DynaGen ES52 User manual

Installation and User Manual for the ES52 Auto Start Engine Controller.
Full Version
File: MAN-0001 R4.0, ES52 User Manual.doc
Date: August 2017
Thank You For Purchasing This DynaGen Product
ES52
Auto Start Engine Controller

Operating & Installation Manual for the ES52 Engine Controller
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Please Read Manual Before Installing Unit
Receipt of Shipment and Warranty Return Information
Upon receipt of shipment, carefully remove the unit from the shipping container and
thoroughly examine the unit for shipping damage. In case of damage, immediately contact
the carrier and request that an inspection report be filed prior to contacting DynaGen.
All returned items are to be shipped prepaid and include a Return Material Authorization
(RMA) number issued by DynaGen.
Limited Warranty
For warranty information refer to the standard terms and conditions of sale at
http://www.dynagen.ca.
Dynagen ES52 Support Webpage
For up-to-date manuals and other information please see the Support section of the Dynagen
website at www.dynagen.ca/support.

Operating & Installation Manual for the ES52 Engine Controller
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ES52 Family of Products –Speed Signal Connector Change Notice
This change will take effect in March of 2011 for all new orders. This applies only to the 2-wire
speed signal connection (for mag pickup or generator output). All other connectors and controller
features remain unchanged.
The existing connector and cable of Figure 2 will be replaced by the connector shown in Figure
1. The maximum voltage rating of 300V will remain unchanged. Please adjust your drawings and
wire harness fabrication accordingly.
The new connector style utilizes industry standard ¼” spade terminals. Customers are advised to
select appropriate (insulated) mates to plug onto the spade terminals (female ¼” insulated crimp
connector).
Please note that the current units ship with an 8ft length of cable with a plug. This cable will
become obsolete with the new connector system and thus will not be provided with shipments.
Figure 1 New Connector 1/4" spade terminals
Figure 2 Old Connector Plug-in with Cable

Operating & Installation Manual for the ES52 Engine Controller
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ES52 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.
J1113-11 Transients Pulse 1A (Supply Disconnect), Pulse 2A (Sudden
Disconnect), Pulse 4 (Starter Motor Engagement),
Pulse 5 (Load Dump). Details of the test parameters
are available, please consult with factory.
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: -40 OC to +70 OC
Operating humidity range: 0 to 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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Table of Contents
1. INTRODUCTION..............................................................................................................................................6
2. WIRING INSTALLATION GUIDELINES.....................................................................................................7
2.1 WIRE SIZING................................................................................................................................................7
2.2 WIRING GUIDELINES....................................................................................................................................8
2.3 TERMINAL DESCRIPTIONS............................................................................................................................9
2.4 GENERAL WIRING DIAGRAM .....................................................................................................................10
2.5 ADJUSTMENTS AND SETUP PROCEDURES ..................................................................................................13
2.5.1 Factory Settings...................................................................................................................................14
2.5.2 Selecting the Engine Speed Range.......................................................................................................14
2.5.3 Low Oil Pressure Switch Verification..................................................................................................15
2.5.4 Selecting a Timer Function..................................................................................................................15
2.5.5 Adjusting Timer Duration....................................................................................................................16
2.5.6 Crank and Crank Rest..........................................................................................................................17
2.5.7 Selecting the Maximum Number of Crank Tries..................................................................................17
2.5.8 Crank Disconnect and Over-speed Pot Adjustment.............................................................................17
2.5.9 Loss of Speed (…During Cranking: DIP 9).........................................................................................17
2.5.10 Warm up..........................................................................................................................................18
3. OPERATION ...................................................................................................................................................19
3.1 ES52 STARTUP /SHUTDOWN BEHAVIOR ...................................................................................................19
3.2 ZERO SPEED RESTART FEATURE ...............................................................................................................19
3.3 FRONT PANEL LED INDICATIONS.........................................................................................................19
4. TROUBLESHOOTING GUIDELINES.........................................................................................................21
5. TECHNICAL NOTES ON FREQUENTLY ASKED QUESTIONS...........................................................23

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1. 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. This 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.

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2. 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.
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).
2.1 Wire Sizing
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.
Terminal
Wire Size
Current max.
Function
CON 1
18
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
10 A
Starter Solenoid/Pilot Relay
6
12
20 A
Battery negative (-)
7
12
20 A
Auto Switch
8
12
20 A
RSC1 (remote start contact connection)
9
12
20 A
RSC2 (remote start contact connection)
10
12
20 A
Start/Stop Connection
11
14
10 A
Fuel Solenoid/Pilot Relay
12
18
300mA
Timer Output
13 to 18
18
300mA
Annunciation Outputs
19
18
300mA
Warmup Output
20
18
300mA
Annunciator Common Ground Only
(DO NOT use this as main ground
connection)

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2.2 Wiring Guidelines
1. WARNING: DO NOT apply external voltage to annunciator outputs (terminals 13 to 18).
This will damage the ES52. If this may occur in your application, place a diode in series with
each affected annunciator output.
2. DO NOT use wire smaller than 18 AWG.
3. 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 25A 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.
4. DO NOT short Crank output or Fuel outputs to ground, as this will cause on board 20Amp
fuse to blow and may result in damage to the ES52’s onboard relays.
5. When replacing fuse, removable terminals and relays, only use factory recommended parts.
6. 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
+12 VDC systems. If the engine controller is used in a +24 VDC system, the onboard
relays MUST be replaced with 24VDC coil relays.
7. DO NOT exceed the maximum rated current and voltage on each of the controller outputs.
Do not exceed 10 Amps for the Fuel output, 10 Amps for the Crank output, and 300mA for
the Annunciation and Timer outputs.
8. 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 un-operable, all other annunciation outputs and the entire front panel
LED’s continue to operate. When the fault is removed and the unit is restarted, the output
resumes proper operation.
9. Two wires must be connected for the speed signal
10. 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.
11. To verify the operation of engine controller outputs, measure voltage (i.e. meter in volts)
when outputs should be ON.

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2.3 Terminal Descriptions
Term #
Description
CON1
(Speed)
Speed signal input for crank disconnect, engine run, and over-speed sensing. Generator
output, magnetic pickup (MPU) sensor, or alternator output can be used.
-Use at least twisted pair wiring for this connection.
-Polarity does not matter.
-Use two female 0.250” inch insulated female quick connects for the connection.
For MPU Sensor:
-One side of the MPU must both be grounded and connected to the controller
otherwise erratic behavior can result.
-Use a shielded MPU with a shielded cable grounded at one end only for best
reliability.
1
Lamp test. Connecting +12/24 VDC to lamp test activates all of the front panel LED’s.
NOTE: Annunciation outputs DO NOT activate under led test.
2
Oil pressure input. For proper operation, oil input must be connected to ground or +12/24
VDC via an oil switch. This switch must be the N.O. type, close on failure (low pressure).
When active shuts down the engine.
3
Temperature switch. For proper operation, temperature input must be connected to
ground or +12/24 VDC via a temperature switch. This switch must be the N.O. type, close
on failure (high temperature). When active shuts down the engine.
4
The Auxiliary input. For proper operation, Aux. Input must be connected to ground or
+12/24 VDC via a sensor switch. This switch must be the N.O. type, close on failure.
When active shuts down the engine.
5
Crank output provides 10Amps maximum. Crank output closes to +12/24 VDC 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. When +12/24 VDC is applied; the controller is in the standby mode waiting for a
Start/Stop signal (+12/24 VDC applied to Start/Stop).
8 - 9
Remote Start Contacts
RSC1 is tied internally to AUTO (terminal 7) and RSC2 is tied internally to Start/Stop
(terminal 10) so when RSC1 and RSC2 are shorted they bring the battery positive that is at
the Auto terminal to the Start/Stop terminal which causes the controller start the engine
(see Start/Stop below) and provide power to the crank and fuel outputs.
This means the current for Crank output and Fuel output will pass through the remote
start contacts. The wiring and the remote device/switch must be rated for this current draw.
If this is a problem an external relay can be used. See the tech note at the end of this
manual.
10
Start/Stop. When +12/24 VDC is applied, the controller is powered and proceeds to start
the engine. The power for the crank output and fuel output is obtained from this
terminal. If the 20A fuse is blown the ES52 will not start.
11
Fuel output provides 10Amps maximum. Fuel output closes to +12/24 VDC when start
signal is actuated, and opens when either an Engine failure is detected or when stop signal

Operating & Installation Manual for the ES52 Engine Controller
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is applied.
12
Timer output. This output has one of four possible functions (Glow Plug, Smart ChokeTM,
Air-Gate or Slow). This output closes to +12/24 VDC when activated.
13
Low Oil pressure output. Oil output closes to +12/24 VDC 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. Temperature output closes to +12/24 VDC when the engine
shuts down due to a high temp condition.
15
Over-crank output. Over-crank output closes to+12/24 VDC when the engine shuts down
due to an Over-crank failure.
16
Over-speed output. Over-speed output closes to +12/24 VDC on an Over-speed failure
and is open otherwise. Flashing output indicates Loss of Speed Signal.
17
Engine running output. Engine Running output closes to+12/24 VDC when the 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. Engine failure output activates on any failure (closes to +12/24
VDC when activated).
19
Warmup output. Output turns on after the controller has been running for 2 minutes and
10 seconds. Output turns on immediately if battery voltage is applied to Start/Stop
(terminal 10) and the speed is greater than the crank disconnect pot setting when the
controller is not cranking.
Pins 12 to 19 Note
The maximum rating of each output depends on how many outputs are on simultaneously on pins 10 to
19. Do not exceed these values:
1 on = 300 mA, 2 on = 230 mA, 3 on = 160 mA, 4 on = 123 mA, 5 on = 91 mA, 6 on = 80 mA, 7 on =
66 mA, 8 on = 52mA.
Good practice is to use 50% of the maximum rating.
20
Common ground - For annunciation outputs only. DO NOT USE AS MAIN GROUND
TO CONTROLLER UNIT.
2.4 General Wiring Diagram
See next page for the wiring diagram and dimensions.
ATTENTION
All ES52 Controllers come with 12VDC Relays for 12V systems.
For 24V systems replace with 24VDC Relays.
ES52 Variant Note:
A diode across Auto and Start/Stop terminals is required on versions of the ES52 with the Cool-
Down feature (ES52 EI, FE, and LT variants). See the tech notes section at the end of this
manual for further information. The standard ES52 version does not require this.

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2.5 Adjustments and Setup Procedures
Warning: The following procedures will require engine operation. Be sure to
follow all safety guidelines and wiring procedures.
The rear of the ES52 controller contains 4adjustable pots, and 9DIP switches.
Potentiometer (Pot) Adjustment
“Potentiometer” is abbreviated as “pot” throughout. To increase a pot’s setting, turn it
clockwise. To decrease it, turn it counter-clockwise. On board Pots are 20 turns nominal,
therefore turn pots fully 20 turns to ensure that you are at either the minimum or maximum
setting.
Potentiometers 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
It takes approximately 20 turns to go to the minimum or maximum value. Turning the pot
counterclockwise decreases the setting. Turning the pot clockwise increases the setting.
Each pot has a clutch to protect from overturning and thus potentially requires one to two turns to
overcome this clutch if the pot is at the minimum or maximum position before the value actually
starts changing.
CRANK TRIES
S1 S2 S3
off
on
off off
on on
on
on
on-Enabled
on on #
1
2
3
4
5
6
setup
off
on
on
on
TIMER
SPEED SETTING
off off
S4 S5
Slow
Choke
- single crank attempt - 4 to 256 sec
Range
on on
off off lo
hi
CRDC OVSP
12 - 140 44 - 300
60 - 4156 300 - 8492
S6
off
on Enabled
CRDC - Crank Disconnect (Hz)
OVSP - Overspeed (Hz)
(52 Model Only)
on
off on
off
on
off
on
off off
off
off
CRANK TRIES
LOSS OF SPEED
WHILE CRANKING
S1 S2 S3
off
on
off off
on on
on #
1
2
3
4
5
6
off
on
on
on
TIMER
SPEED SETTING
off off
OIL VERIFICATION
S4 S5
Glow Plug
on on
off off lo
hi
CRDC OVSP
12 - 140 44 - 300
60 - 4156 300 - 8492
off
on Disabled
S7 S8
S9
(52 Model Only)
Airgate
off
off off Setting
on
off
off-Disabled
on
off
on
off off
off
off on
Label on Rear of ES52 series units.
4
3
2
1

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"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).
2.5.1 Factory Settings
The ES52 is setup with the following settings from the factory:
1. 20 Hz / 300 Hz Crank Disconnect in low or high speed mode respectively.
2. 69 Hz / 1080 Hz Crank / Crank Rest in low or high speed mode respectively.
3. 10s Timer output, Timer set to preheat functionality.
4. DIP switches one and two ON. All other OFF.
The steps to calibrate the ES52 controller to a specific system are as follows:
1. Select the Engine Speed Range (DIP switches 4, 5)
2. Low Oil Pressure Switch Verification –low oil pressure switch enabled or disabled (DIP
switch 6)
3. Select a Timer function - (DIP switches 7 & 8)
4. Adjusting Timer setting - (Only needed for Slow and Glow Plug functions)
5. Crank/rest time calibration
6. Selecting the maximum number of Crank Tries (DIP switches 1, 2 & 3)
7. Crank Disconnect / Over-speed calibration
8. Loss of Speed (During Cranking) –Enable / Disable
See the following sections for a more detailed explanation of each.
2.5.2 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 from DIP switches 4 and 5.
Generator output: When using generator output (50 or 60 Hz) speed range 1 (LO) is required.
Flywheel Alternator: When using a flywheel alternator speed range 1 (LO) will be required.
Refer to engine’s specification for number of poles attached to flywheel.
i.e. 1 pole (60Hz), 2 poles (120 Hz), & 4 poles (240 Hz).
Engine Alternator: An engine alternator would require speed range 1 (LO) or 2 (HI). Refer to
engine’s specification 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 - 140 Hz
44 –300 Hz
2(HI)
ON
ON
60 - 4156 Hz
300 - 8492 Hz
Selecting the Proper Speed Range

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2.5.3 Low Oil Pressure Switch Verification
The low 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 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). Notice 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!
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 bypass period has elapsed.
SW 6
Low Oil Pressure switch verification
ON
Enabled
OFF
Disabled
2.5.4 Selecting a Timer Function
The timer function is configurable from DIP switches 7 & 8. The output terminal associated with
this timer setting is terminal #12. It has four configurable functions, of which two are adjustable:
Glow Plug: The Glow Plug timer is adjustable from 0 - 32 seconds. 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.
Choke: 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.

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16
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 engine’s 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’.
The timer settings are as specified in the following table.
SW 7
SW8
Timer function
Adjustable Time
OFF
OFF
Glow Plug
0 - 32 seconds
ON
OFF
Air-gate
Not Adjustable(10 sec.)
OFF
ON
Choke
Not Adjustable
ON
ON
Slow
0 - 256 seconds
2.5.5 Adjusting Timer Duration
(Glow Plug and ‘Slow’ only, as Air-gate and Choke do not use pot) (0 - 32 seconds For
Glow Plug and 0 - 256 seconds for slow)
For the Glow Plug setting (DIP switches 7 & 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.
For the slow setting (DIP switches 7 & 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 pot resolution is 12.8 seconds/turn.
e) Return to step a.
Re-connect wires to the Timer terminal #12 and Crank terminal # 5 before proceeding to Step 5.

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17
2.5.6 Crank and Crank Rest
Enter Setup Mode by setting DIP switches 1, 2 & 3 to the ON position. Apply power to Auto,
and the over crank LED will flash. The time between flashes indicates the Crank and Crank Rest
time. Adjust pot accordingly to increase or decrease Crank/Rest time.
2.5.7 Selecting the Maximum Number of Crank Tries
The Crank tries are adjustable from DIP switch positions 1, 2 and 3. Select the Crank tries most
appropriate for your application. Note that an extended Crank attempt range is available, which
extends the Crank time to a time spanning from 4 to 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
2.5.8 Crank Disconnect and Over-speed Pot Adjustment
From the factory, the crank disconnect is set to 20 Hz in low speed mode and 300 Hz in high
speed mode. One turn gives approximately 6.4Hz in low speed and approximately 205Hz in high
speed mode.
From the factory, the Over-speed is set to 69 Hz in low speed mode and 1080 Hz in high speed
mode. One turn gives approximately 13Hz in low speed and approximately 410Hz in high speed.
To determine the proper crank disconnect and over speed setpoints the best method is to use a
signal generator (also known as a function generator). If you do not have one you can adjust the
pots knowing the factory defaults and the Hz/turn given above.
2.5.9 Loss of Speed (…During Cranking: DIP 9)
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.Loss of speed is defined as no speed signal for at
least 3 seconds. Loss of speed begins 3 seconds into the crank cycle.
The Loss of Speed While Cranking portion can be disabled via DIP switch # 9. When the DIP
switch is in the UP or ON position, the Loss of Speed While Cranking function is enabled. When

Operating & Installation Manual for the ES52 Engine Controller
18
the DIP switch is in the DOWN or OFF position, 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 for this feature. It is recommended to disable this feature.
The following values are minimal recommended voltages for speed signal:
20 HZ - .075 V (75mV)
60 HZ - .6V (600mV)
4500 HZ - .8V (800 mV)
2.5.10 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 (i.e. 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
19
3. Operation
3.1 ES52 Startup / Shutdown Behavior
Note: The fuel output remains on during crank rest. There is no way to disable this.
3.2 Zero Speed Restart Feature
The ES52 has a starter protection feature where it will not turn on the crank output until the
engine speed is zero.
1. If speed is not zero before cranking, preheat (timer) will be performed but the ES52 will
pause until speed is 0Hz or will go into a failure (alternating over crank and over speed
LEDs flashing) after 30 to 40 seconds.
2. If speed is not zero during engine rest the ES52 will not crank until it is zero. It will sit in
engine rest for 30 to 40 seconds and then go into failure (alternating over crank and over
speed LEDs flashing).
3.3 Front Panel LED INDICATIONS
What the LED’s look like
Condition/Failure
No LED’s ON
“Ready” unit waiting for start signal,
+12/24 VDC to Auto terminal.
“OFF”, no +12/24 VDC to Auto terminal.
Low Oil, steady
Low Oil Pressure Failure
Low Oil, flashing
Auxiliary Input Failure
High Temperature, steady
Over-temperature Failure
Over-crank, steady
Engine would not start after specified
Crank tries.
Over-crank, flashing
Unit is in setup mode. Time between
flashes indicates crank and crank-rest time.
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
for 3 seconds. 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.

Operating & Installation Manual for the ES52 Engine Controller
20
“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 (miss-wired or not
Installed). Engine will crank when oil
switch verifies.
Over-speed and over crank LED's
flash alternately
1. Invalid speed range - check DIP
switches 4 & 5.
2. Crank disconnect set too high
(above over speed setting).
3. Speed was not zero at the start of
cranking (timeout).