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Basler DGC-2020ES Quick Start Instruction Manual

Digital genset controller
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12570 Route 143 • Highland, Illinois 62249-1074 USA
Tel +1 618.654.2341 • Fax +1 618.654.2351
www.basler.com • info@basler.com
DGC-2020ES
Digital Genset Controller
Quick Start Instruction Manual
9469200993, Rev B
November 2019
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  • Page 1 DGC-2020ES Digital Genset Controller Quick Start Instruction Manual Publication 12570 Route 143 • Highland, Illinois 62249-1074 USA Tel +1 618.654.2341 • Fax +1 618.654.2351 9469200993, Rev B www.basler.com • info@basler.com November 2019...
  • Page 2 Proposition 65 warning, we are notifying you that one or more of the Proposition 65 listed chemicals may be present in products we sell to you. For more information about the specific chemicals found in this product, please visit https://www.basler.com/Prop65.

  • Page 3: Conventions Used In This Manual

    9469200993 Preface This instruction manual provides basic installation and setup information for the DGC-2020ES Digital Genset Controller. To accomplish this, the following information is provided: Mounting • • Terminals and connectors Typical applications • BESTCOMSPlus software • ® Configuration •...
  • Page 4 The availability and design of all features and options are subject to modification without notice. Over time, improvements and revisions may be made to this publication. Before performing any of the following procedures, contact Basler Electric for the latest revision of this manual.

  • Page 5: Revision History

    9469200993 Revision History A historical summary of the changes made to this instruction manual is provided below. Revisions are listed in reverse chronological order. Visit www.basler.com to download the latest hardware, firmware, and BESTCOMSPlus revision ® histories. Instruction Manual Revision History...
  • Page 6 9469200993 Contents DGC-2020ES...

  • Page 7: Table Of Contents

    9469200993 Contents Introduction..............................1-1 Mounting..............................2-1 Terminals and Connectors ......................... 3-1 Typical Connections ........................... 4-1 BESTCOMSPlus ............................5-1 ® Configuration .............................. 6-1 BESTlogic™Plus ............................7-1 Controls and Indicators ..........................8-1 Troubleshooting ............................9-1 DGC-2020ES Contents...
  • Page 8 9469200993 Contents DGC-2020ES...

  • Page 9: Introduction

    This Quick Start manual is intended for use by qualified personnel only. Default Settings Each DGC-2020ES is delivered with default settings that are based on average values and may not be appropriate for your application. All settings must be properly configured for your application before running the engine-generator set.

  • Page 10: Engine Protection And Metering

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

  • Page 11: Style Number

    9469200993 MTU Protocol - A DGC-2020ES connected to a genset equipped with an MTU ECU receives oil • pressure, coolant temperature, and engine speed data from the engine controller, along with various alarms and pre-alarms that are MTU specific. In addition, the DGC-2020ES tracks and displays the active fault codes issued by the MTU engine ECU.
  • Page 12 9469200993 Introduction DGC-2020ES...

  • Page 13: 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 14 9469200993 Figure 2-2. Overall Dimensions Mounting DGC-2020ES...

  • Page 15: Terminals And Connectors

    9469200993 3 • Terminals and Connectors All DGC-2020ES terminals and connectors are located on the rear panel. DGC-2020ES terminals consist of a mini-B USB socket and plug-in connectors with spring clamp terminals. Figure 3-1 illustrates the rear panel terminals. Locator letters in the illustration correspond to the terminal block and connector descriptions in Table 3-1.
  • Page 16 Table 3-1. Rear Panel Terminal and Connector Descriptions Locator Description The majority of external, DGC-2020ES wiring is terminated at 8- or 15-position connectors with spring clamp terminals. These connectors plug into headers on the DGC-2020ES. The connectors and headers have a dovetailed edge that ensures proper connector orientation.

  • Page 17: Typical Connections

    9469200993 4 • Typical Connections Typical connection diagrams are provided in this chapter as a guide when wiring the DGC-2020ES for communication, mechanical senders, contact inputs and outputs, sensing, and control power. Connections for Typical Applications Typical connections for applications using three-phase wye, three-phase delta, single-phase AB, and single-phase AC generator voltage sensing are shown on the following pages.
  • Page 18 To ECU CAN bus 12/24V If component is under ECU control, do not connect to DGC-2020ES. Current inputs are 1A or 5A, depending on style. Connect to the ECU on an electronically controlled engine when the Bus sensing inputs are optional, depending on style.
  • Page 19 GEN CKT MAINS CKT GENERATOR ≤ 480V P0071-50 MPU+ MPU– OUT 1 OUT 2 Analog COOLANT Senders FUEL DGC-2020ES SENDER COM OUT 3 OUT 4 INPUT 7 GLOW PLUGS INPUT 6 To ECU Power or INPUT 5 Key-on Terminal INPUT 4...
  • Page 20 GEN CKT MAINS CKT GENERATOR ≤ 480V P0071-51 MPU+ MPU– OUT 1 OUT 2 Analog COOLANT Senders FUEL DGC-2020ES SENDER COM OUT 3 OUT 4 INPUT 7 GLOW PLUGS INPUT 6 To ECU Power or INPUT 5 Key-on Terminal INPUT 4...

  • Page 21: Can Connections

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

  • Page 22: Cem-2020 Connections

    2020ES. It is a remote auxiliary device that provides additional contact inputs and outputs for the DGC- 2020ES. This module interfaces to the DGC-2020ES via CAN, thus the CAN terminals are the only common connections (Figure 4-7) between the DGC-2020ES and CEM-2020. Refer to the CEM-2020 chapter for more information.

  • Page 23: Bestcomsplus

    BESTCOMSPlus uses plugins, allowing the user to manage several different Basler Electric products. The DGC-2020ES plugin must be activated before use. The plugin can be activated automatically by connecting to a DGC-2020ES, or manually by requesting an activation key from Basler Electric.

  • Page 24: Connect A Usb Cable

    DGC-2020ES. USB driver installation progress is shown in the Windows taskbar area. Windows will notify you when installation is complete. Connect a USB cable between the PC and your DGC-2020ES. Apply control power to the DGC-2020ES. Wait until the boot sequence is complete.
  • Page 25 2020ES and the USB cable is connected before opening the Device Manager. See Figure 5-5. Figure 5-5. Device Manager The DGC-2020ES plugin opens indicating that activation was successful. You can now configure the DGC-2020ES communication ports and other settings. DGC-2020ES...
  • Page 26 Manual Activation of the DGC-2020ES Plugin Manual activation of the DGC-2020ES plugin is required only if your initial use of BESTCOMSPlus will be on a PC that is not connected to a DGC-2020ES. Manual activation is described in the following paragraphs.
  • Page 27 Communication between BESTCOMSPlus and the DGC-2020ES is established by clicking on the Connect button on the DGC-2020ES Connection screen (see Figure 5-4) or by clicking on the Connect button on the lower menu bar of the main BESTCOMSPlus screen (Figure 5-1). Download all settings and logic from the DGC-2020ES by selecting Download Settings and Logic from the Communication pull- down menu.
  • Page 28 9469200993 BESTCOMSPlus® DGC-2020ES...

  • Page 29: Configuration

    The DGC-2020ES must be properly configured for operation with a specific application prior to running. An incomplete list of basic settings to consider when configuring the DGC-2020ES is provided below with their locations in BESTCOMSPlus and the front panel. Ensure that all settings required for your application are configured in accordance with the generator/engine manufacturer(s) recommendations, authority having jurisdiction, and customer requirements.

  • Page 30: Saving Settings

    In the Upper Menu Bar, Click Communications > Upload Settings to Device You are prompted to enter the password. The default password is “OEM”. Press Enter or click Log In and the settings are uploaded to the connected DGC-2020ES. Configuration...

  • Page 31: Bestlogic™Plus

    The Active Logic Scheme Digital Genset Controllers must have an active logic scheme in order to function. All Basler Electric DGC- 2020ES units are delivered with a default, active logic scheme pre-loaded in memory. If the function block configuration and output logic of the default logic scheme meets the requirements of your application, then only the operating settings (power system parameters and threshold settings) need to be adjusted before placing the DGC-2020ES in service.

  • Page 32: Programming Bestlogic™Plus

    The view of the Main Logic, 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-2020ES: BESTlogic™Plus...

  • Page 33: Offline Logic Simulator

    An example of the offline logic simulator is shown in Figure 7-2. Output 1 is Logic 0 (red) when Virtual Switch 1 is Logic 0 (red) and Fixed 1 is Logic 1 (green). DGC-2020ES BESTlogic™Plus...

  • Page 34: Example 2 - And Gate Connections

    Example 3 - Multiple Logic Connections In this example, there are two comment boxes, which may be placed on the logic diagram. Double-click a comment box to modify the inside text. Output 3 becomes true when the 27TRIP is true. Output 1 BESTlogic™Plus DGC-2020ES...
  • Page 35 9469200993 becomes true when the High Coolant Temp is true. Output 2 becomes true when the DGC-2020ES is in RUN mode (RUN Mode true). Refer to Figure 7-5. Figure 7-5. Example 3 – Multiple Logic Connections DGC-2020ES BESTlogic™Plus...
  • Page 36 9469200993 BESTlogic™Plus DGC-2020ES...

  • Page 37: Controls And Indicators

    Alarm Indicator. This red LED lights continuously during alarm conditions and flashes during pre-alarm conditions. Not in Auto Indicator. This red LED lights when the DGC-2020ES is not operating in Auto mode. When the DGC-2020ES is operating in Run or Off mode, this LED is on.
  • Page 38 Off Pushbutton and Mode Indicator. Pressing this button places the DGC-2020ES in Off mode. The red Off mode LED lights when the DGC-2020ES is in Off mode. This button also resets the Breaker Management Pre-Alarms and all MTU ECU Alarms.

  • Page 39: Troubleshooting

    9469200993 9 • Troubleshooting If you do not get the results that you expect from the DGC-2020ES, first check the programmable settings for the appropriate function. Use the following troubleshooting procedures when difficulties are encountered in the operation of your genset control system.

  • Page 40: Incorrect Display Of Generator Voltage

    Use a voltmeter connected between the BATT– terminal (17) and the SENDER COM terminal (2) on the DGC-2020ES to verify that there is no voltage difference at any time. Any voltage differences may manifest themselves as erratic sender readings. Wiring should be corrected so that no differences exist.

  • Page 41: Ground Faults Detected In Ungrounded System Applications

    Step 3: If ground faults are detected on a DGC-2020ES in an ungrounded system application, it is recommended that potential transformers be employed on the voltage sensing inputs to provide full isolation between the DGC-2020ES and monitored voltage phases.

  • Page 42: Generator Breaker Does Not Open When It Should

    9469200993 Step 8: Verify the wiring to the breaker from the DGC-2020ES. If it seems OK, you can do a manual close and open by modifying the programmable logic. Map some unused outputs to the OPEN and CLOSE outputs from the Gen Breaker Block in the programmable logic. Map a virtual switch to the logic output that would normally be the breaker open output.

  • Page 43: Mains Breaker Does Not Close After Mains Returns

    CONDITION DETECTION screen to achieve correct detection. Step 5: Verify the wiring to the breaker from the DGC-2020ES. If it seems OK, you can do a manual close and open by modifying the programmable logic. Map some unused outputs to the OPEN and CLOSE outputs from the Gen Breaker Block in the programmable logic.
  • Page 44 9469200993 Troubleshooting DGC-2020ES...
  • Page 46 Highland IL 62249-1074 USA Suzhou Industrial Park 15-06 Peninsula Plaza Tel: +1 618.654.2341 215122 Suzhou Singapore 179098 Fax: +1 618.654.2351 P.R. CHINA Tel: +65 68.44.6445 email: info@basler.com Tel: +86 512.8227.2888 Fax: +65 68.44.8902 Fax: +86 512.8227.2887 email: singaporeinfo@basler.com email: chinainfo@basler.com...
  • Page 47 DGC-2020ES Digital Genset Controller Installation Instruction Manual Publication 12570 Route 143 • Highland, Illinois 62249-1074 USA Tel +1 618.654.2341 • Fax +1 618.654.2351 9469200994, Rev B www.basler.com • info@basler.com November 2019...
  • Page 48 Proposition 65 warning, we are notifying you that one or more of the Proposition 65 listed chemicals may be present in products we sell to you. For more information about the specific chemicals found in this product, please visit https://www.basler.com/Prop65.

  • Page 49: Conventions Used In This Manual

    9469200994 Preface This instruction manual provides information about the installation of the DGC-2020ES Digital Genset Controller. To accomplish this, the following information is provided: Mounting • • Terminals and connectors Typical applications • Power input • Voltage and current sensing •...
  • Page 50 The availability and design of all features and options are subject to modification without notice. Over time, improvements and revisions may be made to this publication. Before performing any of the following procedures, contact Basler Electric for the latest revision of this manual.
  • Page 51 9469200994 Revision History A historical summary of the changes made to this instruction manual is provided below. Revisions are listed in reverse chronological order. Visit www.basler.com to download the latest hardware, firmware, and BESTCOMSPlus revision ® histories. Instruction Manual Revision History...
  • Page 52 9469200994 Contents DGC-2020ES...
  • Page 53 9469200994 Contents Mounting..............................1-1 Terminals and Connectors ......................... 2-1 Typical Connections ........................... 3-1 Power Input ..............................4-1 Voltage and Current Sensing ........................5-1 Speed Signal Inputs ........................... 6-1 Specifications ............................. 7-1 Maintenance ............................... 8-1 Troubleshooting ............................9-1 DGC-2020ES Contents...
  • Page 54 9469200994 Contents DGC-2020ES...

  • Page 55: 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 56 9469200994 Figure 1-2. Overall Dimensions Mounting DGC-2020ES...

  • Page 57: Terminals And Connectors

    9469200994 2 • Terminals and Connectors All DGC-2020ES terminals and connectors are located on the rear panel. DGC-2020ES terminals consist of a mini-B USB socket and plug-in connectors with spring clamp terminals. Figure 2-1 illustrates the rear panel terminals. Locator letters in the illustration correspond to the terminal block and connector descriptions in Table 2-1.

  • Page 58: Operating Power

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

  • Page 59: Generator Current Sensing

    The DGC-2020ES has sensing inputs for A-phase, B-phase, and C-phase generator current. A DGC- 2020ES with a style number of 1xx has a 1 Aac nominal current sensing and a DGC-2020ES with a style number of 5xx indicates 5 Aac nominal current sensing. Generator current sensing terminals are listed in Table 2-3.

  • Page 60: Analog Engine Sender Inputs

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

  • Page 61: Output Contacts

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

  • Page 62: Optional Remote Display Panel Connections

    Remote Display Panel. Twisted-pair conductors are recommended for connecting the communication terminals of the DGC-2020ES and Remote Display Panel. Communication may become unreliable if the connection wires exceed 1,219 m (4,000 ft). Table 2-12 lists the DGC-2020ES terminals that connect to the Remote Display Panel.

  • Page 63: Typical Connections

    9469200994 3 • Typical Connections Typical connection diagrams are provided in this chapter as a guide when wiring the DGC-2020ES for communication, mechanical senders, contact inputs and outputs, sensing, and control power. Connections for Typical Applications Typical connections for applications using three-phase wye, three-phase delta, single-phase AB, and single-phase AC generator voltage sensing are shown on the following pages.
  • Page 64 To ECU CAN bus 12/24V If component is under ECU control, do not connect to DGC-2020ES. Current inputs are 1A or 5A, depending on style. Connect to the ECU on an electronically controlled engine when the Bus sensing inputs are optional, depending on style.
  • Page 65 GEN CKT MAINS CKT GENERATOR ≤ 480V P0071-50 MPU+ MPU– OUT 1 OUT 2 Analog COOLANT Senders FUEL DGC-2020ES SENDER COM OUT 3 OUT 4 INPUT 7 GLOW PLUGS INPUT 6 To ECU Power or INPUT 5 Key-on Terminal INPUT 4...
  • Page 66 GEN CKT MAINS CKT GENERATOR ≤ 480V P0071-51 MPU+ MPU– OUT 1 OUT 2 Analog COOLANT Senders FUEL DGC-2020ES SENDER COM OUT 3 OUT 4 INPUT 7 GLOW PLUGS INPUT 6 To ECU Power or INPUT 5 Key-on Terminal INPUT 4...
  • Page 67 120 ohm, ½ watt terminating resistor should be installed across terminals 14 (CANL) and 13 (CANH). If the DGC-2020ES is not providing one end of the J1939 bus, the stub connecting the DGC-2020ES to the bus should not exceed 914 mm (3 ft) in length.
  • Page 68 2020ES. It is a remote auxiliary device that provides additional contact inputs and outputs for the DGC- 2020ES. This module interfaces to the DGC-2020ES via CAN, thus the CAN terminals are the only common connections (Figure 3-7) between the DGC-2020ES and CEM-2020. Refer to the CEM-2020 chapter for more information.

  • Page 69: Power Input

    9469200994 4 • Power Input Control power for the DGC-2020ES is typically supplied by the genset starter battery. Power from the battery is supplied to an internal power supply that provides power for DGC-2020ES logic, protection, and control functions. Nominal Voltage Input and Acceptable Range of Input Voltage A nominal voltage of 12 or 24 Vdc within a range of 6 to 32 Vdc is accepted.
  • Page 70 9469200994 Power Input DGC-2020ES...

  • Page 71: Voltage And Current Sensing

    The DGC-2020ES has sensing inputs for A-phase, B-phase, and C-phase generator current. Depending on the style number, a DGC-2020ES has a nominal sensing current rating of 1 Aac or 5 Aac. A style number of 1xx indicates 1 Aac nominal current sensing and a style number of 5xx indicates 5 Aac nominal current sensing.
  • Page 72 9469200994 Note Unused current sensing inputs should be shorted to minimize noise pickup. Caution Generator current sensing terminals 37 (IA–), 35 (IB–), and 33 (IC–) must be terminated to ground for proper operation. Voltage and Current Sensing DGC-2020ES...

  • Page 73: Speed Signal Inputs

    Terminals Magnetic pickup connections are provided at terminals 31 (+) and 32 (–). Generator Sensing Voltage The generator voltage sensed by the DGC-2020ES is used to measure frequency and can be used to measure machine speed. Terminals Sensing voltage is applied to terminals 45 (A-phase), 43 (B-phase).
  • Page 74 9469200994 Speed Signal Inputs DGC-2020ES...

  • Page 75: Specifications

    9469200994 7 • Specifications DGC-2020ES electrical and physical characteristics are listed in the following paragraphs. Control Power Nominal ..........12 or 24 Vdc Range ..........6 to 32 Vdc Terminals.......... 18 (+), 17 (–), 16 (chassis ground) Power Consumption Sleep Mode ........4.5 W - LCD heater off, all relays de-energized Normal Operational Mode ....

  • Page 76: Contact Sensing

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

  • Page 77: Oil Pressure Sensing

    VT Ratio Range ........ 1:1 to 125:1 in primary increments of 1 Accuracy* ......... ±3.0% of programmed rated voltage or ±3 Vac Display Resolution ......1 Vac Voltage metering indicates 0 V when generator voltage is below 2% of the full-scale rating. DGC-2020ES Specifications...

  • Page 78: Generator Current (Rms)

    † Applies when temperature is between –40°C to +70°C (–40°F to +158°F). Note For the DGC-2020ES to correctly meter power factor, the generator must be rotating in the same phase sequence as dictated by the generator phase rotation setting. Real Power...
  • Page 79 Metering Range ........ 0 to 5,000 hours Update Interval ......... 6 min Accuracy........... ±1% or actual indication or ±12 min Display Resolution ......1 minute Fuel Level Metering Range ........ 0 to 100% Accuracy........... ±3% (subject to accuracy of sender) Display Resolution ......1.0% DGC-2020ES Specifications...

  • Page 80: Generator Protection Functions

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

  • Page 81: Real Time Clock

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

  • Page 82: Csa Certification

    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 83: Nfpa Compliance

    Respect to the Restriction of Hazardous Substances (ROHS2) NFPA Compliance Designed to comply with NFPA Standard 110, Standard for Emergency and Standby Power. EAC Mark (Eurasian Conformity) • TC RUUS.HO03.B.00742 Physical Weight ..........1.9 lb (0.86 kg) Dimensions........See the Mounting chapter. DGC-2020ES Specifications...
  • Page 84 7-10 9469200994 Specifications DGC-2020ES...

  • Page 85: Maintenance

    Periodically check that the mounting hardware is clean and fastened with the proper amount of torque. DGC-2020ES units are manufactured using state-of-the-art, surface- mount technology. These components are encased in potting material. As such, Basler Electric recommends that no repair procedures be attempted by anyone other than Basler Electric personnel.
  • Page 86 9469200994 Maintenance DGC-2020ES...

  • Page 87: Troubleshooting

    9469200994 9 • Troubleshooting If you do not get the results that you expect from the DGC-2020ES, first check the programmable settings for the appropriate function. Use the following troubleshooting procedures when difficulties are encountered in the operation of your genset control system.

  • Page 88: Incorrect Display Of Generator Voltage

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

  • Page 89: Generator Breaker And Mains Breaker

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

  • Page 90: Generator Breaker Does Not Open When It Should

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

  • Page 91: Dgc-2020Es Front Panel Debug Screen

    Step 5: Verify the wiring to the breaker from the DGC-2020ES. If it seems OK, you can do a manual close and open by modifying the programmable logic. Map some unused outputs to the OPEN and CLOSE outputs from the Gen Breaker Block in the programmable logic.
  • Page 92 9469200994 Troubleshooting DGC-2020ES...
  • Page 94 Highland IL 62249-1074 USA Suzhou Industrial Park 15-06 Peninsula Plaza Tel: +1 618.654.2341 215122 Suzhou Singapore 179098 Fax: +1 618.654.2351 P.R. CHINA Tel: +65 68.44.6445 email: info@basler.com Tel: +86 512.8227.2888 Fax: +65 68.44.8902 Fax: +86 512.8227.2887 email: singaporeinfo@basler.com email: chinainfo@basler.com...
  • Page 95 DGC-2020ES Digital Genset Controller Configuration Instruction Manual Publication 12570 Route 143 • Highland, Illinois 62249-1074 USA Tel +1 618.654.2341 • Fax +1 618.654.2351 9469200995, Rev B www.basler.com • info@basler.com December 2019...
  • Page 96 Proposition 65 warning, we are notifying you that one or more of the Proposition 65 listed chemicals may be present in products we sell to you. For more information about the specific chemicals found in this product, please visit https://www.basler.com/Prop65.

  • Page 97: Conventions Used In This Manual

    9469200995 Preface This instruction manual provides information about the configuration of the DGC-2020ES Digital Genset Controller. To accomplish this, the following information is provided: Device information and security settings • Configuration via BESTCOMSPlus and the front panel • ® Communication settings •...
  • Page 98 The availability and design of all features and options are subject to modification without notice. Over time, improvements and revisions may be made to this publication. Before performing any of the following procedures, contact Basler Electric for the latest revision of this manual.

  • Page 99: Revision History

    9469200995 Revision History A historical summary of the changes made to this instruction manual is provided below. Revisions are listed in reverse chronological order. Visit www.basler.com to download the latest hardware, firmware, and BESTCOMSPlus revision ® histories. Instruction Manual Revision History...
  • Page 100 9469200995 Revision History DGC-2020ES...
  • Page 101 Engine Sender Inputs ..........................7-1 Contact Inputs ............................8-1 Contact Outputs ............................9-1 Breaker Management ..........................10-1 Alarm Configuration ..........................11-1 Generator Protection ..........................12-1 BESTlogic™Plus ............................13-1 Exhaust Treatment ........................... 14-1 Troubleshooting ............................15-1 BESTCOMSPlus Settings Loader Tool ....................16-1 DGC-2020ES Contents...
  • Page 102 9469200995 Contents DGC-2020ES...

  • Page 103: Security

    ® Changing Passwords Passwords can be changed only after communication between the PC and DGC-2020ES is established. Changes to passwords are made through the Device Security Setup screen. Use the Settings Explorer in BESTCOMSPlus to open the General Settings, Device Security Setup screen.
  • Page 104 DGC-2020ES. Verify the passwords obtained from the DGC-2020ES are correct. Once all desired settings have been loaded into the DGC-2020ES, save the settings file. The resulting settings file has the passwords saved as part of the saved settings. At this point, the password information has been successfully saved in the settings file. The process of saving the passwords into the settings file is complete.
  • Page 105 Once connected, click the “Open File” button that is used to load a settings file into the DGC-2020ES. You will be prompted asking if you wish to load settings and logic into the DGC-2020ES. Select Yes if you need to upload settings logic. Select No if all you need to do is update security. If you select No, the settings file opens into BESTCOMSPlus memory.
  • Page 106 9469200995 Security DGC-2020ES...

  • Page 107: Configuration Through The Front Panel

    This chapter provides information on configuring DGC-2020ES settings through the front panel. Display Setup The DGC-2020ES LCD can be customized to fit the needs of your specific application. The options can be adjusted using the front panel controls and through BESTCOMSPlus .

  • Page 108: Settings Menu

    Settings Menu The display structure of the Settings menu on the front panel is provided below. Refer to the Controls and Indicators chapter in the Operation manual for a full description of DGC-2020ES controls and indicators. GENERAL SETTINGS FRONT PANEL HMI ●...
  • Page 109 ○ SECONDS ○ UTC OFFSET ○ DST ENABLED ○ CLK NOT SET WRN ○ VIEW DATE/TIME ● VERSION INFO ● DGC-2020ES ○ FIRMWARE VERSION ■ BOOT CODE VERSION ■ SERIAL NUMBER ■ PART NUMBER ■ MODEL NUMBER ■ LANGUAGE VERSION ■...
  • Page 110 GOV PRM SW (Visible when ECU is configured for MTU ADEC or MTU Smart □ Connect.) ENG STRT PRIME (Visible when ECU is configured for MTU MDEC 304, or MTU □ ECU7/ECU8.) FAN OVERRIDE (Visible when ECU is configured for MTU MDEC 304, or MTU □ ECU7/ECU8.) Configuration through the Front Panel DGC-2020ES...
  • Page 111 # CYCLES (Visible when Cycle is selected for Cranking Style.) ○ CONT TIME (Visible when Continuous is selected for Cranking Style.) ○ CYCLE TIME ○ REST TIME ○ COOLDWN TIME ○ COOLDOWN CONFIG ○ RESTART DELAY ○ OFF MODE COOLDN ○ DGC-2020ES Configuration through the Front Panel...
  • Page 112 RECOGNITION (Visible when an INPUT is selected.) ■ BATTLE OVERRIDE ○ INPUT ■ RECOGNITION (Visible when an INPUT is selected.) ■ LOW LINE OVERRIDE ○ INPUT ■ RECOGNITION (Visible when an INPUT is selected.) ■ Configuration through the Front Panel DGC-2020ES...
  • Page 113 ■ ENG KW OVRLD-2 ■ ENG KW OVRLD-3 ■ MAINTENANCE INTERVAL ○ ENABLE ■ THRESHOLD ■ BATTERY OVERVOLTAGE ○ ENABLE ■ THRESHOLD ■ LOW BATTERY VOLTAGE ○ ENABLE ■ THRESHOLD ■ ACTIVATN DLY ■ DGC-2020ES Configuration through the Front Panel...
  • Page 114 SENDER FAIL ● COOL TEMP SENDR FAIL ○ CONFIG TYPE ■ RECOGNITION ■ ACTIVATN DLY ■ MIN OHMS ■ MAX OHMS ■ SF DISPLAY ■ OIL PRESS SENDR FAIL ○ CONFIG TYPE ■ RECOGNITION ■ Configuration through the Front Panel DGC-2020ES...
  • Page 115 50 OVERCURRENT ● LOW LINE SF (Visible when an input is selected for the Low Line Override programmable function.) ○ 3 / 1 PHASE SETTINGS ○ PICKUP ■ TIME DELAY ■ ALARM CONFIG ■ DGC-2020ES Configuration through the Front Panel...
  • Page 116 ■ UF DROPOUT ■ TIME DELAY ■ LOW LINE SF (Visible when an input is selected for the Low Line Override programmable ■ function.) ALT FREQ SF ■ BUS FAILED ○ TIME DELAY ■ Configuration through the Front Panel DGC-2020ES...
  • Page 117 9469200995 2-11 LOGIC TIMERS TIMER X (X = 1 to 10) ● HOURS ○ MINUTES ○ SECONDS ○ ENTER PASSWORD LOGOUT (Visible when logged in through the front panel.) DGC-2020ES Configuration through the Front Panel...
  • Page 118 2-12 9469200995 Configuration through the Front Panel DGC-2020ES...

  • Page 119: Bestcomsplus

    DGC-2020ES is brought into BESTCOMSPlus by downloading settings and logic from the DGC-2020ES. This gives the user the option of developing a custom setting file by modifying the default logic scheme or by building a unique scheme from scratch.

  • Page 120: System Recommendations

    BESTCOMSPlus software is built on the Microsoft® .NET Framework. The setup utility that installs BESTCOMSPlus on your PC also installs the DGC-2020ES plugin and the required version of .NET Framework (if not already installed). BESTCOMSPlus operates with systems using Windows 7 SP1, ®...
  • Page 121 DGC-2020ES. USB driver installation progress is shown in the Windows taskbar area. Windows will notify you when installation is complete. Connect a USB cable between the PC and your DGC-2020ES. Apply operating power to the DGC- 2020ES. Wait until the boot sequence is complete.

  • Page 122: Installing The Usb Driver If Automatic Installation Fails

    (COM & LPT) branch. Locate the device named CP2101 USB to UART Bridge Controller (COMx). The COM Port number will be displayed in parenthesis (COMx). Be sure operating power is applied to the DGC-2020ES and the USB cable is connected before opening the Device Manager. See Figure 3-5. Figure 3-5. Device Manager The DGC-2020ES plugin opens indicating that activation was successful.

  • Page 123: Establishing Communication

    Manual Activation of the DGC-2020ES Plugin Manual activation of the DGC-2020ES plugin is required only if your initial use of BESTCOMSPlus will be on a PC that is not connected to a DGC-2020ES. Manual activation is described in the following paragraphs.
  • Page 124 9469200995 down menu. BESTCOMSPlus will read all settings and logic from the DGC-2020ES and load them into BESTCOMSPlus memory. See Figure 3-7. Figure 3-7. Processing, Please Wait… Advanced Properties Click the Advanced button on the Connection screen to display the Advanced Properties dialog. Default settings are shown in Figure 3-8.
  • Page 125 View general, detailed build, and system information Lower Menu Bar (DGC-2020ES Plugin) The lower menu bar functions are listed and described in Table 3-3. Table 3-3. Lower Menu Bar (DGC-2020ES Plugin) Menu Button Description Enables you to show/hide the Metering Panel, Settings Panel, or Settings Info Panel.

  • Page 126: Settings Explorer

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

  • Page 127: Metering Explorer

    Right-clicking the hyperlinked setting name will restore the setting to its default value. Note It is possible to save a DGC-2020ES settings file in BESTCOMSPlus with noncompliant settings. However, it is not possible to upload noncompliant settings to the DGC-2020ES.

  • Page 128: Settings File Management

    Figure 3-11. View Menu, BESTspace™, Save Workspace Screen Settings File Management A settings file contains all DGC-2020ES settings, including logic. A settings file assumes a file extension of “∗.bstx”. It is possible to save the logic only as a separate logic library file on the BESTlogicPlus Programmable Logic screen.
  • Page 129 Select the Save button to complete the save. Upload Settings and/or Logic to Device To upload a settings file to the DGC-2020ES, open the file through BESTCOMSPlus or create the file using BESTCOMSPlus. Then pull down the Communication menu and select Upload Settings and Logic to Device.

  • Page 130: Firmware Updates

    Figure 3-13. Settings Comparison Results Screen Firmware Updates Future enhancements to the DGC-2020ES functionality will make a firmware update desirable. Because default settings are loaded when DGC-2020ES firmware is updated, your settings should be saved in a file prior to upgrading firmware. BESTCOMSPlus®...

  • Page 131: Upgrading Firmware In Expansion Modules

    Upgrading Firmware in Expansion Modules The following procedure is used to upgrade firmware in the DGC-2020ES expansion module. This must be completed before upgrading firmware in the DGC-2020ES. If no expansion module is present, proceed to Upgrading Firmware in the DGC-2020ES.
  • Page 132 3-14 9469200995 Place the DGC-2020ES in OFF mode. This can be accomplished by clicking the Off button on the Control screen inside the Metering Explorer or by pressing the Off button on the DGC-2020ES front panel. Enable the expansion module that is present in the system. If it has not already been enabled, enable the expansion module on the SETTINGS >...
  • Page 133 GENERAL SETTINGS > STYLE NUMBER in BESTCOMSPlus. If the style number of the settings file does not match that of the DGC-2020ES into which it is to be loaded, disconnect from the DGC-2020ES, then modify the style number in the settings file.

  • Page 134: Bestcomsplus ® Updates

    Ongoing DGC-2020ES functionality enhancements may make future DGC-2020ES firmware updates desirable. Enhancements to DGC-2020ES firmware typically coincide with enhancements to the DGC- 2020ES plugin for BESTCOMSPlus. When a DGC-2020ES is updated with the latest version of firmware, the latest version of BESTCOMSPlus should also be obtained.

  • Page 135: Communication

    The rear-panel, mini-B USB port enables local communication with a PC running BESTCOMSPlus ® software. The DGC-2020ES is connected to a PC using a standard USB cable. BESTCOMSPlus is a Windows -based communication software package that is supplied with the DGC-2020ES. A detailed ®...
  • Page 136 °C °F Coolant Level 500 ms Coolant Pressure 500 ms DEF Inducement Level - Level of 5246 Inducement Not to Run the Engine DEF Severity Level - Severity of Tank 5245 Low Level DEF Tank 1 Level 1761 Communication DGC-2020ES...
  • Page 137 Throttle (Accelerator Pedal) Position 50 ms Total Engine Hours hours hours Requested 1.5 s Total Fuel Used liters gallons Requested 1.5 s Transmission Oil Pressure Transmission Oil Temperature °C °F Trip Average Fuel Rate liters gallons 500 ms 1029 DGC-2020ES Communication...
  • Page 138 ∗ SPN is suspect parameter number. Caution When the CAN is enabled, the DGC-2020ES ignores the following sender inputs: oil pressure, coolant temperature, and magnetic pickup. Under certain circumstances, the following strings may be displayed on the front panel HMI and in the Metering Explorer of BESTCOMSPlus: •...

  • Page 139: Can Setup

    DGC-2020ES. SPN Conversion Method The most common SPN conversion method is 4 and is the default for the DGC-2020ES. Refer to ECU manufacturer documentation to determine the correct SPN conversion method of the ECU and set the SPN Conversion Method setting in the DGC-2020ES accordingly.
  • Page 140 Select if the ECU is not to be on line at all times. Often ECUs are allowed to go “off line” to conserve battery drain when the engine is not running. The DGC-2020ES will “pulse” it periodically to force it to be active to allow the DGC-2020ES to read data such as coolant temperature and coolant level.

  • Page 141: Ecu Setup

    ECU. The settling time should be set long enough so that any ECU parameters that require time to “settle down” after the ECU is on line can do so. Since the DGC-2020ES may use some of the ECU data for alarm or pre-alarm annunciation, it is important that the data have time to settle.
  • Page 142 When the Engine Parameter Transmit setting is enabled, the DGC-2020ES broadcasts engine metered parameters over CAN. When the Engine Parameter Transmit setting is disabled, transmission of J1939 commands from the DGC-2020ES to the engine are disabled, but commands from the engine to the DGC-2020ES are allowed.
  • Page 143 Stop Request - sent when shutting down the engine. • Idle Request - sent when the Idle Request logic element is true in BESTlogicPlus. • Preheat Request - sent anytime the DGC-2020ES would normally have its PRE relay closed for • engines requiring a preheat contact. •...
  • Page 144 4-10 9469200995 Rated Speed (50 or 60 Hz) - sent based on the Rated Speed setting of the DGC-2020ES. However, • these are reversed if the Alternate Frequency Override is true. A setting of 60 Hz Rated Speed results in 50 Hz being sent and a setting of 50 Hz Rated Speed results in 60 Hz being sent when the Alternate Frequency Override is true.
  • Page 145 The DGC-2020ES sends starter engagement requests to the ECU via the SAE J1939 Engine Start Control PGN. When the DGC-2020ES requests the starter to be engaged it sends a value of 01 (binary) for the two-bit starter engagement parameter. Otherwise the DGC-2020ES sends a value of 00 (binary) for the two-bit starter engagement parameter.

  • Page 146: Remote Display Panel (Optional)

    Fuel leak/Sender failure∗† Sender failure† • ∗ This can be configured in the DGC-2020ES as None, Alarm, or Pre-alarm. See the Contact Inputs chapter for more information. The LED on the Remote Display Panel illuminates when the input that is Communication...
  • Page 147 Additionally, the Remote Display Panel indicates when the DGC-2020ES is not operating in Auto mode and when the generator is supplying load or when the DGC-2020ES is in an alarm state not listed above. Refer to Basler Publication 9318100990 for more information on the Remote Display Panel.
  • Page 148 4-14 9469200995 Communication DGC-2020ES...

  • Page 149: Device Configuration

    In some cases, the ECU takes longer than the DGC-2020ES to power up. The power up delay setting is used to delay the initial pulsing of the ECU for data on DGC-2020ES power up. This setting ranges from 0 to 60 seconds in 1 second increments.

  • Page 150: Eps Supplying Load

    The value of the scale factor setting serves as a multiplier for the threshold setting. For example, if a scale factor contact input is received by the DGC-2020ES and the scale factor setting is 2.000, the threshold setting is doubled (2.000 x Threshold setting).

  • Page 151: Generator Connection

    This setting accepts values from 10 to 450, in increments of 0.01. Battery Volts The nominal voltage of the starter battery is used by the DGC-2020ES to detect and annunciate battery overvoltage and low or weak battery voltage. The Battery Volts settings consist of 12 V and 24 V.

  • Page 152: Phase Rotation

    The Phase Rotation setting allows selection of ABC or CBA rotation according to the phase rotation connection of the machine. The DGC-2020ES calculates the power angle as the angle between the Phase AB voltage and phase B current. An angle compensation factor, determined by the phase rotation setting, is then applied.

  • Page 153: Crank Settings

    1 second. Cranking The DGC-2020ES can be programmed for either cycle or continuous cranking. Cycle cranking provides multiple engine starting attempts. Each starting attempt consists of a fixed interval of engine cranking followed by a rest interval. The Number of Crank Cycles setting accepts values from 1 to 7, in increments of 1.
  • Page 154 2.9 to 150 psi, 0.2 to 10.3 bar, and 20 to 1,034.5 kPa, in increments of 0.1. Cool Down After the load is removed from a genset, the DGC-2020ES implements a smart cooldown function. This function ensures that the engine and turbocharger properly cool down by maintaining engine operation for a user-defined duration.

  • Page 155: Automatic Restart

    Figure 5-4. Settings Explorer, System Parameters, Crank Settings Screen Automatic Restart When enabled, the Automatic Restart clears all alarms automatically if the DGC-2020ES shuts down due to an alarm condition. An attempt to restart the engine is made, after a predetermined time delay, if the ATS contact input is closed.
  • Page 156 Minute settings and will run for the duration established by the Run Period Hours and Run Period Minutes settings. These settings are available for all modes. Run with Load: When enabled, the DGC-2020ES closes the generator breaker during the run time. Week Interval: Accepts values 1 through 52. Enabled when Mode is set to N Week Intervals.

  • Page 157: Sensing Transformers

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

  • Page 158: Relay Control

    Gen CT Primary Amps setting. For example, if a scale factor contact input is received by the DGC-2020ES and the scale factor setting is 2.000, the Gen CT Primary Amps setting is doubled (2.000 x Gen CT Primary Amps).
  • Page 159 If determined to be in low-line configuration, the Low-Line Override function forces the DGC-2020ES into the low-line configuration. If the Low-Line Override function is assigned to a contact output, the state of the contact output and the detected configuration are ORed.
  • Page 160 5-12 9469200995 Device Configuration DGC-2020ES...

  • Page 161: Timekeeping

    9469200995 6 • Timekeeping The DGC-2020ES provides a real-time clock with capacitor backup that is capable of operating the clock for up to 24 hours after power is removed from the controller. As the capacitor nears depletion, an internal backup battery takes over and maintains timekeeping. The battery will maintain the clock for approximately ten years depending on conditions.

  • Page 162: Setting The Time And Date

    Setting the Time and Date Time and date settings are made through BESTCOMSPlus on the Real Time Clock screen (Figure 6-2) of the Metering Explorer. Settings can also be made through the front panel. Figure 6-2. Metering Explorer, Real Time Clock Screen Timekeeping DGC-2020ES...

  • Page 163: Engine Sender Inputs

    Operation A current is provided to each sender. The developed voltage is measured and scaled for use by the internal circuitry. An open circuit or short circuit across the sender terminals will cause the DGC-2020ES to indicate a failed sender.
  • Page 164 If you want to save newly entered sender data as a sender library file, click Create Fuel Settings File and enter a file name and location to save the file. Click the Send Settings button in BESTCOMSPlus to send the sender settings to the DGC-2020ES. Figure 7-1. Settings Explorer, Programmable Senders, Fuel Level Screen...
  • Page 165 If you want to save newly entered sender data as a sender library file, click Create Oil Settings File and enter a file name and location to save the file. Click the Send Settings button in BESTCOMSPlus to send the sender settings to the DGC-2020ES. Figure 7-2. Settings Explorer, Programmable Senders, Oil Pressure Screen...
  • Page 166 Figure 7-3. Settings Explorer, Programmable Senders, Coolant Temperature Screen Sender Failure Detection The DGC-2020ES can be configured to annunciate a pre-alarm or alarm when a loss of signal is detected at the coolant temperature, oil pressure, or fuel level sender input. Contact recognition can be set to Always or While Engine Running Only.
  • Page 167 In a Grounded Delta configuration where one phase (A, B, or C) of the delta connection is grounded, it is likely a Voltage Sensing Fail condition will occur. In Delta connected systems where the DGC-2020ES neutral input is not connected, it is uncertain which line-to-neutral voltages will be monitored by the DGC-2020ES. Spurious Voltage Sensing Fail annunciations could occur.
  • Page 168 9469200995 Engine Sender Inputs DGC-2020ES...

  • Page 169: Contact Inputs

    9469200995 8 • Contact Inputs Contact inputs are available to initiate DGC-2020ES actions. The DGC-2020ES has seven programmable contact sensing inputs. Additional contact inputs can be accommodated with an optional CEM-2020 (Contact Expansion Module). Contact Basler Electric for availability and ordering information.

  • Page 170: Programmable Functions

    Emergency Stop – When an input is assigned to the Emergency Stop Programmable Function, the input functions in a normally-closed manner. When the input is closed, no alarm is annunciated. When the input is open, the DGC-2020ES will open the Start, Run, and Prestart relays and annunciate an Emergency Stop Alarm.
  • Page 171 The Programmable Functions screen is found in the BESTCOMSPlus Settings Explorer under the Programmable Inputs category. If using the front panel, navigate to Settings > Programmable Inputs > Programmable Functions. The BESTCOMSPlus Programmable Functions screen is illustrated in Figure 8-2. Figure 8-2. Settings Explorer, Programmable Inputs, Programmable Functions DGC-2020ES Contact Inputs...
  • Page 172 9469200995 Contact Inputs DGC-2020ES...

  • Page 173: Contact Outputs

    RUN output connections are made through terminals located on the RUN relay. Relay Control In some applications, it may be beneficial to modify the standard operation of the DGC-2020ES Run, Pre- Start, or Start relays. If desired, these relays can be configured to operate outside their predefined functionality.

  • Page 174: Programmable Output Configuration

    Figure 9-2. Example Logic Scheme of Programmable Relays Programmable DGC-2020ES controllers have four programmable output contacts (OUT 1 through 4). An additional 24 contact outputs are provided with an optional CEM-2020 (Contact Expansion Module). An optional CEM- 2020H (Contact Expansion Module - High Current) provides 18 contact outputs.

  • Page 175: Configurable Elements

    If used for an alarm or pre-alarm, the user-assigned name appears in the alarm or pre-alarm annunciation and in the DGC-2020ES event log. Elements can be recognized always or only while the engine is running. A user-adjustable arming delay disables the configurable element during engine startup.
  • Page 176 9469200995 Figure 9-4. Settings Explorer, Programmable Outputs, Configurable Elements Contact Outputs DGC-2020ES...

  • Page 177: Breaker Management

    Breaker Operation The DGC-2020ES will attempt to close a breaker only after verifying that it can be closed. If the breaker cannot be closed, the close request will be ignored. Only one breaker can be closed at a time. Closure to a dead bus can be performed after meeting dead bus threshold and timing requirements set by the user.

  • Page 178: Breaker Configuration

    This feature also enables the DGC-2020ES to transfer the load back to the mains once mains power is restored. Settings include a transfer delay, return delay, max transfer time, and max return time.
  • Page 179 Set up the Gen Breaker in BESTlogicPlus Programmable Logic under the BESTCOMSPlus Settings Explorer, BESTlogicPlus Programmable Logic screen. BESTlogicPlus is not available through the front panel interface. Figure 10-2 illustrates the Gen breaker logic scheme in BESTlogicPlus. DGC-2020ES Breaker Management...
  • Page 180 Click the Save button when the logic setup is complete. From the Communication pull-down menu, select Upload Logic to Device to load the logic into the DGC-2020ES if connected, or save the settings file if working off line. Breaker Management...

  • Page 181: Bus Condition Detection

    RUN or AUTO mode and giving it CLOSE and OPEN commands from the physical inputs if they are available for breaker control. Refer to the Troubleshooting chapter if the breaker does not seem to operate properly. DGC-2020ES Breaker Management...
  • Page 182 10-6 9469200995 Figure 10-3. Settings Explorer, Breaker Management, Bus Condition Detection Breaker Management DGC-2020ES...

  • Page 183: Alarm Configuration

    9469200995 11-1 11 • Alarm Configuration Configuration of DGC-2020ES alarms, pre-alarms, sender failure alarms, and the audible horn is described in the following paragraphs. Alarms To configure alarms using BESTCOMSPlus, open the Alarm screen (Figure 11-1). This screen is found in the Settings Explorer under the Alarm Configuration category.

  • Page 184: Low Coolant Level

    The threshold can be entered in actual volts or a per-unit value. The per-unit threshold value is based on the nominal battery voltage setting found on the System Parameters, Rated Data screen. Alarm Configuration DGC-2020ES...

  • Page 185: Battery Overvoltage

    ECU Coms Fail ECU communication failure pre-alarm settings consist of a single enable/disable setting. If enabled, this pre-alarm is triggered when the DGC-2020ES detects a problem in its J1939 CAN connection to the ECU. Coolant Level Low coolant level pre-alarm settings consist of an enable/disable setting and a threshold setting. If enabled, a low coolant level pre-alarm is triggered when the metered coolant level decreases below the threshold setting.

  • Page 186: Checksum Failure

    After upgrading firmware through BESTCOMSPlus, the checksum failure pre-alarm may trigger. This pre- alarm is not indicative of an error in this case. It can be cleared by cycling power to the DGC-2020ES. If the pre-alarm reoccurs, then it is indicative of an error and corrective action should be taken. See Resetting Alarms, Checksum Failure, below, for more information.
  • Page 187 If enabled, the contact output is closed when an alarm condition exists. The contact output is toggled between open and closed when a pre-alarm condition exists. If the Not in Auto setting is enabled, the horn is disabled when the DGC-2020ES is not operating in Auto mode. DGC-2020ES...
  • Page 188 Speed sender failure settings consist of a single activation delay. An alarm is triggered when a speed sender failure exists for the duration of the activation time delay. Figure 11-4. Settings Explorer, Alarm Configuration, Sender Fail Screen Alarm Configuration DGC-2020ES...

  • Page 189: Generator Protection

    For example, if a scale factor contact input is received by the DGC-2020ES and the scale factor setting is 2.000, the pickup setting will be doubled (2.000 × PU). The element is disabled when Alarm Configuration is set to “None”. Element status is available in BESTlogic™Plus Programmable Logic when “Status Only”...
  • Page 190 For example, if a scale factor contact input is received by the DGC-2020ES and the scale factor setting is 2.000, the pickup setting will be doubled (2.000 × PU). The element is disabled when Alarm Configuration is set to “None”. Element status is available in BESTlogicPlus Programmable Logic when “Status Only”...

  • Page 191: Phase Imbalance

    For example, if a scale factor contact input is received by the DGC-2020ES and the scale factor setting is 2.000, the pickup setting will be doubled (2.000 × PU). The element is disabled when Alarm Configuration is set to “None”. Element status is available in BESTlogicPlus Programmable Logic when “Status Only”...
  • Page 192 For example, if an alternate frequency scale factor contact input is received by the DGC-2020ES and the scale factor setting is 2.000, the pickup setting is doubled (2.000 x PU).
  • Page 193 The scale factor setting is implemented when the DGC-2020ES senses a contact closure at a contact input programmed to activate low-line override. This triggers scaling of the protection settings. The value of the scale factor setting...
  • Page 194 For example, if a scale factor contact input is received by the DGC-2020ES and the scale factor setting is 2.000, the pickup setting will be doubled (2.000 × PU). The element is disabled when Alarm Configuration is set to “None”. Element status is available in BESTlogicPlus Programmable Logic when “Status Only”...

  • Page 195: Bestlogic™Plus

    BESTlogicPlus equations entered and saved in the DGC-2020ES system's nonvolatile memory integrate (electronically wire) the selected or enabled protection and control blocks with control inputs and hardware outputs. A group of logic equations defining the logic of the DGC-2020ES is called a logic scheme.
  • Page 196 True when Remote Input x is active. (Available when IN8 – IN17 an optional CEM-2020 is connected.) Virtual Inputs True when Virtual Input x is active. VIN1 – VIN4 True when Diagnostic Trouble Codes are present. Status Input Active DTC’s Present BESTlogic™Plus DGC-2020ES...
  • Page 197 True when the Audible Horn is active. Status Input Audible Horn Status Input True when the DGC-2020ES is in Auto Mode or the Auto Mode Auto Mode logic element is true. Status Input True when the Automatic Restart function is active.
  • Page 198 Cool Down Timer is true under two circumstances: Timer Active The unit is in auto and ATS is removed, causing the DGC-2020ES to go into a cooldown state. The engine is running (in RUN or AUTO mode with ATS applied) and the load has been removed (i.e.
  • Page 199 True while the Off front panel button is pressed. Status Input Front Panel Buttons True when the restart delay is currently active. Status Input Restart Delay Active True while the Run front panel button is pressed. Status Input Front Panel Buttons DGC-2020ES BESTlogic™Plus...
  • Page 200 True when the Gen Stable condition settings have Generator been exceeded. Stable True when the Exercise Timer has started the Status Input Generator Test generator and run with load is selected. Loaded True when the Exercise Timer has started the Status Input Generator Test generator. BESTlogic™Plus DGC-2020ES...
  • Page 201 Override True when the Idle Request logic element is true. Status Input Idle Request Status Input True when the DGC-2020ES is in the alarm state. In Alarm State Status Input True when the DGC-2020ES is in the connecting In Connecting state.
  • Page 202 Mains Fail Transfer Transferring to Mains True when the DGC-2020ES is in Off Mode or the Status Input Off Mode Off Mode logic element is true. Status Input True when the DGC-2020ES is in Off Mode and Off Mode cooling down.
  • Page 203 True when the DGC-2020ES is indicating that the Run Input Run relay should be closed. Status Input True when the DGC-2020ES is in Run Mode or the Run Mode Run Mode logic element is true. True when the Single Phase Override input is true.
  • Page 204 Generator Protection and has tripped. True when the 50 element is configured as an alarm Generator and has tripped. Protection True when the 81 Over element is configured as an Generator alarm and has tripped. Protection 81 Over BESTlogic™Plus DGC-2020ES...
  • Page 205 True when the metered engine speed (RPM) Shutdown unexpectedly drops to 0 while the engine is running. Alarm Voltage True when the Voltage Sensing Fail is configured as Sensing Fail an alarm and the activation delay has expired. DGC-2020ES BESTlogic™Plus...
  • Page 206 Not 50 Hours regeneration on a Yanmar ECU. Manual Since Last regeneration is blocked. Regen Checksum True when some of the user settings or firmware code has been corrupted. Refer to the Reporting Failure and Alarms chapter for more details. BESTlogic™Plus DGC-2020ES...
  • Page 207 Module Multiple Contact Expansion Modules Connected True when communication from the CEM-2020 to Contact Expansion the DGC-2020ES has been lost. Module Contact Expansion Module Comm Fail Contact True when the connected CEM-2020 does not have the same number of outputs as defined on the...
  • Page 208 True when an issue has been detected in the Inducement Exhaust Gas Recirculation (EGR) system. This is Warning the first level of inducement to correct the issue. There should also be Diagnostic Trouble Codes providing additional information about the issue. BESTlogic™Plus DGC-2020ES...
  • Page 209 Progress, Exhaust System Error, Exhaust System Inducement Indications, etc. This is derived based on ECU Lamp conditions communicated from the Engine ECU to the DGC-2020ES via J1939 CAN Bus communications. Fuel Leak True when the Fuel Leak Detect function is configured as a pre-alarm and the activation delay has expired.
  • Page 210 High Fuel Level True when the High Fuel Level Pre-Alarm settings have been exceeded. Inter Generator True when the DGC-2020ES detects that an Comm Fail individual generator previously connected to a generator network has lost connection. Isuzu DEF Low...
  • Page 211 True when an exhaust system regeneration is in Active progress. Serial Flash When the DGC-2020ES reads data from the serial Read Fail flash, the data is read twice and then compared to verify that the data matches. If it does not match, the read cycle is repeated.
  • Page 212 Low DEF, Purge Required, Exhaust System Error, etc. This reflects the status of the exhaust system Torque Limit lamp, which is communicated from the Engine ECU to the DGC-2020ES via J1939 CAN Bus communications. Voltage True when the Voltage Sensing Fail is configured as Sensing Fail a pre-alarm and the activation delay has expired.
  • Page 213 Table 13-2. Components Group, Names and Descriptions Name Description Symbol Logic Gates Input Output NAND Input Output Input Output Input Output Input Output When an XOR gate has more than two inputs, the output is true whenever an odd number of inputs are true. DGC-2020ES BESTlogic™Plus...
  • Page 214 Switch, Reset, Alarm Silence, Lamp Test, Idle Request, Low Fuel Pre-Alarm, Diesel Particulate Filter Manual Regeneration, Diesel Particulate Filter Regeneration Inhibit, Emergency Stop, Speed Raise, Speed Lower, MTU Cylinder Cutout Disable, and Automatic Breaker Operation Inhibit from PLC. BESTlogic™Plus DGC-2020ES...
  • Page 215 AUTO mode, the generator will cool down and stop. AUTOMODE When this input is true, and the DGC-2020ES is in OFF mode, the DGC-2020ES will switch to AUTO mode. This is a pulsed input. It does not need to be held after the desired mode switch has occurred.
  • Page 216 AUTO mode is true, the unit will remain running. Furthermore, if a condition occurs that normally causes the unit to close its breaker, the unit will close its breaker and reload. BESTlogic™Plus DGC-2020ES...
  • Page 217 Diesel Particulate Filter Regeneration is inhibited when the Set input is true. ECU Connect When true, a Key On signal is applied to the ECU and Override CAN Bus data is updated any time except during the Disconnecting state. DGC-2020ES BESTlogic™Plus...
  • Page 218 Emergency Stop LED on the RDP-110 is illuminated. EXTSTARTDEL If the Set input is true while the DGC-2020ES is in the Pre Start state, the DGC-2020ES will remain in the Pre Start state until the Set input is false.
  • Page 219 Outputs The outputs must be mapped to the contact outputs of the DGC-2020ES that will be used to drive the breaker. Open: This output is pulsed true (closes the output contact it is mapped to) when the DGC-2020ES is providing a signal to the breaker to open.
  • Page 220 When this logic element is true, the generator is forced to start, assume load, and disconnect from the mains, in an open transition. LOGICALM When this input is true, the DGC-2020ES goes into an alarm condition. LOGICPALM When this input is true, the DGC-2020ES goes into a Pre-alarm condition.
  • Page 221 Outputs The outputs must be mapped to the contact outputs of the DGC-2020ES that will be used to drive the breaker. Open: This output is pulsed true (closes the output contact it is mapped to) when the DGC-2020ES is providing a signal to the breaker to open.
  • Page 222 J1939 CAN Bus. OFFMODE When this input is true, the DGC-2020ES will switch to OFF mode. This is a pulsed input. It does not need to be held after the desired mode switch has occurred.
  • Page 223 DGC-2020ES will start and run the generator. RUNMODE When this input is true, and the DGC-2020ES is in OFF mode, the DGC-2020ES will switch to RUN mode. This is a pulsed input. It does not need to be held after the desired mode switch has occurred.

  • Page 224: Logic Schemes

    The Active Logic Scheme Digital Genset Controllers must have an active logic scheme in order to function. All Basler Electric DGC- 2020ES units are delivered with a default, active logic scheme pre-loaded in memory. If the function block configuration and output logic of the default logic scheme meets the requirements of your application, then only the operating settings (power system parameters and threshold settings) need to be adjusted before placing the DGC-2020ES in service.
  • Page 225 9469200995 13-31 To send settings to the DGC-2020ES, it must be connected to a computer through a communications port. Once the necessary connections are made, settings can be uploaded to the DGC-2020ES by selecting Upload Settings and Logic on the Communication pull-down menu.

  • Page 226: Pickup And Dropout Timers

    An example of the offline logic simulator is shown in Figure 13-3. Output 1 is Logic 0 (red) when Virtual Switch 1 is Logic 0 (red) and Fixed 1 is Logic 1 (green). BESTlogic™Plus DGC-2020ES...

  • Page 227: Bestlogic™Plus File Management

    After programming BESTlogicPlus settings, click on the Save button to save the settings to memory. Before the new BESTlogicPlus settings can be uploaded to the DGC-2020ES, you must select Save from the File pull-down menu located at the top of the BESTCOMSPlus main shell. This step will save both the BESTlogicPlus settings and the operating settings to a file.

  • Page 228: 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-2020ES, you must first open the file through BESTCOMSPlus or create the file using BESTCOMSPlus. Then pull down the Communication menu and select Upload Logic.

  • Page 229: Example 3 - Multiple Logic 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-2020ES is in RUN mode (RUN Mode true). Refer to Figure 13-7.
  • Page 230 13-36 9469200995 BESTlogic™Plus DGC-2020ES...

  • Page 231: Exhaust Treatment

    DPF Control DPF control information is sent from the DGC-2020ES to the Engine ECU through PGN Number 57244 (0xE000). A manual regeneration request is sent using SPN 3695, Diesel Particulate Filter Regeneration Force Switch. Regeneration can be inhibited by SPN 3695, Diesel Particulate Filter Regeneration Inhibit Switch.
  • Page 232 9469200995 DPF Status and Pre-Alarms The DGC-2020ES receives DPF status information which is broadcast from the engine ECU in various Parameter Group Numbers (PGN) and Suspect Parameter Numbers (SPN). The DGC-2020ES displays this information on the front panel, and in BESTCOMSPlus, via DPF related pre-alarms. The J1939 parameters and the resulting DGC-2020ES pre-alarms are summarized in the following paragraphs.
  • Page 233 DEF functions which is shown to the right. Most systems will contain one DEF tank, while some may contain two tanks. The DGC-2020ES front panel displays the level of DEF in each tank under Metering > Alarms-Status > J1939 Status > DEF Tank1 LVL% and Metering >...
  • Page 234 SEVERE INDUCEMENT state. Exhaust System Status Annunciation When an exhaust system condition requires annunciation, the DGC-2020ES displays the exhaust system information across the bottom of the front panel screen. The parameters and symbols in the Exhaust System Status Display are listed below. The symbol images below are the actual bit-mapped images that are viewed on the front panel screen of the DGC-2020ES.
  • Page 235 Lamp. When flashing, it indicates a higher degree of severity. An engine shutdown may accompany this symbol. Wait To Start Symbol – This symbol is visible when the engine is in a state of preparation for starting the engine. Examples include engine pre-heating or engine pre-lubrication. • DGC-2020ES Exhaust Treatment...
  • Page 236 With Service Tool Clearing: Invoke 0% torque reduction with service tool clearing until proper DEF • level and quality evaluation. If low level or poor DEF quality is detected during the next monitoring cycle, the severe inducement will be active after the next restart. Exhaust Treatment DGC-2020ES...

  • Page 237: Troubleshooting

    15-1 15 • Troubleshooting If you do not get the results that you expect from the DGC-2020ES, first check the programmable settings for the appropriate function. Use the following troubleshooting procedures when difficulties are encountered in the operation of your genset control system.

  • Page 238: Incorrect Display Of Generator Voltage

    Use a voltmeter connected between the BATT– terminal (17) and the SENDER COM terminal (2) on the DGC-2020ES to verify that there is no voltage difference at any time. Any voltage differences may manifest themselves as erratic sender readings. Wiring should be corrected so that no differences exist.

  • Page 239: Ground Faults Detected In Ungrounded System Applications

    Step 3: If ground faults are detected on a DGC-2020ES in an ungrounded system application, it is recommended that potential transformers be employed on the voltage sensing inputs to provide full isolation between the DGC-2020ES and monitored voltage phases.

  • Page 240: Generator Breaker Does Not Open When It Should

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

  • Page 241: Dgc-2020Es Front Panel Debug Screen

    CONDITION DETECTION screen to achieve correct detection. Step 5: Verify the wiring to the breaker from the DGC-2020ES. If it seems OK, you can do a manual close and open by modifying the programmable logic. Map some unused outputs to the OPEN and CLOSE outputs from the Gen Breaker Block in the programmable logic.
  • Page 242 9469200995 The following parameters are visible on the CEM DEBUG screen: DGC TO CEM BP: DGC-2020ES to CEM-2020 Binary Points. This is the status of the CEM-2020 • output relays being transmitted from the DGC-2020ES to the CEM-2020. This is a 32-bit, bit packed number representing the desired states of the CEM-2020 outputs.

  • Page 243: Bestcomsplus Settings Loader Tool

    USB driver, and the BESTCOMSPlus Settings Loader Tool on your PC. When BESTCOMSPlus installation is complete, a Basler Electric folder is added to the Windows programs menu. This folder is accessed by clicking the Windows Start button and then accessing the...
  • Page 244 16-2 9469200995 Basler Electric folder in the Programs menu. The Basler Electric folder contains an icon that starts the BESTCOMSPlus Settings Loader Tool. Bar Code Reader and Bar Codes The BESTCOMSPlus Settings Loader Tool is compatible with bar code readers, which conform to ®...

  • Page 245: Configuration Settings

    Select an entry and click Upload. A dialog appears which provides connection options for the appropriate type of device. Refer to the Basler product instruction manual for detailed connection information. Once a connection is established, the product settings associated with the entry are uploaded.
  • Page 246 Single Folder location. For example, all settings files for a product are located in “C:\files”. The Location field in the Loader Grid entry for a device contains “C:\documents\settings\DGC-2020ES Settings.bstx”. The BESTCOMSPlus Settings Loader Tool searches in “C:\files” for the file named “DGC- 2020ES Settings.bstx”.

  • Page 247: General Operation

    9469200995 16-5 Connection Options Connection options consist of the three selections described below. Refer to the Basler product instruction manual for detailed connection information. Always Prompt for Connection: When enabled, a dialog appears which provides connection options for the appropriate type of device each time a connection attempt is made.
  • Page 248 Scan bar code. Settings file is automatically highlighted and isolated in the grid. Click Upload. BESTCOMSPlus Settings Loader Tool automatically connects to device and uploads settings. Device connection is automatic unless “Always prompt for connection” is enabled. BESTCOMSPlus Settings Loader Tool DGC-2020ES...
  • Page 250 Highland IL 62249-1074 USA Suzhou Industrial Park 15-06 Peninsula Plaza Tel: +1 618.654.2341 215122 Suzhou Singapore 179098 Fax: +1 618.654.2351 P.R. CHINA Tel: +65 68.44.6445 email: info@basler.com Tel: +86 512.8227.2888 Fax: +65 68.44.8902 Fax: +86 512.8227.2887 email: singaporeinfo@basler.com email: chinainfo@basler.com...
  • Page 251 DGC-2020ES Digital Genset Controller Operation Instruction Manual Publication 12570 Route 143 • Highland, Illinois 62249-1074 USA Tel +1 618.654.2341 • Fax +1 618.654.2351 9469200996, Rev B www.basler.com • info@basler.com December 2019...
  • Page 252 Proposition 65 warning, we are notifying you that one or more of the Proposition 65 listed chemicals may be present in products we sell to you. For more information about the specific chemicals found in this product, please visit https://www.basler.com/Prop65.

  • Page 253: Conventions Used In This Manual

    9469200996 Preface This instruction manual provides information about the operation of the DGC-2020ES Digital Genset Controller. To accomplish this, the following information is provided: Controls and indicators • • Operating modes Metering • Reporting and alarms • Troubleshooting • Conventions Used in this Manual Important safety and procedural information is emphasized and presented in this manual through Warning, Caution, and Note boxes.
  • Page 254 The availability and design of all features and options are subject to modification without notice. Over time, improvements and revisions may be made to this publication. Before performing any of the following procedures, contact Basler Electric for the latest revision of this manual.
  • Page 255 9469200996 Revision History A historical summary of the changes made to this instruction manual is provided below. Revisions are listed in reverse chronological order. Visit www.basler.com to download the latest hardware, firmware, and BESTCOMSPlus revision ® histories. Instruction Manual Revision History...
  • Page 256 9469200996 Contents DGC-2020ES...
  • Page 257 Contents Controls and Indicators ..........................1-1 Operating Modes ............................2-1 Metering ..............................3-1 Alarms ................................ 4-1 MTU Fault Codes ............................5-1 Diagnostic Trouble Codes .......................... 6-1 Yanmar Fault Codes ..........................7-1 Event Recording ............................8-1 Troubleshooting ............................9-1 DGC-2020ES Contents...
  • Page 258 9469200996 Contents DGC-2020ES...

  • Page 259: Controls And Indicators

    9469200996 1 • Controls and Indicators DGC-2020ES controls and indicators are located on the front panel and are intended for local control and monitoring of DGC-2020ES operation. Front panel controls consist of pushbuttons. Front-panel indicators consist of LED (light emitting diode) indicators and a backlit LCD (liquid crystal display).

  • Page 260: Login And Permissions

    Locator Description Not in Auto Indicator. This red LED lights when the DGC-2020ES is not operating in Auto mode. When the DGC-2020ES is operating in Run or Off mode, this LED is on. Run Pushbutton and Mode Indicator. Pressing this button places the DGC-2020ES in Run mode.

  • Page 261: Summary Screen And Configurable Metering

    GEN IA • OIL P • • GEN IB • GEN IC • RPM SRC • • GEN PF • RUN HRS GEN VAB • TEMP • • GEN VAN • TOTAL FUEL USED • GEN VBC DGC-2020ES Controls and Indicators...

  • Page 262: Sleep Mode

    Sleep mode de-energizes the LCD backlight and heater and turns off the front-panel LEDs when no pushbutton activity is detected for 15 minutes and the DGC-2020ES is operating in OFF mode or Auto mode with the engine not running. Normal display operation resumes when any pushbutton is pressed or the genset is started remotely via the ATS input.
  • Page 263 Figure 1-3. One-Line Diagram: Breaker Hardware Status Indication Mains Fail Transfer Status Display Mains Fail Transfer Status can be viewed from three locations; however, the DGC-2020ES must be equipped with Mains Fail Transfer (style number xx2) and Mains Fail Transfer must be enabled.

  • Page 264: Changing A Setting

    GEN VCA ● GEN VAN ● GEN VBN ● GEN VCN ● GEN FREQ ● GEN AMPS A ● GEN AMPS B ● GEN AMPS C ● BUS CONNECT ● BUS VAB ● BUS FREQ ● Controls and Indicators DGC-2020ES...
  • Page 265 NMT-ALIVE STATUS (Visible when ECU is configured for MTU MDEC or MTU ECU7/ECU8.) ○ SPS_NODE ■ SW_TYP ■ SW_VAR ■ SW_ED1 ■ SW_ED2 ■ ■ SW_MOD ■ TRIP FUEL (Visible when ECU is configured for MTU ECU7/ECU8.) ○ TRIP HRS ■ DGC-2020ES Controls and Indicators...
  • Page 266 SPD DMD FL MD (Visible when ECU is configured for MTU ECU7/ECU8 or MTU Smart ■ Connect.) RATED RPM (Visible when ECU is configured for MTU ECU7/ECU8.) ■ RPM (Visible when ECU is configured for MTU ECU7/ECU8.) ■ CAMSHAFT RPM (Visible when ECU is configured for MTU ECU7/ECU8.) ■ Controls and Indicators DGC-2020ES...
  • Page 267 1 PHASE O-RIDE (Visible when the 1-Phase Override programmable function is configured to be driven ○ by an input.) BUS DEAD ○ BUS STABLE ○ BUS FAILED ○ GEN DEAD ○ GEN STABLE ○ GEN FAILED ○ ENG RUNNING ○ DGC-2020ES Controls and Indicators...
  • Page 268 ○ TOTAL FUEL USED ○ ENG COOLANT TEMP ○ COOLNT PRHT DONE ○ FUEL TEMP ○ ENG OIL TEMP ○ ENG INTCLR TEMP ○ INTRCR CLNT LVL ○ FUEL DELV P ○ ENG OIL LEVEL ○ Controls and Indicators DGC-2020ES...
  • Page 269 O-RIDE SPD PNT 7 ○ O-RIDE TIME LMT ○ SPEED LOWER LMT ○ SPEED UPPER LMT ○ TORQUE LOWER LMT ○ TORQUE UPPER LMT ○ J1939 ECU LAMP STATUS ● WARNING LAMP ○ RED LAMP ○ DGC-2020ES Controls and Indicators...
  • Page 270 REGEN REQ FLG ○ ASH CLEAN REQ ○ MAINS FAIL TRANSFER (Visible when DGC-2020ES style number is xx2 and Mains Fail Transfer is enabled.) ● MAINSFAIL XFER STATE ○ DISABLED ( The possible mains fail transfer states are as follows: Power From Mains, ■...
  • Page 271 ○ SECONDS ○ UTC OFFSET ○ DST ENABLED ○ CLK NOT SET WRN ○ VIEW DATE/TIME ● VERSION INFO ● DGC-2020ES ○ FIRMWARE VERSION ■ BOOT CODE VERSION ■ SERIAL NUMBER ■ PART NUMBER ■ MODEL NUMBER ■ LANGUAGE VERSION ■...
  • Page 272 ECU SETUP (Visible when ECU is configured for MTU ADEC, MTU MDEC 304, MTU ■ ECU7/ECU8, or MTU Smart Connect.) TRIP RESET (Visible when ECU is configured for MTU MDEC 304, or MTU □ ECU7/ECU8.) INT OIL PRIME □ Controls and Indicators DGC-2020ES...
  • Page 273 CRANK SETTINGS ● DISCNCT LMIT ○ PRECRNK DELY ○ PRESTRT CNTCT ○ STYLE ○ # CYCLES (Visible when Cycle is selected for Cranking Style.) ○ CONT TIME (Visible when Continuous is selected for Cranking Style.) ○ DGC-2020ES Controls and Indicators...
  • Page 274 PROG FUNCTIONS ● EMERGENCY STOP ○ INPUT ■ AUTO XFER SWITCH ○ INPUT ■ RECOGNITION (Visible when an INPUT is selected.) ■ GRND DELTA O-RIDE ○ INPUT ■ RECOGNITION (Visible when an INPUT is selected.) ■ Controls and Indicators DGC-2020ES...
  • Page 275 LOW FUEL LEVEL ○ ENABLE ■ THRESHOLD ■ HYSTERESIS ■ ENGINE OVERLOAD ○ ENG KW OVRLD 1 ■ ENG KW OVRLD 2 ■ ENG KW OVRLD 3 ■ MAINTENANCE INTERVAL ○ ENABLE ■ THRESHOLD ■ BATTERY OVERVOLTAGE ○ DGC-2020ES Controls and Indicators...
  • Page 276 The HIGH COOLANT TEMP and LOW OIL PRESSURE alarms have an ARMING DLY setting that disables the alarm for the specified time after engine startup. SENDER FAIL ● COOL TEMP SENDR FAIL ○ CONFIG TYPE ■ RECOGNITION ■ ACTIVATN DLY ■ MIN OHMS ■ Controls and Indicators DGC-2020ES...
  • Page 277 ALT FREQ SF ■ 50 OVERCURRENT ● LOW LINE SF (Visible when an input is selected for the Low Line Override programmable function.) ○ 3 / 1 PHASE SETTINGS ○ PICKUP ■ TIME DELAY ■ ALARM CONFIG ■ DGC-2020ES Controls and Indicators...
  • Page 278 UF PICKUP ■ UF DROPOUT ■ TIME DELAY ■ LOW LINE SF (Visible when an input is selected for the Low Line Override programmable ■ function.) ALT FREQ SF ■ BUS FAILED ○ TIME DELAY ■ Controls and Indicators DGC-2020ES...
  • Page 279 9469200996 1-21 LOGIC TIMERS TIMER X (X = 1 to 10) ● HOURS ○ MINUTES ○ SECONDS ○ ENTER PASSWORD LOGOUT (Visible when logged in through the front panel.) DGC-2020ES Controls and Indicators...
  • Page 280 1-22 9469200996 Controls and Indicators DGC-2020ES...

  • Page 281: Operating Modes

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

  • Page 282: Operating Mode Control

    Ready The engine is not running. The DGC-2020ES is ready to run. This is the normal state of the DGC-2020ES in OFF mode, and in AUTO mode when the engine is not running, or in the process of starting or stopping.

  • Page 283: Metering

    The DGC-2020ES provides comprehensive metering of internal and system conditions. These capabilities include extensive parameter metering, status indication and reporting. Metering Explorer DGC-2020ES metering is accessed through the metering explorer menu on the front panel display or the BESTCOMSPlus metering explorer.
  • Page 284 Parameters that do not apply to your engine are marked as either NS (not sent) or NA (not applicable). The Engine screen is found in the BESTCOMSPlus Metering Explorer. If using the front panel, navigate to Metering > Engine. Figure 3-2. Metering Explorer, Engine Screen Metering DGC-2020ES...

  • Page 285: Battery Charger

    Figure 3-3. Metering Explorer, Battery Charger Screen Generator This screen provides metering of generator voltages and currents. See Figure 3-4. The Generator screen is found in the BESTCOMSPlus Metering Explorer. If using the front panel, navigate to Metering > Generator. DGC-2020ES Metering...

  • Page 286: Run Statistics

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

  • Page 287: Status Indication

    Metering > Alarms-Status > Status. Figure 3-7. Metering Explorer, Status Screen 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 red. See Figure 3-8. DGC-2020ES Metering...
  • Page 288 The status is TRUE when the corresponding indicator is red. See Figure 3-9. The Remote Contact Inputs screen is found in the BESTCOMSPlus Metering Explorer under the Inputs category. If using the front panel, navigate to Metering > Alarms-Status > Inputs. Figure 3-10. Metering Explorer, Inputs, Remote Contact Inputs Screen Metering DGC-2020ES...

  • Page 289: Contact Outputs

    The status is TRUE when the corresponding indicator is green. See Figure 3-12. The Remote Contact Outputs screen is found in the BESTCOMSPlus Metering Explorer under the Outputs category. If using the front panel, navigate to Metering > Alarms-Status > Outputs. DGC-2020ES Metering...
  • Page 290 The status is TRUE when the corresponding indicator is green. See Figure 3-13. The Configurable Elements screen is found in the BESTCOMSPlus Metering Explorer under the Outputs category. If using the front panel, navigate to Metering > Alarms-Status > Configurable Elements. Metering DGC-2020ES...

  • Page 291: Emergency Stop

    DGC-2020ES. The PC or laptop running BESTCOMSPlus must be connected to the DGC-2020ES via the USB port (see the Communication chapter in the Configuration manual for details). When running BESTCOMSPlus in Live mode, these buttons interact with the DGC-2020ES in real time.
  • Page 292 Power From Gens: Power is being supplied to the load from the generator bus. Return Timer Active: Return Delay timer is actively counting. Transferring to Mains: Load is being transferred to the mains bus. Disabled: DGC-2020ES is in the OFF or RUN operating mode or in the alarm state. Metering DGC-2020ES...

  • Page 293: Auto Export Metering

    Figure 3-17. Metering, Diagnostics, Sender Inputs Auto Export Metering This function automatically exports metering data over a user-defined period when a DGC-2020ES connection is active. To display the Auto Export Metering screen, click the Tools pull-down menu from the upper menu bar and click Auto Export Metering. Specify the Number of Exports and the Interval between each export.
  • Page 294 3-12 9469200996 Metering DGC-2020ES...

  • Page 295: Alarms

    9469200996 4 • Alarms The DGC-2020ES monitors ECU data, generator protection functions, and engine senders. An alarm or pre-alarm is annunciated when the monitored parameter exceeds its threshold settings. When an alarm condition exists, the engine is stopped by opening the Fuel output contact. An existing pre-alarm condition is annunciated only.

  • Page 296: Contact Expansion Module

    Fuel Filter 1 Leak FUEL 2 LEAK Fuel Filter 2 Leak FUEL LEAK DETECT Fuel Leak Detect GEN REV ROT Reverse Generator Rotation GN BRK CL FL Generator Breaker Close Failure GN BRK OP FL Generator Breaker Open Failure Alarms DGC-2020ES...
  • Page 297 SPD SNDR FAIL Speed Sender Fail Generator Protection 27 UNDVOLT TRP Undervoltage (27) 47 PHS IMBAL TRP Phase Imbalance (47) 50 OVRCURR TRP Overcurrent (50) 59 OVRVOLT TRP Overvoltage (59) 81O OVRFREQ TRP Frequency (81O) 81U UNDFREQ TRP Frequency (81U) DGC-2020ES Alarms...

  • Page 298: Retrieving Alarm Information

    Breaker Fail to Close These pre-alarms are reset by navigating to the Overview screen on the front panel display and holding the Back pushbutton for two seconds. Alarms do not automatically reset. Manually reset alarms by pressing the Off pushbutton. Alarms DGC-2020ES...
  • Page 299 If the problem persists, reload the firmware file through BESTCOMSPlus. See the BESTCOMSPlus chapter in the Configuration manual for more information. Contact Basler Electric Technical Support. The checksum failure pre-alarm can be disabled. This disables only the annunciation of the pre- alarm and does not correct any error conditions.
  • Page 300 9469200996 Alarms DGC-2020ES...

  • Page 301: Mtu Fault Codes

    METERING > ALARMS-STATUS > MTU FAULT CODES. Each fault code is displayed with a fault description and the fault number. If the DGC-2020ES does not have descriptive information about a fault number that was received, the fault description will display as “NO TEXT AVAILABLE”.
  • Page 302 ENG HRS INVALID 2 Checksum fault. ERR REC1 INVALID Checksum fault. ERR REC2 INVALID Checksum fault. LO ECU SUPPLY VOLTS Power supply voltage too low (limit 1). LOLO ECU SUPPLY VOLTS Power supply voltage too low (limit 2). MTU Fault Codes DGC-2020ES...
  • Page 303 SD T CLNT INTERC Intercooler coolant temperature-sensor defect. SD T EXHAUST A Exhaust gas temperature-sensor on A-side defect. SD T EXHAUST B Exhaust gas temperature-sensor on B-side defect. SD P CHARGE AIR Charge air pressure-sensor defect. DGC-2020ES MTU Fault Codes...
  • Page 304 SD BANK 2 TEST Internal ECU fault. SD SPD DEMAND AN Analog speed demand defect. SD SPDMTEST BNCH Short circuit, cable breakage. SD SPINUT Analog spinning value defect. SD LOAD ANLG FLT Filtered analog load pulse signal not available. MTU Fault Codes DGC-2020ES...
  • Page 305 Short circuit in injector cable of cylinder A5. WIRING CYLNDR A6 Short circuit in injector cable of cylinder A6. WIRING CYLNDR A7 Short circuit in injector cable of cylinder A7. WIRING CYLNDR A8 Short circuit in injector cable of cylinder A8. DGC-2020ES MTU Fault Codes...
  • Page 306 Short circuit or open load on transistor output plant 4 (TOP 4). AL WIRING TOP 5 Short circuit or open load on transistor output plant 5 (TOP 5). AL WIRING TOP 6 Short circuit or open load on transistor output plant 6 (TOP 6). MTU Fault Codes DGC-2020ES...
  • Page 307 High Pre-Engine Coolant Temperature (Limit 1). SS PRE ENG T COOLNT High Pre-Engine Coolant Temperature (Limit 2). AL L1 P AUX 2 Auxiliary Pressure 2 Level 1 Alarm. AL L2 P AUX 2 Auxiliary Pressure 2 Level 2 Alarm. DGC-2020ES MTU Fault Codes...
  • Page 308 Sensor Defect In Coil Current 2 Sensor. SD T EXHAUST C Sensor Defect In Exhaust System C Temperature Sensor. SD T EXHAUST D Sensor Defect In Exhaust System D Temperature Sensor. HI T EXHAUST C High Exhaust C Temperature (Limit 1). MTU Fault Codes DGC-2020ES...
  • Page 309 Sensor Defect In Oil Coolant Temperature (R2) Sensor. TD ENG SPD SNS DEV Engine Speed Sensor Deviation. SD ENG SPD SENSR 3 Sensor Defect in Engine Speed Third Sensor. SS T COOL RED 2 Coolant Temperature Red 2 Alarm (Limit 2). DGC-2020ES MTU Fault Codes...
  • Page 310 L1 CAN MAX TIMG RETRD Maximum Timing Retard from CAN (Limit 1). L2 CAN MAX TIMG RETRD Maximum Timing Retard from CAN (Limit 2). L3 CAN MAX TIMG RETRD Maximum Timing Retard from CAN (Limit 3). MTU Fault Codes DGC-2020ES...
  • Page 311 VLV 2 STR L1 P FUEL SEC FLTDIFF Secondary Filter Fuel Pressure Limit 1 Alarm. AL EIL PROTECTION STR Alarm for Protection Module in response to faulty or manipulated EIL. AL EIL ERROR STR EIL Error. DGC-2020ES MTU Fault Codes...
  • Page 312 A Communications Lost. AL NOXB COMM LOST B Communications Lost. AL PHYTRNA COM LST PHYTRON A Communications Lost. AL PHYTRNB COM LST PHYTRON B Communications Lost. SD SMRT NOX HTR Sensor Defect in Smart NO Heater Element Sensor. MTU Fault Codes DGC-2020ES...
  • Page 313 AL SD EXT SPEED DMD SW Channel signals open load. AL SD SPEED DMD Channel signals open load or internal error. INCREASE STR AL SD BINARY SPD DMD Channel signals open load or internal error. LMT STR DGC-2020ES MTU Fault Codes...
  • Page 314 DPF Periodic Rigorous TM Alarm. DPF RIG TM SUPPR DPF Rigorous TM Suppressed Alarm. DPF FLASH READ ERR DPF Flash Memory Read Error Alarm. AL EMISSN FLT Emission Fault Alarm. AL EMISSN FLT2 Emission Fault 2 Alarm. MTU Fault Codes DGC-2020ES...
  • Page 315 Temperature Sensor E2 Wrong Position Alarm. WRONG POS TMP SNS E3 Temperature Sensor E3 Wrong Position Alarm. L1 P CHARGE AIR B Charge Air B Pressure (Limit 1) Alarm. L2 P CHARGE AIR B Charge Air B Pressure (Limit 2) Alarm. DGC-2020ES MTU Fault Codes...
  • Page 316 Bypass Valve Defect Alarm. AL ASH VOLUME Ash Volume Alarm. ECU NT CLS ECO FLAP A ASO Flap A not closed by ECU Alarm. ECU NT CLS ECO FLAP B ASO Flap B not closed by ECU Alarm. MTU Fault Codes DGC-2020ES...
  • Page 317 SCR F1 SU ADBLUE QNTY SCR F1 SU ADBLUE Quantity. SCR F2 SU ADBLUE QNTY SCR F2 SU ADBLUE Quantity. SCR ADBLUE PRESSR SCR ADBLUE Pressure Alarm. SCR SU PRIME REQUEST SCR SU Priming Request Alarm. DGC-2020ES MTU Fault Codes...
  • Page 318 Exhaust Temperature After SCR F3 (Limit 1) Alarm. L2 TEXH AFT SCRF3 Exhaust Temperature After SCR F3 (Limit 2) Alarm. AL MIC5 YELLOW MIC 5 Yellow Alarm. AL MIC5 RED MIC 5 Red Alarm. AL MIC5 COMM LOST MIC 5 Comms Lost Alarm. MTU Fault Codes DGC-2020ES...
  • Page 319 Turbo Charger 5 Overspeed (Limit 1). SS ETC5 OVERSPEED Turbo Charger 5 Overspeed (Limit 2). ADBLUE TEMP HI F1 ADBLUE (DEF) Temperature Too High F1 Alarm. ADBLUE TEMP HI F2 ADBLUE (DEF) Temperature Too High F2 Alarm. DGC-2020ES MTU Fault Codes...
  • Page 320 INJ DRIFT LMT1 CYL A9 Cylinder A9 Injector Drift Limit 1 Alarm. 1041 INJ DRFT LMT1 CYL A10 Cylinder A10 Injector Drift Limit 1 Alarm. 1042 INJ DRIFT LMT1 CYL B1 Cylinder B1 Injector Drift Limit 1 Alarm. MTU Fault Codes DGC-2020ES...
  • Page 321 F2 T DEF TOO HI F2 DEF Temperature Too High Alarm. 1087 LO F2 TEXH BFR SCR F2 Exhaust Temperature before SCR Too Low Alarm. 1088 LO F2 TEXH AFT SCR F2 Exhaust Temperature after SCR Too Low Alarm. DGC-2020ES MTU Fault Codes...
  • Page 322 5-22 9469200996 MTU Fault Codes DGC-2020ES...

  • Page 323: Diagnostic Trouble Codes

    For certain DTCs, if the DGC-2020ES recognizes a pair of SPN and FMI numbers, it displays a single string as listed in Table 6-2. If the DGC-2020ES recognizes an SPN in Table 6-2, but the FMI does not match the FMI in Table 6-2, then it displays the string from Table 6-2 corresponding to the table entry where the FMI is # and a second string corresponding to the FMI number listed in Table 6-3.
  • Page 324 EGR Air Temp Vlt LO Exhaust Gas Recirculation Mixed Air Temp Voltage (Low) EGR Mixed Air Tmp HI Exhaust Gas Recirculation Mixed Air High (Least Severe) EGR MxdAir Tmp MHI Exhaust Gas Recirculation Mixed Air Temp (Moderately High) Diagnostic Trouble Codes DGC-2020ES...
  • Page 325 Exhaust Gas Temperature FUEL TEMP Fuel Temperature Fuel Temp EXT HI Fuel Temp (Extremely High) Fuel Tmp Sns Volt HI Fuel Temp Sensor Input Voltage (High) Fuel Tmp Sns Volt LO Fuel Temp Sensor Input Voltage (Low) DGC-2020ES Diagnostic Trouble Codes...
  • Page 326 CLUTCH SWITCH Clutch Switch CRUISE CNTL SET SW Cruise Control Set Switch CRUISE CNTL COAST SW Cruise Control Coast (Decelerate) Switch CRUISE CNTL RESUME SW Cruise Control Resume Switch CRUISE CNTL ACCEL SW Cruise Control Accelerate Switch Diagnostic Trouble Codes DGC-2020ES...
  • Page 327 Crank Pos Sns MSNG Crank Position Missing Crank Pos Sns In ERR Crank Position Input Pattern Error J1939 NETWORK 1 J1939 Network number 1 Trbo Actuator ERR Turbo Actuator Error ECU/Trbo Comm ERR ECU/Turbo Communication Error DGC-2020ES Diagnostic Trouble Codes...
  • Page 328 Cylinder #6 EUI Circuit QR Code (Invalid) CYLINDER 6 INJECTOR Cylinder 6 Injector CYLINDER 7 INJECTOR Cylinder 7 Injector CYLINDER 8 INJECTOR Cylinder 8 Injector CYLINDER 9 INJECTOR Cylinder 9 Injector CYLINDER 10 INJECTOR Cylinder 10 Injector Diagnostic Trouble Codes DGC-2020ES...
  • Page 329 SPEED SENSOR #2 Engine Speed Sensor #2 O2 SENSOR O2 Sensor INTAKE HEATER #1 Intake Air Heater #1 INTAKE HEATER #2 Intake Air Heater #2 KNOCK SENSOR #1 Knock Sensor 1 HEATER CIRCUIT 2 UEGO Heater Circuit #02 DGC-2020ES Diagnostic Trouble Codes...
  • Page 330 Indicates that Engine Protective System Shutdown Is Approaching 1110 Eng Prot Shutdown Engine Protection Shutdown 1127 TURBOCHG1 BOOST PRS Turbo Charger 1 Boost Pressure 1128 TURBOCHG2 BOOST PRS Turbo Charger 2 Boost Pressure 1129 TURBOCHG3 BOOST PRS Turbo Charger 3 Boost Pressure Diagnostic Trouble Codes DGC-2020ES...
  • Page 331 1240 FUEL LEAKAGE2 Fuel Leakage 2 Parameter 1247 ENGINE POWER Engine Power 1268 IGNITION COIL 1 Engine Ignition Coil 1 1269 IGNITION COIL 2 Engine Ignition Coil 2 1270 IGNITION COIL 3 Engine Ignition Coil 3 DGC-2020ES Diagnostic Trouble Codes...
  • Page 332 Misfire detected on a single engine cylinder 1340 MISFIRE CYLINDER 18 Misfire detected on a single engine cylinder 1341 MISFIRE CYLINDER 19 Misfire detected on a single engine cylinder 1342 MISFIRE CYLINDER 20 Misfire detected on a single engine cylinder Diagnostic Trouble Codes DGC-2020ES...
  • Page 333 Fan Speed Detected (Zero) 1639 Fan Speed HI Fan Speed Detected (High) 1639 Fan Speed LO Fan Speed Detected (Low) 1675 STARTER MODE Engine Starter Mode 1692 INTKMNFLD1 DESIRD PR Engine Intake Manifold Desired Absolute Pressure DGC-2020ES Diagnostic Trouble Codes...
  • Page 334 INJECTOR GROUP 1 Engine Injector Group 1 2798 INJECTOR GROUP 2 Engine Injector Group 2 2899 START ENABL DEV 1 CFG Engine Start Enable Device 1 Configuration 2950 INTK VALVE ACUATOR 1 Intake Valve Actuator 1 Diagnostic Trouble Codes DGC-2020ES...
  • Page 335 3510 SENSOR SUPPLY VOLTS 2 Sensor Supply Voltage 2 3511 SNSR SUPPLY VOLT 3 Sensor Supply Voltage 3 3512 SNSR SUPPLY VOLT 4 Sensor Supply Voltage 4 3513 SNSR SUPPLY VOLT 5 Sensor Supply Voltage 5 DGC-2020ES Diagnostic Trouble Codes...
  • Page 336 AFTTRT1 INTK GAS TMP Aftertreatment 1 Catalyst Intake Gas Temperature 4363 AFTTRT1 OUT GAS TMP Aftertreatment 1 Catalyst Outlet Gas Temperature 4364 SCR CNVRSN EFFICIENCY SCR Conversion Efficiency 4375 AFTTRT1 PUMP DRV % Aftertreatment 1 Catalyst Pump Drive Percentage Diagnostic Trouble Codes DGC-2020ES...
  • Page 337 Run Up Speed is below the LOW LOW threshold 522192 MTU ENGINE BAD Component failure of the MTU engine control ECU 523212 ENGPRT CAN MSG Proprietary MTU CAN Message 523216 PREHTENCMD CAN MSG Proprietary MTU CAN Message DGC-2020ES Diagnostic Trouble Codes...
  • Page 338 CAN Message 523610 TSC1-VE MSG MISSING CAN Message 523611 TSC1-VR MSG MISSING CAN Message 523612 ECU ERROR ECU Error 523613 RAIL PRESSURE Rail Pressure 523615 METERING UNIT VALVE Metering Unit Valve 523617 ECU ERROR ECU Error Diagnostic Trouble Codes DGC-2020ES...
  • Page 339 9469200996 6-17 Table 6-3. DTCs Displayed by the DGC-2020ES (FMI Strings) String Displayed Description DATA HI MOST SEVERE Data is higher than expected at the most severe level DATA LO MOST SEVERE Data is lower than expected at the most severe level...
  • Page 340 6-18 9469200996 Diagnostic Trouble Codes DGC-2020ES...

  • Page 341: Yanmar Fault Codes

    Measured voltage is lower than expected or shorted to a low source CURRENT LO OR OPEN Measured current is lower than expected or the circuit is open CURRENT HI OR SHORTED Measured current is higher than expected or shorted MECHANICAL SYSTM ERR Mechanical system error DGC-2020ES Yanmar Fault Codes...
  • Page 342 ENG OIL PRESS Engine Oil Pressure P1192 INTK MANFLD P SNS intake manifold pressure sensor malfunction P0238 INTK MANFLD P SNS intake manifold pressure sensor malfunction P0237 INTK MANFLD P SNS intake manifold pressure sensor malfunction P1673 Yanmar Fault Codes DGC-2020ES...
  • Page 343 EGR Gas Temperature Sensor Malfunction P041C EGR GAS TMP SNSR EGR Gas Temperature Sensor Malfunction P1675 EE PROM the EEPROM memory inside the engine ECU P0601 SCV (MPROP) Proprietary caption text for YANMAR Diagnostic P0629 Trouble Codes DGC-2020ES Yanmar Fault Codes...
  • Page 344 Diesel Particulate Filter (DPF) Inlet Temperature 3242 P1436 Sensor Malfunction 3242 DPF INLET T SENSR Diesel Particulate Filter (DPF) Inlet Temperature P1428 Sensor Malfunction 3242 DPF INLET T SENSR Diesel Particulate Filter (DPF) Inlet Temperature P1427 Sensor Malfunction Yanmar Fault Codes DGC-2020ES...
  • Page 345 522401 CAMSHAFT SENSOR Camshaft Sensor P0342 522401 CAMSHAFT SENSOR Camshaft Sensor P1341 Proprietary caption text for YANMAR Diagnostic 522571 SCV (MPROP) P1641 Trouble Codes 522571 SCV (MPROP) Proprietary caption text for YANMAR Diagnostic P1643 Trouble Codes DGC-2020ES Yanmar Fault Codes...
  • Page 346 Exhaust Throttle P1441 522750 EXHAUST THROTTLE the Exhaust Throttle P1442 522751 EXHAUST THROTTLE the Exhaust Throttle P1443 522994 ECU INTERNAL ERROR ECU Internal Error P1633 523249 CRANK/CAM SENSOR Crankshaft Sensor or the Camshaft sensor P0008 Yanmar Fault Codes DGC-2020ES...
  • Page 347 ECU Internal Error P1482 523487 ECU INTERNAL ERROR ECU Internal Error P1483 523488 ECU INTERNAL ERROR ECU Internal Error P1484 523489 RAIL PRESSURE Fuel Rail Pressure Sensor P1668 SENSOR 523491 RAIL PRESSURE Fuel Rail Pressure Sensor P1669 SENSOR DGC-2020ES Yanmar Fault Codes...
  • Page 348 9469200996 Yanmar Fault Codes DGC-2020ES...

  • Page 349: Event Recording

    Options->Copy Selection feature. The Download button refreshes the event log list by performing a fresh download of the list from the DGC-2020ES. The Clear button gives the user the option of clearing selected or all event logs. Refer to Figure 8-1.
  • Page 350 Battery Charger 2,Invalid Settings Pre-Alarm CHARGER2 LO CRANKING V P Battery Charger 2,Low Cranking Voltage Pre-Alarm CHARGER2 LOW DC VOLTS P Battery Charger 2, Low Output Voltage Pre-Alarm CHARGER2 SINGLE UNIT FAIL P Battery Charger 2,Single Unit Failure Pre-Alarm Event Recording DGC-2020ES...
  • Page 351 Alarm FUEL LEVL SENDR FAIL Fuel Level Sender Fail Status FUEL LEVL SENDR P Fuel Level Sender Fail Pre-Alarm GEN TEST LOADED Generator Exerciser Test with Load Status GEN TEST UNLOADED Generator Exerciser Test without Load Status DGC-2020ES Event Recording...
  • Page 352 Low Fuel Delivery Pressure Alarm LO SUPPLY VOLTS P Low Voltage Supply Pre-Alarm LOAD TAKEOVER Load Takeover Status LOGIC OUPUT A Logic Output Alarm LOGIC OUPUT P Logic Output Pre-Alarm LOSS OF VOLT Voltage Sensing Fail Status Event Recording DGC-2020ES...
  • Page 353 REV BUS ROT P Reverse Bus Rotation Pre-Alarm REV GEN ROT P Reverse Generator Rotation Pre-Alarm RUNUP SPD LO P Run Up Speed Low Pre-Alarm SERFLASH RD FAIL Serial Flash Read Fail Pre-Alarm SPD SNDR FAIL Speed Sender Fail Status DGC-2020ES Event Recording...
  • Page 354 Start Speed Low Pre-Alarm VOLTAGE SENSE FAIL Voltage Sensing Fail Status VOLTAGE SENSE FAIL A Voltage Sensing Fail Alarm VOLTAGE SENSE FAIL P Voltage Sensing Fail Pre-Alarm UNKNOWN SHUTDOWN A Unknown Shutdown Alarm WEAK BATTERY P Weak Battery Pre-Alarm Event Recording DGC-2020ES...

  • Page 355: Troubleshooting

    9469200996 9 • Troubleshooting If you do not get the results that you expect from the DGC-2020ES, first check the programmable settings for the appropriate function. Use the following troubleshooting procedures when difficulties are encountered in the operation of your genset control system.

  • Page 356: Incorrect Display Of Generator Voltage

    Use a voltmeter connected between the BATT– terminal (17) and the SENDER COM terminal (2) on the DGC-2020ES to verify that there is no voltage difference at any time. Any voltage differences may manifest themselves as erratic sender readings. Wiring should be corrected so that no differences exist.

  • Page 357: Ground Faults Detected In Ungrounded System Applications

    Step 3: If ground faults are detected on a DGC-2020ES in an ungrounded system application, it is recommended that potential transformers be employed on the voltage sensing inputs to provide full isolation between the DGC-2020ES and monitored voltage phases.

  • Page 358: Generator Breaker Does Not Open When It Should

    9469200996 Step 8: Verify the wiring to the breaker from the DGC-2020ES. If it seems OK, you can do a manual close and open by modifying the programmable logic. Map some unused outputs to the OPEN and CLOSE outputs from the Gen Breaker Block in the programmable logic. Map a virtual switch to the logic output that would normally be the breaker open output.

  • Page 359: Dgc-2020Es Front Panel Debug Screen

    CONDITION DETECTION screen to achieve correct detection. Step 5: Verify the wiring to the breaker from the DGC-2020ES. If it seems OK, you can do a manual close and open by modifying the programmable logic. Map some unused outputs to the OPEN and CLOSE outputs from the Gen Breaker Block in the programmable logic.
  • Page 360 9469200996 Troubleshooting DGC-2020ES...
  • Page 362 Highland IL 62249-1074 USA Suzhou Industrial Park 15-06 Peninsula Plaza Tel: +1 618.654.2341 215122 Suzhou Singapore 179098 Fax: +1 618.654.2351 P.R. CHINA Tel: +65 68.44.6445 email: info@basler.com Tel: +86 512.8227.2888 Fax: +65 68.44.8902 Fax: +86 512.8227.2887 email: singaporeinfo@basler.com email: chinainfo@basler.com...
  • Page 363 DGC-2020ES Digital Genset Controller Accessories Instruction Manual Publication 12570 Route 143 • Highland, Illinois 62249-1074 USA Tel +1 618.654.2341 • Fax +1 618.654.2351 9469200997, Rev C www.basler.com • info@basler.com July 2021...
  • Page 364 Proposition 65 warning, we are notifying you that one or more of the Proposition 65 listed chemicals may be present in products we sell to you. For more information about the specific chemicals found in this product, please visit https://www.basler.com/Prop65.
  • Page 365 9469200997 Preface This instruction manual provides information about the accessories for the DGC-2020ES Digital Genset Controller. To accomplish this, the following information is provided: CEM-2020 (Contact Expansion Module) • Conventions Used in this Manual Important safety and procedural information is emphasized and presented in this manual through Warning, Caution, and Note boxes.
  • Page 366 The availability and design of all features and options are subject to modification without notice. Over time, improvements and revisions may be made to this publication. Before performing any of the following procedures, contact Basler Electric for the latest revision of this manual.

  • Page 367: Revision History

    9469200997 Revision History A historical summary of the changes made to this instruction manual is provided below. Revisions are listed in reverse chronological order. Visit www.basler.com to download the latest hardware, firmware, and BESTCOMSPlus revision ® histories. Instruction Manual Revision History...
  • Page 368 9469200997 Revision History DGC-2020ES...
  • Page 369 9469200997 Contents CEM-2020 ..............................1-1 Troubleshooting ............................2-1 DGC-2020ES Contents...
  • Page 370 9469200997 Contents DGC-2020ES...

  • Page 371: General Information

    1 • CEM-2020 General Information The optional CEM-2020 is a remote auxiliary device that provides additional DGC-2020ES contact inputs and outputs. Two types of modules are available. A low current module (CEM-2020) provides 24 contact outputs and high current module (CEM-2020H) provides 18 contact outputs.

  • Page 372: Communications Interface

    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 373: Functional Description

    The CEM-2020 provides 24 programmable contact outputs with the same functionality as the contact outputs on the DGC-2020ES. Outputs 5 through 16 can carry 1 A. Outputs 17 through 28 can carry 4 A. The label text of each contact output is customizable.

  • Page 374: Bestcomsplus ® Software

    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 375 9469200997 Figure 1-1. CEM-2020 Overall Dimensions See Figure 1-2 for CEM-2020H overall dimensions. All dimensions are shown in inches with millimeters in brackets. DGC-2020ES CEM-2020...
  • Page 376 5 inch-pounds (0.56 N•m). Operating Power The Contact Expansion Module operating power input accepts either 12 Vdc or 24 Vdc and tolerates voltage over the range of 6 to 32 Vdc. Operating power must be of the correct polarity. Although reverse CEM-2020 DGC-2020ES...
  • Page 377 Contact Inputs and Contact Outputs The CEM-2020 (Figure 1-3) has 10 contact inputs and 24 contact outputs. The CEM-2020H (Figure 1-4) has 10 contact inputs and 18 contact outputs. Figure 1-3. CEM-2020 Contact Input and Contact Output Terminals DGC-2020ES CEM-2020...
  • Page 378 These terminals provide communication using the SAE J1939 protocol and provide high-speed communication between the Contact Expansion Module and the DGC-2020ES. Connections between the CEM-2020 and DGC-2020ES should be made with twisted-pair, shielded cable. CAN interface terminals are listed in Table 1-2. Refer to Figure 1-5 and Figure 1-6.
  • Page 379 Figure 1-5. CAN Interface with CEM-2020 providing One End of the Bus CEM-2020 (Optional) Stub CAN-H DGC-2020ES Engine CAN-L P0067-85 120 ohm 120 ohm Other Termination Termination Devices Figure 1-6. CAN Interface with DGC-2020ES providing One End of the Bus DGC-2020ES CEM-2020...
  • Page 380 The Remote Contact Outputs screen is found in the BESTCOMSPlus Settings Explorer under the Programmable Inputs category. If using the front panel, navigate to Settings > Programmable Outputs > Configurable Outputs. The BESTCOMSPlus Contact Outputs screen is illustrated in Figure 1-8. CEM-2020 DGC-2020ES...

  • Page 381: Maintenance

    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. Before returning the CEM-2020 for repair, contact Basler Electric Technical Services Department at 618- 654-2341 for a return authorization number.
  • Page 382 1-12 9469200997 CEM-2020 DGC-2020ES...

  • Page 383: Troubleshooting

    9469200997 2 • Troubleshooting If you do not get the results that you expect from the DGC-2020ES, first check the programmable settings for the appropriate function. Use the following troubleshooting procedures when difficulties are encountered in the operation of your genset control system.
  • Page 384 Use a voltmeter connected between the BATT– terminal (17) and the SENDER COM terminal (2) on the DGC-2020ES to verify that there is no voltage difference at any time. Any voltage differences may manifest themselves as erratic sender readings. Wiring should be corrected so that no differences exist.
  • Page 385 Step 3: If ground faults are detected on a DGC-2020ES in an ungrounded system application, it is recommended that potential transformers be employed on the voltage sensing inputs to provide full isolation between the DGC-2020ES and monitored voltage phases.
  • Page 386 9469200997 Step 8: Verify the wiring to the breaker from the DGC-2020ES. If it seems OK, you can do a manual close and open by modifying the programmable logic. Map some unused outputs to the OPEN and CLOSE outputs from the Gen Breaker Block in the programmable logic. Map a virtual switch to the logic output that would normally be the breaker open output.
  • Page 387 CONDITION DETECTION screen to achieve correct detection. Step 5: Verify the wiring to the breaker from the DGC-2020ES. If it seems OK, you can do a manual close and open by modifying the programmable logic. Map some unused outputs to the OPEN and CLOSE outputs from the Gen Breaker Block in the programmable logic.
  • Page 388 9469200997 Troubleshooting DGC-2020ES...
  • Page 390 Highland IL 62249-1074 USA Suzhou Industrial Park 15-06 Peninsula Plaza Tel: +1 618.654.2341 215122 Suzhou Singapore 179098 Fax: +1 618.654.2351 P.R. CHINA Tel: +65 68.44.6445 email: info@basler.com Tel: +86 512.8227.2888 Fax: +65 68.44.8902 Fax: +86 512.8227.2887 email: singaporeinfo@basler.com email: chinainfo@basler.com...

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