Kuhse KEA 293 PST User manual

Operating Instruction
Start/Stop control unit for drive motors
KEA 293 PST
File: BA_KEA 293 PST_EN_Ver 2016-07-01.doc (replacing 2014-10-02) Art.-Nr. 2A293P5000
1
Alfred Kuhse GmbH
Telefon: [phone]
E-mail: [e-mail]
Subject to technical changes
An der Kleinbahn 39,21423 Winsen
Telefax; [phone]
http://www.kuhse.de
______________________________________________________________________________________
1. General description
The KEA 293 PST automatic system is used for the control and monitoring of standalone systems. Both
Diesel and gas motors can be controlled.
All controls, displays and the mimic diagram are arranged in a clear manner. Menu-driven guidance has
been omitted in order to keep the handling simple and the system user-friendly.
The automatic system includes all functions for automatic operation and manual operation. All functions
allocated to the genset are included for sprinkler operation.
Ten displays can be selected as alarms or operational indicators. Provision has been made for remote
acknowledgement of alarms.
The speed is measured via a pick-up frequency and can be monitored for overspeed.
The battery voltage monitor and a start counter and an operating hours counter are integrated.
Ten freely selectable alarm messages are provided for the monitoring of the peripherals and the genset.
There are 10 relay outputs available for controlling the motor and the peripherals, switching power 35 V
DC, 1 A. The function of the 7 relays and all of the parameters can be set via a USB interface. The PARAWIN
software is required for this.
All relevant values and signals can be read out via an add-on module.
The device is delivered with standard parameterisation and labelling.
The operation of the automatic system is simple and straightforward, as it is carried out directly
via the usual buttons, without menu navigation, as with the replacement automatic system.

Operating Instruction KEA 293 PST - 2 / 12 - File: BA_KEA 293 PST_EN_Ver 2016-07-01.doc
2
Alfred Kuhse GmbH
Telefon: [phone]
E-mail: [e-mail]
Subject to technical changes
An der Kleinbahn 39,21423 Winsen
Telefax; [phone]
http://www.kuhse.de
2. Content
1. General description............................................................................................................1
2. Content................................................................................................................................2
3. Revision history .................................................................................................................3
4. Warnings.............................................................................................................................3
5. Displays and keys..............................................................................................................4
6. Functions of the keys........................................................................................................4
6.1. Operating mode keys ..........................................................................................................4
6.2. Start key...............................................................................................................................4
6.3. LED Test button...................................................................................................................4
6.4. Alarm Off button...................................................................................................................4
7. General displays................................................................................................................5
7.1. Monitoring on .......................................................................................................................5
7.2. Automatic system locked .....................................................................................................5
7.3. Start control..........................................................................................................................5
7.4. Failed start / Motor malfunctions..........................................................................................5
8. Operating modes................................................................................................................5
8.1. Off operating mode...............................................................................................................5
8.2. Auto operating mode............................................................................................................5
8.3. Test operating mode ............................................................................................................6
8.4. Sprinkler operation...............................................................................................................6
9. Error messages / Programmable operation indicators..................................................6
9.1. Use as an operational indicator............................................................................................6
9.2. Use as an error message.....................................................................................................6
9.3. Alarms 9 and 10...................................................................................................................6
9.4. Internal error messages .......................................................................................................7
9.4.1...... Overspeed 7
9.4.2...... Speed measurement failed 7
9.4.3...... Engine does not switch off 7
10. Remote acknowledgement................................................................................................7
11. Speed regulation ................................................................................................................7
12. Emergency Stop / Emergency Off (external)...................................................................7
13. Start program......................................................................................................................8
13.1. Start process, diesel engine.................................................................................................8
13.2. Start process, gas engine ....................................................................................................8
14. Technical data ....................................................................................................................9
14.1. Design ..................................................................................................................................9
14.2. Auxiliary voltage ...................................................................................................................9
14.3. Analogue input .....................................................................................................................9
14.4. Digital inputs and outputs.....................................................................................................9
14.5. Serial interface .....................................................................................................................9
14.6. KNG for coupling to other systems (option).........................................................................9
15. Connection diagrams.......................................................................................................10
15.1. KEA 292 connection diagram.............................................................................................10
15.2. Position of the voltage selector and connection terminals.................................................11
16. Drilling template –Scale 1:1 –print without scaling! ..................................................12

Operating Instruction KEA 293 PST - 3 / 12 - File: BA_KEA 293 PST_EN_Ver 2016-07-01.doc
3
Alfred Kuhse GmbH
Telefon: [phone]
E-mail: [e-mail]
Subject to technical changes
An der Kleinbahn 39,21423 Winsen
Telefax; [phone]
http://www.kuhse.de
3. Revision history
Created
Changed
Version
07-05-2013
First edition
07-05-2013
2014-10-02
Connection diagrams updated, layout changed
2014-10-02
2016-07-11
Technical data: Serial interface: Add-on module coupling removed
Options (in preparation) removed: RS-485 + GSM modem
03/02/2015
10-14-2015
Text changed (translate)
10-14-2015
01-07-2016
Change the header
01-07-2016
4. Warnings
1. The information in the service instructions, SA_KEA 293 PST, must be complied with.
2. The connection of the unit must be carried out carefully, as a wrong connection could lead to the destruc-
tion of the unit. The connection regulations must be observed.
3. The installation and commissioning must only be carried out by sufficiently qualified personnel.
4. Applicable regulations, especially those of the VDE must be observed.
5. The parameterisation of the unit must be carried out in such a way that endangerment of persons and
property is excluded.
6. If the battery has to be disconnected, the charging unit must be switched off.
7. The battery negative potential must be earthed at the input terminal on the switchboard. The minimum
cross-section is 10 mm2.
8. The supply voltage (12 or 24 V DC) is selected using a switch located on the circuit board under the
hood.
9. If the supply voltage of the automatic system was switched off, it must only be switched on again after
approx. 20 seconds.
10.All the coils must be provided with a freewheeling diode (for DC voltage) or with a suppressor circuit
matched to the inductance of the coil. This also applies for all relays and inductances that are used in the
switchgear or are externally controlled.

Operating Instruction KEA 293 PST - 4 / 12 - File: BA_KEA 293 PST_EN_Ver 2016-07-01.doc
4
Alfred Kuhse GmbH
Telefon: [phone]
E-mail: [e-mail]
Subject to technical changes
An der Kleinbahn 39,21423 Winsen
Telefax; [phone]
http://www.kuhse.de
5. Displays and keys
6. Functions of the keys
6.1. Operating mode keys
The operating modes are selected via four keys –see illustration above. The selected operating mode is
displayed by LEDs. The keys can be locked via an input (e.g. via connection of an external key-operated
control switch), so that the unauthorised or random change of a defined operating mode is prevented. The
operating modes described below can be selected using the keys.
6.2. Start key
The motor can be started in MANUALoperating mode by actuating this button. If the motor needs to be pre-
heated, the pre-heating device must be externally controlled. Actuating this key is ineffective when the
machine is running or also in any other selected operating mode.
6.3. LED Test button
The functioning of all LEDs of the automatic system can be tested by this button. To control other signal
lights of the switchgear during the lamp test, a relay can be parameterised to this function.
6.4. Alarm Off button
An actuation pulse from this key can be used to cancel the acoustic signal issued by an alarm. The mes-
sage continues to flash. After a second confirmation, it changes over to continuous lighting. After the
cause of the error has been eliminated, the LED display is deleted by actuating the button again.

Operating Instruction KEA 293 PST - 5 / 12 - File: BA_KEA 293 PST_EN_Ver 2016-07-01.doc
5
Alfred Kuhse GmbH
Telefon: [phone]
E-mail: [e-mail]
Subject to technical changes
An der Kleinbahn 39,21423 Winsen
Telefax; [phone]
http://www.kuhse.de
7. General displays
The two upper rows of the LEDs provide important information on the operating processes and error mes-
sages. The displays described below are intended as standard.
7.1. Monitoring on
Using this green LED (after the genset start-up), the release of the operating-dependent delayed alarms is
signalled. As soon as the motor has started up, this LED flashes until the monitoring is released. The display
goes out at the beginning of the shut-down process.
7.2. Automatic system locked
The display is switched on by a signal on the QUICK STOP INPUT (EMERGENCY STOP), or together with such
alarms that lead to the shut-down of the genset. This LED indicates that the automatic system is locked for
further start attempts and thus genset operation is inhibited.
The automatic system is unlocked by selecting the OFFoperating mode (after eliminating the cause of the er-
ror). To do so, any actuated external emergency stop buttons must also be unlocked.
7.3. Start control
The message will be activated as soon as a start request is present in AUTOMATIC mode or if MANUAL or TEST
mode has been selected. The display flashes as long as there is no start release. The display goes out as
soon as the genset exceeds the ignition speed during start-up (recognised from the D+ signal of the genera-
tor and also from the speed sensor signal according to the parameterisation). Switching on the starter is then
inhibited, even if attempted manually.
7.4. Failed start / Motor malfunctions
This alarm is controlled by three criteria. That's why this message has expired needs to be interpreted. The
message is controlled if
the genset has not started at the end of the starting program. This message, FAILED START, is displayed
with a continuous light (without flashing). The automatic system is inhibited.
The automatic system is already running and is brought to a standstill without a stop command. This
message, SPEED MEASUREMENT FAILED, is indicated with a flashing light and the automatic system is inhib-
ited.
the genset continues to run after the stop time has expired. This message, MOTOR DOES NOT SHUT DOWN
flashes, the automatic system is not locked.
8. Operating modes
8.1. Off operating mode
The OFF position is automatically selected (reset function) during the application of battery voltage in order to
prevent the triggering of an unintentional start-up. When switching to OFF from another operating mode:
a genset operation is immediately ended.
previously displayed error messages, except the fault messages 9 and 10, are cleared as long as their
alarm contact is still active.
the automatic system is unlocked. However, if the QUICK STOP (EMERGENCY STOP)input is still active, un-
locking is not possible; the AUTOMATIC SYSTEM LOCKED message remains.
Manual operating mode
The START CONTROL indication flashes as long as there is no start release and the SWITCH ON AUXILIARY
DRIVES signal is present. If no auxiliary drives are required (for start release), terminal 8 from X2, START
RELEASE should be switched with L-. The motor can be started using the START key.
In order to switch off the genset, the OFF or (in the event of the external start command being missing)
AUTOMATIC operating mode must be selected.
8.2. Auto operating mode
After the external start command is present the genset will be started after the parameterised delay time has
elapsed. The START CONTROL indication flashes as long as there is no start release and the SWITCH ON

Operating Instruction KEA 293 PST - 6 / 12 - File: BA_KEA 293 PST_EN_Ver 2016-07-01.doc
6
Alfred Kuhse GmbH
Telefon: [phone]
E-mail: [e-mail]
Subject to technical changes
An der Kleinbahn 39,21423 Winsen
Telefax; [phone]
http://www.kuhse.de
AUXILIARY DRIVES signal is present. If no auxiliary drives are required (for start release), terminal 8 from X2,
START RELEASE should be switched with L-. If the genset has not started at the end of the starting program,
the FAILED START /MOTOR FAULT alarm is issued and the automatic system inhibited. Following the removal of
the start command, the unit is switched off.
In addition to the remote start, the genset can also be started via the Sprinkler command (see further in this
document).
8.3. Test operating mode
After button selection to the TEST position, the start program is triggered. The START CONTROL indication
flashes as long as there is no start release and the SWITCH ON AUXILIARY DRIVES signal is present. If no auxil-
iary drives are required (for start release), terminal 8 from X2, START RELEASE should be switched with L-.
In order to switch off the genset, the OFF or (if the start command is not present) AUTOMATIC operating mode
must be selected.
8.4. Sprinkler operation
The following functions are intended for the operation of an electrical sprinkler pump:
Switching of all switching-off alarms (overspeed alarm remains switched off for electronic speed sensor, de-
mand VDS 2100-22) to warning
Start program to 6 (parameterisable) start attempts
Upon sprinkler request being withdrawn: Cessation of the sprinkler operation after the SPRINKLER RUN-ON
TIME, or only manual switching off
Sprinkler operation is automatically cancelled after the sprinkler requirement is removed after a stipulated
run-on time or can only be ended manually (demand VDS 2100-22). If the automatic system is parameter-
ised for manual shutdown, the LED of the OFF operating mode flashes as soon as the sprinkler input is free.
Stopping can then be carried out via the OFF operating mode (or always via Emergency Stop).
9. Error messages / Programmable operation indicators
Any of the 10 LEDs can either display an error message or be parameterised as an operation indicators.
9.1. Use as an operational indicator
These displays are independent of the selected operating mode. Thus, they can be used as displays of operational con-
ditions via contact inputs as normal signal lamps. The parameterisation is described in the service instructions.
9.2. Use as an error message
The arrival of an error message is displayed by the LED flashing. At the same time, the acoustic signal (for
the entered duration) is controlled. The acoustic signal is switched off with a pulse from the ALARM OFF key
(or automatically after the entered time). However, the LED continues to flash. If the value 0 sec. is entered
for the duration of the horn switch-on, no automatic switch-off is carried out: The horn remains switched on
until manually deleted.
Due to a second button actuation of ALARM OFF, the message switches from flashing to continuously illumi-
nated. Due to the necessary second acknowledgement, e.g. the switching off of the acoustic signal genera-
tor after an automatic switch-off, it can be distinguished which error message has newly occurred.
The display is cleared after the error is eliminated after renewed actuation of the ALARM OFF key.
With messages that lead to the switching-off of the genset, further operation is inhibited and this is indicated
by AUTOMATIC SYSTEM LOCKED. In order to unlock, the OFF operating mode (any actuated external Emergency
OFF buttons must also be unlocked) must be selected.
The parameterisation is described in the service instructions.
9.3. Alarms 9 and 10
Both these alarms can be delayed from 0 to 240 sec. by the signal transmission, i.e. for the alarm contact to
issue an error, the signal must be pending for a parameterised time. Furthermore, both these alarms are also
effective in the Off operating mode (Off), but without switching on the horn. Thus, criteria (e.g. tank overfill-
ing, leakage warning) that always have to be reported can be monitored.

Operating Instruction KEA 293 PST - 7 / 12 - File: BA_KEA 293 PST_EN_Ver 2016-07-01.doc
7
Alfred Kuhse GmbH
Telefon: [phone]
E-mail: [e-mail]
Subject to technical changes
An der Kleinbahn 39,21423 Winsen
Telefax; [phone]
http://www.kuhse.de
9.4. Internal error messages
All possible error messages monitored by the software are described in the following. They can be released or locked.
The parameterisation (release) is described in the service instructions.
9.4.1. Overspeed
For the overspeed monitoring, either the generator frequency or the frequency of a pick-up is used (according to the pa-
rameterisation).
9.4.2. Speed measurement failed
This message is always effective. If all parameterised criteria for the RUNNING message are withdrawn during
operation, the monitoring is switched off. For this reason, the genset is shut down and the automatic system
is locked and the FAILED START /MOTOR ERROR message is displayed.
9.4.3. Engine does not switch off
This message is always effective. If the motor still runs after the stop process has expired (parameterised
though the switch-on duration of the stop solenoid), the stop process is repeated and the FAILED START /
MOTOR ERROR message is displayed. The automatic system is not locked, so that the genset is immediately
ready for operation in the event of a start request (sprinkler request).
10. Remote acknowledgement
Existing alarms can be remotely acknowledged with a signal (L-) on terminal 32. A constant signal provides
the command to unlock only once. The automatic system is also unlocked if all of the deactivating fault mes-
sages can be cleared.
The parameterisation defines which alarms are to be cleared. If the alarm contact is still active, remote
acknowledgement of the message is not possible. If the automatic system has been inhibited by the QUICK
STOP input, it cannot be unlocked by the remote acknowledgement, but only locally by changing the operat-
ing mode to OFF.
11. Speed regulation
The automatic system provides adjusting pulses for the speed controller (if the function is enabled) when in
AUTO and TEST operating modes, if the speed is not within the parameterised window. A pause is made be-
tween two pulses so that the motor has time to execute the command
12. Emergency Stop / Emergency Off (external)
A pulse on the QUICK STOP (EMERGENCY STOP) input is sufficient to trigger the Emergency Stop function.
Thus, independent of the operating mode:
the genset is shut down
the automatic system is locked for further start processes (display: AUTOMATIC SYSTEM LOCKED).
In order to unlock, the system must be changed to OFF operating mode. If the QUICK STOP signal is still pend-
ing, it cannot be unlocked. The AUTOMATIC SYSTEM LOCKED display remains switched on.

Operating Instruction KEA 293 PST - 8 / 12 - File: BA_KEA 293 PST_EN_Ver 2016-07-01.doc
8
Alfred Kuhse GmbH
Telefon: [phone]
E-mail: [e-mail]
Subject to technical changes
An der Kleinbahn 39,21423 Winsen
Telefax; [phone]
http://www.kuhse.de
13. Start program
13.1. Start process, diesel engine
Start delay 2 sec.
Starter on for 10 sec.
Pause 7 sec.
3 start attempts
6 start attempts for sprinkler operation
Delay monitoring on 7 sec.
Sprinkler operation run-on time 0 sec.
Stop time 30 sec.
13.2. Start process, gas engine
Starter on
If the starter speed is exceeded, the switching-on of the ignition is delayed (e.g. after 2 sec.)
Then (another 2 sec.) open gas solenoid valve
Starter now on for another 7 seconds
Then close gas solenoid valve,
Starter off,
Ignition off after 6 sec.,
New start sequence after 1 sec.
The parameterised standard values for a diesel engine are specified here. If diesel engines with preheating
systems are used, an external preheating button must be provided in the MANUAL selector switch position.
The start delay serves as a preheating time during automatic starts.

Operating instructions KEA 293 PST - 9 / 12 - File: BA_KEA 293 PST_EN_Ver 2016-07-01.doc
9
Alfred Kuhse GmbH
Telephone: [phone]
E-mail: [e-mail]
Subject to technical changes
An der Kleinbahn 39,21423 Winsen
Fax: [phone]
http://www.kuhse.de
14. Technical data
14.1. Design
Unit for front installation
Dimension (,, depth) 260 x 170 x 80 mm
Weight approx. 2.2 kg
Installation position arbitrary
Protection class (installed) IP 44
Ambient temperature:
- Storage -20°C - +70 °C
- Operation -10 °C - +50 °C
Standards/regulations DIN VDE 0160
14.2. Auxiliary voltage
Switchable 9-12-15V or 14-24-35V DC
14.3. Analogue input
Battery voltage monitor
14.4. Digital inputs and outputs
Input for generator D+ with pre-excitation for AC generators
10 connections for alarm contacts
13 general control inputs
10 output relays, of which 7 are parameterisable, Contact load max. 35V DC, 1 A
Input for pick-up for the speed measurement
14.5. Serial interface
USB interface for parameterisation.
14.6. KNG for coupling to other systems (option)
Device for clipping onto top-hat rails: KNG (Kuhse Network Gateway) for coupling to other systems via
PROFIBUS DP or Modbus RTU

Operating instructions KEA 293 PST - 10 / 12 - File: BA_KEA 293 PST_EN_Ver 2016-07-01.doc
10
Alfred Kuhse GmbH
Telephone: [phone]
E-mail: [e-mail]
Subject to technical changes
An der Kleinbahn 39,21423 Winsen
Fax: [phone]
http://www.kuhse.de
15. Connection diagrams
15.1. KEA 293 connection diagram

Operating instructions KEA 293 PST - 11 / 12 - File: BA_KEA 293 PST_EN_Ver 2016-07-01.doc
11
Alfred Kuhse GmbH
Telephone: [phone]
E-mail: [e-mail]
Subject to technical changes
An der Kleinbahn 39,21423 Winsen
Fax: [phone]
http://www.kuhse.de
15.2. Position of the voltage selector and connection terminals

Operating instructions KEA 293 PST - 12 / 12 - File: BA_KEA 293 PST_EN_Ver 2016-07-01.doc
16. Drilling template –Scale 1:1 –print without scaling!