Cattron DYNAGEN TOUGH Series TE410 User manual

TOUGH SeriesTM
TE410
User Manual

DynaGenTM TOUGH SeriesTM TE410 - EN
User Manual
2
9M02-9249-A001-EN
Revision A
Revision History
VERSION
DATE
NOTES
1.0
01/2017
Updated to include Rev 1.0 of the typical wiring diagram.
2.0
10/2018
Updated to include new drawing version, R2.0.
Updated switched outputs in Spec.
Updated power in Spec.
7.0
09/2019
A
09/2022
Document rebranded and contact information updated.
Added French Translations for all DANGER/WARNING/CAUTION statements
per UL Requirements.
Any information furnished by Cattron™ and its agents is believed to be accurate and reliable. All specifications are subject to change without notice.
Responsibility for the use andapplication ofCattronproductsrestswiththeendusersinceCattronanditsagentscannotbeawareof allpotentialuses.
Cattronmakesnowarrantiesastonon-infringementnor astothefitness, merchantability,orsustainabilityofanyCattronproductsforanyspecific
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
CattronproductsaresoldpursuanttotheTermsandConditionsofSale,a copyof whichwillbefurnisheduponrequest.Whenusedasa tradename herein,
Cattron means Cattron Holdings, Inc. or one or more subsidiaries of Cattron Holdings, Inc. Cattron™, corresponding logos, and other marks are
trademarksor registeredtrademarksofCattronHoldings,Inc.Othermarksmaybethepropertyofthirdparties.Nothinghereinprovidesalicenseunder
anyCattronoranythirdpartyintellectualpropertyright.

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Contents
1 Introduction.........................................................................................................................................................6
1.1 Specifications..........................................................................................................................................7
2 Installation ..........................................................................................................................................................9
2.1 General Wiring Notes............................................................................................................................10
2.2 Terminal Descriptions ...........................................................................................................................11
2.3 Wiring Harness......................................................................................................................................14
2.4 Typical Wiring Diagram.........................................................................................................................15
2.5 Typical Wiring Diagram with RelayPak.................................................................................................16
2.6 Wiring Considerations...........................................................................................................................17
2.6.1 Remote Start Contact (Start/Stop)...........................................................................................17
2.6.2 Emergency Stop Wiring...........................................................................................................17
2.6.3 Universal 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 ................................................................................................................................30
4 Using the Controller..........................................................................................................................................32
4.1 Modes, Starting and Stopping...............................................................................................................33
4.1.1 Starting / Cranking Behavior....................................................................................................34
4.2 Speed Control Page..............................................................................................................................35
4.3 Four Parameter Display Pages.............................................................................................................35
4.4 DM1 Page.............................................................................................................................................36
4.5 Using Cooldown Mode..........................................................................................................................36

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4.6 Warnings...............................................................................................................................................37
4.7 Failures .................................................................................................................................................38
4.8 Events History.......................................................................................................................................39
5 Settings.............................................................................................................................................................46
5.1 Operator Setup......................................................................................................................................46
5.2 Application Menu...................................................................................................................................47
5.2.1 Tank Level / Float Application Menu........................................................................................48
5.2.2 Wind Machine Application Menu..............................................................................................52
5.3 Switched Inputs.....................................................................................................................................55
5.3.1 Configurable Inputs..................................................................................................................59
5.4 Switched 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
5.7.3 Generator Current..................................................................................................................101
5.8 Communications .................................................................................................................................105
5.8.1 CANbus (J1939).....................................................................................................................105
5.8.2 Modbus (RS485)....................................................................................................................107
5.9 Other Config........................................................................................................................................107
5.9.1 Password ...............................................................................................................................107

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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

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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 Configurator software. TOUGH Series controllers are ideally suited for severe
duty applications where reliability is critical, such as mobile and stationary generators.
Features 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 Configurator Software
•Fast and rugged installation clips
•Passcode protected
•Automatic shutdowns and warnings
•Manual and remote start options
•Momentary Start/Stop inputs
•Pre-heat and many other configurable timers
•Accepts common senders (VDO, Datcon, S&W)
•Custom senders configurable with RapidCore Configurator Software

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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
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 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. Contact Cattron at
www.cattron.com for UL conditions of acceptability.
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)
(Optional heater available, contact Cattron at www.cattron.com)

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Specification
Rating
Weight
Weight w/RelayPak
0.83 lb (0.38 kg)
1.32 lb (0.60 kg)
Dimensions:
-controller (no gasket)
-controller with gasket
-controller with gasket and RelayPak
4.17”x 6.50”x 1.38”(10.59 cm x 16.51 cm x 3.51 cm)
4.41”x 6.79”x 1.38”(11.20 cm x 17.25 cm x 3.51 cm)
4.41”x 6.79”x 3.33”(11.20 cm x 17.25 cm x 8.46 cm)
Electrical Specifications
Specification
Rating
Operating Voltage
5.5 ~ 36 VDC
Standby Current (Minimum)
Auto Mode: 60 mA @ 12 VDC, 38 mA @ 24 VDC (back lighting
off)
Off Mode: 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: 50 ~ 600 VAC True RMS, Accuracy: 2%
Full Scale
Non-UL Range: 50 ~ 670 VAC
Do not connect more than 600 VAC to the controller for UL
approved installations, or 700 VAC for locations where UL is not
required.
AC Current
0 ~ 5 A (Current Transformer), Accuracy: 1% Full Scale
Communications
SAE J1939 (Tier II, III, IV)
External Sensor Power
TG410 only: 5 VDC at a max load of 200 mA

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2 Installation
Generator systems contain high voltage circuitry, and precautions should be taken to protect against electrical
shock. Failing to power down and lock out equipment can cause damage, injury or death.
WARNING
WIRING OF THIS CONTROLLER SHOULD BE PERFORMED BY QUALIFIED ELECTRICIANS
ONLY.
AVERTISSEMENT
LE CÂBLAGE DE CE CONTRÔLEUR NE DOIT ÊTRE EFFECTUÉ QUE PAR DES ÉLECTRICIENS
QUALIFIÉS.
CAUTION
HIGH VOLTAGE MAY BE PRESENT AT THE CONTROLLER.
ATTENTION
UNE HAUTE TENSION PEUT ETRE PRESENTE AU NIVEAU DU CONTROLEUR.
The 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 SAFE OPERATION, CAUTION MUST BE TAKEN AT THE
INSTALLATION SITE TO MAKE SURE IT IS FREE FROM EXCESSIVE MOISTURE, FLUCTUATING
TEMPERATURE, DUST AND CORROSIVE MATERIALS.
ATTENTION
POUR GARANTIR UN FONCTIONNEMENT CORRECT ET SUR, IL FAUT PRENDRE DES
PRECAUTIONS SUR LE SITE D'INSTALLATION POUR S'ASSURER QU'IL SOIT EXEMPT
D'HUMIDITE EXCESSIVE, DE FLUCTUATIONS DE TEMPERATURE, DE POUSSIERE, ET DE
MATERIAUX CORROSIFS.
!
!
!
!
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Choose a mounting surface with the least amount of vibration and not more than 0.125”(3.175 mm) thick.
The following steps outline the mounting procedure:
1. Choose a suitable mounting location based on the criteria above.
2. Create a rectangular cut-out in the panel that is a minimum 3.9”(99 mm) high and 6.2”(158 mm) wide.
3. Place the controller into the panel cut-out so that the LCD screen and buttons are facing out.
4. Place the mounting clips into the designated slots on the top and bottom of the controller.
5. Tighten the screws on the clips until the controller is snug against the panel. Do not over-tighten. The
bottom of the screws should angle very slightly away from the controller.
6. If applicable, snap the RelayPak (RP100) to the back of the controller. Place one side of the RP100’s
tabs into the slot on the back of the controller 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 positive and negative terminals on the battery to prevent voltage drops from negatively impacting the
controller
•Limit the wire length to 20 ft (6.1 m) to any I/O on the controller (e.g., Switched Input, Switched Outputs,
AC Sensing and Analog Inputs)
The TOUGH Series contains a TVS to protect the I/O and internals from a transient on the main battery (the
battery from which the controller is powered). If you have I/O connected to other batteries or power supplies,
those I/O must contain their own voltage transient protection. Otherwise, the I/O and/or controller can be
damaged if the transient exceeds the maximum rated voltage of the I/O. A device that provides this kind of
protection is known as a TVS or a varistor.