Deif AGC 100 User manual

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
INSTALLATION INSTRUCTIONS
Genset Controller, AGC 100
● Mounting
● Terminal overview
● Wiring
● Communication wiring
● Unit dimensions and cutout
Document no.: 4189340752C
SW version: 4.0x.x

1. General information
1.1. Warnings, legal information and safety..................................................................................................3
1.1.1. Warnings and notes ......................................................................................................................3
1.1.2. Legal information and disclaimer ..................................................................................................3
1.1.3. Safety issues ................................................................................................................................3
1.1.4. Electrostatic discharge awareness ...............................................................................................3
1.1.5. Factory settings ............................................................................................................................3
1.1.6. UL applications..............................................................................................................................4
1.2. About the installation instructions...........................................................................................................4
1.2.1. General purpose ...........................................................................................................................4
1.2.2. Intended users ..............................................................................................................................4
1.2.3. Contents and overall structure ......................................................................................................4
2. Mounting
2.1. AGC 100 mounting.................................................................................................................................5
2.1.1. Unit dimensions and panel cutout..................................................................................................5
2.1.2. Tightening torques.........................................................................................................................6
3. Terminals
3.1. Terminal overview and description.........................................................................................................7
3.1.1. Terminal description......................................................................................................................7
4. Wiring
4.1. Wiring diagram.....................................................................................................................................11
4.2. DC connections....................................................................................................................................12
4.3. Digital inputs.........................................................................................................................................13
4.4. Breaker selection..................................................................................................................................13
4.5. Charger alternator connections............................................................................................................14
4.6. 3-phase voltage and current wiring......................................................................................................16
4.6.1. 3-phase wiring, AGC 112.............................................................................................................16
4.6.2. 3-phase AMF wiring, AGC 113....................................................................................................17
4.7. 1-phase voltage and current wiring......................................................................................................18
4.8. Split-phase voltage and current wiring.................................................................................................19
4.9. Power management 3-phase wiring (AGC 145/146)............................................................................20
4.9.1. Mains breaker, AGC 145 ............................................................................................................20
4.9.2. Mains and tie breaker, AGC 146 ................................................................................................21
5. Communication
5.1. Wiring instructions................................................................................................................................22
5.2. Modbus RTU........................................................................................................................................23
5.2.1. Connection with 2-wire shielded cable (recommended)..............................................................23
5.2.2. Connection with 3-wire shielded cable........................................................................................24
5.3. CAN bus engine communication..........................................................................................................25
5.3.1. Connection with 2-wire shielded cable (recommended)..............................................................25
5.3.2. Connection with 3-wire shielded cable........................................................................................26
5.4. External I/O modules............................................................................................................................27
5.5. Additional Operator Panel, AOP-2.......................................................................................................28
AGC 100 installation instructions
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DEIF A/S Page 2 of 28

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 Multi-line 2 unit, the company responsible for the
installation or the operation of the set must be contacted.
The Multi-line 2 unit is not to be opened by unauthorised personnel. If opened anyway, the war-
ranty 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 Multi-line 2 unit may imply work with dangerous currents and voltages. Therefore,
the installation should only be carried out by authorised personnel who understand the risks involved in work-
ing 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.
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.
1.1.5 Factory settings
The Multi-line 2 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.
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General information
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1.1.6 UL applications
These flat surface panel-mounted controllers are intended to be used in Listed Generator Assemblies, where
the suitability of the combination has been determined by Underwriters Laboratories.
1.2 About the installation instructions
1.2.1 General purpose
These Installation Instructions mainly include general product and hardware information, mounting instruc-
tions, terminal strip descriptions, I/O lists and wiring descriptions.
The general purpose of this document is to give the user important information to be used in the installation of
the unit.
Please make sure to read this document before starting to work with the Multi-line 2 unit and
the gen-set to be controlled. Failure to do this could result in human injury or damage to the
equipment.
1.2.2 Intended users
These Installation Instructions are mainly intended for the person responsible for the design and installation.
In most cases, this would be a panel builder designer. Naturally, other users might also find useful information
in the document.
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.
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General information
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2. Mounting
2.1 AGC 100 mounting
The unit is designed for flush mounting by means of eight fixing clamps (IP52), which are included at delivery.
To have IP65, the unit must be ordered with option L (12 fixing clamps and a gasket).
2.1.1 Unit dimensions and panel cutout
The unit is designed for mounting in the panel front.
In order to ensure optimum mounting, the panel door must be cut out according to the following measure-
ments:
H × W = 151.00 × 211.00 + 1.00 mm
H × W = 5.94" × 8.31" + 0.04"
Alarm 1
Alarm 2
Alarm 3
Alarm 4
160.0 (6.30)
220.0 (8.66)
151.0 (5.94)
211.0 (8.30)
61.0 (2.40)
54.0 (2.13)
Multi-line AGC 100
0.3 Nm
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Mounting
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2.1.2 Tightening torques
Unit panel door mounting: 0.3 Nm, 2.7 lb-in (see diagram in "Unit dimensions and panel cutout")
Plug connections (terminals): 0.5 Nm, 4.4 lb-in
AOP-1 and AOP-2 (see diagram below)
Panel door mounting: 0.7 Nm, 6.2 lb-in
Sub-D screw: 0.2 Nm, 1.8 lb-in
DC-DC converter terminals: 0.5 Nm, 4.4 lb-in
220.0 (8.661)
115.0 (4.528)
Display
20.0 (0.787)
0.7 Nm
Screw M3
Bossard BN5687
or similar
0.2 Nm
9P Female
Sub 0
connector
Max. 10 mm
Min. 6 mm
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Mounting
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3. Terminals
3.1 Terminal overview and description
Unit rear view
6 7 83 4 51 2
+ -
Power
supply Status Multi-functional
inputs
Com
RS485
Modbus
49
50
51
B(-)
GND
A(+)
CAN B 57
58
59
CAN H
Com
CAN L
CAN A
53
54
55
CAN H
Com
CAN L
56
52
Generator voltage
33 34 35 36 37 38
L1 N L2 L3NA NA
9 10 11 12 13 14 15 16 1817
Binary inputs
Com
19 20 21 23 24 2522 26 27
Com
R24 R26
Mains voltage
28 29 30 31 32
L1 N L2 L3NA 45 46 47 48 L1 L2 L3
Generator current
39 40 41 42 43 44
MPU Com W/L
RPM inputs
GB MB
Service port
Emergency stop
R21 R22 R23
The RJ11 connector for the PC connection interface box is placed on the side of the unit.
3.1.1 Terminal description
For the relay outputs, the following terms will be used:
NO means Normally Open.
NC means Normally Closed.
Com. means common terminal for the individual relay.
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Terminals
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Terminal Technical data Description
1 Power supply + 6 to 36 V DC (UL/cUL Listed: 7.5 to 32.7 V DC)
2 Power supply – GND
3-4 Status out/configurable See note*. Contact ratings 1 A 24 V DC/V AC Resistive
Multi-functional inputs
5 Common Common for terminal 6, 7 and 8
6 RMI/4 to 20 mA/digital input/
Pt1000
Configurable
7 RMI/4 to 20 mA/digital input/
Pt1000
8 RMI/4 to 20 mA/digital input
Digital inputs
9 Common Common for terminal 10 to 15
10 Digital input Configurable
11 Digital input
12 Digital input
13 Digital input
14 Digital input
15 Digital input
Tacho RPM input
16 RPM input (MPU) Magnetic pickup tacho generator (2-wire)
17 RPM-GND Common for RPM input
18 RPM input (W/L) Magnetic pickup. PNP, NPN or charge alternator W terminal
Relay outputs
19 Common Common for emergency stop terminal 20
20 Emergency stop and common
for 21 to 23
Common for relay 21, 22 and 23 and input for emergency
stop**
21 Relay output Configurable. Function NO. Contact ratings 2 A 30 V DC/V
AC
22 Relay output
23 Relay output
24-25 Relay output Configurable. Function NO. Contact ratings 8 A 30 V DC/V
AC
26-27 Relay output
3-phase mains voltage input
28 Mains voltage L1 Mains voltage and frequency
29 Mains neutral
30 Mains voltage L2
31 Not used, must not be connec-
ted
32 Mains voltage L3
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Terminals
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Terminal Technical data Description
3-phase generator voltage input
33 Gen. voltage, L1 Generator voltage and frequency
34 Gen. neutral
35 Not used, must not be connec-
ted
36 Gen. voltage, L2
37 Not used, must not be connec-
ted
38 Gen. voltage, L3
3-phase generator current input
39 Gen. current L1, s1
Generator current
40 Gen. current L1, s2
41 Gen. current L2, s1
42 Gen. current L2, s2
43 Gen. current L3, s1
44 Gen. current L3, s2
Breaker relays
45 Relay output Generator circuit breaker/configurable, function NO (normal-
ly open)
Contact ratings 2 A 30 V DC/250 V AC
46 Relay output
47 Relay output Mains circuit breaker/configurable, function NC (normally
closed). With "Option M19" the relay is NO.
Contact ratings 2 A 30 V DC/250 V AC
48 Relay output
Modbus RS-485 interface
49 B (-)
Modbus RS-485 RTU or ASCII50 GND
51 A (+)
CAN bus port A: Engine interface
53 CAN-H
CAN J1939 engine communication54 Com
55 CAN-L
Optional CAN bus port B: AOP-2 interface
57 CAN-H
CAN communication line to AOP-258 Com
59 CAN-L
Optional CAN bus port B: External I/O interface
57 CAN-H
CAN communication port to external I/O
58 Com
59 CAN-L
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Terminals
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* The status relay is the uP watchdog output. This relay is normally energised, and the switch is closed after
power-up. If the uP fails or the power is lost, the relay will de-energise and the switch will open. If the unit fails
to start up at power-up, then the relay switch will remain open. The relay is configurable.
** If terminal 20 is used for emergency stop, please see wiring diagram below.
The relay output functions are configurable via the PC utility software and can, among many other functions,
be configured to cover the following in I/O settings:
● Status OK
● Run coil
● Stop coil
● Stop coil (not activated in start seq.)
● Prepare
● Starter(crank)
● Horn
● GB on
● GB off
● MB on
● MB off
It is possible to choose run coil on one relay and stop coil on another, thus supporting engines with double
systems.
The multi-functional inputs can be configured to cover the following functions:
● RMI sensor input
● 4 to 20 mA input
● Binary input with wire break (switch function)
● Pt1000
Tacho RPM input (MPU) can be configured to cover the following functions:
● Magnetic pickup (2-wire)
● NPN or PNP pickup*
* These RPM inputs require external equipment.
Tacho RPM input with capacitor (W/L) can be configured to cover the following functions:
● Magnetic pickup (2-wire)
● W terminal on charger alternator
● NPN or PNP pickup*
* These RPM inputs require external components.
The generator voltage and current input can be configured to the following:
● Voltage 100 to 25000 V primary
● Current 5 to 9000 A primary
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4189340752 UK
Terminals
DEIF A/S Page 10 of 28

4. Wiring
4.1 Wiring diagram
27
26
25
12
Controller
Oli pressure
1
2
R24
R23
RJ11
plug
R22
R21
24
23
22
21
20
19
4
3
15
14
13
11
10
9
Coolant temp.
Overspeed
Remote start
Start enable
Programming
tool
Battery
- +
Emer. STOP
Status
Start prep.
Starter
RUN coil
- + F
Alarm horn
Alarm
Running
1N4007
Rex
D+D-
Charging
alternator
R26
Term. 12 can be used as alarm input if not
used for charger generator terminal D+
Rex: 12 V systems: 47 Ω 4 W
24 V systems: 100 Ω 6 W
If a stop coil is used, the REX resistor can be connected to the starter relay (crank).
The illustrated configuration is an example of settings. The use of the relays can be chosen
freely.
It is important to protect the unit against damage caused by high voltages. Therefore, the fuse
must not be more than 2 A slow-blow.
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Wiring
DEIF A/S Page 11 of 28

4.2 DC connections
* The illustration for the RMI sensors also apply to Pt1000 - but note that only multi-inputs 6 and 7 support
Pt1000.
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Wiring
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4.3 Digital inputs
All digital inputs are 12/24 V DC bi-directional optocoupler type. The typical wiring is illustrated below:
+12/24V DC
Bin IN
Common
0V DC
The digital inputs use fixed signals. Only the mode shift input and the test input (if the timer is
used) use pulse signal.
4.4 Breaker selection
The controller can handle pulse, continuous and compact breakers. Selection of the breaker type is done in
the application configuration with the PC utility software. Output for breaker handling is chosen in the I/O con-
figuration of the PC utility software.
In the table below it is listed which outputs are needed for breaker handling, depending on the breaker type.
Breaker type GB On/MB On/TB On GB Off/MB Off/TB Off
Pulse breaker X X
Continuous breaker X
Compact breaker X X
The pictures below are examples of how to set up breakers.
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Wiring
DEIF A/S Page 13 of 28

Continuous breaker selection
With GB On and MB On configuration
Pulse breaker selection
With GB On, GB Off, MB On and MB Off selection
If the AGC 100 is ordered with option M19, relay 47 will have NO contact.
4.5 Charger alternator connections
The charger alternator can be used as running-feedback in two different ways:
1. Using the D+ terminal connected to terminal 12
2. Using the W terminal connected to the RPM input
Usually only one of these possibilities is used.
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Wiring
DEIF A/S Page 14 of 28

U
Charger
alternator
9
V W
Stator
Brush
Brush
Exciter
coil (rotor)
Excitation
controller
B+ D+ W
1N4007
Rex
2524 12 18 17
Running
feedback
- +
Battery
Run coil RPM
input
Rex: Excitation resistor 12 V systems: 47 Ω 4 W
24 V systems: 100 Ω 6 W
At standstill, the battery + is connected to terminal 9 (common), and a current flows to terminal 12 and via the
D+ input on the alternator to ground (battery -). When the starter is engaged (cranking), the battery will supply
the D+ through the REX resistor, helping the alternator to excite. When the alternator starts to produce volt-
age (excitation OK), the speed of the alternator will be above running speed, and the voltage on term. 12 will
rise to a value higher than the battery voltage and then interrupt the current flow through REX and activate
the running feedback input. Engine is running.
If a stop coil is used, the REX resistor can be connected to the starter relay (crank).
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4189340752 UK
Wiring
DEIF A/S Page 15 of 28

4.6 3-phase voltage and current wiring
4.6.1 3-phase wiring, AGC 112
Island operation
33
36
34
38
40 I1
39
42 I2
41
44 I3
43
s1
s1
s2
s2
GENERATOR
GENERATOR
VOLTAGE
GENERATOR
CURRENT
UL1
UL2
UL3
N
46
45
14
GB
s1
s2
GB OFF feedback
GB ON
command
Supply
Consumer
L1 L2 L3N
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Wiring
DEIF A/S Page 16 of 28

4.6.2 3-phase AMF wiring, AGC 113
3-phase AMF wiring
MAINS
L1 L2 L3N
28 UL1
29
UL2 30
UL3 32
N
33
36
34
38
40 I1
39
42 I2
41
44 I3
43
s1
s1
s2
s2
GENERATOR
MAINS
VOLTAGE
GENERATOR
VOLTAGE
GENERATOR
CURRENT
UL1
UL2
UL3
N
46
45
14
GB
15
48
47
MB
s1
s2
Consumers
MB OFF feedback
GB OFF feedback
GB ON
command
MB ON
command
Supply
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4189340752 UK
Wiring
DEIF A/S Page 17 of 28

4.7 1-phase voltage and current wiring
Island, AGC 112 AMF and load takeover, AGC 113
33
34
40 I1
39
GENERATOR
GENERATOR
VOLTAGE
GENERATOR
CURRENT
UL1
N
46
45
14
GB
s1
s2
GB OFF feedback
GB ON
command
Supply
L1N
MAINS
L1N
28 UL1
29 N
33
34
40 I1
39
GENERATOR
MAINS
VOLTAGE
GENERATOR
VOLTAGE
GENERATOR
CURRENT
UL1
N
46
45
14
GB
15
48
47
MB
s1
s2
Consumers
MB OFF feedback
GB OFF feedback
GB ON
command
MB ON
command
Supply
AGC 100 installation instructions
4189340752 UK
Wiring
DEIF A/S Page 18 of 28

4.8 Split-phase voltage and current wiring
Island, AGC 112 AMF and load takeover, AGC 113
33
36
34
40 I1
39
42 I2
41
s1
s2
GENERATOR
GENERATOR
VOLTAGE
GENERATOR
CURRENT
UL1
UL2
N
46
45
14
GB
s1
s2
GB OFF feedback
GB ON
command
Supply
Consumer
L1 L2N
MAINS
L1 L2N
28 UL1
29
UL2 30
N
33
36
34
40 I1
39
42 I2
41
s1
s2
GENERATOR
MAINS
VOLTAGE
GENERATOR
VOLTAGE
GENERATOR
CURRENT
UL1
UL2
N
46
45
14
GB
15
48
47
MB
s1
s2
Consumers
MB OFF feedback
GB OFF feedback
GB ON
command
MB ON
command
Supply
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Wiring
DEIF A/S Page 19 of 28

4.9 Power management 3-phase wiring (AGC 145/146)
4.9.1 Mains breaker, AGC 145
BUSBAR
L1 L2 L3N
28 UL1
29
UL2 30
UL3 32
N
33
36
34
38
40 I1
39
42 I2
41
44 I3
43
s1
s1
s2
s2
BUSBAR
VOLTAGE
MAINS
VOLTAGE
MAINS
CURRENT
UL1
UL2
UL3
N
46
45
14
MB
s1
s2
Consumers
MB OFF feedback
MB ON
command
Supply
L1 L2 L3N
MAINS
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Wiring
DEIF A/S Page 20 of 28