Installation Instructions

Basic Gen-set Controller

4189340302G (UK)
SW version 2.1X.X

• Mounting

• Board slot positions

• Terminal strip overview

DEIF A/S

• I/O lists

• Wiring

DEIF A/S, Frisenborgvej 33 Tel.: +45 9614 9614, Fax: +45 9614 9615
DK-7800 Skive, Denmark E-mail: [email protected], URL: www.deif.com
BGC Installation Instructions

Table of contents
1. ABOUT THIS DOCUMENT............................................................ 4
GENERAL PURPOSE............................................................................... 4
INTENDED USERS .................................................................................. 4
CONTENTS/OVERALL STRUCTURE .......................................................... 4
2. WARNINGS AND LEGAL INFORMATION................................... 6
LEGAL INFORMATION AND RESPONSIBILITY ............................................. 6
ELECTROSTATIC DISCHARGE AWARENESS ............................................. 6
SAFETY ISSUES ..................................................................................... 6
NOTES .................................................................................................. 6
3. GENERAL PRODUCT INFORMATION ........................................ 7
INTRODUCTION ...................................................................................... 7
TYPE OF PRODUCT ................................................................................ 7
STANDARD FUNCTIONS .......................................................................... 8
STANDARD AND OPTIONAL APPLICATIONS............................................... 9
4. MOUNTING................................................................................... 12
MOUNTING OF THE UNIT....................................................................... 12
PANEL CUTOUT ................................................................................... 12
MOUNTING INSTRUCTIONS ................................................................... 12
5. HARDWARE ................................................................................. 13
BOARD SLOT POSITIONS ...................................................................... 13
UNIT REAR SIDE OVERVIEW ................................................................. 14
TERMINAL STRIP OVERVIEW ................................................................. 15
INPUT/OUTPUT LISTS ........................................................................... 16
6. WIRING ......................................................................................... 25
AC CONNECTIONS ............................................................................... 25
LOAD SHARING LINES........................................................................... 28
BINARY INPUTS.................................................................................... 28
ANALOGUE INPUTS .............................................................................. 29
OPTION H1 (CANOPEN COMMUNICATION) ........................................... 30
OPTION H2 (MODBUS RTU COMMUNICATION) ..................................... 31
OPTION H3 (PROFIBUS DP COMMUNICATION)...................................... 34
OPTION H4 (CAT CCM COMMUNICATION)........................................... 36
OPTION H5 (J1939 AND MTU MDEC COMMUNICATION)...................... 37
OPTION H6 (CUMMINS COMMUNICATION)............................................. 38

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BGC Installation Instructions

7. TECHNICAL INFORMATION ...................................................... 40

TECHNICAL SPECIFICATIONS ................................................................ 40
UNIT DIMENSIONS ................................................................................ 43
DISPLAY DIMENSIONS .......................................................................... 44
PANEL CUTOUT ................................................................................... 45

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BGC Installation Instructions

1. About this document

The purpose of this chapter is to provide general user information

about these installation instructions concerning the general purpose,
the intended users and the overall structure and contents.

General purpose
This document is the Installation Instructions for DEIF’s basic gen-set
controller, the BGC. The document mainly includes general product
information, mounting instructions, terminal strip overviews, I/O lists
and wiring descriptions.

The general purpose of these installation instructions is to give the user

important information to be used in the installation of the unit.

Intended users
These installation instructions are mainly intended for the panel builder
designer in charge. On the basis of this document, the panel builder
designer will give the electrician the information he needs in order to
install the BGC, e.g. detailed electrical drawings. In some cases, the
electrician may use these installation instructions himself.

Contents/overall structure
This document is divided into seven chapters, and in order to make the
structure simple and easy to use, each chapter will begin from the top
of a new page. The following will outline the contents of each of the
seven chapters.

About this document

Chapter 1 includes general information about these installation
instructions as a document. It deals with the general purpose and the
intended users of the installation instructions. Furthermore, it outlines
the overall contents and structure of the document.

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BGC Installation Instructions

Warnings and legal information

Chapter 2 includes information about general legal issues and safety
precautions relevant in the handling of DEIF products. Furthermore, it
introduces some important definitions, which will be used throughout
this document.

General product information

Chapter 3 will deal with the BGC unit in general and its place in the
DEIF product range. It will also include information about standard
functions and the application types relevant to the BGC.

Mounting
Chapter 4 will provide specific information about correct mounting of
the BGC unit.

Hardware
Chapter 5 provides an overview of the individual terminals and slots of
the BGC. It also includes terminal strip overviews and complete I/O
lists.

Wirings
Chapter 6 will present important information about the wiring of the
BGC unit. This will include detailed wiring descriptions.

Technical information
Chapter 7 will present general technical information including technical
specifications, unit dimensions and panel cutout information.

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BGC Installation Instructions

2. Warnings and legal information

This chapter includes important information about general legal issues

relevant in the handling of DEIF products. Furthermore, some overall
safety precautions will be introduced and recommended. Finally, the
highlighted notes, which will be used throughout these installation
instructions, are presented.

Legal information and responsibility

DEIF takes no responsibility for installation or operation of the
generator set. If there is any doubt about how to install or operate the
generator controlled by the BGC unit, the company responsible for the
installation or the operation of the set must be contacted.

The BGC units are not to be opened by unauthorised personnel. If

opened anyway, the warranty will be lost.

Electrostatic discharge awareness

Sufficient care must be taken to protect the terminals against static
discharges during the installation. Once the unit is installed and
connected, these precautions are no longer necessary.

Safety issues
Installing the BGC unit implies work with dangerous currents and
voltages. Therefore, the installation of the BGC should only be carried
out by authorised personnel who understand the risks involved in the
working with live electrical equipment.

Notes
Throughout this document a number of notes with helpful user
information will be presented. To ensure that these are noticed, they
will be highlighted in order to separate them from the general text.

Xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx

DEIF A/S Page 6 of 45

BGC Installation Instructions

3. General product information

This chapter will deal with the BGC unit in general and its place in the
DEIF product range. It will also include information about standard
functions and the application types relevant to the BGC.

Introduction
The BGC is a part of the DEIF Multi-line 2 product family. Multi-line 2 is
a complete range of multi-function generator protection and control
products integrating all the functions you need into one compact and
attractive solution.

The product range consists of different basic versions, which can be

supplemented with the flexible options needed to provide the optimum
solution.

The concept of the BGC is to offer a cost-effective solution to gen-set

builders who need a simple generator protection and control unit. Being
a part of the Multi-line product family the standard functions of the BGC
can be supplemented with a variety of optional functions.

Type of product
The BGC is a micro-processor based control unit containing all
necessary functions for protection of a gen-set and of mains and
generator breaker control.

The BGC contains all necessary 3-phase measuring circuits and

presents all values and alarms on the LCD display. The design of the
BGC allows it to be built directly into the engine side panel or the
switchboard door.

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BGC Installation Instructions

Standard functions
In the following sections the standard functions of the BGC are listed.

Automatic mains failure

• Engine start up
• Mains to generator at a mains failure
• Generator to mains at mains return

Island operation
• Semi-automatic control of the gen-set
• Semi-automatic control of the breakers

Time dependent start/stop

• Automatic gen-set and breaker control
• 8 different start/stop commands

Engine control
• Start preparation
• Start/stop sequences
• Fuel solenoid selection (coil type)

Protection (ANSI #)
• Overcurrent, 2 levels (51)
• Reverse power (32)
• 3 configurable VDO inputs
• Configurable binary inputs:
o Circuit breakers used: 5 binary inputs
o Contactors used: 7 binary inputs

Generator and mains breaker

• Contactor (constant signal)
• Circuit breaker (400 ms pulse)

Note that the five configurable digital inputs can be

used as protection inputs or as function inputs.

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BGC Installation Instructions

Standard and optional applications

In the following sections the standard and optional applications of the
BGC will be presented. In addition, the correct application configuration
for the different applications is listed. It is only possible to use the BGC
unit for one of the purposes, e.g. AMF (Automatic Mains Failure)
operation. The selection must be made on site.

All units are supplied with the following factory setting:

• Automatic mains failure

Automatic mains failure, AMF (no back sync.) (standard)

No. Setting Setting

4320 Gen-set mode Selection display -
4321 Gen-set mode AMF AMF

Island operation (standard)

No. Setting Setting

4320 Gen-set mode Selection display -
4321 Gen-set mode Island operation Island operation

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BGC Installation Instructions

Fixed power operation to mains (Option G2)

No. Setting Setting

4320 Gen-set mode Selection display -
4321 Gen-set mode Fixed power Fixed power

Multiple gen-sets, load sharing (Option G3)

No. Setting Setting

4320 Gen-set mode Selection display -
4321 Gen-set mode Island operation Island operation

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BGC Installation Instructions

Peak shaving (Option G2)

No. Setting Setting

4320 Gen-set mode Selection display -
4321 Gen-set mode Peak shaving Peak shaving

Automatic mains failure, AMF (back sync.) (Option G2)

No. Setting Setting

4320 Gen-set mode Selection display -
4321 Gen-set mode AMF AMF

DEIF A/S Page 11 of 45

BGC Installation Instructions

4. Mounting

In this chapter specific mounting instructions will be given in order to

ensure correct mounting of the BGC unit.

Mounting of the unit

The BGC is designed for direct mounting in the switchboard door. The
technical specifications later in this document include detailed
information about:

• unit dimensions
• panel cutout
• screw hole positions and dimensions

Panel cutout
In order to ensure optimum mounting the switchboard door must be cut
out according to the panel cutout illustration presented in chapter 7.
Please note the indicated tolerance of the cutout hole.

Mounting instructions
The BGC can be mounted in two different ways:

1. by use of 3.5 mm screws with self-cutting threads, maximum

depth in the display is 8 mm

2. by use of the standard fastening clamps. A total of 4 clamps are

needed for proper mounting

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BGC Installation Instructions

5. Hardware

This chapter will present information about the individual terminals and
slots of the BGC unit. It also includes terminal strip overviews and
complete I/O lists.

Board slot positions

The BGC unit housing is divided into board slot positions. This means
that the unit consists of a number of printed circuit boards (PCB)
mounted in numbered slots. The green terminal blocks are then
mounted in the PCBs. Some of these board slots are standard and
some are intended for options. The board slot positions are arranged
as illustrated below.

Slot type Option Slot #1 Slot #2 Slot #3 Slot #4

Terminals 1-46 47-54 55-62 63-80
Main PCB Standard X
Engine communica- H4 Depending
tions PCB
Serial communica- H1, H2, Depending
tions PCB H3
Transducer output F1 Depending
PCB
Transducer output F2 Depending
PCB
Load sharing and G2/G3 X
synchronising PCB
7 digital inputs M13 Depending
4 relay outputs M14/G1 Depending
4 analogue inputs M15 Depending

Only hardware options which will affect the hardware of

the unit are represented in the table. The software
options will be implemented by changing the utility
software of the unit. The absent software options can be
located in the data sheet.

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BGC Installation Instructions

Unit rear side overview

An overview of the terminals is presented below. The slots are
positioned in the unit as follows (seen from the top of the unit):

SLOT # 1

SLOT # 2

SLOT # 3

SLOT # 4
63
47

55
1
6
7

54

62
11
12
16 17

80
20
21

34
33

46

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BGC Installation Instructions

Terminal strip overview

The terminal 36 must be connected depending on the

hardware type of the BGC.

MKII: Terminal 36 should not be connected to earth (Delta V

cannot be selected).
MKIII: Terminal 36 must be connected to earth, if the Delta V
measuring principle is selected in menu 4950.

Identify the hardware type of the BGC (MKII or MKIII) on the

type label which is located on the side of the BGC.

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BGC Installation Instructions

Input/output lists
In the I/O lists presented below the following terms will be used in
connection with the relay outputs:

NO means Normally Open

NC means Normally Closed
Com. means common terminal

Main PCB, slot #1

The main PCB is a standard board and is therefore

always mounted in the unit.

Term. Function Technical data Description

1 +12/24V DC 12 or 24V DC Power supply min.
2 0 (5-36V DC) working voltage 5V DC
continuously
3 NO Relay Mains breaker close
4 Com. 8A, 250V AC command
8A, 24V DC Configurable as pulse,
continuous or compact
5 NO Relay 2 Mains breaker open
6 Com. 8A, 250V AC command
8A, 24V DC If mains breaker is set to
continuous: Configurable
7 U L1 Mains Max. 480V AC phase-
Mains/busbar (or busbar) phase
L1 voltage
8 Not connected
9 U L2 Mains Max. 480V AC phase-
Mains/busbar (or busbar) phase
L2 voltage
10 U Neutral Mains
Mains/busbar (or busbar)
neutral voltage
11 U L3 Mains Max. 480V AC phase-
Mains/busbar (or busbar) phase
L3 voltage

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BGC Installation Instructions

Term. Function Technical data Description

12 U L1 Generator L1 Max. 480V AC phase-
Generator voltage phase
13 Not connected
14 U L2 Generator L2 Max. 480V AC phase-
Generator voltage phase
15 UN Generator
Generator neutral voltage
16 U L3 Generator L3 Max. 480V AC phase-
Generator voltage phase
17 IL1 s1(k) Generator 1/5A AC
current L1
18 IL2 s1(k) Generator 1/5A AC
current L2
19 IL3 s1(k) Generator 1/5A AC
current L3
20 I s2(l) Generator Common for current L1,
Com. current L2, L3 measurements
L1-L2-L3
21 Magn. pickup 0.5-70V AC RPM (running feedback,
34 Magn. pickup. 10-10.000Hz overspeed)/ magnetic
pickup
22 VDO 1 Configurable
(oil pressure)
35 VDO 2 Configurable
(water temperature)
23 VDO 3 Configurable
(fuel tank level)
36 Com. Common for VDO inputs
and
earth on delta V coupling
(see wiring diagram)
24 Digital input 1 Optocoupler Generator breaker
closed feedback/
configurable
37 Digital input 2 Optocoupler Generator breaker open
feedback
25 Digital input 3 Optocoupler Mains breaker closed
feedback/configurable

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BGC Installation Instructions

Term. Function Technical data Description

38 Digital input 4 Optocoupler Mains breaker open
feedback
26 Digital input 5 Optocoupler Engine running feed-
back/configurable
39 Digital input 6 Optocoupler Start enable/ confi-
gurable
27 Digital input 7 Optocoupler Ext. communication
control/configurable
40 Digital input 8 Optocoupler Remote alarm acknow-
ledge/configurable
28 Digital input 9 Optocoupler Auto start/stop/confi-
gurable
41 Com. Common for digital
inputs 1-9
29 NO Relay Generator breaker close
42 Com. 8A, 24V DC command
Configurable as pulse,
continuous or compact
30 NO Relay 3 Generator breaker open
43 Com. 8A, 24V DC command
If generator breaker is
set to continuous:
Configurable
31 NO Relay Start prepare
2A, 24V DC (preheat/prime)
44 NO Relay Fuel solenoid
2A, 24V DC (running coil/stop coil,
selectable)
32 NO Relay Crank
2A, 24V DC
45 NO Relay 1 Configurable
2A, 24V DC
33 NO Relay Horn/configurable
2A, 24V DC
46 Com. Common for terminals
31/32/33/44/45

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BGC Installation Instructions

Options, slot #2 and #3

Only two of the presented options (PCBs) can be

mounted in each unit. They can be placed in slot #2
(terminals 47-54) or #3 (terminals 55-62).

Option F1, 2 x transducer outputs (slot #3)

Term. Function Description

55 Not used
56 0(4) - 20mA out Analogue output 1/3, selectable
57 0
58 Not used
59 Not used
60 0(4) - 20mA out Analogue output 2/4, selectable
61 0
62 Not used

Option F2, 4 x transducer outputs (slot #2)

Term. Function Description

47 Not used
48 0(4) - 20mA out Analogue output 1/3, selectable
49 0
50 Not used
51 Not used
52 0(4) - 20mA out Analogue output 2/4, selectable
53 0
54 Not used

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BGC Installation Instructions

Option H1, Can-open (slot #3)

Term. Function Description

55 Can-H Can-open
56 GND
57 Can-L
58 Can-H
59 GND
60 Can-L
61 Not used
62 Not used

Option H2, Modbus RTU (slot #3)

Term. Function Description

55 DATA + (A) Modbus RTU, RS485
56 GND
57 DATA - (B)
58 Not used
59 DATA + (A)
60 Not used
61 DATA - (B)
62 Not used

Option H3, Profibus DP (slot #3)

Term. Function Description

55 DATA + (B) Pin 3 on 9 pole sub-D connector
56 GND Pin 5 on 9 pole sub-D connector
57 DATA - (A) Pin 8 on 9 pole sub-D connector
58 DATA + (B)
59 GND
60 DATA - (A)
61 Not used
62 Not used

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BGC Installation Instructions

Option H4, Caterpillar CCM engine interface (slot #2)

Term. Function Description

47/55 Not used CAT CCM
48/56 GND
49/57 Not used
50/58 TxD
51/59 Not used
52/60 RxD
53/61 Not used
54/62 Not used

Option M13, 7 x binary outputs

Term. Function Description

47/55 Digital input 11/21 Configurable
48/56 Digital input 12/22 Configurable
49/57 Digital input 13/23 Configurable
50/58 Digital input 14/24 Configurable
51/59 Digital input 15/25 Configurable
52/60 Digital input 16/26 Configurable
53/61 Digital input 17/27 Configurable
54/62 Com.

Option M14, 4 x relay outputs

Term. Function Description

47/55 Relay 6 250V, 8A, configurable
48/56 Com.
49/57 Relay 7 250V, 8A, configurable
50/58 Com.
51/59 Relay 8 250V, 8A, configurable
52/60 Com.
53/61 Relay 9 250V, 8A, configurable
54/62 Com.

Option M14 can be used as relay output control signal

for governor and/or AVR up/down, if required.

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BGC Installation Instructions

Option M15, 4 x 4-20mA analogue inputs

Term. Function Description

47/55 4-20mA input 1 (+) Configurable
48/56 Com. (0)
49/57 4-20mA input 2 (+) Configurable
50/58 Com. (0)
51/59 4-20mA input 3 (+) Configurable
52/60 Com. (0)
53/61 4-20mA input 4 (+) Configurable
54/62 Com. (0)

Option G1, load dependent relays

Term. Function Description

47/55 Relay 6 High load/configurable
48/56 Com. 250V, 8A
49/57 Relay 7 Low load/configurable
50/58 Com. 250V, 8A
51/59 Relay 8 250V, 8A, configurable
52/60 Com.
53/61 Relay 9 250V, 8A, configurable
54/62 Com.

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BGC Installation Instructions

Options, slot #4

Option G2, synchronising with analogue lines

Term. Function Techn. data Description

80 Not used
79 Not used
78 Not used
77 -10…0…10V DC Analogue Frequency/active load
input setpoint. Passive (requires
external power supply)
76 Com. Common Common for terminals 75
and 77
75 -10…0…10V DC Analogue Voltage/VAr/power factor/
/0…10V DC input reactive load setpoint.
(peak shaving) Mains power input for peak
shaving. Passive (requires
external power supply)
74 Digital input 17 Optocoupler Man. raise speed/
configurable
73 Digital input 18 Optocoupler Man. lower speed/
configurable
72 Digital input 19 Optocoupler Man. raise voltage/
configurable
71 Digital input 20 Optocoupler Man. lower voltage/
configurable
70 Com. Common Common for terminals
71-74
69 NO Relay 4 Configurable
5A, 250V AC
5A, 24V DC
68 NO Relay 5 Configurable
5A, 250V AC
5A, 24V DC
67 Com. Common Common for relay outputs
68-69
66 20-0-20mA out Speed governor setpoint output
65 0
64 20-0-20mA out AVR setpoint output
63 0

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BGC Installation Instructions

Option G3, load sharing and synchronising

Term. Function Techn. data Description

80 -5…0…5V DC Analogue I/O Active load sharing line
79 Com. Common Common for load sharing
line
78 -5…0…5V DC Analogue I/O Reactive load sharing
77 -10…0…10V Analogue Frequency/active load
DC input setpoint. Passive (requires
external power supply)
76 Com. Common Common for terminals 75
and 77
75 -10…0…10V Analogue Voltage/VAr/power factor/
DC/0…10V DC input reactive load setpoint.
(peak shaving) Mains power input for peak
shaving. Passive (requires
external power supply)
74 Digital input 17 Optocoupler Man. raise speed/
configurable
73 Digital input 18 Optocoupler Man. lower speed/
configurable
72 Digital input 19 Optocoupler Mode 1 (load sharing)/man.
raise voltage/configurable
71 Digital input 20 Optocoupler Mode 2 (fixed power)/man.
lower voltage/configurable
70 Com. Common Common for terminals 71-
74
69 NO Relay 4 Configurable
5A, 250V AC
5A, 24V DC
68 NO Relay 5 Configurable
5A, 250V AC
5A, 24V DC
67 Com. Common Common for relay outputs
68-69
66 20-0-20mA out Speed governor setpoint output
65 0
64 20-0-20mA out AVR setpoint output
63 0

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BGC Installation Instructions

6. Wiring

This chapter will present important information about the wiring of the
BGC unit and will therefore include detailed wiring descriptions.

AC connections

Island operation

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BGC Installation Instructions

AMF/fixed power/load take over/peak shaving

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BGC Installation Instructions

AMF/fixed power/load take over/peak shaving

Delta V connections

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BGC Installation Instructions

Load sharing lines

BGC BGC BGC

63 64 65 63 64 65 63 64 65

To other
units

DEIF recommends a screened cable, if the cable run is

longer than 5 m between units.

Binary inputs
All binary inputs are 24V DC bi-directional optocoupler. Typical input is:

The binary inputs all use fixed signals (not pulse

signals).

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BGC Installation Instructions

Analogue inputs
The setpoint inputs are passive, i.e. an external power source is
needed. This can be an active output from e.g. a PLC, or a potentiome-
ter can be used.

0…10V DC input using potentiometer

+/-10V input using potentiometer

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BGC Installation Instructions

Option H1 (CANopen communication)

BGC BGC
CANopen Option H1 CANopen Option H1
CAN-H

CAN-L

CAN-H

CAN-L

CAN-H

CAN-L

CAN-H

CAN-L
GND

GND

GND

GND
55 56 57 58 59 60 61 62 55 56 57 58 59 60 61 62

R
CAN-H

CAN-L

PLC or computer

ML2 terminal 55 and 58 are internally connected

ML2 terminal 57 and 60 are internally connected

Connect shield to ground at one end only. Shield

ends must be insulated with tape or insulation
tubing.

Use shielded twisted cable

End resistor R = 120 Ohm

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BGC Installation Instructions

Option H2 (Modbus RTU communication)

Connection with 2-wire screened cable (recommended):

Multi-line Multi-line Multi-line

DATA + (A)
DATA + (A)
DATA + (A)

DATA + (A)
DATA + (A)
DATA + (A)

DATA - (B)
DATA - (B)

DATA - (B)
DATA - (B)

DATA - (B)

DATA - (B)

Not used
Not used
Not used

Not used

Not used
Not used

Not used
Not used

Not used

COM
COM
COM

55 56 57 58 59 60 61 62 55 56 57 58 59 60 61 62 55 56 57 58 59 60 61 62
DATA + (A)
COM
DATA - (B)

PLC or other device

Connect shield to ground at one end only. Shield

ends must be insulated with tape or insulation
tubing.

Use shielded twisted cable

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BGC Installation Instructions

Connection with 3-wire shielded cable:

Multi-line Multi-line Multi-line

DATA + (A)
DATA + (A)
DATA + (A)

DATA + (A)
DATA + (A)
DATA + (A)

DATA - (B)
DATA - (B)

DATA - (B)

DATA - (B)

DATA - (B)
DATA - (B)

Not used
Not used
Not used

Not used

Not used
Not used

Not used

Not used

Not used

COM
COM
COM

55 56 57 58 59 60 61 62 55 56 57 58 59 60 61 62 55 56 57 58 59 60 61 62
DATA + (A)
COM
DATA - (B)

PLC or other device

This solution is only feasible if the COM line is

insulated. Check PLC/other device before connec-
ting.
Non-insulated COM line may result in damage to
the equipment.

Use shielded twisted cable

Connect shield to ground at one end only. Shield

ends must be insulated with tape or insulation
tubing.

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BGC Installation Instructions

Normally, the Modbus does not need bias resistors

(end terminators). These are only needed in case of
very long lines and/or many nodes (>32) on the
Modbus network. If bias resistors are needed, the
calculation should be based on the following data:
- A line internal pull-up bias resistor: 22 kΩ
- B line internal pull-down bias resistor: 22 kΩ
- Receiver input sensitivity: +/-200 mV
- Receiver input impedance: 12 kΩ

2
Cable: Belden 3105A or equivalent. 22 AWG (0.6 mm )
twisted pair, shielded, <40 mΏ/m, min. 95% shield
coverage.

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BGC Installation Instructions

Option H3 (Profibus DP communication)

Connection with 2-wire screened cable (recommended):

Multi-line Multi-line Multi-line

DATA – (A)

DATA + (B)
DATA + (B)

DATA – (A)

DATA – (A)
DATA + (B)

DATA + (B)
DATA – (A)

DATA + (B)

DATA + (B)
DATA – (A)

DATA – (A)
Not used

Not used

Not used

Not used

Not used
Not used

Not used

Not used

Not used
COM

COM

COM
29 30 31 32 33 34 35 36 29 30 31 32 33 34 35 36 29 30 31 32 33 34 35 36
DATA + (B)
COM
DATA – (A)

PLC or other device

Connect shield to ground at one end only. Shield ends

must be insulated with tape or insulation tubing.

Use shielded twisted cable

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BGC Installation Instructions

Connection with 3-wire shielded cable:

Multi-line Multi-line Multi-line

DATA – (A)

DATA + (B)
DATA + (B)

DATA – (A)

DATA – (A)
DATA + (B)

DATA + (B)
DATA – (A)

DATA + (B)

DATA + (B)
DATA – (A)

DATA – (A)
Not used

Not used

Not used

Not used

Not used
Not used

Not used

Not used

Not used
COM

COM

COM
29 30 31 32 33 34 35 36 29 30 31 32 33 34 35 36 29 30 31 32 33 34 35 36
DATA + (B)
COM
DATA – (A)

PLC or other device

This solution is only feasible if the COM line is

insulated. Check PLC/other device before connec-
ting.
Non-insulated COM line may result in damage to
the equipment.

Use shielded twisted cable

Connect shield to ground at one end only. Shield

ends must be insulated with tape or insulation tubing.

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BGC Installation Instructions

Option H4 (CAT CCM communication)

Connection between CCM and BGC

BGC Option H4

GND

RxD
TxD
55 56 57 58 59 60 61 62
2 Tx
3 Rx
7 GND

20 DTR
8 DCD

25-P SUB-D socket

Caterpillar CCM unit

Connect shield to ground at one end only. Shield ends

must be insulated with tape or insulation tubing.

Use shielded twisted cable

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BGC Installation Instructions

Option H5 (J1939 and MTU MDEC communication)

BGC slot #3

CAN-H

CAN-H

CAN-L
CAN-L
GND
55 56 57 58 59 60 61 62

R
CAN-L
CAN-H
GND

ECM Engine Control

Module

BGC terminal 55 and 58 are internally connected

BGC terminal 57 and 60 are internally connected

Connect shield to ground at one end only.

Shield ends must be insulated with tape or
insulation tubing.

Use shielded twisted cable

End resistor R = 120 Ohm

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BGC Installation Instructions

Option H6 (Cummins communication)

BGC slot # 3

Data – (B)

Data – (B)
Data+ (A)
Data+ (A)
GND
55 56 57 58 59 60 61 62

18 Data – (B)
20 GND
21 Data + (A)

Cummins ECM
25-P SUB-D socket
no. 06

BGC terminal 55 and 59 are internally connected

BGC terminal 57 and 61 are internally connected

Connect shield to ground at one end only. Shield

ends must be insulated with tape or insulation
tubing.

Use shielded twisted cable

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BGC Installation Instructions

Normally the communication does not need bias

resistors (end terminators). These are only needed in
case of very long lines between the 2 modules If bias
resistors are needed, the calculation should be based on
the following data:
- A line internal pull-up bias resistor: 22 kΩ
- B line internal pull-down bias resistor: 22 kΩ
- Receiver input sensitivity: +/-200 mV
- Receiver input impedance: 12 kΩ

2
Cable: Belden 3105A or equivalent. 22 AWG (0.6 mm )
twisted pair, shielded, <40 mΏ/m, min. 95% shield
coverage.

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BGC Installation Instructions

7. Technical information

This chapter will present general technical information including

technical specifications, unit dimensions and panel cutout informa-
tion.

Technical specifications

Accuracy: Class 1.0, to IEC 688

Operating temp.: -25…70°C

Climate: Class HSE, to DIN 40040

Meas. voltage: Max. 480 volt phase to phase, +/-20%

Consumption: Max. 0.15VA/phase

Meas. current: -/1 or -/5A AC

Consumption: Max. 0.3VA/phase

Current overload: 4 x In continuously

20 x In, 10 sec. (max. 75A)
80 x In, 1 sec. (max. 300A)

Meas. frequency: 30…70Hz

Aux. supply: 12/24V DC (5-36V DC)

Max. 8W consumption

Binary inputs: Optocoupler, bi-directional

Input voltage
Main board: 5…36V DC
Load share board: 6…36V DC
M13 board: 6…36V DC
Impedance max. 4.7kΩ

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BGC Installation Instructions

Relay outputs: See data in I/O list

Analogue inputs: -10…0…+10V DC

Not galvanically separated
Impedance: 100kΩ

Mounting: Panel mounted

Load sharing lines: -5…0…+5V DC

Galvanically separated

Analogue outputs: 0(4)...20mA

Galvanically separated
Active output (internal supply)
Load max. 500Ω

Safety: To EN 61010-1, installation category

(overvoltage category) III, 600V, pollution de-
gree 2

Galvanic separation: Between AC voltage, AC current and other

I/Os: 3250V AC, 50Hz, 1 min.
Between analogue outputs and load sharing
lines: 500V DC, 1 min.
(Contact DEIF support for additional
information)

EMC/CE: To EN 50081-1/2, EN 50082-1/2

SS4631503 (PL4) and IEC 255-3

Material: All plastic materials are self-extinguishing

according to UL94 (V1)
2
Plug connections: AC current: 4 mm multi-stranded
2
Other: 2.5 mm multi-stranded

PC: RJ-11 for programming interface with 9-pole

Sub-D male

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BGC Installation Instructions

Protection: Unit: IP20

Display: IP52
To IEC 529 and EN 60529

Weight: Approx. 1 kg (2.2 lbs)

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BGC Installation Instructions

Unit dimensions

207
86

148

158

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BGC Installation Instructions

Display dimensions

129 248

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BGC Installation Instructions

Panel cutout

6xØ4
86.0+0.5
-0.0

Max detph in display 9mm.

3.5mm selfcutting threads.
Screws for fastening:
102.0
213.0

208.0
102.0

45.25 45.25

DEIF A/S reserves the right to change any of the above.

DEIF A/S Page 45 of 45