SmartGen MGC120 Genset Controller User Manual

Company Information

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

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 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 History

1 Overview

The MGC120 Petrol Genset Controller is an AMF (Automatic Mains Failure) module suitable for single petrol genset automation and monitoring control. It enables auto start/stop, alarm protection, and ATS switching control through data measurement. The controller features an LED display and button-press operation. Most parameters can be adjusted via the front panel, and all parameters can be modified using PC software via the LINK port. Its simple operation, reliable performance, compact structure, and convenient installation make it widely applicable in various automation systems for petrol gensets.

2 Performance and Characteristics

• Able to collect single-phase voltage of Mains and generator, suitable for 50Hz/60Hz AC systems.
• Switchable display parameters include: Mains voltage (V), Generator voltage (V), Engine cylinder temperature (°C), Generator frequency (Hz), Battery voltage (V), Accumulated running time (H).
• Equipped with Mains electricity monitoring function and AMF function.
• Provides protection for generator under/over voltage, under/over frequency, low oil pressure, and start failure. When these occur, LEDs indicate alarm types, and the controller initiates shutdown protection.
• Uses a stepper motor and programmable outputs to control the air flap.
• Speed signals are derived from the ignition coil primary (requires a diode in series).
• Offers three crank disconnection conditions: generator frequency, speed, and generator frequency + engine speed.
• Equipped with 2 digital inputs with defaults: remote start input and low oil pressure input.
• Equipped with 3 stationary relay outputs: fuel output, start output, and ignition control.
• Equipped with 2 programmable transistor outputs, configurable for common alarm, ETS control, idle speed control, preheating control, GCB close output, MCB close output, and air flap blocking output.
• Features a LINK communication port (requires SmartGen SG72 adapter) for parameter settings, remote monitoring, and firmware upgrades.
• Includes digital tube and LED display with button-press operation.
• Silicone panel and buttons offer high adaptability to extreme temperatures.
• Screen protection uses hard screen acrylic material.
• Modular structure design with anti-flaming ABS plastic housing and embedded installation for a compact and easy setup.

3 Specification

4 Operation

4.1 Control Panel

Figure 1: Front Panel Description depicts the control panel. It features an LED Display showing numerical values (8.8.8.8) and various LED Indicators (MV, GV, °C, Hz, Vdc, Hc). Control buttons include 'Stop', 'Auto/Manual', and 'Start'. An 'Auto Start Module' label is also present.

Start Indicator: Always lit from genset start to normal running; extinguished in other statuses.

Stop Indicator: Flashes during the genset stop procedure; always lit during the stop process; extinguished in other statuses.

4.2 Indicator Description

Table 3: Indicator Description details the function of each indicator icon:

NOTES:

• (1) Generator indicator: Light-on when generator is normal running; flash when generator is abnormal; light-off when generator is unavailable.
• (2) Mains indicator: Light-on when mains is normal; flash when mains is abnormal; light-off when mains is unavailable.

4.3 Push Buttons

Table 4: Button Description outlines the functions of the control buttons:

4.4 Auto Start/Stop Operation

Press the ◯ key; the indicator lights up, indicating the generator is in auto mode.

a) Auto Start Sequence

1. When the remote start signal is active or the mains failure (over/under voltage) delay expires, "Start Delay" time is initiated.
2. After the start delay, preheating relay outputs (if configured), "Preheat Delay" is initiated.
3. Following the preheat delay, the fuel relay outputs, and one second later, the start relay outputs. If the genset fails to start during this time, fuel and start relays stop outputting, and the controller enters "Crank Rest Time" for the next start attempt.
4. If the genset fails to start after the set attempts, the LED indicator will display "Start Failure".
5. If the genset starts successfully, it enters "Safety On" time, during which low oil alarm types are inactive. After "Safety On" time, it enters "Start Idle Delay" (if configured).
6. During "Start Idle Delay", under frequency and under voltage alarms are inhibited. When this delay expires, "Warming Up Delay" is initiated (if configured).
7. After "Warming Up Delay", the genset enters Normal Running status. If genset voltage or frequency is abnormal, controller alarm shutdown will be initiated.

b) Auto Stop Sequence

1. When the remote start input is invalid or the mains normal delay expires, "Stop Delay" time is initiated.
2. Once "Stop Delay" has expired, the "Cooling Down Delay" is initiated.
3. When "Stop Idle Delay" (if configured) starts, idle speed relay outputs.
4. When "ETS Solenoid Hold" begins, the ignition control relay is energized, and the fuel relay is de-energized. The genset enters standby status.

NOTE:

• Pressing the stop key in auto start status will stop the generator and simultaneously enter manual mode.
• The total running timer starts when the generator meets crank disconnection conditions; the last decimal point of the digital tube flashes to indicate the generator is running.

4.5 Manual Start/Stop Operation

Press the ◯ key; the indicator lights off, indicating the generator is in manual mode.

a) Manual Start:

Press the ▶ button to start the genset (refer to 4.4,a), steps 2-7). If low oil pressure or abnormal voltage occurs during running, the controller will initiate a quick stop.

b) Manual Stop:

Press the ■ button to stop the running genset (refer to 4.4,b), steps 2-4).

4.6 Air Flap Control

a) With Engine Cylinder Temperature Sensor:

• Before genset startup: If cylinder temperature is below the set limit for air flap blocking, the air flap is fully blocked. If between dropping and opening limits, it's half open. If above the opening limit, it's fully open.
• During cranking (after more than half countdown): The air flap opens 1/3 of its current position. If start delay finishes but starting is not complete, a new pre-start cylinder temperature estimation occurs.
• After successful start: The air flap opens another 1/3. If cylinder temperature exceeds the opening limit, the air flap opens completely.

b) With Engine Cylinder Temperature Sensor Applied or Sensor Opened Circuit:

• Before genset startup: Air flap is fully blocked.
• First starting attempt: Air flap opens from full blocking and should be completely open in 2s.
• Second starting attempt: Air flap opens from half blocking and should be completely open in 2s.
• If both attempts fail: The opening time for the air flap becomes 10s.
• After successful start: Air flap opens 1/3 at its present position, and after air flap blocking delay, it opens completely.

4.7 ATS Switching Control

• Auto Mode: If Mains is available, ATS switches to Mains. If Mains is abnormal and the genset is running normally, ATS switches to the generator. In other statuses, ATS remains on the Mains position.
• Manual Mode: If the generator close input is active and the genset is running normally, the generator breaker closes. If the generator close input is inactive or the generator is not running normally, the Mains breaker closes.

NOTE: To utilize ATS control, programmable output ports must be configured as GCB close output and MCB close output, and the input port as GCB close input.

5 Protection

1. Generator Overvoltage Shutdown: Alarm occurs when generator voltage exceeds the overvoltage limit and the duration surpasses the generator abnormal delay value.
2. Generator Under Voltage Shutdown: Alarm occurs when generator voltage falls below the under voltage limit and the duration surpasses the generator abnormal delay value after normal running.
3. Generator Over Frequency Shutdown: Alarm and shutdown occur when generator frequency is above the over frequency limit and the duration exceeds the over frequency shutdown delay.
4. Generator Under Frequency Shutdown: Alarm and shutdown occur when generator frequency is below the under frequency limit and the duration exceeds the under frequency shutdown delay after normal running.
5. Low Oil Pressure Input Shutdown: Alarm and shutdown occur when the low oil pressure input is active for 2s after the safety on delay.
6. Fail to Start: Alarm occurs when the start fails after the pre-set start attempts.

6 Connection

Figure 2: Back Panel shows the terminal layout of the MGC120 controller.

Table 5: Terminal Connection Description details each terminal:

NOTE: The COM (red cable) for the stepper motor shall be connected to battery positive.

7 Definition and Range of Parameters

7.1 Parameter Setting Contents and Range

Table 6: Controller Parameters Configuration lists configurable parameters:

Table 7: HMI Configurable Parameters lists HMI parameters:

NOTE: When parameter settings are conducted via PC software, the password (0318) is not needed if it has not been changed. If changed, the module password must be entered on the password screen for the first parameter settings.

7.2 Definable Contents of Programmable Output Ports

Table 8: Definable Contents of Programmable Output Ports

7.3 Definable Contents of Programmable Input Ports

Table 9: Definable Contents of Programmable Input Ports (All GND(B-) Active)

8 Controller Function Settings

Under standby status, press the ▼ button for 3 seconds to enter the password entry screen (Fig. 3). At this moment, the first digit flashes.

Figure 3: Password Entry Screen

• Press ◯, the flashing number adds 1; press ▶, it decreases 1. After correct setting, press ▼ to move.
• For the 2nd, 3rd, and 4th digits, the process is the same as above.
• After the password is entered correctly, it will enter the parameter setting screen (Fig. 4). The serial number of the setting item is displayed. Press ▶, the setting item goes down; press ◯, the setting item goes up.

Figure 4: Parameter Serial Number Screen

• Press ▼ to enter the setting status of the current parameter value. Press ◯ or ▶ to adjust the parameter value. After adjustment, press ▼ to save the data. Press ■ to exit the parameter setting screen.

NOTES:

• Please change parameters (like crank disconnection condition selections, digital inputs, output configurations, and all delays) while the controller is in standby status. Otherwise, alarm shutdown or other fault information may occur.
• Refer to Table 6 for the serial numbers of setting items.
• The over voltage threshold must be larger than the under voltage threshold; otherwise, under/over voltages may occur simultaneously.
• Generator frequency should be set as low as possible when the engine has started, to allow the start motor to disconnect as soon as possible.

9 Commissioning

Before official operation, the following checks are suggested:

• Check all connections and ensure wire diameter is proper.
• Ensure the controller's DC power has a fuse and is correctly connected to the positive and negative terminals of the start battery.
• Take precautions to prevent the engine from cranking successfully (e.g., remove the gas valve connection wire). Ensure everything is correct. Connect the starter battery power, and the controller will conduct the procedure.
• Press the "Start" button; the genset will start. After the set cranking times, the controller will send a "Start Failure" signal. Then press "Stop" to reset the controller.
• Restore the engine cranking prevention action (e.g., reconnect the gas valve wire). Press the Start button again; the genset will start. If everything is normal, the genset will run. During this period, observe the engine's running state, AC generator's voltage, and frequency carefully. If anything unusual occurs, stop the genset and check all wire connections according to this manual.
• For any further questions, please contact SmartGen service personnel.

10 Typical Application

Figure 5: MGC120 Typical Application Diagram 1 illustrates a typical wiring setup.

Figure 6: MGC120 Typical Application Diagram 2 shows another typical wiring configuration.

NOTES:

• S11, S12, S21, S22 are connected separately with orange, pink, yellow, and blue wires, respectively. The stepper motor COM (red wire) shall be connected to the battery positive.
• Terminal 11 must be connected in series with a diode. The diode capacity should be over 1A, and its reverse pressure-standing value should be over 1000V.
• The maximum incoming current for programmable output 1 and output 2 shall be 1A.
• Programmable output 1 shall be set to "Generator Close Output".

11 Installation

11.1 Fixing Clips

• The controller features a panel-embedded design and is fixed by clips during installation.
• Twist the fixing clip screw anticlockwise until it reaches the proper position.
• Pull the fixing clip backwards (towards the back of the module), ensuring both clips are properly seated in their slots.
• Turn the fixing clip screws firmly clockwise until they are secured to the panel.

NOTE: Ensure the clip screws are not overtightened.

11.2 Overall and Cutout Dimensions

Figure 7: Overall and Cutout Dimensions (Unit: mm) shows the physical dimensions.

• 1) Battery Voltage Input: The MGC120 controller is designed for a DC12V battery voltage environment. The battery negative must be securely connected to the engine shell. The wire connecting the controller power (B+/B-) and battery positive/negative must be 1.5mm² or larger. If a floating charger is configured, connect its output wires directly to the battery's positive and negative terminals first, then connect the battery's positive and negative and the controller's power positive and negative individually using separate wires to prevent charger interference with the controller's normal operation.
• Warning: Removing the start battery during operation is strictly prohibited.
• 2) Withstand Voltage Test: When the controller is installed in the control panel and a high voltage test is conducted, disconnect all controller terminals to prevent high voltage from entering and damaging the controller.

12 Fault Finding

Table 10: Fault Finding List provides common symptoms and possible solutions:

For further assistance, visit www.BunduPower.co.za.