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Installation and Operating Instructions

GEN-KEY

Tyco Electronics UK Limited

Crompton Instruments
Freebournes Road, Witham, Essex, CM8 3AH, UK
Tel: +44 1376 509 509
Fax: +44 1376 509 511
 Crompton GEN-KEY
Installation & Operating Instructions

Important safety information is contained in this manual. Users must familiarise

themselves with this information before attempting installation or other procedures.

Crompton Instruments
Freebournes Road
Witham
Essex
CM8 3AH
England

Tel: +44 (0) 1376 509 509

Fax: +44 (0) 1376 509 511
E-Mail: [email protected]

Crompton Instruments GEN-KEY Issue 2 01/2004

Contents Page

Section 1 Introduction 3

Section 2 Installation 4
2.1 Unpacking 4
2.2 Unit Configuration 4
2.3 Mechanical Installation 5
2.4 Electrical Connections 7
2.4.1 Charge Generator current 11
2.4.2 Remote Control 12

Section 3 Commissioning 13

Section 4 Operation 14
4.1 Controls and Indicators 14
4.2 Starting the Engine 15
4.3 Stopping the Engine 15

Section 6 Fault Finding 16

Section 7 Specification 17

Index 19

The unit contains no user-serviceable items. However the GEN-KEY does

contain parts carrying high voltages (derived from the alternator). Any servicing
must be carried out by technicians specifically trained on this type of equipment.
Section 1 Introduction
The GEN-KEY Unit provides basic control and protection in the operation of a generator set. The
unit allows starting and stopping of the engine and indicates status and fault conditions. The
unit monitors:
● Engine temperature,
● Oil pressure,
● Charging generator output and
● Alternator output (voltage and frequency).
It controls:
● Engine fuel supply, via a solenoid
● Starter motor, via a relay.
● Preheating, via a relay (where applicable)
● Alarm horn
In the event that the engine fails to start on a first attempt, up to two more start attempts are
made.
If a fault is detected, the unit shuts down the engine and indicates the failure by flashing a
relevant fault LED.
An On/Off key switch controls module operation and an Engine Start button initiates engine
cranking.
Remote fuel and start inputs provide for remote control of the engine. The unit incorporates a
preheat control output.
Two user-defined inputs are included. Spare 1 lights a red LED on the panel and shuts down the
engine. Spare 2 only lights a red LED on the panel.

3
Section 2 Installation
2.1 Unpacking
Carefully unpack the unit and check for damage. Retain the packing in case of future need, e.g.
for returning the unit for calibration.
Check the contents, as follows:
● One GEN-KEY unit.
● Two Keys
● Operating Manual.
● Screw clamp electrical connectors
● Panel mounting clamps.
Report any shortage or damage to your local sales office as soon as possible.

2.2 Unit Configuration

Set the DIP switches on the top panel to control the mode of operation of the GEN-KEY as
follows. To access the DIP switches, lift the hatch beneath the label on top of the unit.
Switch Function On position Off position
1 Horn duration Continuous 60 seconds
2 Preheat Enable Disable
3 Nominal alternator frequency 50 Hz 60 Hz
4 Nominal alternator voltage 115V 230V
For engine start detection, the GEN-KEY assumes that the engine has started when any of the
inputs is present.

4
Warning : The generator can be started remotely via the Remote Start/Stop input if the
Remote Fuel Input is high, irrespective of the position of the Key switch on the
front panel of this unit. When using the remote start feature, the installer should
connect audible and visible warning devices to meet local safety codes and ensure
that personnel are warned prior to commencing a remote starting sequence.
Warning: Beware of the high voltages connected to this unit.

2.3 Mechanical Installation

The unit is designed for panel mounting. Fixing is by two screw fixings.
1. Remove the fixings from the unit, if fitted, and unscrew the screws in the fixings.
2. Insert the unit in the panel cut-out from the front.
3. Insert the fixings into the slotted holes at the diagonal corners of the unit and tighten
the fixing screws to secure the unit against the panel. Ensure that the unit is properly
secured.

5
Figure 2.1 Front panel size Figure 2.2 Cut-out

Figure 2.3 Side view

6
2.4 Electrical Connections
Warning: Beware of the high voltages connected to this unit.

Figure 2.4 Rear view

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 Figure 2.5 Connections schematic
Connect the unit as shown in Figure 2.5. Be sure to connect the battery supply the right way
round. Note that the mains and generator neutral must be connected to the battery negative.
The fuses should be as follows:
FS1 1A
FS2 1A
FS3 As necessary to power the horn and solenoids.
FS4 1A

8
Table 1 shows the connections and recommended cable sizes. Table 2 describes the functions of
the connections.
Table 1 Unit wiring

Pin Description Cable Notes

size
(mm)
1,2 Positive battery supply input 2.5 Supplies horn and external solenoids
3 Output to Fuel solenoid 2.5 + DC supply from pins 1 & 2
4 Output to Start relay 2.5 + DC supply from pins 1 & 2
5 Output to Preheat 2.5 + DC supply from pins 1 & 2
6 Output to horn 2.5 + DC supply from pins 1 & 2
7 Positive battery supply to Unit 1.0 +12V or +24V
Switch to +batt to enable remote
8 Input from remote fuel switch 0.5 start/stop. See Section 2.4.2
Remote Control.
9 Negative battery supply to Unit 1.0 0V

10 Charge generator output 1.0 See Section 2.4.1 Charge

Generator current.

11 Input from Remote Start/Stop switch 0.5 Switch to +batt to start. See Section
2.4.2 Remote Control.
12 Input from Low Oil Pressure switch 0.5 Switch to 0V.
13 Input from High Temperature switch 0.5 Switch to 0V.
14 Input from Spare switch 1. 0.5 Switch to 0V.
15 Input from Spare switch 2. 0.5 Switch to 0V.
16 Neutral input from alternator 1.0 Unit detects generator voltage &
17 L1 input from alternator 1.0 frequency failure signals.

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Table 2 Connection functions

Pin Function
1,2 Positive battery input. Feeds external solenoids and indicators.

3 Output to Fuel solenoid. +DC from pins 1 & 2. Controls fuel

to engine.
4 Output to Start relay. +DC from pins 1 & 2. Controls starter motor.

5 Output to Preheat solenoid. +DC from pins 1 & 2. Controls engine

preheating, if required.
6 Output to horn. +DC from pins 1 & 2. Alarm output.
7 Battery + supply to Unit. Nominal 12V or 24V according to version.
Input from remote Fuel switch. Switch to battery + to enable remote start/stop.
8
Refer to Section 2.4.2 Remote Control.
9 Battery – (0V) supply to Unit.

10 Charge generator excitation current. Can be used to detect when engine has started.
See Section 2.4.1 Charge Generator current.
Input from remote Start/Stop switch. To enable this input, either the key switch must
11 be On or the Remote Fuel switch input must be at battery +. Refer to Section 2.4.2
Remote Control

12 Input from Low Oil Pressure switch. Normally closed (switched to 0V). Open when oil
pressure is normal. Can be used to detect when engine has started.

13 Input from High Temperature switch. Switched to 0V when engine temperature

exceeds thermostat setting.

14 Spare 1 input. When switched to 0V, lights an indicator on the panel and shuts down
the engine.
15 Spare 2 input. When switched to 0V, lights an indicator on the panel.
16 Output from alternator. Unit uses speed/frequency of alternator output to detect when
17 engine has started.

10
2.4.1 Charge Generator current
The unit uses the Charge Generator Current input to detect when the engine is running. The
GEN-KEY connection effectively replaces the usual charge indicator lamp. It supplies current to
the rotor coil from the battery until the engine is running, at which time the Charge Generator
powers the rotor via the diode trio. The GEN-KEY circuits sense the resultant voltage at pin 10.
This is initially low at near Battery -, as the circuit supplies a high current to the rotor coil, rising
to near Battery + once the engine is running. Figure 2.6 shows the arrangement.

Figure 2.6 Input from Charge Generator

11
2.4.2 Remote Control
Remote control can be achieved using a remote double-pole switch connected as shown in
Figure 2.7.
WARNING: Arrangements must be made to prevent remote starting of the engine while
engine maintenance is being carried out. This can be achieved by using a key
switch as the remote double-pole switch, such that the key can be removed to
prevent remote starting.

Figure 2.7 Remote Control

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Section 3 Commissioning
Warning: Beware of the high voltages connected to this unit.
1. Check that the unit is correctly wired and that the wiring is of a standard and rating
compatible with the system.
2. Check that the correct fuses are fitted.
3. Take temporary steps to prevent the engine from starting – for example, disable the fuel
solenoid (disconnect pin 3).
4. After a visual inspection to ensure it is safe to proceed, connect the battery.
5. Turn the key switch to On.
6. Press the Engine Start button.
7. Check that the engine start sequence commences. After preheating, the starter motor
should, on three occasions, run for 5 seconds and pause for 10 seconds between attempts.
8. Check that the Failed to Start indicator lights.
9. Turn the key switch to Off.
10. Restore the engine to operational state (reconnect the fuel solenoid).
11. Turn the key switch to On.
12. Press the Engine Start button on the panel.
13. Check the start sequence, as follows:
● the Preheat indicator lights for approximately 10 seconds, then
● the starter motor runs
● the engine starts
● the starter motor disengages once the engine is running.
If not, check that the engine is fully operational (fuel available etc.) and check the wiring to
the Unit.
14. Check that the engine runs up to its operating speed. If not and an alarm is present, check
that the alarm is valid and then check the input wiring.
15. Turn the key switch to Off. The engine should stop. Allow time for the engine to come to
rest.
16. Set the remote Start switch (if fitted) to On and check that the engine starts.
17. Set the remote Start/stop switch to Off and check that the engine stops.

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Section 4 Operation
4.1 Controls and Indicators

1 Spare 1 LED. Configurable input 1 contact closed. Engine shut down.

2 Spare 2 LED. Configurable input 2 contact closed. Engine not shut down, warning
alarm only.
3 Green LED. On means engine is running. Flashing means engine is ready to start.
4 Green LED. Alternator generating correct output voltage and frequency.
5 Red LED. Engine failed to start after pre-set number of attempts to start and the start
sequence terminated. Latched alarm. Restart locked out until reset.
6 Red LED. Low oil pressure. Engine shut down. Latched alarm. Restart locked out until reset.
7 Red LED. High engine temperature. Engine shut down. Latched alarm. Restart locked out
until reset.
8 Red LED. Engine over-speed. Engine shut down. Latched alarm. Restart locked out
until reset.

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9 Red LED. Generator voltage failure. Engine shut down. Latched alarm. Restart locked out
until reset.
10 Red. Charge Generator Failure. Does not shut down the engine, warning only.
11 Key switch. ON connects supply to GEN-KEY. OFF disconnects supplies and shuts off the
engine.
12 Engine Start button Initiates engine start sequence provided Key Switch is ON. If the button
is pressed while the engine is running, the engine will stop.
13 Preheat LED. Lights during 10 seconds preheat period, if preheating is
enabled (see section 2.2).
14 Reset button. Resets the latched alarms. Allows a new attempt at starting
the engine.
15 Silence horn. Press and hold the button to perform lamp test.

4.2 Starting the Engine

1. Set the key switch to ON.
2. Press the Engine Start button on the panel or the remote Start button. The engine should
start. The sequence is as follows:
● The Preheat LED lights for approximately 10 seconds while the engine ignition system
preheats (where applicable).
● The starter motor runs
● The engine starts
Once the engine is running,
● The starter motor disengages.
● The green engine and alternator LEDs (3) and (4) light.
● The alarm indicators remain off.

4.3 Stopping the Engine

Set the key switch on the panel to OFF. The engine will stop and all indicators on GEN-KEY will
go off.

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Section 5 Fault Finding
Warning: Beware of the high voltages connected to this unit. Disconnect the unit from all
electrical supplies before attempting any maintenance. Before carrying out any
maintenance on the engine, set the key switch to off and remove the key.
Indicators on the panel will light if a fault is detected. See Section 4.1 Controls and Indicators.
Fault conditions latch so that further operation is prevented. If a fault is indicated, proceed as
follows:
1. Find and fix the fault.
2. Press the Reset button to enable a restart.
3. Press the Engine Start button.

Symptom Possible remedy

Unit is inoperative Check the battery and wiring to the unit.
Check the DC supply.
Check the DC fuse.
Low oil pressure Check engine oil pressure.
fault after Check oil pressure switch and wiring.
engine has fired. Check that oil pressure switch is of the normally closed type
Closes on low oil pressure.
High engine temperature Check engine temperature and cooling.
fault after engine has fired. Check switch and wiring.
Check that temperature switch is of normally open type
(closes on high temperature).
Failed to Start fault. Engine Check fuel solenoid and wiring, fuel and battery.
failed to start after three Reset the GEN-KEY and restart the engine.
attempts. Check for battery + output at pin 3, Fuel Solenoid. Check that
alternator output is connected between pins 16 and 17. Refer
to engine manual.
Preheat inoperative. Check preheating DIP switch (see section 2.2)
Check wiring to engine heater plugs.
Check battery supply.
Check battery + is present at pin 5 of the GEN-KEY during
preheat phase.
Starter motor inoperative. Check wiring to starter relay.
Check battery supply.
Check battery supply is present on the Start output pin 4
of the GEN-KEY.
Check that oil pressure switch is closed, charging alternator is
drawing excitation current, and that no A.C. voltage or
frequency signals are present at terminals 16 & 17.

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Section 6 Specification
Inputs
DC Supply GEN-KEY-12V 12V (8 to 16V) DC
GEN-KEY-24V 24V (16 to 32V) DC

Operating Current GEN-KEY-12V 300mA maximum

GEN-KEY-24V 400mA maximum

Cranking Dropout Battery voltage can be 0V DC for max. 100 ms during

cranking (battery voltage should be at least nominal
voltage before cranking)

Generator Voltage 35 to 300V AC L-N, 10 to 110Hz

Neutral and battery negative must be grounded.

Contact Sensing Oil Pressure Switch (NC)

Temperature Switch (NO)
Remote Start/Stop input (NO)
Configurable input 1 (NO)
Configurable input 2 (NO)

Outputs
Relay Contacts Start relay (12 Amp DC at 12/24V)
Fuel relay (12 Amp DC at 12/24V)
Horn relay (10 Amp DC at 12/24V)
Preheat relay (10 Amp DC at 12/24V)

Charge Generator Excitation current 200mA, maximum 3 Watts.

Display
Failure Annunciators Failed to start
Low Oil Pressure
High Temperature
Over Speed
Voltage Failure
Charging Fail
Configurable Input 1
Configurable Input 2

Status Annunciators Engine Running

Generator Ready
Preheating

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Measurement Accuracy
Generator Voltage 2% of full scale, 35 - 300V AC

Generator Frequency 0.5% of full scale, 10-110 Hz alternator Voltage

Environmental
Operating Temperature -25°C to +70°C (-13°F to +158°F)
Storage Temperature -40°C to +85°C (-40°F to +185°F)

Humidity <93% RH, non condensing

Environmental Rating Standard, Indoors, Altitude less than 2000m

Mode of operation Continuous

Standards
EMC BS EN 50081-2, BS EN 50082-2

Electrical Safety EN 61010-1

Installation Category II

Pollution Degree II

Mechanical
Enclosure DIN 43700 Style housing, 96mm x 96mm Bezel,
92mm cutout

Panel Thickness 10mm (0.4 in) Maximum

Protection Class IP30 front panel, IP20 rear panel

Weight Approximately 0.5 Kg

Programming Selections (DIP Switches)

Generator voltage: 115V or 230V, selectable

Generator frequency: 50Hz or 60 Hz, selectable

Horn duration 60 seconds or continuous, selectable

Pre-heating 10 seconds or disabled, selectable

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Preset Operating Parameters
Starting sequence: Up to three attempts with 5 seconds driving the starter
motor and with a 10 seconds rest between each attempt.

Oil bypass delay: 30 seconds allowed for build-up of oil pressure

Control on delay: No engine faults will be reported during the first 10

seconds of starting, except for engine temperature.

Generator voltage Generator output voltage must be outside the allowed

operating range (-25/+15% of designated value) for 5
seconds before a fault is reported.

Generator speed Generator speed must be outside the allowed operating

range (+3% of designated value) for 5 seconds before
fault is reported.

Speed Upper Limit (50 Hz. Nominal ) 53 Hz

Speed limit for Engine Starting Signal 30 Hz

(50 Hz. Nominal )

Speed Upper Limit (60 Hz. Nominal ) 63 Hz.

Speed limit for Engine Starting Signal 40 Hz.

(60 Hz. Nominal )

Voltage Lower Limit –25%

(115 VAC or 230 VAC)

Voltage Upper Limit +15%

(115 VAC or 230 VAC)

Voltage Limit for Engine Starting 50%

Signal (115 or 230 VAC)

Engine Started Signals Generator Voltage

Generator Frequency
Charge Generator
Oil Pressure
Accessories: Spare keys are avilable for these units. The order code
for these is SPARE-KEY-GK.

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Index
Alternator frequency, 4 Generator voltage failure, 15

Alternator voltage, 4 High engine temperature, 9, 10, 15, 17

Battery charging, 16 Horn, 4, 9, 10, 17

Charge generator, 9, 10, 11 Indicators, 14

Configurable inputs, 14 Key switch, 4, 15

Configuration, 4 Oil bypass delay, 18

Connections, 8, 9 Oil pressure, 4, 9, 10, 14, 17

Control on delay, 17 Operating temperature, 17

Controls, 14 Preheat, 9, 10, 16, 17

DIP switches, 4 Rear view, 7

Engine over-speed, 14 Remote control, 12

Engine start, 15 Remote fuel input, 4, 12

Engine start button, 15 Remote fuel switch, 9, 10, 12

Engine start detection, 4, 11 Remote start/stop, 4, 9, 10, 12

Failed to start, 14, 17 Reset, 15

Fixings, 5 Solenoid control outputs, 17

Fuel solenoid, 9, 10 Spare inputs, 9, 10, 14

Fuel switch, 10 Start relay, 9, 10

Fuses, 8 Starter motor, 13, 17

Generator frequency, 17 Starting sequence, 13, 15

Generator speed, 17 Unpacking, 4

Generator voltage, 17 Warnings, 5, 12

The Information contained in these installation instructions is for use only by installers trained to make electrical power installations and is intended
to describe the correct method of installation for this product. However, Tyco Electronics has no control over the field conditions which influence
product installation.
It is the user's responsibility to determine the suitability of the installation method in the user's field conditions. Tyco Electronics' only obligations
are those in Tyco Electronics' standard Conditions of Sale for this product and in no case will Tyco Electronics be liable for any other incidental,
indirect or consequential damages arising from the use or misuse of the products. Crompton is a trade mark.

Tyco Electronics UK Limited

Crompton Instruments
Freebournes Road, Witham, Essex, CM8 3AH, UK
Tel: +44 1376 509 509 Fax: +44 1376 509 511 http://energy.tycoelectronics.com