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FG Wilson PowerWizard 1.1, Technical Manual

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FG Wilson PowerWizard 1.1 Technical Manual Download Page 3

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5.  SeTPoInT ProGraMMInG 

24

5.1  Digital Input Programming ......................................................................................................................... 24

5.1.1  Digital Inputs ...................................................................................................................................................................24
5.1.2  Dedicated Digital Inputs .............................................................................................................................................24
5.1.3  Programmable Digital Inputs ................................................................................................................................... 25

5.2  relay and Digital output Programming ................................................................................................... 26
5.3  analogue Input Programming ................................................................................................................... 29

6.  reTrofITTInG PoWerWIzarDS 

31

6.1  eST availability and licensing .................................................................................................................... 31
6.2   flash files and field replacement files  ................................................................................................... 31
6.3  Possible eST error messages, their cause and suggested action ......................................................... 34

7. 

STeP THroUGH GUIDeS 

35

7.1  reduced Power Mode (rPM)....................................................................................................................... 35
7.2  Service Maintenance Interval  .................................................................................................................... 36

7.2.1  Reset Service Interval  ................................................................................................................................................. 36
7.2.2  Change Duration of Service Interval Alarm ......................................................................................................... 36
7.2.3  Disable Service Interval Alarm ................................................................................................................................. 36

7.3  Setting up language.................................................................................................................................... 36
7.4  Disabling noT In aUTo ............................................................................................................................... 37
7.5  Disabling Thermo Start (Start aid activation) ......................................................................................... 37

Summary of Contents for PowerWizard 1.1

Page 1: ...PowerWizard 1 1 1 1 2 1 Generating Set Control Technical Manual ...

Page 2: ... 12 3 2 6 Single Event Resetting 12 3 2 7 All Events Resetting 12 3 3 Security 12 3 4 Real Time Clock Programming PowerWizard 2 1 13 3 5 Fuel Priming Engines with Electronic Fuel Lift Pump 13 3 6 Fuel Transfer PowerWizard 2 1 14 3 7 Programmable Cycle Timer PCT PowerWizard 2 1 14 3 7 1 PCT Status 14 3 7 2 Controlling The Outputs 14 3 7 3 PCT Example 14 4 Installation 15 4 1 Power Requirements 15 4...

Page 3: ... EST Availability and Licensing 31 6 2 Flash Files and Field Replacement Files 31 6 3 Possible EST error messages their cause and suggested action 34 7 Step Through Guides 35 7 1 Reduced Power Mode RPM 35 7 2 Service Maintenance Interval 36 7 2 1 Reset Service Interval 36 7 2 2 Change Duration of Service Interval Alarm 36 7 2 3 Disable Service Interval Alarm 36 7 3 Setting up Language 36 7 4 Disab...

Page 4: ...d Engine Monitor 45 1 2 5 Service Maintenance Interval 45 1 3 Events 45 1 4 Generator Monitor Protect 46 1 4 1 Enhanced generator monitor 46 1 4 2 Generator AC monitor 46 1 4 3 Generator AC power monitor 46 1 4 4 Generator over current 47 1 4 5 Generator Over Under Frequency 47 1 4 6 Generator Over Under Voltage 47 1 4 7 Generator Reverse Power 47 1 5 Network 48 1 6 Reduced Power Mode 48 1 7 Input...

Page 5: ... by failure to observe basic safety rules or precautions An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs A person must be alert to potential hazards This person should also have the necessary training skills and tools to perform these functions properly ...

Page 6: ...e controllers allows them to be used in some cases on other applications such as Marine auxiliary generating set switchgear applications industrial engines and generating sets as well as gas generating sets 1 3 PowerWizard Variations Some of the different features of the three versions PowerWizard 1 1 PowerWiard 1 1 and PowerWizard 2 1 are listed in Table 1 Controllers Series Features PowerWizard ...

Page 7: ...ay screen 2 AC overview key 3 Engine overview key 4 Main menu or home key 5 Alarm acknowledge key 6 Event reset key 7 Event log key 8 Auto key 9 Stop key 10 Run key 11 Escape key 12 Up key 13 Right key 14 OK or Enter key 15 Down key 16 Left key Figure 2 PowerWizard Control Module Description ...

Page 8: ... the Escape key is pressed during setpoint programming none of the changes made on screen will be saved to memory Scroll Right The Scroll Right key is used during setpoint adjustment During numeric data entry the Scroll Right key is used to choose which digit is being edited The Scroll Right key is also used during certain setpoint adjustments to select or deselect a check box If a box has a check...

Page 9: ...e no longer any active shutdown events the red light will turn off Alarm Acknowledge Pressing the Alarm Acknowledge will cause the horn relay output to turn off and silence the horn Pressing the key will also cause any yellow or red flashing lights to turn off or to become solid depending on the active status of the alarms Event Reset Key Pressing the Event Reset key will reset all events when the...

Page 10: ...Override Fuel Transfer Battery Voltage Monitor Crank Start Counter Engine Speed Monitor Enhanced Engine Monitor Service Maintenance Interval Diagnostic Resp Config Eng Protect Resp Config Gen Protect Resp Config Customer Event Resp Config Other System Resp Config Enhanced Gen Monitor Generator AC Monitor Gen AC Power Monitor Generator Over Current Gen Over Under Frequency Gen Over Under Voltage Ge...

Page 11: ...inactive The control receives a stop command via the RS 485 SCADA Data Link PowerWizard 2 1 The control has a program cycle timer PCT configured that becomes inactive PowerWizard 2 1 only The PowerWizard begins the cooldown period In order to bypass the cooldown hold down the Stop key for 3 seconds The 2 options PRESS ENTER TO BYPASS and PRESS ESCAPE TO CONTINUE will be shown on the display Press ...

Page 12: ...to the main menu 9 3 2 7 All Events Resetting In addition to the above procedure there is also a simplified process for resetting all events for all modules To reset all events Ensure that the control is in the stopped position 1 Press the Reset Event key from any screen 2 A confirmation prompt will appear 3 Press the OK key to reset all events on all modules Press the Escape key to cancel the res...

Page 13: ...s feature the control must be at current security Level 2 or higher Highlight and press OK to proceed to the password entry screen To setup or change the password enter the new password using the cursor keys Passwords may be 16 digits long To disable the level 2 security password set the password to 0 Press the OK key to save CHANGE SCADA PASSWORD PowerWizard 2 1 only used to setup change or disab...

Page 14: ...onsists of seven independent timers Each timer has the following setpoints setpoints shown are for PCT 1 Day of the Week This permits independent selection of each day 0 Sun 6 Sat that the timer will activate Start Time The time of day in hours and minutes that the timer will activate Run For The duration in hours and minutes for which the timer will be active up to 24 hours Output 1 Active or Ina...

Page 15: ...they do not interfere with each other An example is shown in Figure 5 As shown in the figure all electronics are electrically isolated from higher current loads such as the starter motor All electronics have a common Power Bus and Single Point Reference The chassis ground is a common Power and Transient Ground The electronics such as sensors and control modules have isolated power source paths Hig...

Page 16: ...on the back of the control Not all 70 pins are used The following diagrams show what pins are used and what each pin should be connected to for each version of the control Figures 6 and 7 are shown with all possible connections used For Electronic Engines EUI the passive analogue input numbers 1 and 2 will not be used These are for oil pressure and coolant temperature respectively On EUI engines t...

Page 17: ...MMON MODBUS DATA LINK J1939 CAN DATA LINKS 0 5A AC RMS CAN 1 DATA LINL CAN 1 DATA LINL CAN 1 SHIELD CAN 2 DATA LINL CAN 2 DATA LINL CAN 2 SHIELD MODBUS MODBUS MODBUS REF MPU MAGNETIC PICKUP INPUT MAGNETIC PICKUP INPUT 12 or 24 VDC NOTE B L1 L2 L3 N NOTE A Load are not to exceed 2A of current draw Minimum current 10mA NOTE B Load are not to exceed 300 mA of current draw CT A CT B CT C 5V output 16 ...

Page 18: ...rogrammed for the correct winding ratios when connecting external potential transformers The wye configuration of external potential transformers is preferred for 4 wire wye generating set because of the greater accuracy when loads are unbalanced With the open delta configuration some power parameters cannot be determined These parameters are real power phase A B C and power factor phase A B C For...

Page 19: ...d by the aftersales help desk refer to the contacts list at the back of this manual 4 6 1 Primary J1939 Data Link CAN1 The Primary J1939 Data Link is supported by all of the PowerWizard controls The Primary J1939 Data Link is used for local communication among modules associated with a single generating set The PowerWizard can interface with both Electronic Engines EUI and Mechanical Engines MUI I...

Page 20: ...is a bus topology consisting of a main trunk and small drops The maximum allowable trunk length is 130 ft 40 m and the maximum drop length is 3 ft 1 m The CAN network requires a termination resistor on the extreme ends of the main trunk The topology for the PowerWizard 1 1 and 1 1 is illustrated in Figure 11 PowerWizard 1 1 1 1 CANI CANI CANI SH 50 34 42 J20 Engine ECM CANI CANI CANI SH 50 34 42 J...

Page 21: ...244 m and the maximum drop length is 3 ft 1 m The CAN network requires a termination resistor on the extreme ends of the main trunk The topology for the PowerWizard 2 1 with some remote devices connected is illustrated in Figure 12 Note that more remote devices can be connected as long as the proper lengths are maintained and the termination resistor is placed at the end of the trunk PowerWizard 2...

Page 22: ...iator Note CAN1 indicates the connection for the PowerWizard Primary J1939 data link and CAN2 indicates the connection for the PowerWizard Accessory J1939 data link The PowerWizard 1 1 and 1 1 only supports the Primary J1939 data link For more information on the Primary and Accessory data links refer to the Data Links section PowerWizard 1 1 1 1 Supports one Annunciator module using CAN1 Emergency...

Page 23: ...iator Connection PowerWizard 2 1 Supports one Annunciator module using CAN1 and up to three Annunciators using CAN2 PowerWizard 2 1 CAN 2 800 ft Maximum Annunciator 1 Annunciator 2 Annunciator 3 3 ft Maximum Figure 19 Example illustration of Accessory Data Link Modules and Wire Lengths ...

Page 24: ...rst and second digital inputs are dedicated for the emergency stop and remote initiate function The other 6 digital inputs on the PowerWizard 2 1 4 digital inputs on PowerWizard 1 1 can be programmed for Disabled Command or Status System Events and SCADA Datalink USAGE TYPE SYSTEM EVENT EVENT PARAMETER FAILURE TYPE EVENT DELAY ACTIVE STATE USAGE TYPE SYSTEM EVENT EVENT PARAMETER FAILURE TYPE EVENT...

Page 25: ... Voltage ECS in Stop Raise Speed Idle Mode Command Lower Speed Start Aid Timer Bypass Auto Load Fuel PW1 1 and PW2 1 Inhibit Cool Down 2 System Event System Event can be configured by setting Event Parameters Failure Type Event Delay and Active State The event type is the selection of the Suspect Parameter Number SPN for the input Table 4 gives a list of supported event parameters Event Parameter ...

Page 26: ... Outputs Each relay is capable of handling 2A 30 VDC The relay contacts are not protected against shorts to battery or ground Relay outputs 1 and 2 are typically used for Engine crank and fuel control PowerWizard 2 1 has also two current sink outputs namely digital outputs PowerWizard 1 1 and 1 1 have no digital outputs Each digital output is capable of sinking 300 mA The outputs have diagnostics ...

Page 27: ... necessarily imply the action that is performed Breaker Trip 2 Activated when any event occurs that has an event response configuration set for Breaker Trip 2 This deactivates when the event is neither present nor active This output does not control a circuit breaker unless the user makes the connections to do so This output type should be viewed as having a generic name because the name does not ...

Page 28: ... in Cooldown Digital Input 5 Custom Event Engine Fail to Start Digital Input 6 Custom Event Engine Speed Analog Input 1 Custom Event Control Not in Auto Analog Input 2 Custom Event Gen Current Amp Analog Input 3 Custom Event Generator Circuit Breaker Closed Digital Input 5 Custom Event Generator Circuit Breaker Locked Out Digital Input 6 Custom Event Generator Circuit Breaker Failure to Open Analo...

Page 29: ...ata Link PowerWizard 2 1 Only Desired Engine Speed Command Urea Level Table 8 List of supported parameters Analogue inputs can be configured from menu options MAIN MENU CONFIGURE INPUTS OUTPUTS ANALOGUE INPUTS There are three USAGE TYPES for an available input DISABLED RESISTIVE and VOLTAGE SENDER Each of the inputs can be configured to have HIGH WARNING LOW WARNING HIGH SHUTDOWN or LOW SHUTDOWN w...

Page 30: ...ange and corresponding data range need to be selected The available voltage ranges are given in Table 10 The minimum and maximum data points can be set under the menu of DATA RANGE MIN and DATA RANGE MAX Available Voltage Range 0V to 5V 1V to 5V 0V to 10V Table 10 ...

Page 31: ...me file but in a different language inform the helpdesk and they will send the equivalent file in the required language Available languages are 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 If the file is for a new job not associated wi...

Page 32: ...from within the EST sub menu of Windows or 1 it can be accessed from the Service Tool menu by selecting Utilities Winflash Ensure that the service tool is using RP1210 under Utilities preferences communications 2 Ensure that the communications adapter is connected to the correct port of the PC 3 You should have a screen similar to 4 Press Browse and select the desired flash file Press Begin Flash ...

Page 33: ...e below Select the Field replacement File xml file that you want to load as shown in the screen below 2 The following screen will then be displayed showing the configuration values Select Program ECM to load the configuration values onto the controller Once the configuration values have been successfully 3 loaded the message Programming Complete will be displayed ...

Page 34: ...k Ensure the PowerWizard module is powered up and is not in Reduced Power Mode Check the J1939 wiring between the PowerWizard and the communications adapter particularly the termination resistor s The ECM software file and the ECM are not compatible Process aborted Error Code 163840 Cause The flash file is not compatible with the PowerWizard This is usually seen when trying to flash a module with ...

Page 35: ...s an Emergency Stop or a remote start signal Enabling Reduced Power Mode on Using EST Open EST 1 Ensure that the service tool is using RP1210 under Utilities preferences communications 2 Ensure that the communications adapter is connected to the correct port of the PC 3 Connect to the PowerWizard control Press F8 4 Select Configuration Service Configuration or press F5 5 It will take some tome for...

Page 36: ...u may require a level 3 password to do this or use the service tool to change this password level from 3 to 2 MAIN MENU CONFIGURE RESET COUNTERS SERVICE MAINTENANCE INTERVAL 7 2 2 Change Duration of Service Interval Alarm The duration of the Service Interval can only be changed using the service tool and not from the keypad If the interval in days causes the alarm to be raised before the interval ...

Page 37: ...screen that is used to configure the desired response for the Not In Auto alarm The options available can be viewed or edited A indicates which options are selected The user may select or remove by using the left cursor key If unable to EDIT check that the generating set is in STOP position and that the required password level is used 7 5 Disabling Thermo Start Start Aid Activation To disable the ...

Page 38: ...l Shutdown 98 1 Engine Oil Level Sensor Short High 98 3 Engine Oil Level Sensor Short Low 98 4 High Engine Oil Level Warning 98 15 Low Engine Oil Level Warning 98 17 High Engine Oil Filter Differential Pressure Shutdown 99 0 Low Engine Oil Filter Differential Pressure Shutdown 99 1 Engine Oil Filter Differential Pressure Sensor Short High 99 3 Engine Oil Filter Differential Pressure Sensor Short L...

Page 39: ...Sensor Short Low 173 4 Exhaust Temperature Signal Abnormal 173 8 High Exhaust Temperature Warning 173 15 Low Exhaust Temperature Warning 173 17 High Engine Oil Temperature Shutdown 175 0 Low Engine Oil Temperature Shutdown 175 1 Engine Oil Temperature Sensor Short High 175 3 Engine Oil Temperature Sensor Short Low 175 4 High Engine Oil Temperature Warning 175 15 Low Engine Oil Temperature Warning ...

Page 40: ...16 31 Digital Output 1 Short High 924 3 Digital Output 2 Short High 925 3 Emergency Stop Switch Activated 970 31 High Generator Rear Bearing Temperature Shutdown 1122 0 Low Generator Rear Bearing Temperature Shutdown 1122 1 Generator Rear Bearing Temperature Sensor Short High 1122 3 Generator Rear Bearing Temperature Sensor Short Low 1122 4 High Generator Rear Bearing Temperature Warning 1122 15 L...

Page 41: ...rning 2448 15 Generator Reverse Power Shutdown 2452 1 Generator High Power Warning 2452 15 Generator Reverse Power Warning 2452 17 Service Maintenance Interval Warning 2648 31 Engine Controller Not Responding 3543 9 Utility Breaker System Fault 3546 11 Engine Inlet Manifold Charge Combustion 3783 31 EPS Supplying Load 3829 31 Custom Event 17 Status 3880 31 Custom Event 18 Status 3881 31 Custom Eve...

Page 42: ...enerator Breaker Closed 4004 31 Utility Breaker Closed 4005 31 Engine in Cooldown 4006 31 Generator Control Not in Automatic Warning 4007 31 Generator Breaker Failure to Open 4009 31 Utility Breaker Failure to Open 4010 31 Generator Breaker Failure to Close 4011 31 Utility Breaker Failure to Close 4012 31 Generator Circuit Breaker Open 4013 31 Utility Breaker Open 4014 31 Utility to Generator Tran...

Page 43: ... Engine Fuel Type Configuration List Setpoint allows for selection of Diesel or Natural Gas Fuel Shutoff Solenoid Type Configuration List Type of fuel system solenoid used on the generating set Select Energized to run ETR or Energized to Shut Off ETS Engine Cooldown Speed Configuration List Select engine speed during cooldown rated or idle Engine Operating State Input Configuration List Set to CAN...

Page 44: ... This value is set to match the generator rated frequency 1 3 Engine Monitor Protect 1 3 1 Battery Voltage Monitor Setpoints Engine Monitor Protect Battery Voltage Monitor Setpoint Name Min Value Max Value Units High Battery Voltage Warning Event Threshold 12 50 VDC High Battery Voltage Warning Event Notification Delay Time 0 0 240 sec High Battery Voltage Shutdown Event Threshold 12 50 VDC High B...

Page 45: ...elect Installed or Not installed Number of Engine Cylinders 1 20 n a 1 3 5 Service Maintenance Interval Setpoints Eng Monitor Protect Service Maintenance Interval Setpoint Name Min Value Max Value Units Factory Default Service Maintenance Interval Hours 0 0 2000 hours 500 Service Maintenance Interval Days 0 0 365 days 180 Customer Password Security Level to Reset Service Maintenance Interval 0 0 4...

Page 46: ...or an application requiring a potential transformer set to transformer primary winding value Generator Potential Transformer Secondary Winding Rating 1 240 V For direct sensing leave at default value For an application requiring a potential transformer set to transformer secondary winding value Generator Current Transformer Primary Winding Rating 1 7000 A Set to current transformer primary winding...

Page 47: ... Under Frequency Warning Event Percentage Threshold 80 0 120 0 95 0 Generator Under Frequency Warning Event Notification Delay Time 0 0 120 sec 10 Generator Under Frequency Shutdown Event Percentage Threshold 80 0 120 0 90 0 Generator Under Frequency Shutdown Event Notification Delay Time 0 0 120 sec 4 1 5 6 Generator Over Under Voltage Setpoints Generator Monitor Protect Generator Over Under Volt...

Page 48: ... 1 247 N A SCADA Data Link Access Password 0 0 0xfffff N A SCADA Data Link Connection Timeout Interval 0 1 3600 0 sec RS 485 Bias Resistor Enable Status Disabled Enabled N A 1 7 Reduced Power Mode Setpoints Reduced POWER Mode Delay Time Setpoint Name Min Value Max Value Units Description Reduced power mode delay time 1 100 min The control will run at reduced power mode after delay This mode can be...

Page 49: ...lue Max Value Resolution Units Factory Default Analogue Input Type Value list 0 Analogue Input Range Value list 0 Analogue Input Data Identification Value list 0 Analogue Input Configuration Code 1 25 1 N A 1 Analogue Input Data Range Min 1 50000 0 01 N A 0 Analogue Input Data Range Max 1 50000 0 01 N A 100 Analogue Input High Warning Event Threshold 0 50000 1 N A 100 Analogue Input High Warning E...

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