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
4189340752 UK
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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4189340752 UK
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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4189340752 UK
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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4189340752 UK
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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4189340752 UK
Mounting
DEIF A/S Page 6 of 28

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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4189340752 UK
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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4189340752 UK
Terminals
DEIF A/S Page 8 of 28

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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4189340752 UK
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