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TG350 User Manual R2.0

1. Installation 13 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 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 TE 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 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
2. you can trust TG350 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 02 03 2015 C US 2015 DynaGen Technologies Inc TG350 User Manual Table of Contents User Guide 1 Introduction 3 1 1 Specifications EE EAA cavaive cava aac EEES OR SER NRO RR RED AN 3 2 Installation 4 2 1 General Wiring NOLeS iii iia 6 2 2 Terminal Descriptions tds 6 2 3 Wiring Harnesses iii nt 8 2 4 Typical Wiring Diagram bad 9 2 5 Typical Wiring Diagram with RelayPak sscssssssesssssssesssesssesssssnsesssesssessessseesssessessnessneesneesssessessneesanesssesans 10 2 6 Wiring Considerations d a 11 2 6 1 Remote Start Contact Start Stop cccccceccccssssssssesssesescssssscssessesesascacsssseesesasssstsesecesasaasaciseseesasasstacaceseecasstacieiteseneasesseatens 11 2 0 2 Emergency Stop WII ssa cessa a a So gd SS a tt Ga BS be 11 2 6 3 Universal Sensor ars san ada Dio SU aa on ada 12 2 04 CAN BUS WIN att E AP a O ct o lA 13 A E A O o o II TO 14 3 Using the Controller 14 3 1 Modes Starting and Stopping 00 A id 15 3 2 Using Cooldown Mod G2 xincii sita ied nil etn AA A RO A 17 3 3 FA UreS cuisine add Glide tes a eee aiid hha aha NI 17 4 Settings 17 4 1 Operator Setup eiii enee 18 4 2 Switched Inputs PER RES RR PRE O OO 19 ZEN Voltage Selectas A ai EA A dd a Lu a 21 4 2 2 RPM Frequency Sel Ct ccccc
3. 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 Itis 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 active 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
4. Controller Reading 2 Scaling Factor 208 4 VAC 206 3 VAC 3 Scaling Factor 1 010 TOUGH Series Manual 2015 DynaGen Technologies Inc Settings 40 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 Hz Setpoints gt Low Warning 50 99 Reading at which a warning occurs Hz Setpoints gt Low Failure 50 99 Reading at which a failure occurs Hz Setpoints gt High Warning 101 150 Reading at which a warning occurs Hz Setpoints gt High Failure 101 150 Reading at which a failure occurs TOUGH Series Manual O 2015 DynaGen Technologies Inc Settings 41 4 7 4 7 1 5 Communications The controller has the ability to communicate with other systems over communication buses The following sections relate to settings associated with communications CAN Bus 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 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 t
5. 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 Image 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 Detai
6. Typical Wiring Diagram 2 4 Speed Sensing Max 50VAC Speed Input is used with magnetic pickups flywheel alternator or tachometer CAN Bus J1939 NOT required for generators Shield Review user manual for or electronic engines BAT Emergency Stop more detailed information on wiring and controller configuration Salg EEE qo REE EEE USB Connection 3 2 3 HHE a g BAT H E Start Stop F ES Contacts n A Ll o 3 3d switched inputs can be Engine oi Fuel DC Load Sensor DC Load DC Load configured to detect Temperature Pressure Level Max 1A Input Max 1A Max 1A battery ground or open __ Main connector J4 1 Battery J4 2 Battery DRAWING NOTES NOTE 1 NOTE 2 NOTE 3 NOTE 4 NOTES NOTE 6 NOTE 7 NOTE 8 Your application and wiring may vary Refer to full user manual for detailed information on using your controller www dynagen ca support Switch Input A Switch Input B Switch Input Expansion Connector 3 1 Switch Input D Communication Connector Generator Connector V Reserved Gen Phase A 35 2 Gen Phase B Gen Phase C Switch Output A 3 2 Switch Input E CAN High Neutral Switch Output C J3 3 Switch Output D CAN Low Switch Output B 3 4 Switch Output E CAN Ground 34 13 Sensor Ground Sensor Inpu
7. 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 the 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 C
8. 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 O 2015 DynaGen Technologies Inc Settings 32 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 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 i Battery Level 19 N N Voltage Start Level Engine Run 5 o o 20 40 60 80 100 120 140 Time Minutes The chart ab
9. 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 19 4 2 Switched Inputs The controller has switched inputs which cause the controller to perform a function when activated Settings Name Range Description 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
10. 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 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 Sensor Input B Low impedance sensor input 0 7500hm Sensor Input C Low impedance sensor input 0 7500hm Name Description Provides ground return for 2 wire sensors Sensor Input D Universal sensor input 0 7500hm 0 7 5000hm 0 5 VDC 4 20mA See Universal Sensor section for more information TOUGH Series Manual O 2015 DynaGen Technologies Inc Installation 7 Communications Connector J6 Terminal Name Description 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 flywhe
11. 1b 0 38kg Weight w RelayPak 1 32Ib 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 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 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 e Unplug connectors by pulling on the plug and not the cord e Use fuses where appropriate e Ensure all equipment is properly grounded e Provide support to wires to prevent stress on terminals TOUGH Series Manual 2015 DynaGen Technologies Inc Installation 5 To ensure proper and safe operation caution must be taken at the installat
12. 2 Battery 343 Battery 34 8 Switch Output A_ 34 9 switch output 34 10 Switch Output B 34 11 Sensor Ground USB Connection Communication Connector J6 Review user manual for more detailed information on wiring and controller j configuration BAT aw Relay Pak RP100 Relay D 5 gt N O Contact a didi oO Crank 2 5 a Start Stop eb 3 Contacts x Pre made hamesses are A available Contact Dynagen E Engine Fuel DC Load Sensor DC Load cut inact for more information Temperature Pressure Level Max 1A input Max 1A blli gos acogen hm i Generator Connector V Es Example Belden 9841 Generator Lin Your application and wiring may vary Refer to full user manual for detailed information on using your controller www dynagen ca support TG350 Example w RP100 DWG 1525R1 6 Typical Wiring D 2 5 2015 DynaGen Technologies Inc TOUGH Series Manual Installation 11 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 vers
13. AN 38 4 6 AC MOonitOr isvirisinicnnciaia A A is 39 4 6 Generator Volantes 39 462 Generator FreQUEnEy sm sara patos matr gl Pnad AU A EN E E 40 4 7 Communications 4 7 1 CAN Bus J1939 5 Troubleshooting 41 O 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 e Gasket for water ingress protection resistance 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 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 against moisture e Custom senders configurable with DYNA
14. ANbus 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 O 2015 DynaGen Technologies Inc Using the Controller 17 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 Contacts 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 disable
15. F 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 Failure 2 Config Fail 3 Auxiliary Sensor 1 Auxiliary Sensor 2 Auxiliary Sensor 3 Auxiliary Sensor 4 Load Imbalance More Information TOUGH Series Manual 2015 DynaGen Technologies Inc Settings 25 4 3 1 Group Outputs Group functions have been designed to allow multiple output functions to be bundled together
16. GEN 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 J1939 CAN Bus Magnetic Pickup Input 150 Event Log Clock Exerciser Generator Metering Single or 3 Phase Configurable Switched Inputs Battery Ground Open Resistive Sensors 1 High 0 2 Low Universal Sensor Resistive 0 5V 4 20mA Configurable Switched Outputs 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 Electrical Transients SAE1113 11 TOUGH Series Manual O 2015 DynaGen Technologies Inc Introduction 4 Specification Rating Thermal Shock and Cycling SAE1455 Vibration Profiles SAE1455 Electric Static Discharge SAE1113 13 Mi Aus 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 heater available call factory Weight 0 83
17. 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 20ft 6 1m it is recommended to use BATTERY as the trigger method TOUGH Series Manual O 2015 DynaGen Technologies Inc Settings 21 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
18. 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 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 Mete
19. 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 O 2015 DynaGen Technologies Inc Settings 20 Name 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
20. 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 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 Fu
21. 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 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 occur
22. cccscscsessssssssssssecevsvsssssssssscevsvsusesesssevevastcssossesesesavsususesusesevavassavsesuesesassususasusesevevessetsssarsecavsesuses 21 4 2 3 Configurable INpu S casser is bs BSS DA ad Ai ti a RA S SO ek 22 4 2 4 Start Stop Momentary FUNCTION c cccccccccssssssesescscsssesesssssscecscsescsssnsesecscscsesssecesesasacsesssssssecacscseseessesesasacscsteneneesecacseeeees 22 ALS NIDOS e iN RA O AN ee RAN AN LOA 23 4 3 Switched Outputs O O A E OOO 23 43 Group DPS o ed TEA do de 25 4 23 2 Pull and Hold Coll ae 25 BA SONSOMS ii A A A A a 26 LIE A a da 26 4 4 2 Oil Pressure 4 4 3 Fuel Level AA MERINE SEEI tara o ia A GR a ET RT pn NO 27 FrontiPanel Speed Control aneis A a e Caiana ean 28 4 40 Battery Level sds ida ts OS Se SA CS UBS De a O EIA E SR ati A td 29 O 2015 DynaGen Technologies Inc TG350 User Manual AAO UIE A 30 Fault Monitor Example eis oa a I Se SO de 31 Start on Low High Example sra a A didi Ge an ease da 32 Output on Low High Example ss ss patas rir A Abid Sa a Sad AS ag 33 4 4 1 Custom Sensor Tables aa anos advent Din Malia ody QUA Ara A a ADORA ad AR 34 4 5 TIMES iia a 35 L SANE AGING LOGICS span nar dana Panos Conan aan ANA essa nto ano 35 Preheat Mode marra mi nto e DO A OUR REA es 36 OFF Button FUNCION assistia Dn VA d Fe ellen Dias aes ies DOS en nin aa agende 36 FOZ EXSIciSer ln a A lh eat Aloha O a tall Bastille A RAIMA BSc 37 4 9 Maintenance scam Aa os VAS a AAA
23. d when you enable disable various settings in the controller E 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 2015 DynaGen Technologies Inc Settings 18 4 1 Operator Setup The following settings are used to change the way the user interacts with the 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
24. dvanced 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 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 A 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 O 2015 DynaGen Technologies Inc
25. e 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 1 600 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 signal source connections to the speed sensing terminals are not required TOUGH Series Manual O 2015 DynaGen Technologies Inc Settings 28 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 availabl
26. e 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 O 2015 DynaGen Technologies Inc System Ready Delay to Start Battle Mode Force Regeneration Cooldown Cooldown Timer ee ee Settings 24 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 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 DE
27. e for implementing speed control the settings and parameters to be used as well as the necessary instructions allowing the operator to control the speed TE 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 Display 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 Me
28. e 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 Name 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 39 4 6 AC Monitor The controller has the ability to monitor AC voltage from a generator The following sections are used to configure settings 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 de
29. ed 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 TOUGH Series Manual O 2015 DynaGen Technologies Inc Using the Controller 16 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
30. een 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 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 wh
31. el Solenoid TOUGH Series Manual 2015 DynaGen Technologies Inc Settings 26 4 4 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 44 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 and VDO 250F can only be used if the Close Failure Signal Source is set to Port A 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
32. el alternator Not polarity sensitive and not required if using AC voltage terminals for speed sensing Generator AC Voltage J5 Terminal Name Description Connect to neutral of the generator 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 CANI1939 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 R 485 Common DWG1475 With RelayPak Terminal Color Ja1 Red BATTPOS Battery Positive J41 Red J42 Not Populated J4 2 Not Populated 145 Blak BATTNEG RelayPak Col 44 Not Populated SWINA Switched Input A J4 5 Tan SWINA 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 SWOUTB RelayPak rela
33. he full list ECM Communication Failure Enable Disable If no CAN messages are received for more than 6 seconds the controller shuts down the engine 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 by 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 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 cra
34. ile 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 36 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 O 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 configured 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 bypasse
35. 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 14 2 6 5 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 3 E Do od telay D Relay C Col EE 7 E EJ 3 Using the Controller The LCD 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 15 LCD Display RUNNING Using the Menu System Tas
36. ion 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 O 2015 DynaGen Technologies Inc Installation 6 2 1 General Wiring Notes The following wiring guidelines should be followed 1 Use a minimum of 18AWG wire for all connections 2 Battery 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
37. ions 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 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 ESSA TOUGH Series Manual O 2015 DynaGen Technologies Inc Installation 12 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 a
38. k 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 conditions 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 us
39. ls ohms F y Sunucu y fasi 4 Switched Inputs 2 Engine Ti 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 eg Datcon 02022 00 y Ma 26 160 s J Recharge Setup Trim Offset 0 mp Ms 202 175 je e Ri 6 147 189 7 ngine ee Speer 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 ok cancel TOUGH Series Manual O 2015 DynaGen Technologies Inc Settings 35 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 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
40. nformation 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 Dependent 1 Refer to the sections below for more information on how these settings affect the auxiliary sensors TOUGH Series Manual O 2015 DynaGen Technologies Inc Settings 31 4 4 6 1 Fault Monitor Example In this example a sensor is monitoring the temperature of an engine block If the temperature
41. nk 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 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 TOUGH Series Manual 2015 DynaGen Technologies Inc Troubleshooting 42 Type Information Facebook frifacetookcomiDYNAGEN 3 Spectacle Lake Drive Unit B105 TOUGH Series Manual O 2015 DynaGen Technologies Inc
42. o 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 29 44 5 Battery Level Use the following settings configurations to allow the controller to read and interpret the battery voltage level Name 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 Pre Alarm Timer Start Engine for Recharge Time TOUGH Series Manual O 2015 DynaGen Technologies Inc Settings 30 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 Scena
43. ove 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 33 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 approximately 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 34 4 4 7 Custom
44. ring gt Generator Frequency gt Frequency Source gt RPM Switch Sensors gt Engine Speed gt Auto RPM Nominal gt Primary RPM 60Hz 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 22 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 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 Inpu
45. rio 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 examples 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 i
46. s 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 27 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 Setpoints 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 Voltag
47. s 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 37 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 Sequence Delay for Repeat Days Time Start Pre Alarm Timer Start Engine for Exercise Time TOUGH Series Manual 2015 DynaGen Technologies Inc Settings 38 4 5 3 Maintenance The controller has the ability to count down the time between scheduled maintenance events Once maintenanc
48. 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 O 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 Name 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 rest 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 betw
49. t 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 Description 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 amp Idle Mode Warmup Engin
50. t A Sensor Input B 3 6 3 5 Switch Output F 3 7 Sensor Ground Speed Input Speed Reference STA J7 3 34 14 Sensor Input 3 8 Sensor Input D 374 31939 cabling requires 1202 impedance shielded twisted pair cable Example Belden 7895A Example Belden 9841 Generator DYNAGEN power controls you can trust Wiring Diagrams Drawing Name T6350 Example Drawing Number DWGIAST Drawing Revision 140 Drawing Scale Not To Scale Drawing Size ANSI Ledger Created On 121912012 Modified On 01 13 2014 Created By Everett Pattison Modified By Everett Pattison 2015 DynaGen Technologies Inc TOUGH Series Manual 10 Installation iagram wi BAT Emergency Stop Relay Pak RP100 Schematic Representation Speed Input is used with magnetic pickups flywheel alternator or tachometer Speed Sensing Max 50VAC CAN Bus J1939 J1939 cabling requires Na NOT required for generators held Relay C or electronic engines 1200 impedance shieided High twisted pair cable E Example Belden 7895A Switch Input A Switch Quip Switch Output D Relay B N O Contact Relay Pak Connector 31 2 Coil Ground 31 3 Relay C Coil 31 4 Relay B Coil 31 5 Reserved Relay A Coil _3 Relay Contact 4 Relay B Contact Glowplug LA 341 Battery 34
51. t 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 changing 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 23 4 2 5 Idle Inhibi
52. termine 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 scaling 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
53. thod 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 BANAL RUM 1500 Hold AUTO fa to Adjust REM Speed Control Parameter Page Speed Control Adjust Etr Pressing 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 t
54. y B 44 10 Purple SWOUTB Switched Output B SENGND Sensor Ground J411 Brown SENGND Sensor Ground SENINA Sensor Input A J4 12 Brown SENINA Sensor Input A 713 Bron aa Brom SENS sensors DWG1477 Advanced IO 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 B Gen Current C CT COMMON CT Common PHASE A PHASE B PHASE C NEUTRAL Description Generator Voltage Tough Series Harness Guide DWG 1547R1 1 TOUGH Series Manual O 2015 DynaGen Technologies Inc Installation

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