Deif SGC 421 User manual

SGC 421
Single Genset Controller
User manual
4189341355A

1. Introduction
1.1 About...................................................................................................................................................................................................................................................5
1.2 Function overview .....................................................................................................................................................................................................................5
1.3 About the User manual...........................................................................................................................................................................................................6
1.3.1 General purpose..................................................................................................................................................................................................................6
1.3.2 Software versions..............................................................................................................................................................................................................6
1.4 Warnings and safety................................................................................................................................................................................................................ 6
1.4.1 Symbols for hazard statements..................................................................................................................................................................................6
1.4.2 Symbols for general notes........................................................................................................................................................................................... 6
1.4.3 Electrical safety.................................................................................................................................................................................................................. 7
1.4.4 Safety during installation and operation...............................................................................................................................................................7
1.5 Legal information........................................................................................................................................................................................................................7
1.5.1 Warranty...................................................................................................................................................................................................................................7
1.5.2 Disclaimer...............................................................................................................................................................................................................................7
1.5.3 Copyright................................................................................................................................................................................................................................7
2. Installation
2.1 Dimensions.....................................................................................................................................................................................................................................8
2.2 Tools and materials.................................................................................................................................................................................................................. 8
2.3 Mounting.........................................................................................................................................................................................................................................9
2.4 Terminals......................................................................................................................................................................................................................................10
2.5 Wiring............................................................................................................................................................................................................................................. 12
2.5.1 Typical wiring..................................................................................................................................................................................................................... 12
2.5.2 Wiring guidelines - best practice for grounding............................................................................................................................................13
2.5.3 Analogue inputs...............................................................................................................................................................................................................14
2.5.4 AC connections................................................................................................................................................................................................................15
2.5.5 Rotary actuator outputs..............................................................................................................................................................................................17
2.5.6 Current transformer  ground...........................................................................................................................................................................18
2.5.7 Voltage measurement fuses.....................................................................................................................................................................................18
3. Display and menus
3.1 Display, buttons, and LEDs.................................................................................................................................................................................................19
3.2 Display settings.......................................................................................................................................................................................................................20
3.2.1 Display...................................................................................................................................................................................................................................20
3.2.2 Power save function.....................................................................................................................................................................................................20
3.2.3 Deep sleep.........................................................................................................................................................................................................................20
3.3 Monitoring menu.....................................................................................................................................................................................................................20
3.3.1 Load histogram.................................................................................................................................................................................................................21
3.4 Configuration menu...............................................................................................................................................................................................................21
3.4.1 Auto config exit mode..................................................................................................................................................................................................22
3.5 Configurable parameters...................................................................................................................................................................................................22
3.5.1 Module.................................................................................................................................................................................................................................. 22
3.5.2 Digital inputs.....................................................................................................................................................................................................................25
3.5.3 Analogue inputs..............................................................................................................................................................................................................25
3.5.4 Outputs................................................................................................................................................................................................................................34
3.5.5 Timers.................................................................................................................................................................................................................................. 34
3.5.6 Generator........................................................................................................................................................................................................................... 35
3.5.7 Mains.....................................................................................................................................................................................................................................40
3.5.8 Engine...................................................................................................................................................................................................................................42
3.5.9 Maintenance.....................................................................................................................................................................................................................48
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3.5.10 Rotary actuator............................................................................................................................................................................................................. 48
3.5.11 Display filter.....................................................................................................................................................................................................................49
3.5.12 Password ID.................................................................................................................................................................................................................... 49
3.6 Passwords...................................................................................................................................................................................................................................50
4. Modes of operation
4.1 Operation mode.........................................................................................................................................................................................................................51
4.2 AUTO mode.................................................................................................................................................................................................................................51
4.2.1 Island......................................................................................................................................................................................................................................51
4.2.2 Engine drive...................................................................................................................................................................................................................... 52
4.2.3 Automatic mains failure ...............................................................................................................................................................................52
4.2.4 Site battery monitoring...............................................................................................................................................................................................54
4.2.5 Cyclic mode...................................................................................................................................................................................................................... 56
4.2.6 Remote start/stop ........................................................................................................................................................................................................58
4.2.7 Auto exercise....................................................................................................................................................................................................................59
4.3 Manual mode.............................................................................................................................................................................................................................60
4.4 Test mode....................................................................................................................................................................................................................................61
4.5 Deep sleep...................................................................................................................................................................................................................................61
5. General functions
5.1 AC measurement systems.................................................................................................................................................................................................62
5.2 Nominal settings.....................................................................................................................................................................................................................62
5.2.1 Default nominal settings............................................................................................................................................................................................. 62
5.2.2 Alternative nominal settings.................................................................................................................................................................................... 62
5.3 Breakers....................................................................................................................................................................................................................................... 63
5.3.1 Breaker types....................................................................................................................................................................................................................63
5.3.2 Breaker spring load timer..........................................................................................................................................................................................63
5.4 Load calculations................................................................................................................................................................................................................... 64
5.5 Alarms........................................................................................................................................................................................................................................... 64
6. Engine functions
6.1 Engine sequences...................................................................................................................................................................................................................69
6.2 Engine start functions.........................................................................................................................................................................................................69
6.2.1 Start sequence.................................................................................................................................................................................................................69
6.3 Engine stop functions..........................................................................................................................................................................................................72
6.3.1 Stop sequence..................................................................................................................................................................................................................72
6.3.2 Stop sequence flowchart...........................................................................................................................................................................................73
6.4 Idle mode......................................................................................................................................................................................................................................74
6.5 Coolant temperature.............................................................................................................................................................................................................75
6.6 Engine pre-heater...................................................................................................................................................................................................................77
6.7 Other functions........................................................................................................................................................................................................................78
6.7.1 Maintenance timer...........................................................................................................................................................................................................78
6.7.2 Keyswitch............................................................................................................................................................................................................................78
7. Modbus
7.1 Modbus ..........................................................................................................................................................................................................................................80
7.1.1 About.......................................................................................................................................................................................................................................80
7.1.2 Connection details..........................................................................................................................................................................................................80
7.1.3  communication settings.............................................................................................................................................................................80
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8. CAN bus engine communication
8.1 Overview........................................................................................................................................................................................................................................81
8.1.1 About.......................................................................................................................................................................................................................................81
8.1.2 Default settings.................................................................................................................................................................................................................81
8.1.3 Supported engines..........................................................................................................................................................................................................81
8.1.4 Engine values on the display....................................................................................................................................................................................82
8.2 Engine communication settings....................................................................................................................................................................................82
8.3 Generic J1939.......................................................................................................................................................................................................................... 83
9. Inputs and outputs
9.1 Digital inputs...............................................................................................................................................................................................................................85
9.2 Digital outputs..........................................................................................................................................................................................................................86
10. Troubleshooting
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1. Introduction
1.1 About
The SGC 421 controller contains all the functions needed to protect and control the genset, the genset breaker, and a mains
breaker. The values and alarms are shown on the LCD display screen, and operators can control the system from the
display.
You can use the SGC 421 to monitor the site battery and significantly reduce your fuel consumption. The controller can also
be used to monitor the shelter temperature, engine and alternator parameters, and the true RMS voltage and current.
The controller can do electronic governing for engines with mechanical fuel systems when you have installed a rotary
actuator.
1.2 Function overview
This is an overview of the most important functions.
Monitoring
Use the SGC controller to monitor the site battery and the shelter temperature. The controller can also monitor the mains,
and engine and alternator parameters.
Inputs and outputs
• Analogue current/voltage inputs
• Analogue resistive inputs
• Differential input for site battery voltage
• Digital switch input
• DG alternator input
• Mains voltage input 
• Input for fuel reference selection
• Digital outputs
Communication
• for Modbus communication
• CAN bus engine communication
• USB interface to PC
Modes of operation
The SGC controller can operate in AUTO mode, manual mode, and test mode.
In AUTO mode, you can select these functions:
• Island
• Site battery monitoring
• Automatic mains failure 
• Cyclic mode
• Remote start/stop
• Auto exercise
• Engine drive
Display and language functions
• Backlit display
• Supports many languages, including English, Spanish, and Chinese
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• 2-level password protection
Alarms and event logs
• Event log for 100 events with real-time clock stamps
• Fuel theft alarm
Electronic governing
The SGC 421 can do electronic governing for engines with mechanical fuel systems when you have installed a rotary
actuator.
1.3 About the User manual
1.3.1 General purpose
This document includes important instructions that should be followed during installation and maintenance of the controller.
Only approved personnel can do the installation and maintenance work. The work must comply with all applicable state and
local electrical codes. Efficient and safe operation of the controller is only possible if equipment operation and configuration
is correct, and maintenance is completed.
1.3.2 Software versions
The information in this document relates to software versions:
Software Versions
SGC Application software 9.04
1.4 Warnings and safety
1.4.1 Symbols for hazard statements
WARNING
This shows potentially dangerous situations.
If the guidelines are not followed, these situations could result in death, serious personal injury, and equipment
damage or destruction.
CAUTION
This shows low level risk situation.
If the guidelines are not followed, these situations could result in minor or moderate injury.
1.4.2 Symbols for general notes
NOTE This shows general information.
More information
This shows where you can find more information.
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1.4.3 Electrical safety
You must ground the generator before you install the controller or do maintenance work. Failure to ground the generator
can result in injury or death.
Generators produce high electrical voltages. Do not touch terminals, bare wires, and while the generator and related
equipment are in operation. If you touch the generator, it can give you an electrical shock and result in death. Do not change
the interlocks.
Use the correct size for wires that are used for electrical connections and wirings. This is to make sure that the generator
can operate at the maximum electrical current.
1.4.4 Safety during installation and operation
Before you install the controller, make sure that all power voltage supplies are positively turned off at the source. Remove
the panel fuse to prevent accidental start of the generator. Disconnect the battery cables for the generator from the
negative battery terminal first. This is shown with a NEGATIVE, NEG, or (–). Reconnect the negative cable last. If not, this
can give you an electrical shock and possibly kill you.
Remove the electric power supply before you remove the controller or touch other electrical part. High voltage can cause
injury or death.
With floors of metal or concrete, use rubber insulation mats placed on wooden platforms, when you do work near the
generator or other electrical equipment. Make sure you wear dry clothes and shoes, and that your hands and feet are dry
when you operate electric devices or work with wires. Do not wear jewellery. Jewellery can cause a short circuit, which can
result in shock or burning.
If an accident caused by electric shock occurs, stop the electrical power source immediately. If this is not possible, use a
non-conducting object (for example a rope or a wooden stick) to remove the person with the injuries from the live
conductor. Do not touch the person with injuries. If the person with injuries is unconscious, use first aid and get medical
help immediately.
1.5 Legal information
1.5.1 Warranty
NOTICE
Warranty
The controller is not to be opened by unauthorised personnel. If opened anyway, the warranty will be lost.
1.5.2 Disclaimer
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. If there is a discrepancy, the English version prevails.
1.5.3 Copyright
© Copyright DEIF A/S. All rights reserved.
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2. Installation
2.1 Dimensions
Dimensions
Dimensions
Length: 233.0 mm  in)
Height: 173.0 mm  in)
Depth: 38.5 mm  in)
Panel cut-out
Length: 219.0 mm  in)
Height: 158.0 mm  in)
Tolerance: ± 0.3 mm  in)
2.2 Tools and materials
Tools required for mounting
Tool Used for
Safety equipment Personal protection, according to local standards and
requirements
Screwdriver, PH2 or 5 mm flat Tighten the fixing screw clamps, torque 0.15 N·m  lb-in)
Wire stripper, pliers and cutters Prepare wiring and trim cable ties
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NOTICE
Too much torque damages the screw clamps and/or controller housing
Do not use power tools during the installation.
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
2.3 Mounting
The controller is designed for mounting in the front panel.
Panel cutout:
• Length: 219.0 mm
• Height: 158.0 mm
• Tolerance: ± 0.3 mm
1. Insert the controller in the panel.
2. Insert the screw clamps:
*Click*
3.b.1 3.b.4
3.b.2 3.b.3
3. Tighten the screw clamps to 0.19 Nm. Do not tighten the clamps to more than 0.19 Nm.
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2.4 Terminals
Terminal Text Description Connector
1 GND Power ground

2 BATT + Power supply positive
3 DIG OUT A DC output - A
4 DIG OUT B DC output - B
5 DIG OUT C DC output - C
6 DIG OUT D DC output - D
7 DIG OUT E DC output - E
8 DIG OUT F DC output - F
9 DIG OUT G DC output - G
10  CHG ALT Input for charging alternator control
11 ANLG LOP / DIG J Analogue input for lube oil pressure sensor
Digital input J

12 ANLG FUEL LEVEL / DIG K Analogue input from fuel level sensor
Digital input K
13 ANLG ENG TEMP / DIG L Analogue input for engine temperature sensor
Digital input L
14 ANLG AUX 1 / DIG M
Analogue input auxiliary
Analogue input for shelter temperature sensor
Digital input M
15 ANLG AUX 2 / DIG N Analogue input auxiliary
Digital Input N
16 SCP Sensor common point
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