DynaGen Tough Series User manual

Manual Revision: 7.0.0
Min. FW Revision: 1.88.01
Date Released: 2019-09-25
© 2019 DynaGen Technologies Inc
TG350 User Manual

TG350 User Manual
© 2019 DynaGen Technologies Inc
Table of Contents
User Guide
4
1Introduction
............................................................................................................................................................................... 4
Specifications1.1
6
2Installation
............................................................................................................................................................................... 7
General Wiring Notes2.1
............................................................................................................................................................................... 7
Terminal Descriptions2.2
............................................................................................................................................................................... 10
Wiring Harnesses2.3
............................................................................................................................................................................... 11
Typical Wiring Diagram2.4
............................................................................................................................................................................... 12
Typical Wiring Diagram with RelayPak2.5
............................................................................................................................................................................... 13
Wiring Considerations2.6
....................................................................................................................................................................... 13Remote Start Contact (Start/Stop)
2.6.1
....................................................................................................................................................................... 13Emergency Stop Wiring
2.6.2
....................................................................................................................................................................... 14Universal Sensor
2.6.3
....................................................................................................................................................................... 15CAN Bus Wiring
2.6.4
....................................................................................................................................................................... 17RelayPak (Optional)
2.6.5
19
3Using the Controller
............................................................................................................................................................................... 20
Modes, Starting and Stopping3.1
....................................................................................................................................................................... 21Cranking Behaviour
3.1.1
............................................................................................................................................................................... 21
Using Cooldown Mode3.2
............................................................................................................................................................................... 21
Warnings3.3
............................................................................................................................................................................... 22
Failures3.4
............................................................................................................................................................................... 22
Event Log3.5
27
4Settings
............................................................................................................................................................................... 27
Operator Setup4.1
............................................................................................................................................................................... 28
Switched Inputs4.2
....................................................................................................................................................................... 31Configurable Inputs
4.2.1
............................................................................................................................................................................... 31
Switched Outputs4.3
....................................................................................................................................................................... 34Group Outputs
4.3.1
....................................................................................................................................................................... 34Pull and Hold Coil
4.3.2
............................................................................................................................................................................... 35
Sensors4.4
....................................................................................................................................................................... 35Engine Temperature
4.4.1
....................................................................................................................................................................... 36Oil Pressure
4.4.2
....................................................................................................................................................................... 36Fuel Level
4.4.3
....................................................................................................................................................................... 37Engine Speed
4.4.4
.......................................................................................................................................................................... 39
Front Panel Speed Control
.......................................................................................................................................................................... 40
RPM Output

TG350 User Manual
© 2019 DynaGen Technologies Inc
....................................................................................................................................................................... 40Battery
4.4.5
....................................................................................................................................................................... 42Auxiliary Sensors
4.4.6
.......................................................................................................................................................................... 46
Fault Monitor Example
.......................................................................................................................................................................... 47
Start on Low Example
.......................................................................................................................................................................... 48
Output on High Example
....................................................................................................................................................................... 49Custom Sensor Tables
4.4.7
............................................................................................................................................................................... 50
Timers4.5
....................................................................................................................................................................... 50Engine Logic
4.5.1
.......................................................................................................................................................................... 51
Preheat Mode
.......................................................................................................................................................................... 51
False Restart
.......................................................................................................................................................................... 52
OFF Button Function
.......................................................................................................................................................................... 53
Idle
............................................................................................................................................................................ 53
Warmup Idle
............................................................................................................................................................................ 54
Idle Inhibit
....................................................................................................................................................................... 54Schedulers
4.5.2
.......................................................................................................................................................................... 54
Exerciser
.......................................................................................................................................................................... 56
Weekly Scheduler
.......................................................................................................................................................................... 56
Long Time Run
....................................................................................................................................................................... 56Maintenance
4.5.3
............................................................................................................................................................................... 57
AC Monitor4.6
....................................................................................................................................................................... 57Generator Voltage
4.6.1
.......................................................................................................................................................................... 59
AC Voltage Select
....................................................................................................................................................................... 59Generator Frequency
4.6.2
.......................................................................................................................................................................... 61
RPM / Frequency Select
............................................................................................................................................................................... 62
Communications4.7
....................................................................................................................................................................... 62CAN Bus (J1939)
4.7.1
............................................................................................................................................................................... 62
Other Config4.8
....................................................................................................................................................................... 62Password
4.8.1
....................................................................................................................................................................... 63Settings Name
4.8.2
....................................................................................................................................................................... 63Process Control
4.8.3
65
5Troubleshooting

3
© 2019 DynaGen Technologies Inc
TOUGH Series Manual
User Guide

Introduction 4
© 2019 DynaGen Technologies Inc
TOUGH Series Manual
1Introduction
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

Introduction 5
© 2019 DynaGen Technologies Inc
TOUGH Series Manual
Specification
Rating
Thermal Shock and Cycling
SAE1455
Vibration Profiles
SAE1455
Electric Static Discharge
SAE1113-13: +/-8KV Direct Discharge, +/-15kV Air gap discharge
UL
UL 6200 recognized component. Consult factory 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, call factory)
Weight
Weight w/ RelayPak
0.83lb (0.38kg)
1.32lb (0.60kg)
Dimensions - controller (no gasket)
- controller w/ gasket
- controller w/ gasket and RelayPak
4.17" x 6.50" x 1.38" (10.59cm x 16.51cm x 3.51cm)
4.41" x 6.79" x 1.38" (11.20cm x 17.25cm x 3.51cm)
4.41" x 6.79" x 3.33" (11.20cm x 17.25cm x 8.46cm)
Electrical Specifications
Specification
Rating
Operating Voltage
5.5 ~ 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
+Battery @ 1A Max
Low Resistance Sensors
0 ~ 750Ohm
High Resistance Sensors
0 ~ 7,500Ohm
Universal Sensors
0 ~ 750Ohm, 0 ~ 7,500Ohm, 0 ~ 5 VDC, 4 ~ 20mA
Magnetic Pickup
10 ~ 10,000Hz 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 600VAC to the controller for UL approved installations
or 700VAC for locations where UL is not required.
Communications
SAE J1939 (Tier II, III, IV)
External Sensor Power
TG410 only: 5 VDC at a max load of 200mA

Installation 6
© 2019 DynaGen Technologies Inc
TOUGH Series Manual
2Installation
Generator systems contain high voltage circuitry and precautions to protect against electrical shock should be taken. 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.
The following general electrical safety precaution 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 the cord.
· Use fuses where appropriate.
· Ensure all equipment is properly grounded.
· Provide support to wires to prevent stress on terminals.
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. 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 controller into the panel cutout 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.
TE Series Cutout (Not To Scale)

Installation 7
© 2019 DynaGen Technologies Inc
TOUGH Series Manual
2.1 General Wiring Notes
The following important wiring guidelines should be followed:
1. Use a minimum of 18AWG wire for all connections.
2. Battery + and Battery - 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.
3. Limit the wire length to 20ft (6.1m) 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 the
controller is powered from). 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 know as a TVS or a varistor.
4. 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 included relays in the relaypak.
5. Fusing
a. A fuse should be placed inline with the battery + wire going to the controller power. A 10A fuse is suggested.
b. The AC Voltage A, B, and C lines should be fused near the source of AC voltage with a 1A fuse to protect personnel if
any 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 should be followed:
1. It is recommended to use vibration mounts.
2. For outdoor applications, it is recommended to use a sealed enclosure.
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: 1A)
J4-9
Switched Output C
Outputs +Battery voltage when active (Max Current: 1A)
J4-10
Switched Output B
Outputs +Battery voltage when active (Max Current: 1A)
J4-11
Sensor Ground
Provides ground return for 2-wire (isolated) sensors
J4-12
Sensor Input A
High impedance sensor input (0 - 7,500Ohm)
J4-13
Sensor Input B
Low impedance sensor input (0 - 750Ohm)
J4-14
Sensor Input C
Low impedance sensor input (0 - 750Ohm)
Expansion Connector (J3)
Terminal
Name
Description
J3-1
Switched Input D
Configurable to detect +Battery, Ground, or Open

Installation 8
© 2019 DynaGen Technologies Inc
TOUGH Series Manual
Terminal
Name
Description
J3-2
Switched Input E
Configurable to detect +Battery, Ground, or Open
J3-3
Switched Output D
Outputs +Battery voltage when active (Max Current: 1A)
J3-4
Switched Output E
Outputs +Battery voltage when active (Max Current: 1A)
J3-5
Switched Output F
Outputs +Battery voltage when active (Max Current: 1A)
J3-6
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 information.

Installation 9
© 2019 DynaGen Technologies Inc
TOUGH Series Manual
Communications Connector (J6)
Terminal
Name
Description
J6-1
No Connection
No Connection
J6-2
No Connection
No Connection
J6-3
No Connection
No Connection
J6-4
CAN-H
Communications line for CAN Bus (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
No Connection
No Connection
Generator AC Voltage (J5)
Terminal
Name
Description
J5-1
Phase A
Connect to Phase A of the generator
J5-2
Phase B
Connect to Phase B of the generator
J5-3
Phase C
Connect to Phase C of the generator
J5-4
Neutral
Connect to neutral of the generator

Installation 10
© 2019 DynaGen Technologies Inc
TOUGH Series Manual
2.3 Wiring Harnesses

Installation 11
© 2019 DynaGen Technologies Inc
TOUGH Series Manual
2.4 Typical Wiring Diagram

Installation 12
© 2019 DynaGen Technologies Inc
TOUGH Series Manual
2.5 Typical Wiring Diagram with RelayPak

Installation 13
© 2019 DynaGen Technologies Inc
TOUGH Series Manual
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 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 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 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 mushroom style switch wired in series with the
fuel or ignition supply to ensure reliable and immediate shutdown upon activation.
Shown below is an example wiring diagram of a double pull, 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
inactive when the input detects +Battery voltage.

Installation 14
© 2019 DynaGen Technologies Inc
TOUGH Series Manual
2.6.3 Universal Sensor
Universal Sensors have the ability to be configured to detect different sender types (0 - 750Ohm, 0 - 7,500Ohm, 0 - 5 VDC, 4 -
20mA). The examples shown below are advanced applications of the universal sensor.
NOTE: Custom Sensor tables are required for the universal sender to work with these examples. See the Custom
Sender Table section for more information.
Example #1: The following example shows the correct way for wiring a 4-20mA sensor. The 240Ohm resistor is required to
transform the 4-20mA current into the 0-5V voltage range required 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 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 36V from an external battery bank.
0-36V Wiring Example
NOTE: A TVS (i.e. varistor) is required if the battery is different than the battery the controller is powered from. The
controller's TVS cannot protect the sensor input from transients in this case.

Installation 15
© 2019 DynaGen Technologies Inc
TOUGH Series Manual
2.6.4 CAN Bus Wiring
The following table outlines some items that must be taken into consideration when connecting to a CAN bus engine.
Consideration
Description
Bus Termination
Each end of the bus must be terminated from CAN H to CAN L with 120Ohm +/- 10 Ohm
resistors. The resistor must be able to handle at least 400mW of power dissipation.
Cable Selection
A twisted pair 120Ohm impedance cable is required for communications. For better
protection a shielded twisted pair cable is recommended.
Examples are:
1. Belden 9841 - Shielded cable with one twisted pair, 24AWG
2. Belden 7895A - Shielded cable with two twisted pair, 20AWG
For short runs of 5 feet or less regular 18AWG 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 6 inches from the controller's CAN
(J1939) connector. Three inches is ideal.
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 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 -> CAN Bus (J1939) menu will cause the fuel output to turn
on in Auto mode and stay on.
ECM Wiring

Installation 16
© 2019 DynaGen Technologies Inc
TOUGH Series Manual

Installation 17
© 2019 DynaGen Technologies Inc
TOUGH Series Manual
2.6.5 RelayPak (Optional)
Model Number: RP100-VM
The RelayPak is used to provide up to four built-in slave relays in a compact and easy to wire package. This allows the low
current outputs of the controller to switch on high current relays on the RelayPak.
Note:The relayPak can be used to sense DC voltages up to 39 VDC using one of the Auxiliary Sensor Inputs on the controller.
The 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 Cube
Standards
UL 6200 recognized component. Consult
factory for UL conditions of acceptability.
WARNING: You must use relays in the RelayPak that are suitable for the system voltage. Example: 12V relays in a
12V system and 24V relays in a 24V system.

Installation 18
© 2019 DynaGen Technologies Inc
TOUGH Series Manual

Using the Controller 19
© 2019 DynaGen Technologies Inc
TOUGH Series Manual
3Using the Controller
The LCD display is the primary source of information from the controller. It allows you to view/change settings and monitor the
status of sensors and other engine peripherals.
LCD Display
Using the Menu System
Task
Description
Entering Menu
When in the OFF mode, press the enter button to bring up the menu.
Navigating Menu
Once in the menu, use the up and down arrows to navigate. Pressing enter will move you into
that menu.
Change a Setting
Scroll to the desired value and press enter to select. A check mark should appear beside that
item. Press enter again to save the setting and return to the previous screen.
Scroll Parameters
When in Auto or Running mode, pressing the up and down arrows will scroll through the
parameter pages.
Lock Screen
When in Auto or Running mode, the screen can be locked to a certain parameter page by
pressing Enter and unlocked by pressing Enter again.
Events History
Once in the menu, select Events History to view the most recent controller 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 it will not shut down the engine. See the OFF Button Function
section for more information.
Auto Button
Used for placing the controller into AUTO mode . Once in AUTO mode,
the controller waits for a start command to be received.
Run Button
Used to start the engine manually. The Off button must be used to shut
down the engine if it has been started using the front panel.
Up Button
Used for moving around in the menu, changing a setting's value, or
changing the currently displayed parameter page.
Enter Button
Used for entering the menu system, accepting settings, or locking the
LCD screen when viewing parameters .
Down Button
Used for moving around in the menu, changing a setting's value, or
changing the currently displayed parameter page .
Generator/Engine LED
Green = Engine running with no issues
Amber = Engine running with warnings
Red = Engine shut down on failure