ENGINE PROTECTION CONTROL

TYPE DIP-806/00
INSTRUCTION AND USER MANUAL

FOR ENGINE STOPPAGE ANOMALY

(VIA ELECTROMAGNET OR SOLENOIDS) FOR:

• LOW COOLING LIQUID LEVEL

• INEFFICIENT BATTERY CHARGE ALTERNATOR (BELT
BREAKAGE)
• LOW OIL PRESSURE
• OVERHEATING
• FUEL RESERVE (without engine stopping )
• OVERSPEED. The signal generators are: pre-excitation alternator
from terminal W, or permanent magnet alternator from the yellow
wire, or magnetic transducer (pick-up).

OIL AND BATTERY INDICATORS INCORPORATED IN CONTROL

PARMA ® ITALY

Tel. +39 0521/772021 Fax +39 0521/270218

E-mail: info@elcos.it - HTTP://www.elcos.it
GB DIP-806/00 /2 1
 ENGINE PROTECTION CONTROL TYPE DIP-806/00
This surveys the diesel engine while it is running, and orders stoppage if there are anomalies in the components
controlled by probes.
It has been constructed to be inserted in dashboards, electrical panels, etc...

NOTICES
Warning:
adhere closely to the following advice
- Always install it below equipment that produces or spreads heat.
- When making connections, always follow the enclosed circuit diagram.
- Make sure that the power drain and consumption of the connected equipment is compatible with the
enclosed technical characteristics.
- All technical interventions must be performed with the engine stationary and with terminal 50 of the start
motor disconnected.
- Never use the battery charger for emergency start-up, this could damage the engine protection control.
- To ensure the safety of both persons and the equipment, disconnect the eletrical plant terminals from the
battery poles before connecting an external battery charger.

NOTE: THE HOLE MADE IN THE ENCLOSURE FOR EQUIPMENT INSTALLATION COULD INFLUENCE THE
DEGREE OF PROTECTION OF BOOTH. MEASURES MUST BE TAKEN TO MAINTAIN THE
ORIGINAL DEGREE OF PROTECTION.

THIS DEVICE IS NOT SUITABLE FOR OPERATING UNDER THE FOLLOWING CONDITIONS:
- where the environmental temperature is outside the limites specified in the enclosed technical sheet.
- where there are high levels of heat radiation due to the sun, furnaces, etc.
- where there is the risk of fires or explosions.
- where the device could receive knocks or strong vibrations.

ELECTROMAGNETIC COMPATIBILITY
This protection control functions correctly only if it is inserted in plants that meet CE marking standards. The
protection control meets the requirements of standard EN50082-2, but malfunctions cannot be excluded in
extreme situations.
The installer has the ask of ascertaining that the disturbance levels are below those set out in the standards.

RUNNING AND MAINTENANCE

The following maintenance operations should be performed every week:
- Chek that the indicators work
- Check the condition of the batteries.
- Check that the conductors are tight and check the condition of the terminals.

UNLESS WE MAKE A WRITTEN DECLARATION STATING THE CONTRARY, THIS PANEL IS NOT SUITABLE
FOR USE AS A CRITICAL COMPONENT IN EQUIPMENT OR PLANTS RESPONSIBLE FOR KEEPING
PERSONS OR OTHER LIVING BEINGS ALIVE.

YOUR ELECTRICAL TECHNICIAN CAN TELEPHONE OURS FOR ANY INFORMATION

CONCERNING THIS ENGINE PROTECTION CONTROL
2 GB DIP-806/00 /2
 FUNCTIONS

START KEY (EXTERNALLY MOUNTED)

0
- REST
- MANUAL STOP
- RESET PROTECTION CONTROL
AUT.
- PROTECTION CONTROL SUPPLIED

START.
- ENGINE START-UP

TWIN FUNCTION INDICATORS

- OIL AND BATTERY INDICATORS

On when the key is turned to "AUT". Off when the engine is running with the oil pressure and battery
charging system functioning correctly.
- ANOMALY INDICATORS
Enabled when the ACTIVE PROTECTIONS indicator lights up, they light up when the relevant
anomaly is detected.

ENGINE PROTECTIONS
The overspeed protection is enabled immediately with the key turned to "AUT". All of the other
protections are enabled when the ACTIVE PROTECTIONS indicators lights up (20 seconds after
the key is turned to "AUT" or 20 seconds after the start pulses have finished).
When the protection probes (mounted on the engine) intervene, the engine is stopped. These
interventions are shown by the relevant indicators and can be divided into two groups:

Immediate for: After 3 second delay:

- OIL PRESSURE SWITCH - COOLING LIQUID LEVEL PROBE

- OVERHEATING THERMOSTAT
- BATTERY CHARGE ALTERNATOR
(alternator belt breakage)

- OVERSPEED

BATTERY CHARGE
ALTERNATOR (terminal W)

MAGNETIC TRANSDUCER
(pick-up)

PERMANENT MAGNET
ALTERNATOR (yellow wire)

GB DIP-806/00 /2 3
 FUNCTIONS

ALARM
(FUEL RESERVE )
Enbled with key in "AUT" position. The engine does not stop.

STOP

Obtained in two ways:

- by turning the start key to zero
- when protections intervene.

The protection device uses two different types of stoppage:

- activating the ELECTROMAGNET which pulled the STOP lever for 20 seconds
- disconnecting the supply to the SOLENOID which closes the gasoline passage.

GENERAL ALARM

Obtained through the external mounting of a visual and/or acoustic indicator wich is connected to
the relevant output.
If the alarm (fuel reserve) or protections intervene, it is activated permanently.
RESET: Turn the start key to zero.

4 GB DIP-806/00 /2
 ENGINE PROBES TEST
(WITH PROBES DISCONNECTED)

FUNCTION PERFORMED TEST

LOW COOLING RESISTANCE BETWEEN PROBE AND EARTH:

LIQUID LEVEL W - WITH LIQUID: MAX 6000 W
RADIATOR - WITHOUT LIQUID: ABOVE 6000 W
PROBE

YELLOW
RED
YELLOW 3W USUALLY RELEVANT
CHARGE ENGINE ALTERNATOR
ALTERNATOR GRGB L C STATIONARY
TERMINAL IS
PERMANENT ENGINE RUNNING NEGATIVE WITH
(BELT MAGNET ~ R ~ + LE WITH REGULAR ENGINE STATIONARY
BREAKAGE) ALTERNATOR BELT
D+ ENGINE RUNNING
WITH BROKEN
B+ BELT
PRE-EXCITATION
ALTERNATOR

3W USUALLY OIL
LOW OIL ENGINE
STATIONARY PRESSURE SWITCH
PRESSURE TERMINAL IS
ENGINE RUNNING NEGATIVE WITH
WITH REGULAR ENGINE STATIONARY
LOW OIL PRESSURE
PRESSURE
ENGINE RUNNING
WITH INSUFFICIENT
PRESSURE

3W
OVERHEATING ENGINE AT THERMOSTAT
NORMAL TERMINAL IS
TEMPERATURE USUALLY NEGATIVE
OVERHEATED WHEN ENGINE IS
THERMOSTAT ENGINE TOO HOT

W 3W
FUEL RESERVE USUALLY FLOAT
SUFFICIENT
FUEL
TERMINAL W IS
NEGATIVE WHEN
INSUFFICIENT FUEL IS LOW
FUEL

FLOAT

USE VOLTMETER TO CHECK WITH ALTERNATING CURRENT

OVERSPEED
V~
- PRE-EXCITATION W
ALTERNATOR B+ 6 ÷ 20 VAC
TERMINAL W D+

- MAGNETIC V~
TRANSDUCER 2 ÷ 20 VAC

YELLOW
RED
YELLOW
- PERMANENT V~
MAGNET GRGB L C
4 ÷ 50 VAC
ALTERNATOR
YELLOW WIRE ~ R ~ + LE

NOTE: WHEN THE TEST HAS BEEN COMPLETED RECONNECT THE PROBES
GB DIP-806/00 /2 5
 CIRCUIT

WARNING: DO NOT LINK THE CHARGE CONTROL LAMP TO THE UNIT

30 85
(USE THE STOP LEVER OR
INTERRUPT THEFUEL FLOW)
87 86

2/7

W
157
h 3W
MAX 3
FUSE 48
30 5A

1 50

15/54 FUSE
5A 4 16
30
50

40 41

1 2 3 5 6 7 8 29 30 31 37 39 40
W
B+
D+ DIP-806/00
28 9 13 14 33
(BELT BREAKAGE)

YELLOW OVERSPEED
ADJUSTMENT
RED
YELLOW

GRGB L C

27
~ R ~ + LE
FOR OVERSPEED CONTROL
26 CONNECT TERMINAL 9
OR TERMINALS 13-14
(NOT BOOTH)
ENGINE FLYWHEEL TEETH

DISTANCE
0.5 mm ±0.2

ENGINE NUT AND

CASING COUNTER-NUT

35

6
GB DIP-806/00 /2
 DIAGRAM

SEE "TWIN FUNCTION INDICATORS" ON PAGE 3

OVERSPEED ADJUSTMENT
To calibrate the intervention threshold, perform the following operations in the order indicated:
- Connect the relevant terminals of the protection control.
- Start the engine and bring it up to the speed at wich one wishes the protction control to intervene.
- Turn the trimmer anti-clockwise, stopping when the indicator switches on (set at its maximum).
- The calibrating trimmer has 20 revolutions and each revolution is approximately equal to 300 engine revolutions.
- Turn the start key to zero (reset).
- Repeat the start-up phase and check, by accelerating the engine, that the device intervenes at the chosen threshold.
When the adjustment operations have been terminated, the potentiometer screw should be secured with enamel.
NOTE:
If the connection between the protection control and the charge alternator or magnetic transducer
(pick-up) is broken, the overspeed intervention occurs.

DRIVE
STOP SYSTEMS SET UP EXCITATION
The system is arranged to command SOLENOID
the stopping with SOLENOID. for closing
diesel
For ELECTROMAGNET stopping,
connect terminals 39 and 40. STOP
EXCITATION ELECTROMAGNET
for pulling
STOP lever
39 40

WARNING ACCESSORIES
IF THE FOLLOWING AVAILABLE ON REQUEST
FUNCTIONS ARE NOT (1) START KEY
USED: (2/7) ELECTROMAGNET OR SOLENOID
• OVERSPEED (3) OIL PRESSURE SWITCH
BRIDGE BETWEEN (4) THERMOSTAT
TERMINALS 9 - 13 (16) FUEL FLOAT
9 13 14 (35) MAGNETIC TRANSDUCER (TYPE TM30/50, /60, /85)
(48) HOUOR COUNTER
• LOW COOLING (155) RADIATOR LIQUID LEVEL PROBE
LIQUID LEVEL (157) INDICATOR (MAIN ALARM)
CONNECT TERMINAL MOUNTED ON THE ENGINE
33 TO EARTH (26) PERMANENT MAGNET CHARGE ALTERNATOR
33 (27) ALTERNATOR REGULATOR
(28) PRE-EXCITATION CHARGE ALTERNATOR
(40) START MOTOR
(41) BATTERY

COOLING LIQUID LEVEL PROBE

FOR RADIATORS WITH FOR RADIATORS WITH
PLASTIC EXPANSION TANKS METAL EXPANSION TANKS

155 155
SCREW ROD
ELECTRODES ELECTRODE
7
GB DIP-806/00 /2
 DEVICE TEST
(SIMULATION)
FUNCTION PERFORMED INTERVENTION SIMULATION FUNCTIONS INTERVENTION
(WITH ACTIVE PROTECTIONS (STOP, GENERAL ALARM
AND VISUAL
INDICATOR ON) INDICATOR ON)

LOW COOLING DISCONNECT TERMINAL OF ROD AFTER 3 SECONDS

LIQUID LEVEL MOUNTED ON RADIATOR

CHARGE DISCONNECT WIRE FROM TERMINAL AFTER 3 SECONDS

ALTERNATOR [8] OF DEVICE AND CONNECT
(BELT BREAKAGE) TERMINAL [8] TO EARTH

LOW OIL DISCONNECT WIRE FROM TERMINAL IMMEDIATELY

PRESSURE OF OIL PRESSURE SWITCH AND
CONNECT TO EARTH

OVERHEATING DISCONNECT WIRE FROM TERMINAL IMMEDIATELY

OF THERMOSTAT AND CONNECT
TO EARTH

AFTER 3 SECONDS
FUEL RESERVE DISCONNECT WIRE FROM TERMINAL RELAVANT INDICATOR
W OF FLOAT AND CONNECT TO EARTH LIGHTS UP, BUT ENGINE
DOES NOT STOP

OVERSPEED ACCELERATE ENGINE TO MAXIMUM IMMEDIATELY

SPEED, TURN THRESHOLD
ADJUSTMENT DEVICE SLOWLY
ANTI-CLOCKWISE
(SEE ADJUSTMENTS ON PAGE 7)

NOTE
WHEN THE SIMULATION HAS BEEN COMPLETED, MAKE SURE THAT ALL CONNECTIONS AND
CALIBRATIONS ARE RETURNED TO THEIR ORIGINAL POSITIONS.

TROUBLE SHOOTING

TYPE OF PROBLEM PROBABLE CAUSES REMEDIAL INTERVENTIONS

STARTING MOTOR - No fuel - Fill tank

FUNCTIONS BUT
ENGINE DOES NOT - Fuel supply circuit defect - Check that stop system functions correctly
START (electromagnet or solenoid)
- Consult instructions in engine manual

- Low temperature - Check that pre-heating is functioning

8 GB DIP-806/00 /2
 TROUBLE SHOOTING

TYPE OF PROBLEM PROBABLE CAUSES REMEDIAL INTERVENTIONS

ENGINE STOPPAGE - Low cooling liquid level - Check cooling liquid level
FOR ANOMALY indicator is on

- Belt breakage indicator - Check condition of alternator belt

is on after ACTIVE
PROTECTIONS
indicator lights up

- Low oil pressure - Check engine oil level

indicator is on after
ACTIVE
PROTECTIONS
indicator lights up

- Overheating indicator is - Check engine cooling system

on

- Overspeed indicator is - Check the speed control system

on

Before restarting the engine, make

sure that it is possible to stop it by
blocking the suction pipe.

ENGINE DOES NOT - Stop system (electromagnet - Check the correct mechanical or electrical
STOP or solenoid) is not functioning functioning of the stop system. If the
problem persists, check the stop servorelay.

- Defective engine probes - Check the probes (see ENGINE PROBES

TEST on page 5) and if necessary replace
them

- Defective protection - Check that voltage is correct on terminal [5]

during stop phase (see STOP on page 4),
simulate the function (see PROTECTION
CONTROL TEST on page 8) and if
necessary replace protection control [*]

GB DIP-806/00 /2 9
 TROUBLE SHOOTING

TYPE OF PROBLEM PROBABLE CAUSES REMEDIAL INTERVENTIONS

ENGINE STOPPAGE - Low cooling liquid level - Check probe, clean it, if necessary replace
FOR ANOMALY, indicator is on it
ALTHOUGH ALL SEEMS
TO FUNCTION - Belt breakage indicator - Check charge alternator functions correctly
is on after ACTIVE
PROTECTIONS
indicator lights up

- Low oil pressure - Check, and if necessary replace oil

indicator is on after pressure switch
ACTIVE
PROTECTIONS
indicator lights up

- Overheating indicator is - Check, and if necessary replace thermostat

on

- Overspeed indicator is - Check generator voltage (charge alternator

on W, magnetic transducer, permanent magnet
alternator yellow wire) see ENGINE
PROBES TEST on page 5

- Defective device - Simulate the function of the protection

control (see PROTECTION CONTROL
TEST on page 8), check for anomaly
indicated and if necessary replace
protection control [*]

To reset function turn key to zero

[*] PROTECTION CONTROL REPLACEMENT

Before replacing the protection control, one of our technicians should be telephoned for advice.
When your electrical-technician telephones, he should have the schemes on pages
6-7 available together with the following information:
- Type of equipment installed
- Problem
- Appearance of indicators on dashboard when problem occurred
- Any previous remedial action taken

10 GB DIP-806/00 /2
 ACCESSORIES AVAILABLE ON REQUEST

RADIATOR LIQUID LEVEL PROBE

ROD ELECTRODE
(COMPLETE WITH:
RIVET JUNCTION, BOLT,
NUT, WASHER, GASKET
AND FEMALE
CONNECTOR)
type AST-015/00 code 24.10.12
SCREW ELECTRODES
(COMPLETE WITH:
TERMINALS)

type E 25 code 19.01.15

FRONT PIECE 48 × 96

BOTH HORIZONTAL AND VERTICAL

MOUNTING ARE POSSIBLE

107

FRONT PIECE 48 × 96
(COMPLETE WITH:
FIXING SCREWS,
HORIZONTAL AND
VERTICAL PLATE)
105
type F806 code 26.16.22

EXAMPLE OF MOUNTING
Drill holes into the panel Remove the plate Screw protection control Apply the sticky plate
using the front piece as a from protection control and front piece onto the
template panel

Ø5

FOR OTHER ACCESSORIES AVAILABLE ON REQUEST SEE PAGE 7

SUPPLIED ACCESSORIES DATA FOR ORDERING

MOBILE SOCKETS ENGINE PROTECTION CONTROL

type PMO-134/00 code 80.42.34 type DIP-806/00 12 V code 03.02.05

type PMO-135/00 code 80.42.35 type DIP-806/00 24 V code 03.02.06

GB DIP-806/00 /2 11
 DIMENSIONS TECHNICAL DATA

- BATTERY SUPPLY 12 VDC (MAX 16 VDC)

VOLTAGE or 24 VDC (MAX 32 VDC)

- POWER DRAIN WITH KEY AT ZERO 8 mA

- MAX POWER OUTPUT [5] 3A

Ø 86
7.5

(STOP)

- MAX POWER OUTPUT [7] 3W

(GENERAL ALARM)
49.5
57

Ø 80 - OVERSPEED FREQUENCY INTERVENTION

67

• W / YELLOW 100 ÷ 1200 Hz

• MAGNETIC TRANSDUCER 800 ÷ 9600 Hz

- TEMPERATURE RANGE -10 ÷ +60 °C

- TERMINAL BOARD FASTON 6.35 × 0.8

- DEGREE OF PROTECTION
FOR THE ELECTRONICS IP 65
FOR THE TERMINAL BOARD IP 00

- WEIGHT 460 g

CONFORMITY DECLARATION

We take full responsability for declaring that the equipment:

type: DIP-806/00
used in the ways and for the purposes described in this instruction and user
manual is in conformity with the following directive:
89/336/CEE concerning electromagnetic compatibility
modified by the directive 93/68/CEE
being manufactured and functioning in accordance with the harmonized
standards:
EN 50081-1, EN 50082-2

® Parma, 15/10/1998
S.r.l. President
Via Naviglio Alto, 24/a
43100 PARMA ITALIA
Tel. +39 0521/772021 Fax +39 0521/270218
E-mail: info@elcos.it - HTTP://www.elcos.it
Walter Consigli

12 GB DIP-806/00 /2