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0 Control Systems
Technical Manual
PWTECH/0507/GB
PowerWizard Technical Manual
Introduction ................................................................................................................................
1.2
Applications ................................................................................................................................ 6
1.3
1.4
2.2
2.3
2.4
3.2
3.3
4.2
4.1.2
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
4.2.7
4.3
Security ....................................................................................................................................... 16
4.4
4.5
4.6
4.6.2
4.6.3
INSTALLATION ..................................................................................................................................... 19
5.1
5.2
5.3
5.4
5.5
5.5.2
24
5.6
6.2
5.6.3
5.6.4
5.6.5
5.6.6
5.6.7
5.6.8
32
35
6.1.1
6.1.2
36
38
6.2.2
6.2.3
6.2.4
6.2.5
40
43
40
7.1
7.2
7.2.2
44
8.2
5.6.2
6.2.1
7.3
8
5.6.1
8.1.2
48
8.2.2
8.2.3
8.3
8.4
8.5
General Information
1.1
Introduction
1.2
Applications
The PowerWizard range of generating set control systems is designed for use in a variety of applications. The control
systems can be used on standby and prime power diesel generating sets. The configurability of the controllers
allows them to be used, in some cases, on other applications such as marine auxiliary generating sets, switchgear
applications, industrial engines and generating sets as well as gas generating sets.
1.3
Some of the different features of the two versions, PowerWizard 1.0 and PowerWizard 2.0 are listed in Table 1.
AC Power Metering
DC metering Batt Volts, Eng Hours Run, RPM, Eng Temperature and Oil
Pressure
1.4
Display screen
Auto
AC overview hot-key
Stop
DC overview hot-key
Up cursor
Warning lamp
Escape
Shutdown lamp
Right cursor
Alarm acknowledge
Enter
Lamp test
Down cursor
Run
Left cursor
Basic Operation
STOP Mode
AUTO Mode
3.1
Function Keys
AC Overview hot-key The AC Overview key will navigate the display to the first screen of AC information. The AC
Overview information contains various AC parameters that summarise the electrical operation of the generating set.
(Use the up/down keys to navigate within the AC parameters).
Engine Overview hot-key The Engine Overview key will navigate the display to the first screen of engine information.
The Engine Overview information contains various engine parameters that summarise the operation of the generating
sets. (Use the up/down keys to navigate within the Engine parameters).
Lamp Test Pressing and holding the Lamp Test key will cause all of the LEDs and the display screen pixels to
turn on.
RUN Pressing the Run key will cause the engine to enter the run mode.
AUTO Pressing the Auto key will cause the engine to enter the auto mode.
STOP Pressing the Stop key will cause the engine to enter stop mode.
3.2 Menu Navigators
Scroll Up The Scroll Up key is used to navigate up through the various menus or monitoring screens. The Scroll Up
key is also used during setpoint entry. During numeric data entry the Scroll Up key is used in order to increment the
digits (0-9). If the setpoint requires selection from a list, the Scroll Up key is used to navigate through the list.
Escape The Escape key is used during menu navigation in order to navigate up through the menu/sub-menu
structure. Each key press causes the user to move backwards/upwards through the navigation menus. The Escape key
is also used to exit/cancel out of data entry screens during setpoint programming. If 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 mark inside, pressing the Scroll Right key will cause the check mark
to disappear, disabling the function. If the box does not have a check mark inside, pressing the Scroll Right key will
cause a check mark to appear, enabling the function.
Enter The Enter key is used during menu navigation to select menu items in order to navigate forward/downward
in the menu/sub-menu structure. The Enter key is also used during setpoint programming in order to save setpoint
changes. Pressing the Enter key during setpoint programming causes setpoint changes to be saved to memory.
Scroll Down The Scroll Down key is used to navigate down through the various menus or monitoring screens. The
Scroll Down key is also used during setpoint entry. During numeric data entry the Scroll Down key is used in order to
decrement the digits (0-9). If the setpoint requires selection from a list, the Scroll Down key is used to navigate down
through the list.
Scroll Left The Scroll Left key is used during setpoint adjustment. During numeric data entry, the Scroll Left key is
used to choose which digit is being edited. The Scroll Left key is also used during certain setpoint adjustments to select
or deselect a check box. If a box has a check mark inside, pressing the Scroll Left key will cause the check mark to
disappear, disabling the function. If the box does not have a check mark inside, pressing the Scroll Left key will cause a
check mark to appear, enabling the function.
10
3.3
Alarm Indicators
Yellow Warning Light A flashing yellow light indicates that there are unacknowledged active warnings. A solid yellow
light indicates that there are acknowledged warnings active. If there are any active warnings, the yellow light will
change from flashing yellow to solid yellow after the Alarm Acknowledge key is pressed. If there are no longer any
active warnings, the yellow light will turn off after the Alarm Acknowledge key is pressed.
Red Shutdown Light A flashing red light indicates that there are unacknowledged active shutdown events. A solid
red light indicates that there are acknowledged shutdown events active. If there are any active shutdown events the
red light will change from flashing red to solid red after the Alarm Acknowledge key is pressed. Any condition that has
caused a shutdown event must be manually reset. If there are 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 (if installed). 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. The Alarm Acknowledge may also be configured to send out a global
alarm silence on the J1939 Data Link, which will silence horns on annunciators. Pressing and holding the Alarm
Acknowledge key can be used to reset all active warnings or shutdowns.
11
Detailed Operation
ACTIVE EVENTS
GENSET CONTROL
ENGINE CONTROL
1
0
1
ENGINE OVERVIEW
3/17
OCC 1
*2 OR *3
1/3
OCC 1
*2
ESCAPE
KEY
ENTER
KEY
AC OVERVIEW
CONFIGURE
0kPa
0 rpm
STOPPED
OR
I/O STATUS
23 C
24.8V
2.1Hrs
*2. Scroll down to see all events. Events are listed in the following order. Present,
Active, Inactive. Only SHUTDOWN events can be reset; some events can be set
as a SHUTDOWN. To reset an event, the control must be in STOP. All other
events will become INACTIVE once the condition goes away.
USE
CONTROL
AVG: 481 V
60.2Hz
OR
PREFERENCES
L-L
324V
*3. To RESET: press ENTER to get to the details of the event and then ENTER
again.
CURRENT LEVEL = 2
DROP TO MIN LEVEL
ENTER LEVEL 1 OR 2
ENTER LEVEL 3
CHANGE LEVEL 1 PWD
CHANGE LEVEL 2 PWD
CONFIGURE
SECURITY
SETPOINTS
ENG OPERATE HRS
SETPOINTS
CONTROL
ENGINE MON/PROTECT
EVENTS
GEN MON/PROTECT
I/O
OTHER
CONTROL
AUTOMATIC START/STOP
AVR DESIRED VOLTAGE
GOV DESIRED ENG SPD
*1
ENG MONITOR/PROTECT
BATTERY VOLT MON
ENG COOL TEMP MON
ENG OIL PRES MON
ENG SPEED MON
*1
EVENTS
EVENT I/P FUNCTIONS
EVENT O/P FUNCTIONS
EVENT RESPONSE CFG
EVENT SYSTEM
*1
*1
*1
GEN MON/PROTECT
GEN AC MONITOR
I/O
DIGITAL I/P
RELAY O/P
CONTROL
SPEED ADJUST
PREFERENCES
CONTRAST
PRESSURE
TEMPERATURE
LANGUAGE
DIGITAL INPUTS
RELAY OUTPUTS
*1
DIAGNOSTICS CONFIG
PRESSURES
TEMPERATURES
LEVELS
OTHERS
*1
*1
*1
DIGITAL INPUTS
INPUT #1
INPUT #2
INPUT #3
INPUT #4
INPUT #5
INPUT #6
*1
RELAY OUTPUTS
OUTPUT #1
OUTPUT #2
OUTPUT #3
OUTPUT #4
OUTPUT #5
OUTPUT #6
*1
DIGITAL SELECTORS
DIGITAL SELECTOR #1
DIGITAL SELECTOR #2
DIGITAL SELECTOR #3
DIGITAL SELECTOR #4
OTHER
DIGITAL SELECTORS
REDUCED PWR MODE
*1
and
*1
-2-4-1---56
ADJUST SPEED
0.0 Hz
or
When unsure about your location on the screen, use ESCAPE Key and then refer to
this chart.
*1
*1
12
ACTIVE EVENTS
GENSET CONTROL
ENGINE CONTROL
1
1
0
ENGINE OVERVIEW
3/17
OCC 1
*2 OR *3
1/3
OCC 1
*2
ESCAPE
KEY
ENTER
KEY
AC OVERVIEW
CONFIGURE
0kPa
0 rpm
STOPPED
OR
I/O STATUS
23 C
24.8V
2.1Hrs
*2. Scroll down to see all events. Events are listed in the following order, Present,
Active, Inactive. Only SHUTDOWN events can be reset; some events can be set
as a SHUTDOWN. To reset an event, the control must be in STOP. All other
events will become INACTIVE once the condition goes away.
USE
CONTROL
AVG: 481 V
60.2Hz 0.82
TOTAL kW
OR
PREFERENCES
L-L
324V
LAGGING
216
48%
*3. To RESET: press ENTER to get to the details of the event and then ENTER
again.
CURRENT LEVEL = 2
DROP TO MIN LEVEL
ENTER LEVEL 1 OR 2
ENTER LEVEL 3
CHANGE LEVEL 1 PWD
CHANGE LEVEL 2 PWD
CHANGE SCADA PWA
CONFIGURE
SECURITY
SETPOINTS
TIME DATE
ENG OPERATE HRS
SETPOINTS
CONTROL
ENGINE MON/PROTECT
EVENTS
GEN MON/PROTECT
I/O
NETWORK
OTHER
CONTROL
AUTOMATIC START/STOP
AVR DESIRED VOLTAGE
GOV DESIRED ENG SPD
*1
ENG MONITOR/PROTECT
BATTERY VOLT MON
CRACK/START CTRS
ENG COOL TEMP MON
ENG OIL PRES MON
ENG SPEED MON
SERVICE MAINT INTERVAL
*1
EVENTS
EVENT I/P FUNCTIONS
EVENT O/P FUNCTIONS
EVENT RESPONSE CFG
EVENT SYSTEM
*1
*1
GEN MON/PROTECT
GEN AC MONITOR
GEN AC PWR MONITOR
GEN OVER CURRENT
GEN OVER/UNDER FREQ
GEN OVER/UNDER VOLT
I/O
DIGITAL INPUTS
INPUT #1
INPUT #2
INPUT #3
INPUT #4
INPUT #5
INPUT #6
INPUT #7
INPUT #8
DIGITAL INPUTS
DIGITAL OUTPUTS
RELAY OUTPUTS
SPARE ANNALOG INPUT
NETWORK
DATALINK - SCADA
ADJUST SPEED
0.0 Hz
OUTPUT1
OUTPUT1
PREFERENCES
CONTRAST
PRESSURE
TEMPERATURE
LANGUAGE
*1
1234567
01-0--101----
DIAGNOSTIC CONFIG
PRESSURES
TEMPERATURES
LEVELS
OTHERS
*1
*1
*1
*1
-2-4-----8
1---5671
CONTROL
SPEED ADJUST
PROG CYCLE TIMER
and
*1
DIGITAL I/P
RELAY O/P
DIGITAL O/P
or
When unsure about your location on the screen, use ESCAPE Key and then refer to
this chart.
OTHER
DIGITAL SELECTORS
REDUCED PWR MODE
PROG TRIP POINTS
*1
*1
*1
DIGITAL OUTPUTS
OUTPUT #1
*1
RELAY OUTPUTS
OUTPUT #1
OUTPUT #2
OUTPUT #3
OUTPUT #4
OUTPUT #5
OUTPUT #6
OUTPUT #7
OUTPUT #8
*1
DIGITAL SELECTORS
DIGITAL SELECTOR #1
DIGITAL SELECTOR #2
DIGITAL SELECTOR #3
DIGITAL SELECTOR #4
DIGITAL SELECTOR #5
DIGITAL SELECTOR #6
DIGITAL SELECTOR #7
*1
*1
13
4.2
Technical Operation
If the engine reaches the setpoint for crank terminate speed the engine is deemed running and the engine crank
relay will be deactivated
If the engine fails to start within a preset duration (normally seven seconds) the PowerWizard will stop cranking
and wait for a pre-set time (normally seven seconds) before attempting to start again
If the PowerWizard fails to start within a pre-set number of crank attempts (normally three) the PowerWizard will
activate a Fail to Start shutdown.
2. The PowerWizard begins the cool down period. In order to bypass the cool down hold down the stop key for
3 seconds. The options PRESS ENTER TO BYPASS and PRESS ESCAPE TO CONTINUE will be shown on
the display. Press the Enter key to bypass the cool down sequence or press the Escape key to continue the cool
down sequence.
3. After the cool down cycle, the PowerWizard stops the engine by turning off the fuel control relay.
4.2.3 Event System
The PowerWizard module uses the J1939 standard format for events, whereby an event is defined as a combination of
a suspect parameter number (SPN) and a failure mode identifier (FMI). The SPN defines what is at fault and the FMI
defines how it is at fault (e.g. SPN = 100 = Oil Pressure, FMI = 1 = Low Shutdown would mean the set has shutdown
on a low oil pressure fault). A list of SPN/FMI combinations can be found in appendix A.
PowerWizard modules have separate event logs for events raised by the module itself and those raised by ancillaries
such as the engine ECM.
14
15
Security
There are 3 levels of password protection on the PowerWizard control panel. All of the adjustable setpoints are
associated with a specific level of security required to make an adjustment to the parameter. The passwords only affect
changing setpoints within the control panel. Changing setpoints with the Service Tool does not require passwords.
The level of password protection that is required for each setpoint is identified on the parameter setpoint entry screen.
A security level identification number 1, 2 or 3 next to a padlock symbol is displayed on the parameter setpoint
entry screen. A Level 3 security is used for the most secure setpoints and Level 1 security is used for the least secure
setpoints. If the PowerWizard is currently at the required level of protection when viewing a parameter, the padlock will
not appear.
If a parameter is displayed with a padlock but no security level identification number next to it, the parameter cannot
be changed from the PowerWizard display and the service tool must be used. Level 1 and Level 2 passwords are
disabled when shipped from the factory. Level 1 and Level 2 passwords are user level passwords and can be used if
desired.
The PowerWizard 2.0 also has a SCADA password, which can be used to secure remote communications.
To view the security menu:
MAIN MENU > CONFIGURE > SECURITY
At the top of the security menu the current security level is displayed. Within the security menu are the following
options:
DROP TO MINIMUM LEVEL used to return the current security level to the lowest level set-up. Highlight and press
enter to drop to minimum security level. If no Level 1 or 2 passwords are set-up the minimum level will be 2. If a Level
2 password is set-up, the minimum level will be 1 and if a Level 1 password is set up the minimum level will be 0.
ENTER LEVEL 1 OR 2 used to enter Level 1 or 2 passwords. Highlight and press enter to proceed to the password
entry screen. Passwords can be entered using the cursor keys. In PowerWizard, Level 1 and 2 passwords must be
different. An entered password is compared against the stored Level 1 and 2 passwords, if the password is correct the
PowerWizard will go to the corresponding security level.
ENTER LEVEL 3 used to obtain Level 3 access. The Level 3 security password is reserved for critical setpoints that
should only be changed by a skilled operative. The Level 3 password is a prompt and response password.
Highlight and press enter to proceed to the phone in prompt display. The Level 3 password can be obtained by
contacting the genset manufacturer and providing the 16 digit phone in prompt. The manufacturer will then provide
the relevant response. To enter the 16 digit response press enter again. Passwords can be entered using the cursor
keys. The Level 3 password will expire 10 minutes after the last key pressed.
The Level 3 password can be obtained from the After Sales Helpdesk. Refer to the contacts list at the back of the
manual.
CHANGING LEVEL 1 PASSWORD used to set-up, change or disable a Level 1 password. In order to use this feature
the control must be at current security Level 1 or higher. Highlight and press Enter to proceed to the password entry
screen. To set up or change the password, enter the new password using the cursor keys. Passwords may be 16 digits
long. To disable the Level 1 security password, set the password to 0. Press the Enter key to save.
PowerWizard Technical Manual
16
CHANGING LEVEL 2 PASSWORD used to set up, change or disable a Level 2 password. In order to use this feature
the control must be at current security Level 2 or higher. Highlight and press enter to proceed to the password entry
screen. To set up 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 Enter key to save.
CHANGING SCADA PASSWORD (PowerWizard 2.0 only) used to set-up, change or disable a SCADA password.
Highlight and press enter to proceed to the password entry screen. To set-up or change the password, enter the new
password using the cursor keys. Passwords may be 16 digits long. To disable the SCADA security password, set the
password to 0. Press the Enter key to save.
4.4
The real time clock provides information for the time and date of an automatic time based start/stop control. It also
provides a mechanism for time stamps in the event log. The real time clock is not calibrated and is for information
only. The date and time are set by the user.
1. In order to set the time or date format:
MAIN MENU > CONFIGURE > TIME/DATE
2. To set the time, highlight the time then press the Enter key twice.
3. Use the cursor keys to set the time and press the Enter key to save. Press the Enter key to return.
4. To set the date, highlight the date then press the Enter key twice.
5. Use the cursor keys to set the date and press the Enter key to save. Press the Enter key to return.
6. To set the date format, highlight either the FORMAT DD/MM/YY or FORMAT MM/DD/YY and press the
Enter key.
7. Use the cursor keys to select the required date format and press the Enter key to save.
4.5
Certain engines fitted with an electronic fuel pump do not have a manual priming feature on the engine. In these
circumstances the PowerWizard can be used to energise the fuel lift pump in order to prime the engine.
1. In order to prime the genset:
MAIN MENU > CONTROL > ENGINE FUEL PRIMING
2. To prime the set press the right cursor key, this will initiate a 180 second priming cycle.
3. To exit the priming cycle press the left cursor key.
Note The generating set may only be primed when the set is stopped and there are no active or present shutdown
conditions.
4.6
To utilise the Programmable Cycle Timer feature, one may require a software upgrade. To confirm if a software
upgrade is required, please contact the after sales help desk. Refer to the contact list at the back of this manual.
The Programmable Cycle Timer (PCT) feature allows the operator to program times when two independent tasks,
called PCT outputs, will be activated or deactivated automatically during the week.
This is useful for cases where two or more generating sets are required to automatically share the duty of supplying a
load throughout the week. Using programmable cycle timer, each generating set can be programmed to start and stop
at pre-set times. The cooperation of a transfer switch is required to ensure that the generating sets are not stopped on
load.
PowerWizard Technical Manual
17
Programmable Cycle Timer can also be used in cases where a standby set does not have access to a utility supply to
power a trickle charger. Programmable Cycle Timer can be used to run the set for an hour a week to keep the battery
well charged.
The PCT feature consists of seven independent timers. Each timer has the following setpoints (setpoints shown are for
PCT #1):
Programmable Cycle Timer #1 Activation Day of the Week. This permits independent selection of each day
(Sun > Sat) that the timer will activate
Programmable Cycle Timer #1 Activation Start Time. The time of day (in hours and minutes) that the timer will
activate
Programmable Cycle Timer #1 Active Time. The duration (in hours and minutes) for which the timer will be
active (up to 24 hours)
Programmable Cycle Timer #1 Output #1 Activation Configuration. Determines the first output will be activated
when this timer is active
Programmable Cycle Timer #1 Output #2 Activation Configuration. Determines the second output will be
activated when this timer is active.
Output #1 is used to run the genset. Output #2 can be used to drive relay output 8. Please see the Relay Outputs
section for more information.
4.6.1 PCT Status
The status of the PCTs can be found within the menu structure at:
MAIN MENU > CONTROL > PROG CYCLE TIMER:
PROG CYCLE
OUTPUT 1
OUTPUT 2
: 1234567
: 10- - - - : - 00- - - -
18
Installation
5.1
Power Requirements
The PowerWizard series of generating set controls require a nominal voltage of 12 Vdc or 24 Vdc. If batteries are
used for operating power, a charging source such as an alternator or battery charger is necessary to maintain a stable
supply voltage. Under steady state operation, the PowerWizard controllers on 12V sets have approximately an 850 m
Amp current draw (not including any relay loads).
This current drain can be reduced by approximately a factor of 7 by using the Reduced Power Mode option (RPM).
However it is recommended that generating sets at rest or storage for prolonged periods should have either the battery
charger or isolator switch option fitted.
When connecting the PowerWizard generating set control to the DC power source, make sure that there is only one
common connection to the negative potential of the power source. Make extra effort to avoid any ground loops in the
DC electrical system. A single point common ground for electronics is recommended at the negative battery terminal
or Power Distribution Box. Each electronics sub-system and major engine sub-system should have its own DC network
so that they do not interfere with each other. An example is shown in Figure 7.
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. High current loads such
as starters and solenoids can cause interference and possibly damage to low current loads, such as controllers
and sensors. Extra effort must be made to keep the high current and low current loads electrically separated. The
two types of loads may share common (+)Battery and ()Battery connections, but they should not be electrically
connected. This strategy ensures maximum isolation between high and low current loads.
Electronic Sub-system 1
Electronic Sub-system 2
Generator Set
Sub-system Loads
Electronic Sub-system 3
Starter
Battery
Engine
ECM
19
5.2
Location Considerations
When selecting a location for mounting the PowerWizard generating set control, consider the following:
5.3
Electrical Connections
The PowerWizard control has one 70-pin connector 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 8 and 9 are shown with all possible connections used. For Electronic Engines (EUI), the passive analogue
inputs number 1 and 2 will not be used. These are for oil pressure and coolant temperature respectively. On EUI
engines, those sensors will be wired to the engine ECM and the PowerWizard will get that information from the engine
ECM via the Primary J1939 Data Link.
The method used for the analogue inputs is 1-wire sensors as shown in the diagram.
The discrete inputs are shown connected through normally open contacts to battery negative. These inputs can also
be connected through normally closed contacts to battery negative. In order to do this the active state of the input will
need to be set to active high.
20
0-5A AC
RMS
IB
IA
DISCRETE INPUT 3
COOLANT
TEMP
38
26 27
RELAY
OUTPUTS
(NOTE A)
33 41
32 40
SYSTEM
BATTERY
12 or 24
VDC
Rly1
52 BATTERY (+)
65 BATTERY ()
Rly2
Rly3
LCD DISPLAY
POWERWIZARD 1.0
L1
L2
L3
N
Rly4
Rly5
Rly6
VA
35 43
VB
48 58
VC
DISCRETE INPUT 1
0-600 VAC
RMS
NEUTRAL
13 11
DISCRETE INPUT 4
DISCRETE INPUT 2
CTA
CTB
CTC
DISCRETE INPUT 5
IC
DISCRETE INPUT 6
OIL
PRESS
I AC COMMON
56 46
50 34 42
CAN 1 SHIELD
CAN 1 DATA LINK ()
CAN 1 DATA LINK (+)
39
PASSIVE ANALOG 1 ()
70 55 54 53 45 44
31 47 57
PASSIVE ANALOG 2 ()
37
51 61
67 66
MPU
21
VB
Rly4
Rly3
Rly2
OIL
PRESS
COOLANT
TEMP
SPARE
29
37 30
38
56 46
LOAD
Rly1
52 BATTERY (+)
65 BATTERY (-)
LCD DISPLAY
POWERWIZARD 2.0
L1
L2
L3
N
Rly5
Rly6
Rly7
VA
Rly8
VC
DISCRETE INPUT 1
0-600 VAC
RMS
NEUTRAL
DISCRETE INPUT 2
DISCRETE INPUT 3
IA
DISCRETE INPUT 4
RELAY
OUTPUTS
(NOTE A)
IB
SYSTEM
BATTERY
12 or 24
VDC
0-5A AC
RMS
DISCRETE INPUT 5
70 55 54 53 45 44 36 28
DISCRETE INPUT 7
DISCRETE INPUT 6
2 25 15 1 24 14
IC
DISCRETE INPUT 8
26 27
I COMMON
32 40
62 64 63
50 34 42
CAN 1 SHIELD
CAN 1 DATA LINK ()
CAN 1 DATA LINK (+)
39
PASSIVE ANALOG 1 ()
33 41
31 47 57
5 3 4
PASSIVE ANALOG 2 ()
MODBUS REF
MODBUS ()
MODBUS (+)
CAN 2 SHIELD
CAN 2 DATA LINK ()
CAN 1 DATA LINK (+)
13 11
CTA
CTB
CTC
J1939 CAN
DATA LINKS
MODBUS
DATA LINKS
35 43
PASSIVE ANALOG 3 ()
48 58
51 61
67 66
MPU
22
5.4
Transformer Connections
The PowerWizard can monitor generating set output voltages in the range of 80 VAC to 600 VAC. In order to monitor
voltages greater than 600 Volts, external potential transformers must be used.
Note The PowerWizard must be programmed for the correct winding ratios when connecting external potential
transformers.
Note The wye configuration of external potential transformers is preferred for 4-wire wye generating sets 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 maximum
accuracy, the open delta configuration of external potential transformers should be used only for 3-wire delta
generating sets.
POWERWIZARD
13
PHASE A
PHASE B
PHASE A
PHASE
C
PHASE
B
NEUTRAL
PHASE C
PHASE
A
NEUTRAL
PHASE B
POWERWIZARD
13
11
POWERWIZARD
11
13 9
11
PHASE C
NEUTRAL
7
9
7
POWERWIZARD
13
7
POWERWIZARD
13
9
Figure 10: Wye Configuration of External Potential Transformers (PT) on the 4-Wire
Wye Connected Generating Set
PHASE A
PHASE A
B
PHASE
PHASE C
PHASE B
11
POWERWIZARD
13 11
9
PHASE
A C
PHASE
PHASE B
11 9
PHASE C
POWERWIZARD
13
9
POWERWIZARD
Transformers (PT)
13
Figure 11:PHASE
OpenA Delta Configuration of External Potential
on the 3-Wire Delta Connected Generating Set
PHASE A
B
PHASE
PHASE C
PHASE B
NEUTRAL
PHASE
A C
PHASE
NEUTRAL
PHASE
B
11
POWERWIZARD
13 11
9
11 9
PHASE C
NEUTRAL
23
5.5
Data Links
Name
Description
34
CAN1
42
CAN1 SH
50
CAN1 +
24
On Electronic Engine
Engine Service
Connector
Terminating
Resistor #1B
120 ohm
Engine ECM
J1
CAN +
50
CAN
34
CAN SH
42
CAN SH
CAN
CAN +
A B
Terminating
Resistor #1A
120 ohm
PowerWizard
1.0
J20
CAN1 +
50
CAN1
34
CAN1 SH
42
CAN SH
CAN
CAN +
A B
25
Wiring
The Accessory J1939 communication wires are brought out of the PowerWizard 2.0 as part of the 70-pin AMP
connector. The pins, as designated on the AMP connector, are shown in Table 3:
Pin #
Name
Description
62
CAN2 +
63
CAN2 SH
64
CAN2
26
On Electronic Engine
Engine Service
Connector
Terminating
Resistor #1B
120 ohm
Engine ECM
J1
CAN +
50
CAN
34
CAN SH
42
CAN SH
CAN
CAN +
A B
Terminating
Resistor #1A
120 ohm
PowerWizard
2.0
J20
CAN1 +
50
CAN1
34
CAN1 SH
42
CAN SH
CAN
CAN +
A B
Annunicator
(MCM9)
Terminating
Resistor #2A
120 ohm
A B
Terminating
Resistor #2B
120 ohm
A Secondary
Gen Service
Conn may be
fitted
Customer
Connections
A B
CAN2 +
62
63
CAN +
CAN2
64
64
CAN
CAN2 SH
63
SC1
CAN SH
Figure 14: PowerWizard 2.0 CAN Wiring Diagram (with optional module)
27
5.6
Optional Modules
Emergency Stop
Lamp Test
Overspeed
20
19
Mute
Not In Auto
18
17
7
16
8
15
9
14
10
13
11
12
10
Horn
11
12
13
14
15
16
17
18
19
20
Fail to Start
28
40 to 85C operating temperature range (for ambient temperatures exceeding 85C, the temperature
scanner may deviate in accuracy an additional 1C. Note also that 120C is a failure point. If the ambient
temperature were to exceed 120C, the device would NOT be expected to return to proper operation)
The ambient storage temperature range is 50C to +120C
It is protected against 95% humidity non-condensing, 30C to 60C
Designed to meet relevant European standards for EMI/RFI/Immunity without the use of external filtering (Third
party testing is being pursued).
Dimensions:
Communications Interface:
For J1939 compliance the module complies with the applicable portions of the following:
SAE J1939-21, July 1998, Data Link Layer
SAE J1939-71, January 2002, Application Layer
SAE J1939-73, May 2000, Application Layer Diagnostic
SAE J1939-81, July 1997, Network Management
Customer specific proprietary extensions are also included in the SAE J1939 profile.
Terminal 8: Can-H
Terminal 9: Can-L
Terminal 10: Shield
Terminal 11: PWR+
Terminal 12: PWR
29
LED1
LED2
Red
Yellow
Red
Yellow
Red
Yellow
Red
Yellow
Red
Yellow
Red
Yellow
Red
Yellow
Red
Yellow
Red
Yellow
10
Red
Yellow
11
Red
Yellow
12
Red
Yellow
13
Green
Yellow
14
Green
Yellow
15
Red
Green
16
Red
Green
30
31
When you click OK, the service tool software will automatically restart and reconnect to the data link. Upon
reconnecting, the summary screen will now show the new module name, based on the ECU Instance. In this example,
the new module name will be Alarm Module #1.
5.6.6 Annunciator Global Acknowledge
The Annunciator can be configured to both initiate and respond to an Event Acknowledge message over the J1939
data link. If this setpoint is enabled, the Annunciator events may be acknowledged remotely by pressing the
Alarm Acknowledge button on a PowerWizard or by pressing the Acknowledge button on another Annunciator
that is on the same data link. The default setting for this setpoint is DISABLED, but it can be enabled from the
Service Configuration menu item.
5.6.7 Configuring Annunciator LED Behaviour
To configure the behaviour of the LED pairs, enter the LED Pair Configuration screen by selecting the Service LED
Pair Configuration menu item.
An example of the LED Pair Configuration screen is shown in Figure 17.
32
Each LED pair has four parameters required to configure it. It is best to configure the four columns in order from left
to right; first Trigger Condition, next Severity Level, then Suspect Parameter Number, and finally Failure Mode Identifier
(if required). The reason for the order is because the value set in one column affects the choices available in the
subsequent columns. If a field is greyed out, it is not available due to conditions set in previous columns.
Trigger Condition: There are three possible selections for Trigger Condition: Specific Event, General Event and
Disabled.
Specific Event is used to assign an LED pair to a specific data link parameter such as Oil Pressure, Engine Speed,
Coolant Temperature, etc.
General Event is used to assign an LED pair as a general alarm or shutdown indicator. When configured as General
Event, the LED will not be assigned to a particular parameter. It will respond to any event, regardless of the Suspect
Parameter Number. For this reason, when General Event is selected, the Suspect Parameter Number cannot be
changed.
Disabled is used to disable the LED pair. The remaining three parameters will be greyed out when Disabled is
selected.
Severity Level: Severity Level defines how the LED pair will react to various levels of event conditions. Selections that
begin with Condition Met will respond to J1939 Event messages for FMI 31 Condition Present. For example, LED
pair #1 is configured for Condition Met, Red On, Other Not Used, Horn On with SPN 970 (Emergency Stop Active).
This means that when the Annunciator receives a J1939 message indicating Emergency Stop with FMI 31, the Red
LED will turn on and the Horn will also turn on. Other Not Used indicates that the other LED colour in the pair is
never used. Green Off indicates that the green LED (for example) lights when the condition chosen for this LED pair
is NOT active.
The Severity Level selections imply a J1939 Failure Mode Identifier (FMI) code. Condition Met is equivalent to
FMI 31. High Warning can be FMI 15 or FMI 16. Low Warning can be FMI 17 or FMI 18. High Shutdown is
equivalent to FMI 0. Low Shutdown is equivalent to FMI 1. The FMI column is greyed out for any of these selections.
The only option that will allow an FMI to be configured is Specific Diagnostic Code.
Suspect Parameter Number: The SPN column is used to type in the Suspect Parameter Number for the parameter
assigned to the LED pair. Refer to the SAE J1939 literature for a complete list of supported SPNs.
Note Remember to click the Submit button at the bottom of the LED Pair Configuration screen after making the
selections for each LED pair. Only then will the new settings take effect.
5.6.8 PowerWizard Support of the Annunciator
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 1.0 only supports the Primary J1939
data link. For more information on the Primary and Accessory data links, refer to the Data Links section.
PowerWizard 1.0: Supports one Annunciator module using CAN1.
PowerWizard 1.0
Annunciator
CAN 1
133 ft
maximum
33
PowerWizard 2.0: Supports one Annunciator module using CAN1 and up to three Annunciators using CAN2.
Annunciator 1
PowerWizard 2.0
Annunciator 3
3 ft
maximum
CAN 2
Annunciator 2
800 ft
maximum
Figure 19: Example illustration of Accessory Data Link Modules and Wire Lengths
34
6 Setpoint Programming
The engine/generating set setpoints affect the proper operation and serviceability of the engine, and the accuracy of
information shown on the display screen. The setpoints are programmed in the PowerWizard at the factory.
The setpoints may require changing when the PowerWizard is moved from one engine to another. The setpoints
may also require changing in order to satisfy the requirements of the installation. The setpoints that are stored in the
PowerWizard must match the specified setpoints of the particular generating set. For a list of all available setpoints see
Appendix B.
6.1
Digital inputs are used to inform the PowerWizard of warnings or shutdowns that exist external to the module. Digital
inputs are used for Emergency stop and remote start amongst various other parameters. There are two parts to
programming the Digital Inputs. The first part involves programming the Active State of the Digital Input (Active High
or Active Low). The second part involves programming the Event Input Functions.
Digital Input #1 is dedicated to Emergency Stop. Digital Input #2 is dedicated to Remote Initiate (Remote Start).
The six remaining Digital Inputs on the PowerWizard 2.0 (four remaining Digital Inputs on PowerWizard 1.0) can be
programmed for various other applications.
6.1.1 Programming the Active State of the Digital Input
The digital inputs of the PowerWizard are tied to an internal pull-up resistor. Therefore, if there is no connection to a
digital input, the digital input will sit at a logical high. A ground or -batt input should be used to trigger a Digital Input.
If an Active High configuration is desired, the ground or -batt input should be wired through a normally closed switch.
If an Active Low configuration is desired, the ground or -batt input should be wired through a normally open switch.
1. To program the Active State of the Digital Input, go through the following menu options:
MAIN MENU > CONFIGURE > SETPOINTS > I/O > DIGITAL INPUTS.
2. Select the Digital Input that you want to program. Press the Enter key.
3. Press the Enter key again. The current configuration (either HIGH or LOW) will be highlighted.
4. Use the Scroll Up key and the Scroll Down key in order to change the current configuration to the desired setting
(either HIGH or LOW).
5. Press the Enter key to save the setting.
35
IN
DIGITAL INPUT
(1)
EMERGENCY
STOP
IN
DIGITAL INPUT
(2)
REMOTE START
IN
DIGITAL INPUT
(3)
EVENT INPUT
FUNCTION
(1)
HIGH ENGINE
TEMP
IN
DIGITAL INPUT
(4)
EVENT INPUT
FUNCTION
(2)
LOW OIL
PRESSURE
IN
DIGITAL INPUT
(5)
EVENT INPUT
FUNCTION
(3)
CUSTOM EVENT
IN
DIGITAL INPUT
(6)
EVENT INPUT
FUNCTION
(4)
CUSTOM EVENT
IN
DIGITAL INPUT
(7)
EVENT INPUT
FUNCTION
(5)
CUSTOM EVENT
POWERWIZARD 2.0
ONLY
IN
DIGITAL INPUT
(8)
EVENT INPUT
FUNCTION
(6)
CUSTOM EVENT
Figure 20: Digital inputs are linked to the Event Input Functions
Note As digital inputs #1 and #2 are dedicated, Event Input Function #1 corresponds to Digital Input #3, Event
Input Function #2 corresponds to Digital Input #4, etc.
3. Once in the Input Function menu, the first setting is the Active State. The Active State should always be set to Active
High.
4. The next setting is the Time Delay. While on the Time Delay Setting, press Enter and use the arrow keys to enter the
desired value.
36
5. The next setting is the Suspect Parameter Number (SPN). Press the Enter key in order to choose the SPN. In order
to change event input functions 1 and 2 the service tool or Level 3 password is required. Below is a list of available
SPNs.
Pressures:
Temperatures:
Levels:
Others:
6. After the SPN is chosen, the Failure Mode Identifier (FMI) is the next setting. The following FMIs are available:
Status is used when an event is not essentially high or low but simply exists. An example of this is the Remote Start
command.
37
6.2
There are two parts to programming the Relay Outputs. The first part involves programming the Active State of the
Relay Output (Active High or Active Low). The second part involves programming the Digital Selectors. Relay
Output #1 is dedicated to controlling the starter motor. Relay Output #2 is dedicated to fuel enable.
The six remaining Relay Outputs on the PowerWizard 2.0 (four remaining Relay Outputs on PowerWizard 1.0) can be
programmed for various other applications.
The PowerWizard 1.0 will have six relays: All six will be type A. The PowerWizard 2.0 will have eight relays: Six will be
type A and two will be type C. Type A is defined as one normally-open contact plus common. Type C is defined as two
contacts, normally-open and normally-closed plus common:
RELAY OUTPUTS
TYPE A
TYPE C
38
RELAY OUTPUT
(1)
OUT
FUEL
CONTROL
RELAY OUTPUT
(2)
OUT
RELAY OUTPUT
(3)
OUT
RELAY OUTPUT
(4)
OUT
RELAY OUTPUT
(5)
OUT
DIGITAL
SELECTOR
(1)
DIGITAL
SELECTOR
(2)
DIGITAL
SELECTOR
(3)
DIGITAL
SELECTOR
(4)
DIGITAL
SELECTOR
(5)
DIGITAL
SELECTOR
(6)
0
1
2
3
4
5
6
7
8
9
10
- DISABLED
- AIR SHUTOFF
- START AID
- COMMON WARNING
- COMMON SHUTDOWN
- CRANK ALERT
- AUTO MODE
- BREAKER #1 TRIP
- EVENT O/P FUNCTION
- HIGH % kW
- UNUSED
0
1
2
3
4
5
6
7
8
9
10
- DISABLED
- HORN CONTROL
- COMMON ALARM
- COMMON WARNING
- COMMON SHUTDOWN
- ENGINE STARTED
- RUN MODE
- BREAKER #2 TRIP
- IN COOLDOWN
- UNUSED
- UNUSED
0
1
2
3
4
5
6
7
8
9
10
- DISABLED
- COMMON ALARM
- COMMON WARNING
- COMMON SHUTDOWN
- ENGINE STARTED
- CRANK ALERT
- RATED SPEED
- DISABLE AUX AC SUPPLY
- AUTO MODE
- BREAKER #1 TRIP
- UNUSED
0
1
2
3
4
5
6
7
8
9
10
- DISABLED
- COMMON WARNING
- COMMON SHUTDOWN
- ENGINE STARTED
- CRANK ALERT
- ECU FAULT RESET
- DISABLE AUX AC SUPPLY
- ENGINE START INITIATED
- RUN MODE
- BREAKER #2 TRIP
- UNUSED
RELAY OUTPUT
(6)
OUT
0
1
2
3
4
5
6
7
8
9
10
RELAY OUTPUT
(7)
- DISABLED
- COMMON SHUTDOWN
- ENGINE STARTED
- CRANK ALERT
- ECU FAULT RESET
- RATED SPEED
- DISABLE AUX AC SUPPLY
- AUTO MODE
- BREAKER #1 TRIP
- VOLTS AND Hz WITHIN LIMITS
- UNUSED
OUT
0
1
2
3
4
5
6
7
8
9
10
RELAY OUTPUT
(8)
- DISABLED
- ENGINE STARTED
- CRANK ALERT
- ECU FAULT RESET
- RATED SPEED
- START AID
- COMMON ALARM
- RUN MODE
- BREAKER #2 TRIP
- PROGRAMMABLE CYCLE TIMER OP#2
- UNUSED
OUT
POWERWIZARD 2.0
ONLY
39
40
Temperatures:
Levels:
Others:
41
Others (continued):
6. Select the required SPN and press the Enter key to save.
42
7 Retrofitting PowerWizard
When replacing a PowerWizard or when fitting a new one, ensure that the correct controller type is selected i.e.
PowerWizard 1.0 or PowerWizard 2.0. The differences between these are listed in the PowerWizard Variations section.
PowerWizard modules should be replaced like for like.
The Electrical Connection drawing for the PowerWizard 1.0 and 2.0 are shown in figure 8 and 9 respectively.
7.1
The Electronic Service Tool (EST) used with a laptop provides the mechanism for servicing the PowerWizard controller.
It allows the user to display, view or change the current Configuration files (Field Replacement Files) or the base level
flash files. Therefore EST is an essential service tool for carrying out service operations on the PowerWizard.
Instructions on purchasing and licensing EST can be found on the Dealer website or by contacting the EST Software
License and Support Coordinator. Refer to the contact list at the back of this manual.
7.2
PowerWizard have two main types of files associated with them, the flash file (.fls file) that contains the base code and
the Field Replacement File (.xml file) that contains the configuration information.
Flash Files:
To obtain a replacement flash file or the most recent version of a flash file, please refer to the contact list at the back of
this manual. When enquiring, you will need the Generating Set Serial Number. You will receive the most recent version
of the file associated with that Generatng Set Serial Number. These files are backward compatible.
A choice of language is available.
If the file is for a new job not associated with a Generating set Serial Number, please contact the After Sales Helpdesk.
Refer to the contact list at the back of this manual. The following information is required in order to select the correct
flash file for the controller:
1. Controller type (PowerWizard 1.0 or 2.0).
2. After Market ID (AMID).
3. Language.
Field Replacement Files:
The Field Replacement Files only exist for controllers that have previously been programmed at the factory. Field
Replacement Files for controllers that are in the field and that have not previously been programmed at the factory,
cannot be created by the help desk.
However Field Replacement Files can be used on more than one controller. So if the configuration you want is the
same as a previous set, the same Field Replacement File can be used.
Contact the After Sales Helpdesk supplying the Generating Set Serial Number and they will send you the required Field
Replacement File. Refer to the contact list at the back of this manual.
Note If a Field Replacement File that was created for a PowerWizard 1.0 is loaded onto a PowerWizard 2.0, some of
the items on the PowerWizard 2.0 will not be configured. To configure these items open EST and select Configuration
(SERVICE CONFIGURATION).
43
Figure 24: Screen shot after PowerWizard has successfully installed new software
All the (old) setpoints are preserved when the PowerWizard control is re-flashed.
PowerWizard Technical Manual
44
45
The following screen will then be displayed showing the configuration values:
The communication adapter was unable to connect to the J1939 data link
Cause: EST was unable to see the communication adaptor on the port it is expecting it to be connected to:
Ensure that the communication adapter is connected to the PowerWizard panel and has power
Ensure that the communication adapter is connected to the PC
Ensure that the settings on the service tool are set for the correct port
Ensure the software is configured for the appropriate communication adapter (under utilities -> preferences ->
communications).
No ECMs detected
Cause: EST was unable to detect any PowerWizard modules on the J1939 network:
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).
46
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 PowerWizard
1.0 with a PowerWizard 2.0 flash file (or vice versa):
Use a flash file that is compatible with the level of PowerWizard control you are trying to flash.
Use a flash file that is compatible with the level of PowerWizard control you are trying to flash.
47
Under steady state operation, the PowerWizard controllers on 12V sets have approximately an 850 m Amp current
draw (not including any relay loads).
This can be reduced by approximately a factor of 7 using the Reduced Power Mode (RPM). However it is
recommended that a generating set at rest or in storage for prolonged periods should either have the battery charger
or isolator switch option fitted.
When in reduced power mode, the generating set control will appear powered down. It will also systematically pulse
the control panel lamps. In reduced power mode, the control disables all communications.
If Reduced Power Mode is enabled and the generating set is stopped, the control will enter reduced power mode for a
preset time (normally 30 minutes) after the last key press. The control will awaken from reduced Power Mode upon a
key press, an Emergency Stop or a Remote Start signal.
8.1.1 Enabling Reduced Power Mode Using EST
1. Open EST.
2. Ensure that the service tool is using RP1210 (under Utilities -> preferences -> communications).
3. Ensure that the communications adapter is connected to the correct port of the PC.
4. Connect to the PowerWizard control (Press F8).
5. Select Configuration (Service -> Configuration) or (press F5).
6. It will take some time for the service tool to check which blocks are installed. After about 30 seconds the screen will
look like this:
48
The
Level 3 password is obtained by contacting the After Sales Helpdesk. Refer to the contact list at the back of this
manual. See also section 4.3-Security.
The user may also change the time delay before Reduced Power Mode is activated, by entering the screen
REDUCE POWER MODE
shown below:
DELAY TIME
30 minutes
REDUCE POWER MODE
DELAY TIME
30 minutes
Note - The remote communications (RS485) and the J1939 communications will not operate when the controller is in
Reduced Power Mode. Therefore if using remote communications ensure Reduced Power Mode is disabled.
Since the remote communications options (MCM7/MCM8) uses a RS485/RS232 converter that is powered via a mains
powered charger, we assume that if using remote communications, mains power is available, the controller has a
charger and Reduced Power Mode is disabled.
49
8.2
The service maintenance interval is available on PowerWizard 2.0 and has a flash file default of 500 engine hours or
180 days.
8.2.1 Reset Service Interval Alarm
To reset the Service Interval go to the Engine Overview screen and scroll to the Service Interval screen:
SERV
OR
-1 HRS
5 DAYS
Press Enter
to reset the Service Interval.
This resets the hours/days back to their starting position, for example 500 HRS or 180 DAYS.
You may require a level 3 password to do this.
You may use the service tool to change this password level from 3 to 2.
8.2.2 Change Duration of Service Interval Alarm
The Service Interval duration can be set for both days and hours. If the interval in days causes the alarm to be
raised before the interval hours run is reached, we suggest that you set the interval in days high (example; set to the
maximum of 365 DAYS). The DAYS cannot be disabled.
You must use the service tool (EST) to change the duration of the Service Interval. However the Interval can be viewed
by going to the SERV MAINT INTERVAL screen as follows.
CONFIGURATION SETPOINTS ENG MON/PROTECT SERV MAINT INTERVAL
8.2.3 Disable Service Interval Alarm
If the customer does not want this event he can disable it (setting the event response configuration to disabled will stop
the event from occurring).
CONFIGURATION SETPOINTS EVENTS EVENT RESPONSE CONFIG ENGINE PROTECTION EVENTS
OTHER SYSTEM CONFIG Service Maintenance Interval Warning Event Response Configuration
8.3
Setting Up Language
The Power Wizard module gives the operator the choice of using one of two available languages.
1. Technical English
2. Customer Language
To select your preferred language scroll to the LANGUAGE menu as shown below.
MAIN MENU PREFERENCES LANGUAGE
Use the cursor to highlight the preferred language and press the Enter key to select it.
50
8.4
By default PowerWizard control panels have a generating set not in auto warning. This warning will be active when
the control is in STOP or RUN mode. For certain applications it may be suitable to disable this warning. To disable
Not in Auto perform the following.
Go to MAIN MENU CONFIGURATION SETPOINTS EVENTS EVENT RESPONSE CONFIG OTHER
SYSTEM CONFIG EVENT OTHERS
Scroll to Not in Auto
Select edit by using left cursor key and then press Enter:
View
Edit
View
Edit
This takes you to the screen that is used to configure the desired response for the Not In Auto alarm. The options
available can be viewed or edited:
WARNING
WARNING
AUDIABLE ALERT
AUDIABLE
ALERT
SOFT SHUTDOWN
View
Edit
SOFT
HARDSHUTDOWN
SHUTDOWN
HARD
SHUTDOWN
BRK 1 TRIP
View
Edit
BRK 1
2 TRIP
BRK 2 TRIP
WARNING
AUDIABLE ALERT
WARNING
A
indicates
which options are selected. The user may select or remove
by
using the left cursor key. If unable to
SOFT SHUTDOWN
EDIT check that the set is in STOP position and that the required password level AUDIABLE
is used. ALERT
8.5
HARD SHUTDOWN
SOFT SHUTDOWN
BRK 1 TRIP
HARD SHUTDOWN
BRK 2 TRIP
BRK 1 TRIP
BRK 2 TRIP
To disable the Thermo Start go to the START AID ACTIVATION TIME screen as shown below:
51
9 Contact List
EST Software License and Support Coordinator.
Tel: +44 (0) 28 2826 5228
email: support_tools@fgwilson.com
After Sales Helpdesk
Tel: +44 (0) 28 2826 5001
email: afterSales@fgwilson.com.
(To obtain Flash files/field replacement files, please contact the After Sales Helpdesk)
Please refer to your Secure Dealer Site.
52
SPN
FMI
38
38
38
38
38
15
38
17
82
82
82
82
15
82
17
95
95
95
95
95
15
95
17
96
96
96
96
96
15
96
17
98
98
98
98
98
15
98
17
99
99
99
99
99
15
99
17
100
100
100
100
17
107
107
53
Event Name
SPN
FMI
107
107
107
15
107
17
110
110
110
110
15
110
17
111
111
111
111
111
15
111
17
137
137
137
137
137
15
137
17
167
11
167
31
167
17
168
168
15
168
17
171
171
171
171
171
15
171
17
173
173
173
173
173
15
173
17
175
175
175
175
175
15
175
17
54
Event Name
SPN
FMI
190
190
190
190
190
17
625
639
11
701
701
701
15
701
17
701
31
702
702
702
15
702
17
702
31
703
703
703
15
703
17
703
31
704
704
704
15
704
17
704
31
705
705
705
15
705
17
705
31
706
706
706
15
706
17
706
31
707
707
707
15
707
17
707
31
708
708
17
55
Event Name
SPN
FMI
708
708
15
708
31
709
709
709
15
709
17
709
31
710
710
710
15
710
17
710
31
711
711
711
15
711
17
711
31
712
712
712
15
712
17
712
31
713
713
713
15
713
17
713
31
714
714
714
15
714
17
714
31
715
715
715
15
715
17
715
31
716
716
716
15
716
17
716
31
924
970
31
56
Event Name
SPN
FMI
925
926
1122
1122
1122
1122
1122
15
1122
17
1231
11
1237
31
1239
31
1383
11
1664
31
2433
2433
2433
2433
2433
15
2433
17
2434
2434
2434
2434
2434
15
2434
17
2436
2436
2436
2436
12
2436
15
2436
17
2440
2440
2440
15
2440
17
2448
2448
15
2452
2452
17
2530
2646
2648
31
3567
31
3571
3574
57
Event Name
SPN
FMI
3573
3572
3575
3575
15
3576
15
Loss of Utility
3577
31
Earth Fault
3569
31
Earth Leakage
3570
31
3578
3580
3579
31
3587
3588
3589
3587
3588
3589
3578
15
3580
15
3581
11
520198
31
520232
31
520233
31
520234
31
520237
31
Engine in Cooldown
520199
31
520235
31
520238
31
520236
31
520239
31
58
Appendix B Setpoints
Setpoints are used in the PowerWizard control panel to tailor the control for each installation. To accommodate the
large number of setpoints within PowerWizard the setpoints have been grouped into blocks.
Blocks for Setpoint Configuration
This appendix contains information on the various software blocks in the PowerWizard control. Blocks are functional
groups of setpoints. Blocks can occur in multiple instances and in order to program a setpoint, the block number as
well as the instance number, must be referenced.
BLOCKS FOR SETPOINT CONFIGURATION
Block
Number
Block Name
PowerWizard 1.0
Number of Instances
PowerWizard 2.0
Number of Instances
10
11
12
17
Diagnostics Configuration
18
Automatic Start/Stop
19
21
22
23
34
35
53
Digital Inputs
56
Relay Outputs
72
Event System
75
88
Digital Outputs
94
97
30
30
98
100
Service Maintenance
102
104
Digital Selectors
10
10
105
106
59
Setpoint
Number
Lvl 3
Lvl 2
34
690
kPa
Lvl 2
34
690
kPa
Lvl 2
30
seconds
Lvl 2
34
690
kPa
Lvl 2
34
690
kPa
Lvl 2
30
seconds
Lvl 2
400
1800
rpm
Lvl 3
Lvl 2
49
120
deg. C
Lvl 2
30
seconds
Lvl 2
49
120
deg. C
Lvl 2
30
seconds
Lvl 2
36
deg. C
Lvl 2
30
seconds
Flywheel Teeth
Lvl 3
95
350
N/A
Lvl 3
400
4330
rpm
Lvl 3
400
4330
rpm
Lvl 2
20
seconds
Lvl 3
400
4330
rpm
Lvl 2
20
seconds
Lvl 1
12
50
VDC
Lvl 1
240
seconds
Lvl 1
12
50
VDC
Lvl 1
240
seconds
Lvl 1
25
VDC
Lvl 1
240
seconds
Lvl 1
30
VDC
Lvl 1
240
seconds
Lvl 3
N/A
10
Lvl 2
Lvl 2
Lvl 2
Lvl 2
Lvl 2
Lvl 2
Setpoint Name
Security
Level
Min
Max
Units
Svc Tool
60
Setpoint
Number
Setpoint Name
Security
Level
Min
Max
Units
Lvl 2
Lvl 2
Lvl 2
10
Lvl 2
11
Lvl 2
12
Lvl 2
13
Lvl 2
14
Lvl 2
15
Lvl 2
16
Lvl 2
17
Lvl 2
18
Lvl 2
19
Lvl 2
20
Lvl 2
21
Lvl 2
22
Lvl 2
23
Lvl 2
24
Lvl 2
25
Lvl 2
26
Lvl 2
27
Lvl 2
28
Lvl 2
29
Lvl 2
30
Lvl 2
31
Lvl 2
32
Lvl 2
33
Lvl 2
34
Lvl 2
61
Setpoint
Number
Setpoint Name
Security
Level
Min
Max
Units
35
Lvl 2
36
Lvl 2
37
Lvl 2
38
Lvl 2
39
Lvl 2
40
Lvl 2
41
Lvl 2
42
Lvl 2
43
Lvl 2
44
Lvl 2
45
Lvl 2
46
Lvl 2
47
Lvl 2
48
Lvl 2
49
Lvl 2
50
Lvl 2
51
Lvl 2
52
Lvl 2
53
Lvl 2
54
Lvl 2
55
Lvl 2
56
Lvl 2
57
Lvl 2
58
Svc Tool
59
Lvl 2
60
Lvl 2
61
Lvl 2
62
Lvl 2
63
Lvl 2
62
11
Setpoint
Number
Security
Level
Min
Max
Units
64
Lvl 2
65
Lvl 2
66
Lvl 2
Lvl 2
Lvl 2
Lvl 2
Lvl 2
Lvl 2
Lvl 2
5
6
12
Setpoint Name
Lvl 2
Lvl 2
Lvl 2
10
Lvl 2
11
Lvl 2
12
Lvl 2
13
Lvl 2
14
Lvl 2
15
Lvl 2
16
Lvl 2
17
Lvl 2
Lvl 2
Lvl 2
Lvl 2
Lvl 2
Lvl 2
Lvl 2
Lvl 1
Lvl 1
Lvl 1
63
Setpoint
Number
Setpoint Name
Security
Level
Min
Max
Units
10
Lvl 1
11
Lvl 3
12
Lvl 3
13
Lvl 1
14
Lvl 1
15
Lvl 3
16
Lvl 3
17
Lvl 1
18
Lvl 1
19
Lvl 2
20
Lvl 1
21
Lvl 2
22
Lvl 2
23
Lvl 2
24
Lvl 2
25
Lvl 2
26
Lvl 2
27
Lvl 2
28
Lvl 2
29
Lvl 2
30
Lvl 2
31
Lvl 2
32
Lvl 2
33
Lvl 2
34
Lvl 2
35
Lvl 2
36
Lvl 2
37
Lvl 2
38
Lvl 2
64
Setpoint
Number
Setpoint Name
Security
Level
Min
Max
Units
39
Lvl 2
40
Lvl 2
41
Lvl 1
42
Lvl 1
43
Lvl 1
44
Lvl 1
45
Lvl 3
46
Lvl 3
47
Lvl 1
48
Lvl 1
49
Lvl 3
50
Lvl 3
51
Lvl 1
52
Lvl 1
53
Lvl 2
54
Lvl 1
55
Lvl 2
56
Lvl 2
57
Lvl 2
58
Lvl 2
59
Lvl 2
60
Lvl 2
61
Lvl 2
62
Lvl 2
63
Lvl 2
64
Lvl 2
65
Lvl 2
66
Lvl 1
67
Lvl 1
65
Setpoint
Number
Setpoint Name
Security
Level
Min
Max
Units
68
Lvl 2
69
Lvl 2
70
Lvl 2
71
Lvl 2
72
Lvl 2
73
Lvl 2
74
Lvl 2
75
Lvl 2
Lvl 2
Lvl 2
76
77
78
Lvl 2
79
Lvl 2
80
Lvl 2
81
Lvl 2
82
Lvl 2
83
Lvl 2
84
Lvl 2
85
Lvl 2
86
Lvl 2
87
Lvl 2
88
Lvl 2
89
Lvl 2
90
Lvl 2
91
Lvl 2
92
Lvl 2
93
Lvl 2
94
Lvl 2
95
Lvl 2
96
Lvl 2
66
Setpoint
Number
Security
Level
Min
Max
Units
97
Lvl 2
98
Lvl 2
99
Lvl 2
100
Lvl 2
101
Lvl 2
102
Lvl 2
103
Lvl 2
104
Lvl 2
105
Lvl 2
106
Lvl 2
107
Lvl 2
108
Lvl 2
109
Lvl 2
110
Lvl 2
111
Lvl 2
112
Lvl 2
113
Lvl 2
114
Lvl 2
115
Lvl 2
116
Lvl 2
117
Lvl 2
Lvl 2
118
17
Setpoint Name
119
Lvl 2
120
Lvl 2
Svc Tool
Lvl 2
Lvl 2
Lvl 2
Lvl 2
67
Setpoint
Number
Security
Level
Min
Max
Units
Lvl 2
Lvl 2
Lvl 2
Lvl 2
10
Lvl 2
11
Lvl 2
12
Lvl 2
13
Lvl 2
14
Lvl 2
15
Lvl 2
16
Lvl 2
17
Lvl 2
18
Lvl 2
19
Lvl 2
Lvl 2
20
18
Setpoint Name
21
Lvl 2
22
Lvl 3
23
Lvl 2
24
Lvl 2
25
Lvl 1
26
Lvl 2
27
Lvl 2
28
Lvl 2
29
Lvl 2
30
Lvl 2
31
Lvl 3
Lvl 2
300
seconds
Crank Duration
Lvl 2
300
seconds
Lvl 2
300
seconds
Svc Tool
20
seconds
Lvl 2
20
N/A
68
19
21
22
23
24
Setpoint
Number
Setpoint Name
Security
Level
Min
Max
Units
Cooldown Duration
Lvl 2
30
minutes
Lvl 2
240
seconds
Lvl 1
60
seconds
Lvl 3
100
1000
rpm
10
Svc Tool
11
Svc Tool
12
Svc Tool
13
Svc Tool
14
Lvl 2
15
Svc Tool
Lvl 3
Lvl 3
50000
Lvl 3
240
Lvl 3
7000
Lvl 3
Svc Tool
200
N/A
Lvl 3
Lvl 2
100
50000
Lvl 3
50000
kW
10
Lvl 3
50000
kVA
Lvl 2
100
125
Lvl 2
120
seconds
Lvl 2
100
125
Lvl 2
120
seconds
Lvl 2
60
100
Lvl 2
120
seconds
Lvl 2
60
100
Lvl 2
120
seconds
Lvl 2
80
120
Lvl 2
120
seconds
Lvl 2
80
120
Lvl 2
120
seconds
Lvl 2
80
120
Lvl 2
120
seconds
Lvl 2
80
120
Lvl 2
120
seconds
Lvl 2
80
130
Generating Set Inverse Time Over Current (Amp) Shutdown Event Time
Multiplier
Lvl 2
0.05
10
seconds
Lvl 2
100
300
Lvl 2
0.1
20
seconds
Lvl 2
20
69
Setpoint
Number
Setpoint Name
Security
Level
Min
Max
Units
Lvl 2
30
seconds
Lvl 2
20
Lvl 2
30
seconds
Lvl 3
0.1
10
seconds
Lvl 3
60
seconds
Lvl 3
120
seconds
Lvl 3
20
seconds
Lvl 2
Lvl 3
Lvl 3
Lvl 3
0.1
10
seconds
Lvl 3
60
seconds
Lvl 3
120
seconds
Lvl 3
20
seconds
Lvl 3
Lvl 3
Lvl 3
53
Lvl 2
56
read-only
72
Svc Tool
Svc Tool
Svc Tool
Svc Tool
Svc Tool
Lvl 3
Lvl 2
88
Lvl 2
94
Lvl 2
Lvl 2
Lvl 2
247
N/A
Lvl 2
0xffffffff
N/A
Lvl 2
0.1
3600
seconds
Lvl 2
Lvl 2
Lvl 2
Lvl 2
Lvl 2
98
Lvl 3
N/A
100
Svc Tool
2000
hours
Svc Tool
365
days
Lvl 3
N/A
Lvl 2
400
rpm
Lvl 2
40
500
Hz
34
35
75
96
97
102
120
minutes
20
N/A
70
Setpoint
Number
104
Lvl 2
105
Lvl 2
Lvl 2
Lvl 2
Lvl 2
Lvl 2
read-only
Lvl 2
Lvl 2
Lvl 2
Lvl 2
106
108
109
Setpoint Name
Security
Level
Min
Max
250
Units
seconds
100
-273
1735
deg. C
-250
10000
kPa
Lvl 2
60
seconds
Lvl 3
100
Lvl 2
-273
1735
deg. C
10
Lvl 2
-250
10000
kPa
11
Lvl 2
60
seconds
12
Lvl 2
100
13
Lvl 2
-273
1735
deg. C
14
Lvl 2
-250
10000
kPa
15
Lvl 2
60
seconds
16
Lvl 2
100
17
Lvl 2
-273
1735
deg. C
18
Lvl 2
-250
10000
kPa
19
Lvl 2
60
seconds
Lvl 2
100
Lvl 2
100
50000
Lvl 2
Lvl 2
71
72
Setpoint
Number
Setpoint Name
Engine Oil Pressure Sensor Configuration
Value
Value Name
Sensor
Data Link
Sensor
Data Link
Sensor
18
10
Diesel
Natural Gas
Energized to Run
Energized to Stop
Mechanical
Electronic
No J1939 Support
Rated Speed
Low Idle
CAN Input
Delta (3-Wire)
Delta (4-Wire)
50 Hz
60 Hz
400 Hz
Locked Out
Not Installed
Manual
Automatic
Supervisory Controlled
Externally Controlled
Locked Out
Manual
Automatic
Externally Controlled
Low
High
Low
High
11
12
13
14
15
19
34
35
53
56
73
Setpoint
Number
72
75
88
94
96
97
Setpoint Name
Event Warning Condition Response Auto Reset Enable Status
Value
Value Name
Disabled
Enabled
Disabled
Enabled
Disabled
Enabled
Disabled
Enabled
Disabled
Enabled
Disabled
Enabled
Low
High
2400 baud
4800 baud
9600 baud
14400 baud
19200 baud
28800 baud
38400 baud
57600 baud
115200 baud
None
Odd
Disabled
Enabled
Not Installed
Installed
Disabled
8320
8352
8448
8480
8512
General Diagnostic
16384
16416
16448
16480
16512
16544
74
Setpoint
Number
97
Setpoint Name
Value
Value Name
16576
16608
16640
16672
16738
16739
16740
16741
16742
16743
16744
16745
16746
16747
16748
16749
16750
16755
16768
38
82
95
96
Fuel Level
98
99
100
107
110
111
137
167
168
Battery Voltage
75
Setpoint
Number
2
Setpoint Name
Event Output Function #NN Suspect Parameter Number
Value
Value Name
171
173
Exhaust Temperature
175
190
Engine Speed
625
639
701
Custom Event #1
702
Custom Event #2
703
Custom Event #3
704
Custom Event #4
705
Custom Event #5
706
Custom Event #6
707
Custom Event #7
708
Custom Event #8
709
Custom Event #9
710
711
712
713
714
715
716
924
Digital Output #1
925
Digital Output #2
926
Digital Output #3
970
1122
1231
1237
1383
1390
Gas Pressure
1664
2433
2434
2436
2440
2448
2452
2646
Digital Output #4
2648
Maintenance Lamp
3543
Engine Controller
4000
4001
76
104
105
Setpoint
Number
Setpoint Name
Value
Value Name
4002
4003
4004
4005
4006
Engine in Cooldown
4007
4009
4010
4011
4012
4013
4014
4015
4016
4017
Loss of Utility
4018
4019
4028
Earth Fault
4029
Earth Leakage
Disabled
Use Input #1
Use Input #2
Use Input #3
Use Input #4
Use Input #5
Use Input #6
Use Input #7
Use Input #8
Use Input #9
10
11
Data Link
Low
High
38
82
95
96
Fuel Level
98
99
100
107
110
111
Setpoint
Number
3
Setpoint Name
Event Input Function #NN Suspect Parameter Number
Value
Value Name
137
167
168
Battery Voltage
171
173
Exhaust Temperature
175
701
702
703
704
705
706
707
708
709
710
711
712
713
714
715
716
1122
1239
1390
Gas Pressure
2433
2434
2436
2440
2448
2452
4000
4001
4002
4003
4004
4005
4013
4014
4017
Loss of Utility
4028
Earth Fault
4029
Earth Leakage
78
Setpoint
Number
4
106
109
Setpoint Name
Event Input Function #NN Failure Mode Identifier
Value
Value Name
High Shutdown
Low Shutdown
15
High Warning
17
Low Warning
31
Status
Disabled
Enabled
Pressure
Temperature
Level
38
82
95
96
Fuel Level
98
99
107
111
137
171
173
Exhaust Temperature
175
1122
2433
2434
Not Installed
Installed
Not Installed
Rear
79
80