Cascade CD101 Auto-Start
Controller
Installation and Operations Manual
00-02-0594
04-16-10
Sections 40 & 75
In order to consistently bring you the highest quality, full featured products, we reserve the right to change our
specifications and designs at any time. The latest version of this manual can be found at www.fwmurphy.com.
Please read the following information before installing.
BEFORE BEGINNING INSTALLATION OF THIS MURPHY
PRODUCT:
• Read and follow all installation instructions.
• A visual inspection of this product for damage during shipping is
recommended before mounting.
• It is your responsibility to have a qualified person install this unit and
make sure it conforms to NEC and local codes.
• Disconnect all electrical power to the machine.
• Make sure the machine cannot operate during installation.
• Follow all safety warnings of the machine manufacturer.
• Please contact FW MURPHY immediately if you have any questions.
T able of Conte nt s
Operating the Cascade ............................................................................................................. 1
LED Status Light ....................................................................................................................... 2
Setting Up the Cascade ............................................................................................................ 3
Modes of Operation ....................................................................................................... 3
Installing the Cascade Auto-Start Controller ......................................................................... 4
Tools Needed ................................................................................................................ 4
Mounting the Cascade .................................................................................................. 4
Recommended Wiring Practices ................................................................................... 5
Typical Wiring Diagrams ............................................................................................... 6
Specifications .......................................................................................................................... 12
Tables ..................................................................................................................................... 13
(NOTES)
Operating the Cascade
When power is first applied, all LEDs will flash indicating a Lamp Test function.
To manually start the engine, press the “MAN” (Manual) button. The controller will initiate a normal
start sequence.
In MANUAL MODE, operating the “UP/DOWN” arrow keys will activate Aux outputs 1-4 if they are
configured for SPEED UP / SPEED DOWN.
To manually stop the engine (or turn off the controller), press the “OFF” button.
To place the controller in automatic mode, press the button labeled “AUTO”. The LED next to the
“AUTO” button should come on to indicate that the controller is waiting for the remote start input
to become active to initiate a start sequence.
To reset the controller, press the “OFF” button. Then correct the cause of the shutdown. This will
clear all faults except when the aux inputs are programmed for either shutdown immediate or
warning immediate, or if the engine ECU is broadcasting a shutdown fault.
In the event of a fault that causes the engine to shutdown, the cause of the event will be indicated on one of the
11 status lights on the right hand side of the controller. When the cause of shutdown is corrected, the controller
can resume normal operation.
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LED St atus Light
Eleven LEDs separated into two banks (see “Fig. 1”) are provided
on the faceplate. The LEDs Bank 1 includes 6 LEDs and Bank 2
includes 5. In Setup mode, these banks form a binary code to
indicate either the controller setup configuration or error status,
which is indicated by the last 8 (red) LEDs. Refer to Tables 1, 2, 3
and 4 for configuration and status listings.
One LED is located next to the “AUTO” button to indicate that the
controller is waiting for the remote start input to become active.
The LED status lights are (from top to bottom) see “Fig. 1”:
LEDs Description
Engine
Running
If the green LED is ON, then the unit is receiving a speed signal, indicating that the engine is abov e the
crank cut speed.
ECU Status
Remote Start/
Crank Rest
Low Oil
Pressure
High Engine
Temperature
Overspeed
Underspeed
Overcrank/
Start Fail
Charge Fail
Auxiliary 1
Auxiliary 2
If the green LED is on solid, it indicates that in a J1939 application the ECU and the unit are
communicating properly. If the LED is blinking slowly the ECU is broadcasting a “wait to start” message. If
the LED is blinking fast, the ECU is NOT communicating properly.
If the green LED is on, then the remote start input is active and if the system is in AUTO mode, it will try to
start. If the LED is blinking, the crank cycle has ended and is now in crank rest cycle.
If the red LED is on, the controller has caused the engine to shutdown and lockout. If the LED is blinking,
the engine ECU has transmitted a SPN for an oil pressure related condition. If the LED comes on before
the crank sequence, it indicates the Low Oil Pressure Input is not grounded while the engine is off.
If the red LED is on, the controller has caused the engine to shutdown and lockout. If the LED is blinking,
the engine ECU has transmitted a SPN for an engine temperature related condition.
If the red LED is on, the controller has caused the engine to shutdown and lock out due to engine speed
exceeding the setpoint.
If the red LED is on, the controller has caused the engine to shutdown and lock out due to engine speed
falling below the minimum needed for proper operation.
If the red LED is on, the controller has exceeded the set number of start attempts without receiving a valid
speed signal indicating that engine speed is above crank disconnect. This causes the engine to shutdown
and lockout.
If the red LED is on, it indicates that the battery charging alternator is not charging the cranking batteries,
or that the battery charger fail output is on.
If the red LED is on, it indicates that this custom-configured input is active. On an ECU (ECM) equipped
engine, if this LED is blinking slowly, it indicates that one or more engine parameters are near exceeding
engine manufacturer’s setpoints. If the LED is blinking fast, it indicates that one or more engine parameters
have exceeded setpoints, the ECU has issued a fault - and most likely the engine has shut down.
If the red LED is on it indicates that this custom-configured input is active.
NOTE: If the Overspeed and Underspeed LED’s are both blinking, the controller has lost
its speed signal.
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Setting Up the Cascade
To enter the SETUP MODE, first remove DC power to the Cascade controller for approximately 10
seconds.
On the back of the controller are four DIP switches, set switch #1 to ON (see
schematic at right) then restore DC power. The AUTO mode LED will
blink to indicate that the Cascade is in the SETUP MODE.
When in the SETUP MODE, pressing the “MAN” (Manual) button steps up
thru the entire list of parameters. The pattern of the top six LEDs, LEDs
Bank 1 (see “Fig. 1”), is used to indicate which parameter is selected.
The pattern will change once each time the “MAN” button is pressed.
Pressing the “OFF” button steps up thru all the available values for each
parameter. The pattern of the bottom five LEDs, LEDs Bank 2 (see “Fig. 1”), is used to indicate
which value is selected. The pattern will change once each time the OFF button is pushed.
Pressing the “AUTO” button stores the displayed value.
If any value is changed, it will blink until stored, except a value of zero. If
any value is changed but not stored, and then the parameter is
changed, the value will still be what was shown originally.
If you accidentally go past a desired parameter or value, you can step
back by pressing the down arrow button.
The parameter/value list and corresponding LED indication are shown on
Table 1 – Parameter Values and Corresponding LED Indication.
When you are finished with setup, set switch #1 to in the Normal
Operating Position (OPEN), remove DC power for 10 seconds, then restore DC power.
Modes of Operation
Setup Mode
Refer to the section “Setting Up the Cascade” and “Table 1 – Parameter Values and Corresponding LED
Indication”.
Normal Operating Mode (Engine Control Mode)
The DIP switch #1 must be in the open position in order to enter this mode upon power up. “Table 2 – LED
States for Normal Operating Mode” shows the meaning of each LED state for this mode.
Error Mode
Upon power up, when the DIP switch #1 is in the normal operating position (open position) and an error is
detected in the user configuration, the Error Mode will be accessed. The LEDs will blink fast indicating the error.
To correct the errors before the unit can operate in Engine Control Mode, the user will need to go back to Setup
Mode. “Table 3 – Error Codes LED States” and “Table 4 – Configuration Error Codes” show the meaning of each
LED state and configuration for the Error Mode.
Sleep Mode
In Auto Mode the Cascade will enter Sleep Mode after 2 minutes of inactivity. The unit will exit Sleep Mode on
key press or remote call to run. It will not enter Sleep Mode if there is an active fault.
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Installing the Cascade Auto-S tart Controller
The Cascade controller offers automatic start/stop control with easy configuration for a broad number of engine
driven applications.
Tools Needed
To install the Cascade, you will need:
• #2 Philips (cross head) head screwdriver
• Nut driver to fit #6-32x1/2” machine nuts
• Wire for hook-up (rising cage clamp suitable for 14-24 gage wire)
Mounting the Cascade
A. THIS EQUIPMENT IS SUITABLE FOR USE IN CLASS I, DIVISION
2, GROUPS A, B, C, AND D OR NON-HAZARDOUS LOCATIONS
ONLY.
B. WARNING – EXPLOSION HAZARD – SUBSTITUTION OF
COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I,
DIVISION 2.
C. WARNING – EXPLOSION HAZARD – DO NOT DISCONNECT
EQUIPMENT WHILE THE CIRCUIT IS LIVE OR UNLESS THE AREA
IS KNOWN TO BE FREE OF IGNITABLE CONCENTRATIONS.
NOTE: This unit shall be mounted in a type 1 electrical enclosure for other than indoor
applications.
Cut a 5.63 x 4.06 in. (143 x 103mm) mounting
hole, and drill four 0.169 in. (4.3mm) diameter
holes for the mounting screws. See Schematic
below:
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Recommended Wiring Practices
Warning: The CASCADE is designed for pilot-duty use and its outputs are for
control only. Wire the CASCADE controller with 18 gage stranded wire.
Important: For applications involving automatic start equipment, we strongly
recommend the installation of an appropriate Emergency Stop device.
1. To help prevent electrical noise and voltage drop to the controller during cranking and preheat, wire
the controller DC power connections directly to the cranking battery. This will also help improve “Low
battery” starting capability.
2. When using a battery charger, it should b e connected directly to the battery to help prevent electrical
noise which could cause an engine ECU or associated equipment to operate erratically.
3. Never route low voltage DC wiring in th e same conduit as high voltage AC wiring. Noise from
electrical loads such as motors and variable frequency drives can be cou pled into the engine ECU,
governor, or associated equipment and may cause erratic operation.
4. Always use twisted shielded pair wires for the magnetic pickup wiring. Ground one end of the shield
only.
5. In spark ignited engine applications, always use resistive spark plugs and spark plug wires, as these
greatly reduce the amount of radiated noise.
6. Always place a snubbing diode (sometimes also called an anti-flyback, anti-kickback or reverse bias
diode) directly across any inductive load. This helps eliminate a common source of electrical noise, as
well as increases the operating lifetime of any solid state output.
7. Always use twisted shielded pair communications wiring for RS-485, and SAE standard wire for
J1939. Make sure that terminating resistors (if required) have the correct rating and are installed
properly.
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Typical Wiring Diagrams
Cascade – Basic Engine AC Sensing S peed
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Cascade – Basic Mechanical Engine MPU Sensing Speed
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Cascade – Basic ECU Engine ECU Speed Sensing
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Inc/Dec Throttle (Manual), Line Fill Delay, Low Oil/Coolant Level, Preheat,
Common Alarm
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Mechanical Engine MPU Source Throttling to Pressure,
Low Liquid Level Shutdowns Warmup-Cooldown Output
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Mechanical Engine Winter/Summer Switch, Preheat Output & Timer Run &
Idle Switch Output
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Specifications
• Power input: 9-35VDC continuous - operates during total blackout for 2 se c. min.
• Power consumption: Sleep Mode (Manual): 1mA typical;(Automatic) 4mA typical.
Running Mode (Manual): 20mA typical; (Automatic): 24mA typical.
• Operating/Storage temperature: -40 to 85°C; (-40 to 185°F).
• Humidity: 0-100%, non-condensing.
• Housing: UV stabilized black polycarbonate and epoxy encapsulation. Weather tight and includes sealing
gasket to keep moisture and debris out of enclosure. Properly mounted controller will maintain NEMA4 / IP65
rating of enclosure.
• Vibration: Rated to 6G.
• Impact: Rated to 10G.
• Inputs: Dedicated digital inputs for low oil pressure, high engine temperature, remote start, DC cha rge
fail/Alternator fail. Two aux inputs are configurable for multiple functions.
• Outputs: 7 – 4 auxiliary, configurable (1A DC protected). 3 dedicated outputs for Crank, Fuel/ECU,
Alternator excitation. Outputs are low side FET switches.
• Crank attempts: 3, 5, 10, Continuous.
• Crank Rest: 5-60 seconds, adjustable.
• Shutdown lockout time delay: 5, 10, 15, 20, 25, 30 seconds.
• Crank disconnect speed setting: Field settable 0-9999 RPM (16-60Hz AC freq input).
• Overspeed/underspeed trip point setting: ±5 to 50% of nominal.
• Speed sensing inputs: Magnetic pickup (5-120VAC RMS / 0-10 kHz) & AC frequency (30-600VAC RMS /
16-80 Hz).
• CANbus interface: Directly reads engine speed, oil pressure, coolant temperature, system voltage, & engine
status data* from SAE-J1939 enabled engines.
• MODbus interface: In J1939 applications drives PVA series analog gages. Gages limited to tach (0-3000
rpm), coolant temperature, oil pressure (0-100 & 0-150), DC volts (12v & 24v), AC freq, and audible alarm.
*Engine status data limited to low oil pressure, high engine temperature, “Wait to start” status, Warning & Fault
lamp information, and communication error.
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