Generator Control – Dynagen

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Optimizing Job Site Performance with Generator Control

In today’s fast-paced mobile equipment landscape, efficiency and reliability are key to maximizing productivity and return on investment. One of the most impactful advancements in this regard is the ability to automatically start and stop generators supplying power to mobile and rental equipment. This capability optimizes job site performance and significantly increases operational efficiency, leading to a higher rate of return on investment.

Importance of Reliable Communication

Reliable communication between the controller and the generator is crucial for generators to function effectively, especially those that are mechanically or electronically governed. Any lapse in communication can lead to downtime, reducing productivity and increasing costs. Ensuring seamless interaction between the control systems and the generators is paramount for maintaining a consistent power supply and operational efficiency.

Durability in Harsh Environments

Generators often operate in challenging environments, exposed to harsh weather conditions such as rain, snow, dust, and extreme temperatures. Controllers used to power these solutions must be exceptionally durable and designed to withstand these elements. Robust construction and advanced engineering ensure that these control systems can perform reliably, no matter the environmental conditions.

Efficient Controllers for OEMs

By integrating advanced controllers into mobile generators, Original Equipment Manufacturers (OEMs) can monitor and manage generator performance from virtually anywhere. This integration offers several significant benefits:

Better Management of Start/Stop Times: Control solutions enable precise management of when generators start and stop, optimizing their use and reducing unnecessary run times.

Fuel Consumption Adjustment: Efficiently managing fuel consumption is critical for cost savings. Advanced control systems can adjust fuel usage based on real-time data and operational needs.

Issue Diagnosis: Early detection and diagnosis of potential issues can prevent costly breakdowns. By adding telemetry devices with remote monitoring capabilities, controllers allow for real-time diagnostics, helping to identify and address problems before they escalate.

Reducing Downtime and Increasing Efficiency

One of the most significant advantages of integrating control solutions into mobile generators is the reduction of downtime. With real-time adjustments, these systems ensure that generators are always operating at their best. This reliability translates into less downtime for mobile equipment, enhancing overall job site productivity.

The ability to manage generators brings a new level of efficiency and reliability to job sites. OEMs can achieve significant cost savings and operational improvements by ensuring robust communication, durability in harsh environments, and comprehensive remote monitoring. These advancements enhance performance and provide a competitive edge in today’s demanding industrial landscape.

Generator Controllers

 

DynaGen™ PRO600

DynaGen™ TG410

DynaGen™ TG350

DynaGen™ Retro Kit

 

Telemetry Devices

Messenger BLE

Messenger Lite

VisiTek™ 600

Monitoring Services

remoteIQ telemetry family

Streamline Multi-Pump Control – Control Multiple Pumps From a Single Panel

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Engine Control Panel CANplus™ CP750-E

Many multi-pump systems rely on a Programmable Logic Controller (PLC) to coordinate operations effectively. However, the CP1000 and CP750-E engine control panels offer an alternative by removing the need for a PLC in these intricate arrangements. These panels can control up to six pumps concurrently, including configurations that mix CP1000 and CP750-E panels.

Consider the practicality of overseeing multiple pumps from a single panel—applications requiring multiple pumps are not rare. It’s applicable when a single pump might not meet the required flow or pressure, or when the flow demands fluctuate throughout the day beyond the capacity of one pump. Additionally, applications might require standby pumps to activate automatically should any pump fail. It is also typical that the standby pumps get routinely rotated into service so that all pumps have the same overall utilization.

These pump panels can work together in synchronous or parallel mode. In synchronous mode, the designated number of pumps operate simultaneously, each running at its pre-set speed. This configuration is often employed in scenarios like managing water levels in a retention pond during flood situations, where float switches control activation and deactivation.

Parallel mode is particularly effective for tasks that require constant regulation, such as maintaining specific water levels or flow rates. This setup dynamically adjusts the number of active pumps to sustain the desired regulation.

diagram showing canplus cp1000 controls multiple pumps

Getting Started

As you set up the application, deciding how many pumps you want working and how many will be kept as backups is essential. You could have five active and one backup, split evenly or in any other combination. Then, you will need to determine the workload distribution across the pumps. For example, you may not want any pumps to operate more than fifty hours longer than the others.

CANplus panels start by setting all pump work hours to zero at the beginning of a job. It’ll keep track and cycle which pumps are running to ensure the workload is shared, keeping all pumps within the specified number of job hours of each other, fifty hours in this example.

This video demonstrates a multi-pump application using a CANplus panel.

canplus multi-pump screen

Streamline the coordination of multiple pumps with CANplus™ engine control panels to make your operations smooth and efficient without additional control systems.

RemoteIQ™ QR-Assist™

Fault Diagnostics for CANplus™ Panels and the DynaGen™ 200 Controller

Instant Support & Diagnostics at Your Fingertips

QR-Assist™ is a patented, software-based diagnostic tool designed to support CANplus engine control panels and the DynaGen 200 controller. This innovative tool provides instant access to a comprehensive database of technical system faults and customized, proven solutions, empowering users to resolve issues quickly and effectively.

 

Effortless Use and Powerful Benefits

A key feature of QR-Assist is its seamless integration with CANplus panels and the DynaGen 200 controller. Accessible via smartphones and tablets with a simple scan, QR-Assist eliminates the need for bulky equipment, complex setups, and lengthy troubleshooting procedures – all thanks to the high-resolution color displays on our advanced engine control solutions.

When a fault is detected within the engine, the display generates a unique QR code. By simply scanning the code, users can receive valuable engine diagnostic data, including detailed descriptions and causes of the problem, step-by-step troubleshooting guides, and relevant technical solutions directly from linked OEM websites.

QR-Assist streamlines the process, enabling quick identification of faults and initiating appropriate troubleshooting measures, minimizing downtime and making maintenance and repairs more manageable.

remote iq qr-assist how to on phone screens

 

Say goodbye to downtime and hello to a more efficient and reliable diagnostic experience. Experience the future of troubleshooting with QR-Assist.

Watch QR-Assist in Action      |     Download QR-Assist Flyer
Machine Learning on CANplus™ Engine Control Panels
arm-outstretched-touched-tablet-machine-learning-graphic

Introduced Machine Learning capability on its CANplus™ CP1000 panels for engine and VFD control. Machine Learning delivers the next generation of industry-leading performance and reliability for equipment operators.

Explanation

Look up machine learning online, and you’ll find a myriad of definitions and explanations ranging from highly technical to basic and everything in between. For the CP1000 and CP750-E, machine learning is a function of the engine or VFD control panel that helps it learn what its “Normal Operation” is, so it can alert pump operators when the panel is no longer in the normal range. The normal operating range is specific to your application, engine, or VFD using the panel rather than relying on factory default settings. Machine learning enables your panel to learn and monitor YOUR specific application.

How it Works

Once the CP1000 engine or VFD control panel and application are set up with the desired flows, pressures, and settings, the CP1000 begins the machine-learning process. It cycles through the entire operating range of the application, assessing and learning about all of the sensors and engine or VFD information coming into the panel. The CP1000 uses the information it receives to set up normal levels (green) to indicate that things are going well and operating as expected. It typically takes three to five minutes to complete the sequence.

2.61 psi screen reading

Once the machine learning process is complete, the panel will automatically start monitoring the system. It will identify when operational parameters are trending out of the normal operating range, allowing preemptive action to address the problem.

-3.50 inHG screen reading

It also looks at fluctuations and deviations of all the signals coming in to establish yellow warning and red fault areas. The panel will warn and alert when any monitored parameter moves outside the normal range for a specified amount of time.

2.70 psi screen reading

Machine learning on the CP1000 utilizes powerful, edge-computing capabilities to monitor your application without the need for telemetry. While not required, the CP1000 Machine Learning fully supports remote monitoring when telemetry is added. Each learned parameter has a custom SPN that can trigger notifications when used with RemoteIQ™.

canplus cp1000 with rotary dial

Machine Learning on CANplus CP1000 and CP750-E

Machine learning is an available option on all new CANpl CP1000 and CP75-E panels, effective March 2023. Existing panels can also be upgraded.

Sensorless Cavitation Detection

Detecting Cavitation with CANplus™ Engine Control Panels

Cavitation can severely damage pump equipment and machinery. 

Cavitation is the formation of bubbles within a liquid due to a significant reduction in pressure. Different liquids have varying levels of resistance to cavitation based on factors such as gas concentration and foreign particles. When these bubbles enter an area of higher pressure, the bubbles implode, leading to high-impact forces on metal surfaces, resulting in fatigue and cavitation pits within the pump.

Cavitation can be detected audibly, with acoustic instrumentation, by machine vibration sensors, or by a decrease or change in performance. Cavitation can dramatically affect the performance and lifespan of machinery where liquid is present, making it vital to understand what this phenomenon entails and how best to combat it.

Machine learning detects cavitation on CANplus engine control panels.

Cattron’s CANplus™ engine control panels have built-in machine learning, enabling the panel to detect cavitation without additional sensors. Machine learning delivers unparalleled performance and reliability to the CP1000 and CP750-E engine control panels.

Incorporated into the CANplus control panels, machine learning is a powerful feature that allows the system to learn the unique normal operation patterns for your application, engine, or pump. Unlike traditional preset factory settings, this advanced edge computing adapts to the specific application of your equipment.

The CANplus panel uses engine data from its machine-learning algorithm to identify and notify operators of cavitation conditions before they cause damage. This proactive approach safeguards against unexpected downtime and maintenance costs and ensures that your engines and pumps are operating at their optimal capacity and efficiency.

Not only do our CANplus CP1000 and CP750-E engine control panels offer cavitation detection and machine learning, but they can be seamlessly integrated with our RemoteIQ™ cloud-based monitoring and control solution to provide an extra layer of oversight and management, giving you peace of mind.

Examples of Cavitation and Detection

In a scenario involving the movement of pond water by a pump, debris accumulation within the inlet strainer may impede flow, leading to a restriction in the pump’s intake. This restriction causes a decline in pressure on the suction side, approaching vacuum levels. Eventually, the pressure drops low enough to breach the water’s vapor barrier, resulting in bubbles forming within the centrifugal pump, typically originating near its center. As these water bubbles migrate towards higher-pressure zones, they undergo implosion. CANplus machine learning, trained to recognize the system’s normal behavior, can autonomously identify cavitation instances based solely on the data collected from the engine. This eliminates the need for additional suction and discharge pressure sensors. Integrating pressure transducers into the system further enhances the panel’s capability to detect deviations from the optimal system performance.

Although cavitation in deadheaded pumps is less common, it can still occur under certain conditions. When a pump is deadheaded, the pressure at its inlet diminishes as it attempts to draw in fluid despite the closed valve or system obstructing flow. Much like the situation with a clogged strainer, the vapor barrier is eventually breached, leading to the formation and implosion of bubbles within the pump. CANplus machine learning can also identify this type of cavitation using data from the engine, offering a comprehensive solution for cavitation detection across various scenarios.