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Description
MTU DGC-2020 DIGITAL GENSET CONTROLLER Instruction Manual PDF DOWNLOAD
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MTU DGC-2020 DIGITAL GENSET CONTROLLER Instruction Manual PDF DOWNLOAD
Language : English
Pages : 544
Downloadable : Yes
File Type : PDF
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DESCRIPTION:
MTU DGC-2020 DIGITAL GENSET CONTROLLER Instruction Manual PDF DOWNLOAD
INTRODUCTION:
This instruction manual provides information about the operation and installation of the DGC-2020 Digital Genset Controller. To accomplish this, the following information is provided:
- General Information and Specifications
- Controls and Indicators
- Functional Description
- Graphical User Interface Operation
- Installation
- Setup
- Maintenance and Troubleshooting
- LSM-2020 (Load Share Module)
- CEM-2020 (Contact Expansion Module)
- AEM-2020 (Analog Expansion Module)
- Time Overcurrent Characteristic Curves
- Modbus™ Communication
- PID Tuning Settings
- MTU Fault Codes
TABLE OF CONTENTS:
MTU DGC-2020 DIGITAL GENSET CONTROLLER Instruction Manual PDF DOWNLOAD
COVER ............................................................................................................. 1 INTRODUCTION ...................................................................................................... 3 REVISION HISTORY .................................................................................................. 5 DETAILED FIRMWARE RELEASE HISTORY ................................................................................. 15 CONTENTS .......................................................................................................... 17 1 • GENERAL INFORMATION ........................................................................................... 19 Description.................................................................................................... 21 Features....................................................................................................... 21 Functions...................................................................................................... 21 Generator Protection and Metering.......................................................................... 21 Engine Protection and Metering............................................................................. 21 Event Recording............................................................................................ 21 Auto-Synchronizer.......................................................................................... 22 Contact Inputs and Output Contacts......................................................................... 22 Automatic Transfer Switch Control (Mains Failure).......................................................... 22 Communication.............................................................................................. 22 USB Port............................................................................................... 22 CANbus Interface....................................................................................... 22 Dial-Out Modem......................................................................................... 23 RS-485 Port............................................................................................ 23 AEM-2020 (Analog Expansion Module)............................................................................. 23 CEM-2020 (Contact Expansion Module)............................................................................ 23 LSM-2020 (Load Share Module)................................................................................... 23 Style Number................................................................................................... 23 Specifications................................................................................................. 24 Operating Power............................................................................................ 24 Power Consumption...................................................................................... 24 Battery Ride Through....................................................................................... 24 Current Sensing............................................................................................ 24 1 Aac Current Sensing.................................................................................. 24 5 Aac Current Sensing.................................................................................. 24 Voltage Sensing............................................................................................ 25 Contact Sensing............................................................................................ 25 Terminals.............................................................................................. 25 Programmable....................................................................................... 25 Engine System Inputs....................................................................................... 25 Fuel Level Sensing..................................................................................... 25 Coolant Temperature Sensing............................................................................ 25 Oil Pressure Sensing................................................................................... 26 Engine Speed Sensing................................................................................... 26 Magnetic Pickup.................................................................................... 26 Generator Voltage.................................................................................. 26 Output Contacts............................................................................................ 26 PRESTART, START, and RUN Relays........................................................................ 26 Programmable Relays (12)............................................................................... 26 Terminals(......................................................................................... 26 Metering................................................................................................... 26 Generator and Bus Voltage (rms)........................................................................ 26 Generator Current (rms)................................................................................ 27 Generator and Bus Frequency............................................................................ 27 Apparent Power......................................................................................... 27 Measurement/Calculation Methods.................................................................... 27 Power Factor........................................................................................... 27 Real Power............................................................................................. 27 Measurement/Calculation Methods.................................................................... 27 Oil Pressure........................................................................................... 28 Coolant Temperature.................................................................................... 28 Battery Voltage........................................................................................ 28 Engine RPM............................................................................................. 28 Engine Run Time........................................................................................ 28 Maintenance Timer...................................................................................... 28 Fuel Level............................................................................................. 28 Generator Protection Functions............................................................................. 28 Overvoltage (59) and Undervoltage (27)................................................................. 28 Underfrequency (81U) and Overfrequency (81O)........................................................... 28 Reverse Power (32)..................................................................................... 29 Loss of Excitation (40Q)............................................................................... 29 Overcurrent (51) (Optional)............................................................................ 29 Phase Imbalance (47) (Optional)........................................................................ 29 ROCOF (Rate of Change of Frequency) (81) (Optional).................................................... 29 Vector Shift (78) (Optional)........................................................................... 29 Logic Timers............................................................................................... 29 Communication Interface.................................................................................... 29 USB.................................................................................................... 29 RS-485 (Optional)...................................................................................... 29 RDP-110................................................................................................ 30 CANbus................................................................................................. 30 Modem (Optional)....................................................................................... 30 Real-Time Clock............................................................................................ 30 Clock Holdup........................................................................................... 30 LCD Heater................................................................................................. 31 Type Tests................................................................................................. 31 Shock.................................................................................................. 31 Vibration.............................................................................................. 31 Radio Interference..................................................................................... 31 HALT (Highly Accelerated Life Testing)................................................................. 31 Ignition System........................................................................................ 31 Environment................................................................................................ 31 UL Recognition............................................................................................. 31 CSA Certification.......................................................................................... 32 NFPA Compliance............................................................................................ 32 CE Compliance.............................................................................................. 32 Physical................................................................................................... 32 2 • HUMAN-MACHINE INTERFACE ....................................................................................... 33 Introduction................................................................................................... 35 Front Panel.................................................................................................... 35 Display Operation.............................................................................................. 36 Login and Permissions...................................................................................... 36 Login.................................................................................................. 36 Permissions............................................................................................ 37 Summary Screen and Configurable Metering................................................................... 37 Sleep Mode................................................................................................. 38 Changing a Setting......................................................................................... 38 Front Panel Display Structure.............................................................................. 38 Generator Network Status Display........................................................................... 58 Rear Panel..................................................................................................... 59 3 • FUNCTIONAL DESCRIPTION ........................................................................................ 61 Introduction................................................................................................... 63 DGC-2020 Function Blocks....................................................................................... 63 Power Supply............................................................................................... 63 Battery Voltage Sensing................................................................................ 63 Microprocessor............................................................................................. 63 Zero Crossing Detection................................................................................ 64 Analog-to-Digital Converter............................................................................ 64 Watchdog Timer......................................................................................... 64 Generator Voltage Sensing Inputs........................................................................... 64 Bus Voltage Sensing Inputs................................................................................. 64 Current Sensing Inputs..................................................................................... 64 Analog Engine Sender Inputs................................................................................ 64 Oil Pressure........................................................................................... 64 Coolant Temperature.................................................................................... 64 Fuel Level............................................................................................. 65 Speed Signal Inputs........................................................................................ 65 Generator Voltage Sensing Input........................................................................ 65 Magnetic Pickup Input (MPU)............................................................................ 65 Contact Inputs............................................................................................. 65 Emergency Stop Input................................................................................... 65 Programmable Inputs.................................................................................... 65 Front Panel HMI............................................................................................ 66 LCD.................................................................................................... 66 LED Indicators......................................................................................... 66 Pushbuttons............................................................................................ 66 Remote Display Panel (Optional)............................................................................ 66 Communication Ports........................................................................................ 67 USB.................................................................................................... 67 CANbus................................................................................................. 67 Diagnostic Trouble Codes (DTCs)........................................................................ 70 MTU Fault Codes........................................................................................ 77 RS-485 (Optional)...................................................................................... 77 Modem (Optional)....................................................................................... 77 Output Contacts............................................................................................ 77 PRESTART............................................................................................... 78 START.................................................................................................. 78 RUN.................................................................................................... 78 Programmable........................................................................................... 78 Modes of Operation............................................................................................. 78 OFF........................................................................................................ 78 RUN........................................................................................................ 78 AUTO....................................................................................................... 78 ATS Contact Input...................................................................................... 78 Generator Exerciser.................................................................................... 78 Mains Fail Transfer Functionality...................................................................... 79 Run with Load Logic Element............................................................................ 79 Engine Run Logic Element............................................................................... 79 Demand Start/Stop Function............................................................................. 79 Interoperability of the Run with Load Logic Element and the Demand Start/Stop Function................. 79 Breaker Management............................................................................................. 79 Introduction............................................................................................... 79 Determining Breaker Status................................................................................. 79 Processing Breaker Requests................................................................................ 79 RUN Mode............................................................................................... 80 OFF or AUTO Mode (Not Running)......................................................................... 80 AUTO Mode (Running).................................................................................... 80 Breaker Operation.......................................................................................... 80 Determining if it is Acceptable to Close a Breaker..................................................... 80 Changing the Breaker State............................................................................. 80 Synchronizer Operation..................................................................................... 80 Dead Bus Breaker Close Arbitration............................................................................. 82 Event Recording................................................................................................ 83 4 • BESTCOMSPlus® SOFTWARE ........................................................................................ 89 Introduction................................................................................................... 95 Installation................................................................................................... 95 Installing BESTCOMSPlus®................................................................................... 96 Activate the DGC-2020 Plugin for BESTCOMSPlus®................................................................. 96 Connect a USB Cable........................................................................................ 96 Start BESTCOMSPlus® and Activate DGC-2020 Plugin Automatically............................................. 96 Installing the USB Driver if Automatic Installation Fails.............................................. 98 Manual Activation of the DGC-2020 Plugin................................................................... 99 Requesting an Activation Key........................................................................... 99 Entering an Activation Key............................................................................. 99 Communication.................................................................................................. 99 Modem Communication (Optional)............................................................................. 99 Ethernet Communication..................................................................................... 99 Configure LSM-2020 Network Settings through Device Discovery in BESTCOMSPlus........................... 99 Configure LSM-2020 Network Settings through the Front Panel of the DGC-2020............................101 Alternate Method to Configure LSM-2020 Network Settings through the DGC-2020...........................102 Establishing Communication.................................................................................103 Advanced Properties........................................................................................104 Menu Bars......................................................................................................104 Upper Menu Bar (BESTCOMSPlus® Shell).......................................................................104 Lower Menu Bar (DGC-2020 Plugin)...........................................................................105 Settings Explorer..............................................................................................106 DGC-2020 and System Parameters.................................................................................106 General Settings...............................................................................................107 Front Panel HMI............................................................................................107 Style Number...............................................................................................108 Device Info................................................................................................108 DGC-2020...............................................................................................108 Load Share Module......................................................................................108 Contact Expansion Module...............................................................................108 Analog Expansion Module................................................................................109 Device Security Setup......................................................................................111 Changing Passwords.....................................................................................111 Saving Passwords in a DGC-2020 Settings File...........................................................112 Loading Passwords from a Settings File into the DGC-2020...............................................113 Clock Setup................................................................................................114 Clock Not Set Warning..................................................................................114 Communications.................................................................................................115 CANbus Setup...............................................................................................115 ECU Limitations........................................................................................115 The DGC-2020 Solution..................................................................................116 ECU Setup..................................................................................................116 Volvo Penta............................................................................................117 Cummins................................................................................................118 Diesel Particulate Filter (DPF)........................................................................118 Speed Setup............................................................................................118 MTU....................................................................................................118 Voltage Regulator Setup....................................................................................121 Modem Setup (Optional).....................................................................................121 Dial-Out...............................................................................................122 Dial-In................................................................................................122 Modem Setup through the Front Panel HMI................................................................123 RS485 Setup (Optional).....................................................................................123 System Parameters..............................................................................................124 System Settings and Rated Data.............................................................................124 Genset Electrical Parameters...........................................................................124 Engine Speed Measurement...............................................................................124 EPS Threshold..........................................................................................125 Measurement/Metering Units.............................................................................125 Battery Voltage........................................................................................125 NFPA Compliance Level..................................................................................125 Fuel Level Function....................................................................................125 Power Up Delay.........................................................................................125 Generator Frequency....................................................................................125 Calculated Rated Data..................................................................................125 Remote Module Setup........................................................................................127 Load Sharing Module....................................................................................127 Contact Expansion Module...............................................................................127 Analog Expansion Module................................................................................127 Crank Settings.............................................................................................128 Engine Cooldown........................................................................................128 Off Mode Cooldown......................................................................................128 Restart................................................................................................129 Automatic Restart..........................................................................................130 Exercise Timer.............................................................................................130 Sensing Transformers.......................................................................................131 Generator PT Settings..................................................................................131 Bus Transformer Settings...............................................................................131 Generator CT Settings..................................................................................131 Relay Control..............................................................................................132 Auto Config Detection......................................................................................133 Programmable Inputs............................................................................................133 Contact Inputs.............................................................................................134 Programmable Functions.....................................................................................134 Remote LSM Inputs..........................................................................................136 Remote Contact Inputs......................................................................................136 Remote Analog Inputs.......................................................................................137 Remote RTD Inputs..........................................................................................138 Remote Thermocouple Inputs.................................................................................139 Programmable Outputs...........................................................................................140 Contact Outputs............................................................................................140 Configurable Elements......................................................................................141 Remote Contact Outputs.....................................................................................141 Remote Analog Outputs......................................................................................142 Configurable Protection........................................................................................143 Configurable Protection Scale Factors......................................................................144 Alarm Configuration............................................................................................145 Horn Configuration.........................................................................................145 Horn...................................................................................................145 Not In Auto Horn Enable................................................................................145 Pre-Alarms.................................................................................................145 High Fuel Level........................................................................................146 Low Battery Voltage....................................................................................146 Weak Battery Voltage...................................................................................146 Battery Overvoltage....................................................................................146 Maintenance Interval...................................................................................146 Engine kW Overload.....................................................................................146 Low Fuel Level.........................................................................................147 High Coolant Temp......................................................................................147 Low Coolant Temp.......................................................................................147 Low Coolant Level......................................................................................147 Low Oil Pressure.......................................................................................147 ECU Coms Fail..........................................................................................147 Active DTC.............................................................................................147 AVR Bias Output Limit..................................................................................147 GOV Bias Output Limit..................................................................................147 Intergenset Comm Failure...............................................................................147 LSM Comm Failure.......................................................................................148 ID Missing.............................................................................................148 ID Repeat..............................................................................................148 CEM Comm Failure.......................................................................................148 AEM Comm Failure.......................................................................................148 Checksum Failure.......................................................................................148 Synchronizer Failure...................................................................................148 Breaker Close Failure..................................................................................149 Breaker Open Failure...................................................................................149 Reverse Rotation.......................................................................................149 Rated Data and Per Unit Values.........................................................................149 Alarms.....................................................................................................151 High Coolant Temperature...............................................................................151 Low Oil Pressure.......................................................................................152 Overspeed..............................................................................................152 Low Fuel Level.........................................................................................152 Low Coolant Level......................................................................................152 Sender Fail................................................................................................152 Generator Protection...........................................................................................153 Voltage Protection (27, 59, 47)............................................................................153 Undervoltage (27-1, 27-2)..............................................................................154 Overvoltage (59-1, 59-2)...............................................................................155 Phase Imbalance (47)...................................................................................156 Frequency Protection (81O/U)...............................................................................157 Underfrequency (81U)...................................................................................157 Overfrequency (81O)....................................................................................157 Alternate Frequency Scale Factor.......................................................................157 Per Unit...............................................................................................158 Reverse Power Protection (32R).............................................................................158 Loss of Excitation Protection (40Q)........................................................................159 Overcurrent Protection (51-1, 51-2, 51-3)..................................................................161 Programmable Curves for Overcurrent Protection.........................................................162 Setting Programmable (P) Curves........................................................................162 Loss of Mains Protection...................................................................................163 Vector Shift (78)......................................................................................164 ROCOF (81).............................................................................................164 Breaker Management.............................................................................................165 Breaker Hardware...........................................................................................165 Start up Synchronization...............................................................................166 Mains Failure..............................................................................................167 Bus Condition Detection....................................................................................169 Generator Sensing......................................................................................169 Bus Sensing............................................................................................170 Automatic Synchronizer (Optional)..........................................................................173 Frequency Correction...................................................................................173 Voltage Correction.....................................................................................173 Synchronization Failure................................................................................174 Gain Settings..........................................................................................174 Bias Control Settings..........................................................................................175 AVR Bias Control Settings..................................................................................175 var/PF Control.........................................................................................175 Governor Bias Control Settings.............................................................................177 kW Control - Real Power Control Settings...............................................................177 Multigen Management............................................................................................179 AVR Output.................................................................................................179 Governor Output............................................................................................180 Load Share Output..........................................................................................180 Demand Start/Stop..........................................................................................180 Generator Sequencing.......................................................................................181 Disabled...............................................................................................181 Staggered Service Time.................................................................................181 Balanced Service Time..................................................................................182 Largest Size First.....................................................................................182 Smallest Size First....................................................................................182 Smallest Unit ID.......................................................................................182 Adopt System Mode......................................................................................182 Network Configuration......................................................................................183 Programmable Senders...........................................................................................183 BESTlogic™Plus Programmable Logic..............................................................................184 Logic Timers...............................................................................................184 Settings File Management.......................................................................................184 Opening a Settings File....................................................................................185 Saving a Settings File.....................................................................................185 Upload Settings and/or Logic to Device.....................................................................185 Download Settings and Logic from Device....................................................................185 Printing a Settings File...................................................................................185 Comparing Settings Files...................................................................................185 Upgrading Firmware in the DGC-2020 and Expansion Modules.......................................................186 Upgrading Firmware in Expansion Modules....................................................................187 Upgrading Firmware in the DGC-2020.........................................................................189 Metering Explorer..............................................................................................190 Engine.....................................................................................................192 Generator..................................................................................................192 Power......................................................................................................192 Bias Control...............................................................................................193 Run Statistics.............................................................................................193 Status.....................................................................................................194 Inputs.....................................................................................................194 Contact Inputs.........................................................................................194 Remote LSM Inputs......................................................................................195 Remote Contact Inputs..................................................................................195 Remote Analog Inputs...................................................................................195 Remote RTD Inputs......................................................................................196 Remote Thermocouple Inputs.............................................................................196 Remote Analog Input Values.............................................................................196 Logic Control Relays.......................................................................................198 Logic Control Relays...................................................................................198 Outputs....................................................................................................198 Contact Outputs........................................................................................198 Configurable Elements..................................................................................199 Remote Contact Outputs.................................................................................199 Remote Analog Outputs..................................................................................200 Configurable Protection....................................................................................200 Alarms.....................................................................................................201 Event Log..................................................................................................201 J1939 ECU..................................................................................................203 ECU Data...............................................................................................203 Engine Configuration...................................................................................203 Active DTC and Previously Active DTC...................................................................204 MTU........................................................................................................204 MTU Alarms.............................................................................................204 MTU Fault Codes........................................................................................205 MTU Status.............................................................................................205 MTU Engine Status......................................................................................206 Summary....................................................................................................206 Control....................................................................................................207 Real Time Clock............................................................................................207 Generator Network Status...................................................................................208 Generator Sequencing.......................................................................................208 BESTCOMSPlus® Updates..........................................................................................208 Auto Export Metering...........................................................................................209 5 • BESTlogic™Plus PROGRAMMABLE LOGIC ............................................................................211 Introduction...................................................................................................213 Overview of BESTlogic™Plus.....................................................................................213 BESTlogic™Plus Composition.................................................................................214 I/O....................................................................................................214 Components.............................................................................................228 Elements...............................................................................................230 Logic Schemes..................................................................................................240 The Active Logic Scheme....................................................................................240 Copying and Renaming Preprogrammed Logic Schemes...........................................................240 Sending and Retrieving Logic Schemes.......................................................................240 Retrieving a Logic Scheme from the DGC-2020............................................................240 Sending a Logic Scheme to the DGC-2020.................................................................241 Programming BESTlogic™Plus.....................................................................................241 Pickup and Dropout Timers..................................................................................242 BESTlogic™Plus File Management.................................................................................242 Saving a BESTlogicPlus File................................................................................243 Opening a BESTlogicPlus File...............................................................................243 Protecting a BESTlogicPlus File............................................................................243 Uploading a BESTlogicPlus File.............................................................................243 Downloading a BESTlogicPlus File...........................................................................243 Printing a BESTlogicPlus File..............................................................................243 Clearing the On-Screen Logic Diagram.......................................................................243 BESTlogic™Plus Examples........................................................................................243 Example 1 - AVR Logic Block Connections....................................................................243 Example 2 - AND Gate Connections...........................................................................244 Example 3 - Multiple Logic Connections.....................................................................244 6 • INSTALLATION ..................................................................................................245 General........................................................................................................247 Product Registration...........................................................................................247 Hardware.......................................................................................................247 Mounting.......................................................................................................247 Connections....................................................................................................249 Terminations...............................................................................................249 Operating Power........................................................................................249 Generator Current Sensing..............................................................................249 Generator Voltage Sensing..............................................................................250 Bus Voltage Sensing....................................................................................250 Analog Engine Sender Inputs............................................................................250 Emergency Stop Input...................................................................................251 Optional ESTOP Wiring Method.......................................................................252 Magnetic Pickup Input..................................................................................253 Contact Sensing Inputs.................................................................................253 Output Contacts........................................................................................254 USB Interface..........................................................................................254 RS-485 Communication Port..............................................................................255 CANbus Interface.......................................................................................255 Dial-Out Modem.........................................................................................256 RDP-110 Connections....................................................................................256 Connections for Typical Applications.......................................................................257 3-Phase Wye Connections for Typical Applications.......................................................258 3-Phase Delta Connections for Typical Applications.....................................................259 Single-Phase A-B Connections for Typical Applications..................................................260 Single-Phase A-C Connections for Typical Applications..................................................261 Connections with AEM-2020, CEM-2020, and LSM-2020..........................................................262 Installation for CE Systems....................................................................................262 Installation in a Salt Fog Environment.........................................................................262 7 • SETUP .........................................................................................................263 Introduction...................................................................................................265 DGC-2020 Initial Setup.........................................................................................265 Initial Setup Required to Operate Unit.....................................................................265 General Settings.......................................................................................265 Style Number.......................................................................................265 Communications.........................................................................................266 CANbus Setup (Figure 7-2)..........................................................................266 ECU Setup (Figure 7-3).............................................................................267 System Parameters......................................................................................267 System Settings (Figure 7-4).......................................................................267 Rated Data (Figure 7-5) Note: Click the Edit button to change settings.............................268 Remote Module Setup (Figure 7-6)...................................................................269 Crank Settings (Figure 7-7)........................................................................269 Sensing Transformers (Figure 7-8) Note: Click the Rated Data button to make changes................270 Relay Control..........................................................................................271 Auto Config Detection..................................................................................272 Alarm Configuration....................................................................................272 Horn Configuration (Figure 7-11)...................................................................272 Pre-Alarms.........................................................................................272 Alarms.............................................................................................275 Sender Fail........................................................................................275 Programmable Senders...................................................................................276 Coolant Temperature (Figure 7-15)..................................................................276 Oil Pressure (Figure 7-16).........................................................................277 Percent Fuel Level (Figure 7-17)...................................................................278 Initial Setup (Optional)...................................................................................279 General Settings.......................................................................................279 Front Panel HMI (Figure 7-18)......................................................................279 Device Security Setup..............................................................................280 Clock Setup........................................................................................281 Setting Up DGC-2020 Programmable Inputs and Outputs............................................................281 Enable LSM-2020, CEM-2020, and AEM-2020....................................................................282 Programmable Inputs........................................................................................282 Configuration Instructions.............................................................................282 Configuring contact inputs on the DGC-2020 (See Figure 7-22.)......................................282 Configurable Programmable Functions on the DGC-2020 (See Figure 7-23)..............................284 Configuring Remote LSM Inputs on the LSM-2020 (Load Share Module)..................................287 Configuring Remote Contact Inputs on the CEM-2020 (See Figure 7-25)................................288 Configuring Remote Analog Inputs on the AEM-2020...................................................289 Configuring Remote RTD Inputs on the AEM-2020......................................................291 Configuring Remote Thermocouple Inputs on the AEM-2020.............................................292 Programmable Outputs.......................................................................................293 Configuring Contact Outputs on the DGC-2020............................................................293 Programmable Contact Outputs (See Figure 7-29).....................................................293 Run Relay, Pre-Start Relay, and Start Relay........................................................293 Setting Up Configurable Elements in the DGC-2020.......................................................294 Configuring Remote Contact Outputs on the CEM-2020 (See Figure 7-34)...................................296 Configuring Remote Analog Outputs on the AEM-2020......................................................296 Generator and Bus Breaker Control..............................................................................297 Steps Required to Configure a DGC-2020 for Generator Breaker Control.......................................298 Synchronizer...................................................................................................302 Steps Required to Configure a DGC-2020 Automatic Synchronizer..............................................302 Setting up a DGC-2020 and LSM-2020 for a Load Sharing and kW Control Application...............................314 Load Sharing Overview and Theory of Operation in the DGC-2020..............................................314 kvar Control Overview and Theory of Operation in the DGC-2020..............................................316 Setup of the DGC-2020 and the LSM-2020 for Load Sharing and/or kW Control..................................316 Step by Step Setup Procedures..........................................................................317 Mains Fail Transfer............................................................................................329 Steps Required to Configure a DGC-2020 for Mains Fail Transfer.............................................329 8 • MAINTENANCE AND TROUBLESHOOTING ...............................................................................335 Maintenance....................................................................................................337 Backup Battery for the Real Time Clock.....................................................................337 Troubleshooting................................................................................................337 Communications.............................................................................................337 Ethernet Port Does Not Operate Properly................................................................337 USB Port Does Not Operate Properly.....................................................................338 CANbus Communication Does Not Operate Properly.........................................................338 Inputs and Outputs.........................................................................................338 Programmable Inputs Do Not Operate as Expected.........................................................338 Programmable Outputs Do Not Operate as Expected........................................................338 Metering/Display...........................................................................................338 Incorrect Display of Battery Voltage, Coolant Temperature, Oil Pressure, or Fuel Level.................338 Incorrect Display of Generator Voltage.................................................................338 Incorrect Measurement or Display of Generator Current..................................................339 Incorrect Display of Engine RPM........................................................................339 DGC-2020 Indicates Incorrect Power Factor..............................................................339 LCD is Blank and all LEDs are Flashing at Approximately 2 Second Intervals.............................339 Generator Breaker and Mains Breaker........................................................................339 Generator Breaker Will Not Close to a Dead Bus.........................................................339 Generator Breaker Will Not Close to a Live Bus.........................................................340 Generator Breaker Does Not Open When It Should.........................................................341 Mains Breaker Does Not Open When Mains Fails...........................................................341 Mains Breaker Does Not Close After Mains Returns.......................................................342 Synchronizer...............................................................................................342 Determining if the Synchronizer is Active..............................................................342 Synchronizer Not Active................................................................................342 Synchronizer Active for a Short Time, Then Stops.......................................................343 Synchronizer Does Not Lower Engine Speed Allowing Alignment of Bus and Generator.......................343 Synchronizer Does Not Raise Engine Speed Allowing Alignment of Bus and Generator.......................343 Synchronizer Does Not Lower the Generator Voltage to Achieve Matching of Bus and Generator Voltages....343 Synchronizer Does Not Raise Generator Voltage to Achieve Matching of Bus and Generator Voltages........343 Speed Bias.................................................................................................343 Engine Speed Does Not Change When Speed Bias Voltage Changes...........................................343 Engine Speed Decreases When Speed Bias is Increased....................................................343 Engine Speed Increases When Speed Bias is Decreased....................................................343 Voltage Bias...............................................................................................343 Generator Voltage Does Not Change When Voltage Bias Changes............................................343 Generator Voltage Decreases When AVR Speed Bias is Increased...........................................344 Generator Voltage Increases When Speed Bias is Decreased...............................................344 Load Sharing...............................................................................................344 Generator Breaker Status is not being received by the DGC-2020.........................................344 Generator Runs at Incorrect Speed when Generator Breaker is Closed.....................................344 Generators Do Not Share Load Equally...................................................................345 Load Sharing Works Correctly, but a Single Unit Slows Down.............................................345 DGC-2020 Front Panel Debug Screens.........................................................................346 LOAD SHARE DEBUG.......................................................................................346 CONTROL DEBUG..........................................................................................347 CEM DEBUG..............................................................................................349 AEM DEBUG..............................................................................................350 9 • LSM-2020 (LOAD SHARE MODULE) ..................................................................................351 General Information............................................................................................353 Features.......................................................................................................353 Specifications.................................................................................................353 Operating Power............................................................................................353 Analog Inputs..............................................................................................353 Burden.................................................................................................353 Analog Outputs.............................................................................................353 Voltage Regulator Bias Output..........................................................................353 Governor Bias Output...................................................................................353 Load Share Line Output.................................................................................354 Communication Interface....................................................................................354 CAN....................................................................................................354 Ethernet...............................................................................................354 Type Tests.................................................................................................354 Shock..................................................................................................354 Vibration..............................................................................................354 Ignition System........................................................................................354 HALT (Highly Accelerated Life Testing).................................................................354 Environment................................................................................................354 UL Approval................................................................................................354 CSA Certification..........................................................................................354 NFPA Compliance............................................................................................355 CE Compliance..............................................................................................355 Physical...................................................................................................355 Functional Description.........................................................................................355 Analog Inputs..............................................................................................355 Analog Outputs.............................................................................................355 Output for Voltage Regulator Control...................................................................355 Output for Governor Control............................................................................355 Load Share Line Output.................................................................................355 Generator Sequencing.......................................................................................355 Communications.............................................................................................355 CAN....................................................................................................355 Ethernet Port..........................................................................................356 BESTCOMSPlus® Software.........................................................................................356 LSM-2020 Plugin for BESTCOMSPlus®..........................................................................356 Device Info............................................................................................356 Device Security Setup..................................................................................357 Installation...................................................................................................357 Product Registration.......................................................................................357 Mounting...................................................................................................358 Connections................................................................................................358 Terminations...........................................................................................358 Operating Power........................................................................................359 Analog Inputs..........................................................................................359 Analog Outputs.........................................................................................360 CAN Interface..........................................................................................360 Ethernet Port..........................................................................................362 Connections for Typical Applications.......................................................................362 Connections using AVR’, GOV’, and LS’......................................................................364 Application....................................................................................................364 Interfacing an External Control Device with a DGC-2020 – LSM-2020 System...................................364 Method 1...............................................................................................364 Method 2...............................................................................................365 Maintenance....................................................................................................366 10 • CEM-2020 (CONTACT EXPANSION MODULE) ..........................................................................367 General Information............................................................................................369 Features.......................................................................................................369 Specifications.................................................................................................369 Operating Power............................................................................................369 Contact Inputs.............................................................................................369 Contact Outputs............................................................................................369 Communication Interface....................................................................................369 CANbus.................................................................................................369 Type Tests.................................................................................................369 Shock..................................................................................................369 Vibration..............................................................................................370 Ignition System........................................................................................370 HALT (Highly Accelerated Life Testing).................................................................370 Environment................................................................................................370 UL Approval (CEM-2020 Only)................................................................................370 UL Approval (CEM-2020H Only)...............................................................................370 CSA Certification..........................................................................................370 NFPA Compliance............................................................................................370 CE Compliance..............................................................................................370 Physical...................................................................................................370 Functional Description.........................................................................................371 Contact Inputs.............................................................................................371 Contact Outputs............................................................................................371 CEM-2020...............................................................................................371 CEM-2020H..............................................................................................371 Communications.............................................................................................371 CANbus.................................................................................................371 BESTCOMSPlus® Software.........................................................................................371 Installation...................................................................................................371 Product Registration.......................................................................................371 Mounting...................................................................................................372 Connections................................................................................................373 Terminations...........................................................................................373 Operating Power........................................................................................373 Contact Inputs and Contact Outputs.....................................................................374 CANbus Interface.......................................................................................375 Maintenance....................................................................................................376 11 • AEM-2020 (ANALOG EXPANSION MODULE) ...........................................................................377 General Information............................................................................................379 Features.......................................................................................................379 Specifications.................................................................................................379 Operating Power............................................................................................379 Analog Inputs..............................................................................................379 Burden.................................................................................................379 RTD Inputs.................................................................................................379 Thermocouple Inputs........................................................................................379 Analog Outputs.............................................................................................379 Communication Interface....................................................................................380 CAN....................................................................................................380 Type Tests.................................................................................................380 Shock..................................................................................................380 Vibration..............................................................................................380 Ignition System........................................................................................380 HALT (Highly Accelerated Life Testing).................................................................380 Environment................................................................................................380 UL Approval................................................................................................380 CSA Certification..........................................................................................380 NFPA Compliance............................................................................................380 CE Compliance..............................................................................................380 Physical...................................................................................................381 Functional Description.........................................................................................381 Analog Inputs..............................................................................................381 RTD Inputs.................................................................................................381 Thermocouple Inputs........................................................................................381 Analog Outputs.............................................................................................381 Communications.............................................................................................381 CAN....................................................................................................381 BESTCOMSPlus® Software.........................................................................................381 Installation...................................................................................................381 Product Registration.......................................................................................382 Mounting...................................................................................................382 Connections................................................................................................382 Terminations...........................................................................................382 Operating Power........................................................................................383 AEM-2020 Inputs and Outputs............................................................................384 External Analog Input Connections......................................................................385 External RTD Input Connections.........................................................................386 CAN Interface..........................................................................................386 Maintenance....................................................................................................387 A • TIME OVERCURRENT CHARACTERISTIC CURVES ........................................................................389 Introduction...................................................................................................391 Curve Specifications...........................................................................................391 Time Overcurrent Characteristic Curve Graphs...................................................................392 Time Dial Setting Cross-Reference..........................................................................393 UUsing Table A-3.......................................................................................393 B • Modbus™ COMMUNICATION .........................................................................................411 Introduction...................................................................................................413 General Overview...........................................................................................413 Intended Use of the Communications Protocol................................................................413 Detailed Description of DGC-2020 Modbus™ Protocol..............................................................413 Modbus™ Protocol Overview..................................................................................413 Device Address Field...................................................................................413 Function Code Field....................................................................................414 Data Block Field.......................................................................................414 Error Check Field......................................................................................414 Serial Transmission Details................................................................................414 Message Framing / Timing Considerations....................................................................414 Error Handling and Exception Responses.....................................................................414 Detailed DGC-2020 Message Definition...........................................................................414 Device Address.............................................................................................414 Function Code and Data Block...............................................................................414 Read Holding Registers.................................................................................415 Return Query Data......................................................................................415 Preset Multiple Registers, Non-Broadcast & Broadcast...................................................416 Preset Single Register, Non-Broadcast & Broadcast......................................................416 Data Formats...................................................................................................417 Short Integer Data Format (INT8)...........................................................................417 Integer Data Format (INT16)................................................................................417 Long Integer Data Format (INT32)...........................................................................418 32-bit Bit-Mapped Parameter Mapping........................................................................418 Floating Point Data Format.................................................................................418 Double Precision Data Format (DP)..........................................................................419 Triple Precision Data Format (TP)..........................................................................419 Error Check................................................................................................419 Interdependence of Preset Multiple Register Data...........................................................420 Mapping - DGC-2020 Parameters into Modicon Address Space.......................................................420 Current Parameter Table....................................................................................420 Breaker Management.....................................................................................420 Bias Control Settings..................................................................................421 Pulse Outputs..........................................................................................423 Bus Condition Detection................................................................................423 Senders................................................................................................424 System Configuration and Status........................................................................426 Control................................................................................................429 Communication..........................................................................................430 Protection.............................................................................................433 Alarms.................................................................................................439 Metering...............................................................................................441 Legacy Parameter Table.....................................................................................506 C • TUNING PID SETTINGS ...........................................................................................521 Introduction...................................................................................................523 Tuning Procedures..............................................................................................524 Voltage Controller Tuning Procedure........................................................................524 KP - Proportional Gain.................................................................................524 KI - Integral Gain.....................................................................................524 KD - Derivative Gain...................................................................................524 var/PF Controller Tuning Procedure.........................................................................525 KP - Proportional Gain.................................................................................525 KI - Integral Gain.....................................................................................525 KD - Derivative Gain...................................................................................525 Speed Controller Tuning Procedure..........................................................................526 KP - Proportional Gain.................................................................................526 KI - Integral Gain.....................................................................................526 KD - Derivative Gain...................................................................................526 kW Load Controller Tuning Procedure........................................................................526 KP - Proportional Gain.................................................................................526 KI - Integral Gain.....................................................................................527 KD - Derivative Gain...................................................................................527 Generic Gains for Multiple Machine Types.......................................................................527 D • MTU FAULT CODES ...............................................................................................529 Introduction...................................................................................................529 E • EXHAUST TREATMENT .............................................................................................537 Diesel Particulate Filter (DPF)................................................................................539 Regeneration...............................................................................................539 DPF Control................................................................................................539 Manual Regeneration....................................................................................539 Regeneration Inhibit...................................................................................539 DPF Status and Pre-Alarms..................................................................................540 Exhaust After Treatment Systems (EATS).........................................................................541 Pre-Alarms.................................................................................................541 Exit Conditions for DEF Severe Inducement..................................................................541
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