Winco DGC-2020 User Manual
INSTRUCTION MANUAL
FOR
DIGITAL GENSET CONTROLLER
DGC-2020
****
Publication: 9400200990
Revision: B 11/06
INTRODUCTION
This instruction manual provides information about the operation and installation of the DGC-2020 Digital
Genset Controller. To accomplish this, the following information is provided:
• General Information and Specifications
• Controls and Indicators
• Functional Description
• Graphical User Interface Operation
• Installation
• Maintenance and Troubleshooting
• Appendices containing Time Overcurrent Characteristic Curves and Modbu s™ Communication
WARNING!
To avoid personal injury or equipment damage, only qualified personnel should
perform the procedures in this manual.
NOTE
Be sure that the controller is hard-wired to earth ground with no smaller than 12
AWG copper wire attached to the chassis ground terminal on the rear of the unit.
When the controller is configured in a system with other devices, it is
recommended to use a separate lead to the ground bus from each unit.
9400200990 Rev B DGC-2020 Introduction i
First Printing: September 2006
Printed in USA
© 2006 Basler Electric, Highland Illinois 62249 USA
All Rights Reserved
November 2006
CONFIDENTIAL INFORMATION
of Basler Electric, Highland Illinois, USA. It is loaned for confidential use, subject
to return on request, and with the mutual understanding that it will not be used in
any manner detrimental to the interest of Basler Electric.
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. Should further information be
required, contact Basler Electric.
BASLER ELECTRIC
ROUTE 143, BOX 269
HIGHLAND IL 62249 USA
http://www.basler.com, info@basler.com
PHONE +1 618.654.2341 FAX +1 618.654.2351
ii DGC-2020 Introduction 9400200990 Rev B
PRODUCT REVISION HISTORY
The following information provides a historical summary of the changes made to the embedded software
(firmware), PC software (BESTCOMSPlus), and hardware of the DGC-2020. The corresponding revisions
made to this instruction manual (9400200990) are also summarized. Revisions are listed in chronological
order.
Firmware Version Change
1.00.04, 11/06
BESTCOMSPlus Version Change
1.00.07, 11/06
Hardware Version Change
—, 10/06
Manual Revision Change
B, 11/06
• Initial release
• Initial release
• Initial release
• Initial release
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iv DGC-2020 Introduction 9400200990 Rev B
CONTENTS
SECTION 1 • GENERAL INFORMATION ................................................................................................ 1-1
SECTION 2 • HUMAN-MACHINE INTERFACE....................................................................................... 2-1
SECTION 3 • FUNCTIONAL DESCRIPTION...........................................................................................3-1
SECTION 4 • BESTCOMSPlus SOFTWARE...........................................................................................4-1
SECTION 5 • BESTlogic+ PROGRAMMABLE LOGIC............................................................................. 5-1
SECTION 6 • INSTALLATION .................................................................................................................. 6-1
SECTION 7 • MAINTENANCE AND TROUBLESHOOTING.................................................................... 7-1
APPENDIX A • TIME OVERCURRENT CHARACTERISTIC CURVES...................................................A-1
APPENDIX B • MODBUS™ COMMUNICATION......................................................................................B-1
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vi DGC-2020 Introduction 9400200990 Rev B
SECTION 1 • GENERAL INFORMATION
TABLE OF CONTENTS
SECTION 1 • GENERAL INFORMATION ................................................................................................ 1-1
DESCRIPTION....................................................................................................................................... 1-1
FEATURES............................................................................................................................................ 1-1
FUNCTIONS .......................................................................................................................................... 1-1
Generator Protection and Metering.................................................................................................... 1-1
Engine Protection and Metering......................................................................................................... 1-1
Event Recording................................................................................................................................. 1-1
Auto-Synchronizer.............................................................................................................................. 1-1
Contact Inputs and Output Contacts .................................................................................................. 1-1
Automatic Transfer Switch Control (Mains Failure)............................................................................ 1-2
Communication................................................................................................................................... 1-2
STYLE NUMBER ................................................................................................................................... 1-2
SPECIFICATIONS ................................................................................................................................. 1-3
Operating Power ................................................................................................................................ 1-3
Power Consumption ........................................................................................................................... 1-3
Battery Ride Through ......................................................................................................................... 1-3
Current Sensing ................................................................................................................................. 1-3
Voltage Sensing ................................................................................................................................. 1-4
Contact Sensing ................................................................................................................................. 1-4
Engine System Inputs ........................................................................................................................ 1-4
Output Contacts ................................................................................................................................. 1-5
Metering.............................................................................................................................................. 1-5
Generator Protection Functions ......................................................................................................... 1-7
Logic Timers....................................................................................................................................... 1-7
Communication Interface ................................................................................................................... 1-8
Real-Time Clock................................................................................................................................. 1-8
Type Tests.......................................................................................................................................... 1-9
Environment ....................................................................................................................................... 1-9
Agency Approvals .............................................................................................................................. 1-9
CE Compliance ................................................................................................................................ 1-10
Physical ............................................................................................................................................ 1-10
Figures
Figure 1-1. DGC-2020 Style Chart ............................................................................................................ 1-3
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ii DGC-2020 General Information 9400200990 Rev B
SECTION 1 • GENERAL INFORMATION
DESCRIPTION
The DGC-2020 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 DGC-2020
operation. Basler Electric communication software (BESTCOMSPlus) allows units to be easily customized
for each application. Because of the low sensing burden in the DGC-2020, dedicated potential
transformers (PTs) are not required. A wide temperature-range liquid crystal display (LCD) with
backlighting can be viewed under a wide range of ambient light and temperature conditions.
FEATURES
DGC-2020 Digital Genset Controllers have the following features:
• Local and Remote Generator Control
• Engine and Generator Protection
• Programmable Analog Engine Senders
• ECU Communications via SAE J1939
• 16 Programmable Contact Inputs
• Programmable Logic
• Automatic Transfer Switch Control (Mains Failure)
• Integrated RS485
• Auto Synchronizing
FUNCTIONS
DGC-2020 Digital Genset Controllers perform the following functions:
Generator Protection and Metering
Multifunction generator protection guards against generator overvoltage, undervoltage, underfrequency,
and overfrequency. Overcurrent and phase imbalance protection is available as an option. Each
generator protection function has an adjustable pickup and time delay setting. Sixteen inverse time
curves enable the DGC-2020 to offer overcurrent protection in a variety of applications.
Metered generator 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.
Event Recording
An event log retains a history of system events in nonvolatile memory. Up to 30 event types are retained
and each record contains a time stamp of the first and last occurrence, and the number of occurrences for
each event.
Auto-Synchronizer
An optional automatic synchronizer monitors the bus and generator voltages and supplies discrete
raise/lower correction signals to synchronize the generator voltage, frequency, and slip angle with that of
the bus.
Contact Inputs and Output Contacts
DGC-2020 controllers have one, dedicated emergency stop contact input and 16 programmable contact
inputs. All contact inputs recognize dry contacts. The programmable inputs can be configured to initiate a
9400200990 Rev B DGC-2020 General Information 1-1
pre-alarm or alarm. A programmable input can be programmed to receive an input from an automatic
transfer switch or override DGC-2020 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 four user-programmable output contacts are provided if the style number is
xxAxxxxxx. If the style number is xxBxxxxxx, an additional twelve output contacts are provided.
Additional contact inputs and output contacts can be accommodated with separate I/O modules. Contact
Basler Electric for availability and ordering information.
Automatic Transfer Switch Control (Mains Failure)
The DGC-2020 has the ability to detect a mains failure via a single-phase Bus input. A mains failure is
established when any one of the following conditions are met:
• Bus voltage falls below dead bus threshold
• Bus voltage unstable due to overvoltage or undervoltage
• Bus voltage unstable due to overfrequency or underfrequency
At this time, the DGC-2020 will start the genset and when ready, apply power to the load via the genset.
When the mains returns and is considered stable, the DGC-2020 will transfer the load back to the mains.
Communication
Standard DGC-2020 communication features include a standard USB port and SAE J1939 interface.
Optional communication features include a dial-out modem and RS-485 communication port.
USB Port
A USB communication port can be used with BESTCOMSPlus software to quickly configure a DGC-2020
with the desired settings or retrieve metering values and event log records.
CANBus Interface
A CANBus interface provides high-speed communication between the DGC-2020 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 CANBus 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 or related failures.
The engine DTCs are displayed on the front panel of the DGC-2020 and may be obtained using
BESTCOMSPlus software.
MTU/MDEC Protocol - A DGC-2020 connected to a genset equipped with an MTU MDEC receives
•
Oil pressure, coolant temperature, and engine speed data from the engine controller, along with
various alarms and pre-alarms that are MDEC specific. In addition, the DGC-2020 tracks and displays
the active fault codes issued by the MDEC ECU.
Dial-Out Modem
One of two optional, dial-out modems (a US version or international version) enables remote control,
monitoring, and setting of the DGC-2020. When an alarm or pre-alarm condition occurs, the DGC-2020
can dial up to four telephone numbers, in sequence, until an answer is received and the condition is
annunciated.
RS-485 Port
An optional RS-485 communication port uses the Modbus communication protocol and enables remote
control and monitoring of the DGC-2020 over a polled network.
STYLE NUMBER
Standard-order DGC-2020 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, describe the options included in a specific controller.
Figure 1-1 illustrates the DGC-2020 style number identification chart.
1-2 DGC-2020 General Information 9400200990 Rev B
Figure 1-1. DGC-2020 Style Chart
For example, if a DGC-2020 style number is 51BNBMEAH, the controller would have the following
characteristics and operating features.
5 5 Aac current sensing inputs
1 50/60 hertz nominal generator frequency
B 3 fixed-function output contacts and 12 programmable output contacts
N No RS-485 communication port
B Battery backup for real-time clock during losses of control power
M Internal dial-out modem—US version
E Enhanced generator protection (undervoltage, phase imbalance, overcurrent, overvoltage,
overfrequency, and underfrequency)
A Auto-synchronizer
H LCD heater
SPECIFICATIONS
Operating Power
Nominal: 12 or 24 Vdc
Range: 6 to 32 Vdc (Withstands cranking ride-through down to 6 Vdc
for 500 ms.)
Terminals: 3 (+), 2 (–), 1 (chassis ground)
Power Consumption
Sleep Mode: 5W with all relays non-energized
Normal Operational Mode: 7.9W - Run mode, LCD heater off, 3 relays energized
Maximum Operational Mode: 14.2W - Run mode, LCD heater on, 6 relays energized
Battery Ride Through
Withstands cranking ride-through down to 0 V for 50 ms.
Current Sensing
Burden: 1 VA
Terminals: 68, 69 (A-phase)
71, 72 (B-phase)
74, 75 (C-phase)
1 Aac Current Sensing
Continuous Rating: 0.02 to 1.0 Aac
9400200990 Rev B DGC-2020 General Information 1-3
1 Second Rating: 2 Aac
5 Aac Current Sensing
Continuous Rating: 0.1 to 5.0 Aac
1 Second Rating: 10 Aac
Voltage Sensing
Configuration: Line-to-line or line-to-neutral
Range: 12 to 576 V rms, line-to-line
Frequency: Style selectable, 50/60 Hz or 400 Hz
Frequency Range: 10 to 72 Hz for 50/60 style and 10 to 480 Hz for 400 Hz style
Burden: 1 VA
1 Second Rating: 720 V rms
Generator Sensing Terminals: 41 (A-phase)
39 (B-phase)
37 (C-phase)
35 (Neutral)
Bus Sensing Terminals: 45 (A-phase)
43 (B-phase)
Contact Sensing
Contact sensing inputs include 1 emergency stop input and 16 programmable inputs. The emergency
stop input accepts normally closed, dry contacts. All programmable inputs accept normally open, dry
contacts.
Terminals
Emergency Stop: 46, 47
Programmable
Input 1: 30, 2
Input 2: 29, 2
Input 3: 28, 2
Input 4: 27, 2
Input 5: 26, 2
Input 6: 25, 2
Input 7: 24, 2
Input 8: 23, 2
Input 9: 22, 2
Input 10: 21, 2
Input 11: 20, 2
Input 12: 19, 2
Input 13: 18, 2
Input 14: 17, 2
Input 15: 16, 2
Input 16: 15, 2
Engine System Inputs
∗ Stated accuracies are subject to the accuracy of the senders used.
Fuel Level Sensing
Resistance Range: 33 to 240 Ω nominal
Terminals: 9, 11 (sender common)
Coolant Temperature Sensing
Resistance Range: 62.6 to 637.5 Ω nominal
Terminals: 10, 11 (sender common)
Oil Pressure Sensing
Resistance Range: 34 to 240 Ω nominal
Terminals: 8, 11 (sender common)
1-4 DGC-2020 General Information 9400200990 Rev B
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: 31 (+), 32 (–)
Generator Voltage
Range: 12 to 576 V rms
Terminals: 41 (A-phase)
39 (B-phase)
37 (C-phase)
Output Contacts
Fuel Solenoid, Engine Crank, and Pre-Start Relays
Rating: 30 Adc at 28 Vdc—make, break, and carry ∗
Terminals
Fuel Solenoid: RUN – NO, COM
Pre-Start: PRE – NO, COM
Crank: START – NO, COM
Programmable Relays (12)
Rating: 2 Adc at 30 Vdc—make, break, and carry
Terminals†
Output 1: 52, 51 (common)
Output 2: 53, 51 (common)
Output 3: 54, 51 (common)
Output 4: 56, 55 (common)
Output 5: 57, 55 (common)
Output 6: 58, 55 (common)
Output 7: 60, 59 (common)
Output 8: 61, 59 (common)
Output 9: 62, 59 (common)
Output 10: 64, 63 (common)
Output 11: 65, 63 (common)
Output 12: 66, 63 (common)
∗ Contact rating is reduced for units used in hazardous locations.
† The number of programmable output contacts provided is determined by the output contacts
character of the DGC-2020 style number. Controllers with output contacts option A have 4 program-
mable outputs (Outputs 1, 2, 3, and 4). Controllers with output contacts option B have 12
programmable outputs.
The programmable relays share common terminals: terminal 51 is used for outputs 1, 2, and 3,
terminal 55 is used for outputs 4, 5, and 6, terminal 59 is used for outputs 7, 8, and 9, 63 is used for
outputs 10, 11, and 12.
Metering
Generator 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
9400200990 Rev B DGC-2020 General Information 1-5
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 Frequency
Generator frequency is sensed through the generator voltage input.
Metering Range: 10 to 72 Hz (50/60 Hz)
10 to 480 (400 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 = (V
× IL ×√3) ÷ 1000
L-L
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
× IA ÷ 1000 ÷ √3
AB
× IB ÷ 1000 ÷ √3
BC
× IC ÷ 1000 ÷ √3
CA
Accuracy: ±3% or 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.
Power Factor
Metering Range: 0.2 leading to 0.2 lagging
Calculation Method: PF = P (3-phase average) ÷ S (3-phase average)
Accuracy: ±0.02 ∗
∗ Applies when temperature is between -40°C to +70°C.
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 = V
B-phase kVA = V
C-phase kVA = V
× IA × PF ÷ 1000 ÷ √3
AB
× IB × PF ÷ 1000 ÷ √3
BC
× IC × PF ÷ 1000 ÷ √3
CA
Accuracy: ±3% 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.
Oil Pressure
Metering Range: 0 to 145 psi or 0 to 1,000 kPa
Accuracy: ±3% of actual indication or ±2 psi or ±12 kPa (subject to accuracy of
sender)
Display Resolution: 1 psi or 1 kPa
Coolant Temperature
Metering Range: –40 to 410°F or –40 to 210°C
Accuracy: ±3% or actual indication or ±2° (subject to accuracy of sender)
Battery Voltage
Metering Range: 6 to 32 Vdc
Accuracy: ±3% of actual indication or ±0.2 Vdc
Display Resolution: 0.1 Vdc
1-6 DGC-2020 General Information 9400200990 Rev B
Engine RPM
Metering Range: 0 to 4,500 rpm
Accuracy: ∗ ±2% of actual indication or ±2 rpm
Display Resolution: 2 rpm
∗ When engine speed is below 2% of full-scale, reported rpm is 0.
Engine Run Time
Engine run time is retained in nonvolatile memory.
Metering Range: 0 to 99,999 h
Update Interval: 6 min
Accuracy: ±1% of actual indication or ±12 min
Display Resolution: 1/10 hour
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 h
Update Interval: 6 min
Accuracy: ±1% or actual indication or ±12 min
Display Resolution: 1/10 hour
Fuel Level
Metering Range: 0 to 100%
Accuracy: ±2% (subject to accuracy of sender)
Display Resolution: 1.0%
Generator Protection Functions
Overvoltage (59) and Undervoltage (27)
Pickup Range: 70 to 576 Vac
Pickup Increment: 1 Vac
Inhibit Frequency Range: 20 to 400 Hz (27 function only)
Activation Delay Range: 0 to 30 s
Activation Delay Increment: 0.1 s
Underfrequency (81U) and Overfrequency (81O)
Pickup Range: 45 to 66 Hz (50/60 Hz nominal)
360 to 440 Hz (400 Hz nominal)
Pickup Increment: 0.1 Hz (50/60 Hz nominal)
0.1 Hz (400 Hz nominal)
Activation Delay Range: 0 to 30 s
Activation Delay Increment: 0.1 s
Inhibit Voltage Range: 70 to 576 Vac (81U function only)
Overcurrent (51) (Optional)
Pickup Range: 0.18 to 1.18 Aac (1 A current sensing)
0.9 to 7.75 Aac (5 A current sensing)
Time Dial Range: 0 to 30 s (fixed time curve)
0 to 9.9 (inverse curve time multiplier)
Time Dial Increment: 0.1
Inverse Time Curves: See Appendix A, Time Overcurrent Characteristic Curves
Phase Imbalance (47) (Optional)
Pickup Range: 5 to 100 Vac
Pickup Increment: 1 Vac
Activation Delay Range: 0 to 30 s
Activation Delay Increment: 0.1 s
Logic Timers
Range: 0 to 10 s
9400200990 Rev B DGC-2020 General Information 1-7
Increment: 0.1 s
Accuracy: ±15 ms
Communication Interface
USB
Specification Compatibility: USB 2.0
Data Transfer Speed: 9600 baud
Connector Type: Mini-B jack
RS-485 (Optional)
Baud: 9600
Data Bits: 8
Parity: None
Stop Bits: 1
Terminals: 14 (A), 13 (B), and 12 (shield)
CANBus
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
Terminals: 48 (low), 49 (high), and 50 (shield)
Modem (Optional)
Connector Type: RJ-11 jack
Real-Time Clock
Clock has leap year and selectable daylight saving time correction. Backup capacitor and optional backup
battery sustain timekeeping during losses of DGC-2020 operating power.
Resolution: 1 s
Accuracy: ±1.73 s/d at 25°C
Clock Holdup
Battery Holdup Time (Optional): Approximately 10 yrs
Battery Type: Rayovac BR2032, lithium, coin-type, 3 Vdc, 190 mAh
Basler Electric P/N 38526
CAUTION
Replacement of the backup battery for the real-time clock should be performed
only by qualified personnel.
CAUTION
It is recommended that the battery be removed if the DGC-2020 is to be operated
in a salt-fog environment. Salt-fog is known to be conductive and may short-
circuit the battery.
NOTE
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 real-time clock.
1-8 DGC-2020 General Information 9400200990 Rev B
Type Tests
Shock and Vibration: EN60068-2-6
Dielectric Strength: IEC 255-5
Impulse: EN60664-1
Transients: EN61000-4-4
Static Discharge: EN61000-4-2
Shock
15 G in 3 perpendicular planes
Vibration
Swept over the following ranges for 12 sweeps in each of three mutually perpendicular planes with each
15-minute sweep consisting of the following:
5 to 29 to 5 Hz: 1.5 G peak for 5 min.
29 to 52 to 29 Hz: 0.036” DECS-A for 2.5 min.
52 to 500 to 52 Hz: 5 G peak for 7.5 min.
Radio Interference
Type tested using a 5 W, hand-held transceiver operating at random frequencies centered around 144
and 440 MHz with the antenna located within 150 mm (6”) of the device in both vertical and horizontal
planes.
HALT (Highly Accelerated Life Testing)
Halt Testing is a method used by many high quality manufacturers to prove that their products will provide
the user with many years of reliable service. Halt testing is a method to subject the device to extremes in
temperature, shock, and vibration to simulate years of operation, but in a much shorter period span. Halt
testing allows Basler to evaluate all possible design elements that will add to the increase in the life of this
device. As an example of some of the extreme testing conditions, the DGC-2020 was subjected
to Temperature Tests (Tested over a temperature range of -100°C to +115°C),
Vibration Tests (Swept
over a frequency of 5 to 50 G at +20°C), and Temperature/Vibration Tests (Tested at 40 G over a
temperature range of -80°C to +90°C). Combined temperature and vibration testing at these extremes
proves that the DGC-2020 design is the most rugged device of its type. Please note that the vibration and
temperature extremes noted in this paragraph are specific to HALT testing and do not reflect
recommended operation level. These operational ratings are included in Section 1 of this manual.
Ignition System
Tested in closed proximity to an unshielded, unsuppressed Altronic DISN 800 Ignition System.
Environment
Temperature
Operating: –40 to 70°C (–40 to 158°F)∗
Storage: –40 to 85°C (–40 to 185°F)
Humidity: IEC 68-2-38
Salt Fog: ASTM B 17-73, IEC 68-2-11
Ingress Protection: IEC IP54 for front panel
∗ Display operation is maintained at -40°C when used with an optional LCD heater. Refer to Figure 1-1,
DGC-2020 Style Chart for ordering information. Display operation is maintained at -20°C when the
optional LCD heater is not used.
Agency Approvals
UL/CSA Approvals
“cURus” approved to UL 508 R and CSA C22.2 No.14
CAUTION
To follow UL/CSA guidelines, replacement of the backup battery for the real-time
clock should be performed only by qualified personnel.
9400200990 Rev B DGC-2020 General Information 1-9
NFPA Compliance Complies with NFPA Standard 110, Standard for Emergency and Standby Power.
CE Compliance
This product complies with the requirements of the following EC Directives:
• Low Voltage Directive (LVD) - 73/23/EEC as amended by 93/68/EEC
• Electromagnetic Compatibility (EMC) - 89/336/EEC as amended by 92/31/EEC and 93/68/EEC
This product conforms to the following Harmonized Standards:
• EN 50178:1997 - Electronic Equipment for use in Power Installations
• EN 61000-6-4:2001 - Electromagnetic Compatibility (EMC), Generic Standards, Emission Standard
for Industrial Environments
• EN 61000-6-2:2001 - Electromagnetic Compatibility (EMC), Generic Standards, Immunity for
Industrial Environments
Physical
Weight: 2 kg (4.4 lb)
Dimensions: See Section 6, Installation.
1-10 DGC-2020 General Information 9400200990 Rev B
SECTION 2 • HUMAN-MACHINE INTERFACE
TABLE OF CONTENTS
SECTION 2 • HUMAN-MACHINE INTERFACE.......................................................................................2-1
INTRODUCTION....................................................................................................................................2-1
FRONT PANEL......................................................................................................................................2-1
DISPLAY OPERATION.......................................................................................................................... 2-2
Login and Permissions....................................................................................................................... 2-2
Summary Screen and Configurable Metering....................................................................................2-3
Sleep Mode ........................................................................................................................................ 2-4
Changing a Setting.............................................................................................................................2-4
Front Panel Display Structure ............................................................................................................ 2-4
REAR PANEL ...................................................................................................................................... 2-11
Figures
Figure 2-1. Front Panel HMI......................................................................................................................2-1
Figure 2-2. Metering Screen Branches ..................................................................................................... 2-5
Figure 2-3. Settings Screen Branches ...................................................................................................... 2-6
Figure 2-4. General Settings Screen Branches......................................................................................... 2-6
Figure 2-5. Communications Screen Branches......................................................................................... 2-7
Figure 2-6. System Params Screen Branches.......................................................................................... 2-7
Figure 2-7. Alarm Configuration Screen Branches....................................................................................2-8
Figure 2-8. Generator Protection Screen Branches..................................................................................2-9
Figure 2-9. Breaker Management Screen Branches............................................................................... 2-10
Figure 2-10. DGC-2020 Rear Panel HMI................................................................................................ 2-11
Tables
Table 2-1. Front Panel HMI Descriptions.................................................................................................. 2-2
Table 2-2. Rear Panel HMI Descriptions.................................................................................................2-11
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ii DGC-2020 Human-Machine Interface 9400200990 Rev B
SECTION 2 • HUMAN-MACHINE INTERFACE
INTRODUCTION
This section describes the components of the DGC-2020 human-machine interface (HMI). DGC-2020
HMI components are located on the front panel (controls and indicators) and the rear panel (terminals
and connectors).
FRONT PANEL
Figure 2-1 illustrates the front panel HMI of the DGC-2020. Table 2-1 lists the call-outs of Figure 2-1
along with a description of each HMI component.
Figure 2-1. Front Panel HMI
9400200990 Rev B DGC-2020 Human-Machi n e Interface 2-1
Table 2-1. Front Panel HMI Descriptions
Locator Description
A Liquid Crystal Display. The backlit, 64 by 128 pixel LCD serves as the local information
source for metering, alarms, pre-alarms, and protective functions. Display operation is
maintained at -20°C. An optional LCD heater maintains display operation at -40°C.
B Not in Auto Indicator. This red LED lights when the DGC-2020 is not operating in Auto
mode.
C Alarm Indicator. This red LED lights continuously during alarm conditions and flashes
during pre-alarm conditions.
D Supplying Load Indicator. This green LE D lights when the generator current is greater
than EPS threshold current.
E Alarm Silence Pushbutton. Pressing this button opens the relay output programmed as
the horn output.
F Lamp Test Pushbutton. Pressing this button tests the DGC-2020 indicators by exercising
all LCD pixels and lighting all LEDs.
G Auto Pushb utton and Mode Indicator. Pressing the Auto button places the DGC-2020 in
Auto mode. The green Auto mode LED lights when Auto mode is active.
H Off Pushbutton and Mode Indicator. Pressing this button places the DGC-2020 in Off
mode. The red Off mode LED lights when the DGC-2020 is in Off mode.
I Run Pushbutton and Mode Indicator. Pressing this button places the DGC-2020 in Run
mode. The green Run mode LED lights when Run mode is active.
J Reset Pushbutton. This button is pressed to cancel a settings editing session and discard
any settings changes. When pressed, this button also resets the Breaker Management
Pre-Alarms.
K Arrow Pushbuttons. These four buttons are used to navigate through the front panel
display menus and modify settings.
The left- and right-arrow buttons are used to navigate through the menu levels. The right-
arrow button is pressed to move downward through the menu levels and the left-arrow
button is pressed to move upward.
Within a level, the up-arrow and down-arrow buttons are used to move among items
within the menu level. Pressing the down-arrow button moves to items lower in the list.
Pressing the up-arrow button moves to items higher in the list.
During a settings editing session, the up- and down-arrow buttons are used to raise and
lower the value of the selected setting.
L Edit Pushbutton. Pressing this button starts an editing session and enables changes to
DGC-2020 settings. At the conclusion of an editing session, the Edit pushbutton is
pressed again to save the setting changes.
DISPLAY OPERATION
The front panel display is used to make settings changes and display metering values. Refer to call-outs
J, K, and L in Table 2-1 for information on changing settings through the front panel and navigating
through the Metering screens.
Login and Permissions
Login To login, navigate to the SETTINGS, ENTER PASSWORD screen and press the Edit key. Use the
Up/Down arrow keys to scroll through the characters. Use the Left/Right arrow keys to enter more
characters. Once the password has been entered, press the Edit key to login. A LOGOUT selection now
appears in the list of SETTINGS. To logout, navigate to SETTINGS, LOGOUT and press the Edit key.
The LOGOUT selection is removed from the SETTINGS list.
2-2 DGC-2020 Human-Machine Interface 9400200990 Rev B
Permissions
Communications access through the front panel will not be granted if communications access is active
through the modem or USB. In this case, the front panel will alternately display REMOTE COMMS,
FRONT PANEL IS READ ONLY and the summary screen. Remote access must be ended before gaining
access through the front panel.
Summary Screen and Configurable Metering
The summary screen can be set to standard or scrolling. When set to standard, only the following are
displayed:
• VOLT
• AMP
• PH
• Hz
• OIL
• FUEL
• TEMP
• BATT
When the summary screen is set to scrolling, you can select/configure the metering values that are
displayed. Up to 20 values can be displayed and these values will scroll at a delay time specified by the
user. To select a standard or scrolling summary, navigate to the SETTINGS, GENERAL SETTINGS,
FRONT PANEL HMI screen and edit the SUMMARY VIEW. The SCROLL DELAY setting is also found on
this screen.
To select the scrolling values, navigate to the SETTINGS, GENERAL SETTINGS, FRONT PANEL HMI
screen and edit the CONFIGURABLE METERING. The following values may be selected by the user to
be placed in the scrolling summary:
• NONE (Removes a line from the scrolling list)
• BLANK (Shows nothing on this line)
• OIL P
• TEMP
• BATT V
• RPM
• RPM SRC
• FUEL
• RUN HRS
• GEN VAB
• GEN VBC
• GEN VCA
• GEN VAN
• GEN VBN
• GEN VCN
• BUS Hz
• BUS V
• GEN Hz
• GEN PF
• GEN KWH
• GEN IA
• GEN IB
• GEN IC
• KW A
• KW B
• KW C
• KW TOT
• KVA A
• KVA B
• KVA C
9400200990 Rev B DGC-2020 Human-Machi n e Interface 2-3
Sleep Mode
Sleep mode serves as a power saving feature. If the DGC-2020 is in Off mode or Auto mode not running
and a key is not pressed for more than 15 minutes, the front panel LCD backlight and LCD heater
(optional) are turned off. The DGC-2020 resumes normal display operation when any front panel button is
pressed or the genset is started remotely via the ATS input. If needed, Sleep mode can be permanently
disabled via BESTCOMSPlus or the front panel.
Changing a Setting
To change a setting, navigate to the setting you want to change and press the Edit key. If you are not
already logged in, you will be asked to enter your password at this time. Use the Up/Down arrows to raise
or lower the value. Press the Edit key again when finished.
Front Panel Display Structure
The front panel display begins with the SUMMARY SCREEN. Pressing the Right arrow key will open the
MAIN MENU screen. The MAIN MENU screen consists of METERING and SETTINGS. The METERING
screen branches are shown in Figure 2-2. The SETTINGS screen branches are shown in Figures 2-3
through 2-9.
2-4 DGC-2020 Human-Machine Interface 9400200990 Rev B
METERING
ENGINE
GENERATOR
POWER
RUN STATISTICS
ALARMS-STATUS
P0042-23
10-02-06
ENGINE
OIL PRESSURE
COOLANT TEMP
BATTERY VOLT
RPM
SPEED SRC
FUEL LEVEL
ENGINE LOAD
TOTAL RUN TM
HRS TO MAINT
GENERATOR
GEN VAB
GEN VBC
GEN VCA
GEN VAN
GEN VBN
GEN VCN
GEN FREQ
GEN AMPS A
GEN AMPS B
GEN AMPS C
BUS V
BUS FREQ
POWER
kW A
kW B
kW C
kW TOTAL
kVA A
kVA B
kVA C
kVA TOTAL
PF
CUMULATIVE
CUMULATIVE
TOTAL RUN TIME
LOADED RUN TIME
UNLOADED RUN TIME
SESSION
SESSION
TOTAL RUN TIME
LOADED RUN TIME
UNLOADED RUN TIME
STATUS
EPS SUPP. LOAD
GEN BREAKER
MAINS BREAKER
INPUTS
INPUT 1
INPUT 2
INPUT 3
INPUT 4
INPUT 5
INPUT 6
INPUT 7
INPUT 8
INPUT 9
INPUT 10
INPUT 11
INPUT 12
INPUT 13
INPUT 14
INPUT 15
INPUT 16
RUN STATISTICS
CUMULATIVE
SESSION
ALARMS-STATUS
ALARMS
PRE-ALARMS
STATUS
INPUTS
OUTPUTS
EVENT LOG
J1939 DATA
J1939 ENGINE CONFIG
J1939 ACTIVE DTC
J1939 PREV DTC
MDEC FAULT CODES
Figure 2-2. Metering Screen Branches
OUTPUTS
OUTPUT 1
OUTPUT 2
OUTPUT 3
OUTPUT 4
OUTPUT 5 (Optional)
OUTPUT 6 (Optional)
OUTPUT 7 (Optional)
OUTPUT 8 (Optional)
OUTPUT 9 (Optional)
OUTPUT 10 (Optional)
OUTPUT 11 (Optional)
OUTPUT 12 (Optional)
EVENT LOG
EVENT
EVENT
ACTIVE
OCCURRENCE COUNT
FIRST DATE
FIRST TIME
LAST DATE
LAST TIME
9400200990 Rev B DGC-2020 Human-Machi n e Interface 2-5
SETTINGS
GENERAL SETTINGS
GENERAL SETTINGS
COMMUNICATIONS
SYSTEM PARAMS
ALARM CONFIGURATION
GENERATOR PROTECTION
BREAKER MANAGEMENT
ENTER PASSWORD
P0042-24
09-27-06
Refer to Figure 2-4
COMMUNICATIONS
Refer to Figure 2-5
SYSTEM PARAMS
Refer to Figure 2-6
ALARM CONFIGURATION
Refer to Figure 2-7
GENERATOR PROTECTION
Refer to Figure 2-8
BREAKER MANAGEMENT
Refer to Figure 2-9
Figure 2-3. Settings Screen Branches
GENERAL SETTINGS
FRONT PANEL HMI
FRONT PANEL HMI
CONFIGURE DATE/TIME
VIEW DATE/TIME
VERSION INFO
P0042-25
09-27-06
Figure 2-4. General Settings Screen Branches
SUMMARY VIEW
SCROLL DELAY
LCD CONTRAST
SLEEP MODE
LANGUAGE
CONFIGURABLE METERING
CONFIGURE DATE/TIME
HOURS
MINUTES
SECONDS
MONTH
DAY
YEAR
VERSION INFO
FIRMWARE VERSION
BOOT CODE
SERIAL NUMBER
PART NUMBER
MODEL NUMBER
2-6 DGC-2020 Human-Machine Interface 9400200990 Rev B
COMMUNICATIONS
CANBUS SETUP
CANBUS SETUP
CANBUS ENABLE
RS485 SETUP
P0042-26
09-27-06
RS485 SETUP
COMM BAUD
COMM PARITY
MODBUS ADDR
Figure 2-5. Communications Screen Branches
SYSTEM PARAMS
SYSTEM SETTINGS
CRANK SETTINGS
SENSING TRANS
ENGINE STATISTICS
P0042-27
09-27-06
SYSTEM SETTINGS
GEN CONNECT
RATED kW
RATED VOLTS
RATED FREQ
RATED RPM
COOLDWN TIME
EPS THRESHLD
FUEL LVL TYP
SYSTEM UNITS
BATTERY VOLT
FLYWHL TEETH
SPEED SOURCE
MAINT RESET
NFPA LEVEL
HORN
1 PHASE O-RIDE
CRANK SETTINGS
DISCNCT LMIT
PRECRNK DELY
PRESTRT CNTCT
STYLE
# CYCLES
CYCLE TIME
SENSING TRANS
GEN PT PRI V
GEN PT SEC V
GEN CT PRI A
BUS PT PRI V
BUS PT SEC V
ENGINE STATISTICS
START MONTH
START DAY
START YEAR
# STARTS
HRS TO MAINT
kW-Hrs
TOTAL HRS
LOADED HRS
UNLOADED HRS
Figure 2-6. System Params Screen Branches
9400200990 Rev B DGC-2020 Human-Machi n e Interface 2-7
ALARM CONFIGURATION
PRE-ALARMS
ALARMS
SENDER FAIL
P0042-27
09-27-06
PRE-ALARMS
HIGH COOLANT TEMP
LOW COOLANT TEMP
LOW OIL PRESSURE
LOW FUEL LEVEL
ENGINE OVERLOAD
MAINTENANCE INTERVAL
BATTERY OVERVOLTAGE
LOW BATTERY VOLTAGE
WEAK BATTERY VOLTAGE
HIGH FUEL LEVEL
ENABLE and THRESHOLD settings
for High Coolant Temp, Low Coolant
Temp, Low Oil Pressure, Low Fuel
Level, Engine Overload, Maintenance
Interval, and Battery Overvoltage.
ENABLE, THRESHOLD, and
ACTIVTN DLY settings for Low
Battery Voltage, Weak Battery
Voltage, and High Fuel Level.
ALARMS
HIGH COOLANT TEMP
ENABLE, THRESHOLD, and
ARMING DELAY settings for High
Coolant Temp and Low Oil Pressure.
LOW OIL PRESSURE
LOW FUEL LEVEL
OVERSPEED
SENDER FAIL
COOL TEMP SENDR FAIL
OIL PRESS SENDR FAIL
ENABLE, THRESHOLD, and
ACTIVATN DELAY settings for Low
Fuel Level and Overspeed.
CONFIG TYPE and ACTIVATN DLY
settings for Cool Temp Sendr Fail, Oil
Press Sendr Fail, Fuel Levl Sendr
Fail, and Voltage Sense Fail.
FUEL LEVL SENDR FAIL
VOLTAGE SENSE FAIL
SPEED SENDR FAIL
TIME DELAY setting for Speed Sendr
Fail.
Figure 2-7. Alarm Configuration Screen Branches
2-8 DGC-2020 Human-Machine Interface 9400200990 Rev B
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