Dynagen tg410

TG410 User Manual
Manual Revision: 7.0.0

Min. FW Revision: 1.88.01
Date Released: 2019-09-25
© 2019 DynaGen Technologies Inc
TG410 User Manual
Table of Contents
User Guide
1 Introduction 4
1.1 Specifications
............................................................................................................................................................................... 5
2 Installation 6
2.1 General Wiring Notes
............................................................................................................................................................................... 7
2.2 Terminal Descriptions

............................................................................................................................................................................... 7
2.3 Wiring Harnesses

............................................................................................................................................................................... 10
2.4 Typical Wiring Diagram

............................................................................................................................................................................... 11
2.5 Typical Wiring Diagram with RelayPak

............................................................................................................................................................................... 12
2.6 Wiring Considerations

............................................................................................................................................................................... 13
2.6.1 Remote Start .......................................................................................................................................................................
Contact (Start/Stop) 13
2.6.2 Emergency Stop
.......................................................................................................................................................................
Wiring 13
2.6.3 Universal Sensor
....................................................................................................................................................................... 14
2.6.4 CAN Bus Wiring
....................................................................................................................................................................... 15
2.6.5 Modbus Wiring....................................................................................................................................................................... 17
2.6.6 Current Transformers
....................................................................................................................................................................... 18
2.6.7 RelayPak (Optional)
....................................................................................................................................................................... 20
3 Using the Controller 22

3.1 Modes, Starting and Stopping
............................................................................................................................................................................... 23
3.1.1 Cranking Behaviour
....................................................................................................................................................................... 24
3.2 Using Cooldown Mode

............................................................................................................................................................................... 24
3.3 Warnings............................................................................................................................................................................... 24
3.4 Failures ............................................................................................................................................................................... 25
3.5 Event Log............................................................................................................................................................................... 25
4 Settings 30
4.1 Operator Setup
............................................................................................................................................................................... 30
4.2 Switched ...............................................................................................................................................................................

Inputs 31
4.2.1 Configurable Inputs
....................................................................................................................................................................... 34
4.3 Switched ...............................................................................................................................................................................

Outputs 34
4.3.1 Group Outputs....................................................................................................................................................................... 37
4.3.2 Pull and Hold .......................................................................................................................................................................
Coil 37
4.4 Sensors ............................................................................................................................................................................... 38

4.4.1 Engine Temperature
....................................................................................................................................................................... 38
4.4.2 Oil Pressure ....................................................................................................................................................................... 39
4.4.3 Fuel Level ....................................................................................................................................................................... 39
4.4.4 Engine Speed....................................................................................................................................................................... 40

TG410 User Manual
Front Panel Speed Control

.......................................................................................................................................................................... 42
RPM Output
.......................................................................................................................................................................... 43
4.4.5 Battery ....................................................................................................................................................................... 43
4.4.6 Auxiliary Sensors
....................................................................................................................................................................... 45
Fault Monitor Example
.......................................................................................................................................................................... 49
Start on Low Example
.......................................................................................................................................................................... 50
Output on ..........................................................................................................................................................................
High Example 51
4.4.7 Custom Sensor .......................................................................................................................................................................
Tables 52
4.5 Timers ............................................................................................................................................................................... 53

4.5.1 Engine Logic ....................................................................................................................................................................... 53
Preheat Mode.......................................................................................................................................................................... 54
False Restart
.......................................................................................................................................................................... 54
OFF Button Function
.......................................................................................................................................................................... 55
Idle .......................................................................................................................................................................... 56
Warmup Idle
............................................................................................................................................................................ 56
Idle Inhibit
............................................................................................................................................................................ 57
4.5.2 Schedulers ....................................................................................................................................................................... 57
Exerciser .......................................................................................................................................................................... 57
Weekly Scheduler
.......................................................................................................................................................................... 59
Long Time..........................................................................................................................................................................
Run 59
4.5.3 Maintenance ....................................................................................................................................................................... 59
4.6 AC Monitor
............................................................................................................................................................................... 60
4.6.1 Generator Voltage
....................................................................................................................................................................... 60
AC Voltage Select
.......................................................................................................................................................................... 62
4.6.2 Generator Frequency
....................................................................................................................................................................... 62
RPM / Frequency Select
.......................................................................................................................................................................... 63
4.6.3 Generator Current
....................................................................................................................................................................... 64
Basic Alarms
.......................................................................................................................................................................... 65
IDMT .......................................................................................................................................................................... 65
Load Imbalance
.......................................................................................................................................................................... 66
Dummy Load.......................................................................................................................................................................... 67
EPS Supplying Load
.......................................................................................................................................................................... 67
4.7 Communications
............................................................................................................................................................................... 67
4.7.1 CAN Bus (J1939)
....................................................................................................................................................................... 67
4.7.2 MOD Bus (RS485)
....................................................................................................................................................................... 69
4.8 Other Config

............................................................................................................................................................................... 69
4.8.1 Password ....................................................................................................................................................................... 69
4.8.2 Settings Name....................................................................................................................................................................... 69
4.8.3 Process Control
....................................................................................................................................................................... 69
5 Troubleshooting 71

3
User Guide
TOUGH Series Manual © 2019 DynaGen Technologies Inc

Introduction 4
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
Configuration 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 · Gasket for water ingress protection resistance
· SAE J1939 CAN Bus Protocol · Free RapidCore Configuration Software
· RPM via J1939, Magnetic Pickup, or Generator · Fast and rugged installation clips
· Speed control offset for electronic engines · Passcode protected
· Autostart on low battery and other sensors · Automatic shutdowns and warnings
· Trim feature for AC monitoring and sensors · Manual and Remote start
· Maintenance counter · Momentary Start / Stop inputs
· Exerciser Clock · Pre-heat and many other configurable timers
· 150 Event Log · Accepts common senders (VDO, Datcon, S&W)
· Conformally coated for protection against moisture · Custom senders configurable with RapidCore
Configuration software
Displays:
· Engine Temperature · Engine Speed · Real Time Clock · J1939 DTCs + Custom
· Oil Pressure · AC Metering · Engine Hours Text
· Fuel Level · Battery Voltage · Time to Maintenance · Custom Senders
· Warnings and Failures
Feature Included
DPF / DEF Ready
J1939 CAN Bus
Isolated RS485 Modbus
Magnetic Pickup Input
150 Event Log
Clock / Exerciser
Generator Voltage Metering Single or 3-Phase

Generator Current Metering (with IDMT and Load Imbalance features) Single or 3-Phase
Configurable Switched Inputs 5
Resistive Sensors (1 High Ohm, 1 Low Ohm) 2
Universal Sensor (Resistive, 0-5V, 4-20mA) 2
5V Sensor Output for Electronic Sensors
Configurable Switched Outputs 6

Introduction 5
1.1 Specifications
The TOUGH Series controllers were rigorously tested to ensure durability, reliability and functionality. The following
specifications are a brief summary of the standards to which the controller has been tested. For complete details on the testing
performed please contact DYNAGEN.
Testing Specifications
Specification Rating
Electrical Transients SAE1113-11
Thermal Shock and Cycling SAE1455
Vibration Profiles SAE1455
Electric Static Discharge SAE1113-13: +/-8KV Direct Discharge, +/-15kV Air gap discharge
UL
UL 6200 recognized component. Consult factory for UL conditions of
acceptability.
Physical Specifications
Operating Temperature -40 to +158°F (-40 to +70°C)
LCD Viewing Temperature -4 to +158°F (-20 to +70°C )
(Optional heater available, call factory)
Weight 0.83lb (0.38kg)
Weight w/ RelayPak 1.32lb (0.60kg)
Dimensions - controller (no gasket) 4.17" x 6.50" x 1.38" (10.59cm x 16.51cm x 3.51cm)
- controller w/ gasket 4.41" x 6.79" x 1.38" (11.20cm x 17.25cm x 3.51cm)
- controller w/ gasket and RelayPak 4.41" x 6.79" x 3.33" (11.20cm x 17.25cm x 8.46cm)
Electrical Specifications
Operating Voltage 5.5 ~ 36 VDC
Standby Current (Minimum) Auto Mode: 60mA @ 12VDC, 38mA @ 24VDC (back lighting off)
Off Mode: 80mA @ 12VDC, 45mA @ 24VDC (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 @ 1A Max
Low Resistance Sensors 0 ~ 750Ohm
High Resistance Sensors 0 ~ 7,500Ohm
Universal Sensors 0 ~ 750Ohm, 0 ~ 7,500Ohm, 0 ~ 5 VDC, 4 ~ 20mA
Magnetic Pickup 10 ~ 10,000Hz 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 600VAC to the controller for UL approved installations
or 700VAC for locations where UL is not required.
AC Current 0 ~ 5A (Current Transformer), Accuracy: 1% Full Scale
Communications SAE J1939 (Tier II, III, IV)
Isolated RS485 (Slave Modbus RTU), 2.5kV surges
External Sensor Power TG410 only: 5 VDC at a max load of 200mA

Installation 6
2 Installation
Generator systems contain high voltage circuitry and precautions to protect against electrical shock should be taken. Failing to
power down and lock out equipment can cause damage, injury or death.
WARNING: Wiring of this controller should be performed by qualified electricians only.
The following general electrical safety precaution should be followed:
· Do a thorough inspection of the area before performing any maintenance.
· Keep fluids away from electrical equipment.
· Unplug connectors by pulling on the plug and not the cord.
· Use fuses where appropriate.
· Ensure all equipment is properly grounded.
· Provide support to wires to prevent stress on terminals.
To ensure proper and safe operation, caution must be taken at the installation site to make sure it is free from excessive
moisture, fluctuating temperature, dust and corrosive materials. Choose a mounting surface with the least amount of vibration
and not more than 0.125" (3.175mm) thick.
1) Choose a suitable mounting location based on the criteria above.
2) Create a rectangular cutout in the panel that is minimum 3.9" (99mm) high and 6.2" (158mm) wide.
3) Place the controller into the panel cutout so that the LCD screen and buttons are facing out.
4) Place the mounting clips into the designated slots on the top and bottom of the controller.
5) Tighten the screws on the clips until 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.
TE Series Cutout (Not To Scale)

Installation 7
2.1 General Wiring Notes

The following important wiring guidelines should be followed:
1. Use a minimum of 18AWG wire for all connections.
2. Battery + and Battery - 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.
3. Limit the wire length to 20ft (6.1m) to any I/O on the controller (e.g. Switched Input, Switched Outputs, AC Sensing, and
Analog Inputs).
4. It is good practice to run the AC voltage sensing wiring to the controller in a separate conduit from the AC current sensing
wiring. If the AC voltage is especially noisy (e.g. variable frequency drives) then they MUST be run separately.
5. The TOUGH Series contains a TVS to protect the I/O and internals from a transient on the main battery (the battery the
controller is powered from). 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 know as a TVS or a varistor.
6. 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 included relays in the relaypak.
7. Fusing
a. A fuse should be placed inline with the battery + wire going to the controller power. A 10A fuse is suggested.
b. The AC Voltage A, B, and C lines should be fused near the source of AC voltage with a 1A fuse to protect personnel if
any of these lines become disconnected or damaged.
c. If using the RelayPak the power going to the relay commons should be fused.
8. For noisy environments some guidelines are:

a. Replace speed sensing wire with twisted pair from the sensor to the controller.
b. Consider using isolated sensors (i.e. two terminal) and use twisted pair wiring to connect from engine to controller.
The following enclosure guidelines should be followed:
1. It is recommended to use vibration mounts.

2. For outdoor applications, it is recommended to use a sealed enclosure.
2.2 Terminal Descriptions

Main Connector (J4)
Terminal Name Description
J4-1 +Battery Provides power to the controller from the battery
J4-2 +Battery Provides power to the controller from the battery
J4-3 Ground Provides ground return for the controller
J4-4 Ground Provides ground return for the controller
J4-5 Switched Input A Configurable to detect +Battery, Ground, or Open
J4-6 Switched Input B Configurable to detect +Battery, Ground, or Open
J4-7 Switched Input C Configurable to detect +Battery, Ground, or Open
J4-8 Switched Output A Outputs +Battery voltage when active (Max Current: 1A)
J4-9 Switched Output C Outputs +Battery voltage when active (Max Current: 1A)
J4-10 Switched Output B Outputs +Battery voltage when active (Max Current: 1A)
J4-11 Sensor Ground Provides ground return for 2-wire (isolated) sensors
J4-12 Sensor Input A High impedance sensor input (0 - 7,500Ohm)
J4-13 Sensor Input B Low impedance sensor input (0 - 750Ohm)
J4-14 Sensor Input C Universal sensor input (0 - 750Ohm, 0 - 7,500Ohm, 0 - 5 VDC, 4 - 20mA). See
Universal Sensor section for more information.

Installation 8
Expansion Connector (J3)

J3-1 Switched Input D Configurable to detect +Battery, Ground, or Open
J3-2 Switched Input E Configurable to detect +Battery, Ground, or Open
J3-3 Switched Output D Outputs +Battery voltage when active (Max Current: 1A)
J3-4 Switched Output E Outputs +Battery voltage when active (Max Current: 1A)
J3-5 Switched Output F Outputs +Battery voltage when active (Max Current: 1A)
J3-6 Sensor 5V Provides 5 VDC for electronics sensors.
J3-7 Sensor Ground 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.

Installation 9
Communications Connector (J6)

J6-1 RS485 + (Non-Inverting) Non-Inverting communications line for Modbus (RS485). This is also often
known as A.
J6-2 RS485 - (Inverting) Inverting communications line for Modbus (RS485). This is also often known as
B.
J6-3 No Connection No Connection
J6-4 CAN-H Communications line for CAN Bus (J1939)
J6-5 CAN-L
J6-6 CAN-Shield Connect the shield of the twisted pair cable to this terminal
J6-7 Speed Sensing A Connect to a magnetic pickup, tachometer, or a flywheel alternator. Not polarity
sensitive and not required if using AC voltage terminals for speed sensing.
J6-8 Speed Sensing B Connect to a magnetic pickup, tachometer, or a flywheel alternator. Not polarity
sensitive and not required if using AC voltage terminals for speed sensing.
J6-9 No Connection No Connection
J6-10 RS485-Common Common line for Modbus (RS485)
Generator AC Voltage (J7)

J7-1 Phase A Connect to Phase A of the generator
J7-2 Phase B Connect to Phase B of the generator
J7-3 Phase C Connect to Phase C of the generator
J7-4 Neutral Connect to neutral.
Generator AC Current (J5)

J5-1 Phase A Connect to current transformer for Phase A of the generator
J5-2 Phase B Connect to current transformer for Phase B of the generator
J5-3 Phase C Connect to current transformer for Phase C of the generator
J5-4 CT Common Connect to the commons of the current transformers

Installation 10
2.3 Wiring Harnesses

Installation 11
2.4 Typical Wiring Diagram

Installation 12
2.5 Typical Wiring Diagram with RelayPak

Installation 13
2.6 Wiring Considerations

The following sections are meant to describe certain wiring configurations and are for illustrative purposes only. Not all
applications are the same. Please ensure you modify these examples to fit your unique system requirements.
2.6.1 Remote Start Contact (Start/Stop)

As of Firmware version 1.60 the start/stop is factory defaulted to switch input B (changeable) and the trigger factory defaulted to
Close +BAT. For older firmware versions you must set Start/Stop to Switched Input B or as desired and set the trigger mode to
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.
2.6.2 Emergency Stop Wiring

If Emergency Stop functionality is required, it is mandatory to install an external mushroom style switch wired in series with the
fuel or ignition supply to ensure reliable and immediate shutdown upon activation.
Shown below is an example wiring diagram of a double pull, single throw switch being used to activate the e-stop input and cut
power to the fuel solenoid. In this configuration, the e-stop is activated when there is an open circuit to the switched input and
inactive when the input detects +Battery voltage.

Installation 14
2.6.3 Universal Sensor

Universal Sensors have the ability to be configured to detect different sender types (0 - 750Ohm, 0 - 7,500Ohm, 0 - 5 VDC, 4 -
20mA). The examples shown below are advanced applications of the universal sensor.
NOTE: Custom Sensor tables are required for the universal sender to work with these examples. See the Custom
Sender Table section for more information.
Example #1: The following example shows the correct way for wiring a 4-20mA sensor. The 240Ohm resistor is required to
transform the 4-20mA current into the 0-5V voltage range required by the controller.
4-20mA Wiring Example
Example #2: Sometimes it is required to measure voltages outside the 0-5V range allowed by the controller. To do this you
must use a voltage divider with appropriate scaling resistors. The equation to calculate the resistor values is as follows:
Vout = 5V
Vin = Maximum Voltage to Read
R1 = Common Resistor Value > 10kOhm
R2 = Calculated Resistor Value (Select closest common resistor value)
The following diagram shows the typical wiring of a voltage divider. The resistors' values have been selected to allow the
controller to read up to 36V from an external battery bank.
0-36V Wiring Example
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.

Installation 15
2.6.4 CAN Bus Wiring

The following table outlines some items that must be taken into consideration when connecting to a CAN bus engine.
Consideration Description
Each end of the bus must be terminated from CAN H to CAN L with 120Ohm +/- 10 Ohm
Bus Termination
resistors. The resistor must be able to handle at least 400mW of power dissipation.
A twisted pair 120Ohm impedance cable is required for communications. For better
protection a shielded twisted pair cable is recommended.
Examples are:
Cable Selection
1. Belden 9841 - Shielded cable with one twisted pair, 24AWG
2. Belden 7895A - Shielded cable with two twisted pair, 20AWG
For short runs of 5 feet or less regular 18AWG wiring can often be run.
If using a shielded cable the shield must be connected to ground on one end of the bus only.
Shielding
This prevents loss of data from electromagnetic interference.
The twisted pair cable must terminate no farther than 6 inches from the controller's CAN
Termination at the Controller
(J1939) connector. Three inches is ideal.
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. There are
two ways to provide this time:
· Set a preheat time or increase the preheat time to allow longer time for the ECM to boot up before cranking. The fuel
output turns on at the start of preheat.
· 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

Installation 16

Installation 17
2.6.5 Modbus Wiring

The following table outlines some items that must be taken into consideration when connecting up a Modbus system.
Consideration Description
Each end of the bus must be terminated from A to B with 120Ohm +/- 10 Ohm resistors. The
Bus Termination
resistor must be able to handle at least 400mW of power dissipation.
Shielded twisted pair 120Ohm impedance cable is required for communications. Shield drain
wire is NOT be used for the RS485 common. The cable must have one twisted pair for A and
B and a seperate wire or twisted pair for common.
Cable Selection
An example is Belden 7895A, a two twisted pair, 20AWG, where the second pair can be used
for the RS485 common.
If running power and ground from the battery of your system to a remote device, use the
following guidelines for the gauge of the power and ground wires.
1. Up to 450ft (137.2m) - 22AWG

Distance (Power and Ground)
2. Up to 700ft (213.4m) - 20AWG
3. Up to 1125ft (342.9m) - 18AWG
4. Up to 1800ft (548.6m) - 16AWG
5. Up to 2800ft (853.4m) - 14AWG
The above cable must terminate no farther than 6 inches from the controller's RS485
Termination at the Controller
(Modbus) connector. Three inches is ideal.
Refer to the Example wiring diagram for a wiring example.

Installation 18
2.6.6 Current Transformers

When wiring current transformers into the system you must follow these considerations:
1. The maximum amperage allowed on the secondary is 5A. A 5:X ratio CT should be used where X is the maximum
primary amperage rating (e.g. 200A).
2. The CT power rating should be a minimum of 1VA.
3. The controller CT burden is 0.02Ohms (0.5 VA).
4. The current transformer of each phase must be facing the same direction. See below.
5. The CT Common connection must be connected to the black wire on each current transformer.
6. The wires from the current transformers to the controller should be as short as possible.
7. The CT wires should be run in a separate conduit from the AC voltage wires.
NOTE: If readings are unstable with the configuration shown below, attempt connecting the CT Common's black
wire to the negative terminal of the battery. Ensure the connecting wire is as short as possible.

Installation 19

Installation 20
2.6.7 RelayPak (Optional)

Model Number: RP100-VM
The RelayPak is used to provide up to four built-in slave relays in a compact and easy to wire package. This allows the low
current outputs of the controller to switch on high current relays on the RelayPak.
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.
Electrical Specifications
Operating Voltage 12V / 24V
Output Pilot Duty Rating 5.83A Per Relay @ 12V
Output Resistive Rating 10A Continuous Per Relay @ 12V
40A Momentary Per Relay @ 12V
Relay Style Automotive Cube
Standards
UL 6200 recognized component. Consult
factory for UL conditions of acceptability.
WARNING: You must use relays in the RelayPak that are suitable for the system voltage. Example: 12V relays in a
12V system and 24V relays in a 24V system.

Installation 21

Using the Controller 22
3 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.
LCD Display
Using the Menu System

Task Description
Entering Menu When in the OFF mode, press the enter button to bring up the menu.
Navigating Menu Once in the menu, use the up and down arrows to navigate. Pressing enter will move you into
that menu.
Change a Setting Scroll to the desired value and press enter to select. A check mark should appear beside that
item. Press enter again to save the setting and return to the previous screen.
Scroll Parameters When in Auto or Running mode, pressing the up and down arrows will scroll through the
parameter pages.
Lock Screen When in Auto or Running mode, the screen can be locked to a certain parameter page by
pressing Enter and unlocked by pressing Enter again.
Events History Once in the menu, select Events History to view the most recent controller event. Use the up
and down arrows to navigate to other events. The controller can store up to 150 events. If
more than 150 events occur, the oldest event is deleted to make room for the next event.
Front Panel Items

Item Name Description
Off Button Used for turning off the engine or exiting out of Auto mode. This is not
intended to function as an Emergency Stop as there are conditions in
which it will not shut down the engine. See the OFF Button Function
section for more information.
Auto Button Used for placing the controller into AUTO mode . Once in AUTO mode,
the controller waits for a start command to be received.
Run Button Used to start the engine manually. The Off button must be used to shut
down the engine if it has been started using the front panel.
Up Button Used for moving around in the menu, changing a setting's value, or
changing the currently displayed parameter page.
Enter Button Used for entering the menu system, accepting settings, or locking the
LCD screen when viewing parameters .
Down Button Used for moving around in the menu, changing a setting's value, or
changing the currently displayed parameter page .
Generator/Engine LED Green = Engine running with no issues

Amber = Engine running with warnings
Red = Engine shut down on failure

3.1 Modes, Starting and Stopping

The following table describes the different operating modes of the controller:
Modes
Mode / State Description
OFF When in the OFF mode, the engine cannot be remotely started.
Auto When in the Auto mode, the engine waits to receive a start command.
Running When engine is Running, the controller monitors engine parameters and waits to receive a
stop command.
Failure When a failure occurs, the controller shuts down the engine and displays the reason for
failure. The unit must be reset using the front panel OFF button with the exception of Modbus.
Menu When in the menu mode, settings can be changed and the events history may be viewed.
The following table describes the different methods for starting a controller. Unless using the Manual Run method to start the
controller, the controller must be in AUTO mode.
Starting Methods
Methods Description
Manual Run Pressing the Run button will start the engine. You must press the OFF button to shut down
the engine.
Start / Stop Switched Input When this input is active the engine will start. When the input becomes inactive the engine
will shut down.
Momentary Switched Inputs Switched inputs Momentary Start and Momentary Stop can be used for starting and stopping
of the engine. Unlike other inputs, they only have to be activated for a short period of time.
Battery Recharge When the battery voltage drops below a certain level the engine will start and run for a
predetermined amount of time.
Exerciser When the scheduled exerciser interval occurs the engine will start and run for a
predetermined amount of time.
Weekly Scheduler When a scheduled event occurs the engine will start and run for the programed amount of
time.
Auxiliary Sensors When a properly configured Auxiliary sensor falls below / rises above a certain point the
engine will start as determined by the Auxiliary Sensors -> Mode Select settings.
Modbus Start When a certain command is sent to the controller over Modbus the engine will start. See the
Modbus Reference Manual for more information.
J1939 Start Start/stop command send over the J1939 CANbus. For example from the TR100 or a remote
telemetry device. The controller will display either "J1939 Run" or "J1939 Remote" as the
reason for starting.
ECM Power On This is not a starting mode like the others. In AUTO mode if the Auto button is held for 3s the
fuel output is turned on for 1 hour. "ECM Power On" will be displayed on the screen.
Pressing and holding again within the hour will refresh for another hour. This feature can be
used to turn on or activate equipment powered by the fuel output. Often this is used by a tech
to power the 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.

3.1.1 Cranking Behaviour

Crank disconnect in only monitored at the beginning of cranking. If the engine is already running the starter motor (output set to
Crank) may turn on briefly.
If the controller is programmed to use CAN J1939 or a magnetic pickup (sensor or alternator output) the controller will also
monitor AC Voltage Phase A line for frequency as a backup or secondary means of crank disconnect. This occurs even if AC
Voltage sensing is disabled in the settings.
The oil pressure is not used as a means of crank disconnect.
3.2 Using Cooldown Mode

When the controller is configured to have a cooldown period (See Engine Logic section) for the engine, there is some special
functionality that must be considered.
The cooldown period is special in that during this time, it will accept a Start Command. This means if the engine is cooling
down and a start command is received, the controller will be placed back into a running mode and will not shut down.
Example: The following is an example of how the cooldown functionality works.
1. Remote Start contacts close

2. Engine starts and is in the running mode
3. Remote Start contacts open
4. Engine starts cooldown period
5. User presses RUN button on the front panel
6. Engine moves back into running mode and does not shut down
7. Engine can now only be shut down by using the OFF button or Emergency Stop input
3.3 Warnings
Warnings are conditions that alert the user to possible issues. These get enabled/disabled when you enable/disable various
settings in the controller.
Notable warnings are given in the below table.

Warning Enabled Condition(s) Description

Name
High Fuel High Fuel Level not disabled (in Sensors > Fuel High Fuel Level warning. This is often used to indicate an over
Level Level menu). fueling condition where fuel could be overflowing from the fuel
tank.
Low Low Engine Temp not disabled (in Sensors > Low Engine Temperature warning. This is often used to
Engine Engine Temp. menu). indicate a malfunction of the engine block heater in stationary
Temp generator applications.
Low Oil Switched input set to "Oil Pres. Warn" function. Low oil pressure warning.
Pressure See Switched Inputs. Triggered if switched input
is active during the RUN mode.
3.4 Failures
Failures are conditions that cause the controller to shutdown to prevent damage to the engine or generator. These get
enabled/disabled when you enable/disable various settings in the controller.
Notable failures are given in the below table.

Failure Enabled Condition(s) Description
Name
ECM Enabled if loss of ECM communication is If the controller has not received messages from the ECM for
Communicat enabled. See CAN Bus (J1939). J1939 feature. 6s.
ion Failure
Exception* Always enabled. Occurs when there is an issue that the controller cannot
recover from. For example EMI can cause the
microcontroller to become in a bad state or a software bug
could cause the code to hang triggering the watchdog. In
these cases the controller will reset and enter the failure
state.
*The name is configurable so may not match what is here.

Failure To Disabled when ETS On Duration is set to 0 After ETS countdown is finished if the speed was greater than
Stop seconds. Otherwise it is enabled. If used ETS 50RPM (600RPM for TG350/TG410 firmware 1.88 and
On Duration should be set to at least 2 to 3s greater) for the previous 2s then the controller triggers this
otherwise this failure may occur on a normal failure.
shutdown.
Load See Load Imbalance. AC Current feature. Generator load imbalance. Excessive AC current on one or
Imbalance more of the three phases.
Low Air Switched input set to "Air Pres. Fail" function. Application specific.
Pressure See Switched Inputs. Triggered if switched
input is active during starting.
Low Coolant Switched input set to "Cool. Lvl Fail" function. Low Coolant Level.
Lvl See Switched Inputs. Triggered if switched
input is active.
Low Switched input set to "Hyd Pres. Fail" function. Refers to Low Hydraulic pressure usually. Application
Hydraulic See Switched Inputs. Triggered if switched specific.
input is active during starting.
FILL DEF For electronics engines with a SCR (Seletive The SCR tank needs to be refilled (aka urea tank). Engine
NOW Catalytic Reaction) emissions aftertreatment may not start if this is not performed or may remain in "limp-
only. See J1939 section and J1939 Reference home" mode. DEF stands for diesel exhaust fluid.
manual.
If Battle Mode (see Battle Mode in switched inputs) is active ('Battle Running' is displayed on the screen) the controller will not
shutdown on a failure and no failure information will be displayed on the screen. If battle mode is switched off the controller will
shutdown on any failure that occurred when battle mode was active.
3.5 Event Log

The below table lists all events, warnings, and failures than can appear in the controller's event history. The event history is
accessed in the menu under "Events History".

Event Event Description

Name Type
Power On Event The controller has powered on.
Auto Event The controller has entered AUTO mode. The controller is waiting for a manual or automatic start
Enabled condition such as a remote/start stop command.
Off Event The controller has entered OFF mode (Not in Auto displayed on screen). Automatic starting is
Enabled disabled.
Manual Event A user has pressed the RUN button on the controller.
Start
Start Event The controller has entered cooldown. Cooldown has to be enabled under Timers > Engine Logic.
Cooldown
Remote Event A switched input remote start has been triggered. The controller will start.
Start
Remote Event A switched input remote stop has been triggered. The controller will stop.
Stop
Emergency Event The switched input Emergency Stop has been triggered. The controller has performed an emergency
Stop shutdown skipping cooldown.
Start Event The controller has auto started because of a low starter battery condition. The low battery restart has
Charging to be enabled under Sensors > Battery.
Stop Event The controller has ran for the programmed amount of time to recharge the starter battery and is
Charging shutting down.
Service Event The controller requires maintenance. This has to be enabled under Timers > Maintenance. Also after
Required maintenance is performed the tech has to reset the maintenance counter by going to Timers >
Maintenance > Reset Counter and selecting "Yes".
Reset Event 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.
Service Event The tech has performed service on the engine/generator and has reset the maintenance counter as
Complete mentioned in "Service Required" above.
Exerciser Event The exerciser, if enabled under Timers > Exerciser, has been skipped. This could happen if the
Bypass controller was otherwise running or powered off when an exerciser was scheduled to be performed.
Start Event The controller has auto started to perform an exercise.
Exercise
Stop Event The controller has ran for the programmed exercise and is now shutting down.
Exercise
Log Event The controller Event History has been cleared either from user action (via the RapidCore software) or
Cleared because the controller memory was corrupt.
Modbus Event The controller has auto start from a start command sent to it's RS485 Modbus port.
Start
Modbus Event The controller has auto stopped from a stop command sent to it's RS485 Modbus port.
Stop
Genset Event Applies to the Kubota electronic engine. Level 3 shutdown has occurred.
Disable
Engine Event The engine has successfully started and entered the RUN mode.
Started
J1939 Event The controller has auto started due to a command send over it's CAN J1939 port.
Remote
Idle Speed Event The controller has entered IDLE mode either from the idle switched input, the warmup or cooldown
idle feature under Engine Logic or some other reason. Under speed, under frequency, and under
voltage warnings and failures are disabled.
Rated Event The controller has exited idle mode and has gone back into normal running.
Speed
Sensor 1 Event The controller has auto started due to a auxiliary sensor 1 "start on low" or "start on high" request.
Run

Run
Sensor 1 Event The controller has shutdown due to a auxiliary sensor 1 "start on low" or "start on high" stop request.
Stop
Stop
Switch Event A controller start was triggered by the momentary start switched input.
Start
Switch Event A controller start was triggered by the momentary start switched input.
Stop
Regen Event Electronic engines with a Diesel Particulate Filter (DPF) only. The user requested that the automatic
Inhibited regeneration of the DPF be disabled.
Force Event Electronic engines with a Diesel Particulate Filter (DPF) only. The user requested a manual
Regen regeneration of the DPF.
Auto Event Electronic engines with a Diesel Particulate Filter (DPF) only. The engine ECM has performed an
Regen automatic regeneration of the DPF.
Run
Run
Stop
Stop
Log Time Event 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.
Scheduler Event The controller has auto started due to a daily schedule set up in Timers > Week Scheduler.
Start
Start Event A daily scheduler was canceled either because the controller was not in AUTO mode or start request
Canceled was ignored. A start request being ignored is an internal error and should not occur.
J1939 Start Event Controller started from J1939 using the second J1939 start/stop method. Refer to the J1939 user
guide for more information. This is often used by telemetry devices to start/stop the controller.
Crank Warning The controller has turned it's crank output but has failed to detect the engine is running. After crank
Failed rest (if programmed under Timers > Engine Logic) it will try again.
Low Batt Warning During cranking the battery was lower than normal. The level is set under Sensors > Battery.
InCrank
Charger Warning Indicates a battery charger issue. The controller has a battery charger fault switched input. This is
Fault used to indicate to the controller the charger has a fault.
High Fuel Warning The fuel level raised above the high fuel level warning threshold set under Sensors > Fuel Level.
Level Potential over fueling issue.
Under Warning The generator AC voltage has fallen below the under voltage warning setpoint set under AC Monitor
Voltage > Genset Voltage. Possible issue with the voltage regulator or governing on the engine.
Under Warning The generator speed has fallen below the under speed warning setpoint set under Sensors > Engine
Speed Speed.
Over Warning The generator speed has risen above the over speed warning setpoint set under Sensors > Engine
Speed Speed.
High Warning The engine temperature has risen above the high engine temperature warning under Sensors >
Engine Engine Temp.
Temp
Low Oil Warning The oil pressure has fallen below the low oil pressure warning setpoint under Sensor > Oil Pressure.
Pressure
Low Fuel Warning The fuel level has fallen below the low fuel level warning setpoint under Sensors > Fuel Level.
Level

False Warning After going into the RUN mode the controller has determined the engine has not started after all and
Restart will attempt to do another crank attempt. The fault restart feature under Engine Logic > Timers has to
be enabled.
Breaker Warning The "Breaker Trip" switched output has been activated. This output is used to control the generator
Tripped breaker.
Over Warning The generator AC current has risen above the Over Current warning setpoint under AC Monitor >
Current O.C. Protection > Basic Alarm.
Fuel In Warning The "fuel in basin" switched input has been triggered. This indicates there has been a leak in the fuel
Basin tank.
Low Warning The main starter battery (the battery the controller is powered from) voltage has fallen below the low
Battery battery warning setpoint under Sensors > Battery.
High Warning The main starter battery (the battery the controller is powered from) voltage has risen above the high
Battery battery warning setpoint under Sensors > Battery.
Low Engine Warning The engine temperature has fallen below the low engine temperature warning setpoint set under
Temp Sensors > Engine Temp. > Setpoints.
Battle Warning The "Battle Mode" switched input has been triggered. The controller will not shutdown on any failures.
Running All failures will be ignored.
Under Warning The generator AC frequency has fallen below the Under Frequency warning setpoint set under AC
Frequency Monitor > Genset Freq. > Setpoints.
Over Warning The generator AC frequency has risen above the Over Frequency warning setpoint set under AC
Load Warning The generator load is imbalanced between the A, B, and C phases. This has to be enabled under AC
Imbalance Monitor > O.C. Protection > Imbalance Mode.
Over 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.
High Fuel Warning Doosan G2 electronic engine high fuel warning. This warning comes from the engine ECM over CAN
Temp J1939.
Hi Exhaust Warning Doosan G2 electronic engine high turbine exhaust temperature. This warning comes from the engine
Temp ECM over CAN J1939.
Failed To Failure The controller shut down the engine -- by turning off the Fuel output and (if enabled) by turning on the
Stop Energize-To-Stop output -- but the engine speed did not go to zero after the energize to stop time
(under Timers > Engine Logic).
Breaker Failure The "Breaker Trip" switched output failed to turn off the breaker. This is triggered if the AC Current is
Failed still above 10% of the rated current setpoint. The "breaker trip" failure has to be enabled under AC
Monitor > O.C. Protection > Brk Trip Fail.
Load Failure The generator load is imbalanced between the A, B, and C phases. This has to be enabled under AC
Imbalance Monitor > O.C. Protection > Imbalance Mode with the mode set to ""Shutdown Trip".
Over Failure The generator AC current has risen above the over current failure setpoint set under AC Monitor >
Current O.C. Protection > Basic Alarm.
ECM Failure Electronic engines only. CAN J1939 DM1 stop lamp is active; the ECM has shutdown the engine.
Shutdown
High Failure Engine temperature has risen above the high engine temperature failure setpoint set under Sensors
Engine > Engine Temp.
Temp
Low Oil Failure Engine oil pressure has fallen below the low oil pressure failure setpoint set under Sensors > Oil
Pressure Pressure.
Under Failure Engine speed has fallen below the under speed failure setpoint set under Sensors > Engine Speed.
Speed
Over Failure Engine speed has risen above the over speed failure setpoint set under Sensors > Engine Speed.
Speed
Low Fuel Failure The fuel level has fallen below the low fuel level failure setpoint under Sensors > Fuel Level.
Level
Low Failure The main starter battery (the battery the controller is powered from) voltage has fallen below the low
Battery battery failure setpoint set under Sensors > Battery.

Low Failure The "Low Coolant Level" switched input is active indicating low coolant level failure.
Coolant Lvl
Over Crank Failure The controller exhausted the crank attempts (specified in Timers > Engine Logic > Crank Attempts)
and could not start the engine.
Over Failure The generator AC voltage has risen above the over voltage failure setpoint set under AC Monitor >
Voltage Genset Voltage > Setpoints.
Under Failure The generator AC voltage has fallen below the under voltage failure setpoint set under AC Monitor >
Voltage Genset Voltage > Setpoints.
Regen Failure For electronic engines with a diesel particular filter (DPF) only. The user must perform a regeneration
Needed before running the engine further. Continuing to ignore this message could result in the DPF being
damaged and requiring replacement.
Low Air Failure The "Air Press. Fail" switched input is active. Indicates a low air pressure failure condition.
Pressure
Low Failure The "Hyd Pres. Fail" switched input is active. Indicates a low hydraulic pressure failure condition.
Hydraulic
High Failure The main starter battery (the battery the controller is powered from) voltage has risen above the high
Battery battery failure setpoint set under Sensors > Battery.
Loss Of Failure For electronic engines only. The "Loss of ECM" under J1939 must be enabled. The controller has not
ECM detected engine speed, oil pressure, or engine temperature on it's CAN J1939 port.
Comm
Under Failure The generator AC frequency has fallen below the under frequency failure setpoint set under AC
Over Failure The generator AC frequency has risen above the over frequency failure setpoint set under AC
DPF SRVC Failure For electronic engines with a diesel particulate filter only. Service the DFP ASAP. Damage to the
REQ'D! DPF is possible if the engine is run.
SERVICE Failure For electronic engines with a diesel particulate filter only. Service the DFP ASAP. Damage to the
DPF!!! DPF is likely if the engine is run.
Calibration Failure Doosan G2 electronic engine only. Contact Doosan for more information.
Fail
High Fuel Failure Doosan G2 electronic engine high fuel failure. This failure comes from the engine ECM over CAN
Temp J1939.
Hi Exhaust Failure Doosan G2 electronic engine high turbine exhaust temperature failure. This failure comes from the
Temp engine ECM over CAN J1939.
FILL DEF Failure For electronics engines with a SCR (Seletive Catalytic Reaction) device only. The SCR needs to be
NOW refilled. Engine may not start if this is not performed or may remain in "limp-home" mode. DEF
stands for diesel exhaust fluid.
Engine Failure The controller is in the RUN mode and the engine speed has fallen below the crank disconnect
Stall speed. The engine stall must be enabled under Timers > Engine Logic.

Settings 30
4 Settings
The following section relates to settings that can be changed to alter the way the controller performs its functions. Read and
review these sections carefully to ensure your settings are set correctly for your engine.
4.1 Operator Setup

The following settings are used to change the way the user interacts with the controller. They are not password protected and
can be changed by anyone from the front panel.
Name Range Default Description

Setting
Lamp Test ----- ----- Performs a lamp test on the LEDs when selected.
Display > LCD ----- ----- Reverses the white and black pixels when selected.
Reverse
Display > LCD 5 ~ 95% 50% Changes the contrast of the LCD.
Contrast
Display > Page 1 ~ 10 seconds 5s Amount of time between each auto scroll of the parameter pages.
Scroll
Display > Message 1 ~ 10 seconds 2s Amount of time each message is displayed on the screen before
Pop-Up displaying next message in the buffer.
Display > 0 ~ 10 seconds 2s See DPF/DEF aftertreatment in the J1939 Reference Manual for
DPF/DEF Display more information.
Time
Display > LCD 10 ~ 600 seconds 600s Amount of time the LCD Backlight stays on after button activity
Backlight Timeout stops.
Date / Time > Date 1 ~ 31 days Sets the date.
Change 1 ~ 12 months
-----
2000 ~ 2099
years
Date / Time > Time 0 ~ 23 hours Sets the time.
Change 0 ~ 59 minutes -----
0 ~ 59 seconds
Date / Time > Enable or Disable Turns Daylight Savings Time on or off. This applies to North
Enable
Daylight Savings America only. Disable for other locations.
Units > Fahrenheit or Selects the temperature display format.
Fahrenheit
Temperature Unit Celcius
Units > Pressure PSI or kPa Selects the oil pressure display format.
PSI
Unit
Run from OFF > Enable ~ Disable 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.

Settings 31
4.2 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
A
Switched Input Start / Stop
B
Switched Input Disable
C
D
E
Switched I/O > Switched IN X:

Name Range Description
Function [Menu] See below. The function that the switched input performs when active.
Active Mode [Menu] See below. Determines the operating conditions under which the switched input can
be active. Multiple selections are allowed.
Trigger [Menu] See below. The state of the input determining if it is active or inactive.
Switched I/O > Switched IN X > Function:

Name Active Mode Description
Disabled N/A Input is disabled and has no function.
Start / Stop Auto, Running Starts the engine when active, stops the engine when deactivated. It is
recommended to set the Trigger mode to Close +BAT for better noise
tolerance.
If Trigger mode is set to "Open" or "Close +BAT/GND" the start/stop input

will act like a momentary input. A pulse of 2 to 4 seconds will start
controller. Another pulse of 2 to 4 second duration is required to stop the
controller. If the input is just turned off, the controller will continue to run.
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 emergency stop indication on
the controller. The installer must provide an independent means to shut
down the engine from the emergency stop button such as cutting off fuel.
See the typical wiring diagrams for an example on how to wire up the
emergency stop.
Idle Mode Running See the Idle section under Engine Logic for more information.
Voltage Select 1 Auto Used for changing the system AC voltage configuration. See AC Voltage
Select for more information.
Voltage Select 2 Auto
Charger Fault (Battery Global Controller displays 'Charger Fault' warning when active.
Charger Fault)
Mom. Start (Momentary Auto Starts or stops the engine when momentarily active for at least 2
Start) seconds.These inputs allow the user to wire separate inputs for start and
stop or to use a push button instead of a toggle switch.
Mom. Stop (Momentary Running
Stop)
Momentary stop will only stop the controller when the reason for start was
"momentary start". It will not stop if the front panel run button was used to
start the engine.
Configurable Warning 1 Configurable Controller displays a warning or failure with configurable text* when active.
In the case of the configurable failures a shutdown is also performed.

Settings 32

Configurable Warning 2 Configurable The RapidCore Configuration Software must be used to change the text.
Configurable Failure 1 Configurable The settings under Timers > Trigger Delays > Config Inputs and Timers >
Configurable Failure 2 Configurable Trigger Delays > Config Fail 3 can be set to control the amount of time the
input has to be active to trigger.
Configurable Failure 3 Configurable
Air Press. Fail (Air Cranking Controller displays 'Low Air Pressure' and shuts down engine when active.
Pressure Failure)
Hyd Pres. Fail (Low Cranking Controller displays 'Hydraulic Pressure Failure' and shuts down engine
Hydraulic Pressure when active.
Failure)
Oil Pres Warn (Low Oil Running Controller displays 'Oil Pressure Warning' when active.
Pressure Warning)
Cool. Lvl Fail (Low Global Controller displays 'Low Coolant Lvl' and shuts down engine when active.
Coolant Level Failure)
High Fuel Warning Global Controller displays 'High Fuel Level' warning when active.
Lamp Test Global Controller performs lamp test when active. If the controller is in the
FAILURE mode the LED will remain red. The only indication that the lamp
test is active is the LED indicator will alternate between the green and red
colors. The LED goes back to it's original state when the switched input is
no longer active.
Fuel In Basin Global Controller displays 'Fuel In Basin' warning when active.
Battle Mode After Cranking Controller ignores all warnings and failures when active. Displays 'Battle
Running' when active. If a failure occurs during Battle Mode it is 'latched'
and the engine will shutdown on failure when the controller leaves Battle
Mode.
Start Inhibit Global Controller ignores all start commands and the engine cannot start when
active. Once Start Inhibit becomes inactive, starting is enabled again. If
the engine is running, activating this input will shut down the engine and
place the controller in AUTO mode.
RPM Switch (Primary Auto Used for changing between Primary and Secondary RPM for an engine or
RPM / 60Hz - 50Hz / 60Hz for a generator. See RPM / Frequency Select for more
Secondary RPM / 50Hz information.
Select)
ECM Preheat (ECM Cranking (during the Controls preheating using a switched input. See Switched Input in the
Preheat Signal) Preheat countdown Preheat Mode section.
only)
Remote Reset Global Allows the controller to be reset from a failure mode.
- Momentary action for 3 - 5s in FAILURE mode will place the controller in
OFF mode.
- Momentary action for 3 - 5s in OFF mode will place the controller in
AUTO mode.
- Momentary action for 3 - 5s in RUN mode will place the controller in
AUTO mode. Cool-down is skipped.
NOTE: More than one Active Mode can be selected.
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.
Close GND Input is active when Ground is present at the terminal
Close +BAT/GND Input is active when either +Battery or Ground is present at the terminal.

Settings 33
Name Description
Open 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.

Settings 34
4.2.1 Configurable Inputs

These inputs are used to create custom warnings and failures. Using the RapidCore Configuration Software you can change
the text displayed when the warning or failure occurs. If you select one of these inputs without changing the text it will default to
'Config Warn X' and 'Config Fail X.'
There are also timers associated with the configurable inputs which can be found in the menu under Timers > Trigger Delays >
Config Inputs and Config Fail 3. These timers change the amount of time the input has to be active before the controller
registers the warning or failure.
NOTE: If the switched input becomes inactive before the trigger delay time expires, the warning or failure will not
occur.
Example: The user wants a pump to turn on 30 seconds after a high water level switch is tripped and remain on until the level
switch turns off.
The level switch is connected to Switched Input C and closes to ground when the water level is too high. The words 'Water
Pumping' are also required to be displayed on the controllers LCD screen. The pump is connected to a slave relay which is
controlled by Switched Output D on the controller.
Relevant Settings
Setting Value
Switched Input C -> Function Configurable Warning 1
Switched Input C -> Active Mode Global
Switched Input C -> Trigger Close GND
Configurable Warning 1 Custom Text Water Pumping
Switched Output D -> Warnings Configurable Warning 1
4.3 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.
WARNING: Switched outputs have a floating voltage of approximately 8V when off. If using the outputs for digital
logic, it will be necessary to put a pull-down resistor (1 kOhm) from the output to ground to ensure a low logic level
when output is off.
Default settings:
Switched Default Setting
Output
Switched Fuel Output
Output A
Switched Disable
Output B
Switched Crank Output
Output C
Switched Disable
Output D
Switched Disable
Output E
Switched Disable
Output F
Event Functions
Fuel Cranking, Running Active during cranking and running to supply fuel to engine.
Crank Cranking Active during cranking to start the engine.

Settings 35

Pull Coil Cranking See Pull and Hold Coil section for more information.
LCD Backlight Global Active when LCD Backlight is active.
Voltage Regulator Running Active when engine is starting/running and is not in Idle Mode.
ETS (Energize to Stop) ETS Timer Active during Energize to Stop timer. See ETS On Duration under Timers >
Engine Logic for more details.
Off Mode (Not In Auto) Off Active when the controller is in the OFF mode.
Idle Mode Idle Mode Active when the controller is in IDLE mode. For example when the idle
switched input is active or during warmup and cooldown if warmup idle and
cooldown idle settings under Timers > Engine Logic are enabled.
Battle Mode Battle Mode Active when Battle Mode switched input is active.
System OK (System Auto, Run Active when the controller is in the AUTO and RUN mode and no warnings
Ready) or failures are present.
Delay to Start Delay to Start Timer Active when the Delay to Start timer is active.
Glowplug Preheat, Midheat, Active during the Preheat, Midheat and Postheat timers.
Postheat
Warmup Warmup Timer Active in RUN mode after Warmup timer has expired. Is not active in the
cooling down state or other states. Typically used to apply load to engine
only after it has warmed up and to remove the load on cooldown.
Cooldown Cooldown Timer Active when Cooldown timer is active.
Engine Running Running Active after crank success.
Exercising Exercise Timer Active during the engine exercising cycle.
Batt. Recharge (Battery Battery Recharge Active during the battery recharge cycle.
Recharge) Timer
Maintenance Global Active when Maintenance timer has expired. If the timer has expired when
(Maintenance Required) the controller is in the RUN mode the output does not turn on until the
controller enters the OFF or AUTO mode. See the Maintenance section.
LowBat InCrank (Low Cranking Active when Low Battery During Cranking warning is displayed.
Battery During Cranking)
Aux Sensor 1
Aux Sensor 2 Auxiliary Settings
Active dependent upon settings in the Auxiliary sensor section.
Aux Sensor 3 Dependent
Aux Sensor 4
Force Regen User Controlled When user triggers a Force Regeneration, output is active for 20 seconds
then switches off.
Regen Inhibit User Controlled When user triggers a Regeneration Inhibit, output is active for 20 seconds
then switches off.
Common Failure Any Failure Active when any failure occurs.
RPM Increment Running Output is used to 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 to trigger inputs on an ECM to control speed. See Front
Panel Speed Control section for more information.
DEF Fluid Pump Running Active when DEF Fluid Level falls below the DEF Low Level and stays
active until the level rises above the DEF High Level. See CAN Bus
(J1939) section for more information.
Genset Disable Global Disables the generator during a stationary Regen on Kubota engines (see
Aftertreatment in the J1939 User Manual ) or also during an engine IDLE
condition from the IDLE switched input. Automatic idle is ignored. If the
generator voltage is not below the under voltage setpoint in 10s, the
controller will shut down the engine on "Generator Disable Failure."
Dummy Load Running Output is controlled by the dummy load feature.

Settings 36

Breaker Trip Running Output is controlled by the Over Current Failure, IDMT and Load
Imbalance features. The breaker Trip only reacts to over current faults; It
does not activate for other failures.
Auto Idle Warm-up, Cooldown Active at the start of delay to start until the end of warm-up if warmup idle
is enabled. Also active during cooldown if cooldown idle is enabled. See
Warm-up Idle and Cooldown Idle in Engine Logic. This output does not
react to the Idle switched input.
Rpm Output Running Refer to the RPM Output feature under Sensors > Engine Speed for more
information.
Amb Temp Out Running Used by the J1939 Ambient Air Temperature Control feature. Refer to the
J1939 Reference manual for more details.
Warning Functions
Functions
Low Engine Temperature High Engine Temperature Low Oil Pressure Under Speed
Over Speed Low Fuel Level High Fuel Level Low Battery Voltage
High Battery Voltage Under Frequency Over Frequency AC Under Voltage
AC Over Voltage Over Current Fuel In Basin Battery Charger Fault
Configurable Warning 1 Configurable Warning 2 Auxiliary Sensor 1 Auxiliary Sensor 2
Auxiliary Sensor 3 Auxiliary Sensor 4

Load Imbalance Running AC current phases do not match. (More Information)
DTC Received. (DTC/MIL) Running Active when controller receives a DM1 from the ECM.
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 High Battery Voltage Low Coolant Level Low Air Pressure
Low Hydraulic Pressure Under Frequency Over Frequency AC Under Voltage
AC Over Voltage Over Current (TG410 only) ECM Communication Failure Configurable Failure 1
Configurable Failure 2 Config Fail 3 Auxiliary Sensor 1 Auxiliary Sensor 2
Auxiliary Sensor 3 Auxiliary Sensor 4 ---

Load Imbalance Running AC current phases do not match. (More Information)
Exception Fault* All 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.

Settings 37
4.3.1 Group Outputs

Group functions have been designed to allow multiple output functions to be bundled together and assigned to a single
switched output pin. The definition of a group output follows:
When any of the functions in a group is active (OR logic), the assigned switched output will be active.
Group Functions
Group #1 Group Dependent Must be set from RapidCore Configuration software.
Example: Low AC Frequency, High AC Frequency are bundled in 'Group #1' and assigned to Switched Output D. This output is
connected to an external indicator lamp labeled 'AC Frequency Warnings', allowing one output 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 OFF
Inactive Active ON
Active Inactive ON
Active Active ON
4.3.2 Pull and Hold Coil

On some engine systems the fuel pump has two coils. This is because the initial power on of the fuel solenoid requires
substantial current (Pull Coil), but only needs a small amount of current to hold it in place (Hold Coil).
1. Hold Coil (Fuel) is energized.

2. Pull Coil is energized for the first 1.6 to 1.8 seconds of preheat. If preheat is disabled the pull coil is energized at the
beginning of cranking; the crank output turned off for that time period.
3. This is repeated for each crank attempt.
Configuring a switched output to Pull Coil automatically configures the engine logic necessary for a Pull Coil system.
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

Settings 38
4.4 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.
To configure the behavior of these sensor inputs the user assigns the sensor input to one of the following 7 sensor functions:
· Engine Temperature,
· Oil Pressure,
· Fuel Level
· Auxiliary Sensor 1
Note that there are more sensor functions than sensor inputs as the Auxiliary Sensors can be assigned the same sensor input
as the other sensor functions.
· The Engine Temperature, Oil Pressure, and Fuel Level functions are mostly fixed in functionality but the Auxiliary sensors
can be configured to perform specific shutdowns or special functions (Example: Starting engine on low temperature).
· The Engine Temperature, Oil Pressure, and Fuel Level functions can be set to work with a switch or a sender/sensor but the
Auxiliary sensors can only work with a sender.
Note: The engine speed and battery level are built in and do not need to be assigned to a pin.
4.4.1 Engine Temperature

Use the following settings' configurations to allow the controller to read and interpret data from the engine temperature sensor
or switch.
(Sensors > Engine Temp. menu)

Settings
Signal Source Port A Port A The sensor input pin where the engine temperature switch or sender is
Port B attached.
Port C
Port D *Engine temperature is obtained from the engine controller (ECM)
J1939 Bus* using the CANbus communication port and J1939 protocol.
Sensor Type DAT DAH* DAT DAH Select the sender that is connected to the Signal Source above. If
VDO 250F* using a switch select the action that should occur when the switch is
active.
(custom sender)**
*These are preprogrammed into the controller and cannot be changed.
Close = Warning+ - DAT DAH supports all Datcon type DAH (high range) temperature
sensors such as 02022-00.
Open = Warning+
- VDO 250F supports the VDO 323-420 or equivalent temperature
Close = Failure+ sensor.
Open = Failure+ DAT DAH and VDO 250F can only be used if the Signal Source is set
to Port A, C, or D. To use on other ports store as a custom sender
table using the RapidCore Configuration software.
**A custom table can be created using the RapidCore Configuration

Software. The text (custom sender) will be replaced with the custom
text you choose when creating the sender.
+The switch must close to ground.
Trim Offset -50.0 ~ 50.0°F (- 0.0 F Calibrate a sensor by using the offset to correct errors. Only applies if
10 ~ 100C) Sensor Type has been set to a sender.
Setpoints > Bypass 0 ~ 90 seconds 30 s Amount of time to bypass warnings and failures after engine has
Time started.
Setpoints > Low Disabled, 32 ~ Disabled Reading at which a "Low Engine Temp" warning occurs. Displays 'Low
Warn (Low 200°F (0 ~ 93.30C) Engine Temp' on the screen. Only applies if Sensor Type has been set
Warning) to a sender. Monitored globally including OFF and AUTO.
Setpoints > High Disabled, 50 ~ 200 F 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) 148.90C) mode.

Settings 39

Settings
Setpoints > High Disabled, 50 ~ 220 F Reading at which a "High Engine Temp" failure occurs. Only applies if
Fail (High Failure) 300°F (10 ~ Sensor Type has been set to a sender. Only monitored in the RUN
148.90C) mode.
Note: All temperature settings are entered in terms of Fahrenheit.
4.4.2 Oil Pressure

Use the following settings' configurations to allow the controller to read and interpret data from the oil pressure sensor or
switch.

Signal Port A The sensor input pin where the oil pressure switch or sender is attached.
Source Port B
Port C Port B *Oil pressure is obtained from the engine controller (ECM) using the
Port D CANbus communication port and J1939 protocol.
J1939 Bus*
Sensor Type DAT 100P/R240* Select the sender that is connected to the Signal Source above. If using
VDO 150P/R180* a switch select the action that should occur when the switch is active.
(custom sender)** *These are preprogrammed into the controller and cannot be changed.
- DAT 100P/R240 supports the Stewart - Warner 279B-F and Datcon
Close = Warning+ 2505-00 sender tables.
DAT - VDO 150P/R180 supports the VDO 360-004 oil pressure sender.
Open = Warning+
100P/R240 DAT 100P/R240 and VDO 150P/R180 can not be used on port A. To use
Close = Failure+ (Steart on port A store as a custom sender table using the RapidCore
Open = Failure+ 279B-F) Configuration software.
**A custom table created using the RapidCore Configuration Software.

The text (custom sender) will be replaced with the custom text you
choose when creating the sender.
+The switch must close to ground.
Trim Offset -50.0 ~ 50.0 PSI (- Calibrate a sensor by using the offset to correct errors. Only applies if
0 PSI
344.7 ~ 344.7kPa) Sensor Type has been set to a sender.
Setpoints -> 0 ~ 90 seconds Amount of time to bypass warnings and failures after engine has started.
30 s
Bypass Time
Setpoints -> Disabled, 0.1 ~ 99.0 Reading at which a "Low Oil Pressure" warning occurs. Only applies if
20.0 PSI
Low Warning psi (0.7 ~ 682.6kPa) Sensor Type has been set to a sender.
Setpoints -> Disabled, 0.1 ~ 99.0 Reading at which a "Low Oil Pressure" failure occurs. Only applies if
15.0 PSI
Low Failure psi (0.7 ~ 682.6kPa) Sensor Type has been set to a sender.
Note: All pressure settings are entered in terms of psi.
4.4.3 Fuel Level

Use the following settings' configurations to allow the controller to read and interpret data from the fuel level sensor.

Signal Source Disable The sensor input pin where the fuel level switch or sender is attached.
Port A
Port B Disable
Port C
Port D
Sensor Type DAT R/33- Select the sender that is connected to the Signal Source above. If using a
240* switch select the action that should occur when the switch is active.
VDO R/0-
180* 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)**

Settings 40

- VDO R/0-180 supports a VDO fuel level sensor of the range 0 Ohms to 180
Close = Ohms
Warning+ DAT R33-240 and VDO R/0-180 can not be used on port A. To use on port A
Open = store as a custom sender table using the RapidCore Configuration software.
Warning+
**A custom table created using the RapidCore Configuration Software. The
Close =
text (custom sender) will be replaced with the custom text you choose when
Failure+ creating the sender.
Open =
Failure+ +The switch must close to ground.
Trim Offset -50.0 ~ Calibrate a sensor by using the offset to correct errors. Only applies if Sensor
0.0 %
50.0% Type has been set to a sender.
Setpoints -> 0 ~ 90 Amount of time to bypass warnings and failures after engine has started.
30 s
Bypass Time seconds
Setpoints > Disabled, Reading at which a "Low Fuel Level" warning occurs. Only applies if Sensor
25 %
Low Warning 1 ~ 90% Type has been set to a sender. Only monitored in the RUN mode.
Setpoints > Disabled, Reading at which a "Low Fuel Level" failure occurs. Only applies if Sensor
5%
Low Failure 1 ~ 90% Type has been set to a sender. Only monitored in the RUN mode.
Setpoints > Disabled, Reading at which a "High Fuel Level" warning occurs. Displays 'High Fuel
High Warning 1 ~ 125% Disabled Level' on the screen. Only applies if Sensor Type has been set to a sender.
Monitored globally including OFF and AUTO.
4.4.4 Engine Speed

Use the following settings' configurations to allow the controller to read and interpret speed sensing data.

Signal Source J1939 Bus The source for the engine speed signal.
Mag Pickup
Genset Voltage J1939 -- Engine speed is obtained over the engine CAN
communication bus .
Genset Genset Voltage -- The AC Voltage connector phase A is used for
Voltage engine speed.
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.
Speed Settings > Rated 500 ~ 4000 rpm Speed at which the engine runs under normal operating conditions.
1800
RPM in 1 rpm Warning and failure setpoints are calculated from this setting.
rpm
increments
Speed Settings > Idle 300 ~ 2000 rpm Speed at which the engine runs when it is idling.
RPM in 1 rpm 900 rpm
increments
Speed Settings > Tooth 1 ~ 600 (only applies when Signal Source is set to Mag Pickup) Number of
Count teeth on the flywheel.
If the number of teeth is unknown the following formula can be used.

110 A multimeter must be used to measure the AC frequency (Frequency-
In-Hz below) from the magnetic pickup. The speed (Speed-In-Rpm
below) must be known.
Tooth-Count = (Frequency-In-Hz * 60) / Speed-In-Rpm

Setpoints > Low Warn 20 ~ 99% Reading at which a warning occurs.
90 %
(Under Speed Warning)
Setpoints > Low Fail 20 ~ 99% Reading at which a failure occurs.
85 %
(Under Speed Failure)
Setpoints > High Warn 101 ~ 150% Reading at which a warning occurs.
110 %
(Over Speed Warning)

Settings 41

Setpoints > High Fail 101 ~ 150% A over speed failure is triggered if the speed is above this threshold for
115 %
(Over Speed Failure) 4 seconds.
RPM Control > Min 500 ~ 4000 rpm
Speed in 1 rpm 600 rpm
increments
RPM Control > Max 500 ~ 4000 rpm
2000
Speed in 1 rpm
rpm
increments
RPM Control > Speed 0 to 600 rpm in
Bias 1 rpm 30 rpm Front Panel Speed Control SettingsSee Front Panel Speed Control
increments section for more information on these settings.
RPM Control > Tsc1 Disabled, 10 to
RPM/s 300 rpm in 10 200 rpm
RPM increments
RPM Display Blank
AC Hertz AC
Aux Sensor 1 Hertz
Aux Sensor 2
RPM Switch > 500 ~ 4000 rpm The Rated RPM when the Secondary RPM / 50Hz is selected. See
1500
Secondary (Secondary in 1 rpm RPM / Frequency Select section for more information.
rpm
RPM / 50Hz) increments
RPM Switch > Primary 500 ~ 4000 rpm, The Rated RPM when the Primary RPM / 60Hz is selected. See
1800
(Primary RPM / 60Hz) 1 rpm RPM / Frequency Select section for more information.
rpm
increments
RPM Output See the the RPM Output section for more information.
NOTE: When using J1939 or Genset Voltage as a signal source, connections to the speed sensing terminals are
not required.
IMPORTANT: When using Genset Voltage as a signal source the voltage source must be connected to terminal A
(J7-1). AC frequency is sensed on terminal A only.
NOTE: Speed is monitored at the start of cranking. If there is speed detected above the crank disconnect setting
then cranking and idle is skipped.
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.

Settings 42
4.4.4.1 Front Panel Speed Control

The operator is able to adjust the speed of the engine by using the controller's front panel. This section describes the two
methods available for implementing speed control, the settings and parameters to be used, as well as the necessary
instructions allowing the operator to control the speed.
Speed Control Methods

Setting Description
Front Panel Speed Control using J1939 The controller can instruct the ECM of an electronic engine to adjust its speed by
TSC1 broadcasting the TSC1 command.
Refer to the J1939 Manual for more information.

Front Panel Speed Control using Switched The controller can instruct the ECM of an electronic engine to adjust its speed by
Outputs using switched outputs on the controller set to RPM Increment and RPM
Decrement to interface with digital inputs on the ECM. When the speed is
changed, the corresponding switched output will be on for 1 second each time
increment or decrement is pressed.
See the rest of this section for more information.

Aux 4 Speed Control The Auxiliary sensor 4 is used to determine the setpoint speed. The speed is
adjusted with the TSC1 J1939 command.
Refer to the J1939 Manual for more information.
WARNING: Switched outputs have a floating voltage of approximately 8V when off. If using the outputs for digital
logic, it will be necessary to put a pull-down resistor (1kOhm, 1 Watt) from the output to ground to ensure a low
logic level when output is off.
Front panel speed control using the Switched Outputs
Settings
Name Parent Menu Range Default Description
Speed RapidCore only. Enable or (Programmable from RapidCore Configuration Software only)
Control Engine Speed Disable Disable Enables or disables front panel speed control.
Enable menu.
RPM Sensors > Engine Blank Parameter to display when adjusting speed from front panel.
Display Speed AC Hertz This is used to provide operator feedback in the case that the
Aux Sensor 1 AC Hertz engine RPM affects another parameter such as AC
Aux Sensor 2 Frequency or an Auxiliary Sensor (Example: Flow rate of
pump).
Limit RapidCore only. Speed Bias (Programmable from RapidCore Configuration Software only)
Method Engine Speed Min RPM / Speed Bias The method in which the minimum and maximum speeds the
menu. Max RPM operator is allowed to adjust is determined.
Speed Sensors > Engine 0 ~ 600 RPM The minimum or maximum RPM that the engine speed can be
Bias Speed > RPM in 1 RPM adjusted around the Rated RPM. Example: Rated RPM is
Control increments 30 RPM 1800 and Speed Bias is 150. The minimum RPM will be 1650
and maximum RPM will be 1950. Only valid when the correct
limit method is chosen.
Min 500 ~ 4000 The minimum RPM that can be set using speed control. Only
Speed RPM in 1 valid when the correct Limit Method is chosen.
600 RPM
RPM
increments
Max 500 ~ 4000 The maximum RPM that can be set using speed control. Only
Speed RPM in 1 valid when the correct Limit Method is chosen.
2000 RPM
RPM
increments
Tsc1 Sensors > Engine 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

Settings 43
When the controller is running and there are other functions occurring, the controller will scroll through its display parameters as
usual. When the speed control page is displayed, it will show the Engine Speed as well as the following instructions: Hold
AUTO + Up/Down to Adjust RPM.
Speed Control Parameter Page Speed Control Adjust Page
Pressing and holding the AUTO button will display the screen to the right. If a 'Display Adjust Parameter' is set, it will also be
displayed underneath the Engine Speed. While still holding the AUTO key, press the up or down arrows to adjust the RPM. The
Engine Speed display should update as the engine physically changes its speed to accommodate the speed request.
NOTE: When using switched outputs for speed control, the Set RPM will display '---' instead of the set speed.
4.4.4.2 RPM Output

This feature can be used to turn an output on and off when the speed of the engine/generator rises or falls below a given
speed.
To use this feature a switched output has to be set to "Rpm Output".
(Sensors > Engine Speed)

RPM Output SubMenu ----- -----
RPM Output > 0.2 s to 10 s, 0.2 s 2s Sets the time to wait before turning on or off the
Debounce increment switched output.
RPM Output > Trigger Disable, Under, Over Disable Sets when to turn on the switched output relative to
the Switched RPM setting.
RPM Output > Switch 500 to 3000 rpm, 1 rpm 1800 rpm Sets the RPM to trigger on. Trigger is based off of
RPM increments this setting.
4.4.5 Battery
Use the following settings' configurations to allow the controller to read and interpret the battery voltage level.

Battery Enable ~ Enables or disables the ability to have the engine start on low battery voltage in
Disable
Recharge Disable order to charge it.
Recharge Setup 6.0 - 30.0V Voltage level at which the controller starts the engine to recharge the battery.
10.4 V
-> Level
Recharge Setup 1 ~ 30 Amount of time to display a warning before starting the engine.
5 min
-> Pre-Alarm minutes
Recharge Setup 10 ~ 900 Amount of time to run the engine.
90 min
-> Duration minutes
Setpoints -> Disabled, 6.0 Reading at which a warning occurs.
11.3 V
Low Warning ~ 24.0V
Setpoints -> Disabled, 6.0 Reading at which a failure occurs.
Disabled
Low Failure ~ 24.0V
Setpoints -> Disabled, Reading at which a warning occurs.
Disabled
High Warning 12.0 ~ 32.0V
Setpoints -> Disabled, Reading at which a failure occurs.
Disabled
High Failure 12.0 ~ 32.0V

Settings 44

LowBat InCrank 6.0 ~ 24.0V Screen displays a 'Low Voltage During Cranking' warning if voltage dips below
8.0 V
this level during cranking.
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

Settings 45
4.4.6 Auxiliary Sensors

The Auxiliary sensors are used for supporting custom sensors and triggering actions based on the sensor values. There are
four auxiliary sensors.
Note: there is a fifth sensor - 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 > Auxiliary Sensor 5 in RapidCore). The below menus are for the
Auxiliary Sensors only.
You must use the RapidCore Configuration Software to program a custom sender table to the controller for the auxiliary
sensor(s) that will be used. Otherwise "Undefined Sensor" will appear menu in the front panel menu system. Once a sender
table is programmed to the controller all the other settings can be adjusted from the front panel of the controller.
(Sensors > Aux Sensor 1/2/3/4 menus)

Signal Source Disable The source where to get the signal for the aux. sensor.
Port A
Port B Disable Any port can be used even if it is used by another sensor or aux.
Port C sensor. If the port is in use by other sensor this is known as
Port D overloading the port.
Custom Sender The sender resistance / value curve must be programmed from
(Configuration the RapidCore Configuration Software even if the port is being
Undefine
Software only) ----- overloaded. This tells the controller how to interpret the signal
d
from the port. No front panel configuration is allowed until the
sender curve is programmed to the controller.
Display Enable Determines if the sensor's value is displayed on the screen when
-----
Disable the engine is running.
Active Mode Disable Determines under which operating conditions the Auxiliary Sensor
Global is monitored. Multiple selections are allowed. Does not apply to
OFF Mode (Not in Auto) "Start on Low" or "Start on High"; for those selections the active
Auto Mode mode is always AUTO.
Running
Cranking Refer to the examples in the following pages for information on
After Cranking specific mode functions.
Cooldown
Disable - Input cannot be triggered.
-----
Global - Input can be triggered at any time.
OFF Mode - Input can be triggered while in the OFF mode.
Auto Mode - Input can be triggered while in the AUTO mode.
Running - Input can be triggered after a start command is
received until shut down (cooldown not included).
Cranking - Input can be triggered during cranking.
After Cranking - Input can be triggered after engine has started
until shut down.
Cooldown - Input can be triggered while cooldown timer is active.
Func. Select Fault Monitor Determines how the controller responds to the readings of the
Output on Low auxiliary sensor.
Output on High
Start on Low "x on Low" will turn on the output or start the controller if the
-----
Start on High sensor input falls below the Start Level.
"x on High" will turn on the output or start the controller if the
sensor input rises above the Start Level.
Trim Offset -50.0 ~ 50.0 units. The Calibrate a sensor by using the offset to correct errors.
units depends on the unit
type of the programmed -----
sender table -- 0F, psi, %,
V, A.
Mode Settings > 0 ~ 90, 1 second The amount of time to ignore the sensor input after the desired
Bypass Time increments 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 on power-up.
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

Settings 46

1 ~ 60001, 1 minute controller before turning off the output or shutting down the
increments controller.
If the Run Time is disabled then the start/output is held until the
Stop Level is reached (if enabled) or until the controller is reset or
powered down or, in the case of Start on Low / Start on High, until
the user presses the OFF button.
Note that the run time is not exact. Up to 10 seconds may be

added to the beginning of the run time counter and up to 4
seconds to the end. The run time begins when a start request is
received so crank time, preheat time, etc is included in the Run
Time.
Mode Settings > (Only applies if Func. Select is not set to Fault Monitor) The level
Start Level at which the auxiliary switched output turns on or the engine
starts.
If this is set to Disable, the Aux sensor action defined in Func.

Select is disabled. The Auxiliary sensor becomes display only
(unless Func. Select is set to Fault Monitor).
Mode Settings > Disable (Only applies if "Func. Select" is not set to Fault Monitor) The
Stop Level Temperature: 32 ~ 999, level at which the auxiliary switched input turns off or the engine
1 0F increments is stopped.
Pressure: 1 ~ 6000, 1 psi
increments If Stop Level is disabled the start/output condition is maintained
Level: 1 ~ 99, 1 % ----- until the Run Time expires (if enabled) or until the controller is
increments reset or powered down or in the case of a start until the user
Voltage: 0.1 ~99.9, 0.1 V presses the OFF button.
increments
Setpoints > Low Current: 1 ~ 999, 1 A (Only applies if "Func. Select" is set to Fault Monitor) Reading at
Warning increments which a warning occurs.
Setpoints > Low (Only applies if "Func. Select" is set to Fault Monitor) Reading at
Failure which a failure occurs.
Setpoints > High (Only applies if "Func. Select" is set to Fault Monitor.) Reading at
Warning which a warning occurs.
Setpoints > High (Only applies if "Func. Select" is set to Fault Monitor.) Reading at
Failure which a failure occurs.
Timers > Trigger Delays Aux Sensors menu:
Aux 1 "Func. Select" set to fault monitor: Sets the amount of time to
ignore the input for warning and failure detection purposes. No
Aux 2 warnings or failures will be generated during this time.
Aux 3 "Func. Select" set to other than fault monitor: Sets the amount of
time to delay a start or stop event. If set to larger than 4 s the
Aux 4 1 to 3600 s, 1 s
5s stop delay portion is limited to 4 s. If the trigger for the start or
increments
stop event becomes unavailable during this time the time will be
reset and the controller will wait for the next start/stop trigger.
Limitations: For TG350/TG410 firmware versions below 1.88.01

the maximum range is 45s.
1 1 ~ 600 minutes for firmware versions below 1.78.
If using Output on Low or Output on High one of the switched outputs events must be set to one of the following corresponding
to the Aux. Sensor being configured per the table below.
(Switched I/O > Switched Out A/B/C/D/EF > Events menus)

Name Description
Aux Sensor 1 Used by the Aux. Sensor 1 Output On Low or Output on High
feature.
feature.
feature.

Settings 47
feature.
The display resolution of the auxiliary sensors that are displayed on the screen are different than the resolution used for the
purpose of the comparisons that determine if the start level, stop level, low warning, etc are in effect. The resolutions are given
below.
Sensor Unit Type Comparison Resolution
Temperature 1 0F
Pressure 1 psi
Level 1%
Voltage 0.1 V
Current 1A
Example: if the auxiliary sensor 1 (aux 1) is using a temperature sender curve, set to Output on Low, and the Start Level is set
to 130 0F then the Output will not turn on until the temperature drops to 129 0F since the resolution for comparisons is 1 0F.
The below tables gives all the possible actions that the auxiliary sensors can perform.
Behavior Func. Start Level Run Time Stop Level
Select
Start controller when the sensor Start on Set to value that the Disable Disable
drops below a certain value. Run Low sensor needs to
indefinitely.1 drop below to start.
Turn on an output when the Output on Set to value that the Disable Disable
sensor drops below a certain Low sensor needs to
value. Keep on the output drop below to turn on
A- indefinitely.2 the output.
Indefinitel
y Start controller when the sensor Start on Set to value that the Disable Disable
rises above a certain value. Run High sensor needs to rise
indefinitely.1 above to start.
Turn on an output when the Output on Set to value that the Disable Disable
sensor rises above a certain High sensor needs to rise
value. Keep the output on above to turn on the
indefinitely.2 output.
Start controller when the sensor Start on Set to value that the Set to the desired run Disable
drops below a certain value. Run Low sensor needs to duration.
for a fixed period of time and then drop below to start.
stop controller.
Turn on an output when the Output on Set to value that the Set to the desired Disable
sensor drops below a certain Low sensor needs to duration to keep the
value. Run for a fixed period of drop below to turn on output on.
B - Fixed time and then turn off the output. the output.
Duration Start controller when the sensor Start on Set to value that the Set to the desired run Disable
rises above a certain value. Run High sensor needs to rise duration.
for a fixed period of time and then above to start.
stop controller.
Turn on an output when the Output on Set to value that the Set to the desired Disable
sensor rises above a certain High sensor needs to rise duration to keep the
value. Run for a fixed period of above to turn on the output on.
time and then turn off the output. output.
Start controller when the sensor Start on Set to value that the Disable Set to the value
drops below a certain value. Stop Low sensor needs to the sensor needs
controller when the sensor rises drop below to start. to rise above to
C - Start above a certain value. stop the
Level / controller.
Stop Turn on an output when the Output on Set to value that the Disable Set to the value
Level sensor drops below a certain Low sensor needs to the sensor needs
value. Turn off output when the drop below to turn on to rise above to
sensor rises above a certain the output. turn off the output.
value.

Settings 48
Start controller when the sensor Start on Set to value that the Disable 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. stop the
controller.
Turn on an output when the Output on Set to value that the Disable Set to the value
sensor rises above a certain High sensor needs to rise the sensor needs
value. Turn off output when the above to turn on the to drop below to
sensor drops below a certain output. turn off the output.
value.
Start controller when the sensor Start on Set to value that the Set to the desired Set to the value
drops below a certain value. Stop Low sensor needs to maximum run the sensor needs
controller when the sensor rises drop below to start. duration (i.e. this is to rise above to
above a certain value. Stop the the timeout). stop the
controller after a fixed time if the controller.
stop level is not reached.
Turn on an output when the Output on Set to value that the Set to the desired Set to the value
sensor drops below a certain Low sensor needs to maximum duration to the sensor needs
value. Turn off output when the drop below to turn on keep the output on to rise above to
sensor rises above a certain the output. (i.e. this is the turn off the output.
value. Turn off the output after a timeout).
D - Start fixed time if the stop level is not
Level / reached.
Stop
Level with Start controller when the sensor Start on Set to value that the Set to the desired Set to the value
timeout rises above a certain value. Stop High sensor needs to rise maximum run the sensor needs
controller when the sensor drops above to start. duration (i.e. this is to drop below to
below a certain value. Stop the the timeout). stop the
controller after a fixed time if the controller.
stop level is not reached.
Turn on an output when the Output on Set to value that the Set to the desired Set to the value
sensor rises above a certain High sensor needs to rise maximum duration to the sensor needs
value. Turn off output when the above to turn on the keep the output on to drop below to
sensor drops below a certain output. (i.e. this is the turn off the output.
value. Turn off the output after a timeout).
fixed time if the stop level is not
reached.
E- Trigger warnings and/or failures Fault N/A N/A N/A
Warnings on the sensor. Monitor
/ Failures
Do not perform any actions on the Fault N/A N/A N/A
F- sensor value. Just display the Monitor
Display value to the user. (Disable all
only warnings
and failures)

Settings 49
1 The user must manually stop the controller by pressing the off button.
2 The controller must be
o powered down or
o a reset initiated by
§ going from the RUN mode to the AUTO or OFF mode, or
§ changing a setting in the menu and exiting the menu system.
4.4.6.1 Fault Monitor Example

In this example, a sensor is monitoring the temperature of an engine block. If the temperature rises above 275°F, a warning
message is displayed. If the temperature rises above 350°F, the engine shuts down and a failure message is displayed.
Relevant Settings
Setting Value
Signal Source Same as Engine Temperature
Display Disable (If enabled, controller will display Engine Temperature twice)
Sensor Type Same as Engine Temperature
Sensor Table Name Engine Temp.
Active Range Running
Mode Select Fault Monitor
Setpoints -> Low Warning Disabled
Setpoints -> Low Failure Disabled
Setpoints -> High Warning 275°F
Setpoints -> High Failure 350°F
The chart above 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. 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.

Settings 50
4.4.6.2 Start on Low Example

In this example, a sensor is monitoring the voltage of an external battery bank. If the voltage falls below 10.5V, the engine will
start and run for 40 minutes to charge the battery.
Relevant Settings
Setting Value
Signal Source Sensor Port X
Display Enable
Sensor Type Custom
Sensor Table Name Battery Bank
Active Range N/A (These ranges are fixed for Start on Low / High)
Mode Select Start on Low
Mode Settings -> Active Time 40 minutes
Mode Settings -> Start Level 10.5V
Mode Settings -> Stop Level1 Disabled
1 StopLevel needs to be disabled when the engine is running because the battery voltage will equal the alternator charging
voltage. Having this disabled will force the engine to run for the entire duration of the active time.
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.

Settings 51
4.4.6.3 Output on High Example

In this example, a sensor is monitoring the temperature of an engine. If the temperature rises above 325°F, a fan will turn on to
cool the engine. Once the temperature drops to below 200°F the fan will turn off.
Relevant Settings (Auxiliary Sensor)

Setting Value
Signal Source Same as Engine Temperature
Display Disable (If enabled, controller will display Engine Temperature twice)
Sensor Type Same as Engine Temperature
Sender Table Name Engine Temp.
Active Range Global
Mode Select Output on High
Mode Settings -> Active Time1 Disabled
Mode Settings -> Start Level 325°F
Mode Settings -> Stop Level 200°F
1 Active time is disabled because the fan needs to stay on indefinitely or until 200°F is reached.
Relevant Settings (Switched Outputs)

Setting Value
Switched Output X Auxiliary Sensor X (Choose based on which Auxiliary Sensor is being used)
The chart above shows the connection between engine temperature and time. At approximately 10 minutes run time, the
temperature rises above the 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.

Settings 52
4.4.7 Custom Sensor Tables

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.
NOTE: Custom sender tables can only be created when using the configuration software.
Parameter Description
Name The label that will be displayed in the controller (Engine Temp, Oil Pressure, etc.)
Choose resistance, voltage or current based on the sensor type. Use the Terminal
Input Type
Descriptions section to determine if your sensor is compatible with a sensor port.
Choose temperature, pressure, voltage, current or percentage based on the sensor.
Unit Type This defines what unit of measurement will be displayed on the front panel (0F, psi, V,
A, %).
The following example outlines the steps for creating a custom sensor table:
1. Navigate to the sensor input that will be using your custom sensor table.
2. Select a Name, Input Type and Unit Type for the controller (Definitions in table above).
3. Click the check box next to 'Build Table' (Image Step 1).
4. From the 'Sender' drop down menu, select 'Custom' (Image Step 2).
5. Click the 'Edit' button next to the drop down menu (Image Step 3).
6. Enter the sensor values. Once entered, click Apply then OK.

Settings 53
4.5 Timers
The controller has an internal clock which is used not only to keep time, but to ensure programed events happen at the correct
times. The following sections are used to configure settings associated with timing functions.
NOTE: The controller has an on-board backup battery to keep time even when main power is not supplied to the
unit. This battery has an unpowered (no main power) lifetime of approximately five years.
4.5.1 Engine Logic

The following settings determine how the controller starts and stops the engine. It gives the user the functionality to add delays
and timers to the sequences. Most of the settings have a switched output associated with them that must be set in the
Switched Outputs settings.
NOTE: Setting a timer's value to 0 seconds will disable the timer. Example: If Delay to Start is set to 0 seconds, the
controller will not perform a Delay to Start when starting the engine.
Timers > Engine Logic:

Delay to Start 0 ~ 90 seconds Amount of time to delay the starting of the engine after
0s
receiving a command to start.
DTS Manual Run Disable Delay or Determines if the the Delay to Start timer is used when the
(Delay to Start on Enable Delay Enable Delay front panel RUN button is used to start the engine.
Manual Run)
Preheat Mode Preheat Timer Determines the method used to control enabling the glowplug
Switched Input Preheat Timer output. See the Preheat Mode section for more information.
J1939
Preheat Time 0 ~ 1200 seconds Amount of time the Glowplug output is active before cranking
0 ~ 90 in firmware the engine. Used on diesel engines to warm the engine before
0s
versions below cranking.
1.33.
Crank Time 3 ~ 30 seconds Amount of time the Crank output is active before going to
10 s crank rest. This timer immediately expires upon successful
cranking.
Midheat Time 0 ~ 90 seconds Keeps Glowplug output turned on while cranking but not
0s during crank rest. Output will turn off upon crank failure, crank
success or midheat time expiration.
Crank Rest Time 1 ~ 90 seconds Amount of time to delay between each attempt to start the
15 s
engine.
Crank Attempts 1 ~ 20 Number of attempts to start the engine before going to an
3
overcrank failure.
Fuel In Rest (Fuel Fuel ON or Fuel Determines if the fuel output stays on during the crank rest
Fuel ON
Crank Rest) OFF time.
RPM Disconnect 100 ~ 2000 rpm Speed at which controller determines the engine has started
650 rpm
successfully and turns off the Crank output.
Postheat Time 0 ~ 90 seconds Amount of time the Glowplug output remains on after crank
0s
success and the engine is running.
False Restart
(Restart on False
Start)
Enable false start (engine stall) detection. Refer to the False Restart section.
False Check (False
Restart Detect
Time)
If enabled, after the false restart delay and if the engine speed
goes below the crank disconnect setting (1) disables oil
Engine Stall Enable, Disable Disable pressure shutdown , and (2), after two seconds the controller
will shutdown on an "engine stall" failure.

Settings 54

This prevents an erroneous low oil pressure, under speed, or
under frequency failure. Available in firmware version 1.87 and
above.
Warmup Time 0 ~ 600 s in 5 s After successful cranking, engine delays this amount of time
increments before turning on the Warmup output. This allows the engine
0s
to warm up before applying any load to it. The output will turn
off when the controller enters the Cooldown Delay.
OFF Button Cooldown The function the OFF button on the front panel performs while
Function Shutdown Shutdown engine is running. See the OFF Button Function section for
Force Cooldown more information.
Cooldown Time 0 ~ 6000 s in 5 s Amount of time to cool down the engine after a stop command
increments has been received. During this time the Warmup output turns
0s off and the Cooldown output turns on. If another start
command is received during cool down, the controller will
return to running mode.
ETS On Duration 0 ~ 30 seconds Amount of time the Energize to Stop (ETS) output is on after
(Energize to Stop) the engine has shut down. Time must be greater than 0
seconds for the Energize to Stop function to work.
As of TG350/TG410 version 1.88 the OFF button is disabled

0s
during ETS to prevent possible issues with the engine failing
to shutdown.
If controller still detects speed (RPM) above 600 RPM in the

last two seconds, it goes to a 'Failed to Stop' failure.
Warm-up Idle
Idle Settings
Idle options. See the Idle section for more information.
Cooldown Idle
Auto Idle Link
4.5.1.1 Preheat Mode

The controller has the ability to control the length of the preheat time through 3 different methods. The table below describes
each method:
Preheat Mode Setting (Timers > Engine Logic menu)

Mode Description
Preheat Timer This mode uses the Preheat Time setting in the Engine Logic menu.
Switched Input This mode uses a switched input set to 'ECM Preheat' to determine when to exit
preheat.
The preheat time (in Engine Logic) must be set to a minimum of 5 seconds for
this input to work. If the switched input is or becomes active when the preheat
timer is counting down the controller displays 'ECM Preheating' on the screen
after the preheat counter has finished its countdown. Cranking begins when the
'ECM Preheat' switched input is no longer active.
J1939 This mode uses commands sent from the ECM over J1939 to decide when to
exit preheat.
NOTE: During preheat the Glowplug switched output is on (it needs to be set to a switched output -- see Switched
Outputs).
4.5.1.2 False Restart

The false restart feature is used to monitor and recover from unsuccessful crank attempts where the speed did go above the
crank disconnect and the controller is in the RUN mode. For example the engine might have stalled shortly after cranking.
False Restart settings (under Timers > Engine Logic menu)

Settings 55

False Restart Enable or Determines if the controller will monitor for false starts and
(Restart on False Disable Disable attempt a restart. Controller will only attempt restarting the
Start) engine as many times as determined by Crank Attempts.
False Check 5 ~ 30 sec in Amount of time after successful cranking to monitor for a false
(False Restart 1 second restart. A false restart is defined as the speed dropping below
Detect Time) intervals 250 RPM for 2 seconds. If this time expires and the engines
8s
stalls out, the controller will not attempt a restart.
This time starts from crank success.
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.
For example when the speed is disconnected it takes approximately 2.5 s for the speed sensing to record 0 RPM when the
speed sensing is set to a magnetic input at a speed of 3200Hz/1800RPM. This is 4.5 s including the 2 s for the false restart
delay. So if the desired monitoring period is 10 s, the False Check setting should be set to 15 s.
4.5.1.3 OFF Button Function

The OFF button on the front panel of the controller can be configured to function in 3 different ways while the engine is running.
The table below describes each of these functions:
Function Description
Cooldown This function causes the controller to go into cooldown. Pressing the OFF button
again will cause the engine to shut down.
Shutdown This function bypasses Cooldown and causes the engine to shut down.
Force Cooldown This function causes the controller to activate the cooldown process. Pressing
the OFF button will have no affect as the controller is forcing the engine to
perform a full cool down.
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.

Settings 56
4.5.1.4 Idle
Controller ignores under speed, voltage and frequency warnings and failures when active. If using J1939, the controller will
broadcast TSC1 as the Idle Speed parameter found in the Engine Speed section.
This section explains the general idle functionality.
There are three ways to use idle:

1. Warmup Idle -- Automatically enter the idle mode during warmup for a period of time before going to rated speed. See
Warmup Idle.
2. Cool down Idle -- Idle automatically during cool down. See below.
3. Idle Switched Input -- Idle whenever this switched input is active. See the Idle Mode function under Switched Inputs.

Warmup Timers > Engine Disable
Idle Logic Warm-up
Timer
Oil Temp.
Engine Temp. Refer to the Warmup Idle section.
Idle Timers > Engine [Menu]

Settings Logic
Cooldown Timers > Engine Disable Idle during cooldown.
Disable
Idle Logic Enable
Auto Idle Timers > Engine Disable, If set to breaker trip, the breaker trip will be activated
Link Logic Breaker Trip whenever the controller is in the Idle mode. The breaker trip
will be turned off when Idle mode is exited if it was not in the
latched state.
Disable
If the user delaches the breaker trip output while auto idle is
active the breaker trip will turn off for one second and then
turn back on.
Idle Switched Output
A switched output can be set to Idle to turn on whenever Idle mode is entered. This is useful for electronic governors that have
an idle input to tell the governor to run the engine at idle speed. Note that the switched outputs are meant to drive relays so a
relay must be installed to do the logic to the governor.
4.5.1.4.1 Warmup Idle
This section explains the Warmup Idle functionality.
The warmup idle is used to run the engine at a reduced speed at engine start.
Name Parent Menu Range Defaults Description

Warm- Timers > Engine Disable If enabled the engine is placed in Idle mode during the warm-up period.
up Idle Logic Warm-up
Timer Warm-up Timer -- The engine idles during the duration of the warm-up
Oil Temp. timer countdown.
Engine Oil Temp. -- The oil temperature over J1939 is used to determine the
Temp. Disable extent of the warm-up / Idle period.
Engine Temp. -- Same as Oil Temp. but the engine temperature is
used. The engine temperature can come locally or from J1939.
The oil temp and engine temp selections use the Debounce, Low Point,
and High Point settings below.
Debou Timers > Engine 1 to 10 s, (Warm-up Idle) If the temperature remains between the "Low Point"
nce Logic > Idle 1s 10 s and "High Point" settings for this time exit the warm-up / idle.
Settings increments
Low Timers > Engine 1 to 180 0F, (Warm-up Idle) Continue to idle when the temperature is below this
Point Logic > Idle 10F 32 F setting. Ignore the Debouce.
Settings increments

Settings 57
Name Parent Menu Range Defaults Description

High Timers > Engine 1 to 180 0F, (Warm-up Idle) Always exit idle when the temperature is above this
Point Logic > Idle 10F 50 F setting.
Settings increments
4.5.1.4.2 Idle Inhibit
Use this feature to prevent start up when the Idle mode switch is active.
Settings (Other Config > Idle Inhibit, in the Configuration Software these are under the switched inputs when the idle input is
enabled.)
Remote Start No Prevent the remote start switch input from starting the engine when
(Start / Stop Other Config Inhibit No the idle switch is active.
Switched Input > Idle Inhibit Inhibit Inhibit
Inhibit)
Aux Start (Aux No Prevent Auxiliary 1, 2, 3, and 4 sensors autostart feature from starting
Other Config No
1,2,3,4 Sensor Inhibit the engine when the idle switch is active.
> Idle Inhibit Inhibit
Autostart Inhibit) Inhibit
If the engine is in the IDLE mode because of the Warmup Idle feature, the remote start (start/stop) and auxiliary sensors
autostart can still start the engine.
This prevents starting when the Idle switch is active in the AUTO mode. This will also shutdown the engine if the idle switched
input is activated when the controller is in the delay-to-start, preheat, cranking, and crank reset states. The main purpose is to
prevent a remote start if the idle switch was accidentally left on.
4.5.2 Schedulers
4.5.2.1 Exerciser
The Exerciser function is used to start and run the engine periodically. The following settings configure the Exerciser function.
Exerciser Settings (in Timers menu)

Enable Enable ~ Enables the exerciser feature.
Disable
Disable
Delays -> Pre- 1 ~ 20 Amount of time to display a warning before starting the engine.
5 min
Alarm minutes
Delays -> Run 10 ~ 1500 Amount of time to run the engine.
30 min
Time minutes
Schedule -> Start 1 ~ 31 The day of the month for the first exerciser run. This setting is only used to set
Date the first exerciser run. All subsequent exerciser runs use the Repeat Days
setting to determine when they should run.
8 If the date and time selected is already in the past for the current month then
the exerciser will be started on the next month of the given date. Also if the date
is not yet in the past but the current month does not have that date (e.g.
February 21 and a date of 31 is selected) the exerciser will run on the next
month to have that date (e.g. 31rst of March).
Schedule -> Start 0 ~ 23 The time of day for the exerciser run. If the "Pre-Alarm" setting above is non-
Hour 12 zero then this setting indicates when the pre-alarm warning countdown will
begin. 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
14
Repeat Days subsequent exerciser starts after the first start.
Exerciser Sequence

Settings 58
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.

Settings 59
4.5.2.2 Weekly Scheduler

The weekly scheduler allows up to 16 unique weekly exercise times to be created. By default all schedulers are disabled.
Timers > Week Scheduler:

Name Range Description
Weekday Sunday ~ Saturday The day of the week the exercise will take place on.
Start time 24 hour clock in 1 When the exercise should start on a give day. At the
minute increments selected time a one minute prealarm is displayed on the LCD
screen. The controller starts after this one minute period.
Run time 10 ~ 1440 min in 1 min The duration of the exercise run period. Up to one day.
increments
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: "--- --:-- -----". If enabled the day of week, start time, and duration
will be displayed for the menu. Press enter will enter the sub menu for that exerciser time.
It is recommended to use the RapidCore Configuration Software to enter the times as this provides a much more convenient
interface especially if daily exercise times are wanted.
4.5.2.3 Long Time Run

The Long Time Run counter can be used to shutdown the controller after a very long period of time. This is useful for remote
primary power applications where the user wants to divide run time between two generators. When the countdown expires the
controller will shutdown. Long Time Run is only active if the generator was started manually (i.e. by pressing the front Run
button).
Timers > Long Time Run:

Start Trigger Disable or Manual Start Disable Set to "Manual Start" to enable the Long Time Run feature.
Run Duration 1 ~ 5000 hours in 1 hour The amount of time to run before shutting down.
1 hour
increment
4.5.3 Maintenance
The controller has the ability to count down the time between scheduled maintenance events. Once maintenance is required,
the controller will alert the operator via the LCD screen and a switched output (if enabled) wired to a lamp / horn / buzzer. The
following settings are used to configure the maintenance timer.
(Timers > Maintenance)

Reset Yes or No Once the maintenance count interval expires, use this to reset the time and turn
Counter ----- off the switched output (if enabled). Select Yes to reset the counter and exit the
menu. Select No to exit the menu without resetting the counter.
Enable Enable or Enables or disables the maintenance function.
Disable
Counter Disable
Count 10 ~ 9990 Determines the number of hours between required maintenance. A switched
Interval hours in 5 output can be configured to turn on once the count interval expires.
1000 hours
hour
increments
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.

Settings 60
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. If the timer expires when the controller is in the RUN mode the message is not
displayed.
4.6 AC Monitor
The controller has the ability to monitor AC voltage and current from a generator. The following sections are used to configure
settings associated with AC monitoring.
4.6.1 Generator Voltage

The following settings are used to configure the controller's response to voltage measurements.
(AC Monitor > Genset Voltage menu)

Voltage Disable The wiring configuration of the generator. Disable will disable AC
Source 2-Wire Single voltage and AC frequency sensing and display.
3-Wire Single
3-Wire 3-Phase 2-Wire Single: One 120VAC L-N. Use phase A.
4-Wire 3-Phase 3-Wire Single: 120/240VAC systems. Use phases A and B.
4-Wire Delta 3-Wire 3-Phase: Three phase delta without a ground.
Auto Selection 3-Wire 4-Wire 3-Phase: Three phase Wye system. Center taped ground.
Single 4-Wire Delta: Delta with a ground. The high leg is phase B. For
example if A-N and C-N read 120VAC then B-N will read 208VAC.
Selecting Auto Selection will use the Voltage Select switched inputs to
determine the wiring configuration.
This setting also enables the AC Frequency monitoring and display.

Scaling Factor 0.500 ~ 2.500 in The gain to apply to the AC voltage that is read at the controller. See
1.000
0.001 increments below for more information.
Nominal Volts 50 ~ 800 VAC* in 1 Generator line-to-line voltage output when operating under normal
240 VAC
VAC increments running conditions.
Auto Nominal 50 ~ 800 VAC* in 1 Nominal Volts when using the Voltage Select inputs.
> 1Ph 3-Wire VAC increments
240 VAC
(1-Phase 3-
Wire)
Auto Nominal 50 ~ 800 VAC* in 1
208 VAC
> 3-Phase (1) VAC increments
480 VAC
600 VAC
Auto Scaling > 0.500 ~ 2.500 in Scaling Factor when using the Voltage Select inputs.
1Ph 3-Wire (1- 0.001 increments 1.000
Phase 3-Wire)
Auto Scaling > 0.500 ~ 2.500 in
1.000
3-Phase (1) 0.001 increments
1.000
1.000
Auto Single A-C Phase For 1-Phase 3-Wire when using the Voltage Select inputs. This
A-B Phase
A-B Phase determines which phases the single phase voltage is read from.
Setpoints > 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

Settings 61

Setpoints > 101 ~ 150 % in 1 % Reading at which a warning occurs.
110 %
High Warn increments
Setpoints > 101 ~ 150 % in 1 % Reading at which a failure occurs.
115 %
High Fail increments
*NOTE: 800 VAC applies to software logic only. Do not exceed 600 VAC on the AC Voltage terminals including
during over voltage warning and failure conditions.
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.
Example: The voltage source is a 3-Wire 3-Phase system with a nominal voltage of 208 VAC. The controller is reading 206.3
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

Settings 62
4.6.1.1 AC Voltage Select

The controller has the ability to automatically change its AC sensing (voltage and current) and display configuration through the
use of switched inputs. When using voltage select, the controller will continue to monitor the inputs for 10 seconds after crank
success. Once that time expires, the controller will then display the selected voltage configuration.
The following must be set:

1. Two switched inputs (Switched I/O > Switched IN X > Function ) must be set to the Volt Select 1 and Volt Select 2
switch input functions.
2. AC Monitor > Genset Voltage > Voltage Source must be set to Auto Selection. Rapid Configuration Software note: this
option will not appear unless step one if performed.
The table below shows the relation between the switched inputs status and the voltage configuration.
Volt Select 1 Input Volt Select 2 Input Voltage Configuration

Inactive Inactive 3-Wire Single Phase
Active Inactive 3-Phase (1)
Inactive Active 3-Phase (2)
Active Active 3-Phase (3)
NOTE: Both Volt Select 1 and Volt Select 2 must be assigned to switched inputs. Otherwise the voltage sensing
will be disabled.
The below settings must be set. All except "Auto Single" are menus that contain four settings corresponding to the Volt Select
1 / Volt Select 2 inputs above.
Name Volt Select 2 Input
Genset Voltage > Auto Nominal These settings corresponds to the "Nominal Volts" setting under the AC Monitor > Genset
Voltage menu.
Genset Voltage > Auto Scaling These settings corresponds to the "Scaling Factor" setting under the AC Monitor > Genset
Voltage menu.
Genset Voltage > Auto Single Only applies when voltage sourc is set to 1-Phase 3-Wire. This determines which phases
the single phase voltage is read from: A-C or A-B.
Genset Current > Auto Rated These settings corresponds to the "Rated Amps" setting under the AC Monitor > Genset
Current menu.
Genset Current > Auto Scaling These settings corresponds to the "Scaling Factor" setting under the AC Monitor > Genset
Current menu.
4.6.2 Generator Frequency

Generator AC frequency display on the controller is enabled when the Voltage Source is not set to Disable.
The following settings are used to configure the controller's responses to frequency measurements.
Frequency Settings (in AC Monitor > Genset Freq.)

Name Range Defaul Description
t
Freq. Source 50Hz System This is the wiring configuration of the generator. Selecting Auto
(50Hz) Selection will use the Frequency Select input to determine which
60Hz
60Hz System frequency is used.
Syste
(60Hz)
m
Auto Selection This setting is used by the below setpoints. It does not affect the display
of AC Frequency.
Setpoints > Low Warn Disable, 20 ~ 99 Reading at which a warning occurs.
(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

Settings 63
Name Range Defaul Description

t
Setpoints > High Warn Disable, 101 ~ Reading at which a warning occurs.
(Over-Frequency 150 % in 1 % 110 %
Warning) increments
Setpoints > High Fail Disable, 101 ~ Reading at which a failure occurs.
(Over-Frequency 150 % in 1 % 115 %
Failure) increments
4.6.2.1 RPM / Frequency Select

The controller has the ability to change between Primary RPM / 60Hz and Secondary RPM / 50Hz through the 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 / 60Hz - Secondary RPM / 50Hz
Select). The switched input is only monitored before a start signal has been received. Once a start signal has been
received changing the status of the switched input will have no effect.
· AC Monitor > Genset Freq. > Freq. Source > Auto Selection
· Sensors > Engine Speed > RPM Switch > Primary (Primary RPM / 60Hz)
· Sensors > Engine Speed > RPM Switch > Secondary (Secondary RPM / 50Hz)
The table below shows the correspondence between the switched input status and the RPM / Frequency.
Switched Input Speed / Frequency

Inactive Primary RPM / 60Hz
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.

Settings 64
4.6.3 Generator Current

The following settings are used to configure the controller response to current measurements.
AC Monitor > Genset Current:

Current Source Enable ~ Enables or disables current metering.
Enable
Disable
Turns Ratio 5 ~ 5000 A : 5 The turns ratio of the current transformers.
A in 5 A 100 A : 5A
increments
Scaling Factor 0.500 ~ 1.250 Scaling factor at which the voltage is read into the controller. See below for
in 0.001 1.000 more information.
increments
Rated Amps 5 ~ 5000 A in 1 Maximum current draw the generator can provide when operating under
100 A
A increments normal running conditions.
Auto Rated > 5 ~ 5000 A in 1 Rated Amps when using the Voltage Select inputs.
100 A
1Ph 3-Wire A increments
Auto Rated > 5 ~ 5000 A in 1
100 A
3-Phase (1) A increments
100 A
100A
Auto Scaling > 0.500 ~ 2.250 Scaling Factor when using the Voltage Select inputs.
1.000
1Ph 3-Wire
Auto Scaling > 0.500 ~ 2.250
1.000
3-Phase (1)
Auto Scaling > 0.500 ~ 2.250
1.000
3-Phase (2)
Auto Scaling > 0.500 ~ 2.250
1.000
3-Phase (3)
Dummy Load [Menu] See Dummy Load.

Settings 65
AC Monitor > O.C. Protection:

Basic Alarm [Menu]
See Basic Alarms.
IDMT Protect Disable
Breaker Trip See IDMT.
Shutdown Trip
IDMT Settings [Menu]
Imbalance Mode Disable
Breaker Trip See Load Imbalance.
Shutdown Trip
Imbalance Set [Menu]
Break Trip Fail Disable Shuts down the generator if the generator circuit breaker fails to
Enable trip.
Disable If the Breaker Trip switched output is active - due to IDMT or

Load Imbalance - and if after 10s the measured generator
current is still above 10% of the Rated Current the generator will
shut down.
4.6.3.1 Basic Alarms

The controller can give a warning and/or shutdown on over current. If IDMT is enabled then it overrides the High Failure
shutdown but the warning is still active.
AC Monitor > O.C. Protection > Basic Alarm:

High Warn Disable, 1 ~ 125 % in 1 % 110 % Reading at which a warning occurs.
increments
High Fail Disable, 1 ~ 125 % in 1 % 115 % Reading at which a failure occurs.
increments
Percentages are based on the Rated Amps setting. The warning and failure setpoints apply to each phase separately and not
to the sum of the phases.
4.6.3.2 IDMT
Sets an inverse time trip curve for over-current. When set this overrides the Over Current Failure.

IDMT Protect Disable Disable: Disables the IMDT feature.
Breaker Trip
Shutdown Breaker Trip: If IDMT is active the Breaker Trip switched output is
Trip activated to switch off the main generator breaker. This is a latching
Disable feature.
The operator must press the and keys to reset the

feature.
Shutdown Trip: shuts down the engine.

IDMT Settings > 0.1 ~ 30 in Sets the slope of the IDMT curve. This controls the sensitivity of the
TDS Const (Time 0.1 0.3 trip to over current.
Dial Setting) increments
IDMT Settings > 1 ~ 600 s in How long the current must drop and stay below the rated current to
IDMT Reset 1s 200 s reset the IDMT.

Settings 66

increments
The equation for the IDMT is given as:
Where,
TDS is the time dial setting above.
Is is the Rated Current (A).
I is the actual current measured by the controller (A).
(tr)m is the trip time in seconds.
For example with a Rated Current of 100A and a TDS of 0.1 the IDMT will trigger in:
0.15s if the actual generator current is 1000A.
4.6.3.3 Load Imbalance

Load imbalance provides protection against differences in phase currents.

Imbalance Disable Disable: Disables the Load Imbalance feature.
Mode Trip Only
Shutdown Trip Breaker Trip: If Load Imbalance is active the Breaker Trip
switched output is activated to switch off the main generator
Disable breaker. This is a latching feature.
The operator must press the and keys to reset
the latch.
Shutdown Trip: shuts down the engine.

Imbalance 1 ~ 200 % in 1 The percentage of rated current that any phase must exceed the
Set > % increments 10 % other phases by to trigger a load imbalance.
Imbalance
Imbalance 1 ~ 600 s in 1 The length of time to allow an imbalance before triggering (trip,
Set > % increments 10 s shutdown).
Debounce
The load imbalance formula is given as:
For three phase:
For single phase:
Where,
IA,IB, and IC are the actual current measured by the controller.

Settings 67
Note: Phase Imbalance is the same as load imbalance.
4.6.3.4 Dummy Load

The dummy load feature can be enabled to prevent wet stacking.
AC Monitor > Genset Current > Dummy Load:

Bypass Disabled, 1 ~ 120 s in The amount of time to delay before applying the dummy load.
Disabled
Time 1 s intervals
Load On Disabled, 1 ~ 500 A in The threshold below which the dummy load is applied. There is a 4s
1 A increments debounce time. The bypass time must expire before the load is
Disabled
applied. All phases must drop below this threshold to trigger dummy
load.
Load Off Disabled, 1 ~ 500 A in The threshold above which the dummy load is removed. Dummy load
Disabled
1 A increments is turned off if one phase rises above this threshold.
One of the switched outputs must also be set to dummy load. The output is only turned on when the engine is running.
4.6.3.5 EPS Supplying Load

The EPS (Emergency Power System) Supplying load sets a flag in modbus register 40006 to indicate to the DYNAGEN RA400
remote annunciator that the generator is actively supplying power. If this flag is set the RA400 will light it's EPS Supplying Load
indicator. This is used to meet NFPA110 requirements.
If the actual current measured on any one phase of the generator is above 5% of the AC over current warning set point then the
EPS Supplying load flag is set. For more information on this register refer to the TOUGH Series modbus manual or RA400
manual.
4.7 Communications
The controller has the ability to communicate with other systems over communication buses. The following sections relate to
settings associated with communications.
4.7.1 CAN Bus (J1939)

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.

ECM Model Generic J1939 Choose one of the compatible ECM modules from the list.
John Deere JDEC
Volvo EMS
Generic
This is not a
J1939
complete list. See
the J1939 User
Manual for the full
list.
ECM Enable ~ Disable If no CAN messages are received for more than 6 seconds, the controller
Communicati Disable shuts down the engine.
on Failure
DTC Display Disable Enables or disables active fault messages (DM1) monitoring.
Global Enable Disable
Running Enable
Active DTC Enable ~ Disable Enables or disables the storing of active faults (DM1).
Disable
Log
Read Stored Enable ~ Disable Enables or disables the ability to request stored fault codes from the ECM
Disable
DTC (DM2).

Settings 68

Auto Power Enable ~ Disable When enabled, the fuel relay is enabled in Auto mode so that the ECM is
Disable
ECM already booted up and initialized before the user decides to start the engine.
ECM Power 5 ~ 30 s in 1 s Used in conjunction with Auto Power ECM. When the engine shuts down,
Delay increments the controller waits for the time specified by the ECM Power Delay before
10 s
turning on the fuel relay. This prevents unwanted start ups due to the
engine not being completely shut down.
Cummins Disable or Sending Enables or disables the broadcasting of PGNs required by some Cummins
PGNs Sending Enable Enable engines.
SPN Version 1 Select the SPN conversion method.
Conversion Version 2 Version 3
Version 3
EMS2B Primary For Volvo EMS2B Engine Control Modules only.
Frequency Secondary Primary
Select
EMS2B 40.0 ~ 60.0 % in For Volvo EMS2B Engine Control Modules only.
Accelerator 0.1 % increments 50.0 %
Pedal

Settings 69
4.7.2 MOD Bus (RS485)

The Modbus functionality on the controller provides interface ability to PLCs, SCADA and building management systems. For
detailed information about the Modbus registers and their interpretations please use the Modbus Reference Manual. The
manual can be found at www.dynagen.ca/support.
It uses the Modbus RTU communication protocol and is configured as a slave only.
Name Range / Values Default Description

Device 1 ~ 247 in 1
1 The device address of the controller.
Address increments
Baud Rate 9600, 19200, 38400,
9600 The speed at which the controller (slave) communicates with the master.
(BPS) 57400
4.8 Other Config

This section contains miscellaneous settings.
4.8.1 Password
A password is required to change certain settings. The Password menu is used to change this password and control if and
when the user is prompted for a password.
Other Config > Passcode:

Bypass Disable or Enable Disable If enabled a password is not required to change settings.
Timeout 0 ~ 120 minutes in 1 How long after the password is entered before the user is required to
minute increments enter it again.
The timeout is implemented as a simple countdown timer. The

following apply:
· If the bypass time is changed this new bypass time will not be
10 min
loaded until the countdown timer has expired and the user enters the
password.
· The countdown timer is stored in non-volatile memory and is
"paused" when the controller is powered off. The counter will
resume when the controller is powered on again.
· Any button press in the menu will reset the timer.
Passcode 0000 ~ 9999 0000 The four numeric digits that make up the password.
4.8.2 Settings Name

If storing settings from the RapidCore Configuration Software a custom name can be entered to allow users to determine the
settings that are stored in the controller. This custom name, called "Configuration Name" (ID in the controller) is found under
Options in the settings tab of the Configuration Software. There is no controller menu to set this ID. It can be up to 12
characters long.
The Configuration Name can be viewed in the Device Info > About TG410/TG350 menu. It is labeled ID.
4.8.3 Process Control

The Process Control feature has two different control methods: Main-In and Main-Out. The Main-In maintains a
reservoir/pressure level by controlling the flow of fluid/gas into the reservoir/tank. The Main-Out maintains a reservoir/pressure
level by controlling the flow of fluid/gas from the reservoir/tank. It does this by regulation the speed of the engine over the J1939
CAN bus.
The process control feature takes over on an engine start once the engine has ramped up to the goal speed (after going
through the idle and intermediate ramping).

Settings 70
The controller reads the sensor value from selected Auxiliary Sensor input (1~4) or Transducer Input (Aux 5), compares the
input value with the set-point, and then, based on an algorithm, increments or decrements the speed (RPM) by a certain
amount (controlled by the Gain and delay settings) to maintain the desired set-point outside of the dead-band area. Control
pauses inside the dead-band area. If the sensor input goes beyond a minimum or maximum value, the algorithm will pause and
the RPM will be maintained at a minimum or maximum value.
The algorithm is a fuzzy logic type control with a dead band and a minimum / maximum saturation. The user sets the
aggressiveness of the control with the Gain setting and the response time of the control with the Delay setting.
(Front Panel: Other Config > Process Control menu, RapidCore: Pumping Applications > Closed Loop Control)
Closed Loop > Disabled Main-In controls the level when pumping fluid into a reservoir. Main-Out
System (Control Main-In (Maintain controls the level while pumping fluid out of the reservoir.
Type) In) Disabled
Main-Out
(Maintain Out)
Closed Loop > AUX-1 The Auxiliary Sensor Input function that is providing feedback on the
Sensor In (Sensor AUX-2 reservoir level. Aux-5 refers to the Transducer under the Application
Input) AUX-3 Aux-5 menu.
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.
Closed Loop > Gain 1 ~ 30 in 0.1 The amount to increment or decrement the RPM when the sensed value
increments is outside of the dead-band. This number does not represent an actual
19.0 RPM. A larger gain will generate a larger RPM change than a smaller
gain for the same size error. This value must be tuned for each
installation.
Setpoints > Main-In 1 ~ 900 in 0.1 The level set-point to attempt to maintain. Only applies if System is set
(Maintain In Setpoint) increments 300.0 to In-Keep. This value takes on the units of the Aux sensor set in the
Closed Loop > Sensor In menu.
Setpoints > Main-Out 1 ~ 900 in 0.1 The level set-point to attempt to maintain. Only applies if System is set
(Maintain Out increments 500.0 to Out-Keep. This value takes on the units of the Aux sensor set in the
Setpoint) Closed Loop > Sensor In menu.
Setpoints > 1 ~ 30 in 0.1 The high limit of the dead-band.
Deadband+ (High increments 3.0
Deadband)
Setpoints > 1 ~ 30 in 0.1 The low limit of the dead-band.
Deadband- (Low increments 3.0
Deadband)
Thresholds > High 1 ~ 900, 0.1 The high saturation. The maximum level at which the RPM control is
Edge (High Limit) increments 700.0 fixed. This value takes on the units of the Aux sensor set in the Closed
Loop > Sensor In menu.
Thresholds > Low 1 ~ 900, 0.1 The low saturation. The minimum level at which the RPM control is
Edge (Low Limit) increments 100.0 fixed. This value takes on the units of the Aux sensor set in the Closed
Loop > Sensor In menu.
Thresholds > Max 500 ~ 4000 RPM The fixed RPM that should be used when the level rises above the High
3200
RPM (Max Limit in 1 RPM Edge.
RPM
RPM) increments
Thresholds > Min 500 ~ 4000 RPM The fixed RPM that should be used when the level falls below the Low
1000
RPM (Low Limit in 1 RPM Edge.
RPM
RPM) increments

Troubleshooting 71
5 Troubleshooting
If you are having issues with your controller, please refer to the table below for a solution before contacting technical support.
Issue Solution
Engine starts but the crank output The controller is not receiving a speed signal.
does not turn off 1. Verify the Sensors -> Engine Speed -> Signal Source setting is set correctly.
2. Verify the Timers -> Engine Logic -> RPM Disconnect setting is set correctly.
3. Ensure the correct wiring to the controller. For magnetic pickup, Speed
Sensing A and B terminals are used. For generator voltage, the AC voltage
connections are used.
Sensor always displays its lowest or The sensor could either be open (not connected) or shorted to ground. Verify your
highest value connections and ensure the correct sender table is loaded.
Sensor value acts erratic, bounces, This could be caused by:
or climbs on engine startup 1. Bad ground between sensor and controller. Check that there is a good ground
between negative post on the battery and the battery negative terminal (J4-3)
on the controller. Also check that the connection from the negative post on the
battery to the sensor body is good; if not then add a grounding wire close to
the sensor.
2. The group strap is not sufficient AWG. Ensure the ground and power wiring
can carry the large amperage for the starter motor and other equipment.
3. If using a magnetic pickup sensor for speed sensing it might be generating
noise. Use a shield twisted pair cable from the mag sensor to the controller.
Refer to the typical wiring diagram on how to do this.
4. Try twisted pair cable running both ground and the signal; ground near the
sensor body. Try an isolated sensor (sensor has both a ground post and a
signal post).
Controller displays "Failure To Stop" Either set Energize to Stop under Timers to 0 seconds or increase it's duration. At the
on a shutdown. end of the Energize to Stop time the controller will detect if the engine speed is zero. If
it is not it goes into a "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.
Type Information
Website www.dynagen.ca/support
Email [email protected]
Phone Number (902) 406-0133
Twitter @DynaGenTech
Facebook www.facebook.com/DYNAGEN
3 Spectacle Lake Drive, Unit B105
Address
Dartmouth, NS B3B1W8, Canada

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TG410 User Manual

Manual Revision: 7.0.0

2.2 Terminal Descriptions

2.3 Wiring Harnesses

2.4 Typical Wiring Diagram

2.5 Typical Wiring Diagram with RelayPak

2.6 Wiring Considerations

3 Using the Controller 22

3.2 Using Cooldown Mode

4.2 Switched ...............................................................................................................................................................................

4.3 Switched ...............................................................................................................................................................................

4.4 Sensors ............................................................................................................................................................................... 38

© 2019 DynaGen Technologies Inc

Front Panel Speed Control

4.5 Timers ............................................................................................................................................................................... 53

4.8 Other Config

© 2019 DynaGen Technologies Inc

TOUGH Series Manual © 2019 DynaGen Technologies Inc

Features and Functions:

DPF / DEF Ready

J1939 CAN Bus

Isolated RS485 Modbus

Magnetic Pickup Input

150 Event Log

Generator Voltage Metering Single or 3-Phase

Configurable Switched Outputs 6

TOUGH Series Manual © 2019 DynaGen Technologies Inc

TOUGH Series Manual © 2019 DynaGen Technologies Inc

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.

1) Choose a suitable mounting location based on the criteria above.

TE Series Cutout (Not To Scale)

TOUGH Series Manual © 2019 DynaGen Technologies Inc

2.1 General Wiring Notes

1. Use a minimum of 18AWG wire for all connections.

8. For noisy environments some guidelines are:

The following enclosure guidelines should be followed:

1. It is recommended to use vibration mounts.

2.2 Terminal Descriptions

TOUGH Series Manual © 2019 DynaGen Technologies Inc

Expansion Connector (J3)

TOUGH Series Manual © 2019 DynaGen Technologies Inc

Communications Connector (J6)

Generator AC Voltage (J7)

Generator AC Current (J5)

TOUGH Series Manual © 2019 DynaGen Technologies Inc

2.3 Wiring Harnesses

TOUGH Series Manual © 2019 DynaGen Technologies Inc

2.4 Typical Wiring Diagram

TOUGH Series Manual © 2019 DynaGen Technologies Inc

2.5 Typical Wiring Diagram with RelayPak

TOUGH Series Manual © 2019 DynaGen Technologies Inc

2.6 Wiring Considerations