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.

Long Ranger Watering using Tyro M2M system

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Irrigation of Dutch tulips using M2M

A well-known supplier of irrigation systems and water pumps. In addition, they also maintain agricultural machinery for farmers from the region. We had the opportunity to take a look at a recently delivered system. What we did not know beforehand was that we ended up in beautiful surroundings with stunning, colourful tulip fields.

Cogem water pump and irrigation hose reel from AP

The mechanisation firm has already provided pumps from Cogem and irrigation drums from AP with our M2M system on a number of occasions. In their own workshop, they provide the pumps and reels with an Aquarius M2M transmitter.

Cogem is an Italian manufacturer that delivers generators and pumps on a global scale. Almost every pump has a remote control, which is brand-independent.

AP Mechanical Engineering specializes in the production of machines for the agricultural sector. The irrigation drums of AP are a well-known sight in the countryside. The M2M system, which is explained in more detail below, can also be applied to irrigation drums of other brands.

Operating the M2M system

The system works as follows: The irrigation reel is used to set the length of time the tulips are to be irrigated. As soon as no more irrigation is required, the system sends a signal to the receiver on the pump. The pump is then switched off.

Some systems also come with an additional hand transmitter. This allows you to manually adjust the number of speeds from the tulip field or switch off the system. The distance from the reel to the pump is, in many cases, several hundred meters. The farmer regularly has to move the sprinkler or switch it off. Nothing is more convenient than being able to do this remotely using a remote control.

Mobile Air Compressor Control
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Complete Control Solution for Compact Mobile Equipment

Mobile air compressors are compact, portable machines designed to generate compressed air for various applications across construction, mining, agriculture, and manufacturing industries. These compressors are typically mounted on trailers or skid frames, making them easily transported to job sites and offering efficiency and mobility for demanding environments. OEMs, distributors, and rental equipment operators rely on the air compressor’s ability to operate in remote locations and adapt to various tasks.

 

Fully Integrated and Comprehensive Solution

We offer an integrated engine and compressor control solution for mobile air compressors, including a robust engine controller, remote control, telemetry, and monitoring.

 

Engine Control 

A DynaGen™ engine controller provides an easy-to-use, integrated control panel for mobile air compressors. Its rugged design ensures it can safely and reliably operate in extreme environmental conditions often found in job sites where air compressors are used. Here are just a few of the things that a DynaGen controller can manage:

remoteiq, dynagen, tyro and messenger ble
  • Throttle control
  • Automatic load/unloading of the compressor
  • Display machine air pressure
  • Auto throttle speed to maintain air pressure
  • Control the engine warmup based on the engine coolant temperature
  • Monitor and protect the compressor oil temperature

 

Remote Control  

In addition to the DynaGen controller, air compressors can be equipped with a Tyro™ handheld radio remote control system. Integrating remote controls enables the operator to control functions such as engine start/stop, IDLE rate speed control, and light control from the convenience of a handheld transmitter. This allows workers to operate the machinery from a safe and efficient distance.

 

Remote Monitoring  

DynaGen controllers are also telemetry-ready, should you want to introduce remote monitoring capabilities. Our RemoteIQ™ cloud-based platform provides a secure and cost-effective way to optimize the management of a single machine or an entire fleet of air compressors with GPS location tracking, real-time equipment status, and alert notifications.

Remote monitoring allows operators to access real-time data at any time, from anywhere, on any laptop or mobile device. It alerts the operator to potential issues before they cause damage, ultimately prolonging the compressor’s lifespan and ensuring reliability in demanding conditions.

 

Ease of Integration and Added Value 

What sets us apart is our extensive knowledge of control products and the ability to integrate engine control, radio remote control, and telemetry into a combined solution that improves the air compressor’s performance and simplifies its operation. A single-control solution provides simplicity and increases operator safety while improving overall machine efficiency. For OEMs and distributors looking to enhance their brand, private labeling, incorporating a company’s brand identity, such as name, logo, and color palette, is available.

New XBMCU Multi-Interface Machine Control Unit

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Radio Remote Control Xbmcu LeftOur new XBMCU Multi-Interface Machine Control Unit represents a significant advancement in industrial automation technology, offering seamless integration into PLC systems through multiple serial protocols.

The XBMCU is a compact, multi-interface receiver and machine control unit designed for mobile machines, industrial automation, robotics, and machine-to-machine control. The unit works compatibly with Cattron’s Safe-D-Stop wireless emergency stop, most CattronControl radio remote transmitters, and the latest generation of Remtron wireless devices.

According to the company, what sets the XBMCU apart is its robust capability to support machine-to-machine functionality in both directions, handling high data volumes. The unit features dual CANbus interfaces supporting J1939, CAN FD, CANopen, and CANopen Safety protocols, along with lab-certified PROFINET communications for reliable, real-time data handling with Class C Conformance.

For North American customers, the XBMCU will soon support Ethernet IP protocols certified by ODVA, with plans to incorporate CIP safety, making it a comprehensive solution for systems integrators who previously required multiple products from different manufacturers.

The XBMCU is housed in a rugged IP66-rated aluminum enclosure, making it suitable for the most demanding industrial environments. It features a wide range of 9-36 VDC supply, eight digital inputs that can be combined for Category 3 PL-d configurations, and six 3A digital outputs that can be similarly configured for enhanced safety.

The unit incorporates a black channel wireless interface for secure communications. The XBMCU also supports globally recognized safe industrial protocols, such as PROFIsafe (currently under certification), CIP safety, and CANopen Safety, to ensure reliable protection for personnel and machinery in automation environments. The unit supports IEC 61131 programming via the CattronLink programming tool, allowing for configuration via the CattronLink app or over wireless or Ethernet connections, eliminating the need for complex setup procedures.

The XBMCU is ideal for multiple industrial applications, including:

  • Industrial automation systems and robotics
  • Autonomous guided vehicles
  • Logistics control and monitoring
  • Industrial manufacturing equipment
  • Palletizing and packaging equipment
  • Decentralized control systems

The XBMCU is manufactured at Cattron’s Warren, Ohio, facility, offering customers the advantage of American-made quality and local technical support.