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Basler DGC-2020ES Instruction Manual - Mounting

Manual is about: Digital Genset Controller

Summary of DGC-2020ES

  • Page 1

    Instruction manual for dgc-2020es digital genset controller installation publication: 9469200994 revision: — apr-17.

  • Page 3: Preface

    9469200994 rev — i dgc-2020es preface preface this instruction manual provides information about the installation of the dgc-2020es digital genset controller. To accomplish this, the following information is provided: • mounting • terminals and connectors • typical applications • power input • volta...

  • Page 4

    Ii 9469200994 rev — preface dgc-2020es 12570 state route 143 highland il 62249-1074 usa www.Basler.Com info@basler.Com tel: +1 618.654.2341 fax: +1 618.654.2351 © 2017 by basler electric all rights reserved first printing: april 2017 warning! Read this manual. Read this manual before installing, ope...

  • Page 5

    9469200994 rev — iii dgc-2020es preface this product contains, in part, open source software (software licensed in a way that ensures freedom to run, copy, distribute, study, change, and improve the software) and you are granted a license to that software under the terms of either the gnu general pu...

  • Page 6

    Iv 9469200994 rev — preface dgc-2020es.

  • Page 7: Contents

    9469200994 rev — v dgc-2020es contents contents mounting ...................................................................................................................................................... 1 hardware ....................................................................................

  • Page 8

    Vi 9469200994 rev — contents dgc-2020es csa certification ..................................................................................................................................... 28 ce compliance ..............................................................................................

  • Page 9: Mounting

    9469200994 rev — 1 dgc-2020es mounting mounting dgc-2020es controllers are delivered in sturdy cartons to prevent shipping damage. Upon receipt of a unit, check the part number against the requisition and packing list for agreement. Inspect for damage, and if there is evidence of such, immediately f...

  • Page 10

    2 9469200994 rev — mounting dgc-2020es figure 2. Overall dimensions.

  • Page 11: Terminals And Connectors

    9469200994 rev — 3 dgc-2020es terminals and connectors terminals and connectors all dgc-2020es terminals and connectors are located on the rear panel. Dgc-2020es terminals consist of a mini-b usb socket and plug-in connectors with spring clamp terminals. Figure 3 illustrates the rear panel terminals...

  • Page 12

    4 9469200994 rev — terminals and connectors dgc-2020es table 1. Rear panel terminal and connector descriptions locator description a the majority of external, dgc-2020es wiring is terminated at 8- or 15-position connectors with spring clamp terminals. These connectors plug into headers on the dgc-20...

  • Page 13

    9469200994 rev — 5 dgc-2020es terminals and connectors generator current sensing the dgc-2020es has sensing inputs for a-phase, b-phase, and c-phase generator current. A dgc- 2020es with a style number of 1xx has a 1 aac nominal current sensing and a dgc-2020es with a style number of 5xx indicates 5...

  • Page 14

    6 9469200994 rev — terminals and connectors dgc-2020es table 5. Bus voltage sensing terminals terminal description 46 (bus va) a-phase bus voltage sensing input 48 (bus vb) b-phase bus voltage sensing input 50 (bus vc) c-phase bus voltage sensing input installation in an ungrounded system applicatio...

  • Page 15

    9469200994 rev — 7 dgc-2020es terminals and connectors terminal description 6 (input 4) programmable contact input 4 7 (input 5) programmable contact input 5 8 (input 6) programmable contact input 6 9 (input 7) programmable contact input 7 output contacts the dgc-2020es has three sets of fixed-funct...

  • Page 16

    8 9469200994 rev — terminals and connectors dgc-2020es table 11. Can interface terminals terminals description 13 (can h) can high connection 14 (can l) can low connection 15 (shield) can drain connection note 1. If the dgc-2020es is providing one end of the j1939 bus, a 120 ohm, ½ watt terminating ...

  • Page 17: Typical Connections

    9469200994 rev — 9 dgc-2020es typical connections typical connections typical connection diagrams are provided in this chapter as a guide when wiring the dgc-2020es for communication, mechanical senders, contact inputs and outputs, sensing, and control power. Connections for typical applications typ...

  • Page 18

    10 9469200994 rev — typical connections dgc-2020es figure 5 illustrates typical three-phase delta generator voltage sensing connections. Figure 5. Three-phase delta connections for typical applications generator ≤ 480v 32 31 mpu+ mpu– 38 ia – 37 ia + 36 ib – 35 ib + 34 ic – 33 ic + 45 gen va 43 gen ...

  • Page 19

    9469200994 rev — 11 dgc-2020es typical connections figure 6 illustrates typical single-phase a-b generator voltage sensing connections. Figure 6. Single-phase a-b connections for typical applications generator ≤ 480v 32 31 mpu+ mpu– 38 ia – 37 ia + 36 ib – 35 ib + 34 ic – 33 ic + 45 gen va 43 gen vb...

  • Page 20

    12 9469200994 rev — typical connections dgc-2020es figure 7 illustrates typical single-phase a-c generator voltage sensing connections. Figure 7. Single-phase a-c connections for typical applications generator ≤ 480v 32 31 mpu+ mpu– 38 ia – 37 ia + 36 ib – 35 ib + 34 ic – 33 ic + 45 gen va 43 gen vb...

  • Page 21

    9469200994 rev — 13 dgc-2020es typical connections can connections typical can connections are shown in figure 8 and figure 9 . Note 1. If the dgc-2020es is providing one end of the j1939 bus, a 120 ohm, ½ watt terminating resistor should be installed across terminals 14 (canl) and 13 (canh). 2. If ...

  • Page 22

    14 9469200994 rev — typical connections dgc-2020es cem-2020 connections the cem-2020 (contact expansion module) is an optional module that may be installed with the dgc- 2020es. It is a remote auxiliary device that provides additional contact inputs and outputs for the dgc- 2020es. This module inter...

  • Page 23: Power Input

    9469200994 rev — 15 dgc-2020es power input power input control power for the dgc-2020es is typically supplied by the genset starter battery. Power from the battery is supplied to an internal power supply that provides power for dgc-2020es logic, protection, and control functions. Nominal voltage inp...

  • Page 24

    16 9469200994 rev — power input dgc-2020es.

  • Page 25: Voltage and Current Sensing

    9469200994 rev — 17 dgc-2020es voltage and current sensing voltage and current sensing the dgc-2020es senses generator voltage, generator current, and bus voltage through dedicated, isolated inputs. Generator voltage the dgc-2020es accepts either line-to-line or line-to-neutral generator sensing vol...

  • Page 26

    18 9469200994 rev — voltage and current sensing dgc-2020es note unused current sensing inputs should be shorted to minimize noise pickup. Caution generator current sensing terminals 37 (ia–), 35 (ib–), and 33 (ic–) must be terminated to ground for proper operation..

  • Page 27: Speed Signal Inputs

    9469200994 rev — 19 dgc-2020es speed signal inputs speed signal inputs the dgc-2020es uses signals from the generator voltage sensing inputs and magnetic pickup (mpu) input to detect machine speed. Magnetic pickup voltage supplied by a magnetic pickup is scaled and conditioned for use by the interna...

  • Page 28

    20 9469200994 rev — speed signal inputs dgc-2020es.

  • Page 29: Specifications

    9469200994 rev — 21 dgc-2020es specifications specifications dgc-2020es electrical and physical characteristics are listed in the following paragraphs. Control power nominal ............................................ 12 or 24 vdc range ............................................... 6 to 32 vdc te...

  • Page 30

    22 9469200994 rev — specifications dgc-2020es bus sensing configuration .................................... Line-to-line bus sensing terminals .................... 46 (a-phase) (optional with style number xx2) 48 (b-phase) 50 (c-phase) contact sensing contact sensing inputs include seven programmab...

  • Page 31

    9469200994 rev — 23 dgc-2020es specifications oil pressure sensing resistance range ............................ 5 to 250 Ω nominal terminals.......................................... 52, 2 (sender common) accuracy........................................... ±1.4 Ω or ±2.3% of actual resistance engin...

  • Page 32

    24 9469200994 rev — specifications dgc-2020es generator current (rms) generator current is measured at the secondary windings of user-supplied 1 a or 5 a cts. Metering range ................................ 0 to 5,000 aac ct primary range ........................... 1 to 5,000 aac in primary increme...

  • Page 33

    9469200994 rev — 25 dgc-2020es specifications 3-wire, line-to-line .......................... A-phase kw = v ab × i a × pf ÷ 1000 ÷ √3 b-phase kw = v bc × i b × pf ÷ 1000 ÷ √3 c-phase kw = v ca × i c × pf ÷ 1000 ÷ √3 accuracy........................................... ±5% of the full-scale indicatio...

  • Page 34

    26 9469200994 rev — specifications dgc-2020es generator protection functions overvoltage (59) and undervoltage (27) pickup range ................................... 70 to 1,000 vac pickup increment ............................. 1 vac inhibit frequency range .................. 20 to 66 hz (27 functio...

  • Page 35

    9469200994 rev — 27 dgc-2020es specifications maximum wire length ..................... 4,000 feet (1,219 meters) terminals.......................................... 11 (rdp txd+), 10 (rdp txd–) can differential bus voltage .................... 1.5 to 3 vdc maximum voltage .............................

  • Page 36

    28 9469200994 rev — specifications dgc-2020es shock withstands 15 g in three perpendicular planes. Vibration tested in three mutually perpendicular planes for 8 hours over the following ranges: 3 to 25 hz at 0.063 inches (1.6 mm), peak amplitude 25 to 2,000 hz at 5g radio interference type tested us...

  • Page 37

    9469200994 rev — 29 dgc-2020es specifications ce compliance this product has been evaluated and complies with the relevant essential requirements set forth in the following ec directives and by the eu legislation: • low voltage devices (lvd) - 2014/35/eu • electromagnetic compatibility (emc) - 2014/...

  • Page 38

    30 9469200994 rev — specifications dgc-2020es.

  • Page 39: Maintenance

    9469200994 rev — 31 dgc-2020es maintenance maintenance preventive maintenance consists of periodically checking that the connections between the dgc-2020es and the system are clean and tight. Periodically check that the mounting hardware is clean and fastened with the proper amount of torque. Dgc-20...

  • Page 40

    32 9469200994 rev — maintenance dgc-2020es.

  • Page 41: Troubleshooting

    9469200994 rev — 33 dgc-2020es troubleshooting troubleshooting if you do not get the results that you expect from the dgc-2020es, first check the programmable settings for the appropriate function. Use the following troubleshooting procedures when difficulties are encountered in the operation of you...

  • Page 42

    34 9469200994 rev — troubleshooting dgc-2020es differences may manifest themselves as erratic sender readings. Wiring should be corrected so that no differences exist. Step 6: check the sender wiring and isolate sender wiring from any of the ac wiring in the system. The sender wiring should be locat...

  • Page 43

    9469200994 rev — 35 dgc-2020es troubleshooting step 2: perform insulation resistance tests on the system wiring to check for insulation integrity in the overall system. Step 3: if ground faults are detected on a dgc-2020es in an ungrounded system application, it is recommended that potential transfo...

  • Page 44

    36 9469200994 rev — troubleshooting dgc-2020es metering explorer. Never turn open and close on at the same time. This could damage the breaker and/or motor operator. If everything is working as expected, restore the logic to its original diagram. Generator breaker does not open when it should step 1...

  • Page 45

    9469200994 rev — 37 dgc-2020es troubleshooting open and close outputs from the gen breaker block in the programmable logic. Map a virtual switch to the logic output that would normally be the breaker close output. Map another virtual switch to the logic output that would normally be the breaker clos...

  • Page 46

    38 9469200994 rev — troubleshooting dgc-2020es.

  • Page 47: Revision History

    9469200994 rev — 39 dgc-2020es revision history revision history table 16 provides a historical summary of the changes made to the dgc-2020es hardware. Firmware changes are listed in table 17 and software changes are listed in table 18. The corresponding revisions made to this instruction manual are...

  • Page 48

    40 9469200994 rev — revision history dgc-2020es firmware version and date change • changed to prevent oil pressure crank disconnect from operating if there is a valid rpm source • removed the letter "dpf" from dpf regenerate required and dpf regeneration inhibited strings • added selective catalytic...

  • Page 49

    9469200994 rev — 41 dgc-2020es revision history software version and date change 3.05.02, jan-14 • maintenance release (be1-11 changes) 3.05.03, mar-14 • maintenance release (dgc-2020hd changes) 3.06.00, apr-14 • maintenance release (be1-11 changes) 3.07.00, oct-14 • updated to support firmware vers...

  • Page 50

    42 9469200994 rev — revision history dgc-2020es.

  • Page 52

    12570 route 143 highland il 62249-1074 usa tel: +1 618.654.2341 fax: +1 618.654.2351 email: info@basler.Com no. 59 heshun road loufeng district (n) suzhou industrial park 215122 suzhou p.R. China tel: +86 512.8227.2888 fax: +86 512.8227.2887 email: chinainfo@basler.Com 111 north bridge road 15-06 pe...