Cattron DYNAGEN TOUGH Series TE410 User Manual
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Cattron DYNAGEN TOUGH Series TE410 User Manual

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Summary of Contents for Cattron DYNAGEN TOUGH Series TE410

  • Page 1 TOUGH Series TE410 User Manual...
  • Page 2 Cattron Holdings, Inc., or any of its affiliates or agents shall not be liable for incidental or consequential damages of any kind. All Cattron products are sold pursuant to the Terms and Conditions of Sale, a copy of which will be furnished upon request. When used as a tradename herein, Cattron means Cattron Holdings, Inc.

  • Page 3: Table Of Contents

    DynaGen TOUGH Series TE410 - EN User Manual Contents Introduction ................................. 6 Specifications ............................7 Installation ................................9 General Wiring Notes ..........................10 Terminal Descriptions ........................... 11 Wiring Harness ............................14 Typical Wiring Diagram ......................... 15 Typical Wiring Diagram with RelayPak ....................16 Wiring Considerations ...........................
  • Page 4 DynaGen TOUGH Series TE410 - EN User Manual Warnings ............................... 37 Failures ..............................38 Events History ............................39 Settings ................................46 Operator Setup ............................46 Application Menu ........................... 47 5.2.1 Tank Level / Float Application Menu ..................48 5.2.2 Wind Machine Application Menu ....................52 Switched Inputs .............................
  • Page 5 DynaGen TOUGH Series TE410 - EN User Manual 5.9.2 Settings Name / ID ......................... 107 5.9.3 Process Control ........................108 5.9.4 Pump System ......................... 109 Troubleshooting .............................. 112 Technical Support ............................113 9M02-9249-A001-EN Revision A...

  • Page 6: Introduction

    DynaGen TOUGH Series TE410 - EN User Manual 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.

  • Page 7: 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...
  • Page 8 DynaGen TOUGH Series TE410 - EN User Manual Specification Rating Weight 0.83 lb (0.38 kg) Weight w/RelayPak 1.32 lb (0.60 kg) Dimensions: - controller (no gasket) 4.17” x 6.50” x 1.38” (10.59 cm x 16.51 cm x 3.51 cm) - controller with gasket 4.41”...

  • Page 9: Installation

    DynaGen TOUGH Series TE410 - EN User Manual 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.

  • Page 10: General Wiring Notes

    DynaGen TOUGH Series TE410 - EN User Manual 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.

  • Page 11: Terminal Descriptions

    DynaGen TOUGH Series TE410 - EN User Manual • 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 •...
  • Page 12 DynaGen TOUGH Series TE410 - EN User Manual 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...
  • Page 13 DynaGen TOUGH Series TE410 - EN User Manual 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...

  • Page 14: Wiring Harness

    DynaGen TOUGH Series TE410 - EN User Manual Wiring Harness 9M02-9249-A001-EN Revision A...

  • Page 15: Typical Wiring Diagram

    DynaGen TOUGH Series TE410 - EN User Manual Typical Wiring Diagram 9M02-9249-A001-EN Revision A...

  • Page 16: Typical Wiring Diagram With Relaypak

    DynaGen TOUGH Series TE410 - EN User Manual Typical Wiring Diagram with RelayPak 9M02-9249-A001-EN Revision A...

  • Page 17: Wiring Considerations

    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.

  • Page 18: Universal Sensor

    DynaGen TOUGH Series TE410 - EN User Manual 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.

  • Page 19: Canbus Wiring (J1939)

    DynaGen TOUGH Series TE410 - EN User Manual 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.

  • Page 20: Modbus Wiring

    DynaGen TOUGH Series TE410 - EN User Manual 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.

  • Page 21: Current Transformers

    DynaGen TOUGH Series TE410 - EN User Manual Consideration Description Distance (Power and If you are running power and ground from the battery of your system to a remote Ground) device, use the following guidelines for the gauge of the power and ground wires: •...
  • Page 22 DynaGen TOUGH Series TE410 - EN User Manual CT Wiring 9M02-9249-A001-EN Revision A...

  • Page 23: Relaypak (Optional)

    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 at www.cattron.com. If this capability is used, the fourth relay, Relay D, cannot be used.
  • Page 24 DynaGen TOUGH Series TE410 - EN User Manual 9M02-9249-A001-EN Revision A...

  • Page 25: J6 Speed Inputs

    Filtering means must be provided by the installer if required. The installer must determine the suitability for their application. Cattron does not provide any means of filtering and cannot guarantee compatibility.

  • Page 26: Pumping Applications

    DynaGen TOUGH Series TE410 - EN User Manual Pumping Applications The TE Series of controllers are designed specifically with pumping applications in mind. The TE Series is capable of manual and automatic speed control. • Manual - Manually adjusting the engine speed •...

  • Page 27: Automatic Speed Control

    DynaGen TOUGH Series TE410 - EN User Manual Automatic Speed Control Automatic speed control is triggered by an AutoStart condition. AutoStart conditions include the remote start/stop, auxiliary sensor inputs, and floats. Pressing the RUN button on the front face of the controller or triggering the Key switched input do not trigger the automatic speed control;...
  • Page 28 DynaGen TOUGH Series TE410 - EN User Manual 9M02-9249-A001-EN Revision A...

  • Page 29: Ramp Up And Intermediate Speed

    DynaGen TOUGH Series TE410 - EN User Manual The Auxiliary Sensor 5 (Transducer) feature under the Application menu can be used as a safety shutdown or a warning means in case of a float failure. The following figure demonstrates this functionality. In addition, if the Transducer display setting is enabled, a tank display graphic will be shown adjacent to the float indicators indicating the fill level of the tank.

  • Page 30: Process Control Using Engine Speed

    DynaGen TOUGH Series TE410 - EN User Manual 3.2.3 Process Control using Engine Speed The process control feature is supported in the TE series firmware version 1.91 and above. Process Control (aka closed loop control) is a programmable option that can take over once the goal speed is reached after intermediate.
  • Page 31 DynaGen TOUGH Series TE410 - EN User Manual • Power / Ground - The ECM usually must be powered directly from the battery terminals • Key Switch Input (Ignition Input) - There is usually an input on the ECM that wakes the ECM and tells it a start (crank cycle) is about to begin.

  • Page 32: Using The Controller

    DynaGen TOUGH Series TE410 - EN User Manual Using 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. Using the Menu System Task Description Entering Menu...

  • Page 33: Modes, Starting And Stopping

    DynaGen TOUGH Series TE410 - EN User Manual Item / Symbol Name Description Up/Speed Increment Used for moving around in the menu, changing a setting’s value, or Button incrementing the engine speed in manual mode. Scroll/Enter Button Used for entering the menu system, accepting settings, or changing the currently displayed parameter page.

  • Page 34: Starting / Cranking Behavior

    DynaGen TOUGH Series TE410 - EN User Manual Methods Description 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 When the battery voltage drops below a certain level, the engine will start and run for a predetermined amount of time.

  • Page 35: Speed Control Page

    DynaGen TOUGH Series TE410 - EN User Manual If the controller is programmed to use CAN J1939 or a magnetic pickup (sensor or alternator output), the controller will also monitor the AC Voltage Phase A line for frequency as a backup or secondary means of crank disconnect.

  • Page 36: Dm1 Page

    DynaGen TOUGH Series TE410 - EN User Manual • Engine Speed • Battery • AC Frequency • Current Run Time • Engine Hours • Oil Pressure • Fuel Level • Engine Coolant Temperature If all four lines in a page are set to Blank, then the page is not displayed. If two adjacent rows are set to Blank, the rest of the three pairs of rows move up into the two blank rows’...

  • Page 37: Warnings

    DynaGen TOUGH Series TE410 - EN User Manual 4. Engine starts cooldown period. 5. User presses RUN button on the front panel. 6. Engine moves back into Running Mode and does not shut down. 7. Engine can now only be shut down by using the OFF button or Emergency Stop input. Warnings Warnings are conditions that alert the user to possible issues.

  • Page 38: Failures

    DynaGen TOUGH Series TE410 - EN User Manual Warning Name Enabled Condition(s) Description Low Oil Pressure Switched input set to "Oil Pres. Low oil pressure warning. Warn" function. See the Switched Inputs section. Triggered if switched input is active during the Run Mode.

  • Page 39: Events History

    DynaGen TOUGH Series TE410 - EN User Manual Failure Name Enabled Condition(s) Description Switched input set to “Hyd Pres. Low Hydraulic Refers to Low Hydraulic pressure usually. Fail” function. See the Switched Application specific. Inputs section. Triggered if switched input is active during starting.
  • Page 40 DynaGen TOUGH Series TE410 - EN User Manual Event Name Event Type Description Reset Defaults Event The controller has loaded default settings. This could have been because the user initiated a factory reset from the RapidCore software or because the controller memory has become corrupt. The controller will need to be programmed with the proper settings if applicable.
  • Page 41 DynaGen TOUGH Series TE410 - EN User Manual Event Name Event Type Description Switch Stop Event A controller stop was triggered by the momentary stop switched input. Regen Inhibited Event Electronic engines with a Diesel Particulate Filter (DPF) only. The user requested that the automatic regeneration of the DPF be disabled.
  • Page 42 DynaGen TOUGH Series TE410 - EN User Manual Event Name Event Type Description Under Voltage Warning The generator AC voltage has fallen below the under voltage warning setpoint set under AC Monitor > Genset Voltage. Possible issue with the voltage regulator or speed governor on the engine. Under Speed Warning The generator speed has fallen below the under speed warning...
  • Page 43 DynaGen TOUGH Series TE410 - EN User Manual Event Name Event Type Description Over Voltage Warning The generator AC voltage has risen above the over voltage warning setpoint set under AC Monitor > Genset Voltage. Possible issue with the voltage regulator or speed governor on the engine. High Fuel Temp Warning Doosan G2 electronic engine high fuel temperature warning.
  • Page 44 DynaGen TOUGH Series TE410 - EN User Manual Event Name Event Type Description The “Low Coolant Level” switched input is active indicating low coolant Low Coolant Lvl Failure level failure. The controller exhausted the crank attempts (specified in Timers > Over Crank Failure Engine Logic >...
  • Page 45 DynaGen TOUGH Series TE410 - EN User Manual Event Name Event Type Description Engine Stall Failure The controller is in the Run Mode and the engine speed has fallen below the crank disconnect speed. The engine stall must be enabled under Timers >...

  • Page 46: Settings

    DynaGen TOUGH Series TE410 - EN User Manual 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. Operator Setup The following settings are used to change the way the user interacts with the controller.

  • Page 47: Application Menu

    DynaGen TOUGH Series TE410 - EN User Manual Name Range Default Setting Description • Engine Hours page is desired, then set all lines to “Blank Page 2 Display > Display Line” and that page will not be shown. • Oil Pressure Engine Hours Page 2 Current Run Time is the amount of time the...

  • Page 48: Tank Level / Float Application Menu

    DynaGen TOUGH Series TE410 - EN User Manual 5.2.1 Tank Level / Float Application Menu This menu consists of six sub menus. All the sub menus, with the exception of the Float AutoStart setting under the Function menu and the Transducer menu, are a mirror of their corresponding setting in the main menu. Name Description Function...
  • Page 49 DynaGen TOUGH Series TE410 - EN User Manual Name Range Description RPM Settings > 500 ~ 4000 RPM This is a mirror of the same setting under Sensors > Rated RPM in 1 RPM increments Engine Speed. It determines the final engine speed. This is a mirror of the “Goal Speed”...
  • Page 50 TF2 231F/R240 TF1/TF2 are float sensors; 115F/R240 means it has a TP1 200P/R240 range of 115 °F at 240 Ω. TP2 100P/R240 TP1/TP2 are pressure sensors; contact Cattron at www.cattron.com for more information. Start Stop Sub Menu ---- Start Stop >...
  • Page 51 DynaGen TOUGH Series TE410 - EN User Manual Name Range Description Thresholds > Low Disable The low warning setpoint. Active in Run and Cooldown Warn Modes. 0.1 ~ 510 in 0.1 °F / % / ft increments -9.9 ~ 500 in 0.1 PSI increments Thresholds >...

  • Page 52: Wind Machine Application Menu

    DynaGen TOUGH Series TE410 - EN User Manual Name Range Description Maintain > 1 ~ 30 Deadband- in 0.1 increments 5.2.1.5 Week Scheduler These settings mirror those of the same name in Timers > Schedulers. Name Range Description Scheduler #1 Sub Menu ----- Scheduler #1 >...
  • Page 53 SenderType defined (using the RapidCore Configurator Software). TF1 115F/R240 The other four are factory defined tables. Sensors are TF2 231F/R240 available for these four predefined tables. Contact Cattron TP1 200P/R240 www.cattron.com for information on these sensors. TP2 100P/R240 Wind Machine >...
  • Page 54 DynaGen TOUGH Series TE410 - EN User Manual Name Range Description Controller shuts down on Transducer (Aux Sensor 5) “High Wind Machine > 0.1 ~ 510 in 0.1 Thresholds > High increments Failure” if the transducer value rises above this set point. Fail The Throttling sub menu more or less replicates settings in the Sensors >...

  • Page 55: Switched Inputs

    DynaGen TOUGH Series TE410 - EN User Manual Switched Inputs The controller has five switched inputs which cause the controller to perform a function when activated. The following are the default settings. Default Settings Switched Input Default Value Switched Input A Emergency Stop Switched Input B Start / Stop...
  • Page 56 DynaGen TOUGH Series TE410 - EN User Manual Name Active Mode Description Emergency Stop Global When active, shuts down the engine, displays Emergency Stop, and prevents leaving the OFF Mode. CAUTION THIS SHOULD ONLY BE USED FOR THE EMERGENCY STOP INDICATION ON THE CONTROLLER.
  • Page 57 DynaGen TOUGH Series TE410 - EN User Manual Name Active Mode Description The settings under Timers > Trigger Delays > Config Inputs and Configurable Configurable Timers > Trigger Delays > Config Fail 3 can be set to control the Failure 2 amount of time the input has to be active in order to trigger.
  • Page 58 DynaGen TOUGH Series TE410 - EN User Manual Name Active Mode Description Remote Reset Global Allows the controller to be reset from a Failure Mode. • Momentary action for 3-5 seconds in Failure Mode will place the controller in Off Mode •...

  • Page 59: Configurable Inputs

    DynaGen TOUGH Series TE410 - EN User Manual CAUTION WHEN RUNNING WIRES OVER LONG DISTANCES (OVER 20 FT / 6.1 M), IT IS RECOMMENDED THAT THE +BATTERY BE USED AS THE TRIGGER METHOD. ATTENTION LORSQUE VOUS FAITES PASSER DES FILS SUR DE LONGUES DISTANCES (AU DELA DE 6 M), IL EST RECOMMANDE D'UTILISER +BATTERIE COMME METHODE DE DECLENCHEMENT.

  • Page 60: Switched Outputs

    DynaGen TOUGH Series TE410 - EN User Manual Switched Outputs The controller has switched outputs that are turned on under certain conditions to perform a function. The outputs turn on to +Battery voltage to drive the load when active. The following items are the available functions for switched outputs.
  • Page 61 DynaGen TOUGH Series TE410 - EN User Manual Name Active Mode Description Off Mode (Not In Active when the controller is in the Off Mode. Auto) Active when the controller is in Idle Mode. For example, Idle Mode Idle Mode when the idle switched input is active or during warmup and cooldown if warmup idle and cooldown idle settings under Timers >...
  • Page 62 DynaGen TOUGH Series TE410 - EN User Manual Name Active Mode Description RPM Increment Running Output is used to trigger inputs on an ECM to control speed. See Front Panel Speed Control section for more information. RPM Decrement Running Output is used to trigger inputs on an ECM to control speed.

  • Page 63: Group Outputs

    DynaGen TOUGH Series TE410 - EN User Manual Functions DTC Received Running Active when controller receives a DM1 from the ECM. (DTC/MIL) Failure Functions Functions Overcrank Engine Failed to Stop DM1 Stop Lamp High Engine Temperature Low Oil Pressure Low Fuel Level Under Speed Over Speed Low Battery Voltage...

  • Page 64: Pull And Hold Coil

    DynaGen TOUGH Series TE410 - EN User Manual to indicate there is a warning with the AC frequency. The following table shows the output state based on the Warnings status. Low AC Frequency Warning High AC Frequency Warning Switched Output State Inactive Inactive Inactive...

  • Page 65: Sensors

    DynaGen TOUGH Series TE410 - EN User Manual Sensors The controller has four sensor inputs which can be connected to a variety of different sensors/switches depending on the input. See the Terminal Descriptions section for more information regarding the sensor types supported.
  • Page 66 DynaGen TOUGH Series TE410 - EN User Manual Name Range Default Settings Description Sensor Type DAT DAH* DAT DAH Select the sender that is connected to the Signal Source above. If using a switch, select VDO 250F* the action that should occur when the switch (custom sender)** is active.

  • Page 67: Oil Pressure

    DynaGen TOUGH Series TE410 - EN User Manual 5.5.2 Oil Pressure Use the following settings’ configurations to allow the controller to read and interpret data from the oil pressure sensor or switch. Name Range Default Settings Description Signal Source Port A Port B The sensor input pin where the oil pressure switch or sender is attached.

  • Page 68: Fuel Level

    DynaGen TOUGH Series TE410 - EN User Manual 5.5.3 Fuel Level Use the following settings’ configurations to allow the controller to read and interpret data from the fuel level sensor. Name Range Default Settings Description Signal Source Disable Disable The sensor input pin where the fuel level switch or sender is attached Port A Port B...

  • Page 69: Engine Speed

    Must use J6 pins 7 and 8. If using a distributer, a filter is often required. Contact Cattron at www.cattron.com for more information on using a distributer signal.
  • Page 70 DynaGen TOUGH Series TE410 - EN User Manual Name Range Default Settings Description Speed Settings > 1 ~ 600 (only applies when Signal Source is set to Tooth Count Mag Pickup) Number of teeth on the flywheel. If the number of teeth is unknown, the following formula can be used.
  • Page 71 DynaGen TOUGH Series TE410 - EN User Manual Name Range Default Settings Description RPM Switch > 500 ~ 4000 RPM 1500 RPM The Rated RPM when the Secondary RPM Secondary in 1 RPM / 50 Hz is selected. See RPM / Frequency (Secondary RPM / increments Select...
  • Page 72 DynaGen TOUGH Series TE410 - EN User Manual Speed Control Methods Setting Description Front Panel Speed Control The controller can instruct the ECM of an electronic engine to adjust its using J1939 TSC1 speed by broadcasting the TSC1 command. Refer to the J1939 Reference Manual for more information. Front Panel Speed Control The controller can instruct the ECM of an electronic engine to adjust its using Switched Outputs...
  • Page 73 DynaGen TOUGH Series TE410 - EN User Manual Name Parent Menu Range Default Description Limit RapidCore only. Speed Bias Speed Bias (Programmable from RapidCore Method Engine Speed Configurator Software only) Min RPM / Max menu. The method in which the minimum and maximum speeds the operator is allowed to adjust is determined.

  • Page 74: Battery

    DynaGen TOUGH Series TE410 - EN User Manual CAUTION WHEN USING SWITCHED OUTPUTS FOR SPEED CONTROL, THE SET RPM WILL DISPLAY '---' INSTEAD OF THE SET SPEED. ATTENTION SI VOUS UTILISEZ DES SORTIES COMMUTEES POUR LA COMMANDE DE VITESSE, SET RPM (REGIME MOTEUR DE CONSIGNE EN TOURS/MINUTE) AFFICHERA «...

  • Page 75: Auxiliary Sensors

    DynaGen TOUGH Series TE410 - EN User Manual CAUTION WHEN THE ENGINE IS RUNNING, THE BATTERY VOLTAGE WILL EQUAL THE ALTERNATOR CHARGING VOLTAGE. THE ACTUAL OPEN-CIRCUIT BATTERY VOLTAGE MAY BE LOWER THAN DISPLAYED. ATTENTION QUAND LE MOTEUR TOURNE, LA TENSION DE BATTERIE EST EGALE A LA TENSION DE CHARGE DE L'ALTERNATEUR.
  • Page 76 DynaGen TOUGH Series TE410 - EN User Manual Note: There is a fifth sensor – the Transducer Sensor (Auxiliary Sensor 5 in RapidCore) – that is similar to the Auxiliary Sensors. It is set in the Application Menu > Transducer Menu (or Sensors >...
  • Page 77 DynaGen TOUGH Series TE410 - EN User Manual Name Range Default Description Active Mode Disable ----- Determines under which operating conditions the Auxiliary Sensor is monitored. Multiple selections Global are allowed. Does not apply to “Start on Low” or Off Mode (Not in “Start on High”;...
  • Page 78 DynaGen TOUGH Series TE410 - EN User Manual Name Range Default Description Mode Settings > 0 ~ 90 s ----- The amount of time to ignore the sensor input Bypass Time in 1 s increments after the desired active mode is first entered. Once triggered, the bypass time does not apply again until the device resets (for example, transitioning from Run to the Off or Auto state) or...
  • Page 79 DynaGen TOUGH Series TE410 - EN User Manual Name Range Default Description Setpoints > High (Only applies if Func. Select is set to Fault Failure Monitor.) Reading at which a failure occurs. Timers > Trigger Delays Aux Sensors menu: Aux 1 1 to 45 s Func.
  • Page 80 DynaGen TOUGH Series TE410 - EN User Manual Func. Start Level Run Time Stop Level Behavior Select Start controller when the Start on Set to value that Disable Disable sensor drops below a the sensor needs Indefinitely certain value. Run to drop below to indefinitely.
  • Page 81 DynaGen TOUGH Series TE410 - EN User Manual Func. Start Level Run Time Stop Level Behavior Select Turn on an output when Output Set to value that Disable Set to the value the sensor drops below a on Low the sensor needs the sensor certain value.
  • Page 82 DynaGen TOUGH Series TE410 - EN User Manual Func. Start Level Run Time Stop Level Behavior Select Turn on an output when Output Set to value that Set to the Set to the value the sensor rises above a on High the sensor needs desired the sensor...
  • Page 83 DynaGen TOUGH Series TE410 - EN User Manual Setting Value Setpoints > Low Failure Disabled Setpoints > High Warning 275 °F Setpoints > High Failure 350 °F The following chart shows the connection between engine temperature and time. At approximately 13 minutes run time, the temperature rises above the 275 °F warning threshold, activating the warning display.
  • Page 84 DynaGen TOUGH Series TE410 - EN User Manual Setting Value Mode Select Start on Low Mode Settings > Active Time 40 min Mode Settings > Start Level 10.5 V Mode Settings > Stop Level Disabled Stop Level needs to be disabled when the engine is running because the battery voltage will equal the alternator charging voltage.

  • Page 85: Custom Sender Tables

    Custom Sender Tables are created using the RapidCore Configurator Software when using a sensor that is not supported by Cattron. The Configurator Software has the ability to create these custom tables, allowing the controller to properly read the sensor data.
  • Page 86 DynaGen TOUGH Series TE410 - EN User Manual CAUTION CUSTOM SENDER TABLES CAN ONLY BE CREATED WHEN USING THE CONFIGURATOR SOFTWARE. ATTENTION LES TABLEAUX D’EMISSION PERSONNALISES NE PEUVENT ETRE CREES QU’AVEC LE LOGICIEL CONFIGURATOR. Parameter Description Name The label that will be displayed in the controller (Engine Temp, Oil Pressure, etc.). Input Type Choose resistance, voltage or current based on the sensor type.

  • Page 87: Timers

    DynaGen TOUGH Series TE410 - EN User Manual Timers The controller has an internal clock which is used not only to keep time, but also to ensure that programed events happen at the correct times. The following sections are used to configure settings associated with timing functions.
  • Page 88 DynaGen TOUGH Series TE410 - EN User Manual CAUTION SETTING A TIMER’S VALUE TO 0 SECONDS WILL DISABLE THE TIMER. FOR EXAMPLE, IF DELAY TO START IS SET TO 0 S, THE CONTROLLER WILL NOT PERFORM A DELAY TO START WHEN STARTING THE ENGINE.
  • Page 89 DynaGen TOUGH Series TE410 - EN User Manual Name Range Default Description RPM Disconnect 100 ~ 2000 RPM 650 RPM Speed at which controller determines the engine has started successfully and turns off the Crank output. Postheat Time 0 ~ 90 s Amount of time the Glowplug output remains on after crank success and the engine is running.
  • Page 90 DynaGen TOUGH Series TE410 - EN User Manual Name Range Default Description Auto Idle Link 5.6.1.1 Preheat Mode The controller has the ability to control the length of the preheat time through three different methods. The following table describes each method. Preheat Mode Settings (under Timers >...
  • Page 91 DynaGen TOUGH Series TE410 - EN User Manual Name Range Default Description False Check 5 ~ 30 s Amount of time after successful cranking (False Restart in 1 s intervals to monitor for a false restart. A false Detect Time) restart is defined as the speed dropping below 250 RPM for 2 seconds.
  • Page 92 DynaGen TOUGH Series TE410 - EN User Manual This section explains the general Idle functionality. There are three ways to use Idle, as follows: • Warmup Idle – Automatically enter the Idle Mode during warmup for a period of time before going to rated speed;...
  • Page 93 DynaGen TOUGH Series TE410 - EN User Manual Name Parent Menu Range Default Description Warmup Timers > Disable Disable If enabled, the engine is placed in Idle Idle Engine Logic Mode during the warm-up period. Warm-up Timer Warm-up Timer – The engine idles during Oil Temp.

  • Page 94: Schedulers

    DynaGen TOUGH Series TE410 - EN User Manual This prevents starting when the Idle switch is active in the Auto Mode. This will also shut down the engine if the idle switched input is activated when the controller is in the delay to start, preheat, cranking, and crank reset states.
  • Page 95 DynaGen TOUGH Series TE410 - EN User Manual Exerciser Sequence If the controller is in the Off Mode, if the emergency stop is activated, or if the start inhibit is active, then the exerciser will not run. The event “Bypass Exerciser” will be logged in the Events History and the exerciser will run again at the next scheduled time as determined by the “Repeat Days”...

  • Page 96: Maintenance

    DynaGen TOUGH Series TE410 - EN User Manual When entering the Week Scheduler menu, there will be 16 sub menu items, each corresponding to one of the 16 weekly exercise times. If disabled, the entry will have dashed lines, as shown here: “-------”. If enabled, the day of week, start time, and duration will be displayed for the menu.

  • Page 97: Ac Monitor

    DynaGen TOUGH Series TE410 - EN User Manual The maintenance counter is disabled if “---” is displayed. A negative number indicates the amount of time since the maintenance timer expired. Note: The maintenance timer displays “Service Required” when this time expires. This message is only displayed the next time the controller enters the Run Mode.
  • Page 98 DynaGen TOUGH Series TE410 - EN User Manual Name Range Default Description Auto Nominal > 50 ~ 800 VAC* 208 VAC 3-Phase (1) in 1 VAC increments Auto Nominal > 50 ~ 800 VAC* 480 VAC 3-Phase (2) in 1 VAC increments Auto Nominal >...
  • Page 99 DynaGen TOUGH Series TE410 - EN User Manual Application Note: Scaling Factor The scaling factor setting can be used to calibrate the AC voltage if there are discrepancies between the reading and the actual value. It can also be used if transformers are used to step up / down the voltage. The scaling factor applies to all phases in a system.

  • Page 100: Generator Frequency

    DynaGen TOUGH Series TE410 - EN User Manual Name Volt Select 2 Input These settings correspond to the “Nominal Volts” setting under the AC Genset Voltage > Auto Nominal Monitor > Genset Voltage menu. These settings correspond to the “Scaling Factor” setting under the AC Genset Voltage >...

  • Page 101: Generator Current

    DynaGen TOUGH Series TE410 - EN User Manual use of a switched input. The following settings must be set in order for this feature to function. • Switched I/O > Switched In A/B/C/D/E > Function > RPM Switch (Primary RPM / 60 Hz - Secondary RPM / 50 Hz Select).
  • Page 102 DynaGen TOUGH Series TE410 - EN User Manual Name Range Default Description Auto Rated > 5 ~ 5000 A 100 A Rated Amps when using the AC Voltage 1Ph 3-Wire in 1 A increments Select inputs. Auto Rated > 5 ~ 5000 A 100 A 3-Phase (1) in 1 A increments...
  • Page 103 DynaGen TOUGH Series TE410 - EN User Manual AC Monitor > O.C. Protection > Basic Alarm Name Range Default Description High Warn Disable 110% Reading at which a warning occurs. 1 ~ 125% in 1% increments High Fail Disable 115% Reading at which a failure occurs.
  • Page 104 DynaGen TOUGH Series TE410 - EN User Manual For example, with a Rated Current of 100 A and a TDS of 0.1, the IDMT will trigger in: 0.15 seconds if the actual generator current is 1000 A 1.35 seconds if the actual generator current is 200 A 6.75 seconds if the actual generator current is 120 A 5.7.3.3 Load Imbalance...

  • Page 105: Communications

    The EPS (Emergency Power System) Supplying Load sets a flag in Modbus register 40006 to indicate to the Cattron RA400 remote annunciator that the generator is actively supplying power. If this flag is set, the RA400 will light its EPS Supplying Load indicator. This is used to meet NFPA110 requirements.
  • Page 106 DynaGen TOUGH Series TE410 - EN User Manual Name Range Default Description ECM Model Generic J1939 Generic J1939 Choose one of the compatible ECM modules from the list. John Deere JDEC Volvo EMS This is not a complete list; see the J1939 Reference Manual for the full list.

  • Page 107: Modbus (Rs485)

    For detailed information about the Modbus registers and their interpretations, please refer to the TOUGH Series Modbus Reference Manual, which can be found at www.cattron.com. It uses the Modbus RTU communication protocol and is configured as a slave only.

  • Page 108: Process Control

    DynaGen TOUGH Series TE410 - EN User Manual The Configuration Name can be viewed in the Device Info > About TE410/TE350 menu. It is labeled ID. 5.9.3 Process Control Note: The process control is only enabled in the TE Series 1.91 and above. The Process Control feature has two different control methods: Main-In and Main-Out.

  • Page 109: Pump System

    DynaGen TOUGH Series TE410 - EN User Manual Name Range Default Description Closed Loop > 1 ~ 30 19.0 The amount to increment or decrement Gain in 0.1 increments the RPM when the sensed value is outside of the deadband. This number does not represent an actual RPM.
  • Page 110 DynaGen TOUGH Series TE410 - EN User Manual In RapidCore: • The ramp settings are located under Sensors > Engine Speed > Speed Settings • The float control and tank maximum settings are located under Pumping Applications Name Range Description RUN Button (Manual Run Only Controls when the user can manually adjust the...
  • Page 111 DynaGen TOUGH Series TE410 - EN User Manual Name Range Description Tank Maximum > Disable These settings determine the maximum Aux Sensor Max % value that is equivalent to a full tank. If the sensor 0 ~ 100% value rises above these setpoints, then the value in 0.1% increments displayed in the tank is clamped to these settings.

  • Page 112: Troubleshooting

    TE410 - EN User Manual Troubleshooting If you are having issues with your controller, please refer to the following table for a solution before contacting Cattron at www.cattron.com. Issue Solution Engine starts but the crank output The controller is not receiving a speed signal.

  • Page 113: Technical Support

    DynaGen TOUGH Series TE410 - EN User Manual Technical Support For remote and communication control systems support, parts and repair, or technical support, visit us online at: www.cattron.com/contact. 9M02-9249-A001-EN Revision A...
  • Page 114 Cattron Wireless Automation and Control Solutions Support For remote and communication control systems support, parts and repair, or technical support, visit us online at: www.cattron.com/contact Cattron North America Inc., 655 N River Rd NW, Suite A, Warren, OH 44483 9M02-9249-A001-EN Revision A...

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