Basler DGC-2020 Generator Set Controller: Integrated Control and Debugging Guide

Mains Fail Transfer

Run with Load logic input

Demand Start/Stop

3.2 Self activation logic

The self starting modes of DGC-2020 are independent of each other but have priority logic. If any starting condition is true, the unit will operate; The unit will only shut down when all start-up conditions are false. This design ensures reliable operation under various working conditions.

Circuit breaker management and automatic synchronization

4.1 Circuit Breaker Control

DGC-2020 can control both generator circuit breakers and mains circuit breakers simultaneously. Supports two contact output modes:

Pulse mode: emit pulses of the set width (0.01-0.80 seconds)

Continuous mode: Continuous output holding (applicable to circuit breakers with holding coils)

Before closing the circuit breaker, the controller will verify:

Stable voltage on the generator side

The voltage on the busbar side is stable or determined to be a dead busbar

Synchronization condition met (when closed to live busbar)

4.2 Synchronizer Operation

The automatic synchronizer of DGC-2020 supports two modes:

Phase Lock Loop mode:

The controller adjusts the generator voltage and frequency through the rise and fall signals of the speed regulator and AVR

When the voltage difference, frequency difference, and phase angle difference all meet the set values, issue a closing command

Predictive mode:

Added circuit breaker closing time compensation on the basis of PLL

The controller calculates the advance phase angle based on the measured slip frequency to ensure that the phase angle approaches zero at the moment of circuit breaker contact closure

Troubleshooting steps for synchronizer not working:

Confirm that the style number includes a synchronizer option

Check if the GEN STANBLE and BUS STANBLE status indicator lights are on

Confirm that the controller is initiating a closing request

If the synchronization stops after a brief activation, check if a Sync Fail pre alarm has been triggered

Load distribution and parallel connection of multiple machines (LSM-2020)

5.1 Load distribution principle

DGC-2020 is used in conjunction with LSM-2020 load distribution module to achieve parallel operation of multiple machines. The core mechanism is to simulate load distribution lines:

Each generator's LSM-2020 outputs a 0-10V signal, which is proportional to the actual output kW of the unit

The load distribution lines of all units are connected together, and the intersection voltage reflects the average value per unit of the total system load

Each unit adjusts its own output by using the intersection voltage as the set value for the kW controller

5.2 Parameter tuning of PID controller

Load distribution involves three PID controllers:

Speed controller: Adjust engine speed before parallel synchronization

Voltage controller: Adjust the generator voltage during synchronization before parallel connection

KW load controller: regulating active power distribution during parallel operation

Basic process of parameter tuning:

Set all gains to zero

Adjust the proportional gain (Kp) until the system approaches instability, and then reduce it to half of that value

Using one tenth of Kp as the initial value of the integral gain (Ki), gradually increase it until it becomes unstable and then halve it

If overshoot needs to be reduced, introduce differential gain (Kd) and use it in conjunction with filtering constant (Td)

5.3 Unit sorting and load management

DGC-2020 supports automatic unit start stop sorting based on the following principles:

Rotation of running time: prioritize starting based on the minimum number of running hours

Balanced running time: prioritize starting based on the maximum number of running hours

Capacity priority: Start the unit with the highest or lowest capacity first

ID sorting: Start in sequence according to the set sorting ID

The Demand Start/Stop function automatically starts and stops the unit based on the total system load, achieving economic operation.

CANbus communication and ECU integration

6.1 Supported ECU protocols

The CANbus interface of DGC-2020 supports:

SAE J1939 standard protocol: obtains oil pressure, coolant temperature, engine speed, and can read diagnostic trouble codes (DTCs)

MTU protocol: supports MTU MDEC, MTU ADEC, and MTU ECU7, and can obtain MTU specific alarm and pre alarm information

Volvo Penta Protocol: Supports EDC3 and EMS2 controllers

6.2 ECU Power Management

For ECUs that require power-off to shut down (such as some Detroit Diesel J1939 ECUs), DGC-2020 provides four timer settings:

Engine shutdown time: The time (1-60 seconds) for the ECU to remain powered off after shutdown, ensuring that the engine comes to a complete stop

Pulse cycle: The interval (1-60 minutes) between ECU re powering to obtain data

Stabilization time: The time it takes for data to stabilize after power on (5.5-30 seconds)

Response timeout: Maximum waiting time for attempting communication (1-60 seconds)

6.3 Diagnostic Trouble Code (DTC)

DGC-2020 can receive and store DTCs from ECU. Each DTC contains:

SPN (Suspicious Parameter Number): Identify the diagnostic object

FMI (Failure Mode Identifier): Define the type of fault

Number of occurrences: Record the number of fault activations