HGM501

GENSET CONTROLLER

USER MANUAL
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Table 1- Version History

Date Version Details
2012-07-10 1.0 Original release
2017-02-13 2.0 Modify details, add functions and change CT secondary current from
5mA to 62.5mA.
2022-04-29 2.1 Update the format and font of the manual; update the logo of
SmartGen.
1. Add a new temperature sensor curve;
2023-07-14 2.2
2. Add the high temperature limit setting process.

HGM501 Genset Controller User Manual Page 2 of 17

This manual is suitable for HGM501 series controllers only.
Clarification of signs used within this manual.
Sign Explanation

Note Concerns an operating procedure that needs highlighting.

Indicates a procedure or practice, which, if not strictly observed, can

Caution! result in damage of the equipment.
Indicates a procedure or practice, which, if not strictly observed, can
Warning! result in personal death, serious injury or significant property damage.

HGM501 Genset Controller User Manual Page 3 of 17

 Contents
1. OVERVIEW .................................................................................................................................... 5

2. PERFORMANCE AND CHARACTERISTICS ................................................................................. 5

3. TECHNICAL DATA........................................................................................................................ 6

4. OPERATION .................................................................................................................................. 7
4.1. BUTTON DESCRIPTION .................................................................................................. 7
4.2. START/STOP OPERATION ............................................................................................. 8
5. AUTO PROTECTION ..................................................................................................................... 9

6. TERMINAL .................................................................................................................................. 10

7. CONFIGURABLE PARAMETERS ................................................................................................ 11

7.1. CONFIGURABLE PARAMETERS TABLE ...................................................................... 11
7.2. PARAMETER CONFIGURATION ................................................................................... 13
8. COMMISSIONING....................................................................................................................... 15

9. TYPICAL WIRING DIAGRAM ...................................................................................................... 15

10. INSTALLATION........................................................................................................................... 16

11. TROUBLESHOOTING ................................................................................................................. 17

HGM501 Genset Controller User Manual Page 4 of 17

 1. OVERVIEW

HGM501 gen-set controller is smart digital controller for control and protection of single
gen-set. It can carry out start/stop, data measurement, alarm indication, shutdown protection
and other functions. The controller is fitted with LED indicators; it is reliable and easy to use.
HGM501 gen-set controller contains the microprocessor allows precise measurement of
multiple parameters, which can be configured using controller front panel. With simple wiring,
compact structure and high reliability, HGM501 can be widely used for data display and fault
protection of a large number of diesel and petrol generator sets.

2. PERFORMANCE AND CHARACTERISTICS

1) Nixie tube displays: single phase voltage display and total active power voltage display
(calculated using single phase power, taking load as balanced);
2) Multifunction nixie tube display that can be switched between single phase frequency,
single phase current, battery voltage, total running time (max 999 hours), engine and
generator temperature;
3) Under voltage, over voltage, under frequency, over frequency, over load, over temperature
protection, starting with flashing lights alarm and followed by shutdown protection after
alarm delay;
4) Low oil pressure digital input that immediately shuts down the generator in case of low
oil pressure;
5) Displayed parameters can be selected using touch-buttons;
6) Wide selection of temperature sensor types in settings;
7) All the parameters can be set via front panel for easy and convenient operation;
8) Modular design, anti-flaming ABS plastic enclosure, compact structure, convenient
embedded installation.

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 3. TECHNICAL DATA

Table 2 – Technical Data

Parameter Details
Operating voltage DC9.0V to 18V uninterrupted power supply - DC12V system
used
Overall consumption <2W (Standby mode ≤1W)
Alternator voltage inputs:
Single phase 2-wire (L and N AC 30V - 360V (ph-N)
only) AC 30V - 360V (ph-N)
2-phase 3-wire (L and N only) AC 30V - 360V (ph-N)
3-phase 4-wire (L and N only)
Alternator frequency 50/60Hz
Start relay output 7A DC12V power supply output
Fuel relay output 7A DC12V power supply output
Case dimensions 118 mm x 128 mm x 36 mm
CT Secondary current Rated 62.5mA
Operating Temperature (-25~+70)°C
Operating Humidity (20~90)%RH
Storage Temperature (-30~+80)°C
Protection level IP42
Apply AC1.5kV voltage between high voltage terminal and
Insulation strength low voltage terminal;
The leakage current is not more than 3mA within 1min.
Weight 0.216kg

HGM501 Genset Controller User Manual Page 6 of 17

 4. OPERATION

4.1. BUTTON DESCRIPTION

Fig.1 – HGM501 Front Panel

Table 3 – Key Functions
Icon Function Description
1. In configuration menu, pressing this button enters setting or
confirms;
2. During normal operation, press this button to switch to
FUNCTION
frequency display;
3. In case of alarm shutdown, pressing and holding the button for
1 second will reset the alarm.
1. During parameter configuration, pressing this button increases
the set value;
UP/SCROLL
2. During normal operation press this button to switch to the
upper LED.
1. During parameter configuration pressing the button decreases
DOWN/
the set value;
SCROLL
2. During normal operation the button switches to the lower LED.
1. During parameter configuration pressing this button will return
to the previous menu;
LEFT
2. During normal operation press this button to switch to the next
(upper) LED.
1. During parameter configuration press this button to enter the
RIGHT next menu.
2. During normal operation the button switches to the lower LED.

HGM501 Genset Controller User Manual Page 7 of 17

 4.2. START/STOP OPERATION

STARTING PROCEDURE

In stop mode turn the starter key from OFF to ON position to power on the controller, then
change the starter key position to START to begin cranking; after the engine fires, release the
starter key(crank disconnect condition is gen frequency>14.0Hz), then voltage, power and

frequency windows will show the real measured values. Press or button to
switchover between indicators 1#-6# and multifunctional window will show corresponding

settings. Press button to return to the frequency window.

LED indicators state:
1# Frequency (Hz)
2# Current (A)
3# Battery voltage (V)
4# Run time (H)
5# Engine temp.(℃)
6# Generator temp.(℃)
7# Auto protection If on, auto protection is enabled; if not, it is disabled.
8# Run on indicator Fuel relay output indicator
9# Crank indicator Start output indicator
10# Engine oil warning Low oil pressure indicator
NOTE: Before starting the engine please make sure that all the parameter settings are correct.
NOTE“Engine oil warning”indicator operates according to the oil pressure switch. Before the start of the
gen-set, the light must be on; if it is not, it means that oil pressure switch or its return circuit is faulty; in this
case please do not proceed before clearing up the problem.

STOPPING PROCEDURE

1) Auto stop
If auto protection condition occurs, the system will be stopped automatically;
During normal running of the gen-set, if low oil pressure signal is detected an last for
over 2s, the set will be stopped.
2) Manual stop
Under any circumstances, if starter key is turned from ON to OFF position, it will lead
to shutdown.

HGM501 Genset Controller User Manual Page 8 of 17

5. AUTO PROTECTION

In auto protection mode, except for low oil pressure protection, all the other protections
(voltage, frequency, overload, temperature) are active.
1) Voltage protection
When the limits of rated voltage are exceeded by ±10%, Voltage LED starts flashing; after
7 seconds delay in case of under voltage or 3 seconds delay in case of over voltage,
alarm shutdown is initiated. After that voltage LED continues to flash and shows
pre-alarm value.
2) Frequency protection
50Hz：(45~55)Hz
60Hz：(55~65)Hz
When the set value is exceeded, frequency LED starts flashing; after 7 seconds delay in
case of under frequency and 3 seconds delay in case of over frequency, alarm shutdown
is initiated. After that frequency LED continues to flash and shows pre-alarm value.
3) Overload protection
If the set value is exceeded by 5% or less, alarm will not be initiated;
If the set value is exceeded by more than 5%, power LED will start flashing;
If the set value is exceeded by 5%-7.5% and continuous for more than 3 hours, then alarm
shutdown will be initiated;
If the set value is exceeded by 7.5%-10% and continues for more than 1 hour, alarm
shutdown will be initiated;
If the set value is exceeded by more than 10%, and continues for more than pre-set over
power delay value, alarm shutdown will be initiated (defult: 30s);
After alarm shutdown is initiated power LED continues to flash and shows pre-alarm
value.
4) Low oil pressure protection
Irrespective of whether auto protection mode is enabled or not, genset will shutdown if
low oil pressure occurs and last for more than 2s.
5) High engine temperature protection
If engine temperature exceeds pre-set high temperature threshold, LED window starts
flashing; after 7 seconds delay, protection begins; LED window continues to flash and
shows pre-protection value (for air-cooled engine);
6) High generator temperature protection
When generator temperature exceeds 95℃, LED window starts flashing; after 7 second
delay, protection begins; LED window continues to flash and shows pre-protection value;
7) Battery voltage protection
Battery voltage protection is enabled irrespective of whether auto protection mode is
enabled or not and whether gen-set is running. If battery voltage value is lower than 8V or
higher than 16.5V, Nixie tube or LED display starts flashing, but shutdown protection is
not initiated.
NOTE: During Safety On delay, protection is disabled; after Safety On Delay, when voltage, frequency,
overload, high temperature protection is initiated, fuel output deactivates.

HGM501 Genset Controller User Manual Page 9 of 17

 6. TERMINAL

Fig.2 – HGM501 Back Panel

Table 4 -Terminal Connections Description

Terminal Function Wire size Remarks
1 Generator Voltage L 1.0mm2
2 Generator Voltage N 1.0mm2
3 Load CT Secondary I (out) 1.0mm2 Current Transformer Secondary
4 Load CT Secondary I* (in) 1.0mm2 max current 62.5mA
Can be configured as
programmable digital input
5 Aux. Input1 1.0mm2 port(active connect to B-);
Also can be configured as
generator temp. sensor.
6 Engine Temperature Sensor Input 1.0mm2
Low oil pressure digital or sensor
7 Low Oil Pressure Input 1.0mm2 signal input port; must be
connected to B-
8 Battery Negative Input B- 1.5mm2 Controller power supply input B-
Controller power supply input B+
and fuel relay output (activates
9 Electric Lock ON Signal Input B+ 1.5mm2
when Electric key is turned to ON
position)

HGM501 Genset Controller User Manual Page 10 of 17

Terminal Function Wire size Remarks
Hand-turn start, start relay output
(Output activates when electric
10 Electric Lock START Input 1.5mm2
lock key is turned to START
position)
Rated current 7A; power supplied
11 Start Relay Output 1.5mm2
by terminal 13
Rated current 7A; power supplied
12 Fuel Relay Output 1.5mm2
by terminal 13
Fused and connected to start
13 Fuel/Start Relay Common Port 2.5mm2
battery positive
NOTE: Controller within the LINK port, which connect to SmartGen’s SG72 adapter. It is can be set or
check genset’s real time data via PC software.

7. CONFIGURABLE PARAMETERS

7.1. CONFIGURABLE PARAMETERS TABLE

Table 5 – Configurable Parameters

No Parameter Range Default Description
1P 1P：1P2W
2P 2P：2P3W
1 AC system 1P
3P 3P：3P4W
4P 4P：Double Rated Volts
110 V
115 V
120 V
Generator rated voltage value
2 Rated voltage 130 V 220
selection
220 V
230 V
240V
Rated 50Hz Generator rated frequency
3 50
frequency 60Hz selection
4 Rated power (0.0-99.9)kw 5.0 Generator rated Active power
Enable Auto Enable Irrespective of whether gen-set
5 Enable
protection Disable auto protection is enabled
Unit: A/62.5mA
6 CT Ratio (0-999)/62.5 50/62.5 (Must correspond to the used
current transformer)
L-0 L-0：Not used
Engine L-1 L-1：TE1(SGX Sensor)
7 temperature L-2 L-4 L-2：TE2(SGD Sensor)
sensor type L-3 L-3：TE3(PT100 Sensor)
L-4 L-4：TE4 (See TE4/TG4 Sensor

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No Parameter Range Default Description
L-5 Curve)
L-5: TE5 (Mingzhihui SGD_NPT
Sensor)
Select this according to the used
sensor.
L-0：Not used
L-1：TG1(SGX Sensor)
L-0
L-2：TG2(SGD Sensor)
L-1
L-3：TG3(PT100 Sensor)
Generator L-2
L-4：TG4(See TE4/TG4 Sensor
8 temperature L-3 L-0
Curve)
sensor type L-4
L-5: TG5 (Mingzhihui SGD_NPT
L-5
Sensor)
Select this according to the used
sensor.
Remark:
1) Parts of parameters only can be configured via PC software, e.g. digital input port1.
2) AC system selected "Double Rated Volts" means generator can output two kinds of rated voltage.
TE4/TG4 sensor curve as bellow,

Fig.3 – TE4/TG4 Sensor Curve

HGM501 Genset Controller User Manual Page 12 of 17

 7.2. PARAMETER CONFIGURATION

Before using controller for the first time, parameters must be configured: rated voltage,
rated frequency, rated power set values must comply with the used generator, set C.T. ratio
value should comply to the used current transformer.

1) When the controller is disconnected, press button, then change start key position

from OFF to ON; after the controller is powered on release button and all the three
windows (voltage window, frequency window and multifunctional window will show set
parameters; at the same time voltage window will start flashing showing four choices
(1P/2P/3P/4P) which mean 1P2W, 2P3W, 3P4W and Double Rated Volts respectively.

Use and to choose AC wire type and to confirm and automatically enter
the next menu item;
2) Rated voltage value settings: there are 7 possible variants of voltage

(110/115/120/130/220/230/240V), use and to switchover between them

(each pressing will increase/decrease the value for one step). When the screen shows

the needed value, press to confirm and enter the next menu item;

3) Rated power settings: power LED window first digit will start flashing; use and

to choose a value from 0 to 9, then press to confirm and enter next settings; power

window second digit will start flashing, use and to choose a value from 0 to 9

and to confirm; power window third digit will start flashing, use and to

choose a value from 0 to 9 and to confirm and enter the next menu item;
4) Rated frequency setting: frequency LED indicator illuminates, multifunctional window

starts flashing; press and to choose frequency value (there are 2 choices: 50
and 60Hz), every time you press the button the value will change; when the needed value

is displayed, press to confirm and automatically enter the next setting;

5) Auto protection setting: when auto protection light indicator is on, press to confirm

and auto protection will continue to be enabled; use or to make indicator

flashing and press to disable auto protection. When the light indicator is off, it
means that auto protection is disabled. Enabling this function is recommended;
6) C.T setting: current LED indicator illuminates; multifunctional window first digit will start

flashing; use and to choose a value from 0 to 9, then press to confirm

and enter next settings; multifunctional window second digit will start flashing, use

and to choose a value from 0 to 9 and to confirm; multifunctional window

third digit will start flashing, use and to choose a value from 0 to 9 and
to confirm and enter the next menu item;
7) Engine temperature sensor type setting: when engine temperature indicator is on,

HGM501 Genset Controller User Manual Page 13 of 17

 multifunctional window will start flashing: use and to select temperature
sensor type (there are six choices: L-0，L-1，L-2，L-3，L-4. L-5. L-0 stands for 'no
temperature sensor used'). Every time you press the button, the temperature sensor type

will change; when the needed type is displayed, press button to confirm and
automatically enter the next setting;
8) Generator temperature sensor type setting: the same as 7.
9) High temperature shutdown limit setting: engine temperature indicator illuminates,

multifunctional window first digit will start flashing, use and to choose a

value from 0 to 9 and to confirm; multifunctional window second digit will start

flashing, use and to choose a value from 0 to 9 and to confirm;

multifunctional window third digit will start flashing, use and to choose a

value from 0 to 9 and to confirm and enter the next setting automatically; the range
of temperature setting is 1-600℃ and it is invalid when outside this range.
10) Turn the start key from ON to OFF position to finish configuration.

NOTE: during configuration use button to enter the next menu item and to return to the

previous.
CAUTION: Please change inner controller parameters (rated generator voltage, generator frequency etc.)
only in standby mode, otherwise in can lead to shutdown or other abnormal condition.

HGM501 Genset Controller User Manual Page 14 of 17

 8. COMMISSIONING

It is recommended that the following checks are made before starting the system:
1) Check that all the connections are correct and wire sizes are suitable.
2) Ensure all parameters are configured correctly and oil pressure light is on.
3) Ensure the controller DC power supply is fused and correctly connected to the positive and
negative of starter battery.
4) Take proper measures to prevent the engine from starting (e. g. unplug fuel valve wire).
After checking that there are no faults, connect the starter battery, change start key position
from OFF to ON, and the controller will carry out the procedure.
5) Then change start key position to START to start cranking. After the engine is fired, remove
start key; voltage, frequency and power windows will show true collected values.
6) For further information please contact SmartGen services.

9. TYPICAL WIRING DIAGRAM

Typical wiring diagram is shown below:

Fig.4 – HGM501 Typical Application Diagram

HGM501 Genset Controller User Manual Page 15 of 17

 10. INSTALLATION

The controller is designed for panel mounting, it is held with the help of fixing clips. Overall
and cutout dimensions can be seen below (unit: mm)

Fig.5 – Overall Dimensions and Panel Cutout

1) Battery Voltage Input

NOTE: HGM501 controller is suitable for 9-18 VDC battery voltage. Battery negative must be reliably
connected to the enclosure of the engine. The controller power supply B+ and B- must be connected to battery
positive and negative, and the wire size must not be less then 1.5mm2. In case of floating charger connect
charger output to battery positive and negative directly, then, connect battery positive and negative poles to
controller positive and negative power supply input port using single lines to prevent charger interference into
normal operation of the controller.

WARNING: When the engine is running, start battery must not be removed.
2) AC input
Current transformer with rated secondary current 62.5mA must be externally connected to
the controller current input.

WARNING! When generator is on-load, C. T. secondary must not be open circuit.

3) Withstanding voltage test
CAUTION: If withstanding voltage test is conducted after the controller has already been installed onto the
control panel, please unplug all controller terminal connections in order to prevent high voltage from
damaging it.

HGM501 Genset Controller User Manual Page 16 of 17

 11. TROUBLESHOOTING

Table 6 - Troubleshooting
Problem Possible solution
Check start battery.
Controller does not respond on
Check wiring to the controller
power on
Check DC fuse
Low oil pressure alarm after Check oil pressure sensor and its wiring.
crank disconnect
Check corresponding switch and wiring in accordance
Alarm shutdown during running
with the information on the display
Check fuel return circuit and wiring
Fail to start Check start battery
Consult engine manual
Check the wiring to the starter
Starter motor does not respond
Check start battery

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