Basler Electric DGC-2020HD User Manual

Name: Basler Electric DGC-2020HD
Brand: Basler Electric
SKU: 1503043
Rating: 4.6 (7 reviews)

4.6 (7)

INSTRUCTION MANUAL

FOR

DGC-2020HD

DIGITAL GENSET CONTROLLER

Publication: 9469300990

Revision: B Mar-14

9469300990 Rev B

Preface

This instruction manual provides information about the installation and operation of the DGC-2020HD Digital Genset Controller. To accomplish this, the following information is provided:

•Controls and indicators

•Inputs and outputs

•Protection and control functions

•Reporting and alarms information

•Mounting and connection diagrams

•BESTCOMSPlus® software

•Communication and security

•Maintenance and troubleshooting procedures

•Specifications

•AEM-2020

•CEM-2020

•MTU Fault Codes

•Exhaust Treatment

•Diagnostic Trouble Codes

Conventions Used in this Manual

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

Caution boxes call attention to operating conditions that may lead to equipment or property damage.

Note

Note boxes emphasize important information pertaining to Digital

Genset Controller installation or operation.

Digital Genset Controller

Preface

ii	9469300990 Rev B

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

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.

Basler Electric does not assume any responsibility to compliance or noncompliance with national code, local code, or any other applicable code. This manual serves as reference material that must be well understood prior to installation, operation, or maintenance.

This product contains, in part, open source software (software licensed in a way that ensures freedom to run, copy, distribute, study, change, and improve the software) and you are granted a license to that software under the terms of either the GNU General Public License or GNU Lesser General Public License. The licenses, at the time of sale of the product, allow you to freely copy, modify, and redistribute that software and no other statement or documentation from us, including our End User License Agreement, places any additional restrictions on what you 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 corresponding source code for the version of the programs distributed to you will be sent upon request (contact information is provided above). A fee of no more than our cost of physically performing the source code distribution is charged.

The source code is distributed in the hope that it will be useful, but WITHOUT ANY REPRESENTATION or 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. 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 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 manual.

The English-language version of this manual serves as the only approved manual version.

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 Examples ...................................................................................................................	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 Specifications.............................................................................................................	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

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-of- change 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 timeand 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 singleor 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

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

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.

MODEL NUMBER		STYLE NUMBER
DGC – 2020HD	N	N

Current Sensing

Auto Synchronizer

Terminal Type

Senders

5) 5A CT inputs

1) No Auto Sync

S) Spring

A) Analog

1) 1A CT inputs

2) w/ Auto Sync

R) Resistive

Generator Protection

S)Standard: 27, 32, 40Q, 59, 81O, 81U

E)Enhanced: 27, 32, 40Q, 47, 51, 59, 78, 81O, 81U, 81 ROCOF

Ethernet	Bus Inputs

D) Dual 100BaseT (Copper)	B) Basic Sensing:
F) 100BaseF (Fiber)	1 Bus Input, 4 CTs
	E) Enhanced Sensing:
	E) Enhanced Sensing:
	2 Bus Inputs, 7 CTs	P0071-69
		P0071-69

1 The fuel level sender is always resistive and is not a programmable input.

Figure 1. DGC-2020HD Style 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 CEM2020 chapter for more information.

Introduction

DGC-2020HD

9469300990 Rev B

Specifications

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

Operating Power

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

Power Consumption

Sleep Mode ......................................	12.7 W - LCD heater off, all relays de-energized, and analog outputs
	disabled
Normal Operational Mode ................	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, line-to-line).

Measurement/Calculation Methods
Total .................................................	kVA = (VL-L × IL ×√3) ÷ 1000
4-Wire, Line-to-Neutral.....................	kVA calculated with respect to neutral
3-Wire, Line-to-Line..........................	A-phase kVA = VAB × IA ÷ 1000 ÷ √3
	B-phase kVA = VBC	× IB ÷ 1000 ÷ √3
Accuracy	C-phase kVA = VCA	× IC ÷ 1000 ÷ √3
	±2% of the full-scale indication or ±2 kVA *†

* kVA metering indicates 0 kVA when the generator kVA is below 2% of the full-scale rating.

†Applies when temperature is between −40°C to +70°C (–40°F to +158°F).

Specifications

DGC-2020HD

9469300990 Rev B	9
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).

Note

For the DGC-2020HD to correctly meter power factor, the generator must be rotating in the same phase sequence as dictated by the generator phase rotation setting.

Real Power

Indicates total kW and individual line kW (4-wire, line-to-neutral or 3-wire line-to-line)

Measurement/Calculation Methods
Total .................................................	PF × Total kVA
4-Wire, Line-to-Neutral.....................	kW calculated with respect to neutral
3-Wire, Line-to-Line..........................	A-phase kW = VAB × IA × PF ÷ 1000 ÷ √3
	B-phase kW = VBC × IB × PF ÷ 1000 ÷ √3
Accuracy	C-phase kW = VCA × IC × PF ÷ 1000 ÷ √3
Accuracy	±2% of the full-scale indication or ±2 kW *†

* 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 Functions

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 screen in BESTCOMSPlus®.

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
Time Dial Increment .........................	0.1
Inverse Time Curves ........................	See the Time Overcurrent Characteristic Curves chapter

Caution

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)

Notes

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 DGC2020HD 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 designed to comply with IEC 61000-4 series of specifications 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 Vdc
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

Note

Failure to replace the battery with Basler Electric P/N 38526 may void the warranty.

Caution

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
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.)

Caution

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

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 moistureand 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 shown in inches with millimeters in parenthesis.

0.25			(136.5)
			(136.5)
		5.19

(6.4)
(6.4)	(131.8)
	(131.8)

6.88 (174.8)

7.25 (184.2)

3.44 (87.4)

3.625 (92.1)

P0071-79

10.38

(263.7)

10.75

(273.1)

Figure 2. Panel Cutting and Drilling Dimensions

DGC-2020HD

Mounting

16	9469300990 Rev B

Figure 3. Overall Dimensions

Mounting

DGC-2020HD

9469300990 Rev B

Terminals and Connectors

All DGC-2020HD terminals and connectors are located on the rear panel. DGC-2020HD terminals consist of a mini-B USB jack, a DB-9 connector, Ethernet ports, plug-in connectors with spring clamp terminals, and quarter-inch, male, quick-connect terminals.

Figure 4 illustrates the rear panel terminals. Locator letters in the illustration correspond to the terminal block and connector descriptions in Table 1.


	INPUT 15	45
	INPUT 14	44
	INPUT 13	43
	INPUT 12	42
	INPUT 11	41
	INPUT 10	40
P3	INPUT 9	39
P3	INPUT 8	38
	INPUT 7	37
	INPUT 6	36
	INPUT 5	35
	INPUT 4	34
	INPUT 3	33
	INPUT 2	32
	INPUT 1	31

	COM 10, 11, 12	30
	OUT 12	29
	OUT 11	28
	OUT 10	27
	COM 7, 8, 9	26
	OUT 9	25
P2	OUT 8	24	A
P2	OUT 7	23	A
	COM 4, 5, 6	22
	OUT 6	21
	OUT 5	20
	OUT 4	19
	COM 1, 2, 3	18
	OUT 3	17
	OUT 3	17
	OUT 2	16

	OUT 1	15
	AUX I4−	14
	AUX I4+	13
	AUX I3−	12
	AUX I3+	11
	AUX I2−	10
	AUX I2−	10
P1	AUX I2+	9
P1	AUX I1−	8
	AUX I1+	7
	GEN IC−	6
	GEN IC+	5
	GEN IB−	4
	GEN IB+	3
	GEN IA−	2
	GEN IA+	1

CHASSIS GND

BATT −

BATT +

Not Used

INPUT 16

46 47 48 49 50

A B

Eth 2

Eth 1

CAN 1 LOW

CAN 1 HIGH

SHIELD P5

CAN 2 LOW

CAN 2 HIGH

		D						56	RS-485A
		D						57	RS-485B
								57	RS-485B
								58	RS-485 SHIELD


								59
								59	IRIG-B+
								60	IRIG-B−

								61	RDP-110 TxD+
								62	RDP-110 TxD−	P6
								63	CHASSIS GND	P6
DGC-2020HD								64	AVR +
DGC-2020HD								65	AVR −
								66
								66	GOV +
								67	GOV −
								68	GOV PWM
								69	LOAD SHARE+
			A					70	LOAD SHARE−
			A
				71					FUEL +
					72				FUEL −
	E	PRE				73			Not Used
		PRE					74		OIL +
							74		OIL +
								75	OIL −

							76		OIL I
	START	RUN				77			COOLANT+	P7
	START	RUN			78				COOLANT−
					78				COOLANT−
				79					COOLANT I
				80					ALOG IN 2 +

81 ALOG IN 2 −

											F	+		–		82		ALOG IN 2 I
											F	+		–		83		ALOG IN 1 +
																83		ALOG IN 1 +
										A						84		ALOG IN 1 −
										A						85		ALOG IN 1 I
107	106	105	104	103	102	101	100	99	98	97	96	95	94	93	92	91	90	89	88	87	86
MPU − MPU +		Not Used	BUS 2 VN	BUS 2 VC	Not Used	BUS 2 VB	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
			P9											P8							P0071-12

Figure 4. Rear Panel

DGC-2020HD

Terminals and Connectors

18		9469300990 Rev B
		Table 1. Rear Panel Terminal and Connector Descriptions
	Locator	Description
	A	The majority of external, DGC-2020HD wiring is terminated at 5-, 7-, or 15-position
		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
		wire size of 12 AWG (3.31 mm2).
	B	This male DB-9 connector is provided for external dial-out modem communication and
		the future implementation of other communication protocols. Contact Basler Electric for
		protocol availability.
	C	DGC-2020HD Ethernet communication uses the Modbus™ TCP protocol to provide
		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 DGC-
		2020HD comes equipped with only one port style, not both.

	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 terminals.
	F	An onboard battery maintains DGC-2020HD timekeeping during losses of operating
		power. See the Timekeeping chapter, for instructions on replacing the battery. Failure
		to replace the battery with Basler Electric P/N 38526 may void the warranty.

Terminals

DGC-2020HD connections are dependent on the application. Incorrect wiring may result in damage to the controller.

Note

Be sure that the DGC-2020HD is hard-wired to earth ground with no smaller than 12 AWG (3.31 mm2) copper wire attached to chassis 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.

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

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

Terminal	Description
50 (CHASSIS)	Chassis ground connections
49 (BATT–)	Negative side of operating power input
48 (BATT+)	Positive side of operating power input

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

	Terminals	Description
	1 (IA+)	A-phase current sensing input
	2 (IA–)	A-phase current sensing input
	2 (IA–)
	3 (IB+)	B-phase current sensing input
	4 (IB–)	B-phase current sensing input
	4 (IB–)
	5 (IC+)	C-phase current sensing input
	6 (IC–)	C-phase current sensing input
	6 (IC–)

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

	Terminal	Description
	7 (AUX I1 +)	Programmable current sensing input 1
	8 (AUX I1 –)	Programmable current sensing input 1
	8 (AUX I1 –)
	9 (AUX I2 +)	Programmable current sensing input 2
	10 (AUX I2 –)	Programmable current sensing input 2
	10 (AUX I2 –)
	11 (AUX I3 +)	Programmable current sensing input 3
	12 (AUX I3 –)	Programmable current sensing input 3
	12 (AUX I3 –)
	13 (AUX I4 +)	Programmable current sensing input 4
	14 (AUX I4 –)	Programmable current sensing input 4
	14 (AUX I4 –)

DGC-2020HD

Terminals and Connectors

20	9469300990 Rev B

Caution

Current sensing terminals 2 (IA–), 4 (IB–), 6 (IC–), 8(AUX I1–), 10 (AUX I2–), 12 (AUX I3–), and 14 (AUX I4–) must be terminated to ground for proper operation.

Note

Unused current sensing inputs should be shorted to minimize noise pickup.

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

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

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
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)

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

+ 374 hidden pages

Basler Electric DGC-2020HD User Manual

Preface

Contents

Introduction

Features and Functions

Generator and Bus Protection and Metering

Engine Protection and Metering

Load Sharing

Event Recording

Data Logging

Contact Inputs and Outputs

Automatic Transfer Switch Control (Mains Failure)

Device Security

Communication

Style Number

Optional Features and Capabilities

AEM-2020 (Analog Expansion Module)

CEM-2020 (Contact Expansion Module)

Specifications

Operating Power

Power Consumption

Battery Ride Through

Current Sensing

Generator CTs

Available Programmable CTs

1 Aac Current Sensing

5 Aac Current Sensing

Voltage Sensing

Generator Sensing

Bus 1 Sensing

Bus 2 Sensing (Optional with style number xxxxxxxEx)

Analog Sensing

Current Sensing

Voltage Sensing

Contact Sensing

Contact Input Recognition Time

Contact Output Closure Time

Terminals

Engine System Inputs

Fuel Level Sensing

Coolant Temperature Sensing

Oil Pressure Sensing

Engine Speed Sensing

Output Contacts

PRE (Prestart), START, and RUN Relays

Programmable Relays (12)

Metering

Generator and Bus Voltage (rms)

Generator Current (rms)

Generator and Bus Frequency

Apparent Power

Power Factor

Real Power

Oil Pressure

Coolant Temperature

Fuel Level

Battery Voltage

Engine RPM

Maintenance Timer

Generator Protection Functions

Overvoltage (59) and Undervoltage (27)

Underfrequency (81U) and Overfrequency (81O)

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

Reverse and Forward Power (32)

Loss of Excitation (40Q)

Overcurrent (51) (Optional)

Phase Voltage Imbalance (47) (Optional)

Vector Shift (78) (Optional)

Logic Timers

Communication Interface

Ethernet

External Dial-Out Modem (RS-232)

IRIG-B Time Synchronization

Modbus™ (RS-485)

Real-Time Clock

Clock Holdup

LCD Heater

Type Tests

Shock

Vibration