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Installation

12

© 2012 DynaGen Technologies Inc.

TOUGH Series User Manual

2.5

Relay Pak (RP100)

The Relay Pak (RP100) can be used to control DC devices. Be sure to select relays based on your
system voltage (12 or 24V). Listed below are the wiring connections and their functions.

TERMINAL

FUNCTION

DESCRIPTION

J1-2
J1-5

-Battery

This connection provides a ground return line from the RP100 to
the controller.

J1-6
J1-4
J1-3
J1-1

Relay A (Coil)
Relay B (Coil)
Relay C (Coil)
Relay D (Coil)

Activated by applying 12 / 24V to the terminal. These are
intended to be connection to switched outputs on the controller.

J2
J5
J4
J7

Relay A (Contact)
Relay B (Contact)
Relay C (Contact)
Relay D (Contact)

Connect to high current auxiliary devices. Wire gauge is
dependent upon current requirements.

Pilot Duty Rating: 5.83A per relay
Resistive Rating: 10A per relay (40A Momentary)

J3

A/C Common

(Contact)

Relays A and C share a common contact point. Connect this
terminal to +Battery or -Battery. Wire gauge is dependent upon
amperage requirements.

J6

B/D Common

(Contact)

Relays B and D share a common contact point. Connect this
terminal to +Battery or -Battery. Wire gauge is dependent upon
amperage requirements.

The following is a sample wiring diagram using the RP100. Keep in mind that the wires from connector
J1 are connected to the controllers switched outputs and ground.

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Summary of Contents for Tough TG350AMF

Page 1: ...Manual Revision 1 0 Software Revision 1 2 Date Released 7 24 2012 2012 DynaGen Technologies Inc TG350AMF User Manual ...

Page 2: ... Failures and Events History 19 3 3 Starting Stopping and Controller Modes 20 Emergency Stop and Failures 3 3 1 4 Configuration 23 4 1 Engine Logic 25 4 2 Switched Inputs 27 Voltage Select 4 2 1 28 Configurable Inputs 4 2 2 28 Start Stop Momentary Function 4 2 3 29 4 3 Switched Outputs 30 Pull and Hold Coil 4 3 1 31 4 4 Sensors 33 Auxiliary Sensors 4 4 1 36 Custom Sensor Tables 4 4 2 37 Speed Sens...

Page 3: ...TOUGH Series User Manual 2012 DynaGen Technologies Inc 5 Troubleshooting and Contact Information ...

Page 4: ...nd sensors Maintenance counter Exerciser Clock 100 Event Log Conformally coated for protection against moisture and contaminants Gasket for water ingress protection IP65 Free PC Configurator Software Fast and rugged installation clips Passcode protected Automatic shutdowns and warnings Manual and remote start Momentary start stop inputs Pre heat and many configurable timers Accepts common senders ...

Page 5: ...E1113 13 Physical Specifications SPECIFICATION RATING Operating Temperature 40 to 158 F 40 to 70 C LCD Viewing Temperature 4 to 158 F 20 to 70 C Weight With Relay Pak 1 32lb 0 6kg Dimensions With Relay Pak Height x Width x Depth 4 41 x 6 79 x 3 33 11 20cm x 17 25cm x 8 46cm Electrical Specifications SPECIFICATION RATING Operating Voltage 5 5 36VDC Standby Current 50mA Switched Inputs Battery Groun...

Page 6: ...PTF Oil Pressure Sensor ACC0108 S W 2798 100 PSI 240 ohm 1 8 27 NPTF Pre assembled Harnesses The following DynaGen s harnesses are pre assembled and sold separately Each wire on the harness is 4 feet in length unless otherwise specified in the harness drawings HARNESS PART NUMBER DESCRIPTION Main I O Starter Harness DWG1475 Battery ground 3 switched inputs 3 switched outputs and 3 resistive sensor...

Page 7: ...39 01 2080 Used with Advanced I O Harness Molex 2x5 Connector 39 01 2100 Used with Magnetic Pickup J1939 Interface Harness Molex 2x7 Connector 39 01 2140 Used with Main I O Starter Harness Molex Crimp Pins 39 00 0039 Used with all Molex connectors Molex Crimp Tool 63819 0900 Used with all Molex connectors Tyco 1x4 Connector 1 480702 0 Used with 3 Phase AC Volts Harness Tyco Crimp Pins 350536 1 Use...

Page 8: ...aution must be taken at the installation site to make sure it is free from excessive moisture fluctuating temperature dust and corrosive materials Choose a mounting surface with the least amount of vibration and not more than 0 125 thick To mount the controller follow these instructions 1 Choose a suitable mounting location based on the criteria above 2 Create a rectangular cutout in the panel tha...

Page 9: ...l devices of up to 1A J4 2 Battery J4 3 Battery These connections provide a ground return line from the controller The second Battery connection can be tp provide ground for external devices of up to 1A J4 4 Battery J4 5 Switched Input A Switched inputs are configurable to detect battery voltage ground closed or open See Switched Inputs for more information J4 6 Switched Input B J4 7 Switched Inpu...

Page 10: ...rently not used J3 7 Sensor Ground Provides ground for 2 wire sensors J3 8 Sensor Input D Universal Sensor Input Can be configured using the PC Configurator to sense low resistance high resistance 0 5V or 4 20mA The 4 20mA options requires harness DWG1496 Looking at rear of controoller Universal Sensor Input Port D The Universal Sensor Input has the ability to sense low resistance high resistance ...

Page 11: ...C J5 4 Generator Neutral TERMINAL FUNCTION DESCRIPTION J7 1 Mains Phase A AMF versions only The controller can be configured in AC Monitoring to accommodate various voltage configurations See below for more information J7 2 Mains Phase B J7 3 Mains Phase C J7 4 Mains Neutral Looking at rear of controller Voltage Configurations The controller can be configured in the settings for a variety of diffe...

Page 12: ...9 is for use with electronic engines There are some special precautions that need to be taken when wiring to the electronic control module ECM If controller is not the last device on the bus connect to the existing bus and ensure that there are 120Ω terminating resistors at each end of the bus If controller is the last device on the bus you must install a 120Ω terminating resistor across the CAN H...

Page 13: ...d outputs on the controller J2 J5 J4 J7 Relay A Contact Relay B Contact Relay C Contact Relay D Contact Connect to high current auxiliary devices Wire gauge is dependent upon current requirements Pilot Duty Rating 5 83A per relay Resistive Rating 10A per relay 40A Momentary J3 A C Common Contact Relays A and C share a common contact point Connect this terminal to Battery or Battery Wire gauge is d...

Page 14: ...position if the controller fails by using a normally closed relay to the Mains coil Use limit switches if applicable to disengage the AC voltage to the coil when the switch is in that position This prevents the coil from burning out The following is an example wiring diagram for a transfer switch Keep in mind that there are some items omitted fuses connections to controller etc and that not all co...

Page 15: ...Installation 14 2012 DynaGen Technologies Inc TOUGH Series User Manual 2 7 Typical Wiring Diagram ...

Page 16: ...rs settings and time Warnings and failures will appear on the LCD Screen and will be logged into the Events History of the controller Navigation Buttons B The Navigation Buttons are used to move throughout the menu system change settings and view parameters on the LCD screen SYMBOL FUNCTION DESCRIPTION Up Used for moving around in the menu changing a settings value or changing the currently displa...

Page 17: ...Solid Red Mains Unavailable Load Symbol Only Symbol Only Switch Position Solid Green Switch Active Functional Buttons D The following table describes the function of the Functional Buttons Keep in mind that some buttons may have multiple purposes depending on the status of the controller SYMBOL FUNCTION DESCRIPTION Off Used for turning off the engine or exiting out of AUTO mode All automatic metho...

Page 18: ...he setting you wish to change highlighted press enter to view the options menu for that setting There are generally 2 types of settings One is a list setting that you must scroll up and down to select the option that you want The other type is a numerical setting To change this setting you must use the up and down buttons to scroll to the value you want To change the value quickly press and hold t...

Page 19: ... the Main Menu and then select Events History 3 Press the up or down buttons to browse through the events 4 Press enter to exit out of the Events History From this menu you can scroll up to 150 events using the up and down arrows Keep in mind the events are recorded in order so Event 1 is the most recent event and Event 150 is the oldest event NOTE If a new event is recorded and there are already ...

Page 20: ... section briefly outlines these methods NOTE The LCD backlight will turn off during the first 2 seconds of cranking to limit voltage dip during cranking Manual Start and Stop Manual starting and stopping of the generator can be done through the front panel buttons Pressing the RUN button will start the engine and pressing the OFF button will stop the engine NOTE Cool down time is bypassed when eng...

Page 21: ...e engine if a loss of mains power is detected It can can also be used to control Automatic Transfer Switch functions to allow fully automated power restoration See AMF ATS for more information 3 3 1 Emergency Stop and Failures Emergency Stop A switched input can be configured to Emergency Stop When this input becomes active the controller will immediately turn off the Fuel Relay and turn on the En...

Page 22: ...urce ii Sensor Type iii Trim Offset iv Setpoints b Fuel Level i Signal Source ii Sensor Type iii Trim Offset iv Setpoints c Aux Sensor 1 i Signal Source ii Mode Select iii Trim Offset iv Mode Settings v Setpoints d Aux Sensor 2 i Signal Source ii Mode Select iii Trim Offset iv Mode Settings v Setpoints Timers a Engine Logic i Delay To Start ii Preheat Time iii Crank Time iv Midheat Time v Crank Re...

Page 23: ...age Pop up Rate at which status messages display LCD Backlight Amount of time before the LCD backlight turns off Date Time Date Change Changes the day month and year Time Change Changes the second minute and hour Daylight Saving Determines if daylight savings time is enabled or disabled North America only Units Temperature Units Select between Celsius and Fahrenheit Pressure Units Select between P...

Page 24: ...ime Duration to rest before the next crank attempt Crank Attempts Number of attempts the engine will try to crank before going into a overcrank failure Fuel Crank Rest Fuel Output Determines if the fuel output is on or off during crank rest RPM Disconnect Crank Output The speed at which to disconnect the crank output because the engine has started successfully Post Heat Time Glowplug Output Amount...

Page 25: ... TOUGH Series User Manual The following flowchart shows a typical start up and shutdown sequences for a controller Some items from the Engine Logic section have been omitted included for illustration purposes and may not be used in your application ...

Page 26: ...d Open Input active when open neither Battery or ground is applied Active Modes Actives modes are the modes in which an input is capable of being triggered ACTIVE DESCRIPTION Disable Input is not active and cannot be triggered Global Input active in every mode with the exception of menu system Not In Auto Input active when controller is not in Auto mode Auto Input active when controller is in Auto...

Page 27: ...that there is a charger fault Momentary Start Auto Starts the engine when momentarily activated Momentary Stop Running Stops the engine when momentarily activated Configurable Warning 1 Configurable Displays a warning with custom user text See Configurable Inputs for more information Configurable Warning 2 Configurable Failure 1 Configurable Enters a failure mode and displays custom user text See ...

Page 28: ...ns to test AMF features 4 2 1 Voltage Select The controller can be configured to display different AC voltages depending on the status of the Volt Select switched inputs In order for this feature to function properly the Genset Voltage Source setting must be set to Auto Selection and the Voltage Select Inputs settings found in AC Monitoring must be configured The following table demonstrates the r...

Page 29: ...r a level sensor connected to a switched input becomes active 1 Using the PC Configurator set a switched input to Config Warn 1 and custom text to High Water Warn Wire the level sensor switch to the switched input 2 Set Input Warn 1 under the Trigger Delay menu to 45 seconds 3 Set a switched output to Config Warn 1 and wire that output to a slave relay controlling a pump 4 2 3 Start Stop Momentary...

Page 30: ...t is on Failure Global Turns on when any failure occurs Maintenance Global Turns on when the maintenance clock reaches zero Voltage Regulator Running Turns on when controller is not in idle mode Warm Up Running Turns on after the Warmup Up time has expired as defined in Engine Logic Energy to Stop Running Turns on during ETS On Duration as defined in Engine Logic Glow Plug Preheat Midheat Postheat...

Page 31: ...Volt Warn High Temp Warn Over RPM Fail Battery Fail AC Hz Failure Low Oil Pres Fail Over RPM Warn Coolant Lv Fail Fuel In Basin AMF ATS Outputs FUNCTION ACTIVE MODE DESCRIPTION Generator Coil Global Turns on to move the transfer switch into the generator position See AMF ATS for more information Mains Coil Global Turns on to move the transfer switch into the utility position See AMF ATS for more i...

Page 32: ...m Sensor Tables created using the PC Configurator See Auxiliary Sensors section for more information on functionality Auxiliary Sensor 2 Preloaded Sensor Tables The following table is the default sensors that are preloaded onto the controller and do not require a custom sensor table SENSOR NAME TYPE RESISTANCE RANGE UNIT RANGE DAT DAH Datcon 02022 00 Temperature 4220 54Ω 32 325 F VDO 250F VDO 323 ...

Page 33: ...ll detect a warning or failure based on the sensor reading The Bypass time is the number of seconds to ignore warnings and failures for that sensor after the engine has started Trim Offset This feature is used to calibrate your sensor in the case there are discrepancies between the reading and the actual value When setting the Trim Offset for temperature or oil pressure remember that the units are...

Page 34: ... points at which the controller will detect a warning or failure based on the sensor reading Mode Select Options Mode Select determines how the controller will interpret and act upon the Aux Sensor data The controller can monitor for faults turn on outputs or start the engine Refer to the Scenarios section on the next page for further information on how these settings function SETTING DESCRIPTION ...

Page 35: ...ttings can be configured in such a way that it can provide different Scenarios based on what the Stop Level and Active time are set to Refer to the table below to choose the scenario best suited for your application STOP LEVEL ACTIVE TIME DESCRIPTION Disabled Disabled Once the Start Level is reached the output or engine will turn on indefinitely Disabled Enabled Once the Start Level is reached the...

Page 36: ...re the controller and how it functions As you can see the output turns on at 325 F and stays on until it drops below 200 F The Run Time shown here is the amount of time the fan was on SETTING VALUE REASON Switched Output B Aux Sensor 1 This output will be connected to the slave relay controlling the fan Aux Signal Source Port D This is the port the engine temperature sensor will be connected to Mo...

Page 37: ... or percentage based on the sensor This defines what unit of measurement will be displayed on the front panel when monitoring the sensor Table Values These values are what creates the sensor table and allows the controller to display and monitor the sensor The more values that are entered the more accurate the readings will be NOTE For detailed information about using the sensor table utility plea...

Page 38: ...ctions to the speed sensing terminals are not required Battery Settings The controller has the ability to monitor the battery voltage supplying the controller While monitoring the controller can go into a failure mode if the voltage gets too low or too high as well as start the engine to recharge the battery SETTING DESCRIPTION Battery Recharge Enables or disables the battery recharge function Rec...

Page 39: ...he AC voltage if there is discrepancies between the reading and the actual value It can also be used if potential transformers are used to step down the voltage This setting differs from the Trim Offset in Sensors in that it multiplies by the scaling ratio instead of adding subtracting Example The voltage source is a 3 Wire 3 Phase system with a nominal voltage of 208V The controller is reading 20...

Page 40: ...erator power Manual ATS is a secondary function of AMF ATS see below for details The following drawing shows a basic diagram of how Auto Mains Failure and Automatic Transfer Switch work together Manual ATS Manual ATS mode is a way to manually start the generator and change the ATS position It can only be used when the AMF ATS Mode is set to AMF ATS To run the controller in Manual ATS you must firs...

Page 41: ...with a transfer switch Read the descriptions in the tables below for the meaning of each parameter PARAMETER DESCRIPTION Genset Drive Gen Coil output is constantly on when transferring to generator Genset Trigger Gen Coil output is connected to a normally open or closed relay Genset ATS Delay Time to wait before transferring to generator after Gen Pickup time Mains Drive Mains Coil output is const...

Page 42: ... the ability to count down the time between scheduled maintenance by a technician Once maintenance is required the controller will alert the operator by the LCD screen or a switched output if enabled wired to a lamp horn buzzer The following table describes the settings associated with the maintenance function SETTING DESCRIPTION Enable Counter Enables or disables the maintenance function Count In...

Page 43: ... ability to request stored fault codes from the ECM DM2 See Diagnostic Trouble Codes for more information Auto Power ECM When enabled the fuel relay is enabled in Auto mode so that the ECM is already powered up and initialized before the user decides to start the generator ECM Power Delay Used in conjunction with Auto Power ECM on generator shutdown the controller waits the ECM Power Delay before ...

Page 44: ...rting up and controller has not yet accessed that information If controller displays N A during running and has not shut down on Loss of ECM it means that the controller and ECM are communicating but not receiving those parameters Troubleshooting The following section outlines some common issues seen when wiring and configuring the controller for J1939 ISSUE SOLUTION Check for Communications Set E...

Page 45: ...frame J1939 21 a BAM b RTS CTS c TP DP DTC Display This setting enables or disables active fault messages DM1 monitoring When the DTC DISPLAY feature is enabled the controller can receive active faults in the RUNNING OFF and AUTO modes on the J1939 bus Any new received active faults will trigger a message NEW ACTIVE DTC and the user can read the message on the controller front panel display This n...

Page 46: ...these DTCs appears please consult your engine manufacture for the definition of this fault With some engine manufacturers the text of the message can also vary slightly between engine types When active DTC messages are being received this will cause the controller display to lock and display the messages If multiple active DTCs are received the controller will scroll and display each DTC message T...

Page 47: ...stored message To Trigger a DM2 Request simultaneously press the UP and DOWN keys for a period of 3 seconds in either the AUTO OFF or RUNNING modes The UP and DOWN keys can also be pressed to remove the DM2 message screen If the controller is in the OFF or AUTO mode when the request is triggered the ECM may not be powered on so the controller will energize the fuel relay output and wait for the EC...

Page 48: ...e 3 least significant bits of SPN 5 least significant bits of byte contain the FMI Byte 4 Most significant bit of byte contains CM 7 least significant bits of byte contains OC DTC Conversion Method Version 2 BYTE CONVERSION Byte 1 8 least significant bits of 16 most significant bits of SPN Byte 2 8 most significant bits of 16 most significant bits of SPN Byte 3 3 most significant bits of byte cont...

Page 49: ...and user manuals ISSUE SOLUTION Insert issue here Insert solution here Insert issue here Insert solution here Insert issue here Insert solution here Insert issue here Insert solution here Insert issue here Insert solution here Insert issue here Insert solution here Insert issue here Insert solution here Contact Information Contacting DynaGen can be done by any of the methods below Technical suppor...

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