Cattron DYNAGEN TOUGH Series TE410 User Manual Download

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DynaGen

TOUGH Series

TE410 - EN

User Manual

9M02-9249-A001-EN
Revision A

Terminal

Name

Description

J7-4

Neutral

Connect to neutral of the generator

Generator AC Current (J5)

Terminal

Name

Description

J5-1

Phase A

Connect to current transformer for Phase A of the generator

J5-2

Phase B

Connect to current transformer for Phase B of the generator

J5-3

Phase C

Connect to current transformer for Phase C of the generator

J5-4

CT Common

Connect to the commons of the current transformers

Summary of Contents for DYNAGEN TOUGH Series TE410

Page 1: ...TOUGH SeriesTM TE410 User Manual ...

Page 2: ...ducts rests with the end user since Cattron and its agents cannot be aware of all potential uses Cattron makesno warranties as to non infringement nor as to the fitness merchantability or sustainability of any Cattron products for any specific or general uses Cattron Holdings Inc or any of its affiliates or agents shall not be liable for incidental or consequential damages of any kind All Cattron ...

Page 3: ...niversal Sensor 18 2 6 4 CANbus Wiring J1939 19 2 6 5 Modbus Wiring 20 2 6 6 Current Transformers 21 2 6 7 RelayPak Optional 23 2 6 8 J6 Speed Inputs 25 3 Pumping Applications 26 3 1 Manual Speed Control 26 3 2 Automatic Speed Control 27 3 2 1 AutoStarting on Floats 27 3 2 2 Ramp Up and Intermediate Speed 29 3 2 3 Process Control using Engine Speed 30 3 3 Speed Limiting 30 3 4 Electronic Engines 3...

Page 4: ...hed Outputs 60 5 4 1 Group Outputs 63 5 4 2 Pull and Hold Coil 64 5 5 Sensors 65 5 5 1 Engine Temperature 65 5 5 2 Oil Pressure 67 5 5 3 Fuel Level 68 5 5 4 Engine Speed 69 5 5 5 Battery 74 5 5 6 Auxiliary Sensors 75 5 5 7 Custom Sender Tables 85 5 6 Timers 87 5 6 1 Engine Logic 87 5 6 2 Schedulers 94 5 6 3 Maintenance 96 5 7 AC Monitor 97 5 7 1 Generator Voltage 97 5 7 2 Generator Frequency 100 5...

Page 5: ...DynaGenTM TOUGH SeriesTM TE410 EN User Manual 5 9M02 9249 A001 EN Revision A 5 9 2 Settings Name ID 107 5 9 3 Process Control 108 5 9 4 Pump System 109 6 Troubleshooting 112 7 Technical Support 113 ...

Page 6: ...es and Functions Five Year Warranty SAE J1939 CANbus Protocol RPM via J1939 Magnetic Pickup or Generator Speed control offset for electronic engines AutoStart on low battery and other sensors Trim feature for AC monitoring and sensors Maintenance counter Exerciser Clock 150 Event Log Conformally coated for protection against moisture Gasket for water ingress protection resistance Free RapidCore Co...

Page 7: ...ards to which the controller has been tested For complete details on the testing performed please contact Cattron at www cattron com Testing Specifications Specification Rating Electrical Transients SAE1113 11 Thermal Shock and Cycling SAE1455 Vibration Profiles SAE1455 Electric Static Discharge SAE1113 13 SAE1113 13 8 kV Direct Discharge 15 kV Air Gap Discharge UL UL 6200 recognized component Con...

Page 8: ... 80 mA 12 VDC 45 mA 24 VDC back lighting off Actual consumption could be more depending on connected sensors and other I O Switched Inputs Battery Ground Open Closed Switched Outputs Battery 1 A Max Low Resistance Sensors 0 750 Ω High Resistance Sensors 0 7 500 Ω Universal Sensors 0 750 Ω 0 7 500 Ω 0 5 VDC 4 20 mA Magnetic Pickup 10 10 000 Hz at 1 50 VAC AC Voltage Line To Line UL Approved Range 5...

Page 9: ... following general electrical safety precautions should be followed Do a thorough inspection of the area before performing any maintenance Keep fluids away from electrical equipment Unplug connectors by pulling on the plug and not on the cord Use fuses where appropriate Ensure all equipment is properly grounded Provide support to wires to prevent stress on terminals CAUTION TO ENSURE PROPER AND SA...

Page 10: ... and without pushing on the relays snap the other tab into place The following figures show the TE Series cut out dimensions and an image of the controller 2 1 General Wiring Notes The following important wiring guidelines should be followed Use a minimum of 18 AWG wire for all connections Battery Positive Battery and Battery Negative connections on the controller should be run directly to the pos...

Page 11: ...is recommended that vibration mounts be used For outdoor applications it is recommended that a sealed enclosure be used 2 2 Terminal Descriptions Main Connector J4 Terminal Name Description J4 1 Battery Provides power to the controller from the battery J4 2 Battery Provides power to the controller from the battery J4 3 Ground Provides ground return for the controller J4 4 Ground Provides ground re...

Page 12: ...RS485 Non Inverting Non Inverting communications line for Modbus RS485 This is also often known as A J6 2 RS485 Inverting Inverting communications line for Modbus RS485 This is also often known as B J6 3 No Connection No Connection J6 4 CAN H Communications line for CANbus J1939 J6 5 CAN L J6 6 CAN Shield Connect the shield of the twisted pair cable to this terminal J6 7 Speed Sensing A Connect to...

Page 13: ...generator Generator AC Current J5 Terminal Name Description J5 1 Phase A Connect to current transformer for Phase A of the generator J5 2 Phase B Connect to current transformer for Phase B of the generator J5 3 Phase C Connect to current transformer for Phase C of the generator J5 4 CT Common Connect to the commons of the current transformers ...

Page 14: ...DynaGenTM TOUGH SeriesTM TE410 EN User Manual 14 9M02 9249 A001 EN Revision A 2 3 Wiring Harness ...

Page 15: ...DynaGenTM TOUGH SeriesTM TE410 EN User Manual 15 9M02 9249 A001 EN Revision A 2 4 Typical Wiring Diagram ...

Page 16: ...DynaGenTM TOUGH SeriesTM TE410 EN User Manual 16 9M02 9249 A001 EN Revision A 2 5 Typical Wiring Diagram with RelayPak ...

Page 17: ...The trigger can be set to any of four options but Close BAT gives the best immunity to noise For runs over 20 ft 6 1 m especially in noisy environments Cattron recommends connecting the Start Stop to an external relay The relay needs to be located as close to the controller as possible 2 6 2 Emergency Stop Wiring If Emergency Stop functionality is required it must be an external mushroom style swi...

Page 18: ... TABLES POUR PLUS D INFORMATIONS Example 1 The following example shows the correct way to wire a 4 20 mA sensor The 240 Ω resistor is required to transform the 4 20 mA current into the 0 5 V voltage range required by the controller 4 20 mA Wiring Example Example 2 Sometimes it is required to measure voltages outside the 0 5 V range allowed by the controller To do this you must use a voltage divide...

Page 19: ...iption Bus Termination Each end of the bus must be terminated from CAN H to CAN L with 120 Ω 10 Ω resistors The resistor must be able to handle at least 400 mW of power dissipation Cable Selection A twisted pair 120 Ω impedance cable is required for communications For better protection a shielded twisted pair cable is recommended Examples include the following Belden 9841 Shielded cable with one t...

Page 20: ...nications CANbus J1939 menu which will cause the fuel output to turn on in Auto Mode and stay on ECM Wiring 2 6 5 Modbus Wiring The following table outlines some items that must be taken into consideration when connecting up a Modbus system Consideration Description Bus Termination Each end of the bus must be terminated from A to B with 120 Ω 10 Ω resistors The resistor must be able to handle at l...

Page 21: ...ry is 5 A A 5 X ratio CT should be used where X is the maximum primary amperage rating e g 200 A The CT power rating should be a minimum of 1 V A The controller CT burden is 0 02 Ω 0 5 V A The current transformer of each phase must be facing the same direction as shown in the following figure The CT Common connection must be connected to the black wire on each CT The wires from the current transfo...

Page 22: ...DynaGenTM TOUGH SeriesTM TE410 EN User Manual 22 9M02 9249 A001 EN Revision A CT Wiring ...

Page 23: ...m If this capability is used the fourth relay Relay D cannot be used Electrical Specifications Specification Rating Operating Voltage 12 V 24 V Output Pilot Duty Rating 5 83 A Per Relay 12 V Output Resistive Rating 10 A Continuous Per Relay 12 V 40 A Momentary Per Relay 12 V Relay Style Automotive Cube Standards UL 6200 recognized component Contact Cattron at www cattron com for UL conditions of a...

Page 24: ...DynaGenTM TOUGH SeriesTM TE410 EN User Manual 24 9M02 9249 A001 EN Revision A ...

Page 25: ...ounded in addition to connecting to the controller Not grounding one side of the sensor can cause erratic behavior The first three requirements in this list can be ignored at the customer s own risk but the fourth requirement must be followed otherwise unreliable operation may result The polarity of the speed inputs does not matter Other Speed Signal Sources Other speed sources such as those from ...

Page 26: ... the controller in either of these ways o Using the RUN button on the front face o Using the key switch switched input function Manual speed control is disabled if either of these occur o The controller is running in automatic speed control Pressing the RUN button while in Cooldown Mode will not trigger manual speed control The controller must be in the Off or Auto Modes o A long time run is activ...

Page 27: ...ss control is enabled If process control is enabled process control will take over once the engine has ramped up to the goal speed 3 2 1 AutoStarting on Floats Single or dual floats can be used as means to auto start and stop the engine based on a level of a tank The following figures indicate how the engine responds to the floats If single float is used then only one of the Float 1 or Float 2 swi...

Page 28: ...DynaGenTM TOUGH SeriesTM TE410 EN User Manual 28 9M02 9249 A001 EN Revision A ...

Page 29: ...e Transducer display setting is enabled a tank display graphic will be shown adjacent to the float indicators indicating the fill level of the tank 3 2 2 Ramp Up and Intermediate Speed Once an AutoStart is initiated the engine will go through a ramp up in speed until it reaches the goal speed This is indicated in the following chart Refer to the Other Config Pump System menu for settings indicated...

Page 30: ... Process Control section Settings Other Config Process Control for more information 3 3 Speed Limiting There are three settings that control the absolute or change in speed for all speed control features These settings can be used to prevent engine damage and or provide a safety means for equipment users The TSC1 RPM s setting under Sensors Engine Speed RPM Control limits the rate of change in eng...

Page 31: ... that wakes the ECM and tells it a start crank cycle is about to begin The ECM then begins to monitor engine speed for start detection Start SW Input The input to indicate to crank or start the engine CAN High CAN Low CAN H CAN L The J1939 protocol bus that the ECM and TE350 TE410 use to communicate with one another TSC1 J1939 speed command is sent over this bus as well as engine temperature oil p...

Page 32: ... in Auto or Running Mode the screen can be locked to a certain parameter page by pressing Auto and unlocked by pressing Auto 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 th...

Page 33: ...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 Menu When in the Menu Mode settings c...

Page 34: ...art stop command sent over the J1939 CANbus for example from the TR100 or a remote telemetry device The controller will display either J1939 Run or J1939 Remote as the reason for starting Float AutoStart Start triggered by the Float 1 or Float 2 switched inputs ECM Power On This is not a starting mode like the others In Auto Mode if the AUTO button is held for 3 seconds the fuel output is turned o...

Page 35: ...hat is shown when the controller is running Run Mode It is also displayed in Auto Mode Scrolling to other pages can be done using the Enter button After 30 seconds of button inactivity the controller will revert back to the speed control page The speed control page displays the engine speed the float tank if float AutoStart is enabled and the tank level if Transducer under the Application menu is ...

Page 36: ...ll appear for 5 seconds or until the user scrolls away It will disappear and then it will reappear 50 seconds later if the DTC is active Also the controller LED indicator will turn amber to indicate a warning condition 4 5 Using Cooldown Mode When the controller is configured to have a cooldown period see the Engine Logic section for the engine there is some special functionality that must be cons...

Page 37: ...enabled disabled when you enable disable various settings in the controller Notable warnings are given in the following table Warning Name Enabled Condition s Description High Fuel Level High Fuel Level not disabled in Sensors Fuel Level menu High Fuel Level warning This is often used to indicate an over fueling condition where fuel could be overflowing from the fuel tank Low Engine Temp Low Engin...

Page 38: ...ocontroller to enter a bad state or a software bug could cause the code to hang while triggering the watchdog In these cases the controller will reset and enter the failure state The name is configurable so it may not match what is shown here Failure To Stop Disabled when ETS On Duration Energize to Stop is set to 0 seconds otherwise it is enabled If used ETS On Duration should be set to at least ...

Page 39: ... or automatic start condition such as a remote start stop command Off Enabled Event The controller has entered Off Mode Not in Auto is displayed on screen Automatic starting is disabled Manual Start Event A user has pressed the RUN button on the controller Start Cooldown Event The controller has entered cooldown Cooldown has to be enabled under Timers Engine Logic Remote Start Event A switched inp...

Page 40: ...o started from a start command sent to its RS485 Modbus port Modbus Stop Event The controller has auto stopped from a stop command sent to its RS485 Modbus port Genset Disable Event Applies to the Kubota electronic engine Level 3 shutdown has occurred Engine Started Event The engine has successfully started and entered the Run Mode J1939 Remote Event The controller has auto started due to a comman...

Page 41: ...run feature is enabled under Timers Long Time Run The controller will run for the duration specified under Long Time Run and then automatically shut down Scheduler Start Event The controller has auto started due to a daily schedule set up in Timers Week Scheduler Start Cancelled Event A daily scheduler was cancelled either because the controller was not in Auto Mode or a start request was ignored ...

Page 42: ...n activated This output is used to control the generator breaker Over Current Warning The generator AC current has risen above the over current warning setpoint under AC Monitor O C Protection Basic Alarm Fuel In Basin Warning The fuel in basin switched input has been triggered This indicates there has been a leak in the fuel tank Low Battery Warning The main starter battery the battery from which...

Page 43: ...ed to turn off the breaker This is triggered if the AC Current is still above 10 of the rated current setpoint The breaker trip failure has to be enabled under AC Monitor O C Protection Brk Trip Fail Load Imbalance Failure The generator load is imbalanced between the A B and C phases This has to be enabled under AC Monitor O C Protection Imbalance Mode with the mode set to Shutdown Trip Over Curre...

Page 44: ...y Failure The main starter battery the battery from which the controller is powered voltage has risen above the high battery failure setpoint set under Sensors Battery Loss Of ECM Comm Failure For electronic engines only The Loss of ECM under J1939 must be enabled The controller has not detected engine speed oil pressure or engine temperature on its CAN J1939 port Under Frequency Failure The gener...

Page 45: ...rank disconnect speed The engine stall must be enabled under Timers Engine Logic Transducer Low Failure The transducer aka Auxiliary Sensor 5 reading has fallen below the transducer low failure setpoint set under Application Menu Transducer menu Transducer High Failure The transducer aka Auxiliary Sensor 5 reading has risen above the transducer high failure setpoint set under Application Menu Tran...

Page 46: ...n the J1939 Reference Manual for more information Display LCD Backlight Timeout 10 600 s 600 s Amount of time the LCD Backlight stays on after button activity stops Display Default Application Menu Tank Level Float Application Wind Machine Application Tank Level Float Application configurable using RapidCore software only Sets the front panel application menu The application menu is the first menu...

Page 47: ... the Sensors Auxiliary Sensor 5 menu Date Time Date Change 1 31 days 1 12 months 2000 2099 yr Sets the date Date Time Time Change 0 23 hr 0 59 min 0 59 s Sets the time Date Time Daylight Saving Enable Disable Enable Turns Daylight Saving Time on or off This applies to North America only Disable for other locations Units Temperature Unit Fahrenheit or Celsius Fahrenheit Selects the temperature disp...

Page 48: ... the closed loop control Week Scheduler Set days and times to run the engine Long Time Run Allows the user to specify the length of time the engine will run when manually started Engine is automatically shut down when the time ends 5 2 1 1 Function Menu Name Range Description Float AutoStart Disable Single Float Dual Float Determines the float control system type Floats Disable Fill Tank Empty Tan...

Page 49: ...l 2 Intermediate to Rated 1 300 s in 1 s increments Ramp Times Dwell 3 Rated to Idle 1 300 s in 1 s increments Ramp Times TSC1 RPM s Disable 10 300 RPM s in 10 RPM s increments This is a mirror of the same setting under Sensors Engine Speed Changes in engine speed are limited to this maximum Bump Speed Disable 0 500 RPM in 1 RPM increments This is a mirror of the same setting under Other Config Pu...

Page 50: ...ne of four predefined sender tables can be selected TF1 TF2 are float sensors 115F R240 means it has a range of 115 F at 240 Ω TP1 TP2 are pressure sensors contact Cattron at www cattron com for more information Start Stop Sub Menu Start Stop Bypass Time 0 90 s in 1 s increments For warnings failures this sets the amount of time to ignore the input when Run Mode is first entered For automatic star...

Page 51: ... Modes When the transducer is enabled when the controller is in the Run Mode a tank graphic will be displayed 5 2 1 4 Closed Loop Menu These settings mirror those of the same name in Other Config Process Control Name Range Description Parameters Sub Menu Parameters Delay 1 30 s in 0 1 s increments The control loop delay and gain The Delay and Gain settings affect how regressive the control is to c...

Page 52: ...b Menu There are a total of 16 separate schedulers that can be programmed Scheduler 16 Weekday Scheduler 16 Start Time Scheduler 16 Run Time 5 2 1 6 Long Time Run Menu These settings mirror those of the same name in Timers Long Time Run Name Range Description Start Trigger Disable Manual Start If set to Manual Start enables timed shutdown after the time given in Run Duration below This timer only ...

Page 53: ...s Wind Machine Start Stop Bypass Time 0 90 s in 1 s increments The time to ignore the Transducer Aux Sensor 5 input after an engine start Wind Machine Start Stop Run Time Disabled 1 6000 min in 1 min increments On a Transducer Aux Sensor 5 start the maximum time to run if a stop condition is not triggered Wind Machine Start Stop Start 0 1 510 in 0 1 increments The value of the Transducer Aux Senso...

Page 54: ...eed sent to the ECM when the controller is in normal Running Mode Throttling Dwell Times Warm up Disabled 5 600 s in 5 s increments The time to spend in warm up The engine is idled if idle is enabled Throttling Dwell Times Interm 1 300 s in 1 s increments The time to spend at the intermediate speed Throttling Dwell Times Cooldown Disabled 5 6000 s in 5 s increments The time to spend at cooldown if...

Page 55: ...elow Determines the operating conditions under which the switched input can be active Multiple selections are allowed Trigger Menu See below The state of the input determining if it is active or inactive Switched I O Switched IN X Function Name Active Mode Description Disabled N A Input is disabled and has no function Start Stop Auto Running Starts the engine when active stops the engine when deac...

Page 56: ...ning See the Idle section under Engine Logic for more information Voltage Select 1 Auto Used for changing the system AC voltage configuration See AC Voltage Select for more information Voltage Select 2 Auto Charger Fault Battery Charger Fault Global Controller displays Charger Fault warning when active Mom Start Momentary Start Auto Starts or stops the engine when momentarily active for at least 2...

Page 57: ...lure Mode the LED will remain red The only indication that the lamp test is active is the LED indicator will alternate between the green and red colors The LED goes back to its original state when the switched input is no longer active Fuel In Basin Global Controller displays Fuel In Basin warning when active Battle Mode After Cranking Controller ignores all warnings and failures when active Displ...

Page 58: ...nual Speed Control in the Pumping Applications section for more information Speed Decrease Float Input 1 The connection for Float Sensor 1 and 2 which are used as an AutoStart means Refer to the AutoStarting on Floats section in the Pumping Applications section and the Pump System section for more information Float Input 2 CAUTION MORE THAN ONE ACTIVE MODE CAN BE SELECTED ATTENTION IL EST POSSIBLE...

Page 59: ...he amount of time the input has to be active before the controller registers the warning or failure CAUTION IF THE SWITCHED INPUT BECOMES INACTIVE BEFORE THE TRIGGER DELAY TIME EXPIRES THE WARNING OR FAILURE WILL NOT OCCUR ATTENTION SI L ENTREE COMMUTEE DEVIENT INACTIVE AVANT L EXPIRATION DU DELAI DE DECLENCHEMENT L AVERTISSEMENT OU LA PANNE NE SE PRODUIRA PAS Example The user wants a pump to turn...

Page 60: ...ER LES SORTIES COMME SIGNAUX LOGIQUES NUMERIQUES IL FAUT INSTALLER UNE RESISTANCE PULL DOWN 2 2 KΩ 1 W ENTRE LA SORTIE CONCERNEE ET LA MASSE POUR ASSURER UN NIVEAU LOGIQUE BAS QUAND LA SORTIE EST OFF Default Settings Switched Output Default Setting Switched Output A Fuel Output Switched Output B Disable Switched Output C Crank Output Switched Output D Disable Switched Output E Disable Switched Out...

Page 61: ... only after it has warmed up and to remove the load on cooldown Cooldown Cooldown Timer Active when Cooldown Timer is active Engine Running Running Active after crank success Exercising Exercise Timer Active during the engine exercising cycle Batt Recharge Battery Recharge Battery Recharge Timer Active during the battery recharge cycle Maintenance Maintenance Required Global Active when Maintenanc...

Page 62: ...r will shut down the engine on Generator Disable Failure Dummy Load Running Output is controlled by the Dummy Load feature Breaker Trip Running Output is controlled by the Basic Alarms IDMT and Load Imbalance features The Breaker Trip only reacts to over current faults it does not activate for other failures Auto Idle Warm up Cooldown Active at the start of delay to start until the end of warm up ...

Page 63: ...s an unhandled exception or lockup watchdog triggered it will reset and enter the Failure Mode as an exception fault The name of this fault is configurable from the Configurator Software 5 4 1 Group Outputs Group functions have been designed to allow multiple output functions to be bundled together and assigned to a single switched output pin The definition of a group output follows When any of th...

Page 64: ...ent 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 the first 1 6 to 1 8 seconds of preheat If preheat is disabled the pull coil is energized at the beginning of cranking the crank output turned off for that time period 3 This is repeated for each crank attempt Configuring a switched output to Pull Coil aut...

Page 65: ...sure and Fuel Level functions are mostly fixed in functionality but the Auxiliary Sensors can be configured to perform specific shutdowns or special functions for example starting engine on low temperature The Engine Temperature Oil Pressure and Fuel Level functions can be set to work with a switch or a sender sensor but the Auxiliary sensors can only work with a sender Note The engine speed and b...

Page 66: ... with the custom text you choose when creating the sender The switch must close to ground Trim Offset 50 0 50 0 F 27 8 27 8 C 0 0 F Calibrate a sensor by using the offset to correct errors Only applies if Sensor Type has been set to a sender Setpoints Bypass Time 0 90 s 30 s Amount of time to bypass warnings and failures after engine has started Setpoints Low Warn Low Warning Disabled 32 200 F 0 9...

Page 67: ...er 279B F and Datcon 2505 00 sender tables VDO 150P R180 supports the VDO 360 004 oil pressure sender DAT 100P R240 and VDO 150P R180 cannot be used on port A To use on port A store as a custom sender table using the RapidCore Configurator software A custom table created using RapidCore Configurator Software The text custom sender will be replaced with the custom text you choose when creating the ...

Page 68: ...changed DAT R 33 240 supports a Datcon fuel level sensor of the range 33 Ω to 180 Ω VDO R 0 180 supports a VDO fuel level sensor of the range 0 Ω to 180 Ω DAT R 33 240 and VDO R 0 180 cannot be used on port A To use on port A store as a custom sender table using the RapidCore Configurator software A custom table created using the RapidCore Configurator Software The text custom sender will be repla...

Page 69: ...ame Range Default Settings Description Signal Source J1939 Bus Mag Pickup Genset Voltage Genset Voltage The source for the engine speed signal J1939 Engine speed is obtained over the engine CAN communication bus Genset Voltage The AC Voltage connector phase A is used for engine speed Mag Pickup A magnetic pickup alternator output or the distributer signal can be used to sense speed Must use J6 pin...

Page 70: ...a warning occurs Setpoints Low Fail Under Speed Failure 20 99 85 Reading at which a failure occurs Setpoints High Warn Over Speed Warning 101 150 110 Reading at which a warning occurs Setpoints High Fail Over Speed Failure 101 150 115 A over speed failure is triggered if the speed is above this threshold for 4 seconds RPM Control Min Speed 500 4000 RPM in 1 RPM increments 600 RPM Front Panel Speed...

Page 71: ...NG AND IDLE ARE SKIPPED THE SPEED IS NOT MONITORED DURING DELAY TO START OR PREHEAT AS THIS PROVIDES SOME DEGREE OF PROTECTION AGAINST SPURIOUS SIGNALS DUE TO NOISE THE FUEL INPUT IS TURNED ON AT THE START OF PREHEAT AND OFTEN POWERS EXTERNAL EQUIPMENT THAT CAN CAUSE NOISE ATTENTION LA VITESSE DE ROTATION EST CONTROLEE AVANT D ENGAGER LE DEMARREUR SI LA VITESSE DETECTEE EST SUPERIEURE A LA VITESSE...

Page 72: ...ED OUTPUTS HAVE A FLOATING VOLTAGE OF APPROXIMATELY 8 V WHEN OFF IF USING THE OUTPUTS FOR DIGITAL LOGIC IT WILL BE NECESSARY TO PUT A PULL DOWN RESISTOR 2 2 KΩ 1 WATT FROM THE OUTPUT TO GROUND TO ENSURE A LOW LOGIC LEVEL WHEN OUTPUT IS OFF AVERTISSEMENT LES SORTIES COMMUTEES PRESENTENT UNE TENSION FLOTTANTE D ENVIRON 8 V LORSQU ELLES SONT OFF INACTIVES SI VOUS SOUHAITEZ UTILISER LES SORTIES COMME ...

Page 73: ...00 4000 RPM in 1 RPM increments 2000 RPM The maximum RPM that can be set using speed control Only valid when the correct Limit Method is chosen TSC1 RPM s Sensors Engine Speed RPM Control Disable 10 300 RPM s in 10 RPM s increments 200 RPM s Ignore this setting Refer to the J1939 Reference Manual for information on this setting Speed Control Instructions When the controller is running and there ar...

Page 74: ... battery voltage in order to charge it Recharge Setup Level 6 0 30 0 V 10 4 V Voltage level at which the controller starts the engine to recharge the battery Recharge Setup Pre Alarm 1 30 min 5 min Amount of time to display a warning before starting the engine Recharge Setup Duration 10 900 min 90 min Amount of time to run the engine Setpoints Low Warning Disabled 6 0 24 0 V 11 3 V Reading at whic...

Page 75: ... MAY BE LOWER THAN DISPLAYED ATTENTION QUAND LE MOTEUR TOURNE LA TENSION DE BATTERIE EST EGALE A LA TENSION DE CHARGE DE L ALTERNATEUR LA TENSION REELLE DE LA BATTERIE EN CIRCUIT OUVERT PEUT ETRE INFERIEURE A CELLE AFFICHEE Battery Recharge Sequence 5 5 6 Auxiliary Sensors The Auxiliary sensors are used for supporting custom sensors and triggering actions based on the sensor values There are four ...

Page 76: ...IRES QUI SERONT UTILISES SINON LE MESSAGE UNDEFINED SENSOR CAPTEUR NON DEFINI S AFFICHERA DANS LE MENU DU PANNEAU DE COMMANDE UNE FOIS QU UN TABLEAU D EMISSION EST PROGRAMME DANS LE CONTROLEUR TOUS LES AUTRES PARAMETRES PEUVENT ETRE REGLES A PARTIR DU PANNEAU DE COMMANDE DU CONTROLEUR Sensors Aux Sensor 1 2 3 4 menus Name Range Default Description Signal Source Disable Port A Port B Port C Port D ...

Page 77: ...n the Auto Mode Running Input can be triggered after a start command is received until shutdown cooldown not included Cranking Input can be triggered during cranking After Cranking Input can be triggered after engine has started until shutdown Cooldown Input can be triggered while cooldown timer is active Func Select Fault Monitor Example Output on High Example Output on High Example Start on Low ...

Page 78: ...d so crank time preheat time etc are included in the Run Time Mode Settings Start Level Disable Temperature 32 999 F in 1 F increments Pressure 1 6000 PSI in 1 PSI increments Level 1 99 in 1 increments Voltage 0 1 99 9 V in 0 1 V increments Current 1 999 A in 1 A increments Only applies if Func Select is not set to Fault Monitor The level at which the auxiliary switched output turns on or the engi...

Page 79: ...or 1 Used by the Auxiliary Sensor 1 Output on Low or Output on High feature Aux Sensor 2 Used by the Auxiliary Sensor 2 Output on Low or Output on High feature Aux Sensor 3 Used by the Auxiliary Sensor 3 Output on Low or Output on High feature Aux Sensor 4 Used by the Auxiliary Sensor 4 Output on Low or Output on High feature The display resolution of the auxiliary sensors that are displayed on th...

Page 80: ...d then stop controller Start on Low Set to value that the sensor needs to drop below to start Set to the desired run duration Disable Turn on an output when the sensor drops below a certain value Run for a fixed period of time and then turn off the output Output on Low Set to value that the sensor needs to drop below to turn on the output Set to the desired duration to keep the output on Disable S...

Page 81: ...ontroller when the sensor drops below a certain value Stop controller when the sensor rises above a certain value Stop the controller after a fixed time if the stop level is not reached Start on Low Set to value that the sensor needs to drop below to start Set to the desired maximum run duration i e this is the timeout Set to the value the sensor needs to rise above to stop the controller Turn on ...

Page 82: ...r value Just display the value to the user Fault Monitor Disable all warnings and failures N A N A N A 1 The user must manually stop the controller by pressing the OFF button 2 The controller must be either Powered down or A reset initiated by o Going from the Run Mode to the Auto or Off Mode or o Changing a setting in the menu and exiting the menu system 5 5 6 1 Fault Monitor Example In this exam...

Page 83: ... The engine will continue to run because it has not reached the 350 F failure threshold At 20 minutes run time the temperature falls below the warning threshold and the warning disappears 5 5 6 2 Start on Low Example In this example a sensor is monitoring the voltage of an external battery bank If the voltage falls below 10 5 V the engine will start and run for 40 minutes to charge the battery Rel...

Page 84: ... bank and time At approximately 80 minutes time the voltage falls below the 10 5 V start threshold causing the engine to start The engine runs for the 40 minutes of active time regardless of the voltage reading and then shuts down 5 5 6 3 Output on 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 en...

Page 85: ... which Auxiliary Sensor is being used The following chart 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 5 5 7 Custom Sender Tables Custom Sender Tab...

Page 86: ...le with a sensor port Unit Type Choose temperature pressure voltage current or percentage based on the sensor 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 sender table 1 Navigate to the sensor input that will be using your custom sender table 2 Select a Name Input Type and Unit Type for the contr...

Page 87: ...ATTERY HAS AN UNPOWERED NO MAIN POWER LIFETIME OF APPROXIMATELY FIVE YEARS ATTENTION LE CONTROLEUR DISPOSE D UNE BATTERIE DE SECOURS INTEGREE QUI PERMET DE CONSERVER L HEURE MEME QUAND L UNITE N EST PAS CONNECTE A L ALIMENTATION PRINCIPALE CETTE BATTERIE A UNE DUREE DE VIE D ENVIRON CINQ ANS SANS ALIMENTATION EN L ABSNECE D ALIMENTATION PRINCIPALE 5 6 1 Engine Logic The following settings determin...

Page 88: ...start the engine Preheat Mode Preheat Timer Switched Input J1939 Preheat Timer Determines the method used to control enabling the Glowplug output See the Preheat Mode section for more information Preheat Time 0 1200 s 0 90 s in firmware versions below 1 33 0 s Amount of time the Glowplug output is active before cranking the engine Used on diesel engines to warm the engine before cranking Crank Tim...

Page 89: ... Cooldown Shutdown Force Cooldown Shutdown The function the OFF button on the front panel performs while engine is running See the OFF Button Function section for more information Cooldown Time 0 6000 s in 5 s increments 0 s Amount of time to cool down the engine after a stop command has been received During this time the Warmup output turns off and the Cooldown output turns on If another start co...

Page 90: ...begins when the ECM Preheat switched input is no longer active J1939 This mode uses commands sent from the ECM over J1939 to decide when to exit preheat CAUTION DURING PREHEAT THE GLOWPLUG SWITCHED OUTPUT IS ON IT NEEDS TO BE SET TO A SWITCHED OUTPUT SEE SWITCHED OUTPUTS ATTENTION PENDANT LE PRECHAUFFAGE LA SORTIE COMMUTEE GLOWPLUG VOYANT DE PRECHAUFFAGE EST ACTIVEE ELLE DOIT ETRE PARAMETREE EN SO...

Page 91: ...anel of the controller can be configured to function in three different ways while the engine is running The following table describes each of these functions Function Description Cooldown This function causes the controller to go into cooldown Pressing the OFF button again will cause the engine to shut down Shutdown This function bypasses cooldown and causes the engine to shut down Force Cooldown...

Page 92: ...Disable Idle during cooldown Auto Idle Link Timers Engine Logic Disable Breaker Trip Disable If set to breaker trip the breaker trip will be activated whenever the controller is in the Idle Mode The breaker trip will be turned off when Idle Mode is exited if it was not in the latched state If the user de laches the breaker trip output while Auto Idle is active the breaker trip will turn off for 1 ...

Page 93: ... F in 1 F increments 32 F Warmup Idle Continue to idle when the temperature is below this setting Ignore the Debounce High Point Timers Engine Logic Idle Settings 1 to 180 F in 1 F increments 50 F Warmup Idle Always exit idle when the temperature is above this setting 5 6 1 4 2 Remote Start Inhibit in Idle Use this feature to prevent start up when the Idle Mode switch is active Settings Other Conf...

Page 94: ...t of time to run the engine Schedule Start Date 1 31 8 The day of the month for the first exerciser run This setting is only used to set the first exerciser run All subsequent exerciser runs use the Repeat Days setting to determine when they should run If the date and time selected has already gone by for the current month then the exerciser will be started on the given date in the next month Also...

Page 95: ...ng 5 6 2 2 Week Scheduler The weekly scheduler allows up to 16 unique weekly exercise times to be created By default all schedulers are disabled Timers Week Scheduler Name Range Description Weekday Sunday Saturday The day of the week on which the exercise will take place Start time 24 hour clock in 1 min increments The time at which the exercise should start on the given day At the selected time a...

Page 96: ...lt Description Start Trigger Disable Manual Start Disable Set to Manual Start to enable the Long Time Run feature Run Duration 1 5000 hr in 1 hr increments 1 hr The amount of time to run before shutting down 5 6 3 Maintenance The controller has the ability to count down the time between scheduled maintenance events Once maintenance is required the controller will alert the operator via the LCD scr...

Page 97: ...re Delta Auto Selection 3 Wire Single The wiring configuration of the generator Disable will disable AC voltage and AC frequency sensing and display 2 Wire Single One 120 VAC L N Use phase A 3 Wire Single 120 240 VAC systems Use phases A and B 3 Wire 3 Phase Three phase delta without a ground 4 Wire 3 Phase Three phase Wye system Center taped ground 4 Wire Delta Delta with a ground The high leg is...

Page 98: ...e A C Phase A B Phase A B Phase For 1 Phase 3 Wire when using the AC Voltage Select inputs This determines the phases from which the single phase voltage is read Setpoints Low Warn 50 99 in 1 increments 90 Reading at which a warning occurs Setpoints Low Fail 50 99 in 1 increments 85 Reading at which a failure occurs Setpoints High Warn 101 150 in 1 increments 110 Reading at which a warning occurs ...

Page 99: ... after crank success Once that time expires the controller will then display the selected voltage configuration The following must be set 1 Two switched inputs Switched I O Switched IN X Function must be set to the Volt Select 1 and Volt Select 2 switch input functions 2 AC Monitor Genset Voltage Voltage Source must be set to Auto Selection Rapid Configurator Software note this option will not app...

Page 100: ... to Disable The following settings are used to configure the controller s responses to frequency measurements Frequency Settings in AC Monitor Genset Freq Name Range Default Description Freq Source 50 Hz System 50 Hz 60 Hz System 60 Hz Auto Selection 60 Hz System This is the wiring configuration of the generator Selecting Auto Selection will use the RPM Frequency Select input to determine which fr...

Page 101: ...UTION IF ENABLED THE J1939 TSC1 PGN WILL BE BROADCASTED ACCORDING TO THE SELECTED SPEED OTHERWISE ONLY THE WARNING AND FAILURE SETPOINTS ARE AFFECTED BY THIS FUNCTION ATTENTION S IL EST ACTIVE LE PGN J1939 TSC1 SERA DIFFUSE SELON LA VITESSE SELECTIONNEE DANS LE CAS CONTRAIRE SEULS LES POINTS DE CONSIGNE D AVERTISSEMENT ET DE DEFAILLANCE SONT AFFECTES PAR CETTE FONCTION 5 7 3 Generator Current The ...

Page 102: ...uto Scaling 3 Phase 3 0 500 2 500 in 0 001 increments 1 000 Dummy Load Menu See the Dummy Load section Basic Alarm Menu See the Basic Alarms section IDMT Protect Disable Breaker Trip Shutdown Trip See the IDMT section IDMT Settings Menu Imbalance Mode Disable Breaker Trip Shutdown Trip See the Load Imbalance section Imbalance Set Menu Break Trip Fail Disable Enable Disable Shuts down the generator...

Page 103: ...able Breaker Trip Shutdown Trip Disable Disable Disables the IMDT feature Breaker Trip If IDMT is active the 62 switched output is activated to switch off the main generator breaker This is a latching feature The operator must press the up and down keys to reset the feature Shutdown Trip Shuts down the engine IDMT Settings TDS Const Time Dial Setting 0 1 30 in 0 1 increments 0 3 Sets the slope of ...

Page 104: ... active the 62 RapidCore name switched output is activated to switch off the main generator breaker This is a latching feature The operator must press the up and down keys to reset the latch Shutdown Trip Shuts down the engine Imbalance Set Imbalance 1 200 in 1 increments 10 The percentage of rated current that any phase must exceed the other phases by to trigger a load imbalance Imbalance Set Deb...

Page 105: ... only turned on when the engine is running 5 7 3 5 EPS Supplying Load The EPS Emergency Power System Supplying Load sets a flag in Modbus register 40006 to indicate to the Cattron RA400 remote annunciator that the generator is actively supplying power If this flag is set the RA400 will light its EPS Supplying Load indicator This is used to meet NFPA110 requirements If the actual current measured o...

Page 106: ...est stored fault codes from the ECM DM2 Auto Power ECM Enable Disable 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 s in 1 s increments 10 s Used in conjunction with Auto Power ECM When the engine shuts down the controller waits for the time specified by the ECM Power...

Page 107: ...Range Default Description Bypass Disable or Enable Disable If enabled a password is not required to change settings Timeout 0 120 min in 1 min increments 10 min How long after the password is entered before the user is required to enter it again The timeout is implemented as a simple countdown timer The following apply If the bypass time is changed this new bypass time will not be loaded until the...

Page 108: ... certain amount controlled by the Gain and Delay settings to maintain the desired set point outside of the deadband area Control pauses inside the deadband area If the sensor input goes beyond a minimum or maximum value the algorithm will pause and the RPM will be maintained at a minimum or maximum value The algorithm is a fuzzy logic type control with a deadband and a minimum maximum saturation T...

Page 109: ... increments 3 0 The high limit of the deadband Setpoints Deadband Low Deadband 1 30 in 0 1 increments 3 0 The low limit of the deadband Thresholds High Edge High Limit 1 900 in 0 1 increments 700 0 The high saturation The maximum level at which the RPM control is fixed This value takes on the units of the Aux sensor set in the Closed Loop Sensor In menu Thresholds Low Edge Low Limit 1 900 in 0 1 i...

Page 110: ...en the idle and goal speeds Ramp Setting Interm Delay Intermediate Delay 1 300 s in 1 s increments The amount of time to remain at the intermediate speed Ramp Time Sub menu Ramp Time Dwell 1 Idle to Intermediate 1 300 s in 1 s increments The amount of time to ramp from the idle to intermediate speed Ramp Time Dwell 2 Intermediate to Rated 1 300 s in 1 s increments The amount of time to ramp from t...

Page 111: ...ng Min Speed 500 4000 RPM in 1 RPM increments These are a replication of the RPM Setting menu under the Sensors Engine Speed menu The first three control the minimum and maximum values to which the engine speed can be adjusted The TSC1 RPM s setting controls the maximum rate at which the engine speed can be changed These affect automatic and manual speed control and any other speed control feature...

Page 112: ...of the following Bad ground between sensor and controller Check that there is a good ground between the negative post on the battery and the battery negative terminal J4 3 on the controller Also check that the connection from the negative post on the battery to the sensor body is good if not then add a grounding wire close to the sensor The ground strap is not sufficient AWG Ensure the ground and ...

Page 113: ... SeriesTM TE410 EN User Manual 113 9M02 9249 A001 EN Revision A 7 Technical Support For remote and communication control systems support parts and repair or technical support visit us online at www cattron com contact ...

Page 114: ...tion provided in this document is subject to change without notice Cattron Wireless Automation and Control Solutions Support For remote and communication control systems support parts and repair or technical support visit us online at www cattron com contact Cattron North America Inc 655 N River Rd NW Suite A Warren OH 44483 ...

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