Murphy Engine And Generator Controls Keystart 9620 User Manual

00-02-0657  
revision A, 22nd September 2008  
catalogue section 40 & 75  
Keystart 9620 series  
Engine & Generator Controls  
Installation Instructions  
Please read the following information before installing. A visual inspection of this product for damage during  
shipping is recommended before installation. It is your responsibility to ensure that qualified mechanical and electrical  
technicians install this product. If in doubt, please contact your local Murphy representative.  
GENERAL INFORMATION  
Product specifications  
power supply:  
operating voltage:  
steady state  
brown out / cranking  
WARNING  
7 – 30 VDC  
5 VDC  
current consumption  
< 100mA  
BEFORE BEGINNING INSTALLATION OF THIS PRODUCT  
Disconnect all electrical power to the machine  
inputs:  
fault switch inputs:  
–ve input defined as:  
close to negative DC during fault  
–1V to +1V w.r.t. – ve DC supply  
Make sure the machine cannot operate during installation  
Follow all safety warnings of the machine manufacturer  
Read and follow all installation instructions  
(model 9621 only)  
speed sensing input:  
generator AC (J2+J3 on)  
70 – 270 VAC rms,  
<50 to >60 Hz. nominal  
mag. pickup (J2+J3 off)  
10 – 60 VAC peak,  
<2000 to >6500 Hz. nominal  
General  
(all ratings non-reactive)  
outputs:  
The Keystart 9620 series provides manual start/stop and automatic  
fault shutdown protection for generators, pumps and other engine-  
driven applications.  
run, preheat  
start (crank)  
alarm  
positive DC, switched NO relay contact,  
10 A max. @ 24VDC  
positive DC via keyswitch contacts,  
10 A max. @ 24V DC  
Keystart features a 3 way keyswitch for operator control of the engine,  
with 6 LEDs for indication of status and faults - see ‘front view’ diagram  
for details. Electrical connection and configuration options are at the rear  
- see ‘Rear view, connection and settings’ diagram.  
negative DC (open collector  
NPN transistor), 250mA max.  
calibration/tacho  
to suit 0 – 1 mA, 75 Ohm meter  
output = 0.75mA at rated engine speed  
For each Keystart ordered, the following is supplied:  
1 x Keystart module, fitted with 2 x panel mounting clips  
2 x keys  
these instructions  
adjustable settings:  
preheat timer  
0 or 10 secs (link J1),  
default = 0 secs  
fault override timer  
overspeed trip level  
2 to 20 secs (VR1),  
default = 10 secs  
Panel installation  
Keystart is designed for front-of-panel mounting in a DIN standard  
92 x 92 mm (3.6 x 3.6 in.) cut-out. Allow 75mm (3.0 in.) behind the  
panel for the case depth, keyswitch and cable connection.  
100 to 130 % (VR3) of  
nominal speed calibration (VR2),  
default = 110% (of 50 or 60 Hz)  
Secure the case to the panel with the two ratcheted mounting clips:  
general:  
1.  
2.  
3.  
overall dimensions (w x h x d)  
panel cut-out size  
weight  
96 x 96 x 95 mm / 3.8 x 3.8 x 3.7 in.  
DIN 92 x 92 mm / 3.6 x 3.6 in.  
approx. 300 g / 0.7 lb  
Remove the plastic  
mounting clips from  
the Keystart case:  
release each clip’s  
ratchet mechanism by cut-out (C).  
pulling outwards (A),  
then slide the clip  
At the front of the  
panel, insert the  
Keystart (without  
clips) into the panel  
At the rear of the panel,  
refit the two mounting  
clips into the slots on  
the Keystart case (D).  
Slide each clip forward  
until the arms (E) are  
secured behind the  
panel face. Ratchet  
mechanism (F) prevents  
the clip from moving  
backwards.  
operating temperature  
–35°C to +55°C / –31°F to 131°F  
Model options  
back and off the  
case (B).  
ELECTRICAL CONNECTION (cont.)  
Terminal functions (cont.)  
Pin Function  
Pin Function  
3
Start (crank) output  
With links J2 & J3 ON:  
13 Generator AC Live  
14 Generator AC Neutral  
DANGER !  
HIGH VOLTS  
Pin 3 gives a positive DC, 16 Amp rated output when the key  
is switched to position II (start/crank). To prolong keyswitch  
contact life, connect a slave relay (with suppressed coil)  
between pin 3 and the engine starter solenoid coil - see  
‘typical connection’ diagram below.  
When configuration links J2 and J3 are fitted (the default factory  
setting), terminals 13 and 14 are configured for overspeed  
sensing using a high voltage, generator AC 50/60Hz. signal.  
4
Power Supply, Positive DC  
The input accepts generator AC voltages between 70 and  
270 VAC rms. A 1 Amp anti-surge fuse should be connected  
in series with AC live (pin 13). See ‘speed sensing’ below for  
correct calibration of this input using potentiometers VR2 and  
VR3.  
12 Power Supply, Negative DC  
The Keystart operates with any smooth DC / battery voltage in  
the range 7 – 30V. Supply brown-out protection is fitted as  
standard. Connect a 5 Amp anti-surge fuse in the positive DC  
line (pin 4).  
To configure these terminals to magnetic pickup engine  
speed sensing, see section below.  
5
Charge fail  
The charge fail LED lights, but there is no shutdown or alarm,  
when pin 5 is connected to battery negative. When using a  
charge alternator, connect pin 5 to the alternator warning lamp  
(WL) terminal. (Note: pin 5 supplies the alternator excitation  
current).  
With links J2 & J3 OFF:  
Magnetic pickup signal input  
Magnetic pickup return  
13  
14  
When configuration links J2 and J3 are removed, terminals 13  
and 14 are configured for speed sensing by a magnetic pickup  
and flywheel/gearwheel combination.  
6
7
8
9
Low Oil Pressure (LOP) fault input  
Auxiliary 1 fault input  
High Engine Temperature (HET) fault input  
Auxiliary 2 fault input  
Connect the magnetic pickup to the input using two-core and  
screen cable. To minimise electrical interference on the speed  
signal, connect the cable screen to earth at one end only.  
Use remote switch/relay contacts that connect these inputs  
to battery negative during fault conditions. The Keystart  
shuts down the engine, lights the appropriate fault LED,  
and activates the alarm output. Note: activation of pin 9  
(Aux 2 input) causes engine shutdown and illumination of  
the overspeed LED.  
Magnetic pickup signal requirements are 10 – 60 VAC peak,  
with frequency between 2000 and 6500 Hz. when the engine is  
running at nominal speed. See ‘speed sensing’ below for correct  
calibration of this input using potentiometers VR2 and VR3.  
To configure these terminals for generator AC frequency  
sensing, see section above.  
For all the above inputs, shutdown is inhibited during engine  
cranking and until the end of the fault ‘override’ time (adjustable  
2 – 20 secs using potentiometer VR1, clockwise to increase).  
To reset a shutdown fault condition, turn the key to O (Off) or  
remove the DC power supply.  
Typical connection  
10 Alarm output  
Pin 10 is a semiconductor-based (open collector NPN transistor)  
output that gives a negative DC output immediately after a fault  
shutdown. Output rating is 250mA max.: the output typically  
drives an audible/visible alarm circuit, using a slave relay with  
suppressed coil - see ‘typical connection’ opposite.  
11  
Tachometer (speed calibration) output  
This output is designed to work with a 0 - 1 mA DC ammeter,  
either a) during set-up to aid speed calibration, or b) in normal  
operation to indicate engine speed or generator Hz.  
For calibration, connect meter positive to pin 11 and meter  
negative to battery negative, e.g. at terminal 12. See ‘speed  
sensing and calibration’ below for setup procedure.  
For indication of engine RPM or generator Hz, the 0 – 1mA  
meter requires a custom scale: when correctly calibrated  
using VR2, Keystart gives 0 mA at 0 RPM/Hz. and 0.75mA  
(3/4 scale) at normal running RPM/Hz.  
Murphy - Keystart 9620 series installation instructions  
00-02-0657 revision A 22nd September 2008 p3/4  
SPEED SENSING AND CALIBRATION  
Maintenance and Warranty  
Keystart model 9621 includes a speed sensing input and automatic  
shutdown protection for engine overspeed faults. Before use, model  
9621’s speed input must be correctly configured (using circuit-board  
links J2 and J3) and calibrated (using potentiometers VR2 and VR3).  
The Keystart series contains no user-serviceable parts. Maintenance  
is therefore limited to the following preventative checks:  
Check that all electrical connections are secure.  
Selection of speed signal source: links J2 and J3  
Check that the Keystart is securely clamped in the front of  
panel aperture, and kept free from ingress of water or build  
up of excessive dust/dirt. The front face label and casing may  
be wiped with a clean, damp cloth. Do not use cleaning solvents.  
Links J2 and J3 allow configuration of the speed sensing input  
(terminals 13 and 14) for either generator AC (the factory default  
setting) or magnetic pickup signals. Use small pliers to add or  
remove the links as required:  
Each Keystart is supplied with a two year warranty on materials  
and workmanship. In the event of a fault or technical query, please  
contact your Murphy representative for technical support.  
J2 and J3 Terminal 13 and 14 configuration  
links  
ON  
Generator AC, 70 - 270 VAC rms, 50 or 60 Hz nominal.  
OFF  
Magnetic pickup, 10 – 60 VAC peak, 2000 to 6500 Hz  
nominal.  
Speed calibration  
Speed calibration is a two stage process:  
1) Nominal speed calibration: potentiometer VR2  
The factory default setting is for generator AC speed sensing, with  
standard models for 50 or 60Hz nominal calibration. To recalibrate  
for other systems:  
Select the speed sensing method (generator AC or magnetic  
pickup) using links J2 and J3 as detailed above.  
Turn VR2 fully clockwise (sets calibration for maximum nominal  
frequency).  
Connect a 0 – 1mA, 75 Ohm meter between pin 11 and battery  
negative, as detailed in ‘electrical connection’ above.  
Start and run the engine to nominal (normal running) speed.  
Turn VR2 anti-clockwise (decreasing the calibration frequency)  
until the ammeter rises to read 0.75mA.  
2) Overspeed setting: potentiometer VR3  
VR3 allows adjustment of the overspeed trip point, between  
approximately 100 and 130% of the nominal AC or magnetic pickup  
frequency (as set using VR2). The VR3 factory default setting is  
110% (of either 50 or 60Hz). To adjust the overspeed trip level:  
Turn VR3 fully clockwise (to maximum, approx. 130% of nominal)  
Start and run the engine. Increase engine speed to the required  
overspeed/over-frequency trip level.  
Turn VR3 slowly anti-clockwise (decreasing the overspeed trip  
level) until the Keystart shuts down the engine and indicates  
‘overspeed’.  
Where the engine speed cannot be22 September 2008 adjusted,  
or if the speed signal cannot be simulated (e.g. with an adjustable  
signal generator), an approximate overspeed setting must be made  
(e.g. potentiometer mid-span = approximately 115% of VR2 nominal).  
In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time.  
MURPHY, the Murphy logo, are registered and/or common law trademarks of Murphy Industries, Inc. This document, including  
textual matter and illustrations, is copyright protected by Frank W Murphy Ltd., with all rights reserved. © 2008 Frank W Murphy Ltd.  
FW MURPHY  
FRANK W. MURPHY LTD.  
Church Rd, Laverstock,  
Salisbury, SP1 1QZ, United Kingdom  
Tel: +44 1722 410055  
Fax: +44 1722 410088  
FW MURPHY INTERNATIONAL TRADING (SHANGHAI) CO. LTD.  
Suite 1704, Tower B, City Center of Shanghai; 100 Zunyi Road,  
Shanghai, 200051 China  
Phone: +86 21 6237 2082 Fax: +86 21 6237 2083  
P.O.Box 470248, Tulsa, Oklahoma 74147 USA  
+1 918 317 4100 Fax: +1 918 317 4266  
INDUSTRIAL PANEL DIVISION  
Fax: +1 918 317 4124  
FW MURPHY INSTRUMENTS (HANGZHOU) CO. LTD.  
77 23rd Street, Hangzhou Economic & Technological Development Area  
Hangzhou, Zhejiang 310018 China  
COMPUTRONIC CONTROLS  
MURPHY POWER IGNITION  
41 – 43 Railway Terrace, Nechells,  
Birmingham, B7 5NG, United Kingdom  
Tel: +44 121 327 8500  
Fax: +44 121 327 8501  
Phone: +86 571 8788 6060 Fax: +86 571 8684 8878  
CONTROL SYSTEMS AND SERVICES DIVISION  
P.O.Box 1819, Rosenberg, Texas 77471 USA  
Phone: +1 281 633 4500 Fax: +1 281 633 4588  
Murphy - Keystart 9620 series installation instructions  
00-02-0657 revision A 22nd September 2008 p4/4  

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