Deif AGC-3 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
Automatic Genset Controller, AGC-3
● Mounting
● Board slot positions
● Terminal strip overview
● I/O lists
● Wiring
Document no.: 4189340728E
SW version: 3.4X.X or later

1. General information
1.1. Warnings, legal information and safety.................................................................................................. 4
1.1.1. Warnings and notes ......................................................................................................................4
1.1.2. Legal information and disclaimer ..................................................................................................4
1.1.3. Safety issues ................................................................................................................................ 4
1.1.4. Electrostatic discharge awareness ............................................................................................... 4
1.1.5. Factory settings ............................................................................................................................ 5
1.2. About the Installation Instructions.......................................................................................................... 5
1.2.1. General purpose ...........................................................................................................................5
1.2.2. Intended users ..............................................................................................................................5
1.2.3. Contents and overall structure ......................................................................................................5
2. General product information
2.1. AGC-3 product information.....................................................................................................................6
2.1.1. Introduction....................................................................................................................................6
2.1.2. Type of product..............................................................................................................................6
2.1.3. Options.......................................................................................................................................... 6
2.2. Standard functions................................................................................................................................. 6
2.2.1. Operation modes........................................................................................................................... 6
2.2.2. Engine control................................................................................................................................6
2.2.3. Generator protection (ANSI)..........................................................................................................6
2.2.4. Busbar protection (ANSI)...............................................................................................................7
2.2.5. Display...........................................................................................................................................7
2.2.6. M-Logic..........................................................................................................................................7
2.3. Standard and optional applications........................................................................................................ 7
2.3.1. Automatic Mains Failure, AMF.......................................................................................................8
2.3.2. Island operation............................................................................................................................. 8
2.3.3. Fixed power/base load...................................................................................................................9
2.3.4. Peak shaving................................................................................................................................. 9
2.3.5. Load takeover..............................................................................................................................10
2.3.6. Mains power export (fixed power to mains).................................................................................10
2.3.7. Multiple gensets, load sharing..................................................................................................... 11
2.3.8. Multiple gensets, power management......................................................................................... 11
3. Mounting
3.1. AGC-3 mounting and dimensions........................................................................................................ 12
3.1.1. Mounting of the unit..................................................................................................................... 12
3.1.2. Unit dimensions........................................................................................................................... 12
3.1.3. Panel cutout.................................................................................................................................13
3.1.4. Drilling template in mm (inches) ................................................................................................. 13
3.1.5. Mounting instructions...................................................................................................................14
3.1.6. Tightening torques....................................................................................................................... 14
4. Hardware
4.1. Board slot positions..............................................................................................................................15
4.1.1. Unit top side overview..................................................................................................................16
4.1.2. Terminal strip overviews.............................................................................................................. 17
4.1.3. Input/output lists...........................................................................................................................23
4.1.4. Slot #1, power supply PCB..........................................................................................................23
4.1.5. Slot #1, power supply PCB - AGC mains unit..............................................................................24
4.1.6. Slot #2, serial communication (option H).....................................................................................25
4.1.7. Slot #2, external I/O module (option H8.2).................................................................................. 26
4.1.8. Slot #3, load sharing control (option G3)..................................................................................... 27
4.1.9. Slot #3, 13 binary inputs and 4 relay outputs (option M12)......................................................... 28
4.1.10. Slot #4, relay outputs (option M14.4, standard).........................................................................29
4.1.11. Slot #4, analogue outputs for GOV/AVR or transducer (option E1)........................................... 29
4.1.12. Slot #4, analogue outputs for GOV/AVR or transducer (option EF2).........................................29
4.1.13. Slot #4, combination outputs for GOV/AVR or transducer (option EF4).................................... 30
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4.1.14. Slot #4, PWM output for GOV and combination output for AVR (option EF5)........................... 30
4.1.15. Slot #4, PWM output for GOV and combination output for AVR (option EF6)........................... 30
4.1.16. Slot #4, analogue outputs for GOV/AVR or transducer (option E2)...........................................31
4.1.17. Slot #5, AC measuring...............................................................................................................31
4.1.18. Slot #5, AC measuring - AGC mains unit.................................................................................. 32
4.1.19. Slot #5, AC measuring - AGC BTB unit.....................................................................................33
4.1.20. Slot #6, 7 digital inputs (option M13.6)...................................................................................... 33
4.1.21. Slot #6, 4 relay outputs (option M14.6)......................................................................................34
4.1.22. Slot #6, 4 analogue inputs (option M15.6).................................................................................34
4.1.23. Slot #6, analogue outputs for GOV/AVR or transducer (option F1)........................................... 34
4.1.24. Slot #7, engine interface card (standard)...................................................................................35
4.1.25. Slot #7, engine interface card (standard) AGC mains/BTB....................................................... 36
4.1.26. Slot #8, engine interface communication (option H5)................................................................37
4.1.27. Slot #8, Cummins engine interface communication (option H6)................................................37
4.1.28. Slot #8, 7 digital inputs (option M13.8)...................................................................................... 37
4.1.29. Slot #8, 4 relay outputs (option M14.8)......................................................................................38
4.1.30. Slot #8, external I/O module (option H8.8)................................................................................ 38
5. Wirings
5.1. AC connections.................................................................................................................................... 39
5.1.1. Neutral line (N).............................................................................................................................39
5.1.2. Current transformer grounding.................................................................................................... 39
5.1.3. Fuses...........................................................................................................................................39
5.1.4. Breaker wiring..............................................................................................................................39
5.1.5. 3-phase........................................................................................................................................40
5.1.6. Single phase................................................................................................................................41
5.1.7. 2-phase L1L2...............................................................................................................................42
5.1.8. 2-phase L1L3 (split phase).......................................................................................................... 43
5.1.9. Island mode and power management (option G4/G5/G8)...........................................................44
5.1.10. Power management (option G5), AGC mains........................................................................... 45
5.1.11. Power management (option G5), dual mains - AGC mains.......................................................46
5.1.12. Power management (option G5), AGC BTB..............................................................................47
5.2. DC connections....................................................................................................................................48
5.2.1. Load sharing lines (option G3).....................................................................................................48
5.2.2. Digital inputs................................................................................................................................ 48
5.2.3. Analogue inputs...........................................................................................................................49
5.2.4. Multi-inputs.................................................................................................................................. 50
5.2.5. Digital inputs................................................................................................................................ 51
5.2.6. Pt100/Pt1000...............................................................................................................................51
5.2.7. RMI.............................................................................................................................................. 51
5.2.8. 0 to 40 V DC................................................................................................................................ 52
5.2.9. RPM input....................................................................................................................................52
5.2.10. Stop coil.....................................................................................................................................53
5.2.11. Transistor outputs (open collector outputs)................................................................................54
5.3. Communication.................................................................................................................................... 55
5.3.1. CAN bus (option G4/G5/G8)........................................................................................................55
5.3.2. Modbus (option H2)..................................................................................................................... 56
5.3.3. Profibus DP (option H3)...............................................................................................................58
5.3.4. CAN bus engine communication (option H5)...............................................................................58
5.3.5. Cummins GCS (option H6)..........................................................................................................59
5.3.6. CAN bus engine communication (option H7)...............................................................................60
5.3.7. External I/O module (option H8).................................................................................................. 61
5.3.8. Display cable (option J)............................................................................................................... 61
6. Technical information
6.1. Technical information, AGC-3...............................................................................................................62
6.1.1. Technical specifications .............................................................................................................. 62
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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.
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 up-
dated at the same time as the English document. If there is a discrepancy, the English version prevails.
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 terminals against static discharges during the installation. Once
the unit is installed and connected, these precautions are no longer necessary.
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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.
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 genset 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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2. General product information
2.1 AGC-3 product information
2.1.1 Introduction
The AGC is part of the DEIF Multi-line 2 product family. Multi-line 2 is a complete range of multi-function gen-
erator protection and control products integrating all the functions you need into one compact and attractive
solution.
The concept of the AGC is to offer a cost-effective solution to genset builders, who need a flexible generator
protection and control unit for medium to large genset applications. Being part of the Multi-line product family,
the standard functions can be supplemented with a variety of optional functions.
2.1.2 Type of product
The Automatic Genset Controller is a micro-processor based control unit containing all necessary functions
for protection and control of a genset.
It contains all necessary 3-phase measuring circuits, and all values and alarms are presented on the LCD
display.
2.1.3 Options
The Multi-line 2 product range consists of different basic versions, which can be supplemented with the flexi-
ble options needed to provide the optimum solution. For example, the options cover various protections for
generator, busbar and mains, voltage/var/PF control, various outputs, power management, serial communica-
tion, additional operator display, and so on.
2.2 Standard functions
2.2.1 Operation modes
● Automatic Mains Failure
● Island operation
● Fixed power/base load
● Peak shaving
● Load takeover
● Mains power export
● Remote Maintenance
2.2.2 Engine control
● Start/stop sequences
● Run and stop coil
● Relay outputs for governor control
2.2.3 Generator protection (ANSI)
● 2 × reverse power (32)
● 5 × overload (32)
● 6 × over-current (50/51)
● 2 × over-voltage (59)
● 3 × under-voltage (27)
● 3 × over-/under-frequency (81)
● Voltage-dependent over-current (51V)
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● Current/voltage unbalance (60)
● Loss of excitation/overexcitation (40/32RV)
● Non-essential load/load shedding, 3 levels (I, Hz, P>, P>>)
● Multi-inputs (digital, 4 to 20 mA, 0 to 40 V DC, Pt100, Pt1000 or RMI)
● Digital inputs
2.2.4 Busbar protection (ANSI)
● 3 × over-voltage (59)
● 4 × under-voltage (27)
● 3 × over-frequency (81)
● 4 × under-frequency (81)
● Voltage unbalance (60)
2.2.5 Display
● Prepared for remote mounting
● Push-buttons for start and stop
● Push-buttons for breaker operations
● Status texts
2.2.6 M-Logic
● Simple logic configuration tool
● Selectable input events
● Selectable output commands
2.3 Standard and optional applications
In the following sections, the standard and optional applications of the AGC will be presented. In addition, the
correct application configuration for the different applications is listed. It is only possible to use the unit for one
of the purposes, for example AMF (Automatic Mains Failure). The selection must be made on site.
All units are supplied with AMF as factory setting.
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2.3.1 Automatic Mains Failure, AMF
G
Controller
Load
No. Setting Setting
6071 Genset mode AMF AMF
2.3.2 Island operation
G
Controller
Load
No. Setting Setting
6071 Genset mode Island operation Island operation
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2.3.3 Fixed power/base load
G
Controller
Load
No. Setting Setting
6071 Genset mode Fixed power Fixed power
2.3.4 Peak shaving
G
Controller
Load
P/4-20 mA
TRANSDUCER
No. Setting Setting
6071 Genset mode Peak shaving Peak shaving
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2.3.5 Load takeover
G
Controller
Load
P/4-20 mA
TRANSDUCER
No. Setting Setting
6071 Genset mode Load takeover Load takeover
2.3.6 Mains power export (fixed power to mains)
G
Controller
Load
P/4-20 mA
TRANSDUCER
No. Setting Setting
6071 Genset mode Mains power export Mains power export
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2.3.7 Multiple gensets, load sharing
G
Controller
Load
G
Controller
No. Setting Setting
6071 Genset mode Island operation Island operation
2.3.8 Multiple gensets, power management
For information about the power management application, refer to "Description of Option G4,
G5 and G8".
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3. Mounting
3.1 AGC-3 mounting and dimensions
3.1.1 Mounting of the unit
The unit is designed for mounting inside the panel. The display can be installed on the panel door and con-
nected to the main unit with a display cable.
3.1.2 Unit dimensions
Display or AOP
20.0 (0.787)
230 (9.055)
215(8.465)
115 (4.528)
15 (0.59)
165 (6.486)
115 (4.528)
144 (5.669)
220 (8.661)
115 (4.528)
119(4.689)
Dimensions are given in mm (inches).
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3.1.3 Panel cutout
In order to ensure optimum mounting, the panel door must be cut out according to the panel cutout illustration
in the chapter Technical information.
Required space 222X115mm
Gasket outer 186X77mm
Screws for fastning:
3.5mm selfcutting threads
max. depth in display 9 mm
26.0
= =
==
50.5
66.0
26.0
61.0
174.0
15.0
41.0
Dimensions are given in mm.
3.1.4 Drilling template in mm (inches)
230.0 (9.055)
119.1 (4.689)
6.6 (0.260)
112.6 (4.433)
215.5 (8.484)
114.9 (4.524)
14.3 (0.563)
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3.1.5 Mounting instructions
The unit can be mounted in two different ways:
1. Directly mounted on a DIN rail.
2. Fastened with screws to the rear side of the cabinet. Six screw holes are available for this mounting
method.
DEIF recommends using the screw hole fastening.
Warning in use of chemicals!
Do NOT use chemicals or oils (cutting oil, lubricating oil/grease) on or near by the surfaces of the controller
housing or display panel. These may cause serious damage to the plastic parts and void the warranty.
3.1.6 Tightening torques
Unit panel door mounting: 0.3 Nm, 2.7 lb-in (see diagram in "Unit dimensions")
Plug connections (terminals): 0.5 Nm, 4.4 lb-in
Display, DU-2, 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
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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4. Hardware
4.1 Board slot positions
The unit housing is divided into board slot positions. This means that the unit consists of a number of printed
circuit boards (PCBs) mounted in numbered slots. The green terminal blocks are then mounted in the PCBs.
Some of these board slots are standard and some are intended for options. The board slot positions are ar-
ranged as illustrated below.
Slot type Option Slot #1 Slot #3 Slot #5 Slot #7
Terminals 1-28 37-64 73-89 98-125
Power supply Standard X
AC measurements Standard X
Engine interface Standard X
Load sharing G3 X
Power management G4/G5/G8 X
Engine communication H7 X
I/O extension M12 X
Slot type Option Slot #2 Slot #4 Slot #6 Slot #8
Terminals 29-34 65-72 90-97 126-133
Analogue controller outputs E1/E2 X
Analogue transducer outputs F1 X
Combination outputs EF2/EF4/EF5/EF6 X
Serial communication H2/H3/H8.2 X
Engine communication H5/H6 X
I/O extension cards M13.2 X
I/O extension cards M13.6/M14.6/M15 X
I/O extension cards M13.8/M14.8/H8.8 X
Plant management G7 X
Only hardware options, which will affect the hardware of the unit, are represented in the table.
The software options will be seen through the PC utility software. The software options that are
not represented in the above table can be found in the data sheet.
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4.1.1 Unit top side overview
An overview of the terminals is presented below. The slot positions are as follows:
Ethernet
787776757473 96 979594929190 93
89888785 8683 8482818079
727169 70686765 66
62 6359 60 615856 575553 54 645251504947464443 45 4841403837 39 42
Service port Display
Ethernet
CAN B
CAN A
Power
Self check ok
Alarm inhibit
1
4
9
56
3
7 8
2
1
:The numbers in the drawing above refer to the slot numbers indicated in the table below.
No. Slot
1 #1, terminal 1-28, power supply (standard)
2 #2, terminal 29-36, communication
3 #3, terminal 37-64, inputs/outputs/load sharing
4 #4, terminal 65-72, governor, AVR, inputs/outputs (standard)
5 #5, terminal 73-89, AC measuring (standard)
6 #6, terminal 90-97, inputs/outputs
7 #7, terminal 98-125, engine I/F (standard)
8 #8, terminal 126-133, engine communication, inputs/outputs
9 LED I/F
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4.1.2 Terminal strip overviews
Standard unit
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The hardware shown in slot #3 is option M12 and G3. For a detailed description of these op-
tions, refer to the option manuals.
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Mains unit
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The hardware shown in slot #3 is option M12 and G3. For a detailed description of these op-
tions, refer to the option manuals.
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