Deif SGC 420 User manual
User manual
Single Genset Controller
SGC 420/421
DEIF A/S · Frisenborgvej 33 · DK-7800 Skive · Tel.: +45 9614 9614 · Fax: +45 9614 9615 · [email protected] · www.deif.com
Document no.: 4189341227A
1. Introduction
1.1 About SGC 420/421................................................................................................................................................................................................................... 4
1.2 Key functions............................................................................................................................................................................................................................... 4
1.3 Product overview....................................................................................................................................................................................................................... 4
1.4 Passwords..................................................................................................................................................................................................................................... 5
1.5 Overview of controller buttons...........................................................................................................................................................................................6
1.6 Legal information.......................................................................................................................................................................................................................6
2. Safety instructions
2.1 General safety instructions.................................................................................................................................................................................................. 7
2.2 Electrical safety...........................................................................................................................................................................................................................7
2.3 In operation safety.....................................................................................................................................................................................................................7
3. Technical specifications
3.1 Terminals........................................................................................................................................................................................................................................ 8
3.2 Power supply................................................................................................................................................................................................................................8
3.3 Genset voltage and frequency measurements..........................................................................................................................................................9
3.4 Genset current measurements...........................................................................................................................................................................................9
3.5 Earth Leakage/Fan Current Monitoring......................................................................................................................................................................... 9
3.6 Mains voltage and frequency measurement............................................................................................................................................................ 10
3.7 Digital inputs..............................................................................................................................................................................................................................10
3.8 Analogue resistive sensor inputs.................................................................................................................................................................................. 10
3.9 Analogue inputs used as digital inputs.......................................................................................................................................................................11
3.10 Analogue voltage/current input.................................................................................................................................................................................... 12
3.11 Site battery inputs................................................................................................................................................................................................................ 12
3.12 Magnetic pick-up (MPU) input........................................................................................................................................................................................12
3.13 Digital outputs........................................................................................................................................................................................................................ 13
3.14 Actuator outputs (SGC 421 only)................................................................................................................................................................................. 13
3.15 D+ Charger alternator.........................................................................................................................................................................................................13
3.16 Sensor common point........................................................................................................................................................................................................14
3.17 Communication ports.........................................................................................................................................................................................................14
4. Installation
4.1 Dimensions.................................................................................................................................................................................................................................15
4.2 Mounting in panel....................................................................................................................................................................................................................15
4.3 Terminal details........................................................................................................................................................................................................................ 16
4.4 Typical wiring diagrams.......................................................................................................................................................................................................18
5. Monitoring mode
5.1 Monitoring mode......................................................................................................................................................................................................................20
6. Configuration mode
6.1 Configuration mode............................................................................................................................................................................................................... 22
6.2 Configurable parameters.................................................................................................................................................................................................... 22
6.2.1 Configurable parameters..............................................................................................................................................................................................22
6.2.2 Module..................................................................................................................................................................................................................................23
6.2.3 Digital inputs...................................................................................................................................................................................................................... 25
6.2.4 Analogue inputs................................................................................................................................................................................................................25
6.2.5 Outputs.................................................................................................................................................................................................................................32
6.2.6 Timers...................................................................................................................................................................................................................................32
6.2.7 Generator............................................................................................................................................................................................................................33
6.2.8 Mains.................................................................................................................................................................................................................................... 36
USER MANUAL 4189341227A UK Page 2 of 86
6.2.9 Engine.................................................................................................................................................................................................................................. 37
6.2.10 Maintenance....................................................................................................................................................................................................................40
6.2.11 Password ID.................................................................................................................................................................................................................... 40
6.2.12 Rotary actuator (SGC 421 only)............................................................................................................................................................................. 41
6.3 Digital input source selection...........................................................................................................................................................................................42
6.4 Digital output source selection........................................................................................................................................................................................43
7. Running modes
7.1 Auto mode...................................................................................................................................................................................................................................46
7.2 Manual mode..............................................................................................................................................................................................................................50
7.3 Start and stop sequences...................................................................................................................................................................................................52
8. Load detection
8.1 Load detection in Auto mode........................................................................................................................................................................................... 54
8.2 Load detection in Manual mode......................................................................................................................................................................................54
9. Features
9.1 About Features......................................................................................................................................................................................................................... 55
9.2 Auto config exit mode...........................................................................................................................................................................................................55
9.3 Load histogram........................................................................................................................................................................................................................ 55
10. Alarms
10.1 Alarms.........................................................................................................................................................................................................................................56
11. Modbus communication protocol
11.1 About the Modbus communication protocol.........................................................................................................................................................60
11.2 Modbus connection details............................................................................................................................................................................................. 60
11.3 Modbus functions.................................................................................................................................................................................................................60
12. Modbus communication settings
12.1 Modbus communication settings................................................................................................................................................................................ 61
12.2 Register map (function code 03).................................................................................................................................................................................. 61
12.3 Register map (function code 16).................................................................................................................................................................................. 68
13. Engine communication
13.1 Introduction to engine communication.................................................................................................................................................................... 69
13.2 Default settings......................................................................................................................................................................................................................69
13.3 Supported engines...............................................................................................................................................................................................................69
13.4 Engine values on the display......................................................................................................................................................................................... 69
13.5 Engine communication settings...................................................................................................................................................................................70
13.6 Generic J1939......................................................................................................................................................................................................................... 71
13.7 Wiring.......................................................................................................................................................................................................................................... 72
14. CAN communication
14.1 About the CAN communication protocol................................................................................................................................................................ 73
14.2 CAN communication structure......................................................................................................................................................................................73
14.3 CAN packet structure......................................................................................................................................................................................................... 83
15. Troubleshooting
15.1 Troubleshooting.................................................................................................................................................................................................................... 84
USER MANUAL 4189341227A UK Page 3 of 86
1. Introduction
1.1 About SGC 420/421
This document presents information necessary for operating DEIF's SGC 420/421 genset controllers.
SGC 420/421 are modern and feature rich genset controllers with user friendly HMI and full graphics LCD. The controllers come with
a highly versatile software. Extensive inputs and outputs support a wide variety of industry standard features in diesel/gasoline
genset applications.
SGC 420/421 offer Site battery monitoring which significantly reduces fuel consumption. The controllers support Shelter temperature
monitoring, Auto (AMF, Remote start /stop, Cyclic and Exercise mode), Manual and Test modes.
SGC 421 includes electronic governing for engines with mechanical fuel systems. With a rotary actuator as add-on for air/fuel
charge control, SGC 421 can perform electronic governing of the engine within ISO 8528 class G3 limits.
The DEIF Smart Connect software offers flexibility to configure each individual input and output for a specific function or application.
All parameters can also be configured on the controller.
The powerful micro controller in SGC 420/421 supports a range of complex features, for example:
• LCD display
• True RMS voltage and current monitoring
• RS-485 base communication
• Monitoring of engine and alternator parameters
• Fully configurable inputs and outputs for a wide range of functions
1.2 Key functions
• Genset controller with configurable inputs:
◦ Nine digital inputs
◦ Eight analogue inputs (configurable as digital inputs)
• Seven digital outputs
• Auto (Site battery backup, AMF, Remote start/stop, Cyclic and Exercise) modes, Manual and Test modes
• Site battery monitoring
• Shelter temperature monitoring
• Mains partial healthy detection
• Real time clock
• Fuel theft alarm
• Cyclic timer
• RPM sensing using genset’s output frequency
• Backlit full graphics display
• Integrated electronic governor controller (SGC 421 only)
1.3 Product overview
Features Specifications
Digital switch input 9
Analogue resistive inputs 5
Analogue current/voltage inputs 2
USER MANUAL 4189341227A UK Page 4 of 86
Features Specifications
Differential input (±60 V DC) for Site battery voltage Yes
Mains voltage input (AMF) Yes
DG alternator voltage input, D+ charging alternator I/O Yes
Digital outputs 7
Event logs Yes
USB port for PC based configuration Yes
RS-485 for Modbus communication Yes
Operating battery supply voltage (with -32 V reverse protection) 8 to 32 V DC
Operating temperature range (°C) -20 to 65
Protection class with gasket (included) IP65
Warning auto clear enable/disable Yes
Fuel reference selection input Yes
Analogue 0-5 V input for Speed bias input for E-gov from Load sharing module Yes*
E-gov actuator output Yes*
*Note: SGC 421 only.
1.4 Passwords
The controller is protected from set-up changes with a four digit password.
There are two password levels:
Level Access Factory setting
1 Full access (read and write) 0123
2 Limited access (read) 1111
The passwords can be changed on the controller:
1. Go to Configuration mode.
2. Log on with password level 1.
3. Use the Up and Down buttons to go to Configuration ID, select with the Start button.
4. Use the Up and Down buttons to go to the password to be changed, select with the Start button.
5. Use the Up and Down buttons to choose the first digit for the new password, select with the Start button.
6. Repeat for the next three digits.
7. When all four digits are chosen, the display shows
PASSWORD 1
Password changed
USER MANUAL 4189341227A UK Page 5 of 86
1.5 Overview of controller buttons
Shutdown Alarm
Warning Alarm
Notification
1. Display
2. Mains contactor latching button
3. Stop/Config button
4. Start button
5. Menu navigation up button
6. Menu navigation down button
7. Genset contactor latching button
8. Acknowledge button
9. Mode selection button
1.6 Legal information
Warranty
WARNING
The controller is not to be opened by unauthorised personnel. If the controller is opened anyway, the warranty will be lost.
Disclaimer
DEIF takes no responsibility for installation or operation of the generator set. If there is any doubt about how to install or operate the
engine/generator controlled by the SGC controller, the company responsible for the installation or the operation of the set must be
contacted.
DEIF A/S reserves the right to change any of the contents of this document without prior notice.
The English version of this document always contains the most recent and up-to-date information about the product. DEIF does not
take responsibility for the accuracy of translations, and translations might not be updated at the same time as the English document.
If there is a discrepancy, the English version prevails.
Copyright
© Copyright DEIF A/S 2020. All rights reserved.
USER MANUAL 4189341227A UK Page 6 of 86
2. Safety instructions
2.1 General safety instructions
This document includes important instructions that should be followed during installation and maintenance of the controller.
Installation and maintenance must only be carried out by authorised personnel, and always in accordance with all applicable state
and local electrical codes. Efficient and safe operation of the controller can be acquired only if the equipment is correctly operated,
configured and maintained.
The following notations found in this document can indicate potentially hazardous conditions to the operator, service personnel or
the equipment.
NOTE Highlights an essential element of a procedure to ensure correctness.
CAUTION
Indicates a procedure or practice, which could result in damage or destruction of equipment, if not strictly observed.
WARNING
Indicates a procedure or practice, which could result in injuring personnel or loss of life, if not followed correctly.
2.2 Electrical safety
• Electric shock can cause severe personal injury or death.
• Ensure that the genset is grounded before performing any installation or service.
• Generators produce high electrical voltages, and direct contact with it can cause fatal electrical shock. Prevent contact with
terminals, bare wires, connections, etc., while the generator and related equipment are running. Do not tamper with interlocks.
• To handle the maximum electrical current, the wires used for electrical connections and wirings must be of appropriate size.
2.3 In operation safety
• Before installing the controller, ensure that all power voltage supplies are positively turned off at the source. Disconnect the
generator’s battery cables and remove the panel fuse to prevent accidental start up. Disconnect the cable from the battery post,
indicated by a NEGATIVE, NEG, or (–) first. Reconnect the negative cable last. Failure to do so will result in hazardous and
possibly fatal electrical shock.
• Remove the electric power supply before removing the controller or touching other electrical parts.
• Use extreme caution when working on electrical components. High voltage can cause injury or death.
• With floors of metal or concrete, use rubber insulation mats placed on dry wood platforms when working near the generator or
other electrical equipment.
• Do not wear damp clothing (particularly wet shoes) or allow skin surface to be damp when handling electrical equipment.
• Do not operate any electrical device or wires while standing in water, while barefoot, or while hands or feet are wet. It may result
in severe electrical shock.
• Do not wear jewellery. Jewellery can cause a short circuit within electrical contacts and cause shock or burning.
In case of an accident caused by electric shock, immediately shut down the electrical power source. If this is not possible, try to
release the victim from the live conductor. Avoid direct contact with the victim. Use a non-conducting object (for example a rope or a
wooden stick) to release the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical
help.
USER MANUAL 4189341227A UK Page 7 of 86
3. Technical specifications
3.1 Terminals
The SGC 420/421 use two types of terminal blocks:
Connectors of 5.08 mm pitch Connectors of 10.16 mm pitch
Table 3.1 Terminals
Connector type Pitch Male (on controller) Female (mating part) Quantity
3-pin 5.08 mm 5447366 5441977 1
4-pin 5.08 mm 5447379 5448637 1
5-pin 5.08 mm 5447382 5448640 1
6-pin 5.08 mm 5441919 5441964 1
8-pin 5.08 mm 5441935 5441951 1
9-pin 5.08 mm 5447395 5448653 1
10-pin 5.08 mm 5447405 5448666 1
4-pin 10.16 mm 5474274 5453499 2
3.2 Power supply
Category Specification
Controller terminals 1 (Ground)
2 (Battery or DC+)
Supply voltage range Nominal voltage: 12/24 VDC
Operating range: 8 to 32 V DC
Cranking drop out period 50 ms
Maximum reverse voltage protection -32 V DC
Measurement accuracy (battery voltage) ±1 % full scale
Resolution 0.1 V
Maximum current consumption ~ 200 mA, 12/24 V DC (excluding the current load for the DC outputs and E-
Gov)
Standby current consumption 180 mA, 12 V DC
140 mA, 24 V DC
USER MANUAL 4189341227A UK Page 8 of 86
3.3 Genset voltage and frequency measurements
Category Specifications
Controller terminals
54 (Neutral)
55 (L3)
56 (L2)
57 (L1)
Measurement type True RMS
Phase-to-neutral voltage 32 to 300 V AC RMS
Phase-to-phase voltage 32 to 520 V AC RMS
Voltage accuracy ±1 % of full scale for phase-to-neutral
±1.5 % of full scale for phase-to-phase
Voltage resolution 1 V AC RMS for phase-to-neutral
2 V AC RMS for phase-to-phase
Frequency range 5 to 75 Hz
Frequency accuracy 0.25 % of full scale
Frequency resolution 0.1 Hz
NOTE For single phase applications, it is mandatory to connect the genset phase and neutral cables to the genset controller's
phase L1 and neutral terminals.
3.4 Genset current measurements
Category Specifications
Controller terminals
43 and 42 (for phase L1)
45 and 44 (for phase L2)
47 and 46 (for phase L3)
Measurement type True RMS
Maximum CT secondary current rating 5 A
Burden 0.25 VA
Measurement accuracy ±1.4 % of nominal
3.5 Earth Leakage/Fan Current Monitoring
Category Specifications
Controller terminals 48 and 49
Measurement type True RMS
Maximum CT secondary current rating 5 A
Burden 0.25 VA
Measurement accuracy ±1.4 % of nominal
NOTE Follow the recommended phase sequence while connecting the current transformer (CT).
USER MANUAL 4189341227A UK Page 9 of 86
3.6 Mains voltage and frequency measurement
Category Specifications
Controller terminals
50 (Neutral)
51 (L3)
52 (L2)
53 (L1)
Measurement type True RMS
Phase-to-neutral voltage 32 to 300 V AC RMS
Phase-to-phase voltage 32 to 520 V AC RMS
Voltage accuracy ±2 % of full scale for phase-to-neutral
±2.5 % of full scale for phase-to-phase
Voltage resolution 1 V AC RMS for phase-to-neutral
2 V AC RMS for phase-to-phase
Frequency range 5 to 75 Hz
Frequency accuracy 0.25 % of full scale
Frequency resolution 0.1 Hz
NOTE For single phase applications, it is mandatory to connect the mains phase and neutral cables to the genset controller's
phase L1 and neutral terminals.
3.7 Digital inputs
Category Specifications
Controller terminals 33, 34, 35, 36, 37, 38, 39, 40, 41
Number of inputs 9
Type Negative sensing (connect to ground for activation)
Software configurable options Emergency stop, Remote start/ stop, and more (see Controller overview,
Configurable parameters in the User manual for more details).
3.8 Analogue resistive sensor inputs
Category Specifications
Controller terminals
11 (Oil pressure)
12 (Fuel)
13 (Temperature)
14 (Aux 1)
15 (Aux 2)
Number of inputs 5
Type Ratio-metric sensing
Range 10 to 5000 Ω
Open circuit detection Above 5.5 kΩ
Measurement accuracy ±2 % of full scale (up to 1000 Ω)
USER MANUAL 4189341227A UK Page 10 of 86
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