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Basler DGC-2020ES Instruction Manual

Digital genset controller
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INSTRUCTION MANUAL
FOR
DGC-2020ES
DIGITAL GENSET CONTROLLER
Publication: 9469200990
Revision: B
Feb-14

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  • Page 1 INSTRUCTION MANUAL DGC-2020ES DIGITAL GENSET CONTROLLER Publication: 9469200990 Revision: B Feb-14...

  • Page 3: Conventions Used In This Manual

    9469200990 Rev B Preface This instruction manual provides information about the installation and operation of the DGC-2020ES Digital Genset Controller. To accomplish this, the following information is provided: • Controls and indicators • Inputs and outputs • Protection and control functions •...
  • 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: Table Of Contents

    Run ................................45 Auto ................................. 45 Operating Mode Control .......................... 45 Breaker Management ..........................47 Breaker Status ............................47 Breaker Operation ........................... 47 Breaker Configuration..........................48 Generator Protection ..........................53 Voltage ..............................53 Frequency ..............................56 Overcurrent .............................. 57 DGC-2020ES Contents...
  • Page 6 Installation for CE Systems ........................98 ® BESTCOMSPlus ............................99 System Recommendations ........................100 Installation ............................. 100 Activation of the DGC-2020ES Plugin ....................100 Menu Bars ............................. 103 Settings Explorer ........................... 105 Metering Explorer ..........................105 BESTspace™ ............................106 Settings File Management ........................106 Firmware Updates ..........................
  • Page 7 Security ..............................161 Changing Passwords ..........................161 Saving Passwords in a DGC-2020ES Settings File ................161 Loading Passwords from a Settings File into the DGC-2020ES ............163 Timekeeping ............................165 Clock Setup ............................165 Setting the Time and Date ........................166 Real-Time Clock Specifications ......................
  • Page 8 Remote Contact Output Configuration ....................190 Maintenance ............................191 MTU Fault Codes ............................. 193 Exhaust Treatment ..........................203 Diesel Particulate Filter (DPF) ....................... 203 Exhaust After-Treatment Systems (EATS).................... 205 Diagnostic Trouble Codes ........................207 Revision History ............................217 Contents DGC-2020ES...

  • Page 9: Introduction

    Introduction The DGC-2020ES Digital Genset Controller provides integrated engine-genset control, protection, and metering in a rugged and economical package. Its features set make the DGC-2020ES ideal for standalone genset applications where paralleling or load sharing is not required. Microprocessor based technology allows for exact measurement, setpoint adjustment, and timing functions.

  • Page 10: Style Number

    Any phase of bus voltage is unstable due to overfrequency or underfrequency At this time, the DGC-2020ES will start the genset and when ready, apply power to the load via the genset. The DGC-2020ES implements open transitions to and from the mains. When the mains returns and is considered stable, the DGC-2020ES will transfer the load back to the mains.

  • Page 11: Optional Features And Capabilities

    9469200990 Rev B Figure 1. DGC-2020ES Style Chart For example, a DGC-2020ES with style number 5A2, has the following characteristics and features. 5 Aac Current Sensing Inputs Analog Senders Mains Failure Detection Optional Features and Capabilities CEM-2020 (Contact Expansion Module) The optional CEM-2020 provides 10 additional contact inputs and 18 or 24 additional output contacts (depending on module type) to the DGC-2020ES.
  • Page 12 9469200990 Rev B Introduction DGC-2020ES...

  • Page 13: Controls And Indicators

    9469200990 Rev B Controls and Indicators DGC-2020ES controls and indicators are located on the front panel and are intended for local control and monitoring of DGC-2020ES operation. Front panel controls consist of pushbuttons. Front panel indicators consist of LED (light emitting diode) indicators and a backlit LCD (liquid crystal display).

  • Page 14: Display Operation And Navigation

    Alarm Indicator. This red LED lights continuously during alarm conditions and flashes during pre-alarm conditions. Not in Auto Indicator. This red LED lights when the DGC-2020ES is not operating in Auto mode. When the DGC-2020ES is operating in Run or Off mode, this LED is on.

  • Page 15: Login And Permissions

    ENGINE % LOAD • kvar B ENG INTCLR TEMP kvar C • • • ENG OIL TEMP • kvar TOTAL • FUEL • kW A • FUEL DELV P • kW B • FUEL RATE • kW C DGC-2020ES Controls and Indicators...
  • Page 16 Sleep mode de-energizes the LCD backlight and heater when no pushbutton activity is detected for 15 minutes and the DGC-2020ES is operating in OFF mode or Auto mode with the engine not running. Normal display operation resumes when any pushbutton is pressed or the genset is started remotely via the ATS input.
  • Page 17 HOURS ■ MINUTES ■ SESSION ● SESSION ○ START ■ kW-HRS ■ TOTAL RUN TIME ○ HOURS ■ MINUTES ■ LOADED RUN TIME ○ HOURS ■ MINUTES ■ UNLOADED RUN TIME ○ HOURS ■ MINUTES ■ DGC-2020ES Controls and Indicators...
  • Page 18 INJCT DBR % (Visible when ECU is configured for MTU ECU7/ECU8.) ■ RATED RPM (Visible when ECU is configured for MTU ECU7/ECU8.) ■ INJCT QTY (Visible when ECU is configured for MTU ECU7/ECU8.) ■ RATED KW (Visible when ECU is configured for MTU ECU7/ECU8.) ■ Controls and Indicators DGC-2020ES...
  • Page 19 BATTLE OVERRIDE (Visible when the Battle Override programmable function is configured to be ○ driven by an input.) LOW LINE OVERRIDE (Visible when the Low Line Override programmable function is configured to be ○ driven by an input.) DGC-2020ES Controls and Indicators...
  • Page 20 J1939 DATA (Visible when CAN bus is enabled and ECU is configured for Standard, Volvo Penta, MTU ADEC, ● GM/Doosan, Cummins or MTU Smart Connect.) THROTTLE POSITN ○ LOAD @ CRNT RPM ○ ACTUAL ENG TORQ ○ ENGINE SPEED ○ Controls and Indicators DGC-2020ES...
  • Page 21 TRQ @ PNT 4 ○ SPD @ PNT 5 ○ TRQ @ PNT 5 ○ SPD @ PNT 6 ○ ENDSPEED GOV KP ○ REF ENG TORQUE ○ O-RIDE SPD PNT 7 ○ O-RIDE TIME LMT ○ DGC-2020ES Controls and Indicators...
  • Page 22 ○ 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 23 GOV PARAM SET (Visible when ECU is configured for MTU ECU7/ECU8.) □ CAN RATING SW 1 (Visible when ECU is configured for MTU ECU7/ECU8.) □ CAN RATING SW 2 (Visible when ECU is configured for MTU ECU7/ECU8.) □ DGC-2020ES Controls and Indicators...
  • Page 24 CYCLE TIME ○ COOLDWN TIME ○ OFF MODE COOLDN ○ PRESTART REST CONFIG ○ CONF ■ OIL PRS CRANK DISC ○ ENABLE ■ CRANK DISC PRS ■ AUTOMATIC RESTART ● ENABLE ○ ATTEMPTS ○ INTERVAL ○ Controls and Indicators DGC-2020ES...
  • Page 25 BATT CHRG FAIL ○ INPUT ■ ALARM CONFIG (Visible when an INPUT is selected.) ■ ACTIVATN DLY (Visible when an INPUT is selected.) ■ RECOGNITION (Visible when an INPUT is selected.) ■ LOW COOL LEVEL ○ INPUT ■ DGC-2020ES Controls and Indicators...
  • Page 26 ■ ACTIVE DTC (Visible when DTC is enabled.) ○ ENABLE ■ ECU COMMS FAIL (Visible when CAN BUS is enabled.) ○ ENABLE ■ COOLANT LEVEL (Visible when CAN BUS is enabled.) ○ ENABLE ■ THRESHOLD ■ Controls and Indicators DGC-2020ES...
  • Page 27 LOW LINE SF (Visible when an input is selected for the Low Line Override programmable function.) ○ 3 / 1 PHASE SETTINGS ○ PICKUP ■ HYSTERESIS ■ TIME DELAY ■ FREQ INHIBIT ■ ALARM CONFIG ■ DGC-2020ES Controls and Indicators...
  • Page 28 CLOSE CMD (Visible when configured.) ■ BRK CLOSE FAIL PALM ○ BRK OPEN FAIL PALM ○ BUS CONDITION DETECT ● GEN DEAD ○ THRESHOLD ■ TIME DELAY ■ GEN STABLE ○ OV PICKUP ■ OV DROPOUT ■ UV PICKUP ■ Controls and Indicators DGC-2020ES...

  • Page 29: Display Setup

    LOGOUT (Visible when logged in through the front panel.) Display Setup The DGC-2020ES LCD can be customized to fit the needs of your specific application. Most of the options can be adjusted using the front panel buttons while all options can be adjusted within BESTCOMSPlus ®...

  • Page 30: Remote Display Panel (Optional)

    Initializing Message 2 - This parameter defines the second line of text that appears on the front panel of the DGC-2020ES as it is going through its power up and initializing sequence. Figure 5. Settings Explorer, General Settings, Front Panel HMI Screen Remote Display Panel (optional) Applications that require remote annunciation can use Basler Electric’s Remote Display Panel.
  • Page 31 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 32 9469200990 Rev B Controls and Indicators DGC-2020ES...

  • Page 33: Power Input

    9469200990 Rev B Power Input Operating 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 34 9469200990 Rev B Power Input DGC-2020ES...

  • Page 35: 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 36 9469200990 Rev B 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 37: 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 38 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 6. Settings Explorer, Programmable Senders, Fuel Level Screen...
  • Page 39 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. Settings Explorer, Programmable Senders, Oil Pressure Screen...
  • Page 40 If you want to save newly entered sender data as a sender library file, click Create Cool 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 8. Settings Explorer, Programmable Senders, Coolant Temperature Screen...

  • Page 41: Sender Failure Detection

    9469200990 Rev B 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. The speed sender fail alarm is always enabled.
  • Page 42 9469200990 Rev B Engine Sender Inputs DGC-2020ES...

  • Page 43: 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 44 9469200990 Rev B Speed Signal Inputs DGC-2020ES...

  • Page 45: Contact Inputs

    9469200990 Rev B 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 46: Programmable Functions

    • Automatic Transfer Switch (ATS) - Start and run the generator while the ATS input is true and the DGC-2020ES is in Auto mode. • Grounded Delta Override - Uses Grounded Delta sensing if the generator connection is set for Delta.
  • Page 47 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 11. Figure 11. Settings Explorer, Programmable Inputs, Programmable Functions DGC-2020ES Contact Inputs...
  • Page 48 9469200990 Rev B Contact Inputs DGC-2020ES...

  • Page 49: 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 50: Programmable

    Figure 13. 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 51: Configurable Elements

    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. Configurable element status is available in BESTlogicPlus Programmable Logic when “None”...
  • Page 52 9469200990 Rev B Figure 15. Settings Explorer, Programmable Outputs, Configurable Elements Contact Outputs DGC-2020ES...

  • Page 53: Operating Modes

    In OFF mode, the DGC-2020ES will not start under any circumstance. It cannot be started automatically. Programmable logic functions normally in this mode. In RUN (manual) mode, the DGC-2020ES runs and cannot be shut off automatically. The breaker can be opened or closed through programmable logic inputs. Programmable logic functions normally in this mode.
  • Page 54 9469200990 Rev B Operating Modes DGC-2020ES...

  • Page 55: 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 56: Breaker Configuration

    Before the mains breaker can be closed, it must be configured in BESTCOMSPlus. If both the mains and the generator breakers are configured and open, the DGC-2020ES will close the mains breaker if the mains side of the breaker is stable. If both breakers are configured and the generator breaker is closed, the DGC-2020ES will not close the mains breaker.
  • Page 57 9469200990 Rev B Figure 16. Settings Explorer, Breaker Management, Breaker Hardware Screen DGC-2020ES Breaker Management...
  • Page 58 Status input of the breaker element. This is the only way to indicate breaker status to the DGC-2020ES. If it is desired to have physical inputs that can request breaker open and close commands, connect the desired inputs to the open and close command inputs of the breaker element.

  • Page 59: Bus Condition Detection

    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. Bus Condition Detection (These thresholds determine when the generator and bus are considered to be stable or dead.)
  • Page 60 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 Maintenance and Troubleshooting chapter if the breaker does not seem to operate properly. Breaker Management DGC-2020ES...

  • Page 61: 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 62 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 63: Phase Imbalance

    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 64: Frequency

    For example, a machine that is configurable between 50 or 60 Hz operation. The scale factor setting is implemented when the DGC- 2020ES senses a contact closure at a contact input that is connected to the Alternate Frequency Override Generator Protection DGC-2020ES...

  • Page 65: Overcurrent

    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 66 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 67: Metering

    The DGC-2020ES provides comprehensive metering of internal and system conditions. These capabilities include extensive parameter metering, status indication and reporting. Metering Explorer DGC-2020ES metering is accessed through the metering explorer menu on the front panel display or the ® BESTCOMSPlus metering explorer.

  • Page 68: Engine

    Parameters that do not apply to your engine are marked as either NS (not sent) or NA (not applicable). The Engine screen is found in the BESTCOMSPlus Metering Explorer. If using the front panel, navigate to Metering > Engine. Figure 25. Metering Explorer, Engine Screen Metering DGC-2020ES...

  • Page 69: Generator

    This screen provides Cumulative Run Statistics, Session Run Statistics, and Commission Date. See Figure 28. The Cumulative Run Statistics are tracked from the first time the genset was started. The Session Run Statistics are tracked from the last time the genset was started until the following shutdown. DGC-2020ES Metering...

  • Page 70: Status Indication

    Unloaded Run time can be changed by clicking the Edit Cumulative Run Statistics button. This is helpful when installing the DGC-2020ES into a pre-existing system. This allows the current statistics of the genset to be transferred into the DGC-2020ES for uninterrupted tracking.

  • Page 71: Inputs

    The status is TRUE when the corresponding indicator is red. See Figure 31. The Remote Contact Inputs screen is found in the BESTCOMSPlus Metering Explorer under the Inputs category. If using the front panel, navigate to Metering > Alarms-Status > Inputs. DGC-2020ES Metering...

  • Page 72: Logic Control Relays

    If using the front panel, navigate to Metering > Alarms-Status > Logic Control Relays. Figure 32. Metering Explorer, Inputs, Logic Control Relays Screen Outputs Contact Outputs This screen indicates the status of contact outputs. The status is TRUE when the corresponding indicator is green. See Figure 33. Metering DGC-2020ES...
  • Page 73 Figure 34. Metering Explorer, Outputs, Remote Contact Outputs Screen Configurable Elements This screen indicates the status of configurable elements. It also indicates alarms and pre-alarms of configurable elements. The status is TRUE when the corresponding indicator is green. See Figure 35. DGC-2020ES Metering...

  • Page 74: Control

    DGC-2020ES. The PC or laptop running BESTCOMSPlus must be connected to the DGC-2020ES via the USB port (see the Communication chapter for details). When running BESTCOMSPlus in Live mode, these buttons interact with the DGC-2020ES in real time.

  • Page 75: Auto Export Metering

    9469200990 Rev B Auto Export Metering This function automatically exports metering data over a user-defined period when a DGC-2020ES connection is active. To display the Auto Export Metering screen, click the Tools pull-down menu from the upper menu bar and click Auto Export Metering. Specify the Number of Exports and the Interval between each export.
  • Page 76 9469200990 Rev B Metering DGC-2020ES...

  • Page 77: Reporting And Alarms

    9469200990 Rev B Reporting and Alarms The DGC-2020ES monitors ECU data, generator protection functions, and engine senders. An alarm or pre-alarm is annunciated when the monitored parameter exceeds its threshold settings. When an alarm condition exists, the engine is stopped by opening the Fuel output contact. An existing pre-alarm condition is annunciated only.
  • Page 78 Duplicate CEM SERFLASH RD FAIL Serial Flash Read Failure WEAK BATTERY Weak Battery Voltage Sender Fail COOL SNDR FAIL Coolant Temp Sender Fail FUEL LEVEL SNDR Fuel Level Sender Fail LOSS OF VOLT Voltage Sensing Fail Reporting and Alarms DGC-2020ES...

  • Page 79: Alarm Configuration

    High coolant temperature alarm settings consist of an enable/disable setting, a threshold setting, and an arming delay. If enabled, a high coolant temperature alarm is triggered instantaneously when the engine coolant temperature exceeds the threshold setting. The arming delay disables the high coolant DGC-2020ES Reporting and Alarms...
  • Page 80 High coolant temperature pre-alarm settings consist of an enable/disable setting and a threshold setting. If enabled, a high coolant temperature pre-alarm is annunciated when the engine coolant temperature exceeds the threshold setting for a fixed duration of 60 seconds. System units are configured on the System Settings screen. Reporting and Alarms DGC-2020ES...
  • Page 81 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 DGC-2020ES Reporting and Alarms...
  • Page 82 Resetting Alarms, Checksum Failure, below, for more information. Breaker Close Failure If enabled, this pre-alarm is triggered when the DGC-2020ES has issued a "breaker close" output and has not received "breaker closed" feedback from the breaker within the allowed closing time. The Monitor setting determines whether this condition is monitored only during transitions or always.
  • Page 83 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 84: Retrieving Alarm Information

    Front Panel Display The lists of active alarms and pre-alarms can be viewed by navigating to Metering > Alarms-Status > Active Alarms or Active Pre-alarms. These lists are scrollable by using the Up and Down pushbuttons. Reporting and Alarms DGC-2020ES...

  • Page 85: Resetting Alarms And Pre-Alarms

    Run Statistics screen and click on the Reset Maintenance Interval button. To reset the maintenance interval pre-alarm from the front panel, navigate to the Overview screen and hold the Back pushbutton for 12 seconds. DGC-2020ES Reporting and Alarms...

  • Page 86: Checksum Failure

    If the problem persists, reload the firmware file through BESTCOMSPlus. See the BESTCOMSPlus chapter for more information. Contact Basler Electric Technical Support. The checksum failure pre-alarm can be disabled. This disables only the annunciation of the pre- alarm and does not correct any error conditions.

  • Page 87: Event Recording

    99 occurrences each are retained in memory, a history of nearly 3,000 specific events are retained by the DGC-2020ES. Detailed occurrence information is retained for the most recent 30 occurrences of each event record, and there are 30 event records. Thus the time, date, and engine hours details for up to 900 specific event occurrences are retained in the event log.
  • Page 88 DEF ENGINE DERATE P Diesel Exhaust Fluid Engine Derate Pre-Alarm DEF FLUID EMPTY P Diesel Exhaust Fluid Empty Pre-Alarm DEF FLUID LOW P Diesel Exhaust Fluid Low Pre-Alarm DEF INDUCMT O-RIDE P Diesel Exhaust Fluid Inducement Override Pre-Alarm Event Recording DGC-2020ES...
  • Page 89 Pre-Alarm HIGH COIL TEMP 2 P High Temp Coil 2 Pre-Alarm HIGH COIL TEMP 3 P High Temp Coil 3 Pre-Alarm HIGH COOLANT TEMP A High Coolant Temp Alarm HIGH COOLANT TEMP P High Coolant Temp Pre-Alarm DGC-2020ES Event Recording...
  • Page 90 Low Oil Pressure Pre-Alarm LOW OIL PRESSURE A Low Oil Pressure Alarm LOW OIL PRESSURE P Low Oil Pressure Pre-Alarm LOW STRG TANK LEVEL P Low Storage Tank Level Pre-Alarm MAINS FAIL TEST Mains Fail Test Status Event Recording DGC-2020ES...
  • Page 91 START SPEED LOW P Start Speed Low Pre-Alarm VOLTAGE SENSE FAIL Voltage Sensing Fail Status VOLTAGE SENSE FAIL A Voltage Sensing Fail Alarm VOLTAGE SENSE FAIL P Voltage Sensing Fail Pre-Alarm WEAK BATTERY P Weak Battery Pre-Alarm DGC-2020ES Event Recording...
  • Page 92 9469200990 Rev B Event Recording DGC-2020ES...

  • Page 93: 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 94 9469200990 Rev B Figure 44. Overall Dimensions Mounting DGC-2020ES...

  • Page 95: Terminals And Connectors

    9469200990 Rev B 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 45 illustrates the rear panel terminals. Locator letters in the illustration correspond to the terminal block and connector descriptions in Table 8.

  • Page 96: 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 97: 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 10.

  • Page 98: Analog Engine Sender Inputs

    Inputs are provided for oil pressure, fuel level, and coolant temperature senders. For a listing of oil pressure, fuel level, and coolant temperature senders that are compatible with the DGC-2020ES, refer to the Engine Sender Inputs chapter. Analog engine sender input terminals are listed in Table 13.

  • Page 99: 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 100: 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 19 lists the DGC-2020ES terminals that connect to the Remote Display Panel.

  • Page 101: Typical Connections

    9469200990 Rev B 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 operating 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 102 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 103 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 104 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 105: Can Connections

    120 Ω, 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 106: 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 52) between the DGC-2020ES and CEM-2020. Refer to the CEM-2020 chapter for more information.

  • Page 107: 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 108: System Recommendations

    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...

  • Page 109: Connect A Usb Cable

    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 110: Installing The Usb Driver If Automatic Installation Fails

    Device Manager and expand the Ports (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 57.

  • Page 111: Menu Bars

    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 112 Close BESTCOMSPlus program Communication New Connection Choose new device or DGC-2020ES Close Connection Close communication between BESTCOMSPlus and DGC-2020ES Download Settings and Logic from Download operational and logic settings from the device Device Upload Settings and Logic to Device Upload operational and logic settings to the device...

  • Page 113: Settings Explorer

    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 114: Bestspace

    Figure 60. 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 115 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 116 (Figure 62) is displayed where you can view all settings (Show All Settings), view only the differences (Show Settings Differences), view all logic (Show All Logic Paths), or view only logic differences (Show Logic Path Differences). Select Close when finished. Figure 62. Settings Comparison Results Screen BESTCOMSPlus® DGC-2020ES...

  • Page 117: Firmware Updates

    9469200990 Rev B 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. Note...

  • Page 118: Upgrading Firmware In Expansion Modules

    DGC-2020ES. If no expansion module is present, proceed to Upgrading Firmware in the DGC-2020ES. 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.
  • Page 119 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 120: Bestcomsplus Updates

    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 121: 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 122: Bestlogic™Plus Composition

    Status Input True when the Audible Horn is active. Audible Horn Status Input True when the DGC-2020ES is in Auto Mode or the Auto Mode Auto Mode logic element is true. True when the Automatic Restart function is active. Status Input...
  • Page 123 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 124 True when the 47 element is tripped. Generator Protection Status Input True when the 50 element is tripped. Generator Protection Status Input True when the 81 Over element is tripped. Generator Protection Status Input True when the 81 Under element is tripped. Generator Protection BESTlogic™Plus DGC-2020ES...
  • Page 125 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 True when the DGC-2020ES is in the connecting state. Status Input In Connecting...
  • Page 126 Complete power is deemed good and the DGC-2020ES transfers the load back to utility power. Status Input True when the DGC-2020ES is in Off Mode or the Off Off Mode Mode logic element is true. Status Input True when the DGC-2020ES is in Off Mode and Off Mode cooling down.
  • Page 127 Generator True when the 81 Over element is configured as an Protection alarm and has tripped. 81 Over Generator True when the 81 Under element is configured as an Protection alarm and has tripped. 81 Under DGC-2020ES BESTlogic™Plus...
  • Page 128 True when some of the user settings or firmware code Failure has been corrupted. Refer to the Reporting and Alarms chapter for more details. True when more than one CEM-2020 is connected. Contact Expansion Module Multiple Contact Expansion Modules Connected BESTlogic™Plus DGC-2020ES...
  • Page 129 9469200990 Rev B Name Description Symbol Contact True when communication from the CEM-2020 to the Expansion DGC-2020ES has been lost. Module Contact Expansion Module Comm Fail Contact True when the connected CEM-2020 does not have Expansion the same number of outputs as defined on the System...
  • Page 130 Generator True when a generator breaker close fail pre-alarm Breaker Close occurs. The pre-alarm occurs when the DGC-2020ES Fail has issued a generator breaker close output but does not receive a generator breaker status input that indicates the breaker has closed before the breaker close wait time has expired.
  • Page 131 Mains Breaker True when a mains breaker close fail pre-alarm occurs. Close Fail The pre-alarm occurs when the DGC-2020ES has issued a mains breaker close output but does not receive a mains breaker status input that indicates the breaker has closed before the breaker close wait time has expired.
  • Page 132 This group contains Logic Gates, Pickup and Dropout Timers, Latches, and Comment Blocks. Table 24 lists the names and descriptions of the objects in the Components group. Table 24. Components Group, Names and Descriptions Name Description Symbol Logic Gates Input Output BESTlogic™Plus DGC-2020ES...
  • Page 133 SET (ON) state. When the Reset input is on and the Set input is off, the latch will go to the RESET (OFF) state. If both the Set and Reset inputs are on at the same time, a reset priority latch will go to the RESET (OFF) state. DGC-2020ES BESTlogic™Plus...
  • Page 134 59TRIP True when the 59-1 overvoltage is in a TRIP condition. Connect to another logic block input. 81TRIP True when the 81 frequency is in a TRIP condition. Connect to another logic block input. BESTlogic™Plus DGC-2020ES...
  • Page 135 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 136 AUTO mode is true, the unit will remain running in AUTO mode. 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 137 DGC-2020ES only responds to this logic element when in AUTO mode. 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 138 Open: This input allows a contact input to be mapped that can be used to initiate a manual breaker open request. When this input is pulsed closed while the DGC-2020ES is in RUN or AUTO mode, the breaker will open.
  • Page 139 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 140 Open: This input allows a contact input to be mapped that can be used to initiate a manual breaker open request. When this input is pulsed closed while the DGC-2020ES is in RUN or AUTO mode, the breaker will open.
  • Page 141 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 142: Logic Schemes

    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 143: Sending And Retrieving Logic Schemes

    DGC-2020ES by selecting Download Settings and Logic on the Communication pull-down menu. 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 144: Pickup And Dropout Timers

    Timers tree branch. The Logic Timer Properties Dialog Box will appear. Select the timer you want to use. Timing accuracy is ±15 milliseconds. Initiate Pickup Initiate Output Timer Pickup Time Output P0048-03 Initiate Initiate Dropout Output Timer Dropout Time Output Figure 66. Pickup and Dropout Timer Logic Blocks BESTlogic™Plus DGC-2020ES...

  • Page 145: Bestlogic™Plus File Management

    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 146: Bestlogic™Plus Examples

    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 70.
  • Page 147 9469200990 Rev B Figure 70. Example 3 – Multiple Logic Connections DGC-2020ES BESTlogic™Plus...
  • Page 148 9469200990 Rev B BESTlogic™Plus DGC-2020ES...

  • Page 149: 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 description of BESTCOMSPlus is provided in the BESTCOMSPlus chapter.
  • Page 150 Transmission Oil Pressure Transmission Oil Temperature °C °F Trip Fuel liters gallons Requested 1.5 s Winding 1 Temperature 1124 °C °F Winding 2 Temperature 1125 °C °F Winding 3 Temperature 1126 °C °F ∗ SPN is suspect parameter number. Communication DGC-2020ES...
  • Page 151 ∗ 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...

  • Page 152: Can Setup

    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...

  • Page 153: Ecu Setup

    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 154 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 155 • 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. • Accelerator Pedal Position - sent based on the Accelerator Position setting.
  • Page 156 Idle Request - sent when the Idle Request logic element is true in BESTLogicPlus. • 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 157: Remote Display Panel (Optional)

    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 158 9469200990 Rev B Communication DGC-2020ES...

  • Page 159: 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 160: Eps Supplying Load

    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 161 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 162: Generator Connection

    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 163: Remote Module Setup

    Attempting to start an engine after a normal shutdown but before the engine RPM has settled to zero can stress an engine in certain situations. The Restart Delay inhibits attempts to start the engine immediately after a normal shutdown for the duration of the Restart Delay timer. This delay should allow an engine to DGC-2020ES Configuration...
  • Page 164 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 165: Automatic Restart

    Figure 76. 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 166: Exercise Timer

    The Start Hour and Run Period Hours settings accept values from 0 to 23, in increments of 1 hour. The Start Minute and Run Period Minutes settings accept values from 0 to 59, in increments of 1. If Run with Load is enabled, the DGC-2020ES closes the generator breaker during the run time.

  • Page 167: Relay Control

    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 168 There is a one-second delay in the detection to prevent the DGC-2020ES from alternating between detected configurations. When the DGC-2020ES is in the Off mode or the engine is not running, the Automatic Configuration Detection function is disabled. The DGC-2020ES is assumed to be in the last valid automatically detected configuration.

  • Page 169: 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 170 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 171: Loading Passwords From A Settings File Into The Dgc-2020Es

    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 172 9469200990 Rev B Security DGC-2020ES...

  • Page 173: Timekeeping

    9469200990 Rev B 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 174: Setting The Time And Date

    Figure 83. Metering Explorer, Real Time Clock Screen Real-Time Clock Specifications Resolution ..............1 s Accuracy..............±1.73 s/d at 25°C Clock Holdup Capacitor Holdup Time ..........Up to 24 hours depending on conditions Battery Holdup Time ..........Approximately ten years depending on conditions Timekeeping DGC-2020ES...

  • Page 175: Maintenance And Troubleshooting

    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 176 LCD is Blank and all LEDs are Flashing at Approximately 2 Second Intervals This indicates that the DGC-2020ES does not detect that valid application firmware is installed. The unit is running its boot loader program, waiting to accept a firmware upload.
  • Page 177 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 178 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 179 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 180 9469200990 Rev B Maintenance and Troubleshooting DGC-2020ES...

  • Page 181: Specifications

    9469200990 Rev B Specifications DGC-2020ES electrical and physical characteristics are listed in the following paragraphs. Operating 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 182: 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 183: Output Contacts

    Frequency is sensed through the generator and bus voltage inputs (phases A and B). Metering Range ........ 10 to 72 Hz Accuracy........... ±0.25% or 0.05 Hz Display Resolution ......0.1 Hz Apparent Power Indicates total kVA and individual line kVA (4-wire, line-to-neutral or 3-wire, line-to-line). DGC-2020ES Specifications...
  • Page 184 † 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 185: Generator Protection Functions

    Inhibit Voltage Range ....... 70 to 576 Vac (81U function only) Overcurrent (50) Pickup Range ........0.18 to 1.18 Aac (1 A current sensing) 0.9 to 7.75 Aac (5 A current sensing) Time Dial Range ......0 to 7,200 s (fixed time curve) Time Dial Increment ......0.1 DGC-2020ES Specifications...

  • Page 186: Logic Timers

    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 Ω, ½ watt terminating resistor should be installed across terminals 14 (CANL) and 13 (CANH).

  • Page 187: Real-Time Clock

    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 188: Environment

    Humidity ........... IEC 68-2-38 Salt Spray ......... IEC 68-2-52 Ingress Protection ......IEC IP56 for front panel UL Approval The DGC-2020ES is recognized to applicable Canadian and US safety standards and requirements by Standards used for evaluation: • UL6200 •...

  • Page 189: Cem-2020

    CEM-2020 General Information The optional CEM-2020 is a remote auxiliary device that provides additional DGC-2020ES contact inputs and outputs. Two types of modules are available. A low current module (CEM-2020) provides 24 contact outputs and high current module (CEM-2020H) provides 18 contact outputs.
  • Page 190 Tested in close proximity to an unshielded, unsuppressed Altronic DISN 800 ignition system. HALT (Highly Accelerated Lift 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 191: Functional Description

    The CEM-2020 provides 24 programmable contact outputs with the same functionality as the contact outputs on the DGC-2020ES. Outputs 5 through 16 can carry 1 A. Outputs 17 through 28 can carry 4 A. The label text of each contact output is customizable.
  • Page 192 See Figure 84 for CEM-2020 overall dimensions. All dimensions are shown in inches with millimeters in brackets. Figure 84. CEM-2020 Overall Dimensions See Figure 85 for CEM-2020H overall dimensions. All dimensions are shown in inches with millimeters in brackets. CEM-2020 DGC-2020ES...
  • Page 193 The connectors and headers are uniquely keyed to ensure that the connectors mate only with the correct headers. Connector screw terminals accept a maximum wire size of 12 AWG (3.31 mm ). Maximum screw torque is 5 inch-pounds (0.56 N•m). DGC-2020ES CEM-2020...
  • Page 194 To follow UL guidelines, a fuse must be implemented in the 2Adc contact circuits (Outputs 5 through 16) of the CEM-2020H used in hazardous locations. The suggested fuse size in Adc = (100/Contact Voltage) with a maximum fuse size of 5Adc. CEM-2020 DGC-2020ES...
  • Page 195 9469200990 Rev B Figure 86. CEM-2020 Contact Input and Contact Output Terminals DGC-2020ES CEM-2020...
  • Page 196 These terminals provide communication using the SAE J1939 protocol and provide high-speed communication between the Contact Expansion Module and the DGC-2020ES. Connections between the CEM-2020 and DGC-2020ES should be made with twisted-pair, shielded cable. CAN interface terminals are listed in Table 33. Refer to Figure 88 and Figure 89.
  • Page 197 Figure 88. CAN Interface with CEM-2020 providing One End of the Bus CEM-2020 (Optional) Stub CAN-H DGC-2020ES Engine CAN-L P0067-85 120 ohm 120 ohm Other Termination Termination Devices Figure 89. CAN Interface with DGC-2020ES providing One End of the Bus DGC-2020ES CEM-2020...

  • Page 198: Remote Contact Input Configuration

    The Remote Contact Outputs screen is found in the BESTCOMSPlus Settings Explorer under the Programmable Inputs category. If using the front panel, navigate to Settings > Programmable Outputs > Configurable Outputs. The BESTCOMSPlus Contact Outputs screen is illustrated in Figure 91. CEM-2020 DGC-2020ES...

  • Page 199: Maintenance

    Preventive maintenance consists of periodically checking that the connections between the CEM-2020 and the system are clean and tight. Contact Expansion Modules are manufactured using state-of-the-art surface-mount technology. As such, Basler Electric recommends that no repair procedures be attempted by anyone other than Basler Electric personnel.
  • Page 200 9469200990 Rev B CEM-2020 DGC-2020ES...

  • Page 201: Mtu Fault Codes

    METERING, ALARMS-STATUS, MTU FAULT CODES. Each fault code is displayed with a fault description and the fault number. If the DGC-2020ES does not have descriptive information about a fault number that was received, the fault description will display as “NO TEXT AVAILABLE”.
  • Page 202 INVLD FUEL CNS 1 Fuel consumption counter detect. INVLD FUEL CNS 2 Consumption monitoring 2 not valid. ENG HRS INVALID 1 Engine Hours Counter defect. ENG HRS INVALID 2 Checksum fault. ERR REC1 INVALID Checksum fault. MTU Fault Codes DGC-2020ES...
  • Page 203 CAN controller 1 is in “Bus Off” state. AL CAN1 ERR PASSV CAN controller 1 has signaled a warning. AL CAN2 BUS OFF CAN controller 2 is in “Bus Off” state. AL CAN2 ERROR PASSV CAN controller 2 has signaled a warning. DGC-2020ES MTU Fault Codes...
  • Page 204 Missing data CAN. SD CAN TST OVRSP Missing data CAN. SD CAN ENGAGE SIG Missing data CAN. SD CAN CYL CUTOUT Missing data CAN. SD CAN LOCAL Missing data CAN. SD CAN RCS ENGAGE Missing data CAN. MTU Fault Codes DGC-2020ES...
  • Page 205 Error in timing of injector cylinder A10: timing value too low/high. TIMING CYLNDR B1 Error in timing of injector cylinder B1: timing value too low/high. TIMING CYLNDR B2 Error in timing of injector cylinder B2: timing value too low/high. DGC-2020ES MTU Fault Codes...
  • Page 206 OPN LD CYLNDR B2 Open load in injector cable of cylinder B2. OPN LD CYLNDR B3 Open load in injector cable of cylinder B3. OPN LD CYLNDR B4 Open load in injector cable of cylinder B4. MTU Fault Codes DGC-2020ES...
  • Page 207 Open load on input for emergency stop. LO U PDU Power driver voltage (injectors) too low (limit 1). LOLO U PDU Power driver voltage (injectors) too low (limit 2). HI U PDU Power driver voltage (injectors) too high (limit 1). DGC-2020ES MTU Fault Codes...
  • Page 208 AL WIRING POM STARTER 1 A wiring fault has been detected in the connection of starter 1 of POM. AL WIRING POM STARTER 2 A wiring fault has been detected in the connection of starter 2 of POM. MTU Fault Codes DGC-2020ES...
  • Page 209 ECU configuration changed, switch power off/on. AL SMARTCONCT USB ERR Alarm configuration parameter. AL SMARTCONCT RS485 ERR Alarm configuration parameter. AL SD STOP BUTTON STR Channel signals open load or internal error. AL SD START BUTTON STR Channel signals open load. DGC-2020ES MTU Fault Codes...
  • Page 210 Channel signals open load. AL SD EXT INC IDLE BIN STR Channel signals open load. AL SD EXT INC IDLE BIN BRK Channel signals open load. AL SD RQST PLANT DBR STR Channel signals open load. MTU Fault Codes DGC-2020ES...

  • Page 211: 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 212 9469200990 Rev B 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 213: Exhaust After-Treatment Systems (Eats)

    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Alarms-StatusJ1939 StatusDEF Tank2 LVL%.
  • Page 214 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 215: Diagnostic Trouble Codes

    For certain DTCs, if the DGC-2020ES recognizes a pair of SPN and FMI numbers, it displays a single string as listed in Table 36. If the DGC-2020ES recognizes an SPN in Table 36, but the FMI does not match the FMI in Table 36, then it displays the string from Table 36 corresponding to the table entry where the FMI is # and a second string corresponding to the FMI number listed in Table 37.
  • Page 216 Low Coolant Level string used in event log and/or Alarm and Prealarm annunciation Fuel Rail Prs Vlt HI Fuel Rail Pressure Input Voltage (High) Fuel Rail Prs Vlt LO Fuel Rail Pressure Input Voltage (Low) Fuel Rail Prs LOSS Fuel Rail Pressure Loss Detected Diagnostic Trouble Codes DGC-2020ES...
  • Page 217 Pump Pos Sns In ERR Pump Position Sensor Input Pattern Error Crank Pos Sns Noisy Crank Position Input Noise Crank Pos Sns Curr LO Crank Position Sensor Current (Low) Crank Pos Sns Curr HI Crank Position Sensor Current (High) DGC-2020ES Diagnostic Trouble Codes...
  • Page 218 Cylinder #6 EUI Circuit (Open) Cyl 6 EUI Ckt SHORT Cylinder #6 EUI Circuit (Shorted) Cyl 6 EUI Ckt MECH FL Cylinder #6 EUI Circuit (Mechanical Failure) Cyl 6 EUI QR INVLD Cylinder #6 EUI Circuit QR Code (Invalid) Diagnostic Trouble Codes DGC-2020ES...
  • Page 219 ENGINE REQSTED SPEED Caption String for Engine Requested Speed PWM OUTPUT Caption String for Engine PWM Output Aux Eng SD SW INVLD Auxiliary Engine Shutdown Switch (Invalid) Aux Eng SD SW ACTV Auxiliary Engine Shutdown Switch Active DGC-2020ES Diagnostic Trouble Codes...
  • Page 220 Caption String for Misfire detected on a single engine cylinder 1336 MISFIRE CYLINDER 14 Caption String for Misfire detected on a single engine cylinder 1337 MISFIRE CYLINDER 15 Caption String for Misfire detected on a single engine cylinder Diagnostic Trouble Codes DGC-2020ES...
  • Page 221 Exhaust Gas Recirculation Valve Control Error 2791 EGR Valve Cal ERR Exhaust Gas Recirculation Valve Calibration Error 2791 EGR VALVE CONTROL Caption String for EGR Valve Control 2795 Trbo Act Pos MSMATCH Turbo Actuator Position Mismatch DGC-2020ES Diagnostic Trouble Codes...
  • Page 222 ECU ERROR String for Diagnostic Trouble Code Indicating ECU Error 523602 FAN SPEED Caption String for Engine Fan Speed 523604 RXENGTMP CAN MSG Caption String for CAN Message 523605 TSC1-AE MSG MISSING Caption String for CAN Message Diagnostic Trouble Codes DGC-2020ES...
  • Page 223 Caption String for Metering Unit Valve 523617 ECU ERROR String for Diagnostic Trouble Code Indicating ECU Error Table 37. DTCs Displayed by the DGC-2020ES (FMI Strings) String Displayed Description DATA HI MOST SEVERE Data is higher than expected at the most severe level...
  • Page 224 9469200990 Rev B Diagnostic Trouble Codes DGC-2020ES...

  • Page 225: Revision History

    9469200990 Rev B Revision History Table 38 provides a historical summary of the changes made to the DGC-2020ES hardware. Firmware changes are listed in Table 39 and software changes are listed in Table 40. The corresponding revisions made to this instruction manual are summarized in Table 41. Revisions are listed in chronological order.
  • Page 226 9469200990 Rev B Revision History DGC-2020ES...
  • Page 228 15-06 Peninsula Plaza Tel: +1 618.654.2341 FRANCE 215122 Suzhou Singapore 179098 Fax: +1 618.654.2351 Tel: +33 3.88.87.1010 P.R. CHINA Tel: +65 68.44.6445 email: info@basler.com Fax: +33 3.88.87.0808 Tel: +86 512.8227.2888 Fax: +65 68.44.8902 email: franceinfo@basler.com Fax: +86 512.8227.2887 email: singaporeinfo@basler.com email:...

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