Murphy Engine and Generator Controls Keystart 9620 User's Manual
Contents
1. or if the speed signal cannot be simulated e g with an adjustable signal generator an approximate overspeed setting must be made e g potentiometer mid span approximately 115 of VR2 nominal 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 MURPHY the Murphy logo are registered and or common law trademarks of Murphy Industries Inc This document including textual matter and illustrations is copyright protected by Frank W Murphy Ltd with all rights reserved 2008 Frank W Murphy Ltd FW MURPHY P O Box 470248 Tulsa Oklahoma 74147 USA 1 918 317 4100 Fax 1 918 317 4266 E mail sales fwmurphy com INDUSTRIAL PANEL DIVISION Fax 1 918 317 4124 E mail ipdsales fwmurphy com MURPHY POWER IGNITION Website www murphy pi com CONTROL SYSTEMS AND SERVICES DIVISION P O Box 1819 Rosenberg Texas 77471 USA Phone 1 281 633 4500 Fax 1 281 633 4588 E mail sales fwmurphy com FRANK W MURPHY LTD Church Rd Laverstock Salisbury SP1 1QZ United Kingdom Tel 44 1722 410055 Fax 44 1722 410088 E mail sales fwmurphy co uk Web www fwmurphy co uk COMPUTRONIC CONTROLS 41 43 Railway Terrace Nechells Birmingham B7 5NG United Kingdom Tel 44 121 327 8500 Fax 44 121 327 8501 E mail sales computroniccontrols com Web www computroniccontrols com Murphy Keystart 9620 series installation instructi2. Speed calibration Set J and J3 correctly run engine to nominal speed adjust VR2 to give tacho output of 0 75mA VR3 Overspeed 100 130 of VR2 clockwise to increase ELECTRICAL CONNECTION of high voltage AC circuits Before connection disconnection or handling of these units AN WARNING DANGER OF INJURY OR DEATH Keystart 9621 controllers allow connection DANGER ensure that all AC and DC power supplies are isolated Connection to or disconnection from HIGH VOLTS live wiring may also cause damage to the Keystart s internal components Electrical connection to 0 5 to 1 5 mm 16 20 AWG panel wiring is by spring clamp terminals at the rear e pre strip 8 to 10 mm 0 3 to 0 4 in of insulation from each wire e Above each terminal is a square push button with a diagonal slot Insert a flat head screwdriver into the slot A then push down to towards the front of the Keystart to open the terminal clamp e insert the wire into the terminal B checking that the insulation is clear of the clamp Release the screwdriver spring clamp pressure and check that the wire is secure General connection recommendations Murphy make several recommendations for the electrical connection of engine and generator controllers e minimise controller output load current i e wear tear and potential damage by using slave relays between the controller outputs and high power end devices such as fuel and starter solenoids
3. VAC peak 2000 to 6500 Hz nominal Speed calibration Speed calibration is a two stage process 1 Nominal speed calibration potentiometer VR2 The factory default setting is for generator AC speed sensing with standard models for 50 or 60Hz nominal calibration To recalibrate for other systems e Select the speed sensing method generator AC or magnetic pickup using links J2 and J3 as detailed above e Turn VR2 fully clockwise sets calibration for maximum nominal frequency e Connect a 0 1mA 75 Ohm meter between pin 11 and battery negative as detailed in electrical connection above e Start and run the engine to nominal normal running speed e Turn VR2 anti clockwise decreasing the calibration frequency until the ammeter rises to read 0 75mA 2 Overspeed setting potentiometer VR3 VR3 allows adjustment of the overspeed trip point between approximately 100 and 130 of the nominal AC or magnetic pickup frequency as set using VR2 The VR3 factory default setting is 110 of either 50 or 60Hz To adjust the overspeed trip level e Turn VR3 fully clockwise to maximum approx 130 of nominal e Start and run the engine Increase engine speed to the required overspeed over frequency trip level e Turn VR3 slowly anti clockwise decreasing the overspeed trip level until the Keystart shuts down the engine and indicates overspeed Where the engine speed cannot be22 September 2008 adjusted
4. if enabled followed by activation of the Run output The fault override timer begins as soon as the Run output activates Once the engine is fully running Keystart monitors for faults and shuts down the engine if a fault is detected start crank Maintains the Run output and activates the Start crank output Shutdown fault inputs are disabled and the fault override timer is reset This position spring returns to Run on release Rear view connections and settings Configuration 14 4 Connection run fuel output DC 10A preheat output DC 10A start crank output DC 10A charge fail WL charge fail oil pressure fault input aux 1 fault input engine temp fault input amp 3 aux 2 fault input 10 alarm output DC 250mA 11 tacho calibration output 12 DC power supply Speed input model 9621 only links J2 and J3 ON 13 L gt Generator AC 14 N 70 270 VAC 50 60Hz links J2 and J3 OFF 13 pma ee on l 10 60 VAC 2000 6500Hz J2 vRi o VR2 0 Lo 0o Go a E coho VR3 0 Use a 3 mm 0 1 in flat head screwdriver for potentiometers VR1 VR3 All models J1 preheat link ON for no preheat link OFF for 10 second preheat VR1 Fault override 2 20 secs clockwise to increase Model 9621 only J2 amp J3 speed sensing source pins 13 and 14 both links ON for generator AC 50 60Hz both links OFF for magnetic pala 2000 6500 Hz VR2
5. Keystart 9620 series Engine amp Generator Controls Installation Instructions LD Daw W 4 BEFORE BEGINNING INSTALLATION OF THIS PRODUCT Y Disconnect all electrical power to the machine v Make sure the machine cannot operate during installation Y Follow all safety warnings of the machine manufacturer v Read and follow all installation instructions General The Keystart 9620 series provides manual start stop and automatic fault shutdown protection for generators pumps and other engine driven applications Keystart features a 3 way keyswitch for operator control of the engine with 6 LEDs for indication of status and faults see front view diagram for details Electrical connection and configuration options are at the rear see Rear view connection and settings diagram For each Keystart ordered the following is supplied e 1x Keystart module fitted with 2 x panel mounting clips e 2xkeys e these instructions Panel installation Keystart is designed for front of panel mounting in a DIN standard 92 x 92 mm 3 6 x 3 6 in cut out Allow 75mm 3 0 in behind the panel for the case depth keyswitch and cable connection Secure the case to the panel with the two ratcheted mounting clips 1 2 3 Remove the plastic At the front of the At the rear of the panel mounting clips from panel insert the refit the two mounting the Keystart case Keystart without clips into the slots on release each clip s clips int
6. aters see typical connection diagram below 00 02 0657 revision A 22 September 2008 p2 4 ELECTRICAL CONNECTION cont Terminal functions cont Pin 3 Oo ON OD 10 11 Function Start crank output Pin 3 gives a positive DC 16 Amp rated output when the key is switched to position Il start crank To prolong keyswitch contact life connect a slave relay with suppressed coil between pin 3 and the engine starter solenoid coil see typical connection diagram below Power Supply Positive DC Power Supply Negative DC The Keystart operates with any smooth DC battery voltage in the range 7 30V Supply brown out protection is fitted as standard Connect a 5 Amp anti surge fuse in the positive DC line pin 4 Charge fail The charge fail LED lights but there is no shutdown or alarm when pin 5 is connected to battery negative When using a charge alternator connect pin 5 to the alternator warning lamp WL terminal Note pin 5 supplies the alternator excitation current Low Oil Pressure LOP fault input Auxiliary 1 fault input High Engine Temperature HET fault input Auxiliary 2 fault input Use remote switch relay contacts that connect these inputs to battery negative during fault conditions The Keystart shuts down the engine lights the appropriate fault LED and activates the alarm output Note activation of pin 9 Aux 2 input causes engine shutdown and illumination of the ove
7. e Suppress at source electrical interference from panel relay and engine solenoid coils using flywheel diode or proprietary snubber networks as appropriate Murphy Keystart 9620 series installation instructions e use e use and separate routing for AC and DC wiring harnesses separate wiring for a connection of battery charger to battery b connection of battery to panel DC supply Separate wiring will reduce high frequency battery charger output noise on the panel DC power supply Terminal functions Pin 1 2 Function Run fuel output Preheat output These relay outputs provide control for a the engine s preheater and energised to run fuel ignition circuits When configuration link J3 is on the default setting the Preheat output terminal 2 does not operate If link J3 is removed terminal 2 gives a positive DC output for 10 seconds and the preheat LED lights beginning from when the key is switched to the I RUN position After any preheat time has expired the Run output pin 1 gives a positive DC output operating engine fuel and the green run LED lights The Run output and LED remain active until the operator switches the key to O STOP or until the Keystart initiates an automatic fault shutdown Both Run and Preheat outputs are rated 10 Amp max 24VDC Murphy recommend the connection of slave relays with suppressed coils between these outputs and fuel solenoid coil and engine prehe
8. eter output 0 75mA at rated engine speed start crank calibration tacho adjustable settings preheat timer 0 or 10 secs link J1 default 0 secs 2 to 20 secs VR1 default 10 secs 100 to 130 VR3 of nominal speed calibration VR2 default 110 of 50 or 60 Hz fault override timer overspeed trip level general overall dimensions wxhxd 96 x96 x95 mm 3 8 x 3 8 x 3 7 in panel cut out size DIN 92 x 92 mm 3 6 x 3 6 in weight approx 300 g 0 7 Ib operating temperature 35 C to 55 31 F to 131 F Model options KEY9620 K1 Model KEY9620 Without overspeed protection KEY9621 With overspeed protection selectable AC generator or magnetic pickup sensing Keyswitch type K1 Type 1 chrome bezel K2 Type 2 rubberised standard stock modules are set for AC generator sensing calibrated to either 50 or 60 Hz nominal Non standard NS settings options are available to order GENERAL INFORMATION cont Front view and operation LED indication preheat on amber run fuel on green MURPHY low oil pressure fault shutdown red high engine temperature fault shutdown red overspeed aux 2 fault fault shutdown red charge fail warning red aux 1 fault shutdown red 3 position keyswitch O Off Reset Removes power stops the engine and resets any latched shutdown fault Run Activates the timed Preheat output
9. fitted the default factory setting terminals 13 and 14 are configured for overspeed sensing using a high voltage generator AC 50 60HZ signal The input accepts generator AC voltages between 70 and 270 VAC rms A 1 Amp anti surge fuse should be connected in series with AC live pin 13 See speed sensing below for correct calibration of this input using potentiometers VR2 and VR3 To configure these terminals to magnetic pickup engine speed sensing see section below With links J2 amp J3 OFF Magnetic pickup signal input Magnetic pickup return When configuration links J2 and J3 are removed terminals 13 and 14 are configured for speed sensing by a magnetic pickup and flywheel gearwheel combination Connect the magnetic pickup to the input using two core and screen cable To minimise electrical interference on the speed signal connect the cable screen to earth at one end only Magnetic pickup signal requirements are 10 60 VAC peak with frequency between 2000 and 6500 Hz when the engine is running at nominal speed See speed sensing below for correct calibration of this input using potentiometers VR2 and VR3 To configure these terminals for generator AC frequency sensing see section above Typical connection Emergency S magnetic pickup Notes Overspeed models 9621 only Select P AC or magnetic pickup speed sensing using links J2 amp J3 see rear facia diagram stock u
10. nits are set for generator AC sensing 00 02 0657 revision A 22 September 2008 p3 4 SPEED SENSING AND CALIBRATION Keystart model 9621 includes a speed sensing input and automatic shutdown protection for engine overspeed faults Before use model 9621 s speed input must be correctly configured using circuit board links J2 and J3 and calibrated using potentiometers VR2 and VR3 Maintenance and Warranty The Keystart series contains no user serviceable parts Maintenance is therefore limited to the following preventative checks e Check that all electrical connections are secure Selection of speed signal source links J2 and J3 Links J2 and J3 allow configuration of the speed sensing input terminals 13 and 14 for either generator AC the factory default setting or magnetic pickup signals Use small pliers to add or remove the links as required J2 and J3 Terminal 13 and 14 configuration links e Check that the Keystart is securely clamped in the front of panel aperture and kept free from ingress of water or build up of excessive dust dirt The front face label and casing may be wiped with a clean damp cloth Do not use cleaning solvents Each Keystart is supplied with a two year warranty on materials and workmanship In the event of a fault or technical query please contact your Murphy representative for technical support Generator AC 70 270 VAC rms 50 or 60 Hz nominal OFF Magnetic pickup 10 60
11. o the panel the Keystart case D ratchet mechanism by cut out C Slide each clip forward pulling outwards A until the arms E are then slide the clip secured behind the back and off the panel face Ratchet case B mechanism F prevents the clip from moving backwards 00 02 0657 revision A 22 September 2008 catalogue section 40 amp 75 MURPHY gt Please read the following information before installing A visual inspection of this product for damage during shipping is recommended before installation It is your responsibility to ensure that qualified mechanical and electrical technicians install this product If in doubt please contact your local Murphy representative fT ED a ae aw p WARNING Product specifications ower supply operating voltage steady state 7 30 VDC brown out cranking 5 VDC current consumption lt 100mA inputs fault switch inputs ve input defined as speed sensing input generator AC J2 J3 on close to negative DC during fault 1V to 1V w r t ve DC supply model 9621 only 70 270 VAC rms lt 50 to gt 60 Hz nominal 10 60 VAC peak lt 2000 to gt 6500 Hz nominal mag pickup J2 J3 off outputs all ratings non reactive run preheat positive DC switched NO relay contact 10 A max 24VDC positive DC via keyswitch contacts 10 A max 24V DC alarm negative DC open collector NPN transistor 250mA max to suit 0 1 mA 75 Ohm m
12. ons FW MURPHY INTERNATIONAL TRADING SHANGHAI CO LTD Suite 1704 Tower B City Center of Shanghai 100 Zunyi Road Shanghai 200051 China Phone 86 21 6237 2082 Fax 86 21 6237 2083 E mail mhong fwmurphy com FW MURPHY INSTRUMENTS HANGZHOU CO LTD 77 23 Street Hangzhou Economic amp Technological Development Area Hangzhou Zhejiang 310018 China Phone 86 571 8788 6060 Fax 86 571 8684 8878 EET pS 01 A A L LS USA ISO 9 2000 FM 28221 UK 4SO 9 0 Z 00 02 0657 revision A 22 September 2008 p4 4
13. rspeed LED For all the above inputs shutdown is inhibited during engine cranking and until the end of the fault override time adjustable 2 20 secs using potentiometer VR1 clockwise to increase To reset a shutdown fault condition turn the key to O Off or remove the DC power supply Alarm output Pin 10 is a semiconductor based open collector NPN transistor output that gives a negative DC output immediately after a fault shutdown Output rating is 250mA max the output typically drives an audible visible alarm circuit using a slave relay with suppressed coil see typical connection opposite Tachometer speed calibration output This output is designed to work with a 0 1 mA DC ammeter either a during set up to aid speed calibration or b in normal operation to indicate engine speed or generator Hz For calibration connect meter positive to pin 11 and meter negative to battery negative e g at terminal 12 See speed sensing and calibration below for setup procedure For indication of engine RPM or generator Hz the 0 1mA meter requires a custom scale when correctly calibrated using VR2 Keystart gives 0 mA at 0 RPM Hz and 0 75mA 3 4 scale at normal running RPM Hz Murphy Keystart 9620 series installation instructions Pin 13 14 13 14 Function With links J2 amp J3 ON DANGER Generator AC Live HIGH VOLTS Generator AC Neutral When configuration links J2 and J3 are
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