Deif SGC 121 User Manual
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Deif SGC 121 User Manual

Deif SGC 121 User Manual

Single genset controller
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SGC 121
Single Genset Controller
User manual

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  • Page 1 SGC 121 Single Genset Controller User manual...

  • Page 2: Table Of Contents

    1. Introduction 1.1 About ................................................... 1.2 Function overview ............................................1.3 About the User manual ........................................... 1.3.1 General purpose ..........................................1.3.2 Software versions ..........................................1.4 Warnings and safety ..........................................1.4.1 Symbols for hazard statements ....................................1.4.2 Symbols for general notes ......................................1.4.3 Electrical safety ..........................................
  • Page 3 3.6 Password ..............................................4. Modes of operation 4.1 Operation mode ............................................4.2 AUTO mode ..............................................4.2.1 Island ..............................................4.2.2 Engine drive ............................................4.2.3 Automatic mains failure (AMF) ....................................4.2.4 Remote start/stop ........................................4.2.5 Auto exercise ............................................ 4.3 Manual mode ............................................. 5.

  • Page 4: Introduction

    About The SGC 121 controller contains all the functions needed to protect and control the genset, the genset contactor, and also a mains contactor. All the values and alarms are shown on the LCD display screen. Operators can control the system from the display.

  • Page 5: About The User Manual

    • Event log for 100 events with real-time clock stamps • Fuel theft alarm Electronic governing The SGC 121 can do electronic governing for engines with mechanical fuel systems when you have installed a rotary actuator. About the User manual 1.3.1...

  • Page 6: Safety During Installation And Operation

    DEIF A/S reserves the right to change any of the contents of this document without prior notice. The English version of this document always contains the most recent and up-to-date information about the product. DEIF does not take responsibility for the accuracy of translations, and translations might not be updated at the same time as the English document.

  • Page 7: Installation

    2. Installation Dimensions Length Height Depth Controller 139.0 mm (5.47 in) 114.0 mm (4.49 in) 38.3 mm (1.51 in) Tolerance: ± 0.3 mm (0.01 Panel cut-out 118.0 mm (4.65 in) 93.0 mm (3.66 in) Tools and materials Tools required for mounting Tool Used for Personal protection, according to local standards and...

  • Page 8: Mounting

    Materials required for mounting and wiring Materials Used for Four screw clamps Mounting the controller in the front panel Wires and connectors Wiring third party equipment to the controller terminals Cable ties Securing wiring Mounting The controller is designed for mounting in the front panel. Panel cutout: •...
  • Page 9 Terminal Text Description Power ground BATT + Power supply positive DIG OUT A DC output - A DIG OUT B DC output - B DIG OUT C DC output - C DIG OUT D DC output - D D+ CHG ALT Input for charging alternator control DIG OUT E DC output - E...

  • Page 10: Wiring

    Terminal Text Description CT1 S2 CT input 1 from generator phase L1 CT1 S1 Sensor common point SENSOR COMM MPU input Wiring 2.5.1 Typical wiring NOTE The wiring diagram is only an example. Use the wiring diagram for the specific application during installation. Fuses: •...

  • Page 11: Wiring Guidelines - Best Practice For Grounding

    2.5.2 Wiring guidelines - best practice for grounding It is important to follow these wiring guidelines to get: • Reliable readings from the sensors. • Precise measurement of AC voltage and current. • Best protection from lightning and other earth faults. Example: Typical grounding setup 1.

  • Page 12: Analogue Inputs

    2.5.3 Analogue inputs Resistive sensor inputs Wiring for the sensor common point (SCP) for analogue inputs 1 to 4 (terminals 23 to 26). Wiring for the sensor common point (SCP) for analogue input 2 (terminal 24) when you use it as Fuel level sensor with reference to Battery Negative.

  • Page 13: Ac Connections

    Settings: • Polarity: Close to activate • SW state: Not activated • Logic status: Low 2.5.4 AC connections Three-phase application (4 wires) Three-phase application (3 wires) User manual 4189341354A EN Page 13 of 72...
  • Page 14 Two-phase application L1/L2 (3 wires) Two-phase application L1/L3 (3 wires) Single-phase application (2 wires) User manual 4189341354A EN Page 14 of 72...

  • Page 15: Rotary Actuator Outputs

    Split phase application L1/L2 (3 wires) Split phase application L1/L3 (3 wires) 2.5.5 Rotary actuator outputs The actuator outputs are used when a 4-wired rotary actuator is installed in your application. The integrated electronic governor in the SGC controller is used together with the actuator to create an electronic governing application for mechanical fuel engines.

  • Page 16: Voltage Measurement Fuses

    3. The S2 terminals are grounded but not at the GND terminal. This means that the battery ground (GND terminal) and the CT ground are not the same. The maximum allowable offset between the two ground connections is ±0.5 V. 2.5.7 Voltage measurement fuses If the wires/cables must be protected with fuses, use max.

  • Page 17: Display And Menus

    3. Display and menus Display, buttons, and LEDs Name Function Move the selector up and down on the screen. Navigation To see the Event log, push the Up button and the down button at the same time and hold. Stops the genset if manual or auto mode is selected. Stop When you push the button in auto mode, the running mode also changes to manual mode.

  • Page 18: Display Settings

    Name Function Start Starts the genset if manual mode is selected. Mode selection Push to select the running mode. Display settings 3.2.1 Display To adjust for ambient lighting, configure the display settings. Use the smart connect software to configure the contrast in Module > Display > Contrast. You can also configure the time for when the page on the display changes in Timers >...

  • Page 19: Monitoring Menu

    Monitoring menu The display views change automatically after an adjustable delay time. You can configure this delay time in the configuration menu. You can also change the views manually on the controller with the Up and Down buttons. Display view examples Some of the display views are only shown if you have configured the functions.

  • Page 20: Configurable Parameters

    4. You will see this screen on the display: PASSWORD 5. Enter the password: a. Use the Up and Down buttons to change the number. b. Select a number with the Start button. 6. You can now configure the parameter. 7.
  • Page 21 Parameter Range Default Description This is only when the engine is not in operation. You can configure the adjustable timer with the smart connect software in Timers > General > Power Save Mode Delay Communication (RS485 COMM) Level 2 Range Default Description Communication Mode...

  • Page 22: Digital Inputs

    Auto Exercise – Event 2 (AUTO EXERCISE – 2) Parameter Range Default Description If you enable this parameter, the controller Auto Exercise Enable Not enabled operates in exercise mode for the adjustable (EVENT 2) Disable time duration. Daily Event Occurrence Weekly Daily Configure how often the sequences occur.
  • Page 23 Parameter Range Default Description Engine Coolant Temperature Sensor See Digital input (Digital) Source source selection in Not used Select the source from the list. ((DIG) SOURCE) this document Name Auxiliary Input G You can configure the name of the input. (NAME) (Digital) Polarity Close to Activate...
  • Page 24 Parameter Range Default Description From Monitoring On Always (Digital) Activation If the input is active when the timer expires, the Delay 1 to 60 s controller actives the action for the digital input. ((DIG) ACTIVATION DELAY) If this parameter is enabled, the controller shuts (FLS) Low Fuel Level Enable down the engine when the fuel level is less than...
  • Page 25 Parameter Range Default Description Name Auxiliary Input F You can configure the name of the input. (NAME) (Digital) Polarity Close to Activate Close to Activate Select the polarity for the input. ((DIG) POLARITY) Open to Activate None Notification (Digital) Action Warning None Select the action when the input is activated.

  • Page 26: Outputs

    Parameter Range Default Description ((DIG) ACTIVATION DELAY) None (LOP) Circuit Fault Notification Action Warning None Configure the action for an open circuit failure. (OPEN CKT ALARM) Electrical Trip Shutdown (LOP) Lube Oil Current: 4 to 20 mA Configure the current and pressure values for Pressure Sensor Pressure: 0.0 to 10.0 the 10 measurement points in the calibration...

  • Page 27: Generator

    Parameter Range Default Description Engine Cooling Time When the engine cooling timer expires, the 0 to 300 s (ENG COOL TIME) engine stops. Stop Action Time The time duration for the stop action sequence. 10 to 120 s 30 s (STOP ACTION TIME) Additional Stopping Time...
  • Page 28 Parameter Range Default Description Min Healthy Voltage 50 to 350 V phase- When the voltage has reached the set point, 40 V (MIN HEALTHY VOLT) neutral the genset starts to warm up. Min Healthy Frequency When the frequency has reached the set point, 10 to 75 Hz 40 Hz (MIN HEALTHY FREQ)
  • Page 29 Parameter Range Default Description Alternator Nominal Configure the nominal value for the alternator 100 to 4000 RPM 1800 RPM Speed speed. Alternator Nominal Configure the nominal value for the alternator 10 to 8000 kW 200 kW Power power. Voltage Monitoring (VOLT MONITOR) Parameter Range Default...
  • Page 30 Parameter Range Default Description (OV WARNING THRESHOLD) If the voltage is more than the set point for Over-voltage Warning over-voltage warning (OV WARNING THRESH) Delay (OV WARNING 0.1 to 100 s 10 s when this timer expires, the controller activates DELAY) a warning alarm.
  • Page 31 Parameter Range Default Description (OF WARNING THRESHOLD) If the frequency is more than the set point for Over-frequency over-frequency warning (OF WARNING Warning Delay (OF 0.1 to 100 s 10 s THRESH) when this timer expires, the controller WARNING DELAY) shuts down the engine.

  • Page 32: Mains

    Parameter Range Default Description Unbalanced Load When the delay timer expires, the action for Delay 1 to 600 s unbalanced load is activated if the load is more (UNBAL LOAD DELAY) than the unbalanced set point. Enable If this parameter is enabled, the configured Low Load Enable Not enabled Disable...

  • Page 33: Engine

    Parameter Range Default Description is less than the under-voltage set point (UV trip). (UV) Trip 50 to 298 V phase- If the mains voltage is less than this set point, 55 V (UV TRIP) neutral there is a mains failure. (UV) Return 52 to 300 V phase- The mains returns when the mains voltage is...
  • Page 34 Parameter Range Default Description (DISCONN ON LOP than the oil pressure set point (DISCONN LOP SENS) SENS). Monitor Pressure If this parameter is enabled, the oil pressure is Sensor Before Crank Enable monitored before the engine starts. If the oil Not enabled (MON LLOP BEF Disable...
  • Page 35 Parameter Range Default Description Under-speed Threshold When the speed is less than this set point, the 0 to 3600 RPM 1400 RPM (UNDER SPEED controller shuts down the engine. THRESH) Under-speed Delay If the speed is still less than the under-speed (UNDER SPEED 1 to 60 s set point when the timer expires, the engine...
  • Page 36 Parameter Range Default Description High Battery Voltage The action for high battery voltage is activated Threshold 9.0 to 32.0 V 15 V when the voltage load is more than this set (HIGH VOLT point. THRESHOLD) If the battery voltage is more than the set point High Battery Voltage for high voltage (HIGH VOLT THRESHOLD) Delay...
  • Page 37 Parameter Range Default Description Heater control: If the heater temperature is more than the OFF threshold, the output for Coolant Temperature Control is deactivated. Automatic Fuel Transfer (AFT FUNCTION) Parameter Range Default Description AFT Activation Threshold If the fuel level is less than this threshold, the 0 to 99 % 40 % (AFT ACT...

  • Page 38: Maintenance

    Parameter Range Default Description level is less than the warning set point (Warning Threshold). If the lube oil pressure is more than this set Warning Threshold 0.2 to 10.0 Bar 3 Bar point, the controller activates a warning alarm. 3.5.9 Maintenance Maintenance (MAINT ALARM) Parameter Range...

  • Page 39: Password Id

    Parameter Range Default Description Target Speed 500 to 4000 RPM 500 RPM Target output speed for the engine. Proportional gain for the engine speed Proportional Gain (Kp) 0 to 1000 governor. Integral Gain (Ki) 0 to 2000 Integral gain for the engine speed governor. Derivative Gain (Kd) 0 to 1000 Derivative gain for the engine speed governor.
  • Page 40 1. Go to Configuration menu. 2. Log on with the password for level 1. 3. Use the Up and Down buttons to go to Misc Settings. Push the Start button to select. 4. Use the Up and Down buttons to go to the password you want to change. Select the password with the Start button.

  • Page 41: Modes Of Operation

    4. Modes of operation Operation mode The controller has two running modes: • AUTO: The controller operates automatically, and the operator cannot initiate sequences manually. • Manual: The operator has to initiate all sequences. You can do this with the buttons, Modbus commands, or digital inputs.

  • Page 42: Engine Drive

    4.2.2 Engine drive You can use the SGC to control one engine. The controller has all the necessary functions to control and protect an engine. To use the controller to control an engine drive, go to Generator > Alternator Configuration in the smart connect software.
  • Page 43 • Mains monitoring is enabled. In the smart connect software, go to Mains > Configuration > Mains monitoring and make sure that mains monitoring is enabled. To make sure that auto exercise is not enabled for events 1 and 2, go to Module > Auto Exercise >...

  • Page 44: Remote Start/Stop

    Minimum voltage and frequency set points Generator > Alternator Configuration Parameter Range Default Min Healthy Voltage 10 to 100 % 40 % Min Healthy Frequency 10 to 100 % 40 % 4.2.4 Remote start/stop You can configure digital inputs as remote start/stop inputs (latched type input). You can start and stop the genset remotely by activating the configured remote start/stop inputs.

  • Page 45: Auto Exercise

    Minimum voltage and frequency set points Generator > Alternator Configuration Parameter Range Default Min Healthy Voltage 10 to 100 % 40 % Min Healthy Frequency 10 to 100 % 40 % Timers Timers > Start/Stop Parameter Range Default Warm-Up Delay 0 to 60 s Load Transfer Delay 1 to 60 s...

  • Page 46: Manual Mode

    Manual mode When you select manual mode, you can control the controller from the display and with digital inputs. To go to manual mode, push the Mode selection button. User manual 4189341354A EN Page 46 of 72...

  • Page 47: General Functions

    5. General functions AC measurement systems The AC system can be three-phase, two-phase, single-phase, or split phase. CAUTION Incorrect configuration is dangerous Configure the correct AC configuration. If in doubt, contact the switchboard manufacturer for information. Nominal settings 5.2.1 Default nominal settings Text Range Default...

  • Page 48: Breakers

    Text Range Default Note Check the minimum and maximum values the SGC Nominal load current 0 to 8000 A 350 A can read and display. Remember to include the Check the minimum and maximum values the SGC Nominal 4th CT current 0 to 8000 A 800 A can read and display.

  • Page 49: Load Calculations

    Timers > General Parameter Range Default Breaker Close Delay 0.1 to 30 s Load calculations For automatic mains failure (AMF) applications, you can place the current transformer (CT) on the line from the genset or on the load cable. The load calculations are based on where the CT is placed. If the location of the CT is on the On Alt Output cable, which means the CT is on the genset side, then the load calculations are based on the genset load.
  • Page 50 Alarms and their causes Alarms Causes/Indication Actions The measured oil pressure is less than the configured Shutdown Low Oil Pressure (Sensor) value. Warning Shutdown Warning Low Oil Pressure (Switch) The switch has measured a low oil pressure. Electrical Trip Notification The measured fuel level is less than the configured Shutdown Low Fuel level (Sensor)
  • Page 51 Alarms Causes/Indication Actions Emergency stop is activated. Emergency Stop Shutdown The emergency stop is configured as a digital input, and the input has triggered for longer than the configured time. Shutdown The charge alternator voltage is less than the Warning Charge Fail configured value.
  • Page 52 Alarms Causes/Indication Actions Shutdown Warning DG Phase Reversal Alternator phase sequence (L1-L2-L3) is not correct. Electrical Trip Notification Mains Phase Reversal Error during mains operation. Notification Shutdown LOP/Ckt Open (terminal The oil pressure sensor on terminal 26 is not detected Warning (circuit open).
  • Page 53 Alarms Causes/Indication Actions Shutdown Breaker close failure. Unable to close the genset Warning Fail To Close Gen Output breaker. Electrical Trip Notification Shutdown Fail To Close Mains Breaker close failure. Unable to close the mains Warning Output breaker. Electrical Trip Notification Shutdown Breaker close failure.

  • Page 54: Engine Functions

    6. Engine functions Engine sequences The engine start and stop sequences are started automatically if AUTO mode is selected. In manual mode, the operator has to initiate the sequences. Engine start functions 6.2.1 Start sequence The following drawing shows the start sequence of the genset. Configure the run coil timer to activate the fuel relay output and the idle mode output before pre-heat is completed.
  • Page 55 Timers > General Parameter Range Default Safety Monitoring Delay 10 to 60 s 10 s Warm-Up Delay 0 to 60 s ISV Pull Signal Timer 0.1 s Engine Engine > Preheat Parameter Range Default Preheat Timer 0 to 1200 s 10 s Engine >...
  • Page 56 Start sequence flowchart 1. The controller sends a start signal to the genset. 2. The Start Delay timer is activated. 3. When the Start Delay timer expires, the pre-heating function is activated if this is configured. If pre-heating is not configured, go to step 7 (crank hold). 4.

  • Page 57: Engine Stop Functions

    Engine stop functions 6.3.1 Stop sequence The stop sequence is activated if a stop command is given. The stop sequence includes the cooling down time if the stop is a normal or controlled stop. Timers > General Parameter Range Default Engine Cooling Time 0 to 300 s Stop Action...

  • Page 58: Stop Sequence Flowchart

    6.3.2 Stop sequence flowchart 1. The genset breaker opens if there is a breaker in the application. 2. A stop command is given. You can activate the command with a digital input or Modbus. You can only use the display buttons in manual mode. 3.

  • Page 59: Idle Mode

    Idle mode The purpose of the idle mode function is to allow the engine to operate at idle speed before ramping up to rated speed. You can activate idle mode using a digital input or a timer. If you have configured an input and a timer for idle mode, then the timer is overruled.

  • Page 60: Coolant Temperature

    Stop sequence for idle mode You can also activate idle mode during the stop sequence. Go to Engine > Speed Monitoring > Stopping Idle Time to configure the timer for the idle stop time. If you set the timer to 0 seconds, idle mode is not activated during the stop sequence.
  • Page 61 3. Go to the Outputs tab and select the output you want to use. 4. Use the drop-down list next to the output to select Coolant Heater Control Output as the source. 5. Go to the Engine tab and select Coolant Control. 6.

  • Page 62: Engine Pre-Heater

    Engine pre-heater This function is used to control the temperature of the engine before the engine starts. The function is only active when the engine is stopped. A temperature sensor is used to activate an external heating system to keep the engine at a minimum temperature.

  • Page 63: Other Functions

    Parameter Range Default Description for the engine temperature (Engine Coolant Temp Threshold). Engine Coolant Temp The coolant temperature the engine must reach 10 to 300 °C 25 °C Threshold during pre-heat. Other functions 6.7.1 Maintenance timer The controller has one timer to monitor maintenance intervals. The timer function is based on engine running hours or a due date.
  • Page 64 Engine stop Cooling down Extended stop Keyswitch output User manual 4189341354A EN Page 64 of 72...

  • Page 65: Modbus

    For more information about Modbus in general and the Modbus protocol, refer to the documentation freely available at http://www.modbus.org. Refer to the Modbus tables, available for download at www.deif.com, to see how the controller data is mapped to the Modbus addresses.
  • Page 66 Byte Field Comments Number of registers to write - high byte Number of registers to write must be between 1 to Number of registers to write - low byte Number of data bytes to follow (n) Value at first register Value at last register 7+n/8+n Error check CRC...

  • Page 67: Inputs And Outputs

    8. Inputs and outputs Digital inputs Source Description Not used The digital input is not used. User configured The digital input is configured by the user. The input is activated when the fuel level is less than the configured value. Low fuel level switch The configured alarm is shown.

  • Page 68: Digital Outputs

    Source Description • Mains monitoring is enabled and there is a mains failure. The input is deactivated. The is still a mains failure and the mains breaker opens. When this input is activated an alarm is shown on the display. You can V-belt broken switch configure the alarm type.
  • Page 69 Output source Description Dig In F This output is activated when digital input F is activated. Dig In G This output is activated when digital input G is activated. Dig In H This output is activated when digital input H is activated. Dig In I This output is activated when digital input I is activated.
  • Page 70 Output source Description This output is activated when the shutdown alarm for gross overspeed is Gross over speed shutdown activated. This output is activated when the start relay is activated during the engine Start relay start sequence. This output is activated when the alarm for the temperature sensor (open Temp sensor open circuit circuit) is activated.

  • Page 71: Troubleshooting

    9. Troubleshooting General troubleshooting Fault Action • Check the battery voltage. • Check the fuse on the battery supply. The controller does not power ON. • Check continuity between battery positive and controller terminal 2. • Check continuity between battery ground and controller terminal 1. The controller display freezes or hangs •...
  • Page 72 Fault Action • Check if the MPU signal (if used), and main alternator voltage signal (L1 phase) are received by the controller terminals. The engine runs, but the controller shows genset to be OFF. • Check if the LOP and LLOP are working OK. Check the wiring to the controller.

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