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Cattron DYNAGEN ES52, User Manual

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Cattron DYNAGEN ES52 User Manual Download Page 4

DynaGen

TM

 ES52 - EN 

User Manual 

 

 

 

 

 

 

 

4 

9M02-9253-A001-EN 

Revision A 

1 

Overview 

Please read this manual before installing the unit. 

1.1  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 Cattron.  
All returned items are to be shipped prepaid and include a Return Material Authorization (RMA) number issued 

by Cattron.  

1.2  Limited Warranty  

For warranty information, please refer to the standard terms and conditions of sale at 

www.cattron.com

. 

1.3  DynaGen ES52 Support Webpage 

For up-to-date manuals and other information, please visit 

www.cattron.com

. 

1.4  ES52 Specifications 

 

Parameter 

Specification 

Operating VDC Limits 

3.3 VDC min – 30 VDC max (provided minimum 8 VDC present at 

starting 

Standby Current Draw 

12.2 mA at 12 VDC (12.4 mA at 24 VDC)  

Operating Current Draw 

140 mA at 12 VDC (80 mA at 24 VDC) 

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  

J1113-11 Transients 

Pulse 1A (Supply Disconnect), Pulse 2A (Sudden Disconnect), Pulse 4 

(Starter Motor Engagement), Pulse 5 (Load Dump); details of the test 

parameters are available, please contact Cattron at 

www.cattron.com

 

Speed Sensing Input Accepts 

Generator AC output directly  
Fly Wheel Alternator  
Engine Alternator  
Magnetic Pickup  

Speed Sensing Maximum Rating 

Withstands line voltage up to 300 VAC  

Operating Temperature Range 

-40°C to +70°C 

Operating Humidity Range 

0 to 95% non-condensing  

Fuel & Crank Contact Output 

10A maximum each continuous sourcing (+Bat) output 

Annunciation Outputs 

Sourcing (+Bat) outputs (300 mA maximum per output)  

Lamp Test Terminal 

Close to +Bat to test LEDs 

Summary of Contents for DYNAGEN ES52

Page 1: ...ES52 User Manual ...

Page 2: ...04 2019 Added remote start contact relay to wiring diagram Improved Oil Verification section Clarified that 69 Hz 1080 Hz refers to Over speed not crank disconnect A 09 2021 Document rebranded and contact information updated B 09 2022 Updated branding information Any information furnished by Cattron and its agents is believed to be accurate and reliable All specifications are subject to change wit...

Page 3: ...Factory Settings 13 3 5 2 Selecting the Engine Speed Range 14 3 5 3 Low Oil Pressure Switch Verification 14 3 5 4 Selecting a Timer Function 15 3 5 5 Adjusting Timer Duration 16 3 5 6 Crank and Crank Rest 16 3 5 7 Selecting the Maximum Number of Crank Tries 16 3 5 8 Crank Disconnect and Over Speed Pot Adjustment 17 3 5 9 Loss of Speed During Cranking 17 3 5 10 Warm Up 18 4 Operation 19 4 1 ES52 St...

Page 4: ...ating VDC Limits 3 3 VDC min 30 VDC max provided minimum 8 VDC present at starting Standby Current Draw 12 2 mA at 12 VDC 12 4 mA at 24 VDC Operating Current Draw 140 mA at 12 VDC 80 mA at 24 VDC 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 J1113 11 Transients Pulse 1A ...

Page 5: ...ser Manual 5 9M02 9253 A001 EN Revision A Parameter Specification Actual Unit Weight 0 67 lb 0 30 kg Shipping Weight 1 lb 0 45 kg Unit Dimensions 3 302 x 3 342 x 1 8 Shipping Dimensions 4 10 16 cm x 4 10 16c m x 3 7 62 cm ...

Page 6: ... is required to disable this shutdown when the 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 onboard sockets relays rated 20A at 30 VDC Replaceable Fuse Onboar...

Page 7: ...zing Wiring size and type should be as specified below Use stranded wire since solid wire tends to crack break and loosen over time Terminal Wire Size Current max Function CON 1 18 100 mA Speed signal connection via onboard connector 1 18 100 mA LED Test Switch 2 18 7 mA Oil Pressure Switch 3 18 7 mA High Temperature Switch 4 18 7 mA Auxiliary Input Switch 5 14 10 A Starter Solenoid Pilot Relay 6 ...

Page 8: ... coil rating Note All ES52 engine controllers are shipped standard with 12 VDC coil relays for 12 VDC systems If the engine controller is used in a 24 VDC system the onboard relays MUST be replaced with 24 VDC coil relays DO NOT exceed the maximum rated current and voltage on each of the controller outputs Do not exceed 10A for the Fuel output 10A for the Crank output and 300 mA for the Annunciati...

Page 9: ... N O type close on failure high temperature When active it shuts down the engine 4 Auxiliary input for proper operation auxiliary 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 When active it shuts down the engine 5 Crank output provides 10A maximum Crank output closes to 12 24 VDC during cranking and opens when the engine has s...

Page 10: ...closes to 12 24 VDC when the engine shuts down due to an Over crank failure 16 Over speed output closes to 12 24 VDC on an Over speed failure and is open otherwise Flashing output indicates Loss of Speed Signal 17 Engine running output closes to 12 24 VDC when the engine speed is greater than the crank disconnect setting and it opens when the engine stops Flashing output indicates Crank Rest perio...

Page 11: ... ES52 Controllers come with 12 VDC Relays for 12V systems For 24V systems replace with 24VDC Relays ES52 Variant Note A diode across Auto and Start Stop terminals is required on versions of the ES52 with the Cool Down feature ES52 EI FE and LT variants See the 24 section at the end of this manual for further information The standard ES52 version does not require this Figure 1 Wiring Diagram ...

Page 12: ...viated as pots throughout this document and nine DIP switches Potentiometer Pot Adjustment To increase a pot s setting turn it clockwise To decrease it turn it counterclockwise Onboard pots are 20 turns nominal therefore turn pots fully 20 turns to ensure that you are at either the minimum or maximum setting Each pot has a clutch to protect from overturning and thus potentially requires one to two...

Page 13: ...0 Hz Crank Disconnect in low or high speed mode respectively 10 s Crank Crank Rest 10 s Timer output Timer set to preheat functionality DIP switches 1 and 2 ON all others OFF CRANK TRIES S1 S2 S3 off on off off on on on on on Enabled on on 1 2 3 4 5 6 setup off on on on TIMER SPEED SETTING off off S4 S5 Slow Choke single crank attempt 4 to 256 sec Range on on off off lo hi CRDC OVSP 12 140 44 300 ...

Page 14: ...es 240 Hz Engine alternator An engine alternator would require speed range 1 LO or 2 HI Refer to the engine s specification for pulley ratio and number of poles before selecting the range Magnetic pickup When using a magnetic pickup speed range 2 HI is required Selection of the proper engine speed range is summarized in the following table Range SW 4 SW 5 Crank Disconnect Hz Over Speed Hz 1 LO OFF...

Page 15: ...hoke The choke function is used on gasoline engines having an electric choke The choke output is energized 2 5 seconds into the cranking cycle but only on even numbered Crank attempts exception single crank attempt mode allows choke If the engine speed remains above the Crank Disconnect setting Choke output is turned off but as soon as the speed falls below Crank Disconnect it is re applied This O...

Page 16: ...es to the Timer terminal 12 and the Crank terminal 5 For the Slow setting DIP switches 7 and 8 ON 1 Apply power to Start Stop terminal 10 2 Allow the engine to Crank and start the Engine Running LED turns ON 3 The Timer LED will illuminate measure the time that this LED remains ON 4 Increase or decrease pot setting as required The pot resolution is 12 8 seconds turn 5 Return to step 1 as needed 3 ...

Page 17: ...ator If you do not have one you can adjust the pots knowing the factory defaults and the Hz turn numbers provided above 3 5 9 Loss of Speed During Cranking 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 Loss of speed is defined as no speed signal for at least 3 seconds Loss of speed begins 3 seconds into th...

Page 18: ...rs 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 for example allowing a generator to warm up before connecting the load ...

Page 19: ...or 30 to 40 seconds and then go into failure alternating Over crank and Over speed LEDs flashing 4 3 Oil Verification If Low Oil verification is enabled DIP Switch 6 ON and the low oil pressure switch fails verification the controller will remain in crank rest after the first crank attempt until the oil switch passes verification During this time the low oil pressure lamp will be on solid red The ...

Page 20: ...ranking Was engine Running No speed signal available while cranking The speed signal was zero while running for 3 seconds 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 No other lights ON Low oil pressure light ON Crank rest period cranking will resume soon Oil verification failed see Low Oil ...

Page 21: ... to ensure that controller is set to proper speed range using DIP switches 4 and 5 Engine does not crank Check crank output and start sequence logic Disconnect wire from terminal 5 and confirm battery voltage on terminal when cranking Sequence should be timer amber Timer LED if enabled crank crank rest flashing Run LED and then repeat this for the set crank attempts If it follows the above sequenc...

Page 22: ...timer output do not activate Timer pot set to zero Increase timer pot setting turn pot clockwise Timer LED works OK but timer output does not activate Fault short or overload on timer output Check for fault once fault is corrected then output operation resumes Flashing Over speed LED indicates loss of speed signal Speed signal improperly connected missing or damaged Check speed signal wiring repla...

Page 23: ...ller This problem can sometimes occur in installations where there is AC power from inverters near generator output lines connected to the speed signal cable Avoid running AC lines from inverter in same conduit as generator output lines Install a small step down transformer between the speed sensing wires and the generator output If the neutral from the generator output is not grounded then attach...

Page 24: ...s 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 Over speed LED By leaving the ES52 OFF for 10 seconds before it is returned to the Auto setting the memory will be cleared and the unit will function as intended 3 Step Down Transformer Use on Speed Sensing Cable with Inverter Systems I...

Page 25: ...mer 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 4 Connecting ES52 to a Transfer Sw...

Page 26: ...TM ES52 EN User Manual 26 9M02 9253 A001 EN Revision A 7 Technical Support For remote and communication control systems support parts and repair or technical support visit us online at www cattron com contact ...

Page 27: ...vided in this document is subject to change without notice Cattron Wireless Automation and Control Solutions Support For remote and communication control systems support parts and repair or technical support visit us online at www cattron com contact Cattron North America Inc 655 N River Rd NW Suite A Warren OH 44483 ...

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