DynaGen TOUGH TE350 User Manual

Digital generator controllers

Hide thumbs

page of 81

/ 81
Bookmarks

Quick Links

Download this manual

TE350 User Manual

Manual Revision: 7.0.0

Min. FW Revision: 1.92.07

Date Released: 2019-09-25

Need help?

Do you have a question about the TOUGH TE350 and is the answer not in the manual?

Questions and answers

Summary of Contents for DynaGen TOUGH TE350

Page 1 TE350 User Manual Manual Revision: 7.0.0 Min. FW Revision: 1.92.07 Date Released: 2019-09-25 © 2019 DynaGen Technologies Inc...
Page 2 ..................................28 Speed Control Page / Tank Display ....................................28 Four Parameter Display Pages ....................................28 DM1 Page ....................................29 Using Cooldown Mode ....................................29 Warnings ....................................30 Failures ....................................30 Event Log ....................................31 © 2019 DynaGen Technologies Inc...
Page 3 ....................................72 5.7.1 Generator Voltage ..................................72 AC Voltage Select ..................................74 5.7.2 Generator Frequency ..................................74 RPM / Frequency Select ..................................75 Communications ....................................76 5.8.1 CAN Bus (J1939) ..................................76 Other Config ....................................76 © 2019 DynaGen Technologies Inc...
Page 4 TE350 User Manual 5.9.1 Password ..................................76 5.9.2 Settings Name ..................................77 5.9.3 Process Control ..................................77 5.9.4 Pump System ..................................78 6 Troubleshooting © 2019 DynaGen Technologies Inc...
Page 6 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) TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 7 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 TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 8 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) TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 9 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 TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 10 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. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 11 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 TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 15 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.
Page 16 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. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 17 · 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 TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 19 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.
Page 20 Filtering means must be provided by the installer if required. Installer must determine suitability for their application. Dynagen does not provide any means of filtering and cannot guarantee compatibility. TOUGH Series Manual...
Page 21 If the Bump Speed setting is disabled then the speed will increase by 1 RPM/s with each button push and will increase to 10 RPM/s, 50 RPM/s, and 100 RPM/s each second until 100 RPM/s is obtained if the button is held down. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 22 Single or Dual. When "Float Autostart" is enabled a graphic indicating the positions of the floats is shown in a special page during RUN mode. This special page also indicates the current engine speed and optionally the tank level. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 23 The below 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. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 24 Refer to the Other Config > Pump System menu for settings indicated in the below chart. The Warm-up and Cooldown times can be found in the Timers > Engine Logic menu. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 25 CAN High / CAN Low (CAN-H, CAN-L) - The J1939 protocol bus that the ECM and TE350/TE410 use to communicate with one another. TSC1 (J1939 speed command) is sent over this bus as well as engine temperature, oil pressure, and other parameters. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 27 Used for moving around in the menu, changing a setting's value, or Decrement Button decrementing engine speed in manual mode. Generator/Engine LED Green = Engine running with no issues Amber = Engine running with warnings Red = Engine shut down on failure TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 28 ECM on an electronic engine so a diagnostic tool can obtain information from the ECM. WARNING: See the Using Cooldown Mode section for more information on how it affects starting and stopping. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 29 There are two special pages that can display four parameters each. These two pages must be setup used the RapidCore Configuration Software. The choices of parameters are: · Blank (no parameter displayed for that line) · Engine Speed · Battery TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 30 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 TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 31 In these cases the controller will reset and enter the failure state. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 32 The controller has loaded default settings. This could have been because the user initiated a factory Defaults reset from the RapidCore software or the controller memory has became corrupt. The controller will need to be programmed with the proper settings if applicable. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 33 A user has started the controller using the RUN button and the long time run feature is enabled under start Timers > Long Time Run. The controller will run for the duration specified under "Long Time Run" and then automatically shut down. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 34 Warning The generator AC voltage has risen above the over voltage warning setpoint set under AC Monitor > Voltage Genset Voltage. Possible issue with the voltage regulator or governing on the engine. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 35 CAN J1939 port. Comm Under Failure The generator AC frequency has fallen below the under frequency failure setpoint set under AC Frequency Monitor > Genset Freq. > Setpoints. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 36 Application Menu > Transducer menu. Transducer Failure The transducer (aka Auxiliary Sensor 5) reading has risen above the transducer high failure setpoint High set under Application Menu > Transducer menu. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 37 Change 1 ~ 12 months ----- 2000 ~ 2099 years Date / Time > Time 0 ~ 23 hours Sets the time. Change 0 ~ 59 minutes ----- 0 ~ 59 seconds TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 38 When enabled, allows a user to start the engine using the run RUN from OFF Enable button while in the OFF mode. When disabled the controller must be placed in AUTO mode before the run button can start the engine. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 39 RPM Settings > Goal RPM 500 ~ 4000 RPM in 1 This is a mirror of the "Goal Speed" setting under Other Config RPM increments > Pump System. Dwell Times Sub Menu ----- TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 40 TP1 200P/R240 TP2 100P/R240 TF1/TR2 are float sensors. 115F/R240 means it has a range of 115 at 240 Ohms. TP1/TP2 are pressure sensors. Contact DynaGen for more information. Start Stop Sub Menu ---- TOUGH Series Manual...
Page 41 Application > Function menu. Maintain > 1 ~ 30 in 0.1 increments Values in this range do not cause any change in engine speed. Deadband+ Maintain > 1 ~ 30 in 0.1 increments Deadband- TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 42 RapidCore Configuration TF2 231F/R240 software. The other four are factory defined tables. Sensors are TP1 200P/R240 available for these four predefined tables. Contact DYNAGEN on TP2 100P/R240 these sensors. Wind Machine > Start...
Page 43 / speed decrement buttons. Switched Inputs The controller has five switched inputs which cause the controller to perform a function when activated. Default settings: Switched Input Default Value Switched Input Emergency Stop TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 44 Trigger Delays > Config Fail 3 can be set to control the amount of time the Configurable Failure 3 Configurable input has to be active to trigger. Air Press. Fail (Air Cranking Controller displays 'Low Air Pressure' and shuts down engine when active. Pressure Failure) TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 45 The active modes is only configurable if the Function menu is set to one of the configurable switched input functions. It is fixed for all other functions. Switched I/O > Switched IN X > Trigger: Name Description Close +BAT Input is active when +Battery is present at the terminal. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 46 Input is active when neither +Battery or Ground is present at the terminal. NOTE: When running wires over long distances (over 20ft / 6.1m), it is recommended to use +BATTERY as the trigger method. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 47 Switched Disable Output F Event Functions Name Active Mode Description Fuel Cranking, Running Active during cranking and running to supply fuel to engine. Crank Cranking Active during cranking to start the engine. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 48 10s, the controller will shut down the engine on "Generator Disable Failure." Dummy Load Running Output is controlled by the dummy load feature. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 49 When the controller encounters an unhandled exception or lockup (watchdog triggered) it will reset and enter the failure mode as an exception fault. *The name of this fault is configurable form the Configuration Software. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 50 Note: The pull coil feature does not operate when the fuel output is activated by the Auto Power ECM feature or when requesting stored DTCs (DM2 codes). See the J1939 section for more information on these features. Pull Coil Wiring Example TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 51 Reading at which a "High Engine Temp" warning occurs. Only applies if Warn (High 300°F (10 ~ Sensor Type has been set to a sender. Only monitored in the RUN Warning) 148.9 mode. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 52 Close = Failure *These are preprogrammed into the controller and cannot be changed. - DAT R33-240 supports a Dacon fuel level sensor of the range 33 Ohms to (custom 180 Ohms sender)** TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 53 Mag Pickup -- A magnetic pickup, alternator output, or the distributer signal can be used to sense speed. Must use J6 pins 7 and 8. If using a distributer a filter is often required. Contact DYNAGEN for more information on using a distributer signal.
Page 54 The speed is not monitored during delay-to-start or preheat as this provides some degree of protection against spurious signals due to noise. The fuel input is turned on at the start of preheat and often powers external equipment that can cause noise. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 55 Disable, 10 ~ Ignore this setting. Refer to the J1939 reference manual for RPM/s Speed > RPM 300 RPM/s in information on this setting. 200 RPM Control 10 RPM/s increments Speed Control Instructions TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 56 NOTE: 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. Battery Recharge Sequence TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 58 Mode Settings > Disable (Only applies if Func. Select is not set to Fault Monitor) The ----- Run Time amount of time to turn on the auxiliary switched output or run the TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 59 Aux Sensor 3 Used by the Aux. Sensor 3 Output On Low or Output on High feature. Aux Sensor 4 Used by the Aux. Sensor 4 Output On Low or Output on High feature. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 60 Set to the value rises above a certain value. Stop High sensor needs to rise the sensor needs controller when the sensor drops above to start. to drop below to below a certain value. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 61 Warnings on the sensor. Monitor / Failures Do not perform any actions on the Fault sensor value. Just display the Monitor Display value to the user. (Disable all only warnings and failures) TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 62 275°F warning threshold, activating the warning display. The engine will continue to run because it has not reached the 350°F failure threshold. At 20 minutes run time, the temperatures falls below the warning threshold and the warning disappears. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 63 The chart above shows the connection between a battery bank and time. At approximately 80 minutes time, the voltage falls below the 10.5V start threshold causing the engine to start. The engine runs for the 40 minutes active time regardless of the voltage reading and then shuts down. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 64 325°F start threshold and the fan turns on. The fan continues to run as the temperature declines. When the temperature falls below the 200°F stop threshold, the fan turns off. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 65 5.5.7 Custom Sensor Tables are created using the RapidCore Configuration Software when using a sensor that is not supported by DYNAGEN. The configurator has the ability to create these custom tables, allowing the controller to properly read the sensor data.
Page 66 0 ~ 6000 s in 5 s Amount of time to cool down the engine after a stop command has increments been received. During this time the Warmup output turns off and the TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 67 Tip: It takes up to 2 seconds for the false restart to be triggered. In addition it takes time for the engine speed to drop below 250RPM. These should be measured and added to the desired False Check setting. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 68 WARNING: If the controller receives a command to start from the remote start or front panel run button while in Cooldown, it will leave the Cooldown mode and go back to Running mode. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 69 "High Point" settings for this time exit the warm-up / idle. Settings increments Timers > Engine 1 to 180 (Warm-up Idle) Continue to idle when the temperature is below this Point Logic > Idle 32 F setting. Ignore the Debouce. Settings increments TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 70 The controller will start after the pre-alarm countdown is finished. Schedule -> 1 ~ 28 days Number of days between each exerciser cycle. This setting is applied to all Repeat Days subsequent exerciser starts after the first start. Exerciser Sequence TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 71 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 event log and the exerciser will run again at the next scheduled time as determined by the "Repeat Days" setting. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 72 To determine the amount of time until the next scheduled maintenance, follow these menu steps: Main Menu -> Device Info. -> Maintenance Maintenance counter is disabled if '----' is displayed. A negative number indicates the amount of time since maintenance timer expired. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 73 50 ~ 99 % in 1 % Reading at which a warning occurs. 90 % Low Warn increments Setpoints > 50 ~ 99 % in 1 % Reading at which a failure occurs. 85 % Low Fail increments TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 74 VAC but a calibrated multimeter gives 208.3 VAC. Use the formula below to determine the scaling factor. 1. Scaling Factor = Multimeter Reading / Controller Reading 2. Scaling Factor = 208.4 VAC / 206.3 VAC 3. Scaling Factor = 1.010 TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 75 (Under-Frequency % in 1 % 90 % Warning) increments Setpoints > Low Fail Disable, 20 ~ 99 Reading at which a failure occurs. (Under-Frequency % in 1 % 85 % Failure) increments TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 76 Active Secondary RPM / 50Hz NOTE: If enabled, the J1939 TSC1 PGN will be broadcasted according to the selected speed. Otherwise only the warning and failure setpoints are affected by this function. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 77 CAN Bus (J1939) 5.8.1 This page gives a very short overview of J1939 support (electronic engines). For detailed information about J1939 and all related settings please refer to the J1939 Reference Manual. The manual can be found at www.dynagen.com/support. Name Range...
Page 78 AUX-4 AUX-5 Closed Loop > Delay 1 ~ 30 s in 0.1 s The sampling time of the control algorithm. This value must be tuned for 8.0 s increments each installation. TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 79 Ramp Time Sub menu ----- Ramp Time > Dwell 1 (Idle to 1 ~ 300 s in 1 s The amount of time to ramp from the idle to intermediate speed. Intermediate)* increments TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 80 1.25rpm/s will be used. For example a speed difference of 300RPM and a ramp time of 300s gives 1 RPM/s but 1.25RPM/s will be used instead giving a ramp time of 240s (300 RPM ÷ 1.25 RPM/s = 240s). TOUGH Series Manual © 2019 DynaGen Technologies Inc...
Page 81 "Failure To Stop" failure. DYNAGEN can be contacted by any of the methods below. Technical support is offered Monday - Friday, 8:00am - 4:00pm (EST). If you are unable to contact one of our engineers, please leave a message and they will return your call as soon as possible.

This manual is also suitable for:

Tough te410