DynaGen ES52 User manual

ES52
A
uto Star
t
E
ngine
Controller
Installation and User Manual for the ES52 Auto Start Engine Controller.
Full Version
File: ES52 Rev 2_6_4.doc
November, 2006

Operating & Installation Manual for the ES52 Engine Controller
2
LIMITED WARRANTY POLICY: DynaGen Technologies Inc. hereafter known as the Seller warrants
articles sold hereunder to be free from defects in material and workmanship. These express warranties are
the sole warranties of the Seller and any other warranties, expressed, implied in law, or implied in fact,
are hereby specifically excluded. The Seller’s sole obligation under its warranty shall be, at its option, to
either issue a credit, or repair or replace any article or part thereof, which is proved to be defective. Any
adjustment of credits will be based upon original billing prices. All warranties shall expire 5 years from
date of shipment by the Seller, unless otherwise specified in other written communications from the
Seller. Any replacement product provided to the Buyer shall be subject to the original warranty period,
which will expire 5 years from the date of shipment of the original article. Notice of claimed breach of
warranty must be given within the applicable period. No allowances shall be made to the Buyer for any
transportation, duties, brokerage fees, labor costs, or parts adjustments or repairs, or any other work,
unless said charges are authorized in writing, in advance, by the Seller. The Seller shall, in no event, be
liable for special or consequential damages or for loss of profit. The warranty shall not extend to any
articles or parts thereof which have been installed, used, or serviced, other than in conformity with the
Seller’s application specifications, manuals, bulletins, or instructions, or, if none, shall have been
subjected to improper installation, misuse, or neglect. The warranties shall not apply to any materials or
parts thereof, furnished by the Buyer, or acquired from others at the Buyer’s request and/or to the Buyer’s
specifications or designs. The foregoing limitations on the Seller’s liability in the event of breach of
warranty shall also be the absolute limit of the Seller’s liability in the event of the Seller’s negligence in
manufacture, installation, service, or otherwise, with regard to the articles covered hereby, and upon the
expiration of the stated warranty period, all such liabilities shall terminate.
RETURNS: If any article is claimed to be defective in material or workmanship, the Seller, upon notice
promptly given, will issue a written return material authorization (RMA) with shipping instructions for
return to the Seller. All returns must be accompanied by an RMA number or shipments will not be
accepted by the Seller. Articles which are returned as defective, but are found to meet the specifications
agreed upon, will be subject to a re-testing charge. At the discretion of the Seller, unused and undamaged
Standard Products may, under certain circumstances, be accepted back for credit or exchange. A
restocking charge of 15% will apply. Unused custom designed products will not be accepted back for
credit or exchange.
For questions or comments regarding this product, contact:
DynaGen Technologies Inc.
Phone [phone]
Fax: [phone]
Email: [email protected]
Web Site: www.dynagen.ca

Operating & Installation Manual for the ES52 Engine Controller
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Table of Contents
INTRODUCTION 4
SPECIFICATIONS 5
WIRING INSTALLATION GUIDELINES 6
Wiring Instructions, types and sizes 6
WiringGuidelines 7
Terminal Descriptions 8
General Wiring Diagram 9
Outline Dimension Drawing 10
ADJUSTMENTS AND SETUP PROCEDURES 11
Selecting the Engine Speed Range 12
Oil Switch Verification - Oil Switch Enabled or Disabled 12
Selecting a Timer Function 13
Adjusting Timer Setting 14
Setup Mode Calibration 14
Crank/Rest Time Calibration 15
Crank Disconnect Calibration 15
OverSpeedCalibration 16
Selecting the Maximum Number of Crank Tries 16
WarmUp 16
LED INDICATIONS 17
TROUBLESHOOTING GUIDELINES 18
TECHNICAL NOTES ON FREQUENTLY ASKED QUESTIONS 19
Diode Connections for Using Auto/Off/Test Switch 19
Controller Memory Clear Time 19
Step Down Transformer Use with Inverter Systems 20

Operating & Installation Manual for the ES52 Engine Controller
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INTRODUCTION
The ES52 provides Automatic Start/Stop and protection control for all types of Engine-driven equipment.
Simplicity of use, safety, features, versatility and over-all quality are paramount, providing the most cost
effective and reliable solution available. Ours came to be one of the smallest controllers available, with
the best value per dollar-cost, backed by an Industry Leading 5 Year Warranty.
The ES52 maintains backward compatibility to the extent that it can replace similar products without
substantial rewiring. Functionally, however, it is loaded with unique features:
•"No speed signal" detection: Should the frequency of the speed sensing signal go to Zero while the
engine is running, or fail to appear during cranking, a No Speed Failure is asserted and specifically
indicated. NOTE:Speed signal detection during cranking can be disabled via an onboard Dip Switch.
In some cases when using generator mains as speed signal source it is required to disable this
shutdown (when residual is very low).
•Differential speed sensing inputs (for twisted-pair connection): Very effective interference prevention
by means of noise cancellation.
•Excellent EMI handling: Software detection of, and recovery from, noise corruption.
•Replaceable Relays: Replaceable relays provided within on board sockets. Relays Rated 20Amps at
30VDC
•Replaceable Fuse: On board replaceable 20Amp fuse, mini-fuse (standard automotive type).
•Reverse Polarity Protection: No requirement for series diode on supply.
•3.3VDC to 30VDC, -40ºC to +85ºC Operation: Works anywhere, anytime.
•Zero Speed RestartTM: Prevents starter pinion wear by ensuring that no engagement of the starter is
possible unless the speed is Zero.
•Oil BypassTM: Waits 15 Seconds from start for 1-3 crank tries, and 20 Seconds for more than 3 crank
tries, before enabling Low Oil pressure monitoring. Requires no user setting.
•Four Timer Functions: Glow Plug, Smart ChokeTM, Air-Gate and Slow.
•Rest Time Indication: Provides feedback between crank attempts.
•Warm Up: Turns an output on which can control a load device. Warm Up timer output is provided on
all ES52 units via Terminal 19. Warm Up timer is fixed at 2 Minutes.
•Small Size: 3.302” x 3.342” x 1.842” 0.67lbs

Operating & Installation Manual for the ES52 Engine Controller
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SPECIFICATIONS
Operating VDC limits: 3.3VDC min - 30VDC max
Provided minimum 8VDC Present at Starting.
Standby current draw: 12.2mA at 12VDC (12.4mA at 24VDC)
Operating current draw: 140mA at 12VDC (80mA at 24VDC)
Reverse polarity protected: Internal protection will prevent damage to unit under a reverse
polarity condition. Re-connect power leads properly, and normal
operation will resume.
Speed sensing input accepts: Generator AC output directly
Fly Wheel Alternator
Engine Alternator
Magnetic Pickup
Speed sensing maximum rating: Withstands Line Voltage up to 300VAC
Operating temperature range: -40OC ⇒+85 OC
Operating humidity range: 0 ⇒95% non-condensing
Fuel & Crank contact output: 10Amps maximum each continuous sourcing (+Bat) output
Annunciation outputs: Sourcing (+Bat) outputs (300mA maximum per output)
Lamp Test terminal: Close to +Battery to test LED’s
Actual unit weight: 0.67 lb (0.30kg)
Shipping weight: 1 lb (0.45kg)
Unit dimensions: 3.302” x 3.342” x 1.8”
Shipping dimensions: 4” (10.16cm) x 4” (10.16cm) x 3” (7.62cm)

Operating & Installation Manual for the ES52 Engine Controller
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WIRING INSTALLATION GUIDELINES
Danger: The controller does not generate a warning prior to Automatic Engine
start. Do not work on the Engine while power is applied to the unit. It is highly
recommended that warning signs be placed on Engine equipment indicating the
above.
INSTRUCTIONS
Following these instructions will help avoid common installation problems during wiring and setup.
•Battery must be disconnected before any wiring connections are made.
•Wire length from the engine to the controller should not exceed 6 Meters (20 Feet).
Wiring size and type should be as specified below. Use stranded wire, since solid wire has a tendency to
crack, break and loosen over time.
TYPES AND SIZES
Terminal Wire Size Current max. Function
CON 1 Harness
Supplied 100mA Speed Signal connection via on board connector
1 18 100mA LED Test Switch
2 18 7mA Oil Pressure Switch
3 18 7mA High Temperature Switch
4 18 7mA Auxiliary Input Switch
5 14 10Amps Starter Solenoid/Pilot Relay
6 12 20Amps Battery Negative (-)
7 12 20Amps Auto Switch
8 12 20Amps RSC1 (Remote Start Contact connection)
9 12 20Amps RSC2 (Remote Start Contact connection)
10 12 20Amps Start/Stop connection
11 14 10Amps Fuel Solenoid/Pilot Relay
12 18 300mA Timer Output
13 ⇒18 18 300mA Annunciation Outputs
19 18 300mA Warm Up Output
20 18 300mA Annunciator Common Ground Only
(DO NOT use this as main ground
connection)

Operating & Installation Manual for the ES52 Engine Controller
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WIRING GUIDELINES
1. DO NOT use wire smaller than 18 AWG.
2. The connections supplying DC power to the ES52 panel should preferably run directly from the
battery posts with no splices or other connections except a 25Amp fuse connecting the positive line
directly to the +Battery terminal. Avoid, as much as possible, using chassis (aluminum or iron engine
parts) as return conductor for battery negative voltage; copper wiring is recommended. Failure to
follow the above may result in erratic operation, due to large voltage drops across wiring connections.
3. DO NOT short Crank or Fuel Outputs to ground as this will cause the on board 20Amp fuse to blow
and may result in damage to the ES52’s onboard relays.
4. When replacing fuse, removable terminals and relays, only use factory recommended parts.
5. DO NOT use AC coil slave relays from controller outputs. Use intermediate relays of suitable size
and coil rating.
NOTE: All ES52 engine controllers are shipped standard with 12VDC coil relays for
+12VDC systems. If the engine controller is used in a +24VDC system, the onboard
relays MUST be replaced with 24VDC coil relays.
6. DO NOT exceed the maximum rated Current and Voltage on each of the controller outputs. DO
NOT exceed 10Amps for the Fuel Output, 10Amps for the Crank Output and 300mA for the
Annunciation and Timer outputs.
7. The Annunciation and Timer outputs are internally protected against overload and short circuit
(fault). NOTE: When a fault appears on one of the Annunciation outputs, only that specific output
becomes inoperable, all other Annunciation outputs and the entire front panel LED’s continue to
operate. When the fault is removed and the unit restarted, the output resumes proper operation.
8. Two wires must be connected for the speed signal.
NOTE: A mating connector complete with 8 Feet of cabling is provided as standard with each unit.
9. Diodes are provided across Fuel, Crank, and Annunciation outputs to protect the outputs from
inductive kick-back. Diodes should be placed across slave relay contacts when used to actuate any
inductive loads; such as solenoids; to protect the contacts from damage caused by arcing. In addition
to prolonging the useful life of the relays, placing such diodes will help reduce generated electrical
noise.
10.To verify the operation of Engine controller outputs, measure voltage (i.e. meter in volts) when
outputs should be ON.

Operating & Installation Manual for the ES52 Engine Controller
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TERMINAL DESCRIPTIONS
Term # Description
CON1
Speed Signal Input for Crank Disconnect, Engine Run and Over Speed sensing. Be sure to use
twisted pair wiring for this connection. An 8foot wiring harness is supplied as standard.
300VAC maximum Input voltage.
1 Lamp Test. Connecting +12/24VDC to Lamp Test activates the entire front panel LED’s.
NOTE: Annunciation outputs DO NOT activate under Lamp Test.
2 Oil Pressure Input. For proper operation, Oil Input must be connected to ground or +12/24VDC via
an Oil switch. This switch must be the NO (normally open) type, close on failure (low pressure)
3 Temperature Input. For proper operation, Temperature Input must be connected to ground or
+12/24VDC via a Temperature switch. This switch must be the NO (normally open) type, close on
failure (high temperature)
4 Auxiliary Input. For proper operation, Auxiliary Input must be connected to ground or +12/24VDC
via a sensor switch. This switch must be the NO (normally open) type, close on failure.
5 Crank Output provides 10Amps maximum. Crank Output closes to +12/24VDC during cranking
and opens when the engine has started or during crank rest.
6 Battery ground connection for the controller module. A good ground connection, directly from the
battery, is required for proper operation.
7 Auto Terminal. When +12/24VDC is applied; the controller is in standby mode waiting for a
Start/Stop signal (+12/24 VDC applied to Start/Stop Terminal).
8 RSC1, provided for the connection of one lead from the Remote Start Contacts
9 RSC2, provided for the connection of the other lead from the Remote Start Contacts
10 Start/Stop Terminal. When +12/24VDC is applied, the controller proceeds to starting the engine.
11 Fuel Output provides 10Amps maximum. Fuel Output closes to +12/24VDC when start signal is
actuated, and opens when either an Engine failure is detected or when a Stop signal is applied.
12 Timer Output provides 300mA maximum. This output has one of four possible functions (Glow
Plug, Smart ChokeTM, Air-Gate or Slow). This output closes to +12/24VDC when activated.
13 Low Oil pressure Output provides 300mA maximum. Oil Output closes to +12/24VDC when the
Engine shuts down due to a Low Oil pressure condition. Flashing Low Oil Output indicates an
Auxiliary Input failure.
14 High Temperature Output provides 300mA maximum. Temperature Output closes to +12/24VDC
when the Engine shuts down due to a High Temperature condition.
15 Over Crank Output provides 300mA maximum. Over Crank Output closes to +12/24VDC when the
Engine shuts down due to an Over Crank failure.
16 Over Speed Output provides 300mA maximum. Over Speed Output closes to +12/24VDC on an
Over Speed failure and is open otherwise. Flashing Output indicates Loss of Speed Signal.
17
Engine Running Output provides 300mA maximum. Engine Running Output closes to +12/24VDC
when Engine speed is greater than the Crank Disconnect setting and opens when the Engine stops.
Flashing Output indicates Crank Rest period.
18 Engine Failure Output provides 300mA maximum. Engine Failure Output activates on any failure
Engine Failure Output closes to +12/24VDC when activated.
19 Warm Up Output provides 300mA maximum. Warm Up Output activates after the controller has
been running for 2 Minutes and 10 Seconds.
20 Common ground - For Annunciation Outputs only.
DO NOT USE AS MAIN GROUND TO CONTROLLER UNIT.

Operating & Installation Manual for the ES52 Engine Controller
9
General Wiring Diagram
ATTENTION
All ES52 Controllers come with 12VDC Relays for 12V systems.
For 24V systems replace with 24VDC Relays.
(-)(+)
BATTERY
REMOTE START
STARTER
OR STARTER
SOLENOID
CONTACTS
AUTO/OFF/TEST
OFF
SWITCH
TEST
AUTO
HIGH WATER
TEMP SWITCH
LOW OIL
PRESSURE
SWITCH
LAMP TEST
PUSHBUTTON
SWITCH
25 AMP
FUSE
HIGH TEMP.
SPEED SIGNAL
LED TEST
LOW OIL
AUXILIARY
ENGINE RUN
FAILURE
WARMUP
LOW OIL
HIGH TEMP.
OVERCRANK
OVERSPEED
AUXILIARY SWITCH
LOW OIL PRESS LAMP
HIGH WATER TEMP LAMP
OVERCRANK LAMP
OVERSPEED LAMP
ENGINE STARTED LAMP
COMMON ALARM LAMP
9 5 6 8 7 12 10 11
OFF
ON
CRANK REST
CONNECTOR
SIGNAL
SPEED TIMER
CRANK DISC.
OVERSPEED
3
1
2
4
19
20
123456789 17
18
COMMON
14
16
15
13
TIMER CRANK GROUND AUTO (+Vbat) RSC 1 RSC 2 START STOP FUEL
WARMUP RELAY
TIMER RELAY
FUEL SOLENOID
AND / OR
IGNITION
E
S5
2
G
ENERAL WIRIN
G
DIA
G
RAM
DIP SWITCH
20A FUSE
ADJUSTMENT POTS
RELAY
CRANK
RELAY
FUEL
10A
DIODE

Operating & Installation Manual for the ES52 Engine Controller
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ES52 Outline Dimensions
OVERSPEED
CRANK DISC.
A: #6-32 X 1/2" DEEP
A
A
CONNECTOR
SIGNAL
SPEED
LOW OIL LED TEST HIGH TEMP. AUXILIARY
HIGH TEMP. OVERCRANK OVERSPEED ENGINE RUN
DIP SWITCH
TIMER
20A FUSE
ADJUSTMENT POTS
1 2 3 4
17
OFF
721 3456 98
19 20 18
FAILURE WARMUP COMMON
ON
16 15 14 13
LOW OIL
FUEL
RELAY
FUEL
RSC 2
RSC 1
GROUND
CRANK
START STOP
AUTO (+Vbat)
CRANK
RELAY
5
6
10
9
8
7
11
TIMER 12
3.302”
2.821”
0.250”
1.842”
0.570”
0.821”
0.521”
0.385”
0.486”
0.836”
1.186”
1.536”
1.886”
2.236”
2.
8
8
6”
3.342”
CRANK REST

Operating & Installation Manual for the ES52 Engine Controller
11
ADJUSTMENTS AND SETUP PROCEDURES
Warning: The following procedures will require engine operation. Be sure to follow
all safety guidelines and wiring procedures.
NOTE:
“Potentiometer” is abbreviated as “pot” throughout. To increase a pot’s setting turn it clockwise, to
decrease the pot’s setting turn it counter-clockwise. Onboard pots are 20 turns nominal, therefore turn
pots fully 20+turns to ensure that you are at either the minimum or maximum setting. The rear of the
ES52 controller contains 4adjustable pots and 9Dip Switches.
"Oil BypassTM " period refers to the delay period (fixed at 15 Seconds for 1-3 crank tries and 20 Seconds
for more than 3 crank tries) immediately after the Engine Running LED illuminates (Engine starts).
During this period the Oil Input is bypassed (ignored).
Pots are shown below as they appear on the rear of the ES52 series units
1. Crank Disconnect
2. Over Speed
3. Crank/Rest
4. Timer
Label on the Rear of the ES52 Series Unit
123456789 ON
OF
F
4
3
2
1

Operating & Installation Manual for the ES52 Engine Controller
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The steps to calibrate the ES52 controller to a specific system are as follows:
1. Selecting the Engine Speed Range - Dip Switches 4 and 5
2. Oil Switch Verification - Oil Switch enabled or disabled - Dip Switch 6
3. Selecting a Timer Function - Dip Switches 7 and 8
4. Adjusting Timer setting - Only needed for Glow Plug and Slow Functions
5. Selecting Setup Mode - Dip Switches 1, 2 and 3
6. Crank/Rest Time Calibration
7. Crank Disconnect Calibration
8. Over Speed Calibration
9. Selecting the Maximum Number of Crank Tries - Dip Switches 1, 2 and 3
1: Selecting the Engine Speed Range
Two Speed Ranges are provided to permit greatest accuracy when adjusting Crank Disconnect and Over
Speed settings. The Speed Ranges are selectable through Dip Switches 4 and 5.
Generator output: When using Generator output (50 or 60Hz), Speed Range 1 (LO) is required.
Flywheel Alternator: When using a Flywheel Alternator Speed Range 1 (LO) will be required. Refer to
Engine’s specifications for number of poles attached to flywheel. i.e. 1 pole
(60Hz), 2 poles (120Hz) and 4 poles (240Hz).
Engine Alternator: An engine alternator could require Speed Range 1 (LO) or 2 (HI). Refer to
Engine’s specifications for pulley ratio and number of poles before selecting range.
Magnetic pickup: A magnetic pickup would require Speed Range 2 (HI).
Range SW 4 SW 5 Crank Disconnect (Hz) Over Speed (Hz)
1 (LO) OFF OFF 12 - 140Hz 44 – 300Hz
2 (HI) ON ON 60 - 4156Hz 300 - 8492Hz
Selecting the Proper Speed Range
2: Oil Switch Verification
The Oil Pressure Switch must be the type that opens when oil pressure is normal, and closes on Low Oil
pressure (failure condition or engine stopped). Dip Switch 6 must be set to the ON position if you wish
to enable Oil Verification and set to the OFF position if Oil Verification is to be disabled. If Dip
Switch 6 is ON prior to Cranking, the controller will attempt to verify that the Oil Pressure Switch is
connected and operating properly by checking if the circuit is closed. If the Oil Pressure Switch does not
work or the wire fails to make the connection, the engine will be prevented from starting and the ES52
will assume a ‘wait and see’ mode (indicated by a steady Low Oil and flashing Engine Running LED).
As soon as the Oil Pressure Switch closes, Cranking will proceed as usual. (If the engine starts, the
controller will check for a Low Oil Failure condition only after the Oil BypassTM period). Note that if
this verification was not performed, a ‘bad connection’ of the Oil Switch might go unnoticed until such
time as Oil runs out, and Engine damage occurs!

Operating & Installation Manual for the ES52 Engine Controller
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Note:
i) Oil circuit verification is only performed in the following conditions:
a) On the first Cranking attempt
b) If the Engine has been previously running and more than 5 Minutes of rest has
elapsed.
ii) If Dip Switch 6 is set to the OFF position, the ES52 does not provide Oil verification. The ES52
goes immediately into cranking, it will then check for a Low Oil Failure condition after the
Oil BypassTM period has elapsed.
SW 6 Oil Switch Verification
ON Enabled
OFF Disabled
3: Selecting a Timer Function
The Timer function is configurable from Dip Switches 7 and 8. The Output terminal associated with this
Timer setting is Terminal # 12. It has 4configurable functions of which 2are adjustable:
Glow Plug The Glow Plug timer is adjustable from 0 - 32 Seconds by adjusting the Timer
pot. Glow Plug is a timing function used with Diesel engines. This output is
energized on every Crank attempt for a set time prior to Cranking engine.
Smart ChokeTM The Choke function is used on gasoline engines having an electric Choke. The
Choke Output is energized 2½ Seconds into the cranking cycle, but only on even
numbered Crank attempts (Exception: single crank attempt mode allows choke). If
Engine Speed remains above Crank Disconnect setting, Choke output is turned off;
but as soon as speed falls below Crank Disconnect, it is re-applied. This ON/OFF
regulation will continue, if necessary, as long as the Oil BypassTM period is in
effect.
Air-Gate The Air-Gate Output is used to control an air damper and only actuates for a fixed
10 Seconds immediately after an Over Speed Failure occurs. This feature is used
for some Diesel engines that cannot be stopped quickly enough by merely shutting
off the Fuel in the event of an Over Speed condition. An electrically operated air
damper is installed at the air intake, which effectively ‘gags’ the engine to a stop.
Refer to your Engine’s User Manual for more information.
Slow This function is adjustable from 0 - 256 Seconds via the Timer pot. The Timer
output energizes when Engine speed goes above Crank Disconnect speed (Engine
starts) and remains so for the prescribed duration. It is called “Slow” because it
would presumably be used to tell a Governor to ’go slowly’; for such applications
as irrigation pumps where running slowly for the first minute or two prevents
‘water hammer’.

Operating & Installation Manual for the ES52 Engine Controller
14
The timer settings are as specified in the following table.
SW 7 SW 8 Timer Function Adjustable Time
OFF OFF Glow Plug 0 - 32 Seconds
ON OFF Air-Gate Not Adjustable(10 Sec)
OFF ON Smart ChokeTM Not Adjustable
ON ON Slow 0 - 256 Seconds
4: Adjusting Timer
Glow Plug and Slow only. Air-Gate and Smart ChokeTM do not use the pot.
(0 - 32 Seconds for Glow Plug and 0 - 256 Seconds for Slow)
For the Glow Plug setting (Dip Switches 7 and 8 OFF)
a) Remove wires connected to the Timer Terminal # 12 and Crank Terminal # 5.
b) Apply power to Start/Stop Terminal # 10.
c) Measure the time the Timer LED remains ON.
d) Remove power from Start/Stop Terminal # 10.
e) Increase or Decrease pot setting as required. Resolution is 1.6 Seconds/turn.
f) Return to Step b.
Re-connect wires to the Timer Terminal # 12 and Crank Terminal # 5 before proceeding to Step 5.
For the Slow setting (Dip Switches 7 and 8 ON)
a) Apply power to Start/Stop Terminal # 10.
b) Allow the Engine to Crank and Start, Engine Running LED turns ON.
c) The Timer LED will illuminate, measure the time that the LED remains ON.
d) Increase or Decrease pot setting as required. Resolution is 12.8 Seconds/turn.
e) Return to Step a.
5: Setup Mode Calibration
Setup Mode allows for much easier calibration of Over Speed, Crank Disconnect and Crank/Rest time.
When the unit is removed from Setup Mode, the Over Speed and Crank Disconnect pot settings will be
increased by 15% of calibrated values. NOTE: If Setup Mode is used skip to page 17
To enter Setup Mode: Set Dip Switches 1, 2 and 3 to the ON position.
During Setup Mode the following conditions apply:
•Crank time defaults to present pot value. The Maximum Crank time is 36 Seconds.
•Crank/Rest calibration - Apply power to Auto and Over Crank LED will flash. The time between
flashes indicates the Crank/Rest time. Adjust pot accordingly to increase or decrease Crank/Rest time.
•Crank Disconnect and Over Speed pot calibration - Apply power to Start/Stop. Follow procedure
outlined in Step - 7 (Crank Disconnect Calibration) and Step 8 (Over Speed Calibration).
•Smart ChokeTM and Slow Timer functions are disabled.
•Upon completion, reset Dip Switches 1, 2 and 3 to give desired crank tries.

Operating & Installation Manual for the ES52 Engine Controller
15
6: Crank/Rest Time Calibration
The Crank/Rest pot controls the maximum allowable cranking time per cranking attempt, as well as the
rest time between crank attempts; it is adjustable from 4 - 36 Seconds. Note: The rest time only begins
when Engine speed reaches Zero.
To adjust Crank/Rest time
a) Apply power to Auto Terminal # 7.
b) Remove wire connected to Terminal # 11 (Fuel/Ignition). For gasoline Engines you may
remove the wire from the spark plug.
c) Initiate Cranking by applying power to Start/Stop Terminal # 10.
d) Measure the amount of time the starter remains engaged. Turn pot clockwise to increase (the
resolution is approximately 1.6 Seconds per turn). After the starter turns off, the unit enters
Crank Rest mode, indicated by flashing running LED.
e) Remove power from Start/Stop Terminal # 10 to prevent another start. Re-calibrate pot and
repeat Step c to confirm proper setting.
7: Crank Disconnect Calibration
The Crank Disconnect pot adjusts the speed at which the controller safely disengages the starter.
To adjust Crank Disconnect
a) Turn Over Speed pot fully clockwise 20+turns.
b) Turn Crank Disconnect pot fully clockwise 20+turns.
c) Remove wire connected to Terminal # 11 (Fuel/Ignition). For gasoline Engines you may
remove the wire from the spark coil.
d) Initiate Cranking by applying power to Start/Stop Terminal # 10.
e) Turn Crank Disconnect pot counter-clockwise until the Green LED turns ON and Crank
disengages (Engine will stall due to missing Fuel/Ignition circuit).
f) Remove power from Start/Stop Terminal # 10.
g) Reconnect wire to Terminal # 11 (Fuel/Ignition) or reconnect spark coil wire - The resolution
is 6.4Hz/turn in speed range 1 (LO) and 204.8Hz/turn in speed range 2 (HI).
Note: To proceed to Step 9, you must ensure the controller positively detects engine start-up. If the
running LED turns on momentarily and then the Engine stalls (Loss of Speed: flashing Over Speed), try
decreasing the Crank Disconnect pot (counter-clockwise) one half turn.
Loss of Speed While Cranking: (begins 3 Seconds into crank cycle) - In the event there is a Loss of
Speed, while cranking or running, the unit will shut down, and this is indicated by a flashing Over Speed
LED. The Loss of Speed while Cranking function can be disabled via Dip Switch 9. When Dip Switch 9
is ON, the Loss of Speed while Cranking function is Enabled. When Dip Switch 9 is OFF, the Loss of
Speed while Cranking function is Disabled. NOTE: The Loss of Speed feature is maintained during
all running conditions.
Note: If unit is configured for Generator Output, there may not be enough residual voltage during
cranking. The following values are minimal recommended voltages for speed signal:
20Hz - .075V (75mV)
60Hz - .6V (600mV)
4500Hz - .8V (800 mV)

Operating & Installation Manual for the ES52 Engine Controller
16
8: Over Speed Calibration
The Over Speed pot controls the speed at which an Over Speed failure shutdown is to be asserted.
To adjust Over Speed
a) Start engine by applying power to Start/Stop Terminal # 10 allowing Engine to reach normal
operating speed.
b) Turn the Over Speed pot counter-clockwise, slowly, until an Over Speed failure occurs.
c) Remove power from Start/Stop Terminal # 10.
d) Set the Over Speed pot to required setting. Resolution is 12.8Hz/turn in speed range 1 (LO) and
409.6Hz/turn in speed range 2 (HI).
9: Selecting the Maximum Number of Crank Tries
The Crank tries are selectable from Dip Switches 1, 2 and 3. Select the Crank tries most appropriate for
your application. Note: An extended Crank attempt range is available, which extends the Crank time to a
time spanning from 4 - 256 Seconds.
CRANK ATTEMPTS SWITCH 1 SWITCH 2 SWITCH 3 TIME RANGE
SETUP ON ON ON 4 - 36 Sec
6 OFF ON ON 4 - 36 Sec
5 ON OFF ON 4 - 36 Sec
4 OFF OFF ON 4 - 36 Sec
3 ON ON OFF 4 - 36 Sec
2 OFF ON OFF 4 - 36 Sec
1 ON OFF OFF 4 - 36 Sec
1 OFF OFF OFF 4 - 256 Sec
10: Warm Up
A Warm Up timer is provided on all ES52 series Engine controllers. Terminal # 19 is the Warm Up timer
output. This output energizes 2 Minutes after the Engine running LED turns ON (Speed above Crank
Disconnect setting). When a Stop signal is initiated, the Warm Up output turns OFF.
This Warm Up output can be used to control a load device, which allows a Generator to Warm Up before
connecting the load.

Operating & Installation Manual for the ES52 Engine Controller
17
LED INDICATIONS
FRONT PANEL LED INDICATIONS
What the LED’s look like Condition/Failure
“Ready” unit waiting for start signal,
+12/24VDC to Auto Terminal
No LED’s ON.
“OFF”, no +12/24VDC to Auto Terminal
Low Oil, steady Low Oil Pressure Failure
Low Oil, flashing Auxiliary Input Failure
High Temperature, steady High Temperature Failure
Over Crank, steady Engine would not start after specified
amount of Crank tries
Over Speed, steady Speed Signal present above Over Speed
setting
Over Speed, flashing
Was Engine Cranking?
Was engine Running?
No speed signal available while Cranking
The speed signal was Zero while running.
The Engine has stalled, or the speed signal
has been lost
Engine Running, steady Engine Controller is in running mode of
operation.
Engine Running, flashing Crank Rest period. Cranking will resume
soon.
“Timer”, steady
Is Over Speed LED ON?
Is Engine Running LED ON?
Is the Engine Cranking?
If the Engine is not cranking or
running
10 Second Air-Gate timer
Slow timer feature (pot adjustable)
Choke feature
Glow Plug timer feature (pot adjustable)
Low Oil steady while Engine
Running Flashing Oil switch is not closed (mis-wired or not
Installed). Engine will Crank when Oil
Switch verifies.
Over Speed and Over Crank LED's
flash alternately Invalid speed range –
Check Dip Switches 4 and 5
Crank Disconnect set too high
TROUBLESHOOTING GUIDELINES

Operating & Installation Manual for the ES52 Engine Controller
18
TROUBLE POSSIBLE CAUSE SUGGESTED ACTION
Power leads to unit are reversed Confirm correct wiring for ground and +Bat,
and re-attempt testing.
Unit does not operate when
powered to test mode Bad ground connection from engine to
controller unit. Run wire directly from battery - to the ground Terminal # 6 on controller unit.
Over Speed pot setting too low Increase Over Speed pot setting to desired
value.
Engine starts and immediately
goes into Over Speed shutdown Improper speed range setting Check to ensure that controller is set to
proper speed range (Dip Switches 4 and 5)
Battery is low or Terminals are dirty Clean Terminals and re-charge battery
Crank circuitry wiring improperly
connected Refer to Engine control wiring section and check crank connections
Bad ground connection from Engine to
controller Run wire directly from battery (-) to the ground terminal # 6 on controller unit.
Engine does not crank
Crank relay damaged or onboard fuse is
blown Check wiring, onboard 20Amp fuse and relay. Replace fuse, relay and re-test controller
again
Out of fuel Check fuel level, add fuel if necessary
Ignition control wiring not installed properly Refer to Engine control wiring section and
check ignition connections
Engine cranks but does not start
Fuel relay damaged Check fuel relay and replace if damaged.
Engine starts but shuts down
after “Oil BypassTM period” due
to Low Oil/High Temp/Extra
Oil/Temp/Extra input wiring improperly
connected. Check wiring for proper connections.
Improper speed range setting Check to ensure that controller is set to
proper speed range (Dip Switches 4 and 5)
Fault (short or overload) on one of the
Annunciator outputs Check for fault, once fault is corrected then operation resumes.
Engine starts, but running LED
does not illuminate.
Crank Disconnect pot set too high Decrease Crank Disconnect pot setting
Annunciation output not working Fault (short or overload) on one of the
Annunciator outputs Check for fault, once fault is corrected then annunciation operation resumes.
Timer LED and Timer output
does not activate Timer pot set to zero Increase Timer pot setting, turn pot clockwise
Timer LED works OK but Timer
output does not activate Fault (short or overload) on Timer output. Check for fault, once fault is corrected then output operation resumes.
Speed signal improperly connected,
missing, or damaged. Check speed signal wiring; replace damaged speed signal source.
Crank output damaged, not working Check wiring and replace controller
Flashing Over Speed LED
Starter or Starter Solenoid damaged Replace/repair damaged Starter or Starter
Solenoid.
Flashing Over Speed LED using
Generator output Not enough residual voltage during cranking. Set Dip Switch 9 to OFF if Set to ON
Crank Disconnect set too high Check Crank DisconnectAlternating flashing of Over
Speed & Over Crank Wrong speed range Check speed range
Check Oil switch wiring.Flashing Run LED & solid Oil
LED Oil switch not closed as it should be Turn Dip Switch 6 OFF to disable Oil
Verification.
Avoid running AC lines from Inverter in same
conduit as Generator output lines.
Install a small step down transformer between
the speed sensing wires and the Generator
output.
Solid Oil LED immediately on
start up, without Engine actually
cranking or starting.
False speed signal being detected by
controller. This problem can sometimes
occur in installations where there is AC
power from Inverters near Generator
output lines connected to the speed signal
cable. If the neutral from the Generator output is not
grounded, attach it to ground at Generator.

Operating & Installation Manual for the ES52 Engine Controller
19
TECHNICAL NOTES ON FREQUENTLY ASKED QUESTIONS
1. 10A Diode on Auto/Off/Test Switch on All Units with Cool Down or Energize To Stop Feature
When using a single switch for Auto/Off /Test on any ES50 Series Controller that has the Cool Down feature, a 10A
diode must be installed between Test and Auto with the band pointing to the Auto terminal. This diode allows power
to go to the Auto terminal as well as the Test terminal when the switch is put in Test position. It is necessary to
have the Auto terminal powered as well as the Test terminal when the unit is used in the Test/Manual mode. The
diode offers a one-way jumper that only lets the current go from Test to Auto and not from Auto to Test. If the
controller is to be used in a two switch configuration with one being for Auto and one for Test, the Auto switch has
to be ON as well as the Test switch when the unit is to be used in Test/Manual. If only the Test terminal is provided
with power, the unit will not operate properly.
OFF
AUTO
AUTO
TEST
TEST
10A Diode with Band Pointing to Aut
o
To Auto Terminal # 7
To Start/STop Terminal # 10
+Batt
Diode
C
onnections
f
or Using Auto
/Off/
Test
S
witch
3
Position
S
witch
2. Controller Memory Clear Time
The ES52 needs 10 Seconds for its memory to clear. When the power to the controller is turned OFF and then back
ON again without waiting to clear the memory, a Loss of Speed will be indicated by the ES52 because the
controller remains in Run mode and senses that the generator has stopped. This would be indicated by a Flashing
Over Speed LED. By leaving the ES52 OFF for 10 Seconds before it is returned to the Auto setting the memory
will be cleared and it will function as intended.
3. Step Down Transformer Use on Speed Sensing Cable with Inverter Systems

Operating & Installation Manual for the ES52 Engine Controller
20
In some applications Engine controllers are used on Generators where there is no utility connection and Inverters
are used to provide AC power instead of a utility. Inverters can produce harmonics that can cause small AC signals
to appear on wires that are near any power lines being fed by the Inverter. If the Generator output wires are located
close to a line being powered by an Inverter, a small AC signal can appear on the Generator output lines when the
Inverter is on. This signal can cause the Engine controller to react as if the Generator is running if the speed sensing
wires are connected to the Generator output lines. This small AC signal can cause the controller to appear to have a
Low Oil Failure when the remote start contacts are closed or the controller is put in the Test/Manual mode. The
controller may think the Generator is already running and immediately check to make sure there is Oil Pressure.
Since the Engine really hasn’t started yet, there is no Oil Pressure and the controller sees a Low Oil fault. This is
seen as the Oil LED turning on solid even before the Engine starts to engage the starter.
Without this false speed signal the controller will not look for Oil Pressure until the Engine has started to run and
the Crank disengages if Oil Verification is disabled. Simply installing a small transformer between the Generator
output and the speed sensing terminals on the controller can eliminate this false speed signal. This transformer
should be rated for 120 or 240 Volts on the Input or Primary coil (depending on the Generator output voltage you
are using for speed sensing), and have an Output voltage of around 12VAC on the Secondary of the transformer.
The two wires from the Secondary of the transformer are connected to the two wires of the speed sensing terminals
on the ES52 controller. The Step Down transformer acts to reduce the false speed signal on the line to a level that
the Engine controller will not recognize as the Engine running. A common size transformer that would serve this
purpose would be 24VA.
12VAC
Secondary
Winding
S
tep Down Trans
f
ormer
120VAC
Primary
Winding To Generator Output
Line to Neutral 120VA
C
Twisted pair of wires connected to
speed sensing terminals on ES52