User Manual: HSC960 Genset Controller
User Manual: HSC960 Genset Controller
User Manual: HSC960 Genset Controller
GENSET CONTROLLER
USER MANUAL
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HSC960 GENSET CONTROLLER USER MANUAL
CONTENT
1 OVERVIEW .........................................................................................................................................6
2 PERFORMANCE AND CHARACTERISTICS ....................................................................................7
3 SPECIFICATION .................................................................................................................................9
4 OPERATION......................................................................................................................................10
4.1 KEY FUNCTIONS.......................................................................................................................10
4.2 INDICATOR LIGHT..................................................................................................................... 11
4.3 AUTO START/STOP OPERATION.............................................................................................12
4.3.1 ILLUSTRATION....................................................................................................................12
4.3.2 AUTOMATIC START SEQUENCE ......................................................................................12
4.3.3 AUTOMATIC STOP SEQUENCE ........................................................................................12
4.3.4 MANUAL START/STOP OPERATION .................................................................................13
5 PROTECTION ...................................................................................................................................14
5.1 WARNINGS ................................................................................................................................14
5.2 SHUTDOWN ALARM .................................................................................................................15
6 WIRINGS CONNECTION .................................................................................................................17
7 SCOPES AND DEFINITIONS OF CONFIGURABLE PARAMETERS .............................................20
8 PARAMETERS SETTING .................................................................................................................30
8.1 MENU ITEMS .............................................................................................................................30
8.2 PARAMETERS SETTING ..........................................................................................................30
8.3 INFORMATION ...........................................................................................................................30
8.4 LANGUAGE ................................................................................................................................30
8.5 LCD CONTRAST REGULATION ...............................................................................................30
9 THROTTLE CALIBRATION...............................................................................................................31
10 SENSOR SELECT ..........................................................................................................................32
11 COMMISSIONING ...........................................................................................................................33
12 TYPICAL APPLICATION .................................................................................................................33
13 THE CONNECTION BETWEEN CONTROLLER AND GENSET...................................................35
14 FIXING CLIPS INSTALLATION .......................................................................................................36
15 OVERALL DIMENSION AND PANEL CUTOUT .............................................................................36
16 MATTERS NEED ATTENTION OF INSTALLATION .......................................................................37
16.1 BATTERY VOLTAGE INPUT ....................................................................................................37
16.2 SPEED SENSOR INPUT .........................................................................................................37
16.3 OUTPUT AND EXPANSION RELAY ........................................................................................37
16.4 AC CURRENT INPUT...............................................................................................................37
16.5 WITHDRAW VOLTAGE TEST ..................................................................................................37
1 OVERVIEW
HSC960 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 and speed regulation. The controller adopts large liquid crystal display (LCD) and
selectable Chinese and English interface with easy and reliable operation.
HSC960 genset controllers adopt micro-processor technology with precision parameters measuring,
fixed value adjustment, time setting and set value adjusting and etc..All parameters can be configured
from front panel, or by configurable port, and also can be configured by RS485 communication interface
to adjust and monitor via PC. It can be widely used in all types of automatic genset control system with
compact structure, advanced circuits, simple connections and high reliability.
HSC960, used for single automation systems; it regulates the speed simply by adjust the throttle
opening via the driving stepper motor; auto start/stop of the unit are performed with the help of remote
signal.
Key characteristics,
——132×64 LCD with backlight, multilingual interface (including Chinese and English), pushbutton
operation;
——Suitable for 3-phase 4-wire, 3-phase 3-wire, single phase 2-wire, and 2-phase 3-wire systems with
voltage 120/240V and frequency 50/60Hz;
——Collects and shows 3-phase voltage, current, power parameter and frequency of generator.
Generator
Line voltage (Uab, Ubc, and Uca)
Phase voltage (Ua, Ub, and Uc)
Frequency Hz
Current (IA, IB, IC)
Active Power kW
Reactive Power kvar
Apparent Power kVA
Power Factor PF
Electric Energy kWh
——For generator, controller has over and under voltage, over and under frequency, over current
functions;
——Speed regulation function (via Driving Stepper Motor);
——Precision measure and display parameters about Engine,
Temperature (WT) ℃/℉ (display simultaneously)
Oil Pressure (OP) kPa/psi/bar (display simultaneously)
Fuel Level (FL) % (unit)
Speed (SPD) r/min (unit)
Battery Voltage (VB) V (unit)
Charger Voltage (VD) V (unit)
Hour count (HC) can accumulate to max. 65535 hours.
Start times can accumulate to max. 65535 times.
——Protection: automatic start/stop of the genset, ATS(Auto Transfer Switch) control with perfect failure
indication and protection function;
——ETS (Energize to Stop), idle control, preheat control and raise speed/drop speed control; in addition,
they are all relay output.
——Parameter setting: parameters can be modified while write in EEPROM storage and cannot be lost
even in case of power outage; all parameters can be configured from front panel, or by configurable
port (SG72 must be fitted) and RS485 port to adjust via PC.
——Multiple crank disconnect conditions (speed sensor, oil pressure, generating) are optional;
——Widely power supply range DC(8~35)V, suitable to different start battery voltage environment;
——All parameters used digital adjustment, instead of conventional analog modulation with normal
potentiometer, more reliability and stability;
——Fixed with metal clips;
3 SPECIFICATION
Table 3- Parameters
Items Contents
Operating Voltage DC8.0V to DC35.0V, Continuous Power Supply.
Standby: ≤2W
Power Consumption
Working: <8W (When driving stepper motor is regulating)
Alternator Input Range
3-Phase 4-Wire AC15V - AC360V (ph-N)
2-Phase 3-Wire AC15V - AC360V (ph-N)
Single-Phase 2-Wire AC15V - AC360V (ph-N)
3-Phase 3-Wire AC30V - AC620V (ph-ph)
Alternator Frequency 50Hz/60Hz
Speed Sensor Voltage 1.0V to 24.0V (RMS)
Speed Sensor Frequency 10,000 Hz (max.)
Start Relay Output 16A DC28V supply output
Fuel Relay Output 16A DC28V supply output
Auxiliary Relay Output (1) 7A DC28V supply output
Auxiliary Relay Output (2) 7A DC250V supply output
Auxiliary Relay Output (3) 7A DC250V supply output
Auxiliary Relay Output (4) 7A DC250V supply output
Steady-state Speed Governing Rate <1.5%
Steady-state Speed Fluctuation Rate <0.5%
Sudden Load-on <+10%
Transient Speed Governing Rate
Sudden Load-off >-15%
Recovery Time <5s
Driving Motor DC Motor; Drive current ≤6A
Case Dimension 197mm x 152mm x 47mm
Panel Cutout 186mm x 141mm
Common Reactance Secondary Current Rated: 5A
Working Conditions Temperature: (-25~+70)°C; Humidity: (20~93)%RH
Storage Condition Temperature:(-25~+70)°C
Protection Level IP65 Gasket
Apply AC2.2kV voltage between high voltage terminal and
Insulating Intensity low voltage terminal;
The leakage current is not more than 3mA within 1min.
Net Weight 0.56kg
Manual Mode Pressing this key will set the module into Manual mode.
Auto Mode Pressing this key will set the module into AUTO mode.
Lamp Test Pressing this key will test the lamp if it is working.
4.3.1 ILLUSTRATION
Auto mode is selected by pressing the button; a LED besides the button will illuminate to
confirm the operation.
a) When the “Remote Start” signal is removed, the Stop Delay is initiated.
b) Once this “stop delay” has expired, the “Cooling Delay” is then initiated. Moreover, the generator
indicator is extinguished.
c) During “Stop Idle” Delay (if configured), idle relay is energized.
d) “ETS Solenoid Hold” delay begins, ETS relay is energized while fuel relay is de-energized.
e) "Fail to Stop Delay" begins, complete stop is detected automatically.
f) When generator is stop completely, generator is placed into its standby mode. Otherwise, fail to stop
alarm is initiated and the corresponding alarm information is displayed on LCD.
a) MANUAL START: Manual mode is selected by pressing the button; a LED besides the button
will illuminate to confirm the operation; then press button to start the genset; can detect crank
disconnect condition and generator accelerates to high-speed running automatically. With high
temperature, low oil pressure, over speed and abnormal voltage during generator running, controller
can protect genset to stop quickly. (please refer to No.3~8 of Automatic Start Sequence for detail
procedures.) Pressing button the genset will be on load after the genset is normal running.
b) MANUAL STOP: Press can stop the running generators. (please refer to No.2~6 of Automatic
Stop Sequence for detail procedures).
5 PROTECTION
5.1 WARNINGS
Warnings are not shutdown alarms and do not affect the operation of the genset. Warning alarms
does not lead to shutdown and the alarm information will be displayed on the LCD.
When controller detects shutdown alarm, it will send signal to open breaker and shuts down
generator. Besides, the alarm information will be displayed on the LCD.
6 WIRINGS CONNECTION
Cable
No. Function Remarks
Size
1 B- 2.5mm2 Connected with negative of starter battery
Connected with positive of starter battery. Max. 20A
2 B+ 2.5 mm2
fuse is recommended.
3 EM. Stop 2.5 mm2 Connected with B+ via emergency stop button
Fuel relay output; B+ is supplied by 3 terminal; rated
4 Fuel 1.5 mm2
16A
Start relay output; B+ is supplied by 3 terminal;
5 Crank 1.5 mm2
rated 16A; Connected to starter coil.
6 Aux. Output 1 1.5 mm2 B+ is supplied by 2 terminal; rated 7A
2
7 1.5 mm Always close output; rated 7A;
2
8 Aux. Output 2 1.5 mm Common terminal
2
9 1.5 mm Always open output; rated 7A;
2
10 2.5 mm
Aux. Output 3 Free contact always open; rated 7A; Details see
11 2.5 mm2
free contact output Table 9
12 Aux. Output 4 2.5 mm2
Engine Temp
65 (0-9) 8 SGX
Curve
66 Oil Pressure Curve (0-9) 8 SGX
67 Fuel Level Curve (0-5) 3 SGD
The gain is regulated during the genset is
68 Generator Poles (2-64) 4
idle running.
Temp.S Open
69 (0-2) 1 0 Indicate; 1 Warn; 2 Shutdown
Action
70 OP.S Open Action (0-2) 1 0 Indicate; 1 Warn; 2 Shutdown
Used to set the intermission of
71 Maintenance Time (0-5000)h 30
maintenance time.
0 Negative; 1 Warn; 2 Shutdown
Maintenance
72 (0-2) 0 When maintenance action is set to
Action
Negative, the alarm will reset.
0 Not used; 1 Temp sensor
73 Aux.Sensor1 Type (0-3) 0
2 Pressure sensor; 3 Level sensor
74 Aux.Sensor1 Curve (0-9) 0
When the value of external aux. sensor
75 Aux.S.1 H Warn (0-1000) 0 has exceeded this value, it will initiate
warn alarm.
When the value of external aux. sensor
Aux.S.1 H
76 (0-1000) 0 has exceeded this value, it will initiate
Shutdown
shutdown alarm.
When the value of external aux. sensor
77 Aux.S.1 L Warn (0-1000) 0 has fallen below this value, it will initiate
warn alarm.
When the value of external aux. sensor
Aux.S.1 L
78 (0-1000) 0 has fallen below this value, it will initiate
Shutdown
shutdown alarm.
The throttle opening before the genset is
79 Crank Angle (0-100)% 45
starting.
The initial opening of the throttle after the
80 Crank Disc. Angle (0-100)% 35
genset is started.
81 Idle Speed (0-6000) r/min 900 Offer standard to adjust idle speed.
The rising speed rate during the process
82 Idle Slope 0-6000 10 of genset change idle running status into
rated speed running status.
The gain is regulated during the genset is
83 Idle Gain 1-1000 500
idle running.
84 Rated Speed (0-6000) r/min 1500 Offer standard to adjust rated speed.
85 P Gain 1-3000 1100
The regulated gain when the genset is
86 I Gain 1-3000 35
running in rated speed.
87 D Gain 1-3000 1
No Items Description
0 Not Used Output port is deactivated when “Not Used” is selected.
Include all shutdown alarms and warning alarms. When there is
1 Common Alarm warning alarm only, it is not self-lock; when a shutdown alarm
occurs, it is self-lock until the alarm is reset.
Suitable for genset with electromagnet and will active after “stop idle
2 Energized to Stop
delay”. It is deactivated when the “ETS Solenoid delay” expires.
Used for engine which has idles. Close before starting and open in
3 Idle Control warming up delay; Close during stop idle delay and open when stop
is completed.
4 Preheat Control Close before starting and open before power up;
5 Close Generator When close time is 0, it‟s continuous output.
6 Reserved
7 Open ATS When close time is 0, it‟s disabled.
Close when the generator enters into Warming Up delay (close
8 Raise Speed time: warming up delay) while open when Aux. Raise Speed input is
active.
Close when the generator enters into Stop Idle delay/ Energized to
9 Drop Speed Stop delay (close time: Stop Idle delay) while open when Aux. Drop
Speed input is active.
Action when genset is normal running while deactivated when
10 Generator Run
engine speed is lower than the “crank disconnect speed”.
Close when fuel level is lower than the “Fuel Pump On” value or
when low fuel level warning input is active; Open when fuel level is
11 Fuel Pump Control
higher than the “Fuel Pump Off” and low fuel level warning input is
deactivated;
Close when the generator enters into Warming Up delay while open
12 High Speed Control
after cooling delay.
13 In Auto Mode The controller is in automatic mode.
14 Reserved
15 Reserved
16 Reserved
17 Reserved
Table 10- Defined contents of configurable input ports (All active when connect to grand (B-))
No Items Description
0 Not Used
1 High Temperature Input If these signals are active after safety on delay, shutdown alarm will
2 Low Oil Pressure Input be immediately initiated.
3 Warn Input Only warning and not shutdown if this input is active.
4 Shutdown input Shutdown alarm will be immediately initiated if this input is active.
When the genset is running normally and this signal is activated, if
there is a high temperature situation, the controller will first cool
5 WTH STOP by cool down the generator and then stop it; if the signal is deactivated and
a high temperature situation occurs, the controller will shut down the
gen-set without cooling down.
6 Generator Closed input
7 Reserved
Inhibit High Temperature When it is active, high temperature shutdown will be prohibited.
8
Stop Table8Note 1
Inhibit Low Oil Pressure When it is active, low oil pressure shutdown will be prohibited.
9
Stop Table8Note 2
10 Remote Start
NOTE:
a) There are 3 conditions to make starter disconnected with engine, that is, speed sensor, generator
frequency and oil pressure. Speed sensor and generator frequency can be used separately, oil
pressure needs speed sensor and generator frequency simultaneously for cooperation in order to
make the starter motor is separated with engine immediately and can check crank disconnect exactly.
b) Speed sensor is the magnetic equipment which be installed in starter for detecting flywheel teeth.
8 PARAMETERS SETTING
Start the controller, then press to enter into the parameters setting menu, see fig 1 below:
a) Set Parameters
b) Language
c) Information
When entering password interface, input password (1234) can set parts of the parameter items in
Form 8, and input password (0318) can set all of the parameter items in Form 8. If there is need to set
more parameters (e.g. Voltage, Current Calibration), please contact the factory.
CAUTION:
——Please change the controller parameters when generator is in standby mode only (e. g. Crank
disconnect conditions selection, auxiliary input, auxiliary output, various delay), otherwise,
shutdown and other abnormal conditions may happen.
——Over voltage set value must be higher than under voltage set value, otherwise over voltage and
under voltage condition may occur simultaneously.
——Over speed set value must be higher than under speed set value, otherwise over speed and under
speed condition may occur simultaneously.
——Please set the generator frequency value as low as possible when cranking, in order to make the
starter be separated quickly as soon as possible.
——Auxiliary input 1~5 could not be set as same items; otherwise, there are abnormal functions.
However, the auxiliary output 1~4 can be set as same items.
——If need to shut down after cooling, please set any digital input as “WTH STOP by cool”, then connect
this input port to ground soundly.
8.3 INFORMATION
Note: In this interface, press will display the auxiliary inputs and outputs status.
8.4 LANGUAGE
Simultaneously press and or can adjust contrast in order to make LCD more
distinct. The range of regulation is 0-7.
Note: In setting process, press in any time will break the parameter setting off and return back to main
interface.
9 THROTTLE CALIBRATION
a) Press key to enter into the parameter setting manue, and select controller parameter
settings to access to the throttle calibration page after entering the correct password “8881”.
b) Press key to start calibrating the throttle, and choose Start and End positions through
and keys.
c) When Start position has been selected, controller will drive throttle to close completely (if the
throttle moves in opposite direction, exchange the DC motor wiring of the trottle), and then
a) When reselect sensors, the sensor curve will be transferred into the standard value. For example, if
temperature sensor is SGH (120°C resistor type), its sensor curve is SGH (120°C resistor type); if
select the SGD (120°C resistor type), the temperature sensor curve is SGD curve.
b) When there is difference between standard sensor curves and using sensor, user can chose
“Defined sensor”, and input defined sensor curve.
c) When input the sensor curve, X value (resistor) must be input from small to large, otherwise,
mistake occurs.
d) If select sensor type as “None”, temperature, pressure and fuel level which LCD displays will be
“---”.
e) If there is no pressure sensor only pressure low alarm switch, user must set the sensor as “None”,
otherwise, maybe pressure low alarm shutdown occurs.
f) The headmost or backmost values in the vertical coordinates can be set as same as below,
11 COMMISSIONING
12 TYPICAL APPLICATION
CAUTION! Expand relay with high capacity in start and fuel output is recommend.
Note: Care should be taken not to over tighten the screws of fixing clips.
CUT OUT
HSC960 controller can suit for widely range of battery voltage DC(8~35)V. Negative of battery must
be connected with the engine shell. The diameter of wire which from power supply to battery must be
over 2.5mm2. If floating charge configured, please firstly connect output wires of charger to battery‟s
positive and negative directly, then, connect wires from battery‟s positive and negative to controller‟s
positive and negative input ports in order to prevent charge disturbing the controller‟s normal working.
Speed sensor is the magnetic equipment which be installed in starter and for detecting flywheel teeth.
Its connection wires to controller should apply for 2 cores shielding line. The shielding layer should
connect to No. 17 terminal in controller while another side is hanging in air. The else two signal wires are
connected to No.17 and No.18 terminals in controller. The output voltage of speed sensor should be
within AC(1~24)V (effective value) during the full speed. AC12V is recommended (in rated speed). When
install the speed sensor, let the sensor is spun to contacting flywheel first, then, port out 1/3 lap, and lock
the nuts of sensor at last.
All outputs of controller are relay contact output type. If need to expand the relays, please add
freewheel diode to both ends of expand relay‟s coils (when coils of relay has DC current) or, add
resistance-capacitance return circuit (when coils of relay has AC current), in order to prevent disturbance
to controller or others equipment.
The current input of HSC960 Controller must be connected with external common reactance whose
secondary current must be 5A, meanwhile, the phase and voltage of common reactance must be correct
otherwise the sampling current and active power may be incorrect.
Note: When there is load current, the common reactance secondary side mustn’t be open.
When controller had been installed in control panel, if need the high voltage test, please disconnect
controller‟s all terminal connections, in order to prevent high voltage into controller and damage it.
17 FAULT FINDING
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