Description

FG Wilson PowerWizard 1.1, PowerWizard 1.1+, PowerWizard 2.1 2012 Technical Manual

I’ve seen too many generators sitting dead because somebody used a third-party scan tool or guessed at a setpoint. This FG Wilson PowerWizard 1.1, PowerWizard 1.1+, PowerWizard 2.1 2012 Technical Manual is what you need if you actually want the generator to start, transfer, and shut down the way it was designed. 49 pages of factory documentation, not a reprint from a parts website that left out the grounding details.

Page 5 starts with Important Safety Information – read it. I don’t care if you’ve wired a hundred gensets; the high-voltage DC bus on these modules will bite you if you skip the lockout procedure. The manual covers all three variants: PowerWizard 1.1, 1.1+, and 2.1. Each has different real-time clock and fuel transfer capabilities. The control module description on page 7 shows the pinouts and what each connector does – no guesswork.

PowerWizard Variations and Control Module Description

Section 1.3 breaks down the differences between the three models. The 1.1+ adds the event log and the 2.1 includes the programmable cycle timer (PCT) and real-time clock. If you need to set a service interval or disable the NOT IN AUTO alarm, you need to know which variant you’re holding. The manual lists the exact menu tree for each. Page 26 covers relay and digital output programming – that’s where you map the physical outputs to specific events like “overcrank” or “low coolant temperature.”

Engine Starting Sequence and Stopping Sequence – Factory Timing

Section 3.2.1 gives the crank cycle: preheat (if fitted), crank, check for oil pressure, then verify frequency. The stop sequence in 3.2.2 includes a cooling-down run before the fuel solenoid drops. I’ve had to re-flash controllers because someone interrupted the cooldown and the turbo seized. This manual tells you the minimum cooldown time – it’s in the setpoints, not in a YouTube comment.

Installation: Electrical Connections and Data Links

The installation section starting on page 15 covers power requirements (8–35 VDC), winding connections, and transformer taps. The data link diagrams for the primary J1939 CAN1 and accessory J1939 are on page 19 and 21. If you’re retrofitting a PowerWizard into an older cabinet, you need the pinouts for the MCM9 annunciator – page 22. Don’t wire the CAN bus termination resistor wrong; it’s 120 ohms, and the manual shows the exact location.

Setpoint Programming: Digital Inputs and Outputs

Chapter 5 is where most techs screw up. Digital inputs can be configured as normally open or normally closed, with debounce times listed in the tables. Page 26 has the relay output mapping – you can assign any of the 5 programmable relays to any event. Analogue input programming on page 29 handles sensor curves for temperature and pressure transducers. Do not trust a generic sensor PDF for these curves; the factory values are in this manual.

Step Through Guides: Reduced Power Mode and Service Interval

Section 7 walks you through real-world tasks. Reduced Power Mode (RPM) lets you run the generator at a fixed percentage for load testing – page 35. Resetting the service interval requires navigating to the right menu path, and the manual shows the sequence step by step. Disabling the Thermo Start (start aid) is on page 37 – often needed in hot climates like San Antonio. Do you really want to bypass a cold-start heater in July? Probably not, but if you do, here’s the exact procedure.

This is not a reprint. This is the original OEM file from FG Wilson’s 2012 release. No aftermarket translation errors, no missing pages. You get the factory setpoint tables, wiring diagrams, and event descriptions. If you maintain commercial or industrial standby generators, you need this. FG Wilson 200 kVA, 26 kVA 2013 Parts Catalog – Factory Specs and FG Wilson 27 kVA, 200 kVA 2013 Parts Catalog – Original OEM pair well with this manual for parts lookup. For older equipment, see Drogobych Crane КТА-16, КТА-25, КТА-28 2004 Installation Manual – different machine, same level of factory detail.

One more thing: if you’re used to a Manual Transmission repair guide, this is a different kind of manual – it’s about electronic controls, not gears. But the same principle applies: only use the factory data. Compare it to a Manual Transmission service book; both are useless if somebody wrote down the wrong clearances.

Access the Factory Manual and get the correct wiring, setpoints, and troubleshooting trees for your FG Wilson generator control.

Does this manual cover the PowerWizard 2.1 real-time clock?

Yes. Section 3.4 on page 13 explains how to set the RTC using the front panel buttons. The 1.1 and 1.1+ do not have an RTC.

What is the difference between the 1.1 and 1.1+?

The 1.1+ adds event logging and a few extra programmable inputs. The manual lists the exact differences on page 6.

Can I use this manual to program the annunciator module?

Section 4.7.1 and 4.7.2 cover the MCM9 annunciator support. It shows which events can trigger the remote alarm.

I need the J1939 data link pinout. Where is it?

Page 19. Two pages. Primary and accessory CAN – with termination resistor location.