Trane SmartGen HSC940 Owner's Manual

Owner’s Manual

SmartGen® HSC940
Controller

March 2017 032-5094-1A-EN

Note: “Graphics in this document are for representation only.

Actual model may differ in appearance.”

Table Of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Performance & Characteristics . . . . . . . . . . . . . . . . . . . 4

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Key Operations / Indicator Lights . . . . . . . . . . . . . 6

Auto Start / Stop Operation . . . . . . . . . . . . . . 7

Manual Start / Stop Operation . . . . . . . . . . . . . . . 8

Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Shutdown Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Scope & Denition of Congurable Parameters . . . . . . . . . . . . . 14

Contents & Scope of Parameters . . . . . . . . . . . . . . . . . . 14

Enable Denitions of Programmable Output Ports . . . . . . 19

Dened Contents of Congurable Input Ports . . . . . . . . . . 21

Conditions of Crank Disconnect Selection . . . . . . . . . . . 22

Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Typical Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Connection Between Controller and Genset . . . . . . . . . 25

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Fixing Clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Overall Dimension and Panel Cutout . . . . . . . . . . 27

GSM Short Message Alarm and Remote Control . . . . . . . . . . 28

GSM Short Message Alarm . . . . . . . . . . . . . . . 29

GSM Short Message Remote Control . . . . . . . . . . . . 29

Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2

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Overview

HSC940 genset controllers integrate digitization, intellectualization
and network technology which are used for gas genset automation and
monitor control system of single unit to achieve automatic start/stop,
data measure, alarm protection, three remote: remote control, remote

measuring and remote communication (SG485 module must be tted)

and speed regulation. The controller adopts large liquid crystal display

(LCD) and selectable Chinese, English, Spanish and Russian interface with
easy and reliable operation.

HSC940 genset controllers adopt microprocessor technology with

precision parameters measuring, xed value adjustment, time setting and
set adjusting etc. All parameters can be congured from front panel, or
by congurable port (USB to LINK, SG72 must be tted) to adjust via
PC. It can be widely used in all types of automatic genset control system

with compact structure, advanced circuits, simple connections and high

reliability.

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3

Performance & Characteristics

HSC940, used for single automation systems; it regulates the speed simply by adjust the throttle opening via

the driving stepper motor; auto start/stop of the unit are performed with the help of remote signal.

Key characteristics

• 132×64 LCD with backlight, multilingual interface (including Chinese, English, Spanish and
Russian), pushbutton operation;

• Suitable for 3-phase 4-wire, 3-phase 3-wire, single phase 2-wire, and 2-phase 3-wire systems
with voltage 120/240V and frequency 50/60Hz;

• Collects and shows 3-phase voltage, current, power parameter and frequency of generator.

Generator

Line voltage (Uab, Ubc, and Uca)
Phase voltage (Ua, Ub, and Uc)

Frequency Hz

• For generator, controller has over and under voltage, over and under frequency functions;

• Speed regulation function (via Driving Stepper Motor);

• Precision measure and display parameters about Engine,
Speed (SPD) r/min (unit)
Battery Voltage (VB) V (unit)
Charger Voltage (VD) V (unit)
Hour count (HC) can accumulate to max. 999999 hours.

Start times can accumulate to max. 999999 times.

• Protection: automatic start/stop of the genset, ATS(Auto Transfer Switch) control with perfect

failure indication and protection function;

• ETS (Energize to Stop), idle control, preheat control and raise speed/drop speed control; in

addition, they are all relay output.

• Parameter setting: parameters can be modied and cannot be lost even in case of power
outage; all parameters can be congured from front panel, or by congurable port (SG72 must
be tted) to adjust via PC.

• Multiple crank disconnect conditions (speed sensor, generator frequency) are optional;

• Widely power supply range DC(8~35)V, suitable to different start battery voltage environment;

• All parameters used digital adjustment, instead of conventional analog modulation with normal
potentiometer, more reliability and stability;

• Modular design, self-extinguishing ABS plastic enclosure, pluggable connection terminals and
embedded installation way; compact structure with easy mounting.

4

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Specications

Items Contents

Operating Voltage DC8.0V to DC35.0V, Continuous Power Supply.
Power Consumption Standby: ≤2W

Working: <8W (When driving stepper motor is regulating)

Alternator Input Range

3-Phase 4-Wire
2-Phase 3-Wire
Single-Phase 2-Wire
3-Phase 3-Wire

Alternator Frequency 50Hz/60Hz
Speed Sensor Voltage 1.0V to 24.0V (RMS)

Speed Sensor Frequency 10,000 Hz (max.)
Start Relay Output 5A DC28V supply output
Fuel Relay Output 5A DC28V supply output

Auxiliary Relay Output (1) 5A DC28V supply output
Auxiliary Relay Output (2) 5A DC28V supply output
Auxiliary Relay Output (3) 5A DC28V supply output
Auxiliary Relay Output (4) 5A DC28V supply output
Steady-state Speed Governing Rate <1.5%
Steady-state Speed Fluctuation Rate <0.5%

Transient Speed Governing Rate Sudden Load-on <+10%

Recovery Time <5s
Driving Stepper Motor Mixed 2-phase; Drive current ≤1A
Case Dimension 130mm x 112mm x 39mm
Panel Cutout 110mm x 90mm
Working Conditions Temperature: (-25~+70)°C; Humidity: (20~93)%RH
Storage Condition Temperature:(-25~+70)°C
Protection Level IP55 Gasket
Insulating Intensity Apply AC2.2kV voltage between high voltage terminal and low

Net Weight 0.26kg

AC15V - AC360V (ph-N)
AC15V - AC360V (ph-N)
AC15V - AC360V (ph-N)
AC30V - AC620V (ph-ph)

Sudden Load-off >-15%

voltage terminal; The leakage current is not more than 3mA
within 1min.

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5

4.1 KEY OPERATIONS

Operation

Stop/ Reset

Start Start genset in Manual/Test mode.

Manual Mode

Auto Mode Pressing this key will set the module into AUTO mode.

Set/Conrm

Up/Increase

Down/Decrease

4.2 INDICATOR LIGHTS

Stop running generator in Auto/Manual mode; Lamp test (press

at least 3 seconds); Reset alarm if alarm occurs; During stopping
process, press this button again to stop generator immediately.

Pressing this key will set the module into Manual mode. Press­ing and (or ) simultaneously can adjust LCD contrast.

Pressing this key will view set menu; In parameter setting inter­face, press this key will shift cursor or conrm setting value.

Scrolls the screen up; Shift the cursor up or increase the set
value in parameter setting menu.

Scrolls the screen down; Shift the cursor down or decrease the
set value in parameter setting menu.

Alarm

Gens Normal

Indicator

Stop Indicator Close Gens

Stop

Manual Manual Auto Auto Start Set
Indicator Indicator

6

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Operation

4.3 AUTO START/STOP OPERATION

Auto mode is selected by pressing the button; a LED besides the button will illuminate to conrm the

operation.

Automatic Start Sequence:

1. When “Remote Start” is active, “Start Delay” timer is initiated;

2. “Start Delay” countdown will be displayed on LCD;

3. When start delay is over, preheat relay energizes (if congured), “preheat delay XX s”
information will be displayed on LCD;

4. After the above delay, the Fuel Relay is energized, and then one second later, the throttle of
the driving stepper motor will rotate as the pre-set angle and then the Start Relay is engaged.
The engine is cranked for a pre-set time. If the engine fails to re during this cranking attempt
then the fuel relay and start relay are disengaged for the pre-set rest period; “crank rest time”
begins and wait for the next crank attempt.

5. Should this start sequence continue beyond the set number of attempts, the start sequence
will be terminated, the fourth line of LCD display will be highlighted with black and Fail to Start
fault will be displayed.

6. In case of successful crank attempt, the “Safety On” timer is activated and the throttle of

the driving stepper motor will govern the speed, allowing Low Oil Pressure, High Temperature,

Under speed, Charge Alternator Failure and auxiliary inputs (be congured) to stabilise without
triggering the fault. As soon as this delay is over, “start idle” delay is initiated (if congured).

7. During “start idle” delay, under speed, under frequency, under voltage alarms are inhibited.
When this delay is over, “warming up” delay is initiated (if congured).

8. After the “warming up” delay, if generator status is normal, its indicator will be illuminated.
If generator voltage and frequency have reached on-load requirements, then the generator
close relay will be energized; genset will take load; generator power indicator will illuminate
and generator will enter into Normal Running status. If voltage or frequency is abnormal, the
controller will initiate shutdown alarm (alarm information will be displayed on LCD).

Automatic Stop Sequence:

1. When the “Remote Start” signal is removed, the Stop Delay is initiated.

2. Once this “stop delay” has expired, the Generator Breaker will open and the “Cooling Delay” is

then initiated. Moreover, the generator indicator is extinguished.

3. During “Stop Idle” Delay (if congured), idle relay is energized.

4. “ETS Solenoid Hold” delay begins, ETS relay is energized while fuel relay is de-energized.

5. "Fail to Stop Delay" begins, complete stop is detected automatically.

6. When generator is stop completely, generator is placed into its standby mode. Otherwise, fail

to stop alarm is initiated and the corresponding alarm information is displayed on LCD.

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7

Operation

4.4 MANUAL START/STOP OPERATION

1. MANUAL START: Manual mode is selected by pressing the button; a LED besides the
button will illuminate to conrm the operation.

Then press button to start the genset; can detect crank disconnect condition and
generator accelerates to high-speed running automatically.

With high temperature, low oil pressure, over speed and abnormal voltage during generator
running, controller can protect genset to stop quickly. (please refer to No.3~8 of Automatic
Start Sequence for detail procedures.) The controller will send Close Gen signal after the

genset is normal running.

2. MANUAL STOP: Press can stop the running generators. (please refer to No.2~6 of
Automatic Stop Sequence for detail procedures).

8

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Protection

5.1 WARNINGS

Warnings are not shutdown alarms and do not affect the operation of the genset. Warning alarms does not

lead to shutdown and the alarm information will be displayed on the LCD. Warning alarms types are as follows:

No. Type Description

When the controller detects that there is High Temperature input and

1 High Temperature Warn

2 Low Oil Pressure

3 Fail to Stop

4 Charge Alt Fail

5 Battery Under Voltage

6 Battery Over Voltage

7 Digital Input

8 Loss of Speed Signal

9 Low Coolant Level

10 Low Fuel Level

the shutdown is prohibited, it will initiate a warning alarm and the alarm
information will be displayed on the LCD.

When the controller detects that there is Low Oil Pressure input and the

shutdown is prohibited, it will initiate a warning alarm and the alarm
information will be displayed on the LCD.

After the ETS delay/Fail to Stop delay has expired, if the genset stop

failure, it will initiate a warning alarm and the alarm information will be

displayed on the LCD.

When the controller detects that the charger voltage has fallen below the
pre-set value, it will initiate a warning alarm and the alarm information
will be displayed on the LCD.

When the controller detects that the battery voltage has fallen below the
pre-set value, it will initiate a warning alarm and the alarm information
will be displayed on the LCD.

When the controller detects that the battery voltage has exceeded the
pre-set value, it will initiate a warning alarm and the alarm information
will be displayed on the LCD.

When the digit input port is set as warning and active, it will initiate a

warning alarm and the alarm information will be displayed on the LCD.

When the controller detects the speed is 0 and the Loss of Speed Signal
delay is set as 0, it will initiate a warning alarm and the alarm information

will be displayed on the LCD.

When the controller detects that there is Low Coolant Level input, it will

initiate a warning alarm and the alarm information will be displayed on

the LCD.
When the controller detects that there is Low Fuel Level input, it will

initiate a warning alarm and the alarm information will be displayed on

the LCD.

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9

Protection

5.2 SHUTDOWN ALARM

When controller detects shutdown alarm, it will send signal to open breaker and shuts down generator.
Besides, the alarm information will be displayed on the LCD.

Shutdown alarms as following:

No. Type Description

When the controller detects that there is Emergency Stop input, it will ini-

1 Emergency Stop

2 High Temperature

3 Low Oil Pressure

4 Over Speed

5 Under Speed

6 Loss of Speed Signal

7 Gen Over Volt.

8 Gen Under Volt.

9 Fail To Start

10 Gen Over Freq.

11 Gen Under Freq.

tiate a shutdown alarm and the alarm information will be displayed on the

LCD.
When the controller detects that there is High Temperature input and the

shutdown is allowed, it will initiate a shutdown alarm and the alarm infor-

mation will be displayed on the LCD.

When the controller detects that there is Low Oil Pressure input and the
shutdown is allowed, it will initiate a shutdown alarm and the alarm infor-

mation will be displayed on the LCD.
When the controller detects that the generator speed has exceeded the pre-

set value, it will initiate a shutdown alarm and the alarm information will be

displayed on the LCD.

When the controller detects that the generator speed has fallen below the
pre-set value, it will initiate a shutdown alarm and the alarm information
will be displayed on the LCD.

When the controller detects the speed is 0 and the Loss of Speed Signal

delay is NOT set as 0, it will initiate a shutdown alarm and the alarm infor­mation will be displayed on the LCD.

When the controller detects that the generator voltage has exceeded the

pre-set value, it will initiate a shutdown alarm and the alarm information
will be displayed on the LCD.

When the controller detects that the generator voltage has fallen below the
pre-set value, it will initiate a shutdown alarm and the alarm information
will be displayed on the LCD.

If the engine does not re after the pre-set number of attempts, it will
initiate a shutdown alarm and the alarm information will be displayed on the

LCD.
When the controller detects that the generator frequency has exceeded the

pre-set value, it will initiate a shutdown alarm and the alarm information
will be displayed on the LCD.

When the controller detects that the generator frequency has fallen below
the pre-set value, it will initiate a shutdown alarm and the alarm informa­tion will be displayed on the LCD.

10

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Protection

5.2 SHUTDOWN ALARM continued

When controller detects shutdown alarm, it will send signal to open breaker and shuts down generator.
Besides, the alarm information will be displayed on the LCD.

Shutdown alarms as following:

No. Type Description

12 No gens freq When the controller detects the generator frequency is 0, it will initiate a

shutdown alarm and the alarm information will be displayed on the LCD.

13 Low Fuel Level When the controller detects that the fuel level is lower than the set value or

there is Low Fuel Level input, it will initiate a shutdown alarm and the alarm

information will be displayed on the LCD.

14 Low Coolant Level When the controller detects that there is Low Coolant Level input, it will

initiate a shutdown alarm and the alarm information will be displayed on the

LCD.

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11

Wiring Connections

HSC940 controller’s rear as following:

Description of terminal connection:

No. Function Cable Size Remarks

1 B- 2.5mm

2 B+ 2.5mm

3 EM. Stop 1.5mm
4 Fuel 1.0mm

5 Crank 1.0mm

6 Aux. Output 1 1.0mm
7 Aux. Output 2 1.0mm

8 Aux. Output 3 1.0mm
9 Aux. Output 4 1.0mm

2

2

Connected with negative of starter battery
Connected with positive of starter battery. Max. 20A fuse is

recommended.

2

2

2

Connected with B+ via emergency stop button
Fuel relay output; B+ is supplied by 3 terminal; rated 5A
Start relay output; B+ is supplied by 3 terminal; rated 5A;

Connected to starter coil.

2

2

2

2

B+ is supplied by 2 terminal; rated 5A
B+ is supplied by 2 terminal; rated 5A;
B+ is supplied by 2 terminal; rated 5A;
B+ is supplied by 2 terminal; rated 5A;

12

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Wiring Connections

Continued:

No. Function Cable Size Remarks

10 Aux. Input 1 1.0mm

11 Aux. Input 2 1.0mm

12 Aux. Input 3 1.0mm
13 Aux. Input 4 1.0mm
14 Aux. Input 5 1.0mm
15 GND The common port of sensor; (B-) has already connected.

16 CHARGER(D+) 1.0mm

17 MP2 1.0mm

18 MP1 1.0mm

19 S11 1.0mm

20 S12 1.0mm
21 S21 1.0mm
22 S22 1.0mm
23 RS232 RX 0.5mm

25 RS232 GND 0.5mm

26 Gens AC Voltage (U) 1.0mm

27 Gens AC Voltage (V) 1.0mm

28 Gens AC Voltage (W) 1.0mm

29 Gens AC Voltage (N) 1.0mm

2

2

2

2

2

2

Ground connected is active (B-)

Ground connected is active (B-)

Ground connected is active (B-)
Ground connected is active (B-)
Ground connected is active (B-)

Connected with charger starter’s D+ (WL) terminals. Being

hang up If there is no this terminal.

2

(B-) has already connected. Connected with Speed sensor,

shielding line is recommended.

2

Connected with Speed sensor, shielding line is recommend­ed.

2

2

2

2

Connect to stepper motor. S11 and S12 are belong to one
phase to the motor while S21 and S22 are belong to the

other phase.

Connected to GSM module.24 RS232 TX 0.5mm

2

Connected to U-phase of generator (2A fuse is recommend­ed).

2

Connected to V-phase of generator (2A fuse is recommend­ed).

2

Connected to W-phase of generator (2A fuse is recommend­ed).

2

Connected to N-phase of generator (2A fuse is recommend­ed).

Details see

form 3

NOTE: LINK interface is parameters congured interface that can be programmed by
PC using an SG72 adapter. If there is need to remote control the genset, please use the
SG485 module produced by our company.

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13

Scope & Denitions of Congurable Parameters

7.1 CONTENTS AND SCOPES OF PARAMETERS

Form 1

No Items Range Default Description

1 Start Delay (0-3600)s 1

2 Stop Delay (0-3600)s 1

3 Start Attempts (1-10)times 3

4 Preheat Delay (0-300)s 0

5 Choke Time (0-300)s 0 Power-on time of choke after crank succeeds.

6 Cranking Time (3-60)s 8 Power-on time of starter

7 Crank Rest Time (3-60)s 10

8 Safety On Delay (1-60)s 10

9 Start Idle Time (0-3600)s 0 Idle running time of genset when starting.

10 Warming Up Time (0-3600)s 10

11 Cooling Time (3-3600)s 10 Radiating time before genset stop, after it unloads.
12 Stop Idle (0-3600)s 0 Idle running time when genset stop.

13 ETS Solenoid Hold (0-120)s 20

14 Fail to Stop Delay (0-120)s 0

15 Close Time (0-10)s 5.0

Time from remote start signal is active to start gen­set.

Time from remote start signal is deactivated to gen­set stop.

Maximum crank times of crank attempts. When reach

this number, controller will send start failure signal.
Power-on time of heater plug before starter is pow-

ered up.

The waiting time before second power up when en-

gine start fail.
Alarms for low oil pressure, high temperature, under

speed, under frequency/voltage, charge alt failure
are inactive.

Warming time between genset switch on and high

speed running.

Stop electromagnet’s power on time when genset is
stopping.

Time between ending of genset idle delay and
stopped when “ETS time” is set as 0; Time between

ending of ETS hold delay and stopped when “ETS
time” is not 0.

Pulse width of generator switch on. When it is 0,
means output constantly.

14

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Scope & Denitions of Congurable Parameters

7.1 CONTENTS AND SCOPES OF PARAMETERS continued

Form 1 continued

No Items Range Default Description

Tooth number of the engine, for judging of starter

16 Flywheel Teeth (1-300) 118

17 Gen Abnormal Delay (0-20.0)s 10.0

Gen Over Voltage

18

(Shutdown)

Generator Under

19

Voltage
(Shutdown)

Under Speed (Shut-

20

down)

Over Speed (Shut-

21

down)

Under Frequency

22

(Shutdown)

Over Frequency

23

(Shutdown)

24 Loss of Speed Signal (0-20.0)s 5.0

(30-620)V 264

(30-620)V 88

(0-6000)

r/min

(0-6000)

r/min

(0-75.0)Hz 45.0

(0-75.0)Hz 68.0

1000

4200

crank disconnect conditions and inspecting of engine
speed. See the installation instructions.

The alarm delay of generator over voltage and under
voltage.

When generator voltage has exceed the set value

and the “Gen abnormal delay” has expired, Gen Over
Voltage shutdown alarm is active. When set the value
as 620V, the controller does not detect over voltage

signal.

When generator voltage has fallen below the set
value and the “Gen abnormal delay” has expired,
Gen Under Voltage shutdown alarm is active. When
set the value as 30V, the controller does not detect

under voltage signal.

When engine speed has fallen below the set value
for 10s, Under Speed shutdown alarm is active. It will

initiate a shutdown alarm signal.

When engine speed has exceed the set value for 2s,

Over Speed shutdown alarm is active. It will initiate a
shutdown alarm signal.

When generator frequency has fallen below the set
value but Not equal to 0 for 10s, Under Frequency

shutdown alarm is active. It will initiate a shutdown
alarm signal.

When generator frequency has exceeded the set val-

ue for 2s, Over Frequency shutdown alarm is active. It

will initiate a shutdown alarm signal.
If the set value is 0, only warning and not to shut-

down the generator.

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15

Scope & Denitions of Congurable Parameters

7.1 CONTENTS AND SCOPES OF PARAMETERS continued

Form 1 continued

No Items Range Default Description

Charge Alt Failure

25

(Warning)

Battery Over

26

Voltage (Warning)

Battery Under Volt-

27

age (Warning)

28 Auxiliary Output 1 (0-17) 15 Factory default: Choke Control
29 Auxiliary Output 2 (0-17) 2 Factory default: Energized To Stop

30 Auxiliary Output 3 (0-17) 3 Factory default: Idle Control
31 Auxiliary Output 4 (0-17) 5 Factory default: Close Generator
32 Auxiliary Input 1 (0-15) 1 Factory default: High Temperature Input

Auxiliary Input 1

33

Active
Auxiliary Input 1

34

Delay

35 Auxiliary Input 2 (0-15) 2 Factory default: Low Oil Pressure Input

Auxiliary Input 2

36

Active

Auxiliary Input 2

37

Delay

38 Auxiliary Input 3 (0-15) 10 Factory default: Remote Start

Auxiliary Input 3

39

Active
Auxiliary Input 3

40

Delay

41 Auxiliary Input 4 (0-15) 11 Factory default: Fuel Level Warn

(0-30)V 6.0

(12-40)V 33.0

(4-30)V 8.0

(0-1) 0 Factory default: Close to active

(0-20.0)s 2.0

(0-1) 0 Factory default: Close to active

(0-20.0)s 2.0

(0-1) 0 Factory default: Close to active

(0-20.0)s 2.0

During generator is normal running, when alternator

D+(WL) voltage has fallen below the set value and

remains for 5s, It will initiate a shutdown alarm signal.

When battery voltage has exceeded the set value and
remains for 20s, It will initiate a warning alarm signal.

Only warning and not to shutdown the generator.

When battery voltage has fallen below the set value
and remains for 20s, It will initiate a warning alarm

signal. Only warning and not to shutdown the gener­ator.

16

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Scope & Denitions of Congurable Parameters

7.1 CONTENTS AND SCOPES OF PARAMETERS continued

Form 1 continued

No Items Range Default Description

Auxiliary Input 4

42

Active
Auxiliary Input 4

43

Delay

44 Auxiliary Input 5 (0-15) 3 Factory default: Warn Input

Auxiliary Input 5

45

Active
Auxiliary Input 5

46

Delay

47 Power On Mode (0-2) 0

48 Module Address (1-254) 1 Communication address of controller.
49 Passwords (0-9999) 1234

50 Crank Disconnect (0-2) 2

Disconnect Engine

51

Speed
Disconnect Genera-

52

tor Freq

53 High Temp. Inhibit (0-1) 0

54 Low OP Inhibit (0-1) 0

55 Voltage Input (0-3) 0

56 Rated Speed

(0-1) 0 Factory default: Close to active

(0-20.0)s 2.0

(0-1) 0 Factory default: Close to active

(0-20.0)s 2.0

0: Stop Mode
1: Manual Mode

2: Auto Mode

There are 2 conditions of disconnecting starter with

engine: Generator Frequency and Speed Sensor. Each

condition can be used alone and simultaneously to

separating the start motor and genset as soon as

possible. See Table 4.

(0-3000)

r/min

(10.0-30.0)Hz 14.0

(0-6000)

r/min

360

1500 Offer standard to adjust rated speed.

When the engine speed has exceeded the set value,

starter will be disconnected.

When the generator frequency has exceeded the set

value, starter will be disconnected.

Factory default: High Temp. Shutdown. When high

temperature occurs, shutdown alarm is active. Note 1
Factory default: when low oil pressure occurs, shut-

down alarm is active. Note 2
0: 3P4W; 1: 2P3W

2: 1P2W; 3: 3P3W Note 3

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17

Scope & Denitions of Congurable Parameters

7.1 CONTENTS AND SCOPES OF PARAMETERS continued

Form 1 continued

No Items Range Default Description

57 Idle Speed

58 Idle Slope 0-6000 10

59 Idle Gain 1-1000 150

60 Crank Angle (0-90)° 45 The throttle opening before the genset is starting.

61 Crank Disc. Angle (0-90)° 35

62 Proportional Gain 1-3000 1100
63 Integral Gain 1-3000 20
64 Differential Gain 1-3000 1
65 Total Gain 1-1000 100

66 Window

67 Window Gain 1000-3000 1950
68 Position Gain 0-1000 0
69 Compensate Gain 0-100 0
70 Scheduled Enable (0-1) 0 Factory default: Disable
71 Scheduled Run Mode (0-1) 0 Factory default: Off Load
72 Schedule Period (0-2) 0 Factory default: 0 Monthly
73 Schedule Day (1-31) 1
74 Schedule Week (0-6) 0 Factory default: 0 Daily
75 Schedule Hour (0-23) 0
76 Schedule Minute (0-59) 0
77 Schedule Duration (0-9999) 0
78 GSM Set (0-1) 0 Factory default: Disable

(0-6000) r/

min

(1-1000)

r/min

900 Offer standard to adjust idle speed.

The rising speed rate during the process of genset
change idle running status into rated speed running
status.

The gain is regulated during the genset is idle run­ning.

The initial opening of the throttle after the genset is
started.

The regulated gain when the genset is running in

1

rated speed.

18

032-5094-1A-EN

Scope & Denitions of Congurable Parameters

7.1 CONTENTS AND SCOPES OF PARAMETERS continued

Note 1. If “high temperature inhibit” is congured, or set auxiliary input as “inhibit high
temperature stop” and this input is active, when temperature is higher than the preset
value, or high temperature alarm input is active, controller will send warning signal only
and not stop the unit.

Note 2. If “low oil pressure inhibit” is congured, or set auxiliary input as “inhibit low oil
pressure stop” and this input is active, when oil pressure is lower than the preset value,
or low oil pressure alarm input is active, controller will send warning signal only and not
stop the unit.

Note 3. If “3P3W” is selected, maximum shutdown threshold of “Gens Over Voltage” can

be set as 620V; when select others, maximum shutdown threshold can be set as 360V.

7.2 ENABLE DEFINITION OF PROGRAMMABLE OUTPUT PORTS

Form 2

No Items Description

0 Not Used Output port is deactivated when “Not Used” is selected.

Include all shutdown alarms and warning alarms. When there is warning

1 Common Alarm

2 Energized to Stop

3 Idle Control

4 Preheat Control Close before starting and open before power up;
5 Close Generator When close time is 0, it’s continuous output.

6 Reserved
7 Open ATS When close time is 0, it’s disabled.

8 Raise Speed

alarm only, it is not self-lock; when a shutdown alarm occurs, it is self-lock

until the alarm is reset.

Suitable for genset with electromagnet and will active after “stop idle

delay”. It is deactivated when the “ETS Solenoid delay” expires.

Used for engine which has idles. Close before starting and open in warm-

ing up delay; Close during stop idle delay and open when stop is complet­ed.

Close when the generator enters into Warming Up delay (close time:
warming up delay) while open when Aux. Raise Speed input is active.

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19

Scope & Denitions of Congurable Parameters

7.2 ENABLE DEFINITION OF PROGRAMMABLE OUTPUT PORTS continued

Form 2 continued

No Items Description

Close when the generator enters into Stop Idle delay/ Energized to Stop

9 Drop Speed

10 Generator Run

11 Fuel Pump Control

12 High Speed Control

13 In Auto Mode The controller is in automatic mode.
14 Fuel Relay Output To control fuel relay output.

15 Choke Control

16 Reserved

delay (close time: Stop Idle delay) while open when Aux. Drop Speed input

is active.
Action when genset is normal running while deactivated when engine

speed is lower than the “crank disconnect speed”.
Close when fuel level is lower than the “Fuel Pump On” value or when low

fuel level warning input is active; Open when fuel level is higher than the
“Fuel Pump Off” and low fuel level warning input is deactivated;

Close when the generator enters into Warming Up delay while open after

cooling delay.

Start to output in cranking period; in addition, during safety on running,
output for preset delay.

17 Reserved

20

032-5094-1A-EN

Scope & Denitions of Congurable Parameters

7.2 DEFINED CONTENTS OF CONFIGURABLE INPUT PORTS (ALL ACTIVE WHEN
CONNECT TO GRAND (B-))

Form 3

No Items Description

0 Not Used
1 High Temperature Input
2 Low Oil Pressure Input
3 Warn Input Only warning and not shutdown if this input is active.
4 Shutdown input Shutdown alarm will be immediately initiated if this input is active.

5 WTH STOP by cool

6 Generator Closed input
7 Reserved

Inhibit High

8

Temperature Stop

Inhibit Low Oil

9

Pressure Stop
10 Remote Start
11 Fuel Level Warn
12 Coolant Level Warn
13 Fuel Level Shutdown

Coolant Level
14

Shutdown

15 Inhibit Start Auto

If these signals are active after safety on delay, shutdown alarm will be im-

mediately initiated.

When the genset is running normally and this signal is activated, if there is

a high temperature situation, the controller will rst cool down the gen-

erator and then stop it; if the signal is deactivated and a high temperature

situation occurs, the controller will shut down the gen-set without cooling

down.

When it is active, high temperature shutdown will be prohibited. Note 1

When it is active, low oil pressure shutdown will be prohibited. Note 2

In Auto mode, if this input is active, whether remote start signal activates
or not, the controller will not give a start command to the generator. If

generator is normal running, stop command won’t be executed. When this

input is deactivated, genset will automatically start or stop.

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21

Protection

7.4 CONDITIONS OF CRANK DISCONNECT SELECTION

Form 4

No. Setting Description

0 Gen frequency
1 Speed sensor

2 Speed sensor + Gen frequency

NOTES:

1. There are 2 conditions to make starter disconnected with engine, that is, speed sensor and
generator frequency. They all can be used separately. We recommend that speed sensor
should be using with generator frequency together, in order to make the starter motor is

separated with engine immediately and can check crank disconnect exactly.

2. Speed sensor is the magnetic equipment which be installed in starter for detecting ywheel

teeth.

3. When set as speed sensor, must ensure that the number of ywheel teeth is as same as
setting, otherwise, “over speed shutdown” or “under speed shutdown” may be caused.

4. If genset without speed sensor, please don’t select corresponding items, otherwise, “start fail”

or “loss speed signal” maybe caused.

5. If not select generator frequency in crank disconnect setting, controller will not collect and

display the relative power quantity (can be used in water pump set); if not select speed sensor
in crank disconnect setting, the rotating speed displayed in controller is calculated by

generator signal.

22

032-5094-1A-EN

Parameter Settings

Start the controller, then press to enter into the parameters setting menu, see g 1 below:

1. Set Parameters

2. Information

Fig. 1

Parameters Setting

When entering password interface, input correct password (default: 1234) can set all of the parameter items in
Form 1. If there is need to set more parameters (e.g. Voltage Calibration), please contact the factory.
CAUTION: Please change the controller parameters when generator is in standby mode only
(e. g. Crank disconnect conditions selection, auxiliary input, auxiliary output, various delay),
otherwise, shutdown and other abnormal conditions may happen.

CAUTION: Over voltage set value must be higher than under voltage set value, otherwise
over voltage and under voltage condition may occur simultaneously.
CAUTION: Over speed set value must be higher than under speed set value, otherwise over
speed and under speed condition may occur simultaneously.
CAUTION: Please set the generator frequency value as low as possible when cranking, in

order to make the starter be separated quickly as soon as possible.
CAUTION: Auxiliary input 1~5 could not be set as same items; otherwise, there are abnormal
functions. However, the auxiliary output 1~4 can be set as same items.

CAUTION: If need to shut down after cooling, please set any digital input as “WTH STOP by
cool”, then connect this input port to ground soundly.

Information

LCD will display software version, issue date of the controller.

Note: In this interface, pressing will display the auxiliary inputs and outputs status.
Language

Chinese, English, Spanish and Russian interface can be selected.

Time and Date

The time and date information can be set in this interface.

Pressing the key at any time will quit the setting and return to the previous settings menu.

3. Language

4. Time and Date

032-5094-1A-EN

23

Commissioning

Please make the under procedures checking before commissioning,

1. Ensure all the connections are correct and wires diameter is suitable.

2. Ensure that the controller DC power has fuse, controller‘s positive and negative connected to
start battery are correct.

3. Take proper action to prevent engine to crank disconnect (e. g. Remove the connection wire

of fuel valve). If checking is OK, make the start battery power on; choose manual mode and

controller will executive routine.

4. Set controller under manual mode, press “start” button, genset will start. After the setting

times as setting, controller will send signal of Start Fail; then press “stop” to reset controller.

5. Recover the action of stop engine start (e. g. Connect wire of fuel valve), press start button

again, genset will start. If everything goes well, genset will normal run after idle running (if idle

run be set). During this time, please watch for engine’s running situations and AC generator’s
voltage and frequency. If abnormal, stop genset running and check all wires connection

according to this manual.

6. Select the AUTO mode from controller’s panel, connect remote start signal. genset will be

started automatically and into normal running, then controller send signal to close generator.

7. Cut-off remote start signal, the genset will be stopped automatically and the Open Generator
signal will be send out. If not like this, please check ATS’ wires connection of control part

according to this manual.

8. If there is any other question, please contact Smartgen’s service.

24

032-5094-1A-EN

Typical Application

Typical Application Diagram

CAUTION! Expand relay with high capacity in start and fuel output is recommend.

CAUTION! Expand relay must be used in generator closed outputs.

Connection Between Controller and Genset

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25

Installation

12.1 FIXING CLIPS

Controller is panel built-in design; it is xed by clips when installed.

1. Withdraw the xing clip screw (turn anticlockwise) until it reaches proper position.

2. Pull the xing clip backwards (towards the back of the module) ensuring two clips are inside

their allotted slots.

3. Turn the xing clip screws clockwise until they are xed on the panel.

Note: Care should be taken not to over tighten the screws of xing clips.

26

032-5094-1A-EN

Installation

12.2 OVERALL DIMENSION AND PANEL CUTOUT

1. Battery Voltage Input

HSC940 controller can suit for widely range of battery voltage DC(8~35)V. Negative of battery must be
connected with the engine shell. The diameter of wire which from power supply to battery must be over

2.5mm2. If oating charge congured, please rstly connect output wires of charger to battery’s positive and
negative directly, then, connect wires from battery’s positive and negative to controller’s positive and negative
input ports in order to prevent charge disturbing the controller’s normal working.

2. Speed Sensor Input

Speed sensor is the magnetic equipment which be installed in starter and for detecting ywheel teeth. Its
connection wires to controller should apply for 2 cores shielding line. The shielding layer should connect to No.
17 terminal in controller while another side is hanging in air. The else two signal wires are connected to No.17
and No.18 terminals in controller. The output voltage of speed sensor should be within AC(1~24)V (effective
value) during the full speed. AC12V is recommended (in rated speed). When install the speed sensor, let the
sensor is spun to contacting ywheel rst, then, port out 1/3 lap, and lock the nuts of sensor at last.

3. Output And Expansion Relay

All outputs of controller are relay contact output type. If need to expand the relays, please add freewheel

diode to both ends of expand relay’s coils (when coils of relay has DC current) or, add resistance-capacitance
return circuit (when coils of relay has AC current), in order to prevent disturbance to controller or others

equipment.

4. Withdraw Voltage Test

When controller had been installed in control panel, if need the high voltage test, please disconnect

controller’s all terminal connections, in order to prevent high voltage into controller and damage it.

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27

GSM Short Message Alarm & Remote Control

13.1 GSM SHORT MESSAGE ALARM

When controller detects alarm, it will send short message to phone automatically.

13.2 GSM SHORT MESSAGE REMOTE CONTROL

Users send order message to GSM module, then controller will make actions according to this SMS order and
pass back corresponding operations information. Controllers only execute the orders by pre-set. Detail orders

as following:

No. SMS Orders Pass Back Information Description

When genset is shutdown
alarm

At rest status in stop
mode

At rest status in manual
mode

At rest status in auto
mode

Running status in stop
mode

Running status in manual
mode

Running status in auto
mode

Generator is shutdown
alarm or trip alarm

Cannot start in stop
mode

Cannot start in auto
mode

Status of genset

Start genset

1

2

3

SMS

GENSET

SMS
START

SMS STOP
MODE

GENSET ALARM

SYSTEM IN STOP MODE
GENSET AT REST

SYSTEM IN MANUAL MODE
GENSET AT REST

SYSTEM IN AUTO MODE
GENSET AT REST

SYSTEM IN STOP MODE
GENSET IS RUNNING

SYSTEM IN MANUAL MODE
GENSET IS RUNNING

SYSTEM IN AUTO MODE
GENSET AT RUNNING

GENSET ALARM

STOP MODE NOT START

SMS START OK Start in manual mode

AUTO MODE NOT START

SMS STOP OK Set as stop mode

28

032-5094-1A-EN

GSM Short Message Alarm & Remote Control

13.2 GSM SHORT MESSAGE REMOTE CONTROL continued

Users send order message to GSM module, then controller will make actions according to this SMS order and
pass back corresponding operations information. Controllers only execute the orders by pre-set. Detail orders

as following:

No. SMS Orders Pass Back Information Description

SMS MANUAL

4

MODE

SMS AUTO

5

MODE

6 SMS DETAIL

SMS MANUAL MODE OK Set as manual mode

SMS AUTO MODE OK Set as auto mode

Pass back information

includes: Working Mode;

Generator Voltage;
Generator Frequency; Bat­tery Voltage; Charger Volt-

age; Speed; Total Run Time;
Genset
Status; Alarm Status

Gets details information of genset.

NOTE: Its national and area codes must be added. e.g. China: 8613666666666

NOTE: When sending orders, users need to follow SMS orders in above form and all the letters must be capital.

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29

Symptoms Possible Solutions

Controller no response with
power.

Genset shutdown

Low oil pressure alarm after crank
disconnect

High water temp. alarm after crank
disconnect

Shutdown Alarm in running

Fail to start

Starter no response

Stepping Motor Reverse

GOV is out of control.

Fault Finding

Check starting batteries;

Check controller connection wirings;
Check DC fuse.

Check the water/cylinder temperature is too high or not;
Check the genset AC voltage;
Check DC fuse.

Check the oil pressure sensor and its connections.

Check the temperature sensor and its connections.

Check related switch and its connections according to the informa­tion on LCD;
Check auxiliary input ports.

Check fuel oil circuit and its connections;

Check starting batteries;

Check speed sensor and its connections;
Refer to engine manual.

Check starter connections;

Check starting batteries.
Cross connect the S11 and S12;

Cross connect the S21 and S22;
Change conguration (motor reduce direction) via PC.

Check the speed sensor voltage is no less than 2V when cranking.
Check the connections of S11, S12, S21, S22.

30

032-5094-1A-EN

Smartgen — make your generator smart

Smartgen Technology Co., Ltd.

No.28 Jinsuo Road

Zhengzhou
Henan Province
P. R. China

Tel: [phone]
0086-371-67991553/67992951
0086-371-67981000(overseas)

Fax: [phone]

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

http://www.smartgen.cn

Email: [e-mail]

All rights reserved. No part of this publication may be reproduced in any material form (including
photocopying or storing in any medium by electronic means or other) without the written permission of the

copyright holder.

Applications for the copyright holder’s written permission to reproduce any part of this publication should be
addressed to Smartgen Technology at the address above.

Any reference to trademarked product names used within this publication is owned by their respective

companies.

Smartgen Technology reserves the right to change the contents of this document without prior notice.

Software Version

Date Version Note

2014-06-10 1.0 Original release

Chinese Trademark English Trademark

032-5094-1A-EN

31

032-5094-1A-EN (9 Mar 2017)

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