PowerWizard

Level 1.0 &

Level 2.0
Control Systems
Training
Systems Comparison
Level 1 Level 4 Level 2 Level 3
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PowerWizard
Level 3.0
PowerWizard
Level 4.0
Overview
Common parts from 10 2000kVA;
9 32vdc 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
Control Architecture Level 1.0
J1939 on electronic engines
Hardwired senders on
mechanical engines
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
Digital I/O modules
Remote Annunciator
Real time clock
Service interval counter
Modbus remote communications
using RS485 (2 wire)
Control Architecture Level 2.0
CAN J1939
expansion
network
CAN
J1939
Modbus
Hardwired
senders
Control System Components
with 400 Series engines
AC
Sensing
CTs
E7
A7
D3
B6
Grid Reference
System
A1
Alternator
Breaker and
Power connection
options
Magnetic
pick up
DC Controls
Standard
options
Communications and
CANBUS connection points
Service Tool
Connection
point
Annunciator
Connection
point
Remote
Communications
Connection point
AVR
Ac Sensing
Fuses
Oil & Temp
sender earth
Digital Inputs Relay Outputs
PowerWizard
Digital Module
Digital Output
Sender Inputs
Dc System Components on
Perkins 400 Series engines
EIM
Starter
Motor
Pre-glow
Fuel control
solenoid
Standard
options
Magnetic
pick up
Oil & Temp
senders
Battery Charging
Alternator
Control
System
Connector
Panel Layout
Alarm Lamp
Shutdown
Lamp
Lamp Test
Key
Alarm Mute/
Acknowledge
Key
Run Key
Stop Key
Auto Key
Escape Key
Enter Key
Cursor Keys
Ac
Overview
Key
Engine
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 LEDs 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.
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 base flash file. Each
file contains a customer language and technician English
The service tool can be used to download new base flash
files to the module
The base flash files are referenced by the panel serial number
and can be e-mailed from FG Wilson for that serial number
Control modules cannot be reprogrammed to different levels
Menu Tree
Password Protection
There are 3 levels of password protection on the PowerPort control panel.
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.
From the MAIN MENU, select the CONFIGURE menu.
a. Press the ENTER key in order to select CONFIGURE. SECURITY will be highlighted.
b. Press the ENTER key in order to select SECURITY. DROP TO MIN LEVEL will be displayed.
c. Press the ENTER key to select DROP TO MIN LEVEL
d. 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
Enter Level 1 or 2 Password
From the MAIN MENU, select the CONFIGURE menu.
a. Press the ENTER key in order to select CONFIGURE. SECURITY will be highlighted.
b. Press the ENTER key in order to select SECURITY. DROP TO MIN LEVEL will be
highlighted.
c. Press the DOWN key in order to highlight ENTER LEVEL 1 OR 2
d. 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 at the far
right.
e. Press the UP or DOWN key in order to select the desired number.
f. 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.
g. 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 to 16 digits but can use as few as 1 digit.
Password Protection
Enter level 3 password
From the MAIN MENU, select the CONFIGURE menu.
a. Press the ENTER key to select CONFIGURE. SECURITY will be highlighted.
b. Press the ENTER key in order to select SECURITY. DROP TO MIN LEVEL will be displayed.
c. Press the DOWN key in order to highlight ENTER LEVEL 3. Press ENTER to select ENTER
LEVEL 3 .
d. 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.
e. 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.
f. Press the UP or DOWN key in order to increase or decrease the highlighted digit to the correct
password.
g. 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.
h. Continue to set all 16 digits until the factory provided password is displayed.
i. 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.
a. Press the ENTER key in order to select CONFIGURE. SECURITY will be highlighted.
b. Press the ENTER key in order to select SECURITY. DROP TO MIN LEVEL will be
highlighted
c. Make sure that the current level of security is at least as high as the level of the password to
be changed.
d. Press the DOWN key to highlight CHANGE LEVEL 1 PSWD. Press the ENTER key to
select CHANGE LEVEL 1 PSWD
e. CHANGE LEVEL 1 PSWD is displayed. Use the cursor keys to set the new password.
f. 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.
g. Continue until the desired password is displayed.
h. 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 step 1.d 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. The main purpose for the other
Digital Inputs is to add additional monitoring capabilities. The 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 Status.
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 if the Annunciator is connected
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)
Password levels are to restrict access
Additional I/O Modules
Annunciator Module
16 channel display unit for remote information about the 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
There are 17 pair of LEDs on the annunciators front panel;
16 pairs of LEDs are used to announce events, diagnostics, and ready signals
17th pair of LEDs is used as combined network/module status LED to inform operator
of a problem with the data link connection.
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.
Maximum distance 240metres from generating set
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).
Additional I/O Modules
Thermocouple Module
The Thermocouple Module (TC) is capable of reading twenty inputs from thermocouples
and is also capable of generating diagnostics. The diagnostics that are generated by this
Module are maintained in non-volatile memory
The Thermocouple Module will read the inputs and then calculate the temperature in
Celsius. The Thermocouple Module will then broadcast the information onto the J1939
data link. The PowerPort Module will read the information from the Thermocouple Module
and display the information on the display screen.
The Thermocouple Module is capable of storing twenty diagnostics log entries. The log can
be viewed from the PowerPort Module. All of the diagnostic messages are broadcast on
the J1939 data link. The PowerPort Module reads these messages and reacts depending
on its settings. Any of the inputs can be disabled to prevent unnecessary diagnostic faults.
The Thermocouple Module is configured by using EST on the primary data link.
Additional I/O Modules
Discrete Input/Output Module
This Module is capable of reading twelve discrete inputs, operating eight relay outputs and
can be mounted on the genset or remotely. It is configured using EST.
The Module has twelve inputs with four return channels. These inputs can be activated by
either switching to a return or to battery negative.
Inputs that generate a warning message will auto-reset whenever the input is removed.
Inputs that generate a shutdown message will continue until the input returns to a non-
active state and a reset message is received on the J1939 Data Link.
The Discrete I/O Module has eight " Form C" relay outputs. Each output can be configured
for either general or specific events.
For general events, each output activates whenever any Alarm Condition, Shutdown Condition, or
Alarm and/or Shutdown Condition exists.
For specific events, each output activates when the diagnostic message contains the SPN and FMI
combination that matches the SPN and FMI combination that is programmed for that particular
output.
Additional I/O Modules
Resistive Temperature Device Module
This Module is a temperature scanner capable of reading eight Platinum RTD inputs. The
eight Platinum RTD inputs can have two, three, or four-wire configurations.
The Module is also capable of generating diagnostics. The diagnostics that are generated
by the RTD Module are maintained in non-volatile memory. The RTD Module is capable of
storing the twenty diagnostic log entries.
The Resistive Temperature Device (RTD) Module will read the inputs and then calculate
the temperature in Celsius. The RTD Module will then broadcast the information onto the
J1939 data link.
Each of the 8 inputs have sensor diagnostics in order to detect open or short circuits that
go to the RTD sensors. Over temperature warnings and Shutdowns as well as Under
temperature warnings are detected by comparing the measured temperature to the Low
Warning, the High Warning, the High Shutdown temperatures stored in the module.
Service Tool
The new control modules will be supported by Perkins EST Tools
CANBus J1939 Codes
Failure mode identifier (FMI)
Type of failure that has been experienced by the component
Suspect Parameter Number (SPN)
The SPN is a number that identifies the specific component of the
electronic control system that has experienced a diagnostic code.
Parameter Group Numbers (PGN)
Parameter Groups are organized according to Generator, Utility,
and Bus related parameter quantities.
Summary
Differentiated, integrated solution
Competitively priced, 21
st
century product
Increased feature bundling
Consistent direction
Increased quality and reliability
Industry leading family of control systems
Quality, Increased Functionality and Growth