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TERMINAL DESCRIPTION 

 
 

 Term # 

Description 

CON1 

 

Speed signal input for crank disconnect, engine run, and over-speed sensing. Be 
sure to use twisted pair wiring for this connection. An 8-foot wiring harness is 
supplied as standard. 300 VAC max. input voltage.  

Lamp test. Conn12/24 VDC to lamp test activates all the front panel 
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 N.O. type, close on 

failure (low pressure) 

 3 

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 rest. 

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). 

RSC1, provided for the connection of one lead from the remote start contacts of 
the transfer switch (BROWN connection of 5-wire interconnect harness)

 

RSC2, provided for the connection of other lead from the remote start contacts 
of the transfer switch (GREEN  connection of 5-wire interconnect harness)

 

10 

(Start/Stop) terminal. When +12/24 VDC is applied, the controller proceeds to 
starting the engine.  

11 

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. 

12 

The Preheat/TDES output provides 300mA maximum. This output closes to 
+12/24 VDC when activated. 

13 

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. 

14 

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. 

15 

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.  

16 

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. 

Installation and User Manual for the ES53 Control Module         

 

Summary of Contents for ES53

Page 1: ...ES53 CONTROL MODULE Installation and User Manual for the ES53 Control Module File ES53rev1 31 doc March 1 2005 ...

Page 2: ...e 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 ES53 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...

Page 3: ...on 8 General Wiring Diagram 10 Outline Dimension Drawing 11 CONTROL MODULE OVERVIEW 12 ADJUSTMENTS AND SETUP PROCEDURES 13 Crank Disconnect calibration 13 Over speed calibration 14 Crank Rest time calibration 14 DIP SWITCH CONFIGURATION 14 LOGIC SEQUENCE 16 LED INDICATIONS 17 TROUBLESHOOTING GUIDELINES 18 Installation and User Manual for the ES53 Control Module ...

Page 4: ...e 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...

Page 5: ...rator AC output directly Speed sensing maximum rating Withstands Line voltage 300 V A C Operating temperature range 40 O C 85 O C Operating humidity range 0 95 non condensing Fuel Crank contact output 10 Amps max each Continuous Sourcing bat output Annunciation outputs Sourcing bat outputs 300ma max per output Lamp Test terminal Close to Battery to test LED s Actual unit weight 0 67 lb 0 30kg Ship...

Page 6: ...d wire since solid wire has a tendency to crack break and loosen over time TYPES AND SIZES Terminal Wire Size Current max Function CON 1 Harness supplied 100mA Speed signal connection via on board connector 1 18 100mA LED test switch 2 18 7mA Oil pressure switch 3 18 7mA High Temperature switch 4 18 7mA Auxiliary Input switch 5 14 10 A Starter solenoid pilot relay 6 12 20 A Battery negative 7 12 2...

Page 7: ...6 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 7 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 outpu...

Page 8: ...ndby 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 of the transfer switch BROWN connection of 5 wire interconnect harness 9 RSC2 provided for the connection of other lead from the remote start contacts of the transfer switch GREEN connection of 5 wire interconnect harness 10 Start Stop terminal Whe...

Page 9: ...ine stops Flashing output indicates Crank Rest period 18 Normal Disable to Transfer Switch WHITE connection of 5 wire interconnect harness 19 Emergency Disable to Transfer Switch RED connection of 5 wire interconnect harness 20 Ground connection to Transfer Switch BLACK connection of 5 wire interconnect harness Installation and User Manual for the ES53 Control Module ...

Page 10: ...10 General Wiring Diagram Installation and User Manual for the ES53 Control Module ...

Page 11: ...11 Installation and User Manual for the ES53 Control Module ...

Page 12: ...NE period AND provided the generator frequency has reached at least 55Hz 45Hz for a 50Hz system the transfer switch operator is actuated and the load is switched over to the generator power source On return of the normal source the controller waits for the preset TDEN time to elapse and then enables the transfer switch actuator to return the system load to the Utility After running unloaded for th...

Page 13: ...d ignored Potentiometers are shown below as they appear on the rear of the ES53 series units 1 Crank Disconnect 1 2 3 4 2 Over Speed 3 Crank Rest 4 Preheat TDES 1 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 b Turn Crank Disconnect pot...

Page 14: ...ngines 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 anothe...

Page 15: ... and TDEN function the DIP switch should be in the ON or UP position To disable the TDEC and TDEN function the DIP switch should be in the OFF or DOWN position DIP SWITCH 9 Not Used TIMER FUNCTIONS The following timers are included as standard in the ES53 one of which is adjustable Special time settings are available from the factory 1 TDES Time Delay Engine Start Adjustable from 0 to 32 Seconds T...

Page 16: ...upply NOTE If during the TDEN the utility falls out of the acceptable range again the control module simply returns to a normal operation state and will continue to watch for a return of the utility source and maintain operation from the generator When the TDEN has lapsed the control module proceeds to initiate transfer to the utility source The control module then proceeds to an engine cool down ...

Page 17: ...NT PANEL LED INDICATIONS 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 steady Low Oil Pressure Failure Low Oil flashing Auxiliary Input Failure High Temperature steady Over temperature Failure Over crank steady Engine would not start after specified Crank tries Over Speed steady Speed ...

Page 18: ... and check ignition connections Fuel relay damaged Check fuel relay and replace if damaged Engine starts but shuts down after Oil BypassTM period due to low oil high temp extra Oil temp extra input wiring improperly connected Check wiring for proper connections Fault short or overload on one of the annunciator outputs Check for fault once fault is corrected then operation resumes Crank disconnect ...

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