Owner’s Manual - Home Lifan Power USA

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Owner’s ManualSmartGen HSC940ControllerNote: “Graphics in this document are for representation only.Actual model may differ in appearance.”March 2017032-5094-1A-EN

Table Of ContentsOverview . . . . . . . . . . . . . . . . . . . . . . . . . . . .Performance & Characteristics . . . . . . . . . . . . . . . . . .Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . .Key Operations / Indicator Lights . . . . . . . . . . . .Auto Start / Stop Operation . . . . . . . . . . . . .Manual Start / Stop Operation . . . . . . . . . . . . . .Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . .Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shutdown Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .Scope & Definition of Configurable Parameters . . . . . . . . . . . .Contents & Scope of Parameters . . . . . . . . . . . . . . . . .Enable Definitions of Programmable Output Ports . . . . .Defined Contents of Configurable Input Ports . . . . . . . . .Conditions of Crank Disconnect Selection . . . . . . . . . .Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . .Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . .Typical Application . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connection Between Controller and Genset . . . . . . . .Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fixing Clips . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overall Dimension and Panel Cutout . . . . . . . . .GSM Short Message Alarm and Remote Control . . . . . . . . .GSM Short Message Alarm . . . . . . . . . . . . . .GSM Short Message Remote Control . . . . . . . . . . .Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5094-1A-EN

OverviewHSC940 genset controllers integrate digitization, intellectualizationand network technology which are used for gas genset automation andmonitor control system of single unit to achieve automatic start/stop,data measure, alarm protection, three remote: remote control, remotemeasuring and remote communication (SG485 module must be fitted)and speed regulation. The controller adopts large liquid crystal display(LCD) and selectable Chinese, English, Spanish and Russian interface witheasy and reliable operation.HSC940 genset controllers adopt microprocessor technology withprecision parameters measuring, fixed value adjustment, time setting andset adjusting etc. All parameters can be configured from front panel, orby configurable port (USB to LINK, SG72 must be fitted) to adjust viaPC. It can be widely used in all types of automatic genset control systemwith compact structure, advanced circuits, simple connections and highreliability.032-5094-1A-EN3

Performance & CharacteristicsHSC940, used for single automation systems; it regulates the speed simply by adjust the throttle opening viathe 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 andRussian), pushbutton operation; Suitable for 3-phase 4-wire, 3-phase 3-wire, single phase 2-wire, and 2-phase 3-wire systemswith voltage 120/240V and frequency 50/60Hz; Collects and shows 3-phase voltage, current, power parameter and frequency of generator.GeneratorLine 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 perfectfailure indication and protection function; ETS (Energize to Stop), idle control, preheat control and raise speed/drop speed control; inaddition, they are all relay output. Parameter setting: parameters can be modified and cannot be lost even in case of poweroutage; all parameters can be configured from front panel, or by configurable port (SG72 mustbe fitted) 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 normalpotentiometer, more reliability and stability; Modular design, self-extinguishing ABS plastic enclosure, pluggable connection terminals andembedded installation way; compact structure with easy mounting.4032-5094-1A-EN

SpecificationsItemsOperating VoltagePower ConsumptionAlternator Input Range3-Phase 4-Wire2-Phase 3-WireSingle-Phase 2-Wire3-Phase 3-WireAlternator FrequencySpeed Sensor VoltageSpeed Sensor FrequencyStart Relay OutputFuel Relay OutputAuxiliary Relay Output (1)Auxiliary Relay Output (2)Auxiliary Relay Output (3)Auxiliary Relay Output (4)Steady-state Speed Governing RateSteady-state Speed Fluctuation RateTransient Speed Governing RateRecovery TimeDriving Stepper MotorCase DimensionPanel CutoutWorking ConditionsStorage ConditionProtection LevelInsulating IntensityNet Weight032-5094-1A-ENContentsDC8.0V to DC35.0V, Continuous Power Supply.Standby: 2WWorking: 8W (When driving stepper motor is regulating)AC15V - AC360V (ph-N)AC15V - AC360V (ph-N)AC15V - AC360V (ph-N)AC30V - AC620V (ph-ph)50Hz/60Hz1.0V to 24.0V (RMS)10,000 Hz (max.)5A DC28V supply output5A DC28V supply output5A DC28V supply output5A DC28V supply output5A DC28V supply output5A DC28V supply output 1.5% 0.5%Sudden Load-on 10%Sudden Load-off -15% 5sMixed 2-phase; Drive current 1A130mm x 112mm x 39mm110mm x 90mmTemperature: (-25 70) C; Humidity: (20 93)%RHTemperature:(-25 70) CIP55 GasketApply AC2.2kV voltage between high voltage terminal and lowvoltage terminal; The leakage current is not more than 3mAwithin 1min.0.26kg5

Operation4.1 KEY OPERATIONSStop/ ResetStop running generator in Auto/Manual mode; Lamp test (pressat least 3 seconds); Reset alarm if alarm occurs; During stoppingprocess, press this button again to stop generator immediately.StartStart genset in Manual/Test mode.Manual ModePressing this key will set the module into Manual mode. Pressing and (or ) simultaneously can adjust LCD contrast.Auto ModePressing this key will set the module into AUTO mode.Set/ConfirmUp/IncreaseDown/DecreasePressing this key will view set menu; In parameter setting interface, press this key will shift cursor or confirm setting value.Scrolls the screen up; Shift the cursor up or increase the setvalue in parameter setting menu.Scrolls the screen down; Shift the cursor down or decrease theset value in parameter setting menu.4.2 INDICATOR LIGHTSAlarmGens NormalIndicatorStop IndicatorClose rtSet032-5094-1A-EN

Operation4.3 AUTO START/STOP OPERATIONAuto mode is selected by pressing theoperation.button; a LED besides the button will illuminate to confirm theAutomatic 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 configured), “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 ofthe 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 fire during this cranking attemptthen 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 sequencewill be terminated, the fourth line of LCD display will be highlighted with black and Fail to Startfault will be displayed.6. In case of successful crank attempt, the “Safety On” timer is activated and the throttle ofthe driving stepper motor will govern the speed, allowing Low Oil Pressure, High Temperature,Under speed, Charge Alternator Failure and auxiliary inputs (be configured) to stabilise withouttriggering the fault. As soon as this delay is over, “start idle” delay is initiated (if configured).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 configured).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 generatorclose relay will be energized; genset will take load; generator power indicator will illuminateand generator will enter into Normal Running status. If voltage or frequency is abnormal, thecontroller 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” isthen initiated. Moreover, the generator indicator is extinguished.3. During “Stop Idle” Delay (if configured), 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, failto stop alarm is initiated and the corresponding alarm information is displayed on LCD.032-5094-1A-EN7

Operation4.4 MANUAL START/STOP OPERATION1. MANUAL START: Manual mode is selected by pressing thebutton will illuminate to confirm the operation.button; a LED besides theThen pressbutton to start the genset; can detect crank disconnect condition andgenerator accelerates to high-speed running automatically.With high temperature, low oil pressure, over speed and abnormal voltage during generatorrunning, controller can protect genset to stop quickly. (please refer to No.3 8 of AutomaticStart Sequence for detail procedures.) The controller will send Close Gen signal after thegenset is normal running.2. MANUAL STOP: Presscan stop the running generators. (please refer to No.2 6 ofAutomatic Stop Sequence for detail procedures).8032-5094-1A-EN

Protection5.1 WARNINGSWarnings are not shutdown alarms and do not affect the operation of the genset. Warning alarms does notlead to shutdown and the alarm information will be displayed on the LCD. Warning alarms types are as follows:No.Type1High Temperature Warn2Low Oil Pressure3Fail to Stop4Charge Alt Fail5Battery Under Voltage6Battery Over Voltage7Digital Input8Loss of Speed Signal9Low Coolant Level10Low Fuel Level032-5094-1A-ENDescriptionWhen the controller detects that there is High Temperature input andthe shutdown is prohibited, it will initiate a warning alarm and the alarminformation will be displayed on the LCD.When the controller detects that there is Low Oil Pressure input and theshutdown is prohibited, it will initiate a warning alarm and the alarminformation will be displayed on the LCD.After the ETS delay/Fail to Stop delay has expired, if the genset stopfailure, it will initiate a warning alarm and the alarm information will bedisplayed on the LCD.When the controller detects that the charger voltage has fallen below thepre-set value, it will initiate a warning alarm and the alarm informationwill be displayed on the LCD.When the controller detects that the battery voltage has fallen below thepre-set value, it will initiate a warning alarm and the alarm informationwill be displayed on the LCD.When the controller detects that the battery voltage has exceeded thepre-set value, it will initiate a warning alarm and the alarm informationwill be displayed on the LCD.When the digit input port is set as warning and active, it will initiate awarning alarm and the alarm information will be displayed on the LCD.When the controller detects the speed is 0 and the Loss of Speed Signaldelay is set as 0, it will initiate a warning alarm and the alarm informationwill be displayed on the LCD.When the controller detects that there is Low Coolant Level input, it willinitiate a warning alarm and the alarm information will be displayed onthe LCD.When the controller detects that there is Low Fuel Level input, it willinitiate a warning alarm and the alarm information will be displayed onthe LCD.9

Protection5.2 SHUTDOWN ALARMWhen 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.Type1Emergency Stop2High Temperature3Low Oil Pressure4Over Speed5Under Speed6Loss of Speed Signal7Gen Over Volt.8Gen Under Volt.9Fail To Start10Gen Over Freq.11Gen Under Freq.10DescriptionWhen the controller detects that there is Emergency Stop input, it will initiate a shutdown alarm and the alarm information will be displayed on theLCD.When the controller detects that there is High Temperature input and theshutdown is allowed, it will initiate a shutdown alarm and the alarm information will be displayed on the LCD.When the controller detects that there is Low Oil Pressure input and theshutdown is allowed, 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 exceeded the preset value, it will initiate a shutdown alarm and the alarm information will bedisplayed on the LCD.When the controller detects that the generator speed has fallen below thepre-set value, it will initiate a shutdown alarm and the alarm informationwill be displayed on the LCD.When the controller detects the speed is 0 and the Loss of Speed Signaldelay 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 thepre-set value, it will initiate a shutdown alarm and the alarm informationwill be displayed on the LCD.When the controller detects that the generator voltage has fallen below thepre-set value, it will initiate a shutdown alarm and the alarm informationwill be displayed on the LCD.If the engine does not fire after the pre-set number of attempts, it willinitiate a shutdown alarm and the alarm information will be displayed on theLCD.When the controller detects that the generator frequency has exceeded thepre-set value, it will initiate a shutdown alarm and the alarm informationwill be displayed on the LCD.When the controller detects that the generator frequency has fallen belowthe pre-set value, it will initiate a shutdown alarm and the alarm information will be displayed on the LCD.032-5094-1A-EN

Protection5.2 SHUTDOWN ALARM continuedWhen 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.12TypeNo gens freq13Low Fuel Level14Low Coolant Level032-5094-1A-ENDescriptionWhen the controller detects the generator frequency is 0, it will initiate ashutdown alarm and the alarm information will be displayed on the LCD.When the controller detects that the fuel level is lower than the set value orthere is Low Fuel Level input, it will initiate a shutdown alarm and the alarminformation will be displayed on the LCD.When the controller detects that there is Low Coolant Level input, it willinitiate a shutdown alarm and the alarm information will be displayed on theLCD.11

Wiring ConnectionsHSC940 controller’s rear as following:Description of terminal connection:No.1B-FunctionCable Size2.5mm22B 2.5mm234EM. StopFuel1.5mm21.0mm25Crank1.0mm26789Aux. Output 1Aux. Output 2Aux. Output 3Aux. Output 41.0mm21.0mm21.0mm21.0mm212RemarksConnected with negative of starter batteryConnected with positive of starter battery. Max. 20A fuse isrecommended.Connected with B via emergency stop buttonFuel relay output; B is supplied by 3 terminal; rated 5AStart relay output; B is supplied by 3 terminal; rated 5A;Connected to starter coil.B is supplied by 2 terminal; rated 5AB is supplied by 2 terminal; rated 5A;B is supplied by 2 terminal; rated 5A;B is supplied by 2 terminal; rated 5A;032-5094-1A-EN

Wiring ConnectionsContinued:No.101112131415FunctionAux. Input 1Aux. Input 2Aux. Input 3Aux. Input 4Aux. Input 5GND16CHARGER(D )17MP218MP119202122232425S11S12S21S22RS232 RXRS232 TXRS232 GND26Gens AC Voltage (U)27Gens AC Voltage (V)28Gens AC Voltage (W)29Gens AC Voltage (N)Cable SizeRemarks21.0mmGround connected is active (B-)1.0mm2Ground connected is active (B-)Details see1.0mm2Ground connected is active (B-)form 31.0mm2Ground connected is active (B-)1.0mm2Ground connected is active (B-)The common port of sensor; (B-) has already connected.Connected with charger starter’s D (WL) terminals. Being1.0mm2hang up If there is no this terminal.(B-) has already connected. Connected with Speed sensor,1.0mm2shielding line is recommended.Connected with Speed sensor, shielding line is recommend1.0mm2ed.21.0mmConnect to stepper motor. S11 and S12 are belong to one1.0mm2phase to the motor while S21 and S22 are belong to the1.0mm2other phase.1.0mm20.5mm0.5mmConnected to GSM module.0.5mmConnected to U-phase of generator (2A fuse is recommend1.0mm2ed).Connected to V-phase of generator (2A fuse is recommend1.0mm2ed).Connected to W-phase of generator (2A fuse is recommend1.0mm2ed).Connected to N-phase of generator (2A fuse is recommend1.0mm2ed).NOTE: LINK interface is parameters configured interface that can be programmed byPC using an SG72 adapter. If there is need to remote control the genset, please use theSG485 module produced by our company.032-5094-1A-EN13

Scope & Definitions of Configurable Parameters7.1 CONTENTS AND SCOPES OF PARAMETERSForm 1NoItemsRangeDefault1Start Delay(0-3600)s12Stop Delay(0-3600)s13Start Attempts(1-10)times34Preheat Delay(0-300)s056Choke TimeCranking Time(0-300)s(3-60)s087Crank Rest Time(3-60)s108Safety On Delay(1-60)s109Start Idle Time(0-3600)s010Warming Up Time(0-3600)s101112Cooling TimeStop Idle(3-3600)s(0-3600)s10013ETS Solenoid Hold(0-120)s2014Fail to Stop Delay(0-120)s015Close Time(0-10)s5.014DescriptionTime 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 reachthis number, controller will send start failure signal.Power-on time of heater plug before starter is powered up.Power-on time of choke after crank succeeds.Power-on time of starterThe waiting time before second power up when engine start fail.Alarms for low oil pressure, high temperature, underspeed, under frequency/voltage, charge alt failureare inactive.Idle running time of genset when starting.Warming time between genset switch on and highspeed running.Radiating time before genset stop, after it unloads.Idle running time when genset stop.Stop electromagnet’s power on time when genset isstopping.Time between ending of genset idle delay andstopped when “ETS time” is set as 0; Time betweenending of ETS hold delay and stopped when “ETStime” is not 0.Pulse width of generator switch on. When it is 0,means output constantly.032-5094-1A-EN

Scope & Definitions of Configurable Parameters7.1 CONTENTS AND SCOPES OF PARAMETERS continuedForm 1 continuedNoItemsRangeDefault16Flywheel Teeth(1-300)11817Gen Abnormal Delay(0-20.0)s10.018Gen Over Voltage(Shutdo

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 fitted)

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