Basler Dgc 500 Software

• INSTRUCTION MANUAL for DGC-500 DIGITAL GENSET CONTROLLER Publication: 9 3554 00 990 Revision: D 03/04 • INTRODUCTION This manual provides information concerning the operation and installation of the Basler DGC-500 Digital Genset Controller. To accomplish this, the following information is provided. • Specifications • Functional Description • Communication Software Description • Installation Information • Troubleshooting Information WARNING! To avoid personal injury or equipment damage, only qualified personnel should perform the procedures presented in this manual.

• First Printing: March 2002 Printed in USA Copyright © 2004 Basler Electric, Highland, Illinois 62249 USA March 2004 CONFIDENTIAL INFORMATION Of Basler Electric. 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 interest of Basler Electric. • PRODUCT REVISION HISTORY The following information provides a historical summary of the changes made to the embedded firmware, communication software (BESTCOMS), and hardware of this device. The corresponding revisions made to this instruction manual are also summarized. This revision history is separated into four categories: Firmware Version, BESTCOMS Version, Hardware Version, and Manual Version. All revisions are listed in reverse chronological order.

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Firmware Version Summary 2.04. • Hardware Version (Special Order P/N) Summary D - 10/03 C Implemented firmware version 2.04.XX and BESTCOMS version 1.03.XX C - 09/03 C Added reference to instruction manual on parts list B - 07/03 C Implemented firmware version 2.03.XX and BESTCOMS version 1.02. • CONTENTS SECTION 1 • GENERAL INFORMATION................................................ 1-1 SECTION 2 • HUMAN-MACHINE INTERFACE........................................... 2-1 SECTION 3 • FUNCTIONAL DESCRIPTION............................................. 3-1 SECTION 4 • BESTCOMS SOFTWARE...........................................

• SECTION 1 • GENERAL INFORMATION TABLE OF CONTENTS SECTION 1 • GENERAL INFORMATION................................................ • 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. • 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, describe the options included in a specific device. • SPECIFICATIONS Current Sensing Accuracy: Burden: Terminals: 1 Ampere Inputs Continuous Rating: 1 Second Rating: 5 Ampere Inputs Continuous Rating: 1 Second Rating: ±1% of full scale or ±2 A, whichever is greater 1 VA P10, P11 (A-phase) P12, P14 (B-phase) P15, P17 (C-phase) 0.02 to 1.0 A 2A 0.1 to 5. • Output Contacts—continued UL Recognition Programmable Relays (2) Rating: 2 A at 30 Vdc, make break, and carry Terminals: P33, P34 (Output 1) P36, P38 (Output 2) All DGC-500 controllers are UL recognized per Standard 508, Standard for Industrial Control Equipment (UL File E97035). • SECTION 2 • HUMAN-MACHINE INTERFACE TABLE OF CONTENTS SECTION 2 • HUMAN-MACHINE INTERFACE........................................... FRONT PANEL.................................................................

REAR PANEL...................... • SECTION 2 • HUMAN-MACHINE INTERFACE INTRODUCTION This section describes the components of the DGC-500 human-machine interface (HMI). DGC-500 HMI components are located on the front panel (controls and indicators) and the rear panel (terminals and connectors). FRONT PANEL Figure 2-1 illustrates the front panel HMI of the DGC-500. Table 2-1 lists the call-outs of Figure 2-1 along with a description of each HMI component.

DGC-500 Front Panel HMI Descriptions Call-Out Description A Liquid Crystal Display. The backlit, two line by 16 character LCD is the primary interface for metering, alarms, pre-alarms, and protective functions. The LCD has three standard display modes (Normal, Alternate, and Menu) and one optional display mode (ECU Parameters).

In Normal mode, the displayed parameters correspond to one of the eight labels surrounding the LCD. • Figure 2-2.

DGC-500 Rear Panel HMI Table 2-2. DGC-500 Rear Panel HMI Descriptions Call-Out Terminals Description A P22 CHASSIS GND. This terminal provides the chassis ground connection. The DGC-500 must be hard-wired to earth ground with no smaller than 12 AWG copper wire. B P20 (+), P21 (–) BATT. DGC-500 operating power is applied to these terminals. The DGC-500 accepts a nominal input of 12 Vdc or 24 Vdc.

C P35 (+), P37 (–) P2, P3, P4 DGC-500 HMI Contact Sensing Terminals ESTOP. • Call-Out Terminals D P39 (+), P40 (–) P13 P16 P18 P19 E P23 P26 P29 P30 F P10(1/5A), P11(COM) P12(1/5A), P14(COM) P15(1/5A), P17(COM) Transducer Terminals MPU. These terminals accept the output from a magnetic pickup.

Voltage applied to this input is scaled and conditioned for use as a speed signal. The output from an oil pressure transducer is applied to this input. A current signal lower than 5 mA can be applied between terminal P13 and P19 (SENDER COMM). • Call-Out Terminals K P5 (+), P6 (–) P8 (A), P9 (B) DGC-500 HMI Description Remote Display Terminals Power. These terminals provide operating power to the optional Remote Display Panel (RDP-110). These terminals provide an RS-485 interface for communication with the optional Remote Display Panel (RDP-110). • SECTION 3 • FUNCTIONAL DESCRIPTION TABLE OF CONTENTS SECTION 3 • FUNCTIONAL DESCRIPTION.............................................

3-1 INTRODUCTION............................................................... 3-1 DGC-500 FUNCTION BLOCKS....................................................

3-1 Power Supply..................... • Active DTC..............................................................

CAN Failure............................................................. Audible Alarm............................................................ • Figures Figure 3-1. DGC-500 Function Block Diagram............................................ 3-1 Figure 3-2. Display Mode Navigation..................................................

3-12 Figure 3-3. Alternate Mode Navigation.................................................

3-13 Figure 3-4. Lamp Status Screen............................ • SECTION 3 • FUNCTIONAL DESCRIPTION INTRODUCTION This section describes how the DGC-500 functions and explains its operating features. A detailed description of each function block is provided in the paragraphs under the heading of DGC-500 Function Blocks. DGC-500 operating features are described under the heading of Software Operation. DGC-500 FUNCTION BLOCKS To ease understanding, DGC-500 functions are illustrated in the block diagram of Figure 3-1.

• Circuits relating to the microprocessor inputs are described in the following paragraphs. Zero Crossing Detection The zero crossing of A-phase to B-phase line voltage is detected and used to calculate the generator frequency.

Analog-to-Digital Converter Scaled and conditioned signals representing the sensing voltage, sensing current, coolant temperature, fuel level, oil pressure, and battery voltage are digitized by the microprocessor’s 10-bit analog-to-digital converter. • software allows for the programming of sender characteristics. See Section 4, BESTCOMS Software for more information. Fuel level transducer connections are provided at terminals P16 and P19 (sender common). Speed Signal Inputs The DGC-500 uses signals from the voltage sensing inputs and magnetic pickup input to detect machine speed. Voltage Sensing Inputs Generator voltage applied to the DGC-500 voltage sensing inputs is used to measure frequency and can be used to measure machine speed.

• LEDs The LEDs indicate pre-alarm and alarm conditions along with DGC-500 status and generator status. Pushbuttons The pushbuttons are used to scroll through and select parameters displayed on the LCD, change setpoints, start and stop the generator, and reset alarms. Remote Display Panel Applications that require remote annunciation can use Basler Electric’s Remote Display Panel, RDP-110. Using the RDP-110 with the DGC-500 meets the requirements of NFPA Standard 110. Diagnostic Information Obtained Over the CAN Interface Parameter Transmission Repetition Rate Active diagnostic trouble code 1s Lamp status 1s Previously active diagnostic trouble code on request Request to clear previously active DTCs on request Request to clear active DTCs on request DTCs are reported in coded diagnostic information that includes the Suspect Parameter Number (SPN), Failure Mode Identifier (FMI), and Occurrence Count (OC).

• Programmable Two programmable outputs (PROGRAM OUTPUT1, 2) can be user-configured to close for a variety of conditions. Either programmable output can be programmed to close during any of the following operating conditions.

• Continuous Cranking If desired, engine cranking can be delayed from zero to 30 seconds after initiating engine startup. When continuous engine cranking is initiated, cranking is sustained for a user-adjustable period of one to 60 seconds. A crank disconnect limit setting (10 to 100% of nominal engine speed) selects the desired engine speed above which cranking is terminated. Cycle Cranking If desired, engine cranking can be delayed from zero to 30 seconds after initiating engine startup. • Weak Battery Voltage A weak battery voltage pre-alarm occurs when the battery voltage decreases below the weak battery voltage setpoint for the duration of the weak battery voltage time delay setting. Both settings are made in BESTCOMS. The weak battery voltage setpoint has a setting range of 8 to 16 Vdc for 24 Vdc systems and 4 to 8 Vdc for 12 Vdc systems.

The weak battery voltage time delay has a setting range of 1 to 10 seconds. • Low Oil Pressure A low oil pressure alarm occurs when the engine oil pressure decreases below the low oil pressure alarm setpoint for the duration of the low oil pressure time delay setting. Both settings are made in BESTCOMS. When a low oil pressure alarm occurs, the LCD indicates LOW OIL PRESSURE and the current low oil pressure alarm setting. A 10 second activation time delay prevents low oil pressure annunciation during engine startup.

• CAN Failure (If Equipped) A CAN failure annunciation may be enabled only when the CAN interface is enabled. The CAN interface is enabled through BESTCOMS. When configured to pre-alarm, annunciation occurs when CAN communication stops due to a lost connection between the DGC-500 and ECU, or an ECU malfunction. If CAN communication is lost and the annunciation is configured as an alarm, then a normal alarm sequence will occur, including a CANBUS FAILURE message that appears on the HMI display. ENG STOP LAMP ON WARNING LAMP ON MALFUNC LAMP ON PROTECT LAMP ON NO LAMP IS ON Figure 3-3.

Alternate Mode Navigation Only one lamp status will be displayed on the front panel—the highest priority one that is true. An example of the lamp status screen is shown in Figure 3-4. BESTCOMS may also be used to view the status of all lamps. Lamp Status Screen To be notified that a lamp status exists, the pre-alarm for active DTCs must be enabled through BESTCOMS.

• NOTE Always refer to the engine manual for the meaning of SPN and FMI combinations, especially for proprietary DTC descriptions. In the DTC screen example of Figure 3-5, the first DTC of five is displayed. The SPN is 111 (coolant level), the FMI is 1 (low voltage from the sender, thus we have low coolant level), and the OC is 2 (the engine has had a low coolant level twice before). Refer to the engine manufacturer CAN interface documentation for specific descriptions of codes. Ambient air temperature 9. Total fuel used 22. Air inlet temperature 10.

Engine coolant temperature t 23. Boost pressure 11. Fuel temperature 24.

Intake manifold temperature 12. Engine oil temperature 25. Air filter differential pressure 13. Engine intercooler temperature 26. Exhaust gas temperature 14. Fuel delivery pressure 27.

Battery voltage t 15. Engine oil level 16.

Engine oil pressure 28. Battery voltage (at ECU), switched 17. Coolant pressure 29. Active diagnostic codes 18. Coolant level 30. • Engine Configuration Parameters Engine configuration parameters can be accessed from the ECU Parameters menu. To view these parameters read from the ECU, press the Select/Enter pushbutton while viewing the Engine Configuration (ENGINE CONFIG.) screen.

The following list of all engine configuration parameters is presented in the order in which they appear when pressing the Raise/Scroll pushbutton. • Menu Mode Press the Select/Enter pushbutton while viewing the top-level Menu mode screen (shown in Figure 3-2), to access the four menu branches illustrated in Figure 3-8. Press the Lower/Scroll or Raise/Scroll pushbuttons to view the top of each menu branch. Within Menu 1, 2, 3, or 4, use the Select/Enter pushbutton to move right, the Previous pushbutton to move left, the Raise/Scroll pushbutton to move up, and the Lower/Scroll pushbutton to move down. • Figure 3-9. • Figure 3-10. • Figure 3-11.

• Figure 3-12. • Changing Settings A setting change consists of the following steps. The number of each step corresponds to the numbered call-outs in the setting change example of Figure 3-13. Use the HMI pushbuttons to navigate to the screen of the setting to be changed.

Press the Select/Enter key to access the ENTER KEYCODE screen. Enter the key code by pressing the appropriate HMI pushbuttons in the proper sequence. Key code entries appear as asterisks on the ENTER KEYCODE screen.

• NOTE With Enable ECU Support selected, there is a non-programmable Coolant Level Sender Fail alarm that can annunciate when the engine is either off or running. Coolant level is metered and displayed only when Enable ECU Support is selected in BESTCOMS.

ECU Constraints An external source cannot always turn the engine off without removing power from the ECU. Removing power from the ECU is the only way to remove fuel from the engine and shut it down. • C C C C Pulse Cycle Time - fuel solenoid is open Response Timeout - fuel solenoid is closed Settling Time - fuel solenoid is closed Engine Shut Down - fuel solenoid is open NOTE When ECU support is enabled during Pre-start and Resting, the fuel solenoid is closed. Display Values (ECU Support Enabled) The ECU is able to give the DGC-500 in-depth information about the values it sends. This makes it possible for the DGC-500 to display accurate information when metering these values from the ECU. • System Configuration C C C C RUN, OFF and AUTO are selectable through the front panel HMI and OFF and AUTO are selectable through BESTCOMS.

However, for clarity, the term AUTO will not be used in this section. Auto-Run and Auto-Off will be used instead. Auto-Run means the unit is in Auto while the automatic transfer switch (ATS) is closed, or the user started the engine remotely through BESTCOMS. • Figure 3-15. Normal Program Control Diagram ECU Power Support Program Control If an engine has an ECU, then ECU support should be enabled so that the DGC-500 uses sender data transmitted from the ECU over the J1939 interface.

If the engine can be shut down only by powering off the ECU, then the genset will need ECU power support enabled. An engine with ECU support enabled and a need for ECU power support through the fuel solenoid will follow the ECU power support diagram of Figure 3-16. • After a short time, the old system configuration from the last time the unit was not in reset is checked. If the old system configuration was set to Run or Auto-Run with the ATS closed, then the engine speed is checked against Crank-Disconnect (the rpm value used in deciding when to disengage the starter). If engine speed is above Crank-Disconnect, then the Power Up/Reset state goes to the Running state. • Figure 3-18.

Ready State Diagram Pulsing State The Pulsing State follows the sequence of events shown in Figure 3-19. The Pulsing state will momentarily power up the ECU to update the DGC-500 internal variables. Once a connection is established with the ECU, GATHERING DATA will appear on the LCD for the duration of the settling time. During settling time, the unit processes any previous request for clearing DTCs from the ECU.

• Figure 3-20. Connecting State Diagram Pre-Start State This state will transition immediately to the Running state if the engine speed is above Crank-Disconnect. Otherwise, it will wait here and close the Pre-heat relay for the pre-start time delay duration. If engine speed is below Safe-To-Restart (the rpm value used in deciding when to engage the starter) and the Pre-start time delay is expired or set to zero, then it will transition to the Cranking state. • Figure 3-22. Cranking State Diagram Resting State If the rest period has ended, the unit will transition back to the Cranking state. If the State Machine is following the ECU Power Support diagram, the Fuel Solenoid relay will be closed during the Resting state.

Thus, there is a possibility for the engine to start running during this state. Therefore, when the ECU Power Support diagram is being followed, engine speed is checked to see if it is above crank-disconnect. • Figure 3-24. Running State Diagram Cooling State This state is available only if the unit is in Auto/Off with an unexpired Cool-Down time or if the unit was in the Cranking state when the unit went to Off.

If system configuration changes back to Auto-Run, this state will transition straight into the Running state since the engine should already be running while it is in the Cooling state. • Figure 3-26. Shutting Down State Diagram Alarm State All states except Reset can transition to the Alarm state. The State Machine frequently checks for alarms and pre-alarms before running through each state.

If an alarm is flagged in the initial alarm check, then the unit goes into an Alarm state and waits there for the alarm to clear. If it is in Run/Auto-Run, then the alarm can be cleared only by going to Off. • SECTION 4 • BESTCOMS SOFTWARE TABLE OF CONTENTS SECTION 4 • BESTCOMS SOFTWARE................................................. 4-1 INTRODUCTION............................................................... 4-1 INSTALLATION................................................................ 4-1 Installing BESTCOMS-DGC500-32.......

• Figures - continued Figure 4-10. Pre-Alarms Screen Maint. Interv.-Hi Cool Tab................................... 4-7 Figure 4-11. Alarms Screen, Hi Cool-Low Fuel-Low Oil Tab.................................. 4-8 Figure 4-12. Alarms Screen, Overspeed-Sender Fail Tab....................................

4-9 Figure 4-13. Engine Cranking Screen................................. • SECTION 4 • BESTCOMS SOFTWARE INTRODUCTION BESTCOMS-DGC500-32 software provides a user-friendly communication link between the DGC-500 and the user. An IBM-compatible PC running BESTCOMS can be used to configure the following parameters.

• Basler Electric Digital Genset Controller 500 Version X.XX.XX Copyright 2001 Basler Electric Figure 4-2. BESTCOMS Title and Version Figure 4-3.

Sensing Transformers Screen Establishing Communication Communication between BESTCOMS and the DGC-500 must be established before reading or changing settings. BESTCOMS screen settings are updated only after communication is opened or the communication settings have been changed. • CHANGING SETTINGS DGC-500 settings are arranged into six groups. C C C Sensing Transformers Pre-Alarms Alarms C C C Engine Cranking System Programmable Inputs and Outputs Each setting group has a corresponding button (shown in Figure 4-3) that can be selected to access that group of settings. The six setting groups can also be accessed by clicking Screens on the menu bar and then selecting the desired setting group from the list. • Figure 4-6.

Sensing Transformers Screen Pre-Alarms Click the Pre Alarm button to access the Pre-Alarms screen or click Screens on the menu bar and click PreAlarm Settings. The Pre-Alarms screen consists of four tabs: Low Fuel-Low Cool-Batt. OverVolt., Low Oil-Low Batt Volt-Weak Batt Volt, Audible-Battery Charger-Fuel Level Sender, and Maint. Interv.-Hi Cool.

Low Fuel-Low Cool-Batt. OverVolt Tab The Low Fuel-Low Cool-Batt.

Tab settings of the Pre-Alarms screen are shown in Figure 4-7. • Figure 4-7. Pre-Alarm Screen, Low Fuel-Low Cool-Batt. OverVolt Tab Low Oil-Low Batt Volt-Weak Batt Volt Tab The Low Oil-Low Batt Volt-Weak Batt Volt Tab settings are shown in Figure 4-8.

Each tab setting is described in the following paragraphs. Pre-Alarm Screen, Low Oil-Low Batt Volt-Weak Batt Volt Tab Low Oil Pressure Pre-Alarm - Enable. This setting enables and disables annunciation of a low oil pressure pre-alarm. • Low Oil Pressure Pre-Alarm - Threshold (PSI). This setting selects the oil pressure level that will trigger a low oil pressure pre-alarm. A threshold setting of 3 to 150 psi or 20 to 1,035 kPa may be entered.

A 10 second activation time delay prevents low oil pressure annunciation during engine startup. Low Battery Voltage Pre-Alarm - Enable.

This setting enables and disables annunciation of a low battery voltage pre-alarm. Low Battery Voltage Pre-Alarm - Threshold (Volts). Interv.-Hi Cool Tab The Maint.

Interv. Vcds Lite 1.2 Free Download. -Hi Cool Tab settings are shown in figure 4-10. Each tab setting is described in the following paragraphs. Pre-Alarms Screen, Maint. Interv.-Hi Cool Tab Maintenance Interval Pre-Alarm - Enable. This setting enables and disables annunciation of a maintenance interval pre-alarm. Maintenance Interval Pre-Alarm - Threshold (Hours).

This setting selects the length of the maintenance interval. An interval of zero to 5,000 hours may be selected.

• Figure 4-11. Alarms Screen, Hi Cool-Low Fuel-Low Oil Tab Hi Cool Temperature Alarm - Threshold (Deg F).

This setting selects the coolant temperature that will trigger a high coolant temperature alarm. A threshold setting of 100 to 280 degrees Fahrenheit or 38 to 138 degrees Celsius may be entered. A 60 second activation delay prevents a Hi Coolant Temperature Alarm from occurring at engine startup. Hi Cool Temperature Alarm - Arming Delay (Sec). • Figure 4-12.

Alarms Screen, Overspeed-Sender Fail Tab Overspeed Alarm - Alarm Activation (MilliSecond). This setting adjusts the time delay from when an overspeed alarm condition is detected until it is annunciated and the engine is shut down. A time delay of zero to 500 milliseconds may be entered. Sender Failure Alarm - Cool Temp. Send Fail Alarm. This setting enables and disables alarm annunciation and engine shutdown for a coolant temperature sender failure. • Figure 4-13.

Engine Cranking Screen Pre-Crank Delay (Sec). This setting adjusts the time delay between initiating engine starting and beginning engine cranking. A delay of zero to 30 seconds may be entered. Pre-Start Contact After Disconnect. This setting selects whether or not the pre-start contact remains closed after disconnect occurs. Cycle - Number of Crank Cycles. • Figure 4-14.

System Settings Screen Rated Engine RPM. This setting selects the rated rotating speed of the engine. A value of 750 to 3,600 rpm may be entered. Maintenance Interval Timer Reset.

Selecting this checkbox terminates the maintenance interval pre-alarm and resets the maintenance interval timer back to the programmed value. The Send Settings button must be clicked for the reset to take effect.

Battery Volts. Mugen Mizore Shirayuki Ai Patch. This setting selects either 12 Vdc or 24 Vdc as the starting battery nominal voltage. • CANBus/J1939 Interface - Enable ECU Support. This setting enables and disables the DGC-500 CAN interface. When enabled, the CAN interface allows the DGC-500 to communicate with the engine control unit (ECU).

This setting must be enabled in order to enable DTC support. CANBus/J1939 Interface - Enable DTC Support. This setting enables and disables the viewing of diagnostic trouble codes (DTCs) reported by the ECU. Both the Enable ECU Support and Enable DTC Support settings must be enabled to view DTCs. • Programmable Input - Alarm/Pre-Alarm. Either of these check boxes can be selected to annunciate an alarm or pre-alarm when the selected function triggers the programmable input.

Alarm or pre-alarm annunciation is available only when one the following functions are selected: Auxiliary Input, Battery Charger Fail, Fuel Leak Detect, or Low Coolant Level. Programmable Input - Auxiliary Input Label. This setting field is active only when Auxiliary Input is selected as the programmable input function.

• PROGRAMMABLE SENDERS Click Configure on the menu bar and click Programmable Senders to access the Programmable Senders screen. The Programmable Senders screen has three tabs: Coolant Temperature, Oil Pressure, and Percent Fuel Level. Because the setting fields and buttons of each tab are so similar, only the Coolant Temperature tab settings are described here. The Coolant Temperature tab settings of the Programmable Senders screen are shown in Figure 4-17. • setting range is 32 to 400°F or 0 to 240°C. The oil pressure setting range is 0 to 250 psi or 0 to 1,725 kilopascals.

The fuel level setting range is 0 to 100 percent. Sender Slope. If a sender requires a positive slope, Positive can be selected to invert the values in the Resistance column. Reset Factory Settings. Clicking this button restores the factory-default data points in the Degrees F/Degrees C column and graph.

This does not update the data points in the DGC-500. • Saving Settings Files Saving DGC-500 settings to a file for uploading to other DGC-500 units saves setup time when configuring multiple units to the same configuration. A settings file can also be created in BESTCOMS without being connected to a DGC-500.

The settings of the desired screens can be changed and these settings can then be saved to a file. A settings file is created by clicking the Save Settings File button or clicking File on the menu bar and clicking Save.

• Figure 4-21. ECU Timers Dialog Box Engine Shut Down (Sec.). When going from Running to Shut Down, this setting adjusts the length of time that the DGC-500 stays disconnected from the ECU before starting the first pulse. The Engine Shut Down setting range is 1 to 60 seconds. Setting Time (Millisec.).

This setting adjusts the time to gather data after connecting to the ECU during the Pulsing state. This allows all metered values to be sent and ramp up. • Once a password is changed, it should be stored in a secure location. If a user-defined password is lost or forgotten, contact Basler Electric for instructions on regaining password access.

TERMINATING COMMUNICATION DGC-500 communication is terminated by clicking Communications on the menu bar and clicking Close. If unsaved settings changes were made, you are prompted to save the changes in a new or existing settings file. Click the Select New Application Code button and then navigate to and select the file (S19 file extension) to be used for updating the DGC-500 firmware. The file details are displayed in the File Information section of the Embedded Firmware Upgrade dialog box (Figure 4-24).

Firmware File Information 4. Click the Start Firmware Upgrade Process button.

The Erase Application Code!!!! And Save Settings Before You Continue!!!! Dialog boxes appear and confirm that you want to continue.

• SECTION 5 • INSTALLATION TABLE OF CONTENTS SECTION 5 • INSTALLATION......................................................... 5-1 GENERAL..................................................................... 5-1 HARDWARE................................................................... 5-1 MOUNTING.......... • SECTION 5 • INSTALLATION GENERAL DGC-500 Digital Genset Controllers are delivered in sturdy cartons to prevent shipping damage.

Upon receipt of a system, 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, your Sales Representative, or a Sales Representative at Basler Electric, Highland, Illinois. • Figure 5-2. DGC-500 Overall Dimensions DGC-500 Isolator Kit The optional DGC Isolator Kit provides an economical way to reduce the level of shock and vibration transmitted from a generator to the DGC-500. The DGC Isolator Kit eliminates the need to mount an isolator box on top of the generator conduit box and simplifies wiring considerations. Isolator kits are available with either black- or gray-colored gaskets. • CONNECTIONS DGC-500 connections are dependent on the application.

Incorrect wiring may result in damage to the controller. NOTE Be sure that the DGC-500 is hard-wired to earth ground with no smaller than 12 AWG copper wire attached to the chassis ground terminal (P22) on the rear of the controller. Operating power from the battery must be of the correct polarity. Although reverse polarity will not cause damage, the DGC-500 will not operate. • Figure 5-4. Personal Computer to DGC-500 Connections CAN Connections The CAN connector (J2) on the rear panel mates with the cable assembly (Basler P/N 9 3589 00 002) provided with the DGC-500.

Only units with style numbers F1J AND F5J are supplied with the cable assembly and have connector J2 enabled. The cable assembly is shown in Figure 5-5 and the termination assignments are listed in Table 5-2. Figure 5-6 illustrates typical DGC-500 CAN interface connections. • Figure 5-6. Typical DGC-500 CAN Interface Connections DGC-500 Connections for Typical Applications Figures 5-7 through 5-9 illustrate typical applications using the DGC-500.

Figure 5-7 shows a DGC-500 application using single-phase sensing. Figure 5-8 shows a DGC-500 application using three-phase, delta sensing. Figure 5-9 shows a DGC-500 application using three-phase, wye sensing. • Figure 5-7. Single-Phase DGC-500 Connections 5 N.C. 4 3 2 1 Chassis Ground P4 P22 Horn Contact Sensing Mechanical coolant temperature sender not supplied by Basler. Mechanical fuel level sender not supplied by Basler.

Mechanical oil pressure sender not supplied by Basler. Current inputs are 1 ampere or 5 ampere, depending upon style. • Figure 5-8. Three-Phase Delta DGC-500 Connections 5 N.C. N 4 3 2 1 Chassis Ground Programmable Input 3 7 Programmable Input 2 7 Programmable Input 1 7 Emergency Stop P24 + Contact Sensing Horn Mechanical coolant temperature sender not supplied by Basler. Mechanical fuel level sender not supplied by Basler.

Mechanical oil pressure sender not supplied by Basler. Current inputs are 1 ampere or 5 ampere, depending upon style.

• Figure 5-9. Three-Phase Wye DGC-500 Connections 5 N.C. 4 3 2 1 N Chassis Ground P4 P22 P24 + Contact Sensing Horn Current inputs are 1 ampere or 5 ampere, depending upon style. Mechanical oil pressure sender not supplied by Basler.

Mechanical fuel level sender not supplied by Basler. Mechanical coolant temperature sender not supplied by Basler. • Volvo Penta EDC Applications Engines equipped with Volvo Penta EDC controllers can receive engine control commands (such as start and stop) from the DGC-500 through the SAE J1939 communication interface. To invoke this feature, the EDC must receive a J1939 message containing engine control information within one second of waking (exiting sleep mode). If the EDC does not receive an engine control message within the prescribed time, it will enter the stand-alone mode and ignore any J1939 control messages.

Mechanical fuel level sender not supplied by Basler. Mechanical coolant temperature sender not supplied by Basler. Jumper terminals P35 and P37 if not using an Emergency Stop switch. 5 4 2 3 Chassis Ground P22 Current inputs are 1 ampere or 5 ampere, depending upon style. Mechanical oil pressure sender not supplied by Basler.

5 4 3 2 1 N Programmable Input 3 7 Chassis Ground P4 P22 P24 + Horn Contact Sensing Mechanical oil pressure sender not supplied by Basler. Mechanical fuel level sender not supplied by Basler. Mechanical coolant temperature sender not supplied by Basler. Jumper terminals P35 and P37 if not using an Emergency Stop switch. Current inputs are 1 ampere or 5 ampere, depending upon style.

5 4 3 2 1 N Programmable Input 3 7 Chassis Ground P4 P22 P24 + Horn Contact Sensing Mechanical oil pressure sender not supplied by Basler. Mechanical fuel level sender not supplied by Basler. Mechanical coolant temperature sender not supplied by Basler. Jumper terminals P35 and P37 if not using an Emergency Stop switch. Current inputs are 1 ampere or 5 ampere, depending upon style. • CALIBRATION Prior to delivery, each DGC-500 is factory calibrated and subjected to thorough testing to ensure quality, accuracy, and performance. DGC-500 units should not require field calibration.

However, the following procedure is provided for those users desiring to perform field calibration of their DGC-500. Press the Raise/Scroll pushbutton.

The screen at right is displayed. Apply 2 Aac to the current sensing inputs for phase A (P10 and P11). Press the Lower/Scroll pushbutton. Press the Raise/Scroll pushbutton. The screen at right is displayed. Apply 2 Aac to the current sensing inputs for phase B (P12 and P14). Press the Lower/Scroll pushbutton.

Press the Raise/Scroll pushbutton. The screen at right is displayed. Apply 2 Aac to the current sensing inputs for phase V (P15 and P17).

Press the Raise/Scroll pushbutton. The screen at right is displayed. Connect a resistance of 125 ohms across the oil pressure sender input (P13 and P19). Press the Lower/Scroll pushbutton. Press the Raise/Scroll pushbutton. The screen at right is displayed.

Connect a resistance of 150 ohms across the oil pressure sender input (P13 and P19). Press the Lower/Scroll pushbutton.

Press the Raise/Scroll pushbutton. The screen at right is displayed. • SECTION 6 • MAINTENANCE AND TROUBLESHOOTING PREVENTATIVE MAINTENANCE The only preventative maintenance required on the DGC-500 is to periodically check that the connections between the DGC-500 and the system are clean and tight. DGC-500 units are manufactured using state-ofthe-art, surface-mount technology. As such, Basler Electric recommends that no repair procedures be attempted by anyone other than Basler Electric personnel. • Programmable Inputs Do Not Operate as Expected Step 1. Verify that all wiring is properly connected.

Refer to Figures 5-5 through 5-7. Confirm that the inputs are programmed properly. Ensure that the input at the DGC-500 is actually connected to the BATT– terminal (P21).

Programmable Outputs Do Not Operate as Expected Step 1. Verify that all wiring is properly connected. Refer to Figures 5-5 through 5-7. Confirm that the outputs are programmed properly. • APPENDIX A • PARAMETERS AND SETTINGS INTRODUCTION This appendix lists all DGC-500 parameters along with the setting range/selections for each parameter.

FRONT PANEL ADJUSTABLE PARAMETERS Table A-1 lists the DGC-500 settings that can be adjusted through the HMI.