Woodward EasYgen-300 User manual

37218D

Operation Manual

Software Version starting from 2.0008

Manual 37218D

easYgen-300

Genset Control

Manual 37218D easYgen-300 Series - Genset Control

Page 2/125 © Woodward

WARNING

Read this entire manual and all other publications pertaining to the work to be performed before instal-

ling, 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.

Any unauthorized modifications to or use of this equipment outside its specified mechanical, electrical,

or other operating limits may cause personal injury and/or property damage, including damage to the

equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or "negligence" within

the meaning of the product warranty thereby excluding warranty coverage for any resulting damage,

and (ii) invalidate product certifications or listings.

CAUTION

To prevent damage to a control system that uses an alternator or battery-charging device, make sure

the charging device is turned off before disconnecting the battery from the system.

Electronic controls contain static-sensitive parts. Observe the following precautions to prevent 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.

OUT-OF-DATE PUBLICATION

This publication may have been revised or updated since this copy was produced. To verify that you

have the latest revision, be sure to check the Woodward website:

http://www.woodward.com/pubs/current.pdf

The revision level is shown at the bottom of the front cover after the publication number. The latest

version of most publications is available at:

http://www.woodward.com/publications

If your publication is not there, please contact your customer service representative to get the latest

copy.

Important definitions

WARNING

Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation that, if not avoided, could result in damage to equipment.

NOTE

Provides other helpful information that does not fall under the warning or caution categories.

Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be

correct and reliable. However, Woodward assumes no responsibility unless otherwise expressly undertaken.

Manual 37218D easYgen-300 Series - Genset Control

Revision History

Rev. Date Editor Change

NEW 04-10-15 TP Release

A 05-12-14 TP Minor corrections; MCB closing limit description added; update to reflect version V2.0006

B 06-03-23 TP Minor corrections; wire size conversion chart added; update to reflect version V2.0007 (refer to Update In-

formation on page 9 for more info)

C 07-09-19 TP Minor corrections; update to reflect version V2.0008 (refer to Update Information on page 9 for more info)

D 08-12-01 TE Minor corrections; time of motor stop added

Content

CHAPTER 1. GENERAL INFORMATION..........................................................................................9

Related Documents..................................................................................................................................9

Update Information...................................................................................................................................9

Overview ................................................................................................................................................10

CHAPTER 2. EASYGEN SERIES 300 OVERVIEW .........................................................................12

CHAPTER 3. ELECTROSTATIC DISCHARGE AWARENESS ............................................................13

CHAPTER 4. HOUSING ..............................................................................................................14

Dimensions / Panel Cut-Out ..................................................................................................................14

Installation ..............................................................................................................................................15

CHAPTER 5. WIRING DIAGRAMS................................................................................................16

CHAPTER 6. CONNECTIONS ......................................................................................................20

Terminal Arrangement ...........................................................................................................................20

Power supply..........................................................................................................................................21

Charging Alternator ................................................................................................................................21

Voltage Measuring .................................................................................................................................22

Voltage Measuring: Generator ....................................................................................................23

Voltage Measuring: Mains, [350],[350X].....................................................................................25

MPU (pickup) [320X],[350X] .................................................................................................................27

Discrete Inputs .......................................................................................................................................28

Discrete Inputs: Bipolar Signals...................................................................................................28

Discrete Inputs: Operation Logic .................................................................................................29

Relay Outputs ........................................................................................................................................30

Interfaces ...............................................................................................................................................31

Overview ......................................................................................................................................31

CAN Bus [320X], [350X] ..............................................................................................................32

DPC - Direct Configuration Cable................................................................................................33

Manual 37218D easYgen-300 Series - Genset Control

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CHAPTER 7. OPERATION AND NAVIGATION ............................................................................... 34

Operation and Display ........................................................................................................................... 35

Purpose of the Status LEDs........................................................................................................ 35

Operating the easYgen ............................................................................................................... 35

Acknowledging Alarm Messages ................................................................................................ 35

Configuring the easYgen............................................................................................................. 36

Display of the Operating Values.................................................................................................. 36

Default Operating Value Display ................................................................................................. 37

Cycling Through the Displayed Operating Values ...................................................................... 37

J1939 Visualization [320X], [350X] ............................................................................................. 40

Alarm Messages.......................................................................................................................... 43

Configuration Displays ................................................................................................................ 45

Display Hierarchy ........................................................................................................................ 48

CHAPTER 8. FUNCTIONAL DESCRIPTION ................................................................................... 49

Overview................................................................................................................................................ 49

Application Modes ................................................................................................................................. 50

Application Mode {1 breaker open/close} – [320],[320X],[350],[350X] .................................... 50

Application Mode {2 breakers open/close} – [350],[350X] ......................................................... 50

Operating Modes ................................................................................................................................... 51

Operating Mode STOP................................................................................................................ 51

Operating Mode MANUAL........................................................................................................... 52

Operating Mode AUTOMATIC .................................................................................................... 56

Breaker Closure Limits .......................................................................................................................... 60

Generator Circuit Breaker ........................................................................................................... 60

Mains Circuit Breaker .................................................................................................................. 60

Functional Description of the Oil Pressure Input DI1 ............................................................................ 61

Firing Speed Detection and Crank Termination .................................................................................... 62

Functional Description of the Charging Alternator Input/Output ........................................................... 63

Functional Description of the 2nd CB Close Delay Time........................................................................ 64

Functional Description of the Engine Released Signal ......................................................................... 65

CHAPTER 9. CONFIGURATION................................................................................................... 66

Restoring Default Values....................................................................................................................... 66

Resetting Via the Front Panel ..................................................................................................... 66

Resetting Via LeoPC1 ................................................................................................................. 66

Configuration Via the Front Panel ......................................................................................................... 66

Configuration Using the PC ................................................................................................................... 67

Editing the Configuration File ................................................................................................................ 68

Configuring the Flags ............................................................................................................................ 68

CHAPTER 10. PARAMETERS ..................................................................................................... 70

Measuring .............................................................................................................................................. 71

Application ............................................................................................................................................. 72

Engine.................................................................................................................................................... 73

Engine: Diesel ............................................................................................................................. 73

Engine: Pickup ............................................................................................................................ 73

Engine: Start/Stop Automatic ...................................................................................................... 74

Breaker .................................................................................................................................................. 75

Emergency Power (AMF) ...................................................................................................................... 75

Password ............................................................................................................................................... 75

Manual 37218D easYgen-300 Series - Genset Control

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Monitoring ..............................................................................................................................................76

Monitoring: Generator..................................................................................................................76

Monitoring: Generator Overfrequency .........................................................................................76

Monitoring: Generator Underfrequency ....................................................................................... 77

Monitoring: Generator Overvoltage .............................................................................................78

Monitoring: Generator Undervoltage ...........................................................................................79

Monitoring: Mains ........................................................................................................................80

Monitoring: Mains Failure Limits ..................................................................................................80

Monitoring: Engine Overspeed ....................................................................................................83

Monitoring: Engine Underspeed ..................................................................................................84

Monitoring: Engine Start Fail .......................................................................................................85

Monitoring: Engine Unintended Stop...........................................................................................85

Monitoring: Battery Undervoltage ................................................................................................86

Monitoring: Battery Charge Voltage ............................................................................................87

Monitoring: Interface ....................................................................................................................88

Monitoring: Interface: J1939 Amber Warning Lamp DM1 ...........................................................89

Monitoring: Interface: J1939 Red Stop Lamp DM1 .....................................................................90

Discrete Inputs .......................................................................................................................................91

Relay Outputs ........................................................................................................................................92

Counter ..................................................................................................................................................94

Interfaces ...............................................................................................................................................95

CAN Interface ..............................................................................................................................95

J1939 ...........................................................................................................................................95

System ...................................................................................................................................................96

Codes...........................................................................................................................................96

Factory Settings ...........................................................................................................................96

Parameter Access Level..............................................................................................................96

Flags ............................................................................................................................................97

Versions .......................................................................................................................................98

CHAPTER 11. EVENT LOGGER ..................................................................................................99

GetEventLog Software........................................................................................................................... 99

Installing GetEventLog.................................................................................................................99

Starting GetEventLog ..................................................................................................................99

Resetting the Event Logger .......................................................................................................100

CHAPTER 12. TECHNICAL DATA..............................................................................................101

CHAPTER 13. ACCURACY .......................................................................................................103

APPENDIX A. COMMON...........................................................................................................104

Alarm Classes ......................................................................................................................................104

Conversion Factors and Charts ...........................................................................................................105

Conversion Factors: Temperature.............................................................................................105

Conversion Factors: Pressure ...................................................................................................105

Conversion Chart: Wire Size .....................................................................................................105

APPENDIX B. J1939 PROTOCOL DESCRIPTIONS .....................................................................106

Visualizing J1939 Measuring Values with LeoPC1 .............................................................................106

J1939 Standard Measuring Values ...........................................................................................106

Special EMR Messages.............................................................................................................107

Special S6 Messages ................................................................................................................107

APPENDIX C. FRONT CUSTOMIZATION ....................................................................................108

APPENDIX D. TROUBLESHOOTING ..........................................................................................109

APPENDIX E. LIST OF PARAMETERS........................................................................................114

Manual 37218D easYgen-300 Series - Genset Control

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APPENDIX F. SERVICE OPTIONS............................................................................................. 120

Product Service Options...................................................................................................................... 120

Returning Equipment For Repair......................................................................................................... 120

Packing a Control ...................................................................................................................... 121

Return Authorization Number RAN ........................................................................................... 121

Replacement Parts .............................................................................................................................. 121

How To Contact Woodward................................................................................................................. 122

Engineering Services........................................................................................................................... 123

Technical Assistance........................................................................................................................... 124

Manual 37218D easYgen-300 Series - Genset Control

Illustrations and Tables

Illustrations

Figure 1-2: Functional overview............................................................................................................................................... 10

Figure 4-1: Housing - panel cut-out.......................................................................................................................................... 14

Figure 5-1: Wiring diagram - easYgen-320.............................................................................................................................. 16

Figure 5-2: Wiring diagram - easYgen320X............................................................................................................................. 17

Figure 5-3: Wiring diagram - easYgen350................................................................................................................................ 18

Figure 5-4: Wiring diagram - easYgen350X............................................................................................................................. 19

Figure 6-1: easYgen-300 back view - terminal arrangement.................................................................................................... 20

Figure 6-2: Power supply.......................................................................................................................................................... 21

Figure 6-3: Charging alternator input/output ............................................................................................................................ 21

Figure 6-4: Voltage measuring - generator 3Ph 4W ................................................................................................................. 23

Figure 6-5: Voltage measuring - generator 3Ph 3W ................................................................................................................. 23

Figure 6-6: Voltage measuring - generator 1Ph 3W ................................................................................................................. 23

Figure 6-7: Voltage measuring - generator 1Ph 2W, phase-neutral.......................................................................................... 24

Figure 6-8: Voltage measuring - generator 1Ph 2W, phase-phase............................................................................................ 24

Figure 6-9: Voltage measuring - mains 3Ph 4W....................................................................................................................... 25

Figure 6-10: Voltage measuring - mains 3Ph 3W..................................................................................................................... 25

Figure 6-11: Voltage measuring - mains 1Ph 3W..................................................................................................................... 25

Figure 6-12: Voltage measuring - mains 1Ph 2W..................................................................................................................... 26

Figure 6-13: MPU - principle overview.................................................................................................................................... 27

Figure 6-14: MPU input............................................................................................................................................................ 27

Figure 6-15: Minimum required input voltage depending on frequency .................................................................................. 27

Figure 6-16: Discrete inputs - alarm/control input - positive signal......................................................................................... 28

Figure 6-17: Discrete inputs - alarm/control input - negative signal........................................................................................ 29

Figure 6-18: Discrete inputs - alarm/control inputs - operation logic....................................................................................... 29

Figure 6-19: Relay outputs........................................................................................................................................................ 30

Figure 6-20: Interfaces - overview............................................................................................................................................ 31

Figure 6-21: Interfaces - CAN bus............................................................................................................................................ 32

Figure 6-22: Interfaces - CAN bus - wiring of shielding .......................................................................................................... 32

Figure 6-23: Interfaces - CAN bus topology............................................................................................................................. 32

Figure 7-1: Front panel and display.......................................................................................................................................... 34

Figure 7-2: 6 digit 7 segment LED display............................................................................................................................... 36

Figure 7-3: J1939 fault display ................................................................................................................................................. 41

Figure 7-4: Additional alarm display........................................................................................................................................ 43

Figure 8-2: Discrete input DI1 - oil pressure ............................................................................................................................ 61

Figure 8-3: Starting procedure.................................................................................................................................................. 61

Figure 8-4: Charging alternator input/output ............................................................................................................................ 63

Figure 8-5: AMF application with engine released signal ........................................................................................................ 65

Figure 9-1: Configurable display flags ..................................................................................................................................... 68

Figure 9-2: Flag configuration default...................................................................................................................................... 69

Figure 9-3: Flag configuration custom...................................................................................................................................... 69

Figure 10-1: Voltage/frequency hysteresis ............................................................................................................................... 82

Figure 10-2: Configurable display flags ................................................................................................................................... 97

Figure 11-1: GetEventLog - interface configuration................................................................................................................. 99

Figure 11-2: GetEventLog - event logger content................................................................................................................... 100

Figure 13-4: Paper strips......................................................................................................................................................... 108

Manual 37218D easYgen-300 Series - Genset Control

Tables

Table 1-1: Manual - overview..................................................................................................................................................... 9

Table 2-1: easYgen series 300 product features........................................................................................................................ 12

Table 4-1: Housing - panel cut-out........................................................................................................................................... 14

Table 6-1: Power supply - terminal assignment........................................................................................................................ 21

Table 6-2: Charging alternator input/output - terminal assignment.......................................................................................... 21

Table 6-3: Voltage measuring principles.................................................................................................................................. 22

Table 6-4: Voltage measuring - terminal assignment - generator voltage ................................................................................ 24

Table 6-5: Voltage measuring - terminal assignment - mains voltage...................................................................................... 26

Table 6-6: MPU - terminal assignment..................................................................................................................................... 27

Table 6-7: Discrete input - terminal assignment - alarm/control input - positive signal........................................................... 28

Table 6-8: Discrete input - terminal assignment - alarm/control inputs - negative signal......................................................... 29

Table 6-9: Relay outputs - terminal assignment, part 1 ............................................................................................................ 30

Table 6-10: Interfaces - connection overview........................................................................................................................... 31

Table 6-11: Maximum CAN bus length.................................................................................................................................... 33

Table 7-1: Display - default operating value ............................................................................................................................ 37

Table 7-2: Display of operating values..................................................................................................................................... 39

Table 7-3: J 1939 messages ...................................................................................................................................................... 41

Table 7-4: DM1/DM2 error message composition ................................................................................................................... 42

Table 7-5: Alarm classes........................................................................................................................................................... 43

Table 7-6: Alarm messages....................................................................................................................................................... 45

Table 7-7: Configuration displays ............................................................................................................................................ 48

Table 7-8: Display hierarchy .................................................................................................................................................... 48

Table 8-1: Functional description - Overview.......................................................................................................................... 49

Table 8-1: Discrete input DI1 - oil pressure.............................................................................................................................. 61

Table 10-1: Relay outputs - list of configurable parameters..................................................................................................... 93

Table 11-1: Event logger - operation states ............................................................................................................................ 100

Table 13-1: Conversion factor: temperature........................................................................................................................... 105

Table 13-2: Conversion factor: pressure................................................................................................................................. 105

Table 13-3: Conversion chart: wire size ................................................................................................................................. 105