1. Manuals
  2. Brands
  3. Basler Manuals
  4. Controller
  5. DGC-2020HD
  6. Instruction manual

Basler DGC-2020HD Instruction Manual

Digital genset controller
Hide thumbs Also See for DGC-2020HD:
1
2
3
4
Table Of Contents
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
Table of Contents

Advertisement

Quick Links

Download this manual
INSTRUCTION MANUAL
FOR
DGC-2020HD
DIGITAL GENSET CONTROLLER
Publication: 9469300990
Revision: B
Mar-14

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the DGC-2020HD and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Basler DGC-2020HD

Summary of Contents for Basler DGC-2020HD

  • Page 1 INSTRUCTION MANUAL DGC-2020HD DIGITAL GENSET CONTROLLER Publication: 9469300990 Revision: B Mar-14...

  • Page 3: Conventions Used In This Manual

    9469300990 Rev B Preface This instruction manual provides information about the installation and operation of the DGC-2020HD Digital Genset Controller. To accomplish this, the following information is provided: • Controls and indicators • Inputs and outputs • Protection and control functions •...
  • Page 4 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 5: Table Of Contents

    Nominal Voltage Input and Acceptable Range of Input Voltage ............. 51 Terminal Assignments ..........................51 Power Consumption ..........................51 Battery Ride-Through Capability ......................51 Fuse Protection ............................51 Voltage and Current Sensing ........................53 Generator Voltage ........................... 53 DGC-2020HD Contents...
  • Page 6 AVR Output ............................119 Governor Output ............................ 120 Load Share Output ..........................121 Parameter Selection ..........................121 Demand Start/Stop ..........................121 Generator Sequencing .......................... 123 Network Configuration ........................... 125 Generator Protection ..........................127 Undervoltage (27) ..........................127 Overvoltage (59) ............................ 129 Contents DGC-2020HD...
  • Page 7 Trending ..............................181 Alarms..............................182 BESTCOMSPlus® Software ........................193 System Recommendations ........................194 Installation ............................. 194 Activate the DGC-2020HD Plugin for BESTCOMSPlus® ..............194 Menu Bars ............................. 198 Settings Explorer ........................... 199 Metering Explorer ..........................200 BESTspace™ ............................200 Settings File Management ........................201 Auto Export Metering ..........................
  • Page 8 Connections ............................306 AEM-2020 Configuration ........................312 Remote Analog Inputs Configuration ....................312 Remote RTD Inputs Configuration ......................315 Remote Thermocouple Inputs Configuration ..................317 Remote Analog Outputs Configuration ....................319 Firmware Updates ..........................322 Repair ..............................322 Contents DGC-2020HD...
  • Page 9 Tuning Procedures ..........................362 Generic Gains for Multiple Machine Types ................... 366 MTU Fault Codes ............................. 367 Exhaust Treatment ..........................377 Diesel Particulate Filter (DPF) ....................... 377 Exhaust After-Treatment Systems (EATS).................... 379 Diagnostic Trouble Codes ........................381 Revision History ............................391 DGC-2020HD Contents...
  • Page 10 9469300990 Rev B viii Contents DGC-2020HD...

  • Page 11: Introduction

    2020HD operation. A backlit liquid crystal display (LCD) can be viewed under a wide range of ambient light and temperature conditions. Basler Electric communication software (BESTCOMSPlus®) allows units to be easily customized for each application. Because of the low sensing burden in the DGC-2020HD, dedicated potential transformers (PTs) are not required.

  • Page 12: Event Recording

    Expansion Module. Contact Basler Electric for ordering information. Automatic Transfer Switch Control (Mains Failure) The DGC-2020HD has the ability to detect a mains failure via a single- or three-phase Bus input. A mains failure is established when any one of the following conditions are met: •...
  • Page 13 SAE J1939 Protocol - Oil pressure, coolant temperature, and engine speed data are received from the ECU. In addition, DTCs (Diagnostic Trouble Codes) help diagnose any engine-related failures. The engine DTCs are displayed on the front panel of the DGC-2020HD and may be obtained using BESTCOMSPlus® software.

  • Page 14: Style Number

    The optional CEM-2020 provides 10 additional contact inputs and 18 or 24 additional output contacts (depending on module type) to the DGC-2020HD. The CEM-2020 communicates with the DGC-2020HD through a CAN interface. Up to four CEM-2020s may be used with one DGC-2020HD. Refer to the CEM- 2020 chapter for more information.

  • Page 15: Specifications

    9469300990 Rev B Specifications DGC-2020HD electrical and physical characteristics are listed in the following paragraphs. Operating 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 16: Analog Sensing

    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 Voltage Sensing Rating ..........

  • Page 17: 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. Values outside these ranges are deemed “failed” and the DGC-2020HD will begin timing towards a sender failure condition.

  • Page 18: Metering

    Accuracy........... ±2% of the full-scale indication or ±2 kVA *† kVA metering indicates 0 kVA when the generator kVA is below 2% of the full-scale rating. Applies when temperature is between −40°C to +70°C (–40°F to +158°F). † Specifications DGC-2020HD...
  • Page 19 † 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. Real Power...

  • Page 20: Generator Protection Functions

    Pickup Range ........0.18 to 4 Aac (1 A current sensing) 0.9 to 20 Aac (5 A current sensing) Hysteresis......... 2 % Time Dial Range ......0 to 7,200 s (fixed time curve) 0 to 9.9 (inverse curve time multiplier) Specifications DGC-2020HD...

  • Page 21: Logic Timers

    CAN 2 Terminals ......54 (low), 55 (high), and 53 (shield) Notes If the DGC-2020HD is providing one end of the J1939 bus, a 120 Ω, ½ watt terminating resistor should be installed across terminals 51 (CAN1L) and 52 (CAN1H) and/or 54 (CAN2L) and 55 (CAN2H).

  • Page 22: Real-Time Clock

    Connector Type Mini-B jack Real-Time Clock Clock has leap year and selectable daylight saving time correction. Backup battery sustains timekeeping during losses of DGC-2020HD operating power. Resolution ........1 s Accuracy........... ±1.73 s/d at 25°C (77°F) Clock Holdup Battery Holdup Time ......Approximately 10 yrs Battery Type ........

  • Page 23: Lcd Heater

    25 to 2,000 Hz ........at 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 24: Ul Approval

    • CSA C22.2 No. 14 The DGC-2020HD ground fault protection circuit complies with the Calibration and Withstand tests of UL 1053; as required by UL6200. (See the Time Curve Characteristics chapter for the listing of curves verified to meet UL1053.)

  • Page 25: 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 26 9469300990 Rev B Figure 3. Overall Dimensions Mounting DGC-2020HD...

  • Page 27: Terminals And Connectors

    9469300990 Rev B 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 28: Terminals

    See the Timekeeping 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 Be sure that the DGC-2020HD is hard-wired to earth ground with no smaller than 12 AWG (3.31 mm...

  • Page 29: Generator Current Sensing

    DGC-2020HD will not operate. Operating power terminals are listed in Table 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 30: Generator Voltage Sensing

    Neutral generator voltage sensing input 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. The DGC-2020HD accepts either line-to-line or line-to-neutral bus sensing voltage over the range of 0 to 576 volts, rms line-to-line or 0 to 333 volts, rms line-to-neutral.

  • Page 31: Magnetic Pickup Input

    While input 1 is programmed to recognize an emergency stop input by default, it can be programmed for any function. Information about configuring the programmable inputs is provided in the Contact Inputs chapter. Contact sensing input terminals are listed in Table 10. DGC-2020HD Terminals and Connectors...
  • Page 32 Programmable contact input 16 Output Contacts The DGC-2020HD has three sets of fixed-function output contacts: Pre, Start, and Run. 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. Connections to the three sets of contacts are made at terminals 19 through 24.
  • Page 33 2020HD. RS-485 Interface DGC-2020HD controllers can be monitored and controlled via a polled network using the Modbus™ protocol. The RS-485 port supports a user-selectable baud rate of 1,200, 2,400, 4,800, 9,600, 19,200, 38,400, 57,600, or 115,200. Seven or eight data bits per character can be selected. Odd, even, or no...

  • Page 34: Irig-B Connections

    9469300990 Rev B parity is supported. One or two stop bits are selectable. Modbus register values for the DGC-2020HD are listed and defined in Basler Publication 9469300991, Instruction Manual for DGC-2020HD Digital Genset Controller Modbus™ Protocol. RS-485 interface terminals are listed in Table 14.

  • Page 35: Optional Remote Display Panel Connections

    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).
  • Page 36 9469300990 Rev B Terminals and Connectors DGC-2020HD...

  • Page 37: Typical Applications

    9469300990 Rev B 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 operating power. Connections for Typical Applications Typical connections for applications which use three-phase wye, three-phase delta, single-phase A-B, and single-phase A-C generator voltage sensing are shown on the following pages.
  • Page 38 Governor Raise INPUT 16 Connect to the ECU on an electronically controlled engine. INPUT 15 If component is under ECU control, do not connect to DGC-2020HD. OUT 10 Mains Bkr Status INPUT 14 Connect to CAN 1 (AEM-2020 / CEM-2020 network) only.
  • Page 39 OUT 9 INPUT 16 Connect to the ECU on an electronically controlled engine. INPUT 15 If component is under ECU control, do not connect to DGC-2020HD. OUT 10 Mains Bkr Status INPUT 14 Connect to CAN 1 (AEM-2020 / CEM-2020 network) only.
  • Page 40 OUT 9 INPUT 16 Connect to the ECU on an electronically controlled engine. INPUT 15 If component is under ECU control, do not connect to DGC-2020HD. OUT 10 Mains Bkr Status INPUT 14 Connect to CAN 1 (AEM-2020 / CEM-2020 network) only.
  • Page 41 Connect to the ECU on an electronically controlled engine. Mains Bkr Status INPUT 14 OUT 11 If component is under ECU control, do not connect to DGC-2020HD. Gen Bkr Status INPUT 13 OUT 12 Connect to CAN 1 (AEM-2020 / CEM-2020 network) only.

  • Page 42: Connections For Load Sharing

    Figure 9 illustrates a typical interconnection of two systems tied together using analog and Ethernet load share lines. LOAD Bus Metering Bus Metering Breaker Control Breaker Control Generator Generator Breaker Breaker DGC-2020HD DGC-2020HD Generator Metering Generator Metering AVR + AVR + AVR – AVR – GOV + GOV + GOV –...

  • Page 43: Analog Input Connections

    Typical CAN connections are shown in Figure 11 and Figure 12 Note If the DGC-2020HD is providing one end of the J1939 bus, a 120 Ω, ½ watt terminating resistor should be installed across terminals 51 (CAN1L) and 52 (CAN1H) or 54 (CAN2L) and 55 (CAN2H).
  • Page 44 CAN 2 Bus Stub CAN-H Engine CAN-L 120 ohm 120 ohm Termination Termination P0071-62 Figure 11. CAN Interface with DGC-2020HD Providing One End of the Bus 120 ohm Termination CAN 1 Bus CEM-2020 AEM-2020 CAN-H (Optional, (Optional, up to 4)

  • Page 45: Expansion Module Connections (Can 1)

    The AEM-2020 (Analog Expansion Module) and CEM-2020 (Contact Expansion Module) are optional modules that may be installed 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, and CEM-2020.
  • Page 46 9469300990 Rev B Typical Applications DGC-2020HD...

  • Page 47: Controls And Indicators

    9469300990 Rev B Controls and Indicators DGC-2020HD controls and indicators are located on the front panel and are intended for local control and monitoring of DGC-2020HD operation. Front panel controls consist of sealed membrane pushbuttons. Front panel indicators consist of LED (light emitting diode) indicators and a backlit LCD (liquid crystal display).
  • Page 48 Display operation is maintained down to –40°F (−40°C). Not in Auto Indicator. This red LED lights when the DGC-2020HD is not operating in Auto mode. Alarm Indicator. This red LED lights continuously during alarm conditions and flashes during pre-alarm conditions.

  • Page 49: Programmable Indicator Configuration

    Remove all control power from the DGC-2020HD. Remove the fasteners from the four mounting studs on the DGC-2020HD and separate it from the mounting panel or optional escutcheon plate. Disconnect the nine terminal block connectors; the Start, Run, and Pre relays; and the Ethernet (copper or fiber), USB, and DB-9 connectors.

  • Page 50: Display Operation And Navigation

    Login and Permissions When attempting to change a protected setting, the DGC-2020HD displays the Login Required screen. To log in, use the Up/Down arrow keys to scroll through the characters. Use the Left/Right arrow keys to enter more characters.
  • Page 51 Bus1 Current Phase B Generator average voltage • • Bus1 Current Phase C Generator complex power Phase A • • Bus1 Dead Generator complex power Phase B • • Bus1 Failed Generator complex power Phase C DGC-2020HD Controls and Indicators...
  • Page 52 Bus2 Stable Number of units online • • Bus2 total complex power Off Mode Cooldown • • Bus2 total power factor Oil Pressure • • Bus2 Total vars Oil Temperature • • Bus2 Total Watts PF Mode Controls and Indicators DGC-2020HD...

  • Page 53: Sleep Mode

    Sleep mode de-energizes the LCD backlight and heater when no pushbutton activity is detected for the duration of the LCD Backlight Timeout delay. To enter sleep mode, the DGC-2020HD must be 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 54 Cummins, MTU ADEC, MTU SMC DTC Active Data (Visible when DTC support is enabled) DTC Prev Data (Visible when DTC support is enabled) Gen Network Status Gen Sequencing Status Real Time Clock • Event Log Show Log Reset Controls and Indicators DGC-2020HD...
  • Page 55 Data Log Trending • Protection Settings Group 0 Settings Group 1 Settings Group 2 Settings Group 3 Configurable Protection • Breaker Management Breaker Hardware Bus Condition Synchronizer • Bias Control AVR Bias Control GOV Bias Control DGC-2020HD Controls and Indicators...
  • Page 56 The one-line diagram appears on both the front panel Overview and Summary screens. The Summary screen provides metering for generator and bus parameters as well as breaker controls. The one-line diagram is displayed at the top, generator and bus parameters are displayed below that, and breaker Controls and Indicators DGC-2020HD...
  • Page 57 Figure 18. One-Line Diagram Breaker and Bus States Generator Network Status Display The status of the generator network is available on the front panel of each DGC-2020HD when the ® generator is part of a multi-machine network. The System Type setting (found in the BESTCOMSPlus Settings Explorer, System Parameters, System Settings) configures the machine to be part of a multi- machine network.

  • Page 58: Display Setup

    Front Panel Navigation Path: Settings > General Settings > Front Panel HMI The DGC-2020HD 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 59: Language Selection

    Enabled or Disabled LCD Backlight Timeout 1 to 120 minutes English, French, Language Selection Spanish, or German Enable Scroll Enabled or Disabled Scroll Time Delay 1 to 600 varies seconds Phase Toggle Delay 0 to 120 seconds DGC-2020HD Controls and Indicators...
  • Page 60 9469300990 Rev B Controls and Indicators DGC-2020HD...

  • Page 61: Power Input

    9469300990 Rev B Power Input Operating 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 62 9469300990 Rev B Power Input DGC-2020HD...

  • Page 63: Voltage And Current Sensing

    Neutral generator voltage sensing input Bus Voltage 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).
  • Page 64 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 65: 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-2020HD to indicate a failed sender.
  • Page 66 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-2020HD. Figure 20. Settings Explorer, Programmable Senders, Fuel Level Screen Table 26.
  • Page 67 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-2020HD. Figure 21. Settings Explorer, Programmable Senders, Oil Pressure Screen Table 27.
  • Page 68 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-2020HD. Figure 22. Settings Explorer, Programmable Senders, Coolant Temperature Screen Table 28.

  • Page 69: Sender Failure Detection

    9469300990 Rev B Sender Failure Detection The DGC-2020HD 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. Loss of signal is determined differently for resistive senders than for analog senders.
  • Page 70 9469300990 Rev B Locator Setting Range Increment Unit Status Only, Pre- Alarm Configuration Alarm, or Alarm Activation Delay 0 to 300 seconds Activation Delay 0 to 300 seconds Engine Sender Inputs DGC-2020HD...

  • Page 71: 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 72 9469300990 Rev B Speed Signal Inputs DGC-2020HD...

  • Page 73: Contact Inputs

    9469300990 Rev B Contact Inputs Contact inputs are available to initiate DGC-2020HD functions. The DGC-2020HD has sixteen programmable contact sensing inputs. Additional contact inputs can be accommodated with up to four optional CEM-2020s (Contact Expansion Module). Contact Basler Electric for availability and ordering information.
  • Page 74 Table 30. Settings for Contact Inputs Screen Locator Setting Range Increment Unit Status Only, Pre- Alarm Configuration Alarm, or Alarm Activation Delay 0 to 300 seconds Up to 16 Label Text alphanumeric characters Always or While Contact Recognition Engine Running Only Contact Inputs DGC-2020HD...

  • Page 75: Programmable Functions

    Single-Phase Override - The unit switches to single-phase sensing configuration and uses the Single Phase Override Sensing setting (A-B or A-C). • Single-Phase A-C Override - Indicates to the DGC-2020HD that the machine is configured for single-phase A-C. This is to be used in conjunction with the single-phase override programmable function.
  • Page 76 Unit Contact Inputs 1 to 16 or Input None Always or While Engine Contact Recognition Running Only Single Phase Override A-B or A-C Sensing Status Only, Pre-Alarm, or Alarm Configuration Alarm Activation Delay 0 to 300 seconds Contact Inputs DGC-2020HD...

  • Page 77: Analog Inputs

    DGC-2020HD units with the resistive sender option (style number xxxxxxxxR) are equipped with two analog inputs whereas units with the analog sender option (style number xxxxxxxxA) are equipped with four.

  • Page 78: Alarm Configuration

    Analog input protection operational settings are configured on the Analog Input #x (where x = 1 to 4 (3 and 4 optional)) settings screen (Figure 26) in BESTCOMSPlus. Settings are listed in Table 32. Figure 26. Settings Explorer, Programmable Inputs, Analog Inputs, Analog input #1 Analog Inputs DGC-2020HD...

  • Page 79: Logic Connections

    Analog input protection logic connections are made on the BESTlogicPlus screen in BESTCOMSPlus. The Analog Input 1, Threshold 1 logic block is illustrated in Figure 27. The output is true during a trip condition. The alarm and pre-alarm logic blocks are similar. Figure 27. Analog Input Protection Logic Block DGC-2020HD Analog Inputs...
  • Page 80 9469300990 Rev B Analog Inputs DGC-2020HD...

  • Page 81: Contact Outputs

    Prestart output connections are made through terminals located on the Prestart relay. See the Terminals and Connectors chapter for the location of the Prestart relay on the rear panel of the DGC-2020HD. Start This output closes when engine cranking is initiated by the DGC-2020HD and opens when the magnetic pickup (MPU) or generator frequency indicates that the engine has started.

  • Page 82: Programmable Contact Outputs

    Figure 29. Example Logic Scheme of Programmable Relays Programmable Contact Outputs DGC-2020HD controllers have 12 programmable output contacts (OUT 1 through 12). 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. Up to four CEM-2020s or CEM-2020Hs, in any combination, are supported by the DGC-2020HD.

  • Page 83: 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-2020HD event log. Elements can be recognized always or only while the engine is running. Configurable element status is available in BESTlogicPlus Programmable Logic when “Status Only”...
  • Page 84 Table 33. Settings for Configurable Elements Locator Setting Range Increment Unit Status Only, Pre- Alarm Configuration Alarm, or Alarm Activation Delay 0 to 300 seconds Up to 16 Label Text alphanumeric characters Always or While Contact Recognition Engine Running Only Contact Outputs DGC-2020HD...

  • Page 85: Operating Modes

    In OFF mode, the DGC-2020HD will not start under any circumstance. It cannot be started automatically. Programmable logic functions normally in this mode. In RUN (manual) mode, the DGC-2020HD 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 86 9469300990 Rev B Operating Modes DGC-2020HD...

  • Page 87: Breaker Management

    Initial System Setup Connect the DGC-2020HD according to the appropriate figure in the Typical Applications chapter for the type of generator connection desired (wye, delta, etc.). Set up the basic system parameters that will govern engine operation and alarm and pre-alarm annunciation. Details can be found in the Configuration and Reporting and Alarms chapters.
  • Page 88 Generator and Mains Breaker Control system breaker configurations consist of two breakers controlled by the DGC-2020HD. Figure 35 illustrates a Generator And Mains Breaker Control system breaker configuration without optional load bus metering. Figure 36 illustrates the one-line diagram of the Generator And Mains Breaker Control system breaker configuration as it appears in the BESTCOMSPlus System Settings screen.
  • Page 89 Control Output Metering Control Output Bus 2 Bus 1 DGC-2020HD P0071-76 Figure 37. System Breaker Configuration: Generator and Mains Breaker Control with Optional Load Bus Metering Figure 38. System Breaker Configuration: Generator and Mains Breaker Control with Optional Load Bus...
  • Page 90 After a breaker open or close failure occurs, the DGC-2020HD can attempt to reopen or reclose the breaker a pre-defined number of times. The number of attempts to open or close the breaker and the duration of time between each attempt are user-programmable.
  • Page 91 For generator and mains breaker configurations, the DGC-2020HD can automatically transfer load power from the mains to the genset during a mains failure. This feature also enables the DGC-2020HD to transfer the load back to the mains once mains power is restored.
  • Page 92 Mains Breaker Open Configuration setting. After the mains breaker is open the DGC-2020HD closes its generator breaker to drive the load. When the mains power returns, after the Mains Fail Return Delay time expires, the generator synchronizes to the utility and closes the mains breaker, paralleling the generator to the utility.
  • Page 93 Transfer Fail Alarm is annunciated and the generator is shut down. If the Alarm State Transfer to Mains setting is enabled, the DGC-2020HD can transfer the load to a stable utility when in the alarm state. If this setting is disabled, the DGC-2020HD will not perform any transitions of the load to or from the utility when in the alarm state.
  • Page 94 The following paragraphs provide instructions for setting up the generator and mains breakers in BESTlogicPlus. Generator Breaker a. Drag the Gen Breaker (GENBRK) element into the logic diagram. b. Connect the breaker element open and close outputs to the contact outputs that will drive the breaker. Breaker Management DGC-2020HD...
  • Page 95 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-2020HD if connected, or save the settings file if working off line. Figure 41. Settings Explorer, BESTlogicPlus Programmable Logic...

  • Page 96: Bus Condition Detection

    "stable". Otherwise, it is deemed "failed". Caution The bus condition parameters are critical. They determine when a breaker can be closed. Breaker Management DGC-2020HD...
  • Page 97 Dead Gen Threshold Per Unit based on nominal per unit Dead Gen Activation Delay 0.1 to 600 seconds Gen Failed Activation Delay 0.1 to 600 seconds Overvoltage and Undervoltage Settings Pickup (V L-L) Volts 10 to 99,999 volts DGC-2020HD Breaker Management...

  • Page 98: Breaker Operation

    Factor Breaker Operation The DGC-2020HD attempts to close a breaker only after verifying that it can be closed. If the breaker cannot be closed, the close request is ignored. Only one breaker can be closed at a time. Synchronization is required before closing the breaker to a live bus. Closure to a dead bus can be performed after meeting dead bus threshold and timing requirements set by the user.
  • Page 99 Before the generator breaker can be closed, Generator Breaker Control must be selected. If the generator breaker is already closed, the DGC-2020HD still attempts to close the breaker. It is assumed that since the breaker is already closed, the closure conditions have already been met.
  • Page 100 Dead Gen Close Enable setting Enabled Is Load Is Load Bus Bus stable? dead? Disabled Dead Bus Close Synchronize buses Enable setting Enabled Close Generator Cannot Close Breaker Generator Breaker P0071-74 Figure 43. Generator Breaker Closure Conditions Flow Diagram Breaker Management DGC-2020HD...
  • Page 101 Mains Breaker Control with Load Bus must be selected. If the generator breaker is already closed, the DGC-2020HD still attempts to close the breaker. It is assumed that since the breaker is already closed, the closure conditions have already been met.
  • Page 102 Disabled Dead Bus Close Synchronize buses Enable setting Enabled Cannot Close Close Generator Cannot Close Generator Breaker Breaker Generator Breaker P0071-77 Figure 44. Generator Breaker Closure Conditions Flow Diagram (without Optional Load Bus Metering) Breaker Management DGC-2020HD...
  • Page 103 9469300990 Rev B Mains Breaker Closure Conditions The conditions under which the DGC-2020HD will close the mains breaker are described in the following paragraphs. A flow diagram (Figure 45) is provided to show the conditions under which the mains breaker will close.
  • Page 104 Live Bus Close Generator Enable Setting breaker state Enabled Open Perform sync check Are buses synchronized? Cannot Close Cannot Close Close Mains Breaker Close Mains Breaker Mains Breaker Mains Breaker P0071-73 Figure 45. Mains Breaker Closure Conditions Flow Diagram Breaker Management DGC-2020HD...
  • Page 105 The GENBRK and MAINSBRK logic blocks contain both Open and Close logic outputs that can be configured to energize an output contact, which would in turn operate the breaker. The Breaker Hardware screen in BESTCOMSPlus is used to set the output contact type to pulses or continuous. DGC-2020HD Breaker Management...
  • Page 106 9469300990 Rev B Breaker Management DGC-2020HD...

  • Page 107: Synchronizer

    Breaker Close commands initiated through the front panel of the DGC-2020HD. Any of the above close sources work when the DGC-2020HD is in AUTO mode. Only the Manual Breaker Close Input Contacts can initiate a breaker closure when the DGC-2020HD is in RUN mode.
  • Page 108 AB L-L voltages on the generator side of the breaker must be wired to the GEN VA and GEN VB terminals on the DGC-2020HD. The phase AB L-L voltages on the bus side of the breaker (the bus to which the generator will be connected when the breaker is closed) must be wired to the BUS VA and BUS VB terminals on the DGC-2020HD.

  • Page 109: Configuration

    If using a contact expansion module (CEM-2020) to control the governor or voltage regulator, open the Remote Module Setup screen in the Settings Explorer, under System Parameters. Skip this step if the DGC-2020HD’s available contact outputs for AVR and GOV control are being used. See Figure DGC-2020HD...
  • Page 110 Gen Breaker” into the label text field of Input #9. Enter “Close Gen Breakr” into the label text field of Input #10. Finally, enter “Breaker Status” into the label text field of Input #13. Up to 16 alphanumeric characters are accepted by a label text field. See Figure 48. Synchronizer DGC-2020HD...
  • Page 111 Open the Contact Outputs screen in the Settings Explorer, under Programmable Outputs. Select and label the appropriate outputs for Breaker Close and Breaker Open. If using contact outputs on the DGC-2020HD for Governor and Voltage Regulator control, the contact output can be labeled here as well. See Figure 49.
  • Page 112 If the mains breaker is configured, set the breaker closing time. This is the time used by the anticipatory synchronizer to calculate the advance angle before 0 degrees slip angle at which to issue the breaker close command. Synchronizer DGC-2020HD...
  • Page 113 The Gen Condition Detection screen can be found in the Settings Explorer, under the Breaker Management, Bus Condition Detection category and is illustrated in Figure 51. The Bus 1 Condition Detection and optional Bus 2 Condition Detection screens are also found in the Bus Condition Detection category. DGC-2020HD Synchronizer...
  • Page 114 “failed”. When the voltage and frequency are outside the stable ranges for the duration of the Gen Failed Activation Delay, the generator is deemed “failed”. Open the Synchronizer screen in the Settings Explorer, under Breaker Management. See Figure 52. Synchronizer DGC-2020HD...
  • Page 115 If the sync fail delay expires before the breaker closure occurs, a Sync Fail pre-alarm is annunciated, but the synchronizer continues to run to allow the breaker to be closed manually if desired. The Sync Fail Delay should be set to allow ample time for synchronization and breaker closure to occur. DGC-2020HD Synchronizer...
  • Page 116 Min Output Current (mA) and Max Output Current (mA) - If the Output Type is Current, these parameters must be configured. Set the minimum and maximum current to a range equal to Synchronizer DGC-2020HD...
  • Page 117 Explorer, under Multigen Management. These parameters are identical to those of the AVR output, and should be set in a similar manner. Set up programmable logic to allow the DGC-2020HD to synchronize the generator and close the generator breaker. In BESTlogicPlus Programmable Logic, click on the Elements tab and drag the GENBRK (Generator Breaker) element into the main logic screen.
  • Page 118 Click on the I/O tab and drag the inputs assigned in step 3, above, into the main logic screen. Connect them to the appropriate inputs of the GENBRK block. Drag the outputs assigned in step 4 into the main logic screen and connect them to the appropriate outputs of the GENBRK block. See Figure 56. Synchronizer DGC-2020HD...
  • Page 119 If using analog outputs to bias the voltage regulator and governor, no further setup is necessary. If using output contacts, they must be set up to drive these functions. In BESTlogicPlus programmable logic, click on the Elements tab. Drag the GOVR and AVR logic blocks into the main logic screen. See Figure 57. DGC-2020HD Synchronizer...
  • Page 120 Figure 57. Synchronizer Setup in BESTlogicPlus Step 14 Click on the I/O tab and drag the outputs assigned in step 4 into the main logic screen. Connect the GOVR and AVR blocks to the appropriate output contacts. See Figure 58. Synchronizer DGC-2020HD...
  • Page 121 9469300990 Rev B Figure 58. Synchronizer Setup in BESTlogicPlus Step 15 This concludes the implementation of the automatic synchronizer. DGC-2020HD Synchronizer...
  • Page 122 9469300990 Rev B Synchronizer DGC-2020HD...

  • Page 123: Bias Control

    When using the analog output type, a PID controller controls the voltage bias from the DGC-2020HD to the voltage regulator. The controller adjusts the bias output to drive the error between desired generator voltage and measured generator voltage to zero.
  • Page 124 Table 37. Settings for AVR Bias Control Locator Setting Range Increment Unit Panel Settings Bias Control Output Type Contact or Analog Proportional or Bias Control Contact Type Continuous Correction Pulse Width 0 to 99.9 seconds Correction Pulse Interval 0 to 99.9 seconds Bias Control DGC-2020HD...

  • Page 125: Governor Bias Control Settings

    Front Panel Navigation Path: Settings > Bias Control > Gov Bias Control When the bias control output type is set to contact, the DGC-2020HD adjusts the generator voltage and frequency by issuing speed correction signals to the generator governor. Correction signals are issued in the form of DGC-2020HD output contact closures.
  • Page 126 Figure 60. Settings Explorer, Bias Control Settings, Governor Bias Control Settings Table 38. Settings for Governor Bias Control Locator Setting Range Increment Unit Panel Settings Bias Control Output Type Contact or Analog Continuous or Bias Control Contact Type Proportional Bias Control DGC-2020HD...
  • Page 127 Base Load Level 0 to 100 User Setting or Aux Base Load Level Source Input 1 to 4 Base Load Analog Max 0 to 100 Base Load Analog Min 0 to 100 Breaker Open Setpoint 0 to 100 DGC-2020HD Bias Control...
  • Page 128 9469300990 Rev B Bias Control DGC-2020HD...

  • Page 129: Multiple Generator Management

    AVR Output The AVR output of the DGC-2020HD is used to change the voltage setpoint of the generator. If the response is set for increasing, an increased bias will raise the voltage. If the response is set for decreasing, an increased bias will lower the voltage.

  • Page 130: Governor Output

    9469300990 Rev B Governor Output The governor output of the DGC-2020HD is used to change the speed setpoint of the generator. If the response is set for increasing, an increased bias will increase the speed. If the response is set for decreasing, an increased bias will decrease the speed.

  • Page 131: Load Share Output

    Parameter Selection When it is not necessary for the DGC-2020HD to communicate with the AVR or GOV, these outputs may be utilized for other purposes. Selectable parameters are listed in the Configurable Protection chapter. Param Min corresponds to the minimum output voltage or current setting. Param Max corresponds to the maximum output voltage or current setting.
  • Page 132 For example, a power station normally has a 2,300 W load throughout the day, with an occasional 500 W power swing. Without spinning reserve, the DGC-2020HD starts only the number of generators needed to power the 2,300 W load. When the additional 500 W load is applied, another generator is started and when the additional load is removed, this same generator is shut down.

  • Page 133: Generator Sequencing

    If a mode mismatch occurs, verify that all machines on the network are configured for the same generator sequencing mode. Each DGC-2020HD maintains its own start/stop status with respect to sequencing. When there is a change to generator sequencing mode on any one unit, this change propagates to all connected units that are not in the disabled mode.
  • Page 134 ID. In this configuration, a network of units will respond to a demand start request by starting the unit with the smallest sequencing ID. Units must have unique sequencing IDs to be part of a network. The stopping order is the reverse of the starting order. Multiple Generator Management DGC-2020HD...

  • Page 135: Network Configuration

    ID Repeat pre-alarm is enabled on the Pre-Alarms settings screen, an ID Repeat pre-alarm appears on the front panel and the BESTCOMSPlus metering screen. The BESTCOMSPlus Network Configuration screen is illustrated in Figure 66. Figure 66. Settings Explorer, Multigen Management, Network Configuration DGC-2020HD Multiple Generator Management...
  • Page 136 9469300990 Rev B Multiple Generator Management DGC-2020HD...

  • Page 137: Generator Protection

    9469300990 Rev B Generator Protection Two tiers of generator protection are offered. DGC-2020HD controllers with style number xxSxxxxxx offer standard protection consisting of undervoltage (27), overvoltage (59), overfrequency (81O), underfrequency (81U), power (32), and loss of excitation (40Q) elements. Controllers with style number...

  • Page 138: Logic Connections

    The scale factor setting is implemented when the DGC-2020HD is determined to be in a low-line configuration. If the Low-Line Override function is assigned to a contact input via the Programmable Functions screen, the state of the contact input and the detected configuration are ORed.

  • Page 139: Overvoltage (59)

    Figure 68. Settings Explorer, Generator Protection, Voltage, Undervoltage Overvoltage (59) Six overvoltage protection (59) elements monitor the sensing voltage applied to the DGC-2020HD. An element can be configured to protect against overvoltage when the phase voltage increases above a defined level.
  • Page 140 The scale factor setting is implemented when the DGC-2020HD is determined to be in a low-line configuration. If the Low-Line Override function is assigned to a contact input via the Programmable Functions screen, the state of the contact input and the detected configuration are ORed.

  • Page 141: Phase Voltage Imbalance (47)

    2020HD. An element can be configured to protect against voltage imbalances between any of the three phases. This element is available only in styles xxExxxxxx of the DGC-2020HD. The six, identical phase voltage imbalance protection elements are designated 47-1, 47-2, 47-3, 47-4, 47-5, and 47-6.
  • Page 142 The scale factor setting is implemented when the DGC-2020HD is determined to be in a low-line configuration. If the Low-Line Override function is assigned to a contact input via the Programmable Functions screen, the state of the contact input and the detected configuration are ORed.

  • Page 143: Vector Shift (78)

    This prevents the generator from remaining tied to the mains if the mains returns due to an external reclose device. Vector Shift elements are available only in styles xxExxxxxx of the DGC-2020HD. The two, identical vector shift protection elements are designated 78-1 and 78-2. Element logic connections are made on the BESTlogic™Plus screen in BESTCOMSPlus®...
  • Page 144 When Open Mains Breaker on Trip is enabled, the DGC-2020HD will request the mains breaker to open when a 78 trip is annunciated. When Open Gen Breaker on Trip is enabled, the DGC-2020HD will request the generator breaker to open when a 78 trip is annunciated.

  • Page 145: Frequency (81)

    For all sensing connections, the frequency is measured through the DGC-2020HD A- and B-phase sensing voltage connections. To measure frequency, the voltage sensed by the DGC-2020HD must be greater than 10 Vac. The measured frequency is the average of two cycles of voltage measurement.
  • Page 146 BESTlogicPlus programmable logic. When the Alternate Frequency Override is true, the scale factor setting serves as a multiplier for the pickup settings. For example, if a scale factor contact input is received by the DGC-2020HD and the scale factor setting is 2.000, the pickup setting will be doubled (2.000 x PU).

  • Page 147: Frequency Rate-Of-Change

    Open Mains Breaker or Gen Breaker on Trip When Open Mains Breaker on Trip is enabled, the DGC-2020HD will request the mains breaker to open when an 81 trip is annunciated. When Open Gen Breaker on Trip is enabled, the DGC-2020HD will request the generator breaker to open when an 81 trip is annunciated.

  • Page 148: Overcurrent (51)

    Figure 76. Settings Explorer, Generator Protection, Frequency Overcurrent (51) Six overcurrent protection (51) elements monitor the current applied to the DGC-2020HD. An element can be configured to protect against overcurrent by monitoring a single- or three-phase system, neutral current, positive-sequence current, negative-sequence current, or ground current. This element is available only in styles xxExxxxxx of the DGC-2020HD.
  • Page 149 The Pickup setting is entered based on the CT secondary side (DGC-2020HD). When a single-phase override contact input is received, the DGC- 2020HD automatically switches from the three-phase overcurrent settings to the single-phase overcurrent settings.
  • Page 150 The scale factor setting is implemented when the DGC-2020HD is determined to be in a low-line configuration. If the Low-Line Override function is assigned to a contact input via the Programmable Functions screen, the state of the contact input and the detected configuration are ORed.
  • Page 151 Table curves can be entered regardless of the curve chosen for the protection element. However, the table curve will not be enabled until T1, T2, T3, or T4 is selected as the curve for the protective element. DGC-2020HD Generator Protection...
  • Page 152 A Voltage Restraint threshold of zero (0) disables voltage restraint/control and allows the 51 element to operate normally. Source A Source setting configures an overcurrent element to monitor the voltage at the generator sensing input terminals or the bus sensing input terminals when voltage restraint is enabled. Generator Protection DGC-2020HD...
  • Page 153 Equation 3. Restraint Pickup Level Phase VT Configuration The 51/27R function monitors Vpp. Table 46 shows which voltage measurements are used by each 51 element for each possible phase VT connection. Table 46. Phase VT Connection Cross Reference Phase VT Connection DGC-2020HD Generator Protection...

  • Page 154: Power (32)

    The six, identical power protection elements are designated 32-1, 32-2, 32-3, 32-4, 32-5, and 32-6. Element logic connections are made on the BESTlogicPlus screen in BESTCOMSPlus and element operational settings are configured on the Power settings screen in BESTCOMSPlus. Generator Protection DGC-2020HD...
  • Page 155 In addition to exceeding the threshold established by the Pickup setting, direction of power flow (forward or reverse) must match the Direction setting for the 32 element to operate. In the DGC-2020HD, the forward and reverse directions are defined by the polarity voltage and current connections to the controller as shown in Figure 81.
  • Page 156 The value of the scale factor setting serves as a multiplier for the pickup setting. For example, if a scale factor contact input is received by the DGC-2020HD and the scale factor setting is 2.000, the pickup setting will be doubled (2.000 x PU).

  • Page 157: Loss Of Excitation (40Q)

    Rated kvar on the Rated Data screen. When a single-phase override contact input is received, the DGC-2020HD automatically switches from the three-phase loss of excitation settings to the single- phase loss of excitation settings. A 40Q element monitors three-phase reactive power when three-phase sensing is active or single-phase reactive power if single-phase sensing is active.
  • Page 158 The scale factor setting is implemented when the DGC-2020HD is determined to be in a low-line configuration. If the Low-Line Override function is assigned to a contact input via the Programmable Functions screen, the state of the contact input and the detected configuration are ORed.

  • Page 159: Setting Groups

    Logic Inputs This function monitors logic inputs D0 through D3 and changes the active setting group according to the status of these three inputs. These inputs can be connected to logic expressions such as contact sensing outputs. DGC-2020HD Generator Protection...
  • Page 160 Changing Setting Groups When the DGC-2020HD switches to a new setting group, all functions are reset and initialized with the new operating parameters. The settings change occurs instantaneously so at no time is the DGC-2020HD off line.

  • Page 161: Configurable Protection

    9469300990 Rev B Configurable Protection Configurable protection can be used when the standard protection available with the DGC-2020HD does not meet the needs of the application. Eight configurable protection items are provided. Element Setup Parameter Selection The following parameters can be selected: •...
  • Page 162 Bus 1 kW A Total fuel used Label Text In order to make identification of the items easier, each of the items can be given a user-assigned label. The label is an alphanumeric string with a maximum of 16 characters. Configurable Protection DGC-2020HD...

  • Page 163: Arming Delay

    Alarm. Setting the arming delay to zero will cause an immediate alarm on the oil pressure, and engine cranking could cause a temporary low battery voltage condition which could cause an alarm. In either case, the spurious alarm would prevent the engine from starting. DGC-2020HD Configurable Protection...

  • Page 164: Logic Connections

    Protection # Configurable protection operational settings are configured on the Configurable Protection settings screen (Figure 89) in BESTCOMSPlus or through the front panel. Settings are listed in Table 47. Figure 89. Settings Explorer, Configurable Protection, Configurable Protection #1 Configurable Protection DGC-2020HD...
  • Page 165 0.001 to 3 0.001 Disabled, Over, or Mode Under Threshold –999,999 to 999,999 0.01 Activation Delay 0 to 300 seconds Status Only, Pre- Alarm Configuration Alarm, or Alarm ∗See Parameter Selection, above, for a complete listing of selectable parameters. DGC-2020HD Configurable Protection...
  • Page 166 9469300990 Rev B Configurable Protection DGC-2020HD...

  • Page 167: Metering

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

  • Page 168: Engine

    The Engine metering screen (Figure 91) provides information and metering of engine components. Under certain circumstances, parameters may indicate one of the following codes: NA (not applicable), NC (not connected), NS (not sent), or SF (sender fail). See the Communication chapter for their descriptions. Figure 91. Metering Explorer, Engine Screen Metering DGC-2020HD...

  • Page 169: Generator

    Front Panel Navigation Path: Metering > Bus 1 or Bus 2 Metering of the voltage, current, angle, frequency, and vector shift of Bus 1 and optional Bus 2 is displayed on these screens. See Figure 93. Figure 93. Metering Explorer, Bus 1 and Bus 2 (Optional) Screens DGC-2020HD Metering...

  • Page 170: Bias Control

    Front Panel Navigation Path: Metering > Gen / Bus 1 / Bus 2 > Power This screen provides metering of real power, apparent power, reactive power and power factor of the generator, bus 1, and optional bus 2. See Figure 95. Figure 95. Metering Explorer, Power Screen Metering DGC-2020HD...

  • Page 171: Run Statistics

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

  • Page 172: Status Indication

    Front Panel Navigation Path: Metering > Status > Inputs > Contact Inputs This screen indicates the status of contact inputs, contact input alarms, and contact input pre-alarms. The status is TRUE when the corresponding indicator is lit. See Figure 99. Metering DGC-2020HD...
  • Page 173 Module). When CEM-2020s are connected, the status of the remote contact inputs, configurable remote contact input alarms, and remote contact input pre-alarms are shown on these screens. The status is TRUE when the input indicator is lit. See Figure 101. DGC-2020HD Metering...
  • Page 174 BESTCOMSPlus Navigation Path: Metering Explorer, Inputs, Remote Analog Inputs, AEM # Inputs, AEM # RTD Inputs Front Panel Navigation Path: Metering > Status > Inputs > Remote Analog Input Values > AEM-2020 # > RTD Input Temperatures / Raw RTD Inputs Figure 103 illustrates the BESTCOMSPlus RTD Inputs screen. Metering DGC-2020HD...
  • Page 175 BESTCOMSPlus Navigation Path: Metering Explorer, Inputs, Remote Analog Inputs, AEM # Inputs, AEM # Input Values Front Panel Navigation Path: Metering > Status > Inputs > Remote Analog Input Values > AEM-2020 # Figure 105 illustrates the BESTCOMSPlus Input Values screen. DGC-2020HD Metering...
  • Page 176 Front Panel Navigation Path: Metering > Status > Logic Control Relays This screen displays the status of the sixteen logic control relays. A logic control relay input is true when the corresponding indicator is lit. See Figure 106. Figure 106. Metering Explorer, Inputs, Logic Control Relays Screen Metering DGC-2020HD...

  • Page 177: Outputs

    BESTCOMSPlus Navigation Path: Metering Explorer, Outputs, Configurable Elements Front Panel Navigation Path: Metering > Status > Configurable Elements This screen indicates the status of the eight configurable elements. The status is true when the corresponding indicator is lit. See Figure 109. DGC-2020HD Metering...
  • Page 178 Front Panel Navigation Path: Metering > Status > Outputs > Remote Analog Outputs > AEM -2020 # There are four remote analog output screens, one for each possible AEM-2020 (Analog Expansion Module). Each of these screens displays the scaled and raw values of the four remote analog outputs of Metering DGC-2020HD...

  • Page 179: Configurable Protection

    The ECU Data metering screen (Figure 113) provides information and metering of engine components. Under certain circumstances, parameters may indicate one of the following codes: NA (not applicable), NC (not connected), NS (not sent), or SF (sender fail). See the Communication chapter for their descriptions. DGC-2020HD Metering...

  • Page 180: Engine Configuration

    This screen (Figure 114) provides information and metering of engine parameters. Under certain circumstances, parameters may indicate one of the following codes: NA (not applicable), NC (not connected), NS (not sent), or SF (sender fail). See the Communication chapter for their descriptions. Metering DGC-2020HD...

  • Page 181: Mtu

    Under certain circumstances, parameters may indicate one of the following codes: NA (not applicable), NC (not connected), NS (not sent), or SF (sender fail). See the Communication chapter for their descriptions. Figure 115. Metering Explorer, MTU, MTU Engine Status Screen DGC-2020HD Metering...

  • Page 182: Summary

    Figure 116. Metering Explorer, MTU, MTU Status Screen Summary BESTCOMSPlus Navigation Path: Metering Explorer, MTU, MTU Status Front Panel Navigation Path: Not available through front panel Pertinent bus and engine metering is displayed on the Summary screen. Refer to Figure 117. Metering DGC-2020HD...
  • Page 183 9469300990 Rev B Figure 117. Metering Explorer, Summary Screen DGC-2020HD Metering...

  • Page 184: Control Panel

    DGC-2020HD. The PC or laptop running BESTCOMSPlus must be connected to the DGC-2020HD via the USB, Ethernet, or Modem (see the Communication chapter for details). Using the Metering Explorer in BESTCOMSPlus, open the Control Panel screen.

  • Page 185: Generator Sequencing

    Front Panel Navigation Path: Metering > Gen Sequencing This screen (Figure 120) provides generator sequencing information such as, the next unit to start/stop, power demand, start/stop thresholds, and spinning reserve thresholds. Figure 120. Metering Explorer, Generator Sequencing Screen DGC-2020HD Metering...

  • Page 186: Diagnostics

    Figure 122. Metering Explorer, Diagnostics, Load Share Screen Analysis BESTCOMSPlus Navigation Path: Metering Explorer, Analysis Front Panel Navigation Path: Not available through the front panel Oscillography of nearly all genset parameters can be monitored in real time using the Analysis screen (Figure 123). Metering DGC-2020HD...
  • Page 187 9469300990 Rev B Figure 123. Metering Explorer, Analysis DGC-2020HD Metering...
  • Page 188 9469300990 Rev B Metering DGC-2020HD...

  • Page 189: Reporting And Alarms

    Windows clipboard, or to print the event log. Clicking the Download button performs a fresh download of the list from the DGC-2020HD. The Clear button provides the option of clearing selected or all event logs. Refer to Figure 124.

  • Page 190: Data Logging

    Clicking the Download button performs a fresh download of the list from the DGC-2020HD. The Clear button provides the option of clearing selected or all event logs. Refer to Figure 125. Figure 125. Metering Explorer, Sequence of Events Setup ®...

  • Page 191: Trending

    Front Panel Navigation Path: Settings > Report Configuration > Trending The trend log records the activity of DGC-2020HD parameters over an extended period of time. When enabled, up to six selectable parameters can be monitored over a user-defined duration ranging from 1 to 720 hours.

  • Page 192: Alarms

    Figure 127. Settings Explorer, Report Configuration, Trending Setup Alarms DGC-2020HD units monitor 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 193 Remote display panel alarm settings consist of a single enable/disable setting. If enabled, the Remote Display Panel (RDP-110) annunciates an alarm when BESTlogicPlus logic element RDPPROGALM1 or RDPPROGALM2 receives a true input. Figure 128. Settings Explorer, Alarm Configuration, Alarms DGC-2020HD Reporting and Alarms...
  • Page 194 CAN and DTC support are both enabled, an Active DTC pre-alarm can be enabled to announce the presence of a condition that is causing a DTC to be sent from the ECU to the DGC-2020HD. AEM1 through AEM4 Comms Failure AEM-2020 communication failure pre-alarm settings consist of a single enable/disable setting.
  • Page 195 Ethernet 1 and Ethernet 2 Link Lost Ethernet 1 and Ethernet 2 link lost pre-alarm settings consist of a single enable/disable setting. If enabled, an Ethernet 1 or Ethernet 2 pre-alarm is annunciated if the Ethernet link between the DGC-2020HD and the network is lost.
  • Page 196 Maintenance Interval pre-alarm is annunciated when the DGC-2020HD maintenance timer counts down to zero (0) from the threshold time setting. The maintenance interval pre-alarm can be reset through the DGC-2020HD front panel or by using BESTCOMSPlus. See Resetting Alarms and Pre- Alarms, below.
  • Page 197 Synchronizer Failure pre-alarm is annunciated if the DGC-2020HD is running the auto-synchronizer to align the generator voltage and bus voltage to close a breaker, and the DGC-2020HD does not receive feedback from the breaker status indicating it is closed before the Sync Fail Activation delay time has expired.
  • Page 198 0 or 4 to 28 volts Threshold Per Unit based on nominal Activation Delay 0 to 10 seconds High Fuel Level Settings Threshold 0 to 150 Activation Delay 0 to 30 seconds Low Fuel Level Settings Threshold 10 to 100 Reporting and Alarms DGC-2020HD...
  • Page 199 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-2020HD is not operating in Auto mode. Sender Fail Settings ®...
  • Page 200 Alarm and pre-alarm annunciations for loss of engine speed signals is not user-programmable and operates as follows. If the MPU (magnetic pickup) or generator frequency is programmed as the sole engine speed source and that signal source fails, an alarm (and shutdown) is triggered. If the engine Reporting and Alarms DGC-2020HD...

  • Page 201: User Programmable Alarms

    Status of each active alarm and pre-alarm is displayed on the Alarms screen (Figure 133). This screen is found in the Metering Explorer. Active pre-alarms are listed in the upper panel, alarms are listed in the lower panel. DGC-2020HD Reporting and Alarms...
  • Page 202 Run Statistics screen and click on the Reset Maintenance Interval button. Another way to reset the maintenance interval pre-alarm from the front panel is to hold the Reset pushbutton for 10 seconds while viewing the Overview screen. Reporting and Alarms DGC-2020HD...

  • Page 203: Bestcomsplus® Software

    DGC-2020HD is brought into BESTCOMSPlus by downloading settings and logic from the DGC-2020HD. 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 204: System Recommendations

    BESTCOMSPlus. Manual activation is useful if you want to create a settings file prior to receiving your DGC-2020HD. Note that if a DGC-2020HD is not connected, you will not be able to configure certain Ethernet settings. Ethernet settings can be changed only when an active USB or Ethernet connection is present.
  • Page 205 DGC-2020HD. 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-2020HD. Apply operating power to the DGC- 2020HD. Wait until the boot sequence is complete.
  • Page 206 Manual Activation of the DGC-2020HD Plugin Manual activation of the DGC-2020HD plugin is required only if your initial use of BESTCOMSPlus will be on a PC that is not connected to a DGC-2020HD. Manual activation is described in the following paragraphs.

  • Page 207: Establishing Communication

    Communication between BESTCOMSPlus and the DGC-2020HD is established by clicking on the Connect button on the DGC-2020HD Connection screen (see Figure 137) or by clicking on the Connect button on the lower menu bar of the main BESTCOMSPlus screen (Figure 134). If you receive an “Unable to Connect to Device”...

  • Page 208: Menu Bars

    Recent Files Open a previously opened file Exit Close BESTCOMSPlus program Communication New Connection Choose new device or DGC-2020HD Close Connection Close communication between BESTCOMSPlus and DGC- 2020HD Download Settings and Logic from Download operational and logic settings from the device...

  • Page 209: Settings Explorer

    Opens a saved settings file. Connect: Opens the DGC-2020HD Connection screen which enables you to connect to the DGC-2020HD via USB, modem, or Ethernet. This button only appears when a DGC-2020HD is not connected. Disconnect: Used to disconnect a connected DGC-2020HD. This button only appears when a DGC-2020HD is connected.

  • Page 210: Metering Explorer

    Any number of different workspaces can be saved including a default workspace which loads when the DGC-2020HD plug-in is started. Metering Explorer screens and Settings Explorer screens can be saved independently into the workspace file. A Comments box is provided for writing a description or leaving notes for each saved workspace.

  • Page 211: Settings File Management

    Select the Save button to complete the save. Upload Settings and/or Logic to Device To upload a settings file to the DGC-2020HD, 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 212: Auto Export Metering

    The first export is performed immediately after clicking the Start button. Click the Filter button to select specific metering screens. Figure 145 illustrates the Auto Export Metering screen. BESTCOMSPlus® Software DGC-2020HD...

  • Page 213: Bestcomsplus® Updates

    Ongoing DGC-2020HD functionality enhancements may make future DGC-2020HD firmware updates desirable. Enhancements to DGC-2020HD firmware typically coincide with enhancements to the DGC- 2020HD plugin for BESTCOMSPlus. When a DGC-2020HD is updated with the latest version of firmware, the latest version of BESTCOMSPlus should also be obtained.
  • Page 214 9469300990 Rev B BESTCOMSPlus® Software DGC-2020HD...

  • Page 215: Bestlogic™Plus

    BESTlogicPlus equations entered and saved in the DGC-2020HD 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-2020HD is called a logic scheme.

  • Page 216: Bestlogic™Plus Composition

    Table 57. I/O Group, Output Objects Name Description Symbol Physical Outputs Output x Closes the corresponding contact output on the DGC-2020HD when true (high). Remote Outputs Output x Closes the corresponding remote contact output on an optional CEM-2020 when true (high).
  • Page 217 Name Description Symbol Audible Horn True when the Audible Horn is active. Auto Mode True when the DGC-2020HD is in Auto Mode or the Auto Mode logic element is true. Auto Restart True when the Automatic Restart function is active.
  • Page 218 Low Line True when the Low Line Override logic Override element is true. LS Output Out True when the LS Output Limit settings of Range have been exceeded. Mains Breaker True when the mains breaker is closed. Status BESTlogic™Plus DGC-2020HD...
  • Page 219 Start Input True when the DGC-2020HD is indicating that the Start relay should be closed to start the engine. Switch not in True when the DGC-2020HD is not in Auto Auto Mode. Sync Active True when the auto synchronizer is active to align the generator input and bus input voltages and phases.
  • Page 220 Mode Active True when var mode is active. Communications AEM Connected True when an optional AEM-2020 is connected to the DGC-2020HD. CEM Connected True when an optional CEM-2020 is connected to the DGC-2020HD. Configurable Protection Threshold x Trip...
  • Page 221 In Disconnect True when the DGC-2020HD is in the State disconnect state. In Prestart State True when the DGC-2020HD is in the pre- start state. In Pulsing State True when the DGC-2020HD is in the pulsing state. In Ready State True when the DGC-2020HD is in the ready state.
  • Page 222 9469300990 Rev B Name Description Symbol In Running True when the DGC-2020HD is in the State running state. In Unloading True when the DGC-2020HD is in the State unloading state. Programmable Inputs Analog Inputs True when the analog input connection is Out of Range open.
  • Page 223 (0) while the engine is running. Configurable Protection Threshold x True when the Alarm Configuration is set to Alarm and the threshold has been exceeded. Generator Protection Frequency True when the 81-x element is configured as an alarm and has tripped. DGC-2020HD BESTlogic™Plus...
  • Page 224 Alarm Configuration is set to Element x Alarm, and the Activation Delay has expired. Remote Analog True when the remote analog output connection Outputs is open and the Out of Range Alarm Type is set Out of Range to Alarm. BESTlogic™Plus DGC-2020HD...
  • Page 225 Diesel Exhaust Fluid (DEF) is at a level between 8 and 23%. This pre-alarm indicates a temporary Inducement override of inducement not to operate the Override engine. This is set by the ECU and is not a user setting. DGC-2020HD BESTlogic™Plus...
  • Page 226 True when a generator breaker close fail Breaker Close pre-alarm occurs. The pre-alarm occurs Failure when the DGC-2020HD 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 227 High Fuel Level True when the High Fuel Level Pre-Alarm settings have been exceeded. Inter Generator True when the DGC-2020HD detects that an Comm Fail individual generator previously connected to a generator network has lost connection. IRIG Sync Lost True when the IRIG signal is lost.
  • Page 228 Parameters, Remote Module Setup screen in BESTCOMSPlus. AEM x Comm True when communication from the AEM- Fail 2020 to the DGC-2020HD has been lost. AEM x Not True when the expected serial number on Configured the System Parameters, Remote Module...
  • Page 229 Parameters, Remote Module Setup screen in BESTCOMSPlus. CEM x Comm True when communication from the CEM- Fail 2020 to the DGC-2020HD has been lost. CEM x True when the connected CEM-2020 does Hardware not have the same number of outputs as...
  • Page 230 Oil Pressure True when the Oil Pressure Sender Fail is configured as either Sender Fail a pre-alarm or alarm and the activation delay has expired. Speed Sender True when the Speed Sender Fail activation delay has expired. Fail BESTlogic™Plus DGC-2020HD...
  • Page 231 1 through 8. Latches Reset Priority The latch is set when the Set input is true and the Reset input is Latch false. The latch is cleared when the Reset input is true. DGC-2020HD BESTlogic™Plus...
  • Page 232 The latch is set when the Set input is true. The latch is cleared Latch when the Set input is false and the Reset input is true. Logic Gates ANSI* IEC* Input Output NAND Input Output Input Output Input Output Input Output XNOR Input Output Input Output (INVERTER) BESTlogic™Plus DGC-2020HD...
  • Page 233 Pickup and dropout logic timer logic blocks are shown in Figure 147. Timing accuracy is ±15 milliseconds. Initiate Initiate Output Pickup Pickup Time Timer Output P0048-03 Initiate Initiate Output Dropout Dropout Time Timer Output Figure 147. Pickup and Dropout Timer Logic Blocks DGC-2020HD BESTlogic™Plus...
  • Page 234 The alarm will be silenced when the Set input is true. The alarm can also be silenced by pressing the Alarm Silence button on the front panel of the DGC-2020HD. Alternate When the Set input is true, protection and bus condition...
  • Page 235 Name Description Symbol When the ATS input is true, and the DGC-2020HD is in AUTO mode, the generator will run. This can be used in place of the ATS programmable function if it is desired to generate the ATS signal as a combination of programmable logic rather than a simple contact input.
  • Page 236 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-2020HD...
  • Page 237 AUTO mode and the ATS contact has been removed. External Start If the Set input is true while the DGC-2020HD is in the Pre Start Delay state, the DGC-2020HD will remain in the Pre Start state until the Set input is false.
  • Page 238 Close: This input allows a contact input to be mapped that can be used to initiate a manual breaker close request. When this input is pulsed and the DGC-2020HD is in AUTO or RUN mode, and the generator is stable, a close request will be initiated. If the Dead Bus Close Enable parameter is true, and the bus is dead, the breaker will close.
  • Page 239 Logic Alarm When the Set input is true, the DGC-2020HD goes into an alarm condition. Logic Pre- When the Set input is true, the DGC-2020HD goes into a Pre- Alarm alarm condition.
  • Page 240 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-2020HD is in RUN or AUTO mode, the breaker will open.
  • Page 241 ECU Setup screen in BESTCOMSPlus. Off Mode When the Set input is true, the DGC-2020HD will switch to OFF mode. This is a pulsed input. It does not need to be held after the desired mode switch has occurred.
  • Page 242 Run Mode When the Set input is true, and the DGC-2020HD is in OFF mode, the DGC-2020HD 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 243 A pulse must be present for approximately one second for the setting group change to occur. Single-Phase When the Set input is true, the DGC-2020HD switches to single- Override phase sensing configuration and uses the Single Phase Override Sensing setting (A-B or A-C).

  • Page 244: Logic Schemes

    The Active Logic Scheme Digital Genset Controllers must have an active logic scheme in order to function. All Basler Electric DGC- 2020HD 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-2020HD in service.

  • Page 245: Programming Bestlogic™Plus

    The view of Logic Page 1 through 4, Physical Outputs, Remote Outputs, and LCR Outputs can be automatically arranged by clicking the right mouse button on the window and selecting Auto-Layout. The following must be met before BESTCOMSPlus will allow logic to be uploaded to the DGC-2020HD: •...

  • Page 246: Offline Logic Simulator

    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-2020HD, 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 247: Bestlogic™Plus Examples

    Logic Document from the Protection drop-down button. A password is optional. Uploading a BESTlogicPlus File To upload a BESTlogicPlus file to the DGC-2020HD, you must first open the file through BESTCOMSPlus or create the file using BESTCOMSPlus. Then pull down the Communication menu and select Upload Logic to Device.

  • Page 248: Example 2 - And Gate Connections

    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-2020HD is in RUN mode (RUN Mode true). Refer to Figure 152.

  • Page 249: Communication

    ® The rear-panel, mini-B USB port enables local communication with a PC running BESTCOMSPlus software. The DGC-2020HD is connected to a PC using a standard USB cable. BESTCOMSPlus is a ® Windows -based communication software package that is supplied with the DGC-2020HD. A detailed description of BESTCOMSPlus is provided in the BESTCOMSPlus chapter.
  • Page 250 Automatically configures IP Address, Default Gateway, and Subnet Mask via DHCP. This can be used only if the Ethernet network has a properly configured DHCP server running. The DGC-2020HD does not act as a DHCP server. Redundant Ethernet: Available with dual copper Ethernet ports only. Checking this box disables the settings for Ethernet port 2 and designating it as a redundant port.

  • Page 251: Establishing Ethernet Communication

    192.168.0.0 to 192.168.255.255 If the DGC-2020HD is operating on an isolated network, the Subnet Mask can be left at 0.0.0.0 and the Default Gateway can be chosen as any valid IP address from the same range as the DGC-2020HD IP address.
  • Page 252 9469300990 Rev B Figure 155. DGC-2020HD Connection Screen When communication is established, BESTCOMSPlus reads all settings and logic from the DGC-2020HD and loads them into BESTCOMSPlus memory by default. This feature may be disabled in the Advanced Properties. Advanced Properties Click the Advanced…...

  • Page 253: Can

    (CAN L), 55 (CAN H), and 53 (SHIELD) and is dedicated for communication with Engine Control Units (ECU) and related devices. Applications using an engine-driven generator set controlled by a DGC-2020HD may also have an ECU. The CAN interface allows the ECU and DGC-2020HD to communicate. The ECU reports operating information to the DGC-2020HD through the CAN interface.
  • Page 254 Total Engine Hours hours hours Requested 1.5 s Total Fuel Used liters gallons Requested 1.5 s Transmission Oil Pressure Transmission Oil Temperature °C °F Trip Average Fuel Rate liters/hr gallons/hr On Request 1029 Trip Fuel liters gallons Requested 1.5 s Communication DGC-2020HD...
  • Page 255 ∗ SPN: Suspect Parameter Number Caution When CAN is enabled, the DGC-2020HD 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 and in the Metering Explorer of BESTCOMSPlus: •...

  • Page 256: Ecu Limitations

    100 ms ∗ SPN: Suspect Parameter Number † Requests from the DGC-2020HD to the ECU for various parameters are made by issuing the request. ECU Limitations For some ECUs, an external source cannot stop the engine without removing power from the ECU.

  • Page 257: Can Bus Setup

    DGC-2020HD accordingly. A DGC-2020HD operating on a CAN bus network is identified by a unique address number. The CAN bus address is set internally by the DGC-2020HD when certain types of ECUs are selected on the ECU Setup screen, and in this case, the user-entered value does not apply.
  • Page 258 This parameter sets a unique address number for the DGC-2020HD operating on CAN 2 (ECU). The CAN Address is set internally by the DGC-2020HD when certain types of ECUs are selected on the ECU Setup screen, and in this case, the user-entered value does not apply.
  • Page 259 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-2020HD will “pulse” it periodically to force it to be active to allow the DGC-2020HD to read data such as coolant temperature and coolant level.
  • Page 260 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-2020HD may use some of the ECU data for alarm or pre-alarm annunciation, it is important that the data have time to settle.

  • Page 261: Ecu Setup

    The following paragraphs describe the settings on the ECU Setup screen. Refer to Figure 158. ECU Type The DGC-2020HD can be configured for Standard, Volvo Penta, MTU MDEC, MTU ADEC, MTU ECU7/ECU8, GM/Doosan, Cummins, or MTU Smart Connect. Diesel Particulate Filter (DPF) The diesel particulate filter settings are used when the ECU is configured for Standard, Volvo Penta, MTU ADEC, GM/Doosan, Cummins, or MTU Smart Connect.
  • Page 262 Alternate Voltage Setpoint becomes the active system voltage setpoint when low line override is true. The range in which the DGC-2020HD biases voltage regulator var sharing and voltage trim is dictated by the Voltage Adjust Bandwidth setting. When the voltage regulator is in Field Current Regulation (FCR) mode, the normal desired field current setpoint is set using the Field Current Setting for Field Current Regulation Mode.

  • Page 263: External Modem

    Knee Underfrequency Slope 1 to 5 0.01 RS-232 DGC-2020HD controllers are equipped with an RS-232 port which communicates with an external user- supplied telephone modem with dial-in and dial-out capability. RS-232 Setup ® BESTCOMSPlus Navigation Path: Settings Explorer, Communications, RS232 Setup HMI Navigation Path: Settings >...
  • Page 264 Message strings sent by the DGC-2020HD can be limited to a length supported by the receiving pagers. If a message to be transmitted by the DGC-2020HD exceeds the pager message length limit, it will make multiple calls to transmit the complete message.
  • Page 265 Prior to establishing modem communication, the baud rate used by the PC must match the baud rate used by the DGC-2020HD. The baud rate used by the DGC-2020HD can be set directly through the front panel interface or through BESTCOMSPlus via USB (local) or Ethernet (remote) connection. If using the front panel, navigate to Settings >...

  • Page 266: Modbus™ Setup

    Navigation Path: Settings Explorer, Communications, RS485 Setup HMI Navigation Path: Settings > Communication > RS485 Setup DGC-2020HD controllers can be monitored and controlled via a polled network using the Modbus protocol. The RS-485 port supports a user-selectable baud rate of 1,200; 2,400; 4,800; 9,600; 19,200;...

  • Page 267: Remote Display Panel (Optional)

    † The LED on the Remote Display Panel illuminates when the input that is assigned to this programmable function is closed. ‡ This LED can be reprogrammed in the DGC-2020HD to suit the needs of a particular application. The condition listed above is annunciated by default. See the BESTlogicPlus chapter for information about configuring the RDP Programmable Alarm and Pre-Alarm logic blocks.
  • Page 268 9469300990 Rev B Communication DGC-2020HD...

  • Page 269: Configuration

    MPU and genset frequency. On engines with CAN-compatible ECUs, if MPU or MPU Freq is selected as the Speed Signal Source, the DGC-2020HD uses the CAN interface as the speed source when CAN is enabled. If Gen Freq is set as the Speed Signal Source, the DGC-2020HD uses the generator frequency.
  • Page 270 9469300990 Rev B inputs 1 and 2 can always be selected. Analog inputs 3 and 4 are available to DGC-2020HD units with the analog sender inputs option (style number xxxxxxxxA). Coolant Temperature Source If using a resistive coolant temperature sender, select the Resistive Sender option. This option is only available to DGC-2020HD units with resistive sender inputs (style number xxxxxxxxR).
  • Page 271 Figure 166. Settings Explorer, System Parameters, System Settings Table 76. Settings for System Settings Locator Setting Range Increment Unit Single Generator or System Type Multiple Generator Number Fly Wheel Teeth 1 to 500 Power Up Delay 0 to 60 seconds DGC-2020HD Configuration...

  • Page 272: Rated Data

    Generator (Figure 167), Bus 1(Figure 168), and optional Bus 2 (identical to Figure 168). To edit rated data settings for the generator, bus 1, or optional bus 2, click the Edit button found on any of these screens. Upon clicking the Edit button, the floating Rated Data screen appears. All rated data settings for Configuration DGC-2020HD...

  • Page 273: Voltage Ratings

    The secondary value of the generator CT is dictated by the style number of the controller. A DGC-2020HD with a style number of 1xxxxxxxx uses a nominal CT secondary rating of 1 Aac. A DGC-2020HD with a style number of 5xxxxxxxx uses a nominal CT secondary rating of 5 Aac.

  • Page 274: Power Ratings

    This setting accepts values from 10 to 90, in increments of 0.01. Battery Volts Nominal voltage of the starter battery is used by the DGC-2020HD to detect and annunciate high, low, or weak battery voltage. Battery Volts options are 12 V and 24 V.
  • Page 275 9469300990 Rev B Figure 167. Settings Explorer, System Parameters, Rated Data, Generator Rated Data Screen (Read Only) Figure 168. Settings Explorer, System Parameters, Rated Data, Bus Rated Data Screen (Read Only) DGC-2020HD Configuration...
  • Page 276 –1 to 1 0.01 Rated kW 0 to 1,000,000 0.01 Phase Rotation ABC or ACB Delta, Wye, 1 Phase A-B, 1 Voltage Sensing Phase A-C, Grounded Delta A, B, C, AB, BC, CA, or CT Phase Connection CT ABC Configuration DGC-2020HD...

  • Page 277: Remote Module Setup

    For optional AEM-2020 setup, select Enable, input the appropriate J1939 address, and input the expected serial number. Expected serial numbers are used by the DGC-2020HD to determine which input/output points belong to a module when multiple modules are present. An AEM-2020 Not Configured pre-alarm occurs if the expected serial number does not match the serial number detected on the General Settings, Device Info screen.
  • Page 278 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 Configuration DGC-2020HD...

  • Page 279: Automatic Restart Settings

    Cool Down After the load is removed from a genset, the DGC-2020HD implements a smart cool down function. This function ensures that the engine and turbocharger properly cool down by maintaining engine operation for a user-defined duration.

  • Page 280: Exercise Timer Settings

    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-2020HD closes the generator breaker during the run time.

  • Page 281: Sensing Transformer Ratings

    CT is dictated by the style number of the controller. A DGC-2020HD with a style number of 1xxxxxxxx uses a nominal CT secondary rating of 1 Aac. A DGC- 2020HD with a style number of 5xxxxxxxx uses a nominal CT secondary rating of 5 Aac.

  • Page 282: Relay Control Settings

    The default operational setting for the Start, Run, and Pre-start relays is Predefined or standard. Any of these relays can be logic driven by selecting the Programmable setting. Logic driven programmable relays must be set up using BESTlogicPlus Figure 175 illustrates the BESTCOMSPlus Relay Control screen. Figure 175. Settings Explorer, System Parameters, Relay Control Configuration DGC-2020HD...

  • Page 283: System Configuration Detection Settings

    There is a one-second delay in the detection to prevent the DGC-2020HD from alternating between detected configurations. When the DGC-2020HD is in the Off mode or the engine is not running, the Automatic Configuration Detection function is disabled. The DGC-2020HD is assumed to be in the last valid automatically detected configuration.
  • Page 284 If determined to be in low-line configuration, the Low-Line Override function forces the DGC-2020HD into the low-line configuration. If the Low-Line Override function is assigned to a contact input via the Programmable Functions screen, the state of the contact input and the detected configuration are ORed.

  • Page 285: Device Information

    The model number, together with the style number, describes the options included in a specific device. The style number of the DGC-2020HD is displayed on the BESTCOMSPlus Style Number screen after downloading settings from the device. When configuring DGC-2020HD settings off-line, the style number for the unit to be configured can be entered into BESTCOMSPlus to enable configuration of the required settings.

  • Page 286: Firmware Updates

    Figure 178. Device Info Screen Firmware Updates Future enhancements to the DGC-2020HD functionality will make a firmware update desirable. Because default settings are loaded when DGC-2020HD firmware is updated, your settings should be saved in a file prior to upgrading firmware. Note...

  • Page 287: Upgrading Firmware In Expansion Modules

    DGC-2020HD. If no expansion module is present, proceed to Upgrading Firmware in the DGC-2020HD. Place the DGC-2020HD 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-2020HD front panel.
  • Page 288 From the File pull-down menu, select New, DGC-2020HD. Connect to the DGC-2020HD. Once all settings have been read from the DGC-2020HD, open the saved settings file by selecting File, Open File in the BESTCOMSPlus menu. Then browse for the file to upload.
  • Page 289 General Settings > Style Number in BESTCOMSPlus. If the style number of the settings file does not match that of the DGC-2020HD into which it is to be loaded, disconnect from the DGC-2020HD, then modify the style number in the settings file.
  • Page 290 9469300990 Rev B Device Information DGC-2020HD...

  • Page 291: Security

    9469300990 Rev B Security Multiple levels of DGC-2020HD security give personnel the level of access appropriate for the tasks they routinely perform while securing critical settings from unauthorized access. Access Levels Passwords provide access security for six distinct functional access areas: Read, Control, Operator, Settings, Design, and Administrator (Admin).
  • Page 292 An administrator level is required to upload security settings to the device. Enter the username and password of the administrator and then click the Log In button. The default administrator username is “A” and the default password is “A”. BESTCOMSPlus notifies you when the upload is successful. Security DGC-2020HD...

  • Page 293: Port Access Setup

    If a password is entered incorrectly more than x times (Login Attempts) in y seconds (Login Time Window), then access is prohibited for z seconds (Login Lockout Time). The BESTCOMSPlus Access Control screen is illustrated in Figure 183. Settings are listed in Table 81. DGC-2020HD Security...
  • Page 294 An administrator level is required to upload security to the device. Enter the username and password of the administrator and then click the Log In button. The default administrator username is “A” and the default password is “A”. BESTCOMSPlus notifies you when the upload is successful. Security DGC-2020HD...

  • Page 295: Timekeeping

    The IRIG Decoding signal defines whether or not to decode the year field in the IRIG signal. Refer to the manufacturer of your equipment to determine if the year field is being sent to the DGC-2020HD. Clock Not Set Warning When enabled, this alarm annunciates when the DGC-2020HD has powered up and the clock has not been set.
  • Page 296 Time Zone Minute Offset –59 to 59 minutes Time Format 12 Hour or 24 Hour YYYY-MM-DD Date Format MM-DD-YYYY DD-MM-YYYY DST Configuration Floating Dates or Fixed Dates January, February, March, April, May, June, July, Month August, September, October, November, or December Timekeeping DGC-2020HD...

  • Page 297: Setting The Time And Date

    Table 83. IRIG Terminal Assignments Terminal Function (+) Signal (–) Reference Specifications Interface supports IRIG Standard 200-04, Format B006, and Standard 200-98, Format B002. Input Signal ............... Demodulated (dc level-shifted signal) Input Voltage Range ..........±10 Vdc maximum DGC-2020HD Timekeeping...

  • Page 298: Real-Time Clock Specifications

    Backup Battery for the Real-Time Clock 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 299: Maintenance And Troubleshooting

    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 300: Inputs And Outputs

    Step 1. Verify that all wiring is properly connected. Refer to the Typical Applications chapter. 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.

  • Page 301: Generator Breaker And Mains Breaker

    LCD is Blank and all LEDs are Flashing at Approximately 2 Second Intervals This indicates that the DGC-2020HD does not detect that valid application firmware is installed. The unit is running its boot loader program, waiting to accept a firmware upload.
  • Page 302 Verify that a failure of the mains is detected by the DGC-2020HD. Check status using the 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 Maintenance and Troubleshooting...
  • Page 303 Step 5: Verify the wiring to the breaker from the DGC-2020HD. If it appears correct, 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. Map a virtual switch to the logic output that would normally be the breaker close output.
  • Page 304 Dead or Failed (i.e. not stable). Step 3: Check that the DGC-2020HD is trying to initiate a breaker closure. To determine the sources of breaker close requests, refer to the Breaker Management chapter. Synchronizer Active for a Short Time, Then Stops Step 1: Check if a Sync Fail pre-alarm or a Breaker Close Fail pre-alarm is occurring or has occurred.

  • Page 305: Load Sharing

    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 306 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 307 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 308 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 309 This screen is useful for debugging load share related issues, and kW and var control related issues. It gives visibility into the states of the kW, kvar, Speed Trim, and Voltage controllers in the DGC-2020HD. The Control diagnostics screen is located on the front panel at Metering > Diagnostics > Control.
  • Page 310 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 311 The following parameters are visible on the AEM diagnostics screen:  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.
  • Page 312 9469300990 Rev B Maintenance and Troubleshooting DGC-2020HD...

  • Page 313: Aem-2020

    9469300990 Rev B AEM-2020 The AEM-2020 (Analog Expansion Module) is an optional remote device that provides additional DGC- 2020HD analog inputs and outputs. Up to four AEM-2020s may be used with one DGC-2020HD. Features AEM-2020s have the following features: ...
  • Page 314 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.

  • Page 315: Functional Description

    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, your sales representative, or a sales representative at Basler Electric, Highland, Illinois USA.

  • Page 316: Connections

    Connectors and headers may contain tin- or gold-plated conductors. Tin-plated conductors are housed in a black plastic casing and gold-plated conductors are housed in an orange plastic casing. Mate connectors to headers of the same color only. AEM-2020 DGC-2020HD...

  • Page 317: Operating Power

    Chassis ground connection (SHIELD) P1- – (BATT–) Negative side of operating power input P1- + (BATT+) Positive side of operating power input AEM-2020 Inputs and Outputs Input and output terminals are shown in Figure 187 and listed in Table 85. DGC-2020HD AEM-2020...
  • Page 318 Table 85. Input and Output Terminals Connector Description Operating Power and CAN RTD Inputs 1 - 4 Analog Inputs 1 - 8 and Analog Outputs 1 - 4 Thermocouple 1 Input Thermocouple 2 Input RTD Inputs 5 - 8 AEM-2020 DGC-2020HD...

  • Page 319: External Analog Input Connections

    Figure 189. Analog Inputs - Current Input Connections External RTD Input Connections External 2-wire RTD input connections are shown in Figure 190. Figure 191 shows external 3-wire RTD input connections. AEM-2020 RTD1+ BLACK RTD1– Jumper RTD1C Figure 190. External Two-Wire RTD Input Connections DGC-2020HD AEM-2020...

  • Page 320: Can Interface

    These terminals provide communication using the SAE J1939 protocol and provide high-speed communication between the Analog Expansion Module and the DGC-2020HD. Connections between the AEM-2020 and DGC-2020HD should be made with twisted-pair, shielded cable. CAN interface terminals are listed in Table 86. Refer to Figure 192 and Figure 193.
  • Page 321 Figure 192. CAN Interface with AEM-2020 providing One End of the Bus CEM-2020 AEM-2020 (Optional) Stub CAN-H DGC-2020HD Engine CAN-L P0069-98 120 ohm 120 ohm Termination Termination Other Devices Figure 193. CAN Interface with DGC-2020HD providing One End of the Bus DGC-2020HD AEM-2020...

  • Page 322: Aem-2020 Configuration

    95% of the threshold before the threshold detection will drop out. This hysteresis helps prevent rapid or repeated transitions between trip and dropout in cases where the measured input is nearly equal to a level equal to the threshold. AEM-2020 DGC-2020HD...

  • Page 323: Logic Connections

    Figure 195. Remote Analog Input Protection Logic Block Operational Settings Remote analog input protection operational settings are configured on the AEM x Input #y (where x = 1 to 4 and y = 1 to 8) settings screen (Figure 196) in BESTCOMSPlus. DGC-2020HD AEM-2020...
  • Page 324 Min Input Current 4 to 20 milliamps Max Input Current 4 to 20 milliamps Min Input Voltage 0 to 10 volts Max Input Voltage 0 to 10 volts Disabled, Over, or Mode Under Threshold -999,999 to 999,999 0.01 AEM-2020 DGC-2020HD...

  • Page 325: Remote Rtd Inputs Configuration

    Voltage and Param Max correlates to Max Input Current or Max Input Voltage. Thresholds There are four programmable thresholds for each remote RTD input element. Each threshold has a mode setting, threshold setting, activation delay setting, and an alarm setting. DGC-2020HD AEM-2020...
  • Page 326 Remote RTD input protection operational settings are configured on the AEM x RTD Input #y (where x = 1 to 4 and y = 1 to 8) settings screen (Figure 198) in BESTCOMSPlus. Figure 198. Settings Explorer, Programmable Inputs, Remote Analog Inputs, AEM 1 RTD Input #1 AEM-2020 DGC-2020HD...

  • Page 327: Remote Thermocouple Inputs Configuration

    (0), the input protection is active at all times, including when the engine is not running. If the arming delay is set to a non-zero value, the input protection is inactive when the engine DGC-2020HD AEM-2020...
  • Page 328 Remote Thermocouple input protection operational settings are configured on the AEM x Thermocouple Input #y (where x = 1 to 4 and y = 1 or 2) settings screen (Figure 200) in BESTCOMSPlus. Settings are listed in Table 89. AEM-2020 DGC-2020HD...

  • Page 329: Remote Analog Outputs Configuration

    (where x = 1 to 4 and y = 1 to 4) settings screen in BESTCOMSPlus. BESTCOMSPlus Navigation Path: Settings Explorer, Programmable Outputs, Remote Analog Outputs Front Panel Navigation Path: Settings Explorer > Programmable Outputs > Remote Analog Outputs DGC-2020HD AEM-2020...

  • Page 330: Output Setup

     AEM 3 RTD Input 3 GEN IC   AEM 3 RTD Input 4 GEN kVA A   AEM 3 RTD Input 5 GEN kVA B   AEM 3 RTD Input 6 GEN kVA C AEM-2020 DGC-2020HD...
  • Page 331 Operational Settings Remote analog output operational settings are configured on the AEM x Output #y (where x = 1 to 4 and y = 1 to 4) settings screen (Figure 201) in BESTCOMSPlus. Settings are listed in Table 90. DGC-2020HD AEM-2020...

  • Page 332: Firmware Updates

    Repair Analog 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. Before returning the AEM-2020 for repair, contact the Basler Electric Technical Services Department at 618-654-2341 for a return authorization number.

  • Page 333: Storage

    9469300990 Rev B Storage This device contains long-life aluminum electrolytic capacitors. For devices that are not in service (spares in storage), the life of these capacitors can be maximized by energizing the device for 30 minutes once per year. DGC-2020HD AEM-2020...
  • Page 334 9469300990 Rev B AEM-2020 DGC-2020HD...

  • Page 335: Cem-2020

    Time from a CEM-2020 input application to:  Shut down the generator via an alarm = 700 ms max  Close a relay on board the DGC-2020HD = 300 ms max  Close a relay on board the CEM-2020 = 550 ms max Contact Outputs...
  • Page 336 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 337: Functional Description

    The CEM-2020 provides 24 programmable contact outputs with the same functionality as the contact outputs on the DGC-2020HD. Outputs 1 through 12 can carry 1 A. Outputs 13 through 24 can carry 4 A. The label text of each contact output is customizable.
  • Page 338 9469300990 Rev B Figure 202. CEM-2020 Overall Dimensions See Figure 203 for CEM-2020H overall dimensions. All dimensions are shown in inches with millimeters in parenthesis. CEM-2020 DGC-2020HD...

  • Page 339: Connections

    These connectors plug into headers on the CEM-2020. Also, the connectors and headers have dovetailed edges that ensure proper connector orientation. The connectors and headers are uniquely keyed to ensure that the connectors mate only with the correct headers. DGC-2020HD CEM-2020...

  • Page 340: Contact Inputs And Contact Outputs

    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 5 Adc. CEM-2020 DGC-2020HD...
  • Page 341 9469300990 Rev B Figure 204. CEM-2020 Contact Input and Contact Output Terminals DGC-2020HD CEM-2020...
  • Page 342 These terminals provide communication using the SAE J1939 protocol and provide high-speed communication between the Contact Expansion Module and the DGC-2020HD. Connections between the CEM-2020 and DGC-2020HD should be made with twisted-pair, shielded cable. CAN interface terminals are listed in Table 92. Refer to Figure 206 and Figure 207.
  • Page 343 Figure 206. CAN Interface with CEM-2020 providing One End of the Bus AEM-2020 CEM-2020 (Optional) Stub CAN-H DGC-2020HD Engine CAN-L P0072-01 120 ohm 120 ohm Termination Termination Other Devices Figure 207. CAN Interface with DGC-2020HD providing One End of the Bus DGC-2020HD CEM-2020...

  • Page 344: Cem-2020 Configuration

    A user-adjustable time delay can be set to delay recognition of a contact input. Label Text In order to make identification of the remote contact inputs easier, each of the inputs can be given a user- assigned label. The label is an alphanumeric string with a maximum of 16 characters. CEM-2020 DGC-2020HD...
  • Page 345 Table 93. Settings for CEM x Inputs Locator Setting Range Increment Unit Status Only, Pre- Alarm Configuration Alarm, or Alarm Activation Delay 0 to 300 seconds 16 alphanumeric Label Text characters Always or While Contact Recognition Engine Running Only DGC-2020HD CEM-2020...

  • Page 346: Remote Contact Outputs Configuration

    Refer to the Device Information chapter for information on upgrading firmware in the CEM-2020. Repair 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. CEM-2020...

  • Page 347: Maintenance

    9469300990 Rev B Before returning the CEM-2020 for repair, contact the Basler Electric Technical Services Department at 618-654-2341 for a return authorization number. Maintenance Preventive maintenance consists of periodically checking that the connections between the CEM-2020 and the system are clean and tight.
  • Page 348 9469300990 Rev B CEM-2020 DGC-2020HD...

  • Page 349: Time Curve Characteristics

    9469300990 Rev B Time Curve Characteristics The inverse time overcurrent characteristic curves provided by the DGC-2020HD (style xxExxxxxx only) closely emulate most of the common electromechanical, induction-disk, overcurrent relays sold in North America. To further improve proper relay coordination, a selection of integrated reset or instantaneous reset characteristics are also provided.

  • Page 350: Time Overcurrent Characteristic Curve Graphs

    § The programmable curve allows for four significant digits after the decimal place for every variable. Time Overcurrent Characteristic Curve Graphs The figures after the tables illustrate the characteristic curves of the DGC-2020HD. Table 95 cross- references each curve to existing electromechanical relay characteristics. Equivalent time dial settings were calculated at a value of five times pickup.

  • Page 351: Time Dial Setting Cross-Reference

    User Programmable Time Dial Setting Cross-Reference While the time characteristic curve shapes have been optimized for each relay, time dial settings of Basler Electric relays are not identical to the settings of electromechanical induction disk overcurrent relays. Table 96 helps you convert the time dial settings of induction disk relays to the equivalent setting for Basler Electric relays.
  • Page 352 In applications where the time coordination between curves is extremely close, we recommend that you choose the optimal time dial setting by inspection of the coordination study. In applications where coordination is tight, it is recommended that you retrofit your circuits with Basler Electric electronic relays to ensure high timing accuracy.
  • Page 353 �� �� Equation 14 ���������������� �� �� = where: 46 ������������ �������������� Equation 15 �� which, when M > 1, reduces to: �� = 46 �������� �������� � � ������ �������������� �� ���������������� �� Equation 16 DGC-2020HD Time Curve Characteristics...
  • Page 354 9469300990 Rev B Figure 213. Time Characteristic Curve S1, Short Inverse (Similar to ABB CO-2) Time Curve Characteristics DGC-2020HD...
  • Page 355 9469300990 Rev B Figure 214. Time Characteristic Curve S2, Short Inverse (Similar To GE IAC-55) DGC-2020HD Time Curve Characteristics...
  • Page 356 9469300990 Rev B Figure 215. Time Characteristic Curve L1, Long Inverse (Similar to ABB CO-5) Time Curve Characteristics DGC-2020HD...
  • Page 357 9469300990 Rev B Figure 216. Time Characteristic Curve L2, Long Inverse (Similar To GE IAC-66) DGC-2020HD Time Curve Characteristics...
  • Page 358 9469300990 Rev B Figure 217. Time Characteristic Curve D, Definite Time (Similar To ABB CO-6) Time Curve Characteristics DGC-2020HD...
  • Page 359 9469300990 Rev B Figure 218. Time Characteristic Curve M, Moderately Inverse (Similar to ABB CO-7) DGC-2020HD Time Curve Characteristics...
  • Page 360 9469300990 Rev B Figure 219. Time Characteristic Curve I1, Inverse Time (Similar to ABB CO-8) Time Curve Characteristics DGC-2020HD...
  • Page 361 9469300990 Rev B Figure 220. Time Characteristic Curve I2, Inverse Time (Similar to GE IAC-51) DGC-2020HD Time Curve Characteristics...
  • Page 362 9469300990 Rev B Figure 221. Time Characteristic Curve V1, Very Inverse (Similar to ABB CO-9) Time Curve Characteristics DGC-2020HD...
  • Page 363 9469300990 Rev B Figure 222. Time Characteristic Curve V2, Very Inverse (Similar to GE IAC-53) DGC-2020HD Time Curve Characteristics...
  • Page 364 9469300990 Rev B Figure 223. Time Characteristic Curve E1, Extremely Inverse (Similar to ABB CO-11) Time Curve Characteristics DGC-2020HD...
  • Page 365 9469300990 Rev B Figure 224. Time Characteristic Curve E2, Extremely Inverse (Similar to GE IAC-77) DGC-2020HD Time Curve Characteristics...
  • Page 366 9469300990 Rev B Figure 225. Time Characteristic Curve A, Standard Inverse (BS 142) Time Curve Characteristics DGC-2020HD...
  • Page 367 9469300990 Rev B Figure 226. Time Characteristic Curve B, Very Inverse (BS 142) DGC-2020HD Time Curve Characteristics...
  • Page 368 9469300990 Rev B Figure 227. Time Characteristic Curve C, Extremely Inverse (BS 142) Time Curve Characteristics DGC-2020HD...
  • Page 369 9469300990 Rev B Figure 228. Time Characteristic Curve G, Long Time Inverse (BS 142) DGC-2020HD Time Curve Characteristics...
  • Page 370 For example, if the user selects 5A FLC with a pickup setting of 0.5 A, the per-unit pickup is 0.1 A. The relay will not pick up at less than 0.1 pu I2 for these settings. Time Curve Characteristics DGC-2020HD...

  • Page 371: Tuning Pid Settings

    Voltage and Speed Controllers The voltage and speed controllers are in effect when the DGC-2020HD is synchronizing the generator to a bus. When synchronizing, these controllers adjust the speed and voltage output of the generator to match that of the bus.

  • Page 372: Tuning Procedures

    Set an initial value of 1 for KP. Each time KP is set, disturb the system by changing the voltage on the bus input of the DGC-2020HD so that the DGC-2020HD will try to follow it. Verify that the generator’s output approaches the new value in a stable manner.
  • Page 373 KD and check for stability. Each time KD is raised, disturb the system by changing the voltage on the bus input of the DGC-2020HD so that the DGC-2020HD will try to follow it. Verify that the DGC- 2020HD controls the voltage to go to the new value in a stable manner. Raise KD until the system is unstable, and then lower it to half the value where instability if first attained.
  • Page 374 If it is not possible to obtain stable speed operation, it may be necessary to reduce the control gains in the governor that has its analog bias input driven by the DGC-2020HD. KI - Integral Gain Set the initial value of KI to be a tenth of the value set for KP.
  • Page 375 If it is not possible to obtain stable kW operation, it may be necessary to reduce the control gains in the governor that has its analog bias input driven by the DGC-2020HD. KI - Integral Gain Set the initial value of KI to be a tenth of the value set for KP.

  • Page 376: Generic Gains For Multiple Machine Types

    6 to 12 sets of settings that cover a wide range of machine sizes and engine manufacturers. However, once a set of gains has been determined for a particular machine type, the same gains should work in all identical machines. Tuning PID Settings DGC-2020HD...

  • Page 377: Mtu Fault Codes

    Metering > Status > MTU Fault Codes. Each fault code is displayed with a fault description and the fault number. If the DGC-2020HD does not have descriptive information about a fault number that was received, the fault description will display as “NO TEXT AVAILABLE”.
  • Page 378 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. ERR REC2 INVALID Checksum fault. MTU Fault Codes DGC-2020HD...
  • Page 379 AL CAN2 BUS OFF CAN controller 2 is in “Bus Off” state. AL CAN2 ERROR PASSV CAN controller 2 has signaled a warning. AL EMU PARAM NO SUPPORT EMU parameters are not supported. SD T COOLANT Coolant temperature-sensor defect. DGC-2020HD MTU Fault Codes...
  • Page 380 Missing data CAN. SD CAN LOCAL Missing data CAN. SD CAN RCS ENGAGE Missing data CAN. SD CAN RCS CYL CT Missing data CAN. SD 15V POS SPPLY Internal ECU fault. 15V POS SPPLY Internal ECU fault. MTU Fault Codes DGC-2020HD...
  • Page 381 Error in timing of injector cylinder B3: timing value too low/high. TIMING CYLNDR B4 Error in timing of injector cylinder B4: timing value too low/high. TIMING CYLNDR B5 Error in timing of injector cylinder B5: timing value too low/high. DGC-2020HD MTU Fault Codes...
  • Page 382 OPN LD CYLNDR B5 Open load in injector cable of cylinder B5. OPN LD CYLNDR B6 Open load in injector cable of cylinder B6. OPN LD CYLNDR B7 Open load in injector cable of cylinder B7. MTU Fault Codes DGC-2020HD...
  • Page 383 HI L WATER FUEL PREFILT Water level of fuel prefilter too high (limit 1). LO P COOLANT INTRCOOLR Coolant pressure of intercooler too low (limit 1). SS P COOLANT INTRCOOLR Coolant pressure of intercooler too low (limit 2). DGC-2020HD MTU Fault Codes...
  • Page 384 An open load on POM’s alternator output has been detected. AL BATT NOT CHARGING Battery is not being charged by alternator. AL CAN POM NODE LOST POM is missing on CAN bus. AL NEW POM FOUND New POM found. MTU Fault Codes DGC-2020HD...
  • Page 385 Channel signals open load. AL SD DN BUTTON STR Channel signals open load or internal error. AL SD EXT SPEED DMD SW STR Channel signals open load. AL SD SPEED DMD INCREASE Channel signals open load or internal error. DGC-2020HD MTU Fault Codes...
  • Page 386 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-2020HD...

  • Page 387: Exhaust Treatment

    DPF Control DPF control information is sent from the DGC-2020HD to the Engine ECU through PGN Number 57244 (0xE000). A manual regeneration request is sent using SPN 3696, Diesel Particulate Filter Regeneration Force Switch. Regeneration can be inhibited by SPN 3695, Diesel Particulate Filter Regeneration Inhibit Switch.
  • Page 388 9469300990 Rev B DPF Status and Pre-Alarms The DGC-2020HD receives DPF status information which is broadcast from the engine ECU in various Parameter Group Numbers (PGN) and Suspect Parameter Numbers (SPN). This information is displayed on the front panel and in BESTCOMSPlus, via DPF related pre-alarms. The J1939 parameters and the resulting DGC-2020HD pre-alarms are summarized in the following paragraphs.

  • Page 389: Exhaust After-Treatment Systems (Eats)

    Information. Tank levels are in units of percent. Pre-Alarms Diesel Exhaust Fluid Level diagnostics are sent to the DGC-2020HD from the ECU as SPNs 5245 and 5246 in PGN 65110 (the AT1TI PGN). Suspect Parameter Number 5245 communicates DEF level diagnostics, whereas SPN 5246 communicates DEF Inducement Level status.
  • Page 390 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-2020HD...

  • Page 391: Diagnostic Trouble Codes

    For certain DTCs, if the DGC-2020HD recognizes a pair of SPN and FMI numbers, it displays a single string as listed in Table 100. If the DGC-2020HD recognizes an SPN in Table 100, but the FMI does not match the FMI in Table 100, then it displays the string from Table 100 corresponding to the table entry where the FMI is # and a second string corresponding to the FMI number listed in Table 101.
  • Page 392 Cool Temp MHI Coolant Temp Sensor Input (Moderately High) Cool Temp LO Coolant Temp Sensor Input (Low Least Severe) Coolnt Lvl LO Coolant Level (Low) ENG COOLANT LVL LO Engine Coolant Level is below the LOW threshold Diagnostic Trouble Codes DGC-2020HD...
  • Page 393 ECU Power Low Voltage ECU ERROR ECU Error ECU INTERNAL ERROR Caption string for ECU Internal Error Pump Pos Sns Noisy Pump Position Sensor Input Noise Pump Pos Sns Curr LO Pump Position Sensor Current (Low) DGC-2020HD Diagnostic Trouble Codes...
  • Page 394 Cylinder #5 EUI Circuit (Open) Cyl 5 EUI Ckt SHORT Cylinder #5 EUI Circuit (Shorted) Cyl 5 EUI Ckt MECH FL Cylinder #5 EUI Circuit (Mechanical Failure) Cyl 5 EUI QR INVLD Cylinder #5 EUI Circuit QR Code (Invalid) Diagnostic Trouble Codes DGC-2020HD...
  • Page 395 AUX I/O 13 Caption String for Auxiliary I/O 13 AUX I/O 14 Caption String for Auxiliary I/O 14 AUX I/O 15 Caption String for Auxiliary I/O 15 AUX I/O 16 Caption String for Auxiliary I/O 16 DGC-2020HD Diagnostic Trouble Codes...
  • Page 396 Caption String for Misfire detected on a single engine cylinder 1330 MISFIRE CYLINDER 8 Caption String for Misfire detected on a single engine cylinder 1331 MISFIRE CYLINDER 9 Caption String for Misfire detected on a single engine cylinder Diagnostic Trouble Codes DGC-2020HD...
  • Page 397 2659 EGR Flo Rt LO Exhaust Gas Recirculation Flow Rate (Low Least Severe) 2790 Trbo Cmp Out Tmp HI Turbo Compressor Outlet Temp (Moderately High) 2791 EGR Vlv Pos Invld Exhaust Gas Recirculation Valve Position Invalid DGC-2020HD Diagnostic Trouble Codes...
  • Page 398 523563 INJECTN PERIOD CYL 3 Caption String for Single Cylinder Injection Period 523564 INJECTN PERIOD CYL 4 Caption String for Single Cylinder Injection Period 523565 INJECTN PERIOD CYL 5 Caption String for Single Cylinder Injection Period Diagnostic Trouble Codes DGC-2020HD...
  • Page 399 Caption String for Metering Unit Valve 523617 ECU ERROR String for Diagnostic Trouble Code Indicating ECU Error Table 101. DTCs Displayed by the DGC-2020HD (FMI Strings) String Displayed Description DATA HI MOST SEVERE Data is higher than expected at the most severe level...
  • Page 400 9469300990 Rev B Diagnostic Trouble Codes DGC-2020HD...

  • Page 401: Revision History

    Initial Release • 3.05.03, Mar-14 Updated to support firmware version 1.00.02. Manual Revision and Date Change • A, Nov-13 Initial release • B, Mar-14 Added configurable hysteresis settings to generator protection elements. • Removed product registration information. DGC-2020HD Revision History...
  • Page 402 9469300990 Rev B Revision History DGC-2020HD...
  • Page 404 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:...

Table of Contents