Basler Electric DGC-2020HD User Manual

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INSTRUCTION MANUAL
FOR
DGC-2020HD
DIGITAL GENSET CONTROLLER
Publication: 9469300990
Revision: B Mar-14
9469300990 Rev B i
Preface
This instruction manual provides information about the installation and operation of the DGC-2020HD
Digital Genset Controller. To accomplish this, the following information is provided:
• Controls and indicators
• Inputs and outputs
• Protection and control functions
• Reporting and alarms information
• Mounting and connection diagrams
®
• BESTCOMSPlus software
• Communication and security
• Maintenance and troubleshooting procedures
• Specifications
• AEM-2020
• CEM-2020
• MTU Fault Codes
:
• MTU Fault Codes
• Exhaust Treatment
• Diagnostic Trouble Codes
Conventions Used in this Manual

Important safety and procedural information is emphasized and presented in this manual through
Warning, Caution, and Note boxes. Each type is illustrated and defined as follows.
Warning!
Warning boxes call attention to conditions or actions that may cause

personal injury or death.
Caution
Caution boxes call attention to operating conditions that may lead to
equipment or property damage.
Note
Note boxes emphasize important information pertaining to Digital
Genset Controller installation or operation.
Digital Genset Controller Preface
ii 9469300990 Rev B
12570 State Route 143

Highland IL 62249-1074 USA
www.basler.com
[email protected]
Tel: +1 618.654.2341
Fax: +1 618.654.2351
© 2014 by Basler Electric
All rights reserved
First printing: November 2013
Warning!
READ THIS MANUAL. Read this manual before installing, operating, or maintaining the DGC-2020HD.
Note all warnings, cautions, and notes in this manual as well as on the product. Keep this manual with the
product for reference. Only qualified personnel should install, operate, or service this system. Failure to
follow warning and cautionary labels may result in personal injury or property damage. Exercise caution
at all times.
Basler Electric does not assume any responsibility to compliance or noncompliance with national code, local
code, or any other applicable code. This manual serves as reference material that must be well understood prior
to installation, operation, or maintenance.
This product contains, in part, open source software (software licensed in a way that ensures freedom to run,
copy, distribute, study, change, and improve the software) and you are granted a license to that software under the
terms of either the GNU General Public License or GNU Lesser General Public License. The licenses, at the time
of sale of the product, allow you to freely copy, modify, and redistribute that software and no other statement or
documentation from us, including our End User License Agreement, places any additional restrictions on what you
may do with that software.
For at least three (3) years from the date of distribution of this product, a machine-readable copy of the complete
corresponding source code for the version of the programs distributed to you will be sent upon request (contact
information is provided above). A fee of no more than our cost of physically performing the source code distribution
is charged.
The source code is distributed in the hope that it will be useful, but WITHOUT ANY REPRESENTATION or
WARRANTY or even the implied warranty of MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE.
Refer to the source code distribution for additional restrictions regarding warranty and copyrights.
For a complete copy of GNU GENERAL PUBLIC LICENSE Version 2, June 1991 or GNU LESSER GENERAL
PUBLIC LICENSE Version 2.1, February 1999 refer to www.gnu.org or contact Basler Electric. You, as a Basler
Electric Company customer, agree to abide by the terms and conditions of GNU GENERAL PUBLIC LICENSE
Version 2, June 1991 or GNU LESSER GENERAL PUBLIC LICENSE Version 2.1, February 1999, and as such
hold Basler Electric Company harmless related to any open source software incorporated in this product. Basler
Electric Company disclaims any and all liability associated with the open source software and the user agrees to
defend and indemnify Basler Electric Company, its directors, officers, and employees from and against any and all
losses, claims, attorneys' fees, and expenses arising from the use, sharing, or redistribution of the software.
Review the software website for the latest version of the software documentation.
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.
It is not the intention of this manual to cover all details and variations in equipment, nor does this manual provide
data for every possible contingency regarding installation or operation. The availability and design of all features
and options are subject to modification without notice. Over time, improvements and revisions may be made to
this publication. Before performing any of the following procedures, contact Basler Electric for the latest revision of
this manual.
The English-language version of this manual serves as the only approved manual version.
Preface DGC-2020HD
9469300990 Rev B iii
Contents
Introduction ................................................................................................................................................. 1
Features and Functions............................................................................................................................. 1
Style Number............................................................................................................................................. 4
Optional Features and Capabilities ........................................................................................................... 4
Specifications.............................................................................................................................................. 5
Operating Power........................................................................................................................................ 5
Battery Ride Through ................................................................................................................................ 5
Current Sensing......................................................................................................................................... 5
Voltage Sensing ........................................................................................................................................ 5
Analog Sensing ......................................................................................................................................... 6
Contact Sensing ........................................................................................................................................ 6
Engine System Inputs................................................................................................................................ 7
Output Contacts......................................................................................................................................... 7
Metering..................................................................................................................................................... 8
Generator Protection Functions .............................................................................................................. 10
Logic Timers ............................................................................................................................................ 11
Communication Interface......................................................................................................................... 11
Real-Time Clock ...................................................................................................................................... 12
LCD Heater.............................................................................................................................................. 13
Type Tests............................................................................................................................................... 13
Environment ............................................................................................................................................ 13
UL Approval............................................................................................................................................. 14
CSA Certification ..................................................................................................................................... 14
NFPA Compliance ................................................................................................................................... 14
CE Compliance........................................................................................................................................ 14
Physical ................................................................................................................................................... 14
Mounting .................................................................................................................................................... 15
Hardware ................................................................................................................................................. 15
Dimensions.............................................................................................................................................. 15
Terminals and Connectors....................................................................................................................... 17
Terminals................................................................................................................................................. 18
Connectors .............................................................................................................................................. 25
Typical Applications ................................................................................................................................. 27
Connections for Typical Applications ...................................................................................................... 27
Connections for Load Sharing................................................................................................................. 32
Analog Input Connections ....................................................................................................................... 33
CAN Connections .................................................................................................................................... 33
Expansion Module Connections (CAN 1)................................................................................................ 35
Installation for CE Systems ..................................................................................................................... 35
Controls and Indicators............................................................................................................................ 37
Programmable Indicator Configuration.................................................................................................... 39
Display Operation and Navigation........................................................................................................... 40
Display Setup .......................................................................................................................................... 48
Power Input................................................................................................................................................ 51
Nominal Voltage Input and Acceptable Range of Input Voltage ............................................................. 51
Terminal Assignments ............................................................................................................................. 51
Power Consumption ................................................................................................................................ 51
Battery Ride-Through Capability ............................................................................................................. 51
Fuse Protection ....................................................................................................................................... 51
Voltage and Current Sensing................................................................................................................... 53
Generator Voltage ................................................................................................................................... 53
DGC-2020HD Contents
iv 9469300990
Bus Voltage .............................................................................................................................................

Generator and Bus Current .....................................................................................................................
Engine Sender Inputs ...............................................................................................................................

Connections.............................................................................................................................................
:
Connections.............................................................................................................................................
Compatibility ............................................................................................................................................
Operation.................................................................................................................................................
Programmability.......................................................................................................................................
Characteristic Curves ..............................................................................................................................
Sender Failure Detection.........................................................................................................................
Speed Signal Inputs..................................................................................................................................

Magnetic Pickup ......................................................................................................................................
Generator Sensing Voltage .....................................................................................................................
Contact Inputs ...........................................................................................................................................

Programmable Contact Inputs.................................................................................................................
Analog Inputs ............................................................................................................................................

Input Setup ..............................................................................................................................................
Ranges ....................................................................................................................................................
Thresholds...............................................................................................................................................
Operational Settings ................................................................................................................................
Logic Connections ...................................................................................................................................
Contact Outputs ........................................................................................................................................

Prestart ....................................................................................................................................................
Start .........................................................................................................................................................
Run ..........................................................................................................................................................
Relay Control...........................................................................................................................................
Programmable Contact Outputs..............................................................................................................
Operating Modes.......................................................................................................................................
Off............................................................................................................................................................
Run ..........................................................................................................................................................
Auto .........................................................................................................................................................
Operating Mode Control ..........................................................................................................................
Breaker Management................................................................................................................................
Breaker Status.........................................................................................................................................
System Breaker Configuration ................................................................................................................
Breaker Operation ...................................................................................................................................
Synchronizer .............................................................................................................................................
Operation.................................................................................................................................................
Configuration ...........................................................................................................................................
Bias Control.............................................................................................................................................
AVR Bias Control Settings ....................................................................................................................
Governor Bias Control Settings.............................................................................................................
Multiple Generator Management ...........................................................................................................

AVR Output ...........................................................................................................................................
Governor Output....................................................................................................................................
Load Share Output ................................................................................................................................
Parameter Selection ..............................................................................................................................
Demand Start/Stop ................................................................................................................................
Generator Sequencing ..........................................................................................................................
Network Configuration ...........................................................................................................................
Generator Protection ..............................................................................................................................

Undervoltage (27)..................................................................................................................................
Overvoltage (59)....................................................................................................................................
Contents DGC-2020HD
9469300990 Rev B v
Phase Voltage Imbalance (47) .............................................................................................................. 131

Vector Shift (78)..................................................................................................................................... 133
Frequency (81) ...................................................................................................................................... 135
Overcurrent (51) .................................................................................................................................... 138
Power (32) ............................................................................................................................................. 144
Loss of Excitation (40Q) ........................................................................................................................ 147
Setting Groups....................................................................................................................................... 149
Configurable Protection ......................................................................................................................... 151
Element Setup ....................................................................................................................................... 151
Thresholds............................................................................................................................................. 153
Logic Connections ................................................................................................................................. 154
Operational Settings .............................................................................................................................. 154
Metering ................................................................................................................................................... 157
Metering Explorer .................................................................................................................................. 157
Engine.................................................................................................................................................... 158
Generator .............................................................................................................................................. 159
Bus 1 and Optional Bus 2...................................................................................................................... 159
Bias Control ........................................................................................................................................... 160
Power..................................................................................................................................................... 160
Run Statistics......................................................................................................................................... 161
Synchronization ..................................................................................................................................... 161
Status Indication .................................................................................................................................... 162
Inputs ..................................................................................................................................................... 162
Outputs .................................................................................................................................................. 167
Configurable Protection......................................................................................................................... 169
J1939 ECU ............................................................................................................................................ 169
MTU....................................................................................................................................................... 171
Summary ............................................................................................................................................... 172
Control Panel......................................................................................................................................... 174
How it Works Log In / Sign Up Generator Network Status.....................................................................................................................

Generator Sequencing ..........................................................................................................................
Diagnostics ............................................................................................................................................
174
175
176
Analysis ................................................................................................................................................. 176
Reporting and Alarms............................................................................................................................. 179
Event Logging........................................................................................................................................ 179
Sequence of Events .............................................................................................................................. 179
Data Logging ......................................................................................................................................... 180
Trending ................................................................................................................................................ 181
Alarms.................................................................................................................................................... 182
BESTCOMSPlus® Software .................................................................................................................... 193
System Recommendations ................................................................................................................... 194
Installation ............................................................................................................................................. 194
Activate the DGC-2020HD Plugin for BESTCOMSPlus®...................................................................... 194
Menu Bars ............................................................................................................................................. 198
Settings Explorer ................................................................................................................................... 199
Metering Explorer .................................................................................................................................. 200
BESTspace™ ......................................................................................................................................... 200
Settings File Management..................................................................................................................... 201
Auto Export Metering............................................................................................................................. 202
BESTCOMSPlus® Updates ................................................................................................................... 203
Firmware Updates ................................................................................................................................. 203
BESTlogic™Plus ...................................................................................................................................... 205
Overview of BESTlogic™Plus ................................................................................................................ 205
BESTlogic™Plus Composition ............................................................................................................... 206
Logic Schemes ...................................................................................................................................... 234
DGC-2020HD Contents
vi 9469300990
Programming BESTlogic™Plus..............................................................................................................
Offline Logic Simulator ..........................................................................................................................
BESTlogic™Plus File Management .......................................................................................................
BESTlogic™Plus Examples ...................................................................................................................
Communication .......................................................................................................................................
USB .......................................................................................................................................................
Ethernet .................................................................................................................................................
CAN .......................................................................................................................................................
RS-232 ..................................................................................................................................................
RS-485 ..................................................................................................................................................
Modbus™ Setup.....................................................................................................................................
Remote Display Panel (optional)...........................................................................................................
Configuration...........................................................................................................................................
System Settings.....................................................................................................................................
Rated Data ............................................................................................................................................
Remote Module Setup...........................................................................................................................
Crank Settings .......................................................................................................................................
Automatic Restart Settings....................................................................................................................
Exercise Timer Settings.........................................................................................................................
Sensing Transformer Ratings................................................................................................................
Relay Control Settings...........................................................................................................................
System Configuration Detection Settings..............................................................................................
Device Information..................................................................................................................................
Style Number.........................................................................................................................................
Device Info.............................................................................................................................................
Firmware Updates .................................................................................................................................
Security ....................................................................................................................................................
Access Levels........................................................................................................................................
User Name Setup ..................................................................................................................................
Port Access Setup .................................................................................................................................
Access Control ......................................................................................................................................
Timekeeping ............................................................................................................................................
Clock Setup ...........................................................................................................................................
Setting the Time and Date.....................................................................................................................
IRIG Port................................................................................................................................................
Real-Time Clock Specifications.............................................................................................................
Backup Battery for the Real-Time Clock ...............................................................................................
Maintenance and Troubleshooting .......................................................................................................

Maintenance ..........................................................................................................................................
Storage ..................................................................................................................................................
Troubleshooting.....................................................................................................................................
AEM-2020 .................................................................................................................................................
Features ................................................................................................................................................
Specifications ........................................................................................................................................
Functional Description ...........................................................................................................................
Mounting................................................................................................................................................
Connections...........................................................................................................................................
AEM-2020 Configuration .......................................................................................................................
Remote Analog Inputs Configuration ....................................................................................................
Remote RTD Inputs Configuration ........................................................................................................
:
Remote RTD Inputs Configuration ........................................................................................................
Remote Thermocouple Inputs Configuration ........................................................................................
Remote Analog Outputs Configuration..................................................................................................
Firmware Updates .................................................................................................................................
Repair ....................................................................................................................................................
Contents DGC-2020HD
9469300990 Rev B vii
Maintenance .......................................................................................................................................... 322

Storage .................................................................................................................................................. 323
CEM-2020 ................................................................................................................................................. 325
Features ................................................................................................................................................ 325
Specifications ........................................................................................................................................ 325
Functional Description ........................................................................................................................... 327
Mounting................................................................................................................................................ 327
Connections........................................................................................................................................... 329
CEM-2020 Configuration....................................................................................................................... 334
Remote Contact Inputs Configuration ................................................................................................... 334
Remote Contact Outputs Configuration ................................................................................................ 336
Firmware Updates ................................................................................................................................. 336
Repair .................................................................................................................................................... 336
Maintenance .......................................................................................................................................... 337
Storage .................................................................................................................................................. 337
Time Curve Characteristics.................................................................................................................... 339
Curve Specifications.............................................................................................................................. 339
Time Overcurrent Characteristic Curve Graphs.................................................................................... 340
Tuning PID Settings ................................................................................................................................ 361
Voltage and Speed Controllers ............................................................................................................. 361
kW Load Controller................................................................................................................................ 361
Var/PF Controller................................................................................................................................... 361
Speed Trim Function ............................................................................................................................. 361
Tuning Parameters ................................................................................................................................ 361
Tuning Procedures ................................................................................................................................ 362
Generic Gains for Multiple Machine Types ........................................................................................... 366
MTU Fault Codes..................................................................................................................................... 367
Exhaust Treatment.................................................................................................................................. 377
Diesel Particulate Filter (DPF)............................................................................................................... 377
Exhaust After-Treatment Systems (EATS)............................................................................................ 379
Diagnostic Trouble Codes...................................................................................................................... 381
Revision History...................................................................................................................................... 391
DGC-2020HD Contents
viii 9469300990 Rev B
Contents DGC-2020HD
9469300990 Rev B 1
Introduction
The DGC-2020HD Digital Genset Controller provides integrated engine-genset 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 DGC2020HD
operation. A backlit liquid crystal display (LCD) can be viewed under a wide range of ambient light and
temperature conditions. Basler Electric communication software (BESTCOMSPlus®) allows units to be
easily customized for each application. Because of the low sensing burden in the DGC-2020HD, dedicated
potential transformers (PTs) are not required.
Features and Functions

The DGC-2020HD Digital Genset Controller has the following features:
• Local and remote generator control
• Engine, generator, and loss of mains protection (optional)
• Automatic transfer switch control (mains failure)
• Automatic generator configuration detection
• Generator sequencing
• Generator soft loading/unloading
• Auto synchronizing (optional)
• Programmable analog engine senders
• 16 programmable contact inputs
• Three programmable front panel LEDs, with labels
• Up to four local analog inputs
• A ramping function to load and unload generator smoothly
• Demand start/stop and generator sequencing
• kW and kvar load control
• kW and kvar load sharing via Ethernet or analog load share lines
• Programmable logic
• Exercise timer
• ECU communications via SAE J1939
• Marathon DVR2000E+ voltage regulator control via SAE J1939
• Integrated USB, RS485, and Ethernet communication
• Two J1939 CAN Bus ports
• Additional modules available to expand the capabilities of the DGC-2020HD
:
An overview of DGC-2020HD Digital Genset Controller functions is provided in the following paragraphs.
Generator and Bus Protection and Metering

Multifunction protection guards against overvoltage, undervoltage, excessive forward and reverse power,
underfrequency, and overfrequency. Overcurrent, phase imbalance, loss of mains, and frequency rate-of-
change protection are available as an option. Each protection function has an adjustable pickup and time
delay setting. Sixteen inverse time curves, in addition to user-programmable curves, enable the
DGC2020HD to offer overcurrent protection in a variety of applications. Each protective element can be
assigned to the generator, bus 1 or bus 2.
Metered generator and bus parameters include voltage, current, real power (watts), apparent power (VA),
and power factor (PF).
Engine Protection and Metering

Engine protection features include oil pressure and coolant temperature monitoring, overcrank protection,
ECU-specific protection elements, and diagnostic reporting.
Metered engine parameters include oil pressure, coolant temperature, battery voltage, speed, fuel level,
engine load, coolant level (from ECU), ECU-specific parameters, and run-time statistics.
DGC-2020HD Introduction
2 9469300990 Rev B
Load Sharing
The DGC-2020HD provides analog outputs to the power system in the form of analog bias signals to the
voltage regulator and speed governor. A pulse width modulated (PWM) speed bias output is also available.
When the generator breaker is closed and load sharing is enabled, the DGC-2020HD shares the real
power load proportionally with other generators in the system. Load sharing can be implemented on the
Analog Load Share Line or through Ethernet communications. Reactive power (kvar) sharing is
accomplished through Ethernet communications.
Event Recording
A history of system events are logged in nonvolatile memory. The DGC-2020HD retains records for 128
unique types of events. Each record tracks the number of times that an event has occurred and records a
time stamp of the first and last occurrences.
A Sequence of Events (SER) log is also available. This log tracks the internal and external status of the
DGC-2020HD. Events are scanned at five millisecond intervals with 1,023 events stored per record. All
changes of state that occur during each scan are timeand date-stamped. Sequences of Events reports are
available through BESTCOMSPlus. Over 1,000 records can be retained in nonvolatile memory. When the
SER memory becomes full, the oldest record is replaced by the latest one acquired.
Data Logging
The data logging function of the DGC-2020HD records up to six records of user-selectable, real-time
parameter data. For more information, see the Reporting and Alarms chapter.
Contact Inputs and Outputs

DGC-2020HD controllers have 16 programmable contact inputs. All contact inputs recognize dry contacts.
The programmable inputs can be configured to initiate a pre-alarm or alarm condition. A programmable input
can be programmed to receive a contact input from an automatic transfer switch (ATS). In addition, a
programmable Battle Override function allows overriding of DGC-2020HD alarms and protection functions.
Each programmable input can be assigned a user-defined name for easy identification at the front panel
display and in fault records.
Output contacts include three dedicated relays for energizing an engine’s glow plugs, fuel solenoid, and
starter solenoid. An additional twelve programmable output contacts are provided.
Additional contact inputs and output contacts can be accommodated with an optional CEM-2020 Contact
Expansion Module. Contact Basler Electric for ordering information.
Automatic Transfer Switch Control (Mains Failure)

The DGC-2020HD has the ability to detect a mains failure via a singleor three-phase Bus input. A mains
failure is established when any one of the following conditions are met:
• Any phase of bus voltage falls below the dead bus threshold
• Any phase of bus voltage is unstable due to overvoltage or undervoltage
• Any phase of bus voltage is unstable due to overfrequency or underfrequency
At this time, the DGC-2020HD starts the genset and, when ready, applies power to the load from the
genset. The DGC-2020HD implements open or closed breaker transitions to and from the mains. When the
mains returns and is considered stable, the DGC-2020HD will transfer the load back to the mains and stop
the engine. During closed breaker transitions, the optional Auto Synchronizer can synchronize the
generator to the mains before transferring the load from generator power to utility power.
Device Security
Passwords provide access security for six distinct functional access areas: Read, Control, Operator,
Settings, Design, and Administrator. Each username/password is assigned an access area with access to
that area and each area below it. An administrator password provides access to all six of the functional
areas.
Introduction DGC-2020HD
9469300990 Rev B 3
A second dimension of security is provided by the ability to restrict access for any of the access areas to
only specific communication ports. For example, you could set up security to deny access to control
commands through an Ethernet port.
Security settings affect read and write access. Refer to the Security chapter for more information.
Communication
DGC-2020HD communication features include a mini-B USB port, RS-485 port, two copper Ethernet ports or
one fiber optic Ethernet port (optional), and SAE J1939 interface.
USB Port
The USB communication port can be used with BESTCOMSPlus® software to quickly configure a
DGC2020HD with the desired settings or retrieve metering values and event log records.
RS485 Port
An RS485 communication port uses the Modbus™ communication protocol and enables remote control
and monitoring of the DGC-2020HD over a polled network.
Ethernet Port(s)
Depending on style number, each DGC-2020HD is equipped with either dual copper (100BaseT) Ethernet
communication ports (style xxxxDxxxx) or a fiber optic (100BaseF) Ethernet communication port (style
xxxxFxxxx).
Ethernet ports provide communications between the DGC-2020HD and a PC via BESTCOMSPlus or
other DGC-2020HDs in a network. An Ethernet connection to a PC running BESTCOMSPlus provides
remote metering, setting, annunciation, and control of the DGC-2020HD. Ethernet communication
between DGC-2020HDs allows for generator sequencing on an islanded system.
CAN Interface
The CAN (Control Area Network) interface provides high-speed communication between the DGC2020HD
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. The CAN interface supports the following
protocols:
• SAE J1939 Protocol - Oil pressure, coolant temperature, and engine speed data are received
from the ECU. In addition, DTCs (Diagnostic Trouble Codes) help diagnose any engine-related
failures. The engine DTCs are displayed on the front panel of the DGC-2020HD and may be
obtained using BESTCOMSPlus® software.
• MTU Protocol - A DGC-2020HD connected to a genset equipped with an MTU engine ECU
receives Oil pressure, coolant temperature, and engine speed data from the engine controller,
along with various alarms and pre-alarms that are MTU-specific. In addition, the DGC-2020HD
tracks and displays the active fault codes issued by the MTU engine ECU.
DGC-2020HD Introduction
4 9469300990 Rev B
Style Number
Standard-order DGC-2020HD controllers are identified by a style number which consists of a combination of
letters and numbers that define the controller’s electrical characteristics and operational features. The model
number, together with the style number, describes the options included in a specific controller. Figure 1
illustrates the DGC-2020HD style number identification chart.
MODEL NUMBER STYLE NUMBER
DGC – 2020HD N N
Current Sensing Auto Synchronizer Terminal Type Senders
5) 5A CT inputs 1) No Auto Sync S) Spring A) Analog

1) 1A CT inputs 2) w/ Auto Sync R) Resistive 1
Generator Protection Ethernet Bus Inputs

S) Standard: 27, 32, D) Dual 100BaseT (Copper) B) Basic Sensing:
40Q, 59, 81O, 81U F) 100BaseF (Fiber) 1 Bus Input, 4 CTs
E) Enhanced: 27, 32, 40Q, E) Enhanced Sensing:
47, 51, 59, 78, 81O, 2 Bus Inputs, 7 CTs P0071-69
81U, 81 ROCOF
1 The fuel level sender is always resistive and is not a programmable input.
:
Figure 1. DGC-2020HD Style Chart
Optional Features and Capabilities

AEM-2020 (Analog Expansion Module)
The optional AEM-2020 provides eight remote analog inputs, eight remote RTD inputs, two Type-K remote
thermocouple inputs, and four remote analog outputs to the DGC-2020HD. The AEM-2020 communicates
with the DGC-2020HD through a CAN interface. Up to four AEM-2020s may be used with one DGC-
2020HD. Refer to the AEM-2020 chapter for more information.
CEM-2020 (Contact Expansion Module)

The optional CEM-2020 provides 10 additional contact inputs and 18 or 24 additional output contacts
(depending on module type) to the DGC-2020HD. The CEM-2020 communicates with the DGC-2020HD
through a CAN interface. Up to four CEM-2020s may be used with one DGC-2020HD. Refer to the
CEM2020 chapter for more information.
Introduction DGC-2020HD
9469300990 Rev B 5
Specifications
DGC-2020HD electrical and physical characteristics are listed in the following paragraphs.
Operating Power
Nominal ............................................ 12 or 24 Vdc
Range............................................... 6 to 32 Vdc
Terminals.......................................... 48 (+), 49 (–), 50 (chassis ground)
Power Consumption
12.7 W - LCD heater off, all relays de-energized, and analog outputs
Sleep Mode ......................................
disabled
Normal Operational Mode ................ 18.1 W - Run mode, LCD heater off, START and RUN relays
energized, six programmable relays energized, and analog outputs
enabled
Maximum Operational Mode............ 25 W - Run mode, LCD heater on, all relays energized, and analog
outputs enabled
Battery Ride Through

Starting at 10 Vdc, withstands cranking ride-through down to 0 Vdc for 50 ms
Current Sensing
Burden.............................................. 1 VA
Generator CTs
Terminals.......................................... 1 (+), 2 (–) (A-phase)
3 (+), 4 (–) (B-phase)
5 (+), 6 (–) (C-phase)
Available Programmable CTs
7 (+), 8 (–)
AUX 1Terminals ...............................
9 (+), 10 (–)
AUX 2 Terminals ..............................
11 (+), 12 (–)
AUX 3 Terminals ..............................
13 (+), 14 (–)
AUX 4 Terminals ..............................
(Programmable CTs AUX 2, 3, and 4 are optional with style number xxxxxxxEx.)
1 Aac Current Sensing
Continuous Rating............................ 0.02 to 1.5 Aac
1 Second Rating............................... 10 Aac
5 Aac Current Sensing
Continuous Rating............................ 0.1 to 7.5 Aac
1 Second Rating............................... 50 Aac
Voltage Sensing
Range............................................... 12 to 576 V rms, line-to-line
Frequency ........................................ 50/60 Hz
Frequency Range............................. 10 to 90 Hz
Burden.............................................. 1 VA
1 Second Rating............................... 720 V rms
DGC-2020HD Specifications
6 9469300990 Rev B
Generator Sensing
Line-to-line or line-to-neutral
Configuration....................................
Generator Sensing Terminals .......... 86 (A-phase)
88 (B-phase)
90 (C-phase)
91 (Neutral)
Bus 1 Sensing
Configuration.................................... Line-to-line or line-to-neutral
Bus Sensing Terminals .................... 93 (A-phase)
95 (B-phase)
97 (C-phase)
98 (Neutral)
Bus 2 Sensing (Optional with style number xxxxxxxEx)
Configuration.................................... Line-to-line or line-to-neutral
Bus Sensing Terminals .................... 100 (A-phase)
101 (B-phase)
103 (C-phase)
104 (Neutral)
Analog Sensing
The DGC-2020HD contains two or four (optional) analog inputs.
Current Sensing
Rating ............................................... 4 to 20 mA
Burden.............................................. 84.25 Ω to 87.1 Ω
Voltage Sensing
Rating ............................................... –10 to 10 Vdc
Burden.............................................. 9.75 kΩ to 10.16 kΩ
Contact Sensing
Contact sensing inputs include sixteen programmable inputs. All inputs accept dry contacts. The following
contact input recognition and contact output closure times reflect the maximum possible delay.
Contact Input Recognition Time
This is the amount of time that elapses after a local contact input closes until that closure is available in
logic.
DGC-2020HD................................... 125 ms
CEM-2020 ........................................ 185 ms
Contact Output Closure Time
This is the amount of time that elapses after a contact output closure is true in logic until that contact
output closes.
DGC-2020HD................................... 15 ms
CEM-2020 ........................................ 125 ms
Terminals
Input 1 .............................................. 31, 49
Input 2 .............................................. 32, 49
Input 3 .............................................. 33, 49
Input 4 .............................................. 34, 49
Specifications DGC-2020HD
9469300990 Rev B 7
Input 5 .............................................. 35, 49

Input 6 .............................................. 36, 49
Input 7 .............................................. 37, 49
Input 8 .............................................. 38, 49
Input 9 .............................................. 39, 49
Input 10 ............................................ 40, 49
Input 11 ............................................ 41, 49
Input 12 ............................................ 42, 49
Input 13 ............................................ 43, 49
Input 14 ............................................ 44, 49
Input 15 ............................................ 45, 49
:
Input 15 ............................................ 45, 49
Input 16 ............................................ 46, 49
Engine System Inputs

Stated accuracies are subject to the accuracy of the senders used. Values within these ranges are deemed
“good” and the DGC-2020HD will use them for the appropriate calculation and protection. Values outside
these ranges are deemed “failed” and the DGC-2020HD will begin timing towards a sender failure condition.
Fuel Level Sensing

Resistance Range............................ 0 to 250 Ω nominal
Terminals.......................................... 71 (FUEL +), 72 (FUEL –)
Coolant Temperature Sensing
Resistance Range............................ 10 to 2,750 Ω nominal
Terminals.......................................... 77 (COOLANT +), 78 (COOLANT –)
Oil Pressure Sensing
Resistance Range............................ 0 to 250 Ω nominal
Terminals.......................................... 74 (OIL +), 75 (OIL –)
Engine Speed Sensing
Magnetic Pickup
Voltage Range ................................. 3 to 35 V peak (6 to 70 V peak-peak)
Frequency Range............................. 32 to 10,000 Hz
Terminals.......................................... 106 (MPU +), 107 (MPU –)
Generator Voltage
Range............................................... 12 to 576 V rms
Terminals.......................................... 86 (A-phase)
88 (B-phase)
90 (C-phase)
91 (Neutral)
Output Contacts
PRE (Prestart), START, and RUN Relays
Rating ............................................... 30 Adc at 28 Vdc—General purpose, 3 A pilot duty
Programmable Relays (12)
Rating ............................................... 2 Adc at 30 Vdc—General purpose, 1.2 A pilot duty
The load must be in parallel with a diode rated at least 3 times the coil current and 3 times the coil
voltage.
8 9469300990 Rev B
Terminals
Output 1............................................
15, 18 (common)
Output 2............................................
16, 18 (common)
Output 3............................................
17, 18 (common)
Output 4............................................
19, 22 (common)
Output 5............................................
20, 22 (common)
Output 6............................................
21, 22 (common)
Output 7............................................
23, 26 (common)
Output 8............................................
24, 26 (common)
Output 9............................................
25, 26 (common)
Output 10..........................................
27, 30 (common)
Output 11..........................................
28, 30 (common)
Output 12..........................................
29, 30 (common)
The programmable relays share common terminals: terminal 18 is used for outputs 1, 2, and 3, terminal
22 is used for outputs 4, 5, and 6, terminal 26 is used for outputs 7, 8, and 9, 30 is used for outputs 10,
11, and 12.
Metering
Generator and Bus Voltage (rms)
Metering Range................................ 0 to 576 Vac (direct measurement)
577 to 9,999 Vac (through VT using VT ratio setting)
VT Ratio Range................................ 1:1 to 125:1 in primary increments of 1
Accuracy*......................................... ±1.0% of programmed rated voltage or ±2 Vac
Display Resolution ........................... 1 Vac
* Voltage metering indicates 0 V when generator voltage is below 2% of the full-scale rating.
Generator Current (rms)
Generator current is measured at the secondary windings of user-supplied 1 A or 5 A CTs.
Metering Range................................ 0 to 5,000 Aac
CT Primary Range ........................... 1 to 5,000 Aac in primary increments of 1 Aac
Accuracy*......................................... ±1.0% of programmed rated current or ±2 Aac
Display Resolution ........................... 1 Aac
* Current metering indicates 0 A when generator current is below 2% of the full-scale rating.
Generator and Bus Frequency
Frequency is sensed through the generator and bus voltage inputs (phases A and B).
Metering Range................................ 10 to 90 Hz
Accuracy........................................... ±0.25% or 0.05 Hz
Display Resolution ........................... 0.1 Hz
Apparent Power
Indicates total kVA and individual line kVA (4-wire, line-to-neutral or 3-wire, line-to-line).
Measurement/Calculation Methods
Total ................................................. kVA = (VL-L × IL ×√3) ÷ 1000
4-Wire, Line-to-Neutral..................... kVA calculated with respect to neutral
3-Wire, Line-to-Line.......................... A-phase kVA = VAB × IA ÷ 1000 ÷ √3
B-phase kVA = VBC × IB ÷ 1000 ÷ √3
C-phase kVA = VCA × IC ÷ 1000 ÷ √3
Accuracy ±2% of the full-scale indication or ±2 kVA *†
* kVA metering indicates 0 kVA when the generator kVA is below 2% of the full-scale rating.
† Applies when temperature is between −40°C to +70°C (–40°F to +158°F).
9469300990 Rev B 9
Power Factor
Metering Range................................ 0.2 leading to 0.2 lagging
Calculation Method .......................... PF = cosine of the angle between phase AB voltage (Vab) and
phase A current (Ia) *
Accuracy........................................... ±0.01 †
* In single-phase AC-connected machines, it is the cosine of the angle between phase CA voltage
(Vca) and phase C current (Ic).
† Applies when temperature is between –40°C to +70°C (–40°F to +158°F).
Note
For the DGC-2020HD to correctly meter power factor, the generator
must be rotating in the same phase sequence as dictated by the
generator phase rotation setting.
Real Power
Indicates total kW and individual line kW (4-wire, line-to-neutral or 3-wire line-to-line)
Measurement/Calculation Methods
Total ................................................. PF × Total kVA
4-Wire, Line-to-Neutral..................... kW calculated with respect to neutral
3-Wire, Line-to-Line.......................... A-phase kW = VAB × IA × PF ÷ 1000 ÷ √3
B-phase kW = VBC × IB × PF ÷ 1000 ÷ √3
C-phase kW = VCA × IC × PF ÷ 1000 ÷ √3
Accuracy ±2% of the full-scale indication or ±2 kW *†
* kW metering indicates 0 kW when the generator kW is below 2% of the full-scale rating.
† Applies when temperature is between –40°C to +70°C (–40°F to +158°F).
Oil Pressure
Metering Range................................ 0 to 150 psi, 0 to 10.3 bar, or 0 to 1,034 kPa
Accuracy........................................... ±2% of actual indication or ±1 psi, ±0.07 bar, or ±6.9 kPa (subject to
accuracy of sender)
Display Resolution ........................... 1 psi, 0.07 bar, or 6.9 kPa
Coolant Temperature
Metering Range................................ 32 to 410°F or 0 to 204°C
Accuracy........................................... ±2% of actual indication or as low as ±2° (subject to accuracy of
sender)
Fuel Level
Metering Range................................ 0 to 100%
Accuracy........................................... ±2% (subject to accuracy of sender)
Display Resolution ........................... 1.0%
Battery Voltage
Metering Range................................ 6 to 32 Vdc
Accuracy........................................... ±2% of actual indication or as low as ±0.2 Vdc
Display Resolution ........................... 0.1 Vdc
Engine RPM
0 to 4,500 rpm
Metering Range................................
±2% of actual indication or as low as ±2 rpm
Accuracy*.........................................
2 rpm
Display Resolution ...........................
* When engine speed is below 2% of full-scale, reported rpm is 0.
10 9469300990 Rev B
:
10 9469300990 Rev B
Maintenance Timer
Maintenance timer indicates the time remaining until genset service is due. Value is retained in
nonvolatile memory.
Metering Range................................ 0 to 5,000 hours
Update Interval................................. 0.1 hours
Accuracy........................................... ±1% of actual indication or as low as ±12 minutes
Display Resolution ........................... 1 minute
Generator Protection Functions

Overvoltage (59) and Undervoltage (27)
0 to 576 V
Pickup Range...................................
1V
Pickup Increment .............................
1 to 60 Vac
Hysteresis Range.............................
Inhibit Frequency Range .................. 20 to 90 Hz (27 function only)
Activation Delay Range.................... 0 to 600 s
Activation Delay Increment .............. 0.1 s
Underfrequency (81U) and Overfrequency (81O)
Pickup Range................................... 37.5 to 66 Hz
Pickup Increment ............................. 0.01 Hz
Hysteresis Range............................. 0.1 to 40 Hz
Inhibit Voltage Range....................... 0 to 100% of nominal voltage
Inhibit Voltage Increment ................. 1%
ROCOF (Rate of Change of Frequency) (81) (Optional)
0.2 to 10 Hz/s
Pickup Range...................................
0.1 Hz/s
0.2 Hz/s
Pickup Accuracy...............................
Activation Delay Range.................... 0 to 10,000 ms
Activation Delay Increment .............. 1 ms
Reverse and Forward Power (32)
0 to 200% of nominal input rating
Pickup Range...................................
0.1%
1 to 10%
Loss of Excitation (40Q)
–150 to 0% of Rated kvar*
Pickup Range...................................
0.1%
1 to 10%
®
* Rated kvar is calculated on the System Settings, Rated Data screen in BESTCOMSPlus .
Overcurrent (51) (Optional)

Pickup Range................................... 0.18 to 4 Aac (1 A current sensing)
0.9 to 20 Aac (5 A current sensing)
Hysteresis......................................... 2%
Time Dial Range .............................. 0 to 7,200 s (fixed time curve)
0 to 9.9 (inverse curve time multiplier)
9469300990 Rev B 11
Time Dial Increment .........................0.1

Inverse Time Curves ........................ See the Time Overcurrent Characteristic Curves chapter
Caution
For 1 A current sensing, current shall not exceed 3 amperes for 30
seconds or 4 amperes for 1 second. For 5 A current sensing, current
shall not exceed 15 amperes for 30 seconds or 20 amperes for 1
second. Exceeding the above limits may result in equipment damage.
Phase Voltage Imbalance (47) (Optional)

0 to 150 Vac
Pickup Range...................................
1 Vac
1 to 5 Vac
Vector Shift (78) (Optional)
Pickup Range................................... 2 to 90°
Pickup Increment ............................. 1°
Hysteresis......................................... 0.5 degrees
Accuracy........................................... ±1°
Logic Timers
Hours Setting Range........................ 0 to 250
Hours Setting Increment .................. 1
Minutes Setting Range..................... 0 to 59
Minutes Setting Increment ............... 1
Seconds Setting Range ................... 0 to 59
Seconds Setting Increment.............. 1
Accuracy........................................... ±15 ms
Communication Interface
CAN (SAE J1939)
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
CAN 1 Terminals.............................. 51 (low), 52 (high), and 53 (shield)
CAN 2 Terminals.............................. 54 (low), 55 (high), and 53 (shield)
Notes
1. If the DGC-2020HD is providing one end of the J1939 bus, a 120 Ω, ½ watt
terminating resistor should be installed across terminals 51 (CAN1L) and 52
(CAN1H) and/or 54 (CAN2L) and 55 (CAN2H).
2. If the DGC-2020HD is not part of the J1939 bus, the stub connecting the
DGC2020HD to the bus should not exceed 914 mm (3 ft) in length.
3. The maximum bus length, not including stubs, is 40 m (131 ft).
4. The J1939 drain (shield) should be grounded at one point only. If grounded
elsewhere, do not connect the drain to the DGC-2020HD.
12 9469300990 Rev B
Ethernet
Dual Copper (RJ-45) ........................ 10/100BASE-T (style number xxxxDxxxx)
Fiber Optic (BNC)............................. 10/100BASE-F (style number xxxxFxxxx)
Industrial Ethernet devices designed to comply with IEC 61000-4 series of specifications are
recommended.
External Dial-Out Modem (RS-232)
Protocol ............................................ ASCII
Data Transmission ........................... Full Duplex
Baud ................................................. 4,800 to 115,200
Data Bits........................................... 8
Parity ................................................ None
Stop Bits........................................... 1
Connector Type................................ DB-9 Connector (Male)
IRIG-B Time Synchronization
Standard:.......................................... 200-04, Format B002
Input Signal ...................................... Demodulated (dc level-shifted signal)
Logic High Level............................... 3.5 Vdc, minimum
Logic Low Level ............................... 0.5 Vdc, maximum
Input Voltage Range ........................ –10 to +10 Vdc
Input Resistance .............................. Nonlinear, approximately 4 kΩ at 3.5 Vdc, 3 kΩ at 20 Vdc
Response Time ................................ < 1 cycle
Terminals.......................................... 59 (IRIG-B +), 60 (IRIG-B –)
Modbus™ (RS-485)
Baud ................................................. 1,200 to 115,200
Data Bits........................................... 8
Parity ................................................ None
Stop Bits........................................... 1
Terminals.......................................... 56 (485 A), 57 (485 B), and 58 (485 shield)
RDP-110
2
Minimum Wire Size .......................... 20 AWG (0.52 mm )
Maximum Wire Length ..................... 4,000 feet (1,219 meters)
Terminals.......................................... 61 (RDP-110 TxD+), 62 (RDP-110 TxD–)
USB
Specification Compatibility USB 2.0
Connector Type Mini-B jack
Real-Time Clock
Clock has leap year and selectable daylight saving time correction. Backup battery sustains timekeeping
during losses of DGC-2020HD operating power.
Resolution ........................................ 1s
Accuracy........................................... ±1.73 s/d at 25°C (77°F)
:
Accuracy........................................... ±1.73 s/d at 25°C (77°F)
Clock Holdup
Battery Holdup Time ........................ Approximately 10 yrs
Battery Type..................................... Rayovac BR2032, lithium, coin-type, 3 Vdc, 195 mAh
Basler Electric P/N 38526
9469300990 Rev B 13
Note
Failure to replace the battery with Basler Electric P/N 38526 may void the warranty.
Caution
Replacement of the backup battery for the real-time clock should be performed only
by qualified personnel.
Do not short-circuit the battery, reverse battery polarity, or attempt to recharge the
battery. Observe polarity markings on the battery socket while inserting a new
battery. The battery polarity must be correct in order to provide backup for the
realtime clock.
It is recommended that the battery be removed if the DGC-2020HD is to be
operated in a salt-fog environment. Salt-fog is known to be conductive and may
short-circuit the battery.
LCD Heater
The ambient temperature is monitored by a temperature sensor located near the LCD inside the
DGC2020HD. The LCD heater turns on when the ambient temperature falls below –5°C (23°F). The heater
turns off when the ambient temperature rises above 5°C (41°F). This range of operation implements 10°C
(18°F) of hysteresis between heater turn on and turn off.
Type Tests
Shock
Withstands 15 G in 3 perpendicular planes.
Vibration
Tested for 8 hours in three perpendicular planes.
3 to 25 Hz......................................... at 1.6 mm (0.063 in) peak amplitude
25 to 2,000 Hz.................................. at 5 G
HALT (Highly Accelerated Life Testing)
HALT is used by Basler Electric to prove that our products will provide the user with many years of reliable
service. HALT subjects the device to extremes in temperature, shock, and vibration to simulate years of
operation, but in a much shorter period span. HALT allows Basler Electric to evaluate all possible design
elements that will add to the life of this device. As an example of some of the extreme testing conditions, the
DGC-2020HD was subjected to temperature tests (tested over a temperature range of –85°C to +120°C),
vibration tests (of 5 to 40 G at +30°C), and temperature/vibration tests (tested at 40 G over a temperature
range of –85°C to +120°C). Combined temperature and vibration testing at these extremes proves that the
DGC-2020HD is expected to provide long-term operation in a rugged environment. Note that the vibration
and temperature extremes listed in this paragraph are specific to HALT and do not reflect recommended
operation levels.
Ignition System
Tested in close proximity to an unshielded, unsuppressed Altronic DISN 800 Spark Ignition System.
Environment
Operating Temperature.................... –40 to +70°C (–40 to +158°F)

Storage Temperature ....................... –40 to +85°C (–40 to +185°F)
14 9469300990 Rev B
Salt Fog ............................................ IEC 60068

Ingress Protection ............................ IEC IP56 for front panel
Humidity ........................................... IEC 68-2-78
UL Approval
The DGC-2020HD is recognized to applicable Canadian and US safety standards and requirements by
UL.
Standards used for evaluation:
• UL6200
• CSA C22.2 No. 0
• CSA C22.2 No. 14
The DGC-2020HD ground fault protection circuit complies with the Calibration and Withstand tests of UL
1053; as required by UL6200.
(See the Time Curve Characteristics chapter for the listing of curves verified to meet UL1053.)
Caution
To follow UL guidelines, replacement of the backup battery for the real-time clock
should be performed only by qualified personnel.
CSA Certification
The DGC-2020HD was tested and has met the certification requirements for electrical, plumbing and/or
mechanical products.
Standards used for evaluation:
• CSA C22.2 No. 0
• CSA C22.2 No. 14
NFPA Compliance
Complies with NFPA Standard 110, Standard for Emergency and Standby Power.
CE Compliance
This product has been evaluated and complies with the relevant essential requirements set forth by the
EU legislation.
EC Directives:
• Low Voltage Devices (LVD) – 2006/95/EC
• Electromagnetic Compatibility (EMC) – 2004/108/EC
Harmonized Standards used for evaluation:
• EN 50178 - Electronic Equipment for use in Power Installations
• EN 61000-6-4 - Electromagnetic Compatibility (EMC), Generic Standards, Emission Standard for
Industrial Environments
• EN 61000-6-2 - Electromagnetic Compatibility (EMC), Generic Standards, Immunity for Industrial
Environments
Physical
Weight .............................................. 5.50 lb (2.5 kg)
Dimensions....................................... See the Mounting chapter.
9469300990 Rev B 15
Mounting
DGC-2020HD controllers are delivered in sturdy cartons to prevent shipping damage. Upon receipt of a
unit, check the part number against the requisition and packing list for agreement. Inspect for damage,
and if there is evidence of such, immediately file a claim with the carrier and notify the Basler Electric
regional sales office or your sales representative.
If the device is not installed immediately, store it in the original shipping package in a moistureand dustfree
environment.
Hardware
The front panel is resistant to moisture, salt fog, humidity, dust, dirt, and chemical contaminants.
DGC2020HD controllers are mounted using the four permanently attached 10-24 studs. The torque applied
to the mounting hardware should not exceed 20 inch-pounds (2.2 newton meters).
Dimensions
Panel cutting and drilling dimensions are shown in Figure 2. The horizontal drilling measurement of 10.75
inches has a tolerance of +0.01/–0.01 inches. The horizontal cutout measurement of 10.38 inches has a
tolerance of +0.04/–0 inches. The vertical drilling measurement of 7.25 inches has a tolerance of +0.01/–
0.01 inches. The vertical cutout measurement of 6.88 inches has a tolerance of +0.04/–0 inches. Overall
dimensions are shown in Figure 3. All dimensions are shown in inches with millimeters in parenthesis.
(136.5)
0.25
(6.4) 5.19
(131.8)
:
3.44
(87.4)
3.625
(92.1)
6.88
C
(174.8)
L
7.25
(184.2)
P0071-79
10.38
(263.7)
10.75
(273.1)
Figure 2. Panel Cutting and Drilling Dimensions
DGC-2020HD Mounting
16 9469300990 Rev B
Figure 3. Overall Dimensions
Mounting DGC-2020HD
− BATT
9469300990 Rev B 17
Terminals and Connectors

All DGC-2020HD terminals and connectors are located on the rear panel. DGC-2020HD terminals consist of
a mini-B USB jack, a DB-9 connector, Ethernet ports, plug-in connectors with spring clamp terminals, and
quarter-inch, male, quick-connect terminals.
Figure 4 illustrates the rear panel terminals. Locator letters in the illustration correspond to the terminal
block and connector descriptions in Table 1.
P4
INPUT 15 45 A 51 CAN 1 LOW
52 CAN 1 HIGH
INPUT 14 44
P5
Eth 2
INPUT 13 53 SHIELD
43
CHASSIS GND
INPUT 12 42 54 CAN 2 LOW

55 CAN 2 HIGH
INPUT 11 41 C
INPUT 10 40
Rx
Eth 1
INPUT 9 39
P3 INPUT 8 38 Tx
Eth 1
INPUT 7 37
INPUT 6 36
INPUT 5 35
INPUT 4 34
INPUT 3 33
INPUT 2 32
INPUT 1 31
COM 10, 11, 12 30

OUT 12 29
OUT 11 28
OUT 10 27
COM 7, 8, 9 26
OUT 9 25
OUT 8 24
P2 OUT 7 23 A
COM 4, 5, 6 22
OUT 6 21
OUT 5 20
OUT 4 19
COM 1, 2, 3 18
OUT 3 17
OUT 2 16
+ BATT
OUT 1 15
AUX I4− 14
AUX I4+ 13
AUX I3− 12
AUX I3+ 11
AUX I2− 10
AUX I2+ 9
P1 AUX I1− 8
AUX I1+ 7
GEN IC− 6
:
GEN IC− 6
GEN IC+ 5
GEN IB− 4
GEN IB+ 3
GEN IA− 2
GEN IA+ 1
Not Used
INPUT 16
46 47 48 49 50
AB
D 56
57
RS-485A
RS-485B
58 RS-485 SHIELD
59 IRIG-B+
60 IRIG-B−
61 RDP-110 TxD+
62 RDP-110 TxD−
63 CHASSIS GND P6
AVR +
DGC-2020HD
64
65 AVR −
66 GOV +
67 GOV −
68 GOV PWM
69 LOAD SHARE+
LOAD SHARE−
A
70
71 FUEL +
72 FUEL −
73 Not Used
PRE
E 74 OIL +
75 OIL −
76 OIL I
77 COOLANT+
START RUN
78 COOLANT− P7
79 COOLANT I
80 ALOG IN 2 +
81 ALOG IN 2 −
82 ALOG IN 2 I
F + – 83 ALOG IN 1 +
84 ALOG IN 1 −
A 85 ALOG IN 1 I
MPU − MPU 107
106
105
104
103
102
101
100
86
99
98
97
96
95
94
93
92
91
90
89
88
87
BUS 2 VN
BUS 2 VC
BUS 1 VN
BUS 1 VC
BUS 2 VB
BUS 1 VB
BUS 2 VA
BUS 1 VA
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
GEN VN
GEN VC
GEN VB
GEN VA
+
P9 P8 P0071-12
Figure 4. Rear Panel
DGC-2020HD Terminals and Connectors
18 9469300990 Rev B
Table 1. Rear Panel Terminal and Connector Descriptions

Locator Description
A The majority of external, DGC-2020HD wiring is terminated at 5-, 7-, or 15-position
connectors with spring clamp terminals. These connectors plug into headers on the
DGC-2020HD. The connectors and headers have a dovetailed edge that ensures
proper connector orientation. Each connector and header is uniquely keyed to ensure
that a connector mates only with the correct header. Terminals accept a maximum
2
wire size of 12 AWG (3.31 mm ).
B This male DB-9 connector is provided for external dial-out modem communication and
the future implementation of other communication protocols. Contact Basler Electric for
protocol availability.
C DGC-2020HD Ethernet communication uses the Modbus™ TCP protocol to provide
remote metering, annunciation, and control. Dual copper (100Base-T) ports (style
xxxxDxxxx) use standard RJ-45 jacks while a fiber optic (100Base-F) port (style
xxxxFxxxx) uses two BNC fiber optic connectors.
Ethernet ports have different designations depending on style:
Dual copper (Style xxxxDxxxx) – The RJ-45 jack nearest to the mini-B USB port is
designated as Ethernet port 1 and is reserved for intergenset communications (load
sharing). The other RJ-45 jack is designated as Ethernet port 2 and can be configured
for redundant intergenset communications or for an independent network connection.
Fiber optic (Style xxxxFxxxx) – The fiber optic port is designated as Ethernet port 1
and is reserved for intergenset communications (load sharing).
Figure 4 shows both Ethernet port styles (dual copper and fiber) for clarity. The DGC-
2020HD comes equipped with only one port style, not both.
D The mini-B USB jack mates with a standard USB cable and is used with a PC running
®
BESTCOMSPlus software for local communication with the DGC-2020HD.
E Connections to the Start, Run, and Pre output contacts are made directly to each relay
through quarter-inch, male, quick-connect terminals.
F An onboard battery maintains DGC-2020HD timekeeping during losses of operating
power. See the Timekeeping chapter, for instructions on replacing the battery. Failure
to replace the battery with Basler Electric P/N 38526 may void the warranty.
Terminals
:
Terminals
DGC-2020HD connections are dependent on the application. Incorrect wiring may result in damage to the
controller.
Note
Be sure that the DGC-2020HD is hard-wired to earth ground with no
2
smaller than 12 AWG (3.31 mm ) copper wire attached to chassis
ground (terminal 50) on the rear of the controller.
Operating power from the battery must be of the correct polarity. While
reverse polarity will not cause damage, the DGC-2020HD will not
operate.
The DGC-2020HD terminals are grouped by function and include operating power, current sensing,
voltage sensing, engine sender input, magnetic pickup input, contact sensing, output contacts, CAN
interface, RS-485 interface, AVR control, GOV control, Load Share, IRIG source, Remote Display Panel
connection, USB port, Ethernet communication, and RS-232 communication.
DGC-2020HD terminals are described in the following paragraphs.
Terminals and Connectors DGC-2020HD
9469300990 Rev B 19
Operating Power
The DGC-2020HD operating power input accepts a nominal voltage of 12 Vdc or 24 Vdc and tolerates
voltage over the range of 6 to 32 Vdc. Operating power must be of the correct polarity. While reverse
polarity will not cause damage, the DGC-2020HD will not operate. Operating power terminals are listed in
Table 2.
A fuse should be added for additional protection for the wiring to the battery input of the DGC-2020HD. A
fuse helps prevent wire damage and nuisance trips due to initial power supply inrush current. To follow UL
guidelines, a 5 A maximum, 32 Vdc supplementary fuse must be implemented in the battery input circuit to
the DGC-2020HD.
Table 2. Operating Power Terminals
Terminal Description
50 (CHASSIS) Chassis ground connections
49 (BATT–) Negative side of operating power input
48 (BATT+) Positive side of operating power input
Generator Current Sensing

The DGC-2020HD has sensing inputs for A-phase, B-phase, and C-phase generator current. A
DGC2020HD with a style number of 1xxxxxxxxx has 1 Aac nominal current sensing and a DGC-2020HD
with a style number of 5xxxxxxxx indicates 5 Aac nominal current sensing. Generator current sensing
terminals are listed in Table 3.
Table 3. Generator Current Sensing Terminals
Terminals Description
1 (IA+)
A-phase current sensing input
2 (IA–)
3 (IB+)
B-phase current sensing input
4 (IB–)
5 (IC+)
C-phase current sensing input
6 (IC–)
Programmable Current Sensing

Four user-programmable current sensing inputs are provided for measuring mains current, load bus
current, ground current, or a combination of these. Table 4 lists the programmable current sensing
terminals.
Table 4. Programmable Current Sensing Terminals
7 (AUX I1 +)
Programmable current sensing input 1
8 (AUX I1 –)
9 (AUX I2 +)
10 (AUX I2 –)
11 (AUX I3 +)
12 (AUX I3 –)
13 (AUX I4 +)
14 (AUX I4 –)
20 9469300990 Rev B
Caution
Current sensing terminals 2 (IA–), 4 (IB–), 6 (IC–), 8(AUX I1–), 10
(AUX I2–), 12 (AUX I3–), and 14 (AUX I4–) must be terminated to
ground for proper operation.
Note
Unused current sensing inputs should be shorted to minimize noise
pickup.
Generator Voltage Sensing

The DGC-2020HD accepts either line-to-line or line-to-neutral generator sensing voltage over the range of 0
to 576 volts, rms line-to-line or 0 to 333 volts, rms line-to-neutral. Generator voltage sensing terminals are
listed in Table 5.
Table 5. Generator Voltage Sensing Terminals
86 (GEN VA) A-phase generator voltage sensing input
88 (GEN VB) B-phase generator voltage sensing input
90 (GEN VC) C-phase generator voltage sensing input
91 (GEN VN) Neutral generator voltage sensing input
Bus Voltage Sensing

Sensing of bus voltage enables the DGC-2020HD to detect failures of the mains (utility). Controllers with
style number xxx2xxxxx use bus voltage sensing to perform automatic synchronization of the generator with
the bus. The DGC-2020HD accepts either line-to-line or line-to-neutral bus sensing voltage over the range
of 0 to 576 volts, rms line-to-line or 0 to 333 volts, rms line-to-neutral. Controllers with style number
xxxxxxxEx are equipped with two bus sensing inputs. One is intended for sensing the mains voltage while
the other is intended for sensing the load bus voltage.
Bus voltage sensing terminals are listed in Table 6.
Table 6. Bus Voltage Sensing Terminals

93 (BUS1 VA) A-phase bus voltage sensing input
95 (BUS1 VB) B-phase bus voltage sensing input
97 (BUS1 VC) C-phase bus voltage sensing input
98 (BUS1 VN) Neutral bus voltage sensing input
100 (BUS2 VA) A-phase bus voltage sensing input (optional)
101 (BUS2 VB) B-phase bus voltage sensing input (optional)
103 (BUS2 VC) C-phase bus voltage sensing input (optional)
104 (BUS2 VN) Neutral bus voltage sensing input (optional)
Engine Sender Inputs

Inputs are provided for fuel level, oil pressure, and coolant temperature senders. For a listing of fuel level,
oil pressure, and coolant temperature senders that are compatible with the DGC-2020HD, refer to the
9469300990 Rev B 21
Engine Sender Inputs chapter. The fuel level input accepts resistive senders only. Oil pressure and
coolant temperature inputs accept either resistive or analog senders depending on the style number.
Engine sender input terminals are listed in Table 7.
Table 7. Sender Input Terminals
71 (FUEL +) Fuel level sender input
72 (FUEL –) Fuel level sender return
74 (OIL + / ANALOG IN 4 +) Oil pressure sender input or Analog input 4 +
75 (OIL – / ANALOG IN 4 –) Oil pressure sender return or Analog input 4 –
76 (N.C. / ANALOG IN 4 I) Analog input 4 (I) current input
77 (COOLANT + / ANALOG IN 3 +) Coolant temperature sender input or Analog input 3 +
78 (COOLANT – / ANALOG IN 3 –) Coolant temperature sender return or Analog input 3 –
79 (N.C. / ANALOG IN 3 I) Analog input 3 (I) current input
When using the current input, it must be tied to the voltage input. See the Typical Applications
chapter for a diagram.
Analog Inputs
Two user-programmable analog inputs are provided. These inputs accept a signal range of either 4 to
:
20 mA or 0 to 10 Vdc. Analog input terminals are listed in Table 8.
Table 8. Analog Input Terminals
80 (ANALOG IN 1 +) Auxiliary analog 1 +
81 (ANALOG IN 1 –) Auxiliary analog 1 –
82 (ANALOG IN 1 I) Auxiliary analog 1 (I) current input
83 (ANALOG IN 2 +) Auxiliary analog 2 +
84 (ANALOG IN 2 –) Auxiliary analog 2 –
85 (ANALOG IN 2 I) Auxiliary analog 2 (I) current input
When using the current input, it must be tied to the voltage input. See Typical
Applications chapter for a diagram.
Magnetic Pickup Input

The magnetic pickup input accepts a speed signal over the range of 3 to 35 volts peak and 32 to 10,000
hertz. Magnetic pickup input terminals are listed in Table 9.
Table 9. Magnetic Pickup Input Terminals
105 (MPU–) Magnetic pickup return input
106 (MPU+) Magnetic pickup positive input
Contact Sensing Inputs

Contact sensing inputs consist of sixteen programmable inputs. The programmable inputs accept normally
open, dry contacts. Terminal 49 (BATT–) serves as the common return line for the programmable inputs.
While input 1 is programmed to recognize an emergency stop input by default, it can be programmed for
any function. Information about configuring the programmable inputs is provided in the Contact Inputs
chapter. Contact sensing input terminals are listed in Table 10.
22 9469300990 Rev B
Table 10. Contact Sensing Inputs
49 (BATT–) Common return line for programmable contact inputs
31 (INPUT 1) Programmable contact input 1
Output Contacts
The DGC-2020HD has three sets of fixed-function output contacts: Pre, Start, and Run. The Pre contacts
supply battery power to the engine glow plugs, the Start contacts supply power to the starter solenoid, and
the Run contacts supply power to the fuel solenoid. Connections to the three sets of contacts are made at
terminals 19 through 24. The Pre, Start, and Run relay terminals are listed in Table 11.
Table 11. Fixed-Function Output Contact Terminals
19 (START) Start output contact (Start solenoid)
20 (START)
21 (RUN) Run output contact (Fuel solenoid)
22 (RUN)
23 (PRE) Pre-start output contact (Glow plugs)
24 (PRE)
Twelve programmable output contacts are provided in four sets. Each set of three output contacts shares a
common terminal. Programmable output contact terminals are listed in Table 12.
Table 12. Programmable Output Contact Terminals
15 (OUT 1) Programmable output 1
18 (COM 1, 2, 3) Common connection for outputs 1, 2, and 3
9469300990 Rev B 23
CAN Interface
These terminals provide communication using the SAE J1939 protocol or the MTU protocol and provide
high-speed communication between the DGC-2020HD and an ECU on an electronically controlled
engine. Connections between the ECU and DGC-2020HD should be made with twisted-pair, shielded
cable. CAN interface terminals are listed in Table 13. For typical CAN connections, refer to the Typical
Connections chapter.
Table 13. CAN Interface Terminals
51 (CAN 1 L) CAN 1 low connection
52 (CAN 1 H) CAN 1 high connection
53 (SHIELD) CAN drain connection
54 (CAN 2 L) CAN 2 low connection
55 (CAN 2 H) CAN 2 high connection
Note
1. If the DGC-2020HD is providing one end of the J1939 bus, a
120 Ω, ½ watt terminating resistor should be installed across
terminals 51 (CAN1L) and 52 (CAN1H) or 54 (CAN2L) and 55
(CAN2H)
2. If the DGC-2020HD is not providing one end of the J1939 bus, the
stub connecting the DGC-2020HD to the bus should not exceed
914 mm (3 ft) in length.
4. The J1939 drain (shield) should be grounded at one point only. If
grounded elsewhere, do not connect the drain to the
DGC2020HD.
RS-485 Interface
DGC-2020HD controllers can be monitored and controlled via a polled network using the Modbus™
protocol. The RS-485 port supports a user-selectable baud rate of 1,200, 2,400, 4,800, 9,600, 19,200,
38,400, 57,600, or 115,200. Seven or eight data bits per character can be selected. Odd, even, or no

24 9469300990 Rev B
parity is supported. One or two stop bits are selectable. Modbus register values for the DGC-2020HD are
listed and defined in Basler Publication 9469300991, Instruction Manual for DGC-2020HD Digital Genset
Controller Modbus™ Protocol. RS-485 interface terminals are listed in Table 14.
Table 14. RS-485 Terminals
56 (RS-485 A) RS-485 send/receive A connection
57 (RS-485 B) RS-485 send/receive B connection
58 (RS-485 SHIELD) RS-485 shield connection
Automatic Voltage Regulator (AVR) Control

:
Automatic Voltage Regulator (AVR) Control
AVR control outputs provide control of the generator voltage setpoint. AVR control terminals are listed in
Table 15.
Table 15. AVR Control Output Terminals
64 (AVR +) AVR control output positive
65 (AVR –) AVR control output negative
Governor (GOV) Control

GOV control output contacts provide remote control of the generator speed (RPM) setpoint. GOV control
terminals are listed in Table 16.
Table 16. GOV Control Output Terminals
66 (GOV +) GOV control output positive
67 (GOV –) GOV control output negative
68 (GOV PWM) GOV PWM output for CAT control system interface
Load Share Line

Load share line outputs are measured and used to calculate the per-unitized average load level. This
average is used as the setpoint for the genset’s kW controller. Load share line output terminals are listed in
Table 17.
Table 17. Load Share Line Output Terminals
69 (LOAD SHARE +) Load share line positive
70 (LOAD SHARE –) Load share line negative
IRIG-B Connections
The IRIG-B terminals connect to an IRIG-B source for synchronization of DGC-2020HD timekeeping with
the IRIG-B source. Table 18 lists the IRIG-B source input terminals.
Table 18. IRIG-B Source Input Terminals
59 (IRIG-B +) IRIG-B source input
60 (IRIG-B –) IRIG-B return terminal
9469300990 Rev B 25
Optional Remote Display Panel Connections

Terminals are provided for connection with the optional remote display panel (Basler P/N 9318100114
projection mount or 9318100115 flush mount). These terminals provide dc operating power to the remote
display panel and enable communication between the DGC-2020HD and the remote display panel.
Twisted-pair conductors are recommended for making the connections between the DGC-2020HD and
remote display panel. Communication may become unreliable if the connection wires exceed 1,219 m
(4,000 ft). Table 19 lists the DGC-2020HD terminals that connect to the remote display panel.
Table 19. Remote Display Panel Interface Terminals
61 (RDP TxD +) Remote display panel communication terminal (TxD +)
62 (RDP TxD –) Remote display panel communication terminal (TxD –)
49 (BATT–) Remote display panel power terminal DC COM (–)
48 (BATT+) Remote display panel power terminal 12/24 (+)
Connectors
USB Interface
®
A mini-B USB jack enables local communication with a PC running BESTCOMSPlus software. The DGC-
2020HD is connected to a PC using a standard USB cable equipped with a type A plug on one end (PC
termination) and a mini-B plug on the other end (DGC-2020HD termination).
Ethernet Communications
Dual copper RJ-45 jacks or a BNC fiber optic port provide Ethernet communications between the
DGC2020HD and a PC via BESTCOMSPlus or other DGC-2020HDs in a network. An Ethernet connection
to a PC running BESTCOMSPlus provides remote metering, setting, annunciation, and control of the
DGC2020HD. Ethernet communication between DGC-2020HDs allows for generator sequencing on an
islanded system.
RS-232 Interface
A male DB-9 connector allows the DGC-2020HD controller to connect to an external, user-supplied dialout
modem via the RS-232 interface. The modem enables the DGC-2020HD to dial up to four pager telephone
numbers and annunciate conditions selected by the user. These conditions include any DGC2020HD
alarm or pre-alarm, closure of any programmable contact input, and an active cool down timer.
26 9469300990 Rev B
9469300990 Rev B 27
:
9469300990 Rev B 27
Typical Applications
Typical connection diagrams are provided in this chapter as a guide when wiring the DGC-2020HD for
communication, mechanical senders, contact inputs and outputs, sensing, and operating power.
Connections for Typical Applications

Typical connections for applications which use three-phase wye, three-phase delta, single-phase A-B,
and single-phase A-C generator voltage sensing are shown on the following pages.
Figure 5 illustrates typical three-phase wye generator voltage sensing connections.
DGC-2020HD Typical Applications
28 9469300990 Rev B
LOAD
GEN CKT MAINS CKT

BKR BKR
L1
A
GENERATOR L2
B
≤ 480 V
L3
C
N
N
1 1 1 1 1 1 1
1 2 3 4 5 6 86 88 90 91 7 8 9 10 11 12 13 14 100 101 103 104 93 95 97 98

M P0071-25
P
+IC
–IA
–IB
GEN VB
BUS1 VA
BUS2 VB
AUX +I3
AUX +I4
+IA
BUS1 VB
–IC
GEN VC
AUX –I1
AUX –I3
+IB
BUS1 VN
GEN VA
BUS2 VA
AUX +I1
AUX +I2
GEN VN
AUX –I2
BUS2VC
AUX –I4
BUS2VN
BUS1VC
U
106 MPU+
107 MPU– AVR + 64
AVR – 65
GOV + 66
71 FUEL +
GOV – 67
72 FUEL –
GOV PWM 68
74 ANALOG IN 4 + / OIL + 2 LOAD SHARE + 69
75 ANALOG IN 4 – / OIL – 3 LOAD SHARE – 70
76 ANALOG IN 4 I / N.C. 5 4
77 ANALOG IN 3 + / COOLANT +
DGC-2020HD OUT 1
OUT 2
15
16
Horn
Not in Auto
78 ANALOG IN 3 – / COOLANT – 3
OUT 3 17 Global Alarm
79 ANALOG IN 3 I / N.C. 5
18
0 to 10 V or 80 ANALOG IN 2 + 1 Current inputs are 1A or 5A, depending on style. OUT 4 19 Global Pre-Alarm
4 to 20 mA
source 81 ANALOG IN 2 – 3 Terminals 74 through 79 support analog inputs or resistive senders, OUT 5 20 Open Generator Breaker
2 depending on style (resistive senders shown).
82 ANALOG IN 2 I
5 OUT 6 21 Close Generator Breaker
For optimal metering performance, it is recommended to connect
3
0 to 10 V or 83 ANALOG IN 1 + analog input common to BATT– (49). 22
4 to 20 mA
Labels indicate the functions assigned by the default programmable OUT 7
source 84 ANALOG IN 1 – 3 23 Open Mains Breaker
4 logic to the contact inputs and output contacts.
85 ANALOG IN 1 I OUT 8 24 Close Mains Breaker
5 When using analog current inputs, the ‘+’ and ‘I’ terminals must be
5
tied. OUT 9 25 Governor Raise
46 INPUT 16
6 Connect to the ECU on an electronically controlled engine. 26
4 45 INPUT 15
7 If component is under ECU control, do not connect to DGC-2020HD. OUT 10 27
Mains Bkr Status 44 INPUT 14
8 Connect to CAN 1 (AEM-2020 / CEM-2020 network) only. OUT 11 28
Gen Bkr Status 43 INPUT 13
OUT 12 29
Close Mains Breaker 42 INPUT 12
30
Open Mains Breaker 41 INPUT 11
To ECU Power or
Close Gen Breaker 40 INPUT 10
Key-on Terminal
6
Open Gen Breaker 39 INPUT 9
GLOW PLUGS
38 INPUT 8 Copper Copper Fiber Optic PRE

Mini-B RS-232 Ethernet Ethernet OR Ethernet 7
37 INPUT 7 USB DB-9 Base-100T Base-100T Base-100F
36 INPUT 6
FUEL
35 INPUT 5 RUN
SOLENOID
7
+RDP110 TXD-
–RDP110 TXD-
34 INPUT 4
CHASSIS
SHIELD485
+ IRIGB-
– IRIGB-
CAN1 H
CAN2 H
SHIELD
CAN1 L
CAN2 L
+BATT
–BATT
485A
485B
32 INPUT 2 START SOLENOID

33 INPUT 3
START
7
Emergency Stop 31 INPUT 1 51 52 53 54 55 56 57 58 59 60 61 62 50 49 48
8 12/24V
To CAN 1
To CAN 2
Figure 5. 3-Phase Wye Connections for Typical Applications
Typical Applications DGC-2020HD
9469300990 Rev B 29
Figure 6 illustrates typical three-phase delta generator voltage sensing connections.
LOAD
GEN CKT MAINS CKT

BKR BKR
L1
A
GENERATOR L2
B
≤ 480 V
L3
C
N
N
1 1 1 1 1 1 1
1 2 3 4 5 6 86 88 90 91 7 8 9 10 11 12 13 14 100 101 103 104 93 95 97 98

M P0071-55
P
GEN VC
AUX –I4
BUS2 VC
BUS2 VN
+IC
BUS1 VC
AUX +I1
AUX +I2
AUX +I3
AUX +I4
–IA
–IC
GEN VN
AUX –I1
AUX –I2
AUX –I3
VB
–IB
BUS1 VN
VB
VB
+IA
VA
+IB
VA
VA
U
GEN
GEN
BUS1
BUS1
BUS2
BUS2
106 MPU+
107 MPU– AVR + 64
AVR – 65
GOV + 66
71 FUEL +
GOV – 67
72 FUEL –
GOV PWM 68
74 ANALOG IN4 + / OIL + 2 LOAD SHARE + 69
75 ANALOG IN4 – / OIL – 3 LOAD SHARE – 70
76 ANALOG IN4 I / N.C. 5 4
77 ANALOG IN3 + / COOLANT +

DGC-2020HD OUT 1
OUT 2
15
16
Horn
Not in Auto
78 ANALOG IN3 – / COOLANT – 3

79 ANALOG IN3 I / N.C. 5
18
0 to 10 V or 80 ANALOG IN2 + 1 Current inputs are 1A or 5A, depending on style. OUT 4 19 Global Pre-Alarm
4 to 20 mA
source 81 ANALOG IN2 – 3 Terminals 74 through 79 support analog inputs or resistive senders, OUT 5 20 Open Generator Breaker
82 ANALOG IN2 I OUT 6
5 21 Close Generator Breaker
0 to 10 V or 83 ANALOG IN1 + 3 analog input common to BATT– (49). 22
4 to 20 mA
source 84 ANALOG IN1 – 3 23 Open Mains Breaker
85 ANALOG IN1 I OUT 8 24 Close Mains Breaker
5
46 INPUT 16
4 45 INPUT 15
OUT 12 29
30
To ECU Power or
Close Gen Breaker 40 INPUT 10 Key-on Terminal
6
GLOW PLUGS

Mini-B RS-232 OR
Ethernet Ethernet Ethernet 7
36 INPUT 6
FUEL
35 INPUT 5 RUN
SOLENOID
7
+RDP110 TXD-
–RDP110 TXD-
34 INPUT 4
CHASSIS
SHIELD485
+ IRIGB-
– IRIGB-
CAN1 H
CAN2 H
SHIELD
CAN2 L
CAN1 L
+BATT
–BATT
485A
485B

33 INPUT 3
START
INPUT 1
7
Emergency Stop 31 51 52 53 54 55 56 57 58 59 60 61 62 50 49 48
:
8 12/24V
To CAN 1
To CAN 2
Figure 6. 3-Phase Delta Connections for Typical Applications
30 9469300990 Rev B
Figure 7 illustrates typical single-phase A-B generator voltage sensing connections.
LOAD
GEN CKT MAINS CKT

BKR BKR
L1
A
GENERATOR L2
B
≤ 480 V
N
N
1 1 1 1 1
1 2 3 4 5 6 86 88 90 91 7 8 9 10 11 12 13 14 100 101 103 104 93 95 97 98

M P0071-56
P
AUX +I1
AUX +I2
BUS1 VC
VA
VB
–IA
–IB
AUX +I3
AUX +I4
VB
BUS1 VN
GEN VC
AUX –I1
AUX –I3
AUX –I4
BUS2 VC
BUS2 VN
+IA
+IB
VB
+IC
GEN VN
AUX –I2
–IC
VA
VA
U
BUS1
BUS2
BUS1
GEN
GEN
BUS2
106 MPU+
107 MPU– AVR + 64
AVR – 65
GOV + 66
71 FUEL +
GOV – 67
72 FUEL –
GOV PWM 68
DGC-2020HD OUT 1
OUT 2
15
16
Horn
Not in Auto
18
0 to 10 V or 80 ANALOG IN 2 + 1 Current inputs are 1A or 5A, depending on style. OUT 4 19 Global Pre-Alarm
4 to 20 mA
source 81 ANALOG IN 2 – 3 Terminals 74 through 79 support analog inputs or resistive senders, OUT 5 20 Open Generator Breaker
82 ANALOG IN 2 I OUT 6
0 to 10 V or 83 ANALOG IN 1 + 3 analog input common to BATT– (49). 22
4 to 20 mA
5
46 INPUT 16
4 45 INPUT 15
OUT 12 29
30
To ECU Power or
6
GLOW PLUGS

Mini-B RS-232 OR
36 INPUT 6
FUEL
35 INPUT 5 RUN
SOLENOID
+RDP110 TXD-
–RDP110 TXD-
34 INPUT 4
CHASSIS
SHIELD485
+ IRIGB-
– IRIGB-
SHIELD
CAN1 H
CAN2 H
CAN2 L
CAN1 L
–BATT
+BATT
485A
485B
33 INPUT 3
START
INPUT 1
7
Emergency Stop 31 51 52 53 54 55 56 57 58 59 60 61 62 50 49 48
8 12/24V
To CAN 1
6
To CAN 2
Figure 7. Single-Phase A-B Connections for Typical Applications
9469300990 Rev B 31
Figure 8 illustrates typical single-phase A-C generator voltage sensing connections.
LOAD
GEN CKT MAINS CKT

BKR BKR
L1
A
GENERATOR L3
C
≤ 480 V
N
N
1 1 2 1 1 1
1 2 3 4 5 6 86 88 90 91 7 8 9 10 11 12 13 14 100 101 103 104 93 95 97 98

M P0071-57
P
BUS1 VC
VA
–IA
–IB
+IC
AUX +I1
AUX +I2
AUX +I3
AUX +I4
VB
BUS1 VN
GEN VC
AUX –I1
AUX –I3
AUX –I4
BUS2 VN
+IA
+IB
VB
VB
–IC
GEN VN
AUX –I2
BUS2 VC
VA
VA
U
BUS1
BUS1
GEN
GEN
BUS2
BUS2
106 MPU+
107 MPU– AVR + 64
AVR – 65
GOV + 66
71 FUEL +
GOV – 67
72 FUEL –
GOV PWM 68
DGC-2020HD OUT 1
OUT 2
15
16
Horn
Not in Auto
18
0 to 10 V or 80 ANALOG IN 2 +
OUT 4 19 Global Pre-Alarm
4 to 20 mA 1 Current inputs are 1A or 5A, depending on style.
source 81 ANALOG IN 2 – OUT 5
4 20 Open Generator Breaker
2 Optional. Jumper terminals 88 and 90.
82 ANALOG IN 2 I OUT 6
3 Terminals 74 through 79 support analog inputs or resistive senders,
0 to 10 V or 83 ANALOG IN 1 + depending on style (resistive senders shown). 22
4 to 20 mA
4 For optimal metering performance, it is recommended to connect OUT 7
analog input common to BATT– (49).
6 5 Labels indicate the functions assigned by the default programmable
logic to the contact inputs and output contacts. OUT 9 25 Governor Raise
46 INPUT 16
26
5 45 INPUT 15 tied.
OUT 10 27
Mains Bkr Status 44 INPUT 14 7 Connect to the ECU on an electronically controlled engine.
OUT 11 28
8 If component is under ECU control, do not connect to DGC-2020HD.
OUT 12 29
Close Mains Breaker 42 INPUT 12 9 Connect to CAN 1 (AEM-2020 / CEM-2020 network) only.
30
To ECU Power or
7
GLOW PLUGS

Mini-B RS-232 OR
36 INPUT 6
FUEL
35 INPUT 5 RUN
SOLENOID
8
–RDP110 TXD-
+RDP110 TXD-
34 INPUT 4
CHASSIS
SHIELD485
+ IRIGB-
– IRIGB-
SHIELD
CAN1 H
CAN2 H
CAN1 L
CAN2 L
+BATT
–BATT
485A
485B

33 INPUT 3
START
INPUT 1
8
Emergency Stop 31 51 52 53 54 55 56 57 58 59 60 61 62 50 49 48
9 12/24V
To CAN 1
7
To CAN 2
Figure 8. Single-Phase A-C Connections for Typical Applications
32 9469300990 Rev B
Connections for Load Sharing

Figure 9 illustrates a typical interconnection of two systems tied together using analog and Ethernet load
share lines.
LOAD
Bus Metering Bus Metering
Breaker Control Generator Breaker Control Generator

Breaker Breaker
DGC-2020HD DGC-2020HD
Generator Metering Generator Metering
AVR + 64 AVR + 64
AVR – 65 AVR GEN AVR – 65 AVR GEN
GOV + 66 GOV + 66
67
GOV ENG GOV ENG
GOV – GOV – 67
LS +
– LS
LS +
– LS
Ethernet
Ethernet
69
70
69
70
:
Analog Load Share Line To Other
DGC-2020HDs
Ethernet Load Share Line To Other

DGC-2020HDs
Industrial
Ethernet Switch
Notes: 1 Up to 32 DGC-2020HDs are supported on one network. P0071-68

Figure 9. Analog and Ethernet Connections for Typical Applications
9469300990 Rev B 33
Analog Input Connections

DGC-2020HD controllers with style number xxxxxxxxR are equipped with two analog inputs and those
with style number xxxxxxxxA are equipped with four analog inputs.
Voltage and current analog input connections are shown in Figure 10. When using the current input, the
“+” and “I” terminals must be tied together.
Analog Voltage Input Connection
0 – 10 Vdc ALOG IN +
Voltage ALOG IN –
Transducer ALOG IN I DGC-2020HD
1
49 BATT –
Analog Current Input Connection
4 – 20 mA ALOG IN +
Current ALOG IN –
Transducer ALOG IN I DGC-2020HD
1
49 BATT –
Note: P0071-65
1 For optimal metering performance, it is recommended to
connect analog input common to terminal 49 (BATT –).
Figure 10. Analog Engine Sender Voltage Input Connections
CAN Connections
Typical CAN connections are shown in Figure 11 and Figure 12.
Note
1. If the DGC-2020HD is providing one end of the J1939 bus, a 120 Ω, ½

watt terminating resistor should be installed across terminals 51 (CAN1L)
and 52 (CAN1H) or 54 (CAN2L) and 55 (CAN2H).
2. If the DGC-2020HD is not providing one end of the J1939 bus, the stub
connecting the DGC-2020HD to the bus should not exceed 914 mm (3 ft)
in length.
4. The J1939 drain (shield) should be grounded at one point only. If
grounded elsewhere, do not connect the drain to the DGC-2020HD.
34 9469300990 Rev B
CEM-2020
(Optional,
up to 4) CAN 1 Bus
Stub
CAN-H AEM-2020
(Optional,
CAN-L up to 4)
120 ohm 120 ohm

CAN 1
Termination Termination
DGC-2020HD
CAN 2 Other
Devices CAN 2 Bus
Stub
CAN-H
Engine
CAN-L
120 ohm 120 ohm

Termination Termination P0071-62
Figure 11. CAN Interface with DGC-2020HD Providing One End of the Bus
120 ohm
Termination CAN 1 Bus
CEM-2020 CAN-H AEM-2020

(Optional, (Optional,
up to 4) CAN-L up to 4)
Stub
120 ohm
Termination
DGC-2020HD
CAN 2 Bus
Stub
CAN-H
Other
Engine
Devices CAN-L
120 ohm 120 ohm

Termination Termination P0071-63
Figure 12. CAN Interface with Other Devices Providing One End of the Bus.
9469300990 Rev B 35
Expansion Module Connections (CAN 1)

The AEM-2020 (Analog Expansion Module) and CEM-2020 (Contact Expansion Module) are optional
modules that may be installed with the DGC-2020HD. These modules interface to the DGC-2020HD via
the “CAN 1” interface, thus the CAN terminals (51, 52, and 53) are the only common connections between
the DGC-2020HD, AEM-2020, and CEM-2020. Up to four CEM-2020 modules and up to four AEM-2020
modules are supported on a network. Typical connections are illustrated in Figure 13.
Refer to the AEM-2020 and CEM-2020 chapters for more information.
53) SHIELD GND

DGC-2020HD 52) CAN 1 H CANH CEM-2020 (1)
51) CAN 1 L CANL
GND GND
AEM-2020 (1) CANH CANH CEM-2020 (2)
CANL CANL
GND GND
:
GND GND
CANL CANL
GND 1 GND
CANL CANL
P0071-52
Note:
GND The J1939 drain (shield) should be grounded at one
AEM-2020 (4) CANH 1 point only. If grounded elsewhere, do not connect
CANL the drain to the DGC-2020HD.
Figure 13. DGC-2020HD Expansion Module CAN Connections
Installation for CE Systems

For CE compliant systems, it may be required to route ac voltage and current sensing wires separately
from other wires.
36 9469300990 Rev B
9469300990 Rev B 37
Controls and Indicators

DGC-2020HD controls and indicators are located on the front panel and are intended for local control and
monitoring of DGC-2020HD operation. Front panel controls consist of sealed membrane pushbuttons. Front
panel indicators consist of LED (light emitting diode) indicators and a backlit LCD (liquid crystal display).
DGC-2020HD controls and indicators are illustrated in Figure 14. Lettered locators in Figure 14
correspond to the control and indicator descriptions of Table 20.
Figure 14. Front Panel Controls and Indicators
DGC-2020HD Controls and Indicators
38 9469300990 Rev B
Table 20. Front Panel Control and Indicator Descriptions

Locator Description
Liquid Crystal Display. The backlit, 64 by 128 pixel LCD serves as the local information
A source for metering, alarms, pre-alarms, and protective functions. Display operation is
maintained down to –40°F (−40°C).
:
maintained down to –40°F (−40°C).
B Not in Auto Indicator. This red LED lights when the DGC-2020HD is not operating in Auto
mode.
C Alarm Indicator. This red LED lights continuously during alarm conditions and flashes
during pre-alarm conditions.
D Supplying Load Indicator. This green LED lights when the generator current is greater than
emergency power supply (EPS) threshold current.
Programmable Indicators. These red LEDs light when the corresponding logic element is
E set true. Logic element PROGLED 1 controls the upper LED, PROGLED2 controls the
middle LED, and PROGLED3 controls the lower LED. A card is provided for labeling the
programmable indicators. See Programmable Indicator Configuration, below.
F Alarm Silence Pushbutton. Pressing this button opens the relay output programmed as the
horn output.
G Lamp Test Pushbutton. Pressing this button tests the DGC-2020HD indicators by
exercising all LCD pixels and lighting all LEDs.
H Auto Pushbutton and Mode Indicator. Pressing the Auto button places the DGC-2020HD in
Auto mode. The green Auto mode LED lights when Auto mode is active.
Off Pushbutton and Mode Indicator. Pressing this button places the DGC-2020HD in Off
I mode. The red Off mode LED lights when the DGC-2020HD is in Off mode. This button
also resets the Breaker Management Pre-Alarms and all MTU ECU Alarms.
J Run Pushbutton and Mode Indicator. Pressing this button places the DGC-2020HD in Run
mode. The green Run mode LED lights when Run mode is active.
Reset Pushbutton. This button is pressed to cancel a settings editing session and discard
any settings changes. When pressed momentarily, this button also resets the Breaker
K Management Pre-Alarms and all MTU ECU Alarms. This button is also used to reset the
Maintenance Interval when pressed for 10 seconds while viewing Hours Until Maintenance
or Maintenance Due Pre-Alarm.
Arrow Pushbuttons. These four buttons are used to navigate through the front panel display
menus and modify settings.
The leftand right-arrow buttons are used to navigate through the menu levels. The
rightarrow button is pressed to move downward through the menu levels and the left-arrow
button is pressed to move upward through the menu levels.
L Within a level, the upand down-arrow buttons are used to move among items within the
menu level. Pressing the down-arrow button moves to items lower in the list. Pressing the
up-arrow button moves to items higher in the list.
During a settings editing session, the upand down-arrow buttons are used to raise and
lower the value of the selected setting.
Edit Pushbutton. Pressing this button starts an editing session and enables changes to
M DGC-2020HD settings. At the conclusion of an editing session, the Edit pushbutton is
pressed again to save the setting changes.
Controls and Indicators DGC-2020HD
9469300990 Rev B 39
Programmable Indicator Configuration

Up to three LED indicators may be programmed to suit the needs of a particular application. A replaceable
card (Figure 15) is provided that can be labeled to match the function of each programmable indicator.
Figure 15. Programmable Indicator Label Card
Information about configuring DGC-2020HD logic to control the programmable indicators can be found in
the BESTlogic™Plus chapter.
To label the programmable indicators, perform the following steps.
1. Print the label text on readily-available address label sheets. The label card accommodates
adhesive-backed labels measuring 0.5 by 1.75 inches. Avery part number 18167 is suitable for
this purpose.
2. Remove all control power from the DGC-2020HD.
3. Remove the fasteners from the four mounting studs on the DGC-2020HD and separate it from the
mounting panel or optional escutcheon plate. Disconnect the nine terminal block connectors; the
Start, Run, and Pre relays; and the Ethernet (copper or fiber), USB, and DB-9 connectors.
4. Lay the front panel face-down on a suitable work surface.
5. Grasp the tab of the label card and pull free. The label card tab is located on the rear of the
DGC2020HD, see Figure 16. When facing the back of the panel, the label card tab is on the left.
6. Apply the labels created in step 1 to the label cards. The rectangle outlines on the label card
serve as guides for attaching the labels.
7. After applying the new labels, insert the label card into the slot. Ensure that the label card is
oriented properly by viewing the custom labels through the label windows of the front panel.
8. Move the DGC-2020HD adjacent to the mounting panel or optional escutcheon plate and
reconnect the cables removed in step 3.
9. Secure the DGC-2020HD to the mounting panel or optional escutcheon plate with the fasteners
removed in step 3. The torque applied to the mounting hardware should not exceed 20
inchpounds or 2.2 newton meters.
10. If desired, verify the function of the programmed indicators before returning the DGC-2020HD to
service.
DGC-2020HD Controls and Indicators
40 9469300990 Rev B
Figure 16. Label Card Slot Location
Display Operation and Navigation

The front panel display is used to locally make settings changes and display metering values. Refer to
locators K, L, and M in Table 20 for information on changing settings through the front panel and
navigating through the screens.
Login and Permissions

When attempting to change a protected setting, the DGC-2020HD displays the Login Required screen. To
log in, use the Up/Down arrow keys to scroll through the characters. Use the Left/Right arrow keys to enter
more characters. Once the user name and password have been entered, press the Edit key to login. To
logout, press the Reset key while viewing any screen other than the Overview screen.
If communication access is active through the modem, USB, or Ethernet port, the front panel will display
REMOTE COMMS and the overview screen. If the remote user is logged in to BESTCOMSPlus with
"Control" security access or higher, the front panel can only be used for viewing metering data and
settings information. Remote security access must be ended before modifying settings through the front
panel.
Overview Screen and Configurable Metering

The overview screen is the uppermost screen in the menu structure and is displayed by default. It
displays metering information as well as a one-line diagram of the system’s breaker configuration.
Metering information can be set to standard or scrolling. When set to standard, only the following
:
Metering information can be set to standard or scrolling. When set to standard, only the following
parameters are displayed:
Controls and Indicators DGC-2020HD

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Digital Genset Controller Preface

12570 State Route 143

9469300990 Rev B iii

Bus Voltage .............................................................................................................................................

Engine Sender Inputs ...............................................................................................................................

Speed Signal Inputs..................................................................................................................................

Contact Inputs ...........................................................................................................................................

Analog Inputs ............................................................................................................................................

Contact Outputs ........................................................................................................................................

Multiple Generator Management ...........................................................................................................

Generator Protection ..............................................................................................................................

Phase Voltage Imbalance (47) .............................................................................................................. 131

How it Works Log In / Sign Up Generator Network Status.....................................................................................................................

Maintenance and Troubleshooting .......................................................................................................

9469300990 Rev B vii

Maintenance .......................................................................................................................................... 322

Diagnostic Trouble Codes...................................................................................................................... 381

Revision History...................................................................................................................................... 391

viii 9469300990 Rev B

Features and Functions

Generator and Bus Protection and Metering

Engine Protection and Metering

Contact Inputs and Outputs

Automatic Transfer Switch Control (Mains Failure)

Current Sensing Auto Synchronizer Terminal Type Senders

5) 5A CT inputs 1) No Auto Sync S) Spring A) Analog

Generator Protection Ethernet Bus Inputs

Optional Features and Capabilities

CEM-2020 (Contact Expansion Module)

Battery Ride Through

Input 5 .............................................. 35, 49

Engine System Inputs

Fuel Level Sensing

Generator Protection Functions

Overcurrent (51) (Optional)

Time Dial Increment .........................0.1

Phase Voltage Imbalance (47) (Optional)

Operating Temperature.................... –40 to +70°C (–40 to +158°F)

Salt Fog ............................................ IEC 60068

Figure 2. Panel Cutting and Drilling Dimensions

Figure 3. Overall Dimensions

Terminals and Connectors

INPUT 12 42 54 CAN 2 LOW

COM 10, 11, 12 30

Figure 4. Rear Panel

DGC-2020HD Terminals and Connectors

Table 1. Rear Panel Terminal and Connector Descriptions

Terminals and Connectors DGC-2020HD

Generator Current Sensing

Programmable Current Sensing

DGC-2020HD Terminals and Connectors

Generator Voltage Sensing

Bus Voltage Sensing

Table 6. Bus Voltage Sensing Terminals

Engine Sender Inputs

Terminals and Connectors DGC-2020HD