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

Digital genset controller
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12570 Route 143 • Highland, Illinois 62249-1074 USA
Tel +1 618.654.2341 • Fax +1 618.654.2351
www.basler.com • info@basler.com
DGC-2020ES
Digital Genset Controller
Configuration Instruction Manual
Publication
9469200995, Rev B
December 2019

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  • Page 1 DGC-2020ES Digital Genset Controller Configuration Instruction Manual Publication 12570 Route 143 • Highland, Illinois 62249-1074 USA Tel +1 618.654.2341 • Fax +1 618.654.2351 9469200995, Rev B www.basler.com • info@basler.com December 2019...
  • Page 2 Proposition 65 warning, we are notifying you that one or more of the Proposition 65 listed chemicals may be present in products we sell to you. For more information about the specific chemicals found in this product, please visit https://www.basler.com/Prop65.
  • Page 3 9469200995 Preface This instruction manual provides information about the configuration of the DGC-2020ES Digital Genset Controller. To accomplish this, the following information is provided: Device information and security settings • Configuration via BESTCOMSPlus and the front panel • ® Communication settings •...
  • 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 9469200995 Revision History A historical summary of the changes made to this instruction manual is provided below. Revisions are listed in reverse chronological order. Visit www.basler.com to download the latest hardware, firmware, and BESTCOMSPlus revision ® histories. Instruction Manual Revision History...
  • Page 6 9469200995 Revision History DGC-2020ES...

  • Page 7: Table Of Contents

    Engine Sender Inputs ..........................7-1 Contact Inputs ............................8-1 Contact Outputs ............................9-1 Breaker Management ..........................10-1 Alarm Configuration ..........................11-1 Generator Protection ..........................12-1 BESTlogic™Plus ............................13-1 Exhaust Treatment ........................... 14-1 Troubleshooting ............................15-1 BESTCOMSPlus Settings Loader Tool ....................16-1 DGC-2020ES Contents...
  • Page 8 9469200995 Contents DGC-2020ES...

  • Page 9: Security

    ® Changing Passwords Passwords can be changed only after communication between the PC and DGC-2020ES is established. Changes to passwords are made through the Device Security Setup screen. Use the Settings Explorer in BESTCOMSPlus to open the General Settings, Device Security Setup screen.
  • Page 10 DGC-2020ES. Verify the passwords obtained from the DGC-2020ES are correct. Once all desired settings have been loaded into the DGC-2020ES, save the settings file. The resulting settings file has the passwords saved as part of the saved settings. At this point, the password information has been successfully saved in the settings file. The process of saving the passwords into the settings file is complete.
  • Page 11 Once connected, click the “Open File” button that is used to load a settings file into the DGC-2020ES. You will be prompted asking if you wish to load settings and logic into the DGC-2020ES. Select Yes if you need to upload settings logic. Select No if all you need to do is update security. If you select No, the settings file opens into BESTCOMSPlus memory.
  • Page 12 9469200995 Security DGC-2020ES...

  • Page 13: Configuration Through The Front Panel

    This chapter provides information on configuring DGC-2020ES settings through the front panel. Display Setup The DGC-2020ES LCD can be customized to fit the needs of your specific application. The options can be adjusted using the front panel controls and through BESTCOMSPlus .
  • Page 14 Settings Menu The display structure of the Settings menu on the front panel is provided below. Refer to the Controls and Indicators chapter in the Operation manual for a full description of DGC-2020ES controls and indicators. GENERAL SETTINGS FRONT PANEL HMI ●...
  • Page 15 ○ SECONDS ○ UTC OFFSET ○ DST ENABLED ○ CLK NOT SET WRN ○ VIEW DATE/TIME ● VERSION INFO ● DGC-2020ES ○ FIRMWARE VERSION ■ BOOT CODE VERSION ■ SERIAL NUMBER ■ PART NUMBER ■ MODEL NUMBER ■ LANGUAGE VERSION ■...
  • Page 16 GOV PRM SW (Visible when ECU is configured for MTU ADEC or MTU Smart □ Connect.) ENG STRT PRIME (Visible when ECU is configured for MTU MDEC 304, or MTU □ ECU7/ECU8.) FAN OVERRIDE (Visible when ECU is configured for MTU MDEC 304, or MTU □ ECU7/ECU8.) Configuration through the Front Panel DGC-2020ES...
  • Page 17 # CYCLES (Visible when Cycle is selected for Cranking Style.) ○ CONT TIME (Visible when Continuous is selected for Cranking Style.) ○ CYCLE TIME ○ REST TIME ○ COOLDWN TIME ○ COOLDOWN CONFIG ○ RESTART DELAY ○ OFF MODE COOLDN ○ DGC-2020ES Configuration through the Front Panel...
  • Page 18 RECOGNITION (Visible when an INPUT is selected.) ■ BATTLE OVERRIDE ○ INPUT ■ RECOGNITION (Visible when an INPUT is selected.) ■ LOW LINE OVERRIDE ○ INPUT ■ RECOGNITION (Visible when an INPUT is selected.) ■ Configuration through the Front Panel DGC-2020ES...
  • Page 19 ■ ENG KW OVRLD-2 ■ ENG KW OVRLD-3 ■ MAINTENANCE INTERVAL ○ ENABLE ■ THRESHOLD ■ BATTERY OVERVOLTAGE ○ ENABLE ■ THRESHOLD ■ LOW BATTERY VOLTAGE ○ ENABLE ■ THRESHOLD ■ ACTIVATN DLY ■ DGC-2020ES Configuration through the Front Panel...
  • Page 20 SENDER FAIL ● COOL TEMP SENDR FAIL ○ CONFIG TYPE ■ RECOGNITION ■ ACTIVATN DLY ■ MIN OHMS ■ MAX OHMS ■ SF DISPLAY ■ OIL PRESS SENDR FAIL ○ CONFIG TYPE ■ RECOGNITION ■ Configuration through the Front Panel DGC-2020ES...
  • Page 21 50 OVERCURRENT ● LOW LINE SF (Visible when an input is selected for the Low Line Override programmable function.) ○ 3 / 1 PHASE SETTINGS ○ PICKUP ■ TIME DELAY ■ ALARM CONFIG ■ DGC-2020ES Configuration through the Front Panel...
  • Page 22 ■ UF DROPOUT ■ TIME DELAY ■ LOW LINE SF (Visible when an input is selected for the Low Line Override programmable ■ function.) ALT FREQ SF ■ BUS FAILED ○ TIME DELAY ■ Configuration through the Front Panel DGC-2020ES...
  • Page 23 9469200995 2-11 LOGIC TIMERS TIMER X (X = 1 to 10) ● HOURS ○ MINUTES ○ SECONDS ○ ENTER PASSWORD LOGOUT (Visible when logged in through the front panel.) DGC-2020ES Configuration through the Front Panel...
  • Page 24 2-12 9469200995 Configuration through the Front Panel DGC-2020ES...

  • Page 25: Bestcomsplus

    DGC-2020ES is brought into BESTCOMSPlus by downloading settings and logic from the DGC-2020ES. This gives the user the option of developing a custom setting file by modifying the default logic scheme or by building a unique scheme from scratch.
  • Page 26 BESTCOMSPlus software is built on the Microsoft® .NET Framework. The setup utility that installs BESTCOMSPlus on your PC also installs the DGC-2020ES plugin and the required version of .NET Framework (if not already installed). BESTCOMSPlus operates with systems using Windows 7 SP1, ®...
  • Page 27 DGC-2020ES. USB driver installation progress is shown in the Windows taskbar area. Windows will notify you when installation is complete. Connect a USB cable between the PC and your DGC-2020ES. Apply operating power to the DGC- 2020ES. Wait until the boot sequence is complete.
  • Page 28 (COM & LPT) branch. Locate the device named CP2101 USB to UART Bridge Controller (COMx). The COM Port number will be displayed in parenthesis (COMx). Be sure operating power is applied to the DGC-2020ES and the USB cable is connected before opening the Device Manager. See Figure 3-5. Figure 3-5. Device Manager The DGC-2020ES plugin opens indicating that activation was successful.
  • Page 29 Manual Activation of the DGC-2020ES Plugin Manual activation of the DGC-2020ES plugin is required only if your initial use of BESTCOMSPlus will be on a PC that is not connected to a DGC-2020ES. Manual activation is described in the following paragraphs.
  • Page 30 9469200995 down menu. BESTCOMSPlus will read all settings and logic from the DGC-2020ES and load them into BESTCOMSPlus memory. See Figure 3-7. Figure 3-7. Processing, Please Wait… Advanced Properties Click the Advanced button on the Connection screen to display the Advanced Properties dialog. Default settings are shown in Figure 3-8.
  • Page 31 View general, detailed build, and system information Lower Menu Bar (DGC-2020ES Plugin) The lower menu bar functions are listed and described in Table 3-3. Table 3-3. Lower Menu Bar (DGC-2020ES Plugin) Menu Button Description Enables you to show/hide the Metering Panel, Settings Panel, or Settings Info Panel.
  • Page 32 Opens a saved settings file. Connect: Opens the DGC-2020ES Connection screen which enables you to connect to the DGC-2020ES via USB or a modem. This button only appears when a DGC-2020ES is not connected. Disconnect: Used to disconnect a connected DGC-2020ES. This button only appears when a DGC-2020ES is connected.
  • Page 33 Right-clicking the hyperlinked setting name will restore the setting to its default value. Note It is possible to save a DGC-2020ES settings file in BESTCOMSPlus with noncompliant settings. However, it is not possible to upload noncompliant settings to the DGC-2020ES.
  • Page 34 Figure 3-11. View Menu, BESTspace™, Save Workspace Screen Settings File Management A settings file contains all DGC-2020ES settings, including logic. A settings file assumes a file extension of “∗.bstx”. It is possible to save the logic only as a separate logic library file on the BESTlogicPlus Programmable Logic screen.
  • Page 35 Select the Save button to complete the save. Upload Settings and/or Logic to Device To upload a settings file to the DGC-2020ES, open the file through BESTCOMSPlus or create the file using BESTCOMSPlus. Then pull down the Communication menu and select Upload Settings and Logic to Device.
  • Page 36 Figure 3-13. Settings Comparison Results Screen Firmware Updates Future enhancements to the DGC-2020ES functionality will make a firmware update desirable. Because default settings are loaded when DGC-2020ES firmware is updated, your settings should be saved in a file prior to upgrading firmware. BESTCOMSPlus®...
  • Page 37 Upgrading Firmware in Expansion Modules The following procedure is used to upgrade firmware in the DGC-2020ES expansion module. This must be completed before upgrading firmware in the DGC-2020ES. If no expansion module is present, proceed to Upgrading Firmware in the DGC-2020ES.
  • Page 38 3-14 9469200995 Place the DGC-2020ES in OFF mode. This can be accomplished by clicking the Off button on the Control screen inside the Metering Explorer or by pressing the Off button on the DGC-2020ES front panel. Enable the expansion module that is present in the system. If it has not already been enabled, enable the expansion module on the SETTINGS >...
  • Page 39 GENERAL SETTINGS > STYLE NUMBER in BESTCOMSPlus. If the style number of the settings file does not match that of the DGC-2020ES into which it is to be loaded, disconnect from the DGC-2020ES, then modify the style number in the settings file.
  • Page 40 Ongoing DGC-2020ES functionality enhancements may make future DGC-2020ES firmware updates desirable. Enhancements to DGC-2020ES firmware typically coincide with enhancements to the DGC- 2020ES plugin for BESTCOMSPlus. When a DGC-2020ES is updated with the latest version of firmware, the latest version of BESTCOMSPlus should also be obtained.

  • Page 41: Communication

    The rear-panel, mini-B USB port enables local communication with a PC running BESTCOMSPlus ® software. The DGC-2020ES is connected to a PC using a standard USB cable. BESTCOMSPlus is a Windows -based communication software package that is supplied with the DGC-2020ES. A detailed ®...
  • Page 42 °C °F Coolant Level 500 ms Coolant Pressure 500 ms DEF Inducement Level - Level of 5246 Inducement Not to Run the Engine DEF Severity Level - Severity of Tank 5245 Low Level DEF Tank 1 Level 1761 Communication DGC-2020ES...
  • Page 43 Throttle (Accelerator Pedal) Position 50 ms Total Engine Hours hours hours Requested 1.5 s Total Fuel Used liters gallons Requested 1.5 s Transmission Oil Pressure Transmission Oil Temperature °C °F Trip Average Fuel Rate liters gallons 500 ms 1029 DGC-2020ES Communication...
  • Page 44 ∗ SPN is suspect parameter number. Caution When the CAN is enabled, the DGC-2020ES ignores the following sender inputs: oil pressure, coolant temperature, and magnetic pickup. Under certain circumstances, the following strings may be displayed on the front panel HMI and in the Metering Explorer of BESTCOMSPlus: •...
  • Page 45 DGC-2020ES. SPN Conversion Method The most common SPN conversion method is 4 and is the default for the DGC-2020ES. Refer to ECU manufacturer documentation to determine the correct SPN conversion method of the ECU and set the SPN Conversion Method setting in the DGC-2020ES accordingly.
  • Page 46 Select if the ECU is not to be on line at all times. Often ECUs are allowed to go “off line” to conserve battery drain when the engine is not running. The DGC-2020ES will “pulse” it periodically to force it to be active to allow the DGC-2020ES to read data such as coolant temperature and coolant level.
  • Page 47 ECU. The settling time should be set long enough so that any ECU parameters that require time to “settle down” after the ECU is on line can do so. Since the DGC-2020ES may use some of the ECU data for alarm or pre-alarm annunciation, it is important that the data have time to settle.
  • Page 48 When the Engine Parameter Transmit setting is enabled, the DGC-2020ES broadcasts engine metered parameters over CAN. When the Engine Parameter Transmit setting is disabled, transmission of J1939 commands from the DGC-2020ES to the engine are disabled, but commands from the engine to the DGC-2020ES are allowed.
  • Page 49 Stop Request - sent when shutting down the engine. • Idle Request - sent when the Idle Request logic element is true in BESTlogicPlus. • Preheat Request - sent anytime the DGC-2020ES would normally have its PRE relay closed for • engines requiring a preheat contact. •...
  • Page 50 4-10 9469200995 Rated Speed (50 or 60 Hz) - sent based on the Rated Speed setting of the DGC-2020ES. However, • these are reversed if the Alternate Frequency Override is true. A setting of 60 Hz Rated Speed results in 50 Hz being sent and a setting of 50 Hz Rated Speed results in 60 Hz being sent when the Alternate Frequency Override is true.
  • Page 51 The DGC-2020ES sends starter engagement requests to the ECU via the SAE J1939 Engine Start Control PGN. When the DGC-2020ES requests the starter to be engaged it sends a value of 01 (binary) for the two-bit starter engagement parameter. Otherwise the DGC-2020ES sends a value of 00 (binary) for the two-bit starter engagement parameter.
  • Page 52 Fuel leak/Sender failure∗† Sender failure† • ∗ This can be configured in the DGC-2020ES as None, Alarm, or Pre-alarm. See the Contact Inputs chapter for more information. The LED on the Remote Display Panel illuminates when the input that is Communication...
  • Page 53 Additionally, the Remote Display Panel indicates when the DGC-2020ES is not operating in Auto mode and when the generator is supplying load or when the DGC-2020ES is in an alarm state not listed above. Refer to Basler Publication 9318100990 for more information on the Remote Display Panel.
  • Page 54 4-14 9469200995 Communication DGC-2020ES...

  • Page 55: Device Configuration

    In some cases, the ECU takes longer than the DGC-2020ES to power up. The power up delay setting is used to delay the initial pulsing of the ECU for data on DGC-2020ES power up. This setting ranges from 0 to 60 seconds in 1 second increments.
  • Page 56 The value of the scale factor setting serves as a multiplier for the threshold setting. For example, if a scale factor contact input is received by the DGC-2020ES and the scale factor setting is 2.000, the threshold setting is doubled (2.000 x Threshold setting).
  • Page 57 This setting accepts values from 10 to 450, in increments of 0.01. Battery Volts The nominal voltage of the starter battery is used by the DGC-2020ES to detect and annunciate battery overvoltage and low or weak battery voltage. The Battery Volts settings consist of 12 V and 24 V.
  • Page 58 The Phase Rotation setting allows selection of ABC or CBA rotation according to the phase rotation connection of the machine. The DGC-2020ES calculates the power angle as the angle between the Phase AB voltage and phase B current. An angle compensation factor, determined by the phase rotation setting, is then applied.
  • Page 59 1 second. Cranking The DGC-2020ES can be programmed for either cycle or continuous cranking. Cycle cranking provides multiple engine starting attempts. Each starting attempt consists of a fixed interval of engine cranking followed by a rest interval. The Number of Crank Cycles setting accepts values from 1 to 7, in increments of 1.
  • Page 60 2.9 to 150 psi, 0.2 to 10.3 bar, and 20 to 1,034.5 kPa, in increments of 0.1. Cool Down After the load is removed from a genset, the DGC-2020ES implements a smart cooldown function. This function ensures that the engine and turbocharger properly cool down by maintaining engine operation for a user-defined duration.
  • Page 61 Figure 5-4. Settings Explorer, System Parameters, Crank Settings Screen Automatic Restart When enabled, the Automatic Restart clears all alarms automatically if the DGC-2020ES shuts down due to an alarm condition. An attempt to restart the engine is made, after a predetermined time delay, if the ATS contact input is closed.
  • Page 62 Minute settings and will run for the duration established by the Run Period Hours and Run Period Minutes settings. These settings are available for all modes. Run with Load: When enabled, the DGC-2020ES closes the generator breaker during the run time. Week Interval: Accepts values 1 through 52. Enabled when Mode is set to N Week Intervals.
  • Page 63 CT is dictated by the style number of the controller. A DGC-2020ES with a style number of 1xx uses a nominal CT secondary rating of 1 Aac. A DGC-2020ES with a style number of 5xx uses a nominal CT secondary rating of 5 Aac.
  • Page 64 Gen CT Primary Amps setting. For example, if a scale factor contact input is received by the DGC-2020ES and the scale factor setting is 2.000, the Gen CT Primary Amps setting is doubled (2.000 x Gen CT Primary Amps).
  • Page 65 If determined to be in low-line configuration, the Low-Line Override function forces the DGC-2020ES into the low-line configuration. If the Low-Line Override function is assigned to a contact output, the state of the contact output and the detected configuration are ORed.
  • Page 66 5-12 9469200995 Device Configuration DGC-2020ES...

  • Page 67: Timekeeping

    9469200995 6 • Timekeeping The DGC-2020ES provides a real-time clock with capacitor backup that is capable of operating the clock for up to 24 hours after power is removed from the controller. As the capacitor nears depletion, an internal backup battery takes over and maintains timekeeping. The battery will maintain the clock for approximately ten years depending on conditions.
  • Page 68 Setting the Time and Date Time and date settings are made through BESTCOMSPlus on the Real Time Clock screen (Figure 6-2) of the Metering Explorer. Settings can also be made through the front panel. Figure 6-2. Metering Explorer, Real Time Clock Screen Timekeeping DGC-2020ES...

  • Page 69: Engine Sender Inputs

    Operation A current is provided to each sender. The developed voltage is measured and scaled for use by the internal circuitry. An open circuit or short circuit across the sender terminals will cause the DGC-2020ES to indicate a failed sender.
  • Page 70 If you want to save newly entered sender data as a sender library file, click Create Fuel Settings File and enter a file name and location to save the file. Click the Send Settings button in BESTCOMSPlus to send the sender settings to the DGC-2020ES. Figure 7-1. Settings Explorer, Programmable Senders, Fuel Level Screen...
  • Page 71 If you want to save newly entered sender data as a sender library file, click Create Oil Settings File and enter a file name and location to save the file. Click the Send Settings button in BESTCOMSPlus to send the sender settings to the DGC-2020ES. Figure 7-2. Settings Explorer, Programmable Senders, Oil Pressure Screen...
  • Page 72 Figure 7-3. Settings Explorer, Programmable Senders, Coolant Temperature Screen Sender Failure Detection The DGC-2020ES can be configured to annunciate a pre-alarm or alarm when a loss of signal is detected at the coolant temperature, oil pressure, or fuel level sender input. Contact recognition can be set to Always or While Engine Running Only.
  • Page 73 In a Grounded Delta configuration where one phase (A, B, or C) of the delta connection is grounded, it is likely a Voltage Sensing Fail condition will occur. In Delta connected systems where the DGC-2020ES neutral input is not connected, it is uncertain which line-to-neutral voltages will be monitored by the DGC-2020ES. Spurious Voltage Sensing Fail annunciations could occur.
  • Page 74 9469200995 Engine Sender Inputs DGC-2020ES...

  • Page 75: Contact Inputs

    9469200995 8 • Contact Inputs Contact inputs are available to initiate DGC-2020ES actions. The DGC-2020ES has seven programmable contact sensing inputs. Additional contact inputs can be accommodated with an optional CEM-2020 (Contact Expansion Module). Contact Basler Electric for availability and ordering information.
  • Page 76 Emergency Stop – When an input is assigned to the Emergency Stop Programmable Function, the input functions in a normally-closed manner. When the input is closed, no alarm is annunciated. When the input is open, the DGC-2020ES will open the Start, Run, and Prestart relays and annunciate an Emergency Stop Alarm.
  • Page 77 The Programmable Functions screen is found in the BESTCOMSPlus Settings Explorer under the Programmable Inputs category. If using the front panel, navigate to Settings > Programmable Inputs > Programmable Functions. The BESTCOMSPlus Programmable Functions screen is illustrated in Figure 8-2. Figure 8-2. Settings Explorer, Programmable Inputs, Programmable Functions DGC-2020ES Contact Inputs...
  • Page 78 9469200995 Contact Inputs DGC-2020ES...

  • Page 79: Contact Outputs

    RUN output connections are made through terminals located on the RUN relay. Relay Control In some applications, it may be beneficial to modify the standard operation of the DGC-2020ES Run, Pre- Start, or Start relays. If desired, these relays can be configured to operate outside their predefined functionality.
  • Page 80 Figure 9-2. Example Logic Scheme of Programmable Relays Programmable DGC-2020ES controllers have four programmable output contacts (OUT 1 through 4). An additional 24 contact outputs are provided with an optional CEM-2020 (Contact Expansion Module). An optional CEM- 2020H (Contact Expansion Module - High Current) provides 18 contact outputs.
  • Page 81 If used for an alarm or pre-alarm, the user-assigned name appears in the alarm or pre-alarm annunciation and in the DGC-2020ES event log. Elements can be recognized always or only while the engine is running. A user-adjustable arming delay disables the configurable element during engine startup.
  • Page 82 9469200995 Figure 9-4. Settings Explorer, Programmable Outputs, Configurable Elements Contact Outputs DGC-2020ES...

  • Page 83: Breaker Management

    Breaker Operation The DGC-2020ES will attempt to close a breaker only after verifying that it can be closed. If the breaker cannot be closed, the close request will be ignored. Only one breaker can be closed at a time. Closure to a dead bus can be performed after meeting dead bus threshold and timing requirements set by the user.
  • Page 84 This feature also enables the DGC-2020ES to transfer the load back to the mains once mains power is restored. Settings include a transfer delay, return delay, max transfer time, and max return time.
  • Page 85 Set up the Gen Breaker in BESTlogicPlus Programmable Logic under the BESTCOMSPlus Settings Explorer, BESTlogicPlus Programmable Logic screen. BESTlogicPlus is not available through the front panel interface. Figure 10-2 illustrates the Gen breaker logic scheme in BESTlogicPlus. DGC-2020ES Breaker Management...
  • Page 86 Click the Save button when the logic setup is complete. From the Communication pull-down menu, select Upload Logic to Device to load the logic into the DGC-2020ES if connected, or save the settings file if working off line. Breaker Management...
  • Page 87 RUN or AUTO mode and giving it CLOSE and OPEN commands from the physical inputs if they are available for breaker control. Refer to the Troubleshooting chapter if the breaker does not seem to operate properly. DGC-2020ES Breaker Management...
  • Page 88 10-6 9469200995 Figure 10-3. Settings Explorer, Breaker Management, Bus Condition Detection Breaker Management DGC-2020ES...

  • Page 89: Alarm Configuration

    9469200995 11-1 11 • Alarm Configuration Configuration of DGC-2020ES alarms, pre-alarms, sender failure alarms, and the audible horn is described in the following paragraphs. Alarms To configure alarms using BESTCOMSPlus, open the Alarm screen (Figure 11-1). This screen is found in the Settings Explorer under the Alarm Configuration category.
  • Page 90 The threshold can be entered in actual volts or a per-unit value. The per-unit threshold value is based on the nominal battery voltage setting found on the System Parameters, Rated Data screen. Alarm Configuration DGC-2020ES...
  • Page 91 ECU Coms Fail ECU communication failure pre-alarm settings consist of a single enable/disable setting. If enabled, this pre-alarm is triggered when the DGC-2020ES detects a problem in its J1939 CAN connection to the ECU. Coolant Level Low coolant level pre-alarm settings consist of an enable/disable setting and a threshold setting. If enabled, a low coolant level pre-alarm is triggered when the metered coolant level decreases below the threshold setting.
  • Page 92 After upgrading firmware through BESTCOMSPlus, the checksum failure pre-alarm may trigger. This pre- alarm is not indicative of an error in this case. It can be cleared by cycling power to the DGC-2020ES. If the pre-alarm reoccurs, then it is indicative of an error and corrective action should be taken. See Resetting Alarms, Checksum Failure, below, for more information.
  • Page 93 If enabled, the contact output is closed when an alarm condition exists. The contact output is toggled between open and closed when a pre-alarm condition exists. If the Not in Auto setting is enabled, the horn is disabled when the DGC-2020ES is not operating in Auto mode. DGC-2020ES...
  • Page 94 Speed sender failure settings consist of a single activation delay. An alarm is triggered when a speed sender failure exists for the duration of the activation time delay. Figure 11-4. Settings Explorer, Alarm Configuration, Sender Fail Screen Alarm Configuration DGC-2020ES...

  • Page 95: Generator Protection

    For example, if a scale factor contact input is received by the DGC-2020ES and the scale factor setting is 2.000, the pickup setting will be doubled (2.000 × PU). The element is disabled when Alarm Configuration is set to “None”. Element status is available in BESTlogic™Plus Programmable Logic when “Status Only”...
  • Page 96 For example, if a scale factor contact input is received by the DGC-2020ES and the scale factor setting is 2.000, the pickup setting will be doubled (2.000 × PU). The element is disabled when Alarm Configuration is set to “None”. Element status is available in BESTlogicPlus Programmable Logic when “Status Only”...
  • Page 97 For example, if a scale factor contact input is received by the DGC-2020ES and the scale factor setting is 2.000, the pickup setting will be doubled (2.000 × PU). The element is disabled when Alarm Configuration is set to “None”. Element status is available in BESTlogicPlus Programmable Logic when “Status Only”...
  • Page 98 For example, if an alternate frequency scale factor contact input is received by the DGC-2020ES and the scale factor setting is 2.000, the pickup setting is doubled (2.000 x PU).
  • Page 99 The scale factor setting is implemented when the DGC-2020ES senses a contact closure at a contact input programmed to activate low-line override. This triggers scaling of the protection settings. The value of the scale factor setting...
  • Page 100 For example, if a scale factor contact input is received by the DGC-2020ES and the scale factor setting is 2.000, the pickup setting will be doubled (2.000 × PU). The element is disabled when Alarm Configuration is set to “None”. Element status is available in BESTlogicPlus Programmable Logic when “Status Only”...

  • Page 101: Bestlogic™Plus

    BESTlogicPlus equations entered and saved in the DGC-2020ES system's nonvolatile memory integrate (electronically wire) the selected or enabled protection and control blocks with control inputs and hardware outputs. A group of logic equations defining the logic of the DGC-2020ES is called a logic scheme.
  • Page 102 True when Remote Input x is active. (Available when IN8 – IN17 an optional CEM-2020 is connected.) Virtual Inputs True when Virtual Input x is active. VIN1 – VIN4 True when Diagnostic Trouble Codes are present. Status Input Active DTC’s Present BESTlogic™Plus DGC-2020ES...
  • Page 103 True when the Audible Horn is active. Status Input Audible Horn Status Input True when the DGC-2020ES is in Auto Mode or the Auto Mode Auto Mode logic element is true. Status Input True when the Automatic Restart function is active.
  • Page 104 Cool Down Timer is true under two circumstances: Timer Active The unit is in auto and ATS is removed, causing the DGC-2020ES to go into a cooldown state. The engine is running (in RUN or AUTO mode with ATS applied) and the load has been removed (i.e.
  • Page 105 True while the Off front panel button is pressed. Status Input Front Panel Buttons True when the restart delay is currently active. Status Input Restart Delay Active True while the Run front panel button is pressed. Status Input Front Panel Buttons DGC-2020ES BESTlogic™Plus...
  • Page 106 True when the Gen Stable condition settings have Generator been exceeded. Stable True when the Exercise Timer has started the Status Input Generator Test generator and run with load is selected. Loaded True when the Exercise Timer has started the Status Input Generator Test generator. BESTlogic™Plus DGC-2020ES...
  • Page 107 Override True when the Idle Request logic element is true. Status Input Idle Request Status Input True when the DGC-2020ES is in the alarm state. In Alarm State Status Input True when the DGC-2020ES is in the connecting In Connecting state.
  • Page 108 Mains Fail Transfer Transferring to Mains True when the DGC-2020ES is in Off Mode or the Status Input Off Mode Off Mode logic element is true. Status Input True when the DGC-2020ES is in Off Mode and Off Mode cooling down.
  • Page 109 True when the DGC-2020ES is indicating that the Run Input Run relay should be closed. Status Input True when the DGC-2020ES is in Run Mode or the Run Mode Run Mode logic element is true. True when the Single Phase Override input is true.
  • Page 110 Generator Protection and has tripped. True when the 50 element is configured as an alarm Generator and has tripped. Protection True when the 81 Over element is configured as an Generator alarm and has tripped. Protection 81 Over BESTlogic™Plus DGC-2020ES...
  • Page 111 True when the metered engine speed (RPM) Shutdown unexpectedly drops to 0 while the engine is running. Alarm Voltage True when the Voltage Sensing Fail is configured as Sensing Fail an alarm and the activation delay has expired. DGC-2020ES BESTlogic™Plus...
  • Page 112 Not 50 Hours regeneration on a Yanmar ECU. Manual Since Last regeneration is blocked. Regen Checksum True when some of the user settings or firmware code has been corrupted. Refer to the Reporting Failure and Alarms chapter for more details. BESTlogic™Plus DGC-2020ES...
  • Page 113 Module Multiple Contact Expansion Modules Connected True when communication from the CEM-2020 to Contact Expansion the DGC-2020ES has been lost. Module Contact Expansion Module Comm Fail Contact True when the connected CEM-2020 does not have the same number of outputs as defined on the...
  • Page 114 True when an issue has been detected in the Inducement Exhaust Gas Recirculation (EGR) system. This is Warning the first level of inducement to correct the issue. There should also be Diagnostic Trouble Codes providing additional information about the issue. BESTlogic™Plus DGC-2020ES...
  • Page 115 Progress, Exhaust System Error, Exhaust System Inducement Indications, etc. This is derived based on ECU Lamp conditions communicated from the Engine ECU to the DGC-2020ES via J1939 CAN Bus communications. Fuel Leak True when the Fuel Leak Detect function is configured as a pre-alarm and the activation delay has expired.
  • Page 116 High Fuel Level True when the High Fuel Level Pre-Alarm settings have been exceeded. Inter Generator True when the DGC-2020ES detects that an Comm Fail individual generator previously connected to a generator network has lost connection. Isuzu DEF Low...
  • Page 117 True when an exhaust system regeneration is in Active progress. Serial Flash When the DGC-2020ES reads data from the serial Read Fail flash, the data is read twice and then compared to verify that the data matches. If it does not match, the read cycle is repeated.
  • Page 118 Low DEF, Purge Required, Exhaust System Error, etc. This reflects the status of the exhaust system Torque Limit lamp, which is communicated from the Engine ECU to the DGC-2020ES via J1939 CAN Bus communications. Voltage True when the Voltage Sensing Fail is configured as Sensing Fail a pre-alarm and the activation delay has expired.
  • Page 119 Table 13-2. Components Group, Names and Descriptions Name Description Symbol Logic Gates Input Output NAND Input Output Input Output Input Output Input Output When an XOR gate has more than two inputs, the output is true whenever an odd number of inputs are true. DGC-2020ES BESTlogic™Plus...
  • Page 120 Switch, Reset, Alarm Silence, Lamp Test, Idle Request, Low Fuel Pre-Alarm, Diesel Particulate Filter Manual Regeneration, Diesel Particulate Filter Regeneration Inhibit, Emergency Stop, Speed Raise, Speed Lower, MTU Cylinder Cutout Disable, and Automatic Breaker Operation Inhibit from PLC. BESTlogic™Plus DGC-2020ES...
  • Page 121 AUTO mode, the generator will cool down and stop. AUTOMODE When this input is true, and the DGC-2020ES is in OFF mode, the DGC-2020ES will switch to AUTO mode. This is a pulsed input. It does not need to be held after the desired mode switch has occurred.
  • Page 122 AUTO mode is true, the unit will remain running. Furthermore, if a condition occurs that normally causes the unit to close its breaker, the unit will close its breaker and reload. BESTlogic™Plus DGC-2020ES...
  • Page 123 Diesel Particulate Filter Regeneration is inhibited when the Set input is true. ECU Connect When true, a Key On signal is applied to the ECU and Override CAN Bus data is updated any time except during the Disconnecting state. DGC-2020ES BESTlogic™Plus...
  • Page 124 Emergency Stop LED on the RDP-110 is illuminated. EXTSTARTDEL If the Set input is true while the DGC-2020ES is in the Pre Start state, the DGC-2020ES will remain in the Pre Start state until the Set input is false.
  • Page 125 Outputs The outputs must be mapped to the contact outputs of the DGC-2020ES that will be used to drive the breaker. Open: This output is pulsed true (closes the output contact it is mapped to) when the DGC-2020ES is providing a signal to the breaker to open.
  • Page 126 When this logic element is true, the generator is forced to start, assume load, and disconnect from the mains, in an open transition. LOGICALM When this input is true, the DGC-2020ES goes into an alarm condition. LOGICPALM When this input is true, the DGC-2020ES goes into a Pre-alarm condition.
  • Page 127 Outputs The outputs must be mapped to the contact outputs of the DGC-2020ES that will be used to drive the breaker. Open: This output is pulsed true (closes the output contact it is mapped to) when the DGC-2020ES is providing a signal to the breaker to open.
  • Page 128 J1939 CAN Bus. OFFMODE When this input is true, the DGC-2020ES will switch to OFF mode. This is a pulsed input. It does not need to be held after the desired mode switch has occurred.
  • Page 129 DGC-2020ES will start and run the generator. RUNMODE When this input is true, and the DGC-2020ES is in OFF mode, the DGC-2020ES will switch to RUN mode. This is a pulsed input. It does not need to be held after the desired mode switch has occurred.
  • Page 130 The Active Logic Scheme Digital Genset Controllers must have an active logic scheme in order to function. All Basler Electric DGC- 2020ES units are delivered with a default, active logic scheme pre-loaded in memory. If the function block configuration and output logic of the default logic scheme meets the requirements of your application, then only the operating settings (power system parameters and threshold settings) need to be adjusted before placing the DGC-2020ES in service.
  • Page 131 9469200995 13-31 To send settings to the DGC-2020ES, it must be connected to a computer through a communications port. Once the necessary connections are made, settings can be uploaded to the DGC-2020ES by selecting Upload Settings and Logic on the Communication pull-down menu.
  • Page 132 An example of the offline logic simulator is shown in Figure 13-3. Output 1 is Logic 0 (red) when Virtual Switch 1 is Logic 0 (red) and Fixed 1 is Logic 1 (green). BESTlogic™Plus DGC-2020ES...
  • Page 133 After programming BESTlogicPlus settings, click on the Save button to save the settings to memory. Before the new BESTlogicPlus settings can be uploaded to the DGC-2020ES, you must select Save from the File pull-down menu located at the top of the BESTCOMSPlus main shell. This step will save both the BESTlogicPlus settings and the operating settings to a file.
  • Page 134 Logic Document from the Protection drop-down button. A password is optional. Uploading a BESTlogicPlus File To upload a BESTlogicPlus file to the DGC-2020ES, you must first open the file through BESTCOMSPlus or create the file using BESTCOMSPlus. Then pull down the Communication menu and select Upload Logic.
  • Page 135 Output 3 becomes true when the 27TRIP is true. Output 1 becomes true when the High Coolant Temp is true. Output 2 becomes true when the DGC-2020ES is in RUN mode (RUN Mode true). Refer to Figure 13-7.
  • Page 136 13-36 9469200995 BESTlogic™Plus DGC-2020ES...

  • Page 137: Exhaust Treatment

    DPF Control DPF control information is sent from the DGC-2020ES to the Engine ECU through PGN Number 57244 (0xE000). A manual regeneration request is sent using SPN 3695, Diesel Particulate Filter Regeneration Force Switch. Regeneration can be inhibited by SPN 3695, Diesel Particulate Filter Regeneration Inhibit Switch.
  • Page 138 9469200995 DPF Status and Pre-Alarms The DGC-2020ES receives DPF status information which is broadcast from the engine ECU in various Parameter Group Numbers (PGN) and Suspect Parameter Numbers (SPN). The DGC-2020ES displays this information on the front panel, and in BESTCOMSPlus, via DPF related pre-alarms. The J1939 parameters and the resulting DGC-2020ES pre-alarms are summarized in the following paragraphs.
  • Page 139 DEF functions which is shown to the right. Most systems will contain one DEF tank, while some may contain two tanks. The DGC-2020ES front panel displays the level of DEF in each tank under Metering > Alarms-Status > J1939 Status > DEF Tank1 LVL% and Metering >...
  • Page 140 SEVERE INDUCEMENT state. Exhaust System Status Annunciation When an exhaust system condition requires annunciation, the DGC-2020ES displays the exhaust system information across the bottom of the front panel screen. The parameters and symbols in the Exhaust System Status Display are listed below. The symbol images below are the actual bit-mapped images that are viewed on the front panel screen of the DGC-2020ES.
  • Page 141 Lamp. When flashing, it indicates a higher degree of severity. An engine shutdown may accompany this symbol. Wait To Start Symbol – This symbol is visible when the engine is in a state of preparation for starting the engine. Examples include engine pre-heating or engine pre-lubrication. • DGC-2020ES Exhaust Treatment...
  • Page 142 With Service Tool Clearing: Invoke 0% torque reduction with service tool clearing until proper DEF • level and quality evaluation. If low level or poor DEF quality is detected during the next monitoring cycle, the severe inducement will be active after the next restart. Exhaust Treatment DGC-2020ES...

  • Page 143: Troubleshooting

    15-1 15 • 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 144 Use a voltmeter connected between the BATT– terminal (17) and the SENDER COM terminal (2) on the DGC-2020ES to verify that there is no voltage difference at any time. Any voltage differences may manifest themselves as erratic sender readings. Wiring should be corrected so that no differences exist.
  • Page 145 Step 3: If ground faults are detected on a DGC-2020ES in an ungrounded system application, 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 146 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 147 CONDITION DETECTION screen to achieve correct detection. 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 148 9469200995 The following parameters are visible on the CEM DEBUG screen: DGC TO CEM BP: DGC-2020ES to CEM-2020 Binary Points. This is the status of the CEM-2020 • output relays being transmitted from the DGC-2020ES to the CEM-2020. This is a 32-bit, bit packed number representing the desired states of the CEM-2020 outputs.

  • Page 149: Bestcomsplus Settings Loader Tool

    USB driver, and the BESTCOMSPlus Settings Loader Tool on your PC. When BESTCOMSPlus installation is complete, a Basler Electric folder is added to the Windows programs menu. This folder is accessed by clicking the Windows Start button and then accessing the...
  • Page 150 16-2 9469200995 Basler Electric folder in the Programs menu. The Basler Electric folder contains an icon that starts the BESTCOMSPlus Settings Loader Tool. Bar Code Reader and Bar Codes The BESTCOMSPlus Settings Loader Tool is compatible with bar code readers, which conform to ®...
  • Page 151 Select an entry and click Upload. A dialog appears which provides connection options for the appropriate type of device. Refer to the Basler product instruction manual for detailed connection information. Once a connection is established, the product settings associated with the entry are uploaded.
  • Page 152 Single Folder location. For example, all settings files for a product are located in “C:\files”. The Location field in the Loader Grid entry for a device contains “C:\documents\settings\DGC-2020ES Settings.bstx”. The BESTCOMSPlus Settings Loader Tool searches in “C:\files” for the file named “DGC- 2020ES Settings.bstx”.
  • Page 153 9469200995 16-5 Connection Options Connection options consist of the three selections described below. Refer to the Basler product instruction manual for detailed connection information. Always Prompt for Connection: When enabled, a dialog appears which provides connection options for the appropriate type of device each time a connection attempt is made.
  • Page 154 Scan bar code. Settings file is automatically highlighted and isolated in the grid. Click Upload. BESTCOMSPlus Settings Loader Tool automatically connects to device and uploads settings. Device connection is automatic unless “Always prompt for connection” is enabled. BESTCOMSPlus Settings Loader Tool DGC-2020ES...
  • Page 156 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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