Dynagen ES52 Manual
Contents
1. TROUBLESHOOTING GUIDELINES TROUBLE POSSIBLE CAUSE SUGGESTED ACTION Unit does not operate when Power leads to unit are reversed Confirm correct wiring for ground and bat Bad ground connection from engine to Run wire directly from battery to the value Improper speed range setting Check to ensure that controller is set to proper speedrange Op OWA Crank circuitry wiring improperly Refer to engine control wiring section and controller ground terminal 6 on controller unit Crank relay damaged Or on board fuse 1 Check wiring on board 20A fuse and relay blown Replace fuse relay and re test controller Ignition control wiring not installed Refer to engine control wiring section and Fuel relay damaged Check fuel relay and replace if damaged Oil temp extra input wiring improperly Check wiring for proper connections connected proper speed range DIP switches 4 5 Fault short or overload on one of the operation resumes annunciator outputs Fault short or overload on one of the annunciator outputs annunciation operation resumes annunciator outputs annunciation operation resumes clockwise Fault short or overload on timer output output operation resumes Speed signal improperly connected Check speed signal wiring replace missing or damaged damaged speed signal source Engine starts and immediately goes into Over speed shutdown Engine does not crank Engine cranks but does not start Engine starts bu2. 988 L 92 2 18 ZOTE 988Z Operating amp Installation Manual for the ES52 Engine Controller 12 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 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 The rear of the ES52 controller contains four adjustable pots and nine DIP switches 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 Potentiometers are shown below as they appear the rear of the ES52 series units 1 Crank Disconnect 2 Over Speed 3 Crank Rest Time 4 Timer time CRANK TRIES SPEED SETTING 51 2 3 s4 55 Fange CRDC OVSP TIMER on on setup off 12 140 44 300 off on hi 60 4156 300 8492 957 58 Setting off on CRDC Crank Disconnect Hz off Glow Plug off off on OVSP Overspeed Hz nl offl 56 VERIFICATION onjo rg
3. Note If unit is configured for Generator Output there may not be enough residual voltage during cranking The following values are minimal recommended voltages for speed signal 20 HZ 075 75mV 60 HZ 6V 600mV 4500 HZ 8V 800 mV Operating amp Installation Manual for the ES52 Engine Controller 17 8 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 power to Start Stop 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 Start Stop terminal 10 d Turn Over speed pot to required setting Resolution is 12 8 HZ turn in speed range 1 LO and 409 6 HZ turn in speed range 2 HI 9 SELECTING THE MAX NUMBER OF CRANK TRIES The Crank tries are adjustable from DIP switch positions 1 2 and 3 Select the 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 4 36 sec 10 WARMUP A Warmup timer is provided on all ES52 series engine controllers Terminal 19 is the Warmup 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 Warmup output turns
4. TECHNOLOGIES INC DynaGan 52 Auto Start Engine Controller Installation and User Manual for the ES52 Auto Start Engine Controller Full Version File ES52rev2 63 doc October 24 2006 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 RMA forms are available by contacting DynaGen Technical Support through the contact methods listed below Limited Warranty DynaGen will repair or replace any ES52 controller which proves 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 We welcome your comments and suggestions Please contact us at DynaGen Technologies Inc Phone 1 888 396 2436 902 562 0133 Fax 902 567 0633 Email support dynagen ca WEB SITE www dynagen ca Operating amp Installation Manual for the ES52 Engine Controller Table of Contents INTRODUCTION SPECIFICATIONS WIRING INSTALLATION GUIDELINES Wiring instructions t
5. b Turn Crank Disconnect pot fully clockwise 20 turns c Remove wire connected to Fuel terminal 11 Fuel Ignition For gasoline engines you may remove the wire from the spark coil d Initiate Cranking by applying power to Start Stop terminal 10 e Turn Crank Disconnect pot counter clockwise until the green LED turns ON and Crank disengages engine will stall due to missing Fuel Ignition circuit f Remove power from Start Stop terminal 10 g Reconnect wire to Fuel terminal 11 Fuel Ignition or reconnect spark coil wire The resolution is 6 4 HZ turn in speed range 1 LO and 204 8 HZ turn in speed range 2 HI Note To proceed to STEP 9 you must ensure the controller positively detects engine start up If the running LED turns on momentarily and engine stalls loss of speed flashing Over speed try decreasing the Crank Disconnect pot counter clockwise one half turn 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
6. b Apply power to Start Stop terminal 10 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 5 SETUP MODE CALIBRATION Setup mode allows for much easier calibration of Over speed Crank Disconnect and Crank Rest time When the unit is removed from Setup Mode the Over speed and Crank Disconnect pot settings will be increased by 15 of calibrated values NOTE If setup mode is used skip to page 17 To enter Setup Mode Set DIP switches 1 2 amp 3 to the ON position During setup mode the following conditions apply e Crank time defaults to present potentiometer value The maximum crank time is 36 seconds e Crank Rest calibration Apply power to Auto and over crank LED will flash The time between flashes indicates the Crank Rest time Adjust pot accordingly to increase or decrease Crank Rest time e Crank Disconnect and Over speed pot calibrat
7. 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 governor to go slowly for such applications as irrigation pumps where running slowly for the first minute or two prevents water hammer The timer settings are as specified in the following table Adjustable Time Glow Plug 0 32 seconds Not Adjustable 10 sec Not Adjustable 0 256 seconds Operating amp Installation Manual for the ES52 Engine Controller 15 4 ADJUSTING TIMER 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
8. Engine Controller Operating VDC limits Standby current draw Operating current draw Reverse polarity protected 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 SPECIFICATIONS 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 Generator AC output directly Withstands Line voltage 300 V A C 40 gt 85 9 0 95 non condensing 10 Amps max each continuous sourcing bat output Sourcing bat outputs 300ma max per output Close to Battery to test LEDs 0 67 Ib 0 30kg 11 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 WIRING INSTALLATION GUIDELINES Danger Never work on the engine while its power is on This controller does not generate a warning signal prior to automatic engine start Warning signs should be placed on engine equipment indicating this important safety measure INSTRUCTIONS Following these instruc
9. can be disabled via an on board jumper In some cases when using generator mains as speed signal source it is require 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 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 30 40 to 85 c operation Works anywhere anytime Zero Speed Restart Prevents starter pinion wear by ensuring that no engagement of the starter is possible unless the speed is zero 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 Four Timer Functions Glow Plug Smart Choke Air Gate and Slow Rest Time indication Provides feedback between crank attempts WARMUP Turns an output on which can control a load device Warmup timer output is provided on all ES52 units via terminal 19 Warmup timer is a fixed 2 minutes SMALL SIZE 3 302 x 3 342 x 1 842 0 67165 Operating amp Installation Manual for the ES52
10. off off on Enabled off on Choke on off off off Disabled off off off single crank attempt 4 to 256 sec Slow e a S9 on Enabled off Disabled NOA OO Label on Rear of ES52 series units Operating amp Installation Manual for the ES52 Engine Controller 13 The steps for calibration of the ES52 controller to a specific system are as follows 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 Selecting Setup Mode DIP switches 1 2 amp 3 Crank rest time calibration Crank Disconnect calibration Over speed calibration Selecting the maximum number of Crank Tries DIP switches 1 2 amp 3 1 SELECTING THE ENGINE SPEED RANGE Two speed ranges are provided to permit greatest accuracy 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
11. off This Warmup output can be used to control a load device which allows a generator to warmup before connecting the load Operating amp Installation Manual for the ES52 Engine Controller LED INDICATIONS FRONT PANEL LED INDICATIONS What the LED s look like Condition Failure 12 24 VDC to Auto terminal 18 Over crank steady Over Speed steady Over speed flashing Was engine Cranking Was engine Running Engine would not start after specified Crank tries Speed Signal present above Over Speed setting No speed signal available while Cranking The speed signal was Zero while running The engine has stalled or the speed signal has been lost Engine Running steady 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 Is Engine Running LED ON Is the engine Cranking If the engine is not cranking or running Low Oil steady while Engine Running Flashing 10 second Air gate timer Slow timer feature pot adjustable Choke feature Glow Plug timer feature pot adjustable Oil switch is not closed miss wired or not Installed Engine will crank when oil switch verifies Over speed and over crank LED s flash alternately Invalid speed range check DIP switches 4 amp 5 Crank disconnect set too high Operating amp Installation Manual for the ES52 Engine Controller
12. 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 10 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 TERMINAL DESCRIPTION CONI Speed signal input for crank disconnect engine run and over speed sensing sure to use twisted pair wiring for this connection An 8 foot wiring harness is supplied as standard 300 VAC max input voltage LED s NOTE Annunciation outputs DO NOT activate under led test Oil pressure switch For proper operation oil input must be connected to ground or 12 24 VDC via an oil switch This switch must be the 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 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 10A maximum Crank output closes to 12 24 VDC during cranking and opens when the engine has started or during crank res
13. speed output closes to an 12 24 VDC on an Over speed failure and is open otherwise Flashing output indicates Loss of Speed Signal 1 Engine running output provides 300mA maximum Engine Running output closes to 12 24 VDC when the engine starts speed gt crank disconnect setting and opens when the engine stops Flashing output indicates Crank Rest period 1 2 3 4 5 7 10 11 12 13 14 15 16 7 Operating amp Installation Manual for the ES52 Engine Controller Engine failure output provides 300mA maximum Engine failure output activates on any failure closes to 12 24 VDC when activated 19 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 Operating amp Installation Manual for the ES52 Engine Controller General Wiring Diagram ATTENTION 10 All ES52 Controllers come with 12VDC Relays for 12V systems For 24V systems replace with 24VDC Relays STARTER OR STARTER AUTOIOFF TEST SOLENOID E FUEL SOLENOID TEST ____ REMOTE START AND OR 77 contacts IGNITION eD 777 AUTO TIMER RELAY 2 2 2 2 2 5885 lt wo noo SES CRANK FUEL AUXILIARY SWITC
14. 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 Range SW4 SWS Crank Disconnect Hz Over speed Hz 1 LO 12 140 Hz 44 300 Hz Selecting the Proper Speed Range 2 OIL SWITCH VERIFICATION 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 assume 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 starts the controller will check for a Low Oil failure condition only after the Oil Bypass period Notice that if this verification was not performed a bad connection of the oil switch might go unnoticed until such time as oil ru
15. 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 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 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 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 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 Diodes should be placed across slave
16. H HIGH WATER gt gt es pig act TEMP SWITCH AUXILIARY Sh JIT ai HIGH TEMP 20 FUSE Low qH LED TEST Dp LOW OIL LOW OIL PRESS LAMP Oh ADJUSTMENT POTS HIGH TEMP HIGH WATER TEMP LAMP l LOW OIL CRANK DISC OVERCRANK OVERCRANK LAMP J PRESSURE OVERSPEED OVERSPEED OVERSPEED LAMP l SWITCH CRANK REST e HBBE ENGINE RUN ENGINE STARTED LAMP TIMER FAILURE COMMON ALARM LAMP b SPEED WARMUP SIGNAL COMMON CONNECTOR LAMP TEST PUSHBUTTON SWITCH SPEED SIGNAL BATTERY ES52 GENERAL WIRING DIAGRAM k WARMUP RELAY Operating amp Installation Manual for the ES52 Engine Controller 11 imensions ES52 Outline D NOWWOS aanlivd lt S 0 MBL 153 9 ANYYI S 6109 LNaWLSNray zO asna voz iS 0 Nao QOSSVNOD gt gt 5 g lt S 8 YOLOANNOD TWNOIS 93345 1531 031 MOT 2781 0290 2 1 X 58 9 VEE 98 0 IESE
17. e was connected directly to generator output before Operating amp Installation Manual for the ES52 Engine Controller CALIBRATED TIMER CR REST CR DISCONNECT OVERSPEED CRANK TRIES Operating amp Installation Manual for the ES52 Engine Controller 22
18. he 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 21 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
19. ion apply power to Start Stop Follow procedure outlined in Step 7 Crank Disconnect Calibration and Step 8 Over Speed Calibration e Choke and Slow Timer functions are disabled e On completion reset DIP switches 1 2 amp 3 to give desired crank tries Operating amp Installation Manual for the ES52 Engine Controller 16 6 Crank Rest Time Calibration The Crank Rest Time pot controls the maximum allowable cranking time per Cranking attempt as well as the rest time between Crank attempts it is adjustable from 4 to 36 seconds Note The rest time only begins when engine speed reaches zero To adjust Crank Rest time a Apply power to Auto terminal 7 b Remove wire connected to Fuel terminal 11 Fuel Ignition For gasoline engines you may remove the wire from the spark plug c Initiate Cranking by applying power to Start Stop terminal 10 d Measure the Amount of time the starter remains engaged Turn pot clockwise to increase the resolution is approx 1 6 seconds per turn After the starter turns off the unit enters crank rest mode indicated by flashing running LED e Remove power from Start Stop terminal to prevent another start Re calibrate pot and repeat step c to confirm proper setting 7 Crank Disconnect Calibration The Crank Disconnect potentiometer adjusts the speed at which the controller safely disengages the starter To adjust Crank Disconnect a Turn Over speed pot fully clockwise 20 turns
20. ns out and engine damage occurs Operating amp Installation Manual for the ES52 Engine Controller Note i ii 14 Oil circuit verification is only performed a On the first Cranking attempt b If the engine has been previously running and more than 5 minutes of rest has elapsed 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 Oil switch verification OFF 3 SELECTING A TIMER FUNCTION 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 is used on gasoline engines having an electric choke The choke output is energized 2 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 Oil Bypass
21. nsing 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 20 TECHNICAL NOTES ON FREQUENTLY ASKED QUESTIONS 1 10A Diode On Auto Off Test Switch On All Units With Cool Down Or Energize To Stop Feature 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 Diode Connections For Using Auto OffiTest Switch TestManual To start stop terminal 10 104 diode with band pointing towards auto Off y lt To auto terminal 7 3 switch 2 Controller Memory Clear Time T
22. t Battery ground connection for the controller module A good ground connection directly from the battery is required for proper operation 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 RSC 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 Start Stop terminal When 12 24 VDC is applied the controller proceeds to starting the engine Fuel output provides 10A 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 Slow Air gate Choke This output 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 water 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
23. t shuts down after Oil Bypass period due to low oil high temp extra Engine starts but running LED does not illuminate Annunciation output not working Annunciation output not working Timer LED and timer output does not activate Timer LED works but timer output does not activate Flashing Over speed LED Flashing Over speed LED using Generator output Alternating flashing of over speed amp over crank Flashing run LED amp solid oil LED Crank output damaged not working Check wiring and replace controller Starter or starter solenoid damaged Not enough residual voltage during cranking Crank disconnect set too high 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 Check crank disconnect Check speed range Oil switch not closed as it should be Solid oil LED immediately on start up without engine actually cranking or starting 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 small step down transformer between the speed se
24. the 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 12 secondary Step Down Transformer controller winding Prd To Generator Output Line Neutral 120 AC Speed sensing cabl
25. tions 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 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 CON 1 Harness 100mA Speed signal connection via on board Supplied connector Oil Pressure Switch Auxiliary Input Switch 14 Starter Solenoid PilotRelay 12 20A i Battery negative 12 20A RSCI remote start contact connection 9 12 20A 5 2 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 1 WIRING GUIDELINES DO NOT use wire smaller than 18 AWG 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 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
26. ypes and sizes Wiring guidelines Terminal description General Wiring Diagram Outline Dimension Drawing ADJUSTMENTS AND SETUP PROCEDURES Select the engine speed range Oil switch verification oil switch enabled or disabled Select a timer function Adjusting Timer setting Setup Mode Calibration Crank Rest time calibration Crank Disconnect calibration Over speed calibration Select the maximum number of Crank Tries Warmup LED INDICATIONS TROUBLESHOOTING GUIDELINES Operating amp Installation Manual for the ES52 Engine Controller 1 12 13 14 15 15 16 17 17 17 18 19 INTRODUCTION 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 a 3 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
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