New digital generator set controller

Basler Electric, Highland, Ill., has developed a generator set control system designed to allow any generator set manufacturer to get into the age of digital communications easily and economically. The model DGC-2000 controller is a microprocessor-based digital gen-set controller that provides all of the engine cranking, engine protection and generator set metering capabilities of a conventional engine controller, while allowing user access to a wide range of information.

The DGC-2000 controller comes complete with Windows-based PC communications software, where monitoring and start/stop control of the gen-set can be accomplished via a rear-mounted RS232 communications port. By adding a modem, the gen-set can be accessed from virtually anywhere in the world - simply bring up the DGC-2000 software on a PC and the software will dial the appropriate phone number. With the proper password, an operator can start/stop the gen-set and monitor the status of up to 30 gen-set operating points and 19 alarm/pre-alarm functions.

The controller's software is designed to be easy to use and provides accurate real-time information of the gen-set under control, according to the company, with screens provided to allow for setting a total of 61 parameters. A highly adjustable unit, the DGC-2000 controller also allows for file transfer capability so if multiple machines have the same settings, they can be saved to a file and then downloaded to each DGC-2000 controller in a matter of seconds. This capability, the company said, offers an accurate method for setting up similar generator sets, allowing the input of specific machine information such as serial numbers and job site information.
Additionally, the RS232 communications port can also be converted through readily available converters to RS485, thus facilitating communications with up to 247 DGC-2000 units at distances of up to 4000 ft. through a single communications loop. This permits a local communications network on those facilities where multiple distributed gen-sets are used. The communications network allows for one master PC to individually control up to 247 generator units.

Basler Electric has incorporated a Modbus communications protocol that is widely used in the industry. This is an open protocol that can be adapted to any Modbus application. The company provides a complete listing of the Modbus registers to allow for total access to all information provided by the DGC-2000 controller. An open protocol like Modbus allows for the most flexibility possible and prevents the end-user from being limited from future expansion, the company noted.

The DGC-2000 controller replaces all of the functions normally found in a conventional top-mount metering and control package, according to the company, providing for all the metering, engine protection and engine cranking controls normally required on gen-set applications. It has adjustable tripping thresholds for 19 alarms and pre-alarms, along with 13 output relays for engine control and shutdown functions. It has contact inputs for air box status, emergency stop, automatic transfer switch, battery charger failure and low coolant level. It has inputs for senders for oil pressure, coolant temperature and fuel level. It also accepts three phases of generator voltage and current and a charging alternator input as a back-up speed signal source in case of a magnetic pick-up loss. The unit also monitors the bus voltage and frequency for paralleled generator applications.

If the gen-set needs to be operated locally, the DGC-2000 controller is equally suitable for local gen-set control. It features an easy-to-read front panel that has all the user-friendly functionality and clearly displayed information needed for complete operation of the gen-set, Basler said. The front panel has a back-lit LCD display that has eight gen-set parameters permanently displayed and also has the ability to scroll through 30 total parameters. Front panel LED indication includes Unit Not In Auto, Gen-Set Supplying Load, Run, Off and Auto modes. There are also front panel push buttons for phase toggle, alarm reset, alarm silence, run, off, auto, and display navigation. The DGC-2000 controller also has a standard alarm horn rated at 80 db at 2 ft.