Northern Lights OWN-GEN, WaveNet OWN-GEN Installation And User Manual

OWN-GEN

WaveNet Digital Monitoring System

General Installation

and User Manual

Marine Generators | Marine Diesel Engines | Land-Based Generators

Northern Lights

4420 14th Avenue N.W.
Seattle, WA 98107
Tel: [phone]
Fax: [phone]

Copyright ©2012 Northern Lights, Inc.
All rights reserved. Northern Lights™, and
the Northern Lights logo are trademarks of
Northern Lights, Inc.

Printed in U.S.A.
PART NO.: OWN-GEN 1/12

USER MANUAL

for WaveNet Generator Set Controllers

Table of Contents

WaveNet Specifi cations .....................................2

GROUP 1 - WAVENET CONTROLLER SERIES

1.1 This Manual...........................................3

GROUP 2 - RECEIVING, HANDLING & STORAGE ..4
GROUP 3 - INSTALLATION & WIRING

3.1 Safety Information ................................. 5

3.2 12/24 VDC System Operation ...............5

3.2.1 Relays ................................................6

3.2.2 Relay Fuses .......................................6

3.3 WaveNet Terminals ........................6 - 10

3.3.1 Current Transformer Wiring Note .....10

GROUP 4 -

4.1 Power-Up ............................................ 10

4.2 Controller Alarming ............................. 10

4.3 Controller States ..........................11 - 12

4.3.1

4.4 WaveNet Start / Stop Behavior ....12 - 13

4.5 Controller Sleep ..................................13

4.6 WaveNet Menu System Operation ......13

4.7 Basic Menu .........................................14

4.7.1 Clock Setup ......................................14

4.7.2 Basic Setup ...................................... 15

OPERATION & BASIC USER CONFIGURATION

Locking the WaveNet Screen in Run Mode

. 12

4.7.3 Event History Log ...........................16 - 17

4.8 WaveNet LED Status Indicators ..........18

4.9 Lamp Indication Meanings ............18 -19

4.10 Warnings & Failures ...................19 - 20

4.11 Genset Online ...................................20

GROUP 5 ­GROUP 6 RECOMMENDED MAINTENANCE
GROUP 7 - WAVENET REMOTE PANEL

7.1

7.2

7.2.1 Genset Controller’s Name ................22

7.2.2 State .................................................22

7.2.3 Status Mark ...................................... 22

7.3 On-Line Genset Parameter Mode 22 - 23

GROUP 8 - APPENDEX A: ACCESSORY LIST

8.1

8.2 CT’s (Current Transformers) ...............24

8.3

8.4 WaveNet Fusing ..................................24

GROUP 9 - APPENDIX B: ADDITIONAL DRAWINGS

ADVANCED SETUP ..........................20

.....20

Remote Unit Settings
On-Line Genset Status Mode

WaveNet Controller Harness - Accessories

WaveNet Replaceable 12/24 VDC Relays

................................21

...............21 - 22

....23

..24

.2 6

It may not be reproduced in whole or part without the expressed written permission of Northern Lights, Inc.

© Northern Lights, Inc. 2012. All rights reserved. Litho U.S.A. Publication number:

Proprietary Information

This publication is the sole property of Northern Lights, Inc.

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1

WAVENET SPECIFICATIONS

Table 1: Wavenet Specifi cations

VDC Rating 12/24 VDC
Standby Current

50 mA @ 12 VDC

Consumption
Load Equivalency Number

WaveNet: 1 / WaveNet remote:2(NMEA 2000® Spec. : 1 LEN=50mA)

(LEN)
Operating Temp -40oC to +85oC (-40oF to +185oF)

o

LCD Operating Temp. ** -20
Function

Range

C to +70oC (-4oF to +158oF)
Function Range
Speed Sensing 0-300vac, 0-3600rpm
Voltage Sensing Max 700vac, +/- 1%
Current Sensing * Max 5A, +/- 2%
Frequency Sensing 1 - 100 HZ

o

Engine Temp 10-265

F
Oil Pressure 0-90 PSI
Analog Input 7mA Max
Digital Input 7mA Max

o

LCD Display 128 x 60 Graphic Display, Backlit, 60

viewing angle

LED Display Red, Green, Yellow LED representation, Daytime visible, 60

viewing angle

®

NMEA 2000

Connector DeviceNet Micro-C

Relays replaceable relays for Run signal and Preheat signal, 12 or

24VDC Coil

Dimensions W x H x D: 139 x 113 x 65 mm (5.7 x 4.45 x 2.56 in.)
Weight 0.45 kg (1.0 lb)
* Use of industry standard CT required.

** The LCD display will exhibit color and response time changes at high and low
temperatures respectively but will not be damaged as long as within Operating Temp.

o

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1. WAVENET CONTROLLER SERIES

The WaveNet is designed for use on generator sets
with mechanical engines. It can monitor analog
data from senders on the engine and generator
such as oil pressure, coolant temperature, current,
voltage, engine speed and generator frequency

.

In addition to the monitoring features, the
WaveNet controller can be used to provide
protective warnings or shutdowns.

WaveNet Front View

This manual is divided into two sections:

1. Hardware installation

2. Operation / Confi guration

1.1 THIS MANUAL

WaveNet Back View

OWN-GEN 01/12

3

2. RECEIVING, HANDLING & STORAGE

Receiving:

Every effort is made to ensure that your WaveNet gen-set controller arrives at its destination
undamaged and ready for installation. The packaging is designed to protect the WaveNet internal
components as well as the enclosure. Care should be taken to protect the equipment from impact at
all times. Do not remove the protective packaging until the equipment is at the installation site and
ready to be installed.

When the WaveNet reaches its destination, the customer should inspect the shipping box and controller

for
any signs of damage that may have occurred during transportation. Any damage should be reported
to a Northern Lights representative after a thorough inspection has been completed.

A shipping label affi xed to the shipping box includes a variety of product and shipping information,
such as items and Customer numbers. Make certain that this information matches your order

....

information.

Each WaveNet controller is packaged in its own box. Do not discard the packing material until the
controller is ready for installation.

Handling:
As previously mentioned, each WaveNet gen-set controller is packaged in its own individual box.

Protect the equipment from impact at all times and do not carelessly stack. Once the controller is at
the installation site and ready to be installed, the packaging material may be removed.

Storage:
Although well packaged, this equipment is not suitable for outdoor storage. WaveNet is to be stored

indoors for any period of time, it should be stored with its protective packaging in place. Protect the controller
at all times from excessive moisture, dirty conditions, corrosive conditions, and other contaminants. It is
strongly recommended that the package-protected equipment be stored in a climate-controlled environment
of -20 to 65°C (-4 to 149°F), with a relative humidity of 80% or less. Do not stack other equipment on top
of the stored controllers.

OWN-GEN 01/12

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updated 1-17-12

3. WAVENET SERIES INSTALLATION AND WIRING

3.1 SAFETY INFORMATION

Generator systems contain high voltage circuits. Working on powered equipment can cause damage to
equipment, injury, or death. The following symbols will be used in this document to classify information:

Caution: This is used to indicate something that you should take
special notice of but that is not normally a threat to safety.

Danger: This is used to indicate a potential for injury or death.

Danger - High Voltage: This is similar to Danger above but relates

specifi cally to conditions where high voltage is encountered.

The following general safety precautions should be headed:

1. The WaveNet may carry high Voltage/Current which can cause serious injury or death.
Extreme caution must be exercised when connections are being installed to or from the
controller. All wiring connections must be de-energized before any installations are performed.
Wiring of the WaveNet should be performed by qualifi ed electricians only.

2. AC power may carry high Voltage/Current which can cause serious injury or death.
De-energize all AC power sources before any connections are performed.

3. NEVER energize AC power with AC current sensing connector unplugged. An energized,
unplugged connector could result in severe injury or death. Never unplug an energized
connector.

4.

WaveNet is connected on a NMEA 2000 network. Installation must be made by an

NMEA 2000 certifi ed technician.

3.2 WAVENET 12/24VDC SYSTEM OPERATION

The WaveNet controller can be placed in either 12V or 24V electrical systems.

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3.2.1 RELAYS

The WaveNet controller is designed to operate on 12 or 24 VDC systems. When operating on 12VDC
systems the fuel and preheat outputs require 12VDC relays, and 24VDC relays when operating on
24VDC systems. The WaveNet comes preinstalled with the correct relays depending on the product
number specifi ed when ordered.

Contact Northern Lights if replacement relays are required.

Relays for 12 or 24VDC system operation are as follows:

• 22-42047 for 12VDC operation

• 22-40085 for 24VDC operation

3.2.2 RELAY FUSES

CAUTION: needs to be taken when connecting relay outputs to an inductive load. Due to the
inductive nature of certain loads (starters, pull coils), initial current draw may be higher than stated
in the load specs which could damage the onboard relays.

Output relays are protected by onboard 40A fuse protection. Smaller amperage fuses from many
automotive stores may be used in place of the higher current 40A. If installing lower amperage fuse
protection, be certain that the current draw on each relay does not exceed the fuse current limit.

An approved 40A fuse is: LITTLEFUSE – 257040 (32VDC, 40A, auto fast action)

3.3 WAVENET TERMINALS

Figure 1 on page 6 shows the location of all terminals on the controller and the numbering of all
circuits.

Table 2 lists the minimum wire size, maximum current capacity, name, and function of each circuit.

The wire gauges given in the table are the minimum recommended only.

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updated 1-17-12

WaveNet is connected on a NMEA 2000 network. Installation must be made by an NMEA 2000
certifi ed technician.

Figure 1 - General WaveNet System Wiring Diagram

7

TABLE 2

Table 2: WaveNet Terminal Details

Quick
Fit
Terminals

Analog
Inputs

Digital
Inputs

Terminal Wire Size

Current Max* Functions

(AWG)

Crank 12 40A Crank Output Terminal

1

Battery +
Battery -

12 40A Positive Battery Terminal

1

12 40A Negative Battery Terminal
Fuel 12 40A Fuel Output Terminal
Extra Relay

12 40A Pre-Heat Input Terminal
Extra Relay 12 40A Pre-Heat Output Terminal
Speed 1 18 100mA Speed Signal Connection
Speed 2 18 100mA Speed Signal Connection

Total controller current output (max 60A)

*

1

Ensure wire gauge is suffi cient: otherwise (especially during cranking) there could be a voltage drop across the cable to

the controller from the battery related features of the controller.

Terminal
Detail

Terminal

Location

Wire Size
(AWG)

Current Max. Function

Ground 1 18 7mA N/A
Input 2 2 18 7mA N/A
Input 3 3 18 7mA Engine Temperature Sender

(Low Resistance, Gain of 3)

Input 4 4 18 7mA Oil Pressure Sender

(Low Resistance, Gain of 3)
Input 5 5 18 7mA N/A
Input 6 6 18 7mA N/A
Input 7 7 18 7mA N/A
5V out 8 18 7mA N/A
Terminal

Detail
Input H - GND
Input G - GND
Input F - GND
Input E - GND
Input D - BAT
Input C - BAT
Input B - BAT
Input A - BAT
Emer. Stop

Terminal
Location

Wire Size
(AWG)

Current Max. Function

1 18 7mA N/A
2 18 7mA N/A
3 18 7mA Auxiliary Failure

1

4 18 7mA Option Coolant Level Switch
5 18 7mA N/A
6 18 7mA N/A
7 18 7mA N/A
8 18 7mA N/A
9 18 7mA

Allows Manual Emergency Stop

(Open = Active)
10 10 18 7mA

N/A

1

Ground
Ground

1

Ground input to generate logic high.

11 18 7mA
12 18 7mA

Ground

Ground

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TABLE 2 (CONTINUED)

Digital
Outputs

RS485
(Modbus)

AC
Voltage
Sensing

Terminal
Detail

+ V Bat 1 18 1.5A N/A
Output A 2 18 200mA N/A
Output B 3 18 200mA N/A
Output C 4 18 200mA N/A
Output D 5 18 200mA N/A
Output E 6 18 200mA N/A
Output F 7 18 200mA N/A
Output G 8 18 200mA N/A
Output H 9 18 200mA N/A
+ V Bat 10 18 1.5A N/A
Terminal

Detail
RS485-A 1 18 7mA N/A
Ground 2 18 7mA N/A
RS485-B 3 18 7mA N/A
RS485-A 4 18 7mA N/A
Ground 5 18 7mA N/A
RS485-B 6 18 7mA N/A
Terminal

Detail

Phase A * 1 18 7mA Monitor Generated AC Voltage
Phase B * 2 18 7mA Monitor Generated AC Voltage
Phase C * 3 18 7mA Monitor Generated AC Voltage

Terminal
Location

Terminal
Location

Terminal
Location

Wire Size
(AWG)

Wire Size
(AWG)

Wire Size
(AWG)

Current Max. Function

Current Max. Function

Current Max. Function

Neutral 4 18 7mA AC Voltage Neutral connection

* Place 1A fuse between the hot lines and the voltage sensing terminals of WaveNet.

AC
Current
Sensing

Terminal
Detail

Phase A 1 18 5A Phase A Current Sensing CT ­Phase B 2 18 5A Phase B Current Sensing CT ­Phase C 3 18 5A Phase C Current Sensing CT ­Phase A 4 18 5A Phase A Current Sensing CT +
Phase B 5 18 5A Phase B Current Sensing CT +
Phase C 6 18 5A Phase C Current Sensing CT +

The current transformers (CTs) negative leads must be terminated individually into the WaveNet AC
Current connector. DO NOT CONNECT TOGETHER.

Terminal
Location

It is extremely important to connect each phase to the appropriate terminal location. Never
misphase inputs. Always match terminal details to the matching terminal location

Wire Size
(AWG)

OWN-GEN 01/12

Current Max. Function

9

TABLE 2 (CONTINUED)

updated 1-17-12

NMEA

®

2000

Terminal
Detail

Terminal
Location

Wire Size
(AWG)

Current

Max.
NET-H 1 22 7mA NMEA2000
NET-S 2 22 7mA NMEA2000
NET-L 3 22 7mA NMEA2000
NET-C 4 22 7mA NMEA2000

3.3.1 CURRENT TRANSFORMER (CT) WIRING NOTE

The current transformers (CTs) negative leads must be terminated individually into the
WaveNet AC Current connector. Do not tie the negative leads together to a common ...
neutral or ground. The negative lead of the CT is usually black.

WaveNet is connected on a NMEA 2000 network. Installation must be made by an NMEA
2000 certifi ed technician.

4 WAVENET OPERATION & BASIC USER CONFIGURATION

4.1 POWER-UP

Function

®

Data High

®

Bus Power +

®

Data Low

®

Bus Ground

T

he controller will display the fi rmware and hardware version on the screen and fl ash the indicator lamps

on the side of the controller.

The controller will then enter the OFF mode. By default, it is possible to manually start the generator in
the OFF mode. The user can disable manual start in OFF mode in the basic menu (in which case the
WaveNet must be in the AUTO mode to manually start the generator). See section 4.7.2 on page 15.

Pressing the Info key will cause the controller to enter the AUTO mode. From this mode, the user
can put the controller into RUN mode (i.e. start the generator) manually or from a WaveNet Remote
Panel.

The controller has the ability to remember whether it was in the OFF or AUTO mode the last time it
was powered up and will reenter that mode when it is repowered.

4.2 CONTROLLER ALARMING

If the emergency stop input of the digital input terminal is not connected to ground the controller will
alarm and display “Emergency Stop” when powered. Emergency Stop also forces the controller to the
OFF mode.

To prevent this ground the emergency stop input (pin 9) to ground (pin 12) on the digital input
terminal. See Figure 1 on page 6.

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The WaveNet incorporates 3 primary modes of operation:

1. OFF Mode

2. AUTO Mode

3. RUN Mode

1. OFF Mode – When the WaveNet
is set to the OFF mode, automatic
starting will be disabled. No automatic
controls will be initiated. The OFF
mode may be initiated when no
generator controls are required or
when the controller confi guration
requires adjustment by pressing the
Stop button. The user can disable
manual start in OFF mode in the basic
menu. See section 4.7.2 on page 15.

4.3 CONTROLLER STATES

All of the failures and most of the warnings are disabled when the controller is in the OFF mode.
The controller will beep every few seconds to alert the user that the unit is in the OFF mode and
cannot automatically start. To silence this alarm, press the Stop key.

In OFF mode, you may simultaneously press the Up and Down arrow keys to perform a lamp
test.

2. AUT O Mode - When the WaveNet is set
to the AUT O mode by pressing the Info key,
automatic starting will be enabled.
engine is started,

failures will be automatically

If the

detected allowing for safe engine operation.

While in AUTO mode the controller will
display engine temperature, battery
voltage and engine hours.

OWN-GEN 01/12

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