FGWilson Service

What is an Authorised Service Center - Update

In order that FGW LATCA can offer the highest service support "in country" we have been endeavouring to find partners to become Authorised Service Centers to work with. These ASC's are usually, but not exclusively, existing customers that have a Service support area of their business, sound product knowledge and supply FG Wilson Original parts.

This Service support would include FG Wilson genset installation and commissioning, genset maintenance, genset service and warranty support. The sound product knowledge would have been gained equally from experience in the field and also from training Seminar's held at the FGW LATCA Regional Training Center in Miami. We, on a periodic basis, assess the ASC's on installations, service contracts, administrative and procedural performance, spare parts inventory and local reputation, and when the situation arises we can reccomend the services of the local ASC to new, or prospective genset customers.

 Left to right: Lalith Gunawardena, Garth Jackson, Stephen Hanna and Ruben Byerlee

Following the successful completion of the 6000 panel training course at our Regional Training Centre in Miami, Stephen Hanna of Hipro Farm Supplies (ACE Supercentre) was appointed as an Authorised Service Centre in Jamaica.

     

Who is Authorised?

In the Caribbean region there are now 4 Authorised Service Centers, A.M. Electrical in Barbados,Exel Engineering in Antigua,Genspec Ltd. in Trinidad and now Hipro Farm Supplies in Jamaica. It is equally important to point out that these are the only 4 Authorised Service Centers of FGW LATCA in this region at present.

Garth Jackson

Service Advisor

The New 1106C Perkins Engine.

The New 1106C range of Perkins Engines

On future F G Wilson genset models P180P2 and P200E2 you will be seeing the new fully electronic 1106C Perkins engine fitted. This engine is yet another advance in technology and has some features which I need to share with you.

First of all this is not like a traditional diesel engine, the fuel injection pressures are in the region of 23000 psi./ 1600bar/ 160MPa and the high pressure fuel pipes are specially autofrettaged for this application with a fluid penetration safety hazard. Therefore, if any pipe is removed or loosened for any reason it must be replaced, do not try to bleed this engine in the traditional way, it is self bleeding.

Single-side servicing.

Although the genset DC voltage is 12v, the set will come with two DC batteries, these batteries must be connected in parallel across the starter motor to double the starting current and maintain 12v, not in series. 

Just possible to see twin battery set-up here

Similar to the more familiar 2300/2500/2800 series of Perkins engines this engine is fitted with an ECM, with it's own Electronic Service Tool plug and in this application the ECM is cooled by diesel fuel returning from the injectors.

Fuel pipes visible here, entering and leaving the ECM.

To interrogate the engine ECM a link between terminal 7 and terminal 3a must be made in the panel, this is similar to the terminal 322 and + connection required on the 1300 series ECM. It also has the same consequences as the 1300 series if this link is not opened before starting the set, it will not stop! In normal operation terminal 7 and terminal 3B should be linked, clearly marked below.

Terminal link visible here,3A,7,3B

Along with the introduction of a new engine comes the introduction of new Service items, part numbers, lead-times etc, please contact us when the time comes for a quotation.

 

Garth Jackson

Service Advisor

 

FG Wilson generator with over 50,000 hours

Control panel showing 50,539 hours run

Recently on a field visit I came across an FG Wilson set with the highest genuine hours run I have ever witnessed. On closer investigation the set was manufactured in 1995 as a P300 model and ran in a prime 80hr/week application at a Brewery. The customer carried out the maintenance as per the manufacturer's instructions and timetables, only using genuine parts, preferred lubricating oil and quality fuel, although it may not be much to look at now but it ran for 50,539 hours with little or no major downtime.

Genset condition after 12 years hard service, notice OEM fuel filter

It was decommissioned last year only due to site expansion and the installation of new FG Wilson synchronizing sets, which are now also well into 15,000 hours run.

For the potential genset purchaser, or even current genset owners, this is testament to the benefits of Servicing and Maintaining a genset to the manufacturer's reccommendations (see below), this set gave 12 years service, no corners were cut, no pattern/aftermarket parts were used, the lubricating oil was changed at the reccommended interval, the coolant specific gravity tested and changed as per schedule, valvetrain checks and adjustments made and records kept.

FG Wilson parts are not just reccommended for use during the Warranty period of the genset, they should be used throughout the life of the genset, they will prolong the genset operational life, maintain reliability and reduce downtime, the manufacturer calls it "Preventive Maintenance" for a reason, to prevent downtime.

Moving on, the site now has 3 synchronizing genset installed and commissioned, a p400 model and 2no. p688 models, these sets are also serviced as per manufacturer's instructions and schedules, this time by the local Authorised Service Centre representative. And further expansion may lead to another genset being added in the future.

Installation of the new synchronizing sets

So, when the time comes around again to service your genset, consider the benefit of using Genuine FG Wilson parts as part of your overall maintenance program, the money you may save in the short term purchasing pattern/aftermarket parts may result in premature equipment failure, reduced reliability/ longevity and confidence. And remember when you buy your parts from FG Wilson you have also purchased our support, experience and expertise. 

Garth Jackson

Service Advisor

 

Bleeding Air from the Fuel System on your F G Wilson Generator

Recently we have experienced an increase in the number of customers experiencing problems with purging air from the fuel system after running out of fuel. Each engine is different and it cannot be assumed that the cracking of fuel pipes and spilling diesel will bleed the system, in some cases it will make the situation worse with damage to olives, pipes and hoses.

I have included below the most common engine bleeding methods as described in the manufacturer's literature. Remember that more time should be spent bleeding an engine that cranking it hoping that it will start, a genset needing bled is possible to start, a genset with flat batteries or cooked starter motor cannot!

400 Series

1000 Series

1100 Series with Electronic priming pump

1300 Series

4006/4008 In-Line

4012/4016 Series V engine Early

4012/4016 Series V Engine late

Garth Jackson

Service Advisor

FG Wilson Warranty

Every FGWilson Generator is covered by comprehensive warranty cover against defects in material and workmanship within the warranty period. To ensure the customer benefits from this cover it is important that the complete FG Wilson warranty process is understood. Every genset manual pack has a warranty section near the back, in this section the general warranty statement is laid out detailing FG Wilson's responsibility, the User's responsibility and the warranty limitations. In this warranty statement, references are made to the Warranty Registration Form and the Pre-Delivery inspection sheet, these are included in triplicate in the manual pack along with the Commissioning Sheet. So when a genset is received directly by a customer or by a dealer, they should fill these forms in and return them to us in a timely manner this helps to identify the genset at a later date should a claim be made. If damage is evident on a recently delivered genset then the Pre-Delivery Inspection sheet should be used to submit this information within 72 hours of it's receipt.

The Warranty period of a genset depends on the application of that genset and the hours of usage, a prime power genset has a warranty of 12 months from the date of start-up, a standby genset's warranty last for 24 months as long as it runs no more than 500 hours in each of the 2 years. We recommend that you always use quality diesel fuel, quality lubricating oil to manufacturer's specification, service your genset at the recommended intervals and always use OEM FGW filters. This is even more important during the warranty period of the genset as the warranty may be affected if the customer does not follow FG Wilson reccommendations. For example, it makes it very difficult for us to make a case for a failed engine when there is no service history evident, non OEM filters have been used and oil or diesel fuel is of questionable quality - considering the value of the genset the outlay for a planned maintenance schedule using quality parts and fluids is a small price to pay for peace of mind and will prolong the life of the genset.

What do you do in the event of a suspected warranty failure?

The first thing to do when something has failed is contact FGW Latca, it may as simple as a blown fuse or a more complicated problem, but discussing it with us may resolve the problem before time and money is spent. If it is deemed a warranty failure then the parts must be purchased and the repair completed. The next step is to fill in a warranty claim form, this form needs the genset serial numbers, dates of start-up and failure, hours run and concise information regarding the failure etc. This form should be submitted to LATCA as soon as possible after the failure occurs as we are time-constrained in claim submittal to the manufacturer i.e. a late submittal can result in an automatic denial. Photographs of major engine and alternator failures are required, we may also request that the failed part be returned so it is important to hold any failed parts for six months.

The process for failures of Delphi fuel injection equipment is slightly different, if a problem is suspected with a "Delphi" fuel injection equipment the parts must be removed from the genset and taken to the local Authorised Delphi dealer for inspection, again accompanied with engine serial number, hours run etc. If the failure on the Delphi fuel injection equipment is deemed to be warrantable the parts usually will be repaired or replaced by the Delphi dealer free of charge.

How do you replace the part?

If the part that has failed cannot be replaced from your own stock of parts, then contact the LATCA spare department; Yurima@fgwilsonmiami.com for a quote on the replacement, then purchase it directly from us, carry out the repair and add it's cost to the warranty claim along with any labour involved. When the manufacturer receives the claim and accepts it, these costs will be reimbursed according to alloted labor rates and repair times. Warranty repairs can only be carried out using genuine F.G.Wilson parts, a warranty repair restores the genset to operating condition by repairing or replacing only the defective or failed parts.

What do you do with the failed part?

Do not dispose of any failed parts, hold on to them because they may be requested to be returned to the manufacturer for inspection - this is especially important for high value items.

How long does the process take?

The process depends on several factors involving the customer and us;

1. the failed part itself,

2. the speed with which the failure is reported,

3. the speed with which the part is ordered and replaced,

4. the part availability,

5. the speed of the claim submittal.

After the claim is submitted to the manufacturer there are targets and guidelines which will ensure a quick response. So basically I am asking you to help us help you, the quicker that failures are reported and submitted the better chance there is of a successful claim process.

Garth Jackson

Service Advisor

Safety

Are your Generator Practises Safe?

Handling, installing, owning and maintaining a diesel generator can be a risky business whether you're the end user, the installer, the maintenance contractor or just the man in the street. Let's consider what a diesel generator is from a safety perspective, a heavy cast iron reciprocating engine running on diesel fuel oil, with a sump full of lubricating oil, a radiator full of a water/glycol mix, a rotating fan to cool this radiator, an A.C. generating alternator with A.C. power cables, a set of lead acid D.C. batteries, a power breaker and a basetank full of diesel fuel. When the generator is running it emits hot exhaust gases, noise, vibration ,creates heat in the alternator, heat in the engine expelled as hot air from the radiator and electric current.
So basically the genset can burn you electrically/ thermally and chemically, it can injure you due to the fact it is a rotating machine, it can electrocute you, suffocate you, deafen you, poison you and possibly crush you - so lets avoid all these and look at the risks.

So what are the safety factors to consider for a generator installer?

Handling

The weight and centre of gravity of the genset/associated equipment is important for mechanical handling, the lifting points are marked on most gensets, they should always be lifted at the baseframe or single lift point and never at the separate engine or alternator lifting points. A genset can quickly slide off fork toes if incorrectly handled, lifting a genset with a crane device can damage generator components if forethought is not put into the need for spreader beams etc. The use of jacks, rollers, crowbars, handling on uneven, off-level surfaces must also be taken in to account. A genset damaged during handling is no use to the customer.
Are the people carrying out the genset handling qualified, licensed or at least experienced in this work? - too many times gensets are damaged by installers that are not knowledgeable of the product or the handling method they are carrying out.

Installing.

It may be an obvious question but is everyone agreed on the genset location and orientation before the installation begins? Sets have been half way through room installation before someone realises that it needs rotated 180 degrees! Does the installation require temporary lighting, working at height, confined spaces, the use of portable tools, cartridge tools, welding operations, excavation etc? Are your installers competent in the use of their tools, are the tools suitable for the job, do they have an inspection safety certificate, do they have the necessary personal protection to prevent injuries to their heads, eyes, toes, skin, lungs and feet? If someone is injured during an installation is there a first aider on site? Is there an accident reporting procedure.
Can your installers be seen on site, do they have hi-visibilty clothing available for working at night for example?

There are several ways a fire can start during a generator installation, they usually are as a result of "hot works" i.e. welding/grinding/burning or of an electrical origin. If a fire occurs are measures in place to extinguish it, are your installers trained in the use of/differences in fire extinguishers, fire precautions, gas bottle storage and evacuation procedures?

Are your installers trained in manual handling procedures i.e. how to lift a heavy object without causing personal injury, is the weight of the object to be lifted known? There are several factor influencing manual handling - the task, the individual, the load and the environment - keeping your back straight and bending your knees will not help a 150lb man lift a 500lb object above his head to his colleague!

Working at height, for example installing an exhaust silencer can be a serious risk for site personnel, the use of scaffolding, trestles, access plant, even ladders are all subject to safe practises that can prevent fall injuries. Is the plant being used safe for the height it is being used at, has it been constructed by a competent person, is it level and secured, An injured employee is not a working employee!

Installing the fuel system during a genset installation will sooner or later result in diesel leaks or spillages, are the measures in place to contain and clean diesel spillages - to prevent diesel entering ground water for example, or posing a possible fire hazard?, working with diesel fuel can also result in skin dermatitis with some individuals, are gloves, barrier creams readily available?

Installing the electrical power cables can be quite a physical task during an installation, are your personnel qualified to understand phase rotation, glanding, lug connections, terminal torques, cable trefoiling, trench deration etc, some problems at installation carry right through to genset commission - sometimes with expensive consequences.

Commissioning

When the installation is complete and the genset is installed mechanically and electrically, the next all important step is the commissioning. This will be the first time the genset has run since it was manufactured and the new fuel system, exhaust system, electrical system and operation will be tested for the first time. When the genset runs for the first time it will be creating heat, noise, vibration, exhaust gases and A.C. current - each of these must be checked in turn, is the noise level acceptable for the environment in which the generator is working? Is the exhaust system gastight and expelling the gases satisfactorily? (i.e. no recirculation, no contamination of air conditioning units), is the full load output current carried on the load cables used without heating?, and finally is the fuel system leak-free and operational?

What are the safety factors for the Owner?

So your new genset has been installed and commissioned and you now have standby power, so what responsibilties do you have? Have you read the genset manuals, are you aware of the basic operation of the engine, how to check oil levels, the type of oil used, the coolant level, the type of coolant used, the alternator voltage regulator position, the panel operation? If you have an automatic transfer switch are you aware of its operation and how it works, where the signal wire locate on it and the genset panel? In the event of an emergency could you start/stop the generator, trip the breaker,  changeover/changeback the automatic transfer switch? If you wait until a power failure to learn about the genset you could be putting yourself and others in danger.

Do you know the fuel consumption figures for the genset? - there is nothing worse than sitting pretty during a power cut with everyone around you in darkness and then your genset runs out of fuel! And if it runs out of fuel do you know how to bleed the fuel system. Do you have a fire extinguisher/ fire blanket near the genset should the worst happen?

Do you run the genset occasionally, remember the genset has a D.C. battery just like your car and it can go flat over time, if you have a battery charger fitted to your genset always check that the A.C. supply is actually switched on. Boost charging a flat battery in an emergency can release dangerous acidic gases and sometimes result in an explosion.

Maybe you have a maintenance contractor appointed to look after the genset and believe you don't need to consider any of the above, but you won't know there is a problem with the genset until you need it and invariably your contractor will not be about when this happens. Considerations for the Owner when selecting a maintenance contractor next.

What are the safety considerations for the Maintenance provider?

The greatest risk to the operation of a genset is someone performing work on it without training, model specific information or experience. Do you have the operation and maintenance manual for this model of genset, do you know how the engine, fuel system, cooling system, lubricating system, engine interface/control module works? Do you have the manual for the alternator,understand the AVR, terminal windings, diodes, voltage sensing etc. Can you read the electrical drawing for the genset, do you know the operation of the genset panel/ automatic transfer switch, how to navigate fault menus, troubleshoot and fault-find? - If your answer to any of these is no then you should not work on a FGW genset until you can answer "yes" - you will be a risk to yourself, the genset and others.

Do you understand the warranty procedure for the genset, the service intervals, do you understand that the warranty can be invalidated if incorrect parts, fluids, procedures are used during the genset maintenance? How will you service the genset?, how will you dispose of waste oil, waste coolant, oil filters, fuel filters in an environmentally friendly way? What if the power fails during a oil change service, have you isolated the genset to prevent start-up, have you a plan to get the genset on-line as soon as possible?  Do you keep a record of services, part history, an OEM parts inventory, do you offer emergency cover etc?
Remember if you can do the job safely, professionally and efficiently you will get a good reputation, your business can only benefit from this.

Garth Jackson

Service Advisor

 

Maintenance Procedures for your FG Wilson Generator

Experience indicates that generators become more likely to fail after a number of years in operation. The main reason is ageing of the components, but operating conditions also play a major role. Environmental and operating conditions are also taken into account. Tough conditions such as high ambient temperatures, high vibration levels, humidity, dirt, or heavy loads can significantly shorten component lifetimes and reduce maintenance and component replacement intervals.

Failure of a component may result in damage to other parts of the machine, including the stator and rotor. The maintenance schedules are based on extensive know-how and they provide an effective and systematic means of maintaining a specific type of generator. The maintenance intervals are planned according to those of the diesel engine to avoid unnecessary shutdown time. In order to ensure optimum performance over the entire lifetime of a generator, the recommendation is that periodic inspections be carried out in addition to regular preventive maintenance.

Diesel powered generators are depended on for back-up power systems in the most critical locations: airports, hospitals government, telecommunications and even at war. In standby power applications, diesel generators can start and assume full-rated load in less than 10 seconds. This remarkable set of credentials is unique to diesel engines, but like any mechanical device, maintenance is crucial for ensuring that a diesel powered standby generator will start and run when needed.

Facilities with qualified in-house technical personnel can often perform required preventive maintenance on diesel generators. Other facility managers prefer to contract with a local service provider or power system distributor for regular maintenance service especially if they have generators in multiple locations. (For unplanned maintenance, engine repairs or overhauls, it is always best to use qualified diesel service technicians.) Because of the durability of diesel engines, most maintenance is preventive in nature. Preventive diesel engine maintenance consists of the following operations:

• General inspection

• Lubrication service

• Turbocharger inspection

• Air filter condition

• Cooling system service

• Fuel system service

• Servicing and testing starting batteries

• AC & DC voltage check

• Engine safety and controls

• Regular engine exercise

The best way to keep track of maintenance intervals is to use the running time meter on the generator set to keep an accurate log book of all service performed. This log book will also be important for warranty support.

GENERAL INSPECTION procedure

When the generator set is running, operators need to be alert for mechanical problems that could create unsafe or hazardous conditions. Following are several areas that should be inspected frequently to maintain a reliable operation.

Exhaust system – With the generator set operating, inspect the entire exhaust system including the exhaust manifold, turbo, muffler and exhaust pipe. Check for leaks at all connections, welds, gaskets and joints, and make sure that the exhaust pipes are not heating surrounding areas excessively. Repair any leaks immediately

Fuel system – With the generator set operating, inspect the fuel supply lines, return lines, filters and fittings for cracks or abrasions. Make sure the lines are not rubbing against anything that could cause an eventual breakage. Repair any leaks or alter line routing to eliminate wear immediately.

DC electrical system – Check the terminals on the starting batteries for clean and tight connections. Loose or corroded connections create resistance which can hinder starting.

Engine – Monitor fluid levels, oil pressure and coolant temperatures frequently. Most engine problems give an early warning. Look and listen for changes in engine performance, sound, or appearance that will indicate that service or repair is needed. Be alert for misfires, vibration, excessive exhaust smoke and loss of power or increases in oil or fuel consumption.

LUBRICATION SERVICE procedure

Check the engine oil level when the engine is shut down. For accurate readings on the engine’s dipstick, shut off the engine and wait approximately 10 minutes to allow the oil in the upper portions of the engine to drain back into the crankcase. Follow the engine manufacturer’s recommendations for API oil classification and oil viscosity. Keep the oil level as near as possible to the “full” mark on the dipstick by adding the same quality and brand of oil. Change the oil and filter at the intervals recommended by the manufacturer. Check with the engine manufacturer for procedures for draining the oil and replacing the oil filter.

COOLING SYSTEM SERVICE procedure

Check the coolant level during shutdown periods. Remove the radiator cap after allowing the engine to cool and, if necessary, add coolant until the level is about 3/4-inch below the radiator cap lower sealing surface. Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze and coolant additives. Use a coolant solution as recommended by the engine manufacturer. Inspect the exterior of the radiator for obstructions and remove all dirt or foreign material with a soft brush or cloth. Use care to

avoid damaging the fins. If available, use low pressure compressed air or a stream of water in the opposite direction of normal air flow to clean the radiator. Check the operation of the coolant heater by verifying that hot coolant is being discharged from the outlet hose.

FUEL SYSTEM SERVICE

Diesel fuel is subject to contamination and deterioration over time, and one reason for regular generator set exercise is to use up stored fuel over the course of a year before it degrades. In additional to other fuel system service recommended by the engine manufacturer, the fuel filters should be drained. Water vapor accumulates and condenses in the fuel tank and must also be periodically drained from the tank along with any sediment present. The charge-air piping and hoses should be inspected daily for leaks, holes, cracks or loose connections. Tighten the hose clamps as necessary. Also, inspect the charge-air cooler for dirt and debris that may be blocking the fins. Check for cracks, holes or other damage.

AIR INTAKE

The engine air intake components should be checked. The frequency of cleaning or replacing air cleaner filter elements is primarily determined by the conditions in which the generator set operates. Air cleaners typically contain a paper cartridge filter element which can be cleaned and reused if not damaged.

STARTING BATTERIES

Weak or undercharged starting batteries are the most common cause of standby power system failures. Even when kept fully charged and maintained, lead-acid starting batteries are subject to deterioration over time and must be periodically replaced when they no longer hold a proper charge. Only a regular schedule of inspection and testing under load can prevent generator starting problems.

Testing batteries – Merely checking the output voltage of the batteries is not indicative of their ability to deliver adequate starting power. As batteries age, their internal resistance to current flow goes up, and the only accurate measure of terminal voltage must be done under load. This can be done using a manual battery load tester to verify the condition of each starting battery.

Cleaning batteries – Keep the batteries clean by wiping them with a damp cloth whenever dirt appears excessive. If corrosion is present around the terminals, remove the battery cables and wash the terminals with a solution of baking soda and water. Be careful to prevent the solution from entering the battery cells, and flush the batteries with clean water when done. After replacing the connections, coat the terminals with a light application of petroleum jelly.

Specific gravity check – Use a battery hydrometer to check the specific gravity of the electrolyte in each battery cell. A fully charged battery will have a specific gravity of 1.260. Charge the battery if the specific gravity reading is below 1.215.

Electrolyte level check – Check the level of the electrolyte in the batteries at least every 200 hours of operation. If low, fill the battery cells to the bottom of the filler neck with distilled water.

GENERATOR SET EXERCISE

Generator sets on continuous standby must be able to go from a cold start to being fully operational in a matter of seconds. This can impose a severe burden on engine parts. However, regular exercising keeps engine parts lubricated, prevents oxidation of electrical contacts, uses up fuel before it deteriorates, and, in general, helps provide reliable engine starting. Exercise the generator set at least once a month for a minimum of 30 minutes loaded to no less than one-third of the nameplate rating. Periods of no-load operation should be held to a minimum, because unburned fuel tends to accumulate in the exhaust system (wetstaking). If connecting to the normal load is not convenient for test purposes, the best engine performance and longevity will be obtained by connecting it to a load bank of at least one-third the nameplate rating.

CONCLUSION

With my foundations developed on the service department of a diesel powered generator business I can assure you that some of the benefits are:

• Extended generator lifetime
• Increased generator reliability
• Optimized maintenance cost and minimized repair costs
• Easy to plan maintenance budget

By following the specific manufacturer recommendations for your application, you’ll be assured that your standby power system will start and run when you need it most.

Miguel Cintrón, BSEE | Customer Support Engineer
FG Wilson Latin America & Caribbean | Miramar, FL

What You Should Know About Engine Coolant

One of the most commonly looked over elements in generators is the radiator coolant or “antifreeze”, yet it is one of the most important components to keeping your engine in top notch condition and reducing pre-mature engine wear. Engine coolant is the fluid that “absorbs” heat from the engine and then dissipates it through the radiator, therefore using the correct coolant and mixture directly affects the operating temperature of your engine and its longevity. FG Wilson recommends using a 50/50 mix of ethylene glycol coolant with distilled water, the reason for using distilled water is it’s lack of minerals found in common tap water which can denature the coolant properties and reduce it’s efficiency in the cooling system, some of the advantages of using proper coolant are:

1. Increased boiling point over plain water. This characteristic gives the engine an added margin of safety before the engine begins to overheat which can lead to pre-mature engine wear or catastrophic engine failure.
2. Lower freezing point over plain water. In regions where extreme low temperatures are present, the coolant adds a level of protection against freezing which can lead to the block cracking due to fluid expansion in the engine passages.
3. Rust Inhibitor. Coolant has rust inhibitors that protect against the build up of rust and hard water scaling which is common when using plain water, it can lead to water pump and radiator failures as well as clogging of water passages throughout the engine.
4. Flow Increase. Using properly mixed engine coolant can increase the flow of fluid throughout the engine an average of 14% over plain water.

Routine inspections of the coolant is essential for maintaining proper engine protection and periodic replacement of the coolant is important since it is operating in a hot, hostile environment that will cause the coolant to break down over time. Most importantly, the coolants rust inhibitors get used up, leaving the cooling passages throughout your engine and radiator vulnerable to corrosion and contaminating the coolant with debris.

Rafael Heredia

Service Advisor

FG Wilson: "Why Buy Genuine Parts?"

The two oil filters shown in the pictures above may look the same. However, the oil filter on the left in each picture
shows the wrong part number and is very poor quality. It will also start to disintegrate after limited usage.

This counterfeit filter recently resulted in major early hour and sudden failures of six FG Wilson generating sets powered by 2306 and 2806 Perkins engines. At the time of failure these generating sets were powering critical applications in the Middle East. Rather than buying genuine parts from their local FG Wilson Dealer, the customer in this instance tried to save costs by purchasing counterfeit filters from an unreliable source.

After limited usage, small parts of the counterfeit filter disintegrated and were pumped into the engines resulting in blocked piston cooling jets, followed by piston seizure, conrod failure and damaged crankcase.

This type of failure represents a very real risk of injury to the operator and any other person close to the engine at time of failure.

Save on costs?

Counterfeit parts are less expensive. This is because counterfeit manufacturers use cheaper, lower quality materials to save on costs. They are designed using reverse engineering – i.e. counterfeit manufacturers copy the original component without having access to technical data and design information.

Whereas genuine components are designed to work together to maximise product performance and life span, counterfeit parts are created in isolation without knowledge of how they will perform within an overall package. Counterfeit parts are not tested or validated.

These combined factors can lead to rapid wear, poor performance, higher oil and fuel consumption and ultimately product failure as illustrated above.

Component damage and product failures, caused by the use of non-genuine parts, are not covered by FG Wilson Product Warranty.

Counterfeit parts may be less expensive to purchase, but can customers really afford to take the risk?

“The message to your customers is:
Always use genuine parts!”

FG Wilson Service Tools

In order to properly service customers, dealers must commit themselves to always having the right tools for the job. This includes special equipment designed to interface with todays sophisicated electronic engines and digital control systems. In the end it will save you time and money, increase revenue and keep your customers happy. The following list of service tools are listed by name, part number and appication use:

EST

EST Hardware

Serial Port---997-298

USB Port---915-869

EST Software---650-406

License Fee---Yes, annual renewal

PC Connection Type---Both Serial and USB port versions available

1) Electronic Service Tool (EST) is used for diagnosing engine faults on FG Wilson generator sets fitted with 2300 & 2800 series Perkins engines, monitoring, storing and graphing engine data, testing injectors and sensors, configuring engine parameters, uploading and downloading configuration and emissions files, 2300 & 2800 engine timing and injector codes - engine cannot be timed and injectors cannot be replaced without using EST

2) Electronic Service Tool (EST) is used for configuring Powerwizard control system parameters, bypassing Powerwizard security locks, uploading and downloading configuration and language files

HEUI

HEUI Hardware---936-188

HEUI Software---994-485

License Fee---First license is Included in the price of the software, renewal charges apply thereafter, license expires on 31 DEC 08

PC Connection Type---Serial Port

The HEUI interface kit is used for diagnosing 1300 series engine faults, testing injectors and sensors, monitoring and storing engine data

ECG

ECG Interface Kit---650-880

License fee---N/A

PC Connection Type---Serial Port

The ECG interface kit is used for programming and tuning the Woodward, ECG governor. This governor is used on FG Wilson generator sets fitted with 400 series engines and the electronic governor option.

LCS

LCS Hardware---653-426

LCS Software---Download at <http://www.woodward.com/software/download>

License Fee---Yes, one time fee per install

PC Connection Type---Serial Port

The LCS interface kit is used for programming and tuning the Woodward, LCS governor. This governor, which has now been replaced by the L-series governor, was used on FG Wilson models fitted with 1000 series engines and the electronic governor option. This kit is not compatible with the L-series governor.

L-series

L-series Hardware---917-508

L-series Software---Download at <http://www.woodward.com/software/download>

License Fee---N/A

PC Connection Type---Serial Port

The L-series interface kit is used for programming and tuning the Woodward, L-series governor. This governor is used on FG Wilson generator set models fitted with Perkins 1000 and 1100 series engines and the electronic governor option. This kit is not compatible with the LCS.

Proact

Proact Governor Handheld Programmer---930-342

License Fee---N/A

PC Connection Type---N/A

The Proact handheld programmer is used for programming and tuning FG Wilson generator sets fitted with Perkins 4008,4012, & 4016 series engines and the Woodward, Proact 1 or Proact 2 electronic governor

Heinzmann

Heinzmann Governor Interface Hardware---915-257

Software---915-283

License Fee---N/A

PC Connection Type---Serial Port

The Heinzman governor interface is used for programming and tuning FG Wilson generator sets fitted with Perkins 4006 series engines and the Heinzman, Pandaros electronic governor.

SG2D

SG2D Governor Interface Kit---5417-557

License Fee---N/A

PC Connection Type---Serial Port

The SG2D Governor Interface Kit is used for programming and tuning FG Wilson generator sets fitted with Scania engines and the Woodward, SG2D electronic governor.

Deep Sea

Deep Sea 500 Series Configuration Editor Pack---PP-808PC

License Fee---N/A

PC Connection Type---Serial Port

The Deep Sea 500 series configuration editor pack is used to configure the Deep Sea 500 series control panel that was previously used in some FG Wilson generator sets.

A training seminar is a general prerequisite for service tool purchase. Please contact an FG Wilson Service Advisor for tool quotes and purchasing requirements.

Alex Cabrices

Service Advisor

FGW Latin America & Caribbean

FG Wilson Service Bulletin

This bulletin pertains to FG Wilson products fitted with 400 Amp 3Pole or 4Pole ABB breakers.

The breakers may be shipped with plastic spacers fitted at the customer terminals (see figure 1). This is to prevent the breaker screws at the customer terminals from being over-tightened when there are no copper toes or cable terminations fitted. If over tightened, the screw may protrude beyond the plastic barrier, reducing the insulation protection between the phase and the chassis (see figure 2). They are not fitted or required when copper toes or cable connections are fitted.

Figure 1 – Nylon spacer in place to prevent over-tightening and damage to insulation.

Figure 2 – Over-tightened phase screws with broken/missing insulation.

Action Required:

Remove and discard plastic spacers when fitting customer connections to the breaker.

2: Additionally, if the breaker is expected to be used where the customer terminals are repeatedly removed and refitted, fit copper toes and phase barriers to avoid the need for repeatedly refitting the nylon spacers.

Part No. Description Quantity

10000-04760 Phase Barrier Kit (2 for 3-pole breaker) (3 for 4-pole breaker)

330-037 Copper terminal 1 per pole (e.g. 3 for 3-pole breaker)

500-234 Set screw M10 x 40 1 per pole

503-094 M10 Shakeproof washer 2 per pole

Figure 3 – Toes and phase barriers fitted to protect breaker terminals.

FG Wilson Prime and Standby Ratings

The following ratings are designed to protect your generator set. You can find the generator rating on the name plate or "silver sticker" located either on the alternator connection box or just inside the enclosure door.

STANDBY:

Maximum usage 500 hours per year, up to 300 hours of which may be continuous running, load factor can be up to 100%--NO overload permissible.

PRIME POWER:

Unlimited hours usage, load factor 80%of published prime rating over each 24hr period, 10% overload for 1hr in every 12hrs.

Alex Cabrices

Service Advisor

FGW Latin America & Caribbean

Reconfiguring the Voltage of Your FG Wilson Generator Set

All Systems:

Under normal conditions, rated power is a constant value for any given generator set model. The formula for Power is: P=(V×A) in a single phase system and P=(V ×√3×A) in a three phase system. If you are reconnecting your generator voltage the current will either decrease or increase in order to equate to the genset's rated constant power value. Using basic algebra, we can figure for current if Power and Voltage are known; e.g., a 100 kVA generator set configured for 415 Volts: A=100×1000/(415×√3). We multiplied 100 (The genset's kVA rating) × 1000, since k is the symbol for kilo, which signifies 1000.

In summary, if you are reconfiguring your generator voltage from a 400 Volt system to a 200 Volt system, your maximum rated current will go up. The opposite is true if you are reconfiguring from 200 Volts to 400 Volts; i.e., your maximum rated current will go down.

When configuring a generator from three phase to single phase, the max amp capacity must be reduced by  1/3. If not, damage the stator windings will occur due to overheating.

The opposite is not necessarily true when converting a genset that was designed for single phase operation.

Analog Control Panels:

200 Volt Three Phase System to a 400 Volt Three Phase System

1) Configure as per section 3.3 (Terminal connection diagrams) of the “Alternators” manual and verify the AVR (automatic voltage regulator) voltage sensing leads have been moved to the correct terminals.

2) The three current transformers should to be changed to a smaller size for maximum scale sensitivity and accuracy. The CT ratings should be equal or slightly greater than the new maximum rated current; e.g., a generator rated for 139 Amps should use CTs rated for 150:5

3) The ammeter must match the primary rating of the current transformers; e.g., a 0 - 150 Amp ammeter for CTs rated 150:5.

4) The voltmeter must be changed from 0-300 to 0-500 VAC

5) The breaker trip setpoint must be lowered to match the new maximum generator current rating.

6) The jumper inside the control panel between wires 115 & 110 must be changed to connect wires 115 & 101. The three wires will be adjacent.

7) Start generator and calibrate voltage to the desired setting. This is accomplished by adjusting the voltage potentiometer on the AVR.

200 Volt Single Phase System to a 400 Volt Three Phase System

1) Configure as per section 3.3 (Terminal connection diagrams) of the “Alternators” manual and verify the AVR (automatic voltage regulator) voltage sensing leads have been moved to the correct terminals.

2) The current transformers should to be changed to a smaller size for maximum scale sensitivity and accuracy. The CT ratings should be equal or slightly greater than the new maximum rated current; e.g., a generator rated for 139 Amps should use CTs rated for 150:5 (When configuring from single to three phase, it may be necessary to add an additional CT)

3) The ammeter must match the primary rating of the current transformers; e.g., a 0 - 150 Amp ammeter for CTs rated 150:5.

4) The ammeter selector switch must be replaced for one that selects three phases

5) The voltmeter must be changed from 0-300 to 0-500 VAC

6) The voltmeter selector switch must be replaced for one that selects three phases. The sensing wires must be reconfigured.

7) The breaker trip setpoint must be lowered to match the new maximum generator current rating.

8) The jumper inside the control panel between wires 115 & 110 must be changed to connect wires 115 & 101. The three wires will be adjacent.

9) Start generator and calibrate voltage to the desired setting. This is accomplished by adjusting the voltage potentiometer on the AVR

400 Volt Three Phase System to a 200 Volt Three Phase System

1) Configure as per section 3.3 (Terminal connection diagrams) of the “Alternators” manual and verify the AVR (automatic voltage regulator) voltage sensing leads have been moved to the correct terminals. (it may be necessary to add an additional cable per phase due to the increase in current)

2) The three current transformers must be changed to ones with higher primary winding ratings. The primary winding ratio must be equal or slightly greater than the new maximum generator current rating; e.g., a generator rated for 262 Amps would use 300:5 CTs.

3) The ammeter must match the primary rating of the current transformers; e.g., a 0 - 300 Amp ammeter for CTs rated 300:5.

4) The voltmeter should be changed from 0-500 to 0-300 VAC for maximum scale sensitivity and accuracy.

5) The breaker must be replaced for one with a higher rating. The rating should match the maximum rated generator current.

6) The jumper inside the control panel between wires 115 & 101 must be changed to connect wires 115 & 110. The three wires will be adjacent.

7) Start generator and calibrate voltage to the desired setting. This is accomplished by adjusting the voltage potentiometer on the AVR.

400 Volt Three Phase System to a 200 Volt Single Phase System (generator must be derated)

1) Configure as per section 3.3 (Terminal connection diagrams) of the “Alternators” manual and verify the AVR (automatic voltage regulator) voltage sensing leads have been moved to the correct terminals.

2) The current transformers must be changed to ones with higher primary winding ratings. The primary winding ratio must be equal or slightly greater than the new maximum generator current rating; e.g., a generator rated for 262 Amps would use 300:5 CTs. (it is not necessary to place a CT on the center tap or neutral)

3) The ammeter must match the primary rating of the current transformers; e.g., a 0 - 300 Amp ammeter for CTs rated 300:5.

4) It may be desirable to replace the ammeter selector switch for single phase selection

5) The voltmeter should be changed from 0-500 to 0-300 VAC for maximum scale sensitivity and accuracy.

6) It may be desirable to replace the voltmeter selector switch for single phase selection. The sensing wires must be reconfigured.

7) The breaker must be replaced for one with a higher rating. The rating should match the maximum rated generator current.

8) The jumper inside the control panel between wires 115 & 101 must be changed to connect wires 115 & 110. The three wires will be adjacent.

9) Start generator and calibrate voltage to the desired setting. This is accomplished by adjusting the voltage potentiometer on the AVR.

Digital Control Panels:

200 Volt Single or Three Phase System to a 400 Volt Three Phase System

1) Configure as per section 3.3 (Terminal connection diagrams) of the “Alternators” manual and verify the AVR (automatic voltage regulator) voltage sensing leads have been moved to the correct terminals. (If configuring from single to three phase, it may be necessary to add an additional CT)

2) The breaker trip setpoint must be lowered to match the new maximum generator current rating.

3) The new system voltage configuration must be programmed in the control panel; e.g., Delta, Wye, etc.

4) The new system voltage must be programmed in the control panel. (the voltage sensing wires may need to be reconfigured if changing between single and three phase systems).

5) Start generator and calibrate voltage to the desired setting. This is accomplished by adjusting the voltage potentiometer on the AVR.

400 Volt Three Phase System to a 200 Volt Single or Three Phase System (generator must be derated if reconfiguring for a single phase system)

1) Configure as per section 3.3 (Terminal connection diagrams) of the “Alternators” manual and verify the AVR (automatic voltage regulator) voltage sensing leads have been moved to the correct terminals. (it may be necessary to add an additional cable per phase due to the increase in current)

2) The three current transformers must be changed to ones with higher primary winding ratings (it is not necessary to place a CT on the center tap or neutral). The primary winding ratio must be equal or slightly greater than the new maximum generator current rating; e.g., a generator rated for 262 Amps would use 300:5 CTs.

3) The new primary CT ratings must be programmed in the control panel

4) The new system voltage configuration must be programmed in the control panel; e.g., Delta, Wye, etc.

5) The new system voltage must be programmed in the control panel. (the voltage sensing wires may need to be reconfigured if changing between three and single phase systems).

6) The breaker must be replaced for one with a higher rating. The rating should match the maximum rated generator current.

7) Start generator and calibrate voltage to the desired setting. This is accomplished by adjusting the voltage potentiometer on the AVR.

Download section_2_ammeters_and_current_transformers.pdf

Download section_3_circuit_breakers.pdf

Alex Cabrices

Service Advisor

FGW Latin America & Caribbean

Bleeding the Fuel System on your FG Wilson Generator

My Generator Won’t Start!

    We have recently received an elevated amount of calls complaining of engine start issues or poor load acceptance, most if not all of these issues can be traced back to problems of fuel or lack of sufficient fuel. In the majority of the instances the engine was getting air in the fuel system due to the unit running out of fuel, changing of fuel filters or new units being started in the field for the first time. Air in the fuel system can play havoc on a diesel engine since the trapped air can be found in the fuel filter(s), fuel lines, injectors etc... Proper and complete bleeding of the fuel system is essential in avoiding engine start and load acceptance issues. Some issues involve units that run fine after bleeding the fuel system but won’t start after sitting all night, these units have lost their prime due to a small amount of air penetrating the fuel system and require purging the air out of the system again, in one case the unit would not take more than 50% load, investigations revealed a pinched o ring on one of the fuel line fittings that would draw air in when a higher demand for fuel was needed. There are several methods for checking the fuel system for air, one method involves using a glass fitting in line with the fuel hose allowing you to see bubbles in the fuel line and thus be able to determine if it’s getting air before or after the fuel filter, fuel filter to fuel pump or fuel pump to injectors, other important things to check are the hoses for pin holes, fittings for looseness or over tightened crushing the o ring, cracked fuel filter or seals, broken or cracked injector tubes, loose injectors, dirty fuel that can block flow due to debris, etc.. In effect anything and any place that could allow for air to enter the system or foreign objects to block the flow of fuel to the engine.

Rafael Heredia
Service Advisor
FGW Latin America & Caribbean

FG Wilson Global Parts Distribution Center

FG Wilson Parts System,
Supply Chain Management Extreme!!

During a recent visit to FG Wilson’s parts distribution center in Central England, I got a chance to see what supply chain management really means, an insight if you will to the inner workings of a finely tuned operation moving hundreds of thousands of parts worldwide effectively and efficiently. It all begins with each distributor worldwide, they place their parts order electronically via dedicated parts ordering website where every order is received in one central location at the distribution center in England, at that point it is distributed to a parts specialist that is responsible for specific distributors and sees each parts order through to the end, the specialist is tasked with dividing the orders into priorities according to shipping requirements, i.e. next day, or regular shipping, from there the orders are passed on to warehouse personnel for picking and processed for immediate shipping, any orders received before 2:00 pm are processed and shipped the same day, considering the volume of orders this is quite a fete. Simultaneous to the day to day shipping of parts, additional personnel are hard at work coordinating with hundreds of vendors in estimating demand to keep a constant supply of parts flowing through the distribution center and on to the distributors to get the needed parts into the customers hands as soon a possible. Through sophisticated databases, painstaking records keeping and careful planning the distribution center is able to keep ahead of demand and supply by keeping track of back orders and when each vendor expects to fill the needed demand for parts and in some cases they are able to change vendors in order to speed up the process. Additionally, there is a dedicated help desk at the distribution Center that aids with identifying specific parts according to engine builds and generator serial numbers, using multiple databases and parts identification software they are able to track down the correct part for each equipment as well as make the needed changes to superseded part numbers or add new parts to the system as needed. FG Wilson’s parts distribution network is an impressive conjunction of professionals working together to support the product on the field and satisfy customer needs for reliable power generation.

Rafael Heredia
Service Advisor
FG Wilson Latin America & Caribbean

EIM Overspeed Calibration for FG Wilson Generators (EIM Plus models only)

 

Ensure the MPU (Magnetic Pickup) is installed correctly.
1)    Unscrew and pull out the magnetic pickup that is located near the flywheel of the engine.
2)    Inspect the magnetic tip and ensure that it is clean and free of debris.
3)    Screw the MPU in until the tip makes contact with the top of the flywheel teeth.
4)    Back out the magnetic pickup ½ to ¾ of a turn.

EIM (Engine Interface Module)
1) Turn the ten-turn potentiometer between five to seven turns clockwise or just until you feel a small click - signifying the full span of the pot.
2) Start the generator set. You will notice the overspeed calibration LED illuminated.
3) Slowly turn the potentiometer counter-clockwise until the LED just turns off.
5)    As soon as the LED turns off, start to slowly turn back the potentiometer clockwise just until the led starts to flicker.

Your generator overspeed setpoint is now calibrated!

Alex Cabrices
Service Advisor
FGW Latin America & Caribbean
10431 North Commerce Parkway
Miramar, FL. 33025
(954)433-2212 Bus
(954)433-4431 Fax

Excitation Systems on FG Wilson Generators

Download ar20_arepgb.pdf

Download ar18_19_pmggb.pdf

FG Wilson uses three types of excitation systems:

1)      Shunt

2)      AREP

3)      PMG

When to choose shunt ?

            - single circuit installation

            - power cut acceptable

-   self protection of the alternator

When to choose arep or pmg ?

            - whole installation with several circuits

            - power cut forbidden ( hospitals, ups etc.)

            - high rate of distorting loads.

            - starting of a big motor

            - AREP minimum length required

            -PMG existing shunt machine to be upgraded

AREP / PMG  advantages compared with shunt

                - the short circuit capability that enables a selective

                 protection  in case of overload or short circuit

                 on an installation

Shunt

1. Advantages
   1. Low Cost
   2. Self protected against short circuit (the AVR will immediately switch off the excitation if a short circuit condition is detected by the sensing leads)
   3. No extra length

2. Disadvantages
   1. No short circuit capability (the AVR may detect a short circuit condition when starting a high capacity load, such as a large motor)
   2. Low starting capacity
   3. Sensitive to distorting loads

AREP

3. Advantages
   1. High starting capacity
   2. Short circuit capabilty
   3. No extra length

4. Disadvantages
   1. Specific Winding
   2. Small added cost

PMG

5. Advantages
   1. High starting capacit
   2. Short circuit capabilty
   3. Permanent Magnetism

6. Disadvantages
   1. Extra Length
   2. High number of components
   3. Added cost

Self-Excited ( Shunt ):                                                   

1000,2000,3000,  Alternator Series                               AVR R230A

5000, 6000 Alternator Series                                         AVR R448

8100,9100 Alternator Series                                          AVR 449

PMG Excited:

1000 Alternator Series                                                 Not Available

2000,3000 Alternator Series                                          AVR R438

5000,6000,7000 Alternator Series                                 AVR R448

8100,9100 Alternator Series                                          AVR R449

R449

AREP Excited:

1000,2000,3000 Alternator Series                                 AVR R438

5000,6000,7000 Alternator Series                                 AVR R448 

8000,9000 Alternator Series                                          AVR R449

Alex Cabrices

FGW Service Advisor

622-333 Oil Pressure Switch/Sender

Connections to the oil pressure switch/sender (part no 622-333) on FG Wilson generators are as follows.

Terminal G: Is the sender and wire “OP” should be connected to this terminal – with the wire disconnected, the terminal should read close to 10 ohms to ground with genset off.

Terminal WK: Is the switch and *wire “15” should be connected to this terminal – with the wire disconnected, the terminal should read less than 1 ohm to ground with genset off.

* Wire “15” will not be connected on 2300 & 2800 electronic engines, since the engine’s Electronic Control Module will control the low oil pressure shutdown.

Alex Cabrices

Service Advisor

FGW Latin America & Caribbean

Electronic Service Tool – “EST”

What is EST?

EST is comprised of a hardware and software (The Integrated Parts and Service System or “TIPSS”) interface kit, which a user can use to communicate with Perkins’ 2300/2800 electronic engines (FG Wilson 300 – 750 KVA range) and FG Wilson Powerwizard control panels. This communication is established via a J1939 data link. All in all, the EST interface kit provides the user with an effective tool in diagnosing engine problems and the ability of configuring system parameters.

EST enables the user to:

• Override Powerwizard level three passwords
• Configure and/or change system parameters
• Display, graph and record logs of parameter status
• Display the status of a group of parameters (temperatures, pressures, etc)
• View and clear active and logged diagnostic codes
• View and clear active and logged event codes
• Display, view or change the current Configuration File or Base level Flash File
• Upload, download and save configuration files
• View a list of irregularities logged by the ECM (engine control module)
• Perform diagnostic tests
• Perform calibrations
• Print reports and diagnostic results.

Why should an FG Wilson dealer invest in the Electronic Service Tool?

• It provides the technician with an essential tool by facilitating the troubleshooting of electronic engines. “As a matter of opinion, troubleshooting an electronic engine without EST is like troubleshooting an electrical panel without a multimeter” – Alex Cabrices FGW Latin America & Caribbean Service Advisor
• Essential in replacing an ECM on a Perkins’ 2300/2800 series engine. A blank ECM can only be configured using EST.
• Essential in replacing or retrofitting an FG Wilson Powerwizard control panel module - the new standard in FG Wilson control systems. A blank module can only be configured using EST (installing the base flash file into a blank Powerwizard module).
• Enables the dealer to upload, download and save customer configuration files.
• Allows bypassing Powerwizard level three passwords.
• Enables dealers to update the software versions of customer’s Powerwizard control panels, as required. New software releases can enhance the control panel’s functionality.
• Enables dealers to install additional Powerwizard language files, as required.

What are the requirements for purchasing/owning EST?

• You are required to be an authorized distributor FG Wilson generator sets.
• You are required to attend a training seminar on the proper use of EST.
• You are required to purchase an annual license.

What is the cost of the annual license?

• The cost of the annual license is $700.00; although, the price is subject to change. FG Wilson Latin America & Caribbean does not profit from this license fee.

What special tools or equipment do I need?

• You will need a laptop computer with either a USB or serial port and Windows 2000 or XP. Please keep in mind that EST is fairly demanding on the CPU; hence, the slower the processor, the slower the program will run.

Part Numbers

650-406 – EST Software

915-869= EST Hardware

Please contact the FGW Latin America & Caribbean Service Department to determine if you qualify for a Quote.

Alex Cabrices

Service Advisor

FGW Latin America & Caribbean

P6

Adjusting the Voltage on FG Wilson Generators

WARNING, HIGH VOLTAGE IS PRESENT IN THIS AREA AND THE POSSIBILITY OF ELECTRICUTION EXISTS, EXTREME CAUTION SHOULD BE USED, AND WE RECOMMEND A PROPERLY TRAINED TECHNICIAN TO PERFORM ANY ELECTRICAL REPAIRS OR ADJUSTMENTS.

All FG Wilson generators are shipped with the customers requested voltage pre-adjusted before leaving the warehouse yet sometimes a minor voltage adjustment is required once the unit has been installed and initially started. These adjustments are usually necessary in order to “match” the nominal utility voltage and will help in avoiding transfer issues due to the voltage falling out of the transfer switch parameters.

An example would be a utility nominal voltage of 240 vac and the generator output voltage at 220 vac, depending on the transfer switch settings, this could cause the transfer switch to not accept the generator as a good source due to it being out of the voltage pick-up parameter. The fix is simply to adjust the generator voltage up to 240 vac to match system voltage and the transfer will now proceed normally.

    The voltage adjustments are done by rotating a “pot” or adjustment screw on the voltage regulator while the unit is running. Adjustments should be made to the voltage pot only and should not exceed +/- 5%.

Ralf Heredia
FGW Latin America & Caribbean

Video on Adjusting AVR on FG Wilson Generator R230 AVR

                 

Adjusting Voltage on FG Wilson Generator R230 AVR

Trouble-Shooting Tips 2001 Panel (Series 3)

Continuing our series on troubleshooting tips we will focus this article on fault alarms and the causes and solutions for clearing these.

Fail to Start:

            It is important to note that although this alarm will appear as “fail to Start” it could appear after the engine has started and the board does not see an engine run signal at which time it will shut down on “fail to Start” alarm. The alarm activates after 3 unsuccessful attempts to start also known as over-crank, at this point it looks for a run signal and if not present, it initiates the shutdown/alarm. Conditions that could cause the alarm to activate are as follows:

1.      The engine is given a run command and nothing happens:

·        The battery may be too weak to turn over the starter yet is enough to power the board. Charge or replace the battery

·        The lamp test and battery voltage meter are dead. Check the main fuse F5.

2.      After re-setting the alarm it re-appears after 25 seconds but starter never engaged:

·        Check for battery voltage at EIM wire #4, if no voltage trace back wire to the board for break or chafing.

·        If voltage is present, check cranking fuse on EIM, if good follow wire #51 for continuity to starter solenoid.

·        Check EIM wires #5B and #53 for proper grounding.

·        Check starter for stuck bendix or shorted fields.

3.      The engine cranks but does not start and activates “fail to start” alarm after 3 crank attempts:

·        Check fuel quantity, may have run out of fuel.

·        Check for air in fuel system, bleed if necessary.

·        Check for battery voltage on wire # 3A at EIM, if no voltage trace back wire through link on terminal strip and back to the board.

·        If voltage present check fuel solenoid fuse on EIM, if good follow wire #53 through e-stop, fuel control solenoid, and finally ground.

4.      The engine starts but shuts down on “fail to start” alarm after 25 seconds:

·        Check generator output voltage on wires #108 & #115, check fuses on wires 108,109 & 110, check fuse on voltage regulator, check generator windings and diodes.

·        Check magnetic pick-up and for signal output through wire #57 and #54 on EIM.

Our next article will cover the remaining safety shutdowns for our series 2001 control panel

Ralf Heredia

Service Adviser

FGW Latin America & Caribbean

Training Power Wizard Panel September 14-15th 2006

Powerwizard Control Systems 1.0 and 2.0    

On September 14th and 15th FGW Latin America & Caribbean will be conducting one of its regular FG Wilson product training sessions. The September topic will be on the FG Wilson Powerwizard Control Systems 1.0 &2.0. This training will be in English. The 2-Day course will cover the following topics:

- AC and DC connections from the alternator and engine

- DC charging system and the engine interface module for Powerwizard level one and            - Powerwizard level two control systems

- Control panel set-up, programming and monitoring

- Troubleshooting

- Remote annunciators and remote monitoring

- Service tool and interface software

Cost of the course is $750 USD per participant

Included are all the materials and lunch.

The course will be have limited participation so please contact

Alex Cabrices

Service Advisor

FGW Latin America & Caribbean

Tel: 954-433-2212 ext 19

Fax: 954-433-4431

Alex@FGWilsonMiami.com

Trouble Shooting Tips for FG Wilson 2001 Panel (Part 2)

SAFETY SHUTDOWNS

The 2001 control panel offers 5 engine protection channels or shutdown features, 4 of which are configured by the factory and 1 spare which may be customer configured, they are as follows:

Fail to Start: This protection activates when the engine has been given a start signal and the engine has failed to start. This is factory set to allow 3 attempts to start, each attempt is made up of a 5 second crank cycle followed by a 5 second rest period.

High Engine Temperature: The protection is activated externally by the VDO engine temperature sender. The sender typically switches between 103-105 degrees C (217 – 221 F). This channel is FPT (Fault Protection Timer) protected which means that it will only become active 15 seconds after the engine has started.

Low Oil Pressure: The protection is activated externally by the VDO oil pressure sender. The sender typically switches at 0.8 bar/ 11.75 psi on the 0-5 bar model and 1.25 bar/18.5 psi on the 0-10 bar model. This protection is also FTP protected.

Emergency Stop/Overspeed: This channel combines two protections, the emergency stop will activate once the panel or enclosure (if applicable) emergency stop push button is pressed. The overspeed signal is controlled by the EIM (Engine Interface Module). Once the EIM via the Magnetic Pickup, determines the engine has exceeded the set point, a signal is sent to the 2001 panel and the shutdown activates.

Spare Channel: This protection channel can be configured as either alarm or shutdown by repositioning the blue two-prong link on the 2001 PCB. The protection may also be FPT protected by physically removing link 5A from the PCB.

Protection Activication

To activate any of the five protection channels we require a –ve (neg) to reach the corresponding relay. The relay will energise and at the same time the LED illuminates. Due to the relay energising contact Fx/1 in the fault array will switch and cause CR1 to de-energise hence cutting of the fuel supply to the engine.

On the next article we will get into the inner workings of the control board as it relates to the safety shutdowns.

Ralf Heredia

Service Adviser

FGW Latin America & Caribbean

Trouble Shooting Tips for FG Wilson 2001 Panel (Part 1)

We are starting a multipart series on troubleshooting tips for the 2001 Control System, Starting with this article we will go over the most common issues associated with faults on the 2001 control panel and subsequently we will cover more specific issues in upcoming articles.

INSTALLATION

The first thing we should look at is the installation of the generator and it’s accompanying components. Initial inspection should include checking the following:

•    Proper placement and anchoring of unit on firm and level surface.
•    Check for any signs of physical damage due to shipping or during installation.
•    Adequate ventilation of incoming and outgoing airflow if installed inside a building. (Check installation manual for details).
•    Proper routing and alignment of exhaust system ensuring minimum amount of bends.
•    Correct generator output leads for size and connection to breaker and proper grounding.
•    Proper customer connections to generator terminal board.
(Please refer to the Installation Manual for detailed information on installations)

BASIC START-UP ISSUES

Many basic issues dealing with a no start condition can often be traced to very simple and elementary conditions that can be resolved easily and quickly by performing a visual inspection of the unit and focusing on some of the following items.

•    Is the battery filled with battery acid and is it fully charged (our batteries ship dry) and is it connected correctly to the battery cables?
•    Are the battery cables on tight at the battery terminals and the starter?
•    Check all fluids for proper levels i.e. oil, coolant and battery.
•    Is there fuel in the fuel tank and has the engine been purged of air in the fuel system? Check for loose fuel fittings and fuel leaks.
•    Have the emergency stop buttons been re-set or pulled out? This will prevent the unit from starting and is very common.
•    Has the panel been re-set from any previous faults?
•    Check the main fuse on the terminal block inside the controller box.
•    Check for loose or disconnected wires inside the control box especially the switches and terminal block.

Following these simple steps will undoubtedly resolve most issues related to a “won’t start” condition and will form the basis for performing more detailed troubleshooting techniques if so needed.

Ralf Heredia
Service Advisor

What information do I need when I call FG Wilson for Parts or Service?

Often times when an initial call comes in to FGW Latin America & Caribbean for parts or service the person calling has insufficient information about the unit for the Parts Desk or Service Advisor to be fully helpful and most of the time requires the person calling to go back to the unit to acquire the needed information. FG Wilson provides with each and every generator data plates with information pertaining to that piece of equipment, they are as follows:

Generator Data Plate

This is a large silver colored data sticker with information about the genset as a whole such as;

    Genset Serial Number
    Genset Model Number
    Sales Order Number
    Voltage, Frequency, Connection Type and more

Engine Data Plate

    This is a metal plate mounted on the side of the engine block with the Engine Number specific to that engine, this number is crucial in identifying correct engine parts since there could be literally dozens of engines of the same type and model yet this number identifies this engine exactly and therefore reduces the possibility of ordering the wrong engine parts.

Alternator Data Plate

This is a data plate mounted directly on the AC Alternator which includes the following:
    Alternator Serial Number
    Alternator Frame Number
    Alternator Winding Number

The numbers detailed in bold above are the required numbers from the generator so that you can receive the right parts and the right answers the first time you call.

Ralf Heredia
Service Advisor
FGW Latin America & Caribbean

Never Use Galvanized Piping on Your Fuel Supply Line!

Never supply your FG Wilson generator set with diesel fuel through galvanized piping or diesel fuel that has been stored in galvanized tanks.
Even though this is clearly pointed out in the installation manual provided with your FG Wilson generator set time after time we see early hour failures of injection pumps and injectors due to galvanized piping.
Diesel fuel dissolves the zinc coating and forms a solution that contaminates the fuel supply.
This contaminated fuel will inevitably ends up in the engine’s fuel pump and/or injectors.
One cannot assume this solution will be completely filtered out.
Premature failure will be imminent, if allowed to reach the engine’s internal components.
We recommend black iron, steel or copper piping and storage tanks in order to avert this.

Alex Cabrices
Service Advisor
FGW Latin America & Caribbean

Using Original FG Wilson Parts will protect your investment

In order to ensure maximum operational service life and reduced maintenance costs, always use original FG Wilson parts when servicing your FG Wilson generator set.

Generator sets are designed with auxiliary components that are specified to within precise tolerances; e.g., filter micron ratings.

A perfect example would be FG Wilson generators with the Perkins 1306 HEUI engine (P175HE to P250HE).

The primary fuel filer is rated at two microns – substantially smaller than a human hair and certainly smaller than the micron rating of most aftermarket fuel filters!

The reason for this small micron rating is that there is a piston inside each fuel injector that is used to control the engine’s extremely efficient injection process. These same pistons are lubricated by the system’s diesel fuel after passing through this two-micron filter.

Aftermarket filters with higher micron ratings would allow larger particulates through that could possibly, and most probably, cause damage to the injectors; hence, use original FG Wilson parts, because all filters are not created equal.

Many aftermarket filters may look similar and possibly be less expensive, but looks can be deceiving. A less expensive alternative may cost you more money in the long run.

Alex Cabrices

Service Advisor

FGW Latin America & Caribbean

Tel: 954-433-2212 ext 19

Fax: 954-433-4431

Alex@FGWilsonMiami.com

Protecting your FG Wilson Generator through proper Maintenance

An essential factor to increasing the life of your generator set is proper maintenance of the prime mover. “Prime mover” is the industry term for the section of the generator set that rotates or “moves” the rotor of an AC alternator. This rotation is essential to producing or “generating” electricity. FG Wilson generally uses Perkins diesel engines as prime movers.

It can be considered proper maintenance for one to strictly adhere to or better that of the manufacturer’s recommended maintenance schedule. This information can be located in the Perkins section of your generator set user’s manual.

One of the most critical maintenance items to adhere to in the manufacturer’s recommended maintenance schedule is the interval, or frequency of the engine oil and filter change. This will have a direct impact on the service life of your generator set. It is imperative to know that the manufacturer’s recommended interval is based on fuel sulfur content of less than 0.5% and in some cases, as low as 0.2%. Diesel fuel with sulfur content that low can rarely be purchased in Latin America & the Caribbean. It is recommended to reduce the amount of hours to half of the manufacturer’s suggested; e.g., if the manufacturer has published to change the oil every 500 hours at < 0.5% fuel sulfur content, it is then recommended to increase the interval and reduce the time down to every 250 hours (>1.0%). We suggest this be done regardless, since fuel sulfur is rarely tested by the end user and will most probably be higher in Latin America & the Caribbean. There is a general footnote in most every Perkins manual that states the following:

Alex Cabrices

Service Advisor

FGW Latin America & Caribbean

Training on FG Wilson Power Wizard Panels

Powerwizard Control Systems 1.0 and 2.0

    

On August 7th and 8th, 2006 FGW Latin America & Caribbean will be conducting one of its regular FG Wilson product training sessions.

The August topic will be on the FG Wilson Powerwizard Control Systems 1.0 &2.0

     This training will be in English

      The 2 Day course will cover the following topics

AC and DC connections from the alternator and engine,

DC charging system and the engine interface module for Powerwizard level one and Powerwizard level two control systems

Control panel set-up, programming and monitoring

Troubleshooting

Remote annunciators and remote monitoring

Service tool and interface software

Cost of the course is $750 USD per participant

Included are all the materials and lunch.

The course will be have limited participation so please contact

Alex Cabrices

Service Advisor

FGW Latin America & Caribbean

Tel: 954-433-2212 ext 19

Fax: 954-433-4431

Alex@FGWilsonMiami.com

Resetting Faults and Events on FG Wilson Power Wizard panel

   

Testing your Battery and Starting Circuit on your FG Wilson Generator

T

here are several techniques in the industry for testing the condition of the batteries in your generators. The first and least accurate is the Open Circuit Voltage test (OCV) which measures the voltage of the battery using a volt meter, although it may read an accurate voltage on the battery, it cannot tell you whether the battery will produce the necessary cranking amps during the next crank cycle. Secondly is the Specific Gravity Test which measures the state of charge of a battery using a hydrometer on each cell of the battery; however it will also not tell you if the battery is capable of producing the required cranking amps during a start sequence. Thirdly is the Load Test which is accomplished using a device that is connected to the battery posts and is activated for 15 seconds placing a resistive load on the battery, this is the best of all three methods since it will confirm the cranking capacity of the battery depending on the size of the tester. There is however a forth and more complete method of checking the state of your batteries on your generators, this involves testing the over crank circuit of the generator by allowing the unit to complete it’s full over crank sequence (usually 3 attempts). This accomplishes several things, first it tests your over crank safety circuit, secondly it tests your batteries condition through 3 complete cranking cycles, and lastly it tests the condition of your starter and starting circuits and wires under the most extreme circumstances, if your battery can hold up to the over crank test then you know it is in good condition. While this is the true test for your starting system you should not abandon the other methods all together, since using all of the methods mentioned here will play a more complete role in determining the state of your battery and starting system condition.

 

FG Wilson ATI Transfer switch not transferring to generator power?

We have recently experienced several calls on new installations regarding units refusing to transfer to generator load. The gensets would start and shut down in the auto mode but would not transfer. After verifying system voltage, further investigation determined that the generator output voltage was not matched to utility voltage and in fact was approximately 20 to 30 volts lower, the transfer switch always senses system voltage and determines if it is within pre set parameters before transferring to that load, in these cases a simple adjustment of the generator output voltage resolved the problem and the units began performing perfectly.