SmartGen HGM501 Genset Controller User Manual

1. Overview

The HGM501 gen-set controller is a smart digital controller designed for the control and protection of single gen-sets. It facilitates start/stop operations, data measurement, alarm indication, and shutdown protection. The controller features LED indicators, making it reliable and user-friendly. It utilizes a microprocessor for precise measurement of multiple parameters, configurable via the front panel. Its simple wiring, compact structure, and high reliability make it suitable for data display and fault protection in a wide range of diesel and petrol generator sets.

2. Performance and Characteristics

• Nixie tube displays for single-phase voltage and total active power voltage (calculated with single-phase power, assuming balanced load).
• Multifunction nixie tube display that can show single-phase frequency, single-phase current, battery voltage, total running time (max 999 hours), engine temperature, and generator temperature.
• Protections include: under voltage, over voltage, under frequency, over frequency, over load, and over temperature. It initiates a flashing alarm and then shutdown protection after a delay.
• Low oil pressure digital input provides immediate shutdown of the generator in case of low oil pressure.
• Parameters can be selected using touch-buttons.
• Supports a wide selection of temperature sensor types in settings.
• All parameters can be set via the front panel for ease of operation.
• Modular design with an anti-flaming ABS plastic enclosure, compact structure, and convenient embedded installation.

3. Technical Data

4. Operation

4.1. Button Description

The controller features several buttons for operation:

• FUNC: Used for entering settings, confirming selections, switching to frequency display during normal operation, and resetting alarms (hold for 1 second during alarm shutdown).
• UP/SCROLL (▲): Increases set values during parameter configuration or switches to the upper LED during normal operation.
• DOWN/SCROLL (▼): Decreases set values during parameter configuration or switches to the lower LED during normal operation.
• LEFT: Returns to the previous menu during parameter configuration or switches to the next (upper) LED during normal operation.
• RIGHT: Enters the next menu during parameter configuration or switches to the lower LED during normal operation.

4.2. Start/Stop Operation

Starting Procedure

To start the gen-set:

1. Turn the starter key from OFF to ON to power the controller.
2. Turn the starter key to START to begin cranking.
3. Release the starter key once the engine fires (crank disconnect condition is gen frequency > 14.0Hz).
4. The voltage, power, and frequency windows will display measured values. Use the UP/SCROLL (▲) or DOWN/SCROLL (▼) buttons to switch between indicators 1#-6# and the multifunctional window. Press the FUNC button to return to the frequency window.

LED Indicators State:

• 1#: Frequency (Hz)
• 2#: Current (A)
• 3#: Battery voltage (V)
• 4#: Run time (H)
• 5#: Engine temp.(°C)
• 6#: Generator temp.(°C)
• 7#: Auto protection (Indicates if auto protection is enabled/disabled)
• 8#: Run on indicator (Fuel relay output indicator)
• 9#: Crank indicator (Start output indicator)
• 10#: Engine oil warning (Low oil pressure indicator)

Note: Ensure all parameter settings are correct before starting the engine. The "Engine oil warning" indicator should be ON before starting the gen-set. If it is OFF, the oil pressure switch or its return circuit may be faulty.

Stopping Procedure

1. Auto stop: The system will stop automatically if an auto protection condition occurs. If low oil pressure is detected for over 2 seconds during normal running, the set will stop.
2. Manual stop: Turn the starter key from ON to OFF to shut down the gen-set.

5. Auto Protection

In auto protection mode, all protections except low oil pressure are active:

• Voltage Protection: Flashing LED indicates voltage deviation by ±10%. Shutdown occurs after a delay (7s for under voltage, 3s for over voltage).
• Frequency Protection: Flashing LED indicates frequency deviation from set points (50Hz: 45-55Hz; 60Hz: 55-65Hz). Shutdown occurs after a delay (7s for under frequency, 3s for over frequency).
• Overload Protection: Power LED flashes if overload exceeds 5%. Shutdown is initiated if overload exceeds 5%-7.5% for over 3 hours, or 7.5%-10% for over 1 hour, or more than 10% for the pre-set over power delay value (default: 30s).
• Low Oil Pressure Protection: Genset shuts down if low oil pressure occurs and lasts for more than 2s, regardless of auto protection mode.
• High Engine Temperature Protection: Flashing LED indicates high engine temperature. Shutdown occurs after a 7-second delay.
• High Generator Temperature Protection: Flashing LED indicates generator temperature exceeding 95°C. Shutdown occurs after a 7-second delay.
• Battery Voltage Protection: Flashing display indicates battery voltage below 8V or above 16.5V. Shutdown is not initiated.

Note: During Safety On delay, protection is disabled. After the delay, voltage, frequency, overload, and high temperature protections activate, deactivating fuel output.

6. Terminal Connections

The HGM501 controller back panel has the following terminals:

Note: The LINK port connects to the SmartGen SG72 adapter for PC software configuration and real-time data checking.

7. Configurable Parameters

7.1. Configurable Parameters Table

Remarks:

• Some parameters can only be configured via PC software (e.g., digital input port1, engine high temp. threshold).
• Selecting "Double Rated Volts" for AC system allows the generator to output two kinds of rated voltage.

A graph shows the TE4/TG4 sensor curve with temperature (°C) on the Y-axis and resistance (Ω) on the X-axis, with points like (26,115), (36,100), (184,60), (226,50), (402,40).

7.2. Parameter Configuration

Before initial use, configure parameters such as rated voltage, rated frequency, and rated power to match the generator. Set the C.T. ratio to match the current transformer.

1. AC System: When disconnected, press FUNC, then turn the start key from OFF to ON. Release the button after power-on. The windows will display set parameters. Use UP/SCROLL (▲) and DOWN/SCROLL (▼) to choose the AC wire type (1P/2P/3P/4P) and press FUNC to confirm and enter the next menu.
2. Rated Voltage: Select from 7 voltage variants (110-240V) using UP/SCROLL (▲) and DOWN/SCROLL (▼). Press FUNC to confirm.
3. Rated Power: Set the value using the flashing digits in the power LED window and power window, confirmed by FUNC.
4. Rated Frequency: Select 50Hz or 60Hz using UP/SCROLL (▲) and DOWN/SCROLL (▼). Press FUNC to confirm.
5. Auto Protection: Press FUNC to enable auto protection (indicator ON). Use UP/SCROLL (▲) or DOWN/SCROLL (▼) to make the indicator flash, then press FUNC to disable. Enabling is recommended.
6. CT Setting: Set the CT ratio using the flashing digits in the multifunctional window and power window, confirmed by FUNC.
7. Engine Temperature Sensor Type: Select the sensor type (L-0 to L-4) from the flashing multifunctional window using UP/SCROLL (▲) and DOWN/SCROLL (▼). Press FUNC to confirm.
8. Generator Temperature Sensor Type: Same as step 7.
9. Turn the start key from ON to OFF to finish configuration.

Note: Use the FUNC button to enter the next menu item and the UP/SCROLL (▲) button to return to the previous menu during configuration.

Caution: Change inner controller parameters only in standby mode to avoid shutdown or abnormal conditions.

8. Commissioning

Before starting the system, perform the following checks:

1. Verify all connections and wire sizes are correct and suitable.
2. Ensure all parameters are configured correctly and the oil pressure light is ON.
3. Confirm the controller DC power supply is fused and correctly connected to the battery's positive and negative terminals.
4. Take precautions to prevent the engine from starting (e.g., unplug the fuel valve wire).
5. After confirming no faults, connect the battery, turn the start key from OFF to ON. The controller will initiate the procedure.
6. Turn the start key to START for cranking. After the engine fires, remove the start key. Voltage, frequency, and power windows will display collected values.
7. For further information, contact SmartGen services.

9. Typical Wiring Diagram

A typical wiring diagram is provided, illustrating connections for:

• Generator Voltage L (Terminal 1)
• Generator Voltage N (Terminal 2)
• Load CT Secondary I (out) (Terminal 3)
• Load CT Secondary I* (in) (Terminal 4)
• Aux. Input1 (Terminal 5)
• Engine Temperature Sensor Input (Terminal 6)
• Low Oil Pressure Input (Terminal 7)
• Battery Negative Input B- (Terminal 8)
• Electric Lock ON Signal Input B+ (Terminal 9)
• Electric Lock START Input (Terminal 10)
• Start Relay Output (Terminal 11)
• Fuel Relay Output (Terminal 12)
• Fuel/Start Relay Common Port (Terminal 13)

The diagram also shows connections for the ELECTRIC SWITCH, START, and indicators for BATTERY+, FUEL, and CRANK.

10. Installation

The controller is designed for panel mounting using fixing clips. Overall and cutout dimensions are provided:

• Overall Dimensions: Height 128mm, Width 111mm, Depth 28mm (approximate).
• Cutout Dimensions: Height 121mm, Width 112mm.

1) Battery Voltage Input

Note: The HGM501 controller requires a 9-18 VDC battery. The battery negative must be securely connected to the engine enclosure. Connect the controller's power supply terminals (B+ and B-) to the battery's positive and negative terminals, respectively, using wires of at least 1.5mm². For floating chargers, connect the charger output directly to the battery positive and negative, then use single lines to connect the battery positive and negative poles to the controller's power supply input to prevent charger interference.

Warning: Do not remove the start battery while the engine is running.

2) AC Input

Connect the current transformer with a rated secondary current of 62.5mA to the controller's current input.

Warning: The C.T. secondary must not be an open circuit when the generator is on load.

3) Withstanding Voltage Test

Caution: If performing a withstanding voltage test after the controller is installed on the control panel, unplug all controller terminal connections to prevent high voltage from damaging the unit.

11. Troubleshooting