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DynaGen

ES52 - EN

User Manual

9M02-9253-A001-EN

Revision A

Trouble

Possible Cause

Suggested Action

Engine starts but shuts

down after

Oil Bypass

period due to low oil/high

temperature/auxiliary input

Oil/temp/aux input wiring

improperly connected

Check wiring for proper connections

Engine starts but Running

LED does not illuminate

Improper speed range setting

Check to ensure that controller is set to

proper speed range (using DIP switches

4 and 5)

Fault (short or overload) on

one of the annunciator

outputs

Check for fault; once fault is corrected,

then operation resumes

Crank disconnect pot set too

high

Decrease crank disconnect pot setting

Annunciation output not

working

Fault (short or overload) on

one of the annunciator

outputs

Check for fault; once fault is corrected,

then annunciation operation resumes

Timer LED and 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; replace

damaged speed signal source

Crank output damaged, not

working

Check wiring and replace controller

Starter or starter solenoid

damaged

Replace/repair damaged starter or starter

solenoid

Engine stalled

Check fueling

Flashing Over-speed using

generator output during

cranking

Not enough residual voltage

during cranking

Set DIP switch 9 to OFF

Alternating flashing of Over-

speed and Over-crank

Crank disconnect set too high

Check crank disconnect

Wrong speed range

Check speed range

Flashing Run LED and solid

Oil LED

Oil switch not closed as it

should be

Check oil switch wiring

Turn DIP switch 6 OFF to disable oil

verification

Содержание DYNAGEN ES52

Страница 1: ...ES52 User Manual ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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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