User Manual - Fischer Panda Generators Inc.
Contents
1. an User Manual _ Digital control system for generators FISCHER PANDA GENERATORS INC 4345 NE 12 Terrace Oakland Park Florida 33334 Toll free 800 508 6494 Phone 954 462 2800 Fax 954 462 2801 E Mail service fischerpanda com Web Site www fischerpanda com Document release 001 July 2013 Page 1 User Manual Digital control system for generators Contents Klees ie altos eegen E Es SS CEN COMI GI SIU rms estatico 5 DONES DO ais 5 Ria ne E 5 Pnr OPII rcs srcarpanepoesa desc E E E bepeqenary A E AA E AEE 5 Buttons on panel front side simi aras 7 a Ka EEN 7 EECC TETE a E E TE AT E E E E O I A TEE E E IARA 8 Paner OPIT HE 8 Cable length cable type and usage restrictions GP170 eee 8 A CS NEE 9 Wiring the system linking components sse ee eee eee eee ee eee eee e eee 9 Operating the St Musas licitador 10 Power up power down main displayS cesspit erii rE NE TOATE 10 Marta DOWErFON Oli loas 10 Remote power ON E 10 e reo oo o erase eacvan A A A 10 DIS ay A 9 egez reading Secar emet taci 11 Display 2 Temperature and oil pressure readings sss sees eee eee 11 Display 3 Miscellaneous readings sss sese eee eee ee eee 12 Dispara Ranes EEES sei tia iaa 12 Cleartexe messi osa ee toda datos pda cdas 12 Acoustic alarm alarm output alarm mute ee eee 13 Operatine the Conrad tried 14 Start SOD te enero aos 14 DEMANA MSM E BEE 14 Po PP a E ECO jun 14 Document release 001 July 2013 Page 2 User Manual2. DATA SET READY TO BE DISPLAYED EE 27 Document release 001 July 2013 Page 4 User Manual Digital control system for generators Scope of this document This document addresses the electronic control of asynchronous generators with digital control system made by Fischer Panda It is an operator s manual strictly applying to electronic control unit and HMI user interface For any questions related to the diesel engine fuel system cooling system see the generator manual This document will address manual operation of the system only Alternatively the generator may be remotely operated via its NMEA2000 communication port For understanding how this works see document NMEA 2000 interface on GP170 most recent release number System components The system is built of two components e Graphic panel part number GP1702 commonly referred to as panel Provides HMI and also NMEA2000 connectivity The entire control system is accessed via this device e Control monitoring and load sensing device part number VCS171 commonly referred to as VCS VCS Voltage Control System This component performs the entire generator and diesel engine monitoring and control along with sensing the output current and voltage Power supply The entire assembly will work within a voltage range of 12 36 V DC Power is supplied to the VCS only which in turn feeds the other devices Usually the system is fed from the generator starter b
3. default program data Certain fields in the normal data will not be overwritten or more precisely are not even mirrored in the default program data e Operating time e VCS serial number e Generator serial number e External stop message e Access code for low level security Performing a reset to default To perform such reset to default while the engine is stopped and while one of displays 1 3 is active not display 4 panel setting this will not work press button S2 hold it pressed and then press button S3 Now the screen below will show up Document release 001 July 2013 Page 18 User Manual Digital control system for generators This menu offers 3 options plus transfer to next page Upon first call the default selection is 1 reset to default with digit 1 blinking Press button S5 Start Stop to initiate reset to default The VCS will now perform the reset to default and the panel will show this display Figure 11 Selection menu first page Figure 12 Panel confirming reset to default No further user action is required The VCS will perform the reset to default and reboot with default settings Reboot is similar to power up After rebooting the normal program data will be loaded which now contains factory default settings Changing specific program data programming the VCS This action requires several steps It is strongly recommended not to alter any settings unless all consequences are well
4. LI Panel Show that battle short on the panel is active Some common errors that have shown up in the past are listed below with some suggestion where to Demand mismatch look next In case of any problems prior to contacting Fischer Panda generators please have this data at hand e Generator serial number See Figure 9 Display 3 power output miscellaneous e VCS serial number and software version You may have to attempt programming to get this information see Figure 14 Start VCS programming e What message s is are displayed in the panel Usually by having the above information at hand a Fischer Panda Service staff members will be able to give a very precise instruction on further trouble shooting or even clearly identify the reason of a problem Some common problems encountered in the past e System will not power up o Check Power supply to the VCS X1 o Check ground connections e System will turn off as soon as cranking gear is engaged o Check starter battery voltage and capacity Voltage needs to be above 7 V continuously to start the engine and keep the control system alive e Panel will display initial display see Figure 6 Initial panel display forever without ever advancing to generator display o Check whether you got the right panel for the type of power up remote or manual see Power up power down main displays o If multiple panels are used Check if the power supply on the main panel the one that connect
5. access to operating time Reading log data Understanding the concept of logging data The VCS records all data described in Figure 7 Display 1 generator output Figure 8 Display 2 temperatures and oil pressure and Figure 9 Display 3 power output miscellaneous plus all if any pending clear text message s Two reasons may trigger recording of one such data set e Any shutdown e Based on time each time the operation time counter increments every 6 minutes Document release 001 July 2013 Page 25 User Manual Digital control system for generators Thus such recording will take place while the generator is running only The VCS has two distinct memory regions that are used for data logging e One that holds logging data recorded during an emergency shutdown This is called the alarm memory e One that holds logging data recorded timely every 6 minutes This is called the history data memory Data recorded during an emergency stop of the generator is recorded in the alarm memory while data recorded on a timely basis is stored in the history data memory The VCS memory gives space for a total of 64 alarm data sets and for a total of 104 history data sets This allows the operator to trace back generator status operation mode for more than 11 hours and for the last 64 emergency shutdowns Note that an over crank event is NOT an emergency stop the generator never ran and thus will not trigger an alarm recording Ala
6. cycle between the 4 main displays by pressing S3 These are the readings provided Display 1 Electrical readings Display 1 will show e Generator speed calculated based on frequency of AC output e Frequency sensed on input L1 N CT board e Voltages U1 U2 and U3 These are the voltages sensed on L1 to N L2 to N and L1 to L2 Inputs on CT board This applies in 120 240V output configuration only When set and wired for 120V output only U2 and U3 will be copied from U1 e Output current I1 and 12 Currents sensed through CT1 and CT2 CT board e Power factor sensed on leg 1 U1 11 i gt inductive c gt capacitive e Fuel tank level Will be displayed as vertical bar graph when Figure 7 Display 1 generator output sensor is enabled and connected e Active and apparent power output Notes to display 1 e Starter battery voltage supply voltage of the VCS e Battery voltage is low accuracy reading 6 Active power is calculated based on power factor on leg 1 e Any analog value being shown as indicates either that input is currently disabled or the sensor is broken not connected Display 2 Temperature and oil pressure readings Display 2 will show e Cyl H Cylinder head temperature e Exh M Exhaust manifold temperature e Cool mio Coolant temperature at engine inlet outlet e Coilx Coil temperature The higher reading out of the two coil temperature sensors will be displayed e Alt B Alternator bearing tem
7. details 112 J9 J8 J2 14 J13 J7 J6 Jaja gp Op ds Ps ls AA RSA A d i us eK ec P ds a LE XC2 my J20 XC1 XC6 XC5 Figure 5 VCS171 Connector Labeling Wiring the system linking components Generators are shipped ready wired for usage After installing the panel it needs to be connected to the VCS plug in J1 on the panel Connecting the panel and the generator output usually is the only electrical connection that needs to be done in the field All components come ready wired with the generator It is beyond the scope of this document to give a detailed description on wiring details See the wiring diagram for a complete schematic of generator and control system wiring Document release 001 July 2013 Page 9 User Manual Digital control system for generators rischer Ponda Operating the system Power up power down main displays The entire system may be powered on or off by either manual or remote access Note the panel needs different firmware and thus changing between the two modes will require the panel to be swapped Manual power on off To power the system up or turn it off simply press button S1 On Off on the panel Doing so will toggle the actual status When powered up manually the system may also be powered down remotely via its NMEA2000 interface For details see document NMEA 2000 interface on GP170 most recent release number Remote power on off The system may be remotely
8. known Check with Fischer Panda if in doubt To enter programming mode follow steps mentioned under Performing a reset to default this will then again lead to first page of selection menu being displayed see Figure 11 Selection menu first page Select option 4 e increase blinking number by pressing button S3 e when blinking digit 4 is shown press button S5 Now the panel will show selection page 2 Document release 001 July 2013 Page 19 User Manual Digital control system for generators Figure 13 Selection menu second page Ensure that under Enter selection bottom line option1 program VCS is selected and press S5 How to alter enter any settings Throughout the entire programming process some simple button assignment need to be used The blinking item number character or word may be modified by pressing S3 Doing so will show next available option In case of numbers this will be the next higher digit after digit 9 a rollover to O takes place Digits may only be incremented not decremented To get to a lower digit keep incrementing the actual digit once it reaches 9 upon the next increment it will roll over to O Any number of more digits may be modified digit by digit First set the desired digit in blinking mode then increment it see above To set the digit left to the blinking one into blinking mode press S2 To set the digit right to the blinking one in blinking mode press S4 Any number or
9. on display 3 panel temperature is always displayed as unknown while viewing log data Reading log memory will stop as soon as the first invalid memory access occurs attempt to read empty log memory It may also stopped manually by powering down the panel either by pressing S1 or NMEA2000 interface if started manually or by powering down via remote switch if remote power up is used There is one additional way to revert to normal display mode using NMEA 2000 communication but not by manual access Messages displayed by the panel As mentioned in chapter 2 Operating the system the control system is constantly monitoring the generator and any unusual condition is displayed in clear text This applies to warnings as well as shutdown messages Note the generator will not start as long as any such out of the range condition is active The below Table 3 Panel messages lists all clear text messages shows the message type A Alarm will trigger shutdown W Warning l just for information and where it is generated Shutdown messages are displayed in inverse printing light characters on dark ground Table 3 Panel messages No Message text Type Origin Description O Z S O Voltage on main output is lower than warning W or shutdown A limit In 120 240V configuration either leg may trigger this message Voltage on main output is lower than warning W or shutdown A limit In 120 240V configuration either leg may tri
10. option selected via 52 53 54 may be accepted by pressing S5 If the selected number is outside the valid range it will not be accepted Instead the panel will expect a valid number to be entered After selecting option 1 on second selection page see Figure 13 Selection menu second page this display will show up This display will show VCS software version 3 004 003 in this case and VCS serial number To proceed with programming enter the code as described above Access code for low level security is 4711 After entering this code the first programming page will be displayed Note 3 non successful consecutive attempts to enter the code will cause the system to shut down It may restarted regularly with no restrictions Figure 14 Start VCS programming Document release 001 July 2013 Page 20 User Manual Digital control system for generators Display pages shown during programming in imperial or metric units whichever was selected prior to entering programming mode see Display 3 will show e Total operating time number near the sand glass e Temperature inside the panel and on the VCS board e Relative power output of the generator based on nominal generator power programmed in the VCS e Generator serial number as programmed in the VCS Figure 15 Temperature settings This display shows temperature limits warnings and shutdowns Limits are displayed and programmed either Display 4 Panel setti
11. powered up by jumping pins 1 and 3 on connector J1 of the panel It is recommended to use a switch or relay contact for this No other potential must be connected to these contacts Power to the entire system is on as long as this contact switch is closed Remote power down via NMEA2000 will not work on panels prepared for remote power up Also during some special operations programming the VCS resetting to default the VCS may require a power cycle Panels prepared for remote power on are not capable of power cycling the VCS Whenever a power cycle is required the panel instead now will prompt the user to perform this Initial display Once powered up the green LED above button S1 On Off turns on indicating power up status The panel will show the initial screen Figure 6 Initial panel display The part number as well as the serial number of the device will be shown The serial number is part of the unique manufacturer ID in NMEA 200 communication It is set by Fischer Panda and may not be changed Document release 001 July 2013 Page 10 User Manual Digital control system for generators Tischer Honda Software version is also displayed At the time of writing this document it is 004 010 002 for panels prepared for remote power up and 004 001 0002 for panels prepared for manual power up After showing the initial display for around 3 seconds the panel will flip to the first out of 4 selectable displays The user now may
12. sensor for bearing oil level e Coolant level sensor Enables disables coolant level sensor e Water leak sensor Enables disables water leak sensor e Fuel tank sensor Enables disables fuel level sensor e Remote stop Enables disables remote stop input Figure 27 VCS options to be enabled disabled page II This is the last page in programming sequence Unlike with prior pages the user now may not skip this by pressing S2 Pressing S5 is required here to adjust final options e Phases Select between120 240V or 3 e Coilssetin Select between series 120V and 240V output or parallel 120V output only e Rpm sensor Select between disabled standard or enabled e Coilsused Select between all usually 120 240V and a generators or one usually 50Hz single phase generators Figure 28 Last page in programming mode After adjusting settings as required the no in line with Save to VCS will start blinking To store the recent settings in the VCS flip this to yes and hit S5 To go over the settings again leave this on no and hit S5 Now the display as shown in Figure 15 Temperature settings will be shown and the programming sequence restarts from there After programming the VCS the panel will cause a power cycle and the VCS will return into normal operation No user interaction is required for this Low level security access gives access to normal program data not default and will also not allow
13. to allow engine start even if exhaust manifold got heated up from previous start Shutdown or warning will be triggered if temperature is still above limits after idling period Exh m tem Is high Will be triggered if oil pressure is sensed lower than warning level W Shutdown A may be triggered by either analog sensor output reading less than shutdown limit or by binary oil pressure switch Note that some time delay applies to this reading Right after start up oil pressure monitoring is disabled for a programmable time This is to allow the generator to start and build up oil pressure prior to monitoring it Nominal speed Used for military applications only 17 VCS 18 Oil pressure switch A VCS Shows that oil pressure switch triggered a shutdown Could be additionally to message 16 Battery voltage is low Starter battery voltage is lower than low level warning limit shutdown A limit Panda detected during entire cranking period Load is unbalanced Voltage difference between leg 1 and leg 2 is above limit Tank level is low Tank level below warning level 25 Unexpected stop W Will be triggered if the VCS detects an engine stop speed signal lt 750rppm during normal operation Usually this points to a fuel supply problem or manual interference Once triggered the VCS will complete the stop procedure and latch it See Unlatching from emergency stop or unsuccessful start lock up about how to unlatch 26 Check sea water S
14. 2013 Page 37 User Manual Digital control system for generators Document release 001 July 2013 Page 38 User Manual Digital control system for generators bl L ET Ub a 9 H ro Ub o a 00 ves on n H SIO D f ei En O 7 soD 9 O e E E S Y H 2 3 1 Net 8 D 32 Net C ct 2 o y ji GE H a gt Net H ef 3 3 4 Net L ele N 3 a CH S pa 3 IR lt lt A D Ext GND L B short O Rem start H pa Al reset po Int GND ct y E H i lt e r C i D a sd Ub Ri 2K2 2 Int GND Trood 600 AML Document release 001 July 2013 Page 39 User Manual Digital control system for generators Document release 001 July 2013 Page 40 User Manual N Ben O ds Ben d C D B Sen O te E o ld vn gt vn Ben dd O Q Es L gt O Design revision history Date 1 26 2012 12 03 2012 12 04 2012 12 08 2012 01 09 2013 03 08 2013 03 2 V 2013 05 20 20 13 Description Revision PE wiring generator to terminal mdified cables reorganized Battery charger removed Wire gauges modified signal interfacing modified Wire gauges modified Wiring booster capacitors changed Wire colors sensing leads booster added Optional wiring aide di modified Main output modified Tark and water sensor added Gen cormection modified Name Paul Muell Paul Muell Paul Muell Paul Muell Paul Muell Paul Muell Paul Muell Paul Muell Page 41 Docu
15. 3 always showed a high starter battery voltage message DC Voltage is high at the bottom of the display Clear text messages may be either some kind of information warnings or alarm messages Alarm messages are displayed in inverse printing dark ground light text Alarm messages usually will trigger an emergency shutdown of the generator and prevent it from restart as long as such message is active Insome extreme conditions over cranking the panel will show a warning message over the entire screen and not permit any other action but power down the system In any such extreme condition the user will be prompted to power down Acoustic alarm alarm output alarm mute Whenever an additional clear text message becomes active the acoustic alarm will be triggered unless it has been disabled in the VCS settings This will cause an acoustic signal to be generated in the panel and the contact output Alarm out panel connector J8 pins 6 and 7 to be closed This contact is rated max 48V DC max 1A resistive and fused inside the panel The alarm may be turned off by either e Pressing S2 Alarm Mute on the panel front side e Apply 10 36V on input Al reset panel connector J8 pin4 with reference to panel connector J8 pin 1 Input resistance for this 10 36V signal is 1 5kQ Power supplied on panel connector J9 may be used with an external switch relay contact for this purpose The alarm will now stay mute until another c
16. Digital control system for generators BI ee E e ss 14 Unlatching from emergency stop or unsuccessful start Iock up 15 Over 15 EES EREM 15 Unlatching from emergency stop or unsuccessful start lOCk UP sese eee eee eee eee 15 RUNAME the generalo EE 16 EES 16 lo A ee o o dhtdenasachabaceete E 16 Special features of Fischer Panda Control System 18 ACCESSING J AIL CHING control SELUN Paisa co 18 Pe erto derul EE 18 Changing specific program data programming the VC 19 HOW toalter enter any Seti 20 Display pages shown during programming 21 REGNE OE 0 EE 25 Understanding the concept of logging data 25 PRLS vine OS CAN aaa 26 Messages displayed by the panel srta 28 Troubleshooting o A reo E EA O E EE A Ei 30 Some common problems encountered in the past 30 DE ee Be Tee EE ER Appendix 1 VCS171 Wiring Diagrams sese iaa ai ari ridad 33 Document release 001 July 2013 Page 3 User Manual Digital control system for generators TABLE 1 ANALOG INPUTS PROCESSED BY CONTROL SYSTEM esse eee 17 TABLE 2 BINARY DIGITAL AND MISCELLANEOUS INPUTS PROCESSED BY CONTROL SYSTEM sese eee 17 TABLE PANEL TEE 28 FIGURE 1 PANEL EH Eeer 6 FIGURE Z PANEL FRONT SIDE E 7 FIGURES VES LT LION ING ON eege 7 FIGURE 5 PANEL REAR SIDE CONNECTOR ASSIGNMENT c ccccsscceccseceeecsccsseceeceeeeescceeceaeeeeeeeeeeeeceseeseeeeseeeeseeeees 8 FIGURES INITIAL PANEL DISPLAY Tossa dada 10 FIGURES DISPLAY 1 GENERATOR OUTPUT ee
17. attery Generator AC output voltage as well as output current is potential free from this power supply with insulation strength of 4000V As required by NMEA2000 standard the panel has a potential free NMEA 2000 port working within the limits specified by applicable standards 9 16V Load equivalency of this port is 1 Dimensions Panel GP170 The panel may be mounted in a wall bulkhead or boat s operation panel See Figure 1 Panel dimensions next page for required mounting space All panel connectors are on the rear side Document release 001 July 2013 Page 5 L 20 Els Det Lut 967 pue d 191407 RKE Ap SEN Hal SST ATA KH gt er BUS awen me eu zd HEL aE er ma ea aial dria name DL 36023811 HU DOE WU D s pG HENS Dugun N Su O ded Su UV CC OU 00 Su O E OU ded L i gt L i Su fe c O Q o 00 O User Manual lus LE ww DO SOL H Et BX FN H LG L OSI NA NIO DE Y WW GZ9 G A WW DSZ A WI DF rG ur ol LU C8 Z Ge efltsaWwos anoedsjaed u 5 E LU DG E u z F LU DG DCL brd ur Lx ww GC SOL ul pl ww OO CE L Figure 1 Panel dimensions Page 6 Document release 001 July 2013 User Manual Digital control system for generators rischer Ponda Buttons on panel front side T t e LEDs on panel faceplate y e D1 above button S1 Shows whether entire system is S i pe Dante erc N powered on whe
18. ctor insert a screwdriver in the inner slot Now the wire may be inserted in the outer slot Fischer Panda offers drop cables that match into J10 header with MICRO C or MINI C connector pinning according to NMEA 2000 hardware specification Contact Fischer Panda if such cables are required Connectors J8 and J9 have spring loaded terminals for wires up to 0 75mm AWG18 To unlock the spring connector insert a screwdriver in the inner slot Now the wire may be inserted in the outer slot Cable length cable type and usage restrictions GP170 J10 Cable type and cable length limitations as defined in NMEA 2000 standard apply J9 J8 J9 serves as power supply for digital inputs on J8 It must not be used as a common power supply or junction point See wiring diagram for more specific example on how to wire these Maximum cable length very much depends on the type of switching device that is used and is recommended not to exceed 300 feet J1 This is the serial data link to the VCS includes power supply and a signal that triggers the VCS on off Maximum cable length is 300feet Cables longer than 30 feet shall be shielded with shield connected to supply ground on one end Cable shall be at least 5x0 75mm AWG 18 Document release 001 July 2013 Page 8 User Manual Digital control system for generators VCS171 Below sketch shows the control device VCS171 its connectors with the first pin number See wiring diagram in Appendix for wiring
19. ea water pressure is less then warning W or shutdown A level Note Sea water pressure is monitored after completing idle period only Engine oil level is low W Engine oil level below threshold triggered by binary sensor input Backend oil levelislow W Backend oil level below threshold triggered by binary sensor input Coolant level is low W Coolant level is below threshold triggered by binary sensor input 30 Check air filter Differential pressure on air filter is too high triggered by binary sensor input Air filter may be clogged up Invalid program data Program data set stored in the VCS is not valid 32 Invalid AC calibration AC calibration data stored in the VCS is not valid data Invalid DC calibration A DC calibration data stored in the VCS is not valid data Document release 001 July 2013 Page 29 User Manual Digital control system for generators 34 Check sea water filter A VCS Shows a too high temperature difference between sea water inlet and sea water outlet usually caused by sea water filter being clogged generators that read sea water temperature not a standard option 35 Remotely operated Panel Shows the generator was started is preparing to start due to a remote input start request Panel Shows that demand mismatch has occurred See Demand mismatch about how to resolve this Trouble shooting guidance Note This option needs to be enabled in the VCS and is limited to Battle short is active
20. en O ds Ben d C D B Sen O te E o ld vn gt vn Ben dd O Q Es L gt O VOES17DoOx Generator output Booster interface XI 2 RL 1 21 2 ca 22 2l22 1lx2 1lR2 2l Te l i d ig Fs ii A Booster capacitors RES AA per setting a e L D a Lan a Ti Ya Tel N d I ds LL re E l D Ls ion cap 1 group I a etOur TENCIA HOT Page 34 Document release 001 July 2013 VOS 17 1xxx erer Ke Ke Ke Ko pus i Engine Gnd GRD Engine Gnd y1 Unspecified wires AWG16 1 Smm2 GND Stop solenoid 2 A A E E EE eee Panel interface se FF L J E da y E II VU n F n Ben O ds Ben d C D B Sen O te E o ld vn gt vn Ben dd O Q Es L gt O User Manual Page 35 Document release 001 July 2013 User Manual Digital control system for generators Document release 001 July 2013 Page 36 User Manual Digital control system for generators Exh mami fold LN Conte in E ccs tS Cylinder head Coil sensor 1 AAA 69 Coil sensor 2 A Y Dm Dil pressure E Fuel primer ww EI huron 8103819U 95 epueg 194951 L D OM ASIS XXXLALSDA TY _ AL Oil pressure stop Emer opta ctive fire boy optiomal 600 And TT00 ISSITM TTY 0 1 2 cums 0 02 Di Document release 001 July
21. et in this screen e AC high Main AC output voltage high limit either leg e AClow Main AC output voltage low limit either leg e DChigh DC voltage starter battery VCS supply high limit 6 DClow DC voltage starter battery VCS supply low limit Note e There is no shutdown limit associated to low battery voltage e Unit is 1 10 of a Volt e Certain shutdown delays apply see Figure 20 Delay times for warnings emergency stop Limits shown in this screen e Current Maximum current drawn out of any generator leg e Power Maximum output power e V Delta Maximum voltage difference between the two generator legs usually caused by unbalanced load Note e Units are 1 10Amp for current and 100W for power e There is no shutdown limit associated to V Delta e Certain time delays apply for shutdown Extended usage above warning may also trigger shutdown see Figure 20 Delay times for warnings emergency stop Document release 001 July 2013 Page 22 User Manual Digital control system for generators Figure 20 Delay times for warnings emergency stop Figure 21 Resistance for tank sensor and alarm level Figure 22 Control settings page Figure 23 Control settings page II This screen shows time delays for shutdowns Any shutdown will be triggered if the shutdown limit in case of power output and current Warning level as well exceeds the limit continuously for at least the time given herei
22. forming such special feature via NMEA2000 interface see document NMEA 2000 interface on GP170 most recent release number None of the actions described in this chapter may be performed while the engine is running Access is denied by the panel and the VCS during engine operation Accessing altering control settings The control system needs some data to perform speed regulation monitoring and control of the generator system as described above These data is stored in the VCS not in the panel and is called program data throughout this document Fischer panda Generators has a basic data set for each generator type which then may be altered according to some specific customer requirements enable disable certain options alter warning shutdown limits A copy of the program data that was loaded into the VCS memory is kept on the records for every generator shipped by Fischer Panda Generators Altering program data may be performed either by a reset to default or by changing specific program data programming the VCS Reset to default The VCS holds two copies of programming data in two different memory locations One of these copies is used for normal operation and may be altered by the user while the other one serves as factory default According to their usage these program data is called default data or normal data When performing a reset to default the VCS will overwrite the normal program data with the content of the
23. gen 11 FIGURE 10 DISPLAY 2 TEMPERATURES AND OIL PRESSURE escocia iii E 11 FIGURE 11 DISPLAY 3 POWER OUTPUT MISCELLANEOUS esscoicmmsaiia aii acia 12 FIGURE 12 DISPLAY 4 PANEL SETTIN GS sacado 12 FIGURE 73 SELECTION MENU FIRST PAGE tee eebe 19 FIGURE 14 PANEL CONFIRMING RESET TO DEFAULT ocooccnnccnoconoconccnncconccnononoconoconoconconoconononononaconaronnonononacanaronnnnns 19 FIGURE 15 SELECTION MENU SECOND PAGE gedeien 20 FIGURE 16 START VES E E TUTE 20 CIGURE 17 TEMPERATURE SETTINGS Mc tai 21 FIGURE 16 TEMPERATURE SETTINGS Ucraniano RARO 21 FIGURE 19 OIL AND SEA WATER PRESSURE AND SPEED SETTINGS sss see xx xe ee ee eee 22 FIGURE 20 MAIN OUTPUT VOLTAGE AND BATTERY VOLTAGE a 22 FIGURE 21 POWER AND CURRENT OUTPUT E 22 FIGURE 22 DELAY TIMES FOR WARNINGS EMERGENCY STOP 23 FIGURE 23 RESISTANCE FOR TANK SENSOR AND ALARM LEVEL sees eee eee 23 FIGURE 24 gt CONTROL SETTINGS PAGE E 23 FIGURE 25 CONTROL SETTINGS PAGE Ulsa iii 23 FIGURE 26 CONTROL SETTINGS PAGE llosa tildes 24 FIGURE 27 SPEED CRANKING TIME AND IDLING TIME 24 FIGURE 28 VCS OPTIONS TO BE ENABLED DISABLED DAGET nono non no non onnnnnnnnnononnnonanononoss 24 FIGURE 29 VCS OPTIONS TO BE ENABLED DISABLED PAGEI ono ono nono nonnnnoncnnononononanononoss 25 FIGURE 30 LAST PAGE IN PROGRAMMING MODE sse se ex ee eee 25 FIGURE 31 INVALID MEMORY ACCESS eebe deeg 27 FIGURE 32 TERMINATING DATA LOG READING crenis niaaa AAA EEA aa nabenes 27 FIGURE 33
24. gger this message after adjusting the generator to nominal speed Will be triggered if rectifier heat sink temperature is higher than warning W or shutdown A limits warning W or shutdown A limits A limit H IA WA e warning W or shutdown A limit Document release 001 July 2013 Page 28 User Manual Digital control system for generators Cool w in temp is high Will be generated if the temperature sensed on cooling water inlet is above warning W or shutdown A limit Note that Inlet refers to the engine i e engine inlet and thus heat exchanger outlet Cool w out temp is Will be generated if the temperature sensed on cooling water outlet is high above warning W or shutdown A limit Note that outlet refers to the engine i e engine outet and thus heat exchanger inlet 11 Oil temp is high VCS Will be generated if the temperature sensed on engine oil temp sensor is above warning W or shutdown A limit Cyl head temp is high W A V Will be generated if the temperature sensed on cylinder head is above warning W or shutdown A limit CS Bearing temp is high VCS Will be generated if the temperature sensed on alternator bearing is above warning W or shutdown A limit VCS Will be generated if the temperature sensed on exhaust manifold is above warning W or shutdown A limit Will be triggered only after the engine was started and has passed idling period This is
25. ich are monitored while the generator is on only behave different e Reading will be supplied continuously regardless of whether the generator is running or not Will be invalid reading for oil pressure e While the generator is running readings above below alarm shutdown level will cause a shutdown Unlike with continuously monitored inputs such shutdown will not prevent restarting the generator The generator may be restarted after it has been unlatched see Unlatching from emergency stop or unsuccessful start lock up but after a certain time delay after start that input must come back to normal otherwise a shutdown is triggered again e While the generator is off and unlatched from any previous shutdown these readings will not trigger an alarm message although warning and or alarm level may be exceeded For better understanding take oil pressure as an example o With the generator stopped oil pressure is low This will not trigger an alarm since it is very normal for the oil pressure to be low as long as the engine is not running o Low oil pressure is an alarm that will stop the engine but will not inhibit an engine start Document release 001 July 2013 Page 16 User Manual Digital control system for generators o Once started the oil pressure must be above shutdown limit within a certain time otherwise an emergency shutdown will be triggered Table 2 Binary digital and miscellaneous inputs processed by con
26. ion that will not trigger an actuator response This screen holds speed and time settings Idlespeed Speed that is regulated right after powering up This is used to warm up the generator Nom Speed This is the speed that will be regulated after idling period At this speed the control system will expect the voltage to built up and will then switch over to voltage regulation Idle time Duration of idling period Crank time Maximum cranking time If the engine does not start within this time a start attempt failed message will be issued This screen is used to disable various functions sensors Oil press sensor Enables disables analog oil pressure sensor Enables disables differential sensor on air filter Air intake sensor pressure SW press sensor Enables disables analog sea water pressure sensor Eng Oil level sensor Enables disables engine oil level sensor Panel beeper Enables disables acoustic alarm in panel s Note To enable disable any of the above press button S5 Now the upper n oil press sensor will start blinking and may be flipped to y by pressing S3 Accept any setting by S5 When done with this page hit S2 to get to the next page Document release 001 July 2013 Page 24 User Manual Digital control system for generators This screen again shows some options that may be enabled disabled Operation is as explained above e Bearing level sensor Enables disables
27. k up e Manually by pressing button S5 The clear text message now will become inactive Applies only if the generator was started manually or via NMEA 2000 interface e Via NMEA 2000 interface For details see document NMEA 2000 interface for AGT generators on GP170 most recent release number Applies only if the generator was started manually or via NMEA 2000 interface e Remotely by disengaging the remote start input Applies only if the generator was started by remote start input The generator will not restart as long as the condition that triggered the shutdown is active high temperature overvoltage Some exemptions may apply see below What is monitored for details Emergency shutdowns may continuously be disabled by engaging the battle short input on the panel rear side It is strongly recommended not to do so This is for extreme urgencies only and could possibly lead to severe damage on engine generator and or other equipment Document release 001 July 2013 Page 15 User Manual Digital control system for generators Running the generator How generator control works While running the generator the control system monitors voltage and current and regulates generator speed based on these The control system will try to maintain the output voltage within the specified limits see Figure 22 Control settings page Figure 23 Control settings page Il and Figure 24 Control settings page lll During voltage cont
28. lear text message becomes active If a message becomes inactive and then active again the alarm will be retriggered Disabling the acoustic alarm in the VCS will disable both panel beeper and relay output Alarm mute input will be ignored in such case Document release 001 July 2013 Page 13 User Manual Digital control system for generators Operating the generator Start stop the generator The generator may be started stopped in 3 different ways e Via NMEA 2000 interface For details see document NMEA 2000 interface for AGT generators on GP170 most recent release number e Manually by pressing button S5 Start Stop Doing so will toggle the actual generator status e Via remote input Apply 10 36V on input Rem start panel connector J8 pin3 with reference to panel connector J8 pin 1 Input resistance for this 10 36V signal is 1 5KQ Power supplied on panel connector J9 may be used with an external switch relay contact for this purpose The generator will start and stay on as long as this signal is active 10 36V applied to J8 pin1 The panel will indicate this by showing the clear text message remotely operated The generator may be stopped either via NMEA200 interface manually by pressing button S5 Start Stop or if it was started by remote input by disengaging the remote input switch relay contact Although it may also be stopped by powering down the system it is strongly recomme
29. loaded by pressing S2 Figure 16 Temperature settings II Document release 001 July 2013 Page 21 User Manual Digital control system for generators Figure 17 Oil and sea water pressure and speed settings To disable any alarm or shutdown e For temperatures Set the limit to 255 491F e For Pressure sensors Disable that sensor Limits displayed in this screen e Oilpr Oil pressure reading provided by analog sensor Limits entered hereunder will be ignored if analog oil pressure sensor is not enabled or broken disconnected or short circuited e S W pr Sea water pressure Above mentioned restrictions on sensor apply e Speed Engine speed limit On standard asynchronous generators engine speed is always calculated based on frequency Some special applications use a speed pick up sensor Note in this particular case engine over speed shut down is disabled by setting the limit to 9999 e For speed sensor speed calculation Set limit to 9999 e For tant sensor Set limit to 026 Sensors providing invalid output sensor in short circuit or not connected vvill not be monitored These sensors will not trigger any warning and or shutdown Sensors being disabled will also not trigger any shutdown warning regardless what limits are set for that sensor and or what the actual reading of that sensor Figure 18 Main output voltage and battery voltage Figure 19 Power and current output Limits s
30. m data memory From this point on the process is the same for both history data and alarm data so it will be described once only Upon selecting data access history or alarm data this display may show up right at the first attempt to retrieve data or at some later access to log memory Document release 001 July 2013 Page 26 User Manual Digital control system for generators This indicates an invalid memory access If it happens the first time when accessing any log memory history or alarm this shows there is nothing logged Any invalid memory access will be followed by the next screen Figure 30 Terminating data log reading Figure 29 Invalid memory access The system will reboot now and power up normally Figure 30 Terminating data log reading Log memory reading will terminate as soon as an invalid memory access occurs If the circular buffer that is accessed has overflowed at least once then log memory is endless After reading alarm memory history memory data set HO the next data set transfer will again upload alarm data set 63 history data set 103 Whenever there is at least one logged data set this display will show up when uploading it Valid data detected in log memory Data set no 16 tag of that data set ranges 0 103 for history data and 0 63 for alarm data has been uploaded This may be viewed by pressing S3 or previous data set 15 may be uploaded by pressing S4 Note Da
31. ment release 001 July 2013
32. n e Delay Time delay applicable for current limits e Delay P Time delay applicable for power output limits e Delay Vmax Time delay applicable for high limit on AC voltage output either leg e Delay Vmin Time delay applicable for low limit on AC voltage output either leg Note Be aware of units minutes for warning limits current and power seconds for shutdown limits current power and low voltage and 0 1 second for over voltage This screen shows resistance settings for tank sensor and alarm limit for low level alarm and some generator specifics e Tant full Resistance of sensor at full tank Unit is 0 50 e Tank empty Resistance of sensor at empty tank Unit is 0 50 e Tank alarm Low level tank alarm in units of 0 5 e Poles Number of poles of the backend Fischer Panda standard backends have 2 poles e Act Back Refers to starting procedure Prior to cranking the throttle is brought to idle and then for a certain time back up This certain time is set here This setting has an influence on what speed the generator will start This screen shows some of the generator control settings e Nominal P Nominal generator power Used to calculate the bar graph indication see Figure 9 Display 3 power output miscellaneous Unit is 100W e Nominal f Nominal generator frequency Unit is 0 1Hz e Max freq Maximum frequency Unit is 0 1Hz e Min freq Minimum frequency Unit is 0 1Hz e Pulses rev Pulses per revolu
33. n on or not LED off de e D2 above button S5 Shows generator status O When off Generator is stopped O When on Generator is running O When blinking Generator is transitioning from start to stop or vice versa Buttons on panel faceplate e S1 Used to manually power up or down entire system e S2 Turns off acoustic alarm WWW SCREEN Com e S3 Flips to next screen e S4 Various assignments Read this manual to learn about 6 S5 Manually start stop the generator Note During special interaction reading log data programming the On Off Alarm a ut 1 dh VCS buttons S2 to S5 may also have other functions assigned Read this manual to learn about Figure 2 Panel front side VCS 171 The VCS is mounted inside the generator capsule It is contained within a box on the service side of the generator The VCS171 is mounted inside the box below lannan Figure 3 VCS171 Mounting Box Document release 001 July 2013 Page 7 User Manual Digital control system for generators Electrical connections Panel GP170 All panel connectors are on the rear side and are of the type header board with mating jack cable The cable connector always is the female connector Figure 4 Panel rear side connector assignment Connector J1 has screw clamps suitable for wires up to 0 75mm AWG 18 Connector J10 has spring loaded terminals for wires up to 0 5mm AWG22 To unlock the spring conne
34. nded not to do this This creates a very high thermal and mechanical stress on the engine and generator Demand mismatch Starting by remote start input and stopping manually or by NMEA2000 interface will trigger a demand mismatch The manual or NMEA 2000 stop command is assigned a higher priority since this could be an emergency stop Now the generator will stop although the remote start input signal is still active The generator will stay locked up in demand mismatch until the remote start input is disengaged Demand mismatch status will trigger a clear text message Successful start Generator start is considered successful once engine speed is above 750rpm Now the LED D2 on top of button S5 Start Stop will turn solid on the generator enters idle speed and after idle time is over it will start voltage current regulation see Running the generator Generator status on off may also be retrieved from contact output Status out on panel connector J8 pins 8 and 9 This contact is rated max 48V DC max 1A resistive and fused inside the panel It will be closed as long as generator speed is above 750rpm Unsuccessful start The VCS will crank the engine until engine start has been detected but not longer than a certain time set in the VCS settings If the engine does not start within that cranking time the VCS will give up and trigger a clear text message start attempt failed To unlatch from status follow the procedure bel
35. ngs Once in programming mode e Cool In Coolant temperature at inlet to the engine there is no way to change units e Cool O Coolant temperature at outlet from the engine e Oil t Engine oil temperature Limits warnings and shutdown level accessible in this display e Cyl H Cylinder head temperature Any page with programming data may be either skipped by pressing S2 or settings may be altered by pressing S5 Pressing S5 will put the rightmost digit of the first number in blinking mode in this particular case coolant inlet temperature warning actually set to 110 C Now this number may be altered see How to alter enter any settings or accepted by pressing S5 After being accepted the next number is set into blinking mode and so on going through the whole page Once finished with the last number the user may now proceed to next page by pressing S2 or again press S5 and perform additional settings in this page The VCS stores metric values only which if required are translated by the panel Therefore some small rounding errors may be visible Pressing S2 will lead to the next programming display Limits displayed in this screen e Alt b Alternator bearing temperature limits e Exh m Exhaust manifold temperature limits e Coil Coil temperature limits whatever is entered here will apply to both coil sensors e Rectif Rectifier temperature limits Again temperature limits may be altered press S5 or next screen may be
36. ow Document release 001 July 2013 Page 14 User Manual Digital control system for generators Unlatching from emergency stop or unsuccessful start lock up e Manually by pressing button S5 The clear text message now will become inactive Applies only if the generator was started manually or via NMEA 2000 interface e Via NMEA 2000 interface For details see document NMEA 2000 interface for AGT generators on GP170 most recent release number Applies only if the generator was started manually or via NMEA 2000 interface e Remotely by disengaging the remote start input Applies only if the generator was started by remote start input Over cranking Over cranking is considered after four consecutive unsuccessful starts This may be a very critical situation as it may lead to water ingestion to the engine and permanent damage Over cranking will cause the panel to lock up A warning display will be shown not allowing the user any other operation but powering down It is strongly recommended not to just power cycle the system and retry starting Do not ignore warnings given by the system Contact Fischer Panda if in doubt about further required actions Emergency shutdowns Certain operating conditions may cause an emergency shutdown see below What is monitored After such emergency shutdown the control system is locked up and may be unlocked by following the procedure Unlatching from emergency stop or unsuccessful start loc
37. perature e S W in o Temperature at sea water inlet outlet Figure 8 Display 2 temperatures and oil pressure e Ona DENE OL EE e Oilp Engine oil pressure Notes to display 2 e Temperature reading may be in C or Fahrenheit pressure reading may be psi or bar see Display 4 Panel settings next page Document release 001 July 2013 Page 11 User Manual Digital control system for generators Display 3 Miscellaneous readings Wer lt Display 3 will show 6 Total operating time number near the sand glass 6 Temperature inside the panel and on the VCS board e Relative power output of the generator based on nominal generator power programmed in the VCS e Generator serial number as programmed in the VCS Figure 9 Display 3 power output miscellaneous Display 4 Panel settings Display 4 is used to adjust panel options The user may adjust the blinking line of the above display To do so press S2 and hold it down Now press S3 to either flip between metric or US Standard setting affects temperature and pressure readings or to increment panel backlight or contrast Panel backlight and contrast may be incremented from O to 10 The next increment after 10 sets the number back to zero To set the next selectable option in blinking mode press S4 Panel address is an option for asynchronous generators not having the NMEA interface implemented and may be ignored Figure 10 Display 4 panel set
38. rm data and history data is stored in circular buffers Once the buffer is full the next data set will overwrite the oldest one and so on Each buffer has a tag counting O to 103 for history data and O to 63 for alarm data The highest tag does not necessarily hold the most recent data set once the buffer has overflowed this will change Right before the first overflow the highest tag for history data will be 103 and will hold the most recent data But right after the first or any subsequent overflow the most recent data now will be under tag O The data sets stored during such log process either history or alarm data may be retrieved by using the panel or via the NMEA 2000 port of the panel Whenever retrieving such log data the VCS will detect any attempt to read from a memory location that does not hold valid data will only happen prior to first overflow of circular buffers This is called an invalid memory access and will cause the VCS to reset and revert to normal operation similar to powering it up Retrieving log data To access log data manually via the panel press button S2 hold it down and then press button S3 This is the same procedure as mentioned to above under Performing a reset to default and will end up in showing Figure 11 Selection menu first page This will only work while the generator is stopped and the panel is showing display 1 2 or 3 Selecting 2 will access history data memory while selecting 3 will access alar
39. rol the VCS will not exceed frequency limits entered in VCS program memory Figure 22 Control settings page Figure 22 Control settings page I Overloading the generator too high power demand or too high current per coil will end up with an emergency shutdown Depending on whether the warning or shutdown limit is exceeded different delay times for such shut down may apply What is monitored This is a complete list of inputs that the control system is capable of monitoring Some of them may not be enabled in certain applications Some digital inputs switches and analog inputs may be disabled in software Temperature inputs which are not required are disabled by setting the warning and alarm level to 255 C 450 F Table 1 Analog inputs processed by contro system shows all analog inputs of the control system shows if a reading of that input is provided on the panel R and if a warning VV and alarm A level may be programmed for that input It will further show if that input is monitored continuously C or if it is monitored while the generator is running only table entry is O Exceeding warning levels will trigger a clear text message Exceeding alarm level will trigger an emergency shutdown Different delays apply for such emergency shutdown see Figure 20 Delay times for warnings emergency stop and Figure 17 Oil and sea water pressure and speed settings A fixed delay of 2 seconds applies to all over temperatures Those inputs wh
40. s to CAN bus AND to the VCS is turned on Document release 001 July 2013 Page 30 User Manual Digital control system for generators Generator will start immediately as soon as panel is turned on o Check the remote start input it may be activated You ll see also the message remotely operated Unexpected stops happen again and again o Check the fuel supply system fuel pump fuel filter The generator may not get enough fuel causing the speed to collapse Generator will not start but report unknown messages on the panel such as Fire boy or safety stop or external stop o Check the external stop input It may be enabled in the VCS see Figure 26 VCS options to be enabled disabled page 1 and activated circuit is open Generator will shut down sporadic due to oil pressure low although everything seems to be fine o Check connections on the VCS board Some connectors may not be plugged in correct After maximum cranking time the panel will show start attempt failed although the cranking gear did not crank at all e Again check connectors on VCS board Document release 001 July 2013 Page 31 User Manual Digital control system for generators Revision History Date Release 07 31 2013 Document release 001 July 2013 Page 32 User Manual Digital control system for generators Appendix 1 VCS171 Wiring Diagram Document release 001 July 2013 Page 33 User Manual N B
41. ta set 16 does not necessarily indicate a total of 16 data sets available If this was an alarm memory access and the circular buffer has overflowed than a total of 64 data sets is available To find out continue reading next set until either data set 63 is retrieved or an invalid memory access occurs Figure 31 Data set ready to be displayed After uploading a data set Log data may be viewed by pressing button S3 or previous data set may be uploaded by pressing S4 see above Figure 31 Data set ready to be displayed Viewing that data set pressing S3 will cause Display 1 see Figure 7 Display 1 generator output to be displayed with the readings taken from the uploaded log memory If any clear text message s where active while that data Document release 001 July 2013 Page 27 User Manual Digital control system for generators set was logged it will be displayed Active messages will be updated circularly with an update rate of approx 0 5 seconds Pressing S3 again now will change to display 2 see Figure 8 Display 2 temperatures and oil pressure and then to display 3 see Figure 9 Display 3 power output miscellaneous and then again to the selection display shown inFigure 31 Data set ready to be displayed Now again the user may show this data set again press S3 or upload the previous one Panel temperature sensed inside the panel and not part of any logged data set which is logged and stored in the VCS That is why
42. tings here To leave this display simply press S3 without holding S2 pressed the same time Now Display 1 Electrical readings will be displayed again Notes to panel settings in display 4 1 Whatever settings were selected they will not be stored in EEPROM until this display is left S3 pressed As long as this display is active the panel assumes further user action will take place and waits for it Powering down with this display on will not save any of the most recent panel settings 2 This display shall not be the primary selection while operating the generator for two reasons a LED D2 above button S5 run stop indicator is not updated as long as this display is active b Clear Messages sent by the VCS will not be displayed while this display is active None of the above two items will affect generator monitoring or voltage regulation but the user may not be updated in time NMEA2000 communication works constantly regardless of what display is active Clear text messaging Further to the readings described above 4 displays the panel also may display some messages in clear text Such messages will be displayed in the bottom line of the panel but not while display 4 panel Document release 001 July 2013 Page 12 User Manual Digital control system for generators settings is selected If more than one message is active the panel will cyclically show all messages with an update rate of approx 0 5 seconds Above displays 1
43. tion Required only on special applications using a speed pick up sensor Note The actuator will always keep generator speed within the frequency limits entered in this screen This screen shows settings for booster capacitors Booster capacitors are engaged in case of voltage drops high load surge to provide higher excitation current For details see generator manual e Boost on Booster capacitors will be engaged if output AC voltage falls below this limit e Boost time Time in units of 100ms the booster will sty engaged e Boost off Minimum time in sec booster will stay disengaged e B release Minimum voltage after power up that will enable the booster e B disable Maximum voltage during boosting that will immediately cut off actual booster cycle Document release 001 July 2013 Page 23 User Manual Digital control system for generators Figure 24 Control settings page III Figure 25 Speed cranking time and idling time Figure 26 VCS options to be enabled disabled page Settings in this screen control the actuator AC Voltage This is the target voltage unit is 0 1V The VCS will regulate the generator to provide this output P length The actuator motor works with a pattern of pulses and gaps between pulses This is the length of such pulse in units of 10ms P gap This is the length of a m gaps in units of 10ms P strength Strength of actuator pulses ranging 0 10 Deviaton AC Maximum voltage deviat
44. trol system shows binary inputs of the control system There is no warning associated with a binary input Such input may be active or not active and if active it may just trigger a clear text message M or a shutdown S It may be continuously monitored C or while the generator is running only table entry O Table 1 Analog inputs processed by control system Analoginput TR Frequency ofACoutput INKL x Power tor on Leg XL Exhaust manifold temperature X x IX 0 Sea water temperature inlet X Sea water temperature outlet PX Engine oil pressure 0 Sea water pressure PX XX O Rectifier diodes temperature x x Tanklevel TX A VCS board temperature JM Temperature sensed inside the panel X Table 2 Binary digital and miscellaneous inputs processed by control system Binary input LR CAC Location Al reset X Panel Remote start X Xx Panel Battle short X Xx Panel Oil pressure switch X FO VCS Externalstop LE PX VS Waterleakage XL x vcs Coolantlevel XL II Oillevel LL RES Air intake filter monitor NI X VCS Document release 001 July 2013 Page 17 User Manual Digital control system for generators Operating time Special features of Fischer Panda Control System Any activity mentioned hereunder may be either performed manually via the panel or via NMEA2000 interface This document addresses only manual operation of the system For per
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