HGM6510 Genset Parallel Unit

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: [email protected]
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.
Version history
Date Version Contents
2010-01-01 1.1 Original release
2010-05-10 1.2 Panel dimensions changed;
Terminal numbers in wiring diagram changed.
2010-06-24 1.3 Terminal 34 description corrected.
2010-07-16 1.4 Some details optimized
2012-01-09 1.5 1.Input and output functions description and debugging
procedures added;
2.Back panel diagram updated;
3.HGM6500 Synchronization Plan List and display contents
added.
2012-08-15 1.6
1.Monitoring mode input and power management mode
description added;
2.Generator close input number of wiring diagram corrected.
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CONTENTS
1 OVERVIEW ............................................................................................ 5
2 PERFORMANCE AND CHARACTERISTICS ........................................ 5
3 SPECIFICATION ................................................................................... 8
4 PUSHBUTTONS .................................................................................... 9
5 OPERATION ........................................................................................ 10
5.1 AUTOMATIC OPERATION (MULTIPLE SETS) ........................................................................... 10
5.2 MANUAL OPERATION (MULTIPLE SETS) ................................................................................. 12
6 PROTECTIONS .................................................................................. 14
6.1 WARNING ALARMS .................................................................................................................... 14
6.2 SHUTDOWN ALARMS ................................................................................................................ 17
6.3 TRIP SHUTDOWN ALARMS ....................................................................................................... 20
7 PANEL CONFIGURATION.................................................................. 21
7.1 LCD DISPLAY .............................................................................................................................. 21
7.1.1 Status Display .......................................................................................................................... 21
7.1.2 Engine Display ......................................................................................................................... 21
7.1.3 Generator Display .................................................................................................................... 22
7.1.4 Bus Display .............................................................................................................................. 23
7.1.5 Synchronization Display .......................................................................................................... 23
7.1.6 Alarm Display........................................................................................................................... 23
7.1.7 Event Log ................................................................................................................................. 24
7.1.8 ABOUT Display ..................................................................................................................... 24
7.2 PARAMETER CONFIGURATION................................................................................................ 24
7.3 DATE/TIME SETTING ................................................................................................................. 29
7.4 DATA DISPLAY ............................................................................................................................ 29
7.4.1 Basic Display ........................................................................................................................... 29
7.4.2 ECU Display ............................................................................................................................ 30
8 INPUT AND OUTPUT PORTS CONFIGURATION ............................. 30
8.1 CONFIGURABLE INPUT PORTS 1-9 ......................................................................................... 30
8.2 CONFIGURABLE OUTPUT PORTS 1-5 ..................................................................................... 33
9 EVENT LOG ....................................................................................... 37
10 BACK PANEL ...................................................................................... 38
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11 ECU INTERFACE ............................................................................... 41
12 DEBUGGING PROCEDURE .............................................................. 41
12.1 STEP 1. SINGLE UNIT DEBUGGING ......................................................................................... 41
12.2 STEP 2: MANUAL PARALLEL OPERATION OFF-LOAD ............................................................ 42
12.3 STEP 3: MANUAL PARALLEL OPERATION ON-LOAD .............................................................. 42
12.4 STEP 4: FULLY AUTOMATIC PARALLEL OPERATION ............................................................. 42
13 POWER MANAGEMENT MODE ......................................................... 44
14 TROUBLESHOOTING ......................................................................... 45
13 TYPICAL WIRING DIAGRAMS ........................................................... 46
14 COMMUNICATION INTERFACE ......................................................... 48
15 CASE DIMENSIONS AND PANEL CUTOUT ...................................... 48























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1 OVERVIEW
HGM6510 controller is designed for manual/auto parallel systems of more than 20
generators with similar or different capacity or single gen-set constant power output and
mains parallel. The controller allows automatic start/stop, data measurement, alarm
protection as well as remote control, remote measurement and remote communication. It
has LCD display, selectable Chinese/English interface, and it is reliable and easy to use.
The controller integrates GOV (Engine Speed Governor) and AVR (Automatic
Voltage Regulator) control functions, automatic synchronization and load sharing; it can
be used to parallel with other HGM6510 controller.
HGM6510 controller can accurately monitor multiple running states of the gen-set.
When genset abnormal condition occurs, it splits bus and shuts down the gen-set,
simultaneously the fault condition appears on LCD.
HGM6510 controller is based on 32-bit MPU, has SAE J1939 interface that can
communicate with a number of EFI engines ECU. Multiple parameters such as rotation
speed, water temperature, oil temperature, oil pressure can be transmitted via this
communication interface and displayed on LCD, so there is no need to install additional
sensors and complicated wiring is avoided while electric parameters accuracy is
ensured.
2 PERFORMANCE AND CHARACTERISTICS
2 application modes:
1) parallel operation of multiple gen-sets;
2) gen-set and mains parallel operation, gen-set as constant power output.
One-core 32-bit microprocessor, LCD with backlight, optional languages interface,
touch-button operation;
Complete monitoring: practically all generator electric and non-electric parameters
are monitored, as follows:
Generator electric parameters:
3-phase phase voltage Ua, Ub, Uc Unit: V
3-phase line voltage Uab, Ubc, Uca Unit: V
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3-phase current Ia, Ib, Ic Unit: A
Frequency F1 Unit: Hz
Split phase active power PA, PB, PC Unit: kW
Total phase active power P Unit: Kw
Split phase reactive power RA, RB, RC Unit: kvar
Total phase reactive power P Unit: kvar
Split phase apparent power SA, SB, SC Unit: kVA
Total phase apparent power S Unit: KVA
Split phase power factor PF1, PF2, PF3
Average power factor P
Total active energy Unit: kWh
Total reactive energy Unit: kVarh
Total apparent energy Unit: kVAh
3-phase voltage phase sequence and phase angle detection
Bus/mains electric parameters:
3-phase phase Voltage Ua, Ub, Uc Unit: V
3-phase line Voltage Uab, Ubc, Uca Unit: V
Frequency F1 Unit: Hz
3 phase voltage phase sequence and phase angle detection
Synchronization parameters:
Generator and bus/mains voltage difference detection
Generator and bus/mains phase angle difference detection
Generator and bus/mains frequency difference detection
Generator abnormal conditions:
Over Voltage
Under Voltage
Over Frequency
Under Frequency
Phase Loss
Reverse phase sequence
No power
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Fault display and alarm:
High temperature warning
High temperature shutdown alarm
Low oil pressure warning
Low oil pressure shutdown alarm
Over speed shutdown alarm
Low fuel level warning
Start battery over voltage warning
Start battery under voltage warning
Load over current shutdown
Fail to start alarm
Fail to stop alarm
Emergency shutdown
Close fault
Open fault
Oil pressure sensor open circuit alarm
Reverse power
Reverse phase sequence
ECU communication failure

Multiple operation modes in auto state: on-load running, off load running, demand
parallel running;
Ramp on and ramp off function;
Weekly and monthly start/stop; on-load (parallel operation) or off load
commissioning;
SAE J1939 interface for direct EFI engine monitoring;
True RMS measurement for multiple abnormal electric quantity situations;
Accurate measurement and display of engine electric parameters as well as water
temperature, oil pressure, fuel level and others;
Control and protection: automatic start/stop/parallel operation, synchronization
detection, load sharing and alarm protection;
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Maintenance function, maintenance due warning or shutdown alarm;
For the engines that do not support J1939: temperature, pressure and fuel level
sensors also can be connected externally; multiple ready to use and user-defined
sensor curves;
Free adjustment of input port information that is displayed on LCD via PC software:
Chinese/English support, 20 English letters or 10 Chinese characters maximum;
Close to activate/open to activate configurable input port types; normally
open/normally closed configurable output port types;
All output ports are logic output;
Real-time calendar, clock and total run counter;
Possibility of repeated saving of 99 event logs, which can be inquired on the spot.
Multi-level password protection to avoid misuse by non-qualified personnel;
Gen-set operational parameters can be adjusted from front panel or via PC;
Wide power supply range (8-35) VDC enables compatibility with different battery
voltage environment;
RS485/232C communication interface with MODBUS protocol for remote control,
remote measurement, remote communication and remote adjustment of the gen-set;
to realize four remote (remote controlling, remote measuring, remote
communication and remote adjustment) of the controller;
Modular design, anti-flaming ABS shell, plug-in terminals, compact structure,
convenient panel mounting installation.
3 SPECIFICATION
Parameter Details
Working Voltage DC8. 0V to 35. 0V, uninterruptible power supply
Overall Consumption <3W (Standby mode: 2W)
Alternator Voltage Input:
3 Phase 4 Wire
3 Phase 3 Wire
Single Phase 2 Wire
2 Phase 3 Wire

15V AC - 360 V AC (ph-N)
30V AC - 600 V AC (ph-ph)
15V AC - 360 V AC (ph-N)
15V AC - 360 V AC (ph-N)
True RMS Accuracy 1%
Alternator Frequency 50Hz/60Hz
Speed Sensor Voltage 1. 0 V to 24 V (RMS)
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Parameter Details
Speed Sensor Frequency Maximum 10,000 Hz
Start Relay Output 16 Amp DC28V power supply output
Fuel Relay Output 16 Amp DC28V power supply output
Configurable Relay Output 1 16 Amp DC28V power supply output
Configurable Relay Output 2 16 Amp DC28V power supply output
Configurable Relay Output 3 16 Amp DC28V power supply output
Configurable Relay Output 4 16 Amp 250VAC passive output
Configurable Relay Output 5 16 Amp 250VAC passive output
Case Dimensions 260mm x 182mm x 57mm
Panel Cutout 214mm x 160mm
CT Secondary Current Rated 5A
Working Conditions
Temperature: (-25~+70)C
Humidity: (20~93)% without condensation
Storage Conditions Temperature:(-30~+80)C
Protection Level
IP55: when waterproof rubber gasket installed between
the controller and panel fascia.
IP42: when waterproof rubber gasket is not installed
between the controller and panel fascia.
Insulation Intensity
Object: input/output/power supply
Quote standard: IEC688-1992
Test method: AC1.5kV/1min Leakage current 3mA
Weight 0.90kg
4 PUSHBUTTONS

Stop/Reset
When the genset is running, pressing this button will ramp
off and stop running the generator;
In case of alarm condition, pressing the buttons will reset
alarm;
In stop mode, pressing and holding for 3 seconds will test
panel light indicators (light test);
During shutdown process, pressing this button again will lead
to quick shutdown.

Start
In manual mode pressing this button will start the gen-set
(The button has effect in manual mode only)

Manual Places the gen-set into its manual mode.

Reserved
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Auto Places the gen-set into its auto mode.

Close
Generator
In manual state, when bus bar has voltage, pressing the
button will synchronize generator with bus and, after that,
close generator onto bus; when bus bar has no voltage,
pressing the key will close generator breaker immediately.

Open
generator
In manual state, when start mode is enabled, pressing the
button will transfer load to other generators and then open
breaker; when start mode is not in force, pressing the button
will open the switch immediately.

Up
Scrolls the screen up; in settings menu moves cursor up and
increases the set value.

Down
Scrolls the screen down; in settings menu moves cursor
down and decreases the set value.

Left Scrolls the screen left; in settings menu moves cursor left.

Right Scrolls the screen right; in settings menu moves cursor right.

Confirm In settings menu confirms the set value.
5 OPERATION
5.1 AUTOMATIC OPERATION (MULTIPLE SETS)
Auto mode is activated by pressing button; a LED indicator next to the button will
illuminate to confirm that the gen-set is placed into auto start mode.
Automatic Starting Sequence
Using PC testing software, set one of the 9 configurable inputs as Remote Start On-load
(on demand). When the input activates, every gen-set will be started according to the
pre-set priority procedure, synchronize, enter parallel operation and automatically start
sharing load with other units on the bus.
1. When Remote Start is active, Start Delay starts;
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2. Start Delay countdown is displayed on LCD;
3. When start delay is over, preheat relay energizes (if configured), preheat start delay
XX s message is shown on LCD;
4. When preheat delay is over, fuel relay is energized for 1s (for EFI engines the start
signal is sent via ECU); start relay activates; if engine fails to fire during pre-set crank
time, fuel relay and start relay deactivate and crank rest time begins before the
next crank attempt.
NOTE: If CANBUS is set as active in the controller settings, then engine ECU will
receive the start signal from CANBUS.
5. If engine fails to fire after a pre-set number of attempts, the first line of LCD display
will be highlighted with black and Fail to Start alarm message will be displayed;
6. In case of successful crank attempt, safety on timer starts. During this period, low
oil pressure, high temperature, under speed, charge failure alarms are disabled. As
soon as this delay is over, start idle delay is initiated (if configured).
NOTE: If CANBUS is set as active in the controller settings, then engine speed can be
received directly from ECU.
7. During start idle delay, under speed, under frequency, under voltage alarms are
inhibited. When this delay is over, warming up delay starts (if configured).
8. When warming up delay is over, if generator state is normal, its indicator will be
illuminated. If voltage and frequency has reached on-load requirements, the closing
relay will be energized, generator will accept load, generator power indicator will turn
on, and generator will enter Normal Running state; if voltage and frequency are not
normal, the controller will initiate alarm shutdown (alarm type will be displayed on
LCD alarm page).
9. In case of running in parallel, after warming up delay is over:
a) If bus has no voltage, then the controller will send a closing signal to other parallel
gen-sets, closing relay output will activate to prevent other generators from closing at
the same time.
b) If bus bar has voltage or other gen-sets are already closed, the controller will adjust
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speed and voltage through GOV and AVR to synchronize gen-sets with bus; when
synchronism has been achieved, breaker close signal will be initiated and the gen-set
will be connected to the bus. One they are connected, the controller will gradually
accelerate and share load with other parallel gen-sets.
Stopping Sequence,
1) As soon as Remote Start deactivates, Stop Delay begins.
2) When Stop delay is over, the controller will gradually transfer load to other
generators, open breaker, and Cooling Delay will begin. During cooling delay, if
Remote Start signal becomes active again, the controller will enter parallel state
again. When Cooling Delay is over, Stop Idle Delay starts;
3) During Stop Idle Delay (if it is configured), idle relay is energized. If CANBUS is
enabled in the controller settings, stop function can be carried out directly through
CANBUS;
4) ETS delay begins, ETS relay is energized while fuel relay is de-energized.
5) "Waiting for Complete Stop" begins, complete stop is detected automatically.
6) After complete stop generator is placed into its standby mode. Otherwise, fail to
stop alarm is initiated and the corresponding fail to stop alarm message is shown on
LCD.
5.2 MANUAL OPERATION (MULTIPLE SETS)
1. To activate manual mode press button and an LED indicator next to it will
illuminate; then press button to start the gen-set;
2. When start delay is over, preheat relay is energized (if configured), preheat start
delay XX s message is shown on LCD;
3. When preheat delay is over, fuel relay is energised for 1s (for EFI engines the start
signal is sent via ECU); start relay activates; if the engine fails to fire during pre-set
crank time, fuel relay and start relay deactivate and crank rest time begins before
the next crank attempt.
NOTE: If CANBUS is set as active in the controller settings, then engine ECU will
receive the start signal from CANBUS.
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4. If engine fails to fire after a pre-set number of attempts, the first line of LCD display
will be highlighted with black and Fail to Start alarm message will be displayed;
5. In case of successful crank attempt, safety on timer starts. During this period, low
oil pressure, high temperature, under speed, charge failure alarms are disabled. As
soon as this delay is over, start idle delay is initiated (if configured).
NOTE: If CANBUS is set as active in the controller settings, then engine speed can be
received from ECU directly.
6. During start idle delay, under speed, under frequency, under voltage alarms are
inhibited. When this delay is over, warming up delay starts (if configured).
7. After Warming up Delay is over, the gen-set waits for taking load;
8. Press button, during single unit operation when Warming up Delay is over, if
generator state is normal, the generator state indicator will be illuminated; if voltage
and frequency reach on-load demands, generator power supply indicator illuminates
and normal running state begins; if voltage or frequency values are not normal, the
controller initiates alarm shutdown (corresponding alarm message will be displayed
on LCD).
9. Press button, during parallel operation, when Warming up Delay is over
a. If bus has no voltage, then the controller will send a closing signal to other gen-sets
which are prepare for parallel, and closing relay output will activate to prevent other
generators from closing at the same time.
b. If bus bar has voltage or other gen-sets are already closed, the controller will adjust
speed and voltage through GOV and AVR to synchronize gen-sets with bus; When
When synchronism has been achieved, breaker close signal will be initiated and the
gen-set will be connected to the bus. Once they are connected, the controller will
gradually accelerate and share load with other parallel gen-sets.
10. If during parallel operation open button is pressed, the controller will first
transfer load to other generators, and only then send an opening signal.
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6 PROTECTIONS
When an alarm occurs, common alarm indicator (if configured) will flash and alarm
message will be displayed on LCD.
6.1 WARNING ALARMS
Warnings are not shutdown alarms and do not affect the operation of the gen-set.
Warning does not lead to shutdown, and after warning condition is no longer present,
warning alarm will be cleared automatically. Warning alarms types are as follows:
No Type Active range Description
1
Genset Over
Current
Always active
When the controller detects that gen-set
current has exceeded the pre-set value, it
sends a warning alarm signal and a
warning message is displayed on LCD.
2 Fail To Stop
When after stop
delay is over
When after stop delay is over, if gen-set
output power or oil pressure are not equal
to 0, the generator will initiate warning
alarm and warning alarm message will be
displayed on LCD.
3 Low Fuel Level Always active
When the controller detects that fuel level
has fallen below the pre-set value, it sends
a warning alarm signal and a warning
message is displayed on LCD.
4 Charge Fail
From start idle
to stop idle
When the controller detects that charger
voltage has fallen below the pre-set value,
it sends a warning alarm signal and a
warning message is displayed on LCD.
5 Loss Of Speed
From crank
disconnect to
stop idle
When the controller detects that the
engine speed is zero, it sends a warning
alarm signal and a warning message is
displayed on LCD.
6
Battery Under
Volt
Always active
When the controller detects that start
battery voltage has fallen below the
pre-set value, it sends a warning alarm
signal and a warning message is
displayed on LCD.
7 Battery Over Volt Always active
When the controller detects that start
battery voltage has exceeded the pre-set
value, it sends a warning alarm signal and
a warning message is displayed on LCD.
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No Type Active range Description
8 Gen open fail Always active
When breaker open delay is over, but the
controller has not detected breaker open
signal, it will initiate a warning alarm signal
and a warning message will be displayed
on LCD.
9
Auxiliary Input
1-9
User defined
When controller detected auxiliary input
1-9 warning signal, it will initiate a warning
alarm signal and a warning message will
be displayed on LCD.
10 Maintenance Due Always active
When engine total run time exceeds the
pre-set maintenance value or after a
pre-set date comes, the controller will
initiate a warning alarm signal and a
warning message will be displayed on
LCD. *1
11 Fail to sync time
When
synchronization
is enabled
When within the pre-set synchronization
time, the controller does not detect
synchronization signal within setting time,
it will initiate a warning alarm signal and a
warning message will be displayed on
LCD.
12
Genset Reverse
Phase
When generator
is normal
When the controller detects that generator
phase is not correct (correct phase is L1
L2 L3), it will initiate a warning alarm
signal and a warning message will be
displayed on LCD.
13
Bus Reverse
Phase
When mains
are normal
When the controller detects that mains
phase is not correct (correct phase is L1
L2 L3), it will initiate a warning alarm
signal and a warning message will be
displayed on LCD.
14 MSC Data Error Always active
When the controller detects MSC data
error, it will initiate a warning alarm signal
and a warning message will be displayed
on LCD.
15
MSC Too Few
Sets
Always active
If the number of parallel generators is less
than the pre-set minimum, the controller
will initiate a warning alarm signal and a
warning message will be displayed on
LCD.*2
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No Type Active range Description
16 ECU Warn Always active
If an error message from ECU is received
via CANBUS, the controller will initiate a
warning alarm signal and a warning
message will be displayed on LCD.
17
Negative Phase
Sequen.
After generator
is closed
When the controller detects that load
current unbalance has exceeded the
pre-set value, the controller will initiate a
warning alarm signal and a warning
message will be displayed on LCD.
18
High
Temperature
From start idle
to stop idle
When the controller detects that engine
temperature has exceeded the pre-set
value, the controller will initiate a warning
alarm signal and a warning message will
be displayed on LCD.
19 Low Temperature Always active
When the controller detects that engine
temperature has fallen below the pre-set
value, the controller will initiate a warning
alarm signal and a warning message will
be displayed on LCD.
20 Low Oil Pressure
From start idle
to stop idle
When the controller detects that engine oil
pressure has fallen below the pre-set
value, the controller will initiate a warning
alarm signal and a warning message will
be displayed on LCD.
21 Over Speed
Always active
When the controller detects that engine
speed has exceeded the pre-set value, the
controller will initiate a warning alarm
signal and a warning message will be
displayed on LCD.
22 Under Speed
Waiting for load
cooling down
When the controller detects that engine
speed has fallen below the pre-set value,
the controller will initiate a warning alarm
signal and a warning message will be
displayed on LCD.
23
Genset High
Frequency
Always active
When the controller detects that generator
frequency has exceeded the pre-set
value, the controller will initiate a warning
alarm signal and a warning message will
be displayed on LCD.
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No Type Active range Description
24
Genset Low
Frequency
Waiting for load
cooling down
When the controller detects that generator
frequency has fallen below the pre-set
value, the controller will initiate a warning
alarm signal and a warning message will
be displayed on LCD.
25
Genset Over
Voltage
Always active
When the controller detects generator
voltage has exceeded the pre-set value,
the controller will initiate a warning alarm
signal and a warning message will be
displayed on LCD.
26
Genset Under
Voltage
Waiting for load
cooling down
When the controller detects that generator
voltage has fallen below the pre-set value,
the controller will initiate a warning alarm
signal and a warning message will be
displayed on LCD.
27 Loss of Excitation
During parallel
operation
When the controller detects that gen-set
reactive power has exceeded the pre-set
value, it initiates a warning alarm signal
and a warning message is displayed on
LCD.
Notes
*1: When maintenance time is due, set one of the input ports as Reset Maintenance
Alarm, then the alarm will be cleared by sending an active grounding impulse.
*2: There are 2 possible reasons:
a) Communication line between the controllers disconnects, which interrupts
communication.
b) Other parallel gen-sets controllers have not been powered on.
6.2 SHUTDOWN ALARMS
Shutdown alarm will not disappear until they are reset manually. As soon as shutdown
alarm is initiated, the gen-set will be shut down.

No Type Range Description
1 Emergency Stop Always active
When the controller detects an emergency
shutdown alarm signal, it will initiate alarm
shutdown, and alarm shutdown message
will be displayed on LCD.
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No Type Range Description
2 High Temperature
From start idle
to stop idle
When the controller detects that
water/cylinder temperature has exceeded
the pre-set high temperature shutdown
value, it will initiate alarm shutdown, and
alarm shutdown message will be
displayed on LCD.
3 Low Oil Pressure
From start idle
to stop idle
When the controller detects that oil
pressure has fallen below the pre-set low
OP shutdown value, it will initiate alarm
shutdown, and alarm shutdown message
will be displayed on LCD.
4 Over Speed Always active
When the controller detects that the
generator speed has exceeded the
pre-set overspeed shutdown value, it will
initiate alarm shutdown, and alarm
shutdown message will be displayed on
LCD.
5 Under Speed
Waiting for load
cooling down
When the controller detects generator
speed has fallen below the pre-set
underspeed shutdown value, it will initiate
alarm shutdown, and alarm shutdown
message will be displayed on LCD.
6 Loss of Speed
From crank
disconnect to
stop idle
When the controller detects that gen-set
speed is equal to zero, it will initiate alarm
shutdown, and alarm shutdown message
will be displayed on LCD.
7
Genset High
Frequency
Always active
When the controller detects that generator
frequency has exceeded the pre-set
generator frequency shutdown value, it
will initiate alarm shutdown, and alarm
shutdown message will be displayed on
LCD.
8
Genset Low
Frequency
Waiting for load
cooling down
When the controller detects that generator
frequency has fallen below the pre-set
frequency shutdown value, it will initiate
alarm shutdown, and alarm shutdown
message will be displayed on LCD.
9
Genset Over
Voltage
Always active
When the controller detects that generator
voltage has exceeded the pre-set voltage
shutdown value, it will initiate alarm
shutdown, and alarm shutdown message
will be displayed on LCD.
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No Type Range Description
10
Genset Under
Voltage
Waiting for load
cooling down
When the controller detects that generator
voltage has fallen below the pre-set
voltage shutdown value, it will initiate
alarm shutdown, and alarm shutdown
message will be displayed on LCD.
11
Genset Over
Current
Always active
When the controller detects that generator
current has exceeded the pre-set current
shutdown value, it will initiate alarm
shutdown, and alarm shutdown message
will be displayed on LCD.
12 Fail To Start
If the engine
failed to fire after
the pre-set
number of
attempts
When the engine has failed to fire after the
pre-set number of attempts, the controller
will initiate alarm shutdown, and alarm
shutdown message will be displayed on
LCD.
13
Pressure Sensor
Open
Always active
When the controller detects oil pressure
sensor open circuit, it will initiate alarm
shutdown, and alarm shutdown message
will be displayed on LCD.
14 Auxiliary Input 1-9 User-defined
When the controller detects aux. input
ports shutdown alarm signal, it will initiate
alarm shutdown, and alarm shutdown
message will be displayed on LCD.
15 CANBUS Error
When CANBUS
is set as active
in controller
settings and
after engine is
started.
When the controller detects no signal from
engine ECU, it will initiate alarm
shutdown, and alarm shutdown message
will be displayed on LCD.
16
Negative Phase
Sequen.
After generator
is closed
When the controller detects that load
current unbalance value has exceeded
the threshold, it will initiate alarm
shutdown, and alarm shutdown message
will be displayed on LCD.
17 ECU Warn
When CANBUS
is set as active
in controller
settings and
after engine is
started.
If alarm shutdown signal is received from
ECU through CANBUS, the controller will
initiate alarm shutdown, and alarm
shutdown message will be displayed on
LCD.
HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit ISSUE 2012-08-15 Version 1.6 Page 20 of 48
6.3 TRIP SHUTDOWN ALARMS
When the controller detects electrical trip signal, it immediately disconnects generator
breaker closing relay, which leads to unloading and then generator is cooling down and
stopped.
No Type Range Description
1
Genset Over
Current
Always active
When the controller detects that generator
current has exceeded the pre-set value, it
initiates trip alarm signal and trip
shutdown alarm message appears on
LCD.*1
2
Genset Reverse
Power
During parallel
operation
When the controller detects
has exceeded the pre-set value, it initiates
trip alarm signal and trip shutdown alarm
message appears on LCD.
3
Loss Of
Excitation
During
synchronization
When the controller detects that negative
reactive power has exceeded the pre-set
value, it initiates trip alarm signal and trip
shutdown alarm message appears on
LCD.
4
Negative Phase
Sequen
After generator
breaker is
closed
When the controller detects that load
current unbalance value has exceeded
the pre-set value, it initiates trip alarm
signal and trip shutdown alarm message
appears on LCD.
5 Auxiliary Input 1-9 User-defined
When the controller detects aux. input
ports 1-9 trip shutdown alarm, it initiates
trip alarm signal and trip shutdown alarm
message appears on LCD.
6 MSC Error
When parallel
operation is
enabled
When the controller cannot detect MSC
(multiset communication link), it initiates
trip alarm signal and trip shutdown alarm
message appears on LCD.
7
MSC Too Few
Sets
Always active
If the number of parallel generators is less
than the pre-set number, the controller
initiates trip alarm signal and trip
shutdown alarm message appears on
LCD.
Note *1: E.g. if over current value is set as 110% with 1 hour delay and action is trip
shutdown, then when load current exceeds 110% if within one hour current value does
not fall below 110%, then load will be disconnected and the gen-set will be cooled down
and stopped. Even higher current can lead to switch opening after a short time, for
instance, when full-load current is RMS*2, then switch will be opened after 36 seconds,
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HGM6510 Genset Parallel Unit ISSUE 2012-08-15 Version 1.6 Page 21 of 48
and cooling down and shutdown will follow.
7 PANEL CONFIGURATION
7.1 LCD DISPLAY
7.1.1 STATUS DISPLAY
STATUS 1-1 First Status Screen
STOP MODE
GENSET AT REST
GENSET OPEN
Controller Modes: STOP/MANUAL/AUTO Mode
Genset Working Status
Generator Switch State Indicator

STATUS 1-2 Second Status Screen
UL-N 0 V 0.0 A
UL-L 0V 0.00Hz
Pf = 0.00L 0.0 kW
Generator Average Phase Voltage/Current
Generator Average Line Voltage/Frequency
Generator Average Power Factor, Total Active Power

STATUS 1-3 Third State Screen
F S E123456789
INPUT
OUTPUT
F: fuel output, S: start input, E: emergency shutdown, 1~9
auxiliary input port, 1~5 output ports
Input state: close/open
Output state: close/open

STATUS 1-4 Forth State Screen
MSC Total 3
MSC ID 012
Priority 012
Total number of modules
Module ID
Module priority
7.1.2 ENGINE DISPLAY
ENGINE 2-1 First Engine Screen
SPEED 0 RPM
BATTERY 0.0 V
CHARGE D+ 0.0 V
Engine Speed
Generator Start Battery Voltage
AC Charger D+ Voltage

ENGINE 2-2 Second Engine Screen
OIL PRESSURE
0 kPa
0.0 Bar
0 Psi
Engine Oil Pressure


ENGINE 2-3 Third Engine Display
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HGM6510 Genset Parallel Unit ISSUE 2012-08-15 Version 1.6 Page 22 of 48
FUEL LEVEL 0 %
TEMPERATURE
0
0
Fuel Level
Engine Temperature

ENGINE 2-4 Fourth Engine Screen
STARTS 00000 num Total Number of Starts
HOURS RUN
00000:00:00
Total Run Time: Hours:Minutes:Seconds
MAINTENANCE
00000h
Time till the next engine maintenance.
7.1.3 GENERATOR DISPLAY
GENERATOR 3-1 First Generator Screen
UL-L 0 0 0 V
UL-N 0 0 0 V
F = 0.00Hz 0 RPM
Generator 3-phase Phase Voltage L1-N L2-N L3-N
Generator 3-phase Line Voltage L1-L2 L2-L3 L3-L1
Generator Frequency, Engine Speed

GENERATOR 3-2 Second Generator Screen
IL 0.0 0.0 0.0 A
Pf 0.00 0.00 0.00
APF 0.00L I0 0.0 A
3-phase Current L1 L2 L3
3-phase Power Factor L1 L2 L3
Generator Frequency Power Factor, Generator Phase
Loss Current

GENERATOR 3-3 Third Generator Screen
kW 0.0 0.0 0.0
TkW 0.0 Ramp 0.0
kW% 0.0 Tgt% 0.0
3-phase separate phase Active Power L1 L2 L3
Generator Total Active Power, Pre-set Active Power
Percentage
Active Power Output Percentage, Target Active Power
Percentage

GENERATOR 3-4 Fourth Generator Screen
kVar 0.0 0.0 0.0
TkVar 0.0 Ramp 0.0
kVar% 0.0 Tgt% 0.0
3-phase Reactive Power L1 L2 L3
Total Reactive Power, Pre-Set Reactive Power
Percentage
Reactive Power Output Percentage, Target Reactive
Power Percentage

GENERATOR 3-5 Fifth Generator Screen
kVA 0.0 0.0 0.0
TkVA 0.0
GOV% 0.0 AVR% 0.0
3-phase apparent power L1 L2 L3
Total apparent power
Speed Governing Voltage Output Percentage, Voltage
HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit ISSUE 2012-08-15 Version 1.6 Page 23 of 48
regulation Output Percentage

GENERATOR 3-6 Sixth Generator Screen
kWh 0000000.0
kVAh 0000000.0
kVarh 0000000.0
Total Active Electric Power
Total Apparent Electric Power
Total Reactive Electric Power

GENERATOR 3-7 Seventh Generator Screen
PHASE-SEQUENCE:
LN1-LN2-LN3
000-120-240
Generator Phase-Sequence


7.1.4 BUS DISPLAY
BUS 4-1 First Bus Screen
UL-L 0 0 0 V
UL-N 0 0 0 V
F = 0.00Hz
Bus 3-phase Phase Voltage L1-N L2-N L3-N
Bus 3-phase Line Voltage L1-L2 L2-L3 L3-L1
Bus Frequency

BUS 4-2 Second Bus Display
PHASE SEQUENCE:
LN1-LN2-LN3
000-120-240
Bus Phase-Sequence


7.1.5 SYNCHRONIZATION DISPLAY
Remarks: means the error value meet standard. X means failing standard.
SYN SCOP 5-1 First Screen Display
VOLT DIFF +0.1 V
FREQ DIFF +0.01 Hz
PHASE DIFF +0.1
Voltage Difference Between generator and mains
Frequency Difference Between generator and mains
Phase Difference Between generator and mains
7.1.6 ALARM DISPLAY

ALARMS 6-1 First Alarm Screen
ALARMS:(01/02)
SHUTDOWN ALARM
OP SENSOR OPEN
Total Number of Alarms
Alarm Type: Warning/Shutdown/Trip
Alarm Description

ALARMS 6-2 Second Alarm Screen
ALARMS:(02/02)
SHUTDOWN ALARM
GENERATOR
FAIL TO CLOSE
Total Number of Alarms
Alarm Type: Warning/Shutdown/Trip
Alarm Description
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HGM6510 Genset Parallel Unit ISSUE 2012-08-15 Version 1.6 Page 24 of 48
7.1.7 EVENT LOG
EVENTS 7-1 First Event Log Screen
RECORDS: (01/02)
OVER CURRENT TRIP
2010-12-18 21:31:55
Total Number of Records
Error Type
Record Time

EVENTS 7-2 Second Event Log Screen
RECORDS: (02/02)
GENERATOR
FAIL TO CLOSE
2010-12-18 08:11:07
Total Number of Records
Error Type
Record Time
7.1.8 ABOUT DISPLAY
ABOUT 8-1 First About Screen
MODEL: HGM6510
SOFTWARE:V4.0.2
11-03-08 (2) 03:11:32
Model NO.
Module Software Version
Real-time Clock

ABOUT 8-2 Second About Screen
HARDWARE: V1.3
CPU TEMP:37/98
ISSUE DATE: 2011-06-24
Module Hardware Version


7.2 PARAMETER CONFIGURATION
Press and hold and then press to enter parameter settings password screen.
Use and to increase/decrease digit value 1~9 and or to move
cursor left or right; after you have input the fourth digit press to verify the password.
If the password is correct, you will be able to enter parameter settings menu; otherwise
you will exit to the previous screen. (Factory default password is 1234 and it can be
changed by users)
Press or to scroll parameters up or down. When the needed parameter is
displayed, press to enter settings. When the first digit is highlighted with black,
press or to increase or decrease the value, and press or to move
the cursor right or left. Finally, press to confirm this setting after the user setting the
last digit.
HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit ISSUE 2012-08-15 Version 1.6 Page 25 of 48
During parameter configuration, pressing will exit this menu directly and return to
the main screen.
Parameters list:
No. Parameter Range Default Notes
01 Oil Pressure Warn (1-999)kPa 124kPa/18.0PSI
Return value:
138kPa/20.0PSI
02 Oil Pressure Stop (0-997)kPa 103kPa/14.9PSI
Setting standard:
shutdown value<warning
value<return value
03
Engine Temp
Warn
(81-139)C 90C/194F Return value: 88C/190F
04 Engine Temp Stop (82-140)C 95C/203F
Setting standard:
shutdown value>warning
value>return value
05 Fuel Level Warn (0-100)% 10% Analogue value
06 Start Delay (0-9999)s 5s Timer
07 Preheat Delay (0-300)s 0s Timer
08 Cranking Time (3-60)s 8s Timer
09 Crank Rest Time (3-60)s 10s Timer
10 Safety On Time (1-60)s 10s Timer
11 Over Speed Delay (0-10)s 2s Timer
12 Start idle Time (0-3600)s 10s Timer
13 Warming Up Time (0-3600)s 30s Timer
14 Stop Delay (0-9999)s 30s Timer
15 Cooling Time (0-3600)s 60s Timer
16 Stop Idle Time (0-3600)s 10s Timer
17
ETS Solenoid
Hold
(0-120)s 2s
Timer
18 Fail to Stop Delay (10-120)s 30s Timer
19 Gen. Transient
(0-30)s 5s
Timer
20 Batt Low Delay
(0-9999)s 60s
Timer
21 Batt Over Delay
(0-9999)s 60s
Timer
22
Reverse Power
Time
(0-300)s 10s
Timer
HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit ISSUE 2012-08-15 Version 1.6 Page 26 of 48
No. Parameter Range Default Notes
23
Generator Under
(Warn)
(50-1300)V 196V
On-load value: 207V
Setting standard:
Shutdown value<warning
value<on-load value.
24
Generator Under
(Stop)
(50-1300 )V 184V
Generator under Voltage
shutdown
25
Generator Over
(Warn)
(50-1300)V 265V Return value: 253V
26
Generator Over
(Stop)
(50-1300)V 273V
Setting standard:
shutdown value>warning
value>return value
27
Generator Under
Frequency (Warn)
(0.1-74.9)Hz 42.0Hz
On-load value: 45.0Hz
Setting standard:
Shutdown value<warning
value<on-load value.
28
Generator Under
Frequency (Stop)
(0-74.8)Hz 40.0Hz
Generator Under
Frequency shutdown
29
Generator Over
Frequency (Warn)
(0.1-74.9)Hz 55.0Hz Return value: 52.0Hz
30
Generator Over
Frequency (Stop)
(0.2-75)Hz 57.0Hz
Setting standard:
Shutdown value>warning
value>return value
31 Over Current (50-120)% 100% Analogue Value
32
Flywheel Teeth
(10-500) 118
Used for judging crank
disconnect condition and
detecting engine speed.
33
Under Speed
(Warn)
(1-5999)RPM 1350RPM
On-load value: 1380RPM
Setting standard:
Shutdown value<warning
value<on-load value.
34
Under Speed
(Stop)
(0-5998)RPM 1270RPM Under speed shutdown
35
Over Speed
(Warn)
(1-5999)RPM 1650RPM Return value: 1620RPM
36 Over Speed (Stop) (2-6000)RPM 1710RPM
Setting standard:
Shutdown value>warning
value>return value
37 Over Speed Shoot (0-10)% 10 Analogue Value
38
Battery Under Volt
(Warn)
(0-39.9)V 8.0V Return Value: 9.0V
39 Battery Over Volt (0.1-40)V 33.0V Return Value: 32 V
HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit ISSUE 2012-08-15 Version 1.6 Page 27 of 48
No. Parameter Range Default Notes
(Warn)
40
Charge Fail Volt
(Warn)
(0-39)V 6.0V Analogue Value
41 Language Select (0-2) 0
0:Chinese; 1:English
2: Espanol
42 Change Password
(0-9999) 1234
Numerical Value
43 Module Priority (0-19) 0
The smaller the number,
the higher the priority.
44
Module Addr.
(RS485)
(1-254) 1
RS485 communication
address
45 Generator CT 5-6000:5A 500A Load Current: 500A
46 Full kw Load (0-6000) 345 Unit: kW
47 Full kVar Load (0-6000) 258 Unit: kVar
48 Load Ramp (0-100)% 3% Load/unload speed (%/s)
49 Load Per for Start (0-100)% 80%
Regulates other gen-sets
start load percentage.
50 Load Per for Stop (0-99)% 50%
Regulates other gen-sets
stop load percentage.
51 Sync Upper Freq. (0-2)Hz 0.2Hz Frequency difference
between the generator
and the bus. If is is lower
than positive and higher
than negative, then it is
considered synchronous.
52 Sync Lower Freq (0-2)Hz 0.1Hz
53 Sync Voltage (0-30)V 3V
Voltage difference
between generator and
bus.
54
Synch Phase
Angle
(0-20) 10
Phase difference between
generator and bus.
55 Fail to Sync Time (5-300)s 60s
If after synchronization is
initiated, the gen-set fails
to synchronize after the
delay, Fail to Synchronize
alarm will be initiated.
56 MSC Baud Rate (0-2) 0
Baud rate of MSC
0:330K
1:250K
2:125K


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HGM6510 Genset Parallel Unit ISSUE 2012-08-15 Version 1.6 Page 28 of 48
Other parameters configuration (can only be configured via PC software)
Parameter Default Value
Module Addr. 1
Alternator Selection Yes
Generator Poles Number 4
Magnetic Pickup Yes
Quick On-load Mode No
Start Times 3
Voltage Transformer No
Fuel Pump Control No
Input 1 Remote start on-load (on demand), close to activate
Input 2
Low oil pressure alarm, close to activate, active
period: after safety on delay.
Input 3
High temperature alarm, close to activate, active
period: after safety on delay.
Input 4 Close generator auxiliary input, close to activate
Input 5 Indication, close to activate
Input 6 Working mode selection, close to activate
Input 7 Indication, close to activate
Input 8 Indication, close to activate
Input 9 Indication, close to activate
Output 1 Generator Voltage normal
Output 2 Common alarm
Output 3 Idle/high-speed control
Output 4 Generator close impulse output
Output 5 Generator open impulse output
Generator Rated Freq. 50.0Hz
Generator Rated Volt. 230V
LED1 System in AUTO mode
LED2 Fail to start alarm
LED3 Common shutdown alarm
LED4 Common alarm
Delay Overload Current 100%(500A)
Time multiplier 36
Over Current Action Trip shutdown
Starter disengagement
Generator Frequency
15Hz
Starter disengagement Engine
speed
450RPM
Starter disengagement Oil
Pressure
Not used
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HGM6510 Genset Parallel Unit ISSUE 2012-08-15 Version 1.6 Page 29 of 48
Detect Oil Pressure During
Cranking
No
Scheduled Start/Stop No
MSC ID 0
GOV Settings 0V
AVR Settings 0V
Synch Frequency PID Settings
Configured via HGM6500 PC software.
Synch Voltage PID Settings
Active Power PID Settings
Reactive Power PID Settings
7.3 DATE/TIME SETTING
Press and simultaneously to enter date and time setting. The first digit of the
fourth row will be highlighted with black. Press or to increase/decrease the
value of selected digit and press or to move cursor left or right; after altering
the last digit, press to confirm, press save changes and exit. Press
without press to exit directly without saving.
Date and time order: Year-Month-Date (Week) Hour-Minute-Second
NOTE: Parameters and the date/time must be configured in STOP mode only.
7.4 DATA DISPLAY
7.4.1 BASIC DISPLAY
Speed
Oil Pressure
Coolant Temperature
Fuel Level
Battery/Charger Voltage
Total Run Time/Start Times
Remaining Maintenance Time
Generator Phase Voltage (L1-N, L2-N, L3-N)
Generator Line Voltage (L1-L2, L2-L3, L3-L1)
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Generator Frequency
Load/Generator Current (L1, L2, L3)
Generator Split Phase Active Power (L1, L2, L3)
Generator Total Active Power
Each Phase Power Factor (L1, L2, L3)
Average Power Factor
Generator Each Phase Reactive Power (L1, L2, L3)
Generator 3-phase Total Reactive Power
Generator Total Active/Reactive/Apparent electric energy
Generator Phase Sequence
Bus Phase Voltage (L1-N, L2-N, L3-N)
Bus Line Voltage (L1-L2, L2-L3, L3-L1)
Bus Frequency
Bus Phase Sequence
7.4.2 ECU DISPLAY
Oil Temperature
Coolant Pressure
Inlet Temperature
Exhaust Temperature
Turbocharger Temperature
Fuel Pressure
Fuel Consumption
Total Fuel Consumption
8 INPUT AND OUTPUT PORTS CONFIGURATION
8.1 CONFIGURABLE INPUT PORTS 1-9
No Type Description
0 User configured
The input is configured to perform one of the following
functions:
Indication: display only, no warning or shutdown
Warning: warning only, no shutdown
Shutdown: alarm and immediate shutdown
Electrical Trip: alarm, unloading generator, cooling
down and shutdown
Never active: Input is not active
Always active: always detecting
Active from cranking: detecting from the start of
cranking.
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Active after safety on: input activates after safety on
delay.
1 Alarm Mute
When active, this will disable an output configured as
audible alarm.
2 Alarm Reset
When an alarm is active, resets shutdown and trip
alarm.
3 Alternative Frequency
For EFI engines fitted with ECU CANBUS. When
active, 60Hz is selected.
4 Alternative Voltage For EFI engines fitted with ECU CANBUS
5 Auto Restore Inhibit
In AUTO mode, after the normal operation of
generator, when this input is active, automatic stop will
not be allowed.
6 Auto Start Inhibit
In AUTO mode, when this input is active, automatic
start is not allowed.
7 Reserved
8
Generator Close
Auxiliary Input
Connect to auxiliary contact of generator switch.
9 Generator Load Inhibit
When the input is active, generator breaker will be
inhibited to close.
10 Droop Enable
For EFI engines fitted with ECU CANBUS. When
active, droop is allowed.
11 Lamp Test
When input is active, all LED indicators will be
illuminated.
12
Reserved

13 Reserved
14 Panel Lock
When the input is active, all panel buttons, except for
LEFT, RIGNT, UP, DOWN and CONFIRM will be
locked.
15
Remote Start (Off
load )
In AUTO mode, when this input is active, the gen-set
will be automatically started and after normal
operation it will accept load. Only when this input is not
active, auto stop will be enabled.
16 Remote Start (On-load )
In auto mode, when the input is active, the gen-set will
be automatically started and after normal operation it
will close onto the bus; when input deactivates, the
gen-set will automatically open and stop.
17
Remote Start On Load
(On demand)
In AUTO mode, when this input is active, all the
parallel units are started in the order of priority; then
according to the load, the number of units is
automatically increased or decreased.
18 Scheduled Run Inhibit
In AUTO mode, when the input is active, regular start
is inhibited
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19 Reserved
20
Simulated AUTO
Button
External pushbuttons (not self-locking switch) can be
connected to simulate panel pushbuttons.
21
Simulated MANUAL
Button
22 Simulated STOP Button
23 Reserved
24
Simulated START
Button
25 Transfer to Bus
26 Transfer to generator
27 MSC Alarm inhibit
When MSC is disconnected or data error occurs,
alarm signal will be prohibited.
28 Duty Select
When the input is active, priority is the highest; used to
select main/standby generator.
29
Reset Maintenance
Alarm
When the input is active, the controller will reset
maintenance time to its pre-set value and clear the
alarm.
30
Remote Start in Island
Mode
Reserved
31 Mains Parallel Mode
When the input is active, the generator power output is
constant (output power value is defined via PC
software) and will not share load with other
generators.
32 Speed Raise
Used in mains parallel mode, inching input; when
active, increases generator active power output by
1%.
33 Speed Lower
Used in mains parallel mode, inching input; when
active, decreases generator active power output by
1%.
34 Voltage Raise
Used in mains parallel mode, inching input; when
active, increases generator reactive power output by
1%.
35 Voltage Lower
Used in mains parallel mode, inching input; when
active, decreases generator reactive power output by
1%.
36 Black Start Input
When the input is active:
a) Generator transfer failure alarms will not be
detected;
b) When the gen-set is started generator close output
is simultaneously activated; controls breaker
switch.
Used in case of transformer load to avoid over current
shutdown when the generator is closed.
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37 Auto Mode Input
When the input is active, the controller is in auto mode
and other modes are disabled.
38
Disable Shutdown When the input is active, all the shutdown alarms are
disabled.
39
Monitor Mode Input When the input is active, LCD shows monitoring
mode; in this mode gen-set start and stop are not
controlled, only gen-set parameters are monitored.
40
Power manager mode When the input is active, LCD shows power
management mode; in this mode, the controller does
not start/stop the gen-set, it is only responsible for
synchronization, power sharing, start/stop schedule
and switch opening/closing.
41 Reserved
NOTE: Do not prescribe the same function to configurable inputs 1-9 (except for Not
Used and User-defined), otherwise incorrect operation can occur.
8.2 CONFIGURABLE OUTPUT PORTS 1-5
All output ports have the same options, similar functions can be prescribed to several
output ports.
No Type Description
00 Output Not Used
01 Air Flap Relay
Closes air-flaps during emergency or overspeed
shutdown.
02 Audible Alarm
In case of warning, shutdown, trip; external annunciator
can be connected. When mute alarm input is active,
this output is disabled.
03 Battery High Volts
Active in case of battery over voltage warning alarm.
04 Battery Low Volts
Active in case of battery under voltage warning alarm.
05 Digital Input 7 Active
Activates when input port 7 is active
06 Digital Input 8 Active
Activates when input port 8 is active
07 Digital Input 9 Active
Activates when input port 9 is active
08 Start Relay Output
Active during cranking, deactivates after crank
disconnect.
09 Fuel Relay Output
Active from the start of the gen-set, deactivated after
complete stop.
010
Calling for Scheduled
On
When scheduled start is activated and gen-set is running
(Automatic mode)
011
Charging Alternator
Failure
Active in case of generator charging failure warning
alarm.
012 Close Generator Controls generator switch.( Continuous active)
013 Close Generator Generator impulse close output; output time depends on
HGM6510 GENSET PARALLEL UNIT
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No Type Description
Pulse impulse time.
014 Close Mains Controls mains switch.
015
Close Mains Pulse Mains close impulse output; output time depends on
impulse time.
016
Common Under/Over
Freq. Shutdown
Active in case of under frequency or over frequency
shutdown alarm
017
Common Under/Over
Freq. Warn
Active in case of under frequency or over frequency
warning alarm
018
Common Under/Over
Voltage Shutdown
Active in case of under/over voltage shutdown alarm.
019
Common Under/Over
Voltage Warn
Active in case of under/over voltage warning alarm.
020 Common Alarm
Active in case of generator common warning, common
shutdown, common electrical trip alarms.
021
Common Electrical
Alarm Trip
Active in case of common trip alarm.
022
Common Shutdown
Alarm
Active in case of common shutdown alarm.
023
Common Warn
Alarm
Active in case of common warning alarm.
024
Coolant Temp. High
Pre-alarm for 1#
Active in case of high water/cylinder temperature
warning alarm.
025
Coolant Temp. High
Shutdown for 1#
Active in case of high water/cylinder temperature
shutdown alarm.
026
Cooling Timer in
Progress
Active during cooling delay
027 Check Sync Output Active during synchronization
028 Digital Input 1 Active
Activates when input port 1 is active.
029 Digital Input 2 Active
Activates when input port 2 is active.
030 Digital Input 3 Active
Activates when input port 3 is active.
031 Digital Input 4 Active
Activates when input port 4 is active.
032 Digital Input 5 Active
Activates when input port 5 is active.
033 Digital Input 6 Active
Activates when input port 6 is active.
034 Emergency Stop Active in case of emergency shutdown alarm.
035 Energise to Stop Active during ETS delay
036 Fail To Start Active in case of fail to start alarm.
037 Fuel Pump Control Controlled by fuel level
038 Generator Available
Active when the generator is on-load and during cooling
down.
HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit ISSUE 2012-08-15 Version 1.6 Page 35 of 48
No Type Description
039
Generator High Freq.
Pre-alarm
Active in case of generator over frequency warning
alarm.
040
Generator High Freq.
Shutdown
Active in case of generator over frequency shutdown
alarm.
041
Generator High
Voltage Pre-alarm
Active in case of generator over voltage warning alarm.
042
Generator High
Voltage Shutdown
Active in case of generator over voltage shutdown alarm.
043
Generator Low Freq.
Pre-alarm
Active in case of generator under frequency warning
alarm.
044
Generator Low Freq.
Shutdown
Active in case of generator under frequency shutdown
alarm.
045
Generator Low
Voltage Pre-alarm
Active in case of generator under voltage warning alarm.
046
Generator Low
Voltage Shutdown
Active in case of generator under voltage shutdown
alarm.
047 Louver Control
Activates when the gen-set is started, deactivates after
complete stop.
048 Low Fuel Level Active in case of low fuel level.
049 Loss Of Speed
Active if after safety on delay the controller detects that
engine speed is equal to zero.
050 Mains Failure
Active in case of mains over frequency, under frequency,
over voltage, under voltage or when auxiliary mains
abnormal input is active.
051
Mains High
Frequency
Active in case of mains over frequency.
052 Mains High Voltage
Active in case of mains over voltage.
053
Mains Low
Frequency
Active in case of mains under frequency.
054 Mains Low Voltage
Active in case of mains under voltage.
055
Oil Pressure Low
Pre-alarm for 1#
Active in case of low oil pressure warning alarm.
056
Oil Pressure Low
Shutdown for 1#
Active in case of low oil pressure shutdown alarm.
057
Oil Pressure Sensor
Open Circuit
Active in case of oil pressure sensor open circuit.
058 Open Generator Controls generator load switch
059
Open Generator
Pulse
Generator open impulse output, output time is controlled
by impulse time.
HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit ISSUE 2012-08-15 Version 1.6 Page 36 of 48
No Type Description
060 Open Mains Controls mains load switch.
061 Open Mains Pulse
Mains open impulse output, output time is controlled by
impulse time.
062
Over Current
Pre-alarm
Active in case of generator over current warning alarm.
063 Over Current Trip Active in case of generator over current trip shutdown.
064
Over Speed
Pre-alarm
Active in case of engine over speed warning alarm.
065
Over Speed
Shutdown
Active in case of engine over speed shutdown alarm.
066
Preheat (during
pre-heat timer)
Active from preheat delay till the start of cranking.
067
Preheat (until end of
crank)
Active from preheat delay till the end of cranking.
068
Preheat (until end of
warm timer)
Active from preheat delay till the end of warming up.
069
Preheat (until safety
on)
Active from preheat delay till the end of safety on time.
070 Open Output Controls switch, unloads generator or mains.
071 System in Test Mode Active when the system is in the test mode.
072 System in Auto Mode Active when the system is in the Auto mode.
073
System in Manual
Mode
Active when the system is in the manual mode.
074 System in Stop Mode Active when the system is in the stop mode.
075
Under Speed
Warning
Active in case of under speed warning.
076
Under Speed
Pre-alarm
Active in case of under speed shutdown.
077 Reserved
078
Idle/High-Speed
Control
Active: cranking start idle; stop idle waiting for
complete stop.
079 Pre-oil Supply Output Active: cranking safety on time.
080
Raise Speed
Energized
Reserved
HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit ISSUE 2012-08-15 Version 1.6 Page 37 of 48
No Type Description
081 Excite Generator
Output when started. During safety on running, output 2
seconds without generator Frequency.
082
Drop Speed
Energized
Reserved
083 Preset to Lubricate Active: preheat safety on time.
084 Raise Volt. Output Reserved
085 Drop Volt. Output Reserved
086
Reverse Power
Output
If generator inverse power has exceeded the pre-set
limit, the output activates after a delay
087
Over Power Output If generator power has exceeded the pre-set limit, the
output activates after a delay
088
Low Water
Temperature Warn
Active in case of low temperature warning.
089
Generator Volt.
Normal
Active when generator voltage is normal.
090 ECU Power
For engines with EFI ECU support; controls ECU power
supply.
091 ECU Stop For engines with EFI ECU support; controls ECU stop
NOTE: Functions of 1~5 output ports only can be configured via PC software.
9 EVENT LOG
HGM6510 controller can save a maximum of 99 shutdown logs, including shutdown type,
date and time (warning alarms are not recorded). Once the log is full (99 records), any
subsequent shutdown entry will overwrite the oldest entry in the log, so the log will
always contain the 99 most recent abnormal events.










HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit ISSUE 2012-08-15 Version 1.6 Page 38 of 48
10 BACK PANEL
HGM6510 controller back panel is shown below:

Terminal connections description
Pin Function
Cable
Size
Description
1
DC Power Supply Input
(B-)
2.5mm
2

DC power supply negative input. Connect
externally to start battery negative.
2
DC Power Supply Input
(B+)
2.5mm
2

DC power supply negative input. Connect
externally to start battery negative; 20A fuse
recommended.
3 Emergency Stop 2.5mm
2

Connected to DC voltage via emergency
stop button; provides DC voltage for fuel and
start relay; max. 30A fuse recommended.
4 Fuel Relay Output 2.5mm
2

DC voltage provided by terminal 3; rated
current 16 Amp
5 Crank 2.5mm
2

DC voltage provided by terminal 3; rated
current 16 Amp
6 Aux. Output 1 2.5mm
2
B+ output, rated current 16 Amp.
7 Aux. Output 2 2.5mm
2
B+ output, rated current 16 Amp.
8 Aux. Output 3 2.5mm
2
B+ output, rated current 16 Amp.
9
Charger
Failure/Excitation
1.0mm
2

Generator charger D+ input port; must not
be grounded.
10 Aux. Input 1 1.0mm
2
Digital input
11 Aux. Input 2 1.0mm
2
Digital input
12 Aux. Input 3 1.0mm
2
Digital input
HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit ISSUE 2012-08-15 Version 1.6 Page 39 of 48
Pin Function
Cable
Size
Description
13 Aux. Input 4 1.0mm
2
Digital input
14 Aux. Input 5 1.0mm
2
Digital input
15 Aux. Input 6 1.0mm
2
Digital input
16 Aux. Input 7 1.0mm
2
Digital input
17 Aux. Input 8 1.0mm
2
Digital input
18 Aux. Input 9 1.0mm
2
Digital input
19 Common GND(B-)
1.0mm
2
Connect to gen-set enclosure or starting
battery negative.
20
Magnetic Pickup Sensor
SCR
1.0mm
2

Connect to speed sensor 21
Magnetic Pickup Sensor
+
1.0mm
2

22
Magnetic Pickup Sensor
-
1.0mm
2

23 EFI CAN J1939 SCR 0.5mm
2

Use 120 screened communication line. 24
EFI CAN J1939 Data
Line (H)
0.5mm
2

25 J1939 Data Line (L) 0.5mm
2

26 MSC SCR 0.5mm
2
Use 120 screened communication line to
connect all parallel HGM6510 controllers
together.
27 MSC (H) 0.5mm
2

28 MSC (L) 0.5mm
2

29 GOV Wire B (+) 1.0mm
2
2-core shielded wire recommended with
shielding layer connected to the ground at
GOV end.
30 GOV Wire A (-)
1.0mm
2

31 Not Used
32 AVR Wire B (+) 1.0mm
2
2-core shielded wire recommended with
shielding layer connected to the ground at
AVR end.
33 AVR Wire A (-)
1.0mm
2

34 RS485 SCR 0.5mm
2

PC programming or monitoring port
(isolation), shielding layer grounded at one
end.
35 RS485 A (-) 0.5mm
2

36 RS485 B (+)
0.5mm
2

37
38
39
Aux. Output 5 2.5mm
2

Relay normally open and normally closed
volt-free contacts, rated current 16A
40
Aux. Output 4 2.5mm
2

Relay normally open volt-free contact, rated
current 16A.
41
42
Bus A Phase Sensing
Input
1.0mm
2

Connected to bus A Phase (2A fuse
recommended).
43
Bus B Phase Sensing
Input
1.0mm
2

Connected to bus B Phase (2A fuse
recommended).
44
Bus C Phase Sensing
Input
1.0mm
2

Connected to bus C Phase (2A fuse
recommended).
HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit ISSUE 2012-08-15 Version 1.6 Page 40 of 48
Pin Function
Cable
Size
Description
45 Bus Neutral Line Input 1.0mm
2
Connected to Neutral.
46
Genset A Phase
Sensing
1.0mm
2

Connected to genset A Phase output
(Recommend 2A fuse).
47
Genset B Phase
Sensing
1.0mm
2

Connected to genset B Phase output
(Recommend 2A fuse).
48
Genset C Phase
Sensing
1.0mm
2

Connected to genset C phase output
(Recommend 2A fuse).
49 Genset Neutral Input 1.0mm
2
Connected to generator neutral line.
50
C.T. A Phase Sensing
Input
2.5mm
2

External C.T. secondary coil (Maximum
5A).
51
C.T. B Phase Sensing
Input
2.5mm
2

External C.T. secondary coil (Maximum
5A).
52
C.T. C Phase Sensing
Input
2.5mm
2

External C.T. secondary coil (Maximum
5A).
53 C.T. Common Port 2.5mm
2

External C.T. common port; this port must
at the same time be connected to battery
negative or ground.
54 Not Used
55
Load C.T. Sensing Input 2.5mm
2

External CT secondary coil (Maximum 5A).
HGM6520 ONLY.
56
57 Not Used
58 Pressure Sensor Input 1.0mm
2

Externally connect to a resistance type
sensor.
59 Temp Sensor Input 1.0mm
2

Externally connect to a resistance type
sensor.
60 Fuel Level Sensor Input 1.0mm
2

Externally connect to a resistance type
sensor.
61 Sensor Common Port 1.0mm
2

Sensor common ground, connect to
gen-set enclosure or starter battery
negative.
RS232 Port
PC programming or monitoring port; do not
use this RS485 port at the same time.


DIP Switch 2-bit
For upgrading program
1. Up for normal use;
2. Down for upgrading program




HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit ISSUE 2012-08-15 Version 1.6 Page 41 of 48
11 ECU INTERFACE
HGM6510 controller is fitted with EFI engine ECU interface. Because different
manufactories use different ports and communication protocols, please check if the
controller is suitable for your engine.
This controller can monitor and control some electrical parameters of the engine,
such as speed, oil pressure, temperature. These parameters can be monitored by
standard communication port and there is no need to install corresponding sensors,
which can reduce wiring and enhance reliability.
Please refer to HGM6500 Synchronization Plan List for more information on
engine ports.
12 DEBUGGING PROCEDURE
12.1 STEP 1. SINGLE UNIT DEBUGGING
1) Check the parameter configuration of the controller;
2) Check the gen-set connections and MSC CAN
connection lines between the units. (E.g. if 3
generators are correctly connected, HGM6510 LCD
status screen 1-4 will display Module Number: 3.
See the picture on the right).
3) In manual mode, check if engine and generator data is normal;
4) In manual mode check if switch opens and closes normally;
5) In manual mode, after closing the breaker check if generator frequency can be
adjusted to the rated frequency (e.g. set the rated frequency as 52Hz/48Hz);
6) In manual mode, after closing the breaker check if generator voltage can be adjusted
to the rated voltage (e.g. set the rated voltage as 240V/220V);
7) Activate manual start on-load, check if power factor, active power and reactive
power are normal; if their values are negative, check generator voltage and current
phase sequence, current transformer incoming line direction, current transformer
secondary current dotted terminal;
8) In manual mode do performance tests according to the national standards.
Note: Please refer to HGM6500 Synchronization Plan List for more information on
GOV and AVR settings.
Status
1-4
Module Number 3
Module ID 012
Priority 012
HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit ISSUE 2012-08-15 Version 1.6 Page 42 of 48
12.2 STEP 2: MANUAL PARALLEL OPERATION OFF-LOAD
1) Manually close parallel sets, check that the units synchronization is balanced and
breaker close impulse current is not too high;
2) During parallel operation off load, check that there is no high circumfluence on
HGM6510 current screen;
3) During parallel operation off load, check if the output of active and reactive power is
equal to zero; if it is not, then check if there is power oscillation; if there is, adjust the
gain and stability values of HGM6510 controller, or adjust engine GOV or generator
AVR gain and stability potentiometer to avoid active and reactive power oscillation;
output close to 0.
12.3 STEP 3: MANUAL PARALLEL OPERATION ON-LOAD
1) During manual synchronization, perform on-load test and check if active and reactive
power is evenly distributed between all the gensets;
2) During manual synchronization, perform ramp test to see if there is high overshoot or
power oscillation during this period; if there is, regulate Load Rampx%/s via PC
software;
3) During manual synchronization perform soft load distracting test to see if gen-set
breaker opens after reaching minimum load threshold (%);
4) During manual synchronization, perform impact load test and damp load test to
check if there is power oscillation.
12.4 STEP 4: FULLY AUTOMATIC PARALLEL OPERATION
When the controller is in auto status, if digital input remote start on-load (on demand) is
active, it will carry out fully automatic parallel operation, start and stop. There are 3 ways
of automatic parallel operation:
1) Start on demand: the module with the highest priority starts firstly. When load
exceeds the pre-set start maximum percentage, the second according to the priority
module will start the gen-set, synchronize and share load. When load falls lower than
the preset minimum stop percentage, after stop delay the second module breaker
will be open and the module will be cooled down and stopped.
2) Start all sets initially: all the modules start at the same time; the first module to reach
load condition closes first; when other modules reach load condition, they
HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit ISSUE 2012-08-15 Version 1.6 Page 43 of 48
synchronize one by one. After that the modules monitors the load. If load value falls
below module pre-set shutdown minimum percentage, the module with lowest
priority enters stop delay and then cools down and stops. If load exceeds the preset
start maximum percentage, the generators that are at rest will all start again.
3) Balanced engine running time: Engine with the lowest total run time starts first. When
the running gen-set total run time exceeds the other gen-set balanced running time,
then the gen-set with the next lowest total run time starts (both start on demand or
start all sets initially modes are possible); other gen-sets enter parallel operation
after synchronizing. Opening breaker, unloading and stop is performed automatically.
All the gen-sets are repeatedly started and stopped according to their total run time.























HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit ISSUE 2012-08-15 Version 1.6 Page 44 of 48
13 POWER MANAGEMENT MODE

HGM6510 power management mode can be selected via configurable input port.
HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit ISSUE 2012-08-15 Version 1.6 Page 45 of 48
14 TROUBLESHOOTING
Problem Possible solution
Controller does not
respond to power on
Check starting batteries;
Check the wiring to the controller;
Check the DC fuse.
Check that HGM6510 controller back panel DIP switch is
in the wrong position.
Gen-set shutdown
Check that water/cylinder temperature is not too high;
Check alternator voltage;
Check the DC fuse.
Emergency shutdown
Check emergency shutdown button functions;
Check if the starting battery positive is correctly
connected to the emergency stop input;
Check that there is no open circuit
Low oil pressure alarm
after crank disconnect
Check the oil pressure sensor and its connections.
High water temperature
alarm after crank
disconnect
Check the temperature sensor and its connections.
Alarm shutdown during
running
Check corresponding switch and its wiring according to
the information on LCD; Check auxiliary input port.
Generator fails to close
Check ATS auxiliary input port;
Check generator close relay.
Generator Reverse Phase Check generator voltage phase sequence.
Bus Reverse Phase Check bus voltage phase sequence.
MSC ID Error
MSC ID of the controller is similar to another ID. Try to set
MSC ID using PC software again.
MSC Data Error
Check MSC connection CAN polarity;
Check if 120 matching resistor is correctly connected.
Fail to start
Check fuel return circuit and its connections;
Check starting batteries;
Check speed sensor and its connections;
Refer to engine manual.
Starter motor does not
respond,
Check starter connections;
Check starting batteries.
Gen-set is running, but
ATS does not transfer load
Check ATS;
Check ATS and controller connections.
HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit ISSUE 2012-08-15 Version 1.6 Page 46 of 48
14 TYPICAL WIRING DIAGRAMS
HGM6510 Typical Wiring Diagram

Expansion high-capacity relays for start and fuel output ports are recommended.
HGM6510 Mains Parallel Application

Mains parallel function for HGM6510 controller can be selected via configurable input
HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit ISSUE 2012-08-15 Version 1.6 Page 47 of 48
port. In mains parallel mode, generator will run in parallel with mains and it will only be
able to output a fixed amount of power. Mains parallel operation parameters are shown:












HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit ISSUE 2012-08-15 Version 1.6 Page 48 of 48
HGM6510 Multi-genset Parallel Application

15 COMMUNICATION INTERFACE
The controller is fitted with both standard RS232 and RS485 communication interfaces,
so computer can directly (or through a modem) communicate with controller and perform
remote start/stop, data monitoring and other functions.
RS232/485 interface uses MODBUS communication protocol. MODBUS is a
master-slave protocol, and the controller acts as a slave. When the controller receives a
request from the host (PC or monitoring host), it sends defined format data to the host.
The controller never actively sends data to the host.
16 CASE DIMENSIONS AND PANEL CUTOUT