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
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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
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