Home

TG410 User Manual R2.0

Contents

1. CT COMMON CT Common PHASE A PHASE B PHASE C NEUTRAL Description Generator Voltage Tough Series Harness Guide DWG 1547R1 1 TOUGH Series Manual 2015 DynaGen Technologies Inc 10 Installation Typical Wiring Diagram 2 4 DRAWING NOTES NOTE 1 NOTE 2 NOTE 3 NOTE 4 NOTES NOTE 6 NOTE 7 NOTE 8 BAT Emergency Stop Speed Sensing Speed Input is used with MaxSOVAc magnetic pickups flywheel alternator or tachometer NOT required for generators or electronic engines Battery 5 5 38V USB Connection Sensor Input B 0 7500 Sensor Input C Universal a lt 3 Engine Oil Fuel Temperature Pressure Level __ Main connector 4 1 4 2 Battery Battery Switch Input A Switch Input B Expansion Connector Switch Output F DC Load Max 1A Sensor Input D Universal MOD Bus RS485 TOM CAN Bus 41939 Max 575VAC Review user manual for more detailed information on wiring and controller configuration BAT Start Stop Contacts Switched Inputs can be ie Lead configured to detect battery ground or open Communication Connector Generator Connector A Gen Current A Gen Current B Common Shield High Low CT COMMON
2. Battery 4 20mA Sensor Example 2 Sometimes it is required to measure voltages outside the 0 5V range allowed by the controller To do this you must use a voltage divider with appropriate scaling resistors The equation to calculate the resistor values is as follows Vout 5V _ R1 Vin Maximum Voltage to Read Vout x Vin ia E 1 R2 R1 Common Resistor Value gt 10KOhm R2 Calculated Resistor Value Select closest common resistor value The following diagram shows the typical wiring of a voltage divider The resistors values have been selected to allow the controller to read up to 36V from an external battery bank 0 36V Wiring Example To Universal Sensor Input Battery 0 36V NOTE A TVS i e varistor is required if the battery is different than the battery the controller is powered from The controller s TVS cannot protect the sensor input from transients in this case TOUGH Series Manual 2015 DynaGen Technologies Inc Installation 14 2 6 4 CAN Bus Wiring The following table outlines some items that must be taken into consideration when connecting to a CAN bus engine Consideration Description Bus Termination Each end of the bus must be terminated from CAN H to CAN L with 1200hm 10 Ohm resistors The resistor must be able to handle at least 400mW of power disipation A twisted pair 1200hm cable is required for communications For better protection a shielded
3. Dependent 1 Refer to the sections below for more information on how these settings affect the auxiliary sensors TOUGH Series Manual 2015 DynaGen Technologies Inc Settings 34 4 4 6 1 Fault Monitor Example In this example a sensor is monitoring the temperature of an engine block If the temperature rises above 275 F a warning message is displayed If the temperature rises above 350 F the engine shuts down and a failure message is displayed Relevant Settings Setting Value o Failure Level 300 Warning Level 250 200 Temperature Fahrenheit 150 4 100 50 o o 5 10 15 20 25 30 Time Minutes The chart above shows the connection between engine temperature and time At approximately 13 minutes run time the temperature rises above the 275 F warning threshold activating the warning display The engine will continue to run because it has not reached the 350 F failure threshold At 20 minutes run time the temperatures falls below the warning threshold and the warning disappears TOUGH Series Manual 2015 DynaGen Technologies Inc Settings 35 4 4 6 2 Start on Low High Example In this example a sensor is monitoring the voltage of an external battery bank If the voltage falls below 10 5V the engine will start and run for 40 minutes to charge the battery Relevant Settings Setting Value 1 Stop Level needs to be disabled when the engine is running because the battery
4. you can trust TG410 User Manual MANUAL RUA Engine Speed _ 1802 0 RPM Engine Temp 95_5 F P p OFF AUTO RUN Manual Revision 2 0 0 Min FW Revision 1 64 Date Released 10 03 2015 C US 2015 DynaGen Technologies Inc TG410 User Manual Table of Contents User Guide 1 Introduction 3 4 1 Specifications TN 4 2 Installation 4 2 1 General Wiring Notes iii ias 6 2 2 Terminal Descriptions td 6 2 3 Wiring HANO S O OO a a aaa aa a ata 9 2 4 Typical Wiring Diagram O NN 10 2 5 Typical Wiring Diagram with RelayPak s sscssssssssssssesssesssesssssnsesnsesssesssessseesseessessnecsneeensesssessneesneesanesssessns 11 2 6 Wiring Consider tions a diesen 12 2 6 1 Remote Start Contact Start Stop cccccceccccssssssssesesesescsssssesceseesesasacscscsteesasasssatsesscesasaasacitssseasassticaceseecasssacititeseneesenseaeets 12 2 0 2 Emergency Stop WII niisctialt ai dt ti ts A db idad 12 AS SO O Un O aceite A E ET 2 0 4CAN BUS WIN artta tea tee Ne di A eN ed to MN da Ea Wadi dae DOMO e Ia 2 6 6 Current Transformers ZO Relay Pak Optional A A AE A RO IO E SEDO 3 Using the Controller 17 3 1 Modes Starting and Stopping 3 2 Using Cooldown Mode 3 3 Failures eessen 4 Settings 20 4 1 Operator Setup O TN 21 4 2 Switched Inputs O NN 22 421 Voltage Selectas tr a dad Atlee Sk OI Sid athe te dt bad 24 4 2 2 RPM PEQUE eiii diia 24 4 23 Configurable MPU ici arde AN nd a AN heen AN cnet
5. Active Mode Description Primary RPM 60Hz Auto Used for changing between Primary and Secondary RPM for an engine or Secondary RPM 50Hz 50Hz 60Hz for a generator See RPM Frequency Select for more Select information Preheat Signal Cranking When the Preheat Mode setting in the Engine Logic menu is set to Switched Input it uses this input to determine to control the preheat time Remote Reset Global Allows the controller to be reset from a failure mode Momentary action for 3 5s in FAILURE mode will place the controller in OFF mode Momentary action for 3 5s in OFF mode will place the controller in AUTO mode The RapidCore Configuration Software must be used to change the text Active Modes Name Description Input can be triggered after a start command is received until shut down cooldown not included Input can be triggered during cranking After Cranking Input can be triggered after engine has started until shut down Input can be triggered while cooldown timer is active A NOTE More than one Active Mode can be selected Triggers Name Description Close BAT Input is active when Battery is present at the terminal Close GND Input is active when Ground is present at the terminal Close BAT GND Input is active when either Battery or Ground is present at the terminal Input is active when neither Battery or Ground is present at the terminal A NOTE When running wires over long distances over 20f
6. Emergency Stop Wiring If Emergency Stop functionality is required it is mandatory to install an external mushroom style switch wired in series with the fuel or ignition supply to ensure reliable and immediate shutdown upon activation Shown below is an example wiring diagram of a double pull single throw switch being used to activate the e stop input and cut power to the fuel solenoid In this configuration the e stop is activated when there is an open circuit to the switched input and inactive when the input detects Battery voltage Emergency Stop Input o Emergency Stop Fuel Solenoid Ik il Cr Fuel Relay i T Output o m TOUGH Series Manual 2015 DynaGen Technologies Inc Installation 13 2 6 3 Universal Sensor Universal Sensors have the ability to be configured to detect different sender types 0 7500hm 0 7 5000hm 0 5 VDC 4 20mA The examples shown below are advanced applications of the universal sensor NOTE Custom Sensor tables are required for the universal sender to work with these examples See the Custom Sender Table section for more information Example 1 The following example shows the correct way for wiring a 4 20mA sensor The 2400hm resistor is required to transform the 4 20mA current into the 0 5V voltage range required by the controller 4 20mA Wiring Example To Universal Sensor Input
7. Failure 2 Config Fail 3 Auxiliary Sensor 1 Auxiliary Sensor 2 Auxiliary Sensor 3 Auxiliary Sensor 4 Load Imbalance More Information TOUGH Series Manual O 2015 DynaGen Technologies Inc Settings 28 4 3 1 Group Outputs Group functions have been designed to allow multiple output functions to be bundled together and assigned to a single switched output pin The definition of a group output follows When any of the functions in a group is active OR logic the assigned switched output will be active Group Functions Active Mode Description Group Dependent Must be set from DYNAGEN Configurator software Group Dependent Must be set from DYNAGEN Configurator software Group Dependent Must be set from DYNAGEN Configurator software Group Dependent Must be set from DYNAGEN Configurator software Example Low AC Frequency High AC Frequency are bundled in Group 1 and assigned to Switched Output D This output is connected to an external indicator lamp labeled AC Frequency Warnings allowing one output to indicate there is a warning with the AC frequency The following table shows the output state based on the warnings status Low AC Frequency Warning High AC Frequency Warning Switched Output State 4 3 2 Pull and Hold Coil On some engine systems the fuel pump has two coils This is because the initial power on of the fuel solenoid requires substantial current Pull Coil but only needs a small amount of current to hold it
8. Frequency gt Frequency Source setting must be set to RPM Switch for this feature to work This setting can only be changed when the controller is not in running mode The following settings must be set in order for this feature to function e Switched Input X gt Primary RPM 60Hz Secondary RPM 50Hz Select e AC Metering gt Generator Frequency gt Frequency Source gt RPM Switch e Sensors gt Engine Speed gt Auto RPM Nominal gt Primary RPM 60Hz e Sensors gt Engine Speed gt Auto RPM Nominal gt Secondary RPM 50Hz The table below shows the correspondence between the switched input status and the RPM Frequency Switched Input Frequency NOTE If enabled the TSC1 PGN will be broadcasted according to the selected speed Otherwise only the warning and failure setpoints are affected by this function TOUGH Series Manual O 2015 DynaGen Technologies Inc Settings 25 4 2 3 Configurable Inputs These inputs are used to create custom warnings and failures Using the DYNAGEN Configurator you can change the text displayed when the warning or failure occurs If you select one of these inputs without changing the text it will default to Config Warn X and Config Fail X There are also timers associated with the configurable inputs which can be found in the menu under Timers gt Trigger Delays These timers change the amount of time the input has to be active before the controller registers the warning
9. Open Open Circuit Trim Offset 50 0 50 0 psi 344 7 Calibrate a sensor by using the offset to correct errors 344 7kPa Setpoints gt Bypass Time 0 90 seconds Amount of time to bypass warnings and failures after engine has started Setpoints gt Low Warning 0 1 99 0 psi 0 7 Reading at which a warning occurs 682 6kPa Setpoints gt Low Failure 0 1 99 0 psi 0 7 Reading at which a failure occurs TOUGH Series Manual 2015 DynaGen Technologies Inc Settings 30 Name Range Description Note All pressure settings are entered in terms of psi 4 4 3 Fuel Level Use the following settings configurations to allow the controller to read and interpret data from the fuel level sensor Name Range Description Signal Source Sensor Port X The source from which the sensor data is attained Sensor Type Sensor Table X Select one of the pre configured sensor tables or one of the Close Warning switch functions A custom table can also be created using Open Warning the RapidCore Configuration Software Close Failure Close Ground Open Failure Open Open Circuit Trim Offset 50 0 50 0 Calibrate a sensor by using the offset to correct errors Setpoints gt Bypass Time 0 90 seconds Amount of time to bypass warnings and failures after engine has started Setpoints gt Low Warning 1 90 Reading at which a warning occurs Setpoints gt Low Failure 1 90 Reading at which a failure occurs Set
10. Timers gt Engine Logic gt RPM Disconnect setting is set correctly 3 Ensure the correct wiring to the controller For magnetic pickup Speed Sensing A and B terminals are used For generator voltage the AC voltage connections are used Sensor always displays its lowest or The sensor could either be open not connected or shorted to ground Verify your highest value connections and ensure the correct sender table is loaded Contacting DYNAGEN can be done by any of the methods below Technical support is offered Monday Friday 8 00am 4 00pm EST If you are unable to contact one of our engineers please leave a message and they will return your call as soon as possible Type Information Address 3 Spectacle Lake Drive Unit B105 Dartmouth NS B3B1W8 Canada TOUGH Series Manual O 2015 DynaGen Technologies Inc
11. controller They are not password protected and can be changed by anyone from the front panel Name Range Description Display gt Page Scroll 1 10 seconds Amount of time between each auto scroll of the parameter pages Display gt Message Pop Up 1 10 seconds Amount of time each message is displayed on the screen before displaying next message in the buffer Display gt DPF DEF Display Time O 10 seconds See the J1939 Reference Manual for more information Display gt LCD Backlight Timeout 10 600 seconds Amount of time the LCD Backlight stays on after button activity stops Date Time gt Date Change 1 31 days Sets the date 1 12 months 2000 2099 years Date Time gt Time Change 0 23 hours Sets the time 0 59 minutes 0 59 seconds Date Time gt Daylight Savings Enable Disable Turns Daylight Savings Time on or off Units gt Temperature Unit Selects the temperature display format Units gt Pressure Unit PSI or kPa Selects the oil pressure display format Run from OFF Enable Disable When enabled allows a user to start the engine using the run button while in the OFF mode When disabled the controller must be placed in AUTO mode before the run button can start the engine TOUGH Series Manual 2015 DynaGen Technologies Inc Settings 22 4 2 Switched Inputs The controller has switched inputs which cause the controller to perform a function when activated Settings Name ETS De
12. cranking engine delays this amount of time before turning on the Warmup output This allows the engine to warm up before applying any load to it The output will turn off when the controller enters the Cooldown Delay OFF Button Function Cooldown The function the OFF button on the front panel performs while Shutdown engine is running See the OFF Button Function section for Force Cooldown more information Cooldown Delay 0 600 seconds Amount of time to cool down the engine after a stop TOUGH Series Manual 2015 DynaGen Technologies Inc Settings 39 Description command has been received During this time the Warmup output turns off and the Cooldown output turns on If another start command is received during cool down the controller will return to running mode ETS On Duration Energize to Stop 0 30 seconds Amount of time the Energize to Stop output is on after the engine has shut down If controller still detects speed RPM after this time expires it goes to a Failed to Stop failure Time must be greater than O seconds for the Energize to Stop function to work 4 5 1 1 Preheat Mode The controller has the ability to control the length of the preheat time through 3 different methods The table below describes each method Mode Description A NOTE During preheat the Glowplug switched output is on 4 5 1 2 OFF Button Function The OFF button on the front panel of the controller can be configure
13. settings associated with timing functions AN NOTE The controller has an on board backup battery to keep time even when main power is not supplied to the unit This battery has an unpowered no main power lifetime of approximately five years Engine Logic The following settings determine how the controller starts and stops the engine It gives the user the functionality to add delays and timers to the sequences Most of the settings have a switched output associated with them that must be set in the Switched Outputs settings A NOTE Setting a timer s value to 0 seconds will disable the timer Example If Delay to Start is set to O seconds the controller will not perform a Delay to Start when starting the engine ame s s Range Description Delay to Start 0 90 seconds Amount of time to delay the starting of the engine after receiving a command to start Delay to Start on Manual Run Enable Disable Determines if the the Delay to Start timer is used when the front panel RUN button is used to start the engine Preheat Mode Preheat Timer Determines the method used to control enabling the glowplug Switched Input output See the Preheat Mode section for more information J1939 Preheat Time 0 90 seconds Amount of time the Glowplug output is active before cranking the engine Used on diesel engines to warm the engine before cranking Crank Time 3 30 seconds Amount of time the Crank output is active before going to crank res
14. AN EN AN ER AO 25 4 2 4 Start Stop Momentary FUNCTION ccccccccccsesssesesesessssscsceeescesavscscstusessesesasssiceesecesasasasstisissesesasstiticeseseesasstacitteneneassnseeeees 25 4 2 c dlecinhibity Drain sa Oe iats anid nad aah Aah AS oben arcas da a a aa 26 4 3 Switched Outputs O O OO E 26 4 351 Group Outputs sc A ti a cto db bd 28 4 3 2Pull and Hold Colciencias aa taa beats aaa bie 28 BASONSOES ivi A A A DAA AA ia 29 ATENDIDOS Temperature a Add ida 29 O A NRO 29 O O a RO AO 30 AAA ENDING 30 O 2015 DynaGen Technologies Inc TG410 User Manual Front Panel Speed Conto sseni orner a A aa aida eat aaa 31 AAS Batter A A A MNT tes ee CAN NT RANT aN 32 A ack avec cs Deke esses ibid ante EN car xn A given 33 Fault Monitor Example n naida A A A 34 Start on Low High Examples uc dd A ETEA EEA E da a EEE eE ada R EEEE 35 Qutput on Low High Example arc e EAE A dll aro e aes 36 4 4 7 Custom Sensor Tables cas 37 4S TIMSS A a A a iia 38 IAE LOGIC ii E ATA A DAA og A lt A AD a 38 Preheat MOE A A A SS AAA A AA SA A 39 OFFButton EUNCHON ici A AAA AAA tamara dao 39 A A A A A 40 49 Mantena POP PS PDS DU OO CE EOD BoB PODS a 41 4 6 AC MonNItOF viii art A id 42 4 6 1 Generator Voltages atic cant itaria atten chip dea NA N AET aa end ante e eens 42 4 0 2 Generator Frequency aeii iiti aaa a At dd 43 46 3 Generator CUNA a O TR O O DA O 43 BASICAS a A A A eer ED eRe To ies Rs 44 O 44 oad Imbalances ente
15. Active when any failure occurs RPM Increment Running Output is used to to trigger inputs on an ECM to control speed See Front Panel Speed Control section for more information RPM Decrement Running Output is used to to trigger inputs on an ECM to control speed See Front Panel Speed Control section for more information DEF Fluid Level Running Active when DEF Fluid Level falls below the DEF Low Level and stays active until the level rises above the DEF High Level See CAN Bus J1939 section for more information Disables the generator during a stationary Regen on Kubota engines see Aftertreatment in the J1939 User Manual or also during an engine IDLE condition from the IDLE switched input Automatic idle is ignored If the generator voltage is not below the under voltage setpoint in 10s the controller will shut down the engine on Generator Disable Failure Dummy Load Output is controlled by the dummy load feature Breaker Trip Running Output is controlled by the Over Current Failure or IDMT features and by the Load Imbalance feature Warning Functions Genset Disable Functions Auxiliary Sensor 3 Auxiliary Sensor 4 Load Imbalance More DTC Received Active when Information controller receives a DM1 from the ECM Failure Functions Functions Low Hydraulic Pressure Under Frequency Over Frequency AC Under Voltage AC Over Voltage Over Current TG410 only ECM Communication Failure Configurable Failure 1 Configurable
16. Disable Breaker Trip Failure Enable Disable Shuts down the generator if the generator circuit breaker fails to trip If the Breaker Trip switched output is active due to IDMT or Load Imbalance and if after 10s the measured generator current is still above 10 of the Rated Current the generator will shut down IDMT Mode Disable See IDMT for more information Breaker Trip Shutdown Trip TDS Time Dial Setting 0 1 30 Load Imbalance Mode Disable See Load Imbalance for more information Breaker Trip Shutdown Trip Load Imbalance Delay rze See Dummy Load for more information TOUGH Series Manual 2015 DynaGen Technologies Inc Settings 44 4 6 3 1 Basic Alarms The controller can give a warning and or shutdown on over current If DMT is enabled then it overrides the High Failure shutdown but the warning is still active Name Range Description Setpoints gt High Warning 1 125 Reading at which a warning occurs Percentages based on the Rated Amps value Setpoints gt High Failure 1 125 Reading at which a failure occurs Percentages based on the Rated Amps value 4 6 3 2 IDMT Sets a inverse time trip curve for over current When set this overrides the Over Current Failure Name Range Description IDMT Mode Disable Disable Disables the IMDT feature Breaker Trip Shutdown Trip Breaker Trip If IDMT is active the Breaker Trip switched output is activated to switch off the main generator b
17. If current readings are unstable with this configuration attempt connecting the CT Common s to the negative terminal of the battery Ensure the connecting wire is as short as possible J1939 and RS485 require 1200 impedance shielded twisted pair cable Example Belden 7895A Example Belden 9841 Generator DYNAGEN Switch Input C NN Reserved Gen Current C Switch Output A 3 2 CAN High 15 4 CT Common power controls you can trust Switch Output C 13 3 CAN Low Theogonen coway cono Switch Output B 3 4 Switch Output E CAN Ground Generator Connector V SOLENT ae HAGE ee PURPOSES FoR W Sensor Ground J3 5 Switch Output F Speed Input J7 1 Gen Phase A Project Name Wiring Diagrams Sensor Input A J3 6 Sensor Power 5V Speed Reference Gen Phase B Drawing Name TS410 Example 34 13 Sensor Input B 3 7 Sensor Ground J6 9 Reserved 7 3 Gen Phase Drawing Number pes Drawing Revision 14 0 J4 14 Sensor Input 3 8 Sensor Input D 6 10 RS485 Ground J7 4 Neutral Drawing Scale Not To Soak Drawing Size ANSI B Ledger Created On 12792012 Your application and wiring may vary Refer to full user manual for detailed information on using your controller www dynagen ca support Modified On 0171312014 Created By Everett Pattison o o Modified By Everett Pattison 2015 DynaGen Technologies Inc TOUGH Series Manual 11 Installation Relay Pak RP100 Schematic Representation M
18. La It a de habit tt a E 44 DUMMY Luar AAA AAA AAA Aa 45 4 7 COMMUNICAtIONS iieii ieaiaia a A ici 45 A Ta aaa a gs Gas ora esau ase 45 4 7 2 MOD Bus RACY eats cesar tna apermapniat sath gem EE AEA A dead e lios Saa AEE EEE AEE acarrea aan en 47 5 Troubleshooting 47 2015 DynaGen Technologies Inc User Guide 1 Introduction The TOUGH series controllers are designed to provide complete control protection AC metering and engine instrumentation for both standard and electronic engines The module is easily configured using either the front panel buttons or our DYNAGEN Configurator software TOUGH series controllers are ideally suited for severe duty applications where reliability is critical such as mobile and stationary generators T ier Ready e Features and Functions e 5 Year Warranty Gasket for water ingress protection resistance e e SAE J1939 CAN Bus Protocol e Free RapidCore Configuration Software e RPM via J1939 Magnetic Pickup or Generator e Fast and rugged installation clips e Speed control offset for electronic engines e Passcode protected e Autostart on low battery and other sensors e Automatic shutdowns and warnings e Trim feature for AC monitoring and sensors e Manual and Remote start e Maintenance counter e Momentary Start Stop inputs e Exerciser Clock e Pre heat and many other configurable timers e 150 Event Log e Accepts common senders VDO Datcon S amp W e Conformally coated for protection aga
19. OD Bus RS485 Speed Sensing Common J1939 and RS485 require Max 50VAC 1200 impedance shielded Speed Input is used with A twisted pair cable magnetic pickups fywnee ae o altemator or tachometer ik e A CAN Bus J1939 Example Belden 9841 NOT required for generators 1 Shield Relay E or electronic engines a Max 575VAC BAT Review user manual for Emergency Stop more detailed information Switch input A on wiring and controller configuration Switch Output B Switch Output D gt o la gt gt PA E A A LALLA Relay B N O Contact Fuel Al Glowplug k gt O CT COMMON Relay A USB Connection BAT N O Contact BAT I current readings are unstable with this Re Pak RP1 di Si configuration attempt connecting the CT a Common s to the negative terminal of the battery 49 Ensure the connecting wire is as short as possible a Relay D 5 Relay C BO Gamat H BAT gt Crank G N O Contact E 5 oO Start Stop Picked E Contacts Y Pre made hamesses are 5 Switched Inputs can be available Contact Dynagen Engine oil Fuel DC Load Sensor DC Load configured to detect cx for more information Temperature Pressure Level Max 1A Input Max 1A Bae giomiljorasen _ Relay Pak Connector 34 2 Batey J1 Reay o Cot 3 Battery Coil Ground as Battery Communication Connector Generator Con
20. Pre Alarm Timer Start Engine for Recharge Time TOUGH Series Manual O 2015 DynaGen Technologies Inc Settings 33 4 4 6 Auxiliary The Auxiliary sensors on the controller are used for performing functions based on sensor readings There are two different ways the auxiliary sensors may be utilized Scenario 1 Custom Sensors Use the auxiliary sensors to create custom sensors Current Voltage etc that are not supported by the controller by default engine temperature oil pressure fuel level Scenario 2 Add On Functionality Double up the auxiliary sensor onto the same Sensor Port that is currently being used by one of the other sensors engine temperature oil pressure fuel level This allows you to use the special functions Start on Low Output on High etc in conjunction with those sensors A NOTE You must set the auxiliary sensor port and sensor table to the same values as the other sensor Name Range Description Signal Source Sensor Port X The source from which the sensor data is attained Display Enable Disable Determines if the sensor s value is displayed on the screen when the engine is running Active Mode Disable Determines under which operating conditions the Auxiliary Global Sensor is monitored Multiple selections are allowed Does Not In Auto not apply to Start on Low or Start on High for those Auto State selections the active mode is always Not In Auto Running Cranking Refer to the ex
21. TOUGH Series Manual O 2015 DynaGen Technologies Inc Using the Controller 19 Mode State Description When in the menu mode settings can be changed and the events history may be viewed The following table describes the different methods for starting a controller Unless using the Manual Run method to start the controller the controller must be in AUTO mode Starting Methods Methods Manual Run Start Stop Switched Input Momentary Switched Inputs Battery Recharge Exerciser Auxiliary Sensors Loss of Mains TG350AMF only Modbus Start TG410 only J1939 Start Description Pressing the Run button will start the engine You must press the OFF button to shut down the engine When this input is active the engine will start When the input becomes inactive the engine will shut down Switched inputs Momentary Start and Momentary Stop can be used for starting and stopping of the engine Unlike other inputs they only have to be activated for a short period of time When the battery voltage drops below a certain level the engine will start and run for a predetermined amount of time When the scheduled exerciser interval occurs the engine will start and run for a predetermined amount of time When a properly configured Auxiliary sensor falls below rises above a certain point the engine will start as determined by the Auxiliary Sensors gt Mode Select settings When loss of mains power is detected t
22. WINA Switched Input A SWINB Switohed input B Jas Tan SWINB Switched inpute Switched Input C 347 Tan SWING _ Switched inputC RelayPak relay A das Purple SWOUTA Switched Output A RelayPak relay C J4 9 Purple SWOUTC Switched Output C SW OUTB_ RelayPak relay B 44 10 Purple swouT8_ Switched Output B SEN GND_ Sensor Ground J411 Brown SEN GND Sensor Ground SENINA Sensor Input A 34 12 Brown SENINA Sensor Input A 713 Brom aia Brom SEN NC sensormpao DWG1477 Advanced lO Hamess Tema Purple SWOUTD Switched Output D SWOUTE Bwitched Output E SWOUTF Bwitched Output F Not Populated SEN GND Purple Purple Brown Sensor Ground Sensor Input D Terminal J3 3 is left unpopulated from the factory and can be populated using one of the two indivividual wires that came with the harness a short one with two crimps on both sides and a long one with a crimp on one side and a pigtail on the other If using relay D on the RelayPak insert one end of the short wire into J3 3 and the other end into RelayPak J1 1 If you are not using the relay pack insert the longer wire into J3 3 Color Wire Text PHASE A Terminal PHASE B PHASE C NEUTRAL DWG1479 AC Voltage Sensing Harness Description Generator Voltage Wire Text Description PHASE A PHASE B PHASE Gen Current A Gen Current 8 Gen Current C
23. age Step 1 From the Sender drop down menu select Custom Image Step 2 Click the Edit button next to the drop down menu Image Step 3 Enter the sensor values Once entered click Apply then OK Sender Table Utili fees TG350 Firmware 1 12 ee Close Save To File More Details ohms x F z Sunucu y fasi 4 Switched Inputs 2 Banet t n 129 User Configurable Inputs 2 al te 2 406 140 1 Switched Outputs Signal Source Sensor Port A y M3 330 1492 a poe Sensor Type Datcon DAH e g Datcon 02022 00 y Ma 26 160 s J Recharge Setup Trim Offset 0 mp Ms 202 175 je e M6 147 189 7 ngine ee pes Settings 27 96 221 gt Custom El Setpoints 8 49 275 Engine Temperature Input Type Resistance Unit Type Temperature Mo 7 330 Setpoints a Oil Pressure 10 Setpoints Fuel Level Setpoints 4 Aux Sensor 1 Mode Settings Setpoints 4 Aux Sensor 2 Mode Settings Setpoints 4 Timers Engine Logic 4 Exerciser Delays Schedule Maintenance DAT DAH e g Datcon 02022 00 4 Setpoints 325 F to 32 F F Disable Custom No table built Disable Disable apply ox Cancel TOUGH Series Manual 2015 DynaGen Technologies Inc Settings 38 4 5 4 5 1 Timers The controller has an internal clock which is used not only to keep time but to ensure programed events happen at the correct times The following sections are used to configure
24. age of rated current where if any phase is above this trigger load imbalance Load Imbalance Delay 1 600 seconds The length of time to allow an imbalance before triggering trip shutdown The load imbalance formula is given as For three phase maxtlla Isl la Icl lg Ic gt Rated Amps x Phase_Imbalance_Threshold For single phase 4 1 gt Rated Amps x Phase_Imbalance_Threshold Where lolas and le are the actual current measured by the controller Note Phase Imbalance is the same as load imbalance 4 6 3 4 Dummy Load The dummy load feature can be enabled to prevent wet stacking ame s Range Description Disabled 1 120 The amount of time to delay before applying the dummy load seconds Load On Disabled 1 500A The threshold below which the dummy load is applied There is a4s debounce time The bypass time must expire before the load is applied All phases must drop below this threshold to trigger dummy load Load Off Disabled 1 500A The threshold above which the dummy load is removed Dummy load is turned off if one phase rises above this threshold One of the switched outputs must also be set to dummy load The output is only turned on when the engine is running 4 7 Communications The controller has the ability to communicate with other systems over communication buses The following sections relate to settings associated with communications 4 7 1 CAN B
25. amples in the following pages for information After Cranking on specific mode functions Cooldown Func Select Fault Monitor Determines how the controller responds to the readings of the Output on Low auxiliary sensor Output on High Start on Low Refer to the examples in the following pages for more Start on High information on specific mode functions Trim Offset 50 0 50 0 units Calibrate a sensor by using the offset to correct errors Mode Settings gt Bypass Time 0 90 seconds The amount of time to ignore the sensor input after the selected active mode is entered Once triggered the bypass time does not apply again until the device resets for example transitioning from RUN to the OFF or AUTO state or on power up Mode Settings gt Active Time 1 600 minutes The amount of time to turn on the auxiliary switched output or engine before turning off Mode Settings gt Start Level Sensor Table The level at which the auxiliary switched output or engine Dependent turns on Mode Settings gt Stop Level Sensor Table The level at which the auxiliary switched output or engine Dependent turns off Setpoints gt Low Warning Sensor Table Reading at which a warning occurs Dependent Setpoints gt Low Failure Sensor Table Reading at which a failure occurs Dependent Setpoints gt High Warning Sensor Table Reading at which a warning occurs Dependent Setpoints gt High Failure Sensor Table Reading at which a failure occurs
26. and Battery connections on the controller should be run directly to the positive and negative terminals on the battery to prevent voltage drops from negatively impacting the controller 3 Limit the wire length to 20ft 6 1m to any I O on the controller e g Switched Input Switched Outputs AC Sensing and Analog Inputs 4 It is good practice to run the AC voltage sensing wiring to the controller in a separate conduit from the AC current sensing wiring If the AC voltage is especially noisy e g variable frequency drives then they MUST be run separately The following enclosure guidelines should be followed 1 It is recommended to use vibration mounts 2 For outdoor applications it is recommended to use a sealed enclosure For noisy environments some guidelines are 1 Replace speed sensing wire with twisted pair from sensor genset to controller 2 If sensor readings are or may be affected consider using isolated sensors i e two terminal and use twisted pair wiring to connect from engine to controller 2 2 Terminal Descriptions Main Connector J4 Terminal Name Description Provides power to the controller from the battery Provides power to the controller from the battery Provides ground return for the controller Provides ground return for the controller Configurable to detect Battery Ground or Open Configurable to detect Battery Ground or Open Configurable to detect Battery Ground or Open Outputs Battery
27. and VDO 250F can only be used if the Close Failure Signal Source is set to Port A C or D Open Failure If using a switch it must close to ground It can be normally open or normally closed Open means open circuit A custom table can also be created using the RapidCore Configuration Software custom sender will be replaced with the custom text you choose Trim Offset 50 0 50 0 F 10 Calibrate a sensor by using the offset to correct errors 10 C Setpoints gt Bypass Time 0 90 seconds Amount of time to bypass warnings and failures after engine has started Setpoints gt Low Warning 32 200 F 0 93 3 C Reading at which a warning occurs Setpoints gt High Warning 50 300 F 10 Reading at which a warning occurs 148 90C Setpoints gt High Failure 50 300 F 10 Reading at which a failure occurs 148 9 C Note All temperature settings are entered in terms of Fahrenheit 4 4 2 Oil Pressure Use the following settings configurations to allow the controller to read and interpret data from the oil pressure sensor Name Range Description Signal Source Sensor Port X The source from which the sensor data is attained J1939 Bus Sensor Type Sensor Table X Select one of the pre configured sensor tables or one of the Close Warning switch functions A custom table can also be created using Open Warning the RapidCore Configuration Software Close Failure Close Ground Open Failure
28. associated with AC monitoring 4 6 1 Generator Voltage The following settings are used to configure the controller s response to voltage measurements Description Voltage Source Disable The wiring configuration of the generator Selecting Auto 2 Wire Single Selection will use the Voltage Select inputs to determine 3 Wire Single which wiring configuration is implemented and displayed 3 Wire 3 Phase 4 Wire 3 Phase 4 Wire Delta Auto Selection Scaling Factor 0 500 2 500 Scaling factor at which the voltage is read into the controller See below for more information Nominal Volts 50 800 VAC Voltage at which the generators run when operating under normal running conditions Auto Nominal gt 1 Phase 3 Wire 50 800 VAC Nominal Volts when using the Voltage Select inputs Auto Nominal gt 3 Phase 1 50 800 VAC k i Auto Nominal gt 3 Phase 2 50 800 VAC AN NOTE 800 VAC applies to software logic only Do not exceed 600 VAC on the AC Voltage terminals Scaling Factor when using the Voltage Select inputs Auto Ratios gt 3 Phase 2 Auto Ratios gt 3 Phase 3 A B Phase This determines which phases the voltage is read from V Seipoints gt High Waming Application Note Scaling Factor The scaling factor setting can be used to calibrate the AC voltage if there are discrepancies between the reading and the actual value It can also be used if transformers are used to step up down the voltage The scalin
29. d to function in 3 different ways while the engine is running The table below describes each of these functions Function Description Cooldown This function causes the controller to go into cooldown Pressing the OFF button again will cause the engine to shut down Shutdown This function bypasses Cooldown and causes the engine to shut down Force Cooldown This function causes the controller to activate the cooldown process Pressing the OFF button will have no affect as the controller is forcing the engine to perform a full cool down A WARNING If the controller receives a command to start while in Cooldown it will leave the Cooldown mode and go back to Running mode TOUGH Series Manual 2015 DynaGen Technologies Inc Settings 40 4 5 2 Exerciser The Exerciser function is used start and run the engine periodically This is commonly used to ensure issues with the engine do not arise from sitting idle for too long The following settings configure the Exerciser function Name s Range Description Enable Enable Disable Determines if the engine is automatically exercised periodically Delays gt Pre Alarm 1 20 minutes Amount of time to display a warning before starting the engine When configuring the Start Date and Hour a future time must be selected to run the initial exerciser sequence After the initial sequence the exerciser runs at an interval determined by Repeat Days Exerciser Se
30. display is the primary source of information from the controller It allows you to view change settings and monitor the status of sensors and other engine peripherals TOUGH Series Manual 2015 DynaGen Technologies Inc Using the Controller 18 LCD Display RUNNING Using the Menu System Task Description Entering Menu When in the OFF mode press the enter button to bring up the menu Navigating Menu Once in the menu use the up and down arrows to navigate Pressing enter will move you into that menu Change a Setting Scroll to the desired value and press enter to select A check mark should appear beside that item Press enter again to save the setting and return to the previous screen Scroll Parameters When in Auto or Running mode pressing the up and down arrows will scroll through the parameter pages Lock Screen When in Auto or Running mode the screen can be locked to a certain parameter page by pressing enter and unlocked by pressing enter again Events History Once in the menu select Events History to view the most recent controller event Use the up and down arrows to navigate to other events The controller can store up to 150 events If more than 150 events occur the oldest event is deleted to make room for the next event ois Panel Items item Name Description Off Button Used for turning off the engine or exiting out of Auto mode This is not intended to function as an Emergency Stop as there are conditi
31. ely 10 minutes run time the temperature rises above the 325 F start threshold and the fan turns on The fan continues to run as the temperature declines When the temperature falls below the 200 F stop threshold the fan turns off TOUGH Series Manual O 2015 DynaGen Technologies Inc Settings 37 4 4 7 Custom Sensor Tables Custom Sensor Tables are created using the RapidCore Configuration Software when using a sensor that is not supported by DYNAGEN The configurator has the ability to create these custom tables allowing the controller to properly read the sensor data A NOTE Custom sender tables can only be created when using the configuration software Parameter Description The label that will be displayed in the controller Engine Temp Oil Pressure etc Choose resistance voltage or current based on the sensor type Use the Terminal Descriptions section to determine if your sensor is compatible with a sensor port Input Type Choose temperature pressure voltage current or percentage based on the sensor Unit Type This defines what unit of measurement will be displayed on the front panel F psi V A The following example outlines the steps for creating a custom sensor table Navigate to the sensor input that will be using your custom sensor table Select a Name Input Type and Unit Type for the controller Definitions in table above OahkWN Click the check box next to Build Table Im
32. essing and holding the AUTO button will display the screen to the right If a Display Adjust Parameter is set it will also be displayed underneath the Engine Speed While still holding the AUTO key press the up or down arrows to adjust the RPM The Engine Speed display should update as the engine physically changes its speed to accommodate the speed request A NOTE When using switched outputs for speed control the Set RPM will display instead of the set speed TOUGH Series Manual 2015 DynaGen Technologies Inc Settings 32 44 5 Battery Level Use the following settings configurations to allow the controller to read and interpret the battery voltage level ame Range Description Battery Recharge Enable Disable Enables or disables the ability to have the engine start on low battery voltage in order to charge it Recharge Setup gt Level 6 0 30 0V Voltage level at which the controller starts the engine to recharge the battery Recharge Setup gt Pre Alarm 1 30 minutes Amount of time to display a warning before starting the engine Crank Low Batt 6 0 24 0V Screen displays a Low Voltage During Cranking warning if voltage dips below this level during cranking A NOTE When the engine is running the battery voltage will equal the alternator charging voltage The actual open circuit battery voltage may be lower than displayed Battery Recharge Sequence Monitor Voltage Recharge Required Start
33. g factor applies to all phases in a system Example The voltage source is a 3 Wire 3 Phase system with a nominal voltage of 208 VAC The controller is reading 206 3 VAC but a calibrated multimeter gives 208 3 VAC Use the formula below to determine the scaling factor 1 Scaling Factor Multimeter Reading Controller Reading 2 Scaling Factor 208 4 VAC 206 3 VAC 3 Scaling Factor 1 010 TOUGH Series Manual 2015 DynaGen Technologies Inc Settings 43 4 6 2 Generator Frequency The following settings are used to configure the controller s responses to frequency measurements Description Frequency Source Nominal 50Hz This is the wiring configuration of the generator Selecting Nominal 60Hz Auto Selection will use the Frequency Select input to Auto Selection determine which frequency is used 4 6 3 Generator Current The following settings are used to configure the controller response to current measurements Name Range Description Enable Disable Enables or disables current metering 5 5000A 5A The turns ratio of the current transformers See below for more information Rated Amps when using the Voltage Select inputs Scaling Factor when using the Voltage Select inputs Setpoints gt Rated Amps 5 5000A Maximum current draw the generator can provide when operating under normal running conditions Setpoints gt High Warning 1 125 Disable See Basic Alarms Setpoints gt High Failure 1 125
34. ging these trigger modes is to allow the user to wire a single push button to be used for both starting and stopping the engine Holding the button for too long will cause the engine to shut down immediately after starting and vice versa TOUGH Series Manual 2015 DynaGen Technologies Inc Settings 26 4 2 5 Idle Inhibit Use this feature to prevent start up while in Idle mode Name Range Description Start Stop Switched Enable Disable Prevent the remote start switch input from starting the engine when the Input Inhibit idle switch is active Aux 1 2 3 4 Sensor Enable Disable Prevent Auxiliary 1 2 3 and 4 sensors autostart feature from starting the Autostart Inhibit engine when the idle switch is active If the engine is in the IDLE mode because of the automatic idle feature the remote start start stop and auxiliary sensors autostart can still start the engine 4 3 Switched Outputs The controller has switched outputs that are turned on under certain conditions to perform a function The outputs turn on to Battery voltage to drive the load when active The following items are the available functions for switched outputs WARNING Switched outputs have a floating voltage of approximately 8V when off If using the outputs for digital logic it will be necessary to put a pull down resistor 1k11 from the output to ground to ensure a low logic level when output is off Event Functions Name Active Mode Descripti
35. he engine will start to provide power to the load All the appropriate settings in regards to Auto Mains Failure must be set properly When a certain command is sent to the controller over Modbus the engine will start See the Modbus Reference Manual for more information Start stop command send over the J1939 CANbus For example from the TR100 or a remote telemetry device A WARNING See the Using Cooldown Mode section for more information on how it affects starting and stopping TOUGH Series Manual 2015 DynaGen Technologies Inc Using the Controller 20 3 2 Using Cooldown Mode When the controller is configured to have a cooldown period See Engine Logic section for the engine there is some special functionality that must be considered The cooldown period is special in that during this time it will accept a Start Command This means if the engine is cooling down and a start command is received the controller will be placed back into a running mode and will not shut down Example The following is an example of how the cooldown functionality works Remote Start contacts close Engine starts and is in the running mode Remote Start contacts open Engine starts cooldown period User presses RUN button on the front panel Engine moves back into running mode and does not shut down Engine can now only be shut down by using the OFF button or Emergency Stop input NOORWN Remote Start Operator Presses Con
36. in place Hold Coil 1 Hold Coil Fuel is energized 2 Pull Coil is energized for 2 seconds before cranking 3 Repeat if engine cranking failed Configuring a switched output to Pull Coil automatically configures the engine logic necessary for a Pull Coil system Pull Coil Wiring Example Pull Coil Output Fuel Solenoid TOUGH Series Manual 2015 DynaGen Technologies Inc Settings 29 44 Sensors The controller has sensor ports which can be connected to a variety of different sensor types Temperature Pressure Level etc See the Terminal Descriptions section for more information regarding terminal sensor compatibility Low Ohm High Ohm 0 5V or 4 20mA Most sensors are used to monitor for warnings and failures but the Auxiliary sensors can be used to perform special functions Example Starting engine on low temperature 4 4 1 Engine Temperature Use the following settings configurations to allow the controller to read and interpret data from the engine temperature sensor Name Range Description Signal Source Sensor Port X The source from which the sensor data is attained J1939 Bus Sensor Type DAT DAH DAT DAH supports all Datcon type DAH high range VDO 250F temperature sensors custom sender VDO 250F supports the VDO 323 420 or equivalent Close Warning temperature sensor Open Warning Note DAT DAH
37. inst moisture e Custom senders configurable with DYNAGEN Configurator Displays Engine Temperature e Engine Speed e Real Time Clock e J1939 DTCs Custom Text e Oil Pressure e AC Metering Engine Hours e Custom Senders e Fuel Level e Battery Voltage e Time to Maintenance e Warnings and Failures Feature Included DPF DEF Ready J1939 CAN Bus Isolated RS485 Modbus Magnetic Pickup Input 150 Event Log Clock Exerciser Generator Voltage Metering Generator Current Metering with IDMT and Load Imbalance features Configurable Switched Inputs Resistive Sensors 1 High 11 1 Low 1 Universal Sensor Resistive 0 5V 4 20mA 5V Sensor Output for Electronic Sensors Configurable Switched Outputs TOUGH Series Manual 2015 DynaGen Technologies Inc Introduction 4 1 1 Specifications The TOUGH Series controllers were rigorously tested to ensure durability reliability and functionality The following specifications are a brief summary of the standards to which the controller has been tested For complete details on the testing performed please contact DYNAGEN Testing Specifications Specification Rating Electric Static Discharge SAE1113 13 cAi US UL 6200 recognized component Consult factory for UL conditions of acceptability Physical Specifications Specification Rating Operating Temperature 40 to 158 F 40 to 70 C LCD Viewing Temperature 4 to 158 F 20 to 70 C Optional al avai
38. l source connections to the speed sensing terminals are not required TOUGH Series Manual O 2015 DynaGen Technologies Inc Settings 31 4 4 4 1 Front Panel Speed Control The operator is able to adjust the speed of the engine by using the controller s front panel This section describes the two methods available for implementing speed control the settings and parameters to be used as well as the necessary instructions allowing the operator to control the speed S peed Control Methods Setting ss Description sti lt OW J1939 TSC1 Speed Command The controller can instruct the ECM of an electronic engine to adjust its speed by broadcasting the TSC1 command Switched Outputs The controller can instruct the ECM of an electronic engine to adjust its speed by using switched outputs on the controller set to RPM Increment and RPM Decrement to interface with digital inputs on the ECM When the speed is changed the corresponding switched output will be on for 1 second each time increment or decrement is pressed WARNING Switched outputs have a floating voltage of approximately 8V when off If using the outputs for digital logic it will be necessary to put a pull down resistor 1kOhm 1 Watt from the output to ground to ensure a low logic level when output is off Speed Control Settings Name Range Description Speed Control Enable Enable Disable Enables or disables front panel speed control RPM Di
39. lable call factory Weight 0 83lb 0 38kg Weight w RelayPak 1 32lb 0 60kg Dimensions no gasket 4 17 x 6 50 x 1 38 10 59cm x 16 51cm x 3 51cm no gasket and relay pack 4 41 x 6 79 x 1 38 10 59cm x 16 51cm x 8 46cm with gasket and relay pack 4 41 x 6 79 x 3 33 11 20cm x 17 25cm x 8 46cm Electrical Specifications Specification Rating 38mA 24V Low Resistance Sensors 0 7500hm High Resistance Sensors 0 7 5000hm Magnetic Pickup 10 10 000Hz at 1 50 VAC AC Voltage Line To Line 50 600 VAC True RMS Accuracy 2 Full Scale Do not connect more than 600VAC to the controller Damage may result AC Current TG410 only 0 5A Current Transformer Accuracy 1 Full Scale Communications SAE J1939 Tier Il 111 IV Isolated RS485 Slave Modbus RTU 2 Installation Generator systems contain high voltage circuitry and precautions to protect against electrical shock should be taken Failing to power down and lock out equipment can cause damage injury or death A WARNING Wiring of this controller should be performed by qualified electricians only The following general electrical safety precaution should be followed e Do a thorough inspection of the area before performing any maintenance e Keep fluids away from electrical equipment TOUGH Series Manual 2015 DynaGen Technologies Inc Installation 5 e Unplug connectors by pulling on the plug and not the cord e Use fuses where a
40. mination Cable Selection Distance Power and Ground Each end of the bus must be terminated from A to B with 1200hm resistors If the controller is a device that is not at the end of the bus it does not require a terminating resistor RS485 twisted pair 1200hm cables are required for communications It is recommended that the sheild drain wire if using a shielded cable NOT be used for the RS485 common If the cable doesn t have a spare wire run a separate wire at least 24AWG Examples 1 Belden 9841 One twisted pair 24AWG A separate wire must be run for RS485 common 2 Belden 7895A Two twisted pair 20AWG second pair can be used for the RS485 common or remote device power If powering a remote device need to run a seperate wire for modbus common If running power and ground from the battery of your system to a remote device use the following guidelines for the gauge of the power and ground wires 1 Up to 450ft 137 2m 22AWG 2 Up to 700ft 213 4m 20AWG 3 Up to 1125ft 342 9m 18AWG 4 Up to 1800ft 548 6m 16AWG 5 Up to 2800ft 853 4m 14AWG Communications Wiring To Controllers RS485 Connections COMMON o A o B TOUGH Series Manual O 2015 DynaGen Technologies Inc Installation 16 2 6 6 Current Transformers When wiring current transformers into the system you must follow these considerations 1 The current transformer of each phase must be facing the same direction See bel
41. nector A Fei ccot ss omen pare rer rsasa a1 Gen Cure Relay A Coll Switch Output A 132 Switch input pcan Hion vs4 crcommon Relay A Contact_ Switch Output C 33 3 Switch Output 0 J65 CANtow A c S iagram wi a Your application and wiring may vary Refer to full user manual for detailed information on using your controller www dynagen ca support TG410 Example w RP100 DWG1525R1 6 Typical Wiring D 2 5 Ed O 2015 DynaGen Technologies Inc TOUGH Series Manual Installation 12 2 6 Wiring Considerations The following sections are meant to describe certain wiring configurations for illustrative purposes only Not all applications are the same Please ensure you modify these examples to fit your unique system requirements 2 6 1 Remote Start Contact Start Stop As of Firmware version 1 60 the start stop is factory defaulted to switch input B changeable and the trigger factory defaulted to Close BAT For older firmware versions you must set Start Stop to Switched Input B or as desired and set the trigger mode to Close BAT The trigger can be set to any of four options but Close BAT gives the best immunity to noise For runs over 20ft 6 1m especially in noisy environments Dynagen recommends connecting the Start Stop to an external relay The relay needs to be located as close to the controller as possible Remote device Start Stop Switched Input 2 6 2
42. on Preheat Midheat Active during the Preheat Midheat and Postheat timers Postheat Warmup Timer Cranking Active when Low Battery During Cranking warning is displayed Auxiliary Settings Active dependent upon settings in the Auxiliary sensor section Dependent Fuel Crank Idle Mode Warmup Engine Running Exercising Battery Recharge Maintenance Required Low Battery During Auxiliary Sensor 1 Auxiliary Sensor 2 Auxiliary Settings Active dependent upon settings in the Auxiliary sensor section Dependent Auxiliary Sensor 3 Auxiliary Settings Active dependent upon settings in the Auxiliary sensor section Dependent Auxiliary Sensor 4 Auxiliary Settings Active dependent upon settings in the Auxiliary sensor section Dependent Auto Active when controller is in Auto mode and no warnings or failures are present Delay to Start Timer Active when the Delay to Start timer is active Battle Mode Active when Battle Mode switched input is active User Controlled When user triggers a Force Regeneration output is active for 20 seconds then switches off TOUGH Series Manual 2015 DynaGen Technologies Inc System Ready Delay to Start Battle Mode Force Regeneration Cooldown Cooldown Timer ee ee Settings 27 Name Active Mode Description Regeneration Inhibit User Controlled When user triggers a Regeneration Inhibit output is active for 20 seconds then switches off Any Failure
43. ons in which it will not shut down the engine See the OFF Button Function section for more information Auto Button Used for placing the controller into AUTO mode Once in AUTO mode the controller waits for a start command to be received Run Button Used to start the engine manually The Off button must be used to shut down the engine if it has been started using the front panel Up Button Used for moving around in the menu changing a setting s value or changing the currently displayed parameter page Enter Button Used for entering the menu system accepting settings or locking the LCD screen when viewing parameters Down Button Used for moving around in the menu changing a setting s value or changing the currently displayed parameter page Generator LED Green Engine running with no issues Amber Engine running with warnings Red Engine shut down on failure 3 1 Modes Starting and Stopping The following table describes the different operating modes of the controller Modes Mode State Description When in the OFF mode the engine cannot be remotely started When in the Auto mode the engine waits to receive a start command Running When engine is Running the controller monitors engine parameters and waits to receive a stop command Failure When a failure occurs the controller shuts down the engine and displays the reason for failure The unit must be reset using the front panel OFF button with the exception of Modbus
44. or failure NOTE If the switched input becomes inactive before the trigger delay time expires the warning or failure will not occur Example The user wants a pump to turn on 30 seconds after a high water level switch is tripped and remain on until the level switch turns off The level switch is connected to Switched Input C and closes to ground when the water level is too high The words Water Pumping are also required to be displayed on the controllers LCD screen The pump is connected to a slave relay which is controlled by Switched Output D on the controller Relevant Settings Setting Value Switched Input C gt Function Configurable Warning 1 Switched Input C gt Active Mode Global Switched Input C gt Trigger Close GND Configurable Warning 1 Custom Text Water Pumping Switched Output D gt Warnings Configurable Warning 1 4 2 4 Start Stop Momentary Function When a switched input is configured to Start Stop the trigger modes have different meanings than other inputs The following table describes the trigger mode functionality Trigger Description Close to Battery Input active when Battery is applied Close to Ground Input active when ground is applied Close to Battery Ground Input active when Battery or ground is applied for approximately 2 seconds then deactivated Open Input active when neither Battery or ground is applied for approximately 2 seconds then P deactivated The reason for chan
45. ow 2 The CT Common connection must be connected to the black wire on each current transformer 3 The wires from the current transformers to the controller should be as short as possible A NOTE If readings are unstable with the configuration shown below attempt connecting the CT Common s black wire to the negative terminal of the battery Ensure the connecting wire is as short as possible Load Side Current CT Common Black Phase X White Line Side Generator Max 600VAC CT COMMON TOUGH Series Manual 2015 DynaGen Technologies Inc Installation 17 2 6 7 RelayPak Optional The RelayPak is used to provide built in slave relays in a compact and easy to wire package This allows the low current outputs of the controller to switch on high current relays on the RelayPak Electrical Specifications Specification Rating 40A Momentary Per Relay 12V Standards cl US UL 6200 recognized component Consult factory for UL conditions of acceptability AN WARNING You must use relays in the RelayPak that are suitable for the system voltage Example 12V relays in a 12V system and 24V relays in a 24V system Relay C Coil Relay A Coil Relay B Coil Relay D Coil Coil Ground Relay B DC Load BAT Relay Pak RP100 Relay D Relay C Crank Relay Pak Connector Relay B 7 J a telay D Relay C Col aa 7 15 EJ 3 Using the Controller The LCD
46. points gt High Warning 1 125 Reading at which a warning occurs 44 4 Engine Speed Use the following settings configurations to allow the controller to read and interpret speed sensing data Name Range Description Signal Source J1939 Bus The source from which the sensor data is attained Mag Pickup Genset Voltage Speed Settings gt Rated RPM Speed at which the engine runs under normal operating conditions Warning and failure setpoints are calculated from this setting Speed Settings gt Idle RPM 300 2000 Speed at which the engine runs when it is idling Speed Settings gt Tooth Count a 60 Number of teeth on the flywheel Mag Pickup only Setpoints gt Low Warning 50 99 Reading at which a warning occurs Setpoints gt Low Failure 50 99 Reading at which a failure occurs Setpoints gt High Warning 101 150 Reading at which a warning occurs Setpoints gt High Failure 101 150 Reading at which a failure occurs Front Panel Speed Control Settings N A See Front Panel Speed Control section for more information on these settings RPM Switch gt Secondary RPM 500 4000 The Rated RPM when the Secondary RPM 50Hz is selected 50Hz See RPM Frequency Select section for more information RPM Switch gt Primary RPM 60Hz 500 4000 The Rated RPM when the Primary RPM 60Hz is selected See RPM Frequency Select section for more information AN NOTE When using J1939 or Genset Signal as a signa
47. ppropriate e Ensure all equipment is properly grounded e Provide support to wires to prevent stress on terminals To ensure proper and safe operation caution must be taken at the installation site to make sure it is free from excessive moisture fluctuating temperature dust and corrosive materials Choose a mounting surface with the least amount of vibration and not more than 0 125 3 175mm thick 1 Choose a suitable mounting location based on the criteria above 2 Create a rectangular cutout in the panel that is minimum 3 9 99mm high and 6 2 158mm wide 3 Place the controller into the panel cutout so that the LCD screen and buttons are facing out 4 Place the mounting clips into the designated slots on the top and bottom of the controller 5 Tighten the screws on the clips until the controller is snug against the panel Do not overtighten the bottom of the screws should angle very slightly away from the controller 6 If applicable snap the RelayPak RP100 to the back of the controller Place one side of the RP100 s tabs into the slot on the back of the controller and without pushing on the relays snap the other tab into place 6 200 3 900 Dimensions are in inches Not to scale TOUGH Series Manual 2015 DynaGen Technologies Inc Installation 2 1 General Wiring Notes The following wiring guidelines should be followed 1 Use a minimum of 18AWG wire for all connections 2 Battery
48. quence Delay for Repeat Days Time Start Pre Alarm Timer Start Engine for Exercise Time TOUGH Series Manual O 2015 DynaGen Technologies Inc Settings 41 4 5 3 Maintenance The controller has the ability to count down the time between scheduled maintenance events Once maintenance is required the controller will alert the operator via the LCD screen and a switched output if enabled wired to a lamp horn buzzer The following settings are used to configure the maintenance timer ame a Range Description Reset Counter Enable Disable Once the maintenance count interval expires use this setting to reset the time and turn off the switched output if enabled Enable Counter Enable Disable Determines the number of hours between required maintenance A switched output can be configured to turn on once the count interval expires Counter Interval 10 9990 hours Enables or disables the maintenance function To determine the amount of time until the next scheduled maintenance follow these menu steps Main Menu gt Device Info gt Maintenance Maintenance counter is disabled if is displayed A negative number indicates the amount of time since maintenance timer expired TOUGH Series Manual 2015 DynaGen Technologies Inc Settings 42 4 6 AC Monitor The controller has the ability to monitor AC voltage and current from a generator The following sections are used to configure settings
49. reaker This is a latching feature The operator must press the a and Y keys to reset the feature Shutdown Trip shuts down the engine TDS Time Dial Setting 0 1 30 Sets the slope of the IDMT curve This controls the sensitivity of the trip to over current Reset Time 1 600 seconds How long the current must drop and stay below the rated current to reset the IDMT The equation for the IDMT is given as TDS 13 5 tm 7 E Where TDS is the time dial setting above is the Rated Current A l is the actual current measured by the controller A t is the trip time in seconds For example with a Rated Current of 100A and a TDS of 0 1 the IDMT will trigger in 0 15s if the actual generator current is 1000A 1 35s if the actual generator current is 200A 6 75s if the actual generator current is 120A 4 6 3 3 Load Imbalance Load imbalance provides protection against differences in phase currents Description Load Imbalance Mode Disable Disable Disables the Load Imbalance feature Breaker Trip Shutdown Trip Breaker Trip If Load Imbalance is active the Breaker Trip switched output is activated to switch off the main generator breaker This is a latching feature The operator must press the a and a7 keys to reset the latch Shutdown Trip shuts down the engine TOUGH Series Manual 2015 DynaGen Technologies Inc Settings 45 Name Range Description Load Imbalance 1 200 The percent
50. scription List See Below The function that the switched input performs when active Active Modes List See Below Determines the operating conditions under which the switched input can be active Multiple selections are allowed List See Below The state of the input determining if it is active or inactive Functions Name Active Mode Description Disabled Input is disabled and has no function Start Stop Auto Running Starts the engine when active stops the engine when deactivated It is recommended to set the Trigger mode to Close BAT for better noise tolerance WARNING The Triggers are different from the regular triggers for this function See the Start Stop Momentary Function section for more information Emergency Stop Global Shuts down the engine when active and displays Emergency Stop Idle Mode Running Controller ignores under speed voltage and frequency warnings and failures when active If using J1939 the controller will broadcast TSC1 as the Idle Speed parameter found in the Engine Speed section Voltage Select 1 Auto Used for changing the systems voltage configuration See Voltage Select for more information Voltage Select 2 Auto Used for changing the systems voltage configuration See Voltage Select for more information Stops the engine when momentarily active Approximately 2 seconds Configurable Failure 1 Configurable Controller displays a warning with configurable text and shuts down engine when ac
51. splay Nothing Blank Parameter to display when adjusting speed from front panel AC Frequency This is used to provide operator feedback in cases where the Auxiliary Sensor 1 engine RPM affects another parameter such as AC Auxiliary Sensor 2 dead or an Auxiliary Sensor Example Flow rate of pump RPM Control gt Limit Method Speed Bias This regulates the minimum maximum speeds within which Min RPM Max RPM the operator may make adjustments RPM Control gt Speed Bias The minimum maximum RPM the engine speed may be adjusted based on the Rated RPM Example Rated RPM is 1800 and Speed Bias is 150 The minimum RPM will be 1650 and maximum RPM will be 1950 Only valid when the correct limit method is chosen RPM Control gt Minimum RPM 500 4000 The minimum RPM that can be set using speed control Only valid when the correct Limit Method is chosen RPM Control gt Maximum RPM 500 4000 The maximum RPM that can be set using speed control Only valid when the correct Limit Method is chosen Speed Control Instructions When the controller is running and there are other functions occurring the controller will scroll through its display parameters as usual When the speed control page is displayed it will show the Engine Speed as well as the following instructions Hold AUTO Up Down to Adjust RPM MANUAL RUM MAMUAL RUM 1500 Hold AUTO fa to Adjust RPH Speed Control Parameter Page Speed Control Adjust T Pr
52. t 6 1m it is recommended to use BATTERY as the trigger method TOUGH Series Manual O 2015 DynaGen Technologies Inc Settings 24 4 2 1 Voltage Select The controller has the ability to automatically change its AC voltage display mode and its associated warnings and failures through use of switched inputs The AC Metering gt Generator Voltage gt Voltage Configuration setting must be set to Auto Selection When using voltage select the controller will continue to monitor the inputs for 10 seconds after crank success Once that time expires the controller will then display the selected voltage configuration The table below shows the correspondence between the switched inputs status and the voltage configuration Volt Select 1 Input Volt Select 2 Input Voltage Configuration Inactive 3 Wire Single Phase A NOTE Both Voltage Select 1 and Voltage Select 2 must be assigned to switched inputs for the feature to function properly The following settings are affected by the Voltage Select Inputs 1 AC Monitor gt Generator Voltage gt Auto Nominal 2 AC Monitor gt Generator Voltage gt Auto Scaling Factor 3 AC Monitor gt Generator Current gt Auto Rated Amps 4 AC Monitor gt Generator Current gt Auto Scaling Factor 4 2 2 RPM Frequency Select The controller has the ability to change between Primary RPM 60Hz and Secondary RPM 50Hz through the use of a switched input The AC Metering gt Generator
53. t This timer immediately expires upon successful cranking Midheat Time 0 90 seconds Keeps Glowplug output turned on while cranking but not during crank rest Output will turn off upon crank failure crank success or midheat time expiration Crank Rest Time 1 90 seconds Amount of time to delay between each attempt to start the engine Crank Attempts 1 20 Number of attempts to start the engine before going to an overcrank failure Fuel Crank Rest Fuel ON Determines if the fuel output stays on during the crank rest Fuel OFF time RPM Disconnect 100 2000 rpm Speed at which controller determines the engine has started successfully and turns off the Crank output Postheat Time 0 90 seconds Amount of time the Glowplug output remains on after crank success and the engine is running Restart on False Start Enable Disable Only applies to remote start Determines if the controller will monitor for false starts and attempt a restart Controller will only attempt restarting the engine as many times as determined by Crank Attempts False Restart Detect Time 5 30 seconds Only applies to remote start Amount of time after successful cranking to monitor for a false restart If this time expires and the engines stalls out the controller will not attempt a restart Auto Idle Enable Disable Determines if the controller will automatically enter Idle Mode during the Warmup and Cooldown delays Warmup Time 0 600 seconds After successful
54. tacts Close RUN Button Engine Starts Controllers leaves Running Mode Cooldown Mode Remote Start Contacts Open Engine Running Cooldown Timer Starts 3 3 Failures Failures are conditions that cause the controller to shutdown to prevent damage to the engine or generator These get enabled disabled when you enable disable various settings in the controller ETA failures are given in the below table Failure Name Name Enabled Condition s Description ECM Communication Enabled if loss of ECM communication is If the controller has not received messages from Failure enabled See CAN Bus J1939 the ECM for 6s Failure To Stop Disabled when ETS On Duration is set to 0 After ETS countdown is finished if the speed was seconds Otherwise it is enabled ETS should be greater than 50RPM for the previous 2s then the set to at least 2 to 3s otherwise this failure may controller triggers this failure not occur Load Imbalance See Load Imbalance Generator load imbalance Excessive AC current on one or more of the three phases 4 Settings The following section relates to settings that can be changed to alter the way the controller performs its functions Read and review these sections carefully to ensure your settings are set correctly for your engine TOUGH Series Manual O 2015 DynaGen Technologies Inc Settings 21 4 1 Operator Setup The following settings are used to change the way the user interacts with the
55. tive Configurable Failure 2 Configurable Controller displays a warning with configurable text and shuts down engine when active Configurable Failure 3 Configurable Controller displays a warning with configurable text and shuts down engine when active Air Pressure Failure Cranking Controller displays Air Pressure Failure and shuts down engine when active Hydraulic Pressure Cranking Controller displays Hydraulic Pressure Failure and shuts down engine Failure when active Low Oil Pressure Running Controller displays Oil Pressure Warning when active Warning Low Coolant Level Global Controller displays Coolant Level Failure and shuts down engine when Failure active High Fuel Warning Global Controller displays High Fuel Level warning when active Lamp Test Global Controller performs lamp test when active Fuel In Basin Global Controller displays Fuel In Basin warning when active Battle Mode Running Controller ignores all warnings and failures when active If a failure occurs during Battle Mode it is latched and the engine will shutdown on failure when the controller leaves Battle Mode Start Inhibit Auto Controller ignores all start commands and the engine cannot start when active Once Start Inhibit becomes inactive starting is enabled again If the engine is running activating this input will shut down the engine TOUGH Series Manual 2015 DynaGen Technologies Inc Settings 23 Name
56. twisted pair cable is recommended Cable Selection Examples are 1 Belden 9841 One twisted pair 24AWG 2 Belden 7895A Two twisted pair 20AWG second pair can be used for power Shieldin If using a shielded cable the shield must be connected to ground on one end of the bus only 9 This prevents loss of data from electromagnetic interference Communications Wiring To Controller s J1939 Connections SHIELD ion EE H For the ECM to function it must first receive power for a short time before cranking to allow it to boot up It is common practice to connect the fuel relay output to a slave relay to trigger the key input of the ECM There are two ways to configure this e The fuel relay is on during Preheat therefore increasing the Preheat time in the Engine Logic menu will allow longer time for the ECM to boot up before cranking or e Turning on the Auto Power ECM setting in the Communications gt CAN Bus J1939 menu enables the fuel relay to be on when controller is in Auto mode This way the ECM will be always be on except when the controller is in the OFF mode ECM Wiring Slave Relay Fuel Output Key Input Oo Engine Control Module TOUGH Series Manual O 2015 DynaGen Technologies Inc Installation 15 2 6 5 Modbus Wiring The following table outlines some items that must be taken into consideration when connecting up a Modbus system Consideration Description Bus Ter
57. us J1939 For detailed information about J1939 settings and functions please use the J1939 Reference Manual The manual can be found at www dynagen com support Name Range Description ECM Model Generic J1939 Choose one of the compatible ECM modules from the list John Deere JDEC Volvo EMS This is not a complete list See the J1939 User Manual for the full list ECM Communication Failure Enable Disable If no CAN messages are received for more than 6 seconds the controller shuts down the engine TOUGH Series Manual 2015 DynaGen Technologies Inc Settings 46 Name Range Description DTC Display Enable Disable Enables or disables active fault messages DM1 monitoring Active DTC Log Enable Disable Enables or disables the storing of active faults DM1 Read Stored DTC Enable Disable Enables or disables the ability to request stored fault codes from the ECM DM2 Auto Power ECM Enable Disable When enabled the fuel relay is enabled in Auto mode so that the ECM is already booted up and initialized before the user decides to start the engine ECM Power Delay 5 30 seconds Used in conjunction with Auto Power ECM When the engine shuts down the controller waits for the time specified by the ECM Power Delay before turning on the fuel relay This prevents unwanted start ups due to the engine not being completely shut down Cummins PGNs Enable Disable Enables or disables the broadcasting of PGNs required b
58. using AC voltage terminals for speed sensing J6 10 RS485 Common Common line for Modbus RS485 Generator AC Voltage J7 Terminal Name Description Generator AC Current J5 Terminal Name Description J5 1 Connect to current transformer for Phase A of the generator J5 2 Connect to current transformer for Phase B of the generator J5 3 Connect to current transformer for Phase C of the generator J5 4 Connect to the commons of the current transformers TOUGH Series Manual 2015 DynaGen Technologies Inc Installation 2 3 Wiring Harnesses DWG1478 TG350 Mag Pickup and J1939 Harness DWG1522 TG410 Mag Pickup and Comm Harness Terminal Color Wire Text Description Terminal Color Wire Text Description 6 4 Not Populated RS485A Modbus A J6 2 Not Populated 362 Bue _Rs485 B Modbus B Not Populated E Not Populated J6 4 White CAN HIGH CAN 31939 High CANHIGH CAN J1939 High 16 5 White CANLOW CAN J1939 Low CAN LOW CAN J1939 Low CAN GND _ CAN J1939 Shield PEED INPUT Speed Input SPEED REF Speed Reference 16 9 Not Populated Not Populated Not Populated RS485 GND_ RS485 Common DWG1475 With RelayPak Terminal Color Ja1 Red Batt Pos Battery Positive J41 Red J4 2 Not Populated J4 2 Not Populated 43 Blak BATTNEG RelayPak Coil J44 Not Populated SWINA Switched Input A J4 5 Tan S
59. voltage when active Max Current 1A Outputs Battery voltage when active Max Current 1A Outputs Battery voltage when active Max Current 1A Provides ground return for 2 wire isolated sensors High impedance sensor input 0 7 5000hm Low impedance sensor input 0 7500hm Sensor Input C Universal sensor input 0 7500hm 0 7 5000hm 0 5 VDC 4 20mA See Universal Sensor section for more information x J3 Terminal Name Description Switched Input D Configurable to detect Battery Ground or Open Provides 5 VDC for electronics sensors TOUGH Series Manual 2015 DynaGen Technologies Inc Installation 7 Terminal Name Description Provides ground return for 2 wire sensors J3 8 Sensor Input D Universal sensor input 0 7500hm 0 7 500Ohm 0 5 VDC 4 20mA See Universal Sensor section for more information TOUGH Series Manual 2015 DynaGen Technologies Inc Installation 8 Communications Connector J6 Terminal Name Description Communications line for Modbus RS485 CAN H Communications line for CAN Bus J1939 CAN Shield Connect the shield of the twisted pair cable to this terminal J6 7 Speed Sensing A Connect to a magnetic pickup tachometer or a flywheel alternator Not polarity sensitive and not required if using AC voltage terminals for speed sensing J6 8 Speed Sensing B Connect to a magnetic pickup tachometer or a flywheel alternator Not polarity sensitive and not required if
60. voltage will equal the alternator charging voltage Having this disabled will force the engine to run for the entire duration of the active time 20 15 1 lt i Battery Level 19 N N Voltage Start Level Engine Run j 5 o o 20 40 60 80 100 120 140 Time Minutes The chart above shows the connection between a battery bank and time At approximately 80 minutes time the voltage falls below the 10 5V start threshold causing the engine to start The engine runs for the 40 minutes active time regardless of the voltage reading and then shuts down TOUGH Series Manual O 2015 DynaGen Technologies Inc Settings 36 4 4 6 3 Output on Low High Example In this example a sensor is monitoring the temperature of an engine If the temperature rises above 325 F a fan will turn on to cool the engine Once the temperature drops to below 200 F the fan will turn off Relevant Settings Auxiliary Sensor Setting Value 1 Active time is disabled because the fan needs to stay on indefinitely or until 200 F is reached Relevant Settings Switched Outputs Setting Value Switched Output X Auxiliary Sensor X Choose based on which Auxiliary Sensor is being used 350 7 Start Level 300 250 Stop Level Temperature Fahrenheit 150 100 50 o o 5 10 15 20 25 30 Time Minutes The chart above shows the connection between engine temperature and time At approximat
61. y Cummins engines SPN Conversion Version 1 Select the SPN conversion method Version 2 Version 3 EMS2B Frequency Select Primary For Volvo EMS2B Engine Control Modules only Secondary EMS2B Accelerator Pedal 40 0 60 0 For Volvo EMS2B Engine Control Modules only TOUGH Series Manual 2015 DynaGen Technologies Inc Settings 47 4 7 2 MOD Bus RS485 The Modbus functionality on the controller provides interface ability to PLCs SCADA and building management systems For detailed information about the Modbus registers and their interpretations please use the Modbus Reference Manual The manual can be found at www dynagen com support Name Description Range Values Device Address The device address of the controller 1 247 Baud Rate BPS The speed at which the controller slave 9600 19200 38400 57400 communicates with the master i PEE The controller always communicates in F Communication Protocol Modbus RTU Modbus RTU Fixed Slave Master Configuration The controller is always the slave and must Slave Fixed be queried by the master 5 Troubleshooting If you are having issues with your controller please refer to the table below for a solution before contacting technical support Issue Solution Engine starts but the crank output The controller is not receiving a speed signal does not turn off 1 Verify the Sensors gt Engine Speed gt Signal Source setting is set correctly 2 Verify the

Download Pdf Manuals

Related Search

Related Contents

PaseoBebe.com  Kensington EU64325 Mouse User Manual  Samsung GT-S5363 Kasutusjuhend  Sears Thermometer 50455 User's Manual  TA7011 and TA7012 User`s Manual    Manual de instruções Circulador de imersão MPC, pt  MANUAL DEL USUARIO  Samsung MG23J5133AM Manual de Usuario  User Manual - INLIS - Integrated Land Information Service  

Copyright © All rights reserved. Failed to retrieve file