- Power Module:
- PM3516 (S/N: NBR1-UP)
- PMG3516 (S/N: JKK1-UP)
Introduction
This Special Instruction provides basic troubleshooting procedures for the AGC-4 controller. Do not perform this procedure until you have read and understand the information.
Safety Section
| NOTICE |
|---|
Installing and operating the controller involves working with dangerous currents and voltages. The installation must only be performed by authorized personnel who have been trained to work with live electrical equipment. |
Note: When working with the controller there are hazardous live currents and voltages. Do not touch any AC measurement inputs as the inputs could lead to serious injury or death.
| NOTICE |
|---|
The DEIF controller must not be tampered with by unauthorized personnel. If the controller is opened, the warranty becomes void. |
| NOTICE |
|---|
The controller is delivered from the factory with default factory settings. The settings are based on average values and are not necessarily the correct settings for the engine/generator set. Check the settings before running the engine/generator set. |
Troubleshooting Procedure
Navigating the Display
 | |
| Illustration 1 | g03733279 |
(1) Stop button (2) Start button (3) Info button (4) Alarm lamp (5) Select button (6) Remote button (7) Local button (8) Breaker open/close button | |
To change the controller mode, press remote (6) or local (7) button. The genset is controlled remotely by the power management system in the "REMOTE" mode. In "LOCAL" mode the genset is controlled directly by the display.
Press breaker open/close (8) once to close the breaker. When the breaker is closed the green "ON" lamp will be illuminated. Press breaker open/close (8) again to open the breaker. With the breaker open the green "ON" lamp will turn off.
To acknowledge alarms, use the arrow keys to place the cursor under "ACK" on the display screen and press select button (5). Acknowledging the alarm will turn on alarm lamp (4). Unacknowledged alarms cause the alarm lamp (4) to flash
Symptom Based Troubleshooting
| Symptom | Probable Cause | Repair |
|---|---|---|
| Display (DU-2) is not working | Bad connection or no connection from the AGC-4 controller to the DU-2 display | Check the wiring, ensure that connectors are connected, and pins are secured |
| No power supply | Verify 24 V power on terminals 1-2 and 98-99 | |
| The AOP-1 is not working | Bad or no connection from the AGC-4 controller to the DU-2 display | Check the wiring, ensure that connectors are connected, and pins are secured |
| Bad or no connection from the DU-2 display to the AOP-1. | Ensure that the ethernet cable is securely connected at both ends | |
| The AOP-1 is not programmed | Program the AOP-1 using the DEIF Utility Software. | |
| AGC-4 controller does not power up | No power supply | Verify 24 V power on terminals 1-2 and 98-99 |
| Internal fault in the AGC-4 | Check whether the Self check OK LED is green. If the lamp is not green, and the 24 V supply on terminals 1-2 is OK, then replace the controller | |
| Analog load sharing is not working | Voltage higher than 15V DC has been connected to the load sharing terminals | Replace the controller |
| Analog load sharing line is short-circuited | Check the analog load sharing line. Remove the fault | |
| No Ethernet connection (Ethernet error | The AGC-4 controller has overheated | Reboot the controller |
| Internal fault in the AGC-4 | ||
| Bad or no Ethernet connection to the AGC-4 | Check the Ethernet cable (straight or twisted) | |
| Controller is losing/changing parameters or options | The AGC-4 controller has overheated | 1. Reboot the AGC-4 controller 2. Reload the backup of the batch file. If the problem persists, replace the control?le |
| Relay output is not working | Relay is welded together | Replace the controller |
| Relay is burnt out | ||
| CAN bus A and/or B is not working | The CAN bus line is longer than 300 m (984 ft) | The total cable length exceeds the maximum distance. Shorten the CAN bus line |
| The CAN bus line is not terminated with 120 ohm resistors | Connect a 120 ohm resistor between Can HI and LO at each end of the CAN bus line | |
| J1939 Engine Communication (CAN bus) is not working | The CAN bus line is short-circuited | Check the CAN bus line. Remove the fault. |
| There is no power supply on terminals 98-99 | Check the 24 V power supply on terminals 98-99. | |
| CAN bus line is not end terminated with 120 ohm resistors | Connect a 120 ohm resistor between Can HI and LO at AGC-4 end of the CAN bus line. Note: Some equipment has a built-in 120 ohm end resistor | |
| Digital input is not working | Wiring fault | Check the voltage between the input terminal and the input common. The input should be between 8 and 32 V when the input is activated |
| Input is burnt out | Replace the controller | |
| Analog input is not working | Wiring fault | Check the analog signal between input terminal and input common |
| Input is burnt out | Replace the controller | |
| Analog output is not working | Wiring fault | Disconnect the wiring and check the output value using a multimeter |
| Output has been overloaded and damaged | Replace the controller | |
| Start prepare/Run coil output is not working | Wiring fault | Check the wiring diagram for the correct circuit |
| Output relay is welded together or burnt out | Replace the controller | |
| Internal communication error (Int. Comm. Fail) | No power supply on terminals 98-99 | Check the 24V DC power supply on terminals 98-99 |
| Internal fault in the AGC-4 | Replace the controller | |
| Genset does not start | EMCP not in "AUTO"mode | Place the EMCP in "AUTO" mode |
Interface Testing Procedures
Option M12:13 x DI, 4 x DO (slot 3)
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| Illustration 2 | g03733546 |
Typical example of the Inputs/outputs icon | |
Connect to the AGC-4 controller using the DEIF Utility Software. In the utility software, click the "Inputs/Outputs" tab on the left menu, as shown above.
Option M15: 4 × 4 to 20 mA (slot 6/8)
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| Illustration 3 | g03733558 |
Connect to the AGC-4 controller using the DEIF Utility Software. In the utility software, click "Show/Hide" the real-time readings window icon on the top menu bar, as shown above.
In the utility software, the Data tracer window opens. Click "Add". Select "Analogue 91, 93, 95 and 97 (slot 6)" and "Analogue 127, 129, 131 and 133 (slot 8)" and then click "OK". The analogue value of each input is shown.
If the values for all inputs are zero, then this option is not interfacing with the main controller. Try disconnecting one of the connected sensors. The value should now be negative.
Option EF6: PWM, 2 × +/-25 mA (slot 4)
PMW Governor (GOV) Output
Use an oscilloscope or multi-meter to measure the PWM output on terminals 69-70. If the measured value is above 0% (0% ON, 100% OFF) then the option is working.
If this output is 0% (0% ON, 100% OFF) then adjust parameter "2550 GOV output offset" to 100%. Be sure that nominal setting 1 is selected in menu 6006, and the controller is in REMOTE or LOCAL mode. If the output is still 0%, then this option is not working and the controller needs to be replaced.
Automatic Voltage Regulator (AVR) Output
Use a multi-meter to measure the output on terminals 71-72. If the measured value is above or below zero then the option is working. (The output is a +/- 25 mA output converted to voltage with a resistor across terminals 71-72.)
If the output is zero then adjust parameter "2670 AVR output. offset" to 100%. Be sure that nominal setting 1 is selected in menu 6006, and the controller is in REMOTE or LOCAL mode. If the output is still zero, then this option is not working and the controller needs to be replaced.
Option H5: CAN Engine Interface (slot 2)
Using the display, go to SETUP > SYST > COMM. Press the "Up" button until parameter "7560 Engine I/F" is visible. If this parameter is visible, then the option is activated.
Troubleshooting Alarms
Common Alarms
| Issue | Cause |
|---|---|
| GB Close Fail | The controller activated the signal to close the breaker, but breaker position feedback did not change state |
| GB Open Fail | The controller activated the signal to open the breaker, but breaker position feedback did not change state |
| GB Position Fail | No feedback for breaker position (terminals 26 and 27). Alternatively, feedback on both open (terminal 26) and closed (terminal 27) breaker positions or feedback on both open (terminal 26) and closed (terminal 27) breaker positions |
| Int. Comm. Fail | The controller has lost communication with the engine interface PCB. Check whether there is 24V DC on terminals 98 (+) and 99 (-). If voltage is present and the connector is seated correctly, the AGC-4 controller may have a fault. Replace the controller. |
| Start Failure | The controller has performed three start attempts, but the genset failed to start. |
| Stop Failure | The controller has commanded the genset to stop, however running feedback is still present |
| Running Feed-back Fail | The generator is running, but running feedback is not present |
| Generator Breaker (GB) External Trip | The breaker has been tripped manually by the breaker protection settings |
| Alarm | Alarm Text | Description | Possible Causes |
|---|---|---|---|
| 1000 | -P> 1 | Reverse power | Lack of fuel, clogged fuel filters, and so on. The engine was shut down without tripping the GB governor regulation failure |
| 1010 | _-P> 2 | ||
| 1030 | I> 1 | Over current | High load short circuit |
| 1040 | _I> 2 | ||
| 1050 | _I> 3 | ||
| 1060 | _I> 4 | ||
| 1090 | G I> inv. | Inverse time overcurrent | High load short circuit |
| 1110 | G Iv> | Voltage-dependent overcurrent | High load short circuit |
| 1130 | I>> 1 | Fast overcurrent | High load short circuit |
| 1140 | _I>> 2 | ||
| 1150 | G U> 1 | Generator overvoltage | AVR regulation failure high grid voltage (if parallel to grid) |
| 1160 | _G U> 2 | ||
| 1170 | G U< 1 | Generator under voltage | AVR regulation failure Low grid voltage (if parallel to grid) |
| 1180 | _G U< 2 | ||
| 1190 | _G U< 3 | ||
| 1210 | G f> 1 | Generator over frequency | Governor regulation failure High grid frequency (if parallel to grid) |
| 1220 | _G f> 2 | ||
| 1230 | _G f> 3 | ||
| 1240 | G f< 1 | Generator under frequency | Governor regulation failure Low grid frequency (if parallel to grid) |
| 1250 | _G f< 2 | ||
| 1260 | _G f< 3 | ||
| 1270 | BB U> 1 | Bus bar over voltage | High grid voltage |
| 1280 | _BB U> 2 | ||
| 1290 | _BB U> 3 | ||
| 1300 | BB U< 1 | Bus bar under voltage | Low grid voltage |
| 1310 | _BB U< 2 | ||
| 1320 | _BB U< 3 | ||
| 1330 | _BB U< 4 | ||
| 1350 | BB f> 1 | Bus bar over frequency | High grid frequency |
| 1360 | _BB f> 2 | ||
| 1370 | _BB f> 3 | ||
| 1380 | BB f< 1 | Bus bar under frequency | Low grid frequency |
| 1390 | _BB f< 2 | ||
| 1400 | _BB f< 3 | ||
| 1410 | _BB f< 4 | ||
| 1450 | P> 1 | Generator overload | High load |
| 1460 | _P> 2 | ||
| 1470 | _P> 3 | ||
| 1480 | _P> 4 | ||
| 1490 | _P> 5 | ||
| 1500 | Unbalance I 1 | Generator unbalanced current | Unbalanced phase-phase loads |
| 1510 | G Unbalance U | Generator unbalanced voltage | Unbalanced phase-neutral loads |
| 1520 | -Q> | Loss of excitation | AVR regulation failure |
| 1530 | Q> | Over excitation | |
| 1540 | Neg. seq. I | Negative sequence current | Unbalanced phase-phase loads |
| 1550 | G neg. seq. U | Negative sequence voltage | Unbalanced phase-neutral loads |
| 1570 | Zero seq. I | Zero sequence current | Earth fault |
| 1580 | G zero seq. U | Zero sequence voltage | |
| 1620 | BB Unbalance U | Bus bar unbalanced voltage | Unbalanced phase-phase loads |
| 1710 | Unbalance I 2 | Bus bar unbalanced current | Unbalanced phase-neutral loads |
| 1761 | G P dep. Q< | Power dep. reactive power import | Loss of excitation AVR regulation failure |
| 1791 | G P dep. Q> | Power dep. reactive power ex-port | Overload Over excitation AVR regulation failure |
| 1981 | GB Ext. tripped | Generator breaker externally tripped | GB was manually tripped due to the breaker protection settings |
Genset Does Not Start
If the controller does not start the genset follow the troubleshooting steps listed below.
- Ensure that the EMCP is in "AUTO" mode.
- Check that the AGC-4 "Self Check OK" lamp is green. If the lamp is not green, replace the controller.
- Check the display for alarms. The "Start Failure" alarm should be present as it confirms that the AGC-4 has attempted to start the genset three times.
If the controller is in "REMOTE" mode and no alarms are present, check the settings and/or replace the controller.
- If the "Start Failure" alarm is present, switch the controller to "LOCAL" mode using the display panel.
- If the "Start Failure" alarm is present, switch the controller to "LOCAL" mode using the display panel.
- Acknowledge all alarms.
- Verify that there is 24 V on terminal 118.
- Press the "START" button on the display panel.
- Check for 24 V on terminal 119 while cranking the engine.
Note: There is a short delay between pressing the "START" button and the 24 V supply on terminal 119.
If continuity is present when the AGC-4 attempts to start the genset, the problem is external to the controller. Troubleshoot the system outside of the controller.
If continuity is not present, replace the controller.
Breaker Closing Problems
If the generator breaker does not close as expected, or if there is a breaker alarm follow the steps below.
- If the engine starts but the generator does not close, check the display for any alarms. If there are no alarms and the controller is in "REMOTE" mode, check the controller settings. Repair or replace the controller as necessary.
- If there is a "GB Close Gail" alarm or any other alarm, acknowledge the alarms, start the genset, and press the breaker close button on the display while in "LOCAL" mode.
- Check for continuity on terminals 17-18 on the AGC-4.
Note: The signal on terminals 17-18 will be a pulse signal.
If continuity is present when the controller attempts for send the close command, the problem is external to the controller and further troubleshooting is necessary.
If no continuity is present, replace the controller.
Replacing the AGC-4 Controller
Follow the steps below in order to replace the controller.
- Connect to the faulty controller to a laptop with the DEIF utility software using an ethernet or usb cable.
- Supply the controller with 24 V power on terminal 1 and ground terminal (2) .
- Save the batch file from the controller. If you cannot save the batch file, then save one from a similar generator set.
Note: Update the genset, running hours and so on, after uploading the batch file.
- Isolate the bus bar measurement terminals by removing the fuses and activating the local E-stop on the genset.
- Disconnect the controller power.
- Disconnect the display panel.
- Disconnect all of the green terminal blocks from the faulty controller.
- Remove the controller mounting screws from the switchboard.
- Install the new controller, attach the controller to the switchboard using the screws removed in Step 8.
- Connect the controller to 24 V power.
- Connect the new controller to a laptop computer with the DEIF utility software using an ethernet or USB cable.
- Download the saved batch file to the new controller.
- Connect the controller to the display panel.
- Put the controller in "LOCAL" mode and press the "START" button to verify genset operation.
- After verifying that the controller is operating properly, stop the genset and put the AGC-4 in "REMOTE" mode.