Procom DGC-7RR User manual

OPERATING INSTRUCTIONS DGC-7RR
START MON GON STOP


-
Fail to Start Fail to Stop
VIEW / PROGRAM
RESET
PROCOM
Emergency
Low Fuel
HWT/HCTLLOP
V-Belt
Canopy oCD Voltage
D Freq
Battery
D C-7R
Over speed
O/C Crank Solenoid
R
Auto
Man.
Test
Off
MRM PROCOM
PROCOMPROCOM
PROCOM Pvt Ltd
Plot No. : 20-21, Industrial Estate,
Sector - 59, Phase-II, Faridabad (Haryana)
Ph.: 0129-4700400(10 Lines)
Email: [e-mail]
Web: www.mrmprocom.com

DGC-7R Digital Genset Controller
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Index

DGC-7R Digital Genset Controller
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1.0 Introduction
2.0 Protection, Supervision Salient features
3.0 Measurement & Display
4.0 Annunciations
5.0 Contacts
6.0 Timers
7.0 Switches Description
8.0 Annunciations Description
9.0 Lamp Test
10.0 Operating Mode
10.1 Auto Mode
10.2 Manual Mode
10.3 Off Mode
10.4 Test Mode
10.5 Remote Mode
11.0 Programming mode
11.1 Parameter Mode
11.2 Annunciation Mode
11.3 Programming Solenoid Mode
12.0 Faults
12.1 Internal Faults
12.2 External Faults
12.3 Fault Reset
13.0 Communication
14.0 Model Selection
15.0 Terminal description
16.0 Specifications
17.0 Connection Diagram

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1.0 Introduction
•16 Bit RISC, state of art,
microcontroller based System.
•True RMS measurement of all
measured parameters with 1% accuracy
of measured value (Not full scale)
Backlit LCD Display for easy reading
and parameter settings. No need to
consult the manual while programming
the unit.
•All the inputs, such as Mains, Generator
and Battery voltages are fully isolated,
providing the freedom to design a
totally isolated system. This avoids and
prevents malfunctioning/ burning of the
unit.
•Fully operational up to 4V. Can
withstand a voltage dip up to 0V for
1sec.
•Many variants are available to suit
various system requirements. See model
selection chart
•23 window annunciation
•All system parameters are user
programmable
•Suitable for all types of engines
including the one requiring choke.
•Easy selection of modes by a simple
press of a switch
•All digital inputs are optically isolated
for enhanced reliability
•All outputs are through potential free
contacts for system stability and
reliability
•All contacts are protected by TVS to
strengthen the EMI/EMC capabilities of
the unit.
•Up to 6 potential free annunciation
contacts. These contacts can be
configured, in any combination, for
announcing any one or more of the 19
possible conditions
•Housed in 92X192mm Din Standard
housing.
•Over 80 Variants
2.0 Protection, Supervision Salient features
•Mains 3 phase monitoring for
under/over voltage, under/over
frequency and Phase voltages
unbalance.
•Generators single phase monitoring and
protection for under/over voltage,
under/over frequency and over
speeding.
•DC Battery Voltage supervision (Under
& Over voltage)
•8 digital input for system protection
•DG Fail to Start supervision
•DG fail to Stop supervision
•User programmable engine warm up
time, before the load is switched to
generator.
•Mains Restoration supervision
•User programmable Cranking attempt.
•User programmable Crank Time and
delay between two successive cranks
•External engine running signal
•External signal for remote operation
•Programmable option for Choke
3.0 Measurement & Display
16 segment 2 line LCD displays the following parameters. Some of the parameters are model
dependent and are available in only those models.
•Mains 3 Phase voltage
•Mains Frequency
•Generator Voltage
•Generator Frequency
•Battery Voltage
•Generator Run Hour
•RPM
•Programmed settings
•Room/Canopy Temperature (Select
Model)
•BTS Voltage (Select Model)
•Current 1 Phase (Select model)
•LLOP through Sensor
•HWT/HCT through Sensor

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•Fuel through Sensor
Normally the display auto scrolls and displays a set of parameter for 10 seconds, but any time the
Next key (  ) can be pressed to select the next parameter window.
4.0 Annunciations
DGC-7R is equipped with the following annunciations for system status and faults
•Load on generator (GON)
•Load on Mains (MON)
•Mains : Healthy/Unhealthy
•Generator On
•DG Fail to Start (fault)
•DG Fail to Stop (fault)
•Emergency (Shut down Command)
•LLOP (Fault)
•HWT(Fault)
•Fuel (Fault)
•DG frequency(Fault)
•DG Voltage (Fault)
•DG Over Speed (Fault)
•V-Belt (Fault)
•Canopy Temperature (Fault)
•Over Current (Fault)
•Battery (Warning)
•Crank (Annunciation)
•Fuel Sol (Annunciation)
•Auto (Annunciation)
•Manual (Annunciation)
•Test (Annunciation)
•Off (Annunciation)
5.0 Contacts
The following potential contacts are provided. Annunciation contacts are available in models
requested with Annunciation features.
•Mains Contactor: MCB (NC)
•Generator Contactor: GCB (N0)
•Crank (NO)
•Fuel (NO)
•Hooter (NO)
•Choke (NO). This contact can be used
as a general purpose annunciation
contact if the choke function is not used
•Optional 5 contacts(NO) for
annunciations. The choke contact can
be used as annunciation contacts in
engines not requiring choke.
6.0 Timers
DGC-7R is equipped with the following timers:
•Mains voltage supervision timer
(variable)
•Mains frequency supervision
timer(variable)
•Mains voltage unbalance supervision
timer (variable)
•Generator voltage supervision timer
(variable)
•Generator Frequency Unhealthy
supervision timer (variable)
•Generator over speed supervision timer
(Variable)
•Choke pre start timer (Variable)
•Choke post start timer (Variable)
•Max. crank duration timer (variable)
•Crank gap timer (variable)
•No. of crank attempts (variable)
•DG warm up timer(variable)
•Mains restoration timer (variable)
•DG re-cooling timer (variable)
•Stop Solenoid on time (variable)
•Fuel supervision time (variable)
•LLOP supervision time (variable)
•HWT supervision time (variable)
•Auxiliary Supply Under/Over voltage
supervision & warning timer (Fixed)
•Canopy supervision timer(variable)
•Over Current supervision
Timer(variable)

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•V-Belt supervision timer (variable)
•Delay between GCB to MCB switching
(Variable)
•Hooter Reset Time(variable)
7.0 Switches Description
DGC-7R has 12 switched are provided on its front panel. The table below describes the operation of
these.
S.No. Switch Symbol Switch Function Description
1

Next Normal operation mode: In this mode, it is
used to change the parameters being displayed
on LCD.
Programming Mode: Next key is used to
select the next parameter to be programmed.
2

Increment This key is only active during Programming
Mode and is used to increment the value of the
parameters under programming.
3
-
Decrement This key is only active during programming
mode and is used to decrement the value of the
parameter under programming.
4 R Reset Reset key resets the Hooter and Fault signals.
The first press shall reset the hooter and next
shall reset the faults. A long press of 1 Sec shall
reset both.
5

&
-
Programming
Mode Entry
If both the keys are pressed simultaneously the
unit will enter in Programming Mode.
6 START To start Generator in Manual Mode.
7 STOP To stop Generator in Manual Mode.
8 MCB In Manual Mode this toggles the mains
contactor, On/Off
9 GCB In Manual Mode this toggles the generator
contactor, On/Off
10 Auto To select Auto Mode.
11 Man. To select Manual Mode.
12 Test To select Test Mode.
13 Off To select Off Mode.
Auto, Man., Test & Off are Radio buttons and only one can be active at a time.
8.0 Annunciations Description
DGC-7R has 23 annunciations on its front panel. These either announce the faults or indicated the
status of the system.
S.
No.
Nomenclature Description
1 Fail Start This LED blinks when the engine Fails to Start.
2 Fail stop This LED blinks when the engine Fails to Stop.
3 Emergency This LED blinks when the engine is Stopped in emergency.
4 LLOP This LED blinks when the engine is stopped on LLOP fault.
5 HWT This LED blinks when the engine is stopped on HWT fault.
6 Fuel This LED blinks when the engine is stopped on Low Fuel fault.
7 Canopy This LED blinks when the engine is stopped on high canopy
temperature fault.

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8 DG Freq This LED blinks when the engine is stopped on frequency fault.
9 DG Vol This LED blinks when the engine is stopped on voltage fault.
10 Over Speed This LED blinks when the engine is stopped on over speed fault.
11 V-Belt This LED blinks when the engine is stopped on V-Belt fault.
12 Battery This LED blinks when the Auxiliary supply is outside the limits.
Warning only.
13 O/C This LED blinks when the engine is stopped on over current fault.
14 Crank This LED lights up while the engine is being cranked..
15 Fuel Sol This LED lights up while the fuel solenoid is active.
16 Mains Steady while Main is healthy else starts blinking.
17 MCB Steady when MCB is engaged.
18 GCB Steady when GCB is engaged.
19 Generator Steady while generator is running.
20 Auto This LED is On if the unit is in Auto Mode.
21 Man. This LED is On if the unit is in Manual Mode.
22 Test This LED is On if the unit is in Test Mode.
23 Off This LED is On if the unit is in OFF Mode.
9.0 Lamp Test
Switching on the power of the unit with RESET switch pressed shall force the entire annunciation
LEDS to blink and display shall show the DGC-7R Model type along with the version number of
the software. This state shall persist till the switch is kept pressed and on release of the switch DGC-
7R shall start functioning normally.
10.0 Operating Mode
DGC-7R is equipped with 5 operation modes, namely Auto, Manual, Test, Off and Remote Mode.
The first four modes can be selected by pressing the corresponding switch, from the front panel. The
remote mode is selected by a digital signal at its terminal.
10.1 Auto Mode
DGC-7R monitors the Mains supply, if Mains supply varies beyond set limit of under/over voltage
or under/over frequency or voltage unbalance for more than their individual programmed
supervision time, DGC-7R releases the MCB contactor (to protect the contactor from failure
because of low input voltage) and attempts to starts the generator.
DGC-7R gives cranks the engine by activating the inbuilt, potential free, crank contact. Crank
command is withdrawn if the engine start is detected, either by external engine start input or by
build up of generator voltage. Max duration of crank command is user settable.
In case of non start of the engine DGC-7R re-cranks it till it starts or user programmed crank
attempts are exhausted. If generator fails to start after the maximum programmed crank attempts,
Fail to Start LED starts blinking, indicating start failure and the hooter is switched on.
After successful start of the generator, it is allowed to warm up for a user programmed time before
the load is transferred to generator.
While the generator is running DGC-7R monitors it for external fault (LLOP, HWT, Emergency,
Fuel, V-Belt, Over Current and Canopy temperature) and internal faults on voltage and frequency.
Over Current Fault could also be internal fault in models having provision to measure and
monitor the current.
On persistence of any fault for more than the programmed supervision delay, for that fault,
generator is stopped, corresponding fault is announced & hooter is switched on.
On restoration of healthy mains supply, continuously, for the programmed duration the load is
transferred to the mains and generator is stopped after expiry of re-cooling time. In case mains
again become unhealthy during the re-cooling period the load is switched to generator.
10.2 Manual Mode
DGC-7R, in this mode is under the manual control of the operator for starting and stopping of the
generator. Engine has to be started manually by manually pressing “Start” switch. The “Start”

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switch shall not operate if GCB contact is closed, to provide protection to generator. Once the
generator is started the load can be switched to generator by pressing “GCB” switch or to mains
by pressing MCB switch. At any given time, either of GCB or MCB can be operational. Attempt
to switch on GCB while MCB is on will be ignored and vice versa. Both MCB and GCB key have
dual function of either switching ON or OFF the respective contactor. A press shall toggle the
state. Continuously pressing these keys shall keep toggling the status. To stop the generator,
switch off the GCB contactor and press “STOP” key. Any attempt to stop the generator, while the
GCB contact is engaged, shall be ignored.
While the generator is running DGC-7R protects the generator by monitoring all internal and
external faults.
10.3 Off Mode
This mode is selected to completely shut down the system. By default the load is transferred to
Mains, but Mains contactor can also be switched off/On manually.
10.4 Test Mode
This mode helps the engineer to test the health of the engine. The engine can be started, as in Auto
Mode, even when the Mains voltage is healthy. The load is not transferred to the generator. In case
of Mains failure, while in this mode, the load is automatically transferred to the generator. Please
note that the generator will not automatically switch off in this mode. To switch off the generator
select either Auto, Manual or Off mode. “GCB” & “MCB” keys are active in this mode. DGC-7R
protects the generator by monitoring all internal and external faults.
10.5 Remote Mode
Remote mode is a subset of Auto Mode. Till Remote Pin of DGC-7R is left open, the unit works
in Auto Mode. DGC-7R is put in Remote Mode by pulling Remote Pin low to battery negative. In
Remote Mode the unit shall not initiate the generator start process till the Remote Pin is held low.
On release of this pin and if the mains is unhealthy , the engine start process will be initiated. The
generator shall stop either on Mains becoming healthy or Remote Pin again going low. The
engine shall stop after the re-cooling time. While the generator is running DGC-7R protects the
generator by monitoring all internal and external faults.
11.0 Programming mode
DGC-7R has provision to program the operating parameters and annunciations separately.
Programming Mode can be entered any time by simultaneously pressing

&
-
switches. As soon as
DGC-7R enters the programming mode the Display Screen shall display “Select Pra/Ann +” in fist Row and
“Parameter Mode” in second row, ”Pressing “

” Switch will take the units in parameter programming
mode. To program the annunciation contacts scroll the screen by pressing

. The display shall now display
“Annunciator Mode”. Press “

” Switch to enter annunciation contacts programming mode. While in
Program Mode, the first row of LCD displays parameter/annunciation contact name/number under
programming and second row contains the parameter value. Please note that 20sec of inactivity will take the
unit back in normal mode and all the changes done shall be cancelled. The following tables gives the
detailed descriptions.
11.1 Parameter Mode
S.No Parameter
name on first
row of LCD
Explanation of parameter Factory
setting
Setting Range
Please note: Operating Mode cannot be changed if the unit
has stopped on a fault condition or the engine is cranking

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Common to all Models
1 Mains O/V Max. Permissible voltage, above
this the voltage is treated unhealthy
& Generator is started.
270V 80-300V
2 Mains U/V Min. permissible voltage, below
this the voltage is treated unhealthy
& Generator is started
180V 80-270V
3 Mains Sup
Delay
Time for which the Mains voltage
has to be unhealthy (Under or Over
voltage as defined above in 1 & 2)
before starting the Generator.
10Sec 0-999Sec
4 Mains O/F Max. Permissible Mains
frequency, above this frequency
the Mains is treated unhealthy &
Generator is started.
55Hz 40-65Hz
5 Mains U/F Min. permissible Mains frequency,
below this frequency the Mains is
treated unhealthy & Generator is
started.
45Hz 40-65Hz
6 Mains Freq
Delay
Time for which the Mains
frequency has to be unhealthy
(under or over voltage as defined
above in 4 & 5) before starting the
Generator.
10Sec 0-999 Sec.
7 Mains Vol
Unbal
(Not available
In Single phase
version)
Max. Permissible voltage
difference between two phases of
mains. Above this the voltage is
treated to be unbalanced and
Generator is started.
Disable* 10-100 Disable*
8 Unbalance
Delay
Duration for which unbalance can
be allowed before starting the
Generator. This parameter is not
available if (7) is set to disabled.
10Sec 0-999Sec
9 Gen Start Delay The starting of generator is delayed
by this time after the mains
unhealthy timers have expired and
the mains contact has been
released. This is required in certain
applications where immediate
generator starting is not required
but the mains contactor are to be
protected. This timer is
automatically reset, if during this
duration the mains become
healthy for “Mains Restoration
Delay” (26)
Disable* 0-999
10 Gen Start Unit The generator start delay(9) can be
programmed in seconds or
minutes. This parameter is not
available if (9) is disabled.
Sec Sec-Min
11 Generator O/V Max. Permissible Generator
voltage, above this the Generator
voltage is treated unhealthy & the
Generator is stopped on voltage
270V 80-270V

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fault.
12 Generator U/V Min. permissible Generator
voltage, below this the Generator
voltage is treated unhealthy & the
Generator is stopped on voltage
fault.
180V 80-270V
13 Gen Sup Delay Duration for which generator
Over/Under voltage condition can
be tolerated before stopping the
Generator.
30Sec 0-999Sec
14 Generator O/F Max. Permissible Generator
frequency, above this the
Generator frequency is treated
unhealthy & the Generator is
stopped on frequency fault.
55Hz 40-65Hz
Disable*
15 Generator U/F Min. permissible Generator
frequency, below this the
Generator frequency is treated
unhealthy & the Generator is
stopped frequency fault.
45Hz 40-65Hz
Disable*
16 Gen Freq Delay Duration for which Generator
Over/Under frequency condition
can be tolerated before stopping
the Generator.This setting is not
available if (12)&(13) are disabled
10Sec 0-999 Sec.
17 Generator O/S The maximum Generator
frequency beyond which over
speed is detected
65Hz 40-80Hz
Disable*
18 Gen O/S Delay Time for which over speeding is
allowed. This parameter is not
available if (17) is disabled.
2 Sec 0-999Sec
19 Choke Pre Time Activate the choke for this time
before cranking
Disable 1-100Sec
Disable*
20 Choke Post
Time
Keep the choke for this time after
the engine has started. This setting
is not available if (19) is disabled
Disable 1-100Sec
Disable*
21 No Of Crank The maximum number of cranks
that shall be issued to start the
Engine
3 0-10
22 Crank Time Maximum crank time 5Sec 0-25 sec
23 Crank Delay The delay between two successive
cranks
5Sec 0-100Sec
24 Gen Pick Vol This parameter specifies the
generator voltage at which the is
presumed to have started and crank
has to be terminated
100V 70-150V
25 Warm Up Time Generator warm up time. The load
is transferred to generator after
expiry of this time
0Sec 0-999Sec
26 Mains Rest
Delay
Mains restoration Delay:
The time for which Mains should
be continuously healthy before
stopping the Generator.
30Sec 0-999Sec
27 Gen Recool The time for which generator is 30Sec 0-999Sec

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Time allowed to run on no load before
switching off
28 Stop Sol On
Time
The time for which stop solenoid
will be kept active while stopping
the engine
30Sec 0-999Sec
29 Fuel Level in % Fuel Level in %. Below this level
the fuel fault shall be acivated
15% 10-100%
30 Fuel Delay Duration for which the Fuel level
should be continuously low to be
recognized as a fault and action
initiated. This fault is always
enabled.
2 Sec 0-999Sec
31 Lube Low
Pressure
The minimum acceptable pressure
in Kg/cm
2
. Below this level the
LLOP fault shall be activated
2.5Kg/cm
2
0-8.5 Kg/cm
2
32 LLOP Delay Duration for which the LLOP
signal should be continuously
active to be recognized as a fault
and action initiated. This fault is
only enabled while the generator is
running.
2 Sec 0-999Sec
33 HW
Temperature
The maxi. Temperature at which
the engine is allowed to operate
70
o
C 10-120
o
C
34 HWT/HCT
Delay
Duration for which the HWT
signal should be continuously
active to be recognized as a fault
and action initiated. This fault is
always enabled.
2 Sec 0-999Sec
35 O/C Delay Duration for which the external or
internal over current (for models
which have internal current
measurement) be recognized as a
fault and action initiated. This fault
is only enabled while the generator
is running.
2Sec 0-999
Disable*
36 V-Belt Delay Duration for which the V-Belt
signal should be continuously
active to be recognized as a fault
and action initiated. This fault is
only enabled while the generator is
running.
2Sec 0-999
37 Canopy Delay Duration for which the external or
internal (Models with canopy
temp. measurements) Canopy
Temperature fault should be
continuously present to be
recognized as a fault and action
initiated. This fault is only enabled
while the generator is running.
2 Sec 0-999Sec
38 GCB to MCB
Delay
User programmable delay when
the load is transferred from
Generator to Mains.
2 Sec 1-5 Sec
39 Hooter Reset
Tim
Duration for which the hooter shall
be ON, if not externally reset,
while announcing a fault.
30Sec 0-999Sec
40 DC O/V Max. permissible Auxiliary supply 30V 10-40V

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voltage. If Auxiliary voltage is
higher than this for 10sec the
Battery LED starts blinking (only
warning).
Disable*
41 DC U/V Min. permissible Auxiliary supply
voltage. If Auxiliary voltage is
lower than this for 10sec the
Battery LED starts blinking (only
warning).
10V 10-40V
Disable*
42 Gen On Time Max. duration for which the
generator is allowed to work
continuously
Disable* 10-999Min
43 Gen Rest Time If the generator has run
continuously as per (39), the
generator is given rest irrespective
of the mains condition. In case of
mains unhealthy during this time
the mains contact is deactivated
but the generator is not started.
This is unavailable if (39) is
Disabled
This timer is automatically reset, if
during this duration the mains
become healthy for “Mains
Restoration Delay” (26)
Disable* 10-999Min
For models with internal Current Measurement
44 CT Ratio External CT Ratio 1 1-200
45 O/C The current above which the over
current fault monitoring has to
start. The timer for it is as
described in 33. Setting it to
disable will doesn’t disable the
external over current fault. This
fault is only enabled while the
generator is running.
6Amp 1-999Amps
Disable*
For models with BTS Voltgae Measurement
46 BTS Under Vol The min. permissible voltage of
BTS. The generator shall not be
started, even if the mains voltage
becomes unhealthy till the BTS
voltage is above this limit.
42V 18-70V
47 BTS Vol Delay BTS voltage has to continuously
below (43) limit for this duration
for starting the generator
5Sec 0-999Sec
For models with Room Temperaure Measurement
48 Room Temp The max. permissible room
temperature. The generator shall
not be started, even if the mains
voltage becomes unhealthy till the
Room temperature is below this
limit
27Deg 18-40Deg
49 Room Temp
Delay
Room Temperature has to
continuously above (45) limit for
this duration for starting the
generator
5Sec 0-999Sec

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For models with Room Temperaure and BTS Voltage Measurement
Any of (43) or (45) condition being satisfied shall start the generator
For models with Canopy Temperaure Measurement
49 Canopy Temp Max. permissible Canopy
temperature before the engine is
shut down.
70 20-99
* This parameter can be disabled while programming
11.2 Annunciation Mode
When DGC-7R enters this mode, it allows programming of 6 contact free annunciations. Please
note that in case ANN1 shall not be available if in parameter mode Choke function is enabled. In
case it was, previously disabled and ANN1 has been assigned a annunciation, and later the
choke was enabled, the assigned annunciation to ANN1 shall be automatically disabled. In such
case the user is advice to reassign the annunciation contacts after enabling the choke
S.No Parameter name on first
row of LCD
Setting Factory Setting and remark
1 Mains OK 0-ANN1-ANN6 0
2 Mains Not OK 0-ANN1-ANN6 6
3 DG Running 0-ANN1-ANN6 0
4 DG Not Running 0-ANN1-ANN6 0
5 Load on DG 0-ANN1-ANN6 0
6 Load on Mains 0-ANN1-ANN6 0
7 Fail to Start 0-ANN1-ANN6 1
8 Fail to stop 0-ANN1-ANN6 2
9 LLOP Fault 0-ANN1-ANN6 3
10 HWT/HCT Fault 0-ANN1-ANN6 3
11 DG Vol Fault 0-ANN1-ANN6 5
12 DG Freq Fault 0-ANN1-ANN6 5
13 DG O/S Fault 0-ANN1-ANN6 5
14 Low Fuel 0-ANN1-ANN6 4
15 O/C Fault 0-ANN1-ANN6 0
16 Canopy Fault 0-ANN1-ANN6 0
17 V-Belt Fault 0-ANN1-ANN6 0
18 Battery Unhelath 0-ANN1-ANN6 0
19 Room Temp High 0-ANN1-ANN6 0
20 BTS Vol Low 0-ANN1-ANN6 0
0 Means no contact. Room Temp, and BTS Vol Low are model dependent
11.3 Programming Solenoid Mode
For changing the solenoid mode first press (R) (reset) button, than simultaneously press +ve and –
ve button while the reset button is pressed. The first row of LCD shall display “ FuelSolType”.
There are two possible modes.
Mode 0 In this mode fuel solenoid contact changes from Open to Close at the time of cranking
and remains close till the genset is running. For stopping the generator this contact opens.
Mode 1 In this mode fuel solenoid contact remains open at the time of cranking and till the genset
is running. For stopping the generator this contact closes for a user programmed time.
Mode 2 Same as Mode 0 with additional feature of deactivating the crank when the Lube Oil
Pressure is build(LLOP Fault is removed).
Mode 3 Same as Mode 1 with additional feature of deactivating the crank when the Lube Oil
Pressure is build(LLOP Fault is removed).
Don’t change the mode while generator is running. It’s a good practice to switch OFF and than
switch ON the battery supply after changing this mode.
12.0 Faults

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There are two categories of faults
oInternal Faults
oExternal faults
12.1 Internal Faults
Internal faults are the faults, which do not need any external signals and are detected by the system
itself. They are:
oGenerator Fails to Start.
oGenerator Voltage Unhealthy
oGenerator Frequency Unhealthy.
oGenerator Over Speed.
oGenerator Fails to Stop.
oOver Current ( In models with built in Current measurements)
oLLOP
oHWT
oFuel
oBattery Under or Over voltage (Warning only).
12.2 External Faults
Those faults which cannot be sensed by the unit itself (these faults are not reflected by the
generator voltage) and are to be provided externally. They are:
oCanopy Temperature
oEmergency
oOver Current (External)
V-Belt
12.3 Fault Reset
oInternal Faults & LLOP fault: All internal faults and LLOP fault can be reset by pressing (R)
switch after the generator is stopped.
oExternal Fault except LLOP & V-Belt faults: These faults cannot be reset till the engine is
running and/or fault conditions persist. Once the faults are rectified, the fault can be reset by pressing
Reset switch (R). In case the engine fails to stop “STOP KEY” can be pressed for manual attempt to
stop engine
13.0 Communication
Half Duplex, RS485 communication running in slave mode: The communication can be used for the
following:
•Programming the parameters
•Reading instantaneous parameters
•Reading system conditions
•Reading fault status.
•Remote Operation
14.0 Model Selection
The nomenclature for selecting the model is as follows:
DGC-7R
-1P/3P for Single Phase /3 Phase Mains monitoring
-A for Annunciation Contacts are required
-B for BTS Vol
-N for Canopy Temperature
-T for Room Temp
-I for Current single Phase
-C for Communication
S.No Desired Features Model Name
1 Current, Room Temp, Communication, 3 phase
mains
DGC-7R-I-T-C-3P
2 Annunciation, BTS Voltage, Room Temp,
Single Phase mains monitoring
DGC-7R-1P-A-T-B
Please note:

DGC-7R Digital Genset Controller
Cat_DGC-7R-04-08-VERB1-0.doc Page 15/18
a) Only one temperature measurement out of Room and Canopy can selected at a time
b) Out of BTS Voltage, Room/Canopy Temperature and Current only 2 parameters can be selected
at the same time.
c) Single Phase unit can have provision for KW, PF and KWhr
15.0 Terminal description
Terminal Number Description
1 Mains R Phase Voltage
2 Mains Y Phase Voltage
3 Mains B Phase Voltage
4 Mains Neutral
5 Generator Voltage
6 Generator Neutral
7 These connections depend upon the models. Please see Table A in
15.1 for details.
8
9
10
11 Remote
12 Engine Running( Started)
13 HWT Sensor
14 Fuel Sensor
15 Canopy Temperature
16 Emergency
17 LLOP Sensor
18 V-Belt
19 External Over Current digital Input
20 Auxiliary supply +ve
21 Auxiliary supply -ve
22,23 Mains Circuit Breaker
24,25 Generator Circuit Breaker
26,27 Crank
28 Hooter
29 Common for hooter and fuel
30 Fuel
31 ANN1 or Choke
32 ANN2 (Optional)
33 Common for ANN1 & ANN2
34 ANN3
35 ANN4
36 ANN5
37 ANN6
38 Common for ANN3 – ANN6
15.1 Table A
Parameters in models Pin 7 Pin8 Pin9 Pin10
Basic Model -- -- -- --
Current CT+ CT- -- --
BTS Voltage -- -- BTS+ BTS-
Room Temperature Temp+ Temp- -- --
Canopy Temperature Temp+ Temp- -- --
BTS Vol + Room/Canopy Temperature Temp+ Temp- BTS+ BTS-
BTS Vol + Current CT+ CT- BTS+ BTS-

DGC-7R Digital Genset Controller
Cat_DGC-7R-04-08-VERB1-0.doc Page 16/18
Current + Room/Canopy Temperature CT+ CT- Temp+ Temp-
16.0 Specifications
AC voltage withstand 330 VAC (Phase to neutral)
Measurement Accuracy 1%
Surge 1.2/50Usec 2.5KV
Battery Voltage Suitable for 12V/24 VDC System
Min. voltage to power on 9V
Min Running Voltage after
Power on 4V
Max. Battery Voltage 35V
DC Interruption time 1 Sec.
Contact(MCB) NC, 230V / 6A
Contact(GCB) NO, 230V / 6A
Contact(Hooter) NO, 230V / 6A
Contact(Fuel) NO, 230V / 6A
Contact(Crank) NO, 230V / 6A
Contact ANN1 NO, 230V / 6A
Contact(ANN2-ANN 6 ) NO, 230V / 1A
Cut out Dimensions 186mm X 90mm
Depth 120mm
Digital Input Level Battery Voltage (Negative)

DGC-7R Digital Genset Controller
Cat_DGC-7R-04-08-VERB1-0.doc Page 17/18
It is our endeavour to constantly upgrade our products, hence specifications are subject to change without any notic
DG
Main
1 Main R Phase Remote Start 11
2 Main Y Phase HWT 13
3 Main B Phase Low Fuel 14
4 Main Neutral Canopy Temp. 15
18 MCB Check Back Emergency 16
22 MCB NC Contact LLOP 17
23 MCB NC Contact Crank NO 26
7 Not Connected Crank NO 27
8 Not Connected Hooter 28
19 GCB Check Back Common 29
9 Not Connected Fuel 30
10 Not Connected ANN1- NO 31
24 GCB NO Contact ANN2-NO 32
25 GCB NO Contact Common 1-2 33
5 Generator R
phase
ANN3-NO 34
6 Generator Neutral ANN4-NO 35
21 Battery Negative ANN5-NO 36
20 Battery Positive ANN6-NO 37
12 Engine Start Common 3-6 38
M