Hubbell Diesel Engine Fire Pump Controller LX3000 Bedienungsanleitung

Page 1 of 17

Hubbell Industrial Controls, Inc.

A subsidiary of Hubbell Incorporated

4301 Cheyenne Dr.

Archdale, NC 27263

Telephone (336) 434-2800

FAX (336) 434-2803

Instruction Manual

Model LX3000

Diesel Engine

Fire Pump Controller

Publication No. 203

December 2003

BBELL

Instruction Manual

LX3000 Diesel Fire Pump Controller

Introduction

Model LX3000 engine controllers, automatically control the operation of diesel engine driven centrifugal fire

pumps.

Installation

1. Consult the Controller nameplate to verify that the DC voltage and ground polarity matches the engine

battery. Also verify that the Controller AC power requirement matches available AC power.

2. Set the CONTROLLER ON / OFF - RESET SWITCH (inside controller) to the OFF position.

CAUTION: Before drilling and punching holes in the cabinet for wiring connections, cover the

components inside the cabinet with a protective covering. Debris may cause shorts or

prevent operation of components.

3. 2 holes are pre-punched in the top left side of the cabinet for conduit entry.

4. Connect the water line to the INLET side of the solenoid valve located on the left side of the Controller.

Connect a drain line to the DRAIN side of the valve.

5. Connect Engine and Battery leads to TB1-1 through 12, connect the AC input to TB2-1 through 5, and

connect required alarm contacts, all per the Field Connection drawing supplied with the controller.

6. Connect remote start normally closed input contacts (if used) to TB1-13 and battery common.

7. Connect lockout/low suction normally open input contacts (if allowed by local jurisdiction) to TB1-14 and

battery common.

Start Up Instructions

1. Adjust the pressure switch set points to meet water system requirements. The adjustment switches are

located on the pressure switch control board, which is contained inside the pressure recorder enclosure.

Open the pressure recorder door and loosen the two chart plate screws. Swing the chart plate outwards to

gain access to the pressure switch control board. Set the STOP (HIGH) pressure setting on the upper three

switches. Set the START (LOW) pressure setting on the lower three switches.

The Green LED on the left (Excitation Voltage) indicates that the Gauge Transducer is connected and

power is available to the recorder. The middle LED (Relay Status) is bi-colored to indicate the status of the

output relay contacts. If this LED is green, pressure is above the Stop pressure. If the LED is red, pressure

is below the Start pressure. The red LED to the right (CAUTION) indicates the Start pressure is set higher

than the Stop pressure and needs to be corrected.

2. Set the recorder time using a coin or screwdriver to turn the chart hub clockwise to the time indicator on

the right side of the chart.

3. Remove the pen tip cover. If necessary, adjust the pen with the adjusting screw in the upper left corner of

the dial plate. The recorder accuracy is 2% of scale.

4. Adjust the weekly Test Timer for the correct timing settings as follows:

Set the time

1) Press the Reset button to clear the memory

2) Press and hold the clock symbol key during entire time setting procedure.

a) Press the Day key to bring the actual day of the week into display.

b) Press the hbutton to set the hours and the mbutton to set the minutes. If the keys are depressed for

more than a second, the digits will advance rapidly.

c) Release the clock key when finished with the settings. The colon between the hours and minutes will

be flashing indicating the timer has started.

Programming

1) To set the Timer to start the engine once a week and run for a selected period of time.

Press Timer once (do not keep depressed) The display will show “1ON and “--:--“for the time.

a) Press h+ m+ to set the ON time.

b) Press Day to select the day of the week to run.

c) Press Timer key to enter program. The display will show 1”OFF”.

d) Program OFF command using steps b-d above.

e) Press the key to return to time od day display.

2) To review the programming

a) Press Timer key to review the individual commands as preprogrammed, at any time, be brought

consecutively into the display for revision or checking. Revisions are carried out by writing over the

existing programs using the steps outlined above.

5. Set Control Settings – also see attached drawing for locations of items 5 through 11.

a. Set the pressure switch start time delay (P/SWT DELAY SEC) on the Main Logic Board. The

adjustment range is 0 to 15 seconds in 1 second increments.

b. Set the AC Power Loss Delay Time on the Main Logic Board. The adjustment range is 0 to 90

seconds in 6 second increments.

c. Set the Auto Stop time switch (SW6). Settings are none, 15 minutes or 30 minutes.

d. Set the AC PowerLoss Start switch (SW4–2). Setting is on or off.

e. Set the AC Loss Audible Alarm switch (SW4-1). Setting is on or off.

6. Controller Testing

a. Verify pressure is above the Stop setting.

b. Turn CONTROLLER ON / OFF SWITCH to the ON position

Check the Test Timer to make sure that the Timer contacts are not about to close. Closure of the Timer

contacts during testing causes incorrect results.

Manual Start

a. Turn the AUTOMATIC / MANUAL SWITCH to the MANUAL position.

b. Operate the MANUAL CRANK # 1 switch or the MANUAL CRANK # 2 switch. Release as soon as the

engine starts.

c. Turn the AUTOMATIC / MANUAL SWITCH to the AUTO position to stop the engine.

Automatic Engine Cranking in TEST

a. Disconnect engine wire from TB1-1 to prevent starting.

b. Press the TEST PUSHBUTTON on the weekly TEST TIMER. The solenoid valve opens to discharge

water, and the pressure switch contacts close to initiate cranking.

c. The controller will crank the engine on battery 1 for 15 second intervals followed by 15 second rest period.

It will then crank 15 seconds on battery 2, followed by 15 second rest period. This cycle is repeated 3

times, then cranking should will stop and the FAILURE TO START light comes on, the alarm sounds, and

the Common TROUBLE relay is energized.

d. Turn the CONTROLLER ON / OFF to the OFF position.

e. Reconnect the starter motor cable(s).

Automatic Pressure Start

a. With the AUTOMATIC / MANUAL SWITCH in the AUTO position, lower the system pressure below the

Start pressure.

b. The engine will start and run until pressure is above the Stop setting and the STOP button is pressed, or the

CONTROLLER ON / OFF SWITCH is turned to the OFF position, or the optional Automatic Stop Timer,

typically set for 15 or 30 minutes, stops the engine.

Battery Failure Test

a. With the AUTOMATIC / MANUAL SWITCH in the AUTO position, disconnect the battery wire on

TB1-6. The BATTERY NO.1 FAILURE LED should come on within two minutes. The alarm should

sound and the Common TROUBLE relay should energize. Reconnect the wire to TB1-6. Reset the alarm

by turning the CONTROLLER ON / OFF - RESET SWITCH from CONTROLLER ON to OFF - RESET

position then back to the CONTROLLER ON position.

b. Disconnect the battery wire on TB1-8. The BATTERY NO.2 FAILURE LED should come on within two

minutes. The alarm should sound and the Common TROUBLE relay should energize. Reconnect the wire

to TB1-8. Reset the alarm by turning the CONTROLLER ON / OFF - RESET SWITCH from

CONTROLLER ON to OFF - RESET position then back to the CONTROLLER ON position.

Charger Failure Test

aWith the AUTOMATIC / MANUAL SWITCH in the AUTO position, disconnect the wire on TB1-6, and

disconnect the AC input to charger(s) no. 1. BATTERY NO.1 FAILURE & CHARGER 1 FAILURE light

should come on within two minutes. The alarm should sound and the Common TROUBLE relay should

energize. Reconnect the wire to TB1-6, reset the alarm by turning the CONTROLLER ON / OFF - RESET

SWITCH from CONTROLLER ON to OFF - RESET position then back to the CONTROLLER ON

position.

bRepeat the above for battery No. 2 & charger(s) no. 2, using the wire on TB1-8

Low Oil Pressure Test

a. With the AUTOMATIC / MANUAL SWITCH in the AUTOMATIC position, start the engine by

depressing the TEST PUSHBUTTON on the Weekly Timer.

b. Wait 10 seconds for the Oil Pressure Delay interval to expire, then momentarily jumper TB1-4 to TB1-11.

The alarm will sound and the Common Trouble relay will energize. The LOW OIL PRESSURE LED will

come on and remain on after the engine stops.

c. Turn the CONTROLLLER ON / OFF - RESET SWITCH to the OFF - RESET position then back to the

CONTROLLER ON position to reset the LOW OIL PRESSURE Alarm.

High Water Temperature Test

a. WITH the AUTOMATIC / MANUAL SWITCH in the AUTOMATIC position, start the engine by

depressing the TEST PUSHBUTTON on the Weekly Timer.

b. Momentarily jumper the TB1-5 to TB1-11. The alarm will sound and the Common Trouble relay will

energized. The HIGH WATER TEMPERATURE LED will come on and remain on after the engine stops.

c. Turn the CONTROLLLER ON / OFF - RESET SWITCH to the OFF - RESET position then back to the

CONTROLLER ON position to reset the HIGH WATER TEMPERATURE Alarm.

Optional Remote Start

a. With the AUTOMATIC / MANUAL SWITCH in the AUTO position, open the remote start contacts, TB1-12

& 13, starting the engine.

b. Turn the CONTROLLER ON / OFF SWITCH to the OFF position to stop engine.

c. Close the remote start contacts.

Optional AC Power Failure Start (if enabled)

a. With the AUTOMATIC / MANUAL SWITCH to the AUTO position, disconnect the AC power supply to the

Controller.

b. After the pre-set time delay (0 to 90 seconds) the engine will start. The audible alarm should sound, AC

POWER LOSS LED will come on, and both the Common TROUBLE and AC POWER LOSS relays will

energize.

c. Reconnect the AC power to reset the alarms.

d. Turn the CONTROLLER ON / OFF - RESET SWITCH to the OFF - RESET position to stop the engine.

End of Startup Testing

Switches

1. Automatic/Manual – Selects automatic or manual mode.

2. Crank Battery 1 – Cranks the engine using battery 1.

3. Crank Battery 2 – Cranks the engine using battery 2.

4. Stop – Stops the engine in automatic if there are no start conditions and control switch is in “Auto”.

5. Normal/ Silence – Silences optional pump house alarm only. Standard alarms required NFPA 20 cannot be

silenced.

Troubleshooting

Hazardous voltage

will shock, burn,

or cause death.

Do not touch

until ALL power

is disconnected.

!DANGER

WARNING: Disconnect AC power to the Controller before servicing to prevent shock or accident

hazard.

Before troubleshooting, perform the following checks:

a. visual inspection for physical damage.

b. ensure that all switches are in the normal operating position.

c. ensure that the engine controls are set for operation.

d. ensure that all wiring connections are secure.

e. review the Startup procedure for proper operation to help determine if one of the system boards is faulty.

Table 6-1 Troubleshooting

Condition Possible cause Checks Action

Batteries Voltmeters should read

at least 12.5 or 25 VDC

Check each battery in

bank for correct voltage

Check electrolyte

Test and recharge bad

battery(s)

Replace battery(s) with

good battery(s)

Check battery and

ground connections

Check battery voltage

Check battery cables

and connections

Clean and tighten

connections as

necessary

Engine does not crank

with MANUAL

START

Battery circuits

Check engine starter

cables and connections

Clean and tighten

connections as

necessary

Engine does not crank

using MANUAL

START - Battery No. 1

MANUAL CRANK #1

switch

Check battery voltage

while holding

MANUAL CRANK #1

switch

Refer to schematic

Use volt/ohm meter to

determine which

component is faulty

Engine does not crank

using MANUAL

START - Battery No. 2

MANUAL CRANK #2

switch

Check battery voltage

while holding

MANUAL CRANK #2

switch

Refer to schematic

Use volt/ohm meter to

determine which

component is faulty

If voltage checks indicate batteries and circuits OK then the engine starter or the pilot (or starting)

contactors are faulty.

Table 6-1 Troubleshooting (Continued)

Condition Possible cause Checks Action

Water and fuel solenoid

circuits

Check battery voltage

Check WATER and

FUEL Relay

Clean and tighten

connections

Replace Engine Relay

Board

Replace Main Logic

Board

Engine cranks but does

not start

Water and fuel solenoid

valves

Check solenoids

Check fuel and water

lines

Check engine, fuel, fuel

filter

Replace solenoid(s) or

valve(s)

Complete necessary

engine repairs

Engine continues to

crank after starting

AUTOMATIC /

MANUAL SWITCH

set to AUTO

Test Mode Active

Engine Crank Relay or

Main Logic Board

faulty

Engine Run signal

absent

Magnetic Pickup or

circuit faulty

Check Crank 1 and

Crank 2 relays on

Engine Relay Board

Check Run LED on

Main Logic Board

Check for Pickup signal

at Main Logic Board

Replace Engine Relay

Board.

Replace Main Logic

Board

Replace magnetic

Pickup

Engine does not crank

in TEST or AUTO

Engine cranks with

MANUAL START

Water and fuel

solenoids energized

Relay, or Main Logic

Board faulty

Check Crank 1 and

Crank 2 relays on

Engine Relay Board

Replace Engine Relay

Board

Replace Main Logic

Board

Engine does not crank

in AUTO when water

pressure decreases

Engine cranks with

MANUAL START

Pressure Switch, or

Main Logic Board

faulty

Press P/S TEST button If cranking cycle begins

refer to Appendix B

Pressure Switch /

Recorder

Replace Main Logic

Board

Table 6-1 Troubleshooting (Continued)

Condition Possible cause Checks Action

Engine stops without

having to press STOP

button or before run

time is complete

Water and Fuel

solenoid circuits and

valves, or

Main Logic Board

faulty

Check Water and Fuel

Relay

Replace Engine Relay

Board

Replace Main Logic

Board

Test Timer or Test

Pushbutton does not

start engine

AUTOMATIC /

MANUAL SWITCH in

AUTO

Engine starts after

pressure drop

No power to solenoid

drain valve, or faulty

valve

Faulty Timer

Check Water Dump

Solenoid Relay

Check solenoid valve

Check Timer

program

Replace Engine Relay

Board

Replace valve

Replace Timer

Alarm does not sound,

Associated light not on

Alarm faulty

LED Display faulty

Main Logic Board

faulty

Check alarm Replace alarm

Replace LED Display

Replace Main Logic

Board

No BATTERY

FAILURE indication

Engine cranks

Power Sense Board

faulty

Main Logic Board

faulty

Check Power Sense

Board

Replace Power Sense

Board

Replace Main Logic

Board

Table 6-1 Troubleshooting (Continued)

Condition Possible cause Checks Action

No HIGH ENGINE

TEMP indication

Water temperature

switch

Connect a jumper

across the water

temperature switch on

the engine

Start engine with

MANUAL START

switch

Verify that engine starts

and alarm sounds

Replace water

temperature switch

Engine overspeed does

not stop engine

No indication

Indication but engine

does not stop under

overspeed simulation

Faulty or mis-adjusted

magnetic sensor

Main Logic Board

faulty

Check sensor

installation

Replace sensor

Replace Main Logic

Board

Cranking and rest

periods greater than or

less than 15 ±2 sec.

Engine cranks less than

six times

Engine continues to

crank in AUTO

position but does not

start

Main Logic Board

faulty

Check Main Logic

Board

Replace Main Logic

Board

Controller does not

crank engine with good

battery

Engine cranking and

indication OK

Engine Relay Board

faulty

Main Logic Board

faulty

Check Engine Relay

Board

Check Main Logic

Board

Replace Engine Relay

Board

Replace Main Logic

Board

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