Woodward easYgen-1700 User manual

Technical Manual
easYgen-1700
Genset Control
37798A
easYgen-1700

Woodward GmbH
Handwerkstr. 29 — 70565 Stuttgart — Germany
Phone [phone]‑510
Fax [phone]‑101
[email protected]
© 2019 Woodward GmbH
2 easYgen-1700 37798A

Brief Overview
Fig. 1: easYgen-1700
1 Terminals 1 to 22: Power supply, relays, discrete inputs, MPU, D+, ...
2Terminals 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 Terminals 56 to 61: Analog inputs
7 Terminals 49 to 55 (screwable): Generator and Ground current, Discrete Input 08
8 Terminals 45 to 48: Generator voltage
9 Terminals 41 to 44: Mains voltage
10 Terminals 36 to 40: Relay outputs
The easYgen-1700 is a control unit for engine-generator system management
applications.
The control unit can be used in applications such as: co-generation, stand-by, AMF, 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:
• Device easYgen genset control
All terminal connectors that need to be screwe are delivered with plug and jack
3easYgen-170037798A
Brief Overview

• Clamp fastener installation material (4x)
• »Installation Procedure Supplement« paper with links to the latest edition of
Technical Documentation and software for download:(http://www.wwdmanuals.com/
easygen-1700)
Con󰍓guration software and Technical Manual are available at Woodward website:http://
www.woodward.com/easYgen-1700.aspx
4 easYgen-1700 37798A
Brief Overview

Sample application setup
Fig. 2: Sample application setup
The image above shows a typical application of the easYgen control unit. It is used as
control unit of an AMF (automatic mains failure) application with a single genset.
•In this case, it will function as an engine control with generator, mains and engine
protection.
5easYgen-170037798A
Brief Overview

• The control unit can open and close the generator circuit breaker (GCB) and the
mains circuit breaker (MCB).
Transition procedures are described in chapter ╚═▷ “Transition Procedures”.
6 easYgen-1700 37798A
Brief Overview

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Table of Contents
1 General Information 10
1.1 About this Manual 10
1.1.1 Revision History 10
1.1.2 Symbols Used in this manual 10
1.2 Copyright And Disclaimer 12
1.3 Service And Warranty 12
1.4 Safety 13
1.4.1 Intended Use 13
1.4.2 Personnel 14
1.4.3 General hazard warnings 14
2 System Overview 16
2.1 Display and Status Indicators 16
2.2 Features and Functions of easYgen 1700 17
2.3 Functions 19
2.4 Intended Use of This Control 20
3 Installation 21
3.1 Mounting 21
3.2 Wiring 21
3.3 Interfaces 28
3.4 Install ToolKit-SC 28
4Con󰍏guration 30
4.1 Access to the Control 30
4.1.1 Front Panel: Operating and Display Elements 30
4.1.2 Front Panel Control 33
4.1.2.1 HMI Screens Without Password Level 34
4.1.3 Con󰍓gure ToolKit-SC 36
4.1.3.1 Con󰍓gure Communication 36
4.1.3.2 Manage Con󰍓guration Data 37
4.1.3.3 Con󰍓gure Customized Language 37
4.1.4 Access via ToolKit-SC Con󰍓guration Tool 39
4.2 Parameters 40
4.2.1 Parameter Menu Structure 40
4.2.2 Parameter Settings Menu--HMI Access 41
4.2.3 Con󰍓gure Measurement 42
4.2.4 Con󰍓gure Application 44
4.2.4.1 Con󰍓gure Inputs and Outputs 44
4.2.4.2 Con󰍓gure Engine 61
4.2.4.3 Con󰍓gure TEST Run 63
4.2.4.4 Con󰍓gure Breakers 64
7easYgen-170037798A
Table of Contents

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.5 Con󰍓gure Monitoring 65
4.2.5.1 Monitoring Mains 65
4.2.5.2 Monitoring Generator 67
4.2.5.3 Monitoring Breakers 71
4.2.5.4 Monitoring Engine 71
4.2.5.5 CAN Interface 72
4.2.5.6 Other Monitoring 73
4.2.6 Con󰍓gure Interfaces 74
4.2.6.1 Con󰍓gure GSM Module 74
4.2.7 Con󰍓gure Maintenance 76
4.2.8 Con󰍓gure Counters 77
4.2.9 Con󰍓gure Switchable Parameter Set 78
4.2.10 Con󰍓gure Language / Clock 79
4.2.11 Con󰍓gure System Management 79
4.2.12 Con󰍓gure HMI 80
4.3 Selectable Inputs/Outputs/Sensors 80
4.3.1 Programmable Sensors 80
4.3.2 Programmable Inputs 82
4.3.3 Programmable Outputs 85
4.4 Status Menu 89
4.4.1 HMI Status Screens 89
4.4.2 ToolKit-SC Status Screens 90
5 Operation 93
5.1 Warning/Alarm Signaling 93
5.1.1 Alarm Acknowledgment 93
5.2 Operation Modes 94
5.2.1 Operation Mode AUTO 94
5.2.2 Operation Mode MANual 95
5.2.3 Operation Mode STOP 95
5.3 START/STOP Operation 95
5.3.1 Start engine to supply load 96
5.3.2 Stop engine after mains supplying load (again) 98
5.3.3 MANual START/STOP 100
5.4 Transition Procedures 100
5.4.1 Disconnect during cranking 100
5.4.2 Manual Breaker Transition 101
6 Commissioning 103
7 Interfaces and Protocols 104
7.1 J1939 104
8 Technical Speci󰍏cations 110
8.1 Measuring and Monitoring 113
8 easYgen-1700 37798A
Table of Contents

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9 Appendix 115
9.1 Alarms and Warnings 115
9.1.1 Alarm Classes 115
9.1.2 Warnings 115
9.1.3 Shutdown Alarms 117
9.1.4 Trip and Stop Alarms 118
9.1.5 Trip Alarms 119
9.2 Trouble Shooting 119
9.3 Data Telegrams 120
9.3.1 Modbus Basics 120
9.3.1.1 Data Frame Format 120
9.3.1.2 Modbus Communication Protocol 121
9.3.1.3 Information Frame Format 121
9.3.1.4 Address Code 121
9.3.1.5 Function Code 121
9.3.1.6 Data Field 122
9.3.1.7 Error Check Code (CRC) 123
9.3.1.8 Error Handling 127
9.3.2 Read Holding Registers 03_hex 127
9.3.3 Force Single Coil 05H_hex 151
9.3.4 Preset Single Register 06H_hex 152
9.3.4.1 Generator Status 152
9.3.4.2 Remote Start Status 153
9.3.4.3 Breaker Status 153
10 Index 156
9easYgen-170037798A
Table of Contents

1 General Information
1.1 About this Manual
1.1.1 Revision History
Rev. Date Editor Changes
A 2019-05 PW NEW Software Revision 2.0.0.1 and ToolKit-SC version 1.5.0.4
Technical Manual
• In ╚═▷ “Wiring”:
◦ terminal ratings and descriptions updated in ╚═▷ Tab. ;
◦ corrections in ╚═▷ Fig. 6.
• Chapter ╚═▷ “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 ╚═▷ “Con󰍓gure Analog Inputs”;
• In ╚═▷ “Technical Speci󰍓cations” voltage ranges for the alternator
and AC measurement updated to UL6200.
• Added description of analog inputs in ╚═▷ “Technical
Speci󰍓cations”.
• Adjusted data telegram entries in ╚═▷ “Data Telegrams”.
NEW 2018-11 PC Describes device implemented software version 1.1 and
ToolKit-SC version 1.4.0.2
Technical Manual
• Release = 1st issue
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.
10 easYgen-1700 37798A
1 General Information
1.1 About this Manual

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
»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.
11easYgen-170037798A
1 General Information
1.1 About this Manual

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.
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
12 easYgen-1700 37798A
1 General Information
1.2 Copyright And Disclaimer

• 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 ╚═▷ “Technical Speci󰍓cations”.
• Steps to be taken for commissioning are outlined in ╚═▷ “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.
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.
13easYgen-170037798A
1 General Information
1.4 Safety

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!
14 easYgen-1700 37798A
1 General Information
1.4 Safety

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.
15easYgen-170037798A
1 General Information
1.4 Safety

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 ╚═▷ “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.
16 easYgen-1700 37798A
2 System Overview

Fig. 3: easYgen-1700
2.2 Features and Functions of easYgen 1700
Functional Blocks
Item easYgen-1700
Monochrome Display (with
backlight)
Dimension 4.3”
Pixel 240 x 128
AMF ●
Input Port Number 8
Output port Number 8
Sensor number 5
Neutral (earth) current ●
Schedule function ●
RS485 ●
GSM ●
17easYgen-170037798A
2 System Overview
2.2 Features and Functions of easYgen 1700

Item easYgen-1700
J1939 ●
USB ●
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 Display 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
• 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).
• 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
• For Mains, controller has over and under voltage, over and under frequency, loss of
phase and phase sequence wrong detection functions
• For generator, controller has over and under voltage, over and under frequency, loss
of phase, phase sequence wrong, over and reverse power, over current functions
• 3 󰍓xed analog sensors (temperature, oil pressure and fuel level)
• Flexible sensors can be set as temperature sensor, oil pressure sensor or level
sensor
• Precision measure and display parameters about Engine, Temp. (WT) °C/°F both be
displayed Oil pressure (OP) kPa/psi/bar all be displayed Fuel level (FL) %(unit) Speed
18 easYgen-1700 37798A
2 System Overview
2.2 Features and Functions of easYgen 1700

(SPD) r/min (unit) Battery Voltage (VB) V (unit) Charger Voltage (VD) V (unit) Hour
count (HC) can accumulate to max. 65535 hours. Start times can accumulate to
max. 65535 times
• Protection: automatic start/stop of the genset, ATS (Auto Transfer Switch) control
with perfect failure indication and protection function
•All output ports are relay-out
• Parameter setting: parameters can be modi󰍓ed and stored in internal FLASH
memory and cannot be lost even in case of power outage; most of them can be
adjusted using front panel of the controller and all of them can be modi󰍓ed using
ToolKit-SC con󰍓guration software on PC via USB or RS485 ports
• More kinds of curves of temperature, oil pressure, fuel level can be used directly and
users can de󰍓ne the sensor curves by themselves
•Multiple crank disconnect conditions (generator frequency, speed sensor, oil
pressure) are optional
• Widely power supply range DC (8 to 35) V, suitable to di󰍒erent start battery voltage
environment
•Event log, real-time clock, scheduled start & stop generator (can be set as start
genset once a day/week/month whether with load or not)
• Logon wallpaper and display time are user-de󰍓ned
• Can be used on pumping units and as an indicating instrument (indicate and alarm
are enable only, relay is inhibited)
• With maintenance function. Actions (warning or shutdown) can be set when
maintenance time out
• All parameters are digital adjusted (instead of conventional analog modulation with
normal potentiometer) for more reliability and stability
•Waterproof security level IP55 due to rubber seal installed between the controller
enclosure and front panel
• Metal 󰍓xing clips enable perfect in high temperature environment
• Modular design, self-extinguishing ABS plastic enclosure, pluggable connection
terminals and embedded installation way; compact structure with easy mounting
• Accumulation of total run time and total electric energy of A and B. Users can reset it
for convenience.
2.3 Functions
• Protection: automatic start/stop of the genset, ATS (Auto Transfer Switch) control
with failure indication and protection function
• All output ports are relay-out
•Parameter settings: parameters can be modi󰍓ed and stored in internal FLASH
memory and cannot be lost even in case of a power outage; most of them can be
adjusted using front panel of the controller and all of them can be modi󰍓ed using
ToolKit-SC on a PC via USB or RS485 ports.
19easYgen-170037798A
2 System Overview
2.3 Functions

• Temperature, oil pressure and fuel level curves can be used directly and users can
de󰍓ne the sensor curves by themselves.
• Multiple crank disconnect conditions (generator frequency, speed sensor, oil
pressure) are optional.
• Event log, real-time clock, scheduled start & stop generator (can be set as start
genset once a day/week/month with or without load).
• Start-up logo and display time are user-de󰍓ned.
• Can be used on pumping units and as an indicating instrument (indicate and alarm
are enable only, relay is inhibited).
• Maintenance function: Actions (warning or shutdown) can be set when maintenance
time out.
• Instead of conventional analog modulation with a potentiometer, all parameters use
digital adjustment for more reliability and stability.
•Accumulative total run time and total electric energy of A and B. The user can reset
it to 0 and re-accumulate the value, which allows to count the total value.
2.4 Intended Use of This Control
easYgen-1700 genset controllers are used for genset automation and monitor control
system of single unit, o󰍒ering:
• automatic mains failure protection (AMF),
• automatic start/stop,
• data measurement,
• alarm protection and
•three remote features: control, measuring and communication.
The controller is equipped with large monochrome display and o󰍒ers Chinese, English or
other language interface with easy and reliable operation.
The easYgen genset controllers use 32 bits micro-processor technology with features
such as precision parameters measuring, 󰍓xed value adjustment, time setting or
threshold adjusting. Most of these parameters can be set on the front panel and all
parameters can be set using a computer (via USB port) and can be adjusted and
monitored with the help of RS-485 port. The controllers can be used for a number of
automatic genset control systems. They have a compact structure, easy connections and
are highly reliable.
20 easYgen-1700 37798A
2 System Overview
2.4 Intended Use of This Control