Controls J1939 User manual

Product Manual
EngineDisplay & Control
J1939EControlsGCPSystems
Part Number: C3-D7115
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
PANEL OPERATION……..……....………………………………………….………………………………………….……………….....3
ENGINE START, STOP ANDTHROTTLE
MODULE CONNECTOR…...………………………………………………………..…………………………………….………………………4
14-PIN MODULE CONNECTOR WIRE IDENTIFICATION
HARNESS ASSEMBLY
PANEL CONNECTOR ……………………………………………………………………………………………………………..………………5
21- PINMODULE CONNECTORWIRE IDENTIFICATION
ENGINE ALARMS, CODES AND MESSAGES……………………………………………………………………………............6
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………………………………………….…………...…8
CONTROL PANEL SPECIFIC SAFETY ALARMS
CONTROL PANEL ANALOG AND DIGITAL INPUTS……………………………………………………………………...…9
CONTROL PANEL RELAY OUTPUTS…………………………………………………………………..………………………....…12
MENU SYSTEM……………………………………………………………………………………………..……………………………………....…14
MENU ACCESS, EXIT AND NAVIGATION
MENUS TO VIEW INFORMATION
MENUS TO CONFIGURE MODULE SETTINGS
DTC CODES…………………………………………………………………………………………………..………………………………….…....…18

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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 = 650 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.

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PANEL OPERATION
MANUAL OPERATION
1) Engine Start - Turn key to CRANK 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)
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
Analog #1 Input
7
J1939 High
14
Digital #1 Input
Primary Connector
14 Pin
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)
21 Pin 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
P
Analog Input 1
X
Digital Input 1
Engine Harness
Connector (21 Pin)

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ENGINE ALARMS, CODES AND MESSAGES
Engine ECU Alarm/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) Illuminate the appropriate LED indicator lamp
a. Yellow Lamp = Alarm
b. Red Lamp = Engine Shut Down
2) Displays the trouble code
3) Displays a code description on the LCD screen
DTC Code &
Message
Red Lamp

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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
6
0 - 100
PSI
Low Oil Press Alarm
5
0 - 100
PSI
Oil Press Alarm Delay
0:10
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
244
150 - 300
Deg F
High Temp Alarm
245
150 - 300
Deg F
Temp Alarm Delay
0:10
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 enabled to be used.
Analog Inputs
Input
Heading
Default
Connector
Pin
Analog 1
Function
None
21 Pin
P
Digital Inputs
Input
Heading
Default
Connector
Pin
Digital 1
Function
None
21 Pin
X

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Analog 1 Function Options
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.
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 Function Options
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. 3)

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Digital Function Activation
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 RELAY OUTPUTS
The panel is shipped from the factory with the bold print 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
The relays are rated at 5 amps.
Relay Functions –A total of four relays can be assigned for different uses depending on
application.
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.

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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. Hi Coolant Temp Alarm –Relay closes if a high engine temperature shutdown is
detected.
i. Overspeed Alarm –Relay closes if an overspeed 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. Throttle B1 –Reserved for OEM applications.
o. Throttle B0 –Reserved for OEM applications.
2) Relay Polarity
a. Positive - Relay acts as a normally open contact.
b. Invert - Relay acts as a normally closed contact.
3) Relay Initialized 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 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
Input Configuration
(1)
(PASSWORD PROTECTED)
Output Configuration
(2)
Throttle Configuration
(3)
Engine Safety Configuration
(4)
Module Configuration
(5)
CAN Configuration
(6)
Viewing Menus
Configuration
Menus

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Configuration Menus
(1)
Input Configuration
Analog 1 Function (Fuel Level Settings)
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 Setup - Pre Set to Run Signal
Relay Output 3 Setup (Function, Polarity, Initial State)
Relay Output 4 Setup (Function, Polarity, Initial State)
(3)
Throttle Configuration
Throttle Type - Throttle Type Selection (Default = TSC Vernier)
TSC Mode Selection
TSC Min Speed Selection
TSC Max Speed Selection
TSC Ramp Rate Selection
Throttle Curve Selection
Multistate Speed 1 Selection
Multistate Speed 2 Selection
Multistate Speed 3 Selection
Multistate Speed 4 Selection
(4)
Engine Safety Configuration
Sender Check Bypass Time Period Selection
Fuel Level Check On/Off Selection
Low Fuel Level Pre Alarm % Selection
Low Fuel Level Alarm % Selection
Fuel Level Alarm Delay Time 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

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Over speed Alarm Time Delay Selection
(5)
Module Configuration
Display Contrast - Pre Set
Display Backlight - Pre Set
Display Intensity - Pre Set
English/Metric Selection
Hourmeter Source
Hourmeter Setting (if not ECU)
Battery Volt Source
Clear Operation Log Yes/No
Clear Alarm Log Yes/No
(6)
CAN Configuration
TSC1 Address (Default = 234)
Source Address (Default = 44)
Engine Address (Default = 0)
Oil/Fuel Transmit

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DTC CODES (Diagnostic Trouble Codes).
Note: If a DTC is not defined, the standard J1939 SPN.FMI format will be displayed.
Fault
Index
Description
0
DTC 108: MAP pressure high
1
DTC 107: MAP voltage low
2
DTC 118: ECT voltage high
3
DTC 117: ECT voltage low
4
DTC 116: ECT higher than expected stage 1
5
DTC 113: IAT voltage high
6
DTC 112: IAT voltage low
7
DTC 2229: BP pressure high
8
DTC 129: BP pressure low
9
DTC 563: Vbat voltage high
10
DTC 562: Vbat voltage low
11
DTC 643: Sensor supply voltage 1 high
12
DTC 642: Sensor supply voltage 1 low
13
DTC 123: TPS1 voltage high
14
DTC 122: TPS1 voltage low
15
DTC 223: TPS2 voltage high
16
DTC 222: TPS2 voltage low
17
DTC 221: TPS1-2 higher than expected
18
DTC 121: TPS1-2 lower than expected
19
DTC 2122: FPP1 voltage high
20
DTC 2123: FPP1 voltage low
21
DTC 2128: FPP2 voltage high
22
DTC 2127: FPP2 voltage low
23
DTC 2115: FPP1 higher than IVS
24
DTC 2139: FPP1 lower than IVS
25
DTC 2116: FPP2 higher than IVS
26
DTC 2140: FPP2 lower than IVS
27
DTC 2126: FPP1-2 higher than expected
28
DTC 2121: FPP1-2 lower than expected
29
DTC 524: Oil pressure low
30
DTC 171: Adaptive-learn gasoline bank1 high
31
DTC 172: Adaptive-learn gasoline bank1 low
32
DTC 1155: Closed-loop gasoline bank1 high
33
DTC 1156: Closed-loop gasoline bank1 low
34
DTC 1157: Closed-loop gasoline bank2 high
35
DTC 1158: Closed-loop gasoline bank2 low
36
DTC 1151: Closed-loop LPG high
37
DTC 1152: Closed-loop LPG low
38
DTC 1153: Closed-loop NG high
39
DTC 1154: Closed-loop NG low
40
DTC 174: Adaptive-learn gasoline bank2 high
41
DTC 175: Adaptive-learn gasoline bank2 low

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42
DTC 1161: Adaptive-learn LPG high
43
DTC 1162: Adaptive-learn LPG low
44
DTC 1163: Adaptive-learn NG high
45
DTC 1164: Adaptive-learn NG low
46
DTC 261: Injector 1 open or short to ground
47
DTC 264: Injector 2 open or short to ground
48
DTC 267: Injector 3 open or short to ground
49
DTC 270: Injector 4 open or short to ground
50
DTC 273: Injector 5 open or short to ground
51
DTC 276: Injector 6 open or short to ground
52
DTC 279: Injector 7 open or short to ground
53
DTC 282: Injector 8 open or short to ground
54
DTC 285: Injector 9 open or short to ground
55
DTC 288: Injector 10 open or short to ground
56
DTC 262: Injector 1 coil shorted
57
DTC 265: Injector 2 coil shorted
58
DTC 268: Injector 3 coil shorted
59
DTC 271: Injector 4 coil shorted
60
DTC 274: Injector 5 coil shorted
61
DTC 277: Injector 6 coil shorted
62
DTC 280: Injector 7 coil shorted
63
DTC 283: Injector 8 coil shorted
64
DTC 286: Injector 9 coil shorted
65
DTC 289: Injector 10 coil shorted
66
DTC 2300: Spark coil 1 primary open or short to ground
67
DTC 2303: Spark coil 2 primary open or short to ground
68
DTC 2306: Spark coil 3 primary open or short to ground
69
DTC 2309: Spark coil 4 primary open or short to ground
70
DTC 2312: Spark coil 5 primary open or short to ground
71
DTC 2315: Spark coil 6 primary open or short to ground
72
DTC 2318: Spark coil 7 primary open or short to ground
73
DTC 2321: Spark coil 8 primary open or short to ground
74
DTC 2324: Spark coil 9 primary open or short to ground
75
DTC 2327: Spark coil 10 primary open or short to ground
76
DTC 2301: Spark coil 1 primary shorted
77
DTC 2304: Spark coil 2 primary shorted
78
DTC 2307: Spark coil 3 primary shorted
79
DTC 2310: Spark coil 4 primary shorted
80
DTC 2313: Spark coil 5 primary shorted
81
DTC 2316: Spark coil 6 primary shorted
82
DTC 2319: Spark coil 7 primary shorted
83
DTC 2322: Spark coil 8 primary shorted
84
DTC 2325: Spark coil 9 primary shorted
85
DTC 2328: Spark coil 10 primary shorted
86
DTC 217: ECT higher than expected stage 2
87
DTC 111: IAT higher than expected stage 1
88
DTC 127: IAT higher than expected stage 2