Eaton Diesel Plus
Eaton Diesel Plus
Eaton Diesel Plus
Contents
Description Page Description Page
1. INTRODUCTION..........................................................................3 4.4 Output Relays ......................................................................... 10
1.1 Safety.........................................................................................3 4.4.1 Relay Functions............................................................ 10
1.2 Warranty....................................................................................3 4.4.2 Future #1 - Future # 2................................................... 10
1.3 Safety Precautions....................................................................3 4.4.3 Engine Alarm Functions .............................................. 10
1.4 Product Overview .....................................................................3 5. PROGRAMMING ...................................................................... 10
2. INSTALLATION AND ELECTRICAL CONNECTIONS ................3 5.1 Introduction ............................................................................ 10
2.1 Mounting...................................................................................3 5.2 Navigation .............................................................................. 10
2.2 Pressure Sensor Connections .................................................3 6. HISTORY, DIAGNOSTICS AND STATISTICS .......................... 14
2.3 Electrical Connections..............................................................3 6.1 System History ....................................................................... 14
2.3.1 Wire Sizes .......................................................................4 6.2 Statistics.................................................................................. 14
2.4 System Pressure Connection ..................................................4 6.3 Controller Diagnostics ........................................................... 15
3. HARDWARE DESCRIPTION .......................................................4 7. COMMUNICATION ................................................................... 15
3.1 General ......................................................................................4 7.1 USB ......................................................................................... 15
3.1.1 Battery Chargers.............................................................4 7.1.1 Information Download ................................................ 15
3.1.2 Three Step Charge .........................................................4 7.1.2 Custom Message Upload ............................................ 15
3.1.3 Charger Shut Down........................................................4 7.1.3 Firmware Update ......................................................... 15
3.1.4 AC Input Fuse Protection ...............................................5 7.1.4 Language Upload......................................................... 15
3.1.5 Battery Charger Message History .................................5 7.2 Embedded Webpage.............................................................. 15
3.1.6 Charger Setup: Lead Acid / NiCad ................................5 7.3 RS485 Serial Port ................................................................... 15
3.1.7 Forced Charging .............................................................5 7.4 RS232 Serial Port ................................................................... 15
3.1.8 Specifications .................................................................5 8. CUSTOM MESSAGES.............................................................. 16
3.1.9 Operating Temperature .................................................5 APPENDIX A: MAIN MENU TREE ............................................... 17
3.2 Front Operator Panel................................................................5 APPENDIX B: REGIONAL SETTINGS MENU TREE.................... 18
3.2.1 The LEDs .........................................................................6 APPENDIX C: PRESSURE SETTINGS MENU TREE ................... 19
3.2.2 Pushbuttons....................................................................7 APPENDIX D: TIMER VALUES MENU TREE .............................. 20
3.3 Display Board Access Area......................................................7 APPENDIX E: CUSTOM INPUT/OUTPUT MENU TREE ............. 21
3.4 Power I/O Board........................................................................7 APPENDIX E(a): CUSTOM INPUTS MENU TREE....................... 22
3.5 Engine Board ............................................................................7 APPENDIX E(b): CUSTOM OUTPUTS MENU TREE .................. 23
3.6 External Pushbuttons ...............................................................7 APPENDIX E(c): CUSTOM LIGHTS MENU TREE ....................... 24
3.6.1 Stop .................................................................................7 APPENDIX F: MAIN MENU PASSWORD MENU TREE.............. 25
4. OPERATION.................................................................................7 APPENDIX G: CUSTOM MESSAGE LOAD & ACTIVATION ...... 26
4.1 General ......................................................................................7 APPENDIX K: ................................................................................ 27
4.2 Start Sequence .........................................................................8 APPENDIX L: ALARM/STATUS MESSAGES ............................. 28
4.2.1 Manual Start Sequence .................................................8 9. INITIAL START UP .................................................................... 29
4.2.2 Automatic Start Sequence.............................................8 9.1 Automatic Start Test .............................................................. 29
4.2.3 Run Period Timer............................................................8 9.2 Manual Start Test ................................................................... 29
4.2.4 Sequential Start Timer ...................................................8 9.3 Test Start Test ......................................................................... 29
4.3 Program Descriptions ..............................................................9 9.4 Weekly Exerciser Test ............................................................ 30
4.3.1 Control Inputs .................................................................9
4.3.2 Control Input Descriptions.............................................9
4.3.3 Loss of DC Power ...........................................................9
4.3.4 Speed Switch Malfunction ............................................9
4.3.5 Electrical Connection Status..........................................9
4.3.6 Audible Alarm Silencing................................................9
4.3.7 Power Failure Alarm ....................................................10
The Diesel Plus Controller is a comprehensive, multi-function Refer to the appropriate field connection drawing affixed to the
microprocessor based Fire Pump Controller. enclosure door, for all wiring information pertaining to the
incoming AC power supply, batteries and engine wiring.
Designed to meet the needs of markets worldwide, the Diesel
Plus controller is certified by the following authorities: Terminals 1 through 12, 301 and 302, located on the lower
Underwrites Laboratories (UL), Underwriters Laboratories of terminal block, are for interconnection to the respective
Canada (ULC), Factory Mutual (FM), Canadian Standards terminals on the diesel engine terminal block.
Association (CSA), New York Department of Buildings (NYSB), Incoming AC line voltage is clearly marked L, N and G (ground)
and CE. located on the lower terminal block.
Install necessary conduit using proper methods and tools.
Terminals 11 through 34, located on the customer connections 3.1.1 Battery Chargers
side of the I/O board are for connecting various input devices to Battery chargers are independent chargers producing a
the Diesel Plus. The customer Input terminals on the I/O board maximum of 10 amps each at full rate. Each battery charger is
are rated for 30 VDC. fully electronic and will protect itself by shutting down during a
continued short circuit.
CAUTION The maximum current draw that the chargers will draw when
Do not apply an AC voltage to these terminals. operating at 100% charging rate is:
12 Volt System 24 Volt System
Terminals 60 through 95, located on the I/O Board, are for
1.6 amps - 120V 3.2 amps - 120V
connection of all output relay functions. These terminals are of
0.8 amps - 240V 1.6 amps - 240V
the pull-apart variety for ease of wiring.
3.1.2 Three Step Charge
NOTE The battery chargers incorporate a three step charge to
All field connections and AC wiring must be brought into the enclosure guarantee the fastest charge times while optimizing battery life.
through the lower right or bottom right side ONLY (refer to labels affixed
The three steps are referred to as Bulk mode, Overcharge Mode
inside enclosure).
and Float mode.
*OTHERWISE WARRANTY IS VOID.*
Bulk
In Bulk mode, a current of 10 Amps is delivered into the battery
2.3.1 Wire Sizes until the voltage reaches 2.4 Volts per cell for Lead Acid
For control wiring, use #14 AWG wire for all electrical Batteries. (14.4 Volts for a 12 Volt battery). At this point, the
connections. battery has recovered approximately 90% of its capacity.
For power wiring sizes refer to Appendix K. When the charger senses this state, it switches to the
Overcharge mode.
2.4 System Pressure Connection
The bulk mode charging may take up to 24 hours depending on
The FD120 is supplied with a Pressure Sensor, or as an option, a the battery capacity and the level to which it was discharged.
Pressure Switch. The charge mode is recorded in the Diesel Plus message
history.
The “TEST” drain connection, located to the left of the system
pressure connection, should be piped to a drain or to waste. Overcharge
In the Overcharge mode, the voltage on the battery is held at
NOTE 14.4 Volts and the current into the battery declines. This mode is
maintained until the current into the battery declines to
Water lines to the drain valve and pressure switch must be free from dirt 1.5 Amps. At this moment, the battery is approximately 99%
and contamination. charged and the charger will change to Float Mode.
The main controller panel interfaces with either the pressure The overcharge mode charging may take up to 12 hours
sensor or the optional pressure switch. The controller must be depending on the battery capacity and the level to which it was
programmed for the appropriate device. discharged. The charge mode is recorded in the Diesel Plus
message history.
Using the standard pressure sensor, the actual pressure is
displayed on the top left hand corner of the LCD display. Precise Float
start and stop pressure set points can be programmed into the In Float Mode, the charger maintains the battery voltage at
controller via the membrane keypad. Pressure readings are also 2.23 Volts per cell for a lead acid battery (13.4 Volts for a 12 Volt
recorded in the memory during alarm situations or pressure battery). Once Bulk and Overcharge modes are completed, the
deviations. charger will maintain the battery charge in Float mode by
regulating to 13.3V. If the charger cannot maintain the battery
With the Pressure Switch option, the LCD will display “OK” if capacity while in Float mode, the charger will begin a new
the pressure is satisfied, and “LOW”, if the contacts on the charging sequence by entering Bulk mode.
pressure switch change state. The memory will record “Low
Pressure” when the pressure drops below the set point. 3.1.3 Charger Shut Down
The charger will automatically shut down if there is no load
3. HARDWARE DESCRIPTION connected to the output or if there is a short on the load side of
the charger. In addition, the charger will not operate if a battery
3.1 General is connected incorrectly or if the wrong voltage of battery is
connected.
The purpose of this section is to familiarize the reader with the
Diesel Plus Controller hardware, its nomenclature, and to list
the unit’s specifications.
3.1.4 AC Input Fuse Protection To select 24 Volt battery charger cycle with NiCad batteries, set
The AC Supply is protected by a 6 amp fuse which will blow in DIP switches 3 and 6 to the ON position and all other DIP
case of a breakdown of the charger. This fuse will not blow as a switches to the OFF position.
result of overloading of the charger since the electronics will
shutdown the charger in this event before the fuse blows. If this 24
24 Volt
Volt --NiCa
NiCadd
fuse is blown the charger must be replaced. ON
ON 1 2 4 5 7 8
OFF
OFF 3 6
3.1.5 Battery Charger Message History
The Diesel Plus message history will record Charging Voltage
and Amperage as well as error messages. The following will be 3.1.7 Forced Charging
recorded according to the conditions that exist. There is provision for the battery chargers to provide a forced
“NO BATTERY” is recorded if no battery is attached to the charge to the batteries. The Forced Charge function will only
charger. activate immediately after applying power to the charger with
DIP Switch 8 in the ON position and a battery connected.
“BATTERY ERROR” is recorded if a battery is connected to the
charger but the voltage is not within the minimum and When the charger is in the forced charge mode, it will attempt
maximum thresholds for the selected battery type. to recover a battery by delivering 10 amps. If the battery does
not reach the minimum battery voltage (8 volts for a 12 volt
“ERROR, RECOVERING” is recorded if the maximum battery system; 18 volts for a 24 volt system) within 5 minutes, the
charger output voltage (31.4V) has been exceeded. recovery attempt will terminate. Once the battery reaches it’s
minimum battery voltage, the normal charge sequence will
3.1.6 Charger Setup: Lead Acid / NiCad commence.
DIP switches on the charger can be used to select a number of
Forced charging will only occur once per battery charger power
options including battery type and voltage as well as Forced
cycle.
Charging. Options currently supported for the charger include
12 or 24 Volt Lead Acid and NiCad Batteries. 12 Volt
12 Volt - Lead
- Lea d Acid Acid 12 Volt
12 Volt - NiCad
- NiCa d
Lead Acid ON
ON 1 2 3 4 5 6 7 ON
ON 1 2 3 4 5 7
To select 12 Volt battery charge cycle with Lead Acid batteries OFF
OFF 8 OFF
OFF 6 8
set all DIP switches to the OFF position.
24 Volt
24 Volt - dLead
- Lea Acid Acid 24 Volt
24 Volt - NiCad
- NiCa d
12
12Volt
Volt -- Lea
Lead Acid
d Acid ON
ON 1 2 4 5 6 7 ON
ON 1 2 4 5 7
OFF
OFF 3 8 OFF
OFF 3 6 8
ON 1
ON 2 3 4 5 6 7 8
OFF
OFF
NOTE
To select 24 Volt battery charger cycle with Lead Acid batteries, When installing a replacement charger in controllers prior to the Diesel
set DIP switch 3 to the ON position and all other DIP switches to Plus – DIP Switch number 5 must be switched to the ON position.
the OFF position.
24 Volt - Lead Acid 3.1.8 Specifications
24 Volt - Lea d Ac id
Voltage Input: 90 - 240VAC - Auto detect
ON 1
ON 2 4 5 6 7 8 Voltage Output: 12-24VDC-DIP switch selectable
OFF
OFF 3
Hertz: Operates on 50 / 60Hz
NiCad
3.1.9 Operating Temperature
To select 12 Volt battery charger with NiCad batteries, set DIP The operating temperature range of the FD120 is:
switch 6 to the ON position and all other DIP switches to the 4 to +40 deg. C (39 to +104 deg. F).
OFF position. Temperatures lower or higher than those specified may cause
damage to the diesel engine controller.
12 Volt - NiCad
12 Volt - NiCa d
ON
ON 1 2 3 4 5 7 8 3.2 Front Operator Panel
OFF 6 The front operator panel, depending on the installation, is
normally accessible from the outside of the door. The front
panel provides a means to:
• Alert the user to specific conditions
• Program the controller
• Set and monitor the operating parameters
• Perform a manual start of the controller.
The Diesel Plus Controller front panel serves two primary The fourth line of the display indicates the time remaining on
functions: output and input. The output function consists of: any active timers, alarms without an associated LED, and
custom messages.
• A four-line, 40 character LCD display module
• Twenty Four LED outputs: 3.2.1 The LEDs
• Engine Run - This green LED will be illuminated when there is
Engine Run Interlock On
power present in the controller and the microprocessor
Remote Start Speed Switch Fault board is powered up.
Deluge Valve ECM Selector in Alt. Position • Remote Start - This green LED will be illuminated after
receiving a start signal on the remote start input.
Low Pressure Fuel Injection Malfunction
(Terminals 11 and 34)
Fail to Start Low Fuel
• Deluge Valve - This green LED will be illuminated after
Charger #1 Failure Low Suction Pressure receiving a start signal from special starting equipment. This
is a normally closed contact that is required to be opened to
Charger #2 Failure Low Oil Pressure start. A factory installed jumper wire must be removed to use
Battery #1 Failure Engine Overspeed these contacts. (Terminals 11 and 35)
Battery #2 Failure High Engine Temperature • Low Pressure - This green LED will flash when the system
pressure has dropped below the programmed low pressure
Six (6) user defined LEDs. alarm set point. This LED will be fully illuminated when the
There are nine input functions accessible via the pushbuttons: pressure falls below the pressure start point.
• Silence Alarm • Fail to Start - This red LED will be illuminated if the controller
has not received an engine run signal from the engine after
• Engine Test attempting to crank the engine a total of 6 times
• Data | Print • Battery # 1 Failure - This red LED will be illuminated during
• Lamp Test the cranking cycle when the controller detects a weak or
discharged battery, i.e. 67% of rated voltage, or less, or
• Reset | Save/Exit whenever a battery cable is disconnected.
• Up • Battery # 2 Failure - This red LED will be illuminated during
the cranking cycle when the controller detects a weak or
• Down
discharged battery, i.e. 67% of rated voltage, or less, or
• Ack. Alarm whenever a battery cable is disconnected.
• Menu • Charger # 1 Failure - This red LED will be illuminated when
the supply power to the charger is lost or when the charger
A four-line, 40-character alphanumeric LCD Display module is
malfunctions (alarm contacts are fed into the controller from
used to display all Diesel Plus monitored parameters, set
the charging unit). The engine continues to run. To avoid
points, and messages in easy to read formats. The display has a
nuisance alarms, the AC Power Failure Alarm set point can be
green high contrast background that allows clear visibility of
increased.
any information displayed. The display is continuously lit for
clear visibility under poorly lit or no light conditions. • Charger # 2 Failure - This red LED will be illuminated when
the supply power to the charger is lost or when the charger
Seven different displays can be presented via the LCD display:
malfunctions (alarm contacts are fed into the controller from
• Status Display the charging unit). The engine continues to run. To avoid
nuisance alarms, the AC Power Failure Alarm set point can be
• Set Points Display increased.
• Statistics Display • Interlock On - This green LED will flash when the interlock
• Diagnostics Display input is received, signaling that another controller or device
has locked out the controller. (Terminals 11 and 39)
• History Display
• Speed Switch Fault - This red LED will be illuminated if the
• Data/Print Display controller is running, the engine run signal is lost and the oil
• Message History Display pressure does not drop. (Terminals 2 and 4)
The “Home” screen display will show the current date and • ECM Selector in Alt. Position - This red LED will be
time, current pressure, Battery #1 voltage and charging amps, illuminated when the controller receives a signal from the
Battery #2 voltage and charging amps and whether Automatic engine indicating the engine is running on the alternate ECM.
Shutdown is ON or OFF. (Terminal 301)
• Fuel Injection Malfunction - This red LED will be illuminated 3.3 Display Board Access Area
when the controller receives a signal from the engine
indicating there is a fuel injection malfunction. (Terminal 302) The display board is housed in a protective case that is
mounted on the inside of the controller door. Access to
• Low Fuel - This red LED will be illuminated when the communication ports and terminals is possible when the
controller receives a signal from the fuel level switch controller door is open.
indicating there is low fuel. (Terminals 11 and 38)
• Low Suction Pressure/Low Foam Level - This red LED will NOTE
illuminate when a low suction pressure signal has been To allow for uniform identification, the frame of reference when
received. A low suction pressure switch can be added to the discussing the access area is with the panel door open and the user facing
controller as option P7. (Terminals 11 and 37) the back of the Diesel Plus controller.
• Low Oil Pressure - This red LED will be illuminated when the
controller receives a signal from the engine indicating there Located on the bottom of the chassis is the USB port, Ethernet
is low oil pressure. (Terminal 4) port, and the I/O board communication cable. The RS232 and
RS-485 ports are located on the right hand side of the chassis.
• Engine Overspeed - This red LED will be illuminated when the
controller receives a signal from the engine indicating there The display contrast adjustments can be made via the open
is an engine overspeed condition. (Terminal 3) potentiometer dial in the back of the chassis.
• | Ack. - The enter and acknowledge button serves two 4.1 General
functions. When navigating the main display, the enter button
will allow the user to enter/exit the message history, This section specifically describes the operation and functional
statistics, and diagnostics. When in the menu system, the use of the Diesel Plus controller. The practical use of and
enter button will allow the user to change the programmed operation within each category will be discussed. In this
set points, and navigate to the next menu item. section, it is assumed that prior sections of this manual were
reviewed and that the operator has a basic understanding of
• Menu - Pressing the menu will allow the user access to the the hardware.
programming mode of the controller. When in the
programming mode, the menu button will serve as a back
button in most cases to return to the previous menu heading.
subsequent drivers from starting” - NFPA, Pamphlet 20, Pump Start (Terminal 36)
Chapter 12. When this input is in the “Connected” state, the Diesel Plus
controller will initiate an automatic start sequence. This input is
The sequential start timer (SST) delays the starting of a fire
typically wired to a separate pressure switch when the use of a
pump in response to the pressure sensor or “Pump start” input.
pressure sensor is not desired.
It does not delay a “Remote start” or “Deluge valve start.”
With a SST in each controller, any pump may be selected as the NOTE
lead pump by appropriate setting of the timers. If the lead
pump restores the pressure in less than the time delays applied When the controller is programmed for foam operation, the pump start
to the lag pumps, then the lag pumps will not start. input will be a normally closed input that will open to initiate a start.
In addition, the provision of a sequential start timer, set to a few Low Suction/Low Foam Level (Terminal 37)
seconds delay, will prevent the lead pump controller from When this input is in the “Connected” state, the Diesel Plus
responding to momentary hydraulic transient pressure loss controller will signal a visual indication on the main display
which would otherwise start the fire pump unnecessarily. board for Low Suction. If the controller is programmed for Low
Suction Shutdown it will initiate the shutdown sequence. Refer
The SST can be programmed from 0 - 300 seconds. Typically,
to Appendix D to program Low Suction Shutdown. When the
each pump should be delayed by 10 seconds from the pump
controller is setup for a foam system, all references to Low
ahead of it. If hydraulic transients are a problem, all timers can
Suction Shutdown will be changed to Low Foam Interlock.
be adjusted for a few seconds extra time delay.
Low Fuel (Terminal 38)
4.3 Program Descriptions When this input is in the “Connected” state, the Diesel Plus
controller will signal an audible and visual indication on the
Refer to Appendix A attached. main display board for Low Fuel Level. The Common Alarm
relay will also de-energize for remote monitoring of this alarm.
4.3.1 Control Inputs
The Diesel Plus has six (6) individual input control signals and Interlock On (Terminal 39)
ten (10) programmable inputs. When this input is in the “Connected” state, the Diesel Plus
controller will not permit a start of the motor except in manual
mode. This input is typically used in backup style systems. For
CAUTION
example, the Engine Running contacts from the backup Diesel
SEVERE DAMAGE COULD BE CAUSED TO THE MICROPROCESSOR BOARDS Engine Controller are wired into this input. When the Diesel
IF A VOLTAGE IS APPLIED TO THESE INPUTS. THEY ARE INTERNALLY Engine is running, it will lock out the Diesel Plus panel and
POWERED. prevent it from starting.
Inputs (1-10)
4.3.2 Control Input Descriptions These are programmable inputs and will function based on
The Control Input state definitions are as follows. how they are programmed. Refer to Appendix E(a) for
programming details.
Connected - When the input is shorted by an external contact or
connection.
4.3.3 Loss of DC Power
Unconnected - When the input is NOT shorted by an external A visual indication and audible alarm is provided to indicate DC
contact or connection. power loss due to one or both batteries being disconnected
from the controller. This indication will also be provided if the
The Control Input operations are defined as follows. controller is not operating due to an electronic board failure.
Requires Battery charger DIP switch #5 to be ON.
NOTE
Terminal 11 is common to all of the inputs outlined below. 4.3.4 Speed Switch Malfunction
A visual indication and audible alarm is provided to indicate
Remote Start (Terminal 34) when the following condition has occurred: The controller is
When this input is in the “Connected” state, the Diesel Plus running, the engine run signal has been lost and the oil
controller will initiate a manual start sequence. This input is pressure has not dropped. (Terminals 2 and 4)
typically wired to a remote pushbutton to allow for remote
manual starting of the controller. 4.3.5 Electrical Connection Status
The Diesel Plus controller constantly monitors the health of the
Deluge Valve (Terminal 35)
engine starter solenoids. A visual indication and audible alarm
When this input is in the “Unconnected” state, the Diesel Plus
is provided if the Diesel Plus detects that the engine starter
controller will initiate a manual start sequence. This input is
solenoid is disconnected or damaged.
typically wired to remote water control equipment that starts
the controller before the pressure sensor does. As this input
requires a normally closed contact to open to initiate the start, a
4.3.6 Audible Alarm Silencing
jumper is factory installed. The jumper must be removed in A separate audible alarm silence switch is provided which can
order to utilize this optional input. manually silence the alarm buzzer for optional alarms. The
silencing switch is located adjacent to the visual indicator.
Following is a description of each programmable set point. Pressure Settings - Refer to Appendix C. Following are the
descriptions of each menu item:
Please Enter Password - If the password is enabled, the user
will be prompted to enter the password at this time. If there are • Pressure Sensor - Some applications do not require a
no buttons pressed for five (5) seconds, the controller will pressure sensor to sense the system pressure in order to
switch back to the automatic mode. start the pump motor when required. In order to accomplish
this. The pressure sensor can be disabled through this menu
Language - Three (3) languages are offered as standard. They
item. Once disabled, the pressure start point, pressure stop
are English, French, or Spanish. A fourth language can be
point, low pressure alarm, and high pressure alarm set-points
added utilizing the USB port. Consult Eaton for available
will be removed from the menu system. Refer to 0 for the
languages. Refer to for programming.
Pump Start input to use instead of the pressure sensor.
Regional Settings - Refer to Appendix B. Following are the
• Pressure Start Point - The value programmed determines at
descriptions of each menu item:
which pressure the controller will initiate a start sequence.
• Change Date - Factory set, however, this parameter allows
• Pressure Stop Point - The value programmed determines the
the user to set the current date.
pressure the system must reach before the controller will
• Change Time - Factory set to Mountain Standard Time (MST). automatically stop the fire pump motor, via the running
This menu item allows the user to adjust the time to the local period timer. If the system pressure does not exceed the
time. The clock is of the 24-hour type. programmed Pressure Stop Point, the fire pump motor will
continue to run.
• Low Pressure Alarm - A low pressure alarm point can be engine has started to run. If the RPT is programmed to start at
selected that will be recorded in the controller’s history. the Stop Pressure, the timer will start timing once the system
pressure has reached the programmed Stop Pressure Point. If
• High Pressure Alarm - A high pressure alarm point can be
the RPT is programmed to start timing once the engine is
selected that will be recorded in the controller’s history.
running then the timer will start timing once the engine has
• Stop Mode - The stop mode is user selectable. If the stop reached a running condition. If the Stop Mode is
mode is programmed for Manual, the engine must be programmed for Manual stop the RPT will not be active. It will
stopped via the local stop pushbutton, whether or not the not be active on Deluge Valve Starts or Remote Starts. While
engine started via an automatic start. If the stop mode is it is timing the amount of time left on the timer will be
programmed for Automatic, the controller will stop the displayed on the fourth line of the display.
engine automatically after all starting causes have been
• RPT Start Mode - The point at which the run period timer
returned to normal and the run period timer has timed out.
starts timing is programmable. If it is programmed to start
• Proof Pressure Switch - An external pressure switch will timing after the engine has started, the RPT will start timing
activate the Input #2 input as a starting input. This menu item once a signal has been received from the engine speed
will only be active when the controller is programmed for a switch. If it is programmed to start timing once the Stop
Foam Pump Controller. Pressure Point has been reached, the RPT will start timing
when the system pressure has risen above the programmed
• Low Suction Shutdown/Foam Interlock - The controller can Pressure Stop Point.
be programmed to shutdown when a low suction condition is
present. If this is desired, the user will select Enabled. • Weekly Test Timer - A Weekly Timer can be programmed that
will automatically start and run the fire pump engine. The
There will also be a shutdown delay timer built in (Range: 0- Weekly Timer is set by adjusting the day, hour, and minute of
30 Seconds, Default: 10 Seconds) along with the selection of the desired weekly run time, the length of time that this test
either a Manual or Automatic reset. shall be performed, and a Test Interval (TI) (Range 1-
If Manual Reset is selected, the Ack./Alarm button on the 52 Weeks) that will run the test every TI weeks. While the
keypad must be activated to reset the alarm. weekly test timer is timing, the remaining time will be
displayed on the fourth line of the display.
If an Automatic Reset (default reset mode) is selected, a delay
timer (Range: 0-30 Seconds, Default: 10 Seconds) must be set. • AC Power Failure Alarm - This setting is used to delay the AC
The controller will continually verify if the input is still active. Power failure alarm. The time can be increased to prevent
Once the input has been removed, the timer will start timing. nuisance alarms caused by short interruptions to the AC
Once the timer has finished timing, out the controller will return power.
to the automatic run mode. • AC Power Failure Start - If “Enabled” , the controller will
When the shutdown delay timer is timing, the time left on the automatically start upon the loss of AC power. The start delay
timer will be displayed on the fourth line of the display. When is based on the AC Power Failure Alarm delay setting. Time
the controller is shutdown on Low Suction, the display will read range is between 0 & 300 seconds. If “disabled” AC power
Low Suction Shutdown. The display will also show the failure will have no affect on the starting of the engine.
automatic reset time delay when timing. Low Suction In order to protect the engine, during the AC Power Failure
Shutdown will not work on Remote Starts. Start, an OVERSPEED condition, LOW OIL PRESSURE or HIGH
ENGINE TEMP alarm will automatically shutdown the engine.
ATTENTION
• Sequential Start Timer (SST) - The SST can be set to delay
NFPA 20, SECTION 2-9.9, SPECIFICALLY PROHIBITS THE INSTALLATION OF the starting of the pump when a low-pressure condition
ANY DEVICE IN THE SUCTION PIPING THAT WILL RESTRICT STARTING OR exists. If during the timing of the sequential timer, the
STOPPING OF THE FIRE PUMP. EATON CORPORATION ASSUMES NO pressure rises above the pressure start point, the timer will
LIABILITY WHEN THIS FUNCTION IS USED. stop timing and the starting sequence will discontinue. When
the SST is timing, the time left will be displayed on the fourth
• Pressure Deviation - A pressure setting may be selected, such line of the display. The SST will not work on Remote Starts.
that any change in pressure greater than this setting, will
Custom Input/Output - Refer to Appendix E. Following are the
record the pressure fluctuation in the alarm memory.
descriptions for each menu item:
• Hourly Pressure Recording - The controller can be set so that
Custom Inputs - The optional inputs have the ability to be
it will take a pressure reading every hour on the hour. If this
programmed with predetermined values or custom values.
feature is not required it can be disabled by selecting
The Custom Input Menu will display each input, what it is
Disabled.
programmed for and if there are any associated optional relays
Timer Values - Refer to Figure #6. Following are the descriptions and / or lights linked to the input. Refer to Table 2 for the generic
for each menu item: values the optional inputs can be programmed for. When this
input is received a message will be stored in memory using the
• Run Period Timer (RPT) - The run period timer is used to
programmed label.
automatically stop the engine after a programmed time. It
can be programmed to operate based on either of two
separate conditions, the stop pressure point or when the
Table 2. Generic Custom Input Labels outputs can be programmed for. Following is a description of
the menu items in the Custom Outputs menu.
Input Table 3. Generic Outputs
Custom Input #1
Alarm
Relief Valve Discharge
High Fuel Low Pressure
Jockey Pump Run High Pressure
Secondary Pump Run Common Alarm
Low Reservoir Low Fuel
High Reservoir Low Suction
Reservoir Empty Interlock On
Pump Room Door Open Fail To Start
Supervisory Power Fail Engine Run
Low Room Temperature Engine Test Running
Fuel Spill Weekly Test Timing
Low Hydraulic Pressure Call to Start
System Overpressure AC Power Failure Alarm
AC Power Failure Start
• Label - If the input label is set to Custom Input #1, this menu Low Room Temperature
item will become active and allow the user to enter the Remote Start
desired input name in. The label will be limited to 20 Deluge Start
characters in length and will include all standard ASCII Manual Start
characters.
Low Pressure Start
• Energize Common Alarm - If required, the common alarm Pump Start
relay (6CR) can be programmed to change states when this RPT Timing
input is received. Default value is Disabled.
Sequential Start Timing
• Link to Relay - All inputs can be linked to an output relay. If Charger #1 Failure
the relay has been linked to another input or is programmed Charger #2 Failure
for another alarm, the program will show what the output is
Battery #1 Failure
programmed for and ask if the relay should be reassigned.
Default value is Disabled. Battery #2 Failure
Off Mode
• Link to Light - All inputs can be linked to one of the future
Manual Mode
LED’s. If the LED is already linked to another input or is
programmed for another alarm, the program will show what Auto Mode
the LED is programmed for and ask if the LED should be Pump Room Trouble
reassigned. Default value is Disabled. Engine Room Trouble
• Latched Until Reset - The alarm signal can be programmed to Controller Trouble
latch in an on state until the ACK/ALARM or RESET buttons Sensor Failure
are pressed. In this case if there are any associated relays or Backup Battery Low
LED’s linked to the input, they will stay active until the ACK/ Low Oil Pressure
ALARM or RESET buttons are pressed. Default value is No. High Engine Temperature
• Normal Input State - All inputs can be programmed to Overspeed Shutdown
operate using a normally open or normally closed or ECM Sel. Switch in Alt.
normally closed input. Default value is Open. Fuel Injection Malfunc.
• Timer - A timer can be programmed to delay the time before Fuel Stop
the alarm becomes active. Default value is 0 seconds. Range Crank Battery #1
is 0-500 seconds. The timer will reset if the input is removed Crank Battery #2
before the time has timed out.
Coil #1 Failure
Custom Outputs - The optional output relays, as well as the Coil #2 Failure
Future 1 and 2 relays can be programmed to operate based on Speed Switch Fault
generic values. The Custom Output Menu will display each
output, what it is programmed for and if there are any
associated future inputs and/ or lights linked to the output.
Please refer to Table 3 for the generic values the optional
• Latched Until Reset - Output relays can be set as latching 6.1 System History
relays. Pressing the ACK/ALARM or RESET buttons will
unlatch them. Default value is No. The Diesel Plus controller will record the last 10,000 alarm/
status messages in its memory that can be viewed on the main
• Fail Safe - Output relays can be programmed to energize display, saved to a USB disk drive, or viewed on the embedded
under normal conditions (fail safe) or de-energize under webpage.
normal conditions. Default value is No.
In order to view the messages on the display press the up or
• Timer - Each output relay can be programmed as a time delay down arrow buttons from the main screen until the display
relay. Either as an On delay or as an Off delay. If it is set for On shows “Display Message History”. Press the Ack. Alarm button
Delay (default) the relay will delay for the programmed time to view the message history. The display will now show three
prior to activating the relay. If it is set for Off Delay the relay messages at a time. Pressing the up or down arrow buttons will
will activate instantly and then de-activate after the allow navigation showing the most recent message to the
programmed time. oldest message. Refer to Appendix K for common messages
Custom Lights - The six (6) optional LED’s can be programmed and their meaning.
for alarms that do not have an associated LED or one of the Refer to Section 7 to save the message history to a USB disk
custom inputs. In this section of the program, the LED’s can be drive or to view the message history on the embedded
programmed for one of the values listed in Table 4. As a default webpage.
the LED’s will be programmed for Undefined.
Table 4. Custom Lights 6.2 Statistics
Alarm The Diesel Plus controller will record a number of statistical
points for a quick review of how the system has been operating.
High Pressure
The statistics can be viewed on the main display, saved to a
Common Alarm USB disk drive, or viewed on the embedded webpage.
Engine Test Running
In order to view the statistics on the display press the up or
Weekly Test Timing
down arrow buttons from the main screen until the display
Call To Start shows “Display Controller Statistics” . Press the Ack. Alarm
AC Power Failure Alarm button to view the statistics. The display will show the statistics
AC Power Failure Start that the controller has recorded. Refer to Table 5 for the
Low Room Temperature statistics included with the controller.
Manual Start Refer to Section 7 to save the controller statistics to a USB disk
Low Pressure Start drive or to view the message history on the embedded
Pump Start webpage.
RPT Timing Table 5. Controller Statistics
Sequential Start Timing
Statistic Range
Off Mode
Powered Time 000000.0-999999.9
Manual Mode
Engine Run Time 00000.0-99999.9
Auto Mode
Number of Calls to Start 00000-99999
Pump Room Trouble
Number of Starts 00000-99999
Engine Room Trouble
Last Engine Start Date & Time
Controller Trouble
Last Engine Run Time 0000.0-9999.9
Sensor Failure
Last Low Pressure Start Date & Time
Backup Battery Low
Minimum Battery #1 Voltage Unlimited
Fuel Stop
Minimum Battery #2 Voltage Unlimited
Crank Battery #1
Maximum Battery #1 Voltage Unlimited
Crank Battery #2
Maximum Battery #2 Voltage Unlimited
Coil #1 Failure
Minimum Battery #1 Amperage Unlimited
Coil #2 Failure
Minimum Battery #2 Amperage Unlimited
Maximum Battery #1 Amperage Unlimited
6. HISTORY, DIAGNOSTICS AND STATISTICS
Maximum Battery #2 Amperage Unlimited
The Diesel Plus controller will record a number of items in its Minimum System Pressure Unlimited
memory to assist with troubleshooting of the system and/or the Maximum System Pressure Unlimited
fire pump controller.
Last System Startup Date & Time
These include system history, system statistics, and controller Last Engine Test Date & Time
diagnostics. Last Low Oil Pressure Date & Time
Refer to Section 7 to save the controller diagnostics to a USB • Refer to Section 8 for the creation of the custom message file.
disk drive or to view the message history on the embedded
webpage.
7.1.3 Firmware Update
• Contact the factory or an authorized trained representative for
assistance.
7. COMMUNICATION
The Diesel Plus controller comes complete with a number of
7.1.4 Language Upload
communication protocols that can be used for the collection of • Contact the factory or an authorized trained representative for
information. assistance.
The communication protocols that are included with the 7.2 Embedded Webpage
controller are USB, Ethernet and Modbus.
The controller has a built-in webpage that can be used to view
The ports included with the controller are USB, Ethernet, and the main display of the controller and its current status.
RS485.
Contact the factory or an authorized trained representative for
7.1 USB assistance in accessing the webpage.
The USB port is used to download the controller message 7.3 RS485 Serial Port
history, statistics, diagnostics, status and configuration data to
a USB disk drive. The USB port can also be used to upload Contact the factory or an authorized trained representative for
custom messages, additional languages, and update the assistance.
microprocessor firmware.
7.4 RS232 Serial Port
This port is used with the optional printer (X1) to initiate a print
cycle.
NOTE
All cells need to be formatted as text.
Figure 1. Custom Message Examples
Specific Alarms (4)
Column A contains the message that will scroll along the fourth Column C is used to enter the alarm event number. Refer to
line of the display. The message can be up to one hundred (100) Table 8 for the alarm events and their corresponding number.
characters in length. Table 8. Specific Alarm Events
Column B contains the message type reference number. Refer
to Table 7 for the message types. Number Event Number Event
MENU PASSWORD
ACK
SELECT
LANGUAGE ACK ACK
LANGUAGE
© ª
REGIONAL GO TO
ACK
SETTINGS APPENDIX B
© ª
PRESSURE GO TO
ACK
SETTINGS APPENDIX C
© ª
GO TO
TIMER VALUES ACK
APPENDIX D
© ª
CUSTOM GO TO
ACK
INPUT/OUTPUT APPENDIX E
© ª
SYSTEM CONSULT
ACK
CONFIG MENU FACTORY
© ª
MAIN MENU GO TO
ACK
PASSWORD APPENDIX F
© ª
REGIONAL
SETTINGS
ACK
SET DAY OF
MENU CHANGE DATE ACK SET MONTH ACK SET DAY ACK SET YEAR ACK
WEEK
© ª ACK
© ª
NEXT MENU ITEM
ACK
© ª
PRESSURE SET STAR T
MENU ACK ACK N E X T M E N U IT E M
S T A R T P O IN T PRESSURE
© ª
PRESSURE SET STOP
MENU ACK ACK N E X T M E N U IT E M
S T O P P O IN T PRESSURE
© ª
SET LO W
LO W PRESSU RE
MENU ALARM
ACK PRESSURE ACK N E X T M E N U IT E M
ALARM
© ª
S E T H IG H
H IG H P R E S S U R E
MENU ALARM
ACK PRESSURE ACK N E X T M E N U IT E M
ALARM
© ª
SET STOP
MENU STOP M ODE ACK ACK N E X T M E N U IT E M
MODE
© ª
ENABLED O N FO AM
SYSTEM S O N LY
© ª
SET LO W
L O W S U C T IO N SET SHUTDOW N SET RESET S E T A U T O M A T IC
MENU ACK S U C T IO N ACK ACK ACK
SHUTDO W N SHUTDO W N
DELAY MODE R E S E T T IM E
© ª ACK
N E X T M E N U IT E M
PRESSURE SET PRESSURE
MENU ACK ACK N E X T M E N U IT E M
D E V IA T IO N D E V IA T IO N
© ª
H O URLY SET HO URLY
MENU PRESSURE ACK PRESSURE ACK N E X T M E N U IT E M
R E C O R D IN G R E C O R D IN G
© ª
N E X T M E N U IT E M
TIMER VALUES
ACK
© ª
RPT START SET RPT START
MENU ACK ACK NEXT MENU ITEM
MODE MODE
© ª
WEEKLY TEST SET WEEKLY SET TEST
MENU ACK ACK SET DAY ACK SET TIME ACK
TIMER TEST TIMER INTERVAL
© ª ACK
© ª ACK
© ª
SEQUENTIAL SET SEQUENTIAL
MENU ACK ACK NEXT MENU ITEM
START TIMER START TIMER
© ª
CUSTOM INPUT/
OUTPUT
ACK
CUSTOM GO TO
MENU ACK
INPUTS APPENDIX E(a)
© ª
CUSTOM GO TO
MENU ACK
OUTPUTS APPENDIX E(b)
© ª
CUSTOM GO TO
MENU ACK
LIGHTS APPENDIX E(c)
© ª
C U S T O M IN P U T S
ACK
M ENU S E L E C T IN P U T
ACK
S E L E C T IN P U T
M ENU
TYPE
ACK
S E T IN P U T
M ENU IN P U T L A B E L ACK ACK N E X T M E N U IT E M
LABEL
© ª
A U D IB L E S E T A U D IB L E
M ENU ACK ACK N E X T M E N U IT E M
ALARM ALARM
© ª
COMMON SET COM M ON
M ENU ACK ACK N E X T M E N U IT E M
ALARM RELAY ALARM RELAY
© ª
S E T L IN K T O
M ENU L IN K T O R E L A Y ACK ACK N E X T M E N U IT E M
RELAY
© ª
S E T L IN K T O
M ENU L IN K T O L IG H T ACK ACK N E X T M E N U IT E M
L G IH T
© ª
© ª
N O R M A L IN P U T SET NORMAL
M ENU ACK ACK N E X T M E N U IT E M
STATE IN P U T S T A T E
© ª
SET D ELAY SET DELAY
M ENU D E L A Y T IM E R ACK ACK ACK N E X T M E N U IT E M
T IM E R T IM E
© ª
N E X T M E N U IT E M
CUSTOM
OUTPUTS
ACK
ACK
SELECT ALARM
MENU
TYPE
ACK
© ª
AUDIBLE SET AUDIBLE
MENU ACK ACK NEXT MENU ITEM
ALARM ALARM
© ª
MENU FAIL SAFE ACK SET FAIL SAFE ACK NEXT MENU ITEM
© ª
SET DELAY SET TIMER SET DELAY
MENU DELAY TIMER ACK ACK ACK ACK NEXT MENU ITEM
TIMER STYLE TIME
© ª
CUSTOM LIGHTS
ACK
ACK
ACK
MAIN MENU
MENU
PASSWORD
ACK
SELECT CUSTOM
DATA MESSAGES
ACK
CUSTOM MESSAGES
SELECT LOAD ACK WILL BE UPLOADED
SELECT CUSTOM
DATA MESSAGES
ACK
MENU
APPENDIX K:
• For control wiring, use #14 AWG wire for all electrical
connections except battery connections.
• For battery connection, terminals 6, 7, 8 and 11, use the
following:
#10 AWG: 0' to 25' (7.62 m)
# 8 AWG: 25' to 50' (15.2 m)
9. INITIAL START UP pressure is satisfied. The RPT is programmed by the user; the
factory setting is 30 minutes.
Ensure that circuit breakers CB1 and CB2 are in the OFF (0)
position. If the Sequential Timer is > 0 seconds, automatic start will be
delayed by the number of seconds programmed.
Ensure that AC power is supplied to terminals L and N, and G is
grounded. 9.2 Manual Start Test
Connect engine batteries to the controller, terminals 6, 8 and 11.
Turn the mode selector switch to the “Manual” position
If batteries are connected in wrong polarity the battery voltage
will read zero. Press the Crank #1 pushbutton. The Engine will crank and start,
the “Engine Run” annunciator will illuminate.
Turn circuit breakers CB1 and CB2 ON (“1” position).
Turn the mode selector switch to the “OFF” position. Wait for
Pressure (start) is factory preset at 1 PSI.
engine to stop. Turn the mode selector switch to the “Manual”
Turn the mode selector switch to the “OFF” position position.
Disconnect the factory installed interlock jumper wire located Press the Crank #2 pushbutton. The Engine will crank and start,
on terminals 11 and 39 the “Engine Run” annunciator will illuminate.
Ensure that the Diesel is programmed to user’s specifications. Turn the mode selector switch to the “OFF” position. The
Refer to section 6 in this manual. engine will stop.