DEIF AGC-4 diesel generator set integrated controller

DEIF AGC-4 diesel generator set integrated controller

Standard Machine Functions, Measurement Systems, and Application Modes

Standard core functional modules

Operating mode system

Covering all mainstream power station control modes: AMF mains backup, isolated grid independent operation, fixed base load, peak shaving, load transfer, reverse mains power transmission, multi unit analog equalization (option G3), power management system (options G4/G5/G8).

Complete timing sequence for engine start stop

Built in standardized start/stop logic: pre lubrication, preheating, multiple start attempts, offline judgment, cooling shutdown, emergency stop control, supports dual start motors, idle operation, temperature control start/stop expansion.

ANSI standard generator protection (timed limit)

Integrated complete set of electrical fault protection for the unit: reverse power 32, multi-stage overload, multi-stage overcurrent 50/51, under/over-voltage 27/59, high and low frequency 81, demagnetization 40, excitation overload, current/voltage imbalance, under excitation, voltage limited short circuit protection, supporting graded fault actions (alarm/circuit breaker tripping/shutdown).

Busbar protection

Multi level overvoltage, undervoltage, frequency anomaly, and voltage imbalance protection for busbars, used for fault isolation on the grid side.

Human Machine Unit DU-2

Split type LCD operation screen, can be remotely installed, integrated with start stop, on/off buttons, and status text display; Optional TDU touch screen;

M-Logic built-in logic tool

The controller comes with a simple PLC style logic and is configured through USW software. It supports digital input, alarm, and operating status as triggering events, and outputs commands such as control relays, mode switching, and constant value switching.

Measurement system configuration

Support three types of power grid measurement architectures, switch through menu 9130:

Three phase system (default): Three phase three wire/four wire, can be directly connected to low voltage such as 400V, high voltage requires PT voltage transformer, and distributes two sets of transformation ratio parameters for motor and busbar;

Phase separation system (120/240V American standard): L1/L3 180 ° phase architecture, separate phase voltage alarm judgment rules;

Single phase system: single-phase zero line measurement, suitable for single-phase generator sets;

Support fast switching of 4 sets of rated parameter groups (voltage/frequency/power), with one click switching for mobile power stations and multi condition units; The voltage range scaling function is suitable for high and low voltage systems ranging from 0.4kV to 250kV, and synchronously changes the power and transformer parameter range through scaling.

Eight standard application conditions (with single line diagram and timing process)

Each operating condition is accompanied by a control flowchart, power variation curve, and single line topology diagram:

AMF mains power failure (no synchronous return to the grid): automatic start-up due to mains voltage loss delay, opening and closing of the mains power switch and generator switch; Directly shut down when the mains power is restored, without synchronous grid connection;

AMF brings back grid synchronization: After the mains power is restored, it is synchronized with the grid first, and the load is smoothly transferred before shutting down. It supports short-term parallel overlapping delay;

Lonely network operation: no mains power, the unit is independently loaded, and the frequency and voltage are autonomously adjusted;

Power ramp (active P/reactive Q independent ramp): Slowly increase or decrease the load during grid connection/disconnection to avoid impact;

Fixed base load operation: maintain constant active/reactive power output after the unit is connected to the grid;

Warm up idle ramp: limit output power during the cooling stage to protect the engine;

Peak Shaving: Monitor the incoming power of the mains, automatically start the machine when the load exceeds the set value, and reduce the peak value of the mains power;

Load Takeover: Synchronize the transfer of all loads from the mains to the generator;

MPE for mains power transmission: fixed power of the unit is transmitted in reverse to the grid;

Supporting 4~20mA mains power transmitter access scheme, used for peak shaving/load transfer to collect incoming power.

Four basic operating modes

Semi automatic: The controller automatically adjusts voltage, frequency, and synchronization, but manual instructions are required for start stop/opening/closing;

Test mode: divided into no-load test, load test, and complete load transfer test. Set the test duration and automatically restore the original mode upon completion;

Manual: Fully turn off automatic adjustment, manually jog speed and pressure regulation, manually open and close switches, without synchronous automatic logic;

Lockout Block Mode: For maintenance purposes only, automatic start-up and shutdown are prohibited. The operating unit will disconnect and cool down, blocking the automatic process and only retaining the alarm function.

Classification of Single Line Topology Diagrams

No power management: single machine AM, isolated network, peak shaving, load transfer, single parallel machine;

Equipped with power management (G4/G5/G8): multi unit isolated grid, grid connection, multi bus segmentation, ATS dual power supply, energy storage/photovoltaic hybrid energy system, remote operation and maintenance architecture;

Complete set of standard control flow chart

The manual contains dozens of timing diagrams: mode switching, mains power on/off, generator on/off, start/stop, synchronization, peak shaving, etc AMF、 Test the entire process logic, label the functions, triggering conditions, and fault jump branches of each timer.

Standardized timing sequence for start stop and circuit breaker

Startup process: Pre start delay, startup relay output, speed/oil pressure/frequency operation judgment, disengagement of motor, idle transition; Support multiple operational feedbacks (magnetic pickup MPU, oil pressure, frequency, digital contacts); Dual start motor rotation logic;

Shutdown process: Normal cooling shutdown, emergency shutdown without cooling, distinguish the source of shutdown instructions (panel/remote/protection trip);

Circuit breaker timing: spring energy storage delay, opening and closing feedback detection, synchronous locking, overlapping parallel time, maintenance extraction locking function;

Principles of Complete Generator/Busbar Protection (ANSI Standard)

All protections are timed logic: the timer starts when the measured value exceeds the limit, automatically resets when it falls back, and executes the corresponding fault level action when it exceeds the limit.

Phase sequence/phase rotation protection: distinguish between single machine and multi machine busbar systems, monitor generator/busbar voltage separately, and set only alarm, circuit breaker tripping, and shutdown for faults;

Demagnetization protection 40: Monitor the capacitive reactive power input of the generator, set the rated kW percentage, and draw the stable operating boundary curve of the generator;

Voltage limit overcurrent 51V: In the event of a short circuit, the voltage drop automatically reduces the overcurrent setting to avoid tripping due to low voltage short circuit current; Built in 6-point voltage current setting curve;

Current imbalance protection: calculated in two modes: maximum and minimum difference or three-phase average value, to prevent single-phase overload from burning the winding;

Voltage imbalance protection: monitoring three-phase voltage difference, adapting capacitor compensation for imbalance faults;

Overexcitation protection: limit the upper limit of inductive reactive power of the generator to avoid overheating of the iron core; Optional C2 function can expand the complete unit P-Q capacity curve protection;

Provide a detailed explanation of the voltage/current measurement reference switching (phase voltage/line voltage menu parameters affect all protection thresholds).

Governor GOV and Voltage Regulator AV PID Control System

PID Universal Control Architecture

The three loops of proportional Kp, integral Ti, and differential Td are independently adjustable, respectively controlling the four closed loops of frequency, active power sharing, voltage, and reactive power sharing; Provide formulas, output characteristic curves, and parameter tuning guidance.

P: Instantaneous correction deviation, the higher the gain, the faster the response but prone to oscillation;

I: Eliminating steady-state static error, the longer the integration time, the smoother the adjustment;

D: Suppress oscillations and enhance system stability;

Multiple sets of dedicated PID controllers

Frequency PID (isolated network basic regulation);

Active power PID (grid connected base load);

Active power sharing PID (multi machine parallel);

Voltage PID (requires D1 option);

Reactive power/power factor PID;

Reactive power sharing PID;

Relay based speed and voltage regulation logic

When there is no analog output, pulse point-to-point adjustment is used, which includes static continuous output, dynamic pulse interval, and dead zone. The pulse period and minimum conduction time can be set;

Droop adjustment function

The frequency/voltage adjustment difference is adjustable from 0% to 10%, suitable for existing differential parallel units on site, divided into high and low adjustment difference curve cases; Support compensation and adjustment parameters for constant speed units; Distinguish frequency related dynamic adjustment curves for compensating active power output in power grid fluctuations.

Complete Control Logic for Simultaneous Grid Connection

Dynamic synchronization (default)

The generator maintains a small positive sliding frequency, gradually reduces the phase difference, and pre sends closing pulses to compensate for the inherent opening time of the circuit breaker in advance, to prevent reverse power impact; Provide all tuning parameters for sliding frequency, pressure difference, and phase window; Schematic diagram of load distribution principle after synchronization.

Static synchronization

Extremely low sliding frequency, precise phase alignment before closing, suitable for zero load and no impact scenarios, finely controlled phase angle by phase PI regulator.

CBE special function for closing before excitation

Start by first closing the circuit breaker and then establishing the voltage, suitable for transformer soft start scenarios, supporting a complete set of parameters for speed threshold, excitation delay, and fault alarm, and distributing two types of process diagrams for motors and busbars.

Simultaneous locking conditions

Multiple safety interlock logic, including grid restoration delay after power outage, input prohibition during closing, independent synchronous relay output, and circuit breaker spring energy storage interlock.

Expansion of Additional Functions (Full System Auxiliary Control)

This chapter is the largest chapter in the manual, covering all auxiliary functions such as engine, cooling, load, communication, logic, timing, input and output

Engine start stop matching function

Multiple operational feedback: digital contacts, magnetic pickup MPU, oil pressure analog quantity;

Dual start motor rotation logic;

Idle control: low-temperature temperature control automatic idle, configurable idle speed and delay;

Engine heater: automatically starts insulation when the water temperature is below the threshold;

Fuel pump level control: 4~20mA level sensor, high and low level start stop pump, fuel shortage alarm;

Cooling and fan management

Up to 4 sets of cooling fans can be started and stopped in stages according to water temperature, with automatic rotation and balanced operation hours. Fan fault alarms and staggered current limiting during startup can be triggered;

Unit capacity reduction Derate

Water temperature, environment, ECU engine message, analog signal trigger power load limit, proportional/inverse scaling curve to prevent high temperature overload tripping;

Level 3 Non Important Load Unloading NEL

Gradual removal of secondary loads during low-frequency/unit overload to prevent power loss throughout the entire station;

Complete control of circuit breaker

5 types of circuit breakers (pulse, continuous, compact, ATS passive, etc.), spring energy storage delay, circuit breaker position fault, extraction maintenance mode (locking synchronization, shielding fault alarm), and bus tie segmentation logic;

Various timed controls

Maintenance timer: triggers maintenance reminders when running for hours;

Command timing: automatic start stop of the unit at different times;

Engine oil change timing;

Automatic correction during daylight saving time;

Periodic battery testing: Regularly start the motor to check the battery capacity and support asymmetric voltage monitoring of dual battery packs;

Input-output system

Digital DI: More than 50 programmable functions (emergency stop, remote start stop, locking, mode switching, etc.), all defined and action scene comparison table;

Multi input: Supports 4-20mA, 0-40V, Pt100/100, oil/water/fuel RMI resistance sensors, each sensor provides a standard resistance temperature/pressure comparison table;

Analog output: active and reactive power transmission, externally given;

Relay output: alarm, control, limit contact classification;

Logic and Communication Tools

M-Logic: graphical logic programming, event triggered relay, mode, and constant value switching;

RRCR radio load reception: 4-channel switch input setting with multiple power/power factor settings;

USW upper communication: Modbus RTU/ASCII, remote monitoring, firmware upgrade;

Event record: 500 events+500 alarms+battery test logs, with time stamps, first in first out coverage;

Protection fault classification Fail Class

Classification of 9-level fault actions: only alarm, generator trip, shutdown, mains trip, safety shutdown (load protection), forced shutdown, etc., distinguish different actions under the two states of unit operation/shutdown, and each protection can independently allocate fault levels and interlock relay outputs;

Other auxiliary functions

Load offset and power factor offset settings;

Local manual speed and pressure regulation;

Access lock: Cabinet door lock prohibits panel modification of parameters;

Switch board fault input: External cabinet failure locks and starts the machine;

Internal battery backup: store parameters/logic, backup is required before replacing the battery;

Master clock compensation: adapted to islanded power frequency timing errors;

General PID Extended Loop

Independent external universal PID module, capable of collecting external temperature, pressure and other signals through analog input, outputting 4-20mA adjustment signal, supporting gain compensation and M-Logic linkage, used for third-party equipment linkage control of boilers and cooling systems.