Woodward easYgen-2000 Series User manual

easYgen-2000 Series
Manual Genset Control
easYgen-2200/2500
Software Version 1.0103 or higher
37535B

© 2013
Designed in Germany
Woodward GmbH
Handwerkstrasse 29
70565 Stuttgart
Germany
Telephone: [phone]
Fax: [phone]
email: [email protected]
Internet: http://www.woodward.com
37535BeasYgen-2200/2500 | Genset Control2

Brief Overview
Fig. 1: easYgen-2000 Series (housing variants)
A easYgen-2200 (plastic housing with display)
B easYgen-2500 (plastic housing with display)
1 Analog output and generator CT terminal
2 Mains/generator/busbar PT terminal
3Service port connector (USB/RS-232)1
4 Relay outputs terminal
5 Discrete inputs terminal
6 CAN bus interface terminal #1
7 CAN bus interface terminal #2 (easYgen-2200
Package P2 only)
8 Analog input/outputs terminal and discrete
inputs terminal
9 Relay outputs terminal
10 CAN bus interface terminal #2
11 RS-485 interface terminal
1 Optional configuration cable for ToolKit configuration
software and external extensions/applications
required:
– USB connector: DPC-USB direct configuration
cable – P/N 5417-1251
– RS-232 connector: DPC-RS-232 direct configura‐
tion cable – P/N 5417-557
The easYgen-2000 Series are control units for engine-generator
system management applications.
The control units can be used in applications such as: co-genera‐
tion, stand-by, AMF, peak shaving, import/export or distributed
generation.
Brief Overview
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Fig. 2: Sample application setup
A typical application mode for the control unit is the use for mains
parallel operation.
nIn this case, the easYgen will function as an engine control with
generator, mains and engine protection.
nThe control unit can open and close the generator circuit
breaker (GCB) and the mains circuit breaker (MCB).
For a listing of additional application modes and setups
please refer to chapter Ä Chapter 6 “Application”
on page 359.
The easYgen-2200/2500 controllers are available in
different packages. The differences are listed below.
Sample application setup
Packages
Brief Overview
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easYgen-2000 Series easYgen-2200 easYgen-2500
Package P1 Package P2 Package P1
MPU input 31---131
Discrete inputs 8 8 10
Relay outputs 6 6 11
Analog inputs 3 3 4
Analog outputs 1 1 4
CAN bus interfaces 1 2 2
RS-485 interface --- --- 1
1 The MPU input (if available) or an external ECU
signal can be used as speed source.
The following parts are included in the scope of delivery. Please
check prior to the installation that all parts are present.
Fig. 3: Scope of delivery - schematic
A easYgen-2200/2500 genset control
B Product CD (configuration software and manual)
C Clamp fastener installation material - 4x
D Screw kit installation material - 8x
To create a *.WSET file with ToolKit
(“Save from Device to File”) please use the US version
of the *.WTOOL file. This must be done this way for
devices running software version 1.00xx.
Failure to do so causes problems to import the
*.WSET file via ToolKit (“Load Settings File to Device”)
if the device is running software version 1.01xx or
higher.
Please refer to Ä Chapter 5.1.2 “Install ToolKit Config‐
uration Files” on page 333 for details.
Scope of delivery
Save/load *.WSET file
Brief Overview
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Brief Overview
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Table of contents
1General Information................................................................................................................ 17
1.1 About This Manual.................................................................................................................... 17
1.1.1 Revision History........................................................................................................................ 17
1.1.2 Depiction Of Notes And Instructions......................................................................................... 19
1.2 Copyright And Disclaimer.......................................................................................................... 20
1.3 Service And Warranty............................................................................................................... 21
1.4 Safety........................................................................................................................................ 21
1.4.1 Intended Use............................................................................................................................. 21
1.4.2 Personnel.................................................................................................................................. 22
1.4.3 General Safety Notes................................................................................................................ 22
1.4.4 Protective Equipment And Tools............................................................................................... 25
2 System Overview..................................................................................................................... 27
2.1 Display And Status Indicators................................................................................................... 27
2.2 Hardware Interfaces (Terminals)............................................................................................... 27
2.3 Application Modes Overview..................................................................................................... 28
3 Installation............................................................................................................................... 31
3.1 Mount Unit (Plastic Housing)..................................................................................................... 31
3.1.1 Clamp Fastener Installation....................................................................................................... 33
3.1.2 Screw Kit Installation................................................................................................................. 34
3.2 Setup Connections.................................................................................................................... 36
3.2.1 Terminal Allocation.................................................................................................................... 36
3.2.2 Wiring Diagrams........................................................................................................................ 38
3.2.3 Power Supply............................................................................................................................ 41
3.2.4 Charging Alternator................................................................................................................... 42
3.2.5 Voltage Measuring.................................................................................................................... 43
3.2.5.1 Generator Voltage..................................................................................................................... 43
3.2.5.2 Mains Voltage............................................................................................................................ 50
3.2.5.3 Busbar Voltage.......................................................................................................................... 56
3.2.6 Current Measuring..................................................................................................................... 62
3.2.6.1 Generator Current..................................................................................................................... 62
3.2.6.2 Mains Current............................................................................................................................ 64
3.2.6.3 Ground Current......................................................................................................................... 65
3.2.7 Power Measuring...................................................................................................................... 66
3.2.8 Power Factor Definition............................................................................................................. 67
3.2.9 Magnetic Pickup Unit (MPU)..................................................................................................... 68
3.2.10 Discrete Inputs.......................................................................................................................... 69
3.2.11 Relay Outputs (LogicsManager)................................................................................................ 71
3.2.12 Analog Inputs............................................................................................................................ 72
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3.2.13 Analog Outputs.......................................................................................................................... 76
3.2.14 Serial Interfaces........................................................................................................................ 78
3.2.14.1 RS-485 Interface....................................................................................................................... 78
3.2.15 Service Port............................................................................................................................... 79
3.3 CAN Bus Interfaces................................................................................................................... 80
3.4 Connecting 24 V Relays............................................................................................................ 83
4 Configuration........................................................................................................................... 85
4.1 Basic Setup............................................................................................................................... 85
4.1.1 Configure Language/Clock........................................................................................................ 85
4.1.2 Configure Display...................................................................................................................... 89
4.1.3 Lamp Test................................................................................................................................. 89
4.1.4 Enter Password......................................................................................................................... 89
4.1.5 System Management................................................................................................................ 92
4.1.6 Password System...................................................................................................................... 93
4.2 Configure Measurement............................................................................................................ 93
4.2.1 Configure Transformer.............................................................................................................. 98
4.3 Function Of Inputs And Outputs.............................................................................................. 101
4.3.1 Discrete Inputs........................................................................................................................ 101
4.3.2 Discrete Outputs...................................................................................................................... 104
4.4 Configure Monitoring............................................................................................................... 107
4.4.1 Generator................................................................................................................................ 107
4.4.1.1 Generator Operating Voltage / Frequency.............................................................................. 107
4.4.1.2 Generator Overfrequency (Level 1 & 2) ANSI# 81O............................................................... 108
4.4.1.3 Generator Underfrequency (Level 1 & 2) ANSI# 81U............................................................. 109
4.4.1.4 Generator Overvoltage (Level 1 & 2) ANSI# 59...................................................................... 111
4.4.1.5 Generator Undervoltage (Level 1 & 2) ANSI# 27.................................................................... 112
4.4.1.6 Generator Time-Overcurrent (Level 1, 2 & 3) ANSI# 50/51.................................................... 114
4.4.1.7 Generator Reverse/Reduced Power (Level 1 & 2) ANSI# 32R/F............................................ 115
4.4.1.8 Generator Overload IOP (Level 1 & 2) ANSI# 32.................................................................... 117
4.4.1.9 Generator Overload MOP (Level 1 & 2) ANSI# 32.................................................................. 118
4.4.1.10 Generator Unbalanced Load (Level 1 & 2) ANSI# 46............................................................. 120
4.4.1.11 Generator Voltage Asymmetry................................................................................................ 122
4.4.1.12 Generator Ground Fault (Level 1 & 2)..................................................................................... 123
4.4.1.13 Generator Phase Rotation....................................................................................................... 127
4.4.1.14 Generator Inverse Time-Overcurrent ANSI# IEC 255............................................................. 129
4.4.1.15 Generator Lagging Power Factor (Level 1 & 2)....................................................................... 132
4.4.1.16 Generator Leading Power Factor (Level 1 & 2)....................................................................... 133
4.4.2 Mains....................................................................................................................................... 135
4.4.2.1 Mains Operating Voltage / Frequency..................................................................................... 136
4.4.2.2 Mains Decoupling.................................................................................................................... 137
4.4.2.3 Mains Overfrequency (Level 1 & 2) ANSI# 81O...................................................................... 138
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4.4.2.4 Mains Underfrequency (Level 1 & 2) ANSI# 81U.................................................................... 140
4.4.2.5 Mains Overvoltage (Level 1 & 2) ANSI# 59............................................................................. 141
4.4.2.6 Mains Undervoltage (Level 1 & 2) ANSI# 27........................................................................... 142
4.4.2.7 Mains Voltage Increase........................................................................................................... 144
4.4.2.8 Mains Time-Dependent Voltage.............................................................................................. 146
4.4.2.9 QV Monitoring......................................................................................................................... 149
4.4.2.10 Change Of Frequency............................................................................................................. 151
4.4.2.11 Mains Voltage Phase Rotation................................................................................................ 155
4.4.3 Engine..................................................................................................................................... 157
4.4.3.1 Engine Overspeed (Level 1 & 2) ANSI# 12............................................................................. 157
4.4.3.2 Engine Underspeed (Level 1 & 2)........................................................................................... 158
4.4.3.3 Engine/Generator Speed Detection........................................................................................ 159
4.4.3.4 Engine/Generator Active Power Mismatch.............................................................................. 161
4.4.3.5 Engine/Mains Active Power Mismatch.................................................................................... 162
4.4.3.6 Engine/Generator Unloading Mismatch.................................................................................. 163
4.4.3.7 Engine Start Failure................................................................................................................. 164
4.4.3.8 Engine Shutdown Malfunction ................................................................................................ 164
4.4.3.9 Engine Unintended Stop ........................................................................................................ 165
4.4.3.10 Engine Operating Range Failure............................................................................................. 166
4.4.3.11 Engine Charge Alternator (D+)................................................................................................ 167
4.4.4 Breaker.................................................................................................................................... 168
4.4.4.1 Configure GCB........................................................................................................................ 168
4.4.4.2 Synchronization GCB ............................................................................................................. 170
4.4.4.3 Configure MCB........................................................................................................................ 171
4.4.4.4 Synchronization MCB ............................................................................................................. 173
4.4.4.5 Generator/Busbar/Mains Phase Rotation................................................................................ 174
4.4.5 Flexible Limits.......................................................................................................................... 175
4.4.6 Miscellaneous.......................................................................................................................... 179
4.4.6.1 Alarm Acknowledgement......................................................................................................... 179
4.4.6.2 CAN Bus Overload.................................................................................................................. 180
4.4.6.3 CAN Interface 1....................................................................................................................... 181
4.4.6.4 CAN Interface 2....................................................................................................................... 181
4.4.6.5 CAN Interface 2 - J1939 Interface........................................................................................... 182
4.4.6.6 J1939 Interface - Red Stop Alarm........................................................................................... 183
4.4.6.7 J1939 Interface - Amber Warning Alarm................................................................................. 184
4.4.6.8 Battery Overvoltage (Level 1 & 2)........................................................................................... 185
4.4.6.9 Battery Undervoltage (Level 1 & 2)......................................................................................... 186
4.4.6.10 Multi-Unit Parameter Alignment.............................................................................................. 187
4.4.6.11 Multi-Unit Missing Members.................................................................................................... 189
4.5 Configure Application.............................................................................................................. 190
4.5.1 Configure Breakers................................................................................................................. 190
4.5.1.1 Dead Bus Closing GCB........................................................................................................... 191
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4.5.1.2 Synchronization GCB/MCB..................................................................................................... 192
4.5.1.3 Dead Bus Closing MCB........................................................................................................... 193
4.5.1.4 Open GCB............................................................................................................................... 194
4.5.1.5 Open MCB............................................................................................................................... 195
4.5.1.6 Transition Modes (Breaker Logic)........................................................................................... 195
4.5.1.7 Parameters.............................................................................................................................. 200
4.5.1.8 Breakers GCB......................................................................................................................... 201
4.5.1.9 Breakers MCB......................................................................................................................... 205
4.5.1.10 Synchronization....................................................................................................................... 207
4.5.2 Inputs And Outputs.................................................................................................................. 208
4.5.2.1 Analog Inputs.......................................................................................................................... 208
4.5.3 Discrete Inputs........................................................................................................................ 215
4.5.4 External Discrete Inputs.......................................................................................................... 219
4.5.5 Discrete Outputs (LogicsManager).......................................................................................... 220
4.5.6 External Discrete Outputs....................................................................................................... 221
4.5.7 Analog Outputs 1/2.................................................................................................................. 222
4.5.8 Analog Outputs 3/4.................................................................................................................. 226
4.5.9 Engine..................................................................................................................................... 229
4.5.9.1 Engine Type............................................................................................................................ 229
4.5.9.2 Engine Start/Stop.................................................................................................................... 236
4.5.9.3 Magnetic Pickup Unit............................................................................................................... 241
4.5.9.4 Idle Mode................................................................................................................................. 242
4.5.10 Emergency Run....................................................................................................................... 244
4.5.11 Automatic Run......................................................................................................................... 246
4.5.11.1 Load Dependent Start Stop (LDSS)........................................................................................ 248
4.5.11.2 Critical Mode........................................................................................................................... 262
4.5.12 Configure Controller................................................................................................................ 269
4.5.12.1 Frequency Control................................................................................................................... 271
4.5.12.2 Load Control............................................................................................................................ 276
4.5.12.3 Derating Of Power .................................................................................................................. 282
4.5.12.4 Frequency Depending Derating Of Power.............................................................................. 284
4.5.12.5 Voltage Control........................................................................................................................ 286
4.5.12.6 Power Factor Control.............................................................................................................. 290
4.5.12.7 Load Share Control................................................................................................................. 296
4.5.12.8 Discrete Raise/Low/Function................................................................................................... 306
4.6 Configure Interfaces................................................................................................................ 308
4.6.1 CAN Interface 1....................................................................................................................... 308
4.6.1.1 Additional Server SDOs (Service Data Objects)..................................................................... 310
4.6.1.2 Receive PDO {x} (Process Data Object)................................................................................. 311
4.6.1.3 Transmit PDO {x} (Process Data Object)................................................................................ 313
4.6.2 CAN Interface 2....................................................................................................................... 317
4.6.2.1 CANopen Interface.................................................................................................................. 317
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