HGM6000K Series

Automatic Generator Module

USER MANUAL

Smartgen Technology
 Chinese trademark

English trademark

Smartgen — make your generator smart

Smartgen Technology Co., Ltd.

No. 28 Jinsuo Road

Zhengzhou city

Henan Province

P. R. China

Tel: +86-371-67988888/67981888

+86-371-67991553/67992951

+86-371-67981000(overseas)

Fax: 0086-371-67992952

Web: http://www.smartgen.com.cn

http://www.smartgen.cn

Email: sales@smartgen.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.

Smartgen Technology reserves the right to change the contents of this document

without prior notice.

Software Version
Version Date Note
1.0 2009-07-18 Original release.
Add oil pressure sensor SGX, temperature sensor SGX,
1.1 2009-09-01
and power on mode select.
1.2 2009-11-01 Add edition display function.
1.3 2009-12-25 Amend sensor curve function.
Add output port high speed output function; Add input
port 4 and 5 function.
1.4 2010-06-17 Amend products appearance picture, panel cutout size
long wide all increase 2, controller applicable working
temperature.
1.5 2010-07-07 Optimize some detail parts of the operator Manual.
1.6 2010-12-03 Gens speed and frequency was changed to a screen.
1.7 2011-06-20 Modify single-phase/three phase input of parameter
range.
1.8 2012-8-14 Modify parameters.
1.9 2013-8-13 Add “Number of poles” item.
 HGM6000K Series Automatic Generator Module

CONTENT
1 SUMMARY ................................................................................. 5
2 PERFORMANCE AND CHARACTERISTICS ............................. 6
3 SPECIFICATION ........................................................................ 8
4 OPERATION .............................................................................. 9
4.1 KEY FUNCTION....................................................................................... 9
4.2 DISPLAY DESCRIBE ............................................................................. 10
4.3 AUTOMATIC OPERATION ..................................................................... 11
4.4 MANUAL OPERATION........................................................................... 13
5 PROTECTION .......................................................................... 15
5.1 WARN .................................................................................................... 15
5.2 SHUTDOWN ALARM ............................................................................. 16
6 CONNECTING TERMINAL ...................................................... 19
7 PARAMETER RANGE AND DEFINE........................................ 22
7.1 PARAMETERS TABLE (TABLE 1) ......................................................... 22
7.2 OUTPUT 1-4 TABLE (TABLE 2) ............................................................. 29
7.3 DIGIT INPUT 1-5 TABLE (TABLE 3) ...................................................... 30
7.4 SENSOR (TABLE 4)............................................................................... 30
7.5 CONDITION OF CRANK SUCCEED (TABLE 5) .................................... 31
8 SETTING PARAMETER ........................................................... 32
9 SENSOR SETTINGS ............................................................... 33
10 COMMISSIONING.................................................................... 34
11 TYPICAL WIRING DIAGRAM ................................................... 35
12 INSTALLATION ........................................................................ 37
13 FAULT FINDING ....................................................................... 39

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 HGM6000K Series Automatic Generator Module

1 SUMMARY

HGM6000K series Genset controller integrating digital, intelligent and network

techniques is used for automatic control system of diesel generator. It can carry
out functions including automatic start/stop, data measure and alarm protective.
The controller uses LCD display, with operation easy and reliable.
HGM6000K series Genset controller uses micro-processing technique which can
carry out precision measure, constant value adjustment, timing and threshold
setting and etc. functions. It can be widely used in all types of generator automatic
control system for compact structure, advanced circuits, simple connections and
high reliability, can be widely applied to various types of generating units
automation system.

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 HGM6000K Series Automatic Generator Module

2 PERFORMANCE AND CHARACTERISTICS

■ HGM6000K controller has four types:

HGM6010K/6010KC: Automatic Start Module, it controls genset to start/stop by
remote start signal;
HGM6020K/6020KC: Based on HGM6010K/6010KC and add mains AC
monitoring, Mains/Genset automatic switching control functions (AMF), especially
suitable for the automation system composed by Mains and Genset.
Note1: HGM6010KC/6020KC with RS485 interface, HGM6010K/6020K without RS485
interface.
Note2: And then take HGM6010KC/6020KC with text as an example to describe.
■ Using microprocessor as a core, graphics LCD with big screen and backlight,
display between character and icon display, key touch for operation;
■ Have a RS485 port with Modus communication protocol;
■ Adapt to 3phase-4wires, single phase-2wires or 2phase-3 wires (120/240V) ,
50/60Hz AC power system;
■ Measure and display 3 phase voltage, 3 phase current, frequency, power etc.
parameter of Mains and Gens;
■ Precision measure and display of

Mains Gens
Line voltage (Uab, Ubc, and Uca) Line voltage (Uab, Ubc, and Uca)
Phase voltage (Ua, Ub, and Uc) Phase voltage (Ua, Ub, and Uc)
Frequency HZ Frequency HZ

Load
Power Current IA, IB, IC
Active power KW
Inactive power KVar
Apparent power KVA
Power factor Cos
Accumulate total gens power kWh
■ Mains have over voltage, under voltage, loss phase function; Gens have over
voltage, under voltage, over frequency, under frequency, over current function;
■ Precision measure and display parameters about Engine,

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 HGM6000K Series Automatic Generator Module

Temp. (WT), °C/ °F both are display

Oil pressure (OP), kPa/Psi/Bar all be display
Fuel oil level (FL), % (unit)
Speed (SPD), RPM (unit)
Voltage of Battery (VB) V (unit)
Voltage of Charger (VD) V (unit)
Hour count (HC) can accumulate Max. 999999 hours.
Starting up can accumulate Max.999999 times.
■ Control protection: Automatic crank/stop of diesel engine, load transfer(ATS
control) and completely faults display protection;
■ With ETS, idle control, pre-heat control, raises speed control functions, and all
types of them are belong to relay output;
■ Parameters setting: Allow user to modify setting and store them by inside
internal FLASH memory, the parameters cannot be lost even with power off. All
of parameters can be set not only from the front panel, but by PC via SG72 (an
adaptor, USB-LINK-RS485) module; or, through RS485 port via PC;
■ Most of temperature, pressure, oil level sensor can be directly used, and also
user can define sensor curve by themselves;
■ Multiple crank disconnection conditions can be selected.(Speed sensor, oil
pressure, gens);
■ Power supply range is wide(8~35)VDC, accommodating to different starting
battery voltage environments;
■ All parameters use digital modulation, abandoning analog modulation using
conventional electronic potentiometer, more reliability and stability;
■ Modular configuration design, Flame Retardant ABS plastic shell, inserted type
connection terminals, flush type installation, compact structure, easy
installation.

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3 SPECIFICATION

Operating Voltage DC8.0V to 35.0V, Continuous

Power Consumption <3W(Standby mode: ≤2W)
Alternator Input Range
3-Phase 4 Wire AC15V - AC360V (ph-N)
2-Phase 3 Wire AC15V - AC360V (ph-N)
Single phase 2 Wire AC15V - AC360V (ph-N)
Frequency 50Hz - 60Hz
Magnetic AC voltage 1.0V to 24V (effective value)
Magnetic AC Frequency 10,000 Hz (max)
Start Relay Output 16 Amp DC28V at supply voltage.
Fuel Relay Output 16 Amp DC28V at supply voltage.
(1) 7Amp DC28V at supply voltage,
Auxiliary Relay Output
(2)7Amp AC250V free voltage contact,
(1-4)
(3, 4)16Amp AC250V free voltage contact.
Overall Dimensions 209mm x 153mm x 55mm
Panel cutoff 186mm x 141mm
Operating Temp. Range Temperature: (-25~+70)ºC Humidity: (20~90)%RH
Storage Condition Temperature: (-30~80)ºC
IP55: when waterproof rubber ring added between
controller and its panel.
Protective Level
IP42: when waterproof rubber ring not have between
controller and its panel.
Object: among in input/output/power
Insulation Intensity Quote standard: IEC688-1992
Test way: AC1.5 kV / 1min 3mA leakage current
C. T. Secondary 5A (rated )
Weight 0.69kg

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4 OPERATION

4.1 KEY FUNCTION

Can stop genset under mode of Manual/Auto;
Can reset alarming under Stop;
To test panel indicators are OK or not, pressing this
Stop/ Reset
key at least 3 seconds;
During stopping process, press this again can stop
genset immediately.

Start To start genset under Manual or Auto mode.

Pressing this key will set the module into manual

Manual
mode.
Pressing this key will set the module into automatic
Automatic
mode.
Pressing and controller is under manual testing
Running with mode.
load Under this mode, genset will run with load automatic
when gens are normal. (HGM6010KC without)
Enters into Set menu after pressing this, and can
Set/ Confirm
shift cursor to confirm.
Page up Screen pages turning;
/increase Shift cursor and increase its position no. in setting.
Page down Screen pages turning;
/decrease Shift cursor and decrease its position no. in setting.

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4.2 DISPLAY DESCRIBE

Mains: line voltage Uab, Ubc, Uca Mains: phase voltage Ua, Ub, Uc

Mains: frequency (Hz) F1 Genset: line voltage Uab, Ubc, Uca

Genset: phase voltage Ua, Ub, Uc Genset: speed, frequency (Hz) F2

Load: current IA, IB, IC Load: active power (kW), inactive

power (kVar), apparent power (kVA)

Accumulate total gens power kWh Battery voltage BAT, Charger

Power factor voltage CHARG, Liquid level**%

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 HGM6000K Series Automatic Generator Module
Water temperature Gens oil pressure

Gens hours count Gens starts count

Gens status, Gens status delay countdown display

4.3 AUTOMATIC OPERATION

This mode is activated by pressing the . LED indicator is illuminating beside the
button confirms this action.
Sequence of Auto Start,
1. HGM6020KC, When Mains is abnormal (over and under voltage, or miss
phase), enters into mains ―abnormal delay‖ and LCD display count down time.
When mains abnormal delay is over, enter into ―start delay‖.
2. HGM6010KC, entries into ―start delay‖ as soon as ―Remote Start‖ is input valid.
3. ―Count down‖ of start delay is displayed in LCD.
4. When start delay is over, preheat relay is outputting (if be equipped), ―preheat
start delay XX s‖ is displayed in LCD.
5. When preheat relay is over, oil relay is outputting 1s and then start relay-output;
if genset fails in starting during ―cranking time‖, the oil and start relays stop
outputting and enters into ―crank rest time‖ and wait for next attempt.
6. If genset fails in starting within setting attempt times, LCD start-up failure
alarming icon flash.

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7. Whatever times to start genset successfully, it will enter into ―safety on time‖.
During this period, alarms of low oil pressure, hi-temperature, under speed,
charge fail and Aux. input (been configured) are inactive. As soon as this delay
is over, genset will enter into ―start idle delay‖ (if this be configured).
8. During ―start idle delay‖, alarms of under speed, under frequency, under voltage
are inactive. As soon as this delay is over, genset will enter into ―warming up
time delay‖ (if this be configured).
9. When ―warming up time delay‖ is over, gens status indicator is light if gens
normal. If alternator‘s voltage, frequency meets to requirement of load, gens will
close and relay is outputting, then genset will enter into normal running with load
and gens indicator is light; if genset voltage and frequency is abnormal,
controller will alarm and stop engine (gens alarming is displayed LCD).
Sequence of Auto Stop,
1. HGM6020KC, when Mains recovery during genset running, enters into mains
voltage ―normal delay‖ and its indicator light after Mains normal be confirmed.
―Start delay‖ is beginning.
2. HGM6010KC, genset enters into ―stop delay‖ as soon as ―Remote Start‖ putting
is inactive.
3. As soon as ―stop delay‖ is over, genset enters into ―High Speed cooling delay‖.
Mains are close and breaker is disconnected. After switch ―rest time delay‖,
mains are close and relay is output as well as with loading. Gens‘ indicator is
dark while mains‘ light.
4. Idle relay has power and outputs as soon as entering ―stop idle relay‖ (If this
been configured).
5. When enters ―ETS relay‖, ETS relay has power and outputs. Oil relay‘s output is
disconnected.
6. When genset enters ―stop time‖, automatic to decide whether genset is stopped
or not.
7. When genset will enter into ―over stop time‖ as soon as genset is stopped. If
genset failed to stop and controller will alarm (―stop failed‖ will be displayed in
LCD).
Note: This page is nonce genset status, genset status delay countdown display,
for example:

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At the first line, NO 4 is the Start interval state; 3s is the countdown to remain time
intervals of Start interval.
Gens Status List:
0: Genset Waiting 1: Start preheat 2: Fuel output 3: Start 4: Start Interval
5: Safety run 6: Start Idling 7: Start warm-up 8: Wait for the Load
9: Normal Run 10: Stop for cooling 11: Stop idling 12: ETS stop
13: Wait for stop steady 14: Shutdown failures

4.4 MANUAL OPERATION

1. HGM6020KC, Auto starts mode is active when press and its indicator is

illuminating. Press , then controller under ―Manual Test Mode‖ and its

indicator is illuminating. Under the both modes, press to start genset, and it
can automatic detect start successfully and accelerate to Hi-speed running. If

there is Hi-temperature, low oil level and voltage abnormal during diesel genset

running, controller can protect genset to stop quickly (detail procedures please

refer to No.4~9 of Auto start operation). Under ―Manual Test Mode ‖, genset
with load is decided by Mains is normal or not. If mains are normal, loading

switch is never transferred; while mains are abnormal, loading switch is

transferred into gens side. Under ―Manual Test Mode ‖, after genset runs well
in high speed, no matter mains is normal or not, loading switch must be

transferred into gens side.

2. HGM6010KC, Auto starts mode is active when press , and its indicator is

illuminating. Then press to start genset, it can automatic detect start

successfully and genset automatic accelerates to Hi-speed running. If there is

Hi-temperature, low oil level and voltage abnormal during diesel genset running,

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 HGM6000K Series Automatic Generator Module

controller can protect genset to stop quickly (detail procedures please refer to

No.4~9 of Auto start operation). After genset runs well in High speed, controller

will send signal of gens close.

3. Manual stop, press can shutdown the running genset (detail procedures

please refer to No.3~7 of Auto stop operation).

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5 PROTECTION

5.1 WARN
Warns are non-critical alarm conditions and do not affect the operation of the
genset system; they serve to draw the operators attention to an undesirable
condition.
In the event of a warning, the module will display at the last screen of LCD.
Warn is shown as the below:
HIGH ENGINE TEMPERATURE WARN, if the module detects that the engine
coolant temperature has exceeded the high engine temperature setting level after
the Safety On timer has expired and the input of Inhibit WTH stop is activated, a
warn will occur. At the same time LCD screen icon lighten.
LOW OIL PRESSURE WARN, if the module detects that the engine oil pressure
has fallen below the low oil pressure setting level after the Safety On timer has
expired and the input of Inhibit OPL stop is activated, a warning will occur. At the
same time LCD screen icon lighten.
LOSS OF SPEED SIGNAL WARN, if the speed sensing signal is lost, a warning
will occur and the lost speed delay set to zero, a warning will occur. At the same
time LCD screen icon lighten.
GENSET OVER CURRENT WARN, if the module detects a genset output current
in excess of the setting and the over current delay set to zero, a warning is
initiated. At the same time LCD screen icon lighten.
FAIL TO STOP WARN, if the module detects the engine is still running when the
‗Fail to stop timer‘ expires, a warning is initiated. At the same time LCD screen
icon lighten.
START BATTERY OVER VOLTAGE WARN, if the module detects that the plant
DC supply has risen above the high volts setting level, a warning is initiated. At the
same time LCD screen icon lighten.
START BATTERY UNDER VOLTAGE WARN, if the module detects that the plant
DC supply has fallen below the low volts setting level, a warning is initiated. At the
same time LCD screen icon lighten.
LOW FUEL LEVEL WARN, if the module detects that the engine oil level has
fallen below the low level setting level has expired, a warning will occur. At the
same time LCD screen icon lighten.

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FAILED TO CHARGE WARN, if the module detects that the charge of volts has
fallen below the setting level has expired, a warning will occur. At the same time
LCD screen icon lighten.
GENSET OVER VOLTAGE WARN, if the module detects a genset output voltage
in excess of the setting a warning is initiated. At the same time LCD screen
icon lighten.
GENSET UNDER VOLTAGE WARN, if the module detects a genset output voltage
below the setting a warning is initiated. At the same time LCD screen icon
lighten.
OVER SPEED WARN, if the engine speed exceeds the setting value a warning is
initiated. At the same time LCD screen icon lighten.
UNDER SPEED WARN, if the engine speed falls below the setting value after the
Safety On timer has expired, a warning is initiated. At the same time LCD screen
icon lighten.
GENSET OVER FREQUENCY WARN, if the module detects a genset output
frequency in excess of the setting value a warn in is initiated. At the same time
LCD screen icon lighten.
GENSET UNDER FREQUENCY WARN, if the module detects a genset output
frequency below the setting value after the Safety On timer has expired, a warning
is initiated. At the same time LCD screen icon lighten.

5.2 SHUTDOWN ALARM

Shutdowns are latching and stop the genset. The alarm must be cleared, and the
fault removed to reset the module.
NOTE: The alarm condition must be rectified before a reset will take place.
If the alarm condition remains it will not be possible to reset the unit (The
exception to this is the Low Oil Pressure alarm, as the oil pressure will be
low with the engine at rest).
EMERGENCY STOP, removal of the +ve DC Supply from the Emergency Stop
input initiates the following sequence, firstly it will initiate a controlled shutdown of
the genset and prevent any attempt to restart the genset until the Emergency stop
push-button has been reset. Secondly it removes the +ve DC supply from both the
Fuel Solenoid and Starter Solenoid. At the same time LCD screen flicker.
HIGH ENGINE TEMPERATURE, if the module detects that the engine coolant
temperature has exceeded the high engine temperature setting level after the
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 HGM6000K Series Automatic Generator Module

Safety On timer has expired, a shutdown will occur. At the same time LCD screen
flicker.
LOW OIL PRESSURE, if the module detects that the engine oil pressure has
fallen below the low oil pressure setting level after the Safety On timer has
expired, a shutdown will occur. At the same time LCD screen flicker.
OVERSPEED, if the engine speed exceeds the setting value a shutdown is
initiated. At the same time LCD screen flicker.
UNDERSPEED, if the engine speed falls below the setting value after the Safety
On timer has expired, a shutdown is initiated. At the same time LCD screen
flicker.
LOSS OF SPEED SIGNAL, if the speed sensing signal is lost, a shutdown is
initiated. At the same time LCD screen flicker.
GENSET OVER FREQUENCY, if the module detects a genset output frequency
in excess of the setting value a shutdown is initiated. At the same time LCD
screen flicker.
GENSET UNDER FREQUENCY, if the module detects a genset output frequency
below the setting value after the Safety On timer has expired, a shutdown is
initiated. At the same time LCD screen flicker.
GENSET OVER VOLTAGE, if the module detects a genset output voltage in
excess of the setting value a shutdown is initiated. At the same time LCD screen
flicker.
GENSET UNDER VOLTAGE, if the module detects a genset output voltage
below the setting value after the Safety On timer has expired, a shutdown is
initiated. At the same time LCD screen flicker.
GENSET OVER CURRENT, if the module detects a genset output current in
excess of the setting value is initiated, a shutdown is initiated. At the same time
LCD screen flicker.
FAIL TO START, if the engine does not fire after the pre-set number of attempts
has been made a shutdown will be initiated. At the same time LCD screen
flicker.
AUXILIARY INPUTS, if an auxiliary input has been configured as a shutdown the
appropriate information will be displayed. At the same time LCD screen
flicker.

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NO GENSET ALARM SHUTDOWN, when the controller detects to genset

frequency equals to zero, the controller sends out the shutdown alarm signal. At
the same time LCD screen flicker.
TEMPERATURE SENSOR OPEN CIRCUIT, when the controller detects to
temperature sensor open circuit, the controller sends out the shutdown alarm
signal. At the same time LCD screen flicker.
OIL PRESSURE SENSOR OPEN CIRCUIT, when the controller detects to oil
pressure sensor open circuit, the controller sends out the shutdown alarm signal.
At the same time LCD screen flicker.

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6 CONNECTING TERMINAL

HGM6010KC compared with HGM6020KC, is less a Mains three phase AC input

terminal. The HGM6010KC and HGM6020KC backplane is as following.

Pin Function Dim Description

DC plant supply System DC negative input.
1 2.5mm2
input (-ve) (Battery Negative).
System DC positive input.
DC plant supply
2 2.5mm2 (Battery Positive).
input (+ve)
(Recommended Maximum Fuse 20A)
Emergency stop Plant supply +ve. Also supplies fuel &
3 2.5mm2
input start outputs.
Plant supply +ve from pin 3.
4 Fuel relay output 1.5mm2
16 Amp rated.
Plant supply +ve Connect to starter
Start relay
5 1.5mm2 from pin 3. starting coil.
output
16 Amp rated.
Plant supply +ve
Auxiliary output
6 1.5mm2 from pin 2.
relay 1
7 Amp rated.
Closed output,
7
7 Amp rated. Reference table 2
Auxiliary output Relay common
8 1.5mm2
relay 2 point
Open output,
9
7 Amp rated.
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 HGM6000K Series Automatic Generator Module
Pin Function Dim Description
10 Auxiliary output
2.5mm2
11 relay 3 Free volt contacts.
12 Auxiliary output 16 Amp rated
2.5mm2
13 relay 4
Charge fail /
14 1.0mm2 Do not connect to ground (battery –ve)
excite
Magnetic pickup
15
+ve
Connect to Magnetic Pickup device
Magnetic pickup
16
-ve
Connecting water/cylinder
Temp. sensor
17 temperature resistance type
input
sensor. Reference
Oil pressure Connect to oil pressure table 4
18
input sensor.
19 Liquid level input Connect to liquid level sensor.
20 Auxiliary input 1 1.0mm2 Switch to -ve
2 Reference table 3
21 Auxiliary input 2 1.0mm Switch to -ve
Remote start
22 1.0mm2 Switch to -ve
input
CT secondary
23 1.5mm2 Connect to secondary of A monitoring CT
for A
CT secondary
24 1.5mm2 Connect to secondary of B monitoring CT
for B
CT secondary Connect to secondary of C monitoring
25 1.5mm2
for C CT.
CT secondary
26 1.5mm2 See also back install instructions.
common
Gens A voltage Connect to Genset A output
27 1.0mm2
monitoring (Recommend 2A fuse)
Gens B voltage Connect to Genset B output
28 1.0mm2
monitoring (Recommend 2A fuse)
Gens C voltage Connect to Genset C output
29 1.0mm2
monitoring (Recommend 2A fuse)
Gens neutral
30 1.0mm2 Connect to Genset neutral terminal.
input
Mains A voltage Connect to mains A output.
31 1.0mm2
monitoring (Recommend 2A fuse)
Mains B voltage Connect to mains B output.
32 1.0mm2
monitoring (Recommend 2A fuse)
Mains C voltage Connect to mains C output.
33 1.0mm2
monitoring (Recommend 2A fuse)

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 HGM6000K Series Automatic Generator Module
Pin Function Dim Description
Mains neutral
34 1.0mm2 Connect to mains neutral terminal.
input
RS485 port
35 0.5mm2
common GND
Use only 120Ω RS485 approved cable.
36 RS485 port A(-) 0.5mm2
37 RS485 port B(+) 0.5mm2
38 Auxiliary input 4 1.0mm2 Switch to -ve
39 Auxiliary input 5 1.0mm2 Switch to -ve
40 Common port 1.0mm2 Auxiliary input common port

Note:
1. These terminals of 31, 32, 33, and 34 are not used for HGM6010KC
module.
2. Back LINK interface as a parameter programming interface, used by SG72
adapter PC controller programming.

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7 PARAMETER RANGE AND DEFINE

All parameters of HGM6000K series as follows:

Note: small brackets set item number 6010KC.

7.1 PARAMETERS TABLE (TABLE 1)

Num Parameter Range Default Remark
Mains volt
P 01 (0-3600)s 10
normal delay Mains transient delay,
Mains volt suited for ATS(automatic
P 02 abnormal (0-3600)s 5 transfer switch)
delay
When mains voltage is
under than the point, mains
Mains under under voltage are active.
P 03 (30-360)V 184
volt When the point is zero,
mains under voltage are
disabled.
When mains voltage is over
than the point, mains over
Mains over
P 04 (30-360)V 276 voltage are active. When
volt
the point is 360V, mains
over voltage are disabled.
It‘s the delay from mains is
Transfer
opened to genset closing or
P 05 switch (0-99.9)s 1.0
from genset is opened to
interval
mains closing.
It‘s the delay from remote
P 06 start signal is active or
Start delay (0-3600)s 1
(P01) mains is failure, to start
genset.
It‘s the delay from remote
P 07 start signal is inactive or
Stop delay (0-3600)s 1
(P02) mains is normal, to stop
genset.
When engine start no
success, most of cranking
P 08 Number of numbers. When reach
(1-10)Times 3
(P03) Crank setting crank numbers,
controller send out start fail
signal.
Before the starter adds the
P 09
Preheat time (0-300)s 0 electricity, preheat plug add
(P04)
to the electricity in advance.
P 10 The starter adds the time of
Cranking time (3-60)s 8
(P05) the electricity each time.

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 HGM6000K Series Automatic Generator Module
Num Parameter Range Default Remark
When the engine start not
P 11 Crank interval successful, in the second
(3-60)s 10
(P06) time plus electric before the start
of the waiting time.
At this time, low oil
pressure, high water
temperature, under speed,
P 12 under frequency, under
Safe run time (1-60)s 10
(P07) voltage and charging failure
and auxiliary input
(configured) alarm is void
volume.
P 13 Start genset idle running
Start idle time (0-3600)s 0
(P08) time.
Genset entered high speed
P 14 Warming up
(3-3600)s 10 operation, in the warm-up
(P09) time
before closed for time.
After unloading in genset,
P 15
Cooling time (3-3600)s 10 the time needed to cool
(P10)
before shutdown.
P 16 When stop idling genset
Stop idle time (0-3600)s 0
(P11) running time.
P 17 ETS solenoid It‘s the delay for energizing
(0-120)s 20
(P12) hold to stop.
When "ETS solenoid
shutdown output time" for
zero, idle time delay stop
steady to time, and when
P 18 Fail to stop
(0-120)s 0 "ETS solenoid hold output
(P13) delay
time" is not equal to zero,
from ETS solenoid
shutdown delay end to stop
steady need of time.
Mains or Genset switch
P 19 ATS close closing pulse width, when it
(0-10)s 5.0
(P14) time is zero, output is
continuous.
The flywheel teeth on
engine starter teeth, used
for starters separation
P 20 Flywheel
(10-300) 118 condition judgment and
(P15) teeth
engine speed detection, see
behind the installation
instructions.

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 HGM6000K Series Automatic Generator Module
Num Parameter Range Default Remark
Gens
P 21 Too high or too low voltage
abnormal (0-20.0)s 10.0
(P16) genset alarm delay.
delay
When genset voltage is
over than the point, genset
Gens over
P 22 over shutdown voltage is
volt (30-360)V 264
(P17) active. When the point is
shutdown
360V, genset over voltage is
disabled.
When genset voltage is
under than the point, genset
Gens under
P 23 under shutdown voltage is
volt (30-360)V 196
(P18) active. When the point is
shutdown
30V, genset under voltage is
disabled.
When the engine speed is
under than the point and
P 24 Under speed
(0-6000)RPM 1200 hold great than 10 seconds,
(P19) shutdown
genset under shutdown
speed is active.
When the engine speed is
over than the point and hold
P 25 Over speed
(0-6000)RPM 1710 great than 2 seconds,
(P20) shutdown
genset over shutdown
speed is active.
When genset frequency is
Gens under low than the point, genset
P 26
freq (0-75.0)Hz 45.0 low frequency shutdown
(P21)
shutdown and hold great than 10
seconds is active.
When genset frequency is
Gens over over than the point and hold
P 27
freq (0-75.0)Hz 57.0 great than 2 seconds,
(P22)
shutdown genset over shutdown
frequency is active.
When engine temperature
sensor value is large than
this point and remain for 2
High seconds, send out
P 28
temperature (80-140)°C 98 shutdown alarm. When the
(P23)
shutdown value is 140, send out
warning alarm. (It‘s suited
for engine temperature
sensor only).

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 HGM6000K Series Automatic Generator Module
Num Parameter Range Default Remark
When engine oil pressure
sensor value is less than
this point and remain for 2
Low oil seconds, send out
P 29
pressure (0-400)kPa 103 shutdown alarm. When the
(P24)
shutdown value is zero, send out
warning alarm. (It‘s suited
for oil pressure sensor
only).
When low Fuel level sensor
P 30 Low Fuel value is less than this point
(0-100)% 10
(P25) level and remain for 10 seconds,
send out warning alarm.
When speed is zero and
remain for the delay, send
P 31 Lose speed
(0-20.0)s 5.0 out shutdown alarm. When
(P26) delay
the delay is zero, send out
warning alarm.
When genset voltage is
over than the point, genset
P 32 Gens over over warning voltage is
(30-360)V 256
(P27) volt warn active. When the point is
360V, genset over voltage is
disabled.
When genset voltage is
under than the point, genset
P 33 Gens under under warning voltage is
(30-360)V 205
(P28) volt warn active. When the point is
30V, genset under voltage is
disabled.
When the engine speed is
P 34 Under speed under than the point, genset
(0-6000)RPM 1350
(P29) warn under warning speed is
active.
When the engine speed is
P 35 Over speed over than the point, genset
(0-6000)RPM 1650
(P30) warn over warning speed is
active.
When genset frequency is
P 36 Gens under low than the point, genset
(0-75.0)Hz 47.0
(P31) freq warn under warning frequency is
active.
When genset frequency is
P 37 Gens over over than the point, genset
(0-75.0)Hz 55.0
(P32) freq warn over warning frequency is
active.

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 HGM6000K Series Automatic Generator Module
Num Parameter Range Default Remark
During genset is running,
when charge alternator
P 38 Charge fail WL/D+ voltage is low than
(0-30)V 6.0
(P33) volt this point and remain for 5
seconds, genset will
warning alarm.
When genset battery
voltage is over than the
P 39 Battery over point and hold for 20
(12-40)V 33.0
(P34) volt seconds, battery over
voltage signal is active. It‘s
a warning alarm.
When genset battery
voltage is less than the point
P 40 Battery under and hold for 20 seconds,
(4-30)V 8.0
(P35) volt battery under voltage signal
is active. It‘s a warning
alarm.
When engine temperature
sensor value is large than
High this point, send out warning
P 41
temperature (80-140)ºC 95 alarm. When the value is
(P36)
warn 140, send out warning
alarm. (It‘s suited for engine
temperature sensor only).
When engine oil pressure
sensor value is less than
Low oil this point send out warning
P 42
pressure (0-400)kPa 124 alarm. When the value is
(P37)
warn zero, send out warning
alarm. (It‘s suited for oil
pressure sensor only)
P 43
CT rate (5-6000)/5 500 Current transformer rate
(P38)
P 44 Full load Mains or genset set
(5-5000)A 500
(P39) current maximum rated current.
Over current When the load current is
P 45
shutdown (50-130)% 120 over than the point, the over
(P40)
percentage current delay is initiated.
When load current is over
than the point and hold
Over current
P 46 great than the timer, send
shutdown (0-3600)s 1296
(P41) out over current signal.
delay
When the delay is zero,
over current is disabled.

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 HGM6000K Series Automatic Generator Module
Num Parameter Range Default Remark
Over current When the load current is
P 47
warn (50-130)% 110 over than the point, over
(P42)
percentage current warn icon illume.
Switching
P 48
value output1 (0-11) 2 ETS solenoid to stop
(P43)
set
Switching
P 49
value output 2 (0-11) 3 Idle control
(P44)
set
Switching
P 50
value output 3 (0-11) 5 Close Gens
(P45)
set
Switching
P 51 Close mains (6010KC has
value output 4 (0-11) 6
(P46) no function).
set
P 52 Aux. input1 High Temperature alarm
(0-10) 1
(P47) set switch input
P 53 Aux. input 1
(0-20.0)s 2.0
(P48) delay
P 54 Aux. input 2
(0-10) 2 Low oil pressure input
(P49) set
P 55 Aux. input 2
(0-20.0)s 2.0
(P50) delay
P 56 Aux. input 3
(0-10) 3 Auxiliary warning input
(P51) set
P 57 Aux. input 3
(0-20.0)s 2.0
(P52) delay
P 58 Aux. input 4
(0-10) 6 Oil engine closed state input
(P53) set
P 59 Aux. input 4
(0-20.0)s 2.0
(P54) delay
P 60 Aux. input 5
(0-10) 10 Remote start input
(P55) set
P 61 Aux. input 5
(0-20.0)s 2.0
(P56) delay
0: Stop mode
P 62 Module
(0-2) 0 1: Manual mode
(P57) power on
2: Auto mode
P 63 Module
(1-254) 1
(P58) address
P 64 Passwords
(0-9999) 1234
(P59) set
Crank
P 65 success Setting item is given in
(0-5) 2
(P60) condition Table 5.
select

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 HGM6000K Series Automatic Generator Module
Num Parameter Range Default Remark
When engine speed is large
P 66 Speed
(0-3000)RPM 360 than this point, starter will
(P61) disconnect
disconnect.
When genset frequency is
P 67 Freq
(10-30)Hz 14 large than this point, starter
(P62) disconnect
will disconnect.
When engine oil pressure is
P 68 OP
(0-400)kPa 200 large than this point, starter
(P63) disconnect
will disconnect.
0 3P 4L
P 69 Select AC
1 2P 3L 0 3P4L(3 phase 4 wire)
(P64) system
2 1P 2L
P70 Select temp.
(0-8) 08 SGX
(P65) sensor
P71 Select press (0-8)
08 SGX
(P66) sensor
P72 Select liquid
(0-5) 03 SGD
(P67) level sensor
Need to set up eight first
acts of the current data set
the number of items, the
Temperature
second act to set the
P73 sensor
resistance value of the third
(P68) custom curve
act to set the resistance
setting
value of the temperature
corresponding to the value
of.
Need to set up eight first
acts of the current data set
the number of items, the
Oil pressure
second act to set the
P74 sensor
resistance value, the third
(P69) custom curve
act to set the resistance
setting
value of the pressure
corresponding to the value
of.
Need to set up eight first
acts of the current data set
Liquid level the number of items, the
P75 sensor second act to set the
(P70) custom curve resistance value, the third
setting act to set the resistance
value of the value of the
corresponding level.

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 HGM6000K Series Automatic Generator Module
Num Parameter Range Default Remark
Number of magnetic poles,
P76 Number of used for calculating rotating
(2-32) 04
(P71) poles speed of generator without
speed sensor.

7.2 OUTPUT 1-4 TABLE (TABLE 2)

Num Content Description
0 Not used Output is no use when select this
The designated programmable output relay will
1 Common alarm energize when any warning or shutdown fault
circuit has been activated.
The designated programmable output relay will
energize when a stop signal has been
2 ETS solenoid hold activated. The output will remain ETS solenoid
for pre-set timer once the engine has come to a
complete stop, then de-energizes.
The designated programmable output relay will
energize when the idle delay is not zero. The
3 Idle control output contact would typically be connected to
the ―idle/run‖ input control of an electronic
governor.
The designated programmable output relay will
energize during the preheat delay timer period
and also energize until the engine receive a
4 Preheat control
crank success signal. The preheat output is
typically used for an engine starting aid such as
glow plugs.
5 Close Gens Switch genset breaker on.
6 Close Mains Switch mains breaker on.(HGM6010KC)
When closing time set to zero, time off to
continue, this function when the feeder, namely
7 Open ATS
for continues when closed on, does not have
this function.
In the process of warm-up when he entered the
suction, suck time for high-speed warm-up
8 Raise speed control
delay time. Raise speed auxiliary input effective
disconnect.
Enter into stop idling process or to ETS
solenoid stop (when alarm stop) sucked, and
9 Drop speed control
suck time to stop idling delay time. Drop speed
when the auxiliary valid disconnect.
10 Pre-supply oil control
High speed warm-up, ready to on-load, normal
11 High speed output
operating, output after high speed cooling.

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 HGM6000K Series Automatic Generator Module

7.3 DIGIT INPUT 1-5 TABLE (TABLE 3)

Num Content Description
0 Not used
1 High Temp. input After the end of the delay in the safe operation,
if the signal is active, genset will immediately
2 Low OP alarm input
alarm shutdown.
3 Auxiliary warn input Auxiliary warn alarm digital input.
Auxiliary shutdown When power on, if active, genset will shut down
4
alarm input immediately.
During engine running, if the engine occur high
temperature shutdown, when the input is
5 Stop after cooled
active, the engine will first initiate cooling delay
and then stop, else will stop immediately.
6 Gens closed input The input state of genset closed.
7 Mains closed input The input state of Mains closed.
When it is active, during engine running, if the
engine appears high temperature, the engine
8 Inhibit high temp. stop
will only send out high temperature warning
alarm, not stop.
When it is active, during engine running, if the
engine appears low oil pressure, the engine will
9 Inhibit OPL STOP
only send out low oil pressure warning alarm,
not stop.
In automatic state, controller remote starts the
10 Remote start input
signal effectively when starting.

7.4 SENSOR (TABLE 4)

Num Items Content Remark
0 Not used
1 Defined Res. Type
2 VDO
3 SGH(Huanghe sensor)
Defined input resistance
Temperature 4SGD(DongKang
1 range is 0-999.9 ohm,
Sensor sensor)
factory default is SGX
5 CURTIS
6 DATCON
7 VOLVO-EC
8 SGX
0 Not used
Defined input resistance
Pressure 1 Defined Res. Type
2 range is 0-999.9 ohm,
Sensor 2 VDO 10Bar
factory default is SGX
3 SGH(Huanghe sensor)

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 HGM6000K Series Automatic Generator Module
Num Items Content Remark
4 SGD(DongKang
sensor)
5 CURTIS
6 DATCON 10Bar
7 VOLVO-EC
8 SGX
0 Not used
1 Defined RT
Defined input resistance
Fuel level 2 SGH
3 range is 0-999.9 ohm,
Sensor 3 SGD
factory default is SGD
4 Reserved 1
5 Reserved 2

7.5 CONDITION OF CRANK SUCCEED (TABLE 5)

Num Content
0 Magnetic sensor
1 Genset
2 Magnetic sensor+Genset
3 Magnetic sensor + Oil pressure
4 Genset + Oil pressure
5 Genset+Magnetic sensor + Oil pressure

1． The crank disconnect condition has three kinds, the magnetic pickup sensor
and the genset voltage can be used alone, the oil pressure must be used with
the magnetic pickup sensor and the genset voltage, the purpose is to make
the starter and the engine to disconnect as soon as possible.
2． Magnetic pickup sensor is installed in the engine block number of magnetic
device testing flywheel.
3． When choosing magnetic pickup sensor, ensure engine flywheel teeth setting,
otherwise may appear over speeding shutdown or loss speed shutdown.
4． If the genset is not magnetic pickup sensors, please don't choose
corresponding, otherwise this will occur fail to start or loss of speed alarm and
shutdown.
5． If the genset has no oil pressure sensor, please don't choose corresponding.
6． If the genset starting conditions has not be selected, the controller will not
measure and display the relative parameters (This can be applied to the pump
set), if not choose magnetic pickup sensor, the speed signal will come from
the generating AC signal.

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 HGM6000K Series Automatic Generator Module

8 SETTING PARAMETER

After controller powered on, press to enter into the parameters setting menu:
◙ Set parameters
When entering password, entering "1234" can set the item 1 to 47in the table
(parameters table [Table 1]), entering "0318" can set all items.
NOTE:
a． When the controller type is HGM6010KC, you will not have a table with a 1-5;
the programmable output 1-4 will have no power of some mains switch output.
b． Please modify the parameters (such as crank disconnect, input and output
configuration, various time, etc.) in standby mode, otherwise it might alarm
shutdown or other abnormal behavior.
c． The over-voltage threshold must be greater than the under-voltage threshold;
otherwise both will occur at the same time over-voltage and under-voltage
situation.
d． The over-speed threshold must be greater than under-speed threshold,
otherwise you will receive both the over speed and under speed.
e． As far as possible set the frequency (crank disconnect) to lower numerical, in
order to quickly crank disconnect when crank success.
f． Configurable input port 1-5 cannot set for the same items, otherwise cannot
appear correct function, configurable output 1-4 can be set for the same item.
g． If need to shutdown after cooling, please set any one configurable input as "
stop after cooling ", then connect this input with GND.
◙ Information
LCD will display the controller software version, issue date.

Note: Press the key will display the states of configurable input port and
output port state.
◙ Set language
User may set display interface language as Chinese, English and Spanish.

* Remark: Press the key will exit setting interface at any time.

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 HGM6000K Series Automatic Generator Module

9 SENSOR SETTINGS

1． When the choice sensor, the sensor to standard curve will call. If factory set
temperature sensor for SGX (resistance-type), sensor curve for SGX
(resistance-type), 120 degrees Celsius (elected SGD type), resistively curve
for temperature sensor SGD curve.
2． If use standard sensor with the curve, can differ option "item sensor curve
input", after adjusting adjustment can be determined according to save.
3． When the input sensor curve, X (resistance) must be in accordance with the
order of big from small, otherwise will enter errors.
4． When the sensor is choosing "nothing", the sensor curves no affection, LCD
display temperature or pressure for---.
5． If there is no pressure sensor, only low pressure alarm switch, it must be
alarm settings for pressure sensor "nothing", otherwise may appear oil
pressure low alarm shutdown.
6． Can set up several point of forehand or several point of backmost ordinate the
same. The following picture:

Common unit’s conversion table

1N/m2 (pa) 1kgf/cm2 1bar (1b/in2) psi

1Pa 1 1.02x10－5 1×10-5 1.45×10-4

1kgf/cm2 9.8×104 1 0.98 14.2

1bar 1×105 1.02 1 14.5

1psi 6.89x103 7.03×10-2 6.89×10-2 1

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 HGM6000K Series Automatic Generator Module

10 COMMISSIONING

Before operation, inspections that are recommended as follows should be carried

out:
1) Check and assure that all connections are correct, and that diameter of line is
suitable;
2) The DC power supply of controller is equipped with fuse, and the positive
supply (+Ve) and negative supply (-Ve) connected with battery are connected
correctly;
3) The emergency stop input is connected with the positive supply (+Ve) of the
battery through the NC terminal and fuse of emergency stop button;
4) The suitable operation should be taken to prevent the engine from crank
success (such as dismantling the connection of fuel), check and assure that it
is correct, then connect with battery, select manual mode, the controller will
execute program;
5) Press down the starting button on the panel of controller , the engine will crank,
after starts have been carried out according to setting crank numbers, the
controller sends the signal that indicates crank failure; Press the Stop/Reset
key to make the controller resetting;
6) Restore the measure that prevents the engine from crank success (such as
restoring the connection of fuel), press down the starting button again, the
engine will crank, if crank is normal, the genset will operate from idle operation
(if idle has been set) to normal operation. In the meantime, observe the
operation situation of engine and the voltage and frequency of the AC genset.
If there is abnormal, stop the genset, then check connections of each part
according to this handbook;
7) Select automatic state through front panel, then switch on the mains voltage,
the controller switches over ATS (if it exist) to mains on load after pass through
the mains normal delay, after cooling time, and then shut down to go into
standby state until the mains is abnormal again;
8) After the mains is abnormal again, the Genset will automatically crank into
normal operation state, and then close genset relay, control the ATS to switch
transfer to genset on load. If the situation is not same as described above,
check the connection of control part of the ATS according to this handbook;

9) If there are other questions, please contact the technical personnel of

Smartgen immediately.

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 HGM6000K Series Automatic Generator Module

11 TYPICAL WIRING DIAGRAM

HGM6010KC Typical wiring diagram

HGM6020KC Typical wiring diagram

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 HGM6000K Series Automatic Generator Module

Single phase 2 wires (HGM6020KC)

2-phase 3 wires (HGM6020KC)

Note: Recommend that the output of crank and Fuel expand high capacity relay.

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 HGM6000K Series Automatic Generator Module

12 INSTALLATION

The controller is designed to panel installation mode, and it is fixed by clamps

when it is installed. The overall dimension and panel tapping dimension are given
as follows:

1． Battery voltage input

HGM6000K series controller can be applicable to (8-35VDC) battery voltage
environment, battery anode must be reliable connect engine shell B + and B-
controller power battery anode and cathode connections is not less than 2.5, if
there was the float electrical, please put the charger output wire directly to
battery is negative, and from the battery is connected to the anode separately
on the power input, positive controller to prevent the normal operation of the
controller battery charger interference.
2． Speed sensor input
Speed sensor is installed in the engine block of magnetic device testing
flywheel teeth, it should be used with the controller of attachment 2 core
shielding line, shielding layer on the 16th pin controller, the other end terminal,
the other two are respectively in signal controller, and meet the terminals15th
and 16th pin. At full speed sensor output voltage range should be in 1-24VAC
(RMS), recommend voltage for 12VAC (in the rated speed). When the velocity
sensor can be installed to contact the flywheel spinning sensor first, then pour
out 1/3 laps, finally will lock nut on the sensor.
3． Output and relays
Controller for all output relay contacts output, if need to expand relays, please
will expand relay coil free-wheeling diode (increased ends when extended
relay coil links DC) or increase resistance and capacitance loop (when

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 HGM6000K Series Automatic Generator Module

extended relay coil links AC), in order to prevent interference controller or

other equipment.
4． Alternating current input
HGM6000K series controller to external input current transformer, electric
current transformer side must be 5A, while the current transformers for
phases and the phase of the input voltage must be correct, otherwise the
current and sampling the active power may be incorrect.
Note: A. ICOM must connect battery anode power controllers.
B. When the load current, the transformer secondary side is strictly open
circuit.
5． Withstand Voltage test
When controller had been installed in control panel, if need the high voltage
test, please disconnect controller‘s all terminal connections, in order to
prevent high voltage into controller and damage it.

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 HGM6000K Series Automatic Generator Module

13 FAULT FINDING

Symptom Possible Remedy

Check the battery and wiring to the unit. Check
Genset inoperative the DC supply.
Check the DC fuse.
Check water/cylinder temperature whether or not
too high.
Genset shutdown
Check AC genset voltage.
Check the DC fuse.
If an Emergency Shutdown switch is not fitted,
ensure that a positive is connected to the
Emergency shutdown input.
Emergency shutdown
Check emergency shutdown switch is functioning
correctly.
Check wiring is not open circuit.
Check engine oil pressure.
Low oil Pressure alarm (after Check oil pressure switch/sensor and wiring.
crank success) Check configured polarity (if applicable) is
correct.
Check engine temperature.
High Temp. alarm (after
Check switch/sensor and wiring.
crank success)
Check configured polarity is correct.
Check relevant switch and wiring of fault indicated
Shutdown fault operates on LCD display.
Check configuration of input.
Check wiring of fuel solenoid.
Check battery supply.
Crank no success
Check wiring of the speed sensing signal.
Refer to engine manual.
Check wiring of fuel solenoid.
Check fuel.
Check battery supply.
Crank failure Check battery supply is present on the Fuel
output of the module.
Check the speed sensing signal is present on the
6000K series inputs. Refer to engine manual.
Unit operation but ATS Check ATS.
Check the connection between the ATS and the
controller.
Check wiring.
RS485 communication Check COM ports set correctly.
abnormal Check the A and B RS485 line is reversed.
Check of RS485 conversion module.

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 HGM6000K Series Automatic Generator Module

Symptom Possible Remedy

Check the PC communications port is damaged.
Suggest that the A and B lines of the 485
network should be terminated at each end with a
120Ω resistor.

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