Woodward easYgen-2000 Series User manual

37427
Configuration
Software Version 1.xxxx
Manual 37427
easYgen-2000 Series
Genset Control

Manual 37427 easYgen-2000 Series - Genset Control
Page 2/339 © Woodward
WARNING
Read this entire manual and all other publications pertaining to the work to be performed before
installing, operating, or servicing this equipment. Practice all plant and safety instructions and
precautions. Failure to follow instructions can cause personal injury and/or property damage.
The engine, turbine, or other type of prime mover should be equipped with an overspeed
(overtemperature, or overpressure, where applicable) shutdown device(s), that operates totally
independently of the prime mover control device(s) to protect against runaway or damage to the
engine, turbine, or other type of prime mover with possible personal injury or loss of life should the
mechanical-hydraulic governor(s) or electric control(s), the actuator(s), fuel control(s), the driving
mechanism(s), the linkage(s), or the controlled device(s) fail.
Any unauthorized modifications to or use of this equipment outside its specified mechanical, electrical,
or other operating limits may cause personal injury and/or property damage, including damage to the
equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or "negligence" within
the meaning of the product warranty thereby excluding warranty coverage for any resulting damage,
and (ii) invalidate product certifications or listings.
CAUTION
To prevent damage to a control system that uses an alternator or battery-charging device, make sure
the charging device is turned off before disconnecting the battery from the system.
Electronic controls contain static-sensitive parts. Observe the following precautions to prevent
damage to these parts.
•
Discharge body static before handling the control (with power to the control turned off, contact a
grounded surface and maintain contact while handling the control).
•
Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around printed circuit boards.
•
Do not touch the components or conductors on a printed circuit board with your hands or with
conductive devices.
OUT-OF-DATE PUBLICATION
This publication may have been revised or updated since this copy was produced. To verify that you
have the latest revision, be sure to check the Woodward website:
http://www.woodward.com/pubs/current.pdf
The revision level is shown at the bottom of the front cover after the publication number. The latest
version of most publications is available at:
http://www.woodward.com/publications
If your publication is not there, please contact your customer service representative to get the latest
copy.
Important definitions
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation that, if not avoided, could result in damage to equipment.
NOTE
Provides other helpful information that does not fall under the warning or caution categories.
Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be
correct and reliable. However, Woodward assumes no responsibility unless otherwise expressly undertaken.
© Woodward
All Rights Reserved.

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Revision History
Rev.
Date
Editor
Changes
NEW
09-06-09
TE
Release
Content
Document Overview...............................................................................................................................
CHAPTER 1. GENERAL INFORMATION ..................................................................................... 11
11
Abbreviations ......................................................................................................................................... 12
Configuration Via The Front Panel.........................................................................................................
CHAPTER 2. CONFIGURATION ................................................................................................ 13
13
Configuration Using The PC .................................................................................................................. 14
Install ToolKit Configuration and Visualization Software...............................................................14
Configure ToolKit........................................................................................................................... 15
ToolKit Files................................................................................................................................... 16
Language-Dependent SID Files ...............................................................................................................17
SID Files for Using ToolKit on the CAN Bus With Other CANopen Devices.............................................17
Loading WSET Files of Previous Revisions .............................................................................................17
Connect ToolKit and the easYgen Unit ......................................................................................... 18
View easYgen Data with ToolKit ................................................................................................... 19
Configure the easYgen with ToolKit .............................................................................................. 20
The Settings File Function of ToolKit ............................................................................................ 20
Function of the Inputs and Outputs ........................................................................................................ 21
Configure Language / Clock...................................................................................................................
CHAPTER 3. PARAMETERS..................................................................................................... 25
26
Configure Display................................................................................................................................... 29
Lamp Test .............................................................................................................................................. 29
Enter Password ...................................................................................................................................... 30
System Management ............................................................................................................................. 32
System Management: Password System ..................................................................................... 34
Configuration .......................................................................................................................................... 35
Configure Measurement......................................................................................................................... 36
Configure Measurement: Configure Transformer ......................................................................... 42
Generator .................................................................................................................................................42
Busbar......................................................................................................................................................44
Mains PT ..................................................................................................................................................45
Mains Current Transformer ......................................................................................................................45
Ground Current Transformer....................................................................................................................46

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Configure Monitoring ............................................................................................................................. 47
Configure Monitoring: Generator .................................................................................................. 47
Configure Monitoring: Generator, Operating Voltage / Frequency........................................................... 48
Configure Monitoring: Generator, Overfrequency (Levels 1 & 2) ANSI# 81O .......................................... 49
Configure Monitoring: Generator, Underfrequency (Levels 1 & 2) ANSI# 81U ........................................ 51
Configure Monitoring: Generator, Overvoltage (Levels 1 & 2) ANSI# 59 ................................................. 53
Configure Monitoring: Generator, Undervoltage (Levels 1 & 2) ANSI# 27 ............................................... 55
Configure Monitoring: Generator, Time-Overcurrent Monit. (Levels 1, 2 & 3) ANSI# 50/51..................... 57
Configure Monitoring: Generator, Reverse/Reduced Power (Levels 1 & 2) ANSI# 32R/F....................... 59
Configure Monitoring: Generator, Overload IOP (Levels 1 & 2) ANSI# 32............................................... 61
Configure Monitoring: Generator, Overload MOP (Levels 1 & 2) ANSI# 32............................................. 63
Configure Monitoring: Generator, Unbalanced Load (Levels 1 & 2) ANSI# 46 ........................................ 65
Configure Monitoring: Generator, Voltage Asymmetry............................................................................. 68
Configure Monitoring: Generator, Ground Fault (Levels 1 & 2)................................................................ 70
Configure Monitoring: Generator, Phase Rotation ................................................................................... 73
Configure Monitoring: Generator, Inverse Time-Overcurrent Monitoring ANSI# IEC 255........................ 75
Configure Monitoring: Generator, Lagging Power Factor Monitoring (Levels 1 & 2)................................ 79
Configure Monitoring: Generator, Leading Power Factor Monitoring (Levels 1 & 2)................................ 81
Configure Monitoring: Mains ......................................................................................................... 83
Configure Monitoring: Mains, Operating Voltage / Frequency ................................................................. 83
Configure Monitoring: Mains, Decoupling ................................................................................................ 85
Configure Monitoring: Mains, Overfrequency (Levels 1 & 2) ANSI# 81O................................................. 87
Configure Monitoring: Mains, Underfrequency (Levels 1 & 2) ANSI# 81U............................................... 89
Configure Monitoring: Mains, Overvoltage (Levels 1 & 2) ANSI# 59........................................................ 91
Configure Monitoring: Mains, Undervoltage (Levels 1 & 2) ANSI# 27...................................................... 93
Configure Monitoring: Mains, Phase Shift................................................................................................ 95
Configure Monitoring: Mains, Voltage Phase Rotation - {2oc} ................................................................. 98
Configure Monitoring: Engine ..................................................................................................... 100
Configure Monitoring: Engine, Overspeed (Levels 1 & 2) ANSI# 12...................................................... 100
Configure Monitoring: Engine, Underspeed (Levels 1 & 2).................................................................... 102
Configure Monitoring: Engine/Generator, Speed Detection (Speed/Frequency Mismatch) ................... 104
Configure Monitoring: Engine, Generator Active Power Mismatch ........................................................ 106
Configure Monitoring: Engine, Mains Active Power Mismatch............................................................... 107
Configure Monitoring: Engine, Generator Unloading Mismatch ............................................................. 108
Configure Monitoring: Engine, Start Failure ........................................................................................... 109
Configure Monitoring: Engine, Shutdown Malfunction ........................................................................... 110
Configure Monitoring: Engine, Unintended Stop.................................................................................... 111
Configure Monitoring: Engine, Operating Range Failure ....................................................................... 112
Configure Monitoring: Engine, Charge Alternator (D+) .......................................................................... 113
Configure Monitoring: Breaker Monitoring .................................................................................. 114
Configure GCB....................................................................................................................................... 114
Configure Synchronization GCB ............................................................................................................ 115
Configure MCB {2oc} ............................................................................................................................. 116
Configure Synchronization MCB............................................................................................................ 118
Configure Monitoring: Breakers, Generator / Busbar / Mains Phase Rotation - {2oc}............................ 119
Configure Monitoring: Flexible Limits.......................................................................................... 120
Configure Monitoring: Miscellaneous.......................................................................................... 124
Configure Monitoring: Miscellaneous, Alarm Acknowledgement ........................................................... 124
Configure Monitoring: Miscellaneous, Configure CAN bus overload...................................................... 125
Configure Monitoring: Miscellaneous, Configure CAN Interface 1 ......................................................... 126
Configure Monitoring: Miscellaneous, Configure CAN Interface 2 ......................................................... 127
Configure Monitoring: Miscellaneous, Configure CAN Interface 2, J1939 Interface............................... 128
Configure Monitoring: Miscellaneous, Battery, Overvoltage (Levels 1 & 2) ........................................... 131
Configure Monitoring: Miscellaneous, Battery, Undervoltage (Levels 1 & 2) ......................................... 133
Configure Monitoring: Miscellaneous, Multi-Unit Parameter Alignment ................................................. 135
Configure Monitoring: Miscellaneous, Multi-Unit Missing Members....................................................... 137
Configure Application........................................................................................................................... 138
Configure Application: Configure Breakers................................................................................. 138
Operation Of The Circuit Breakers......................................................................................................... 140
Configure Application: Configure Breakers, Dead Bus Detection Limit.................................................. 148
Configure Application: Configure Breakers, GCB .................................................................................. 149
Configure Application: Configure Breakers, MCB .................................................................................. 153
Configure Application: Configure Breakers, Synchronization................................................................. 155

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Configure Application: Configure Inputs and Outputs .................................................................156
Configure Analog Inputs (FlexIn)............................................................................................................156
Configure Discrete Inputs.......................................................................................................................166
Configure External Discrete Inputs.........................................................................................................169
Discrete Outputs (LogicsManager).........................................................................................................170
External Discrete Outputs (LogicsManager)...........................................................................................171
Configure Analog Outputs ......................................................................................................................171
Configure Application: Configure Engine .................................................................................... 176
Configure Application: Configure Engine, Engine Type..........................................................................176
Configure Application: Configure Engine, Start/Stop..............................................................................182
Configure Application: Configure Engine, MPU......................................................................................187
Configure Application: Configure Engine, Idle Mode..............................................................................188
Configure Application: Configure Emergency Run......................................................................189
Configure Application: Configure Automatic Run........................................................................191
Configure Application: Automatic, Start In AUTOMATIC Operating Mode (LogicsManager) .................191
Configure Application: Automatic, Stop In AUTOMATIC Operating Mode (LogicsManager)..................192
Configure Application: Automatic, Load-Dependent Start/Stop (LDSS) .................................................193
Configure Application: Automatic, Start w/o Load (LogicsManager).......................................................209
Configure Application: Automatic, Operation Modes ..............................................................................209
Configure Application: Automatic, Critical Mode (Sprinkler Operation, LogicsManager) ........................210
Configure Application: Configure Controller ................................................................................ 215
Overview ................................................................................................................................................215
PID Tuning Example ..............................................................................................................................216
Configure Application: Controller, Frequency Control ............................................................................217
Configure Application: Controller, Load Control .....................................................................................223
Configure Application: Controller, Voltage Control .................................................................................229
Configure Application: Controller, Power Factor Control ........................................................................234
Configure Application: Controller, Load Share Control...........................................................................238
Configure Application: Controller, Discrete Raise/Low/Function ............................................................245
Configure Interfaces............................................................................................................................. 246
Configure Interfaces: Configure CAN Interfaces (FlexCAN) .......................................................246
Configure CAN Interface 1 .....................................................................................................................246
Configure CAN Interface 2 .....................................................................................................................255
Load Share Parameters .........................................................................................................................260
Configure Interfaces: Configure RS-232 Interfaces .................................................................... 261
Configure Serial Interface 1....................................................................................................................261
Configure Interfaces: Configure RS-485 Interfaces .................................................................... 262
Configure Serial Interface 2....................................................................................................................262
Configure LogicsManager .................................................................................................................... 263
Configure LogicsManager: Configure Internal Flags................................................................... 263
Configure LogicsManager: Set Timer.......................................................................................... 264
LogicsManager: Daily Time Set Point ....................................................................................................264
LogicsManager: Active Time Set Point...................................................................................................264
LogicsManager: Weekly Time Set Point.................................................................................................265
Configure Counters .............................................................................................................................. 266
Configure Counters: Maintenance Call ....................................................................................... 266
Configure Counters: Operation Hours, kWh, and kvarh.............................................................. 267
Configure Counters: Start Counter.............................................................................................. 268
Alarm Classes ......................................................................................................................................
APPENDIX A. MISCELLANEOUS ............................................................................................ 269
269
Conversion Factors .............................................................................................................................. 270
Temperature ................................................................................................................................ 270
Pressure ...................................................................................................................................... 270

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Structure and Description of the LogicsManager ...................................................................................
APPENDIX B. LOGICSMANAGER ........................................................................................... 271
271
Configuration of the Command Chain.................................................................................................... 272
Logical Symbols................................................................................................................................... 272
Logical Outputs.................................................................................................................................... 273
Logical Outputs: Internal Flags ................................................................................................... 273
Logical Outputs: Internal Functions ............................................................................................ 274
Priority Hierarchy of the Logical Outputs .................................................................................... 275
Logical Outputs: Relay Outputs .................................................................................................. 276
Logical Command Variables................................................................................................................ 277
Logical Command Variables: Group 00: Flags Condition 1........................................................ 278
Logical Command Variables: Group 01: Alarm System ............................................................. 280
Logical Command Variables: Group 02: Systems Condition...................................................... 281
Logical Command Variables: Group 03: Engine Control............................................................ 282
Logical Command Variables: Group 04: Applications Condition ................................................ 283
Logical Command Variables: Group 05: Engine Related Alarms............................................... 284
Logical Command Variables: Group 06: Generator Related Alarms.......................................... 285
Logical Command Variables: Group 07: Mains Related Alarms ................................................ 286
Logical Command Variables: Group 08: System Related Alarms .............................................. 286
Logical Command Variables: Group 09: Discrete Inputs............................................................ 287
Logical Command Variables: Group 10: Analog Inputs.............................................................. 287
Logical Command Variables: Group 11: Clock and Timer ......................................................... 287
Logical Command Variables: Group 12: External Discrete Inputs 1 .......................................... 288
Logical Command Variables: Group 13: Discrete Outputs ......................................................... 288
Logical Command Variables: Group 14: External Discrete Outputs 1........................................ 289
Logical Command Variables: Group 15: Flexible Limits ............................................................. 289
Logical Command Variables: Group 18: Transistor Outputs ...................................................... 289
Factory Setting..................................................................................................................................... 290
Factory Setting: Functions .......................................................................................................... 290
Factory Setting: Relay Outputs ................................................................................................... 300
Discrete Inputs ............................................................................................................................ 304
Data Sources .......................................................................................................................................
APPENDIX C. ANALOG MANAGER ......................................................................................... 305
305
Group 00: Internal Values ........................................................................................................... 305
Group 01: Generator Values....................................................................................................... 306
Group 02: Mains Values ............................................................................................................. 306
Group 05: Controller Set Points .................................................................................................. 307
Group 06: DC Analog Input Values............................................................................................. 307
Group 07: Engine Values............................................................................................................ 308
Reference Values ................................................................................................................................ 310
Generator Rated Voltage ............................................................................................................ 310
Mains Rated Voltage................................................................................................................... 310
Rated Frequency......................................................................................................................... 311
Generator Rated Active Power ................................................................................................... 311
Generator Rated Reactive Power ............................................................................................... 312
Mains Rated Active Power.......................................................................................................... 312
Mains Rated Reactive Power...................................................................................................... 313
Generator Rated Apparent Power .............................................................................................. 313
Mains Rated Apparent Power ..................................................................................................... 314
Generator / Mains Power Factor................................................................................................. 315
Generator Rated Current ............................................................................................................ 316
Mains Rated Current................................................................................................................... 316
Rated Speed ............................................................................................................................... 316
Battery Voltage............................................................................................................................ 317
Busbar 1 Rated Voltage.............................................................................................................. 317
Display Value Format.................................................................................................................. 317

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Resetting the Event History.........................................................................................................
APPENDIX D. EVENT HISTORY.............................................................................................. 318
318
Resetting the Event History Using the Front Panel ................................................................................318
Event List................................................................................................................................................318
Alarm List ...............................................................................................................................................318
Time-Dependent Overshoot Monitoring...............................................................................................
APPENDIX E. TRIGGERING CHARACTERISTICS....................................................................... 321
321
Two-Level Overshoot Monitoring ......................................................................................................... 322
Two-Level Undershoot Monitoring ....................................................................................................... 323
Two-Level Reversed/Reduced Load Monitoring..................................................................................324
Two-Level Unbalanced Load Monitoring ............................................................................................. 325
One-Level Asymmetry Monitoring........................................................................................................ 326
VDO Input "Pressure" (0 to 5 bar / 0 to 72 psi) - Index "III" .................................................................
APPENDIX F. CHARACTERISTICS OF THE VDO INPUTS .......................................................... 327
327
VDO Input "Pressure" (0 to 10 bar / 0 to 145 psi) - Index "IV"............................................................. 328
VDO Input "Temperature" (40 to 120 °C / 104 to 248 °F) - Index "92-027-004".................................. 329
VDO Input "Temperature" (50 to 150 °C / 122 to 302 °F) - Index "92-027-006".................................. 330
Pt100 RTD............................................................................................................................................ 331
Abbreviations .......................................................................................................................................
APPENDIX G. LDSS FORMULAS........................................................................................... 332
332
LDSS Mode Reserve Power ................................................................................................................ 332
Isolated Operation ....................................................................................................................... 332
Changing the Engine Combination to Increase Rated Power.................................................................332
Changing the Engine Combination to Reduce Rated Power..................................................................332
Mains Parallel Operation (Import/Export Control) ....................................................................... 332
Starting the First Engine Combination (no engine supplies the busbar).................................................332
Changing the Engine Combination to Increase Rated Power.................................................................332
Changing the Engine Combination to Reduce Rated Power..................................................................332
Stopping the Last Engine Combination (load close to minimum load)....................................................332
LDSS Mode Generator Load................................................................................................................ 333
Isolated Operation ....................................................................................................................... 333
Changing the Engine Combination to Increase Rated Power.................................................................333
Changing the Engine Combination to Reduce Rated Power (except dynamic set point is not matched)333
Mains Parallel Operation (Import/Export Control) ....................................................................... 333
Starting the First Engine Combination (no engine supplies the busbar).................................................333
Changing the Engine Combination to Increase Rated Power.................................................................333
Changing the Engine Combination to Reduce Rated Power (except dynamic set point is not matched)333
Stopping the Last Engine Combination (load close to minimum load)....................................................333
LDSS Dynamic ..................................................................................................................................... 333
Product Service Options ......................................................................................................................
APPENDIX H. SERVICE OPTIONS .......................................................................................... 334
334
Returning Equipment For Repair ......................................................................................................... 334
Packing A Control........................................................................................................................ 335
Return Authorization Number RAN ............................................................................................. 335
Replacement Parts............................................................................................................................... 335
How To Contact Woodward ................................................................................................................. 336
Engineering Services ........................................................................................................................... 337
Technical Assistance ........................................................................................................................... 338

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Figures and Tables
Figures
Figure 2-1: ToolKit - Options window ..................................................................................................................................... 15
Figure 2-2: ToolKit - visualization screen ................................................................................................................................ 19
Figure 2-3: ToolKit - analog value trending screen .................................................................................................................. 19
Figure 2-4: ToolKit - configuration screen ............................................................................................................................... 20
Figure 3-1: Code level display.................................................................................................................................................. 31
Figure 3-2: Configure measurement - generator type selection ................................................................................................ 37
Figure 3-3: AC power triangle.................................................................................................................................................. 39
Figure 3-4: Monitoring - calculated generator ground fault...................................................................................................... 70
Figure 3-5: Monitoring - calculated generator ground current - vector diagram....................................................................... 71
Figure 3-6: Monitoring - generator inverse time-overcurrent - "Normal inverse" characteristic .............................................. 75
Figure 3-7: Monitoring - generator inverse time-overcurrent - "Highly inverse" characteristic ............................................... 76
Figure 3-8: Monitoring - generator inverse time-overcurrent - "Extremely inverse" characteristic .......................................... 76
Figure 3-9: Monitoring - generator lagging power factor ......................................................................................................... 79
Figure 3-10: Monitoring - generator leading power factor........................................................................................................ 81
Figure 3-11: Monitoring - phase shift ....................................................................................................................................... 95
Figure 3-12: Monitoring - plausibility check n/f..................................................................................................................... 104
Figure 3-13: Monitoring - flexible limits - data source selection............................................................................................ 121
Figure 3-14: Monitoring - miscellaneous – parameter alignment ........................................................................................... 135
Figure 3-15: Normally Open / Normally Closed contacts....................................................................................................... 149
Figure 3-16: Analog input scaling - table (example)............................................................................................................... 156
Figure 3-17: Discrete inputs - alarm/control inputs - operation logic ..................................................................................... 166
Figure 3-18: Monitoring - analog outputs - data source selection........................................................................................... 173
Figure 3-19: Configure application - engine - preglow criterion selection.............................................................................. 177
Figure 3-20: Start /stop sequence - diesel engine.................................................................................................................... 178
Figure 3-21: Start /stop sequence - gas engine - successful .................................................................................................... 180
Figure 3-22: Start /stop sequence - gas engine - unsuccessful ................................................................................................ 181
Figure 3-23: Engine - firing speed and engine delayed monitoring ........................................................................................ 183
Figure 3-24: Engine - Auxiliary services timing..................................................................................................................... 186
Figure 3-25: Automatic run - engine start conditions ............................................................................................................. 192
Figure 3-26: Automatic - Critical operation at busbar ............................................................................................................ 210
Figure 3-27: Automatic - Critical operation at generator ........................................................................................................ 212
Figure 3-28: Controllers - Behavior of the derivative parameter ............................................................................................ 216
Figure 3-29: CAN bus load/var sharing, diagram ................................................................................................................... 240
Figure 3-30: Load sharing - grouping ..................................................................................................................................... 243
Figure 3-31: Interfaces - Principle of PDO mapping .............................................................................................................. 250
Figure 3-32: LogicsManager - function overview .................................................................................................................. 271
Figure 3-33: LogicsManager - display in ToolKit .................................................................................................................. 272
Figure 3-34: LogicsManager - display on LCD screen........................................................................................................... 272
Figure 3-35: Reference values - power factor scaling............................................................................................................. 315
Figure 3-36: Triggering characteristics - three-level time-dependent overshoot montitoring................................................. 321
Figure 3-37: Triggering characteristics - two-level overshoot montitoring............................................................................. 322
Figure 3-38: Triggering characteristics - two-level undershoot montitoring........................................................................... 323
Figure 3-39: Triggering characteristics - two-level reversed/reduced load montitoring ......................................................... 324
Figure 3-40: Triggering characteristics - two-level unbalanced load montitoring .................................................................. 325
Figure 3-41: Triggering characteristics - one-level asymmetry montitoring........................................................................... 326
Figure 3-42: Analog inputs - characteristics diagram VDO 0 to 5 bar, Index "III"................................................................. 327
Figure 3-43: Analog inputs - characteristics diagram VDO 0 to 10 bar, Index "IV"............................................................... 328
Figure 3-44: Analog inputs - characteristics diagram VDO 40 to 120 °C, Index "92-027-004" ............................................. 329
Figure 3-45: Analog inputs - characteristics diagram VDO 50 to 150 °C, Index "92-027-006" ............................................. 330
Figure 3-46: Analog inputs - characteristics diagram Pt100 ................................................................................................... 331

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Tables
Table 1-1: Manual - overview................................................................................................................................................... 11
Table 3-1: Configuration - standard values - configure language/clock.................................................................................... 26
Table 3-2: Daylight saving time - configuration example......................................................................................................... 29
Table 3-3: Daylight saving time - examplary dates................................................................................................................... 29
Table 3-4: Configuration - standard values - enter password.................................................................................................... 30
Table 3-5: Configuration - standard values - system management............................................................................................ 32
Table 3-6: Configuration - standard values - system management: password system............................................................... 34
Table 3-7: Measurement - standard values - configure measurement ....................................................................................... 36
Table 3-8: Measurement - standard values - configure transformer.......................................................................................... 42
Table 3-9: Monitoring - standard values - configure generator monitoring .............................................................................. 47
Table 3-10: Monitoring - standard values - configure generator operating voltage / frequency................................................ 48
Table 3-11: Monitoring - standard values - generator overfrequency ....................................................................................... 49
Table 3-12: Monitoring - standard values - generator underfrequency ..................................................................................... 51
Table 3-13: Monitoring - standard values - generator overvoltage ........................................................................................... 53
Table 3-14: Monitoring - standard values - generator undervoltage ......................................................................................... 55
Table 3-15: Monitoring - standard values - generator time-overcurrent ................................................................................... 57
Table 3-16: Monitoring - standard values - generator reverse / reduced power ........................................................................ 59
Table 3-17: Monitoring - standard values - generator overload IOP......................................................................................... 61
Table 3-18: Monitoring - standard values - generator overload MOP....................................................................................... 63
Table 3-19: Monitoring - standard values - generator unbalanced load .................................................................................... 65
Table 3-20: Monitoring - standard values - generator voltage asymmetry................................................................................ 68
Table 3-21: Monitoring - standard values - generator ground fault........................................................................................... 71
Table 3-22: Monitoring - standard values - generator voltage phase rotation ........................................................................... 73
Table 3-23: Monitoring - standard values - generator inverse time-overcurrent ....................................................................... 77
Table 3-24: Monitoring - standard values - generator lagging power factor ............................................................................. 79
Table 3-25: Monitoring - standard values - generator leading power factor ............................................................................. 81
Table 3-26: Monitoring - standard values - configure mains monitoring.................................................................................. 83
Table 3-27: Monitoring - standard values - configure mains operating voltage / frequency..................................................... 83
Table 3-28: Monitoring - standard values - mains decoupling.................................................................................................. 85
Table 3-29: Monitoring - standard values - mains overfrequency............................................................................................. 87
Table 3-30: Monitoring - standard values - mains underfrequency........................................................................................... 89
Table 3-31: Monitoring - standard values - mains overvoltage................................................................................................. 91
Table 3-32: Monitoring - standard values - mains undervoltage............................................................................................... 93
Table 3-33: Monitoring - standard values - mains phase shift .................................................................................................. 95
Table 3-34: Monitoring - standard values - mains voltage phase rotation................................................................................. 98
Table 3-35: Monitoring - standard values - engine overspeed ................................................................................................ 100
Table 3-36: Monitoring - standard values - engine underspeed .............................................................................................. 102
Table 3-37: Monitoring - standard values - plausibility control n/f......................................................................................... 105
Table 3-38: Monitoring - standard values - generator active power mismatch ....................................................................... 106
Table 3-39: Monitoring - standard values - mains active power mismatch............................................................................. 107
Table 3-40: Monitoring - standard values - generator unloading mismatch............................................................................ 108
Table 3-41: Monitoring - standard values - engine start failure .............................................................................................. 109
Table 3-42: Monitoring - standard values - engine shutdown malfunction............................................................................. 110
Table 3-43: Monitoring - standard values - engine unintended stop ....................................................................................... 111
Table 3-44: Monitoring - standard values - engine dead bus operation................................................................................... 112
Table 3-45: Monitoring - standard values - engine charge alternator failure .......................................................................... 113
Table 3-46: Monitoring - standard values - breaker monitoring - GCB .................................................................................. 114
Table 3-47: Monitoring - standard values - breaker monitoring - GCB synchronization........................................................ 115
Table 3-48: Monitoring - standard values - breaker monitoring - MCB ................................................................................. 116
Table 3-49: Monitoring - standard values - breaker monitoring - MCB synchronization ....................................................... 118
Table 3-50: Monitoring - standard values - mains voltage phase rotation............................................................................... 119
Table 3-51: Monitoring - standard values - flexible limits...................................................................................................... 120
Table 3-52: Monitoring - flexible limit examples ................................................................................................................... 120
Table 3-53: Monitoring - flexible limits - analog value examples .......................................................................................... 122
Table 3-54: Monitoring - flexible limits - parameter IDs........................................................................................................ 123
Table 3-55: Monitoring - standard values - CAN bus overload .............................................................................................. 125
Table 3-56: Monitoring - standard values - CANopen interface 1 .......................................................................................... 126
Table 3-57: Monitoring - standard values - CANopen interface 2 .......................................................................................... 127
Table 3-58: Monitoring - standard values - J1939 interface.................................................................................................... 128
Table 3-59: Monitoring - standard values - J1939 interface red stop lamp ............................................................................. 129
Table 3-60: Monitoring - standard values - J1939 interface amber warning lamp .................................................................. 130
Table 3-61: Monitoring - standard values - battery overvoltage ............................................................................................. 131
Table 3-62: Monitoring - standard values - battery undervoltage ........................................................................................... 133
Table 3-63: Monitoring - standard values - multi-unit parameter alignment monitoring........................................................ 135
Table 3-64: Monitoring - standard values - multi-unit missing members monitoring............................................................. 137

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Table 3-65: Application - standard values - configure breakers.............................................................................................. 138
Table 3-66: Application - standard values - configure GCB................................................................................................... 149
Table 3-67: Application - standard values - configure MCB .................................................................................................. 153
Table 3-68: Application - standard values - configure synchronization.................................................................................. 155
Table 3-69: Application - standard values - configure analog inputs...................................................................................... 156
Table 3-70: Application - standard values - configure analog input table A / B ..................................................................... 157
Table 3-71: Analog inputs - table characteristics - parameter IDs .......................................................................................... 158
Table 3-72: Application - standard values - configure analog inputs 1 to 3............................................................................ 159
Table 3-73: Discrete inputs - terminal assignment.................................................................................................................. 166
Table 3-74: Application - standard values - configure discrete inputs.................................................................................... 166
Table 3-75: Discrete inputs - parameter IDs ........................................................................................................................... 168
Table 3-76: Application - standard values - configure discrete inputs.................................................................................... 169
Table 3-77: External discrete inputs - parameter IDs.............................................................................................................. 169
Table 3-78: Relay outputs - assignment.................................................................................................................................. 170
Table 3-79: Discrete outputs - parameter IDs ......................................................................................................................... 170
Table 3-80: External discrete outputs - parameter IDs............................................................................................................ 171
Table 3-81: Analog outputs 1/2 - parameter table................................................................................................................... 171
Table 3-82: Application - standard values - configure analog outputs 1/2.............................................................................. 171
Table 3-83: Analog outputs 3/4 - parameter table................................................................................................................... 172
Table 3-84: Application - standard values - configure analog outputs 3/4.............................................................................. 172
Table 3-85: Analog outputs - signal type selection................................................................................................................. 174
Table 3-86: Application - standard values - configure engine type......................................................................................... 176
Table 3-87: Application - standard values - configure start/stop ............................................................................................ 182
Table 3-88: Application - standard values - configure MPU .................................................................................................. 187
Table 3-89: MPU input - typical configurations ..................................................................................................................... 187
Table 3-90: Application - standard values - configure idle mode ........................................................................................... 188
Table 3-91: Application - standard values - configure emergency run ................................................................................... 190
Table 3-92: Application - standard values - configure automatic run ..................................................................................... 191
Table 3-93: Load-dependent start/stop - parameters for reserve power operation .................................................................. 193
Table 3-94: Load-dependent start/stop - parameters for generator load operation.................................................................. 194
Table 3-95: Application - standard values - configure load dependent start/stop.................................................................... 196
Table 3-96: Application - standard values - configure load dependent start/stop IOP ............................................................ 201
Table 3-97: Load-dependent start/stop - dynamic influence on stopping a genset.................................................................. 204
Table 3-98: Application - standard values - configure load dependent start/stop MOP.......................................................... 205
Table 3-99: Application - standard values - configure critical mode ...................................................................................... 214
Table 3-100: Application - standard values - configure frequency control............................................................................. 217
Table 3-101: Application - standard values - configure load control ...................................................................................... 223
Table 3-102: Application - standard values - configure voltage control ................................................................................. 229
Table 3-103: Application - standard values - configure power factor control......................................................................... 234
Table 3-104: Application - standard values - configure load share......................................................................................... 241
Table 3-105: Application - standard values - configure discrete raise/lower function ............................................................ 245
Table 3-106: Application - standard values - configure CAN interface 1............................................................................... 246
Table 3-107: Application - standard values - configure CAN interface 1: additional Server SDOs ....................................... 249
Table 3-108: Application - standard values - configure CAN interface 1: receive PDOs ....................................................... 250
Table 3-109: Application - standard values - configure CAN interface 1: transmit PDOs...................................................... 252
Table 3-110: Application - standard values - configure CAN interface 2............................................................................... 255
Table 3-111: Application - standard values - configure CAN interface 2: CANopen............................................................. 255
Table 3-112: Application - standard values - configure CAN interface 2: J1939 ................................................................... 257
Table 3-113: Application - standard values - configure CAN interface: load share................................................................ 260
Table 3-114: Application - standard values - configure RS-232 interface: serial interface 1.................................................. 261
Table 3-115: Application - standard values - configure RS-485 interface: serial interface 2.................................................. 262
Table 3-116: Application - standard values - configure LogicsManager ................................................................................ 263
Table 3-117: Internal flags - parameter IDs ............................................................................................................................ 263
Table 3-118: Application - standard values - configure counters............................................................................................ 266
Table 3-119: LogicsManager - command overview ............................................................................................................... 271
Table 3-120: LogicsManager - logical symbols...................................................................................................................... 272
Table 3-121: Relay outputs - terminal assignment.................................................................................................................. 276
Table 3-122: Analog Manager - display value format ............................................................................................................ 307
Table 3-123: Event history - event list.................................................................................................................................... 318
Table 3-124: Event history - alarm list.................................................................................................................................... 320
Table 3-125: Analog inputs - characteristics diagram VDO 0 to 5 bar, Index "III" ................................................................ 327
Table 3-126: Analog inputs - characteristics diagram VDO 0 to 10 bar, Index "IV".............................................................. 328
Table 3-127: Analog inputs - characteristics diagram VDO 40 to 120 °C, Index "92-027-004" ............................................ 329
Table 3-128: Analog inputs - characteristics diagram VDO 50 to 150 °C, Index "92-027-006" ............................................ 330
Table 3-129: Analog inputs - characteristics diagram Pt100................................................................................................... 331

Manual 37427 easYgen-2000 Series - Genset Control
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Chapter 1.
General Information
Document Overview
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Type
English
German
easYgen-2000 Series
easYgen-2000 Series - Installation
37426
DE37426
easYgen-2000 Series - Configuration
this manual

37427
DE37427
easYgen-2000 Series - Operation
37428
DE37428
easYgen-2000 Series - Application
37429
-
easYgen-2000 Series - Interfaces
37430
-
easYgen-2000 Series - Parameter List
37431
DE37431
easYgen-2000 Series - Brief Operation
Information
37432
DE37432
Table 1-1: Manual - overview
Intended Use The unit must only be operated for the uses described in this manual. The prerequisite for a proper
and safe operation of the product is correct transportation, storage, and installation as well as careful operation
and maintenance.
NOTE
This manual has been developed for a unit fitted with all available options. Inputs/outputs, functions,
configuration screens and other details described, which do not exist on your unit may be ignored.
The present manual has been prepared to enable the configuration of the unit. On account of the large
variety of parameter settings, it is not possible to cover every possible combination. The manual is
therefore only a guide. In case of incorrect entries or a total loss of functions, the default settings can
be taken from the Parameter List 37431 or from ToolKit and the respective *.SID file.
NOTE
Some parameters, inputs, and outputs are dependent on the configured application mode
(parameter 3401 on page 139) regarding their availability and/or function. The following abbreviations
indicate the application mode for which the concerned information is valid:
{0} {0 (breaker control)} Application mode setting "None" - "Measuring transducer and engine
control function"
The control unit enables engine start/stop and generator measuring and protection – no breaker
control.
{1o} {1 (breaker) open} Application mode setting "GCB open" - "1 breaker control function"
The control unit enables engine start/stop and generator measuring and protection – "GCB
open" breaker control.
{1oc} {1 (breaker) open/close} Application mode setting "GCB" - "1 breaker control function"
The control unit enables engine start/stop and generator measuring and protection – full
generator breaker control for stand-by power applications with soft generator load transfer.
{2oc} {2 (breaker) open/close} Application mode setting "GCB/MCB" - "2 breaker control function"
The control unit enables engine start/stop and generator measuring and protection – full
generator breaker control for stand-by power applications with soft generator load transfer plus
emergency power, open/closed transition, and interchange load transfer applications.

Manual 37427 easYgen-2000 Series - Genset Control
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Abbreviations
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The following abbreviations are frequently used throughout this and all other easYgen manuals:
CB Circuit Breaker
CL Code Level
CT Current Transformer
CCW Counter-Clockwise
CW Clockwise
DI Discrete Input
DO Discrete (Relay) Output
ECU Engine Control Unit
GCB Generator Circuit Breaker
IOP Isolated Operation in Parallel
LDSS Load-Dependent Start/Stop operation
MCB Mains Circuit Breaker
MOP Mains Operation in Parallel
MPU Magnetic Pickup Unit
N.C. Normally Closed (break) contact
N.O. Normally Open (make) contact
PF Power Factor
PID Proportional Integral Derivative controller
PLC Programmable Logic Control
P/N Part Number
PT Potential (Voltage) Transformer
S/N Serial Number

Manual 37427 easYgen-2000 Series - Genset Control
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Chapter 2.
Configuration
Configuration Via The Front Panel
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Operation of the unit via the front panel is explained in the operation manual 37428. This manual will familiarize
you with the unit, the meanings/functions of the buttons, and the display.

Manual 37427 easYgen-2000 Series - Genset Control
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Configuration Using The PC
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Install ToolKit Configuration and Visualization Software
CAUTION
Woodward’s ToolKit software (version 3.1 or higher) is required when configuring the unit via a PC.
ToolKit from 3.1
If not already installed, download and install the ToolKit software. Please proceed as follows for this:
•Open your web browser and go to http://www.woodward.com/software/
•Select ToolKit in the list and click the Go button
•Download and install the file as described on the download page
Minimum system requirements for installing ToolKit:
•Microsoft Windows® Vista, XP
•Microsoft .NET Framework Ver. 3.5
•600 MHz Pentium® CPU
•96 MB of RAM
•Minimum 800 by 600 pixel screen with 256 colors
•Serial Port
NOTE
Please note that you must register on the website prior to downloading the software.
Microsoft .NET Framework 3.5 must be installed on your computer to be able to install ToolKit. If not
already installed, Microsoft .NET Framework 3.5 will be installed automatically. You must be connected
to the internet for this.
NOTE
If your computer is equipped with a Bluetooth interface please deactivate it temporary for the case that
ToolKit is freezing building up a connection.

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Configure ToolKit
Open ToolKit via Start menu -> Program ->Woodward -> ToolKit 3.x
You may configure the default settings of ToolKit by selecting Tools -> Options from the toolbar. The options
window will be displayed where you may select the default COM port and the default path for the configuration
files. We recommend configuring a dedicated ToolKit data file directory (e.g. C:\Data\ToolKit) instead of storing
the configuration files in the ToolKit installation directory (e.g. C:\Program Files\Woodward\ToolKit). The
changes become effective after restarting ToolKit.
Figure 2-1: ToolKit - Options window

Manual 37427 easYgen-2000 Series - Genset Control
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NOTE
Be sure to have the correct *.SID and *.WTOOL files for your unit ready. The SID file must not be
renamed!
When installing the *.SID and *.WTOOL files on a computer, it is recommended to create a dedicated
ToolKit data file external to the ToolKit program. An example of this would be to create a Woodward
ToolKit folder in a Data directory to store the *.SID and *.WTOOL files. The data files should be kept
separate from the program files. Mixing data and program files makes backing up files more difficult
and uninstalling the files incomplete.
ToolKit Files
ToolKit is using the following files:
*.WTOOL
File name composition: [P/N1]-[Revision]_[Language ID]_[P/N2]-[Revision]_[# of visualized gens].WTOOL
Example file name: 8440-1884-NEW_US_5418-3090-NEW_32.WTOOL
Content of the file: Display screens and pages for online configuration, which are associated with the
respective *.SID file
*.SID
File name composition: [P/N2]-[Revision].SID
Example file name: 5418-3090-NEW.SID
Content of the file: All display and configuration parameters available in ToolKit
*.WSET
File name composition: [user defined].WSET
Example file name: easYgen_settings.WSET
Content of the file: Default settings of the ToolKit configuration parameters provided by the SID file or
user-defined settings read out of the unit.
P/N1 = Part number of the unit
P/N2 = Part number of the software in the unit
NOTE
The P/N2 and revision information in the *.SID file name is used for identifying the unit and must not be
renamed.
When opening a *.WTOOL file, ToolKit will look for the respective SID file in the SID file location,
configured in the Options dialog (refer to Figure 2-1).
The *.SID files have identical names regardless of the language and are located in the respective
language folders delivered with the unit. If it happens that you need to switch between different
languages in ToolKit, we recommend to store your *.SID (and *.WTOOL & *.WSET) files in different
folders to avoid confusion. In this case you only need to change the path information as described
under Configure ToolKit on page 15 to switch the language. Refer to the Language-Dependent SID Files
section on page 17 for more details.

Manual 37427 easYgen-2000 Series - Genset Control
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Language-Dependent SID Files
Every language comes with a separate *.sid file. At the moment, only English and German are provided. Due to
current internal structures the *.sid files for every specific language have the same file name.
Therefore, a user will only be able to check the language by opening the *.sid file using an editor. Another
possibility is to select New from SID defaults from the Settings menu in ToolKit. If you select the respective
*.sid file then, a Settings Editor window opens, which displays the language ID ("us" or "de") in the title.
If a "German" version of *.wtool (8440-1884-NEW_de_5418-3090-NEW_32.wtool) tries to open an English
*.sid file, error messages and a red cross are displayed on the screen upon connecting.
If it is required that both language versions of the *.sid file are stored on the computer, because the user wants to
be able to switch between the languages, the *.sid files need to be stored in separate subfolders and the subfolder
name needs to show the name of the appropriate language.
If the user needs to change the language, the appropriate *.sid file needs to be selected by using the ToolKit menu
Tools -> Options -> SID file directories. The folder with the desired language needs to be on top position.
ToolKit needs to be closed and the *.wtool file must be opened again, to ensure that the new *.sid file will be
loaded.
SID Files for Using ToolKit on the CAN Bus With Other CANopen Devices
If a PC with ToolKit is connected to the easYgen via a CAN bus with other external CANopen devices (like a
Phoenix Contact I/O expansion board, for example), it may happen that ToolKit cannot establish a connection
with the easYgen because it looks for a SID file for such an external device, which does not exist.
A special *.sid file can be created in this case. Contact Woodward for support or create a *.sid file with the
following content:
<?xml version="1.0" encoding="utf-8"?>
<ServiceInterfaceDefinition xmlns:xsi="http://www.w3.org/2001/XMLSchema-instance" Identifier="[add the
required device application name here]" Specification="EmptyFile">
</ServiceInterfaceDefinition>
The file name must be the same as the Identifier plus the extension *.sid. The file must be stored to the
configured SID file directory.
Loading WSET Files of Previous Revisions
There may be incompatibilities between different easYgen P/Ns and revisions of the same P/N when loading a
*.wset file, saved from an easYgen into an easYgen with a different P/N and/or revision. Proceed as follows to
avoid that settings may get lost or transferred incorrectly:
Select from the ToolKit menu Settings -> Save from Device to File… to store the current easYgen settings (note
that the correct *.sid file is available). Then select from the ToolKit menu Settings -> Load Settings File to
Device… to load the stored settings into a different easYgen (take care that you provide the correct *.sid file in
the same language that was used to store the *.wset file). If the P/Ns and/or revisions of the easYgens differ, you
will be prompted to resolve the differences. If you are sure that the *.wset file is compatible with the easYgen,
proceed with Next. If you are not sure, proceed with Resolve Differences (please note that this feature is not
supported properly by the CANopen driver). If you select Resolve Differences it may take some minutes until the
next window opens, because ToolKit reads out all settings from the device to compare them with those in the
*.wset file. Then, a Compare Differences window will open and display all differences in value and/or parameter
name. Most of the name differences can be mapped according to the same index number within the parameter
name. Settings of parameters with selectable options cannot be mapped.
Verify all settings after loading them into the different easYgen! To verify the settings save them again from the
easYgen to a *.wset file. Then select ftom the ToolKit menu Settings -> Compare Settings File Differences and
open both, the (old) *.wset file loaded into the easYgen before, and the newly saved *.wset file. If there are no
value differences displayed, the load process was successful. If there are any value differences, take care that they
will be adjusted properly.
If there are any name differences, take care that the settings of the new parameters will be verified to fit the
application purpose.

Manual 37427 easYgen-2000 Series - Genset Control
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Connect ToolKit and the easYgen Unit
For configuration of the unit via ToolKit please proceed as follows:
•Connect the null modem communications cable between your laptop/PC and the control unit. Plug the null
modem cable into the RS-232 serial port on unit and the other side to a serial COM port of the laptop/PC. If
the laptop/PC does not have a serial port to connect the null modem cable to, use a USB to serial adapter.
•Open ToolKit via Start menu -> All Programs -> Woodward -> ToolKit 3.x
•From the main ToolKit window, click File then select Open Tool..., or click the Open Tool icon on the
tool bar.
•Locate and select the desired tool file (*.WTOOL) in the ToolKit data file directory and click Open.
•From the main ToolKit window, click Device then click Connect, or select the Connect icon on the
toolbar.
•The Connect dialog window will open if the option is enabled.
•Select the COM port that is connected to the communication cable.
•Click the OK button.
•If the Communications window opens, select ToolConfigurator under Tool Device and close the
Communications window.
•The identifier of the device that ToolKit is connected to will display in the status bar.
•Now you are able to edit the easYgen parameters. Any changes made are written to the control memory
automatically.
NOTE
A null modem serial cable must be used for communicating with the easYgen-2000 Series to ensure
that the controller functions properly. The connection will not work if you are using a straight cable (a
null modem cable has crosslinked transmit and receive lines in contrast to a straight serial cable).
NOTE
Depending on the computer used and the installed operation system, problems with the
communication via an infrared connection may occur.
NOTE
It is also possible to connect to the unit via CAN bus. If a suitable CAN adapter is used, this may be
selected in the Connect window. We recommend to use the IXXAT USB-to-CAN converter using the VCI
V3 driver.
Be sure to configure the correct baud rate and timeout in the Properties dialog of the Connect window.
The Password for CAN Interface 1 (parameter 10402 on page 31) must be entered before being able to
edit the parameters.

Manual 37427 easYgen-2000 Series - Genset Control
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View easYgen Data with ToolKit
The following figure shows a visualization screen of ToolKit:
Figure 2-2: ToolKit - visualization screen
Navigation through the various visualization and configuration screens is performed by clicking on the
and icons, by selecting a navigation button, or by selecting a screen from the drop-down list to the right of
the arrow icons.
It is possible to view a trend chart of up to eight values with the trending tool utility of ToolKit. The following
figure shows a trending screen of the measured battery voltage value:
Figure 2-3: ToolKit - analog value trending screen
Each visualization screen provides for trending of monitored values by right-clicking on a value and selecting the
"Add to trend" function. Trending is initiated by clicking on the Start button. Clicking the Export… button will
save the trend data to a Comma Separated Values (CSV) file for viewing, editing or printing with office software,
like Microsoft Excel, etc. The Properties… button is used to define high and low limits of the scale, sample rate,
displayed time span and color of the graph. The trend functionality is not available if ToolKit is used utilizing a
CAN bus connection to the unit.

Manual 37427 easYgen-2000 Series - Genset Control
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Configure the easYgen with ToolKit
The following figure shows a configuration screen of ToolKit:
Figure 2-4: ToolKit - configuration screen
Entering a new value or selecting a value from a defined list will change the value in a field. The new value is
written to the controller memory by changing to a new field or pressing the Enter key.
Navigation through the various configuration and visualization screens is performed by clicking on the
and icons, by selecting a navigation button, or by selecting a screen from the drop-down list to the right of
the arrow icons.
The Settings File Function of ToolKit
ToolKit allows you to manage device application settings as well as file based settings.
To create a settings file you can save a devices' settings to a file or create device settings from application (SID)
defaults.
After you have a settings file, you can view and edit it, compare it to another settings file, associate it with a
different application, or merge it with an application file (OH2 only).
Settings files can be exported to a Hypertext Markup Language (html) file for viewing, editing or printing with
office software, like Microsoft Excel, etc.
Refer to the ToolKit Help for a description of working with settings. From the main ToolKit window, click Help
then click Help Contents to open the ToolKit Help window.