HGM6400 V1.0 en PDF

HGM6410/6420 AUTO START MODULE
CONTENT
1 SUMMARY ................................................................................................................. 4
2 PERFORMANCE AND CHARACTERISTICS...................................................... 4
3 SPECIFICATION ....................................................................................................... 6
4 OPERATION............................................................................................................... 7
4.1 LCD display........................................................................................................ 7
4.2 Key function ....................................................................................................... 9
4.3 Automatic operation ........................................................................................ 10
4.4 Manual operation..............................................................................................11
5 PROTECTION.......................................................................................................... 12
5.1 Warning alarm /Pre-alarm.............................................................................. 12
5.2 Shutdowns......................................................................................................... 13
5.3 Electrical trips .................................................................................................. 15
6 CONFIGURATION .................................................................................................. 16
6.1 Parameter Setting ............................................................................................ 16
6.2 Editing the current data/time ......................................................................... 19
7 DEFINITION OF DIGIT INPUTS AND OUTPUTS ............................................ 20
7.1 Digit input 1-6................................................................................................... 20
7.2 Digit output 1-6 ................................................................................................ 22
8 BACK BOARD ......................................................................................................... 28
9 CONNECTING TERMINAL .................................................................................. 28
10 FAULT FINDING ..................................................................................................... 31
11 TYPICAL WIRING DIAGRAM ............................................................................. 33
11.1 3-phase 4 wires ................................................................................................. 33
11.2 3-phase 3 wires ................................................................................................. 34
11.3 single phase 2 wires .......................................................................................... 34
11.4 2-phase 3 wires ................................................................................................. 34
12 IDMT TRIPPING CURVES (TYPICAL) .............................................................. 35
13 LINK TO PC ............................................................................................................. 36
14 CANBUS CONNECT ............................................................................................... 37
14.1 CUMMINS ISB/ISBE.......................................................................... 37
14.2 CUMMINS QSL9................................................................................ 37
14.3 CUMMINS QSM11 ............................................................................. 38
14.4 DETROIT DIESEL DDEC III / IV ........................................................ 39
14.5 DEUTZ EMR2 .................................................................................... 39
14.6 JOHN DEERE.................................................................................... 40
14.7 MTU MDEC........................................................................................ 40
14.8 PERKINS ........................................................................................... 41
14.9 SCANIA ............................................................................................. 41
14.10 VOLVO EDC3 .................................................................................... 42
14.11 VOLVO EDC4 .................................................................................... 42
14.12 VOLVO-EMS2 .................................................................................... 43
14.13 BOCSH .............................................................................................. 44
15 INSTALLATION ...................................................................................................... 45
HGM6410/6420 Auto Start Module ISSUE 2008-8-10 Version 1.0 Page 3 of 45

1 SUMMARY
HGM6400 Series generator controller integrating digital, intelligent and network
techniques is used for automatic control system of diesel generator. It can carry
out functions including automatic start/stop, data measure and alarming. The
controller uses LCD display, optional Chinese and English display interface with
operation easy and reliable.
HGM6400 Series generator controller uses micro-processing technique which

can carry out precision measure, constant value adjustment, timing and threshold
setting and etc. of multi-parameters. It can be widely used in all types of generator
automatic control system for compact structure, advanced circuits, simple
connections and high reliability.
HGM6400 Series generator controller have a port of SAE J1939. It can connect
engine that possess J1939 ECU.
2 PERFORMANCE AND CHARACTERISTICS

◆ HGM6400 controller has two types: HGM6410:
ASM (Automatic Start Module) HGM6420: AMF
(Automatic Mains Failure Module)
◆ Using microprocessor as a core, graphics LCD with big screen and backlight,
display between Chinese and English, key touch for operation.
◆ Configurable single phase 2 wires or three phase 3 wires or three phase 4

wires AC system input;
◆ Control protection: Automatic start/stop, load transfer and alarming of

generator;
◆ Parameters setting: Allow user to modify setting and store them inside internal
FLASH memory, the parameters can not be lost even with power down.
◆ Five channel analog inputs, may joint with Resistive-type temperature/

pressure/ fuel level sensors, Several temperature and pressure sensors can
be used directly (ie. VDO, DATCON, CUMMINS), also may select “user
defined” sensor via entering 16 point curves;
◆ Functions including RTC(real time clock) and hours count;
◆ Display of generator cumulated electric energy;
◆ Security password-protected programming levels.
◆ Several crank success conditions are optional;

◆ Built-in speed/frequency detecting units can accurately judge the states such
as crank success and over speed;
◆ 99 historical records can be stored circularly and inquiring of the records can
be made on site;
◆ Power supply range is wide, accommodating to different starting battery

voltage environments;
◆ All parameters use digital modulation, abandoning analog modulation using

conventional electronic potentiometer, reliability and stability are increased;
◆ Built-in watch dog can never be dead halt, ensuring smooth program
execution;
◆ Modular configuration design, inserted type connection terminals, flush type

installation, compact structure, easy installation.

3 SPECIFICATION
Operating Voltage DC8. 0V to 35. 0V, Continuous Power Supply
Power Consumption <3W
Alternator Input Range
Single phase 2 wire 15V AC - 360 V AC (ph-N)
3-Phase 4 Wire 15V AC - 360 V AC (ph-N)
3-Phase 3 Wire 30V AC - 600 V AC (ph-ph)
2-Phase 3 Wire 30V AC - 600 V AC (ph-ph)
Alternator Input Frequency 50Hz - 60 Hz at rated engine speed
Magnetic Input Range +/- 1. 0 V to 70 V Peak
Magnetic Input Frequency 10,000 Hz (max) at rated engine speed.
Start Relay Output 16 Amp DC at supply voltage.
Fuel Relay Output 16 Amp DC at supply voltage.
Auxiliary Relay Output (1-4) (1-3)16 Amp DC at supply voltage,(4)6A
250VAC
Close Mains Relay 16A 250VAC free voltage contact
Close Generator Relay 16A 250VAC free voltage contact
Dimensions 240mm x 172mm x 57mm
Panel cutout 214mm x 160mm
Charge Fail / Excitation Range 0 V to 35 V
Operating Temperature Range -30 to +70°C
Storage Condition Temperature: (-20 - 80)°C
C. T. Burden 2. 5VA
C. T. Secondary 5A
Weight 0. 90kg

4 OPERATION
4.1 LCD DISPLAY

It is possible to manually scroll to display the different pages of information by repeatedly
operating the next page button.
Page order:
• Status display
• Instrument display
• Alarms display
• Event log
4.1.1 STATUS PAGE

This LCD will show: Generator state, Mains state, Breaker closed/ opened state.
Mains on load:
System in Stop mode Now, System in stop mode, Mains normal,

Mains normal generator at rest, Mains on load.
Generator at Rest
Mains on Load
Generator on load:
System in Manual mode Now, System in stop mode, Gens on load.

L-N 220V 300A 50.0Hz This screen also indicates the average line
L-L 381V 48.7KW to neutral voltage, highest of the 3 phase
Gens on Load currents, generator frequency, average line to
line voltage and total kilo Watts.
4.1.2 INSTRUMENT PAGE

INSTRUMENT PAGE CONTENT
• Engine speed
• Oil Pressure
• Coolant temperature
• Engine Hours Run
• DC Battery Voltage
• Charge alternator voltage
• Modem status (GSM)
• Generator AC Voltage Line-Neutral
• Generator AC Voltage Line-Line
• Generator Line Current (Displays load current when CTs are located in the load feed, and
the module is suitably configured).
(Displays mains load when CTs are located in the load feed, and the module is suitably
configured).

• Generator
Output
• Number of
starts
• Fuel level (%)
• Mains (Utility) AC Voltage Line-Neutral
• Mains (Utility) AC Voltage Line-Line
• Mains (Utility) Frequency (Hz)
If enhanced instrumentation is selected, the following instrumentation will become
available, if supported by the engine manufacturer.
• Engine oil temperature
• Inlet manifold temperature
• Coolant pressure
• Fuel pressure
• Fuel consumption
• Total fuel used
• Turbo pressure
exemple : Engine speed
Now, Engine speed is 1500RPM.

Engine speed
1500RPM rectangle denot current speed; hollow
triangle denot value of warn; solid
triangle denot value of shutdown;
Note: push to chenge the item.
4.1.3 ALARMS PAGE

Exemple: warn alarm
The module is warning that the engine oil
Alarm 01/02 pressure has fallen below a pre set level. The
Low oil press generator is not shutdown.
Warn
Exemple: ECU alarm

Now have 1 alarm,
Alarm 01/01 Current alarm is number 1.
ECU Shutdown SPN=110:
High coolant Temp Coolant Temp
110,3,High FMI=3:
High

4.1.4 EVENT PAGE
exemple :event log
Now have 12 records,
Gens Shutdown records Current record is number 1.
record 01/12 The third line: type of alarm
Failed to Start The four line: date and time of the event
2006-01-02 06:03:05
4.2 KEY FUNCTION

This button places the module into its Stop/reset
mode. When engine is running, pressing this key will
stop the engine. When a shutdown alarm occur,
Stop/ Reset key
pressing this key will reset alarm. In stop mode,
pressing this key over 3 second will test LED mounted
on the panel.
In manual or manual test mode, pressing this key will
Start key
start engine.
Manual mode Pressing this key will set the module into manual
key/ mode. In setting parameter status, pressing this key
Config ‘-‘ key will decease setting value.
Manual test Pressing this key will set the module into manual test
mode/ mode. In setting parameter status, pressing this key
Config ‘+’ key will increase setting value.
Auto key / Pressing this key will set the module into automatic
Config ‘enter’ mode. In setting parameter status, pressing this key
key will shift cursor or confirm setting value.
Gens At manule mode,push this buttont the Gens will on/off
close/open key load (without reference to Gens normal or not).
Mains At manule mode,push this buttont the Mains will on/off
close/open key load (without reference to Mains normal or not).
Up key At a page, change item from down to up
Down key At a page, change item from up to down
Page key Push , circularly display Status page, Instrument

page, Alarms page, Event page

4.3 AUTOMATIC OPERATION

The following description details the sequences followed by a module containing
the standard ‘factory configuration’. Always refer to your configuration source for
the exact sequences and timers observed by any particular module in the field.
This mode is activated by pressing the pushbutton. An LED indicator beside

the button confirms this action.
When a Remote Start signal is applied to the remote start input (Hgm6410) or
when mains voltage occur over-voltage, under-voltage, over-frequency, under-
frequency (Hgm6420), the following sequence is initiated:
To allow for false signals the mains abnormal timer is initiated (only Hgm6420),
Then the Start Delay timer is initiated. After this delay, if the pre-heat output
option is selected then the pre-heat timer is initiated, and the corresponding
auxiliary output (if configured) will energize.
NOTE: If the Remote Start signal is removed (Hgm6410) during the Start Delay
timer, or if mains voltage is normal (Hgm6420) during the mains abnormal timer,
the unit will return to a stand-by state.
After the above delays the Fuel Solenoid is energized, then one second later, the
Starter Motor is engaged. The engine is cranked for a pre-set time period. If the
engine fails to fire during this cranking attempt then the starter motor is
disengaged for the pre-set rest period. Should this sequence continue beyond the
set number of attempts, the start sequence will be terminated and Fail to Start
fault will be displayed on the LCD screen.
When the engine fires, the starter motor is disengaged and locked out at a pre-set
frequency from the Alternator output. Alternatively a Magnetic Pickup mounted on
the flywheel housing can be used for speed detection (This is selected by PC
using the HGM6400 series configuration software). Rising oil pressure can also
be used to disconnect the starter motor, however it cannot be used for under
speed or over speed detection.
After the starter motor has disengaged, the Safety On timer is activated, allowing
Oil Pressure, High Engine Temperature, Under-speed, Charge Fail and any
delayed Auxiliary fault inputs to stabilize without triggering the fault.
Once the engine is running, the Warm Up timer, if selected is initiated, allowing
the engine to stabilize before accepting the load.
If an auxiliary output has been selected to give a load transfer signal, this would
then activate.
NOTE: A load transfer will not be initiated until the Oil Pressure has risen. Thus
preventing excessive wear on the engine.
On removal of the Remote Start signal, the Stop delay timer is initiated, once it
has timed out, the load Transfer signal is de-energized, removing the load. The
Cooling timer is then initiated, allowing the engine a cooling down period off load
before shutting down. Once the Cooling timer expires the Fuel Solenoid is
de-energized, bringing the generator to a stop.
4.4 MANUAL OPERATION
●HGM6420: This manual mode is activated by pressing the pushbutton.
This manual test mode is activated by pressing the pushbutton. An LED

indicator beside the button confirms this action. In any of the two modes, pressing
the pushbutton will initiate the start sequence.
If the pre-heat output option is selected this timer is then initiated, and the
auxiliary output selected is energized.
After the above delay the Fuel Solenoid is energized, then the Starter Motor is
engaged.
The engine is cranked for a pre-set time period. If the engine fails to fire during
this cranking attempt then the starter motor is disengaged for the pre-set rest
period. Should this sequence continue beyond the set number of attempts, the
start sequence will be terminated and Fail to Start fault will be displayed on the
LCD screen
When the engine fires, the starter motor is disengaged and locked out at a pre-set
frequency from the Alternator output. Alternatively a Magnetic Pickup mounted on
the flywheel housing can be used for speed detection (This is selected by PC
using the HGM6400 series configuration software). Rising oil pressure can also
be used to disconnect the starter motor, however it cannot be used for under
speed or over speed detection.
After the starter motor has disengaged, the Safety On timer is activated, allowing
Oil Pressure, High Engine Temperature, Under-speed, Charge Fail and any
delayed Auxiliary fault inputs to stabilize without triggering the fault.
Once the engine is running, the Warm Up timer, if selected is initiated, allowing
the engine to stabilize before it can be loaded.

In manual mode, generator take load or no load depend on pushbutton /
In manual test mode, generator will take load regardless of mains supply normal
or abnormal.
●Hgm6410: This manual mode is activated by pressing the pushbutton. An

LED indicator beside the button confirms this action. In any of the two modes,
pressing the pushbutton will initiate the start sequence.
The start sequence is similar as the above.
In above process, when the Warm Up timer has expired, if the remote start signal
is active, generator will take load, if inactive, generator will not take load.
In above process, pressing key will bring the generator to a stop.
In manual mode, generator take load or no load depend on pushbutton
5 PROTECTION
5.1 WARNING ALARM /PRE-ALARM

Warnings or pre-alarms are non-critical alarm conditions and do not affect the
operation of the generator system, they serve to draw the operators attention to
an undesirable condition.
In the event of a warning alarm or pre-alarm, the module will display on the LCD
screen.
Warning alarms is shown as the below:
HIGH ENGINE TEMPERATURE: if the module detects that the engine coolant
temperature has exceeded the high engine temperature pre-alarm setting level
after the Safety On timer has expired, a warning will occur.
LOW OIL PRESSURE, if the module detects that the engine oil pressure has
fallen below the low oil pressure pre- alarm setting level after the Safety On timer
has expired, a warning will occur.
OVERSPEED, if the engine speed exceeds the pre-alarm trip a warning is

initiated.
UNDERSPEED, if the engine speed falls below the pre-set pre-alarm after the
Safety On timer has expired, a warning is initiated.
LOSS OF SPEED SIGNAL, if the speed sensing signal is lost during cranking, a
warning will occur.
GENERATOR HIGH FREQUENCY, if the module detects a generator output

frequency in excess of the pre-set pre-alarm, a warning is initiated.
GENERATOR LOW FREQUENCY, if the module detects a generator output

frequency below the pre-set pre-alarm after the Safety On timer has expired, a
warning is initiated.
GENERATOR HIGH VOLTAGE if the module detects a generator output voltage

in excess of the pre-set trip a shutdown is initiated.
GENERATOR LOW VOLTAGE if the module detects a generator output voltage

below the below the pre-set pre-alarm after the Safety On timer has expired, a
warning is initiated.
GENERATOR HIGH CURRENT, if the module detects a generator output current

in excess of the pre-set trip a warning is initiated.
FAIL TO STOP, If the module detects the engine is still running when the ‘Fail to
stop timer’ expires, a warning is initiated.
BATTERY HIGH VOLTAGE, if the module detects that the plant DC supply has
risen above the high volts setting level, a warning is initiated.
BATTERY LOW VOLTAGE, if the module detects that the plant DC supply has
fallen below the low volts setting level, a warning is initiated.
AUXILIARY INPUTS, if an auxiliary input has been configured as a warning the

appropriate information will be displayed.
ECU WARN, If the module is configured for CAN instruments and receives an
“warn” message from the engine control unit, ‘ECU warn” is shown on the
module’s display and a warning alarm is generated.
5.2 SHUTDOWNS
Shutdowns are latching and stop the Generator. The alarm must be cleared, and
the fault removed to reset the module.
NOTE: The alarm condition must be rectified before a reset will take place. If
the alarm condition remains it will not be possible to reset the unit (The
exception to this is the Low Oil Pressure alarm, as the oil pressure will be
low with the engine at rest). Any subsequent warnings or shutdowns that
occur will be displayed steady, therefore only the first-up shutdown will
appear displaying.
EMERGENCY STOP, removal of the +ve DC Supply from the Emergency Stop
input initiates the following sequence, firstly it will initiate a controlled shutdown of
the Generator and prevent any attempt to restart the Generator until the
Emergency Stop push-button has been reset. Secondly it removes the +ve DC
supply from both the Fuel Solenoid and Starter Solenoid.
HIGH ENGINE TEMPERATURE if the module detects that the engine coolant
temperature has exceeded the high engine temperature trip setting level after the
Safety On timer has expired, a shutdown will occur.
LOW OIL PRESSURE, if the module detects that the engine oil pressure has
fallen below the low oil pressure trip setting level after the Safety On timer has
expired, a shutdown will occur.
OVERSPEED, if the engine speed exceeds the pre-set trip a shutdown is initiated.
UNDERSPEED, if the engine speed falls below the pre-set trip after the Safety On
timer has expired, a shutdown is initiated.
LOSS OF SPEED SIGNAL, if the speed sensing signal is lost during cranking, a
shutdown is initiated.
GENERATOR HIGH FREQUENCY if the module detects a generator output

frequency in excess of the pre-set trip a shutdown is initiated.
GENERATOR LOW FREQUENCY, if the module detects a generator output

frequency below the pre-set trip after the Safety On timer has expired, a shutdown
is initiated.
GENERATOR HIGH VOLTAGE if the module detects a generator output voltage

in excess of the pre-set trip a shutdown is initiated.
GENERATOR LOW VOLTAGE if the module detects a generator output voltage

below the below the pre-set trip after the Safety On timer has expired, a shutdown
is initiated.

in excess of the pre-set trip a warning is initiated. This warning will continue for a
period of time depending upon the level of overload that the generator is subjected
to, and the configuration setting for Generator Over Current in the HGM6400
series configuration software.
For instance the factory default settings for Generator High Current allow for a
loading of the generator to 110% for one hour. That is to say if the generator load
level exceeds the trip point by 10%, a warning alarm will occur while the overload
condition exists. If the load level does not drop to normal levels within one hour,
the engine is stopped, the HGM6400 module displaying either shutdown alarm or
electrical trip alarm depend upon module configuration.
NOTE: Higher overload levels will result in a faster acting shutdown condition. For
instance with the factory default configuration, an overload level twice that of the
trip level ( typically 200%) will result in a Generator High Current shutdown
condition after 36 seconds. For details of the relationship between the overload
and the shutdown time, please see the Appendix section of this manual.
FAIL TO START, if the engine does not fire after the pre-set number of attempts
has been made a shutdown will be initiated.
OIL PRESSURE SENDER OPEN CIRCUIT, if the module detects a loss of signal
from the oil pressure sender (open circuit) a shutdown is initiated.
AUXILIARY INPUTS, if an auxiliary input has been configured as a shutdown the

appropriate information will be displayed.
ECU SHUTDOWN, If the module is configured for CAN instruments and receives
an “error” message from the engine control unit, ‘ECU shutdown” is shown on the
module’s display and a warning alarm is generated.
CAN DATA FAIL ,If the module is configured for CAN operation and does not
detect data on the engine Can datalink, a shutdown will occur and ‘Can data fail’
is shown on the module’s display.
5.3 ELECTRICAL TRIPS

Electrical trips are latching and stop the Generator but in a controlled manner. On
initiation of the electrical trip condition the module will de-energize the ‘Load
Transfer’ Output to remove the load from the generator. Once this has occurred
the module will start the Cooling timer and allow the engine to cool, off-load before
shutting down the engine. The alarm must be accepted and cleared, and the fault
removed to reset the module.

in excess of the pre-set trip a warning is initiated.
If this over current condition continues for an excess period of time, then the alarm
is escalated to either a shutdown or electrical trip condition (depending upon
module configuration). For further details of the over current alarm, please see
Over Current Shutdown Alarm.
AUXILIARY INPUTS, if an auxiliary input has been configured as an electrical trip

the appropriate information will be displayed.
6 CONFIGURATION
Although full configuration of the module is possible using the HGM6400 series
configuration software, selected parameters that may require adjustment in the
field are able to be adjusted via the module’s fascia.
NOTE: Care should be taken to ensure that changes made via the front panel
editor are carefully recorded and fed back to the generator supplier if applicable.
This is to safeguard against using the HGM6400 series configuration software to
configure the module at a later date, possibly overwriting the changes made using
the front panel editor. When using the HGM6400 series configuration software to
make configuration changes, the first operation should be to “read configuration
from controller” to ensure that any changes made to the controller’s configuration
by the front panel editor are ‘loaded’ into the PC before any changes are made.
Full details of this procedure can be found in the HGM6400 series configuration
software manual.
6.1 PARAMETER SETTING
Pressing down both and keys will show the interface to enter
password. The default password is “1234” when it leaves factory. When setting
each item, after selecting this item, press the key ‘enter’ to enter the setting
interface, then press the key ‘-‘ or ‘+’ to adjust the numerical value, press the key
‘enter’ to move the cursor, finally press the key ‘enter’ to confirm the set
parameter.
In setting process, pressing key will quit and return main LCD screen.
Configurable parameters is shown in the below table.

Parameter Range Default Remark
Return:
01 Low pressure 124kPa/
(1-399)kPa 138kPa/ 20.
(pre-alarm) 18.0PSI
0PSI
02 Low pressure 103kPa/
(0-398)kPa
(shutdown) *3 14. 9PSI
03 High temperature 90oC/ Return:
(81-139)oC
(pre-alarm) 194oF 88oC/190oF
04 High temperature (82-140)oC 95oC/
(shutdown) *4 203oF
05 Fuel level
(0-100)% 10%
(warning)
06 Start delay (0-9999s) 5s
07 Pre-heat delay (0-300s) 0s
08 Crank time (3-60s) 5s
09 Crank rest time (3-60s) 10s
10 Safety on time (5-60s) 10s
11 Over speed/ over shoot time (0-10s) 2s
12 Start idle time (0-3600s) 10s
13 Warm up time (0-3600s) 30s
14 Transfer time (0-600s) 2s
15 Return time (0-9999s) 30s
16 Coolant down time (0-3600s) 60s
17 Stop idle time (0-3600s) 10s
18 ETS Solenoid hold time (0-120s) 20s
19 Fail to stop delay (10-120)s 30s
20 Generator transient delay (0-30s) 5s
21 Mains transient delay *1 (0-30s) 2s
(50-360V Return:
22 Mains low voltage (trip) *1 184V
/624) *2 207V
(50-360V Return:
23 Mains high voltage (trip) *1 276V
/624) *2 253V
Return:
24 Mains low frequency (trip) *1 (0-75Hz ) 45. 0Hz
48. 0Hz
Return:
25 Mains high frequency (trip) *1 (0-75Hz) 55. 0Hz
52. 0Hz
26 Generator low voltage (50-360V
184V
(shutdown) /624) *2
27 Generator high voltage (50-360V Return:
196V
(warning) /624) *2 207V
28 Generator high voltage (50-360V Return:
265V
(warning) /624) *2 253V
29 Generator high voltage (50-360V
273V
(shutdown) /624) *2
30 Generator low frequency
(0-74. 8 Hz) 40. 0Hz
(shutdown)
31 Generator low frequency
(0. 1-74. 9 Hz) 42. 0Hz
(warning)
32 Generator high frequency Return:
(0. 1-74. 9 Hz) 55. 0Hz
(warning) 52. 0Hz
33 Generator high frequency
(0. 2-75 Hz) 57. 0Hz
(shutdown)
34 Over current percent (50-120%) 100%
35 Flywheel teeth (10-500) 118
36 Under speed
(0-5998 RPM) 1270
(shutdown)
37 Under speed Return:
(1-5999 RPM) 1350
(warning) 1380RPM
38 Over speed Return:
(1-5999 RPM) 1650
(warning) 1620RPM
39 Over speed
(2-6000 RPM) 1710
(shutdown)
40 Over shoot percent (0-10%) 0
41 Battery low voltage
(0-39. 9 V) 8. 0V
(warning)
42 Battery over voltage
(0. 1-40V) 33. 0V
(warning)
43 Charge failure
(0-39V) 6. 0V
(warning)
0: Chinese
44 Language select (0-1) 0
1: English
45 Password (0-9999) 1234
Note:
*1: Only HGM6420 is used
*2: 360V is Line-Nature voltage, 624V is Line-Line voltage (3-phase 3 wires).
*3: If Low pressure (shutdown) set to 0, a stop signal is inhibitable.
*4: If high temperature (shutdown) set to 140, a stop signal is inhibitable.
Other parameters configuration, (only adjust via HGM6400 configurable software)

Parameter Default
Address 1
Generator Yes
Generator pole number 4
Magnetic Pickup Unit Yes
AC system 3-phase 4 wires
Fast loading feature No
Start number 3
Immediate mains dropout Not used
Voltage transformer No
J1939 enable and engin type No
J1939 enhanced enable No
Oil pressure sensor SGD 10Bar
Engine temperature sensor SGD 120 degrees C
Fuel level sensor VDO Ohm Range (10-180)
Fuel pump control No
Digit input1 Remote start on load, close to active
Digit input2 Indication, close to active, always active
Parameter Default
Digit input3 Warning, close to active, always active
Digit input4 Shutdown, close to active, always active
Digit input5 Shutdown, close to active, active from safety on
Digit input6 Electrical trip, close to active, always active
Digit output1 Preheat output (during preheat timer)
Digit output2 Common alarm
Digit output3 ETS output
Digit output4 Idle / run control
Digit output5 Close generator
Close mains (HGM6420)
Digit output6
Not used (HGM6410)
LED1 System in stop mode
LED2 Fail to start
LED3 Common shutdown alarm
LED4 Common alarm
Current transformer first side
500A
current
Generator full current 500A
Delayed over current percent 100% (500A)
Time multiplier
36
(over current)
Action (over current) Electrical trip
Generator frequency
15Hz
(starter disconnect)
Engine speed
450RPM
Oil pressure
Not used
Detect oil pressure during
Yes
cranking
Schedule start No
6.2 EDITING THE CURRENT DATA/TIME
Pressing down both the key and key will show the setting data/time
interface. The setting sequence is year -month -date (week) hour :minute :second.
Note: Setting must be in stop mode.

7 DEFINITION OF DIGIT INPUTS AND OUTPUTS
7.1 DIGIT INPUT 1-6

The below parameters only can be set by HGM6400 configurable software.
Content Description
The input is configured to perform an auxiliary function, this may be
any of the following:
Indication (annunciation only, no alarm or shutdown)

Warning (Alarm only, no shutdown)
Shutdown (Alarm and shutdown)
Electrical Trip (Alarm/off-load generator followed by shutdown after
cooling)
The function also has an activation time associated with it chosen

from the following list:
User configured
Never active -This switches off the input if not in use.
Always active -The input selected to be an indication or alarm even
when the module is in the STOP/RESET MODE.
Active from starting -The Auxiliary input is only active once an
attempt to start the generator is made. It will remain active until the
generator is at rest again.
Active from safety on - Auxiliary inputs are only active once the
Safety On timer has timed out. This allows a delay on start up for
faults, such as Oil Pressure and High Engine Temperature
Warnings, or other shutdown conditions which require a delay
during start-up, such as Under-voltage.
When active, this will disable an output configured to ‘audible alarm’,
Alarm mute
without resetting the module’s alarm condition.
Reset alarm When an alarm is active, it will be cleared.
If this input is active the HGM6400 will operate thus:
To use this function the HGM6400 should be placed in the AUTO
mode. In the event of a remote start /mains failure the generator will
be instructed to start and take load. On removal of the remote start
signal/ mains return the module will continue to run the generator on
Auto Restore
load until this AUTO RESTORE INHIBIT input is removed. Once
Inhibit
the input is removed the module will transfer the load back to the
mains supply and follow a normal generator stop sequence. This
input allows the HGM6400 to be fitted as part of a system where the
manual restoration to mains is controlled remotely or by an
automated system.
This input is used to provide an over-ride function to prevent the
HGM6400 from starting the generator in the event of a remote start/
Auto start Inhibit
mains out of limits condition occurring. If this input is active and a
remote start signal/ mains failure occurs the HGM6400 will not give
Content Description
a start command to the generator. If this input signal is then
removed, the HGM6400 will operate as if a remote start/ mains
failure has occurred, starting and loading the generator. This
function can be used to give a ‘AND’ function so that a generator
will only be called to start if the mains fails and another condition
exists which requires the generator to run. If the ‘Auto start Inhibit’
signal become active once more it will be ignored until the module
has returned the mains supply on load and shutdown.
The HGM6400 module will monitor the incoming single or three
phase supply for Over Voltage, Under Voltage, Over Frequency or
Under Frequency. It may be required to monitor a different mains
supply or some aspect of the incoming mains not monitored by the
Auxiliary Mains
module. If the devices providing this additional monitoring are
Fail
connected to operate this input, the HGM6420 will operate as if the
incoming mains supply has fallen outside of limits, the generator will
be instructed to start and take the load. Removal of the input signal
will cause the module to act if the mains has returned to within limits.
This input is used to provide feedback to allow the HGM6400 to give
Generator true indication of the contactor or circuit breaker switching status. It
Closed Auxiliary should be connected to the generator load switching device auxiliary
contact.
This input is used to prevent the HGM6400 from loading the
Generator Load generator. If the generator is already on load, activating this input
Inhibit will cause the HGM6400 to unload the generator. Removing the
input will allow the generator to be loaded again.
This input is used to provide a test facility for the front panel
Lamp Test indicators fitted to the HGM6400 module. When the input is
activated all LED and LCD indicators will illuminate.
This input is used to provide feedback to allow the HGM6420 to give
Main closed true indication of the contactor or circuit breaker switching status. It
Auxiliary should be connected to the mains load switching device auxiliary
contact.
This input is used to prevent the HGM6420 from loading the mains
Mains Load supply. If the mains supply is already on load activating this input
Inhibit will cause the module to unload the mains supply. Removing the
input will allow the mains to be loaded again.
This input is used to provide security to the installation. If the Panel
lock input is active, the module will not respond to operation of the
Mode select or start buttons. This allows the module to be placed
into a specific mode (such as Auto) and then secured. The
Panel Lock
operation of the module is not affected and the operator will still be
able to view the various instrumentation pages etc. (Front panel
configuration access is barred while system lock is active). When
active, the icon will display on line 1 of the LCD display.
Remote Start on If this input is active, the HGM6400 will operate thus:
Content Description
load To use this function the HGM6400 should be placed in the AUTO
mode. The module will perform the start sequence as described
earlier in this manual.
If this input is active operation will be similar to the ‘Remote Start on
Remote Start off load’ function except that the generator will not be instructed to take
load the load. This function can be used where an engine only run is
required e. g. for exercise.
Scheduled run
In automatic mode, this will inhibit the engine to scheduled run.
inhibit
This function is provided to over-ride the HGM6420 module’s
internal monitoring function. If this input is active the module will not
respond to the state of incoming AC mains supply unless the
Simulate Mains
monitored AC mains supply is out of limits AND this input is inactive.
available
This can be used to control the operation of the generator during a
mains failure by allowing generator operation only if equipment
operation requires the generator to run
7.2 DIGIT OUTPUT 1-6

The below parameters can only be set by HGM6400 configurable software.
Content Description
Output Not Used The output in not used.
The output controls the closing of the air-flaps in an
Air flap Relay
Emergency Stop or Over-speed situation.
This output is intended to drive an external Klaxon or
alarm indicator and will be active upon the module
triggering a warning, shutdown or electrical trip
alarm.
Audible alarm
This external alarm can be ‘muted’, without resetting
the module’s alarm condition by activating an
auxiliary input that has been configured to “Alarm
Mute”.
This output indicates that a Battery High Voltage
Battery High Voltage
alarm has occurred.
This output indicates that a Battery Low Voltage
Battery Low Voltage
alarm has occurred.
ECU POWER
ECU STOP
Reversed
The output mimics the operation of the start relay.
Start relay energized
Can be used to control external logic circuitry.
The output mimics the operation of the fuel relay.
Fuel relay energized
Can be used to control external logic circuitry.
Calling for Scheduled run This output indicates that a scheduled run in is

Content Description
progress.
This output indicates that a failure of the auxiliary
Charge alternator failure
charging alternator on the generator has occurred.
This output source is intended to be used to control
the load switching device. Whenever the HGM6400
Close Generator
module selects the generator to be on load this
control source will be active.
module selects the mains to be on load, this control
Close Generator Pulse
source will be active for the duration of the ‘Breaker
Close Pulse Timer’. Once this timer has expired, the
output source will once again become in-active.
Close Mains
module selects the mains to be on load this control
source will be active.
Close Mains Pulse
Close Pulse Timer’. Once this timer has expired the
output source will once again become in-active.
Combined under & over The output indicates that either an under frequency
Frequency warning or over frequency warning has been activated.
Combined under & over The output indicates that either an under frequency
Frequency shutdown or over frequency shutdown has been activated.
Combined under & over The output indicates that either an under voltage or
voltage shutdown over voltage shutdown has been activated.
Combined under & over The output indicates that either an under voltage or
voltage warning over voltage warning has been activated.
The output indicates that a warning, electrical trip or
shutdown alarm has been activated. Reset rules as
Common alarm
above, depending on whether it is a Warning or a
Shutdown fault.
The output indicates that an electrical trip alarm has
Common Electrical Trip been activated. This output can only be reset by
alarm removal of the fault and by then pressing the Stop
Reset button.
The output indicates that a shutdown alarm has
been activated. This output can only be reset by
Common Shutdown alarm removal of the fault and by then pressing the Stop
Reset button or by using an external ‘Alarm Reset’
Input.

Content Description
The output indicates that a warning alarm has been
activated. This output is normally self-resetting on
Common Warning alarm removal of the fault. However, it is possible to
configure the module such that the warning alarms
are
Coolant temperature 1 high This output indicates that a high engine coolant
temperature 1 warning
pre-alarm (pre-alarm) has occurred.
shutdown temperature 1 shutdown has occurred.
Cooling down timer in This output source will be active when the cooling
progress off-load timer is running.
Reserved
Digital Input 1active This output indicates that Digital input 1 is active.
This output indicates that an Emergency stop alarm
Emergency Stop
has occurred.
The output controls the fuel solenoid on an ETS type
generator, energizing for the time period selected in
the Edit Timer Menu. The normal fuel output (pin 4)
Energize to stop should not be connected to the fuel solenoid,
however it can be used for controlling panel
instruments and other functions required whilst the
engine is running.
The output indicates that the engine has not started
Fail to start alarm after the specified number of attempts, selected in
the Edit Miscellaneous Menu.
The output is used to control a fuel transfer pump.
Once the ‘fuel pump on’ level has been reached the
Fuel Pump Control module will activate the fuel pump control output.
This output will remain active until the ‘fuel pump off’
level is reached.
This output indicates when the generator is ready to
accept load, i. e. after safety on and warm up timers
Generator Available have timed out. It could be used to connect to an
Automatic Transfer System or PLC to give a signal
that the set is available.
Generator High Frequency This output indicates that a Generator High
Pre-alarm Frequency Warning (pre- alarm) has occurred.
Generator High Frequency This output indicates that a Generator High
Shutdown Frequency Shutdown has occurred.
Content Description
Generator High Voltage This output indicates that a Generator High Voltage
Pre-alarm Warning (pre- alarm) has occurred.
Generator High Voltage This output indicates that a Generator High Voltage
Shutdown Shutdown has occurred.
Generator Low Frequency This output indicates that a Generator Low
Pre-alarm Frequency Warning (pre- alarm) has occurred.
Generator Low Frequency This output indicates that a Generator Low
Shutdown Frequency Shutdown has occurred.
Generator Low Voltage This output indicates that a Generator Low Voltage
Pre-alarm Warning (pre- alarm) has occurred.
Generator Low Voltage This output indicates that a Generator Low Voltage
Shutdown Shutdown has occurred.
The output controls the opening of the louvers on
Louver control engine starting and closure when engine has
stopped.
This output indicates that the level of fuel has fallen
Low Fuel Level
below the low fuel alarm trip point.
This output indicates that a loss of speed alarm has
Loss of speed
occurred.
This output indicates that the module has sensed
that a failure of the incoming AC mains supply. This
output will become active whenever the mains
Mains Failure
voltage or frequency goes out of limits, or if the
auxiliary mains failure input active (if used) and the
mains transient timer has expired.
that the incoming AC
Mains High frequency
mains supply has exceeded the frequency limit
setting.
Mains High voltage
mains supply voltage has exceeded the voltage limit
setting.
Mains Low frequency that the incoming AC
mains supply has fallen below the frequency setting.
Mains Low voltage
mains supply voltage has fallen below the voltage
limit setting.
Oil pressure 1 low This output indicates that a low oil pressure 1
Pre-alarm warning (pre-alarm) has occurred.
shutdown shutdown has occurred.
Content Description
This output indicates that the module has detected
Oil Press sender Open
an open circuit failure in the Oil Pressure transducer
circuit
circuit.
Open Generator
source will be active.
Open Generator Pulse module selects the mains to be on load, this control
open Pulse Timer’.
Open Mains
control source will be active.
control source will be active for the duration of the
Open Mains Pulse
‘Breaker open Pulse Timer’. Once this timer has
expired the output source will once again become
in-active and the HGM6420 will issue commands to
load the generator.
Over current This output indicates that the over-current warning
Pre-alarm (pre-alarm) level has been reached.
This output indicates that the over-current trip level
Over current trip
been reached.
This output indicates that an over speed warning
Over speed Pre-alarm
(pre-alarm) has occurred.
This output indicates that an over speed shutdown
Over speed Shutdown
has occurred.
The output controls the pre-heater. Pre-heat output
Pre-heat (during
is available for the duration of the pre-heat timer,
preheat timer)
which terminates prior to cranking.
The output controls the pre-heater. As ‘Pre-heat
Pre-heat (until end of
(during preheat timer)’ mode but pre-heat is also
cranking)
available during cranking.
Pre-heat (until end of
(until safety on)’ but pre-heat continues to be
warming)
available until the warm-up timer has elapsed
Pre-heat (until safety on) (until end of cranking)’ but pre-heat is also available
while waiting for the delayed alarms to become

Content Description
active.
Open breaker
module has taken load this control source will be
active.
System in Manual Test This output indicates that the module is in the test
Mode mode.
The output indicates that the module is in the Auto
System in Auto Mode
mode.
System in Manual This output indicates that the module is in the manual
Mode mode.
The output indicates that the module is in the Stop
System in Stop Mode
mode.
This output indicates that an under speed warning
Under speed Warning
(pre-alarm) has occurred.
This output indicates that an under speed shutdown
Under speed Shutdown
has occurred.
This output indicates that an auto restore inhibit has
Waiting for manual restore
occurred.
This output is active from cranking, continues to be
active until the start idle timer has elapsed; Also this
Idle/ run control output is active during the period of the stop idle
timer, continues to be active until the engine has
stopped.
Reversed -
Raise speed This output is active during the warming up timer.
This output is available for the period of the crank
timer. This output will energize for 2 second during
Excite generator
the period of the safety on timer if generator has no
voltage.
This output is available during the period of the
Drop speed coolant down timer, and remain until the engine has
stopped.
This output is active from cranking, continues to be
Preset to Lubricate
active until the safety timer has elapsed.
pre-alarm temperature 2 warning (pre-alarm) has occurred.
shutdown temperature 2 shutdown has occurred.
Pre-alarm warning (pre-alarm) has occurred.
shutdown shutdown has occurred.
ECU communicate fail When communication is fail,this output is active

Content Description
ECU warn When get ECU warn message,this output is active
When get ECU shutdown warn message, this output
ECU shutdown
is active
8 BACK BOARD
The back board of hgm6410 and hgm6420 Controller is shown as follows:
9 CONNECTING TERMINAL
Pin Function Dim Description
DC Plant Supply Input System DC negative input.
1 2. 5mm
(-ve) (Battery Negative).
System DC positive input.
DC Plant Supply Input (Battery Positive).
2 2. 5mm
(+ve) (Recommended Maximum Fuse
20A)
Plant Supply +ve. Also supplies
fuel & start outputs.
3 Emergency Stop Input 2. 5mm
(Recommended Maximum Fuse
32A)
Plant Supply +ve from pin 3.
4 Fuel relay Output 2. 5mm
16 Amp rated.
Plant Supply +ve from pin 3.
5 Start relay Output 2. 5mm
16 Amp rated.
Plant Supply +ve.
6 Auxiliary Output relay 1 2. 5mm
16 Amp rated.
Plant Supply +ve.
7 Auxiliary Output relay 2 2. 5mm
16 Amp rated.
8 Auxiliary Output relay 3 2. 5mm Plant Supply +ve.
16 Amp rated.
Do not connect to ground (battery
9 Charge fail / excite 1. 0mm
–ve)
10 Auxiliary input 1 1. 0mm Switch to -ve
Connect to a good clean earth
16 Functional Earth 1. 0mm
point
17 Magnetic pickup +ve 1. 0mm Connect to Magnetic Pickup
18 Magnetic pickup -ve 1. 0mm device
19 Oil Pressure Input2 1. 0mm Connect to Oil pressure sender
20 Free voltage contacts. 16 Amp
21 Auxiliary Output relay 4 2. 5mm rated.
22
23 Not connected -
24 RS485 port Common 0. 5mm
Use only 120Ω RS485 approved
25 RS485 port A(+) 0. 5mm
cable
26 RS485 port B(-) 0. 5mm
27 Auxiliary Output relay 6 Free voltage contacts, N/C, 16
2. 5mm
28 (close mains output) Amp rated.
29 Auxiliary Output relay 5 Free voltage contacts, N/O, 16

2. 5mm
30 (Close generator output) Amp rated.
Mains L1 voltage Connect to mains L1 output

31 1. 0mm
monitoring (Recommend 2A fuse)
32 1. 0mm
33 1. 0mm
34 Mains Neutral input 1. 0mm Connect to mains Neutral terminal
Generator L1 voltage Connect to Generator L1 output
35 1. 0mm
Generator L2 voltage Connect to Generator L2 output
36 1. 0mm
Generator L3 voltage Connect to Generator L3 output (
37 1. 0mm
Connect to Generator Neutral
38 Generator Neutral input 1. 0mm
terminal (AC)
39 CT Secondary for L1 2. 5mm Connect to secondary of L1

monitoring CT
Connect to secondary of L2
40 CT Secondary for L2 2. 5mm
monitoring CT
Connect to secondary of L3
41 CT Secondary for L3 2. 5mm
monitoring CT
Connect to secondary of all
42 CT secondary common 2. 5mm
monitoring CT’s
Coolant Temperature Connect to Coolant Temperature
43 Input2 1. 0mm
sender
44 Oil Pressure Input1 1. 0mm Connect to Oil pressure sender
Coolant Temperature Connect to Coolant Temperature

45 Input1 1. 0mm
sender
46 Fuel Level input 1. 0mm Connect to Fuel Level sender
47 Sender Common Return 1. 0mm Return feed for senders*.
49
CAN Use only 120Ω approved
50 0.5mm
(SAE J1939) cable
51
RS232 To PC(2-RXD、3-TXD、5-GND)
Note:
1. These terminals of 31, 32, 33, 34 is not used for HGM6410 module.
2. The RS232/485 serial port is used for monitoring the module by connecting
with PC.
PART CONNECTOR FUNCTION DETAILS

1. Emergency Stop input. Internally linked to Starter and Fuel outputs. If this input
is not connected to positive the module will be locked out, and if the engine is
running it will shutdown immediately. The Positive Supply is also removed
from Starter and Fuel outputs, therefore only a single pole Emergency
Shutdown button is required.
2. Charge Fail input / Excitation output. Supplies excitation to the Plant Battery
Charging Alternator, also an input for the Charge Fail detection circuitry.
3. Auxiliary input. This is a negative switched configurable input. It is possible to
configure the input to be a normally closed signal or a normally open signal.
4. RS485 port. Use only screened 120Ω cable approved specifically for use in
RS485 applications.
5. Sensor sensing input. Connect to resistive type sender.

10 FAULT FINDING
Symptom Possible Remedy
Check the battery and wiring to the unit. Check the
Unit is inoperative
DC supply. Check the DC fuse.
Check DC supply voltage is not above 35 Volts or
Unit shuts down below 8 Volts. Check the operating temperature is
not above 70 °C. Check the DC fuse.
If an Emergency Stop Switch is not fitted, ensure
Unit locks out on Emergency that a positive is connected to the Emergency Stop
Stop input. Check emergency stop switch is functioning
correctly. Check Wiring is not open circuit.
Ensure that Magnetic pick-up screen is only
Intermittent Magnetic Pick- up connected at one end, if connected at both ends,
sensor fault this enables the screen to act as an aerial and will
pick up random voltages.
Check engine oil pressure. Check oil pressure
switch/ sender and wiring. Check configured
Low oil Pressure fault
polarity (if applicable) is correct (i.e. Normally Open
operates after engine has
or Normally Closed) or that sender is compatible
fired
with the HGM6400 Module and is correctly
configured.
Check engine temperature. Check switch/sender
High engine temperature fault and wiring. Check configured polarity (if applicable)
operates after engine has is correct (i.e. Normally Open or Normally Closed)
fired. or that sender is compatible with the HGM6400
Module.
Check relevant switch and wiring of fault indicated
Shutdown fault operates
on LCD display. Check configuration of input.
Check relevant switch and wiring of fault indicated
Warning fault operates
on LCD display. Check configuration of input.
Check wiring of fuel solenoid. Check fuel. Check
Fail to Start is activated after battery supply. Check battery supply is present on
pre-set number of attempts to the Fuel output of the module. Check the speed
start sensing signal is present on the HGM6400 inputs.
Refer to engine manual.
Continuous starting of Check that there is no signal present on the
generator when in AUTO “Remote Start” input. Check configured polarity is
correct.
Check Start Delay timer has timed out. If remote
Generator fails to start on
start fault, check signal is on “Remote Start” input.
receipt of Remote Start
Confirm input is configured to be used as “Remote
signal.
Start”.
Check wiring to engine heater plugs. Check battery
Pre-heat inoperative supply. Check battery supply is present on the
Pre-heat output of module. Check pre-heat has
Symptom Possible Remedy
been selected in your configuration.
Check wiring to starter solenoid. Check battery
supply. Check battery supply is present on the
Starter motor inoperative
Starter output of module. Ensure that the
Emergency Stop input is at +Ve.
Check Warm up timer has timed out. Ensure
Engine runs but generator will
generator load inhibit signal is not present on the
not take load
module inputs.
Check engine is operating correctly. Check sender
and wiring paying particular attention to the wiring
Incorrect reading on Engine
to terminal 47. Check that sender is compatible
gauges
with the HGM6400 Module and is correctly
configured.

11 TYPICAL WIRING DIAGRAM
11.1 3-PHASE 4 WIRES

HGM6410 Typical wiring diagram
HGM6420 Typical wiring diagram

11.3 SINGLE PHASE 2 WIRES

12 IDMT TRIPPING CURVES (TYPICAL)

HGM6410/6420 Delayed over-current protection
Current as a multiple of the trip-point setting (tripping curve = 36)
The details refer to ‘hgm6400 configurable software manual’.

13 LINK TO PC
The module has a RS485 and a RS232 communication port on the rear. The
HGM6400 configuration software allows the modules to be connected to a PC via
a RS485-RS232 transducer or direct connected to a PC. Once connected the
various operating parameters within the module can be viewed or edited as
required by the engineer. This software allows easy controlled access to these
values and also has diagnostic monitoring facilities.
Communication parameters
Item Default
Module address 1 (range: 1-254)
Baud rate 9600bps
Data bits 8bit
Parity bit None
Stop bit 1bit
Please download the HGM6400 configuration software from the below web site.
http://www.smartgen.com.cn/
Note: RS485 and RS232 can’t be used at the one time.

14 CANBUS CONNECT
14.1 CUMMINS ISB/ISBE
Cummins ISB
HGM6400
OEM Harness NOTES
TERMINAL
connector B
Fuel relay output 39 Key switch input.
Connects directly to engine
Start relay output -
starter solenoid.
Use to control
a 30A external Using PC configuration
slave relay to software select the relevant
Aux output 1
supply DC engine and configure “aux
battery power output 1” to be “ECU Power”
to 01,07,12,13
Cummins ISB 9
HGM6400
pin Deutsch NOTES
TERMINAL
Connector
Screen for the J1939 cable.
SAE J1939
Connect at Cummins ECU end
shield
only.
J1939 + Use only screened
SAE J1939 120 impedance cable
CAN(H)
signal approved specifically for use in
CANbus applications.
J1939 - Use only screened
SAE J1939 120 impedance cable approved
CAN(L)
return specifically for use in CANbus
applications.
The HGM6400 mode must be configured engine ECU :Cummins ISB
14.2 CUMMINS QSL9

Engines in the QSL9 range are fitted with the CM850 Engine Control Module.
(ECM). This system allows engine instrumentation and diagnostics via the
J1939 link.
Cummins
HGM6400 CM850 50 pin
NOTES
TERMINAL OEM
connector
Fuel relay output 39 Key switch input.
starter solenoid.

Cummins
HGM6400 CM850 9 pin
NOTES
TERMINAL Deutsch
connector
SAE J1939
Connect at Cummins ECU end
shield-E
only.
SAE J1939 120 impedance cable
CAN(H)
signal-C approved specifically for use in
SAE J1939 120 impedance cable
CAN(L)
return-D approved specifically for use in
The HGM6400 mode must be configured engine ECU :Cummins-CM850
14.3 CUMMINS QSM11

Engines in the QSM11 range are fitted with the CM570 Engine Control
Module. (ECM). This system allows engine instrumentation and diagnostics
via the J1939 link.
Cummins engines fitted with the CM570 ECM: QSM11 G1, QSM11 G2
(This list is not exhaustive, contact Cummins for further details)
Cummins
HGM6400
QSM11 OEM NOTES
TERMINAL
connector C1
Use DSE fuel relay to drive
external relay closing Cummins
Fuel relay output 5&8
terminals 5 (Run/Stop) and 8
(common return)
starter solenoid.
Cummins
HGM6400 CM570 3 pin
NOTES
TERMINAL data link
connector
C Connect at Cummins ECU end
only.
120 impedance cable
CAN(H) A
approved specifically for use in
CAN(L) B
The HGM6400 mode must be configured engine ECU :Cummins ISB
14.4 DETROIT DIESEL DDEC III / IV

HGM6400 Detroit NOTES
TERMINAL connector
Use to control
a 30A external
Fuel relay output slave relay to
power the
DDEC ECU
starter solenoid.
CAN GND -
Connect at one end only.
CAN(H) CAN(H)
CAN(L) CAN(L)
The HGM6400 mode must be configured engine ECU :generic J1939
14.5 DEUTZ EMR2

Deutz Vehicle
HGM6400
side (F) NOTES
TERMINAL
connector
Use to control
a 30A external
slave relay to
Fuel relay output supply DC
battery power
to pin 14. Fuse
at 16 amps.
starter solenoid.
Connects directly to battery
- 1
negative
CAN GND - Screen for the J1939 cable.
CAN(H) 12
CAN(L) 13
The HGM6400 mode must be configured engine ECU :VolvoEDC4
14.6 JOHN DEERE

John Deere
HGM6400
21-pin Deutsch NOTES
TERMINAL
connector
G = Switched ECU power,
Fuel relay output G,J
J = Ignition
Start relay output D Start
CAN GND -
CAN(H) V
CAN(L) U
The HGM6400 mode must be configured engine ECU :john Deere
14.7 MTU MDEC

Fitted to MTU series 2000 and series 4000 engines.
HGM6400
MDEC X1 NOTES
TERMINAL
Fuel relay output BE1 Run input of MDEC
Start relay output BE9 Start input of MDEC
CAN GND E
J1939 + Use only screened 120
impedance cable approved
CAN(H) G
specifically for use in CANbus
applications.
J1939 - Use only screened 120
CAN(L) F
applications.
The HGM6400 mode must be configured engine ECU :mtu-MDEC-303
14.8 PERKINS
Engines in the Perkins range are fitted with the ADEM3 or ADEM4 Engine
control module. This system allows engine control and diagnostics via the
J1939 link.
Perkins engines fitted with the ADEM3 / ADEM4: 2306 2506 1106 2806
(This list is not exhaustive, contact Perkins for further details)
Perkins
HGM6400 Customer
NOTES
TERMINAL interface
connector
Powers up ECU and enables
Fuel relay output 1,10,15,33,34
the injectors.
starter solenoid.
CAN GND -
120 impedance cable
CAN(H) 31
120 impedance cable
CAN(L) 32
The HGM6400 mode must be configured engine ECU :Perkins
14.9 SCANIA
Scania engines fitted with the S6 ECU: DC9 DC 12 DC 16
This list is not exhaustive, contact Scania for further details
The functions of the S6 coordinator are built within the DSE controller
negating the need to fit this device to the engine controller.
HGM6400 Scania EMS
NOTES
TERMINAL B1 connector
Fuel relay output 3 Ignition U15
starter solenoid.
CAN GND -
CAN(H) 9 J1939 + Use only screened
120 impedance cable
120 impedance cable
CAN(L) 10
The HGM6400 mode must be configured engine ECU :Scania
14.10 VOLVO EDC3

Fitted to Volvo Penta engine types: TAD1240, TAD1241, TAD1242
(This list is not exhaustive, contact Volvo Penta for further details)
Volvo TAD12
HGM6400 “Stand alone
NOTES
TERMINAL connector”
terminal
Fuel relay output H TAD12 STOP input.
Start relay output E TAD12 START input.
Using PC configuration
software select the relevant
Aux output P
engine and configure “aux
output” to be “ECU POWER”
Volvo TAD12
HGM6400 Data bus
NOTES
TERMINAL Connector
terminal
CAN GND -
120 impedance cable
CAN(H) 1
120 impedance cable
CAN(L) 2
The HGM6400 mode must be configured engine ECU :Volvo
14.11 VOLVO EDC4

Fitted to Volvo Penta engine types : TD520, TAD520 (optional), TD720,
TAD720 (optional), TAD721, TAD722 (This list is not exhaustive, contact
Volvo Penta for further details)
Volvo EDC 4
HGM6400
connector NOTES
TERMINAL
terminal
Use to control
a 30A external
slave relay to
Fuel relay output supply DC
battery power
to pin 14. Fuse
at 16 amps.
starter solenoid.
Connects directly to battery
1
negative
CAN GND -
120 impedance cable approved
CAN(H) 12
applications.
J1939 - Use only screened 120
CAN(L) 13
applications.
The HGM6400 mode must be configured engine ECU :VolvoEDC4
14.12 VOLVO-EMS2
Fitted to Volvo Penta engine types : TAD734, TAD940, TAD941, TAD1640,
TAD1641, TAD1642 (This list is not exhaustive, contact Volvo Penta for
further details)
Volvo EMS2
HGM6400
connector NOTES
TERMINAL
terminal
Using PC software select the
relevant engine and configure
aux output 1 6
“aux output 1”to be “ECU
STOP”
Using PC software select the
relevant engine and configure
aux output 2 5
“aux output 2”to be “ECU
POWER”
3 DC Supply negative
4 DC Supply positive
CAN GND -
CAN(H) 1(Hi)
applications.
CAN(L) 2(Lo)
applications.
The HGM6400 mode must be configured engine ECU :Volvo-EMS2
14.13 BOCSH
Fitted to Yuchai BOCSH engine.
HGM6400 42-pin NOTES
TERMINAL connector
Fuel relay output 1.40 Ignition U15
- Connects directly to engine
Start relay output
starter solenoid.
CAN GND - Screen for the J1939 cable.
CAN（H） 1.35 J1939 + Use only screened
CAN（L） 1.34 J1939 - Use only screened
Batteries 2-pin connector

Negative of 1 DC Supply negative
batteries
Positive of 2 DC Supply positive
batteries
The HGM6400 mode must be configured engine ECU ：BOCSH.

15 INSTALLATION
The controller is designed to panel installation mode, and it is fixed by clamps
when it is installed. The overall dimension and panel tapping dimension are given
as follows:

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HGM6410/6420 AUTO START MODULE

HGM6410/6420 Auto Start Module ISSUE 2008-8-10 Version 1.0 Page 3 of 45

HGM6400 Series generator controller uses micro-processing technique which

2 PERFORMANCE AND CHARACTERISTICS

◆ Configurable single phase 2 wires or three phase 3 wires or three phase 4

◆ Control protection: Automatic start/stop, load transfer and alarming of

◆ Five channel analog inputs, may joint with Resistive-type temperature/

◆ Functions including RTC(real time clock) and hours count;

◆ Display of generator cumulated electric energy;

◆ Security password-protected programming levels.

◆ Several crank success conditions are optional;

◆ Power supply range is wide, accommodating to different starting battery

◆ All parameters use digital modulation, abandoning analog modulation using

◆ Modular configuration design, inserted type connection terminals, flush type

HGM6410/6420 Auto Start Module ISSUE 2008-8-10 Version 1.0 Page 5 of 45

HGM6410/6420 Auto Start Module ISSUE 2008-8-10 Version 1.0 Page 6 of 45

4.1 LCD DISPLAY

operating the next page button.

4.1.1 STATUS PAGE

System in Stop mode Now, System in stop mode, Mains normal,

System in Manual mode Now, System in stop mode, Gens on load.

4.1.2 INSTRUMENT PAGE

HGM6410/6420 Auto Start Module ISSUE 2008-8-10 Version 1.0 Page 7 of 45

exemple : Engine speed

Now, Engine speed is 1500RPM.

Note: push to chenge the item.

4.1.3 ALARMS PAGE

Exemple: ECU alarm

HGM6410/6420 Auto Start Module ISSUE 2008-8-10 Version 1.0 Page 8 of 45

Note: push to chenge the item.

4.2 KEY FUNCTION

Down key At a page, change item from up to down

Page key Push , circularly display Status page, Instrument

HGM6410/6420 Auto Start Module ISSUE 2008-8-10 Version 1.0 Page 9 of 45

4.3 AUTOMATIC OPERATION

This mode is activated by pressing the pushbutton. An LED indicator beside

4.4 MANUAL OPERATION

●HGM6420: This manual mode is activated by pressing the pushbutton.

This manual test mode is activated by pressing the pushbutton. An LED

the pushbutton will initiate the start sequence.

HGM6410/6420 Auto Start Module ISSUE 2008-8-10 Version 1.0 Page 11 of 45

In manual mode, generator take load or no load depend on pushbutton /

●Hgm6410: This manual mode is activated by pressing the pushbutton. An

pressing the pushbutton will initiate the start sequence.

The start sequence is similar as the above.

In above process, pressing key will bring the generator to a stop.

In manual mode, generator take load or no load depend on pushbutton

5.1 WARNING ALARM /PRE-ALARM

Warning alarms is shown as the below:

OVERSPEED, if the engine speed exceeds the pre-alarm trip a warning is

GENERATOR HIGH FREQUENCY, if the module detects a generator output

GENERATOR LOW FREQUENCY, if the module detects a generator output

GENERATOR HIGH VOLTAGE if the module detects a generator output voltage

GENERATOR LOW VOLTAGE if the module detects a generator output voltage

GENERATOR HIGH CURRENT, if the module detects a generator output current

AUXILIARY INPUTS, if an auxiliary input has been configured as a warning the

GENERATOR HIGH FREQUENCY if the module detects a generator output

GENERATOR LOW FREQUENCY, if the module detects a generator output

GENERATOR HIGH VOLTAGE if the module detects a generator output voltage