Deif AGC 200 Series - User Manual

The DEIF Multi-line 2 series is a range of control units designed for generator set applications, offering comprehensive functionality for settings, governor, AVR, and protection checks, as well as overall unit adjustment. These guidelines are primarily intended for commissioning engineers responsible for setting up and verifying the unit's operation.

Function Description

The Multi-line 2 unit serves as a central controller for engine/generator sets, managing various aspects of their operation. Its core function revolves around a PID (Proportional-Integral-Derivative) controller, which is crucial for maintaining stable and efficient performance. The unit incorporates several specialized controllers:

Frequency Controller: This controller manages the generator's frequency when operating in island mode (stand-alone), ensuring stable frequency output independent of an external grid.
Power Controller: When the Multi-line 2 is running with a fixed power or base load, the power controller regulates the generator's power output.
P Load Share Controller: In load sharing mode, this controller ensures equitable distribution of active power among parallel-running generators.
Voltage Controller: Similar to the frequency controller, the voltage controller maintains the generator's voltage when operating in island mode.
Reactive Power Controller: This controller manages the reactive power (VAr) output when the Multi-line 2 is operating with a fixed VAr load.
Q Load Share Controller: In reactive load sharing mode, this controller ensures balanced distribution of reactive power among parallel-running generators.

The unit also includes robust protection features to safeguard the generator set from various operational anomalies. These protections are configurable and cover aspects like alarm setpoints, delays, relay outputs, activation conditions, fail classes, and inhibits.

Usage Features

Commissioning the Multi-line 2 involves a systematic, step-by-step process to ensure proper integration and operation with the engine/generator set.

Settings Check: This initial phase involves verifying and adjusting all nominal, alarm, function control, speed controller, and voltage controller settings. These adjustments can be made either through the unit's display or via the PC utility software. Nominal values, such as frequency, power, current, voltage, and RPM, are set according to the generator's specifications. Alarm settings, including reverse power and overcurrent thresholds, are configured based on customer and application requirements. Function control settings, which encompass the entire functionality of the Multi-line 2, are carefully reviewed and adjusted for desired unit control. Speed and voltage controller settings are initially set to provide a slow regulation, with low Kp and Td values and high Ti values, to ensure stability before fine-tuning.
Governor Check: This step ensures the Multi-line 2 can successfully operate with the engine's speed governor. The governor itself should be tuned according to the engine manufacturer's instructions to ensure smooth operation without hunting before the Multi-line 2's control function is activated.
- Speed Setting: An initial speed setting is performed, with the procedure depending on the interfacing method (relay output, analogue output, or EIC, J1939). For relay output, the generator is run with no load, and the frequency is adjusted to the base frequency (50 or 60 Hz) on the speed governor. For analogue output, the Multi-line 2 is set to manual operation (or switchboard control for PPM units) to disable its control outputs while keeping generator protection active. The generator is then run with no load, and the frequency is set to the base frequency on the speed governor. EIC, J1939 interfacing adjusts RPM from the factory side, so manual speed setting is not required.
- Speed Droop: The speed governor must have a droop of 3-4% (speed dropping 3-4% from no load to full load when the Multi-line 2 is not in control). This is crucial for stability, especially when using relay outputs for governor control, and for ensuring equal load sharing in parallel operations. While 0% droop is possible with analogue interfacing, a droop adjustment is recommended for safety.
- Speed Range: When using analogue interfacing, the resistor across the output terminals is selected to achieve the necessary speed range, typically fNOM +3 Hz, to allow for full load operation.
- Terminals: The governor can be interfaced via analogue (+/-25 mA or 0-20 mA signal) or digital (two relays for increase/decrease) connections.
AVR Check: Similar to the governor check, this ensures the Multi-line 2 can operate effectively with the Automatic Voltage Regulator (AVR). The AVR should be tuned according to the manufacturer's instructions to ensure smooth generator operation before the Multi-line 2's control function is activated.
- Voltage Setting: An initial voltage level setting is made, again depending on the interfacing. For relay output, the generator runs with no load, and the voltage is adjusted to nominal voltage on the AVR. For analogue output, the Multi-line 2 is set to manual operation, and the voltage is set to nominal on the AVR.
- Voltage Droop: The generator AVR must have a voltage droop of 3-4% (voltage dropping 3-4% from no load to full reactive load when the Multi-line 2 has no control). This ensures equal VAr sharing among parallel-running generators.
- Voltage Range: The voltage range, similar to the speed range, must be wide enough for voltage droop and full load, typically +/-10% * UNOM.
- Terminals: The AVR can be interfaced via analogue (+/-25 mA or 0-20 mA signal) or digital (two relays for increase/decrease) connections.
Protections Check: This involves verifying the configuration of all alarms, including their setpoints, delays, relay outputs, activation conditions, fail classes, and inhibits. These settings are critical and must align with national rules, additional protection equipment, and the required use of protections (e.g., tripping non-essential loads, breaker tripping, engine stopping).
Adjustment: This final phase involves fine-tuning the PID controllers.
- PID Controller Adjustment: The Kp, Ti, and Td values for all controllers are initially set low. The tuning process starts with Kp: increase it step-by-step until the genset becomes unstable, then set it to 50% of that value. Next, tune Ti: with Kp set, raise Ti to a high value (e.g., 30s), then decrease it step-by-step until instability begins, and set it to 1.5-1.7 times that value. Finally, tune Td: increase it step-by-step until instability, then set it to 50-70% of that value. Readjustments may be necessary if the genset remains unstable.
- Manual Governor and AVR Control: This feature allows for manual manipulation of regulation deviations, useful for tuning when load jumps are difficult to achieve. It can be activated by pressing the "up" or "down" arrows for more than 2 seconds, or via digital inputs/AOP buttons in semi-auto mode.
- Semi-auto Mode (AGC 200/AGC-3/AGC-4 only): In this mode, the "setp" value can be changed using the up/down arrows, modifying the governor or AVR setpoint.
- Auto and Test Mode (AGC 200/AGC-3/AGC-4 only): Similar to semi-auto, but activating digital inputs/AOP buttons changes the regulation setpoint without opening the regulation window.
- Relay Output Adjustments: If relay outputs are used for governor/AVR, the minimum pulse time (ON time) and period time (PER time) must be adjusted. Recommended starting points are 500-1000 ms ON time and 2500-5000 ms period time for the governor, and 100 ms ON time and 500 ms period time for the AVR, with period time approximately 5xON time.
- Resulting Speed/Voltage Curve: Testing with load jumps helps verify the speed/voltage control. An optimal result shows 2-3 overshoots before stabilizing after a sudden load change. If more overshoots occur, the Kp factor should be decreased.

Maintenance Features

The Multi-line 2 unit is designed for reliable operation, but proper installation and initial setup are key to its longevity and performance. The document emphasizes that the unit should not be opened by unauthorized personnel, as this will void the warranty. Regular checks of settings and protections during commissioning contribute to preventative maintenance, ensuring the unit operates within safe and optimal parameters. The troubleshooting guide provides a structured approach to identifying and resolving common issues, such as unstable load sharing, inability to take full load, or incorrect speed/voltage responses, by suggesting remedies like adjusting speed/voltage droop, checking initial settings, or swapping connections. This proactive approach to problem-solving helps maintain the system's integrity and reduces downtime.

Deif AGC 200 Series Specifications

General

Engine Start Outputs	2
Analog Outputs	2
Number of Generator Phases	3
Number of Mains Phases	3
Communication Ports	RS485, USB
Operating Temperature	-25°C to +70°C
Storage Temperature	-40 to +85 °C
Protection Rating	IP20
Display	Graphical LCD