Hubbell Industrial Controls, Inc.
A subsidiary of Hubbell Incorporated
4301 Cheyenne Dr.
HUBBELL
Archdale, NC 27263
Telephone (336) 434-2800
FAX (336) 434-2803
Instruction Manual
Model LX3000
Diesel Engine
Fire Pump Controller
Publication No. 203
December 2003
Page 1 of 17
2) Press and hold the Ÿ clock symbol key during entire time setting procedure.
a) Press the Day key to bring the actual day of the week into display.
b) Press the h button to set the hours and the m button to set the minutes. If the keys are depressed for
more than a second, the digits will advance rapidly.
c) Release the Ÿ clock key when finished with the settings. The colon between the hours and minutes will
be flashing indicating the timer has started.
Programming
1) To set the Timer to start the engine once a week and run for a selected period of time.
Press Timer once (do not keep depressed) The display will show “1ON and “--:--“for the time.
a)
b)
c)
d)
e)
Press h+ m+ to set the ON time.
Press Day to select the day of the week to run.
Press Timer key to enter program. The display will show 1”OFF”.
Program OFF command using steps b-d above.
Press the Ÿ key to return to time od day display.
2) To review the programming
a)
Press Timer key to review the individual commands as preprogrammed, at any time, be brought
consecutively into the display for revision or checking. Revisions are carried out by writing over the
existing programs using the steps outlined above.
5. Set Control Settings – also see attached drawing for locations of items 5 through 11.
a. Set the pressure switch start time delay (P/SWT DELAY SEC) on the Main Logic Board. The
adjustment range is 0 to 15 seconds in 1 second increments.
b. Set the AC Power Loss Delay Time on the Main Logic Board. The adjustment range is 0 to 90
seconds in 6 second increments.
c. Set the Auto Stop time switch (SW6). Settings are none, 15 minutes or 30 minutes.
d. Set the AC PowerLoss Start switch (SW4–2). Setting is on or off.
e. Set the AC Loss Audible Alarm switch (SW4-1). Setting is on or off.
6. Controller Testing
a. Verify pressure is above the Stop setting.
b. Turn CONTROLLER ON / OFF SWITCH to the ON position
Check the Test Timer to make sure that the Timer contacts are not about to close. Closure of the Timer
contacts during testing causes incorrect results.
Manual Start
a. Turn the AUTOMATIC / MANUAL SWITCH to the MANUAL position.
b. Operate the MANUAL CRANK # 1 switch or the MANUAL CRANK # 2 switch. Release as soon as the
engine starts.
c. Turn the AUTOMATIC / MANUAL SWITCH to the AUTO position to stop the engine.
Automatic Engine Cranking in TEST
a. Disconnect engine wire from TB1-1 to prevent starting.
b. Press the TEST PUSHBUTTON on the weekly TEST TIMER. The solenoid valve opens to discharge
water, and the pressure switch contacts close to initiate cranking.
c. The controller will crank the engine on battery 1 for 15 second intervals followed by 15 second rest period.
It will then crank 15 seconds on battery 2, followed by 15 second rest period. This cycle is repeated 3
times, then cranking should will stop and the FAILURE TO START light comes on, the alarm sounds, and
the Common TROUBLE relay is energized.
d. Turn the CONTROLLER ON / OFF to the OFF position.
e. Reconnect the starter motor cable(s).
Automatic Pressure Start
a. With the AUTOMATIC / MANUAL SWITCH in the AUTO position, lower the system pressure below the
Start pressure.
b. The engine will start and run until pressure is above the Stop setting and the STOP button is pressed, or the
CONTROLLER ON / OFF SWITCH is turned to the OFF position, or the optional Automatic Stop Timer,
typically set for 15 or 30 minutes, stops the engine.
Battery Failure Test
a. With the AUTOMATIC / MANUAL SWITCH in the AUTO position, disconnect the battery wire on
TB1-6. The BATTERY NO.1 FAILURE LED should come on within two minutes. The alarm should
sound and the Common TROUBLE relay should energize. Reconnect the wire to TB1-6. Reset the alarm
by turning the CONTROLLER ON / OFF - RESET SWITCH from CONTROLLER ON to OFF - RESET
position then back to the CONTROLLER ON position.
b. Disconnect the battery wire on TB1-8. The BATTERY NO.2 FAILURE LED should come on within two
minutes. The alarm should sound and the Common TROUBLE relay should energize. Reconnect the wire
to TB1-8. Reset the alarm by turning the CONTROLLER ON / OFF - RESET SWITCH from
CONTROLLER ON to OFF - RESET position then back to the CONTROLLER ON position.
Charger Failure Test
a
With the AUTOMATIC / MANUAL SWITCH in the AUTO position, disconnect the wire on TB1-6, and
disconnect the AC input to charger(s) no. 1. BATTERY NO.1 FAILURE & CHARGER 1 FAILURE light
should come on within two minutes. The alarm should sound and the Common TROUBLE relay should
energize. Reconnect the wire to TB1-6, reset the alarm by turning the CONTROLLER ON / OFF - RESET
SWITCH from CONTROLLER ON to OFF - RESET position then back to the CONTROLLER ON
position.
b Repeat the above for battery No. 2 & charger(s) no. 2, using the wire on TB1-8
Low Oil Pressure Test
a. With the AUTOMATIC / MANUAL SWITCH in the AUTOMATIC position, start the engine by
depressing the TEST PUSHBUTTON on the Weekly Timer.
b. Wait 10 seconds for the Oil Pressure Delay interval to expire, then momentarily jumper TB1-4 to TB1-11.
The alarm will sound and the Common Trouble relay will energize. The LOW OIL PRESSURE LED will
come on and remain on after the engine stops.
c. Turn the CONTROLLLER ON / OFF - RESET SWITCH to the OFF - RESET position then back to the
CONTROLLER ON position to reset the LOW OIL PRESSURE Alarm.
High Water Temperature Test
a. WITH the AUTOMATIC / MANUAL SWITCH in the AUTOMATIC position, start the engine by
depressing the TEST PUSHBUTTON on the Weekly Timer.
b. Momentarily jumper the TB1-5 to TB1-11. The alarm will sound and the Common Trouble relay will
energized. The HIGH WATER TEMPERATURE LED will come on and remain on after the engine stops.
c. Turn the CONTROLLLER ON / OFF - RESET SWITCH to the OFF - RESET position then back to the
CONTROLLER ON position to reset the HIGH WATER TEMPERATURE Alarm.
Optional Remote Start
a. With the AUTOMATIC / MANUAL SWITCH in the AUTO position, open the remote start contacts, TB1-12
& 13, starting the engine.
b. Turn the CONTROLLER ON / OFF SWITCH to the OFF position to stop engine.
c. Close the remote start contacts.
Optional AC Power Failure Start (if enabled)
a. With the AUTOMATIC / MANUAL SWITCH to the AUTO position, disconnect the AC power supply to the
Controller.
b. After the pre-set time delay (0 to 90 seconds) the engine will start. The audible alarm should sound, AC
POWER LOSS LED will come on, and both the Common TROUBLE and AC POWER LOSS relays will
energize.
c. Reconnect the AC power to reset the alarms.
d. Turn the CONTROLLER ON / OFF - RESET SWITCH to the OFF - RESET position to stop the engine.
End of Startup Testing
Switches
1. Automatic/Manual – Selects automatic or manual mode.
2. Crank Battery 1 – Cranks the engine using battery 1.
3. Crank Battery 2 – Cranks the engine using battery 2.
4. Stop – Stops the engine in automatic if there are no start conditions and control switch is in “Auto”.
5. Normal/ Silence – Silences optional pump house alarm only. Standard alarms required NFPA 20 cannot be
silenced.
Troubleshooting
Hazardous voltage
will shock, burn,
or cause death.
Do not touch
!
DANGER
until ALL power
is disconnected.
WARNING: Disconnect AC power to the Controller before servicing to prevent shock or accident
hazard.
Before troubleshooting, perform the following checks:
a. visual inspection for physical damage.
b. ensure that all switches are in the normal operating position.
c. ensure that the engine controls are set for operation.
d. ensure that all wiring connections are secure.
e. review the Startup procedure for proper operation to help determine if one of the system boards is faulty.
Table 6-1 Troubleshooting
Possible cause Checks
Condition
Action
Batteries
Voltmeters should read Check electrolyte
at least 12.5 or 25 VDC
Test and recharge bad
Check each battery in
battery(s)
bank for correct voltage
Replace battery(s) with
good battery(s)
Battery circuits
Check battery and
ground connections
Clean and tighten
connections as
necessary
Engine does not crank
with MANUAL
START
Check battery voltage
Check battery cables
and connections
Check engine starter
cables and connections
Clean and tighten
connections as
necessary
Engine does not crank
using MANUAL
START - Battery No. 1
MANUAL CRANK #1 Check battery voltage
Refer to schematic
Use volt/ohm meter to
determine which
switch
while holding
MANUAL CRANK #1
switch
component is faulty
Engine does not crank
using MANUAL
START - Battery No. 2
MANUAL CRANK #2 Check battery voltage
Refer to schematic
Use volt/ohm meter to
determine which
switch
while holding
MANUAL CRANK #2
switch
component is faulty
If voltage checks indicate batteries and circuits OK then the engine starter or the pilot (or starting)
contactors are faulty.
Table 6-1 Troubleshooting (Continued)
Possible cause Checks
Condition
Action
Water and fuel solenoid Check battery voltage
circuits
Clean and tighten
connections
Replace Engine Relay
Board
Replace Main Logic
Board
Check WATER and
FUEL Relay
Engine cranks but does
not start
Water and fuel solenoid Check solenoids
Replace solenoid(s) or
valve(s)
valves
Check fuel and water
lines
Check engine, fuel, fuel Complete necessary
filter
engine repairs
Engine continues to
crank after starting
Engine Crank Relay or Check Crank 1 and
Replace Engine Relay
Board.
Main Logic Board
faulty
Crank 2 relays on
Engine Relay Board
AUTOMATIC /
MANUAL SWITCH
set to AUTO
Replace Main Logic
Board
Engine Run signal
absent
Check Run LED on
Main Logic Board
Replace magnetic
Pickup
Or
Test Mode Active
Magnetic Pickup or
circuit faulty
Check for Pickup signal
at Main Logic Board
Engine does not crank
in TEST or AUTO
Relay, or Main Logic
Board faulty
Check Crank 1 and
Crank 2 relays on
Engine Relay Board
Replace Engine Relay
Board
Engine cranks with
MANUAL START
Replace Main Logic
Board
Water and fuel
solenoids energized
Engine does not crank
in AUTO when water
pressure decreases
Pressure Switch, or
Main Logic Board
faulty
Press P/S TEST button If cranking cycle begins
refer to Appendix B
Pressure Switch /
Recorder
Engine cranks with
MANUAL START
Replace Main Logic
Board
Table 6-1 Troubleshooting (Continued)
Condition
Possible cause
Water and Fuel
solenoid circuits and
valves, or
Checks
Action
Engine stops without
having to press STOP
button or before run
time is complete
Check Water and Fuel
Relay
Replace Engine Relay
Board
Main Logic Board
faulty
Replace Main Logic
Board
Test Timer or Test
Pushbutton does not
start engine
No power to solenoid
drain valve, or faulty
valve
Check Water Dump
Solenoid Relay
Replace Engine Relay
Board
AUTOMATIC /
MANUAL SWITCH in
AUTO
Faulty Timer
Check solenoid valve
Replace valve
Replace Timer
Check Timer
program
Engine starts after
pressure drop
Alarm does not sound,
Associated light not on
Alarm faulty
Check alarm
Replace alarm
LED Display faulty
Replace LED Display
Replace Main Logic
Board
Main Logic Board
faulty
No BATTERY
FAILURE indication
Power Sense Board
faulty
Check Power Sense
Board
Replace Power Sense
Board
Engine cranks
Main Logic Board
faulty
Replace Main Logic
Board
Table 6-1 Troubleshooting (Continued)
Possible cause Checks
Condition
Action
No HIGH ENGINE
TEMP indication
Water temperature
switch
Connect a jumper
across the water
temperature switch on
the engine
Replace water
temperature switch
Start engine with
MANUAL START
switch
Verify that engine starts
and alarm sounds
Engine overspeed does
not stop engine
No indication
Faulty or mis-adjusted
magnetic sensor
Check sensor
installation
Replace sensor
Replace Main Logic
Board
Main Logic Board
faulty
Indication but engine
does not stop under
overspeed simulation
Cranking and rest
periods greater than or
Main Logic Board
faulty
Check Main Logic
Board
Replace Main Logic
Board
less than 15 ± 2 sec.
Engine cranks less than
six times
Engine continues to
crank in AUTO
position but does not
start
Controller does not
crank engine with good faulty
battery
Engine Relay Board
Check Engine Relay
Board
Replace Engine Relay
Board
Engine cranking and
indication OK
Main Logic Board
faulty
Check Main Logic
Board
Replace Main Logic
Board
Table 6-1 Troubleshooting (Continued)
Condition
Possible cause
Checks
Action
Engine does not crank
with Remote Start
Remote switch faulty
Check switch and
switch circuits
Repair circuits
Replace switch
Main Logic Board
faulty
Cranks when water
pressure decreases
Check Main Logic
Board
Replace Main logic
Board
Engine does not start
after AC power loss
Power Sense Board or
Main Logic Board
faulty
Check Power Sense
Board
Replace Power Sense
Board
Replace Main Logic
Board
Check Main Logic
Board
Engine does not stop
with optional AUTO
STOP
Another start condition Check controller start
present
conditions
Main Logic Board
faulty
Check Main Logic
Board
Replace Main Logic
Board
Note
The above troubleshooting guide does not represent all possible conditions or problems. If the above
information can not resolve a problem, consult the factory or a local representative for further assistance.
Pressure Switch / Recorder
Changing the Chart Paper
First, locate the “change chart” button (#3) located in the upper left
corner of the recorder. Press and hold this button for approximately one
(1) second until the pen begins to move to the left of the chart. Wait
until the pen has moved completely off of the chart. To remove the
chart paper, unscrew (counter-clockwise) the “hub” knob at the center
of the chart. Remove the old chart paper and position the new one so
that the correct time coincides with the time line groove on the chart
plate. Refer to Figure 3 for the location of the time line groove on the
Figure 1
left side of the chart plate. Re-attach the chart “hub” knob and screw securely (by hand) against the chart.
Press the “change chart” button (#3) again for approximately one (1) second until the pen begins to move back
onto the chart paper.
Pen replacement
Slide the used pen cartridge off the pen arm. Slide on new cartridge and remove tip cover.
To replace the pen, loosen the two screws that hold
the pen arm and the pen cartridge, and metal pen arm
be removed as an assembly. Refer to Figure 3 for
the location of the pen arm screws. Unsnap the
plastic “U” clip tab of the pen cartridge from the
metal pen arm (see Figure 2), remove and discard the
old pen cartridge. Replace the new cartridge by
opening the hinge and snapping it securely around
the metal pen arm.
Figure 2
Figure 3 - RECORDER ASSEMBLY
Figure 4
Pressure Settings
SEE NOTE
(3) Status LED’S
Stop Pressure
Start Pressure
Battery Charger
Introduction
The Power Sense Board monitors the charging current and voltage of both chargers. LED’s indicate that the
chargers are supplying current output, that the battery / charger voltage is above 90%, and that AC Power is
available to power the chargers.
Specifications
LED Indication
READY, green
On indicates float condition
CHARGING, yellow
CHARGE CURRENT, green
On indicates charge in progress
Charging current greater than or equal to current indicated
WARNING: Lead acid batteries generate explosive gases during normal operation.
Precautions: Do not work alone.
Wear eye protection and protective clothing.
Have soap and water available in case of skin contact with acid.
If acid enters eye, immediately flush eyes with cold running water for ten minutes and
get medical attention.
If problems develop, check all connections and clean the battery terminal connections. Use the LED indicators
on the chargers and the LOBC as an aid to determine the cause of any potential problems. Return faulty
chargers to the factory.
CAUTION: Always disconnect the AC power source before disconnecting the batteries when
performing maintenance.
Troubleshooting Chart
Symptom
Possible cause
Solution
All charger LED’s off,
cabinet CHARGER FAILURE
indicating light on
1) No AC power
1) Check for 120 V Charger power
2) Hubbell recommends that the
charger be returned for repair
2) Charger AC fuse blown
Charge Current LED’s scroll,6
cabinet CHARGER FAILURE
indicating light on
1) Battery connections
reversed,
1) Check battery connections
2) Hubbell recommends that the
charger be returned for repair
2) Charger DC fuse blown
6
The charger LED’s scroll in order as follows: Charge Current LED’s 10 A to 2 A, Charging, Ready.
Troubleshooting Chart (Continued)
Symptom
Possible cause
Solution
Charging LED blinking,
Battery voltage high due to
Engine charging circuit
Troubleshoot engine charging
circuit
supplying charging voltage
above control charger value.
10 A Charge Current LED
flashing
Charger stopped charging due
to high temperature
Allow charger time to cool
Improve ventilation in area
Ready LED does not come on,
Batteries do not charge fully
1) Battery capacity too high
1) Check battery rating, must be
less than 200 Ah
2) Excessive load on batteries
3) Short to ground
2) Verify load is normal
3) Clear the short
4) Battery terminals corroded
5) Battery has faulty cell
4) Clean battery terminals
5) Check battery/Replace
Contact the local Hubbell representative to request additional information, parts, or drawings.
Location and Description of Control Settings
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