Hubbell Switch LX3000 User Manual

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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