Basler DGC-2020HD Installation Instructions Manual
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Basler DGC-2020HD Installation Instructions 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-2020HD
Digital Genset Controller
Installation Instruction Manual
9469300994, Rev H
Publication
June 2022

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  • Page 1 DGC-2020HD Digital Genset Controller Installation Instruction Manual Publication 12570 Route 143 • Highland, Illinois 62249-1074 USA 9469300994, Rev H Tel +1 618.654.2341 • Fax +1 618.654.2351 www.basler.com • info@basler.com June 2022...
  • 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 9469300994 Preface This instruction manual provides information about the installation of the DGC-2020HD 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 9469300994 Preface DGC-2020HD...
  • Page 7 9469300994 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 8 9469300994 Revision History DGC-2020HD...

  • Page 9: Table Of Contents

    9469300994 Contents Mounting..............................1-1 Terminals and Connectors ......................... 2-1 Typical Applications ........................... 3-1 Power Input ..............................4-1 Voltage and Current Sensing ........................5-1 Speed Signal Inputs ........................... 6-1 Specifications ............................. 7-1 Maintenance ............................... 8-1 Troubleshooting ............................9-1 DGC-2020HD Contents...
  • Page 10 9469300994 Contents DGC-2020HD...

  • Page 11: 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 12 Two DIN rails, one located above the other, are required for mounting the DGC-2020HD. One flange and two set screws on the DGC-2020HD secure it to the DIN rails. The flange clips onto the upper rail and the set screws attach to the bottom rail. See Figure 1-2 for flange and set screw locations.
  • Page 13 Rear Panel Units with style xPxxxxxxx are mounted flush against a panel. In this configuration, the DGC-2020HD has no HMI. Four clearance holes are provided for mounting. The rear of the DGC-2020HD faces outward for convenient access to terminals and connections.
  • Page 14 9469300994 Figure 1-4. Rear Panel Drilling Dimensions for Style xPxxxxxxx Overall Dimensions Overall dimensions are shown in Figure 1-5. All dimensions are shown in inches with millimeters in parenthesis. Mounting DGC-2020HD...
  • Page 15 9469300994 Figure 1-5. Overall Dimensions DGC-2020HD Mounting...
  • Page 16 9469300994 Mounting DGC-2020HD...

  • Page 17: Terminals And Connectors

    9469300994 2 • Terminals and Connectors All DGC-2020HD terminals and connectors are located on the rear panel. DGC-2020HD terminals consist of a mini-B USB jack, a DB-9 connector, Ethernet ports, plug-in connectors with spring clamp terminals, and quarter-inch, male, quick-connect terminals.
  • Page 18 See the Maintenance chapter for instructions on replacing the battery. Failure to replace the battery with Basler Electric P/N 38526 may void the warranty. Terminals DGC-2020HD connections are dependent on the application. Incorrect wiring may result in damage to the controller. Note...
  • Page 19 DGC-2020HD will not operate. Control power terminals are listed in Table 2-2. A fuse should be added for additional protection for the wiring to the battery input of the DGC-2020HD. A fuse helps prevent wire damage and nuisance trips due to initial power supply inrush current. To follow UL guidelines, a 5 A maximum, 32 Vdc supplementary fuse must be implemented in the battery input circuit to the DGC-2020HD.
  • Page 20 DGC-2020HD and monitored voltage phases. Bus Voltage Sensing Sensing of bus voltage enables the DGC-2020HD to detect failures of the mains (utility). Controllers with style number xxx2xxxxx use bus voltage sensing to perform automatic synchronization of the generator with the bus.
  • Page 21 9469300994 Installation in an Ungrounded System Application When the DGC-2020HD 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-2020HD and monitored voltage phases.
  • Page 22 Programmable Output Contacts Rated for 30-Ampere Duty The DGC-2020HD has three sets of output contacts rated for 30-ampere duty. Their functions are set to Pre, Start, and Run by default, but are fully programmable through BESTCOMSPlus. The Pre contacts supply battery power to the engine glow plugs, the Start contacts supply power to the starter solenoid, and the Run contacts supply power to the fuel solenoid.
  • Page 23 DGC-2020HD and an ECU on an electronically controlled engine. Connections between the ECU and DGC-2020HD should be made with twisted-pair, shielded cable. CAN interface terminals are listed in Table 2-12. For typical CAN connections, refer to the Typical Connections chapter.
  • Page 24 One or two stop bits are selectable. RS-485 Modbus supports a single Modbus Master only. Modbus register values for the DGC-2020HD are listed and defined in Basler Publication 9469300998, Instruction Manual for DGC-2020HD Digital Genset Controller Modbus Protocol.
  • Page 25 A mini-B USB jack enables local communication with a PC running BESTCOMSPlus software. The ® DGC-2020HD 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-2020HD termination). Ethernet Communications Dual copper RJ-45 jacks or an ST fiber optic port provide Ethernet communications between the DGC- 2020HD and a PC via BESTCOMSPlus or other DGC-2020HDs in a network.
  • Page 26 A male DB-9 connector allows the DGC-2020HD controller to connect to an external, user-supplied dial- out modem via the RS-232 interface. The modem enables the DGC-2020HD to dial up to four pager telephone numbers and annunciate conditions selected by the user. These conditions include any DGC-2020HD alarm or pre-alarm, closure of any programmable contact input, and an active cool down timer.

  • Page 27: Typical Applications

    9469300994 3 • Typical Applications Typical connection diagrams are provided in this chapter as a guide when wiring the DGC-2020HD for communication, mechanical senders, contact inputs and outputs, sensing, and control power. Connections for Typical Applications General connections for DGC-2020HD communication, contact inputs, contact outputs, mechanical senders, and control power are shown in Figure 3-1.
  • Page 28 Figure 3-1. Connections for Communication, Senders, Contact Inputs and Outputs, and Control Power Figure 3-2 illustrates typical three-phase wye connections for all DGC-2020HD bus voltage sensing connections: Generator, Bus 1, and Bus 2. Use the terminal numbers listed below for connecting the desired bus type.
  • Page 29 P0081-53 Figure 3-2. 3-Phase Wye Bus Voltage Sensing Connections Figure 3-3 illustrates typical three-phase delta connections for all DGC-2020HD bus voltage sensing connections: Generator, Bus 1, and Bus 2. Use the terminal numbers listed below for connecting the desired bus type. Refer to the Terminals and Connectors chapter for rear panel terminal numbering.
  • Page 30 P0081-55 Figure 3-4. Single-Phase A-B Connections Figure 3-5 illustrates typical single-phase A-C connections for all DGC-2020HD bus voltage sensing connections: Generator, Bus 1, and Bus 2. Use the terminal numbers listed below for connecting the desired bus type. Refer to the Terminals and Connectors chapter for rear panel terminal numbering.
  • Page 31 9469300994 Generator Bus Generator Load Generator Bus Metering 1 2 3 4 5 6 DGC-2020HD P0081-57 Figure 3-6. No Breaker Control Connections Generator Load Bus Breaker Generator Bus Generator Load Generator Generator Load Bus Generator Breaker Breaker Metering Bus Metering...
  • Page 32 Status Control Output 1 2 3 4 5 6 Bus 1 DGC-2020HD P0081-60 Notes: An auxiliary CT is only required for mains breaker power measurement. Mains breaker power measurement is required for the Zero Power Transfer or Mains Power Control functions.
  • Page 33 1 2 3 4 5 6 100 101 103 104 Bus 1 Bus 2 DGC-2020HD P0081-63 Notes: An auxiliary CT is only required if group breaker power measurement is desired. Group breaker power measurement is required for the group breaker Zero Power Transfer function.
  • Page 34 1 2 3 4 5 6 100 101 103 104 Bus 1 Bus 2 DGC-2020HD P0081-66 Notes: An auxiliary CT is only required if group breaker power measurement is desired. Group breaker power measurement is required for the group breaker Zero Power Transfer function.
  • Page 35 9469300994 Figure 3-19. Generator and Two Tie Breaker Control Connections Connections for Load Sharing Figure 3-20 illustrates a typical interconnection of two systems tied together using analog and Ethernet load share lines. DGC-2020HD Typical Applications...
  • Page 36 Figure 3-20. Analog and Ethernet Connections for Typical Applications Analog Input Connections DGC-2020HD controllers with style number xxxxxxxxR are equipped with two analog inputs and those with style number xxxxxxxxA are equipped with four analog inputs. Voltage and current analog input connections are shown in the following figures. When using the current input, the “+”...
  • Page 37 9469300994 3-11 To achieve electromagnetic interference immunity on the analog inputs, clamp two ferrite beads (Fair-Rite P/N 0431176451) in series around all of the wires. Place the ferrite beads close to the DGC-2020HD analog input terminals. Analog Voltage Input Connection Figure 3-21.
  • Page 38 3-12 9469300994 Figure 3-23. Analog Inputs, Current Input Connections, Type III 2-Wire Current Loop Circuit Figure 3-24. Analog Inputs, Current Input Connections, Type IV 2-Wire Current Loop Circuit Typical Applications DGC-2020HD...
  • Page 39 PWM signal. If the DGC-2020HD is not located close to the engine, it is recommended to employ a device to convert analog signals to PWM signals located close to the device being driven by the PWM signal.
  • Page 40 Typical CAN connections are shown in Figure 3-26 and Figure 3-27 Notes If the DGC-2020HD is providing one end of the J1939 bus, a 120 ohm, ½ watt terminating resistor should be installed across terminals 51 (CAN1L) and 52 (CAN1H) or 54 (CAN2L) and 55 (CAN2H).
  • Page 41 (Voltage Regulation Expansion Module) are optional modules that may be connected with the DGC- 2020HD. These modules interface to the DGC-2020HD via the “CAN 1” interface, thus the CAN terminals (51, 52, and 53) are the only common connections between the DGC-2020HD, AEM-2020, CEM-2020, and VRM-2020.
  • Page 42 Installation in an Ungrounded System Application When the DGC-2020HD 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-2020HD and monitored voltage phases.

  • Page 43: Power Input

    9469300994 4 • Power Input Control power for the DGC-2020HD is typically supplied by the genset starter battery. Power from the battery is supplied to an internal power supply that provides power for DGC-2020HD 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 44 9469300994 Power Input DGC-2020HD...

  • Page 45: Voltage And Current Sensing

    Sensing of bus voltage enables the DGC-2020HD to detect failures of the mains (utility). The DGC-2020HD accepts bus sensing over the range of 12 to 576 volts rms L-L (7 to 333 volts rms L-N). Controllers with style number xxx2xxxxx measure bus voltage sensing to perform automatic synchronization of the generator with the bus.
  • Page 46 8 (AUX I1–), 10 (AUX I2–), 12 (AUX I3–), and 14 (AUX I4–) must be terminated to ground for proper operation. Note Unused current sensing inputs should be shorted to minimize noise pickup. Voltage and Current Sensing DGC-2020HD...

  • Page 47: Speed Signal Inputs

    Terminals Magnetic pickup connections are provided at terminals 106 (+) and 107 (–). Generator Sensing Voltage The generator voltage sensed by the DGC-2020HD is used to measure frequency and can be used to measure machine speed. Terminals Sensing voltage is applied to terminals 86 (A-phase), 88 (B-phase), 90 (C-phase), and 91 (Neutral).
  • Page 48 9469300994 Speed Signal Inputs DGC-2020HD...

  • Page 49: Specifications

    9469300994 7 • Specifications DGC-2020HD electrical and physical characteristics are listed in the following paragraphs. Control Power Nominal ..........12 or 24 Vdc Range ..........6 to 32 Vdc Terminals.......... 48 (+), 49 (–), 50 (chassis ground) Power Consumption Sleep Mode ........12.7 W - LCD heater off, all relays de-energized, and analog outputs disabled Normal Operational Mode ....
  • Page 50 Bus Sensing Terminals ....100 (A-phase) 101 (B-phase) 103 (C-phase) 104 (Neutral) Analog Sensing The DGC-2020HD contains two or four (optional) analog inputs. Current Sensing Rating ..........4 to 20 mA Burden ..........84.25 Ω to 87.1 Ω Accuracy........... ±2% Voltage Sensing Rating ..........
  • Page 51 Engine System Inputs Stated accuracies are subject to the accuracy of the senders used. Values within these ranges are deemed “good” and the DGC-2020HD will use them for the appropriate calculation and protection. Fuel Level Sensing Resistance Range ......0 to 250 Ω nominal Terminals..........
  • Page 52 GOV Output Voltage Rating ........–10 to 10 Vdc Current Rating ........4 to 20 mA GOV PWM Output PWM Output ........Pulse width modulated square wave, 500 Hz (±100 Hz) Zero Error Output Duty Cycle... 69.8% (±2.0%) Specifications DGC-2020HD...
  • Page 53 † Applies when temperature is between −40°C to +70°C (–40°F to +158°F). Power Factor Metering Range ........ 0.2 leading to 0.2 lagging Calculation Method ......PF = cosine of the angle between phase AB voltage (Vab) and phase A current (Ia) * Accuracy........... ±0.01 † DGC-2020HD Specifications...
  • Page 54 C current (Ic). † Applies when temperature is between –40°C to +70°C (–40°F to +158°F). Note For the DGC-2020HD to correctly meter power factor, the generator must be rotating in the same phase sequence as dictated by the generator phase rotation setting.
  • Page 55 * Rated kvar is calculated on the System Settings, Rated Data screen in BESTCOMSPlus ® Current Imbalance (46) (Optional) Pickup Range ........0.18 to 4 Aac (1 A current sensing) 0.9 to 20 Aac (5 A current sensing) Hysteresis......... 2 % DGC-2020HD Specifications...
  • Page 56 Time Delay Range ......0 to 60 s Time Delay Increment ...... 0.1 s Overcorrection Coefficient Range ..1 to 1.3 Overcorrection Coefficient Inc..0.01 Transient Delay Time Range ... 0 to 10 s Transient Delay Time Increment ..0.1 Specifications DGC-2020HD...
  • Page 57 Maximum Voltage ......–32 to +32 Vdc with respect to negative battery terminal Communication Rate ......250 kb/s CAN 1 Terminals ......51 (low), 52 (high), and 53 (shield) CAN 2 Terminals ......54 (low), 55 (high), and 53 (shield) DGC-2020HD Specifications...
  • Page 58 7-10 9469300994 Notes If the DGC-2020HD is providing one end of the J1939 bus, a 120 ohm, ½ watt terminating resistor should be installed across terminals 51 (CAN1L) and 52 (CAN1H) or 54 (CAN2L) and 55 (CAN2H). If the DGC-2020HD is not providing one end of the J1939 bus, the stub connecting the DGC-2020HD to the bus should not exceed 914 mm (3 ft) in length.
  • Page 59 The ambient temperature is monitored by a temperature sensor located near the LCD inside the DGC-2020HD. The LCD heater turns on when the ambient temperature falls below –5°C (23°F). The heater turns off when the ambient temperature rises above 5°C (41°F). This range of operation implements 10°C (18°F) of hysteresis between when the heater turns on and turns off.
  • Page 60 10 to 150 Hz at 2.5 G 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 61 9469300994 7-13 The DGC-2020HD is a Listed Device as a Protective Relay applicable to the Canadian and US safety standards and requirements by UL. The product is covered under UL File (E97033 NRGU/ NRGU7). The DGC-2020HD ground fault protection circuit complies with the Calibration and Withstand tests of UL 1053;...
  • Page 62 7-14 9469300994 Specifications DGC-2020HD...

  • Page 63: Maintenance

    Backup Battery Replacement The backup battery for the real-time clock is a standard feature of the DGC-2020HD. A battery is used to maintain clock function during loss of power supply voltage. In mobile substation and generator applications, the primary battery system that supplies the DGC-2020HD power supply may be disconnected for extended periods (weeks, months) between uses.
  • Page 64 9469300994 Maintenance DGC-2020HD...

  • Page 65: Troubleshooting

    9469300994 9 • Troubleshooting If you do not get the results that you expect from the DGC-2020HD, 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 66 Figure 9-2. Device Manager Step 3. In the Properties windows, select the Driver tab and click Update Driver. See Figure 9-3. Figure 9-3. DGC-2020HD Properties Step 4. Select Browse My Computer for Driver Software as shown in Figure 9-4. Troubleshooting...
  • Page 67 9469300994 Figure 9-4. Update Driver Software - DGC-2020HD Step 5. Click Browse and navigate to C:\Program Files\Basler Electric\USB Device Drivers\USBIO. Click Next. See Figure 9-5. Figure 9-5. Update Driver Software - DGC-2020HD Step 6. If a Windows Security window (Figure 9-6) appears, click Install.
  • Page 68 Check to determine if there are multiple ECUs on the engine. If so, consult the engine manufacturer’s documentation to determine the CAN Bus 2 address of the ECU that will respond to rpm requests. Set the Engine ECU Address setting under the CAN Bus 2 (ECU) Troubleshooting DGC-2020HD...
  • Page 69 Use a voltmeter connected between the BATT– terminal (P4-49) and the sender negative terminals on the DGC-2020HD 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 70 9469300994 Step 2. Ensure that the proper current is present at the DGC-2020HD current sensing inputs 1, 2, 3, 4, 5, and 6. Step 3. Verify that the current sensing transformer ratios are correct. Step 4. Confirm that the current sensing transformers are correct and properly installed.
  • Page 71 Verify the breaker is receiving a close command. Breaker close command sources are: The DGC-2020HD itself when the automatic mains fail transfer (ATS) feature is enabled. • The DGC-2020HD itself when the Run with Load logic element receives a Start pulse in the • programmable logic.
  • Page 72 Metering Explorer in BESTCOMSPlus and verify that the Mains Failed status LED is lit when the power on the DGC-2020HD bus voltage input is either out of voltage or frequency range. If necessary, modify the settings on the Settings, Breaker Management, Bus Condition screen to achieve correct detection.
  • Page 73 Initiate a breaker close request by one of the methods listed in the Breaker Management chapter in the Configuration manual. Step 3: Check for raise and/or lower pulses coming from the DGC-2020HD if the governor or AVR bias control output type is contact. Step 4: Check the governor and/or AVR bias analog outputs on the DGC-2020HD with a volt meter if the governor or AVR bias control output type is analog.
  • Page 74 Load Anticipation Large Frequency Overshoot on Recovery Kla Gain may be too high and GOV output may be saturated. See Figure 9-8. Navigate to Settings, Bias Control Settings, Governor Bias Control Settings and decrease Load Anticipation, Kla Gain. Troubleshooting DGC-2020HD...
  • Page 75 Settings, Governor Bias Control Settings and decrease Load Anticipation, Tla Washout Filter Constant. Figure 9-9. Tla Too High Causing Recovery Overshoot Poor Recovery Kla Gain may be too low. See Figure 9-10. Navigate to Settings, Bias Control Settings, Governor Bias Control Settings and increase Load Anticipation, Kla Gain. DGC-2020HD Troubleshooting...
  • Page 76 Generator Voltage Does Not Change When Voltage Bias Changes As a test, you can force a fixed voltage on the AVR bias output by setting the Min Output Voltage and Max Output Voltage to the same value by navigating to Settings, Programmable Outputs, Analog Output Troubleshooting DGC-2020HD...
  • Page 77 If the input status is correct, but the Gen Breaker status under Metering, Status, Bus Condition, Gen is not, check the PLC logic, and verify that the Gen Breaker fed into the DGC-2020HD is tied in logic to the Status input on the Gen Breaker logic element.
  • Page 78 Step 2: Verify generator breaker status is being correctly received as described in Generator Breaker Status is not being received by the DGC-2020HD. If the status is correct, proceed to Step 3. Step 3: Check the Load Share Line operating voltage range by examining the Min. and Max. Voltage parameters found in BESTCOMSPlus®...
  • Page 79 Step 10: If it appears that something is driving the load share line but it is not the DGC-2020HD on one of the non-running units, search for an external device that is driving or loading down the load share lines.
  • Page 80 DGC-2020HD Front Panel Diagnostics Screens There are several diagnostic screens in the DGC-2020HD that can be useful for debugging load sharing issues and I/O module related issues. The following debug screens are available: Load Share Line, Control, AEM-2020, CEM-2020, VRM, Mains Power and VRM Control.
  • Page 81 To Mains logic element is true, the Watt Demand will be equal to the base load set point. When the generator breaker is open or the kW controller is disabled, the Watt Demand will always be equal to the value calculated from the voltage that the DGC-2020HD sees on its load share line. •...
  • Page 82 Ramp Status: This indicates the current kvar ramp direction as None, Up, or Down. var Ramp Demand: This is the normalized var demand that is ramped from the initial var loading • upon generator breaker closure to the desired var output. The rate at which the ramp occurs is Troubleshooting DGC-2020HD...
  • Page 83 Volt Error: This is the normalized difference between the measured generator voltage and the • voltage to which the DGC-2020HD is trying to synchronize. It will be 0.00 at all times except when the DGC-2020HD is trying to synchronize its generator inputs to its bus input. When synchronizing, this will typically be 0.000 or some relatively small number and move a small...
  • Page 84 9-20 9469300994 • DGC To AEM BP: DGC-2020HD to AEM-2020 Binary Points. This is a 32-bit, bit packed number representing the binary points transmitted from the DGC-2020HD to the AEM-2020. Debug at this level is not necessary. • AEM To DGC BP: AEM-2020 to DGC-2020HD Binary Points. This is a 32-bit, bit packed number representing the binary points transmitted from the AEM-2020 to the DGC-2020HD.
  • Page 85 This screen is useful for debugging VRM-2020 control related issues. It gives visibility into the states of the VRM-2020 regulation modes and limiters in the DGC-2020HD. The VRM Control diagnostics screen is located on the front panel at Metering > Diagnostics > VRM Control.
  • Page 86 9-22 9469300994 Troubleshooting DGC-2020HD...
  • Page 88 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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