Woodward easYgen-400 User manual

Technical Manual
easYgen-400
Genset Control
B37884A
easYgen-400

Woodward GmbH
Handwerkstr. 29 — 70565 Stuttgart — Germany
Phone [phone]‑510
Fax [phone]‑101
[email protected]
© 2019 Woodward GmbH
2 easYgen-400 B37884A

Brief Overview
Fig. 1: easYgen-400
1 Terminals 21 to 24: Digital inputs 01 to 03, COMMON
2 Terminals 25 to 28: Generator voltage
3Terminals 33 to 36: Generator current
4 USB type B service port for PC/laptop with ToolKit-SC
5 Terminals 1 to 14: Power Supply, Fuel/Gas, Starter, D+, Relay 01 to04, AI 01 to 04
6 Terminals 15 to 17: Magnetic Pickup
7Terminals 18 to 20: CAN (J1939) interface
The easYgen-400 is a control unit for engine-generator management applications.
The control unit can be used in simple Start/Stop applications.
Scope of delivery
The following parts are included in the covering box. Please check prior to installation that
all parts are present:
• Device easYgen genset control
All terminal connectors that need to be screwed are delivered with plug and jack
• Clamp fastener installation material (4x)
• »Installation Procedure Supplement« paper with links to the latest edition of
Technical Documentation and software for download:(http://www.wwdmanuals.com/
easYgen-400)
3easYgen-400B37884A
Brief Overview

Con󰍓guration software and Technical Manual are available at Woodward website:http://
www.woodward.com/easYgen-400.aspx
Sample application setup
Fig. 2: Sample application setup
4 easYgen-400 B37884A
Brief Overview

A typical application mode for the control unit is the use for non parallel operation in a
single genset application.
• In this case, the easYgen will function as an engine control with generator and
engine protection.
• The control unit can open and close the circuit breaker .
Transition procedures are described in chapter ╚═▷ “Transition Procedures”.
5easYgen-400B37884A
Brief Overview

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Table of Contents
1 General Information 9
1.1 About this Manual 9
1.1.1 Revision History 9
1.1.2 Symbols Used in this manual 10
1.2 Copyright And Disclaimer 12
1.3 Service And Warranty 12
1.4 Safety 13
1.4.1 Intended Use 13
1.4.2 Personnel 14
1.4.3 General hazard warnings 14
2 System Overview 16
2.1 Display and Status Indicators 16
2.2 Features and Functions of both easYgen-400 and -1400 17
2.3 Functions 20
2.4 Intended Use of This Control 20
3 Installation 21
3.1 Mounting 21
3.2 Wiring 21
3.3 Interfaces 26
3.4 Install ToolKit-SC 27
4Con󰍏guration 28
4.1 Access to the Control 28
4.1.1 Front Panel: Operating and Display Elements 28
4.1.2 Front Panel Control 30
4.1.2.1 HMI Screens Without Password Level 31
4.1.3 Con󰍓gure ToolKit-SC 34
4.1.3.1 Con󰍓gure Communication 34
4.1.3.2 Manage Con󰍓guration Data 34
4.1.3.3 Select Language 34
4.1.4 Access via ToolKit-SC Con󰍓guration Tool 35
4.2 Parameters 36
4.2.1 Parameter Menu Structure 36
4.2.2 Parameter Settings Menu--HMI Access 37
4.2.3 Con󰍓gure Measurement 38
4.2.4 Con󰍓gure Application 40
4.2.4.1 Con󰍓gure Inputs and Outputs 40
4.2.4.2 Con󰍓gure Engine 46
4.2.4.3 Con󰍓gure TEST Run 48
4.2.4.4 Con󰍓gure Breakers 49
6 easYgen-400 B37884A
Table of Contents

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.5 Con󰍓gure Monitoring 50
4.2.5.1 Monitoring Generator 50
4.2.5.2 Monitoring Breakers 51
4.2.5.3 Monitoring Engine 51
4.2.5.4 Other Monitoring 52
4.2.6 Con󰍓gure Maintenance 52
4.2.7 Con󰍓gure Counters 52
4.2.8 Con󰍓gure Language / Clock 53
4.2.9 Con󰍓gure System Management 54
4.2.10 Con󰍓gure HMI 54
4.3 Selectable Inputs/Outputs/Sensors 55
4.3.1 Programmable Sensors 55
4.3.2 Programmable Inputs 56
4.3.3 Programmable Outputs 57
4.4 Status Menu 58
4.4.1 HMI Status Screens 58
4.4.2 ToolKit-SC Status Screens 59
5 Operation 62
5.1 Warning/Alarm Signaling 62
5.1.1 Alarm Acknowledgment 62
5.2 Operation Modes 62
5.2.1 Operation Mode AUTO 63
5.2.2 Operation Mode MANual 63
5.2.3 Operation Mode STOP 63
5.3 START/STOP Operation 64
5.3.1 Start engine to supply load 64
5.3.2 Stop engine 65
5.3.3 MANual START/STOP 67
5.4 Transition Procedures 67
5.4.1 Disconnect during cranking 67
6 Commissioning 69
7 Interfaces and Protocols 70
7.1 J1939 70
8 Technical Speci󰍏cations 76
8.1 Measuring and Monitoring 79
9 Appendix 81
9.1 Alarms and Warnings 81
9.1.1 Alarm Classes 81
9.1.2 Warnings 81
9.1.3 Shutdown Alarms 82
9.2 Trouble Shooting 83
7easYgen-400B37884A
Table of Contents

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Index 86
8 easYgen-400 B37884A
Table of Contents

1 General Information
1.1 About this Manual
1.1.1 Revision History
Rev. Date Editor Changes
A 2019-05 PW NEW Software Revision 2.0.0.1 and ToolKit-SC version 1.5.0.4
Corrections/Repairs
• Fixed the following in HMI software:
◦󰍓xed the version name to 4 digits;
◦ possibility to close GCB when engine not running;
◦ kvar spelling;
◦ impossibility to mute the horn with easYlite-200;
◦ HMI user de󰍓ned sensor curves displaying messy codes in
other languages
◦ after gen closed, if changed breaker close delay by Toolkit-sc,
6550 countdown error occurred in HMI;
◦ when change to OEM plant theme and Terminal users theme,
press close/open button in manual mode, error occurred in
breaker page;
◦ Horn/Alarm Acknowledge / Alarm reset function
◦ "Traditional Chinese" implemented
◦ changed name easYgen400/easYgen1400 to easYgen-400/
easYgen-1400 in controller information page;
◦ status LED not turning on if the "Conventional Engine" was
selected, easYgen and genset in STOP condition, START
button pressed;
◦ maintenance counter resetting
◦ Polish translation errors
◦modi󰍓ed con󰍓guration of auto test mode, including number
of input ports, LED display order, and level sensor changed
from 󰍔exible sensor to resistor type sensor;
◦ J1939 standard and setpoint idle
◦ Volvo EMS2 50/60Hz rated speed selection
◦ overload monitoring not using the "return" value;
◦ Volvo EMS2 rated frequency selection and rated speed
modi󰍓cation;
◦ mains breaker warning in MAN mode;
◦ operation mode changing from MAN with closed GCB to MCB;
◦ breaker status in MAN mode;
◦ removed all ECU types with Modbus;
◦ removed “Baud rate and Modbus slave ID” parameters;
9easYgen-400B37884A
1 General Information
1.1 About this Manual

Rev. Date Editor Changes
◦ parameter naming change: in order to align with ToolKit,
changed “Current” to “Limit” and “Low fuel level” to “Fuel
level warning” in HMI parameter con󰍓g screen;
• Fixed the following in ToolKit-SC :
◦󰍓xed the version name of 2 digits displayed on ToolKit to 4
digits;
◦ removed WWDMODEM-3G related parameters;
◦ removed “emergency stop input”;
◦ removed “Baud rate and Modbus slave ID”parameters;
◦ removed all ECU types with Modbus.
Technical Manual
•In ╚═▷ “Wiring”:
◦terminal ratings and descriptions updated in ╚═▷ Tab.
◦corrections in ╚═▷ Fig. 6
•Chapter ╚═▷ “Con󰍓gure Inputs and Outputs” supplemented with
an external LED module
•Minor adjustments of items in con󰍓guration menu descriptions
•In ╚═▷ “Technical Speci󰍓cations” voltage ranges for the alternator
and AC measurement updated to UL6200
•Added description of analog inputs in ╚═▷ “Technical
Speci󰍓cations”
NEW 2018-11 PC Describes device implemented software version 1.8 and
ToolKit-SC version 1.4.0.2
Technical Manual
• Release = 1st issue
1.1.2 Symbols Used in this manual
Safety instructions
Safety instructions are marked with symbols. The safety instructions are always
introduced by signal words that express the severity of the danger.
DANGER!
This combination of symbol and signal word indicates an immediately dangerous situation
that can cause death or severe injuries if not avoided.
10 easYgen-400 B37884A
1 General Information
1.1 About this Manual

WARNING!
This combination of symbol and signal word indicates a possibly dangerous situation that
can cause death or severe injuries if it is not avoided.
CAUTION!
This combination of symbol and signal word indicates a possibly dangerous situation that
can cause slight injuries if it is not avoided.
NOTICE!
This combination of symbol and signal word indicates a possibly dangerous situation that
can cause property and environmental damage if it is not avoided.
Tips and recommendations
This symbol indicates useful tips and recommendations as well as information on e󰍕cient
and trouble-free operation.
Additional markings
To highlight instructions, results, lists, references, and other elements, the following
markings are used in these instructions:
Marking Explanation
__▶ Step-by-step instructions
⇨Results of action steps
╚═▷ References to sections of these instructions and to other
relevant documents
• Listing without 󰍓xed sequence
»Buttons« Operating elements (e.g. buttons, switches), display
elements (e.g. signal lamps)
»Display« Screen elements (e.g. buttons, programming of function
keys)
[Screen xx / Screen xy /
Screen xz] ...
Menu path.
The following information and setting refer to a page on
the HMI screen or ToolKit located as described here.
Some parameters/settings/screens are available only either
in ToolKit or on the HMI/display.
11easYgen-400B37884A
1 General Information
1.1 About this Manual

Dimensions in Figures
All dimensions with no units speci󰍓ed are in mm.
1.2 Copyright And Disclaimer
Disclaimer
All information and instructions in this manual have been provided under due
consideration of applicable guidelines and regulations, the current and known state of the
art, as well as our many years of in-house experience. Woodward assumes no liability for
any damages due to:
• Failure to comply with the instructions in this manual
• Improper use / misuse
• Willful operation by non-authorized persons
• Unauthorized conversions or non-approved technical modi󰍓cations
• Use of non-approved spare parts
The originator is solely liable for the full extent for damages caused by such conduct. The
obligations agreed-upon in the delivery contract, the general terms and conditions, the
manufacturer’s delivery conditions, and the statutory regulations valid at the time the
contract was concluded, apply.
Copyright
This manual is protected by copyright. No part of this manual may be reproduced in any
form or incorporated into any information retrieval system without written permission of
Woodward GmbH.
Delivery of this manual to third parties, duplication in any form - including excerpts - as
well as exploitation and/or communication of the content, are not permitted without a
written declaration of release by Woodward GmbH.
Actions to the contrary will entitle us to claim compensation for damages. We expressly
reserve the right to raise any further accessory claims.
1.3 Service And Warranty
Opening the device will nullify any warranty!
CAUTION!
Any unauthorized modi󰍓cations or use of this equipment outside its speci󰍓ed mechanical,
electrical, or other operating limits may cause personal injury and/or property damage,
including damage to the equipment.
Any such unauthorized modi󰍓cations
12 easYgen-400 B37884A
1 General Information
1.2 Copyright And Disclaimer

• constitute "misuse" and/or "negligence" as per the product warranty
• thereby exclude warranty coverage for any resulting damage, and
• invalidate product certi󰍓cations or listings.
Our Customer Service is available for technical information. Please see page 2 for contact
details.
In addition, our employees are interested in any new information and experiences that
arise from usage and could be valuable for improving our products.
Warranty terms
Please enquire about the terms of warranty from your nearest Woodward representative.
To 󰍓nd your closest Customer Service representative, go to: ══▷ http://
www.woodward.com/Directory.aspx
1.4 Safety
1.4.1 Intended Use
The easYgen unit has been designed and constructed solely for the intended use
described in this manual.
• Intended use requires operation of the control unit within the range outlined in the
speci󰍓cations listed in ╚═▷ “Technical Speci󰍓cations”.
• Steps to be taken for commissioning are outlined in ╚═▷ “Commissioning”.
• Intended use includes compliance with all instructions and safety notes presented in
this manual.
•Any use which exceeds or di󰍒ers from the intended use shall be considered improper
use.
• No claims for any kind for damage will be considered if such claims result from
improper use.
NOTICE!
Damage due to improper use!
Improper use of the remote panel unit may cause damage to the control unit as well as to
the connected components.
Improper use includes, but is not limited to:
•Operation outside the speci󰍓ed operating conditions.
13easYgen-400B37884A
1 General Information
1.4 Safety

1.4.2 Personnel
WARNING!
Hazards due to insu󰈢ciently quali󰈠ed personnel!
If unquali󰍓ed personnel perform work on or with the control unit hazards may arise which
can cause serious injury and substantial damage to property.
• Therefore, all work must only be carried out by appropriately quali󰍓ed personnel.
This manual speci󰍓es the personnel quali󰍓cations required for the di󰍒erent areas of work,
listed below:
• Well trained for electrical installations.
• Aware of the local safety regulations.
•Experienced in working with electronic measuring and control devices.
• Allowed to manage the controlled (engine/generator) system.
The workforce must only consist of persons who can be expected to carry out their work
reliably. Persons with impaired reactions due to, for example, the consumption of drugs,
alcohol, or medication are prohibited.
When selecting personnel, the age-related and occupation-related regulations governing
the operating location must be observed.
1.4.3 General hazard warnings
Hazards by system controlled
DANGER!
Moving parts and dangerous electricity!
Be aware that the remote control of a system that is managing life-threatening engine-
generator-electricity parts must be adapted to the local situation!
The following safety notes cover both the device itself and basics of the overall genset
system. The dedicated genset-system safety instruction must be considered, too!
14 easYgen-400 B37884A
1 General Information
1.4 Safety

Prime mover safety
WARNING!
Hazards due to insu󰈢cient prime mover protection
The engine, turbine, or any other type of prime mover must be equipped with an
overspeed (over-temperature, or over-pressure, where applicable) shutdown device(s)
that operates independently of the prime mover control device(s) to protect from
runaway or damage to the engine, turbine, or any other type of prime mover. Failure to
comply with this also poses the risk of personal injury or loss of life if the mechanical-
hydraulic governor(s) or electric control(s), the actuator(s), fuel control(s), the driving
mechanism(s), the linkage(s), or the controlled device(s) fail.
15easYgen-400B37884A
1 General Information
1.4 Safety

2 System Overview
General notes
The easYgen is a stand-alone genset controller with measuring, monitoring, and breaker
control functionality. It comes with an easily mountable plastic housing covering a
thoroughly tested electronic-electrical system.
Display and buttons of the HMI o󰍒er access to states and values, as well as access to the
application. Password protection enables the assignment of multiple operation access
levels. Remote access, monitoring, visualization, and con󰍓guration are possible via
integrated interfaces. Communication between easYgens using PLC control or as a
network member o󰍒ers an enhanced system management range; additionally supported
by easy to implement accessories.
For even higher challenges in genset control, the easYgen series o󰍒ers further solutions
encompassing complex and ambitious applications.
For dedicated protection tasks, ask Woodward for its protection (relay) solutions.
Operation Modes
• See ╚═▷ “Operation Modes”
2.1 Display and Status Indicators
General Notes
HMI and the con󰍓guration software enable access to control, settings, and visualization.
The front panel o󰍒ers a number of functionally de󰍓ned buttons and a set of menu
management buttons. LEDs visualize 󰍓xed states, the graphic display works together with
the menu management buttons to show all necessary information.
Restrictions
Full access to all parameters and settings with con󰍓guration software only!
HMI access o󰍒ers a number of information screens in general, and enables - password-
protected - access to parameters and settings.
16 easYgen-400 B37884A
2 System Overview

Fig. 3: easYgen-400
2.2 Features and Functions of both easYgen-400 and -1400
Both, easYgen-400 and easYgen-1400, are very similar in hardware and software. The
easYgen-1400 is the device with the higher functionality. For purposes of comparison and
better di󰍒erentiation, both are described below.
easYgen-400 is intended to be used for single automation systems, auto start/stop of
the unit is performed using a remote signal.
easYgen-1400 has all the functions of the easYgen-400 as well as automatic mains
failure function (AMF), which is particularly well-suited for single automation systems that
include mains and generator.
Functional Blocks
Item easYgen-400 easYgen-1400
LCD (with backlight) Dimension 2.8” 2.8”
17easYgen-400B37884A
2 System Overview
2.2 Features and Functions of both easYgen-400 and -1400

Item easYgen-400 easYgen-1400
Pixel 132 x 64 132 x 64
AMF no ●
Digital input ports 3 3
Output ports 6 6
Sensors 4 4
Schedule function ● ●
J1939 ● ●
USB (Type B) ● ●
Real-time clock ● ●
Event log ● ●
Key characteristics
•With ARM-based 32-bit SCM, highly integrated hardware, high reliability level.
• Multilingual interface (English, Chinese, Spanish, Russian, Portuguese, Turkish,
Polish, and French) making commissioning convenient for factory personnel.
• Improved LCD with high wear-resistance and scratch resistance due to hard screen
acrylic.
• Silicon panel and pushbuttons for better operation in high-temperature
environments.
• Equipped with CAN bus port for communicating with the J1939 genset. Monitoring
frequently-used data on ECU machine, such as water temperature, oil pressure,
speed, fuel consumption, ECU machine, and additionally also control start, stop,
raising speed, and speed droop via CAN bus port.
• Suitable for 3-phase 4-wire, 3-phase 3-wire, single phase 2-wire, and 2-phase 3-wire
systems with voltage 120/240 V and frequency 50/60 Hz.
•easYgen-1400 only: Collects and shows 3-phase voltage, current, power
parameter, and frequency of generator and additionally 3-phase mains voltage.
Mains/Generator Line voltage (UAB, UBC, and UCA), Phase voltage (UA, UB, and UC).
•easYgen-400 only: Collects and shows 3-phase voltage, current, power parameter
and frequency of generator. Generator Line voltage (UAB, UBC, and UCA), Phase
voltage (UA, UB, and UC).
• Phase sequence, frequency, Load current IA, IB, IC
• Each phase: Total active power [kW], Total reactive power [kvar], Total apparent
power [kVA], Average power factor PF
•Accumulated Total generator power [kWh], [kvarh], [kVAh]
•easYgen-1400 only: For Mains, controller can detect over and under voltage, over
and under frequency, loss of phase and incorrect phase sequence.
18 easYgen-400 B37884A
2 System Overview
2.2 Features and Functions of both easYgen-400 and -1400

• For generator, controller can detect overvoltage and undervoltage, overfrequency
and underfrequency, loss of phase, incorrect phase sequence, overpower and
reverse power, overcurrent.
• 2 󰍓xed analog sensors: Engine temperature and oil pressure.
• Precision measure and display parameters about engine, temp. (WT) °C/°F can both
be displayed oil pressure (OP) kPa/psi/bar Speed (SPD) r/min (unit) battery boltage
(VB) V (unit) charger voltage (VD) V (unit) hour count (HC) can accumulate max.
65535 hours. Start times can accumulate max. 65535 times.
• Protection: automatic start/stop of the genset.
•easYgen-1400 only: ATS (Auto Transfer Switch) control with failure indication and
protection function.
• All output ports are relay-out.
• Parameter settings: Parameters can be modi󰍓ed and stored in internal FLASH
memory and cannot be lost even in case of a power outage; most can be adjusted
on the front panel of the controller and all can be modi󰍓ed using ToolKit-SC
con󰍓guration software on the computer via USB port.
•Various temperature and oil pressure curves are available. More sensor curves can
be de󰍓ned as per user requirements.
• Multiple crank disconnect options (generator frequency, speed sensor, oil pressure)
are available.
• Wide power supply range DC (8 to 35) V, suitable for di󰍒erent start battery voltage
environment.
• Event log, real-time clock, scheduled start & stop generator (can be set as start
genset once a day/week/month with or without load).
• Logon wallpaper and display time are user-de󰍓ned.
• Can be used on pumping units and as an indicating instrument (indicate and alarm
are "enable" only, relay is inhibited).
• Maintenance function. Actions such as warning or shutdown can be set when the
maintenance timer reaches its speci󰍓ed time.
• All parameters are digitally adjusted (instead of conventional analog modulation with
normal potentiometer) for more reliability and stability.
• International Protection Rating IP55 due to rubber seal installed between the
controller enclosure and front panel.
•Metal 󰍓xing clips enable high stability in high temperature environment.
• Modular design, self-extinguishing ABS plastic enclosure, pluggable connection
terminals and embedded installation way; compact structure with easy mounting.
• Total run time and total electric energycan be reset for convenience.
• Customizable start-up screen (text/image).
• Customizable HMI status screens (content) via drag-and-drop.
19easYgen-400B37884A
2 System Overview
2.2 Features and Functions of both easYgen-400 and -1400

2.3 Functions
• Protection: automatic start/stop of the genset, ATS (Auto Transfer Switch) control
with failure indication and protection function
• All output ports are relay-out
• Parameter settings: parameters can be modi󰍓ed and stored in internal FLASH
memory and cannot be lost even in case of a power outage; most of them can be
adjusted using front panel of the controller and all of them can be modi󰍓ed using
ToolKit-SC on a PC via USB port.
• Temperature and oil pressure curves can be used directly and users can de󰍓ne the
sensor curves by themselves.
• Multiple crank disconnect conditions (generator frequency, speed sensor, oil
pressure) are optional.
•Event log, real-time clock, scheduled start & stop generator (can be set as start
genset once a day/week/month with or without load).
• Start-up logo and display time are user-de󰍓ned.
• Can be used on pumping units and as an indicating instrument (indicate and alarm
are enable only, relay is inhibited).
• Maintenance function: Actions (warning or shutdown) can be set when maintenance
time out.
• Instead of conventional analog modulation with a potentiometer, all parameters use
digital adjustment for more reliability and stability.
• Accumulative total run time and total electric energy of A and B. The user can reset
it to 0 and re-accumulate the value, which allows to count the total value.
2.4 Intended Use of This Control
easYgen-400 genset controllers are used for genset automation and monitor control
system of single unit, o󰍒ering:
• automatic start/stop,
•data measurement,
• alarm protection and
• three remote features: control, measuring and communication.
The easYgen genset controllers use 32 bits micro-processor technology with features
such as precision parameters measuring, 󰍓xed value adjustment, time setting or
threshold adjusting. Most of these parameters can be set on the front panel and all
parameters can be set using a computer (via USB port). The controllers can be used for a
number of automatic genset control systems. They have a compact structure, easy
connections and are highly reliable.
20 easYgen-400 B37884A
2 System Overview
2.3 Functions