Basler DGC-2020HD Service manual

12570 Route 143 •Highland, Illinois 62249-1074 USA
Tel [phone] •Fax [phone]
www.basler.com •[email protected]
Publication
9469300994, Rev H
June 2022
DGC-2020HD
Digital Genset Controller
Installation 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.

9469300994 i
DGC-2020HD Preface
Preface
This instruction manual provides information about the installation of the DGC-2020HD Digital Genset
Controller. To accomplish this, the following information is provided:
•Mounting
•Terminals and connectors
•Typical applications
•Power input
•Voltage and current sensing
•Speed signal inputs
•Specifications
•Maintenance and troubleshooting
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-2020HD Instruction Manual Catalog
Available instruction manuals for the DGC-2020HD are listed in Table 1.
Table 1. Instruction Manuals
Part Number
Description
9469300993
Quick Start
9469300994
Installation (this manual)
9469300995
Configuration
9469300996
Operation
9469300997
Accessories
9469300998
Modbus® Protocol

ii 9469300994
Preface DGC-2020HD
12570 State Route 143
Highland IL 62249-1074 USA
www.basler.com
[e-mail]
Tel: [phone]
Fax: [phone]
© 2022 by Basler Electric
All rights reserved
First printing: October 2016
Warning!
READ THIS MANUAL.
Read this manual before installing, operating, or maintaining the DGC-2020HD.
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.

9469300994 iii
DGC-2020HD 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 Public License or GNU Lesser General Public License. The licenses, at the time
of sale of the product, allow you to freely copy, modify, and redistribute that software and no other statement or
documentation from us, including our End User License Agreement, places any additional restrictions on what you
may do with that software.
For at least three (3) years from the date of distribution of this product, a machine-readable copy of the complete
corresponding source code for the version of the programs distributed to you will be sent upon request (contact
information is provided above). A fee of no more than our cost of physically performing the source code distribution
is charged.
The source code is distributed in the hope that it will be useful, but WITHOUT ANY REPRESENTATION or
WARRANTY or even the implied warranty of MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE.
Refer to the source code distribution for additional restrictions regarding warranty and copyrights.
For a complete copy of GNU GENERAL PUBLIC LICENSE Version 2, June 1991 or GNU LESSER GENERAL
PUBLIC LICENSE Version 2.1, February 1999 refer to www.gnu.org or contact Basler Electric. You, as a Basler
Electric Company customer, agree to abide by the terms and conditions of GNU GENERAL PUBLIC LICENSE
Version 2, June 1991 or GNU LESSER GENERAL PUBLIC LICENSE Version 2.1, February 1999, and as such
hold Basler Electric Company harmless related to any open source software incorporated in this product. Basler
Electric Company disclaims any and all liability associated with the open source software and the user agrees to
defend and indemnify Basler Electric Company, its directors, officers, and employees from and against any and all
losses, claims, attorneys' fees, and expenses arising from the use, sharing, or redistribution of the software.
Review the software website for the latest version of the software documentation.
Portions of this software are copyright © 2014 The FreeType Project (www.freetype.org). All rights reserved.
The following statement applies only to the fontconfig library:
fontconfig/COPYING
Copyright © 2000,2001,2002,2003,2004,2006,2007 Keith Packard
Copyright © 2005 Patrick Lam
Copyright © 2009 Roozbeh Pournader
Copyright © 2008,2009 Red Hat, Inc.
Copyright © 2008 Danilo Šegan
Copyright © 2012 Google, Inc.
Permission to use, copy, modify, distribute, and sell this software and its documentation for any purpose is hereby
granted without fee, provided that the above copyright notice appear in all copies and that both that copyright
notice and this permission notice appear in supporting documentation, and that the name of the author(s) not be
used in advertising or publicity pertaining to distribution of the software without specific, written prior permission.
The authors make no representations about the suitability of this software for any purpose. It is provided "as is"
without express or implied warranty.
THE AUTHOR(S) DISCLAIMS ALL WARRANTIES WITH REGARD TO THIS SOFTWARE, INCLUDING ALL
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS, IN NO EVENT SHALL THE AUTHOR(S) BE
LIABLE FOR ANY SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES OR ANY DAMAGES WHATSOEVER
RESULTING FROM LOSS OF USE, DATA OR PROFITS, WHETHER IN AN ACTION OF CONTRACT,
NEGLIGENCE OR OTHER TORTIOUS ACTION, ARISING OUT OF OR IN CONNECTION WITH THE USE OR
PERFORMANCE OF THIS SOFTWARE.

iv 9469300994
Preface DGC-2020HD

9469300994 v
DGC-2020HD 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
H, Jun-22
•Added three new figures under Analog Input Connections in the Typical
Connections chapter
•Updated UL specifications for UL 6200:2019
G, Dec-21
•Added more information on the Governor PWM Output Connections
•Updated UL / CSA specifications
F, Aug-21
•Added support for firmware version 2.06.00 and BESTCOMSPlus version
4.05.00
•Added “Installing previous firmware versions” caution box to Preface
•Corrected terminal numbers in Table 2-8
•Added description of Emergency Stop Input
•Added EMI immunity connections for analog inputs
•Removed Load Share Output current rating from Specifications
E, Oct-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
D2, Apr-19
•Updated Proposition 65 statement
D1, Oct-18
•Added Proposition 65 statement
D, Jul-18
•Added style options for DIN Rail and Rear Panel mounting configurations
•Removed “LCD is blank and all LEDs are flashing…” from
Troubleshooting chapter
C, May-18
•Maintenance release
B, May-17
•Added support for firmware version 2.04.00 and BESTCOMSPlus version
3.17.00
•Added accuracies for Fuel Level Sensing, Coolant Temperature Sensing,
and Oil Pressure Sensing
•Updated EAC specs
•Added patent about load anticipation
A, Dec-16
•Updated UL Approval statement in the Specifications chapter
•Added Group Start and Group Stop Requests to the Troubleshooting
chapter
—, Oct-16
•Initial release

vi 9469300994
Revision History DGC-2020HD

9469300994 vii
DGC-2020HD Contents
Contents
Mounting..................................................................................................................................................... 1-1
Terminals and Connectors.........................................................................................................................2-1
Typical Applications ................................................................................................................................... 3-1
Power Input ................................................................................................................................................ 4-1
Voltage and Current Sensing..................................................................................................................... 5-1
Speed Signal Inputs ................................................................................................................................... 6-1
Specifications ............................................................................................................................................. 7-1
Maintenance............................................................................................................................................... 8-1
Troubleshooting .........................................................................................................................................9-1

viii 9469300994
Contents DGC-2020HD

9469300994 1-1
DGC-2020HD Mounting
1 • Mounting
DGC-2020HD 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 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.
DGC-2020HD controllers may be mounted in one of three configurations depending on style: Front Panel,
DIN Rail, or Rear Panel. These configurations are described in the following paragraphs.
Front Panel Configuration
Units with styles xNxxxxxxx and xTxxxxxxx are mounted through the panel. Four permanently attached
10-24 studs are provided for mounting. The front panel HMI is resistant to moisture, salt fog, humidity,
dust, dirt, and chemical contaminants and faces outward for easy access.
Hardware
The torque applied to the mounting hardware should not exceed 20 inch-pounds (2.2 newton meters).
Dimensions
For Front Panel mounting, panel cutting and drilling dimensions are shown in Figure 1-1. All dimensions
are shown in inches with millimeters in parenthesis.
Figure 1-1. Panel Cutting and Drilling Dimensions

1-2 9469300994
Mounting DGC-2020HD
In Figure 1-1, the horizontal drilling measurement of 10.75 inches has a tolerance of +0.01/–0.01 inches.
The horizontal cutout measurement of 10.38 inches has a tolerance of +0.04/–0 inches. The vertical
drilling measurement of 7.25 inches has a tolerance of +0.01/–0.01 inches. The vertical cutout
measurement of 6.88 inches has a tolerance of +0.04/–0 inches.
DIN Rail Configuration
Units with style xRxxxxxxx are mounted on DIN rails. In this configuration, the DGC-2020HD has no HMI.
The rear of the DGC-2020HD faces outward for convenient access to terminals and connections.
Hardware
Two DIN rails, one located above the other, are required for mounting the DGC-2020HD. One flange and
two set screws on the DGC-2020HD secure it to the DIN rails. The flange clips onto the upper rail and the
set screws attach to the bottom rail. See Figure 1-2 for flange and set screw locations.
Figure 1-2. DIN Rail Flange and Setscrew Locations for Style xRxxxxxxx
Use two steel Top Hat rails, 35 mm x 7.5 mm, that are a minimum of 13 inches (330 mm) in length. DIN
Rail mounting hardware should be spaced no more than 6 inches (152 mm) apart for proper support.
Using the supplied hex key, hand tighten set screws until they stop. Locking inserts help maintain set
screw tightness. Hand tightening is recommended to ensure proper locking insert performance.
Dimensions
DIN Rail mounting dimensions are shown in Figure 1-3. All dimensions are shown in inches with
millimeters in parenthesis.

9469300994 1-3
DGC-2020HD Mounting
Figure 1-3. DIN Rail Mounting Dimensions for Style xRxxxxxxx
Rear Panel
Units with style xPxxxxxxx are mounted flush against a panel. In this configuration, the DGC-2020HD has
no HMI. Four clearance holes are provided for mounting. The rear of the DGC-2020HD faces outward for
convenient access to terminals and connections.
Hardware
Use four #10 screws with appropriate hardware. The torque applied to the mounting hardware should not
exceed 20 inch-pounds (2.2 newton meters).
Dimensions
For Rear Panel mounting, panel drilling dimensions are shown in Figure 1-4. All dimensions are shown in
inches with millimeters in parenthesis.

1-4 9469300994
Mounting DGC-2020HD
Figure 1-4. Rear Panel Drilling Dimensions for Style xPxxxxxxx
Overall Dimensions
Overall dimensions are shown in Figure 1-5. All dimensions are shown in inches with millimeters in
parenthesis.

9469300994 1-5
DGC-2020HD Mounting
Figure 1-5. Overall Dimensions

1-6 9469300994
Mounting DGC-2020HD

9469300994 2-1
DGC-2020HD Terminals and Connectors
2 • Terminals and Connectors
All DGC-2020HD terminals and connectors are located on the rear panel. DGC-2020HD terminals consist
of a mini-B USB jack, a DB-9 connector, Ethernet ports, plug-in connectors with spring clamp terminals,
and quarter-inch, male, quick-connect terminals.
Figure 2-1 illustrates the rear panel terminals. Locator letters in the illustration correspond to the terminal
block and connector descriptions in Table 2-1.
Figure 2-1. Rear Panel
CAN 1 LOW
CAN 1 HIGH
SHIELD
CAN 2 LOW
CAN 2 HIGH
51
52
53
54
55
RS-485A
RS-485B
RS-485 SHIELD
IRIG-B+
IRIG-B−
RDP-110 TxD+
RDP-110 TxD−
CHASSIS GND
AVR +
AVR −
GOV +
GOV −
GOV PWM
LOAD SHARE+
LOAD SHARE−
Eth 1
57
58
59
60
61
62
63
64
65
66
67
68
69
70
FUEL +
FUEL −
Not Used
OIL +
OIL −
OIL I
COOLANT+
COOLANT−
COOLANT I
ALOG IN 2 +
ALOG IN 2 −
ALOG IN 2 I
ALOG IN 1 +
ALOG IN 1 −
ALOG IN 1 I
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
OUT 1
AUX I4−
AUX I4+
AUX I3−
AUX I3+
AUX I2−
AUX I2+
AUX I1−
AUX I1+
GEN IC−
GEN IC+
GEN IB−
GEN IB+
GEN IA−
GEN IA+
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
OUT 12
OUT 11
OUT 10
COM 7, 8, 9
OUT 9
OUT 8
OUT 7
COM 4, 5, 6
OUT 6
OUT 5
OUT 4
COM 1, 2, 3
OUT 3
OUT 2
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
P0071-12
CHASSIS GND
BATT −
BATT +
Not Used
INPUT 16
50
49
48
47
46
INPUT 14
INPUT 13
INPUT 12
INPUT 11
INPUT 10
INPUT 9
INPUT 8
INPUT 7
INPUT 6
INPUT 5
INPUT 4
INPUT 3
INPUT 2
INPUT 1
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
BUS 2 VC BUS 2 VN
Not Used
MPU +
MPU −
BUS 2 VB
Not Used
BUS 2 VA
Not Used
BUS 1 VN BUS 1 VC
Not Used
BUS 1 VB
Not Used
BUS 1 VA
Not Used
GEN VN GEN VC
Not Used
GEN VB
Not Used
GEN VA 86
87 88 89 90 91 92 93 94 95 96 97 98
99
100 101 102 103 104 105 106 107
COM 10, 11, 12
INPUT 15
RUNSTART
PRE
DGC-2020HD
+–
C
D
B
E
F
A
A
A
A
A
Tx
Rx
P1
P2
P3
P4
P5
P6
P7
P8P9
Eth 1
Eth 2
56

2-2 9469300994
Terminals and Connectors DGC-2020HD
Table 2-1. Rear Panel Terminal and Connector Descriptions
Locator
Description
A
The majority of external, DGC-2020HD wiring is terminated at 5-, 7-, or 15-position
connectors with spring clamp terminals. These connectors plug into headers on the
DGC-2020HD. The connectors and headers have a dovetailed edge that ensures
proper connector orientation. Each connector and header is uniquely keyed to ensure
that a connector mates only with the correct header. Terminals accept a maximum
wire size of 12 AWG (3.31 mm2). Remove (strip) 0.4 inch (10 mm) of insulation from
each wire end inserted into a connector terminal.
B
This male DB-9 connector is provided for external dial-out modem communication and
the future implementation of other communication protocols. Contact Basler Electric for
protocol availability.
C
DGC-2020HD Ethernet communication uses the Modbus®TCP protocol to provide
remote metering, annunciation, and control. Dual copper (100Base-T) ports (style
xxxxDxxxx) use standard RJ-45 jacks and a fiber optic (100Base-FX) port (style
xxxxFxxxx) uses one ST fiber optic connector.
Ethernet ports have different designations depending on style:
•Dual copper (Style xxxxDxxxx) – The RJ-45 jack nearest to the mini-B USB port is
designated as Ethernet port 1 and is reserved for intergenset communications
(load sharing). The other RJ-45 jack is designated as Ethernet port 2 and can be
configured for redundant intergenset communications or for an independent
network connection.
•Fiber optic (Style xxxxFxxxx) – The ST fiber optic port is designated as Ethernet
port 1 and is reserved for intergenset communications (load sharing).
Figure 2-1 shows both Ethernet port styles (dual copper and fiber) for clarity. The
DGC-2020HD comes equipped with only one port style, not both.
D
The mini-B USB jack mates with a standard USB cable and is used with a PC running
BESTCOMSPlus
®
software for local communication with the DGC-2020HD.
E
Connections to the Start, Run, and Pre output contacts are made directly to each relay
through quarter-inch, male, quick-connect terminals.
F
An onboard battery maintains DGC-2020HD timekeeping during losses of control
power. See the Maintenance chapter for instructions on replacing the battery. Failure
to replace the battery with Basler Electric P/N 38526 may void the warranty.
Terminals
DGC-2020HD connections are dependent on the application. Incorrect wiring may result in damage to the
controller.
Note
Be sure that the DGC-2020HD is hard-wired to earth ground with no
smaller than 12 AWG copper wire attached to chassis ground
(terminal 50) on the rear of the controller.
The DGC-2020HD terminals are grouped by function and include control power, current sensing, voltage
sensing, engine sender input, magnetic pickup input, contact sensing, output contacts, CAN interface,
RS-485 interface, AVR control, GOV control, Load Share, IRIG source, Remote Display Panel
connection, USB port, Ethernet communication, and RS-232 communication.
DGC-2020HD terminals are described in the following paragraphs.

9469300994 2-3
DGC-2020HD Terminals and Connectors
Control power
The DGC-2020HD control power input accepts a nominal voltage of 12 Vdc or 24 Vdc and tolerates
voltage over the range of 6 to 32 Vdc. Control power must be of the correct polarity. While reverse
polarity will not cause damage, the DGC-2020HD will not operate. Control power terminals are listed in
Table 2-2.
A fuse should be added for additional protection for the wiring to the battery input of the DGC-2020HD. A
fuse helps prevent wire damage and nuisance trips due to initial power supply inrush current. To follow
UL guidelines, a 5 A maximum, 32 Vdc supplementary fuse must be implemented in the battery input
circuit to the DGC-2020HD.
Table 2-2. Control Power Terminals
Terminal
Description
50 (CHASSIS)
Chassis ground connections
49 (BATT–)
Negative side of control power input
48 (BATT+)
Positive side of control power input
Generator Current Sensing
The DGC-2020HD has sensing inputs for A-phase, B-phase, and C-phase generator current. A
DGC-2020HD with a style number of 1xxxxxxxxx has 1 Aac nominal current sensing and a DGC-2020HD
with a style number of 5xxxxxxxx indicates 5 Aac nominal current sensing. Generator current sensing
terminals are listed in Table 2-3.
Table 2-3. Generator Current Sensing Terminals
Terminals
Description
1 (IA+)
A-phase current sensing input
2 (IA–)
3 (IB+)
B-phase current sensing input
4 (IB–)
5 (IC+)
C-phase current sensing input
6 (IC–)
Programmable Current Sensing
Four user-programmable current sensing inputs are provided for measuring mains current, load bus
current, ground current, or a combination of these. Table 2-4 lists the programmable current sensing
terminals.
Table 2-4. Programmable Current Sensing Terminals
Terminal
Description
7 (AUX I1 +)
Programmable current sensing input 1
8 (AUX I1 –)
9 (AUX I2 +)
Programmable current sensing input 2
10 (AUX I2 –)
11 (AUX I3 +)
Programmable current sensing input 3
12 (AUX I3 –)
13 (AUX I4 +)
Programmable current sensing input 4
14 (AUX I4 –)

2-4 9469300994
Terminals and Connectors DGC-2020HD
Caution
Current sensing terminals 2 (IA–), 4 (IB–), 6 (IC–), 8(AUX I1–), 10
(AUX I2–), 12 (AUX I3–), and 14 (AUX I4–) must be terminated to
ground for proper operation.
Note
Unused current sensing inputs should be shorted to minimize noise
pickup.
Generator Voltage Sensing
The DGC-2020HD accepts either line-to-line or line-to-neutral generator sensing voltage over the range
of 0 to 576 volts, rms line-to-line or 0 to 333 volts, rms line-to-neutral. Generator voltage sensing terminals
are listed in Table 2-5.
Table 2-5. Generator Voltage Sensing Terminals
Terminal
Description
86 (GEN VA)
A-phase generator voltage sensing input
88 (GEN VB)
B-phase generator voltage sensing input
90 (GEN VC)
C-phase generator voltage sensing input
91 (GEN VN)
Neutral generator voltage sensing input
Installation in an Ungrounded System Application
When the DGC-2020HD is controlling equipment that is part of an ungrounded system, it is
recommended that potential transformers be employed on the voltage sensing inputs to provide full
isolation between the DGC-2020HD and monitored voltage phases.
Bus Voltage Sensing
Sensing of bus voltage enables the DGC-2020HD to detect failures of the mains (utility). Controllers with
style number xxx2xxxxx use bus voltage sensing to perform automatic synchronization of the generator
with the bus. The DGC-2020HD accepts either line-to-line or line-to-neutral bus sensing voltage over the
range of 0 to 576 volts, rms line-to-line or 0 to 333 volts, rms line-to-neutral. Controllers with style number
xxxxxxxEx are equipped with two bus sensing inputs. One is intended for sensing the mains voltage while
the other is intended for sensing the load bus voltage.
Bus voltage sensing terminals are listed in Table 2-6.
Table 2-6. Bus Voltage Sensing Terminals
Terminal
Description
93 (BUS1 VA)
A-phase bus voltage sensing input
95 (BUS1 VB)
B-phase bus voltage sensing input
97 (BUS1 VC)
C-phase bus voltage sensing input
98 (BUS1 VN)
Neutral bus voltage sensing input
100 (BUS2 VA)
A-phase bus voltage sensing input (optional)
101 (BUS2 VB)
B-phase bus voltage sensing input (optional)
103 (BUS2 VC)
C-phase bus voltage sensing input (optional)
104 (BUS2 VN)
Neutral bus voltage sensing input (optional)