DynaGen Tough TG350AMF User manual

Manual Revision: 1.0
Software Revision: 1.2
Date Released: 7/24/2012
© 2012 DynaGen Technologies Inc.
TG350AMF User Manual

TOUGH Series User Manual
© 2012 DynaGen Technologies Inc.
Table of Contents
1Introduction
................................................................................................................................... 41.1 Specifications
................................................................................................................................... 51.2 Accessories
2Installation
................................................................................................................................... 82.1 Main I/O Starter Harness
................................................................................................................................... 92.2 Advanced I/O Harness
................................................................................................................................... 102.3 3-Phase AC Volts Harness
................................................................................................................................... 112.4 Magnetic Pickup / J1939 Interface Harness
................................................................................................................................... 122.5 Relay Pak (RP100)
................................................................................................................................... 132.6 AMF / ATS Wiring
................................................................................................................................... 142.7 Typical Wiring Diagram
3Using The Controller
................................................................................................................................... 173.1 Using the Menu System
................................................................................................................................... 183.2 Warnings, Failures and Events History
................................................................................................................................... 193.3 Starting, Stopping and Controller Modes
.......................................................................................................................................................... 20Emergency Stop and Failures3.3.1
4Configuration
................................................................................................................................... 234.1 Engine Logic
................................................................................................................................... 254.2 Switched Inputs
.......................................................................................................................................................... 27Voltage Select4.2.1
.......................................................................................................................................................... 28Configurable Inputs4.2.2
.......................................................................................................................................................... 28Start / Stop (Momentary Function)4.2.3
................................................................................................................................... 294.3 Switched Outputs
.......................................................................................................................................................... 30Pull and Hold Coil4.3.1
................................................................................................................................... 314.4 Sensors
.......................................................................................................................................................... 33Auxiliary Sensors4.4.1
.......................................................................................................................................................... 36Custom Sensor Tables4.4.2
.......................................................................................................................................................... 37Speed Sensing and Battery4.4.3
................................................................................................................................... 384.5 AC Monitoring
.......................................................................................................................................................... 39AMF / ATS4.5.1
................................................................................................................................... 414.6 Exerciser and Maintenance
................................................................................................................................... 424.7 CAN Bus (J1939)
.......................................................................................................................................................... 44Diagnostic Trouble Codes4.7.1
.......................................................................................................................................................... 45DM1 Messages4.7.2
.......................................................................................................................................................... 46DM2 Messages4.7.3
.......................................................................................................................................................... 47DTC Conversion Methods4.7.4

TOUGH Series User Manual
© 2012 DynaGen Technologies Inc.
5Troubleshooting and Contact Information

Introduction 3
© 2012 DynaGen Technologies Inc.TOUGH Series User Manual
1 Introduction
The TOUGH series controllers are designed to provide complete control, protection, AC volts metering,
and engine instrumentation for both standard and electronic engines. The module is easily configured
using either the front panel buttons or our PC 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 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 voltage inputs and sensors
Maintenance counter
Exerciser Clock
100 Event Log
Conformally coated for protection against
moisture and contaminants
Gasket for water ingress protection IP65
Free PC 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 configurable timers
Accepts common senders (VDO, Datcon,
Murphy, and more)
Custom senders configurable with PC software
Displays:
Oil Pressure
Engine Temperature
Fuel Level
Oil Level
Hour Meter
RPM
Real Time Clock
AC Volts and Hz
Battery Voltage
J1939 DTC codes with
custom text
2 Custom Sensors
FEATURE
INCLUDED
J1939 CANbus
Magnetic Pickup Input
100 Event Log
Clock / Exerciser
Generator Metering
3-Phase
Mains Metering (AMF + ATS)
3-Phase
Configurable Switched Inputs
5
Resistive Sensors
3
Universal Sensor (Resistive, 0-5V, 4-20mA)
1
User Configurable Switched Outputs (+Fuel and Crank)
4

Introduction 4
© 2012 DynaGen Technologies Inc.TOUGH Series User Manual
1.1 Specifications
Testing 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.
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 )
Weight (With Relay Pak)
1.32lb (0.6kg)
Dimensions (With Relay Pak)
(Height x Width x Depth)
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
50mA
Switched Inputs
+Battery, Ground, Open, Closed
Switched Outputs
+Battery @ 1A Max
Low Resistance Sensor (Ports B and C)
0 - 750Ω
High Resistance Sensors (Port A)
0 - 7,500Ω
Universal Sensor (Port D)
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
Communications
SAE J1939 (Tier II, III, IV) and USB

Introduction 5
© 2012 DynaGen Technologies Inc.TOUGH Series User Manual
1.2 Accessories
The following items are available to be purchased from DynaGen to be used with the TOUGH Series
controllers.
ACCESSORY
PART NUMBER
DESCRIPTION
Relay Pak
RP100
Snap-on Relay Pak with 3 x 12V @ 40A relays
Enclosure (NMEA 1)
ENC0080
Steel enclosure with cutout and vibration mounts
Silicon Gasket
ENC0059
Replacement Silicon Gasket
Mounting Clip
ENC0068
Replacement Mounting Clip
12V Relays
RLY0053
Replacement 12V Relays
24V Relays
RLY0054
Replacement 24V Relays
USB Cable
ACC0084
Programming and firmware update cable
Temperature Sensor
ACC0027
Datcon 100-280C, 1/8”- 27 NPTF
Temperature Sensor
ACC0098
Datcon 100-280C, 3/8” – 18 NPTF
Temperature Sensor
ACC0099
Datcon 100-280C, 1/2” – 14 NPTF
Oil Pressure Sensor
ACC0108
S & W (2798) 100 PSI, 240 ohm, 1/8”- 27 NPTF
Pre-assembled Harnesses
The following DynaGen's harnesses are pre-assembled and sold separately. Each wire on the harness is
4 feet in length unless otherwise specified in the harness drawings.
HARNESS
PART NUMBER
DESCRIPTION
Main I/O Starter Harness
DWG1475
Battery, ground, 3 switched inputs, 3 switched
outputs, and 3 resistive sensors.
Main I/O Starter Harness for
Relay Pak
DWG1476
Battery, ground, 3 switched inputs, 3 resistive
sensors, and connections from the switched
outputs to the external Relay Pak connector.
Advanced I/O Harness
DWG1477
2 Switched Inputs, 3 Switched Outputs, and 1
Universal Sensor.
Magnetic Pickup / J1939
Interface Harness
DWG1478
J1939 and Magnetic Pickup
3-Phase AC Volts Harness
(Genset or Mains)
DWG1479
AC Voltage Sensing. Two of these harnesses are
required for genset and mains monitoring.
4 - 20mA
DWG1496
Required for universal sensor (Port D) to function
as a 4 - 20mA input.

Introduction 6
© 2012 DynaGen Technologies Inc.TOUGH Series User Manual
Custom Harness Component List
If DynaGen harnesses are not suitable for your application, custom harnesses can be created using the
following part list:
COMPONENT
PART NUMBER
NOTES
Molex 2x3 Connector
39-01-2060
Used with Relay Pak harness.
Molex 2x4 Connector
39-01-2080
Used with Advanced I/O Harness.
Molex 2x5 Connector
39-01-2100
Used with Magnetic Pickup / J1939 Interface
Harness.
Molex 2x7 Connector
39-01-2140
Used with Main I/O Starter Harness.
Molex Crimp Pins
39-00-0039
Used with all Molex connectors.
Molex Crimp Tool
63819-0900
Used with all Molex connectors.
Tyco 1x4 Connector
1-480702-0
Used with 3-Phase AC Volts Harness.
Tyco Crimp Pins
350536-1
Used with 3-Phase AC Volts Harness.
Tyco Crimp Tool
90546-1
Used with 3-Phase AC Volts Harness.
18 AWG Wire
N/A
Used with every harness.

Installation 7
© 2012 DynaGen Technologies Inc.TOUGH Series User Manual
2 Installation
Safety Precautions
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.
Mounting the Controller
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.
To mount the controller follow these instructions.
1) Choose a suitable mounting location based on the criteria above.
2) Create a rectangular cutout in the panel that is 3.9" high and 6.2" wide.
3) If applicable, snap the Relay Pak (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.
4) Place the controller into the panel cutout so that the LCD screen and buttons are facing out.
5) Place the mounting clips into the designated slots on the top and bottom of the controller.
6) 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.

Installation 8
© 2012 DynaGen Technologies Inc.TOUGH Series User Manual
2.1 Main I/O Starter Harness
The Main I/O Starter Harness (or equivalent) is required to provide power to the controller. It also has
inputs and outputs that can be interfaced to outside devices / components. There are 2 versions of this
harness offered:
1. Standard - This version does not have the pre-wired connections to an external connector that
plugs into the Relay Pak.
2. Relay Pak - This version has Ground and Switched Outputs A, B, and C wired to an external
connector that plugs into the Relay Pak.
TERMINAL
FUNCTION
DESCRIPTION
J4-1
+Battery
These connections connect battery power to the controller.
The second +Battery connection can be used to power
external devices of up to 1A.
J4-2
+Battery
J4-3
-Battery
These connections provide a ground return line from the
controller. The second -Battery connection can be tp
provide ground for external devices of up to 1A.
J4-4
-Battery
J4-5
Switched Input A
Switched inputs are configurable to detect battery voltage,
ground, closed, or open. See Switched Inputs for more
information.
J4-6
Switched Input B
J4-7
Switched Input C
J4-8
Switched Output A
Each switched output provides +Battery voltage when active
and can supply up to 1A of current.
Switched Output A is locked to Fuel Relay
Switched Output B is configurable.
Switched Output C is locked to Crank Relay.
J4-9
Switched Output C
J4-10
Switched Output B
J4-11
Sensor Ground
Provides ground for 2-wire sensors.
J4-12
Sensor Input A
High resistance sensor (0 - 7,500Ω)
J4-13
Sensor Input B
Low resistance sensor (0 - 750Ω)
J4-14
Sensor Input C
Low resistance sensor (0 - 750Ω)
Looking at rear of controller
25

Installation 9
© 2012 DynaGen Technologies Inc.TOUGH Series User Manual
2.2 Advanced I/O Harness
The Advanced I/O Harness is only required if the number of inputs and outputs on the Main I/O Starter
Harness are not sufficient to meet the requirements of your application.
TERMINAL
FUNCTION
DESCRIPTION
J3-1
Switched Input D
Switched inputs are configurable to detect battery voltage,
ground, closed, or open. See Switched Inputs for more
information.
J3-2
Switched Input E
J3-3
Switched Output D
Each switched output provides +Battery voltage when active
and can supply up to 1A of current. They can be
configurable to functions listed in Switched Outputs .
J3-4
Switched Output E
J3-5
Switched Output F
J3-6
No Connection
This terminal is currently not used.
J3-7
Sensor Ground
Provides ground for 2-wire sensors.
J3-8
Sensor Input D
(Universal Sensor Input)
Can be configured using the PC Configurator to sense low
resistance, high resistance, 0 - 5V, or 4 - 20mA. The 4-
20mA options requires harness DWG1496.
Looking at rear of controoller
Universal Sensor Input (Port D)
The Universal Sensor Input has the ability to sense low resistance, high resistance, 0 - 5V and 4 - 20mA
sensors. In order to configure this input you must use the PC Configurator. See for more information.
To use the sensor as 4 - 20mA it requires wiring harness DWG1496. The following directions describe
how to install the harness:
1. Place the crimp side of the 4 - 20mA wire into connector position J3-7.
2. Place Sensor Input D wire into the 'Run' channel of the Scotchlok connector.
3. Place the other side of the 4 - 20mA wire into the 'Stop' channel of the Scotchlok connector.
4. Drive the U-Contact down and latch the top cover.
25
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