Engine Controller - Martin Diesel Inc
Contents
1. TECHNOLOGIES INC DynaGan MD10 Engine Controller Installation and User Manual for the MD10 Engine Controller Full Version File MartinDieseIMD10rev1 2 Doc June 12 2001 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 the COMPANY All returned items must be shipped prepaid and include a return material authorization RMA number issued by the COMPANY RMA forms are available by contacting the COMPANY Limited Warranty The COMPANY DynaGen Technologies Inc warrants the product with specifications as explained herein The COMPANY shall repair or replace any MD10 controller which prove to be defective under normal and proper use within three years from the date of shipment This constitutes the only warranty and no other warranty shall be implied For questions or comments regarding this product contact DynaGen Technologies Inc Phone 902 562 0133 Fax 902 567 0633 Email sales dynagensystems com WEB SITE www dynagensystems com Operating amp Installation Manual for the Martin Diesel MD10 Engine Controller Table of Contents INTRODUCTION SPECIFICATIONS WIRING INSTALLATION GUIDELINES Wiring instructions types and2. 6 on controller unit Check auto and place power to No Power to auto on unit i p E auto terminal if necessary Refer to proper setup of over speed pot Engine Starts and Running LED Comes ON immediately after the controller goes into overspeed Over speed Pot Set too Low Clean terminals and re charge battery change battery if necessary Measure the voltage at crank Crank circuitry wiring terminal ensure there is Vbat improperly connected or bad on If not replace on board relay board relay If Vbat is available at engine controller check wiring Fault short or overload on one Correct fault and operation Engine starts but M of the annunciation outputs should resume running LED does not Speed signal harness may be Measure the AC voltage illuminate a defective or bad connection available at speed signal plug Remove short or overload on Pull coil output does not Short or overload on pull coil output a slave relay may be activate output required on overload fault Max output is 300mA Check speed signal connector Engine cranks and gets Speed signal output not to ensure that it is plugged in up to full speed but connected damaged or missing probe yo me ne starter does not voltage available at speed disengage Running signal connector LED then begins to Re calibrate crank disconnect flash indicating crank CTank disconnect pot set to high rest i i i Wrong Speed range re Dip Sw
3. Zero Speed Restart Prevents starter pinion wear by ensuring that no engagement of the starter is possible unless the engine is stopped Oil Bypass Failure 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 Requires no user setting Rest Time indication Provides feedback between crank attempts SMALL SIZE 3 302 x 3 342 x 1 842 0 671bs Operating amp Installation Manual for the Martin Diesel MD10 Engine Controller SPECIFICATIONS Operating VDC limits 3 3VDC min 30VDC max Standby current draw 8 mA Operating current draw 175mA Reverse polarity protected Internal protection will prevent damage to unit under a reverse polarity condition Re connect power leads properly and normal operation will resume Speed sensing input accepts Magnetic pickup Engine alternator Flywheel alternator Generator AC output directly Speed sensing maximum rating Withstands Line voltage 300 V A C Operating temperature range 40 C gt 485 C Operating humidity range 0 95 non condensing Fuel amp Crank output 10 Amps max each Continuous sourcing bat output Kick back diodes provided on Fuel amp crank output Pull coil Output 300 mA Max switches to Vbat Kick back diode provided on pull coil output Lamp Test terminal Close to Battery to test LEDs Actual unit weight 0 67 Ib 0 30kg Shipping weight 1 Ib 0 45k
4. Manual for the Martin Diesel MD10 Engine Controller 10 WIRING GUIDELINES DO NOT use wire smaller than 18 AWG The connections supplying DC power to the MD10 should preferably run directly from the battery posts with no splices or other connections Avoid as much as possible using chassis aluminum or iron engine 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 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 MD10 on board relays When replacing fuse removable terminals and relays only use factory recommended parts DO NOT use AC coil slave relays from controller outputs Use intermediate relays of suitable size and coil rating NOTE All MD10 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 DO NOT exceed the maximum rated current and voltage on each of the controller outputs Do not exceed 10 amps for the Fuel output and 10 amps for the Crank output and 300ma for the annunciation and timer outputs The annunciation and timer outputs are internally protected against overload and short circuit fault NOTE When a fault appears on one of the
5. Steady Over Speed steady Engine Controller is in running mode of Engine Running steady op pas e oe Engine Running flashing Loss of speed signal Engine stall Over speed flashing Engine overload Bad or Broken Speed Signal Operating amp Installation Manual for the Martin Diesel MD10 Engine Controller 11 ADJUSTMENTS AND SETUP PROCEDURES Warning The following procedures will require engine operation Be sure to follow all safety guidelines and wiring procedures NOTE Potentiometer is abbreviated as pot throughout To increase a pot s setting turn it clockwise to decrease it counter clockwise These Pots are 20 turns nominal therefore turn pots fully 20 turns to ensure that you are at either the minimum or maximum setting The rear of the MD10 controller contains two adjustable pots and eight DIP switches Failure Bypass delay will occur for a period of 15 seconds after the starter has disengaged and the engine is running engine running LED on After Bypass delay has expired the engine controller then looks for failures such as Low Oil High Temp and Aux The steps for calibration of the MD10 to a specific system is as follows 1 Select the engine speed range switch 4 and 5 2 Crank Limiter calibration switch 6 3 Crank Disconnect calibration 4 Over Speed calibration 1 SELECTING THE ENGINE SPEED RANGE Two speed ranges are provided to permit greatest accuracy when adjusting Cran
6. annunciation outputs only that specific output becomes un operable all other annunciation outputs and all the front panel LED s continue to operate When fault is removed the unit is restarted and the output resumes proper operation Two wires must be connected for the speed signal NOTE A mating connector complete with 8 feet of cabling is provided as standard with each unit Diodes are provided across Fuel Crank and annunciation outputs to protect the outputs from inductive kick back Also 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 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 Martin Diesel MD10 Engine Controller Q303ddv 10 NMWYa S L NIOS LSY 00 Ann z ON OMG awa azis WvS9vIO ONI IM LYVISOLNY SAIS OLAN ONI S3I90 IONHO31 N39VNAGO UD NEA E au Sabo pupa SWALSAS OQA vC YOS SAVIJY OQ vC SWALSAS DUAZI YOJ SAVI3H OQACI SIOA vZ zi ananya Q3sn LON 8did FALL Xnv doils Ldid YATEVNA BILINM MNvNO Idla 39Nv4 Q33dS Sdl 39NVvH Q33dS tdid dasn
7. sizes Outline Dimension Drawing Wiring Guidelines General Wiring Diagram LED INDICATIONS ADJUSTMENTS AND SETUP PROCEDURES Select the engine speed range Crank Limiter calibration Crank Disconnect calibration Over speed calibration TROUBLESHOOTING GUIDELINES Operating amp Installation Manual for the Martin Diesel MD10 Engine Controller OoxNA 11 11 12 12 13 14 INTRODUCTION The MD10 provides start stop 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 a 3 year warranty No speed signal detection Should the frequency of the speed sensing signal go to zero while the engine is running a No Speed Failure is asserted and specifically indicated Two selectable speed ranges Allows for multiple speed signal use such as 1 Magnetic pickup sensor 2 Alternator output 3 direct generator output connection REPLACEABLE RELAYS Replaceable relays provided within on board sockets Relays Rated 20 Amps at 30 VDC REPLACEABLE FUSE On board replaceable 20A fuse mini fuse standard automotive type Reversed supply protection No requirement for series diode on supply 3 3V to 30V A0 c to 85 c operation Works anywhere any time
8. LON did Q3sn LON ZdlQ q3Sn LON lad ov AO0 X NI I wou ML AVAX XILAS YOLIINNOIJ paten a HOLIMS did NNSIS a r a 440 BLOSYEZI adds Manis LJ 5885868686 1Sal an A Cd T 9 assasyano oe TOS B3lNvis L SOC apo E ki Eis gt NVEO S10d INSWLSnray as a ra Gal LIO MOT HOLINS zq jo MOT n dW3L HOIH asn4 voz M i JNa HOH 2 ANTH AVIS YO dOIS XhV i 1100 Tind ANIM HOLIMS Xnv ja iu NO e 103 Tina im COAT um NYO j i AYOLOVA oopmHecv e i te SLVOIGNI L j SIVNINBYIL 6089 xS N33AL38 mo sann N3wOBE eela a ZZS mi gt sla e FIFI 2 alo Z Ton Uma g FRI WON dois pa lt lt a ojo m 430 Jos n4 a E po NOW Luvs HOLIMS 13S3M ON LO 3Nnf ZL Q3AOW3H 02 91 WNINYAL 00 AON 8 Q3SN LON SYM did e 00 AINC Sc 0300Y NolldlJos3d TWNINYSL YOLVIONANNY I Ia3 osdav aia NOLLdld3S3a NS 3NOZ SNOISIAZY Operating amp Installation Manual for the Martin Diesel MD10 Engine Controller 10 LED INDICATIONS What the LED s look like Condition Failure n Ready unit waiting for start signal 12 24 PO ERTEN VDC to Auto terminal Low Oil steady High Temperature steady Aux
9. NO JlMVISOLInv SIYIS OLAN ONE SSISOVONHOSL NHOVNAG vo TIE MR DW Goboupor Q3sn LON 8dl INIL XAV dOLS Ldid HJIB8VN3 YALINN MNVYO Idia SONVY Qd3dS Sdl SONVY Q33dS tdia Q3Sn LON dl Qq3sn LON Zdl dasn LON lala MO193NNOO HOLMS did n WN IS 440 8LISHEZI daads HHBBBBRH Q33dS33 A0 NO n OSIQ MNvHO S10d AN3WISnNaY ue Asa an zO 110 MAT ASN4 voc E18 dN3L H IH AN dols xnv AN T3 AN T3 Tan YINVYO q r Hog FOYT DOSSOSDD 2E4YLEERB Suad nr SSS G3ThwISNI FRIZOSQZ AYOLOWS o 776 SLVOIGNI 2 ee STWNINSAL oo N33A138 roe SINNT N3OMBH to 3Nnf ZI Q3AON3H OZ l INNIAH3LL v 00 AON 8 Qasn LON SYM Zdid oo ANF ez daddy NOlldlHoS3d WNINH3L YOLVIONNNNY t oo A nr cz daddy WNINH3L HOLVIDNDNNVY L QI3 0Nddv aia Nol1dlJos3aa Aa 3NOZ SNOISIA3M 0620 DU revel 048 0 3 342 SNilSAS DUAbZ HOS SAVAY DUAYZ SN3lSAS DUAZI H59nOMHl ZE I v 0 385 WNSIS q33dS 30 SSOT S31VOIONI Q334SM3AO ONIHSW14 V Nad 3NIONJ3 d33dS83 AO0 Xnv ddl HOIH MNO MOI X04 SAVI3H DUAZI Q 4 0 836 1 186 1 536 1 886 2 886 41280 le8 0 lega 4c0 Operating amp Installation
10. e one turn g Remove power from Auto terminal 7 Operating amp Installation Manual for the Martin Diesel MD10 Engine Controller 13 h Reconnect wire to Fuel terminal 11 Fuel Ignition or reconnect spark plug wire Note To proceed to step 7 you must ensure the controller positively detects engine start up If the running LED turns on momentarily and engine stalls loss of speed flashing Overspeed try increasing the Crank Disconnect pot one full turn 4 Over Speed calibration The Over speed pot controls the speed at which an Over speed failure shutdown is to be asserted To adjust Over speed a Start engine by applying a grounded signal to the start terminal 10 allow engine to reach normal operating speed b Turn Over speed pot counter clockwise slowly until an Over speed failure occurs c Remove power from Auto terminal 7 d Turn Overspeed pot approximately 1 to 2 full turns Operating amp Installation Manual for the Martin Diesel MD10 Engine Controller 14 TROUBLESHOOTING GUIDELINES TROUBLE POSSIBLE CAUSE SUGGESTED ACTION Correct wiring for ground and Power leads to unit are reversed Vbat and re attempt testing Unit does not operate 20 Amp on board fuse is blown Replace fuse and re test when ground is applied Run wire di E e directly from battery to start terminal Switch Bad ground connection from ground to the ground terminal iti engine to controller unit to the start position 8 i
11. g Unit dimensions 3 407 x 3 407 x 0 57 Shipping dimensions 4 10 16cm x 4 10 16cm x 3 7 62cm Operating amp Installation Manual for the Martin Diesel MD10 Engine Controller WIRING INSTALLATION GUIDELINES Danger The controller does not generate a warning prior to engine start Do not work on the engine while power is applied to the unit It is recommended that warning signs be placed on engine equipment indicating the above INSTRUCTIONS Following these instructions will help avoid common installation problems during wiring and setup e Battery must be disconnected before any wiring connections are made e Wire length from the engine to the controller should not exceed 6 meters 20 feet e All failure inputs have a 3 second delay before shutdown occurs 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 TYPES AND SIZES 3 18 tina Oil pressure switch 3 18 7m Engine Temperature swih 4 18 7m SopwilayIpu 6 18 ioa Banery negi 0 3 10 S 0A Fused Auto GVb o 12 im Star input connection Grounded input only Operating amp Installation Manual for the Martin Diesel MD10 Engine Controller G3 OHddv 30 NMvMO S 1 N xwos A38 7 IST 00 anr oz ON OMG Fwa zzi SNOISN3NIG 3NTL
12. ing on the starter output The Starter output energizes for a 15 seconds period then proceeds to a rest period of 15 seconds After the rest period the engine controller cranks the engine again for a full 15 seconds This cycle continues until the engine has started or the user releases the start switch Once the speed goes above the crank disconnect setting the starter output turns off and the engine running LED turns on When Dip Switch 6 is in the OFF position the system works as follows When the Start Input activates the unit proceeds to turning on the starter output The Starter output energizes as long as the Start switch is left in the start position Once the speed goes above the crank disconnect setting the starter output turns off and the engine running LED turns on 3 Crank Disconnect calibration The Crank Disconnect potentiometer adjusts the speed at which the controller safely disengages the starter To adjust Crank Disconnect b Turn Over speed pot fully clockwise 20 turns c Turn Crank Disconnect pot fully clockwise 20 turns d Remove wire connected to Fuel terminal 11 Fuel Ignition For gasoline engines you may remove the wire from the spark plug e Initiate Cranking by applying a grounded signal to the Start terminal 10 f Turn Crank Disconnect pot counter clockwise until the green LED turns ON and Crank disengages engine will stall due to missing Fuel Ignition circuit Turn Crank Disconnect pot fully clockwis
13. itch settings Battery is low or terminals are dirty Engine does not crank Operating amp Installation Manual for the Martin Diesel MD10 Engine Controller
14. k Disconnect and Over speed settings The speed ranges are selectable from DIP switches 4 and 5 The speed sensing input will be compatible with Martin Diesel alternator signal which is as follows Cranking Specs 0 5Vrms 50Hz Running speed 8Vrms 325Hz NOTE To simplify installation all units will be pre calibrated pots and dip switches to the most common settings as follows Generator output speed range Dip Switch 4 amp 5 OFF Crank disconnect 20Hz Overspeed 70Hz Crank limiter OFF Dip Switch 6 OFF Generator output When using generator output coupled with a transformer 50 or 60 Hz speed range 1 is required Engine Alternator An engine alternator would require speed range 1 or 2 Refer to engine s specification for pulley ratio and number of poles before selecting range Operating amp Installation Manual for the Martin Diesel MD10 Engine Controller 12 Magnetic pickup A magnetic pickup would require speed range 2 The speed range settings are as outlined in the table below Crank Disconnect Hz Over speed Hz 2 Crank Limiter calibration Dip Switch 6 The Starter limiter feature provides a rest period for the starter system This feature protects against starter overheating and damaged batteries This Starter limiter can be either enabled or disabled by Dip Switch 6 When Dip Switch 6 is in the ON position the system works as follows When the Start Input activates the unit proceeds to turn
Download Pdf Manuals
Related Search