Smartgen MGC100 User manual

MGC100
PETROL GENSET CONTROLLER
USER MANUAL

MGC100 Petrol Genset Controller User Manual Page 2 of 16
CONTENT
1 OVERVIEW ......................................................................................................................................................5
2 PERFORMANCE AND CHARACTERS ............................................................................................................5
3 SPECIFICATION..............................................................................................................................................6
4 OPERATION ....................................................................................................................................................7
4.1 PUSHBUTTONS .......................................................................................................................................7
4.2 CONTROL PANEL AND ICON DECRIPTION ...........................................................................................7
4.2.1 CONTROLLER PANEL.......................................................................................................................7
4.2.2 ALARM ICON INDICATION...............................................................................................................8
4.2.3 PANEL INDICATOR...........................................................................................................................8
4.3 OPERATION .............................................................................................................................................8
4.3.1 REMOTE START SEQUENCE............................................................................................................8
4.3.2 REMOTE STOP SEQUENCE..............................................................................................................8
4.3.3 MANUAL START/STOP....................................................................................................................9
5 PROTECTION..................................................................................................................................................9
6 CONNECTION .............................................................................................................................................. 10
7 DEFINITION AND RANGE OF PARAMETERS ............................................................................................. 11
8 PARAMETERS SETTING ............................................................................................................................. 14
8.1 PARAMETERS REGULATION ............................................................................................................... 14
8.2 RESTORE FACTORY SETTINGS........................................................................................................... 14
8.3 ELIMINATE ACCUMULATED TIME...................................................................................................... 14
9 CASE DIMENSIONS..................................................................................................................................... 15
10 TYPICAL APPLICATION............................................................................................................................ 16
11 FAULT FINDING......................................................................................................................................... 16

MGC100 Petrol Genset Controller User Manual Page 3 of 16
Chinese trademark
English trademark
SmartGen —make your generator smart
SmartGen Technology Co., Ltd.
No.28 Jinsuo Road
Zhengzhou
Henan Province
P. R. China
Tel: [phone]
[phone] (overseas)
Fax: [phone]
Web: www.smartgen.com.cn/
www.smartgen.cn/
Email: [e-mail]
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.
Table 1 Version Hsitory
Date
Version
Content
2015-06-29
1.0
Original release.
2016-12-12
1.1
1. Modify AC default, over speed threshold, crank disconnect conditions,
crank disconnect speed, safety running delay and programmable
outputs default ;
2. Add gen under/over frequency protection functions;
3. Add gen under/over frequency threshold and under/over frequency
shutdown delay parameter.
4. Programmable output ports add “Air Flap Choke” function
2022-07-22
1.2
Update company logo and manual format.

MGC100 Petrol Genset Controller User Manual Page 4 of 16
Table 2 Notation Clarification
Sign
Instruction
NOTE
Highlights an essential element of a procedure to ensure correctness.
CAUTION!
Indicates a procedure or practice, which, if not strictly observed, could result in
damage or destruction of equipment.
WARNING!
Indicates a procedure or practice, which could result in injury to personnel or loss
of life if not followed correctly.

MGC100 Petrol Genset Controller User Manual Page 5 of 16
1OVERVIEW
MGC100 Petrol Genset Controller is designed for start and protection of single genset. It allows
manual and remote start/stop, data measurement, alarm indication, shutdown protection functions.
The controller fit with LED display, button-press operation, and it achieves precise measurement of
various parameters, protection and control of genset. All of parameters can be configured from front
panel. The controller which can be widely used in data display and fault protection of a number of small
diesel and petrol genset with easy operation, reliable work, compact structure and simple connections.
2PERFORMANCE AND CHARACTERS
——Multifunctional Nixie tube display, press button to operate;
Switchable displayed battery:
Generate voltage V
Generate frequency Hz
Accumulated running time (maximum is 9999h) H
Battery voltage V
——There is a red LED on the panel for displaying working and alarm status;
——Chose to control Petrol Genset or Diesel Genset via connection;
——Suitable for 3-phase 4-wire, 3-phase 3-wire, 2-phase 3-wire, single phase 2-wire (120V/240V)
systems with frequency 50/60/Hz;
——Protection function for gen under/over volt, over speed, fail to stop, emergency stop, high
water temp, low oil pressure; when in protection, LED indicates alarm, and goes shutdown
protection;
——Generator rotate speed can derive from gen frequency or speed sensor;
——4-way digital input (high water temperature input, low oil pressure input, remote input, urgency
stop input;
——2 relay output (start output, fuel output) and the fuel output is programmable output port;
——1 flexible transistor output can be set to preheat output, alarm output, energize to stop output
and idle output, etc;
——Three start success conditions (speed sensor, generator, speed sensor+ generator) can be
chosen;
——Parameter setting: parameters can be modified and stored in internal EEPROM memory and
cannot be lost even in case of power outage; all of them can be adjusted using front panel of
the controller;
——Modular design, anti-flaming ABS plastic enclosure, embedded installation way; compact
structure with easy mounting.

MGC100 Petrol Genset Controller User Manual Page 6 of 16
3SPECIFICATION
Table 3 Technical Parameters
Item
Contents
Working Voltage
DC9.0V to 18.0V, continuous power supply (suitable for DC12V
system)
Overall Consumption
Regular working:<1W (Standby mode:<0.4W)
AC Volt Input:
3-phase 4-wire
3-phase 3-wire
2-phase 3-wire
Single phase 2-wire
AC 30V –AC 360V (ph-N)
AC 50V –AC 620V (ph-ph)
AC 30V –AC 360V (ph-N)
AC 30V –AC 360V (ph-N)
AC Frequency
50Hz/60Hz
Speed Sensor Voltage
1.0V to 24V(effective value)
Speed Sensor Frequency
10000Hz(Max)
Start Relay
7A DC12V power supply
Fuel Relay
7A DC12V power supply
Flexible Transistor
1A DC12V connect to (B+)
Overall Dimensions
105.8mm x 61mm x 36.6mm
Panel Cutout
92mm x 44mm
Working Temperature
(-25~+70)°C
Working Humidity
(20~93)%RH
Storage Temperature
(-25~+70)°C
Protection Level
IP55 Gasket
Insulation
Apply AC2.2kV voltage between high voltage terminal and low
voltage terminal; The leakage current is not more than 3mA within
1min.
Weight
94g

MGC100 Petrol Genset Controller User Manual Page 7 of 16
4OPERATION
4.1 PUSHBUTTONS
Table 4 Keys Description
Icon
Definition
Explain
Stop/-
Stop the running genset.
In stop status, press it to stop generator immediately.
In stop status, press it to reset any shutdown alarm.
In stop status, press it for more than 2s to test if the nixie tube and panel
indicator are normal.
In setting menu, upturn or decrease parameter value (it can be
double-clicked).
In setting menu, press it for more than 3s to exit this menu.
Page/Confirm
Switch display contents of nixie tube in normal status.
Pressing it for more than 3 seconds entry the parameter configuration
menu.
In setting menu, press this button to modify and save value.
Run/+
Manual start in stop status.
In setting menu, downturn or increase parameter value (it can be
double-clicked).
4.2 CONTROL PANEL AND ICON DECRIPTION
4.2.1 CONTROLLER PANEL
Fig.1 Controller Panel

MGC100 Petrol Genset Controller User Manual Page 8 of 16
4.2.2 ALARM ICON INDICATION
Table 5 Alarm Icon Indication
Icon
Descripiton
Icon
Descripiton
Emergency Stop Alarm
Over Speed Alarm
High Temp Alarm
Low Oil Pressure Alarm
Fail to Start Alarm
Over/Under Volt Alarm
4.2.3 PANEL INDICATOR
Working status indicator: in start delay duration, start indicator will blink; in other working duration,
the indicator will always light; in stop status, the indicator will extinguish.
Stop status indicator: in stop process, stop indicator will blink; in stop duration, the indicator will
always light; in start status, the indicator will extinguish.
4.3 OPERATION
4.3.1 REMOTE START SEQUENCE
a) When remote start signal is active, “Start Delay” timer is initiated;
b) When start delay is over, preheat relay energizes (if configured), “Preheat delay” is initiated;
c) After the above delay, the Fuel Relay is energized, and then one second later (if configured),
the Start Relay is engaged and the Preheat Relay switch off. If genset fails to fire during this
cranking attempt then the fuel relay and start relay are disengaged for the pre-set rest period;
“Crank Rest Time” begins and wait for the next crank attempt (after the “Crank Rest Time”
delay start for 3s, preheat and ETS start to output; after “Crank Rest Time” finished, ETS switch
off, and after fuel output for 1s, preheat switch off);
d) Should this start sequence continue beyond the set number of attempts, the fail to start
indicator will be illuminated;
e) In case of successful crank attempt, the “Safety On” timer is activated, allowing Low Oil
Pressure Input and Under Pressure are inhibited. As soon as this delay is over, “start idle”
delay is initiated (if configured);
f) During “Start Idle” delay, under pressure alarm is inhibited. When this delay is over, “Warming
Up” delay is initiated (if configured);
g) After the “Warming Up” delay, genset will enter into Normal Running status.
4.3.2 REMOTE STOP SEQUENCE
a) After remote start, when remote start signal is invalid, “Stop Delay” timer is initiated;
b) Once this “stop delay” has expired, the “Cooling Delay” is then initiated;
c) During “Stop Idle” Delay (if configured), idle relay is energized;
d) “ETS Solenoid Hold” begins, ETS relay is energized while fuel relay is de-energized;
e) “Fail to Stop Delay”begins, complete stop is detected automatically;
f) Genset is placed into standby mode after its “After Stop Time”.

MGC100 Petrol Genset Controller User Manual Page 9 of 16
4.3.3 MANUAL START/STOP
a) Press to start genset. It will detect complete start and accelerate to high-speed running
automatically. With high temperature, low oil pressure, over speed and volt abnormal during
genset running, controller can protect it to stop quickly (Please refer to Start Sequence b-g).
b) Press to stop the running genset (Please refer to Stop Sequence b-f).
NOTE:
a) The genset can be stopped manually in remote start status; at this time, remote input is inhibited and it will be
active when remote input is closed again.
b) After start conditions are satisfied, accumulative running timer will be initiated; at the same time, the last
blinking decimal of nixie tube indicates that genset works normally.
5PROTECTION
1) Low Oil Pressure: detect after Safety On, Alarm Stop when Low Oil Pressure input is active and
lasts for 2s.
2) High Temperature: detect when start, Alarm Stop when High Temperature is active and lasts
for 2s.
3) Over Speed: detect when start, Alarm Stop after duration exceeds Over Speed Stop Delay.
4) Gen Over Volt: Alarm Stop when the controller detects genset voltage exceeds overvoltage
value and delay exceeds abnormal delay.
5) Gen Under Volt: Alarm Stop when the controller detects genset voltage less than under voltage
value and delay less than abnormal delay.
6) Emergency Stop: ETS output immediately when Emergency Stop is active, in the meanwhile
fuel, preheat and start signal are cut off and Emergency Shutdown Alarm Signal is sent.
7) Fail to Start: Alarm Stop when start failed in preset start times.
8) Gen Under Frequency: When genset is normal running, controller detects gen frequency falls
below under frequency value and the “under frequency” delay has expired, under frequency
shutdown alarm will be sent.
9) Gen Over Frequency: Detection when start genset, if gen frequency exceeds over frequency
value and the “over frequency” delay has expired, over frequency shutdown alarm will be sent.

MGC100 Petrol Genset Controller User Manual Page 10 of 16
6CONNECTION
Fig.2 Rear Panel
Table 6 Terminal Connection Description
No.
Function
Cable Size
Note
1
B-
1.0mm2
Connected with negative of starter battery.
2
B+
1.0mm2
Connected with negative of starter battery. If wire length
is over 30m, better to double wires in parallel. Max. 10A
fuse is recommended.
3
Start Relay Output
1.0mm2
B+ power is supplied by terminal 2, rated 7A.
Connected with start coil of starter.
4
Fuel Relay Output
1.0mm2
B+ power is supplied by terminal 2, rated 7A.
5
Controller Types
1.0mm2
When this terminal short connected with (B+), it used as
diesel genset controller.
When this terminal connected with nothing, it used as
petrol genset controller.
6
High Temperature
1.0mm2
Ground connected is active (B-).
7
Low Oil Pressure
1.0mm2
Ground connected is active (B-).
8
Emergency Stop
1.0mm2
Ground connected is active (B-).
9
Remote Start
1.0mm2
Ground connected is active (B-).
10
Aux. Transistor
1.0mm2
B- power is supplied by terminal 1, rated 1A.
11
Magnetic Pickup 2
(B-) has already connected
with controller innerly.
0.5mm2
Connected with Rotate Speed Sensor, shielding line is
recommended.
12
Magnetic Pickup 1
0.5mm2
13
N
1.0mm2
Connected with N wire.
14
W phase voltage monitor
1.0mm2
Connected with W phase (2A fuse is recommended).
15
V phase voltage monitor
1.0mm2
Connected with V phase (2A fuse is recommended).
16
U phase voltage monitor
1.0mm2
Connected with U phase (2A fuse is recommended).

MGC100 Petrol Genset Controller User Manual Page 11 of 16
7DEFINITION AND RANGE OF PARAMETERS
Table 7 Parameter Content and Range
No.
Content
Parameter Range
Default
Description
P00
AC
(0-3)
0
0: Single phase 2-wire
1: 2-phase 3-wire
2: 3-phase 3-wire
3: 3-phase 4-wire
P01
Over Volt Threshold
(30-620)V
264
When generate voltage exceed this value and
last for “Abnormal Delay”, then it is regarded as
over voltage and at the same time “Gen
Abnormal” signal will be sent. When set value
is 620V, it won’t detect over voltage signal.
P02
Under Volt
Threshold
(30-620)V
196
When generate voltage is under this value and
last for “Abnormal Delay”, then it is regarded as
under voltage and at the same time “Gen
Abnormal” signal will be sent. When set value
is 30V, it won’t detect under voltage signal.
P03
Gen Abnormal
Delay
(0-20)s
10
Alarm delay value of generate over or under
voltage.
P04
Start Delay
(0-3600)s
1
Time from remote start signal is active to start
the genset.
P05
Stop Delay
(0-3600)s
1
Time from remote stop signal is deactivated to
stop the genset.
P06
Start Attempts
(1-10)times
3
It is maximum of start attempts when starter
failed to start. When reach set attempts the fail
to start alarm will be initiated.
P07
Preheat Delay
(0-300)s
0
Time of pre-powering heat plug before starter
is powered up.
P08
Crank Time
(3-60)s
8
Time of starter power up.
P09
Crank Rest Time
(3-60)s
10
The waiting time before second power up when
engine start fail.
P10
Safety On Time
(1-60)s
5
Alarms for low oil pressure and under voltage
are inactive.
P11
Start Idle Time
(0-3600)s
0
Idle running time of genset when starting.
P12
Warming Up Time
(3-3600)s
10
Warming time between genset close and high
speed running.
P13
Cooling Time
(3-3600)s
10
Radiating time before stop genset, after it
unloads.
P14
Stop Idle Time
(0-3600)s
0
dle running time when pump unit stop.
P15
ETS Hold Time
(0-120)s
20
Stop electromagnet’s power on time when
pump unit is stopping.
P16
Stop Time
(0-120)s
0
Time between ending of pump unit idle delay
and stopped when “ETS Time” is set as 0;
Time between ending of ETS hold delay and

MGC100 Petrol Genset Controller User Manual Page 12 of 16
No.
Content
Parameter Range
Default
Description
stopped when “ETS Time” is not 0.
P17
Flywheel Teeth
(10-300)
118
Teeth number of the engine, for judging of
starter separation conditions and inspecting of
engine speed. See the following Installation
Instruction.
P18
Over Speed
Threshold
(0-6000)r/min
3500
When rotate speed exceed this threshold and
last over the delay value, over speed shutdown
alarm signal will be sent.
(No detection for over speed signals if it is set
as 0).
P19
Over Speed Delay
(0-20)s
2
When rotate speed exceed over speed
threshold and last over the delay value, over
speed alarm signal will be sent.
P20
Poles
(2-16)
2
Set genset poles.
P21
Disc. Condition
(0-2)
1
Disconnected condition. Separate condition of
starter and engine are gen sensor and
magnetic sensor, in order that separate stater
motor and engine as soon as possible.
P22
Disc. Speed
(0-6000)r/min
840
In starting process, if genset rotate speed
exceed this value, it is regarded as genset start
success, starter will separate.
P23
Disc. Freq
(10-30)Hz
14
In starting process, if genset frequency exceed
this value, that is genset start success, starter
will separate.
P24
Fuel Output Select
(0-1)
0
0: Fuel output; 1: Stop output (ETS Output).
P25
Aux. Output 1
(0-9)
5
Configuration see form “Aux. Output
Defination”
P26
Gen Under Freq
Threshold
(0-75.0)Hz
45.0
When gen frequency falls below this threshold
and last over the delay value, under frequency
shutdown alarm signal will be sent.
(No detection for under frequency signals if it
is set as 0).
P27
Under Freq
Shutdown Delay
(0-60)s
10
Gen under frequency delay value.
P28
Gen Over Freq
Threshold
(0-75.0)Hz
57.0
When gen frequency exceeds this threshold
and last over the delay value, over frequency
shutdown alarm signal will be sent.
(No detection for over frequency signals if it is
set as 0)
P29
Over Freq
Shutdown Delay
(0-60)s
2
Gen over frequency delay value.
CLb1
Ua
Correct A phase voltage value.
CLb2
Ub
Correct B phase voltage value.
CLb3
Uc
Correct C phase voltage value.

MGC100 Petrol Genset Controller User Manual Page 13 of 16
No.
Content
Parameter Range
Default
Description
CLb4
Uab
Correct AB wire voltage.
CLb5
Ubc
Correct BC wire voltage.
CLb6
Uca
Correct CA wire voltage.
Table 8 Defined Contents of Aux. Output Ports
No.
Content
Description
0
Not Used
When this is chosen, output port won’t output.
1
Preheat Output
Close before start, open before energize.
2
Common Alarm
When stop alarm is initiated, this alarm will self-lock untill alarm reset.
3
Idle Output
Used for engine which has idles. Close before starting and open in
warming up delay; Close during stopping idle process and open when stop
is completed.
4
ETS Output
Used for some genset which has stop electromagnet. Close before
stoping idle ended. Open when “ETS Delay” ended.
5
Air Flap Choke
Used for genset with choke valve electromagnet. Close when gen start
and open when safety running delay is over.
6
Reserved
7
Reserved
8
Reserved
9
Reserved
Table 9 Crank Disconnect Conditions Selection
No.
Content
0
Magnetic Sensor
1
Generator
2
Magnetic Sensor + Generator
NOTE:
1) Magnetic sensor is magnetic device which detects numbers of flywheel teeth installed in generator.
2) If magnetic sensor is selected, please insure numbers of flywheel teeth is same with set value, otherwise,
“Over Speed Shutdown” may be caused.
3) If genset without magnetic sensor, please don’t select corresponding items, otherwise, “Start Failure” may be
caused.
4) If generate isn’t selected, the controller won’t detect over/under voltage; if magnetic sensor isn’t selected,
speed of genset is converted via generate signal.

MGC100 Petrol Genset Controller User Manual Page 14 of 16
8PARAMETERS SETTING
8.1 PARAMETERS REGULATION
When the controller is running, press for 3s, it will enter into parameter number menu and LED
will display :
1) Press and to downturn/upturn parameter number;
2) After parameter number is selected, press to enter into parameter setting menu; press
and to increase/decrease parameter value (it can be double-clicked);
3) Press to confirm modification and save value;
4) For multiple parameters, step (1-3) can be repeat done for setting;
5) After parameter setting, press for 3s to exit parameter setting status.
8.2 RESTORE FACTORY SETTINGS
In emergency stop input status, press and for 5s at the same time, it can restore to
default and “reset” will be displayed on LED.
8.3 ELIMINATE ACCUMULATED TIME
Press and for 5s at the same time, accumulated running time will be reset an “hclr” will
be displayed on LED.
NOTE:
——Over voltage threshold must be greater than under voltage threshold.
——When start successfully, generator frequency need to be set lower as soon as possible in order to starter
separate sooner.
——Number of setting contents refers to “Parameter Content and Range (Table 7)”.
——Only in parameter number menu can exit from parameter setting status. If there is no press operation in
parameter number menu, it will exit in 30s automatically.

MGC100 Petrol Genset Controller User Manual Page 15 of 16
9CASE DIMENSIONS
Controller is panel built-in design; it is fixed by clips when installed.
Fig.3 Case Dimensions
1) Battery Voltage Input
NOTE: MGC100 controller can suit for widely range of battery voltage DC(9~18)V. Negative of battery must be
connected with the engine shell soundly. The diameter of wire which from power supply to battery must be over 1.0mm2.
If floating charge configured, please firstly connect output wires of charger to battery’s positive and negative directly,
then, connect wires from battery’s positive and negative to controller’s corresponding input ports in order to prevent
charge disturbing the controller’s normal working.
WARN: In running process, removing start battery is strictly prohibit.
2) Speed Sensor Input
NOTE: Speed sensor is magnetic equipment which is installed on engine body for testing flywheel teeth number. 2
core shielding wire is used for the connection of the sensor and controller. The wire is supposed to be connected to 11
terminal of controller with one end and the other end hanging in the air. The other two signal lines connect separately to
11, 12 terminal. Speed sensor output voltage is supposed to be at AC (1-24)V (virtual value) when it is in full speed range,
and AC12V (when in rated rotate speed) is recommened. When install the speed sensor, screw it to contact the flywheel
firstly, inverse it with 1/3 circle, and then tighten the nut finally.
3) Withstand Voltage Test
CAUTION: When controller has been installed in control panel, if the high voltage test is needed, please disconnect
controller’s all terminals in order to prevent high voltage into controller and damage it.

MGC100 Petrol Genset Controller User Manual Page 16 of 16
10 TYPICAL APPLICATION
Fig.4 Typical Application
NOTE: When it controls petrol genset, terminal 4 connects with ignition control; when it controls diesel genset,
terminal 5 needs to short connect with B+, terminal 4 needs to connect with fuel output.
11 FAULT FINDING
Table 10 Fault Finding
Symptoms
Possible Solutions
Controller no response with
power
Check starting batteries;
Check controller connection wirings;
Check DC fuse.
Crank not disconnect
Check fuel oil circuit and its connections;
Check starting batteries;
Check speed sensor and its connections;
Refer to engine manual.
Shutdown alarm in running
Check related switch and its connections according to the
information on LED.
Starter no response
Check starter connections;
Check starting batteries.
_________________________________