)

Fig.5 - HGM6110NC Typical Application Diagram

Fig.6 - HGM6120NC Typical Application Diagram

Fig.7 - HGM6110CAN Typical Application Diagram

Fig.8 - HGM6120CAN Typical Application Diagram

Fig.9 - Single Phase 2 Wire

Fig.10 - 2 Phase 3 Wire

Note: It is recommended that the output of crank and Fuel expand high capacity relay.

12 Installation

12.1 Fixing Clips

• The module is secured in the panel fascia using the supplied fixing clips.
• Withdraw the fixing clip screw (turn anticlockwise) until it reaches the proper position.
• Pull the fixing clip backward (towards the back of the module), ensuring all four clips are inside their allotted slots.
• Turn the fixing clip screws clockwise until they contact the panel.
• Take care not to overtighten the fixing clip screws.

12.2 Overall Dimension and Panel Cutout

(Image description: Diagrams showing the case dimensions and panel cutout dimensions for the HGM6100N controller in millimeters.)

Fig.11 - Case and Overall Dimensions

13 Connections of Controller with J1939 Engine

13.1 CUMMINS ISB/ISBE

Table 13 - Connector B

13.2 CUMMINS QSL9

Suitable for CM850 engine control mode.

Table 14 - 9 Pins Connector

Table 15 - 50 Pins Connector

13.3 CUMMINS QSM11 (IMPORT)

Suitable for CM570 engine control mode. Engine type is QSM11 G1, QSM11 G2.

Table 16 - 9 Pins Connector

Table 17 - C1 Connector

Table 18 - 3 Pins Data Link Connector

13.4 CUMMINS QSX15-CM570

Suitable for CM570 engine control module. Engine type is QSX15.

Table 19 - 50 Pins Connector

Table 20 - 9 Pins Connector

13.5 CUMMINS GCS-MODBUS

Suitable for GCS engine control module. Use RS485-MODBUS to read engine information. Engine types are QSX15, QST30, QSK23 / 45/60/78, and so on.

Table 21 - D-SUB Connector 06

Table 22 - D-SUB Connector 06

13.6 CUMMINS QSM11

Table 23 - Engine OEM Connector

13.7 CUMMINS QSZ13

Table 24 – Engine OEM Connector

13.8 DETROIT DIESEL DDEC III / IV

Table 25 - Engine CAN Connector

13.9 DEUTZ EMR2

Suitable for BOSCH common rail pump engine.

Table 26 - F Connector

13.10 JOHN DEERE

Table 27 - 21 Pins Connector

13.11 MTU MDEC

Suitable for MTU engines, 2000 series, 4000 series.

Table 28 X1 Connector

13.12 MTU ADEC(SMART MODULE)

Suitable for MTU engine with ADEC (ECU8) and SMART module.

Table 29 – ADEC (X1 port)

Table 30 - SMART (X4 port)

13.13 MTU ADEC(SAM MODULE)

Suitable for MTU engine with ADEC (ECU7) and SAM module.

Table 31 – ADEC (X1 port)

Table 32 – SAM (X23 port)

13.14 PERKINS

Suitable for ADEM3/ ADEM4 engine control mode. Engine type is 2306, 2506, 1106, and 2806.

Table 33 - Connector

13.15 SCANIA

Suitable for S6 engine control mode. Engine type is DC9, DC12, and DC16.

Table 34 - B1 Connector

13.16 VOLVO EDC3

Suitable engine control mode is TAD1240, TAD1241, and TAD1242.

Table 35 - "Stand alone" Connector

Table 36 - "Data bus" Connector

Note: When this engine type is selected, preheating time should be set to at least 3 seconds.

13.17 VOLVO EDC4

Suitable engine types are TD520, TAD520 (optional), TD720, TAD720 (optional), TAD721, TAD722, and TAD732.

Table 37 - Connector

13.18 VOLVO-EMS2

Volvo Engine types are TAD734, TAD940, TAD941, TAD1640, TAD1641, and TAD1642.

Table 38 - Engine CAN Port

Note: When this engine type is selected, preheating time should be set to at least 3 seconds.

13.19 YUCHAI

Suitable for BOSCH common rail pump engine.

Table 39 - Engine 42 Pins Port

Table 40 – Engine 2 Pins Port

13.20 WEICHAI

Suitable for Weichai BOSCH common rail pump engine.

Table 41 – Engine Port

Note: If there are any questions regarding connection between the controller and ECU communication, please contact Smartgen service.

14 Fault Finding

Table 42 Fault Finding