SmartGen HGM1790N Genset Controller User Manual

1. Overview

The HGM1790N genset controller is suitable for single unit automation and monitoring control, and can also be used for pumping units. It enables manual start/stop of the genset and automatic start/stop via a remote start signal. The controller supervises and protects genset operation by gathering and analyzing data such as voltage, current, water temperature, and oil pressure, indicating fault conditions and facilitating maintenance. Its graphical LCD and touch-button operation provide a clear and intuitive user experience. Parameter thresholds and delay values can be adjusted via the front panel or a USB port connected to PC software.

2. Performance and Characteristics

• Graphical LCD display with backlight, LED indicator, and touch-button operation.
• Hard screen acrylic material protects the screen.
• Silicone panel and buttons offer increased adaptability to high and low temperatures.
• Power supply range: DC (8~35)V, compatible with 12V or 24V starting batteries.
• Measures and displays generator single-phase voltage, current, frequency, power, and load percentage.
• Displays precision measured engine parameters: Oil Pressure (kPa), Fuel Level (%), Battery Voltage (V), Temperature (°C), Total Running Time (H, max. 199999 hours), Engine Speed (RPM).
• Accumulated Start Times (max. 199999 times, displayed on PC).
• Includes genset fault protection and display functions.
• Supports 3 working modes: manual, auto, stop.
• Compatible with various user-definable temperature, pressure, and fuel level sensors. Sensors can be used in parallel with an annunciator to increase protection levels.
• Multiple crank disconnect conditions can be selected (engine speed sensor, oil pressure, generator frequency).
• One configurable input port can be set as a digital input or liquid level sensor.
• Two fixed relay outputs (fuel relay, start relay).
• Three configurable output ports can be set as common alarm output, preheat output, or idle control output.
• Parameters can be set, modified, and saved in internal FLASH storage, ensuring data retention during power loss. Most parameters are adjustable via the front panel or PC software via a Type-B USB port.
• Features digital regulation of all parameters for higher reliability and stability.
• Modular design with a self-extinguishing ABS plastic enclosure and embedded installation for a small, compact structure with easy mounting.

3. Specification

Table 2 Technical Parameters

4. Operation

4.1. Front Panel Description

The front panel features an LCD display, indicator lights, and touch buttons. Key components include:

• Alarm Indicator: Indicates alarm status.
• Display: Shows generator parameters and status.
• Pagedown Button: Used to scroll through display pages.
• Auto Mode Button: Selects automatic operation mode.
• Stop Mode Button: Selects stop mode.
• Stop Button: Shuts down the genset or resets alarms.
• Start Button: Starts the genset.

4.2. Indicator Description

• Stop status indicator light: Genset is in stop mode.
• Auto status indicator light: Genset is in auto mode.
• Manual start indicator light: Genset is in manual mode.
• Alarm indicator light: Blinks slowly (1 time/s) when a worn alarm occurs; blinks fast (5 times/s) when a shutdown alarm occurs.

4.3. Panel Keys

Table 3 Key Descriptions

4.4. LCD Icons

Table 4 LCD Icons

4.5. Display Description

The LCD displays various parameters:

• Generator: Phase voltage L1, frequency F.
• Load: Active power, current.
• Load percentage.
• Oil pressure, temperature.
• Fuel level, total running time.
• Battery voltage, engine speed.
• Parameter setting.

NOTE:

• When active power is negative, please check voltage and current connection.
• When pressure, temperature, and liquid level sensors are not displayed, it means they are not used. Displaying "OFF" indicates sensors are open circuit.
• When total running time is lower than 20000 hours, the value before the decimal point represents running hours, and the value after the decimal point represents 1/10 hour.

4.6. Auto Start/Stop Operation

Auto mode is selected by pressing the ⚙️ button, confirmed by an illuminated LED.

Automatic Start Sequence:

1. When "Remote Start" is active (Terminal 6 connected to B-), "Start Delay" timer initiates.
2. After "Start Delay", preheat relay energizes (if configured), and "Preheat Delay" starts counting.
3. Following "Preheat Delay", the Fuel Relay (if configured) energizes, and one second later, the Start Relay engages. If the genset fails to fire during "Cranking Time", the fuel relay and start relay stop. "Crank Rest Time" begins, awaiting the next crank attempt.
4. If the start sequence exceeds the set number of attempts, it terminates, displaying "Fail to Start" on the LCD with a blinking alarm indicator.
5. Upon successful cranking, the "Safety On" timer activates, inhibiting Low Oil Pressure, High Temperature, and other alarms. "Start Idle" delay (if configured) initiates afterward.
6. During "Start Idle" delay, under speed, under frequency, and under voltage alarms are inhibited. "Warming up" delay (if configured) initiates upon completion of "Start Idle" delay.
7. Once "Warming up" delay is over, the genset starts normal running. Abnormal generator voltage or frequency triggers shutdown alarm signals.

Automatic Stop Sequence:

1. When the "Remote Start" signal is removed, "Stop Delay" initiates.
2. After "Stop Delay" expires, "Cooling Delay" initiates.
3. During "Stop Idle" Delay (if configured), the idle relay energizes.
4. "ETS Solenoid Hold" begins, energizing the ETS relay while the fuel relay de-energizes.
5. "Fail to Stop Delay" begins; complete stop is detected automatically.
6. The generator enters standby mode after its "After stop" delay. Otherwise, a "Fail to Stop" alarm is initiated (LCD display ❗).

NOTE:

• Pressing the Stop button in auto start status simultaneously stops the genset and enters stop mode.
• During crank rest delay, preheat and ETS functions energize when fuel output is de-energized and crank rest time countdown is less than 7s. After crank rest delay, ETS output de-energizes, fuel relay starts output, and preheat relay output is off before crank.

4.7. Manual Start/Stop Operation

1. MANUAL START: Press the ▶️ button to start the genset. Refer to Section 4.6 for detailed procedures. The controller protects the genset from high temperature, low oil pressure, over speed, and abnormal voltage during running.
2. MANUAL STOP: Press the ? button to shut down the running genset. Refer to Section 4.6 for detailed procedures.

5. Protection

Table 5 Controller Alarms

6. Wiring Connection

Fig.2 Controller Back Panel

The controller has multiple terminals for various connections:

• 1 B-: DC Voltage Input Negative. Connect to negative of starting battery.
• 2 B+: DC Voltage Input Positive. Connect to positive of starting battery. Use 1.5mm² wire; for lengths over 30m, consider double wires in parallel. Max. 20A fuse recommended.
• 3 Em.Stop Input: Connect to emergency stop normally closed button. B+ voltage input is active.
• 4 Fuel Output: B+ supplied by No.3 point, rated 1A.
• 5 Crank Output: B+ supplied by No.3 point, rated 1A.
• 6 Remote Start Input: Ground connected is active (B-).
• 7 Aux. Input: Connect to low fuel level coil or fuel level resistor type sensor if configured as level sensor.
• 8 Oil Pressure Input: Connect to low oil pressure coil or resistor type sensor.
• 9 Engine Temp. Input: Connect to high water/cylinder temp. coil or temperature resistor type sensor.
• 10 Magnetic Pickup: Connect to speed sensor. Shielded wire is recommended. The other end of speed sensor connects to B-.
• 11 Gen Volt Monitoring: Connect to generator voltage output port. (2A fuse recommended).
• 12 Input: 1.0mm² recommended.
• 13 Load Current (Inlet Loop): Connect to secondary coil of current transformer (Rated 5A).
• 14 Load Current (Outlet Loop): Connect to secondary coil of current transformer (Rated 5A).
• 15 Aux. Output 1: B+ supplied by No.2 point, rated 1A.
• 16 Aux. Output 2: B+ supplied by No.2 point, rated 1A.
• 17 Aux. Output 3: B+ supplied by No.2 point, rated 1A.

NOTE: Type-B USB port is for PC software connection, parameter configuration, and data monitoring.

7. Parameter Range and Definition

7.1 Parameters Contents and Range

Table 7 Parameter Setting Contents and Range

7.2 Definable Contents of Relay Outputs

Table 8 Definable Contents of Relay Outputs

7.3 Definable Contents of Digital Inputs

Table 9 Definable Contents of Digital Inputs (Active When GND (B-) Connected)

7.4 Sensor Selection

Table 10 Sensor Selection

7.5 Conditions of Crank Disconnect Selection

Table 11 Crank Disconnect Conditions Selection

1) There are 3 conditions to make the starter separate from the engine: Speed, generator frequency, and oil pressure. These can be used separately, but oil pressure is recommended to be used together with speed and generator frequency for faster starter disconnection.

2) The speed sensor is magnetic equipment installed in the starter for detecting flywheel teeth.

3) When setting by speed, ensure the number of flywheel teeth matches the setting; otherwise, "over speed shutdown" or "under speed shutdown" may occur.

4) If the genset does not have a speed sensor, do not select corresponding items, otherwise, "start fail" or "loss speed signal" may occur.

5) If the genset does not have an oil pressure sensor, do not select corresponding items.

6) If generator frequency is not selected in crank disconnect setting, the controller will not collect and display relative electric quantity (usable in water pump sets). If speed is not selected, the speed displayed is calculated by generator signal.

8. Controller Function Setting

8.1. Parameter Setting

Hold and press the ⚙️ button for 2s to enter the password interface. The first digit will blink.

Fig.3 Password Interface

1) Press the ▶️ button to increase the value of the blinking digit and the ⬇️ button to decrease it. Press ⚙️ to move the cursor.

2) Repeat the procedure for the 2nd to 4th digits.

3) If the password is correct, the parameter configuration interface appears. Press ⚙️ to scroll down and ⬇️ to scroll up through the set items and their parameters.

Fig.4 Parameter Configuration Interface

4) Press the ▶️ button to set the current item. When the first digit starts blinking, use the same method as for the password to enter the set value.

Attention:

• Change controller parameters only when the generator is in standby mode (e.g., Crank disconnect conditions selection, configurable input/output, various delays). Otherwise, shutdown and other abnormal conditions may occur.
• Refer to Table 7 for parameter serial numbers.
• Parameter values can only be set within their specified ranges.
• Over voltage set value must be higher than under voltage set value to avoid simultaneous over and under voltage conditions.
• Over speed set value must be higher than under speed set value to avoid simultaneous over and under speed conditions.
• Set generator frequency as low as possible during cranking to ensure quick starter separation upon crank disconnect.
• Before selecting the fuel level sensor type, set a configurable input port type to 8.
• Pressing the ? button at any time can stop the current parameter setting immediately.

8.2. LCD Contrast Adjustment

When the genset is in standby status, simultaneously hold and press the ⚙️ and ⬇️ keys for 2s to enter the LCD contrast adjustment interface. The LCD contrast increases one level every 1s without releasing the buttons. There are 6 levels to select.

Fig.5 LCD Contrast

8.3. Generator Flywheel Teeth Automatic Adjustment

In manual mode, if crank disconnect conditions are set to "2 Speed + Generator Frequency" or "5 Generator Frequency + Speed + Oil Pressure" (with generator frequency and speed not being 0), the controller will automatically adjust generator flywheel teeth based on gen frequency and poles when ⚙️ and ⬇️ are pressed simultaneously for 0.5s.

9. Sensor Settings

a) Sensors are all resistor types. Some standard sensor curves are available for selection via PC software (refer to Table 10).

b) When inputting sensor curves, the X value (resistance) must be entered from smallest to largest to avoid errors.

c) If the sensor type is set to "not used", the sensor curve will not function, and the LCD will display "---".

d) If only a low oil pressure alarm switch is present without an oil pressure sensor, the pressure sensor can be set as "low digital input is active" or "high digital input is active".

e) The headmost or backmost values in the vertical coordinates can be set as shown in the figure.

Fig.6 Sensor Curve

Table 12 Normal Pressure Unit Conversion Table

10. Commissioning

Ensure the following checks are made before commissioning:

1. Verify all connections are correct and wire diameters are suitable.
2. Ensure the controller's DC power has a fuse and that the positive and negative terminals are correctly connected to the starting battery.
3. Take appropriate action to prevent engine crank success (e.g., remove the fuel valve connection wire). If checks are satisfactory, power on the starting battery, select manual mode, and the controller will execute its routine.
4. Set the controller to manual mode, press the "start" button; the genset will start. After the set cranking time, the controller will send a "Start Failure" signal. Press "stop" to reset the controller.
5. Reverse the action to prevent engine crank success (e.g., reconnect the fuel valve wire), press start again; the genset will start. If all goes well, the genset will run normally after idle running (if set). During this time, monitor the engine's running status and AC generator's voltage and frequency. If abnormal, stop the genset and check all wire connections according to this manual.
6. For any further questions, please contact SmartGen service personnel.

11. Typical Application

Fig.7 HGM1790N Typical Application Diagram

CAUTION: Crank and fuel output ports should use extended large capacity relays.

CAUTION: When a sensor port is configured as "high digital input is active", hanging in air means a high electrical level; connecting to power supply positive is prohibited.

12. Installation

12.1. Fixing Clips

1. The controller is designed for panel installation and is fixed by clips.
2. Withdraw the fixing clip screw (turn anticlockwise) until it reaches the proper position.
3. Pull the fixing clip backwards (towards the back of the module) to ensure both clips are inside their allotted slots.
4. Turn the fixing clip screws clockwise until they are fixed on the panel.

NOTE: Be careful not to overtighten the screws of the fixing clips.

12.2. Overall Dimension

Fig.8 Overall and Cutout Dimensions

BATTERY VOLTAGE INPUT

The HGM1790N series controller supports a wide range of battery voltages (DC 8~35V). The negative terminal of the battery must be connected to the engine shell. The wire connecting the power supply to the battery must be over 1.5mm². If a floating charger is used, connect the charger's output wires to the battery's positive and negative terminals directly first, then connect the battery's positive and negative wires to the controller's positive and negative input ports to prevent charger interference with the controller's normal operation.

SPEED SENSOR INPUT

The speed sensor is magnetic equipment installed in the starter to detect flywheel teeth. Its connection wires to the controller should be a 2-core shielding line. The shielding layer should connect to Terminal 1 in the controller, while the other end is left in the air. The other two signal wires connect to Terminals 1 and 10 in the controller. The speed sensor's output voltage should be within AC(1~24)V (effective value) at full speed. AC12V is recommended (at rated speed). When installing the speed sensor, spin the sensor to contact the flywheel, then back out 1/3 lap, and finally lock the sensor nuts.

OUTPUT AND EXPAND RELAYS

All controller outputs are relay contact output types. If relays need to be expanded, add a freewheel diode to both ends of the expand relay's coils (for coils with DC current) or increase resistance-capacitance return circuit (for coils with AC current) to prevent disturbance to the controller or other equipment.

AC INPUT

The controller's current input must connect to an external current transformer. The current transformer's secondary side current must be 5A. Ensure the phases of the current transformer and input voltage are correct; otherwise, current collection and active power may be inaccurate.

WARNING: When there is load current, the transformer's secondary side must not be open-circuited.

WITHSTAND VOLTAGE TEST

If a high voltage test is required after the controller is installed in the control panel, disconnect all controller terminal connections to prevent high voltage from entering and damaging the controller.

13. Fault Finding

Table 13 Fault Finding