PowerWizard_Technical_1-1_1-1plus_2-1

PowerWizard1.1,1.1+&2.1GeneratingSetControlTechnicalManual

CONTENTS

IMPORTANTSAFETYINFORMATION5

1.GENERALINFORMATION61.1Introduction.....................................................................................................................................................61.2Applications.....................................................................................................................................................61.3PowerWizardVariations...............................................................................................................................61.4PowerWizardControlModuleDescription...............................................................................................7

2.USERINTERFACEOVERVIEW82.1HotKeys...........................................................................................................................................................82.2ControlKeys.....................................................................................................................................................82.3NavigationKeys..............................................................................................................................................82.4EventKeysandIndicators............................................................................................................................9

3.DETAILEDOPERATION103.1PowerWizardMenuTrees...........................................................................................................................103.2TechnicalOperation.....................................................................................................................................113.2.1EngineStartingSequence.........................................................................................................................................113.2.2EngineStoppingSequence......................................................................................................................................113.2.3EventSystem.................................................................................................................................................................113.2.4EventState......................................................................................................................................................................113.2.5EventViewing...............................................................................................................................................................123.2.6SingleEventResetting................................................................................................................................................123.2.7AllEventsResetting.....................................................................................................................................................123.3Security...........................................................................................................................................................123.4RealTimeClockProgramming(PowerWizard2.1)..................................................................................133.5FuelPrimingEngineswithElectronicFuelLiftPump.........................................................................133.6FuelTransfer(PowerWizard2.1).................................................................................................................143.7ProgrammableCycleTimer(PCT)(PowerWizard2.1).............................................................................143.7.1PCTStatus........................................................................................................................................................................143.7.2ControllingTheOutputs............................................................................................................................................143.7.3PCTExample:.................................................................................................................................................................144.INSTALLATION154.1PowerRequirements....................................................................................................................................154.2LocationConsiderations..............................................................................................................................164.3ElectricalConnections.................................................................................................................................164.4WindingConnections..................................................................................................................................174.5TransformerConnections............................................................................................................................184.6DataLinks......................................................................................................................................................194.6.1PrimaryJ1939DataLink(CAN1)...............................................................................................................................194.6.2AccessaryJ1939DataLink.........................................................................................................................................214.7OptionalModules.........................................................................................................................................224.7.1Annunciator(MCM9)....................................................................................................................................................224.7.2PowerWizardSupportoftheAnnunciator.........................................................................................................22

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5.SETPOINTPROGRAMMING245.1DigitalInputProgramming........................................................................................................................245.1.1DigitalInputs..................................................................................................................................................................245.1.2DedicatedDigitalInputs............................................................................................................................................245.1.3ProgrammableDigitalInputs...................................................................................................................................255.2RelayandDigitalOutputProgramming...................................................................................................265.3AnalogueInputProgramming...................................................................................................................29

6.RETROFITTINGPOWERWIZARDS316.1ESTAvailabilityandLicensing....................................................................................................................316.2FlashFilesandFieldReplacementFiles...................................................................................................316.3PossibleESTerrormessages,theircauseandsuggestedaction.........................................................34

7.STEPTHROUGHGUIDES357.1ReducedPowerMode(RPM)......................................................................................................................357.2ServiceMaintenanceInterval....................................................................................................................367.2.1ResetServiceInterval.................................................................................................................................................367.2.2ChangeDurationofServiceIntervalAlarm.........................................................................................................367.2.3DisableServiceIntervalAlarm.................................................................................................................................367.3SettingupLanguage...................................................................................................................................367.4DisablingNOTINAUTO...............................................................................................................................377.5DisablingThermoStart(StartAidActivation).........................................................................................37

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APPENDIXASPN/FMILIST38

APPENDIXBSETPOINTTABLES431.1Control...........................................................................................................................................................431.1.1AutomaticStart/Stop...................................................................................................................................................431.1.2AVRDesiredVoltage....................................................................................................................................................441.1.3GovernorDesiredEngineSpeed............................................................................................................................441.2EngineMonitor/Protect.............................................................................................................................441.2.1BatteryVoltageMonitor.............................................................................................................................................441.2.2Crank/StartCounter..................................................................................................................................................441.2.3EngineSpeedMonitor................................................................................................................................................451.2.4EnhancedEngineMonitor.........................................................................................................................................451.2.5ServiceMaintenanceInterval...................................................................................................................................451.3Events.............................................................................................................................................................451.4GeneratorMonitor/Protect.......................................................................................................................461.4.1Enhancedgeneratormonitor...................................................................................................................................461.4.2GeneratorACmonitor................................................................................................................................................461.4.3GeneratorACpowermonitor..................................................................................................................................461.4.4Generatorovercurrent..............................................................................................................................................471.4.5GeneratorOver/UnderFrequency.......................................................................................................................471.4.6GeneratorOver/UnderVoltage.............................................................................................................................471.4.7GeneratorReversePower..........................................................................................................................................471.5Network..........................................................................................................................................................481.6ReducedPowerMode..................................................................................................................................481.7Inputs&Outputs..........................................................................................................................................481.7.1DigitalInputs..................................................................................................................................................................481.7.2DigitalOutputs..............................................................................................................................................................481.7.3RelayOutputs................................................................................................................................................................481.7.4AnalogueInputs............................................................................................................................................................48

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IMPORTANTSAFETYINFORMATIONMostaccidentsthatinvolveproductoperation,maintenanceandrepairarecausedbyfailuretoobservebasicsafetyrulesorprecautions.Anaccidentcanoftenbeavoidedbyrecognizingpotentiallyhazardoussituationsbeforeanaccidentoccurs.Apersonmustbealerttopotentialhazards.Thispersonshouldalsohavethenecessarytraining,skillsandtoolstoperformthesefunctionsproperly.

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ControllersSeriesFeaturesPowerWizard1.1PowerWizard1.1+PowerWizard2.1

ACVolts,CurrentandFrequencymeteringXXX

ACPowermetering--X

DCmeteringBattVolts,EngineHoursRun,rpm,EngineTemperatureandOilPressureXXX

AnalogueInputs233

ProgrammableInputChannels466

ProgrammableRelayOutputs668

ProgrammableSinkOutput002

RealTimeClock--X

40EventFaultLogXXX

2DisplayLanguages(customerlanguage+TechEnglish)XXX

ServiceIntervalCounter--X

CAN1J1939DataLinkXXX

CAN2J1939DataLink--X

SCADARS485Modbusremotemonitoringandcontrol--X

1.GENERALINFORMATION

1.1Introduction

Figure1:PowerWizardControlPanelThecontrollerisavailableinthreeversions,PowerWizard1.1,PowerWizard1.1+andPowerWizard2.1.Thesearebasedondifferentfeaturesets.ThisApplicationandInstallationGuideisintendedtocoverthePowerWizardGeneratingsetControlanditsapplicationingeneratingsetsystems.Theintendedaudienceforthisguideincludesgeneratingsetsystemdesigners,servicesupportpersonnel,dealersandservicetechnicians,contractorsandcustomers.1.2ApplicationsThePowerWizardproductlineofgeneratingsetcontrollersisdesignedforuseinawiderangeofapplications.TheycanbeusedonstandbyandprimepowerdieselgeneratingsetsincludingFGWilsonandOlympianbrands.Theconfigurabilityofthecontrollersallowsthemtobeused,insomecases,onotherapplicationssuchasMarineauxiliarygeneratingset,switchgearapplications,industrialenginesandgeneratingsetsaswellasgasgeneratingsets.1.3PowerWizardVariations

Someofthedifferentfeaturesofthethreeversions,PowerWizard1.1,PowerWiard1.1+andPowerWizard2.1arelistedinTable1.Table1:FeaturesavailableonPowerWizardModules6

1.4PowerWizardControlModuleDescription

1

234

56

7

89101112

131415

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1.Displayscreen2.ACoverviewkey3.Engineoverviewkey4.Mainmenuorhomekey5.Alarmacknowledgekey6.Eventresetkey7.Eventlogkey8.Autokey9.Stopkey10.Runkey11.Escapekey12.Upkey13.Rightkey14.OKorEnterkey15.Downkey16.Leftkey

Figure2:PowerWizardControlModuleDescription

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2.USERINTERFACEOVERVIEW

2.1HotKeysACOverviewkeyTheACOverviewkeywillnavigatethedisplaytothefirstscreenofACinformation.TheACOverviewinformationcontainsvariousACparametersthatsummarisetheelectricaloperationofthegeneratingset.(Usetheup/downkeystonavigatewithintheACparameters.)

EngineOverviewkeyTheEngineOverviewkeywillnavigatethedisplaytothefirstscreenofengineinformation.TheEngineOverviewinformationcontainsvariousengineparametersthatsummarisetheoperationofthegeneratingset.(Usetheup/downkeystonavigatewithintheEngineparameters.)

MainMenukeyTheMainMenukeywillnavigatethedisplaytothemainmenuscreen.Pressingthenavigationkeyswillallowaccesstomenusatalllevels.2.2ControlKeysRUNPressingtheRunkeywillcausetheenginetoentertherunmode.

AUTOPressingtheAutokeywillcausetheenginetoentertheautomode.

STOPPressingtheStopkeywillcausetheenginetoenterstopmode.2.3NavigationKeysScrollUpTheScrollUpkeyisusedtonavigateupthroughthevariousmenusormonitoringscreens.TheScrollUpkeyisalsousedduringsetpointentry.DuringnumericdataentrytheScrollUpkeyisusedtoincrementthedigits(09).Ifthesetpointrequiresselectionfromalist,theScrollUpkeyisusedtonavigatethroughthelist.

EscapeTheEscapekeyisusedduringmenunavigationinordertonavigateupthroughthemenu/sub-menustructure.Eachkeypresscausestheusertomovebackwards/upwardsthroughthenavigationmenus.TheEscapekeyisalsousedtoexit/canceloutofdataentryscreensduringsetpointprogramming.IftheEscapekeyispressedduringsetpointprogramming,noneofthechangesmadeonscreenwillbesavedtomemory.

ScrollRightTheScrollRightkeyisusedduringsetpointadjustment.Duringnumericdataentry,theScrollRightkeyisusedtochoosewhichdigitisbeingedited.TheScrollRightkeyisalsousedduringcertainsetpointadjustmentstoselectordeselectacheckbox.Ifaboxhasacheckmarkinside,pressingtheScrollRightkeywillcausethecheckmarktodisappear,disablingthefunction.Iftheboxdoesnothaveacheckmarkinside,pressingtheScrollRightkeywillcauseacheckmarktoappear,enablingthefunction.

the/OK/TheEnterkeyisusedTheEnterkeyisalsousedtoselectmenuitemsorderinordertosave/changes.OKEntermenusubmenustructure.duringmenunavigationduringsetpointprogrammingtonavigateforwardsetpointdownwardinPressingtheEnterkeyduringsetpointprogrammingcausessetpointchangestobesavedtomemory.

ScrollDownTheScrollDownkeyisusedtonavigatedownthroughthevariousmenusormonitoringscreens.TheScrollDownkeyisalsousedduringsetpointentry.DuringnumericdataentrytheScrollDownkeyisusedinordertodecrementthedigits(09).Ifthesetpointrequiresselectionfromalist,theScrollDownkeyisusedtonavigatedownthroughthelist.

ScrollLeftTheScrollLeftkeyisusedduringsetpointadjustment.Duringnumericdataentry,theScrollLeftkeyisusedtochoosewhichdigitisbeingedited.TheScrollLeftkeyisalsousedduringcertainsetpointadjustmentstoselectordeselectacheckbox.Ifaboxhasacheckmarkinside,pressingtheScrollLeftkeywillcausethecheckmarktodisappear,disablingthefunction.Iftheboxdoesnothaveacheckmarkinside,pressingtheScrollLeftkeywillcauseacheckmarktoappear,enablingthefunction.

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2.4EventKeysandIndicatorsYellowWarningLightAflashingyellowlightindicatesthatthereareunacknowledgedactivewarnings.Asolidyellowlightindicatesthatthereareacknowledgedwarningsactive.Ifthereareanyactivewarnings,theyellowlightwillchangefromflashingyellowtosolidyellowaftertheAlarmAcknowledgekeyispressed.Iftherearenolongeranyactivewarnings,theyellowlightwillturnoffaftertheAlarmAcknowledgekeyispressed.

RedShutdownLightAflashingredlightindicatesthatthereareunacknowledgedactiveshutdownevents.Asolidredlightindicatesthatthereareacknowledgedshutdowneventsactive.IfthereareanyactiveshutdowneventstheredlightwillchangefromflashingredtosolidredaftertheAlarmAcknowledgekeyispressed.Anyconditionthathascausedashutdowneventmustbemanuallyreset.Iftherearenolongeranyactiveshutdownevents,theredlightwillturnoff.

AlarmAcknowledgePressingtheAlarmAcknowledgewillcausethehornrelayoutputtoturnoffandsilencethehorn.Pressingthekeywillalsocauseanyyelloworredflashinglightstoturnoffortobecomesoliddependingontheactivestatusofthealarms.

EventResetKeyPressingtheEventResetkeywillresetalleventswhenthecontrolisinthestoppedposition.However,ResetAllEventswillnotresetPresentevents.

EventLogKeyPressingtheEventLogkeywillnavigatetotheActiveEventsmenu.Inordertoscrollthroughtheevents,usetheupanddownkeys.Afterhighlightinganevent,presstheOKkeytoseeinformationabouttheeventsuchastheSPNandtheFMI.

EMERGENCYSTOPPushbuttonAredlock-downpushbuttonthatimmediatelyshutsdownthegeneratingsetandwillinhibitstartuntilthepushbuttonhasbeenreleasedbyturningitclockwise.Priortorestartingtheset,thisfaultmustberesetbypressingtheStopbuttononthemoduleandresettingthefaultintheEventLogMenu.

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3.DETAILEDOPERATION

3.1PowerWizardMenuTrees

MainMenuViewControlConfigureSoftwareInfoPreferences

EventLogEngineOverviewACOverviewI/OStatusNetworkStaus

Volt/HzControlIdle/RatedFuelTransferEngineFuelPriming

SecurityInputs&OutputsAllSetpointsEngineOperatingHours

DigitalInputsRelayOutputsDigitalOutputsAnalogInputsPrimaryDatalink

DigitalInputsRelayOutputsDigitalOutputsAnalogInputs

ControlEngineMonitor/protectionEventsGenMonitor/protectionInputs&Outputs

PowerWizard1.1,1.1+MenuStructure

AutomaticStart/StopAVRDesiredVoltageGovDesiredSpeedFuelTransfer

BatteryVoltageMonitorEngineSpeedMonitor

DiagnosticRespConfigEngProtectRespConfigGenProtectRespConfigCustomerEventRespConfigOtherSystemRespConfig

GeneratorACMonitorGenOver/UnderFrequencyGenOver/UnderVoltage

ContrastPressureTemperatureLampTestLanguage

Figure3:PowerWizard1.1,1.1+MenuTree


MainMenuViewControlConfigureSoftwareInfoPreferences

EventLogEngineOverviewACOverviewI/OStatusNetworkStaus

DigitalInputsRelayOutputsDigitalOutputsAnalogInputsPrimaryDatalink

PowerWizard2.1MenuStructure

Volt/HzControlIdle/RatedProgramCycleTimerFuelTransferEngineFuelPrimingSecurityInputs&OutputsAllSetpointsEngineOperatingHoursRestCountersTime&Date

ContrastPressureTemperatureVolumeLampTestLanguage

Figure4:PowerWizard2.1MenuTree

AccesoryDatalinkMODBUSSerial

DigitalInputsRelayOutputsDigitalOutputsAnalogInputsControlEngineMonitor/protectionEventsGenMonitor/ProtectionNetworkReducedPowerModeProgTripPointsInputs&OutputsCrankCounterStartCounterServMaintIntervalkWhMeterkVArhMeter

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AutomaticStart/StopAVRDesiredVoltageGovDesiredSpeedS/DOverrideFuelTransferBatteryVoltageMonitorCrank/StartCounterEngineSpeedMonitorEnhancedEngineMonitorServiceMaintenanceIntervalDiagnosticRespConfigEngProtectRespConfigGenProtectRespConfigCustomerEventRespConfigOtherSystemRespConfigEnhancedGenMonitorGeneratorACMonitorGenACPowerMonitorGeneratorOverCurrentGenOver/UnderFrequencyGenOver/UnderVoltageGeneratorReservePowerDatalink-Serial


3.2TechnicalOperation

3.2.1EngineStartingSequence

1.

ThePowerWizardreceivesanenginestartsignal.Thesignalwillbeoneofthree.

TheoperatorpressestheRunkeyThecontrolisinautoandtheremoteinitiatedigitalinputbecomesactiveThecontrolreceivesastartcommandviatheRS-485SCADADataLink(PowerWizard2.1only)Thecontrolhasaprogramcycletimer(PCT)configuredthatbecomesactive(PowerWizard2.1only).

2.

3.4.

ThePowerWizardchecksthesystembeforebeginningthecrankingsequence.ThePowerWizardchecksthattherearenoshutdowneventspresentandthatallpreviousshutdowneventshavebeenreset.Iftheengineisequippedwithaformofstartaidsuchasthermostartitwillenteraprestartsequence.ThePowerWizardbeginsthecranksequencebyactivatingtheenginecrankrelayandthefuelcontrolrelay.

IftheenginereachesthesetpointforcrankterminatespeedtheengineisdeemedrunningandtheenginecrankrelaywillbedeactivatedIftheenginefailstostartwithinapresetduration(normallysevenseconds)thePowerWizardwillstopcrankingandwaitforapresettime(normallysevenseconds)beforeattemptingtostartagainIfthePowerWizardfailstostartwithinapresetnumberofcrankattempts(normallythree)thePowerWizardwillactivatea

FailtoStartshutdown.

3.2.2EngineStoppingSequence

1.

ThePowerWizardreceivesanenginestopsignal.Thesignalwillbeoneoffour.

TheoperatorpressesthestopKeyThecontrolisinautoandtheremoteinitiatedigitalinputbecomesinactiveThecontrolreceivesastopcommandviatheRS-485SCADADataLink(PowerWizard2.1)Thecontrolhasaprogramcycletimer(PCT)configuredthatbecomesinactive(PowerWizard2.1only)

2.

3.

ThePowerWizardbeginsthecooldownperiod.InordertobypassthecooldownholddowntheStopkeyfor3seconds.TheoptionsPRESSENTERTOBYPASSandPRESSESCAPETOCONTINUEwillbeshownonthedisplay.PresstheEnterkeytobypassthecooldownsequenceorpresstheEscapekeytocontinuethecooldownsequence.Afterthecooldowncycle,thePowerWizardstopstheenginebyturningoffthefuelcontrolrelay.

3.2.3EventSystemThePowerWizardmoduleusestheJ1939standardformatforevents,wherebyaneventisdefinedasacombinationofasuspectparameternumber(SPN)andafailuremodeidentifier(FMI).TheSPNdefineswhatisatfaultandtheFMIdefineshowitisatfault(e.g.SPN=100=OilPressure,FMI=1=LowShutdownwouldmeanthegeneratingsethasshutdownonalowoilpressurefault).AlistofSPN/FMIcombinationscanbefoundinappendixA.PowerWizardmoduleshaveseparateeventlogsforeventsraisedbythemoduleitselfandthoseraisedbyancillariessuchastheengineECM.

3.2.4EventStateEventsinPowerWizardmayexistinoneofthreestates,present,activeandinactive.PresentTheconditioncausingtheeventisongoingandaffectingsystembehavior.Ifaneventispresentitcannotbereset.ActiveTheeventisnolongerpresentandcanberesetbytheuser.Howeverithasbeenlatchedbytheeventsystemandneedstoberesetbeforetheenginecanberestarted.InactiveTheeventwasactiveatsometimebutisnolongeractiveandisnotaffectingsystembehaviour.Inactiveeventsexistforhistoricalpurposesonly.

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3.2.5EventViewingTherearetwowaystoviewevents.PressingtheEVENTLOGkeynavigatesdirectlytotheACTIVEEVENTSmenu.TheotherwayistousetheMainMenu:

1.

2.3.

4.

FromtheMAINMENU/VIEW,highlightEVENTLOGSandpresstheEnterkey.TheACTIVEEVENTSmenuwillbedisplayed.Inthismenu,alistofallinstalledECMswillalsobedisplayedwiththenumberofthetotalofpresentandactiveevents.HighlightanECMandpresstheenterkeytoviewthatECMseventlog.InordertoscrollthroughtheeventsusetheUpandDownkeys.Eventsareorderedwithpresenteventsfirst,activeeventsnextandinactiveeventslast.Withintheseclassificationstheyareorderedbyenginerunhours(orrealtimeclockonPowerWizard2.1).PressEnterafterhighlightinganeventtoseeadditionalinformationsuchasSPN,FMI,timeanddateoffirstoccurrence,time

anddateoflastoccurrence(PowerWizard2.1only),enginehoursatfirstoccurrenceandenginehoursatlastoccurrence.

3.2.6SingleEventResettingAflashingredshutdownlightindicatesthereisanunacknowledgedshutdownevent.TheredshutdownlightwillchangefromflashingredtosolidredwhentheAlarmAcknowledgedkeyispressed.Onceafaulthasbeencheckedandthecauserectified,usethefollowingprocedureinordertoresettheevent.

1.2.3.4.5.6.7.8.9.

PresstheStopkey.EntertheEVENTLOGSoptionfromtheMAINMENU/VIEW.SelectanECMfromthelist.Scrollthroughtheeventsinordertohighlighttheeventtobereset.Makesuretheeventstatusisactive(notpresent).PresstheEnterkey.RESETwillbehighlightediftheconditionisnolongerpresentandthecontrolisinstop.PresstheEnterkeyagain.Thefaultwillclear.PresstheEscapeorMainMenukeyinordertogetbacktothemainmenu.

3.2.7AllEventsResettingInadditiontotheaboveprocedurethereisalsoasimplifiedprocessforresettingalleventsforallmodules.Toresetallevents,

1.2.3.4.

Ensurethatthecontrolisinthestoppedposition.PresstheResetEventkeyfromanyscreen.Aconfirmationpromptwillappear.PresstheOKkeytoresetalleventsonallmodules.PresstheEscapekeytocanceltheresetoperation.Note:

ThePowerWizardmustbeinstopmodetoresetevents.Presenteventscannotbereset

3.3SecurityThereare3levelsofpasswordprotectiononthePowerWizardcontrolpanel.Alloftheadjustablesetpointsareassociatedwithaspecificlevelofsecurityrequiredtomakeanadjustmenttotheparameter.Thepasswordsonlyaffectchangingsetpointswithinthecontrolpanel.ChangingsetpointswiththeServiceTooldoesnotrequirepasswords.Thelevelofpasswordprotectionthatisrequiredforeachsetpointisidentifiedontheparametersetpointentryscreen.Asecuritylevelidentificationnumber1,2or3nexttoapadlocksymbolisdisplayedontheparametersetpointentryscreen.ALevel3securityisusedforthemostsecuresetpointsandLevel1securityisusedfortheleastsecuresetpoints.IfthePowerWizardiscurrentlyattherequiredlevelofprotectionwhenviewingaparameter,thepadlockwillnotappear.Ifaparameterisdisplayedwithapadlockbutnosecuritylevelidentificationnumbernexttoit,theparametercannotbechangedfromthePowerWizarddisplayandtheservicetoolmustbeused.Levels1and2passwordsaredisabledasshippedfromthefactory.Levels1Level2passwordsareuserlevelpasswordsandcanbeusedifdesired.ThePowerWizard2.1alsohasaSCADApassword,whichcanbeusedtosecureremotecommunications.Toviewthesecuritymenu,MAINMENU>CONFIGURE>SECURITYAtthetopofthesecuritymenuthecurrentsecuritylevelisdisplayed.Withinthesecuritymenuarethefollowingoptions,12

DROPTOMINLEVELusedtoreturnthecurrentsecurityleveltothelowestlevelsetup.HighlightandpressOKtodroptominimumlevelsecurity.IfnoLevels1or2passwordsaresetuptheminimumlevelwillbe2.IfaLevel2passwordissetup,theminimumlevelwillbe1andifaLevel1passwordissetuptheminimumlevelwillbe0.ENTERLEVEL1OR2usedtoenterLevel1or2passwords.HighlightandpressOKtoproceedtothepasswordentryscreen.Passwordscanbeenteredusingthecursorkeys.InPowerWizardLevel1and2passwordsmustbedifferent.AnenteredpasswordiscomparedagainstthestoredLevels1and2passwords,ifthepasswordiscorrectthePowerWizardwillgotothecorrespondingsecuritylevel.ENTERLEVEL3usedtoobtainLevel3access.TheLevel3securitypasswordisreservedforcriticalsetpointsthatshouldonlybechangedbyaskilledoperative.TheLevel3passwordisapromptandresponsepassword.HighlightandpressOKtoproceedtothephoneinpromptdisplay.TheLevel3passwordcanbeobtainedbycontactingthegeneratingsetmanufacturerandprovidingthe16digitphoneinprompt.Themanufacturerwillthenprovidetherelevantresponse.Toenterthe16digitresponsepressOKagain.Passwordscanbeenteredusingthecursorkeys.TheLevel3passwordwillexpire10minutesafterthelastkeypressed.TheLevel3passwordcanbeobtainedfromtheAfterSalesHelpdesk.Refertothecontactlistatthebackofthemanual.CHANGELEVEL1PASSWORDusedtosetup,changeordisableaLevel1password.InordertousethisfeaturethecontrolmustbeatcurrentsecurityLevel1orhigher.HighlightandpressOKtoproceedtothepasswordentryscreen.Tosetuporchangethepassword,enterthenewpasswordusingthecursorkeys.Passwordsmaybe16digitslong.TodisabletheLevel1securitypassword,setthepasswordto0.PresstheOKkeytosave.CHANGELEVEL2PASSWORDusedtosetup,changeordisableaLevel2password.InordertousethisfeaturethecontrolmustbeatcurrentsecurityLevel2orhigher.HighlightandpressOKtoproceedtothepasswordentryscreen.Tosetuporchangethepassword,enterthenewpasswordusingthecursorkeys.Passwordsmaybe16digitslong.Todisablethelevel2securitypasswordset,thepasswordto0.PresstheOKkeytosave.CHANGESCADAPASSWORD(PowerWizard2.1only)usedtosetup,changeordisableaSCADApassword.HighlightandpressOKtoproceedtothepasswordentryscreen.Tosetuporchangethepassword,enterthenewpasswordusingthecursorkeys.Passwordsmaybe16digitslong.TodisabletheSCADAsecuritypassword,setthepasswordto0.PresstheOKkeytosave.3.4RealTimeClockProgramming(PowerWizard2.1)Therealtimeclockprovidesinformationforthetimeanddateofanautomatictimebasedstart/stopcontrol.Italsoprovidesamechanismfortimestampsintheeventlog.Therealtimeclockisnotcalibratedandisforinformationonly.Thedateandtimearesetbytheuser.

1.

2.3.4.5.6.7.

Inordertosetthetimeordateformat:MAINMENU>CONFIGURE>TIME/DATETosetthetime,highlightthetimethenpresstheOKkeytwice.UsethecursorkeystosetthetimeandpresstheOKkeytosave.PresstheEscapekeytoreturn.Tosetthedate,highlightthedatethenpresstheOKkeytwice.UsethecursorkeystosetthedateandpresstheOKkeytosave.PresstheOKkeytoreturn.Tosetthedateformat,highlighteithertheFORMATDD/MM/YYorFORMATMM/DD/YYandpresstheOKkey.UsethecursorkeystoselecttherequireddateformatandpresstheOKkeytosave.

3.5FuelPrimingEngineswithElectronicFuelLiftPumpCertainenginesfittedwithanelectronicfuelpumpdonothaveamanual-primingfeatureontheengine.InthesecircumstancesthePowerWizardcanbeusedtoenergizethefuelliftpumpinordertoprimetheengine.

1.

2.3.

Inordertoprimethegeneratingset:MAINMENU>CONTROL>ENGINEFUELPRIMINGToprimethesetpresstherightcursorkey,thiswillinitiatea180secondprimingcycle.Toexittheprimingcyclepresstheleftcursorkey.Note:

Thegeneratingsetmayonlybeprimedwhenstoppedandtherearenoactiveorpresentshutdownconditions.

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3.6FuelTransfer(PowerWizard2.1)Fuelpumpinconnectionwithfuellevelmeasurementcanbecontrolledtotransferdieseltothefueltank.

1.

2.3.4.

InordertosettheFuelTransferoperation:MAINMENU>CONTROL>FUELTRANSFERTostartorstopfuelpump,highlightthePUMPCONTROLthenpresstheOKkey.UsethecursorkeytoselectSTARTFUELPUMPorSTOPFUELPUMPandpresstheOKkey.AutoFuelLoadPumpOnandOffthresholdsaresetat25%and75%respectively.

3.7ProgrammableCycleTimer(PCT)(PowerWizard2.1)TheProgrammableCycleTimer(PCT)featureallowstheoperatortoprogramtimeswhentwoindependenttasks,calledPCToutputs,willbeactivatedordeactivatedautomaticallyduringtheweek.Thisisusefulforcaseswheretwoormoregeneratingsetsarerequiredtoautomaticallysharethedutyofsupplyingaloadthroughouttheweek.Usingaprogrammablecycletimer,eachgeneratingsetcanbeprogrammedtostartandstopatpre-settimes.Thecooperationofatransferswitchisrequiredtoensurethatthegeneratingsetsarenotstoppedonload.ProgrammableCycleTimercanalsobeusedincaseswhereastandbygeneratingsetdoesnothaveaccesstoautilitysupplytopoweratricklecharger.TheProgrammableCycleTimercanbeusedtorunthegeneratingsetforanhouraweektokeepthebatterywellcharged.ThePCTfeatureconsistsofsevenindependenttimers.Eachtimerhasthefollowingsetpoints(setpointsshownareforPCT#1):

DayoftheWeekThispermitsindependentselectionofeachday(0=Sun,6=Sat)thatthetimerwillactivateStartTimeThetimeofday(inhoursandminutes)thatthetimerwillactivateRunFor-Theduration(inhoursandminutes)forwhichthetimerwillbeactive(upto24hours)Output#1Active(orInactive)Determinesthefirstoutputwillbeactivated(ornot)whenthistimerisactiveOutput#2Active(orInactive)Determinesthesecondoutputwillbeactivated(ornot)whenthistimerisactive.

Output#1isusedtorunthegeneratingset.Output#2canbeusedtodriverelayoutput8.PleaseseetheRelayOutputssectionformoreinformation.

3.7.1PCTStatusThestatusofthePCTscanbefoundwithinthemenustructureat:MAINMENU>CONTROL>PROGCYCLETIMER:

ThetoprowdisplaysthesevenPCTs(#1to#7)ThemiddlerowisforOUTPUT#1ThebottomrowisforOUTPUT#2

3.7.2ControllingTheOutputsThestatusofeachoutputisindicatedbya1,0or-inthePROGCYCLEcolumnunder#1to#71ThePCTisconfiguredandcurrentlydrivingtheoutput.0ThePCTisconfiguredbutnotcurrentlydrivingtheoutput.-ThePCThasnotbeenconfigured:

3.7.3PCTExample:

PCT#1isenabled-Output1isnotselected.Output2isselectedbutiscurrentlyinactive.PCT#7isenabledOutput1isselectedbutcurrentlyisinactive.Output2isnotselected.PCT#2toPCT#6aredisabled.TheywillnotactivateOutput1orOutput2.

PCTPCTPCT

OUTPUT1OUTPUT2

1234567------00------

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4.INSTALLATION

4.1PowerRequirementsThePowerWizardseriesofgeneratingsetcontrolsrequireanominalvoltageof12Vdcor24Vdc.Ifbatteriesareusedforoperatingpower,achargingsourcesuchasanalternatororbatterychargerisnecessarytomaintainastablesupplyvoltage.Understeadystateoperation,thePowerWizardcontrollerson12Vsetshavelessthan1Acurrentdraw(notincludinganyrelayloads).Thisvaluewillbelowerforcontrollerson24Vsets.Thiscurrentdraincanbereducedbyapproximatelyafactorof7byusingtheReducedPowerModeoption(RPM).Howeveritisrecommendedthatageneratingsetatrestorinstorageforprolongedperiodsshouldhaveeitherthebatterychargerorisolatorswitchoptionfitted.WhenconnectingthePowerWizardgeneratingsetcontroltotheDCpowersource,makesurethatthereisonlyonecommonconnectiontothenegativepotentialofthepowersource.MakeextraefforttoavoidanygroundloopsintheDCelectricalsystem.AsinglepointcommongroundforelectronicsisrecommendedatthenegativebatteryterminalorPowerDistributionBox.EachelectronicssubsystemandmajorenginesubsystemshouldhaveitsownDCnetworksothattheydonotinterferewitheachother.AnexampleisshowninFigure5.Asshowninthefigureallelectronicsareelectricallyisolatedfromhighercurrentloads,suchasthestartermotor.AllelectronicshaveacommonPowerBusandSinglePointReference.ThechassisgroundisacommonPowerandTransientGround.Theelectronics,suchassensorsandcontrolmodules,haveisolatedpowersourcepaths.Highcurrentloadssuchasstartersandsolenoidscancauseinterferenceandpossiblydamagetolowcurrentloads,suchascontrollersandsensors.Extraeffortmustbemadetokeepthehighcurrentandlowcurrentloadselectricallyseparated.Thetwotypesofloadsmaysharecommon(+)and(-)batteryconnections,buttheyshouldnotbeelectricallyconnected.Thisstrategyensuresmaximumisolationbetweenhighcurrentandlowcurrentloads.

GeneratingSetIsolationDCSupplySystem

ElectronicSubsystem1ElectronicSubsystem2

ElectronicSubsystem3

GeneratorSetSubsystemLoads

Starter

EngineECM

-+Battery

Figure5:GeneratingSetNetworkIsolationThebatterydisconnectswitchislocatedonthenegativelegofthebatterysupply.Ifabatterychargeristobeused,itshouldbeconnectedonthebatterysideofthedisconnectswitch,soasnottopowertheelectronics.Mostbatterychargersarenottobeusedaspowersupplies.Properbatterychargeroperationrequiresthattheactualbatteryloadispresent.

15

4.2LocationConsiderationsWhenselectingalocationformountingthePowerWizardgeneratingsetcontrol,considerthefollowing:

Protectionfromhigh-voltageandhigh-currentdevicesProtectionfromdeviceswhichmayproduceelectromagneticinterferenceProtectionfromexcessivevibration.Thecontrolsaredesignedtowithstandnormalgeneratingsetvibrations.Thecontrolsshouldnotbemounteddirectlytotheengineblock.Protectionfromdirectexposuretowater.Onceinstalled,thePowerwizardcontrolsaresealedtoalevelofIPLevel22forresistancetomoisture.ThecontinuousoperatingrangeofthePowerWizardgeneratingsetcontrolsis-20to+70Cambient.

4.3ElectricalConnectionsThePowerWizardcontrolhasone70-pinconnectoronthebackofthecontrol.Notall70pinsareused.Thefollowingdiagramsshowwhatpinsareusedandwhateachpinshouldbeconnectedtoforeachversionofthecontrol.Figures6and7areshownwithallpossibleconnectionsused.ForElectronicEngines(EUI),thepassiveanalogueinputnumbers1and2willnotbeused.Theseareforoilpressureandcoolanttemperaturerespectively.OnEUIengines,thosesensorswillbewiredtotheengineECMandthePowerWizardwillgetthatinformationfromtheengineECMviathePrimaryJ1939DataLink.Themethodusedfortheanalogueinputsis1-wiresensorsasshowninthediagram.Thediscreteinputsareshownconnectedthroughnormallyopencontactstobatterynegative.Theseinputscanalsobeconnectedthroughnormallyclosedcontactstobatterynegative.Inordertodothistheactivestateoftheinputwillneedtobesettoactivehigh.

Figure6:PowerWizard1.1&1.1+ControlElectricalConnections

16

VCVAVBNEUTRALIAICOMMONIBICCAN2DATALINL(+)CAN2DATALINL(-)CAN1DATALINL(+)CAN2SHIELDCAN1DATALINL(-)CAN1SHIELDMODBUS(+)MODBUS(-)MODBUSREFMAGNETICPICKUPINPUT(-)MAGNETICPICKUPINPUT(+)DISCRETEINPUT1DISCRETEINPUT2DISCRETEINPUT3DISCRETEINPUT4DISCRETEINPUT5DISCRETEINPUT6DISCRETEINPUT7DISCRETEINPUT8PASSIVEANALOG2(-)PASSIVEANALOG2(+)PASSIVEANALOG1(-)PASSIVEANALOG1(+)PASSIVEANALOG3(+)PASSIVEANALOG3(-)5VoutputL1L2L3N

CTA

CTB

CTC

J1939CANDATALINKS

MODBUS

MPU

DATALINK

131197314757395034426264635346766

POWERWIZARD2.1

LCDDISPLAY

0-600VACRMS

0-5AACRMS

696552

DISCRETESINKINGOUTPUT1BATTERY(-)BATTERY(+)Rly1Rly2Rly3Rly4Rly5Rly6Rly7Rly8

51614858354333413240262722515124147055545345443628

16

564638373029

SYSTEMBATTERY12or24VDC

LOAD

RELAYOUTPUTS(NOTEA)

+12or+24VDCNOTE(B)

NOTEA:Loadarenottoexceed2Aofcurrentdraw(Minimumcurrent10mA)NOTEB:Loadarenottoexceed300mAofcurrentdraw

Figure7:PowerWizard2.1ControlElectricalConnections4.4WindingConnectionsThewiringconnectionsbetweenthegeneratingsetandPowerWizarddependonthewindingconfigurationsofthegenerator.Refertothefollowingconnectiondiagarms.

PhaseA

PhaseB

PhaseCNuetral

Figure8:Threephase4-wire(seriesorparallel)starPhaseA

PhaseB

PhaseCNuetral

Figure9:Threephase4-wireDelta

13

11

97

13

11

97

17

PhaseA

PhaseB

PhaseCNuetral

Figure10:Threephase3-wireDelta.PhaseA

PhaseB

PhaseCNuetral

Figure11:Singlephase3-wire(DoubleDelta)PhaseA

PhaseB

PhaseCNuetral

13

11

97

13

11

97

13

11

97

Figure12:Singlephase2-wire(DoubleDelta)4.5TransformerConnectionsThePowerWizardcanmonitorgeneratoroutputvoltagesintherangeof80VACto600VAC.Inordertomonitorvoltagesgreaterthan600Volts,externalpotentialtransformersmustbeused.Note:

ThePowerWizardmustbeprogrammedforthecorrectwindingratioswhenconnectingexternalpotentialtransformersThewyeconfigurationofexternalpotentialtransformersispreferredfor4-wirewyegeneratingsetbecauseofthegreateraccuracywhenloadsareunbalanced.Withtheopendeltaconfiguration,somepowerparameterscannotbedetermined.TheseparametersarerealpowerphaseA,B,CandpowerfactorphaseA,B,C.Formaximumaccuracy,theopendeltaconfigurationofexternalpotentialtransformersshouldbeusedonlyfor3-wiredeltageneratingsets.POWERWIZARD

13

PhaseAPhaseBPhaseCNeutral

11

9

7

Figure13:WyeConfigurationofExternalPotentialTransformers(PT)onthe4-wireWyeconnectedGenerator

18

PhaseAPhaseBPhaseC

POWERWIZARD

13

11

9

Figure14:OpenDeltaConfigurationofExternalPotentialTransformers(PT)onthe3-wireDeltaconnectedGeneratingSetPOWERWIZARD13PhaseA

PhaseBPhaseCNeutral

11

9

Figure15:OpenDeltaConfigurationOfExternalPotentialTransformers(PT)onthe4-wireWyeconnectedGeneratingset4.6DataLinksThePowerWizardsupportsupto3differentdatalinks:

OnePrimaryJ1939DataLinkOneAccessoryJ1939DataLink(PowerWizard2.1only)OneSystemControlandDataAcquisition(SCADA)DataLink(PowerWizard2.1only).

ForinformationontheSCADAsystemrefertothefollowingmanuals:

PowerWizardMonitoringSoftware(availablewithMCM7andMCM8options)PowerWizardModbusApplicationsGuide(providedbytheaftersaleshelpdesk,refertothecontactslistatthebackofthis

manual.

4.6.1PrimaryJ1939DataLink(CAN1)ThePrimaryJ1939DataLinkissupportedbyallofthePowerWizardcontrols.ThePrimaryJ1939DataLinkisusedforlocalcommunicationamongmodulesassociatedwithasinglegeneratingset.ThePowerWizardcaninterfacewithbothElectronicEngines(EUI)andMechanicalEngines(MUI).InMUIengines,theenginesensorsarewireddirectlytothePowerWizard.ThePrimaryJ1939DataLinkutilizestheSocietyofAutomotiveEngineers(SAE)J1939protocolandrequireshardwarecomplianttothehigh-speedControllerAreaNetwork(CAN)2.0BprotocoldefinedintheInternationalStandardsOrganization(ISO)11898-2document,runningat250kbitspersecond.ThePrimaryJ1939DataLinksupportsappropriateSAEJ1939BroadcastParameterGroupNumbers(PGN)andSuspectParameterNumbers(SPN)forengineandgeneratingsetdataanddiagnostics.

19

WiringThePrimaryJ1939communicationwiresarebroughtoutofthePowerWizardaspartofthe70-pinAMPconnector.Thepins,asdesignatedontheAMPconnector,areshowninTable2.Pin#NameDescription34CAN1-Differential(-)forCAN42CAN1SHShieldforCAN50CAN1+Differential(+)forCANTable2:PrimaryJ1939DataLinkon70-pinConnectorNetworkTopologyThephysicaltopologyoftheCANnetworkusedinthePrimaryJ1939DataLinkisabustopology,consistingofamaintrunkandsmalldrops.Themaximumallowabletrunklengthis130ft(40m)andthemaximumdroplengthis3ft(1m).TheCANnetworkrequiresaterminationresistorontheextremeendsofthemaintrunk.ThetopologyforthePowerWizard1.1and1.1+isillustratedinFigure11.

OnElectronicEngine

EngineServiceConnector

TerminatingResistor#1B

120Ohms

C

FG

CANSH

CAN-CAN+

EngineECM

CANI+CANI-CANISH

J1

503442

AB

PrimaryGenServiceTool

TerminatingResistor#1A

C

FG

CANSH

CAN-CAN+

PowerWizard1.1/1.1+

CANI+CANI-CANISH

J20

503442

120Ohms

AB

Figure16:PowerWizard1.1,1.1+CANWiringDiagram

20

4.6.2AccessaryJ1939DataLinkTheAccessoryJ1939DataLinkissupportedbythePowerWizard2.1.TheAccessoryDataLinkisusedforlocalorremotecommunicationamongmodulesassociatedwithasinglegeneratingset.Thisincludesannunciatorsandotherexpansionmodules.TheAccessoryJ1939DataLinkutilizesthesameSAEstandardsasCAN1.WiringPin#NameDescription62CAN2-Differential(-)forCAN63CAN2SHShieldforCAN64CAN2+Differential(+)forCANTable3:AccessoryJ1939DataLinkon70-pinConnectorNetworkTopologyThephysicaltopologyoftheCANnetworkusedintheAccessoryJ1939DataLinkisabustopology,consistingofamaintrunkandsmalldrops.Themaximumallowabletrunklengthis800ft(244m)andthemaximumdroplengthis3ft(1m).TheCANnetworkrequiresaterminationresistorontheextremeendsofthemaintrunk.ThetopologyforthePowerWizard2.1withsomeremotedevicesconnectedisillustratedinFigure12.Notethatmoreremotedevicescanbeconnected,aslongastheproperlengthsaremaintainedandtheterminationresistorisplacedattheendofthetrunk.

OnElectronicEngine

EngineServiceConnector

TerminatingResistor#1B120Ohms

CFG

CANSHCAN-CAN+

EngineECMCANI+CANI-CANISH

J1503442

AB

PrimaryGenServiceTool

TerminatingResistor#1A

CFG

CANSHCAN-CAN+

PowerWizard2.1

CANI+CANI-CANISH

J20503442

120OhmsAB

TerminatingResistor#2A120OhmsAB

AsecondaryGenServiceConnmaybetted

TerminatingResistor#2B120OhmsAB

Annunciator(MCM9)

CANI+CANI-CANISH

626463

6364SC1

CANI+CANI-CANISH

Figure17:PowerWizard2.1CANWiringDiagram(withoptionalmodule)

21

4.7OptionalModules

4.7.1CANAnnunciator(MCM9)ThePowerWizardAnnunciatorservestodisplaygeneratingsetsystemalarmconditionsandstatusindications.TheAnnunciatorhasbeendesignedforuseonthePowerWizardJ1939CommunicationNetwork.ItisusedinRemoteapplicationsbeingmountedseparatefromthegeneratingsettoprovideremoteindicationofsystemoperatingandalarmconditions.ThePowerWizardAnnunciatorisconfigurabletothestandardsofNFPA99/110

EmergencyStopFailtostartHighenginetemperatureLowoilpressureOverspeedLowcoolantlevelLowbatteryvoltageLowbatterychargingvoltageNotinautoLowfuellevelUnder/overvoltageUnder/overfrequencyGeneratingsetonloadMainsonloadUtilityfailedGeneratingsetfailedJ1939networkstatus

4.7.2PowerWizardSupportoftheAnnunciatorNote:

Lamptest

Mute

CAN1indicatestheconnectionforthePowerWizardPrimaryJ1939datalinkandCAN2indicatestheconnectionforthe

PowerWizardAccessoryJ1939datalink.ThePowerWizard1.1and1.1+onlysupportsthePrimaryJ1939datalink.FormoreinformationonthePrimaryandAccessorydatalinks,refertotheDataLinkssection.PowerWizard1.1,1.1+:SupportsoneAnnunciatormoduleusingCAN1.

22

PowerWizard1.1,1.1+

CAN1

133FTMaximum

Figure18:PowerWizard1.1,1.1+andAnnunciatorConnectionPowerWizard2.1:SupportsoneAnnunciatormoduleusingCAN1anduptothreeAnnunciatorsusingCAN2

Annunciator1

PowerWizard2.1

3ftMaximum

CAN2

800ftMaximum

Annunciator3

Annunciator2

Figure19:ExampleillustrationofAccessoryDataLinkModulesandWireLengths

23

5.SETPOINTPROGRAMMINGTheengine/generatingsetpointsaffecttheproperoperationandserviceabilityoftheengineandtheaccuracyofinformationshownonthedisplayscreen.ThesetpointsareprogrammedinthePowerWizardatthefactory.ThesetpointsmayrequirechangingwhenthePowerWizardismovedfromoneenginetoanotherengine.Thesetpointsmayalsorequirechanginginordertosatisfytherequirementsoftheinstallation.ThesetpointsthatarestoredinthePowerWizardmustmatchthespecifiedsetpointsoftheparticulargeneratingset.ForalistofallavailablesetpointsseeAppendixB.5.1DigitalInputProgramming

5.1.1DigitalInputsThemainpurposeforthedigitalinputsistoaddadditionalmonitoringcapabilitiesfortheengineorthegeneratingset.Thedigitalinputsaretiedtoaninternalpull-upresistorinsidethecontrol.Therefore,ifthereisnoconnectiontoadigitalinput,thenthedigitalinputwillreadasaphysicalhigh.Agroundorbatterynegativeinputshouldbewired,throughaswitch,toeachdigitalinput.Ifanactivehighconfigurationisdesired,thenthebatterynegativeinputshouldbewiredthroughanormallyclosedswitch.Ifanactivelowconfigurationisdesired,thenthebatterynegativeinputshouldbewiredthroughanormallyopenswitch.ThereareeightdigitalinputsonthePowerWizard.Thefirstandseconddigitalinputsarededicatedfortheemergencystopandremoteinitiatefunction.Theother6digitalinputsonthePowerWizard2.1(4digitalinputsonPowerWizard1.1)canbeprogrammedfor:Disabled,CommandorStatus,SystemEventsandSCADADatalink.INTOE-STOP

INTOREMOTEINITIATE

IN

IN

IN

IN

IN

IN

DIGITALINPUT{1}

DIGITALINPUT{2}

DIGITALINPUT{3}

DIGITALINPUT{4}

DIGITALINPUT{5}

DIGITALINPUT{6}

USAGETYPE:SYSTEMEVENTEVENTPARAMETERFAILURETYPEEVENTDELAYACTIVESTATEUSAGETYPE:SYSTEMEVENTEVENTPARAMETERFAILURETYPEEVENTDELAYACTIVESTATEUSAGETYPE:SYSTEMEVENTEVENTPARAMETERFAILURETYPEEVENTDELAYACTIVESTATEUSAGETYPE:SYSTEMEVENTEVENTPARAMETERFAILURETYPEEVENTDELAYACTIVESTATEUSAGETYPE:SYSTEMEVENTEVENTPARAMETERFAILURETYPEEVENTDELAYACTIVESTATEUSAGETYPE:SYSTEMEVENTEVENTPARAMETERFAILURETYPEEVENTDELAYACTIVESTATE

Figure20:Digitalinputsconfiguration

5.1.2DedicatedDigitalInputsEmergencyStopInputThisinputshouldbewiredtobatterynegativethroughanemergencystopswitch.Theinputcanbesettoactivateonanactivehigh(normallyclosedcontact)oranactivelow(normallyopencontact).RemoteInitiateInputThisinputshouldbewiredtobatterynegativethroughaRemoteInitiateswitch.TheinputcanonlybesettoactivateonanActiveLow(normallyopencontact).IftheinputisactiveandthecontrolisintheAUTOmode,thentheenginewillattempttostartandrun.Oncetheinputbecomesinactive,theenginewillenterintocooldown(Ifprogrammedtodoso)andwillthenstop.24

5.1.3ProgrammableDigitalInputsTheinputscanbeprogrammedthroughthefollowingmenuoptions:MAINMENU>CONFIGURE>INPUTS&OUTPUTS>DIGITALINPUTSTheusagetypecanbeselectedfromthefollowing:

DisabledSettoaCommandorStatus;refertotheCommandorStatussectionbelowSettoSystemEventsandcanbeconfiguredtotriggerwarningsorshutdownsinthecontrol.SystemeventconfigurationsdeterminethePowerWizardresponsetoanysupportedeventSettoSCADAdatalink.InthiscasethestateoftheinputwillbeplacedintotheappropriateMODBUSregister.Noalarmsor

warningswillbegeneratedbythecontrol.1.CommandorStatusCommand/StatuscanbeconfiguredbyselectingParametersandActiveState.Thesupportedparametersorcomponentsare:

ECSinRunECSinAutoECSinStopIdleModeCommandStartAidTimerBypassInhibitCoolDown

RaiseVoltageLowerVoltageRaiseSpeedLowerSpeedAutoLoadFuel(PW1.1+andPW2.1)

2.SystemEventSystemEventcanbeconfiguredbysetting:EventParameters,FailureType,EventDelayandActiveState.TheeventtypeistheselectionoftheSuspectParameterNumber(SPN)fortheinput.Table4givesalistofsupportedeventparameters.EventParameterListPressuresEngineoilpressureGasPressureTemperaturesEnginecoolanttemperatureEngineoiltemperatureExhausttemperatureGeneratorRearBearingTemperatureGeneratorWinding#1TemperatureLevelsEnginecoolantlevelEngineoillevelFuellevelExternalfueltanklevelOtherEmergencyStopEPSSupplyingLoad(PowerWizard2.1)GeneratorCircuitBreakerClosedGeneratorCircuitBreakerOpenBatteryChargingSystemVoltageCustomEventFuelLeakDetectedGeneratorCurrentGeneratorPowerInletManifoldChargeCombustionAirDamperClosedBatteryChargerFailureEarthFaultEarthLeakageTable4

25

AftertheSPNischosen,theFailureModeIdentifier(FMI)isthenextsetting.ThefollowingFMIsareavailable:

HighWarning(example:HighTemperatureWarning)LowWarning(example:LowTemperatureWarning)HighShutdown(example:HighTemperatureShutdown)LowShutdown(example:HighTemperatureShutdown)Status(example:FueltankLeak).

Statusisusedwhenaneventisnotessentiallyhighorlowbutsimplyexists.AnexampleofthisistheEmergencyStop.3.SCADADatalinkWhenadigitalinputisconfiguredasSCADADataLink,thestateoftheinputwillbeplacedintothecorrespondingMODBUSregisterforremotemonitoring.TheActiveStateoftheinputcanbeselectedasHIGHorLOW.TheHIGHoptionshouldbeusedforanormallyclosedswitchandtheLOWoptionshouldbeusedforanormallyopenswitch.5.2RelayandDigitalOutputProgrammingThePowerWizard1.1and1.1+havesixtype-Arelays.ThePowerWizard2.1haseightrelays.Sixofthesearetype-Arelaysandtheothertwoaretype-Crelays.Type-Aisdefinedasonenormally-opencontactpluscommon.Type-Cisdefinedastwocontacts,normally-openandnormally-closedpluscommon.

RelayOutputs

TypeATypeC

Figure21:RelayOutputsEachrelayiscapableofhandling2A@30VDC.Therelaycontactsarenotprotectedagainstshortstobatteryorground.Relayoutputs1and2aretypicallyusedforEnginecrankandfuelcontrol.PowerWizard2.1hasalsotwocurrentsinkoutputs,namelydigitaloutputs.PowerWizard1.1and1.1+havenodigitaloutputs.Eachdigitaloutputiscapableofsinking300mA.Theoutputshavediagnosticsforashorttobatterywhenthedriverison.Ifashorttobatterypersistsforfiveseconds,thenthedriverwillbedisableduntiltheconditionisnolongerpresent.Note:ThedigitaloutputsareinternallycontrolledandtheactivestateshouldalwaysbesettoHIGH.Therelayanddigitaloutputscanbeconfiguredtothefollowingselections:

DisabledSettoastatusorcommandSettoasystemeventSettoaSCADAcommand

Anoutputremainsintheinactivestatewhentheoutputisdisabled.ThecontroldisplayandtheSCADAshowsthestatusoftheoutputasDisabled.Anoutputisactivebasedontheinternallogicofthecontrolwhentheoutputissettoastatusoracommand.AnoutputisactivebasedontheactivestatusofaninternaleventortheactivestatusofeventsthatarecommunicatedfromotherdevicesacrosstheCANdatalinkwhentheoutputissettoasystemevent.AnactivestateissentovertheModbuswhenanoutputisconfiguredfortheSCADAdatalink.

26

COMMAND/STATUS

StatusCommand

RunModeAirShutoff

AutoModeProgrammableCycleTimerOutput#2

StopModekWrelayTrip#1

PackagenotinAutokWrelayTrip#2

FuelControlRelayCommonAlarm

StarterMotorRelayBreaker#1Trip

StartAidBreaker#2Trip

DisableAuxACSupplyReducedPowerOff

CrankAlertTransferFuelIn

EngineStartInitiatedTransferFuelOut(1)

EngineStartedVoltageRaiseCommand

RatedSpeedVoltageLowerCommand

V/HzwithinLimitsSpeedRaiseCommand

EngineinCooldownSpeedLowerCommand

PackagewaitingonDelayonStopNominalFrequencySelectionLow/High(1)

HornControlNominalVoltageSelectionLow/High(1)

CommonWarning

CommonShutdown

ECUFaultReset

Theproceduresthatmustbeperformedinordertoprogramtheoutputsdependontheusagetypefortheoutput.Usagetypesareactivatedfromthemenuoptionsbelow.MAINMENU>CONFIGURE>INPUTS&OUTPUTS>RELAYOUTPUTSMAINMENU>CONFIGURE>INPUTS&OUTPUTS>DIGITALOUTPUTS1.COMMAND/STATUS

Table5givesalistofavailablestatusesandcommands.Table5(1)AvailablewithcomplexsoftwareAutoModeActivatedaftertheautokeyhasbeenpressedoraModbuscommandisgiventosetengineoperatingmodetoauto(register302)andwhilethecontrolremainsintheautomode.GeneratorBreakerTrip1ActivatedwhenanyeventoccursthathasaneventresponseconfigurationsetforBreakerTrip#1.Thisdeactivateswhentheeventisneitherpresentnoractive.Thisoutputdoesnotcontrolacircuitbreakerunlesstheusermakestheconnectionstodoso.Thisoutputtypeshouldbeviewedashavingagenericnamebecausethenamedoesnotnecessarilyimplytheactionthatisperformed.BreakerTrip2ActivatedwhenanyeventoccursthathasaneventresponseconfigurationsetforBreakerTrip#2.Thisdeactivateswhentheeventisneitherpresentnoractive.Thisoutputdoesnotcontrolacircuitbreakerunlesstheusermakestheconnectionstodoso.Thisoutputtypeshouldbeviewedashavingagenericnamebecausethenamedoesnotnecessarilyimplytheactionthatisperformed.CommonAlarmActivatedanytimethatthecontrolinitiatesand/ordetectseitherashutdowneventorawarningevent.Thisdeactivateswhennowarningsorshutdownsarepresentoractive.DisableAuxACSupplyTheDisableAuxACSupplyisintendedtobeusedinordertodisconnectthebatterycharger,heatersetcwhentheengineisrunning.Itisactivatedwhentheenginestartisinitiated.ThisdeactivateswhentheengineisstoppedortheRPMisequaltozero.TripPoint#1ActivatedwhenProgrammableTripPoint1isactive.ProgrammableTripPoint1isactivatedbasedonthehighpercentkW,accordingtotheuserconfigurablethresholds.InCooldownRequiresthattheCooldownDurationsetpointissetgreaterthanzero.Activatedwhenanenginestophasbeeninitiatedandthecooldowncyclebegins.Thisdeactivateswhenthecooldowntimerhasexpiredandremainsdeactivatedanytimethegeneratingsetisnotincooldown.RunModeActivatedaftertherunkey(8)hasbeenpressedoraModbuscommandisgiventosettheEngineOperatingModetoRun(register302)andwhilethePowerWizardremainsintheRunmode.StartAidRequiresthatthesetpointforStartAidActivationTimeistobesetgreaterthanzero.Itisactivatedwhentheenginestartisinitiated.Theenginestartalsostartsthetimer.ThisdeactivatesafterStartAidActivationTimeexpires.

27

SYSTEMEVENT

PressureGenFrequency

EngineOilPressureGenRealPower

GasPressureGenVoltage

TemperaturePrimaryDataLink

EngineCoolantTemperatureSCADADataLink(PW2.1Only)

EngineOilTemperatureServiceIntervalExpired

ExhaustTemperatureUnexpectedEngS/D

GenRearBearingTempEarthFault

GenWinding#1TempEarthLeakage

LevelsEngineController

EngineCoolantLevelFuelLeak

EngineOilLevelAirDamperClosed

FuelLevelBatteryChargerFail

ExternalTankFuelLevelGenBreakerOpen

OthersGenBreakerClosed

AnySPNCustomEvents

AccessoryDataLink(PW2.1Only)DigitalInput#1CustomEvent

BatteryChargingSysVoltDigitalInput#2CustomEvent

BatteryVoltageDigitalInput#3CustomEvent

EmergencyStopSwitchDigitalInput#4CustomEvent

EngineinCooldownDigitalInput#5CustomEvent

EngineFailtoStartDigitalInput#6CustomEvent

EngineSpeedAnalogInput#1CustomEvent

ControlNotinAutoAnalogInput#2CustomEvent

GenCurrent(Amp)AnalogInput#3CustomEvent

GeneratorCircuitBreakerClosedDigitalInput#5CustomEvent

GeneratorCircuitBreakerLockedOutDigitalInput#6CustomEvent

GeneratorCircuitBreakerFailuretoOpenAnalogueInput#1CustomEvent

GeneratorCircuitBreakerFailuretoCloseAnalogueInput#2CustomEvent

UtilitytoGeneratorTransferFailureAnalogueInput#3CustomEvent

AnyWarningFMI02DataErratic:IntermittentorIncorrect

AnyShutdownFMI03VoltageAboveNormalorShortedtoHighSource

AnyWarningorShutdown

LowWarningFMI04VoltageBelowNormalorShortedtoLowSource

HighWarningFMI05CurrentBelowNormalorOpenCircuit

High/LowWarningFMI06CurrentAboveNormalorGroundedCircuit

LowShutdownFMI07MechanicalSystemNotRespondingorOutofAdjustment

HighShutdownFMI08AbnormalFrequency:PulseWidthorPeriod

High/LowShutdownFMI09AbnormalUpdateRate

LowWarningorShutdownFMI10AbnormalRateofChange

HighWarningorShutdownFMI11RootCauseNotKnown

High/LowWarningorHigh/LowShutdownFMI12BadIntelligentDeviceorComponent

High/LowWarningorHigh/LowShutdownorDiagnosticFMI13OutofCalibration

AnyDiagnostic

ConditionExistsFMI14SpecialInstruction

conditions.Table728

V&HzWithinLimitsThenormaloperatingrangeisdefinedasbeingneitherabovethehighwarningorshutdownthresholds,norbelowthelowwarningorshutdownthresholds.Activatedwhenmeasuredgeneratorvoltageandfrequency(thatiscalculatedasapercentageofratedvoltageandfrequency)arebothwithinthenormaloperatingrange.Thisdeactivateswheneitherthemeasuredgeneratorvoltageorthefrequencyareoutsidethenormaloperatingrange.2.SYSTEMEVENTEVENTPARAMETERandEVENTTRIGGERconditionneedtobeselectedforSYSTEMEVENT.Table6isalistofavailablesystem

events.Table6EVENTTRIGGERisusedtoselectthedesiredconditioninordertotriggertheevent.Table7isalistoftheavailabletrigger

MapDescription

Map1VDOPressureCurve4

Map2Pressure246-8150

Map3VDOTemperatureCurve1

Map4Temp191-6587

Map5VDOTemperatureCurve2

Map6Temp349-2458

Map7FozmulaLevel1

Map8Linear0to2000ohm

Map9XQFuel1

Map10XQFuel2

Map11-25FutureUse

3.SCADADATALINKWhenanoutputisconfiguredfortheSCADAdatalink,itsactivestatecanbesentovertheModbus.5.3AnalogueInputProgrammingPowerWizard2.1and1.1+havethreeanalogueinputchannelsandPowerWizard1.1hastwo.ForaMechanicalUnitInjectorEngine(MUI),twooftheinputsarededicatedtomonitortheenginecoolanttemperatureandtheengineoilpressure.TheAnalogueInput#3hasadefaultconfigurationto"disabled".AllthreeanalogueinputscanbeprogrammedtomonitoranysupportedparameterinTable8foranElectronicUnitInjectorEngine(EUI).InthiscasetheengineoilpressuresensorandtheenginecoolanttemperaturesensorarewiredtotheEngineECMandnottothePowerWizard.TemperaturesEngineCoolantTemperatureEngineOilTemperaturePressuresEngineOilPressureLevelsEngineFuelLevelExternalTankFuelLevelOtherCustomerParameter#1CustomerParameter#2CustomerParameter#3SCADADataLink(PowerWizard2.1Only)DesiredEngineSpeedCommandUreaLevelTable8:ListofsupportedparametersAnalogueinputscanbeconfiguredfrommenuoptions:MAINMENU>CONFIGURE>INPUTS&OUTPUTS>ANALOGUEINPUTSTherearethreeUSAGETYPESforanavailableinput:DISABLED,RESISTIVEandVOLTAGESENDER.EachoftheinputscanbeconfiguredtohaveHIGHWARNING,LOWWARNING,HIGHSHUTDOWNorLOWSHUTDOWNwiththresholds.Eacheventassociatedwiththeinputalsohasaprogrammabletimedelay.1.ResistivesenderDATAIDENTIFICATIONforaresistivesendercanbeselectedfromthelistinTable8,e.g.temperature,pressureorlevel.TheMAPSELECTIONNUMBERisusedtoselectamapinconnectionwiththesender.PowerWizardhasupto25mapsavailableforresistivesendersasshowninTable9.Eachmapisdefinedinfactoryandcontainsupto25interpolationpoints.

Table929

2.VoltagesenderForavoltagesender,thedesiredvoltagerangeandcorrespondingdatarangeneedtobeselected.TheavailablevoltagerangesaregiveninTable10.TheminimumandmaximumdatapointscanbesetunderthemenuofDATARANGEMINandDATARANGEMAX.AvailableVoltageRange0Vto5V1Vto5V0Vto10VTable10

30

6.RETROFITTINGPOWERWIZARDSWhenreplacingaPowerWizardorwhenfittinganewone,ensurethatthecorrectcontrollertypeisselectedi.e.PowerWizard1.1orPowerWizard2.1.ThedifferencesbetweenthesearelistedinthePowerWizardVariationssection.TheElectricalConnectiondrawingsareshownintheElectricalConnectionssection.6.1ESTAvailabilityandLicensingTheElectronicServiceTool(EST)usedwithalaptopprovidesthemechanismforservicingthePowerWizardcontroller.Itallowstheusertodisplay,vieworchangethecurrentConfigurationfiles(FieldReplacementFiles)orthebaselevelflashfiles.ThereforeESTisanessentialservicetoolforcarryingoutserviceoperationsonthePowerWizard.InstructionsonpurchasingandlicensingESTcanbefoundontheFGWilsonDealerwebsitePowerUp2orbycontactingtheESTSoftwareLicenseandSupportCoordinator.Tel:+44(0)2828265228email:support_tools@fgwilson.com6.2FlashFilesandFieldReplacementFilesPowerWizardshavetwomaintypesoffilesassociatedwiththem,theflashfile(.flsfile)thatcontainsthebasecodeandtheFieldReplacementFile(.xmlfile)thatcontainstheconfigurationinformation.FlashFiles:ToobtainareplacementflashfileorthemostrecentversionofaflashfilecontacttheFGWilsonAfterSalesHelpdeskTel:+44(0)2828265001emailafterSales@fgwilson.com.WhenenquiringpleasesupplythegeneratingsetSerialNumber.TheHelpdeskwillsendyouthemostrecentversionofthefileassociatedwiththatgeneratingsetSerialNumber.Thesefilesarebackwardcompatible.Ifyourequirethesamefilebutinadifferentlanguageinformthehelpdeskandtheywillsendtheequivalentfileintherequiredlanguage.Availablelanguagesare:English,French,German,Spanish,Italian,Portuguese,Dutch,Danish,Swedish,Finnish,Norwegian,Russian,Chinese,Japanese,Greek,Arabic,Icelandic,Hungarian,Turkish,Czech,Estonian,Latvian,Lithuanian,Polish,Slovak,Slovene.IfthefileisforanewjobnotassociatedwithageneratingsetSerialNumber,thenthefollowinginformationisrequiredinordertoselectthecorrectflashfileforthecontroller.

1.2.3.

Controllertype(PowerWizard1.1,1.1+or2.1)AfterMarketID(AMID)FGWilsonorOlympian.Language

Itisintendedtohaveanonlinewebbasedfacilitydevelopedthatwillmakethesefilesavailableonline24/7.Note:

WhenanewFlashFilesisloadedtheconfigurationfileremainsunchanged.

FieldReplacementFiles:TheFieldReplacementFilesonlyexistforcontrollersthathavepreviouslybeenprogrammedatthefactory.FGWilsoncannotcreateFieldReplacementFilesforcontrollersthatareinthefieldandthathavenotpreviouslybeenprogrammedatthefactory.HoweverFieldReplacementFilescanbeusedonmorethanonecontroller.Soiftheconfigurationyouwantisthesameasapreviousset,thesameFieldReplacementFilecanbeused.Thesameprocedureisusedagainforobtainingthisfile.ContacttheFGWilsonAfterSalesHelpdesksupplyingtheGeneratingsetSerialNumberandtheywillsendyoutherequiredFieldReplacementFile.Note:IfaFieldReplacementFilethatwascreatedforaPowerWizard1.1isloadedontoaPowerWizard2.1,someoftheitemsonthePowerWizard2.1willnotbeconfigured.ToconfiguretheseitemsopenESTandselectConfiguration(SERVICECONFIGURATION).FieldreplacementfilesfromaPWX.0cannotbeusedonPWX.1.

31

UsingESTtoloadFlashFilesItisrecommendedtousethelatestversionoftheservicetool.Whileanyversionfrom2004Aonwardsshouldwork,itiseasiertofollowscreenshotsandmenunavigationifthelatestversionisused.

1.

2.3.4.

OpenESTWinflash(ThisshouldbeaseparateoptiontoElectronicServiceToolfromwithintheESTsubmenuofWindowsoritcanbeaccessedfromtheServiceToolmenubyselectingUtilities->WinflashEnsurethattheservicetoolisusingRP1210(underUtilities->preferences->communications)EnsurethatthecommunicationsadapterisconnectedtothecorrectportofthePCYoushouldhaveascreensimilarto:

Press,Browseandselectthedesiredflashfile

1.2.

PressBeginFlashWhenyousee:

Yourefinished.Allthe(old)setpointsarepreservedwhenthePowerWizardcontrolisre-flashed.

32

UsingESTtoloadFieldReplacementFiles

1.

OpenESTECMReplacementbyselectingtheServiceCopyConfigurationECMReplacementmenuitem,asshowninthefigurebelow.

2.

SelecttheFieldreplacementFile(.xmlfile)thatyouwanttoloadasshowninthescreenbelow.

Thefollowingscreenwillthenbedisplayedshowingtheconfigurationvalues.

3.

SelectProgramECMtoloadtheconfigurationvaluesontothecontroller.OncetheconfigurationvalueshavebeensuccessfullyloadedthemessageProgrammingCompletewillbedisplayed.33

6.3PossibleESTerrormessages,theircauseandsuggestedactionThecommunicationadapterwasunabletoconnecttotheJ1939datalink.Cause:ESTwasunabletoseetheCommunicationadaptorontheportitisexpectingittobeconnectedto

EnsurethatCommunicationadapterisconnectedtothePowerWizardpanelandhaspowerEnsurethatthecommunicationadapterisconnectedtothePCEnsurethatthesettingsontheservicetoolaresetforthecorrectportEnsurethatthecommunicationadapterisusingRP1210(underutilities->preferences->communications)

NoECMsdetectedCause:ESTwasunabletodetectanyPowerWizardmodulesontheJ1939network.

EnsurethePowerWizardmoduleispoweredupandisnotinReducedPowerModeChecktheJ1939wiringbetweenthePowerWizardandthecommunicationsadapter,particularlythetermination

resistor(s).TheECMsoftwarefileandtheECMarenotcompatible.Processaborted.-ErrorCode:163840Cause:TheflashfileisnotcompatiblewiththePowerWizard.Thisisusuallyseenwhentryingtoflashamodulewithsoftwareforadifferentmodule,suchastryingtoflashaPW1.1withaflashfileforaPW1.1+or2.1.

UseaflashfilethatiscompatiblewiththelevelofPowerWizardcontrolyouaretryingtoflash.

NoflashfileselectedfortheECMCause:ThiserrormessageisseenwhentryingtouseaflashfilethatisnotsuitableforanylevelofPowerWizardcontrol.

UseaflashfilethatiscompatiblewiththelevelofPowerWizardcontrolyouaretryingtoflash.

34

7.STEPTHROUGHGUIDES

7.1ReducedPowerMode(RPM)Understeadystateoperation,thePowerWizardcontrollerson12Vgeneratingsetshavelessthan1Acurrentdraw(notincludinganyrelayloads).Thisvaluewillbelowerforcontrollerson24Vgeneratingsets.Thiscanbereducedbyapproximatelyafactorof7byusingtheReducedPowerMode(RPM).Howeveritisrecommendedthatgeneratingsetsatrestorinstorageforprolongedperiodsshouldeitherhavethebatterychargerorisolatorswitchoptionfitted.Wheninreducedpowermodethegeneratingsetcontrolwillappearpowereddown.Itwillalsosystematicallypulsethecontrolpanellamps.InReducedPowerModethecontroldisablesallcommunications.IfReducedPowerModeisenabledandthegeneratingsetisstoppedthecontrolwillenterreducedpowermodeapresettime(normally30minutes)afterthelastkeypress.TheControlwillawakenfromReducedPowerModeuponakeypress,anEmergency-Stoporaremotestartsignal.EnablingReducedPowerModeonUsingEST

1.2.3.4.5.6.

OpenESTEnsurethattheservicetoolisusingRP1210(underUtilities->preferences->communications)EnsurethatthecommunicationsadapterisconnectedtothecorrectportofthePC.ConnecttothePowerWizardcontrol(PressF8).SelectConfiguration(Service->Configuration)or(pressF5).Itwilltakesometomefortheservicetooltocheckwhichblocksareinstalled.Afterabout30secondsthescreenwilllooklikethis:

7.8.9.

SelectElectronicControlModuleReducedPowerMode.AtthesetpointElectronicControlModuleReducedPowerModeEnableStatusClickonDisabledandchangeittoEnabled.EnsuretheElectronicControlModuleReducedPowerModedelaytimeissettoanappropriatetime(suchas30minutes).

10.Yourefinished.DisconnectESTfromthePowerWizard.EnablingReducedPowerModeUsingKeypadToenabletheReducedPowerModeonthePowerWizardbyusingthekeypadgototheReducedPowerModescreenasshownbelow.MAINMENU>CONFIGURE>SETPOINTS>REDUCEDPOWERMODE

Enterthefollowingscreen:

REDUCEDPOWERMODEENABLESTATUS

DISABLED

35

ALevel3passwordisrequiredtoallowtheusertoenterthisscreenandtoenabletheReducedPowerMode.TheusermayalsochangethetimedelaybeforetheReducedPowerModeisactivatedbyenteringthescreenshownbelow.

REDUCEDPOWERMODEDELAYTIME30MINS

Note:

Theremotecommunications(RS485)andtheJ1939communicationswillnotoperatewhenthecontrollerisinReduced

PowerMode.ThereforeifusingremotecommunicationsensureRPMisdisabled.Sincetheremotecommunicationsoptions(MCM7/MCM8)usesaRS485/RS232converterthatispoweredviaamainspoweredcharger,weassumethatifusingremotecommunicationsmainspowerisavailableandthecontrollerhasachargerandRPMisdisabled.7.2ServiceMaintenanceIntervalTheServiceMaintenanceIntervalisavailableonPowerWizard2.1andhasaflashfiledefaultof500enginehoursor180days.

7.2.1ResetServiceIntervalToclearaServiceMaintenanceIntervalWarning,thetimermustbereset,ratherthantheevent,becausethecountdowntimerhasreachedzero.Thistimercanberesetfromthedisplaytoreturntotheprogrammedinterval.Youmayrequirealevel3passwordtodothisorusetheservicetooltochangethispasswordlevelfrom3to2.MAINMENU>CONFIGURE>RESETCOUNTERS>SERVICEMAINTENANCEINTERVAL

7.2.2ChangeDurationofServiceIntervalAlarmThedurationoftheServiceIntervalcanonlybechangedusingtheservicetoolandnotfromthekeypad.Iftheintervalindayscausesthealarmtoberaisedbeforetheintervalhoursrunisreachedwesuggestthatyousettheintervalindayshigh(example:settothemaximumof365DAYS).TheDAYScannotbedisabled.

7.2.3DisableServiceIntervalAlarmThiswarningcanonlybedisabledbyusingtheEventResponseConfiguration.DeselectingtheWarningandAudibleAlertunderEDITwillstoptheeventfromoccurring.MAINMENU>CONFIGURE>ALLSETPOINTS>EVENTS>EVENTRESPONSECONFIG>ENGPROTECTCONFIG>OTHERS>SERVMAINTINTERVALWARNINGCONFIG>EDIT7.3SettingLanguageThePowerWizardmodulegivestheoperatorthechoiceofusingoneoftwoavailablelanguages.

1.2.

TechnicalEnglishCustomerLanguage

ToselectyourpreferredlanguagescrolltotheLANGUAGEmenuasshownbelow.MAINMENUPREFERENCESLANGUAGEUsethecursertohighlightthepreferredlanguageandpresstheOKkeytoselectit.Note:

PreferencesisthelastoptiononthemainmenuandLanguageisthelastoptioninPreferences.

36

7.4DisablingNOTINAUTOBydefaultPowerWizardcontrolpanelshaveageneratingsetnotinautowarning.ThiswarningwillbeactivewhenthecontrolisinSTOPorRUNmode.Forcertainapplicationsitmaybesuitabletodisablethiswarning.TodisableNotInAutoperformthefollowing.MAINMENU>CONFIGURE>SETPOINTS>EVENTS>EVENTRESPONSECONFIGureOTHERSYSTEMCONFIGScrollto"GenControlNotinAutoWarningConfig"SelecteditbyusingleftcursorkeyandthenpressEnter

VIEW

ENTER

Thistakesyoutothescreenthatisusedtoconfigurethedesiredresponseforthe"NotInAuto"alarm.Theoptionsavailablecan

beviewedoredited.

WARNING

AUDIBLEALERT

ACTIVEONLY

Aindicateswhichoptionsareselected.Theusermayselectorremovebyusingtheleftcursorkey.IfunabletoEDITcheckthatthegeneratingsetisinSTOPpositionandthattherequiredpasswordlevelisused.7.5DisablingThermoStart(StartAidActivation)TodisabletheThermoStartgototheSTARTAIDACTIVATIONTIMEscreenasshownbelow:MAINMENU>CONFIGURE>SETPOINTS>CONTROL>AUTOSTART/STOPPressenterandthenscrolldowntillyoucometotheSTARTAIDACTIVATIONTIMEscreen.Onceatthisscreen,setthetimeto0seconds.

37

EventNameSPNFMI

ExternalTankHighFuelLevelShutdown380

ExternalTankLowFuelLevelShutdown381

ExternalTankFuelLevelSensorShortHigh383

ExternalTankFuelLevelSensorShortLow384

ExternalTankHighFuelLevelWarning3815

ExternalTankLowFuelLevelWarning3817

HighStartingAirPressureShutdown820

LowStartingAirPressureShutdown821

StartingAirPressureSensorShortHigh823

StartingAirPressureSensorShortLow824

HighStartingAirPressureWarning8215

LowStartingAirPressureWarning8217

HighFuelFilterDifferentialPressureShutdown950

LowFuelFilterDifferentialPressureShutdown951

FuelFilterDifferentialPressureSensorShortHigh953

FuelFilterDifferentialPressureSensorShortLow954

HighFuelFilterDifferentialPressureWarning9515

LowFuelFilterDifferentialPressureWarning9517

HighFuelLevelShutdown960

LowFuelLevelShutdown961

FuelLevelSensorShortHigh963

FuelLevelSensorShortLow964

HighFuelLevelWarning9615

LowFuelLevelWarning9617

HighEngineOilLevelShutdown980

LowEngineOilLevelShutdown981

EngineOilLevelSensorShortHigh983

EngineOilLevelSensorShortLow984

HighEngineOilLevelWarning9815

LowEngineOilLevelWarning9817

HighEngineOilFilterDifferentialPressureShutdown990

LowEngineOilFilterDifferentialPressureShutdown991

EngineOilFilterDifferentialPressureSensorShortHigh993

EngineOilFilterDifferentialPressureSensorShortLow994

HighEngineOilFilterDifferentialPressureWarning9915

LowEngineOilFilterDifferentialPressureWarning9917

LowEngineOilPressureShutdown1001

EngineOilPressureSensorShortHigh1003

EngineOilPressureSensorShortLow1004

LowEngineOilPressureWarning10017

HighAirFilterDifferentialPressureShutdown1070

LowAirFilterDifferentialPressureShutdown1071

AirFilterDifferentialPressureSensorShortHigh1073

AirFilterDifferentialPressureSensorShortLow1074

HighAirFilterDifferentialPressureWarning10715

LowAirFilterDifferentialPressureWarning10717

HighEngineCoolantTemperatureShutdown1100

EngineCoolantTemperatureSensorShortHigh1103

EngineCoolantTemperatureSensorShortLow1104

HighEngineCoolantTemperatureWarning11015

LowEngineCoolantTemperatureWarning11017

HighEngineCoolantLevelShutdown1110

LowEngineCoolantLevelShutdown1111

1.1SPN/FMIList38

APPENDIXA

EventNameSPNFMI

EngineCoolantLevelSensorShortHigh1113

EngineCoolantLevelSensorShortLow1114

HighEngineCoolantLevelWarning11115

LowEngineCoolantLevelWarning11117

HighFireExtinguisherPressureShutdown1370

LowFireExtinguisherPressureShutdown1371

FireExtinguisherPressureSensorShortHigh1373

FireExtinguisherPressureSensorShortLow1374

HighFireExtinguisherPressureWarning13715

LowFireExtinguisherPressureWarning13717

LowBatteryChargingSystemVoltageWarning16717

HighBatteryVoltageShutdown1680

HighBatteryVoltageWarning16815

LowBatteryVoltageWarning16817

HighAmbientAirTemperatureShutdown1710

LowAmbientAirTemperatureShutdown1711

AmbientAirTemperatureSensorShortHigh1713

AmbientAirTemperatureSensorShortLow1714

HighAmbientAirTemperatureWarning17115

LowAmbientAirTemperatureWarning17117

HighExhaustTemperatureShutdown1730

LowExhaustTemperatureShutdown1731

ExhaustTemperatureSensorShortHigh1733

ExhaustTemperatureSensorShortLow1734

ExhaustTemperatureSignalAbnormal1738

HighExhaustTemperatureWarning17315

LowExhaustTemperatureWarning17317

HighEngineOilTemperatureShutdown1750

LowEngineOilTemperatureShutdown1751

EngineOilTemperatureSensorShortHigh1753

EngineOilTemperatureSensorShortLow1754

HighEngineOilTemperatureWarning17515

LowEngineOilTemperatureWarning17517

EngineOverSpeedShutdown1900

EngineUnderSpeedShutdown1901

EngineSpeedSensorErraticorNotPresent1902

EngineSpeedSensorOpen1905

EngineUnderSpeedWarning19017

SoftwareVersionMismatch23431

SCADADataLinkFault62511

PrimaryDataLinkFault63911

CustomEvent#1HighShutdown7010

CustomEvent#1LowShutdown7011

CustomEvent#1HighWarning70115

CustomEvent#1LowWarning70117

CustomEvent#1Status70131













39

EventNameSPNFMI
































DigitalOutput#1ShortHigh9243

DigitalOutput#2ShortHigh9253

EmergencyStopSwitchActivated97031

HighGeneratorRearBearingTemperatureShutdown11220

LowGeneratorRearBearingTemperatureShutdown11221

GeneratorRearBearingTemperatureSensorShortHigh11223

GeneratorRearBearingTemperatureSensorShortLow11224

HighGeneratorRearBearingTemperatureWarning112215

LowGeneratorRearBearingTemperatureWarning112217

HighGeneratorWinding#1TemperatureShutdown11240

HighGeneratorWinding#1TemperatureWarning112415





AccessoryDataLinkFault123111

FuelTankLeak123931

UnexpectedEngineShutdown138311

HighGasPressureShutdown13900

LowGasPressureShutdown13901

HighGasPressureWarning139015

LowGasPressureWarning139017

EngineFailuretoStart166431

HighRightExhaustTemperatureShutdown24330

LowRightExhaustTemperatureShutdown24331

RightExhaustTemperatureSensorShortHigh24333

RightExhaustTemperatureSensorShortLow24334

40

EventNameSPNFMI

RightExhaustTemperatureSignalAbnormal24338

HighRightExhaustTemperatureWarning243315

LowRightExhaustTemperatureWarning243317

HighLeftExhaustTemperatureShutdown24340

LowLeftExhaustTemperatureShutdown24341

LeftExhaustTemperatureSensorShortHigh24343

LeftExhaustTemperatureSignalAbnormal24348

LeftExhaustTemperatureSensorShortLow24344

HighLeftExhaustTemperatureWarning243415

LowLeftExhaustTemperatureWarning243417

GeneratorOverFrequencyShutdown24360

GeneratorUnderFrequencyShutdown24361

EngineSpeed-GeneratorOutputFrequencyMismatchWarning24362

GeneratorOutputSensingSystemFailure243612

GeneratorOverFrequencyWarning243615

GeneratorUnderFrequencyWarning243617

GeneratorOverVoltageShutdown24400

GeneratorUnderVoltageShutdown24401

GeneratorOverVoltageWarning244015

GeneratorUnderVoltageWarning244017

GeneratorOverCurrentShutdown24480

GeneratorOverCurrentWarning244815

GeneratorReversePowerShutdown24521

GeneratorHighPowerWarning245215

GeneratorReversePowerWarning245217

ServiceMaintenanceIntervalWarning264831

EngineControllerNotResponding35439

UtilityBreakerSystemFault354611

EngineInletManifoldChargeCombustion378331

EPSSupplyingLoad382931





























41

EventNameSPNFMI













AirDamperClosed400031

ATSinNormalPosition400131

ATSinEmergencyPosition400231

BatteryChargerFailure400331

GeneratorBreakerClosed400431

UtilityBreakerClosed400531

EngineinCooldown400631

GeneratorControlNotinAutomaticWarning400731

GeneratorBreakerFailuretoOpen400931

UtilityBreakerFailuretoOpen401031

GeneratorBreakerFailuretoClose401131

UtilityBreakerFailuretoClose401231

GeneratorCircuitBreakerOpen401331

UtilityBreakerOpen401431

UtilitytoGeneratorTransferFailureShutdown40150

UtilitytoGeneratorTransferFailureWarning401515

GeneratortoUtilityTransferFailureWarning401615

LossofUtility401731

GeneratorBreakerLockedOut401831

UtilityBreakerLockedOut401931

EarthFault402831

EarthLeakage402931

LowBatteryCrankingVoltageWarning425617

42Setpoints>Control>AutomaticStart/Stop

SetpointNameMinValueMaxValueUnitsDescription

Enginestartfaultprotectionactivationdelaytime0300SecTimedelaytopreventshutdownduringstartupfromlowoilpressureetc.

CrankDuration5300SecAmountoftimethecontrolenergizes(cranks)thestartingmotor

CrankCycleRestInterval5300SecTimethecontrolde-energizesthestartingmotorbetweencrankcycles

EnginePurgeCycleTime020Sec

MaximumNumberofCrankCycles120N/aNumberofcrank/restcyclesthatthecontrolwilltry.

CooldownDuration030MinThetimeallowingtheenginetorunafteranormalshutdownisinitiated

StartAidActivationTime0240SecAmountoftimethecontrolactivatesstartaidcontroloutput.Setto10secondsforaEUIwithprelubeoption.

CrankAlertActivationTime060SecAmountoftimethecontrolactivatescrankalertoutput.

CrankTerminateRPM1001000RPMEnginespeedsettingusedinordertodisengagethestartingmotorduringenginecranking

EngineFuelTypeConfigurationListSetpointallowsforselectionofDieselorNaturalGas

FuelShutoffSolenoidTypeConfigurationListTypeoffuelsystemsolenoidusedonthegeneratingset.SelectEnergizedtorun(ETR)orEnergizedtoShutOff(ETS).

EngineCooldownSpeedConfigurationListSelectenginespeedduringcooldown-ratedoridle.

EngineOperatingStateInputConfigurationListSettoCANInputforcommonengineinterfaceenginesandsettoHardWiredfornon-commonengineinterfaceEUIenginesandnon-EUIengines.

EngineIdleOperationEnableStatusEngineList

FuelPrimingFeatureEnableStatusList

EngineCoolantTemperatureSensorConfigurationListSettoSensorforMUIEnginesandsettoDataLinkforEUIEngines.

EngineOilPressureSensorConfigurationListSettoSensorforMUIEnginesandsettoDataLinkforEUIEngines.

LowIdleLowEngineOilPressureWarningEventThreshold34690Kpa

LowIdleLowEngineOilPressureShutdownEventThreshold34690Kpa

LowEngineOilPressureStepSpeed4001800RPMWhentheenginespeedbelowthis,theLowIdlesetpointisused.Setto800RPMforenginesratedat1000or1200RPM.Setto1200RPMforenginesratedat1500or1800RPM.

EmergencyStopInputActiveStateConfiguration

1.2Control

1.2.1AutomaticStart/Stop43

Setpoints>EngineMonitor/Protect>BatteryVoltageMonitor

SetpointNameMinValueMaxValueUnits

HighBatteryVoltageWarningEventThreshold1250VDC

HighBatteryVoltageWarningEventNotificationDelayTime0.0240sec

HighBatteryVoltageShutdownEventThreshold1250VDC

HighBatteryVoltageShutdownEventNotificationDelayTime0.0240sec

LowBatteryVoltageWarningEventThreshold0.025.0VDC

LowBatteryVoltageWarningEventNotificationDelayTime0.0240sec

LowBatteryChargingSystemVoltageWarningEventThreshold0.030VDC

LowBatteryChargingSystemVoltageWarningEventNotificationDelayTime0.0240sec

LowCrankingVoltageWarningEventThreshold0.030.0VDC

LowCrankingVoltageWarningEventNotificationDelayTime0.0240sec

Setpoints>Control>AVRDesiredVoltage


MaximumGeneratorVoltageOutputBiasPercentage0100%TheMaximumGeneratorOutputvoltageBiasPercentisthemaximumvalueaboveandbelowtheNominalVoltagethatthecontrolwillsendarequestforwhenadjustingthevoltagefromthecontrolscreen

GeneratorNominalOutputVoltage10050000VTheGeneratorNominalOutputVoltageisthedesiredoutputvoltageofthegeneratingset.Thisvalueissettomatchthegeneratorratedvoltage.

Setpoints>Control>GovernorDesiredEngineSpeed


MaximumEngineSpeedRange02000rpmTheMaximumEngineSpeedRangeisthemaximumvalueaboveandbelowtheNominalEngineSpeedthatPowerWizardwillsendarequestforwhenadjustingthespeedfromthecontrolscreen

GeneratorNominalOutputFrequency40500HzThisvalueissettomatchthegeneratorratedfrequency

Setpoints>EngineMonitor/Protect>Crank/StartCounter

SetpointNameMinValueMaxValueUnitsFactoryDefaultDescription

CustomerSecurityPasswordLeveltoResetCrank/StartCounters04n/a3PasswordlevelrequiredinordertoresettheCrank/StartCounters

1.2.2AVRDesiredVoltage1.2.3GovernorDesiredEngineSpeed1.3EngineMonitor/Protect

1.3.1BatteryVoltageMonitor1.3.2Crank/StartCounter44

Setpoints>EngineMonitor/Protect>EngineSpeedMonitor


FlywheelTeeth95350N/A

EngineOverSpeedShutdownThreshold4004330rpmSetto118%ofratedspeed

EngineUnderSpeedWarningEventThreshold4004330rpmSetto86%ofratedspeed

EngineUnderSpeedWarningEventNotificationDelayTime0.020.0sec.

EngineUnderSpeedShutdownEventThreshold4004330rpmSetto82%ofratedspeed

EngineUnderSpeedShutdownEventNotificationDelayTime0.020.0sec.

EngineSpeedSensorConfigurationValueList

DescriptionofEventResponseSelection

ActiveOnlyOnlydisplayseventintheeventlog(nohistoryontheevent)

WarningEventlogged,amberwarningstatusLED

AudibleAlertActivatesrelayoutputconfiguredashorncontrol

SoftShutdownShutdowneventallowscooldowncycle

HardShutdownShutdowneventskipscooldowncycleforfastengineshutdown

Breaker1TripActivatesrelayoutputconfiguredasbreaker1trip

Breaker2TripActivatesrelayoutputconfiguredasbreaker2trip

FTPSuppresstheeventuntiltheengineisrunningandthefaultprotectiontimerhasexpired

Setpoints>EngMonitor/Protect>ServiceMaintenanceInterval

SetpointNameMinValueMaxValueUnitsFactoryDefault

ServiceMaintenanceIntervalHours0.02000hours500

ServiceMaintenanceIntervalDays0.0365days180

CustomerPasswordSecurityLeveltoResetServiceMaintenanceInterval0.04N/A3

Setpoints>EngineMonitor/Protect>EnhancedEngineMonitor


EngineCylinderTemperatureSensorInstallationStatusValueListSelectInstalledorNotinstalled

NumberofEngineCylinders120n/a

1.3.3EngineSpeedMonitor1.3.4EnhancedEngineMonitor1.3.5ServiceMaintenanceInterval1.4Events45

GeneratorConnectionConfigurationValueListConfigurationscanbe:Star/WyeDelta/3WireDelta/4WireSinglePhase2WireSinglePhase3Wire

GeneratorPotentialTransformerPrimaryWindingRating150000VFordirectsensingleaveatdefaultvalue.Foranapplicationrequiringapotentialtransformersettotransformerprimarywindingvalue.

GeneratorPotentialTransformerSecondaryWindingRating1240VFordirectsensingleaveatdefaultvalue.Foranapplicationrequiringapotentialtransformersettotransformersecondarywindingvalue

GeneratorCurrentTransformerPrimaryWindingRating17000ASettocurrenttransformerprimarywindingvalue

GeneratorCurrentTransformerSecondaryWindingRating15ACanonlybesetto1or5

NumberofGeneratorPoles0200N/A

GeneratorRatedFrequencyValueList

GeneratorRatedVoltage10050000V

GeneratorRatedPower150000kW

GeneratorRatedApparentPower150000kVA

Setpoints>GeneratorMonitor/Protect>EnhancedGeneratorMonitor

SetpointNameMinValueMaxValueUnitsFactoryDefaultDescription

GeneratorWindingTemperatureSensorInstallationStatusValueListSettoInstalledwhenatemperaturemoduleisinstalledontheaccessorydatalink

NumberofGeneratorBearingTemperatureSensorsValueList

Setpoints>GenMonitor/Protect>GenACPowerMon

SetpointNameMinValueMaxValueUnitsFactoryDefault

CustomerPasswor

Documents

PowerWizard_Technical_1-1_1-1plus_2-1