Hubbell Industrial Controls, Inc.
A subsidiary of Hubbell Incorporated
4301 Cheyenne Dr.
Archdale, NC 27263
Instruction Manual
Model LX3000
HUBBELL
Telephone (336) 434-2800
FAX (336) 434-2803
Diesel Engine
Fire Pump Controller
Publication No. 203
December 2003
Page 1 of 17
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.
AUTION: Before drilling and punching holes in the cabinet for wiring connections, cover the
C
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 h button to set the hours and the m button 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
a With 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.
b Repeat 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,
POWER LOSS
LED will come on, and both the Common
TROUBLE
AC POWER LOSS
and
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
AC
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,
!
DANGER
or cause death.
Do not touch
until ALL power
is disconnected.
ARNING: Disconnect AC power to the Controller before servicing to prevent shock or accident
W
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.
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