Kuhse KEA 112 MOBL User manual

S
Operation Manual
Start-Stop Control Unit
for Stand-alone Gensets
KEA 112 MOBL
TA112MX3-E
07-01-25
Replaces: January 2006
Failed to Start
Generator Overload
Battery Undervoltage
Common Alarm
Start Indication
Automatic Mode locked
Alarm Monitoring on
231 233 229
V
50.02 Hz GEN.
The control unit KEA 112 MOBL is used for stand-alone (mobile) gensets. The complete engine and
generator protection is included. The relay functions and the parameters can be set by software. The
automatic control unit uses the RZ 071-D of the KEA 070 series. As the KEA 112 has the same size and is
mounted in the same manner as the former KEA 072, it can be interchanged without difficulty.
Exchangeable paper strips label for four user defined LED-indicators and four operation indicators. All
alarms, all actual and reference values are shown on the display. The illuminated display shows two lines of
16 characters with a character height of 10 mm, so that it can easily be read from a large distance. The
parameters can be set by the keys and the display or with the ParaWin software via the serial interface
(optical fibre).
The hardware for this KEA is fixed and cannot be extended.
Important information!
The control unit is easy to operate as it is operated without menu navigation
but directly by the usual keys as all the previous control units.
Alfred Kuhse GmbH, D-21423 Winsen/Luhe, An der Kleinbahn 39. Telefon [phone], Fax [phone], http://www.kuhse.de

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CONTENTS
Functions Page 3
Basic operation Page 3
Handling of the display Page 3
− Contrast setting Page 3
Parameterisation Page 4
General parameters, Group 0 Page 4
Display and push-buttons Page 5
− ALARM MONITORING ON Page 5
− AUTOMATIC MODE LOCKED Page 5
− START INDICATION Page 5
− COMMON ALARM Page 5
− Four customer designed indicators Page 6
− Mimic diagram / Voltage monitor Page 6
− Operation mode keys Page 6
− START button Page 6
− LED TEST button Page 6
− ALARM OFF button Page 6
Warning notes Page 7
Document history TA112MX3 Page 7
Technical data Page 8
TABLE OF CONTENTS OF THE ASSOCIATED DESCRIPTIONS
Because of the wide range of available functions, this operation manual is divided into a number of
documents. The following list shows the functions that are included in this control system.
Function Page
Operation modes
− Auxiliary drive control
− Operation mode OFF
− Operation mode MANUAL
− Manual speed control
− Operation mode AUTO
− External start command
− Operation mode TEST
− Sprinkler operation
9
Alarm monitoring
− Alarm announcing and acknowledgement
− Description of alarms
o Engine does not come to a standstill
o Engine fails to start
o Engine fault
o Overspeed
o Alarms 13 and 14
o Battery voltage monitor
o Alarms of analogue signals
o Generator CB tripped
o Generator CB does not cut off
o Alarms of the voltage monitor
o Monitoring of the currents
o Running hours till maintenance elapsed
o Maintenance period exceeded
− Response diagram for thermal overload
11
Actual values 14
Additional functions
− Frequency control for isolated operation
− Voltage regulator for isolated operation
− Immediate stop (emergency stop)
− Start sequence
16
Service Manual SA112MX3-E
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FUNCTIONS
The following functions are implemented:
− Start-stop for diesel and gas engine with checking of preliminary start-enable conditions,
− Monitor for generator voltage, frequency and rotating field (asymmetry),
− Generator current monitor: Over-current, short-circuit, unbalanced currents and thermal overload (bimetal
relay),
− 44 alarm signals, 19 of them can be configured by the customer (text and triggering),
− Battery monitor and two analogue inputs for direct connection of VDO sensors,
− Two alarms are possible for each analogue input,
− Potential-free analogue output for direct actuation of a speed controller,
− Parameterisation via optical fibre or directly via the keys and the display.
BASIC OPERATION OF THE CONTROL UNIT
The control unit is simple to operate by the push buttons and without menu navigation as all previous
KUHSE models. The operation mode is selected via four keys. In MANUAL and TEST modes, the generator
supply is executed using the buttons that are arranged in the mimic diagram.
The START button can be used for a manual start in MANUAL mode. The LED TEST and ALARM OFF buttons
are self-explanatory.
In normal operation, the display must only be used for showing current alarms and actual values. The menu
is easy to use: select the required group (alarms or actual values) with the [→] and [←]buttons, then view
the required actual value or current alarm with the [↑] and [↓] buttons.
OPERATION OF THE DISPLAY
Values or parameters are selected, as you would read a book. The further down listed groups are arranged as
'pages'. You can scroll forwards and backwards through these groups by pressing the [→] and [←]keys. The
entries of each group can be read from top to bottom like lines of a text. Select a line by pressing the keys [↓]
(down) and [↑] (up). The selection starts again with the other end of the 'page', when the top or bottom of the
'page' is reached.
Hold down the LED TEST button and press [←] to select directly the ACTUAL VALUES group, hold down
LED TEST and press [→] to display the group CURRENT ALARMS.
To modify a parameter, first enter the relevant IDENT-NUMBER. However, parameters of group 0, -GENERAL
PARAMETERS-, can be modified without entering this number. Parameters are modified as follows:
1. Select the required parameter group with the [←] and [→] buttons. One or two parameters are displayed.
2. Press OFF and LED TEST (function: PARA ON or PARA OFF) together. This opens parameterisation mode
as can be seen by the specific cursor [█]. The selection of the group cannot be changed now.
3. Select the required parameter line (if two are displayed) with the [↓] and [↑] buttons.
4. Press OFF and ALARM OFF (ENTER function) together to select the parameter line. The shape of the cursor
confirms the selection, as it underscores (e.g. 196) now the part of the parameter that is to be modified.
The chosen parameter cannot be deselected now.
5. Select the figure or letter of the parameter that you want to modify with the [←] and [→] cursor keys.
Numerical parameters can be increased or decreased by increments of 1 with the [↑] and [↓] buttons.
Press the same buttons to negate parameters that are displayed with a letter (+/- signs, alarm coding etc.).
6. Press OFF and ALARM OFF together to store the displayed parameter. Press OFF and LED TEST instead of
OFF and ALARM OFF to abort parameterisation.
Display contrast setting
Hold down LED TEST and press key [↑] to increase the display contrast (makes the display darker) or LED
TEST and key [↓] to lower it (makes the display lighter).
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PARAMETERISATION
The parameterisation is described in the SERVICE MANUAL. The following section describes
parameterisation of the basic settings, Group 0. The parameters may be modified without using an IDENT-
NUMBER. Select Group 0 using the [←] and [→] buttons.
General Parameters, Group 0
KEA 112 MOBL
KUHSE GmbH
Control unit type is displayed.
90567 ORDER NM
R
12345 F-NUMBER
Display of the KUHSE order number and the control units production
number. This information is important for later contact with the factory.
SOFTWARE
001/25.04.05
Software date and version number.
Input the IDENT- and PIN NUMBERS. Parameterisation is described in the
SERVICE MANUAL.
You don't need to enter a valid IDENT-NUMBER to modify parameters o
f
this group.
***** IDENT-NM
R
***** PIN NUMBER
BACK LIGHT OF
120 sec DELAY
F
Duration of display illumination. The background illumination is switched
on for this time when any key is pressed. The switch-off delay starts afte
r
each last press of a button. This period can be set in increments of 10
seconds from 10 to 2400 seconds. The light remains on if any alarm is
p
resent.
In normal operation it is useful to use the [←] and [→] buttons between the
display of actual values and the current alarm signals. Parameter groups are
skipped over in normal operation if this parameter is set to [-], so only one
key strike changes bewteen ACTUAL VALUES and CURRENT ALARMS.
Enter a [+] if you want to change a parameter to view the parameter groups.
Irrespective of this setting, you can always press LED TEST and [←] to go
direct to ACTUAL VALUES or LED TEST and [→] to CURRENT ALARMS.
SHOW PARAMETERS
+ [+]YES [-]NO
.LANGUAGE
0 0=DE, 1=UK
All text is available in two languages (e.g. German and English). You can
select the language with this parameter: Enter [0] for German or [1] fo
r
English.
Date and time.
The software clock on the control unit has to be set after any power failure.
The control unit is fitted with a battery-
b
uffered hardware clock if events
are to be saved or printed (Option).
03.05.05
12:17:35
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DISPLAY AND PUSH BUTTONS
Important operation indicators Customer defined indicators
Disp
2
characte
Operation mode buttons other push buttons
lay, illuminated
lines, each with 16
rs, 10 mm high
Generator voltage
Gen.CB On button
Gen. CB Off button
Gen. CB is on
Alarm Monitoring on
Automatic Mode locked
Start Indication
Common Alarm
Failed to Start
Generator Overload
Battery Undervoltage
These buttons are also used for parameterisation
Parameterisation
OFF and LED TEST buttons Function: PARA ON / OFF
OFF and Alarm OFF buttons Function: ENTER
Contrast setting
LED TEST and ↑buttons Increase contrast
LED TEST and ↓buttons Decrease contrast
ALARM MONITORING ON
This green display signals that the delayed alarms have been enabled after the genset has started. This
display flashes until the alarm monitoring is enabled as soon as the engine has fired. This signal is switched
off at the beginning of the shutdown procedure.
AUTOMATIC MODE LOCKED
This red indicator lights up when a shutdown alarm is present or when the external IMMEDIATE STOP is
activated. Select the operation mode OFF to unlock the unit. The external IMMEDIATE STOP is still active if
the signal is not cancelled in the OFF mode.
START INDICATION
This indicator is activated if a start command in AUTOMATIC mode is present or if the operation mode
MANUAL or TEST is selected. The light flashes at the standstill of the engine until the start is enabled. The
indicator is switched off as soon as the engine exceeds the ignition speed (this can be sensed by the terminal
D+ of the charging dynamo or by a speed sensor signal). It is now no longer possible to switch on the starter
motor. Although the raising generator voltage is used for the signal 'ENGINE HAS FIRED', this does not switch
the START INDICATION off if the speed sensing has failed.
COMMON ALARM
This yellow indicator flashes and the audible signal is on if a new alarm is triggered. The audible signal is
silenced when the ALARM OFF button is pressed once. The display automatically changes to the page with
the ACTUAL ALARMS.
You can select the alarm you want to acknowledge by the buttons [↑] and [↓] if more than one alarm are
present at the same time. The alarms are marked by 'NEW' for unacknowledged or by 'ACKN' for
acknowledged alarms.
The yellow indicator stops flashing and lights steadily when all alarms have been acknowledged and is
switched off when all alarms have been deleted.
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FOUR CUSTOMER DESIGNED INDICATORS
The function of the four indicators of the right row can be set as required. You can use them to announce
selected important alarms (in addition to the display) or for system messages. You can also use digital inputs
(e.g. terminals 27 and 28) of the relay unit RZ 071-D if they are function free.
MIMIC DIAGRAM / VOLTAGE MONITOR
Four red and two green indicators are provided for the generator voltage monitoring. They show if the
voltage is within the nominal range or if and which deviations are present.
These indicators, located under the generator symbol signalise:
f < f >
U < U >
Underfrequency Overfrequency
Undervoltage, Overvoltage
Phase sequence
The two green indicators show, that all monitored functions of voltage, frequency and phase sequence are
within their limits. The red ones show only failures if the associated function is enabled. All functions of the
voltage monitor and all limits can be parameterised. The undervoltage failure is also shown if the phase
sequence is disturbed or left turning.
The associated indicator starts flashing if an enabled function is out of its limits. Both green indicators
remain on until the response delay of this function is up. The red indicator lights then steadily and the
controller states now the voltage as DISTURBED.
The red indicator distinguishes as soon as the function is back again within its limits and the release delay is
started. Both green indicators are flashing during this delay time. They change to a steady light and the
voltage is stated as normal when the release delay time is up.
The indicators for the generator voltage are switched off in the operation mode OFF or if in AUTOMATIC
mode a start command is absent.
OPERATION MODE BUTTONS
Press the OFF, MANUAL, AUTO or TEST buttons to activate the corresponding operation mode. The selection
may be locked by a key-operated switch (using an input on the relay unit).
The speed can be set manually in the operation modes MANUAL and TEST. To do this, select the SPEED value
in ACTUAL VALUES and hold the MANUAL or TEST button down. Press in addition the buttons [↑] and [↓] to
increase or decrease the speed signal sent to the engine.
START BUTTON
You can start the engine by pressing this button in the MANUAL mode. When the start sequence is defined
for a gas engine, the start sequence will be executed correspondingly. This button has no effect if the engine
is running or in any other operation mode. If the engine has to be preheated, the preheating device must be
externally actuated.
LED TEST BUTTON
Use this button to check that all LEDs of the control unit are functioning correctly. This button is also used
as a multi-function button for parameterisation and contrast setting.
ALARM OFF BUTTON
Pressing this button silences the acoustic signal that sounds when a new alarm is triggered. Pressing the
button a second time deletes the selected alarm, if the event that triggered the alarm is over. Further functions
are described in the ALARM MONITORING document.
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WARNING NOTES
− Care must be taken when connecting the device, as it may be destroyed if incorrectly connected.
− All details of the connection specifications must be fulfilled.
− The PE(N) must be connected for security reasons to terminal 5 on the X403.
− The leakage current of the noise filters is 22 mA in case of a 2-phase voltage lost.
− Only adequately qualified personnel should undertake the installation and commissioning.
− The relevant regulations, especially the VDE regulations, must be observed.
− The SERVICE MANUAL should be read carefully before commissioning.
− The device must be parameterised in such a way that any risk to persons or property is prevented.
− The charging device must be switched off before the battery is disconnected.
− The negative pole of the battery must be grounded at the input terminal of the switchboard. The
minimum conductor cross-section is 10 mm2.
− The screens of the analogue input wiring must be connected to the earth screws on the KEA cover, and
must have no connection to any other metal parts.
− The supply voltage can be set to 12 or 24 V DC with a switch on the RZ 071-D.
− When the supply voltage of the control unit has been switched off, you must wait at least 20 seconds
before applying it again.
− All coils must be fitted with reverse diodes to prevent high voltage peaks. All other coils or inductive
loads must also be fitted with suppressor elements. The same applies for all relays and inductors that are
used in the switchboard or controlled externally.
− The shielding of the analogue wiring must only be connected the earth screws beside the terminal strip
X 401 and may have no galvanic connection to any other metal parts.
DOCUMENT HISTORY
Revision Modification Released Revision Modification Released
01/2006 First edition 06-01-11
07-01-25 Maintenance periods, menu structure 07-01-25
Manual voltage control
Changes without further notice reserved.

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TECHNICAL DATA
KEA Controller
− Device for frontal installation, dimensions: (⇒,⇑, depth) 260 x 170 x 100 mm,
− Weight approx. 2.2 kg, can be installed wherever required,
− Protection class (installed) IP 44,
− Ambient temperature: Storage -20°C ... +70°C, Operation 0°C … +55°C
− Supply voltage convertible 9-12-15V or 14-24-35V DC,
− 3 customer defined relays, 35 V DC, 1 A. (e.g. for acoustic signallers),
− Standards/regulations VDE 100, Part 710.
Analogue Inputs and Outputs
− 3-phase generator voltage monitor. It can be set in increments of 1 Volt. If the rotary field is incorrect, the
display shows <U.
U
Nom 230/400 volts. They can be set from 50 to 300 volts. Accuracy class 1.
− Generator frequency monitor 50 or 60 Hz. It can be set to any value between 40 and 70 Hz. Accuracy
class 1.
− 3-phase generator current monitor. Accuracy class 1.
− INom 5 Amp: measuring range 0.1 – 15 Amp. It can be set in increments of 20 mA.
− Battery voltage monitor.
− Input for pick-up.
− Analogue input for oil pressure and motor temperature VDO sensors.
− Analogue output for speed governor.
Relay unit RZ 071-D:
− Device for attachment on a mounting rail, dimensions: (⇒,⇑, depth) 300 x 100 x 90 mm,
− Weight approx. 0.7 kg, can be installed wherever required,
− Protection class IP 00,
− Fitted with:
o Input for charging dynamo D+ with pre-excitation for AC alternators,
o 14 ports for alarm contacts,
o 14 general control inputs,
o 12 relays, of which 8 can be configured, contact load:
2 relays max. 35 V, 20 A DC, 10 relays 250 V AC, 6 A.
Serial interfaces
Optical fibre interface for parameterisation.
Option: Relay unit RZ 071-E
− Device for attachment on a mounting rail, dimensions: (⇒,⇑, depth) 210 x 100 x 50 mm,
− Weight approx. 0.5 kg, can be installed wherever required, protection class IP 00,
− Fitted with 15 relays, of which 14 can be configured, contact load max. 250 V AC, 6 Amps.
Changes without further notice reserved.

OPERATION MODES 112-MOBL-3
OPERATION MODES
The operation modes can be selected using four buttons. The LED above the corresponding button indicates
the selected operation mode. The buttons can be electrically locked via an input (e.g. by connecting an
external key-operated switch), to prevent unauthorised or accidental change of an operation mode. The
operation modes described further down can be activated with these buttons.
AUXILIARY DRIVE CONTROL
A relay with the AUXILIARY DRIVE ON function (if set) is energised each time before the engine is started.
The indication START INDICATION flashes. A feedback signal must be sent if starting is enabled (e.g. gas
pipe-tightness confirmed, exhaust gas valve open, pre-lubrication pressure reached). The flashing START
CONTROL lights steadily (as long as the engine has not fired) and the starter motor can be activated when a
start is enabled.
The input 'STARTING RELEASED' must be permanently connected with the negative potential, if this function
(Enabling of Start) is not required, otherwise the system will not start!
OPERATION MODE OFF
The mode OFF is automatically selected when battery voltage is applied (reset function), to prevent an
accidental start-up. When the system is switched to OFF from another operation mode:
− The genset operation is terminated immediately,
− Any alarms are deleted, except alarms 13 und 14 if their alarm contacts are still activated,
− The control system is unlocked if no signal is present at the IMMEDIATE STOP input.
OPERATION MODE MANUAL
The auxiliary drives are switched on when the control unit has been switched to MANUAL mode. Pressing the
START button, after the start is enabled by the auxiliary drivers, starts the engine. The generator CB can be
switched on by pressing GEN. ON (I) if the generator voltage is within its limits and no alarm that switches
the generator off is present.
Pressing the GEN. OFF (O) button switches the generator CB off. The generator CB is operated only
manually in this operation mode.
Pressing the On-button has no effect if the voltage of the generator is not within the preset limits. A remote
start command does not cause the generator to be switched on automatically.
Select operation mode OFF to shutdown the genset or AUTO if there is no automatic start.
Manual Speed Control
The speed can be set manually in the operation modes MANUAL and TEST. To do this, select the SPEED value
or the GENERATOR LOAD in ACTUAL VALUES and hold the MANUAL or TEST button down. Press in addition
the buttons [↑] and [↓] to increase or decrease the speed signal sent to the engine.
Manual Voltage Adjust
The generator voltage can be set manually in the operation modes MANUAL and TEST. To do this, select the
display with the GENERATOR VOLTAGE in ACTUAL VALUES and hold the MANUAL or TEST button down.
Press in addition the buttons [↑] and [↓] to increase or decrease the voltage control signal sent to the engine.
OPERATION MODE AUTO
The genset is started after a remote start command when the start delay time is up. The auxiliary drives are
switched on and the start sequence is begins when the start is enabled. The FAIL TO START alarm is triggered
and the control unit is blocked if the genset has not started up at the end of the start sequence. The generator
CB is switched on as soon as the genset has run up and the generator voltage and frequency are within their
limits.
A delay time follows (command-off delay) after the remote command is removed. After that, the generator
CB is switched off. To prevent the engine from a heat increase, the generator set will run unloaded for the
configured cooling down period, and then it will be shutdown.
EXTERNAL START COMMAND
In this operation mode the genset can be activated by two external start commands:
− Start with generator operation,
− Start without generator operation for an easy stand-by.
Operation Modes 112- MOBL-3 / 07-01-25 9 / 18 Changes without further notice reserved.

OPERATION MODES 112-MOBL-3
In the case of a Remote start command with generator operation, the genset is started and switches the
generator CB on.
The Start without generator operation can be used, for example, to supply more delicate consumers. If, for
example, the generator power is sudden needed, the genset can be started up via this input. The genset starts
but don't take the load. If a remote start command now occurs, the system is able to switch immediately to
generator supply.
OPERATION MODE TEST
The auxiliary drives are switched on when the system is switched to TEST MODE. The start sequence begins
when the start is enabled. The generator CB is switched on by pressing the GEN. ON (I) or switched off or by
GEN OFF (O).
The generator is switched on if a REMOTE START WITH GENERATOR OPERATION command is applied. It is in
this case not possible to switch off the generator CB manually.
Select operation mode OFF to shutdown the genset or AUTO if there is no automatic start.
SPRINKLER OPERATION
The following functions are provided for operation of an electric sprinkler pump:
− Set all alarms as warning ones,
− Start sequence with 10 (can be set by customer) start attempts,
− For the run-up of the sprinkler pump: break or no break for the normal consumers,
− You can select when the sprinkler is no longer required, if the Sprinkler operation is
cancelled after the COOLING DOWN PERIOD AFTER SPRINKLER or
is manually switched off.
The time stage for the COOLING DOWN PERIOD AFTER SPRINKLER CAN be set from 10 to 2400 seconds.
The sprinkler operation is not terminated automatically but must be ended manually if this stage is set to 0
seconds.
If this is the case, the OFF mode indicator flashes.
The genset can now only be stopped via IMMEDIATE STOP or the mode OFF.
The break duration of the normal consumers for the run-up of the sprinkler pump can be set from 0 to
24 seconds. The emergency consumers are not switched off if it is set to 0 sec.
The consumers are switched to generator supply if during the sprinkler operation a REMOTE START WITH
GENERATOR OPERATION occurs. The normal consumers are switched off after expiry of the COMMAND-OFF
DELAY when the remote start command is cancelled.
The sprinkler mode prevents that the genset is switched off or shutdown due to an alarm. If a shutdown
alarm is triggered, however, the common alarm SHUTDOWN is issued.
DOCUMENT HISTORY OF OPERATION MODES
Revision Modification Released Revision Modification Released
06-01-11 First edition 05-12-02
06-11-25 Format 06-11-25
Manual voltage control
Operation Modes 112- MOBL-3 / 07-01-25 10 / 18 Changes without further notice reserved.