ES52 User Manual R2.10
Contents
1. Flashing Over speed LED using Generator output Alternating flashing of over speed amp over crank Flashing run LED amp solid oil LED Timer pot set to zero pot clockwise Fault short or overload on timer output Speed signal improperly connected missing or damaged Crank output damaged not working 21 Increase timer pot setting turn Check for fault once fault is corrected then output operation resumes Check speed signal wiring replace damaged speed signal source Check wiring and replace controller Starter or starter solenoid damaged Not enough residual voltage during cranking Wrong speed range Replace repair damaged starter or starter solenoid Cut jumper next to DIP switch 8 or set DIP switch 9 to OFF if present on model Crank disconnect set too high Check crank disconnect Check speed range Solid oil LED immediately on start up without engine actually cranking or starting Oil switch not closed as it should be False speed signal being detected by controller This problem can sometimes occur in installations where there is AC power from inverters near generator output lines connected to the speed signal cable Check oil switch wiring Turn DIP switch 6 OFF to disable oil verification Avoid running AC lines from inverter in same conduit as generator output lines Install a sma2. The Auxiliary input For proper operation Aux Input must be connected to ground or 12 24 VDC via a sensor switch This switch must be the N O type close on failure Crank output provides 10Amps maximum Crank output closes to 12 24 VDC during cranking and opens when the engine has started or during crank rest GE Battery ground connection for the controller module A good ground connection directly from the battery is required for proper operation 7 Auto terminal When 12 24 VDC is applied the controller is in the standby mode waiting for a Start Stop signal 12 24 VDC applied to Start Stop 8 RSC1 provided for the connection of one lead from the remote start contacts 9 RSC2 provided for the connection of other lead from the remote start contacts Remote Start Contacts Notes When RSC1 and RSC2 are closed i e shorted they connect the Auto terminal terminal 7 which is connected to Batt to the Start Stop terminal terminal 10 RSC1 is tied internally to the AUTO terminal and RSC2 is tied internally to the Start Stop terminal The current for the Starter Crank Relay and Fuel Solenoid Fuel Relay pass through the remote start contacts The wiring must be rated for the max 20A current draw Mounting an external relay close to the controller and controlling the relay coil with the remote switch can be used for longer distances When using with a Vigilant Series transfer switch an external relay is required if t
3. 16 2 5 7 Crank Disconnect and Over speed Pot Adjustment sss 17 E GE Eege EE 18 29 9 Warm EE 18 OPERATION m 19 3 1 POUR ME IER C MUTDELC ErEETTDm 19 3 2 FRONT PANEL LED INDICATIONS AAA 19 TROUBLESHOOTING GUIDELINES seseseseseseseseseseseseosseoeseosseoeososososoeosseosesososososososososososososososesosereseseses 20 TECHNICAL NOTES ON FREQUENTLY ASKED QUESTIONS eeeereeee eterne einen tn anetntnn 22 Operating amp Installation Manual for the ES52 Engine Controller The ES52 provides Automatic Start Stop and protection control for all types of Engine driven equipment Simplicity of use safety features versatility and over all quality are paramount providing the most cost effective and reliable solution available Ours came to be one of the smallest controllers available with the best value per dollar cost backed by an Industry Leading 5 Year Warranty The ES52 maintains backward compatibility to the extent that it can replace similar products without substantial rewiring Functionally however it is loaded with unique features No speed signal detection Should the frequency of the speed sensing signal go to Zero while the engine is running or fail to appear during cranking a No Speed Failure is asserted and specifically indicated NOTE Speed signal detection during cranking can be disabled via an onboard Dip Switch In so
4. may not be enough residual voltage during cranking The following values are minimal recommended voltages for speed signal 20 HZ 075 V 75mV 60 HZ DV 600mV 4500 HZ 8V 800 mV A Warm up timer is provided on all ES52 series engine controllers Terminal 19 is the Warm up timer output This output energizes 2 minutes after the engine running LED turns on i e Speed above crank disconnect setting When a stop signal is initiated the Warm up output turns off This Warm up output can be used to control a load device which allows a generator to warm up before connecting the load Operating amp Installation Manual for the ES52 Engine Controller The maximum hour count is 99 999 9 hours Once the maximum is reached it will continue to display the maximum unless the hour meter is reset through an authorized dealer What the LED s look like Condition Failure No LED s ON Ready unit waiting for start signal 12 24 VDC to Auto terminal OFF no 12 24 VDC to Auto terminal Low Oil stead Low Oil Pressure Failure Low Oil flashing Auxiliary Input Failure High Temperature stead Over temperature Failure Crank tries Speed Signal present above Over Speed setting Over speed flashing Was engine Cranking No speed signal available while cranking Was engine Running The speed signal was zero while running for 3 seconds The engine has stalled or the speed signal has been lost Engine Running ste
5. settings are as specified in the following table sw7 SW8 Timerfunction Adjustable Time Glow Plug 0 32 seconds Sec Not Adjustable 0 256 seconds Glow Plug and Slow only as Air gate and Choke do not use pot 0 32 seconds For Glow Plug and 0 256 seconds for slow For the Glow Plug setting DIP switches 7 amp 8 off a Remove wires connected to the Timer terminal 12 and Crank terminal 5 b Apply power to Start Stop terminal 10 c Measure the time the Timer LED remains ON d Remove power from Start Stop terminal 10 e Increase or decrease pot setting as required Resolution is 1 6 seconds turn f Return to step b For the slow setting DIP switches 7 amp 8 on a Apply power to Start Stop terminal 10 b Allow the engine to Crank and start Engine Running LED turns ON c The Timer LED will illuminate measure the time that the LED remains ON d Increase or decrease pot setting as required pot resolution is 12 8 seconds turn e Return to step a Re connect wires to the Timer terminal 12 and Crank terminal 5 before proceeding to Step 5 Enter Setup Mode by setting DIP switches 1 2 amp 3 to the ON position Apply power to Auto and the over crank LED will flash The time between flashes indicates the Crank and Crank Rest time Adjust pot accordingly to increase or decrease Crank Rest time The Crank tries are adjustable from DIP switch positions 1 2 and 3 Select t
6. the connector shown in Figure 1 The maximum voltage rating of 300V will remain unchanged Please adjust your drawings and wire harness fabrication accordingly The new connector style utilizes industry standard LA spade terminals Customers are advised to select appropriate insulated mates to plug onto the spade terminals female 1 4 insulated crimp connector Please note that the current units ship with an 8ft length of cable with a plug This cable will become obsolete with the new connector system and thus will not be provided with shipments Figure 1 New Connector 1 4 spade terminals Figure 2 Old Connector Plug in with Cable Operating amp Installation Manual for the ES52 Engine Controller ES52 Specifications Operating VDC limits Standby current draw Operating current draw Reverse polarity protected J1113 11 Transients Speed sensing input accepts Speed sensing maximum rating Operating temperature range Operating humidity range Fuel amp Crank contact output Annunciation outputs Lamp Test terminal Actual unit weight Shipping weight Unit dimensions Shipping dimensions 3 3VDC min 30VDC max Provided minimum 8VDC Present at Starting 12 2mA at 12VDC 12 4mA at 24VDC 140mA at 12VDC 80mA at 24VDC Internal protection will prevent damage to unit under a reverse polarity condition Re connect power leads properly and normal operation will resume Pulse 1A Supply Di
7. C Engine Run Timer Dip Switch Off 18 eat con 19 Failure 18 2 H Lamp Test 20 LEE lt O Speed Sensing Optional Warman Ground Output MPU ALT Load 25A or Gen Out Fuse Co C Sg par e ESS Wiring Diagram Battery DWG1462R1 2 12VDC or 24VDC Timer Output Load Remote Start Contacts Annunciator A 6 32 X 1 2 DEEP Operating amp Installation Manual for the ES52 Engine Controller 12 LEE me w een Lee Tee 2 eneen Lass CRANK GROUND AUTO Vbat RSC 1 START STOP RSC 2 FUEL TIMER EE Lnonooees CRANK FUEL RELAY RELAY AUXILIARY G amp 4 HIGH TEMP ei 20A FUSE LOW OIL Q2 LED TEST Q 1 ADJUSTMENT POTS i HOW Ol HIGH TEMP CRANK ts OVERCRANK OVERSPEED OVERSPEED CRANK aen E EES ER ENGINE RUN FAILURE SPEED WABMUP SIGNAL CONNECTOR COMMON DYNAGEN TECHNOLOGIES INC ES52 SERIES AUTOSTART OUTLINE DIMENSIONS meme 627R1 The rear of the ES52 controller contains 4 adjustable pots and 9 DIP switches Potentiometer Pot Adjustment Potentiometer is abbreviated as pot throughout To increase a pot s setting turn it clockwise To decrease it turn it counter clockwise On board Pots are 20 turns nominal therefore turn pots fully 20 turns to ensure that you are at either the minimum or maximum setting Potentiometers are shown below as they appear on the rear of the ES52 series units 1 Crank Disconnect 2 Over Sp
8. DYNAGEN power controls you can trust ES52 Auto Start Engine Controller Installation and User Manual for the ES52 Auto Start Engine Controller Full Version File MAN 0001 R2 10 ES52 User Manual doc Date August 20 2012 Thank You For Purchasing This DynaGen Product Please Read Manual Before Installing Unit Receipt of Shipment and Warranty Return Information Upon receipt of shipment carefully remove the unit from the shipping container and thoroughly examine the unit for shipping damage In case of damage immediately contact the carrier and request that an inspection report be filed prior to contacting DynaGen All returned items are to be shipped prepaid and include a Return Material Authorization RMA number issued by DynaGen Limited Warranty For warranty information refer to the standard terms and conditions of sale at http www dynagen ca Dynagen ES52 Support Webpage For up to date manuals and other information please see the Support section of the Dynagen website at www dynagen ca support Operating amp Installation Manual for the ES52 Engine Controller ES52 Family of Products Speed Signal Connector Change Notice This change will take effect in March of 2011 for all new orders This applies only to the 2 wire speed signal connection for mag pickup or generator output All other connectors and controller features remain unchanged The existing connector and cable of Figure 2 will be replaced by
9. ES52 needs 10 seconds for its memory to clear When the power to the controller is turned off and then back on again without waiting a few seconds to clear the memory a loss of speed will be indicated by the ES52 because the controller remains in run mode and senses that the generator has stopped This would be indicated by a Flashing Overspeed LED By leaving the ES52 OFF for 10 seconds before it is returned to the Auto setting the memory will be cleared and it will function as intended Operating amp Installation Manual for the ES52 Engine Controller ER 3 Step Down Transformer Use On Speed Sensing Cable With Inverter Systems In some applications engine controllers are used on generators where there is no utility connection and inverters are used to provide AC power instead of a utility Inverters can produce harmonics that can cause small AC signals to appear on wires that are near any power lines being fed by the inverter If the generator output wires are located close to a line being powered by an inverter a small AC signal can appear on the generator output lines when the inverter is on This signal can cause the engine controller to react as if the generator is running if the speed sensing wires are connected to the generator output lines This small AC signal can cause the controller to appear to have a Low Oil Failure when the remote start contacts are closed or the controller is put in the manual test mode The controller may think th
10. ady Engine Controller is in running mode of operation Engine Running flashing Crank rest period Cranking will resume soon Timer steady Is Over speed LED ON 10 second Air gate timer Is Engine Running LED ON Slow timer feature pot adjustable Is the engine Cranking Choke feature If the engine is not cranking or Glow Plug timer feature pot runnine adjustable Low Oil steady while Oil switch is not closed miss wired or Engine Running Flashing not Installed Engine will crank when oil switch verifies Over speed and over crank LED s Invalid speed range check DIP flash alternately switches4 amp 5 Crank disconnect set too high Operating amp Installation Manual for the ES52 Engine Controller 20 Unit does not operate Power leads to unit are Confirm correct wiring for ground when powered to test reversed and bat and re attempt testing mode Bad ground connection from Run wire directly from battery engine to controller unit to the ground terminal 6 on controller unit Engine starts and Over speed pot setting too low Increase Over speed pot setting immediately goes into to desired value Over speed shutdown Improper speed range setting Check to ensure that controller is set to proper speed range Dip SWA4 amp 5 Engine does not crank Clean terminals and re charge dirt batter Crank circuitry wiring Refer to engine control wiring improperly connected section and check crank connection
11. connector complete with 8 feet of cabling is provided as standard with each unit 10 Diodes are provided across Fuel Crank and Annunciation outputs to protect the outputs from inductive kick back Diodes should be placed across slave relay contacts when used to actuate any inductive loads such as solenoids to protect the contacts from damage caused by arcing In addition to prolonging the useful life of the relays placing such diodes will help reduce generated electrical noise 11 To verify the operation of engine controller outputs measure voltage i e meter in volts when outputs should be ON Operating amp Installation Manual for the ES52 Engine Controller 2 3 Terminal Descriptions CON1 Speed signal input for crank disconnect engine run and over speed sensing Be sure to use twisted pair wiring for this connection Polarity does not matter Use female 0 250 inch insulated female quick connect Lamp test Connecting 12 24 VDC to lamp test activates all of the front panel LED s NOTE Annunciation outputs DO NOT activate under led test 2 Oil pressure input For proper operation oil input must be connected to ground or 12 24 VDC via an oil switch This switch must be the N O type close on failure low pressure Temperature switch For proper operation temperature input must be connected to ground or 12 24 VDC via a temperature switch This switch must be the N O type close on failure high temperature
12. e generator is already running and immediately check to make sure there is oil pressure Since the engine really hasn t started yet there is no oil pressure and the controller sees a low oil fault This is seen as the Oil LED turning on solid even before the engine starts to engage the starter Without this false speed signal the controller will not look for oil pressure until the engine has started to run and the crank disengages if oil verification is disabled Simply installing a small transformer between the generator output and the speed sensing terminals on the controller can eliminate this false speed signal This transformer should be rated for 120 or 240 volts on the input or primary coil depending on the generator output voltage you are using for speed sensing and have an output voltage of around 12VAC on the secondary of the transformer The two wires from the secondary of the transformer are connected to the two wires of the speed sensing terminals on the ES52 controller The step down transformer acts to reduce the false speed signal on the line to a level that the engine controller will not recognize as the engine running A common size transformer that would serve this purpose would be 24VA Step Down Transformer Connections On Speed Sensing Cable 120VAC primary winding Plugs into engine 12v AC secondary Step Down Transformer controller To Generator Output gt ele Line Neutral 120 4C Speed sensing cable wa
13. e parts as return conductor for battery negative voltage copper wiring is recommended Failure to follow the above may result in erratic operation due to large voltage drops across wiring connections 4 DO NOT short Crank output or Fuel outputs to ground as this will cause on board 20Amp fuse to blow and may result in damage to the ES52 s onboard relays 5 When replacing fuse removable terminals and relays only use factory recommended parts 6 DO NOT use AC coil slave relays from controller outputs Use intermediate relays of suitable size and coil rating NOTE All ES52 engine controllers are shipped standard with 12VDC coil relays for 12 VDC systems If the engine controller is used in a 24 VDC system the onboard relays MUST be replaced with 24VDC coil relays 7 DO NOT exceed the maximum rated current and voltage on each of the controller outputs Do not exceed 10 Amps for the Fuel output 10 Amps for the Crank output and 300mA for the Annunciation and Timer outputs 8 The Annunciation and Timer outputs are internally protected against overload and short circuit fault NOTE When a fault appears on one of the annunciation outputs only that specific output becomes un operable all other annunciation outputs and the entire front panel LED s continue to operate When the fault is removed and the unit is restarted the output resumes proper operation 9 Two wires must be connected for the speed signal NOTE A mating
14. eed 3 Crank Rest 4 Timer CRANK sae SPEED SETTING TIMER S2 54 S5 Range CRDC OVSP sa Model Only on un off off lo 12 140 44 300 S7 S8 Setting 6 Onion o ae 500 e402 CRDC Cenk Disconnect Hz f off Glow Plu CADG Crank Disconnect Hz Lett off Ge Plug OIL VERIFICATION on Enabled off Disabled off off off single crank attempt 4 to 256 sec LOSS OF SPEED c S9 on Enabled off Disabled Label on Rear of ES52 series units Oil Bypass period refers to the delay period fixed at 15 seconds for 1 3 crank tries and 20 seconds for more than 3 crank tries immediately after the Engine Running LED illuminates Engine starts During this period the oil input is bypassed ignored The steps to calibrate the ES52 controller to a specific system are as follows 1 2 3 4 5 6 T 8 See the following sections for a more detailed explanation of each Select the Engine Speed Range DIP switches 4 5 Oil Switch Verification oil switch enabled or disabled DIP switch 6 Select a Timer function DIP switches 7 amp 8 Adjusting Timer setting Only needed for Slow and Glow Plug functions Crank rest time calibration Selecting the maximum number of Crank Tries DIP switches 1 2 amp 3 Crank Disconnect Over speed calibration Loss of Speed During Cranking Enable Disable Two speed ranges are provided to permit greatest accurac
15. fully counterclockwise 20 2 turns 3 Turn the Over Speed pot fully clockwise 20 2 turns Adjusting the Crank Disconnect Pot 4 Measure the frequency of the speed source during cranking if you do not know it 5 Adjust the crank disconnect pot using the Hz turn information above to a value above the cranking frequency Keep in mind the two turn tolerance 6 Run unit as required and readjust pot as required for reliable start and to prevent grinding of the starter Limit cranking time while performing this calibration to prevent damage to the starter Adjusting the Over Speed Pot Operating amp Installation Manual for the ES52 Engine Controller 7 Run unit and adjust over speed counterclockwise until unit shuts down on over speed failure 8 Then adjust over speed pot clockwise to the desired headroom Loss of Speed While Cranking begins 3 seconds into crank cycle In the event there is a loss of speed while cranking or running the unit will shut down and this is indicated by a flashing Over speed LED The Loss of Speed While Cranking function can be disabled via DIP switch 9 When the DIP switch is in the UP or ON position the Loss of Speed While Cranking function is enabled When the DIP switch is in the DOWN or OFF position the Loss of Speed While Cranking function is disabled NOTE The Loss of Speed feature is maintained during all running conditions Note If unit is configured for Generator Output there
16. he Crank and Fuel peak current is above 10A as the remote start contacts on the switch are rated to 10A If using another brand transfer switch check the contact rating before installing See the tech note at the end of this manual 10 Start Stop terminal When 412 24 VDC is applied the controller proceeds to start the engine Fuel output provides 10Amps maximum Fuel output closes to 12 24 VDC when start signal is actuated and opens when either an Engine failure is detected or when stop signal is applied The Timer output provides 300mA maximum This output has one of four possible functions Glow Plug Smart Choke Air Gate or Slow This output Operating amp Installation Manual for the ES52 Engine Controller closes to 12 24 VDC when activated Low Oil pressure output provides 300mA maximum Oil output closes to 12 24 VDC when the engine shuts down due to a Low Oil pressure condition Flashing Low Oil output indicates an Auxiliary Input failure High Temperature output provides 300mA maximum Temperature output closes to 12 24 VDC when the engine shuts down due to a high temp condition Over crank output provides 300mA maximum Over crank output closes to 12 24 VDC when the engine shuts down due to an Over crank failure Over speed output provides 300mA maximum Over speed output closes to 12 24 VDC on an Over speed failure and is open otherwise Flashing output indicates Loss of Speed Signal Engine running output pr
17. he Crank tries most appropriate for your application Note that an extended Crank attempt range is available which extends the Crank time to a time spanning from 4 to 256 seconds Operating amp Installation Manual for the ES52 Engine Controller 6 OFF ON ON 4 36 sec ON ON ON ON 4 256 sec 2 5 7 Crank Disconnect and Over speed Pot Adjustment The Crank disconnect pot turned fully counterclockwise gives a frequency of 12Hz in low speed mode and 60Hz in high speed mode One turn gives about 6 4Hz in low speed and 205Hz in high speed The Over speed pot turned fully counterclockwise gives a frequency of 44Hz in low speed mode and 300Hz in high speed mode One turn gives about 13Hz in low speed and about 410Hz in high speed It takes approximately 20 turns to go to the minimum or maximum value Each pot has a clutch and thus requires one to two turns to overcome this clutch before the value actually starts changing Since it is not known exactly when the clutch is overcome the above numbers have an error of approximately two turns Turning the pot counterclockwise decreases the crank disconnect over speed Turning the pot clockwise increases the crank disconnect over speed To determine the proper crank disconnect and over speed the best method is to use a signal generator also known as a function generator If you do not have one follow this procedure 1 Power unit in Auto 2 Turn the Crank Disconnect pot
18. is used on gasoline engines having an electric choke The choke output is energized 27 seconds into the cranking cycle but only on even numbered Crank attempts Exception single crank attempt mode allows choke If engine speed remains above Crank Disconnect setting Choke output is turned off but as soon as speed falls below Crank Disconnect it is re applied This ON OFF regulation will continue if necessary as long as the Oil Bypass period is in effect Air gate The air gate output is used to control an air damper and only actuates for a fixed 10 seconds immediately after an Over speed Failure occurs This feature is used for some Diesel engines that cannot be stopped quickly enough by merely shutting off the Fuel in the event of an Over speed condition An electrically operated air damper is installed at the air intake which effectively gags the engine to a stop Refer to engine s manual for more information Slow This function is adjustable from 0 256 seconds via the Timer pot The Timer output energizes when engine speed goes above Crank Disconnect speed engine starts and remains so for the prescribed duration It is called Slow because it would presumably be used to tell a Operating amp Installation Manual for the ES52 Engine Controller governor to go slowly for such applications as irrigation pumps where running slowly for the first minute or two prevents water hammer The timer
19. ll step down transformer between the speed sensing wires and the generator output If the neutral from the generator output is not grounded attach it to ground at generator Operating amp Installation Manual for the ES52 Engine Controller 22 1 10A Diode On Auto Off Test Switch On All Units With Cool Down Or Energize To Stop Feature ONLY This tech note does NOT apply to standard ES52 A or ES52 D units When using a single switch for auto off test on any ES50 series controller that has the cool down feature a 10A diode must be installed between test and auto with the band pointing to the auto terminal This diode allows power to go to the auto terminal as well as the test terminal when the switch is put in test position It is necessary to have the auto terminal powered as well as the test terminal when the unit is used in the test manual mode The diode offers a one way jumper that only lets the current go from test to auto and not from auto to test If the controller is to be used in a two switch configuration with one being for auto and one for test the Auto Switch has to be ON as well as the test switch when the unit is to be used in test manual If only the test terminal is provided with power the unit will not operate properly To start stop terminal 10 v 10A diode with band pointing towards auto To auto terminal 7 lt q To switch 2 Controller Memory Clear Time The
20. me cases when using generator mains as speed signal source it is required to disable this shutdown when residual is very low Differential speed sensing inputs for twisted pair connection Very effective interference prevention by means of noise cancellation Excellent EMI handling Software detection of and recovery from noise corruption Replaceable Relays Replaceable relays provided within on board sockets Relays Rated 20Amps at 30VDC Replaceable Fuse On board replaceable 20Amp fuse mini fuse standard automotive type Reverse Polarity Protection No requirement for series diode on supply 3 3VDC to 30VDC 40 C to 85 C Operation Works anywhere anytime TM Zero Speed Restart Prevents starter pinion wear by ensuring that no engagement of the starter is possible unless the speed is Zero TM Oil Bypass Waits 15 Seconds from start for 1 3 crank tries and 20 Seconds for more than 3 crank tries before enabling Low Oil pressure monitoring This requires no user setting TM Four Timer Functions Glow Plug Smart Choke Air Gate and Slow Rest Time Indication Provides feedback between crank attempts Warm Up Turns an output on which can control a load device Warm Up timer output is provided on all ES52 units via Terminal 19 Warm Up timer is fixed at 2 Minutes Small Size 3 302 x 3 342 x 1 842 0 67lbs Operating amp Installation Manual for the ES52 Engine Controller Danger The controller does no
21. ovides 300mA maximum Engine Running output closes to 12 24 VDC when the engine speed is greater than the crank disconnect setting and opens when the engine stops Flashing output indicates Crank Rest period Engine failure output provides 300mA maximum Engine failure output activates on any failure closes to 12 24 VDC when activated Warmup output provides 300mA protection Output turns on after controller has been running for 2 minutes and 10 seconds Common ground For annunciation outputs only DO NOT USE AS MAIN GROUND TO CONTROLLER UNIT 2 4 General Wiring Diagram See next page for the wiring diagram and dimensions ATTENTION All ES52 Controllers come with 12VDC Relays for 12V systems For 24V systems replace with 24VDC Relays A diode across Auto and Start Stop terminals is required on versions of the ES52 with the Cool Down or Energize To Stop features See the tech notes section at the end of this manual for further information The standard ES52 versions ES52 A and ES52 D do not require this Operating amp Installation Manual for the ES52 Engine Controller Hi S Auxiliary ino oo 9 de Outputs ari Temp Crank Fuel Internal Battery Tiwa He Relay Relay 99 LL es y Low Oil 13 i 20A Fuse High Tem Z May ete r be EN E eng switched to Kaes 14 C Overcrank Crank Disc o 15 Battery Overspeed wr Overspeed 46 Crank Rest z ULDTHIL L I
22. s Bad ground connection from Run wire directly from battery engine to controller to the ground terminal 6 on controller unit Crank relay damaged Or on Check wiring on board 20A fuse board fuse is blown and relay Replace fuse relay and re test controller again Engine cranks but does Out of fuel Check fuel level add fuel if not start necessary Ignition control wiring not Refer to engine control wiring installed properly section and check ignition connections Fuel relay damaged Check fuel relay and replace if damaged Engine starts but shuts Oil temp extra input wiring Check wiring for proper down after Oil improperly connected connections Bypass period due to low oil high temp extra Engine starts but Improper speed range setting Check to ensure that controller is running LED does not set to proper speed range DIP illuminate switches 4 5 Fault short or overload on Check for fault once fault is one of the annunciator outputs corrected then operation resumes Crank disconnect POT set too Decrease crank disconnect pot Annunciation output not Fault short or overload on Check for fault once fault is one of the annunciator outputs corrected then annunciation operation resumes Operating amp Installation Manual for the ES52 Engine Controller Timer LED and timer output does not activate Timer LED works O K but timer output does not activate Flashing Over speed LED
23. s connected directly to generator output before Operating amp Installation Manual for the ES52 Engine Controller 24 4 Connecting ES52 to Dynagen VTS2 Transfer Switch The ES52 remote start contacts carry high current up to 20A peak during starting Therefore they cannot be connected directly to a transfer switch Use an intermediate relay to limit the current the remote start contacts on the transfer switch needs switch Long distance High current path RSC1 RSC2 VTS2 Battery 4 Transfer Switch Battery RSC1 RSC2 ES52 Operating amp Installation Manual for the ES52 Engine Controller
24. sconnect Pulse 2A Sudden Disconnect Pulse 4 Starter Motor Engagement Pulse 5 Load Dump Details of the test parameters are available please consult with factory Generator AC output directly Fly Wheel Alternator Engine Alternator Magnetic Pickup Withstands Line Voltage up to 300VAC O O 40 Cto 85 C 0 to 95 non condensing 10Amps maximum each continuous sourcing Bat output Sourcing Bat outputs 300mA maximum per output Close to Battery to test LED s 0 67 Ib 0 30kg 1 Ib 0 45kg 3 302 x 3 342 x 1 8 4 10 16cm x 4 10 16cm x 3 7 62cm Operating amp Installation Manual for the ES52 Engine Controller Table of Contents 1 2 4 5 INTRODUCTION E 6 WIRING INSTALLATION GUIDELINES qu sesssssesecessesecsessesecsessesecsessesecserseseesesseseesesseseeserseseeserseseeses 7 2 1 KEE H 2 2 LINCRCIUD ZB VC 8 2 3 TERMINAL DESCRIP MONS MM 9 2 4 GENERAL WIRING DIAGRAM stet tree EP EHE ERE Re EHE re ERR eH I He ti e ete rte rn 10 2 5 ADJUSTMENTS AND SETUP PROCEDURES eene enne tnnt tnnt etre enne 13 2 5 1 Selecting The Engine Speed Range sse eene nete ener 14 25 2 Oil Switch kKeriticatton tienenie tenen tenete tenete yeiai nennen 14 2 5 8 Selecting a Timer Function eese entente teen entente enne enne 15 25 4 Adjusting Timer Re D 16 25 5 Crank and Crank Rest eere ei tee re e e HE EROS GEHE E EH ates Gotta tan edd 16 2 5 6 Selecting The Maximum Number Of Crank Ties sse
25. sume a wait and see mode indicated by a steady Low Oil and flashing Engine Running LED As soon as the oil pressure switch closes Cranking will proceed as usual If the engine s starts the controller will check for a Low Oil failure condition only after the Oil Bypass M period Notice that if this verification was not Operating amp Installation Manual for the ES52 Engine Controller 15 performed a bad connection of the oil switch might go unnoticed until such time as oil runs out and engine damage occurs Note i Oil circuit verification is only performed in the following conditions a On the first Cranking attempt b If the engine has been previously running and more than 5 minutes of rest has elapsed ii If DIP switch 6 is set to the off position the ES52 does not provide oil verification The ES52 goes immediately into cranking it will then check for a low oil failure condition after the oil bypass period has elapsed sw6 Oil switch verification Enabled Disabled The timer function is configurable from DIP switches 7 amp 8 The output terminal associated with this timer setting is terminal 12 It has four configurable functions of which two are adjustable Glow Plug The Glow Plug timer is adjustable from 0 32 seconds Glow Plug is a timing function used with Diesel engines This output is energized on every Crank attempt for a set time prior to Cranking engine Choke The choke function
26. t generate a warning prior to Automatic Engine start Do not work on the Engine while power is applied to the unit It is highly recommended that warning signs be placed on Engine equipment indicating the above Following these instructions will help avoid common installation problems during wiring and setup e Battery must be disconnected before any wiring connections are made Wire length from the engine to the controller should not exceed 6 meters 20 feet Wiring size and type should be as specified below Use stranded wire since solid wire has a tendency to crack break and loosen over time board connector 20A RSC1 remote start contact connection El ae RSC2 remote start contact connection 20 18 300mA Annunciator Common Ground Only DO NOT use this as main ground connection Operating amp Installation Manual for the ES52 Engine Controller 2 2 Wiring Guidelines 1 WARNING DO NOT apply external voltage to annunicator outputs terminals 13 to 18 This will damage the ES52 If this may occur in your application place a diode in series with each affected annunciator output 2 DO NOT use wire smaller than 18 AWG 3 The connections supplying DC power to the ES52 panel should preferably run directly from the battery posts with no splices or other connections except a 25A fuse connecting the positive line directly to the Battery terminal Avoid as much as possible using chassis aluminum or iron engin
27. y when adjusting Crank Disconnect and Over speed settings The speed ranges are selectable from DIP switches 4 and 5 Generator output When using generator output 50 or 60 Hz speed range 1 LO is required Flywheel Alternator When using a flywheel alternator speed range 1 LO will be required Refer to engine s specification for number of poles attached to flywheel i e 1 pole 60Hz 2 poles 120 Hz amp 4 poles 240 Hz Engine Alternator An engine alternator would require speed range 1 LO or 2 HI Refer to engine s specification for pulley ratio and number of poles before selecting range Magnetic pickup A magnetic pickup would require speed range 2 HI SW5 Crank Disconnect Hz Over speed Hz Range 2972 12 140 Hz 44 300 Hz 60 4156 Hz 300 8492 Hz Selecting the Proper Speed Range The oil pressure switch must be the type that opens when oil pressure is normal and closes on Low Oil pressure failure condition or engine stopped DIP switch 6 must be set to the ON position if you wish to enable oil verification and set to the OFF position if oil verification is to be disabled If DIP switch 6 is ON prior to Cranking the controller will attempt to verify that the pressure switch is connected and operating properly by checking if the circuit is closed If the oil pressure switch does not work or the wire fails to make the connection the engine will be prevented from starting and the ES52 will as
Download Pdf Manuals
Related Search