DynaGen TG410 User Manual Download Page 1

Page: 1 / 67

Manual Revision: 5.0.0

Min. FW Revision: 1.82

Date Released: 14/03/2017

TG410 User Manual

Summary of Contents for TG410

Page 1: ...Manual Revision 5 0 0 Min FW Revision 1 82 Date Released 14 03 2017 2017 DynaGen Technologies Inc TG410 User Manual ...

Page 2: ...ring 2 6 2 14 Universal Sensor 2 6 3 15 CAN Bus Wiring 2 6 4 17 Modbus Wiring 2 6 5 18 Current Transformers 2 6 6 20 RelayPak Optional 2 6 7 22 3 Using the Controller 23 Modes Starting and Stopping 3 1 24 Using Cooldown Mode 3 2 24 Warnings 3 3 25 Failures 3 4 25 Event Log 3 5 26 4 Settings 26 Operator Setup 4 1 27 Switched Inputs 4 2 29 Configurable Inputs 4 2 1 29 Switched Outputs 4 3 32 Group O...

Page 3: ...le 51 Warmup Idle 52 Idle Inhibit 52 Schedulers 4 5 2 52 Exerciser 54 Weekly Scheduler 54 Long Time Run 54 Maintenance 4 5 3 55 AC Monitor 4 6 55 Generator Voltage 4 6 1 57 AC Voltage Select 57 Generator Frequency 4 6 2 58 RPM Frequency Select 59 Generator Current 4 6 3 60 Basic Alarms 60 IDMT 61 Load Imbalance 62 Dummy Load 62 EPS Supplying Load 62 Communications 4 7 62 CAN Bus J1939 4 7 1 64 MOD...

Page 4: ...3 2017 DynaGen Technologies Inc TOUGH Series Manual User Guide ...

Page 5: ...on against moisture Gasket for water ingress protection resistance Free RapidCore Configuration Software Fast and rugged installation clips Passcode protected Automatic shutdowns and warnings Manual and Remote start Momentary Start Stop inputs Pre heat and many other configurable timers Accepts common senders VDO Datcon S W Custom senders configurable with DYNAGEN Configurator Displays Engine Temp...

Page 6: ...158 F 20 to 70 C Optional heater available call factory Weight Weight w RelayPak 0 83lb 0 38kg 1 32lb 0 60kg Dimensions controller no gasket controller w gasket controller w gasket and RelayPak 4 17 x 6 50 x 1 38 10 59cm x 16 51cm x 3 51cm 4 41 x 6 79 x 1 38 11 20cm x 17 25cm x 3 51cm 4 41 x 6 79 x 3 33 11 20cm x 17 25cm x 8 46cm Electrical Specifications Specification Rating Operating Voltage 5 5...

Page 7: ... the installation site to make sure it is free from excessive moisture fluctuating temperature dust and corrosive materials Choose a mounting surface with the least amount of vibration and not more than 0 125 3 175mm thick 1 Choose a suitable mounting location based on the criteria above 2 Create a rectangular cutout in the panel that is minimum 3 9 99mm high and 6 2 158mm wide 3 Place the control...

Page 8: ...This protects personnel if any of these lines become disconnected and short or touch items or personnel c If using the RelayPak the power going to the relay commons should be fused 7 For noisy environments some guidelines are a Replace speed sensing wire with twisted pair from the sensor to the controller b Consider using isolated sensors i e two terminal and use twisted pair wiring to connect fro...

Page 9: ...witched Output D Outputs Battery voltage when active Max Current 1A J3 4 Switched Output E Outputs Battery voltage when active Max Current 1A J3 5 Switched Output F Outputs Battery voltage when active Max Current 1A J3 6 Sensor 5V Provides 5 VDC for electronics sensors J3 7 Sensor Ground Provides ground return for 2 wire sensors J3 8 Sensor Input D Universal sensor input 0 750Ohm 0 7 500Ohm 0 5 VD...

Page 10: ...rminals for speed sensing J6 8 Speed Sensing B Connect to a magnetic pickup tachometer or a flywheel alternator Not polarity sensitive and not required if using AC voltage terminals for speed sensing J6 9 No Connection No Connection J6 10 RS485 Common Common line for Modbus RS485 Generator AC Voltage J7 Terminal Name Description J7 1 Phase A Connect to Phase A of the generator J7 2 Phase B Connect...

Page 11: ...Installation 10 2017 DynaGen Technologies Inc TOUGH Series Manual 2 3 Wiring Harnesses ...

Page 12: ...Installation 11 2017 DynaGen Technologies Inc TOUGH Series Manual 2 4 Typical Wiring Diagram ...

Page 13: ...Installation 12 2017 DynaGen Technologies Inc TOUGH Series Manual 2 5 Typical Wiring Diagram with RelayPak ...

Page 14: ...e trigger can be set to any of four options but Close BAT gives the best immunity to noise For runs over 20ft 6 1m especially in noisy environments Dynagen recommends connecting the Start Stop to an external relay The relay needs to be located as close to the controller as possible 2 6 2 Emergency Stop Wiring If Emergency Stop functionality is required it is mandatory to install an external mushro...

Page 15: ...red by the controller 4 20mA Wiring Example Example 2 Sometimes it is required to measure voltages outside the 0 5V range allowed by the controller To do this you must use a voltage divider with appropriate scaling resistors The equation to calculate the resistor values is as follows Vout 5V Vin Maximum Voltage to Read R1 Common Resistor Value 10kOhm R2 Calculated Resistor Value Select closest com...

Page 16: ...an often be run Shielding If using a shielded cable the shield must be connected to ground on one end of the bus only This prevents loss of data from electromagnetic interference Termination at the Controller The twisted pair cable must terminate no farther than 6 inches from the controller s CAN J1939 connector Three inches is ideal Communications Wiring It is common practice to use the fuel outp...

Page 17: ...Installation 16 2017 DynaGen Technologies Inc TOUGH Series Manual ...

Page 18: ...ommon The cable must have one twisted pair for A and B and a seperate wire or twisted pair for common An example is Belden 7895A a two twisted pair 20AWG where the second pair can be used for the RS485 common Distance Power and Ground If running power and ground from the battery of your system to a remote device use the following guidelines for the gauge of the power and ground wires 1 Up to 450ft...

Page 19: ...nimum of 1VA 3 The current transformer of each phase must be facing the same direction See below 4 The CT Common connection must be connected to the black wire on each current transformer 5 The wires from the current transformers to the controller should be as short as possible 6 The CT wires should be run in a separate conduit from the AC voltage wires NOTE If readings are unstable with the confi...

Page 20: ...Installation 19 2017 DynaGen Technologies Inc TOUGH Series Manual ...

Page 21: ...et to a Universal Input such at Sensor Input D Refer to drawing DWG1552 on our website for more information If this capability is used Relay D cannot be used Electrical Specifications Specification Rating Operating Voltage 12V 24V Output Pilot Duty Rating 5 83A Per Relay 12V Output Resistive Rating 10A Continuous Per Relay 12V 40A Momentary Per Relay 12V Relay Style Automotive Cube Standards UL 62...

Page 22: ...Installation 21 2017 DynaGen Technologies Inc TOUGH Series Manual ...

Page 23: ...ontroller event Use the up and down arrows to navigate to other events The controller can store up to 150 events If more than 150 events occur the oldest event is deleted to make room for the next event Front Panel Items Item Name Description Off Button Used for turning off the engine or exiting out of Auto mode This is not intended to function as an Emergency Stop as there are conditions in which...

Page 24: ...they only have to be activated for a short period of time Battery Recharge When the battery voltage drops below a certain level the engine will start and run for a predetermined amount of time Exerciser When the scheduled exerciser interval occurs the engine will start and run for a predetermined amount of time Weekly Scheduler When a scheduled event occurs the engine will start and run for the pr...

Page 25: ...s back into running mode and does not shut down 7 Engine can now only be shut down by using the OFF button or Emergency Stop input 3 3 Warnings Warnings are conditions that alert the user to possible issues These get enabled disabled when you enable disable various settings in the controller Notable warnings are given in the below table Warning Name Enabled Condition s Description High Fuel Level ...

Page 26: ... was greater than 50RPM for the previous 2s then the controller triggers this failure Load Imbalance See Load Imbalance AC Current feature Generator load imbalance Excessive AC current on one or more of the three phases Low Air Pressure Switched input set to Air Pres Fail function See Switched Inputs Triggered if switched input is active during starting Application specific Low Coolant Lvl Switche...

Page 27: ...Message Pop Up 1 10 seconds Amount of time each message is displayed on the screen before displaying next message in the buffer Display DPF DEF Display Time 0 10 seconds See DPF DEF aftertreatment in the J1939 Reference Manual for more information Display LCD Backlight Timeout 10 600 seconds Amount of time the LCD Backlight stays on after button activity stops Date Time Date Change 1 31 days 1 12 ...

Page 28: ...tem 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 Approximately 2 seconds These inputs allow the user to wire separate inputs for start and stop or to use a push button instead ...

Page 29: ... Select for more information ECM Preheat ECM Preheat Signal Cranking during the Preheat countdown only Controls preheating using a switched input See Switched Input in the Preheat Mode section Remote Reset Global Allows the controller to be reset from a failure mode Momentary action for 3 5s in FAILURE mode will place the controller in OFF mode Momentary action for 3 5s in OFF mode will place the ...

Page 30: ...ning 1 Custom Text Water Pumping Switched Output D Warnings Configurable Warning 1 4 3 Switched Outputs The controller has switched outputs that are turned on under certain conditions to perform a function The outputs turn on to Battery voltage to drive the load when active The following items are the available functions for switched outputs WARNING Switched outputs have a floating voltage of appr...

Page 31: ...Front Panel Speed Control section for more information RPM Decrement Running Output is used to to trigger inputs on an ECM to control speed See Front Panel Speed Control section for more information DEF Fluid Pump Running Active when DEF Fluid Level falls below the DEF Low Level and stays active until the level rises above the DEF High Level See CAN Bus J1939 section for more information Genset Di...

Page 32: ... Coolant Level Low Air Pressure Low Hydraulic Pressure Under Frequency Over Frequency AC Under Voltage AC Over Voltage Over Current TG410 only ECM Communication Failure Configurable Failure 1 Configurable Failure 2 Config Fail 3 Auxiliary Sensor 1 Auxiliary Sensor 2 Auxiliary Sensor 3 Auxiliary Sensor 4 Name Active Mode Description Load Imbalance Running AC current phases do not match More Informa...

Page 33: ... warning with the AC frequency The following table shows the output state based on the warnings status Low AC Frequency Warning High AC Frequency Warning Switched Output State Inactive Inactive OFF Inactive Active ON Active Inactive ON Active Active ON 4 3 2 Pull and Hold Coil On some engine systems the fuel pump has two coils This is because the initial power on of the fuel solenoid requires subs...

Page 34: ...e controller to read and interpret data from the engine temperature sensor or switch Sensors Engine Temp menu Name Range Description Signal Source Port A Port B Port C Port D J1939 Bus The sensor input pin where the engine temperature switch or sender is attached Engine temperature is obtained from the engine controller ECM using the CANbus communication port and J1939 protocol Sensor Type DAT DAH...

Page 35: ...0P R240 VDO 150P R180 custom sender Close Warning Open Warning Close Failure Open Failure Select the sender that is connected to the Signal Source above If using a switch select the action that should occur when the switch is active These are preprogrammed into the controller and cannot be changed DAT 100P R240 supports the Stewart Warner 279B F and Datcon 2505 00 sender tables VDO 150P R180 suppo...

Page 36: ... 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 seconds Amount of time to bypass warnings and failures after engine has started Setpoints Low Warning Disabled 1 90 Reading at which a Low Fuel Level warning occurs Only applies if Sensor Type has been set to a sender Only monitored in the RUN mode Setpoints Low Failure D...

Page 37: ...ontrol Max Speed RPM Control Speed Bias RPM Control Tsc1 RPM s RPM Display Blank AC Hertz Aux Sensor 1 Aux Sensor 2 RPM Switch Secondary Secondary RPM 50Hz 500 4000 The Rated RPM when the Secondary RPM 50Hz is selected See RPM Frequency Select section for more information RPM Switch Primary Primary RPM 60Hz 500 4000 The Rated RPM when the Primary RPM 60Hz is selected See RPM Frequency Select secti...

Page 38: ...tor 1kOhm 1 Watt from the output to ground to ensure a low logic level when output is off Front panel speed control using the Switched Outputs Settings Name Parent Menu Range Description Speed Control Enable Configuration Software only Engine Speed menu Enable Disable Enables or disables front panel speed control RPM Display Sensors Engine Speed Nothing Blank AC Frequency Auxiliary Sensor 1 Auxili...

Page 39: ... settings configurations to allow the controller to read and interpret the battery voltage level Name Range Description Battery Recharge Enable Disable Enables or disables the ability to have the engine start on low battery voltage in order to charge it Recharge Setup Level 6 0 30 0V Voltage level at which the controller starts the engine to recharge the battery Recharge Setup Pre Alarm 1 30 minut...

Page 40: ...Settings 39 2017 DynaGen Technologies Inc TOUGH Series Manual ...

Page 41: ...art on Low or Start on High for those selections the active mode is always AUTO Refer to the examples in the following pages for information on specific mode functions Disable Input cannot be triggered Global Input can be triggered at any time OFF Mode Input can be triggered while in the OFF mode Auto Mode Input can be triggered while in the AUTO mode Running Input can be triggered after a start c...

Page 42: ...xpires if enabled or until the controller is reset or powered down or in the case of a start until the user presses the OFF button Setpoints Low Warning Only applies if Func Select is set to Fault Monitor Reading at which a warning occurs Setpoints Low Failure Only applies if Func Select is set to Fault Monitor Reading at which a failure occurs Setpoints High Warning Only applies if Func Select is...

Page 43: ...d 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 Start controller when the sensor rises above a certain value Run for a fixed period of time and then stop controller Start on High Set to value that the sensor needs to rise above to start Set to the desired run duration Disable T...

Page 44: ...e to turn off the output Start controller when the sensor rises above a certain value Stop controller when the sensor drops below a certain value Stop the controller after a fixed time if the stop level is not reached Start on High Set to value that the sensor needs to rise above to start Set to the desired maximum run duration i e this is the timeout Set to the value the sensor needs to drop belo...

Page 45: ...levant Settings Setting Value Signal Source Same as Engine Temperature Display Disable If enabled controller will display Engine Temperature twice Sensor Type Same as Engine Temperature Sensor Table Name Engine Temp Active Range Running Mode Select Fault Monitor Setpoints Low Warning Disabled Setpoints Low Failure Disabled Setpoints High Warning 275 F Setpoints High Failure 350 F The chart above s...

Page 46: ...on Low High Mode Select Start on Low Mode Settings Active Time 40 minutes Mode Settings Start Level 10 5V Mode Settings Stop Level1 Disabled 1 Stop Level needs to be disabled when the engine is running because the battery voltage will equal the alternator charging voltage Having this disabled will force the engine to run for the entire duration of the active time The chart above shows the connecti...

Page 47: ...le Name Engine Temp Active Range Global Mode Select Output on High Mode Settings Active Time1 Disabled Mode Settings Start Level 325 F Mode Settings Stop Level 200 F 1 Active time is disabled because the fan needs to stay on indefinitely or until 200 F is reached Relevant Settings Switched Outputs Setting Value Switched Output X Auxiliary Sensor X Choose based on which Auxiliary Sensor is being us...

Page 48: ...sistance voltage or current based on the sensor type Use the Terminal Descriptions section to determine if your sensor is compatible 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 0F psi V A The following example outlines the steps for creating a custom sensor tabl...

Page 49: ...200 seconds 0 90 in firmware versions below 1 33 Amount of time the Glowplug output is active before cranking the engine Used on diesel engines to warm the engine before cranking Crank Time 3 30 seconds Amount of time the Crank output is active before going to crank rest This timer immediately expires upon successful cranking Midheat Time 0 90 seconds Keeps Glowplug output turned on while cranking...

Page 50: ...ve when the preheat timer is counting down the controller displays ECM Preheating on the screen after the preheat counter has finished its countdown Cranking 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 NOTE During preheat the Glowplug switched output is on it needs to be set to a switched o...

Page 51: ...ction in 3 different ways while the engine is running The table below describes each of these functions Function Description Cooldown This function causes the controller to go into cooldown Pressing the OFF button again will cause the engine to shut down Shutdown This function bypasses Cooldown and causes the engine to shut down Force Cooldown This function causes the controller to activate the co...

Page 52: ...or one section and then turn back on 4 5 1 4 1 Warmup Idle This section explains the Warmup Idle functionality The warmup idle is used to run the engine at a reduced speed at engine start Name Parent Menu Range Description Warm up Idle Timers Engine Logic Disable Warm up Timer Oil Temp Engine Temp If enabled the engine is placed in Idle mode during the warm up period Warm up Timer The engine idles...

Page 53: ...engine This prevents starting when the Idle switch is active in the AUTO mode This will also shutdown the engine if the idle switched input is activated when the controller is in the delay to start preheat cranking and crank reset states The main purpose is to prevent a remote start if the idle switch was accidentally left on 4 5 2 Schedulers Enter topic text here 4 5 2 1 Exerciser The Exerciser f...

Page 54: ...plied to all subsequent exerciser starts after the first start Exerciser Sequence If the controller is in the OFF mode if the emergency stop is activated or if the start inhibit is active then the exerciser will not run The event Bypass Exerciser will be logged in the event log and the exerciser will run again at the next scheduled time as determined by the Repeat Days setting ...

Page 55: ...er wants to divide run time between two generators When the countdown expires the controller will shutdown Long Time Run is only active if the generator was started manually i e by pressing the front Run button Timers Long Time Run Name Range Description Start Trigger Disable Default Manual Start Set to Manual Start to enable the Long Time Run feature Run Duration 1 5000 hours in 1 hour increment ...

Page 56: ...en B N will read 208VAC Selecting Auto Selection will use the Voltage Select switched inputs to determine the wiring configuration This setting also enables the AC Frequency monitoring and display Scaling Factor 0 500 2 500 The gain to apply to the AC voltage that is read at the controller See below for more information Nominal Volts 50 800 VAC Generator voltage output when operating under normal ...

Page 57: ...sed if transformers are used to step up down the voltage The scaling factor applies to all phases in a system Example The voltage source is a 3 Wire 3 Phase system with a nominal voltage of 208 VAC The controller is reading 206 3 VAC but a calibrated multimeter gives 208 3 VAC Use the formula below to determine the scaling factor 1 Scaling Factor Multimeter Reading Controller Reading 2 Scaling Fac...

Page 58: ... Volt Select 2 inputs above Name Volt Select 2 Input Genset Voltage Auto Nominal These settings corresponds to the Nominal Volts setting under the AC Monitor Genset Voltage menu Genset Voltage Auto Scaling These settings corresponds to the Scaling Factor setting under the AC Monitor Genset Voltage menu Genset Voltage Auto Single Only applies when voltage sourc is set to 1 Phase 3 Wire This determi...

Page 59: ...RPM Switch Primary RPM 60Hz Secondary RPM 50Hz Select The switched input is only monitored before a start signal has been received Once a start signal has been received changing the status of the switched input will have no effect AC Monitor Genset Freq Freq Source Auto Selection Sensors Engine Speed RPM Switch Primary Primary RPM 60Hz Sensors Engine Speed RPM Switch Secondary Secondary RPM 50Hz T...

Page 60: ...actor at which the voltage is read into the controller See below for more information Rated Amps 5 5000A Maximum current draw the generator can provide when operating under normal running conditions Auto Rated 1Ph 3 Wire 5 5000A 5A Rated Amps when using the Voltage Select inputs Auto Rated 3 Phase 1 5 5000A 5A Auto Rated 3 Phase 2 5 5000A 5A Auto Rated 3 Phase 3 5 5000A 5A Auto Scaling 1Ph 3 Wire ...

Page 61: ...Name Range Description High Warn Disable 1 125 Reading at which a warning occurs High Fail Disable 1 125 Reading at which a failure occurs Percentages are based on the Rated Amps setting The warning and failure setpoints apply to each phase separately and not to the sum of the phases 4 6 3 2 IDMT Sets an inverse time trip curve for over current When set this overrides the Over Current Failure AC M...

Page 62: ...me Range Description Imbalance Mode Disable Breaker Trip Shutdown Trip Disable Disables the Load Imbalance feature Breaker Trip If Load Imbalance is active the Breaker Trip switched output is activated to switch off the main generator breaker This is a latching feature The operator must press the and keys to reset the latch Shutdown Trip shuts down the engine Imbalance Set Imbalance 1 200 The perc...

Page 63: ...hase of the generator is above 5 of the AC over current warning set point then the EPS Supplying load flag is set For more information on this register refer to the Tough Series modbus manual or RA400 manual 4 7 Communications The controller has the ability to communicate with other systems over communication buses The following sections relate to settings associated with communications 4 7 1 CAN ...

Page 64: ...ore turning on the fuel relay This prevents unwanted start ups due to the engine not being completely shut down Cummins PGNs Enable Disable Enables or disables the broadcasting of PGNs required by Cummins engines SPN Conversion Version 1 Version 2 Version 3 Select the SPN conversion method EMS2B Frequency Select Primary Secondary For Volvo EMS2B Engine Control Modules only EMS2B Accelerator Pedal ...

Page 65: ...ble Default Enable If enabled a password is not required to change settings Timeout 0 120 minutes in 1 minute increments Default 10 minutes 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 countdown timer has ...

Page 66: ...oir Main Out controls the level while pumping fluid out of the reservoir Closed Loop Sensor In Sensor Input AUX 1 AUX 2 AUX 3 AUX 4 AUX 5 Transducer The Auxiliary Sensor Input function that is providing feedback on the reservoir level Aux 5 refers to the Transducer under the Application menu Closed Loop Delay 1 30 s in 0 1 s increments The sampling time of the control algorithm Closed Loop Gain 1 ...

Page 67: ...ed Sensing A and B terminals are used For generator voltage the AC voltage connections are used Sensor always displays its lowest or highest value The sensor could either be open not connected or shorted to ground Verify your connections and ensure the correct sender table is loaded Contacting DYNAGEN can be done by any of the methods below Technical support is offered Monday Friday 8 00am 4 00pm ...

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