Hubbell LX3000 User Manual

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Hubbell Industrial Controls, Inc.

HUBBELL

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

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.

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-punchedin 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 TB1-1through 12, connect the AC input toTB2-1through 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 TB1-13and battery common.

7.Connect lockout/low suction normally open input contacts (if allowed by local jurisdiction) to TB1-14and 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-coloredto 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 them 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“--:--“forthe 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-dabove.

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 TB1-1to 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 toTB1-6.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 toTB1-8.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 toTB1-6,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 TB1-4toTB1-11.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 TB1-5toTB1-11.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 theAUTO 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 theAUTO position, disconnect the AC power supply to the Controller.

b.After the pre-settime delay (0 to 90 seconds) the engine will start. The audible alarm should sound,AC POWER LOSS LED will come on, and both the CommonTROUBLE andAC POWER LOSS relays will energize.

c.Reconnect the AC power to reset the alarms.

d.Turn the CONTROLLER ON / OFF - RESET SWITCHto the OFF - RESETposition 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,

! DANGER or cause death. Do not touch

until ALL power is disconnected.

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 6-1Troubleshooting

Condition

Possible cause

Checks

Action

 

Batteries

Voltmeters should read

Check electrolyte

 

 

at least 12.5 or 25 VDC

Test and recharge bad

 

 

Check each battery in

 

 

battery(s)

 

 

bank for correct voltage

 

 

Replace battery(s) with

 

 

 

good battery(s)

 

Battery circuits

Check battery and

Clean and tighten

 

 

ground connections

connections as

Engine does not crank

 

 

necessary

 

Check battery voltage

 

with MANUAL

 

 

START

 

Check battery cables

 

 

 

and connections

 

 

 

Check engine starter

Clean and tighten

 

 

cables and connections

connections as

 

 

 

necessary

 

 

 

 

Engine does not crank

MANUAL CRANK #1

Check battery voltage

Refer to schematic

using MANUAL

switch

while holding

Use volt/ohm meter to

START - Battery No. 1

 

MANUAL CRANK #1

determine which

 

 

switch

component is faulty

Engine does not crank

MANUAL CRANK #2

Check battery voltage

Refer to schematic

using MANUAL

switch

while holding

Use volt/ohm meter to

START - Battery No. 2

 

MANUAL CRANK #2

determine which

 

 

switch

component is faulty

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

Table 6-1Troubleshooting (Continued)

Condition

Possible cause

Checks

Action

 

 

 

 

 

Water and fuel solenoid

Check battery voltage

Clean and tighten

 

circuits

 

connections

 

 

Check WATER and

Replace Engine Relay

 

 

Board

 

 

FUEL Relay

Engine cranks but does

 

Replace Main Logic

 

 

 

 

Board

not start

 

 

 

 

 

 

Water and fuel solenoid

Check solenoids

Replace solenoid(s) or

 

valves

Check fuel and water

valve(s)

 

 

lines

 

 

 

Check engine, fuel, fuel

Complete necessary

 

 

filter

engine repairs

 

 

 

 

Engine continues to

Engine Crank Relay or

Check Crank 1 and

Replace Engine Relay

crank after starting

Main Logic Board

Crank 2 relays on

Board.

AUTOMATIC /

faulty

Engine Relay Board

Replace Main Logic

 

 

MANUAL SWITCH

 

 

Board

set to AUTO

Engine Run signal

Check Run LED on

Replace magnetic

 

Or

absent

Main Logic Board

Pickup

Test Mode Active

Magnetic Pickup or

Check for Pickup signal

 

 

circuit faulty

at Main Logic Board

 

 

 

 

 

Engine does not crank

Relay, or Main Logic

Check Crank 1 and

Replace Engine Relay

in TEST or AUTO

Board faulty

Crank 2 relays on

Board

Engine cranks with

 

Engine Relay Board

 

 

 

 

MANUAL START

 

 

Replace Main Logic

 

 

 

Water and fuel

 

 

Board

 

 

 

solenoids energized

 

 

 

 

 

 

 

Engine does not crank

Pressure Switch, or

Press P/S TEST button

If cranking cycle begins

in AUTO when water

Main Logic Board

 

refer to Appendix B

pressure decreases

faulty

 

Pressure Switch /

Engine cranks with

 

 

Recorder

 

 

 

MANUAL START

 

 

Replace Main Logic

 

 

 

 

 

 

Board

 

 

 

 

Table 6-1Troubleshooting (Continued)

Condition

Possible cause

Checks

Action

 

 

 

 

Engine stops without

Water and Fuel

Check Water and Fuel

Replace Engine Relay

having to press STOP

solenoid circuits and

Relay

Board

button or before run

valves, or

 

 

time is complete

 

 

 

 

Main Logic Board

 

Replace Main Logic

 

faulty

 

 

 

Board

 

 

 

 

 

 

 

Test Timer or Test

No power to solenoid

Check Water Dump

Replace Engine Relay

Pushbutton does not

drain valve, or faulty

Solenoid Relay

Board

start engine

valve

 

 

AUTOMATIC /

Faulty Timer

Check solenoid valve

 

MANUAL SWITCH in

Replace valve

 

AUTO

 

Check Timer

Replace Timer

 

 

Engine starts after

 

program

 

pressure drop

 

 

 

 

 

 

 

Alarm does not sound,

Alarm faulty

Check alarm

Replace alarm

Associated light not on

LED Display faulty

 

Replace LED Display

 

 

 

Main Logic Board

 

Replace Main Logic

 

 

Board

 

faulty

 

 

 

 

 

 

 

 

No BATTERY

Power Sense Board

Check Power Sense

Replace Power Sense

FAILURE indication

faulty

Board

Board

Engine cranks

Main Logic Board

 

Replace Main Logic

 

faulty

 

Board

 

 

 

 

 

 

 

 

Table 6-1Troubleshooting (Continued)

Condition

Possible cause

Checks

Action

No HIGH ENGINE

Water temperature

Connect a jumper

Replace water

TEMP indication

switch

across the water

temperature switch

 

 

temperature switch on

 

 

 

the engine

 

 

 

Start engine with

 

 

 

MANUAL START

 

 

 

switch

 

 

 

Verify that engine starts

 

 

 

and alarm sounds

 

 

 

 

 

Engine overspeed does

 

 

 

not stop engine

Faulty or mis-adjusted

Check sensor

Replace sensor

No indication

magnetic sensor

installation

 

 

 

 

Main Logic Board

 

Replace Main Logic

Indication but engine

faulty

 

Board

 

 

 

does not stop under

 

 

 

overspeed simulation

 

 

 

 

 

 

 

Cranking and rest

Main Logic Board

Check Main Logic

Replace Main Logic

periods greater than or

faulty

Board

Board

less than 15 ± 2 sec.

 

 

 

Engine cranks less than

 

 

 

six times

 

 

 

Engine continues to

 

 

 

crank in AUTO

 

 

 

position but does not

 

 

 

start

 

 

 

 

 

 

 

Controller does not

Engine Relay Board

Check Engine Relay

Replace Engine Relay

crank engine with good

faulty

Board

Board

battery

 

 

 

Engine cranking and

Main Logic Board

Check Main Logic

Replace Main Logic

indication OK

faulty

Board

Board

 

 

 

 

 

Table 6-1Troubleshooting (Continued)

Condition

Possible cause

Checks

Action

 

 

 

 

Engine does not crank

Remote switch faulty

Check switch and

Repair circuits

with Remote Start

Main Logic Board

switch circuits

Replace switch

 

 

 

Cranks when water

faulty

Check Main Logic

Replace Main logic

pressure decreases

 

Board

Board

 

 

 

 

Engine does not start

Power Sense Board or

Check Power Sense

Replace Power Sense

after AC power loss

Main Logic Board

Board

Board

 

faulty

 

 

 

 

Check Main Logic

Replace Main Logic

 

 

Board

 

 

Board

 

 

 

 

 

 

 

Engine does not stop

Another start condition

Check controller start

 

with optional AUTO

present

conditions

 

STOP

Main Logic Board

Check Main Logic

Replace Main Logic

 

 

faulty

Board

Board

 

 

 

 

Note

The above troubleshooting guide does not represent all possible conditions or problems. If the above information can not resolve a problem, consult the factory or a local representative for further assistance.

Figure 1

Pressure Switch / Recorder

Changing the Chart Paper

First, locate the “change chart” button (#3) located in the upper left corner of the recorder. Press and hold this button for approximately one

(1) second until the pen begins to move to the left of the chart. Wait

until the pen has moved completely off of the chart. To remove the chart paper, unscrew (counter-clockwise)the “hub” knob at the center

of the chart. Remove the old chart paper and position the new one so that the correct time coincides with the time line groove on the chart plate. Refer to Figure 3 for the location of the time line groove on the

left side of the chart plate. Re-attachthe chart “hub” knob and screw securely (by hand) against the chart. Press the “change chart” button (#3) again for approximately one (1) second until the pen begins to move back onto the chart paper.

Pen replacement

Slide the used pen cartridge off the pen arm. Slide on new cartridge and remove tip cover.

To replace the pen, loosen the two screws that hold the pen arm and the pen cartridge, and metal pen arm be removed as an assembly. Refer to Figure 3 for the location of the pen arm screws. Unsnap the plastic “U” clip tab of the pen cartridge from the metal pen arm (see Figure 2), remove and discard the old pen cartridge. Replace the new cartridge by opening the hinge and snapping it securely around the metal pen arm.

Figure 2

Figure 3 - RECORDER ASSEMBLY

Figure 4

Pressure Settings

SEE NOTE

(3) Status LED’S

Stop Pressure

Start Pressure

Battery Charger

Introduction

The Power Sense Board monitors the charging current and voltage of both chargers. LED’s indicate that the chargers are supplying current output, that the battery / charger voltage is above 90%, and that AC Power is available to power the chargers.

Specifications

LED Indication

 

READY, green

On indicates float condition

CHARGING, yellow

On indicates charge in progress

CHARGE CURRENT, green

Charging current greater than or equal to current indicated

WARNING: Lead acid batteries generate explosive gases during normal operation.

Precautions: Do not work alone.

Wear eye protection and protective clothing.

Have soap and water available in case of skin contact with acid.

If acid enters eye, immediately flush eyes with cold running water for ten minutes and get medical attention.

If problems develop, check all connections and clean the battery terminal connections. Use the LED indicators on the chargers and the LOBC as an aid to determine the cause of any potential problems. Return faulty chargers to the factory.

CAUTION:Always disconnect the AC power source before disconnecting the batteries when performing maintenance.

Troubleshooting Chart

Symptom

Possible cause

Solution

 

 

 

 

 

All charger LED’s off,

1)

No AC power

1)

Check for 120 V Charger power

cabinet CHARGER FAILURE

 

 

2)

Hubbell recommends that the

indicating light on

 

 

2)

Charger AC fuse blown

 

charger be returned for repair

 

 

 

 

 

 

 

Charge Current LED’s scroll,6

1)

Battery connections

1)

Check battery connections

cabinet CHARGER FAILURE

 

reversed,

2)

Hubbell recommends that the

indicating light on

 

 

2)

Charger DC fuse blown

 

charger be returned for repair

 

 

 

 

 

6 The charger LED’s scroll in order

as follows: Charge Current LED’s

10 A to 2 A, Charging, Ready.

Troubleshooting Chart (Continued)

Symptom

Possible cause

Solution

 

 

 

Charging LED blinking,

Battery voltage high due to

Troubleshoot engine charging

 

Engine charging circuit

circuit

 

supplying charging voltage

 

 

 

above control charger value.

 

 

 

 

 

10 A Charge Current LED

Charger stopped charging due

Allow charger time to cool

flashing

to high temperature

Improve ventilation in area

Ready LED does not come on,

1)

Battery capacity too high

1)

Check battery rating, must be

Batteries do not charge fully

 

 

 

less than 200 Ah

 

2)

Excessive load on batteries

2)

Verify load is normal

 

3)

Short to ground

3)

Clear the short

 

4)

Battery terminals corroded

4)

Clean battery terminals

 

5)

Battery has faulty cell

5)

Check battery/Replace

 

 

 

 

 

Contact the local Hubbell representative to request additional information, parts, or drawings.

Location and Description of Control Settings