Cattron DYNAGEN TOUGH Series TE410 User manual

TOUGH SeriesTM
TE410
User Manual

DynaGenTM TOUGH SeriesTM TE410 - EN
User Manual
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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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!
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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.

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•The switched outputs already contain a kickback diode. Do not connect relays with an internal kickback
diode to a switched output as the output may be shorted. This includes relays in the RelayPak
•Fusing:
- A fuse should be placed in line with the battery positive wire going to the controller power; a 10 A
fuse is suggested
- The AC Voltage A, B and C lines should be fused near the source of AC voltage with a 1 A fuse to
protect personnel if any of these lines becomes disconnected or damaged
- If using the RelayPak, the power going to the relay commons should be fused
•For noisy environments, some guidelines are as follows:
- Replace speed sensing wires with twisted pair from the sensor to the controller
- Consider using isolated sensors (i.e., two terminal) and use twisted pair wiring to connect from the
engine to the controller
When possible, the following enclosure guidelines should be followed:
•It is recommended that vibration mounts be used
•For outdoor applications, it is recommended that a sealed enclosure be used
2.2 Terminal Descriptions
Main Connector (J4)
Terminal
Name
Description
J4-1
+Battery
Provides power to the controller from the battery
J4-2
+Battery
Provides power to the controller from the battery
J4-3
Ground
Provides ground return for the controller
J4-4
Ground
Provides ground return for the controller
J4-5
Switched Input A
Configurable to detect +Battery, Ground, or Open
J4-6
Switched Input B
Configurable to detect +Battery, Ground, or Open
J4-7
Switched Input C
Configurable to detect +Battery, Ground, or Open
J4-8
Switched Output A
Outputs +Battery voltage when active (Max Current: 1 A)
J4-9
Switched Output C
Outputs +Battery voltage when active (Max Current: 1 A)
J4-10
Switched Output B
Outputs +Battery voltage when active (Max Current: 1 A)
J4-11
Sensor Ground
Provides ground return for 2-wire (isolated) sensors
J4-12
Sensor Input A
High impedance sensor input (0-7,500 Ω)
J4-13
Sensor Input B
Low impedance sensor input (0-750 Ω)
J4-14
Sensor Input C
Universal sensor input (0-750 Ω, 0-7,500 Ω, 0-5 VDC, 4-20mA). See
the Universal Sensor section for more information.

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Expansion Connector (J3)
Terminal
Name
Description
J3-1
Switched Input D
Configurable to detect +Battery, Ground, or Open
J3-2
Switched Input E
Configurable to detect +Battery, Ground, or Open
J3-3
Switched Output D
Outputs +Battery voltage when active (Max Current: 1 A)
J3-4
Switched Output E
Outputs +Battery voltage when active (Max Current: 1 A)
J3-5
Switched Output F
Outputs +Battery voltage when active (Max Current: 1 A)
J3-6
Sensor 5 V
Provides 5 VDC for electronic sensors
J3-7
Sensor Ground
Provides ground return for 2-wire sensors
J3-8
Sensor Input D
Universal sensor input (0-750 Ω, 0-7,500 Ω, 0-5 VDC, 4-20 mA). See
the Universal Sensor section for more information.
Communications Connector (J6)
Terminal
Name
Description
J6-1
RS485 + (Non-Inverting)
Non-Inverting communications line for Modbus (RS485). This is
also often known as A.
J6-2
RS485 - (Inverting)
Inverting communications line for Modbus (RS485). This is also
often known as B.
J6-3
No Connection
No Connection
J6-4
CAN-H
Communications line for CANbus (J1939)
J6-5
CAN-L
J6-6
CAN-Shield
Connect the shield of the twisted pair cable to this terminal.
J6-7
Speed Sensing A
Connect to a magnetic pickup, tachometer, 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
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 to Phase B of the generator
J7-3
Phase C
Connect to Phase C of the generator

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Terminal
Name
Description
J7-4
Neutral
Connect to neutral of the generator
Generator AC Current (J5)
Terminal
Name
Description
J5-1
Phase A
Connect to current transformer for Phase A of the generator
J5-2
Phase B
Connect to current transformer for Phase B of the generator
J5-3
Phase C
Connect to current transformer for Phase C of the generator
J5-4
CT Common
Connect to the commons of the current transformers

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2.3 Wiring Harness

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2.4 Typical Wiring Diagram

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2.5 Typical Wiring Diagram with RelayPak

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2.6 Wiring Considerations
The following sections are meant to describe certain wiring configurations and are for illustrative purposes only.
Not all applications are the same. Please ensure that you modify these examples to fit your unique system
requirements.
2.6.1 Remote Start Contact (Start/Stop)
As of firmware version 1.60, the Start/Stop is factory defaulted to switch input B (changeable) and the trigger is
factory defaulted to Close +BAT. For older firmware versions, you must set Start/Stop to Switched Input B or as
desired and set the trigger mode to Close +BAT. The trigger can be set to any of four options but Close +BAT
gives the best immunity to noise.
For runs over 20 ft (6.1 m), especially in noisy environments, Cattron recommends connecting the Start/Stop to
an external relay. The relay needs to be located as close to the controller as possible.
2.6.2 Emergency Stop Wiring
If Emergency Stop functionality is required, it must be an external mushroom-style switch wired in series with the
fuel or ignition supply to ensure reliable and immediate shutdown upon activation.
The following figure shows is an example wiring diagram of a double pole, single throw switch being used to
activate the e-stop input and cut power to the fuel solenoid. In this configuration, the e-stop is activated when
there is an open circuit to the switched input, and it is inactive when the input detects battery positive voltage.

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2.6.3 Universal Sensor
Universal Sensors have the ability to be configured to detect different sender types (0-750 Ω, 0-7,500 Ω,
0-5 VDC, 4-20 mA). The examples shown below are advanced applications of the universal sensor.
CAUTION
CUSTOM SENDER TABLES ARE REQUIRED FOR THE UNIVERSAL SENDER TO WORK WITH
THESE EXAMPLES. SEE THE CUSTOM SENDER TABLES SECTION FOR MORE INFORMATION.
ATTENTION
LES TABLEAUX CUSTOM SENDER (EMETTEUR PERSONNALISE) SONT NECESSAIRES POUR
QUE L'EMETTEUR UNIVERSEL FONCTIONNE AVEC CES EXEMPLES. VOIR LA SECTION
CUSTOM SENDER TABLES CUSTOM SENDER TABLES POUR PLUS D'INFORMATIONS.
Example #1: The following example shows the correct way to wire a 4-20 mA sensor. The 240 Ωresistor is
required to transform the 4-20 mA current into the 0-5 V voltage range required by the controller.
4-20 mA Wiring Example
Example #2: Sometimes it is required to measure voltages outside the 0-5 V range allowed by the controller. To
do this you must use a voltage divider with appropriate scaling resistors. The equation to calculate the resistor
values is as follows:
VOUT = (R1/(R1+R2)) × VIN Where: VOUT = 5 V
VIN = Maximum Voltage to Read
R1 = Common Resistor Value > 10 kΩ
R2 = Calculated Resistor Value (select closest common
resistor value)
The following diagram shows the typical wiring of a voltage divider. The resistors’values have been selected to
allow the controller to read up to 36 V from an external battery bank.
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0-36 V Wiring Example
CAUTION
A TVS (I.E., VARISTOR) IS REQUIRED IF THE BATTERY IS DIFFERENT THAN THE BATTERY
FROM WHICH THE CONTROLLER IS POWERED. THE CONTROLLER’S TVS CANNOT PROTECT
THE SENSOR INPUT FROM TRANSIENTS IN THIS CASE.
ATTENTION
UN TVS (VARISTANCE) EST NECESSAIRE SI LA BATTERIE EST DIFFERENTE DE CELLE QUI
ALIMENTE LE CONTROLEUR. DANS CE CAS, LE TVS DU CONTROLEUR NE PEUT PAS
PROTEGER L'ENTREE CAPTEUR CONTRE LES TRANSITOIRES.
2.6.4 CANbus Wiring (J1939)
The following table outlines some items that must be taken into consideration when connecting to a CANbus
engine.
Consideration
Description
Bus Termination
Each end of the bus must be terminated from CAN H to CAN L with 120 Ω +/- 10 Ω
resistors. The resistor must be able to handle at least 400 mW of power dissipation.
Cable Selection
A twisted pair 120 Ω impedance cable is required for communications. For better
protection, a shielded twisted pair cable is recommended.
Examples include the following:
•Belden 9841 - Shielded cable with one twisted pair, 24 AWG
•Belden 7895A - Shielded cable with two twisted pair, 20 AWG
For short runs of 5 ft or less, regular 18 AWG wiring can 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 six inches from the controller’s
CAN (J1939) connector. Three inches is ideal.
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Communications Wiring
It is common practice to use the fuel output to trigger the ECM key input to enable the ECM before cranking. For
some ECMs to function, they must be powered/enabled for a certain period before cranking to allow time for the
ECM to boot up. There are two ways to provide this time:
•Set a preheat time or increase the preheat time to allow a longer time for the ECM to boot up before
cranking; the fuel output turns on at the start of preheat
•Enable the Auto Power ECM setting in the Communications > CANbus (J1939) menu, which will cause
the fuel output to turn on in Auto Mode and stay on
ECM Wiring
2.6.5 Modbus Wiring
The following table outlines some items that must be taken into consideration when connecting up a Modbus
system.
Consideration
Description
Bus Termination
Each end of the bus must be terminated from A to B with 120 Ω +/- 10 Ω resistors.
The resistor must be able to handle at least 400 mW of power dissipation.
Cable Selection
Shielded twisted pair 120 Ω impedance cable is required for communications.
Shield drain wire is NOT to be used for the RS485 common. The cable must have
one twisted pair for A and B and a separate wire or twisted pair for common.
An example is Belden 7895A, a two twisted pair, 20 AWG, where the second pair
can be used for the RS485 common.