Controls C3M-100 User manual

Product Manual
Engine Control
Mechanical Engine
Part Number: C3M-100
Revision: 2.0
______________________________________________________________________________________________________________________________________
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
PANEL OPERATION…………….…………………………………………………………………………………….…………………………….……….2
MANUAL OPERATION
MODULE CONNECTORS…………………………………………………………………………………………………….………………….……….3
PRIMARY 14 PIN MODULE CONNECTOR
ENGINE ALARMS, CODES AND MESSAGES……………………………………………………………………………........………...5
WARNINGS & ALARMS
ALARM EVENT LOG
INDICATION LAMPS
CONTROL PANEL SPECIFIC ALARMS AND SHUT DOWNS………………………………………….…………..……….6
CONTROL PANEL DIGITAL INPUT…………………………………………………………………………………………………..………….8
DIGITAL FUNCTIONS
CONTROL PANEL RELAY OUTPUTS…………………………………………………………………..………………………........................9
RELAY FUNCTIONS, POLARITY & INITIAL STATE
MENU SYSTEM……………………………………………………………………………………………..……………..……………………………………..11
MENU ACCESS, EXIT AND NAVIGATION
VIEWING MENUS
CONFIGURATION MENUS

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PANEL OPERATION
MANUAL OPERATION
1) Engine Start - Turn key to CRANK position
2) Engine Stop - Turn key to OFF position

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MODULE CONNECTORS
Primary Connector
14 Pin

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C O N T R O L S Y S T E M S & S O L U T I O N S
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MODULE CONNECTOR (14 Pin)
Pin
Function
Pin
Function
1
Fuel Solenoid
8
MPU
2
Water Temp
9
Battery Positive
3
Battery Positive
10
Key Auto Detect
4
Auto Crank Signal
11
Switched Power to C3M
5
Preheat Signal
12
Battery Negative
6
N/O Relay #1
13
Fuel Level
7
Oil Pressure
14
Digital #1 Input
CAUTION:
Maximum current draw for signal circuits is 5 amps

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ENGINE ALARMS, CODES AND MESSAGES
WARNINGS & ALARMS
When parameter is outside of its limits, the control panel flashes that parameter the display and
illuminates the yellow lamp. If the condition worsens beyond the alarm set point, the red lamp
illuminates, the engine shuts down and an alarm message appears on the display identifying the
cause.
ALARM EVENT LOG
The Alarm Log creates an entry allowing the service and/or operator to view the last 32 events. An
event is considered either a warning or shutdown. Each event is time stamped with engine run time
hours. Access the Alarm Event Log menu to view.
Above is an example of high engine speed alarm at 352.9 hours. The most recent event will be the
first displayed in the log.
Warning
Yellow Warning Lamp ON and 2010
RPM Flashing
Alarm/Shutdown
Red Shutdown Lamp ON and Text
Message with value on display

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INDICATION LAMPS
The panel has two lamp indicators.
Engine
Fault/Shutdown
Lamp
Engine
Warning
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. 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 Sender Type
S-W
S-W/Switch/VDO
Fuel Level Check
Run
Off / Always / Run
Low Fuel Pre-Alarm
20
0-100
%
Low Fuel Alarm
1
0-100
%
Fuel Alarm Delay
5
0-59
Sec.
Oil Pressure Sender
S-W
S-W / VDO
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 DIGITAL INPUT
The panel provides the analog and digital inputs defined below located in the Input Configuration
menu. The panel is shipped from the factory with the highlighted inputs enabled in the panel. Inputs
not highlighted need to be enabled/configured in the menu system to be used.
Input
Heading
Default
Options
Connector
Pin
Digital 1
Normally
Open
Open / Closed
16 Pin
Connector
B
Function
None
Message
None
Check
Always
Off / Always / Run
DIGITAL FUNCTIONS
The digital inputs can be configured for different uses depending on the application. These
include the following:
1) Alarm –Engine shutdown when 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.
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 provides relay outputs defined below located in the Output Configuration menu. The
relays are rated at 5 amps.
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
Ground output
only
Function
None
Polarity
Positive
Initial State
Off
Relay 2
Function
Fuel/Run
16 Pin
Connector
R
Polarity
Positive
Initial State
On
Relay 3
Function
Preheat
16 Pin
Connector
J
Polarity
Positive
Initial State
Off
Relay 4
Function
None
Polarity
Positive
Initial State
Off
RELAY FUNCTIONS
Available relays can be assigned for different uses.
a. None - Assign to “none” when not used.
b. Throttle B1 - Reserved for OEM applications.
c. Throttle B0 - Reserved for OEM applications.
d. 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.
e. 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.
f. Pre Alarm & Alarm - Energizes an external audible alarm when a pre alarm or alarm
condition is present. Pressing the ENTER button will silence.
g. Alarm Horn - Energizes an external audible alarm when an alarm condition is present.
Pressing the ENTER button will silence.

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h. 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.
i. Switch Trip - Relay will be active if digital input is active.
j. 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.
k. Custom 1 - Reserved for OEM applications.
l. Preheat - Relay will be active during programmed preheat period. Used to drive a
preheat relay.
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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MENU SYSTEM
To Enter Menu System
Hold MENU button and press ENTER button.
Menu Navigation
Press MENU button to scroll menu options.
Press the UP arrow button to enter menu.
Press the DOWN arrow button to reverse.
Exit Menu System
Hold MENU button and press ENTER button.
To Change a Setting
Press the 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.
MAIN MENUS
Operation Event Log
View Last 32 Events (Start, Stop, Alarms)
Alarms Event Log
View Last 32 ECU and Controller Alarms)
Module Information Menu
Control Unit Part# View
Control Unit Software Version View
Controller Setup Menus
Input Configuration
(1)
(PASSWORD PROTECTED)
Output Configuration
(2)
Throttle Configuration
(3)
Engine Safety Configuration
(4)
Module Configuration
(5)
Calibration
(6)
Configuration
Menus
Viewing
Menus

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CONFIGURATION MENUS
(1)
Input Configuration
Digital Input 1 - Setup (NO/NC, Action, Message, When Active, Delay)
(2)
Output Configuration
Relay Output 1 Setup (Function, Polarity, Initial State)
Relay Output 2 - Pre Set to Fuel/Run
Relay Output 3 - Pre Set to Preheat
Relay Output 4 Setup - Pre Set to Crank Signal
(3)
Throttle Configuration
Throttle Type - Throttle Type Selection (Default = Off)
(4)
Engine Safety Configuration
Sender Check Bypass Time Period Selection
Fuel Sender Type
Fuel Level Check (Off / Always / Run)
Low Fuel Level Pre-Alarm % Selection
Low Fuel Level Alarm % Selection
Fuel Alarm Time Delay Selection
Oil Pressure Check On/Off Selection
Low Oil Pressure Pre Alarm % Selection
Low Oil Pressure Alarm % Selection
Oil Pressure Alarm Time Delay Selection
Engine Temperature Check On/Off
Engine Temperature Pre Alarm Selection
Engine Temperature Alarm Selection
Engine Temperature Alarm Time Delay Selection
Battery Volt Check On/Off
Low Battery Volt Pre Alarm Selection
High Battery Volt Pre Alarm Selection
Battery Volt Trim Setting
Over Speed Alarm On/Off
Over Speed Alarm RPM Setting
Over Speed Alarm Time Delay Selection
(5)
Module Configuration
Preheat M:S (Default 0:00)
Hour Meter
Clear Operation Log Yes/No
Clear Alarm Log Yes/No