The ES52 generator controller, ES52(F) and the unavailable BCM-12?

July 25, 2019, 09:58:12 pm

Hi,
I've recently had 10K Powertech generator problems. Serial# KJC25DAB3844KRR Model# PTS 10KSIRRFT. Twice with labored starting, sputtering, shaking the coach for 3-5 secs followed by smooth running, then premature shutdown before the batts are fully charged. Once after a 1.25 hr run and another after 19 minutes only to manually reset/restart immediately and then run smoothly until batts reached float, approximately 2 more hours, give or take. Neither the idiot light on the dash nor the Dynagen ES52F controller on the genset ever indicated any faults.

Previous owner never really used genset. Imagine a 2002 coach with 230hrs on genset at most! First thing we did was oil and oil filter change and both fuel filters. We now have 350hrs. Spoke today with Powertech and they couldn't determine if we have an exciter version of generator which would positively impact durability some. But not enough in their view to overcome the lack of PO's gen use. We're scheduled to replace the bearing this coming week. Also plan on replacing the ES52F controller.

Many forum members have installed the Dynagen ES52 available from partsfortechs.com without any issues. We want to do the same. But I also wanted to know why the "F" was added to our OEM unit. Dennis at PartsForTechs asked Paul at Dynagen for the archival material which has the exact parameters differentiating the ES52 from the Foretravel installed ES52F. There is little difference between the "F" model and the current 2019 year standard model of ES52, which makes it easy to program the ES52 to duplicate the Foretravel version in our coach.

The following text in italics is the material I received:

Hello Michael,
Paul @ Dynagen sent me a a library of all the variations of ES50/51/52 that DynaGen had built in the past. There are a lot. The only ones that are active are the spreadsheet you saw from yesterday but the archive will be helpful for cross referencing functions.

Here is what the DynaGen settings are for your existing ES52F:

LOW SPEED RANGE ONLY (For 50-60Hz signal from gen)
CRANK DISCONNECT FIXED AT 22Hz (Easy to change on std model)
OVER-SPEED IS DISABLED (You can effectively do this by increasing the threshold to the max on the std. version - but I prefer to keep that protection set at 67-69 Hz)
OIL VERIFICATION IS DISABLED
CRANK TRIES FIXED AT 3 (Easy to change on std model)
CRANK/REST TIME FIXED AT 10 SECONDS (Easy to change on std model)
TIMER LIMITED TO PREHEAT ONLY – DETERMINED BY JUMPER ON BACK OF UNIT. IF JUMPER UNCUT PREHEAT = 16 SECONDS. IF JUMPER CUT PREHEAT = 8 SECONDS (Easy to adjust timer POT on std model - no jumper needed)
NO LOSS OF SPEED WHILE CRANKING

I personally see no reason why the standard ES52 that we have could not be used, when the dip switches and adjustments are made accordingly.

Regards
Thanks,
Dennis Risser
Advanced Service And Parts, LLC
Index of /
(717) 274-9396

One more piece in controlling the gen start/stop that I haven't solved. The BCM-12. Which I think functions like a battery voltage monitor and switch to start/stop signal the ES52 whenever the auto start switch at the dash is ON. I have not found the BCM-12 anywhere except on Beamalarm and the forum. The BCM appears to be no longer available. Because we have a Xantrex 2012 Freedom inverter with Xanbus I am hoping the Xantrex AGS will replace the BCM. I'd like to eliminate the possibility of the gen shutting down due to errant signals from the OEM BCM to the ES52.

I haven't had much success getting generator techs to engage with me over any of this. They see nothing to do because our gen hasn't gone kaput yet. When I pressed them for more info about changing the bearing they all agree with Powertech that it is a smart thing when maintaining low usage generators.

Thanks,
Michael

Re: The ES52 generator controller, ES52(F) and the unavailable BCM-12?

Reply #1 – July 25, 2019, 10:07:33 pm

I replaced a failed ES52 some years ago. If memory serves me I got it online from Canada. Programming was easy, just remember to program all functions. Been working just fine.
Just had the end bearing replaced on my 10K brushless under 2000 hours. The bearing was dry and rough, not real bad but it was time.

Re: The ES52 generator controller, ES52(F) and the unavailable BCM-12?

Reply #2 – July 25, 2019, 11:03:05 pm

Mike,
Sorry I hadn't gotten around to answering your PM as yet, I have been busy dealing with a fuel system issue, and the fact is, I don't remember much about the ES52 that I put in, but I don't believe it had an 'F' in the model number. I just set the dip switches as the instructions I found somewhere, or perhaps they came with it... I do remember that before the I received the new one, I switched the relays and got the old one working again. One of the relays was intermittent and it was the one which initiated cranking. When it would start before that, it would run smoothly and produce power as designed. I ordered two new relays for the old one to keep as a spare and put the new one in. That is pretty much all I can remember about it at this point. We do have the 8KW version, though I doubt that makes any difference in regards to the ES52.
Don
As regards the BCM-12, I haven't been able to locate it though I have looked pretty extensively in the dash area. It is NOT on the board that pulls up in the 2000 and earlier unicoaches as it is in other coaches of the same year. Yet, our auto start works fine so I guess it must be somewhere... I would really like to find it, as I have a brand new Magnum networked auto start control module that I would like to install to have more control over the process.

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