Deep Sea to SmartGen Generator Controller Cross Reference: Model Matching and Feature Mapping

Deep Sea Electronics (DSE) and SmartGen are two of the most widely used generator controller brands in the world. DSE controllers, manufactured in the United Kingdom, are the standard choice in many European, Middle Eastern, and African generator packages. SmartGen controllers, manufactured in China, are supplied as standard or optional equipment on thousands of generator sets from Chinese manufacturers, and are increasingly used as cost-effective replacements in service and upgrade projects. When a controller fails, or when a generator set is upgraded with remote monitoring and automatic transfer functions, the service engineer and the buyer must identify the correct controller model, understand the feature differences, and complete the wiring and configuration change. This guide provides a practical Deep Sea to SmartGen controller cross reference with model matching tables, feature mapping, wiring guidance, and B2B sourcing advice.

The tables in this guide compare the DSE and SmartGen controller families by function, list the typical equivalent models, and explain the feature differences that affect the replacement decision. The installer must verify the generator control requirements, the ATS system, the communication protocol, and the existing wiring before replacing a controller, because the controllers are not plug-and-play interchangeable even when the functions match.

Understanding Generator Controller Families

DSE controller families include the 6000 series (basic manual and auto start), the 7000 series (automatic mains failure, ATS, and advanced protection), the 8000 series (advanced monitoring and synchronization), and the 8610/8620 (AMF with remote monitoring). SmartGen controller families include the HGM100 series (manual start), the HGM400 series (auto start), the HGM6000 series (advanced AMF), the HGM6100/6200 series (AMF with remote monitoring), and the HSC900 series (ATS controllers). The function class of the controller determines the equivalent models, and the comparison must be made within the same class: a basic auto-start controller cannot be replaced by an advanced synchronization controller without additional hardware, and an advanced AMF controller should not be downgraded to a basic model.

The controller’s function class is defined by the following capabilities: manual and electric start, automatic mains failure (AMF), automatic transfer switch (ATS) control, load sharing and synchronization, remote monitoring via RS485/Modbus or Ethernet, and the number of digital and analogue inputs and outputs. The cross-reference tables below map the DSE and SmartGen models by these capabilities.

Controller Model Cross Reference Table

The following table shows the typical equivalent models between the DSE and SmartGen families. The equivalence is by function class, not by exact hardware compatibility.

The DSE7320 and the SmartGen HGM6110/HGM6120 are the most commonly compared pair, because both are AMF controllers for single generator sets with ATS control. The feature differences are detailed in the next section.

Feature Mapping: DSE7320 vs SmartGen HGM6110/HGM6120

When replacing a DSE7320 with a SmartGen HGM6120, or vice versa, the service engineer must map the features and inputs. The table below compares the key features of the two controllers:

The replacement requires a complete rewiring of the control panel, because the terminal numbering, the input functions, and the relay assignments differ between the brands. The service engineer must create a new wiring diagram from the controller manual, configure the new controller for the engine and alternator parameters, and test the start, stop, mains failure, and transfer sequences. The Deep Sea controller supply channel and the SmartGen controller supply channel both provide the controllers, the configuration tools, and the technical support.

Wiring and Configuration Differences

The physical wiring of a DSE controller and a SmartGen controller is different: the terminal numbers, the connector layout, the input assignments, and the relay outputs are not compatible. The replacement process includes the following steps. First, record the existing wiring diagram and the function of each terminal of the old controller. Second, identify the engine sensors (magnetic pickup, coolant temperature, oil pressure), the fuel solenoid, the starter, the battery charger, the ATS signals, and the remote start signal. Third, map each function to the corresponding terminal of the new controller using the new controller’s manual. Fourth, build the new wiring loom or adapt the existing loom with the correct terminal identification. Fifth, configure the new controller’s parameters: engine type, pickup frequency, temperature and pressure sensor types, mains and generator voltage settings, protection limits, and ATS logic. Sixth, test the complete sequence: manual start, auto start on mains failure, load transfer, retransfer, and shutdown.

The configuration software is brand-specific: DSE uses the DSE Configuration Suite (with a USB cable or a DSE USB adapter), and SmartGen uses the SmartGen PC tool (with a USB or RS232 cable). The configuration file from one brand cannot be imported into the other, so the parameters must be entered manually in the new controller. The installer should keep a copy of the new configuration file and the wiring diagram in the panel documentation.

Function Class Selection Guide

The correct replacement controller is selected by the function class, not by the model name. Use the following guide to choose the controller class:

• Manual start only: choose a DSE6110 or SmartGen HGM100 equivalent. The operator starts and stops the generator manually, with basic protection.
• Auto start on remote signal: choose a DSE6120 or SmartGen HGM410 equivalent. The controller starts and stops the generator on a remote contact, with engine instrumentation.
• Auto mains failure with ATS control: choose a DSE7020/DSE7320 or SmartGen HGM6110/HGM6120 equivalent. The controller detects mains failure, starts the generator, transfers the load, and retransfers.
• AMF with remote monitoring: choose a DSE7310/DSE7410 or SmartGen HGM6120N/HGM6160N equivalent. The controller adds RS485 Modbus, remote start/stop, and alarm reporting.
• Multiple genset parallel and synchronization: choose a DSE8610/DSE8620 or SmartGen HGM6510/HGM6600 equivalent, with the system designed by an experienced engineer.

For a standard standby generator with an ATS, the AMF class is the correct choice, and the DSE7320 or the SmartGen HGM6120 provides the required functions. For a generator used only as manual backup without an ATS, the auto start class is sufficient and costs less.

Compatibility with ATS and Other Control Equipment

The controller must be compatible with the automatic transfer switch in the system. The ATS may be a contactor type, controlled by the controller’s relays, or a motorized changeover switch, controlled by a separate ATS controller. In the first case, the AMF controller directly operates the contactors through its relay outputs; in the second case, the AMF controller sends the start signal to the ATS controller, which manages the changeover. The replacement controller must support the same ATS control mode, and the changeover logic must be configured correctly. The controller must also be compatible with the engine’s speed sensor (magnetic pickup), the fuel solenoid, the battery charger, and the remote monitoring system, and the voltage and frequency settings must match the site supply.

For parallel systems, the controllers must support the synchronization and load-sharing protocol (e.g., CAN bus or digital load share), and the replacement must match the existing system architecture. The SmartGen HGM6600 series and the DSE8610 series both support advanced parallel operation, but the wiring, the CAN connection, and the configuration are different, so the system design must be updated.

Sourcing B2B Generator Controllers and Spare Parts

Generator controller replacements are sourced by service companies, panel builders, and distributor networks. The buyer should specify the function class, the engine type, the ATS type, the communication requirement, and the display requirement, and the supplier should confirm the exact model and the configuration options. The supplier should provide the controller manual, the wiring diagram support, and the configuration software access. For service companies that support mixed fleets, a supplier covering both DSE and SmartGen, with stock of the common models and the configuration accessories, simplifies the procurement. The generator spare parts supplier can consolidate the controller, the sensors, the ATS components, and the engine parts in a single shipment, with the warranty and the technical documentation.

When replacing a controller, the buyer should also check the related spare parts: the speed sensor, the temperature and pressure sensors, the fuel solenoid, the battery charger, and the ATS contactors, because a failing controller is often accompanied by a failing sensor. The speed sensor and the battery charger are the most common associated failures, and both should be tested during the replacement project.

Wiring and Harness Considerations for Controller Replacement

The physical replacement of a Deep Sea controller with a SmartGen controller, or the upgrade in the opposite direction, requires a careful review of the wiring and the harness. The two brands use different connector layouts, different terminal numbering, and different input and output configurations, so a direct plug-and-play replacement is rarely possible. The harness must be re-pinned or replaced, and the installer should map each function between the two controllers before the work begins: the start signal, the fuel relay, the crank signal, the magnetic pickup input, the voltage and current sensing, the alarm inputs, and the outputs for the governor and the actuator. The speed sensor (magnetic pickup) wiring is particularly important, because the polarity and the shield connection affect the speed measurement and the protection functions.

The controller replacement also affects the power supply and the auxiliary equipment. The DC supply rating, the battery charger interface, and the alarm relay ratings should be verified against the new controller specification. The installer should use the manufacturer’s wiring diagrams and should document the new harness for the site file. The Deep Sea controller supplier and the SmartGen controller supplier both provide the wiring documentation and the technical support for the conversion.

Remote Monitoring, Communications and Feature Mapping

The modern generator controller is also a communication device: it reports the generator status to the remote monitoring system, sends the alarm notifications, and records the event history. Deep Sea and SmartGen controllers differ in the communication interfaces and the protocols, and the feature mapping must cover the communication functions in addition to the control functions. The Deep Sea controller range includes the 7000 and 8000 series with the integrated communication options, while the SmartGen controller range includes the HGM series with the similar remote monitoring capability. The replacement project should verify that the new controller supports the communication protocol used by the existing monitoring platform, or should plan the upgrade of the platform at the same time.

The feature mapping table below summarizes the functional correspondence between the popular controller series:

The generator controller functions are the same in principle across the two brands: the automatic start, the protection, the monitoring, and the communication. The difference is in the implementation, and the replacement project should verify each function in the test before the controller is placed in service. The generator spare parts supplier should provide the controllers, the harnesses, the sensors, and the technical support for the complete conversion.

Cost Analysis and Lifecycle Considerations for Controller Replacement

The decision to replace a Deep Sea controller with a SmartGen controller, or to upgrade within the same brand, should be based on the total cost of the lifecycle, not only the controller price. The lifecycle cost includes the controller price, the harness and the installation cost, the configuration and the commissioning cost, the training cost for the operators, the spare parts and the service cost, and the downtime cost during the changeover. The SmartGen controllers are often priced below the equivalent Deep Sea models, and the local technical support and the fast delivery can reduce the project cost further, but the buyer should verify that the new controller meets all the required functions and the communication requirements before the savings are calculated. The changeover project should also consider the standardization benefit: a fleet that uses a single controller brand reduces the training, the spares stock, and the documentation complexity.

The controller replacement is also a point of the technical upgrade. The older Deep Sea controllers have the limited communication and monitoring functions, while the newer SmartGen and Deep Sea models provide the remote monitoring, the event logging, and the integration with the building management systems. The upgrade should be planned with the future requirements: the parallel operation, the load management, the remote start, and the telemetry should be selected in the new controller specification, and the speed sensor, the governor, the actuator, and the battery charger should be reviewed as part of the project, because the controller performance depends on the quality of the connected sensors and the actuators. The upgrade project should end with the full load test, the parallel test if applicable, and the training for the operators, and the records should be added to the generator file.

The lifecycle plan should also define the spare parts strategy for the controller: the control modules, the display, the relays, and the sensors are the serviceable items, and the critical site should stock the complete spare controller or the exchange unit. The Deep Sea controller supplier and the SmartGen controller supplier provide the exchange and the repair services, and the generator spare parts supplier should coordinate the controller project with the engine and the alternator parts supply to minimize the downtime and the logistics cost.

For the panel builders and the service companies that work with both brands, the training and the documentation are part of the conversion project. The technicians should be trained on the new controller configuration software, the wiring diagram, and the troubleshooting procedures, and the training records should be kept for the quality system. The site documentation should be updated with the new controller model, the wiring diagram, the configuration file, and the spare parts list, and the operators should be briefed on the new display and the alarm messages. The changeover should be scheduled with the maintenance window, and the risk of the changeover failure should be mitigated by the tested fallback procedure. These project management details determine the success of the controller replacement as much as the controller specification itself, and the supplier should support the complete process from the selection to the commissioning.

Frequently Asked Questions