DEIF AGC 100 series generator set controller

DEIF AGC-100 Generator Set Controller: Complete Installation and Wiring Guide

The DEIF AGC-100 series is an economical controller designed specifically for generator control, integrating functions such as generator protection, automatic start/stop, synchronization, grid connection, and power management. This series of controllers is widely used in backup power sources, mobile generator sets, and industrial self owned power stations due to its compact size, flexible configuration, and reliable performance. This article is based on the AGC-100 installation manual, systematically explaining the installation requirements, terminal functions, wiring specifications, and communication configuration of the equipment, providing comprehensive technical guidance for installation engineers and switchgear manufacturers.

Product Overview

1. Series model

The AGC-100 series includes multiple models to adapt to different application scenarios:

Model Function Description

AGC 112 Island mode operation, controlling the generator circuit breaker

AGC 113 automatic mains fault switching mode, controlling the generator circuit breaker and main circuit breaker

AGC 145 power management mode, controlling the generator circuit breaker and main circuit breaker

AGC 146 power management mode, controlling the generator circuit breaker, main circuit breaker, and bus tie circuit breaker

2. Main characteristics

Integrated measurement: Three phase true RMS measurement, parameters such as voltage, current, frequency, power, etc

Protection functions: reverse power, overcurrent, overvoltage, undervoltage, overclocking, underflocking, etc

Engine interface: speed sensor input, charging generator monitoring, start/stop control

Communication interface: Modbus RTU, CAN bus (J1939 engine communication)

Scalability: Supports external I/O modules and additional operation panels

3. Certification and Standards

Compliant with EN 61010-1 electrical safety standard

Compliant with EN 61000-6-1/2/3/4 electromagnetic compatibility standards

UL/cUL certification (applicable to UL508 listed generator components)

Protection level: IP52 (standard), optional IP65 (with sealing gasket and additional buckle)

Installation requirements and mechanical dimensions

1. Installation method

AGC-100 is designed for embedded installation on the front of the panel. The standard configuration comes with 8 fixed buckles to achieve IP52 protection level. If IP65 protection is required, an optional L (including 12 buckles and gaskets) must be ordered.

2. Panel opening size

The size of the panel opening is:

Height: 151.00 mm (+1.00 mm)

Width: 211.00 mm (+1.00 mm)

The imperial unit is 5.94 inches x 8.31 inches (+0.04 inches)

3. Tightening torque

Partial torque

Panel door installation 0.15-0.20 Nm (1.4-1.8 lb in)

Plug terminal 0.5 Nm (4.4 lb in)

AOP-1/AOP-2 panel installation 0.7 Nm (6.2 lb in)

Sub-D connector screw 0.2 Nm (1.8 lb in)

DC-DC converter terminal 0.5 Nm (4.4 lb in)

Terminal definition and functional description

The AGC-100 is equipped with multiple terminal blocks at the rear, including power supply, digital input, analog input, speed input, relay output, voltage and current measurement, communication interface, etc.

1. Power and status output (terminals 1-4)

Terminal functional technical parameters

1. Positive pole of power supply 6-36 V DC (UL/cUL: 7.5-32.7 V DC)

2. Negative GND of power supply

3-4 state output/configurable 1 A @ 24 V DC/V AC, resistive load

Terminal 3-4 is the output of the microprocessor watchdog, and the relay is engaged during normal operation; Relay release in case of power failure or microprocessor malfunction.

2. Multi functional input (terminals 5-8)

Terminal Function Description

5 common terminals for terminals 6-8

6 multifunctional inputs 1 can be configured as 4-20mA input, digital input Pt1000

7 Multi functional inputs 2 Same as above

8 Multi functional inputs 3 Same as above

These inputs can be configured as remote alarm suppression, operation mode switching, analog monitoring, or temperature sensor inputs.

3. Digital input (terminals 9-15)

Terminal Function Description

9 common end for terminals 10-15

10-15 digital input 1-6 12/24V DC bidirectional optocoupler, configurable

Digital input can be used for emergency stop, start enable, operation feedback, mode selection, alarm confirmation and other functions.

4. Speed input (terminals 16-18)

Terminal Function Description

16 RPM input (MPU) magneto electric speed sensor (2-wire)

17 RPM-GND speed sensor common terminal

18 RPM input (W/L) magneto electric, PNP, NPN or charging generator W terminal input

The speed input supports various signal sources such as magneto electric sensors, Hall effect sensors, and charging generator W terminals.

5. Relay output (terminals 19-27)

Terminal Function Contact Capacity

19 Public end (emergency stop) -

20 Emergency stop input and common terminal -

21-23 relay output 1-3 2 A @ 30 V DC/V AC

24-25 relay output 4 8 A @ 30 V DC/V AC

26-27 relay output 5 8 A @ 30 V DC/V AC

The relay output can be configured as: running coil, stopping coil, starting preparation, starting motor, closing, opening, alarm horn, status OK, etc. Supports dual system engines (independent operation coil and stop coil).

6. Three phase voltage and current input (terminals 28-48)

Main voltage input:

Terminal 28: L1

Terminal 29: N

Terminal 30: L2

Terminal 32: L3

Generator voltage input:

Terminal 33: L1

Terminal 34: N

Terminal 36: L2

Terminal 38: L3

Generator current input:

Terminal 39-40: L1 current (s1/s2)

Terminal 41-42: L2 current (s1/s2)

Terminal 43-44: L3 current (s1/s2)

Circuit breaker relay:

Terminal 45-46: Generator circuit breaker (normally open, 2A @ 30V DC/250V AC)

Terminal 47-48: Main circuit breaker (normally closed, optional M19 for normally open)

7. Communication interface (terminals 49-59)

Modbus RS-485：

Terminal 49: B (-)

Terminal 50: GND

Terminal 51: A (+)

CAN bus (port A):

Terminal 53: CAN-H

Terminal 54: COM

Terminal 55: CAN-L

Optional CAN bus (port B):

Terminals 57-59: Used for AOP-2 additional operation panel or external I/O module (optional H8)

Wiring specifications

1. DC power supply wiring

The auxiliary power input needs to be protected by a 2A slow melting fuse

Power supply voltage range: 6-36 V DC

Suggest using DEIF DCP-2 power supply or equivalent products

2. Digital input wiring

The digital input is a bidirectional optocoupler type, and the typical input circuit is as follows:

Input conduction voltage: 8-36 V DC

Input shutdown voltage:<2 V DC

Typical input impedance: 4.7 k Ω

3. Circuit breaker control

AGC-100 supports three types of circuit breakers:

Circuit breaker type closing output opening output

Pulse type requires

Continuous type required or not

Compact models require

Select the circuit breaker type through PC configuration software and allocate the corresponding relay output in the I/O configuration.

4. Monitoring of charging generator (D+and W terminals)

AGC-100 supports two monitoring methods for charging generators:

Method 1: Connect the D+terminal to terminal 12

Connect the positive terminal of the battery through a REX resistor (12V system: 47 Ω/4W; 24V system: 100 Ω/6W)

When starting, the current flows through REX to assist in exciting the generator

After the generator generates electricity, the voltage at terminal 12 increases, cutting off the excitation current and providing operational feedback

Method 2: Connect the W terminal to the speed input (terminal 18)

Directly monitor the AC frequency of the charging generator

Provide speed signal and operational status feedback

5. AC measurement wiring

Three phase system (AGC 112):

The generator voltage is directly connected to terminals 33-38

The generator current is connected to terminals 39-44 through CT

Suitable for islanded operation mode

Three phase AMF system (AGC 113):

Simultaneously connect the main voltage (terminals 28-32) to the generator voltage

Suitable for automatic mains power fault switching applications

Single phase system:

Connect the voltage to L1 and N

Current connection to L1 CT

Phase separation system:

Voltage connection to L1, L2, and N

Connect current to L1 and L2 CT

6. Power management wiring (AGC 145/146)

AGC 145 (Main Circuit Breaker):

Connect the main voltage, generator voltage, and current

Relay output controls generator circuit breaker and main circuit breaker

AGC 146 (main circuit breaker+bus tie circuit breaker):

In addition to the main circuit breaker, additionally control the bus tie circuit breaker

Suitable for power management between two busbars

Communication interface configuration

1. Modbus RTU

Interface: RS-485, 2-wire system

Supporting protocols: Modbus RTU or ASCII

Maximum bus length: 300 meters

Cable recommendation: Belden 3106A or equivalent (22 AWG shielded twisted pair, shielding coverage ≥ 95%)

Terminal resistor: When the bus length exceeds 30 meters, 120 Ω terminal resistors need to be installed at both ends

2. CAN bus engine communication

Interface: CAN J1939

Maximum bus length: 300 meters

Cable recommendation: Belden 3106A or equivalent (22 AWG shielded twisted pair, shielding coverage ≥ 95%)

Terminal resistor: 120 Ω terminal resistors need to be installed at both ends of the bus

3. External I/O modules

Connected via CAN bus, supports optional H8 external I/O module

Bus length ≤ 300 meters

Use Belden 3106A or equivalent cable

When sharing the bus with AOP-2, the total terminal resistance should be 120 Ω

4. Additional operation panel AOP-2

Connect through CAN port B

Comes with DC-DC converter and 2 x 1 meter RJ12 connection cable

Maximum bus length: 300 meters

Use Belden 3106A or equivalent cable

Summary of Technical Specifications

1. Electrical parameters

Project Parameters

Auxiliary power supply 6-36 V DC (UL/cUL: 7.5-32.7 V DC)

Maximum power consumption of 8W

Measurement voltage range 100-25000 V (primary side)

Measure current range 5-9000 A (primary side, through CT)

Measurement frequency 30-70 Hz

Accuracy Class 1.0

2. Input/output specifications

Project Parameters

Digital input 12/24V DC bidirectional optocoupler, input impedance 4.7k Ω

Multi functional input 4-20mA, digital input Pt1000

Speed input magneto electric, PNP, NPN, W terminals

Relay output (low power) 2A @ 30V DC/V AC

Relay output (high power) 8A @ 30V DC/V AC

Status output 1A @ 24V DC/V AC

3. Environmental conditions

Project Parameters

Working temperature -25 ℃ to+70 ℃

Storage temperature -40 ℃ to+70 ℃

Humidity 95% RH (non condensing)

Protection level IP52 (standard), IP65 (optional L)

4. Precautions for UL application

The controller is only applicable to generator components that have been certified by UL

Power supply voltage range: 7.5-32.7 V DC

Use 60/75 ° C copper wire

Installed on the flat surface of Type 1 casing

Compliant with NEC (USA) or CEC (Canada) specifications

Installation precautions

1. Safety Warning

Installation work can only be carried out by authorized electrical personnel

It is strictly prohibited to touch the AC measurement input terminal when the equipment is live

Pay attention to electrostatic protection during installation

The factory setting is the average value, and adjustments must be made according to the actual generator set before operation

2. Wiring requirements

All AC measurement circuits must be protected by 2A slow melting fuses

When the relay output drives inductive loads, a noise suppression circuit must be installed

Modbus and CAN buses must use shielded twisted pair cables, with the shielding layer grounded at one end

Bus terminal resistors must be installed according to specifications

3. Check after installation

Confirm that all terminals are securely connected and the torque meets the requirements

Confirm the size of the panel opening and the installation of the buckle in place

Confirm that the power polarity is correct and the voltage range meets the specifications

Confirm that the communication cable wiring is correct and the terminal resistor has been installed

Summary of Application Value

The AGC-100 generator controller provides a cost-effective solution for generator control with its compact design, flexible configuration, and reliable performance. Its main value lies in:

Easy installation: standard panel embedded installation, regular hole size, simple buckle fixation

Clear terminals: The terminal block has clear functional zoning, complete labeling, and is easy to connect

Flexible configuration: supports multiple operating modes (islanding, AMF, power management) to adapt to different application scenarios

Rich interfaces: digital input, multifunctional input, speed input, relay output, communication interfaces are all available

Communication capability: Supports Modbus RTU and CAN J1939, can be connected to the upper computer monitoring system

Scalability: Supports external I/O modules and additional operation panels to meet complex system requirements

Environmental adaptation: Wide working temperature range, IP52/IP65 protection level, suitable for various installation environments