Cattron DYNAGEN TOUGH Series TE410 Bedienungsanleitung

TOUGH SeriesTM

TE410

User Manual

DynaGenTM TOUGH SeriesTM TE410 - EN

User Manual

9M02-9249-A001-EN

Revision A

Revision History

VERSION

DATE

NOTES

1.0

01/2017

Updated to include Rev 1.0 of the typical wiring diagram.

2.0

10/2018

Updated to include new drawing version, R2.0.

Updated switched outputs in Spec.

Updated power in Spec.

7.0

09/2019

09/2022

Document rebranded and contact information updated.

Added French Translations for all DANGER/WARNING/CAUTION statements

per UL Requirements.

Any information furnished by Cattron™ and its agents is believed to be accurate and reliable. All specifications are subject to change without notice.

Responsibility for the use andapplication

ofCattronproductsrestswiththeendusersinceCattronanditsagentscannotbeawareof allpotentialuses.

Cattronmakesnowarrantiesastonon-infringementnor astothefitness, merchantability,orsustainabilityofanyCattronproductsforanyspecific

or general uses. Cattron Holdings, Inc., or any of its affiliates or agents shall not be liable for incidental

or consequential damages of any kind. All

CattronproductsaresoldpursuanttotheTermsandConditionsofSale,a copyof whichwillbefurnisheduponrequest.Whenusedasa tradename

herein,

Cattron means Cattron Holdings, Inc. or one or more subsidiaries of Cattron Holdings, Inc. Cattron™, corresponding logos, and other marks are

trademarksor registeredtrademarksofCattronHoldings,Inc.Othermarksmaybethepropertyofthirdparties.Nothinghereinprovidesalicenseunder

anyCattronoranythirdpartyintellectualpropertyright.

DynaGenTM TOUGH SeriesTM TE410 - EN 
User Manual 
 
 
 
 
 
 
 

9M02-9249-A001-EN 
Revision A 
Contents 
 
Introduction.........................................................................................................................................................6 
1 Specifications..........................................................................................................................................7 
Installation ..........................................................................................................................................................9 
1 General Wiring Notes............................................................................................................................10 
2 Terminal Descriptions ...........................................................................................................................11 
3 Wiring Harness......................................................................................................................................14 
4 Typical Wiring Diagram.........................................................................................................................15 
5 Typical Wiring Diagram with RelayPak.................................................................................................16 
6 Wiring Considerations...........................................................................................................................17 
6.1 Remote Start Contact (Start/Stop)...........................................................................................17 
6.2 Emergency Stop Wiring...........................................................................................................17 
6.3 Universal Sensor......................................................................................................................18 
6.4 CANbus Wiring (J1939)...........................................................................................................19 
6.5 Modbus Wiring.........................................................................................................................20 
6.6 Current Transformers...............................................................................................................21 
6.7 RelayPak (Optional).................................................................................................................23 
6.8 J6 Speed Inputs.......................................................................................................................25 
Pumping Applications.......................................................................................................................................26 
1 Manual Speed Control..........................................................................................................................26 
2 Automatic Speed Control......................................................................................................................27 
2.1 AutoStarting on Floats .............................................................................................................27 
2.2 Ramp Up and Intermediate Speed ..........................................................................................29 
2.3 Process Control using Engine Speed......................................................................................30 
3 Speed Limiting ......................................................................................................................................30 
4 Electronic Engines ................................................................................................................................30 
Using the Controller..........................................................................................................................................32 
1 Modes, Starting and Stopping...............................................................................................................33 
1.1 Starting / Cranking Behavior....................................................................................................34 
2 Speed Control Page..............................................................................................................................35 
3 Four Parameter Display Pages.............................................................................................................35 
4 DM1 Page.............................................................................................................................................36 
5 Using Cooldown Mode..........................................................................................................................36 

DynaGenTM TOUGH SeriesTM TE410 - EN 
User Manual 
 
 
 
 
 
 
 

9M02-9249-A001-EN 
Revision A 
6 Warnings...............................................................................................................................................37 
7 Failures .................................................................................................................................................38 
8 Events History.......................................................................................................................................39 
Settings.............................................................................................................................................................46 
1 Operator Setup......................................................................................................................................46 
2 Application Menu...................................................................................................................................47 
2.1 Tank Level / Float Application Menu........................................................................................48 
2.2 Wind Machine Application Menu..............................................................................................52 
3 Switched Inputs.....................................................................................................................................55 
3.1 Configurable Inputs..................................................................................................................59 
4 Switched Outputs..................................................................................................................................60 
4.1 Group Outputs..........................................................................................................................63 
4.2 Pull and Hold Coil.....................................................................................................................64 
5 Sensors.................................................................................................................................................65 
5.1 Engine Temperature ................................................................................................................65 
5.2 Oil Pressure .............................................................................................................................67 
5.3 Fuel Level.................................................................................................................................68 
5.4 Engine Speed...........................................................................................................................69 
5.5 Battery......................................................................................................................................74 
5.6 Auxiliary Sensors .....................................................................................................................75 
5.7 Custom Sender Tables............................................................................................................85 
6 Timers ...................................................................................................................................................87 
6.1 Engine Logic ............................................................................................................................87 
6.2 Schedulers...............................................................................................................................94 
6.3 Maintenance.............................................................................................................................96 
7 AC Monitor............................................................................................................................................97 
7.1 Generator Voltage....................................................................................................................97 
7.2 Generator Frequency.............................................................................................................100 
7.3 Generator Current..................................................................................................................101 
8 Communications .................................................................................................................................105 
8.1 CANbus (J1939).....................................................................................................................105 
8.2 Modbus (RS485)....................................................................................................................107 
9 Other Config........................................................................................................................................107 
9.1 Password ...............................................................................................................................107 

DynaGenTM TOUGH SeriesTM TE410 - EN

User Manual

9M02-9249-A001-EN

Revision A

5.9.2 Settings Name / ID.................................................................................................................107

5.9.3 Process Control......................................................................................................................108

5.9.4 Pump System.........................................................................................................................109

6 Troubleshooting..............................................................................................................................................112

7 Technical Support...........................................................................................................................................113

DynaGenTM TOUGH SeriesTM TE410 - EN

User Manual

9M02-9249-A001-EN

Revision A

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 RapidCore 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:

•Five-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 monitoring and sensors

•Maintenance counter

•Exerciser Clock

•150 Event Log

•Conformally coated for protection against moisture

•Gasket for water ingress protection resistance

•Free RapidCore Configurator Software

•Fast and rugged installation clips

•Passcode protected

•Automatic shutdowns and warnings

•Manual and remote start options

•Momentary Start/Stop inputs

•Pre-heat and many other configurable timers

•Accepts common senders (VDO, Datcon, S&W)

•Custom senders configurable with RapidCore Configurator Software

DynaGenTM TOUGH SeriesTM TE410 - EN

User Manual

9M02-9249-A001-EN

Revision A

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

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 Cattron at www.cattron.com.

Testing Specifications

Specification

Rating

Electrical Transients

SAE1113-11

Thermal Shock and Cycling

SAE1455

Vibration Profiles

SAE1455

Electric Static Discharge

SAE1113-13: SAE1113-13: +/-8 kV Direct Discharge

+/-15 kV Air Gap Discharge

UL 6200 recognized component. Contact Cattron at

www.cattron.com 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, contact Cattron at www.cattron.com)

DynaGenTM TOUGH SeriesTM TE410 - EN

User Manual

9M02-9249-A001-EN

Revision A

Specification

Rating

Weight

Weight w/RelayPak

0.83 lb (0.38 kg)

1.32 lb (0.60 kg)

Dimensions:

-controller (no gasket)

-controller with gasket

-controller with gasket and RelayPak

4.17”x 6.50”x 1.38”(10.59 cm x 16.51 cm x 3.51 cm)

4.41”x 6.79”x 1.38”(11.20 cm x 17.25 cm x 3.51 cm)

4.41”x 6.79”x 3.33”(11.20 cm x 17.25 cm x 8.46 cm)

Electrical Specifications

Specification

Rating

Operating Voltage

5.5 ~ 36 VDC

Standby Current (Minimum)

Auto Mode: 60 mA @ 12 VDC, 38 mA @ 24 VDC (back lighting

off)

Off Mode: 80 mA @ 12 VDC, 45 mA @ 24 VDC (back lighting off)

Actual consumption could be more depending on connected

sensors and other I/O.

Switched Inputs

+Battery, Ground, Open, Closed

Switched Outputs

+Battery @ 1 A Max

Low Resistance Sensors

0 ~ 750 Ω

High Resistance Sensors

0 ~ 7,500 Ω

Universal Sensors

0 ~ 750 Ω, 0 ~ 7,500 Ω, 0 ~ 5 VDC, 4 ~ 20 mA

Magnetic Pickup

10 ~ 10,000 Hz at 1 ~ 50 VAC

AC Voltage (Line-To-Line)

UL Approved Range: 50 ~ 600 VAC True RMS, Accuracy: 2%

Full Scale

Non-UL Range: 50 ~ 670 VAC

Do not connect more than 600 VAC to the controller for UL

approved installations, or 700 VAC for locations where UL is not

required.

AC Current

0 ~ 5 A (Current Transformer), Accuracy: 1% Full Scale

Communications

SAE J1939 (Tier II, III, IV)

External Sensor Power

TG410 only: 5 VDC at a max load of 200 mA

DynaGenTM TOUGH SeriesTM TE410 - EN

User Manual

9M02-9249-A001-EN

Revision A

2 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.

AVERTISSEMENT

LE CÂBLAGE DE CE CONTRÔLEUR NE DOIT ÊTRE EFFECTUÉ QUE PAR DES ÉLECTRICIENS

QUALIFIÉS.

CAUTION

HIGH VOLTAGE MAY BE PRESENT AT THE CONTROLLER.

ATTENTION

UNE HAUTE TENSION PEUT ETRE PRESENTE AU NIVEAU DU CONTROLEUR.

The following general electrical safety precautions 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 on the cord

•Use fuses where appropriate

•Ensure all equipment is properly grounded

•Provide support to wires to prevent stress on terminals

CAUTION

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.

ATTENTION

POUR GARANTIR UN FONCTIONNEMENT CORRECT ET SUR, IL FAUT PRENDRE DES

PRECAUTIONS SUR LE SITE D'INSTALLATION POUR S'ASSURER QU'IL SOIT EXEMPT

D'HUMIDITE EXCESSIVE, DE FLUCTUATIONS DE TEMPERATURE, DE POUSSIERE, ET DE

MATERIAUX CORROSIFS.

DynaGenTM TOUGH SeriesTM TE410 - EN

User Manual

9M02-9249-A001-EN

Revision A

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. Create a rectangular cut-out in the panel that is a minimum 3.9”(99 mm) high and 6.2”(158 mm) wide.

3. Place the controller into the panel cut-out so that the LCD screen and buttons are facing out.

4. Place the mounting clips into the designated slots on the top and bottom of the controller.

5. Tighten the screws on the clips until the controller is snug against the panel. Do not over-tighten. The

bottom of the screws should angle very slightly away from the controller.

6. If applicable, snap the RelayPak (RP100) to the back of the controller. Place one side of the RP100’s

tabs into the slot on the back of the controller and, without pushing on the relays, snap the other tab into

place.

The following figures show the TE Series cut-out dimensions and an image of the controller.

2.1 General Wiring Notes

The following important wiring guidelines should be followed:

•Use a minimum of 18 AWG wire for all connections

•Battery Positive (+Battery) and Battery Negative connections on the controller should be run directly to

the positive and negative terminals on the battery to prevent voltage drops from negatively impacting the

controller

•Limit the wire length to 20 ft (6.1 m) to any I/O on the controller (e.g., Switched Input, Switched Outputs,

AC Sensing and Analog Inputs)

The TOUGH Series contains a TVS to protect the I/O and internals from a transient on the main battery (the

battery from which the controller is powered). If you have I/O connected to other batteries or power supplies,

those I/O must contain their own voltage transient protection. Otherwise, the I/O and/or controller can be

damaged if the transient exceeds the maximum rated voltage of the I/O. A device that provides this kind of

protection is known as a TVS or a varistor.

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