Smartgen GM620

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AMF620
AUTO START MODULE
OPERATING MANUAL
HGM610/620 AUTO START MODULE
CONTENT
1.
SUMMARY.......................................................................................................................................................... 3
2.
PERFORMANCE AND CHARACTERISTICS .............................................................................................. 3
3.
OPERATION.......................................................................................................................................................4
3.1 OPERATION PANEL
............................................................................................................................................. 4
3.2 AUTOMATIC OPERATION
...................................................................................................................................... 5
3.3 MANUAL OPERATION
..........................................................................................................................................6
3.4 RUN ON LOAD
..................................................................................................................................................... 6
4.
BACK BOARD ................................................................................................................................................... 7
5.
PARAMETERS SETTING CONTENT ..........................................................................................................10

TABLE 1 LIST OF CONTENT AND RANGE FOR PARAMETER
.....................................................................10
SETTING
TABLE 2 LIST OF DEFINABLE CONTENT FOR CONFIGURABLED OUTPUT .......................................14
PORTS 1 TO 4
TABLE 3 LIST OF DEFINABLE CONTENT FOR CONFIGURABLED INPUT
.......................................................16
PORTS
TABLE 4 SELECTION FOR SENSORS
.......................................................................................................................17
TABLE 5 CONDITIONS FOR CRANK SUCCESS
.........................................................................................................18
6.
SETTING PARAMETER.................................................................................................................................18
1.
2.
3.
4.
5.
HISTORY RECORD
............................................................................................................................................. 18
SET DATE AND TIME
..........................................................................................................................................18
SET PARAMETERS
............................................................................................................................................. 18
INFORMATION
.................................................................................................................................................... 19
SET LANGUAGE
.................................................................................................................................................19
7.
SENSOR CONFIG ........................................................................................................................................... 19
8.
COMMUNICATION..........................................................................................................................................20
9.
SPECIFICATION..............................................................................................................................................20
10. OPERATION .....................................................................................................................................................21

11. TYPICAL APPLICATION ................................................................................................................................ 22
12. INSTALLATION ................................................................................................................................................23
13. TROUBLESHOOTING .................................................................................................................................... 23
HGM610/620 MODULE
ISSUE 2009-02-18 Version 2.1
Page 2 of 24
1. SUMMARY
HGM610/620 Series generator 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 alarming. The controller uses
LCD display, optional Chinese and English display interface with operation easy and
reliable.
HGM600 Series generator controller uses micro-processing technique which can carry
out precision measure, constant value adjustment, timing and threshold setting and etc.
of multi-parameters. It can be widely used in all types of generator automatic control
system for compact structure, advanced circuits, simple connections and high reliability.
2. PERFORMANCE AND CHARACTERISTICS

HGM600 controller have two types:
1. HGM610: Automatic engine start;

2. HGM620: AMF(automatic mains failure)
Using microprocessor as a core, graphics LCD with big screen and backlight, display
between Chinese and English, key touch for operation.
Precision measure and display of
mains voltage(RMS)
mains current(RMS)
mains frequency
mains active power
mains power factor
generator voltage(RMS)
generator current(RMS)
generator frequency
generator active power
generator power factor
generator temperature
generator pressure
generator fuel level
start battery voltage
Configurable single phase or three phase voltage input;
Control protection: Automatic start/stop, load transfering and alarming of generator;
Parameters setting:Allow user to modify setting and store them inside internal FLASH
memory, the parameters can not be lost even with power down.
Automatic control of shutter which is mounted onto the generator room wall.
Five channel anolog inputs, may joint with Voltage-type or Resistive-type
temperature/ pressure/ fuel level sensors, Several temperature and pressure sensors
HGM610/620 MODULE
Page 3 of 24
can be used directly(i.e. VDO, DATCON, CUMMINS, PT100). also may select user
defined sensor via entering 8 point curves;
Functions including RTC(real time clock) and hours count;
Display of generator cumulated electric energy;
Security password-protected programming levels.
Several crank success conditions are optional;
Built-in speed/frequency detecting units can accurately judge the states such as crank
success and over speed;
99 historical records can be stored circularly and inquiring of the records can be made
on site;
Power supply range is wide (DC: 8 to 35V), accommodating to different starting
battery voltage environments;
All parameters use digital modulation, abandoning anolag modulation using
conventional electronic potentiometer, reliability and stability are increased;
Built-in watch dog can never be dead halt, ensuring smooth program execution;
Modular configuration design, inserted type connection terminals, flush type
installation, compact structure, easy installation.
3. OPERATION
3.1 Operation Panel
HGM620 front panel
LCD display screen can display multi -parameters of generator such as voltage, current,
Battery voltage, various parameters of engine such as engine rotating speed, engine oil
pressure, cooling water temperature, also can display multi-states and alarming amount.
HGM610/620 MODULE
Page 4 of 24
push-button. The
function is used to change a programming value while in the
programming mode. When this push-button is held down, the displayed value will be
decremented to a lower value as desired.
push-button. The
function is used to change a programming value while in the
programming mode or to select a desired programming menu loop. When this
push-button is held down, the displayed value will be incremented to a higher value as
desired.
push-button. The
function is used to entering in setting menu, shifting cursor
in setting and confirming the set information.
push-button. The
engine-generator set.
function is used to initiate a manual start signal to the
push-button. The
generator set.
function is used to initiate a stop signal to the engine
push-button and LED light viewing window. The

automatic operation of the engine-generator set.
function is used to initiate
push-button and LED light viewing window. The

automatic operation of the engine-generator set.
function is used to initiate
push-button. The
function is used to initiate load test of the engine generator
set when connected to an associated transfer switch.
light viewing window. The
illuminates (flashes) when any pre-programmed
warning or shutdown fault has been activated.
3.2 Automatic operation

This mode is activated by pressing the
push-button confirms this action.
push-button. The LED indicator beside the
When mains is abnormal, the following sequence is initiated:

First the Mains abnormal timer is initiated. After this delay, the start timer is initiated.
After the above delays the Fuel Solenoid is energised, and the Starter Motor is
engaged.
The engine is cranked for a pre-set time period. If the engine fails to fire during this
cranking then the starter motor is disengaged for the pre-set rest period. Should this
sequence continue beyond the set number of attempts, the start sequence will be
terminated and Fail to Start fault will be displayed on LCD.
HGM610/620 MODULE
Page 5 of 24
When the engine fires, the starter motor is disengaged and locked out at a pre-set
frequency from the Alternator output. Alternatively a Magnetic Pickup mounted on the
flywheel housing can be used for speed detection.
After the starter motor has disengaged, the Wait for oil pressure timer is activated.
Once the engine is running, the Warm Up timer is initiated, allowing the engine to
stabilize before accepting the load. After this delay, send out a closing gens signal.
When mains is normal, the mains normal delay timer is initiated, once it has timed out,
the closing gens signal is de-energised, then the closing mains signal is active.
When the mains normal delay has time out, the Stop delay timer is initiated. After this
delay, the Cooling timer is then initiated, allowing the engine a cooling down period off
load before shutting down. Once the Cooling timer expires the Fuel Solenoid is
de-energised, bringing the generator to a stop.
3.3 Manual Operation

To initiate a start sequence in MANUAL, press the
pushbutton. When the controller
is in the manual mode (indicated by an LED indicator beside the button), pressing the
button will initiate the start sequence.
If the pre-heat output is selected the preheat delay is initiated, and the digit output
selected is energised.
After the above delay the Fuel Solenoid is energised, then the Starter Motor is
engaged.
The engine is cranked for a pre-set time period. If the engine fails to fire during this
cranking attempt then the starter motor is disengaged for the pre-set rest period. Should
this sequence continue beyond the set number of attempts, the start sequence will be
terminated and Fail to Start fault will be displayed on LCD.
When the engine fires, the starter motor is disengaged and locked out at a pre-set
frequency from the Alternator output. Alternatively a Magnetic Pickup mounted on the
flywheel housing can be used for speed detection.
After the starter motor has disengaged, the oil bypass timer is activated.
Once the engine is running, the Warm Up timer is initiated, allowing the engine to
stabilize before accepting the load.
Selecting
de-energises the FUEL SOLENOID, bringing the generator to a stop.
3.4 Run on load

When mains voltage is normal, press the key
generator is normal, press the
HGM610/620 MODULE
, then press the key
, after
, it will pop up the LOAD TEST menu, pressing the key
Page 6 of 24
will switch mains off-load, then switch generator on-load.
4. BACK BOARD
The back board of HGM610 Controller is shown as follows:
The back board of HGM620 Controller is shown as follows:
5. CONNECTING TERMINAL
Connecting Terminal A with 16 Pins

Diameter
No.
Function
Description
of Wire
1
RS485 Port A(+)
Interconnecting wiring to/ from the
HGM600 engine /generator controller
communication port shall utilize #22
0.5mm AWG (min.) 2 conductor, twisted,
2
RS485 port B(-)
shielded cable. The drain (shield) wire
must be connected at the HGM 600
controller end.
3
Magnetic Pickup Input
0.5mm
4
0.5mm
Connecting with Magnetic Pickup
5
0.5mm
common
6
Configurabled Input Port 1
1.0mm Active connected with Setting Item Is
Given in Table 3.
7
1.0mm Grounding(- Ve)
8
1.0mm
HGM610/620 MODULE
Page 7 of 24
No.
Function
9
10
11

Diameter
of Wire
1.0mm
1.0mm
1.0mm
12
Sensors Common
1.5mm
13
Temperature Sensor Input
1.0mm
14
Oil Pressure Sensor Input
1.0mm
15
Aux. Sensor1
1.0mm
16
Aux. Sensor2
1.0mm
Description
Connecting to engine body near the

sensor
Connecting with Coolant Temperature
Sensor, Voltage-type or Resistive-type.
Connecting with Oil Pressure Sensor,
Voltage-type or Resistive-type.
Configurable sensor, Setting Item Is
Voltage-type
or Given in Table
Resistive-type.
4.
Connecting Terminal B with 8 Pins

Diameter
No.
Function
of Wire
Remarks
17
Generator L1 current
transformer connection.
2.5mm
Externally Connecting with Secondary

Coil of Current Transformer (Rated 5A)
18
2.5mm
Externally Connecting with secondary

19
2.5mm
Externally Connecting with secondary

20
Current Transformer
Common
2.5mm
refer to the installation instructions for

detailed information.
21
Generator L1 voltage input.
1.0mm
Connect to alternator L1 output. (Fuse

of 2A Is Recommended)
22
1.0mm

23
1.0mm

24
Generator N sensing input.
1.0mm
Connect to alternator N output.
Connecting Terminal C with 14 Pins

Diameter
No.
Function
of Wire
Remarks
25
DC Supply -ve.
2.5mm
System DC negative input.
26
DC Supply +ve.
2.5mm
System DC positive input. Fuse of Max.

20A Is Recommended.
27
Emergency Stop Input
2.5mm
Connecting
with
+Ve
Emergency Stop Button
28
Fuel Relay Output
2.5mm
Supplied with +Ve from Port 27, Rated

at 16A
HGM610/620 MODULE
through
Page 8 of 24
Diameter
of Wire
No.
Function
29
Configurabled Output Port

1
30

2
31

3
32
Crank Relay Output

at 10A
2.5mm
2.5mm
37
38

at 16A
Normal Opening Output, Rated at 16A

4
2.5mm
Close Generator Relay

Output
1.5mm
Normal Opening Port for Relay, Rated

at 16A, 250VAC
1.0mm
Connecting with charge alternator

terminal WL or D+. if the terminal
mounted on the Charger alternator isnt
exist, dont connect. if THE input is
Anolag3 (voltage-type sensor), please
order from factory, Setting Item Is Given
in Table 4.
Charging alternator D+(or

WL) Port Input or Anolag 3
input
Common Port for Relay

Normal Closing Output, Rated at 16A,
250VAC
35
36

at 16A
at 10A
33
34
Remarks
Connecting Terminal D with 8 Pins

Diameter
No.
Function
of Wire
39
Remarks
Mains position
1.0mm
Active connected with Grounding(- Ve)
Close Mains Relay Output
1.5mm
Normal Opening and Normal Closing

Port for Relay, Rated at 16A, 250V
43
Mains L1 voltage input.
1.0mm
Connect to Mains L1 output. (Fuse of

2A Is Recommended)
44
1.0mm

2A Is Recommended)
45
1.0mm

2A Is Recommended)
46
Mains N sensing input.
1.0mm
Connect to Mains N output.
40
41
42
HGM610/620 MODULE
Page 9 of 24
6. PARAMETERS SETTING
The performance parameter of the controller of HGM600 is given as follows:
Table 1 List of Content and Range for Parameter Setting

No
1
Item
Mains normal delay
Setting Range
(0-9999S)
Mains abnorm delay
(0-9999S)
Mains over voltage
(30-360V)
276
Mains under voltage
(30-360V)
184
Mains over frequency (0-75.0Hz)
55.0
Mains low frequency
(0-75.0Hz)
45.0
Transfer rest time
(0-999.9S)
1.0
Start delay
(0-9999S)
Stop delay
(0-9999S)
10
Close time
(0-10.0S)
3.0
11
Gens over voltage
(30-360V)
264
12
Gens under voltage
(30-360V)
196
HGM610/620 MODULE
Default
10
description
Mains transient delay, suited
for ATS(automatic transfer
switch)
When mains voltage is over
than the point, mains over
voltage is active. when the
point is 360V, mains over
voltage is disabled.
When mains voltage is under
than the point, mains under
voltage is active. when the
point is zero, mains under
voltage is disabled.
When mains frequency is
over than the point, mains
over frequency is active.
when the point is 75.0Hz,
mains over frequency
is
disabled.
When mains frequency is
low than the point, mains low
frequency is active. when the
point is zero, mains low
frequency is disabled.
its the delay from mains is
opened to generator closing
or from generator is opened
to mains closing.
Its the delay from remote
start signal is active or mains
is failure, to start generator.
Its the delay from remote
start signal is inactive or
mains is normal, to stop
generator.
Mains or Gens switch
closing pulse width, when it
is zero, output is continue.
When generator voltage is
over
than
the
point,
generator over voltage is
active. when the point is
360V, generator over voltage
is disabled.
When generator voltage is
under
than the point,
Page 10 of 24
No
Item
13
Gens over frequency
(0-75.0Hz)
57.0
14
Gens low frequency
(0-75.0Hz)
40.0
15
CT rate
(5-6000)/5
500
16
Full load current
(5-6000)A
500
17
Over current percent
(50-130)%
120
18
Over current delay
(0-9999)S
1296
19
20
21
22
23
24
25
26
Number of start
Cranking time
Crank rest time
Oil bypass delay
Start idle time
Warming up time
Cooling time
Stop idle time
(1-9)
(3-60S)
(3-60S)
(1-60S)
(0-9999S)
(3-9999S)
(3-9999S)
(0-9999S)
3
5
10
10
0
10
10
0
27
ETS solenoid hold
(0-120S)
30
28
29
30
Fail to stop delay

Shutter open time
Preheat time
(0-120S)
(0-300S)
(0-300S)
0
0
0
31
Crank disconnect
(1-7)
32
Flywheel
numbers
(10-300)
33
Over speed
HGM610/620 MODULE
Setting Range
teeth
(0-6000RPM)
Default
description
generator under voltage is
active. when the point is 30V,
generator under voltage is
disabled.
When generator frequency is
over than the point and hold
great than 3 seconds,
generator over frequency is
active. when the point is
75.0Hz,
generator
over
frequency is disabled.
low than the point, generator
low frequency is
active.
when the point is 0Hz,
generator low frequency is
disabled.
Current transformer rate
Mains or generator set
maximum rated current.
When the load current is
over than the point, the over
current delay is initiated.
When load current is over
than the point and hold great
than the timer, send out over
current signal. when the
delay is zero, over current is
disabled.
numbers of crank cycles.
Its the delay for energizing

to stop.
Setting Item Is Given

Table 5.
in
118
1710
When the engine speed is

over than the point and hold
great than 2 seconds,
generator over speed
is
Page 11 of 24
No
Item
Setting Range
Default
34
Under speed
(0-6000RPM)
1200
35
Gens pole numbers
(2-16p)
36
Freq disconnect
(14-30Hz)
14
37
WL volts disconnect
(0-30V)
8.0
38
Speed disconnect
(0-3000RPM)
360
39
Run out fail-safe
(1-2)
40
Low oil pressure
(0-400)kPa
103
41
Low oil press delay
(0-20.0)S
2.0
42
High temperature
(80-140)
celsius degree
95
43
High
delay
(0-20.0)S
2.0
temperature
HGM610/620 MODULE
description
active.
When the engine speed is
under than the point and
hold great than 10 seconds,
generator under speed is
active.
Generator pole numbers
large than this point, starter
will disconnect.
When charge alternator
WL/D+ voltage is large than
this
point,
starter
will
disconnect.
When engine speed is large
than this point, starter will
disconnect.
When disabled, this feature
will inhibit the run output and
allow the ETS solenoid
energize until the controller
receives a speed sensing
signal,
thus
preventing
possible
damage
from
starting the engine with no
speed sensing for
crank
disconnect and overspeed.
When engine oil pressure
sensor value is less than this
point, the low oil pressure
delay start. when the value is
zero, low oil pressure signal
is disabled. (its suited for oil
pressure sensor only)
When the value is zero, its a
warning
alarm,
not
a
shutdown alarm. (its suited
for oil pressure sensor only)
When engine temprature
sensor value is large than
this
point,
the
high
temperature delay start.
when the value is 140, high
temperature
signal
is
disabled. (its suited for
engine temperature sensor
only).
When the value is zero, its a
warning
alarm,
not
a
shutdown alarm. (its suited
Page 12 of 24
No
Item
44
Low fuel level
(0-100)%
45
Battery over volts
(12.0-40.0V)
33.0
46
Battery under volts
(4.0-30.0V)
8.0
47
Charge failure volt
(0.0-30.0V)
6.0
48
Gens transient
(1-25S)
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
Digit input1
Digit input2
Digit input3
Digit input4
Digit input5
Digit input6
Digit input1 delay
Digit input2 delay
Digit input3 delay
Digit input4 delay
Digit input5 delay
Digit input6 delay
Digit output1
Digit output2
Digit output3
Digit output4
Communication addr
66
Temperature sensor
67
Oil pressure sensor
68
Select analog1
HGM610/620 MODULE
Setting Range
Default
10
(1-254)
13
14
15
02
05
10
2.0
2.0
0.0
1.0
2.0
0.0
08
10
11
2
1
(1-11)
(1-23)
(0.0-20.0S)
(1-60)
(1-11)
(1-5)
6
1
description
for
engine
temperature
sensor only).
When fuel level sensor value
is less than this point and
remain for 10 seconds, send
out warning alarm.
When generator battery
voltage is over than the point
and and remain
for 20
seconds, battery over vlltage
signal is active. its a warning
alarm.
When generator battery
voltage is less than the point
and and remain
for 20
seconds,
battery
under
vlltage signal is active. its a
warning alarm.
During generator is running,
when
charge
alternator
WL/D+ voltage is low than
this point and remain for 5
seconds,
generator
will
shutdown and alarm.
Generator voltage transient
delay
from
normal
to
abnormal
Auxiliary digital input
See below table 3
Transient delay
Auxiliary digital output

See behind table 2
Communication address
Select engine temperature
sensor. see behind table 4
Select engine oil pressure
sensor. see behind table 4
Configurable analog sensor
Page 13 of 24
No
Item
Setting Range
69
Select analog2
(1-5)
70
Select analog3
(1-3)
71
Temperature unit
(1-2)
72
Pressure unit
(1-3)
73
Sensor curve
74
Select line
(1-2)
Default
description
1#. see behind table 4
1
2
Select display temperature
1
unit on LCD.
Select display oil pressure
1
unit on LCD.
Refer to the setting information behind.
Select mains or generator
1
sensing line.
Table 2 List of Definable Content for Configurabled Output Ports 1 to 4

No.
1
Definition
not used
Common alarm
Open shutter
Not alarm in crank
Excitate Gens
Fuel relay on
Crank relay on
Energised to stop
(ETS)
Idle control
10
Raise speed
11
Drop speed
HGM610/620 MODULE
description
The designated programmable output relay will energize

when any warning or shutdown fault circuit has been
activated.
In automation mode, the shutter which is a window that
mounted on generator room wall will open before the
generator start. In manual mode, shutter will open at
sametime as fuel relay outputing. This output will hold,
until generator stop.
Shielding generator high engine temprature, low oil
pressure, over speed alarm during starter is starting. its
energising whill cranking, it will de-energise after oil
pressure is normal. Its suited for some special engines.
Excite alternator by supplying 12V or 24VDC for
generator rotor, its energising whill cranking,
de-energising after alternator voltage is normal.
when the engine RUN (i.e. FUEL) energizes prior to the
engine starting. The output will remain on until the engine
has reached a stop or shutdown command.
when the engine starter energizes. The output will remain
on until the engine has reached crank disconnect speed.
when a stop signal has been activated. The output will
remain energized for pre-set timer once the engine has
come to a complete stop, then de-energizes.
when the idle delay is not zero. The output contact would
typically be connected to the idle/run input control of an
electronic governor.
Its active from entering warming to switching load on.
Its active from idling in stopping to engine has been
stopped.
Page 14 of 24
No.
Definition
12
Preheat output
13
Gens being running
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Stop mode
Gens running
AUTO mode
Manual mode
Auto running
Manual running
Not used
Running on load
Not used
Close mains
Close gens
Open mains & gens
Low oil pressure
High temperture
Over speed
Under speed
30
Failed to start
31
Failed to stop
32
Emergency stop
33
PC emergency stop
34
Loss of speed
35
Failed to Charge
36
Battery over volts
37
Battery low volts
38
39
40
41
Mains volt normal

Gens volt normal
Mains volt abnormal
Gens volt abnormal
42
Over current
HGM610/620 MODULE
description
during the preheat delay timer period until the engine start
to crank. The preheat output is typically used for an
engine starting aid such as glow plugs.
when the engine has started and has reached crank
disconnect speed.
Its active when generator enter standby state.
Its active from entering warming to cooling down.
Its active in automation mode.
Its active in manual mode.
Generator is running in automation mode.
Generator is running in manual mode.
Generator is running on load.
Switch mains breaker on.
Switch generator breaker on.
Switch breaker off. the output delay is 5 seconds.
Low oil pressure shutdown alarm.
High engine temperture shutdown alarm.
Over speed shutdown alarm.
Under speed shutdown alarm.
If the engine does not fire after the pre-set number of
attempts has been made a shutdown will be initiated.
If the module detects the engine is still running when the
Fail to stop timer expires, its active.
Removal of the +VE DC Supply from the Emergency Stop
input initiates the following sequence, firstly it will initiate a
controlled shutdown of the Generator and prevent any
attempt to restart the Generator until the Emergency Stop
push-button has been reset. Secondly it removes the +VE
DC supply from both the Fuel Solenoid and Starter
Solenoid.
The emergency stop is come from PC (personal
Computer) or the monitor room.
Loss of speed shutdown alarm
If the module does not detect a voltage from the warning
light terminal on the auxiliary charge alternator, its active.
If the module detects that the plant DC supply has risen
above the high volts setting level, its active.
If the module detects that the plant DC supply has fallen
below the low volts setting level, its active.
When mains voltage is normal, thr output is active.
When generator voltage is normal, thr output is active.
When mains voltage is abnormal, thr output is active.
When generator voltage is abnormal, thr output is active.
If the module detects a generator output current in excess
of the pre-set trip the warning is initiated.
Page 15 of 24
No.
43
44
45
46
47
48
49
50
51
52
Definition
Digit input1 state
Digit input2 state
Digit input3 state
Digit input4 state
Digit input5 state
Digit input6 state
Alarm(delay 60s)
Mains closed port
Remote start port
Not used
53
Shutdown alarm out
54
Warning alarm out
55
Low fuel level out
description
When the input terminals is connected to VE DC, these
are active.
Shutdown alarm output. after 60 seconds it is inactive.
The inport state of mains closed.
The inport state of remote start.
when any shutdown fault circuit has been activated.
when any warning fault circuit has been activated.
If the fuel level detected by the fuel level sender falls
below the low fuel level setting, this warning will occur.
56
Not used
57
Not used
58
Not used
59
Not used
60
Not used
Note: The 38, 40, 50 item of HGM610 is Not used.
Table 3 List of Definable Content for Configurabled Input Ports

No.
1
2
3
description
Definition
Not used
Over speed input
Low fuel level
Shutter status
5
6
7
Auxiliary warn
Auxiliary shutdown
Not used
Stop after cooled
9
10
11
12
13
14
15
16
17
18
19
20
Inhibit start
Gen closed input
Aux. charger fail
Low water level
high Temp input
Low OP input
Remote start input
Inhibit Load input
Low engine temp
Breaker tripped
Remote emerg.stop
High oil level
HGM610/620 MODULE
Auxiliary Over speed digital input

Auxiliary Low fuel level digital input
Shutter status digital input. Its active when shutter is
opened.
Auxiliary warn alarm digital input.
Auxiliary shutdown alarm digital input.
During engine running, if the engine occur high
temperature shutdown, when the input is active, the
engine will first initiate cooling delay and then stop,
else will stop immediately.
This will inhibit generator to start when it is active.
The inport state of generator closed.
Auxiliary charger charge failsure digit input..
Low water level digit input.
High engine temperature digital input
Low oil pressure digit input
Auxiliary Remote start input
Engine runs but mains and generator will not take load.
Auxiliary Low engine temperature input.
Auxiliary Breaker tripped input.
Auxiliary Remote emergency stop input.
Auxiliary High oil level input.
Page 16 of 24
No.
21
22
23
Definition
Low fuel pressure
Gen breaker open
Failed to sync
description
Auxiliary Low fuel pressure input.
Auxiliary Generator breaker open input.
Auxiliary Failed to sync input.
Table 4 Selection for Sensors

No
defined
1 not used
2 defined voltage type
3 defined resistive type
4 VDO 120 degree
5 DATCON 120 degree
Temperature
6 SG 120 degree
Sensor
7 DATCON high
8 DATCON high
9 MURPHY
10 CUMMINS
11 PT100
1 not used
2 defined volt_type
3 defined res_type
4 VDO 10 bar
5 DATCON 10 bar
Oil pressure
6 SG 10 bar
Sensor
7 VDO 5 bar
8 DATCON 7 bar
9 DATCON 5 bar
10 MURPHY 7 bar
11 CMB812
1 Not used
2 defined voltage type(Temperature)
Auxiliary
3 defined voltage type (Fuel level)
Sensor1
4 defined resistive type(emperature)
5 defined resistive type(Fuel level)
1 Not used
2 defined voltage type(Pressure)
3 defined voltage type(Temperature)
Auxiliary
Sensor2
4 defined resistive type(Pressure)
5
defined
resistive
type
(Temperature)
1 Not used
Auxiliary
2 Charger W/L
Sensor3
3 defined voltage type(oil Pressure)
description
1 Configurable
voltage
type input voltage range
is 0-30Vdc
2 Configurable
resistive
type input resistance
range is 0-9999 ohm
1 Configurable voltage
type
input
voltage
range is 0-30Vdc
2 Configurable resistive
range is 0-9999 ohm
1 Configurable
voltage
type input voltage range
is 0-5.0Vdc
2 Configurable
resistive
range is 0-9999 ohm
Configurable voltage type

input voltage range is
0-30Vdc
Note: please specify on ordering when Auxiliary Sensor3 is selected for defined voltage
type(Pressure).
HGM610/620 MODULE
Page 17 of 24
Table 5 Conditions for Crank Success

No.
1
2
3
4
5
6
7
Setting Content
Magnetic Pickup
Charge Alternator D+(or WL)
Magnetic Pickup and Charge Alternator D+(or WL)
Generating Frequency
Magnetic Pickup and Generating Frequency
Generating Frequency and Charge Alternator D+(or WL)
Magnetic Pickup, Charge Alternator and Generating Frequency
7. SETTING PARAMETER
After the controller is powered up, press the key
1 History record
2 Set Date and time
3 Set Parameters
4 Information
5 Set Language/
to enter into the setting interface:
1. History record
When looking for history record, press
button to lookup nest
record,press UP or DOWN to lookup previous or next item of current record.
The controller may store 99 records circularly. The record will be stored
when these below events has happen:
Emergency stop shutdown
High temperature shutdown
Low oil pressure shutdown
Over speed shutdown
Auxiliary shutdown alarm
Failed to start
Failed to stop
Loss of speed shutdown
Failed to charge shutdown
Generator under frequency shutdown
Low water level warning
Low fuel level warning
Generator voltage annormal shutdown
Under speed shutdown
Generator Over frequency shutdown
Start generator
2. Set date and time
The max number is 2099-12-31 and 23:59:59
3. Set parameters
The default password is 1234 when it leaves factory. The senior setting
password is fixed as 0318. When setting each item, after selecting this item,
press the key
HGM610/620 MODULE
to enter the setting interface, then press the key

or
Page 18 of 24
to adjust the numerical value, press the key

finally press the key
to move the cursor,
to confirm the set parameter.
NOTE:
a Please set parameters in stop mode, else shutdown or other event
may occur.
b The over value point must be great than the under value.
c The configurable input 1 to 6 cant set as same item.The
configurable output 1 to 4 allow to set as same item.
d When the crank disconnect has been selected for charge WL,
Run output fail safe must set as Enabled .
e Configurable output2 cant been seted as Energise to stop,
Common alarm, Droop speed , Idle control, Open generator
etc,
because the output supply come from #27 terminal(Emergency
stop).
4. Information
LCD will display the controller software version, issue date. Note: press
the key DOWN will display the states of configurable input 1 to 6.
5. Set language
User may set display interface language as Chinese or English.
Hint: Press the key OFF will exit at any time.
8. SENSOR CONFIG
1. if the used sensor curve is not same as the standard curve, please adjust in
Sensor curve.
2. When entering the sensor curve, X value (voltage or resistance ) must be from
small value to big value.
3. if the oil pressure sensor is not exist and the oil pressure alarm switch is exist,
please set Oil pressure sensor as not used, else low oil pressure shutdown will
occur.
4. if the sensor curve slope is positive, please according to the below curve Diagram
HGM610/620 MODULE
Page 19 of 24
common units conversion table

N/m2(pa)
kgf/cm2
bar
(1b/in2) psi
1Pa
1.0197210-5
110-5
1.4503810-4
1kgf/cm2
9.80665104
0.980665
14.2233
1bar
1105
1.01972
14.5038
1psi
6.89476103
7.030710-2
6.8947610-2
9. COMMUNICATION
Serial port: RS485

Protocl: MODBUS
Baud rate: 9600bps
Data bit: 8bits
parity bit: none
stop bit: 1bit or 2 bit
address: 1-254
The detail information refer to HGM600 communication protocol manual.
10. SPECIFICATION
Operating Voltage
DC8.0V to 35.0V, Continuous Power Supply
Power Consumption
<3W
AC Generator Voltage Input
(0 to 300)V (Single-Phase) or
(0 to 520)V (Three-Phase)
AC Generator Frequency
50 to 60Hz
Magnetic Pickup Voltage
1.0 to 70V
Magnetic Pickup Frequency
Max. 10000Hz
Crank Relay Output
16Amp
DC24V
Fuel Relay Output
16Amp
DC24V
Configurabled Output Port 1
10Amp
DC24V
HGM610/620 MODULE
Page 20 of 24
16Amp
DC24V
10Amp
DC24V
16Amp
DC24V
Close Generator Relay
16Amp
DC24V
Close Mains Relay
16Amp
DC24V
Overall Dimension
192mm x144mm x87.5mm
Cut out Dimension
186mm x139mm
Rated Current of Current Transformer 5A

Operating Condition
Temperature: (0-50)celsius degree

Humidity: (20-90)%
Storage Condition
Temperature: (-20 - 60)celsius degree
11. OPERATION
Before operation, inspections that are recommended as follows should be carried out:
a. Check and assure that all connections are correct, and that diameter of wire is
suitable;
b. 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;
c. The emergency stop input is connected with the positive supply (+Ve) of the battery
through the NC terminal and fuse of emergency stop button;
d. 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;
e. 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;
f. 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 scrank, if
crank is normal, the generator 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 generator. If there is abnormal, stop the generator,
then check connections of each part according to this handbook;
g. 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;
h. After the mains is abnormal again, the Generator will automatically crank into normal
operation state, and then close generator relay, control the ATS to switch transfer to
HGM610/620 MODULE
Page 21 of 24
generator on load. If the situation is not same as described above, check the
connection of control part of the ATS according to this handbook;
i. If there are other questions, please contact the technical personnel of our company in
time.
12. TYPICAL APPLICATION
Typical Application Diagram for HGM610 Generator Automatic Controller
Typical Application Diagram for HGM620 Generator Automatic Controller
HGM610/620 MODULE
Page 22 of 24
13. 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:
14. TROUBLESHOOTING
Fault Symptom
Measures May Be Taken
The controller is not work
Check the battery voltage

Check connections of the controller
Check DC fuse
Generator stop
Check if engine temperature is over high

Check voltage of AC generator
Check DC fuse
Check if the function of emergency stop button is correct.

Controller emergency stop Check if the positive supply (+VE) of battery is correctly
connected with emergency stop input.
Low oil pressure alarm
after crank success
Check oil pressure input and its connection
High water temperature

alarm after crank success
Check temperature input and its connection
Check related switches and connections according to

shutdown during operation information displayed by LCD
Check configurabled input ports
Fail to crank
Check actuator and its connections

Check fuel
Check battery voltage
Check Magnetic Pickup and its connections
Refer to handbook of engine
Fail to Start
Check connections of starter

Check battery
HGM610/620 MODULE
Page 23 of 24

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PERFORMANCE AND CHARACTERISTICS .............................................................................................. 3

BACK BOARD ................................................................................................................................................... 7

PARAMETERS SETTING CONTENT ..........................................................................................................10

SENSOR CONFIG ........................................................................................................................................... 19

10. OPERATION .....................................................................................................................................................21

ISSUE 2009-02-18 Version 2.1

2. PERFORMANCE AND CHARACTERISTICS

1. HGM610: Automatic engine start;

ISSUE 2009-02-18 Version 2.1

HGM610/620 AUTO START MODULE

3.1 Operation Panel

HGM620 front panel

ISSUE 2009-02-18 Version 2.1

HGM610/620 AUTO START MODULE

function is used to initiate a manual start signal to the

function is used to initiate a stop signal to the engine

push-button and LED light viewing window. The

function is used to initiate

push-button and LED light viewing window. The

function is used to initiate

3.2 Automatic operation

push-button. The LED indicator beside the

When mains is abnormal, the following sequence is initiated:

ISSUE 2009-02-18 Version 2.1

HGM610/620 AUTO START MODULE

3.3 Manual Operation

de-energises the FUEL SOLENOID, bringing the generator to a stop.

3.4 Run on load

, then press the key

, it will pop up the LOAD TEST menu, pressing the key

ISSUE 2009-02-18 Version 2.1

HGM610/620 AUTO START MODULE

will switch mains off-load, then switch generator on-load.

The back board of HGM610 Controller is shown as follows:

The back board of HGM620 Controller is shown as follows:

Connecting Terminal A with 16 Pins

ISSUE 2009-02-18 Version 2.1

HGM610/620 AUTO START MODULE

Configurabled Input Port 4

Temperature Sensor Input

Oil Pressure Sensor Input

Connecting to engine body near the

Connecting Terminal B with 8 Pins

Externally Connecting with Secondary

Externally Connecting with secondary

Externally Connecting with secondary

refer to the installation instructions for

Generator L1 voltage input.

Connect to alternator L1 output. (Fuse

Generator L2 voltage input.

Connect to alternator L2 output. (Fuse

Generator L3 voltage input.

Connect to alternator L3 output. (Fuse

Generator N sensing input.

Connect to alternator N output.

Connecting Terminal C with 14 Pins

System DC negative input.