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RA400 User Manual R1.4

1. E f Modbus Ec cs 210 SJE V pw Battery l Oups 7LF Ae RE 816 3 Banery Gem TOT viu mj5 s iain ofa Input Power 1 1 o t oz o A og rli faig User J4 J ur fuse is Note that the danda connect to wiring designations follow Generator Chassis the transceiver or to the electrical manufactures ground EARTH datasheets and not the EIA 485 Di ene RA 400 System Wiring Diagram Figure 4 General System Wiring DWG1453 Rev 1 2 14 of 43 The following table lists the various parts of the RA400 that can be ordered from either DynaGen or other sources The DynaGen orderable parts in the table give the DynaGen Part Number Table 4 RA400 Parts List On Shore Technology EDZ950 3 N A Inc On Shore Technology 02950 2 Inc On Shore Technology EDZ950 5 N A Inc MALE FEMALE 6 FT ACC0085 N A N A PCB0048R2 0 N A N A DWG1454 Hoffman ASE8X8X4 equivalent or equivalent Mean Well LPL 18 12 ACC0120 1 Power supply is enclosed IP64 rating and rated from 30 C to 70 C with derating after 50 C See pages 42 and 43 for the datasheet Indoor use only User Manual for the RA4
2. PART QUANTITY DESCRIPTION A 1 DUAL ROW PLUG 2x3 6 POSITION MINIFIT JR MOLEX 39 01 2060 B 3 FEMALE CRIMP TERMINAL MOLEX 39 00 0039 c 2 Femole Quick Connect 2 520183 2 D 1 1200 1 4W RESISTOR CF1 41205 TR E 1 Belden 7895A Gable F AR Clear Heat Shrink Tubing 1 Moin Lobel cable H 1 Wire Lobel 1 1 Wire Lobel 2 E Wire Lobel 3 K 1 320 Ohm Resistor Lobel ma Gen DYNAGEN TECHNOLOGIES INC GSC400 RS 485 Power Harness eese 22 DWG1454 13 MW 18W Single Jameco SKU Number 210105 ELECTRONICS Output Switching Power Supply L P L 1 8 series W Features 90 132VAC input only Fully encapsulated with IP67 level Protections Short circuit Over load Over voltage Over temperature Cooling by free air convection Pass LPS 100 full load burn in test Suitable for LED lighting and moving sign applications High reliability Low cost 2 years warranty LPS 1P67 FE C Ew SPECIFICATION MODEL LPL 8 2 LPL 18 24 LPL 18 36 0 VOLTAGE 12v 24V 36V RATED CURRENT 1 5A 075A 05 CURRENT RANGE 0 15 0 075 0 05 RATED POWER 18W 18W ourpur RIPPLE amp NOISE max fot 20mVo o 150 200mVp p VOLTAGE TOLERANCE 23 0 LINE REGULATI
3. 00 00 Jumper plug on 2pins in red circle 2 RS232 E connector ai Reset button 00000 00000 Figure 5 Reset switch and jumper location 2 Place the firmware file will have file extension S19 and hcO8sprg exe in the same directory User Manual for the RA400 Remote Annunicator 29 of 43 3 Check which COM port the cable is plugged into on your computer the HCO8SPRG exe program will need the COM port number of the PC If you are using a serial to USB adapter follow these steps this is for Windows XP a Right click on my computer in the start menu and click properties The System Properties Window will open b Click on the Device Manager button Another window called Device Manager will open Scroll down the window to Ports COM amp LPT If you do not see this make sure the USB adapter is plugged in and that the driver was installed This option will not show if there are no COM ports on your computer and the USB to serial adapter is not detected d Click on the plus sign next to the Ports COM amp LPT You should see the COM port that your adapter uses appear This is the COM port you will use below 4 Use the PC command prompt mode In WINDOWS XP start menu run CMD the PC will open a command prompt window also know as DOS 5 You will need to either store the two files see step 1
4. RA 400 Installation Draning This drawing is an aul seim DwGIAGERLO Figure 2 Size and placement of mounting holes User Manual for the RA400 Remote Annunicator 9 of 43 The RA400 can be powered from a 12VDC or 24VDC source It will not operate below 6VDC and voltages above 30VDC may damage the unit All connectors on the RA400 use plug in screw terminals which are included with the RA400 The installer inserts the wire s into the screw terminal secures the wire using a flathead screwdriver and plugs the screw terminal into the terminal socket on the RA400 Table 1 on page 11 lists the minimum wire size maximum current capacity name and function of each circuit The wire gages given in the table are the minimum recommended only User Manual for the RA400 Remote Annunicator 10 of 43 Modbus 1 o Pin 1 NC Pin 2 Pin 3 Pin 4 B Modbus 2 0 9 9 9 pin 5 NC Short Jumper J13 if last device on net Jumper J13 Default 2 pin Master Slave position 1 OFF master ON Slave BAUD position 2 OFF 9600 ON 19200 Device ID positions 3 to 8 3 on address of 1 4 on address of 2 Pin 1 Jumper J2 Default is master 9600 addr 1 3pin Switch E Ensure Pins 1 and 2 are shorted Sw Default DIP Switch User Input
5. Front Panel Button Alarm Silence e Lamp Test Modbus 2 wire simplex Communications 9600 and 19200 BAUD rates supported Built in terminating resistor selectable by jumper on board Isolated 2800ft run with Beldin 9841 R5232 Firmware updates via 5232 User Inputs Two digital inputs 16V input maximum reverse polarity protected Dimensions W x H x D 203 2 x 2032 x 38 1 mm 8 x8 x 15 in Weight 0 68 Kg 1 5 Lb Three LEDs Indicators are on in standby Communication Status Not In Auto and System Ready The RA400 maintains communication There is no sleep mode for the RA400 User Manual for the RA400 Remote Annunicator 4 of 43 Table of Contents 1 RA400 Remote Annunicator 1 1 This Manual 1 2 Receiving Handling and Storage 1 3 RA400 Product Number Identification 2 RA400 Series Installation and Wiring 24 Safety Information 2 2 _GSC400 Firmware Versio 2 3 Mounting Location 2 3 1 RA400 Mounting Dimensions 2 4 RA400 Terminals 2 5 RA400 Parts Lisi 2 6 RA400 Installation Guide 2 6 1 Run Modbus wiring from GSC400 to the RA400 Wire the GSC400 Mount the 8 x 8 x 4 Pull Wire the RA400 GSC400 Front Panel Configuration RA400 Configuration 3 RA400 Operatioi 3 1 Power up 3 2 Reset and Low Power Behavior 3 3 Communication Status 3 4 Determining GSC400 Mode from the RA400 3 5 RA400 LED Status Indicato
6. Solid Amber Failure Warning condition OFF ON ON Flashing Amber Event condition Solid Amber Warning condition Solid Red Failure condition Check the GSC400 for programmed events User Manual for the RA400 Remote Annunicator 25 of 43 Common Fault Indicator uses the Common Fault 1 feature of the GSC400 With this feature you can set single or multiple failures warnings and or events to trigger this indictor OFF Solid Amber Warning condition ON Solid Red Failure condition Battery Charge Failure is lit if either or both of the GSC400 Charger 1 Fault or Charger 2 Fault configurable switched input features are active ON OFF Solid Red Failure condition Solid Amber Warning condition Configurable Indicator 1 uses the GSC400 Config Warn 1 and Config Fail 1 configurable switched inputfeatures Configurable Indicator 2 uses the GSC400 Config Warn 2 and Config Fail 2 configurable switched input features Configurable Indicators 1 and 2 each have a white area on the label for writing the desired text Configurable Indicator 1 is above Configurable Indicator 2 Use any permanent marker with an ultra fine tip or a fine tip OFF Solid Green Solid Red System Ready System Not Ready OFF Flashing Green Generator is preparing to run Solid Green Generator is running OFF Solid Green EPS is supplying loa
7. 1 Userinput2 Power EARTH Pin 1 V Pin 1 Pwr Pin 2 Gnd 6 30VDC 3W 9 9 9 GND Figure 3 RA400 terminals as seen from the rear Refer to following tables for more detailed information User Manual for the RA400 Remote Annunicator 11 of 43 Table 1 RA400 Terminal Details Wire sizes given below are the minimum recommended only Depending on the length of the cable run you may require a larger gauge wire VDC 1 18 Main power for the device 2 18 Ground for the device Earth 3 18 Chassis or electrical earth 7 Allowable voltage range is 6VDC to 30VDC Connect this to the chassis of the generator or ground of the electrical system preferred 1 Do not connect The positive A for 2 wire AG 2 20 modbus COM 3 24 Modbus common ground B 4 24 The negative B for 2 wire modbus NC 5 N A Do not connect 7 There are two terminals provided to enable the installer to daisy chain multiple RA400 units together If the RA400 is the last device on the communications bus the two pins of J13 the modbus terminating resister jumper must be shorted together factory default This must be connected to the GSC400 modbus ground Power 1 18 30 Digital input Ground 2 18 N A terminals Apply voltage across the two pins to activate the digital input The digital inputs have specific fun
8. 14 10 Reserved bits 4 0 Not In Auto Mode Indicator green if event status is cleared red if severity is 3 off otherwise event status has priority over the severity bits 9 5 Battery Charger Failure Indicator red if severity is 3 off otherwise bits 14 10 Low Battery Volts Indicator check register 40085 first amber if severity of 1 otherwise off bits 4 0 High Battery Volts Indicator check register 40085 first amber if severity of 1 otherwise off bits 9 5 Low Cranking Volts Indicator amber if severity is 1 off otherwise bits 14 10 Reserved bits 4 0 Common Fault Indicator flashing amber if severity is 1 amber if severity is 2 red if severity is 3 off otherwise bits 14 5 Reserved Reserved Overcrank Indicator If Bit 0 is set Red LED turns on regardless of Bit 1 else if Bit 1 is set GSC400 Front 0 Amber LED turns on else LED turns OFF if both bits are cleared Panel LED Status Reserved bits and 11 Configurable Indicator 1 amber if bit 9 set no audible alarm red if bit 11 set audible alarm off otherwise If bit 11 is set status of bit 9 should be ignored bits 10 and 12 Configurable Indicator 2 amber if bit 10 set no audible alarm red if bit 12 set audible alarm off otherwise If bit 12 is set status of bit 10 should be ignored Configurable Indicators 1 and 2 each have a white area on the label for writing the desired text Configurable Indicator 1 is above Configur
9. RA400 requires at least 6VDC although it is recommended 9VDC or greater in case of voltage drops or other unforeseen issues A simple two prong AC wall adapter can be used to provide power It must be able to supply a minimum of 3 Watts 250mA at 12V 125mA at 24V Dynagen also sells a 12VDC power supply ACC0120 indoor use only Remote Power User Manual for the RA400 Remote Annunicator 19 of 43 Connect positive and negative wires from the generator battery Refer to Figure 4 on page 13 The GSC400 must have firmware version 2 00 or higher Version 2 03 or higher is preferred To determine the firmware version cycle power to the GSC400 and observed the screen The hardware and firmware versions will display for a few sections before the GSC400 goes into the OFF or AUTO mode For firmware version 2 00 the default are address 1 and baud rate 57600 For firmware version 2 03 or greater the default is address 1 and baud rate 9600 This section assumes the GSC400 front panel menu is being used The PC Interface can also be used to configure the GSC400 Note The GSC400 is a slave device only and cannot act as a master 1 Modbus BAUD rate The RA400 can only support 9600 default and 19200 Set the BAUD rate in the Advanced Menu Set Modbus Baud Rate to either of these values 2 Modbus Device ID The RA400 can support slave address in the range of 1 default to 63 except addresses 2 to 4 which ar
10. as seen from the rear on page 10 2 Press and hold the Alarm Silence button for 3 4 seconds Does the RA400 perform a lamp test The indicators should flash green and then red If none of them flash or only some of them you may have a defective unit Contact DynaGen Technical Support for further information 4 The Communication Status LED is flashing red 1 Check that the firmware in the GSC400 is 2 00 or greater To do this cycle the power to the GSC400 and observe the firmware version on power up 2 Ensure that you have the modbus A B and ground connections to the GSC400 and RA400 correct As a quick test try reversing the A and B leads on the RA400 side In addition make sure there is a ground wire from the GSC400 modbus connector to the RA400 modbus common terminal User Manual for the RA400 Remote Annunicator 34 of 43 3 Check the baud rate in the GSC400 front panel menu system under Advanced Menu gt Set Modbus and confirm that the DIP switch on the RA400 is set to the correct BAUD rate The RA400 can only operate on two BAUD rates 9600 and 19200 Refer to Table 2 RA400 DIP Switch on page 12 for the switch position meaning 4 Check that the RA400 is set to a master If you are using the DynaLink WS100 WS200 device on the same modbus network then the RA400 must be set as a slave and refer to the DynaLink user manual for more information 5 Check that switches 3 to 8 are set correctly on the RA400 to
11. in the current directory or use CHDIR to change the current directory to the directory folder containing these two files n the figure below the current directory is C Documents and Settings wmanning lt lt C WINDOWS system32 cmd exe Microsoft Window Version 5 1 2600 pyright 19 1 Microsoft Corp Documents and Settings wmanning gt Figure 6 DOS screen To use CHDIR to change the current directory type CHDIR and then one space and then the file directory enclosed in quotations In the figure below the current directory was changed from C Documents and Settings wmanning to C Documents and Settings wmanning Desktop lt lt C AWINDOWSIsystem32 cmd exe BEE wwnann ing De User Manual for the RA400 Remote Annunicator 30 of 43 Figure 7 DOS CHDIR command 6 Once you are in the directory that the files were placed type the command hc08sprg 1 0 9600 xxx s19 where a The 1 refers to the COM port of the computer where you obtained in step 3 above The 9600 is the BAUD rate of the RA400 Ensure that switch 2 of the 8 position DIP switch SW2 on the RA400 see Table 2 on page 12 is in the OFF position The of xxx s19 is the name of the firmware s19 file you have b 7 Press enter You will see the following info appear if you entered everything correctly Note The numbers may not be the same INDOWS system32 cm D 9688 Project al al Boot lo
12. wiring damage and mechanical damages Inspect annunciator for loose fasteners terminals and wiring connections Check all hardware including annunciator wiring terminals etc for any looseness due to vibrations etc Clean area around annunciator Periodically inspect and remove any debris dirt from within or near the annunciator Check for any overheating due to loose connections Check for any discoloration melting or blistering of any wiring or connections Perform regular testing of annunciator Perform regular testing of the annunciator to check for proper operation User Manual for the RA400 Remote Annunicator 28 of 43 DynaGen may from time to time change the software on the RA400 i e firmware to fix bugs improve performance or add features The RA400 provides the user with the capability of easily upgrading the firmware with a 9 serial cable Follow the below steps to load new firmware on the RA400 You will need the HCOB8SPRG exe program It is recommended that once the software has been updated that the software revision be marked on the RA400 for future reference 1 Remove power from the RA400 a Connect one end of the 9 serial cable with DB9 COM port to the PC b Connect the other end of the cable to the DP9 RS232 connector on the RA400 c Move the jumper on J2 over to the left side as outlined by the red circle in the figure below
13. 00 Remote Annunicator 32 of 43 10 The program will verify that the memory has been programmed properly It should say OK next to Memory verified If it does not try programming again Figure 12 Programmer ok 11 Place the J2 jumper back in its original place User Manual for the RA400 Remote Annunicator 1 The RA400 appears to be operational indicators are lit but does not respond Check that the voltage to the RA400 power inputs is 6V or above Voltages between 4 5V and 6V may cause the computer on the RA400 to reset but not the drivers controlling the LED indicators This has the effect of making the RA400 appear operational when in fact it is not 2 The RA400 LED Indicators appear dimmer than usual The RA400 LED feature protection which decreases the current to the LED indicators with increase in ambient temperature This protects the LED and increases its life The user should not notice the indicators diming until the temperature is above 40 C to 50 C If the LEDs are dimmer than usual there could be a problem causing heat buildup behind the RA400 Remove the RA400 and check all connections If it continues the RA400 could be defective 3 The RA400 appears dead No indicators are on 1 Confirm that power and ground are connected properly Measure on the three pin power terminal to ensure at least 6VDC is at the terminal in the proper polarity Refer to Figure 3 RA400 terminals
14. 00 Remote Annunicator This section will step you though the installation and setup of the RA400 to communicate with the GSC400 While reading the next sections refer to Table 5 and to Table 4 RA400 Parts List on page 14 for the required optional parts and tools Table 5 RA400 Installation Part List Molex Digikey Crimp contacts for Molex Crimper 63819 0900 wmoo26 nD Modbus Plug Mating plug for 8 950400 Modbus 9 Terminal Contacts 7 mm Contacts crimp on wire crimps 18 24 39100 0039 Allow wire to be AWG inserted into plug Molex Digikey Allow wire inserted into Extraction Too 0011030044 wm9918 ND ACC0097 to be removed a Connections to 0 250 wida GSC400 power and Female Quick The N A lese can be found at your ground spades for local electronics parts store RA400 power E TS RU N A Crimp quick connects PARERE Modbus A B and Gnd eed Pal Belden 9841 N A connections between Ras GSC400 and RA400 Allied Electronics www alliedelec com PIN 216 8230 Mebane Modbus A B and Gnd twisted pair ene connections and power SSANG pani Belden 7895A N A connections between j GSC400 and RA400 EUR Limited to 11251 modbus gt Premade Sft adapter Dynagen cable to plug into DWGMB DWG1454 DWG1454 gc400 with pigtails on other end The cable for the Modbus A and B connections should be twisted pair cable with an
15. 11 Switch 1 Switch 2 and Switch 4 on 1 2 8 11 all other switches are off E ES ON ON ON ON ON ON ON ON ON User Manual for the RA400 Remote Annunicator Use 1209 impedance twisted pair shielded cable with a drain wire such os Beldin 9841 24AWG Can run power and ground in sane Cable as the modbus twisted pair as long os not powering relays colis or other switching or inductive loads Use Beldin 78954 or simular 20AWG for communication 18AWG for power This cable is limited to runs of 1125ft due to its IBAWG wire for power see table to the right Dynagen sells a 5ft harness with a terminating resistor thot can be cut out that can be connected to the RA 400 or run out to terminal block for longer runs P N 0461454 Use following table to specify gage of power and ground wires Length m FD Wire Gauge 9 13 450 22 197 213 a50 700 26 213 343 700 1125 1 348 549 25 1800 x 549 853 1800 28007 Terninate drain wire at GSC400 and RA 400 Modbus GND COM terminal Place 120Qterninating resisters on either end of the bus The RA 400 has an internal resistor controlled by Jumper J13 Short J13 to terminate bus at RA 400 Factory default Twisted Pair Shielded 1200 Impedance
16. 6 2436 902 406 0133 Fax 902 567 0633 Email support dynagen ca WEB SITE www dynagen ca User Manual for the RA400 Remote Annunicator 3 of 43 RA400 Specifications Intended for indoor stationary mounting only Please consult factory for Uses Locations outdoor or high vibration locations 650400 Firmware 65 400 firmware version 2 00 is requi Requirement recommended See installation instructions for more information VDC Rating 610 30 VDC Be Rane Min 1 3 Watts at 12VDO 109 1 75 Watts at 30VDC 59 3 Watts 250mA at 12V 125mA at 24V Operating Temp 40 C to 85 40 F to 185 LED Indication Type Green Amber Red Normal Warning Failure Overcrank X X Overspeed X X Emergency Stop X High Engine m Temperature Tow Oil Pressure Xx Low Coolant Level x Low Coolant Temperature Low x Engine Temperature Low Fuel Level x x Tiaria Communication Status Not In Auto x x High Battery Volts x X Low Battery Volts x x Common Fault X X Tow Cranking Volts X Battery Charger Failure User Configurable 1 X X User Configurable 2 X X System Read X X Generator Running X EPS Supplying Load X LEDs will gradually dim when temperature rises above 30 C to protect the LEDs and prolong their life Audible Alarm buzzer 71 to 86dB at 2ft Typ Depending on installation this could be lower
17. AGE VAC 60Hz Figure 15 Page 2 of ACC0120 datasheet Taken from http www jameco com
18. DYNAGEN power controls you can trust RA400 GSC400 Remote Annunciator igh Battery vots Low Baten Vos Id T High Engine Low cranking vots ato Chae Low ot Pressure Cy LJ e gt tow tend x ox O 1r EPS Supplying Load ma Installation and User Manual Revision 1 4 Full Version File MAN 0081R1 4 RA400 User Manual doc November 2011 Thank You For Purchasing This DynaGen Product Please Read Manual Before Installing Unit Receipt of Shipment and Warranty Return Information Upon receipt of shipment carefully remove the unit from the shipping container and thoroughly examine the unit for shipping damage In case of damage immediately contact the carrier and request that an inspection report be filed prior to contacting DynaGen All returned items are to be shipped prepaid and include a Return Material Authorization RMA number issued by DynaGen RMA forms are available by contacting DynaGen Technical Support through the contact methods listed below Limited Warranty The RA400 Remote Annunicator carries a one year warranty For more information refer to the standard terms and conditions of sale at http Awww dynagen Support For to date manuals and other support see http www dynagen ca support We welcome your comments and suggestions Please contact us at DynaGen Technologies Inc Phone 1 888 39
19. F mode System Enable will place the GSC400 in the AUTO mode if the GSC400 is currently in the OFF mode 2 If Digital Input 2 is triggered If GSC400 is in AUTO mode Start will start the generator if the GSC400 is in the AUTO mode If GSC400 is in RUNNING mode Stop will stop the generator if the GSC400 is in the RUNNING mode This includes going though any cool down period if enabled Activating digital input 2 in any other state other than RUNNING and AUTO will have no effect Only one digital input can be activated at any one time Each digital input must be active for at least 0 5 seconds before the functionality outlined above is triggered After a trigger neither digital input can be triggered again for at least 0 5 seconds These features are to prevent accidental triggering There may be a delay between input activation and the resulting GSC400 action because the RA400 must communicate the action to the GSC400 A digital input is triggered by applying 5V or greater between its power and ground connections See Figure 4 General System Wiring Diagram on page 13 for the location of the digital input connectors User Manual for the RA400 Remote Annunicator 27 of 43 The actions in Table 7 should be performed routinely Inspect annunciator mounting location for possible safety issues Table 7 Recommended Maintenance Inspect mounting location for any safety or fire issues Inspect for dirt
20. K 217F 25 C OTHERS DIMENSION 140302 W H PACKING 0 175Kg 70 13 3 0 58 NOTE 1 All parameters NOT specially mentioned are measured at 115VAC input rated load and 25 C of ambient temperature 2 Ripple amp noise are measured at 20MHz of bandwidth by using a 12 twisted pair wire terminated with a 0 14 amp 47uf parallel capacitor 3 Tolerance includes set up 4 The power supply is considered a component which will be installed a final equipment he final equipment must be re confimed that i still meets EMC directve tolerance line regulation and load regulation Figure 14 Page 1 of ACC0120 datasheet Model number is LPL 18 12 Taken from http www jameco com Jameco SKU Number 210105 ELECTRONICS 18W Single Output Switching Power Supply MW MEAN WELL LP L 1 8 series W Mechanical Specification 300 Unit mm 300 Lr ACIL Brown ee 18AWG 1015 Ned V Biack 31 3i W Block Diagram fosc 60KHz LOAD POWER RECTIFIERS w WP o EMIFILTER RECTIFIERS H SWITCHING amp OV i FILTER 3 DETECTION x 2 CIRCUIT W Derating Curve W Static Characteristics 25 109 1 wb o 4 LOAD ow AMBIENT TEMPERATURE T6 HORIZONTAL 2 wo no INPUT VOLT
21. ON 0 LOAD REGULATION 12 0 SETUP RISE TIME 1500ms 30ms 115VAC HOLD UP TIME 20ms 115VAC at full load VOLTAGE RANGE 90 192VAC FREQUENCY RANGE 47 6392 EFFICIENCY TTY 80 83 AC CURRENT 05 15 INRUSH CURRENT max start 40A 1T5VAC LEAKAGE CURRENT 0 25mA 115VAC Above 105 rated output power Protedion type Hiccup mode recovers automatically after fault condition is removed 138 162V 27 6 32 4V 414 488 PROTECTION OVER VOLTAGE Protection type Shutoff alp voltage clamping by zener diode TL 1407C U1 detect on main contol IC OVER TEMPERATURE Protection type Shut down recovers automatically afler temperature goes down WORKING TEMP 30 70 C Refer to output load derating curve WORKING HUMIDITY 20 90 RH non condensing EWROMWENT STORAGE TEMP HUMIDITY 40 80 C 10 95 RH TEMP COEFFICIENT 40 03 C 0 5C VIBRATION 10 500Hz 2G 10min cycle period for 60min each along X Y Z axes SAFETY STANDARDS Design referto UL1310 Class 2 TUV EN60950 1 EN61347 2 13 CANICSA C22 2 No 223 M91 IP67 approved WITHSTAND VOLTAGE VMP O P 3KVAC SAFETY amp iSOLATIONRESISTANCE UP OIP gt 100M Ohms 500VDC 251C 70 RH EMC EMI CONDUCTION amp RADIATION Compliance to EN55022 CISPR22 Class B FCC Part 15 HARMONIC CURRENT Compliance to 1000 3 2 3 EMS IMMUNITY Compliance to EN61000 4 M 11 ENV50204 EN55024 light industry level criteria A MTBF 1207 AKhrs MIL HDB
22. able Indicator 2 TBO is set Low Battery Volts Indicator is red If bit9 is High Low cleared read register 40007 to determine if indicator should Battery Volts be amber or off Failure Indicator If bit 10 is set High Battery Volts Indicator is red If bito is Override cleared read register 40008 to determine if indicator should be amber or off Reserved User Manual for the RA400 Remote Annunicator 38 of 43 User Manual for the RA400 Remote Annunicator The following pages contain various drawings that may be useful 1 1 6250 1 6280 1 6290 ae ie HOFFMAN PULL BOX ASE8X8X4 painted ASG8X8X4 galvanized This drawing is based on the T Hoffman ASEBXEX4 ASGBXEXA 1 1090 CAD drawing www hoF Franon l ine con ALL dimensions ore referenced From the outside edge of the cose 0000 81 1090 0600 Iis Hoffman 8x8x4 Pull Box DwG1457R1 0 Figure 13 Hoffman 8x8x4Pull Box X H pu Er lr as t La momomo a N oe zs Notes 1 Unterminated ends of wire to have 3 8 strip 2 Black heatshrink over cable jacket seams 3 Remove shield and foil but do not cut drain wire Use Beldan 7895A cable or equivalent WIRE HARNESS PARTS LIST
23. ader for HC lt S 08 Ue m Sarge com Clong 28 gt large 5085 1 450 Bytes total Oxi 900 QxFFFF ing for HC S 8 reset ACK Figure 8 Valid command response Otherwise you will see this info User Manual for the RA400 Remote Annunicator 31 of 43 re you sure to program part y N 1 D 9608 Project ahs 219 Inc 8sprg Developer s Serial Bootloader for HC lt S 8 Uer 9 0 41 05 FC protocol versions supported lt HCaB gt 8x03 Clarge HCO8 8085 Slong SUB large 588 wire mode with verification supressed Single dual wire mode use with care batch mode no questions speed in bps 19 file TS 8 Power on the RA400 You will see the following info appear numbers shown may not be the same a BEE received Uxfc good ion 9406 Cons SUB read connand supported 5 Incoses nz AN 16 4 68 gt rev 1 Ee E 0x001900 AxBOFIBF x001100 0x001 9x811400 0x0117FF 768 bytes 32 bytes original vector table GxFFCO Bootloader user table xF9CB are you sure to progran part y N 9 Type y if you want to start programming or type n if you want to cancel Then presses the ENTER key the firmware will start to load A new line will appear with the percent of memory programmed so far When this reaches 100 the programmer is finished are you sure to progran part y N1 y Memory programing W UxBBLBRU 4 User Manual for the RA4
24. ank rest The Generator Running Indicator will be flashing green RUNNING Mode The Generator Running Indicator will be green The RA400 Indicators will gradually dim when temperature rises above 30 C to protect the indicators and prolong their life This will not be noticeable unless the ambient temperate is very high The master RA400 continuously reads the GSC400 and sends updates to the slave RA400 units in addition to updating its own indicators The RA400 units should respond within two to three seconds of a change in the GSC400 status If using a DynaLink device it could take up to 30 seconds for the RA400 units to update after a change in the GSC400 status especially if a user is viewing data from the DynaLink device on a web browser The DynaLink device is purchased separately and allows the user the ability to monitor GSC400 data over Ethernet or dial up Refer to the DynaLink user manual for more information LED indicators will be illuminated on the RA400 depending upon the condition of the slave GSC400 The colors of the LED indicators represent the following unless otherwise specified Green Represents Normal Active Conditions Amber w Represents Warning Conditions Red e Represents Failure Conditions A lamp test can be performed by holding down the Alarm Silence button for a period of 3 seconds During the lamp test all red LEDs will be on for 2 seconds User Ma
25. buzzer No Audible Alarm 1 Sound Audible Alarm b4 Warning Failure Feature Enabled Disabled 0 Disabled 1 Enabled The follow conditions will turn off the corresponding LED indicator unless otherwise stated below 1 BIT b0 event status OR BIT b4 feature enabled disabled are equal to 0 2 Bits b2 b1 severity is 0 Bit b3 controls whether the buzzer audible alarm sounds unless otherwise stated below assuming bits b0 and b4 are set and the b1 2 are not cleared bits 4 0 System Ready Indicator red if event status cleared green is event sel bits 9 5 Reserved bits 14 10 High Engine Temperature Indicator amber if severity set to 1 red if severity set to 3 off otherwise Bits 4 0 Low Oil Pressure Indicator amber if severity set to 1 red if severity set 1o 3 off otherwise bits 9 5 Overspeed Indicator amber if severity set to 1 red if severity set to 3 off otherwise bits 14 10 Emergency Stop Indicator red if severity set to 3 off otherwise bit 4 0 Low Coolant Level Aux Indicator red if severity set to 3 off otherwise bits 9 5 Low Coolant Temperature Indicator amber if severity set to 3 off otherwise bits 14 10 Low Fuel Level Indicator amber if severity set to 1 red if severity set to 3 off otherwise biis 40 Reserved bits 9 5 EPS Supplying Load Indicator green if event status is set off otherwise User Manual for the RA400 Remote Annunicator 37 of 43 biis
26. could not establish communications with the GSC400 Try the following 1 If using the Dynagen supplied harness DWG1454 connect the RA400 directly to the end of the harness If the RA400 works in this case then it may be a wiring issue 2 Check the firmware version on the GSC400 Requires firmware version 2 00 or latter RA400 will communicate with GSC400 with firmware version 1 38 or latter but not all lamp indications will work or work properly 3 Ensure that the modbus A and B connections are not reversed on the GSC400 and RA400 Ensure that the modbus ground is connected to the RA400 modbus connector and the GSC400 modbus connector Refer to Figure 4 on page 13 4 Ensure the BAUD rate is the same on all slaves and master RA400 units and in the GSC400 front panel menu 5 If a slave ensure that the modbus device address is set to an address of 2 3 or 4 6 If a master ensure the GSC400 device address switches 3 to 8 on the master RA400 is set correctly and that it matches that in the front panel of the GSC400 User Manual for the RA400 Remote Annunicator gt 8 e B This section explains the operation of the RA400 from a day to day user perspective On power up the annunicator will emit a short beep from the buzzer and then enter a lamp test During the lamp test all red LEDs will be on for 2 seconds and then all green LEDs will be on for 2 seconds Note that the amber color is produced b
27. ction tool D to remove the wire 2 Power and Ground Termination optional a Crimp 0 250 quick connects E with a crimper F onto the power and ground wires b Connect these to the GSC400 Battery and Battery terminals The GSC400 has an extra one of these terminals for this purpose If both Battery and Battery terminals are taken run the power and ground wires directly to the battery If the GSC400 is the last device on the modbus network add a 1200hm resistor near the GSC400 Option B Intermediate Terminal Block DynaGen sells an accessory harness DWG1454 that has a 2x3 Molex connector and power and ground terminals installed The harness can be run out to a terminal block and the main cable to the RA400 can be run from this terminal block The harness is 5 feet long 1 Insert the harness 2x3 Molex plug into the GSC400 2x3 modbus terminal 2 If the GSC400 is not the last device on the modbus network cut the resistor from the harness If making your own cable make sure to add the 1200hm resistor if the GSC400 is the last device on the network 3 If you are powering the RA400 from the battery follow this step Otherwise wrap the extra power and ground in electrical tape to prevent accidental Shorting Plug the power red wire and ground black wire with the female quick connects for the RA400 to the extra Battery and Battery spades on the GSC400 If these are not available then run to the battery t
28. ctionality See section 3 7 Digital Inputs 1 and 2 on page 26 Reverse polarity protected to 30V Damage will occur if the voltage exceeds this User Manual for the RA400 Remote Annunicator 12 of 43 Table 2 RA400 DIP Switch 1 Controls whether the RA400 is a master or slave OFF master ON slave Default is OFF master These control the BAUD rate OFF 9600 ON 19200 Default is OFF 9600 Switches 3 to 8 are the device ID of the GSC400 unit connected to the RA400 if switch 1 is OFF or the device ID of the RA400 if switch 1 is ON The device ID can range from 1 to 63 Default is address 1 See Table 3 to determine the position of the switches for other addresses en Note All DIP switches in the OFF position places the RA 400 in a factory test mode To exit this mode move at least one switch to on position and cycle power Table 3 Device ID DIP Switch Position OFF is indicated by a series of lines ON is used to denote that the switch is in the ON position ON ON ON ON ON ES ON ON ON E ON ON ON E To determine the position of the switches for device IDs between 10 and 28 turn on the switches whose numbers shown above in brackets add up to the device ID There is a unique combination for each device ID E g Device ID
29. d The alarm may sound when one or more of the LED indictors are lit Refer to Table 6 to determine under which events the alarm will be triggered The alarm will remain on until the indicator or indictors that caused the alarm are deactivated or the Alarm Silence button is pressed The alarm can be silenced by pressing the Alarm Silence button To re activate the alarm assuming that the event that caused the alarm is still active press and hold the Alarm Silence button for 3 seconds until a lamp test is performed After the lamp test the buzzer will be re activated for alarming User Manual for the RA400 Remote Annunicator 26 of 43 The digital inputs on the RA400 have the following functionality if triggered you will need to know which mode the GSC400 is currently in refer to section 3 4 Note only a master RA400 unit has the following functionality The digital inputs on slave RA400 units are ignored If a local start was performed Start button pressed on GSC400 then the generator can only be shutdown by triggering an OFF command from the RA400 1 If Digital Input 1 is triggered If GSC400 is in any mode except OFF System Disable will place the GSC400 in the OFF mode if it is in any state other than the OFF mode including the RUNNING mode If the GSC400 is running the controller will shutdown normally except it will cancel any cool down period if cool down is enabled If GSC400 is in OF
30. e reserved for slave RA400 units Set the address of the GSC400 to the desired value in the Advanced Menu Set Modbus Device Address menu User Manual for the RA400 Remote Annunicator 20 of 43 After making changes to the configuration switch located on the back of the RA400 you must cycle the power to the RA400 Power off the RA400 wait one second and then power on the RA400 The RA400 can operate as either a master or slave device If the GSC400 is the only other modbus device on your network you need to configure the RA400 as a master If you wish to have multiple RA400s on the same network configure one as a master and the others up to three as slaves The three Slaves must have a modbus address of 2 3 or 4 The GSC400 can be set to an address of 1 or to an address between 6 and 63 on the master RA400 Follow the instructions below to configure each RA400 RA400 Master Mode Ensure there are no devices using address 2 3 or 4 except RA400 slaves The RA400 master unit reserves these for slave RA400s Placing other devices at these addresses can cause unexpected results possible damage to equipment and or harm to personnel With the RA400 in master mode it will send requests to the GSC400 for GSC400 status updates The RA400 will then turn on or off its indicators and buzzer as required It will also send the status updates to addresses 2 3 and 4 for the RA400 slaves 1 Set swi
31. erminals 4 Connect the other end 3 or 5 wires to a terminal block User Manual for the RA400 Remote Annunicator 18 of 43 The RA400 is designed to fit in an 8x8x4 screw cover pull box The RA400 replaces the screw cover and the four mounting holes on the RA400 align with the cover threads on the pull box The modbus A B and ground wires as well as the power and ground wires must be run into the panel In addition the RA400 has an EARTH connection that must be connected to the ground of the electrical system The next section will detail how to make the connections to the RA400 Refer to Table 1 RA400 Terminal Details on page 11 when reading this section 1 Connect the modbus A B and ground wires to one of the two five pin screw terminals It does not mater which one but all three wires have to be on the same connector If the RA400 is not the last device on the modbus network remove the jumper from J13 Connect the RA400 EARTH wire located on the three pin screw terminal J14 to the ground of the electrical system and the Pull Box if used ES There are two options for powering the RA400 locally or remotely generator battery If powered locally without a battery the RA400 will loose power when the utility power is lost until the generator is running and supplying power Local Power An AC DC power supply can be used to power the RA400 from the building s electrical system The
32. give the desired device ID Check that the GSC400 Device ID under Advanced Menu gt Set Modbus gt Device Address match that switches 3 to 8 on the RA400 Refer to Table 3 Device ID DIP Switch Position on page 12 to determine the meaning of the DIP switches 3 The Genset is starting but the Generator Running Indicator on the RA400 is not flashing green Check that the firmware in the GSC400 is 2 00 or greater To do this cycle the power to the GSC400 and observe the firmware version on power up On the RA400 the Generator Running LED will flash green to indicate that the genset is starting up delay to start cranking crank rest etc If you are using a DynaLink device the delay between a GSC400 action and the corresponding RA400 annunciation of that action is much longer than using an RA400 as a master Maximum Response Time 1 RA400 master 2 3s 2 WS100 WS200 as master with 1 RA400 with single RA400 configuration file 5s 3 WS100 WS200 as master with 1 RA400 with four RA400 configuration file 45s 4 WS100 WS200 as master with 4 RA400 with 4 RA400 configuration file 30s 5 The Common Fault Indicator is not turning on even though selected my Failures Warnings Events in the Advanced Common Faults menu on the GSC400 front panel and one or more of my Failure Warning Event selected is active on the GSC400 Communications are fine Communication Status Indicator is green User Manual for t
33. he RA400 Remote Annunicator 35 of 43 1 The Common Fault Indicator uses the Common Fault 1 feature of the GSC400 Ensure that you set your Failures Warnings Events using Failure Table 1 Warning Table 1 and Events Table 1 menus located under the Common Faults menu in the Advanced menu of the GSC400 front panel menu system 2 Additionally settings may have been changed with the PC Interface Open the GSC400 PC Interface and go to the Faults tab under the GSC400 Update tab Click the Read Faults button at the bottom to get the information from the GSC400 Under the Common 1 tab the Common Faults Common Warnings and Common Events should all be selected in the Modbus box The ones not selected will not be sent over modbus to the RA400 The purpose of the Modbus selection is to allow control over which event type to display locally and which type to send remotely over modbus They all are selected by default from the factory and can only be changed from the PC Interface User Manual for the RA400 Remote Annunicator 36 of 43 Table 8 Modbus Register Map Reserved Each event uses 5bits b4 b3 b2 bi bO where bO is the least significant bit The event status warning or shutdown occurring 0 Not Active 1 Active b2 b1 The severity of the event O Take No Action 1 Warning Acknowledge 2 Action Required 3 Take Immediate Action shutdown b3 Alarm Action indicates if GSC400 is sounding
34. impedance of 1200hms such as G1 G2 and G3 Note the impedance of the cable is not the same as the resistance of the wires Check with the cable manufacturer to ensure you have the proper impedance cable A third wire is User Manual for the RA400 Remote Annunicator 16 of 43 needed to connect the modbus ground between the GSC400 and RA400 The cable drain wire if using a shielded twisted pair cable may be used for this purpose Each end of the bus must be terminated with 120Ohm resistors If you are powering the RA400 from the battery the wires for the RA400 power and ground can be run in the same cable such as G2 as the modbus communication wires as long as there is no inductive or noisy equipment being powered from the cable Noise from the power wires can introduce noise on the modbus communication wires affecting communications Refer to the table in Figure 4 to determine the proper gauge of wire to use for power and ground On the GSC400 end the cable wires G1 G2 can be run from the RA400 directly to the GSC400 Option A or run to an intermediate terminal block Option B The installer can order a special harness G3 from Dynagen or make their own that runs from the terminal block to the GSC400 The terminal block must be protected from water dripping splash and accidental shorting Since the wires will be exposed it should be also located away from any source of noise motors etc More information about
35. nual for the RA400 Remote Annunicator 24 of 43 and then all green LEDs will be on for 2 seconds Note that the amber color is produced by a combination of the green and red LEDs Table 6 lists the LED indicators on the RA400 their definition and colors ON Table 6 Front Panel LED Indicators Solid Red Failure condition on the final crank attempt Solid Amber Warning condition which occurs after the first unsuccessful starting attempt when there are crank attempts still remaining ON Solid Red Solid Amber Failure Warning condition ON Solid Red Emergency Stop Active ON Solid Red Solid Amber Failure Warning condition Also used to indicate Low Engine Temperature Shorted or Open sender warning failure ON Solid Red Solid Amber Failure Warning condition ON Solid Red Failure condition ON Solid Amber Warning condition Note This is called Low Engine Temperature on the GSC400 ON Solid Red Solid Amber Failure Warning condition ON OFF Flashing Red no communication with GSC400 takes up to 8 seconds to transition from green to red Solid Green communication with GSC400 ok ON OFF Solid Red GSC400 is in the OFF mode Automatic start is disabled Solid Green GSC400 is in the AUTO mode ON OFF Solid Red Solid Amber Failure Warning condition ON OFF Solid Red
36. ready for installation Storage The packaging is not suitable for outdoor storage If the RA400 is to be stored indoors for any period of time it should be stored with its protective packaging in place Protect the remote annunicator at all times from excessive moisture dirty conditions corrosive conditions and other contaminants It is strongly recommended that the package protected equipment be stored in a climate controlled environment of 20 to 65 C 4 to 149 F with a relative humidity of 80 or less Do not stack other equipment on top of the remote annunicator User Manual for the RA400 Remote Annunicator 6 of 43 The RA400 series product numbering scheme i e serial number provides various information including options selection by the customer about the unit A serial number has the format given in Figure 1 Uniquely indentifies the particular unit Figure 1 RA400 product numbering scheme User Manual for the RA400 Remote Annunicator 7 of 43 Generator systems contain high voltage circuitry Failing to power down and lock out equipment can cause damage to the equipment or injury or death to personnel The symbols below will be used in this document to classify information Indicates something that you should take special note of but that is not a threat to safety Indicates a potential for injury or death DANGER HIGH This is similar to Danger above but relates specifically to VOLTAGE condi
37. rs 3 6 Alarm Buzzer and Alarm Silence 3 7 Digital Inputs 1 and 2 4 Recommended Maintenance 5 Upgrading RA400 Firmware Appendix A Troubleshootin Appendix B Modbus Appendix Drawings Specs User Manual for the RA400 Remote Annunicator 5 of 43 This manual is divided into two sections 1 Hardware installation Configuration 2 Operation Receiving and Handling Every effort is made to ensure that your RA400 Remote Annunicator arrives at its destination undamaged and ready for installation The packaging is designed to protect the RA400 from both electrostatic discharge and mechanical damage Care should be taken to protect the equipment from impact at all times Do not remove the protective packaging until the equipment is at the installation site and ready to be installed When the RA400 reaches its destination the customer should inspect the shipping box and controller for any signs of damage that may have occurred during transportation Any damage should be reported to a DynaGen representative after a thorough inspection has been completed A shipping label affixed to the shipping box includes a variety of product and shipping information such as items and customer numbers Make certain that this information matches your order information Each RA400 is packaged in its own box Do not discard the packing material until the controller is
38. tch 1 of SW2 to the OFF position to set RA400 as master 2 Set switch 2 of SW to either the OFF position for 9600BPS or to the ON position for 19200BPS This should match what was set in the GSC400 front panel menu and those of the slaves 3 On SW2 set DIP switches 3 to 8 to set the modbus device ID modbus address of the GSC400 This should match what was set in the GSC400 front panel menu RA400 Slave Mode Set switch 1 of SW2 to the ON position to set RA400 as slave 2 Set switch 2 of SW2 to either the OFF position for 9600BPS or to the ON position for 19200BPS 3 On SW2 set DIP switches 3 to 8 to set the modbus device ID modbus address of this RA400 User Manual for the RA400 Remote Annunicator 21 of 43 Final Setup 1 Reset power to the RA400 by unplugging the three pin screw terminal connector wait one to two seconds and plug in the connector again OR Press the push button on the back of the RA400 not the button on the front The RA400 should go though a lamp test red flash then green flash and sound the buzzer If this does not occur the unit may be defective Contact DynaGen for further information The Communication Status indicator should be green This indicates that the RA400 has established or is trying to establish communications with the GSC400 Wait for 8 seconds after power up to ensure communication is established If the Communication Status LED is flashing red then the RA400
39. the two options can be found in section 2 6 2 below Ensure that the generator is disabled before doing any work on it or the GSC400 There are two options for terminating the wires on the GSC400 side The bolded letters in brackets in the below paragraphs make reference to Table 5 Modbus Common Note Older GSC400 LXB LSB units have an internal 100Ohm resistor between modbus common and battery This may cause damage to the GSC400 modbus transceiver in some applications It is recommended to run a jumper from modbus common to battery negative on the GSC400 To determine if this resistor is in your unit disconnect the modbus cable from the GSC400 and measure resistance from modbus ground common on the GSC400 modbus terminal pin 2 to the GSC400 battery negative terminal If it reads 100Ohms then your unit has the resistor User Manual for the RA400 Remote Annunicator 17 of 43 A Direct Run Use this option for best reliability and best immunity to noisy environments The installer obtains the individual connectors and installs them on the cable wires The installer would then insert the connectors into the appropriate GSC400 terminals 1 Modbus Termination a Crimp the contacts C onto the three wires for modbus A B and ground b Insert these wires into the plug B Refer to Figure 4 on page 13 for the modbus terminal pin out C If you accidently insert the wrong wire into the connector you can use the extra
40. tions where high voltage is encountered GSC400 firmware version should be at least 2 00 and above with version 2 03 recommended To determine the firmware version cycle power to the GSC400 and observed the screen The hardware and firmware versions will display for a few sections before the GSC400 goes into the OFF or AUTO mode Note for firmware version 2 00 the default Modbus BAUD rate is set to 57600 This will have to be changed to 9600 RA400 default or 19200 as these are the only two BAUD rates the RA400 supports The RA400 Remote Annunicator must be properly mounted for safe operation Caution must be taken at the installation site to make sure the site is free from condensing humidity extreme temperature fluctuations beyond 40 C to 85 C and corrosive materials Intended for indoor stationary mounting only Please consult factory for outdoor or high vibration mounting locations User Manual for the RA400 Remote Annunicator 8 of 43 The annunicator is designed to fit in a common 8 x 8 x 4 breakout box for example Hoffman ASG8X8X4 Refer to Figure 13 Hoffman 8x8x4Pull Box on page 40 Also see Figure 2 Size and placement of mounting holes below for the RA400 mounting dimensions Figure 2 gives the dimensions of the RA400 mounting holes 8 0000 Ro 1e50 x4 T i x4 43000 8 0000 COOOGOOOCOC coooncooGco2o 02800 C 18500
41. y a combination of the green and red LEDs After lamp test concludes all of the front panel LED indicators will turn OFF The Communication Status LED indicator will then turn green and the annunicator panel will attempt to establish communication If communication is unsuccessful after approximately 7 8 seconds the Communication Status indicator will flash red and the buzzer will sound If the voltage powering the RA400 drops below 6V the microcontroller on the RA400 will reset but the LED drivers which control the LEDs may not To the user it would appear that the RA400 is operational when it is in fact not Once the voltage rises to 6V again the RA400 will perform an LED test and sound the buzzer as it normally does when power is applied In master mode after 7 5s of no communication with the GSC400 the RA400 will sound the alarm turn off all LED indicators and turn the Communication Status LED indicator flashing red The GSC400 controller has three main modes of operation OFF AUTO and RUNNINNG You can tell what mode the GSC400 is in by looking at the Not In Auto and Generator Running Indicators on the RA400 OFF Mode The Not In Auto Indicator will be red and the alarm will sound unless it was silenced User Manual for the RA400 Remote Annunicator 23 of 43 AUTO Mode The Not In Auto indicator will be green and the Generator Running Indicator will be off Generator is in delay to start preheating cranking and cr

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