The KS-105 is a compact, integrated engine monitoring and control panel designed for manual start and stop operations, primarily for Yanmar engines. It features a robust, powder-coated steel case with welded corners for enhanced support and minimized vibration, allowing direct mounting into an engine's mounting foot. The internal electronics module is potted, providing water tightness and superior vibration/shock protection, making it suitable for demanding environments.
Function Description:
The KS-105 serves as a manual engine control panel, providing essential monitoring and start/stop functionalities. It incorporates a key switch with four positions: OFF, RUN, CRANK, and PRE-HEAT.
- Engine Start and Crank Protection: When the key is turned to the CRANK position, the KS-105 energizes the crank signal, fuel pull signal, and fuel hold signal to initiate engine cranking. It includes an over-crank protection feature that discontinues cranking after 30 seconds if the engine doesn't start. Additionally, a starter re-engage protection prevents the starter from engaging while the engine is already running by disabling the crank signal.
- Engine Pre-Heat/Glow Plug Control: In the PRE-HEAT position, the KS-105 energizes the pre-heat signal for a default period of 4 seconds. This period can be extended to 10 seconds if engine connector pin W1 (pre-heat interval select) is grounded. The yellow GLOW PLUG lamp illuminates during pre-heat operation. The glow plug signal is also energized during cranking.
- Engine Stop: Turning the key switch to the OFF position stops the engine.
- Engine Safety Shutdowns: The panel is equipped with safety shutdown features for critical engine conditions:
- Low Oil Pressure: Triggers a shutdown if oil pressure falls below a specified threshold. There is a 10-second bypass period during engine start to allow pressure to build.
- High Engine Temperature: Initiates a shutdown if the engine temperature exceeds a specified limit.
- Shutdown bypass is active for 10 seconds during engine start.
- Altitude Compensation: The panel supports altitude compensation, indicated by a dedicated lamp, when a signal is received from an engine-mounted altitude compensation module.
- Hour Meter: An integrated hour meter displays the engine's total run hours.
- Provisions for Auto Start: The KS-105 is designed with an architecture that allows for future upgrades to an auto-start version within the same product platform.
Important Technical Specifications:
- Voltage:
- Input Voltage Range: 7-28V
- Nominal Operating Voltage: 12.6V
- Reverse Battery Protection: 15.0V
- Load Dump Protection: 60.0V
- Module Operating Current Draw (Outputs Off): 10.0mA
- Module Operating Current Draw (Maximum): 3.10A
- Operating Range: 5.5 VDC to 36 VDC
- Temperature:
- Operating Temperature Range: -40°C to 80°C (-40°F to 176°F) for the potted electronics module.
- Operating Temperature Range (overall): -40°C to 125°C
- Storage Temperature Range: -50°C to 130°C
- Operating Relative Humidity Range: to 80%RH
- Storage Humidity Range: to 95%RH
- Output Drive Capacities:
- Fuel Hold: 3A
- Fuel Pull (Independent Power Source): 150.0mA
- Glow Plug (Independent Power Source): 150.0mA
- Starter (Independent Power Source): 150.0mA
- Panel Ratings: 3 Amp Maximum
- Fuel Hold: 2.1A max @ 12V sourcing
- Crank and Preheat: 500mA max (Close to Ground)
- Inputs:
- Wetting current @ 12V (Lo Oil P, Hi Temp Trips): 8.0mA
- Wetting Current Preheat Interval: 200.0uA
- Vibration:
- Random Wide-Band Acceleration: 20g for 25 hours
- Sine Wave Frequency Range: 10-200Hz
- Sine Wave Acceleration (Exciter): 24.53m/s² (2.5g)
- Sine Wave Test Duration: 3 hours per axis
- Sine Wave Sweep Rate: 9 minutes
- Shock:
- Functional: 196m/s² (20g)
- Destructive: 980m/s² (100g)
- Dimensions: Approximately 7.14 inches (height) x 3.62 inches (width) x 4.88 inches (depth).
Usage Features:
- High Intensity LED Lamps: Five high-intensity LED lamps provide clear visual indications for:
- Oil Pressure (red): Illuminates when oil pressure is low.
- Coolant Temperature (red): Illuminates when engine temperature is high.
- Alternator Charge (red): Illuminates when an alternator excite signal is received.
- Glow Plug (yellow): Illuminates during pre-heat and cranking.
- Altitude Compensation (green): Illuminates when the altitude compensation signal is active.
- Water Tight Key Switch: The key switch is an independently water-tight component, rated IP67, with a plug-and-play connector. Individual keys are protected by a rubber boot.
- Plug and Play Connector: The KS-105 utilizes a 10-inch pigtail to a Delphi 15422562 connector for easy integration with the Yanmar engine harness.
- Selectable Pre-Heat Interval: The pre-heat duration can be selected between 4 or 10 seconds by grounding a specific circuit (connector pin W1).
- Product Identification: Each panel includes a product label with the part number (KS-105) and an individual serial number for identification.
Maintenance Features:
- Replacement Components: The manual provides a detailed list of replacement components, including the enclosure, graphic overlay, monitoring board/harness, hour meter, key switch assembly, hardware, screws, washers, and spacers. This facilitates easy ordering and replacement of parts.
- Technical Assistance: Controls Inc offers technical assistance for operational and troubleshooting questions, reachable by phone. Users are advised to have the product part number and serial number available when contacting support.
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