DynaGen Tough Series User manual

Manual Revision: 1.3.0
Min. FW Revision: 1.40.14
Date Released: 05/11/2013
© 2013 DYNAGEN Technologies Inc
TG410 User Manual
Property of American Airlines

TOUGH Series Manual
© 2013 DYNAGEN Technologies Inc
Table of Contents
1Introduction
................................................................................................................................... 41.1 Specifications
2Installation
................................................................................................................................... 62.1 Terminal Descriptions
................................................................................................................................... 82.2 Typical Wiring Diagram
................................................................................................................................... 92.3 Typical Wiring Diagram with Relay Pak
................................................................................................................................... 102.4 Wiring Considerations
.......................................................................................................................................................... 10
Emergency Stop Wiring
2.4.1
.......................................................................................................................................................... 11
Universal Sensor
2.4.2
.......................................................................................................................................................... 12
CAN Bus Wiring
2.4.3
.......................................................................................................................................................... 13
Modbus Wiring
2.4.4
.......................................................................................................................................................... 14
Current Transformers
2.4.5
.......................................................................................................................................................... 15
RelayPak (Optional)
2.4.6
3Using the Controller
................................................................................................................................... 173.1 Modes, Starting and Stopping
................................................................................................................................... 183.2 Using Cooldown Mode
4Settings
................................................................................................................................... 194.1 Operator Setup
................................................................................................................................... 204.2 Switched Inputs
.......................................................................................................................................................... 22
Voltage Select
4.2.1
.......................................................................................................................................................... 22
RPM / Frequency Select
4.2.2
.......................................................................................................................................................... 23
Configurable Inputs
4.2.3
.......................................................................................................................................................... 23
Start / Stop (Momentary Function)
4.2.4
................................................................................................................................... 244.3 Switched Outputs
.......................................................................................................................................................... 26
Group Outputs
4.3.1
.......................................................................................................................................................... 26
Pull and Hold Coil
4.3.2
................................................................................................................................... 274.4 Sensors
.......................................................................................................................................................... 27
Engine Temperature
4.4.1
.......................................................................................................................................................... 27
Oil Pressure
4.4.2
.......................................................................................................................................................... 28
Fuel Level
4.4.3
.......................................................................................................................................................... 28
Engine Speed
4.4.4
......................................................................................................................................................... 29Front Panel Speed Control
.......................................................................................................................................................... 30
Battery Level
4.4.5
.......................................................................................................................................................... 31
Auxiliary
4.4.6
......................................................................................................................................................... 32Fault Monitor Example
......................................................................................................................................................... 33Start on Low / High Example
......................................................................................................................................................... 34Output on Low / High Example
.......................................................................................................................................................... 35
Custom Sender Tables
4.4.7
................................................................................................................................... 364.5 Timers
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.......................................................................................................................................................... 36
Engine Logic
4.5.1
......................................................................................................................................................... 37Preheat Mode
......................................................................................................................................................... 37OFF Button Function
.......................................................................................................................................................... 38
Exerciser
4.5.2
.......................................................................................................................................................... 39
Maintenance
4.5.3
................................................................................................................................... 404.6 AC Monitor
.......................................................................................................................................................... 40
Generator Voltage
4.6.1
.......................................................................................................................................................... 41
Generator Frequency
4.6.2
.......................................................................................................................................................... 41
Generator Current
4.6.3
................................................................................................................................... 424.7 Communications
.......................................................................................................................................................... 42
CAN Bus (J1939)
4.7.1
.......................................................................................................................................................... 43
MOD Bus (RS485)
4.7.2
5Troubleshooting
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Introduction 3
© 2013 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 DYNAGEN
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:
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 IP65
Free DYNAGEN Configurator Software
Fast and rugged installation clips
Passcode protected
Automatic shutdowns and warnings
Manual and Remote start
Momentary Start / Stop inputs
Pre-heat and many other configurable timers
Accepts common senders (VDO, Datcon)
Custom senders configurable with DYNAGEN
Configurator
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
DPF / DEF Ready
J1939 CAN Bus
Isolated RS485 Modbus
Magnetic Pickup Input
150 Event Log
Clock / Exerciser
Generator Voltage Metering
Single, 3-Phase
Generator Current Metering
Single, 3-Phase
Configurable Switched Inputs
5
Resistive Sensors (1 High Ω, 1 Low Ω)
2
Universal Sensor (Resistive, 0-5V, 4-20mA)
2
5V Sensor Output for Electronic Sensors
Configurable Switched Outputs
6
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Introduction 4
© 2013 DYNAGEN Technologies Inc
TOUGH Series Manual
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
Thermal Shock and Cycling
SAE1455
Vibration Profiles
SAE1455
Electric Static Discharge
SAE1113-13
Physical Specifications
Specification
Rating
Operating Temperature
-40 to +158°F (-40 to +70°C)
LCD Viewing Temperature
-4 to +158°F (-20 to +70°C )
(Optional heater available, call factory)
Weight
Weight w/ RelayPak
0,83lb (0.38kg)
1.32lb (0.60kg)
Dimensions
Dimensions w/ RelayPak
4.17" x 6.50" x 1.38" (10.59cm x 16.51cm 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 ~ 36VDC
Standby Current
60mA @ 12V
38mA @ 24V
Switched Inputs
+Battery, Ground, Open
Switched Outputs
+Battery @ 1A Max
Low Resistance Sensors
0 ~ 750Ω
High Resistance Sensors
0 ~ 7,500Ω
Universal Sensors
0 ~ 750Ω, 0 ~ 7,500Ω, 0 ~ 5VDC, 4 ~ 20mA
Magnetic Pickup
10 ~ 10,000Hz at 1 ~ 50VAC
AC Voltage (Line-To-Line)
50 ~ 575VAC True RMS, Accuracy: 1% Full Scale
AC Current (TG410 only)
0 ~ 5A (Current Transformer), Accuracy: 1% Full Scale
Communications
SAE J1939 (Tier II, III, IV)
Isolated RS485 (Slave Modbus RTU)
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TOUGH Series Manual
2 Installation
Generator systems contain high voltage circuitry and precautions to protect against it 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" 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" high and 6.2" 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 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 RP100s tabs into the slot
on the back of the controller and without pushing on the relays, snap the other tab into place.
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TOUGH Series Manual
2.1 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 sensors.
J4-12
Sensor Input A
High impedance sensor input (0 - 7,500Ω)
J4-13
Sensor Input B
Low impedance sensor input (0 - 750Ω)
J4-14
Sensor Input C
Universal sensor input (0 - 750Ω, 0 - 7,500Ω, 0 - 5VDC, 4 - 20mA) See
Universal Sensor section for more information.
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: 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
Sensor 5V
Provides 5V for electronics sensors.
J3-7
Sensor Ground
Provides ground return for 2-wire sensors.
J3-8
Sensor Input D
Universal sensor input (0 - 750Ω, 0 - 7,500Ω, 0 - 5VDC, 4 - 20mA) See
Universal Sensor section for more information.
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TOUGH Series Manual
Communications Connector (J6)
Terminal
Name
Description
J6-1
RS485-A
Communications line for Modbus (RS485)
J6-2
RS485-B
Communications line for Modbus (RS485)
J6-3
No Connection
No Connection
J6-4
CAN-L
Communications line for CAN Bus (J1939)
J6-5
CAN-H
Communications line for CAN Bus (J1939)
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.
J7-4
Neutral
Connect to neutral.
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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TOUGH Series Manual
2.2 Typical Wiring Diagram
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Installation 9
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TOUGH Series Manual
2.3 Typical Wiring Diagram with Relay Pak
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Installation 10
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TOUGH Series Manual
2.4 Wiring Considerations
The following sections are meant to describe certain wiring configurations for illustrative purposes. Not all applications are the
same and make sure to modify these examples to better fit your system.
2.4.1 Emergency Stop Wiring
If Emergency Stop functionality is required, it is mandatory to install an external mushroom style switched 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 use 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.
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Installation 11
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TOUGH Series Manual
2.4.2 Universal Sensor
Universal Sensors have the ability to be configured to detect different sender types (0 - 750Ω, 0 - 7,500Ω, 0 - 5VDC, 4 - 20mA).
The examples shown below are advanced applications of the universal sensor.
NOTE: Custom Sender 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 240Ω resistor is required to
change the 4-20mA current into a 0-5V voltage level that the controller can understand.
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 > 10kΩ
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
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Installation 12
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TOUGH Series Manual
2.4.3 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
device that is not at the end of the bus, it does not require a terminating resistor.
Cable Selection
1. Belden 9841 - One twisted pair, 24AWG
2. Belden 7895A - Two twisted pair, 20AWG, second pair can be used for power
Shielding
When using a Belden style cable, the shield must be grounded on one end of the bus. This
prevents loss of data from electromagnetic interference.
Communications Wiring
For the ECM to function, it must first receive power for a short time before cranking to allow it to boot up. It is common practice
to use the fuel relay output connected to a relay to trigger the key input of the ECM. There are two ways to configure this:
The fuel relay is on during Preheat therefore increasing the Preheat time in the Engine Logic menu will allow longer
time for the ECM to boot up before cranking.
Turning on the Auto Power ECM setting in the Communications -> CAN Bus (J1939) menu enables the fuel relay to be
on when controller is in Auto mode. This way the ECM will be always be on except when in OFF mode.
ECM Wiring
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TOUGH Series Manual
2.4.4 Modbus Wiring
The following table outlines some items that must be taken into consideration when connecting up a Modbus system.
Consideration
Description
Bus Termination
device that is not at the end of the bus, it does not require a terminating resistor.
Cable Selection
1. Belden 9841 - One twisted pair, 24AWG, the shield of this cable must be used for
Modbus common.
2. Belden 7895A - Two twisted pair, 20AWG, second pair can be used for power
Distance (Power and Ground)
If running power and ground from the battery of your system to another device, use the
following guidelines for the gauge of the power and ground wires:
1. Up to 450ft - 22AWG
2. Up to 700ft - 20AWG
3. Up to 1125ft - 18AWG
4. Up to 1800ft - 16AWG
5. Up to 2800ft - 14AWG
Communications Wiring
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TOUGH Series Manual
2.4.5 Current Transformers
When wiring current transformers into the system you must follow these considerations:
1. The current transformer of each phase must be facing the same direction. See below.
2. The CT Common connection must be connected the black wire on each current transformer.
3. The wires from the current transformers to the controller should be as short as possible.
NOTE: If readings are unstable with the configuration shown below, attempt connecting the CT Common's to the
negative terminal of the battery. Ensure the connecting wire is as short as possible.
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Installation 15
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TOUGH Series Manual
2.4.6 RelayPak (Optional)
The RelayPak is used to provide built-in slave relays in a compact and easy to wire package. This allows the low current
outputs of the controller to switch high current relays on the RelayPak.
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
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.
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Using the Controller 16
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TOUGH Series Manual
3 Using the Controller
The LCD display is the primary source of information of the controller. The LCD 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 now be 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
parameters pages.
Lock Screen
When in Auto or Running mode, you can lock the screen onto a certain parameter page by
pressing enter. You can unlock the screen 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 shutdown the engine. See the OFF Button Function
section for more information
Auto Button
Used for placing the controller into Auto mode. Once in Auto the controller
waits for a start command to be received.
Run Button
Used to start the engine manually. Must use the Off button to shutdown
the engine if started from front panel.
Up Button
Used for moving around in the menu, changing a settings 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 settings value, or
changing the currently displayed parameter page.
Generator LED
Green = Engine running with no issues
Amber = Engine running with warnings
Red = Engine shutdown on failure
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Using the Controller 17
© 2013 DYNAGEN Technologies Inc
TOUGH Series Manual
3.1 Modes, Starting and Stopping
The following table describes the different operating modes of the controller:
Modes
Mode / State
Description
OFF
When in the OFF mode, the engine cannot be remotely started.
Auto
When in the Auto mode, the engine waits to receive a start command.
Running
When engine is Running, the controller monitors engine parameters and waits to receive a
stop command.
Failure
When a failure occurs, the controller shuts down the engine and displays reason for failure.
The unit must be reset using the front panel OFF button with the exception of Modbus.
Menu
When in the menu you can change settings and view the events history.
The following table describes the different methods in which a controller can start. The controller must be in the AUTO mode in
order to start for all methods with the exception of Manual Run.
Starting Methods
Methods
Description
Manual Run
Pressing the Run button will start the engine. You must press the OFF button to shutdown
the engine.
Start / Stop Switched Input
When this input is active the engine will start. When the input becomes inactive the engine
will shutdown.
Momentary Switched Inputs
Switched inputs Momentary Start and Momentary Stop 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.
Auxiliary Sensors
When a properly configured Auxiliary sensor falls below / rises above a certain point the
engine will start as determined by the Auxilairy Sensors -> Mode Select settings.
Loss of Mains
(TG350AMF only)
When loss of mains power is detected the engine will start to provide power to the load. All
the appropriate settings in regards to Auto Mains Failure must be set properly.
Modbus Start
(TG410 only)
When a certain command is sent to the controller over Modbus the engine will start. See the
Modbus Reference Manual for more information.
WARNING: See the Using Cooldown Mode section for more information on how it affects starting and stopping.
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Using the Controller 18
© 2013 DYNAGEN Technologies Inc
TOUGH Series Manual
3.2 Using Cooldown Mode
When the controller is configured to have a cooldown period (See Engine Logic section) for 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 that 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 shutdown.
Example: The following is an example of how the cooldown functionality works.
1. Remote Start contacts close
2. Engine starts and is in the running mode
3. Remote Start contacts open
4. Engine starts cooldown period
5. User presses RUN button on the front panel
6. Engine moves back into running mode and does not shutdown
7. Engine can now only be shutdown by the OFF button or Emergency Stop input
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Settings 19
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TOUGH Series Manual
4 Settings
The following section relates to settings that can be changed to alter the way the controller performs its functions. Read and
review these sections carefully to ensure your settings are set correctly for your engine.
4.1 Operator Setup
The following settings are used to change the way the user interacts with the controller. They are not password protected and
can be changed by anyone from the front panel.
Name
Range
Description
Lamp Test
Function
Performs a lamp test on the LED's when selected.
Display -> LCD Reverse
Function
Reverses the white and black pixels when selected.
Display -> LCD Contrast
5 ~ 95%
Changes the contrast of the LCD.
Display -> Page Scroll
1 ~ 10 seconds
Amount of time between each auto scroll of the parameter
pages.
Display -> Message Pop-Up
1 ~ 10 seconds
Amount of time each message is displayed on the screen
before displaying next message in buffer.
Display -> DPF/DEF Display Time
0 ~ 10 seconds
See the J1939 Reference Manual for more information.
Display -> LCD Backlight Timeout
10 ~ 600 seconds
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
Sets the date.
Date / Time -> Time Change
0 ~ 23 hours
0 ~ 59 minutes
0 ~ 59 seconds
Sets the time.
Date / Time -> Daylight Savings
Enable ~ Disable
Turns Daylight Savings Time on or off.
Units -> Temperature Unit
°F or °C
Selects the units in which temperature is displayed.
Units -> Pressure Unit
PSI or kPa
Selects the units in which oil pressure is displayed.
Run from OFF
Enable ~ Disable
When enabled, allows user to start engine using the run
button while in the OFF mode. When disabled the controller
must be placed in AUTO mode before the run button can
start the engine.
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