REVGUARD 2 Diesel Engine Safety Solutions

Installation, Operation and Maintenance

REVGUARD 2
Automatic Overspeed Detection
Shutdown System

Instructions for the Installation,

Programming, and Testing of REVGUARD 2

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REVGUARD 2 Diesel Engine Safety Solutions
Installation, Operation and Maintenance
GENERAL INFORMATION
The following instructions are designed to assist in the
installation, operation and maintenance of Revguard 2.
Product users and maintenance personnel should thoroughly
review this manual prior to working on the Revguard 2. To A Warning indicates a hazardous situation that, if not avoided,
avoid possible injury to personnel or damage to equipment, all could result in death or serious injury to personnel. The text of
instructions, including the WARNING AND CAUTION notes must the warning describes the hazard and details of the precautions
be strictly followed and adhered to. Modifying this product, that must be applied before the step of the procedure is carried
substituting for non-factory parts, or using maintenance out.
procedures other than outlined in the manual may affect
performance, be hazardous to personnel and equipment, and
may void any applicable warranties. A Caution indicates a hazardous situation that, if not avoided,
could result in minor or moderate injury. The text of the
caution describes the hazard and details of the precautions that
SAFETY must be applied before the step of the procedure is carried out.
Service, repair, and overhaul of equipment should be carried
out by qualified personnel only. Do not conduct servicing,
overhauls, or repairs until all requirements in the instructions
have been read and understood. Read the entirety of each step
A Notice contains supplementary information that may be
before carrying it out. Certain operations may be hazardous
useful to the operator and may appear before or after a
and could cause injury to personnel or damage to equipment if
particular step in the procedure.
the instructions are not carried out exactly as described. Self-
protection is the fundamental responsibility of the operator.
Appropriate safety gear includes, but is not limited to safety
footwear, safety glasses, and safety gloves. Users should
observe all approved safety procedures instituted at the facility
or site where this product is manipulated and/or inspected.
Perform programming and testing in a well-ventilated area.
Failure to be in a well-ventilated area could lead to carbon
monoxide poisoning.

Incorrectly wired units can cause serious

injury to personnel from electrical shock, and damage
to equipment. Electrical connections must only be It is recommended that only genuine Revguard 2 activation kits
installed by qualified and/or licensed personnel. Keep are utilized to ensure proper Revguard 2 function.
clear of valve path to prevent injury as a heavy
compression spring is used to close the valve. Ensure
valve is in CLOSED position prior to installation to PRODUCT SUPPORT
prevent injury to personnel. All necessary settings and alterations to the Revguard 2 are
described in this manual. Please contact factory for assistance if
any difficulties arise during installation, operation, testing,
maintenance, or troubleshooting. Failure to follow all the
instructions described in the manual or any unauthorized
modification of Revguard 2 products may result in serious
personal injury or product damage and will void any applicable
warranty on the Revguard 2 product.
For technical assistance, call +1 780-465-4429.

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REVGUARD 2 Diesel Engine Safety Solutions
Installation, Operation and Maintenance

TABLE OF CONTENTS

SECTION TITLE PAGE

A PRODUCT DESCRIPTION …………………………………………………………………………………………………….…..…………………… 4

B SYSTEM DESCRIPTION …………………………………………………………………………………………………………………..……..…….. 4

C REVGUARD AND MAJOR KIT COMPONENTS………………………………………….…………………………..………………….……… 5

D CONNECTION DIAGRAMS …………………………..………………………………………….…………………………..……………….……… 8

E STEP-BY-STEP PROGRAMMING PROCEDURE …………………………………………….……………………..………..…….……… 13

F OPERATION MODES …………………….………………..…………………………………………………………………………………………… 16

G MAINTENANCE …………………………….………………………………………………………………..………………………..…………….….. 18

H TROUBLESHOOTING GUIDE ………………………………………………………..………………………………………………………….…. 18

I WARRANTY …………………………………………………………………………………………………………………………………………..…… 19

BEFORE WIRING UNIT PLEASE SEE PAGE 8 TO SELECT PROPER WIRING DIAGRAM AND
PREVENT DAMAGE TO YOUR SYSTEM

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REVGUARD 2 Diesel Engine Safety Solutions
Installation, Operation and Maintenance
A. PRODUCT DESCRIPTION
Revguard 2 is a surface mounted speed switch. Overall dimensions are given below.

Input Power: Supply Voltage Standard 12 or 24 VDC with reverse polarity protection
(10.8 – 26.2 VDC)

Input Signal: Frequency Range 10 Hz – 10,000 Hz

Input Amplitude ~ 1.3VAC mag pickup, ~ 7VAC alternator
(permissible range: 1VAC – 20VAC)
Input Signal Type Sine wave or square wave (from alternator/mag. pick-up)
Setpoint Repeatability Less than 1% Deviation

Output Signal: Contact Relay 4A max (trip indicated by red LED)

Operating Temperature Range: -40° C to 85° C (-22° F to 167° F)

Certification: Ingress Protection IP54

B. SYSTEM DESCRIPTION
The Revguard 2 Speed Switch is designed to monitor engine RPM ENGINE SHUTDOWN SEQUENCE
and immediately shutdown the engine in the event of an
overspeed condition. The module monitors engine RPM using a
frequency based signal typically from a flywheel sensing magnetic
Step 1: Step 2: Step 3: Step 4:
pickup device, or a signal from the engine alternator. When the
Engine speed Output is Output is Revguard2 determines
engine speed exceeds the programmed trip point, Revguard 2 will
exceeds activated for turned off for if engine is shutdown. If
immediately activate an output signal that can be used to trigger programmed 1 second 5 seconds engine is still running,
an Air Intake Shutoff Valve system or other related hardware. shutdown (default). (default). loop back to Step 2 for
speed. a maximum of 5 times
Revguard 2 activation kits include a momentary toggle switch and a (default).
LED indicator light (for remote interface/function and system
feedback).
This system can be connected to several styles of shutdown
Refer to the Programming section of this manual for instructions systems. Connection diagrams for several popular shutdown
detailing the set-up process of RPM presets. No calculations or systems are shown in this document below. Contact the factory if
knowledge with respect to drive ratio of the alternator is required the shutdown system you want to interface with is not shown.
during Revguard 2 configuration/teaching.

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 REVGUARD 2 Diesel Engine Safety Solutions
Installation, Operation and Maintenance
C. REVGUARD AND MAJOR ACTIVATION KIT COMPONENTS

Revguard 2 Speed Switch Module

Remove the four (4) fasteners and lift the blue cover (see Figure 1) to reveal the Revguard 2 module shown in Figure 2.

Fastener Fastener

Cover

Fastener Fastener

Figure 1: The Revguard 2 module lies underneath the blue cover.

SET Pushbutton TEST Pushbutton

Trip Point
Reduction % (TPR)
10%
Status LED 20%
30%
Trip Output LED 50%

Figure 2: Buttons and LEDs on the Revguard 2 Speed Switch Module

Before using this product, the installer must obtain the proper For safe operation, ensure that ambient temperature at the
power supply for the system. The system will function with any mounting site is between -40° C and 85° C (-22° F to 167° F) and
standard 12V or 24V battery system. The power should be that the unit will not be subject to immersion or excessive
continuous and not switched/keyed off when the engine is splash/spray (IP54). Typical installation locations include under
turned off. Additionally, a safe mounting site for the module dash or inside a protective enclosure.
should be determined before making any connections.

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REVGUARD 2 Diesel Engine Safety Solutions
Installation, Operation and Maintenance
Terminal Strip OP+ Terminal – the purpose of this terminal is to provide the
trigger signal to the shutdown system. This terminal has a
The terminal strip is comprised of 8 terminals. Revguard 2 maximum output capability of 4 Amps.
comes with crimp-on for terminals to allow for easy wire
connection to the terminal strip. Revguard 2 Activation Kit
BT+/BT- Terminals – the purpose of these terminals are to To ensure proper function it is recommended that only
provide power to the Revguard 2 module. Revguard 2 will
Revguard 2 activation kits (AK2) are utilized with Revguard 2.
function with any standard 12 or 24 V system. However, wiring
from Revguard 2 should not be directly connected to the Several activation kits are available for properly interfacing
battery and must be interfaced with the appropriate circuit Revguard 2 to various shutdown system types. See Table 1
breaker (see the appropriate connection diagram for your below to select proper kit for your shutdown system.
shutdown system).
Activation Activation Battery External
SP+ / SP- Terminals – the purpose of these terminals are to Kit Method Relay
provide the input signal to the Revguard 2 module. The AK2-E1-RM* Electric 12V
Yes
incoming signal may originate from an alternator or a magnetic AK2-E2-RM* Electric 24V
pick-up device rated at 10Hz – 10,000Hz with an amplitude of AK2-E1-XM* Electric 12V
~1.3VAC (mag pickup) or ~7VAC (alternator). In noisy AK2-E2-XM* Electric 24V
environments, the operator may opt to shield and/or twist No
AK2-P2-SM Pneumatic 24V
together the positive and ground wiring to ensure that EMI is AK2-P1-M Pneumatic 12V
mitigated from surrounding non-Revguard 2 components (refer
Table 1: Revguard 2 Activation Kit Configurations
to Figure 3 for an illustration). In this case the wire shield
*Chalwyn name branded kits available by adding -CH to kit
should be connected to the GND terminal on Revguard 2.
number (e.g. AK2-E1-XM-CH)
Note: With some alternator connections only the SP+ terminal
needs to be connected as long as the alternator and Revguard2 Major Kit Components
share a common ground.
Shielding
Fuse (12V/24V at 30A)

Revguard 2 and the shutdown system are to be directly

powered from a 12 or 24 VDC battery with a 30A fuse. The fuse
is necessary to prevent excessive damage/fire in the event of a
short or internal hardware failure. The fuse is sized to provide
the necessary current to activate the shutdown system. If an
alternate fusing arrangement is desired, contact the factory to
determine the circuit protection will work correctly.
Positive and Ground Wiring are twisted together
Figure 3: Twisted Pair with Shielding WARNING: Revguard 2 and the shutdown system should not be
connected to a keyed-on power source. If the user attempts to
GND Terminal – the purpose of this terminal is to provide an key-off during a runaway situation, both Revguard 2 and the
electrical return path for the momentary remote switch and the shutdown system will be unpowered and will not function.
remote LED.

BTN Terminal – The purpose of this terminal is to provide

connection for a remote momentary normally-open switch.
When connected, the momentary switch and the TEST
pushbutton will have the same function and can be used
interchangeably.

LMP Terminal - The purpose of this terminal is to provide

connection for a remote LED light. The wire from the LMP Figure 4: Fuse holder with 30A fuse
terminal should connect directly to the positive terminal of the
remote LED (or to momentary lighted switch). When
connected, the remote LED light will function in the same way
as the Status LED. This terminal can source a maximum of
200mA.

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REVGUARD 2 Diesel Engine Safety Solutions
Installation, Operation and Maintenance
Major Kit Components - continued
Remote Status Light (24VDC)
External Relay (12V/24V at 80A)
Revguard 2 has a provision for a remote output lamp which
As the output of Revguard 2 is limited, some shutdown systems allows the user to remotely monitor the Revguard 2 Status LED.
will require an external relay. Shutdown kits are available for The remote Status LED has the exact same functionality as
all valve styles with the appropriately sized relay. The Revguard 2’s Status LED, and thus the interpretations provided
connection diagrams indicate when an external relay is for LED behavior also apply to this component.
required. The provided relays are sized to correctly handle the
large inductive loads that occur in some shutdown valves.
Contact the factory if you desire to utilize an alternate relay
style.

Kits requiring a relay come complete with the appropriate

spade terminals and connection block for the relay.

Note: The shutdown system will not function if an external Figure 7: Remote Status LED (24VDC)
relay is not utilized as documented in the circuit diagrams
below.
Remote Status Light (12VDC) – on Lighted
Momentary Switch

The light on the lighted momentary switch performs the same

function as the remote LED above. The light is part of the
switch rather than separate.

Figure 5: Relay
Pneumatic Solenoid (12V/24V)

Lighted Remote Momentary Switch (12V) Air-actuated valves require a pneumatic solenoid for system
Remote Momentary Switch (24V) shutdown activation. The pneumatic solenoid is electrically
controlled and must remain normally-closed during regular
Revguard 2 has a provision for a remote momentary switch
operation. During a shutdown attempt, the pneumatic solenoid
interface. The remote switch simulates the function of the TEST
allows pressurized air to flow through the valve’s air line closing
pushbutton on Revguard 2. The remote momentary switch is
especially important in situations where the user opts to install the valve shut. Only pneumatic activation kits include the
the module in hard-to-reach areas due to operational pneumatic solenoid.
considerations.
The pneumatic solenoid is not recommended to be mounted
WARNING: The remote switch must be a momentary normally - directly on the valve itself. The solenoid should be installed in a
open switch style. Other switch styles will not function correctly
location free of excessive heat, vibration and contaminants.
with Revguard 2.

The momentary switch is included in all Revguard 2 activation

kits. The switch may be equipped with a military style cover
that protects from accidental discharge.

Figure 6: 12VDC Remote Lighted Momentary Switch

(left); 24VDC Remote Momentary Switch (center); Figure 8: Pneumatic Solenoid
Military Cover (right)

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REVGUARD 2 Diesel Engine Safety Solutions
Installation, Operation and Maintenance

D. CONNECTION DIAGRAMS
Refer to provided activation kit and valve and using the table below reference the appropriate connection diagram for your
shutdown system:

Valve Style Actuation Possible Activation Kit(s) See Figure Below

Amot 4261/4262 Two wire electric solenoid

Chalwyn SVX (12/24VDC) Figure 9 -
Rigsaver SGE AK2-E1-RM (12V) Connection Diagram for
Rigsaver XT AK2-E1-RM-CH (12V) Electric, 12V Systems
(non-ISE solenoid)
Chalwyn SVR2/SVR3/SVR4 AK2-E2-RM (24V)
Roda Deaco RB2A (2in 12/24 VDC BF) Three wire electric AK2-E2-RM-CH (24V) Figure 10 -
Roda Deaco RB3A (3in 24VDC BF) solenoid (12/24VDC) Connection Diagram for
Roda Deaco Swing Gate Electric, 24V Systems
(non-ISE solenoid)

Chalwyn MPX, PVX, and PVA Pneumatic, to be Figure 11-

(European Units) interfaced with 24VDC AK2-E2-XM-CH Connection Diagram for
pneumatic solenoid Pneumatic, 24V SVA-200
System

Chalwyn MPX, PVX, and PVA Pneumatic, to be AK2-P1-M Figure 11 -

(Non-European Units) interfaced with 24VDC AK2-P2-SM Connection Diagram for
pneumatic solenoid Pneumatic, 12/24V System

Amot 4261/4262 Figure 12 -

Rigsaver Pneumatic With AK2-P1-M Connection Diagram for
Roda Deaco Swing Gate 12/24VDC Pneumatic AK2-P2-SM Pneumatic, 12V System
Solenoid

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REVGUARD 2 Diesel Engine Safety Solutions
Installation, Operation and Maintenance
Electric Solenoid, 12V System

Note: For bold

wires, see wire
gauge selection
chart above.
INCLUDED IN KIT

SOLENOID WIRES
COLOR FUNCTION
RED HOLD
(LOW CURRENT)
WHITE PULL
(HIGH CURRENT)
BLACK GROUND

FIGURE 9: Connection Diagram for Electric, 12V Systems

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REVGUARD 2 Diesel Engine Safety Solutions
Installation, Operation and Maintenance

Electric Solenoid, 24V System

Note: For bold

wires, see wire
gauge selection
chart above.

SOLENOID WIRES
COLOR FUNCTION
RED HOLD
(LOW CURRENT)
WHITE PULL
(HIGH CURRENT)
BLACK GROUND

FIGURE 10: Connection Diagram for Electric, 24V Systems

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REVGUARD 2 Diesel Engine Safety Solutions
Installation, Operation and Maintenance

Pneumatic Solenoid, 24V SVA-200 System

See pneumatic kit installation guide for full details

SVA-200 WIRING
TERMINAL FUNCTION
Terminal 1 Connected to OP+ on Revguard
Terminal 2 Connected to Battery Return
Terminal 3 Not Connected
Terminal 4 Not Connected
Figure 11: Connection Diagram for Pneumatic, 24V SVA-200 System

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REVGUARD 2 Diesel Engine Safety Solutions
Installation, Operation and Maintenance
Pneumatic Solenoid, 12VDC System

NOTE:
AIR HOSES AND FITTINGS
ARE INCLUDED IN KIT.

Figure 12: Connection Diagram for Pneumatic, 12/24V System

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 REVGUARD 2 Diesel Engine Safety Solutions
Installation, Operation and Maintenance
E. STEP-BY-STEP PROGRAMMING PROCEDURE
Status LED SET Pushbutton TEST Pushbutton

Remote
Momentary
Status LED
Switch (12V
(24V only)
light built into
switch)

You have finished programming Revguard 2 to trip at the

Desired Engine Shutdown Speed. The module is ready for
normal operation.
% Trip Point Reduction (TPR)
10%
20%
% Trip Point Reduction LED Selection
Trip Output LED 30%
Behaviour Indication Engine
50%
Type
FOR BOTH CASES (DO THIS FIRST):
After wiring Revguard circuit, note if status LED is flashing. If 10% LED When activated (i.e. “SET [red] Constant
not flashing, flip remote switch on and off and verify operation (topmost Pushbutton is pressed), the Engine speed
of valve (with engine off) CAUTION: If valve does not operate LED) Shutdown Speed will be set to the
check wiring and repeat this step. If LED is flashing you must – Solid On
Teach Engine Speed divided by a
proceed to set the speed with the engine running before the Green
factor of 0.90 (eg. 1000rpm/.9 =
manual operation can be checked.
1111 rpm shutdown speed)

CASE 1: Mobile Equipment with Variable RPM 20% LED When activated (i.e. “SET [red] Constant
Capability and tachometer readout (second LED Pushbutton is pressed), the Engine speed
from the top) Shutdown Speed will be set to the
Refer to the above illustrations on this page. – Solid On
Teach Engine Speed divided by a
Green
factor of 0.80 (eg. 1000rpm/.8 =
1. Press and hold the SET (red) Pushbutton until the Status
1250 rpm shutdown speed)
LED flashes on and off.
When activated (i.e. “SET [red] Constant
2. Determine which % Trip Point Reduction (TPR) LED is lit: 30% LED Pushbutton is pressed), the Engine Speed
a. If 50% TPR LED is lit, continue to Step 3. (third LED Shutdown Speed will be set to the (may also
b. If 10%, 20%, or 30% TPR LED is lit, press and release from the top)
the SET Pushbutton to toggle through each TPR LED Teach Engine Speed divided by a be used for
– Solid On
until the 50% TPR LED is illuminated. Green factor of 0.70 (eg. 1000rpm/.7 = variable
1429 rpm shutdown speed) speed)
3. Determine the Desired Engine Shutdown Speed and
multiply this value by the Trip Point Reduction value 50% LED When activated (i.e. “SET [red] Variable
(0.50). This is the “Teach Engine Speed” value. Record this (bottommost Pushbutton is pressed), the Engine speed
value below. LED) Shutdown Speed will be set to the
Teach Engine Speed: _____________ – Solid On
Teach Engine Speed divided by a
Green
factor of 0.50. (eg. 4000 rpm
4. Rev and hold engine at the Teach Engine Speed recorded
in Step 3. shutdown speed = 2000rpm/.5)

5. While engine RPM is held at the Teach Engine Speed, push

and release the TEST (black) pushbutton once to program
CASE 2: Constant RPM Engines (i.e. Compressor
the RPM threshold (or alternatively, press and Generators) and/or no tachometer readout
immediately release the remote momentary switch). All
LED’s on the module should now turn off. Refer to the above illustrations on this page.

1. Press and hold the SET (red) pushbutton until the Status
LED flashes on and off.
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REVGUARD 2 Diesel Engine Safety Solutions
Installation, Operation and Maintenance
2. Determine which % Trip Point Reduction (TPR) LED is lit:
a. Press and release the SET Pushbutton to toggle 4. Rev and hold engine at engine load RPM. While engine is
through to the desired Trip Point Reduction of 10%, at engine load RPM, push and release the TEST (black)
20% or 30%. (NOTE: 10% may be too sensitive. If it is pushbutton once to program the RPM threshold (or
choose 20%.) The chosen TPR LED will be illuminated. alternatively, press and release the remote momentary
TPR selection is the preference of the installer and switch). All LED’s on the module should now turn off.
depends on the circumstances of the engine. Contact
technical support if unsure. You have finished programming Revguard 2 to trip at the
Desired Engine RPM Shutdown Speed. The module is ready
% TPR Election Factor* for normal operation.
10% 0.90
*(Desired engine RPM = engine load RPM/Factor)
20% 0.80
30% 0.70

CAUTION: Ensure Revguard 2 is configured and working in run mode under normal operation by verifying all LEDs are off. If Revguard 2 is
in configuration mode, press and hold the SET (red) Pushbutton to return to run mode. If Revguard 2 is in fault mode (see p.17), press and
hold the TEST (black) Pushbutton or Momentary Switch for at least 5 seconds to return to run mode. NOTE: Revguard2 requires an engine
RPM signal to exit TEACH mode. If the unit does not exit TEACH mode check the wiring for either the mag pickup or alternator
a. Mag pickup: should read ~ 1.3 VAC between SP+ and SP- (@ 1.6 kHz)
b. Alternator: should read ~ 7 VDC on SP+ (no connection to SP-).

Testing Revguard2 (All Cases)

Remote
Momentary
Status LED
Switch (12V
(24V only)
light built into
switch)

A. WITH ENGINE OFF (testing manual shutdown functionality ONLY) NOTE: many sites require the test to be done with the engine
running.
1. Toggle momentary switch up (1 second) and release.
2. You should hear the valve trip (i.e. close).
3. Reset the valve (to open position) before starting engine.

B. WITH ENGINE RUNNING (testing Programmed RPM Threshold, i.e. automatic shutdown)
1. Press and hold the Momentary Switch and do not release. The momentary switch light will flash on and off.
2. While the Momentary Switch is firmly held on, increase engine RPM until the “Teach Engine Speed” (described above;
it is often 50% of overspeed RPM) is reached. At this point, the shutdown system will activate. CAUTION: If the valve
fails to trip, see the Troubleshooting Guide.
3. Reset the valve (to open position) before starting engine.

CAUTION: If system does not operate as described see Troubleshooting Guide on page 17.

NOTE: To test using the Revguard2 unit directly substitute the TEST (black) pushbutton on the Revguard unit for “Momentary
switch” in the above instructions.

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 REVGUARD 2 Diesel Engine Safety Solutions
Installation, Operation and Maintenance
F. OPERATION MODES
Revguard 2 has four modes of operation including: configuration/teach mode, run mode, test mode, and error mode. The lights on the
unit will indicate to the user the current mode of operation.
SET Pushbutton TEST Pushbutton

Trip Point
Reduction % (TPR)
10%
Status LED 20%
30%
Trip Output LED 50%

Figure 14: Buttons and LEDs on the Revguard 2 Speed Switch Module

Operation Mode Status LED Trip Point Reduction LEDs See Page
(on Revguard 2 or remote)
Configuration/Teach (push test Rapid flash One of the green LEDS will 16
pushbutton for less than 5 sec.) be illuminated
Run Off All green LEDs off 16
Test (only while pressing and continuously Rapid flash One of the green LEDs will
holding test pushbutton) be illuminated 16
Fault (Error) Slow Flash All green LEDs off 17

1. Configuration/Teach Mode: (a) Trigger Regardless of Engine Speed – Simply pressing

• Used to program the RPM limitation. and immediately releasing the Test Button (or toggle
• When in Configuration/Teach Mode, the Status LED, switch) will trigger the shutdown system regardless of
and one of the four green LEDs on the right hand side engine speed or whether engine is on/off. Revguard 2
will be solid on. will enter the shutdown sequence as described in the
run mode section above. NOTE: On many vehicles, it is
best to shut down the engine normally, trip the valve,
2. Run Mode:
and then try to start the engine normally to show the
• This is Revguard 2’s normal operating state. Run
safety inspector successful air intake shutdown.
mode is automatically accessed after start-up. During
run mode, all LEDs remain off. No user input is
(b) Trigger with Engine Speed - Because it is not desirable
[Link] mode, all LEDs remain off. No user input
to reach such high RPM levels (red-line) to verify the
is required.
functionality of the system, the operator can test the
system at the trip point reduction (TPR) engine speed
3. Test Mode: (described in the programming section). If the user
• Revguard 2 can also be used to test the shutdown presses and holds the Test Button (or switch) for five
system or manually trigger a shutdown. There are seconds the status LED will illuminate and the
two approaches that can be used for appropriate TRP LED will illuminate. While continuing
testing/manually triggering: to hold the test button slowly increase the engine
speed. At the TPR engine speed Revguard 2 will enter
the shutdown sequence.
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REVGUARD 2 Diesel Engine Safety Solutions
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4. Fault (Error) Mode:
Fault Mode is entered only when Revguard 2 reaches the
programmed number of output attempts (5 maximum) and
the engine has not been shut down.

If RevGuard 2 enters the fault mode it means that the Once fault mode is activated, the Trip Output LED will be
shutdown system has failed. In the event of an actual over- turned off and the Status LED will begin flashing on and off.
speed situation, all personnel should immediately move to Revguard 2 will continue to remain in this state until the
a safe distance from the engine/vehicle. Failure to do so condition is acknowledged by the user and the TEST
could lead to serious bodily injury or even death. pushbutton (or switch) is pressed and held for longer than 5
seconds to clear the fault and return the unit to run mode.
All other buttons remain inactive during this time.

LED Indicators Trip Output LED

Status LED Behaviour Indication

(on Revguard 2 module and remote switch) Flashing on/off Revguard 2 is attempting to stop the
engine:
Behaviour Indication
When the light is on, the output
Slowly flashing Unit is in configuration mode and is ready to trigger signal is activated.
on/off after the “SET be programmed. See Step 2 through Step 5 of
Pushbutton” is the applicable RPM programming procedure. Solid Off Revguard 2 is not attempting to
pressed for 5 trigger a system shutdown.
seconds.

Rapidly flashing Unit is in test mode and ready for testing. See
on/off after the the testing procedure.
“TEST Pushbutton”
has been held for 5
seconds.

Slowly flashing Revguard 2 shutdown system has faulted.

on/off after module
power-up. See page 17 for more details.

OR

Slowly flashing
on/off without
pressing the “SET” or
“TEST” Pushbuttons.

Solid on for 10 - 15 The valve has been tripped and Revguard 2

seconds. detected a successful shutdown.

Solid Off Revguard 2 is in normal operation.

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REVGUARD 2 Diesel Engine Safety Solutions
Installation, Operation and Maintenance
G. MAINTENANCE
BI-ANNUAL MAINTENANCE
To ensure proper operation of the Revguard 2 Shutdown
System, regular attention to the fundamental functionality of
the product is required. The following maintenance schedule is • Ensure that all electrical wires are properly supported and
recommended: free from damage.
• Ensure that all terminals on the module and all terminals
MONTHLY MAINTENANCE to the adjacent components are tight and secure.
• Ensure that there is no electrical corrosion to the
• Perform test shutdown procedure on page 15 terminals.

H. TROUBLESHOOTING GUIDE
PROBLEM RECOMMENDED ACTION

Unit will not exit TEACH Revguard2 requires an engine RPM signal to exit TEACH mode. If the unit does not exit TEACH mode check the
mode wiring for either the mag pickup or alternator
a. Alternator: should read ~ 7 VDC on SP+ (no connection to SP-)
b. Mag pickup: should read ~ 1.3 VAC between SP+ and SP- (@ 1.6 kHz)
NOTE: disconnecting power to unit will not work. To exit TEACH MODE the unit must have an rpm signal.

Status LED flashing slow • If status light does not clear, unit is in fault state. Press and hold the TEST Pushbutton for 5 seconds to
and the unit is not clear.
reacting to commands • If issue still present, disconnect power to unit for 30 seconds. Reconnect power and retest.
from either button. • If issue persists, power on unit – press and hold the TEST Pushbutton until run mode is entered. Re-
program and retest.

Trip Output LED is Check wiring connections to valve and relay (if equipped).
illuminated but valve does
not close. If valve solenoid still does not function despite receiving adequate power and being correctly wired (per the
applicable connection diagram), the valve (ASOV) may need to be serviced/repaired.

If relay (if equipped) is tripping, check power into and out of relay.
i. If there is no input power into relay, check feed circuit.
ii. If there is no power from relay but input power is good and relay trips, replace relay.

Revguard 2 does not Check and verify that Revguard 2 is receiving the appropriate power supply.
respond to any inputs. If Revguard 2 is not powered appropriately, re-check the wiring configuration.

Revguard 2 trips the valve Check the ground wire to the module. Revguard 2 must have a reliable battery return connection.
as soon as it is connected Repair ground as necessary.
without the engine
running.

“Check Engine” light Clear the code. Re-start the engine and run normally.
comes on after valve is
tripped. NOTE: At times, tripping the valve may generate or set a code in the ECM. On many vehicles, it is best to shut
down the engine normally, trip the valve, and then try to start the engine normally to show the safety
inspector successful air intake shutdown.

IOM-1520-001 Rev. 17 Page 17 of 19

REVGUARD 2 Diesel Engine Safety Solutions
Installation, Operation and Maintenance
TROUBLESHOOTING GUIDE (Continued)

PROBLEM RECOMMENDED ACTION

During testing, valve does Refer to the applicable connection diagrams from Section D of this document.
not trip at the Teach
Engine RPM. Perform a detailed visual inspection for the configuration and integrity of the following items:
i. Wiring between the alternator (or magnetic pick-up) and Revguard 2 module.
ii. Wiring between valve’s actuation hardware and Revguard 2 module.
iii. Wiring to and from the relay (for manually activated systems).

If problems persist, attempt to re-teach the shutdown speed and re-test.

Revguard 2 will not accept Verify the following conditions for each component:
programming. It is in
configuration mode but a. Alternator
will not accept engine i. Alternator signal must come from “R” stud or one of the stator windings.
RPM setting. ii. Alternator signal must be an AC signal approximately 7 VAC.
iii. Alternator signal must be between 10 to 10,000 hertz.

b. Magnetic Pick-Up
i. Magnetic pick-up must be installed 1/2 to 1 turns from bottoming out.
ii. Magnetic pick-up must receive a clean and unshared signal. The ECM and Revguard 2 both require their
own clean signal.

c. Vehicle ECM Tach Output Signal

i. ECM signal output must be a frequency, not a voltage.
ii. ECM signal must use independent output signal line with no other connections. Do not share line.

I. WARRANTY Because of the many variables and requirements associated

with any particular installation AMOT Controls Corporation,
The warranty on new Revguard 2 products is one year from
Roper Industries, Inc. or any of their affiliated entities assume
date of shipment. All warranty claims must be approved by
no responsibility or liability for actual use beyond that covered
customer service prior to returning the product.
by this warranty.
This warranty does not cover components supplied by others.
Warranty claims on such components will be allowed only as Individuals using the Revguard 2 product must analyze all
per limits extended by those suppliers. aspects of their application design and exercise their own
independent judgment in evaluating product selection and
The Revguard 2 warranty does not cover any product that has
determining product appropriateness for their specific
been abused, repaired or altered, or put in service for which it
application and system requirements. Responsibility for proper
was not intended. AMOT Controls Corporation reserves the
selection, use, and maintenance of any product remains solely
right to change material and design without prior notice and is
with the purchaser and end user.
not responsible for any inconvenience this may cause.

For Technical Support - Call +1 780 465 4429 or Fax +1 780 469 6275
AMERICAS, ASIA EUROPE, MIDDLE EAST, AFRICA

4320 Roper Road, NW Western Way, Bury St. Edmunds

Edmonton, AB T6B 3T8 Suffolk, England IP33 3SZ
Canada

Email info@[Link] Email sales@[Link]

[Link] [Link]

IOM-1520-001 Rev. 17 Page 18 of 19

REVGUARD 2 Diesel Engine Safety Solutions
Installation, Operation and Maintenance
REVISION CHANGE DESCRIPTION
10 REVISED PER RCR-1448.
11 REVISED PER RCR-1456.
12 REVISED PER RCR-1480.
13 REVISED PER RCR-1556.
14 REVISED PER RCR-1569.
15 REVISED PER RCR-1592.
16 REVISED PER RCR-1734
17 REVISED PER RCR-1844

IOM-1520-001 Rev. 17 Page 19 of 19