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USER MANUAL
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English trademark
CONTENTS
1 OVERVIEW ...............................................................................................................................5
2 MODULES COMPARISON ....................................................................................................... 6
3 PERFORMANCE AND CHARACTERISTICS .......................................................................... 6
4 SPECIFICATION ....................................................................................................................... 9
5 OPERATION ............................................................................................................................ 10
5.1 INDICATOR LIGHT ......................................................................................................... 10
5.2 PUSHBUTTONS ............................................................................................................. 11
5.3 LCD DISPLAY ................................................................................................................. 12
5.3.1 MAIN DISPLAY ........................................................................................................... 12
5.3.2 USER MENU AND PARAMETERS SETTING MENU ................................................ 14
5.4 AUTO START/STOP OPERATION ................................................................................ 17
5.5 MANUAL START/STOP OPERATION ........................................................................... 18
5.6 SWITCH CONTROL PROCEDURES ............................................................................. 18
5.6.1 MANUAL TRANSFER PROCEDURES ...................................................................... 18
5.6.2 AUTOMATIC CONTROL PROCEDURE .................................................................... 19
6 PROTECTIONS ...................................................................................................................... 20
6.1 WARNING ALARMS ....................................................................................................... 20
6.2 SHUTDOWN ALARMS ................................................................................................... 22
6.3 TRIP AND STOP ALARMS ............................................................................................. 24
6.4 TRIP ALARM................................................................................................................... 25
7 WIRING CONNECTION ......................................................................................................... 26
8 SCOPES AND DEFINITIONS OF PROGRAMMABLE PARAMETERS ............................... 28
8.1 CONTENTS AND SCOPES OF PARAMETERS ............................................................ 28
8.2 ENABLE DEFINITION OF PROGRAMMABLE OUTPUT PORTS .................................. 39
8.2.1 DEFINED PERIOD OUTPUT ...................................................................................... 43
8.2.2 DEFINED COMBINATION OUTPUT .......................................................................... 44
8.3 DEFINED CONTENTS OF PROGRAMMABLE INPUT PORTS (ALL ACTIVE WHEN
CONNECT TO GRAND (B~)) ..................................................................................................... 45
8.4 SELECTION OF SENSORS ........................................................................................... 47
8.5 CONDITIONS OF CRANK DINSCONNECT SELECTION ............................................. 48
9 PARAMETERS SETTING ...................................................................................................... 48
10 SENSORS SETTING .............................................................................................................. 49
11 COMMISSIONING .................................................................................................................. 49
11.1 STEP 1. SINGLE UNIT DEBUGGING............................................................................. 49
11.2 STEP 2: MANUAL PARALLEL OPERATION OFF-LOAD............................................... 49
11.3 STEP 3: MANUAL PARALLEL OPERATION ON-LOAD ................................................ 49
11.4 STEP 4: AUTOMATIC PARALLEL OPERATION............................................................ 51
12 TYPICAL APPLICATION ........................................................................................................51
13 POWER MANAGEMENT MODE ............................................................................................53
14 LOAD SHEDDING ...................................................................................................................54
15 INSTALLATION .......................................................................................................................55
16 CONNECTIONS OF CONTROLLER WITH J1939 ENGINE ..................................................56
1 OVERVIEW
HGM9510 controller is designed for manual/auto parallel system generators with similar or
different capacity. Additionally, it is suitable for single unit constant power output and mains
paralleling. It allows automatic start/stop, parallel running, data measurement, alarm protection as
well as remote control, remote measurement and remote communication function. It fit with LCD
display, optional Chinese, English and other languages interface, and it is reliable and easy to
use.
Utilizing the GOV (Engine Speed Governor) and AVR (Automatic Voltage Regulator) control
function, the controller is able to synchronize and share load automatically; it can be used to
parallel with other HGM9510 controller.
HGM9510 controller also monitors the engine, indicating the operational status and fault
conditions accurately. When abnormal condition occurs, it splits bus and shuts down the genset,
simultaneously the exact failure mode information is indicated by the LCD display on the front
panel. SAE J1939 interface enables the controller to communicate with various ECU (ENGINE
CONTROL UNIT) which fitted with J1939 interface.
The powerful 32-bit Microprocessor contained within the module allows for precision parameters
measuring, fixed value adjustment, time setting and set value adjusting and etc..Majority
parameters can be configured from front panel, and all parameters can be configured by USB
interface (or RS485) to adjust via PC. It can be widely used in all types of automatic gen-set
control system with compact structure, advanced circuits, simple connections and high reliability.
2 MODULES COMPARISON
HGM HGM HGM HGM HGM HGM HGM HGM HGM HGM
9210 9220 9310 9320 9410 9420 9610 9620 9510 9520
Dimension 3.7” 4.3”
LCD
pixel 132 x 64 480 x 272
AMF ● ● ● ● ●
BUS Monitoring ●
Parallel connection ● ●
Expansion module ● ●
Input Port 7 7 7 7 7 7 8 8 7 7
Output Port 8 8 8 8 8 8 8 8 8 8
Sensor Number 5 5 5 5 5 5 5 5 5 5
Neutral (Earth)
● ●
current
Schedule function ● ● ● ● ● ● ● ● ● ●
ETHERNET ● ●
RS485 ● ● ● ● ● ● ● ●
GSM ● ● ● ● ● ●
J1939 ● ● ● ● ● ●
USB ● ● ● ● ● ● ● ● ● ●
LINK ● ●
Real-time clock ● ● ● ● ● ● ● ● ● ●
Event log ● ● ● ● ● ● ● ● ● ●
Micro SD card ● ●
NOTE:
(1) Two of the outputs are fixed: start output and fuel output.
(2)HGM9510’s analog sensors are composed by 3 fixed sensors (temperature, pressure, level)
and 2 configurable sensors.
NOTE: The features of HGM9210/HGM9220/HGM9310/HGM9320/HGM9410/
HGM9420/HGM9520/HGM9610/HGM9620 controllers mentioned in this document may change,
please check the corresponding user manual for accurate information.
With ARM-based 32-bit SCM, high integration of hardware and more reliable;
480x272 LCD with backlight, multilingual interface (including English, Chinese or other
languages) which can be chosen at the site, making commissioning convenient for factory
personnel;
Improved LCD wear-resistance and scratch resistance due to hard screen acrylic;
Silicon panel and pushbuttons for better operation in high/low temperature environment;
RS485 communication port enable remote control, remote measuring, remote communication
via ModBus protocol.
Fitted with CANBUS port and can communicate with J1939 genset. Not only can you
monitoring frequently-used data (such as water temperature, oil pressure, engine speed, fuel
consumption and so on) of ECU machine, but also control start, stop, raising speed and
speed droop via CANBUS port.
Suitable for 3-phase 4-wire, 3-phase 3-wire, single phase 2-wire, and 2-phase 3-wire systems
with voltage 120/240V and frequency 50/60Hz;
Collects and shows 3-phase voltage, current, power parameter and frequency of Bus/mains.
For Bus, controller has loss of phase and phase sequence wrong detection functions; For
generator, controller has over voltage, under voltage, over frequency, under frequency, over
current, over power, reverse power, loss of phase, phase sequence wrong detection
functions;
Synchronization parameters : Voltage Difference Between Bus and Mains, Frequency
Difference Between Bus and Mains, Phase Difference Between Bus and mains;
Multiple running modes in auto state: with load running, off load running, demand parallel
running;
Ramp on and ramp off function;
3 fixed sensors (temperature, oil pressure and liquid level);
2 configurable sensors can be set as sensor of temperature, oil pressure or fuel level;
More kinds of curves of temperature, oil pressure, fuel level can be used directly and users
can define the sensor curves by themselves;
Precision measure and display parameters about Engine,
Temp. (WT) °C/°F (unit) both be displayed
Oil pressure (OP) kPa/psi/bar(unit) all be displayed
Fuel level (FL) %(unit)
Speed (SPD) r/min(unit)
Battery Voltage (VB) V (unit)
Charger Voltage (VD) V (unit)
4 SPECIFICATION
Parameter Details
Working Voltage DC8. 0V to 35. 0V, uninterruptible power supply
Overall Consumption <4W (Standby mode: ≤2W)
AC Input:
3 Phase 4 Wire AC 15V - 360V (ph-N)
3 Phase 3 Wire AC 30V - 620V (ph- ph)
Single Phase 2 Wire AC 15V - 360V (ph-N)
2 Phase 3 Wire AC 15V - 360V (ph-N)
Alternator Frequency 50Hz/60Hz
Speed Sensor Voltage 1. 0 V to 24 V (RMS)
Speed Sensor Frequency Maximum 10,000 Hz
Start Relay Output 16A DC28V power supply output
Fuel Relay Output 16A DC28V power supply output
Flexible Relay Output 1 7A DC28V power supply output
Flexible Relay Output 2 7A DC28V power supply output
Flexible Relay Output 3 7A DC28V power supply output
Flexible Relay Output 4 7A 250VAC passive output
Flexible Relay Output 5 7A 250VAC passive output
Flexible Relay Output 6 7A 250VAC passive output
Case Dimensions 266mm x 182mm x 45mm
Panel Cutout 214mm x 160mm
CT Secondary Current Rated 5A
Working Conditions Temperature: (-25~+70)°C Humidity: (20~93)%RH
Storage Conditions Temperature:(-30~+80)°C
Protection Level IP55 Gasket
Apply AC2.2kV voltage between high voltage terminal and low
Insulation Intensity voltage terminal;
The leakage current is not more than 3mA within 1min.
Weight 0.95kg
5 OPERATION
5.2 PUSHBUTTONS
Manual Mode Press this key and controller enters in Manual mode.
Auto Mode Press this key and controller enters in Auto mode.
Mute/Reset Alarming sound off; If trip alarm occurs, pressing the button
Alarm at least 3 seconds can reset this alarm.
1) Screen scroll;
Up/Increase
2) Up cursor and increase value in setting menu.
1) Screen scroll;
Down/Decrease
2) Down cursor and decrease value in setting menu.
1) Screen scroll;
Left
2) Left move cursor in setting menu.
1) Screen scroll;
Right
2) Right move cursor in setting menu.
WARNING: Default password is 00318, user can change it in case of others change the
advanced parameters setting. Please clearly remember the password after changing. If you forget
it, please contact SmartGen services and send all information in the controller page of “ABOUT”
to us.
Main screen show pages; use to scroll the pages and to scroll the screen.
★Main Screen, including as below,
Gen: voltage, frequency, current, active power, reactive power
Bus: voltage, frequency
Engine: speed, temperature, oil pressure
Some status
★Status, including as below,
Status of genset and ATS
★Engine, including as below,
Engine speed, engine temperature, engine oil pressure, fuel level, flexible sensor 1, flexible
sensor 2, battery voltage, charger voltage, engine accumulated run, accumulated start times.
NOTE: If connected with J1939 engine via CANBUS port, this page also includes: coolant
pressure, coolant level, fuel temperature, fuel pressure, inlet temperature, exhaust temperature,
turbo pressure, total fuel consumption and so on. (Different engine with different parameters)
★Generator, including as below,
Phase voltage, line voltage, frequency, phase sequence, current, Active Power(positive and
negative), total active power (positive and negative), Reactive Power(positive and negative), total
reactive power (positive and negative), Apparent Power, total apparent power, Power
Factor(positive and negative), average power factor (positive and negative), accumulated
energy (kWh, kVarh, kVAh), multi power, earth current, negative sequence current.
NOTE: Power factor shows as following,
Remark:
P stands for active power
Q stands for inactive power
Note:
1. Input active power, generator send active power to load.
2. Output active power, load supply electricity to generator.
3. Input reactive power, generator send reactive power to load.
4. Output reactive power, load send reactive power to generator.
★Bus, including as below,
Phase voltage, line voltage, frequency, phase sequence
★SNYC, including as below,
Volt difference, freq difference, angle difference, active power percentage, target active power
percentage, reactive power percentage, target reactive power percentage, GOV percentage, AVR
percentage and MSC status
★Alarm:
NOTE: For ECU alarms and shutdown alarms, if the alarm information is displayed, check
engine according to it, otherwise, please check the generator manual according to SPN alarm
code.
★Event log
Make records about all start/stop events (shutdown alarm, trip and stop alarm, manual /auto start
or stop) and the real time when alarm occurs.
★Others, including,
Time and Date, maintenance due, input/output ports status.
★About, including,
Issue time of software and hardware version, product PD number.
Auto mode is selected by pressing the button; a LED besides the button will illuminate to
confirm the operation.
Automatic Start Sequence:
1) When “Remote Start” is active, “Start Delay” timer is initiated;
2) “Start Delay” countdown will be displayed on LCD;
3) When start delay is over, preheat relay energizes (if configured), “preheat delay XX s”
information will be displayed on LCD;
4) After the above delay, the Fuel Relay (if configured) is energized, and then one second later,
the Start Relay is engaged. The engine is cranked for a pre-set time. If the engine fails to fire
during this cranking attempt then the fuel relay and start relay are disengaged for the pre-set
rest period; “crank rest time” begins and wait for the next crank attempt.
5) Should this start sequence continue beyond the set number of attempts, the start sequence
will be terminated, the first line of LCD display will be highlighted with black and Fail to Start
fault will be displayed.
6) In case of successful crank attempt, the “Safety On” timer is activated, allowing Low Oil
Pressure, High Temperature, Under speed and Charge Alternator Failure inputs to stabilise
without triggering the fault. As soon as this delay is over, “start idle” delay is initiated (if
configured).
7) During “start idle” delay, under speed, under frequency, under voltage alarms are inhibited.
When this delay is over, “warming up” delay is initiated (if configured).
8) In the case of a single generator system, after the “warming up” delay, if generator status is
normal, its indicator will be illuminated. If generator voltage and frequency have reached
on-load requirements, then the generator close relay will be energized; genset will take load;
generator power indicator will illuminate and generator will enter into Normal Running status.
If voltage or frequency is abnormal, the controller will initiate shutdown alarm (alarm
information will be displayed on LCD).
9) In case of running in parallel, after the warming up delay:
a) If bus has no voltage, then the controller will send a closing signal to other waiting parallel
gensets and generator close relay will activate, this prevents other sets in the system from
attempting to close their own breakers at the same time.
b) If bus has voltage or other gensets are already closed, the controller will adjust speed and
voltage through GOV and AVR to synchronize the gensets to the bus; when synchronism
requirements has been achieved, breaker close signal will be initiated and the genset will be
paralleled with the bus. Once they are paralleled, the controller will control the generator to
gradually accelerate and share load with other paralleled gensets.
1) Manual mode is selected by pressing the button; a LED besides the button will illuminate
to confirm the operation; then press button to start the gen-set; can detect crank
disconnect condition and generator accelerates to high-speed running automatically. With
high temperature, low oil pressure, over speed and abnormal voltage during generator
running, controller can protect genset to stop quickly (please refer to No.3~9 of Automatic
Start Sequence for detail procedures).
2) MANUAL STOP: Press can shuts down the running generators. (Please refer to
No.2~7 of Automatic Start Sequence for detail procedures).
NOTE: In “manual mode”, the procedures of ATS please refer to Switch Control Procedure of
generator in this manual.
Opening operation:Press ,
1) In case of single unit running, the controller sends open breaker signal.
2) During parallel operation, if button is pressed, first of all, the controller will transfer load
to other generators, and only then send an opening signal.
5.6.2 AUTOMATIC CONTROL PROCEDURE
When controller is in auto mode, the switch control procedure is automatic control procedure.
Note: The auxiliary close input should be configured necessarily and make sure the
connection is correct.
6 PROTECTIONS
7 WIRING CONNECTION
NOTE: USB ports in controller rear panel are configurable parameter ports, user can directly
program controller via PC.
NOTE: Please refer to the Modules Comparison in this manual for more products’ functions.
NOTE:
a. There are 3 conditions to make starter disconnected with engine, that is, speed sensor,
generator frequency and engine oil pressure. They all can be used separately. We
recommend that engine oil pressure should be using with speed sensor and generator
frequency together, in order to make the starter motor is separated with engine immediately
and can check crank disconnect exactly.
b. Speed sensor is the magnetic equipment which be installed in starter for detecting flywheel
teeth.
c. When set as speed sensor, must ensure that the number of flywheel teeth is as same as
setting, otherwise, “over speed stop” or “under speed stop” may be caused.
d. If genset without speed sensor, please don’t select corresponding items, otherwise, “start fail”
or “loss speed signal” maybe caused.
e. If genset without oil pressure sensor, please don’t select corresponding items.
f. If not select generator frequency in crank disconnect setting, controller will not collect and
display the relative power quantity (can be used in water pump set); if not select speed sensor
in crank disconnect setting, the rotating speed displayed in controller is calculated by
generator frequency and number of poles.
9 PARAMETERS SETTING
CAUTION: Please change the controller parameters when generator is in standby mode
only (e. g. Start conditions selection, configurable input, configurable output, various delay),
otherwise, alarming to stop and other abnormal conditions may happen.
NOTE: Maximum set value must over minimum set value in case that the condition of too
high as well as too low will happen.
NOTE: When setting the warning alarm, please set the correct return value; otherwise,
maybe there is abnormal alarm. When setting the maximum value, the return value must less
than setting; when setting the minimum value, the return value must over setting.
NOTE: Please set the generator frequency value as low as possible when cranking, in
order to make the starter be separated quickly as soon as crank disconnect.
10 SENSORS SETTING
1) When reselect sensors, the sensor curve will be transferred into the standard value. For
example, if temperature sensor is SGX (120°C resistor type), its sensor curve is SGX (120°C
resistor type); if select the SGD (120°C resistor type), the temperature sensor curve is SGD
curve.
2) When there is difference between standard sensor curves and using sensor, user can adjust it
in “curve type”.
3) When input the sensor curve, X value (resistor) must be input from small to large, otherwise,
mistake occurs.
4) If select sensor type as “None”, sensor curve is not working.
5) If corresponding sensor has alarm switch only, user must set this sensor as “None”, otherwise,
maybe there is shutdown or warning.
6) The headmost or backmost values in the vertical coordinates can be set as same as below,
11 COMMISSIONING
12 TYPICAL APPLICATION
HGM9510 typical application diagram
Note: Fuse F1:min. 2A; max. 20A. Fuse F2:max. 32A. Users should select suitable
fuse depend on practical application.
HGM9510 Genset Parallel Unit ISSUE 2016-11-03 Version 1.2 Page 51 of 64
HGM9510 GENSET PARALLEL UNIT
3 Phase 3 Wire
2 Phase 3 Wire
Note: Mains parallel function for HGM9510 controller can be selected via configurable
input port. In mains parallel mode, generator will run in parallel with mains and it will only be
able to output a fixed amount of power. (Set load mode as Gen control mode).
14 LOAD SHEDDING
Manual Trip
If NEL manual trip input is active (earthed failing edge is active), NEL1 will trip without delay; If
NEL manual trip input is active again, NEL2 will trip; If NEL manual trip input is active the third
time, NEL3 will trip. During this process, the controller do not detect if the genset power has
exceed the NEL trip value or not.
If NEL manual reconnection input is active (earthed failing edge is active), NEL3 will reconnect
without delay; If NEL manual reconnection input is active again, NEL2 will reconnect; If NEL
manual reconnection input is active the third time, NEL1 will reconnect. During this process, the
controller detects the genset power: if the genset power has fallen below the NEL reconnection
value, then the input is active; if it doesn’t, the input is deactivated.
Note: When auto trip and auto reconnection are enabled, manual trip is still active.
15 INSTALLATION
Controller is panel built-in design; it is fixed by clips when installed. The controller’s overall
dimensions and cutout dimensions for panel, please refers to as following,
Terminals of controller
3 pins data link connector Remark
CAN communication shielding
CAN GND C
line(connect with ECU terminal only)
CAN(H) A Using impedance 120Ω connecting line
CAN(L) B Using impedance 120Ω connecting line
Engine type: Cummins ISB
16.4 CUMMINS QSX15-CM570
It is suitable for CM570 engine control module. Engine type is QSX15.
Terminals of controller 50 pins connector Remark
Fuel relay output 38 Oil spout switch
Start relay output - Connect to starter coil directly
16.14 PERKINS
It is suitable for ADEM3/ ADEM4 engine control module. Engine type is 2306, 2506, 1106, and
2806.
Terminals of controller Connector Remark
Fuel relay output 1,10,15,33,34
Start relay output - Connect to starter coil directly
CAN communication shielding
CAN GND - line(connect with controller’s terminal
only)
CAN(H) 31 Using impedance 120Ω connecting line
CAN(L) 32 Using impedance 120Ω connecting line
Engine type: Perkins
HGM9510 Genset Parallel Unit ISSUE 2016-11-03 Version 1.2 Page 60 of 64
HGM9510 GENSET PARALLEL UNIT
16.15 SCANIA
It is suitable for S6 engine control module. Engine type is DC9, DC12, and DC16.
Terminals of controller B1 connector Remark
Fuel relay output 3
Start relay output - Connect to starter coil directly
CAN communication shielding
CAN GND - line(connect with controller’s terminal
only)
CAN(H) 9 Using impedance 120Ω connecting line
CAN(L) 10 Using impedance 120Ω connecting line
Engine type: Scania
16.18 VOLVO-EMS2
Volvo Engine types are TAD734, TAD940, TAD941, TAD1640, TAD1641, and TAD1642.
Terminals of controller Engine’s CAN port Remark
ECU stop
programmable output 1 6
Configurable output 1 “ECU stop”
ECU power
Programmable output 2 5
Configurable output 2 “ECU power”
3 Negative power
4 Positive power
CAN communication shielding
CAN GND - line(connect with controller’s terminal
only)
CAN(H) 1(Hi) Using impedance 120Ω connecting line
CAN(L) 2(Lo) Using impedance 120Ω connecting line
Engine type: Volvo-EMS2
NOTE: When this engine type is selected, preheating time should be set to at least 3 seconds.
16.19 YUCHAI
It is suitable for BOSCH common rail pump engine.
Terminals of controller Engine 42 pins port Remark
Fuel relay output 1.40 Connect to engine ignition lock
Start relay output - Connect to starter coil directly
CAN communication shielding
CAN GND - line(connect with controller’s this terminal
only)
CAN(H) 1.35 Using impedance 120Ω connecting line
CAN(L) 1.34 Using impedance 120Ω connecting line
16.20 WEICHAI
It is suitable for Weichai BOSCH common rail pump engine.
Terminals of controller Engine port Remark
Fuel relay output 1.40 Connect to engine ignition lock
Start relay output 1.61
CAN communication shielding
CAN GND - line(connect to the controller at this end
only)
CAN(H) 1.35 Using impedance 120Ω connecting line
CAN(L) 1.34 Using impedance 120Ω connecting line
Engine type: GTSC1
NOTE: If there is any question of connection between controller and ECU communication,
please feel free to contact Smartgen’s service.
HGM9510 Genset Parallel Unit ISSUE 2016-11-03 Version 1.2 Page 62 of 64
HGM9510 GENSET PARALLEL UNIT
17 USB
Users can set the controller’s parameters and monitor the controller’s status via the test software
which provided by Smatgen company. The connection way between PC and controller as
following:
18 FAULT FINDING