DGC-2020HD

Digital Genset Controller

Installation Instruction Manual

12570 Route 143 • Highland, Illinois 62249-1074 USA Publication

Tel +1 618.654.2341 • Fax +1 618.654.2351 9469300994, Rev F
[Link] • info@[Link] August 2021
 WARNING: California's Proposition 65 requires special warnings for
products that may contain chemicals known to the state of California to
cause cancer, birth defects, or other reproductive harm. Please note that
by posting this Proposition 65 warning, we are notifying you that one or
more of the Proposition 65 listed chemicals may be present in products
we sell to you. For more information about the specific chemicals found
in this product, please visit [Link]
9469300994 i

Preface
This instruction manual provides information about the installation of the DGC-2020HD Digital Genset
Controller. To accomplish this, the following information is provided:
• Mounting
• Terminals and connectors
• Typical applications
• Power input
• Voltage and current sensing
• Speed signal inputs
• Specifications
• Maintenance and troubleshooting

Conventions Used in this Manual

Important safety and procedural information is emphasized and presented in this manual through
Warning, Caution, and Note boxes. Each type is illustrated and defined as follows.

Warning!

Warning boxes call attention to conditions or actions that may cause

personal injury or death.

Caution
Caution boxes call attention to operating conditions that may lead to
equipment or property damage.

Note
Note boxes emphasize important information pertaining to Digital
Genset Controller installation or operation.

DGC-2020HD Instruction Manual Catalog

Available instruction manuals for the DGC-2020HD are listed in Table 1.
Table 1. Instruction Manuals
Part Number Description
9469300993 Quick Start
9469300994 Installation (this manual)
9469300995 Configuration
9469300996 Operation
9469300997 Accessories
9469300998 Modbus® Protocol

DGC-2020HD Preface
ii 9469300994

12570 State Route 143

Highland IL 62249-1074 USA
[Link]
info@[Link]
Tel: +1 618.654.2341
Fax: +1 618.654.2351

© 2021 by Basler Electric

All rights reserved
First printing: October 2016

Warning!

READ THIS MANUAL. Read this manual before installing, operating, or maintaining the DGC-2020HD.
Note all warnings, cautions, and notes in this manual as well as on the product. Keep this manual with
the product for reference. Only qualified personnel should install, operate, or service this system.
Failure to follow warning and cautionary labels may result in personal injury or property damage.
Exercise caution at all times.

Caution
Installing previous versions of firmware may result in compatibility issues causing the inability to
operate properly and may not have the enhancements and resolutions to issues that more recent
versions provide. Basler Electric highly recommends using the latest version of firmware at all times.
Using previous versions of firmware is at the user’s risk and may void the warranty of the unit.

Basler Electric does not assume any responsibility to compliance or noncompliance with national code, local code,
or any other applicable code. This manual serves as reference material that must be well understood prior to
installation, operation, or maintenance.

For terms of service relating to this product and software, see the Commercial Terms of Products and Services
document available at [Link]/terms.
This publication contains confidential information of Basler Electric Company, an Illinois corporation. It is loaned for
confidential use, subject to return on request, and with the mutual understanding that it will not be used in any
manner detrimental to the interests of Basler Electric Company and used strictly for the purpose intended.
It is not the intention of this manual to cover all details and variations in equipment, nor does this manual provide
data for every possible contingency regarding installation or operation. The availability and design of all features
and options are subject to modification without notice. Over time, improvements and revisions may be made to this
publication. Before performing any of the following procedures, contact Basler Electric for the latest revision of this
manual.
The English-language version of this manual serves as the only approved manual version.

Preface DGC-2020HD
9469300994 iii

This product contains, in part, open source software (software licensed in a way that ensures freedom to run,
copy, distribute, study, change, and improve the software) and you are granted a license to that software under the
terms of either the GNU General Public License or GNU Lesser General Public License. The licenses, at the time
of sale of the product, allow you to freely copy, modify, and redistribute that software and no other statement or
documentation from us, including our End User License Agreement, places any additional restrictions on what you
may do with that software.
For at least three (3) years from the date of distribution of this product, a machine-readable copy of the complete
corresponding source code for the version of the programs distributed to you will be sent upon request (contact
information is provided above). A fee of no more than our cost of physically performing the source code distribution
is charged.
The source code is distributed in the hope that it will be useful, but WITHOUT ANY REPRESENTATION or
WARRANTY or even the implied warranty of MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE.
Refer to the source code distribution for additional restrictions regarding warranty and copyrights.
For a complete copy of GNU GENERAL PUBLIC LICENSE Version 2, June 1991 or GNU LESSER GENERAL
PUBLIC LICENSE Version 2.1, February 1999 refer to [Link] or contact Basler Electric. You, as a Basler
Electric Company customer, agree to abide by the terms and conditions of GNU GENERAL PUBLIC LICENSE
Version 2, June 1991 or GNU LESSER GENERAL PUBLIC LICENSE Version 2.1, February 1999, and as such
hold Basler Electric Company harmless related to any open source software incorporated in this product. Basler
Electric Company disclaims any and all liability associated with the open source software and the user agrees to
defend and indemnify Basler Electric Company, its directors, officers, and employees from and against any and all
losses, claims, attorneys' fees, and expenses arising from the use, sharing, or redistribution of the software.
Review the software website for the latest version of the software documentation.
Portions of this software are copyright © 2014 The FreeType Project ([Link]). All rights reserved.
The following statement applies only to the fontconfig library:

fontconfig/COPYING

Copyright © 2000,2001,2002,2003,2004,2006,2007 Keith Packard

Copyright © 2005 Patrick Lam
Copyright © 2009 Roozbeh Pournader
Copyright © 2008,2009 Red Hat, Inc.
Copyright © 2008 Danilo Šegan
Copyright © 2012 Google, Inc.

Permission to use, copy, modify, distribute, and sell this software and its documentation for any purpose is hereby
granted without fee, provided that the above copyright notice appear in all copies and that both that copyright
notice and this permission notice appear in supporting documentation, and that the name of the author(s) not be
used in advertising or publicity pertaining to distribution of the software without specific, written prior permission.
The authors make no representations about the suitability of this software for any purpose. It is provided "as is"
without express or implied warranty.

THE AUTHOR(S) DISCLAIMS ALL WARRANTIES WITH REGARD TO THIS SOFTWARE, INCLUDING ALL
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS, IN NO EVENT SHALL THE AUTHOR(S) BE
LIABLE FOR ANY SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES OR ANY DAMAGES WHATSOEVER
RESULTING FROM LOSS OF USE, DATA OR PROFITS, WHETHER IN AN ACTION OF CONTRACT,
NEGLIGENCE OR OTHER TORTIOUS ACTION, ARISING OUT OF OR IN CONNECTION WITH THE USE OR
PERFORMANCE OF THIS SOFTWARE.

DGC-2020HD Preface
iv 9469300994

Preface DGC-2020HD
9469300994 v

Revision History
A historical summary of the changes made to this instruction manual is provided below. Revisions are
listed in reverse chronological order.
Visit [Link] to download the latest hardware, firmware, and BESTCOMSPlus® revision
histories.
Instruction Manual Revision History
Manual
Change
Revision and Date
F, Aug-21 • Added support for firmware version 2.06.00 and BESTCOMSPlus version
4.05.00.
• Added “Installing previous firmware versions” caution box to Preface.
• Corrected terminal numbers in Table 2-8.
• Added description of Emergency Stop Input.
• Added EMI immunity connections for analog inputs.
• Removed Load Share Output current rating from Specifications.
E, Oct-19 • Removed Rev Letter from all pages
• Changed sequential numbering to sectional numbering
• Moved Instruction Manual Revision History into Preface
• Removed standalone Revision History chapter
D2, Apr-19 • Updated Proposition 65 statement
D1, Oct-18 • Added Proposition 65 statement
D, Jul-18 • Added style options for DIN Rail and Rear Panel mounting configurations.
• Removed “LCD is blank and all LEDs are flashing…” from
Troubleshooting chapter.
C, May-18 • Maintenance release
B, May-17 • Added support for firmware version 2.04.00 and BESTCOMSPlus version
3.17.00
• Added accuracies for Fuel Level Sensing, Coolant Temperature Sensing,
and Oil Pressure Sensing
• Updated EAC specs
• Added patent about load anticipation
A, Dec-16 • Updated UL Approval statement in the Specifications chapter
• Added Group Start and Group Stop Requests to the Troubleshooting
chapter
—, Oct-16 • Initial release

DGC-2020HD Revision History

vi 9469300994

Revision History DGC-2020HD

9469300994 vii

Contents
Mounting..................................................................................................................................................... 1-1
Terminals and Connectors ......................................................................................................................... 2-1
Typical Applications ................................................................................................................................... 3-1
Power Input ................................................................................................................................................ 4-1
Voltage and Current Sensing ..................................................................................................................... 5-1
Speed Signal Inputs ................................................................................................................................... 6-1
Specifications ............................................................................................................................................. 7-1
Maintenance ............................................................................................................................................... 8-1
Troubleshooting ......................................................................................................................................... 9-1

DGC-2020HD Contents
viii 9469300994

Contents DGC-2020HD
9469300994 1-1

1 • Mounting
DGC-2020HD controllers are delivered in sturdy cartons to prevent shipping damage. Upon receipt of a
unit, check the part number against the requisition and packing list for agreement. Inspect for damage,
and if there is evidence of such, immediately file a claim with the carrier and notify the Basler Electric
regional sales office or your sales representative.
If the device is not installed immediately, store it in the original shipping package in a moisture- and dust-
free environment.
DGC-2020HD controllers may be mounted in one of three configurations depending on style: Front Panel,
DIN Rail, or Rear Panel. These configurations are described in the following paragraphs.

Front Panel Configuration

Units with styles xNxxxxxxx and xTxxxxxxx are mounted through the panel. Four permanently attached
10-24 studs are provided for mounting. The front panel HMI is resistant to moisture, salt fog, humidity,
dust, dirt, and chemical contaminants and faces outward for easy access.

Hardware
The torque applied to the mounting hardware should not exceed 20 inch-pounds (2.2 newton meters).

Dimensions
For Front Panel mounting, panel cutting and drilling dimensions are shown in Figure 1-1. All dimensions
are shown in inches with millimeters in parenthesis.

Figure 1-1. Panel Cutting and Drilling Dimensions

DGC-2020HD Mounting
1-2 9469300994

In Figure 1-1, the horizontal drilling measurement of 10.75 inches has a tolerance of +0.01/–0.01 inches.
The horizontal cutout measurement of 10.38 inches has a tolerance of +0.04/–0 inches. The vertical
drilling measurement of 7.25 inches has a tolerance of +0.01/–0.01 inches. The vertical cutout
measurement of 6.88 inches has a tolerance of +0.04/–0 inches.

DIN Rail Configuration

Units with style xRxxxxxxx are mounted on DIN rails. In this configuration, the DGC-2020HD has no HMI.
The rear of the DGC-2020HD faces outward for convenient access to terminals and connections.

Hardware
Two DIN rails, one located above the other, are required for mounting the DGC-2020HD. One flange and
two set screws on the DGC-2020HD secure it to the DIN rails. The flange clips onto the upper rail and the
set screws attach to the bottom rail. See Figure 1-2 for flange and set screw locations.

Figure 1-2. DIN Rail Flange and Setscrew Locations for Style xRxxxxxxx
Use two steel Top Hat rails, 35 mm x 7.5 mm, that are a minimum of 13 inches (330 mm) in length. DIN
Rail mounting hardware should be spaced no more than 6 inches (152 mm) apart for proper support.
Using the supplied hex key, hand tighten set screws until they stop. Locking inserts help maintain set
screw tightness. Hand tightening is recommended to ensure proper locking insert performance.

Dimensions
DIN Rail mounting dimensions are shown in Figure 1-3. All dimensions are shown in inches with
millimeters in parenthesis.

Mounting DGC-2020HD
9469300994 1-3

Figure 1-3. DIN Rail Mounting Dimensions for Style xRxxxxxxx

Rear Panel
Units with style xPxxxxxxx are mounted flush against a panel. In this configuration, the DGC-2020HD has
no HMI. Four clearance holes are provided for mounting. The rear of the DGC-2020HD faces outward for
convenient access to terminals and connections.

Hardware
Use four #10 screws with appropriate hardware. The torque applied to the mounting hardware should not
exceed 20 inch-pounds (2.2 newton meters).

Dimensions
For Rear Panel mounting, panel drilling dimensions are shown in Figure 1-4. All dimensions are shown in
inches with millimeters in parenthesis.

DGC-2020HD Mounting
1-4 9469300994

Figure 1-4. Rear Panel Drilling Dimensions for Style xPxxxxxxx

Overall Dimensions
Overall dimensions are shown in Figure 1-5. All dimensions are shown in inches with millimeters in
parenthesis.

Mounting DGC-2020HD
9469300994 1-5

Figure 1-5. Overall Dimensions

DGC-2020HD Mounting
1-6 9469300994

Mounting DGC-2020HD
9469300994 2-1

2 • Terminals and Connectors

All DGC-2020HD terminals and connectors are located on the rear panel. DGC-2020HD terminals consist
of a mini-B USB jack, a DB-9 connector, Ethernet ports, plug-in connectors with spring clamp terminals,
and quarter-inch, male, quick-connect terminals.
Figure 2-1 illustrates the rear panel terminals. Locator letters in the illustration correspond to the terminal
block and connector descriptions in Table 2-1.

P4
A

CHASSIS GND
INPUT 15 45 51 CAN 1 LOW

INPUT 16
Not Used
INPUT 14 44 52 CAN 1 HIGH

BATT +
BATT −
P5

Eth 2
INPUT 13 43 53 SHIELD
INPUT 12 42 54 CAN 2 LOW
INPUT 11 41
46 47 48 49 50
C 55 CAN 2 HIGH
INPUT 10 40
INPUT 9 39 Rx

Eth 1
Eth 1
P3 INPUT 8 38 A B Tx
INPUT 7 37
INPUT 6 36 56 RS-485A
INPUT 5 35 D 57 RS-485B
INPUT 4 34 58 RS-485 SHIELD
INPUT 3 33 59 IRIG-B+
INPUT 2 32 60 IRIG-B−
INPUT 1 31 61 RDP-110 TxD+
62 RDP-110 TxD−
COM 10, 11, 12
OUT 12
30
29
63 CHASSIS GND P6
64 AVR +
OUT 11 28 DGC-2020HD 65 AVR −
OUT 10 27 66 GOV +
COM 7, 8, 9 26 67 GOV −
OUT 9 25 68 GOV PWM
OUT 8 24 69 LOAD SHARE+
P2 OUT 7 23 A 70 LOAD SHARE−
COM 4, 5, 6 22 A
OUT 6 21 71 FUEL +
OUT 5 20 72 FUEL −
OUT 4 19 73 Not Used
PRE
COM 1, 2, 3 18 E 74 OIL +
OUT 3 17 75 OIL −
OUT 2 16 76 OIL I
77 COOLANT+
START RUN
OUT 1
AUX I4−
15
14
78 COOLANT− P7
79 COOLANT I
AUX I4+ 13 80 ALOG IN 2 +
AUX I3− 12 81 ALOG IN 2 −
AUX I3+ 11
AUX I2− 10 F + –
82
83
ALOG IN 2 I
ALOG IN 1 +
AUX I2+ 9 84 ALOG IN 1 −
P1 AUX I1− 8
A 85 ALOG IN 1 I
AUX I1+ 7
GEN IC− 6
107
106
105
104
103
102
101

100
99
98
97
96
95
94
93
92
91
90
89
88
87
86

GEN IC+ 5
GEN IB− 4
BUS 2 VN
BUS 2 VC

BUS 1 VN
BUS 1 VC
BUS 2 VB

BUS 2 VA

BUS 1 VB

BUS 1 VA
Not Used

Not Used

Not Used

Not Used

Not Used

Not Used

Not Used

Not Used
GEN VN
GEN VC

GEN VB

GEN VA

GEN IB+ 3
MPU −
MPU +

GEN IA− 2
GEN IA+ 1

P9 P8 P0071-12

Figure 2-1. Rear Panel

DGC-2020HD Terminals and Connectors

2-2 9469300994

Table 2-1. Rear Panel Terminal and Connector Descriptions

Locator Description
A The majority of external, DGC-2020HD wiring is terminated at 5-, 7-, or 15-position
connectors with spring clamp terminals. These connectors plug into headers on the
DGC-2020HD. The connectors and headers have a dovetailed edge that ensures
proper connector orientation. Each connector and header is uniquely keyed to ensure
that a connector mates only with the correct header. Terminals accept a maximum
wire size of 12 AWG (3.31 mm2). Remove (strip) 0.4 inch (10 mm) of insulation from
each wire end inserted into a connector terminal.
B This male DB-9 connector is provided for external dial-out modem communication and
the future implementation of other communication protocols. Contact Basler Electric for
protocol availability.
C DGC-2020HD Ethernet communication uses the Modbus® TCP protocol to provide
remote metering, annunciation, and control. Dual copper (100Base-T) ports (style
xxxxDxxxx) use standard RJ-45 jacks and a fiber optic (100Base-FX) port (style
xxxxFxxxx) uses one ST fiber optic connector.
Ethernet ports have different designations depending on style:
• Dual copper (Style xxxxDxxxx) – The RJ-45 jack nearest to the mini-B USB port is
designated as Ethernet port 1 and is reserved for intergenset communications
(load sharing). The other RJ-45 jack is designated as Ethernet port 2 and can be
configured for redundant intergenset communications or for an independent
network connection.
• Fiber optic (Style xxxxFxxxx) – The ST fiber optic port is designated as Ethernet
port 1 and is reserved for intergenset communications (load sharing).
Figure 2-1 shows both Ethernet port styles (dual copper and fiber) for clarity. The
DGC-2020HD comes equipped with only one port style, not both.
D The mini-B USB jack mates with a standard USB cable and is used with a PC running
BESTCOMSPlus® software for local communication with the DGC-2020HD.
E Connections to the Start, Run, and Pre output contacts are made directly to each relay
through quarter-inch, male, quick-connect terminals.
F An onboard battery maintains DGC-2020HD timekeeping during losses of control
power. See the Maintenance chapter for instructions on replacing the battery. Failure
to replace the battery with Basler Electric P/N 38526 may void the warranty.

Terminals
DGC-2020HD connections are dependent on the application. Incorrect wiring may result in damage to the
controller.
Note
Be sure that the DGC-2020HD is hard-wired to earth ground with no
smaller than 12 AWG copper wire attached to chassis ground
(terminal 50) on the rear of the controller.

The DGC-2020HD terminals are grouped by function and include control power, current sensing, voltage
sensing, engine sender input, magnetic pickup input, contact sensing, output contacts, CAN interface,
RS-485 interface, AVR control, GOV control, Load Share, IRIG source, Remote Display Panel
connection, USB port, Ethernet communication, and RS-232 communication.
DGC-2020HD terminals are described in the following paragraphs.

Terminals and Connectors DGC-2020HD

9469300994 2-3

Control power
The DGC-2020HD control power input accepts a nominal voltage of 12 Vdc or 24 Vdc and tolerates
voltage over the range of 6 to 32 Vdc. Control power must be of the correct polarity. While reverse
polarity will not cause damage, the DGC-2020HD will not operate. Control power terminals are listed in
Table 2-2.
A fuse should be added for additional protection for the wiring to the battery input of the DGC-2020HD. A
fuse helps prevent wire damage and nuisance trips due to initial power supply inrush current. To follow
UL guidelines, a 5 A maximum, 32 Vdc supplementary fuse must be implemented in the battery input
circuit to the DGC-2020HD.
Table 2-2. Control Power Terminals
Terminal Description
50 (CHASSIS) Chassis ground connections
49 (BATT–) Negative side of control power input
48 (BATT+) Positive side of control power input

Generator Current Sensing

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

Programmable Current Sensing

Four user-programmable current sensing inputs are provided for measuring mains current, load bus
current, ground current, or a combination of these. Table 2-4 lists the programmable current sensing
terminals.
Table 2-4. Programmable Current Sensing Terminals
Terminal Description
7 (AUX I1 +)
Programmable current sensing input 1
8 (AUX I1 –)
9 (AUX I2 +)
Programmable current sensing input 2
10 (AUX I2 –)
11 (AUX I3 +)
Programmable current sensing input 3
12 (AUX I3 –)
13 (AUX I4 +)
Programmable current sensing input 4
14 (AUX I4 –)

DGC-2020HD Terminals and Connectors

2-4 9469300994

Caution
Current sensing terminals 2 (IA–), 4 (IB–), 6 (IC–), 8(AUX I1–), 10
(AUX I2–), 12 (AUX I3–), and 14 (AUX I4–) must be terminated to
ground for proper operation.

Note
Unused current sensing inputs should be shorted to minimize noise
pickup.

Generator Voltage Sensing

The DGC-2020HD accepts either line-to-line or line-to-neutral generator sensing voltage over the range
of 0 to 576 volts, rms line-to-line or 0 to 333 volts, rms line-to-neutral. Generator voltage sensing terminals
are listed in Table 2-5.
Table 2-5. Generator Voltage Sensing Terminals
Terminal Description
86 (GEN VA) A-phase generator voltage sensing input
88 (GEN VB) B-phase generator voltage sensing input
90 (GEN VC) C-phase generator voltage sensing input
91 (GEN VN) Neutral generator voltage sensing input

Installation in an Ungrounded System Application

When the DGC-2020HD is controlling equipment that is part of an ungrounded system, it is
recommended that potential transformers be employed on the voltage sensing inputs to provide full
isolation between the DGC-2020HD and monitored voltage phases.

Bus Voltage Sensing

Sensing of bus voltage enables the DGC-2020HD to detect failures of the mains (utility). Controllers with
style number xxx2xxxxx use bus voltage sensing to perform automatic synchronization of the generator
with the bus. The DGC-2020HD accepts either line-to-line or line-to-neutral bus sensing voltage over the
range of 0 to 576 volts, rms line-to-line or 0 to 333 volts, rms line-to-neutral. Controllers with style number
xxxxxxxEx are equipped with two bus sensing inputs. One is intended for sensing the mains voltage while
the other is intended for sensing the load bus voltage.
Bus voltage sensing terminals are listed in Table 2-6.
Table 2-6. Bus Voltage Sensing Terminals
Terminal Description
93 (BUS1 VA) A-phase bus voltage sensing input
95 (BUS1 VB) B-phase bus voltage sensing input
97 (BUS1 VC) C-phase bus voltage sensing input
98 (BUS1 VN) Neutral bus voltage sensing input
100 (BUS2 VA) A-phase bus voltage sensing input (optional)
101 (BUS2 VB) B-phase bus voltage sensing input (optional)
103 (BUS2 VC) C-phase bus voltage sensing input (optional)
104 (BUS2 VN) Neutral bus voltage sensing input (optional)

Terminals and Connectors DGC-2020HD

9469300994 2-5

Installation in an Ungrounded System Application

When the DGC-2020HD is controlling equipment that is part of an ungrounded system, it is
recommended that potential transformers be employed on the voltage sensing inputs to provide full
isolation between the DGC-2020HD and monitored voltage phases.

Engine Sender Inputs

Inputs are provided for fuel level, oil pressure, and coolant temperature senders. For a listing of fuel level,
oil pressure, and coolant temperature senders that are compatible with the DGC-2020HD, refer to the
Engine Sender Inputs chapter in the Configuration manual. The fuel level input accepts resistive senders
only. Oil pressure and coolant temperature inputs accept either resistive or analog senders depending on
the style number.
Engine sender input terminals are listed in Table 2-7.
Table 2-7. Sender Input Terminals
Terminal Description
71 (FUEL +) Fuel level sender input
72 (FUEL –) Fuel level sender return
74 (OIL + / ANALOG IN 4 +) Oil pressure sender input or Analog input 4 +
75 (OIL – / ANALOG IN 4 –) Oil pressure sender return or Analog input 4 –
76 (N.C. / ANALOG IN 4 I) Analog input 4 (I) current input∗
77 (COOLANT + / ANALOG IN 3 +) Coolant temperature sender input or Analog input 3 +
78 (COOLANT – / ANALOG IN 3 –) Coolant temperature sender return or Analog input 3 –
79 (N.C. / ANALOG IN 3 I) Analog input 3 (I) current input∗

∗ When using the current input, it must be tied to the voltage input. See the Typical Applications
chapter for a diagram.

Analog Inputs
Two user-programmable analog inputs are provided. These inputs accept a signal range of either 4 to
20 mA or 0 to 10 Vdc. Analog input terminals are listed in Table 2-8.
Table 2-8. Analog Input Terminals
Terminal Description
80 (ANALOG IN 2 +) Auxiliary analog 2 +
81 (ANALOG IN 2 –) Auxiliary analog 2 –
82 (ANALOG IN 2 I) Auxiliary analog 2 (I) current input∗
83 (ANALOG IN 1 +) Auxiliary analog 1 +
84 (ANALOG IN 1 –) Auxiliary analog 1 –
85 (ANALOG IN 1 I) Auxiliary analog 1 (I) current input∗

∗ When using the current input, it must be tied to the voltage input. See Typical Applications chapter
for a diagram.

Magnetic Pickup Input

The magnetic pickup input accepts a speed signal over the range of 3 to 35 volts peak and 32 to 10,000
hertz. Magnetic pickup input terminals are listed in Table 2-9.

DGC-2020HD Terminals and Connectors

2-6 9469300994

Table 2-9. Magnetic Pickup Input Terminals

Terminals Description
107 (MPU–) Magnetic pickup return input
106 (MPU+) Magnetic pickup positive input

Contact Sensing Inputs

Contact sensing inputs consist of sixteen programmable inputs. The programmable inputs accept
normally open, dry contacts. Terminal 49 (BATT–) serves as the common return line for the
programmable inputs. While input 1 is programmed to recognize an emergency stop input by default, it
can be programmed for any function. Information about configuring the programmable inputs is provided
in the Contact Inputs chapter in the Configuration manual. Contact sensing input terminals are listed in
Table 2-10.
Table 2-10. Contact Sensing Inputs
Terminal Description
49 (BATT–) Common return line for programmable contact inputs
31 (INPUT 1) Programmable contact input 1
32 (INPUT 2) Programmable contact input 2
33 (INPUT 3) Programmable contact input 3
34 (INPUT 4) Programmable contact input 4
35 (INPUT 5) Programmable contact input 5
36 (INPUT 6) Programmable contact input 6
37 (INPUT 7) Programmable contact input 7
38 (INPUT 8) Programmable contact input 8
39 (INPUT 9) Programmable contact input 9
40 (INPUT 10) Programmable contact input 10
41 (INPUT 11) Programmable contact input 11
42 (INPUT 12) Programmable contact input 12
43 (INPUT 13) Programmable contact input 13
44 (INPUT 14) Programmable contact input 14
45 (INPUT 15) Programmable contact input 15
46 (INPUT 16) Programmable contact input 16

Emergency Stop Input

The emergency stop input is intended for use with a normally closed switch and recognizes an
emergency stop input when the connection from terminal 31 (INPUT 1 by default) to ground is removed.
While input 1 is programmed to recognize an emergency stop input by default, it can be programmed for
any function.

Programmable Output Contacts Rated for 30-Ampere Duty

The DGC-2020HD has three sets of output contacts rated for 30-ampere duty. Their functions are set to
Pre, Start, and Run by default, but are fully programmable through BESTCOMSPlus. The Pre contacts
supply battery power to the engine glow plugs, the Start contacts supply power to the starter solenoid,
and the Run contacts supply power to the fuel solenoid. Connections to the DGC-2020HD Start, Run, and
Pre output contacts are made directly to each relay through quarter-inch, male, quick-connect terminals.

Terminals and Connectors DGC-2020HD

9469300994 2-7

Note
It is recommended in all applications where contact outputs drive relay
coils that a reverse biased diode be implemented in parallel with the
relay coil for EMI suppression.

Programmable Output Contacts Rated for 2-Ampere Duty

Twelve programmable output contacts rated for 2-ampere duty are provided in four sets. Each set of
three output contacts shares a common terminal. Programmable output contact terminals are listed in
Table 2-11.
Table 2-11. Programmable Output Contact Terminals
Terminal Description
15 (OUT 1) Programmable output 1
16 (OUT 2) Programmable output 2
17 (OUT 3) Programmable output 3
18 (COM 1, 2, 3) Common connection for outputs 1, 2, and 3
19 (OUT 4) Programmable output 4
20 (OUT 5) Programmable output 5
21 (OUT 6) Programmable output 6
22 (COM 4, 5, 6) Common connection for outputs 4, 5, and 6
23 (OUT 7) Programmable output 7
24 (OUT 8) Programmable output 8
25 (OUT 9) Programmable output 9
26 (COM 7, 8, 9) Common connection for outputs 7, 8, and 9
27 (OUT 10) Programmable output 10
28 (OUT 11) Programmable output 11
29 (OUT 12) Programmable output 12
30 (COM 10, 11, 12) Common connection for outputs 10, 11, and 12

CAN Interface
These terminals provide communication using the SAE J1939 protocol or the mtu protocol and provide
high-speed communication between the DGC-2020HD and an ECU on an electronically controlled
engine. Connections between the ECU and DGC-2020HD should be made with twisted-pair, shielded
cable. CAN interface terminals are listed in Table 2-12. For typical CAN connections, refer to the Typical
Connections chapter.
Table 2-12. CAN Interface Terminals
Terminals Description
51 (CAN 1 L) CAN 1 low connection
52 (CAN 1 H) CAN 1 high connection
53 (SHIELD) CAN drain connection
54 (CAN 2 L) CAN 2 low connection
55 (CAN 2 H) CAN 2 high connection

DGC-2020HD Terminals and Connectors

2-8 9469300994

Notes
1. If the DGC-2020HD is providing one end of the J1939 bus, a 120
ohm, ½ watt terminating resistor should be installed across
terminals 51 (CAN1L) and 52 (CAN1H) or 54 (CAN2L) and 55
(CAN2H)
2. If the DGC-2020HD is not providing one end of the J1939 bus, the
stub connecting the DGC-2020HD to the bus should not exceed
914 mm (3 ft) in length.
3. The maximum bus length, not including stubs, is 40 m (131 ft).
4. The J1939 drain (shield) should be grounded at one point only. If
grounded elsewhere, do not connect the drain to the DGC-
2020HD.
5. It is recommended to upgrade the firmware in all AEM-2020s and
CEM 2020s that share a CAN bus network with a VRM-2020.
Upgrade CEM-2020s to firmware version 1.01.05 or later.
Upgrade AEM 2020s to firmware version 1.00.06 or later.

RS-485 Interface
DGC-2020HD controllers can be monitored and controlled via a polled network using the Modbus™
protocol. The RS-485 port supports a user-selectable baud rate of 1,200, 2,400, 4,800, 9,600, 19,200,
38,400, 57,600, or 115,200. Seven or eight data bits per character can be selected. Odd, even, or no
parity is supported. One or two stop bits are selectable. RS-485 Modbus supports a single Modbus
Master only. Modbus register values for the DGC-2020HD are listed and defined in Basler Publication
9469300998, Instruction Manual for DGC-2020HD Digital Genset Controller Modbus® Protocol. RS-485
interface terminals are listed in Table 2-13.
Table 2-13. RS-485 Terminals
Terminal Description
56 (RS-485 A) RS-485 send/receive A connection
57 (RS-485 B) RS-485 send/receive B connection
58 (RS-485 SHIELD) RS-485 shield connection

Automatic Voltage Regulator (AVR) Control

AVR control outputs provide control of the generator voltage setpoint. AVR control terminals are listed in
Table 2-14.
Table 2-14. AVR Control Output Terminals
Terminal Description
64 (AVR +) AVR control output positive
65 (AVR –) AVR control output negative

Governor (GOV) Control

GOV control output contacts provide remote control of the generator speed (RPM) setpoint. GOV control
terminals are listed in Table 2-15.
Table 2-15. GOV Control Output Terminals
Terminal Description
66 (GOV +) GOV control output positive

Terminals and Connectors DGC-2020HD

9469300994 2-9

Terminal Description
67 (GOV –) GOV control output negative
68 (GOV PWM) GOV PWM output for CAT control system interface

Load Share Line

Load share line outputs are measured and used to calculate the per-unitized average load level. This
average is used as the setpoint for the genset’s kW controller. Load share line output terminals are listed
in Table 2-16.
Table 2-16. Load Share Line Output Terminals
Terminal Description
69 (LOAD SHARE +) Load share line positive
70 (LOAD SHARE –) Load share line negative

IRIG-B Connections
The IRIG-B terminals connect to an IRIG-B source for synchronization of DGC-2020HD timekeeping with
the IRIG-B source. Table 2-17 lists the IRIG-B source input terminals.
Table 2-17. IRIG-B Source Input Terminals
Terminal Description
59 (IRIG-B +) IRIG-B source input
60 (IRIG-B –) IRIG-B return terminal

Optional Remote Display Panel Connections

Terminals are provided for connection with the optional remote display panel (Basler P/N 9318100114
projection mount or 9318100115 flush mount). These terminals provide dc control power to the remote
display panel and enable communication between the DGC-2020HD and the remote display panel.
Twisted-pair conductors are recommended for making the connections between the DGC-2020HD and
remote display panel. Communication may become unreliable if the connection wires exceed 1,219 m
(4,000 ft). Table 2-18 lists the DGC-2020HD terminals that connect to the remote display panel.
Table 2-18. Remote Display Panel Interface Terminals
Terminal Description
61 (RDP TxD +) Remote display panel communication terminal (TxD +)
62 (RDP TxD –) Remote display panel communication terminal (TxD –)
49 (BATT–) Remote display panel power terminal DC COM (–)
48 (BATT+) Remote display panel power terminal 12/24 (+)

Connectors
USB Interface
A mini-B USB jack enables local communication with a PC running BESTCOMSPlus® software. The
DGC-2020HD is connected to a PC using a standard USB cable equipped with a type A plug on one end
(PC termination) and a mini-B plug on the other end (DGC-2020HD termination).

Ethernet Communications
Dual copper RJ-45 jacks or an ST fiber optic port provide Ethernet communications between the DGC-
2020HD and a PC via BESTCOMSPlus or other DGC-2020HDs in a network. The ST type fiber optic port
uses a 1,300 nanometer, near-infrared (NIR) light wavelength transmitted via two strands of multimode
optical fiber, one for receive (RX) and the other for transmit (TX).
DGC-2020HD Terminals and Connectors
2-10 9469300994

An Ethernet connection to a PC running BESTCOMSPlus provides remote metering, setting,

annunciation, and control of the DGC-2020HD. Ethernet communication between DGC-2020HDs allows
for generator sequencing on an islanded system.

RS-232 Interface
A male DB-9 connector allows the DGC-2020HD controller to connect to an external, user-supplied dial-
out modem via the RS-232 interface. The modem enables the DGC-2020HD to dial up to four pager
telephone numbers and annunciate conditions selected by the user. These conditions include any
DGC-2020HD alarm or pre-alarm, closure of any programmable contact input, and an active cool down
timer.

Terminals and Connectors DGC-2020HD

9469300994 3-1

3 • Typical Applications
Typical connection diagrams are provided in this chapter as a guide when wiring the DGC-2020HD for
communication, mechanical senders, contact inputs and outputs, sensing, and control power.

Connections for Typical Applications

General connections for DGC-2020HD communication, contact inputs, contact outputs, mechanical
senders, and control power are shown in Figure 3-1.
General bus voltage sensing connections in three-phase wye, three-phase delta, single-phase A-B and
single-phase A-C configurations are shown in the figures listed below.
• Three-phase wye ........................................................................... Figure 3-2
• Three-phase delta.......................................................................... Figure 3-3
• Single-phase A-B ........................................................................... Figure 3-4
• Single-phase A-C........................................................................... Figure 3-5
Connections for pre-configured breaker control schemes are shown in the figures listed below.
• No breaker control ......................................................................... Figure 3-6
• Generator breaker control ............................................................. Figure 3-7
• Generator breaker control with optional mains breaker status ...... Figure 3-8
• Generator and mains breaker control ............................................ Figure 3-9
• Generator and mains breaker control with load bus sensing ........ Figure 3-10
• Generator and group breaker control ............................................ Figure 3-11
• Generator and group breaker control with load bus sensing ........ Figure 3-12
• Generator, group, and mains breaker control ............................... Figure 3-13
• Generator breaker control to segmented system .......................... Figure 3-14
• Generator and group breaker control to segmented system ......... Figure 3-15
• Generator and tie breaker control.................................................. Figure 3-16
• Tie breaker control ......................................................................... Figure 3-17
• Dual tie breaker control ................................................................. Figure 3-18
• Generator and two tie breaker control ........................................... Figure 3-19
Although three-phase wye sensing connections are shown in the breaker control diagrams, other bus
voltage sensing configurations (figures 3-2 through 3-5) may be used instead.

DGC-2020HD Typical Applications

3-2 9469300994

Figure 3-1. Connections for Communication, Senders, Contact Inputs and Outputs, and Control Power
Figure 3-2 illustrates typical three-phase wye connections for all DGC-2020HD bus voltage sensing
connections: Generator, Bus 1, and Bus 2. Use the terminal numbers listed below for connecting the
desired bus type. Refer to the Terminals and Connectors chapter for rear panel terminal numbering.
For Generator voltage sensing, VA = 86, VB = 88, VC = 90, and VN = 91.
For Bus 1 voltage sensing, VA = 93, VB = 95, VC = 97, VN = 98.
For Bus 2 voltage sensing, VA = 100, VB = 101, VC = 103, VN = 104.

Typical Applications DGC-2020HD

9469300994 3-3

B
C

VA VB VC VN

DGC-2020HD
Voltage Connections
P0081-53

Figure 3-2. 3-Phase Wye Bus Voltage Sensing Connections

Figure 3-3 illustrates typical three-phase delta connections for all DGC-2020HD bus voltage sensing
connections: Generator, Bus 1, and Bus 2. Use the terminal numbers listed below for connecting the
desired bus type. Refer to the Terminals and Connectors chapter for rear panel terminal numbering.
For Generator voltage sensing, VA = 86, VB = 88, and VC = 90.
For Bus 1 voltage sensing, VA = 93, VB = 95, and VC = 97.
For Bus 2 voltage sensing, VA = 100, VB = 101, and VC = 103.
A
B
C

VA VB VC

DGC-2020HD
Voltage Connections
P0081-54

Figure 3-3. 3-Phase Delta Connections

Figure 3-4 illustrates typical single-phase A-B connections for all DGC-2020HD bus voltage sensing
connections: Generator, Bus 1, and Bus 2. Use the terminal numbers listed below for connecting the
desired bus type. Refer to the Terminals and Connectors chapter for rear panel terminal numbering.
For Generator voltage sensing, VA = 86, VB = 88, and VN = 91.
For Bus 1 voltage sensing, VA = 93, VB = 95, VN = 98.
For Bus 2 voltage sensing, VA = 100, VB = 101, VN = 104.

DGC-2020HD Typical Applications

3-4 9469300994

B
C

VA VB VC VN

DGC-2020HD
Voltage Connections
P0081-55

Figure 3-4. Single-Phase A-B Connections

Figure 3-5 illustrates typical single-phase A-C connections for all DGC-2020HD bus voltage sensing
connections: Generator, Bus 1, and Bus 2. Use the terminal numbers listed below for connecting the
desired bus type. Refer to the Terminals and Connectors chapter for rear panel terminal numbering.
For Generator voltage sensing, VA = 86, VC = 90, and VN = 91.
For Bus 1 voltage sensing, VA = 93, VC = 97, VN = 98.
For Bus 2 voltage sensing, VA = 100, VC = 103, VN = 104.
A
B
C

VA VB VC VN

DGC-2020HD
Voltage Connections
P0081-56

Figure 3-5. Single-Phase A-C Connections

Typical Applications DGC-2020HD

9469300994 3-5

Generator Bus
L1 A

L2 B
Generator
L3 C Load

N N

Generator
Bus Metering

86 88 90 91 1 2 3 4 5 6

DGC-2020HD
P0081-57

Figure 3-6. No Breaker Control Connections

Generator
Breaker Load Bus
Generator Bus
L1 A

L2 B
Generator
L3 C Load

N N
Generator Generator
Generator Breaker Breaker Load Bus
Bus Metering Status Control Output Metering

86 88 90 91 1 2 3 4 5 6 93 95 97 98
Bus 1
DGC-2020HD
P0081-58

Figure 3-7. Generator Breaker Control Connections

Load
Generator Mains
Breaker Breaker Mains Bus
Generator Bus Load Bus
L1 A

L2 B
Generator
L3 C

N N
Generator Generator
Generator Load Bus Mains Breaker
Breaker Breaker
Bus Metering Metering Status (optional)
Status Control Output

86 88 90 91 1 2 3 4 5 6 93 95 97 98 7 8
Bus 1 1
DGC-2020HD
P0081-59

Notes:
1 An auxiliary CT is only required for mains breaker power measurement. Mains breaker
power measurement is required for the Zero Power Transfer or Mains Power Control
functions.

Figure 3-8. Generator Breaker Control Connections with Optional Mains Breaker Status

DGC-2020HD Typical Applications

3-6 9469300994

Load
Generator Mains
Breaker Breaker Mains Bus
Generator Bus Load Bus
L1 A

L2 B
Generator
L3 C

N N
Generator Generator Mains
Generator Mains Breaker Mains Bus
Breaker Breaker Breaker
Bus Metering Control Output Metering
Status Control Output Status

86 88 90 91 1 2 3 4 5 6 7 8 93 95 97 98

1 Bus 1
DGC-2020HD
P0081-60

Notes:
1 An auxiliary CT is only required for mains breaker power measurement. Mains breaker power measurement is required for the Zero
Power Transfer or Mains Power Control functions.

Figure 3-9. Generator and Mains Breaker Control Connections

Load
Generator Mains
Breaker Breaker Mains Bus
Generator Bus Load Bus
L1 A

L2 B
Generator
L3 C

N N
Generator Generator Mains
Generator Mains Breaker Mains Bus
Breaker Breaker Breaker
Bus Metering Control Output Metering
Status Control Output Status

86 88 90 91 1 2 3 4 5 6 100 101 103 104 7 8 9 10 11 12 93 95 97 98

Bus 2 1 Bus 1
DGC-2020HD
P0081-61

Notes:
1 An auxiliary CT is only required for mains breaker power measurement. Mains breaker power measurement is required for the Zero
Power Transfer or Mains Power Control functions.

Figure 3-10. Generator and Mains Breaker Control with Load Bus Sensing Connections

To other generators
Generator Group
Breaker Group Breaker Load Bus
Generator Bus Bus
L1 A

L2 B
Generator
Load
L3 C

N N
Generator Generator Group
Generator Group Bus Group Breaker
Breaker Breaker Breaker
Bus Metering Metering Control Output
Status Control Output Status

86 88 90 91 1 2 3 4 5 6 93 95 97 98 7 8
Bus 1 1
DGC-2020HD
P0081-62

Notes:
1 An auxiliary CT is only required if group breaker power measurement is desired. Group breaker power measurement is required for
the group breaker Zero Power Transfer function.

Figure 3-11. Generator and Group Breaker Control Connections

Typical Applications DGC-2020HD

9469300994 3-7

To other generators
Generator Group
Breaker Group Breaker Load Bus
Generator Bus Bus
L1 A

L2 B
Generator
Load
L3 C

N N
Generator Generator Group
Generator Group Bus Group Breaker Load Bus
Breaker Breaker Breaker
Bus Metering Metering Control Output Metering
Status Control Output Status

86 88 90 91 1 2 3 4 5 6 93 95 97 98 7 8 9 10 11 12 100 101 103 104

Bus 1 1 Bus 2
DGC-2020HD
P0081-63

Notes:
1 An auxiliary CT is only required if group breaker power measurement is desired. Group breaker power measurement is required for
the group breaker Zero Power Transfer function.

Figure 3-12. Generator and Group Breaker Control with Load Bus Sensing Connections

Load
To other generators
Generator Group Mains
Breaker Group Breaker Breaker Mains Bus
Generator Bus Bus Load Bus
L1 A

L2 B
Generator
L3 C

N N
Group Group Mains
Generator Generator Mains
Generator Group Bus Breaker Breaker Mains Breaker
Breaker Breaker Breaker Bus
Bus Metering Metering Control Control Output
Status Control Output Status Output Status Metering

86 88 90 91 1 2 3 4 5 6 100 101 103 104 13 14 7 8 9 10 11 12 93 95 97 98

Bus 2 1 1 Bus 1
DGC-2020HD
P0081-64

Notes:
1 Auxiliary CTs are only required if mains breaker and/or group breaker power measurement is desired. Power measurement through the group or mains breaker is required for Zero Power Transfer
through that breaker. Mains breaker power measurement is required for the Mains Power Control function.

Figure 3-13. Generator, Group, and Mains Breaker Control Connections

Generator Segmented
Breaker System Bus
Generator Bus
L1 A

L2 B To Segmented
Generator System
L3 C

N N
Generator Generator
Generator Breaker Breaker Segmented System
Bus Metering Status Control Output Bus Metering

86 88 90 91 1 2 3 4 5 6 93 95 97 98
Bus 1
DGC-2020HD
P0081-65

Figure 3-14. Generator Breaker Control to Segmented System Connections

DGC-2020HD Typical Applications

3-8 9469300994

To other generators
Generator Group Segmented
Breaker Group Breaker
Generator Bus System Bus
L1 Bus A

L2 B To Segmented
Generator
System
L3 C

N N
Generator Generator Group
Generator Group Bus Group Breaker Segmented System
Breaker Breaker Breaker
Bus Metering Metering Control Output Bus Metering
Status Control Output Status

86 88 90 91 1 2 3 4 5 6 93 95 97 98 7 8 9 10 11 12 100 101 103 104

Bus 1 1 Bus 2
DGC-2020HD
P0081-66

Notes:
1 An auxiliary CT is only required if group breaker power measurement is desired. Group breaker power measurement is required for
the group breaker Zero Power Transfer function.

Figure 3-15. Generator and Group Breaker Control to Segmented System Connections

To Segmented System “B”

Generator Segmented
Segmented Tie Breaker
Breaker System Bus “C”
Generator Bus System Bus “B”
L1 A

L2 B To Segmented
Generator
System “C”
L3 C

N N
Generator Generator Segmented Tie
Generator Tie Breaker Segmented System
Breaker Breaker System Bus Breaker
Bus Metering Control Output Bus “C” Metering
Status Control Output “B” Metering Status

86 88 90 91 1 2 3 4 5 6 93 95 97 98 7 8 9 10 11 12 100 101 103 104

Bus 1 1 Bus 2
DGC-2020HD
P0081-67

Notes:
1 Auxiliary CTs are only required if tie breaker power measurement is desired. Tie breaker power measurement is required for the
Zero Power Transfer function across the tie breaker.

Figure 3-16. Generator and Tie Breaker Control Connections

Segmented Tie Breaker Segmented

System Bus “A” System Bus “B”
A A
To Segmented To Segmented
System “A” B B System “B”

C C

N N
Tie
Tie Breaker Segmented System
Segmented System Breaker
Control Output Bus “B” Metering
Bus “A” Metering Status

86 88 90 91 1 2 3 4 5 6 93 95 97 98
Bus 1
DGC-2020HD
P0081-68

Figure 3-17. Tie Breaker Control Connections

To Segmented System “B”

Segmented Tie Breaker Segmented Tie Breaker Segmented

System Bus “A” 1 System Bus “B” 2 System Bus “C”
A A
To Segmented B B To Segmented
System “A” System “C”
C C

N N
Tie Tie
Segmented System Tie Breaker 1 Segmented System Breaker 2 Tie Breaker 2 Segmented System
Breaker 1
Bus “A” Metering Control Output Bus “B” Metering Control Output Bus “C” Metering
Status Status

86 88 90 91 1 2 3 4 5 6 93 95 97 98 7 8 9 10 11 12 100 101 103 104

Bus 1 1 Bus 2
DGC-2020HD
P0081-69

Notes:
1 Auxiliary CTs are only required if Tie Breaker 2 power measurement is desired. Tie Breaker 2 power measurement is required for
the Zero Power Transfer function across Tie Breaker 2.

Figure 3-18. Dual Tie Breaker Control Connections

Typical Applications DGC-2020HD

9469300994 3-9

Figure 3-19. Generator and Two Tie Breaker Control Connections

Connections for Load Sharing

Figure 3-19 illustrates a typical interconnection of two systems tied together using analog and Ethernet
load share lines.

DGC-2020HD Typical Applications

3-10 9469300994

Figure 3-20. Analog and Ethernet Connections for Typical Applications

Analog Input Connections

DGC-2020HD controllers with style number xxxxxxxxR are equipped with two analog inputs and those
with style number xxxxxxxxA are equipped with four analog inputs.
Voltage and current analog input connections are shown in Figure 3-20. When using the current input, the
“+” and “I” terminals must be tied together.

Typical Applications DGC-2020HD

9469300994 3-11

To achieve electromagnetic interference immunity on the analog inputs, clamp two ferrite beads (Fair-Rite
P/N 0431176451) in series around all of the wires. Place the ferrite beads close to the DGC-2020HD
analog input terminals.

Analog Voltage Input Connection

0 – 10 Vdc ALOG IN +
Voltage ALOG IN –
Transducer ALOG IN I DGC-2020HD
1
49 BATT –

Analog Current Input Connection

4 – 20 mA ALOG IN +
Current ALOG IN –
Transducer ALOG IN I DGC-2020HD
1
49 BATT –

Note: P0071-65

1 For optimal metering performance, it is recommended to

connect analog input common to terminal 49 (BATT –).
Figure 3-21. Analog Engine Sender Voltage Input Connections

Governor PWM Output Connections

Governor PWM output allows interfacing with select CAT control systems. Governor PWM output
connections are shown in Figure 3-21.

PWM
Governor Bias
Input
Not Used 66 GOV +
PWM In – 67 GOV –
PWM In + 68 GOV PWM DGC-2020HD

P0076-88

Figure 3-22. Governor PWM Output Connections

DGC-2020HD Typical Applications

3-12 9469300994

CAN Connections
Typical CAN connections are shown in Figure 3-22 and Figure 3-23.

Notes
1. If the DGC-2020HD is providing one end of the J1939 bus, a 120
ohm, ½ watt terminating resistor should be installed across
terminals 51 (CAN1L) and 52 (CAN1H) or 54 (CAN2L) and 55
(CAN2H).
2. If the DGC-2020HD is not providing one end of the J1939 bus, the
stub connecting the DGC-2020HD to the bus should not exceed
914 mm (3 ft) in length.
3. The maximum bus length, not including stubs, is 40 m (131 ft).
4. The J1939 drain (shield) should be grounded at one point only. If
grounded elsewhere, do not connect the drain to the DGC-
2020HD.
5. It is recommended to upgrade the firmware in all AEM-2020s and
CEM 2020s that share a CAN bus network with a VRM-2020.
Upgrade CEM-2020s to firmware version 1.01.05 or later.
Upgrade AEM 2020s to firmware version 1.00.06 or later.

Figure 3-23. CAN Interface with DGC-2020HD Providing One End of the Bus

Typical Applications DGC-2020HD

9469300994 3-13

Figure 3-24. CAN Interface with Other Devices Providing One End of the Bus.

Expansion Module Connections (CAN 1)

The AEM-2020 (Analog Expansion Module), CEM-2020 (Contact Expansion Module), and VRM-2020
(Voltage Regulation Expansion Module) are optional modules that may be connected with the DGC-
2020HD. These modules interface to the DGC-2020HD via the “CAN 1” interface, thus the CAN terminals
(51, 52, and 53) are the only common connections between the DGC-2020HD, AEM-2020, CEM-2020,
and VRM-2020. A CAN interface configured for 250 kbps supports the following combinations of AEM-
2020, CEM-2020 and VRM-2020 modules:
• Up to six CEM-2020s, two AEM-2020s, and one VRM-2020
• Up to five CEM-2020s, three AEM-2020s, and one VRM-2020
• Up to four CEM-2020s, four AEM-2020s, and one VRM-2020
On a CAN configured for 125 kbps, only up to two AEM-2020 modules are supported if a VRM-2020 is
used. Typical connections are illustrated in Figure 3-24.
Refer to the AEM-2020, CEM-2020, and VRM-2020 chapters in the Accessories manual for more
information.

DGC-2020HD Typical Applications

3-14 9469300994

53) SHIELD
DGC-2020HD 52) CAN 1 H
51) CAN 1 L 1

GND
AEM-2020 (1) CANH
CANL

Note:
GND
The J1939 drain (shield)
AEM-2020 (2) CANH 1 should be grounded at one
CANL point only. If grounded
elsewhere, do not connect the
drain to the DGC-2020HD.
GND
AEM-2020 (3) CANH
CANL

GND
AEM-2020 (4) CANH
CANL

GND
CEM-2020 (1) CANH
CANL

GND
CEM-2020 (2) CANH
CANL

GND
CEM-2020 (3) CANH
CANL

GND
CEM-2020 (4) CANH
CANL

GND
VRM-2020 CANH
CANL P0071-52

Figure 3-25. DGC-2020HD Expansion Module CAN Connections

Installation for CE Systems

For CE compliant systems, it may be required to route ac voltage and current sensing wires separately
from other wires.

Installation in an Ungrounded System Application

When the DGC-2020HD is controlling equipment that is part of an ungrounded system, it is
recommended that potential transformers be employed on the voltage sensing inputs to provide full
isolation between the DGC-2020HD and monitored voltage phases.

Typical Applications DGC-2020HD

9469300994 4-1

4 • Power Input
Control power for the DGC-2020HD is typically supplied by the genset starter battery. Power from the
battery is supplied to an internal power supply that provides power for DGC-2020HD logic, protection, and
control functions.

Nominal Voltage Input and Acceptable Range of Input Voltage

A nominal voltage of 12 or 24 Vdc within a range of 6 to 32 Vdc is accepted. Control power must be of the
correct polarity. Although reverse polarity will not cause damage, the DGC-2020HD will not operate.

Terminal Assignments
Input power is applied to terminals 48 (BATT+) and 49 (BATT–), with terminal 50 (CHASSIS GND)
serving as the chassis ground connection.

Power Consumption
The amount of power consumed by the DGC-2020HD varies based on the selected operating mode. The
power saving Sleep mode consumes 12.7 watts with all relays de-energized and analog outputs disabled.
Normal Operational Mode consumes 18.1 watts in Run mode with the LCD heater off, START and RUN
relays energized, six programmable relays energized, and analog outputs enabled. Maximum Operational
Mode consumes 25 watts in Run mode with the LCD heater on, all relays energized, and analog outputs
enabled.

Battery Ride-Through Capability

Starting at 10 Vdc, the DGC-2020HD withstands cranking ride-through down to 0 Vdc for 50 milliseconds.

Fuse Protection
To follow UL guidelines, a 5 A maximum, 32 Vdc supplementary fuse, rated for no less than 26 A2s, must
be implemented in the battery input circuit to the DGC-2020HD.

DGC-2020HD Power Input

4-2 9469300994

Power Input DGC-2020HD

9469300994 5-1

5 • Voltage and Current Sensing

The DGC-2020HD senses generator voltage, generator current, and bus voltage through dedicated,
isolated inputs.

Generator Voltage
The DGC-2020HD accepts either line-to-line or line-to-neutral generator sensing voltage over the range
of 12 to 576 volts rms L-L (7 to 333 volts rms L-N). Single-phase generator voltage is sensed across
phases A and B. Generator voltage sensing terminals are listed in Table 5-1.
Table 5-1. Generator Voltage Sensing Terminals
Terminal Description
86 (GEN VA) A-phase generator voltage sensing input
88 (GEN VB) B-phase generator voltage sensing input
90 (GEN VC) C-phase generator voltage sensing input
91 (GEN VN) Neutral generator voltage sensing input

Bus Voltage
Sensing of bus voltage enables the DGC-2020HD to detect failures of the mains (utility). The
DGC-2020HD accepts bus sensing over the range of 12 to 576 volts rms L-L (7 to 333 volts rms L-N).
Controllers with style number xxx2xxxxx measure bus voltage sensing to perform automatic
synchronization of the generator with the bus. Single-phase bus voltage is sensed across phases A and
B. Bus voltage sensing terminals are listed in Table 5-2.
Table 5-2. Bus Voltage Sensing Terminals
Terminal Description
93 (BUS 1 VA) Bus 1 A-phase voltage sensing input
95 (BUS 1 VB) Bus 1 B-phase voltage sensing input
97 (BUS 1 VC) Bus 1 C-phase voltage sensing input
98 (BUS 1 VN) Bus 1 Neutral voltage sensing input
100 (BUS 2 VA) Bus 2 A-phase voltage sensing input
101 (BUS 2 VB) Bus 2 B-phase voltage sensing input
103 (BUS 2 VC) Bus 2 C-phase voltage sensing input
104 (BUS 2 VN) Bus 2 Neutral voltage sensing input

Generator and Bus Current

The DGC-2020HD has sensing inputs for A-phase, B-phase, and C-phase generator current. One, or up
to four (optional), user-programmable CTs are provided for sensing current on bus 1, optional bus 2, and
generator ground current. Depending on the style number, a DGC-2020HD has a nominal sensing current
rating of 1 Aac or 5 Aac. A style number of 1xxxxxxxx indicates 1 Aac nominal current sensing and a style
number of 5xxxxxxxx indicates 5 Aac nominal current sensing. Generator current sensing terminals are
listed in Table 5-3 and load bus current sensing terminals are listed in Table 5-4.

DGC-2020HD Voltage and Current Sensing

5-2 9469300994

Table 5-3. Generator Current Sensing Terminals

Terminal Description
1 (IA+)
A-phase generator current sensing input
2 (IA–)
3 (IB+)
B-phase generator current sensing input
4 (IB–)
5 (IC+)
C-phase generator current sensing input
6 (IC–)

Table 5-4. Bus Current Sensing Terminals

Terminal Description
7 (AUX I1+)
User-programmable current sensing input 1
8 (AUX I1–)
9 (AUX I2+)
User-programmable current sensing input 2
10 (AUX I2–)
11 (AUX I3+)
User-programmable current sensing input 3
12 (AUX I3–)
13 (AUX I4+)
User-programmable current sensing input 4
14 (AUX I4–)

Caution
Generator current sensing terminals 2 (IA–), 4 (IB–), and 6 (IC–) and
user-programmable current sensing terminals 8 (AUX I1–), 10 (AUX
I2–), 12 (AUX I3–), and 14 (AUX I4–) must be terminated to ground for
proper operation.

Note
Unused current sensing inputs should be shorted to minimize noise
pickup.

Voltage and Current Sensing DGC-2020HD

9469300994 6-1

6 • Speed Signal Inputs

The DGC-2020HD uses signals from the generator voltage sensing inputs, magnetic pickup (MPU) input,
or both inputs to detect machine speed.

Magnetic Pickup
Voltage supplied by a magnetic pickup is scaled and conditioned for use by the internal circuitry as a
speed signal source. The MPU input accepts a signal over the range of 3 to 35 volts peak and 32 to
10,000 hertz.

Terminals
Magnetic pickup connections are provided at terminals 106 (+) and 107 (–).

Generator Sensing Voltage

The generator voltage sensed by the DGC-2020HD is used to measure frequency and can be used to
measure machine speed.

Terminals
Sensing voltage is applied to terminals 86 (A-phase), 88 (B-phase), 90 (C-phase), and 91 (Neutral).

DGC-2020HD Speed Signal Inputs

6-2 9469300994

Speed Signal Inputs DGC-2020HD

9469300994 7-1

7 • Specifications
DGC-2020HD electrical and physical characteristics are listed in the following paragraphs.

Control Power
Nominal ............................................ 12 or 24 Vdc
Range ............................................... 6 to 32 Vdc
Terminals.......................................... 48 (+), 49 (–), 50 (chassis ground)

Power Consumption
Sleep Mode ...................................... 12.7 W - LCD heater off, all relays de-energized, and analog outputs
disabled
Normal Operational Mode ................ 18.1 W - Run mode, LCD heater off, START and RUN relays
energized, six programmable relays energized, and analog outputs
enabled
Maximum Operational Mode ............ 25 W - Run mode, LCD heater on, all relays energized, and analog
outputs enabled

Battery Ride Through

Starting at 10 Vdc, withstands cranking ride-through down to 0 Vdc for 50 ms

Current Sensing
Burden .............................................. 1 VA

Generator CTs
Terminals.......................................... 1 (+), 2 (–) (A-phase)
3 (+), 4 (–) (B-phase)
5 (+), 6 (–) (C-phase)

Available Programmable CTs

AUX 1Terminals ............................... 7 (+), 8 (–)
AUX 2 Terminals .............................. 9 (+), 10 (–)
AUX 3 Terminals .............................. 11 (+), 12 (–)
AUX 4 Terminals .............................. 13 (+), 14 (–)
Programmable CTs AUX 2, 3, and 4 are optional with style number xxxxxxxEx.

1 Aac Current Sensing

Continuous Rating ............................ 0.02 to 1.5 Aac
1 Second Rating ............................... 10 Aac

5 Aac Current Sensing

Continuous Rating ............................ 0.1 to 7.5 Aac
1 Second Rating ............................... 50 Aac

DGC-2020HD Specifications
7-2 9469300994

Voltage Sensing
Range ............................................... 12 to 576 V rms, line-to-line
Frequency ........................................ 50/60 Hz
Frequency Range ............................. 10 to 90 Hz
Burden .............................................. 1 VA
1 Second Rating ............................... 720 V rms

Generator Sensing
Configuration .................................... Line-to-line or line-to-neutral
Generator Sensing Terminals .......... 86 (A-phase)
88 (B-phase)
90 (C-phase)
91 (Neutral)

Bus 1 Sensing
Configuration .................................... Line-to-line or line-to-neutral
Bus Sensing Terminals .................... 93 (A-phase)
95 (B-phase)
97 (C-phase)
98 (Neutral)

Bus 2 Sensing (Optional with style number xxxxxxxEx)

Configuration .................................... Line-to-line or line-to-neutral
Bus Sensing Terminals .................... 100 (A-phase)
101 (B-phase)
103 (C-phase)
104 (Neutral)

Analog Sensing
The DGC-2020HD contains two or four (optional) analog inputs.

Current Sensing
Rating ............................................... 4 to 20 mA
Burden .............................................. 84.25 Ω to 87.1 Ω
Accuracy........................................... ±2%

Voltage Sensing
Rating ............................................... –10 to 10 Vdc
Burden .............................................. 9.75 kΩ to 10.16 kΩ
Accuracy........................................... ±2%

Contact Sensing
Contact sensing inputs include sixteen programmable inputs. All inputs accept dry contacts. The following
contact input recognition and contact output closure times reflect the maximum possible delay.

Contact Input Recognition Time

This is the amount of time that elapses after a local contact input closes until that closure is available in
logic.
DGC-2020HD ................................... 125 ms
CEM-2020 ........................................ 185 ms

Specifications DGC-2020HD
9469300994 7-3

Contact Output Closure Time

This is the amount of time that elapses after a contact output closure is true in logic until that contact
output closes.
DGC-2020HD ................................... 15 ms
CEM-2020 ........................................ 125 ms

Notes
A contact input is true (on) if the input is connected to battery ground
with a resistance of less than 240 ohms.
The maximum length of wire that can be accommodated depends on
the resistance of the wire, and the resistance of the contacts of the
device driving the input at the far end of the wire.
The maximum wire length can be calculated as follows:
Lmax = (240 – Rdevice)/(Resistance per Foot of Desired Wire)

Terminals
Input 1 .............................................. 31, 49
Input 2 .............................................. 32, 49
Input 3 .............................................. 33, 49
Input 4 .............................................. 34, 49
Input 5 .............................................. 35, 49
Input 6 .............................................. 36, 49
Input 7 .............................................. 37, 49
Input 8 .............................................. 38, 49
Input 9 .............................................. 39, 49
Input 10 ............................................ 40, 49
Input 11 ............................................ 41, 49
Input 12 ............................................ 42, 49
Input 13 ............................................ 43, 49
Input 14 ............................................ 44, 49
Input 15 ............................................ 45, 49
Input 16 ............................................ 46, 49

Engine System Inputs

Stated accuracies are subject to the accuracy of the senders used. Values within these ranges are
deemed “good” and the DGC-2020HD will use them for the appropriate calculation and protection.

Fuel Level Sensing

Resistance Range ............................ 0 to 250 Ω nominal
Terminals.......................................... 71 (FUEL +), 72 (FUEL –)
Accuracy........................................... ±0.8 Ω or ±1.9% of actual resistance

Coolant Temperature Sensing

Resistance Range ............................ 10 to 2,750 Ω nominal
Terminals.......................................... 77 (COOLANT +), 78 (COOLANT –)
Accuracy........................................... ±1.2 Ω or ±2.1% of actual resistance

Oil Pressure Sensing

Resistance Range ............................ 0 to 250 Ω nominal
Terminals.......................................... 74 (OIL +), 75 (OIL –)
Accuracy........................................... ±0.8 Ω or ±2.0% of actual resistance
DGC-2020HD Specifications
7-4 9469300994

Engine Speed Sensing

Magnetic Pickup
Voltage Range ................................. 3 to 35 V peak (6 to 70 V peak-peak)
Frequency Range ............................. 32 to 10,000 Hz
Terminals.......................................... 106 (MPU +), 107 (MPU –)

Generator Voltage
Range ............................................... 12 to 576 V rms
Terminals.......................................... 86 (A-phase)
88 (B-phase)
90 (C-phase)
91 (Neutral)

Output Contacts
PRE (Prestart), START, and RUN Relays
Rating ............................................... 30 Adc at 28 Vdc—General purpose, 3 A pilot duty∗

Programmable Relays (12)

Rating ............................................... 2 Adc at 30 Vdc—General purpose, 1.2 A pilot duty∗
∗ The load must be in parallel with a diode rated at least 3 times the coil current and 3 times the coil
voltage.

Terminals
Output 1............................................ 15, 18 (common)
Output 2............................................ 16, 18 (common)
Output 3............................................ 17, 18 (common)
Output 4............................................ 19, 22 (common)
Output 5............................................ 20, 22 (common)
Output 6............................................ 21, 22 (common)
Output 7............................................ 23, 26 (common)
Output 8............................................ 24, 26 (common)
Output 9............................................ 25, 26 (common)
Output 10.......................................... 27, 30 (common)
Output 11.......................................... 28, 30 (common)
Output 12.......................................... 29, 30 (common)
The programmable relays share common terminals: terminal 18 is used for outputs 1, 2, and 3, terminal
22 is used for outputs 4, 5, and 6, terminal 26 is used for outputs 7, 8, and 9, 30 is used for outputs 10,
11, and 12.

Analog Outputs
AVR Output
Voltage Rating .................................. –10 to 10 Vdc
Current Rating .................................. 4 to 20 mA

GOV Output
Voltage Rating .................................. –10 to 10 Vdc
Current Rating .................................. 4 to 20 mA

GOV PWM Output

PWM Output ..................................... Pulse width modulated square wave, 500 Hz (±100 Hz)
Zero Error Output Duty Cycle........... 69.8% (±2.0%)
Specifications DGC-2020HD
9469300994 7-5

Minimum Voltage (hi) ....................... 10 Vdc

Maximum Voltage (lo) ...................... 0.5 Vdc when driving external 5.1 kΩ load to 13 Vdc external pull-up.
No-Load PWM Voltage Amplitude ... 14 V nominal

Load Share Output

Voltage Rating .................................. –10 to 10 Vdc

Metering
Generator and Bus Voltage (rms)
Metering Range ................................ 0 to 576 Vac (direct measurement)
577 to 99,999 Vac (through VT using VT ratio setting)
VT Ratio Range ................................ 1:1 to 125:1 in primary increments of 1
Accuracy* ......................................... ±1.0% of programmed rated voltage or ±2 Vac
Display Resolution ........................... 1 Vac
* Voltage metering indicates 0 V when generator voltage is below 2% of the full-scale rating.

Generator Current (rms)

Generator current is measured at the secondary windings of user-supplied 1 A or 5 A CTs.
Metering Range ................................ 0 to 5,000 Aac
CT Primary Range ........................... 1 to 5,000 Aac in primary increments of 1 Aac
Accuracy* ......................................... ±1.0% of programmed rated current or ±2 Aac
Display Resolution ........................... 1 Aac
* Current metering indicates 0 A when generator current is below 2% of the full-scale rating.

Generator and Bus Frequency

Frequency is sensed through the generator and bus voltage inputs (phases A and B).
Metering Range ................................ 10 to 90 Hz
Accuracy........................................... ±0.25% or 0.05 Hz
Display Resolution ........................... 0.1 Hz

Apparent Power
Indicates total kVA and individual line kVA (4-wire, line-to-neutral or 3-wire, line-to-line).

Measurement/Calculation Methods
Total ................................................. kVA = (VL-L × IL ×√3) ÷ 1000
4-Wire, Line-to-Neutral ..................... kVA calculated with respect to neutral
3-Wire, Line-to-Line .......................... A-phase kVA = VAB × IA ÷ 1000 ÷ √3
B-phase kVA = VBC × IB ÷ 1000 ÷ √3
C-phase kVA = VCA × IC ÷ 1000 ÷ √3
Accuracy........................................... ±2% of the full-scale indication or ±2 kVA *†
* kVA metering indicates 0 kVA when the generator kVA is below 2% of the full-scale rating.
† Applies when temperature is between −40°C to +70°C (–40°F to +158°F).

Power Factor
Metering Range ................................ 0.2 leading to 0.2 lagging
Calculation Method .......................... PF = cosine of the angle between phase AB voltage (Vab) and
phase A current (Ia) *
Accuracy........................................... ±0.01 †

DGC-2020HD Specifications
7-6 9469300994

* In single-phase AC-connected machines, it is the cosine of the angle between phase CA voltage (Vca)
and phase C current (Ic).
† Applies when temperature is between –40°C to +70°C (–40°F to +158°F).

Note
For the DGC-2020HD to correctly meter power factor, the generator
must be rotating in the same phase sequence as dictated by the
generator phase rotation setting.

Real Power
Indicates total kW and individual line kW (4-wire, line-to-neutral or 3-wire line-to-line).

Measurement/Calculation Methods
Total ................................................. PF × Total kVA
4-Wire, Line-to-Neutral ..................... kW calculated with respect to neutral
3-Wire, Line-to-Line .......................... A-phase kW = VAB × IA × PF ÷ 1000 ÷ √3
B-phase kW = VBC × IB × PF ÷ 1000 ÷ √3
C-phase kW = VCA × IC × PF ÷ 1000 ÷ √3
Accuracy........................................... ±2% of the full-scale indication or ±2 kW *†
* kW metering indicates 0 kW when the generator kW is below 2% of the full-scale rating.
† Applies when temperature is between –40°C to +70°C (–40°F to +158°F).

Oil Pressure
Metering Range ................................ 0 to 150 psi, 0 to 10.3 bar, or 0 to 1,034 kPa
Sensing Resistance Range .............. 0 to 250 Ω nominal
Sensing Accuracy ............................ ±0.8 Ω or ±2.0% of actual resistance
Display Resolution ........................... 1 psi, 0.07 bar, or 6.9 kPa

Coolant Temperature
Metering Range ................................ 32 to 410°F or 0 to 204°C
Sensing Resistance Range .............. 10 to 2,750 Ω nominal
Sensing Accuracy ............................ ±1.2 Ω or ±2.1% of actual resistance

Fuel Level
Metering Range ................................ 0 to 100%
Sensing Resistance Range .............. 0 to 250 Ω nominal
Sensing Accuracy ............................ ±0.8 Ω or ±1.9% of actual resistance
Display Resolution ........................... 1.0%

Battery Voltage
Metering Range ................................ 6 to 32 Vdc
Accuracy........................................... ±2% of actual indication or as low as ±0.2 Vdc
Display Resolution ........................... 0.1 Vdc

Engine RPM
Metering Range ................................ 0 to 4,500 rpm
Accuracy* ......................................... ±2% of actual indication or as low as ±2 rpm
Display Resolution ........................... 2 rpm
* When engine speed is below 2% of full-scale, reported rpm is 0.

Specifications DGC-2020HD
9469300994 7-7

Maintenance Timer
Maintenance timer indicates the time remaining until genset service is due. Value is retained in
nonvolatile memory.
Metering Range ................................ 0 to 5,000 hours
Update Interval ................................. 0.1 hours
Accuracy........................................... ±1% of actual indication or as low as ±12 minutes
Display Resolution ........................... 1 minute

Protection Functions
Overvoltage (59) and Undervoltage (27)
Pickup Range ................................... 0 to 576 V
Pickup Increment ............................. 1 V
Hysteresis Range ............................. 1 to 60 Vac
Inhibit Frequency Range .................. 20 to 90 Hz (27 function only)
Activation Delay Range .................... 0 to 600 s
Activation Delay Increment .............. 0.1 s

Underfrequency (81U) and Overfrequency (81O)

Pickup Range ................................... 37.5 to 66 Hz
Pickup Increment ............................. 0.01 Hz
Hysteresis Range ............................. 0.1 to 40 Hz
Activation Delay Range .................... 0 to 600 s
Activation Delay Increment .............. 0.1 s
Inhibit Voltage Range ....................... 0 to 100% of nominal voltage
Inhibit Voltage Increment ................. 1%

ROCOF (Rate of Change of Frequency) (81) (Optional)

Pickup Range ................................... 0.2 to 10 Hz/s
Pickup Increment ............................. 0.1 Hz/s
Pickup Accuracy ............................... 0.2 Hz/s
Activation Delay Range .................... 0 to 10,000 ms
Activation Delay Increment .............. 1 ms

Reverse and Forward Power (32)

Pickup Range ................................... 0 to 200% of nominal input rating
Pickup Increment ............................. 0.1%
Hysteresis Range ............................. 1 to 10%
Activation Delay Range .................... 0 to 600 s
Activation Delay Increment .............. 0.1 s

Loss of Excitation (40Q)

Pickup Range ................................... –150 to 0% of Rated kvar*
Pickup Increment ............................. 0.1%
Hysteresis Range ............................. 1 to 10%
Activation Delay Range .................... 0 to 600 s
Activation Delay Increment .............. 0.1 s
* Rated kvar is calculated on the System Settings, Rated Data screen in BESTCOMSPlus®.

Current Imbalance (46) (Optional)

Pickup Range ................................... 0.18 to 4 Aac (1 A current sensing)
0.9 to 20 Aac (5 A current sensing)
Hysteresis......................................... 2 %

DGC-2020HD Specifications
7-8 9469300994

Time Dial Range .............................. 0 to 7,200 s (fixed time curve)

0 to 99 (46 – K factor curve)
Time Dial Increment ......................... 1
Inverse Time Curves ........................ See the Time Overcurrent Characteristic Curves chapter in the
Configuration manual.

Overcurrent (51) (Optional)

Pickup Range ................................... 0.18 to 4 Aac (1 A current sensing)
0.9 to 20 Aac (5 A current sensing)
Hysteresis......................................... 2 %
Time Dial Range .............................. 0 to 7,200 s (fixed time curve)
0 to 9.9 (inverse curve time multiplier)
Time Dial Increment ......................... 0.1
Inverse Time Curves ........................ See the Time Overcurrent Characteristic Curves chapter in the
Configuration manual.

Caution
For 1 A current sensing, current shall not exceed 3 amperes for 30
seconds or 4 amperes for 1 second. For 5 A current sensing, current
shall not exceed 15 amperes for 30 seconds or 20 amperes for 1
second. Exceeding the above limits may result in equipment damage.

Phase Current Differential (87) (Optional)

Minimum Restrained Pickup ............ 0.1 to 1 (multiples of tap)
Minimum Restrained Increment ....... 0.01
2nd Slope Pickup ............................... 0.1 to 20 (in multiples of tap)
2nd Slope Increment ......................... 0.01
Restraint Slope ................................ 15 to 60 %
Restraint Slope Increment................ 1%
Alarm Slope ...................................... 50 to 100%
Alarm Slope Increment..................... 1%
Unrestrained Tripping Pickup ........... 0 to 21 (in multiples of tap)
Unrestrained Tripping Increment ..... 1
2nd Harmonic .................................... 5 to 75%
2nd Harmonic Increment ................... 1%
5th Harmonic ..................................... 5 to 75%
5th Harmonic Increment .................... 1%
Time Delay ....................................... 0 to 60 s
Time Delay Increment ...................... 0.1 s
Transient Operate Time ................... 0.4 to 10 s
Transient Operate Time Increment .. 0.1 s
Transient Delay Time ....................... 0 to 10
Transient Delay Time Increment ...... 0.1 s

Neutral Current Differential (87N) (Optional)

Iop Minimum ..................................... 0.1 to 5 A
Iop Minimum Increment.................... 0.01 A
Hysteresis......................................... 5%
Time Delay Range ........................... 0 to 60 s
Time Delay Increment ...................... 0.1 s
Overcorrection Coefficient Range .... 1 to 1.3
Overcorrection Coefficient Inc. ......... 0.01
Transient Delay Time Range ........... 0 to 10 s
Transient Delay Time Increment ...... 0.1

Specifications DGC-2020HD
9469300994 7-9

Phase Voltage Imbalance (47) (Optional)

Pickup Range ................................... 0 to 150 Vac
Pickup Increment ............................. 1 Vac
Hysteresis Range ............................. 1 to 5 Vac
Activation Delay Range .................... 0 to 600 s
Activation Delay Increment .............. 0.1 s

Vector Shift (78) (Optional)

Pickup Range ................................... 2 to 90°
Pickup Increment ............................. 1°
Hysteresis......................................... 0.5 degrees
Accuracy........................................... ±1°

Field Overvoltage
Pickup Range ................................... 1 to 120 Vdc
Pickup Increment ............................. 1 Vdc
Time Delay Range ........................... 0 to 30 s
Time Delay Increment ...................... 0.1 s

Loss of Sensing
Time Delay Range ........................... 0 to 600 s
Time Delay Increment ...................... 0.1 s
Voltage Balanced Level Range ........ 0 to 100%
Voltage Balanced Level Increment .. 0.1%
Voltage Unbalanced Level Range ... 0 to 100% (three-phase mode only)
Voltage Unbalanced Level Inc. ........ 0.1% (three-phase mode only)
Fault Current Range ......................... 0.9 to 20 A
Fault Current Increment ................... 0.001 A

Exciter Diode Monitor (Optional)

Pickup Range ................................... 0.1 to 10 A
Pickup Increment ............................. 0.1 A
Time Delay Range ........................... 0 to 30 s
Time Delay Increment ...................... 0.1 s

Logic Timers
Hours Setting Range ........................ 0 to 250
Hours Setting Increment .................. 1
Minutes Setting Range ..................... 0 to 59
Minutes Setting Increment ............... 1
Seconds Setting Range ................... 0 to 59
Seconds Setting Increment .............. 1
Accuracy........................................... ±15 ms

Communication Interface
CAN (SAE J1939)
Differential Bus Voltage.................... 1.5 to 3 Vdc
Maximum Voltage ............................ –32 to +32 Vdc with respect to negative battery terminal
Communication Rate ........................ 250 kb/s
CAN 1 Terminals .............................. 51 (low), 52 (high), and 53 (shield)
CAN 2 Terminals .............................. 54 (low), 55 (high), and 53 (shield)

DGC-2020HD Specifications
7-10 9469300994

Notes
1. If the DGC-2020HD is providing one end of the J1939 bus, a 120
ohm, ½ watt terminating resistor should be installed across
terminals 51 (CAN1L) and 52 (CAN1H) or 54 (CAN2L) and 55
(CAN2H).
2. If the DGC-2020HD is not providing one end of the J1939 bus, the
stub connecting the DGC-2020HD to the bus should not exceed
914 mm (3 ft) in length.
3. The maximum bus length, not including stubs, is 40 m (131 ft).
4. The J1939 drain (shield) should be grounded at one point only. If
grounded elsewhere, do not connect the drain to the DGC-
2020HD.
5. It is recommended to upgrade the firmware in all AEM-2020s and
CEM 2020s that share a CAN bus network with a VRM-2020.
Upgrade CEM-2020s to firmware version 1.01.05 or later.
Upgrade AEM 2020s to firmware version 1.00.06 or later.

Ethernet
Dual Copper Connector ................... RJ-45, 10/100BASE-T (style number xxxxDxxxx)
Fiber Optic Connector ...................... ST, 100BASE-FX (style number xxxxFxxxx)
Fiber Optic Cable ............................. 1300 nanometer, near-infrared (NIR) light wavelength transmitted via
two strands of multimode optical fiber, one for receive (RX) and the
other for transmit (TX).
Industrial Ethernet devices designed to comply with IEC 61000-4 series of specifications are
recommended.

External Dial-Out Modem (RS-232)

Protocol ............................................ ASCII
Data Transmission ........................... Full Duplex
Baud ................................................. 4,800 to 115,200
Data Bits ........................................... 8
Parity ................................................ None
Stop Bits ........................................... 1
Connector Type ................................ DB-9 Connector (Male)

IRIG-B Time Synchronization

Standard: .......................................... 200-04, Format B002
Input Signal ...................................... Demodulated (dc level-shifted signal)
Logic High Level ............................... 3.5 Vdc, minimum
Logic Low Level ............................... 0.5 Vdc, maximum
Input Voltage Range ........................ –10 to +10 Vdc
Input Resistance .............................. Nonlinear, approximately 4 kΩ at 3.5 Vdc, 3 kΩ at 20 Vdc
Response Time ................................ < 1 cycle
Terminals.......................................... 59 (IRIG-B +), 60 (IRIG-B –)

Modbus® (RS-485)
Baud ................................................. 1,200 to 115,200
Data Bits ........................................... 8
Parity ................................................ None
Stop Bits ........................................... 1

Specifications DGC-2020HD
9469300994 7-11

Terminals.......................................... 56 (485 A), 57 (485 B), and 58 (485 shield)

RS-485 Modbus supports a single Modbus Master only.

RDP-110
Minimum Wire Size .......................... 20 AWG (0.52 mm2)
Maximum Wire Length ..................... 4,000 feet (1,219 meters)
Terminals.......................................... 61 (RDP-110 TxD+), 62 (RDP-110 TxD–)

USB
Specification Compatibility ............... USB 2.0
Connector Type ................................ Mini-B jack

Real-Time Clock
Clock has leap year and selectable daylight saving time correction. Backup battery sustains timekeeping
during losses of DGC-2020HD control power.
Resolution ........................................ 1 s
Accuracy........................................... ±1.73 s/d at 25°C (77°F)

Clock Holdup
Battery Holdup Time ........................ Approximately 10 years
Battery Type ..................................... Rayovac BR2032, lithium, coin-type, 3 Vdc, 195 mAh
Basler Electric P/N 38526

Note
Failure to replace the battery with Basler Electric P/N 38526 may void
the warranty.

Caution
Replacement of the backup battery for the real-time clock should be
performed only by qualified personnel.
Do not short-circuit the battery, reverse battery polarity, or attempt to
recharge the battery. Observe polarity markings on the battery socket
while inserting a new battery. The battery polarity must be correct in
order to provide backup for the real-time clock.
It is recommended that the battery be removed if the DGC-2020HD is
to be operated in a salt-fog environment. Salt-fog is known to be
conductive and may short-circuit the battery.

LCD Heater
DGC-2020HDs with the default monochrome LCD option (style xNxxxxxxx) are equipped with an LCD
heater. The ambient temperature is monitored by a temperature sensor located near the LCD inside the
DGC-2020HD. The LCD heater turns on when the ambient temperature falls below –5°C (23°F). The
heater turns off when the ambient temperature rises above 5°C (41°F). This range of operation
implements 10°C (18°F) of hysteresis between when the heater turns on and turns off.

DGC-2020HD Specifications
7-12 9469300994

Type Tests
Shock
Withstands 15 G in 3 perpendicular planes.

DGC-2020HD with DIN Rail mount (style xRxxxxxxx) and Rear Panel mount (style xPxxxxxxx)
Withstands 10 G, 3 times, in 3 perpendicular planes.

Vibration
Tested for 8 hours in three perpendicular planes.
3 to 25 Hz ......................................... at 0.063 in (1.6 mm) peak amplitude
25 to 2,000 Hz .................................. at 5 G

DGC-2020HD with DIN Rail mount (style xRxxxxxxx) and Rear Panel mount (style xPxxxxxxx)
Tested for 2 hours and 40 minutes in three perpendicular planes.
10 to 150 Hz at 2.5 G

HALT (Highly Accelerated Life Testing)

HALT is used by Basler Electric to prove that our products will provide the user with many years of
reliable service. HALT subjects the device to extremes in temperature, shock, and vibration to simulate
years of operation, but in a much shorter period span. HALT allows Basler Electric to evaluate all possible
design elements that will add to the life of this device. As an example of some of the extreme testing
conditions, the DGC-2020HD was subjected to temperature tests (tested over a temperature range of
–85°C to +120°C), vibration tests (of 5 to 40 G at +30°C), and temperature/vibration tests (tested at 40 G
over a temperature range of –85°C to +120°C). Combined temperature and vibration testing at these
extremes proves that the DGC-2020HD is expected to provide long-term operation in a rugged
environment. Note that the vibration and temperature extremes listed in this paragraph are specific to
HALT and do not reflect recommended operation levels.

Ignition System
Tested in close proximity to an unshielded, unsuppressed Altronic DISN 800 Spark Ignition System.

Environment
Operating Temperature .................... –40 to +158°F (–40 to +70°C)∗
Storage Temperature ....................... –40 to +185°F (–40 to +85°C)
Salt Fog ............................................ IEC 60068
Ingress Protection ............................ IEC IP56 for front panel
Humidity ........................................... IEC 68-2-78
∗ The operating temperature of DGC-2020HD units with the color touch screen display option
(style xTxxxxxxx) is derated to –4 to +158°F (–20 to +70°C).

Agency, Standards, and Directives

UL Approval
The DGC-2020HD is a Recognized Component applicable to the Canadian and US safety standards and
requirements by UL. The product is covered under UL File (E97035 FTPM2/FTPM8).
The DGC-2020HD is a Listed Device as a Protective Relay applicable to the Canadian and US safety
standards and requirements by UL. The product is covered under UL File (E97033 NRGU/ NRGU7).

Specifications DGC-2020HD
9469300994 7-13

The DGC-2020HD ground fault protection circuit complies with the Calibration and Withstand tests of UL
1053; as required by UL6200. Field Testing is required when the DGC-2020HD is used for Ground Fault
Protection as described within UL 1053 Section 31.
See the Time Curve Characteristics chapter in the Configuration manual for the listing of curves verified to
meet UL1053.
Caution
To follow UL guidelines, replacement of the backup battery for the
real-time clock should be performed only by qualified personnel.

CSA Certification
The DGC-2020HD is Certificated under CSA report 1042505 (LR23131-138S) and evaluated to the
following standards through CSA:
• CSA C22.2 No. 0
• CSA C22.2 No. 14

CE Compliance
This product has been evaluated and complies with the relevant essential requirements set forth in the
following EC Directives and by the EU legislation:
• Low Voltage Devices (LVD) - 2014/35/EU
• Electromagnetic Compatibility (EMC) - 2014/30/EU
• Hazardous Substances (ROHS2) -2011/65/EU
Harmonized Standards used for evaluation:
• EN 50178 - Electronic Equipment for use in Power Installations
• EN 61000-6-4 - Electromagnetic Compatibility (EMC), Generic Standards, Emission Standard for
Industrial Environments
• EN 61000-6-2 - Electromagnetic Compatibility (EMC), Generic Standards, Immunity for Industrial
Environments
• EN 50581 – Technical Documentation for the Assessment of Electrical and Electric Products with
Respect to the Restriction of Hazardous Substances (ROHS2)

NFPA Compliance
Designed to comply with NFPA Standard 110, Standard for Emergency and Standby Power.

EAC Mark (Eurasian Conformity)

• TC RUUS.HO03.B.00742

Maritime Recognition
American Bureau of Shipping (ABS) – For current certificates, see [Link].

Patent
Basler Electric. Load anticipation feature. US Patent 9,574,511, filed May 21, 2015, and issued February
21, 2017.

Physical
Weight .............................................. 5.70 lb (2.59 kg)
Dimensions....................................... See the Mounting chapter.
DGC-2020HD Specifications
7-14 9469300994

Specifications DGC-2020HD
9469300994 8-1

8 • Maintenance
Preventive maintenance consists of periodically checking that the connections between the DGC-2020HD
and the system are clean and tight. Periodically check that the mounting hardware is clean and fastened
with the proper amount of torque. DGC-2020HD units are manufactured using state-of-the-art, surface-
mount technology. These components are encased in potting material. As such, Basler Electric
recommends that no repair procedures be attempted by anyone other than Basler Electric personnel.

Storage
This device contains long-life aluminum electrolytic capacitors. For devices that are not in service (spares
in storage), the life of these capacitors can be maximized by energizing the device for 30 minutes once
per year.

Backup Battery Replacement

The backup battery for the real-time clock is a standard feature of the DGC-2020HD. A battery is used to
maintain clock function during loss of power supply voltage. In mobile substation and generator
applications, the primary battery system that supplies the DGC-2020HD power supply may be
disconnected for extended periods (weeks, months) between uses. Without battery backup for the real
time clock, clock functions will cease if battery input power is removed.
The backup battery has a life expectancy of approximately five years depending on conditions. After this
time, you should contact Basler Electric to order a new battery, Basler Electric P/N 38526.

Caution
Replacement of the backup battery for the real-time clock
should be performed only by qualified personnel.
Do not short-circuit the battery, reverse battery polarity, or
attempt to recharge the battery. Observe polarity markings next
to the battery socket when inserting a new battery. The battery
polarity must be correct in order to provide backup for the real-
time clock.

Note
Failure to replace the battery with Basler Electric P/N 38526
may void the warranty.

Battery Replacement Procedure

Battery access is located on the rear of the DGC-2020HD. See the Terminals and Connectors chapter for
battery location.
Step 1: Remove the DGC-2020HD from service.
Step 2: Locate the battery socket on the rear of the DGC-2020HD. Remove the old battery. Consult
your local ordinance for proper battery disposal.
Step 3: Insert the new battery so that the polarity markings on the battery match the polarity markings
next to the battery socket.
Step 4: Return the DGC-2020HD to service.

DGC-2020HD Maintenance
8-2 9469300994

Maintenance DGC-2020HD
9469300994 9-1

9 • Troubleshooting
If you do not get the results that you expect from the DGC-2020HD, first check the programmable settings
for the appropriate function. Use the following troubleshooting procedures when difficulties are
encountered in the operation of your genset control system.

Communications
Ethernet Communication Does Not Work Properly
Step 1. Verify that the proper port of your computer is being used. For more information, refer to the
Communication chapter in the Configuration manual.
Step 2. Verify the network configuration of the DGC-2020HD is set up properly. For more information,
refer to the Communication chapter in the Configuration manual.
Step 3. Verify that all Ethernet devices comply with IEC 61000-4 series of specifications for Industrial
Ethernet Devices. Commercial devices are not recommended and may result in erratic network
communications.

USB Communication Does Not Work Properly

Step 1. Verify that the proper port of your computer is being used. For more information, refer to the
Communication chapter in the Configuration manual.

USB Driver Did Not Install Properly on Windows® 7, 8, or 10

Step 1. If the message in Figure 9-1 is shown, close all programs and restart the computer.

Figure 9-1. Driver Software Installation

Step 2. Open the Windows®Device Manger as shown in Figure 9-2. Right-click on DGC-2020HD (or
Unknown Device) under Other Devices and select Properties.

DGC-2020HD Troubleshooting
9-2 9469300994

Figure 9-2. Device Manager

Step 3. In the Properties windows, select the Driver tab and click Update Driver. See Figure 9-3.

Figure 9-3. DGC-2020HD Properties

Step 4. Select Browse My Computer for Driver Software as shown in Figure 9-4.

Troubleshooting DGC-2020HD
9469300994 9-3

Figure 9-4. Update Driver Software - DGC-2020HD

Step 5. Click Browse and navigate to C:\Program Files\Basler Electric\USB Device Drivers\USBIO.
Click Next. See Figure 9-5.

Figure 9-5. Update Driver Software - DGC-2020HD

Step 6. If a Windows Security window (Figure 9-6) appears, click Install.

DGC-2020HD Troubleshooting
9-4 9469300994

Figure 9-6. Windows Security

Step 7. The window in Figure 9-7 appears if driver installation was successful.

Figure 9-7. Driver Software Update Successful

CAN Communication Does Not Work Properly

Step 1: Verify that there is a 120-ohm termination resistor on each end of the bus section of the wiring,
and that there are not any termination resistors at any node connections that are on stubs from
the main bus.
Step 2: Check all CAN wiring for loose connections and verify that the CAN H and CAN L wires have
not gotten switched somewhere on the network.
Step 3: Verify that the cable length of the bus section of the wiring does not exceed 40 meters (131
feet), and verify that any stubs from the main bus do not exceed 3 meters (9.8 feet) in length.
Step 4: If the engine is equipped with a Volvo or mtu ECU, verify that the ECU Configuration setting is
set to match the actual ECU configuration.

RPM Control over CAN Bus Does Not Function

Step 1: Check that Engine Parameter Transmit under the CAN Bus 2 (ECU) settings is enabled.
Step 2: Check that CAN Bus RPM Request under Speed Setup is set to enabled.
Step 3: Check to determine if there are multiple ECUs on the engine. If so, consult the engine
manufacturer’s documentation to determine the CAN Bus 2 address of the ECU that will
respond to rpm requests. Set the Engine ECU Address setting under the CAN Bus 2 (ECU)
Troubleshooting DGC-2020HD
9469300994 9-5

settings to that value. The Engine ECU Address setting under the CAN Bus 2 (ECU) settings
should be set to the address the Engine ECU claims on the J1939 network.
Step 4: Consult the engine manufacturer’s documentation and connect to the ECU with a service tool
to determine if the ECU will respond only to communications from a particular CAN Bus
Address. Set the CAN Bus address under the CAN Bus 2 (ECU) settings to that value. The
CAN Bus address under the CAN Bus 2 (ECU) settings is the Address the DGC claims on the
J1939 network.

Inputs and Outputs

Programmable Inputs Do Not Operate as Expected
Step 1. Verify that all wiring is properly connected. Refer to the Typical Applications chapter.
Step 2. Confirm that the inputs are programmed properly.
Step 3. Ensure that the input at the DGC-2020HD is actually connected to the BATT– terminal (P4-49).

Programmable Outputs Do Not Operate as Expected

Step 1. Verify that all wiring is properly connected. Refer to the Typical Applications chapter.
Step 2. Confirm that the outputs are programmed properly.

Metering/Display
Incorrect Display of Battery Voltage, Coolant Temperature, Oil Pressure, or Fuel Level
Step 1. Verify that all wiring is properly connected. Refer to the Typical Applications chapter.
Step 2. Confirm that the sender negative terminals are connected to the negative battery terminal and
the engine-block side of the senders. Current from other devices sharing this connection can
cause erroneous readings.
Step 3. If the displayed battery voltage is incorrect, ensure that the proper voltage is present between
the BATT+ terminal (P4-48) and the sender negative terminals.
Step 4. Verify that the correct senders are being used.
Step 5. Use a voltmeter connected between the BATT– terminal (P4-49) and the sender negative
terminals on the DGC-2020HD to verify that there is no voltage difference at any time. Any
voltage differences may manifest themselves as erratic sender readings. Wiring should be
corrected so that no differences exist.
Step 6: Check the sender wiring and isolate sender wiring from any of the ac wiring in the system. The
sender wiring should be located away from any power ac wiring from the generator and any
ignition wiring. Separate conduits should be used for sender wiring and any ac wiring.

Incorrect Display of Generator Voltage

Step 1. Verify that all wiring is properly connected. Refer to the Typical Applications chapter.
Step 2. Ensure that the proper voltage is present at the DGC-2020HD voltage sensing inputs (P8-86,
P8-88, P8-90, and P8-91).
Step 3. Verify that the voltage transformer ratio and sensing configuration is correct.
Step 4. Confirm that the voltage sensing transformers are correct and properly installed.

Incorrect Measurement or Display of Generator Current

Step 1. Verify that all wiring is properly connected. Refer to the Typical Applications chapter.

DGC-2020HD Troubleshooting
9-6 9469300994

Step 2. Ensure that the proper current is present at the DGC-2020HD current sensing inputs 1, 2, 3, 4,
5, and 6.
Step 3. Verify that the current sensing transformer ratios are correct.
Step 4. Confirm that the current sensing transformers are correct and properly installed.

Incorrect Display of Engine RPM

Step 1. Verify that all wiring is properly connected. Refer to the Typical Applications chapter.
Step 2. Verify that the Flywheel Teeth setting is correct.
Step 3. Verify that the prime mover governor is operating properly.
Step 4. Verify that the measured frequency of the voltage at the MPU input (P9-106 and P9-107) is
correct.
Step 5. If the MPU is shared with the governor, verify that the polarity of the MPU input to the governor
matches the polarity of the MPU input to the DGC-2020HD.

DGC-2020HD Indicates Incorrect Power Factor

Check the rotation of the machine and the labeling of the A-B-C terminals. The machine must be rotating
in the same phase sequence as dictated by the generator phase rotation setting for correct power factor
metering. A power factor indication of 0.5 with resistive load present is a symptom of incorrect phase
rotation.

Ground Faults Detected in Ungrounded System Applications

Step 1: Verify that there is no connection from the neutral connection of the generator to the system
ground.
Step 2: Perform insulation resistance tests on the system wiring to check for insulation integrity in the
overall system.
Step 3: If ground faults are detected on a DGC-2020HD in an ungrounded system application, it is
recommended that potential transformers be employed on the voltage sensing inputs to provide
full isolation between the DGC-2020HD and monitored voltage phases.
Step 4: If potential transformers are in place, remove the connectors from the DGC-2020HD one at a
time. If removal of a connector removes the ground fault, check the system wiring to that
connector and out into the system to verify that connections are secure and all wiring insulation
is in good condition.

Generator Breaker and Mains Breaker

Generator Breaker Will Not Close to a Dead Bus
Step 1: Review the description of how the generator breaker logic element functions contained in the
GENBRK logic element description in the BESTlogic™Plus chapter in the Configuration manual.
Step 2: Review the section on breaker close requests in the Breaker Management chapter in the
Configuration manual.
Step 3: Navigate to the Settings, Breaker Management, Breaker Hardware, Gen Breaker screen and
set Dead Bus Closure to Enable.
Step 4: Verify that the Generator status is stable. The breaker will not close if the generator status is
not stable. Check status by using the Metering Explorer in BESTCOMSPlus and verify that
when the generator is running, the Generator Stable status LED is lit. If necessary, modify the
settings on the Settings, Breaker Management, Bus Condition screen.
Step 5: Verify the bus status is Dead. Check status by using the Metering Explorer in BESTCOMSPlus
and verify that when the generator is running, the Bus Dead status LED is lit. If necessary,
modify the settings on the Settings, Breaker Management, Bus Condition screen.
Troubleshooting DGC-2020HD
9469300994 9-7

Step 6: Verify the connections in BESTlogicPlus Programmable Logic to the generator breaker logic
element. The Status input must be driven by an “A” or normally open contact from the
generator breaker. The Open and Close command inputs on the left side of the logic block are
inputs for open and close commands. These can be wired to physical inputs if it is desired to
have open and close command switches. If they are wired, they must either be pulsed inputs,
or some logic must be employed so that the open and close command inputs are never driven
at the same time. If these are both driven at the same time, the breaker is receiving open and
close commands simultaneously. The breaker will not change state if it is being commanded to
open and close at the same time.
Step 7: Verify the breaker is receiving a close command. Breaker close command sources are:
• The DGC-2020HD itself when the automatic mains fail transfer (ATS) feature is enabled.
• The DGC-2020HD itself when the Run with Load logic element receives a Start pulse in the
programmable logic.
• The DGC-2020HD itself when started from the Exercise Timer and the Run with Load box
is checked in the Generator Exerciser settings.
• Manual Breaker Close Input Contacts applied to the Open and Close inputs on the left side
of the Generator Breaker logic element in the programmable logic.
Step 8: Verify the wiring to the breaker from the DGC-2020HD. If it appears correct, you can manually
close and open by modifying the programmable logic. Map some unused outputs to the Open
and Close outputs from the Gen Breaker Block in the programmable logic. Map a virtual switch
to the logic output that would normally be the breaker open output. Map another virtual switch
to the logic output that would normally be the breaker close output. Connect with
BESTCOMSPlus, and exercise the virtual switches using the Control panel located in the
Metering Explorer. Never turn open and close on at the same time. This could damage the
breaker and/or motor operator. If everything is working as expected, restore the logic to its
original diagram.

Generator Breaker Does Not Open When It Should

Step 1: Review the description of how the generator breaker logic element functions contained in the
GENBRK logic element description in the BESTlogicPlus chapter in the Configuration manual.
Step 2: Review the section on breaker operation requests in the Breaker Management chapter in the
Configuration manual.
Step 3: Verify the connections in BESTlogicPlus Programmable Logic to the generator breaker logic
element. The Status input must be driven by an “A” or normally open contact from the generator
breaker. The Open and Close command inputs on the left side of the logic block are inputs for
open and close commands. These can be wired to physical inputs if it is desired to have open
and close command switches. If they are wired, they must either be pulsed inputs, or some
logic must be employed so that the open and close command inputs are never driven at the
same time. If these are both driven at the same time, the breaker is receiving open and close
commands simultaneously. The breaker will not change state if it is being commanded to open
and close at the same time.
Step 4: Verify the breaker is receiving an open command. Breaker open command sources are:
• The DGC-2020HD itself when the automatic transfer (ATS) feature is enabled.
• The DGC-2020HD itself when the Run with Load logic element receives a Stop pulse in the
programmable logic.
• The DGC-2020HD itself when shutting down the engine due to an active alarm.
• The DGC-2020HD itself when ending a run session from the Exercise Timer and the Run
with Load box is checked in the Generator Exerciser settings.
• Manual Breaker Open Input Contacts applied to the Open and Close inputs on the left side
of the Generator Breaker logic element in the programmable logic.

DGC-2020HD Troubleshooting
9-8 9469300994

Step 5: Verify the wiring to the breaker from the DGC-2020HD. If it appears correct, you can manually
close and open by modifying the programmable logic. Map some unused outputs to the Open
and Close outputs from the Gen Breaker Block in the programmable logic. Map a virtual switch
to the logic output that would normally be the breaker open output. Map another virtual switch
to the logic output that would normally be the breaker close output. Connect with
BESTCOMSPlus, and exercise the virtual switches using the Control panel located in the
Metering Explorer. Never turn open and close on at the same time. This could damage the
breaker and/or motor operator. If everything is working as expected, restore the logic to its
original diagram.

Mains Breaker Does Not Open When Mains Fails

Step 1: Verify that a Mains Breaker has been configured by examining the settings on the Settings,
Breaker Management, Breaker Hardware screen.
Step 2: Verify the mains breaker has been correctly included in the programmable logic.
Step 3: Verify that the Mains Fail Transfer parameter is set to Enabled on the Settings, Breaker
Management, Breaker Hardware screen.
Step 4: Verify that a failure of the mains is detected by the DGC-2020HD. Check status using the
Metering Explorer in BESTCOMSPlus and verify that the Mains Failed status LED is lit when
the power on the DGC-2020HD bus voltage input is either out of voltage or frequency range. If
necessary, modify the settings on the Settings, Breaker Management, Bus Condition screen to
achieve correct detection.
Step 5: Verify the wiring to the breaker from the DGC-2020HD. If it appears correct, you can do a
manual close and open by modifying the programmable logic. Map some unused outputs to the
Open and Close outputs from the Gen Breaker Block in the programmable logic. Map a virtual
switch to the logic output that would normally be the breaker close output. Map another virtual
switch to the logic output that would normally be the breaker close output. Connect with
BESTCOMSPlus, and exercise the virtual switches using the Control panel located in the
Metering Explorer. Never turn open and close on at the same time. This could damage the
breaker and/or motor operator. If everything is working as expected, restore the logic to its
original diagram.

Mains Breaker Does Not Close After Mains Returns

Step 1: Verify that a Mains Breaker has been configured by examining the settings on the Settings,
Breaker Management, Breaker Hardware screen.
Step 2: Verify the mains breaker has been correctly included in the programmable logic.
Step 3: Verify that the Mains Fail Transfer parameter is set to Enabled on the Settings, Breaker
Management, Breaker Hardware screen.
Step 4: Verify that stable mains power is detected by the DGC-2020HD. Check status using the
Metering Explorer in BESTCOMSPlus and verify that the Mains Stable status LED is lit when
the power on the DGC-2020HD bus voltage input is good. If necessary, modify the settings on
the Settings, Breaker Management, Bus Condition screen to achieve correct detection.
Step 5: Verify the wiring to the breaker from the DGC-2020HD. If it appears correct, you can do a
manual close and open by modifying the programmable logic. Map some unused outputs to the
Open and Close outputs from the Gen Breaker Block in the programmable logic. Map a virtual
switch to the logic output that would normally be the breaker open output. Map another virtual
switch to the logic output that would normally be the breaker close output. Connect with
BESTCOMSPlus, and exercise the virtual switches using the Control panel located in the
Metering Explorer. Never turn open and close on at the same time. This could damage the
breaker and/or motor operator. If everything is working as expected, restore the logic to its
original diagram.

Troubleshooting DGC-2020HD
9469300994 9-9

Synchronizer
Determining if the Synchronizer is Active
Step 1: Disable the speed trim function.
Step 2: Initiate a breaker close request by one of the methods listed in the Breaker Management
chapter in the Configuration manual.
Step 3: Check for raise and/or lower pulses coming from the DGC-2020HD if the governor or AVR bias
control output type is contact.
Step 4: Check the governor and/or AVR bias analog outputs on the DGC-2020HD with a volt meter if
the governor or AVR bias control output type is analog.
Step 5: The voltages or raise/lower pulses should be changing when the synchronizer is active. If there
are no raise/lower pulses, or if the analog bias voltages do not change, the synchronizer is not
active.

Synchronizer Not Active

Step 1: Check style number to verify that the DGC-2020HD has the synchronizer option. If the
synchronizer option does not exist in the style number, you may contact Basler Electric and
request a style number change.
Step 2: Check status using the Metering Explorer in BESTCOMSPlus® and verify that when the
generator is running, the Generator Stable status LED is lit and the Bus Stable LED is lit. Adjust
the Bus Condition Detection settings accordingly. The synchronizer will never activate if the Bus
is Dead or Failed (i.e. not stable).
Step 3: Check that the DGC-2020HD is trying to initiate a breaker closure. To determine the sources of
breaker close requests, refer to the Breaker Management chapter in the Configuration manual.

Synchronizer Active for a Short Time, Then Stops

Step 1: Check if a Sync Fail pre-alarm or a Breaker Close Fail pre-alarm is occurring or has occurred.
The synchronizer stops acting when such a pre-alarm occurs. Press the Off button or the Reset
button on the DGC-2020HD front panel to clear these pre-alarms.
Step 2: Verify that the Sync Fail Activation delay is sufficiently long to allow the synchronizer to
complete the synchronization process.
Step 3: Verify that the Breaker Close Wait time is not too short causing a pre-alarm to occur before the
breaker closes when a breaker close is initiated by the DGC-2020HD.

Synchronizer Does Not Lower Engine Speed Allowing Alignment of Bus and Generator
Navigate to the Settings, Programmable Outputs, Analog Output Settings, GOV Output screen and set
Speed Response to Decreasing.

Synchronizer Does Not Raise Engine Speed Allowing Alignment of Bus and Generator
Using the front panel HMI, navigate to the Settings > Programmable Outputs > Analog Output Settings >
GOV Output screen and change the Speed Response setting from Increasing to Decreasing.

Synchronizer Does Not Lower the Generator Voltage to Achieve Matching of Bus and
Generator Voltages
Navigate to the Settings, Programmable Outputs, Analog Output Settings, AVR Output screen and set
Voltage Response to Decreasing.

DGC-2020HD Troubleshooting
9-10 9469300994

Synchronizer Does Not Raise Generator Voltage to Achieve Matching of Bus and
Generator Voltages
Navigate to the Settings, Programmable Outputs, Analog Output Settings, AVR Output screen and
change the Voltage Response setting from Increasing to Decreasing.

Speed Bias
Engine Speed Does Not Change When Speed Bias Voltage Changes
Verify that the engine speed will change when the speed bias changes. As a test, you can force a voltage
on the speed bias output by setting the Min Output Voltage and Max Output Voltage to the same value by
navigating to Settings, Programmable Outputs, Analog Output Settings, GOV Output. If the bias is current
based, you can force a fixed current by setting the Governor Output Voltage Minimum and Maximum to
the same value by navigating to Settings, Programmable Outputs, Analog Output Settings, GOV Output.
If the speed still does not change when varying the bias:
• Verify that the governor or ECU is equipped and configured to accept bias inputs.
• Check connections to verify the wiring to the governor bias is correct.
• If you have an engine with an ECU, check ECU programming to verify it is set up to accept a
speed bias input.

Engine Speed Decreases When Speed Bias is Increased

Navigate to the Settings, Programmable Outputs, Analog Output Settings, GOV Output screen and set
Speed Response to Decreasing.

Engine Speed Increases When Speed Bias is Decreased

Navigate to the Settings, Programmable Outputs, Analog Output Settings, GOV Output screen and set
Speed Response to Decreasing.

Load Anticipation
Large Frequency Overshoot on Recovery
Kla Gain may be too high and GOV output may be saturated. See Figure 9-8. Navigate to Settings, Bias
Control Settings, Governor Bias Control Settings and decrease Load Anticipation, Kla Gain.

Troubleshooting DGC-2020HD
9469300994 9-11

Figure 9-8. Kla Gain Too High, GOV Output Saturated, Frequency Overshoots on Recovery
Tla Washout Filter Constant may be too high. Load anticipation output bias is held too long and has
significant magnitude after frequency reached nominal. See Figure 9-9. Navigate to Settings, Bias Control
Settings, Governor Bias Control Settings and decrease Load Anticipation, Tla Washout Filter Constant.

Figure 9-9. Tla Too High Causing Recovery Overshoot

Poor Recovery
Kla Gain may be too low. See Figure 9-10. Navigate to Settings, Bias Control Settings, Governor Bias
Control Settings and increase Load Anticipation, Kla Gain.

DGC-2020HD Troubleshooting
9-12 9469300994

Figure 9-10. Kla Too Low – Frequency Recovery Improved with ~2 Hz Deviation
Tla Washout Filter Constant may be too low. GOV output decays rapidly before speed dip has finished.
See Figure 9-11. Navigate to Settings, Bias Control Settings, Governor Bias Control Settings and
increase Load Anticipation, Tla Washout Filter Constant.

Figure 9-11. Tla Too Low Causing Poor Recovery

Voltage Bias
Generator Voltage Does Not Change When Voltage Bias Changes
As a test, you can force a fixed voltage on the AVR bias output by setting the Min Output Voltage and
Max Output Voltage to the same value by navigating to Settings, Programmable Outputs, Analog Output

Troubleshooting DGC-2020HD
9469300994 9-13

Settings, AVR Output. If the bias is current based, you can force a fixed current by setting the Min Output
Current and Max Output Current to the same value by navigating to Settings, Programmable Outputs,
Analog Output Settings, AVR Output.
If the voltage still does not change when varying the bias:
• Verify that the AVR is equipped and configured to accept bias inputs.
• Check connections to verify the wiring to the AVR bias is correct.
• If you have a digital voltage regulator, verify it is set up and programmed to accept a voltage bias
input.

Generator Voltage Decreases When AVR Speed Bias is Increased

Navigate to the Settings, Programmable Outputs, Analog Output Settings, AVR Output screen and set
Voltage Response to Decreasing.

Generator Voltage Increases When AVR Bias is Decreased

Navigate to the Settings, Programmable Outputs, Analog Output Settings, AVR Output screen and set
Voltage Response to Decreasing.

Load Sharing
Generator Breaker Status is not being received by the DGC-2020HD
Step 1: Close the generator breaker. Verify that the DGC-2020HD sees the status indicating the
generator breaker is closed. This is found on the front panel or in BESTCOMSPlus® under
Metering, Status, Bus Condition, Gen.
Step 2: If the status is not correct, check the digital input status on the DGC-2020HD through which the
breaker status is fed. Examine the input with BESTCOMSPlus® under Metering, Inputs, Contact
Inputs or Metering, Inputs, Remote Contact Inputs.
Step 3: If the input status is correct, but the Gen Breaker status under Metering, Status, Bus Condition,
Gen is not, check the PLC logic, and verify that the Gen Breaker fed into the DGC-2020HD is
tied in logic to the Status input on the Gen Breaker logic element.
Step 4: Make any corrections and re-check that the status is received correctly.

Generator Runs at Incorrect Speed when Generator Breaker is Closed

Step 1: Verify generator breaker status is being correctly received as described in Generator Breaker
Status is not being received by the DGC-2020HD. If the status is correct, proceed to the steps
below.
Step 2: Check the range set for the DGC-2020HD Governor Bias output by examining the Min. and
Max. Output voltage or current settings under Settings, Programmable Outputs, Analog Output
Settings, GOV Output. Verify that this range is valid for the governor or engine specified.
Step 3: Perform the tests in Speed Bias, above, to verify that setting the output to different values
within its range causes engine speed to vary in the desired manner.
Step 4: Measure the voltage or current on the governor analog bias signal from theDGC-2020HD. This
signal is found on terminals P6-67 (GOV–) and P6-66 (GOV+). If the output is at the midpoint of
its range, the generator should run at rated speed.
Step 5: Check the LS Input parameter on the Load Share Line screen found on the front panel at
Metering > Diagnostics > Load Share Line. Check if the normalized value from the Load Share
Line screen corresponds to the value measured at DGC-2020HD terminals P6-67 (GOV–) and
P6-66 (GOV+). If the normalized value is 0.00, the output should be in the midpoint of its range.
If the normalized value is 1.00, the output should be in the maximum point of its range. If the
normalized value is –1.00, the output should be in the minimum point of its range. Any other
values are scaled within the range. If the normalized value and the measured output do not

DGC-2020HD Troubleshooting
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match up, either there are wiring errors, or some external device is driving the governor bias
signal at the same time as theDGC-2020HD. Correct this conflicting situation if it exists.
Step 6: Check that the signal being measured at the DGC-2020HD terminals P6-67 (GOV–) and P6-66
(GOV+) is carried to the actual governor bias inputs on the engine governor. Measurements
should be the same as they were on theDGC-2020HD. If not, correct the wiring errors.
Step 7: Check if there are any relay contacts in the path between the DGC-2020HD governor bias
outputs and the engine governor’s bias input. Any relay contacts that are used to switch load
share lines, governor analog speed bias signals, or voltage regulator analog voltage bias
signals must use a relay intended for low voltage, low current applications to preserve signal
integrity. Signal relays, not power relays, must be used for this application. Verify the relay
contacts are not affecting the signal.
Step 8: If speed trim is enabled, verify that the speed trim set point is at the correct value for desired
operation.

Generators Do Not Share Load Equally

Step 1: Verify that load sharing is enabled in Settings, Bias Control, GOV Bias Control, kW Control.
Step 2: Verify generator breaker status is being correctly received as described in Generator Breaker
Status is not being received by the DGC-2020HD. If the status is correct, proceed to Step 3.
Step 3: Check the Load Share Line operating voltage range by examining the Min. and Max. Voltage
parameters found in BESTCOMSPlus® under Settings, Multigen Management, Load Share
Output. The range must be the same for all machines in the load share system.
Step 4: Measure the Load Share line voltage at terminals P6-70 (LS–) and P6-69 (LS+) on theDGC-
2020HD. The same voltage should be present on each DGC-2020HD. If not, correct any
issues.
Step 5: Examine the LS Input on the front panel of the DGC-2020HD under Metering > Diagnostics >
Load Share Line. This is the voltage read from the load share lines by the DGC-2020. Verify
this voltage matches the voltage read with a voltmeter across DGC-2020HD terminals P6-70
(LS–) and P6-69 (LS+). Verify the same LS Input is present on all the machines in the load
share system. If they are not equal, examine the load share line wiring and correct any issues.
Step 6: Check if there are any contacts in the load share line path between theDGC-2020HDs. Any
relay contacts that are used to switch load share lines, governor analog bias signals, or voltage
regulator analog voltage bias signals must use a relay intended for low voltage, low current
applications to preserve signal integrity. Signal relays, not power relays, must be used for this
application. Verify the relay contacts are not affecting the signal.
Step 7: If there are still issues, disconnect the load share line from the DGC-2020HD. Run a single
machine with load, and verify that it loads and unloads correctly, and runs at the correct speed.
Repeat for each machine.
Step 8: Re-attach load share lines to all DGC-2020HDs that are part of the load sharing system. Run
the Single machine with load, and verify that it loads and unloads correctly, and runs at the
correct speed. If the machine slows down when the generator breaker is closed, check the load
share line voltage. It should be equal, on a normalized basis, to the normalized kW produced
by the generator. As an example, if the generator is loaded to 50% capacity, the Load Share
Line voltage should be at the midpoint of the range. If it is not, something is driving the load
share line that should not be. The single unit should be the only device driving the load share
lines.
Step 9: Disconnect the load share lines from each non-running machine and see if the speed of the
running machine is correct. If a particular DGC-2020HD on a non-running machine seems to
affect the performance of the running machine, that DGC-2020HD may be damaged such that
the Load Share Line contacts are sticking, causing the DGC-2020HD to drive the load share
line even though the generator breaker is open. Tap the relays to see if the problem clears up.
If so, a faulty DGC-2020HD relay is indicated. Replace the DGC-2020HD, or wire in external

Troubleshooting DGC-2020HD
9469300994 9-15

contacts to remove the DGC-2020HD from the load share system when the generator breaker
is closed.
Step 10: If it appears that something is driving the load share line but it is not the DGC-2020HD on one
of the non-running units, search for an external device that is driving or loading down the load
share lines.
Step 11: Repeat the preceding 3 steps for each machine.

Load Sharing Works Correctly, but a Single Unit Slows Down

With all units running, load sharing works correctly, but a single unit slows down after the generator
breaker is closed.
Step 1: Disconnect the load share line from the DGC-2020HD. Run the single machine with load, and
verify that it loads and unloads correctly, and runs at the correct speed. Repeat for each
machine.
Step 2: Re-attach load share lines to all DGC-2020HDs that are part of the load sharing system. Run
the Single machine with load, and verify that it loads and unloads correctly, and runs at the
correct speed. If the machine slows down when the generator breaker is closed, check the load
share line voltage. It should be equal, on a normalized basis, to the normalized kW produced
by the generator. As an example, if the generator is loaded to 50% capacity, the Load Share
Line voltage should be at the midpoint of the range. If it is not, something is driving the load
share line that should not be. The single unit should be the only device driving the load share
lines.
Step 3: Disconnect the load share lines from each non-running machine and see if the speed of the
running machine is correct. If a particular DGC-2020HD on a non-running machine seems to
affect the performance of the running machine, that DGC-2020HD may be damaged such that
the Load Share Line contacts are sticking, causing the DGC-2020HD to drive the load share
line even though the generator breaker is open. Tap the relays to see if the problem clears up.
If so, a faulty DGC-2020HD relay is indicated. Replace the DGC-2020HD, or wire in external
contacts to remove the DGC-2020HD from the load share system when the generator breaker
is closed.
Step 4: If it appears that something is driving the load share line but it is not the DGC-2020HD on one
of the non-running units, search for an external device that is driving or loading down the load
share lines.
Step 5: Repeat the preceding 3 steps for each machine.

Group Start and Group Stop Requests

Generator Does Not Start During an Island Group Start Request or Mains Parallel Group
Start Request
Step 1: Verify that a Group Start Request is active. In the BESTCOMSPlus Metering Explorer, navigate
to DGC-2020HD > System Status > Breaker. Examine the Group Start Req column for nonzero
entries. Nonzero entries indicate active group start requests.
Step 2: Check that the generator to start is in the same Generator Group in the Group Segment
Settings as the breaker generating the Group Start Request. Only generators in the same
Generator Group as the Generator Group configured for the breaker issuing the Group Start
Request will respond.
Step 3: Verify that the generators to be started are in Auto mode, the System Type under the System
Settings is configured as Segmented Bus System, and Sequencing and Demand Start/Stop are
enabled.
Step 4: Verify that the generator to be started does not have an active Run with Load Stop as this will
supersede Group Start Requests and prevent the generator from starting.

DGC-2020HD Troubleshooting
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Step 5: If a particular machine is expected to start, but does not, check the sequencing status and
verify that the settings are properly configured. Group Start Requests for Start One or Start
Demand Based may not start all units because the unit in question may not have been within
the set of generators that should have started based on the sequencing criterion.

Generator Does Not Stop During a Group Stop Request

Step 1: Verify that a Group Stop Request is active. In the BESTCOMSPlus Metering Explorer, navigate
to DGC-2020HD > System Status > Breaker. Examine the Group Stop Req column for nonzero
entries. Nonzero entries indicate active group stop requests.
Step 2: Check that the generator to stop is in the same Generator Group in the Group Segment
Settings as the breaker generating the Group Stop Request. Only generators in the same
Generator Group as the Generator Group configured for the breaker issuing the Group Stop
Request will respond.
Step 3: Verify that the generators to be stopped are in Auto mode and Sequencing and Demand
Start/Stop are enabled.
Step 4: Verify that the generator to be stopped does not have an active Run with Load Start and is not
running due to an applied ATS contact. Either case will supersede Group Stop Requests and
prevent the generator from stopping.

DGC-2020HD Front Panel Diagnostics Screens

There are several diagnostic screens in the DGC-2020HD that can be useful for debugging load sharing
issues and I/O module related issues. The following debug screens are available: Load Share Line,
Control, AEM-2020, CEM-2020, VRM, Mains Power and VRM Control.

Load Share Line

This screen is useful for debugging load share related issues, and kW and var control related issues. It
gives visibility into the parameters metered and controlled by the DGC-2020HD.
The Load Share Line diagnostics screen is located on the front panel at Metering > Diagnostics > Load
Share Line.
The following parameters are visible on the Load Share Line diagnostics screen:
• LS Input: Voltage the DGC-2020HD sees on its load share line input. Terminals P6-70 (LS–) and
P6-69 (LS+). This measurement is useful for debugging load share issues. Normally, all
machines that have their generator breakers closed should measure the same voltage for LS
Input. If this voltage differs, check for wiring errors, or problems with any relay contacts in the load
share line wiring. Any relay contacts that are used to switch load share lines, governor analog
speed bias signals, or voltage regulator analog bias signals must use a relay intended for low
voltage, low current applications to preserve signal integrity. Signal relays, not power relays, must
be used for this application.
• Speed Bias: This is the normalized value to which the DGC-2020HD drives the governor analog
bias output. If the value is –1.0, the output will be driven to the minimum value of the governor
bias output range. If the value is 1.0, the output will be driven to the maximum value of the
governor bias output range. If the value is 0.000, the output will be driven to the midpoint value
(i.e. half way between maximum and minimum values) of the governor bias output range. If the
generator breaker is open, or if the generator breaker is closed and speed trim and kW control
are disabled, the output from the DGC-2020HD will be the midpoint of the range, indicating the
generator should run at rated speed. Any relay contacts that are used to switch load share lines,
governor analog speed bias signals, or voltage regulator analog voltage bias signals must use a
relay intended for low voltage, low current applications to preserve signal integrity. Signal relays,
not power relays, must be used for this application.
• Voltage Bias: This is the normalized value to which the DGC-2020HD drives the voltage regulator
analog bias output. If the value is –1.0, the output will be driven to the minimum value of the

Troubleshooting DGC-2020HD
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voltage regulator bias output range. If the value is 1.0, the output will be driven to the maximum
value of the voltage regulator bias output range. If the value is 0.00, the output will be driven to
the midpoint value (i.e. half way between maximum and minimum values) of the voltage regulator
bias output range. If the generator breaker is open, voltage trim and kvar control are disabled, so
the output from the DGC-2020HD will be the midpoint of the range, indicating the voltage
regulator should operate at rated voltage. Any relay contacts that are used to switch load share
lines, governor analog speed bias signal, or voltage regulator analog voltage bias signals must
use a relays intended for low voltage, low current applications to preserve signal integrity. Signal
relays, not power relays, must be used for this application.
• Watt Demand: This is the normalized kW demand requested by the DGC-2020HD. It is the
desired amount of power that the generator produces. It is normalized such that 1.0 indicates the
full kW capacity of the generator, 0.5 indicates 50% of the generator’s capacity, etc. When the
generator breaker is closed, and the kW controller is enabled, the Watt Demand indicates what
level of power should be generated. In an island load share system, this will correspond to the
value read on the load share lines. If the load share lines are at the 50% point of the load share
voltage range, the Watt Demand will be 0.50. If the generator breaker is closed, and the Parallel
To Mains logic element is true, the Watt Demand will be equal to the base load set point. When
the generator breaker is open or the kW controller is disabled, the Watt Demand will always be
equal to the value calculated from the voltage that the DGC-2020HD sees on its load share line.
• kW Total: This is the normalized kW being produced by the generator. A value of 1.0 represents
full machine capacity, 0.5 represents 50% of machine capacity, etc.
• Rated kW: This is the rated kW of the machine that should be equal to the Rated kW setting
under Settings, System Parameters, Rated Data.
• var Demand: This is the normalized var demand requested by the DGC-2020HD. It is the desired
about of var that the generator should produce. It is normalized such that 1.0 indicates the full var
capacity of the generator, 0.5 indicates 50% of the generator’s capacity, etc. When the generator
breaker is closed, and the var/PF controller is enabled, the var demand indicates what level of
reactive power should be generated. If the generator breaker is closed, and the Parallel To Mains
logic element is true, the var Demand will be equal to the kvar set point (%) if the controller is in
var control mode, or will equal the var value that will maintain the machine Power Factor at the
PF set point if the controller is in Power Factor mode. When the generator breaker is open or the
var/PF controller is disabled, the var Demand will always be 0.0. When running with the generator
breaker closed and the Parallel To Mains logic element is false (i.e. the generators are an
islanded system), the var Demand will be 0.0 as well. The DGC-2020HD runs in var Droop when
on an island system.
• kvar Total: This is the normalized kvar being produced by the generator. A value of 1.0
represents full machine capacity, 0.5 represents 50% of machine capacity, etc.
• Rated kvar: This is the calculated rated kvar of the machine, calculated from the rated kW of the
machine and the rated power factor of the machine according to var is equal to the square root of
(VA2 – Watt2).
• Load Share Active: This indicates when the load share line output contacts are closed.

Control
This screen is useful for debugging load share related issues, and kW and var control related issues. It
gives visibility into the states of the kW, kvar, Speed Trim, and Voltage controllers in the DGC-2020HD.
The Control diagnostics screen is located on the front panel at Metering > Diagnostics > Control.
The following parameters are visible on the Control diagnostics screen:
• kW Ramp Status: This indicates the current kW ramp direction as None, Up, or Down.
• kW Ramp Demand: This is the normalized kW demand that is ramped from the initial kW loading
upon generator breaker closure to the desired kW set point. The rate at which the ramp occurs is
set by the Ramp Rate (%) in the Governor Bias Control settings. Note the rate is in terms of
percentage of machine capacity, it is not the time to ramp from zero up to the current desired kW
DGC-2020HD Troubleshooting
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level. Thus, at low loading it may appear that the ramp is skipped. If the system is loaded to only
10% and a unit is brought on line with a ramp rate of 10% per second, it takes only one second to
reach 10% of capacity.
• kW Demand: This is the normalized requested kW demand on the generator. It is normalized
such that 1.0 indicates the full kW capacity of the generator, 0.5 indicates 50% of the generator’s
capacity, etc. When the generator breaker is closed, and the kW controller is enabled, the Watt
Demand indicates what level of power should be generated. In an island load share system, this
will correspond to the normalized value read on the load share lines. If the load share lines are at
the 50% point of the load share voltage range, the Watt Demand will be 0.5. If the generator
breaker is closed, and the Parallel To Mains logic element is true, the Watt Demand will be equal
to the base load set point. When the generator breaker is open or the kW controller is disabled,
the Watt Demand will always be equal to the value calculated from the voltage that the DGC-
2020HD sees on its load share line.
• Speed PID: This is the output value of the Speed PID controller. It will normally range
between -1.0 and 1.0, and will be zero any time the generator breaker is open, unless
synchronization is in progress. If the Speed Trim is enabled, the Speed PID will be nonzero when
the generator breaker is closed if there is any difference between the machine speed and the
Speed Trip Set Point parameter.
• kW PID: This is the output value of the kW PID controller. It will normally range between –1.0 and
1.0, and will be zero any time the generator breaker is open. If the kW Controller is enabled, the
kW PID will be nonzero when the generator breaker is closed if there is any difference between
the normalized kW generation and the Watt Demand value of the machine. If the kW controller is
disabled, the kW PID will always be zero.
• Speed Error: This is the normalized difference between the measured generator frequency and
the Speed Trip Set Point. A value of 1.0 means the difference is equal to the speed trip set point;
a value of –1.0 means the difference is equal to the negative of the speed trim set point. When
the generator breaker is open, or if Speed Trim is disabled, this will always be 0.000 unless
synchronization is in progress. When speed trip is enabled, and the generator breaker is closed,
this will typically be 0.000 or some relatively small number and move a small amount above and
below 0.000 as the speed trim controller corrects for any speed errors.
• kW Error: This is the normalized difference between the measured generator kW generation and
the Watt Demand described above. A value of 1.0 means the difference is equal to the Rated kW
of the machine; a value of –1.0 means the difference is equal to the negative of the Rated kW of
the machine. When the generator breaker is open, or if kW control is disabled, this will always be
0.000. When kW control is enabled, and the generator breaker is closed, this will typically be
0.000 or some relatively small number and move a small amount above and below 0.000 as the
kW controller corrects for kW errors. If a load is added or dropped from the system, the error will
be a non-zero value until the kW controller brings the kW generation to the desired level.
• Speed Bias: This is the normalized value to which the governor analog bias output of the DGC-
2020HD will be driven to accomplish desired kW and speed trim control. It is equal to the sum of
the kW PID and the Speed PID. If the value is –1.0, the speed bias output will be driven to the
minimum value of the governor bias output range. If the value is 1.0, the output will be driven to
the maximum value of the governor bias output range. If the value is 0.00, the output will be
driven to the midpoint value (i.e. half way between maximum and minimum values) of the
governor bias output range. If the generator breaker is open, or if the generator breaker is closed
and speed trim and kW control are disabled, the Speed Bias value will be 0.00, driving the bias
output to the midpoint of the governor bias output range indicating the generator should run at
rated speed.
• PF Setpoint: This is the power factor setpoint that will be used by the kvar controller when it is in
the Power Factor regulation mode.
• var Ramp Status: This indicates the current kvar ramp direction as None, Up, or Down.
• var Ramp Demand: This is the normalized var demand that is ramped from the initial var loading
upon generator breaker closure to the desired var output. The rate at which the ramp occurs is

Troubleshooting DGC-2020HD
9469300994 9-19

set by the Ramp Rate (%) parameter in the AVR Bias Control settings. Note the rate is in terms of
percentage of machine capacity, it is not the time to ramp from zero up to the current desired var
level. Thus, at low var loading it may appear that the ramp is skipped. If the system is loaded to
only 10% and a unit is brought on line where the load rate is 10% per second, it takes only one
second to reach 10% of capacity.
• var Demand: This is the normalized requested kvar demand on the generator. It is normalized
such that 1.0 indicates the full kvar capacity of the generator, 0.5 indicates 50% of the generator’s
capacity, etc. When the generator breaker is closed, and the var/PF controller is enabled, the var
Demand indicates what level of reactive power should be generated. In an island load share
system, this will be determined by the droop characteristics set by the Droop Percentage and
Voltage Droop Gain parameters. If the generator breaker is closed, and the Parallel To Mains
logic element is true, the var Demand will be equal to the kvar set point if the var/PF controller is
in var mode or it will be calculated from the amount of kW being generated to maintain desired
machine Power Factor when the var/PF controller is in Power Factor control mode. When the
generator breaker is open, or the var/PF controller is disabled, the var Demand will be zero.
• Volt PID: This is the current output value of the Voltage PID controller. It will normally range
between –1.0 and 1.0, and will generally be zero at all times unless synchronization is in
progress.
• kvar PID: This is the current output value of the kvar PID controller. It will normally range between
–1.0 and 1.0, and will be zero any time the generator breaker is open. If the var/PF controller is
enabled, the kvar PID will be nonzero when the generator breaker is closed if there is any
difference between the normalized kvar generation and the var Demand value of the machine. If
the var/PF controller is disabled, the kvar PID will always be zero.
• Volt Error: This is the normalized difference between the measured generator voltage and the
voltage to which the DGC-2020HD is trying to synchronize. It will be 0.00 at all times except when
the DGC-2020HD is trying to synchronize its generator inputs to its bus input. When
synchronizing, this will typically be 0.000 or some relatively small number and move a small
amount above and below 0.000 as voltage controller corrects for any voltage errors.
• kvar Error: This is the normalized difference between the measured generator kvar generation
and the var Demand described above. A value of 1.0 means the difference is equal to the Rated
kvar of the machine; a value of –1.0 means the difference is equal to the negative of the Rated
kvar of the machine. When the generator breaker is open, or if var/PF controller is disabled, this
will always be 0.000. When var/PF control is enabled, and the generator breaker is closed, this
will typically be 0.000 or some relatively small number and move a small amount above and
below 0.000 as the var/PF controller corrects for var errors. If a reactive load is added or dropped
from the system, the error will be nonzero until the var/PF controller brings the var generation to
the desired level.
• Voltage Bias: This is the normalized value to which the voltage regulator analog bias output of the
DGC-2020HD will be driven to accomplish desired kvar and Voltage control. It is equal to the sum
of the Volt PID and the kvar PID. If the value is –1.0, the voltage bias output will be driven to the
minimum value of the voltage regulator analog bias output range. If the value is 1.0, the output
will be driven to the maximum value of the voltage regulator analog bias output range. If the value
is 0.000, the output will be driven to the midpoint value (i.e. half way between maximum and
minimum values) of the voltage regulator analog bias output range. If the generator breaker is
open, or if the generator breaker is closed and kvar control is disabled, the Volt Bias value will be
0.00, driving the bias output to the midpoint of the voltage regulator analog bias output range
indicating the voltage regulator should operate the generator at rated voltage.

AEM-2020
This screen shows the binary data that is being sent between the AEM-2020 (Analog Expansion Module)
and the DGC-2020HD.
The AEM diagnostics screen is located on the front panel at Metering > Diagnostics > AEM.
The following parameters are visible on the AEM diagnostics screen:

DGC-2020HD Troubleshooting
9-20 9469300994

• DGC To AEM BP: DGC-2020HD to AEM-2020 Binary Points. This is a 32-bit, bit packed number
representing the binary points transmitted from the DGC-2020HD to the AEM-2020. Debug at this
level is not necessary.
• AEM To DGC BP: AEM-2020 to DGC-2020HD Binary Points. This is a 32-bit, bit packed number
representing the binary points transmitted from the AEM-2020 to the DGC-2020HD. Debug at this
level is not necessary.

CEM-2020
This screen shows the binary data that is being sent between the CEM-2020 (Contact Expansion Module)
and the DGC-2020HD.
The CEM diagnostics screen is located on the front panel at Metering > Diagnostics > CEM.
The following parameters are visible on the CEM diagnostics screen:
• DGC To CEM BP: DGC-2020HD to CEM-2020 Binary Points. This is the status of the CEM-2020
output relays being transmitted from the DGC-2020HD to the CEM-2020. This is a 32-bit, bit packed
number representing the desired states of the CEM-2020 outputs. The left-most bit is the first output,
etc.
• CEM To DGC BP: CEM-2020 to DGC-2020HD Binary Points. This is the status of the CEM-2020
inputs being transmitted from the CEM-2020 to the DGC-2020HD. This is a 32-bit, bit packed number
representing the metered states of the CEM-2020 inputs. The left most bit is the first input, etc.

VRM
This screen shows the binary data that is being sent between the VRM-2020 (Voltage Regulator
Expansion Module) and the DGC-2020HD.
The VRM diagnostics screen is located on the front panel at Metering > Diagnostics > VRM.
The following parameters are visible on the VRM diagnostics screen:
• DGC To VRM BP: DGC-2020HD to VRM-2020 Binary Points. This is a 32-bit, bit packed number
representing the binary points transmitted from the DGC-2020HD to the VRM-2020. Debug at this
level is not necessary.
• VRM To DGC BP: VRM-2020 to DGC-2020HD Binary Points. This is a 32-bit, bit packed number
representing the binary points transmitted from the VRM-2020 to the DGC-2020HD. Debug at this
level is not necessary.

Mains Power
This screen is useful for debugging mains power control mode related issues. It gives visibility into the
states of the mains power controller in the DGC-2020HD.
The Mains Power diagnostics screen is located on the front panel at Metering > Diagnostics > Mains
Power.
The following parameters are visible on the Mains Power diagnostics screen:
• Total Mains kW: This displays the measured kW level of the mains.
• Error: This is the normalized difference between the measured system generated kW and the kW the
DGC-2020HD is trying to achieve.
• Baseload: This displays the commanded baseload to maintain import/export or peak shave level.
• Sys Gen kW: This displays the cumulative kW output of participating generators.
• Sys Rated kW: This displays the total kW capacity of participating generators.
• Total System kW: This displays the cumulative kW output of participating generators summed with
the total imported kW from mains.

Troubleshooting DGC-2020HD
9469300994 9-21

• Baseload Setpt: This displays the active baseload setpoint.

• Peak Shv Setpt: This displays the active peak shave setpoint.
• Im/Ex Setpt: This displays the active import/export setpoint.

VRM Control
This screen is useful for debugging VRM-2020 control related issues. It gives visibility into the states of
the VRM-2020 regulation modes and limiters in the DGC-2020HD.
The VRM Control diagnostics screen is located on the front panel at Metering > Diagnostics > VRM
Control.
The following parameters are visible on the VRM Control diagnostics screen:
• VRM AVR Setpoint: This displays the AVR mode setpoint.
• VRM FCR Setpoint: This displays the FCR mode setpoint.
• VRM AVR Ref: This displays the final AVR setpoint (reference) after other factors such as raise/lower
biases or an active limiter.
• VRM FCR Ref: This displays the final FCR setpoint (reference) after other factors such as raise/lower
biases or an active limiter.
• VRM Control Output: This displays the VRM control output (PID) in per unit.
• VRM AVR Error: This displays the difference between the AVR reference and the measured voltage
in per unit.
• VRM FCR Error: This displays the difference between the FCR reference and the measured current
in per unit.
• VRM OEL Reference: This displays the calculated OEL reference in per unit of takeover OEL or
summing point OEL depending on configuration.
• VRM OEL Takeover Err: This displays the difference between the takeover OEL reference and the
measured field current in per unit.
• VRM OEL Summing Err: This displays the difference between the summing point OEL reference and
the measured field current in per unit.
• VRM OEL Summing Bias: This displays the OEL Summing control output (PID) in per unit.
• VRM UEL Reference: This displays the calculated UEL reference in per unit.
• VRM UEL Error: This displays the difference between the UEL reference and the measured field
current in per unit.
• VRM UEL Bias: This displays the UEL control output (PID) in per unit.
• VRM Tracking Error: This displays the difference of the inactive mode setpoint in relation to the active
mode setpoint in percent.
• EDM Ripple: The exciter diode ripple is reported by the exciter diode monitor (EDM) as the induced
ripple in the exciter field current.

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