INTPAN
INTERMEDIATE
Agenda
§Powerwizard Overview
§ EIM
§ Powerwizard 1.0 & 2.0 Schematics
§ Powerwizard 1.1, 1.1+ & 2.1
Schematics
§ Powerwizard Status & Configuration
Menu’s
§ Remote Annunciators
§Flash Files & Field Replacement Files
Aims
§ Understand FG Wilson electrical schematics
on control systems to ease faultfinding
§ Understand all the FG Wilson control systems
and their different applications
§ Understand how to commission and adjust
FG Wilson control systems
Powerwizard Control Panel range
PW1.0 PW1.1 PW2.0 PW1.1+ PW2.1
Overview
§ Common parts from 10 – 2000kVA
§ 9 - 32v Dc Operating range
§ 2 Display Languages
§ Technician English or Customer language
§ Common Engine wiring system
§ Programmed using standard EST Service tool
§ Sheet steel module
§ Spare fault channels
§ J1939 communication with Electronic Control
Modules
Level 1.0 Control System
§ Alarm / Shutdown Protection - Fail to Start, Low Oil Pressure,
High Coolant Temperature, Overspeed and;
§ Low / High Battery Volts
§ Static Battery Charger Failure
§ Underspeed
§ Loss of Speed signal detection
§ 2 spare fault channels
§ 20 Event Fault log
§ J1939 CAN 1 data link for Service tool
§ No remote communications
§ AC Metering – Volts, Amps, Frequency
§ DC Metering – Battery Volts, Hours Run, Engine Jacket Water
Temperature, Lube Oil Pressure, Engine Speed
Level 2.0 Control System
§ Auto Start controls, protection and metering as Level 1.0 and;
§AC Metering – kW, kVA, kVar, Power
Factor, kW hours, kVar hours
§ DC Metering – Crank Attempt counter,
Start counter
§ Alarm/Shutdown Protection - Under/Over
Volts, Under/Over Frequency, Overcurrent
§ 4 spare fault channels
§ CAN 2 J1939 Accessory Data Link
§ Remote Annunciator
§ Real time clock
§ Service interval counter
§ Modbus remote communications using RS485 (2 wire)
P/W Control System – Components
Engine control relays
(EIM replacement)
MCB protection
(in place of fuses)
AVR
CT location AC and DC terminals
colour coded
Circuit breaker
Customer
Load cable connections (PW)
gland area
‘Plug & Play’ Options
Chassis (PW)
Level 1.1 Control System
§ Auto Start controls, protection and metering as Level 1.0 and;
§ 2 Analogue Inputs
§ 4 Programmable Input Channels
§ 6 Programmable relay Outputs
§ 40 Event Fault log
§ Dedicated key to reset all events
§ Main menu and event log short cut key
§ No EIM required
Level 1.1+ Control System
§ Auto Start controls, protection and metering as Level 1.0 &
1.1 and;
§ All options available
§ 3 Analogue Inputs
§ 6 Programmable Input Channels
§ 6 Programmable relay Outputs
§ Upgradeable at module level
§ 40 Event Fault log
§ Dedicated key to reset all events
§ Main menu and event log short cut key
§ No EIM required
Level 2.1 Control System
§ Auto Start controls, protection and metering as Level 2.0 and;
§ All options available
§ AC Power Metering – kW, kVA, kVar, Power Factor, kW hours, kVar hours
§ DC Metering – Crank Attempt counter, Start counter
§ 3 Analogue Inputs
§ 6 Programmable Input Channels
§ 6 Programmable relay Outputs
§ 1 Programmable Sink Output
§ 40 Event Fault log
§ Dedicated key to reset all events
§ Main menu and event log short cut key
§ No EIM required
§ CAN 2 J1939 Accessory Data Link
§ Remote Annunciator
§ Real time clock
§ Service interval counter
§ Modbus remote communications using RS485 (2 wire)
Connections Overview
CAN J1939
expansion
network (Level 2.0 & 2.1 Only)
Hardwired
senders
CAN Modbus
J1939
Engine Interface Module (EIM)
Only fitted to 1.0 & 2.0
§ Fused Relays For
§ Starter Motor
§ Glow Plug Preheat
§ Fuel Solenoid
§ LED Illuminates when Circuit is
Energized
§ 2 Models “PLUS” & “SR” with
12v and 24v options
§ “PLUS” Models send Shutdown
Signal to Panel for Overspeed
Engine Interface Module (EIM)
1. Glow Plug Symbol
2. Fuel Symbol
3. Fuel Solenoid Fuse
4. Fuel LED
5. Main Connector Socket
6. Glow Plug Fuse
7. Glow Plug LED
8. Secondary Socket
9. Starter Solenoid LED
10. Starter LED
11. Overspeed Setup LED*
12. Overspeed Adjust*
13. Starter Symbol
* EIM Plus only
Engine Interface Module Plus
MPU input Engine running signal OUT
Safety relay DC negative Overspeed signal OUT
Fuel signal OUT Fuel signal IN
Pre-glow signal OUT Pre-glow signal IN
DC power supply (-) Starter Motor signal IN
Starter Motor signal OUT DC power supply (+)
Powerwizard 2.0 Schematic
EIM CT’s
AC Sensing fuses
3 Pole Breaker
CHARGING ALTERNATOR AC SOCKET
STARTER MOTOR
START AID
EMERGENCY STOP
OIL PRESSURE/ENGINE TEMP SENDERS
FUEL CONTROL SOLENOID
FUEL LIFT PUMP SOLENOID
Powerwizard 1.1+ & 2.1
Schematic
Battery Supply
AC SENSING
RELAY OUTPUTS
SENDER INPUTS + EARTH
REMOTE MPU
BATTERY
COMMUNICATIONS DIGITAL INPUTS
CHARGER
CONNECTION POINT OPTION
DC ENGINE
Panel Layout 1.1, 1.1+ & 2.1
Panel Layout 1.0 & 2.0
Shutdown Lamp
Lamp Test Key
Alarm Mute/
Acknowledge Key
Auto Key
Alarm Lamp
Run Key Stop Key
Ac Overview
Key Escape Key
Enter Key
Engine Cursor Keys
Overview Key
Navigation Keys
AC Overview – The “AC Overview” key will navigate the display to first screen of AC information.
Engine Overview – The “Engine Overview” key will navigate the display to the first screen of engine
information.
Alarm Acknowledge / Mute – Pressing the “Mute / Acknowledge” key 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. The “Acknowledge” key may also be configured
to send out a “Global Alarm Silence ” on “J1939 Data Link” which will silence horns on annunciators.
Lamp Test – Pressing and holding the “Lamp Test” key will cause all of the LED’s and the display screen pixels
to turn on until the key is released.
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 the “STOP” mode.
Escape – The “ESCAPE” key is used during menu navigation in order to navigate up through the menu
structure. Each key press causes the user to move backwards/upwards through the navigation menus. The
“Escape” key is also used to 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.
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 setpoints changes. Pressing the “Enter” key during setpoint programming
causes setpoint changes to be saved to memory.
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 “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.
Additional Keys for P/W 1.1, 1.1+ & 2.1
Hot Keys
Main menu hot key – The Main menu key will navigate the display to the main menu
screen. Pressing navigation keys can select sub-menus and go through the menus at
all levels.
Event Keys and Indicators
Reset Key – Pressing the Reset key will reset all events when the control is in
the stopped position. However “Reset All Events” will not reset “Present” events.
Event Log Key – Pressing the Event Log key will navigate to the “Active Events”
menu. In order to scroll through the events, use the up and down key. After
highlighting an event, press the “OK” key to see information about the event such
as the SPN and the FMI.
PowerWizard Status Menus
§ Engine / Alternator Overview
PowerWizard Status Menus 1.0 & 2.0
§ I/O Status
§ Digital Outputs
§ Digital Inputs
Menu Tree, High level (P/W 1.0 & 2.0)
Note : * Powerwizard 2.0 only
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Menu Tree, Setpoints (P/W 1.0 & 2.0)
Note : * Powerwizard 2.0 only
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PowerWizard Status Menus 1.1, 1.1+ & 2.0
§ I/O Status
§ Digital Outputs
§ Digital Inputs
Menu Tree, (P/W 1.1, 1.1+ & 2.1)
Note : * Powerwizard 2.1 only
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Password Protection
There are 3 levels of password protection on the PowerWizard
§ 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
§ If the password level is currently at the required level of protection
when viewing a parameter, the padlock will not appear
Drop to Minimum Security Level
§ The first option on the security screen is “DROP TO MIN LEVEL”. This
would be used when leaving the control. If it is not initiated manually,
the controller will automatically revert to minimum level after 10 minutes
Password Protection
§ From the “MAIN MENU”, select the “CONFIGURE” menu
§ Press the “ENTER” key in order to select “CONFIGURE”. “SECURITY”
will be highlighted
§ Press the “ENTER” key in order to select “SECURITY”. “DROP TO MIN
LEVEL” will be displayed
§ Press the “ENTER” key to select “DROP TO MIN LEVEL”
§ The system will now be at the minimum level of security
Note: The current level of security is displayed at the top of he
display any time the system is in the “SECURITY” screen.
Password Protection
To enter Level 1 or 2 Password
§ From the “MAIN MENU”, select the “CONFIGURE” menu
§Press the “ENTER” key in order to select “CONFIGURE”. “SECURITY” will
be highlighted
§Press the “ENTER” key in order to select “SECURITY”. “DROP TO MIN
LEVEL” will be highlighted
§Press the “DOWN” key in order to highlight “ENTER LEVEL 1 OR 2”
§Press the “ENTER” key in order to select “ENTER LEVEL 1 or 2”. “ENTER
PASSWORD FOR DESIRED LEVEL” is displayed. Also shown is a 16 digit
display with 0 highlighted on the right hand side
§Press the “UP” or “DOWN” key in order to select the desired number
§Press the “RIGHT” key in order to highlight the next character to be
entered. Press the “UP” or “DOWN” key in order to select the desired
number
Password Protection
§ Continue until the correct password has been entered for the
corresponding level. When all digits of the password are correctly entered
press the “ENTER” key. The current level of password protection is
displayed and parameters can be set
Note: The panel will go to the highest level of security authorized by
the password.
Note: Passwords can have from 1 to 16 digits.
Password Protection
To enter level 3 password
§ From the “MAIN MENU”, select the “CONFIGURE” menu
§ Press the “ENTER” key to select “CONFIGURE”. “SECURITY” will be
highlighted
§ Press the “ENTER” key in order to select “SECURITY”. “DROP TO MIN
LEVEL” will be displayed
§ Press the “DOWN” key in order to highlight “ENTER LEVEL 3”. Press
“ENTER” to select “ENTER LEVEL 3 ”
§ A 16 digit number is shown and “ENTER RESPONSE” is highlighted.
Copy this number and call the factory to obtain the password, do not exit
from this screen
§ When the factory response is received, press “ENTER” to select “ENTER
RESPONSE”. “ENTER RESPONSE” is displayed. Also shown is a 16 digit
entry field where the password will be entered
Password Protection
§ When the factory response is received, press “ENTER” to select
“ENTER RESPONSE”. “ENTER RESPONSE” is displayed. Also
shown is a 16 digit entry field where the password will be entered
§ Press the “UP” or “DOWN” key in order to increase or decrease the
highlighted digit to the correct password
§ Press the “RIGHT” key in order to highlight the next character to be
entered. Press the “UP” or “DOWN” key in order to increase or
decrease the highlighted digit to the correct password
§ Continue to set all 16 digits until the factory provided password is
displayed
§ When all digits of the factory password are correctly entered, press
the “ENTER” key. The current level (LEVEL 3) of security is
displayed and parameters can be set
Password Protection
Change level 1 or level 2 password
§ From the “MAIN MENU”, select the “CONFIGURE” menu
§ Press the “ENTER” key in order to select “CONFIGURE”. “SECURITY”
will be highlighted
§ Press the “ENTER” key in order to select “SECURITY”. “DROP TO MIN
LEVEL ”will be highlighted
§ Make sure that the current level of security is at least as high as the level
of the password to be changed
§ Press the “DOWN ” key to highlight “CHANGE LEVEL 1 PSWD.” Press
the “ENTER” key to select “CHANGE LEVEL 1 PSWD”
§ “CHANGE LEVEL 1 PSWD” is displayed. Use the cursor keys to set the
new password
§ Press the “RIGHT” key in order to highlight the next character to be
entered. Press the UP or “DOWN” key in order to increase or decrease the
highlighted digit to the desired number
§ Continue until the desired password is displayed
§ Press the “ENTER” key. The password is now set
§ Note: To change level 2 password, substitute “CHANGE LEVEL 2
PSWD” for “CHANGE LEVEL 1 PSWD” in the step above.
§ Note: To disable a security level, set the password to a single zero.
Digital Inputs
§ There are 6 digital inputs on Level 1.0 and 8 digital inputs on Level
2.0
§ 4 of these inputs will always be used;
§ Digital Input #1 – Is used for the emergency stop
§ Digital Input #2 – Is used for remotely starting and stopping the generator
set. If the input is active and the engine mode switch is in AUTO, the engine
will attempt to start and run. Once the input becomes inactive the engine
will enter into cooldown (if programmed) and then stop
§ Digital Input #3 – Is used for High Engine Temperature shutdown
§ Digital Input #4 – Is used for Low Oil Pressure shutdown
§ The remainder of the inputs can be configured to add additional
monitoring capabilities
§ Inputs can be configured by going to the “Event I/P Functions”
parameter under the “Setpoints” menu
§ The Digital Input parameter can only be set to “Active High” or “Active
Low” in order to initiate a High Warning, Low Warning, High Shutdown, Low
Shutdown, or Statusx
Digital Outputs
§ There are 6 digital outputs on Level 1.0 and 8 digital outputs on
Level 2.0
§ Depending on model 2 or 3 of these outputs will always be used;
§ Digital Output #1 – Engine Crank (Starter Motor control )
§ Digital Output #2 – Fuel Control
§ Digital Output #3 – Thermostart (dependent on genset model)
§ The remainder of the Outputs can be configured to add various other
applications
§ The relays are internally controlled by PowerWizard. The active state
is programmable but should always be set to active high
§ The digital selectors determine what conditions cause the Relay
Outputs 3 to 8 to become active
§ In order to program the Digital Selectors, select the following menu
options:
§ MAIN MENU > CONFIGURE >
OTHER > DIGITAL SELECTORS.
Data Links
§ The digital module has up to three different data links depending
on level
§ Two CANBUS (J1939) Data Links
§ Used for local communication among modules associated with a single
genset e.g. ECM, Annunciators etc.
§ Operates at speeds up to 250kbps
§ CAN 1 is used to connect from the digital module to an ECM
§ The service tool should be connected to the Can 1 connection to enable
programming of the digital module
§ CAN 2 is used by the Remote Annunciator
§ The service tool should be connected to the CAN 2 connection to enable
programming of the Annunciator when the Annunciator is connected
Data Links
§ One RS485 SCADA (Systems Control And Data Acquisition) Data
Link
§ Uses MODBUS protocol at speeds up to 2.4kbps
§ Can be used to connect remotely through a modem using a RS485 to
RS232 converter
§ Half Duplex connection (2 wires)
§ Different password levels to restrict access
Annunciator Module
§ 16 channel display unit for remote information on current system
status
§ Can be used to announce faults and/or status signals, it also allows
the operator to silence the horn or acknowledge faults to the system.
§ Connects to the CAN2 J1939 data link on the PowerWizard Level 2.0
module
§ Annunciator’s front panel has 17 pair of LED’s;
§ 16 pairs of LEDs used to indicate events, diagnostics, and ready
signals
§ 17th pair of LEDs used as combined network/module status LED to
indicate data link connection problems
§ Each pair of LEDs consists of two of the following 3 colors: green,
yellow, and red
§ E.g. A pair of red and yellow LEDs may be configured for Engine Oil
Pressure. If a low engine oil pressure Warning is read over the data link,
the Annunciator will flash the Yellow LED and the siren will sound. If the
low engine oil pressure Shutdown is read over the data link, the
Annunciator will flash the Red LED and the siren will sound
Annunciator Module
§ Programmed using Electronic Service Tool
§ In the the “Configuration” screen. Each LED pair has four settings:
Suspect Parameter Number (SPN), Trigger Type, Trigger Severity
Level, and Failure Mode Identifier (FMI)
Annunciator Maximum Distances
Panel Configuration
§ The control module is software configured
§ Set points can be adjusted by the operator or service engineer from
the front of the module or by using the service tool depending on the
password level required
§ Set points are password protected
§ Display language is controlled by the Flash file
§ Each file contains a customer language and technician English
§ EST Service tool used to download Flash files to the module
§ Modules cannot be reprogrammed to different levels
Service Tool
§ The PowerWizard modules can be programmed using EST
Replacing a PowerWizard
§ Flash Files and Field Replacement Files
§ PowerWizard Panels 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
§ Replacement flash files can be downloaded from PowerUp2
§ The following information can be used to select the correct flash file for
the controller:
§Sales Order Number
§Genset Serial Number
§Engine Serial Number
§Control Panel Production Order Number
Replacing a PowerWizard
§ Flash Files and Field Replacement Files
§ Field Replacement Files:
§ Field Replacement Files only exist for controllers that have previously
been programmed at the factory
§ Field Replacement Files can be used on more than one controller
§ Replacement Field Replacement files can be downloaded from PowerUp2
§ The following information can be used to select the correct Field
Replacement file for the controller:
§ Sales Order Number
§ Genset Serial Number
§ Engine Serial Number
§ Control Panel Production Order Number
Replacing a PowerWizard
§Using EST to load Flash Files
§ Open EST Winflash
§This should be a separate
option to “Electronic Service
Tool” from within the EST sub
menu of Windows or it can be
accessed from the Service Tool
menu by selecting “Utilities” ->
“Winflash”
§ Ensure that the
communications adapter is
connected to the correct port of
the PC
§ Click “Browse” and select
desired flash file
§ Click “Begin Flash”
Replacing a PowerWizard
§ Using EST to load Flash Files
§ When the screen below appears, the Flash File download has been
completed successfully.
Replacing a PowerWizard
§ Using EST to load Field
Replacement Files
§ Open EST ECM Replacement
by selecting the Service > Copy
Configuration > ECM
Replacement menu item
Replacing a PowerWizard
§ Using EST to load Field
Replacement Files
§ Select the Field replacement
File (.xml file) that you wish to
load
Replacing a PowerWizard
§ Using EST to load Field
Replacement Files
§ 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
downloaded the message
“Programming Complete” will be
displayed.
Questions
