ELCOS DIP-804/00 Instruction Manual

ENGINE PROTECTION DEVICE
TYPE
THE ENGINE IS STOPPED (VIA ELECTROMAGNET
OR SOLENOID) IN CASES OF ANOMALY FOR:
• INEFFICIENT BATTERY CHARGE ALTERNATOR (BELT BREAKAGE)
• LOW OIL PRESSURE
• OVERHEATING
• FUEL RESERVE (without stopping engine)
OIL AND BATTERY INDICATORS INTEGRATED INTO THE DEVICE
GB DIP-804/00/2 1
DIP-804/00
INSTRUCTION AND USER MANUAL
®
PARMA ITALY
E-mail: [email protected] - HTTP://www.elcos.it
Fax [phone]
Tel. [phone]

This surveys the fonctioning of the diesel engine and stops it if there are anomalies in the parts controlled by
probes.
It has been designed to be installed in cavities in dashboards, electric panels, etc.
NOTICES
Warning:
adhere closely to the following advice
- Always install under other equipment which produces or spreads heat.
- Always follow the circuit diagram when making connections.
- Check that the line loading and the consumption of the connected equipment are compatible with the
enclosed technical characteristics.
- All technical interventions must be performed with the engine stationary and terminal 50 of the starter
motor disconnected.
- Never use a battery charger for the emergency start-up, this could damage the equipment.
- To protect the safety of persons and the equipment, before connecting an external battery charger,
disconnect the electrical plant terminals from the battery poles.
NOTE: THE HOLE IN THE CASING USED TO INSTALL THE EQUIPMENT, COULD INFLUENCE THE LEVEL OF
PROTECTION OF BOTH. STEPS MUST BE TAKEN TO MAINTAIN THE ORIGINAL LEVEL OF
PROTECTION.
THIS DEVICE IS NOT SUITABLE FOR OPERATING IN THE FOLLOWING CONDITIONS:
- Where the environmental temperature is outside the limits indicated in the enclosed technical sheet.
- Where there are high levels or heat from radiation caused by the sun, ovens or the like.
- Where there is the risk of fire or explosions.
- Where the device can receive strong vibrations or knocks.
The following maintenance operations should be performed every week:
- check that the indicators function;
- check the batteries;
- check that the conductors are tight, check the condition of the terminals.
CONDUCTION AND MAINTENANCE
ELECTROMAGNETIC COMPATIBILITY
This device functions correctly only if inserted in plants which conform with the CE marking standards; it meets the
exemption requirements of the standard EN50082-2 but it cannot be excluded that malfunctions could occur in
extreme cases due to particular situations.
The installer has the task of checking that the disturbance levels are within the requirements of the standards.
YOUR ELECTRICAL TECHNICIAN CAN ASK US ANYTHING ABOUT THIS
PRODUCT BY TELEPHONING ONE OF OUR TECHNICIANS
UNLESS WE MAKE A WRITTEN DECLARATION STATING THE CONTRARY, THIS PANEL IS NOT SUITABLE
FOR USE AS A CRITICAL IN EQUIPMENT OR PLANTS RESPONSIBLE FOR KEEPING PERSONS OR OTHER
LIVING BEINGS ALIVE
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ENGINE PROTECTION DEVICE TYPE DIP-804/00

GB DIP-804/00 /2 3
IGNITION KEY TWIN-FUNCTION INDICATORS
ENGINE PROTECTIONS
- REST
- MANUAL STOP
- RESET PROTECTION
- DEVICE SUPPLY
- START ENGINE
0
AUT.
START
These are on when the key is turned to "AUT".
They switch off when the engine is running and
the oil pressure and battery recharger are
regular.
The engine protections are enabled when the ENGINE PROTECTIONS ACTIVE indicator is
on (20 seconds after turning the key to "AUT" or, in any case 20 seconds after the end of the start
impulse).
The interventions of the protection probes (mounted on the engine), shown by the relevant visual
indicators, stop the engine and can be divided into two groups:
These are enabled after the PROTECTIONS
ACTIVE indicator switches on, and they
switch on when the relevant anomaly is
detected.
- OIL AND BATTERY INDICATORS
- ANOMALY INDICATORS
After a 3 second delay for:Immediately for:
- OIL PRESSURE SWITCH
- OVERHEATING THERMOSTAT
- BATTERY CHARGE ALTERNATOR
(ALTERNATOR BELT BREAKAGE)
MAIN ALARM
This is obtained in three ways:
By turning the ignition key to zero
Because of protections intervention
-
-
The protection device uses two different types of stoppage:
- activating the ELECTROMAGNET which pulled the STOP lever for 20 seconds
- disconnecting the supply to the SOLENOID which closes the gasoline passage.
Enabled when the ignition key is turned to "AUT", without stopping the engine.
This can be obtained by mounting a visual and/or acoustic indicator externally connected to the
relevant output.
This is continuously activated if the protections or fuel reserve alarm intervene.
RESET: This is obtained by turning the ignition key to zero.
(MOUNTED EXTERNALLY)
STOPPING
ALARM
(FUEL RESERVE )
FUNCTIONING

4 GB DIP-804/00 /2
1235678293031373940
B+
D+
YELLOW
RED
YELLOW
GRGB LC
R LE +~~
39 40
DIP-804/00
h
1
48 3
416
41
40
28
26
27
30
50
30
15/54
50
W
157
3W
MAX
(BELT BREAKAGE)
WARNING DO NOT CONNECT THE CHARGE CONTROL BULB INTO THE PLANT
SEE "TWIN FUNCTION INDICATIONS" ON PAGE 3
FUSE
5A
FUSE
5A
CIRCUIT DIAGRAM
85
30
86
87
2/7

GB DIP-804/00 /2 5
(1) IGNITION KEY
(2/7) DRIVE-EXCITED MAGNET OR SOLENOID
(3) OIL PRESSURE SWITCH
(4) THERMOSTAT
(16) FUEL FLOAT
(48) HOUR COUNTER
(157) INDICATOR (GENERAL ALARM)
(26) PERMANENT MAGNET CHARGE
ALTERNATOR REGULATOR
(27) ALTERNATOR REGULATOR
(28) PRE-EXCITATION CHARGE
ALTERNATOR
(40) STARTER MOTOR
(41) BATTERY
ON REQUEST
ACCESSORIES
MOUNTED ON THE ENGINE
The system is arranged to command
the stopping with SOLENOID.
For ELECTROMAGNET stopping,
connect terminals 39 and 40.
STOP SYSTEMS SET UP DRIVE
EXCITATION
STOP
EXCITATION
SOLENOID
for closing
diesel
ELECTROMAGNET
for pulling
STOP lever
39 40

6 GB DIP-804/00 /2
(SIMULATION)
FUNCTION PERFORMED INTERVENTION SIMULATION
(WITH INDICATOR ON
PROTECTIONS ARE ACTIVE)
FUNCTIONS INTERVENTION
(STOP, GENERAL ALARM
AND VISUAL INDICATOR ON)
RECHARGE
ALTERNATOR
(BELT BREAKAGE)
LOW OIL
PRESSURE
OVERHEATING
FUEL RESERVE
AFTER 3 SECONDS
IMMEDIATELY
IMMEDIATELY
AFTER 3 SECONDS
THE RELEVANT INDICATOR
WILL LIGHT UP WITHOUT
STOPPING THE ENGINE
DISCONNECT THE WIRE FROM
TERMINAL [8] OF THE DEVICE AND
CONNECT TERMINAL [8] TO EARTH
DISCONNECT THE WIRE FROM THE
OIL PRESSURE SWITCH TERMINAL
AND CONNECT IT TO EARTH
DISCONNECT THE WIRE FROM THE
THERMOSTAT AND CONNECT IT
TO EARTH
DISCONNECT THE WIRE FROM THE
W TERMINAL OF THE FLOAT AND
CONNECT IT TO EARTH
NOTE
WHEN THE SIMULATION HAS BEEN COMPLETED ENSURE THAT ALL OF THE CONNECTIONS
ARE RETURNED TO THEIR ORIGINAL POSITIONS
DEVICE TEST

(WITH PROBES DISCONNECTED)
NOTE: WHEN THE TEST HAS BEEN COMPLETED RECONNECT THE PROBES
FUNCTION PERFORMED TEST
RECHARGE
ALTERNATOR
(BELT BREAKAGE)
LOW OIL
PRESSURE
OVERHEATING
FUEL RESERVE
ENGINE
STATIONARY
ENGINE
STATIONARY
ENGINE RUNNING
WITH REGULAR
BELT
ENGINE RUNNING
WITH REGULAR
PRESSURE
ENGINE WITH
NORMAL
TEMPERATURE
SUFFICIENT FUEL
ENGINE RUNNING
WITH BROKEN
BELT
ENGINE RUNNING
WITH INSUFFI-
CIENT PRESSURE
ENGINE
OVERHEATING
INSUFFICIENT
FUEL
NORMALLY THE
RELEVANT
TERMINAL OF THE
BATTERY CHARGE
ALTERNATOR IS
NEGATIVE WITH
THE ENGINE
STATIONARY
NORMALLY THE
TERMINAL OF THE
OIL PRESSURE
SWITCH IS
NEGATIVE WITH
THE ENGINE
STATIONARY
NORMALLY THE
TERMINAL OF THE
THERMOSTAT IS
NEGATIVE WHEN
THE ENGINE IS
TOO HOT
NORMALLY THE W
TERMINAL OF THE
FLOAT IS
NEGATIVE WHEN
THE FUEL IS
RUNNING OUT
D+
B+
GRGB LC
R LE +~~
YELLOW
YELLOW
RED
PERMANENT
MAGNET
ALTERNATOR
PRE-EXCITATION
ALTERNATOR
OIL PRESSURE
SWITCH
THERMOSTAT
FLOAT
W
3W
3W
3W
3W
GB DIP-804/00 /2 7
ENGINE PROBES TEST

8 GB DIP-804/00 /2
TYPE OF PROBLEM PROBABLE CAUSES REMEDIAL INTERVENTIONS
THE STARTER MOTOR
FUNCTIONS BUT THE
ENGINE DOES NOT
START
- Lack of fuel
- Fuel supply circuit defect
- Low temperature
- Fill the tank
- Check that the stop system (solenoid or
electromagnet) functions
Consult the engine instruction manual
- Check that the preheating functions
- The belt breakage
indicator lights up after
the PROTECTIONS
ACTIVE indicator
lights up
- The low oil pressure
indicator lights up after
the PROTECTIONS
ACTIVE indicator
lights up
- The overheating
indicator lights up
ENGINE STOPS FOR
ANOMALY
ENGINE DOES NOT
STOP UNDER ANY
CONDITIONS
- Stop system
(electromagnet or
solenoid) does not
function
- Defective engine
probes
- Defective device
- Check the condition of the alternator belt
- Check the engine oil level
- Check the engine cooling system
- Check the correct mechanical or electrical
functioning of the stop system. If the
problem persists, check the stop
servo-relay.
- Test the probes (see ENGINE PROBES
TEST on page 3) and if necessary replace
them.
- Check that during the stop phase there is
voltage on terminal (5) (see STOP on
page 3), simulate the function (see DEVICE
TEST on page 5 and if necessary replace
the device (*)
TROUBLE SHOOTING

GB DIP-804/00 /2 9
- The belt breakage
indicator lights up after
the PROTECTIONS
ACTIVE indicator
lights up
- The low oil pressure
indicator lights up after
the PROTECTIONS
ACTIVE indicator
lights up
- The overheating
indicator lights up
- Defective device
TYPE OF PROBLEM PROBABLE CAUSES REMEDIAL INTERVENTIONS
ENGINE STOPS FOR
ANOMALLY THOUGH
ALL APPEARS TO BE
REGULAR
- Check the function of the charge alternator
- Test and, if necessary, replace the oil
pressure switch
- Test and, if necessary, replace the
thermostat
- Simulate the functioning of the device (see
DEVICE TEST on page 5) and if necessary
replace it (*)
Turn the key to zero to reset the functioning
Before replacing the device, we suggest that you telephone one of our technicians for advice.
When your technician-electrician phones he must have the scheme on page 5 available together with the
following information:
- Type of equipment installed
- Problem encountered
- Condition of the indicators on the dashboard when the problem occurred
- Any remedial interventions performed
[*] DEVICE REPLACEMENT
TROUBLE SHOOTING

10 GB DIP-804/00 /2
SEE PAGE 5
ACCESSORIES DATA FOR ORDERING
MOBILE SOCKETS
type PMO-134/00 code 40804234
ENGINE PROTECTION DEVICE
type code
type code
DIP-804/00 12 V
DIP-804/00 24 V
00030201
00030202
ACCESSORIES AVAILABLE ON REQUEST

11GB DIP-804/00 /2
Ø86
Ø80
67
57
49.5 7.5
- BATTERY SUPPLY 12 VDC (MAX 16 VDC)
VOLTAGE or 24 VDC (MAX 32 VDC)
- CIRCUIT LOADING WITH KEY
TURNED TO ZERO 8 mA
- MAXIMUM LOAD ON OUTPUT [5] 3 A
(STOP)
- MAXIMUM LOAD ON OUTPUT [7] 3 W
(GENERAL ALARM)
- TEMPERATURE RANGE -10 ÷ +60 °C
- TERMINAL BOARD FASTON 6.35 × 0.8
- DEGREE OF PROTECTION:
FOR THE ELECTRONICS IP 65
FOR THE TERMINAL BOARD IP 00
- WEIGHT 450 g
TECHNICAL DATADIMENSIONS

Remarks
12 GB DIP-804/00 /2