Smartgen MGC120 User manual

MGC120

PETROL GENSET CONTROLLER

USER MANUAL

SMARTGEN (ZHENGZHOU) TECHNOLOGY CO., LTD.

Chinese trademark

English trademark

SmartGen —make your generator smart

SmartGen Technology Co., Ltd.

No.28 Jinsuo Road

Zhengzhou

Henan Province

P. R. China

Tel: 0086-371-67988888/67981888

0086-371-67991553/67992951

0086-371-67981000(overseas)

Fax: 0086-371-67992952

Web: www.smartgen.com.cn

www.smartgen.cn

Email: sales@smartgen.cn

photocopying or storing inanymedium byelectronic means orother) without the written permission of the

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.

Version Hsitory

Date

Version

Content

2017-11-07

1.0

Original release.

MGC120 Petrol Genset Controller User Manual

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CONTENT

1 OVERVIEW ............................................................................................................................................. 4

2 PERFORMANCEAND CHARACTERS.................................................................................................. 4

3 SPECIFICATION..................................................................................................................................... 5

4 OPERATION............................................................................................................................................ 6

4.1 CONTROL PANEL............................................................................................................................ 6

4.2 INDICATOR DESCRIPTION ............................................................................................................ 6

4.3 PUSH BUTTONS.............................................................................................................................. 7

4.4 AUTO START/STOP OPERATION................................................................................................... 7

4.5 MANUAL START/STOP OPERATION ............................................................................................. 8

4.6 AIR FLAP CONTROL ....................................................................................................................... 8

4.7 ATS SWITCHING CONTROL........................................................................................................... 8

5 PROTECTION......................................................................................................................................... 9

6 CONNECTION ........................................................................................................................................ 9

7 DEFINITION AND RANGE OF PARAMETERS.....................................................................................11

7.1 PARAMETER SETTINGS ...............................................................................................................11

7.2 PROGRAMMABLE OUTPUTS CONTENT DEFINITION.............................................................. 14

7.3 PROGRAMMABLE INPUTS CONTENT DEFINITION .................................................................. 14

8 CONTROLLER FUNCTION SETTINGS............................................................................................... 15

9 COMMISSIONING ................................................................................................................................ 16

10 TYPICALAPPLICATION..................................................................................................................... 16

11 INSTALLATION.................................................................................................................................... 18

11.1 FIXING CLIPS............................................................................................................................... 18

11.2 OVERALLAND CUTOUT DIMENSIONS..................................................................................... 18

12 FAULT FINDING.................................................................................................................................. 19

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1OVERVIEW

MGC120 Petrol Genset Controller belongs to AMF module, which is suit for single petrol genset

automation and monitoring control. According to data measuring, it allows auto start/stop genset, alarm

protection and ATS switching control functions. The controller fits with LED nixie tube display and

button-press operation. Most parameters can be adjusted from the front pannel of controller and all

parameters can be changed from PC sofware via LINK port. It is can be widely used in various petrol

genset with easy operation, reliable work, compact structure and easy mounting.

2PERFORMANCE AND CHARACTERS

——Collecting single phase voltage of mains and generator, which suit for 50Hz/60Hz AC system.

——Switchable displayed parameters:

Mains voltage (V)

Generator voltage (V)

Engine cylinder temperature (℃)

Generator frequency (Hz)

Battery voltage (V)

Accumulated running time(H)

——With mains electricity monitoring and AMF functions;

——Protection function for generator under/over volt, under/over frequency, low oil pressure, and

fail to start protection functions; when in protection, LED indicates alarm, and goes shutdown

protection;

——Using stepper motor and programmable outputs to control air flap (close/open air flap

according to the cylinder temperature);

——Speed signals derive from ignition coil primary (diode need to be in series);

——Three crank disconnect conditions can be optional (generator frequency, speed, and speed +

gen frequency);

——2 discrete inputs, which default set as remote start input and low oil pressure input;

——3 fixed relay outputs (fuel output, start output and ignition control);

——2 programmable transistor outputs, which can be set as common alarm output, ETS control,

idle control , preheat control, close GCB output, close MCB output and air flap blocked output;

——LINK communication port (SmartGen specialized SG72 adapter): via LINK port to realize

controller parameter settings, remote monitoring control and firmware upgrade functions.

——Nixie tube and LED display with button-press operation;

——Silicone panel and buttons with a premium performance to working in the extremely high/low

temperature;

——Screen protection adopt hard screen acrylic material;

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

structure with easy mounting;

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3SPECIFICATION

Items

Contents

Working Voltage

DC12V power supply system

Overall Consumption

Regular working:<2W(stepper motor is excluded)

Standby mode:<0.5W

AC Volt Input:

Mains Single Phase

Generator Single Phase

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

Alternator Frequency

50Hz/60Hz

Starter Relay Output

10ADC30V DC B+ supply output

Fuel Relay Output

10ADC30V DC B+ supply output

Ignition Relay Output

10ADC30V DC B- supply output

Flexible Transistor Output

1A connect to 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 Condition

Temperature:(-25~+70)°C Humidity:(20~93)%RH

Storage Condition

Temperature:(-25~+70)°C

Protection Level

Front panel IP55

Insulation

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

terminal; The leakage current is not more than 3mA within 1min.

Weight

0.15kg

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4OPERATION

4.1 CONTROL PANEL

Start indicator: it is always light from genset start to normal running, and in other status, the indicator

will extinguish.

Stop indicator: it is blink when genset enter into stop sequence; always light when stop and in other

status, the indicator will extinguish.

4.2 INDICATOR DESCRIPTION

Icon

Defination

Icon

Defination

Mains voltage indication

Generator under/over frequency alarm

shutdown

Generator voltage indication

Generator under/over voltage alarm shutdown

Engine cylinder temperature

indication

Low oil pressure alarm shutdown

Generator frequency indication

Fail to start

Battery voltage indication

Generator indication

Total running time indication

Mains indication

Note:

1) Generator indicator: light-on when generator is normal running; blink when generator is abnormal;

light-off when generator is unavailable.

2) Mains indicator: light-on when mains is normal; blink when mains is abnormal; light-off when mains is

unavailable.

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4.3 PUSH BUTTONS

Buttons Description

Icons

Function

Description

Stop/Reset

Stop the running genset both in manual mode and in auto mode, and

simultaneously controller switches 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 nixie tube

and panel LED indicators are OK.

In setting menu, press this button to exit this menu.

Auto/Manual Switch

Increased value

Press this key, if auto indicator lights on, controller states in auto mode; if

auto indicator lights off, controller states in manual mode.

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

value

Start

Decreased value

In manual mode, press this key to start genset.

In setting menu, press this key to upturn or decrease the parameter value

Down

Switch display contents of nixie tube.

Pressing this button for more than 3 seconds to entry the parameter

setting menu;

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

4.4 AUTO START/STOP OPERATION

After pressing key, indicator besides this key lights on, which stands for generator-set states

in auto mode.

Auto Start Sequence

1) When remote start signal is active or mains failure(over/under voltage) delay is expired, “Start

Delay” timer is initiated;

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

3) 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.

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

indicator will be illuminated.

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

Pressure Input is inhibited. As soon as this delay is over, “start idle” delay is initiated (if

configured).

6) During “start idle” delay, under frequency and under volt alarms are inhibited. When this delay is

over, “warming up” delay is initiated (if configured).

7) After the “warming up” delay, genset will enter into Normal Running status. If genset voltage or

frequency is abnormal, corresponding alarms will be initiated.

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Auto Stop Sequence

1) When remote start signal is invalid or mains normal delay is expired, “Stop Delay” timer is

initiated;

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

3) During “Stop Idle” Delay (if configured), idle relay is energized.

4) “ETS Solenoid Hold” begins, ignition control relay is energized while fuel relay is de-energized,

and then genset entry standby status.

Note:

1) Press stop key in auto start status, generator-set will stop and enter into manual mode simultaneously.

2) Total running timer initiate when generator meet crank disconnected conditions, meanwhile, the last

decimal point of the nixie tube flashes to indicate that the generator is running.

4.5 MANUAL START/STOP OPERATION

After pressing key, indicator besides this key lights off, which stands for generator-set states

in manual mode.

a) Manual start: press button to start genset (Please refer to Start Sequence 2-7). With low

oil pressure and voltage abnormal during genset running, controller can protect it to stop quickly.

b) Manual Stop: Press button to stop the running genset (Please refer to Stop Sequence

2-4).

4.6 AIR FLAP CONTROL

a) With engine cylinder temperature sensor

When generator-set starts up, If the engine cylinder temperature is below the set air flap

closing cylinder limit, the air flap is closed.

After entering safety on delay, If the engine cylinder temperature is above the set air flap

opening cylinder limit, the air flap is open;

if engine cylinder temperature is always below the set air flap opening cylinder limit, it will

stay in closed status, and generator-set cannot take load.

b) Without engine cylinder tempoerature sensor or sensor is open circuit

Generator-set starts up, during the first start attempt, the air flap full block, the second start

attempt, the air flap block 2/3, after the third start attempt, the air flap blocked 1/3. After the

crank disconnect, air flap is open after the delay.

4.7 ATS SWITCHING CONTROL

Auto mode: mains is available, ATS switches to mains; if mains failure and generator-set is normal

running, ATS switches to generator. Other status, ATS stays in mains station.

Manual mode: if close generator input is active, then generator closed; if close generator input is

deactivated, then mains closed.

Note: if use ATS control function, the programmable output need to be configured as GCB close output

and MCB close output, meanwhile, input need to be configured as GCB close input.

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5PROTECTION

1) Generator over voltage shutdown: alarm occurs when the controller detects generator voltage

exceeds overvoltage limit and the duration exceeds the generator abnormal delay value.

2) Generator under voltage shutdown: detect after generator-set normal running and alarm occurs

when generator voltage is below under voltage limit and the duration exceeds the generator

abnormal delay value.

3) Generator over frequency shutdown: it will alarm shutdown when generator frequency is above

over frequency limit and duration exceeds over frequency shutdown delay.

4) Generator under frequency shutdown: it will detect after generator-set normal running and

alarm shutdown when generator frequency is below under frequency limit and duration

exceeds under frequency shutdown delay.

5) Low oil pressure input shutdown: detect after safety on delay, alarm shutdown when low oil

pressure input is active and lasts for 2s.

6) Fail to start: alarm occurs when fail to start after pre-set start attempts.

6CONNECTION

No.

Function

Cable Size

Note

B-

2.0mm2

Connected with negative of starter battery.

B+

2.0mm2

Connected with positive of starter battery.

Max. 20A fuse is recommended.

Crank Output

1.5mm2

B+ power is supplied by terminal 2, rated 10A.

Connected with start coil of starter.

Fuel Output

1.5mm2

B+ power is supplied by terminal 2, rated 10A.

Ignition Control

1.5mm2

B- power is supplied by termainal 1, rated 10A.

Remote Start Input

1.0mm2

Aux. input 1, discrete signal input, Ground connected is

active (B-).

Oil Pressure Input

1.0mm2

Aux. input 2, discrete signal input, Ground connected is

active (B-).

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No.

Function

Cable Size

Note

Temp Sensor

1.0mm2

Connect with resistor type temperature sensor.

Aux. Output 1

1.0mm2

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

Aux. Output 2

1.0mm2

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

Speed Signal

1.0mm2

Connect with ignition coil primary, and diode need to be

in series.

S22

Use stepper

motor

Comes with

lead

Connect with pink cable of stepper motor.

S21

Connect with orange cable of stepper motor.

S12

Connect with yellow cable of stepper motor.

S11

Connect with blue cable of stepper motor.

Mains (L-N) Monitoring

Input

1.0 mm2

Connect with mains output port (2A fuse is

recommended)

1.0 mm2

Generator (L-N)

Monitoring Input

1.0 mm2

Connect with generator voltage output port (2A fuse is

recommended)

1.0 mm2

Note: if 5-wire system stepper motor is used, red cable need hanging in the air.

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