INSTALLATION INSTRUCTIONS

Genset Controller, AGC 100

Mounting
Terminal overview
Wiring
Communication wiring
Unit dimensions and cut-out

DEIF A/S Frisenborgvej 33 DK-7800 Skive Tel.: +45 9614 9614 Fax: +45 9614 9615 info@deif.com www.deif.com

isenborgvej 33 DK-7800 Skive Tel.: +45 9614 9614 Fax: +45 9614 9615 info@deif.com www.deif.com
14 9614 Fax: +45 9614 9615 info@deif.com www.deif.com

Document no.: 4189340752B

SW version: 4.0x.x

AGC 100 Installation Instructions

4189340752 UK

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

3. Terminals
3.1. Terminal overview and description.........................................................................................................6
3.1.1. Terminal description......................................................................................................................6

4. Wiring
4.1. Wiring diagram.....................................................................................................................................10
4.2. DC connections....................................................................................................................................11
4.3. Digital inputs.........................................................................................................................................12
4.4. Breaker selection..................................................................................................................................12
4.5. Charger alternator connections............................................................................................................13
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
5.1.1. 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. CANbus 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

6. Unit dimensions and panel cut-out

6.1. Unit dimensions and panel cut-out.......................................................................................................29

DEIF A/S

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AGC 100 Installation Instructions

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General information

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 general text.
Warnings
Warnings indicate a potentially dangerous situation, which could result in death, personal injury 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 warranty 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 working with live electrical equipment.
Be aware of the hazardous live currents and voltages. Do not touch any AC measurement inputs 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.

DEIF A/S

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AGC 100 Installation Instructions

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General information

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 instructions, 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.

DEIF A/S

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AGC 100 Installation Instructions

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Mounting

2. Mounting
2.1 AGC 100 mounting
The unit is designed for flush mounting by means of 8 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).
Detailed information on switchboard cut-out and unit dimensions can be found later in this
document.

DEIF A/S

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Terminals

3. Terminals
3.1 Terminal overview and description
Unit rear view

RS485
Modbus

R23

R22

R21

Emergency stop

RPM inputs

19 20 21 22 23 24 25 26 27
Com

W/L

Binary inputs

Com

Multi-functional
inputs

10 11 12 13 14 15 16 17 18
MPU

Status

9
Com

2
-

Com

1
+

Power
supply

R24

R26
B(-)

49

GND 50
A(+) 51
52
CAN H 53

Service port

CAN A

Com 54
CAN L 55
56
CAN H 57

CAN B

Com 58

Mains voltage

Generator voltage

Generator current

CAN L 59
GB
MB

L1 N L2 NA L3
28 29 30 31 32

L1 N NA L2 NA L3
33 34 35 36 37 38

L1
L2
L3
39 40 41 42 43 44

45 46 47 48

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.

DEIF A/S

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Terminals

Terminal

Technical data

Description

Power supply +

636V DC (UL/cUL Listed: 7.532.7V DC)

Power supply

GND

3-4

Status out/configurable

See note*. Contact ratings 1 A 24V DC/V AC Resistive

Multi-functional inputs

Common

Common for terminal 6, 7 and 8

RMI/4...20 mA/digital input

Configurable

RMI/4...20 mA/digital input

RMI/4...20 mA/digital input

Digital inputs

Common

Common for terminal 1015

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 pick-up tacho generator (2-wire)

17

RPM-GND

Common for RPM input

18

RPM input (W/L)

Magnetic pick-up. PNP, NPN or charge alternator W terminal

19

Common

Common for emergency stop terminal 20

20

Emergency stop and common

for 2123

Common for relay 21, 22 and 23 and input for emergency

stop**

21

Relay output

22

Relay output

Configurable. Function NO. Contact ratings 2 A 30V DC/V

AC

23

Relay output

24-25

Relay output

26-27

Relay output

Relay outputs

Configurable. Function NO. Contact ratings 8 A 30V DC/V

AC
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 connected

32

Mains voltage L3
3-phase generator voltage input

33

DEIF A/S

Gen. voltage, L1

Generator voltage and frequency

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Terminals

Terminal

Technical data

Description

34

Gen. neutral

35

Not used, must not be connected

36

Gen. voltage, L2

37

Not used, must not be connected

38

Gen. voltage, L3
3-phase generator current input

39

Gen. current L1, s1

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

Generator current

Breaker relays
45

Relay output

46

Relay output

47

Relay output

48

Relay output

Generator circuit breaker/configurable, function NO (normally

open)
Contact ratings 2 A 30V DC/250V AC
Mains circuit breaker/configurable, function NC (normally
closed). With "Option M19" the relay is NO.
Contact ratings 2 A 30V DC/250V AC
Modbus RS485 interface

49

B (-)

50

GND

51

A (+)

Modbus RS485 RTU or ASCII

CANbus port A: Engine interface

53

CAN-H

54

Com

55

CAN-L

CAN J1939 engine communication

Optional CANbus port B: AOP-2 interface

57

CAN-H

58

Com

59

CAN-L

CAN communication line to AOP-2

Optional CANbus port B: External I/O interface

57

CAN-H

58

Com

59

CAN-L

DEIF A/S

CAN communication port to external I/O

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Terminals

* 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
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

420 mA input
Binary input with wire break (switch function)

Tacho RPM input (MPU) can be configured to cover the following functions:

Magnetic pick-up (2-wire)

NPN or PNP pick-up*

* These RPM inputs require external equipment.

Tacho RPM input with capacitor (W/L) can be configured to cover the following functions:

Magnetic pick-up (2-wire)

W terminal on charger alternator
NPN or PNP pick-up*

* These RPM inputs require external components.

The generator voltage and current input can be configured to the following:

Voltage 10025000 V primary

Current 59000 A primary

DEIF A/S

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Wiring

4. Wiring
4.1 Wiring diagram
Controller

Charging
alternator
D-

Running

D+

1N4007

12
Programming
tool

Rex

Alarm

27

R26

26
Alarm horn
RUN coil
Starter
Start prep.
Emer. STOP

Status
-

Battery

25

R24

24
23
22
21

RJ11
plug
15

R23
R22

14
13

R21

20

11

19

10

Oli pressure
Coolant temp.
Overspeed

Remote start
Start enable

3
1
2

Term. 12 can be used as alarm input if not

used for charger generator terminal D+
Rex: 12 V systems: 47 4 W
24 V systems: 100 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.

DEIF A/S

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Wiring

4.2 DC connections
Engine communication

Modbus

Controller

External I/O and AOP 2

Controller

Controller

CAN H

53

B (-)

49

CAN H

57

Com

54

GND

50

Com

58

CAN L

55

A (+)

51

CAN L

59

Multi-functional inputs,
RMI sensors

Multi-functional inputs,
Analogue 4-20 mA

Controller

RMI

RMI

RMI

Controller

Controller

16
17

DEIF A/S

Controller

5
Tacho input
Magnetic pickup/
Tacho generator

Multi-functional inputs,
Binary input

+24V DC

Controller

18
out 17

Tacho input
NPN/PNP pickup

Tacho input
W input from charger
alternator
B+ W
B-

Controller

18
17

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AGC 100 Installation Instructions

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Wiring

4.3 Digital inputs

All digital inputs are 12/24V 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 configuration 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

Continuous breaker

Compact breaker

The pictures below are examples of how to set up breakers.

DEIF A/S

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AGC 100 Installation Instructions

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Continuous breaker selection

With GB On and MB On configuration

Wiring

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.

DEIF A/S

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Wiring

AGC 100 Installation Instructions

4189340752 UK

Running
feedback
Run coil
9

24 25

12

Rex

Battery
-

RPM
input
18
17

1N4007

B+

D+

Brush
Exciter
coil (rotor)

Charger
alternator
Stator

Brush
Excitation
controller

Rex: Excitation resistor

12 V systems: 47 4 W
24 V systems: 100 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-

DEIF A/S

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AGC 100 Installation Instructions

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Wiring

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).

DEIF A/S

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Wiring

4.6 3-phase voltage and current wiring

4.6.1 3-phase wiring, AGC 112
Island operation

Consumer
N

L1

L2

L3
Supply

45

GB ON
command

46

GB

s2
s1

14

GB OFF feedback

33

UL1

36
34

UL2 GENERATOR
VOLTAGE
N

38

UL3

40
39
s2
s1

42
41
s2
s1

44
43

I1
I2 GENERATOR
CURRENT
I3

GENERATOR

DEIF A/S

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Wiring

4.6.2 3-phase AMF wiring, AGC 113

3-phase AMF wiring

MAINS
N

L1

L2

L3
28

UL1

29

30

UL2

32

UL3

15

MB OFF feedback

47

MB ON
command

MAINS
VOLTAGE

Supply

MB
48

Consumers

45

GB ON
command

46

GB

s2
s1

14

GB OFF feedback

33

UL1

36
34

UL2 GENERATOR
VOLTAGE
N

38

UL3

40
39
s2
s1

42
41
s2
s1

44
43

I1
I2 GENERATOR
CURRENT
I3

GENERATOR

DEIF A/S

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Wiring

4.7 1-phase voltage and current wiring

Island, AGC 112
N

AMF and load takeover, AGC 113

L1

MAINS
N

Supply

L1
28

UL1

29

MAINS
VOLTAGE

Supply
45

GB ON
command

46

15

MB OFF feedback

47

MB ON
command

MB
GB
14

GB OFF feedback

48

Consumers

45

GB ON
command

46

s2
s1

GENERATOR

33

UL1

34

40
39

I1

GENERATOR
VOLTAGE

GB

GENERATOR
CURRENT

s2
s1

14

GB OFF feedback

33

UL1

34

40
39

GENERATOR
VOLTAGE

I1 GENERATOR
CURRENT

GENERATOR

DEIF A/S

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Wiring

4.8 Split-phase voltage and current wiring

Island, AGC 112

AMF and load takeover, AGC 113

Consumer
N

L1

MAINS

L2

L1

L2

Supply

28

UL1

29

30

UL2

15

MB OFF feedback

47

MB ON
command

MAINS
VOLTAGE

Supply
45

GB ON
command

46

MB
GB
14

GB OFF feedback

48

Consumers

45

GB ON
command

46
33

UL1

36

UL2 GENERATOR
VOLTAGE
N

34

s2
s1

40
39
s2
s1

42
41

GB

I1

GB OFF feedback

33

UL1

36

UL2 GENERATOR
VOLTAGE
N

34

I2 GENERATOR
CURRENT

s2
s1

GENERATOR

14

40
39
s2
s1

42
41

I1
I2 GENERATOR
CURRENT

GENERATOR

DEIF A/S

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Wiring

4.9 Power management 3-phase wiring (AGC 145/146)

4.9.1 Mains breaker, AGC 145
BUSBAR
N

L1

L2

L3
28

UL1

29

30

UL2

32

UL3

BUSBAR
VOLTAGE

Supply

Consumers

45

MB ON
command

46

MB

s2
s1

33

UL1

34

36

UL2

38

UL3

39
s2

42
41
s2
s1

L1

MB OFF feedback

40

s1

14

L2

44
43

MAINS
VOLTAGE

I1

I2

MAINS
CURRENT

I3

L3

MAINS

DEIF A/S

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Wiring

4.9.2 Mains and tie breaker, AGC 146

BUSBAR
N

L1

L2

L3
28

UL1

29

30

UL2

32

UL3

15

TB OFF feedback

47

TB ON
command

BUSBAR
VOLTAGE

Supply

TB
48

Consumers

45

MB ON
command

46

MB

s2
s1

33

UL1

34

36

UL2

38

UL3

39
s2

42
41
s2
s1

L1

MB OFF feedback

40

s1

14

L2

44
43

MAINS
VOLTAGE

I1

I2

MAINS
CURRENT

I3

L3

MAINS

DEIF A/S

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Communication

5. Communication
5.1 Wiring instructions
5.1.1 Wiring instructions
Cable
Belden 3106 A or equivalent. 22 AWG (0.324 mm2) shielded twisted pair, min. 95% shield coverage.
Cable shield
Connect the cable shield to earth at one end only.
GND terminal connection
In case of communication problems, the GND terminals of the unit and the external device can be linked together using a third wire.
CANbus termination resistor
The size of the terminating resistors should be 120 1%, 0.5 W resistor.
Never connect the GND terminal to earth directly or through the shield!
If the GND terminal is connected to a PLC or other device, the GND connection of this device
must be isolated from earth!
Maximum length of the CANbus line is 400 m.

DEIF A/S

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Communication

5.2 Modbus RTU

5.2.1 Connection with 2-wire shielded cable (recommended)
Multi-line 2

Multi-line 2

Multi-line 2

DATA + (A)

DATA (GND)

DATA - (B)

DATA + (A)

DATA (GND)

DATA - (B)

DATA + (A)

DATA (GND)

DATA - (B)

29

30

31

29

30

31

29

30

31

DATA - (B)

DATA (GND)

DATA + (A)

PLC or other device

DEIF A/S

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Communication

5.2.2 Connection with 3-wire shielded cable

Multi-line 2

Multi-line 2

Multi-line 2

DATA (GND)

DATA - (B)

DATA + (A)

DATA (GND)

DATA - (B)

DATA + (A)

DATA (GND)

DATA - (B)

30

31

29

30

31

29

30

31

DATA (GND)

DATA + (A)

DATA - (B)

DATA + (A)
29

PLC or other device

For wiring details, please refer to Wiring instructions in this section.

In case of very long lines on the network, terminating resistors might be needed (typically 120
1%, 0.5 W).
The calculation should be based on the following data:
A line internal pull-up bias resistor: 22 k
B line internal pull-down bias resistor: 22 k
Receiver input sensitivity: +/-200 mV
Receiver input impedance: 12 k

DEIF A/S

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Communication

5.3 CANbus engine communication

5.3.1 Connection with 2-wire shielded cable (recommended)
Multi-line 2
CAN-H

Com

CAN-L

53

54

55

CAN-H

Com

CAN-L

ECM
engine control module

DEIF A/S

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Communication

5.3.2 Connection with 3-wire shielded cable

Multi-line 2
CAN-H

Com

CAN-L

53

54

55

CAN-H

Com

CAN-L

ECM
engine control module

DEIF A/S

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Communication

5.4 External I/O modules

57

120

120

Option H8

AGC 100

CAN-H

58
59

CAN-L

I/O RUN

BECKHOFF

I/O EER

ON

1 2 3 4 5 6 7 8

For wiring details, please refer to Wiring instructions in this section.

If external I/O modules "Option H8" are used together with AOP-2, the total terminal resistance
of the AOP-2 and the external I/O controller must be 120 .

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Communication

5.5 Additional Operator Panel, AOP-2

App./Bootl.

CAN L
59

CAN H
57

End res.

Additional operators panel AOP-2

OFF
ON

CAN 1

CAN 2

Red
Brown/white
Red/white
Black/white
Black
Brown

Black/white

Black

Red
Brown/white
Red/white

R=120

-+

5V DC

1
Cable shield

1...6

24V DC

-+

Comm. to
next units

Status relay

1...6
6 - Black: GND
5 - Black/white: +5V DC
4 - Brown: Not used
3 - Red: CAN L
2 - Brown/white: CAN GND
1 - Red/white: CAN H

Left CAN port (CAN 1)

NO
Common
NC

DIN rail

Terminal block

6 - Black: Relay common

5 - Black/white: Relay NO
4 - Brown: Relay NC
3 - Red: CAN L
2 - Brown/white: CAN GND
1 - Red/white: CAN H

Right CAN port (CAN 2)

For wiring details, please refer to Wiring instructions in this section.

If external I/O modules "Option H8" are used together with AOP-2, the total end resistance of
the AOP-2 and the external I/O controller must be 120 .
A DC/DC converter for the DC supply voltage and 2x1 m cable with an RJ12 plug in one end
and stripped wires in the other end are included in the AOP-2 delivery.

DEIF A/S

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AGC 100 Installation Instructions

4189340752 UK

Unit dimensions and panel cut-out

6. Unit dimensions and panel cut-out

6.1 Unit dimensions and panel cut-out
220.0 (8.66)

Multi-line

AGC 100
0.3 Nm

Alarm 1
Alarm 2

160.0 (6.30)

Alarm 4

151.0 (5.94)

Alarm 3

54.0 (2.13)

61.0 (2.40)

211.0 (8.30)

Panel cut-out
H x W = 151 x 211 + 1 mm
H x W = 5.94" x 8.31" + 0.04"

Dimensions are in mm (inches).

DEIF A/S

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