Woodward easYgen-3000 User manual

easYgen-3000 Series
Manual Genset Control
easYgen-3100/3200 P1/P2
Software Version 1.211 or higher
37532G

© 2015
This is no translation but the original Technical Manual.
Designed in Germany.
Woodward GmbH
Handwerkstrasse 29
70565 Stuttgart
Germany
Telephone: [phone]
Fax: [phone]
Email: [email protected]
Internet: http://www.woodward.com
37532GeasYgen-3100/3200 P1/P2 | Genset Control2

Brief Overview
Fig. 1: easYgen-3000 Series (housing variants)
A easYgen-3200 (plastic housing with display)
B easYgen-3100 (sheet metal housing)
1 Mains/generator/busbar PT terminal
2 Analog inputs/outputs and generator CT terminal
3 CAN bus interface connector #1
4 CAN bus interface connector #2
5 Discrete inputs terminal
6 Relay outputs terminal
7 RS-232 interface connector
8 RS-485 interface connector
The easYgen-3000 Series are control units for engine-generator
system management applications.
The control units can be used in applications such as: co-genera‐
tion, stand-by, AMF, peak shaving, import/export or distributed
generation.
The easYgen-3000 Series is also applicable for island, island par‐
allel, mains parallel and multiple unit mains parallel operations.
Brief Overview
37532G easYgen-3100/3200 P1/P2 | Genset Control 3

Fig. 2: Sample application setup
A typical application mode for the control unit is the use for mains
parallel operation.
nIn this case, the easYgen will function as an engine control with
generator, mains and engine protection.
nThe control unit can open and close the generator circuit
breaker (GCB) and the mains circuit breaker (MCB).
For a listing of additional application modes and setups
please refer to chapter Ä Chapter 6 “Application”
on page 417.
The easYgen-3100/3200 controllers are available in
different packages. The differences are listed below.
Sample application setup
Packages
Brief Overview
37532GeasYgen-3100/3200 P1/P2 | Genset Control4

easYgen-3100/3200 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
The following parts are included in the scope of delivery. Please
check prior to the installation that all parts are present.
Fig. 3: Scope of delivery - schematic
A easYgen-3100/3200 genset control
B Product CD (configuration software and manual)
C Clamp fastener installation material - 4x
(easYgen-3200 only)
D Screw kit installation material - 12x
(easYgen-3200 only)
Scope of delivery
Brief Overview
37532G easYgen-3100/3200 P1/P2 | Genset Control 5

Brief Overview
37532GeasYgen-3100/3200 P1/P2 | Genset Control6

Table of contents
1General Information................................................................................................................ 17
1.1 About This Manual.................................................................................................................... 17
1.1.1 Revision History........................................................................................................................ 17
1.1.2 Depiction Of Notes And Instructions......................................................................................... 23
1.2 Copyright And Disclaimer.......................................................................................................... 24
1.3 Service And Warranty............................................................................................................... 25
1.4 Safety........................................................................................................................................ 25
1.4.1 Intended Use............................................................................................................................. 25
1.4.2 Personnel.................................................................................................................................. 26
1.4.3 General Safety Notes................................................................................................................ 27
1.4.4 Protective Equipment And Tools............................................................................................... 30
2 System Overview..................................................................................................................... 33
2.1 Display And Status Indicators................................................................................................... 33
2.2 Hardware Interfaces (Terminals)............................................................................................... 34
2.3 Application Modes Overview..................................................................................................... 35
3 Installation............................................................................................................................... 37
3.1 Mount Unit (Sheet Metal Housing)............................................................................................ 37
3.2 Mount Unit (Plastic Housing)..................................................................................................... 39
3.2.1 Clamp Fastener Installation....................................................................................................... 40
3.2.2 Screw Kit Installation................................................................................................................. 41
3.3 Setup Connections.................................................................................................................... 42
3.3.1 Terminal Allocation.................................................................................................................... 42
3.3.2 Wiring Diagram.......................................................................................................................... 43
3.3.3 Power Supply............................................................................................................................ 45
3.3.4 Charging Alternator................................................................................................................... 46
3.3.5 Voltage Measuring.................................................................................................................... 47
3.3.5.1 Generator Voltage..................................................................................................................... 47
3.3.5.2 Mains Voltage............................................................................................................................ 55
3.3.5.3 Busbar Voltage.......................................................................................................................... 61
3.3.6 Current Measuring..................................................................................................................... 64
3.3.6.1 Generator Current..................................................................................................................... 64
3.3.6.2 Mains Current............................................................................................................................ 66
3.3.6.3 Ground Current......................................................................................................................... 67
3.3.7 Power Measuring...................................................................................................................... 68
3.3.8 Power Factor Definition............................................................................................................. 69
3.3.9 Magnetic Pickup Unit (MPU)..................................................................................................... 70
3.3.10 Discrete Inputs.......................................................................................................................... 71
3.3.11 Relay Outputs (LogicsManager)................................................................................................ 73
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3.3.12 Analog Inputs (0 to 500 Ohm | 0/4 to 20 mA)............................................................................ 74
3.3.13 Analog Outputs.......................................................................................................................... 77
3.3.13.1 Analog Outputs (±20 mA, ± 10 V, PWM).................................................................................. 77
3.3.14 Serial Interfaces........................................................................................................................ 78
3.3.14.1 RS-485 Interface....................................................................................................................... 78
3.3.14.2 RS-232 Interface....................................................................................................................... 79
3.4 CAN Bus Interfaces................................................................................................................... 80
3.5 Connecting 24 V Relays............................................................................................................ 82
4 Configuration........................................................................................................................... 85
4.1 Basic Setup............................................................................................................................... 85
4.1.1 Configure Language/Clock........................................................................................................ 85
4.1.2 Configure Display...................................................................................................................... 89
4.1.3 Lamp Test................................................................................................................................. 89
4.1.4 Enter Password......................................................................................................................... 89
4.1.5 System Management................................................................................................................ 92
4.1.6 Password System...................................................................................................................... 93
4.2 Configure Measurement............................................................................................................ 94
4.2.1 Configure Transformer.............................................................................................................. 99
4.2.2 External Mains Active Power................................................................................................... 102
4.2.3 External Mains Reactive Power.............................................................................................. 103
4.3 Function Of Inputs And Outputs.............................................................................................. 103
4.3.1 Discrete Inputs........................................................................................................................ 103
4.3.2 Discrete Outputs...................................................................................................................... 106
4.4 Configure Monitoring............................................................................................................... 109
4.4.1 Generator................................................................................................................................ 109
4.4.1.1 Generator Operating Voltage / Frequency.............................................................................. 110
4.4.1.2 Generator Overfrequency (Level 1 & 2) ANSI# 81O............................................................... 110
4.4.1.3 Generator Underfrequency (Level 1 & 2) ANSI# 81U............................................................. 112
4.4.1.4 Generator Overvoltage (Level 1 & 2) ANSI# 59...................................................................... 113
4.4.1.5 Generator Undervoltage (Level 1 & 2) ANSI# 27.................................................................... 115
4.4.1.6 Generator Time-Overcurrent (Level 1, 2 & 3) ANSI# 50/51.................................................... 116
4.4.1.7 Generator Reverse/Reduced Power (Level 1 & 2) ANSI# 32R/F............................................ 117
4.4.1.8 Generator Overload IOP (Level 1 & 2) ANSI# 32.................................................................... 119
4.4.1.9 Generator Overload MOP (Level 1 & 2) ANSI# 32.................................................................. 121
4.4.1.10 Generator Unbalanced Load (Level 1 & 2) ANSI# 46............................................................. 122
4.4.1.11 Generator Voltage Asymmetry................................................................................................ 124
4.4.1.12 Generator Ground Fault (Level 1 & 2)..................................................................................... 125
4.4.1.13 Generator Phase Rotation....................................................................................................... 129
4.4.1.14 Generator Inverse Time-Overcurrent ANSI# IEC 255............................................................. 131
4.4.1.15 Generator Lagging Power Factor (Level 1 & 2)....................................................................... 134
4.4.1.16 Generator Leading Power Factor (Level 1 & 2)....................................................................... 136
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4.4.1.17 Generator Voltage Restrained Overcurrent Monitoring - ANSI #51........................................ 137
4.4.2 Mains....................................................................................................................................... 139
4.4.2.1 Mains Operating Voltage / Frequency..................................................................................... 139
4.4.2.2 Mains Decoupling.................................................................................................................... 140
4.4.2.3 Mains Overfrequency (Level 1 & 2) ANSI# 81O...................................................................... 147
4.4.2.4 Mains Underfrequency (Level 1 & 2) ANSI# 81U.................................................................... 148
4.4.2.5 Mains Overvoltage (Level 1 & 2) ANSI# 59............................................................................. 149
4.4.2.6 Mains Undervoltage (Level 1 & 2) ANSI# 27........................................................................... 151
4.4.2.7 Mains Voltage Increase........................................................................................................... 152
4.4.2.8 Mains Time-Dependent Voltage.............................................................................................. 154
4.4.2.9 QV Monitoring......................................................................................................................... 157
4.4.2.10 Change Of Frequency............................................................................................................. 159
4.4.2.11 Mains Voltage Phase Rotation................................................................................................ 163
4.4.2.12 Mains Import Power (Level 1 & 2)........................................................................................... 164
4.4.2.13 Mains Export Power (Level 1 & 2)........................................................................................... 166
4.4.2.14 Mains Lagging Power Factor (Level 1 & 2)............................................................................. 167
4.4.2.15 Mains Leading Power Factor (Level 1 & 2)............................................................................. 169
4.4.2.16 Blocking of Mains Protection................................................................................................... 170
4.4.3 Engine..................................................................................................................................... 171
4.4.3.1 Engine Overspeed (Level 1 & 2) ANSI# 12............................................................................. 171
4.4.3.2 Engine Underspeed (Level 1 & 2)........................................................................................... 172
4.4.3.3 Engine/Generator Speed Detection........................................................................................ 173
4.4.3.4 Engine/Generator Active Power Mismatch.............................................................................. 175
4.4.3.5 Engine/Mains Active Power Mismatch.................................................................................... 176
4.4.3.6 Engine/Generator Unloading Mismatch.................................................................................. 177
4.4.3.7 Engine Start Failure................................................................................................................. 178
4.4.3.8 Engine Shutdown Malfunction ................................................................................................ 178
4.4.3.9 Engine Unintended Stop ........................................................................................................ 179
4.4.3.10 Engine Operating Range Failure............................................................................................. 180
4.4.3.11 Engine Charge Alternator (D+)................................................................................................ 181
4.4.3.12 Cylinder Temperature.............................................................................................................. 182
4.4.4 Breaker.................................................................................................................................... 188
4.4.4.1 Configure GCB........................................................................................................................ 188
4.4.4.2 Synchronization GCB ............................................................................................................. 189
4.4.4.3 Configure MCB........................................................................................................................ 190
4.4.4.4 Synchronization MCB ............................................................................................................. 192
4.4.4.5 Generator/Busbar/Mains Phase Rotation................................................................................ 193
4.4.5 Flexible Limits.......................................................................................................................... 194
4.4.6 Miscellaneous.......................................................................................................................... 199
4.4.6.1 Alarm Acknowledgement......................................................................................................... 199
4.4.6.2 Free Configurable Alarms....................................................................................................... 200
4.4.6.3 CAN Bus Overload.................................................................................................................. 201
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37532G easYgen-3100/3200 P1/P2 | Genset Control 9

4.4.6.4 CAN Interface 1....................................................................................................................... 202
4.4.6.5 CAN Interface 2....................................................................................................................... 203
4.4.6.6 CAN Interface 2 - J1939 Interface........................................................................................... 204
4.4.6.7 J1939 Interface - Red Stop Alarm........................................................................................... 205
4.4.6.8 J1939 Interface - Amber Warning Alarm................................................................................. 206
4.4.6.9 Battery Overvoltage (Level 1 & 2)........................................................................................... 207
4.4.6.10 Battery Undervoltage (Level 1 & 2)......................................................................................... 208
4.4.6.11 Multi-Unit Parameter Alignment.............................................................................................. 209
4.4.6.12 Multi-Unit Missing Members.................................................................................................... 211
4.4.6.13 Neutral Interlocking................................................................................................................. 212
4.5 Configure Application.............................................................................................................. 212
4.5.1 Configure Breakers................................................................................................................. 212
4.5.1.1 Dead Bus Closing GCB........................................................................................................... 213
4.5.1.2 Synchronization GCB/MCB..................................................................................................... 215
4.5.1.3 Dead Bus Closing MCB........................................................................................................... 216
4.5.1.4 Open GCB............................................................................................................................... 217
4.5.1.5 Open MCB............................................................................................................................... 218
4.5.1.6 Transition Modes (Breaker Logic)........................................................................................... 218
4.5.1.7 Parameters.............................................................................................................................. 222
4.5.1.8 Breakers GCB......................................................................................................................... 225
4.5.1.9 Breakers MCB......................................................................................................................... 229
4.5.1.10 Synchronization....................................................................................................................... 232
4.5.1.11 Neutral Interlocking................................................................................................................. 234
4.5.2 Inputs And Outputs.................................................................................................................. 235
4.5.2.1 Analog Inputs.......................................................................................................................... 235
4.5.2.2 External Analog Inputs............................................................................................................ 242
4.5.3 Discrete Inputs........................................................................................................................ 246
4.5.4 External Discrete Inputs.......................................................................................................... 249
4.5.5 Discrete Outputs (LogicsManager).......................................................................................... 251
4.5.6 External Discrete Outputs....................................................................................................... 253
4.5.7 Analog Outputs........................................................................................................................ 254
4.5.7.1 Analog Outputs 1 and 2........................................................................................................... 254
4.5.8 External Analog Outputs......................................................................................................... 258
4.5.9 Engine..................................................................................................................................... 260
4.5.9.1 Engine Type............................................................................................................................ 260
4.5.9.2 Engine Start/Stop.................................................................................................................... 267
4.5.9.3 Magnetic Pickup Unit............................................................................................................... 273
4.5.9.4 Idle Mode................................................................................................................................. 274
4.5.10 Emergency Run....................................................................................................................... 276
4.5.11 Automatic Run......................................................................................................................... 278
4.5.11.1 Load Dependent Start Stop (LDSS)........................................................................................ 281
4.5.11.2 Critical Mode........................................................................................................................... 294
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