Controls C3-G8386 User manual

Product Manual
Engine Display & Control Panel
J1939 Engines
Part Number: C3-G8386
Revision: 1.0
______________________________________________________________________________________________________________________________________
Copyright Controls, Inc.
P.O. Box 368 • Sharon Center, OH 44274
Phone [phone] • Fax [phone] • www.controlsinc.com

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TABLE OF CONTENTS
PRIOR TO STARTING ENGINE…….……………………………………………………………………….……………….………..……...2
THROTTLE SETTINGS
CLUTCH CONTROL
CAN BUS SETTINGS
PANEL OPERATION………..…....………………………………………….………………………………………….………………............4
ENGINE START
ENGINE STOP
THROTTLE CONTROL
MODULE CONNECTORS………………………………….…………………………………………………………….……………………………5
PRIMARY 14 PIN MODULE CONNECTOR
SECONDARY 23 PIN MODULE CONNECTOR
PANEL CONNECTORS……………....………………………………………………...…………………………………………………………….…7
ENGINE HARNESS CONNECTOR 21 PIN
WIRES PROVIDED FOR CUSTOMER INSTALLATION
ENGINE ALARMS, CODES AND MESSAGES……………………………………………………………………………......……...8
ENGINE ECU ALARMS/DE-RATE/SHUT DOWNS
PANEL ALARM ANNUNCIATION AND CODE READER
PANEL INDICATION LAMPS
ACTIVE AND STORED ENGINE ECU CODES
CONTROL PANEL SPECIFIC ALARMS AND SHUT DOWNS……………………………………….………….……10
CONTROL PANEL SPECIFIC SAFETY ALARMS
CONTROL PANEL ANALOG AND DIGITAL INPUTS………………………………………………………………………11
ANALOG INPUTS
DIGITAL INPUTS
ANALOG INPUT OPTIONS
DIGITAL INPUT OPTIONS
CONTROL PANEL RELAY OUTPUTS…………………………………………………………………..………………………….......…14
RELAY OUTPUTS
RRELAY OUTPUT OPTIONS
CLUTCH CONFIGURATION………………………………………………………………………………………………………...……………17
MENU SYSTEM……………………………………………………………………………………………..…………………………………..…….……18
MENU ACCESS, EXIT AND NAVIGATION
MENUS TO VIEW INFORMATION
MENUS TO CONFIGURE MODULE SETTINGS

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PRIOR TO STARTING ENGINE
Prior to starting the engine, select the proper throttle control mode required for application.
These settings are accessed in the Throttle Configuration menu.
Throttle Configuration
Throttle Type - Throttle Type Selection (Default = Vernier)
TSC Mode Selection
TSC Min Speed Selection (Default = 800 rpm)
TSC Max Speed Selection (Default = 2400 rpm)
TSC Bump Speed (Default = 20 rpm)
TSC Ramp Rate Selection (Default = 100 rpm/sec)
Throttle Curve Selection
Multistate Speed 1 Selection
Multistate Speed 2 Selection
Multistate Speed 3 Selection
Multistate Speed 4 Selection
MANUAL THROTTLE OPTIONS
1) Vernier Throttle (Default)
Vernier throttle is standard up and down throttle between the minimum and maximum
selections. The ramp rate is the rate of acceleration in rpm’s per second. The control panel uses
J1939 throttle, also called “torque speed control” or TSC1.
2) Multistate Throttle
Multistate throttle provides for one, two, three or four specific operating speeds. Pressing the up
and down buttons adjusts engine speed between the selected multistate speed selections.
HYDRO-THROTTLE OPTIONS
1) Manual Mode –Engine Speed can be changed within the programmed range using the Hare /
Turtle buttons
2) Automatic Mode –Opening and closing the hydro Throttle Switch can change engine speed
between the programmed Minimum Speed and the Last Operating Speed for each run. The last
Operating Speed is the speed at which the engine was last when the Hydro Throttle switch was
opened, or the Throttle switch was changed to “Automatic”.
Clutch Control
Thispanel contains a clutch control toggle switch. The output of this switch ison the 31-Pin
Accessory Connector –Pin 1. When the toggle is placed in the “On” position, the throttle will go to
the minimum speed and the signal to the output is connected after a one second delay. Whenthe
toggle is switched to the “Off” position, the throttle will return to the last operating speed and the
signal will shut-off aftera one second delay.

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CAN Communication
Communication between the panel and the engine ECU occurs over the two wire CAN bus (CAN
High wire and CAN Low wire). It is necessary that the panel and engine ECU settings be the same
for the following parameters. The communication settings are available in the CAN Configuration
menu shown below.
CAN Configuration Menu
Source Address (Default = 44) Available 3, 17, 228, 4, 43, 44
TSC1 Address (Default = 3) Available 3, 17, 228, 4, 43, 44
Engine Address (Default = 0)
Oil/Fuel Transmit

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PANEL OPERATION
1) Engine Start - Turn key to run position
2) Engine Stop –Turn key to off position
3) Engine Throttle –Push up and down buttons
Manual Throttle Control
With the key in the RUN position, the panel operates manually by pressing the up and down
buttons. An arrow will indicate increasing or decreasing engine speed.
Up Arrow
Increase
Speed
Decrease
Speed

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MODULE CONNECTORS
Primary Connector
14 Pin
Secondary Connector
23 Pin

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Primary Connector (14 Pin)
Pin
Function
Pin
Function
1
Relay #2 -ECU Signal
8
J1939 Low
2
Relay #1
9
Relay #3 Common
3
Relay #3
10
Not Used
4
Relay #2 & #4 Common
11
Battery Positive
5
Relay #4
12
Battery Negative
6
Relay #1 Common
13
Fuel Level
7
J1939 High
14
DI #1 E-Stop
Secondary Connector (23 Pin)
Pin
Function
Pin
Function
Pin
Function
1
RY 5 - Clutch #1
9
Battery +(RY 5 Common)
16
Relay 6
2
Not Used
10
Not Used
17
DI #2 Hydro-Throttle
3
Not Used
11
Not Used
18
DI#3 Remote E-Stop
4
Not Used
12
Not Used
19
Digital #4 Input
5
Not Used
13
Not Used
20
Digital #5 Input
6
Not Used
14
Not Used
21
Digital #6 Input
7
Not Used
15
Relay 7
22
Digital #7 Input
8
Relay 7/8 Common
23
Relay 8
CAUTION:
Maximum current draw for signal circuits is 5 amps

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PANEL CONNECTORS
Engine Harness Connector –Deutsch 21 pin (HDP24-24-21PE)
Accessory Harness Connector –Deutsch 31 pin (HDP24-24-31PE)
31 Pin Accessory Connector
Pin
Function
1
Clutch #1 Output
8
Relay #7 & #8 Common
13
Digital #9 Input
14
Digital #8 Input
15
Relay #7 Output
16
Relay #6 Output
18
Digital #3 Input (Remote E-Stop)
19
Digital #4 Input
20
Digital #5 Input
21
Digital #6 Input
22
Digital #7 Input
23
Relay #8 Output
24
Digital #1 Input (E-Stop)
25
Fuel Level
31
Battery Negative
21 Pin Engine Harness Connector
Pin
Function
B
Battery Positive
E
Battery Negative
G
Key On Power
D
Crank Signal
V
J1939 High
U
J1939 Low
J
Alternator Excite
L
Analog Throttle Emulator
M
Analog Throttle Emulator
C
Analog Throttle Emulator
R
Digital Throttle Emulator
S
Digital Throttle Emulator
Accessory
Connector (31 Pin)
Engine Harness
Connector (21 Pin)

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ENGINE ALARMS, CODES AND MESSAGES
ENGINE ECU ALARMS/DE-RATE/SHUT DOWNS
It is important to understand panel operation with respect to engine safety protections, alarms, and
fault codes. The panel operates with J1939 engines. These engines have an ECU (engine control
unit) which is essentially a computer that runs the engine. When engine parameters are out of
normal operating ranges, the ECU takes specific actions which can include the following:
1) Broadcast a trouble code
2) Broadcast a red or yellow lamp
3) De-rate the engine
4) Shut down the engine
5) Turn on alarm horn
It is the engine ECU that de-rates or shuts down the engine when it is not operating within normal
parameters. This includes more common shut downs like high engine temperature and low oil
pressure but can encompass a large range of parameters depending on the ECU.
PANEL ALARM ANNUNCIATION AND CODE READER
This panel is configured to operate with standard J1939 engines where engine de-rate and
shutdowns are managed by the engine ECU. The panel communicates with the engine ECU and
serves as a trouble code reader. When the engine ECU broadcasts a trouble code (called an
SPN.FMI code) the panel does the following:
1) Illuminates the appropriate LED indicator lamp
a. Yellow Lamp = Alarm
b. Red Lamp = Engine Shut Down
2) Displays the trouble code (standard SPN.FMI code)
3) Displays a code description on the LCD screen
4) Displays the occurrence count of the code
Occurrence
Count
Red Lamp
Code
Description
SPN.FMI
Code

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INDICATOR LAMPS
The panel red (alarm) and amber (pre alarm) lamp indicators.
ACTIVE AND STORED ENGINE ECU CODES
The panel also provides the ability to check the engine ECU for all ACTIVE and STORED engine ECU
codes. These codes can be viewed via the Active Codes and Stored Codes menus. In addition, the
control panel has its own Alarm Event Log menu that shows the last 16 engine ECU alarms as well as
any control panel specific alarms.
Engine
Fault
Lamp
Engine
Alarm
Lamp

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CONTROL PANEL SPECIFIC ALARMS AND SHUT DOWNS
The panel has its own engine safety alarms and shut downs that can be enabled. These alarms and
shut downs are managed by the control panel independent from the engine ECU. The available
options are listed below and can be accessed via the Engine Safety Configuration menu.
Each alarm must be enabled in the Engine Safety Configuration menu to activate.
Heading
Default
Range
Units
Sender Check Bypass
0:10
0:05 –1:00
Min:Sec
Fuel Level Check
Off
Off / Always / Run
Low Fuel Pre Alarm
20
0 - 100
%
Low Fuel Alarm
1
0 - 100
%
Fuel Alarm Delay
0:05
0:01 –1:40
Sec
Oil Pressure Check
Run
Off / Always / Run
Low Oil Press Pre Alarm
15
0 - 100
PSI
Low Oil Press Alarm
10
0 - 100
PSI
Oil Press Alarm Delay
5
0:01 –1:40
Sec
Temperature Check
Run
Off / Always / Run
Low Temp Pre Alarm
0
0 - 300
Deg F
Low Temp Alarm
0
0 - 300
Deg F
High Temp Pre Alarm
220
150 - 300
Deg F
High Temp Alarm
230
150 - 300
Deg F
Temp Alarm Delay
0:05
0:01 –1:40
Min:Sec
Battery Volts Check
Off
Off / Always / Run
Low Battery Pre Alarm
12.0
0.0 –40.0
Volts
Hi Battery Pre Alarm
15.0
0.0 –40.0
Volts
Over Speed Check
Off
Off / Always / Run
Over Speed Alarm
3000
650 - 5000
RPM
Over Speed Alarm Delay
0:05
0:01 –1:40
Min:Sec
1) Off / Always / Run –Describes when the parameter will be monitored for alarm conditions. Run
refers to when the engine is running. Off disables the alarm conditions. Always enables the alarm
constantly regardless of engine state.
2) Alarm Delay –The time period, after Sender Check Bypass, that the parameter must be on the
alarm condition before the alarm becomes latched.

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CONTROL PANEL ANALOG AND DIGITAL INPUTS
The panel is shipped from the factory with the bold print inputs pre-wired and enabled
in the panel. Inputs not in bold print need to be wired and enabled to be used.
Analog Inputs
Input
Heading
Default
Connector
Pin
Analog 1
Function
Fuel Level
(Stewart-Warner Scale)
31-Pin
25
Digital Inputs
Input
Heading
Default
Connector
Pin
Digital 1
Normally
Open
31-Pin
24
Function
Alarm
Message
E-Stop
Check
Always
Digital 2
Normally
Closed
-
-
Function
Hydro-Throttle
Message
None
Check
Always
Digital 3
Normally
Open
31-Pin
18
Function
Alarm
Message
Remote E-Stop
Check
Always
Digital 4
Normally
Open
31-Pin
19
Function
Available
Message
None
Check
Always
Digital 5
Normally
Open
31-Pin
20
Function
Available
Message
None
Check
Always
Digital 6
Normally
Open
31-Pin
21
Function
Available
Message
None
Check
Always

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Digital 7
Normally
Open
31-Pin
22
Function
Available
Message
None
Check
Always
Digital 8
Normally
Open
31-Pin
14
Function
Available
Message
None
Check
Always
Digital 9
Normally
Open
31-Pin
13
Function
Available
Message
None
Check
Always
ANALOG #1 INPUT FUNCTIONS
1) Fuel Level S-W –Fuel amount, in percentage, can be measured and displayed on the C3
module using a standard Stewart Warner scale sender of 240 ohms –33 ohms. 240 = Empty
and 33 = Full. Sender ground must be common with battery negative.
2) Fuel Level VDO –Fuel amount, in percentage, can be measured and displayed on the C3
module using a VDO scale sender of 10 ohms –180 ohms. 10 = Empty and 180 = Full.
Sender ground must be common with battery negative.
3) Oil Pressure PSI –Oil pressure, in PSI, can be measured and displayed on the C3 module
using a standard Stewart Warner scale sender of 240 ohms –33 ohms. 240 = 0 PSI and 33
= 100 PSI. Sender ground must be common with battery negative.
4) Oil Pressure bar –Oil pressure, in bar, can be measured and displayed on the C3 module
using a standard Stewart Warner scale sender of 240 ohms –33 ohms. 240 = 0 bar and 33 =
7 bar. Sender ground must be common with battery negative.
5) Oil Pressure VDO PSI –Oil pressure, in PSI, can be measured and displayed on the C3
module using a standard Stewart Warner scale sender of 10 ohms –180 ohms. 10 = 0 PSI
and 180 = 150 PSI. Sender ground must be common with battery negative.
6) Oil Pressure bar –Oil pressure, in bar, can be measured and displayed on the C3 module
using a standard Stewart Warner scale sender of 10 ohms –180 ohms. 240 = 0 bar and 33
= 10 bar. Sender ground must be common with battery negative.
7) Rheostat –Speed control can be accomplished by connecting a 5 K potentiometer in series
with the flex analog input. Engine speed will vary with the change in resistance value.
8) 0 - 5 VDC –Reserved for OEM applications.
9) Ratiometric - Reserved for OEM applications.

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10) 4-20mA - Reserved for OEM applications.
11) Switch –This setting allows for a switch to be connected rather than an analog sender. Set
Analog 1 Message to assign a label to the switch device.
12) None –Set to None when no functionality is required.
DIGITAL FUNCTIONS
The digital inputs can be configured for different uses depending on the application. These
include the following:
1) Alarm –Engine shutdown once active with display message as assigned. A red lamp will also
be illuminated.
2) Pre Alarm –Warning message will be displayed along with a yellow lamp when active.
3) Soft Alarm –Recoverable Alarm. Engine will shut down as soon as this input is tripped, but
will recover to running if the condition is cleared quickly enough.
4) Aux Throttle Up –Mimics the front panel key press for speed control.
5) Aux Throttle Down - Mimics the front panel key press for speed control.
6) Return to Idle –Engine will resume its pre-designated idle speed.
7) Return to Operating Speed –Engine will return to its pre-designated operating speed.
8) Hydro-Throttle - Closing this input to ground will allow the engine to run at the last operating
speed. Opening the circuit will return the engine to idle.
DIGITAL FUNCTION MONITORING
Off / Always / Run –Describes when the parameter will be monitored for alarm conditions. Run
refers to when the engine is running. Off disables the alarm conditions. Always enables the alarm
constantly regardless of engine state.
DIGITAL FUNCTION DELAYS
Alarm Delay –The time period, after Sender Check Bypass, that the parameter must be on the alarm
condition before the alarm becomes latched.

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CONTROL PANEL RELAY OUTPUTS
The panel is shipped from the factory with the highlighted outputs enabled and pre-
wired in the panel.
Relay
Heading
Default
Connector
Pin
Relay 1
Function
-
-
Polarity
Positive
Initial State
Off
Relay 2
Function
Fuel/Run
21 Pin
Connector
G
Polarity
Positive
Initial State
On
Relay 3
Function
-
-
Polarity
Positive
Initial State
Off
Relay 4
Function
-
-
Polarity
Positive
Initial State
Off
Relay 5
Function
Clutch #1
31-Pin
Connector
1
Polarity
Positive
Initial State
Off
Relay 6
Function
31-Pin
Connector
16
Polarity
Positive
Initial State
On
Relay 7
Function
31-Pin
Connector
15
Polarity
Positive
Initial State
Off
Relay 8
Function
31-Pin
Connector
23
Polarity
Initial State
The relays are rated at 5 amps.

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RELAY FUNCTIONS
Available relays can be assigned for different uses.
a. None - Assign to “none” when not used.
b. Pre Alarm - Relay will be active when there is a pre alarm condition. Typically used to
drive an alarm horn or lamp. Also can be used to send a signal to a monitoring
station.
c. Alarm - Relay will be active when there is an alarm condition. Typically used to drive
an alarm horn or lamp. Also can be used to send a signal to a monitoring station.
d. Pre Alarm & Alarm - Energizes an external audible alarm when a pre alarm or alarm
condition is present. Pressing the ENTER button will silence.
e. Alarm Horn - Energizes an external audible alarm when an alarm condition is present.
Pressing the ENTER button will silence.
f. Engine Run - Relay will be active when engine RPM is greater than 600. Typically used
to drive an auxiliary circuit such as louvers or send a signal to a monitoring station.
g. Low Oil Press Alarm - Relay closes if a low oil pressure shutdown is detected.
h. High Coolant Temp Alarm - Relay closes if a high engine temperature shutdown is
detected.
i. Over Speed Alarm - Relay closes if an over speed shutdown is detected.
j. Over Crank Alarm - Relay closes if an over crank alarm is detected.
k. Low Fuel Level Alarm - Relay closes if a low fuel level shutdown is detected.
l. Fuel / Run - Relay will be active during an engine start request and while the engine is
running. Used to drive the engine’s ECU circuit. Also active when requesting active
and stored J1939 codes.
m. Custom 1 - Reserved for OEM applications.
n. Clutch 1 - Closes when Clutch 1 conditions are met.
o. Clutch 2 - Closes when Clutch 2 conditions are met.
p. Input 1-9 - Closes if the associated input is active.
q. Throttle B0 - Reserved for OEM applications.
r. Throttle B1 - Reserved for OEM applications.

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RELAY POLARITY
a. Positive - Relay acts as a normally open contact.
b. Invert - Relay acts as a normally closed contact.
RELAY INITIAL STATE
a. On - Relay is activated upon power up.
b. Off - Relay is not activated upon power up.

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CLUTCH CONFIGURATION
Output relays can be assigned to turn on or off based on engine speed or engine load.
1) Make selections for clutch #1 or clutch#2 in the Clutch Configuration menu.
2) Assign an output relay to clutch #1 or clutch #2 in the Output Configuration menu.
Clutch Configuration
#1 Engage Trip (Default = Hydro-Throttle Off)
#1 Engage Speed (Default = 800 RPM)
#1 Engage Load (Default = 0%)
#1 Engage Coolant Temperature (Default = 150°F)
#1 Engage Delay (Default = 0:01)
#1 Engage Interval (Default = 0:00)
#1 Release Trip (Default = Hydro-Throttle On)
#1 Release Speed (Default = 800 RPM)
#1 Release Load (Default = 0%)
#1 Release Coolant Temperature (Default =150°F)
#1 Release Delay (Default = 0:00)
#1 Release Interval (Default = 0:00)
#2 Engage Trip (Default = None)
#2 Engage Speed (Default = 800 RPM)
#2 Engage Load (Default = 0%)
#2 Engage Coolant Temperature (Default = 150°F)
#2 Engage Delay (Default = 0:00)
#2 Engage Interval (Default = 0:00)
#2 Release Trip (Default = None)
#2 Release Speed (Default = 650 RPM)
#2 Release Load (Default = 0%)
#2 Release Coolant Temperature (Default =150°F)
#2 Release Delay (Default = 0:00)
#2 Release Interval (Default = 0:00)

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MENU SYSTEM
To Enter Menu System
Hold MENU button and press ENTER button.
Menu Navigation
Press MENU button to scroll menu options.
Press UP arrow button to enter menu.
Press DOWN arrow button to reverse.
Exit Menu System
Hold MENU button and press ENTER button.
To Change a Setting
Press ENTER button to bring up brackets [ ].
Press UP arrow button and DOWN arrow button to change setting.
Press ENTER button to make selection, brackets disappear.
Recycle key to the OFF position after changing a setting.

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MAIN MENUS
Active Engine Fault Codes
View/Scroll Active Fault Codes
Stored Engine Fault Codes
View/Scroll Stored Fault Codes
Operation Event Log
View Last 32 Events (Start, Stop, Alarms)
Alarms Event Log
View Last 32 ECU and Controller Alarms)
Engine Parameters
View ECU Engine Information
(% Load, Torque, Oil Temp, etc.)
Engine Identification
Engine Model # View
Engine Serial # View
Module Information
Control Unit Part# View
Control Unit Software Version View
Controller Setup
Parameter Configuration
(1)
(PASSWORD PROTECTED)
Input Configuration
(2)
Output Configuration
(3)
Throttle Configuration
(4)
Engine Safety Configuration
(5)
Module Configuration
(6)
CAN Configuration
(7)
Clutch Configuration
(8)
Viewing Menus
Configuration
Menus