Deif CGC 400 Product guide

DEIF A/S · Frisenborgvej 33 · DK-7800 Skive · Tel.: [phone] · Fax: [phone] · [e-mail] · www.deif.com
DEIF A/S · Frisenborgvej 33 · DK-7800 Skive · Tel.: [phone] · Fax: [phone] · [e-mail] · www.deif.com
DEIF A/S · Frisenborgvej 33 · DK-7800 Skive · Tel.: [phone] · Fax: [phone] · [e-mail] · www.deif.com
DESIGNER'S REFERENCE HANDBOOK
Compact Genset Controller, CGC 400
● General product information
● Functional description
● Additional functions
● Protections
Document no.: 4189340786B
SW version: 1.00

1. General information
1.1. Warnings, legal information and safety..................................................................................................5
1.1.1. Warnings and notes ......................................................................................................................5
1.1.2. Legal information and disclaimer ..................................................................................................5
1.1.3. Safety issues ................................................................................................................................5
1.1.4. Electrostatic discharge awareness ...............................................................................................5
1.1.5. Factory settings ............................................................................................................................6
1.2. About the designer's reference handbook..............................................................................................6
1.2.1. General purpose ...........................................................................................................................6
1.2.2. Intended users ..............................................................................................................................6
1.2.3. Contents and overall structure ......................................................................................................6
2. General product information
2.1. Introduction.............................................................................................................................................7
2.1.1. Introduction....................................................................................................................................7
2.2. Type of product......................................................................................................................................7
2.3. Options...................................................................................................................................................7
2.3.1. Options .........................................................................................................................................7
2.4. PC utility software warning.....................................................................................................................7
2.4.1. PC USW warning ..........................................................................................................................7
3. Passwords
3.1. Passwords and parameter access.........................................................................................................8
3.1.1. Password.......................................................................................................................................8
3.1.2. Parameter access..........................................................................................................................9
4. Functional descriptions
4.1. Standard functions...............................................................................................................................10
4.1.1. Standard functions ......................................................................................................................10
4.1.2. Operation modes.........................................................................................................................10
4.1.3. Engine control..............................................................................................................................10
4.1.4. Generator protection (ANSI) .......................................................................................................10
4.1.5. Busbar protection (ANSI) ............................................................................................................11
4.1.6. Display.........................................................................................................................................11
4.1.7. M-Logic........................................................................................................................................11
4.2. Terminal strip overview........................................................................................................................11
4.2.1. Reference to Installation Instructions...........................................................................................11
4.3. Measurement systems.........................................................................................................................11
4.3.1. Single phase system....................................................................................................................11
4.3.2. Split phase system.......................................................................................................................12
4.3.3. Three-phase system....................................................................................................................12
4.4. Applications..........................................................................................................................................13
4.4.1. Applications and genset modes...................................................................................................13
4.4.2. Application design........................................................................................................................13
4.4.3. AMF (no back synchronisation)...................................................................................................15
4.4.4. Island operation...........................................................................................................................16
4.4.5. Load takeover..............................................................................................................................16
4.5. Running mode description....................................................................................................................16
4.5.1. Manual mode...............................................................................................................................16
4.5.2. Test mode....................................................................................................................................17
4.5.3. Simple test...................................................................................................................................17
4.5.4. Full test........................................................................................................................................17
4.5.5. Block mode..................................................................................................................................18
4.6. Single-line diagrams.............................................................................................................................18
4.6.1. Application illustration .................................................................................................................18
4.6.2. Automatic Mains Failure..............................................................................................................19
4.6.3. Island operation...........................................................................................................................19
4.6.4. Load takeover..............................................................................................................................20
CGC 400 DRH 4189340786 UK
DEIF A/S Page 2 of 96

4.7. Flowcharts............................................................................................................................................20
4.7.1. Flowcharts...................................................................................................................................20
4.7.2. Mode shift....................................................................................................................................21
4.7.3. MB open sequence......................................................................................................................22
4.7.4. GB open sequence......................................................................................................................23
4.7.5. Stop sequence.............................................................................................................................24
4.7.6. Start sequence.............................................................................................................................25
4.7.7. MB close sequence.....................................................................................................................26
4.7.8. GB close sequence......................................................................................................................27
4.7.9. Load takeover..............................................................................................................................28
4.7.10. Island operation.........................................................................................................................29
4.7.11. Automatic Mains Failure, AMF...................................................................................................30
4.7.12. Test sequence...........................................................................................................................31
4.8. Sequences...........................................................................................................................................32
4.8.1. Sequences...................................................................................................................................32
4.8.2. Start sequence.............................................................................................................................33
4.8.3. Start sequence conditions...........................................................................................................34
4.8.4. Running feedback........................................................................................................................35
4.8.5. Stop sequence.............................................................................................................................38
4.8.6. Breaker sequences......................................................................................................................40
4.8.7. AMF timers..................................................................................................................................40
5. Display and menu structure
5.1. Reference to operator's manual...........................................................................................................43
6. Engine communication
6.1. Reference to H5 manual......................................................................................................................44
6.1.1. Engine communication ...............................................................................................................44
7. Additional functions
7.1. Start functions......................................................................................................................................45
7.1.1. Start functions..............................................................................................................................45
7.1.2. Digital feedbacks.........................................................................................................................45
7.1.3. Analogue tacho feedback............................................................................................................46
7.1.4. Oil pressure.................................................................................................................................47
7.2. Phase sequence error..........................................................................................................................49
7.2.1. Description of phase sequence error ..........................................................................................49
7.3. Breaker types.......................................................................................................................................49
7.3.1. Breaker types...............................................................................................................................49
7.4. Breaker spring load time......................................................................................................................49
7.4.1. Principle.......................................................................................................................................50
7.5. Alarm inhibit..........................................................................................................................................51
7.5.1. Run status (6160)........................................................................................................................53
7.6. Access lock..........................................................................................................................................54
7.7. Digital mains breaker control................................................................................................................56
7.8. Command timers..................................................................................................................................57
7.9. Running output.....................................................................................................................................58
7.10. Idle running.........................................................................................................................................59
7.10.1. Idle running................................................................................................................................59
7.10.2. Description.................................................................................................................................59
7.10.3. Examples...................................................................................................................................60
7.10.4. Inhibit.........................................................................................................................................61
7.10.5. Running signal...........................................................................................................................61
7.10.6. Idle speed flowcharts.................................................................................................................61
7.10.7. Start...........................................................................................................................................62
7.10.8. Stop...........................................................................................................................................63
7.11. Engine heater.....................................................................................................................................63
7.11.1. Engine heater alarm..................................................................................................................64
7.12. Ventilation...........................................................................................................................................64
CGC 400 DRH 4189340786 UK
DEIF A/S Page 3 of 96

7.12.1. Max. ventilation alarm................................................................................................................65
7.13. Not in auto..........................................................................................................................................65
7.14. Fuel pump logic..................................................................................................................................65
7.14.1. Fuel fill check.............................................................................................................................66
7.15. Fail class............................................................................................................................................67
7.15.1. Fail class....................................................................................................................................67
7.15.2. Engine running...........................................................................................................................67
7.15.3. Engine stopped..........................................................................................................................68
7.15.4. Fail class configuration..............................................................................................................68
7.16. Service timers.....................................................................................................................................69
7.17. Wire fail detection...............................................................................................................................70
7.18. Digital inputs.......................................................................................................................................71
7.18.1. Functional description................................................................................................................72
7.19. Outputs...............................................................................................................................................74
7.19.1. Functional description................................................................................................................75
7.20. Multi-inputs.........................................................................................................................................76
7.20.1. Multi-inputs................................................................................................................................76
7.20.2. 4-20 mA ....................................................................................................................................77
7.20.3. Pt100/Pt1000.............................................................................................................................77
7.20.4. RMI inputs..................................................................................................................................77
7.20.5. RMI oil........................................................................................................................................77
7.20.6. RMI water..................................................................................................................................78
7.20.7. RMI fuel.....................................................................................................................................79
7.20.8. Illustration of configurable inputs...............................................................................................80
7.20.9. Configuration.............................................................................................................................81
7.20.10. Scaling of 4-20 mA inputs........................................................................................................81
7.20.11. Binary ......................................................................................................................................83
7.21. Input function selection.......................................................................................................................83
7.22. Language selection............................................................................................................................84
7.22.1. Language selection ...................................................................................................................84
7.23. Text in status line...............................................................................................................................84
7.23.1. Standard texts............................................................................................................................85
7.24. Counters.............................................................................................................................................86
7.25. M-Logic...............................................................................................................................................87
7.26. Buzzer................................................................................................................................................87
7.26.1. Buzzer .......................................................................................................................................87
7.27. USW communication..........................................................................................................................87
7.27.1. USW communication ................................................................................................................87
7.28. Nominal settings.................................................................................................................................88
7.28.1. How to change the nominal settings..........................................................................................88
7.29. Scaling................................................................................................................................................88
7.30. Differential measurement...................................................................................................................89
7.30.1. Differential measurement...........................................................................................................89
7.31. Filename extension............................................................................................................................91
7.31.1. Filename extension ...................................................................................................................91
7.32. Modbus parameters...........................................................................................................................91
7.32.1. Modbus parameters ..................................................................................................................91
7.33. Battery low voltage alarm timer..........................................................................................................91
7.33.1. Battery low voltage alarm timer ................................................................................................91
8. Protections
8.1. General.................................................................................................................................................93
8.1.1. General........................................................................................................................................93
8.2. Voltage-dependent (restraint) overcurrent...........................................................................................95
9. Parameter list
9.1. Related parameters..............................................................................................................................96
9.1.1. Related parameters ....................................................................................................................96
CGC 400 DRH 4189340786 UK
DEIF A/S Page 4 of 96

1. General information
1.1 Warnings, legal information and safety
1.1.1 Warnings and notes
Throughout this document, a number of warnings and notes with helpful user information will be presented.
To ensure that these are noticed, they will be highlighted as follows in order to separate them from the gener-
al text.
Warnings
Warnings indicate a potentially dangerous situation, which could result in death, personal in-
jury or damaged equipment, if certain guidelines are not followed.
Notes
Notes provide general information, which will be helpful for the reader to bear in mind.
1.1.2 Legal information and disclaimer
DEIF takes no responsibility for installation or operation of the generator set. If there is any doubt about how
to install or operate the engine/generator controlled by the unit, the company responsible for the installation or
the operation of the set must be contacted.
The unit is not to be opened by unauthorised personnel. If opened anyway, the warranty will be
lost.
Disclaimer
DEIF A/S reserves the right to change any of the contents of this document without prior notice.
1.1.3 Safety issues
Installing and operating the unit may imply work with dangerous currents and voltages. Therefore, the instal-
lation should only be carried out by authorised personnel who understand the risks involved in working with
live electrical equipment.
Be aware of the hazardous live currents and voltages. Do not touch any AC measurement in-
puts as this could lead to injury or death.
DEIF do not recommend to use the USB as the primary power supply for the unit.
1.1.4 Electrostatic discharge awareness
Sufficient care must be taken to protect the terminal against static discharges during the installation. Once the
unit is installed and connected, these precautions are no longer necessary.
CGC 400 DRH 4189340786 UK General information
DEIF A/S Page 5 of 96

1.1.5 Factory settings
The unit is delivered from factory with certain factory settings. These are based on average values and are
not necessarily the correct settings for matching the engine/generator set in question. Precautions must be
taken to check the settings before running the engine/generator set.
1.2 About the designer's reference handbook
1.2.1 General purpose
This Designer's Reference Handbook mainly includes functional descriptions, presentation of display unit and
menu structure, the procedure for parameter setup and reference to parameter lists.
The general purpose of this document is to provide useful overall information about the functionality of the
controlelr and its applications. This document also offers the user the information he needs in order to suc-
cessfully set up the parameters needed in his specific application.
Please make sure to read this document before starting to work with the controller and the
genset to be controlled. Failure to do this could result in human injury or damage to the equip-
ment.
1.2.2 Intended users
This Designer's Reference Handbook is mainly intended for the panel builder designer in charge. On the ba-
sis of this document, the panel builder designer will give the electrician the information he needs in order to
install the unit, e.g. detailed electrical drawings. In some cases, the electrician may use these installation in-
structions himself.
1.2.3 Contents and overall structure
This document is divided into chapters, and in order to make the structure simple and easy to use, each
chapter will begin from the top of a new page.
CGC 400 DRH 4189340786 UK General information
DEIF A/S Page 6 of 96

2. General product information
2.1 Introduction
2.1.1 Introduction
This chapter will deal with the unit in general and its place in the DEIF product range.
The CGC, short for Compact Genset Controller, is part of the DEIF Compact Genset Controller range, based
on standard advanced software of Multi-line 2. The concept of the CGC is to offer a cost-effective solution to
genset builders, who need a flexible generator protection and control unit for small single to medium and
large genset applications.
2.2 Type of product
The compact genset controller is a micro-processor based control unit containing all necessary functions for
protection and control of a genset.
It contains all necessary 3-phase measuring circuits, and all values and alarms are presented on the LCD
display.
The CGC 400 will come in two different variants: CGC 412 and CGC 413.
The CGC 412 is the unit that is able to perform auto start, and the CGC 413 is able to make the automatic
mains failure (AMF) sequences. The hardware for the two products is different, therefore some of the sequen-
ces described in this document are only relevant to one of the variants. You will find a detailed description of
the available functions in each product in the chapter "Standard Functions".
For detailed specifications of the hardware, please refer to the datasheet.
2.3 Options
2.3.1 Options
When ordering the CGC 400, it comes with a number of features, which were options in the other DEIF prod-
ucts.
The customer cannot add or remove any of these features/options.
The included features are A1, C2, H2, H5.
2.4 PC utility software warning
2.4.1 PC USW warning
It is possible to remote-control the genset from the PC utility software or AGI. To avoid person-
al injury, make sure that it is safe to remote-control the genset.
DEIF do not recommend to use the USB as the primary power supply for the unit.
CGC 400 DRH 4189340786 UK General product information
DEIF A/S Page 7 of 96

3. Passwords
3.1 Passwords and parameter access
3.1.1 Password
The unit includes three password levels. All levels can be adjusted in the PC software.
Available password levels:
Password level Factory setting Access
Customer Service Master
Customer 2000 X
Service 2001 X X
Master 2002 X X X
A parameter cannot be entered with a password that is ranking too low. But the settings can be displayed
without password entry.
Each parameter can be protected by a specific password level. To do so, the PC utility software must be
used. Enter the parameter to be configured and select the correct password level.
CGC 400 DRH 4189340786 UK Passwords
DEIF A/S Page 8 of 96

The password level can also be changed from the parameter view in the column "Level".
3.1.2 Parameter access
To gain access to adjust the parameters, the password level must be entered:
If the password level is not entered, it is not possible to enter the parameters.
The customer password can be changed in jump menu 9116. The service password can be
changed in jump menu 9117. The master password can be changed in jump menu 9118.
The factory passwords must be changed if the operator of the genset is not allowed to change
the parameters.
It is not possible to change the password at a higher level than the password entered.
CGC 400 DRH 4189340786 UK Passwords
DEIF A/S Page 9 of 96

4. Functional descriptions
4.1 Standard functions
4.1.1 Standard functions
This section includes functional descriptions of standard functions as well as illustrations of the relevant appli-
cation types. Flowcharts and single-line diagrams will be used in order to simplify the information.
The standard functions are listed in the following paragraphs.
The table below describes the genset modes that are available, depending on the variant of the CGC to be
used.
Application Comment
Automatic Mains Failure (AMF) (no back sync.) CGC 413
Island operation CGC 412/CGC 413
Load takeover CGC 413
On the hardware point of view, the CGC 412 has a lighter specification than the CGC 413.
The table below describes which points differ from each other.
Feature (terminal numbers) Available on CGC 412 Available on CGC 413
Mains measurement (term. 28 to 32) No Yes
Extra multi-inputs (term. 58 and 59) No Yes
Extra binary inputs (term. 56 and 57) No Yes
4.1.2 Operation modes
● Automatic Mains Failure
● Island operation
● Load takeover
4.1.3 Engine control
● Start/stop sequences
● Run and stop coil
4.1.4 Generator protection (ANSI)
● 2 x reverse power (32)
● 5 x overload (32)
● 4 x overcurrent (50/51)
● 2 x overvoltage (59)
● 3 x undervoltage (27)
● 3 x over-/underfrequency (81)
● Multi-inputs (digital, 4-20 mA, Pt100, Pt1000 or RMI)
● Digital inputs
CGC 400 DRH 4189340786 UK Functional descriptions
DEIF A/S Page 10 of 96