Operating Manual
Control Unit
for Island mode Gensets
KEA 092 - INS
TA92IX1-E
June 2011
Replaces: April 2004
OFF
CONTROLS ON
START INDICATION
AUTOM. DEVICE LOCKED
OVERCRANK / ENGINE FAULT
ALARM 1
ALARM 6
ALARM 2
ALARM 7
ALARM 3
ALARM 8
ALARM 4
ALARM 9
ALARM 5
ALARM 10
MANUAL
AUTO
TEST
START
LED
TEST
ALARM
OFF
APPLICATION OF THE CONTROL UNIT
The control unit KEA 092 is designed for controlling island mode gensets. It has the same dimensions as the KEA 082. Two phases of the generator
voltage are monitored for
− Under- and overvoltage,
− Under- and overfrequency,
The software covers:
− Start by a remote command,
− Switching to generator supply,
− Frequency control of gensets voltage,
− Genset monitoring and protection,
− Cooling-down/shutdown of the genset at the
end of a remote operation,
− Software for sprinkler mode.
The control unit is fitted with the following facilities for monitoring of the assembly and the genset:
− Voltage sensor for generator,
− 10 externally connected alarm signals,
− 4 alarms of the generator voltage monitoring,
programmable to alarms 1 to 10,
− DC battery voltage monitor.
Ten relays, max. contact rating 35 DC, 1 amp., are
provided for the controlling of the genset and the
assembly. The functions of 7 relays are programmable via an RS 232 communication port.
The unit is delivered with the standard alarm labelling (easy to change by paper strips) and standard
parameters. A customers programming and labelling is available for extra charge.
A common control system can also be connected to
the RS 232 port.
Alfred Kuhse GmbH, D-21423 Winsen/Luhe, An der Kleinbahn 39
Telefon +49 (0)4171 798-0, Fax +49 (0)4171 798-117, http: //www.kuhse.de
Certificated ISO 9001 since 1995
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Precaution Hints
All applicable regulations, especially those of VDE, are to be observed.
Programming of the unit must be carried out in such a way that any danger to people or equipment is impossible.
A thorough knowledge of this Operating Manual is essential for design and commissioning.
A faulty connection may cause permanent damage to the unit.
Contents
Operation
Operation mode OFF
Operation mode MANUAL
Operation mode AUTO
Operation mode TEST
Push-button START
Push-button LED TEST
Push-button ALARM OFF
Frequency control
Emergency Stop / Emergency off
Sprinkler mode
page 2
page 3
page 3
page 3
page 3
page 3
page 3
page 3
page 3
page 4
page 4
Basic indications
Controls on
Automatic device locked
Start indication
Overcrank / Engine fault
Mimic diagram / Voltage sensors
Alarms 9 and 10
Alarm signals
Overcranking / Engine fault
Generator CB tripped
Internal alarms of the volt. sensor
Technical data
Order number
page 4
page 4
page 4
page 4
page 4
page 5
page 5
page 5
page 5
page 5
page 5
page 6
page 6
OPERATION
LEDs for basic indications
LEDs for alarms
LED Gen. voltage
CONTROLS ON
START INDICATION
AUTOM. DEVICE LOCKED
OVERCRANK / ENGINE FAULT
ALARM 1
ALARM 6
ALARM 2
ALARM 7
ALARM 3
ALARM 8
ALARM 4
ALARM 9
ALARM 5
ALARM 10
Push-button Gen. on
Push-button Gen. off
Signal: Gen. is on
OFF
MANUAL
AUTO
TEST
Push-buttons for mode select
START
LED
TEST
ALARM
OFF
common push-buttons
The operating modes are selected by four pushbuttons with integrated LEDs, showing the actual
selected mode. The push-button selector may be
electrically locked by an input (eg. by connecting a
key-operated control switch). This avoids an unintentional or unacceptable change of a decided selection. The following modes are selected by the
four push-buttons.
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OPERATING MODE OFF
This operating mode is automatically selected
− Switching-off of all indicated alarm signals,
when the supply voltage is applied to the unit.
except alarm signals 13 and 14, as long as the
When this mode is selected from an active mode,
corresponding alarm contact is active,
the following is initiated:
− Reset of the control unit, in case the external
− Shutdown of the genset (if running),
EMERGENCY STOP contact is not active.
OPERATION MODE MANUAL
The engine may be started by pressing the pushhas no affect in case the generator voltage is not
button START in the MANUAL mode. The load is
within its programmed limits.
switched on with the push-button GEN. ON if the
The remote start command does not affect an
engine is running and the generator voltage and
automatic generator circuit breaker closing. To
frequency are within their programmed limits. On
stop the genset, the operating mode is to be set to
pressing the push-button GEN. OFF, the generator
OFF (no remote start command alive) to AUTOC.B. is disconnected again. Pressing the ON button
MATIC.
OPERATION MODE AUTO
The genset will start after the start delay time by a
When remote start command is removed, the generator C.B. is switched off. To prevent the engine
remote start command. If the genset should not be
from a heat increase, the genset will run unloaded
running after the complete cranking sequence, the
for an adjusted cooling down period, and then will
alarm signal OVERCRANK/ENGINE FAULT will
be shutdown.
occur and the control unit will be locked.
When the genset, after running up, has reached
Additionally to the remote start command the gennominal voltage and frequency, the generator cirset start can be initiated also by the SPRINKLER
cuit breaker is closed.
MODE (see further down).
OPERATION MODE TEST
The starting sequence is initiated on selecting this
The generator is switched on if during the TEST
operating mode. The genset can be loaded with the
mode operation a remote start command is given.
push-button GEN. ON (I), if the engine is running
To stop the genset, the operating mode is to be set
to OFF or (no remote start command alive) to
and the generator voltage and frequency are within
their programmed limits. Switching off the load
AUTOMATIC
takes place by the push-button GEN. OFF(O).
PUSH-BUTTON START
In case operating mode MANUAL is selected, the
In case the diesel engine requires pre-glowing,
engine can be cranked by pressing the push-button
arrangements for this must be realized externally.
START. If the starting sequence is programmed
When another operating mode is selected or when
for a gas engine, this sequence will run.
generator set is running, the push-button is not
active.
PUSH-BUTTON LED TEST
The operative readiness of all LEDs can be
this test other signal lights, assembled in
checked by this push-button, without initiating or
switchboard panels, a relay can be programmed to
suppressing an actual alarm signal. To include in
this function.
PUSH-BUTTON ALARM OFF
By a pulse of this push-button, the audible signal
ble LED signal may be switched-off by pressing
caused by an alarm signal, will be silenced. After
the push-button once again.
having eliminated the source of trouble, the visiFREQUENCY CONTROL AT INSULAR SUPPLY MODE
If this function is enabled, the control unit emits
limit values. There is a break between two speed
adjusting pulses to the speed control device if the
commands, which enables the engine to follow
frequency of the genset is not within programmed
the command.
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EMERGENCY STOP / EMERGENCY OFF (EXTERNAL)
The EMERGENCY STOP / EMERGENCY OFF func− the generator is switched off,
tion must be provide by external push-buttons.
− the genset is shutdown,
Additional a signal must be given to the input
− the automatic operation is locked, indicated by
IMMEDIATE STOP of the KEA. By this, independAUTOMATIC DEVICE LOCKED.
ent of the operating mode,
SPRINKLER MODE
The following functions are provided for the op− Termination of sprinkler mode automatically
eration of a fire-fighting pump:
or manually,
− Changing of the shutdown mode of the alarms
− Disconnection of consumer load for switching
to warning mode,
on of the sprinkler pump.
− 10 starting attempts,
If the control unit is programmed for manual shutdown, the LED of the operating mode OFF is blinking at the end of a sprinkler command. In this case the engine must be shut down either by the button
Off or by the external
Emergency stop.
.
BASIC INDICATIONS
The both upper rows with LEDs show important
status and fault information of the system. The
following four basics indications are provided.
CONTROLS ON
After starting-up of the genset, this green LED
until the alarm monitoring is on. The indication is
signal indicates, that the delayed monitored
switched-off, as soon as the shutdown procedure
alarms are activated. As soon as the engine has
is beginning.
reached the firing speed, the LED start blinking
AUTOMATIC MODE LOCKED
To reset the control unit, the push-button selector
This indication shows, that an external EMERhas to be set to position OFF (RESET). Prior to this,
GENCY STOP push-button has been pressed or that
an alarm signal has caused the genset to shutthe reason for the trouble has to be eliminated, or
down. The red LED indicates, that the control unit
the EMERGENCY STOP push-button has to be unloas well as the genset is locked for any further
cked.
starting attempt.
START INDICATION
This signal is lighting, if there is a starting deflashing. When the start is enabled, the LED
mand, processed by the control unit at AUTOchanges to steady light.
MATIC mode or if the operating mode MANUAL or
The indication is switched-off as soon as the dyTEST is selected. As long as there is no enable
namo D+ signalises the exceeding the firing
signal for starting, the LED START INDICATION is
speed. Now, it is not possible, to actuate the
starter motor, not even manually.
OVERCRANK / ENGINE FAULT
This signal is switched-on, in case
control unit (with signal AUTOMATIC UNIT
1. the genset has not started after the complete
LOCKED),
starting sequence (simultaneously with signal
3. the genset is still running even after complete
AUTOMATIC UNIT LOCKED),
stop time has elapsed (without signal AUTO2. the genset came to a standstill without any
MATIC UNIT LOCKED).
shut-down command emitted by the automatic
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MIMIC DIAGRAM / VOLTAGE SENSOR
The mimic diagram shows the genset and the bus
its. The generator supply is indicated by the green
bar. The green LED below the generator symbol
LEDs below the OFF (O) push-buttons.
shows that the generator voltage is within its limALARM SIGNALS
If an alarm signal comes up, the corresponding
LED is blinking and the audible signal is switched
on. The audible signal is cancelled either automatically after it's programmed operating time or
by one push of the button ALARM OFF. The LED
indication changes then to a steady lighting. A
next alarm signal coming up acts in the same
manner, i.e. its LED is blinking, the audible signal
is on. The LED can be cancelled, if the alarm
signal was only warning and the reason for it is
not active anymore.
Alarm signals, shutting the engine down, lock the
automatic operation. This is shown by the signal
Autom. Device locked. The operation mode OFF
must be selected for unlocking the automatic operation.
If during the automatic mode the generator trips
due to a warning signal (eg. Generator Overload)
the engine will shutdown after the cooling down
period and lock the automatic operation.
GENERATOR CB TRIPPED
The alarm signal is internally triggered in case no
place after running out of the generator closing
pulse.
feed back signal GENERATOR CB IS ON takes
INTERNAL ALARMS OF THE VOLTAGE SENSOR
The frequency and voltage faults of the generator
That means, if eg. a mains undervoltage occurs,
may be indicated as alarm signals. For this, one or
the engine starts and the alarm MAINS UNDERmore function has to be programmed with a valid
VOLTAGE is triggered. If the voltage is later on
(1..10) alarm signal number. Such an alarm has no
within its limits, the engine shuts down but the
affect to the actual state of the voltage monitors.
alarm is monitored until it is cancelled.
ALARMS 9 AND 10
These two alarms may be delayed from contract
however without the audible signal. Criteria,
closing 0 up to 250 sec., i.e. the alarm contact
which have to be always monitored, can be conmust be active for the programmed time delay to
nected here (eg. tank filling level, leakage warninitiate an alarm signal. Furthermore these two
ing).
alarms are also active in the operating mode OFF,
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TECHNICAL DATA
DESIGN
− Flush mounted unit
− Dimensions (W/H/D) 260 x 170 x 80 mm
− Weight: approx. 2.2 kg
− Mounting position any
− Protective grade IP 44 (built-in)
− Ambient temperature
storage -20°...+70°C
operation: 0°...+55°C
− Standards: DIN VDE 0160
POWER SUPPLY
− selectable: 9-12-15 or 14-24-35 volts DC
ANALOGUE INPUTS
Two phase generator voltage monitor, settable in
steps of 1 volt:
− UNom 3x400 volts, range from 240 - 480 volts.
− Generator frequency 45 to 65 Hz, can be continuously set 40 to 70 Hz.
− Battery voltage monitor.
DIGITAL IN- / OUTPUTS
− Input for charging dynamo D+ with preexcitation
− 10 terminals for alarm signal contacts
− 8 terminal for common signals
− 10 outgoing relays, 7 of them can be programmed, max. contact rating 35 volts DC, 1 amp.
Serial Interface
RS 232 port for programming, for coupling to a
common control system via extra hard- / software
or to the remote telephone monitoring TELEMON.
Order number: 2A92I60.xx