USER MANUAL
Contents
1. 13 o 13 8 3 ELIMINATE ACCUMULATED 001 13 ICASE OIMNE RR 14 Y i86 100 TERM 15 11 FAULT IUIBISICE M 15 MGC100 Petrol Genset Controller Version 1 0 2015 06 29 Page 2 of 15 2 SmartGen A ideas for power MGC100 Petrol Genset Controller User Manual J N Chinese trademark 5 r t Ge n 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 http www smartgen com cn http 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 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 omartgen Technology reserves the right to change the2. 10 10 10 10 0 Uj 7 SmartGen ideas for power MGC100 Petrol Genset Controller User Manual Parameter Range Default Description and stopped when ETS time is set as 0 Time between ending of ETS hold delay and stopped when ETS Hold output time is not 0 Teeth number of the engine for judging of p17 Flywheel Teeth 10 300 118 starter conditions and of engine speed See the following Installation Instruction When rotate speed exceed this value and Over Speed P18 Threshold 0 6000 r min 1710 last for the delay over speed shutdown alarm signal will be sent When rotate speed exceed over speed Over opeed P 19 0 20 s threshold and last for the delay over speed Delay 20 Poles 2 16 alarm signal will be sent Disconnected condition Separate condition of starter and engine are gen sensor and magnetic sensor in order that separate stater motor and engine as soon as possible In starting process if genset rotate speed Disc Speed 0 6000 r min 360 exceed this value it is regarded as genset start success starter will separate In starting process if genset frequency Disc Freq 10 30 H 14 exceed this value that is genset start success starter will separate Fuel Output 0 Fuel output Select MN 1 Stop output ETS output Configuration see form Aux Output Aux Output 1 0 9 am Defination Ua CoredAphsewotgeviue 2w ora pase tage vet
3. Correct phase voltage value 17 Correct AB wire voltage 5 OoretBCwrevtag 0 56 OoretCAwrewoge 5 M 0 21 Disc Condition 0 2 O r OJO r og O O O MGC100 Petrol Genset Controller Version 1 0 2015 06 29 Page 11 of 15 ON SmartGen ideas for power MGC100 Petrol Genset Controller User Manual Aux Output Defination 2 Not Used When this is chosen output port won t output Close before start open before energize When stop alarm is initiated this alarm will self lock untill alarm reset Used for engine which has idles Close before starting and open in 3 Idle Output warming up delay Close during stopping idle process and open when stop is completed Used for some genset which has stop magnetic Close before stoping idle ended Open when ETS Delay ended 5 Reserved 9 40 2 6 O 7 O 8 O 9 O Crank Success Conditions Magnetic Sensor Generate Magnetic Sensor Generate Anite 1 Magnetic sensor is magnetic device which detects numbers of flywheel teeth installed in generator 2 If magnetic sensor is selected please insure numbers of flywheel teeth is same with set value otherwise Over Speed Shutdown maybe caused 3 lIfgenset without magnetic sensor please don t sel
4. IN smartGen MGC100 PETROL GENSET CONTROLLER USER MANUAL 5 Genset Controller SMARTGEN ZHENGZHOU TECHNOLOGY CO LTD SmartGen MGC100 Petrol Genset Controller User Manual CONTENT 2 WAG VE 4 2 4 5 6 4 1 ea OS 0 0 ee ere eer 6 42 CONTROL FANE orisi n EvIxEVESE VR EVELVEUR USE Ma VM EVEVE UU S VEV VV ERUEUR IUSSI E UVEUEUN S S NU UEM UDUR US LAE URMEURUEE 6 4 2 1 Warn ICON 7 BZ 22181218119 7 4 3 OPERAT TION ua C 7 4 3 1 Remote Start Sequence esses sees 7 4 3 2 Remote Stop Sequence 7 d AA 7 4 3 3 Manual Start Stop ume WEE 8 5 PROTEGQGT ION sssssvsusssss ais ll Rees 8 6 CONNECTION een Ee 5 9 7 DEFINITION AND RANGE OF PARAMETERS 0 ssccccccccceeeeeeeeceaeesesssseeeeceeeeeeeeeeeeeeeeaaaaaas 10 8 PARAMETERS CA 13 8 1 PARAMETERAEBISCWIA NEN
5. contents of this document without prior notice Version Hsitory 2015 06 29 Original release MGC100 Petrol Genset Controller Version 1 0 2015 06 29 Page 3 of 15 2 SmartGen KA MGC100 Petrol Genset Controller User Manual 1 OVERVIEW MGC100 Petrol Genset Controller is designed for start and protection of single genset It allows manual and remote start stop data measurement alarm indicate 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 2 PERFORMANCE AND CHARACTERS Multifunctional Nixie tube display press button to operate Switchable displayed battery e Generate voltage V e Generate frequency Hz e Accumulated running time maximum is 9999h H e 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 emergen
6. arded as under voltage and at the same time gen abnormal signal will be sent When set value is 30V it won t detect under voltage signal Gen Abnormal 0 20 s 10 Alarm delay value of generate over or under Delay voltage Time from remote start signal is active to start 04 Start Delay 0 3600 s 1 the genset Time from remote stop signal is deactivated 05 Stop Delay 0 3600 s to stop the genset It is maximum of start attempts when starter Under Volt Threshold 0 02 30 620 V 196 Start Attempts 1 10 07 Preheat Delay 0 300 s 08 Crank Time 9 605 Crank Rest Time 3 60 s 10 Safety On Time 1 60 11 Start Idle Time 0 3600 Warmin U Time 13 Cooling Time 3 3600 s 14 Stop Idle Time 0 3600 5 15 ETS Hold Time 0 120 s 2 pump unit Is stopping 16 0 120 s Time between ending of pump unit idle delay MGC100 Petrol Genset Controller Version 1 0 2015 06 29 Page 10 of 15 failed to start When reach set attempts the fail to start alarm will be initiated Time of pre powering heat plug before starter is powered up Time of starter power up The waiting time before second power up when engine start fail CO 0 0 i 5 Alarms for low oil pressure and under voltage are inactive Warming time between genset close and high Radiating time before stop genset after it dle running time when pump unit stop Stop electromagnets power on time when
7. cy 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 rotate 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 flexible output 7 flexible transistor output can be set to preheat output alarm output energize to stop output and idle output etc wo start success conditions rotate speed sensor generate 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 Version 1 0 2015 06 29 Page 4 of 15 FON SmartGen 3 SPECIFICATION DC9 0V to 18 0V continuous power supply suitable for DC12V Working Voltage system Overall Consumption Regular working 1W Standby mode lt 0 4W AC Volt Input 3 phase 4 wire AC 30V AC 360V ph N 3 phase 3 wire AC 50V AC 620V ph ph 2 phase 3 wire AC 30V AC 360V ph Single phase 2 wire AC 30V AC 360V ph AC Frequency 50Hz 60Hz Speed Sensor Voltage 1 0V to 24V effective va
8. e manual Check related switch and its connections according to the Shutdown Alarm in running information on LED Controller no response with Crank not disconnect Check starter connections Starter no response Check starting batteries MGC100 Petrol Genset Controller Version 1 0 2015 06 29 Page 15 of 15
9. ect corresponding items otherwise start fail maybe caused 4 If generate isn t selected the controller won t detect over under voltage if magnetic sensor isn t selected rotate speed of genset is converted via generate signal MGC100 Petrol Genset Controller Version 1 0 2015 06 29 Page 12 of 15 FON SmartGen SISSE HERE MGC100 Petrol Genset Controller User Manual 8 PARAMETERS SETTING 8 1 PARAMETERS REGULATION When the controller is running press for 3s it will enter into parameter number menu and LED nn will dispa OO S to downturn upturn parameter number 2 After parameter number is selected press 9 to enter into parameter setting menu Ch to increase decrease parameter value it can be double clicked 3 Press to confirm modification and save value 4 For multiple parameters step 1 3 can be repeat done for setting 5 After parameter setting pressi for 3s to exit parameter setting status 8 2 RESTORE FACTORY SETTINGS In emergency stop input status press Oo and for 5s at the same time it can restore to default and reset will be displayed on LED 8 3 ELIMINATE ACCUMULATED TIME Press hana Oro 5s at the same time accumulated running time will be reset an hclr will be displayed on LED Aud Over voltage threshold must be greater than under voltage threshold When start successfully generator frequency need to be
10. es in parallel Max 10A fuse is recommended Connected with start coil of starter 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 0mm Ground connected is active B Low Oil Pressure 1 0mm Ground connected is active B Emergency Stop 1 0mm Ground connected is active B tart Relay Output Controller Types 1 0mm Remote Start 1 0mm Ground connected is active B Aux Transistor 1 0mm B power is supplied by terminal 1 rated 1A Magnetic Pickup 2 has already connected 0 5mm Connected with Rotate Speed Sensor shielding line with controller innerly is recommended MGC100 Petrol Genset Controller Version 1 0 2015 06 29 Page 9 of 15 SmartGen ideas for power MGC100 Petrol Genset Controller User Manual 7 DEFINITION AND RANGE OF PARAMETERS Parameter Setting Parameter Range Default Description lt lt 0 Single phase 2 wire 1 2 phase 3 wire in 7 2 3 phase 3 wire 3 3 phase 4 wire When generate voltage exceed this value and last for Abnormal Delay then it is Over Volt regarded as over voltage and at the same 01 30 620 264 2 Threshold time gen abnormal signal will be sent When set value is 620V it won t detect over voltage signal When generate voltage is under this value and last for Abnormal Delay then it is reg
11. hibited 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 5 PROTECTION 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 undervoltage value and delay less than abnormal delay 6 Emergency Shutdown ETS output immediately when Emergency Shutdown is active in the meanwhile fuel preheat and start signal are cut off and Emergency Shutdown Alarm Signal is send 7 Failto Start Alarm Stop when start failed in preset start times MGC100 Petrol Genset Controller Version 1 0 2015 06 29 Page 8 of 15 A SmartGen AA emen MGC100 Petrol Genset Controller User Manual 6 CONNECTION TO IGNITION CONTROL an No Function Cable Size Connected with negative of starter battery Connected with negative of starter battery If wire B 1 0mm length is over 30m better to double wir
12. lue opeed Sensor Frequency 10000Hz Max Working Condition Temperature 25 70 C Humidity 20 93 RH Storage Condition Temperature 25 70 C Apply AC2 2kV voltage between high voltage terminal and low Insulation voltage terminal The leakage current is not more than 3mA within 1min Weight MGC100 Petrol Genset Controller Version 1 0 2015 06 29 Page 5 of 15 2 smartGen 4 OPERATION 4 1 PUSHBUTTONS Buttons Description Stop the running genset In stop status press this button to stop generator immediately In stop status press this button to reset any shutdown alarm In stop status press this button for more than 2s to test if the nixie tube and panel indicator are right In setting menu upturn or decrease parameter value it can be double clicked In setting menu press this button for more than 3s to exit this menu owitch display contents of nixie tube in normal status Pressing this button for more than 3 seconds entry the parameter Page Confirm configuration menu In setting menu press this button to modify and save value Manual start in stop status In setting menu downturn or increase parameter value it can be double clicked 4 2 CONTROL PANEL MGC100 Petrol Genset Controller Version 1 0 2015 06 29 Page 6 of 15 E SmartGen KA MGCI00 Petrol Genset Controller User Manual 4 2 1 Warn Icon Indication RK Emergency Shutdown Alarm Over Speed Alarm High Temp Alarm L
13. ow Oil Pressure Alarm m Fail to Start Alarm 1 Over Under Volt Alarm 4 2 2 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 otop 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 inhibi
14. set lower as soon as possible in order to starter separate sooner Number of setting contents refers to Parameter Setting 7 Only in parameter number menu can exit from parameter setting status If there is no press operation in parameter number menu it will exit in 30s automatically MGC100 Petrol Genset Controller Version 1 0 2015 06 29 Page 13 of 15 A SmartGen AA emen MGC100 Petrol Genset Controller User Manual 9 CASE DIMENSIONS Controller is panel built in design it is fixed by clips when installed 105 80mm 90 40rnm 92mm 7 1 Battery Voltage Input NOTE MGC100 controller can suit for widely range of battery voltage DC 9 18 V Negative of battery must be connected with the engine shell soundly The diameter of wire which from power supply to battery must be over 1 0mm If floating charge configured please firstly connect output wires of charger to battery s positive and negative directly then connect wires from battery s positive and negative to controller s corresponding input ports in order to prevent charge disturbing the controller s normal working Darn In running process removing start battery is strictly prohibit 2 Speed Sensor Input Note Speed sensor is magnetic equipment which is installed on engine body for testing flywheel teeth number 2 core shielding wire is used for the connection of the sensor and controller The wire is
15. supposed to be connected to 11 terminal of controller with one end and the other end hanging in the air The other two signal lines connect separately to 11 12 terminal Speed sensor output voltage is supposed to be at AC 1 24 V virtual value when it is in full speed range and AC12V when in rated rotate speed is recommened When install the speed sensor screw it to contact the flywheel firstly inverse it with 1 3 circle and then tighten the nut finally 3 Withstand Voltage Test Caution When controller has been installed in control panel if the high voltage test is needed please disconnect controllers all terminals in order to prevent high voltage into controller and damage it MGC100 Petrol Genset Controller Version 1 0 2015 06 29 Page 14 of 15 2 smartGen 10 TYPICAL APPLICATION U L1 2 T 22 T B A I E l fr B 1 5 2 EN gt s 2 m 5 o E TOIGNITION O SUL o 9 CONTROL 1 X wagwenc 9 1 2 T a MU lt A ate when it controls petrol genset terminal 4 connects with ignition control when it controls diesel genset terminal 5 needs to short connect with B terminal 4 needs to connect with fuel output 11 FAULT FINDING Check starting batteries Check controller connection wirings power Check DC fuse Check fuel oil circuit and its connections Check starting batteries Check speed sensor and its connections Refer to engin
16. ted 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 NO Remote Stop Sequence a After remote start when remote start signal is invalid Stop Delay timer is initiated b Oncethis 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 Version 1 0 2015 06 29 Page 7 of 15 SmartGen BEA ideas for power MGC100 Petrol Genset Controller User Manual 4 3 3 Manual Start Stop a Press button to start genset It will detect complete start and accelerates 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 button to stop the running genset Please refer to Stop Sequence b f A Note a The genset can be stopped manually in remote start status at this time remote input is in
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