Control System Description And Trouble Shooting; Control System Description And Identification - FG Wilson OLYMPIAN 1001 Series Manual

4. CONTROL SYSTEM DESCRIPTION AND TROUBLE
SHOOTING
4.1

Control System Description and Identification

4.1.1 Description: An advanced electronic control system
has been designed and installed to control and monitor the
generating set. Depending on the requirements of the set,
one of several different standard control systems may be
fitted. These include the 1001 Series Keystart System,
2001 Series Autostart System, 4001 Series Deluxe
Autostart System 4001E Series Enhanced Deluxe
Autostart System and the PowerWizard Autostart Systems.
Other more specialised systems may be installed for
specific installations in which case separate
documentation is provided.
These control systems consist of three major components
working together - a control panel, an engine interface
module (EIM), and an alternator output circuit breaker.
The control panel provides a means of starting and
stopping the generating set, monitoring its operation and
output, and automatically shutting down the set in the
event of a critical condition arising such as low oil pressure
or high engine coolant temperature. A 1001, 2001, 4001,
4001E or PowerWizard Series Panel is installed as
appropriate for the requirements of the generating set
installation.
The Engine Interface Module is a sealed, engine mounted
module that provides switching relays for the Starter Motor
Solenoid, Glow Plug and Fuel Solenoid. Each of these
circuits is protected with individual fuses mounted in the
module. Individual LED's illuminate when each circuit is
energised. The Engine Interface Module is available in four
models depending on the type of control panel being used
- the 12 volt EIM SR, the 12 volt EIM Plus, 24 volt EIM SR
and the 24 volt EIM Plus. The table below indicates which
EIM module is used on which generating sets:
Panel
Fitted
1001
2001
4001
4001E
PowerWizard
The power output circuit breaker serves to protect the
alternator by automatically disconnecting the load in the
event of overload or short circuit. It also provides a means
of switching the generating set output.
4.1.2 Panel Equipment (1001, 2001, 4001, 4001E):
Before starting or running the generating set, the operator
should become fully acquainted with the instruments and
controls. The instruments should be observed from time to
time while the generating set is running so that any
abnormal readings can be detected before problems arise.
Figure 4.1 shows typical diagrams of each of the control
panels. Addition of optional equipment will add items to
the panel so the panel fitted on the generating set may be
slightly different from the typical ones shown. The
following descriptions explain the function of each item on
the panels:
1. AC VOLTMETER - A voltmeter that indicates the AC
voltage generated at the alternator output terminals.
The reading indicated on the voltmeter will vary
depending on the position of the voltmeter selector
switch (item 2). It should not, however, vary while
the set is operating. If the meter gives no reading
while the generating set is running, ensure that the
AC voltmeter selector switch is not in the OFF
position.
2. AC VOLTMETER SELECTOR SWITCH - A selector
switch allowing the operator to select voltage reading
between phases or between a phase and neutral.
The OFF position allows the voltmeter "zero"
position to be checked while the generating set is
running.
Sets up to 150kVA Sets above 150kVA
(12 volt systems) (24 volt systems)
12 Volt EIM SR 24 Volt EIM Plus
12 Volt EIM Plus 24 Volt EIM Plus
12 Volt EIM Plus 24 Volt EIM Plus
12 Volt EIM Plus 24 Volt EIM Plus
12 Volt EIM SR 24 Volt EIM SR
3. AC AMMETER - An ammeter that indicates the AC
electrical current being delivered which is dependant
on the connected load. A separate reading from
each of the phases is possible using the ammeter
selection switch (item 4). If the meter gives no
reading while the generating set is running, ensure
that the AC ammeter selector switch is not in the
OFF position.
4. AC AMMETER SELECTOR SWITCH- A selector
switch allowing the operator to select a current
reading from each of the phases. The OFF position
allows the ammeter "zero" position to be checked
while the generating set is running.
5. FREQUENCY METER - A meter that indicates the
output frequency of the generating set. At partial
load the frequency will be slightly higher than
normal, depending on the droop of the governor. In
practice, no load frequencies of approximately 52
and 62 Hz for 50 Hz and 60 Hz respectively, are
considered normal. The frequencies will fall, as the
set is loaded, to 50 Hz and 60 Hz at full load.
6. HOURS RUN METER - A meter that indicates the
total number of hours of generating set operation to
aid in maintenance.
7. ENGINE WATER TEMPERATURE GAUGE - A
temperature gauge connected to a sensor in the
engine to monitor engine coolant temperature. The
normal operating temperature should be
approximately 85°C (185°F).
8. DC BATTERY VOLTMETER - A voltmeter that
indicates the state of charge of the battery. When
the engine is at standstill the normal battery voltage
will be 12 to 14 volts on a 12 volt system and 24 to
28 volts on a 24 volt system. During starting, the
needle will drop to about 70% of normal and oscillate
as the engine cranks. Once the engine has started,
the needle should return to its normal value. If the
battery charging alternator is charging correctly, the
voltage reading will always be higher with the
generating set running than when it is stopped.
9. ENGINE OIL PRESSURE GAUGE - A gauge to
monitor engine oil pressure from the moment the
engine is cranked. The proper oil pressure rating
should be approximately 35 to 60 p.s.i. for 50 Hz and
45 to 65 p.s.i. for 60 Hz. On cold engines the oil
pressure will be significantly higher until the engine
warms up.
10. FAULT INDICATOR LAMPS - Fault lamps that
illuminate to indicate that the protective circuitry has
sensed the indicated condition. The lamp should be
red on conditions for which the system will initiate a
shutdown of the set. For alarms, the lamp can be
red or amber.
11. LAMP TEST PUSHBUTTON - A button to test the
fault lamps and to reset an alarm warning lamp and
circuitry after an alarm has been initiated.
12. KEY SWITCH (1001 Series Only) - A four position
switch that provides a means of starting and
operating the generating set.
Position "O" - Off/Reset
Power is turned off and protection circuitry is reset in
this position.
Position "l" - On
DC power is supplied to the control system and the
fault protection timer relay is initiated.
Position "
DC power is supplied to the thermostart circuit, if
fitted.
Position "
DC power is supplied to the starter motor to crank
the engine. The thermostart circuit is also powered,
if fitted.
4
" - Thermostart
" - Start