Woodward easYgen-300 User manual

37218
easYgen-300
Genset Control
Operation Manual
Software Version 1.0xxx
Manual 37218

Manual 37218 easYgen-300 Series - Genset Control
WARNING
Read this entire manual and all other publications pertaining to the work to be performed before install-
ing, 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 (overtempera-
ture, 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 gov-
ernor(s) or electric control(s), the actuator(s), fuel control(s), the driving mechanism(s), the linkage(s),
or the controlled device(s) fail.
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 dam-
age 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.
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.
d-
be correct and reliable. Howe ard Governor Company assumes no responsibility
unless otherwise expressly undertaken.
© Woo pany
All Rights Reserved.
Woodward Governor Company reserves the right to update any portion of this publication at any time. Information provided by Woo
ward Governor Company is believed to ver, Woodw
dward Governor Com
Page 2/114 © Woodward

Manual 37218 easYgen-300 Series - Genset Control
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Revision History
Rev. Date Editor Change
NEW 04-10-15 TP Release
Content
CHAPTER 1. GENERAL INFORMATION..........................................................................................8
Related Documents.................................................................................................................................8
Overview .................................................................................................................................................9
CHAPTER 2. EASYGEN SERIES 300 OVERVIEW .........................................................................11
CHAPTER 3. ELECTROSTATIC DISCHARGE AWARENESS............................................................12
CHAPTER 4. HOUSING ..............................................................................................................13
Dimensions / Panel Cut-Out .................................................................................................................13
Installation .............................................................................................................................................14
CHAPTER 5. WIRING DIAGRAMS ...............................................................................................15
CHAPTER 6. CONNECTIONS......................................................................................................19
Terminal Arrangement ..........................................................................................................................19
Power supply.........................................................................................................................................20
Charging Alternator ...............................................................................................................................20
Voltage Measuring ................................................................................................................................21
Voltage Measuring: Generator ...................................................................................................22
Voltage Measuring: Mains, [350], [350X]....................................................................................24
MPU (pickup) [320X], [350X] ................................................................................................................26
Discrete Inputs ......................................................................................................................................27
Discrete Inputs: Bipolar Signals..................................................................................................27
Discrete Inputs: Operation Logic ................................................................................................28
Relay Outputs .......................................................................................................................................29
Interfaces ..............................................................................................................................................30
Overview .....................................................................................................................................30
CAN Bus - [320X], [350X] ..........................................................................................................31
DPC - Direct Configuration Cable...............................................................................................31
CHAPTER 7. OPERATION AND NAVIGATION ...............................................................................32
Operation and Display ..........................................................................................................................33
Purpose of the Status LEDs .......................................................................................................33
Operating the easYgen...............................................................................................................33
Acknowledging Alarm Messages................................................................................................33
Configuring the easYgen ............................................................................................................34
Display of the Operating Values .................................................................................................34
Cycling Through the Displayed Operating Values......................................................................35
J1939 Visualization [320X], [350X].............................................................................................37
Alarm Messages .........................................................................................................................38
Configuration Displays................................................................................................................41

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CHAPTER 8. FUNCTIONAL DESCRIPTION................................................................................... 44
Overview............................................................................................................................................... 44
Application Modes ................................................................................................................................45
Application Mode {1 breaker open/close} – [320], [320X], [350], [350X] ................................... 45
Application Mode {2 breakers open/close} – [350], [350X] ........................................................ 45
Operating Modes .................................................................................................................................. 46
Operating Mode STOP............................................................................................................... 46
Operating Mode MANUAL.......................................................................................................... 47
Operating Mode AUTOMATIC ................................................................................................... 51
Breaker Closure Limits ......................................................................................................................... 54
Functional Description of the Oil Pressure Input DI1 ........................................................................... 55
Firing Speed Detection ......................................................................................................................... 56
Functional Description of the Charging Alternator Input/Output .......................................................... 57
Functional Description of the 2nd CB Close Delay Time....................................................................... 58
Functional Description of the Engine Released Signal ........................................................................ 59
CHAPTER 9. CONFIGURATION .................................................................................................. 60
Restoring Default Values...................................................................................................................... 60
Resetting Via the Front Panel .................................................................................................... 60
Resetting Via LeoPC1 ................................................................................................................ 60
Configuration Via the Front Panel ........................................................................................................ 60
Configuration Using the PC .................................................................................................................. 61
Editing the Configuration File ............................................................................................................... 62
Configuring the Flags ........................................................................................................................... 62
CHAPTER 10. PARAMETERS ..................................................................................................... 64
Measuring ............................................................................................................................................. 65
Application ............................................................................................................................................ 66
Engine................................................................................................................................................... 67
Engine: Diesel ............................................................................................................................ 67
Engine: Pickup ........................................................................................................................... 67
Engine: Start/Stop Automatic ..................................................................................................... 68
Breaker ................................................................................................................................................. 69
Emergency Power (AMF) ..................................................................................................................... 69
Monitoring ............................................................................................................................................. 70
Monitoring: Generator ................................................................................................................ 70
Monitoring: Generator Overfrequency........................................................................................ 70
Monitoring: Generator Underfrequency ..................................................................................... 71
Monitoring: Generator Overvoltage............................................................................................ 72
Monitoring: Generator Undervoltage.......................................................................................... 73
Monitoring: Mains ....................................................................................................................... 74
Monitoring: Mains Failure Limits ................................................................................................74
Monitoring: Engine Overspeed................................................................................................... 76
Monitoring: Engine Underspeed................................................................................................. 77
Monitoring: Engine Start Fail...................................................................................................... 78
Monitoring: Engine Unintended Stop ......................................................................................... 78
Monitoring: Battery Undervoltage............................................................................................... 79
Monitoring: Battery Charge Voltage ........................................................................................... 80
Monitoring: Interface................................................................................................................... 81
Discrete Inputs...................................................................................................................................... 82
Relay Outputs ....................................................................................................................................... 83
Counter ................................................................................................................................................. 84
Interfaces .............................................................................................................................................. 85
CAN Interface............................................................................................................................. 85
J1939.......................................................................................................................................... 85
System.................................................................................................................................................. 86
Parameter Access Level ............................................................................................................ 86
Flags........................................................................................................................................... 86
Versions...................................................................................................................................... 87

Manual 37218 easYgen-300 Series - Genset Control
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CHAPTER 11. EVENT LOGGER..................................................................................................88
GetEventLog Software..........................................................................................................................88
Installing GetEventLog................................................................................................................88
Starting GetEventLog .................................................................................................................88
Resetting the Event Logger ........................................................................................................89
CHAPTER 12. TECHNICAL DATA ...............................................................................................90
CHAPTER 13. ACCURACY .........................................................................................................92
APPENDIX A. COMMON ............................................................................................................93
Alarm Classes .......................................................................................................................................93
Conversion Factors ...............................................................................................................................94
Conversion factors: Temperature ...............................................................................................94
Conversion factors: Pressure .....................................................................................................94
APPENDIX B. J1939 PROTOCOL DESCRIPTIONS .......................................................................95
J1939 Measuring Values ......................................................................................................................95
J1939 Standard Measuring Values ............................................................................................95
Special EMR messages..............................................................................................................96
Special S6 messages .................................................................................................................96
APPENDIX C. FRONT CUSTOMIZATION ......................................................................................97
APPENDIX D. TROUBLESHOOTING ............................................................................................98
APPENDIX E. LIST OF PARAMETERS .......................................................................................103
APPENDIX F. SERVICE OPTIONS .............................................................................................109
Product Service Options .....................................................................................................................109
Returning Equipment For Repair ........................................................................................................109
Packing a Control .....................................................................................................................110
Return Authorization Number RAN ..........................................................................................110
Replacement Parts..............................................................................................................................110
How To Contact Woodward ................................................................................................................111
Engineering Services ..........................................................................................................................112
Technical Assistance ..........................................................................................................................113

Manual 37218 easYgen-300 Series - Genset Control
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Illustrations and Tables
Illustrations
Figure 1-2: Functional overview................................................................................................................................................9
Figure 4-1: Housing - panel cut-out.........................................................................................................................................13
Figure 5-1: Wiring diagram – easYgen 320.............................................................................................................................15
Figure 5-2: Wiring diagram – easYgen320X...........................................................................................................................16
Figure 5-3: Wiring diagram – easYgen350..............................................................................................................................17
Figure 5-4: Wiring diagram – easYgen350X...........................................................................................................................18
Figure 6-1: easYgen-300 back view - terminal arrangement...................................................................................................19
Figure 6-2: Power supply.........................................................................................................................................................20
Figure 6-3: Charging alternator input/output...........................................................................................................................20
Figure 6-4: Voltage measuring - generator 3Ph 4W ................................................................................................................22
Figure 6-5: Voltage measuring - generator 3Ph 3W ................................................................................................................22
Figure 6-6: Voltage measuring - generator 1Ph 3W ................................................................................................................22
Figure 6-7: Voltage measuring - generator 1Ph 2W ................................................................................................................23
Figure 6-8: Voltage measuring - mains 3Ph 4W......................................................................................................................24
Figure 6-9: Voltage measuring - mains 3Ph 3W......................................................................................................................24
Figure 6-10: Voltage measuring - mains 1Ph 3W....................................................................................................................24
Figure 6-11: Voltage measuring - mains 1Ph 2W....................................................................................................................25
Figure 6-12: MPU - principle overview...................................................................................................................................26
Figure 6-13: MPU input...........................................................................................................................................................26
Figure 6-14: Minimum required input voltage depending on frequency .................................................................................26
Figure 6-15: Discrete inputs - alarm/control input - positive signal .......................................................................................27
Figure 6-16: Discrete inputs - alarm/control input - negative signal.......................................................................................28
Figure 6-17: Discrete inputs - alarm/control inputs - operation logic......................................................................................28
Figure 6-18: Relay outputs ......................................................................................................................................................29
Figure 6-19: Interfaces - overview...........................................................................................................................................30
Figure 6-20: Interfaces - CAN bus...........................................................................................................................................31
Figure 6-21: Interfaces - CAN bus - wiring of shielding.........................................................................................................31
Figure 6-22: Interfaces - CAN bus – schematic wiring and termination..................................................................................31
Figure 7-1: Front panel and display.........................................................................................................................................32
Figure 7-2: 6 digit 7 segment LED display..............................................................................................................................34
Figure 7-3: J1939 fault display................................................................................................................................................38
Figure 7-4: Additional alarm display.......................................................................................................................................39
Figure 8-2: Discrete input DI1 - oil pressure...........................................................................................................................55
Figure 8-3: Starting procedure.................................................................................................................................................55
Figure 8-4: Charging alternator input/output...........................................................................................................................57
Figure 8-5: AMF application with engine released signal.......................................................................................................59
Figure 9-1: Configurable display flags ....................................................................................................................................62
Figure 9-2: Flag configuration default.....................................................................................................................................63
Figure 9-3: Flag configuration custom.....................................................................................................................................63
Figure 10-1: Voltage/frequency hysteresis ..............................................................................................................................75
Figure 10-2: Configurable display flags ..................................................................................................................................86
Figure 11-1: GetEventLog - interface configuration................................................................................................................88
Figure 11-2: GetEventLog – event logger content...................................................................................................................89
Figure 13-1: Paper strips..........................................................................................................................................................97

Manual 37218 easYgen-300 Series - Genset Control
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Tables
Table 1-1: Manual - overview....................................................................................................................................................8
Table 2-1: easYgen series 300 product features.......................................................................................................................11
Table 4-1: Housing - panel cut-out ..........................................................................................................................................13
Table 6-1: Power supply - terminal assignment.......................................................................................................................20
Table 6-2: Charging alternator input/output - terminal assignment.........................................................................................20
Table 6-3: Voltage measuring principles.................................................................................................................................21
Table 6-4: Voltage measuring - terminal assignment - generator voltage................................................................................23
Table 6-5: Voltage measuring - terminal assignment - mains voltage.....................................................................................25
Table 6-6: MPU - terminal assignment....................................................................................................................................26
Table 6-7: Discrete input - terminal assignment - alarm/control input - positive signal..........................................................27
Table 6-8: Discrete input - terminal assignment - alarm/control inputs - negative signal........................................................28
Table 6-9: Relay outputs - terminal assignment, part 1 ...........................................................................................................29
Table 6-10: Relay outputs – configurable parameters..............................................................................................................29
Table 6-11: Interfaces - connection overview..........................................................................................................................30
Table 7-1: Display of operating values....................................................................................................................................36
Table 7-2: J 1939 messages .....................................................................................................................................................38
Table 7-3: Alarm classes..........................................................................................................................................................39
Table 7-4: Alarm messages......................................................................................................................................................40
Table 7-5: Configuration displays............................................................................................................................................43
Table 8-1: Functional description - Overview .........................................................................................................................44
Table 8-1: Discrete input DI1 - oil pressure.............................................................................................................................55
Table 10-1: Relay outputs - list of configurable parameters....................................................................................................83
Table 11-1: Event logger - operation states .............................................................................................................................89

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Chapter 1.
General Information
Related Documents
≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Type English German
easYgen-300 Series
easYgen-300 – Manual this manual Ö37218 GR37218
Additional Manuals
LeoPC1 – User Manual 37146 GR37146
PC program for configuration, parameter visualization, remote control, data logging, language upload, alarm and user management,
and event recorder management. This manual describes the use of LeoPC1 software.
LeoPC1 – Engineering Manual 37164 GR37164
PC program for configuration, parameter visualization, remote control, data logging, language upload, alarm and user management,
and event recorder management. This manual describes the programming of LeoPC1 software.
Table 1-1: Manual - overview

Manual 37218 easYgen-300 Series - Genset Control
© Woodward Page 9/114
Overview
≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Figure 1-2: Functional overview

Manual 37218 easYgen-300 Series - Genset Control
Page 10/114 © Woodward
The easYgen-300 Series generator set control ions:
• Gen-set control
• Engine and gen
• Engine data measurement -
o including oil pressure and temperature, coolant temperature, battery voltage, speed,
r trip and engine shutdown
ic mains failu genset th autom gine start on failure
open transition breaker control
s communications t gine controllers and plant managem t systems
T esignation is as follows:
ler provides the following funct
erator protection
service hours, etc.
• Generator voltage measurement
• Engine crank sequencing
• Alarm display with circuit breake
• AMF (automat
dre) standby control wi atic en a mains detection an
• CAN bu o en en
ype d
easYgen -xxx
Option
[ ] no option
[X] = option X (MPU and CAN capable)
[320] = Model '320' (1 circuit breaker)
[350] = Model '350' (2 circuit breakers)
Model
[300] = Series
Type
E
ASYGEN-350X (standard easYgen 350 with 2 CBs, MPU & CAN)
Introl unit must only be operated as described in this manual. The prerequisite for a proper
and roduct is correct transportation, storage, and installation as well as careful operation
and ma
xamples:
E
EASYGEN-320 (standard easYgen 320 with 1 CB)
ntended Use The co
safe operation of the p
intenance.
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 installation and commissioning of the unit. Be-
cause 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 enclosed list of parameters.