Woodward easYgen-3000 User manual

37468
Installation
Software Version: 1.15xx or higher
Manual 37468
easYgen-3000 Series
Genset Control

Manual 37468 easYgen-3000 Series - Genset Control
Page 2/67 © 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OUT-OF-DATE PUBLICATION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.
© Woodward
All Rights Reserved.

Manual 37468 easYgen-3000 Series - Genset Control
© Woodward Page 3/67
Revision History
Rev.
Date
Editor
Changes
NEW
10-05-05
TE
Release based on 37414B
Content
Document Overview.................................................................................................................................
CHAPTER 1. GENERAL INFORMATION .......................................................................................7
7
CHAPTER 2. ELECTROSTATIC DISCHARGE AWARENESS............................................................ 8
Application................................................................................................................................................
CHAPTER 3. MARINE USAGE....................................................................................................9
9
Plastic Housing ......................................................................................................................................
CHAPTER 4. HOUSING ...........................................................................................................10
11
Panel Cutout ................................................................................................................................11
Dimensions ..................................................................................................................................12
Clamp Fastener Installation.........................................................................................................13
Screw Kit Installation....................................................................................................................14
Sheet Metal Housing..............................................................................................................................15
Dimensions ..................................................................................................................................15
Installation....................................................................................................................................16
Terminal Arrangement ...........................................................................................................................17
CHAPTER 5. WIRING DIAGRAMS.............................................................................................18
Power Supply.........................................................................................................................................
CHAPTER 6. CONNECTIONS ...................................................................................................20
21
Charging Alternator................................................................................................................................22
Voltage Measuring (FlexRange) ............................................................................................................23
Voltage Measuring: Generator.....................................................................................................23
Voltage Measuring: Mains ...........................................................................................................30
Voltage Measuring: Busbar (System 1) 1Ph 2W.........................................................................36
Current Measuring .................................................................................................................................39
Generator Current........................................................................................................................39
Mains Current 1-Phase................................................................................................................41
Ground Current............................................................................................................................42
Power Measuring ...................................................................................................................................43
Power Factor Definition..........................................................................................................................43
MPU (Pickup).........................................................................................................................................45
Discrete Inputs .......................................................................................................................................46
Discrete Inputs: Signal Polarity....................................................................................................46
Discrete Inputs: Operation Logic .................................................................................................48
Relay Outputs (LogicsManager) ............................................................................................................49
Analog Inputs (FlexIn)............................................................................................................................50
Wiring Two-Pole Senders............................................................................................................50
Wiring Single-Pole Senders.........................................................................................................51
Wiring Single and Two-Pole Senders Simultaneously ................................................................52
Analog Outputs ......................................................................................................................................53
Controller Wiring..........................................................................................................................53

Manual 37468 easYgen-3000 Series - Genset Control
Page 4/67 © Woodward
Interfaces............................................................................................................................................... 54
RS-485 Serial Interfaces ............................................................................................................. 54
RS-232 Serial Interface (Serial Interface #1, Interface #1)......................................................... 55
CAN Bus Interfaces (FlexCAN)................................................................................................... 55
Bus Shielding............................................................................................................................... 57
CHAPTER 7. TECHNICAL DATA ...............................................................................................58
CHAPTER 8. ENVIRONMENTAL DATA.......................................................................................61
CHAPTER 9. ACCURACY ........................................................................................................62
Suitable D-SUB Connector Housings....................................................................................................
APPENDIX A. USEFUL INFORMATION.......................................................................................64
64
CAN Bus Pin Assignments of Third-Party Units.................................................................................... 64
D-SUB DE9 Connector................................................................................................................ 64
RJ45/8P8C Connector ................................................................................................................ 65
IDC / Header Connector.............................................................................................................. 65
Connecting 24 V Relays ........................................................................................................................ 66

Manual 37468 easYgen-3000 Series - Genset Control
© Woodward Page 5/67
Figures and Tables
Figures
Figure 4-1: easYgen-3200 - plastic housing.............................................................................................................................. 10
Figure 4-2: easYgen-3100 - sheet metal housing...................................................................................................................... 10
Figure 4-3: Plastic housing - panel-board cutout ...................................................................................................................... 11
Figure 4-4: Plastic housing easYgen-3200 - dimensions .......................................................................................................... 12
Figure 4-5: Plastic housing - drill plan...................................................................................................................................... 14
Figure 4-6: Sheet metal housing easYgen-3100 - dimensions .................................................................................................. 15
Figure 4-7: Sheet metal housing - drill plan.............................................................................................................................. 16
Figure 4-8: easYgen-3200 - terminal arrangement - rear view ................................................................................................. 17
Figure 4-9: easYgen-3100 - terminal arrangement.................................................................................................................... 17
Figure 5-1: Wiring diagram – overview.................................................................................................................................... 18
Figure 6-1: Power supply.......................................................................................................................................................... 21
Figure 6-2: Power supply - crank waveform at maximum load ................................................................................................ 21
Figure 6-3: Charging alternator input/output ............................................................................................................................ 22
Figure 6-4: Voltage measuring - generator ............................................................................................................................... 23
Figure 6-5: Voltage measuring - generator windings, 3Ph 4W OD .......................................................................................... 24
Figure 6-6: Voltage measuring - generator measuring inputs, 3Ph 4W OD.............................................................................. 24
Figure 6-7: Voltage measuring - generator windings, 3Ph 4W................................................................................................. 25
Figure 6-8: Voltage measuring - generator measuring inputs, 3Ph 4W..................................................................................... 25
Figure 6-9: Voltage measuring - generator windings, 3Ph 3W................................................................................................. 26
Figure 6-10: Voltage measuring - generator measuring inputs, 3Ph 3W................................................................................... 26
Figure 6-11: Voltage measuring - generator windings, 1Ph 3W............................................................................................... 27
Figure 6-12: Voltage measuring - generator measuring inputs, 1Ph 3W................................................................................... 27
Figure 6-13: Voltage measuring - generator windings, 1Ph 2W (phase-neutral) ...................................................................... 28
Figure 6-14: Voltage measuring - generator measuring inputs, 1Ph 2W (phase-neutral).......................................................... 28
Figure 6-15: Voltage measuring - generator windings, 1Ph 2W (phase-phase) ........................................................................ 29
Figure 6-16: Voltage measuring - generator measuring inputs, 1Ph 2W (phase-phase)............................................................ 29
Figure 6-17: Voltage measuring - mains................................................................................................................................... 30
Figure 6-18: Voltage measuring - mains PT windings, 3Ph 4W............................................................................................... 31
Figure 6-19: Voltage measuring - mains measuring inputs, 3Ph 4W........................................................................................ 31
Figure 6-20: Voltage measuring - mains PT windings, 3Ph 3W............................................................................................... 32
Figure 6-21: Voltage measuring - mains measuring inputs, 3Ph 3W........................................................................................ 32
Figure 6-22: Voltage measuring - mains PT windings, 1Ph 3W............................................................................................... 33
Figure 6-23: Voltage measuring - mains measuring inputs, 1Ph 3W........................................................................................ 33
Figure 6-24: Voltage measuring - mains PT windings, 1Ph 2W (phase-neutral)...................................................................... 34
Figure 6-25: Voltage measuring - mains measuring inputs, 1Ph 2W (phase-neutral)............................................................... 34
Figure 6-26: Voltage measuring - mains PT windings, 1Ph 2W (phase-phase)........................................................................ 35
Figure 6-27: Voltage measuring - mains measuring inputs, 1Ph 2W (phase-phase)................................................................. 35
Figure 6-28: Voltage measuring - busbar (system 1) 1Ph 2W (phase-phase)............................................................................ 36
Figure 6-29: Voltage measuring - busbar PT windings, 1Ph 2W (phase-neutral)..................................................................... 37
Figure 6-30: Voltage measuring - busbar measuring inputs, 1Ph 2W (phase-neutral).............................................................. 37
Figure 6-31: Voltage measuring - busbar PT windings, 1Ph 2W (phase-phase)....................................................................... 38
Figure 6-32: Voltage measuring - busbar measuring inputs, 1Ph 2W (phase-phase)................................................................ 38
Figure 6-33: Current measuring - generator.............................................................................................................................. 39
Figure 6-34: Current measuring - generator, L1 L2 L3............................................................................................................. 40
Figure 6-35: Current measuring - generator, phase Lx.............................................................................................................. 40
Figure 6-36: Current measuring - mains current ....................................................................................................................... 41
Figure 6-37: Current measuring - mains, phase Lx................................................................................................................... 41
Figure 6-38: Current measuring - ground current ..................................................................................................................... 42
Figure 6-39: Power measuring - direction of power.................................................................................................................. 43
Figure 6-40: MPU - principle overview.................................................................................................................................... 45
Figure 6-41: MPU input............................................................................................................................................................ 45
Figure 6-42: Minimal necessary input voltage depending on frequency................................................................................... 45
Figure 6-43: Discrete inputs - alarm/control input - positive signal.......................................................................................... 46
Figure 6-44: Discrete inputs - alarm/control input - negative signal......................................................................................... 47
Figure 6-45: Discrete inputs - alarm/control inputs - operation logic ....................................................................................... 48
Figure 6-46: Relay outputs........................................................................................................................................................ 49
Figure 6-47: Analog inputs - wiring two-pole senders.............................................................................................................. 50
Figure 6-48: Analog inputs - wiring single-pole senders .......................................................................................................... 51
Figure 6-49: Analog inputs - wiring single- and two-pole senders ........................................................................................... 52
Figure 6-50: Analog controller output - Wiring and external jumper setting............................................................................ 53

Manual 37468 easYgen-3000 Series - Genset Control
Page 6/67 © Woodward
Figure 6-51: RS-485 interface #1 - overview............................................................................................................................ 54
Figure 6-52: RS-485 Modbus - connection for half-duplex operation...................................................................................... 54
Figure 6-53: RS-485 Modbus - connection for full-duplex operation....................................................................................... 54
Figure 6-54: RS-232 interface - overview................................................................................................................................. 55
Figure 6-55: CAN bus #1 - overview........................................................................................................................................ 55
Figure 6-56: CAN bus #2 - overview........................................................................................................................................ 55
Figure 6-57: Interfaces - CAN bus - termination ...................................................................................................................... 56
Figure 6-58: Interfaces - shielding............................................................................................................................................ 57
Figure 9-1: CAN bus pin assignment - D-SUB DE9 connector................................................................................................ 64
Figure 9-2: CAN bus pin assignment - RJ45/8P8C connector.................................................................................................. 65
Figure 9-3: CAN bus pin assignment - IDC / Header ............................................................................................................... 65
Figure 9-4: Interference suppressing circuit - connection......................................................................................................... 66
Tables
Table 1-1: Manual - overview..................................................................................................................................................... 7
Table 4-1: Plastic housing - panel cutout.................................................................................................................................. 11
Table 6-1: Conversion chart - wire size .................................................................................................................................... 20
Table 6-2: Power supply - terminal assignment........................................................................................................................ 21
Table 6-3: Charging alternator input/output - terminal assignment .......................................................................................... 22
Table 6-4: Voltage measuring - terminal assignment - generator voltage................................................................................. 23
Table 6-5: Voltage measuring - terminal assignment - generator, 3Ph 4W OD........................................................................ 24
Table 6-6: Voltage measuring - terminal assignment - generator, 3Ph 4W............................................................................... 25
Table 6-7: Voltage measuring - terminal assignment - generator, 3Ph 3W............................................................................... 26
Table 6-8: Voltage measuring - terminal assignment - generator, 1Ph 3W............................................................................... 27
Table 6-9: Voltage measuring - terminal assignment - generator, 1Ph 2W (phase-neutral)...................................................... 28
Table 6-10: Voltage measuring - terminal assignment - generator, 1Ph 2W (phase-phase)...................................................... 29
Table 6-11: Voltage measuring - terminal assignment - mains voltage .................................................................................... 30
Table 6-12: Voltage measuring - terminal assignment - mains, 3Ph 4W.................................................................................. 31
Table 6-13: Voltage measuring - terminal assignment - mains, 3Ph 3W.................................................................................. 32
Table 6-14: Voltage measuring - terminal assignment - mains, 1Ph 3W.................................................................................. 33
Table 6-15: Voltage measuring - terminal assignment - mains, 1Ph 2W (phase-neutral)......................................................... 34
Table 6-16: Voltage measuring - terminal assignment - mains, 1Ph 2W (phase-phase)........................................................... 35
Table 6-17: Voltage measuring - terminal assignment - busbar (system 1) 1Ph 2W (phase-phase).......................................... 36
Table 6-18: Voltage measuring - terminal assignment - busbar, 1Ph 2W (phase-neutral)........................................................ 37
Table 6-19: Voltage measuring - terminal assignment - busbar, 1Ph 2W (phase-phase).......................................................... 38
Table 6-20: Current measuring - terminal assignment - generator current................................................................................ 39
Table 6-21: Current measuring - terminal assignment - generator, L1 L2 L3........................................................................... 40
Table 6-22: Current measuring - terminal assignment - generator, phase Lx............................................................................ 40
Table 6-23: Current measuring - terminal assignment - mains current..................................................................................... 41
Table 6-24: current measuring - terminal assignment - mains, phase Lx.................................................................................. 41
Table 6-25: Current measuring - terminal assignment - ground current ................................................................................... 42
Table 6-26: MPU - terminal assignment................................................................................................................................... 45
Table 6-27: Discrete input - terminal assignment ..................................................................................................................... 47
Table 6-28: Relay outputs - terminal assignment...................................................................................................................... 49
Table 6-29: Analog inputs - terminal assignment - wiring two-pole senders............................................................................ 50
Table 6-30: Analog inputs - terminal assignment - wiring single-pole senders ........................................................................ 51
Table 6-31: Analog inputs - terminal assignment - wiring single- and two-pole senders ......................................................... 52
Table 6-32: Bias signal outputs - analog or PWM.................................................................................................................... 53
Table 6-33: RS-485 interface #1 - pin assignment.................................................................................................................... 54
Table 6-34: RS-232 interface - pin assignment......................................................................................................................... 55
Table 6-35: CAN bus #1 - pin assignment................................................................................................................................ 55
Table 6-36: CAN bus #2 - pin assignment................................................................................................................................ 55
Table 6-37: Maximum CAN bus length.................................................................................................................................... 56
Table 9-1: CAN bus pin assignment - D-SUB DE9 connector................................................................................................. 64
Table 9-2: CAN bus pin assignment - RJ45/8P8C connector ................................................................................................... 65
Table 9-3: CAN bus pin assignment - IDC / Header................................................................................................................. 65
Table 9-4: Interference suppressing circuit for relays............................................................................................................... 66

Manual 37468 easYgen-3000 Series - Genset Control
© Woodward Page 7/67
Chapter 1.
General Information
Document Overview
≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Type
English
German
easYgen-3000 Series
easYgen-3000 Series - Installation
this manual

37468
DE37468
easYgen-3000 Series - Configuration
37469
DE37469
easYgen-3000 Series - Operation
37470
DE37470
easYgen-3000 Series - Application
37471
-
easYgen-3000 Series - Interfaces
37472
-
easYgen-3000 Series - Parameter List
37473
DE37473
easYgen-3200 - Brief Operation Information
37399
GR37399
easYgen-3100 - Brief Operation Information
37474
-
RP-3000 Remote Panel
37413
-
Table 1-1: Manual - overview
Intended Use The unit must only be operated in the manner described by this manual. The prerequisite for a
proper and safe operation of the product is correct transportation, storage, and installation as well as careful oper-
ation and maintenance.
What are the differences between the easYgen-3000 Series Package P1 & Package P2?
easYgen-3000 Series
Package P1
Package P2
Freely configurable PID controllers
-
3
External discrete inputs / outputs via CANopen (maximum)
16 / 16
32 / 32
External analog inputs / outputs via CANopen (maximum)
-
16 / 4
NOTE
This manual has been developed for a unit fitted with all available options. Inputs/outputs, functions,
configuration screens, and other details described, which do not exist on your unit, may be ignored.
The present manual has been prepared to enable the installation and commissioning of the unit. Due to
the large variety of parameter settings, it is not possible to cover every combination. The manual is
therefore only a guide. In case of incorrect entries or a total loss of functions, the default settings may
be taken from the Parameter List 37473 or from ToolKit and the respective *.SID file.

Manual 37468 easYgen-3000 Series - Genset Control
Page 8/67 © Woodward
Chapter 2.
Electrostatic Discharge Awareness
All electronic equipment is static-sensitive, some components more than others. To protect these components
from static damage, you must take special precautions to minimize or eliminate electrostatic discharges.
Follow these precautions when working with or near the control.
1. Before doing maintenance on the electronic control, discharge the static electricity on your body to ground
by touching and holding a grounded metal object (pipes, cabinets, equipment, etc.).
2. Avoid the build-up of static electricity on your body by not wearing clothing made of synthetic materials.
Wear cotton or cotton-blend materials as much as possible because these do not store static electric
charges as easily as synthetics.
3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam cups, cigarette packages, cello-
phane wrappers, vinyl books or folders, plastic bottles, etc.) away from the control, modules, and work
area as much as possible.
4. Opening the control cover may void the unit warranty.
Do not remove the printed circuit board (PCB) from the control cabinet unless absolutely necessary. If you
must remove the PCB from the control cabinet, follow these precautions:
•Ensure that the device is completely voltage-free (all connectors have to be disconnected).
•Do not touch any part of the PCB except the edges.
•Do not touch the electrical conductors, connectors, or components with conductive devices or with
bare hands.
•When replacing a PCB, keep the new PCB in the plastic antistatic protective bag it comes in until you
are ready to install it. Immediately after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.
CAUTION
To prevent damage to electronic components caused by improper handling, read and observe the pre-
cautions in Woodward manual 82715, Guide for Handling and Protection of Electronic Controls, Printed
Circuit Boards, and Modules.
NOTE
The unit is capable to withstand an electrostatic powder coating process with a voltage of up to 85 kV
and a current of up to 40 µA.

Manual 37468 easYgen-3000 Series - Genset Control
© Woodward Page 9/67
Chapter 3.
Marine Usage
CAUTION
The following notes are very important for marine usage of the easYgen genset control and have to be
followed.
NOTE
The specified marine approvals are only valid for metal housing units. They are only valid for plastic
housing units, if they are installed using the screw kit (refer to Screw Kit Installation on page 14). In
this case, all
12 screws must be used and tightened accordingly.
Application
≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
The easYgen-3000 Series has an internally isolated power supply.
If the easYgen is to be used on bridge and deck zones, an EMI filter (i.e. TIMONTA FSS2-65-4/3) must be used for
the power supply inputs.
Some additional, independent safety and protection devices are necessary to meet safety requirements of Rules
and Regulations of marine Classification Societies.
The easYgen is type approved by LR Lloyd's Register.
Please consider for final functional arrangements to comply with appropriate Lloyd's Register Rules as subject of
the Plan Approval process.

Manual 37468 easYgen-3000 Series - Genset Control
Page 10/67 © Woodward
Chapter 4.
Housing
The controls of the easYgen-3000 Series are available with two different housings. Refer to the applicable section
for detailed information about installation and technical data of the respective housing type.
Plastic housing for front panel flush mounting with graphical LC display (easYgen-3200)
Figure 4-1: easYgen-3200 - plastic housing
Sheet metal housing for switch cabinet back mounting without display (easYgen-3100)
Figure 4-2: easYgen-3100 - sheet metal housing