Controls C3-100-AS User manual

Product Manual
EngineDisplay & Control
J1939Engines
Part Number: C3-100-AS
Revision: 3.0
______________________________________________________________________________________________________________________________________
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
MANUAL THROTTLE SETTINGS
PANEL OPERATION……..……....………………………………………….………………………………………….………………………………........3
ENGINE START, STOP AND THROTTLE
MANUAL OPERATION
AUTO START/STOP OPERATION
SLEEP MODE
MODULE CONNECTOR…...………………………………………………………..…………………………………….……………………………………...…6
14 PIN MODULE CONNECTOR WIRE IDENTIFICATION
PANNEL CONNECTOR…...………………………………………………………..…………………………………….……………………………………....…8
ENGINE ALARMS, CODES AND MESSAGES……………………………………………………………………………...................................9
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………………………………………….…………...................…11
CONTROL PANEL SPECIFIC SAFETY ALARMS
CONTROL PANEL ANALOG AND DIGITAL INPUTS………………………………………………………………………………....…12
CONTROL PANEL RELAY OUTPUTS…………………………………………………………………..………………………............................…14
MENU SYSTEM……………………………………………………………………………………………..……………………………………............................…16
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 Selection (Default = TSC Vernier)
TSC Mode Selection (Default = Primary)
TSC Min Speed Selection (Default = 650 RPM)
TSC Max Speed Selection (Default = 2400 RPM)
TSC Bump Speed Selection (Default = 20 RPM)
TSC Ramp Rate Selection (Default = 100 RPM/Sec)
Throttle Curve Selection (Default = Linear)
Multistate Speed 1 Selection (Default = 650 RPM)
Multistate Speed 2 Selection (Default = 650 RPM)
Multistate Speed 3 Selection (Default = 650 RPM)
Multistate Speed 4 Selection (Default = 650 RPM)
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.
Throttle Configuration Settings –Standard Throttle
Heading
Default
Range
Units
Your Settings
Min Control Speed
650
650-2750
RPM
Max Control Speed
2400
650-2750
RPM
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.
Throttle Configuration Settings –Multistate Throttle
Heading
Default
Range
Units
Your Settings
Manual Throttle Operation
Multistate
Multistate
4
1-4
Speeds
Speed 1
650
650-2750
RPM
Speed 2
650
650-2750
RPM
Speed 3
650
650-2750
RPM
Speed 4
650
650-2750
RPM
Multistate Speeds –Programmed speed settings must be in an increasing order. For
example, Speed 1 = 1000, Speed 2 = 1400, Speed 3 = 1500.

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PANEL OPERATION
MANUAL OPERATION
1) Engine Start - Turn key to the RUN position
2) Engine Stop - Turn key to the OFF position
3) Engine Throttle - Push the UP and DOWN arrow 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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AUTO START/STOP OPERATION
1) Engine Start - Turn key to AUTO position
Engine start/stop based on auto start/stop settings. Panel display shows “Auto Start ARMED”
message. The engine starts when the remote start input wire is grounded. The engine stops
with the remote start wire is not grounded.
Automatic Throttle Control
With the key in the AUTO position, automatic throttle control is active and the panel manages
engine speed. Instructions on automatic start configurations are listed below.
Auto Operation Settings
Auto Start Configuration
Auto Start Time Delay Selection (Default = 0:10)
Preheat Time Selection (Default = 0:00)
Crank Time Selection (Default = 0:10)
Rest Time Selection (Default = 0:10)
Warm Up Speed Selection (Default = 800 RPM)
Warm Up Time Selection (Default = 0:10)
Operate Speed Selection (Default = 1800 RPM)
Cool Down Speed Selection (Default = 650 RPM)
Cool Down Time Selection (Default = 0:10)
Crank Cycles Selection (Default = 5)
Fault Bypass Period Selection (Default = 0:10)
Crank Hold Delay Selection (Default = 0 TSec)
Crank Release Speed Selection (Default = 400 RPM)
Recharge Monitor On/Off (Default = Off)
Recharge Voltage Selection (Default = 119 Vx10)
Recharge Delay Selection (Default = 60 Sec)
Recharge Run Time Selection (Default = 15 Min)
Next Recharge Time Interval Selection (Default = 45 Min)

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SLEEP MODE
To minimize current draw, the panel goes into a sleep mode two minutes after being set in auto
mode. In sleep mode, the display goes blank and the red lamp blinks once every ten seconds. The
engine ECU is also turned off.
Upon receiving a signal from a float or transducer the panel wakes up, the display turns back on and
normal operation commences.
Pushing any of the four buttons wakes up the panel and turns the display on. It will return to sleep
mode after a two minute period.
For service purposes, to keep engine ECU powered, access the menu system. The engine ECU
remains on when the menu system is active.
Red Lamp

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MODULE CONNECTOR
Primary Connector
14 Pin

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Primary Connector (14 Pin)
Pin
Function
Pin
Function
1
Relay #2 –Fuel/Run
8
J1939 Low
2
Relay #1 –Pre Alarm
9
Relay #3 Common
3
Relay #3 - Alarm
10
Key Auto Detect
4
Relay #2 & #4 Common
11
Battery Positive
5
Relay #4 –Crank
12
Battery Negative
6
Relay #1 Common
13
Analog #1 Input
7
J1939 High
14
DI #1 –Auto Start
CAUTION:
Maximum current draw for signal circuits is 5 amps

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PANEL CONNECTORS (RECOMMENDED)
1. Engine Harness Connector –Deutsch 21 pin (HDP24-24-21PE)
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

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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
4) Displays the occurrence count of the code
Occurrence
Count
Code
Description
SPN.FMI
Code
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/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. 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 enabled to be used.
Analog Inputs
Input
Heading
Default
Connector
Pin
Analog 1
Function
None
14 Pin
13
Message
None
Digital Inputs
Input
Heading
Default
Connector
Pin
Digital 1
Function
Auto Start
14 Pin
14

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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 SW 100 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 SW 125 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 = 125 PSI. Sender ground must be common with battery negative.
5) Oil Pressure SW 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.
6) Oil Pressure VDO PSI –Oil pressure, in PSI, can be measured and displayed on the C3 module
using a standard VDO scale sender of 10 ohms –180 ohms. 10 = 0 PSI and 180 = 150 PSI.
Sender ground must be common with battery negative.
7) Oil Pressure VDO bar –Oil pressure, in bar, can be measured and displayed on the C3 module
using a standard VDO scale sender of 10 ohms –180 ohms. 10 = 0 bar and 180 = 7 bar.
Sender ground must be common with battery negative.
8) 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.
9) None –Set to None when no functionality is required.

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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
Relay 1
Function
Pre Alarm
Polarity
Positive
Initial State
Off
Relay 2
Function
Fuel/Run
Polarity
Positive
Initial State
On
Relay 3
Function
Alarm
Polarity
Positive
Initial State
Off
Relay 4
Function
Crank
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. 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.
c. 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.
d. 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.
e. 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.

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f. Pre Alarm & Alarm Horn –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.
h. Low Oil Pressure Alarm –Relay closes if a low oil pressure shutdown is detected.
i. High Coolant Temperature Alarm –Relay closes if a high engine temperature
shutdown is detected.
j. Over Speed Alarm –Relay closes if an overspeed shutdown is detected.
k. Over Crank Alarm –Relay closes if an over crank alarm is detected.
l. Low Fuel Level Alarm –Relay closes if a low fuel level shutdown is detected.
m. Throttle B1 –Reserved for OEM applications.
n. Throttle B0 –Reserved for OEM applications.
o. Custom 1 - Reserved for OEM applications.
p. Preheat –Relay will be active during programmed preheat period. Used to drive a
preheat relay.
q. Crank –Relay will be active during auto crank period. Used to drive a starter relay.
r. Start Warning –Relay will be active during auto start delay period. Typically used to
drive the low side of an alarm horn or light.
s. Start & Alarm Horn –Energizes an external audible alarm during the auto start
process. Sounds alarm before the engine starts. Pressing the ENTER button will
silence.
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 the MENU button and press the ENTER button.
Menu Navigation
Press the MENU button to scroll through the menu options.
Press the UP arrow button to enter menu.
Press the DOWN arrow button to reverse.
Exit Menu System
Hold the MENU button and press the ENTER button.
To Change a Setting
Press the ENTER button to bring up brackets [ ].
Press the UP arrow button and DOWN arrow button to change setting.
Press the 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)
Auto Start Configuration
(7)
Viewing
Menus
Configuration
Menus

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Configuration Menus
(1)
Input Configuration
Analog 1 Setup (Function, Message)
Digital Input 1 –Pre Set to Auto Start
(2)
Output Configuration
Relay Output 1 - Pre Set to Pre Alarm
Relay Output 2 - Pre Set to Fuel/Run
Relay Output 3 - Pre Set to Alarm
Relay Output 4 - Pre Set to Crank
(3)
Throttle Configuration
Throttle Type Selection (Default = TSC Vernier)
TSC Mode Selection (Default = Primary)
TSC Min Speed Selection (Default = 650 RPM)
TSC Max Speed Selection (Default = 2400 RPM)
TSC Bump Speed Selection (Default = 20 RPM)
TSC Ramp Rate Selection (Default = 100 RPM/Sec)
Throttle Curve Selection (Default = Linear)
Multistate Speed 1 Selection (Default = 650 RPM)
Multistate Speed 2 Selection (Default = 650 RPM)
Multistate Speed 3 Selection (Default = 650 RPM)
Multistate Speed 4 Selection (Default = 650 RPM)

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(4)
Engine Safety Configuration
Sender Check Bypass Time Period Selection (Default = 0:10)
Fuel Level Check Off/Always/Run (Default = Off)
Low Fuel Level Pre Alarm Selection (Default = 20%)
Low Fuel Level Alarm Selection (Default = 1%)
Fuel Level Alarm Time Delay Selection (Default = 0:05)
Oil Pressure Check Off/Always/Run (Default = Run)
Low Oil Pressure Pre Alarm Selection (Default = 6 PSI)
Low Oil Pressure Alarm Selection (Default = 5 PSI)
Oil Pressure Alarm Time Delay Selection (Default = 0:10)
Engine Temperature Check Off/Always/Run (Default = Run)
Low Temperature Pre Alarm Selection Deg. F (Default = 0F)
Low Temperature Alarm Selection Deg. F (Default = 0F)
High Temperature Pre Alarm Selection Deg. F (Default = 244F)
High Temperature Alarm Selection Deg. F (Default = 245F)
Engine Temperature Alarm Time Delay Selection (Default = 0:10)
Battery Volt Check Off/Always/Run (Default = Off)
Low Battery Volt Pre Alarm Selection (Default = 12.0 V)
High Battery Volt Pre Alarm Selection (Default = 15.0 V)
Battery Volt Trim Setting (Default = 5 100mV)
Over Speed Alarm Off/Always/Run (Default = Off)
Over Speed Alarm RPM Setting (Default = 3000 RPM)
Over Speed Alarm Time Delay Selection (Default = 0:05)
(5)
Module Configuration
Pressure & Temperature Units (Default = English)
Hour Meter Source (Default = Engine ECU)
Hour Meter Setting (Default = 0 Hours)
Display Battery Source (Default = J1939)
Pre Alarms Displayed (Default = 4)
Clear Operation Log Yes/No (Default = No)
Clear Alarm Log Yes/No (Default = No)
(6)
CAN Configuration
TSC1 Address (Default = 3)
Source Address (Default = 44)
Engine Address (Default = 0)
Oil/Fuel Transmit On/Off (Default = Off)