HGM4020DC GENSET CONTROLLER
USER MANUAL
CONTENT
1 2 3 4
OVERVIEW ........................................................................................................................................... 3 PERFORMANCE AND CHARACTERISTICS ...................................................................................... 3 SPECIFICATION OPERATION ............................................................................................................ 5 OPERATION ......................................................................................................................................... 6 4.1 KEY FUNCTION....................................................................................................................... 6 4.2 CONTROLLER PANEL ............................................................................................................ 7 4.3 AUTO START/STOP OPERATION .......................................................................................... 7 4.3.1 ILLUSTRATION ......................................................................................................................... 7 4.3.2 AUTO START SEQUENCE ....................................................................................................... 7 4.3.3 AUTO STOP SEQUENCE ......................................................................................................... 8 4.4 MANUAL START/STOP OPERATION ..................................................................................... 8 4.5 EMERGENCY START UP........................................................................................................ 8 4.6 GENERATOR AUTO START CONDITIONS............................................................................ 8 4.7 STOP CONDITIONS SELECTION .......................................................................................... 8 4.8 MAINS HAVE RULES .............................................................................................................. 9 5 PROTECTION ...................................................................................................................................... 9
5.1 WARNINGS .............................................................................................................................. 9 5.2 SHUTDOWN ALARMS .......................................................................................................... 12 5.3 TRIP AND STOP ALARMS .................................................................................................... 14 6 WIREING CONNECTION ................................................................................................................... 14 7 SCOPES AND DEFINITIONS OF PROGRAMMABLE PARAMETERS ............................................ 16
7.1 CONTENTS AND SCOPES OF PARAMETERS ................................................................... 16 7.2 DEFINABLE CONTENT LIST OF PROGRAMMABLE OUTPUT PORTS 1-5 ...................... 22 7.3 DEFINABLE CONTENTS OF PROGRAMMABLE INPUT PORTS 1-7 ................................ 24 7.4 SELECTION OF SENSORS .................................................................................................. 25 7.5 CONDITIONS OF CRANK DISCONNECT SELECTION ...................................................... 26 8 PARAMETERS SETTING ................................................................................................................... 26
8.1 CONTROLLER PARAMETER SETTING .............................................................................. 26 8.2 CONTROLLER INFORMATION ............................................................................................ 26 8.3 LANGUAGE SELECTION ...................................................................................................... 27 8.4 EVENT LOG ........................................................................................................................... 27 8.5 MAINTENANCE ..................................................................................................................... 27 9 SENSOR SETTING ............................................................................................................................ 28 10 COMMISSIONING .............................................................................................................................. 28 11 TYPICAL APPLICATION ..................................................................................................................... 29 12 INSTALLATION ................................................................................................................................... 29
12.1 FIXING CLIPS ........................................................................................................................ 29 12.2 OVERALL DIMENSION ......................................................................................................... 30
1
OVERVIEW
HGM4020DC genset controller is specially designed for mobile communication base station, and its functions are completely followed by the actual situation of the mobile station. It not only fits with auto start/stop genset function in multiple boot conditions, data measurement function, alarm protection function and etc, but also can control switches of 6 rectifiers at most and their parameters, at the same time it can monitor machine room temperature and voltage of battery packs to automatically start/stop genset and ensure normal working of base station.
HGM4020DC genset controller adopts micro-processor technology with precise parameters measuring, fixed value adjustment, time setting and set value adjusting functions and etc. All parameters can be configured from front panel or through programmable interface (USB or RS485 interface) via PC. It can be widely used in all types of automatic genset control system with compact structure, advanced circuits, simple connections and high reliability. 2
PERFORMANCE AND CHARACTERISTICS
— 132x64 LCD with backlit, selectable language interface (Chinese and English), push-button
operation;
— Hard-screen acrylic material been used to protect screen with great wear-resisting and
scratch-resisting performance.
— Silicone panel and pushbuttons, which can be used in extreme temperature environment.
— Two ways of RS485 communication port, one of which controls rectifiers and provide 5V power for
them, and the other is used for remote control.
— 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 mains 3-phase voltage/frequency parameters.
Mains
Line voltage (Uab, Ubc, and Uca) Phase voltage (Ua, Ub, and Uc) Frequency Hz Phase sequence
— For Mains, controller has over and under voltage and loss of phase detection functions, and mains
have rules can be selected.
— Precisely collects parameters about Engine.
Oil Pressure (OP) kPa/psi/bar
Fuel Level (FL) %(unit) Fuel Quantity Left L(unit) Speed (RPM) r/min (RPM) Voltage of Battery V (unit) Voltage of Charger V (unit) Hour count accumulation Start times accumulation
— Machine room temperature can be collected, if temperature is too high, air conditioner in the machine
will be started;
— Battery pack voltage(48V) can be collected, if battery pack is under voltage, generator will be started
to charge the battery;
— 6 start conditions can be grouped at random: mains abnormal signal, remote start signal, mains
abnormal and temperature of machine room is high, mains abnormal and battery pack voltage is low, scheduled start, and cyclic start/stop;
— 4 selectable stop requirements and battery charging completed groups to complete stop after mains
abnormal and battery voltage low;
— 5 relay output ports, and they are respectively 1 start output port, 1 fuel level output port, 3
programmable output ports;
— 6 digital input ports, in which input port 5 and input port 6 can be multiplexed as flexible sensor 1 and
flexible sensor 2;
— 2 flexible sensors, which can be selected as temperature sensor, pressure sensor or fuel level sensor;
flexible sensor 1 also can be configured as machine room temperature sensor;
— Multiple temperature, pressure and fuel level sensors can be used directly and parameters can be
users-defined;
— Fits with switches to control rectifiers, and functions of setting output voltage and current;
— Multiple crank disconnect conditions (speed sensor, generating and oil pressure) can be selected; — Access monitoring function, which can provide security for the machine room; — With emergency start function;
— With scheduled not run function(monthly, weekly, daily, duration time can be set); — With inhibit to run setting, which shall inhibit genset to run in auto mode;
— With cyclic start/stop function, controlling genset start/stop for how much time circularly;
— With run log and real-time clock. Maximum 50 running records can be memorized (loop save); — With maintenance log. Maximum 20 records can be memorized (loop save); — With event log. Maximum 99 records can be memorized (loop save);
— Parameter setting function: users can configure parameters and users-defined parameters will be
stored in the internal FLASH to avoid parameters lost in case of power dropout. All parameters can be configured from front panel or through programmable interface (USB or RS485 interface) via PC; — Waterproof security level IP65 due to rubber seal installed between the controller enclosure and panel fascia;
— With metal fixing clips;
— Modular design, anti-flaming ABS plastic enclosure, pluggable connection terminals and embedded installation way; compact structure with easy mounting.
3
SPECIFICATION OPERATION
Table 2 – Technical Parameters
Items Operating Voltage Power Consumption Alternator Volt Input Range 3Phase 4Wire 3Phase 3Wire Single Phase 2Wire 2Phase 3Wire Alternator Frequency Speed sensor voltage Speed sensor Frequency Start Relay Output Fuel Relay Output Fan Relay Output Programmable Relay Output 1 Programmable Relay Output 2 Battery Pack Volt Input RS485-1 Interface RS485-2 Interface Case Dimension Panel Cutout Working Conditions Storage Condition Protection Level Insulating Intensity Net Weight <3W (standby ≤2W) 15V AC - 360 V AC (ph-N) 30V AC - 620 V AC (ph-ph) 15V AC - 360 V AC (ph-N) 15V AC - 360 V AC (ph-N) 50Hz/60Hz 1.0V to 24.0V (RMS) 10,000 Hz (max.) 8 A DC28V DC B+ power supply output 8 A DC28V DC B+ power supply output 8 A DC28V DC B+ power supply output 8 A DC28V DC B+ power supply output 8 A DC28V DC B+ power supply output 0V DC - 35 V DC Communication port with rectifiers Baud rate 9600bps; 2 stop bit; no parity check Communication protocol YD 6313 135mm x 110mm x 44mm 116mm x 90mm Temperature: (-25~+70)°C; Relative Humidity: (20~93)%RH Temperature: (-30~+80)°C Front panel: IP65 Apply AC2.2kV voltage between high voltage terminal and low voltage terminal; The leakage current is not more than 3mA within 1min. 0.32kg Contents DC48V continuous; Range (20-65)V;
4
OPERATION
4.1 KEY FUNCTION
Table 3 - Key Function Description
Icon Function Description Stop running generator in Auto/Manual mode; In case of alarm condition, pressing the button will reset alarms; In stop mode, pressing and holding the button for 3 seconds will test indicator lights (lamp test); During stopping process, press this button again to stop generator immediately. Under manual mode, press this button will start genset; press this button during genset start up, genset will jump to next status and genset can fast-boot. Pressing this key will set the module into manual mode. Pressing this key will set the module into auto mode. Reserved Pressing this key will enter into Main Menu; In setting parameter status, press this key will shift cursor or confirm setting value. Scrolls the screen up; Shift the cursor up or increase the set value in parameter setting menu. Scrolls the screen down; Shift the cursor down or decrease the set value in parameter setting menu. Stop/ Reset Start Manual Auto Close/Open Set/Confirm Up/Increase Down/Decrease
4.2 CONTROLLER PANEL
Fig.1 - HGM4020DC Front Panel Indication
NOTE: Part of indicator lights illustration:
Alarm Indicators: slowly flash when warning alarms occur; fast flash when shutdown alarms occur; light is off when no alarms occur.
Status Indicators: Light is off when genset is standby; flash once per second during start up or shut down; always on when in normal operation.
4.3 AUTO START/STOP OPERATION 4.3.1 ILLUSTRATION Press
, and its indicator lights up, which means controller enters Auto Start mode.
4.3.2 AUTO START SEQUENCE
a) When pre-set start conditions is satisfied, auto mode indicator flashes and meanwhile “start delay”
countdown is displayed on LCD;
b) After start delay, preheat relay outputs (if configured), and “preheat time
x s” is shown on LCD.
c) When preheat delay is over, fuel relay outputs for 1s and then start relay outputs; if engine crank fails
during cranking time, the fuel relay and start relay is deactivated and enter into “crank rest time” to wait for next crank.
d) If engine crank fails within setting times, the fifth line of LCD turns black and “failed to start” alarm
appears on the fifth line of LCD display at the same time.
e) In case of successful crank attempt, “safe time x s” starts. During this period, low oil pressure, under
speed, charge failure alarms and auxiliary inputs (if configured) are disabled. As soon as this delay is over, “start idle x s” is initiated (if configured).
f) In the process of “start idle speed”, under speed, under frequency, under voltage alarms are inacitve.
When this delay is over, “start warm up x s” starts (if configured).
g) When warming up is over, if generator state is normal, then its indicator will be illuminated. If generator
voltage has reached on-load requirements, the controller shall control rectifiers to output, and output indicators shall be displayed on LCD. Generator goes into normal running state; if generator voltage is abnormal, the controller will initiate shutdown alarm (shutdown alarm will be displayed on LCD).
4.3.3 AUTO STOP SEQUENCE a) b) c) d) e) f)
If pre-set start conditions cannot be satisfied, “stop delay x s” will be started.
When stop delay is over, “cooling time x s” is started, and rectifier output is closed; When “stop idle x s” (if configured) starts, idle speed relay is energized;
When “ETS hold time x s” starts, ETS relay is energized. Fuel relay output is deactivated;
When “wait stop x s” starts, the controller automatically detects whether the genset stops completely; When genset stops completely, it enters standby status; If genset fails to stop, controller will initiate “failed to stop warn” alarm (“fail to stop warn” is displayed on LCD).
4.4 MANUAL START/STOP OPERATION a) Manual Start: Press
and controller enters Manual Mode. A LED besides the button will be
illuminated; In this mode, press button to start the genset, and controller shall automatically judge crank success and accelerate to high speed running. If low oil pressure, over speed and abnormal voltage occurs during genset running, controller can effectively protect genset to stop (for detailed procedures please refer to No.b~g of Auto start sequence). When genset goes into normal running, the controller shall control rectifiers to output.
b) Manual Stop: Press key and it can stop the running genset. (for detailed procedures please refer
to No.b~f of Auto stop sequence) 4.5 EMERGENCY START UP
Simultaneously press and in manual mode and tit can force generator to crank. At this time, successful start will not be judged according to crank disconnect conditions, but operator will have to control crank disconnect manually; when operator observes that the engine has fired, he/she should release the button and start output will be deactivated, safety on delay will be initiated. 4.6 GENERATOR AUTO START CONDITIONS
There are 6 generator auto start conditions. Genset will start up in case any one condition is satisfied; after genset is started automatically, if corresponding stop condition is reached, genset will stop.
Table 4 – Start Conditions
No. 1 2 3 4 Conditions Mains Fail Start Remote Start Cycle Run Scheduled Run Mains Fail And Pile Under Volt Start Description Genset will start when mains is abnormal. Genset will start when remote start signal is active. Genset will start when its stop time is over cyclic stop time (single unit cycle). Genset will start when scheduled start timer is due. Corresponding Stop Conditions Genset will stop when mains is normal. Genset will stop when remote start signal is deactivated. Genset will stop when normal running time is over cyclic start time (single unit cycle) . Genset will stop when scheduled running timer is overdue. If mains is normal, battery pack Genset will start when mains charging time reaches to charging is abnormal and battery complete time or complied with voltage is lower than the selected stop conditions, genset will pre-set limit of battery pack. stop. Genset will start when mains Genset will stop when mains is is abnormal and machine normal and machine room room temperature is higher temperature is under the setting than the setting temperature temperature lower limit. upper limit. 5 6 Mains Fail And Room Temp High Start 4.7 STOP CONDITIONS SELECTION
When mains is abnormal and pile is under voltage, genset will be started. If mains goes back to normal status and battery pack charging time reaches to charge completion time or complied with selected stop conditions, genset will stop. Optional stop contions are as below:
0: Pile Volt is higher than the upper limit and load current is lower than the lower limit; 1: Pile volt is higher than the upper limit; 2: Load current is lower than the lower limit;
3: Pile Volt is higher than the upper limit or load current is lower than the lower limit;
NOTE: Load current lower limit detection is active only while genset is normal running and meanwhile genset will stop only when load current detection time is reached.
4.8 MAINS HAVE RULES
Mains have rules suit for 3P4W/3P3W AC system.
Table 5 – Mains Have Rules
No. 1 2 3 4 5 5
Rules Description B/C phase cannot be missing; One of phase B/C can be missing; Two of phase B/C can be missing; One of three phases can be missing; Two of three phases can be missing; Phase A must be electrified. Phase A can not be electrified. PROTECTION
5.1 WARNINGS
When controller detects warning signals, it is warning only and not to stop the genset. Besides, the LCD displays the warning information.
Table 6 - Warning Alarm Types
No. 1 2 Type Low Pressure Warn Description 3 4 5 6 7 8 9 10 When the controller detects that the oil pressure has fallen below the pre-set value, it will initiate a warning alarm and the corresponding alarm information will be displayed on LCD. After ETS hold time/wait stop delay has expired, if gen-set does not stop Failed to Stop Warn completely, it will initiate a warning alarm and the corresponding alarm information will be displayed on LCD. When the controller detects that the fuel level has fallen below the pre-set Low Fuel Level value, or detects that the low fuel level warning input is active, it will initiate Warn a warning alarm and the corresponding alarm information will be displayed on LCD. Reserved When the controller detects that battery voltage has fallen below the Bat. Under Volt pre-set value, it will initiate a warning alarm and the corresponding alarm Warn information will be displayed on LCD. When the controller detects that battery voltage has exceeded the pre-set Bat. Over Volt value, it will initiate a warning alarm and the corresponding alarm Warn information will be displayed on LCD. When the controller detects that the auxiliary input warning signals, it will Input Warn initiate a warning alarm and the corresponding alarm information will be displayed on LCD. When the controller detects that the engine speed is 0 and the delay is 0, it Loss Speed Warn will initiate a warning alarm and the corresponding alarm information will be displayed on LCD. When the controller detects that the temperature of machine room has Room Temp High exceeded pre-set temp. value (including sensor open circuit), it will initiate Warn a warning alarm and the corresponding alarm information will be displayed on LCD. When the controller detects that the oil pressure sensor is open circuit and Oil Sensor Open the action selects “Warning”, it will initiate a warning alarm and the Warn corresponding alarm information will be displayed on LCD.
No. 11 12 13 14 15 16 17 Type Fuel Sensor Open Warn Description 18 19 When the controller detects that the fuel level sensor is open circuit and the action selects “Warning”, it will initiate a warning alarm and the corresponding alarm information will be displayed on LCD. When controller detects the genset voltage is higher than the set value, it Gen Over Voltage will send warning signals and the corresponding alarm information will be Warn displayed on LCD. When controller detects the voltage is lower than the set value, it will send Gen Under warning signals and the corresponding alarm information will be displayed Voltage Warn on LCD. Reserved Reserved Reserved Reserved When genset running time has exceeded the user-set maintenance time Maintenance Time and the action selects “Warning”, it will initiate a warning alarm and the Warn corresponding alarm information will be displayed on LCD. The maintenance alarm will reset if the action selects “Inactive”. When the controller detects that external battery “failed to charge” input is Failed to Charge IN active, it will initiate a warning alarm and the corresponding alarm information will be displayed on LCD. When the controller detects that battery pack voltage has fallen below the Pile Under Voltage pre-set lower limit value, it will initiate a warning alarm and the Warn corresponding alarm information will be displayed on LCD. When the controller detects that door inhibit input is active, it will initiate a warning alarm and the corresponding alarm information will be displayed on LCD. If the config. sensor 1 is set as temperature sensor, when the controller detects that the temperature sensor 1 is open circuit and the action selects “Warn”, it will initiate a warning alarm and the corresponding alarm information will be displayed on LCD. If the config. Sensor 1 is set as oil pressure sensor, when the controller detects that the oil pressure sensor is open circuit and the action selects “Warn”, it will initiate a warning alarm and the corresponding alarm information will be displayed on LCD. If the config. sensor 1 is set as level sensor, when the controller detects that the level sensor is open circuit and the action selects “Warn”, it will initiate a warning alarm and the corresponding alarm information will be displayed on LCD. If the config. sensor 2 is set as temperature sensor, when the controller detects that the temperature sensor is open circuit and the action selects “Warn”, it will initiate a warning alarm and the corresponding alarm information will be displayed on LCD. If the config. Sensor 2 is set as oil pressure sensor, when the controller detects that the oil pressure sensor is open circuit and the action selects “Warn”, it will initiate a warning alarm and the corresponding alarm information will be displayed on LCD. If the config. sensor 2 is set as level sensor, when the controller detects that the level sensor is open circuit and the action selects “Warn”, it will initiate a warning alarm and the corresponding alarm information will be displayed on LCD. 20 21 22 23 24 Door Inhibit Warn Reserved Reserved Temp 1 Open Warn Pressure 2 Open Warn Level 2 Open Warn Temp 2 Open Warn Pressure 3 Open Warn Level 3 Open Warn 25 26 27 28 29
No. 30 Type Description 31 32 33 34 35 36 When the controller detects that config. Sensor 1 temperature (sensor High type: temperature sensor) has exceeded the pre-set value, it will initiate a Temp.1 Warn warning alarm and the corresponding alarm information will be displayed on LCD. When the controller detects that config. sensor 1 oil pressure (sensor type: Low Pressure 2 oil pressure sensor) has fallen below the pre-set value, it will initiate a Warn warning alarm and the corresponding alarm information will be displayed on LCD. When the controller detects that config. Sensor 1 fuel level (sensor type: Low Level 2 Warn level sensor) has fallen below the pre-set value, it will initiate a warning alarm and the corresponding alarm information will be displayed on LCD. When the controller detects that config. Sensor 2 temperature (sensor High type: temperature sensor) has exceeded the pre-set value, it will initiate a Temp.2 Warn warning alarm and the corresponding alarm information will be displayed on LCD. When the controller detects that config. sensor 2 oil pressure (sensor type: Low Pressure 3 oil pressure sensor) has fallen below the pre-set value, it will initiate a Warn warning alarm and the corresponding alarm information will be displayed on LCD. When the controller detects that config. Sensor 2 fuel level (sensor type: Low Level 3 Warn level sensor) has fallen below the pre-set value, it will initiate a warning alarm and the corresponding alarm information will be displayed on LCD. When any one of inputs is configured as “Low Oil Level Warn”, and is input Low Oil Level port is active, controller will initiate a warning alarm and the corresponding Warn IN alarm information will be displayed on LCD.
5.2 SHUTDOWN ALARMS
When controller detects shutdown alarm, it will immediately control rectifiers to stop outputting and stop the genset, and the corresponding alarm information will be displayed on LCD.
Table 7 – Shutdown Alarms
No. 1 2 3 4 5 6 7 8 Type Emergency Stop Alarm Over Speed Shutdown Under Speed Shutdown Loss Speed Shutdown Reserved Reserved Gen Over Volt Shutdown Gen Under Volt Shutdown Over Current Shutdown Failed To Start High Temp. Shutdown Low Pressure Shutdown No Gen Freq Shutdown Input Shutdown Fuel Level Shutdown Oil Sensor Open Shut. Fuel Sensor Open Shut Reserved Maintenance Time Shut. Description When controller detects emergency stop input is active, it will send stop signals and the corresponding alarm information will be displayed on LCD. When controller detects the engine speed value is higher than the set value, it will send stop signals and the corresponding alarm information will be displayed on LCD. When controller detects the speed value is lower than the set value, it will send stop signals and the corresponding alarm information will be displayed on LCD. When controller detects speed value equals to 0, and delay value isn’t 0, it will send stop signals and the corresponding alarm information will be displayed on LCD. When controller detects the generator voltage value is higher than the set value, it will send stop signals and the corresponding alarm information will be displayed on LCD. When controller detects the voltage value is lower than the set value, it will send stop signals and the corresponding alarm information will be displayed on LCD. When controller detects the current value is higher than the set value and duration time is over than over current delay, and alarm action selects “shutdown”, it will send stop signals and the corresponding alarm information will be displayed on LCD. If genset start fails within setting of start times, controller will send stop signals and the corresponding alarm information will be displayed on LCD. When controller detects temperature of water/cylinder is higher than the set value, it will send stop signals and the corresponding alarm information will be displayed on LCD. When controller detects oil pressure is lower than the set value, it will send stop signals and the corresponding alarm information will be displayed on LCD. When controller detects genset voltage is 0, it will send stop signals and the corresponding alarm information will be displayed on LCD. When controller detects active external shutdown alarm signals, it will send stop signals and the corresponding alarm information will be displayed on LCD. When controller detects the sample value, which adopted by the programmable fuel level sensor, is lower than the pre-set value, it will send stop signals and the corresponding alarm information will be displayed on LCD. When controller detects sensor, which connects to oil pressure sensor, is open circuit, and the action selects “shutdown”, it will send stop signals and the corresponding alarm information will be displayed on LCD. When controller detects sensor, which connects to fuel level sensor, is open circuit, and the action selects “shutdown”, it will send stop signals and the corresponding alarm information will be displayed on LCD. When genset operation time exceeds maintenance time that user pre-set and the action selects “shutdown”, it will send stop signals and the corresponding alarm information will be displayed on LCD. 9 10 11 12 13 14 15 16 17 18 19
No. 20 Type Temp 1 Open Shutdown Pressure 2 Open Shut. Level 2 Open Shutdown Temp 2 Open Shutdown Pressure 3 Open Shut. Level 3 Open Shutdown High Temp. 1 Shutdown Low Pressure 2 Shutdown Low Fuel Level 2 Shutdown High Temp. 2 Shutdown Low Pressure 3 Shutdown Low Fuel Level 3 Shutdown Description When controller detects temp. sensor, which connects to programmable sensor 1, is open circuit, and the action selects “shutdown”, it will send stop signals and the corresponding alarm information will be displayed on LCD. When controller detects pressure sensor, which connects to programmable sensor 1, is open circuit, and the action selects “shutdown”, it will send stop signals and the corresponding alarm information will be displayed on LCD. When controller detects fuel level sensor，which connects to programmable sensor 1, is open circuit, and the action selects “shutdown”, it will send stop signals and the corresponding alarm information will be displayed on LCD. When controller detects temp. sensor, which connects to programmable sensor 2, is open circuit, and the action selects “shutdown”, it will send stop signals and the corresponding alarm information will be displayed on LCD. When controller detects pressure sensor, which connects to programmable sensor 2, is open circuit, and the action selects “shutdown”, it will send stop signals and the corresponding alarm information will be displayed on LCD. When controller detects fuel level sensor，which connects to programmable sensor 2, is open circuit, and the action selects “shutdown”, it will send stop signals and the corresponding alarm information will be displayed on LCD. When controller detects the sample value, which adopted by the programmable sensor 1(sensor type is temp. sensor), is higher than the pre-set value, it will send stop signals and the corresponding alarm information will be displayed on LCD. When controller detects the sample value, which adopted by the programmable sensor 1(sensor type is pressure sensor), is lower than the pre-set value, it will send stop signals and the corresponding alarm information will be displayed on LCD. When controller detects the sample value, which adopted by the programmable sensor 1 (sensor type is level sensor), is lower than the pre-set value, it will send stop signals and the corresponding alarm information will be displayed on LCD. When controller detects the sample value, which adopted by the programmable sensor 2(sensor type is temp. sensor), is higher than the pre-set value, it will send stop signals and the corresponding alarm information will be displayed on LCD. When controller detects the sample value, which adopted by the programmable sensor 2(sensor type is pressure sensor), is lower than the pre-set value, it will send stop signals and the corresponding alarm information will be displayed on LCD. When controller detects the sample value, which adopted by the programmable sensor 2 (sensor type is level sensor), is lower than the pre-set value, it will send stop signals and the corresponding alarm information will be displayed on LCD. 21 22 23 24 25 26 27 28 29 30 31
5.3 TRIP AND STOP ALARMS
When controller detects trip and stop alarms, it will immediately control rectifiers to stop outputting, and stop the genset after cooling time.
Table 8 – Trip and Stop Alarms
No. 1 Type Over Current ELE Trip Description When controller detects the genset current is over than the pre-set value (delay time is expired) and the action selects “trip and stop”, it will send alarm signals and the corresponding alarm information will be displayed on LCD. 6 WIREING CONNECTION
Fig.2 – Rear Panel Drawing
Table 9 –Terminal Wire Connection
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Function PE RS485+ RS485- GND EM. STOP AUX. INPUT 1 AUX. INPUT 2 AUX. INPUT 3 GND ENGINE TEMP OIL PRESSURE FUEL LEVEL AUX. SENSOR POWER SUPPLY 48V+ POWER SUPPLY 48V- PE RS485+ RS485- 0V 5V MP1 MP2 Battery Voltage B+ Battery Voltage B- FUEL (8A) CRANK (8A) FAN (8A) AUX. OUTPUT 1 (8A) AUX. OUTPUT 2 (8A) Mains R-phase voltage monitoring input Mains S-phase voltage monitoring input Mains T-phase voltage monitoring input Mains line N1 Input Cable Size Remark 1.0mm2 Ground connected terminal for anti-thunder; 0.5mm2 Communication terminal for connecting remote monitoring device; 0.5mm2 Resistance-120Ω shielding wire is recommended; single end of which shall be ground connected. 1.0mm2 Connects B-; 1.0mm2 Ground connected is active (B-); 1.0mm2 Ground connected is active (B-); For settings 21.0mm Ground connected is active (B-); please see Table 12. 1.0mm2 Ground connected is active (B-); 1.0mm2 Connects B-; 1.0mm2 Act as programmable sensor 1, For settings please or digital input 5; see Table 13. 1.0mm2 Connects oil pressure resistive sensor; 21.0mm Connects level resistive sensor; 1.0mm2 Act as programmable sensor 2, For settings please or digital input 6; see Table 13. 2.5mm2 Connects battery positive; if it is over 30m, be in parallel with double wires; max. 20A fuse is advised. 22.5mm Connects battery negative; 1.0mm2 Ground connected terminal for anti-thunder; 0.5mm2 Communication terminal for connecting remote monitoring device; 20.5mm Resistance-120Ω shielding wire is recommended; single end of which shall be ground connected. 0.5mm2 Power for rectifier module; 0.5mm2 0.5mm2 Connects turbo sensor; shielding wire is advised; MP2 0.5mm2 connects B- inside controller already. 1.0mm2 Connects starter battery positive; 1.0mm2 Connects starter battery negative; 1.5mm2 Free volts relay output, rated 8A; 1.5mm2 1.5mm2 Free volts relay output, rated 8A; 1.5mm2 1.5mm2 Free volts relay output, rated 8A; 1.5mm2 1.5mm2 Free volts relay output, rated 8A; 1.5mm2 1.5mm2 Free volts relay output, rated 8A; 1.5mm2 Connected to R-phase of mains (2A fuse 1.0mm2 recommended). Connected to S-phase of mains (2A fuse 1.0mm2 recommended). Connected to T-phase of mains (2A fuse 1.0mm2 recommended). 21.0mm Connected to line N of mains
7
SCOPES AND DEFINITIONS OF PROGRAMMABLE PARAMETERS
7.1 CONTENTS AND SCOPES OF PARAMETERS
Table 10 - Parameters Settings and Scope
No. Mains 1 2 3 Items Range Default Description 0: 3 Phase, 4 Wire(3P4W); 1: 2 Phase, 3 Wire (2P3W); 2: 1 Phase, 2 Wire (1P2W); 3: 3 Phase, 3 Wire (3P3W). The time from mains abnormal to normal or from normal to abnormal; When mains voltage has exceeded the set value, Mains Over Voltage is active. When set the value as 620V, the controller does not detect over voltage signal. Backlash: 10V. When mains voltage has fallen below the set value, Mains Under Voltage is active. When set the value as 30V, the controller does not detect under voltage signal. Backlash: 10V. 0: A: Must have; B/C can’t lack; 1:A: Must have; B/C can lack one; 2:A: Must have; B/C can lack two; 3:A: Can have; A/B/C can lack one; 4:A: Can have; A/B/C can lack two; Time from auto start signal is active to genset is started. Time from auto start signal is deactivated to genset is stopped. Power-on time of heater plug before starter is powered up. Power-on time of starter for each time. The waiting time before second power up when engine start fails. Alarms for low oil pressure, under speed, under frequency/voltage, charge alt failure are inactive. Idle speed running time of genset at starting. Warming time before genset takes load, after it goes into high speed running. Radiating time before genset stop, after it unloads. Idle speed running time at genset stopping. Stop electromagnet’s power on time at genset stopping. When “ETS time” is set as 0, it is time needed between ending of genset idle delay and genset complete stop; When “ETS time” is not 0, it is time between ending of ETS hold delay and genset complete stop. Keeping open time of Louver after genset’s complete stop; Mains AC System Mains Normal Delay Mains Abnormal Delay Mains Over Voltage (0-3) (0-3600)s (0-3600)s 0 10 5 4 (30-620)V 276 5 Mains Under Voltage (30-620)V 184 6 Timers 1 2 3 4 5 6 7 8 9 10 11 Mains Have Rules (0-4) 0 Start Delay Stop Delay Pre-heat Delay Cranking Time Crank Rest Time Safety On Time Start Idle Time Warming Up Time Cooling Time Stop Idle Time ETS Solenoid Hold (0-3600)s (0-3600)s (0-300)s (3-60)s (3-60)s (1-60)s (0-3600)s (0-3600)s (3-3600)s (0-3600)s (0-120)s 1 1 0 8 10 10 0 10 10 0 20 12 Stop Duration (0-120)s 0 13 Engine Louver Hold Open (0-3600)s 30
No. 1 Items Flywheel Teeth Under Speed Shutdown Over Speed Shutdown Loss Speed Delay Range (10.0-300.0) Default 118.0 Description Tooth number of the engine, it is for judging starter crank disconnect conditions and inspecting engine speed. When engine speed has fallen below the set value and delay time is expired, “Under Speed Shutdown” is active. It will initiate a shutdown alarm signal. When engine speed has exceeded the set value and delay time is expired, “Over Speed Shutdown” is active. It will initiate a shutdown alarm signal. It is delay time after speed signal lost, if the delay time is set as 0s, it is only warning not shutdown. When battery voltage has exceeded the set value and remains for 20s, it will initiate a warning alarm signal. It is only warning, not to shutdown the generator. When battery voltage has fallen below the set value and remains for 20s, It will initiate a warning alarm signal. It is only warning, not to shutdown the generator. As generator is normal running, when voltage difference between alternator D+(WL) and B+ exceeds the set value and remains for 5s, it will initiate a charging failure warning alarm signal. Maximum times of crank attempts. When it reaches this number, controller will send start failure signal. Crank disconnect conditions: generating, speed and oil pressure, aiming at disconnect the motor and engine as soon as possible. When engine speed is higher than the set value, then it is considered that genset start is successful, and starter will be disconnected. During starting process, when generator voltage is higher than the set value, starter will be disconnected. During starting process, when generator oil pressure is higher than the set value, then it is considered that genset start is successful, and starter will be disconnected. When crank disconnect condition contains oil pressure, if engine oil pressure is higher than pre-set value and delay time is expired, then it is considered that genset start is successful, and starter will be disconnected. Over volt shutdown setpoint and delay value; when it is set to 620V, over voltage shutdown signal shall not be detected; Under volt shutdown setpoint and delay value; when it is set to 30V, under voltage shutdown signal shall not be detected; When generating voltage is higher than this value, then it is considered that over voltage 2 (0-6000)RPM 1200 3 (0-6000)RPM 1710 4 (0-20.0)s 5.0 5 Battery Over Volt (12.0-40.0)V 33.0 6 Battery Under Volt (4.0-30.0)V 8.0 7 Charge Alt. Fail (0.0-30.0)V 6.0 8 9 Start Attempts Disconnect Conditions Disconnect Speed (1-10) times (0-6) 3 2 10 (0-3000)RPM 360 11 Disconnect Voltage (0-99.9)V 14.0 12 Disconnect OP (0-400)kPa 200 13 Disconnect OP Time (0.0-20.0)s 0.0 Generator 1 Over Volt Shutdown 2 3 4 5 Under Volt Shutdown Over Volt Warn (3.0-99.9)V (0-60.0)s (3.0-99.9)V (0-60.0)s (3.0-99.9)V 60.0 10.0 40.0 10.0 58.0
No. Items Range Default Description is established, and meanwhile warning alarm is initiated. When it is set to 620V, warning signal shall not be detected; When sample voltage is lower than this, then it is considered under voltage is established, and meanwhile warning signal is initiated. When it is set to 30V, warning signal shall not be detected. It used for load over current calculating. 0: Not used; 1: Warn; 2: Shutdown; 3: ELE Trip. Over current delay starts when load current exceeded the set percentage value. 0: Definite Time; 1: IDMT(Inverse Definite Minimum Time). Definite Time: over current delay value IDMT: delay multiplier value. 6 Load 1 2 Under Volt Warn (3.0-99.9)V 46.0 Full Load Current Over Current (5-6000)A (0-3) (50-130)% (0-1) 50 2 120 0 30 36 0 0 0 0 0 0 0 0 0 0 0 0 3 Over Current Delay (0-3600)s (1-36) (0-23)h: (0-59)min (0-23)h: (0-59)min (0-23)h: (0-59)min (0-23)h: (0-59)min (0-23)h: (0-59)min (0-23)h: (0-59)min Inhibit Run 1 2 3 4 5 6 Inhibit Run 1 Start Inhibit Run 1 Stop Inhibit Run 2 Start Inhibit Run 2 Stop Inhibit Run 3 Start In auto mode, inhibit genset running between start time and end time. Inhibit Run 3 Stop Analog Sensors Oil Pressure Sensor Curve Type Open Act 1 2 (0-12) (0-2) 8 1 3 Low OP Shutdown (0-400)kPa 103 4 Low OP Warn (0-400)kPa 124 Default as SGX. For details please see Table 13. 0 : Indication (oil pressure sensor will show “+++”); 1: Warn; 2: Shutdown When the oil pressure of the external sensor falls below the set value (only detect after “safety on delay”), “low oil pressure” shutdown alarm is initiated. If it is configured as 0, “low oil pressure” alarm signal will not be initiated (only applicable for oil pressure sensor). When the oil pressure of the external sensor falls below the set value (only detect after “safety on delay”), “low oil pressure” warning alarm is initiated. If it is configured as 0, “low oil pressure” alarm signal will not be initiated (only applicable for oil pressure sensor). Default is SGD. For details please see Table 13. 0: Indication (fuel level sensor will show “+++”); 1: Warn; 2: Shutdown When the fuel level of the external sensor falls below the set value (always detect), “low fuel level” shutdown alarm is initiated. If Fuel level Sensor 1 2 3 Curve Type Open Act (0-7) (0-2) 3 1 0 Low Level Shutdown (0-100)%
No. Items Range Default Description it is configured as 0, “low fuel level” alarm signal will not be initiated. When the fuel level of the external sensor falls below the set value (always detect), “low fuel level” warning alarm is initiated. If it is configured as 0, “low fuel level” alarm signal will not be initiated. If fuel level falls below the pre-set value and lasts for over 10s, “fuel pump on” signal will be initiated. If fuel level exceeds the pre-set value and lasts for over 10s, “fuel pump off” signal will be initiated. 0: Disable; 1: Enable Convert the fuel level percentage display to volume display. 0: Digital input 5; 1: Temperature sensor; 2: Pressure sensor; 3: Level sensor; 4: Room temperature sensor. Make a choice according to sensor type; for details please see Table 13. 0: Indication (related sensor will show “+++”); 1: Warn; 2: Shutdown. Set this according to the sensor type; For temp. sensor, if sampling value exceeds the pre-set value, controller will initiate shutdown alarms. If it is set as 140, shutdown alarms will not be sent. For oil pressure sensor and fuel level sensor, if sampling value falls below the pre-set value, controller will initiate shutdown alarms. If it is set as 0, shutdown alarms will not be sent. Set this according to the sensor type; For temp. sensor, if sampling value exceeds the pre-set value, controller will initiate warning alarms. If it is set as 140, warning alarms will not be sent. For oil pressure sensor and fuel level sensor, if sampling value falls below the pre-set value, controller will initiate warning alarms. If it is set as 0, warning alarms will not be sent. If temperature of machine room exceeds the pre-set value, controller will initiate warning alarms. When temp. sensor is selected, fan open/close is based on the values. 0: Digital input 6; 1: Temperature sensor; 4 Low Level Warn (0-100)% 20 5 6 7 8 Fuel Pump On Fuel Pump Off Fuel Tank Capacity Enable Fuel Tank Capacity (0-100)% (0-100)% (0-1) (0-10000)L 25 80 0 1000 Auxiliary Sensor 1 1 Sensor Type (0-4) (0-10) (0-10) (0-5) (0-10) (0-2) 4 2 3 Curve Type Open Act 9 1 4 Shutdown Value (0-400) 98 5 Warn Value (0-400) 95 6 7 Room Temp. High Warn Fan On Temp (0-60)℃ (0-400) ℃ (0-400) ℃ (0-3) 40 85 80 0 8 Fan Off Temp Aux. Sensor 2 1 Sensor Type
No. Items Range (0-10) (0-10) (0-5) (0-2) Default Description 2: Oil pressure sensor; 3: Fuel level sensor; Make a choice according to sensor type; for details please see Table 13. 0: Indication (related sensor will show “+++”); 1: Warn; 2: Shutdown. Set this according to the sensor type; For temp. sensor, if sampling value exceeds the pre-set value, controller will initiate shutdown alarms. If it is set as 140, shutdown alarms will not be sent. For oil pressure sensor and fuel level sensor, if sampling value falls below the pre-set value, controller will initiate shutdown alarms. If it is set as 0, shutdown alarms will not be sent. Set this according to the sensor type; For temp. sensor, if sampling value exceeds the pre-set value, controller will initiate warning alarms. If it is set as 140, warning alarms will not be sent. For oil pressure sensor and fuel level sensor, if sampling value falls below the pre-set value, controller will initiate warning alarms. If it is set as 0, warning alarms will not be sent. Factory default: emergency stop alarm input, for details please see Table 12. 0: close to activate; 1: open to activate. It is time from detection of the input port is active to action confirm. Factory default: remote start (on load), for details please see Table 12. 0: close to activate; 1: open to activate. It is time from detection of the input port is active to action confirm. Factory default: door inhibit input, for details please see Table 12. 0: close to activate; 1: open to activate. It is time from detection of the input port is active to action confirm. Factory default: not used, for details please see Table 12. 0: close to activate; 1: open to activate. It is time from detection of the input port is active to action confirm. Factory default: not used, for details please see Table 12. 0: close to activate; 1: open to activate. It is time from detection of the input port is active to action confirm. Factory default: not used, for details please see Table 12. 0: close to activate; 1: open to activate. It is time from detection of the input port is active to action confirm. 2 3 Curve Type Open Act 3 1 4 Shutdown Value (0-400) 98 5 Warn Value (0-400) 95 Digital Input Ports (0-31) 1 Input 1 Setting (0-1) (0-20.0)s (0-31) 2 Input 2 Setting (0-1) (0-20.0)s (0-31) 3 Input 3 Setting (0-1) (0-20.0)s (0-31) 4 Input 4 Setting (0-1) (0-20.0)s (0-31) 5 Input 5 Setting (0-1) (0-20.0)s (0-31) 6 Input 6 Setting (0-1) (0-20.0)s 3 0 2.0 9 0 2.0 22 0 2.0 0 0 2.0 0 0 2.0 0 0 2.0
No. Items Relay Output Ports 1 2 3 4 5 1 2 Output 1 Output 2 Output 3 Output 4 Output 5 Power On Mode Module Address Range (0-50) (0-50) (0-50) (0-50) (0-50) (0-2) (1-254) (0-9999) (1-20)s (0.0-99.9)V (0.0-99.9)A (1-6) (0-1) (0-2) (1-31) (0-6) (0-23)h (0-59)min (0-30000)min Default 20 19 38 0 0 0 1 0318 3 53.5 50.0 4 0 0 1 0 0 0 30 Description Factory default: fuel output, for details please see Table 11. Factory default: start output, for details please see Table 11. Factory default: fan output, for details please see Table 11. Factory default: not used, for details please see Table 11. Factory default: not used, for details please see Table 11. 0: Stop Mode; 1: Manual Mode; 2: Auto Mode. It is communication address of the controller. For details please see NOTE 2. It is used to set date of controller. Pulse output time of opening door remotely; 0: Disable; 1: Enable Cyclic selection: 0: Monthly; 1: Weekly; 2: Daily; Day(cyclic selection: 0: monthly) Week(cycle selection: 1: weekly) Time(Hour) Time(Minute) Duration time Module Settings 3 Password 4 Date and Time 5 Door Opening Time 6 Rectifier Volt 7 Rectifier Current 8 Rectifier Amount Inhibit Auto Start 1 Inhibit Auto Start Set 2 Inhibit AutoStartTim Auto Start Mains Abnormal Start 1 Start Set Remote Start 1 Start Set Cycle Start 1 Start Set 2 3 Cycle Run Time Cycle Stop Time (0-1) (0-1) (0-1) (0-6000)min (0-6000)min (0-1) (0-1) (0-1) (0-2) (1-31) (0-6) (0-23)h (0-59)min (0-30000)min 0 1 0 0 0 1 0 0 0 1 0 0 0 30 1 0 0: Not Start; 1: Start 0: Not Start; 1: Start 0: Not Start; 1: Start It is genset running time, if the set time is arrived, genset will stop. It is genset standby time, if the set time is arrived, genset will start. 0: Not Start; 1: Start 0: Disable; 1: Enable 0: Off-load; 1: On-load Cyclic selection: 0: Monthly; 1: Weekly; 2: Daily. Day(cyclic selection: 0: monthly) Week(cyclic selection: 1: weekly) Time(Hour) Time(Minute) Duration time 0: Not Start; 1: Start 0: Pile Volt High and Current Low 1: Pile Volt High Scheduled Run 1 Start Set 2 Scheduled Run 3 Scheduled Period Mains Abnormal And Pile Low Volt Start 1 Start Set (0-1) 2 Stop Condition (0-3)
No. Items Range Default Description 2: Current Low 3: Pile Volt High or Current Low It is battery voltage when battery is completely charged. It is battery pack under voltage limit. If voltage of battery falls below the setting value, genset will be started. It is the maximum time to charge for once. When load current of switch power is lower than the set value, and battery voltage is higher than the upper limit value as well, genset will be allowed to stop. When genset is normal running, if load current is below pre-set lower limit value, this delay will be started. When battery charging time exceeds the set value, and if temperature of machine room is high, air conditioner will be started. 0: Not Start; 1: Start; Genset will start up if machine room is higher than this value. After genset starts up because of the high temp. of machine room, if room temp. falls below the set value, genset will stop. 3 4 5 6 Pile Volt Upper Limit Pile Volt Lower Limit Charge Finish Time Under Current (0-100.0)V (0-100.0)V (1-6000)min (1-100)% 58.0 45.0 720 15 7 8 Under Current Delay Minimum Charge Time (10-3600)s (0-360)min 30 30 1 28 22 Mains Abnormal And Room Temp. High Start 1 Start Set (0-1) Room Temp. Upper 2 (15-55)ºC Limit 3 Room Temp. Lower Limit (15-55)ºC NOTES:
1) When parameter configuration is operated via PC software, there is no need to input password if default password
(0318) isn’t changed. On the contrary, if default password has been changed or it is the first time to set parameters via PC, password is needed to input in the password interface.
2) After the correct password is entered, before LCD backlit gets dark, parameter setting interface can be entered directly
by inputting parameter serial at secondary entering the password interface.
7.2 DEFINABLE CONTENT LIST OF PROGRAMMABLE OUTPUT PORTS 1-5
Table 11 – Definable Contents of Programmable Outputs 1~5
No. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Items Not Used Function Description Output port don’t output when it is chosen. Include all shutdown alarms, trip and stop alarms and warning alarms. Common Alarm When there is warning alarm only, it is not self-locked; when a shutdown alarm occurs, it is self-locked until the alarm is reset. Common ELE Trip Output when a common trip shutdown alarm occurs. Common Shutdown Output when a shutdown alarm occurs. Common Warn Alarm Output when a common warning alarm occurs. When warning, trip shutdown and shutdown alarms appear, audible alarm output is fixed for 300s, during which if any button on the panel is Audible Alarm pressed, or “alarm mute” input is active, or any keys on the panel is active, the alarms shall be removed. Applicable for genset with stop electromagnet; it shall pull in when stop Energized to Stop idle speed running ends and disconnect when the set ETS delay is over. Applicable for genset with idle speed; it shall pull in when genset starts Idle Control and disconnect when warming up is initiated; it shall pull in during stop idle speed process and disconnect when genset stops completely. Preheat Control Close before start and open before power up; Raise Speed Action while in hi-speed warming up running period. Drop Speed Action while in the period time from stop idle speed to wait for stop. Reserved Reserved Reserved Reserved
No. 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 Items Reserved Reserved Fuel Pump Control High Speed Control Crank Out Fuel Out Generator Excite Advance Oil Output Room Fan Control Run Out Timing Start Charge Alt. Fail In Auto Mode In Manual Mode In Stop Mode High Room Temp Warn Mains Abnormal Louvre Control Battery Over Volt Battery Under Volt Tele. Open Door Failed to Start Pre-Oil Fan Control Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Function Description Close when fuel level is lower than the “fuel pump on” value or when low fuel level warning input is active; Open when fuel level is higher than the “fuel pump off” value and low fuel level warning input is deactivated; Close when the generator enters into warming up time and open after cooling delay. Output while engine is cranking. Action at generator start; disconnect at “wait for stop”. Output in start period. If there is not generator frequency during high-speed running, it shall output for 2 seconds again. Output while genset is between the periods from pre-heat to stop idle speed. Output is controlled according to the upper/lower limit of the engine room temperature. Output while genset is between periods from normal running to hi-speed cooling. Output while genset is in the period of scheduled start. Output when charger fails to charge the batteries. Action while system is in auto mode. Action while system is in manual mode. Action while system is in stop mode. When temperature of machine room reaches the “room high temp warn” limit, alarms will be initiated. Action when mains over/under frequency, over/under voltage or aux. mains abnormal input is active. Action when genset starts up and disconnect after genset stops and “louver hold open” time is expired. Output when battery voltage high warning occurs. Output when battery voltage low warning occurs. This output is remotely controlled by Modbus-RTU protocol, and output time is “Telecontrol Open Door Output Time”. Output when engine fails to start. Output while genset is between periods from pre-heat to safety running. It is controlled by fan open and fan close according to temperature value of temp. sensor selected for programmable sensor 1.
7.3 DEFINABLE CONTENTS OF PROGRAMMABLE INPUT PORTS 1-7
Table 12 - Definable Contents of Programmable Inputs 1~7(Ground connected (B-) is active.) No. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Items Not Used Alarm Mute Reset Alarm Emergency Stop High Temp Shutdown Low OP Shutdown Fuel Level Warn Warn Input Shutdown Input Remote Start Onload Remote Start Offload Reset Maint. Time Panel Lock Inhibit Timing Start Inhibit Auto Start Remote Control Charge Alt Fail IN Low Oil Level Warn Manual/Auto Switch Reserved Idle Input Reserved Control At Gate Aux. Mains Fail Aux. Mains OK Pile Under Volt Reserved Reserved Reserved Reserved Reserved Reserved Function Description Input port is inactive. If input port is active, “audible alarm” output will be inhibited. If input port is active, shutdown alarms and ELE trip alarms can be reset. If input port is active, genset will alarm shutdown immediately. After safety on delay is expired, if this input is active, genset will alarm shutdown immediately. After safety on delay is expired, if this input is active, genset will alarm shutdown immediately. If this input is active, controller will send low fuel level warning alarm signal. If this input is active, controller will send external warning alarm signal. If this input is active, genset will alarm shutdown immediately. When this input is active in auto mode, genset starts automatically and takes on load after normal running. Otherwise, genset will stop automatically if this input is deactivated. When this input is active in auto mode, genset starts automatically and without taking load after normal running. Otherwise, genset will stop automatically if this input is deactivated. When this input port is valid, reset the maintenance time countdown, it is invalid for the maintenance date. When input is active, all keys expect are inactive. will display on the right side of fifth line of LCD main page. When input port is active in auto mode, genset scheduled run is inhibited. When input port is active in auto mode, genset auto start is inhibited. When the input is active, keys on the panel are locked except for keys and remote mode will display on the LCD. Remote module pattern and start/stop operation can be switched by keys on the panel. When the input is active, controller will send failed to charge warning. When input port is active, controller will initiate low oil level warning alarm. When input is active, it switches to auto mode automatically, panel buttons and local operation are inactive; When input is inactive, it switches to manual mode automatically, remote operation is inhibited. When the input is active, idle speed control starts outputting. When the input is active, controller will send access control input warning. Simulate mains is abnormal. Simulate mains is normal. When the input is active, it is considered battery is under voltage. If crank disconnect conditions are configured, genset will be started in auto mode.
7.4 SELECTION OF SENSORS
Table 13 – Sensors Selection
No. Items Content 0 Not used 1 Defined Curve 2 VDO 3 SGH 4 SGD 5 CURTIS 6 DATCON 7 VOLVO-EC 8 SGX 9 PT100 10 Reserved 0 Not used 1 Defined Curve 2 VDO 10Bar 3 SGH 4 SGD 5 CURTIS 6 DATCON 10Bar 7 VOLVO-EC 8 SGX 9 Reserved 10 Reserved 11 Digital Closed 12 Digital Open 0 Not used 1 Defined Curve 2 SGH 3 SGD 4 Reserved 5 Reserved 6 Digital Closed 7 Digital Open Remark 1 Temperature Sensor Defined resistance range is 0Ω~999.9Ω. 2 Pressure Sensor Defined resistance range is 0Ω~999.9Ω. 3 Fuel Level Sensor Defined resistance range is 0Ω~999.9Ω. NOTE: The room temperature sensor’s curve type is the same as temperature sensor’s.
7.5 CONDITIONS OF CRANK DISCONNECT SELECTION
Table 14 – Crank Disconnect Conditions
No. 0 1 2 3 4 5 6 Setting Content Speed Gen frequency Speed + Gen frequency Speed +Oil pressure Gen frequency + Oil pressure Speed + Gen frequency + Oil pressure Oil pressure a) There are 3 conditions to make starter separate with engine; speed, generator frequency and
oil pressure, and all of them can be used separately. It is recommended to use oil pressure and speed cooperatively, for the purpose of disconnecting the starter motor as soon as possible. b) Speed means real rotation speed detected by the speed sensor. Speed sensor is the magnetic
equipment which is installed in starter for detecting flywheel teeth.
c) In case speed is selected, it must be confirmed that the number of flywheel teeth is as same as
the setting, otherwise, “over speed shutdown” or “under speed shutdown” may be caused.
d) If genset does not fit speed sensor, please don’t select corresponding items, otherwise, “start
fail” or “loss speed signal” maybe caused.
e) If genset does not fit oil pressure sensor, please don’t select corresponding items. 8
PARAMETERS SETTING
8.1 CONTROLLER PARAMETER SETTING After controller is powered on, press as follows:
1 Set Parameters 2 Information 3 Set Language 4 Event Log 5 Maintenance 6 Run Log
7 Maintenance Log
When password is inputted, “0318” can set all parameter items in Table 10. If the password is changed, parameter setting can only be accessed by inputting the same password as the controller via PC software configuration. If more parameters are needed to set, or password is forgot, for example, voltage/current calibration, please contact the factory. Attention:
a) Please change the controller parameters when generator is in standby mode only (e. g. Crank disconnect conditions selection, auxiliary input, auxiliary output, various delay), otherwise, shutdown and other abnormal conditions may occur.
b) Over voltage set limit must be higher than under voltage set limit, otherwise over voltage and under voltage condition may occur simultaneously.
c) Over speed set value must be higher than under speed set value, otherwise over speed and under speed condition may occur simultaneously.
d) Please set the generator frequency value as low as possible at cranking, in order to make the starter be separated quickly as soon as possible.
e) Auxiliary input 1~6 could not be set as the same items; otherwise, they are abnormal functions. However, the auxiliary output 1~5 can be set as the same items.
f) Programmable sensor 1 and sensor 2 both can be set as discrete input or analog input port. If discrete input port is selected, corresponding discrete input settings are active; otherwise, if analog input is selected, corresponding sensor parameters settings are active. 8.2 CONTROLLER INFORMATION
a) LCD will display development information of the controller, such as software version, hardware and
and it shall enter parameter setting menu. Menu items are
issue date of the controller. b)
NOTE: In this interface, press
and auxiliary inputs and outputs status shall display.
c) LCD contrast control
d) Press and or and simultaneously to adjust LCD contrast ratio and make LCD character display more clearly. Contrast ratio adjustment range: 0-7. 8.3 LANGUAGE SELECTION
Chinese and English can be optional. 8.4 EVENT LOG
View event log from this interface, including start/stop information and shutdown alarm information log. It can record and display up to 99 pieces. 8.5 MAINTENANCE
It needs to input password at entering into the maintenance interface, default is 0 (if password is changed, please contact with SmartGen service personnel or sales personnel). Setting maintenance parameters will refresh maintenance time.
NOTE: Refresh maintenance time and enter into the next maintenance period in maintenance interface when “Maintenance Due Alarm” occurs.
9
SENSOR SETTING
─ When sensors are reselected, sensor curve will be transferred into the standard value. For example,
if temperature sensor is SGH (120°C resistor type), its sensor curve is SGH (120°C resistor type); if it is SGD (120°C resistor type), the temperature sensor curve is SGD curve.
─ When there is difference between standard sensor curves and used sensor, user can adjust it in
“curve type”.
─ When sensor curve is inputted, X value (resistor) must be inputted from small to large, otherwise,
mistake occurs.
─ If there is not oil pressure sensor, but there is only low oil pressure alarm switch, user must set the
oil pressure sensor as “None”, otherwise, maybe low oil pressure shutdown occurs.
─ The headmost or backmost values in the vertical coordinates can be set as same as below:
Table 15 - Common Unit Conversion Table
1Pa 1kgf/cm2 1bar 1psi 10 COMMISSIONING
Please make sure the following checks are made before commissioning:
— Ensure all the connections are correct and wire diameter is suitable.
— Ensure controller DC power has fuse, and controller’s positive and negative connection with start
battery are correct.
— Take proper action to prevent engine from crank success (e. g. remove the connection wire of fuel
valve). If checking is OK, make the start battery power on; choose manual mode and controller will execute routine.
— Set controller under manual mode, press “start” button, genset will start. After the cranking times preset,
controller will send signal of Start Failure; then press “stop” to reset controller.
— Recover the action to prevent engine from crank success (e. g. connect wire of fuel valve), press start
button again, genset will start. If everything goes well, genset will goes normal running after idle speed running (if configured). During this time, please watch for engine’s running situation and AC generator’s voltage and frequency. If something abnormal occurs, stop genset and check all wire connections according to this manual.
— If there is any other question, please contact SmartGen’s service.
N/m2 (pa) 1 9.8x104 1x105 6.89x103 kgf/cm2 1.02x105 1 1.02 －7.03x102 －bar 1x105 0.98 1 －6.89x102 －(p/in2.psi) 1.45x104 14.2 14.5 1 －
11 TYPICAL APPLICATION
Fig. 3 - Typical Application Drawing
Fig. 4 - Single Phase 2-Wire Connection Diagram
Fig. 5 - 2-Phase 3-Wire Connection Diagram
NOTE: Expand relay with high capacity in start and fuel output is needed.
12 INSTALLATION 12.1 FIXING CLIPS ─ ─ ─ ─
Controller is panel built-in design; it is fixed by clips when installed.
Withdraw the fixing clip screw (turn anticlockwise) until it reaches proper position.
Pull the fixing clip backwards (towards the back of the module) ensuring two clips are inside their allotted slots.
Turn the fixing clip screws clockwise until they are fixed on the panel.
NOTE: Care should be taken not to over tighten the screws of fixing clips.
12.2 OVERALL DIMENSION
Fig.6 - Overall Dimensions
HGM4020DC controller is applicable for 48VDC battery voltage environment. Negative of battery must be connected with the engine shell. Diameter of wire that connects controller power B+/B- with battery positive/negative mustn’t be less than 2.5mm2. If floating charger is configured, please firstly connect output wires of charger to battery’s positive and negative directly, then, connect wires from battery’s positive and negative to controller’s positive and negative input ports in order to prevent charger from disturbing the controller’s normal working.
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SPEED SENSOR INPUT
Speed sensor is the magnetic equipment which is installed in starter and is used for detecting flywheel teeth. Its connection wires with controller should apply 2 cores shielding line. The shielding layer should connect to No. 16 terminal in controller while another side is hanging up. The other two signal wires are connected to No. 21 and No. 22 terminals in controller respectively. The output voltage of speed sensor should be within (1~24)V AC(effective value) during the full speed. 12VAC is recommended (at rated speed). When the speed sensor is installed, let the sensor spun to contacting flywheel first, then, port out 1/3 lap, and lock the nuts of sensor at last.
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OUTPUT AND EXPAND RELAYS
All outputs of controller are relay contact output type. If it needs to expand the relays, please add freewheel diode to both ends of expansion relay’s coils (when coils of relay has DC current) or, increase resistance-capacitance return circuit (when coils of relay has AC current), in order to prevent disturbance to controller or other equipments.
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WITHSTAND VOLTAGE TEST
When controller had been installed on control panel, if high voltage test is needed, please disconnect controller’s all terminal connections, in order to prevent high voltage from entering controller and damaging it.
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