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Basler DGC-500 Instruction Manual

Manual is about: DIGITAL GENSET CONTROLLER

Summary of DGC-500

  • Page 1

    Instruction manual for digital genset controller dgc-500 publication: 9355400990 revision: h 02/14.

  • Page 3: Introduction

    Introduction this instruction manual provides information about the operation and installation of the dgc-500 digital genset controller. To accomplish this, the following information is provided: • general information and specifications • controls and indicators • functional description • communicat...

  • Page 4

    First printing: march 2002 printed in usa © 2014 basler electric, highland illinois 62249 usa all rights reserved february 2014 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 installa...

  • Page 5: Revision History

    Revision history the following information provides a historical summary of the changes made to the dgc-500 hardware, firmware, and software. The corresponding revisions made to this instruction manual (9355400990) are also summarized. Revisions are listed in reverse chronological order. Bestcoms so...

  • Page 6

    Hardware (standard order p/n) version and date change k, 09/03 • added reference to instruction manual on parts list. J, 07/03 • implemented firmware version 2.03.Xx and bestcoms version 1.02.Xx. H, 06/03 • circuit board layout revised to improve manufacturing process. G, 04/02 • initial release har...

  • Page 7

    Manual revision and date change c, 09/03 • added descriptions associated with new settings: canbus address, engine stop/start configuration, and genset’s kw rating. • added information pertaining to dgc isolator kits. • added volvo penta edc application information and diagrams. • updated pre-alarm ...

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  • Page 9: Contents

    Contents section 1 • general information ................................................................................................ 1-1 section 2 • human-machine interface ....................................................................................... 2-1 section 3 • functional descrip...

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  • Page 11: Section 1

    Section 1 • general information table of contents section 1 • general information ................................................................................................ 1-1 description.............................................................................................................

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  • Page 13: Section 1

    Section 1 • general information description the dgc-500 digital genset controller provides integrated engine-generator set control, protection, and metering in a single package. Microprocessor based technology allows for exact measurement, setpoint adjustment, and timing functions. Front panel contr...

  • Page 14

    Applications that require remote annunciation can use the remote display panel, rdp-110. This display panel annunciates all dgc-500 alarms, pre-alarms, and operating conditions. Style and part numbers standard-order dgc-500 controllers are identified by a style number. Special-order dgc-500 controll...

  • Page 15

    Table 1-1. Special-order dgc-500 controllers part number style number special features 9355400111 f5j0 400 hz nominal frequency 9355400112 f1j0 9355400127 f5j1 9355400128 f1j1 9355400113 f5j0 curus recognized for use in hazardous locations 9355400114 f1j0 9355400129 f5j1 9355400130 f1j1 specificatio...

  • Page 16

    Engine system inputs ∗ stated accuracies are subject to the accuracy of the senders used. Fuel level sensing accuracy: ±3% of indication or ±2% ∗ range: 33 to 240 Ω nominal terminals: p16, p19 (common) coolant temperature sensing accuracy: ±3% of indication (37°c to 115°c (99°f to 239°f)) ±2°, which...

  • Page 17

    Underfrequency (81u) and overfrequency (81o) pickup range: 45 to 65 hz (50/60 hz nominal) 360 to 440 hz (400 hz nominal) pickup increment: 0.1 hz inhibit voltage range: 70 to 576 vac (applies to 81u function only) time delay range: 0 to 30 s time delay increment: 0.1 s overcurrent (51) pickup range:...

  • Page 18

    Environment temperature range operating: –20 to 60 °c (–4 to 140°f) storage: –40 to 85 °c (–40 to 185°f) type tests 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 ...

  • Page 19

    Nfpa compliance all dgc-500 controllers comply with nfpa standard 110, standard for emergency and standby power systems. Physical weight: 680 g (1.5 lb) 9355400990 rev h dgc-500 general information 1-7.

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  • Page 21: Section 2

    Section 2 • human-machine interface table of contents section 2 • human-machine interface ....................................................................................... 2-1 introduction.............................................................................................................

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  • Page 23: Section 2

    Section 2 • human-machine interface introduction this section describes the components of the dgc-500 human-machine interface (hmi). Dgc-500 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 f...

  • Page 24

    Table 2-1. Front panel hmi descriptions call- out description a liquid crystal display. The backlit, two line by 16 character lcd is the primary interface for metering, alarms, pre-alarms, and protective functions. The lcd has three standard display modes (normal, alternate, and menu) and one option...

  • Page 25

    Figure 2-2. Rear panel hmi 9355400990 rev h dgc-500 human-machine interface 2-3.

  • Page 26

    Table 2-2. Rear panel hmi descriptions call- out terminals description a p22 chassis gnd. This terminal provides the chassis ground connection. The dgc-500 must be hard-wired to earth ground with no smaller than 12 awg copper wire. B p20 (+, p21 (–) batt. Dgc-500 operating power is applied to these ...

  • Page 27

    Call- out terminals description h j2 sae j1939 connector. This connector is enabled on controllers with a style number of fxj and provides high-speed communication between the dgc-500 and the ecu on an electronically controlled engine. I j1 rs-232 communication port. This db9 connector uses serial c...

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  • Page 29: Section 3

    Section 3 • functional description table of contents section 3 • functional description ........................................................................................... 3-1 introduction...........................................................................................................

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    Running state ................................................................................................................................... 3-34 cooling state .................................................................................................................................... 3-...

  • Page 31: Section 3

    Section 3 • functional description introduction this section describes how the dgc-500 functions and explains its operating features. A detailed description of each function block is provided in the paragraphs under the heading of dgc-500 function blocks. Dgc-500 operating features are described und...

  • Page 32

    Analog-to-digital converter scaled and conditioned signals representing the sensing voltage, sensing current, coolant temperature, fuel level, oil pressure, and battery voltage are digitized by the microprocessor’s 10-bit analog-to-digital converter. The digitized information is stored in random acc...

  • Page 33

    Speed signal inputs the dgc-500 uses signals from the voltage sensing inputs and magnetic pickup input to detect machine speed. Voltage sensing inputs generator voltage applied to the dgc-500 voltage sensing inputs is used to measure frequency and can be used to measure machine speed. Sensing voltag...

  • Page 34

    Remote display panel applications that require remote annunciation can use basler electric’s remote display panel, rdp-110. Using the rdp-110 with the dgc-500 meets the requirements of nfpa standard 110. The rdp-110 uses a standard, two-terminal rs-485 interface to communicate with the dgc-500 and r...

  • Page 35

    Table 3-1. Ecu parameters obtained from can interface ecu parameter metric units english units update rate decimal place spn ∗ throttle (accelerator pedal) position % % 50 ms 10 th 91 percent load at current rpm % % 50 ms none 92 actual engine percent torque % % engine speed dependent none 513 engin...

  • Page 36

    Table 3-2. Engine configuration parameters obtained from can interface engine configuration parameter ∗ metric units english units update rate decimal place spn † engine speed at idle point 1 rpm rpm 5 s none 188 percent torque at idle point 1 % % 5 s none 539 engine speed at point 2 rpm rpm 5 s non...

  • Page 37

    Table 3-3. Diagnostic information obtained over the can interface parameter transmission repetition rate active diagnostic trouble code 1 s lamp status 1 s previously active diagnostic trouble code on request request to clear previously active dtcs on request request to clear active dtcs on request ...

  • Page 38

    Programmable two programmable outputs (program output1, 2) can be user-configured to close for a variety of conditions. Either programmable output can be programmed to close during any of the following operating conditions. • cooldown timer active • eps supplying load • pre-start condition in effect...

  • Page 39

    Continuous cranking if desired, engine cranking can be delayed from zero to 30 seconds after initiating engine startup. When continuous engine cranking is initiated, cranking is sustained for a user-adjustable period of one to 60 seconds. A crank disconnect limit setting (10 to 100% of nominal engin...

  • Page 40

    Bestcoms. The weak battery voltage setpoint has a setting range of 8 to 16 vdc for 24 vdc systems and 4 to 8 vdc for 12 vdc systems. The weak battery voltage time delay has a setting range of 1 to 10 seconds. Maintenance interval a maintenance interval pre-alarm occurs when the dgc-500 maintenance t...

  • Page 41

    Low fuel level a low fuel level alarm occurs when the fuel level decreases below the setpoint programmed in bestcoms. When a low fuel level alarm occurs, the lcd indicates low fuel level and the current low fuel level alarm setting. The low fuel level setpoint has a setting range of zero to 100 perc...

  • Page 42

    Generator run statistics the dgc-500 compiles statistics for both individual generator run sessions and the cumulative total of all generator run sessions. Generator run statistics are stored in dgc-500 nonvolatile memory and displayed on the run statistics screen of bestcoms. When the dgc-500 and/o...

  • Page 43

    Corresponding 59 time delay, an overvoltage condition is annunciated. Both overvoltage pickup settings have a range of 70 to 576 vac and both overvoltage time delay settings have a range of 0 to 30 seconds. An overvoltage annunciation can be user-selected to trigger a pre-alarm (warning) or alarm (s...

  • Page 44

    • d, definite • m, moderately inverse • i1, inverse • i2, inverse • v1, very inverse • v2, very inverse • e1, extremely inverse • e2, extremely inverse • a, standard inverse • b, very inverse • c, extremely inverse • g, long inverse an overcurrent annunciation can be user-selected to trigger a pre-a...

  • Page 45

    Figure 3-3. Alternate mode navigation diagnostic trouble codes (dtcs) when the optional sae j1939 communication is enabled, access to the diagnostic trouble codes (dtcs) is available through the alternate display mode. The dtcs are the last two screens in the alternate mode display list. If there ar...

  • Page 46

    To be notified that a lamp status exists, the pre-alarm for active dtcs must be enabled through bestcoms. When one or more active dtcs exist in the ecu, a lamp status indicating the severity of the combined dtcs should exist. After the pre-alarm is annunciated (by led indicator, horn, and/or dial-ou...

  • Page 47

    The following list includes all of the engine system monitoring parameters read from the ecu (if supported) in the order in which they appear when pressing the raise/scroll pushbutton, having started from the ecu parameters menu. 1. Throttle position 2. Percent load at current rpm 3. Actual engine p...

  • Page 48

    Figure 3-6. Ecu parameters navigation engine configuration parameters engine configuration parameters can be accessed from the ecu parameters menu. To view these parameters read from the ecu, press the select/enter pushbutton while viewing the engine configuration (engine config.) screen. The follow...

  • Page 49

    Figure 3-7. Engine configuration menu navigation menu mode press the select/enter pushbutton while viewing the top-level menu mode screen (shown in figure 3-2), to access the four menu branches illustrated in figure 3-8. Press the lower/scroll or raise/scroll pushbuttons to view the top of each menu...

  • Page 50

    Menu 1 dgc-500 pre-alarms and alarms are viewed and configured in menu 1. Figure 3-9 illustrates the menu 1 screens. Menu 2 system configuration settings are viewed and configured in menu 2. Figure 3-10 illustrates the menu 2 screens. Menu 3 dgc-500 calibration, transformer ratios, and transducer fa...

  • Page 51

    Figure 3-9. Menu 1 navigation 9355400990 rev h dgc-500 functional description 3-21.

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    Figure 3-10. Menu 2 navigation 3-22 dgc-500 functional description 9355400990 rev h.

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    Figure 3-11. Menu 3 navigation 9355400990 rev h dgc-500 functional description 3-23.

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    Figure 3-12. Menu 4 navigation figure 3-13. Menu 5 navigation 3-24 dgc-500 functional description 9355400990 rev h.

  • Page 55

    Changing settings a setting change generally consists of the following steps. The number of each step corresponds to the numbered call-outs in the setting change example of figure 3-14. 1. Use the hmi pushbuttons to navigate to the screen of the setting to be changed. 2. Press the select/enter key t...

  • Page 56

    Front panel adjustable parameters most dgc-500 settings can be viewed at the front panel display. The settings that can be adjusted at the front panel are listed in table 3-4. With the exception of the time and date, all of the listed settings are protected by the front-panel key code. Table 3-4. Fr...

  • Page 57

    The dgc-500 solution the dgc-500 resolves ecu constraints by using four user-programmable timers that are accessed through bestcoms. Each timer setting is described in the following paragraphs. Pulse cycle time. This timer setting establishes the time, in minutes, that the dgc-500 waits before pulsi...

  • Page 58

    Ecus with an external fuel solenoid the dgc-500 supports ecus that are able to cut-off fuel from the engine without powering the ecu off. The dgc-500 requests engine run-time every minute to keep the ecu from going into a sleep mode. After the pulse cycle timer expires, the dgc-500 checks whether ec...

  • Page 59

    • cranking. Cranks the engine until it is above the crank disconnect speed. • resting. Occurs between crank cycles and does not crank the engine. • running. The unit is now running and no longer cranking. • cooling. Cool down running engine if a load is or was applied when going to auto-off mode. • ...

  • Page 60

    Figure 3-17. Ecu power support program control diagram initial state - power up/reset this state begins after cycling power to the dgc-500, or after a software reset (i.E. A watchdog timeout) has occurred. The unit will stay in reset for a short time. During this time, the firmware version number ap...

  • Page 61

    Figure 3-18. Power up/reset state diagram ready state the dgc-500 will be in ready state when system configuration is off/auto-off. If the system configuration changes to run/auto-run, then it will check to see if it needs to go to the connecting, pre- start or running state. If ecu support is selec...

  • Page 62

    Pulsing state the pulsing state follows the sequence of events shown in figure 3-20. The pulsing state will momentarily power up the ecu to update the dgc-500 internal variables. Once a connection is established with the ecu, gathering data will appear on the lcd for the duration of the settling tim...

  • Page 63

    Figure 3-22. Pre-start state diagram cranking state this state will engage the starter and transition to the running state once engine speed is above crank- disconnect. During the cranking state, the crank-type is checked. If the crank-type is cycle crank, then the unit will transition to the restin...

  • Page 64

    Figure 3-24. Resting state diagram running state if the system configuration changes to off/auto-off, then the unit transitions to the cooling state. If system configuration is set to auto-run, then the cool-down timer is reset or incremented here if a load is applied and removed from the engine. If...

  • Page 65

    Figure 3-26. Cooling state diagram shutting down state the shutting down state follows the sequence of events shown in figure 3-27. If the engine shut down timer expires, the unit transitions to the ready state. If system configuration changes back to run/auto- run, then this state will transition t...

  • Page 66

    Figure 3-28. Alarm state diagram 3-36 dgc-500 functional description 9355400990 rev h.

  • Page 67: Section 4

    Section 4 • bestcoms software table of contents section 4 • bestcoms software .................................................................................................. 4-1 introduction..............................................................................................................

  • Page 68

    Figure 4-19. Generator protection scree, 27 tab ................................................................................... 4-17 figure 4-20. Generator protection screen, 59 tab ................................................................................. 4-18 figure 4-21. Generator prot...

  • Page 69: Section 4

    Section 4 • bestcoms software introduction dgc-500 bestcoms software provides a user-friendly communication link between the dgc-500 and the user. An ibm-compatible pc running bestcoms can be used to configure the following parameters. • sensing transformer ratios • programmable contact inputs and p...

  • Page 70

    Establishing communication communication between bestcoms and the dgc-500 must be established before reading or changing settings. Bestcoms screen settings are updated only after communication is opened or the communication settings have been changed. Open the dgc-500 communication port by clicking ...

  • Page 71

    Sending and receiving settings when communication is enabled, dgc-500 settings can be sent or received through bestcoms. Sending settings setting changes are sent to the dgc-500 by clicking the send settings button. This causes all settings to become the dgc-500 settings. Settings can also be sent t...

  • Page 72

    Pre-alarms click the pre alarm button to access the pre-alarms screen or click screens on the menu bar and click pre-alarm settings. The pre-alarms screen consists of five tabs: low fuel-low cool-batt. Overvolt., low oil-low batt volt- weak batt volt, audible-battery charger-fuel level sender, maint...

  • Page 73

    Low oil-low batt volt-weak batt volt tab the low oil-low batt volt-weak batt volt tab settings are shown in figure 4-7. Each tab setting is described in the following paragraphs. Figure 4-7. Pre-alarm screen, low oil-low batt volt-weak batt volt tab low oil pressure pre-alarm - enable. This setting ...

  • Page 74

    Figure 4-8. Pre-alarms screen, audible-fuel level sender tab audible alarm. This setting enables and disables an audible pre-alarm and alarm annunciation. Fuel level sender failure pre-alarm. This setting enables and disables annunciation of a fuel level sender failure pre-alarm. Maint. Interv.-hi c...

  • Page 75

    Maintenance interval pre-alarm - enable. This setting enables and disables annunciation of a maintenance interval pre-alarm. Maintenance interval pre-alarm - threshold (hours). This setting selects the length of the maintenance interval. An interval of zero to 5,000 hours may be selected. Refer to t...

  • Page 76

    Figure 4-11. Alarms screen, hi cool-low fuel-low oil tab hi cool temperature alarm - alarm enable. This setting enables and disables annunciation of a high coolant temperature alarm and engine shutdown. A 60 second activation delay prevents a hi coolant temperature alarm from occurring at engine sta...

  • Page 77

    Figure 4-12. Alarms screen, overspeed-sender fail tab overspeed alarm - threshold (% of rated). This setting selects the percentage of overspeed that triggers an overspeed alarm and engine shutdown. The threshold is adjustable from 105 to 140 % of nominal speed. Overspeed alarm - alarm activation (m...

  • Page 78

    Figure 4-13. Engine cranking screen pre-crank delay (sec). This setting adjusts the time delay between initiating engine starting and beginning engine cranking. A delay of zero to 30 seconds may be entered. Pre-start contact after disconnect. This setting selects whether or not the pre-start contact...

  • Page 79

    Figure 4-14. System setting screen front panel sleep mode enabled. Selecting this checkbox enables the activation of sleep mode when the dgc-500 is in off mode for more than 15 minutes. When sleep mode is active, the front panel leds, lcd, and lcd backlight are turned off to reduce power consumption...

  • Page 80

    Canbus/j1939 interface - enable ecu support. This setting enables and disables the dgc-500 can interface. When enabled, the can interface allows the dgc-500 to communicate with the engine control unit (ecu). This setting must be enabled in order to enable dtc support. Canbus/j1939 interface - enable...

  • Page 81

    Figure 4-15. Settings screen, input setup tab output setup tab the output setup tab settings of the settings screen are shown in figure 4-16. (not all settings are visible in the illustration.) each tab setting is described in the following paragraphs. Figure 4-16. Settings screen, output setup tab ...

  • Page 82

    • battery charger failure alarm • battery charger failure pre-alarm • battery overvoltage pre-alarm • coolant temperature sender failure alarm • cooldown timer active • emergency stop alarm • eps supplying load • fuel leak alarm • fuel leak pre-alarm • fuel sender failure pre-alarm • high coolant te...

  • Page 83

    3 phase – 51 pickup. This setting selects the overcurrent pickup threshold for three-phase generator connections. A 51 pickup setting of 0.18 to 1.18 aac (style x1x1) or 0.9 to 7.75 aac (style x5x1) may be entered. 3 phase – 51 time dial. When three-phase generator connections are used, this setting...

  • Page 84

    47 tab the 47 tab contains the phase imbalance settings shown in figure 4-18 and described in the following paragraphs. Figure 4-18. Generator protection screen, 47 tab 47 – pickup. This setting selects the level of voltage imbalance, between generator phases, that will cause a phase imbalance picku...

  • Page 85

    Figure 4-19. Generator protection scree, 27 tab 3 phase – 27 pickup. This setting selects the undervoltage pickup threshold for three-phase generator connections. A three-phase undervoltage pickup occurs when the average of the three-phase voltage decreases below the 27 pickup setting. A three-phase...

  • Page 86

    Figure 4-20. Generator protection screen, 59 tab 3 phase – 59 pickup. This setting selects the overvoltage pickup threshold for three-phase generator connections. A three-phase overvoltage pickup occurs when the average of the three-phase voltage increases above the 59 pickup setting. A 59 pickup se...

  • Page 87

    Figure 4-21. Generator protection screen, 81 tab 81u – pickup. This setting selects the level of frequency that will cause an underfrequency pickup. For 50/60 hertz generator frequency sensing, an 81u pickup setting of 45 to 65 hertz may be entered. For 400 hertz generator frequency sensing, an 81u ...

  • Page 88

    2. Select the automatically adjust for daylight savings time check box if automatic compensation for daylight savings time is desired. 3. Click the send settings to dgc button to set the dgc-500 real-time clock with the pc's time and date. The dgc-500 real-time clock settings can be viewed and verif...

  • Page 89

    Figure 4-23. Programmable senders screen, coolant temperature tab sender slope. If a sender requires a positive slope, positive can be selected to invert the values in the resistance column. Reset factory settings. Clicking this button restores the factory-default data points in the degrees f/degree...

  • Page 90

    Figure 4-24. Run statistics screen cumulative run statistics. This area of the run statistics screen displays the total running time, unloaded running time, and loaded running time since the genset/dgc-500 was commissioned. The number of engine starts and time remaining until maintenance is also dis...

  • Page 91

    Figure 4-25. Event log screen display in engine hours. Placing a check in this checkbox causes the event log screen to display events time-stamped with elapsed engine hours. An empty checkbox causes the event log screen to display events time-stamped with real-time clock data. Settings files bestcom...

  • Page 92

    Opening settings files to open a dgc-500 settings file, click the open settings file button or click file on the menu bar and click open. An open dialog box will appear and enable you to select a dgc-500 settings file (dg5 extension) for retrieval into bestcoms. Rs-232 configuration when communicati...

  • Page 93

    Ecu related time values – setting time (millisec.). This setting adjusts the time to gather data after connecting to the ecu during the pulsing state. This allows all metered values to be sent and ramp up. Metered values are sent by the ecu at different rates as designated by the j1939 protocol. Val...

  • Page 94

    Embedded firmware embedded firmware is the operating program that controls the actions of the dgc-500. The dgc-500 stores firmware in nonvolatile flash memory that can be reprogrammed through the rs-232 communication port. It is not necessary to replace eprom chips when updating the firmware with a ...

  • Page 95

    Figure 4-30. Firmware file information 4. Click the start firmware upgrade process button. The erase application code!!!! And save settings before you continue!!!! Dialog boxes appear and confirm that you want to continue. Click yes in both dialog boxes to begin transferring the firmware file to the...

  • Page 97: Section 5

    Section 5 • installation table of contents section 5 • installation .................................................................................................................. 5-1 general ............................................................................................................

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  • Page 99: Section 5

    Section 5 • installation general dgc-500 digital genset controllers are delivered in sturdy cartons to prevent shipping damage. Upon receipt of a system, check the part number against the requisition and packing list for agreement. Inspect for damage, and if there is evidence of such, immediately fi...

  • Page 100

    Figure 5-2. Dgc-500 overall dimensions dgc-500 isolator kit the optional dgc isolator kit provides an economical way to reduce the level of shock and vibration transmitted from a generator to the dgc-500. The dgc isolator kit eliminates the need to mount an isolator box on top of the generator condu...

  • Page 101

    Connections dgc-500 connections are dependent on the application. Incorrect wiring may result in damage to the controller. Dgc-500 terminations all dgc-500 terminals are located on the rear panel of the controller. There are three types of interface terminals. J1, a db9 connector, is used as a tempo...

  • Page 102

    Figure 5-4. Personal computer to dgc-500 connections can connections the can connector (j2) on the rear panel mates with the cable assembly (basler p/n 9358900002) provided with the dgc-500. Only units with style numbers f1j and f5j are supplied with the cable assembly and have connector j2 enabled....

  • Page 103

    Figure 5-6. Typical dgc-500 can interface connections dgc-500 connections for typical applications figures 5-7 through 5-9 illustrate typical applications using the dgc-500. Figure 5-7 shows a dgc-500 application using single-phase sensing. Figure 5-8 shows a dgc-500 application using three-phase, d...

  • Page 104: Dgc-

    Figure 5-7. Dgc-500 connections, single-phase, a-b p4 p3 p2 p 37 p 35 programmable ou tpu t 2 programmable ou tpu t 1 pre-start fu el crank generator circuit breaker p 17 p 14 p 11 start solenoid solenoid fuel p 36 p 38 p 33 p 34 k1 n .O . Eme rgenc y stop progra mmable in p u t 2 progra mmable in p...

  • Page 105: Dgc-

    Figure 5-8. Dgc-500 connections, single-phase, a-c p4 p3 p2 p 37 p 35 programmable ou tpu t 2 programmable ou tpu t 1 pre-start fu el crank generator circuit breaker p 17 p 14 p 11 start solenoid solenoid fuel p 36 p 38 p 33 p 34 k1 n .O . Eme rgenc y stop progra mmable in p u t 2 progra mmable in p...

  • Page 106: Dgc-

    Figure 5-9. Dgc-500 connections, three-phase delta p4 p3 p2 p3 7 p3 5 progr am ma ble out put 2 progr am ma ble out put 1 pre -sta rt fuel cran k g en er a t o r ci rcui t bre ake r p1 7 p1 4 p1 1 sta r t so len o id so len o id fu el p3 6 p3 8 p3 3 p3 4 k1 n .O. Em e rg e nc y st op pr o gr a m m a...

  • Page 107: Dgc-

    Figure 5-10. Dgc-500 connections, three-phase wye p4 p3 p2 p 37 p 35 programmable ou tpu t 2 programmable ou tpu t 1 pre-start fu el crank generator circuit breaker p 17 p 14 p 11 start solenoid solenoid fuel p 36 p 38 p 33 p 34 k1 n .O . Eme rgenc y stop progra mmable in p u t 2 progra mmable in p ...

  • Page 108

    Volvo penta edc iii applications engines equipped with volvo penta edc iii controllers can receive engine control commands (such as start and stop) from the dgc-500 through the sae j1939 communication interface. To invoke this feature, the edc iii must receive a j1939 message containing engine contr...

  • Page 109: Dgc-

    Figure 5-11. Volvo penta edc iii application, single-phase, a-b connections 1 2 3 4 5 p4 p3 p2 p 37 p 35 programmable ou tpu t 2 programmable ou tpu t 1 pre-start generator circuit breaker p 17 p 14 p 11 p 36 p 38 p 33 p 34 eme rgenc y stop progra mmable in p u t 2 progra mmable in p u t 3 chassis g...

  • Page 110: Dgc-

    Figure 5-12. Volvo penta edc iii application, single-phase, a-c connections 1 2 3 4 5 p4 p3 p2 p 37 p 35 programmable ou tpu t 2 programmable ou tpu t 1 pre-start generator circuit breaker p 17 p 14 p 11 p 36 p 38 p 33 p 34 emergenc y stop progra mmable in p u t 2 progra mmable in p u t 3 chassis g ...

  • Page 111: Dgc-

    Figure 5-13. Volvo penta edc iii application, three-phase, delta connections 1 2 3 4 5 p4 p3 p2 p 37 p 35 programmable ou tpu t 2 programmable ou tpu t 1 pre-start p 17 p 14 p 11 p 36 p 38 p 33 p 34 eme rgenc y stop progra mmable in p u t 2 progra mmable in p u t 3 chassis g ro u n d c ont a c t s e...

  • Page 112: Dgc-

    Figure 5-14. Volvo penta edc iii application, three-phase, wye connections 1 2 3 4 5 p4 p3 p2 p 37 p 35 programmable ou tpu t 2 programmable ou tpu t 1 pre-start p 17 p 14 p 11 p 36 p 38 p 33 p 34 eme rgenc y stop progra mmable in p u t 2 progra mmable in p u t 3 chassis g ro u n d c ont a c t s e n...

  • Page 113

    Special contact sensing input considerations dgc-500 controllers, with version m or earlier hardware, may require additional protection for the contact sensing inputs when used in environments with high levels of electrical noise. Additional protection can be implemented by connecting external noise...

  • Page 114

    Entering calibration mode calibration is accomplished by performing the instructions called out on each of the hmi calibration menu screens. The calibration menu screens reside in a branch of menu 3: sensing devices. Figure 5-16 illustrates the process of entering the calibration mode and the follow...

  • Page 115

    6. Press the raise/scroll pushbutton. The screen at right is displayed. Apply 2 aac to the current sensing inputs for phase v (p15 and p17). Press the lower/scroll pushbutton. 7. Press the raise/scroll pushbutton. The screen at right is displayed. Connect a resistance of 30 ohms across the coolant t...

  • Page 116

    22. Press the raise/scroll pushbutton. The screen at right is displayed. Connect a resistance of 175 ohms across the oil pressure sender input (p13 and p19). Press the lower/scroll pushbutton. 23. Press the raise/scroll pushbutton. The screen at right is displayed. Connect a resistance of 200 ohms a...

  • Page 117: Section 6

    Section 6 • maintenance and troubleshooting table of contents section 6 • maintenance and troubleshooting .................................................................... 6-1 preventative maintenance ...................................................................................................

  • Page 118

    This page intentionally left blank. Ii dgc-500 maintenance and troubleshooting 9355400990 rev h.

  • Page 119: Section 6

    Section 6 • maintenance and troubleshooting preventative maintenance the only preventative maintenance required on the dgc-500 is to periodically check that the connections between the dgc-500 and the system are clean and tight. This device contains long-life, aluminum electrolytic capacitors. For d...

  • Page 120

    Step 6. If the mpu is shared with the governor, verify that the polarity of the mpu input to the governor matches the polarity of the mpu input to the dgc-500. Programmable inputs do not operate as expected step 1. Verify that all wiring is properly connected. Refer to figures 5-7 through 5-14. Step...

  • Page 121: Characteristic Curves

    Appendix a • time overcurrent characteristic curves table of contents appendix a • time overcurrent characteristic curves ................................................... A-1 introduction.................................................................................................................

  • Page 122

    This page intentionally left blank. Ii dgc-500 time overcurrent characteristic curves 9355400990 rev h.

  • Page 123: Characteristic Curves

    Appendix a • time overcurrent characteristic curves introduction the inverse time overcurrent characteristic curves provided by the dgc-500 (style xxx1 only) closely emulate most of the common electromechanical, induction-disk, overcurrent relays sold in north america. Curve specifications timing ac...

  • Page 124

    Table a-1. Time characteristic curve constants curve selection curve name trip characteristic constants a b c n k s1 s, s1, short inverse 0.2663 0.03393 1.0000 1.2969 0.0280 s2 s2, short inverse 0.0286 0.02080 1.0000 0.9844 0.0280 l1 l, l1, long inverse 5.6143 2.18592 1.0000 1.0000 0.0280 l2 l2, lon...

  • Page 125

    Table a-2. Characteristic curve cross-reference curve curve name similar to s1 s, s1, short inverse abb co-2 s2 s2, short inverse ge iac-55 l1 l, l1, long inverse abb co-5 l2 l2, long inverse ge iac-66 d d, definite time abb co-6 m m, moderately inverse abb co-7 i1 i, i1, inverse time abb co-8 i2 i2...

  • Page 126

    Table a-3 .Time dial setting cross-reference curve equivalent to electromechanical relay time dial setting 0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 basler electric equivalent time dial setting s, s1 abb co-2 0.3 0.8 1.7 2.4 3.4 4.2 5.0 5.8 6.7 7.7 8.6 9.7 l, l1 abb co-5 0.4 0.8 1.5 2.3 3.3 ...

  • Page 127

    Figure a-1. Time characteristic curve s, s1, short inverse (similar to abb co-2) 9355400990 rev h dgc-500 time overcurrent characteristic curves a-5.

  • Page 128

    Figure a-2. Time characteristic curve s2, short inverse (similar to ge iac-55) a-6 dgc-500 time overcurrent characteristic curves 9355400990 rev h.

  • Page 129

    Figure a-3. Time characteristic curve l, l1, long inverse (similar to abb co-5) 9355400990 rev h dgc-500 time overcurrent characteristic curves a-7.

  • Page 130

    Figure a-4. Time characteristic curve l2, long inverse (similar to ge iac-66) a-8 dgc-500 time overcurrent characteristic curves 9355400990 rev h.

  • Page 131

    Figure a-5. Time characteristic curve d, definite time (similar to abb co-6) 9355400990 rev h dgc-500 time overcurrent characteristic curves a-9.

  • Page 132

    Figure a-6. Time characteristic curve m, moderately inverse (similar to abb co-7) a-10 dgc-500 time overcurrent characteristic curves 9355400990 rev h.

  • Page 133

    Figure a-7. Time characteristic curve i, i1, inverse time (similar to abb co-8) 9355400990 rev h dgc-500 time overcurrent characteristic curves a-11.

  • Page 134

    Figure a-8. Time characteristic curve i2, inverse time (similar to ge iac-51) a-12 dgc-500 time overcurrent characteristic curves 9355400990 rev h.

  • Page 135

    Figure a-9. Time characteristic curve v, v1, very inverse (similar to abb co-9) 9355400990 rev h dgc-500 time overcurrent characteristic curves a-13.

  • Page 136

    Figure a-10. Time characteristic curve v2, very inverse (similar to ge iac-53) a-14 dgc-500 time overcurrent characteristic curves 9355400990 rev h.

  • Page 137

    Figure a-11. Time characteristic curve e, e1, extremely inverse (similar to abb co-11) 9355400990 rev h dgc-500 time overcurrent characteristic curves a-15.

  • Page 138

    Figure a-12. Time characteristic curve e2, extremely inverse (similar to ge iac-77) a-16 dgc-500 time overcurrent characteristic curves 9355400990 rev h.

  • Page 139

    Figure a-13. Time characteristic curve a, standard inverse 9355400990 rev h dgc-500 time overcurrent characteristic curves a-17.

  • Page 140

    Figure a-14. Time characteristic curve b, very inverse a-18 dgc-500 time overcurrent characteristic curves 9355400990 rev h.

  • Page 141

    Figure a-15. Time characteristic curve c, extremely inverse 9355400990 rev h dgc-500 time overcurrent characteristic curves a-19.

  • Page 142

    Figure a-16. Time characteristic curve g, long time inverse a-20 dgc-500 time overcurrent characteristic curves 9355400990 rev h.

  • Page 143: Appendix B

    Appendix b • parameters and settings introduction this appendix lists all dgc-500 parameters along with the setting range/selections for each parameter. Front panel adjustable parameters table b-1 lists the dgc-500 settings that can be adjusted through the hmi. Table b-1. Hmi adjustable settings par...

  • Page 144

    Parameter setting range cycle crank time 5 - 15 sec dtc support on or off ecu control output select fuel or pre-start contact ecu pulsing disable or enable ecu pulse cycle time 1 - 60 min ecu response time-out 1 - 60 sec ecu settling time 5,500 - 30,000 msec ecu support on or off engine shutdown tim...

  • Page 145

    Parameter setting range low oil pressure alarm threshold 3 - 150 psi maintenance interval pre-alarm threshold 0 - 5,000 hrs maintenance interval pre-alarm enable on or off nfpa level 0, 1, or 2 no-load cool-down delay 1 - 60 min number of flywheel teeth 50 - 500 number of crank cycles 1 - 7 oil pres...

  • Page 146

    Parameter setting range undervoltage inhibit 20 - 400 hz unit id 1 - 247 unit system english or metric weak battery voltage pre-alarm threshold 4 - 8 vdc or 8 - 16 vdc weak battery voltage pre-alarm delay 1 - 10 sec weak battery voltage pre-alarm enable on or off b-4 dgc-500 parameters and settings ...

  • Page 147: Appendix C

    Appendix c • settings record introduction this appendix provides a complete list of dgc-500 settings. This list is provided in the form of a settings record that you can use to record information relative to your application. Dgc-500 settings are organized in the following groups. • sensing transfor...

  • Page 148

    Dgc-500 settings record genset id __________________________________ date __________________________________ dgc-500 serial number ______________________ firmware version _______________________ sensing transformer settings parameter setting generator ct primary amps generator pt primary volts gener...

  • Page 149

    Pre-alarm settings parameter setting battery charger failure pre-alarm enable battery overvoltage pre-alarm enable battery overvoltage pre-alarm threshold engine maintenance cycle pre-alarm level fuel level sender failure pre-alarm enable high coolant temperature pre-alarm enable high coolant temper...

  • Page 150

    Parameter setting low oil pressure alarm threshold oil pressure sender fail alarm overspeed alarm delay overspeed alarm enable overspeed alarm threshold sender failure alarm time delay generator protection settings parameter setting overcurrent pickup - 3 phase overcurrent pickup - single phase over...

  • Page 151

    Parameter setting undervoltage alarm configuration - single phase undervoltage pickup - single phase undervoltage time - single phase undervoltage time - 3 phase undervoltage inhibit - single phase undervoltage alarm configuration - 3 phase communication settings parameter setting baud rate parity u...

  • Page 152

    This page intentionally left blank. C-6 dgc-500 settings record 9355400990 rev h.

  • Page 154

    12570 state route 143 highland il 62249-1074 usa tel: +1 618.654.2341 fax: +1 618.654.2351 email: info@basler.Com p.A.E. Les pins 67319 wasselonne cedex france tel: +33 3.88.87.1010 fax: +33 3.88.87.0808 email: franceinfo@basler.Com no. 59 heshun road loufeng district (n) suzhou industrial park 2151...