TABLE OF CONTENTS 1. INTRODUCTION 2, CONTROL SYSTEM OVERVIEW. 2.1 Panet Equipment... 2.2 Environmental Consraints 23 Power Supply... 2.4 DC Contrel inputs. 2.5 DC Contol Outputs 26 DC Sender Inputs. 2.7 AC Voltage Inputs 2.8.AC Current Inputs 2.8 Communication Interface 3. CONTROL, 4. OPERATING INSTRUCTIONS. 4.4 Automatic Mode Of Operation... 4.2 Manual Mode of Operation ...onesennn 4.3 Display Menus. . 5. FAULT CONDITIONS ....- 5.1 Internal Fault Conditions .. 5.2 External Fault Condtions 6. CONFIGURATION... 6.1 System Menu... 6.2 Setpoints Men... 6.6 Calibrate Menu 7. CONTROL SYSTEM OPTIONS AND UPGRADES. 7.4 Battery Trickle Charger 7.2 Heaters. an 7.3 Electric Fuel Transfer Pumps. 7-4 Remote Annunciator Interface, 7.5 Remote Control and Monitoring, 8. CONTROL SYSTEM FAULT FINDING/TROUBLE SHOOTING GUIDE. 8, SPECIFICATION. ‘© Copyright 1999 FG. Wison (Engineering) Limited. All ightsrese Document: MAN-AGOOO Issue: 2 Dato: 0509 Part No.276-0494. INTRODUCTION ‘The ACCESS 4000 mioraprocessor based generator conirol panel is an auto-start system providing a comprehensive array of operational features, Utilising the latest advances in embedded microprocessor technology, surface mount printed circuit board assembly and software development techniques, the design provides for a powerful, easy to se system together with high accuracy for all metering and protection functions. (Once activated the ACCESS 4000 module carries aut all the start and slop procedures for the engine, indicates the operational status and ‘auk conditions; and automatically shuts down the generator set in the ‘event of critical condition arising. ‘A ange of optional features alfow other functions such as an open protocol communication interface, for communicating with Supervisory Control And Data Acquistion (SCADA) systems, or remote monitoring Via. a vo ree relay interface module. ‘The module is housed in a robust plastic case for front panel mounting within a control panel. Connection tothe unit is via locking plugs and sockets. ‘The ACCESS 4000 provides the following advanced features: ‘© Microprocessor based circuitry ‘¢ NFPA 110 Level 1 compliance + NEMA 1 enclosure ‘+ Large format alpha-numeric Liquid Crystal Display ‘* Open protocot communication interface ‘© Digital sor 1 phase voltage and current metering ‘+ Digital engine parameter metering © Upto 16 faull circuits utilising analogue and digital inputs ‘= 20event faut log memory ‘+ Password protected operator levels. ‘¢ Site programmable using the integral Keypad or Laptop PC. ‘+ Configuration stored in non-volatile memory ‘CONTROL SYSTEM OVERVIEW ‘The following installation guidelines are provided for general information only. For specifc site installation information, consult your local desler as required. ‘CAUTION: 1 Altinstalation andlor service work performed must be done by ‘quslfed personnel only. Fallue te do so may cause personal injury or death 24 Panel Equipment ‘The ACCESS 4000 control panel consists of three main parts; ‘an ACCESS 4000 control module, external control equipment and a panel enclosure. Figuie 2.1 shows a fully optionised diagram of an ACCESS 4000 control panel. Note: © The addition of non-standard optional equipment may ada items not shown here. The following descriptions explain the function of each item on the panel, a more detailed description of the control module folows in section 3. Figure 2.4 - Diagram of a Typical ACCESS 4000 Control Panel 1. ACCESS 4900 Control Module 2, Panal Enclosure - housing the module and associated external controls. 3. Audible Alarm -a buzzer that sounds on sensing a fault condition, [option] 4. Emergency Stop push-button - 2 red lock-dewn button Is used fo intiate an emergency stop signal to the generator set. This wil cause the ‘engine to immediately stop and be prohibited {form operation until the button is released. 5. Voltage Adjust Control - a potentiometer providing manual control ofthe generator output voltage (AVR excitation). [option] 8. Thormostart Control-a momentary action button is used to pre-heat the engine prior to cranking. {option} 7. Control Switch -a three position switch ccontrolkng the mode of operation. Refer to the ‘operating instructions for detailed information. © pw In this positon, the engine wil start and operate continuously providing ne shutdown faut ondiions ae active. Al protective functions wil ‘be operative inthis mode. There wil be no start, dolay or slop (cooldown) delay inthis mode. © or Manually initiates a stop signal tothe generator ‘and prohisits automatic startngiunning. The control switch must be retumed to this position following @ shutdown fault condition before any further generator set operation wil occur. © suro In this position, starting and stopping of the ‘engine will be controlled by the REMOTE START contact. With the contact closed, the ‘generator set wil start and run, With the contact removed, the generator set wil stop and return to standby,8, Fue! Transfer System Run - a momentary action button used to inate the operation ofthe fuel transfer system. [option] 8. Fue! Transfer System Stop -a lock-down button used to cancel the operation of the uel transfer system. [option} 10. Battery Charger Boost - a two position switch controling the engine starter battery charging voltage. [option] 11. Speed Adjust Control - a potentiometer providing manval, Control of the generator output frequency (engine speed). {Option} 2.2 Environmental Constraints ‘The module when mounted correctly within a panel will conform to IEC 528 IP-56 and NEMA 1. The panel should be vibration isolated from the engine and altemator and protected against excessive temperature swings, 23 Power Supply ‘The ACCESS 4000 control system is designed to operate on any direct current (DC) battery supply io the range 9 to 32 volts. The battery negative must be grounded to the engine block, usually via the starter motor negative terminal. An intemal batiery is not provided and is not necessary. conta age ” 0298 400 K— vec eee Figure 22 - Typical DC Control Input Wiring 24 DE Control Inputs ‘All DC control inputs to the ACCESS 4000 are optically isolated for protection ftom noise and transient spikes. All inputs are designed to switch law ie. to the battery negative including the emote start contact. The use of POWERED CONTACTS may damage the control module. 28 OC Control Outputs ‘All de control outputs from the ACCESS 4000 are vol-ree relay ‘contacts. The contacts are rated for 2 Amps at 30Vde and are isolated Form C type. The use of interposing relays between the ACCESS 4000 and the extemal device is necessary to prevent potential internal damage due to excessive current. For loads ‘generating switching spikes, the application of kansient Suppress is alo recommenced. Now: © Onpower toss ALL oupus wil sth othe de-energised ste oo tos oy eae scene 109 [rr O ° cag Figure 2.3 - Typical DC Control Cutput Wiring 2.6 DG Sender Inputs Both engine sender inputs {oil pressure and engine ‘coolant temperature) are designed to operate with vatlable resistive typo senders. kay Figure 2.4 - Typical DC Sender Input Wiring 27 AC Voltage Inputs ‘The ACCESS 4000 is designed using a multtapped potential transformer forall AC voage input in the range 60 - 300Vac, using one of four tappings on the high accuracy potential transformers fied external to the ACCESS 4000 (Agure 25), Standard singe or three phase systems can be accommodated using ‘one af five alternator winding configurations 3s. ‘shown in figure 2.6. High voltage systems may be interfaced using additional specialised transformers. WARNING ! The incorrect connection of the AC Voltage Inputs will damage the controlier. Ensure that correct primary voltage tapping connections are made. 320v oO 250, | 130V 25vims ev N 0 Figure 2.5 - Mult-tap Transformer3Ph aw Let L-N ‘Connection 1 u “ ( = Series Star & or Parallel ae Star Connection 2 a 3Ph aw B Leb 6 L-N Series Delta * =— — Fd Edged — — Connection 5 Ensure correct primary tapping onnections are made (see figure 2.5) Figure 2.6- Typical AC Vollage Input Wiring 2.8 AC Current Inputs ‘The ACCESS 4000 is designed to measure current indirectly using ‘current vansformers. The maximum secondary current is § Amps. Iis recommended for improved accuracy that an independent six wire unearthed connection arrangement is adopted as. shown in figure 27, u u b N Figure 2.7 - Typical AC Current Input Wiking ‘Communication interface ‘An industry standard RS422/485 communications pont is Provided for both factory programming and customer interface. ‘Connections to the module should be made using individually ‘screened twisted pair cable. Connection for 2 or 4 wire operation wil be determined by site and operational conditions. Please also refer to section 3.2, 2 ; sez: 100 poze 00” Tet} * RetO-} Re} Reo} of A G We RS422) 2 Wre R5406)3. CONTROL, ‘The ACCESS 4000 control module utilises both analogue and digital Inputs and outputs to perform its control and manitaring functions, The ‘module provides the means of sterting and stopping the generating ‘set, monitoring its operation and output, and automatically shutting down the set in he event of a crtical condition arising such as low lubricating oil pressure or high engine coolant temperature. ‘The main component of the module fronts the membrane keypad, the features of which are described as follows with reference to figure 3.1 Figute 3.1 - ACCESS 4000 Control Module (ont view) 1. CURSOR CLUSTER. The arrow keys aro used fo navigate around the stalus menus oF for programming values within the configuration menu. The “UP Key" wil intease numerical values of parameters or selpoinis. The ‘DOWN Key’ will decrease numerical values of parameters or setpois. The "LEFT Key" will move the cursor to the previous item in the menu screens orto the let when programming parameterp or setpoins. The "RIGHT Key' will move the cursor tothe next tem in the menu screens orto the right when programing parameters or selpoins 2. LCD VIEWING WINDOW. The backlit LCD display is mounted behind and visible through the cleer lexan viewing window. 3. ESCAPE Key. Pressing this key will exit from any menu or [programming screen without saving the new value, 4. ENTER Key. Use ofthis pad selects the menu item or amends the ‘sew programmed parameter or setpoint, This key is also used to acknowledge and reset alarms or shutdowns from within the alarm log menu, 5. ALARM MUTE. De-energises the common aterm output relay thus ‘muting any audible alarm (siren) if ited. 6. FAULT LED. The fault LED ilyminates when any pre-programmed fault has been activated. The LED will fash quickly alerting the user to shutdown (critical) condition. The LED will ash slowly alerting the user to an alarm (non-critical) condition. Once all shutdowns have been acknowledged the LED will ‘go solid’ and de-energise once they are all reset 7. Power LED. illuminates when the unit is powered in the healthy state. @ ° ° ° Q coos ir poor =O Figure 3.2 - ACCESS 4000 Control Module (rear view) 8. Electrical Connections. Connections to the ACCESS 4000 are via locking plug and sockets. 9, Diagnostic LED's, The ACCESS 4000 provides {four diagnostic Light Emiting Diodes to faciftate simple module diagnosis. Their functions and symbols ere described 3 follows: @ rue. controt soLenoio. ‘This LED is iluminated whenever the module has called for the engine to un. The LED mirrors the status of the output relay which ‘controls the fuel control solenoid © STARTER CONTROL SOLENOID ‘This LED is lluminated whenover the module i initiating an engine crank cycle. The LED mirrors the status ofthe output relay which ‘controls the auxiiary starter solenaid. O warcunos This LED flashes on and offal regular intervas indicating thatthe microprocessors functioning normally FT remote controt ‘This LED is illuminated whenever the module is being controlled ftom a remote signal ie. via the communication facility or via the remote start Input 10. Expansion Port, Provision for expansion of the ACCESS 4000's functional capabilty is provided {or using the expansion port. Far further details ‘on the options aveilable, refer to your local dealer. 114. Serial Number Label. A two part seriat number label detaits the unit part number, individual unit serial number and generator set works order umber. Please quote all three tems of information when requesting dealer or factory suppor. 12, Communications Set Up. Set all dip switches to ‘ON" in a single ACCESS 4000 system. In a mutiple ACCESS 4000 system, set dip ‘switches to "ON" on the unit furthest away from the MCM2(PC) / MCM3{Tel) leaving the ‘switches on the intermediate units to “OFF” positon,Connector DC" Fuel control solenoid control - COM 2 Battery positive Input 9 -32Va6 a Batiery negative Input OVde 4 ‘Sender earth reference Input Vdc s Not Used 8 Not Used 7 ‘Water temperature sender ‘Output 13m a Oil pressure sender Output 37.5mA, a Programmable relay no.2-COM _| Volt Free 10___ | Fuel control solenoid control - NiG_| VoR Free it Not Used 12 __| Future development ‘Von Free. High engine temperature switch input Input active low [14 Run switch input Input active low 75___| Remo sta switch input Input active ow 16 ‘Spare input 2 Input - active low 17 ‘Spare input 4 Input - active low 18 Programmable relay NIC Vok Free 79 | Fuet conto solenoid contoi= NO —| Vor Free 20 ‘Magnetic Pickup (+) 5 - 30Vac (wart. pin 21) 2 ‘Magnetic Pickup (-) 8 ~30Vac (wrt, pin 20) Z| Low of pressure switch input Input active ow 23 Emergency stop switch input Input - active low 24 [Auto switch input Input ective low Fy Input active ow 25 Input aative ow 7 Programmable relay no. 2 - N/O- Voit Free 28 | Slater solenoid contol COM | Volt Free 23___| Stater solenoid control NO Voit Free 30 [ Starter solenoid contol AWC Volt Freo 31__| Comion alarm = COM: Vat Free 32 [ Common slarm= NiO Voit Free 33___| Common slam = NIC Vot Free 4 Programmable relay no. 1 - COM Voit Free: 35 Programmable relay no. 1 - N/O- Volt Free 36 Programmable relay no. 1 - NIC ‘AC Gurrent - Phase G (send) Volt Free, Signal Type 'AC Current - Phase B (send) ‘AC Current - Phase A (send) ‘AC Current - Phase C (return) ‘AC Current - Phage A (retvrn) 0-5Aae "AC Voltage ~ Phase A (lve) '25Vac nominal (wert pin 9) [AC Volage - Phase © (neutral) 6 pin 10 ‘AC Current - Phase B (ceturn) 0-5Aac ‘AC Voltage - Phase A (neutral) see pin ‘AC Voltage - Phase C (ive) 25Vac nominal (wt pin 7) AC Voltage - Phase B (neutral) see pin 12 ‘AC Voltage - Phase B (Ive) 728Vee nominal (wet pin 11) Tsolatod power supply - postive ‘Communication receive - RX. ‘Communications receive - AX ‘Communications transmit -TX- ‘Communications transmit -TX+ Isolated power supply — common 4, OPERATING INSTRUCTIONS ‘The ACCESS 4000 control system is required to operate with an external changeover system designed to handle all ‘mains sensing and load transfer functions. The ACCESS. 4000 controller will start and stop the engine in either a local “manual” oF remote “automatic” mode. When a "required to eun’ command is issued, the controler issues ‘engine fue! control solenoid on and starter motor crank ‘output signals. The engine speed is monitored and once ‘engine firing speed has been reached the module terminates the crank signal. While the engine accelerates vp to and runs at nominal speed, the ACCESS 4000 continually monitors the engine speed signal. Should the ‘engine speed exceed the setpoint determined ty the OVERSPEED fault condition, the engine is shutdown by termination of the fuel control solenoid on signal, In addition to the OVERSPEED fault condition, the ACCESS 4000 continuously monitors all other necessary ‘engine conditions, together with additional optional fauk conditions as required by the customer. For detailed Information on all fault conditions. refer to section 5. ‘On removal ofthe ‘required to run’ command, the engine will automatically stop. ‘The ACCESS 4000 includes all necessary user programmable timer functions to enable start, cranking fand stop (cooldown) time delays. Far futher information (on configuration of the ACCESS 4000, refer to section 6 4.4 Automate Mode Of Operation When the ACCESS 4000 control panel is selected {for Automatic (AUTO) standby operation using the Control Switch (ref. Figure 1.1 -ttern 7), the generating set wil automaticaly start and run upon activation of the remote start contact input. The ‘engine will attempt to crank after the start delay timer expires. Note: the start sequence will NOT be initiated if any shutdown fault condition is present. ‘Assuming the engine starts and accelerales ‘Successfully, the ACCESS 4000 will default to display on the LCD an OVERVIEW screen, Once the generating sat reaches rated voltage and {frequency the disconnection of the mains from the load and connection of the generator to the load is handled by the changeover system.‘The generator continues supplying the load unt the remote start signal is removed, the panel is switched to OFF or a shutdown ‘aul condition arises, if@ shutdown fault condition arises, and before any further operation of the generator set can occur, an ‘operator is required to acknowledge the fault and, wilhin the ALARM LOG menu, reset the fault(a). In addition the controller ‘must be switched to OFF and back to AUTO before the system will respond to a new or continuing remote start signal ‘The generating set may continue to run on no load for cooling purposes before stopping automatically and returning to automatic standby. 4.2 Manual Mode of Operation ‘When the ACCESS 4000 contol panel is selected for Manual (RUN) operation using the Control Switch (ref. Figure 1.1-ttem 7), the generating set wil automatically start and run. Note: the start sequence will NOT be initiated if any shutdown fault ‘condition is present. Assuming the engine starts and accelerates successfully, the ACCESS 4000 will default to display on the LCD an OVERVIEW screen. ‘The generator continues to supply any load applied to it until the Control Switch is switched to the OFF or AUTO positions or a shutdown faull condition arises. If shutdown fautt condition arises, and before any further operation of the generator set can ‘occur, an operator is required to acknowledge the fault and, ‘within the ALARM LOG menu, reset the faui(s). tn adcition, the ‘controller must be switched to OFF and back to RUN before the system wil respond. 43. Display Menus. ‘The ACCESS 4000 disptays all user interface information on a ‘series of pre-programmed screens on the Liquid Crystal Display ihe contrller enters a boostrap all system parameters. ‘After approximately five seconds the contrller defaults to display the main menu, All further information relating to the ‘generator system may be accessed through a series af main and ‘Subordinate menus, the selection of which is performed by the ‘operator. ‘4.3.1 Main Menu: This top level user interface menu provides the operator with the opportunity to select detalled information _ ‘Setpoint (100 - 15500 Vac) - Defines the maximum allowable ‘generator voltage level ‘Time Delay (0 - 99 sec) - Defines the fauit transient re through petiod ‘Action (alarm, shutdown) - Defines how the generator will respond to the fault Vokage Low Ve ‘Setpoint (100 - 15500 Vac) - Defines the minimum allowable ‘generator voltage level Time Delay (0 - 89 sec) - Defines the fault transient ride through period ‘Action (alarm, shutdown) - Defines how the generator will respond to the fault Frequency High E> ‘Setpoint (50 - 70 Hz) - Defines the maximum allowable generator frequency level Time Delay (0 - 99 see) - Defines the fault transient rte through period ‘Action (alarm, shutdown) - Defines how the generator will respond to the fault Frequency Low F> ‘Setpoint 40 - 60 Hz) - Defines the minimum allowable generator frequency level Time Delay (0 - 98 sec) - Defines tho Fault transient ride through eriod 83 2 ‘Action (alarm, shutdown) - Defines how the ‘generator will respond to the fault ‘Qyerspeed ‘Setpoint (1000 - 4200 rpm) - Defines the maximum ‘allowable engine speed Overload > ‘Setpoint (1 - 999A) - Defines the maximum Allowable generator current level, This is normally ‘specified as 110% of full load current. The t delay is fixed at 60 minutes in any 12 hour period. Action (alam, shutdown) - Defines how the ‘eneraoe wil respond tothe faut Battery Votage Hiah V>= ‘Setpoint (12 - 34 Vde) - Defines the maximum aowable engine battery volage ‘Time Delay (0-98 sec}- Defines the faut transient side through period Batlory Voltage Low V< ‘Setpoint (9 - 24Vdc) - Defines the minimum allowable engine battery voltage ‘Time Delay (0 - 99 sac - Defines the fauk transient ride through period : Battery Charger Fail ‘Setpoint (9 - 28Vdc) - Defines the minimum ‘allowable battery charging voltage ‘Time Delay (0 - 99 66c) -Dofines the faut transient ‘ide through period ‘Setpoint (1 - 9 bar) - Defines the normal minimum engine lubricating oll pressure (1 Bar = 14.5 PSI) ‘Appr High Engine Temperature ‘Setpoint (90 - 105°C) - Defines the normal maximum ‘engine coolant temperature Low Tem, ‘Setpoint (20-88°C) - Defines the minimum engine Coolant tempersture [Not in Auto (enabled, digabled) - Defines whether the faults enabled oF disabled EPT Dela ‘Time Delay (0 - 99 sec) - Defines the engine fault condition inhibit time period Inputs Menu ‘Win his menu selection the operator may change settings relating tothe four external fault inputs. A level two password is cequired for entry. Depending ‘nthe number of optional faut inpuls specified at time of order, a series of upto fourteen screens may a presented requesting input or conformation of dala entry. A typical screen is shown below:64 E itete tere ‘The cursorkays are used to modify the vahes, the UP and DOWN keys cause the value to increment and decrement and the LEFT and RIGHT keys move the cursor along the dala field, Pressing ENTER will input a new value or confirm the existing value. The controller wil automatically move onto the next [programming screen. ESCAPE will retum the controler to the ‘configure sub-menu. aut Input 4 ‘Time Delay (0 - 99 sec) - Defines the fault transient ride through period Action (alarm, shutdown) - Defines how the generator will respond tothe fault FPT Delay (enabled, disabled) - Defines ifthe faut is tobe inhibited during startup Fault Input 2 ‘Time Detay (0 - 99 sec) - Defines the fault transient ride through period ‘Action (alarm, shutdown) - Defines how the generator will, respond tothe fault FPT Delay (enabled, disabled) - Defines ifthe fauit is tobe Inhibited during startup Fault Input 3 ‘Time Delay (0-99 sec) - Defines the fauit transient ride through period ‘Action (alarm, shutdown) - Defines how the generator will respond to the fault FPT Delay (enabled, disabled) - Defines ifthe faut is tobe Inhibited during startup Fault Input 4 ‘Time Delay (0-99 sec) - Defines the fauit transient ride through etiod ‘Action (alarm, shutdown) - Defines how the generator wil respond to the fautt FPT Delay (enabled, disabled) - Defines i the fault is tobe Inhibited during startup ‘Remote Stan ‘Time Delay On (0 - 99 500) - Defines the delay period between ‘ceiving the remote start signal and the controller initiating the ‘engine start sequence. ‘Time delay Off (0- 99 min) - Defines the delay period between ‘receiving the remote stop signal and the controler terminating the engine run signal Outputs Menu ‘Within this menu selection the operator may change settings relating to the optional two programmable relay outputs and the ‘expansion port. A level two password is required for entry. ‘Depending on the number of optional outputs specified at time of ‘order, a ¢eries of up to three screens may be presented ‘requesting input or conformation of data entry. A typical screen is shown below; 2 ‘The cursor keys are used to modify the values, the UP and DOWN keys cause the value to scroll through the option lst. Pressing ENTER will mput a Rew value or confirm the existing value. The ‘controler wil automaticaly move onto the next programming screen, ESCAPE will tum the Controller to the configure sub-menu.‘Qutput Retay 4 ‘Action - Defines under what alarmvstatus condiion the output ‘lay wil energise 1. Running - generator started ang producing rated speed and voltage 2. Alarm - alarm fault condition active 3, Shutdawn - shutdown fault condition active 4. Ready to Load - generator started in automatic and producing rated speed and voltage 5. Overspeed - the controller has detected an engine overspeed condition 6 Overioed - the controler has detected an overtoad fault condition 7. Not Defined - future development 8. Not Defined - future development 8. Not Defined - future development Output Relay 2 Action - Defines under what alamwstatus coneition the output relay will energise 1. Running - generator started and producing feted speed and voltage 2. Alatm - atarm fault condition active ‘3. Shutdown - shutdown fault condition active 4, Ready to Load - generator started in automatic and producing rated speed and voltage 8. Overspeed - the controller has detected an engine ‘overspeed condition 6. Overload - the controller has detected an overload fault condition 7. Not Defined - future development ‘8. Not Defined - future development: 9. Not Defined - future development: Expansion Pot ‘Aion - Defies the mode of operation of the expansion port 1. Annuneiator - controls the remote annunclator interface ‘module Data Logger - not yet available {contact factory for detals) ‘Modem - not yet available (contact factory for details) ‘Not Defined - future development ‘Not Defined - future development ‘Not Defined - future development Not Defined - future development [Not Defined - future development ‘Not Defined - future development SPN eaen “65 Security Menu ‘Within this menu selection the operator may change the level ‘one, level two oF remote access passwords. In order to change ‘the password the original password must frst be entered: ae = er aint ‘The controtier will then promet for entry of the new password: A T i ohh and then a further confirmation. feta ptperr “The new password MUST be shtered correctly on both screens before it will be accepted. The cursor keys are used to modity the values, the UP and DOWN keys cause the value to increment and decrement and the LEFT and RIGHT keys move the cursor along the data field. Pressing ENTER wil input a new value. ESCAPE will relum the contalies to the configure sub- ‘menu. Entering a level 1 password enables the operator to change only ‘the level 1 password. Entering the level 2 password enables the ‘operator to change either the level 1 or level 2 passwords. Entering the remote access password enables the operator to change only the remote access password. 6.6 Calibrate Menu While each ACCESS 4000 unit is fully calibrated before it leaves the factory, thare may be a requirement to re-calbrate during ‘commissioning. Within tis menu selection the operator may ‘only modtty factory calloraton settings, returning all gain values {to one (1) and offset values to zero (0) wil return the unit to the factory calibrated default. A level thtes password is cequired for ‘entry and so may only be performed by suitebly qualified and authorised personnel. A series of sixteen screens will be ‘resented requesting input or conformation of data entry. ‘The fist inthe series is a8 shown below: eiaLt[N elm} tle rs] “The cursor keys are used fo modify the values, the UP and DOWN keys cause the value to increment and decrement ond the LEFT and RIGHT keys move the cursor along the data fel. Pressing ENTER will input a new value or confim the existing value, The controller wit automatically move onto the next programming screen. ESCAPE wil alum the controller to the ‘configure sub-menu. For detailed information on the procedure for re-caibrating the contol please contact your local dealer. ‘CONTROL SYSTEM OPTIONS AND UPGRADES A large variety of options may be fitted to customise the controt ‘system for a specific instalation. The following sections cover the use and operation of these option TA Battery Trickle Charger A battery trickle charger is fited as standard. These chargers are designed to ensure that the engine starter batteries maintain 18 their chargo even if the gener ‘operated for long periods.12 73 Control switches for the chargers are not normaly fitted to ‘Prevent inadvertent switching off ofthe charger. However, a6 an addtional option a Battery Charger Boost Control may be fited. ‘The Boost Control overrides the automatic contral mechanism of the charger that would normally reduce the charging level as the ‘battery becomes charged. This can alow faster charging of the bbattery. However, care must be taken to only use the boost ‘control for a short time to avoid overcharging the batlery and/or boiling the battery dry. ‘As an option, a battery charger ammeter may be fitted to the ‘control panel in order forthe operator to monitor the functioning of the battery charger. Heaters {In addition to conventional space heaters that are useful in keeping the generating set warm and dy in cold or humid ‘environments, four types of heater may de fited on the ‘generating set. emersion type heaters (engine heaters) may be fited in the engine cootant system to eneure thal the engine és exsy to start ‘and able to take load more quickly. il sump heaters may be fitted to the engine sump cass to ensure thatthe lubricating ail viscosity fs maintained so aiding in engine stating ond load acceptance ‘Attemator anti-condengation heaters may be fitted to the ‘akternator stator windings to keep them dry in humid conditions. Battery trace heaters may be filted to the engine starter battery ‘system to maintain the battery electrolyte at a temperature which will ensure good battery performance under engine starting conditions, Electric Fuel Transfer Pumps Ful transfer pumps are required when fuel must be transferred from a buk storage tank to the generating set day tank. “The controls consist of two illuminated pushbuttons on the control panel door. The red button is a combined trip lamp and stop button. The green button is a run lamp and manual start push-button, To operate the pump manually, ensure the fed push-bulton isin the ‘on” poston (pulled out). Press and hold the green push- button to manualy run the pump. The pump will only run inthe ‘anual mode while the green button is held in To operate the pump in automatic mode, just ensure that the red. push-button is in the "ON" position (pulled out). The pump will start run automatically when the fuel level is low and wil jtumninate the green run lamp. When the tank is ful, the purnp is ‘automatically turned off and the green lamp is extinguished. ‘The red lamp wil ituninate if there has been an electrical overtoad, Gare must be taken to ensure that the pump is primed with fue! prior to operation to lubricate the seals. Also, the pump should never be run when the bulk tanks are amply or when valves on ‘he fuel fil lines are closed. 167.4 Remote Annunclator Interface {Sea Appendix A) ‘A hardware package is available to remotely monitor the {generating set. A series of sixteen fault condition monitoring ‘relays activate to signal, via Form C voltfree contacts, a remote ‘annunciator. Connection details are provided with the option Fault Cause Romedy. Engine speed is | Speed control Referto 3 qualified unstable dynamics are ‘generating set annunca imorpery setup | fetnian 7.5 Remote Control and Monitoring FALTO | Theenginehas no | Check uct A hardware and software package is available to remotely START fuel supply. levelipressure_ ‘Gantrol and monitor the generating set either directly with a PC HIGH ENGINE | Engine stops dueto | Check engine was not Grover teaphone Ine vsinga moder Detales eraing HIGH ENGINE | Engine stop Check ona inctrucone are povided wit he option packege TEMP feu | Nah engine ‘An open potacol communication pot avaiable fo emote control and monitor the generating set via a Building Check radiator for ‘Management System (BMS) or Supervisory Control And Data obstructions. Acquisition (SCADA) system. Detailed protocol information is vale rom your local dole, vin oat CONTROL SYSTEM FAULT FINDING/TROUBLE SHOOTING sue Retertoa quaified {umber of auts ay cause Ihe ACCESS 4000 contr module generating st too funcon corey. Fife fo fe ftowing et of pel problems. For further detailed information or any problems not LOWOIL Engine stops due to | Check oil level fisted, please Consut Your local desir pressure | tortuniseaagen CAUTION fault displayed pressure: 1 there are NO usar servicable parts within the ACCESS Rotor toe quaifiod 41000 control module. Any atemp to open the module wll ee cena ea ‘result in termination of the product warranty. Al faut finding and service procedures must be undertaken by technician EMERGENCY | Emergency Stop | Check and release suslfed and authorised personnel only. ‘STOP fault pushbutton has emergency stop displayed been pressed buttons. Incorrect Incorrect VT 8 GT | Verity that the VT & voltage or fatio programming | CT ratios are conect ‘current meter LCD does not | Mi veecing display soreen Incorrect primary PT | Verify that PT input text connection voltages tapping connections are correct (see figure 2.5 Starter motor not} Check the starter motor ‘engaging LED on the rear of the £28) Lunt it should energise Incorrect primary PT | Verify that PT ratios ‘on for a few seconds and. ratio setting are comrect then off, ‘Check the fuel control LED on the rear of the Unit, it should energise on, ‘Shutdown fault | Check the fault log for ‘condition active | active shutdown faults Refer to.a qualified generating set technician Starter motor | Crank cut-out Adjust the setpoint down stays engaged | setpoint in the after the engine | system menu is stats toolarge Engine has Refer to a qualified ‘overspeed during | generating set techni Inadequate MPU | Check the connections of the MPU. AVR dynamics are | Refer toa qualified improperty setup | generating set technician Inconect engine | Incorectwiring | Very that the votage temperature or | connection and current sensing cilpressure wimg is as per the meter teading spproprite wing (or displaying diagram Co) Incorrect anaiogue | Refer to a qualified calibration generating set technician fluctuates or is unstable. 7| 9, SPECIFICATION Power Supply 9 - 32 Vo, negative ground (voltage dip transient, 4.BV do for 50 ms) ‘Operating Temperature +10 to +50° Ingress Protection 1EC 628 1P-66, NEMA 1 Power Consumption ‘8 Watts (maximum) AG Metering Accuracy Engine Parameter Accuracy accuracy), Inputs: Engine Speed Sensing (Magnetic Pick up) AC Voltage (nominal) AC Current (nominal) Engine Paremeters: Dial inputs ‘Outputs: 215%@ 256 £1.0% @ 25°C (plus sender 60He - £0,000H2, -30Vac (ams) 110 480Vac (Lt y63.5 - 277Vac (LN) 50-60 Hz 0-60 Variable resistance type senders ‘Switch to power supply negative 2A, 30 Vide, Form & 18APPENDIX A REMOTE ANNUNCIATOR BOARD. ‘The remote annunciator board has sixteen relays which can be programmed through ACCESS 4000 to switch extemal devices (lights, alarms, sirens, efc) when a shutdown/alarm activates. There are two units associated with the remote ‘annunciator, the ANNUNCIATOR MODULE and the REMOTE ANNUNCIATOR RELAY BOARD. These are connected to-each other via @ 20 way ribbon cable as shown in the diagram below. REMOTE ACCESS 4000 20 WAY RIBBON ANNUNCIATOR CABLE RELAY BOARD. ROd>-ozczZ> mreooe ‘The Annunciator units are connected to the ACCESS panel in the following way. 4. A cover on the side of the ACCESS 4000 is removed and the ANNUNCIATOR MODULE Is connected to the ‘ACCESS via a 15 way D connector. The module should be held in place with the screws provided. 2 Select the correct setting for SW/1 on the REMOTE ANNUNCIATOR RELAY BOARD shown In the diagram below. Set it to either 12V or 24V according to your battery voltage and then connect the supply voltage to the board at the BATT and GND terminals 3. Use the 20 way RIBBON CABLE {o connect the ANNUNCIATOR MODULE to the REMOTE ANNUNCIATOR: RELAY BOARD on ECt nay | [rewyo we] [moe za] [mor a COCC CCRC OCHO HSER EEE OEELE Relay Relay 14 REMOTE ANNUNCIATOR RELAY BOARD When a shutdown or alarm occurs, information is transmitted from the ACCESS to the REMOTE ANNUNCIATOR: RELAY BOARD. Al the RELAY BOARD the signals are used to switch the relays associated with the particular shutdowns or alarms. 9For example in the diagram below pins 1 and 3 are normally connected through relay 4, Whenever the faut FAIL TO START occurs the relay will switch and pins 1 and 2 will be connected, FAIL TO START RELAY 1 Ec2 ‘Tho foun and their associated ping on the green connectors EC2 and EC3 are shown in the table below. Aiso shown are the pins that are normally connected through the relays when the Shutdown / Alarm are not activated. ‘SHUTDOWN / ALARM PIN NUMBERS PINS normally, connected Connector EGE FALTOSTART 1 z a 7s ‘OVERSPEED o 3 3 4.48 EISTOP 7 a 9 7&9 HIGH COOLANT TEMPERATURE [10 12 oa 7 LOW Of, PRESSURE, 73 1445 13815 NOTIN AUTO 16 1718 16818 ‘UNDER FREQUENCY 9 20 3t 19431 ‘OVER FREQUENCY 22, 24 282A ‘Connector ECS. UNDER VOLTS, 25 a “OVER VOLTS: 28 29 30 23 & 0 ‘OVERLOAD. a 3233 Sia 33 "APPROACHING LOW OT cr 3536 836 PRESSURE, "APPROACHING HIGH ENGINE W 3S rE ‘TEMPERATURE "APPROACHING LOWGOOLANT | 45 aaa ‘TEMPERATURE LOW BATTERY VOLTS zs, qe HIGH BATTERY VOLTS. a8 a Relay Contact Ratings: 10 Amps at 125V AC 7 Amps at 250V AC 7Amps at 30V DC