Dynalco Catalyst Monitor User Manual

5450 NW 33rd Ave, Suite 104

Fort Lauderdale, FL 33309

3211 Fruitland Ave

Los Angeles, CA 90058

Catalyst Monitor

6-Channel Monitor

Version 2

Installation and Operation Manual

Rev. I

P/N145F-12964

PCO - 00007462

(c) Copyright 2014, Dynalco Controls

All Rights Reserved

Published: November 7, 2014

IMPORTANT - PLEASE READ BEFORE PROCEEDING!

This manual applies to all Version2 Catalyst Monitors.

The Dynalco Catalyst Monitor is designed for reliable and rugged operation on engines
with NSCR and oxidation catalysts. This product has been designed and tested to
meet the demands required in many industrial and hazardous locations meeting
critical CSA standards. The performance is directly related to the quality of the
installation and knowledge of the user in operating and maintaining the instrument. To
ensure continued operation to the design specifications, personnel should read this
manual thoroughly before proceeding with installation, operation and maintenance of
this instrument. If this product is used in a manner not specified by Dynalco, the
protection provided by it against hazards may be impaired.

WARNING

•

Failure to follow proper instructions may cause any one of the following
situations to occur: Loss of life; personal injury; property damage; damage to
this instrument; and warranty invalidation.

•

For clarification of instructions in this manual or assistance with your
application, contact Dynalco at [phone] or [phone] or send email to

[e-mail]

•

Additional manuals and CSA certificates are available at www.dynalco.com

•

Follow all warnings, cautions, and instructions marked on and supplied with the
product.

•

Use only qualified personnel to install, operate, program and maintain the
product.

•

Educate your personnel in the proper installation, operation, and maintenance of
the product.

•

Install equipment as specified in the installation section of this manual. Follow
appropriate local and national codes. Only connect the product to power
sources and end devices specified in this manual.

•

Any repair is only to be performed by Dynalco using factory documented
components. Tampering or unauthorized substitution of parts and procedures
can affect the performance and cause unsafe operation of your process.

•

All equipment doors must be closed and protective covers must be in place
unless qualified personnel are performing maintenance.

•

Shutdown / alarms should be tested monthly for proper operation (see page 14)

•

Please see page 22 for CSA specific installation instructions.

1

System Overview

The Dynalco Catalyst Monitor is designed to address the EPA mandate regarding continuous
monitoring of catalyst inlet temperature and differential pressure on both spark-ignited and
diesel engines. It is capable of reading up to 6 input channels, calculating differential values,
providing alarm / shutdown outputs as well as allowing all parameters to be logged to an
internal flash memory. An RS-485 Modbus link for communications to a DCS or PLC is also
provided.

Additionally, the Catalyst Monitor is capable of calculating the engine catalyst inlet
temperature based on a 4 hour rolling average per latest EPA requirements.

Basic operation:

The Catalyst Monitor will be in “stopped” or non-monitoring mode until a run indication is
sensed. This is selectable as either a contact closure or magnetic pickup input. Once
“running” mode is sensed, the Catalyst Monitor will read all inputs at a rate of 100 msec per
channel. If any input crosses either an over or under threshold, the unit will invoke a flashing
red LED on the front panel as well as an output trip (solid-state relay) that can be used for
alarm or shutdown. Any trips will also cause the Catalyst Monitor to date / time stamp
whenever a trip threshold is crossed. The monitor will log the last (10) alarm events for each
channel input. These may be viewed on the front display.

All data is also accessible via an RS485 serial Modbus link.

Data logging functions can also be enabled where logged values are saved to an onboard
flash memory.

4-Hour Rolling Average Logs:

The EPA 4-hour rolling average is configured to log the instantaneous catalyst inlet
temperature every 15 minutes. The instantaneous values are then used to calculate 1-hour
averages which are used to calculate a 4-hour average. The 4-hour average is a rolling
average allowing logged data from previous engine run times to be included with next run
times. When the “EPA Average” is enabled, the Catalyst Monitor will log continuously as long
as it has received an engine run signal.

IMPORTANT:

A run signal (either digital or RPM input) must be selected in order to properly log the
4-hour rolling average. (See page 10 for configuring run signal.)

Additional Data Logging:

The Catalyst Monitor also allows additional data logging of any monitored values where they
will be saved to an internal flash memory. Up to 10 log events may be selected, including
logging of the catalyst differential pressure at user programmable intervals.

2

Flash Memory:

The onboard flash memory is sufficient to hold up to 500,000 data values with date / time
stamp. When the Catalyst Monitor receives an engine run signal (either contact closure or
mag pickup signal) the unit begins monitoring all enabled inputs. Following that, the monitor
will begin logging data as configured. The logged data is temporarily saved to RAM memory
which holds 56 logged values. The logged values remain in RAM until any of (3) events
occur:

1) The RAM is full.

2) The monitor receives an engine stop signal.

3) The user initiates a “Stop Logging” command.

Following any of the above events, the data in RAM is transferred to the non-volatile flash
memory. These values can be downloaded at any time to a PC using Dynalco’s download
cable and Log Reader software.

IMPORTANT - Input Power Requirements:

It is important that the input supply power be a reliable source with battery backup if needed.
If input power is interrupted or disconnected while the monitor is logging data, any data that
has not yet been stored to flash memory may be lost. This manual contains information on
page 14 that describes the steps required to safely disconnect power without risk of losing
data.

Additional Features

• 5 - Digit Hourmeter Function (non-resettable)

• Engine RPM Display

• Fully programmable from front keypad

• ¼ DIN package (3 ½” width X 3 ½” height) for panel mount

Specifications

Input Types J or K type thermocouple (ungrounded) accurate to +/- 0.2 %

4 - 20 mA
0 – 1 VDC
0 - 5 VDC

0 – 10 VDC
Digital Input Closure to ground indicates run condition (or use pulsed input)
Pulsed Input Magnetic pickup input for RPM display & to indicate run condition
Relay Outputs 2 Digital Outputs rated @ 0.15 A / 48 VDC
Input Power 10 – 36 VDC
Display Backlit Graphic Display
Data Logging Internal Flash Memory to retain data logged values w/ date & time stamp
Communications Modbus
Connections Two-Part Terminal Blocks
Operating Temperature Range - 40 to + 70 Deg C
Certification CSA Class I, Division 2, Groups A, B, C, D

3

User Interface

The Catalyst Monitor is configured via the keypad on the front panel which includes a
graphical backlit LCD display capable of displaying alpha numeric values and custom
engineering units of measure. The keypad implements a menu system, which is navigated
using the up, down, left, right, enter and escape buttons.

Installation:

The Catalyst Monitor is a standard ¼ DIN package, designed to be panel mounted. The
cutout dimensions are shown below.

4

The Catalyst Monitor has integral mounting clips for securing into the panel. The following
drawings illustrate the mounting procedure.

5

Terminal Connections

PIN

Description

PIN

Description

All connections are made via the removable connectors on the back of the unit.

1 GND (Power Gnd) 13 Channel 1 (-)
2 VIN (10 - 36 VDC input) 14 Channel 1 (+)
3 GND (mag pickup input) 15 Channel 2 (-)
4 RPM + (mag pickup input) 16 Channel 2 (+)
5 Receive Data (-) 17 Channel 3 (-)
6 Receive Data (+) 18 Channel 3 (+)
7 Transmit Data (-) 19 Channel 4 (-)
8 Transmit Data (+) 20 Channel 4 (+)
9 Alarm 1 21 Channel 5 (-)
10 Alarm 1 22 Channel 5 (+)
11 Alarm 2 23 Channel 6 (-)
12 Alarm 2 24 Channel 6 (+)

Also used for USB download

cable assembly p/n 270A-13020

(see page 16)

Terminal screws to be tightened to 4 inch-pounds torque.

See page 21 for complete wiring information.

6

Outline Dimensions

7