DGC-500

DGC-500
DIGITAL GENSET
CONTROLLER

Basler Electric’s Digital Genset Controller (DGC-500) offers a low cost microprocessor based integrated
alternative for the control and monitoring of small to medium sized gensets. Control includes engine
starting and shutdown as well as system monitoring and remote annunciation. DGC allows user inputs
and programming to provide a reliable, customizable genset controller. This unique design has features
not found in competitive models. It monitors and displays eight engine and generator parameters on the
front panel and up to a total of 18 parameters via the front panel scrolling feature. The DGC-500 offers
one of the most flexible designs. It has user-definable alarms, pre-alarms, timers, cranking cycles, sender
inputs, J1939 Engine Communications (optional), and programmable inputs and outputs.

FEATURES
• Microprocessor based
• Flash memory
• Displays 18 engine/generator parameters
• Has user programmable analog sender inputs for oil pressure, coolant temperature
and fuel level
• Controls engine starting and stopping DESCRIPTION,
• PC-configurable with BESTCOMS PC software included with every unit FUNCTIONS and
• Programmable engine cranking SPECIFICATIONS
• Programmable alarms and pre-alarms
• (3) 30A rated output relays can eliminate interposing relays.
pages 2 - 4
• NFPA-110 Level 1 compatible (non-air damper application)
• NFPA-99 Standard for Health Care Facilities
• Programmable inputs (3) FRONT PANEL DISPLAY
• Programmable outputs (2) and
• Generator protection
• Remote annunciation via 2-wire communications and Basler's RDP-110 (optional)
OUTLINE DRAWINGS
• Data logging pages 5 and 6
• UL recognized, File E97035
• Real time clock
• Successful Start counter INTERCONNECT
• CSA certified, File LR 23131
• UL, Class 1 Div 2; Groups A, B, C, D, Zone 2; Temperature Code T5, cURus recognized
DRAWING
component for hazardous location use (select models). page 7
• SAE J1939 CANBUS communications for direct ECM communications (optional feature)
• Displays Engine Fault Codes (via Canbus DTCs)
• Volvo/Penta J1939 CANBUS compatible via J1939 option
ORDERING
ADDITIONAL INFORMATION INFORMATION
INSTRUCTION MANUAL page 8
Request Publication 9355400990

ROUTE 143, BOX 269 HIGHLAND, ILLINOIS 62249, U.S.A. PHONE 618-654-2341 FAX 618-654-2351

SNH-6
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DGC-500

DESCRIPTION
DGC-500 Digital Genset Controller utilizes microprocessor based technology to provide the most versatile system for
genset control, protection and monitoring. This microprocessor design allows easy customization of the controller's
functions to fit virtually every application's needs. DGC-500 accepts conventional engine sender inputs that can be
customized by the simple-to-use BESTCOMS PC software to obtain maximum accuracy and allows the user to not be locked
in to a specific sender type. It is also possible to get all of the engine information directly from the engine's ECU via CANBUS
and J1939. This saves time and money spent on buying, mounting, and connecting additional senders. Standard features
enable the user to meet the requirements of NFPA-110 Level 1 for non-air damper equipped engines.

FUNCTIONS
GENSET MONITORING
Generator Engine
Voltage (3 phase line-to-line, single phase and Oil pressure Hours to next service
3 phase line-to-neutral) Coolant temperature Total run time
Current (3 phases) Fuel level Engine RPM
kVA total and per phase Battery voltage Others as provided by
Frequency J1939 communications

GENSET PROTECTION
Generator
Undervoltage (27) Underfrequency (81U) Phase Imbalance (47)
Overvoltage (59) Overfrequency (81O) Generator Overcurrent (51)
All Generator Protection features are programmable as Alarms or Pre-alarms.

Engine
Alarms (Shutdowns) Pre-Alarms (Warnings)
Low Oil Pressure Low Oil Pressure
High Coolant Temperature High Coolant Temperature
Low Fuel Level Low Fuel Level
Overspeed Low Coolant Temperature
Overcrank Low Battery Voltage
Emergency Stop Button Input High Battery Voltage
Low Coolant Level Weak Battery
Sender Failure Battery Charger Failure
Fuel Leak
Maintenance Interval Timer
All Alarms and Pre-Alarms can be enabled or disabled via the BESTCOMS PC software.

ENGINE CONTROL
Cranking Control: Cycle or Continuous (Fully Programmable)
Engine Cooldown: Smart Cooldown function saves fuel and engine life.
Successful Start Counter: Counts and records successful engine starts
Timers:
Engine Cooldown Timer: 0-60 minutes
Engine Maintenance Timer: 0-5000 hours
Pre-Alarm Time Delays for Weak/Low Battery Voltage: 1-10 seconds
Alarm Time Delay for Overspeed: 0-500 mseconds
Alarm Time Delay for Sender Failure: 0-30 seconds
Arming Time Delays after Crank Disconnect:
Low Oil Pressure 5-15 seconds
High Coolant Temperature 0-30 seconds
Pre-Crank Delay: 0-30 seconds
Crank Cycle Time Delay: 0-60 seconds
Sleep Mode: Conserves battery power by turning off nonessential functions within the DGC.

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 DGC-500

FUNCTIONS, continued
EVENT RECORDING
The DGC has an event recorder that provides a record of alarms, pre-alarms, engine starts, engine stops, engine
runtime loaded, engine runtime unloaded, last run date, and many other events that are all date and time stamped to
help the user determine the cause and effect of issues related to the generator set.

COMMUNICATIONS
J1939 Communications (Optional)
J1939 CANBUS communications allows the DGC to communicate to the engine's ECU (Engine Control Unit) to gather
critical engine information like oil pressure, engine coolant temperature, RPM, battery voltage, and many more. By
utilizing the ECU, adding analog engine senders is no longer required. This, alone, can save substantial money for the
installer. It also eliminates any errors or discrepancies between the ECU data and the data displayed on the DGC that
may be present due to analog sender inaccuracies or incompatibility. 47 engine parameters in all can be obtained via
the ECU. We also can derive the added benefit of having access to the ECU's diagnostic troubleshooting codes, or
DTC's. The DTC's provide information about the engine's operating conditions and communicates these via J1939, to
the DGC, thus eliminating the need for hand-held service tools to diagnose simple engine issues.

With Volvo engines, we can also access areas of the protocol to allow for direct engine communications that provide
additional savings to the installer. The DGC can provide direct communications to Volvo ECUs to allow the ECU to
crank and stop the engine, thus eliminating the need to add more circuitry for cranking the engine. The DGC can also
adjust the engine speed to allow for regulator frequency compensation setting.

PC Communications
The DGC is fully programmable via the rear mounted RS-232 DB9 connector. The DGC-500 may be programmed via
Windows 98/XP/NT software. This software permits the user to set each adjustable DGC parameter one-at-a-time and
also allows for complete file transfers of all the parameters of a DGC for fast, simple DGC configuration. The software is
available via download from the Basler website, and it is available at no extra charge.

Remote Display Panel Communications

The DGC also comes with an integrated RS-485 port for two-wire communication to Basler Electric's RDP-110, remote
display panel. The RDP-110 may be placed up to 4000 feet away from the DGC and provide remote indication of the
necessary parameters to meet the requirements of NFPA-110 (non-damper equipped engines). This communications
port provides the annunciation of 17 operating and alarm indications and does this with the requirement of only FOUR
wires. The function of the four wires includes two for power and two for communications.

SPECIFICATIONS
INPUTS and DISPLAY RANGES
Power Supply Input
Battery Voltage 8-32 Vdc (12 or 24 Vdc nominals)
Negative Ground Systems
Battery Drop Ride Through 6 Vdc for .75 seconds
Power Dissipated 16 Watts
Display Range for Battery Input 3-36 Vdc

Generator Sensing Input

Voltage
Input Range 12-576 Vac, <1 VA Burden
Display Range 0-999 Vac
Accuracy ±0.5% or ±1 Vrms, whichever is greater @ 25°C, with phase
selector switch and panel indication
Frequency
Display Range 4-70 Hz (50/60 Hz nominal)
4-450 Hz (400 Hz nominal models only)
Accuracy ±.25% of indication or ±0.2 Hz, whichever is greater @ 25°C

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DGC-500

SPECIFICATIONS, continued

INPUTS and DISPLAY RANGES, continued

Generator Sensing Input, continued
Current
Input Range 0 to 5 or 0 to 1A AC (two models), <1 VA Burden
Display Range 0-5,000 Aac
Accuracy ±0.5% or ±1 Arms, whichever is greater @ 25°C, with phase
selector switch and panel indication
kVA
Input Range Calculated for Voltage and Current Inputs
Display Range 0-9,999 kVA
Accuracy ±0.5% of indication or ±1 kVA, whichever is greater @ 25°C, with
phase selector switch and panel indication
Engine Inputs
Oil Pressure
Display Range 3-150 PSI (103-999 kPA)
Accuracy ±0.5% or ±1 PSI/1 kPA, whichever is greater at @25°C
Sender Input Range 33-240 Ω
Communications Parameter is available via J1939 CANBUS
Coolant Temperature
Display Range 100°F-300°F (37°C-149°C)
Accuracy ±0.5% or ±1°F/°C, whichever is greater at @ 25°C
Sender Input Range 62.6-637.5 Ω
Communications Parameter is available via J1939 CANBUS
Engine Run Time
Display Range 0-99,999 hours
Accuracy ±0.5% or ±1 hour, whichever is greater @ 25°C
Communications Parameter is available via J1939 CANBUS
Fuel Level
Display Range 0-100%
Accuracy ±0.5% or ±1%, whichever is greater @ 25°C
Sender Input Range 33-240 Ω
Communications Not available via CANBUS
Engine RPM
Display Range 750-3600 RPM
Accuracy ±0.5% or ±2 RPM, whichever is greater @ 25°C
Sender Input Mag Pickup, 3 Vpeak min. to 35 V peak into 10 K Ω impedance
(32 Hz - 10 kH)
Communications Parameter is available via J1939 CANBUS
Contact Inputs 3 Programmable inputs (Emergency Stop and 3 programmable
contact inputs)
Indication accuracies of the parameters developed from mechanical senders are subject to the accuracy of the sender.

OUTPUTS
Contact Ratings 30 A* @ 28Vdc make, break and carry (Crank, Fuel Solenoid, and
Pre-crank contacts)
2 A @ 24 Vdc make, break and carry (2 programmable contacts)
*30 A contact are derated to 3A for Class 1 Div 2 models
Remote Display Panel Outputs RS-485 communications output to Basler Electric RDP-110 remote
display module

ENVIRONMENTAL
Vibration 10 to 500 Hz @5 Gs
Shock 15 Gs in each of three mutually perpendicular axes
Ambient operating temperature -20°C to +60°C
Storage temperature -40°C to +85°C
Salt Fog Testing Per ASTM 117B-1989 for 100 hours
Weight 1.5 lb (680 g)
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 DGC-500

DGC-500 FRONT PANEL DISPLAY

Figure 1 shows the front panel human-machine interface (HMI) for a DGC-500.

Figure 1 - Front Panel

FRONT PANEL LED INDICATORS:

Run: Green - Indicates the engine is running (operating).

Off: Red - Indicates the engine is not running (shutdown).
Auto: Green - Indicates the unit is in the AUTO mode of operation.
Not-in-Auto: Red - Indicates unit is not in the AUTO mode.
Alarm: Red - Indicates an alarm situation by continuous illumination. Indicates a Pre-alarm by flashing.
Supplying Load: Green - Indicates the system is supplying more than 2% of rated current to a connected load.

PACKAGING:

DGC-500 is delivered ready to install. It utilizes 1/4" quick connect fasteners for interconnection to the genset.

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DGC-500

DIMENSIONS

Figure 2 - Dimensions - Top View

Figure 3 - Case Cutout Dimensions (285.8)

11.250
0

Digital
Genset
Controller - 500
DGC

Generator Generator Generator Generator

Voltage Amps Phase Frequency

Not In Supplying
Auto Alarm Load
Oil Fuel Coolant Battery
Pressure Level Temperature Voltage

Phase Alarm Lamp

Toggle Silence Test

Select Display
Raise Lower Previous
Enter Toggle
Scroll Scroll

Run Off Auto

7.750
(196.9)
Figure 4 - Dimensions - Front View

NOTES: 1. Dimensions in parentheses are in millimeters.

2. All drawings and data subject to change without notice.

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 DGC-500

CONNECTIONS

Figure 5 - DGC-500 Direct Connected Three-Phase Line-to-Neutral Sensing

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DGC-500

ORDERING INFORMATION
OPTIONAL EQUIPMENT Vibration Isolation Kit, P/N 9355406101
A vibration isolation kit is available to allow the DGC to be
Audible Alarm Horn mounted directly to the genset where vibration levels
An audible alarm horn is available that is rated at 80db exceed the DGC's vibration ratings. This kit comes
from 2 feet (0.6 meters) to provide an audible alarm complete with vibration isolators and a gasket seal that
indication to meet NFPA-110. This horn is remotely maintains the front panel's integrity to prevent the
mounted from the DGC-500 and can be ordered by entrance of foreign non-liquid materials. The following
specifying Basler Part Number 29760. chart indicates the frequency response of the vibration
isolation kit.
Remote Annunciation Display Panel
Applications and specifications requiring remote
annunciation can be satisfied by using Basler's Remote
Display Panel, RDP-110. Request product bulletin SNE
for Remote Display Panel, RDP-110. The panel needs
only four wires to annunciate all of the alarms, pre-alarms
and operating conditions of the DGC-500. This product
meets the requirements of NFPA-110 for non-air damper
equipped engines.

Vibration Isolated Enclosure

DGC-500 can be mounted in an optional two-piece metal
enclosure that has four vibration isolators installed. Basler
can also customize this enclosure to your specific needs,
adding terminal strips or cabling for customer intercon-
nection, alarm horns, emergency stop buttons, etc.

SAMPLE SPECIFICATION
The engine generator control system shall be a microprocessor based design that incorporates both engine control
and monitoring of the engine and generator and displays these monitored quantities on a front panel LCD display.
There shall be options for CT secondary selection and the addition of J1939 engine communications. The device
shall meet the requirements of NFPA-110 Level 1 and shall provide contacts for remote annunciation. It shall provide
the user the option of setup and adjustment via a Personal Computer or via the front panel pushbuttons. The device
shall be a Basler Electric Model DGC-500; there are no equals.

STYLE CHART

Example: DGC-500-F5J1 consists of the basic DGC-500 digital genset controller, equipped with the provision to communicate
with a separately available RDP-110 Remote Display Panel to meet the requirements of NFPA-110, 5 amp secondary current
transformers, SAE J1939 engine communication, and multifunction generator protection.

ISO em
Syst
Basler

lity
®

Qua R e g
i st e r e d
Highland, IL: ISO 9001
Wasselonne, France: ISO 9001
Taylor, TX: ISO 9001

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Tel +33 3.88.87.1010 Fax +33 3.88.87.0808 Tel +1 618.654.2341 Fax +1 618.654.2351 Suzhou, Jiangsu Province, PRC 215200
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