Basler DGC-2020ES User manual

12570 Route 143 •Highland, Illinois 62249-1074 USA
Tel [phone] •Fax [phone]
www.basler.com •[email protected]
Publication
9469200997, Rev C
July 2021
DGC-2020ES
Digital Genset Controller
Accessories Instruction Manual

WARNING: California's Proposition 65 requires special warnings for
products that may contain chemicals known to the state of California to
cause cancer, birth defects, or other reproductive harm. Please note that
by posting this Proposition 65 warning, we are notifying you that one or
more of the Proposition 65 listed chemicals may be present in products
we sell to you. For more information about the specific chemicals found
in this product, please visit https://www.basler.com/Prop65.

9469200997 i
DGC-2020ES Preface
Preface
This instruction manual provides information about the accessories for the DGC-2020ES Digital Genset
Controller. To accomplish this, the following information is provided:
•CEM-2020 (Contact Expansion Module)
Conventions Used in this Manual
Important safety and procedural information is emphasized and presented in this manual through
Warning, Caution, and Note boxes. Each type is illustrated and defined as follows.
Warning!
Warning boxes call attention to conditions or actions that may cause
personal injury or death.
Caution
Caution boxes call attention to operating conditions that may lead to
equipment or property damage.
Note
Note boxes emphasize important information pertaining to Digital
Genset Controller installation or operation.
DGC-2020ES Instruction Manual Catalog
Available instruction manuals for the DGC-2020ES are listed in Table 1.
Table 1. Instruction Manuals
Part Number
Description
9469200993
Quick Start
9469200994
Installation
9469200995
Configuration
9469200996
Operation
9469200997
Accessories (this manual)

ii 9469200997
Preface DGC-2020ES
12570 State Route 143
Highland IL 62249-1074 USA
www.basler.com
[e-mail]
Tel: [phone]
Fax: [phone]
© 2021 by Basler Electric
All rights reserved
First printing: April 2017
Warning!
READ THIS MANUAL.
Read this manual before installing, operating, or maintaining the DGC-2020ES.
Note all warnings, cautions, and notes in this manual as well as on the product. Keep this manual with
the product for reference. Only qualified personnel should install, operate, or service this system.
Failure to follow warning and cautionary labels may result in personal injury or property damage.
Exercise caution at all times.
Caution
Installing previous versions of firmware may result in compatibility issues causing the inability to
operate properly and may not have the enhancements and resolutions to issues that more recent
versions provide. Basler Electric highly recommends using the latest version of firmware at all times.
Using previous versions of firmware is at the user’s risk and may void the warranty of the unit.
Basler Electric does not assume any responsibility to compliance or noncompliance with national code, local code,
or any other applicable code. This manual serves as reference material that must be well understood prior to
installation, operation, or maintenance.
For terms of service relating to this product and software, see the Commercial Terms of Products and Services
document available at www.basler.com/terms.
This publication contains confidential information of Basler Electric Company, an Illinois corporation. It is loaned for
confidential use, subject to return on request, and with the mutual understanding that it will not be used in any
manner detrimental to the interests of Basler Electric Company and used strictly for the purpose intended.
It is not the intention of this manual to cover all details and variations in equipment, nor does this manual provide
data for every possible contingency regarding installation or operation. The availability and design of all features
and options are subject to modification without notice. Over time, improvements and revisions may be made to this
publication. Before performing any of the following procedures, contact Basler Electric for the latest revision of this
manual.
The English-language version of this manual serves as the only approved manual version.

9469200997 iii
DGC-2020ES Revision History
Revision History
A historical summary of the changes made to this instruction manual is provided below. Revisions are
listed in reverse chronological order.
Visit www.basler.com to download the latest hardware, firmware, and BESTCOMSPlus®revision
histories.
Instruction Manual Revision History
Manual
Revision and Date
Change
C, Jul-21
•Removed CEM-2020 UL Recognition for use in Hazardous Locations
•Minor text edits
B, Nov-19
•Removed Rev Letter from all pages.
•Changed sequential numbering to sectional numbering.
•Moved Instruction Manual Revision History into Preface.
•Removed standalone Revision History chapter.
A1, Apr-19
•Updated Proposition 65 statement
A, Sep-18
•Updated output contacts ratings and added hazardous location
specs in the CEM-2020 chapter
•
Updated Revision History chapter
—, Apr-17
•Initial release

iv 9469200997
Revision History DGC-2020ES

9469200997 v
DGC-2020ES Contents
Contents
CEM-2020 .................................................................................................................................................. 1-1
Troubleshooting ......................................................................................................................................... 2-1

vi 9469200997
Contents DGC-2020ES

9469200997 1-1
DGC-2020ES CEM-2020
1 • CEM-2020
General Information
The optional CEM-2020 is a remote auxiliary device that provides additional DGC-2020ES contact inputs
and outputs. Two types of modules are available. A low current module (CEM-2020) provides 24 contact
outputs and high current module (CEM-2020H) provides 18 contact outputs.
Features
CEM-2020s have the following features:
•10 Contact Inputs
•18 Contact Outputs (CEM-2020H) or 24 Contact Outputs (CEM-2020)
•Functionality of Inputs and Outputs assigned by BESTlogic™Plus Programmable Logic
•Communications via CAN
Specifications
Operating Power
Nominal ..................................................12 or 24 Vdc
Range .....................................................8 to 32 Vdc (Withstands cranking ride-through down to
6 Vdc for 500 ms)
Maximum Power Dissipation
CEM-2020 ...............................................14 W
CEM-2020H ............................................8 W
Contact Inputs
The CEM-2020 contains 10 programmable inputs that accept dry contacts.
Time from a CEM-2020 input application to:
•Shut down the generator via an alarm = 700 ms max
•Close a relay on board the DGC-2020ES = 300 ms max
•Close a relay on board the CEM-2020 = 550 ms max
Notes
A CEM-2020 contact input is true (on) if the input is connected to
battery ground with a resistance of less than 200 ohms.
The maximum length of wire that can be accommodated depends on
the resistance of the wire, and the resistance of the contacts of the
device driving the input at the far end of the wire.
The maximum wire length can be calculated as follows:
Lmax = (200 –Rdevice)/(Resistance per Foot of Desired Wire)
Contact Outputs
Ratings
CEM-2020
Outputs 5 through 16 ..............................1 Adc at 30 Vdc, Form C *
Outputs 17 through 28 ............................4 Adc at 30 Vdc, Form C – 1.2 A Pilot Duty †

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CEM-2020 DGC-2020ES
CEM-2020H
Outputs 5 through 16 ..............................2 Adc at 30 Vdc, Form C *
Outputs 17 through 22 ............................10 Adc at 30 Vdc, Form C – 1.2 A Pilot Duty †
* Gold contacts intended for low voltage signaling to dry circuits. Not rated for inductive loads or pilot duty.
† For pilot duty, the load must be in parallel with a diode rated at least 3 x the coil current and 3 x the coil
voltage.
Communications Interface
CAN
Differential Bus Voltage...........................1.5 to 3 Vdc
Maximum Voltage ...................................–32 to +32 Vdc with respect to negative battery terminal
Communication Rate...............................250 kb/s
Type Tests
Shock
Withstands 15 G in three perpendicular planes.
Vibration
Swept over the following ranges for12 sweeps in each of three mutually perpendicular planes with each
15-minute sweep consisting of the following:
5 to 29 to 5 Hz .........................................1.5 G peak for 5 min.
29 to 52 to 29 Hz.....................................0.036 in (0.914 mm) Double Amplitude for 2.5 min.
52 to 500 to 52 Hz...................................5 G peak for 7.5 min.
Ignition System
Tested in close proximity to an unshielded, unsuppressed Altronic DISN 800 ignition system.
HALT (Highly Accelerated Lift Testing)
HALT is used by Basler Electric to prove that our products will provide the user with many years of
reliable service. HALT subjects the device to extremes in temperature, shock, and vibration to simulate
years of operation, but in a much shorter period span. HALT allows Basler Electric to evaluate all possible
design elements that will add to the life of this device. As an example of some of the extreme testing
conditions, the CEM-2020 was subjected to temperature tests (tested over a temperature range of –80°C
to +130°C), vibration tests (of 5 to 50 G at +25°C), and temperature/vibration tests (tested at 10 to 20 G
over a temperature range of –60°C to +100°C). Combined temperature and vibration testing at these
extremes proves that the CEM-2020 is expected to provide long-term operation in a rugged environment.
Note that the vibration and temperature extremes listed in this paragraph are specific to HALT and do not
reflect recommended operation levels. These operational ratings are included in this section.
Environment
Humidity ..................................................Complies with IEC 68-2-38
Temperature
Operating.................................................–40 to +158°F(–40 to +70°C)
Storage ...................................................–40 to +185°F(–40 to +85°C)
UL Approval (CEM-2020 Only)
The CEM-2020 and CEM-2020H are Recognized Components applicable to the Canadian and US safety
standards and requirements by UL. The product is covered under UL File (E97035 FTPM2/FTPM8) and
evaluated to the following standards through UL:
•UL6200
•CSA C22.2 No. 14

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DGC-2020ES CEM-2020
CSA Certification
The CEM-2020 and CEM-2020H are Certificated under CSA report 1042505 (LR23131-138S) and
evaluated to the following standards through CSA:
•CSA C22.2 No. 0
•CSA C22.2 No. 14
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) - 2014/30/EU
•Hazardous Substances (ROHS2) -2011/65/EU
Harmonized Standards used for evaluation:
•EN 50178 - Electronic Equipment for use in Power Installations
•EN 61000-6-4 - Electromagnetic Compatibility (EMC), Generic Standards, Emission Standard for
Industrial Environments
•EN 61000-6-2 - Electromagnetic Compatibility (EMC), Generic Standards, Immunity for Industrial
Environments
•EN 50581 – Technical Documentation for the Assessment of Electrical and Electric Products with
Respect to the Restriction of Hazardous Substances (ROHS2)
NFPA Compliance
Designed to comply with NFPA Standard 110, Standard for Emergency and Standby Power.
EAC Mark (Eurasian Conformity)
•TC RUUS.HO03.B.00742
Physical
Dimensions..............................................See Installation later in this chapter.
Weight
CEM-2020 ...............................................2.25 lb (1.02 kg)
CEM-2020H ............................................1.90 lb (0.86 kg)
Functional Description
Contact Inputs
The CEM-2020 provides 10 programmable contact inputs with the same functionality as the contact
inputs on the DGC-2020ES. The label text of each contact input is customizable.
Contact Outputs
CEM-2020
The CEM-2020 provides 24 programmable contact outputs with the same functionality as the contact
outputs on the DGC-2020ES. Outputs 5 through 16 can carry 1 A. Outputs 17 through 28 can carry 4 A.
The label text of each contact output is customizable.
CEM-2020H
The CEM-2020H provides 18 programmable contact outputs with the same functionality as the contact
outputs on the DGC-2020ES. Outputs 5 through 16 can carry 2 A. Outputs 17 through 22 can carry 10 A.
The label text of each contact output is customizable.

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CEM-2020 DGC-2020ES
Communications
CAN
A Control Area Network (CAN) is a standard interface that enables communication between the CEM-
2020 and the DGC-2020ES.
BESTCOMSPlus®Software
BESTCOMSPlus provides the user with a point-and-click means to set and monitor the Contact
Expansion Module. Installation and operation of BESTCOMSPlus is described in the BESTCOMSPlus
chapter.
Installation
Contact Expansion Modules are delivered in sturdy cartons to prevent shipping damage. Upon receipt of
a module, check the part number against the requisition and packing list for agreement. Inspect for
damage, and if there is evidence of such, immediately file a claim with the carrier and notify the Basler
Electric regional sales office or your sales representative.
If the device is not installed immediately, store it in the original shipping package in a moisture- and dust-
free environment.
Mounting
Contact Expansion Modules are contained in a potted plastic case and may be mounted in any
convenient position. The construction of a Contact Expansion Module is durable enough to mount directly
on a genset using ¼-inch hardware. Hardware selection should be based on any expected
shipping/transportation and operating conditions. The torque applied to the mounting hardware should not
exceed 65 in-lb (7.34 N•m).
See Figure 1-1 for CEM-2020 overall dimensions. All dimensions are shown in inches with millimeters in
brackets.

9469200997 1-5
DGC-2020ES CEM-2020
Figure 1-1. CEM-2020 Overall Dimensions
See Figure 1-2 for CEM-2020H overall dimensions. All dimensions are shown in inches with millimeters in
brackets.

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CEM-2020 DGC-2020ES
Figure 1-2. CEM-2020H Overall Dimensions
Connections
Contact Expansion Module connections are dependent on the application. Incorrect wiring may result in
damage to the module.
Note
Operating power from the battery must be of the correct polarity.
Although reverse polarity will not cause damage, the CEM-2020 will
not operate.
Be sure that the CEM-2020 is hard-wired to earth ground with no
smaller than 12 AWG copper wire attached to the chassis ground
terminal on the module.
Terminations
The terminal interface consists of plug-in connectors with screw-down compression terminals.
CEM-2020 connections are made with one 5-position connector, two 18-position connectors, and two 24-
position connectors with screw-down compression terminals. These connectors plug into headers on the
CEM-2020. The connectors and headers have dovetailed edges that ensure proper connector orientation.
The connectors and headers are uniquely keyed to ensure that the connectors mate only with the correct
headers. Connector screw terminals accept a maximum wire size of 12 AWG (3.31 mm2). Maximum
screw torque is 5 inch-pounds (0.56 N•m).
Operating Power
The Contact Expansion Module operating power input accepts either 12 Vdc or 24 Vdc and tolerates
voltage over the range of 6 to 32 Vdc. Operating power must be of the correct polarity. Although reverse

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DGC-2020ES CEM-2020
polarity will not cause damage, the CEM-2020 will not operate. Operating power terminals are listed in
Table 1-1.
It is recommended that a fuse be added for additional protection for the wiring to the battery input of the
Contact Expansion Module. A Bussmann ABC-7 fuse or equivalent is recommended.
Table 1-1. Operating Power Terminals
Terminal
Description
P1- (SHIELD)
Chassis ground connection
P1- – (BATT–)
Negative side of operating power input
P1 + (BATT+)
Positive side of operating power input
Contact Inputs and Contact Outputs
The CEM-2020 (Figure 1-3) has 10 contact inputs and 24 contact outputs. The CEM-2020H (Figure 1-4)
has 10 contact inputs and 18 contact outputs.
Figure 1-3. CEM-2020 Contact Input and Contact Output Terminals

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CEM-2020 DGC-2020ES
Figure 1-4. CEM-2020H Contact Input and Contact Output Terminals
CAN Interface
These terminals provide communication using the SAE J1939 protocol and provide high-speed
communication between the Contact Expansion Module and the DGC-2020ES. Connections between the
CEM-2020 and DGC-2020ES should be made with twisted-pair, shielded cable. CAN interface terminals
are listed in Table 1-2. Refer to Figure 1-5 and Figure 1-6.
Table 1-2. CAN Interface Terminals
Terminal
Description
P1- HI (CAN H)
CAN high connection (yellow wire)
P1- LO (CAN L)
CAN low connection (green wire)
P1- (SHIELD)
CAN drain connection

9469200997 1-9
DGC-2020ES CEM-2020
Notes
1. If the CEM-2020 is providing one end of the J1939 bus, a 120
ohm, ½ watt terminating resistor should be installed across
terminals P1- LO (CANL) and P1- HI (CANH).
2. If the CEM-2020 is not part of the J1939 bus, the stub connecting
the CEM-2020 to the bus should not exceed 914 mm (3 ft) in
length.
3. The maximum bus length, not including stubs, is 40 m (131 ft).
4. The J1939 drain (shield) should be grounded at one point only. If
grounded elsewhere, do not connect the drain to the CEM-2020.
Figure 1-5. CAN Interface with CEM-2020 providing One End of the Bus
Figure 1-6. CAN Interface with DGC-2020ES providing One End of the Bus
DGC-2020ES
CEM-2020
(Optional)
P0067-96
Engine
120 ohm
Termination
CAN-H
CAN-L
Other
Devices
120 ohm
Termination
Bus
Stub
DGC-2020ES
Other
Devices
P0067-85
Engine
120 ohm
Termination
CAN-H
CAN-L
CEM-2020
(Optional)
120 ohm
Termination
Bus
Stub

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CEM-2020 DGC-2020ES
Remote Contact Input Configuration
The CEM-2020 provides 10 contact inputs. Each of the 10 contact inputs can be independently
configured to annunciate an alarm or pre-alarm when the input senses a contact closure. A user-
adjustable time delay can be set to delay recognition of a contact input. By default, all inputs are
configured so that they do not trigger an alarm or pre-alarm.
To make identifying the contact inputs easier, a user-assigned name can be given to each input.
Contacts can be recognized always or only while the engine is running.
The remote contact inputs are incorporated into a BESTlogicPlus programmable logic scheme by
selecting them from the I/O group in BESTlogicPlus. For more details, refer to the BESTlogicPlus chapter
in the Configuration manual.
Remote contact input status is available in BESTlogicPlus Programmable Logic when “None” is selected
for Alarm Configuration.
The Remote Contact Inputs screen is found in the BESTCOMSPlus Settings Explorer under the
Programmable Inputs category. If using the front panel, navigate to Settings > Programmable Inputs >
Configurable Inputs. The BESTCOMSPlus Remote Contact Inputs screen is illustrated in Figure 1-7.
Figure 1-7. Settings Explorer, Programmable Inputs, Remote Contact Inputs Screen
Remote Contact Output Configuration
To make identifying the contact outputs easier, each of the contact outputs can be given a user-assigned
name.
The contact outputs are incorporated into a BESTlogicPlus programmable logic scheme by selecting
them from the I/O group in BESTlogicPlus. For more details, refer to the BESTlogicPlus chapter in the
Configuration manual.
The Remote Contact Outputs screen is found in the BESTCOMSPlus Settings Explorer under the
Programmable Inputs category. If using the front panel, navigate to Settings > Programmable Outputs >
Configurable Outputs. The BESTCOMSPlus Contact Outputs screen is illustrated in Figure 1-8.

9469200997 1-11
DGC-2020ES CEM-2020
Figure 1-8. Settings Explorer, Programmable Outputs, Remote Contact Outputs Screen
Firmware Updates
Refer to the Device Information chapter in the Configuration manual for information on upgrading
firmware in the CEM-2020.
Repair
Contact Expansion Modules are manufactured using state-of-the-art surface-mount technology. As such,
Basler Electric recommends that no repair procedures be attempted by anyone other than Basler Electric
personnel.
Before returning the CEM-2020 for repair, contact Basler Electric Technical Services Department at 618-
654-2341 for a return authorization number.
Maintenance
Preventive maintenance consists of periodically checking that the connections between the CEM-2020
and the system are clean and tight.
Storage
This device contains long-life aluminum electrolytic capacitors. For devices that are not in service (spares
in storage), the life of these capacitors can be maximized by energizing the device for 30 minutes once
per year.

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