Basler DGC-2020ES Instruction Manual
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Basler DGC-2020ES Instruction Manual

Digital genset controller
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INSTRUCTION MANUAL
FOR
DGC-2020ES
DIGITAL GENSET CONTROLLER
Installation
Publication: 9469200994
Revision: —
Apr-17

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  • Page 1 INSTRUCTION MANUAL DGC-2020ES DIGITAL GENSET CONTROLLER Installation Publication: 9469200994 Revision: — Apr-17...
  • Page 3 9469200994 Rev — Preface This instruction manual provides information about the installation of the DGC-2020ES Digital Genset Controller. To accomplish this, the following information is provided: • Mounting • Terminals and connectors • Typical applications • Power input • Voltage and current sensing •...
  • Page 4 The availability and design of all features and options are subject to modification without notice. Over time, improvements and revisions may be made to this publication. Before performing any of the following procedures, contact Basler Electric for the latest revision of this manual.
  • Page 5 For a complete copy of GNU GENERAL PUBLIC LICENSE Version 2, June 1991 or GNU LESSER GENERAL PUBLIC LICENSE Version 2.1, February 1999 refer to www.gnu.org or contact Basler Electric. You, as a Basler Electric Company customer, agree to abide by the terms and conditions of GNU GENERAL PUBLIC LICENSE Version 2, June 1991 or GNU LESSER GENERAL PUBLIC LICENSE Version 2.1, February 1999, and as such...
  • Page 6 9469200994 Rev — Preface DGC-2020ES...

  • Page 7: Table Of Contents

    Output Contacts ............................23 Metering ..............................23 Generator Protection Functions ......................26 Logic Timers ............................26 Communication Interface......................... 26 Real-Time Clock ............................27 Liquid Crystal Display (LCD) ........................27 Type Tests ............................... 27 Environment ............................28 UL Approval ............................. 28 DGC-2020ES Contents...
  • Page 8 Communications ............................33 Inputs and Outputs ..........................33 Metering/Display ............................33 Ground Faults Detected in Ungrounded System Applications ..............34 Generator Breaker and Mains Breaker ....................35 DGC-2020ES Front Panel Debug Screen ....................37 Revision History ............................39 Contents DGC-2020ES...

  • Page 9: Mounting

    Inspect for damage, and if there is evidence of such, immediately file a claim with the carrier and notify the Basler Electric regional sales office or your sales representative.
  • Page 10 9469200994 Rev — Figure 2. Overall Dimensions Mounting DGC-2020ES...

  • Page 11: Terminals And Connectors

    9469200994 Rev — Terminals and Connectors All DGC-2020ES terminals and connectors are located on the rear panel. DGC-2020ES terminals consist of a mini-B USB socket and plug-in connectors with spring clamp terminals. Figure 3 illustrates the rear panel terminals. Locator letters in the illustration correspond to the terminal block and connector descriptions in Table 1.

  • Page 12: Connections

    DGC-2020ES terminal groups are described in the following paragraphs. Operating Power The DGC-2020ES operating power input accepts either 12 Vdc or 24 Vdc and tolerates voltage over the range of 6 to 32 Vdc. Operating power must be of the correct polarity. Although reverse polarity will not cause damage, the DGC-2020ES will not operate.

  • Page 13: Generator Current Sensing

    The DGC-2020ES has sensing inputs for A-phase, B-phase, and C-phase generator current. A DGC- 2020ES with a style number of 1xx has a 1 Aac nominal current sensing and a DGC-2020ES with a style number of 5xx indicates 5 Aac nominal current sensing. Generator current sensing terminals are listed in Table 3.

  • Page 14: Analog Engine Sender Inputs

    C-phase bus voltage sensing input Installation in an Ungrounded System Application When the DGC-2020ES is controlling equipment that is part of an ungrounded system, it is recommended that potential transformers be employed on the voltage sensing inputs to provide full isolation between the DGC-2020ES and monitored voltage phases.

  • Page 15: Output Contacts

    A mini-B USB socket enables local communication with a PC running BESTCOMSPlus software. The DGC-2020ES is connected to a PC using a standard USB cable equipped with a type A plug on one end (PC termination) and a mini-B plug on the other end (DGC-2020ES termination).

  • Page 16: Optional Remote Display Panel Connections

    Remote Display Panel. Twisted-pair conductors are recommended for connecting the communication terminals of the DGC-2020ES and Remote Display Panel. Communication may become unreliable if the connection wires exceed 1,219 m (4,000 ft). Table 12 lists the DGC-2020ES terminals that connect to the Remote Display Panel.

  • Page 17: Typical Connections

    9469200994 Rev — Typical Connections Typical connection diagrams are provided in this chapter as a guide when wiring the DGC-2020ES for communication, mechanical senders, contact inputs and outputs, sensing, and control power. Connections for Typical Applications Typical connections for applications using three-phase wye, three-phase delta, single-phase AB, and single-phase AC generator voltage sensing are shown on the following pages.
  • Page 18 To ECU CAN bus 12/24V If component is under ECU control, do not connect to DGC-2020ES. Current inputs are 1A or 5A, depending on style. Connect to the ECU on an electronically controlled engine when the Bus sensing inputs are optional, depending on style.
  • Page 19 To ECU CAN bus 12/24V If component is under ECU control, do not connect to DGC-2020ES. Current inputs are 1A or 5A, depending on style. Connect to the ECU on an electronically controlled engine when the Bus sensing inputs are optional, depending on style.
  • Page 20 To ECU CAN bus 12/24V If component is under ECU control, do not connect to DGC-2020ES. Current inputs are 1A or 5A, depending on style. Connect to the ECU on an electronically controlled engine when the Bus sensing inputs are optional, depending on style.

  • Page 21: Can Connections

    120 ohm, ½ watt terminating resistor should be installed across terminals 14 (CANL) and 13 (CANH). If the DGC-2020ES is not providing one end of the J1939 bus, the stub connecting the DGC-2020ES to the bus should not exceed 914 mm (3 ft) in length.

  • Page 22: Cem-2020 Connections

    2020ES. It is a remote auxiliary device that provides additional contact inputs and outputs for the DGC- 2020ES. This module interfaces to the DGC-2020ES via CAN, thus the CAN terminals are the only common connections (Figure 10) between the DGC-2020ES and CEM-2020. Refer to the CEM-2020 chapter for more information.

  • Page 23: Power Input

    9469200994 Rev — Power Input Control power for the DGC-2020ES is typically supplied by the genset starter battery. Power from the battery is supplied to an internal power supply that provides power for DGC-2020ES logic, protection, and control functions. Nominal Voltage Input and Acceptable Range of Input Voltage A nominal voltage of 12 or 24 Vdc within a range of 6 to 32 Vdc is accepted.
  • Page 24 9469200994 Rev — Power Input DGC-2020ES...

  • Page 25: Voltage And Current Sensing

    The DGC-2020ES has sensing inputs for A-phase, B-phase, and C-phase generator current. Depending on the style number, a DGC-2020ES has a nominal sensing current rating of 1 Aac or 5 Aac. A style number of 1xx indicates 1 Aac nominal current sensing and a style number of 5xx indicates 5 Aac nominal current sensing.
  • Page 26 9469200994 Rev — Note Unused current sensing inputs should be shorted to minimize noise pickup. Caution Generator current sensing terminals 37 (IA–), 35 (IB–), and 33 (IC–) must be terminated to ground for proper operation. Voltage and Current Sensing DGC-2020ES...

  • Page 27: Speed Signal Inputs

    Terminals Magnetic pickup connections are provided at terminals 31 (+) and 32 (–). Generator Sensing Voltage The generator voltage sensed by the DGC-2020ES is used to measure frequency and can be used to measure machine speed. Terminals Sensing voltage is applied to terminals 45 (A-phase), 43 (B-phase).
  • Page 28 9469200994 Rev — Speed Signal Inputs DGC-2020ES...

  • Page 29: Specifications

    9469200994 Rev — Specifications DGC-2020ES electrical and physical characteristics are listed in the following paragraphs. Control Power Nominal ..........12 or 24 Vdc Range ..........6 to 32 Vdc Terminals.......... 18 (+), 17 (–), 16 (chassis ground) Power Consumption Sleep Mode ........4.5 W - LCD heater off, all relays de-energized Normal Operational Mode ....

  • Page 30: Contact Sensing

    Stated accuracies are subject to the accuracy of the senders used. Values within these ranges are deemed “good” and the DGC-2020ES will use them for the appropriate calculation and protection. Values outside these ranges are deemed “bad” and the DGC-2020ES will begin timing towards a sender failure condition.

  • Page 31: Output Contacts

    VT Ratio Range ........ 1:1 to 125:1 in primary increments of 1 Accuracy* ......... ±3.0% of programmed rated voltage or ±3 Vac Display Resolution ......1 Vac Voltage metering indicates 0 V when generator voltage is below 2% of the full-scale rating. DGC-2020ES Specifications...
  • Page 32 † Applies when temperature is between –40°C to +70°C (–40°F to +158°F). Note For the DGC-2020ES to correctly meter power factor, the generator must be rotating in the same phase sequence as dictated by the generator phase rotation setting. Real Power...
  • Page 33 Metering Range ........ 0 to 5,000 hours Update Interval ......... 6 min Accuracy........... ±1% or actual indication or ±12 min Display Resolution ......1 minute Fuel Level Metering Range ........ 0 to 100% Accuracy........... ±3% (subject to accuracy of sender) Display Resolution ......1.0% DGC-2020ES Specifications...

  • Page 34: Generator Protection Functions

    Activation Delay Increment ....0.1 s Note The maximum voltage that can be safely applied to the DGC-2020ES is 576 V. The pickup range is higher so that when the low-line override is used, and the scale factor is 0.5 or less, effective protection levels of 500 V can be reached with a scale factor of 0.5.

  • Page 35: Real-Time Clock

    Communication Rate ......250 kb/s Terminals.......... 14 (low), 13 (high), and 15 (shield) Notes If the DGC-2020ES is providing one end of the J1939 bus, a 120 ohm, ½ watt terminating resistor should be installed across terminals 14 (CANL) and 13 (CANH).

  • Page 36: Environment

    HALT (Highly Accelerated Life Testing) HALT is used by Basler Electric to prove that our products will provide the user with many years of reliable service. HALT subjects the device to extremes in temperature, shock, and vibration to simulate years of operation, but in a much shorter period span.

  • Page 37: Ce Compliance

    Designed to comply with NFPA Standard 110, Standard for Emergency and Standby Power. EAC Mark (Eurasian Conformity) EAC Mark (Eurasian Conformity) TC RUUS.HO03.B.00210 • TP TC 004/2011 • TP TC 020/2011 Physical Weight ..........1.9 lb (0.86 kg) Dimensions........See the Mounting chapter. DGC-2020ES Specifications...
  • Page 38 9469200994 Rev — Specifications DGC-2020ES...

  • Page 39: Maintenance

    Periodically check that the mounting hardware is clean and fastened with the proper amount of torque. DGC-2020ES units are manufactured using state-of-the-art, surface- mount technology. These components are encased in potting material. As such, Basler Electric recommends that no repair procedures be attempted by anyone other than Basler Electric personnel.
  • Page 40 9469200994 Rev — Maintenance DGC-2020ES...

  • Page 41: Troubleshooting

    9469200994 Rev — Troubleshooting If you do not get the results that you expect from the DGC-2020ES, first check the programmable settings for the appropriate function. Use the following troubleshooting procedures when difficulties are encountered in the operation of your genset control system.

  • Page 42: Ground Faults Detected In Ungrounded System Applications

    Step 1. Verify that all wiring is properly connected. Refer to the Typical Connections chapter. Step 2. Ensure that the proper current is present at the DGC-2020ES current sensing inputs 33, 34, 35, 36, 37, and 38. Step 3. Verify that the current sensing transformer ratios are correct.

  • Page 43: Generator Breaker And Mains Breaker

    Generator Breaker logic element in the programmable logic. Step 8: Verify the wiring to the breaker from the DGC-2020ES. If it seems OK, you can do a manual close and open by modifying the programmable logic. Map some unused outputs to the OPEN and CLOSE outputs from the Gen Breaker Block in the programmable logic.
  • Page 44 Generator Breaker logic element in the programmable logic. Step 5: Verify the wiring to the breaker from the DGC-2020ES. If it seems OK, you can do a manual close and open by modifying the programmable logic. Map some unused outputs to the OPEN and CLOSE outputs from the Gen Breaker Block in the programmable logic.

  • Page 45: Dgc-2020Es Front Panel Debug Screen

    Step 5: Verify the wiring to the breaker from the DGC-2020ES. If it seems OK, you can do a manual close and open by modifying the programmable logic. Map some unused outputs to the OPEN and CLOSE outputs from the Gen Breaker Block in the programmable logic.
  • Page 46 9469200994 Rev — Troubleshooting DGC-2020ES...

  • Page 47: Revision History

    9469200994 Rev — Revision History Table 16 provides a historical summary of the changes made to the DGC-2020ES hardware. Firmware changes are listed in Table 17 and software changes are listed in Table 18. The corresponding revisions made to this instruction manual are summarized in Table 19. Revisions are listed in chronological order.
  • Page 48 SPN's in Diagnostic Trouble Codes • Modified front panel so that if MTU Fault Codes are in effect while an alarm or pre-alarm is in effect, the DGC-2020ES will alternate between the Alarm or Pre-alarm display and the MTU Fault Code display •...
  • Page 49 • Added MTU Combined Red Alarm status to logic • Added Chinese language support • 3.15.00, Aug-16 Maintenance release (DGC-2020HD changes) Table 19. Instruction Manual Revision History Manual Change Revision and Date • —, Apr-17 Initial release DGC-2020ES Revision History...
  • Page 50 9469200994 Rev — Revision History DGC-2020ES...
  • Page 52 Highland IL 62249-1074 USA Suzhou Industrial Park 15-06 Peninsula Plaza Tel: +1 618.654.2341 215122 Suzhou Singapore 179098 Fax: +1 618.654.2351 P.R. CHINA Tel: +65 68.44.6445 email: info@basler.com Tel: +86 512.8227.2888 Fax: +65 68.44.8902 Fax: +86 512.8227.2887 email: singaporeinfo@basler.com email: chinainfo@basler.com...

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