om

DGC-1000

.c
DIGITAL GENSET
CONTROLLER

ls
ua
an
Basler Electric's Digital Genset Controller (DGC-1000) 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

tM
programming to provide a reliable, customizable genset controller. This unique design has features not
found in any competitive models. It monitors and displays eight engine and generator parameters on the
front panel and up to a total of 28 parameters via the front panel scrolling feature. The DGC-1000 offers the
most flexible design possible. It has user-definable alarms, pre-alarms, timers, cranking, sender inputs,
ar
J1939 engine communications, programmable inputs and outputs with the optional Auxiliary 1/0 feature
and an on-board modem for external communications from virtually anywhere.
lP

FEATURES DESCRIPTION and

• Microprocessor based SPECIFICATIONS
Flash memory
•
pages 2 and 3
Displays 28 engine/generator parameters
ca

• Uses SAE J1939 CANBUS communications for engine parameters

• Has user programmable analog sender inputs for oil pressure, coolant
temperature and fuel level FRONT PANEL DISPLAY
• Controls engine starting and stopping and
tri

• PC-configurable with BESTCOMS PC software included with every unit OUTLINE DRAWINGS
• Programmable engine cranking pages 4 and 5
• Programmable alarms and pre-alarms
NFPA-110 Level 1 compatible (non-air damper application)
lec

• Optional integral dial-out modem

• Optional Auxiliary 1/0 module

INTERCONNECT
• Remote annunciation via 2-wire communications and Basler's RDP-110 DRAWING
• UL recognized, File Number E97035 page 6
• CSA certified, File Number LR23131
.E

ADDITIONAL INFORMATION ORDERING

INSTRUCTION MANUAL INFORMATION
Request Publication 9358900990 pages 7 and 8
w

··�

§l Basler Electric
ww

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

SNF-4
1-02
DGC-1000

om
DESCRIPTION
DGC-1000 Digital Genset Controller utilizes microprocessor based technology to provide a versatile system for genset

.c
control, protection and monitoring. This microprocessor design allows customization of the controller's functions to fit virtually
every application's needs. DGC-1000 has conventional engine sender inputs. These can be customized via the BESTCOMS
PC software to allow virtually any sender to be used. It is also possible for the user to get the engine information from the
engine control module and use CANBUS, SAE J1939. This saves money and time normally spent on buying and installing
senders and mag pickups. DGC-1000 offers an optional dial-out modem to announce alarms and pre-alarms to a computer

ls
or pager. There is also an optional auxiliary 1/0 module that allows for four more contact inputs and eight Form C outputs.
Optional features enable the user to meet the requirements of NFPA-11 0 Level 1 for non-air damper equipped engines.

ua
SPECIFICATIONS

INPUTS MONITORING

an
DC power input (Battery): GENERATOR
12Vdc nominal systems (8-16Vdc) Generator voltage:
24Vdc nominal systems (16-32Vdc) 0 to 600 Vac

tM
(both Negative Ground systems) Display range is 0 to 15,000V
Power dissipated is 16 Watts. Accuracy is ±0.5% of indication or 1Vrms@25°C,
Generator voltage input: whichever is greater (with phase selection switch
12-576Vac continuous, 50/60Hz@ <1 VA and panel indication)
Generator line current: 1 or 5 Amp input@ <1 VA
ar
Oil pressure sender: 0 to 100 PSI (33-240Q) Generator Frequency:
Coolant temperature: 100°F to 300°F (37oC to 149°C) Derived from voltage inputs
(62.6-637.5Q) Display range is 4 to 70 Hz
Speed input: Magnetic pickup 3V peak minimum Accuracy is ±0.25% of indication or 0.1Hz@25°C,
lP

to 35V peak into a 1OkQ (32Hz-1OkHz) impedance whichever is greater

Fuel level: 0-100% (240-33Q)
Contact Sensing Inputs: Emergency Stop, Low Coolant Line current input (CT):
ca

Level, Automatic Transfer Switch 0 to 5 Aac or 0 to 1 Aac RMS

SAE J1939 CANBUS communications Display range is 0 to 5000 A
Accuracy is ±0.5% of indication or 1Arms@25°C,
OUTPUTS whichever is greater (with phase selection switch
and panel indication)
tri

Contact ratings: 1OA@24Vdc make, break, and carry

(Crank, Fuel solenoid) kVA: Calculated from voltage and current inputs
2A@24Vdc make, break, and carry Display range is 0 to 9999kVA
(EPS supplying load, Alarms, Pre-start,
lec

Accuracy is ±0.5% of indication or ±0.1 kVA,

pre-alarms) whichever is greater@25°C
NFPA-110 output to RDP-110
kW: Calculated from voltage and current inputs
ENVIRONMENTAL SPECIFICATIONS Display range is 0 to 9999kW
Accuracy is ±0.5% of indication or ±0.1kW,
.E

Vibration: 10 to 500 Hz@2 Gs

whichever is greater@25°C
Shock: 15 Gs in each of three mutually perpendicular axes
Ambient operating temperature: -40°C to + 70°C
Power Factor:
Salt Fog Testing: Per ASTM 1178-1989 for 100 hours
Calculated from voltage and current inputs
Weight (max.): 1.9 pounds (0.86 kilograms)
Display range is + 1.0 to -1.0PF both leading
and lagging (all four quadrants)
w

Accuracy is ±0.01 PF of indication@25°C

kWh: Display range 0-999,999,999kWH

ww

Accuracy is ±0.5% of reading or ±1kWH,

whichever is greater@25°C

2
 DGC-1000

om
SPECIFICATIONS, continued
ENGINE GENERATOR SET PROTECTION

.c
Oil pressure: Alarms:
Input from sender or SAE J1939 CANBUS • Low oil pressure • Sender failure
Display range is 3 to 100 PSI or 103-1035kPS • Overspeed • Low coolant level
Accuracy is ±0.5% or ±1PSI/1kPA, • Overcrank • Low fuel level
whichever is greater@25°C • Emergency Stop button input
Sender input is 33-240Q High coolant temperature

ls
•

Coolant temperature: Pre-Alarms:

Input from sender or SAE J1939 CANBUS Low oil pressure High battery voltage

ua
• •

Display range is 100°F to 300°F (3JGC to 149°C} • Engine kW overload • Low battery voltage
Accuracy is ±0.5% or ±1°F/1 oc, • Maintenance interval timer • Fuel Leak

whichever is greater@25°C • High coolant temperature • Weak battery

Sender input is 62.6-637.5Q • Low coolant temperature • Low fuel level

an
• Battery charger failure
Battery voltage:
Input from battery is 8 to 36Vdc TIMERS
Display range is 3 to 36Vdc Engine cooldown: 0 to 60 minutes
Accuracy is ±0.5% of indication or ±0.1 volts, Engine maintenance: 0 to 5000 hours

tM
whichever is greater@25°C Pre-Alarm time delays:
Weak battery and low battery voltage: 1-10 seconds
Engine run-time: Alarm time delays:
Display range is 0 to 99,999 hours Overspeed: 0-500ms
Accuracy is ±0.5% of indication or ±1 hour, Sender failure: 0-10 seconds
ar
whichever is greater@25°C Arming delays after crank disconnect:
Low oil pressure: 5-15 seconds
Fuel level: High coolant temperature: 50-150 seconds
lP

Input from sender Pre-crank delay: 0-30 seconds

Display range is 0-100%
Accuracy is ±0.5% of indication or 1% @25°C,
whichever is greater SERIAL COMMUNICATIONS
ca

Sender input is 240-33Q

The DGC-1000 is fully programmable via the RS-232 DB9
RPM: connector. The DGC-1 000 may be programmed via the
Input from magnetic pickup or SAE provided Windows® 95/98/NT software. This software
J1939 CANBUS permits individual parameter setting or complete file
tri

Display range: 750 to 3600 RPM transfers from a personal computer to the DGC-1000 for
Accuracy: ±0.5% of indication or ±2 RPM, fast, accurate setup of the DGC-1000.
whichever is greater@ 25°C
lec

J1939 CANBUS communications allows the DGC-1000 to

NOTE: Final engine parameter accuracies are subject communicate to the engine's ECM to gather information
to sender accuracy. about the engine, i.e. oil pressure, engine coolant tem­
perature, RPM, battery voltage and many more. By using
the ECM, conventional mechanical senders are no longer
TOTAL MONITORED PARAMETERS required. This can save substantial money in installation
.E

and purchasing of the senders. It also removes any errors

GENERATOR between the information displayed between the ECM and
Voltage (three phases and three phases to neutral) DGC-1 000 that may be present due to inaccuracies in the
Current (three phases) kWH senders.
kW total and per phase Power Factor
kVA total and per phase Frequency The DGC-1000 also has an RS-485 port for four-wire
w

communications to the RDP-110 remote display unit. This

ENGINE unit may be placed 4000 feet from the DGC-1000 and
Oil pressure Hours to next service provides NFPA-110 (for non-air damper equipped
ww

Coolant temperature Total run time engines) compatible annunciation of 17 operating and
Fuel level Engine RPM alarm indications with only four wires.
Battery voltage
3
DGC-1000
-1l-4t�'···

om
DGC-1000 FRONT PANEL DISPLAY

Figure 1 shows the front panel human-machine interface (HMI) for a DGC-1000.

.c
Digital
Gensel
Controller
DGC-1000

ls
ua
Generator Generator Generator Generator

Voltage Amps Phase Frequency

Nolin Supplying

[..___ ]
Auto
Alarm Load

0 0 0
____..

an
r=l
Coolant Battery Run

Pressure Temperature Voltage Time

L=J
B
tM 0 0 0
ar
lP

Figure 1 - Front Panel

FRONT PANEL LED INDICATORS:
ca

Run: Indicates the engine is running (operating).

Off: Indicates the engine is not running (shutdown).
Auto: Indicates the unit is in the AUTO mode of operation.
Not-in-Auto: Indicates unit is not in the AUTO mode.
Alarm: Indicates an alarm situation by continuous illumination. Indicates a Pre-alarm by flashing.
tri

Supplying Load: Indicates the system is supplying power to a connected load.

lec

PACKAGING:

DGC-1000 is delivered ready to install. It utilizes 1/4" quick connect fasteners for interconnection to the genset.
.E
w
ww

4
 DGC-1000

om
DIMENSIONS

.c
10 75(273 0)
0 218(5 537)
10.25(260 4) DIA HOLE(4 PL)

0 25(6 4)

.J

ls
ua
(22.2) TOLERANCE ON ALL CUT OUT
I 6 75 7 25
DIMENSIONS ±0.01 (0.254) (171.4) (184.2)

an
1 o.25(6.4)
'
t'
02609-11

L"�"�"------� I
Ell-------------------------Ell

Figure 2 - Dimensions- Top View

tM Figure 3 - Case Cutout Dimensions
ar
lP

.88
(22.2)
ca

1------ 11.25 -------1

(285.8)

!§.
tri

.
DGC-1000

6.00
(152.4)
lec

���Bs ·-· ...

J
·" , _...
_".,_�_ ..'
"_· _B_
· B_
"
" -B
·-·

L___ _ -
.E

Figure 4 - Dimensions- Side View Figure 5- Dimensions- Front View

w
ww

NOTES: 1. Dimensions in parentheses are in millimeters.

2. All drawings and data subject to change without notice.
5
 .c
0
G)
0
I
.....
c
(j) c
c

GENERATOR

ls
CIRCUIT
BREAKER

1:

ua
"TT B
TO
=· BUS
c
...
CD c
en
I�

an
I

c
Q
('")
......
I

{
Cl
·:: ·; CAN HI

�
1' 1'
Cl CAN LO
.
Cl �

tM
c
HORN L,------J L,------J
w w w
... (f)
<(1-
(f)
<(1-
(f)
<(f­ OIL PRESSURE
CD IO IO IO
a.o "-"' <l.<(
-
n
SENDING
FUEL LEVEL

('") UNITS n
c COOLANT TEMP
0
DGC-1000
(f)
::I

ar
I-

::I �� SENDER RETURN IP46�

z
CD ::>w
Orr:
-
n
CD
z
s:::::L m
...... n

lP
::::r
... ...
-
CD
CD
I 0
"'"0
::::r z
en
1:1:1
ca
en
CD
r-
:;·
CD
-
I
c
tri
I /i\ CONNECT TO P3, P6 AND P9 FOR 1 AMP SECONDARY CTs
:z: CONNECT TO P4, P7 AND P10 FOR 5 AMP SECONDARY CTs
CD
c
- 1� STEWART WARNER P/N 411K OR EQUIVALENT. NOT USED IF J19391S USED.
...
1:1:1 fa\ ISS PRO P/N R8925 OR EQUIVALENT
lec

(I)
CD
/4\ STEWART WARNER P/N 334P OR EQUIVALENT. NOT USED IF J19391S USED.

::I
en
ffi IF AN EMERGENCY STOP SWITCH IS NOT USED, JUMPER TERMINALS P17 AND P18.

::I I� TIED DIRECTLY TO ENGINE CHASSIS.

CCI
ffi NOT USED IF CAN IS USED.

M J1939 SHIELD SHOULD BE GROUNDED AT ONLY ONE POINT. IF GROUNDED

.E

ELSEWHERE IN THE SYSTEM, CUT J1939 SHIELD CONNECTION TO UNIT.

ffi IF UNIT IS NOT PROVIDING ONE END OF THE J1939 BACKBONE, THEN CUT JUMPER
TO REMOVE ON-BOARD TERMINATION RESISTOR. ALSO, IF NOT PART OF THE
BACKBONE, THE STUB CONNECTING THE UNIT TO THE BACKBONE SHOULD NOT
EXCEED 3 FEET IN LENGTH.
 DGC-1000
,;:S::£�%�-f;%6��;,

om
ORDERING INFORMATION

OPTIONAL EQUIPMENT Audible Alarm Horn, Basler P/N 29760

An audible alarm horn is available that is rated at 80db

.c
Additional 1/0 (Input/Output)
from 2 feet {0.6 meters) to provide an audible alarm
For those applications where more input and output
indication to meet NFPA-110. This horn is remotely
contacts are needed to customize the DGC-1000 to
mounted from the DGC-1000 and can be ordered by
the application, Basler offers an additional card that
specifying Basler Part Number 29760.
has four inputs and eight output contacts. These
contacts may be assigned for the particular desired

ls
Remote Annunciation Display Panel
function by using the PC software to label the inputs
Applications and specifications requiring remote
so the front panel LCD displays the proper message
annunciation can be satisfied by using Basler's
and the outputs can be easily programmed for any

ua
Remote Display Panel, RDP-110. Request product
desired outcome.
bulletin SNE for Remote Display Panel, RDP-11o. The
panel needs only four wires to annunciate all the
Dial out modems
alarms, pre-alarms and operating conditions of the
Basler Electric offers two modem boards for use with

an
DGC-1000. This product meets the requirements of
the DGC-1000 for dial out capability to inform a pager
NFPA-110 for non-air damper equipped engines.
that an alarm or pre-alarm has occurred with the DGC-
1000. Up to four phone numbers can be dialed and
Vibration Isolated Enclosure
will be called in sequence until an answer is received.
DGC-1000 can be mounted in an optional two-piece

The modems come in two operating temperature

ranges. The standard modem is rated from ooc to
+50°C, and the extended operating temperature range
device will accommodate temperatures from -40°C to
tM
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 interconnection, alarm horns, emergency
ar
stop buttons, etc.
+70°C. Please see the style chart for ordering
information.
lP

Enhanced Communications
SAMPLE SPECIFICATION
This enhanced communications option allows the user
to have advanced communications with the DGC- The engine generator control system shall be a
1000. This option provides all of the standard PC microprocessor based design that incorporates both
ca

software features found in all of Basler's B ESTCOMS engine control and monitoring of the engine and
software, i.e. fast and easy set-up of all system generator and displays these monitored quantities on
configurations, alarms, pre-alarms, 1/0 configuration a front panel LCD display. The device shall meet the
and modem set-up, and much more. It provides requirements of NFPA-110 Level 1 and shall provide
tri

enhanced PC communication by providing remote contacts for remote annunciation. It shall provide the
start-stop control of the genset, remote viewing of user the option of setup and adjustment via a
faults, remote resetting of faults, and remote metering Personal Computer or via the front panel pushbuttons.
lec

of the engine/generator parameters, 28 in all, of the The device shall be a Basler Electric Model DGC-
DGC-1000. The remote PC monitoring of the DGC- 1000; there are no equals.
1000 requires the internal modem option and allows
the user the dial-in and dial-out capability normally
found in only the most expensive controllers. It does
.E

this while utilizing the innovative low cost, easy to

operate and install DGC-1000 package.
w
ww

7
DGC-1000

om
ORDERING INFORMATION, continued

STYLE CHART

.c
L..._ o G c 1 ooo
..- ___-___ l
_....�
-
D D
-,-
D
MODEL NO.

ls
ua
Auxiliary 1/0 Dial-out Modems Communications

0) No dial-out modem
ffi
N) No Auxiliary. 1/0 N) Standard
A) 4 inputs/8 outputs 1) Std dial-out modem C) Enhance
2) Extended operating

an
temperature range
modem

NOTES:

&

tM
Requires dial-out modem.

Example: DGC-1OOO-A2C consists of the basic DGC-1000 digital genset controller, equipped with auxiliary 1/0 of 4 inputs
and 8 outputs, an extended temperature range modem capable of operating in ambient temperatures of -40° to +70°C, and
ar
enhanced communications.
lP
ca
tri
lec
.E

§®Basler Electric
w
ww

ROUTE 143, BOX 269, HIGHLAND, ILLINOIS U.S.A. 62249 P.A.E. Les Pins, 67319 Wasselonne Cedex FRANCE
PHONE 618-654-2341 FAX 618-654-2351 PHONE (33-3-88) 87-1010 FAX (33-3-88) 87-0808
http://www.basler.com, [email protected]
8

Printed in U.S.A.