Controls C4F-2011 User manual

PRODUCT MANUAL
ENGINE CONTROL SYSTEM
Part Number: C4F-2011
Revision: 2.0
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1
TABLE OF CONTENTS
PANEL INSTALLATION…….…………………………………………………………………………………….………………………………….4
MOUNTING LOCATION
PANEL DIMENSIONS
HARNESSES USED WITH CONTROLLER
PANEL OPERATION…………………………………………………………………………………………………….……………………………….5
ENGINE START
ENGINE STOP
ENGINE SPEED CONTROL
CLUTCH ENGAGE/DISENGAGE
ALARM CODES & SAFTEY SHUTDOWNS………………………...……………………………………………….………………….7
ENGINE ECU ALARM CODES
CLUTCH ALARM CODES
CONTROLLER ALARM OPERATION AND CODES
SAFETY SHUTDOWNS
PANEL SETTINGS………………………………………………………………………………………………........……………………………………....9
TWO OPTIONS FOR CHANGING PANEL SETTINGS
PC BASED –CI STATION
MENU NAVIGATION (PASSWORD PROTECTED)
PANEL FUNCTIONALITY……………………………………..…………………………………………………………………………….…….…13
OPERATION LOG
ALARM LOG
CONTROLLER SETUP MENU SYSTEM……………………….…...……………………………………………..………………………15
QUICK SETUP
ENGINE PARAMETER CONFIGURATION
INPUT CONFIGURATION
OUTPUT CONFIGURATION
THROTTLE CONFIGURATION
ENGINE SAFETY CONFIGRUATION
CAN CONFIGURATION
MAINTENANCE SCHEDULES
EMISSIONS CONFIGURATION
CLUTCH CONFIGURATION

2
MODULE CONNECTORS….…………….……………………………………………………………….…………………………………..….22
WARRANTY………………………………………….…………………………………………………………………………………………....24

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PANEL INSTALLATION
MOUNTING LOCATION
To ensure a long life from your control panel, please review the following installation guidelines.
HEAT: Be sure to take into account excessive heat areas when mounting your control panel.
Stay away from turbo chargers, exhaust manifolds, diesel particulate filters or any other location
that would put the control panel in the vicinity of excessive heat
SHOCK AND VIBRATION: Mount the control panel using vibration isolators designed to
handle the weight and load of the control panel. When designing a bracket, be sure to take
into consideration the arm of the bracket to reduce or eliminate the spring board effect of
engine vibrations.
CONVIENCE OF USE: Study the final assembly of the piece of equipment and how it will be
used. Take into account the operator when locating the panel. Ease of access to the hinges of
the cover, key switch and display are all critical in allowing the operator to successfully and
safely operate the control panel. Extension harnesses are available from Controls Inc. if the
engine harness being used does not allow for proper location selection.
WEATHER AND WASHDOWN: The control panel is designed to be weather tight and can be
used in open outdoor conditions. The enclosure has a Gore vent, located on the rear of the
enclosure, which will allow for breathing between the interior of the control enclosure and the
outside environment. Be sure to keep the clear lid closed during wash down and not directly
spray the Gore vent area.
HARNESS ROUTING: The use of commons sense with respect to harness routing and drip
loops can go a long way in the prevention of unintended water intrusion. Also take into
account the stresses put on the harnessing and the proximity to heat sources as well. For spark
ignited engine, be sure to keep the panel wiring at least 12 inches from the ignition wires.

4
MOUNTING DIMENSIONS
Use the dimensions below to mount the control panel or design a bracket for your equipment.
HARNESSES USED WITH CONTROLLER
This controller is installed with Controls Inc harness part numbers 70-1403 and 70-2303 on Scania
J1939 Final Tier 4 engines with 24 VDC battery systems. Contact Controls Inc for details.

5
PANEL OPERATION
ENGINE START
Rotate the key to the right to the Crank position and hold while the engine starting circuit is energized
and rotates the engine. Once the engine fires, release the key and a spring will rotate the key back to
the Run position where it will stay until you desire to turn the engine off.
For Scania engines, the key provides a start/run signal to the controller (into Connector A, Pin 14 of the
controller). Upon receiving the key start signal, the controller broadcasts a “START” command over
the J1939 CANbus to the engine ECU. Upon receiving the “START” command message from the
controller, the engine ECU initiates engine start.
ENGINE STOP
Return the engine to LOW SPEED and DISENGAGE the clutch. Once the clutch is DISENGAGED and
the engine is at LOW SPEED, rotate the key to the Off position. The key removes the run signal from
the controller. With the run signal removed, the controller sends a “STOP” command message to the
engine ECU. Upon receiving the “STOP” command message, the engine ECU initiates engine stop.
ENGINE SPEED CONTROL
The control panel controls the engine’s speed over the CANbus using J1939 Torque Speed Control
(TSC1). The unit is set up with a special TWO-STATE throttle system.
•Low Speed (STATE 1 = 750 rpm)
•High Speed (STATE 2 = 1800 rpm)
The low and high speeds are selectable via a password protected menu setting.
The engine starts at low speed. At low speed, throttle is adjustable via the UP and DOWN arrow
buttons on the controller between 650 rpm and 1200 rpm.
When the “CLUTCH” button is pressed for 3 seconds, the controller does the following:
1) Sends a CLUTCH ENGAGE command to the clutch system (via the CANbus)
2) Increases engine speed to HIGH SPEED

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When the clutch has been engaged, a CLUTCH ENGAGED message is provided. When engine speed
increases, an UP arrow is displayed on the screen next to ENGINE RPM.
When the “CLUTCH BUTTON” is pressed with the engine at HIGH SPEED, the controller does the
following:
1) Decreases engine speed to LOW SPEED
2) Sends a CLUTCH DISENGAGE command to the clutch system (via the CANbus)
When engine speed decreases, a DOWN arrow is displayed on the screen next to ENGINE RPM. When
the clutch has been disengaged, a CLUTCH DISENGAGED message is provided.
DO NOT SHUT ENGINE OFF UNTIL CLUTCH HAS BEEN DISENGAGED AND
ENGINE SPEED IS RETURNED TO LOW SPEED.

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ALARM CODES & SAFETY SHUTDOWNS
ENGINE ALARM CODES
Once the engine is started, the engine’s ECU has primary control over the operation of the engine
under safe conditions. If the ECU detects that any of its critical parameters are out of tolerance, the
ECU can take a variety of actions including derating of the engine horsepower or complete engine
shut down. The display will illuminate the red or yellow LED as instructed by the ECU and display any
trouble code as presented from the ECU. Some engine manufacturers have unique codes that the
control panel will show in lieu of the J1939 DM1 messaging. Otherwise codes will be displayed as
J1939 SPN (Suspect Parameter Number) and FMI (Failure Mode Identifier).
CLUTCH ALARM CODES
The controller has been integrated with the clutch control system. This means that any clutch alarms
or codes are also broadcast on the screen by the controller.
CONTROLLER ALARM OPERATION AND CODES
The controller also has the ability to monitor parameters and system directly. The controller provides
the following:
Feeder Remote Stop Input
(Normally Open, Close to Ground to Energize)
Function:
1) Shut Down Engine
2) Disengage Clutch via J1939 command
3) Red Lamp
4) “E-Stop Engaged” Message
Overload Alarm Output
(5A max)
Function:
1) 24 VDC signal to energize feeder system
2) When overload alarm is active (rpm drops
below 1600 rpm),the 24 VDC signal is stopped
which stops the feeder system.

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SAFETY SHUTDOWNS
In the event of an engine shutdown initiated by the engine ECU or the Feeder Remote Stop, the
controller immediately sends a “CLUTCH DISENGAGE” command to the clutch controller and stops
sending the 24VDC feeder system signal.
Overload Alarm Operation
When engine rpm drops below 1600 for 2 seconds
1) 24 VDC feeder signal is stopped (de-energized)
2) Yellow Lamp Illumination
3) “Overload Alarm” display message
4) NO Engine Shutdown, NO Clutch Disengagement
1) Alarm clears when rpm returns to 1800
2) Yellow lamp clears
3) Display message clears
4) 24 VDC feeder signal energizes (turns on) feeder system

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PANEL SETTINGS
TWO OPTIONS FOR CHANGING PANEL SETTINGS
There are two methods for programming your control panel. One is by using the modules built in
menu system and the other is done using a PC based application called CI Station.
PC BASED
The CI Station is available in a kit form that includes the PC application, USB programming adapter,
power supply and interconnect harnessing. The CI Station allows the user to save configurations and
reuse them over and over for production line programming or to configure replacement panels to
match the original OEM programming. Contact Controls Inc. for more details.

10
MENU NAVIGATION
To access the control panel menu system, place the key in the Run position and press the Menu key.
While pressing the Menu key, a message will appear to also press the Enter key.
Once you have accessed the menu system, the four key pad will be used for menu navigation and
therefore not available for engine speed control if the engine is running. The menu system is broken
into two main sections, the operator menu and the controller setup menu. The operator menu
contains information about the engine and control panel. The topics will vary based on the engine
type and control panel model. Pressing the Menu key will index the menu topic to the next item in the
list. The index is circular so you will eventually wrap around to the beginning of the operator menu
structure. Pressing the Enter key will index the topics backward. Once you have arrived at a menu
topic that you would like to explore more, press the Up arrow key. The Up arrow key will index the
screen each time it is pressed. Pressing the Down arrow key will index in the reverse order. Pressing
the Menu key at any time while in a menu will step you out to the main menu topic heading. To exit
the menu, simple press the Menu and Enter keys simultaneously.

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CONTROLLER SETUP
When navigating through the Operator menu you will arrive at the Controller Setup screen. To
configure the module to new settings, you can enter into this area by pressing the Up arrow key.
The next screen will ask for a password. If no password, or an incorrect password is used,
navigation into the menu is still possible and permitted, however, the ability to make changes will be
restricted. To enter the password, press the Enter key and brackets will appear. Use the Up and Down
arrow keys to set each digit individually, pressing the Enter key to index to the next digit from left to
right.
Once the last digit is entered, the brackets will disappear and the digits will be represented with
asterisks. Pressing the Up arrow will index you to the Quick Setup menu and programming can
continue.

12
Navigating the Controller Setup menu structure is done in the same manner as the Operator menu
system. Menu will index to the next topic, the Up arrow will access the topic, etc. To make changes to
the settings, you will need to locate the item you are looking to modify under the appropriate topic
and then press the Enter key and the editing brackets will appear allowing you to make changes to the
value or change the selection. Once you have made your selection or changed the value, simply press
Enter again to accept it and the editing brackets will be removed.

13
PANEL FUNCTIONALITY
STANDARD FEATURES
The control panel has many options that can be configured, enabled or selected that will enhance the
operation of the equipment. A list of items is below with descriptions on the selection and use of
each.
OPERATION LOG
The operation log will record the engine start and stop events and tag them with the engine run time
hours. The Alarm can be viewed in the Operator menu area and can be cleared in the Module
Configuration section of the Controller Setup menu.
ALARM LOG
Any monitored prealarm or alarm will be recorded in the Operator menu section. The event will be
tagged with the actual engine run time hours at which the event occurred. The log stores the last 32
events and can be cleared in the Module Configuration section on the Controller Setup menu.

14

15
CONTROLLER SETUP MENU
The tables below represent the typical options found in the Controller Setup menu system. These may
vary based on firmware levels and versions, but consistency thought the product line is of the utmost
importance.
QUICK SETUP
The Quick Setup menu is available to allow a user to quickly set up the basic configuration of the
control panel to match the engine. Selections in the Quick Setup will propagate into other areas of
the control panel programming. For more detailed options, you can use the main menu structures
that follow.
Heading
Default
Range
Engine Manufacturer
Scania
Cat/Cummins/Deutz/Hatz/Isuzu/Iveco/JCB/John
Deere/Kohler/Kubota Diesel/MTU/Perkins/PSI
/Standard/Yanmar/Zenith
TSC Min Speed
650
650-4000
TSC Max Speed
1200
650-4000
Performance Display
Off
On/Off
ENGINE PARAMETER CONFIGURATION
The Engine Parameters Configuration menu allows you to configure each critical engine parameter to
the source of the information. Sender type, scale and input channel to the module can be selected
here. You will first select the parameter, then the properties associated with each one.
Heading
Default
Range
Engine Type
Electronic
Mechanical/Electronic
Parameter
Speed
Coolant Temp
Oil Pressure
Fuel Level
Voltage

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Hour meter
Speed Source
J1939
Mag Pick Up / J1939
Temperature Source
J1939
Analog / J1939
Oil Pressure Source
J1939
Analog / J1939
Fuel Level Source
Analog
Analog/J1939
Fuel Level Sender
S-W
SW/VDO/0-90ohm
Fuel Channel
Secondary Pin 3
Various
Voltage Source
Batt-J1939
Batt-J1939/Alt-J1939/Elect-J1939/Internal
Batt Volt Trim (100mV)
4
Hour meter
Engine ECU
Internal/Engine ECU
Hour meter (Internal Only)
0 Hours
INPUT CONFIGURATION
The Input Configuration menu allow you to set up eight discreet switch inputs that can be treated as
engine safety switches, remote throttle commands, or other desired behaviors. Common text
messages for power unit applications are preloaded. Up to four custom messages can be assigned to
inputs. It is highly suggested to use the CI Station PC application for loading custom messages.
Heading
Default
Range
Configure
Channels
Channels/Custom Message
Digital Input
1
1-9
Action
Alarm
Prealarm/Alarm/Auto Start/Throttle Up/
Throttle Down/Return to Idle/Return to
Operating Speed/High Float/Low
Float/Auto Start Inhibit/Shutdown
Override/Regen Request/Regen Inhibit
Check
Off
Off/Always/Run
Message
Low Water
*See List
Delay
0:00
0-5 Min
Normally
Open
Open/Closed
Default Assignments
1
Start Engine

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2
High/Low Button
3
E-Stop
Configure
Custom Message
Custom Message
1
1-4
Top Line Message
Alpha Numeric 14 Characters Max
Bottom Line Message
Alpha Numeric 14 Characters Max
OUTPUT CONFIGURATION
The Output Configuration menu allows you to select relay operations. Many predefined events can be
associated with a relay closure for either engine operation, SCADA system integration, clutch control
or driving an audible alarm.
Heading
Default
Range
Output
Relay 1
Relay 1-8
Function
None
Prealarm/Alarm/Pre+Alarm Horn/Alarm
Horn/Engine Run/Low Oil Pressure
Alarm/High Coolant Temp
Alarm/Overspeed Alarm/Over Crank
Alarm/Low Fuel Alarm/Low Fuel
Prealarm/Fuel-Run/High Water
Level/Preheat/Crank/Start
Warning/Start+Alarm Horn/Unit in
Auto/Unit in Manual/Clutch 1/Clutch
2/Pull In/Throttle Hi-Lo/Throttle
Up/Throttle Down/Regen Active/DEF Low
Level/Throttle B0/Throttle B1
Polarity
Positive
Positive/Negative
Initial State
On
On/Off
Allow Power Down
On
On/Off
Pull Release Delay
1 Second
1-10
Default Assignments
Relay 2
Fuel/Run
Relay 5
Common Alarm
Relay 6
Overload Alarm

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THROTTLE CONFIGURATION
The unit is pre-set for two-state throttle. The pre-set menu (password protected) settings are shown
in the table below.
Low Speed = 750 rpm
High Speed = 1800 rpm
Low speed is adjustable via the UP and DOWN arrows between 650 rpm and 1200 rpm)
Heading
Default
Range
Throttle Type
TSC Vernier
TSC Vernier/TSC Multistate/TSC Hi-
Lo/MODBUS/TSC Analog/Off
TSC Mode
Primary
Primary/Remote
TSC Min Speed
650
650-4000 RPM
TSC Max Speed
1200
650-4000 RPM
TSC Bump Speed
10
1-100 RPM
TSC Ramp Rate
50
10-2000 RPM/SEC
Throttle Curve
Linear
Linear/Exponential
Multistate Speed 1
750
650-4000 RPM
Multistate Speed 2
1800
650-4000 RPM
Multistate Speed 3
650
650-4000 RPM
Multistate Speed 4
650
650-4000 RPM
Governor Mode
Isochronous
Isochronous/Droop
ENGINE SAFETY CONFIGURATION
The Engine Safety Configuration menu enables the user to set warning and shutdowns for the critical
engine parameters. Care should be taken when configuring to match the engine manufacturers
recommended guidelines.
Heading
Default
Range
Sender Check Bypass
0:10 Seconds
0:05 -1:00
Parameter
Fuel Level
Oil Pressure
Temperature
Battery Voltage
Overspeed

19
Speed Limit
Fuel Level Check
Off
Off/Always/Run
Low Fuel Prealarm @
20%
0-100%
Low Fuel Alarm @
1%
0-100%
Fuel Level Alarm Action
Shutdown
Shutdown/Force to
Idle/Speed Limit/Disabled
Fuel Alarm Delay
0:05 Seconds
0:00-1:40
Oil Pressure Check
Run
Off/Always/Run
Low Oil Pressure Prealarm @
6 psi
0-100 psi
Low Oil Pressure Alarm @
5 psi
0-100 psi
Oil Pressure Alarm Action
Shutdown
Oil Pressure Alarm Delay
0:10
0:00-1:40
Temperature Check
Run
Off/Always/Run
High Temperature Prealarm @
244 deg F
150-300 deg F
High Temperature Alarm @
245 deg F
150-300 deg F
Coolant Temperature Alarm Action
Shutdown
Temp Alarm Delay
0:10
Battery Volts Check
Off
Off/Always/Run
Low Battery Prealarm @
12.0 VDC
0.0-40.0 VDC
High Battery Voltage Prealarm @
15.0 VDC
0.0-40.0 VDC
Overspeed Alarm
Off
On/Off
Overspeed Alarm @
3000 RPM
650-5000 RPM
Overspeed Alarm Delay
0:05
0:00-1:40
CAN CONFIGURATION
The CAN Configuration menu allows the user to set the engine manufacturer, individual CAN address
as well as the ability to turn on or off individual parameters to be transmitted over the J1939 CAN Bus
for tie into the InControl Technologies telemetry devices.