Winco DGC-2020 User Manual

INSTRUCTION MANUAL FOR DIGITAL GENSET CONTROLLER DGC-2020 Publication: 9400200990 Revision: K 01/09

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Figure 4-27. Programmable Functions Settings A Auto Transfer Switch Input: Select Input (None,

Figure 4-28. Remote LSM InputsSettings A Input Type: Voltage or Current. B Min/Max Input Voltag

Select the input typeB and amount of hysteresisC. A user-adjustable arming delayD disables analog input recognition during engine startup. When enable

Remote Thermocouple Inputs An optional AEM-2020 (Analog Expansion Module) provides two thermocouple inputs. To make identifying the thermocouple input

Figure 4-33. Contact Outputs Settings A Label Text: An alphanumeric character string with a ma

BESTCOMSPlus settings for remote contact inputs (DGC-2020, Programmable Outputs, Remote Contact Outputs) are illustrated in Figure 4-35. Figure 4-35

4-38 DGC-2020 BESTCOMSPlus Software 9400200990 Rev K

9400200990 Rev K DGC-2020 BESTCOMSPlus Software 4-39 down to zero from the threshold time setting. The maintenance interval pre-alarm can be reset t

9400200990 Rev K DGC-2020 General Information i SECTION 1  GENERAL INFORMATION TABLE OF CONTENTS SECTION 1  GENERAL INFORMATION ...

4-40 DGC-2020 BESTCOMSPlus Software 9400200990 Rev K GOV Bias Output Limit GOV bias output limit settingsO consist of an enable/disable setting and

Figure 4-38. Pre-Alarms Configuration A High Fuel Level: Enable or Disable, threshold is adjust

4-42 DGC-2020 BESTCOMSPlus Software 9400200990 Rev K

Note: ECU Support must be enabled on the Communications, CANbus Setup screen before this alarm can be configured. Figure 4-39. Alarms Configuration

Figure 4-40. Sender Fail Configuration A Coolant Temp Sender Fail: None, Alarm, or Pre-Alarm, t

The hysteresis settingD functions as an undervoltage dropout by preventing rapid switching of the pickup output. A frequency-based inhibit settingE pr

settings. For example, if a scale factor contact input is received by the DGC-2020 and the scale factor setting is 2.000, the pickup setting will be d

Figure 4-46. Generator Capability Curve vs. 40Q Response If reactive power is within the 40Q tripping region for the duration of the 40Q activation

ii DGC-2020 General Information 9400200990 Rev K Underfrequency (81U) and Overfrequency (81O) ...

4-50 DGC-2020 BESTCOMSPlus Software 9400200990 Rev K Overcurrent Protection (51-1, 51-2, 51-3) Two sets of overcurrent settings are provided for eac

Figure 4-48. Overcurrent Protection Settings A Pickup: Adjustable from 0.9 to 7.75 Aac for 5 Aa

During synchronization of the generator with the bus (Anticipatory mode only), the DGC-2020 uses the breaker closing timeJ to calculate the optimum ti

Figure 4-50. Bus Condition Detection Settings A Dead Bus Threshold: Adjustable from 0 to 4,800

that is required to compensate for the breaker closure time by monitoring the frequency difference between the generator and the bus. BESTCOMSPlus aut

4-56 DGC-2020 BESTCOMSPlus Software 9400200990 Rev K

droop is also the mode when the generator breaker is closed if kW load sharing is disabled. If it is desired to disable voltage droop, set the droop p

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Expected rpm reduction in droop - (actual load/machine capacity)  (droop percentage/100)  rated speed. If the actual rpm drop does not match the exp

9400200990 Rev K DGC-2020 General Information 1-1 SECTION 1  GENERAL INFORMATION DESCRIPTION The DGC-2020 Digital Genset Controller provides integr

Figure 4-55. Governor Output Settings A Output Type: Voltage or Current. B Response: Increasi

Figure 4-57. Demand Start/Stop A Demand Start Stop Enable: Enable or Disable. B Delayed Start L

Balanced Service Time If this mode is selected, units will seek to sort the start priority of all non-disabled networked units in ascending order of s

BESTCOMSPlus network configuration settings (DGC-2020, Multigen Management, Network Configuration) are illustrated in Figure 4-59. Figure 4-59. Netw

Figure 4-60. Programmable Senders Settings A Sender Points: Accepts up to 11 user-defined sende

Opening a Settings File To open a new instance of a settings file into BESTCOMSPlus, pull down the File menu and choose Open. The Open dialog box appe

A dialog box will appear and notify you if any differences were found. The BESTCOMSPlus Settings Compare dialog box (Figure 4-62) is displayed where y

CAUTION The order in which the components are upgraded is critical. Assuming a system of a DGC-2020 and expansion modules is in a state where the DGC-

8. Click on the Upload button and the Proceed with Device Upload screen will appear. Select Yes or No. 9. After selecting Yes, the DGC-2020 Selection

1-2 DGC-2020 General Information 9400200990 Rev K Contact Inputs and Output Contacts DGC-2020 controllers have one, dedicated emergency stop contact

f. Click the Upload button and follow the instructions that appear to begin the upgrade process. g. After the upload is complete, disconnect communic

9400200990 Rev K DGC-2020 BESTCOMSPlus Software 4-71 5. Load the new settings file into the DGC-2020. a. Disconnect communication from the DGC-202

4-72 DGC-2020 BESTCOMSPlus Software 9400200990 Rev K METERING EXPLORER The Metering Explorer is a convenient tool within BESTCOMSPlus used to naviga

P0042-1509-20-06ACEBD Figure 4-66. Metering, Docking Options Table 4-2. Explanation of Call-Outs on Figure 4-66 Call-Out Symbol Explanation A Holdin

Engine This screen provides information and metering of engine components. Refer to Figure 4-67. Figure 4-67. Metering, Engine Generator This screen

Bias Control This screen provides Var/PF mode status and operating levels. Refer to Figure 4-70. Figure 4-70. Metering, Bias Control Run Statistics

Figure 4-72. Metering, Status Inputs Contact Inputs This screen indicates the status of contact inputs, contact input alarms, and contact input pre-a

Remote LSM Inputs When an optional LSM-2020 (Load Share Module) is connected, the value of the analog inputs is displayed on this screen. Voltage is d

Remote RTD Inputs When an optional AEM-2020 (Analog Expansion Module) is connected, the status of the remote RTD inputs, remote RTD input alarms, and

Figure 4-79. Metering, Inputs, Remote Analog Input Values The Calibrate button shown in Figure 4-79 opens the Analog Input Temperature Calibration s

AEM-2020 (ANALOG EXPANSION MODULE) The optional AEM-2020 provides eight remote analog inputs, eight remote RTD inputs, two remote thermocouple inputs,

Outputs Contact Outputs This screen indicates the status of contact outputs. The status is TRUE when the corresponding LED is green. Refer to Figure 4

Figure 4-83. Metering, Outputs, Remote Contact Outputs Remote Analog Outputs When an optional AEM-2020 (Analog Expansion Module) is connected, the s

Figure 4-85. Metering, Alarms Event Log The event log provides a historical record of event occurrences detected by the DGC-2020. It is saved in nonv

Figure 4-86. Metering, Event Log, Sorted by Date When viewed with BESTCOMSPlus, the event log can be sorted by Event ID, Description, Occurrence, Da

Figure 4-88. Metering, ECU Data Engine Configuration This screen displays Engine Configuration. Refer to Figure 4-89. Figure 4-89. Metering, Engin

Figure 4-90. Metering, Download DTC MTU The MTU reports operating information to the DGC-2020 through the CANbus interface when the ECU is configured

MTU Status MTU Status is reported on this screen. The status is TRUE when the corresponding LED is red. Refer to Figure 4-93. Figure 4-93. Metering,

Summary This screen displays a metering summary. Refer to Figure 4-95. Figure 4-95. Metering, Summary 9400200990 Rev K DGC

Control Controls for stopping/starting the engine, controls for opening/closing breakers, and controls for opening/closing switches are accessed thro

Generator Network Status This screen (Figure 4-98) displays the detected sequencing IDs of the LSM-2020’s on the network. This can only be accomplishe

1-4 DGC-2020 General Information 9400200990 Rev K Part Numbers A ten-digit part number specifies the electrical characteristics and operational feat

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9400200990 Rev K DGC-2020 BESTlogic+ Programmable Logic i SECTION 5  BESTlogic+ PROGRAMMABLE LOGIC TABLE OF CONTENTS SECTION 5  BESTlogic+ PROGRA

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SECTION 5  BESTlogic+ PROGRAMMABLE LOGIC INTRODUCTION BESTlogic+ Programmable Logic is a programming method used for managing the input, output, prot

BESTlogic+ Composition There are three main groups of objects used for programming BESTlogic+. These groups are I/O, Components, and Elements. For det

Name Description Symbol Status Input Auto Restart TRUE when the Automatic Restart function is active. Status Input Battery Charger Fail TRUE when th

Name Description Symbol Status Input Front Panel Buttons TRUE while the EDIT front panel button is pressed. Status Input Front Panel Buttons TRUE wh

Name Description Symbol Status Input Load Share Module Load Share Module Connected. TRUE when an optional LSM-2020 is connected to the DGC-2020. Sta

Name Description Symbol Alarms Analog Expansion Module Remote Analog Inputs 1-8 TRUE when Over 1, Over 2, Under 1, Under 2, or Out of Range is config

Name Description Symbol Hi Coolant Temp TRUE when the High Coolant Temp Alarm settings have been exceeded. Low Coolant Level TRUE when the Low Coo

9400200990 Rev K DGC-2020 General Information 1-5 Contact Sensing Contact sensing inputs include 1 emergency stop input and 16 programmable inputs.

Name Description Symbol Battery Charger Fail TRUE when the Battery Charger Fail function is configured as a Pre-Alarm and the activation delay has e

Name Description Symbol Hi Coolant Temp TRUE when the High Coolant Temp Pre-Alarm threshold has been exceeded. High Fuel Level TRUE when the High

Name Description Symbol Senders Coolant Temp Sender Fail TRUE when the Coolant Temp Sender Fail is configured as either a Pre-Alarm or Alarm and the

Name Description Symbol XOR Input Output 0 0 0 0 1 1 1 0 1 1 1 0 XNOR Input Output 0 0 1 0 1 0 1 0 0 1 1 1 NOT (INVERTER) Input Output 0

Table 5-3. Elements Group, Names and Descriptions Name Description Symbol Protection 27-1TRIP TRUE when the 27-1 undervoltage is in a TRIP condition

Name Description Symbol Other ATS When this logic element is TRUE, and the DGC-2020 is in AUTO mode, the generator will run. This can be used in pla

Name Description Symbol COOLDOWNREQ RUN Mode If the unit is in RUN mode when the Cool Down Request is received, the unit is forced to unload and open

Name Description Symbol GENBRK This element is used to connect the breaker open and close output signals from the DGC-2020 to physical output contac

Name Description Symbol MAINSBRK This element is used to connect the breaker open and close output signals from the DGC-2020 to physical output cont

Name Description Symbol PARTOMAINS Setting this logic element to TRUE indicates to the DGC-2020 that it is paralleled to a utility. When parallele

1-6 DGC-2020 General Information 9400200990 Rev K Programmable Relays (12) Rating: 2 Adc at 30 Vdc—make, break, and carry Terminals† Output 1: 5

Name Description Symbol STARTOUTPUT This element is used to drive the start output relay from logic when the Start Output Relay configuration is set

CAUTION Modifying a logic scheme in BESTCOMSPlus does not automatically make that scheme active in the DGC-2020. The modified scheme must be uploaded

Pickup and Dropout Timers A pickup timer produces a TRUE output when the elapsed time is greater than or equal to the Pickup Time setting after a FALS

Opening a BESTlogic+ File To open a saved BESTlogic+ file, click on the Logic Library drop-down button on the BESTlogic+ Programmable Logic toolbar an

Example 2 - AND Gate Connections Figure 5-5 illustrates a typical AND gate connection. In this example, Output 11 will become active when the Low Fuel

9400200990 Rev K DGC-2020 Installation i SECTION 6  INSTALLATION TABLE OF CONTENTS SECTION 6  INSTALLATION ...

ii DGC-2020 Installation 9400200990 Rev K Figure 6-16. Single-Phase A-B Connections for MTU MDEC ECU Applications...

SECTION 6  INSTALLATION GENERAL DGC-2020 controllers are delivered in sturdy cartons to prevent shipping damage. Upon receipt of a system, check the

Figure 6-2. Overall Dimensions 6-2 DGC-2020 Installation 9400200990 Rev K

CONNECTIONS DGC-2020 connections are dependent on the application. Incorrect wiring may result in damage to the controller. NOTE Be sure that the DGC-

9400200990 Rev K DGC-2020 General Information 1-7 Apparent Power Indicates total kVA and individual line kVA (4-wire, line-to-neutral or 3-wire, lin

Table 6-2. Generator Current Sensing Terminals Terminal Description 68 (IA–) 69 (IA+) A-phase current sensing input 71 (IB–) 72 (IB+) B-phase current

Table 6-5. Sender Input Terminals Terminal Description 8 (OIL) Oil pressure sender input 9 (FUEL) Fuel level sender input 10 (COOLANT) Coolant temp

6-6 DGC-2020 Installation 9400200990 Rev K Magnetic Pickup Input The magnetic pickup input accepts a speed signal over the range of 3 to 35 volts pe

9400200990 Rev K DGC-2020 Installation 6-7 Table 6-9. Programmable Output Contact Terminals Terminal Description 51 (COM 1, 2, 3) Common connection

NOTES 1.) If the DGC-2020 is providing one end of the J1939 bus, a 120  terminating resistor should be installed across terminals 48 (CANL) and 49 (

9400200990 Rev K DGC-2020 Installation 6-9 Dial-Out Modem DGC-2020 controllers with style number xxxxxMxxx have an internal modem with dial-in, dial

3-Phase Wye Connections for Typical Applications Figure 6-6. 3-Phase Wye Connections for Typical Applications 6-10 DGC-2020 Installation 9400200990

3-Phase Delta Connections for Typical Applications Figure 6-7. 3-Phase Delta Connections for Typical Applications 9400200990 Rev K DGC-2020 Installa

Single-Phase A-B Connections for Typical Applications Figure 6-8. Single-Phase A-B Connections for Typical Applications 6-12 DGC-2020 Installation

Single-Phase A-C Connections for Typical Applications Figure 6-9. Single-Phase A-C Connections for Typical Applications 9400200990 Rev K DGC-2020 In

1-8 DGC-2020 General Information 9400200990 Rev K Maintenance Timer Maintenance timer indicates the time remaining until genset service is due. Valu

6-14 DGC-2020 Installation 9400200990 Rev K Connections for Volvo Penta EDC III Applications Engines equipped with Volvo Penta EDC III controllers c

3-Phase Wye Connections for Volvo Penta EDC III Applications Figure 6-10. 3-Phase Wye Connections for Volvo Penta EDC III Applications 9400200990 Rev

3-Phase Delta Connections for Volvo Penta EDC III Applications Figure 6-11. 3-Phase Delta Connections for Volvo Penta EDC III Applications 6-16 DGC-

Single-Phase A-B Connections for Volvo Penta EDC III Applications Figure 6-12. Single-Phase A-B Connections for Volvo Penta EDC III Applications 9400

Single-Phase A-C Connections for Volvo Penta EDC III Applications Figure 6-13. Single-Phase A-C Connections for Volvo Penta EDC III Applications 6-18

9400200990 Rev K DGC-2020 Installation 6-19 Connections for MTU MDEC ECU Applications MTU MDEC ECUs, supplied on some Detroit Diesel engines, can re

3-Phase Wye Connections for MTU MDEC ECU Applications Figure 6-14. 3-Phase Wye Connections for MTU MDEC ECU Applications 6-20 DGC-2020 Installatio

3-Phase Delta Connections for MTU MDEC ECU Applications Figure 6-15. 3-Phase Delta Connections for MTU MDEC ECU Applications 9400200990 Rev K DGC-

Single-Phase A-B Connections for MTU MDEC ECU Applications Figure 6-16. Single-Phase A-B Connections for MTU MDEC ECU Applications 6-22 DGC-2020 I

Single-Phase A-C Connections for MTU MDEC ECU Applications Figure 6-17. Single-Phase A-C Connections for MTU MDEC ECU Applications 9400200990 Rev

Logic Timers Range: 0 to 10 s Increment: 0.1 s Accuracy: 15 ms Communication Interface USB Specification Compatibility: USB 2.0 Data Transfer Spe

Connections with AEM-2020, CEM-2020, and LSM-2020 The AEM-2020 (Analog Expansion Module), CEM-2020 (Contact Expansion Module), and LSM-2020 (Load Shar

9400200990 Rev K DGC-2020 Maintenance and Troubleshooting i SECTION 7  MAINTENANCE AND TROUBLESHOOTING TABLE OF CONTENTS SECTION 7  MAINTENANCE A

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SECTION 7  MAINTENANCE AND TROUBLESHOOTING MAINTENANCE Preventative maintenance consists of periodic replacement of the backup battery (optional) and

7-2 DGC-2020 Maintenance and Troubleshooting 9400200990 Rev K Step 3. Verify that all Ethernet devices comply with IEC 61000-4 series of specifica

9400200990 Rev K DGC-2020 Maintenance and Troubleshooting 7-3 Step 2. Ensure that the proper current is present at the DGC-2020 current sensing in

7-4 DGC-2020 Maintenance and Troubleshooting 9400200990 Rev K the logic output that would normally be the breaker close output. Map another virtual

9400200990 Rev K DGC-2020 Maintenance and Troubleshooting 7-5 Synchronizer Determining if the Synchronizer is Active Step 1: Disable the speed tr

7-6 DGC-2020 Maintenance and Troubleshooting 9400200990 Rev K If the speed still does not change when varying the bias:  Verify that the gov

9400200990 Rev K DGC-2020 LSM-2020 (Load Share Module) i SECTION 8  LSM-2020 (LOAD SHARE MODULE) TABLE OF CONTENTS TTSECTION 8  LSM-2020 (LOAD SH

CAUTION Replacement of the backup battery for the real-time clock should be performed only by qualified personnel. Do not short-circuit the battery, r

ii DGC-2020 LSM-2020 (Load Share Module) 9400200990 Rev K Figures UUFigure 8-1. Device Info Screen...

9400200990 Rev K DGC-2020 LSM-2020 (Load Share Module) 8-1 SECTION 8  LSM-2020 (LOAD SHARE MODULE) GENERAL INFORMATION The LSM-2020 is a remote aux

8-2 DGC-2020 LSM-2020 (Load Share Module) 9400200990 Rev K Communication Interface CANbus Differential Bus Voltage: 1.5 to 3 Vdc Maximum Voltage:

9400200990 Rev K DGC-2020 LSM-2020 (Load Share Module) 8-3 CE Compliance This product complies with the requirements of the following EC Directives:

8-4 DGC-2020 LSM-2020 (Load Share Module) 9400200990 Rev K Generator Sequencing Machines can be added or removed from the power system based on load

Figure 8-1. Device Info Screen A Application Version: When configuring Load Share Module settin

Figure 8-2. Device Security Setup Screen A Access Level/Password: Read-only value obtained when

5.50 [139.7]151617186.38 [162.0]7.50 [190.5] 8.38 [212.8]1.39 [35.3]1234567891011121314P0052-36P2J3 Figure 8-3. LSM-2020 Overall Dimensions Connection

8-8 DGC-2020 LSM-2020 (Load Share Module) 9400200990 Rev K Operating Power The LSM-2020 operating power input accepts either 12 Vdc or 24 Vdc and to

CANbus Interface These terminals provide communication using the SAE J1939 protocol and provide high-speed communication between the LSM-2020 and the

UL/CSA Approval “cURus” recognized to UL Standard 508 & CSA Standard C22.2 No. 14. CSA certified to CSA C22.2 No. 14. Part Numbers 9400200105 and

AEM-2020(Optional)DGC-2020Other DevicesP0053-59Engine120 ohmTerminationCAN-HCAN-LCEM-2020 (Optional)LSM-2020120 ohmTerminationBusStub Figure 8-5. CANb

DGC-2020GEN ENGINEGOVLSM-2020AVR17181415101112CANLCANHGNDAVR+AVR-GOV+GOV-504948 CANLCANHGND56LS+LS-DGC-2020GEN ENGINEGOVLSM-2020AVR17181415101112CANLC

Connections using AVR’, GOV’, and LS’ Additional terminals provide a landing point to add series resistance to the GOV, AVR, and LS analog outputs. Th

123456789101112131415161718EthernetLSM-2020AVR+AVR-AVR’GOV+GOV-GOV’CANLCANHGNDV+IN-I+LS+LS-LS’B-B+GNDGovernorAnalog Aux InputDGC-2020CANLCANHSHIELDP00

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9400200990 Rev K DGC-2020 CEM-2020 (Contact Expansion Module) i SECTION 9  CEM-2020 (CONTACT EXPANSION MODULE) TABLE OF CONTENTS SECTION 9  CEM-2

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9400200990 Rev K DGC-2020 CEM-2020 (Contact Expansion Module) 9-1 SECTION 9  CEM-2020 (CONTACT EXPANSION MODULE) GENERAL INFORMATION The optional C

9-2 DGC-2020 CEM-2020 (Contact Expansion Module) 9400200990 Rev K HALT (Highly Accelerated Life Testing) HALT is used by Basler Electric to prove th

BESTCOMSPlus SOFTWARE BESTCOMSPlus provides the user with a point-and-click means to set and monitor the Contact Expansion Module. Installation and op

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Connections Contact Expansion Module connections are dependent on the application. Incorrect wiring may result in damage to the module. NOTE Operating

Figure 9-2. CEM-2020 Input Contact and Output Contact Terminals CANbus Interface These terminals provide communication using the SAE J1939 protocol

NOTES 1.) If the CEM-2020 is providing one end of the J1939 bus, a 120  terminating resistor should be installed across terminals P1- LO (CANL) and

9400200990 Rev K DGC-2020 AEM-2020 (Analog Expansion Module) i SECTION 10  AEM-2020 (ANALOG EXPANSION MODULE) TABLE OF CONTENTS SECTION 10  AEM-2

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9400200990 Rev K DGC-2020 AEM-2020 (Analog Expansion Module) 10-1 SECTION 10  AEM-2020 (ANALOG EXPANSION MODULE) GENERAL INFORMATION The optional A

10-2 DGC-2020 AEM-2020 (Analog Expansion Module) 9400200990 Rev K Type Tests Shock 15 G in 3 perpendicular planes Vibration Swept over the following

9400200990 Rev K DGC-2020 AEM-2020 (Analog Expansion Module) 10-3 FUNCTIONAL DESCRIPTION A functional description of the AEM-2020’s inputs and outpu

Mounting Analog Expansion Modules are contained in an encapsulated plastic case and may be mounted in any convenient position. The construction of a A

is mounted permanently to the board. Connector screw terminals accept a maximum wire size of 12 AWG. Thermocouple connectors accept a maximum thermoco

9400200990 Rev K DGC-2020 Human-Machine Interface i SECTION 2  HUMAN-MACHINE INTERFACE TABLE OF CONTENTS SECTION 2  HUMAN-MACHINE INTERFACE ...

Table 10-2. Input and Output Terminals Connector Description P1 Operating Power and CANbus P2 RTD Inputs 1 - 8 P3 Analog Inputs 1 - 8 and Analog Ou

Table 10-3. CANbus Interface Terminals Terminal Description P1- HI (CAN H) CAN high connection (yellow wire) P1- LO (CAN L) CAN low connection (gree

AEM-2020DGC-2020Other DevicesP0053-63Engine120 ohmTerminationCAN-HCAN-LLSM-2020(Optional)CEM-2020(Optional)120 ohmTerminationBusStub Figure 10-6. CANb

9400200990 Rev K DGC-2020 Time Overcurrent Characteristic Curves i APPENDIX A  TIME OVERCURRENT CHARACTERISTIC CURVES TABLE OF CONTENTS APPENDIX A

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APPENDIX A  TIME OVERCURRENT CHARACTERISTIC CURVES INTRODUCTION The inverse time overcurrent characteristic curves provided by the DGC-2020 (style xx

A-2 DGC-2020 Time Overcurrent Characteristic Curves 9400200990 Rev K Table A-1. 51 Time Characteristic Curve Constants Trip Characteristic Constants

9400200990 Rev K DGC-2020 Time Overcurrent Characteristic Curves A-3 Table A-2. Characteristic Curve Cross-Reference Curve Curve Name Similar To S1

A-4 DGC-2020 Time Overcurrent Characteristic Curves 9400200990 Rev K Table A-3 .Time Dial Setting Cross-Reference Electromechanical R

Figure A-1. Time Characteristic Curve S, S1, Short Inverse (Similar to ABB CO-2) 9400200990 Rev K DGC-2020 Time Overcurrent Characteristic Curves A

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A-6 DGC-2020 Time Overcurrent Characteristic Curves 9400200990 Rev K Figure A-2. Time Characteristic Curve S2, Short Inverse (Similar To GE IAC-55)

9400200990 Rev K DGC-2020 Time Overcurrent Characteristic Curves A-7 Figure A-3. Time Characteristic Curve L, L1, Long Inverse (Similar to ABB CO-5

Figure A-4. Time Characteristic Curve L2, Long Inverse (Similar To GE IAC-66) A-8 DGC-2020 Time Overcurrent Characteristic Curves 9400200990 Rev

Figure A-5. Time Characteristic Curve D, Definite Time (Similar To ABB CO-6) 9400200990 Rev K DGC-2020 Time Overcurrent Characteristic Curves A-9

Figure A-6. Time Characteristic Curve M, Moderately Inverse (Similar to ABB CO-7) A-10 DGC-2020 Time Overcurrent Characteristic Curves 9400200990

Figure A-7. Time Characteristic Curve I, I1, Inverse Time (Similar to ABB CO-8) 9400200990 Rev K DGC-2020 Time Overcurrent Characteristic Curves

Figure A-8. Time Characteristic Curve I2, Inverse Time (Similar to GE IAC-51) A-12 DGC-2020 Time Overcurrent Characteristic Curves 9400200990 Rev

Figure A-9. Time Characteristic Curve V, V1, Very Inverse (Similar to ABB CO-9) 9400200990 Rev K DGC-2020 Time Overcurrent Characteristic Curves

Figure A-10. Time Characteristic Curve V2, Very Inverse (Similar to GE IAC-53) A-14 DGC-2020 Time Overcurrent Characteristic Curves 9400200990 Re

Figure A-11. Time Characteristic Curve E, E1, Extremely Inverse (Similar to ABB CO-11) 9400200990 Rev K DGC-2020 Time Overcurrent Characteristic C

SECTION 2  HUMAN-MACHINE INTERFACE INTRODUCTION This section describes the components of the DGC-2020 human-machine interface (HMI). DGC-2020 HMI com

Figure A-12. Time Characteristic Curve E2, Extremely Inverse (Similar to GE IAC-77) A-16 DGC-2020 Time Overcurrent Characteristic Curves 94002009

Figure A-13. Time Characteristic Curve A, Standard Inverse 9400200990 Rev K DGC-2020 Time Overcurrent Characteristic Curves A-17

Figure A-14. Time Characteristic Curve B, Very Inverse A-18 DGC-2020 Time Overcurrent Characteristic Curves 9400200990 Rev K

Figure A-15. Time Characteristic Curve C, Extremely Inverse 9400200990 Rev K DGC-2020 Time Overcurrent Characteristic Curves A-19

Figure A-16. Time Characteristic Curve G, Long Time Inverse A-20 DGC-2020 Time Overcurrent Characteristic Curves 9400200990 Rev K

9400200990 Rev K DGC-2020 Modbus Communication i APPENDIX B  MODBUS COMMUNICATION TABLE OF CONTENTS APPENDIX B  Modbus COMMUNICATION ...

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9400200990 Rev K DGC-2020 Modbus Communication B-1 APPENDIX B  MODBUS COMMUNICATION INTRODUCTION General Overview An optional feature of the DGC-

B-2 DGC-2020 Modbus Communication 9400200990 Rev K Data Block Field The query Data block contains additional information needed by the slave to perf

9400200990 Rev K DGC-2020 Modbus Communication B-3  Function 08, Subfunction 00 - Diagnostics: Return Query Data  Function 16 - Preset Multiple

2-2 DGC-2020 Human-Machine Interface 9400200990 Rev K Table 2-1. Front Panel HMI Descriptions Locator Description A Liquid Crystal Display. The bac

B-4 DGC-2020 Modbus Communication 9400200990 Rev K Preset Multiple Registers, Non-Broadcast & Broadcast Preset Multiple Registers - General QUER

9400200990 Rev K DGC-2020 Modbus Communication B-5  There are several instances of registers that are grouped together (signified as DP or TP) to

B-6 DGC-2020 Modbus Communication 9400200990 Rev K Long Integer Data Format (INT32) The Modbus long integer data format uses two consecutive holding

9400200990 Rev K DGC-2020 Modbus Communication B-7 The second register contains the low-order 16 bits of double precision data, and is the actual d

B-8 DGC-2020 Modbus Communication 9400200990 Rev K MAPPING - DGC-2020 PARAMETERS INTO MODICON ADDRESS SPACE Table Conventions Table B-3 uses the con

9400200990 Rev K DGC-2020 Modbus Communication B-9 Table B-3. Legacy Parameter Table Holding Register Parameter Range Read/Write Supported Data For

B-10 DGC-2020 Modbus Communication 9400200990 Rev K Holding Register Parameter Range Read/Write Supported Data Format Units 40049 Threshold 3-100

9400200990 Rev K DGC-2020 Modbus Communication B-11 Holding Register Parameter Range Read/Write Supported Data Format Units 40082 Alarm Codes indiv

B-12 DGC-2020 Modbus Communication 9400200990 Rev K Holding Register Parameter Range Read/Write Supported Data Format Units 40110 Phase a RMS Curre

9400200990 Rev K DGC-2020 Modbus Communication B-13 Holding Register Parameter Range Read/Write Supported Data Format Units 40287-97 RESERVED

9400200990 Rev K DGC-2020 Human-Machine Interface 2-3 Permissions If communications access is active through the modem or USB, the front panel will

B-14 DGC-2020 Modbus Communication 9400200990 Rev K Holding Register Parameter Range Read/Write Supported Data Format Units 40322 Active DTC Number

9400200990 Rev K DGC-2020 Modbus Communication B-15 Holding Register Parameter Range Read/Write Supported Data Format Units 40354 Previous DTC Numb

B-16 DGC-2020 Modbus Communication 9400200990 Rev K Holding Register Parameter Range Read/Write Supported Data Format Units 40372 CAN Communications

9400200990 Rev K DGC-2020 Modbus Communication B-17 Holding Register Parameter Range Read/Write Supported Data Format Units 40388 CANbus ECU Confi

B-18 DGC-2020 Modbus Communication 9400200990 Rev K Holding Register Parameter Range Read/Write Supported Data Format Units 40444 Coolant Level 0

9400200990 Rev K DGC-2020 Modbus Communication B-19 Holding Register Parameter Range Read/Write Supported Data Format Units 40468 Override Speed Po

B-20 DGC-2020 Modbus Communication 9400200990 Rev K Holding Register Parameter Range Read/Write Supported Data Format Units 40509-604 RESERVED

9400200990 Rev K DGC-2020 Modbus Communication B-21 Holding Register Parameter Range Read/Write Supported Data Format Units 40640 Gen Protection Pr

B-22 DGC-2020 Modbus Communication 9400200990 Rev K Holding Register Parameter Range Read/Write Supported Data Format Units 40761 MTU Pre-alarms 0-

9400200990 Rev K DGC-2020 Modbus Communication B-23 Register Description Type Units Scaling Factor R/W Range 42052 Mains Breaker Status Int32 N/

INTRODUCTION This instruction manual provides information about the operation and installation of the DGC-2020 Digital Genset Controller. To accomplis

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

B-24 DGC-2020 Modbus Communication 9400200990 Rev K Register Description Type Units Scaling Factor R/W Range 42328 kw Integrator Limit Plus Float

9400200990 Rev K DGC-2020 Modbus Communication B-25 Register Description Type Units Scaling Factor R/W Range 42768 Gen Sensing Stable Overfrequenc

B-26 DGC-2020 Modbus Communication 9400200990 Rev K Register Description Type Units Scaling Factor R/W Range 43502 Pre-Start Contact Config Int32

9400200990 Rev K DGC-2020 Modbus Communication B-27 Register Description Type Units Scaling Factor R/W Range 43574 Speed Signal Source Uint32 N/

B-28 DGC-2020 Modbus Communication 9400200990 Rev K Register Description Type Units Scaling Factor R/W Range 43616 DST End Week of Month Int32 N/

9400200990 Rev K DGC-2020 Modbus Communication B-29 Register Description Type Units Scaling Factor R/W Range 43776 Virtual Input 1 Open Int32 N/

B-30 DGC-2020 Modbus Communication 9400200990 Rev K Register Description Type Units Scaling Factor R/W Range 44262 1 Phase Overcurrent Curve (51-1)

9400200990 Rev K DGC-2020 Modbus Communication B-31 Register Description Type Units Scaling Factor R/W Range 44306 Underfrequency Alarm Configurat

B-32 DGC-2020 Modbus Communication 9400200990 Rev K Register Description Type Units Scaling Factor R/W Range 44338 3 Phase Undervoltage Activation

9400200990 Rev K DGC-2020 Modbus Communication B-33 Register Description Type Units Scaling Factor R/W Range 44396 3 Phase Reverse Power Alarm Con

9400200990 Rev K DGC-2020 Human-Machine Interface 2-5  BUS V  BUS FREQ  SYNCHRONIZER POWER  kW A  kW B  kW C  kW TOTAL  kVA A  kVA

B-34 DGC-2020 Modbus Communication 9400200990 Rev K Register Description Type Units Scaling Factor R/W Range 44516 Overspeed Alarm Enable Uint32

9400200990 Rev K DGC-2020 Modbus Communication B-35 Register Description Type Units Scaling Factor R/W Range 44578 Maintenance Interval Pre-Alarm

B-36 DGC-2020 Modbus Communication 9400200990 Rev K Register Description Type Units Scaling Factor R/W Range 44634 GOV Bias Output Limit Pre-alarm

9400200990 Rev K DGC-2020 Modbus Communication B-37 Register Description Type Units Scaling Factor R/W Range 44812 Alarm Metering Int32 N/A N/A

B-38 DGC-2020 Modbus Communication 9400200990 Rev K Register Description Type Units Scaling Factor R/W Range 44828 Local Input Metering Int32 N/A

9400200990 Rev K DGC-2020 Modbus Communication B-39 Register Description Type Units Scaling Factor R/W Range 44858 Session Total Engine Run Hrs. I

B-40 DGC-2020 Modbus Communication 9400200990 Rev K Register Description Type Units Scaling Factor R/W Range 44956 Local Configurable Inputs Alarm

9400200990 Rev K DGC-2020 Modbus Communication B-41 Register Description Type Units Scaling Factor R/W Range 44966 Remote Outputs Status Bits Int3

B-42 DGC-2020 Modbus Communication 9400200990 Rev K Register Description Type Units Scaling Factor R/W Range 45504 Analog Input 3 Metering Value In

9400200990 Rev K DGC-2020 Modbus Communication B-43 Register Description Type Units Scaling Factor R/W Range 45538 AEM Input Threshold Status Bits

2-6 DGC-2020 Human-Machine Interface 9400200990 Rev K ALARMS-STATUS  ALARMS  PRE-ALARMS  MTU FAULT CODES (Visible when ECU is configured for M

B-44 DGC-2020 Modbus Communication 9400200990 Rev K Register Description Type Units Scaling Factor R/W Range 45544 AEM Input Threshold Alarm Bits R

9400200990 Rev K DGC-2020 Modbus Communication B-45 Register Description Type Units Scaling Factor R/W Range 45548 AEM Input Threshold Alarm Bits

B-46 DGC-2020 Modbus Communication 9400200990 Rev K Register Description Type Units Scaling Factor R/W Range 45554 AEM Input Threshold Pre-Alarm Bi

9400200990 Rev K DGC-2020 Modbus Communication B-47 Register Description Type Units Scaling Factor R/W Range 45562 Analog Output 2 Metering Value

B-48 DGC-2020 Modbus Communication 9400200990 Rev K Register Description Type Units Scaling Factor R/W Range 45570 Configurable Protection Alarm Bit

9400200990 Rev K DGC-2020 Modbus Communication B-49 Register Description Type Units Scaling Factor R/W Range 45576 Gen Kvar B Int32 KiloVAr N/A

B-50 DGC-2020 Modbus Communication 9400200990 Rev K Register Description Type Units Scaling Factor R/W Range 46018 J1939-Rated RPM Uint32 Raw ECU P

9400200990 Rev K DGC-2020 Modbus Communication B-51 Register Description Type Units Scaling Factor R/W Range 46052 J1939-ADEC Cylinder Cutout Code

B-52 DGC-2020 Modbus Communication 9400200990 Rev K Register Description Type Units Scaling Factor R/W Range 46104 J1939-ADEC T Intercooler Limit Hi

9400200990 Rev K DGC-2020 Tuning PID Settings i APPENDIX C  TUNING PID SETTINGS TABLE OF CONTENTS APPENDIX C  TUNING PID SETTINGS ...

P0053-51SETTINGSGENERAL SETTINGSCOMMUNICATIONSSYSTEM PARAMSPROGRAMMABLE INPUTSPROGRAMMABLE OUTPUTSALARM CONFIGURATIONGENERATOR PROTECTIONBREAKER MANAG

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9400200990 Rev K DGC-2020 Tuning PID Settings C-1 APPENDIX C  TUNING PID SETTINGS INTRODUCTION The LSM-2020 (Load Share Module) and DGC-2020 utiliz

C-2 DGC-2020 Tuning PID Settings 9400200990 Rev K TUNING PROCEDURES Voltage Controller Tuning Procedure The voltage controller is tuned prior to the

9400200990 Rev K DGC-2020 Tuning PID Settings C-3 Var/PF Controller Tuning Procedure Once desired voltage controller performance is obtained, the Va

C-4 DGC-2020 Tuning PID Settings 9400200990 Rev K and the speed it is trying to reach. The important thing is that the generator’s output behaves in

9400200990 Rev K DGC-2020 Tuning PID Settings C-5 KD - Derivative Gain If the performance with KP and KI alone is satisfactory, you may stop here. O

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ROUTE 143, BOX 269 HIGHLAND, IL 62249 USA http://www.basler.com, [email protected] PHONE +1 618-654-2

2-8 DGC-2020 Human-Machine Interface 9400200990 Rev K o UTC OFFSET o DST ENABLED  VIEW DATE/TIME  VERSION INFO o FIRMWARE VERSION o BOOT CODE VE

9400200990 Rev K DGC-2020 Human-Machine Interface 2-9 o RATED FREQ o RATED RPM o COOLDWN TIME o OFF MODE COOLDN o EPS  EPS THRESHLD  LOW LINE OV

2-10 DGC-2020 Human-Machine Interface 9400200990 Rev K o AEM SETUP  ENABLE  CANBUS ADDR (Visible when AEM-2020 is enabled.)  VERSION INFO (Visi

9400200990 Rev K DGC-2020 Human-Machine Interface 2-11 PROGRAMMABLE INPUTS  CONFIGURABLE INPUTS o INPUT X (X = 1 to 26)  ALARM CONFIG  ACTIVATN

2-12 DGC-2020 Human-Machine Interface 9400200990 Rev K  OVER 2  THRESHOLD  ALARM CONFIG  UNDER 1  THRESHOLD  ALARM CONFIG  UNDER 2  THRESHOL

9400200990 Rev K DGC-2020 Human-Machine Interface 2-13 o MAINTENANCE INTERVAL  ENABLE  THRESHOLD o BATTERY OVERVOLTAGE  ENABLE  THRESHOLD o LOW

First Printing: November 2006 Printed in USA © 2009 Basler Electric, Highland Illinois 62249 USA All Rights Reserved January 2009 CONFIDENTIAL

NOTE The HIGH COOLANT TEMP and LOW OIL PRESSURE alarms have an ARMING DLY setting that disables the alarm for the specified time after engine startup.

9400200990 Rev K DGC-2020 Human-Machine Interface 2-15  CURVE  ALARM CONFIG  32 REVERSE POWER o 3 / 1 PHASE SETTINGS  PICKUP  HYSTERESIS  TI

2-16 DGC-2020 Human-Machine Interface 9400200990 Rev K o REGUL OFFSET o CLOSING ANGLE o VG>VB o TIME DELAY o FAIL DELAY BIAS CONTROL  AVR BIAS

9400200990 Rev K DGC-2020 Human-Machine Interface 2-17  BL ALG MAX (Visible when LSM-2020 is enabled.)  BL ALG MIN (Visible when LSM-2020 is ena

REAR PANEL All DGC-2020 terminals and connectors are located on the rear panel. Rear panel terminals and connectors are illustrated in Figure 2-4. (To

9400200990 Rev K DGC-2020 Human-Machine Interface 2-19 Table 2-2. Rear Panel HMI Descriptions Locator Description A, D The majority of external, DG

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9400200990 Rev K DGC-2020 Functional Description i SECTION 3  FUNCTIONAL DESCRIPTION TABLE OF CONTENTS SECTION 3  FUNCTIONAL DESCRIPTION ...

ii DGC-2020 Functional Description 9400200990 Rev K AUTO Mode (Running)...

SECTION 3  FUNCTIONAL DESCRIPTION INTRODUCTION This section describes how the DGC-2020 functions. A detailed description of each function block is pr

9400200990 Rev K DGC-2020 Introduction iii REVISION HISTORY The following information provides a historical summary of the changes made to this ins

3-2 DGC-2020 Functional Description 9400200990 Rev K Zero Crossing Detection The zero crossing of A-phase to B-phase or A-phase to C-phase (user-sel

9400200990 Rev K DGC-2020 Functional Description 3-3 Coolant temperature sender connections are made at terminals 10 and 11 (sender common). Fuel Le

3-4 DGC-2020 Functional Description 9400200990 Rev K Connections for the programmable inputs are provided at terminals 15 (Input 16) through 30 (Inp

9400200990 Rev K DGC-2020 Functional Description 3-5 USB The rear-panel, mini-B USB socket enables local communication with a PC running BESTCOMSPlu

ECU Parameter Metric Units English Units Update Rate Decimal Place  SPN Total fuel used liters gallons requested 1.5 s none 250 Trip fuel liters

9400200990 Rev K DGC-2020 Functional Description 3-7 Table 3-3. Diagnostic Information Obtained Over the CANbus Interface Parameter Transmission Rep

3-8 DGC-2020 Functional Description 9400200990 Rev K 265, SD BANK 2 TEST 266, SD SPD DEMAND AN 267, SD SPDMTEST BNCH 269, SD LOAD PLS ANLG 270, SD

9400200990 Rev K DGC-2020 Functional Description 3-9 input is open (emergency stop condition), the Pre-Start, Crank, and Fuel outputs open. When the

3-10 DGC-2020 Functional Description 9400200990 Rev K Generator Exerciser The unit will start at the designated time and will run for the specified

9400200990 Rev K DGC-2020 Functional Description 3-11 The type of response given for a local request depends on the operating mode of the DGC-2020.

iv DGC-2020 Introduction 9400200990 Rev K BESTCOMSPlus Version and Date Change 2.03.00, 01/09  Added Export to File feature.  Added settings for

3-12 DGC-2020 Functional Description 9400200990 Rev K Breaker close sources are:  The DGC-2020 itself when the automatic transfer (ATS) feature is

9400200990 Rev K DGC-2020 Functional Description 3-13 Table 3-4. Event List Event String Event Description Event Type 27-1 UNDVOLT TRP A 27-1 Unde

3-14 DGC-2020 Functional Description 9400200990 Rev K Event String Event Description Event Type ATS INPUT CLOSED ATS Input Status AUTO RESTART A

9400200990 Rev K DGC-2020 Functional Description 3-15 Event String Event Description Event Type GN BKR OP FL P Generator Breaker Fail to Open Pre

3-16 DGC-2020 Functional Description 9400200990 Rev K Event String Event Description Event Type LOST ECU COMM P Loss of ECU Communication Pre-Ala

9400200990 Rev K DGC-2020 Functional Description 3-17 Event String Event Description Event Type RTD_IN_X_O2 A (X = 1 to 8) User Configurable Analo

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9400200990 Rev K DGC-2020 BESTCOMSPlus Software i SECTION 4  BESTCOMSPlus SOFTWARE TABLE OF CONTENTS TTSECTION 4  BESTCOMSPlus SOFTWARE...

ii DGC-2020 BESTCOMSPlus Software 9400200990 Rev K Frequency Protection (81O/U) ...

9400200990 Rev K DGC-2020 BESTCOMSPlus Software iii Figure 4-17. ECU Setup ...

9400200990 Rev K DGC-2020 Introduction v Firmware Package Version and Date Change 1.08.01, 01/09  Changed time dial range of 51 element fixed time

iv DGC-2020 BESTCOMSPlus Software 9400200990 Rev K Figure 4-78. Metering, Inputs, Remote Thermocouple Inputs...

SECTION 4  BESTCOMSPlus SOFTWARE INTRODUCTION BESTCOMSPlus is a Windows®-based, PC application that provides a user-friendly, graphical user interfac

Table 4-1. System Requirements for BESTCOMSPlus and the .NET Framework Component Requirement Processor 400 MHz RAM 128 MB 25 MB (if .NET Framework is

The BESTCOMSPlus splash screen is shown for a brief time. See Figure 4-3. Figure 4-3. Splash Screen The BESTCOMSPlus platform window opens. If a DG

Click on the Activate button when you are ready to enter the activation key you received from Basler Electric. The Device Needs Activated pop-up will

Figure 4-7. DGC-2020 Connection USB Communication If connecting to the DGC-2020 through a USB cable, select USB via Serial RS232, USB, and enter COM

Modem Communication If connecting to the DGC-2020 through a telephone line, select USB via Serial RS232, Modem, and enter Phone Number. To select the

10.0.0.0 - 10.255.255.255 172.16.0.0 - 172.31.255.255 192.168.0.0 - 192.168.255.255 If the LSM-2020 is operating on an isolated network, the Sub

Figure 4-10. Processing, Please Wait… MENU BARS The menu bars are located near the top of the BESTCOMSPlus screen (see Figure 4-1). The upper menu ba

Help  About... View general, detailed build, and system information Lower Menu Bar (DGC-202

vi DGC-2020 Introduction 9400200990 Rev K DGC-2020 Hardware Version and Date Change P, 01/09  Release firmware package 1.08.01 and BESTCOMSPlus 2.0

GENERAL SETTINGS General DGC-2020 settings consist of settings controlling the HMI display and indicators. Additional general settings include style n

Style Number When a PC operating BESTCOMSPlus is communicating with a DGC-2020, the style number of the DGC-2020 is automatically displayed on the BES

When on-line, read-only information includes the application versionY, boot code versionZ, application buildAA, serial numberBB, application part numb

9400200990 Rev K DGC-2020 BESTCOMSPlus Software 4-13

 OEM Access. This password level allows access to all settings. The default, OEM-access password is OEM.  Settings Access. This password level all

Figure 4-15. Clock Setup A UTC Offset (min): Adjustable from -1,440 to 1,440 minutes in increme

selected, the Fuel Solenoid output will still close during cranking and genset operation to provide a separate indication that the genset is running.

9400200990 Rev K DGC-2020 BESTCOMSPlus Software 4-17 secondary base speed is 1,800 rpm. The Accelerator Position settingC is expressed as a percenta

Figure 4-17. ECU Setup A ECU Type: Standard, Volvo Penta, MTU MDEC, MTU ADEC, or MTU ECU7. B Sp

9400200990 Rev K DGC-2020 BESTCOMSPlus Software 4-19  81O Trip Alarm  81U Trip Alarm  27-1 Trip Pre-Alarm  27-2 Trip Pre-Alarm  32 Trip Pr

9400200990 Rev K DGC-2020 Introduction vii CONTENTS SECTION 1  GENERAL INFORMATION ...

 Overspeed Alarm  Scheduled Maintenance Pre-Alarm  Switch Not in Auto  Transfer Fail Alarm  Virtual Output X Status (X = 1 to 8)  Weak Bat

Figure 4-19. RS-485 Setup A Baud Rate: A value of 1200, 2400, 4800, or 9600 may be selected. B

4-22 DGC-2020 BESTCOMSPlus Software 9400200990 Rev K immediately. Furthermore, if an Off Mode Cooldown is in progress and the OFF button is pressed,

9400200990 Rev K DGC-2020 BESTCOMSPlus Software 4-23 Single-Phase Override The DGC-2020 will switch to single-phase voltage sensingQ when a contact

Figure 4-20. System Settings A Generator Connection: Delta, Wye, 1-Phase A-B, 1-Phase A-C, or

Contact Expansion Module A J1939 AddressC must be entered when the optional CEM-2020 is enabledD. Select number of CEM-2020 outputsE. Analog Expansion

Figure 4-22. Engine Crank Settings A Cranking Style: Cycle or Continuous. B Number of Crank Cy

Exercise Timer The exercise timer is used to start the genset at a predetermined time and run for the user-defined period. The modeA defines how often

Bus Transformer Settings Primary and secondary bus transformer ratings are used by the automatic transfer switch function, which monitors a single-pha

Figure 4-26. Contact Inputs Settings A Alarm Configuration: None, Alarm, or Pre-Alarm. B Activ