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