HGM1880

Automatic Control Module

USER MANUAL

Smartgen Technology
Smartgen Technology Co., Ltd
No. 28 Jinsuo Road
Zhengzhou
Henan Province
P. R. China
Tel: 0086-371-67988888/67981888
0086-371-67991553/67992951/67992952
0086-371-67981000(overseas)
National Free Tel: 4000318139
Fax: 0086-371-67992952/67981000
Web: http://www.smartgen.com.cn
http://www.smartgen.cn
Email: sales@smartgen.com.cn

All rights reserved. No part of this publication may be reproduced in any material form
(including photocopying or storing in any medium by electronic means or other)
without the written permission of the copyright holder.
Applications for the copyright holder’s written permission to reproduce any part of this
publication should be addressed to Smartgen Technology at the address above.
Any reference to trademarked product names used within this publication is owned by
their respective companies.
Smartgen Technology reserves the right to change the contents of this document
without prior notice.

Software Version
Date Version Note
2009-11-20 1.0 Original release.
2010-05-31 1.1 Optimize details in Manual.
2010-07-21 1.2 Add alternator poles.
2010-11-05 1.3 Add function of setting parameters via front
panel and over current alarm when loading.
2011-06-16 1.4 Add over-current action option.
2016-01-01 1.5 Modify Typical Application.
 HGM1880 Automatic Control Module

CONTENT
1. SUMMARY ................................................................................................................................ 4

2. PERFORMANCE AND CHARACTERISTICS .......................................................................... 4

3. SPECIFICATION ....................................................................................................................... 5

4. OPERATION ............................................................................................................................. 6

4.1. PANEL KEYS .......................................................................................................................... 6

4.2. LCD ICONS ............................................................................................................................ 6

4.3. DISPLAY DESCRIPTION ........................................................................................................... 7

4.4. OPERATION INSTRUCTION ....................................................................................................... 7

5. PROTECTION........................................................................................................................... 9

6 PARAMETER RANGE AND DEFINITION ................................................................................... 10

6.1 PARAMETERS CONFIGURATION (TABLE 1) .............................................................................10

6.2 D DEFINITION OF PROGRAMMABLE OUTPUTS (TABLE 2) ......................................................... 12

6.3 DEFINITION OF PROGRAMMABLE INPUTS (ACTIVE WHEN CONNECT TO GND (B-)) (TABLE 3) ...13

6.4 SENSOR OPTION (FORM 4) ....................................................................................................13

6.5 CONDITIONS OF CRANK DISCONNECT (TABLE 5) ....................................................................14

7 PARAMETER SETTING .........................................................................................................15

8 CONNECTIONS...................................................................................................................... 16

9 OVERALL DIMENSIONS (PANEL CUTOUT 78MMX66MM) .................................................17

10 TYPICAL APPLICATION .........................................................................................................17

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1. SUMMARY
HGM1880 is an auto start module. It has 3 working modes which can be select
through push button in the panel. It can control the genset to start/stop by manual or
remote start signal. When controller detected faults (such as low oil pressure,
water/cylinder temperature, emergency stop alarm, and over speed), it can
disconnect the fuel relay and stop. LCD in the panel displays faults status and offers
real alarm signals.

2. PERFORMANCE AND CHARACTERISTICS

♦ Use microprocessor as its core. LCD display with push button operation.
♦ Power supply range is (8~35) VDC, suitable for start environment of 12V or 24V.
♦ With sensors input ports, to realize digital display of electrical parameters,
including,
Gens voltage (V)
Gens frequency (Hz)
Gens current (A)
Engine temperature (ºC)
Engine oil pressure (kPa)
Speed (rpm)
Accumulated hours run (h)
Battery voltage (V)
Engine fuel level (%)
◙ Sensors threshold can be set to warn and pre-alarm, including,
Low oil pressure
High temperature of water/ cylinder
Over speed/under speed
Emergency stop
Fail to start
Fail to stop
Gens over/under voltage
Gens over/under frequency
Battery over/under voltage
Low fuel level
♦ Idle speed control and energized to stop (ETS);
♦ 3 working modes: Manual, Automatic, and Stop;
♦ Controller can be set as engine controller via software configuration (controller

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does not select voltage input), suitable for pump unit control;
♦ Red light-emitting diodes (LED) installed in the panel displays working and
alarming status;
♦ Multiple sensors of temperature, pressure, and oil level can be used directly and
its parameters can be defined. The sensors of temperature and pressure can be
paralleled use with temperature and pressure alarm;
♦ Multiple crank disconnect conditions are optional (such as magnetic pickup, oil
pressure and gens);
♦ 2 fixed relay outputs (fuel output, start output);
♦ 1 programmable output which can be set as common alarm output, fail to stop
output, preheat output or idle control output;
♦ User can edit and save the parameters in FLASH memory of controller and not
lost even power off. All parameters can be set via front panel or link port via PC
testing software (with SG72 adaptor). An USB port is needed only without
connecting battery to set parameters;
♦ Modular design, anti-flaming ABS plastic shell, embedded mounting. Compact
structure with small size. Advanced SCM control, stable performance and
convenient operation.

3. SPECIFICATION
Item Content
Working Voltage DC8. 0V to 35. 0V, Continuous Power Supply
Standby, 12V-0.3W, 24V-0.4W
Power Consumption
Working, 12V-1W, 24V-1.1W
Alternator voltage
1P2W 15V AC ~ 360 V AC (ph-N)
Input
Alternator Frequency 50/60Hz
Magnetic Pickup Voltage 1V to 24V (active value)
Magnetic Pickup
Max. 10kHz
Frequency
Max. accumulative run 99999.9 hours
time
Start Relay Output 1Amp DC28V DC B+ power supply
Fuel Relay Output 1Amp DC28V DC B+ power supply
Stop Relay Output 1Amp DC28V DC B+ power supply
Idle Relay Output 1Amp DC28V DC B+ power supply
Programmable Relay
1Amp DC28V DC B+ power supply
Output
Digital Input Active when connected to B-
Case Dimensions 88mm x 76mm x 44mm
Panel Cutout 78mm x 66mm
Temperature: (-25~+70)ºC
Working conditions
Humidity: (20~90)% without condensation
Storage Condition Temperature: (-30~+80)ºC

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Item Content
IP55: when waterproof rubber gasket added between
controller and its panel.
Protection Level
IP42: when waterproof rubber gasket not have between
controller and its panel.
Object: among input/output/power
Insulation Intensity Quote standard: IEC688-1992
Test way: AC1.5kV/1min 1mA leakage current
Weight 0.15kg

4. OPERATION
4.1. Panel Keys
Key Definition Description
Press this key to enter into Manual Mode. In
Manual/Decrease
parameter setting, press this to decrease values.
Press this key to enter into Auto Mode. In
Auto/Increase
parameter setting, press this to increase values.
Press this key, genset stops and enters into
Stop
standby mode; Press this to reset an alarm.
Turn Page Used for turning pages in LCD; in parameter
/Confirm setting, can shift cursor and confirm setting.
Alarm Indicator This indicator will illuminate when an alarm occurs.

4.2. LCD Icons

Icon Definition Icon Definition
High Temp. Alarm Auto Mode
Low Oil Pressure Stop Mode
Over Speed Alarm Manual Mode
Under Speed Alarm Gens Volts Indication
Emergency Stop Battery Volts Indication
High Voltage Speed Unit (Per Minute)
Low Voltage Oil Pressure Unit
Fail to start Voltage Unit
Fail to stop Fuel Level Unit (%)
Voltage Abnormal Temperature Unit
Auxiliary Alarm Frequency Unit
Normal Run Hours Count
Fuel Level Low A Load Current

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4.3. Display Description

Gens, phase voltage Ua, frequency F Battery voltage, engine speed

Oil pressure, water temperature Liquid level %, accumulated run time

Parameters setting Loading, current la, engine speed

4.4. Operation Instruction

Controller has 3 working modes, Stop ( ), Manual start ( ), Automatic ( ).

 Manual Start ( )

◆ This mode is activated by pressing the ( ) (hold 1 second), LED indicator beside
the button illuminates and confirms this action. Preheat is outputting firstly and
preheat delay begins. Fuel output 1 second before preheat delay is over, and then
preheat output opens, starter is energized to output and engine cranks. When
gens frequency is over the preset, starter is power off, genset starts successfully
and enters into safety on delay. When the delay is over, idle delay begins. When
the delay is over, idle delay closes and genset runs in high speed.

 Automatic ( )

◆ This mode is activated by pressing the ( ) (hold 1 second), LED indicator beside
the button illuminates and confirms this action. When remote start signal is active
(remote start input connected to B-), genset will start automatically after start
delay. Preheat is outputting firstly and preheat delay begins. Fuel output 1 second

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before preheat delay is over, and then preheat output opens, starter is energized
to output (If crank disconnect within specified times, module is started; if fail to
disconnect every time, common alarm annunciator illuminates) and enters into
safety on delay. When delay is over, enters into idle delay. After it is over, idle
delay closes and genset runs in high speed.
Note: In the interval of start attempts, fuel output opens. After 3 seconds of start interval
delay, pre-heating and ETS is outputting. After start interval delay is over, ETS
output is disconnecting and fuel output. The pre-heating output is disconnected
before starting.
♦ When remote start signal input is inactive, genset enters into idle after stop delay.
Idle relay disconnects and fuel relay is also disconnects after idle delay is over.
ETS is outputting and genset will stop automatically. When genset is steadily
stopped, ETS is disconnected.

 Stop ( ),

♦ During genset in normal running (Manual or Auto mode), this mode is activated by
pressing the ( ) (hold 1 second). LED indicator beside the button confirms this
action and is illuminating and genset enters into idle delay process. Idle delay
opens. After idle delay is over, fuel output opens ETS output and genset stops.
When genset is steadily stopped, ETS is disconnected.
♦ When genset has fault alarm, pressing this key (hold 1 second) can remove it.
Press over 1 second, all LED indicators in the panel will illuminate (lamp test).
♦ Under stop mode, press this key at least 1 second, ETS is outputting and all
lamps in the panel are illuminating (lamp test). After releasing the Stop button,
ETS output opens immediately and the lamp test is over.
♦ When genset in stop mode, controller only responds to emergency stop signal.
Note: the programmable output ports can be set as “ETS output”, “idle output” or
“Preheat output” via PC. Therefore, those 3 functions couldn’t activate
simultaneously. All above description just means the procedure of controller’s logic
action and supposes that the 3 functions were active.

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5. PROTECTION
1) LOW OIL PRESSURE, controller will start to detect after safety delay is over and
alarm shutdown before 2 seconds.
2) HIGH ENGINE TEMPERATURE, controller will start to detect after safety delay is
over and alarm to shutdown before 3 seconds.
3) LOW FUEL LEVEL WARNING, when the fuel level is lower than the setting value
and lasts for 10 seconds, controller will send signal of low fuel level. Only warning
and not shutdown.
4) OVERSPEED, detecting from cranking, alarm to shutdown before 2 seconds.
5) UNDERSPEED, detecting after idle delay is over. Alarm of under speed is sent to
shutdown before 15 seconds.
6) FAIL TO START, if failed to start within the set start times, alarm to shutdown.
7) FAIL TO STOP, when stop delay is over, genset cannot stop, a warning will be
sent, but this value not lock and save.
8) HIGH BATTERY VOLTAGE, when battery voltage is higher than the preset for 20
seconds, high battery voltage warning signal will be sent but not shutdown.
9) LOW BATTERY VOLTAGE, when battery voltage is lower than the preset for 20
seconds, low battery voltage warning signal will be sent but not shutdown.
10) EMERGENCY STOP, when emergency stop input is active, ETS immediately
output, cut off signals of oil, pre-heating and start. Emergency stop alarm signal
will be sent.
11) GENS OVER VOLTAGE, when the sample voltage is continuously higher than
the preset 5 seconds, gens voltage over signal will be sent, alarm to shutdown in
the meantime.
12) GENS UNDER VOLTAGE, when the sample voltage is continuously lower than
the preset 5 seconds, gens voltage low signal will be sent, alarm to shutdown in
the meantime.
13) LOAD OVER CURRENT, when loading current is over the preset and continues
to the specified delay, over current alarm signal will be sent, “A” is flashing.
14) COMMON ALARM, when there is over/under speed, high engine temperature,
low oil pressure，emergency stop, fail to start, fail to stop, battery voltage high/low,
common alarm led is flashing and common alarm output.

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6. PARAMETER RANGE AND DEFINITION

6.1 Parameters Configuration (Table 1)
No Items Range Default Description
Delay from mains abnormal or remote
P00 Start Delay (0-3600)s 1
start active to start engine.
Delay from mains abnormal or remote
P01 Stop Delay (0-3600)s 1
start inactive to stop engine.
Maximum start times. If failed to start
P02 Start Times (1-9)times 3 within start attempts, controller will
send an alarm signal.
Preheat Time used for powering pre-heat plug
P03 (0-300)s 0
Time before energizing starter.
P04 Crank Time (3-60)s 8 Time for energizing starter.
Crank Rest Time for waiting another cranking if
P05 (3-60)s 10
Time failed to start at the first time.
Alarms of low oil pressure, high
Safety Run temperature, under speed, under
P06 (1-60)s 10
Time frequency, under voltage, charge
failure, are disabled.
P07 Start Idle (0-3600)s 0 Idle running time when started.
Time for warming up before close
P08 Warm Up (3-3600)s 10
breaker.
Cooling
P09 (3-3600)s 10 Time for cooling before stopping.
Time
P10 Stop Idle (0-3600)s 0 Idle run time during stopping.
P11 ETS Delay (0-120)s 20 Delay for energizing to stop.
If “ETS solenoid hold” set as 0, it is
the time from end of idle delay to
Genset At
P12 (0-120)s 0 gen-set at rest; if not 0, it is from end
Rest
of ETS solenoid delay to genset at
rest.
Number of flywheel teeth, can detect
Flywheel
P13 (10-300) 118 disconnection conditions and engine
Teeth
speed.
P14 Power Mode (0-2) 0 Default: Stop Mode
Gens
Delay of over voltage or under voltage
P15 Abnormal (0-20.0)s 10.0
alarm.
Delay
When the voltage is over the point, a
Gens Over shutdown alarm will be sent. When
P16 (30-360)V 264
Voltage the point is 360V, Gens Over Voltage
is disabled.

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No Items Range Default Description

When the voltage is under the point, a
Gens Under shutdown alarm will be sent. When
P17 (30-360)V 196
Voltage the point is 30V, Gens Under Voltage
is disabled.
When the engine speed is under the
Under
P18 (0-6000)RPM 1200 point for 10s, shutdown alarm signal
Speed
is sent.
When the engine speed over the
P19 Over Speed (0-6000)RPM 1710 point for 2s, shutdown alarm signal is
sent.
When the frequency is under the
Under
P20 (0-75.0)Hz 45.0 point for 10s, shutdown alarm signal
Frequency
is sent.
Over When the frequency is over the point
P21 (0-75.0)Hz 57.0
Frequency for 2s, shutdown alarm signal is sent.
When the sensor value is over this
point for 2s, send out shutdown
High
P22 (80-140)ºC 98 alarm. When the value is 140, alarm
Temperature
signal won’t be sent. (only suited for
temperature sensor)
When engine oil pressure sensor
value is under this point for 2s, send
Low Oil
P23 (0-400)kPa 103 out shutdown alarm. When the value
Pressure
is 0, send out warning alarm. (only
suited for oil pressure sensor)
When fuel level sensor value under
Fuel Level
P24 (0-100)% 10 this point and remains for 10s, send
Low
out warning alarm.
Poles (2-16)
P25 4 Poles number of the generator.
Number
When the battery voltage over the
Battery Over point and holds for 20s, battery over
P26 (12-40)V 33.0
Voltage voltage signal is enabled. It’s a
warning alarm.
When the battery voltage under the
Battery
point and holds for 20s, battery under
P27 Under (4-30)V 8.0
voltage signal is enabled. It’s a
Voltage
warning alarm.
P28 CT Rate (5-6000)/5 500 Default: 500:5
Full Load Rated current of generator used for
P29 (5-1900)A 500
Current calculating over current.
P30 Over (50-130) 120 When load current exceeds this

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No Items Range Default Description

Current (%) preset value, over current delay
begins.
Over When load current exceeds this
P31 Current (0-3600)s 1296 preset value for delay timer, then over
Delay current occurs.
Digital
P32 (0-6) 1 Default: Common Alarm Output
Output
Default: Aux. shutdown Alarm
P33 Aux. Input (0-6) 4 When program the input as 0, fuel
level sensor can be set.
Aux. Input The delay for input active when aux.
P34 (0-20.0)s 2.0
Delay input is set as digital input.
Module
P35 (1-254) 1 The address of the controller.
Address
Crank (0-5) Conditions of disconnecting starter
P36 1
Disconnect See Table 5 (gens, OP and magnetic pickup)
Engine When engine speed over this point,
P37 (0-3000)RPM 360
Speed starter will disconnect.
Engine When generator frequency is over
P38 (10-30)Hz 14
Frequency this point, starter will disconnect.
Engine Oil When engine oil pressure over this
P39 (0-400)kPa 200
Pressure point, starter will disconnect.
Temp.
P40 (0-10) 06 SGD (120ºc Resistor type)
Sensor
P41 OP Sensor (0-10) 06 SGD (10Bar Resistor type)
Liquid Level Digital input should be set as Not
P42 (0-7) 0
Sensor Used when using the sensor.
Load Over 0: Warning; 1: Stop;
P43 (0-2) 0
Current 2: Coolant to stop

6.2 D definition of Programmable Outputs (Table 2)

No Items Description
0 Not used Output port is inactive when select this.
All shutdown alarms and warning alarm are included. When
Common warning alarm input is activated only, this alarm is not
1
alarm self-locked; when shutdown alarm is activated, this alarm is
self-locked until alarm reset.
Suitable for the genset with stop electromagnet. The
2 ETS Control electromagnet closes when stop idle is over. And opens when
EST delay is over.
Suitable for the genset with idle speed. It closes when starting
3 Idle control and opens when entering into high speed warm up. Also closes
during stop idle process and opens when genset is steadily
stopped.

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No Items Description
Preheat
4 It closes before starting and opens before starter is power on.
control
Switch On
5 Gens output with load.
Output
6 Reserved

6.3 Definition of Programmable Inputs (Active When Connect To

GND (B-)) (Table 3)
No Description Notes
0 Not Used
High Temp Alarm After genset is started successfully, it will
1
Input alarm to shut down immediately if this input
2 Low OP Alarm Input is active.
3 Reserved Only warning not stops if this input is active.
Auxiliary Shutdown Genset will alarm to shut down immediately
4
Alarm if this input is active.
Digital When this input is active and genset in
Inputs normal running, if the temperature is higher,
genset will stop immediately after hi-speed
5 Coolant to Stop
cooling; when this signal is inactive, if the
temperature is higher, genset will stop
immediately.
6 Reserved

7 Reserved

8 Fuel Level Sensor See Table 4.

6.4 Sensor option (form 4)

Items Content Remark
0 Not used
1 activated when digit input low
2 activated when digit input
high
3 defined resistance type
Defined resistance type input
Temperature 4 VDO
range is 0~999.9Ω, default is
Sensor 5 SGH (yellow river sensor)
SGD type sensor
6 SGD (Dongkang sensor )
7 CURTIS
8 DATCON
9 VOLVO-EC
10 SGX 120 DEGREE
0 Not used
1 activated when digit input low
Defined resistance type input
Oil pressure 2 activated when digit input
range is 0~999.9Ω, default is
Sensor high
SGD type sensor.
3 defined resistance type
4 VDO

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Items Content Remark

5 SGH (yellow river sensor)
6 SGD(Dongkang sensor )
7 CURTIS
8 DATCON 10Bar
9 VOLVO-EC
10 SGX 10Bar
0 Not used
1 activated when digit input low
2 activated when digit input Defined resistance type input
high range is 0~999.9Ω, default is
Fuel Level SGD type sensor.
Sensor 3 defined resistance type When defining fuel level sensor,
4 SGH (yellow river sensor) programmable input should be
5 SGD (Dongkang sensor ) configured as 0 firstly.
6 Reserved 1
7 Reserved 2
6.5 Conditions of Crank Disconnect (Table 5)
No Content
0 Magnetic Pickup
1 Gens
2 Magnetic Pickup + Gens
3 Magnetic Pickup + Oil pressure
4 Gens+ Oil pressure
5 Gens + Magnetic Pickup+ Oil pressure

1) There are 3 conditions to make starter separate with engine, magnetic pickup, gens
can be used separately and engine oil pressure can be used with magnetic pickup,
gens together and in order to make the starter motor is separated with engine
immediately.
2) Magnetic pickup is the magnetic equipment which be installed in starter and for
detecting f flywheel tooth.
3) When magnetic pickup is chosen, ensure that the number of flywheel teeth is as
same as the preset, otherwise, “over speed” stop or “under speed” stop maybe
caused.
4) If genset has no magnetic pickup, don’t select corresponding items, otherwise, “fail
to stop” or “loss of speed signal” maybe be caused.
5) If genset has no oil pressure sensor, don’t select corresponding items
6) If gens has not been chosen, controller will not detect and display the electrical
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parameters (can be used in pump unit); if magnetic pickup has not been chosen, the
rotating speed displayed in controller is calculated on gens signal.

7. PARAMETER SETTING
1) Under standby mode, press and simultaneously to enter into password
interface. The first digital begins flashing and then input the password: 0318.
2) Press key to increase value, to decrease value and to shift the bit;
3) Adjust the second to the forth digital according to above setting procedure.
4) If the password is correct, the setting menu will display the item number and the
parameter. Press key to scroll items up while press key to scroll down.
5) Press key to set the current item. (Same procedures as password setting)
Input Password: Parameter Setting:

Notes:

1) Please set the parameters in standby mode only (like sensor selection,
programmable inputs and outputs, multiple delays); otherwise, shutdown alarm and
other abnormal conditions may appear.
2) Each setting value must within its allowed range, or it cannot be changed.

3) Over voltage threshold must greater than under voltage threshold, otherwise, over

voltage and under voltage may appear at the same time.

4) Over speed threshold must greater than under threshold, otherwise, over speed and

under speed may appear at the same time.

5) Engine frequency should be set as low as possible when crank disconnect in order to

make the starter separate quickly.

6) The series number of setting items is consistent with the series number in Parameter

Configuration (Table 1).

7) When defining fuel level sensor, programmable input should be configured as 0

firstly.
* Remark1: during setting, press can immediately stop the current setting at any

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time.
*Remark2: in Manual mode, if select “Magnetic Pickup + Gens” or “Gens+ Magnetic
Pickup + Oil Pressure”, and gens frequency and speed is not 0,
press and simultaneously (at least 0.5 second), controller will adjust the number
of flywheel teeth automatically according to gens frequency and alternator poles.

8. CONNECTIONS
♦ Terminal1 (B-): Connected to plant battery negative.
♦ Terminal 2 (B+): Connected to plant battery positive.
♦ Terminal 3 (Emergency stop input): Output B+. External emergency stop normally
close button.
♦ Terminal 4 (Fuel Output): Output B+. External fuel relay. Contact capacity is 1A.
♦ Terminal 5 (Start Output): Output B+. External start relay. Contact capacity is 1A.
♦ Terminal 6 (Remote Start Input): Remote start input port, active when connected
to B-.
♦ Terminal 7 (Configurable Input): Configurable input ports. Digital input signal or
fuel level sensor signal can be input through configuration. Active when
connected to B-.
♦ Terminal 8 (Oil Pressure Input): Low oil pressure or sensor signal input, active
when connected to B-.
♦ Terminal 9 (Engine Temp. Input): Water/cylinder high temperature or sensor signal
input, active when connected to B-
♦ Terminal 10 (L), 11 (N): External Alternator voltage signal, for detecting crank
disconnect and offering over/under speed protection.
♦ Terminal 12 (Idle Output): Idle speed control output (output B+), Contact capacity
is 1A.
♦ Terminal 13 (Stop Output): ETS output (output B+), Contact capacity is 1A.
♦ Terminal 14 (Configurable Output): Configurable output (output B+); the digital
output can be set via PC. Contact capacity is 1A.
♦ Terminal 15 (Magnetic Pickup): Magnetic head signal input, recommended using
shielded wire, connecting to GND at one end.
♦ LINK port: Use SG72 programming cable to connect with the USB for parameter
programming.

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9. OVERALL DIMENSIONS (Panel Cutout 78mmx66mm)

10. TYPICAL APPLICATION

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