Energy Division

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Installation and Operating Instructions

KEY-START Series

Tyco Electronics UK Limited

Crompton Instruments
Freebournes Road, Witham, Essex, CM8 3AH, UK
Tel: +44 1376 509 509
Fax: +44 1376 509 511
Contents Page
Section 1 Introduction 3

Section 2 Installation 4
2.1 Unpacking 4
2.2 Mechanical Installation 4
2.3 Electrical Connections 6
2.3.1 Charge Generator current 11

Section 3 Commissioning 12

Section 4 Operation 13
4.1 Controls and Indicators 13
4.2 Programming (STOP versions only) 14
4.3 Starting the Engine 14
4.4 Stopping the Engine (STOP versions only) 14
4.5 Stopping the Engine (All other versions) 14

Section 5 Fault Finding 15

Section 6 Setting Up 16
6.1 Meter Calibration 16
6.2 Speed Trip Setting 16

Section 7 Specification 17

Section 8 Index 19

Warning: The unit contains no user-serviceable items. Some models contain parts carrying
high voltages (derived from the alternator). Any servicing must be carried out by
technicians specifically trained on this type of equipment.

Important safety information is contained in this manual. Users must familiarise themselves
with this information before attempting installation or other procedures.

KEYSTART MANUAL Issue 3 08/2005

Section 1 Introduction
The KEY-START range of Engine Protection Units provides for control and protection of a
generator set. The unit allows starting and stopping of the engine and indicates status and fault
conditions. In the event of a fault, the unit automatically shuts the engine down, indicating the
first-up failure on front panel LED annunciators.
The following models are available:

Product Codes
KEY-START Standard KEY-START Unit
KEY-START-ALT -“- With Overspeed Sensing From Generator Voltage
KEY-START-MAG -“- With Overspeed Sensing From Magnetic Pickup
KEY-START-ETM KEY-START Unit With Elapsed Time Meter
KEY-START-ETM-ALT -“- With Overspeed Sensing From Generator Voltage
KEY-START-ETM- MAG -“- With Overspeed Sensing From Magnetic Pickup
KEY-START-STOP KEY-START Unit With Stop Button
KEY-START-STOP-ALT -“- With Overspeed Sensing From Generator Voltage
KEY-START-STOP-MAG -“- With Overspeed Sensing From Magnetic Pickup
KEY-START-ETM-STOP KEY-START Unit With Elapsed Time Meter & Stop Button
KEY-START-ETM-STOP-A -“- With Overspeed Sensing From Generator Voltage
KEY-START-ETM-STOP-M -“- With Overspeed Sensing From Magnetic Pickup
SPARE-KEY-KS Spare Keys (x2)
The unit monitors:
● Engine temperature,
● Oil pressure,
● Charging generator output,
● One or two auxilary inputs
● Engine speed via Alternator output - ALT version only,
● Engine speed via Magnetic pickup output – MAG version only.
● Engine running hours - ETM version only
Since the ALT and MAG versions can sense engine speed, they provide an output to drive a
O/1mA dc tachometer. The unit controls:
● Engine fuel supply, via an external solenoid,
● Starter motor, via the front panel key switch,
● Preheating, via a transistor output,
● Alarm.
If a fault is detected, the unit shuts down the engine and indicates the failure by flashing a
relevant fault LED. An Off/Run/Start key switch on the front panel controls module operation and
initiates engine cranking. An Auxiliary Shutdown input is included. If this input becomes active
(low), it lights an LED and shuts down the engine.
The ETM versions include an hours-run meter to register and display the engine running hours.
The programmable STOP versions include a front panel mounted Stop button and two auxiliary
inputs. DIP switches allow configuration of ‘energize to stop’ mode for use with a stop solenoid,
and when the stop button is pressed the stop relay solenoid energizes for a period of 20
seconds. The unit can also function in normal ‘energize to run’ with a fuel solenoid.

3
Section 2 Installation
2.1 Unpacking
Carefully unpack the unit and check for damage. Retain the packing in case of future need, e.g.
for returning the unit for calibration.
Check the contents, as follows:
● One KEY-START unit.
● Two Keys
● Operating Manual.
● Screw clamp electrical connectors.
● Panel mounting clamps.
Report any shortage or damage to your local sales office as soon as possible.

2.2 Mechanical Installation

The unit is designed for panel mounting. Fixing is by two screw fixings.
Panel fascia size is 72 mm x 72 mm (2.8 in x 2.8 in). It requires a panel cut-out 69 mm x 69 mm
(2.72 in x 2.72 in).
1. Remove the fixings from the unit, if fitted, and unscrew the screws in the fixings.
2. Insert the unit in the panel cut-out from the front.
3. Insert the fixings in the slotted at the diagonal corners of the unit and tighten the fixing
screws to secure the unit against the panel.

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KEY-START-ETM KEY-START

KEY-START-STOP Figure 2.1 Front View

Figure 2.2 Side view

5
2.3 Electrical Connections

Warning: Beware of the high voltages connected to this unit.

Figure 2.3 KEY-START & KEY-START-ETM rear view

Figure 2.4 KEY-START-ALT & KEY-START-ETM-ALT rear view

Figure 2.5 KEY-START-MAG & KEY-START-ETM-MAG rear view

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 Figure 2.6 KEY-START-STOP
& KEY-START-ETM-STOP rear view

Figure 2.7 KEY-START-STOP-ALT

& KEY-START-ETM-STOP-ALT rear view

Figure 2.8 KEY-START-STOP-MAG

& KEY-START-ETM-STOP-MAG rear view

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Be sure to connect the battery supply the right way round.
On ALT versions, fuse should be rated 1A.
If necessary, set up the Speed Trip and Meter Calibration preset potentiometers on the rear
panel. Refer to Section 6 Setting Up.

Screened cable must be used for connecting the Magnetic Pickup, ensuring that the
screen is grounded at the end ONLY.

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Table 1 shows the connections and recommended cable sizes. Table 2 describes the functions of
the connections.

Table 1 Unit wiring

Pin Description Cable Notes
size
(mm2)
1 Input from Charge Generator 1.0
2 Input from Temperature Switch 1.0 Switch to "0" volt
3 Input from Oil Pressure Switch 1.0 Switch to "0" volt
4 Input from Auxiliary Shut Down Switch 1.0 Switch to "0" volt
5 Output to Pre-heat 1.0 +DC supply from key switch
(Programmable as Alarm on STOP versions) (not direct battery)
6 Common Alarm 2.5 +DC supply from key switch
(Not used on STOP versions)
7 Output to Fuel Solenoid (Programmable 2.5 +DC supply from key switch
Fuel/Stop Solenoid on STOP versions)
8 Negative Battery supply to KeyStart 2.5
9 + Battery Output 2.5 +DC supply from key switch
10 + Battery supply to unit. 2.5 Supplies common alarm and
external solenoid via key switch.
11 Start Output 2.5 +DC supply from key switch
-ALT option Alternator voltage neutral input.
12 1.0
-MAG option Magnetic pick-up input.
-ALT option Alternator voltage L1 phase input
13 1.0
-MAG option Magnetic pick-up input
14 -ALT and -MAG versions Tachometer - O/P 1.0 0-1mA
14 -ALT and -MAG versions Tachometer + O/P 1.0 0-1mA

16 Input from Auxiliary input 2

(STOP versions only) 1.0 Switch to “0” volt

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Table 2 Connection functions

Pin Functions
1 Input from charge generator.
Input from temperature switch. Switched to “0” VDC when engine temperature exceeds
2
thermostat setting.
Input from oil pressure switch. The oil pressure switch must be the type that opens
3
when oil pressure is normal, and closes on low oil pressure.
Auxiliary–1 input. Normally open contact. When switched to “0” VDC the engine shuts
4
down. (Programmable on STOP versions as warning or shutdown)
Pre-heat output. When unit is first energised, output is active for ten seconds.
5
(Programmable on STOP versions as Pre-heat or Alarm output)
6 Alarm output (This terminal not used on STOP versions – use Pin 5 instead)
Output to Fuel solenoid. +DC supplies from Pin 10 via key switch.
7
(Programmable for Fuel solenoid /Stop solenoid on STOP versions)
8 Negative battery input for supply the unit.
9 + Battery output
10 + Battery input
11 Start Output
-ALT option Alternator voltage neutral input. (used for speed sensing)
12
-MAG option Magnetic pick-up input. (used for speed sensing)
-ALT option Alternator voltage L1 phase input. (used for speed sensing)
13
-MAG option Magnetic pick-up input. (used for speed sensing)
14 -ALT & -MAG option Negative output for tachometer. (0-1 mA)
15 -ALT & -MAG option Positive output for tachometer. (0-1 mA)
Auxiliary–2 input. Available on STOP versions only. Programmable as warning or
16
shutdown. Activates when switched to “0” VDC (contact is closed)

10
2.3.1 Charge Generator current
The unit uses the Charge Generator Current input to detect when the engine is running. The
connection effectively replaces the usual charge indicator lamp. It supplies current to the rotor
coil from the battery until the engine is running, at which time the Charge Generator powers the
rotor via the diode trio. Electronic circuits sense the resultant voltage at pin 1. This is initially low
at near Battery -, as the circuit supplies a high current to the rotor coil, rising to near Battery +
once the engine is running. Figure 2.9 shows the arrangement.

Figure 2.9 Input from Charge Generator

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Section 3 Commissioning
Warning: Beware of the high voltages connected to the -ALT version.
1. Check that the unit is correctly wired and that the wiring is of a standard and rating
compatible with the system.
2. Check that the correct fuses are fitted.
3. Take temporary steps to prevent the engine from starting – for example, disable the fuel
solenoid (disconnect pin 7).
4. After a visual inspection to ensure it is safe to proceed, connect the battery supply to pin 10.
5. Turn the key switch to the Run position (I). Check that the Preheat indicator lights for ten
seconds.
6. Turn the key switch to the Start position (II). Check that the starter motor runs but that the
engine does not start.
7. Repeat steps 5 and 6 to confirm that the engine will not start.
8. Turn the key switch to Off (O).
9. Restore the engine to operational state (reconnect the fuel solenoid).
10. Turn the key switch to Run (I) and check that the Preheat indicator lights for ten seconds.
11. Turn the key switch to Start (II). Check that the starter motor runs and the engine starts.
12. Once the engine is running, release the switch to the Run (I) position.
13. Check that the engine runs up to its operating speed. If not and an alarm is present, check
that the alarm is valid and then check the input wiring.
14. Allow the engine to run for at least 6 minutes to check that the running-hours counter
updates (ETM option only).
15. (Stop version only) press the STOP button and check that the engine stops.
16. Turn the key switch to Off (O). The engine should stop.

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Section 4 Operation
4.1 Controls and Indicators

Alternative panel design

with ETM

Alternative panel design

with stop button

Number Comment
1 Protection ON LED. This indicates that the controller is protecting the engine
against low oil pressure and over-temperature faults. Protection against
these faults begins 20 seconds after engine startup, at which time the LED
lights. (Over speed, auxiliary shutdown and charge generator are monitored at
all times.)
2 Preheat Period LED. Lights during 10 seconds preheat period.
3 Low oil pressure failure LED. Low oil pressure. Engine shut down. Latched
alarm. Restart locked out until reset.
4 High temperature failure LED. High engine temperature. Engine shut down.
Latched alarm. Restart locked out until reset.
5 Charge generator failure LED. This does not shut down the engine.
6 Over speed failure LED. Engine over-speed. Engine shut down. Latched
alarm. Restart locked out until reset.
7 Auxiliary shutdown LED. Connecting pin 4 to “0” VDC shuts down the
engine. Latched alarm. Restart locked out until reset.
8 Key Switch. Connects / disconnects supply to unit and starts and stops
the engine.

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4.2 Programming (STOP versions only)
The DIP switch can be found underneath an access panel. Remove the switch cover using a
screwdriver, and use the screwdriver to select the required switch positions. The product
function can modified as follows:
Switch Function OFF ON
1 Configurable output (pin 5) Preheat Alarm
2 Solenoid type Fuel Stop
3 Auxiliary 1 I/P Shutdown Warning
4 Auxiliary 2 I/P Shutdown Warning

4.3 Starting the Engine

1. Set the key switch on the front panel to the (I) Run position. The unit will power up and:
● energise the fuel solenoid, activating the engine fuel system.
● energise the Preheat output for ten seconds. The Preheat LED lights and the engine
ignition system preheats. After ten seconds, the Preheat output is de-energised and the
Preheat LED goes Off. (Prehead LED not fitted on STOP versions).
● After 20 seconds, the Protection On LED lights as the unit begins monitoring for oil
pressure and over-temperature faults. If the engine has not been started successfully
within 20 seconds of power-up, the alarm will sound.
2. Set the key switch on the front panel to the (II) Start position and hold it against the spring
return. The unit provides an output for the start relay on pin 11. The starter should run and
the engine should start.
3. When the engine has started, release the key switch to the (I) Run position.

4.4 Stopping The Engine (STOP versions only)

If programmed for a Fuel solenoid: Press the STOP button (Fuel solenoid is de-energised). The
engine will stop and Restart locked out until reset. Alternatively set the key-switch to Off position
(0).
If programmed for a Stop solenoid: Press the STOP button (Stop solenoid will be energised for
20 seconds).

4.5 Stopping The Engine (All other versions)

Set the key switch to Off (0). The engine will stop, the DC supply will be removed from the unit
circuits and the solenoid relay and alarm output de-energised. All indicators will go off.

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Section 5 Fault Finding
Warning: Beware of the high voltages connected to the ALT version while the alternator is
running. Disconnect the unit from all electrical supplies before attempting
any maintenance.

Before carrying out any maintenance on the engine, set the key switch to Off (O) and remove
the key.
Indicators on the panel will light if a fault is detected. See Section 4.1 Controls and Indicators.
Fault conditions latch so that further operation is prevented. If a fault is indicated, proceed as
follows:
1. Find and fix the fault.
2. Switch the unit off to enable a restart.
3. Restart the engine.
Any fault detected by the KEY-START unit will light an LED on the front panel and generate an
alarm output. The unit will suppress any oil pressure or high temperature fault indications that
occur in the first 20 seconds after the engine has started. After the initial 20 seconds, Low Oil
Pressure, High Temperature, Over Speed and Auxiliary shutdown failures will shut off the
engine fuel supply to stop the engine. Any alarm condition will be latched until the KEY-START
unit is switched off by turning the key switch to Off (O).

Symptom Possible remedy

Check the battery and wiring to the unit.
Unit is inoperative. Check the DC supply.
Check the DC fuse. (if there is one)
Check engine oil level and pressure.
Oil pressure fault after Check oil pressure switch, and wiring.
engine has started. Check that oil pressure switch is of the normally closed type
(opens when oil pressure is normal if engine running).
Check engine temperature and cooling systems.
Engine temperature fault Check temperature switch and wiring.
after engine has fired. Check that temperature switch is of normally open type
(closes on high temperature).
Check fuel solenoid and wiring, Fuel and battery. Reset the
Failed to Start fault. KEY-START and restart the engine.
Check for battery + output at Fuel Solenoid.
Check wiring to starter solenoid.
Starter motor
Check battery supply.
inoperative.
Check battery supply is present on the start output.
Check wiring to engine heater plugs.
Preheat inoperative. Check battery supply.
Check + VDC (Not direct from battery, this output is transistor
max. 200mA.) is present at Pin 5 during preheat phase.
Engine will not stop Check DIP switch setting on STOP version.

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Section 6 Setting Up
When a KEY-START unit is supplied with the -ALT and -MAG option, it can detect engine speed
and provides additional facilities. An engine trip and alarm will occur if the engine runs over
speed and a tachometer or frequency meter can be connected to indicate engine
speed/alternator frequency. Preset potentiometers on the rear panel allow for speed trip setting
and tachometer/frequency meter calibration .

6.1 Meter Calibration

The meter output is designed for a 1 mA fsd 75 Ohm meter.
The factory default settings are as follows:
-ALT option 50 Hz nominal alternator frequency gives 0.75 mA.
-MAG option 1500 rev/min nominal engine speed with 172 flywheel teeth
gives 0.75 mA
1. Set the engine to run at its nominal speed and measure the alternator output frequency or
engine speed.
2. If the meter is calibrated (in Hz or Revs/Min), adjust the Meter Calibration preset so that the
meter reads the correct value for the measured alternator frequency/engine speed.
Alternatively, the preset should be set for 75% of fsd at the nominal engine speed such that
the full scale range is 0 (0 mA) to 130% (1 mA) of engine nominal speed (this is the factory
default).

6.2 Speed Trip Setting

The factory default settings are as follows:
-ALT option trips at 57.5 Hz
-MAG option trips at 1500 rev/min.
1. Set the Speed Trip preset fully counterclockwise.
2. Disconnect the load from the alternator.
3. Measure the alternator output frequency.
4. Start up the engine and adjust the engine speed for the maximum permitted alternator
output frequency; e.g. 57.5 Hz for 50 Hz nominal or 69 Hz for 60 Hz nominal.
5. Carefully turn the Speed Trip preset clockwise until the Over Speed LED lights and the
engine shuts down.
6. Reduce the engine speed setting, restart the engine, increase the engine speed and check
that an overspeed shut down occurs at the preset high alternator output frequency (e.g. 57.5
or 69 Hz).

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Section 7 Specification
Inputs
DC Supply 8 to 32V DC
Operating Current 200mA maximum
Cranking Dropout Battery voltage can be 0V DC for max. 100 ms during
cranking (battery voltage should be at least nominal
voltage before cranking)
Generator Voltage (-ALT option) 35 to 300V AC L-N, 10 to 110Hz
Magnetic Pickup (-MAG option) 3 to 35 Volts peak, 35Hz to 10kHz
Contact Sensing Oil Pressure Switch (NC)
Temperature Switch (NO)
Auxiliary Shutdown (NO)
Tachometer 0 to 1 mA DC into 75 Ohm meter
(MAG and ALT option only)
Hour Meter (-ETM opton) 7-digit electromechanical counter 0 to 999999.9 hours

Outputs
Relay Contacts Start relay (12 Amp DC at 12/24V)
Fuel relay (12 Amp DC at 12/24V)
Horn relay (5 Amp DC at 12/24V)
Preheat output (200mA maximum at 12/24V DC)
Charge Generator Excitation current 200mA, maximum 3 Watts.

Display
Failure Annunciators Low Oil Pressure
High Temperature
Charging Fail
Over Speed
Auxiliary Shutdown
Status Annunciators Protection On
Preheating On

Measurement Accuracy
Generator Frequency (-ALT option) 1% of full scale, 10 - 110 Hz alternator Voltage
Engine Speed (-MAG option) 0.25% of full scale, 35 - 10,000Hz magnetic pickup
Overspeed Trip 1% of full scale
Running hours 10 pulses per hour (6 minute resolution)

Environmental
Operating Temperature -25°C to +70°C (-13°F to +158°F)
Storage Temperature -40°C to +85°C (-40°F to +185°F)
Humidity <93% RH, non condensing

17
Environmental Rating Standard, Indoors, Altitude less than 2000m
Mode of operation Continuous

Standards
EMC BS EN 50081-2, BS EN 50082-2
Electrical Safety EN 61010-1
Installation Category II
Pollution Degree II

Mechanical
Enclosure DIN 43700 Style housing, 72mm x 72mm Bezel,
69mm x 69mm cutout
Panel Thickness 10mm (0.4 in) Maximum
Protection Class IP30 front panel, IP20 rear panel
Weight Approximately 0.4 Kg

Range of calibration (Rear adjustments)

-ALT option Meter calibration adjustment range 25% - 200% of
nominal frequency. Overspeed Trip adjustment
range 10 - 110 Hz
-MAG option Meter calibration adjustment range 25% - 200% of
nominal RPM. Overspeed Trip adjustment range
35Hz to 10kHz

Preset Operating Parameters

Protection on delay: Engine faults other than over-temperature are not
reported for the first 20 seconds from power-on.
Preheating duration: Energised for 10 seconds from power-on.

Factory Settings as supplied

-ALT option 50Hz Nominal, tachometer output 0/1mA = 0/66.7 Hz
Overspeed Trip is preset to 57.5 Hz

-MAG option 1500 RPM Nominal, 172 Teeth, tachometer

output 0/1mA = 0/2000 RPM
Overspeed Trip is preset to 1725 RPM

Accessories: Spare keys are available for these units. The order
code for these is: SPARE-KEY-KS

18
Index
Auxiliary shutdown, 14, 16, 20 Over speed, 14, 16
Charge generator, 12, 14 Over-temperature, 14
Connections, 7, 8, 9 Preheat, 14
Cut-out size, 4 Protection ON LED, 14
Engine start detection, 12 Rear view, 6, 7
Factory defaults, 18 Setting up, 18
Fascia size, 4 Speed trip, 18
Fixings, 4 Unpacking, 4
Fuses, 9 Warnings, 2
High temperature, 16
Key switch, 3, 15
Meter calibration, 18
Oil pressure, 14, 16, 20

19
The Information contained in these installation instructions is for use only by installers trained to make electrical power installations and is intended
to describe the correct method of installation for this product. However, Tyco Electronics has no control over the field conditions which influence
product installation.
It is the user's responsibility to determine the suitability of the installation method in the user's field conditions. Tyco Electronics' only obligations
are those in Tyco Electronics' standard Conditions of Sale for this product and in no case will Tyco Electronics be liable for any other incidental,
indirect or consequential damages arising from the use or misuse of the products. Crompton is a trade mark.

Tyco Electronics UK Limited

Crompton Instruments
Freebournes Road, Witham, Essex, CM8 3AH, UK
Tel: +44 1376 509 509 Fax: +44 1376 509 511 http://energy.tycoelectronics.com