$35
FILE DETAILS:
MTU DIGITAL GENSET CONTROLLER DGC-2020 Instructions Manual PDF DOWNLOAD
Language : English
Pages : 338
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
MTU DIGITAL GENSET CONTROLLER DGC-2020 Instructions Manual PDF DOWNLOAD
COVER ............................................................................................................. 1 INTRODUCTION .................................................................................................. 4 REVISION HISTORY .............................................................................................. 5 CONTENTS ...................................................................................................... 9 1 - GENERAL INFORMATION ........................................................................................... 11 DESCRIPTION.................................................................................................... 13 FEATURES....................................................................................................... 13 FUNCTIONS...................................................................................................... 13 Generator Protection and Metering.......................................................................... 13 Engine Protection and Metering............................................................................. 13 Event Recording............................................................................................ 13 Auto-Synchronizer.......................................................................................... 13 Contact Inputs and Output Contacts......................................................................... 14 Automatic Transfer Switch Control (Mains Failure).......................................................... 14 Communication.............................................................................................. 14 USB Port............................................................................................... 14 CANbus Interface....................................................................................... 14 Dial-Out Modem......................................................................................... 14 RS-485 Port............................................................................................ 14 AEM-2020 (ANALOG EXPANSION MODULE)............................................................................. 15 CEM-2020 (CONTACT EXPANSION MODULE)............................................................................ 15 LSM-2020 (LOAD SHARE MODULE)................................................................................... 15 STYLE AND PART NUMBERS......................................................................................... 15 Style Number............................................................................................... 15 Part Numbers............................................................................................... 16 SPECIFICATIONS................................................................................................. 16 Operating Power............................................................................................ 16 Power Consumption...................................................................................... 16 Battery Ride Through....................................................................................... 16 Current Sensing............................................................................................ 16 1 Aac Current Sensing.................................................................................. 16 5 Aac Current Sensing.................................................................................. 16 Voltage Sensing............................................................................................ 16 Contact Sensing............................................................................................ 17 Terminals.............................................................................................. 17 Engine System Inputs....................................................................................... 17 Fuel Level Sensing..................................................................................... 17 Coolant Temperature Sensing............................................................................ 17 Oil Pressure Sensing................................................................................... 17 Engine Speed Sensing................................................................................... 17 Output Contacts............................................................................................ 17 Fuel Solenoid, Engine Crank, and Pre-Start Relays...................................................... 17 Programmable Relays (12)............................................................................... 18 Metering................................................................................................... 18 Generator Voltage (rms)................................................................................ 18 Generator Current (rms)................................................................................ 18 Generator Frequency.................................................................................... 18 Apparent Power......................................................................................... 19 Power Factor........................................................................................... 19 Real Power............................................................................................. 19 Oil Pressure........................................................................................... 19 Coolant Temperature.................................................................................... 19 Battery Voltage........................................................................................ 19 Engine RPM............................................................................................. 19 Engine Run Time........................................................................................ 19 Maintenance Timer...................................................................................... 20 Fuel Level............................................................................................. 20 Generator Protection Functions............................................................................. 20 Overvoltage (59) and Undervoltage (27)................................................................. 20 Underfrequency (81U) and Overfrequency (81O)........................................................... 20 Reverse Power (32)..................................................................................... 20 Loss of Excitation (40Q)............................................................................... 20 Overcurrent (51) (Optional)............................................................................ 20 Phase Imbalance (47) (Optional)........................................................................ 20 Logic Timers............................................................................................... 21 Communication Interface.................................................................................... 21 USB.................................................................................................... 21 RS-485 (Optional)...................................................................................... 21 CANbus................................................................................................. 21 Modem (Optional)....................................................................................... 21 Real-Time Clock............................................................................................ 21 Clock Holdup........................................................................................... 21 Type Tests................................................................................................. 22 Shock.................................................................................................. 22 Vibration.............................................................................................. 22 Radio Interference..................................................................................... 22 HALT (Highly Accelerated Life Testing)................................................................. 22 Ignition System........................................................................................ 22 Environment................................................................................................ 22 UL/CSA Approval............................................................................................ 23 Part Numbers 9400200105 and 9400200106................................................................. 23 NFPA Compliance............................................................................................ 23 CE Compliance.............................................................................................. 23 Physical................................................................................................... 23 2 - HUMAN-MACHINE INTERFACE ....................................................................................... 25 INTRODUCTION................................................................................................... 27 FRONT PANEL.................................................................................................... 27 DISPLAY OPERATION.............................................................................................. 28 Login and Permissions...................................................................................... 28 Login.................................................................................................. 28 Permissions............................................................................................ 29 Summary Screen and Configurable Metering................................................................... 29 Sleep Mode................................................................................................. 29 Changing a Setting......................................................................................... 30 Front Panel Display Structure.............................................................................. 30 REAR PANEL..................................................................................................... 44 3 - FUNCTIONAL DESCRIPTION ........................................................................................ 47 INTRODUCTION................................................................................................... 49 DGC-2020 FUNCTION BLOCKS....................................................................................... 49 Power Supply............................................................................................... 49 Battery Voltage Sensing................................................................................ 49 Microprocessor............................................................................................. 49 Zero Crossing Detection................................................................................ 50 Analog-to-Digital Converter............................................................................ 50 Watchdog Timer......................................................................................... 50 Generator Voltage Sensing Inputs........................................................................... 50 Bus Voltage Sensing Inputs................................................................................. 50 Current Sensing Inputs..................................................................................... 50 Analog Engine Sender Inputs................................................................................ 50 Oil Pressure........................................................................................... 50 Coolant Temperature.................................................................................... 50 Fuel Level............................................................................................. 51 Speed Signal Inputs........................................................................................ 51 Generator Voltage Sensing Input........................................................................ 51 Magnetic Pickup Input (MPU)............................................................................ 51 Contact Inputs ............................................................................................ 51 Emergency Stop Input................................................................................... 51 Programmable Inputs.................................................................................... 51 Front Panel HMI............................................................................................ 52 LCD.................................................................................................... 52 LED Indicators......................................................................................... 52 Pushbuttons............................................................................................ 52 Remote Display Panel (Optional)............................................................................ 52 Communication Ports........................................................................................ 52 USB.................................................................................................... 53 CANbus................................................................................................. 53 Diagnostic Trouble Codes (DTCs)........................................................................ 54 MTU Fault Codes........................................................................................ 55 RS-485 (Optional)...................................................................................... 56 Modem (Optional)....................................................................................... 56 Output Contacts............................................................................................ 56 Pre-Start.............................................................................................. 57 Crank.................................................................................................. 57 Fuel................................................................................................... 57 Programmable........................................................................................... 57 MODES OF OPERATION............................................................................................. 57 OFF........................................................................................................ 57 RUN........................................................................................................ 57 AUTO....................................................................................................... 57 ATS Contact Input...................................................................................... 57 Generator Exerciser.................................................................................... 58 Mains Fail Transfer Functionality...................................................................... 58 Run with Load Logic Element............................................................................ 58 Engine Run Logic Element............................................................................... 58 Demand Start/Stop Function............................................................................. 58 Interoperability of the Run with Load Logic Element and the Demand Start/Stop Function................. 58 BREAKER MANAGEMENT............................................................................................. 58 Introduction............................................................................................... 58 Determining Breaker Status................................................................................. 58 Processing Breaker Requests................................................................................ 58 RUN Mode............................................................................................... 59 OFF or AUTO Mode (Not Running)......................................................................... 59 AUTO Mode (Running).................................................................................... 59 Breaker Operation.......................................................................................... 59 Determining if it is Acceptable to Close a Breaker..................................................... 59 Changing the Breaker State............................................................................. 59 Synchronizer Operation..................................................................................... 59 EVENT RECORDING................................................................................................ 60 4 - BESTCOMSPlus SOFTWARE ......................................................................................... 67 INTRODUCTION................................................................................................... 71 INSTALLATION................................................................................................... 71 Installing BESTCOMSPlus.................................................................................... 72 STARTUP AND ACTIVATION......................................................................................... 72 Starting BESTCOMSPlus...................................................................................... 72 Activating the DGC-2020 Plug-In............................................................................ 73 Requesting an Activation Key........................................................................... 73 Entering an Activation Key............................................................................. 74 COMMUNICATION.................................................................................................. 74 USB Communication.......................................................................................... 75 Installing the USB Driver if Automatic Installation Fails.............................................. 75 Modem Communication........................................................................................ 76 Ethernet Communication..................................................................................... 76 Establishing Communication................................................................................. 77 MENU BARS...................................................................................................... 78 Upper Menu Bar (BESTCOMSPlus Shell)........................................................................ 78 File................................................................................................... 78 Communication.......................................................................................... 78 Tools.................................................................................................. 78 Window................................................................................................. 78 Help................................................................................................... 79 Lower Menu Bar (DGC-2020 Plug-In).......................................................................... 79 View................................................................................................... 79 Open File.............................................................................................. 79 Connect/Disconnect..................................................................................... 79 Print Preview Metering................................................................................. 79 Options................................................................................................ 79 Send Settings.......................................................................................... 79 SETTINGS EXPLORER.............................................................................................. 79 DGC-2020 AND SYSTEM PARAMETERS................................................................................. 79 GENERAL SETTINGS............................................................................................... 80 Front Panel HMI............................................................................................ 80 Style Number............................................................................................... 81 Device Info................................................................................................ 81 DGC-2020............................................................................................... 81 Load Share Module...................................................................................... 81 Contact Expansion Module............................................................................... 81 Analog Expansion Module................................................................................ 81 Device Security Setup...................................................................................... 83 Changing Passwords..................................................................................... 84 Clock Setup................................................................................................ 84 COMMUNICATIONS................................................................................................. 85 CANbus Setup............................................................................................... 85 ECU Limitations........................................................................................ 86 The DGC-2020 Solution.................................................................................. 86 ECU Setup.................................................................................................. 86 Modem Setup (Optional)..................................................................................... 88 Dial-Out............................................................................................... 90 Dial-In................................................................................................ 90 RS-485 Setup (Optional).................................................................................... 90 SYSTEM PARAMETERS.............................................................................................. 91 System Settings............................................................................................ 91 Genset Electrical Parameters........................................................................... 91 Engine Speed Measurement............................................................................... 91 Engine Cooldown........................................................................................ 91 Off Mode Cooldown...................................................................................... 91 EPS Threshold.......................................................................................... 92 Measurement/Metering Units............................................................................. 92 Battery Voltage........................................................................................ 92 NFPA Compliance Level.................................................................................. 92 Horn................................................................................................... 92 Single-Phase Override.................................................................................. 93 Fuel Level Function.................................................................................... 93 Power Up Delay......................................................................................... 93 Auto Config Detection.................................................................................. 93 Relay Control.......................................................................................... 93 Remote Module Setup........................................................................................ 94 Load Sharing Module.................................................................................... 94 Contact Expansion Module............................................................................... 95 Analog Expansion Module................................................................................ 95 Crank Settings............................................................................................. 95 Automatic Restart.......................................................................................... 96 Exercise Timer............................................................................................. 97 Sensing Transformers....................................................................................... 97 Generator PT Settings.................................................................................. 97 Generator CT Setting................................................................................... 97 Bus Transformer Settings............................................................................... 98 PROGRAMMABLE INPUTS............................................................................................ 98 Contact Inputs............................................................................................. 98 Programmable Functions..................................................................................... 99 Remote LSM Inputs..........................................................................................100 Remote Contact Inputs......................................................................................101 Remote Analog Inputs.......................................................................................101 Remote RTD Inputs..........................................................................................103 Remote Thermocouple Inputs.................................................................................104 PROGRAMMABLE OUTPUTS...........................................................................................104 Contact Outputs............................................................................................104 Configurable Elements......................................................................................105 Remote Contact Outputs.....................................................................................105 Remote Analog Outputs......................................................................................106 CONFIGURABLE PROTECTION........................................................................................107 ALARM CONFIGURATION............................................................................................108 Pre-Alarms.................................................................................................108 High Fuel Level........................................................................................108 Low Battery Voltage....................................................................................108 Weak Battery Voltage...................................................................................108 Battery Overvoltage....................................................................................108 Maintenance Interval...................................................................................108 Engine KW Overload.....................................................................................109 Low Fuel Level.........................................................................................109 High Coolant Temp......................................................................................109 Low Coolant Temp.......................................................................................109 Low Coolant Level......................................................................................109 Low Oil Pressure.......................................................................................109 ECU Coms Fail..........................................................................................109 Active DTC.............................................................................................109 AVR Bias Output Limit..................................................................................109 GOV Bias Output Limit..................................................................................110 Intergenset Comm Failure...............................................................................110 LSM Comm Failure.......................................................................................110 ID Missing.............................................................................................110 ID Repeat..............................................................................................110 CEM Comm Failure.......................................................................................110 AEM Comm Failure.......................................................................................110 Checksum Failure.......................................................................................110 Alarms.....................................................................................................112 High Coolant Temperature...............................................................................112 Low Oil Pressure.......................................................................................112 Overspeed..............................................................................................112 Low Fuel Level.........................................................................................112 Low Coolant Level......................................................................................112 Sender Fail................................................................................................113 GENERATOR PROTECTION...........................................................................................114 Voltage Protection (27, 59, 47)............................................................................114 Undervoltage (27-1, 27-2)..............................................................................114 Overvoltage (59-1, 59-2)...............................................................................115 Phase Imbalance (47)...................................................................................116 Frequency Protection (81O/U)...............................................................................117 Underfrequency (81U)...................................................................................117 Overfrequency (81O)....................................................................................117 Reverse Power Protection (32)..............................................................................118 Loss of Excitation Protection (40Q)........................................................................118 Overcurrent Protection (51-1, 51-2, 51-3)..................................................................120 BREAKER MANAGEMENT.............................................................................................121 Breaker Hardware...........................................................................................121 Bus Condition Detection....................................................................................123 Automatic Synchronizer (Optional)..........................................................................124 Frequency Correction...................................................................................125 Voltage Correction.....................................................................................125 Synchronization Failure................................................................................125 BIAS CONTROL SETTINGS..........................................................................................126 AVR Bias Control Settings..................................................................................126 Var/PF Control.........................................................................................126 Governor Bias Control Settings.............................................................................128 kW Control - Real Power Control Settings...............................................................128 MULTIGEN MANAGEMENT............................................................................................130 AVR Output.................................................................................................130 Governor Output............................................................................................130 Load Share Output..........................................................................................131 Demand Start/Stop..........................................................................................131 Generator Sequencing.......................................................................................132 Disabled...............................................................................................132 Staggered Service Time.................................................................................132 Balanced Service Time..................................................................................133 Largest Size First.....................................................................................133 Smallest Size First....................................................................................133 Smallest Unit ID.......................................................................................133 Adopt System Mode .....................................................................................133 Network Configuration......................................................................................133 PROGRAMMABLE SENDERS...........................................................................................134 BESTLOGIC+ PROGRAMMABLE LOGIC..................................................................................135 Logic Timers...............................................................................................135 FILE MANAGEMENT................................................................................................135 Settings Files.............................................................................................135 Opening a Settings File................................................................................136 Uploading a Settings File..............................................................................136 Downloading a Settings File............................................................................136 Saving a Settings File.................................................................................136 Printing a Settings File...............................................................................136 Comparing Settings Files...............................................................................136 Upgrading Firmware in DGC-2020 and Expansion Modules.......................................................137 Upgrading Firmware in Expansion Modules................................................................138 Upgrading Firmware in the DGC-2020.....................................................................139 METERING EXPLORER..............................................................................................142 Engine.....................................................................................................144 Generator..................................................................................................144 Power......................................................................................................144 Bias Control...............................................................................................145 Run Statistics.............................................................................................145 Status.....................................................................................................145 Inputs.....................................................................................................146 Contact Inputs.........................................................................................146 Remote LSM Inputs......................................................................................147 Remote Contact Inputs..................................................................................147 Remote Analog Inputs...................................................................................147 Remote RTD Inputs......................................................................................148 Remote Thermocouple Inputs.............................................................................148 Remote Analog Input Values.............................................................................148 Outputs....................................................................................................150 Contact Outputs........................................................................................150 Configurable Elements..................................................................................150 Remote Contact Outputs.................................................................................150 Remote Analog Outputs..................................................................................151 Alarms.....................................................................................................151 Event Log..................................................................................................152 J1939 ECU..................................................................................................153 ECU Data...............................................................................................153 Engine Configuration...................................................................................154 Active DTC and Previously Active DTC...................................................................154 MTU........................................................................................................155 MTU Alarms.............................................................................................155 MTU Fault Codes........................................................................................155 MTU Status.............................................................................................156 MTU Engine Status......................................................................................156 Summary....................................................................................................157 Control....................................................................................................158 Real Time Clock............................................................................................158 Generator Network Status...................................................................................159 UPDATING BESTCOMSPlus SOFTWARE.................................................................................159 CONVERTING SETTINGS FILES......................................................................................159 5 - BESTlogic+ PROGRAMMABLE LOGIC .................................................................................161 INTRODUCTION...................................................................................................163 OVERVIEW OF BESTlogic+.........................................................................................163 BESTlogic+ Composition.....................................................................................164 I/O....................................................................................................164 Components.............................................................................................172 Elements...............................................................................................173 LOGIC SCHEMES..................................................................................................180 The Active Logic Scheme....................................................................................180 Copying and Renaming Preprogrammed Logic Schemes...........................................................180 Sending and Retrieving Logic Schemes.......................................................................180 Retrieving a Logic Scheme from the DGC-2020............................................................180 Sending a Logic Scheme to the DGC-2020.................................................................180 PROGRAMMING BESTlogic+.........................................................................................181 Pickup and Dropout Timers..................................................................................182 BESTlogic+ FILE MANAGEMENT.....................................................................................182 Saving a BESTlogic+ File...................................................................................182 Opening a BESTlogic+ File..................................................................................183 Protecting a BESTlogic+ File...............................................................................183 Uploading a BESTlogic+ File................................................................................183 Downloading a BESTlogic+ File..............................................................................183 Printing a BESTlogic+ File.................................................................................183 Clearing the On-Screen Logic Diagram.......................................................................183 BESTlogic+ EXAMPLES............................................................................................183 Example 1 - AVR Logic Block Connections....................................................................183 Example 2 - AND Gate Connections...........................................................................184 Example 3 - Multiple Logic Connections.....................................................................184 6 - INSTALLATION ..................................................................................................185 GENERAL........................................................................................................187 PRODUCT REGISTRATION...........................................................................................187 HARDWARE.......................................................................................................187 MOUNTING.......................................................................................................187 CONNECTIONS....................................................................................................189 Terminations...............................................................................................189 Operating Power........................................................................................189 Generator Current Sensing..............................................................................189 Generator Voltage Sensing..............................................................................190 Bus Voltage Sensing....................................................................................190 Analog Engine Sender Inputs............................................................................190 Emergency Stop Input...................................................................................191 Magnetic Pickup Input..................................................................................192 Contact Sensing Inputs.................................................................................192 Output Contacts........................................................................................192 USB Interface..........................................................................................193 RS-485 Communication Port..............................................................................193 CANbus Interface.......................................................................................193 Dial-Out Modem.........................................................................................195 RDP-110 Connections....................................................................................195 Connections for Typical Applications.......................................................................195 3-Phase Wye Connections for Typical Applications.......................................................196 3-Phase Delta Connections for Typical Applications.....................................................197 Single-Phase A-B Connections for Typical Applications..................................................198 Single-Phase A-C Connections for Typical Applications..................................................199 Connections for Volvo Penta EDC III Applications...........................................................200 3-Phase Wye Connections for Volvo Penta EDC III Applications...........................................201 3-Phase Delta Connections for Volvo Penta EDC III Applications.........................................202 Single-Phase A-B Connections for Volvo Penta EDC III Applications......................................203 Single-Phase A-C Connections for Volvo Penta EDC III Applications......................................204 Connections for MTU MDEC ECU Applications..................................................................205 3-Phase Wye Connections for MTU MDEC ECU Applications..................................................206 Single-Phase A-B Connections for MTU MDEC ECU Applications.............................................208 Single-Phase A-C Connections for MTU MDEC ECU Applications.............................................209 Connections with AEM-2020, CEM-2020, and LSM-2020..........................................................210 INSTALLATION FOR CE SYSTEMS....................................................................................210 INSTALLATION IN A SALT FOG ENVIRONMENT.........................................................................210 7 - MAINTENANCE AND TROUBLESHOOTING ...............................................................................211 MAINTENANCE....................................................................................................213 Backup Battery for the Real Time Clock.....................................................................213 TROUBLESHOOTING................................................................................................213 Communications.............................................................................................213 Ethernet Port Does Not Operate Properly................................................................213 USB Port Does Not Operate Properly.....................................................................214 CANbus Communication Does Not Operate Properly.........................................................214 Inputs and Outputs.........................................................................................214 Programmable Inputs Do Not Operate as Expected.........................................................214 Programmable Outputs Do Not Operate as Expected........................................................214 Metering/Display...........................................................................................214 Incorrect Display of Battery Voltage, Coolant Temperature, Oil Pressure, or Fuel Level.................214 Incorrect Display of Generator Voltage.................................................................214 Incorrect Measurement or Display of Generator Current..................................................214 Incorrect Display of Engine RPM........................................................................215 Generator Breaker and Mains Breaker........................................................................215 Generator Breaker Will Not Close to a Dead Bus.........................................................215 Generator Breaker Will Not Close to a Live Bus........................................................215 Generator Breaker Does Not Open When It Should.........................................................216 Mains Breaker Does Not Open When Mains Fails...........................................................216 Mains Breaker Does Not Close After Mains Returns.......................................................216 Synchronizer...............................................................................................217 Determining if the Synchronizer is Active..............................................................217 Synchronizer Not Active ..............................................................................217 Synchronizer Active for a Short Time, Then Stops.......................................................217 Synchronizer Does Not Lower Engine Speed Allowing Alignment of Bus and Generator.......................217 Synchronizer Does Not Raise Engine Speed Allowing Alignment of Bus and Generator.......................217 Synchronizer Does Not Lower the Generator Voltage to Achieve Matching of Bus and Generator Voltages....217 Synchronizer Does Not Reduce Generator Voltage to Achieve Matching of Bus and Generator Voltages.......217 Speed Bias.................................................................................................217 Engine Speed Does Not Change When Speed Bias Voltage Changes...........................................217 Engine Speed Decreases When Speed Bias is Increased....................................................218 Engine Speed Increases When Speed Bias is Decreased....................................................218 Voltage Bias...............................................................................................218 Generator Voltage Does Not Change When Voltage Bias Changes............................................218 Generator Voltage Decreases When AVR Speed Bias is Increased...........................................218 Generator Voltage Increases When Speed Bias is Decreased...............................................218 8 - LSM-2020 (LOAD SHARE MODULE ...................................................................................219 GENERAL INFORMATION............................................................................................221 FEATURES.......................................................................................................221 SPECIFICATIONS.................................................................................................221 Operating Power............................................................................................221 Analog Inputs..............................................................................................221 Analog Outputs.............................................................................................221 Voltage Regulator Bias Output..........................................................................221 Governor Bias Output...................................................................................221 Load Share Line Output.................................................................................221 Communication Interface....................................................................................222 CANbus.................................................................................................222 Ethernet...............................................................................................222 Type Tests.................................................................................................222 Shock..................................................................................................222 Vibration..............................................................................................222 Ignition System........................................................................................222 HALT (Highly Accelerated Life Testing).................................................................222 Environment................................................................................................222 UL Approval................................................................................................222 NFPA Compliance............................................................................................222 CE Compliance..............................................................................................223 Physical...................................................................................................223 FUNCTIONAL DESCRIPTION.........................................................................................223 Load Share Overview........................................................................................223 Analog Inputs..............................................................................................223 Analog Outputs.............................................................................................223 Output for Voltage Regulator Control...................................................................223 Output for Governor Control............................................................................223 Load Share Line Output.................................................................................223 Generator Sequencing.......................................................................................224 Communications.............................................................................................224 CANbus.................................................................................................224 Ethernet Port..........................................................................................224 BESTCOMSPlus SOFTWARE..........................................................................................224 LSM-2020 Plugin for BESTCOMSPlus...........................................................................224 Device Info............................................................................................224 Device Security Setup..................................................................................225 INSTALLATION...................................................................................................226 Product Registration.......................................................................................226 Mounting...................................................................................................226 Connections................................................................................................227 Terminations...........................................................................................227 Operating Power........................................................................................228 Analog Inputs..........................................................................................228 Analog Outputs.........................................................................................228 CANbus Interface.......................................................................................229 Ethernet Port..........................................................................................230 Connections for Typical Applications.......................................................................230 Connections using AVR’, GOV’, and LS’......................................................................232 APPLICATION....................................................................................................232 Interfacing an External Control Device with a DGC-2020 – LSM-2020 System...................................232 MAINTENANCE....................................................................................................233 9 - CEM-2020 (CONTACT EXPANSION MODULE) ...........................................................................235 GENERAL INFORMATION............................................................................................237 FEATURES.......................................................................................................237 SPECIFICATIONS.................................................................................................237 Operating Power............................................................................................237 Contact Inputs.............................................................................................237 Output Contacts............................................................................................237 Communication Interface....................................................................................237 CANbus.................................................................................................237 Type Tests.................................................................................................237 Shock..................................................................................................237 Vibration..............................................................................................237 Ignition System........................................................................................237 HALT (Highly Accelerated Life Testing).................................................................238 Environment................................................................................................238 UL Approval................................................................................................238 NFPA Compliance............................................................................................238 CE Compliance..............................................................................................238 Physical...................................................................................................238 FUNCTIONAL DESCRIPTION.........................................................................................238 Contact Inputs.............................................................................................238 Output Contacts............................................................................................238 Communications.............................................................................................238 CANbus.................................................................................................238 BESTCOMSPlus SOFTWARE..........................................................................................239 INSTALLATION...................................................................................................239 Product Registration.......................................................................................239 Mounting...................................................................................................239 Connections................................................................................................240 Terminations...........................................................................................240 Operating Power........................................................................................240 Contact Inputs and Output Contacts.....................................................................240 CANbus Interface.......................................................................................241 MAINTENANCE....................................................................................................242 10 - AEM-2020 (ANALOG EXPANSION MODULE) ...........................................................................243 GENERAL INFORMATION............................................................................................245 FEATURES.......................................................................................................245 SPECIFICATIONS.................................................................................................245 Operating Power............................................................................................245 Analog Inputs..............................................................................................245 RTD Inputs.................................................................................................245 Thermocouple Inputs........................................................................................245 Analog Outputs.............................................................................................245 Communication Interface....................................................................................245 CANbus.................................................................................................245 Type Tests.................................................................................................246 Shock..................................................................................................246 Vibration..............................................................................................246 Ignition System........................................................................................246 HALT (Highly Accelerated Life Testing).................................................................246 Environment................................................................................................246 UL Approval................................................................................................246 NFPA Compliance............................................................................................246 CE Compliance..............................................................................................246 Physical...................................................................................................246 FUNCTIONAL DESCRIPTION.........................................................................................247 Analog Inputs..............................................................................................247 RTD Inputs.................................................................................................247 Thermocouple Inputs........................................................................................247 Analog Outputs.............................................................................................247 Communications.............................................................................................247 CANbus.................................................................................................247 BESTCOMSPlus SOFTWARE..........................................................................................247 INSTALLATION...................................................................................................247 Product Registration.......................................................................................247 Mounting...................................................................................................248 Connections................................................................................................248 Terminations...........................................................................................248 Operating Power........................................................................................249 AEM-2020 Inputs and Outputs............................................................................249 External RTD Input Connections.........................................................................250 CANbus Interface.......................................................................................250 MAINTENANCE....................................................................................................252 A - TIME OVERCURRENT CHARACTERISTIC CURVES ........................................................................253 INTRODUCTION...................................................................................................255 CURVE SPECIFICATIONS...........................................................................................255 TIME OVERCURRENT CHARACTERISTIC CURVE GRAPHS...................................................................256 B - MODBUS COMMUNICATION ..........................................................................................275 INTRODUCTION...................................................................................................277 General Overview...........................................................................................277 Intended Use of the Communications Protocol................................................................277 DETAILED DESCRIPTION OF DGC-2020 MODBUS PROTOCOL...............................................................277 Modbus Protocol Overview...................................................................................277 Device Address Field...................................................................................277 Function Code Field....................................................................................277 Data Block Field.......................................................................................278 Error Check Field......................................................................................278 Serial Transmission Details................................................................................278 Message Framing / Timing Considerations....................................................................278 Error Handling and Exception Responses.....................................................................278 DETAILED DGC-2020 MESSAGE DEFINITION...........................................................................278 Device Address.............................................................................................278 Function Code and Data Block...............................................................................278 Read Holding Registers.................................................................................279 Return Query Data......................................................................................279 Preset Multiple Registers, NonBroadcast & Broadcast....................................................280 Preset Single Register, NonBroadcast & Broadcast.......................................................280 DATA FORMATS...................................................................................................281 Short Integer Data Format (INT8)...........................................................................281 Integer Data Format (INT16)................................................................................281 Long Integer Data Format (INT32)...........................................................................282 Floating Point Data Format.................................................................................282 Double Precision Data Format (DP)..........................................................................282 Triple Precision Data Format (TP)..........................................................................283 Error Check................................................................................................283 Interdependence of Preset Multiple Register Data...........................................................283 MAPPING DGC-2020 PARAMETERS INTO MODICON ADDRESS SPACE........................................................284 Table Conventions..........................................................................................284 Legacy Parameter Table.....................................................................................284 MTU module type........................................................................................292 MTU speed demand switch................................................................................292 MTU RPM request for engine.............................................................................292 0.18-1.18 Aac for 1A CTs, .........................................................................296 0.90-7.75 Aac for 5A CTs...........................................................................296 0.0-9.9 for 40607=0-15 (inverse),..................................................................296 0.0-30.0s for 40607=16 (fixed).....................................................................296 0-15 for inverse, 16 for fixed ....................................................................296 0=None, 1=Pre-Alarm, 2=Alarm.......................................................................296 0.18-1.18 Aac for 1A CTs, .........................................................................296 0.90-7.75 Aac for 5A CTs...........................................................................296 0.0-9.9 for 40607=0-15 (inverse),..................................................................296 0.0-30.0s for 40607=16 (fixed).....................................................................296 0-15 for inverse, 16 for fixed ....................................................................296 0=None, 1=Pre-Alarm, 2=Alarm.......................................................................296 Volts AC...........................................................................................296 0.0-30.0 seconds...................................................................................296 0=None, 1=Pre-Alarm, 2=Alarm.......................................................................296 Volts AC...........................................................................................296 0.0-30.0 seconds...................................................................................296 Hertz..............................................................................................296 0=None, 1=Pre-Alarm, 2=Alarm.......................................................................296 Volts AC...........................................................................................296 0.0-30.0 seconds...................................................................................296 Hertz..............................................................................................296 0=None, 1=Pre-Alarm, 2=Alarm.......................................................................296 Volts AC...........................................................................................296 0.0-30.0 seconds...................................................................................296 0=None, 1=Pre-Alarm, 2=Alarm.......................................................................296 Volts AC...........................................................................................296 0.0-30.0 seconds...................................................................................296 0=None, 1=Pre-Alarm, 2=Alarm.......................................................................296 45.0-55.0 Hz for 50-Hz config.,....................................................................296 0.0-30.0 seconds...................................................................................296 Volts AC...........................................................................................296 0=None, 1=Pre-Alarm, 2=Alarm.......................................................................296 45.0-55.0 Hz for 50-Hz config.,....................................................................296 360.0-440.0 Hz for 400-Hz unit.....................................................................296 0.0-30.0 seconds...................................................................................296 0=None, 1=Pre-Alarm, 2=Alarm.......................................................................296 b16-b31 UNASSIGNED.................................................................................296 b0 = overvoltage trip,.............................................................................296 b6-b15 UNASSIGNED..................................................................................296 b16-b31 UNASSIGNED.................................................................................296 b0 = overvoltage pre-alarm,........................................................................297 b6-b15 UNASSIGNED..................................................................................297 b16-b31 UNASSIGNED.................................................................................297 b0 = overvoltage alarm,............................................................................297 b6-b15 UNASSIGNED..................................................................................297 b0 = High Charge Air Temp,.........................................................................297 b8-b15 UNASSIGNED..............................................................................297 b0 = High ECU Temp,............................................................................298 b13-b15 UNASSIGNED.............................................................................298 Current Parameter Table....................................................................................298 Breaker Management.....................................................................................298 Bias Control Settings..................................................................................299 Pulse Outputs..........................................................................................300 Bus Condition Detection................................................................................300 Senders................................................................................................301 Coolant Temperature Sender Fail Configuration Type.................................................301 Coolant Temperature Sender Fail Activation Delay...................................................301 Oil Pressure Sender Fail Configuration Type........................................................301 Oil Pressure Sender Fail Activation Delay..........................................................301 Fuel Level Sender Fail Configuration Type..........................................................301 Fuel Level Sender Fail Activation Delay............................................................301 Voltage Sensing Fail Configuration Type............................................................301 Voltage Sensing Fail Activation Delay..............................................................301 FUTURE USE.........................................................................................301 System Configuration and Status........................................................................301 Rated Volts........................................................................................301 Pre-Start Contact Config...........................................................................302 System Units.......................................................................................302 Battery Volts......................................................................................302 Off Mode Status....................................................................................302 Run Mode Status....................................................................................302 Auto Mode Status...................................................................................302 Virtual Input 1 Status.............................................................................302 Virtual Input 2 Status.............................................................................302 Virtual Input 3 Status.............................................................................302 Virtual Input 4 Status.............................................................................302 RTC Clock Hour.....................................................................................302 RTC Minute.........................................................................................302 RTC Second.........................................................................................302 RTC Month..........................................................................................302 RTC Day............................................................................................302 RTC Year...........................................................................................302 RTC DST Enable.....................................................................................302 Gen PT Primary.....................................................................................302 Gen PT Secondary...................................................................................302 Gen CT Primary.....................................................................................302 Bus PT Primary.....................................................................................302 Bus PT Secondary...................................................................................302 Cranking Style.....................................................................................302 Number of Crank Cycles.............................................................................302 Cycle Crank Time...................................................................................302 Continuous Crank Time..............................................................................302 Crank Disconnect Limit.............................................................................302 Pre Crank Delay....................................................................................302 Configured Gen Connection..........................................................................302 Gen Rated Frequency................................................................................302 Rated Kw...........................................................................................302 Rated Engine RPM...................................................................................302 No Load Cool Down Time.............................................................................302 EPS Current Threshold..............................................................................302 Fuel Level Function................................................................................302 Number Flywheel Teeth..............................................................................302 Speed Signal Source................................................................................303 NFPA Level.........................................................................................303 Horn Enable........................................................................................303 Single Phase Override Sensing......................................................................303 RESERVED...........................................................................................303 LCD Contrast Value.................................................................................303 Front Panel Sleep Mode.............................................................................303 RESERVED...........................................................................................303 UTC Offset.........................................................................................303 DST Configuration..................................................................................303 Start/End Time Reference...........................................................................303 DST Bias Hours.....................................................................................303 DSP Bias Minutes...................................................................................303 DST Start Month....................................................................................303 DST Start Day......................................................................................303 DST Start Week of Month............................................................................303 DST Start Day of Week..............................................................................303 DST Start Hour.....................................................................................303 DST Start Minute...................................................................................303 DST End Month......................................................................................303 DST End Day........................................................................................303 DST End Week of Month..............................................................................304 DST End Day of Week................................................................................304 DST End Hour.......................................................................................304 DST End Minute.....................................................................................304 EPS Low Line Scale Factor..........................................................................304 Rated Power Factor.................................................................................304 Prestart Rest Configuration........................................................................304 Oil Pressure Crank Disconnect......................................................................304 Crank Disconnect Pressure..........................................................................304 Crank Disconnect Pressure in KPA...................................................................304 Power Up Delay.....................................................................................304 Auto Config Detect Enable..........................................................................304 Low Line Detect Threshold..........................................................................304 Single Phase Detect Threshold......................................................................304 FUTURE USE.........................................................................................304 Control................................................................................................304 Emergency Stop.....................................................................................304 Remote Start.......................................................................................304 Remote Stop........................................................................................304 Run Mode...........................................................................................304 Off Mode...........................................................................................304 Auto Mode..........................................................................................304 Alarm Reset........................................................................................304 Gen Breaker Open...................................................................................304 Gen Breaker Close..................................................................................304 Mains Breaker Open.................................................................................304 Mains Breaker Close................................................................................304 RESERVED...........................................................................................304 Virtual Input 1 Close..............................................................................304 Virtual Input 1 Open...............................................................................305 Virtual Input 2 Close..............................................................................305 Virtual Input 2 Open...............................................................................305 Virtual Input 3 Close..............................................................................305 Virtual Input 3 Open...............................................................................305 Virtual Input 4 Close..............................................................................305 Virtual Input 4 Open...............................................................................305 ESTOP Latch Status.................................................................................305 FUTURE USE.........................................................................................305 Communication..........................................................................................305 RESERVED...........................................................................................305 DHCP Enabled.......................................................................................305 Active IP Address..................................................................................305 Gateway IP Address.................................................................................305 Subnet Mask........................................................................................305 RESERVED...........................................................................................305 FUTURE USE.........................................................................................305 Protection.............................................................................................305 3 Phase Overcurrent Pickup (51-1)..................................................................305 3 Phase Overcurrent Time Dial (51-1)...............................................................305 3 Phase Overcurrent Curve (51-1)...................................................................305 3 Phase Overcurrent Alarm Configuration (51-1).....................................................305 1 Phase Overcurrent Pickup (51-1)..................................................................305 1 Phase Overcurrent Time Dial (51-1)...............................................................305 1 Phase Overcurrent Curve (51-1)...................................................................306 1 Phase Overcurrent Alarm Configuration (51-1).....................................................306 Phase Imbalance Pickup.............................................................................306 Phase Imbalance Activation Delay...................................................................306 Phase Imbalance Alarm Configuration................................................................306 3 Phase Undervoltage Pickup (27-1).................................................................306 3 Phase Undervoltage Activation Delay (27-1).......................................................306 3 Phase Undervoltage Inhibit Frequency (27-1)......................................................306 3 Phase Undervoltage Alarm Configuration (27-1)....................................................306 1 Phase Undervoltage Pickup (27-1).................................................................306 1 Phase Undervoltage Activation Delay (27-1).......................................................306 1 Phase Undervoltage Inhibit Frequency (27-1)......................................................306 1 Phase Undervoltage Alarm Configuration (27-1)....................................................306 3 Phase Overvoltage Pickup (59-1)..................................................................306 3 Phase Overvoltage Activation Delay (59-1)........................................................306 3 Phase Overvoltage Alarm Configuration (59-1).....................................................306 1 Phase Overvoltage Pickup (59-1)..................................................................306 1 Phase Overvoltage Activation Delay (59-1)........................................................306 1 Phase Overvoltage Alarm Configuration (59-1).....................................................306 Underfrequency Pickup..............................................................................306 Underfrequency Activation Delay....................................................................306 Underfrequency Inhibit Voltage.....................................................................306 Underfrequency Alarm Configuration.................................................................307 Overfrequency Pickup...............................................................................307 Overfrequency Activation Delay.....................................................................307 Overfrequency Alarm Configuration..................................................................307 3 Phase Overcurrent Pickup (51-2)..................................................................307 3 Phase Overcurrent Time Dial (51-2)...............................................................307 3 Phase Overcurrent Curve (51-2)...................................................................307 3 Phase Overcurrent Alarm Configuration (51-2).....................................................307 1 Phase Overcurrent Pickup (51-2)..................................................................307 1 Phase Overcurrent Time Dial (51-2)...............................................................307 1 Phase Overcurrent Curve (51-2)...................................................................307 1 Phase Overcurrent Alarm Configuration (51-2).....................................................307 3 Phase Undervoltage Pickup (27-2).................................................................307 3 Phase Undervoltage Activation Delay (27-2).......................................................308 3 Phase Undervoltage Inhibit Frequency (27-2)......................................................308 3 Phase Undervoltage Alarm Configuration (27-2)....................................................308 1 Phase Undervoltage Pickup (27-2).................................................................308 1 Phase Undervoltage Activation Delay (27-2).......................................................308 1 Phase Undervoltage Inhibit Frequency (27-2)......................................................308 1 Phase Undervoltage Alarm Configuration (27-2)....................................................308 3 Phase Overvoltage Pickup (59-2)..................................................................308 3 Phase Overvoltage Activation Delay (59-2)........................................................308 3 Phase Overvoltage Alarm Configuration (59-2).....................................................308 1 Phase Overvoltage Pickup (59-2)..................................................................308 1 Phase Overvoltage Activation Delay (59-2)........................................................308 1 Phase Overvoltage Alarm Configuration (59-2).....................................................308 Alarms.................................................................................................309 High Coolant Temp Alarm Enable.....................................................................309 High Coolant Temp Alarm Threshold..................................................................309 Metric High Coolant Temp Alarm Threshold...........................................................309 High Coolant Temp Alarm Activation Delay...........................................................309 Low Oil Press. Alarm Enable........................................................................309 Low Oil Press. Alarm Threshold.....................................................................309 Metric Low Oil Press. Alarm Threshold..............................................................309 Low Oil Press. Alarm Arming Delay..................................................................309 Overspeed Alarm Enable.............................................................................310 Overspeed Alarm Threshold..........................................................................310 Overspeed Alarm Activation Delay...................................................................310 Low Fuel Level Alarm Enable........................................................................310 Low Fuel Level Alarm Threshold.....................................................................310 Low Fuel Level Alarm Activation Delay..............................................................310 High Coolant Temp Pre-Alarm Enable.................................................................310 High Coolant Temp Pre-Alarm Threshold..............................................................310 Metric High Coolant Temp Pre-Alarm Threshold.......................................................310 Low Coolant Temp Pre-Alarm Enable..................................................................310 Low Coolant Temp Pre-Alarm Threshold...............................................................310 Metric Low Coolant Temp Pre-Alarm Threshold........................................................310 High Fuel Level Pre-Alarm Threshold ...............................................................310 High Fuel Level Pre-Alarm Enable...................................................................310 High Fuel Level Pre-Alarm Activation Delay ........................................................310 Low Fuel Level Pre-Alarm Enable....................................................................310 Low Fuel Level Pre-Alarm Threshold.................................................................310 Low Battery Pre-Alarm Enable.......................................................................310 Low Battery Pre-Alarm Threshold....................................................................310 Low Battery Pre-Alarm Activation Delay.............................................................310 Weak Battery Pre-Alarm Enable......................................................................310 Weak Battery Pre-Alarm Threshold...................................................................310 Weak Battery Pre-Alarm Activation Delay............................................................310 Battery Overvoltage Pre-Alarm Enable...............................................................310 Low Oil Press. Pre-Alarm Enable....................................................................310 Low Oil Press. Pre-Alarm Threshold.................................................................310 Metric Low Oil Press. Pre-Alarm Threshold..........................................................310 Engine Overload 1 Pre-Alarm Enable.................................................................310 Engine Overload 1 Pre-Alarm Threshold..............................................................310 Maintenance Interval Pre-Alarm Enable..............................................................311 Maintenance Interval Pre-Alarm Threshold...........................................................311 Speed Sender Fail Activation Delay.................................................................311 ECU Low Coolant Level Alarm Enable.................................................................311 ECU Low Coolant Level Alarm Threshold..............................................................311 ECU Low Coolant Level Pre-Alarm Enable.............................................................311 ECU Low Coolant Level Pre-Alarm Threshold..........................................................311 Battery Overvoltage Alarm Threshold................................................................311 Engine Overload 1 Pre-Alarm........................................................................311 3 Phase Hysteresis.................................................................................311 Engine Overload 1 Pre-Alarm........................................................................311 Engine Overload 1 Pre-Alarm........................................................................311 Engine Overload 1 Pre-Alarm........................................................................311 Engine Overload 2 Pre-Alarm Enable.................................................................311 Engine Overload 2 Pre-Alarm........................................................................311 Engine Overload 2 Pre-Alarm........................................................................311 3 Phase Hysteresis.................................................................................311 Engine Overload 2 Pre-Alarm........................................................................311 Engine Overload 2 Pre-Alarm........................................................................311 Engine Overload 2 Pre-Alarm........................................................................311 Engine Overload 3 Pre-Alarm Enable.................................................................311 Engine Overload 3 Pre-Alarm........................................................................311 Engine Overload 3 Pre-Alarm........................................................................311 3 Phase Hysteresis.................................................................................311 Engine Overload 3 Pre-Alarm........................................................................311 Engine Overload 3 Pre-Alarm........................................................................311 Engine Overload 3 Pre-Alarm........................................................................311 AEM Comm Failure Pre-alarm Enable..................................................................312 Checksum Failure Pre-alarm Enable..................................................................312 RESERVED...........................................................................................312 Metering...............................................................................................312 Gen VAB Metering...................................................................................312 Gen VBC Metering...................................................................................312 Gen VCA Metering...................................................................................312 Gen VAN Metering...................................................................................312 Gen VBN Metering...................................................................................312 Gen VCN Metering...................................................................................312 Gen IA Metering....................................................................................312 Gen IB Metering....................................................................................312 Gen IC Metering....................................................................................312 Gen kVA A Metering.................................................................................312 Gen kVA B Metering.................................................................................312 Gen kVA C Metering.................................................................................312 Gen kVA Total Metering.............................................................................312 Gen kW A Metering..................................................................................312 Gen kW B Metering..................................................................................312 Gen kW C Metering..................................................................................312 Gen kW Total Metering..............................................................................312 Gen PF Lagging.....................................................................................312 Active Speed Source................................................................................312 Engine Speed Metering..............................................................................312 Engine Load Metering...............................................................................312 Coolant Temp. Metering.............................................................................312 Oil Pressure Metering..............................................................................312 Battery Voltage Metering...........................................................................312 Fuel Level Metering................................................................................312 ECU Coolant Level Metering.........................................................................312 Cool Down Time Remaining...........................................................................312 Alarm Metering.....................................................................................313 Pre-Alarm Metering.................................................................................313 MTU Alarm Metering.................................................................................313 MTU Pre-Alarm Metering.............................................................................313 Sender Fail Alarm Metering.........................................................................313 Protection Alarm Metering..........................................................................313 FUTURE USE.........................................................................................313 Local Input Metering...............................................................................314 Local Output Metering..............................................................................314 Status Metering....................................................................................314 Hours Until Maintenance............................................................................314 Cum. Total Engine Run Hrs..........................................................................314 Cum. Total kW-Hrs..................................................................................314 Cum. Total kW-Mins.................................................................................314 Commission Date Month..............................................................................314 Commission Date Day................................................................................314 Commission Date Year...............................................................................314 Cumulative Number of Engine Starts.................................................................315 Session Start Date Month...........................................................................315 Session Start Date Day.............................................................................315 Session Start Date Year............................................................................315 Generator Status...................................................................................315 8 = CONNECTING State...............................................................................315 FUTURE USE.........................................................................................315 RESERVED...........................................................................................315 Global Alarm.......................................................................................315 Global Pre-Alarm...................................................................................315 Local Configurable Inputs Pre-Alarm Bits...........................................................315 Local Configurable Inputs Alarm Bits...............................................................316 Configurable Elements Status Bits..................................................................316 Configurable Elements Pre-Alarm Bits...............................................................316 Configurable Elements Alarm Bits...................................................................316 Remote Inputs Status Bits..........................................................................316 Remote Outputs Status Bits.........................................................................317 CEM Alarm Bits.....................................................................................317 Remote Configurable Inputs Pre-Alarm Bits..........................................................317 Remote Configurable Inputs Alarm Bits..............................................................317 AEM Alarm Bits.....................................................................................317 RESERVED...........................................................................................317 Generator Frequency................................................................................317 Bus Frequency......................................................................................317 Power Factor.......................................................................................317 RESERVED...........................................................................................317 ECU Lamp Status....................................................................................317 Number of DTC’s....................................................................................317 RESERVED...........................................................................................317 Analog Input 1 Metering Value......................................................................317 C - TUNING PID SETTINGS ...........................................................................................329 INTRODUCTION...................................................................................................331 TUNING PROCEDURES..............................................................................................332 Voltage Controller Tuning Procedure........................................................................332 KP - Proportional Gain.................................................................................332 KI - Integral Gain.....................................................................................332 KD - Derivative Gain...................................................................................332 Var/PF Controller Tuning Procedure.........................................................................333 KI - Integral Gain.....................................................................................333 KD - Derivative Gain...................................................................................333 Speed Controller Tuning Procedure..........................................................................333 KP - Proportional Gain.................................................................................333 KI - Integral Gain.....................................................................................334 KD - Derivative Gain...................................................................................334 kW Load Controller Tuning Procedure........................................................................334 KP - Proportional Gain.................................................................................334 KI - Integral Gain.....................................................................................334 KD - Derivative Gain...................................................................................335 GENERIC GAINS FOR MULTIPLE MACHINE TYPES.......................................................................335
DESCRIPTION:
MTU DIGITAL GENSET CONTROLLER DGC-2020 Instructions 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: