SmartGen MGC120 Petrol Genset Controller User Manual

SmartGen MGC120 Petrol Genset Controller

PETROL GENSET CONTROLLER USER MANUAL

SmartGen — make your generator smart SmartGen Technology Co., Ltd. No.28 Jinsuo Road Zhengzhou Henan Province P. R. China Tel: +86-371-67988888/67981888/67992951 +86-371-67981000 (overseas) Fax: +86-371-67992952 Web: www.smartgen.com.cn/ www.smartgen.cn/ Email: sales@smartgen.cn

All rights reserved. No part of this publication may be reproduced in any material form (including photocopying or storing in any medium by electronic means or other) without the written permission of the copyright holder. Applications for the copyright holder’s written permission to reproduce any part of this publication should be addressed to SmartGen Technology at the address above. Any reference to trademarked product names used within this publication is owned by their respective companies. Smart SmartGen Technology res erves the right to change the contents of this document without prior notice.

Table 1 Version Hsitory

2019-02-22

| ****

1.2

| Fixed the logic description for air flap control;

Fixed the default value for stepping motor as 250Hz;

Fixed the stepping motor wirings in typical application diagram and add notes for it.

2022-08-18| 1.3| Updated company logo and manual format.
 |  |

OVERVIEW

MGC120 Petrol Genset Controller belongs to AMF module, which is suitable for single petrol genset automation and monitoring control. It can realize auto start/stop genset, alarm protection and ATS switching control functions by data measuring. The controller applies LED display and button-press operation. Most parameters can be adjusted from the front pannel of the controller and all parameters can be changed by PC sofware via LINK port. With simple operation, reliable performance, and compact structure and convenient installation advantages it can be widely used in various automation system for petrol genset.

PERFORMANCE AND CHARACTERS

——Able to collect single phase voltage of Mains and generator, which is suitable for 50Hz/60Hz AC system;
——Switchable display parameters:

• Mains voltage (V)
• Generator voltage (V)
• Engine cylinder temperature (°C)
• Generator frequency (Hz)
• Battery voltage (V)
• Accumulated running time (H)

——Equipped with Mains electricity monitoring function and AMF function;
——Protection function for generator under/over volt, under/over frequency, low oil pressure, and start failure protection functions; when they occur, LED indicates alarm types, and controller conducts shutdown protection;
——Using stepper motor and programmable outputs to control air flap;
——Speed signals derive from ignition coil primary (diode needs to be in series);
——Able to choose from three crank disconnection conditions (generator frequency, speed, and speed + gen frequency);
——Equipped with 2 digital inputs with defaults: remote start input and low oil pressure input;
——Equipped with 3 stationary relay outputs (fuel output, start output and ignition control);
——Equipped with 2 programmable transistor outputs, which can be set as common alarm output, ETS control, idle speed control, preheating control, GCB close output, MCB close output and air flap blocking output;
——Equipped with LINK communication port (SmartGen SG72 adapter applied): it is able to realize controller parameter settings, remote monitoring control and firmware upgrade functions.
——Digital tube and LED display with button-press operation;
——Silicone panel and buttons with higher ability to adapt to extremely high/low temperature;
——Screen protection adopts hard screen acrylic material;
——Modular structure design, anti-flaming ABS plastic housing, embedded installation way; compact structure and easy installation.

Table 2 Technical Parameters

Standby mode: <0.5W

AC Volt Input: Mains Single Phase

Generator Single Phase

| ****

AC 30V – AC 360V (ph-N) AC 30V – AC 360V (ph-N)

Alternator Frequency| 50Hz/60Hz
Starter Relay Output| 10A DC30V DC B+ supply output
Fuel Relay Output| 10A DC30V DC B+ supply output
Ignition Relay Output| 10A DC30V DC B- supply output
Flexible Transistor Output| 1A    connecting with DC B+ supply output
Stepper Motor Recommended| 24BYJ48-12V(stepper angle 5.625° reduction ratio 16:1)
Overall Dimensions| 95mm x 86mm x 46.5mm
Panel Cutout| 78mm x 66mm
Working Temperature| (-25~+70)°C
Working Humidity| (20~93)%RH
Storage Temperature| (-25~+70)°C
Protection Level| Front panel IP55

Insulation Strength

| Apply AC2.2kV voltage between high voltage terminal and low

voltage terminal and the leakage current is not more than 3mA within 1min.

Weight| 0.15kg

OPERATION

CONTROL PANEL

Fig.1 Front Panel Description

Start indic
ator: it is always light from genset start to normal running, and in other status, the indicator will extinguish. Stop indicator: it flashes when genset enter enters stop procedureprocedure; it is always light in the process of stop and in other status the indicator will extinguish.

INDICATOR DESCRIPTION

Table 3 Indicator Description

NOTES

1. Generator indicator: light-on when generator is normal running; flash when generator is abnormal; light-off whengenerator is unavailable;
2. Mains indicator: light-on when mains is normal; flash when mains is abnormal; light-off when mains is unavailable.

Table 4 Button Description

| ****

Stop/Reset

| Stop the running genset both in manual mode and in auto mode, and change controller to the manual mode.

In stop process, re-press this button to stop generator immediately. In alarm status, press this button to reset any shutdown alarms.

In stop mode, press this button for more than 3s to test if the digital tube and LED indicators are OK.

In parameter setting process, press this button to exit the setting.

****| Auto/Manual Value Increase| Press this key, if auto indicator lights on, controller is in auto mode; if auto indicator lights off, controller is in manual mode.

In parameter setting, press this key to downturn or increase the values.

****| Start

Value Decrease

| In manual mode, press this key to start genset.

In parameter setting, press this key to upturn or decrease the values.

|

Down

| Changeover the display contents of digital tube.

Enter the parameter setting by pressing it for more than 3 second. In parameter setting, it confirms the set information.

AUTO START/STOP OPERATION

Press key and the indicator besides lights on, which means generator is in auto mode

Auto Start Sequence

1. When remote start signal is active or mains failure (over/under voltage) delay is expired, “StartDelay” time is initiated;
2. When start delay is over, preheating relay outputs (if configured), “preheat delay” is initiated;
3. After the above delay, the fuel relay outputs, and one second later, the start relay outputs;During the starting time if the genset fails to start, fuel relay and start relay stop outputting,enter “Crank Rest Time” and wait for next start;
4. If the genset fails to start during the set starting attempts, LED indicator will display startfailure;
5. f the genset starts successfully during the starting attempts, it enters “Safety On” time, duringwhich low oil alarm types are inactive; After “Safety On” time, it enters “Start Idle Delay” (ifconfigured);
6. During “Start Idle Delay”, under frequency and under volt alarms are inhibited; When this delayis over, “Warming Up Delay” is initiated (if configured);
7. After the “warming up delay”, genset will enter into Normal Running status. If genset voltage orfrequency is abnormal, controller alarm shutdown will be initiated.

Auto Stop Sequence

1. When remote start input is invalid or mains normal delay is expired, “Stop Delay” time isinitiated;
2. Once this “stop delay” has expired, the “Cooling Down Delay” is then initiated;
3. When “Stop Idle Delay” (if configured) starts, idle speed relay outputs;
4. When “ETS Solenoid Hold” begins, ignition control relay is energized and fuel relay isde-energized; Genset enters standby status.

NOTE

1. Press stop key in auto start status, generator will stop and enter into manual mode simultaneously.
2. Total running timer starts when generator meets crank disconnection conditions, meanwhile, the last decimalpoint of the digital tube flashes to indicate that the generator is running.

MANUAL START/STOP OPERATION

Press key, indicator besides lights off, which means generator is in manual mode

Manual start: press   to start genset (Please refer to 4.4,a), 2~7). If low oil pressure and abnormal voltage occur during the running process, controller shall protect it to stop quickly.

Manual Stop: press and it can stop the running genset (Please refer to 4.4,b), 2~4).

AIR FLAP CONTROL

Engine cylinder temperature sensor is applied

• Before the genset starts up, If the cylinder temperature is below the set cylinder temperaturelimit of air flap blocking, the air flap is at the position of full blocking; if it is between thetemperature limits of air flap dropping and air flap opening, then the air flap is at the position ofhalf opening; if it is above the temperature limit of air flap opening, the air flap shall be at theposition of full opening;
• In the cranking process when the starting countdown goes more than half, the air flap opens1/3 at current position; when start delay is finished but starting is not completed, next pre-startcylinder temperature estimation starts;
• After successful start, the air flap opens 1/3 again at present position; when the cylindertemperature is over the temperature limit of air flap opening, the air flap shall open completely

Engine cylinder temperature sensor is applied, or sensor is opened circuit:
Before genset starts up, air flap is at the position of full blocking. For the first starting attempt, theair flap opens from full blocking and it shall open completely in 2s; for the second starting attempt, the air flap opens from the position of half blocking and in 2s it opens completely; if the two attempts both failed, the opening time for air flap becomes 10s. After successful start, air flap opens 1/3 at present position and meanwhile after air flap blocking delay the air flap opens completely.

ATS SWITCHING CONTROL

Auto mode: if Mains is available, ATS switches it to Mains; if Mains is abnormal and genset is running normally, ATS switches it to generator. In other status, ATS lies at the Mains position. Manual mode: if generator close input is active, then when genset is running normally, the generator breaker shall be closed; if generator close input is inactive or the generator is not running normally, then the Mains breaker shall be closed

NOTE: To use ATS control function, the programmable output ports shall be configured as GCB close output and MCB close output, and meanwhile input port shall be configured as GCB close input.

PROTECTION

1. Generator overvoltage shutdown: alarm occurs when the controller detects generator voltageexceeds overvoltage limit and the duration exceeds the generator abnormal delay value.
2. Generator under voltage shutdown: the controller detects after genset normal running andwhen generator voltage is below under voltage limit and the duration exceeds the generatorabnormal delay value alarm occurs.
3. Generator over frequency shutdown: alarm and shutdown occur when generator frequency isabove over frequency limit and duration exceeds over frequency shutdown delay.
4. Generator under frequency shutdown: the controller detects after generator-set normalrunning and alarm and shutdown occur when generator frequency is below under frequencylimit and duration exceeds under frequency shutdown delay.
5. Low oil pressure input shutdown: the controller detects after safety on delay, alarm andshutdown occur when low oil pressure input is active and lasts for 2s.
6. Fail to start: alarm occurs when start still fails after pre-set start attempts.

CONNECTION

Table 5 Terminal Connection Description

Max. 20A fuse is recommended.

3| Crank Output| 1.5mm2| B+ power is supplied by terminal 2, rated 10A.

Connected with start coil of starter.

4| Fuel Output| 1.5mm2| B+ power is supplied by terminal 2, rated 10A.
5| Ignition Control| 1.5mm2| B- power is supplied by termainal 1, rated 10A.
6| Remote Start Input| 1.0mm2| Aux.      input       1,      discrete signal        input,

Ground-connected is active (B-).

7| Oil Pressure Input| 1.0mm2| Aux.  input  2,  discrete  signal  input, Ground

connected is active (B-).

8| Engine Temp. Sensor| 1.0mm2| Connected with resistor-type temperature sensor.
9| Aux. Output 1| 1.0mm2| B- power is supplied by termainal 1, rated 1A.
10| Aux. Output 2| 1.0mm2| B- power is supplied by termainal 1, rated 1A.

11

| ****

Speed Signal Input

| ****

1.0mm2

| Connected with ignition coil primary, and diode in series is needed. (Over rated 1A, reverse durable

voltage is over 1000V.)

12| Motor S22| ****

Apply stepper motor self-contained wires

| Connect with blue cable of stepper motor.
13| Motor S21| Connect with yellow cable of stepper motor.
14| Motor S12| Connect with pink cable of stepper motor.
15| Motor S11| Connect with orange cable of stepper motor.
16| Mains  Phase  Voltage

(L-N) Monitoring Input

| 1.0 mm2| Connect with mains output port (2A fuse is

recommended).

17| 1.0 mm2
No.| Function| Cable Size| Note
---|---|---|---
18| Generator             Phase

Voltage                    (L-N) Monitoring Input

| 1.0 mm2| Connect with generator voltage output port (2A fuse is recommended).
19| 1.0 mm2

NOTE: The COM (red cable) for stepper motor shall be connected to battary positive

DEFINITION AND RANGE OF PARAMETERS
PARAMETER SETTING CONTENTS AND RANGE

Table 6 Controller Parameters Configuration

abnormal

to normal or from normal to abnormal is used for ATS to switch.

P01| Mains         Abnormal

Delay

| (0-3600)s| 5

P02

| Mians Under Volt Value| ****

(30-360)V

| ****

184

| If the voltage sample is lower than it, under voltage of Mains is considered; When it is set

30V, under voltage signal shall not be detected.

P03

| Mains      Over    Volt Value| ****

(30-360)V

| ****

276

| If the voltage sample is higher than it, over voltage of Mains is considered; When it is set

360V, overvoltage signal shall not be detected.

P04

| ****

Transfer Delay

| ****

(0-99.9)s

| ****

1.0

| It is the time interval for transferring switch from mains open to generator close or from

generator open to mains close.

P05

| ****

Mains Options

| ****

(0-1)

| ****

0

| 0: AMF (mains abnormal start enabled in auto mode)

1: Display Only (only monitoring mains voltage)

P06| Start Delay| (0-3600)s| 1| Time duration from remote start signal is

active to engine startup.

P07| Stop Delay| (0-3600)s| 1| Time duration from remote start signal is

deactivated to engine stop.

P08

| ****

Start Attempts

| ****

(1-10)

| ****

3

| It is maximum start attempts when starter fails

to    start.    When   it    reaches     set    attempts controller shall send out start failure signal.

P09| Cranking Time| (3-60)s| 8| Time for starter to be energized every time.
P10| Crank Rest Time| (3-60)s| 10| The waiting time before second power up when

engine start fails.

P11| Safety On Delay| (1-60)| 10| Alarms for low oil pressure, under frequency

and under voltage are deactivated.

P12| Warming Up Time| (0-3600)s| 10| Warming-up time before breaker close after

high speed running for genset.

P13| Cooling Time| (3-3600)s| 10| Radiating time before genset stop after genset

is unloaded.

P14| ETS Solenoid Hold| (0-120)s| 20| The  time  for  Stop      electromagnet to  be

energized before genset stop.

generator

close. 0s stands for constant output.

P16| Engine Cylinders| (1-2)| 1| It is used for judging starter disconnection

conditions and detecting engine speed.

P17

| ****

Generator Poles

| ****

(2-64)

| ****

2

| Number of engine poles. This value is used for

calculating engine speed when controller is without speed sensor .

P18| Generator Abnormal

Delay

| (0-20.0)s| 10.0| Alarm delay for generator under/over voltage.

P19

| ****

Generator Over Volt limit for Shutdown

| ****

(30-360)V

| ****

264

| When generator voltage is higher than this threshold and lasts for the set generator abnormal delay, then it shall consider over voltage and shutdown alarm will be initiated. (No detection for over volt signals if it is set as

360V).

P20

| ****

Generator Under Volt limit for Shutdown

| ****

(30-360)V

| ****

196

| When sample voltage falls below this threshold and lasts for the delay time, it is considered under voltage and shutdown alarm shall be initiated.

(No detection for under volt signals if it is set

as 30V).

P21

| ****

Under      Frequency Shutdown

| ****

(0-75.0)Hz

| ****

45.0

| When generator frequency falls below this threshold and lasts for the delay time, then it is considered under frequecy and shutdown alarm

signal will be initiated.

P22

| ****

Over        Frequency Shutdown

| ****

(0-75.0)Hz

| ****

57.0

| When generator frequency is over than this threshold and lasts for the delay time, then it is considered over frequecy and shutdown alarm

signal will be initiated.

P23| Under      Frequency

Shutdown Delay

| (0-60)s| 10| Delay value of generator under frequency.
P24| Over        Frequency

Shutdown Delay

| (0-60)s| 2| Delay value of generator over frequency.

P25

| ****

Air    Flap     Blocking Delay

| ****

(0-60)s

| ****

5

| It is available for not applying engine cylinder temp. Sensor. After successful start, the air flap shall keep at the present position for such

time and then shall open completely.

P26| Air    Flap     Blocking

Cylinder Temp.

| (0-200)°C| 30| In the starting process if cylinder temperature

is lower than this value, air flap shall close.

P27

| ****

Air      Flap       Open Cylinder Temp.

| ****

(0-200)°C

| ****

60

| After genset starts successfully, if cylinder temperature is higher than this value, air flap shall open. If it is between the blocking value

and opening value, the air flap opens 1/2.

P28| Aux. Output 1| (0-9)| 5| Default function: generator close output. For

details please see Table 8.

details please see Table 8.

P30| Power     On    Mode

Selection

| (1-2)| 1| 1: Manual Mode

2: Auto Mode

P31| Module Address| (1-254)| 1| Communication address with PC software.
P32| Password| (0-9999)| 0318| Controller password.

P33

| ****

Crank Disconnection Conditions

| ****

(0-2)

| ****

2

| 0: Generator frequency

1: Engine Speed

2: Generator frequency + engine speed

It is used for judging crank disconnection condition.

P34

| Disconnection Engine Speed| ****

(0-3000)r/min

| ****

840

| When engine speed is over this value, it is considered that start is successful and starter

will be disconnected.

P35

| ****

Disconnection     Gen. Frequency

| ****

(0-30.0)Hz

| ****

14.0

| In the starting process when generator frequency exceeds this value, it is considered that start is successful and starter will be

disconnected.

P36

| ****

Temp Sensor Types

| ****

(0-4)

| ****

0

| 0: Not used

1: PT100

2: NTC-1K

3: Reserved

4: Users-defined resistor curves

Table 7 HMI Configurable Parameters

advance before starter is powered on.

2| Start Idle Time| (0-3600)s| 0| Idling speed running time when genset is

starting.

3| Stop Idle Time| (0-3600)s| 0| Idling speed running time when genset is

stopping.

4| Stepper          Motor

Frequency

| (100-500)Hz| 250| Rotation steps for the motor per second.

5

| ****

Stepper                      Motor Steps

| ****

(0-2000)

| ****

128

| Step numbers needed for motor rotating 90°; calculation        formula: 360            reduction ratio/( step angle4);

For example: 128 = 360 16/(5.6252*4).

6| Ignition Output| (0-1)| 0| 0: Output when stop

1: Output when start

7| Fuel Output| (0-1)| 0| 0: Fuel Output

1: ETS Output

8| Digital Input 1| (0-6)| 1| Configure the function of controller terminal 6;

Default: remote start input, for details please

9

| ****

Digital Input 2

| ****

(0-6)

| ****

2

| Configure the function of controller terminal 7; Default: low oil pressure input, for details

please     see Table 9.

NOTE: when parameter settings are condcuted via PC software, it is needless to entry the password if default password (0318) has not been changed; if it has been changed and it is the first time to conduct parameter settings via PC software, it is needed to entry the module password on the password screen

DEFINABLE CONTENTS OF PROGRAMMABLE OUTPUT PORTS

Table 8 Definable Contents of Programmable Output Ports

untill alarm reset.
2| ETS Control| It is used for some gensets with stop electromagnet. Pull-in occurs when

“stop idle speed” ends. Open occurs when “ETS Delay” ends.

3

| ****

Idle Speed Control

| It is used for engines with idling speed. Pull-in occurs when the engine starts. Open occurs when it enters “Warming-up”. Pull-in occurs in the stopping process of idling speed and open occurs when the genset stops

completely.

4| Preheating Control| Close before start, open before energization.
5| Gen Close Output| Generator close outputs when generator is normally running.
6| Mains Close Output| Mains close outputs after mains normal delay ends.
7| Air Flap Choke| It outputs when engine starts, and it disconnects when engine has started.
8| Reserved|
9| Reserved|

DEGINED CONTENTS OF PROGRAMMABLE INPUT PORTS

Table 9 Definable Contents od Programmable Input Ports (All GND(B-) Active)

active.
2| Low Oil Pressure Input| After safety on delay is finished, generator shutdown alarm occurs

immidiately if this signal is active.

3

| ****

Gen Close Input

| In manual mode, and under the condition that genset is normally

running, generator close outputs when this sigal is active, otherwise, mains close outputs.

4| Reserved|
5| Reserved|
6| Reserved|

CONTROLLER FUNCTION SETTINGS

Under standby status, press for 3s, it will enter password entry screen (Fig.3). At this moment the first digital flashes.

Press and the flashing number adds 1; Press and it decreases 1. After correct setting, press to move.

For the 2/3/4 digitals it is the same as a) above

After the password is passed it will enter parameter setting screen (Fig.4). At this moment itdisplays the serial number of the setting item. Press and the setting item goes down

Press and the setting item goes up

Fig.4 Parameter Serial Number Screen

Press and it enters the setting status of the current parameter value. Press or and the parameter value can be adjusted. After adjustment press and the data shall be saved. Press and the parameter setting screen shall exit.

NOTES

• Please change the parameters (such as crank disconnection condition selections, digital inputs, outputconfigurations and all delays) in standby status, otherwise alarm shutdown or other fault information mayoccur.
• For the serial numbers of setting items please refer to the serial numbers in Table 6.
• Over voltage threshold must be larger than under voltage threshold, otherwise under/over voltages may occurat the same time.
• Generator frequency shall be set as low as possible when the engine has started, so that the start motor canseparate as soon as possible.

COMMISSIONING

Before official operation, the follow ing checks are suggested to do

• Check all the c onnections are correct a nd wire diameter is properproper.
• Make sure that the controller DC power has fuse, and it is correctly connected to the positive and negative of start battery.
• Take proper action to prevent engine from crank ing success fully (e. g. Remove the connection wire of gas valve). Make sure everything is correct. Connect starter battery power, and the controller shall conduct the procedure procedure;
• Press “ Start” button, and genset will start. After the set cranking times, controller will send signal of Start Failure; and then p ress “ Stop” to reset controller.
• Recover the action of prevent ing engine from crank ing success fully (e. g. Recover the wire of gas valve)valve). Press Start button again, and genset will start. If everything goes well, genset will \ normalnormally running. During this period , please observe engine’s running statestate, AC generator’s voltage and frequency carefully . If there is something unusual , stop the running genset and check all wire connectionconnections according to this manual.
• For a ny other questions please contact with SmartG en service personnel.

1. S11, S12, S21, S22 are separately connected with orange wire, pink wire, yellow wire, and blue wire, andstepper motor COM (red wire) shall be connected with the battery positive.
2. erminal 11 must be connected in series with diode. Diode capacity shall be over 1A, and reversepressure-standing value shall be over 1000V.
3. The maximum incoming current for programmable output 1 and output 2 shall be 1A.

1. Programmable output 1 shall be set “Generator Close Output”.
2. S11, S12, S21, S22 shall be connected separately with the stepper motor orange wire, pink wire, yellow wireand blue wire; stepper motor COM (red wire) shall be connected with battery positive.
3. Terminal 11 must be in series with diode. Diode capacity shall be over 1A and the reverse pressure-standingvalue shall be over 1000V.

INSTALLATION

FIXING CLIPS

— The controller is panel-embedded design and the panels are fixed by clips in installation.
— Twist the fixing clip screw anticlockwise until it reaches proper position.
— Pull the fixing clip backwards (towards the back of the module), ensuring two clips are right inside their allotted slots.
— Turn the fixing clip screws firmly clockwise until they are fixed on the panel

NOTE: Pay attention to that the clip screws shall not be turned too tightened

OVERALL AND CUTOUT DIMENSIONS

Battery Voltage In put

MGC1 20 controller is only suitable for DC 12 V battery voltage environment . battery Negative must be connected with the engine shell soundly. The diameter of the wire which connects controller power B+/B B- and battery positive/negative must be over (or eq ual to) 1. 5mm 2. If floating charge r is configured, please firstly connect charger output wires to battery’s positive and negative directly, and then connect battery’s positive and negative and controller power’s positive and negative individually by anothe another wires in order to prevent charge charger disturbing the controller’s normal working.

With stand Voltage Test

When the controller has been installed in the control panel, if the high vo ltage test is conductedconducted, please disconnect controller’s all terminals in order to prevent high voltage entering controller and damag ing it.

FAULT FINDING

Table 10 Fault Finding List

Controller no response with power

| Check starting batteries;

Check controller connecting wirings; Check DC fuse.

Genset shutdown| Check AC generator voltage.
Low    oil    pressure     alarm     after

successful start

| Check oil pressure sensor and the wirings.
Shutdown alarm in running process| Check related switches and the wirings according LED indicators.

Start failure

| Check fuel circuit and its connections; Check starting batteries;

Check speed sensor and its connections;

Refer to engine manual.

Non response for starter| Check starter connections;

Check starting batteries.

Air        flap         stepper             motor contrarotation or rotation only in

one direction

| ****

Check connection wiring order of stepper motor.

References

• smartgen.cn/
• smartgen.com.cn/

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