Kutai electronics EC-22 User manual

KUTAI ELECTRONICS INDUSTRY CO., LTD.
TEL : [phone] FAX : [phone] Website : www.kutai.com.tw
Headquarters : No.3, Ln. 201, Qianfu St., Qianzhen Dist., Kaohsiung City 806037, Taiwan
EC-22
Auto Start Control Unit for DENYO Generator
Operation Manual
* All manufacturer names and numbers are used for reference purpose only
and do not imply that any part is the product of these manufacturer.

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EC-22 2
SECTION 1 : INTRODUCTION
The EC-22 is an Auto Start Control Unit designed for
DENYO generators. It can accept signals from a
remote switch or an automatic transfer switch (ATS) to
automatically start or stop the generator. The unit will
make 3 cranking attempts.
The circuit was controlled by a microprocessor for full
digital processing, reliable performance, and
significantly reduced size. The circuit board is potted
with UL94-V0 rated epoxy resin, enable to use in harsh
environments.
SECTION 2 : FEATURES
●Small size, low cost and high stability.
●Very low power consumption in standby mode.
●Potentiometer time delay settings.
●Three cranking attempts.
●Generator fault indicator and alarm output contacts.
●Energize-to-Run and Energize-to-Stop selectable.
SECTION 3 : INSTRUCTIONS
3.1 Operation
When operate in Auto mode, set Key switch at OFF
position (Stop), at this time the Start and Stop for
Generator will take control by EC-22 Control Unit.
When EC-22 receives external remote start signal, the
control module will automatically enter Start procedure.
First, the Pre-Heat Timer will start to count down and
output terminal will be active. When time delay counts
up the engine Start Terminal will send output signal to
drive the starter motor. The Pre-Heat Timer and
Cranking Timer can be set by potentiometer.
If the engine cannot start up after Cranking timer
counts up. It will return to warm-up cycle and execute
the second starting procedure. If the engine fails to
start in 3 times (Internal preset), EC-22 will judge
engine star failure, and the FAIL Indicator LED will light
up.
The EC-22 will judge whether the engine is running
according to the following two parameters. When any
one of the conditions is met, the EC-22 control module
will stop sending the starter motor signal to prevent the
starter motor from being damaged by the high engine
speed.
● Established AC frequency is greater than 18 Hz
●Charging voltage of generator
12V battery system is up to 7 Vdc or more
24V battery system is up to 14 Vdc or more
When remote start signal was terminated during
Engine running, the EC-22 will in process Stop
procedure by following the Shutdown setting and Timer
count down.
3.2 Time Delay Settings and Adjustments
Various Time delay setting and adjument
● STOP：Engine Shutdown Timer
【Adjustment Range：1 20 seconds】
●PRE_HEAT：Engine Pre-Heat Timer
【Adjustment Range：1 10 seconds】
●START：Engine Cranking Timer
【Adjustment Range：1 20 seconds】
3.3 DIP Switch Settings and Adjustments
EC-22 Control Module has 2P DIP Switch for function
setting
●SW. 1：DC Voltage for Battery system
【ON：24V OFF：12V】
●SW.2：Engine Shutdown Mode
【ON：Energize-to-Stop OFF：Energize-to-Run】
3.4 Status for Indicator LED
●REMOTE：External Remote start input signal
●FAIL：No AC voltage output when engine is running
Engine Failure Shutdown
Engine Start Failure
NOTE!!
In addition to preheating output control, the
preheating delay is also the interval between two
starts. Unless there is a special control
requirement, even if the Engine doesn't need
preheating function, this time delay is still
recommended to set for 5 seconds to ensure the
starter motor will not be damaged by overheating
during repeated starting.
NOTE!!
DENYO Generator set should set DIP SW2 at OFF
position.
NOTE!!
If the AC power supply suddenly disappears
while Engine is running, the FAIL indicator will
light up to indicate a system failure, but the EC-22
will not stop the engine. The failure may cause by
malfunction AVR or the AC signal is off-line. At
this time, the Engine should be stopped
manually, then find out main cause of failure and
eliminate before performing the Auto Start
function. If the generator is started by remote
control without solving the failure problem, the
AC frequency may not be detected, which may
damage the starter motor because it will fail to
detach after operation.

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EC-22 3
3.5 Electrical Characteristic
ITEM
DESCRIPTION
DC Input Voltage Range
9 - 36 Vdc
Alternator AC Input Voltage Range
10 - 300 Vac @ 50/60 Hz
Operating Temperature
-20 to + 60 ˚C
Relative Humidity
Max. 90%
Static Power Consumption
Running power consumption : Less than 3 watts
Standby power consumption : 0W
3.6 Electrical Connections
PIN No.
DESCRIPTION
NOTES
BATT+
Battery Positive ( B+ )
Connect to the positive terminal of the battery. Wiring capacity must
be greater than 35Amp
BATT
Battery Negative ( B)
Connect to the negative terminal of the battery. Wiring capacity must
be greater than 35Amp
START
Engine Start Signal output
terminal.
Connect to Starter Motor Auxiliary voltage
(Output capacity：30 Amp @ 12/24 Vdc)
PRE-HEAT
Engine pre-heat signal
output terminal
Connect to Engine Preheat heate
(Output capacity：30 Amp @ 12/24 Vdc)
AC220V
Generator AC voltage
Power input terminal
(Input range：5 300 Vac）
When AC input frequency is greater than18 Hz, the EC-22 will cut
the starter motor output signal
AC220V
CHARGE
Charging alternator DC
voltage input terminal
When the input voltage of 12V Battery is greater than 7 Vdc (24V
Battery is greater than 14Vdc) the control unit will cut the starter
motor output signal
REM.
Remote start dry contact
signal input terminals
Contacts Open –engine stop
Contacts Closed –engine running
REM.
FAIL
Generator failure auxiliary
output terminals
Contacts open –normal status
Contacts closed –engine failure
Output capacity：3 Amp @ 12/24 Vdc
●FAIL contacts states：
No AC voltage output when engine is running
Engine Failure Shutdown
Engine Start Failure
FAIL
ACC
Engine stop signal output
terminal
Connect to ACC pin of the key start switch on Denyo Generator. For
other brands of generator this is engine stop signal output terminal.
(Output capacity：10 Amp @ 12/24 Vdc)
AR/O
DENYO key start switch
AR/O terminal
Connects to the AR/O pin of the key start switch on Denyo Generator.
For other brands of generator this terminal has no function and no
wiring is required.
(Output capacity：5 Amp @ 12/24 Vdc)
AR/I
DENYO key start switch
AR/I terminal
Connects to the AR/I pin of the key start switch on Denyo Generator.
For other other brands of generator this terminal has no function and
no wiring is required.
P2
DENYO key start switch
P2 terminal
Connects to the P2 pin of the key start switch on Denyo Generator.
For other brands of generator this terminal has no function and no
wiring is required.
(Output capacity：5 Amp @ 12/24 Vdc)

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EC-22 4
3.7 DIMENSIONS & TERMINAL CONFIGURATION
NOTE!!
When use charge alternator to determine if engine is running, do not connect Battery (+)
terminal to charge alternator terminal directly. Must connect a High current diode in series
between Battery (+) terminal and charge alternator terminal to isolate battery (+) voltage and
charge alternator voltage.
ON
12
Unit : mm [inch]
EC-22
5.2
[0.22"]
138.0 [5.43"]
162.0 [6.38"]
88.0 [3.46"]
112.0 [4.41"]
33.0 [1.30"]
18.3 [0.72"]
250250 010

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EC-22 5
SECTION 4 : WIRING DIAGRAM
ACC R2
R1
B
AR
P2
P1
C
STARTER SWITCH
EMERGENCY STOP BUTTON
CHARGING AMMETER
+
-
FUSE
OIL PRESS GAUGE
WATER TEMP. GAUGE
A
PRE-HEAT
LAMP GLOW
PLUG
BATTERY SWITCH
BATTERY
+ -
STARTER
CHARGING
GENERATOR
CHARGING
GENERATOR STARTER
BATTERY
BATTERY SWITCH
+ -
P1
SWITCH STARTER
EMERGENCY STOP BUTTON
FUSE
CHARGING AMMETER
C
A
PRE-HEAT
P2
AR
LAMP GLOW
PLUG
R2
B
ACC
R1
OIL PRESS GAUGE
WATER TEMP. GAUGE
GENERATOR
R S T
NFB
TO LOAD
AC220V
GENERATOR
T S R
AC220V
TO LOAD
NFB
DIODE
ORIGINAL CONNECT WIRE DIAGRAM CONNECT WIRE DIAGRAM WITH AUTO START MODULE EC-22
PRE-HEAT
START BATT- BATT+
P2
AR/I
AR/0
ACC
CHARGE
AC220 AC220
FAILSTART
REMOTE
FAILSTART
REMOTE
EC-22
G
G