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DGC-2020HD
User Manual
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User Manual
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Basler Electric DGC-2020HD User Manual

INSTRUCTION MANUA L
FOR
DGC-2020HD
DIGITAL GENSET CONTROLLE R
Publication: 9469300990 Revision: B Mar-14
9469300990 Rev B i
Caution
Note
This instruction manual provides information about the installation and operation of the DGC-2020HD Digital Genset Controller. To accomplish this, the following information is provided:
• Controls and indicators
• Inputs and outputs
• Protection and control functions
• Reporting and alarms information
• Mounting and connection diagrams
• BESTCOMSPlus
• Communication and security
• Maintenance and troublesh ooting pr oc edures
• Specifications
• AEM-2020
• CEM-2020
• MTU Fault Codes
• Exhaust Treatment
• Diagnostic Trouble Codes
Conventions Used in this Ma nua l
®
software
Important safety and procedural information is emphasized and presented in this manual through Warning, Caution, and Note boxes. Each type is illustrated and defined as follows.
Warning!
Warning boxes call attention to conditions or actions that may cause personal injury or death.
Caution boxes call attention to operating conditions that may lead to equipment or property damage.
Note boxes emphasize important information pertaining to Digital Genset Controller installation or operation.
Digital Genset Controller Preface
ii 9469300990 Rev B
Basler Electric does not assume any responsibility to compliance or noncompliance with national code, local code,
This product contains, in part, open source software (software licensed in a way that ensures freedom to run, terms of either the GNU General Public License or GNU Lesser General Public License. The licenses, at the time documentation from us, including our End User License Agreement, places any additional restrictions on what you
corresponding source code for the version of the programs distributed to you will be sent upon request (contact
The source code is distributed in the hope that it will be useful, but WITHOUT ANY REPRESENTATION or
Review the software website for the latest version of the software documentation.
For terms of service relating to this product and software, see the Commercial Terms of Products and Services document available at www.basler.com/terms.
It is not the intention of this manual to cover all details and variations in equipment, nor does this manual provide
manual.
The English-language version of this manual serves as the only approved manual version.
12570 State Route 143
Highland IL 62249-1074 USA
www.basler.com
info@basler.com
Tel: +1 618.654.2341
Fax: +1 618.654.2351
© 2014 by Basler E lectric
All rights reserved
First printing: November 2013
Warning!
READ THIS MANUAL. Read this manual before installing, operating, or maintaining the DGC-2020HD.
Note all warnings, cautions, and notes in this manual as well as on the product. Keep this manual with the product for reference. Only qualified personnel should install, operate, or service this system. Failure to follow warning and cautionary labels may result in personal injury or property damage. Exercise caution at all times.
or any other applicable code. This manual serves as reference material that must be well understood prior to installation, operation, or maintenance.
copy, distribute, study, change, and improve the software) and you are granted a license to that software under the of sale of the product, allow you to freely copy, modify, and redistribute that software and no other statement or may do with that software.
For at least three (3) years from the date of distribution of this product, a machine-readable copy of the complete information is provided above). A fee of no more than our cost of physically performing the source code distribution
is charged.
WARRANTY or even the implied warranty of MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. Refer to the source code distribution for additional restrictions regarding warranty and copyrights.
For a complete copy of GNU GENERAL PUBLIC LICENSE Version 2, June 1991 or GNU LESSER GENERAL PUBLIC LICENSE Version 2.1, February 1999 refer to www.gnu.org or contact Basler Electric. You, as a Basler Electric Company customer, agree to abide by the terms and conditions of GNU GENERAL PUBLIC LICENSE Version 2, June 1991 or GNU LESSER GENERAL PUBLIC LICENSE Version 2.1, February 1999, and as such hold Basler Electric Company harmless related to any open source software incorporated in this product. Basler Electric Company disclaims any and all liability associated with the open source software and the user agrees to defend and indemnify Basler Electric Company, its directors, officers, and employees from and against any and all losses, claims, attorneys' fees, and expenses arising from the use, sharing, or redistribution of the software.
data for every possible contingency regarding installation or operation. 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
Preface DGC-2020HD
9469300990 Rev B iii

Contents

Introduction ................................................................................................................................................. 1
Features and Functions ............................................................................................................................. 1
Style Number ............................................................................................................................................. 4
Optional Features and Capabilities ........................................................................................................... 4
Specifications .............................................................................................................................................. 5
Operating Power ........................................................................................................................................ 5
Battery Ride Through ................................................................................................................................ 5
Current Sensing ......................................................................................................................................... 5
Voltage Sensing ........................................................................................................................................ 5
Analog Sensing ......................................................................................................................................... 6
Contact Sensing ........................................................................................................................................ 6
Engine System Inputs................................................................................................................................ 7
Output Contacts ......................................................................................................................................... 7
Metering ..................................................................................................................................................... 8
Generator Protection Functions .............................................................................................................. 10
Logic Timers ............................................................................................................................................ 11
Communication Interface......................................................................................................................... 11
Real-Time Clock ...................................................................................................................................... 12
LCD Heater .............................................................................................................................................. 13
Type Tests ............................................................................................................................................... 13
Environment ............................................................................................................................................ 13
UL Approval ............................................................................................................................................. 14
CSA Certification ..................................................................................................................................... 14
NFPA Compliance ................................................................................................................................... 14
CE Compliance ........................................................................................................................................ 14
Physical ................................................................................................................................................... 14
Mounting .................................................................................................................................................... 15
Hardware ................................................................................................................................................. 15
Dimensions .............................................................................................................................................. 15
Terminals and Connectors ....................................................................................................................... 17
Terminals ................................................................................................................................................. 18
Connectors .............................................................................................................................................. 25
Typical Applications ................................................................................................................................. 27
Connections for Typical Applications ...................................................................................................... 27
Connections for Load Sharing ................................................................................................................. 32
Analog Input Connections ....................................................................................................................... 33
CAN Connections .................................................................................................................................... 33
Expansion Module Connections (CAN 1) ................................................................................................ 35
Installation for CE Systems ..................................................................................................................... 35
Controls and Indicators ............................................................................................................................ 37
Programmable Indicator Configuration .................................................................................................... 39
Display Operation and Navigation ........................................................................................................... 40
Display Setup .......................................................................................................................................... 48
Power Input ................................................................................................................................................ 51
Nominal Voltage Input and Acceptable Range of Input Voltage ............................................................. 51
Terminal Assignments ............................................................................................................................. 51
Power Consumption ................................................................................................................................ 51
Battery Ride-Through Capability ............................................................................................................. 51
Fuse Protection ....................................................................................................................................... 51
Voltage and Current Sensing ................................................................................................................... 53
Generator Voltage ................................................................................................................................... 53
DGC-2020HD Contents
iv 9469300990 Rev B
Bus Voltage ............................................................................................................................................. 53
Generator and Bus Current ..................................................................................................................... 53
Engine Sender Inputs ............................................................................................................................... 55
Connections ............................................................................................................................................. 55
Compatibility ............................................................................................................................................ 55
Operation ................................................................................................................................................. 55
Programmability ....................................................................................................................................... 55
Characteristic Curves .............................................................................................................................. 55
Sender Failure Detection ......................................................................................................................... 59
Speed Signal Inputs .................................................................................................................................. 61
Magnetic Pickup ...................................................................................................................................... 61
Generator Sensing Voltage ..................................................................................................................... 61
Contact Inputs ........................................................................................................................................... 63
Programmable Contact Inputs ................................................................................................................. 63
Analog Inputs ............................................................................................................................................ 67
Input Setup .............................................................................................................................................. 67
Ranges .................................................................................................................................................... 67
Thresholds ............................................................................................................................................... 67
Operational Settings ................................................................................................................................ 68
Logic Connections ................................................................................................................................... 69
Contact Outputs ........................................................................................................................................ 71
Prestart .................................................................................................................................................... 71
Start ......................................................................................................................................................... 71
Run .......................................................................................................................................................... 71
Relay Control ........................................................................................................................................... 71
Programmable Contact Outputs .............................................................................................................. 72
Operating Modes ....................................................................................................................................... 75
Off ............................................................................................................................................................ 75
Run .......................................................................................................................................................... 75
Auto ......................................................................................................................................................... 75
Operating Mode Control .......................................................................................................................... 75
Breaker Management ................................................................................................................................ 77
Breaker Status ......................................................................................................................................... 77
System Breaker Configuration ................................................................................................................ 77
Breaker Operation ................................................................................................................................... 88
Synchronizer ............................................................................................................................................. 97
Operation ................................................................................................................................................. 97
Configuration ........................................................................................................................................... 99
Bias Control ............................................................................................................................................. 113
AVR Bias Control Settings .................................................................................................................... 113
Governor Bias Control Settings ............................................................................................................. 115
Multiple Generator Management ........................................................................................................... 119
AVR Output ........................................................................................................................................... 119
Governor Output .................................................................................................................................... 120
Load Share Output ................................................................................................................................ 121
Parameter Selection .............................................................................................................................. 121
Demand Start/Stop ................................................................................................................................ 121
Generator Sequencing .......................................................................................................................... 123
Network Configuration ........................................................................................................................... 125
Generator Protection .............................................................................................................................. 127
Undervoltage (27) .................................................................................................................................. 127
Overvoltage (59) .................................................................................................................................... 129
Contents DGC-2020HD
9469300990 Rev B v
Phase Voltage Imbalance (47) .............................................................................................................. 131
Vector Shift (78) ..................................................................................................................................... 133
Frequency (81) ...................................................................................................................................... 135
Overcurrent (51) .................................................................................................................................... 138
Power (32) ............................................................................................................................................. 144
Loss of Excitation (40Q) ........................................................................................................................ 147
Setting Groups ....................................................................................................................................... 149
Configurable Protection ......................................................................................................................... 151
Element Setup ....................................................................................................................................... 151
Thresholds ............................................................................................................................................. 153
Logic Connections ................................................................................................................................. 154
Operational Settings .............................................................................................................................. 154
Metering ................................................................................................................................................... 157
Metering Explorer .................................................................................................................................. 157
Engine.................................................................................................................................................... 158
Generator .............................................................................................................................................. 159
Bus 1 and Optional Bus 2 ...................................................................................................................... 159
Bias Control ........................................................................................................................................... 160
Power..................................................................................................................................................... 160
Run Statistics ......................................................................................................................................... 161
Synchronization ..................................................................................................................................... 161
Status Indication .................................................................................................................................... 162
Inputs ..................................................................................................................................................... 162
Outputs .................................................................................................................................................. 167
Configurable Protection ......................................................................................................................... 169
J1939 ECU ............................................................................................................................................ 169
MTU ....................................................................................................................................................... 171
Summary ............................................................................................................................................... 172
Control Panel ......................................................................................................................................... 174
Generator Network Status ..................................................................................................................... 174
Generator Sequencing .......................................................................................................................... 175
Diagnostics ............................................................................................................................................ 176
Analysis ................................................................................................................................................. 176
Reporting and Alarms ............................................................................................................................. 179
Event Logging ........................................................................................................................................ 179
Sequence of Events .............................................................................................................................. 179
Data Logging ......................................................................................................................................... 180
Trending ................................................................................................................................................ 181
Alarms.................................................................................................................................................... 182
BESTCOMSPlus® Software .................................................................................................................... 193
System Recommendations ................................................................................................................... 194
Installation ............................................................................................................................................. 194
Activate the DGC-2020HD Plugin for BESTCOMSPlus® ...................................................................... 194
Menu Bars ............................................................................................................................................. 198
Settings Explorer ................................................................................................................................... 199
Metering Explorer .................................................................................................................................. 200
BESTspace™ ......................................................................................................................................... 200
Settings File Management ..................................................................................................................... 201
Auto Export Metering ............................................................................................................................. 202
BESTCOMSPlus® Updates ................................................................................................................... 203
Firmware Updates ................................................................................................................................. 203
BESTlogic™Plus ...................................................................................................................................... 205
Overview of BESTlogic™Plus ................................................................................................................ 205
BESTlogic™Plus Composition ............................................................................................................... 206
Logic Schemes ...................................................................................................................................... 234
DGC-2020HD Contents
vi 9469300990 Rev B
Programming BESTlogic ™Plus.............................................................................................................. 235
Offline Logic Simulator .......................................................................................................................... 236
BESTlogic™Plus File Management ....................................................................................................... 236
BESTlogic™Plus Ex amp les ................................................................................................................... 237
Communication ....................................................................................................................................... 239
USB ....................................................................................................................................................... 239
Ethernet ................................................................................................................................................. 239
CAN ....................................................................................................................................................... 243
RS-232 .................................................................................................................................................. 253
RS-485 .................................................................................................................................................. 256
Modbus™ Setup ..................................................................................................................................... 256
Remote Display Panel (optional) ........................................................................................................... 257
Configuration ........................................................................................................................................... 259
System Settings ..................................................................................................................................... 259
Rated Data ............................................................................................................................................ 262
Remote Module Setup ........................................................................................................................... 267
Crank Settings ....................................................................................................................................... 267
Automatic Restart Settings .................................................................................................................... 269
Exercise Timer Settings......................................................................................................................... 270
Sensing Transformer Ratings ................................................................................................................ 271
Relay Control Settings ........................................................................................................................... 272
System Configuration Detection Settings .............................................................................................. 273
Device Information .................................................................................................................................. 275
Style Number ......................................................................................................................................... 275
Device Info ............................................................................................................................................. 275
Firmware Updates ................................................................................................................................. 276
Security .................................................................................................................................................... 281
Access Levels ........................................................................................................................................ 281
User Name Setup .................................................................................................................................. 281
Port Access Setup ................................................................................................................................. 283
Access Control ...................................................................................................................................... 283
Timekeeping ............................................................................................................................................ 285
Clock Setup ........................................................................................................................................... 285
Setting the Time and Date ..................................................................................................................... 287
IRIG Port ................................................................................................................................................ 287
Real-Time Clock Specificat ions ............................................................................................................. 288
Backup Battery for the Real-Time Clock ............................................................................................... 288
Maintenance and Troubleshooting ....................................................................................................... 289
Maintenance .......................................................................................................................................... 289
Storage .................................................................................................................................................. 289
Troubleshooting ..................................................................................................................................... 289
AEM-2020 ................................................................................................................................................. 303
Features ................................................................................................................................................ 303
Specifications ........................................................................................................................................ 303
Functional Description ........................................................................................................................... 305
Mounting ................................................................................................................................................ 305
Connections ........................................................................................................................................... 306
AEM-2020 Configuration ....................................................................................................................... 312
Remote Analog Inputs Configuration .................................................................................................... 312
Remote RTD Inputs Configuration ........................................................................................................ 315
Remote Thermocouple Inputs Configuration ........................................................................................ 317
Remote Analog Outputs Configuration .................................................................................................. 319
Firmware Updates ................................................................................................................................. 322
Repair .................................................................................................................................................... 322
Contents DGC-2020HD
9469300990 Rev B vii
Maintenance .......................................................................................................................................... 322
Storage .................................................................................................................................................. 323
CEM-2020 ................................................................................................................................................. 325
Features ................................................................................................................................................ 325
Specifications ........................................................................................................................................ 325
Functional Description ........................................................................................................................... 327
Mounting ................................................................................................................................................ 327
Connections ........................................................................................................................................... 329
CEM-2020 Configuration ....................................................................................................................... 334
Remote Contact Inputs Configuration ................................................................................................... 334
Remote Contact Outputs Configuration ................................................................................................ 336
Firmware Updates ................................................................................................................................. 336
Repair .................................................................................................................................................... 336
Maintenance .......................................................................................................................................... 337
Storage .................................................................................................................................................. 337
Time Curve Characteristics.................................................................................................................... 339
Curve Specifications .............................................................................................................................. 339
Time Overcurrent Characteristic Curve Graphs .................................................................................... 340
Tuning PID Settings ................................................................................................................................ 361
Voltage and Speed Controllers ............................................................................................................. 361
kW Load Controller ................................................................................................................................ 361
Var/PF Controller ................................................................................................................................... 361
Speed Trim Function ............................................................................................................................. 361
Tuning Parameters ................................................................................................................................ 361
Tuning Procedures ................................................................................................................................ 362
Generic Gains for Multiple Machine Types ........................................................................................... 366
MTU Fault Codes ..................................................................................................................................... 367
Exhaust Treatment .................................................................................................................................. 377
Diesel Particulate Filter (DPF) ............................................................................................................... 377
Exhaust After-Treatment Systems (EATS)............................................................................................ 379
Diagnostic Trouble Codes ...................................................................................................................... 381
Revision History ...................................................................................................................................... 391
DGC-2020HD Contents
viii 9469300990 Rev B
Contents DGC-2020HD
9469300990 Rev B 1

Introduction

The DGC-2020HD Digital Genset Controller provides integrated engine-genset control, protection, and metering in a single package. Microprocessor based technology allows for exact measurement, setpoint adjustment, and timing functions. Front panel controls and indicators enable quick and simple DGC­2020HD operation. A backlit liquid crystal display (LCD) can be viewed under a wide range of ambient light and temperature conditions. Basler Electric communication software (BESTCOMSPlus®) allows units to be easily customized for each application. Because of the low sensing burden in the DGC-2020HD, dedicated potential transformers (PTs) are not required.

Features and Functions

The DGC-2020HD Digital Genset Controller has the following features:
• Local and remote generator control
• Engine, generator, and loss of mains protection (optional)
• Automatic transfer switch control (mains failure)
• Automatic generator configuration detection
• Generator sequencing
• Generator soft loading/unloading
• Auto synchronizing (optional)
• Programmable analog engine senders
• 16 programmable contact inputs
• Three programmable front panel LEDs, with labels
• Up to four local analog inputs
• A ramping function to load and unload generator smoothly
• Demand start/stop and generator sequencing
• kW and kvar load control
• kW and kvar load sharing via Ethernet or analog load share lines
• Programmable logic
• Exercise timer
• ECU communications via SAE J1939
• Marathon DVR2000E+ voltage regulator control via SAE J1939
• Integrated USB, RS485, and Ethernet communication
• Two J1939 CAN Bus ports
• Additional modules available to expand the capabilities of the DGC-2020HD
An overview of DGC-2020HD Digital Genset Controller functions is provided in the following paragraphs.

Generator and Bus Protection and Metering

Multifunction protection guards against overvoltage, undervoltage, excessive forward and reverse power, underfrequency, and overfrequency. Overcurrent, phase imbalance, loss of mains, and frequency rate-of­change protection are available as an option. Each protection function has an adjustable pickup and time delay setting. Sixteen inverse time curves, in addition to user-programmable curves, enable the DGC­2020HD to offer overcurrent protection in a variety of applications. Each protective element can be assigned to the generator, bus 1 or bus 2.
Metered generator and bus parameters include voltage, current, real power (watts), apparent power (VA), and power factor (PF).

Engine Protection and Metering

Engine protection features include oil pressure and coolant temperature monitoring, overcrank protection, ECU-specific protection elements, and diagnostic reporting.
Metered engine parameters include oil pressure, coolant temperature, battery voltage, speed, fuel level, engine load, coolant level (from ECU), ECU-specific parameters, and run-time statistics.
DGC-2020HD Introduction
2 9469300990 Rev B

Load Sharing

The DGC-2020HD provides analog outputs to the power system in the form of analog bias signals to the voltage regulator and speed governor. A pulse width modulated (PWM) speed bias output is also available. When the generator breaker is closed and load sharing is enabled, the DGC-2020HD shares the real power load proportionally with other generators in the system. Load sharing can be implemented on the Analog Load Share Line or through Ethernet communications. Reactive power (kvar) sharing is accomplished through Ethernet communications.

Event Recording

A history of system events are logged in nonvolatile memory. The DGC-2020HD retains records for 128 unique types of events. Each record tracks the number of times that an event has occurred and records a time stamp of the first and last occurrences.
A Sequence of Events (SER) log is also available. This log tracks the internal and external status of the DGC-2020HD. Events are scanned at five millisecond intervals with 1,023 events stored per record. All changes of state that occur during each scan are time- and date-stamped. Sequences of Events reports are available through BESTCOMSPlus. Over 1,000 records can be retained in nonvolatile memory. When the SER memory becomes full, the oldest record is replaced by the latest one acquired.

Data Logging

The data logging function of the DGC-2020HD records up to six records of user-selectable, real-time parameter data. For more information, see the Reporting and Alarms chapter.

Contact Inputs and Outputs

DGC-2020HD controllers have 16 programmable contact inputs. All contact inputs recognize dry contacts. The programmable inputs can be configured to initiate a pre-alarm or alarm condition. A programmable input can be programmed to receive a contact input from an automatic transfer switch (ATS). In addition, a programmable Battle Override function allows overriding of DGC-2020HD alarms and protection functions. Each programmable input can be assigned a user-defined name for easy identification at the front panel display and in fault records.
Output contacts include three dedicated relays for energizing an engine’s glow plugs, fuel solenoid, and starter solenoid. An additional twelve programmable output contacts are provided.
Additional contact inputs and output contacts can be accommodated with an optional CEM-2020 Contact Expansion Module. Contact Basler Electric for ordering information.

Automatic Transfer Switch Control (Mains Failure)

The DGC-2020HD has the ability to detect a mains failure via a single- or three-phase Bus input. A mains failure is established when any one of the following conditions are met:
• Any phase of bus voltage falls below the dead bus threshold
• Any phase of bus voltage is unstable due to overvoltage or undervoltage
• Any phase of bus voltage is unstable due to overfrequency or underfrequency
At this time, the DGC-2020HD starts the genset and, when ready, applies power to the load from the genset. The DGC-2020HD implements open or closed breaker transitions to and from the mains. When the mains returns and is considered stable, the DGC-2020HD will transfer the load back to the mains and stop the engine. During closed breaker transitions, the optional Auto Synchronizer can synchronize the generator to the mains before transferring the load from generator power to utility power.

Device Security

Passwords provide access security for six distinct functional access areas: Read, Control, Operator, Settings, Design, and Administrator. Each username/password is assigned an access area with access to that area and each area below it. An administrator password provides access to all six of the functional areas.
Introduction DGC-2020HD
9469300990 Rev B 3
A second dimension of security is provided by the ability to restrict access for any of the access areas to only specific communication ports. For example, you could set up security to deny access to control commands through an Ethernet port.
Security settings affect read and write access. Refer to the Security chapter for more information.

Communication

DGC-2020HD communication features include a mini-B USB port, RS-485 port, two copper Ethernet ports or one fiber optic Ethernet port (optional), and SAE J1939 interface.
USB Port
The USB communication port can be used with BESTCOMSPlus® software to quickly configure a DGC­2020HD with the desired settings or retrieve metering values and event log records.
RS485 Port
An RS485 communication port uses the Modbus™ communication protocol and enables remote control and monitoring of the DGC-2020HD over a polled network.
Ethernet Port(s)
Depending on style number, each DGC-2020HD is equipped with either dual copper (100BaseT) Ethernet communication ports (style xxxxDxxxx) or a fiber optic (100BaseF) Ethernet communication port (style xxxxFxxxx).
Ethernet ports provide communications between the DGC-2020HD and a PC via BESTCOMSPlus or other DGC-2020HDs in a network. An Ethernet connection to a PC running BESTCOMSPlus provides remote metering, setting, annunciation, and control of the DGC-2020HD. Ethernet communication between DGC-2020HDs allows for generator sequencing on an islanded system.
CAN Interface
The CAN (Control Area Network) interface provides high-speed communication between the DGC­2020HD and the engine control unit (ECU) on an electronically controlled engine. This interface provides access to oil pressure, coolant temperature, and engine speed data by reading these parameters directly from the ECU. When available, engine diagnostic data can also be accessed. The CAN interface supports the following protocols:
• SAE J1939 Protocol - Oil pressure, coolant temperature, and engine speed data are received
from the ECU. In addition, DTCs (Diagnostic Trouble Codes) help diagnose any engine-related failures. The engine DTCs are displayed on the front panel of the DGC-2020HD and may be obtained using BESTCOMSPlus® software.
• MTU Protocol - A DGC-2020HD connected to a genset equipped with an MTU engine 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-2020HD tracks and displays the active fault codes issued by the MTU engine ECU.
DGC-2020HD Introduction
4 9469300990 Rev B
MODEL NUMBER

STYLE NUMBER

DGC – 2020HD
P0071-69
Current Sensing
5) 5A CT inputs
1) 1A CT inputs
N N
Generator Protection
,
S) Standard: 27, 32, 40Q,
59 81O, 81U
E) Enhanced: 27, 32, 40Q,
47, 51, 59, 78, 81O, 81U, 81 ROCOF
Ethernet
D) Dual 100BaseT (Copper) F) 100BaseF (Fiber)
Terminal Type
S) Spring
Auto Synchronizer
1) No Auto Sync
2) w/ Auto Sync
The fuel level sender is always resistive and is not a programmable input.
1
Senders
A) Anal og R) Resi st ive
1
Bus Inputs
B) Basic Sensing:
1 Bus Input, 4 CTs
E) Enhanced Sensing:
2 Bus Inputs, 7 CTs
Style Number
Standard-order DGC-2020HD controllers are identified by a style number which consists of a combination of letters and numbers that define the controller’s electrical characteristics and operational features. The model number, together with the style number, describes the options included in a specific controller. Figure 1 illustrates the DGC-2020HD style number identification chart.

Optional Features and Capabilities

AEM-2020 (Analog Expansion Module)

The optional AEM-2020 provides eight remote analog inputs, eight remote RTD inputs, two Type-K remote thermocouple inputs, and four remote analog outputs to the DGC-2020HD. The AEM-2020 communicates with the DGC-2020HD through a CAN interface. Up to four AEM-2020s may be used with one DGC-2020HD. Refer to the AEM-2020 chapter for more information.

CEM-2020 (Contact Expansion Module)

The optional CEM-2020 provides 10 additional contact inputs and 18 or 24 additional output contacts (depending on module type) to the DGC-2020HD. The CEM-2020 communicates with the DGC-2020HD through a CAN interface. Up to four CEM-2020s may be used with one DGC-2020HD. Refer to the CEM- 2020 chapter for more information.
Figure 1. DGC-2020HD Style Chart
Introduction DGC-2020HD
9469300990 Rev B 5

Specifications

DGC-2020HD electrical and physical characteristics are listed in the following paragraphs.

Operating Power

Nominal ............................................ 12 or 24 Vdc
Range ............................................... 6 to 32 Vdc
Terminals.......................................... 48 (+), 49 (–), 50 (chassis ground)

Power Consumption

Sleep Mode ...................................... 12.7 W - LCD heater off, all relays de-energized, and analog outputs
disabled
Normal Operational Mode ................ 18.1 W - Run mode, LCD heater off, START and RUN relays
energized, six programmable relays energized, and analog outputs enabled
Maximum Operational Mode ............ 25 W - Run mode, LCD heater on, all relays energized, and analog
outputs enabled

Battery Ride Through

Starting at 10 Vdc, withstands cranking ride-through down to 0 Vdc for 50 ms

Current Sensing

Burden .............................................. 1 VA

Generator CTs

Terminals.......................................... 1 (+), 2 (–) (A-phase)
3 (+), 4 (–) (B-phase) 5 (+), 6 (–) (C-phase)

Available Programmable CTs

AUX 1Terminals ............................... 7 (+), 8 (–)
AUX 2 Terminals .............................. 9 (+), 10 (–)
AUX 3 Terminals .............................. 11 (+), 12 (–)
AUX 4 Terminals .............................. 13 (+), 14 (–)
(Programmable CTs AUX 2, 3, and 4 are optional with style number xxxxxxxEx.)

1 Aac Current Sensing

Continuous Rating ............................ 0.02 to 1.5 Aac
1 Second Rating ............................... 10 Aac

5 Aac Current Sensing

Continuous Rating ............................ 0.1 to 7.5 Aac
1 Second Rating ............................... 50 Aac

Voltage Sensing

Range ............................................... 12 to 576 V rms, line-to-line
Frequency ........................................ 50/60 Hz
Frequency Range ............................. 10 to 90 Hz
Burden .............................................. 1 VA
1 Second Rating ............................... 720 V rms
DGC-2020HD Specifications
6 9469300990 Rev B

Generator Sensing

Configuration .................................... Line-to-line or line-to-neutral
Generator Sensing Terminals .......... 86 (A-phase)
88 (B-phase) 90 (C-phase) 91 (Neutral)

Bus 1 Sensing

Configuration .................................... Line-to-line or line-to-neutral
Bus Sensing Terminals .................... 93 (A-phase)
95 (B-phase) 97 (C-phase) 98 (Neutral)

Bus 2 Sensing (Optional with style number xxxxxxxEx)

Configuration .................................... Line-to-line or line-to-neutral
Bus Sensing Terminals .................... 100 (A-phase)
101 (B-phase) 103 (C-phase) 104 (Neutral)

Analog Sensing

The DGC-2020HD contains two or four (optional) analog inputs.

Current Sensing

Rating ............................................... 4 to 20 mA
Burden .............................................. 84.25 Ω to 87.1 Ω

Voltage Sensing

Rating ............................................... –10 to 10 Vdc
Burden .............................................. 9.75 kΩ to 10.16 kΩ

Contact Sensing

Contact sensing inputs include sixteen programmable inputs. All inputs accept dry contacts. The following contact input recognition and contact output closure times reflect the maximum possible delay.

Contact Input Recognition Time

This is the amount of time that elapses after a local contact input closes until that closure is available in logic.
DGC-2020HD ................................... 125 ms
CEM-2020 ........................................ 185 ms

Contact Output Closure Time

This is the amount of time that elapses after a contact output closure is true in logic until that contact output closes.
DGC-2020HD ................................... 15 ms
CEM-2020 ........................................ 125 ms

Terminals

Input 1 .............................................. 31, 49
Input 2 .............................................. 32, 49
Input 3 .............................................. 33, 49
Input 4 .............................................. 34, 49
Specifications DGC-2020HD
9469300990 Rev B 7
Input 5 .............................................. 35, 49
Input 6 .............................................. 36, 49
Input 7 .............................................. 37, 49
Input 8 .............................................. 38, 49
Input 9 .............................................. 39, 49
Input 10 ............................................ 40, 49
Input 11 ............................................ 41, 49
Input 12 ............................................ 42, 49
Input 13 ............................................ 43, 49
Input 14 ............................................ 44, 49
Input 15 ............................................ 45, 49
Input 16 ............................................ 46, 49

Engine System Inputs

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

Fuel Level Sensing

Resistance Range ............................ 0 to 250 Ω nominal
Terminals.......................................... 71 (FUEL +), 72 (FUEL –)

Coolant Temperature Sensing

Resistance Range ............................ 10 to 2,750 Ω nominal
Terminals.......................................... 77 (COOLANT +), 78 (COOLANT –)

Oil Pressure Sensing

Resistance Range ............................ 0 to 250 Ω nominal
Terminals.......................................... 74 (OIL +), 75 (OIL –)

Engine Speed Sensing

Magnetic Pickup
Voltage Range ................................. 3 to 35 V peak (6 to 70 V peak-peak)
Frequency Range ............................. 32 to 10,000 Hz
Terminals.......................................... 106 (MPU +), 107 (MPU –)
Generator Voltage
Range ............................................... 12 to 576 V rms
Terminals.......................................... 86 (A-phase)
88 (B-phase) 90 (C-phase) 91 (Neutral)

Output Contacts

PRE (Prestart), START, and RUN Relays

Rating ............................................... 30 Adc at 28 Vdc—General purpose, 3 A pilot duty∗

Programmable Relays (12)

Rating ............................................... 2 Adc at 30 Vdc—General purpose, 1.2 A pilot duty∗
∗The load must be in parallel with a diode rated at least 3 times the coil current and 3 times the coil
voltage.
DGC-2020HD Specifications
8 9469300990 Rev B
Terminals
Output 1............................................ 15, 18 (common)
Output 2............................................ 16, 18 (common)
Output 3............................................ 17, 18 (common)
Output 4............................................ 19, 22 (common)
Output 5............................................ 20, 22 (common)
Output 6............................................ 21, 22 (common)
Output 7............................................ 23, 26 (common)
Output 8............................................ 24, 26 (common)
Output 9............................................ 25, 26 (common)
Output 10.......................................... 27, 30 (common)
Output 11.......................................... 28, 30 (common)
Output 12.......................................... 29, 30 (common)
The programmable relays share common terminals: terminal 18 is used for outputs 1, 2, and 3, terminal 22 is used for outputs 4, 5, and 6, terminal 26 is used for outputs 7, 8, and 9, 30 is used for outputs 10, 11, and 12.

Metering

Generator and Bus Voltage (rms)

Metering Range ................................ 0 to 576 Vac (direct measurement)
577 to 9,999 Vac (through VT using VT ratio setting)
VT Ratio Range ................................ 1:1 to 125:1 in primary increments of 1
Accuracy* ......................................... ±1.0% of programmed rated voltage or ±2 Vac
Display Resolution ........................... 1 Vac
* Voltage metering indicates 0 V when generator voltage is below 2% of the full-scale rating.

Generator Current (rms)

Generator current is measured at the secondary windings of user-supplied 1 A or 5 A CTs.
Metering Range ................................ 0 to 5,000 Aac
CT Primary Range ........................... 1 to 5,000 Aac in primary increments of 1 Aac
Accuracy* ......................................... ±1.0% of programmed rated current or ±2 Aac
Display Resolution ........................... 1 Aac
* Current metering indicates 0 A when generator current is below 2% of the full-scale rating.

Generator and Bus Frequency

Frequency is sensed through the generator and bus voltage inputs (phases A and B).
Metering Range ................................ 10 to 90 Hz
Accuracy........................................... ±0.25% or 0.05 Hz
Display Resolution ........................... 0.1 Hz

Apparent Power

Indicates total kVA and individual line kVA (4-wire, line-to-neutral or 3-wire, li ne -to-line).
Measurement/Calcula tio n Meth ods
Total ................................................. kVA = (V
4-Wire, Line-to-Neutral ..................... kVA calculated with respect to neutral
3-Wire, Line-to-Line .......................... A-phase kVA = V
B-phase kVA = V C-phase kVA = V
Accuracy........................................... ±2% of the full-scale indication or ±2 kVA *†
× IL ×√3) ÷ 1000
L-L
× IA ÷ 1000 ÷ √3
AB
× IB ÷ 1000 ÷ √3
BC
× IC ÷ 1000 ÷ √3
CA
* kVA metering indicates 0 kVA when the generator kVA is below 2% of the full-scale rating. † Applies when temperature is between −40°C to +70°C (–40°F to +158°F).
Specifications DGC-2020HD
9469300990 Rev B 9
Note

Power Factor

Metering Range ................................ 0.2 leading to 0.2 lagging
Calculation Method .......................... PF = cosine of the angle between phase AB voltage (Vab) and
phase A current (Ia) *
Accuracy........................................... ±0.01 †
* In single-phase AC-connected machines, it is the cosine of the angle between phase CA voltage
(Vca) and phase C current (Ic).
† Applies when temperature is between –40°C to +70°C (–40°F to +158°F).
For the DGC-2020HD to correctly meter power factor, the generator must be rotating in the same phase sequence as dictated by the generator phase rotation setting.

Real Power

Indicates total kW and individual line kW (4-wire, line-to-neutral or 3-wire line-to-line)
Measurement/Calcula tio n Meth ods
Total ................................................. PF × Total kVA
4-Wire, Line-to-Neutral ..................... kW calculated with respect to neutral
3-Wire, Line-to-Line .......................... A-phase kW = V
B-phase kW = V C-phase kW = V
Accuracy........................................... ±2% of the full-scale indication or ±2 kW *†
× IA × PF ÷ 1000 ÷ √3
AB
× IB × PF ÷ 1000 ÷ √3
BC
× IC × PF ÷ 1000 ÷ √3
CA
* kW metering indicates 0 kW when the generator kW is below 2% of the full-scale rating. † Applies when temperature is between –40°C to +70°C (–40°F to +158°F).

Oil Pressure

Metering Range ................................ 0 to 150 psi, 0 to 10.3 bar, or 0 to 1,034 kPa
Accuracy........................................... ±2% of actual indication or ±1 psi, ±0.07 bar, or ±6.9 kPa (subject to
accuracy of sender)
Display Resolution ........................... 1 psi, 0.07 bar, or 6.9 kPa

Coolant Temperature

Metering Range ................................ 32 to 410°F or 0 to 204°C
Accuracy........................................... ±2% of actual indication or as low as ±2° (subject to accuracy of
sender)

Fuel Level

Metering Range ................................ 0 to 100%
Accuracy........................................... ±2% (subject to accuracy of sender)
Display Resolution ........................... 1.0%

Battery Voltage

Metering Range ................................ 6 to 32 Vdc
Accuracy........................................... ±2% of actual indication or as low as ±0.2 Vdc
Display Resolution ........................... 0.1 Vdc

Engine RPM

Metering Range ................................ 0 to 4,500 rpm
Accuracy* ......................................... ±2% of actual indication or as low as ±2 rpm
Display Resolution ........................... 2 rpm
* When engine speed is below 2% of full-scale, reported rpm is 0. DGC-2020HD Specifications
10 9469300990 Rev B

Maintenance Timer

Maintenance timer indicates the time remaining until genset service is due. Value is retained in nonvolatile memory.
Metering Range ................................ 0 to 5,000 hours
Update Interval ................................. 0.1 hours
Accuracy........................................... ±1% of actual indication or as low as ±12 minutes
Display Resolution ........................... 1 minute

Generator Protection Func t ions

Overvoltage (59) and Undervoltage (27)

Pickup Range ................................... 0 to 576 V
Pickup Increment ............................. 1 V
Hysteresis Range ............................. 1 to 60 Vac
Inhibit Frequency Range .................. 20 to 90 Hz (27 function only)
Activation Delay Range .................... 0 to 600 s
Activation Delay Increment .............. 0.1 s

Underfrequency (81U) and Overfrequency (81O)

Pickup Range ................................... 37.5 to 66 Hz
Pickup Increment ............................. 0.01 Hz
Hysteresis Range ............................. 0.1 to 40 Hz
Activation Delay Range .................... 0 to 600 s
Activation Delay Increment .............. 0.1 s
Inhibit Voltage Range ....................... 0 to 100% of nominal voltage
Inhibit Voltage Increment ................. 1%

ROCOF (Rate of Change of Frequency) (81) (Optional)

Pickup Range ................................... 0.2 to 10 Hz/s
Pickup Increment ............................. 0.1 Hz/s
Pickup Accuracy ............................... 0.2 Hz/s
Activation Delay Range .................... 0 to 10,000 ms
Activation Delay Increment .............. 1 ms

Reverse and Forward Power (32)

Pickup Range ................................... 0 to 200% of nominal input rating
Pickup Increment ............................. 0.1%
Hysteresis Range ............................. 1 to 10%
Activation Delay Range .................... 0 to 600 s
Activation Delay Increment .............. 0.1 s

Loss of Excitation (40Q)

Pickup Range ................................... –150 to 0% of Rated kvar*
Pickup Increment ............................. 0.1%
Hysteresis Range ............................. 1 to 10%
Activation Delay Range .................... 0 to 600 s
Activation Delay Increment .............. 0.1 s
* Rated kvar is calculated on the System Settings, Rated Data s c reen in BEST COMSPlus

Overcurrent (51) (Optional)

Pickup Range ................................... 0.18 to 4 Aac (1 A current sensing)
0.9 to 20 Aac (5 A current sensing)
Hysteresis......................................... 2 %
Time Dial Range .............................. 0 to 7,200 s (fixed time curve)
0 to 9.9 (inverse curve time multiplier)
®
.
Specifications DGC-2020HD
9469300990 Rev B 11
Caution
Notes
Time Dial Increment ......................... 0.1
Inverse Time Curves ........................ See the Time Overcurrent Characteristic Curves chapter
For 1 A current sensing, current shall not exceed 3 amperes for 30 seconds or 4 amperes for 1 second. For 5 A current sensing, current shall not exceed 15 amperes for 30 seconds or 20 amperes for 1 second. Exceeding the above limits may result in equipment damage.

Phase Voltage Imbalance (47) (Optional)

Pickup Range ................................... 0 to 150 Vac
Pickup Increment ............................. 1 Vac
Hysteresis Range ............................. 1 to 5 Vac
Activation Delay Range .................... 0 to 600 s
Activation Delay Increment .............. 0.1 s

Vector Shift (78) (Optional)

Pickup Range ................................... 2 to 90°
Pickup Increment ............................. 1°
Hysteresis......................................... 0.5 degrees
Accuracy........................................... ±1°

Logic Timers

Hours Setting Range ........................ 0 to 250
Hours Setting Increment .................. 1
Minutes Setting Range ..................... 0 to 59
Minutes Setting Increment ............... 1
Seconds Setting Range ................... 0 to 59
Seconds Setting Increment .............. 1
Accuracy........................................... ±15 ms

Communication Interface

CAN (SAE J1939)

Differential Bus Voltage .................... 1.5 to 3 Vdc
Maximum Voltage ............................ –32 to +32 Vdc with respect to negative battery terminal
Communication Rate ........................ 250 kb/s
CAN 1 Terminals .............................. 51 (low), 52 (high), and 53 (shield)
CAN 2 Terminals .............................. 54 (low), 55 (high), and 53 (shield)
1. If the DGC-2020HD is providing one end of the J1939 bus, a 120 Ω, ½ watt
terminating resistor should be installed across terminals 51 (CAN1L) and 52 (CAN1H) and/or 54 (CAN2L) and 55 (CAN2H).
2. If the DGC-2020HD is not part of the J1939 bus, the stub connecting the DGC-
2020HD to the bus should not exceed 914 mm (3 ft) in length.
3. The maximum bus length, not including stubs, is 40 m (131 ft).
4. The J1939 drain (shield) should be grounded at one point only. If grounded
elsewhere, do not connect the drain to the DGC-2020HD.
DGC-2020HD Specifications
12 9469300990 Rev B

Ethernet

Dual Copper (RJ-45) ........................ 10/100BASE-T (style number xxxxDxxxx)
Fiber Optic (BNC) ............................. 10/100BASE-F (style number xxxxFxxxx)
Industrial Ethernet devices des ig ned to comply with IE C 61000-4 series of specif ic ations are recommended.

External Dial-Out Modem (RS-232)

Protocol ............................................ ASCII
Data Transmission ........................... Full Duplex
Baud ................................................. 4,800 to 115,200
Data Bits ........................................... 8
Parity ................................................ None
Stop Bits ........................................... 1
Connector Type ................................ DB-9 Connector (Male)

IRIG-B Time Synchronization

Standard: .......................................... 200-04, Format B002
Input Signal ...................................... Demodulated (dc level-shifted signal)
Logic High Level ............................... 3.5 Vdc, minimum
Logic Low Level ............................... 0.5 Vdc, maximum
Input Voltage Range ........................ –10 to +10 Vdc
Input Resistance .............................. Nonlinear, approximately 4 kΩ at 3.5 Vdc, 3 kΩ at 20 V dc
Response Time ................................ < 1 cycle
Terminals.......................................... 59 (IRIG-B +), 60 (IRIG-B –)

Modbus™ (RS-485)

Baud ................................................. 1,200 to 115,200
Data Bits ........................................... 8
Parity ................................................ None
Stop Bits ........................................... 1
Terminals.......................................... 56 (485 A), 57 (485 B), and 58 (485 shield)

RDP-110

Minimum Wire Size .......................... 20 AWG (0. 52 mm2)
Maximum Wire Length ..................... 4,000 feet (1,219 meters)
Terminals.......................................... 61 (RDP-110 TxD+), 62 (RDP-110 TxD–)
USB
Specification Compatibility USB 2.0 Connector Type Mini-B jack

Real-Time Clock

Clock has leap year and selectable daylight saving time correction. Backup battery sustains timekeeping during losses of DGC-2020HD operating power.
Resolution ........................................ 1 s
Accuracy........................................... ±1.73 s/d at 25°C (77°F)

Clock Holdup

Battery Holdup Time ........................ Approximately 10 yrs
Battery Type ..................................... Rayovac BR2032, lithium, coin-type, 3 Vdc, 195 mAh
Basler Electric P/N 38526
Specifications DGC-2020HD
9469300990 Rev B 13
Note
Caution
Failure to replace the battery with Basler Electric P/N 38526 may void the warranty.
Replacement of the backup battery for the real-time clock should be performed only by qualified personnel.
Do not short-circuit the battery, reverse battery polarity, or attempt to recharge the battery. Observe polarity markings on the battery socket while inserting a new battery. The battery polarity must be correct in order to provide backup for the real­time clock.
It is recommended that the battery be removed if the DGC-2020HD is to be operated in a salt-fog environment. Salt-fog is known to be conductive and may short-circuit the battery.

LCD Heater

The ambient temperature is monitored by a temperature sensor located near the LCD inside the DGC­2020HD. The LCD heater turns on when the ambient temperature falls below –5°C (23°F). The heater turns off when the ambient temperature rises above 5°C (41°F). This range of operation implements 10°C (18°F) of hysteresis between heater turn on and turn off.

Type Tests

Shock

Withstands 15 G in 3 perpendicular planes.

Vibration

Tested for 8 hours in three perpendicular planes.
3 to 25 Hz ......................................... at 1.6 mm (0.063 in) peak amplitude
25 to 2,000 Hz .................................. at 5 G

HALT (Highly Accelerated Life Testing)

HALT is used by Basler Electric to prove that our products will provide the user with many years of reliable service. HALT subjects the device to extremes in temperature, shock, and vibration to simulate years of operation, but in a much shorter period span. HALT allows Basler Electric to evaluate all possible design elements that will add to the life of this device. As an example of some of the extreme testing conditions, the DGC-2020HD was subjected to temperature tests (tested over a temperature range of –85°C to +120°C), vibration tests (of 5 to 40 G at +30°C), and temperature/vibration tests (tested at 40 G over a temperature range of –85°C to +120°C). Combined temperature and vibration testing at these extremes proves that the DGC-2020HD is expected to provide long-term operation in a rugged environment. Note that the vibration and temperature extremes listed in this paragraph are specific to HALT and do not reflect recommended operation levels.

Ignition System

Tested in close proximity to an unshielded, unsuppressed Altronic DISN 800 Spark Ignition System.

Environment

Operating Temperature .................... –40 to +70°C (–40 to +158°F)
Storage Temperature ....................... –40 to +85°C (–40 to +185°F)
DGC-2020HD Specifications
14 9469300990 Rev B
Caution
Salt Fog ............................................ IEC 60068
Ingress Protection ............................ IEC IP56 for front panel
Humidity ........................................... IEC 68-2-78

UL Approval

The DGC-2020HD is recognized to applicable Canadian and US safety standards and requirements by UL. Standards used for evaluation:
• UL6200
• CSA C22.2 No. 0
• CSA C22.2 No. 14
The DGC-2020HD ground fault protection circuit complies with the Calibration and Withstand tests of UL 1053; as required by UL6200. (See the Time Curve Characteristics chapter for the listing of curves verified to meet UL1053.)
To follow UL guidelines, replacement of the backup battery for the real-time clock should be performed only by qualified personnel.

CSA Certification

The DGC-2020HD was tested and has met the certification requirements for electrical, plumbing and/or mechanical products. Standards used for evaluation:
• CSA C22.2 No. 0
• CSA C22.2 No. 14

NFPA Compliance

Complies with NFPA Standard 110, Standard for Emergency and Standby Power.

CE Compliance

This product has been evaluated and complies with the relevant essential requirements set forth by the EU legislation.
EC Directives:
• Low Voltage Devices (LVD) – 2006/95/EC
• Electromagnetic Compatibility (EMC) – 2004/108/EC
Harmonized Standards used for evaluation:
• EN 50178 - Electronic Equipment for use in Power Installations
• EN 61000-6-4 - Electromagnetic Compatibility (EMC), Generic Standards, Emission Standard for
Industrial Environments
• EN 61000-6-2 - Electromagnetic Compatibility (EMC), Generic Standards, Immunity for Industrial
Environments

Physical

Weight .............................................. 5.50 lb (2.5 kg)
Dimensions....................................... See the Mounting chapter.
Specifications DGC-2020HD
9469300990 Rev B 15
10.38
(263.7)
10.75
(273.1)
6
.
8
8
(
1
7
4.8
)
7
.
25
(
1
8
4
.
2
)
C
L
3.
4
4
(
8
7
.
4
)
3.
62
5
(
9
2
.
1
)
(
1
3
6
.
5
)
5.
19
(
1
3
1
.
8
)
P0071-79
0.
25
(
6
.
4
)

Mounting

DGC-2020HD controllers are delivered in sturdy cartons to prevent shipping damage. Upon receipt of a unit, check the part number against the requisition and packing list for agreement. 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.
If the device is not installed immediately, store it in the original shipping package in a moisture- and dust­free environment.

Hardware

The front panel is resistant to moisture, salt fog, humidity, dust, dirt, and chemical contaminants. DGC­2020HD controllers are mounted using the four permanently attached 10-24 studs. The torque applied to the mounting hardware should not exceed 20 inch-pounds (2.2 newton meters).

Dimensions

Panel cutting and drilling dimensions are shown in Figure 2. The horizontal drilling measurement of 10.75 inches has a tolerance of +0.01/–0.01 inches. The horizontal cutout measurement of 10.38 inches has a tolerance of +0.04/–0 inches. The vertical drilling measurement of 7.25 inches has a tolerance of +0.01/–
0.01 inches. The vertical cutout measurement of 6.88 inches has a tolerance of +0.04/–0 inches. Overall dimensions are shown in Figure 3. All dimensions are s hown in inches with mi llim eter s in pare nthesis.
DGC-2020HD Mounting
Figure 2. Panel Cutting and Drilling Dimensions
16 9469300990 Rev B
Figure 3. Overall Dimensions
Mounting DGC-2020HD
CAN
1
LOW
CAN 1 HIGH
SHIELD
CAN 2 LOW
CAN 2 HIGH
51 52 53 54 55
RS-485A RS-485B
RS-485 SHIELD
IRIG-B+
IRIG-B− RDP-110 TxD+ RDP-110 TxD−
CHASSIS GND
AVR +
AVR − GOV + GOV −
GOV PWM LOAD SHARE+ LOAD SHARE−
Eth 1
57 58 59 60 61 62 63 64 65 66 67 68 69 70
FUEL + FUEL −
Not Used
OIL + OIL −
OIL I COOLANT+ COOLANT− COOLANT I
ALOG IN 2 + ALOG IN 2 −
ALOG IN 2 I
ALOG IN 1 + ALOG IN 1 −
ALOG IN 1 I
71 72 73 74 75 76 77 78 79 80 81 82 83 84 85
OUT 1 AUX I4− AUX I4+ AUX I3− AUX I3+ AUX I2− AUX I2+ AUX I1− AUX I1+
GEN IC− GEN IC+ GEN IB− GEN IB+ GEN IA− GEN IA+
15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
OUT 12 OUT 11 OUT 10
COM 7, 8, 9
OUT 9
OUT 8
OUT 7
COM 4, 5, 6
OUT 6
OUT 5
OUT 4
COM 1, 2, 3
OUT 3
OUT 2
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
P0071-12
CHASSIS GND
BATT −
BATT +
Not Used
INPUT 16
5049484746
INPUT 14 INPUT 13 INPUT 12 INPUT 11 INPUT 10
INPUT 9 INPUT 8 INPUT 7 INPUT 6 INPUT 5 INPUT 4 INPUT 3 INPUT 2 INPUT 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
BUS 2 VC
BUS 2 VN
Not Used
MPU +
MPU −
BUS 2 VB
Not Used
BUS 2 VA
Not Used
BUS 1 VN
BUS 1 VC
Not Used
BUS 1 VB
Not Used
BUS 1 VA
Not Used
GEN VN
GEN VC
Not Used
GEN VB
Not Used
GEN VA 86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
COM 10, 11, 12
INPUT 15
RUN
START
PRE
DGC-2020HD
+
–
C
D
B
E
F
A
A
A
A
A
Tx
Rx
P1
P2
P3
P4
P5
P6
P7
P8P9
Eth 1
Eth 2
56
9469300990 Rev B 17

Terminals and Connectors

All DGC-2020HD terminals and connectors are located on the rear panel. DGC-2020HD terminals consist of a mini-B USB jack, a DB-9 connector, Ethernet ports, plug-in connectors with spring clamp terminals, and quarter-inch, male, quick-connect terminals.
Figure 4 illustrates the rear panel terminals. Locator letters in the illustration correspond to the terminal block and connector descriptions in Table 1.
DGC-2020HD Terminals and Connectors
Figure 4. Rear Panel
18 9469300990 Rev B
Locator
Description
A
The majority of external, DGC-2020HD wiring is terminated at 5-, 7-, or 15-position
wire size of 12 AWG (3.31 mm2).
B
This male DB-9 connector is provided for external dial-out modem communication and protocol availability.
C
DGC-2020HD Ethernet communication uses the Modbus™ TCP protocol to provide
D
The mini-B USB jack mates with a standard USB cable and is used with a PC running BESTCOMSPlus® software for local communication with the DGC-2020HD.
E
Connections to the Start, Run, and Pre output contacts are made directly to each relay through quarter-inch, male, quick-connect term ina ls.
F
An onboard battery maintains DGC-2020HD timekeeping during losses of operating to replace the battery with Basler Electric P/N 38526 may void the warranty.
Note
Table 1. Rear Panel Terminal and Connector Descriptions
connectors with spring clamp terminals. These connectors plug into headers on the DGC-2020HD. The connectors and headers have a dovetailed edge that ensures proper connector orientation. Each connector and header is uniquely keyed to ensure that a connector mates only with the correct header. Terminals accept a maximum
the future implementation of other communication protocols. Contact Basler Electric for
remote metering, annunciation, and control. Dual copper (100Base-T) ports (style xxxxDxxxx) use standard RJ-45 jacks while a fiber optic (100Base-F) port (style xxxxFxxxx) uses two BNC fiber optic connectors.
Ethernet ports have different designations depending on style: Dual copper (Style xxxxDxxxx) – The RJ-45 jack nearest to the mini-B USB port is
designated as Ethernet port 1 and is reserved for intergenset communications (load sharing). The other RJ-45 jack is designated as Ethernet port 2 and can be configured for redundant intergenset communications or for an independent network connection.
Fiber optic (Style xxxxFxxxx) – The fiber optic port is designated as Ethernet port 1 and is reserved for intergenset communications (load sharing).
Figure 4 shows both Ethernet port styles (dual copper and fiber) for clarity. The DGC­2020HD comes equipped with only one port style, not both.
power. See the Timekeeping chapter, for instructions on replacing the battery. Failure

Terminals

DGC-2020HD connections are dependent on the application. Incorrect wiring may result in damage to the controller.
Be sure that the DGC-2020HD is hard-wired to earth ground with no smaller than 12 AWG (3.31 mm ground (terminal 50) on the rear of the controller.
Operating power from the battery must be of the correct polarity. While reverse polarity will not cause damage, the DGC-2020HD will not operate.
2
) copper wire attached to chassis
The DGC-2020HD terminals are grouped by function and include operating power, current sensing, voltage sensing, engine sender input, magnetic pickup input, contact sensing, output contacts, CAN interface, RS-485 interface, AVR control, GOV control, Load Share, IRIG source, Remote Display Panel connection, USB port, Ethernet communication, and RS-232 communication.
DGC-2020HD terminals are described in the following paragraphs.
Terminals and Connectors DGC-2020HD
9469300990 Rev B 19
Terminal
Description
50 (CHASSIS)
Chassis ground connections
49 (BATT–)
Negative side of operating power input
48 (BATT+)
Positive side of operating power input
Terminals
Description
1 (IA+)
2 (IA–)
3 (IB+)
4 (IB–)
5 (IC+)
6 (IC–)
Terminal
Description
7 (AUX I1 +)
8 (AUX I1 –)
9 (AUX I2 +)
10 (AUX I2 –)
11 (AUX I3 +)
12 (AUX I3 –)
13 (AUX I4 +)
14 (AUX I4 –)

Operating Power

The DGC-2020HD operating power input accepts a nominal voltage of 12 Vdc or 24 Vdc and tolerates voltage over the range of 6 to 32 Vdc. Operating power must be of the correct polarity. While reverse polarity will not cause damage, the DGC-2020HD will not operate. Operating power terminals are listed in Table 2.
A fuse should be added for additional protection for the wiring to the battery input of the DGC-2020HD. A fuse helps prevent wire damage and nuisance trips due to initial power supply inrush current. To follow UL guidelines, a 5 A maximum, 32 Vdc supplementary fuse must be implemented in the battery input circuit to the DGC-2020HD.
Table 2. Operating Power Terminals

Generator Current Sensing

The DGC-2020HD has sensing inputs for A-phase, B-phase, and C-phase generator current. A DGC­2020HD with a style number of 1xxxxxxxxx has 1 Aac nominal current sensing and a DGC-2020HD with a style number of 5xxxxxxxx indicates 5 Aac nominal current sensing. Generator current sensing terminals are listed in Table 3.
Table 3. Generator Current Sensing Terminals
A-phase current sensing input
B-phase current sensing input
C-phase current sensing input

Programmable Current Sensing

Four user-programmable current sensing inputs are provided for measuring mains current, load bus current, ground current, or a combination of these. Table 4 lists the programmable current sensing terminals.
Table 4. Programmable Current Sensing Terminals
Programmable current sensing input 1
Programmable current sensing input 2
Programmable current sensing input 3
DGC-2020HD Terminals and Connectors
Programmable current sensing input 4
20 9469300990 Rev B
Caution
Note
Terminal
Description
86 (GEN VA)
A-phase generator voltage sensing input
88 (GEN VB)
B-phase generator voltage sensing input
90 (GEN VC)
C-phase generator voltage sensing input
91 (GEN VN)
Neutral generator voltage sensing input
Terminal
Description
93 (BUS1 VA)
A-phase bus voltage sensing input
95 (BUS1 VB)
B-phase bus voltage sensing input
97 (BUS1 VC)
C-phase bus voltage sensing input
98 (BUS1 VN)
Neutral bus voltage sensing input
100 (BUS2 VA)
A-phase bus voltage sensing input (optional)
101 (BUS2 VB)
B-phase bus voltage sensing input (optional)
103 (BUS2 VC)
C-phase bus voltage sensing input (optional)
104 (BUS2 VN)
Neutral bus voltage sensing input (optional)
Current sensing terminals 2 (IA–), 4 (IB–), 6 (IC–), 8(AUX I1–), 10 (AUX I2–), 12 (AUX I3–), and 14 (AUX I4–) mus t be te r mina ted to ground for proper operation.
Unused current sensing inputs should be shorted to minimize noise pickup.

Generator Voltage Sensing

The DGC-2020HD accepts either line-to-line or line-to-neutral generator sensing voltage over the range of 0 to 576 volts, rms line-to-line or 0 to 333 volts, rms line-to-neutral. Generator voltage sensing terminals are listed in Table 5.
Table 5. Generator Voltage Sensing Terminals

Bus Voltage Sensing

Sensing of bus voltage enables the DGC-2020HD to detect failures of the mains (utility). Controllers with style number xxx2xxxxx use bus voltage sensing to perform automatic synchronization of the generator with the bus. The DGC-2020HD accepts either line-to-line or line-to-neutral bus sensing voltage over the range of 0 to 576 volts, rms line-to-line or 0 to 333 volts, rms line-to-neutral. Controllers with style number xxxxxxxEx are equipped with two bus sensing inputs. One is intended for sensing the mains voltage while the other is intended for sensing the load bus voltage.
Bus voltage sensing terminals are listed in Table 6.
Table 6. Bus Voltage Sensing Terminals

Engine Sender Inputs

Inputs are provided for fuel level, oil pressure, and coolant temperature senders. For a listing of fuel level, oil pressure, and coolant temperature senders that are compatible with the DGC-2020HD, refer to the
Terminals and Connectors DGC-2020HD
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