Cascade CD101 Auto-Start Controller - 4norpro.com

1 MURPHY, the Murphy logo, Cascade , and SWICHGAGE(r) are registered and/or common law trademarks ofMurphy Industries, Inc. This document, including textual matter and illustrations, is copyright protected by Murphy Industries, Inc., with all rights reserved. (c) 2004 Murphy Industries, 00-02-0594 page 1 of 12 Cascade CD101 Auto-Start ControllerInstallation and Operations Manual Version: 7-05 Section 40 & 75 DescriptionThe Cascade Controller offers automatic start /stop control with easy configuration fora broad number of engine driven input:9-35 VDC continuous - operates during total blackout for 2 sec. min. Power consumption:Sleep Mode (Manual): 1mA typical;(Automatic) 4mA Mode (Manual): 20mA typical; (Automatic): 24mA temperature:-40 to 85 C; (-40 to 185 F).

2 Humidity:0-100%, non-condensing. Housing:UV stabilized black polycarbonate and epoxy encapsulation. Weather tightand includes sealing gasket to keep moisture and debris out of enclosure. Properlymounted Controller will maintain NEMA4 / IP65 rating of :Rated to 6G. Impact:Rated to :Dedicated digital inputs for low oil pressure, high engine temperature,remote start , DC charge fail/Alternator fail. Two aux inputs are configurable for mul-tiple functions. Outputs:7 4 auxiliary, configurable (1A DC protected). 3 dedicated outputs forCrank, Fuel/ECU, Alternator attempts:3, 5, 10, Rest:5-60 seconds, lockout time delay:5, 10, 15, 20, 25, 30 disconnect speed setting:Field settable 0-9999 RPM (16-60Hz AC freq input).

3 Overspeed/underspeed trip point setting: 5 to 50% of sensing inputs:Magnetic pickup (5-120 VAC RMS / 0-10 kHz) & AC fre-quency (30-600 VAC RMS / 16-80 Hz).CANbus interface:Directly reads engine speed, & engine status data* from SAE-J1939 enabled interface:In J1939 applications drives PVA series analog gages*Engine status data limited to low oil pressure, high engine temperature, Wait tostart status, Warning & Fault lamp information, and communication Install, You Will Need:#2 Phillips (cross head) head screwdriverNut driver to fit #6-32x1/2 machine nutsWire for hook-up (rising cage clamp suitable for 14-24 gage wire). Mounting the CascadeCut a x in.

4 (143 x 103mm) mounting hole, and drill four in.( mm)diameter holes for the mounting screws. See Schematic below:Recommended Wiring Practices help prevent electrical noise and voltage drop to the Controller during crankingand preheat, wire the Controller DC power connections directly to the crankingbattery. This will also help improve Low battery starting using a battery charger, it should be connected directly to the battery tohelp prevent electrical noise which could cause an engine ECU or associatedequipment to operate route low voltage DC wiring in the same conduit as high voltage ACwiring. Noise from electrical loads such as motors and variable frequency drivescan be coupled into the engine ECU, governor, or associated equipment and maycause erratic use twisted shielded pair wires for the magnetic pickup wiring.

5 Ground oneend of the shield spark ignited engine applications, always use resistive spark plugs and sparkplug wires, as these greatly reduce the amount of radiated place a snubbing diode (sometimes also called an anti-flyback, anti-kick-back or reverse bias diode) directly across any inductive load. This helps elimi-nate a common source of electrical noise, as well as increases the operating life-time of any solid state use twisted shielded pair communications wiring for RS-485, and SAEstandard wire for J1939. Make sure that terminating resistors (if required) havethe correct rating and are installed read the following information before installing.

6 A visual inspection of this product for damage during shippingis recommended before mounting. It is your responsibility to have a qualified person install this unit and make sure it con-forms to NEC and local INFORMATIONW arning:The Cascade is designed for pilot-duty use and its outputs are forcontrol only. Wire the Cascade Controller with 18 gage stranded :For applications involving automatic start equipment, we stronglyrecommend the installation of an appropriate Emergency Stop device. WARNINGBEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT Disconnect all electrical power to the machine. Make sure the machine cannot operate during installation.

7 Follow all safety warnings of the machine manufacturer. Read and follow all installation Out DimensionsGasket OPEN1 2 3 4 in. (167 mm) in. (154 mm) in. (143 mm) x in. (143 x 103 mm). in. (114 mm) in. (103 mm) in. (127 mm) in. ( mm)diameter 4 places Remote call to run 12 Aux. 2 in 11 Aux. 3 out 13 Aux. 4 out 14 Not used 15 Aux. 1 in 10Hi engine temp. 9Lo oil press. 8AC LineAC NeutralMag. Pickup +Mag. Pickup Alt. Excite. 7 Aux. 2 out 6 Aux. 1 out 5 Crank 4 Fuel/ECU 3-V Batt. 2+V Batt. 124 25 26 27 LISTED LISTEDE236550 RCUSI nstallation 00-02-0594 page 2 of 12 LED Status LightsEleven LEDs separated into two banks (see Fig.)

8 1 ) are provided on the LEDs Bank 1 includes 6 LEDs and Bank 2 includes 5. In Setup mode, thesebanks form a binary code to indicate either the Controller setup configuration or errorstatus, which is indicated by the last 8 (red) LEDs. Refer to Tables 1, 2, 3 and 4 forconfiguration and status LED is located next to the auto button to indicate that the Controller is wait-ing for the remote start input to become active. The LED status light are (from top to bottom) see Fig. 1 : Engine running- If the green LED is ON, then the unit is receiving a speed signal,indicating that the engine is above the crank cut status- If the green LED is on solid, it indicates that in a J1939 application theECU and the unit are communicating properly.

9 If the LED is blinking slowly theECU is broadcasting a wait to start message. If the LED is blinking fast, theECU is NOT communicating start / Crank Rest- If the green LED is on, then the remote start input isactive and if the system is in auto mode, it will try to start . If the LED is blink-ing, the crank cycle has ended and is now in crank rest oil pressure- If the red LED is on, the Controller has caused the engine to shut-down and lockout. If the LED is blinking, the engine ECU has transmitted a SPNfor an oil pressure related Engine Temperature- If the red LED is on, the Controller has caused theengine to shutdown and lockout.

10 If the LED is blinking, the engine ECU has trans-mitted a SPN for an engine temperature related If the red LED is on, the Controller has caused the engine to shutdownand lock out due to engine speed exceeding the If the red LED is on, the Controller has caused the engine to shutdownand lock out due to engine speed falling below the minimum needed for If the red LED is on, the Controller has exceeded the set number of startattempts without receiving a valid speed signal indicating that engine speed isabove crank disconnect. This causes the engine to shutdown and Fail- If the red LED is on it indicates that the battery charging alternator isnot charging the cranking batteries, or that the battery charger fail output is 1- If the red LED is on it indicates that this custom-configured input is an ECU (ECM) equipped engine, if this LED is blinking slowly, it indicatesthat one or more engine parameters are near exceeding engine manufacturer s set-points.