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Cattron DYNAGEN ES52 User Manual

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Summary of Contents for Cattron DYNAGEN ES52

  • Page 1 ES52 User Manual...
  • Page 2 Cattron Holdings, Inc., or any of its affiliates or agents shall not be liable for incidental or consequential damages of any kind. All Cattron products are sold pursuant to the Terms and Conditions of Sale, a copy of which will be furnished upon request. When used as a tradename herein, Cattron means Cattron Holdings, Inc.

  • Page 3: Table Of Contents

    User Manual Contents Overview ................................4 Receipt of Shipment and Warranty Return Information ................4 Limited Warranty ............................. 4 DynaGen ES52 Support Webpage ......................4 ES52 Specifications ..........................4 Introduction ................................. 6 Wiring Installation Guidelines ..........................7 Wire Sizing .............................. 7 Wiring Guidelines ............................

  • Page 4: Overview

    All returned items are to be shipped prepaid and include a Return Material Authorization (RMA) number issued by Cattron. Limited Warranty For warranty information, please refer to the standard terms and conditions of sale at www.cattron.com. DynaGen ES52 Support Webpage For up-to-date manuals and other information, please visit www.cattron.com.
  • Page 5 DynaGen ES52 - EN User Manual 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) 9M02-9253-A001-EN Revision A...

  • Page 6: Introduction

    DynaGen ES52 - EN User Manual 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 is one of the smallest controllers available, with the best value per dollar- cost, backed by an industry leading five-year or 17,500-hour warranty.

  • Page 7: Wiring Installation Guidelines

    DynaGen ES52 - EN User Manual Wiring Installation Guidelines WARNING THE CONTROLLER DOES NOT GENERATE A WARNING PRIOR TO AUTOMATIC ENGINE START. DO NOT WORK ON THE ENGINE WHILE POWER IS APPLIED TO THE UNIT. IT IS HIGHLY RECOMMENDED THAT WARNING SIGNS BE PLACED ON THE ENGINE EQUIPMENT INDICATING THE ABOVE.

  • Page 8: Wiring Guidelines

    DynaGen ES52 - EN User Manual Wiring Guidelines WARNING DO NOT APPLY EXTERNAL VOLTAGE TO ANNUNCIATOR OUTPUTS (TERMINALS 13 TO 18). THIS WILL DAMAGE THE ES52. IF THIS MAY OCCUR IN YOUR APPLICATION, PLACE A DIODE IN SERIES WITH EACH AFFECTED ANNUNCIATOR OUTPUT. •...

  • Page 9: Terminal Descriptions

    DynaGen ES52 - EN User Manual Terminal Descriptions Terminal # Description CON1 (Speed) Speed signal input for crank disconnect, engine run, and Over-speed sensing. Generator output, magnetic pickup (MPU) sensor, or alternator output can be used. • Use at least twisted pair wiring for this connection. Polarity does not matter.
  • Page 10 DynaGen ES52 - EN User Manual Terminal # Description Start/Stop when +12/24 VDC is applied, the controller is powered and proceeds to start the engine. The power for the crank output and fuel output is obtained from this terminal. If the 20A fuse is blown, then the ES52 will not start. Fuel output provides 10A maximum.

  • Page 11: General Wiring Diagram

    DynaGen ES52 - EN User Manual General Wiring Diagram Please see the following figures for the wiring diagram (Figure 1) and dimensions (Figure ATTENTION: All 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).

  • Page 12: Adjustments And Setup Procedures

    DynaGen ES52 - EN User Manual Figure 2: Dimensions Adjustments and Setup Procedures WARNING THE FOLLOWING PROCEDURES WILL REQUIRE ENGINE OPERATION. BE SURE TO FOLLOW ALL SAFETY GUIDELINES AND WIRING PROCEDURES. The rear of the ES52 controller contains four adjustable potentiometers (abbreviated as “pots” throughout this document and nine DIP switches.

  • Page 13: Factory Settings

    DynaGen ES52 - EN User Manual Potentiometers are shown in Figure 3 as they appear on the rear of the ES52 series units. Figure 4 shows the label on the rear of these units. 1 – Crank Disconnect 2 – Over-Speed 3 –...

  • Page 14: Selecting The Engine Speed Range

    DynaGen ES52 - EN User Manual The steps to calibrate the ES52 controller to a specific system are as follows: 1. Select the Engine Speed Range (DIP switches 4 and 5). 2. Low Oil Pressure Switch Verification – verify the low oil pressure switch is enabled or disabled (DIP switch 6).

  • Page 15: Selecting A Timer Function

    DynaGen ES52 - EN User Manual Note that if this verification was not performed, a ‘bad connection’ of the oil switch might go unnoticed until such time as the oil runs out and engine damage occurs! Note: Oil circuit verification is only performed under the following conditions: a.

  • Page 16: Adjusting Timer Duration

    DynaGen ES52 - EN User Manual SW 7 SW 8 Timer Function Adjustable Time Glow Plug 0 - 32 seconds Air-gate Not Adjustable (fixed at 10 s) Choke Not Adjustable Slow 0 - 256 seconds 3.5.5 Adjusting Timer Duration This section applies to the Glow Plug and Slow timer functions only, as Air-gate and Choke do not use pots. The Glow Plug is adjustable from 0 - 32 seconds;...

  • Page 17: Crank Disconnect And Over-Speed Pot Adjustment

    DynaGen ES52 - EN User Manual Crank Attempts Switch 1 Switch 2 Switch 3 Time Range SETUP 4 - 36 sec 4 - 36 sec 4 - 36 sec 4 - 36 sec 4 - 36 sec 4 - 36 sec 4 - 36 sec 4 - 256 sec 3.5.8 Crank Disconnect and Over-Speed Pot Adjustment...

  • Page 18: Warm Up

    DynaGen ES52 - EN User Manual 3.5.10 Warm Up A Warm-up timer is provided on all ES52 series engine controllers. 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).

  • Page 19: Operation

    DynaGen ES52 - EN User Manual Operation ES52 Startup / Shutdown Behavior Note: The fuel output remains on during crank rest. There is no way to disable this. Zero Speed Restart Feature The ES52 has a starter protection feature where it will not turn on the crank output until the engine speed is zero. •...
  • Page 20 DynaGen ES52 - EN User Manual What The LEDs Look Like Condition / Failure Low Oil, steady No other lights ON? Low Oil Pressure Failure Is Engine Running Flashing? Oil switch is not closed (mis-wired or not installed); engine will crank when oil switch verifies Low Oil, flashing Auxiliary Input Failure...

  • Page 21: Troubleshooting Guidelines

    DynaGen ES52 - EN User Manual Troubleshooting Guidelines Trouble Possible Cause Suggested Action Over-crank LED flashing Unit is in setup mode; all DIP Set the DIP switches properly switches are ON All DIP switches are not ON The unit is damaged; replace it Unit does not operate;...
  • Page 22 DynaGen ES52 - EN User Manual Trouble Possible Cause Suggested Action Engine starts but shuts Oil/temp/aux input wiring Check wiring for proper connections down after Oil Bypass improperly connected period due to low oil/high temperature/auxiliary input Engine starts but Running Improper speed range setting Check to ensure that controller is set to LED does not illuminate...
  • Page 23 DynaGen ES52 - EN User Manual Trouble Possible Cause Suggested Action Solid Oil LED immediately False speed signal being Avoid running AC lines from inverter in on start-up, without engine detected by controller. This same conduit as generator output lines actually cranking or starting problem can sometimes occur Install a small step-down transformer...

  • Page 24: Technical Notes On Frequently Asked Questions

    DynaGen ES52 - EN User Manual Technical Notes on Frequently Asked Questions 1. 10A Diode on Auto/Off/Test Switch on All Units with Cool-Down Feature ONLY! (EI, FE, and LT variants) This tech note does NOT apply to standard ES52 units. When using a single switch for auto/off/test on any ES52 series controller that has the cool-down feature,...
  • Page 25 DynaGen ES52 - EN User Manual 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.

  • Page 26: Technical Support

    DynaGen ES52 - EN User Manual Technical Support For remote and communication control systems support, parts and repair, or technical support, visit us online at: www.cattron.com/contact. 9M02-9253-A001-EN Revision A...
  • Page 27 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 9M02-9253-A001-EN Revision A...

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