1. Introduction
The Smartgen MGC100 is a compact and reliable genset controller designed for small power gasoline generators. It provides automatic start/stop control, comprehensive protection functions, and a clear LED display for monitoring essential generator parameters. This manual provides detailed instructions for the installation, operation, and maintenance of the MGC100 controller.
2. Product Overview
2.1 Features
- Automatic start/stop control for gasoline generators.
- Integrated protection functions including low oil pressure, high temperature, over speed, over/under voltage, emergency stop, and fail to start.
- LED display for real-time monitoring of generator parameters such as running time, battery voltage, AC voltage, and frequency.
- Intuitive pushbutton interface for easy operation and parameter setting.
- Compact panel built-in design for easy installation.
2.2 Controller Components
The MGC100 controller features a front panel with indicators and control buttons, and a rear panel with terminal connections.
Front Panel Indicators:
- Running Time Indicator: Displays total operating hours.
- Battery Volt. Indicator: Shows the battery voltage.
- Alarm Indicator: Illuminates to indicate an active alarm condition.
- Stop Indicator: Indicates the generator is stopped.
- Gen Volt. Indicator: Displays the generator's AC voltage.
- Gen Freq. Indicator: Shows the generator's frequency (Hz).
- Running Indicator: Indicates the generator is currently running.
The rear panel provides access to the terminal block for all necessary electrical connections.
3. Specifications
3.1 Dimensions
The controller is designed for panel built-in installation and is fixed by clips. The approximate dimensions are 106mm (width) x 91mm (height) x 57mm (depth).
3.2 Electrical Parameters
- Battery Voltage Input: DC9-18V. The negative terminal of the battery must be soundly connected to the engine shell. The wire diameter from the power supply to the battery must be over 1.0mm². If a floating charge is configured, first connect the charger's output wires directly to the battery's positive and negative terminals, then connect the battery's B+ (DC9-18V) positive and negative to the controller's corresponding input ports to prevent charging from disturbing the controller's normal operation.
3.3 Terminal Connection Description
| No. | Function | Cable Size | Note |
|---|---|---|---|
| 1 | B- | 1.0mm² | Connected with negative of starter battery. |
| 2 | B+ | 1.0mm² | Connected with positive of starter battery. If wire length is over 30m, better to double wires in parallel. Max. 10A fuse is recommended. |
| 3 | Start Relay Output | 1.0mm² | B+ power is supplied by terminal 2, rated 7A. Connected with start coil of starter. |
| 4 | Fuel Relay Output | 1.0mm² | B+ power is supplied by terminal 2, rated 7A. |
| 5 | Controller Types | 1.0mm² | When this terminal short circuit with (B-), it is used as a diesel genset controller. When this terminal is connected with nothing, it is used as a petrol genset controller. |
| 6 | High Temperature | 1.0mm² | Ground connected is active (B-). |
| 7 | Low Oil Pressure | 1.0mm² | Ground connected is active (B-). |
| 8 | Emergency Stop | 1.0mm² | Ground connected is active (B-). |
| 9 | Remote Start | 1.0mm² | Ground connected is active (B-). |
| 10 | Aux. Transistor | 1.0mm² | B-power is supplied by terminal 1, rated 1A. |
| 11 | Magnetic Pickup 2 (B+) | 0.5mm² | Connected with Rotate Speed Sensor, shielding line is recommended. |
| 12 | Magnetic Pickup 1 | 0.5mm² | Connected with N wire. |
| 13 | N | 1.0mm² | Connected with W phase (2A fuse is recommended). |
| 14 | W phase voltage monitor | 1.0mm² | Connected with W phase (2A fuse is recommended). |
| 15 | V phase voltage monitor | 1.0mm² | Connected with V phase (2A fuse is recommended). |
| 16 | U phase voltage monitor | 1.0mm² | Connected with U phase (2A fuse is recommended). |
3.4 Auxiliary Output Ports
| No. | Content | Description |
|---|---|---|
| 0 | Not Used | When this is chosen, output port will not output. |
| 1 | Preheat Output | Closes before start, opens before energize. |
| 2 | Common Alarm | When stop alarm is initiated, this alarm will self-lock until the alarm is reset. |
| 3 | Idle Output | Used for engines with idle function. Closes before starting and opens during warming up delay; closes during stopping idle process and opens when stop is completed. |
| 4 | ETS Output | Used for some gensets with stop electromagnet. Closes before stopping idle ends. Opens when "ETS Delay" ends. |
| 5 | Air Flap Choke | Used for gensets with choke valve electromagnet. Closes when genset starts and opens when safety running delay is over. |
| 6 | Reserved | |
| 7 | Reserved | |
| 8 | Reserved | |
| 9 | Reserved |
3.5 Crank Disconnect Conditions
| No. | Content |
|---|---|
| 1 | Magnetic Sensor |
| 2 | Generator |
| 3 | Magnetic Sensor + Generator |
4. Installation and Setup
4.1 Mounting
The MGC100 controller is designed for panel built-in installation. It is secured using clips after being inserted into the panel cutout.
4.2 Wiring Diagram
Refer to the following diagram for typical application wiring. Ensure all connections are secure and follow local electrical codes.
Wiring Notes:
- When controlling a petrol genset, terminal 4 connects with ignition control; when controlling a diesel genset, terminal 5 needs to short circuit with B-, and terminal 4 needs to connect with fuel output.
- Speed Sensor Input: A magnetic speed sensor is typically installed on the engine body for testing flywheel teeth number. Two core shielding wire is used for the connection of the sensor and controller. The wire is supposed to be connected to terminal 11 of the controller with one end and the other end hanging in the air. The other two wires connect separately to terminal 12. The speed sensor is passive, and its maximum input voltage is AC12V (when in rated rotate speed). When installing the speed sensor, screw it to contact the flywheel first, average it with 1/3 circle, and then tighten the nut.
- Withstand Voltage Test: If a high voltage test is required after the controller has been installed in the control panel, please disconnect all terminals of the controller to prevent high voltage from damaging it.
5. Operation
5.1 Pushbuttons
| Icon | Definition | Explanation |
|---|---|---|
| Stop/- | Stops the running genset. In stop status, press to stop generator immediately or to reset any shutdown alarm. Press for more than 2s to test the nixie tube and panel indicator. In setting menu, decreases parameter value (double-clickable). Press for more than 3s to exit the menu. | |
| Page/Confirm | Switches display contents of the nixie tube in normal status. Pressing for more than 3 seconds enters the parameter configuration menu. In setting menu, presses this button to modify and save the value. | |
| Run/+ | Manual start in stop status. In setting menu, increases parameter value (double-clickable). |
5.2 Alarm Icon Indication
| Icon | Description | Icon | Description |
|---|---|---|---|
| Emergency Stop Alarm | Over Speed Alarm | ||
| High Temp Alarm | Low Oil Pressure Alarm | ||
| Fail To Start Alarm | Over/Under Volt Alarm |
5.3 Manual Start/Stop
- To start genset: Press the Run/+ button. The controller will accelerate to high-speed running automatically. With high temperature, low oil pressure, over speed, and abnormal voltage during genset running, the controller will protect it by stopping quickly.
- To stop genset: Press the Stop/- button.
Note:
- The genset can be stopped manually in remote start status; at this time, remote input is inhibited and will become active when remote input is closed again.
- After start conditions are satisfied, the accumulative running timer will be initiated; at the same time, the last blinking/decimal of the nixie tube indicates that the genset is working normally.
5.4 Protection Functions
- Low Oil Pressure: Detected after Safety On. An alarm stop occurs when the Low Oil Pressure input is active and lasts for 2 seconds.
- High Temperature: Detected when starting. An alarm stop occurs when High Temperature is active and lasts for 2 seconds.
- Over Speed: Detected when starting. An alarm stop occurs after the duration exceeds the Over Speed Stop Delay.
- Gen Over Volt: An alarm stop occurs when the controller detects genset voltage exceeding the overvoltage value and the delay exceeds the abnormal delay.
- Gen Under Volt: An alarm stop occurs when the controller detects genset voltage less than the undervoltage value and the delay is less than the abnormal delay.
- Emergency Stop: The ETS output activates immediately when Emergency Stop is active. Simultaneously, fuel, preheat, and start signals are cut off, and an Emergency Shutdown Alarm Signal is sent.
- Fail To Start: An alarm stop occurs when starting fails within the preset start times.
- Gen Under Frequency: When the genset is running normally, the controller detects if the generator frequency falls below the under-frequency value and the "under frequency" delay has expired. An under-frequency shutdown alarm will be sent.
- Gen Over Frequency: Detected when starting the genset. If the generator frequency exceeds the over-frequency value and the "over frequency" delay has expired, an over-frequency shutdown alarm will be sent.
5.5 Parameter Setting
To enter the parameter configuration menu, press the Page/Confirm button for more than 3 seconds. The LED will display "P00".
- Press Stop/- and Run/+ to decrease/increase the parameter number.
- After selecting the parameter number, press Page/Confirm to enter the parameter setting menu. Use Stop/- and Run/+ to increase/decrease the parameter value (double-clickable).
- Press Page/Confirm to modify and save the value.
- For multiple parameters, repeat steps 1-3.
- After parameter setting, press Stop/- for 3s to exit the parameter setting status.
5.6 Restore Factory Settings
In emergency stop input status, press Page/Confirm and Stop/- for 5 seconds simultaneously. The unit will restore to default settings, and "reset" will be displayed on the LED.
5.7 Eliminate Accumulated Time
Press Page/Confirm and Run/+ for 5 seconds simultaneously. The accumulated running time will be reset, and "hour" will be displayed on the LED.
Note for Parameter Setting:
- The overvoltage threshold must be greater than the undervoltage threshold.
- When starting successfully, the generator frequency needs to be set lower as soon as possible to ensure the starter separates sooner.
- The number of setting contents refers to "Parameter Content and Range (Table 7)" (not provided in source).
- Exiting the parameter setting status is only possible from the parameter number menu. If no button is pressed in the parameter number menu, it will exit automatically in 30 seconds.
6. Maintenance
To ensure the longevity and reliable operation of your Smartgen MGC100 controller, perform regular checks:
- Keep the controller clean and free from dust and moisture.
- Periodically inspect all wiring connections for tightness and corrosion.
- Ensure the generator's battery is in good condition and properly charged.
- Verify that all sensors (oil pressure, temperature, speed) are functioning correctly.
For any complex issues or repairs, it is recommended to consult with a qualified technician.
7. Troubleshooting
This section provides solutions to common issues you might encounter with the MGC100 controller.
| Symptoms | Possible Solutions |
|---|---|
| Controller no response with power | Check starting batteries; Check controller connection wirings; Check DC fuse. |
| Crank not disconnect | Check fuel oil circuit and its connections; Check starting batteries; Check speed sensor and its connections; Refer to engine manual. |
| Shutdown alarm in running | Check related switch and its connections according to the information on LED. |
| Starter no response | Check starter connections; Check starting batteries. |
8. User Tips
- Always ensure proper grounding for all components to prevent electrical interference and ensure safety.
- When performing any wiring, double-check all connections against the provided diagram to avoid damage to the controller or generator.
- For optimal performance, keep the controller's display and buttons clean and free from debris.
- Familiarize yourself with the alarm icons and their meanings to quickly diagnose issues.
9. Warranty and Support
For any technical assistance, warranty claims, or further inquiries, please contact the seller or manufacturer's support channels. Keep your purchase records handy for faster service.
