Woodward easYgen-100 Series User manual

Technical Manual
easYgen-800
Genset Control
easYgen-800
Document ID: B37691A, Revision D - Build 51671
Version 3.0.1.3
Released

Manual (original)
This is no translation but the original Technical Manual in English.
Designed in Germany and Poland; manufactured in China.
Woodward GmbH
Handwerkstr. 29
70565 Stuttgart
Germany
Telephone: [phone]‑510
Fax: [phone]‑101
E-mail: [email protected]
Internet: http://www.woodward.com
© 2021 Woodward GmbH. All rights reserved.
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Brief Overview
Fig. 1: easYgen-800
1 Terminals 1 to 22: Power supply, relays, discrete inputs, MPU, D+, ...
2 Terminals 23 to 26: CAN (J1939)
3 Terminals 33 to 35: RS-485 interface
4 USB service port for PC/laptop with ToolKit-SC
5 Terminals 62 to 64: RS-232 interface
6 ETHERNET interface connector (RJ-45)
7Terminals 56 to 61: Analog inputs
8 Terminals 49 to 55 (screwable): Generator and Ground current, discrete input 8
9 Terminals 45 to 48: Generator voltage
10 Terminals 41 to 44: Intentionally not implemented
11 Terminals 36 to 40: Relay outputs
12 SD micro card slot
The easYgen-800 is a control units for engine-generator system management
applications.
The control unit can be used in applications such as: co-generation, stand-by or
distributed generation.
Scope of delivery
The following parts are included in the covering box. Please check prior to the installation
that all parts are present:
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• Device easYgen genset control•
All screwable terminal connectors are delivered with plug and jack
• Clamp fastener installation material (4x)•
• »Installation Procedure Supplement« paper with links to the latest edition of•
Technical Documentation and software for download:
(http://wwdmanuals.com/easYgen-800)
Con󰍓guration software and Technical Manual are available at Woodward website:
http://wwdmanuals.com/easYgen-800
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Sample application setup
Fig. 2: Sample application setup
A typical application mode for the control unit is the use for non parallel operation in a
single genset application.
•In this case, the easYgen will function as an engine control with generator and •
engine protection.
• The control unit can open and close the circuit breaker .•
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Transition procedures are described in chapter ╚═▷ “5.4 Transition Procedures”.
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Table of Contents
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11█
1.1 About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11█
1.1.1 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11█
1.1.2 Symbols Used in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13█
1.2 Copyright And Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14█
1.3 Service And Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15█
1.4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15█
1.4.1 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15█
1.4.2 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16█
1.4.3 General hazard warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16█
2 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18█
2.1 Display and Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18█
2.2 Features and Functions of both easYgen-800 and -1800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19█
2.3 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22█
2.4 Intended Use of This Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22█
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24█
3.1 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24█
3.2 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24█
3.3 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31█
3.3.1 Ethernet Interface Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31█
3.4 Micro SD Card Slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32█
3.5 Install ToolKit-SC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33█
4Con󰍏guration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34█
4.1 Access to the Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34█
4.1.1 Front Panel: Operating and Display Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34█
4.1.2 Front Panel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37█
4.1.2.1 HMI Screens Without Password Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37█
4.1.3 Con󰍓gure ToolKit-SC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40█
4.1.3.1 Con󰍓gure Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40█
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4.1.3.2 Manage Con󰍓guration Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40█
4.1.3.3 Con󰍓gure Customized Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41█
4.1.4 Access via ToolKit-SC Con󰍓guration Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42█
4.2 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43█
4.2.1 Parameter Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43█
4.2.2 Parameter Settings Menu--HMI Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45█
4.2.3 Con󰍓gure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45█
4.2.4 Con󰍓gure Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47█
4.2.4.1 Con󰍓gure Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47█
4.2.4.2 Con󰍓gure Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63█
4.2.4.3 Con󰍓gure TEST Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65█
4.2.4.4 Con󰍓gure Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66█
4.2.5 Con󰍓gure Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66█
4.2.5.1 Monitoring Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66█
4.2.5.2 Monitoring Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70█
4.2.5.3 Monitoring Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70█
4.2.5.4 CAN Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72█
4.2.5.5 Other Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72█
4.2.6 Con󰍓gure Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73█
4.2.6.1 Con󰍓gure GSM Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74█
4.2.6.2 Con󰍓gure Ethernet Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76█
4.2.7 Con󰍓gure Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77█
4.2.8 Con󰍓gure Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79█
4.2.9 Con󰍓gure Switchable Parameter Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80█
4.2.10 Con󰍓gure Language / Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81█
4.2.11 Con󰍓gure System Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81█
4.2.12 Con󰍓gure HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82█
4.3 Selectable Inputs/Outputs/Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82█
4.3.1 Programmable Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82█
4.3.2 Programmable Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84█
4.3.3 Programmable Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87█
4.4 Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91█
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4.4.1 HMI Status Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91█
4.4.2 ToolKit-SC Status Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92█
4.4.3 Con󰍓gure For Using Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95█
4.4.3.1 IKD 1 I/O Expansion Board for Woodward Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95█
5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97█
5.1 Warning/Alarm Signaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97█
5.1.1 Alarm Acknowledgment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97█
5.2 Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98█
5.2.1 Operation Mode AUTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98█
5.2.2 Operation Mode MANual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98█
5.2.3 Operation Mode STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99█
5.3 START/STOP Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99█
5.3.1 Start engine to supply load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99█
5.3.2 Stop engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100█
5.3.3 MANual START/STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102█
5.4 Transition Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102█
5.4.1 Disconnect during cranking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102█
6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104█
7 Interfaces and Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105█
7.1 J1939 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105█
8 Technical Speci󰍏cations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111█
8.1 Measuring and Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114█
9 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116█
9.1 Alarms and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116█
9.1.1 Alarm Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116█
9.1.2 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116█
9.1.3 Shutdown Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118█
9.1.4 Trip and Stop Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119█
9.1.5 Trip Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120█
9.2 Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120█
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9.3 Data Telegrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121█
9.3.1 Modbus Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121█
9.3.1.1 Data Frame Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121█
9.3.1.2 Modbus Communication Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122█
9.3.1.3 Information Frame Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122█
9.3.1.4 Address Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122█
9.3.1.5 Function Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122█
9.3.1.6 Data Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123█
9.3.1.7 Error Check Code (CRC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124█
9.3.1.8 Error Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128█
9.3.2 Read Holding Registers 03_hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129█
9.3.3 Force Single Coil 05H_hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154█
9.3.4 Preset Single Register 06H_hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155█
9.3.4.1 Generator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155█
9.3.4.2 Remote Start Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155█
9.3.4.3 Breaker Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156█
10 Glossary and List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157█
11 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158█
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1 General Information
1.1 About this Manual
1.1.1 Revision History
Rev. Date Editor Changes
D 2021-12 MK Corrections/Repairs Technical Manual
• Corrected voltage range ph-N according to UL ╚═▷ “8 Technical•
Speci󰍓cations”.
• Deleted 'pending' at EAC approval ╚═▷ “8 Technical•
Speci󰍓cations”.
• Adjusted data telegram entries for Expansion Switch in ╚═▷ “9.3•
Data Telegrams”.
• Updated download link.•
CSoftware Revision 3.0.1.3 and ToolKit-SC version 1.5.1.3
B 2019-05 PW NEW Software Revision 3.0.1.2 and ToolKit-SC version 1.5.0.4
NEW features & functions
• Display optimization for Main page and Engine page of•
temperature sensor and oil pressure sensor;
• AIs 01-03 reworked. All sensors can be set as temperature,•
pressure and level ones.
See ╚═▷ “4.2.4.1.3 Con󰍓gure Analog Inputs”;
• Delay On/O󰍒 added to the logic 󰍔ag output;•
• Polish added in the PC software language package;•
• Expansion module lamp panel easYlite-200 added;•
• Breaker plausibility check at start in the manual mode enhanced;•
• Acknowledge button in the web interface added;•
• Response button command “SMS ACK” for GSM text added;•
• Support of woodward IKD1 and IKD2 added, each module with 8•
inputs and 8 outputs.
• The arrow down button addded as the lamp test button.•
• Added Limits for AIs 1-3 same as AI 4-55;•
• Fixed AI 2 output con󰍓guration delay to Max. working time and•
value 0=unlimited. There shall be a remark on the ToolKit SC;
• Fixed KingBAND ECU data display;•
• Changed 26 MTU-ADEC & 27 MTU-ADEC-SAM to issue speed•
command at stop status;
• Changed 3: VDO to 3: VDO 120 for temperature sensor curve.•
• Fixed bugs:•
◦ easYgen breaker feedback not being used;◦
11easYgen-800B37691A
1 General Information
1.1 About this Manual
Released

Rev. Date Editor Changes
◦ easYgen-800/1800 sensor data 󰍔uctuation after repower on.◦
Technical Manual
• In ╚═▷ “3.2 Wiring”:•
◦ terminal ratings and descriptions updated in ╚═▷ Table ;◦
◦ corrections in ╚═▷ Fig. 6.◦
• Chapter ╚═▷ “4.2.4.1 Con󰍓gure Inputs and Outputs”•
supplemented with an external LED module.
•Minor adjustments of items in con󰍓guration menu descriptions. •
•Added description of ECU sensors. •
See ╚═▷ “4.2.4.1.3 Con󰍓gure Analog Inputs”;
• In ╚═▷ “4.4.3 Con󰍓gure For Using Accessories” , a chapter on the•
IKD module added, replacing WWDIN16/WWDOUT16.
• Added overcurrent and ground fault delay time formulas in ╚═▷•
“4.2.5.1 Monitoring Generator ”.
• In ╚═▷ “8 Technical Speci󰍓cations” voltage ranges for the•
alternator and AC measurement updated to UL6200.
• Added description of analog inputs in ╚═▷ “8 Technical•
Speci󰍓cations”.
• Adjusted data telegram entries in ╚═▷ “9.3 Data Telegrams”.•
A 2018-03 GG Describes device implemented software version 2.2 and
ToolKit-SC version 1.4.0.2
Technical Manual
• Release = 1st issue•
12 easYgen-800 B37691A
1 General Information
1.1.1 Revision History
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1.1.2 Symbols Used in this manual
Safety instructions
Safety instructions are marked with symbols. The safety instructions are always
introduced by signal words that express the severity of the danger.
DANGER!
This combination of symbol and signal word indicates an immediately dangerous
situation that can cause death or severe injuries if not avoided.
WARNING!
This combination of symbol and signal word indicates a possibly dangerous situation that
can cause death or severe injuries if it is not avoided.
CAUTION!
This combination of symbol and signal word indicates a possibly dangerous situation that
can cause slight injuries if it is not avoided.
NOTICE!
This combination of symbol and signal word indicates a possibly dangerous situation that
can cause property and environmental damage if it is not avoided.
Tips and recommendations
This symbol indicates useful tips and recommendations as well as information on
e󰍕cient and trouble-free operation.
Additional markings
To highlight instructions, results, lists, references, and other elements, the following
markings are used in these instructions:
Marking Explanation
__▶ Step-by-step instructions
⇨Results of action steps
╚═▷ References to sections of these instructions and to other
relevant documents
• Listing without 󰍓xed sequence
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1 General Information
1.1.2 Symbols Used in this manual
Released

Marking Explanation
»Buttons« Operating elements (e.g. buttons, switches), display
elements (e.g. signal lamps)
»Display« Screen elements (e.g. buttons, programming of function
keys)
[Screen xx / Screen xy /
Screen xz] ...
Menu path.
The following information and setting refer to a page on
the HMI screen or ToolKit located as described here.
Some parameters/settings/screens are available only
either in ToolKit or on the HMI/display.
Dimensions in Figures
All dimensions with no units speci󰍓ed are in mm.
1.2 Copyright And Disclaimer
Disclaimer
All information and instructions in this manual have been provided under due
consideration of applicable guidelines and regulations, the current and known state of the
art, as well as our many years of in-house experience. Woodward assumes no liability for
any damages due to:
• Failure to comply with the instructions in this manual•
• Improper use / misuse•
•Willful operation by non-authorized persons •
• Unauthorized conversions or non-approved technical modi󰍓cations•
•Use of non-approved spare parts •
The originator is solely liable for the full extent for damages caused by such conduct. The
obligations agreed-upon in the delivery contract, the general terms and conditions, the
manufacturer’s delivery conditions, and the statutory regulations valid at the time the
contract was concluded, apply.
Copyright
This manual is protected by copyright. No part of this manual may be reproduced in any
form or incorporated into any information retrieval system without written permission of
Woodward GmbH.
Delivery of this manual to third parties, duplication in any form - including excerpts - as
well as exploitation and/or communication of the content, are not permitted without a
written declaration of release by Woodward GmbH.
14 easYgen-800 B37691A
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1.2 Copyright And Disclaimer
Released

Actions to the contrary will entitle us to claim compensation for damages. We expressly
reserve the right to raise any further accessory claims.
1.3 Service And Warranty
Opening the device will nullify any warranty!
CAUTION!
Any unauthorized modi󰍓cations or use of this equipment outside its speci󰍓ed
mechanical, electrical, or other operating limits may cause personal injury and/or
property damage, including damage to the equipment.
Any such unauthorized modi󰍓cations
• constitute "misuse" and/or "negligence" as per the product warranty•
• thereby exclude warranty coverage for any resulting damage, and•
• invalidate product certi󰍓cations or listings.•
Our Customer Service is available for technical information. Please see page 2 for contact
details.
In addition, our employees are interested in any new information and experiences that
arise from usage and could be valuable for improving our products.
Warranty terms
Please enquire about the terms of warranty from your nearest Woodward representative.
To 󰍓nd your closest Customer Service representative, go to: ══▷ http://
www.woodward.com/Directory.aspx
1.4 Safety
1.4.1 Intended Use
The easYgen unit has been designed and constructed solely for the intended use
described in this manual.
• Intended use requires operation of the control unit within the range outlined in the•
speci󰍓cations listed in ╚═▷ “8 Technical Speci󰍓cations”.
• Steps to be taken for commissioning are outlined in ╚═▷ “6 Commissioning”.•
• Intended use includes compliance with all instructions and safety notes presented in•
this manual.
• Any use which exceeds or di󰍒ers from the intended use shall be considered improper•
use.
• No claims for any kind for damage will be considered if such claims result from•
improper use.
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1 General Information
1.3 Service And Warranty
Released

NOTICE!
Damage due to improper use!
Improper use of the remote panel unit may cause damage to the control unit as well as
to the connected components.
Improper use includes, but is not limited to:
•Operation outside the speci󰍓ed operating conditions. •
1.4.2 Personnel
WARNING!
Hazards due to insu󰈢ciently quali󰈠ed personnel!
If unquali󰍓ed personnel perform work on or with the control unit hazards may arise which
can cause serious injury and substantial damage to property.
• Therefore, all work must only be carried out by appropriately quali󰍓ed personnel.•
This manual speci󰍓es the personnel quali󰍓cations required for the di󰍒erent areas of work,
listed below:
• Well trained for electrical installations.•
• Aware of the local safety regulations.•
• Experienced in working with electronic measuring and control devices.•
• Allowed to manage the controlled (engine/generator) system.•
The workforce must only consist of persons who can be expected to carry out their work
reliably. Persons with impaired reactions due to, for example, the consumption of drugs,
alcohol, or medication are prohibited.
When selecting personnel, the age-related and occupation-related regulations governing
the operating location must be observed.
1.4.3 General hazard warnings
Hazards by system controlled
DANGER!
Moving parts and dangerous electricity!
Be aware that the remote control of a system that is managing life-threatening engine-
generator-electricity parts must be adapted to the local situation!
The following safety notes cover both the device itself and basics of the overall genset
system. The dedicated genset-system safety instruction must be considered, too!
16 easYgen-800 B37691A
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1.4.2 Personnel
Released

Prime mover safety
WARNING!
Hazards due to insu󰈢cient prime mover protection
The engine, turbine, or any other type of prime mover must be equipped with an
overspeed (over-temperature, or over-pressure, where applicable) shutdown device(s)
that operates independently of the prime mover control device(s) to protect from
runaway or damage to the engine, turbine, or any other type of prime mover. Failure to
comply with this also poses the risk of personal injury or loss of life if 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.
17easYgen-800B37691A
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1.4.3 General hazard warnings
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2 System Overview
General notes
The easYgen is a stand-alone genset controller with measuring, monitoring, and breaker
control functionality. It comes with an easily mountable plastic housing covering a
thoroughly tested electronic-electrical system.
Display and buttons of the HMI o󰍒er access to states and values, as well as access to the
application. Password protection enables the assignment of multiple operation access
levels. Remote access, monitoring, visualization, and con󰍓guration are possible via
integrated interfaces. Communication between easYgens using PLC control or as a
network member o󰍒ers an enhanced system management range; additionally supported
by easy to implement accessories.
For even higher challenges in genset control, the easYgen series o󰍒ers further solutions
encompassing complex and ambitious applications.
For dedicated protection tasks, ask Woodward for its protection (relay) solutions.
Operation Modes
• See ╚═▷ “5.2 Operation Modes”•
2.1 Display and Status Indicators
General Notes
HMI and the con󰍓guration software enable access to control, settings, and visualization.
The front panel o󰍒ers a number of functionally de󰍓ned buttons and a set of menu
management buttons. LEDs visualize 󰍓xed states, the graphic display works together with
the menu management buttons to show all necessary information.
Restrictions
Full access to all parameters and settings with con󰍓guration software only!
HMI access o󰍒ers a number of information screens in general, and enables - password-
protected - access to parameters and settings.
18 easYgen-800 B37691A
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Fig. 3: easYgen-800
2.2 Features and Functions of both easYgen-800 and -1800
Both easYgen-800 and easYgen-1800 are very close in hardware and software. The
easYgen-1800 is the device with more/higher functionality. For comparison and better
di󰍒erentiation both are described below.
easYgen-800 is intended to be used for single automation systems, auto start/stop of
the unit are performed with the help of remote signal.
easYgen-1800 has all functions of easYgen-800 as well as automatic mains failure
function (AMF), particularly well suited for single automation systems that include mains
and generator.
Functional Blocks
Item easYgen-800 easYgen-1800
LCD (with backlight) Dimension 4.3” 4.3”
Pixel 480 x 272 480 x 272
AMF no ●
Input Port Number 8 8
Output port Number 8 8
Sensor number 5 5
Neutral (earth) current ● ●
Schedule function ● ●
19easYgen-800B37691A
2 System Overview
2.2 Features and Functions of both easYgen-800 and -1800
Released

Item easYgen-800 easYgen-1800
RS485 ● ●
Ethernet ● ●
GSM ● ●
J1939 ● ●
USB ● ●
Micro SD card (slot) ● ●
Real-time clock ● ●
Event log ● ●
Key characteristics
• With ARM-based 32-bit SCM, highly integrated hardware, high reliability level•
• Multilingual interface (including English, Chinese or other customer speci󰍓c•
languages) which can be chosen at the site, making commissioning convenient for
factory personnel
•Improved LCD wear-resistance and scratch resistance due to hard screen acrylic •
• Silicon panel and pushbuttons for better operation in high-temperature environment•
• RS-485 communication port enabling remote control, remote measuring, remote•
communication via ModBus protocol
• SMS (Short Message Service) function: When genset is alarming, controller can send•
short messages via SMS automatically to max. 5 telephone numbers (external GSM
modem is needed). Besides this, generator status can be controlled and checked.
• Equipped with CAN bus port to communicate with J1939 genset. Monitoring•
frequently-used data such as water temperature, oil pressure, speed, fuel
consumption and so on of ECU machine, and additionally also control start, stop,
raising speed, and speed droop via CAN bus port
• Suitable for 3-phase 4-wire, 3-phase 3-wire, single phase 2-wire, and 2-phase 3-wire•
systems with voltage 120/240 V and frequency 50/60 Hz
•easYgen-1800 only: Collects and shows 3-phase voltage, current, power•
parameter and frequency of generator or mains. Mains/Generator Line voltage (UAB,
UBC, and UCA), Phase voltage (UA, UB, and UC).
•easYgen-800 only: Collects and shows 3-phase voltage, current, power parameter •
and frequency of generator. Generator Line voltage (UAB, UBC, and UCA), Phase
voltage (UA, UB, and UC).
• Phase sequence, frequency, Load current IA, IB, IC •
• Each phase: Total active power [kW], Total reactive power [kvar], Total apparent•
power [kVA], Average power factor PF
• Accumulated Total generator power [kWh], [kvarh], [kVAh], and Earth current•
20 easYgen-800 B37691A
2 System Overview
2.2 Features and Functions of both easYgen-800 and -1800
Released