Smartgen MGC100 User manual

MGC100

PETROL GENSET CONTROLLER

USER MANUAL

 
MGC100 Petrol Genset Controller User Manual Page 2 of 16 
CONTENT 
OVERVIEW ......................................................................................................................................................5 
PERFORMANCE AND CHARACTERS ............................................................................................................5 
SPECIFICATION..............................................................................................................................................6 
OPERATION ....................................................................................................................................................7 
1 PUSHBUTTONS .......................................................................................................................................7 
2 CONTROL PANEL AND ICON DECRIPTION ...........................................................................................7 
2.1 CONTROLLER PANEL.......................................................................................................................7 
2.2 ALARM ICON INDICATION...............................................................................................................8 
2.3 PANEL INDICATOR...........................................................................................................................8 
3 OPERATION .............................................................................................................................................8 
3.1 REMOTE START SEQUENCE............................................................................................................8 
3.2 REMOTE STOP SEQUENCE..............................................................................................................8 
3.3 MANUAL START/STOP....................................................................................................................9 
PROTECTION..................................................................................................................................................9 
CONNECTION .............................................................................................................................................. 10 
DEFINITION AND RANGE OF PARAMETERS ............................................................................................. 11 
PARAMETERS SETTING ............................................................................................................................. 14 
1 PARAMETERS REGULATION ............................................................................................................... 14 
2 RESTORE FACTORY SETTINGS........................................................................................................... 14 
3 ELIMINATE ACCUMULATED TIME...................................................................................................... 14 
CASE DIMENSIONS..................................................................................................................................... 15 
TYPICAL APPLICATION............................................................................................................................ 16 
FAULT FINDING......................................................................................................................................... 16 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

MGC100 Petrol Genset Controller User Manual Page 3 of 16

Chinese trademark

English trademark

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

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.

SmartGen Technology reserves the right to change the contents of this document without prior notice.

Table 1 Version Hsitory

Date

Version

Content

2015-06-29

1.0

Original release.

2016-12-12

1.1

1. Modify AC default, over speed threshold, crank disconnect conditions,

crank disconnect speed, safety running delay and programmable

outputs default ;

2. Add gen under/over frequency protection functions;

3. Add gen under/over frequency threshold and under/over frequency

shutdown delay parameter.

4. Programmable output ports add “Air Flap Choke” function

2022-07-22

1.2

Update company logo and manual format.

MGC100 Petrol Genset Controller User Manual Page 4 of 16

Table 2 Notation Clarification

Sign

Instruction

NOTE

Highlights an essential element of a procedure to ensure correctness.

CAUTION!

Indicates a procedure or practice, which, if not strictly observed, could result in

damage or destruction of equipment.

WARNING!

Indicates a procedure or practice, which could result in injury to personnel or loss

of life if not followed correctly.

MGC100 Petrol Genset Controller User Manual Page 5 of 16

1OVERVIEW

MGC100 Petrol Genset Controller is designed for start and protection of single genset. It allows

manual and remote start/stop, data measurement, alarm indication, shutdown protection functions.

The controller fit with LED display, button-press operation, and it achieves precise measurement of

various parameters, protection and control of genset. All of parameters can be configured from front

panel. The controller which can be widely used in data display and fault protection of a number of small

diesel and petrol genset with easy operation, reliable work, compact structure and simple connections.

2PERFORMANCE AND CHARACTERS

——Multifunctional Nixie tube display, press button to operate;

Switchable displayed battery:

Generate voltage V

Generate frequency Hz

Accumulated running time (maximum is 9999h) H

Battery voltage V

——There is a red LED on the panel for displaying working and alarm status;

——Chose to control Petrol Genset or Diesel Genset via connection;

——Suitable for 3-phase 4-wire, 3-phase 3-wire, 2-phase 3-wire, single phase 2-wire (120V/240V)

systems with frequency 50/60/Hz;

——Protection function for gen under/over volt, over speed, fail to stop, emergency stop, high

water temp, low oil pressure; when in protection, LED indicates alarm, and goes shutdown

protection;

——Generator rotate speed can derive from gen frequency or speed sensor;

——4-way digital input (high water temperature input, low oil pressure input, remote input, urgency

stop input;

——2 relay output (start output, fuel output) and the fuel output is programmable output port;

——1 flexible transistor output can be set to preheat output, alarm output, energize to stop output

and idle output, etc;

——Three start success conditions (speed sensor, generator, speed sensor+ generator) can be

chosen;

——Parameter setting: parameters can be modified and stored in internal EEPROM memory and

cannot be lost even in case of power outage; all of them can be adjusted using front panel of

the controller;

——Modular design, anti-flaming ABS plastic enclosure, embedded installation way; compact

structure with easy mounting.

MGC100 Petrol Genset Controller User Manual Page 6 of 16

3SPECIFICATION

Table 3 Technical Parameters

Item

Contents

Working Voltage

DC9.0V to 18.0V, continuous power supply (suitable for DC12V

system)

Overall Consumption

Regular working:<1W (Standby mode:<0.4W)

AC Volt Input:

3-phase 4-wire

3-phase 3-wire

2-phase 3-wire

Single phase 2-wire

AC 30V –AC 360V (ph-N)

AC 50V –AC 620V (ph-ph)

AC 30V –AC 360V (ph-N)

AC Frequency

50Hz/60Hz

Speed Sensor Voltage

1.0V to 24V(effective value)

Speed Sensor Frequency

10000Hz(Max)

Start Relay

7A DC12V power supply

Fuel Relay

7A DC12V power supply

Flexible Transistor

1A DC12V connect to (B+)

Overall Dimensions

105.8mm x 61mm x 36.6mm

Panel Cutout

92mm x 44mm

Working Temperature

(-25~+70)°C

Working Humidity

(20~93)%RH

Storage Temperature

(-25~+70)°C

Protection Level

IP55 Gasket

Insulation

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

voltage terminal; The leakage current is not more than 3mA within

1min.

Weight

94g

MGC100 Petrol Genset Controller User Manual Page 7 of 16

4OPERATION

4.1 PUSHBUTTONS

Table 4 Keys Description

Icon

Definition

Explain

Stop/-

Stop the running genset.

In stop status, press it to stop generator immediately.

In stop status, press it to reset any shutdown alarm.

In stop status, press it for more than 2s to test if the nixie tube and panel

indicator are normal.

In setting menu, upturn or decrease parameter value (it can be

double-clicked).

In setting menu, press it for more than 3s to exit this menu.

Page/Confirm

Switch display contents of nixie tube in normal status.

Pressing it for more than 3 seconds entry the parameter configuration

menu.

In setting menu, press this button to modify and save value.

Run/+

Manual start in stop status.

In setting menu, downturn or increase parameter value (it can be

double-clicked).

4.2 CONTROL PANEL AND ICON DECRIPTION

4.2.1 CONTROLLER PANEL

Fig.1 Controller Panel

MGC100 Petrol Genset Controller User Manual Page 8 of 16

4.2.2 ALARM ICON INDICATION

Table 5 Alarm Icon Indication

Icon

Descripiton

Icon

Descripiton

Emergency Stop Alarm

Over Speed Alarm

High Temp Alarm

Low Oil Pressure Alarm

Fail to Start Alarm

Over/Under Volt Alarm

4.2.3 PANEL INDICATOR

Working status indicator: in start delay duration, start indicator will blink; in other working duration,

the indicator will always light; in stop status, the indicator will extinguish.

Stop status indicator: in stop process, stop indicator will blink; in stop duration, the indicator will

always light; in start status, the indicator will extinguish.

4.3 OPERATION

4.3.1 REMOTE START SEQUENCE

a) When remote start signal is active, “Start Delay” timer is initiated;

b) When start delay is over, preheat relay energizes (if configured), “Preheat delay” is initiated;

c) After the above delay, the Fuel Relay is energized, and then one second later (if configured),

the Start Relay is engaged and the Preheat Relay switch off. If genset fails to fire during this

cranking attempt then the fuel relay and start relay are disengaged for the pre-set rest period;

“Crank Rest Time” begins and wait for the next crank attempt (after the “Crank Rest Time”

delay start for 3s, preheat and ETS start to output; after “Crank Rest Time” finished, ETS switch

off, and after fuel output for 1s, preheat switch off);

d) Should this start sequence continue beyond the set number of attempts, the fail to start

indicator will be illuminated;

e) In case of successful crank attempt, the “Safety On” timer is activated, allowing Low Oil

Pressure Input and Under Pressure are inhibited. As soon as this delay is over, “start idle”

delay is initiated (if configured);

f) During “Start Idle” delay, under pressure alarm is inhibited. When this delay is over, “Warming

Up” delay is initiated (if configured);

g) After the “Warming Up” delay, genset will enter into Normal Running status.

4.3.2 REMOTE STOP SEQUENCE

a) After remote start, when remote start signal is invalid, “Stop Delay” timer is initiated;

b) Once this “stop delay” has expired, the “Cooling Delay” is then initiated;

c) During “Stop Idle” Delay (if configured), idle relay is energized;

d) “ETS Solenoid Hold” begins, ETS relay is energized while fuel relay is de-energized;

e) “Fail to Stop Delay”begins, complete stop is detected automatically;

f) Genset is placed into standby mode after its “After Stop Time”.

MGC100 Petrol Genset Controller User Manual Page 9 of 16

4.3.3 MANUAL START/STOP

a) Press to start genset. It will detect complete start and accelerate to high-speed running

automatically. With high temperature, low oil pressure, over speed and volt abnormal during

genset running, controller can protect it to stop quickly (Please refer to Start Sequence b-g).

b) Press to stop the running genset (Please refer to Stop Sequence b-f).

NOTE:

a) The genset can be stopped manually in remote start status; at this time, remote input is inhibited and it will be

active when remote input is closed again.

b) After start conditions are satisfied, accumulative running timer will be initiated; at the same time, the last

blinking decimal of nixie tube indicates that genset works normally.

5PROTECTION

1) Low Oil Pressure: detect after Safety On, Alarm Stop when Low Oil Pressure input is active and

lasts for 2s.

2) High Temperature: detect when start, Alarm Stop when High Temperature is active and lasts

for 2s.

3) Over Speed: detect when start, Alarm Stop after duration exceeds Over Speed Stop Delay.

4) Gen Over Volt: Alarm Stop when the controller detects genset voltage exceeds overvoltage

value and delay exceeds abnormal delay.

5) Gen Under Volt: Alarm Stop when the controller detects genset voltage less than under voltage

value and delay less than abnormal delay.

6) Emergency Stop: ETS output immediately when Emergency Stop is active, in the meanwhile

fuel, preheat and start signal are cut off and Emergency Shutdown Alarm Signal is sent.

7) Fail to Start: Alarm Stop when start failed in preset start times.

8) Gen Under Frequency: When genset is normal running, controller detects gen frequency falls

below under frequency value and the “under frequency” delay has expired, under frequency

shutdown alarm will be sent.

9) Gen Over Frequency: Detection when start genset, if gen frequency exceeds over frequency

value and the “over frequency” delay has expired, over frequency shutdown alarm will be sent.

MGC100 Petrol Genset Controller User Manual Page 10 of 16

6CONNECTION

Fig.2 Rear Panel

Table 6 Terminal Connection Description

No.

Function

Cable Size

Note

B-

1.0mm2

Connected with negative of starter battery.

B+

1.0mm2

Connected with negative of starter battery. If wire length

is over 30m, better to double wires in parallel. Max. 10A

fuse is recommended.

Start Relay Output

1.0mm2

B+ power is supplied by terminal 2, rated 7A.

Connected with start coil of starter.

Fuel Relay Output

1.0mm2

B+ power is supplied by terminal 2, rated 7A.

Controller Types

1.0mm2

When this terminal short connected with (B+), it used as

diesel genset controller.

When this terminal connected with nothing, it used as

petrol genset controller.

High Temperature

1.0mm2

Ground connected is active (B-).

Low Oil Pressure

1.0mm2

Ground connected is active (B-).

Emergency Stop

1.0mm2

Ground connected is active (B-).

Remote Start

1.0mm2

Ground connected is active (B-).

Aux. Transistor

1.0mm2

B- power is supplied by terminal 1, rated 1A.

Magnetic Pickup 2

(B-) has already connected

with controller innerly.

0.5mm2

Connected with Rotate Speed Sensor, shielding line is

recommended.

Magnetic Pickup 1

0.5mm2

1.0mm2

Connected with N wire.

W phase voltage monitor

1.0mm2

Connected with W phase (2A fuse is recommended).

V phase voltage monitor

1.0mm2

Connected with V phase (2A fuse is recommended).

U phase voltage monitor

1.0mm2

Connected with U phase (2A fuse is recommended).

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