Winco DGC-500 User Manual

INSTRUCTION MANUALforDGC-500DIGITAL GENSET CONTROLLERPublication: 9 3554 00 990Revision: D 03/04

DGC-500 General Information 1-3SPECIFICATIONSCurrent SensingAccuracy: ±1% of full scale or ±2 A,whichever is greaterBurden: 1 VATerminals: P10, P11 (A

DGC-500 General Information1-4WARNING! – EXPLOSION HAZARD(9 3554 00 113 and 9 3554 00 114 only)Substitution of components may impair suitabilityfor Cl

DGC-500 HMI iSECTION 2 • HUMAN-MACHINE INTERFACETABLE OF CONTENTSSECTION 2 • HUMAN-MACHINE INTERFACE ... 2-1IN

DGC-500 HMI 2-1Figure 2-1. DGC-500 Front Panel HMISECTION 2 • HUMAN-MACHINE INTERFACEINTRODUCTIONThis section describes the components of the DGC-500

DGC-500 HMI2-2Table 2-1. DGC-500 Front Panel HMI DescriptionsCall-Out DescriptionA Liquid Crystal Display. The backlit, two line by 16 character LCD i

DGC-500 HMI 2-3Figure 2-2. DGC-500 Rear Panel HMITable 2-2. DGC-500 Rear Panel HMI DescriptionsCall-Out Terminals DescriptionAP22 CHASSIS GND. This te

Call-Out Terminals DescriptionDGC-500 HMI2-4DP39 (+), P40 (–)P13P16P18P19Transducer TerminalsMPU. These terminals accept the output from a magnetic pi

Call-Out Terminals DescriptionDGC-500 HMI2-5KP5 (+), P6 (–)P8 (A), P9 (B)Remote Display TerminalsPower. These terminals provide operating power to th

DGC-500 Functional Description iSECTION 3 • FUNCTIONAL DESCRIPTIONTABLE OF CONTENTSSECTION 3 • FUNCTIONAL DESCRIPTION ...

DGC-500 Functional DescriptioniiActive DTC ...3-10CAN Failure ...

DGC-500 Introduction iWARNING!To avoid personal injury or equipment damage, only qualified personnel shouldperform the procedures presented in this ma

DGC-500 Functional Description iiiFiguresFigure 3-1. DGC-500 Function Block Diagram ... 3-1Figure 3-2. Displa

DGC-500 Functional Description 3-1Figure 3-1. DGC-500 Function Block DiagramSECTION 3 • FUNCTIONAL DESCRIPTIONINTRODUCTIONThis section describes how t

DGC-500 Functional Description3-2Circuits relating to the microprocessor inputs are described in the following paragraphs.Zero Crossing DetectionThe z

DGC-500 Functional Description 3-3software allows for the programming of sender characteristics. See Section 4, BESTCOMS Software for moreinformation.

DGC-500 Functional Description3-4LEDsThe LEDs indicate pre-alarm and alarm conditions along with DGC-500 status and generator status.PushbuttonsThe pu

DGC-500 Functional Description 3-5Table 3-1. ECU Parameters Obtained from CAN InterfaceECU ParameterMetricUnitsEnglishUnitsUpdateRateDecimalPlacetSPNT

DGC-500 Functional Description3-6CAUTIONWhen the CAN interface is enabled, the DGC-500 will ignore the followingsender inputs: oil pressure, coolant t

DGC-500 Functional Description 3-7Table 3-3. Diagnostic Information Obtained Over the CAN InterfaceParameterTransmissionRepetition RateActive diagnost

DGC-500 Functional Description3-8NOTEThe run-time counter and maintenance timer values are updated in volatile memory once perminute. Updated values a

DGC-500 Functional Description 3-9Continuous CrankingIf desired, engine cranking can be delayed from zero to 30 seconds after initiating engine startu

ii DGC-500 IntroductionCONFIDENTIAL INFORMATIONOf Basler Electric. It is loaned for confidential use, subject to return on request,and with the mutual

DGC-500 Functional Description3-10Weak Battery VoltageA weak battery voltage pre-alarm occurs when the battery voltage decreases below the weak batter

DGC-500 Functional Description 3-11Low Oil PressureA low oil pressure alarm occurs when the engine oil pressure decreases below the low oil pressure a

DGC-500 Functional Description3-12Figure 3-2. Display Mode NavigationCAN Failure (If Equipped)A CAN failure annunciation may be enabled only when the

DGC-500 Functional Description 3-13Figure 3-3. Alternate Mode Navigation1. ENG STOP LAMP ON2. WARNING LAMP ON3. MALFUNC LAMP ON4. PROTECT LAMP ON5. NO

DGC-500 Functional Description3-14NOTEAlways refer to the engine manual for the meaning of SPN and FMI combinations,especially for proprietary DTC des

DGC-500 Functional Description 3-15Figure 3-6. ECU Parameters Navigation9. Total fuel used10. Engine coolant temperature t11. Fuel temperature12. Engi

DGC-500 Functional Description3-16Figure 3-7. Engine Configuration Menu NavigationEngine Configuration ParametersEngine configuration parameters can b

DGC-500 Functional Description 3-17Figure 3-8. Menu Mode NavigationMenu ModePress the Select/Enter pushbutton while viewing the top-level Menu mode sc

DGC-500 Functional Description3-18Figure 3-9. Menu 1 Navigation

DGC-500 Functional Description 3-19Figure 3-10. Menu 2 Navigation

DGC-500 Introduction iiiPRODUCT REVISION HISTORYThe following information provides a historical summary of the changes made to the embedded firmware,c

DGC-500 Functional Description3-20Figure 3-11. Menu 3 Navigation

DGC-500 Functional Description 3-21Figure 3-12. Menu 4 Navigation

DGC-500 Functional Description3-22Figure 3-13. SettingChange ExampleChanging SettingsA setting change consists of the following steps. The number of e

DGC-500 Functional Description 3-23NOTEWith Enable ECU Support selected, there is a non-programmable Coolant LevelSender Fail alarm that can annunciat

DGC-500 Functional Description3-24NOTEWhen ECU support is enabled during Pre-start and Resting, the fuel solenoid isclosed.Figure 3-14. Screens Shown

DGC-500 Functional Description 3-25System ConfigurationC RUN, OFF and AUTO are selectable through the front panel HMI and OFF and AUTO are selectablet

DGC-500 Functional Description3-26Figure 3-15. Normal Program Control DiagramFigure 3-16. ECU Power Support Program Control DiagramNOTEECU power suppo

DGC-500 Functional Description 3-27Figure 3-17. Power Up/Reset State DiagramAfter a short time, the old system configuration from the last time the un

DGC-500 Functional Description3-28Figure 3-18. Ready State DiagramFigure 3-19. Pulsing State DiagramPulsing StateThe Pulsing State follows the sequenc

DGC-500 Functional Description 3-29Figure 3-20. Connecting State DiagramFigure 3-21. Pre-Start State DiagramPre-Start StateThis state will transition

iv DGC-500 IntroductionHardware Version(Special Order P/N) SummaryD - 10/03C Implemented firmware version 2.04.XX and BESTCOMS version 1.03.XXC - 09/0

DGC-500 Functional Description3-30Figure 3-22. Cranking State DiagramFigure 3-23. Resting State DiagramResting StateIf the rest period has ended, the

DGC-500 Functional Description 3-31Figure 3-24. Running State DiagramFigure 3-25. Cooling State DiagramCooling StateThis state is available only if th

DGC-500 Functional Description3-32Figure 3-26. Shutting Down State DiagramFigure 3-27. Alarm State DiagramNOTEWith ECU Support enabled, if an alarm wa

DGC-500-500 BESTCOMS Software iSECTION 4 • BESTCOMS SOFTWARETABLE OF CONTENTSSECTION 4 • BESTCOMS SOFTWARE...

DGC-500 BESTCOMS SoftwareiiFigures - continuedFigure 4-10. Pre-Alarms Screen Maint. Interv.-Hi Cool Tab ...4-7Figure 4

DGC-500 BESTCOMS Software 4-1Figure 4-1. Basler Electric Folder ContentsSECTION 4 • BESTCOMS SOFTWAREINTRODUCTIONBESTCOMS-DGC500-32 software provides

DGC-500 BESTCOMS Software4-2Figure 4-3. Sensing Transformers ScreenFigure 4-4.Communication Initiation ScreenFigure 4-5. Password Dialog BoxEstablishi

DGC-500 BESTCOMS Software 4-3CHANGING SETTINGSDGC-500 settings are arranged into six groups.C Sensing TransformersC Pre-AlarmsC AlarmsC Engine Crankin

DGC-500 BESTCOMS Software4-4Figure 4-6. Sensing Transformers ScreenPre-AlarmsClick the Pre Alarm button to access the Pre-Alarms screen or click Scree

DGC-500 BESTCOMS Software 4-5Figure 4-7. Pre-Alarm Screen, Low Fuel-Low Cool-Batt. OverVolt TabFigure 4-8. Pre-Alarm Screen, Low Oil-Low Batt Volt-Wea

DGC-500 Introduction vCONTENTSSECTION 1 • GENERAL INFORMATION... 1-1SECTION 2 • HUMAN-MACHINE INTERFACE .

DGC-500 BESTCOMS Software4-6Figure 4-9. Pre-Alarms Screen, Audible-Battery Charger-Fuel Level Sender TabLow Oil Pressure Pre-Alarm - Threshold (PSI).

DGC-500 BESTCOMS Software 4-7Figure 4-10. Pre-Alarms Screen, Maint. Interv.-Hi Cool TabMaint. Interv.-Hi Cool TabThe Maint. Interv.-Hi Cool Tab settin

DGC-500 BESTCOMS Software4-8Figure 4-11. Alarms Screen, Hi Cool-Low Fuel-Low Oil TabHi Cool Temperature Alarm - Threshold (Deg F). This setting select

DGC-500 BESTCOMS Software 4-9Figure 4-12. Alarms Screen, Overspeed-Sender Fail TabOverspeed Alarm - Alarm Activation (MilliSecond). This setting adjus

DGC-500 BESTCOMS Software4-10Figure 4-13. Engine Cranking ScreenPre-Crank Delay (Sec). This setting adjusts the time delay between initiating engine s

DGC-500 BESTCOMS Software 4-11Figure 4-14. System Settings ScreenRated Engine RPM. This setting selects the rated rotating speed of the engine. A valu

DGC-500 BESTCOMS Software4-12Figure 4-15. Settings Screen, Input Setup TabCANBus/J1939 Interface - Enable ECU Support. This setting enables and disabl

DGC-500-500 BESTCOMS Software 4-13Figure 4-16. Settings Screen, Output Setup TabProgrammable Input - Alarm/Pre-Alarm. Either of these check boxes can

DGC-500 BESTCOMS Software4-14Figure 4-17. Programmable Senders Screen, Coolant Temperature TabPROGRAMMABLE SENDERSClick Configure on the menu bar and

DGC-500-500 BESTCOMS Software 4-15NOTEWhen metric values are used and changes are made to the oil pressure senderdata points, undesirable internal rou

DGC-500 General Information iSECTION 1 • GENERAL INFORMATIONTABLE OF CONTENTSSECTION 1 • GENERAL INFORMATION...

DGC-500 BESTCOMS Software4-16Figure 4-19. CommunicationsConfigure Dialog BoxFigure 4-20. ECU Timers Menu SelectionSaving Settings FilesSaving DGC-500

DGC-500-500 BESTCOMS Software 4-17Figure 4-21. ECU Timers Dialog BoxFigure 4-22. ChangePassword Dialog BoxEngine Shut Down (Sec.). When going from Run

DGC-500 BESTCOMS Software4-18CAUTIONIf power is lost or communication is interrupted during file transfer, the DGC-500will not recover and will cease

DGC-500-500 BESTCOMS Software 4-19Figure 4-24. Firmware File InformationFigure 4-25. File Transfer Status3. Click the Select New Application Code butt

DGC-500 Installation iSECTION 5 • INSTALLATIONTABLE OF CONTENTSSECTION 5 • INSTALLATION... 5-1GE

DGC-500 Installation 5-1Figure 5-1. DGC-500 Cutout DimensionsSECTION 5 • INSTALLATIONGENERALDGC-500 Digital Genset Controllers are delivered in sturdy

DGC-500 Installation5-2Figure 5-2. DGC-500 Overall DimensionsDGC-500 Isolator KitThe optional DGC Isolator Kit provides an economical way to reduce th

DGC-500 Installation 5-3NOTEBe sure that the DGC-500 is hard-wired to earth ground with no smaller than 12AWG copper wire attached to the chassis grou

DGC-500 Installation5-4Figure 5-4. Personal Computer to DGC-500 ConnectionsFigure 5-5. CAN Cable AssemblyCAN ConnectionsThe CAN connector (J2) on the

DGC-500 Installation 5-5Figure 5-6. Typical DGC-500 CAN Interface ConnectionsDGC-500 Connections for Typical ApplicationsFigures 5-7 through 5-9 illus

DGC-500 General Information 1-1SECTION 1 • GENERAL INFORMATIONDESCRIPTIONThe DGC-500 Digital Genset Controller provides integrated engine-generator se

DGC-500 Installation5-6P4P3P2P37P35ProgrammableOutput 2ProgrammableOutput 1Pre-StartFuelCrankGENERATORCIRCUITBREAKERP17P14 P11STARTSOLENOIDSOLENOIDFUE

DGC-500 Installation 5-7P4P3P2P37P35ProgrammableOutput 2ProgrammableOutput 1Pre-StartFuelCrankGENERATORCIRCUITBREAKERP17 P14 P11STARTSOLENOIDSOLENOIDF

DGC-500 Installation5-8P4P3P2P37P35ProgrammableOutput 2ProgrammableOutput 1Pre-StartFuelCrankGENERATORCIRCUITBREAKERP17 P14 P11STARTSOLENOIDSOLENOIDFU

DGC-500 Installation 5-9Volvo Penta EDC ApplicationsEngines equipped with Volvo Penta EDC controllers can receive engine control commands (such as sta

DGC-500 Installation5-101 2 3 4 5P4P3P2P37P35ProgrammableOutput 2ProgrammableOutput 1Pre-StartGENERATORCIRCUITBREAKERP17P14 P11P36 P38P33 P34E

DGC-500 Installation 5-111 2 3 4 5P4P3P2P37P35ProgrammableOutput 2ProgrammableOutput 1Pre-StartP17 P14 P11P36 P38P33 P34EmergencyStopProgramma

DGC-500 Installation5-121 2 3 4 5P4P3P2P37P35ProgrammableOutput 2ProgrammableOutput 1Pre-StartP17 P14 P11P36 P38P33 P34EmergencyStopProgrammab

DGC-500 Installation 5-13Figure 5-13. Calibration Mode NavigationFigure 5-14. Successful and Unsuccessful Calibration ScreensCALIBRATIONPrior to deliv

DGC-500 Installation5-144. Press the Raise/Scroll pushbutton. The screen at right is displayed. Apply2 Aac to the current sensing inputs for phase A (

DGC-500 Installation 5-1520. Press the Raise/Scroll pushbutton. The screen at right is displayed.Connect a resistance of 125 ohms across the oil pres

DGC-500 General Information1-2Figure 1-1. DGC-500 Style Number ChartSTYLE AND PART NUMBERSStandard-order DGC-500 controllers are identified by a style

DGC-500 Maintenance and Troubleshooting 6-1SECTION 6 • MAINTENANCE AND TROUBLESHOOTINGPREVENTATIVE MAI

DGC-500 Maintenance and Troubleshooting6-2Programmable Inputs Do Not Operate as ExpectedStep 1. Verify that all wiring is properly connected. Refer to

DGC-500 Appendix A-1APPENDIX A • PARAMETERS AND SETTINGSINTRODUCTIONThis appendix lists all DGC-500 parameters along with the setting range/selections

Parameter Setting RangeDGC-500 AppendixA-2Crank Disconnect Limit 10 - 100%Cranking Style Continuous or CycleCycle Crank Time 5 - 15 secDTC Support On

Parameter Setting RangeDGC-500 AppendixA-3Low Fuel Level Alarm Threshold 0 - 100%Low Fuel Level Pre-Alarm Enable On or OffLow Fuel Level Pre-Alarm Lev

DGC-500 Appendix B-1APPENDIX B • DGC-500 SETTINGS RECORDINTRODUCTIONThis appendix provides a complete list of DGC-500 settings. This list is provided

DGC-500 AppendixB-2DGC-500 SETTINGS RECORDGenset ID Date DGC-500 Serial Number Firmware Version Sensing Transformer SettingsParameter SettingGenerat

DGC-500 Appendix B-3Pre-Alarm SettingsParameter SettingBattery Charger Failure Pre-Alarm EnableBattery Overvoltage Pre-Alarm EnableBattery Overvoltage

DGC-500 AppendixB-4Alarm Settings – ContinuedParameter SettingLow Fuel Level Alarm EnableLow Fuel Level Alarm ThresholdLow Oil Pressure Alarm EnableLo