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Introduction

4

© 2019 DynaGen Technologies Inc

TOUGH Series Manual

1

Introduction

The TOUGH series controllers are designed to provide complete control, protection, AC metering, and engine instrumentation
for both standard and electronic engines. The module is easily configured using either the front panel buttons or our RapidCore
Configuration software. TOUGH Series controllers are ideally suited for severe duty applications where reliability is critical such
as mobile and stationary generators.

Features and Functions:

·

5 Year Warranty

·

SAE J1939 CAN Bus 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 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 RapidCore
Configuration software

Displays:

·

Engine Temperature

·

Oil Pressure

·

Fuel Level

·

Engine Speed

·

AC Metering

·

Battery Voltage

·

Real Time Clock

·

Engine Hours

·

Time to Maintenance

·

J1939 DTCs + Custom
Text

·

Custom Senders

·

Warnings and Failures

Feature

Included

J1939 CAN Bus

Magnetic Pickup Input

150 Event Log

Clock / Exerciser

Generator Metering

Single or 3-Phase

Configurable Switched Inputs (+Battery, Ground, Open)

5

Resistive Sensors (1 High Ohm, 2 Low Ohm)

3

Universal Sensor (Resistive, 0-5V, 4-20mA)

1

Configurable Switched Outputs

6

1.1

Specifications

The TOUGH Series controllers were rigorously tested to ensure durability, reliability and functionality. The following
specifications are a brief summary of the standards to which the controller has been tested. For complete details on the testing
performed please contact DYNAGEN.

Testing Specifications

Specification

Rating

Electrical Transients

SAE1113-11

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Содержание Tough Series

Страница 1: ...Manual Revision 7 0 0 Min FW Revision 1 88 01 Date Released 2019 09 25 2019 DynaGen Technologies Inc TG350 User Manual ...

Страница 2: ...top Wiring 2 6 2 14 Universal Sensor 2 6 3 15 CAN Bus Wiring 2 6 4 17 RelayPak Optional 2 6 5 19 3 Using the Controller 20 Modes Starting and Stopping 3 1 21 Cranking Behaviour 3 1 1 21 Using Cooldown Mode 3 2 21 Warnings 3 3 22 Failures 3 4 22 Event Log 3 5 27 4 Settings 27 Operator Setup 4 1 28 Switched Inputs 4 2 31 Configurable Inputs 4 2 1 31 Switched Outputs 4 3 34 Group Outputs 4 3 1 34 Pul...

Страница 3: ...Mode 51 False Restart 52 OFF Button Function 53 Idle 53 Warmup Idle 54 Idle Inhibit 54 Schedulers 4 5 2 54 Exerciser 56 Weekly Scheduler 56 Long Time Run 56 Maintenance 4 5 3 57 AC Monitor 4 6 57 Generator Voltage 4 6 1 59 AC Voltage Select 59 Generator Frequency 4 6 2 61 RPM Frequency Select 62 Communications 4 7 62 CAN Bus J1939 4 7 1 62 Other Config 4 8 62 Password 4 8 1 63 Settings Name 4 8 2 ...

Страница 4: ...3 2019 DynaGen Technologies Inc TOUGH Series Manual User Guide ...

Страница 5: ...ed 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 RapidCore Configuration software Displays Engine Temperature Oil Pressure Fuel Level Engine Speed AC Metering Battery Voltage Real Time Clock Engine Hours Time...

Страница 6: ...m 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 36 VDC Standby Current Minimum Auto Mode 60mA 12VDC 38mA 24VDC back lighting off Off Mode 80mA 12VDC 45mA 24VDC back lighting off Actual consumption could be more depending on connected sensors and other I O Switched Inputs Battery Ground Open Closed Switched Outputs Batter...

Страница 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...

Страница 8: ...of these lines become disconnected or damaged c If using the RelayPak the power going to the relay commons should be fused 6 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 from engine to controller The following enclosure guidelines ...

Страница 9: ...ltage 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 No Connection No Connection 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 VDC 4 20mA See Universal Sensor section for more informati...

Страница 10: ...achometer or a flywheel alternator Not polarity sensitive and not required if using AC voltage terminals for speed sensing J6 8 Speed Sensing B Connect to a magnetic pickup tachometer or a flywheel alternator Not polarity sensitive and not required if using AC voltage terminals for speed sensing J6 9 No Connection No Connection J6 10 No Connection No Connection Generator AC Voltage J5 Terminal Nam...

Страница 11: ...Installation 10 2019 DynaGen Technologies Inc TOUGH Series Manual 2 3 Wiring Harnesses ...

Страница 12: ...Installation 11 2019 DynaGen Technologies Inc TOUGH Series Manual 2 4 Typical Wiring Diagram ...

Страница 13: ...Installation 12 2019 DynaGen Technologies Inc TOUGH Series Manual 2 5 Typical Wiring Diagram with RelayPak ...

Страница 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...

Страница 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...

Страница 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...

Страница 17: ...Installation 16 2019 DynaGen Technologies Inc TOUGH Series Manual ...

Страница 18: ... VM in RP100 VM refers to this voltage sensing capability Refer to drawing DWG1552 under www dynagen ca support If this capability is used the forth relay 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 ...

Страница 19: ...Installation 18 2019 DynaGen Technologies Inc TOUGH Series Manual ...

Страница 20: ...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...

Страница 21: ...p can be used for starting and stopping of the engine Unlike other inputs they only have to be activated for a short period of time 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 Schedu...

Страница 22: ...the engine there is some special functionality that must be considered The cooldown period is special in that during this time it will accept a Start Command This means if the engine is cooling down and a start command is received the controller will be placed back into a running mode and will not shut down Example The following is an example of how the cooldown functionality works 1 Remote Start ...

Страница 23: ... is set to 0 seconds Otherwise it is enabled If used ETS On Duration should be set to at least 2 to 3s otherwise this failure may occur on a normal shutdown After ETS countdown is finished if the speed was greater than 50RPM 600RPM for TG350 TG410 firmware 1 88 and greater for the previous 2s then the controller triggers this failure Load Imbalance See Load Imbalance AC Current feature Generator l...

Страница 24: ... a factory reset from the RapidCore software or the controller memory has became corrupt The controller will need to be programmed with the proper settings if applicable Service Complete Event The tech has performed service on the engine generator and has reset the maintenance counter as mentioned in Service Required above Exerciser Bypass Event The exerciser if enabled under Timers Exerciser has ...

Страница 25: ... Scheduler Start Event The controller has auto started due to a daily schedule set up in Timers Week Scheduler Start Canceled Event A daily scheduler was canceled either because the controller was not in AUTO mode or start request was ignored A start request being ignored is an internal error and should not occur J1939 Start Event Controller started from J1939 using the second J1939 start stop met...

Страница 26: ...under AC Monitor Genset Voltage Possible issue with the voltage regulator or governing on the engine High Fuel Temp Warning Doosan G2 electronic engine high fuel warning This warning comes from the engine ECM over CAN J1939 Hi Exhaust Temp Warning Doosan G2 electronic engine high turbine exhaust temperature This warning comes from the engine ECM over CAN J1939 Failed To Stop Failure The controller...

Страница 27: ...he Loss of ECM under J1939 must be enabled The controller has not detected engine speed oil pressure or engine temperature on it s CAN J1939 port Under Frequency Failure The generator AC frequency has fallen below the under frequency failure setpoint set under AC Monitor Genset Freq Setpoints Over Frequency Failure The generator AC frequency has risen above the over frequency failure setpoint set ...

Страница 28: ...ount of time each message is displayed on the screen before displaying next message in the buffer Display DPF DEF Display Time 0 10 seconds 2s See DPF DEF aftertreatment in the J1939 Reference Manual for more information Display LCD Backlight Timeout 10 600 seconds 600s Amount of time the LCD Backlight stays on after button activity stops Date Time Date Change 1 31 days 1 12 months 2000 2099 years...

Страница 29: ...top the controller If the input is just turned off the controller will continue to run Emergency Stop Global When active shuts down the engine displays Emergency Stop and prevents leaving the OFF mode CAUTION This should only be used for emergency stop indication on the controller The installer must provide an independent means to shut down the engine from the emergency stop button such as cutting...

Страница 30: ...ontroller ignores all warnings and failures when active Displays Battle Running when active If a failure occurs during Battle Mode it is latched and the engine will shutdown on failure when the controller leaves Battle Mode Start Inhibit Global Controller ignores all start commands and the engine cannot start when active Once Start Inhibit becomes inactive starting is enabled again If the engine i...

Страница 31: ...es Inc TOUGH Series Manual Name Description Open Input is active when neither Battery or Ground is present at the terminal NOTE When running wires over long distances over 20ft 6 1m it is recommended to use BATTERY as the trigger method ...

Страница 32: ... controllers LCD screen The pump is connected to a slave relay which is controlled by Switched Output D on the controller Relevant Settings Setting Value Switched Input C Function Configurable Warning 1 Switched Input C Active Mode Global Switched Input C Trigger Close GND Configurable Warning 1 Custom Text Water Pumping Switched Output D Warnings Configurable Warning 1 4 3 Switched Outputs The co...

Страница 33: ...er Active during the battery recharge cycle Maintenance Maintenance Required Global Active when Maintenance timer has expired If the timer has expired when the controller is in the RUN mode the output does not turn on until the controller enters the OFF or AUTO mode See the Maintenance section LowBat InCrank Low Battery During Cranking Cranking Active when Low Battery During Cranking warning is di...

Страница 34: ...nder Voltage AC Over Voltage Over Current Fuel In Basin Battery Charger Fault Configurable Warning 1 Configurable Warning 2 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 Information DTC Received DTC MIL Running Active when controller receives a DM1 from the ECM Failure Functions Fu...

Страница 35: ...e is a warning with the AC frequency The following table shows the output state based on the warnings status Low AC Frequency Warning High AC Frequency Warning Switched Output State 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 require...

Страница 36: ...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 VDO 250F custom sender Close Warning Open Warning Close Failure Open Failure DAT DAH 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 a...

Страница 37: ...stom sender table using the RapidCore Configuration software A custom table created using the RapidCore Configuration Software The text custom sender will be replaced with the custom text you choose when creating the sender The switch must close to ground Trim Offset 50 0 50 0 PSI 344 7 344 7kPa 0 PSI Calibrate a sensor by using the offset to correct errors Only applies if Sensor Type has been set...

Страница 38: ...UTO 4 4 4 Engine Speed Use the following settings configurations to allow the controller to read and interpret speed sensing data Name Range Default 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...

Страница 39: ...PM 50Hz is selected See RPM Frequency Select section for more information RPM Switch Primary Primary RPM 60Hz 500 4000 rpm 1 rpm increments 1800 rpm The Rated RPM when the Primary RPM 60Hz is selected See RPM Frequency Select section for more information RPM Output See the the RPM Output section for more information NOTE When using J1939 or Genset Voltage as a signal source connections to the spee...

Страница 40: ...ut is off Front panel speed control using the Switched Outputs Settings Name Parent Menu Range Default Description Speed Control Enable RapidCore only Engine Speed menu Enable or Disable Disable Programmable from RapidCore Configuration Software only Enables or disables front panel speed control RPM Display Sensors Engine Speed Blank AC Hertz Aux Sensor 1 Aux Sensor 2 AC Hertz Parameter to display...

Страница 41: ...tput SubMenu RPM Output Debounce 0 2 s to 10 s 0 2 s increment 2 s Sets the time to wait before turning on or off the switched output RPM Output Trigger Disable Under Over Disable Sets when to turn on the switched output relative to the Switched RPM setting RPM Output Switch RPM 500 to 3000 rpm 1 rpm increments 1800 rpm Sets the RPM to trigger on Trigger is based off of this setting 4 4 5 Battery ...

Страница 42: ... 6 0 24 0V 8 0 V Screen displays a Low Voltage During Cranking warning if voltage dips below this level during cranking NOTE When the engine is running the battery voltage will equal the alternator charging voltage The actual open circuit battery voltage may be lower than displayed Battery Recharge Sequence ...

Страница 43: ...le Global OFF Mode Not in Auto Auto Mode Running Cranking After Cranking Cooldown Determines under which operating conditions the Auxiliary Sensor is monitored Multiple selections are allowed Does not apply to Start 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...

Страница 44: ... 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 set to Fault Monitor Reading at which a warning occurs Setpoints High Failure On...

Страница 45: ...e output on indefinitely 2 Output on High Set to value that the sensor needs to rise above to turn on the output Disable Disable B Fixed Duration Start controller when the sensor drops below a certain value Run for a fixed period of time and 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...

Страница 46: ...off the output after a fixed time if the stop level is not reached Output on Low Set to value that the sensor needs to drop below to turn on the output Set to the desired maximum duration to keep the output on i e this is the timeout Set to the value the sensor needs to rise above to turn off the output Start controller when the sensor rises above a certain value Stop controller when the sensor dr...

Страница 47: ...yed Relevant 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 a...

Страница 48: ...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...

Страница 49: ...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...

Страница 50: ...nt 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 table 1 Navigate to the senso...

Страница 51: ...ed to control enabling the glowplug output See the Preheat Mode section for more information Preheat Time 0 1200 seconds 0 90 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 Time 3 30 seconds 10 s Amount of time the Crank output is active before going to crank rest This timer...

Страница 52: ...ling to shutdown If controller still detects speed RPM above 600 RPM in the last two seconds it goes to a Failed to Stop failure Warm up Idle Idle options See the Idle section for more information Idle Settings Cooldown Idle Auto Idle Link 4 5 1 1 Preheat Mode The controller has the ability to control the length of the preheat time through 3 different methods The table below describes each method ...

Страница 53: ...disconnected it takes approximately 2 5 s for the speed sensing to record 0 RPM when the speed sensing is set to a magnetic input at a speed of 3200Hz 1800RPM This is 4 5 s including the 2 s for the false restart delay So if the desired monitoring period is 10 s the False Check setting should be set to 15 s 4 5 1 3 OFF Button Function The OFF button on the front panel of the controller can be conf...

Страница 54: ... turn off for one second and then turn back on Idle Switched Output A switched output can be set to Idle to turn on whenever Idle mode is entered This is useful for electronic governors that have an idle input to tell the governor to run the engine at idle speed Note that the switched outputs are meant to drive relays so a relay must be installed to do the logic to the governor 4 5 1 4 1 Warmup Id...

Страница 55: ... is to prevent a remote start if the idle switch was accidentally left on 4 5 2 Schedulers 4 5 2 1 Exerciser The Exerciser function is used to start and run the engine periodically The following settings configure the Exerciser function Exerciser Settings in Timers menu Name Range Default Description Enable Enable Disable Disable Enables the exerciser feature Delays Pre Alarm 1 20 minutes 5 min Am...

Страница 56: ... 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 ...

Страница 57: ...en 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 Default Description Start Trigger Disable or Manual Start Disable Set to Manual Start to enable the Long Time Run feature Run Duration 1 5000 hours in 1 hour increment 1 hour The amount of time to run before sh...

Страница 58: ...AC 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 in 0 001 increments 1 000 The gain to apply to the AC voltage that is read at the controller See below for more information Nominal Volts 50 800 VAC in 1 VAC increments 240 VAC Generator line to li...

Страница 59: ...ion Note Scaling Factor The scaling factor setting can be used to calibrate the AC voltage if there are discrepancies between the reading and the actual value It can also be used if transformers are used to step up down the voltage The scaling factor applies to all phases in a system Example The voltage source is a 3 Wire 3 Phase system with a nominal voltage of 208 VAC The controller is reading 2...

Страница 60: ...me 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 determines which phases the single ph...

Страница 61: ...al Name Range Defaul t Description Setpoints High Warn Over Frequency Warning Disable 101 150 in 1 increments 110 Reading at which a warning occurs Setpoints High Fail Over Frequency Failure Disable 101 150 in 1 increments 115 Reading at which a failure occurs ...

Страница 62: ... 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 The table below shows the correspondence between the switched input status and the RPM Frequency Switched ...

Страница 63: ...bility to request 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...

Страница 64: ...l feature takes over on an engine start once the engine has ramped up to the goal speed after going through the idle and intermediate ramping The controller reads the sensor value from selected Auxiliary Sensor input 1 4 or Transducer Input Aux 5 compares the input value with the set point and then based on an algorithm increments or decrements the speed RPM by a certain amount controlled by the G...

Страница 65: ...increments 3 0 The high limit of the dead band Setpoints Deadband Low Deadband 1 30 in 0 1 increments 3 0 The low limit of the dead band Thresholds High Edge High Limit 1 900 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 0 1 increm...

Страница 66: ...on the battery to the sensor body is good if not then add a grounding wire close to the sensor 2 The group strap is not sufficient AWG Ensure the ground and power wiring can carry the large amperage for the starter motor and other equipment 3 If using a magnetic pickup sensor for speed sensing it might be generating noise Use a shield twisted pair cable from the mag sensor to the controller Refer ...

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