Basler DGC-500 User manual

INSTRUCTION MANUAL
FOR
DIGITAL GENSET CONTROLLER
DGC-500
Publication: 9355400990
Revision: H 02/14

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
•Communication Software Description
•Installation
•Maintenance and Troubleshooting
WARNING!
To avoid personal injury or equipment damage, only qualified personnel should
perform the procedures in this manual.
NOTE
Be sure that the DGC-500 is hard-wired to earth ground with no smaller than 12
AWG copper wire attached to the ground terminal on the rear of the unit case.
When the DGC-500 is configured in a system with other devices, it is
recommended to use a separate lead to the ground bus from each unit.
9355400990 Rev H DGC-500 Introduction i

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 installation or operation. The availability and design
of all features and options are subject to modification without notice. Should further information be
required, contact Basler Electric.
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.
The English-language version of this manual serves as the only approved manual version.
BASLER ELECTRIC
ROUTE 143, BOX 269
HIGHLAND IL 62249 USA
www.basler.com, inf[email protected]
PHONE [phone] FAX [phone]
CONFIDENTIAL INFORMATION
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.
ii DGC-500 Introduction 9355400990 Rev H

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 Software
Version and Date Change
1.05, 03/05 •Added configurable ECU contact, pulsing, and sleep mode disables,
and single-phase A-C sensing.
1.04, 09/04 •Added generator protection, event log, real-time clock, and run
statistics.
1.03, 10/03 •Added Engine Start/Stop Configuration setting to accommodate Volvo
Penta EDC applications. Added CANBus Address setting and the
Genset kW Rating setting.
1.02, 03/03 •Added settings for support of SAE J1939 interface and 400 Hz
operation.
1.01, 07/02 •Increased the maximum setting of the Global Sender Failure Alarm
Time Delay from 10 seconds to 30 seconds
1.00, 03/02 •Initial release
Application Firmware
Version and Date Change
3.06, 03/05 •Added configurable ECU contact, pulsing, and sleep mode disables,
and single-phase A-C sensing.
3.05, 09/04 •Added generator protection, event log, real-time clock, run statistics,
and sleep mode.
2.04, 10/03 •Added Engine Start/Stop Configuration setting to accommodate Volvo
Penta EDC applications. Added CANBus Address setting and Genset
kW Rating setting.
2.03, 03/03 •Added support for SAE J1939 interface and 400 Hz operation.
2.01, 07/02 •Increased the maximum Sender Failure Alarm time delay setting from
10 seconds to 30 seconds.
1.00, 03/02 •Initial release
Hardware (Standard
Order P/N)
Version and Date
Change
Q, 12/04 •Modified current metering circuitry.
P, 11/04 •BESTCOMS version 1.04/01 released to address compatibility issue
with MicrosoftWindowsXP SP2.
N, 09/04 •Implemented a higher-performance microprocessor and added an
external memory (EEPROM) chip.
M, 06/04 •Increased moisture resistance by adding conformal coating to the
printed circuit board assembly.
L, 10/03 •Implemented firmware version 2.04.XX and BESTCOMS version
1.03.XX.
9355400990 Rev H DGC-500 Introduction iii

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
Hardware (Special
Order P/N)
Version and Date
Change
H, 12/04 •Modified current metering circuitry.
G, 11/04 •BESTCOMS version 1.04.01 released to address compatibility issue
with MicrosoftWindowsXP SP2.
F, 09/04 •Implemented a higher-performance microprocessor and added an
external memory (EEPROM) chip.
E, 06/04 •Increased moisture resistance by adding conformal coating to the
printed circuit board assembly.
D, 10/03 •Implemented firmware version 2.04.XX and BESTCOMS version
1.03.XX.
C, 09/03 •Added reference to instruction manual on parts list.
B, 07/03 •Implemented firmware version 2.03.XX and BESTCOMS version
1.02.XX.
A, 06/03 •Circuit board layout revised to improve manufacturing process.
Manual
Revision and Date Change
H, 02/14 •Removed product registration information
•Added electrolytic capacitor maintenance recommendation
G, 01/08 •Added description of watchdog timer to Section 3, Functional
Description.
•Added manual part number and revision to page footers.
F, 03/05 •Added description of sleep mode disable setting.
•Added information about ECU contact configuration and pulsing
settings.
•Changed all “Volvo Penta EDC” references to “Volvo Penta EDC III”.
•Added J1939 interface parameters to Appendix C, DGC-500 Settings
Record.
E, 09/04 •Added text and illustrations describing added real-time clock,
generator run statistics, event log, and generator protection functions.
•Added Time Overcurrent Characteristic Curves appendix.
•Modified style chart to accommodate generator protection option.
•Added torque specification for mounting hardware.
D, 03/04 •Added suitability and warning statements concerning compliance of
part numbers 9355400113 and 9355400114 with cURus Standard
1604.
iv DGC-500 Introduction 9355400990 Rev H

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 and Alarm information in Section 3, Functional
Description to include metric equivalents for settings.
B, 03/03 •Revised style chart to show NFPA compliance as standard, J1939
support as optional.
•Added coverage for part numbers 9355400111, 112, 113, and 114.
•Added information about J1939 interface, ECU support, and state
machine operation where appropriate.
•Revised BESTCOMS section to accommodate new ECU settings.
•Created new appendix of settings list with range for each setting.
A, 07/02 •Added instructions to Section 3, Functional Description for viewing
firmware version.
•Revised the maximum setting of Sender Failure Alarm Time from 10
seconds to 30 seconds in Tables 3-1 and 3-2.
•Replaced actual BESTCOMS version number in Figure 4-2 with
generic version number.
—, 02/02 •Initial release
9355400990 Rev H DGC-500 Introduction v

This page intentionally left blank.
vi DGC-500 Introduction 9355400990 Rev H

CONTENTS
SECTION 1 •GENERAL INFORMATION ................................................................................................ 1-1
SECTION 2 •HUMAN-MACHINE INTERFACE ....................................................................................... 2-1
SECTION 3 •FUNCTIONAL DESCRIPTION........................................................................................... 3-1
SECTION 4 •BESTCOMS SOFTWARE .................................................................................................. 4-1
SECTION 5 •INSTALLATION .................................................................................................................. 5-1
SECTION 6 •MAINTENANCE AND TROUBLESHOOTING.................................................................... 6-1
APPENDIX A •TIME OVERCURRENT CHARACTERISTIC CURVES...................................................A-1
APPENDIX B •PARAMETERS AND SETTINGS.....................................................................................B-1
APPENDIX C •SETTINGS RECORD ......................................................................................................C-1
9355400990 Rev H DGC-500 Introduction vii

This page intentionally left blank.
viii DGC-500 Introduction 9355400990 Rev H

SECTION 1
•
GENERAL INFORMATION
TABLE OF CONTENTS
SECTION 1 •GENERAL INFORMATION ................................................................................................ 1-1
DESCRIPTION....................................................................................................................................... 1-1
FEATURES............................................................................................................................................ 1-1
FUNCTIONS.......................................................................................................................................... 1-1
OUTPUTS.............................................................................................................................................. 1-1
OPTIONAL EQUIPMENT ...................................................................................................................... 1-1
STYLE AND PART NUMBERS ............................................................................................................. 1-2
Style Numbers.................................................................................................................................... 1-2
Part Numbers ..................................................................................................................................... 1-2
SPECIFICATIONS................................................................................................................................. 1-3
Current Sensing ................................................................................................................................. 1-3
Voltage Sensing ................................................................................................................................. 1-3
Frequency........................................................................................................................................... 1-3
Contact Sensing................................................................................................................................. 1-3
Engine System Inputs ........................................................................................................................ 1-4
Calculated Data.................................................................................................................................. 1-4
Generator Protection Functions ......................................................................................................... 1-4
Output Contacts ................................................................................................................................. 1-5
Horn Output........................................................................................................................................ 1-5
Communication Interface ................................................................................................................... 1-5
Environment ....................................................................................................................................... 1-6
Type Tests.......................................................................................................................................... 1-6
UL Recognition................................................................................................................................... 1-6
CSA Certification................................................................................................................................ 1-6
NFPA Compliance.............................................................................................................................. 1-7
Physical.............................................................................................................................................. 1-7
Figures
Figure 1-1. Style Number Identification Chart ........................................................................................... 1-2
Table
Table 1-1. Special-Order DGC-500 Controllers ........................................................................................ 1-3
9355400990 Rev H DGC-500 General Information i

This page intentionally left blank.
ii DGC-500 General Information 9355400990 Rev H

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 controls and indicators enable quick and simple DGC-500
operation. Basler Electric communication software (BESTCOMS-DGC500-32) allows units to be easily
customized for each application. Because of the low sensing burden in the DGC-500, neither dedicated
potential transformers (PTs) nor current transformers (CTs) are required. A wide temperature-range liquid
crystal display (LCD) with backlighting can be viewed under a wide range of ambient light and
temperature conditions.
An event log retains a history of system events in nonvolatile memory. Up to 30 event types are retained
and each record contains a time stamp and the number of occurrences for each event.
Optional, multifunction generator protection guards against generator overvoltage, undervoltage, under-
frequency, overfrequency, overcurrent, and phase imbalance. Each generator protection function has an
adjustable pickup and time delay setting. Sixteen inverse time curves enable the DGC-500 to offer
overcurrent protection in a variety of applications.
An optional, SAE J1939 interface provides high-speed communication between the DGC-500 and the
engine control unit (ECU) on an electronically controlled engine. This interface provides access to oil
pressure, coolant temperature, and engine speed data by reading these parameters directly from the
ECU. When available, engine diagnostic data can also be accessed.
FEATURES
DGC-500 Digital Genset Controllers have the following features.
•Resistant to high moisture, salt fog, humidity, dust, dirt, and chemical contaminants
•Resistant to the entrance of insects and rodents
•Suitable for mounting in any top mount enclosure
•Suitable for controlling isolated generating systems or paralleled generating systems
•Serial link communications and BESTCOMS software eases access to setup parameters
•Compliant with National Fire Prevention Association (NFPA) Standard 110
•Optional SAE J1939 interface provides high-speed communication with the ECU on electronically
controlled engines
FUNCTIONS
DGC-500 Digital Genset Controllers perform the following functions.
•Engine cranking control
•Generator voltage metering
•Generator frequency metering
•Generator current metering
•Engine coolant temperature metering
•Engine coolant temperature protection
•Engine oil pressure metering
•Engine oil pressure protection
•Fuel level sensing
•Fuel level sender protection
•Fuel leak detector
•Engine cool down
•VA metering
•Engine rpm metering
•Engine run time metering
•Battery voltage metering
•Battery condition monitoring
•Engine maintenance monitoring
•Engine diagnostic reporting
•Event log stores a history of up to 30 system
event types
•Multifunction generator protection (optional)
OUTPUTS
Five isolated, form A output contacts are provided: Engine Crank, Fuel Solenoid, Pre-Start, and two user-
programmable outputs.
OPTIONAL EQUIPMENT
An optional Remote Annunciation Display Panel (RDP-110) is available for use with the DGC-500.
9355400990 Rev H DGC-500 General Information 1-1

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 controllers
are specified by ten-digit part numbers
Style Numbers
The electrical characteristics and operational features of a standard-order DGC-500 are defined by a
combination of letters and numbers that make up the style number. The model number, together with the
style number, describes the options included in a specific device. Figure 1-1 illustrates the DGC-500 style
number identification chart.
Figure 1-1. Style Number Identification Chart
For example, if a DGC-500 style number if F5J1, the device has the following characteristics and
operating features.
F…. Compliance to NFPA Standard 110
5…. 5 ampere current sensing inputs
J…. ECU communication through the SAE J1939 protocol
1…. Multifunction generator protection
The DGC-500 style number is printed on a label located on the circuit board near the voltage and current
input connections. Upon receipt of a unit, be sure to check the style number against the requisition and
the packing list to ensure that they agree.
Part Numbers
A ten-digit part number specifies the electrical characteristics and operational features of special-order
DGC-500 controllers. Table 1-1 lists the special-order DGC-500 controllers available along with
descriptions of their operating features.
1-2 DGC-500 General Information 9355400990 Rev H

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
SPECIFICATIONS
Current Sensing
Accuracy: ±1% of full scale or ±2 A, whichever is greater
Burden: 1 VA
Terminals: P10, P11 (A-phase)
P12, P14 (B-phase)
P15, P17 (C-phase)
1 Ampere Inputs
Continuous Rating: 0.02 to 1.0 A
1 Second Rating: 2 A
5 Ampere Inputs
Continuous Rating: 0.1 to 5.0 A
1 Second Rating: 10 A
Voltage Sensing
Accuracy: ±1% of full scale or ±2 V, whichever is greater
Burden: 1 VA
Range: 12 to 576 V rms, line-to-line
1 Second Rating: 720 V rms
Terminals: P23 (A-phase), P26 (B-phase), P29 (C-phase), P30 (Neutral)
Frequency
Accuracy: ±0.25% of reading or ±0.2 Hz, whichever is greater
Display Range: 4 to 70 Hz
4 to 450 Hz (P/N 3555400111, 9355400112 only)
Contact Sensing
Emergency Stop Input
Type: Normally-closed dry contacts
Terminals: P35, P39
Programmable Inputs (3)
Type: Normally-open dry contacts
Terminals: P2, P21 (Input 1)
P3, P21 (Input 2)
P4, P21 (Input 3)
9355400990 Rev H DGC-500 General Information 1-3

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 Ωnominal
Terminals: P16, P19 (common)
Coolant Temperature Sensing
Accuracy: ±3% of indication (37°C to 115°C (99°F to 239°F))
±2°, whichever is greater at 25°C (77°F) ∗
Range: 62.6 to 637.5 Ωnominal
Terminals: P18, P19 (common)
Oil Pressure Sensing
Accuracy: ±3% of indication (0 to 690 kPa) or ±12 kPa, whichever is greater at 25°C
(77°F)
Range: 34 to 240 Ωnominal
Terminals: P13, P19 (common)
Battery Voltage Sensing
Accuracy: ±3% of indication or ±0.2 V, whichever is greater
Nominal: 12 or 24 Vdc
Range: 8 to 32 Vdc (battery dip ride-through to 6 Vdc for 0.75 sec)
Burden: 16 W maximum
Terminals: P20 (+), P21 (–)
Magnetic Pickup Sensing
Voltage Range: 3 V to 35 V peak continuous into 13 kΩ(during cranking)
Frequency Range: 32 to 10,000 Hz
Terminals: P39 (+), P40 (–)
Engine RPM Sensing
Accuracy: ±0.5% of indication or ±2 rpm, whichever is greater at 25°C (77°F)
Range: 750 to 3,600 rpm
Calculated Data
Voltamperes
Accuracy: ±2% indication or ±2 kVA, whichever is greater
Range: 0 to 9,999 kVA
Engine Run Time
Accuracy: ±0.5% of reading or ±1 hour, whichever is greater at 25°C (77°F)
Range: 0 to 99,999 hours
Maintenance Interval
Accuracy: ±0.5% of reading or ±1 hr, whichever is greater at 25°C (77°F)
Range: 0 to 5,000 hours
Generator Protection Functions
Overvoltage (59) and Undervoltage (27)
Pickup Range: 70 to 576 Vac
Pickup Increment: 1 Vac
Inhibit Frequency Range: 20 to 400 Hz (applies to 27 function only)
Time Delay Range: 0 to 30 s
Time Delay Increment: 0.1 s
1-4 DGC-500 General Information 9355400990 Rev H

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: 0.18 to 1.18 Aac (1 A current sensing)
0.9 to 7.75 Aac (5 A current sensing)
Time Dial Range: 0 to 30 s (fixed time delay)
0 to 9.9 (inverse curve time multiplier)
Time Dial Increment: 0.1 s
Inverse Time Curves: See Appendix A, Time Overcurrent Characteristic Curves
Phase Imbalance (47)
Pickup Range: 5 to 100 Vac
Pickup Increment: 1 Vac
Time Delay Range: 0 to 30 s
Time Delay Increment: 0.1 s
Output Contacts
Engine Crank, Fuel Solenoid, and Pre-Start Relays
Rating: 30 A at 28 Vdc, make, break, and carry ∗
Terminals: K1-N.O., COM (Engine Crank)
K2-N.O., COM (Fuel Solenoid)
K5-N.O., COM (Pre-Start)
∗The contact rating is reduced to 3 A for part numbers 9355400113 and 9355400114 when used in a
hazardous location.
Programmable Relays (2)
Rating: 2 A at 30 Vdc, make, break, and carry
Terminals: P33, P34 (Output 1)
P36, P38 (Output 2)
Horn Output
Voltage: 24 Vdc or battery voltage, whichever is less
Current: 15 mAdc maximum
Compatible Device: Basler P/N 29760
Terminals: P24 (+), P25 (–)
Communication Interface
Full Duplex RS-232
Connection: Female DB-9 connector (J1)
Baud: 1200, 2400, or 9600
Data Bits: 8
Parity: None, Odd, or Even
Stop Bit: 1
SAE J1939 Interface
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
9355400990 Rev H DGC-500 General Information 1-5

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 following:
5 to 29 to 5 Hz: 1.5 G peak for 5 min.
29 to 52 to 29 Hz: 0.036” DECS-A for 2.5 min.
52 to 500 to 52 Hz: 5 G peak for 7.5 min.
Salt Fog
Tested per ASTM-117B-1989
Radio Interference
Type tested using a 5 W, hand-held transceiver operating at random frequencies centered around 144
and 440 MHz with the antenna located within 150 mm (6”) of the device in both vertical and horizontal
planes.
Dielectric Strength
2,352 Vac at 50/60 Hz for 1 second between voltage sensing inputs and all other circuits.
500 Vac at 50/60 Hz for 1 minute between any of the following groups.
Current Sensing Inputs: 8 mA
RS-232 Port: 6 mA
UL Recognition
All DGC-500 controllers are UL recognized per Standard 508, Standard for Industrial Control Equipment
(UL File E97035).
Part Numbers 9355400113 and 9355400114
cURus recognized per Standard 1604, Electrical Equipment for Use in Class Iand II, Division 2, and
Class III Hazardous (Classified) Locations, Class I, Division 2, Groups A, B, C, D, Zone 2,
Temperature Code T5.
This equipment is suitable for use in Class I, Division 2, Groups A, B, C, D, or nonhazardous locations
only.
CSA Certification
Certified per Standard CAN/CSA-C22.2, Number 14-95, CSA File LR 23131 (excludes P/N 9355400113
and 9355400114).
WARNING! - EXPLOSION HAZARD
(9355400113 and 9355400114 only)
Substitution of components may impair suitability for Class I, Division 2.
Do not disconnect equipment unless power has been switched off or the area is
known to be non-hazardous.
1-6 DGC-500 General Information 9355400990 Rev H

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

This page intentionally left blank.
1-8 DGC-500 General Information 9355400990 Rev H