Introduction to Perkins Powered

Generators
Perkins 400 Series

TEACH

COACH

LEARN

Perkins Shibaura Engines Limited

1996 saw the opening of the
Perkins/Shibaura joint venture
production facility on the
Peterborough site

400 Series Engine Family

Stage 3 Compliant

404D-22
Engine Family

2.2 litres

4 cylinder

403D-15

1.5 litres

3 cylinder
T= Turbocharged, TA= Turbocharged Air to Air Aftercooler, e.g. 404D-22TA
C & D emission compliant engines available

400 Series - Engine Nomenclature

Engine Type

Build Number
Year of Manufacture

GN 65432 U 120024 H
Engine serial number
Engine Family 400
Series

Country of
Manufacture

Engine Nomenclature
400C Series
Configuration
402C-05
403C-07
403C-11
403C-15
403C-17
404C-15
404C-22
404C-22T

Family Name
HBxxxxx
HDxxxxx
HHxxxxx
HLxxxxx
xxxxx
HNxxxxx
HPxxxxx
HRxxxxx

400D Series
Configuration
402D-05
403D-07
403D-11
403D-15
403D-15T
403D-17
404D-15
404D-22
404D-22T

Family Name
GGxxxxx
GHxxxxx
GJxxxxx
GKxxxxx
GLxxxxx
xxxxx
GMxxxxx
GNxxxxx
GPxxxxx

New Product
Offerings

Bore (mm)

Stroke
(mm)

Swept
Volume
(litres)

402D-05

67

72

0.507

403D-07

67

72

0.762

403D-11

77

81

1.131

403D-15

84

90

1.496

403D-15T

84

90

1.496

403D-17

84

100

1.662

404D-15

77

81

1.508

404D-22

84

100

2.216

404D-22T

84

100

2.216

404D-22TA

84

100

2.216

Emissions compliance levels

EC

Europe

EPA North America

19P<37
37P<56
56P<75

P<8
8P<19
19P<37
37P<56

2005
2006
2007
2008
2009
Stage II (5.5, 9.5, 0.8) Stage III A (5.5, 7.5, 0.6)
Stage II (5.0, 8.3, 0.4)

Stage III A (5.0, 4.7, 0.4)

Tier 2 (8.0,
Tier 2 (6.6,
Tier 2 (5.5,
Tier 2 (5.0,

Tier 4B (6.6, 7.5, 0.4)

Tier 4B (6.6, 7.5, 0.4)
Tier 4A (5.0, 7.5, 0.3)

7.5,
7.5,
7.5,
7.5,

0.8)
0.8)
0.6)
0.4)

Tier 3 (5.0, 4.7, 0.3 )

2010

2011

2012

2013

2014

2015

Stage III B (5.0, 4.7, 0.025)

Stage III B (5.0, 3.49, 0.025)

Tier 4B (5.0, 4.7, 0.03)

Tier 4B (5.0, 4.7, 0.03)

400 Series products cover several power bands which, post- Stage II/Tier
2, will have differences in emissions limits, phasing, and nomenclature
Depending on rated power, 400 Series products will be certified to
EU Stage 3A
EPA Tier 3
EPA Tier 4A
EPA Tier 4B

400D Industrial Power Range

Expanded product line-up provides complete certification
coverage
Existing models have been re-developed to meet the new
legislation
Additional models have been introduced to provide greater
coverage and flexibility
Introduction and changeover will take place through
2007 to meet the legislation introduction date of
1 January 2008

400D Product Enhancements

Characteristic

Change

Achieved Improvement
400C to 400D

Benefit to customer

Ratings

Current 400C ratings maintained

Ease of changeover in installation

New Models

403D-17, 403D-15T,

Increase options for customers in midrange, TA engine increases power range

by 10%

404D-22TA

Installed
Package Size

Engine envelope as 400C

Lower fan position option on
403D-15 upwards

Ease of changeover in installation/reduce

package size

Improved cooling allows smaller

radiator to be used

Noise

Further Reduction in bare engine dBA

+ low noise fan options

Easier to meet machine noise legislation,

cost saving in noise attenuation

SFC

Maintain Tier 2 levels

Level cost of ownership

Governing

Improved governing recovery and

stability

Improved driveability, lower idle speeds

available

PTO

SAE A-A and SAE A PTO fixing

introduced as standard:significantly
increased torque available

SAE standard fitting; more choice of

hydraulic pump suppliers;

404D-22TA More power!

Builds on the success of the 404C-22T.

Turbocharged and Air-to-Air after-cooled engine
increases the power of the 400 Series range by
10%!
Power kW (hp)
49.2 (66.0)

Rated Speed rpm

2800

Max Torque Nm @ rpm

200.0 @ 1800

Same engine package size as the turbo equals

class-leading power to envelope and power
density

Customer specified after-cooler

Level Cost of Ownership,

Easier Servicing
Servicing Achievements

500 hours service interval as standard

1,000 hours tappet (lash) adjustment

New servicing options available

dipstick either side
remote oil filter (under development)
timing case oil filler cap

Oil consumption as 400C

Measured SFC as 400C

400 Series Technology

Progression
Stage 1
100 Series

Stage 2
400C Series

Stage 3+
400D Series

IDI
Naturally aspirated
2v Cylinder heads

Turbo-Charged
2v Cylinder Heads

2v Cylinder Heads

Improved Governing

Improved governing

Timing control

Significant noise improvement

Constant speed
electronic governor
option

After cooling

Minimise Customer Impact by Stage

Variable Speed electronic

governor option

400D - Even Quieter!

Already leading the market in low noise, 400D provides over 2dB(A)
loaded noise improvement!

Direct //$ customer value of lower sound attenuation cost on machine

Estimated that sound

attenuation on a machine costs
50-75 per dB(A) of reduction

SPL (dBA) 100% Load

90.0
88.0

Reduced fan speed capability

due to improved cooling

SPL (dBA)

86.0
84.0
82.0

Cylinder block redesign for

noise improvement

80.0
78.0
76.0
1600

1800

2000

2200

2400

2600

Engine Speed (rpm)

403C-15

403D-15

2800

3000

3020

Timing case stiffening for

noise improvement

Low noise fan options

General Information
Compression Ignition (Diesel)
In-Direct Injection
2, 3 or 4 cylinder, four stroke engine
Liquid cooled
Linerless
Three piece helical gear train
Excellent fuel consumption
Emission Compliant to Tier 2 and Tier 3

Identify the engine components

10

11

12

13

Cylinder Head Face (403C-11)

Pre combustion
chambers

Additional
cooling paths

Pre-combustion Chamber

Sectioned cylinder head

Top Cover Design

Streamlining of Inlet Manifold

Closed Circuit Breather (CCB)

Environmental benefit
Proven system
Cost effective design
Gradeability to 35 degrees
Fitted to top cover

Closed Circuit Breather (CCB)

Adapter used on Turbo
variants
Engine installer must route
pipe to turbo inlet
Diaphragm vent hole

Crankshaft Assembly

Bearing holders
Holder
retaining
bolts

Rear main oil seal

Crankshaft Assembly

Crankshaft Bearing Holder

Positioning
Thrust Washer
groove
Bite mark
on outside edge
Plain

Bite mark
on inside edge

4 - Palm (Rear)
3
2

1 - Nose (Front)

Piston Design & Cylinder Overhaul

NOTE : Cylinder will not be
rebored for overhaul
User must purchase a tested
long engine, due to tolerances
required with calibration and
setting of timing and fuel
delivery.

New Piston and Oil Control Ring

404C.22T New Piston and Top Ring

Lubrication Circuit

Oil Filter Design

Lubricating oil Change Every 500

Hours
(Or once per year)
Drain oil when hot.

Always change oil filter at same time.

Fit new filters hand tight only.
Change Fuel Filters
Check Drive (V) Belt tension
Check Batteries, top up if required.
Check Air filter

Lube oil Filter

Oil Feed Pipe

Oil Pressure Relief Valves

Oil Pump (Exploded View)

Shims

Fitting Idler Hub

Special service tool is needed to install the idler hub.

3 Sizes of tool available for different engines.

Oil Specification
Recommended fluids include API CH-4
Maintained drain plug position.
Service Period maintained at 500 Hours

Camshaft
The Camshaft now has three bob weights on the 400D engine,
to assist with governing.

Improved Governing
Governing Achievements
Significantly improved response, recovery times and constant speed
load acceptance over 400C
8% Governing on Variable ratings
Variable Speed Electronic Governor (ECG) Option

How?
1.

Brand new Governor design incorporating

optimised lever ratio for improved engine
response

2.

Improved tolerance and manufacturing of

Governor components

All Speed Governor

1

Sto
p

7
9
2

10

3
8

11
Ma
x.

Removing the governor link

Governor Rack

Timing case assembly

Start Spring

Angleich Governing System

Angleich unit
Gives tailored torque curves
and increased torque back
up
Improved control of low
speed ratings
More robust design gives
longer life

Angleich Governing System

Removal of Front Housing

New Removal Procedure for
front housing
Setting engine in position for
fitting new housing
Ensuring more accurate setting
New Calibration tooling needed.
(see notes)

Note : For full detailed description see SOTA manual, (brief

description below)
IF BCD is fitted further instructions can be found

Setting of Fuel screw on new housing

Note : For full detailed description see SOTA manual, (brief

description below)
IF BCD is fitted further instructions can be found

Final Setting of Front housing.

Note : For full detailed description see SOTA manual, (brief

description below)
IF BCD is fitted further instructions can be found

Genset Compensator Spring

Compensator
Spring

Polished slider
contact surface

Boost Compensation Device

Installed on Turbo Charger Engines

Prevents Overfuelling
Aids Smoke Limiting
NOTE : For Removing and refitting see SOTA manual.

High Idle Tamper Evident Cap

Fitted Additionally to Maximum Fuel and Speed caps

New style nut

Tamper evident cap

The Fuel System

Injectors

Injection
pump

Fuel filter
Fuel feed pump
From
Fuel
tank

Cassette type fuel injection pump

Delivery
Valve

Cassette fuel pump

Runs on main camshaft
Rack operated delivery
valves

Fuel
inlet
Rack
Pump
housing

Cam follower

Fuel injection pump timing

Cassette type pump

All fuel pumps no longer spill timed.

Pump is fitted with different thickness shims, for different timing
settings.
Thicker Shim retards timing. Fit new shims every time pump is
reinstalled. Replace shims of same size.

Fuel Injection Pump

(103.15)

Introduction of Compact Timing

Device

Delivery valve plunger

Introduction of Compact Timing

Device

CTD sub
port

CTD Cut

Fuel Injectors

Injector spray patterns

Spray pattern difference
between single and
multi-hole injectors

High Pressure Pipes Optimised

Fuel Pump Return

Vent pipe

Vent pipe washers

Only 1 special washer per injector

Fuel Filtration

Genuine Powerpart filters

only!!

Earlier type
Japanese sourced
filter

Fuel Filter Design

Fuel Lift Pumps

Fuel Lift Pump Design

400D Cooling Improvements

Redesigned cylinder head coolant channels
More even flow of coolant, less hotspots
Top tank temperature increased from 1100 to 1120

404C-22

20.6kWm @ 1500rpm

Ambient Clearance

53.0C

404D-22

20.6kWm @ 1500rpm

Ambient Clearance

59.0C

6C
improvement

>10% improvement in ambient clearance!!

Liquid Cooled Engine

Daily Checks
Check Coolant (Water) level.

Cooling System

COOLING SYSTEM

A point to remember is that 1/16" (1.58mm) of scale retards as

much heat transfer as 4 " (114mm) of cast iron!
Loose scale within the cooling system will also cause
blockages within
the radiator, oil coolers and charge coolers
Without inhibitors in the coolant normal engine vibration causes
vacuous pockets on many internal surfaces (especially cylinder
liners).
The chemicals within the inhibited coolant effectively put a
protective layer on all the internal surfaces within the engine.
The following diagram should clarify this explanation.

COOLING SYSTEM

Coolant Pump

Thermostat

404C.22T Bypass Blanking

Thermostat

Bypass blanking
thermostat used on
turbo as standard

403C-11 Thermostat
Separate
thermostat
assembly

Bypass
pipe

Thermoswitch
set to 110
degrees

Alternative oil pressure switch

Engine Protection.
The Engine is protected from the following situations:
Low oil pressure (LOP)
High Water [coolant] temperature (HWT)
Overspeed (OS)
An option is available for low coolant level (LCL, or LWL)
Using switches / sensors

Coolant (Water) Temperature

sensor
2,500

Ohms

1000
20 C
Thermistor sensing devices
Resistance (Ohms) varies with temperature
The Sensor has a Negative Temperature Coefficient (NTC). As temperature
increases its resistance decreases
Sends signal to EIM / Power Wizard

Oil Pressure Sensor

Engine Oil Pressure
Sensor
Used for engine
protection,
Warning/Shutdown
Provides signal for
pressure gauge,
Sends signal to EIM, or
Power Wizard

Heavy Duty Electrical Connectors

Designed to reduce contamination/corrosion to
terminals

Heavy Duty Electrical Connectors

Electrical shut off solenoid (ESOS) with fly lead

Heavy Duty Electrical Connectors

Fly lead omitted on some later builds

Speed Pick Up Sensor (MPU)

1. Locknut.
2. Pick-up (MPU)
3. 1mm air gap.
4. Starter gear tooth
5. Flywheel housing

Any Questions
before the next
section?

Installation Considerations.
There are a number of things we need to consider.
Ambient Temperatures
Access
Environment
Noise

UNDERSTANDING NOISE AND ITS EFFECTS

130
UNCOMFORTABLY
LOUD

VERY LOUD

MODERATELY
LOUD
QUIET
VERY QUIET

110
90

PNEUMATIC DRILL

1500KW SET AT 7 METER

85 DBA HEAVY TRAFFIC AT 5 METERS

80

80 DBA 50KW SET AT 7

METERS

60

NORMAL CONVERSATION

40

ALLOWABLE HUMAN EXPOSURE IN

HOURS

20

90DBA 8 HOURS

105DBA 1 HOUR

DBA

100DBA 6 HOURS

110DBA 30 MINUTES
115DBA 15 MINUTES

De-rating for Altitude.

Naturally aspirated engines will create slightly more
exhaust smoke.
Always go on the side of caution.
Check the specification information before Quoting!

Typical De-rate chart.

?
ANY QUESTIONS?

Leroy Somer Alternator

Features
Low distortion
High efficiencies
Adaptable for
both
PMG & AREP
systems

Alternators (Exploded view)

Alternator Shunt + PMG Principle

AVR (Automatic Voltage Regulator)

POWER FACTOR, KW, KVA

E- VOLTAGE
W-WATTS

I-CURRENT

KVA IS THE APPARENT POWER IS THE SUM OF THE NEGATIVE POWER

AND THE POSITIVE POWER (SHADED AREA)
KW IS THE REAL POWER WHICH IS THE POSITIVE POWER
PF IS THE REAL POWER DIVIDED BY THE APPARENT POWER

ALTERNATOR AND ACCESSORIES

RECTIFIER ASSY
EXCITER ASSY

STATOR

ARMATURE

END BEARING
AVR

TYPICAL DESIGN

Engine Interface Module.

E.I.M
Engine Interface Module (EIM)
This unit is a sealed engine mounted module
that provides switching relays for the starter
and ignition circuits. It also provides overspeed protection. There are automotive
type fuses protecting each circuit. LEDs light
to show that the circuit is energised. The overspeed is factory set at 55Hz, the indicator
light should just be off, although it will
occasionally flicker.

PowerWizard

Level 1.0 &

Level 2.0
Control Systems Training

Systems Comparison

New
Systems

Level 2

Level 3

Level 4

So
lu
t io
ns

Current
Systems

Level 1

PowerWizard
Level 3.0

PowerWizard
Level 4.0

Overview

Common parts from 10 2000kVA;

9 32vdc Operating range

2 Display Languages;

Technician English or Customer language

Common Engine wiring system

Programmed using standard EST Service tool

Sheet steel module

Spare fault channels

J1939 communication with Electronic Control Modules

Level 1.0 Control System

Alarm / Shutdown Protection - Fail to Start, Low Oil Pressure, High Coolant Temperature,
Overspeed and;

Low / High Battery Volts

Static Battery Charger Failure

Underspeed

Loss of Speed signal detection

2 spare fault channels

20 Event Fault log

J1939 CAN 1 data link for Service tool

No remote communications

AC Metering Volts, Amps, Frequency

DC Metering Battery Volts, Hours Run, Engine Jacket Water Temperature, Lube Oil
Pressure, Engine Speed

Control Architecture Level 1.0

Hardwired senders on
mechanical engines
J1939 on electronic engines

Level 2.0 Control System

Auto Start controls, protection and metering as Level 1.0 and;
AC Metering kW, kVA, kVar, Power Factor, kW hours, kVar hours
DC Metering Crank Attempt counter, Start counter
Alarm / Shutdown Protection - Under / Over Volts, Under / Over Frequency, Overcurrent
4 spare fault channels
CAN 2 J1939 Accessory Data Link
Digital I/O modules

Remote Annunciator

Real time clock

Service interval counter

Modbus remote communications using

RS485 (2 wire)

Control Architecture Level 2.0

CAN J1939
expansion
network
Hardwired
senders
CAN
J1939

Modbus

A1

A7

AC
Remote
Service
Annunciator
Tool
Sensing
Communications
Alternator
Connection
Communications and
AVRConnection
B6
Connection
pointAc Sensing
point
point
CANBUS
connection
points
DC Controls
Fuses
Magnetic
CTs

pick up
Breaker and
Power connection
options

Standard Grid Reference

Control System Components with 400
options
Series
engines System
Digital Output

D3
Sender Inputs

Relay Outputs

Digital Inputs

PowerWizard
Digital Module

E7
Oil & Temp
sender earth

EIM
Magnetic
pick up

Dc System Components
on Perkins 400
Standard
Battery Charging
Series engines
Fuel control
Alternator

options

Pre-glow
solenoid

Starter
Motor

Control
System
Connector
Oil & Temp
senders

Panel Layout
Alarm Lamp

Shutdown
Lamp

Lamp Test
Key

Alarm Mute/
Acknowledge
Key
Engine
Overview
Key

Ac
Overview
Key

Run Key
Stop Key

Auto Key
Escape Key
Enter Key
Cursor Keys

Navigation Keys
AC Overview The AC Overview key will navigate the display to first screen of AC information.
Engine Overview The Engine Overview key will navigate the display to the first screen of engine
information.
Alarm Acknowledge / Mute Pressing the Mute / Acknowledge key will cause the horn relay output to turn
off and silence the horn. Pressing the key will also cause any yellow or red flashing lights to turn off
or to become solid depending on the active status of the alarms. The Acknowledge key may also be
configured to send out a Global Alarm Silence on J1939 Data Link which will silence horns on
annunciators.
Lamp Test Pressing and holding the Lamp Test key will cause all of the LEDs and the display screen
pixels to turn on until the key is released.
RUN Pressing the RUN key will cause the engine to enter the RUN mode.
AUTO Pressing the AUTO key will cause the engine to enter the AUTO mode.
STOP Pressing the STOP key will cause the engine to enter the STOP mode.
Escape The ESCAPE key is used during menu navigation in order to navigate up through the menu
structure. Each key press causes the user to move backwards/upwards through the navigation
menus. The Escape key is also used to cancel out of data entry screens during setpoint
programming. If the Escape key is pressed during setpoint programming, none of the changes
made on screen will be saved to memory.
Enter The Enter key is used during menu navigation to select menu items in order to navigate
forward/downward in the menu/sub-menu structure. The Enter key is also used during setpoint
programming in order to save setpoints changes. Pressing the Enter key during setpoint
programming causes setpoint changes to be saved to memory .

Alarm Indicators
Yellow Warning Light A flashing yellow light indicates that there are
unacknowledged active warnings. A solid yellow light indicates
that there are acknowledged warnings active. If there are any
active warnings the yellow light will change from flashing yellow
to solid yellow after the Alarm Acknowledge key is pressed. If
there are no longer any active warnings, the yellow light will turn
off after the Acknowledge key is pressed.

Red Shutdown Light A flashing red light indicates that there are
unacknowledged active shutdown events. A solid red light
indicates that there are acknowledged shutdown events active. If
there are any active shutdown events the red light will change
from flashing red to solid red after the Alarm Acknowledge key is
pressed. Any condition that has caused a shutdown event must be
manually reset. If there are no longer any active shutdown
events, the red light will turn off.

Panel Configuration
The control module is software configured
Set points can be adjusted by the operator or service
engineer from the front of the module or by using the
service tool depending on the password level required
Set points are password protected
Display language is controlled by the base flash file.
Each file contains a customer language and technician
English
The service tool can be used to download new base
flash files to the module

The base flash files are referenced by the panel serial

number and can be e-mailed from FG Wilson for that serial
number

Control modules cannot be reprogrammed to different

levels

Menu Tree

Password Protection

There are 3 levels of password protection on the PowerPort control panel.

The level of password protection that is required for each setpoint is identified on the parameter
setpoint entry screen. A security level identification number 1, 2, or 3 next to a padlock symbol is
displayed on the parameter setpoint entry screen.

If the password level is currently at the required level of protection when viewing a parameter, the
padlock will not appear.

Drop to Minimum Security Level

The first option on the security screen is DROP TO MIN LEVEL. This would be used when
leaving the control. If it is not initiated manually, the controller will automatically
revert to minimum level after 10 minutes.
From the MAIN MENU, select the CONFIGURE menu.
a. Press the ENTER key in order to select CONFIGURE. SECURITY will be highlighted.
b. Press the ENTER key in order to select SECURITY. DROP TO MIN LEVEL will be
displayed.
c. Press the ENTER key to select DROP TO MIN LEVEL
d. The system will now be at the minimum level of security
Note: The current level of security is displayed at the top of he display any time the system
is in the SECURITY screen.

Password Protection
Enter Level 1 or 2 Password
From the MAIN MENU, select the CONFIGURE menu.
a. Press the ENTER key in order to select CONFIGURE. SECURITY will be highlighted.
b. Press the ENTER key in order to select SECURITY. DROP TO MIN LEVEL will be
highlighted.
c. Press the DOWN key in order to highlight ENTER LEVEL 1 OR 2
d. Press the ENTER key in order to select ENTER LEVEL 1 or 2. ENTER PASSWORD FOR
DESIRED LEVEL is displayed. Also shown is a 16 digit display with 0 highlighted at the
far right.
e. Press the UP or DOWN key in order to select the desired number.
f. Press the RIGHT key in order to highlight the next character to be entered. Press the
UP or DOWN key in order to select the desired number.
g. Continue until the correct password has been entered for the corresponding level. When
all digits of the password are correctly entered press the ENTER key. The current
level of password protection is displayed and parameters can be set.
Note: The panel will go to the highest level of security authorized by the password.
Note: Passwords can have to 16 digits but can use as few as 1 digit.

Password Protection
Enter level 3 password
From the MAIN MENU, select the CONFIGURE menu.
a. Press the ENTER key to select CONFIGURE. SECURITY will be highlighted.
b. Press the ENTER key in order to select SECURITY. DROP TO MIN LEVEL will be
displayed.
c. Press the DOWN key in order to highlight ENTER LEVEL 3. Press ENTER to select
ENTER LEVEL 3 .
d. A 16 digit number is shown and ENTER RESPONSE is highlighted. Copy this number
and call the factory to obtain the password, do not exit from this screen.
e. When the factory response is received, press ENTER to select ENTER RESPONSE.
ENTER RESPONSE is displayed. Also shown is a 16 digit entry field where the
password will be entered.
f. Press the UP or DOWN key in order to increase or decrease the highlighted digit to
the correct password.
g. Press the RIGHT key in order to highlight the next character to be entered. Press the
UP or DOWN key in order to increase or decrease the highlighted digit to the
correct password.
h. Continue to set all 16 digits until the factory provided password is displayed.
i. When all digits of the factory password are correctly entered, press the ENTER key.
The current level (LEVEL 3) of security is displayed and parameters can be set.

Password Protection
Change level 1 or level 2 password
From the MAIN MENU, select the CONFIGURE menu.
a. Press the ENTER key in order to select CONFIGURE. SECURITY will be highlighted.
b. Press the ENTER key in order to select SECURITY. DROP TO MIN LEVEL will be
highlighted
c. Make sure that the current level of security is at least as high as the level of the
password to
be changed.
d. Press the DOWN key to highlight CHANGE LEVEL 1 PSWD. Press the ENTER key to
select CHANGE LEVEL 1 PSWD
e. CHANGE LEVEL 1 PSWD is displayed. Use the cursor keys to set the new password.
f. Press the RIGHT key in order to highlight the next character to be entered. Press the
UP or DOWN key in order to increase or decrease the highlighted digit to the desired
number.
g. Continue until the desired password is displayed.
h. Press the ENTER key. The password is now set.
Note: To change level 2 password, substitute CHANGE LEVEL 2 PSWD for CHANGE LEVEL
1
PSWD in step 1.d above.
Note: To disable a security level, set the password to a single zero.

Digital Inputs
There are 6 digital inputs on Level 1.0 and 8 digital inputs on Level 2.0;

4 of these inputs will always be used;

Digital Input #1 Is used for the emergency stop.

Digital Input #2 Is used for remotely starting and stopping the generator set. If the input is
active and the engine mode switch is in AUTO, the engine will attempt to start and run. Once the
input becomes inactive the engine will enter into cooldown (if programmed) and then stop.

Digital Input #3 Is used for High Engine Temperature shutdown

Digital Input #4 Is used for Low Oil Pressure shutdown

The remainder of the inputs can be configured. The main purpose for the other
Digital Inputs is to add additional monitoring capabilities. The inputs can be
configured by going to the Event I/P Functions parameter under the Setpoints
menu. The Digital Input parameter can only be set to Active High or Active Low
in order to initiate a High Warning, Low Warning, High Shutdown, Low Shutdown, or
Status.

Data Links
The digital module has up to three different data links depending on level:

Two CANBUS (J1939) Data Links

Used for local communication among modules associated with a single Genset e.g.
ECM, Annunciators etc.

Operates at speeds up to 250kbps

CAN 1 is used to connect from the digital module to an ECM

CAN 2 is used by the Remote Annunciator

The service tool should be connected to the Can 1 connection to enable

programming of the digital module
The service tool should be connected to the CAN 2 connection to enable
programming of the Annunciator if the Annunciator is connected

One RS485 SCADA (Systems Control And Data Acquisition) Data Link

Uses MODBUS protocol at speeds up to 2.4kbps

Can be used to connect remotely through a modem using a RS485 to RS232 converter

Half Duplex connection (2 wires)

Password levels are to restrict access

Additional I/O Modules

Annunciator Module

16 channel display unit for remote information about the current system status.

Can be used to announce faults and/or status signals, it also allows the operator to silence
the horn or acknowledge faults to the system.

Connects to the CAN2 J1939 data link on the PowerWizard Level 2.0 module

There are 17 pair of LEDs on the annunciators front panel;

16 pairs of LEDs are used to announce events, diagnostics, and ready signals

17th pair of LEDs is used as combined network/module status LED to inform operator of a
problem with the data link connection.

Each pair of LEDs consists of two of the following 3 colors: green, yellow, and red.

E.g. A pair of red and yellow LEDs may be configured for Engine Oil Pressure. If a low
engine oil pressure Warning is read over the data link, the Annunciator will flash the
Yellow LED and the siren will sound. If the low engine oil pressure Shutdown is read
over the data link, the Annunciator will flash the Red LED and the siren will sound.

Maximum distance 240metres from generating set

Programmed using Electronic Service Tool

In the the Configuration screen. Each LED pair has four settings: Suspect Parameter
Number (SPN), Trigger Type, Trigger Severity Level, and Failure Mode Identifier (FMI).

Additional I/O Modules

Thermocouple Module

The Thermocouple Module (TC) is capable of reading twenty inputs from

thermocouples and is also capable of generating diagnostics. The diagnostics that
are generated by this Module are maintained in non-volatile memory

The Thermocouple Module will read the inputs and then calculate the temperature
in Celsius. The Thermocouple Module will then broadcast the information onto the
J1939 data link. The PowerPort Module will read the information from the
Thermocouple Module and display the information on the display screen.

The Thermocouple Module is capable of storing twenty diagnostics log entries.

The log can be viewed from the PowerPort Module. All of the diagnostic messages
are broadcast on the J1939 data link. The PowerPort Module reads these
messages and reacts depending on its settings. Any of the inputs can be disabled
to prevent unnecessary diagnostic faults.

The Thermocouple Module is configured by using EST on the primary data link.

Additional I/O Modules

Discrete Input/Output Module

This Module is capable of reading twelve discrete inputs, operating eight relay
outputs and can be mounted on the Genset or remotely. It is configured using EST.

The Module has twelve inputs with four return channels. These inputs can be
activated by either switching to a return or to battery negative.

Inputs that generate a warning message will auto-reset whenever the input is
removed. Inputs that generate a shutdown message will continue until the input
returns to a non-active state and a reset message is received on the J1939 Data
Link.

The Discrete I/O Module has eight " Form C" relay outputs. Each output can be
configured for either general or specific events.

For general events, each output activates whenever any Alarm Condition, Shutdown
Condition, or Alarm and/or Shutdown Condition exists.

For specific events, each output activates when the diagnostic message contains the SPN
and FMI combination that matches the SPN and FMI combination that is programmed for that
particular output.

Additional I/O Modules

Resistive Temperature Device Module

This Module is a temperature scanner capable of reading eight Platinum RTD

inputs. The eight Platinum RTD inputs can have two, three, or four-wire
configurations.

The Module is also capable of generating diagnostics. The diagnostics that are
generated by the RTD Module are maintained in non-volatile memory. The RTD
Module is capable of storing the twenty diagnostic log entries.

The Resistive Temperature Device (RTD) Module will read the inputs and then
calculate the temperature in Celsius. The RTD Module will then broadcast the
information onto the J1939 data link.

Each of the 8 inputs have sensor diagnostics in order to detect open or short
circuits that go to the RTD sensors. Over temperature warnings and Shutdowns as
well as Under temperature warnings are detected by comparing the measured
temperature to the Low Warning, the High Warning, the High Shutdown
temperatures stored in the module.

Service Tool

The new control modules will be supported by Perkins EST Tools

CANBus J1939 Codes

Failure mode identifier (FMI)

Type of failure that has been experienced by the component

Suspect Parameter Number (SPN)

The SPN is a number that identifies the specific component of

the electronic control system that has experienced a
diagnostic code.

Parameter Group Numbers (PGN)

Parameter Groups are organized according to Generator,

Utility, and Bus related parameter quantities.

Summary
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Competitively priced, 21st century product

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Increased quality and reliability

Industry leading family of control systems