Single Genset Controllers, SGC 421

Main features

• Auto, manual and remote start/stop modes with night

restriction option

• 8 analogue inputs, fully configurable

• 9 digital inputs, fully configurable

• 7 digital outputs, fully configurable

• Modbus over RS-485

• Manually configurable from the controller front buttons or

from a PC using DEIF’s configuration software

• Backlit full graphics LCD with power saving feature for

extended battery lifetime
SGC 421
• Parameter configuration at customer’s site
General description • Supports the battery charging alternator I/O interface

• Supports Auto mode (site battery monitoring, AMF, remote

The SGC 421 controllers are modern AMF genset controllers with
start/stop, auto exercise and cyclic) and manual operation
a user-friendly HMI and full graphics LCD.
modes
They include voltage and frequency measurement for mains and
gensets, and electrical load measurement (true RMS). • Magnetic Pickup Unit (MPU) interface for engine speed
measurement
Fully configurable analogue and digital inputs/outputs are
provided for various features. • Auto exercise mode (2 events) to start and stop the genset
for a preconfigured time
Modbus over RS-485 and CAN ports is available for remote
• Built-in electronic Governing function for variable speed
communication.
monitoring
Start and stop gensets remotely using the Remote start/stop
• Monitors 1-phase/3-phase voltage, frequency, load current
function.
and power factor for generator
Deep sleep mode is a useful feature that extends the battery
• Monitors engine safety parameters like lube oil pressure,
lifetime by suspending the normal controller functions of when
engine temperature, fuel level and more
the genset is off.

Monitoring engine safety, electrical load, site battery backup • Monitors telecom site battery backup level and shelter
voltage and shelter temperature (to reduce fuel consumption). temperature to reduce engine running and fuel consumption
at telecom tower sites
Configure parameters from a PC using DEIF’s configuration
• Controls start relay, fuel relay, alarm horn and more as
software (Microsoft Windows based). Connect to the PC through
digital outputs
the controller’s USB Type-B port.

In addition, the SGC 421 controller also includes an integrated • Event log for 100 events with real time clock (RTC) stamps
electronic governing function. and engine running hours information

• Counters for engine starts, engine trips, engine running

hours, genset and Mains kWh, kVAh, kvarh

• Measures mains kW, kVA

• Built-in electronic governing function with the help of a

rotary actuator
SGC 421
Specifications

Power supply Technical specifications

• 8 to 28 V DC continuous Maximum standby current:

• ~0.09 A @ 12 V or 24 V DC
• Power transients, in compliance with ISO 7637-2
• 1 A (additional) for the actuator

Crank-start dropout survival period

Operating conditions • 50 ms for a drop from 12 V DC
• Able to survive 0 V for 50 ms
• Operation -20 to 65 °C
Charging alternator interface
• Storage -30 to 70 °C • 0.25 A @ 12 V DC
• 0.125 A @ 24 V DC
In compliance with IEC 60068-2-1, 2
• Diagnostic voltage measurement

Digital outputs
Environment • 5 x 1 A high-side drivers configurable for pre-heat, horn
and more
• Vibration: 2G in X,Y and Z axes, in compliance with IEC
• 2 x 5 A high-side drivers configurable for start relay, stop
60068-2-6
solenoid, fuel relay, contactors and more
• Shock: 15 g for 11 ms, in compliance with IEC 60068-2-27

• Humidity: 0 to 95 % RH, in compliance with IEC 60068-2-78 Digital inputs

• 9 x switch-to-ground inputs for lube oil, temp, fuel level
• Protection degree: IP65 for front face with optional gasket, in and more
compliance with IEC 60529

• EMI/EMC: In compliance with IEC 61000-6-2, 4 Analogue inputs

• 5 x resistive inputs (10 to 1000 Ω), fully configurable
• 1 x 4 to 20 mA (LOP) / 0 to 5 V input
• 1 x 0 to 5 V input
Approvals • 1 x differential input (± 60 V DC) for site battery voltage

• CE approved:
Mains/genset voltage measurement
- Comply to the EU Low Voltage Directive: EN 61010-1 Safety
requirements for electrical equipment for measurement, • 32 to 300 V AC RMS @ 5 to 75 Hz for phase-to neutral
control, and laboratory use - Part 1: General requirements
- Comply to the EU EMC directive EN 61000-6-2, 4 Load current measurement
• TÜV • 0 to 5 A AC RMS for current transformer (CT) secondary

• UL
E-governor module interface
• 1 A, 2-phase output for rotary actuators
• 2.5 ± 2 V input for target speed bias
• 2.5 V for zero bias

Dimensions
• External dimensions: 207 mm x 160 mm x 38.5 mm
• Mounting panel cut: 189 mm x 143 mm
Front of controller:

Rear of controller:

.
Technical specifications

Terminals

The SGC 421 use two types of terminal blocks:

Connectors of 5.08 mm pitch Connectors of 10.16 mm pitch

Terminals

Connector type Pitch Male (on controller) SM part no. Female (mating part) SM part no. Quantity

3-pin 5.08 mm 5447366 SM0003213 5441977 SM0003292 1

4-pin 5.08 mm 5447379 SM0003207 5448637 SM0003451 1

5-pin 5.08 mm 5447382 SM0003205 5448640 SM0003293 1

6-pin 5.08 mm 5441919 SM0003203 5441964 SM0003452 1

8-pin 5.08 mm 5441935 SM0003201 5441951 SM0003294 1

9-pin 5.08 mm 5447395 SM0003198 5448653 SM0003453 1

10-pin 5.08 mm 5447405 SM0003196 5448666 SM0003501 1

4-pin 10.16 mm 5474274 SM0003195 5453499 SM0001163 2

Power supply

Category Specification

1 (Ground)
Controller terminals
2 (Battery or DC+)

Supply voltage range 8 to 28 V DC (suitable for 12/24 V DC system)

Cranking drop out period 50 ms

Maximum reverse voltage protection -32 V DC

Measurement accuracy (battery voltage) ±1 % full scale

Resolution 0.1 V

~ 0.4 A, 12 V DC (excluding the current load for the high side

Maximum current consumption
driver outputs)

Standby current consumption ~0.09 A, 12/24 V

Genset voltage and frequency measurements

Category Specifications

54 (Neutral)
55 (L3)
Controller terminals
56 (L2)
57 (L1)

Measurement type True RMS

Phase-to-neutral voltage 32 to 300 V AC RMS

Phase-to-phase voltage 32 to 520 V AC RMS

±1 % of full scale for phase-to-neutral

Voltage accuracy
±1.5 % of full scale for phase-to-phase

1 V AC RMS for phase-to-neutral

Voltage resolution
2 V AC RMS for phase-to-phase

Frequency range 5 to 75 Hz

Frequency accuracy 0.25 % of full scale

Frequency resolution 0.1 Hz

For single genset applications, it is mandatory to connect the genset phase and neutral cables to the genset controller's
phase L1 and neutral terminals.

Genset current measurements

Category Specifications

43 and 42 (for phase L1)

Controller terminals 45 and 44 (for phase L2)
47 and 46 (for phase L3)

Measurement type True RMS

Maximum CT secondary current rating 5A

Burden 0.25 VA

Measurement accuracy ±1.4 % of nominal

Earth leak measurements

Category Specifications

Controller terminals 48 and 49

Measurement type True RMS

Maximum CT secondary current rating 5A

Burden 0.25 VA

Measurement accuracy ±1 % of nominal

Follow the recommended phase sequence while connecting the current transformer (CT).
Mains voltage and frequency measurement

Category Specifications

50 (Neutral)
51 (L3)
Controller terminals
52 (L2)
53 (L1)

Measurement type True RMS

Phase-to-neutral voltage 32 to 300 V AC RMS

Phase-to-phase voltage 32 to 520 V AC RMS

±2 % of full scale for phase-to-neutral

Voltage accuracy
±2.5 % of full scale for phase-to-phase

1 V AC RMS for phase-to-neutral

Voltage resolution
2 V AC RMS for phase-to-phase

Frequency range 5 to 75 Hz

Frequency accuracy 0.25 % of full scale

Frequency resolution 0.1 Hz

For single phase applications, it is mandatory to connect the mains phase and neutral cables to the genset controller's
phase L1 and neutral terminals.

Digital inputs

Category Specifications

Controller terminals 33, 34, 35, 36, 37, 38, 39, 40, 41

Number of inputs 9

Type Negative sensing (connect to ground for activation)

0.8 V DC maximum (measured at the genset controller’s

Low level threshold
terminals and battery ground terminal)

8 V DC minimum (measured at the genset controller’s terminals

High level threshold
and battery ground terminal)

Emergency stop, Remote start/ stop, etc. (see Controller

Software configurable options
overview, Configurable parameters for more details).

Analogue resistive sensor inputs

Category Specifications

11 (LOP)
12 (Fuel)
Controller terminals 13 (Temperature)
14 (Aux 1)
15 (Aux 2)

Number of inputs 5

Type Ratio-metric sensing

Range 10 to 1000 Ω
Open circuit detection Above 5.5 kΩ

Measurement accuracy ±2% of full scale (for range 50 to 1000 Ω)

 Analogue voltage/current input (only SGC 421)

Category SGC 421 specifications

21 (Aux3)
Controller terminal
23 (Aux4)

Measurement type Analogue voltage/current sensing

0 to 5 V DC
Range
4 to 20 mA

Accuracy ±1.25 % of full scale

For genset paralleling application, configure input Aux4 on terminal 23 to accept a 0 to 5 V DC speed bias signal generated by a
LSM (Load Sharing Module).

Site battery inputs

Category Specifications

Controller terminals 24, 25

Number of inputs 2

Type Differential

Range ±60 V

Resolution 0.1 V

Accuracy ±2 % of full scale (0 to DC+ max./0 to DC- max.)

Site battery run hours

In this feature, controller calculates the run hours for which the site runs on the battery backup. Site battery run hours are
incremented only when both the mains and genset contactors are not latched and when site battery voltage is greater than low
battery voltage threshold.

Magnetic pick-up (MPU) input

Category Specifications

Controller terminal 22

Measurement type Single ended

Frequency range 10 to 10 kHz

Input voltage range 200 mV to 45 V AC RMS

The Magnetic pick-up (MPU) is an inductive sensor fitted on the engine flywheel for the engine speed sensing. The output of the
MPU is a sine-wave signal.

Digital outputs

Category Specifications

Controller terminals 3, 4, 5, 6, 7, 8, 9

Number of outputs 7

Type High side driver

5 A (3 and 4)
Maximum current rating
1 A (5, 6, 7, 8, 9)
 Start relay, Fuel relay, Close genset contactor, close mains
Software configurable options contactor, Stop solenoid and many more (see Controller
overview, Configurable parameters for more details).

• Do not connect the Starter motor relay and the Stop solenoid directly to the controller's output terminals. It is
recommended to connect terminals 3 and 4 to Start and Stop.
• Genset and mains contactor latching relays should be compiled against 4 kVA surge as per IEC-61000-4-5 standard.

Actuator outputs

Category Specifications

Controller terminal 17, 18. 19 and 20

Type Stepper motor drive

Max. current 1A

The actuator outputs are used only for the Rotary actuator, if installed. The Rotary actuator is a 4-wire actuator that is used for
creating an electronic governing application in case of a mechanical fuel system engine. In diesel engines, the Rotary actuator's
shaft output gets mechanically connected to the stop lever or the throttle lever of an in-line or rotary fuel injection pump. In case of
petrol or natural gas engines, the Rotary actuator's shaft output gets connected to the throttle/charge control valve.

It is recommended to follow the connection details of the Rotary actuator connector and SGC 421.

D+ CHG ALT

Category Specifications

Controller terminal 10

0 to VBATT
Voltage range
VBATT = 8 to 30 V DC

Excitation PWM (current limited to 250 mA)

Accuracy ±2 % of full scale

The charge fail is a combined input and output terminal. When the genset starts, the terminal provides controlled power output to
excite the charging alternator. After the excitation is successfully done, the controller reads the charging alternator's output voltage
for monitoring its health. The action for charge fail is configurable.

Sensor common point

Category Specifications

Controller terminal 16

Range ±2 V

Accuracy ±2 % of full scale

Resolution 0.1 V
 The sensor common point (SCP) terminal 16 of the controller should be directly connected to an electrically sound point on
the engine body. This point on the engine body should serve as a common reference point for all analogue sensors such
as those for measuring lube oil pressure, engine temperature and fuel level. The electrical cable used for the connection
should not be shared with any other electrical connection. Such a wiring practice is strongly recommended to ensure that
there is negligible potential difference, if any, between the engine body and the controller's SCP terminal, and, predictable
and accurate analogue sensor measurements are always available in a wide variety of field conditions.

Communication ports

Category Specifications

USB 2.0 type B for connection to PC with DEIF Smart Connect

USB
software

Half Duplex
Max. Baud Rate 115200
Data connection 2-wire
RS-485 Serial Port Termination resistor of 120 Ω is provided between output
terminals A and B
Common-mode operating range
Maximum distance of line is 1200 m

30 (GND)
Controller terminals 31 (A)
32 (B)

Baud rate: 250 kbps

CAN Packet size: 8 bytes
Termination resistor of 120 Ω is provided

Controller terminals for CAN 58 and 59

• The RS-485 port on the controller supports a protocol based on Modbus.

• Use two core shielded twisted pair cable for Modbus RS-485 connection.
• Terminal 30 should be connected to master’s isolated ground only.

• Keep terminal 30 connection open if shielded cable is not available.

• Do not connect terminal 30 to the negative battery terminal (DC -).
Terminal details
Rear view of the controller with terminal details

Terminal Text Description Connector

1 GND Power ground

2 BATT + Power supply positive

3 OUT A High side driver output A

4 OUT B High side driver output B

5 OUT C High side driver output C BCP-508-10GN

6 OUT D High side driver output D

7 OUT E High side driver output E

8 OUT F High side driver output F

9 OUT G High side driver output G

10 D+ CHG ALT Input for charging alternator control

Terminal Text Description Connector

Analogue input from Lube Oil Pressure

11 ANLG LOP / DIG J Sensor/ Digital Input J

Analogue input from Fuel Level

12 ANLG FUEL LEVEL / DIG K Sensor/Digital Input K

Analogue input from Engine Temperature

13 ANLG ENG TEMP / DIG L Sensor/ Digital Input L BCP-508-6GN

Analogue input auxiliary/Analogue input

14 ANLG AUX 1 / DIG M from Shelter Temperature Sensor/Digital
Input M
15 ANLG AUX 2 / DIG N Analogue input auxiliary/Digital Input N

16 SCP Sensor common point

17 GOV_ACT – OUT1 Output for actuator (only SGC 421)

18 GOV_ACT – OUT2 Output for actuator (only SGC 421)

BCP-508-4GN
19 GOV_ACT – OUT3 Output for actuator (only SGC 421)

20 GOV_ACT – OUT4 Output for actuator (only SGC 421)

Analogue input auxiliary/0-5 V/4-20 mA

21 ANLG AUX 3/DIG 0 (LOP)/ Digital Input O

22 MPU Input from engine speed sensor (Inductive)

Analogue input auxiliary/0-5 V/4-20 BCP-508-5GN

23 ANLG AUX 4/DIG P mA/Digital Input P

24 Site BATT I/P Input 1 from Site battery

25 Site BATT I/P Input 2 from Site battery

26 RESERVED RESERVED

27 RESERVED RESERVED
N/A
28 RESERVED RESERVED

29 RESERVED RESERVED

30 RS 485 GND RS-485 GND

31 RS 485 A RS-485 A BCP-508-3GN

32 RS 485 B RS-485 B

33 DIG IN A Input from switch A

34 DIG IN B Input from switch B

35 DIG IN C Input from switch C

36 DIG IN D Input from switch D

37 DIG IN E Input from switch E BCP-508-9GN

38 DIG IN F Input from switch F

39 DIG IN G Input from switch G

40 DIG IN H Input from switch H

41 DIG IN I Input from switch I

Terminal Text Description Connector

42 GEN CT IN L1-2 CT input 2 from Phase L1

43 GEN CT IN L1-1 CT input 1 from Phase L1

44 GEN CT IN L2-2 CT input 2 from Phase L2

45 GEN CT IN L2-1 CT input 1 from Phase L2

BCP-508-8GN
46 GEN CT IN L3-2 CT input 2 from Phase L3

47 GEN CT IN L3-1 CT input 1 from Phase L3

48 GEN CT IN EL2 CT input 2 from Earth Leakage

49 GEN CT IN EL1 CT input 1 from Earth Leakage

50 MAINS V N Voltage input from Mains Neutral

51 MAINS V L3 Voltage input from Mains Phase L3

52 MAINS V L2 Voltage input from Mains Phase L2

53 MAINS V L1 Voltage input from Mains Phase L1

BCP-508-7GN-4PA
54 GEN V N Voltage input from Gen Neutral

55 GEN V L3 Voltage input from Gen L3

56 GEN V L2 Voltage input from Gen L2

57 GEN V L1 Voltage input from Gen L1

58 CAN L (RESERVED) CAN Low

59 CAN H (RESERVED) CAN High

BCP-508-4GN
60 RESERVED RESERVED

61 RESERVED RESERVED