Cattron DYNAGEN ES52 User manual

ES52
User Manual

DynaGenTM ES52 - EN
User Manual
2
9M02-9253-A001-EN
Revision A
Revision History
VERSION
DATE
NOTES
2.10
08/2012
Improved crank disconnect procedure. Added VTS2 connection to technical
notes. Made other minor changes.
3.0
12/2015
Updated Troubleshooting note for flashing Over-speed. Updated technical
notes for 10A diode to apply only to EI, FE and LT (cooldown). Removed
reference to hour meter; not available on ES52. Updated wiring guidelines
section. Changed max temp in Specifications. Clarified that Aux Input is also
failure, as for Oil and Temp. Cleaned up Troubleshooting section on loss of
speed during cranking. Added new DynaGen logo. Changed wiring diagram to
clarify that Auto/Test switch is actually a switch. Clarified section on Test/RSC.
Reorganized remote start contacts and added section on pins 12 to 19 in I/O
table. Added 20A fuse blown to unit inoperable section in Troubleshooting.
4.0
08/2017
Added Zero Speed RestartTM feature to manual. Added default settings. Added
title page picture. Relabeled “Oil Switch Verification”. Added section to
Troubleshooting about unit not cranking. Added flashing Over-crank to LED
tables.
5.0
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 without notice.
Responsibility for the use and application of Cattron products rests with the end user since Cattron and its agents cannot be aware of all potential uses.
Cattron makes no warranties as to non-infringement nor as to the fitness, merchantability, or sustainability of any Cattron products for any specific
or general uses. 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. or one or more subsidiaries of Cattron Holdings, Inc. Cattron™, corresponding logos, and other marks
are
trademarks or registered trademarks of Cattron Holdings, Inc. Other marks may be the property of third parties. Nothing herein provides a license under
any Cattron or any third party intellectual property right.

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User Manual
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Revision A
Contents
1 Overview.............................................................................................................................................................4
1.1 Receipt of Shipment and Warranty Return Information ..........................................................................4
1.2 Limited Warranty .....................................................................................................................................4
1.3 DynaGen ES52 Support Webpage .........................................................................................................4
1.4 ES52 Specifications ................................................................................................................................4
2 Introduction.........................................................................................................................................................6
3 Wiring Installation Guidelines .............................................................................................................................7
3.1 Wire Sizing ..............................................................................................................................................7
3.2 Wiring Guidelines ....................................................................................................................................8
3.3 Terminal Descriptions .............................................................................................................................9
3.4 General Wiring Diagram .......................................................................................................................11
3.5 Adjustments and Setup Procedures .....................................................................................................12
3.5.1 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 Startup / Shutdown Behavior ......................................................................................................19
4.2 Zero Speed Restart Feature .................................................................................................................19
4.3 Oil Verification .......................................................................................................................................19
4.4 Front Panel LED Indications .................................................................................................................19
5 Troubleshooting Guidelines..............................................................................................................................21
6 Technical Notes on Frequently Asked Questions ............................................................................................24
7 Technical Support.............................................................................................................................................26

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User Manual
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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

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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)

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Revision A
2 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.
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, as follows:
•“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 can be disabled via an onboard Dip Switch. In some
cases when using the generator main power as the speed signal source, it 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: Onboard replaceable 20A fuse, mini-fuse (standard automotive type)
•Reverse Polarity Protection: No requirement for series diode on supply
•3.3 VDC to 30 VDC, -40ºC to +85ºC Operation: Works anywhere, anytime
•Zero Speed RestartTM: Prevents starter pinion wear by ensuring that no engagement of the starter is
possible unless the speed is Zero
•Oil BypassTM: 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; this requires no user setting
•Four Timer Functions: Glow Plug, Smart ChokeTM, Air-Gate and Slow
•Rest Time Indication: Provides feedback between crank attempts
•Warm Up: Turns on an output which can control a load device; Warm Up timer output is provided on all
ES52 units via Terminal 19 and Warm Up timer is fixed at 2 minutes
•Small Size: 3.302” x 3.342” x 1.842”; 0.67 lb

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Revision A
3 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.
Following these instructions will help avoid common installation problems during wiring and setup:
•Battery must be disconnected before any wiring connections are made
•Wire length from the engine to the controller should not exceed 6 m (20 ft)
3.1 Wire Sizing
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 12 20 A Battery Negative (-)
7 12 20 A Auto Switch
8 12 20 A RSC1 (Remote Start Contact Connection)
9 12 20 A RSC2 (Remote Start Contact Connection)
10 12 20 A Start/Stop Connection
11 14 10 A Fuel Solenoid/Pilot Relay
12 18 300 mA Timer Output
13 to 18 18 300 mA Annunciation Outputs
19 18 300 mA Warm up Output
20 18 300 mA Annunciator Common Ground Only
(DO NOT use this as main ground connection)
!

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3.2 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.
•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 the chassis (aluminum or iron engine parts) as a
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 the wiring connections
•DO NOT short the Crank output or Fuel outputs to ground, as this will cause the onboard 20A fuse to
blow and may result in damage to the ES52’s onboard relays
•When replacing the 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 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 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 the entire front panel LEDs continue to
operate. When the fault is removed and the unit is restarted, the output resumes proper
operation.
•Two wires must be connected for the speed signal
•Diodes are provided across Fuel, Crank, and Annunciation outputs, to protect the outputs from inductive
kick-back. Diodes should be placed across slave 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
•To verify the operation of engine controller outputs, measure voltage (i.e., set meter to read in volts)
when outputs should be ON
!

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3.3 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.
•Use two female 0.250” inch insulated female quick connects for the connection.
For MPU Sensor:
•One side of the MPU must both be grounded and connected to the controller,
otherwise erratic behavior can result.
Use a shielded MPU with a shielded cable grounded at one end only for best reliability.
1 Lamp test connecting +12/24 VDC to lamp test activates all the front panel LEDs.
Note: Annunciation outputs DO NOT activate under LED test.
2 Oil pressure input 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).
When active, it shuts down the engine.
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). 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 started, or during crank rest.
6 Battery ground connection for the controller module. A good ground connection, directly
from the battery, is required for proper operation.
7 Auto 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 - 9
Remote Start Contacts
RSC1 is tied internally to Auto (terminal 7) and RSC2 is tied internally to Start/Stop
(terminal 10), so when RSC1 and RSC2 are shorted, they bring the battery positive that is
at the Auto terminal to the Start/Stop terminal which causes the controller to start the
engine (see Start/Stop below) and provide power to the crank and fuel outputs.
This means the current for Crank output and Fuel output will pass through the remote
start contacts. The wiring and the remote device/switch must be rated for this current
draw. If this is a problem, then an external relay can be used. See the 25 section at the
end of this manual.

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Terminal # Description
10 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.
11 Fuel output provides 10A maximum. Fuel output closes to +12/24 VDC when start signal
is actuated, and it opens when either an engine failure is detected or when the stop signal
is applied.
12 Timer output has one of four possible functions (Glow Plug, Smart Choke, Air-Gate or
Slow). This output closes to +12/24 VDC when activated.
13 Low oil pressure 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 temperature output closes to +12/24 VDC when the engine shuts down due to a
high temperature condition.
15 Over-crank output 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 period.
18 Engine failure output activates on any failure (closes to +12/24 VDC when activated).
19 Warm up output turns on after the controller has been running for 2 minutes and 10
seconds. Output turns on immediately if battery voltage is applied to Start/Stop (terminal
10) and the speed is greater than the crank disconnect pot setting when the controller is
not cranking.
Note: Pins 12 to 19
The maximum rating of each output depends on how many outputs are on simultaneously on pins 12
to 19. Do not exceed these values:
1 on = 300 mA, 2 on = 230 mA, 3 on = 160 mA, 4 on = 123 mA, 5 on = 91 mA, 6 on = 80 mA,
7 on = 66 mA, 8 on = 52 mA
Good practice is to use 50% of the maximum rating.
20 Common ground for annunciation outputs only. DO NOT USE AS MAIN GROUND TO
CONTROLLER UNIT.