Kuhse KEA 292 INS User manual

Operating instructions
Automatic start/stop system for stand-alone gensets
For product: KEA 292 INS
File: BA_KEA 292 INS_EN_Ver 2016-07-01.doc Item no.
2A292I5000
1
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
_________________________________________________________________________________
1. Use and basic operation
The KEA 292 INS automatic system is used for power generation units that operate in standalone
mode.
The function of the output relay and the parameters can be set with a PC.
Because the KEA 292 has the same dimensions and fastenings as its predecessor, replacement is
simple.
Ten parameterisable alarm and operating indicators –which can be labelled by easily replaceable
paper strips –as well as four general displays are displayed through LEDs.
The parameterisation can be performed using the serial USB interface with the PARAWIN parameteri-
sation program.
Important note!
The operation of the automatic system is simple and uncomplicated as it is carried out via the usual
buttons –without menu guidance –as for all previous automatic systems.
2. Revision history
Created
Changed
Version
07-05-2013
First edition
07-05-2013
01/10/2014
Connection diagrams updated
01/10/2014
01/07/2016
Change the header
01/07/2016

Operating instructions KEA 292 INS - 2 / 13 - File: BA_KEA 292 INS_EN_Ver 2016-07-01.doc
2
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
3. Content
1. Use and basic operation....................................................................................................1
2. Revision history .................................................................................................................1
3. Content................................................................................................................................2
4. General description ...........................................................................................................3
5. Warnings.............................................................................................................................3
6. Displays and keys..............................................................................................................4
7. Functions of the keys ........................................................................................................4
7.1. Operating mode keys...........................................................................................................4
7.2. Start key...............................................................................................................................4
7.3. LED Test button ...................................................................................................................4
7.4. Alarm Off button...................................................................................................................4
8. General displays ................................................................................................................5
8.1. Monitoring on .......................................................................................................................5
8.2. Automatic system locked .....................................................................................................5
8.3. Start control..........................................................................................................................5
8.4. Failed start / Motor malfunctions..........................................................................................5
8.5. Mimic diagram / Voltage monitor..........................................................................................5
9. Operating modes................................................................................................................6
9.1. Off operating mode ..............................................................................................................6
9.2. Manual operating mode .......................................................................................................6
9.3. Auto operating mode............................................................................................................6
9.4. Test operating mode............................................................................................................6
9.5. Sprinkler operation...............................................................................................................7
10. Error messages / Programmable operation indicators..................................................7
10.1. Use as an operational indicator ...........................................................................................7
10.2. Use as an error message.....................................................................................................7
10.3. Alarms 9 and 10...................................................................................................................7
10.4. Internal error messages.......................................................................................................8
10.4.1. Error messages of the voltage monitor 8
10.4.2. Overspeed 8
10.4.3. Speed measurement failed 8
10.4.4. Engine does not switch off 8
10.4.5. Generator circuit breaker tripped 8
10.4.6. Switching off generator hindered 8
11. Remote acknowledgement................................................................................................8
12. Frequency control..............................................................................................................8
13. Emergency Stop / Emergency Off (external)...................................................................9
14. Start program .....................................................................................................................9
14.1. Start process, diesel engine.................................................................................................9
14.2. Start process, gas engine ....................................................................................................9
15. Technical data ..................................................................................................................10
15.1. Design................................................................................................................................10
15.2. Auxiliary voltage.................................................................................................................10
15.3. Analogue inputs .................................................................................................................10
15.4. Digital inputs and outputs...................................................................................................10
15.5. Serial interface ...................................................................................................................10
15.6. KNG for coupling to other systems (option).......................................................................10
16. Connection diagrams ......................................................................................................11
16.1. KEA 292 connection diagram.............................................................................................11
16.2. Position of the voltage selector and connection terminals.................................................12
17. Drilling template –Scale 1:1 –print without scaling! ..................................................13

Operating instructions KEA 292 INS - 3 / 13 - File: BA_KEA 292 INS_EN_Ver 2016-07-01.doc
3
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
4. General description
The KEA 292 INS 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 ar-
ranged in a clear manner. Menu-driven guidance has been omitted in order to keep the handling sim-
ple 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.
The generator voltage is monitored across 2-phases. The voltage and frequency are monitored for
levels that are either too high or too low.
Ten displays can be selected as alarms or operation indicators. Provision has been made for remote
acknowledgement of alarms.
The speed is measured via a pick-up or the generator frequency and can be monitored for overspeed.
The battery voltage monitor, a start counter and an operating hours counter are integrated.
Ten freely selectable alarm messages are provided for the monitoring of the peripherals, the genset
and the generator switch.
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 inter-
face. 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.
5. Warnings
1. The information in the service instructions, SA_KEA 292 INS, must be complied with.
2. The connection of the unit must be carried out carefully, as a wrong connection could
lead to the destruction of the unit. The connection regulations must be observed.
3. The PE(N) must be connected to the point marked with the earthing symbol.
4. The installation and commissioning must only be carried out by sufficiently qualified
personnel.
5. Applicable regulations, especially those of the VDE must be observed.
6. The parametrisation of the unit must be carried out in such a way that endangerment of
persons and property is excluded.
7. If the battery has to be disconnected, the charging unit must be switched off.
8. The battery negative potential must be earthed at the input terminal on the switchboard.
The minimum cross-section is 10 mm2.
9. The supply voltage (12 or 24 V DC) is selected using a switch located on the circuit
board under the hood.
10. If the supply voltage of the automatic system was switched off, it must only be
switched on again after approx. 20 seconds.
11. All the coils must be provided with a freewheeling diode (for DC voltage) or with a sup-
pressor 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 instructions KEA 292 INS - 4 / 13 - File: BA_KEA 292 INS_EN_Ver 2016-07-01.doc
4
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
6. Displays and keys
7. Functions of the keys
7.1. 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.
7.2. Start key
The motor can be started in MANUALoperating mode by actuating this button. If the motor needs to be
preheated, 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.
7.3. LED Test button
The functioning of all LEDs of the automatic system can be tested by this button. To control other sig-
nal lights of the switchgear during the lamp test, a relay can be parameterised to this function.
7.4. Alarm Off button
An actuation pulse from this key can be used to cancel the acoustic signal issued by an alarm. The
message 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 instructions KEA 292 INS - 5 / 13 - File: BA_KEA 292 INS_EN_Ver 2016-07-01.doc
5
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
8. General displays
The two upper rows of the LEDs provide important information on the operating processes and error
messages. The displays described below are intended as standard.
8.1. 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 re-
leased. The display goes out at the beginning of the shut-down process.
8.2. 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 error). To do so, any actuated external emergency stop buttons must also be unlocked.
8.3. 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 through the D+
signal of the generator, through the speed sensor signal or through the generator voltage, in accord-
ance with the parameterisation). Switching on the starter is then inhibited, even if attempted manually.
The starting generator voltage interrupts the start but does not cause the START CONTROL indicator to
extinguish.
8.4. 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 dis-
played 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
inhibited.
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.
8.5. Mimic diagram / Voltage monitor
The mimic diagram displays the generator and the generator breaker. The green LED below the gen-
erator symbol indicates that the voltage is within the limits. The LED flashes as soon as the voltage is
within limits again, but the release time has not expired yet.
The position of the generator switch is indicated through the green LED underneath the OFF
key (O). In the event of the GENERATOR BREAKER TRIPPING (if parameterised), this LED flash-
es in quick succession after a longer off period.

Operating instructions KEA 292 INS - 6 / 13 - File: BA_KEA 292 INS_EN_Ver 2016-07-01.doc
6
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
9. Operating modes
9.1. 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 operat-
ing mode:
a genset operation is immediately ended
previously displayed error messages, except the fault messages 9 and 10, are deleted as long as
their alarm contact is still active
the automatic system is unlocked. However, if the QUICK STOP (EMERGENCY STOP)input is still ac-
tive, unlocking is not possible; the AUTOMATIC SYSTEM LOCKED message remains.
9.2. 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. If the generator
voltage lies within the nominal ranges with its voltage and frequency values, the generator can be
switched on with the GEN-ON(I) key or off again with the GEN-OFF (O) key. The actuation of the ON
key remains ineffective if the generator voltage does not lie within the specified limits.
All switching processes are only carried out manually and not automatically. Even a remote start order
does not lead to the automatic switch-on of the generator. In order to switch off the genset, the OFF or
(in the event of the remote start command being missing) AUTOMATIC operating mode must be select-
ed.
9.3. 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 AUXILIARY DRIVES signal is present. If no auxiliary drives are required (for start release), ter-
minal 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 inhibit-
ed. After the start-up of the genset, the generator is switched on as soon as the nominal generator
voltage and frequency are reached.
After removal of the start command, the generator is switched off immediately. In order to prevent heat
build-up, if it was loaded the genset continues to run without load for the run-on time set and then is
shut down.
In addition to the remote start, the genset can also be started via the Sprinkler command (see further
in this document).
9.4. Test operating mode
After button selection to the TEST position, the start program is triggered. The START CONTROL indica-
tion 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-.
If the generator voltage lies within the nominal values parameterised with its voltage and frequency
values, the generator can be switched on with the GEN-ON(I) key or off with the GEN-OFF (O) key.
If a remote start command occurs during test operation, the system switches to generator operation.
Then, it is not possible to manually switch off the generator circuit breaker. A manual operation of the
switch is only possible after the remote start command has been withdrawn.
In order to switch off the genset, the OFF or (if the remote start command is not present) AUTOMATIC
operating mode must be selected.

Operating instructions KEA 292 INS - 7 / 13 - File: BA_KEA 292 INS_EN_Ver 2016-07-01.doc
7
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
9.5. Sprinkler operation
The following functions are intended for the operation of an electrical sprinkler pump:
Switching of all shutdown alarms (overspeed alarm remains switched off for electronic speed sen-
sor, demand VDS 2100-22) to warning
Optionally, the inhibition of the generator switch-off function for GENERATOR OVERCURRENT, for ex-
ample
Start program to 6 (parameterisable) start attempts
Upon sprinkler request being withdrawn: Cessation of the sprinkler operation after the SPRINKLER
IDLE TIME, or only manual switching off
for the duration of the acceleration time of the sprinkler pump: Switching off of the normal consum-
ers or no interruption.
The supply of the sprinkler pumps is usually taken care of directly by the generator and thus prior to
the switch to the emergency power consumers. If a sprinkler request is arises, the genset starts. In the
event of an additional request from the remote start command, the consumers can be switched off for
a parameterisable period of time in order for enough energy to be available to allow the sprinkler pump
to start up. Furthermore, it is possible to parameterise that the consumer switches remain switched on
or switch off in the event of an overload on the side of the consumers.
Sprinkler operation is automatically cancelled after the sprinkler requirement is removed after an en-
tered idle time or can only be ended manually (demand VDS 2100-22). If the automatic system is pa-
rameterised 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).
10. Error messages / Programmable operation indicators
Any of the 10 LEDs can either display an error message or be parameterised as an operation indica-
tors.
10.1. Use as an operational indicator
These displays are independent of the selected operating mode. Thus, they can be used as displays
of operational conditions via contact inputs as normal signal lamps. The parameterisation is described
in the service instructions.
10.2. 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 il-
luminated. Due to the necessary second acknowledgement, e.g. the switching off of the acoustic sig-
nal generator after an automatic switch-off, it can be distinguished which error message has newly oc-
curred.
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 in-
dicated by AUTOMATIC SYSTEM LOCKED. In order to unlock, the OFF operating mode (any actuated ex-
ternal Emergency OFF buttons must also be unlocked) must be selected.
If the generator is switched off due to a warning alarm in automatic operation, the engine is stopped after the idle
time and the automatic system is locked.
The parameterisation is described in the service instructions.
10.3. Alarms 9 and 10
Both these alarms can be delayed from 0 to 240 sec. by the signal transmission, i.e. for the alarm con-
tact to issue an error, the signal must be pending for a parametrised time. Furthermore, both these
alarms are also effective in the Off operating mode (Off), but without switching on the horn. Thus, crite-
ria (e.g. tank overfilling, leakage warning) that always have to be reported can be monitored.

Operating instructions KEA 292 INS - 8 / 13 - File: BA_KEA 292 INS_EN_Ver 2016-07-01.doc
8
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
10.4. Internal error messages
All possible error messages monitored by the software are described in the following. They can be re-
leased or locked. The parameterisation (release) is described in the service instructions.
10.4.1. Error messages of the voltage monitor
The criteria of the voltage monitor, recognised as faulty, released for monitoring (<U, >U, <f, >f), can
be displayed. They can, individually or collectively, control an error message or only be displayed.
The criteria of the voltage monitor (recognised as faulty) released for monitoring (<U, >U, <f, >f) can
be displayed. They can, individually or collectively, control an error message or only be displayed.
10.4.2. Overspeed
For the overspeed monitoring, either the generator frequency or the frequency of a pick-up is used
(according to the parameterisation).
10.4.3. 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 au-
tomatic system is locked and the FAILED START /MOTOR ERROR message is displayed.
10.4.4. Engine does not switch off
This message is always effective. If the motor still runs after the stop process has expired (parameter-
ised 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
can immediately switch to generator operation in the event of a start request (sprinkler request).
10.4.5. Generator circuit breaker tripped
The alarm is internally controlled if no generator feedback occurs after the GENERATOR IS ON switch-on
pulse has expired. After a generator circuit breaker trips, the GENERATOR IS ON LED flashes in brief
pulses after a longer off period, the acoustic signal sounds and the collective alarm message is
switched on. The first actuation of ALARM OFF switches off the acoustic signal and a second press of
ALARM OFF acknowledges the message.
If the message is not acknowledged, the genset switches off after the idle time in automatic operation.
10.4.6. Switching off generator hindered
The alarm is given if no GENERATOR IS OFF feedback is registered approx. 2 seconds after the switch-
off command for the generator circuit breaker. The genset includes a renewed start command and
switches into generator operation. If a switch-off alarm occurs, the genset is now stopped.
11. 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 deac-
tivating fault messages 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 operating mode to OFF.
12. Frequency control
The automatic system provides adjusting pulses for the speed controller (if the function is enabled)
when in AUTO and TEST operating modes, if the frequency is not within the parameterised window. A
pause is made between two pulses so that the motor has time to execute the command.

Operating instructions KEA 292 INS - 9 / 13 - File: BA_KEA 292 INS_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
13. Emergency Stop / Emergency Off (external)
A pulse on the QUICK STOP (EMERGENCY STOP) input is sufficient to trigger the Emergency Stop func-
tion. Thus, independent of the operating mode:
the generator is switched off
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
pending, it cannot be unlocked. The AUTOMATIC SYSTEM LOCKED display remains switched on.
14. Start program
14.1. Start process, diesel engine
1. Start delay 2 sec.
2. Starter on for 10 sec.
3. Pause 7 sec.
4. 3 start attempts
5. 6 start attempts for sprinkler operation
6. Delay MONITORING ON 7 sec.
7. Switch-off delay 60 sec.
8. Idle time 180 sec.
9. Sprinkler operation idle time 0 sec.
10.Stop time 30 sec.
14.2. Start process, gas engine
1. Starter on
2. If the starter speed is exceeded, the switching-on of the ignition is delayed (e.g. after 2 sec.)
3. Then (another 2 sec.) open gas solenoid valve
4. Starter now on for another 7 seconds
5. Then close gas solenoid valve
6. Starter off
7. Ignition off after 6 sec.
8. New start sequence after 1 sec.
The parameterised standard values for a diesel engine are specified here. If Diesel engines with pre-
heating 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 292 INS - 10 / 13 - File: BA_KEA 292 INS_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. Technical data
15.1. 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
15.2. Auxiliary voltage
Switchable 9-12-15V or 14-24-35V DC
15.3. Analogue inputs
2-phase generator voltage monitor for nominal voltage 400 V, adjustable in 1 Volt steps
- Adjustable 250 - 480 Volt
- Generator frequency 45 to 65 Hz, adjustable in 0.01 Hz steps from 40 to 70 Hz
Battery voltage monitor
15.4. 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
15.5. Serial interface
USB interface for parameterisation, for coupling via an additional mode to a control system or to a remote
monitoring
15.6. 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