Murphy 9620 User Manual

W

6

2

00-02-0657

Keystart 9

0 series

rev ision A, 22

nd

September 2008

catalogue section 40 & 75

Engine & Generator Controls

Installation Instructions

Please read th e f ollow ing informatio n before i nstalling. A visual inspection of this product for damage dur ing
shipping is recommended before installation. It is your responsibility to ensure that qualified mechanical and el ec trical
technicians install this product. If i n doubt, please contac t your local Murphy representat ive.

GENERAL INFORMATION

Product specifications

power supply:

ARNING

BEFORE BEGINNING INSTALLATION OF TH IS PRODUCT

Disconnect all electrical power to the machine
Make sure the m a chi n e cann ot operate during installatio n
Follow all safety warnings of the mach ine manufacturer
Read and follow all installation instruction s

General

The Keystart 9620 series provides manual start/stop and automatic
fault shutdown protection for generators, pumps and other engine­driven applicat ions.

Keyst art features a 3 way keyswitch for operator control of th e engine,
with 6 LEDs for indication of status and faults - see ‘front view’ diagram
for details. Electrical connection an d configurat ion option s are at the rear

- see ‘Rear view, connection and settings’ diagram.
For each Keystart ordered, the following is supplied:

• 1 x Keystart module, fitted with 2 x panel mounting clips

• 2 x keys

• 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.) c ut-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
mounting clips from
the Keystart case:
release each clip ’s
ratchet mechanism by
pulling outwards (A),
then slide the clip
back and off the
case (B).

At the front of the
panel, insert the
Keystart (without
clips ) into th e panel
cut-out (C).

At the rear of the panel,
refit the two mounting
clips into the slots on
the Keystart case (D).
Slide each clip forward
until the arms ( E) are
secured behind the
panel face. Ratchet
mechani sm (F ) prevents
the clip from moving
backwards.

operating voltage:
steady state
brown out / cranking

current consumption < 100mA

inputs:

fault switch inputs: close to negative DC during fault

–ve input defined as: –1V to +1V w.r.t. – ve DC supply

speed sensing input:
generator AC (J2+J3 on)

mag. pickup (J2+J3 off)

outputs:

run, preheat positive D C, switched NO relay contact,

start (crank) positive DC via keyswitch contacts,

alarm negative DC (open collector

calibration/tacho to suit 0 – 1 mA, 75 Ohm meter

output = 0.75mA at rated engine speed

adjustable settings:

preheat timer 0 or 10 secs (link J1),

fault ov erride timer 2 to 20 secs (VR1),

overspeed trip level 100 to 130 % (VR3) of

general:

overall dimensions (w x h x d) 96 x 96 x 95 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 lb
operating temperature –35°C to +55°C / –31°F to 131°F

70 – 270 VAC rms,

<50 to >60 Hz. nominal

10 – 60 VAC peak,

<2000 to >6500 Hz. nominal

(all ratings non-reactive)

10 A max. @ 24VDC

10 A max. @ 24V DC

NPN transistor), 250mA max.

nominal speed calibration (VR2),

default = 110% (of 50 or 60 Hz)

Model options

7 – 30 VDC

5 VDC

(model 9621 only)

default = 0 secs

default = 10 secs

GENERAL INFORMATION (cont.)

Front view and operation

Rear view, connections and settings

ELECTRICAL CONNECTION

WARNING: DANG ER OF INJURY OR DEATH. Ke ystart 9621 cont r ol lers allow connection
of high voltage AC cir cui t s . Bef or e connect i on, disconnection or handl ing of these units,

DANGER !

HIGH VOL TS

Electrical connection to 0.5 to 1.5 mm² / 16 – 20 AWG panel wiring is
by spring-clamp terminal s at the rear.

•

pre-strip 8 to 10 mm / 0.3 to 0.4 in. of ins ulation from each wire.

• Ab ove each terminal i s 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 ter minal cl amp.

• insert the wire into the terminal (B), checking that the insulation is

clear of the cl amp. Release the screwdri ver/spring clamp pressure
and check that the wire is secure.

General connecti on r ecommendat i ons

Murphy make several recommendations for the electrical connection
of engine and generator controllers.

• 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.

• Suppress (at source) electrical interference from panel relay and

engine solenoid coils, using flywheel diode or proprietary snubber
networ ks as appropriate.

Murphy - Keystart 9620 series installation instructions 00-02-0657 revision A 22nd September 2008 p2/4

ensure that all AC and DC power suppli es ar e i sol ated. Connection to or disconnection from
live wiring may also cause damage to t he Keystart’s internal components.

• use separate routing for AC and DC wiring harnesses.

• use separate wiring for a) connection of battery charger to battery,

and 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 f unct ions

Pin Function

Run (fuel) output

1

Preheat output

2

These r elay 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 oper ate. 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 swi tches 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 suppress ed coils between these outputs and fuel
solenoid coil and engine preheaters - see ‘typical connection’
diagram below.