INSTRUCTION MANUAL

for

DGC-1000 DIGITAL GENSET CONTROLLER

Digital Genset Controller Basler
R

DGC-1000

Generator Voltage

Generator Amps

Generator Phase

Generator Frequency Not In Auto Supplying Load

Alarm

Oil Pressure

Coolant Temperature

Battery Voltage

Run Time

Phase Toggle Select Enter Display Toggle

Alarm Silence

Lamp Test

Raise Scroll

Lower Scroll

Previous

Run

Off

Auto

D2839-10.vsd 12-04-98

Publication: 9 3275 00 990 Revision: C 04/2000

INTRODUCTION
This manual provides information concerning the installation and operation of the DGC-1000 Digital Genset Controller. To accomplish this, the following is provided. General Information Specifications Functional Description Installation Information Setup Software Description Testing Procedures

WARNING!
TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE, ONLY QUALIFIED PERSONNEL SHOULD PERFORM THE PROCEDURES PRESENTED IN THIS MANUAL. REMOVE POWER FROM THE DGC-1000 PRIOR TO PERFORMING MAINTENANCE OR REPAIR ON ANY COMPONENT OF THE GENERATOR SET. FAILURE TO DO SO CAN RESULT IN PERSONAL INJURY OR EQUIPMENT DAMAGE.

DGC-1000 Introduction

First Printing: March 1999 Printed in USA 1999, 2000 Basler Electric Co., Highland, IL 62249 April 2000

CONFIDENTIAL INFORMATION
OF BASLER ELECTRIC COMPANY, HIGHLAND, IL. IT IS LOANED FOR CONFIDENTIAL USE, SUBJECT TO RETURN ON REQUEST, AND WITH THE MUTUAL UNDERSTANDING THAT IT WILL NOT BE USED IN ANY MANNER DETRIMENTAL TO THE INTEREST OF BASLER ELECTRIC COMPANY.

It is not the intention of this manual to cover all details and variations in equipment, nor does this manual provide data for every possible contingency regarding installation or operation. The availability and design of all features and options are subject to modification without notice. Should further information be required, contact Basler Electric Company, Highland, Illinois.

BASLER ELECTRIC ROUTE 143, BOX 269 HIGHLAND, IL 62249 USA http://www.basler.com, info@basler.com PHONE 618-654-2341
ii

FAX 618-654-2351
DGC-1000 Introduction

PRODUCT REVISION HISTORY

The following information provides a historical summary of the changes made to the embedded software (firmware) and hardware of this device. The corresponding revisions made to this instruction manual are also summarized. This revision history is separated into four categories: Software Version, BESTCOMS Version, Hardware Version, and Manual Version. All revisions are listed in chronological order. Software Version 2.01 - 03/99 2.02 04/99 2.04 06/99 2.11 05/00 Change Initial release Alarm relay closes on overcrank condition and the horn is checked for enabling before activation. Enhanced modem functions. Added programmable inter dial-out cycle delay and programmable number of rings before modem picks-up.

BESTCOMS Version 1.01.00 03/99 1.03.00 06/99 1.03.01 06/99 1.04.00 05/00 Initial release

Change

Added auxiliary I/O and modem programming functionality.. Added WindowsNT capability. Added programmable inter dial-out cycle delay and programmable number of rings before modem picks-up.

Hardware Version 03/99 Manual Version and ECO/ECA Rev None 03/99 Rev A 06/00 7992 Rev B 09/99 - 6043 Rev C 05/00 - 7533 Initial Release Initial Release

Change

Change

Added the Style Chart to Section 1, the optional auxiliary I/O output contact functions (Figure 2-3) and all related sections. Corrected minor errors in the manual, and changed Section 5, Testing, to correct terminal numbers in the test procedures. Added Revision History and a Warning to the Introduction, and UL recognition and CSA certification to Section 1, Specifications. Corrected error on Page 3-2, Battery Charger Failure, and Page 3-14, Menu 2 paths. Deleted reference to Run output solenoid in Section 5, Testing. Added description to Section 6, BESTCOMS Software, Settings Definition, Modem Communications Setup. Deleted Section 7, Manual Change Information. Added Index.

DGC-1000 Introduction

iii

CONTENTS
INTRODUCTION............................................................................................................................................ I SECTION 1 GENERAL INFORMATION.................................................................................................. 1-1 DESCRIPTION ....................................................................................................................................... 1-1 FEATURES ............................................................................................................................................ 1-1 FUNCTIONS........................................................................................................................................... 1-1 OUTPUTS .............................................................................................................................................. 1-1 OPTIONAL EQUIPMENT ...................................................................................................................... 1-1 Auxiliary Inputs And Outputs .............................................................................................................. 1-1 Dial-Out Modems ................................................................................................................................ 1-2 Enhanced Communications................................................................................................................ 1-2 Remote Annunciation Display Panel (RDP-110) ................................................................................ 1-2 MODEL AND STYLE NUMBER DESCRIPTION .................................................................................. 1-2 General ............................................................................................................................................... 1-2 Sample Style Number......................................................................................................................... 1-2 SPECIFICATIONS ................................................................................................................................. 1-3 Current Sensing Inputs ....................................................................................................................... 1-3 Voltage Sensing Inputs....................................................................................................................... 1-3 Frequency ........................................................................................................................................... 1-3 Contact Sensing Inputs....................................................................................................................... 1-3 Engine System Inputs......................................................................................................................... 1-3 Output Contacts .................................................................................................................................. 1-4 Calculated Data .................................................................................................................................. 1-4 Hardware ............................................................................................................................................ 1-5 SECTION 2 HUMAN-MACHINE INTERFACE (CONTROLS AND INDICATORS) ............................... 2-1 GENERAL .............................................................................................................................................. 2-1 FRONT PANEL DISPLAY ..................................................................................................................... 2-1 DGC-1000 CONNECTIONS................................................................................................................... 2-2 SECTION 3 FUNCTIONAL DESCRIPTION............................................................................................ 3-1 GENERAL .............................................................................................................................................. 3-1 INPUTS .................................................................................................................................................. 3-2 Battery Operating Voltage .................................................................................................................. 3-2 Contact Sensing Inputs....................................................................................................................... 3-2 Transducer Inputs ............................................................................................................................... 3-2 Speed Signal Inputs............................................................................................................................ 3-3 Voltage Inputs ..................................................................................................................................... 3-3 Current Inputs ..................................................................................................................................... 3-3 Serial Communications Input.............................................................................................................. 3-3 Optional Contact Sensing Inputs ........................................................................................................ 3-3 MICROPROCESSOR............................................................................................................................. 3-3 Formulas ............................................................................................................................................. 3-3 Related Circuits................................................................................................................................... 3-4 OUTPUTS .............................................................................................................................................. 3-4 Emergency Stop Contact Input Interaction......................................................................................... 3-4 Remote Display Panel ........................................................................................................................ 3-4 Optional Auxiliary Outputs .................................................................................................................. 3-5 PHONE MODEMS.................................................................................................................................. 3-5 Type of Service ................................................................................................................................... 3-5 Telephone Company Procedures ....................................................................................................... 3-5 If Problems Arise................................................................................................................................. 3-5 SOFTWARE ........................................................................................................................................... 3-5 Cooldown Timer.................................................................................................................................. 3-5 Speed Source Failure ......................................................................................................................... 3-6 iv DGC-1000 Introduction

Cranking.............................................................................................................................................. 3-6 Alarms................................................................................................................................................. 3-7 Pre-Alarms .......................................................................................................................................... 3-8 Power-Up Sequence........................................................................................................................... 3-9 Display Modes .................................................................................................................................... 3-9 Normal Mode ...................................................................................................................................... 3-9 Menu Mode ......................................................................................................................................... 3-9 Exiting Menu Mode ........................................................................................................................... 3-18 Modifying Setpoints .......................................................................................................................... 3-19 Alternate Display Mode..................................................................................................................... 3-20 FACTORY KEY CODE SETTING........................................................................................................ 3-20 ALLOWABLE KEY CODE PUSHBUTTONS ...................................................................................... 3-21 PARAMETERS AND DEFAULT SETTINGS ...................................................................................... 3-21 Front Panel Adjustable Parameters.................................................................................................. 3-21 All Parameters .................................................................................................................................. 3-21 SECTION 4 INSTALLATION .................................................................................................................. 4-1 GENERAL .............................................................................................................................................. 4-1 HARDWARE .......................................................................................................................................... 4-1 MOUNTING ............................................................................................................................................ 4-1 CONNECTIONS ..................................................................................................................................... 4-3 COMMUNICATION CONNECTORS AND SETTINGS ......................................................................... 4-7 RS-232 Connector .............................................................................................................................. 4-7 Communication Settings..................................................................................................................... 4-7 SECTION 5 TESTING .............................................................................................................................. 5-1 INTRODUCTION .................................................................................................................................... 5-1 EQUIPMENT REQUIRED ...................................................................................................................... 5-1 INITIAL TEST PROCEDURE................................................................................................................. 5-1 METERING TEST PROCEDURES........................................................................................................ 5-3 Metering Battery And Generator Voltages.......................................................................................... 5-3 Metering Generator Current................................................................................................................ 5-5 Oil Pressure ........................................................................................................................................ 5-5 Coolant Temperature.......................................................................................................................... 5-5 Percent Fuel Level.............................................................................................................................. 5-5 Engine Speed (RPM).......................................................................................................................... 5-5 Generator Power Factor ..................................................................................................................... 5-6 Generator kW And kVA ...................................................................................................................... 5-6 CRANKING TEST PROCEDURES ....................................................................................................... 5-6 Crank Cycle ........................................................................................................................................ 5-6 Running............................................................................................................................................... 5-7 PROTECTIVE FUNCTION TEST PROCEDURES ................................................................................ 5-7 Overcrank ........................................................................................................................................... 5-7 Overspeed .......................................................................................................................................... 5-7 Low Oil Pressure ................................................................................................................................ 5-7 High Coolant Temperature ................................................................................................................. 5-8 Emergency Stop ................................................................................................................................. 5-8 Low Coolant Level .............................................................................................................................. 5-8 Low Fuel Level.................................................................................................................................... 5-9 SECTION 6 DGC-1000 BESTCOMS SOFTWARE ................................................................................ 6-1 GENERAL .............................................................................................................................................. 6-1 INSTALLATION ..................................................................................................................................... 6-1 Operating Requirements..................................................................................................................... 6-1 Installing The Program On Your PC With Windows 95..................................................................... 6-1 INITIALIZING COMMUNICATIONS WITH THE BESTCOMS SOFTWARE......................................... 6-2 CHANGING THE PROGRAMS COMMUNICATION PARAMETERS .................................................. 6-3 CHANGING LOGON PASSWORDS ..................................................................................................... 6-4 DGC-1000 Introduction v

CHANGING SETTINGS......................................................................................................................... 6-4 MENUS................................................................................................................................................... 6-4 File Menu ............................................................................................................................................ 6-4 Communications Menu ....................................................................................................................... 6-5 Screens Menu..................................................................................................................................... 6-5 Configure Menu .................................................................................................................................. 6-5 Metering Menu .................................................................................................................................... 6-5 Help Menu........................................................................................................................................... 6-5 SETTINGS DEFINITIONS...................................................................................................................... 6-6 Sensing Transformers Settings .......................................................................................................... 6-6 Low Fuel, Low Cool Temperature And Battery Over Voltage Pre-Alarm Settings ............................. 6-7 Maintenance Interval, Engine kW Over Load, And Hi Coolant Temperature Pre-Alarm Settings ..... 6-8 Low Oil Pressure, Low And Weak Battery Voltage Pre-alarm Settings ............................................. 6-9 Audible And Battery Charger Failure Pre-Alarm Settings ................................................................ 6-10 Hi Cool Temperature, Low Oil Pressure, And Low Fuel Level Alarm Settings ................................ 6-11 Overspeed And Sender Failure Alarm Settings................................................................................ 6-12 Crank Settings .................................................................................................................................. 6-13 System Settings ................................................................................................................................ 6-14 Auxiliary Input Contact Setup ........................................................................................................... 6-15 Auxiliary Output Setup ...................................................................................................................... 6-16 Modem Communications Setup........................................................................................................ 6-16 Modem Dial-Out Conditions.............................................................................................................. 6-18 Metering ............................................................................................................................................ 6-19 APPENDIX A DGC-1000 SETTINGS RECORD................................................................................................. A-1 INTRODUCTION ................................................................................................................................... A-1 DGC-1000 SETTINGS RECORD.......................................................................................................... A-2 INDEX................................................................................................................................................................................................................................................I-1

vi

DGC-1000 Introduction

SECTION 1 GENERAL IN FORMATION

DESCRIPTION
DGC-1000 Digital Genset Controllers use microprocessor based technology to provide integrated enginegenerator set control, protection, and metering in a single package. Microprocessor based technology allows for exact measurement, set point adjustment, and timing functions. The DGC-1000 allows for quick and simple operation from the front panel. Basler Electric software (BESTCOMS-DGC1000-32) allows units to be easily customized for each application. Because of the low sensing burden in the DGC-1000, neither dedicated potential transformers nor current transformers are required. A heated wide temperature range liquid crystal display (LCD) display with backlighting allows the display to be viewed under any ambient light and temperature conditions. This combination of features in the DGC-1000 yields significant savings in installation and setup costs.

FEATURES
DGC-1000 Digital Genset Controllers have the following features. Resistant to high moisture, salt fog, humidity, dust, dirt, and chemical contaminants. Resistant to the entrance of insects and rodents. Suitable for mounting in any top mount enclosure. Suitable for controlling isolated generating systems or paralleled generating systems. Serial link communications and the Basler Electric software package eases the users access to setup parameters.

FUNCTIONS
DGC-1000 Digital Genset Controllers perform the following functions. 13. Watt metering 1. Engine cranking control 14. VA metering 2. Generator voltage metering 15. Engine rpm metering 3. Generator frequency metering 16. Power factor metering 4. Generator current metering 17. Watt-hour metering 5. Engine coolant temperature metering 18. Engine run time metering 6. Engine coolant temperature protection 19. Battery voltage metering 7. Engine oil pressure metering 20. Battery condition monitoring 8. Engine oil pressure protection 21. Engine maintenance monitoring 9. Fuel level sensing 22. Overload protection 10. Fuel level sender protection 23. Low coolant level detection 11. Fuel leak detector 24. Battery Charger Failure monitoring 12. Engine cool down

OUTPUTS
There are six isolated form A output contacts. Two are for engine cranking control and the remaining four are for the various protection and annunciation features. See Specification, Output Contacts in this section for additional information.

OPTIONAL EQUIPMENT
Optional equipment (see the following style number characteristic chart) available to the DGC-1000 is: Auxiliary inputs and outputs Dial-out modems Enhanced communications

Auxiliary Inputs And Outputs For those applications where more input and output contacts are needed to customize the DGC-1000 to the application, the auxiliary I/O assembly is an option that adds four sets of input and eight sets of output DGC-1000 General Information 1-1

contacts. These input contacts may be assigned to the desired function by using the BESTCOMS software to label the inputs so that the front panel LCD displays the proper message and the output contacts can be easily programmed for any desired outcome. Dial-Out Modems Two dial-out modems are available that inform a pager that an alarm or pre-alarm condition has occurred. In each of these modems, up to four phone numbers can be dialed and will be dialed in sequence until an answer is received. The standard modem is rated for an operating temperature of 0C (32F) to 50C (122F) received. The extended operating temperature range modem is rated for an operating temperature of -40C (-40F) to 70C (158F). Enhanced Communications Enhanced communications provides remote start/stop genset control, remote fault viewing and reset, and remote engine/generator parameter metering. This option requires a dial-out modem. Remote Annunciation Display Panel (RDP-110) Applications that require remote annunciation can use the Remote Display Panel, RDP-110. This display panel can annunciate all the DGC-1000 alarms, pre-alarms, and operating conditions.

MODEL AND STYLE NUMBER DESCRIPTION

General The DGC-1000 electrical characteristics and operational features are defined by a combination of letters and numbers that make up the style number. The model number, together with the style number, describe the options included in a specific device and appear on a sticker located on the analog board near the three-phase CT input connections. Upon receipt of a unit, be sure to check the style number against the requisition and the packing list to ensure that they agree. Sample Style Number Style number identification chart (Figure 1-1) defines the electrical characteristics and operational features included in DGC-1000 units. For example, if the style number were DGC-1000-A1C, the device would have the following: DGC-1000 (A) (1) (C) Digital Genset Controller Auxiliary Inputs and Outputs Standard Dial-out Modem Enhanced Communications

DGC-1000
MODEL NO.

Auxiliary I/O N) No auxiliary I/O A) 4 inputs/8 outputs

Dial-Out Modems 0) No dial-out modem 1) Std dial-out modem 2) Extended operating temperature range modem

Communications N) Standard C) Enhanced 1

NOTES: 1 Requires dial-out modem.

D2850-11.vsd 06-07-99

Figure 1-1. Style Number Identification Chart 1-2 DGC-1000 General Information

SPECIFICATIONS
DGC-1000 Digital Genset Controllers have the following features and capabilities. Current Sensing Inputs Current range 1 Ampere Input 5 Ampere Input Accuracy Burden Voltage Sensing Inputs Range Accuracy Burden Frequency Range Accuracy 4 to 70 hertz 0.25% of reading or 0.1 Hz whichever is greater at 25C (77F)

0.02 to 1 ampere continuously, 2.0 amperes for one second 0.1 to 5 amperes continuously, 10.0 amperes for one second 0.5% of reading or 1 ampere whichever is greater at 25C (77F) 1 volt-ampere

12 to 576 volts RMS, 50 or 60 hertz continuously, 720 volts RMS for one second 0.5% of reading or 1 volt whichever is greater at 25C (77F) 1 volt-ampere

Contact Sensing Inputs Emergency Stop Battery Charger Failure Automatic Transfer Switch Low Coolant Level Engine System Inputs

Normally closed dry contact Normally open dry contact Normally open dry contact Normally open dry contact

Final engine parameter accuracys are subject to sender accuracy. Fuel Level Sensing Range Accuracy Fuel Leak Sensing Recommended fuel level transducer: ISSPRO, part number R-8925 or equivalent 0 to 100% corresponds to 240 to 33 ohms. 1% at 25C (77F) Normally open contact from fuel leak sensor. Less than 5 ohms across fuel level input indicates fuel leak Recommended coolant temperature transducer: Stewart-Warner, part number 334-P or equivalent 62.6 to 637.5 ohms From 37C (99F) to 115C (239F): 0.5% of the reading or 1 degree whichever is greater at 25C (77F) Unit displays 0 below 104 kilopascals (15 PSI). Recommended oil pressure transducer: StewartWarner, part number 411-K or equivalent 34 to 240 ohms

Coolant Temperature Sensing

Range Accuracy

Oil Pressure Sensing

Range

DGC-1000 General Information

1-3

Oil Pressure Sensing -Continued Accuracy From 0 to 690 kilopascals: 0.5% of reading or 1 kilopascal whichever is greater at 25C (77F) From 0 to 100 PSI: 0.5% of reading or 1 PSI whichever is greater at 25C (77F) 12 or 24 volts nominal, 8 to 32 volts dc, battery dip ride through to 6 volts for 0.75 seconds 0.5% of reading or 0.1 volts whichever is greater at 25C (77F) 16 watts maximum 3 volts peak (during cranking) to 35 volts peak continuous into 10 kilo-ohms 32 to 10,000 hertz 750 to 3,600 RPM 0.5% of reading or 2 RPM whichever is greater at 25C (77F)

Battery Voltage Sensing Range Accuracy Burden Magnetic Pickup Sensing Voltage Range Frequency Range Engine RPM Sensing Range Accuracy Output Contacts Contact Ratings For Engine Cranking Control

The START and FUEL SOLENOID relays are rated for 10 amperes at 30 Vdc, make, break, and carry The PRE-START, ALARM, PRE-ALARM and EMERGENCY POWER SYSTEM SUPPLYING LOAD relays are rated for 2 amperes at 30 Vdc, make, break, and carry The auxiliary output relay contacts are rated for 2 amperes at 30 Vdc, make, break, and carry

Contact Ratings For Protection Features

Contact Ratings For Auxiliary Outputs

Calculated Data Power Factor (PF) Range Accuracy Kilo Volt-Amperes Range Accuracy Kilowatts Range Accuracy Kilowatt Hours Range Accuracy

+1.0 to -1.0, both leading and lagging 0.01 PF at 25C (77F) 0 to 9,999 kVA 0.5% of reading or 0.1 kVA whichever is greater at 25C (77F) 0 to 9,999 kW 0.5% of reading or 0.1 kW whichever is greater at 25C (77F) 0 to 999,999,999 kWh 0.5% of reading or 1 kWh whichever is greater at 25C (77F)

1-4

DGC-1000 General Information

Engine Run Time Range Accuracy Maintenance Interval Range Accuracy Hardware Phone Modem Standard Operating Temperature Range Extended Operating Temperature Range

0 to 99,999 hours 0.5% of reading or 1 hour whichever is greater at 25C (77F) 0 to 5,000 hours 0.5% of reading or 1 hour whichever is greater at 25C (77F)

FCC, Part 68 approved modems. 0C to 50C (32F to 122F) -40C to 70C (-40F to 158F)

Communication Port Interface Rear RS-232 UL Recognized/CSA Certified

9,600 baud, 8N1 full duplex UL Recognized per Standard 508, UL File No. E97035. CSA Certified per Standard CAN/CSAC22.2 No. 14-95, CSA File No. LR 23131. 2,352 Vac at 50/60 Hz for one second between voltage sensing inputs and all other circuits. 500 Vac at 50/60 Hz for one minute between any of the following groups Current Transformer 8 mA Communications Port - RS-232 - 6 mA

Isolation

Radio Frequency Interference (RFI)

Type tested using a 5 watt, hand-held transceiver operating at random frequencies centered around 144 and 440 megahertz with the antenna located within 6 inches (15 centimeters) of the device in both vertical and horizontal planes

Environment Operating Temperature Range Storage Temperature Range Salt Fog

-40C to 70C (-40F to 158F) -40C to 85C (-40F to 185F) Qualified to ASTM-117B-1989 with no power applied to the device, in a top mount enclosure for the 100 hour test duration The device withstands 2 g in each of three mutually perpendicular planes, swept over the range of 10 to 500 Hz for a total of six sweeps, 15 minutes each sweep, without structural damage or degradation of performance 15 g

Vibration

Shock

Weight

Maximum weight 2.0 pounds (0.91 kilograms)

DGC-1000 General Information

1-5

SECTION 2 HUMAN-MA CHINE INTERFACE (Controls And Indicators)

GENERAL
This section provides a description of the DGC-1000 Digital Genset Controller human machine interface and illustrates the menu tree.

FRONT PANEL DISPLAY

Figure 2-1 shows the front panel human-machine interface (HMI) for a DGC-1000. Descriptions in Table 2-1 refer to callouts in Figure 2-1.
Basler

Digital

Genset Controller

DGC-1000

D
Generator Voltage Generator Amps Generator Phase Generator Frequency Not In Auto Alarm Supplying Load

E F

Oil Pressure

Coolant Temperature

Battery Voltage

Run Time Phase Toggle Alarm Silence Lamp Test

Select Raise Scroll Lower Scroll Enter Previous

Display Toggle

G
Run Off Auto

R
D2839-13 12-04-98

Figure 2-1. DGC-1000 Front Panel Table 2-1. DGC-1000 HMI (Controls And Indicators) A Two line by twenty character LCD provides the primary visual interface for metering, alarms, pre-alarms, and protective functions. In the normal mode, labels appear above and below the display. In the alternate display mode, labels and the displayed value appear on the display. Red LED turns ON when the device is not in the AUTO mode. Red LED turns ON continuously for all alarm conditions and flashes for pre-alarm conditions.

B C

DGC-1000 Human-Machine Interface

2-1

Table 2-1. DGC-1000 HMI (Continued) D E F G H I J K L M N O P Q R Green LED turns ON when the generator is supplying more than two percent of rated current. Pushbutton used to silence the audible alarm. Pushbutton used to exercise all segments of the LCD and to illuminate all LEDs. Pushbutton used to place the device in AUTO mode. Green LED turns ON when the device is in the AUTO mode. Pushbutton used to place the unit in the OFF mode. Red LED turns ON when the device is in the OFF mode. Pushbutton used to place the device in the RUN mode. Green LED turns ON when the device is in the RUN mode. Pushbutton used to scroll through the displays available in the normal display mode. Pushbutton used to scroll through the display modes. Pushbutton used to scroll through previous menu levels. Pushbutton used to enter menu sublevels and select set points. Pushbutton used to scroll backward through the menus and to decrement set points. Pushbutton used to scroll forward through the menus and to increment set points.

DGC-1000 CONNECTIONS
Quick connect type terminals make wiring the DGC-1000 a simple task. The connections accept one inch female quick connect These operations are made even easier by user friendly labeling near the terminal strips. Once wired, these terminals can easily be removed to facilitate DGC-1000 removal for out of circuit testing or maintenance. Figure 2-2 shows the DGC-1000 rear panel connections. Descriptions in Table 2-2 refer to callouts in Figure 2-2. Figure 2-3 shows the optional auxiliary input and output contacts. Table 2-2. DGC-1000 Connections A B C D E F G H I J K Connection points for the speed sensing inputs. Connection points for sending unit inputs. Connection points for voltage sensing inputs. Connection points for current sensing inputs. Connection points for horn. Connection points for relay output contacts. RS-232 serial communication port. Connection points for remote displays in accordance with the National Fire Protection Agency specifications. Connection point for chassis ground. Connection points for operating power. Connection points for contact sensing inputs.

2-2

DGC-1000 Human-Machine Interface

K A

CHASSIS GND

BATTERY +

EMERGENCY STOP

ATS

CLNT LEVEL

CHRGR FAIL

MAG PICK-UP + -

OIL PRESS

FUEL LEVEL

CLNT TEMP

VOLT PH A

VOLT PH B

VOLT PH C

VOLT NEUTRL

A(-)

REMOTE DISPLAY B(+) BAT- BAT+

AUX 1

AUX 2

AUX 3

AUX 4

AUX 5

AUX 6

AUX 7

AUX 8

AUXILIARY I/O PCB ASSEMBLY

G
RS-232 COM1
AUX 1 INPUT AUX 2 INPUT AUX 3 INPUT AUX 4 INPUT

START

FUEL SOLENOID

PRESTART

ALARM

PREALARM

EPS SUPPLYING LOAD

HORN

1 A

5 A COM PHASE A CT

1 A

5 A COM PHASE B CT

1 A

5 A COM PHASE C CT

Figure 2-2. DGC-1000 Digital Genset Controller Rear Panel DGC-1000 Human-Machine Interface 2-3

S/N
D2850-17.vsd 06-09-99

Output Contacts

AUX 1

AUX 2

AUX 3

AUX 4

AUX 5

AUX 6

AUX 7

AUX 8

AUXILIARY I/O PCB ASSEMBLY

AUX 1 INPUT

AUX 2 INPUT

AUX 3 INPUT

AUX 4 INPUT

Input Contacts

D2850-18.vsd 06-09-99

Figure 2-3. Auxiliary Input And Output Assembly

2-4

DGC-1000 Human-Machine Interface

SECTION 3 FUNCTIONA L DESCRIPTION

GENERAL
DGC-1000 Digital Genset Controllers use microprocessor based technology to provide integrated enginegenerator set control, protection, and metering in a single package. Microprocessor based technology allows for exact measurement, setpoint adjustment, and timing functions. Refer to the following paragraphs for the DGC-1000 functional description. Circuit functional description is divided into Inputs, Microprocessor, Outputs, Phone Modems, and Software. Circuit functions illustrated in Figure 3-1 are described in the following paragraphs.

Figure 3-1. DGC-1000 Functional Block Diagram DGC-1000 Functional Description 3-1

INPUTS
There are seven types of inputs to the DGC-1000 Controller. They are: Operating (Battery) DC Power Contact Sensing Sending Units Speed Signals Voltage Sensing Current Sensing Serial Communications RS-232 Port

The following paragraphs describe these inputs. Battery Operating Voltage Required operating voltage is a nominal 12 or 24 Vdc. Operating voltage may be in the range of 8 to 32 Vdc. An internal switching power supply uses the battery voltage to generate a +12 Vdc, -12 Vdc, +5 Vdc, a stable +5 Vdc reference, and an isolated +5 Vdc. The isolated +5 Vdc supply is for the RS-232 serial communications port. The dc reference voltage is for internal use. Battery operating voltage is conditioned (filtered and reduced to a level suitable for microprocessor input) and sensed by the microprocessor. Contact Sensing Inputs Four external contact sensing inputs (Emergency Stop, Automatic Transfer Switch, Low Coolant Level, and Battery Charger Failure) provide external stimulus to the DGC-1000 Controller. Emergency Stop This input is continuously monitored. An open circuit indicates an Emergency Stop. Opening this circuit removes power from all output relays. Automatic Transfer Switch This input is continuously monitored by the microprocessor and is used to start the engine when in the auto mode. A closed contact initiates the start sequence. Low Coolant Level This input is continuously monitored by the microprocessor. When battery (-) potential is connected to this input, a low coolant level is indicated. Battery Charger Failure This input is continuously monitored by the microprocessor. When battery (-) potential is connected to this input, a battery charger failure is indicated. Transducer Inputs Coolant Temperature A current of less than 20 milliamperes is provided to the coolant temperature transducer (sending unit). The developed voltage is measured and scaled for use by the internal circuitry. Oil Pressure A current of less than 20 milliamperes is provided to the oil pressure transducer. The developed voltage is measured and scaled for use by the internal circuitry. Fuel Level And Fuel Leak A current of less than 20 milliamperes is provided to the fuel level transducer. The developed voltage is measured and scaled for use by the internal circuitry. The internal fuel level transducer failure circuitry and the fuel leak detector also use this input. An open circuit across these terminals will indicate a failed 3-2 DGC-1000 Functional Description

fuel level transducer. A resistance of less than 5 ohms is used to indicate either a failed fuel level transducer or a fuel leak detector contact closure. Speed Signal Inputs Generator Voltage The voltage from the monitored generator is scaled and conditioned for use by the internal circuitry as a speed signal source circuitry. Differential amplifiers provide isolation for these inputs. Magnetic Pickup The voltage from the magnetic pickup is scaled and conditioned for use by the internal circuitry as a speed signal source. Voltage Inputs Monitored generator voltages are sensed and scaled to levels suitable for use by the internal circuitry. Differential amplifiers provide isolation for these inputs. Internal circuitry selects line-to-line, line-to-neutral or single-phase values. Menu selections by the user determine these switch settings. Current Inputs Monitored generator currents are sensed and scaled to values suitable for use by the internal circuitry. Internal current transformers provide isolation. Two taps on the primary of these transformers accommodate either one or five ampere circuits. Serial Communications Input This serial communications link connects via optically isolated circuitry to the microprocessor. Enhanced access to device setup is available through this port. BESTCOMS-DGC1000-32 software provides easy access to these functions. Optional Contact Sensing Inputs If the DGC-1000 has the auxiliary input and output option, there are four programmable contact sensing inputs. Each input is designed to accept a normally open contact. The contact is connected between the input and battery minus. These inputs may be programmed through the BESTCOMS PC program with an up to eight character name and as alarm, pre-alarm, or neither outputs. The default names are AUX IN 1, AUX IN 2, AUX IN 3, and AUX IN 4. When the contact sensing input is closed, the front panel display shows the name of the closed input if it was programmed as alarm or pre-alarm. If neither is programmed, no indication is given on the front panel display. Programming the input as neither is useful when a call to a pager without an alarm or pre-alarm is necessary or to close additional contacts using the auxiliary outputs.

MICROPROCESSOR
Software programmed in the erasable programmable read-only memory (EPROM) controls the overall functionality of the device and makes all decisions based on programming and system inputs. Formulas that are used to determine the various calculated quantities and circuits related to microprocessor inputs are described in the follow paragraphs. Formulas Formulas used in calculating the various quantities are provided in the following paragraphs. For line-to-neutral (VL-N) voltage sensing:

Vab = Vbc = Vca =

Va

+ Va Vb + Vb
2 2

Vb + Vb Vc + Vc Vc + Vc Va + Va
2

For all three-phase voltage sensing configurations: DGC-1000 Functional Description 3-3

kVA:

kVA A Phase = (Vab Ia) divided by (1000 times square-root of three) kVA B Phase = (Vbc Ib) divided by (1000 times square-root of three) kVA C Phase = (Vca Ic) divided by (1000 times square-root of three) Total kVA = kVA A Phase + kVA B Phase + kVA C Phase kW A Phase = kVA A Phase times Power Factor kW B Phase = kVA B Phase times Power Factor kW C Phase = kVA C Phase times Power Factor Total kW = Total kVA PF

kW:

Power Factor (PF) = Cosine of the measured angle between voltage and current zero crossings Related Circuits Zero Crossing Detection The zero crossing of the A phase voltage or A to B line voltage and the B phase current is detected and used to calculate the phase angle between the current and voltage. This zero crossing is also used to measure the generator frequency. Signal Switching Solid state switches, under microprocessor control, select the voltage or current sensing signal that is applied to the RMS to dc converter. The resulting signal is sent to the twelve bit analog-to-digital converter where it is digitized for use by the microprocessor. RMS To DC Converter Scaled and conditioned signals representing the voltage and current sensing inputs are used as the input to the RMS to dc converter. This converter output is a dc level proportional to the RMS value of the input. Analog To Digital Converter Signals from the RMS to dc converter, coolant temperature sensing input, fuel level sensing input, and the oil pressure sensing input are digitized by the twelve-bit analog to digital converter. The digitized information is stored in random access memory (RAM). This information is used by the microprocessor for all metering and protection functions.

OUTPUTS
Each output relay is controlled by the microprocessor and the emergency stop contact input. All outputs are electrically isolated from each other and from the internal circuitry. Two outputs (start and fuel solenoid) are associated with engine cranking functions. The remaining four outputs (Figure 3-1) are associated with the various features and pre-start. Emergency Stop Contact Input Interaction When the emergency stop contact input is open, all output contacts open. When the emergency stop contact input is closed and a signal is given by the microprocessor, the output contacts close Remote Display Panel When the DGC-1000 is combined with the RDP-110, many of the alarm and pre-alarm conditions are indicated remotely. The following alarms are indicated by LEDs and an audible alarm on the RDP-110: low coolant level, high coolant temperature, low oil pressure, overcrank, overspeed, emergency stop, fuel leak/fuel level sender failure, and engine sender unit failure. The following pre-alarms are also displayed on the RDP-110: high coolant temperature, low coolant temperature, low oil pressure, low fuel level, battery overvoltage, weak battery, and battery charger failure. In addition to these alarms and pre-alarms, the RDP-110 also indicates when the RUN/OFF/AUTO switch is not in auto and when the EPS is supplying load.

3-4

DGC-1000 Functional Description

Optional Auxiliary Outputs If the DGC-1000 has the auxiliary input and output option, there are eight programmable output contacts. These outputs may be programmed through the BESTCOMS PC program to close when any of the selected inputs is active. Multiple outputs may be programmed to close when a single input is active. Also, multiple inputs may be programmed to close a single output.

PHONE MODEMS
Two modem boards with dial-in, dial-out capability are available as optional equipment on the DGC-1000. The standard modem is rated from 0C to 50C. The extended operating temperature range modem is rated from -40C to 70C. With the optional phone modem boards, the DCG-1000 can dial out to inform a pager that an alarm or pre-alarm condition has occurred. Up to four phone numbers can be dialed in sequence until an answer is received. The modem supplied with the DGC-1000 is registered with the FCC under part 68. Type of Service The DGC-1000 is designed to be used on standard device telephone lines and connects to the telephone line by means of a standard jack called the USOC RJ-11C. Connection to telephone company provided coin service (central office implemented systems) is prohibited. Connection to party lines service are subject to state tariffs. Telephone Company Procedures The goal of the telephone company is to provide you with the best service it can. In order to do this, it may occasionally be necessary for them to make changes in their equipment, operations or procedures. These changes might affect your service or the operation of your equipment, the telephone company will give you notice, in writing, to allow you to make any changes necessary to maintain uninterrupted service. In certain circumstances, it may be necessary for the telephone company to request information from you concerning the equipment, which you have connected to your telephone line. Upon request of the telephone company, provide the FCC registration number and the ringer equivalence number (REN); both items are listed on the label on the modem on the rear of the DGC-1000. The sum of all of the RENs on your telephone lines should be less than five in order to assure proper service from the telephone company. In some cases, a sum of five may not be usable on a given line. If Problems Arise If any of your telephone equipment is not operating properly, you should immediately remove it from your telephone line because it may cause harm to the telephone network. If the telephone company notes a problem, they may temporarily disconnect service. When practical, they will notify you in advance of this disconnection. If advance notice is not feasible, you will be notified as soon as possible. When you are notified, you will be given the opportunity to correct the problem and informed of your right to file a complaint with the FCC. Contact your telephone company if you have any questions about your telephone line.

SOFTWARE
Software embedded in the DGC-1000 controls all aspects of device functionality. This comprises powerup initialization, front panel set up and configuration, input contact status monitoring, protective function detection and annunciation, system parameter monitoring, output contact status control, and RS-232 serial communications. Cooldown Timer In the Auto mode, this feature allows the engine to cool down by running unloaded for a programmed period of time. The cooldown period of 0 to 60 minutes is programmed from the BESTCOMS software in 5-minute increments. This cooldown period will start when the load is removed. If load is removed from the generator prior to the ATS contact opening, the timer will start and continue to count while the ATS contact opens. At the time of the ATS contact opening, the remaining time of the cooldown timer will be DGC-1000 Functional Description 3-5

used and once the total remaining time is consumed the engine will shutdown. A setting of 0 is used when no cooldown period is desired. Speed Source Failure This function monitors the signal from the speed signal source selected from the BESTCOMS software. If only one source is selected and the signal from that source is lost, an alarm and a shutdown occurs and SPEED SIGNAL SOURCE FAILURE is displayed on the LCD display. If both magnetic pickup and generator voltage are selected as speed signal sources and the magnetic pickup unit (MPU) fails, the DGC-1000 will switch to using generator voltage as the speed signal source and the LCD display will alternate between displaying the run time and MPU on the display. If the generator voltage signal also fails, an alarm and shutdown occurs. This function checks for the presence of a signal only; it is not a sender continuity check. Cranking The DGC is programmable for either cycle crank or continuous crank. If cycle cranking is chosen, the number of crank cycles allowed before the system shuts down can be selected. A crank cycle is defined as 5 to 15 seconds of crank followed by an equal number of seconds of rest, selectable in 1 second increments. The maximum number of cycles the DGC-1000 will allow is 7. If NFPA 100 Level 1 is chosen, the number of crank cycles is 5. If a delay to crank feature has been selected, the DGC will close the pre-start contact upon receipt of a start command. The pre-start contact is programmable to either remain energized or to drop out after the delay has expired. Figure 3-2 illustrates one normal and four abnormal engine starts (crank curves).

Overspeed Setpoint

SPEED

100% Setpoint

3 Crank Disconnect Setpoint 1

D2843-18.VSD 02-24-99

2 1

TIME
Figure 3-2. Normal And Abnormal Engine Crank Curves Abnormal Start Curve One This curve shows the typical cycle crank when a start signal is received. When the signal is received the fuel solenoid and start contacts close and engine speed begins to increase. The fuel solenoid and start contacts remain closed until the crank cycle time is met. The start contact will open if the prime mover speed increases past the crank disconnect speed setting. The fuel solenoid contact remains closed above the crank disconnect speed. If the prime mover fails to start after the prescribed time, the rest 3-6 DGC-1000 Functional Description

timer is started and the starter solenoid and fuel solenoid contacts are opened. The crank cycle is repeated until the prime mover speed increases past the crank disconnect setpoint or the programmed number of crank cycles has been met and an overcrank condition occurs. Abnormal Start Curve Two This curve shows a failure to start condition. The prime mover reaches the crank disconnect setpoint but fails to start. If this condition occurs, the DGC1000 has cranked the engine through one cycle of crank time and the engine is coasting down to a stop. After the rest period time has expired, the DGC1000 will continue to cycle crank for the remainder of the crank cycles or the engine starts. Abnormal Start Curve Three This curve shows an engine start but the engine fails to reach rated speed. If this condition occurs, the start contact opens and the engine continues to run until it is turned off. Abnormal Start Curve Four This curve shows a typical overspeed occurrence. If this condition occurs, the engine, upon reaching the overspeed setpoint, will be shut down by the DGC1000 opening the fuel solenoid contact and annunciate an alarm by closing the alarm contact. Normal Start Curve Five This curve shows a typical normal start and run condition. When this occurs, the start contact opens after the prime mover passes through the crank disconnect speed setpoint. The engine speed increases until the 100% setpoint is reached. Alarms Reset of all alarms can only be done locally by setting the Auto/Off/Run switch to the OFF position. All alarm conditions will light a red LED (labeled Alarm) along with displaying the condition on the LCD screen and sounding the optional audible alarm. All alarms have a common Form A contact. When an alarm condition occurs, the display indicates the cause of the alarm, the form A Alarm contact closes, and the fuel solenoid contact opens which shuts down the engine. Overcrank Alarm When the crank timer times out, cranking terminates. At that time, the common alarm contacts close and the LCD displays the message OVERCRANK and the current overcrank setting. Overspeed Alarm If the engine speed exceeds the overspeed value programmed by the BESTCOMS software and continues until the programmed delay time expires, an overspeed alarm occurs. At that time, the common alarm contact closes and the LCD displays the message OVERSPEED and the current overspeed setting. High Coolant Temperature Alarm If the engine coolant temperature exceeds the level programmed by the BESTCOMS software, an alarm occurs. At that time, the common alarm contact closes and the LCD displays the message HIGH COOLANT TEMP and the current high coolant temperature setting. Low Oil Pressure Alarm If the oil pressure decreases below the low oil pressure alarm setting programmed by the BESTCOMS software, an alarm occurs. At that time, the common alarm contact closes and the LCD displays the message LOW OIL PRESSURE and the current low oil pressure alarm setting. Engine Sender Fault Alarm If a failure of an engine sender (transducer) is enabled by the BESTCOMS software and a failure occurs, an alarm occurs. At that time, the common alarm contact closes and the LCD displays the message SENDER FAILURE and the failed sender. If a short circuit is detected across the fuel level transducer/fuel leak detector input, the message SENDER FAIL/FUEL LEAK is displayed. DGC-1000 Functional Description 3-7

Low Fuel Level Alarm If the fuel level decreases below the low fuel level alarm setting programmed by the BESTCOMS software, an alarm occurs. At that time, the common alarm contact closes and the LCD displays the message LOW FUEL LEVEL and the current low fuel level alarm setting. Low Coolant Level Alarm This alarm will shut down the engine when a loss of coolant is detected via low coolant level contact input. At that time, the common alarm contact closes and the LCD displays the message LOW COOLANT LEVEL. Pre-Alarms All pre-alarms are reset by correcting the cause of the pre-alarm. All pre-alarm conditions illuminate the red alarm LED with a 50% duty cycle at a frequency of 0.5 hertz and sounding the optional audible alarm at the same rate. All pre-alarms have a common Form A contact. The LCD displays all pre-alarms in the following manner: Low Oil Pressure, High Coolant Temperature, and Battery Voltage pre-alarms are shown on the main display with their current values alternately flashing with a dark field at a frequency of 0.5 hertz and a duty cycle of 50%. All other pre-alarms are individually displayed in sequence, using the alternate main display mode, whereby each pre-alarm value is alternately flashed with a dark field at a frequency of 0.5 hertz and a duty cycle of 50%. All pre-alarmed parameters are displayed in this manner before non-pre-alarmed parameters. Using a PC and the BESTCOMS software, the customer can program the audible pre-alarms to be OFF or ON. The audible pre-alarms can be reset by the Alarm Silence pushbutton. High Coolant Temperature Pre-Alarm If engine coolant temperature increases above the high coolant temperature pre-alarm setpoint programmed by the BESTCOMS software for the programmed delay time, a pre-alarm occurs. Low Coolant Temperature Pre-Alarm If engine coolant temperature decreases below the low coolant temperature pre-alarm setpoint programmed by the BESTCOMS software for the programmed delay time, a pre-alarm occurs. Weak Battery Pre-Alarm If the battery voltage drops below 60% of the nominal voltage for more than 2 seconds during engine cranking, a pre-alarm occurs. The message Weak Battery is displayed in the alternate display mode and is reset by scrolling through the alternate display. Low Battery Voltage Pre-Alarm If the battery voltage decreases below the low battery voltage value programmed by the BESTCOMS software, a pre-alarm occurs. Battery Over Voltage Pre-Alarm If the battery voltage exceeds the battery over voltage level programmed by the BESTCOMS software, a pre-alarm occurs. Low Fuel Level Pre-Alarm If the fuel level decreases below the low fuel level pre-alarm value programmed by the BESTCOMS software, a pre-alarm occurs. Engine Overload Pre-Alarm If the engine load exceeds the engine overload level pre-alarm value programmed by the BESTCOMS software, a pre-alarm occurs. Battery Charger Failure Pre-Alarm If a battery charger failure is detected via the battery charger fail contact input, a pre-alarm occurs.

3-8

DGC-1000 Functional Description

Power-Up Sequence When battery power is first applied, the DGC-1000 initiates a power up sequence. The version of embedded software is displayed on the LCD and the memory is checked. Then all configuration data stored in non-volatile EEPROM is brought into main memory. Immediately after this, the LCD display begins in the Normal mode. When the Normal mode is displayed, all enabled functions are activated and input monitoring begins. NOTE The run time counter, kilowatt-hour meter and maintenance timers are updated in volatile memory every minute. The updated value is saved to non-volatile memory only when auto/off/run mode of operation is changed. Should the battery power source fail during operation these values will not be updated and the change in value incurred since the last change of mode will not be saved. This information is irretrievably lost. Display Modes Pressing the Display Toggle pushbutton when in the Normal display mode allows the user to scroll through the Normal, Alternate, and Menu display modes. Figure 3-3 shows the top level display modes. Normal Mode This displays the various engine and generator parameters as described by the front panel overlay. Pressing the Phase Toggle pushbutton after the engine is running scrolls through the voltage and current measurements that are available. Menu Mode After pressing the Display Toggle pushbutton twice to begin the Menu display mode (first time selects the Alternate mode), pressing Select/Enter begins the next level of menus. Pressing the Raise/Scroll or Lower/Scroll pushbutton (Figure 3-4) allows the user to scroll through the menu display mode screens. Pressing the Display Toggle pushbutton returns the display to the Normal mode. Menu 1. Menu 1 is the alarm and pre-alarm menu. Pressing Select/Enter (Figure 3-5) from this menu begins the 1.x menu level. Pressing Raise/Scroll and Lower/Scroll from this menu scrolls through the 1.x menu level. Menu 1.1. Menu 1.1 displays the overspeed alarm. Pressing Select/Enter begins the 1.1.1 level of menus and displays the function activation level. Pressing Select/Enter displays the setting. This is not adjustable from the front panel. Pressing Previous goes back to the 1.1.1 level. Pressing Raise/Scroll or Lower/Scroll begins the 1.1.2 function activation delay level of menus. Pressing Select/Enter displays the activation delay time once the level has been exceeded. This is not adjustable from the front panel. Pressing Previous twice goes back to the 1.1 level. Pressing Raise/Scroll goes to the 1.2 menu level. Pressing Lower/Scroll goes to the 1.13 menu level.
Display Toggle

Normal Mode

Display Toggle

Alternate Mode

Display Toggle

Menu Mode

D2557-18 04-22-97

Display Toggle

Figure 3-3. Top Level Display Modes

Menu 1.2. Menu 1.2 displays the high coolant temperature alarm. Pressing Select/Enter begins the 1.2.1 level of menus and displays the function activation level. Pressing Select/Enter displays the setting. This is not adjustable from the front panel. Pressing Previous goes back to the 1.2.1 level. Pressing Raise/Scroll or Lower/Scroll begins the 1.2.2 function activation delay level of menus. Pressing Select/Enter displays the activation delay time once the engine crank disconnect speed is exceeded. This is not adjustable from the front panel. DGC-1000 Functional Description 3-9

Pressing Previous twice goes back to the 1.2 level. Pressing Raise/Scroll goes to the 1.3 menu level Pressing Lower/Scroll goes to the 1.1 menu level.

Enter Menu Mode

D/T

Menu Mode Intro Screen

Enter

Menu 1 Main Alarms and Pre-Alarms

Raise

Lower Raise

Menu 2 System Configuration

Lower Raise

Menu 3 Sensing Devices

Lower Raise

Menu 4 Engine Parameters and Cranking

Lower

D2609-01 04-23-97

Figure 3-4. Menu Display Modes 3-10 DGC-1000 Functional Description

Menu 1 Main Alarms and Pre-Alarms

Prev

Enter Prev

Menu 1.1 Overspeed Alarm

Lower Raise

Lower Raise

Menu 1.14 Engine Maintenance Cycle Pre-Alarm

Raise Lower

Menu 1.2 High Coolant Temperature Alarm

Lower Raise

Menu 1.13 Engine kiloWatt Overload Pre-Alarm

Raise Lower

Menu 1.3 High Coolant Temperature Pre-Alarm

Lower Raise

Menu 1.12 Battery Charger Failure Pre-Alarm

Raise Lower

Menu 1.4 Low Coolant Temperature Pre-Alarm

Lower Raise

Menu 1.11 Battery OverVoltage Pre-Alarm

Raise Lower

Menu 1.5 Low Oil Pressure Alarm

Lower Raise

Menu 1.10 Low Battery Pre-Alarm

Raise Lower

Menu 1.6 Low Oil Pressure Pre-Alarm

Lower Raise

Menu 1.9 Weak Battery Pre-Alarm

Raise Lower Lower Raise

Menu 1.7 Low Fuel Raise Level Alarm

Menu 1.8 Low Fuel Level Lower Pre-Alarm

Raise
D2840-03 12-15-98

Figure 3-5. Menu 1 DGC-1000 Functional Description 3-11

Menu 1.3. Menu 1.3 displays high coolant temperature pre-alarm. Pressing Select/Enter begins the 1.3.1 level of menus and displays the function activation level. Pressing Select/Enter displays the setting. This is not adjustable from the front panel. Pressing Previous goes back to the 1.3.1 level. Pressing Raise/Scroll or Lower/Scroll begins the 1.3.2 function activation delay level of menus. Pressing Select/Enter displays the activation delay time once the engine crank disconnect speed is exceeded. This is not adjustable from the front panel. Pressing Previous twice goes back to the 1.3 level. Pressing Raise/Scroll goes to the 1.4 menu level Pressing Lower/Scroll goes to the 1.2 menu level. Menu 1.4. Menu 1.4 displays low coolant temperature pre-alarm. Pressing Select/Enter begins the 1.4.1 level of menus and displays the function activation level. Pressing Select/Enter displays the setting. This is not adjustable from the front panel. Pressing Previous goes back to the 1.4.1 level. Pressing Raise/Scroll or Lower/Scroll begins the 1.4.2 function activation delay level of menus. Pressing Select/Enter displays the activation delay time once the level has been exceeded. This is not adjustable from the front panel. Pressing Previous twice goes back to the 1.4 level. Pressing Raise/Scroll goes to the 1.5 menu level Pressing Lower/Scroll goes to the 1.3 menu level. Menu 1.5. Menu 1.5 displays low oil pressure alarm. Pressing Select/Enter begins the 1.5.1 level of menus and displays the function activation level. Pressing Select/Enter displays the setting. This is not adjustable from the front panel. Pressing Previous goes back to the 1.5.1 level. Pressing Raise/Scroll or Lower/Scroll begins the 1.5.2 function activation delay level of menus. Pressing Select/Enter displays the activation delay time once the engine crank disconnect speed is exceeded. This is not adjustable from the front panel. Pressing Previous twice goes back to the 1.5 level. Pressing Raise/Scroll goes to the 1.6 menu level Pressing Lower/Scroll goes to the 1.4 menu level. Menu 1.6. Menu 1.6 displays low oil pressure pre-alarm. Pressing Select/Enter begins the 1.6.1 level of menus and displays the function activation level. Pressing Select/Enter displays the setting. This is not adjustable from the front panel. Pressing Previous goes back to the 1.6.1 level. Pressing Raise/Scroll or Lower/Scroll begins the 1.6.2 function activation delay level of menus. Pressing Select/Enter displays the activation delay time once the engine crank disconnect speed is exceeded. This is not adjustable from the front panel. Pressing Previous twice goes back to the 1.6 level. Pressing Raise/Scroll goes to the 1.7 menu level Pressing Lower/Scroll goes to the 1.5 menu level. Menu 1.7. Menu 1.7 displays low fuel level alarm. Pressing Select/Enter begins the 1.7.1 level of menus and displays the function activation level. Pressing Select/Enter displays the setting. This is adjustable from the front panel. Pressing Previous goes back to the 1.7.1 level. Pressing Raise/Scroll or Lower/Scroll begins the 1.7.2 function activation delay level of menus. Pressing Select/Enter displays the activation delay time once the level has been exceeded. After pressing Raise/Scroll or Lower/Scroll, the user will be instructed to enter the user key code. After entering the user key code followed by pressing Select/Enter twice, the setting will be adjustable with the Raise/Scroll and Lower/Scroll keys. After the desired setting has been selected, press Select/Enter to save the new settings. Pressing Previous twice goes back to the 1.7 level. Pressing Raise/Scroll goes to the 1.8 menu level Pressing Lower/Scroll goes to the 1.6 menu level. Menu 1.8. Menu 1.8 displays low fuel level pre-alarm. Pressing Select/Enter begins the 1.8.1 level of menus and displays the function activation level. Pressing Select/Enter displays the setting. This is adjustable from the front panel. Pressing Previous goes back to the 1.8.1 level. Pressing Raise/Scroll or Lower/Scroll begins the 1.8.2 function activation delay level of menus. Pressing Select/Enter displays the activation delay time once the level has been exceeded. After pressing Raise/Scroll or Lower/Scroll, the user will be instructed to enter the user key code. After entering the user key code followed by pressing Select/Enter twice, the 3-12 DGC-1000 Functional Description

setting will be adjustable with the Raise/Scroll and Lower/Scroll keys. After the desired setting has been selected, press Select/Enter to save the new settings. Pressing Previous twice goes back to the 1.8 level. Pressing Raise/Scroll goes to the 1.9 menu level Pressing Lower/Scroll goes to the 1.7 menu level. Menu 1.9. Menu 1.9 displays weak battery pre-alarm. Pressing Select/Enter begins the 1.9.1 level of menus and displays the function activation level. Pressing Select/Enter displays the setting. This is not adjustable from the front panel. Pressing Previous goes back to the 1.9.1 level. Pressing Raise/Scroll or Lower/Scroll begins the 1.9.2 function activation delay level of menus. Pressing Select/Enter displays the activation delay time once the level has been exceeded. This is not adjustable from the front panel. Pressing Previous twice goes back to the 1.9 level. Pressing Raise/Scroll goes to the 1.10 menu level Pressing Lower/Scroll goes to the 1.8 menu level. Menu 1.10. Menu 1.10 displays low battery pre-alarm. Pressing Select/Enter begins the 1.10.1 level of menus and displays the function activation level. Pressing Select/Enter displays the setting. This is not adjustable from the front panel. Pressing Previous goes back to the 1.10.1 level. Pressing Raise/Scroll or Lower/Scroll begins the 1.10.2 function activation delay level of menus. Pressing Select/Enter displays the activation delay time once the level has been exceeded. This is not adjustable from the front panel. Pressing Previous twice goes back to the 1.10 level. Pressing Raise/Scroll goes to the 1.11 menu level Pressing Lower/Scroll goes to the 1.9 menu level. Menu 1.11. Menu 1.11 displays battery over voltage pre-alarm. Pressing Select/Enter begins the 1.11.1 level of menus and displays the function activation level. Pressing Select/Enter displays the setting. This is not adjustable from the front panel. Pressing Previous goes back to the 1.11.1 level. Pressing Raise/Scroll or Lower/Scroll begins the 1.11.2 function activation delay level of menus. Pressing Select/Enter displays the activation delay time once the level has been exceeded. This is not adjustable from the front panel. Pressing Previous twice goes back to the 1.11 level. Pressing Raise/Scroll goes to the 1.12 menu level Pressing Lower/Scroll goes to the 1.10 menu level. Menu 1.12. Menu 1.12 displays battery charger failure pre-alarm. Pressing Select/Enter begins the 1.12.1 level of menus and displays the function activation level. Pressing Select/Enter displays the setting. This is not adjustable from the front panel. Pressing Previous goes back to the 1.12.1 level. Pressing Raise/Scroll or Lower/Scroll begins the 1.12.2 function activation delay level of menus. Pressing Select/Enter displays the activation delay time once the level has been exceeded. This is not adjustable from the front panel. Pressing Previous twice goes back to the 1.12 level. Pressing Raise/Scroll goes to the 1.13 menu level Pressing Lower/Scroll goes to the 1.11 menu level. Menu 1.13. Menu 1.13 displays kilowatt overload pre-alarm. Pressing Select/Enter begins the 1.13.1 level of menus and displays the function activation level. Pressing Select/Enter displays the setting. This is not adjustable from the front panel. Pressing Previous goes back to the 1.13.1 level. Pressing Raise/Scroll or Lower/Scroll begins the 1.13.2 function activation delay level of menus. Pressing Select/Enter displays the activation delay time once the level has been exceeded. This is not adjustable from the front panel. Pressing Previous twice goes back to the 1.13 level. Pressing Raise/Scroll goes to the 1.14 menu level Pressing Lower/Scroll goes to the 1.12 menu level. Menu 1.14. Menu 1.14 display engine maintenance pre-alarm. Pressing Select/Enter begins the 1.14.1 level of menus and displays the function activation level. Pressing Select/Enter displays the setting. This is not adjustable from the front panel.

DGC-1000 Functional Description

3-13

Pressing Previous goes back to the 1.14.1 level. Pressing Raise/Scroll or Lower/Scroll begins the 1.14.2 function activation delay level of menus. Pressing Select/Enter displays the activation delay time once the level has been exceeded. This is not adjustable from the front panel. Pressing Previous twice goes back to the 1.14 level. Pressing Raise/Scroll goes to the 1.1 menu level. Pressing Lower/Scroll goes to the 1.13 menu level. Pressing Previous from any 1.x level menu goes to menu 1. Pressing Raise/Scroll goes to menu 2. Pressing Lower/Scroll goes to menu 3. Menu 2. Menu 2 system configuration. Pressing Select/Enter from this menu (Figure 3-6) begins the 2.x level of menus. Pressing Raise/Scroll and Lower/Scroll from this menu scrolls through the 2.x levels of menus. Menu 2.1. Menu 2.1 displays generator voltage sensing connection. Pressing Select/Enter begins the 2.1.1 level and displays the sensing configuration. This is not adjustable from the front panel.
Raise

Menu 2 System Configuration

Prev

Enter

Pressing Previous goes back to the 2.1 level. Pressing Raise/Scroll goes to menu 2.2. Pressing Lower/Scroll goes to the 2.4 menu. Menu 2.2. Menu 2.2 displays options. Pressing Select/Enter (Figure 3-7) begins the 2.2.1 level and displays the speed signal source selection. This is not adjustable from the front panel. Pressing Previous goes back to the 2.2 level. Pressing Raise/Scroll or Lower/Scroll goes to menu 2.2.2 and displays metric conversion. Pressing Select/Enter displays the status of this feature. To change to the metric display press Raise/Scroll and enter the user key code followed by the Select/Enter key. Press Raise/Scroll and then Select/Enter. The display will indicate that the new setting has been saved. Press previous twice to go to menu 2.2. Press Raise/Scroll to go to menu 2.3. Press Lower/Scroll to go to menu 2.1. Menu 2.3. Menu 2.3 changes user key code. Press Select/Enter and then the user key code followed by Select/Enter twice. Press the key sequence for the new key code followed by Select/Enter twice. The user will be asked to re-enter the new key code. After entering the new key code followed by Select/Enter twice, the display will indicate the new code has been saved.
Lower

Menu 2.1 Generator Connection

Lower Raise

Menu 2.2 Options

Lower Raise

Menu 2.3 User Front Panel Key Code

Lower Raise

Menu 2.4 Global Pre-Alarm Buzzer Enable

D2609-03 04-23-97

Figure 3-6. Menu 2

Pressing Raise/Scroll will go to menu 2.4. Pressing Lower/Scroll will go menu 2.2.

3-14

DGC-1000 Functional Description

Menu 2.4. Menu 2.4 pre-alarm audible alarm enable. Pressing Select/Enter will display the status of the pre-alarm audible alarm. This feature is not adjustable from the front panel. Pressing Previous will go to menu 2.4. Pressing Raise/Scroll will go to menu 2.1. Lower/Scroll will go to menu 2.3. Pressing

Menu 2.2 Options

Prev

Enter

Pressing Previous from any 2.x menu will go to menu 2. Pressing Raise/Scroll goes to menu 3. Pressing Lower/Scroll goes to menu 1. Menu 3. Menu 3 sensing devices. Pressing Select/Enter (Figure 3-8) begins the 3.1 level of menus Menu 3.1. Menu 3.1 transformer ratios menu. Menu 3.1.1 (Figure 3-9) displays generator potential transformer primary voltage rating. Pressing Select/Enter displays the value. This is not adjustable from the front panel. Pressing Previous twice goes to menu 3.1. Pressing Raise/Scroll goes to menu 3.1.2. Pressing Lower/Scroll goes to menu 3.1.5.

Raise

Menu 2.2.1 Speed Signal Source

Lower Raise

Lower

Menu 2.2.2 Metric Conversion

D2609-04 04-23-97

Figure 3-7. Menu 2.2

Menu 3 Sensing Devices

Prev

Prev

Menu 3.1 Transformer Ratios

Enter

Enter
Raise

Menu 3.1 Transformer Ratios

Menu 3.1.1 Generator PT's Primary Rating Lower Raise

Raise

Lower Raise

Menu 3.2 Sender Failure Alarms

Menu 3.1.2 Generator PT's Secondary Rating Lower Raise Menu 3.1.3 Generator CT's Primary Rating
D2609-05 05-15-97

Lower Raise

Lower

Menu 3.3 Input Calibration Function

Lower

D2839-04 12-17-98

Figure 3-8. Menu 3

Figure 3-8. Menu 3.1

DGC-1000 Functional Description

3-15

Menu 3.1.2. Menu 3.1.2 displays the generator potential transformer secondary voltage rating. Pressing Select/Enter displays the value. This is not adjustable from the front panel. Pressing Previous goes to menu 3.1. Pressing Raise/Scroll goes to menu 3.1.3 Pressing Lower/Scroll goes to menu 3.1.1. Menu 3.1.3. Menu 3.1.3 displays the generator current transformer primary current rating. Pressing Select/Enter displays the value. This is not adjustable from the front panel. Pressing previous goes to menu 3.1. Pressing Raise/Scroll goes to menu 3.1.1. Pressing Lower/Scroll goes to menu 3.1.2. Pressing Raise/Scroll from menu 3.1 goes to menu 3.2. Menu 3.2. Menu 3.2 sender failure alarm menu. Pressing Select/Enter (Figure 3-10) begins menu 3.2.1 Menu 3.2.1. Menu 3.2.1 displays coolant temperature sensor failure alarm. Pressing Select/Enter displays the status of this alarm. This is not adjustable from the front panel. Pressing Previous goes to menu 3.2.1. Pressing Raise/Scroll goes to menu 3.2.2. Pressing Lower/Scroll goes to menu 3.2.5. Menu 3.2.2. Menu 3.2.2 displays oil pressure sensor failure alarm. Pressing Select/Enter displays the status of this alarm. This is not adjustable from the front panel. Pressing Previous goes to menu 3.2.2. Pressing Raise/Scroll goes to menu 3.2.3. Pressing Lower/Scroll goes to menu 3.2.1 Menu 3.2.3. Menu 3.2.3 displays speed signal failure alarm. Pressing Select/Enter displays the status of this alarm. This is not adjustable from the front panel. Pressing Previous goes to menu 3.2.3. Pressing Raise/Scroll goes to menu 3.2.4. Pressing Lower/Scroll goes to menu 3.2.2. Menu 3.2.4. Menu 3.2.4 displays voltage sensing failure alarm. Pressing Select/Enter displays the status of this alarm. This is not adjustable from the front panel. Pressing Previous goes to menu 3.2.4.

Prev

Menu 3.2 Sender Failure Alarms

Enter

Menu 3.2.1 Cool. Temp. Sensor Failure Alarm Enabled or Disabled

Lower Raise

Lower Raise

Menu 3.2.5 Sensor Failure Alarm Delay

Raise Lower

Menu 3.2.2 Oil Pressure Sensor Failure Alarm Enabled or Disabled

Lower

Menu 3.2.4 Generator Sensing Voltage Failure Alarm Enabled or Disabled

Raise Lower

Raise

Menu 3.2.3 Speed Signal Failure Alarm Enabled or Disabled

D2609-07 05-15-97

Figure 3-10. Menu 3.2

Pressing Raise/Scroll goes to menu 3.2.5. Pressing Lower/Scroll goes to menu 3.2.3.

3-16

DGC-1000 Functional Description

Menu 3.2.5. Menu 3.2.5 displays sensor failure alarm time delay. Pressing Select/Enter displays the delay time. After pressing Raise/Scroll or Lower/Scroll the user will be instructed to enter the user key code. After entering the user key code followed by pressing Select/Enter twice, the setting will be adjustable with the Raise/Scroll and Lower/Scroll keys. After the desired setting has been selected, press Select/Enter to save the new setting. Pressing Previous goes to menu 3.2. Pressing Raise/Scroll goes to menu 3.2.1. Pressing Lower/Scroll goes to menu 3.2.4. Pressing Raise/Scroll from menu 3.2 goes to menu 3.3. Pressing Lower/Scroll from menu 3.2 goes to menu 3.1. Menu 3.3. Menu 3.3 displays the input calibration function. This function is for Basler Electric Company use only. For more information contact Basler Electric Company. Pressing Previous goes to menu 3. Pressing Raise/Scroll from menu 3 goes to menu 4. Pressing Lower/Scroll goes to menu 2. Menu 4. Menu 4 (Figure 3-11) displays engine parameters and cranking. Pressing Select/Enter from menu 4 begins menu 4.1. Menu 4.1. Menu 4.1 displays cool down time. After pressing Raise/Scroll or Lower/Scroll, the user will be instructed to enter the user key code. After entering the user key code followed by pressing Select/Enter twice, the setting will be adjustable with the Raise/Scroll and Lower/Scroll keys. After the desired setting has been selected, press Select/Enter to save the new setting. Pressing Previous goes to menu 4.1. Pressing Raise/Scroll goes to menu 4.2. Pressing Lower/Scroll goes to menu 4.7. Menu 4.2. Menu 4.2 displays cranking mode. Pressing Select/Enter displays the cranking mode selected. This is not adjustable from the front panel. Pressing Previous goes to menu 4.2. Pressing Raise/Scroll goes to menu 4.3. Pressing Lower/Scroll goes to menu 4.1.
Prev

Menu 4 Engine Parameters and Cranking

Enter

Menu 4.1 Cool Down Time Lower Raise Menu 4.2 Cranking Mode Lower Raise Menu 4.3 No. of Crank Cycles Lower Raise Menu 4.4 Continuous Crank Time

Raise

Lower Menu 4.7 Pre-Crank Contact After Cranking Raise Lower Menu 4.6 Pre-Crank Delay Raise Lower Raise Lower Menu 4.5 Cycle Crank Time

D2609-08 04-23-97

Figure 3-11. Menu 4 Menu 4.3. Menu 4.3 displays the number of crank cycles. Pressing Select/Enter displays the number of crank cycles selected. This is not adjustable from the front panel. Pressing Previous goes to menu 4.3. Pressing Raise/Scroll goes to menu 4.4. Pressing Lower/Scroll goes to menu 4.2. Menu 4.4. Menu 4.4 displays continuous crank time. Pressing Select/Enter displays the continuous crank time selected. This is not adjustable from the front panel. Pressing Previous goes to menu 4.4. Pressing Raise/Scroll goes to menu 4.5. Pressing Lower/Scroll goes to menu 4.3. Menu 4.5. Menu 4.5 displays cycle crank time. Pressing Select/Enter displays the cycle crank time selected. This is not adjustable from the front panel. Pressing Previous goes to menu 4.5. Pressing Raise/Scroll goes to menu 4.6. Pressing Lower/Scroll goes to menu 4.4. DGC-1000 Functional Description 3-17

Menu 4.6. Menu 4.6 displays precrank delay time. After pressing Raise/Scroll or Lower/Scroll, the user will be instructed to enter the user key code. After entering the user key code followed by pressing Select/Enter twice, the setting will be adjustable with the Raise/Scroll and Lower/Scroll keys. After the desired setting has been selected press Select/Enter to save the new setting. Pressing Previous goes to menu 4.6. Pressing Raise/Scroll goes to menu 4.7. Pressing Lower/Scroll goes to menu 4.5. Menu 4.7. Menu 4.7 displays the status of the Precrank contact after cranking. After pressing Raise/Scroll or Lower/Scroll, the user will be instructed to enter the user key code. After entering the user key code followed by pressing Select/Enter twice, the setting will be adjustable with the Raise/Scroll and Lower/Scroll keys. After the desired setting has been selected, press Select/Enter to save the new setting. Pressing Previous goes to menu 4.7. Pressing Raise/Scroll goes to menu 4.1. Pressing Lower/Scroll goes to menu 4.6. Pressing Previous twice goes to the normal display mode. Exiting Menu Mode You may exit Menu mode (from any menu level) by pressing the Display Toggle pushbutton (see Figure 3-12). If the Display Toggle pushbutton is pressed before a parameter setpoint change has been saved, then the old setpoint value is preserved. NOTE Using DISPLAY TOGGLE to exit Menu mode will save the users place within the menu system so that the next time Menu mode is entered, the display will return to the same screen. As an alternative, pressing Previous allows the user to back out of the menu mode one level at a time so that the next time menu mode is entered, the display will start at the top of the menu structure.

Any Menu Mode Level

Previous

Display Toggle

Exit Menu Mode

D2609-09 04-23-97

Figure 3-12. Exiting Menu Mode 3-18 DGC-1000 Functional Description

Modifying Setpoints To modify an existing setpoint, press the Select/Enter pushbutton (Figure 3-13). Press Raise/Scroll or Lower/Scroll buttons to raise or lower the current parameter setpoint. Press the Select/Enter pushbutton to save the modified setpoint value, or press the Previous pushbutton to exit the parameter setting screen without changing the value. Once in the menu mode, the first time an attempt is made to change a setting that is front panel adjustable, the user will be prompted to enter the keycode. Upon successful entry of the keycode, the user may modify any of the adjustable settings without re-entering the keycode during the current menu mode session. The only exception to this is changing the keycode itself. Changing the keycode always requires entry of the existing keycode. Also, whether the keycode is actually changed or not, any further changes to other settings after that will require the keycode to be entered once again. Leaving the Menu mode after an editing session automatically terminates the editing privilege. Press the Display Toggle pushbutton to exit the menu mode.

Menu y.y Setpoint = value

Enter Edit Setpoint

Lower Setpoint

Lower

Accept, Inc, or Dec?

Raise

Raise Setpoint

Enter Accept Setpoint

Menu y.y New setpoint saved

D2609-10 04-23-97

Figure 3-13. Modifying Setpoints DGC-1000 Functional Description 3-19

Alternate Display Mode After pressing the Display/Toggle pushbutton to enter the alternate display mode, pressing the Raise/Scroll or Lower/Scroll pushbutton allows the user to scroll through the alternate display mode screens. The quantities are displayed in the following order. OIL PRESSURE COOLANT TEMPERATURE FUEL LEVEL BATTERY VOLTAGE TOTAL KILOWATT LOAD HOURS TO NEXT SERVICE GENERATOR A-B VOLTAGE GENERATOR B-C VOLTAGE ( 3-PHASE SENSING ONLY) GENERATOR C-A VOLTAGE (3-PHASE SENSING ONLY) GENERATOR A-N VOLTAGE (3-PHASE L-N SENSING) GENERATOR B-N VOLTAGE (3-PHASE L-N SENSING) GENERATOR C-N VOLTAGE (3-PHASE L-N SENSING) GENERATOR PHASE A CURRENT ( 3-PHASE SENSING ONLY) GENERATOR PHASE B CURRENT ( 3-PHASE SENSING ONLY) GENERATOR PHASE C CURRENT ( 3-PHASE SENSING ONLY) PHASE A kVA ( 3-PHASE SENSING ONLY) PHASE B kVA ( 3-PHASE SENSING ONLY) PHASE C kVA ( 3-PHASE SENSING ONLY) TOTAL kVA GENERATOR PHASE A KILOWATTS ( 3-PHASE SENSING ONLY) GENERATOR PHASE B KILOWATTS ( 3-PHASE SENSING ONLY) GENERATOR PHASE C KILOWATTS ( 3-PHASE SENSING ONLY) GENERATOR TOTAL KILOWATT-HOURS GENERATOR POWER FACTOR GENERATOR FREQUENCY TOTAL RUN HOURS ENGINE SPEED UNIT IDENTIFICATION NUMBER

FACTORY KEY CODE SETTING

Factory preprogrammed key code setting. 1. Raise/Scroll 2. Lower/Scroll 3. Select/Enter 4. Previous 5. Display Toggle 6. Enter 7. Enter

3-20

DGC-1000 Functional Description

ALLOWABLE KEY CODE PUSHBUTTONS

User key codes are one to eight presses of any of the following acceptable pushbuttons in any order, except Previous twice consecutively. When used, the key code must be followed by two presses of the Select/Enter pushbutton. Raise/Scroll Lower/Scroll Select/Enter Previous Display/Toggle Phase Toggle Alarm Silence Lamp Test

PARAMETERS AND DEFAULT SETTINGS

Front Panel Adjustable Parameters All settings are viewable at the front panel. The following settings are adjustable at the front panel. Sensor failure alarm time delay Metric conversion function Low fuel pre-alarm level Low fuel alarm level Precrank contact after cranking Cool down time Precrank time delay From 1 to 10 seconds in 1 second increments ON or OFF 10 to 100% 2 to 50% OPEN or CLOSED From 0 to 60 minutes in 5 minute increments From 0 to 30 seconds in 1 second increments

All Parameters Specific parameters (settings) are not adjustable at either the front panel or through computer communications. These settings are identified in the following list as (not adjustable). All other parameters may be set through computer communications. Only those settings identified in the previous paragraph are adjustable at the front panel. The following list provides the parameters and the default setting. Metric Conversion (ON, OFF) default is OFF Generator Connection (3-phase, line-to-line; 3-phase, line-to-neutral; or single-phase, phases A and B); the default is 3-phase, line-to-neutral. Gen. PT Primary (1 - 15000 V) default is 480 V Gen. PT Secondary (1 - 480 V) default is 480 V Gen. CT Primary (1 - 5000 A) default is 500 A Cooldown time (0 - 60 minutes) default is 0 minutes Generator Speed Signal Sources = MPU/Gen Overspeed Alarm default is ON: Threshold (105 - 140%) default is 110% Activation Delay (10 - 500 milliseconds) default is 50 milliseconds High Coolant Temperature Alarm default is ON: Threshold (100 - 280F) default is 275F Arming Delay (not adjustable) is 60 seconds High Coolant Temperature Pre-alarm is ON: Threshold (100 - 280F) default is 250F Arming Delay default is 60 seconds Low Oil Pressure Alarm default is ON: Threshold (3 - 100 PSI) default is 15 PSI Arming Delay (5 - 15 seconds) default is 10 seconds Low Oil Pressure Pre-alarm default is ON: Threshold (3 - 100 PSI) default is 25 PSI Arming Delay (5 - 15 seconds) default is 10 seconds DGC-1000 Functional Description 3-21

Low Coolant Temperature Pre-alarm is OFF: Threshold (40 - 100F) default is 50F Arming Delay (0 - 15 seconds) default is 0 seconds Low Fuel Level Pre-alarm is OFF: Threshold (10 - 100 %) default is 25 % Activation Delay (not adjustable) is 0 seconds Low Fuel Level Alarm is ON Threshold (0 50%) default is 2 %. Activation Delay (not adjustable) is 0 seconds Weak Battery Pre-alarm is OFF: Threshold (4 - 8/8 - 16 V) default is 7.2/15.0 V (for 12/24 V systems) Activation Delay (1 - 10 seconds) default is 2 seconds Low Battery Pre-alarm is OFF: Threshold (6 - 12/12 - 24 V) default is 9.0/20.0 V (for 12/24 V systems) Activation Delay (1 - 10 seconds) default is 10 seconds Battery Overvoltage Pre-alarm is OFF: Threshold (14 - 16/24-32 V) default is 15.0/30.0 V (for 12/24 V systems) Activation Delay (not adjustable) is 0 seconds Battery Charger Failure Pre-alarm is OFF: Activation Delay (not adjustable) is 0 seconds Global Sender Failure Alarm Delay (1 - 10 seconds) default is 10 seconds: (This covers the oil pressure sender, generator sensing voltage, and speed signal sources) Speed Signal Failure Alarm (ON, OFF) default is OFF. Oil Pressure Sender Failure Alarm (ON, OFF) default is OFF. Generator Sensing Voltage Failure Alarm (ON, OFF) default is OFF. Coolant Temperature Sender Failure Alarm (ON, OFF) default is OFF. Arming Delay (5 - 30 minutes) default is 5 minutes (Global) Pre-alarm Buzzer default is ON. Maintenance Interval Pre-alarm default is OFF: Threshold (0 - 5000 hours) default is 500 hours Activation Delay (not adjustable) is 0 hours Engine kW Overload Pre-alarm is OFF: Threshold (95 - 140%) default is 105% Activation Delay (not adjustable) is 0 seconds Cranking style (CONTINUOUS/CYCLE) is CYCLE # crank cycles (1 - 7 cycles) default is 2 cycles Cycle crank time (5 - 15 seconds) default is 5 seconds Continuous crank time (1 - 60 seconds) default is 10 seconds Pre-crank delay (0 - 30 seconds) default is 0 seconds Pre-start contact after crank disconnect is OFF (OPEN)

3-22

DGC-1000 Functional Description

SECTION 4 INSTALLATI ON
GENERAL
DGC-1000 Digital Generator Controllers are delivered in sturdy cartons to prevent shipping damages. Upon receipt of the unit, check for damage, and if there is evidence of such, immediately file a claim with the carrier and notify the Basler Electric Regional Sales Office, your Sales Representative or Sales Representative at Basler Electric, Highland, Illinois. If the controller is not installed immediately, store it in the original shipping package in a moisture and dust free environment.

HARDWARE
DGC-1000 Controllers are packaged for mounting in any top mount enclosure. The front panel is resistant to moisture, salt fog, humidity, dust, dirt, and chemical contaminants. It also inhibits insect and rodent entrance. DGC-1000 Controllers are mounted using the permanently attached 10-32 by 5/8 inch (1/2 inch usable) studs.

MOUNTING
Case cutout dimensions are shown in Figure 4-1. Overall dimensions are shown in Figures 4-2 and 4-3.

10.75 (273.0) 10.25 (260.4) 0.25 (6.4) 0.218 (5.537) DIA. HOLE (4 PL)

TOLERANCE ON ALL CUT OUT DIMENSIONS + OR - 0.01 (0.254)

6.75 7.25 (171.4) (184.2)

0.25 (6.4) D2609-11 04-24-97

Figure 4-1. Cutout Dimensions In Inches (Millimeters) DGC-1000 Installation 4-1

Figure 4-2. DGC-1000 Overall Dimensions In Inches (Millimeters) 4-2 DGC-1000 Installation

Figure 4-3. DGC-1000 Overall Dimensions In Inches (Millimeters)

CONNECTIONS
CAUTION Be sure the controller battery input polarity is wired correctly. Although reverse polarity will not damage the controller, the DGC will not operate.

NOTE Be sure the controller is hard-wired to earth ground with no smaller than 12 AWG copper wire attached to the ground terminal on the rear of the controller. Except as noted above, connections should be made with minimum wire size of 14 AWG. Be sure to use the correct input power for the power supply. Figure 4-4 is a typical ac connection diagram for direct connected single-phase sensing system. Figure 4-5 is a typical ac connection diagram for direct connected three-phase line-to-line sensing system. Figure 4-6 is a typical ac connection diagram for direct connected three-phase line-to-neutral sensing system. Figure 4-7 is a typical DGC-1000 system ladder diagram.

DGC-1000 Installation

4-3

PH A

PH B

PH C

P15

PHASE CCT

PHASE BCT

PHASE ACT

AUTOMATIC TRANSFER SWITCH

NEUT.

BATTERY P16 CHARGER FAIL

OUTPUT RELAYS

EPS SUPPLYING LOAD

PRE-ALARM

ALARM

PRE-START

FUEL SOLENOID

MASTER START

4-4
GENERATOR CIRCUIT BREAKER L1 L2

TO BUS GENERATOR 480V

N

1 1
P6 P7

5 P31 P10 1A 5A

N.C.
P45 + P34 P35 P36 VOLT. VOLT. VOLT. VOLT. P37 COM HORN COM
1A 5A

P18 COM
1A 5A

P11 P8 P5

P9 P3 P4

P17

EMERGENCY STOP

OIL PRESSURE FUEL LEVEL COOLANT TEMP

P38 P39 P40 4 3 2 FUEL LEAK DETECTOR

LOW P14 COOLANT LEVEL

CONTACT SENSING

SENDING UNITS

DGC1000
P33

P41 GND

MPU
+ P32

5A
+ P1

MAGNETIC PICK-UP BATTERY

P29 P30

P27 P28

P23 P24

P21 P22

P19 P20

P25 P26

P2

FUEL SOLENOID

START SOLENOID

CONNECT TO P3 AND P6 FOR 1 AMP SECONDARY CT'S CONNECT TO P4 AND P7 FOR 5 AMP SECONDARY CT'S

STEWART WARNER P/N 411-K OR EQUIVALENT

ISS PRO P/N R8925 OR EQUIVALENT

STEWART WARNER P/N 334-P OR EQUIVALENT

D2839-14.vsd 04-28-00

Figure 4-4. DGC-1000 Direct Connected Single-Phase, Three-wire Sensing DGC-1000 Installation

IF AN EMERGENCY STOP SWITCH IS NOT USED, JUMPER TERMINALS P17 AND P18.

GENERATOR CIRCUIT BREAKER

A
B

TO BUS C

GENERATOR 480V

N
1 P31 P10 1A 5A

1
P9

1
P6 P7

5 P45 + P34 P35 P36 P37 COM PH A PH B PH C HORN NEUT. COM

1A 5A

N.C.
P11 COM
1A 5A

P18

P8

P5

P3 P4

P17

EMERGENCY STOP

VOLT. VOLT. VOLT. VOLT.

P15

PHASE CCT

PHASE BCT

PHASE ACT

AUTOMATIC TRANSFER SWITCH

OIL PRESSURE FUEL LEVEL

P38 P39 2

P14

LOW COOLANT LEVEL

CONTACT SENSING OUTPUT RELAYS

SENDING UNITS

COOLANT TEMP

P40 4

FUEL LEAK DETECTOR

BATTERY P16 CHARGER FAIL

DGC1000
P33

P41 GND

MPU
+ P32 MASTER START

EPS SUPPLYING LOAD

PRE-ALARM

ALARM

PRE-START

FUEL SOLENOID

5A
+ P1

MAGNETIC PICK-UP BATTERY

P29 P30

P27 P28

P23 P24

P21 P22

P19 P20

P25 P26

P2

FUEL SOLENOID

START SOLENOID

CONNECT TO P3, P6 AND P9 FOR 1 AMP SECONDARY CT'S CONNECT TO P4, P7 AND P10 FOR 5 AMP SECONDARY CT'S

Figure 4-5. DGC-1000 Direct Connected Three-Phase Line-to-Line Sensing DGC-1000 Installation

STEWART WARNER P/N 411-K OR EQUIVALENT

ISS PRO P/N R8925 OR EQUIVALENT

STEWART WARNER P/N 334-P OR EQUIVALENT

D2839-15 04-28-00

IF AN EMERGENCY STOP SWITCH IS NOT USED, JUMPER TERMINALS P17 AND P18.

4-5

PH A

PH B

PH C

P15

PHASE CCT

PHASE BCT

PHASE ACT

AUTOMATIC TRANSFER SWITCH

NEUT.

BATTERY P16 CHARGER FAIL

OUTPUT RELAYS

EPS SUPPLYING LOAD

PRE-ALARM

ALARM

PRE-START

FUEL SOLENOID

MASTER START

4-6
GENERATOR CIRCUIT BREAKER

A
B GENERATOR 480V

TO BUS C N

N
1 P31 P10 1A 5A

1
P9

1
P6 P7

5 P45 + P34 P35 P36 VOLT. VOLT. VOLT. VOLT. P37 COM HORN COM
1A 5A

N.C.
P11 COM
1A 5A

P18

P8

P5

P3 P4

P17

EMERGENCY STOP

OIL PRESSURE FUEL LEVEL COOLANT TEMP

P38 P39 P40 4 3 2 FUEL LEAK DETECTOR

P14

LOW COOLANT LEVEL

CONTACT SENSING

SENDING UNITS

DGC1000
P33

P41 GND

MPU
+ P32

5A
+ P1

MAGNETIC PICK-UP BATTERY

P29 P30

P27 P28

P23 P24

P21 P22

P19 P20

P25 P26

P2

FUEL SOLENOID

START SOLENOID

CONNECT TO P3, P6 AND P9 FOR 1 AMP SECONDARY CT'S CONNECT TO P4, P7 AND P10 FOR 5 AMP SECONDARY CT'S

STEWART WARNER P/N 411-K OR EQUIVALENT

ISS PRO P/N R8925 OR EQUIVALENT

STEWART WARNER P/N 334-P OR EQUIVALENT

D2839-16.vsd 04-28-00

Figure 4-6. DGC-1000 Direct Connected Three-Phase Line-to-Neutral Sensing DGC-1000 Installation

IF AN EMERGENCY STOP SWITCH IS NOT USED, JUMPER TERMINALS P17 AND P18.

8-32Vdc

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61
AUX 4 AUX 8 AUX 3 AUX 2 IB 1 OR 5A P8 P9/P10 IC 1 OR 5A P11 P29 EPS SUPPLYING LOAD P30 P21 PRE-START P22 P23 ALARM P24 P26 P25 EMERGENCY STOP BUTTON 5A

DGC-1000
P O W E R INPUT

P1+

P2-

P41 HORN P31 P45

P15 P14 P16

ATS LOW COOLANT LEVEL BATTERY CHARGER FAILURE

P18 P17 P33 P39 P38 P40 OUTPUTS P20 P19

FUEL LEAK DETECTOR FUEL LEVEL SENDER OIL PRESSURE SENDER COOLANT TEMP SENDER

MPU P32

FUEL SOLENOID START SOLENOID

P27

PRE-ALARM

P28

GENERATOR SENSING
VA VB VC N P34 P35 P36 P37 P3/P4 IA 1 0R 5A P5 P6/P7

TO GENERATOR OUTPUT TERMINALS 100-480 VAC NOMINAL INPUT. FOR SINGLE PHASE SENSING OMIT VC. FOR DELTA OMIT N INPUT.

PROGRAMMABLE OUTPUT CONTACTS WITH AUX. I/O OPTION.

OPTIONS ON AUX. BD.

AUX 1 INPUT AUX 1 AUX 2 INPUT AUX 3 INPUT AUX 4 INPUT

OPTIONAL PROGRAMMABLE CONTACTS LOCATED ON AUXILIARY BOARD

RJ11 MODEM

OPTIONAL FOR REMOTE COMMUNICATION

DB9 RS232

FOR LOCAL SET-UP AND CONTROL

AUX 5 AUX 6

AUX 7

D2559-26.vsd 04-28-00

Figure 4-7. DGC-1000 System Ladder Diagram DGC-1000 Installation 4-7

COMMUNICATION CONNECTORS AND SETTINGS

RS-232 Connector The RS-232 connector is a DB-9 female connector. Connector pin numbers, functions, names, and signal directions are shown in Table 4-1. Figure 4-8 provides the RS-232 cable connection diagram. Table 4-1. RS-232 Pinouts Pin 1 2 3 4 5 6 7 8 9 N/C Transmit Data Receive Data N/C Signal Ground N/C N/C N/C N/C Function Name ---(TXD) (RXD) ---(GND) ------------Direction N/A From DGC-1000 Into DGC-1000 N/A N/A N/A N/A N/A N/A

9-PIN PC-AT MALE DB-9 1 RXD TXD 2 3 4 SGND 5

TO DGC1000 FEMALE DB-9 1 2 3 4 5 6 7 8

D2839-17 01-13-98

TXD RXD

SGND

Figure 4-8. Personal Computer To DGC-1000 Communication Settings Communication settings are the formal set of conventions controlling the format and relative timing of message exchange between two communications terminals. Default settings baud rate = 9600, parity = None, and stop bits = 1.

4-8

DGC-1000 Installation

SECTION 5 TESTING
INTRODUCTION
This section provides a procedure for testing the DGC-1000 using the preset factory default settings.

EQUIPMENT REQUIRED
DC Power Supply, 12 or 24 Volts 2 Amp Fuse Voltage Source, 60 hertz, 0 to 120V Current Source, 60 hertz, 0 to 5A Signal Generator, Sine Wave, 0 to 5k hertz, 0 to 5V Digital Voltmeter, 4 1/2 Digits (Fluke 8050A or Equivalent) Continuity Tester Four Single-Pole Switches 2 each, 250 ohm variable resistors 1 each 2500 ohm variable resistor

INITIAL TEST PROCEDURE

Unless otherwise specified, the test procedures in this manual use the default parameter settings provided in Table 5-1.

Table 5-1. Default Parameter Settings PARAMETER Comm Baud Rate Remote Delay Time Comm Parity Device Address Embedded Code Version No. Settings Source Generator Connection NFPA Level Unit System Battery Volts Generator Frequency Rated Engine RPM Number Flywheel Teeth Genset kW Rating No Load Cool Down Time Generator PT Primary Voltage Generator PT Secondary Voltage Generator CT Primary Current Low Fuel Alarm Enable Low Fuel Alarm Threshold Low Fuel Pre-alarm Enable Low Fuel Pre-alarm Threshold DGC-1000 Testing SETTING 9600 Baud 1 Millisecond/10 None 125 Ver. No. 1.0.0 User 3-ph L-N 0 English 24 Volts 60 Hz 1800 RPM 126 300 kilowatt 0 Minutes 480 Vac 480 Vac 500 Aac ON 2% Full Tank OFF 25% Full Tank 5-1

PARAMETER Low Coolant Temperature Pre-alarm Enable Low Coolant Temperature Pre-alarm Threshold Battery Overvoltage Pre-alarm Enable Battery Overvoltage Pre-alarm Threshold Maintenance Interval Pre-alarm Enable Maintenance Interval Pre-alarm Threshold Engine kW Overload Pre-alarm Enable Engine kW Overload Pre-alarm Threshold High Coolant Temperature Pre-alarm Enable High Coolant Temperature Pre-alarm Threshold Low Oil Pressure Pre-alarm Enable Low Oil Pressure Pre-alarm Threshold Low Battery Voltage Pre-alarm Enable Low Battery Voltage Pre-alarm Threshold Low Battery Voltage Pre-alarm Activation Time Delay Weak Battery Pre-alarm Enable Weak Battery Pre-alarm Threshold Weak Battery Pre-alarm Activation Time Delay High Coolant Temperature Alarm Enable High Coolant Temperature Alarm Threshold High Coolant Temperature Alarm Arming Delay After Crank Disconnect Low Oil Pressure Alarm Enable Low Oil Pressure Alarm Threshold Low Oil Pressure Alarm Arming Delay After Crank Disconnect Overspeed Alarm Enable Overspeed Alarm Threshold Overspeed Alarm Activation Time Delay Coolant Temperature Sender Failure Alarm Enable Oil Pressure Sender Failure Alarm Enable Speed Failure Alarm Enable Loss of Generator Voltage Alarm Enable Pre-alarm Buzzer Enable Battery Charger Failure Pre-alarm Enable Global Sender Failure Alarm Time Delay Coolant Temp. Sender Failure Alarm Activation Time Delay Cranking Style Number of Crank Cycles Cycle Crank Time Continuous Crank Time Crank Disconnect Limit Pre-Crank Delay Pre-crank Contact After Crank Disconnect Generator Speed Mode Generator Rotation 5-2 OFF

SETTING 50 Degrees F OFF 30.0 VDC OFF 500 Hours OFF 105 % of Rated ON 250 Degrees F ON 25 PSI OFF 20.0 VDC 10 Seconds OFF 15.0 VDC 2 Seconds ON 275 Degrees F 60 Seconds ON 15 PSI 10 Seconds ON 110% of Rated 50 Millisecond OFF OFF OFF OFF ON OFF 10 Seconds 5 Minutes Cycle 2 5 Seconds 10 Seconds 30 % of Rated 0 Seconds Open MPU/GEN A-B-C DGC-1000 Testing

Step 1. Connect the DGC-1000 test setup as shown in Figure 5-1. Step 2. Apply operating voltage to battery voltage terminals. Result: The LCD displays DGC 1000 and the software version for approximately one second before switching to the normal display mode and at the same time, the Alarm sounds. The audible alarm will sound continuously when Not In Auto or in Alarm. The audible alarm may be silenced by pressing the Alarm Silence switch on the front panel. Step 3 Press the Off switch to place the DGC-1000 in the OFF position. Step 4. Verify that LEDs Not In Auto and Off are ON, the Alarm LED is flashing, and the LCD backlight is ON with system parameters displayed. Step 5. Press the Lamp Test switch and verify that all six LEDs are ON (Not In Auto, Alarm, and Off are red; Supplying Load, Run, and Auto are green). All LCD pixels should be visible. Step 6. Verify Run, Off, and Auto switches, along with their respective LEDs, toggle as each switch is operated. Not In Auto LED should be OFF when Auto is selected. Step 7. Verify that switches Raise/Scroll, Lower/Scroll, Select/Enter, Previous, and Display/Toggle are functional by scrolling through the unit menus.

METERING TEST PROCEDURES

Metering Battery And Generator Voltages NOTE Displayed voltage is equal to the generator potential transformer primary voltage setting times the applied voltage divided by the generator potential transformer secondary voltage setting. Step 1. Verify that the battery input (terminals P1 and P2) voltage is 24.0 Vdc. Step 2. Verify that the DGC-1000 displayed value is 24.0 0.5 Vdc. Step 3. Apply 120.0 Vac, 60.0 hertz to phase A (line-to-neutral) generator voltage input (terminals P34 and P37). Step 4. Verify that the DGC-1000 generator frequency displayed value is 60.0 0.2 hertz. Step 5. Verify that the DGC-1000 phase A to neutral voltage displayed value is 120.0 2.0 Vac. Step 6. Remove the voltage. Step 7. Apply 120.0 Vac, 60.0 hertz to phases A and B generator voltage input (terminals P34 and P35). Step 8. Verify that the DGC-1000 generator A to B voltage displayed value is 120.0 2.0 Vac. Step 9. Remove the voltage. Step 10. Apply 120.0 Vac, 60.0 hertz (line-to-neutral) to phase B generator voltage input (terminals P35 and P37). Step 11. Verify that the DGC-1000 line-to-neutral voltage displayed value is 120.0 2.0 Vac. Step 12. Remove the voltage. Step 13. Apply 120.0 Vac, 60.0 hertz to phases B and C generator voltage input (terminals P35 and P36). Step 14. Verify that the DGC-1000 generator B to C voltage displayed value is 120.0 2.0 Vac. Step 15. Remove the voltage. Step 16. Apply 120.0 Vac, 60.0 hertz (line-to-neutral) to phase C generator voltage input (terminals P36 and P37). Step 17. Verify that the DGC-1000 line-to-neutral voltage displayed value is 120.0 2.0 Vac. Step 18. Remove the voltage. Step 19. Apply 120.0 Vac, 60.0 hertz to phases C and A generator voltage input (terminals P36 and P34). Step 20. Verify that the DGC-1000 generator C to A voltage displayed value is 120.0 2.0 Vac. Step 21. Remove the voltage.

DGC-1000 Testing

5-3

PH A

PH B

P15

PHASE CCT

PHASE BCT

PHASE ACT

AUTOMATIC TRANSFER SWITCH

PH C OIL PRESSURE FUEL LEVEL COOLANT TEMP

NEUT.

BATTERY P16 CHARGER FAIL

OUTPUT RELAYS

EPS SUPPLYING LOAD

PRE-ALARM

ALARM

PRE-START

FUEL SOLENOID

MASTER START

5-4
P31 P10 1A 5A

N.C.
P45 + P34 P35 P36 VOLT. VOLT. VOLT. VOLT. P37 COM HORN COM
1A 5A

P18 COM
1A 5A

P11

P9

P8

P6 P7

P5

P3 P4

P17

EMERGENCY STOP

P38 P39 P40

P14

LOW COOLANT LEVEL

CONTACT SENSING

SENDING UNITS

FUEL LEAK DETECTOR

DGC1000
P33

P41 GND

MPU
+ P32

5A
+ P1

Figure 5-1. Test Set Diagram

BATTERY
P29 P30 P27 P28 P23 P24 P21 P22 P19 P20 P25 P26

MAGNETIC PICK-UP

P2

D2839-11.vsd 04-28-00

DGC-1000 Testing

Metering Generator Current

NOTE Displayed current is equal to the generator current transformer primary current setting times the applied current divided by one or five (the nominal current value). Step 1. Apply 1.000 Aac to the DGC-1000 generator five ampere phase A CT input (terminals P4 and P5). Step 2. Verify that the DGC-1000 phase A current displayed value is 100.0 2.0 amperes. Step 3. Remove the current. Step 4. Apply 1.000 Aac to the DGC-1000 generator five ampere phase B CT input (terminals P7 and P8). Step 5. Verify that the DGC-1000 phase B current displayed value is 100.0 2.0 amperes. Step 6. Remove the current. Step 7. Apply 1.000 Aac to the DGC-1000 generator five ampere phase C CT input (terminals P10 and P11). Step 8. Verify that the DGC-1000 phase C current displayed value is 100.0 2.0 amperes. Step 9. Remove the current. Oil Pressure Step 1. Apply 60 ohms across the Oil Pressure transducer input (terminals P38 and P2). Step 2. Verify that the DGC-1000 displayed value is 80 2.0 PSI. Coolant Temperature Step 1. Apply 100 ohms across the Coolant Temperature transducer input (terminals P40 and P2). Step 2. Verify that the DGC-1000 displayed value is 205 4.0 C. Percent Fuel Level Step 1. Apply 137 ohms across the Fuel Level transducer input (terminals P39 and P2). Step 2. Verify that the DGC-1000 displayed value is 50 2.0%. Engine Speed (RPM)

NOTE RPM as derived from the MPU is equal to [MPU output frequency (hertz) times 60] divided by the number of flywheel teeth. RPM as derived from the generator is equal to [generator output voltage frequency] divided by the rated generator frequency (Hertz) times the rated RPM. Step 1. Apply a 5 Vac, 3,780 hertz sine wave to the DGC-1000 magnetic pickup unit inputs (terminals P32 and P33). Step 2. Verify that the DGC-1000 displayed value is 1,800 36 RPM. Step 3. Remove the voltage.

DGC-1000 Testing

5-5

Generator Power Factor

NOTE The DGC-1000 uses phase A voltage and phase B current for Power Factor calculations. Therefore, if this test is performed with the current lagging the voltage by 120 degrees, the displayed Power Factor will be approximately 1.00. Step 1. Apply 120 Vac to phase A to neutral generator voltage inputs (terminals P34 and P37). Step 2. Apply 1.0 Aac to phase B current transformer inputs (terminals P7 and P8) in phase with the phase A to neutral voltage. Step 3. Verify that the DGC-1000 displayed value is -0.50 0.02. Step 4. Remove voltage and current. Generator kW And kVA NOTE The displayed kW is equal to the kVA times the Power Factor. Step 1. Apply in parallel 120 Vac to phase A to neutral (terminals P34 and P37), phase B to neutral (terminals P35 and P37), and phase C to neutral (terminals P36 and P37). Step 2. Apply in series and in phase with the voltage 1 Aac to Phase A current transformer input (terminals P3 and P5), Phase B current transformer input (terminals P6 and P8), and Phase C current transformer input (terminals P9 and P11). Step 3. Verify that the DGC-1000 displayed value for individual phase kW is -30 2 kW. Step 4. Verify that the DGC-1000 displayed value for total kW is -90 2 kW. Step 5. Verify that the DGC-1000 displayed value for individual phase kVA is 60 2 kVA. Step 6. Verify that the DGC-1000 displayed value for total kVA is within 180 5 kVA. Step 7. Remove voltage and current.

CRANKING TEST PROCEDURES

Crank Cycle NOTE The DGC will go into Overcrank if the Off switch is not pressed before two crank cycles expire. Pressing Off will reset this condition if it occurs. Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Step 8. Step 9. Step 10. Step 11. Step 12. Step 13. 5-6 Verify that all output contacts are open. Press the Run switch on the front panel. Verify that the DGC-1000 displays CRANKING STATUS. Verify that only the Master Start, Auxiliary Start, Fuel Solenoid, and Pre-Start output contacts are closed during CRANKING CYCLE. Verify that only the Pre-Start contact remains closed during RESTING. Press the Off switch on the front panel. Press the Auto switch on the front panel. Apply a contact closure across the Automatic Transfer Switch input (terminals P15 and P2). Verify that the DGC-1000 displays CRANKING STATUS. Verify that only the Master Start, Auxiliary Start, Fuel Solenoid, and Pre-Start output contacts are closed during CRANKING CYCLE. Verify that only the Pre-Start contact remains closed during RESTING. Press the Off switch on the front panel. Open the contact across the Automatic Transfer Switch inputs. DGC-1000 Testing

Running Step 1. Press the Run switch on the front panel. Step 2. Within 5 seconds of beginning cranking, apply in parallel 120 Vac to phase A to neutral (terminals P34 and P37), phase B to neutral (terminals P35 and P37), and phase C to neutral (terminals P36 and P37). Step 3. Verify that only the Fuel Solenoid output contact is closed. Step 4. Verify that the DGC-1000 normal mode display now meters the active generator values listed on the front panel instead of displaying READY. Step 5. Press the Off switch on the front panel. Step 6. Remove the voltage. Step 7. Press the Auto switch on the front panel. Step 8. Apply a contact closure across the Automatic Transfer Switch input (terminals P15 and P2). Step 9. Within 5 seconds of beginning cranking, apply in parallel 120 Vac to phase A to neutral (terminals P34 and P37), phase B to neutral (terminals P35 and P37), and phase C to neutral (terminals P36 and P37). Step 10. Verify that only the Fuel Solenoid output contact is closed. Step 11. Verify that the DGC-1000 normal mode display now meters the active generator values listed on the front panel instead of displaying READY. Step 12. Press the Off switch on the front panel. Step 13. Remove the voltage. Step 14. Open the contact across the Automatic Transfer Switch inputs.

PROTECTIVE FUNCTION TEST PROCEDURES

Overcrank Step 1. Press the Run switch on the front panel. Step 2. Verify that after two crank cycles the DGC-1000 display indicates GEN OVER-CRANK ALARM and that only the Alarm output contacts are closed. Step 3. Press the Off switch on the front panel and verify that the DGC-1000 resets to the Ready mode and that all output contacts open. Overspeed Step 1. Apply in parallel 120 Vac to phase A to neutral (terminals P34 and P37), phase B to neutral (terminals P35 and P37), and phase C to neutral (terminals P36 and P37). Step 2. Apply a 5 Vac, 4,000 hertz sine wave to the DGC-1000 MPU inputs (terminals P32 and P33). Step 3. Press the Run switch on the front panel. Step 4. Slowly increase the frequency to the DGC-1000 MPU input until an overspeed shutdown occurs. Step 5. Verify shutdown occurs within 4,158 83 hertz (1,980 38 RPM). Step 6. Verify that the DGC-1000 display indicates GEN OVERSPEED ALARM and that only the Alarm output contacts are closed. Step 7. Remove the voltages. Step 8. Press the Off switch on the front panel and verify that the DGC-1000 resets to the Ready mode and that all output contacts open. Low Oil Pressure Step 1. Apply in parallel 120 Vac to phase A to neutral (terminals P34 and P37), phase B to neutral (terminals P35 and P37), and phase C to neutral (terminals P36 and P37). Step 2. Press the Run switch on the front panel. Step 3. Wait ten seconds after crank disconnect. Increase the resistance across the Oil Pressure sender input (terminals P38 and P2) until a Pre-alarm occurs. Step 4. Verify that the DGC-1000 display value is 25 2 PSI when Pre-alarm occurs. DGC-1000 Testing 5-7

Step 5. Verify that the DGC-1000 displays an alternately flashing dark field in the oil pressure location and that the Pre-alarm output contact has closed. Step 6. While monitoring displayed oil pressure, further increase the resistance across the Oil Pressure sender input until a low oil pressure shutdown occurs. NOTE Oil Pressure displayed value is 0 below 15 PSI. Step 7. Verify that the DGC-1000 displayed value is within 0 to 17 PSI when shutdown occurs. Step 8. Verify that the DGC-1000 display indicates LOW OIL PRESSURE ALARM and that only the Alarm output contacts are closed. Step 9. Remove the voltage and return the resistance to 60 ohms. Step 10. Press the Off switch on the front panel and verify that the DGC-1000 resets to the Ready mode and that all output contacts open. High Coolant Temperature Step 1. Apply in parallel 120 Vac to phase A to neutral (terminals P34 and P37), phase B to neutral (terminals P35 and P37), and phase C to neutral (terminals P36 and P37). Step 2. Press the Run switch on the front panel. Step 3. Wait 60 seconds after crank disconnect. Decrease the resistance across the Coolant Temperature sender input (terminals P40 and P2) until a Pre-alarm occurs. Step 4. Verify that the DGC-1000 display value is 250 5 degrees when Pre-alarm occurs. Step 5. Verify that the DGC-1000 displays an alternately flashing dark field in the coolant temperature location and that the Pre-alarm output contact has closed. Step 6. While monitoring displayed coolant temperature, further decrease the resistance across the Coolant Temperature sender input until an over temperature shutdown occurs. Step 7. Verify that the DGC-1000 displayed value is 275 6 degrees when shutdown occurs. Step 8. Verify that the DGC-1000 indicates OVER TEMP ALARM and that only the Alarm and Pre-alarm output contacts are closed. Step 9. Remove the voltage and return the resistance to 100 ohms. Step 10. Press the Off switch on the front panel and verify that the DGC-1000 resets to the Ready mode and that all output contacts open. Emergency Stop Step 1. Apply in parallel 120 Vac to phase A to neutral (terminals P34 and P37), phase B to neutral (terminals P35 and P37), and phase C to neutral (terminals P36 and P37). Step 2. Press the Run switch on the front panel. Step 3. Open the contact across the Emergency Stop inputs (terminals P17 and P18). Step 4. Verify that the DGC-1000 indicates EMERGENCY SHUTDOWN SWITCH PRESSED and that all output contacts are open. Step 5. Reapply the contact closure across the Emergency Stop inputs. Step 6. Press the Off switch on the front panel and verify that the DGC-1000 resets to the Ready mode and that all output contacts open. Step 7. Remove the voltage. Low Coolant Level Step 1. Apply in parallel 120 Vac to phase A to neutral (terminals P34 and P37), phase B to neutral (terminals P35 and P37), and phase C to neutral (terminals P36 and P37). Step 2. Press the Run switch on the front panel. Step 3. Close the Low Coolant Level contact. Step 4. Verify that the DGC-1000 indicates LOW COOLANT LEVEL and that the Alarm contact is closed. Step 5. Open the Low Coolant Level contact. 5-8 DGC-1000 Testing

Step 6. Press the Off switch on the front panel and verify that the DGC-1000 resets to the Ready mode and that all output contacts open. Step 7. Remove the voltage. Low Fuel Level Step 1. Apply 30 ohms across the Fuel Level transducer input (terminals P39 and P2). Step 2. Press the Display/toggle pushbutton to enter the alternate display mode, and press the Raise/Scroll pushbutton to access the Fuel Level quantity screen. Verify that the DGC-1000 displayed value is 100%. Step 3. Increase the resistance until the LOW FUEL alarm occurs. Verify that only the alarm contact closes. Step 4. Slowly decrease the resistance until the DGC-1000 resets to the Ready mode. Verify that all output contacts are open and the resistance is 2365 ohms. This completes the Test Procedures.

DGC-1000 Testing

5-9

SECTION 6 DGC-1000 BESTCOMS SOFTWARE

GENERAL
BESTCOMS-DGC-1000-32 Software is an application that enhances communication between the personal computer (PC) user and the DGC-1000. BESTCOMS-DGC-1000-32 Software (hereinafter called BESTCOMS) provides a user friendly environment for changing DGC-1000 settings. The interface software also allows users to save the current setting configurations and data information to a disk. Users can save multiple setups for later use which saves setup time when configuring multiple units. Without BESTCOMS, users must be familiar with the limited functional operations at the DGC-1000 front panel.

INSTALLATION
BESTCOMS software contains a setup utility that installs the program on your PC. When it installs the program, an uninstall icon is created that you may use to uninstall (remove) the program from your PC. The minimum operating requirements are listed in the following paragraph. Operating Requirements To use DGC-1000 Windows software, you will need the following: IBM compatible PC, 486DX2 or faster, and a minimum of four megabytes of RAM Microsoft Windows 95, 98, or NT. 3.5 inch floppy drive RS-232 Serial port and cable to connect the PC and DGC-1000

Installing The Program On Your PC With Windows 95 1. Insert disk 1 in the 3.5 inch floppy drive 2. From the Task Bar select Start then Run 3. Enter a:\Setup.exe and press enter or click on Browse and select the A: drive and double click Setup.exe. Configuring The System Communication with a DGC-1000 unit can be done by a direct cable connection or through a modem. The installation section of the manual has the RS-232 serial link connection pinouts. For a direct connection use a standard RS-232 cable.

DGC-1000 BESTCOMS Software

6-1

INITIALIZING COMMUNICATIONS WITH THE BESTCOMS SOFTWARE

Select the DGC-1000 icon from Program Manger or select DGC-1000 under the Basler Electric directory under Programs in the Start Menu. A momentary dialog box (splash screen) opens that displays the Basler Electric Logo, program name, and revision identification. After the splash screen the initial screen (Figure 6-1) will follow. Pull down the Communications menu select Open and then RS232. This will open the Comm Port screen like the one shown in Figure 6-2.

Figure 6-1. Initial Screen

Figure 6-2. Comm Port Screen This screen shows the current communication parameters. If these are correct, select the appropriate comm port and press the Initialize button. If the port is available, the Logon Password screen (Figure 6-3) appears. Type in your password and press OK. If you press Cancel the comm port will be closed and you will have to initialize communications again. If the communication parameters shown on the Comm Port screen are incorrect, see the following paragraphs on Changing The Programs Communication Parameters.

6-2

DGC-1000 BESTCOMS Software

NOTE The default Limited Access password is DGC and the default Full Access password is DGC-1000. Passwords are case sensitive.

Figure 6-3. Password

CHANGING THE PROGRAMS COMMUNICATION PARAMETERS

You do not have to be logged onto a DGC unit in order to change the PC communications parameters. To change the communications parameters, pull down the Configure menu and select RS232. This will bring up the screen shown in Figure 6-4. When you are logged onto a unit and change a parameter, by selecting Save you are saving the changes both to the PC and to the DGC unit. When not logged onto the DGC unit, the parameters are only saved to the PC.

NOTE To change the communications parameters in the DGC, you must be logged on and have full password access.

Figure 6-4. Communications Configure Screen DGC-1000 BESTCOMS Software 6-3

CHANGING LOGON PASSWORDS

To change Logon passwords you must be currently logged onto a DGC unit. Pull down the Communication menu and select Change Password. When this is done, the Change Password (Figure 6-5) screen will appear. There are two option buttons on the top of the screen. Select the level of the password you wish to change. Enter the new password in the first text box and repeat it again in the bottom text box. After entering the new password, press the OK button. If both passwords that you entered match, the new password is sent to the DGC.

NOTE Passwords are case sensitive. If you logged in with the limited access password, you are only allowed to change the limited access password.

Figure 6-5. Change Password

CHANGING SETTINGS
Settings are arranged in five groups. Sensing Transformers Pre-Alarms Alarm Crank System Auxiliary I/O Modem

To change settings, you must first select the screen associated with the setting. When you are logged on with the limited access password, you can see all of the current settings in the unit but cannot change all of them. The settings that can not be changed will be disabled so that you can not select them. Double clicking on any white rectangular box will allow you to change (if allowed) that setting. Once all of the settings have been entered, pull down the Communications menu and select Send to DGC. This will send the settings to the DGC and verify them.

MENUS
File Menu 1) 2) 3) New Starts a new settings file and loads the default settings into the file. Open - Opens a saved settings file from a disk. Save - Saves the current settings to a file on a disk. The file will be saved with the extension .dgc. DGC-1000 BESTCOMS Software

6-4

4) 5) 6) 7)

Save As Saves an opened settings file to a new file on a disk. Properties Allows the user to set a GenSet ID, GenSet Serial Number, and file comments to a settings file. See Figure 6-6. Print - Used to print a hard copy of the settings file. Exit - Used to exit the program.

Figure 6-6. Properties Screen Communications Menu 1) 2) 3) 4) 5) 6) Open - Used to initiate communications with the DGC-1000. Close - Used to terminate communications with the DGC-1000. Send to DGC - Used to send the settings to the DGC-1000. Get from DGC - Used to retrieve the present settings from the DGC-1000. Remote Start/Stop Used to start and stop the engine when the DGC-1000 is in AUTO. Change Password - Used to change the logon passwords. The current level of access determines which passwords may be changed.

Screens Menu 1) 2) 3) 4) 5) 8) 9) 10) Sensing Transformers settings - Used to program the sensing transformer ratings. Pre-Alarms settings - Used to program pre-alarm settings. Alarm settings- Used to program alarm settings. Crank settings - Used to program engine cranking settings. System settings - Used to program system parameters. Input/Output settings Used to program the auxiliary input and output settings. Modem settings Used to program the modem settings. Metering settings Used to program the metering settings.

Configure Menu 1) RS232 - Used to program the communication settings.

Metering Menu 1) Enable Metering Used to enable or disable metering when the program is logged onto a DGC-1000.

Help Menu 1) About - Displays current software version number.

DGC-1000 BESTCOMS Software

6-5

SETTINGS DEFINITIONS
Definitions for all of the available settings are provided in the following paragraphs. Sensing Transformers Settings Refer to Figure 6-7 for the Sensing Transformers Settings screen. Generator PT Primary Volts - Rating of the primary side of transformer used to sense generator voltage. Generator PT Secondary Volts - Rating of secondary side of transformer used to sense generator voltage. Generator CT Primary Amps - Rating of primary side of transformer used to sense generator current.

Figure 6-7. Sensing Transformers Screen

6-6

DGC-1000 BESTCOMS Software

Low Fuel, Low Cool Temperature And Battery Over Voltage Pre-Alarm Settings Refer to Figure 6-8 for the Low Fuel, Low Cool Temperature and Battery Over Voltage Pre-Alarm Settings screen. Low Fuel Pre-Alarm 1) 2) 1) 2) 1) 2) Enable - Used to enable or disable the annunciation of the pre-alarm. Threshold - Pre-Alarm will sound when the fuel level drops below this set level. Enable - Used to enable or disable the annunciation of the pre-alarm. Threshold - Pre-Alarm will sound when the coolant temperature falls below this level. Enable - Used to enable or disable the annunciation of the pre-alarm. Threshold - Non-adjustable. Threshold is 30 volts for a 24 volt system and 15 volts for a 12 volt system.

Low Cool Temperature Pre-Alarm

Battery Over Voltage Pre-Alarm

Figure 6-8. Low Fuel, Low Cool Temperature, And Battery Over Voltage Pre-Alarm Settings Screen DGC-1000 BESTCOMS Software 6-7

Maintenance Interval, Engine kW Over Load, And Hi Coolant Temperature Pre-Alarm Settings Refer to Figure 6-9 for Maintenance Interval, Engine kW Over Load, And Hi Coolant Temperature PreAlarm Settings screen. Maintenance Interval Pre-Alarm 1) 2) 1) 2) 1) 2) Enable - Used to enable or disable the annunciation of the pre-alarm. Threshold - Sets the amount of time in hours that the next maintenance interval is due. Enable - Used to enable or disable the annunciation of the pre-alarm. Threshold - Sets the kilowatt level for the generator that will sound the pre-alarm. Enable - Used to enable or disable the annunciation of the pre-alarm. Threshold - Pre-Alarm will sound when the coolant temperature rises above this level.

Engine kW Over Load Pre-Alarm

Hi Coolant Temperature Pre-Alarm

Figure 6-9. Maintenance Interval, Engine kW Over Load, And Hi Coolant Temperature Screen 6-8 DGC-1000 BESTCOMS Software

Low Oil Pressure, Low And Weak Battery Voltage Pre-alarm Settings Refer to Figure 6-10 for the Low Oil Pressure, Low Battery Voltage, And Weak Battery Voltage Pre-alarm Settings screen. Low Oil Pressure Pre-Alarm 1) 2) 1) 2) 1) 2) Enable - Used to enable or disable the annunciation of the pre-alarm. Threshold - Pre-Alarm will sound when the Oil Pressure falls below this level. Enable - Used to enable or disable the annunciation of the pre-alarm. Threshold - Pre-Alarm will sound when the Battery Voltage falls below this level. Enable - Used to enable or disable the annunciation of the pre-alarm. Threshold - Pre-Alarm will sound when the Battery Voltage falls below this level during cranking. This is a latching type Pre-Alarm and must be reset from the front panel.

Low Battery Voltage Pre-Alarm

Weak Battery Voltage Pre-Alarm

Figure 6-10. Low Oil Pressure, Low And Weak Battery Voltage Pre-alarm Settings Screen DGC-1000 BESTCOMS Software 6-9

Audible And Battery Charger Failure Pre-Alarm Settings Refer to Figure 6-11 for the Audible and Battery Charger Failure Pre-Alarm Settings screen. Audible Alarm 1) 1) Enable - Used to enable or disable the horn on the DGC-1000. Enable - Used to enable or disable the external contact to indicate the battery charger has failed. Battery Charger Failure Pre-Alarm

Figure 6-11. Audible And Battery Charger Failure Pre-Alarm Settings Screen

6-10

DGC-1000 BESTCOMS Software

Hi Cool Temperature, Low Oil Pressure, And Low Fuel Level Alarm Settings Refer to Figure 6-12 for the Hi Cool Temperature And Low Oil Pressure Alarm Settings screen. Hi Cool Temperature Alarm 1) 2) 3) Enable - Used to enable or disable the annunciation of the alarm. Threshold - Sets the threshold level for the coolant temperature. Arming Delay Not adjustable - After the coolant temperature is above the threshold for 60 seconds, the engine will be shutdown. Enable - Used to enable or disable the annunciation of the alarm. Threshold - Sets the threshold level for low oil pressure before engine shutdown occurs. Arming Delay - Sets the amount of time delay, after crank disconnect, before the Oil Pressure Alarm becomes active. Enable - Used to enable or disable the annunciation of the alarm. Threshold - Sets the threshold level for low fuel level alarm.

Low Oil Pressure Alarm 1) 2) 3)

Low Fuel Level Alarm 1) 2)

Figure 6-12. Hi Cool Temperature And Low Oil Pressure Alarm Settings Screen DGC-1000 BESTCOMS Software 6-11

Overspeed And Sender Failure Alarm Settings Refer to Figure 6-13 for the Overspeed And Sender Failure Alarm Settings screen. Overspeed Alarm 1) 2) 3) Alarm Enable - Used to enable or disable the annunciation of the alarm. Threshold - Sets the threshold level for engine speed, before shutdown occurs. Alarm Activation - Sets the amount of time the engine speed must be above the threshold before the engine is shutdown. Cool Temp. Send Fail Alarm On/Off - Used to turn On or turn Off the alarm function. Cool Temp Alarm Delay - Sets the amount of time the signal must be lost before the engine is shutdown. Oil Press. Sender Fail Alarm On/Off - Used to turn On or turn Off the alarm function. Loss of Gen. Voltage Alarm On/Off - Used to turn On or turn Off the alarm function. Global Sender Failure Alarm Time Delay (Sec) - Sets the amount of time any of the signals (Oil Pressure, Loss of Generator Voltage, or Speed Sender Failure) must be lost before the engine is shutdown.

Sender Failure Alarm 1) 2) 3) 4) 5)

Figure 6-13. Overspeed And Sender Failure Alarm Settings Screen 6-12 DGC-1000 BESTCOMS Software

Crank Settings Refer to Figure 6-14 for the Crank Settings screen. Cranking Style Used to select either the continuous or cycle cranking methods. Crank Disconnect Limit (% of Rated) Used to select the engine speed above which the cranking process will be terminated. Pre-Crank Delay (Sec) Used to select the time between initiating engine start and actual beginning of engine cranking. Pre-Start Contact After Disconnect Used to select whether or not the pre-crank contact will remain closed after disconnect occurs. Cycle 1) 2) 3) Number of Crank Cycles - Used to select the number of times the engine may be cranked before an overcrank condition occurs. (Available only if Cycle Cranking is selected.) Cycle Crank Time (Sec) - Used to select the duration of each crank attempt for cycle cranking. Continuous Crank Time (Sec) - Used to select the duration of the single crank attempt before an overcrank condition occurs. (Available only if Continuous Cranking is selected.)

Figure 6-14. Crank Settings Screen DGC-1000 BESTCOMS Software 6-13

System Settings Refer to Figure 6-15 for the System Settings screen. 1) 2) 3) 4) 5) 6) 7) 8 9) 10) 11) 12) 13) Gensets kW Rating - Used to enter the generators kilowatt load rating. No Load Cool Down Time - Used to select the time between the generators load being removed and when the engine actually stops on a remote shutdown. Rated Engine RPM - Used to enter the engines rated RPM. Battery Volts - Used to select the systems starting batterys nominal voltage. NFPA Level - Used to select whether or not NFPA requirements are in effect. # Flywheel Teeth - Used to enter the number of teeth on the engines flywheel. Generator Speed Mode - Used to select which sources are available for calculating engine speed. Generator Connection - Used to select the generator connection scheme. Generator Frequency - Used to select the generator rated output frequency. Unit System - Used to select English or Metric unit system for PC settings and front panel display on DGC-1000. Generator Rotation - Used to select either ABC or ACB phase rotation. Embedded Software Version - Shows the DGC-1000 embedded software version. You must be logged onto a DGC unit for this function to be operational. Maintenance Interval Timer Reset - Used to terminate the Maintenance Due pre-alarm and reset the maintenance interval timer back to the programmed level. This is done when logged onto a DGC-1000 by clicking the box so that a check mark is displayed, then open the Communications menu and select Send to DGC. After the command is sent to the DGC the box is cleared. Total kW Hours Reset - used to reset the kilowatt hours to zero. This is done when logged onto a DGC-1000 by clicking the box so a check mark is displayed, then open the Communications menu and select Send to DGC. After the command is sent to the DGC the box is then cleared.

14)

Figure 6-15. System Settings Screen

6-14

DGC-1000 BESTCOMS Software

Auxiliary Input Contact Setup Refer to Figure 6-16 for the Auxiliary Input And Output Contact Setup screen. Aux Input #1 1) 2) 1) 2) 1) 2) 1) 2) Input Label - Used to set the user programmable label for the specific input. Alarm/Pre-Alarm Used to select the input as either an alarm or pre-alarm. Input Label - Used to set the user programmable label for the specific input. Alarm/Pre-Alarm Used to select the input as either an alarm or pre-alarm. Input Label - Used to set the user programmable label for the specific input. Alarm/Pre-Alarm Used to select the input as either an alarm or pre-alarm. Input Label - Used to set the user programmable label for the specific input. Alarm/Pre-Alarm Used to select the input as either an alarm or pre-alarm.

Aux Input #2

Aux Input #3

Aux Input #4

Figure 6-16. Auxiliary Input Contact Setup Screen DGC-1000 BESTCOMS Software 6-15

Auxiliary Output Setup Refer to Figure 6-17 for the Auxiliary Output Setup screen. There are eight sets of output contacts. Each of the eight outputs can be programmed to close when any of the selected inputs is active. Also, multiple outputs can be programmed to close when one input is active. Use the vertical scroll bar to scroll through all of the input selections.

Figure 6-17. Auxiliary Output Setup Screen

Modem Communications Setup If this option is installed on your DGC-1000, the DGC-1000 can dial an alphanumeric pager when any of the selected inputs has been activated. Figure 6-18 shows the Modem Communications Setup screen. NOTE It is very important to log off of the DGC-1000 after set-up is completed. When you are logged on, the dial-in or dial-out functions are disabled. When a fault occurs for which dial-out has been programmed, the modem will dial out and send a message. During the dial-out time, neither dial-in nor local RS-232 access is available. Access is available after the message has been sent or during the modem offline delay. If no access is allowed, removing the fault and cycling the power to the DGC1000 resets the DGC-1000 and allows access. 1) Phone Number #1 through #4 These numbers are the phone numbers that the DGC1000 dials when the selected input is activated. The numbers are dialed in sequence until a connection is made. DGC-1000 BESTCOMS Software

6-16

2) 3) 4) 5)

Site Information This programmable label identifies the source of the pager message. It is sent to the pager when the dial-out connection is made. Pager ID Number These numbers identify the specific pager that is being addressed when the corresponding phone number is dialed by the DGC-1000. Inter Dial-out Time Delay This delay is the amount of time between dial-out attempts. This delay allows time for the modem to reset. Pager Buffer Limit This limit should be set to match (equal to or less than) the specific pager buffer size. If the message length exceeds that which is allowed, another call is made and the message continues. Pager Communications Data Format This setting controls the data format for the dialout modem. Telelocator alphanumeric protocol (TAP Version 1.7) is implemented in the DGC-1000 for communications with a pager. The protocol specifies seven data bits with even parity. Some pager companies may use eight data bits and no parity. Rings For Modem Answer This is the number of rings allowed before the modem picks up the line and negotiates a connection. The number of rings is to provide time for an operator to answer the phone before the modem picks up. Operating the system in this manner allows a telephone to share a line with a modem. Modem Off-line Delay This is the amount of time allowed between dial-out attempts should a dial-out attempt fail. This allows time for a user to dial into the DGC-1000.

6)

7)

8)

Figure 6-18. Modem Communication Setup Screen DGC-1000 BESTCOMS Software 6-17

Modem Dial-Out Conditions This screen (Figure 6-19) selects which event will cause the DGC-1000 to perform the dial-out function. To view the entire list of events, use the vertical scroll bar to scroll through the event list.

Figure 6-19. Modem Dial-Out Condition Screens 6-18 DGC-1000 BESTCOMS Software

Metering DGC-1000 Windows software provides a means to monitor the metering data and alarm status. The metering data and the alarm status are refreshed approximately every 1.5 seconds. Summary The metering is separated into six different screens. There is one screen, Summary, that shows all the available metering values from the DGC-1000 (Refer to Figure 6-20). The other five screens have a detailed subset of these metering values available. To enable metering you must be logged onto a unit and then open the Metering menu and select enable metering. If you are not on the metering screen the program will change to the metering screen and start updating the values. When metering is disabled all of the metering screens will be grayed out showing they are inactive.

Figure 6-20. Metering Screen DGC-1000 BESTCOMS Software 6-19

Alarms The pre-alarms and alarms are all shown on one screen (refer to Figure 6-21). When a pre-alarm becomes active the LED next to the name of the pre-alarm will be green. A description of the alarm will be shown on top of the screen and the computer speaker will begin to beep. The label on top of the screen will contain the same alarm until it goes away and then it will show the next pre-alarm going down the list that is active. When an alarm becomes active the LED next to the name of the alarm will be red. The screen will jump to the alarm tab and the computer speaker will begin to beep. If the alarm type is a Sender Failure the type of sender that failed will be indicated in the Sender Failure type area.

Figure 6-21. Metering - Alarms Screen The top portion of the screen contains icon buttons for New File, File Open, Save File, Print File and a button for each screen. Refer to Figure 6-22. New File - Overwrites the current settings with default settings as a starting point. File Open - Open a currently saved settings file. File Save - Saves the settings that are being edited to a settings file. Print File - Prints a hard copy of the settings.

Figure 6-22. Metering Screen Icons 6-20 DGC-1000 BESTCOMS Software

The Generator Status gives the last received state of the generator if you are logged on. When metering is enabled this is updated continuously along with the other meter readings. When metering is disabled it only checks the generator status when another communication event happens, i.e. logon, send settings, or get settings. Emergency Stop button - This button is used to shut the generator down in an emergency. You must be logged onto the DGC for this button to be active. When this button is selected it will change into an Emergency Reset button.

DGC-1000 BESTCOMS Software

6-21

APPENDIX A DGC-1 000 SETTINGS RECORD

INTRODUCTION
This appendix provides a complete listing of all DGC-1000 settings. This listing is in the form of a settings record that you may use to record information relative to your system. These settings sheets may be removed and photo copied.

DGC-1000 Appendix

A-1

DGC-1000 SETTINGS RECORD

Genset ID DGC-1000 Serial Number Date Software Version Number

Parameter
FREQUENCY BATTERY VOLTAGE UNITS NFPA LEVEL SENSING CONNECTION PARITY BAUD RATE ADDRESS GENERATOR PT PRIMARY GENERATOR PT SECONDARY GENERATOR CT PRIMARY FLYWHEEL TEETH RATED RPM COOLDOWN TIME GENERATOR RATING ALTERNATOR FREQUENCY SPEED SIGNAL SOURCE PHASE ROTATION OVERSPEED ALARM THRESHOLD DELAY HIGH COOLANT TEMP ALARM THRESHOLD DELAY HIGH COOLANT TEMP PRE-ALARM THRESHOLD ARMING DELAY

User Setting

A-2

DGC-1000 Appendix

Parameter
LOW OIL PRESSURE ALARM THRESHOLD ARMING DELAY LOW OIL PRESSURE PRE-ALARM THRESHOLD ARMING DELAY LOW COOLANT TEMPERATURE PRE-ALARM THRESHOLD ARMING DELAY LOW FUEL LEVEL ALARM THRESHOLD LOW FUEL LEVEL PRE-ALARM THRESHOLD WEAK BATTERY PRE-ALARM THRESHOLD ACTIVATION DELAY LOW BATTERY PRE-ALARM THRESHOLD ACTIVATION DELAY BATTERY OVERVOLTAGE PRE-ALARM THRESHOLD BATTERY CHARGER FAILURE PRE-ALARM

User Setting

DGC-1000 Appendix

A-3

Parameter
UNIT IDENTIFICATION NUMBER

User Setting

GLOBAL SENDER FAILURE ALARM ARMING DELAY GLOBAL PRE-ALARM BUZZER MAINTENANCE INTERVAL PRE-ALARM THRESHOLD ENGINE KILOWATT OVERLOAD PRE-ALARM THRESHOLD CRANKING STYLE CRANK CYCLES CYCLE CRANK TIME CONTINUOUS CRANK TIME PRE-CRANK DELAY PRE-START CONTACT AFTER DISCONNECT CRANK DISCONNECT SPEED SAFE RESTART SPEED AUXILIARY INPUT # 1 AUXILIARY INPUT # 2 AUXILIARY INPUT # 3 AUXILIARY INPUT # 4

A-4

DGC-1000 Appendix

INDEX
A
Alarms ............................................. 3-7, 6-20 Alarm Settings Hi Cool Temperature .......................... 6-11 Low Fuel Level ................................... 6-11 Low Oil Pressure ................................ 6-11 Overspeed.......................................... 6-12 Sender Failure.................................... 6-12 ALLOWABLE KEY CODE ...................... 3-21 Alternate Display Mode .......................... 3-20 Analog To Digital Converter ..................... 3-4 Auxiliary Input And Output Assembly ....... 2-4 Auxiliary Inputs And Outputs .................... 1-1

F
FACTORY SETTINGS ........................... 3-20 FEATURES .............................................. 1-1 Formulas .................................................. 3-3 Frequency ................................................ 1-3 FRONT PANEL DISPLAY ........................ 2-1 Functional Block Diagram ........................ 3-1 functional description................................ 3-1 FUNCTIONS ............................................ 1-1

H
Hardware........................................... 1-5, 4-1

B
Battery Operating Voltage ........................ 3-2

I
INITIALIZING COMMUNICATIONS ......... 6-2 INPUTS .................................................... 3-2

C
Calculated Data........................................ 1-4 changing parameters ........................................... 6-3 passwords ............................................ 6-4 Settings ................................................ 6-4 Communication settings ........................... 4-8 CONNECTIONS................................ 2-2, 4-3 Connections .................................................. rear panel ............................................. 2-2 Contact sensing inputs optional................ 3-3 Contact Sensing Inputs ............................ 3-2 continuous cycle....................................... 3-6 Cooldown Timer ....................................... 3-5 crank cycle ............................................... 3-6 Current Inputs........................................... 3-3 Cutout Dimensions ................................... 4-1

L
Ladder Diagram 4-7

M
Menu 1 ................................................... 3-11 Menu 2 ................................................... 3-14 Menu 3 ................................................... 3-15 Menu 4 ................................................... 3-17 Menu Display Modes .............................. 3-10 Menu Mode .............................................. 3-9 MENUS .................................................... 6-4 Metering ................................................. 6-19 MICROPROCESSOR............................... 3-3 Modem Problems ..................................... 3-5 Modifying Setpoints ................................ 3-19 MOUNTING.............................................. 4-1

D
Dial-Out Modems ..................................... 1-2 Display Modes.......................................... 3-9 Display Toggle.......................................... 3-9

N
Normal Mode............................................ 3-9

E
Emergency Stop button.......................... 6-21 Emergency Stop Contact Input Interaction ................................................ 3-4 Engine Crank Curves ............................... 3-6 Engine System Inputs .............................. 1-3 Enhanced Communications ..................... 1-2

O
Optional Auxiliary Outputs........................ 3-5 Optional Contact Sensing Inputs .............. 3-3 OPTIONAL EQUIPMENT ......................... 1-1 Output Contacts ....................................... 1-4 OUTPUTS ......................................... 1-1, 3-4 Overall Dimensions .................................. 4-2

Equipment Required ..........................5-1

Exiting Menu Mode................................. 3-18

DGC-1000 Index

I-1

P
Parameters all 3-21 front panel adjustable ......................... 3-21 password default .................................................. 6-3 Password ................................................. 6-2 Pre-Alarm Settings Audible ............................................... 6-10 Battery Charger Failure ...................... 6-10 Battery Overvoltage.............................. 6-7 Engine kW Over Load .......................... 6-8 Hi Coolant Temperature ....................... 6-8 Low And Weak Battery Voltage............ 6-9 Low Fuel............................................... 6-7 Low Oil Pressure .................................. 6-9 Maintenance Interval ............................ 6-8 Pre-Alarm Settings Low Cool .............................................. 6-7 Phase Toggle .......................................... 3-9 Phone Modem Type of Service .................................... 3-5 PHONE MODEMS ................................... 3-5 Power-Up Sequence ................................ 3-9 Pre-Alarms ............................................... 3-8

T
TEST PROCEDURE CRANKING .......................................... 5-6 INITIAL ................................................. 5-1 METERING .......................................... 5-3 PROTECTIVE FUNCTION ................... 5-7 Testing Transducer Inputs .................................... 3-2

U
UL Recognized......................................... 1-5

V
Voltage Inputs .......................................... 3-3 Voltage Sensing Inputs ............................ 1-3

Z
Zero Crossing Detection........................... 3-4

R
Rear Panel ............................................... 2-3 Remote Annunciation Display Panel ........ 1-2 Remote Display Panel.............................. 3-4 RMS To DC Converter ............................. 3-4 RS-232 connector .................................... 4-8

S
Serial Communications Input ................... 3-3 Settings Crank.................................................. 6-13 FACTORY .......................................... 3-20 Sensing Transformers .......................... 6-6 System ............................................... 6-14 SETTINGS DEFINITIONS........................ 6-6 Setup Auxiliary Input..................................... 6-15 Auxiliary Output .................................. 6-16 Modem Communicatons .................... 6-16 Modem Dial-Out ................................. 6-18 setup utility ............................................... 6-1 Signal Switching ....................................... 3-4 SOFTWARE ............................................. 3-5 Software BESTCOMS-DGC-1000-32.................. 6-1 Operating Requirements ...................... 6-1 SPECIFICATIONS ................................... 1-3 Speed Signal Inputs ................................. 3-3 Speed Source Failure............................... 3-6 STYLE NUMBER ..................................... 1-2 Style Number Identification Chart............. 1-2

I-2

DGC-1000 Index

ROUTE 143, BOX 269 HIGHLAND, IL 62249 USA http://www.basler.com, info@basler.com PHONE 618-654-2341 FAX 618-654-2351