Woodward easYgen-600 User manual

Technical Manual
easYgen-600
Genset Control
B37698
easYgen-600
Released

Woodward GmbH
Handwerkstr. 29 — 70565 Stuttgart — Germany
Phone [phone]‑510
Fax [phone]‑101
[email protected]
© 2019 Woodward GmbH
2 easYgen-600 B37698
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3easYgen-600B37698
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Brief Overview
Fig. 1: easYgen-600
1 Terminals 1 to 14: Power supply, Relays, D+...
2 Terminals 27 to 30: Generator voltage
3 USB type B service port for PC/laptop with ToolKit-SC
4 Terminals 23 to 26: Generator current
5 Terminals 35 to 37: RS-485 interfaceTerminals 41 to 44: CAN (J1939) interface
6 Terminals 15 to 22 and 38 to 40: MPU, Analog Inputs, Discrete inputs
The easYgen-600 are control units for engine-generator management applications.
The control units can be used in simple Start/Stop applications.
Scope of delivery
The following parts are included in the covering box. Please check prior to the installation
that all parts are present:
• Device easYgen genset control
All screwable terminal connectors 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-600)
Con󰍓guration software and Technical Manual are available at Woodward web site:http://
www.woodward.com/easYgen-600.aspx
4 easYgen-600 B37698
Brief Overview
Released

Sample application setup
Fig. 2: Sample application setup
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 .
5easYgen-600B37698
Brief Overview
Released

Transition procedures are described in chapter ╚═▷ “Transition Procedures”.
6 easYgen-600 B37698
Brief Overview
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Table of Contents
1 General Information 10
1.1 About this Manual 10
1.1.1 Revision History 10
1.1.2 Symbols Used in this manual 10
1.2 Copyright And Disclaimer 12
1.3 Service And Warranty 12
1.4 Safety 13
1.4.1 Intended Use 13
1.4.2 Personnel 13
1.4.3 General hazard warnings 14
2 System Overview 15
2.1 Display and Status Indicators 16
2.2 Features and Functions of both easYgen-600 and -1600 17
2.3 Functions 19
3 Installation 21
3.1 Mounting 21
3.2 Wiring 21
3.3 Interfaces 27
3.4 Install ToolKit-SC 27
4Con󰍏guration 29
4.1 Access to the Control 30
4.1.1 Front Panel: Operating and Display Elements 30
4.1.2 Front Panel Control 32
4.1.2.1 HMI Screens Without Password Level 33
4.1.3 Con󰍓gure ToolKit-SC 36
4.1.3.1 Con󰍓gure Communication 36
4.1.3.2 Manage Con󰍓guration Data 36
4.1.3.3 Select Language 36
4.1.4 Access via ToolKit-SC Con󰍓guration Tool 37
4.2 Parameters 38
4.2.1 Parameter Menu Structure 38
4.2.2 Parameter Settings Menu--HMI Access 39
4.2.3 Con󰍓gure Measurement 40
4.2.4 Con󰍓gure Application 42
4.2.4.1 Con󰍓gure Inputs and Outputs 42
4.2.4.2 Con󰍓gure Engine 48
4.2.4.3 Con󰍓gure TEST Run 50
4.2.4.4 Con󰍓gure Breakers 51
4.2.5 Con󰍓gure Monitoring 51
7easYgen-600B37698
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.5.1 Monitoring Generator 51
4.2.5.2 Monitoring Breakers 53
4.2.5.3 Monitoring Engine 53
4.2.5.4 Other Monitoring 53
4.2.6 Con󰍓gure Interfaces 54
4.2.7 Con󰍓gure Maintenance 54
4.2.8 Con󰍓gure Counters 54
4.2.9 Con󰍓gure Language / Clock 55
4.2.10 Con󰍓gure System Management 56
4.2.11 Con󰍓gure HMI 56
4.3 Selectable Inputs/Outputs/Sensors 57
4.3.1 Programmable Sensors 57
4.3.2 Programmable Inputs 58
4.3.3 Programmable Outputs 59
4.4 Status Menu 60
4.4.1 HMI Status Screens 60
4.4.2 ToolKit-SC Status Screens 61
5 Operation 64
5.1 Warning/Alarm Signaling 65
5.1.1 Alarm Acknowledgment 65
5.2 Operation Modes 65
5.2.1 Operation Mode AUTO 66
5.2.2 Operation Mode MANual 66
5.2.3 Operation Mode STOP 66
5.3 START/STOP Operation 66
5.3.1 Start engine to supply load 67
5.3.2 Stop engine 68
5.3.3 MANual START/STOP 70
5.4 Transition Procedures 70
5.4.1 Disconnect during cranking 70
6 Commissioning 72
7 Interfaces and Protocols 74
7.1 J1939 74
8 Technical Speci󰍏cations 80
8.1 Measuring and Monitoring 84
9 Appendix 86
9.1 Alarms and Warnings 86
9.1.1 Alarm Classes 86
9.1.2 Warnings 86
9.1.3 Shutdown Alarms 87
9.2 Trouble Shooting 88
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3 Data Telegrams 89
9.3.1 General Information 89
9.3.2 Supported Function Codes 91
9.3.2.1 Function # 01 (01h) – Read COIL STATUS 91
9.3.2.2 Function # 03 (03h) – Read Holding Registers 92
9.3.2.3 Function # 05 (05h) – Force Single Coil 93
9.3.3 Function #1 Coil Status Map 94
9.3.4 Function #3 Register Map 98
9.3.5 Function #5 Remote coils Map 101
10 Index 106
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1 General Information
1.1 About this Manual
1.1.1 Revision History
Rev. Date Editor Changes
A 2019-05 PW NEW Software Revision 3.0.0.1 and ToolKit-SC version 1.5.0.4
Technical Manual
• In ╚═▷ “Wiring”:
◦ terminal ratings and descriptions updated in ╚═▷ Tab.
◦ corrections in ╚═▷ Fig. 6
• Chapter ╚═▷ “Con󰍓gure Inputs and Outputs” supplemented with
an external LED module
• Minor adjustments of items in con󰍓guration menu descriptions
• 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 2018-03 GG Describes device implemented software version 2.4 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.
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.
10 easYgen-600 B37698
1 General Information
1.1 About this Manual
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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.
Dimensions in Figures
All dimensions with no units speci󰍓ed are in mm.
11easYgen-600B37698
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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
• 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.
12 easYgen-600 B37698
1 General Information
1.2 Copyright And Disclaimer
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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.
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.
13easYgen-600B37698
1 General Information
1.4 Safety
Released

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!
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.
14 easYgen-600 B37698
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1.4 Safety
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15easYgen-600B37698
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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-600 B37698
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2.1 Display and Status Indicators
Released

Fig. 3: easYgen-600
2.2 Features and Functions of both easYgen-600 and -1600
Both easYgen-600 and easYgen-1600 are very close in hardware and software. The
easYgen-1600 is the device with more/higher functionality. For comparison and better
di󰍒erentiation both are described below.
easYgen-600 is intended to be used for single automation systems, auto start/stop of
the unit are performed with the help of remote signal.
easYgen-1600 has all functions of easYgen-600 as well as automatic mains failure
function (AMF), particularly well suited for single automation systems that include mains
and generator.
Functional Blocks
Item easYgen-600 easYgen-1600
LCD (with backlight) Dimension 3.5” 3.5”
Pixel 132 x 64 132 x 64
AMF no ●
Digital input ports 5 5
Output ports 6 6
Sensors 3 3
Schedule function ● ●
RS485 ● ●
J1939 ● ●
USB (Type B) ● ●
Real-time clock ● ●
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2.2 Features and Functions of both easYgen-600 and -1600
Released

Item easYgen-600 easYgen-1600
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 wear-resistance and scratch resistance due to hard screen acrylic
•Silicon panel and pushbuttons for better operation in high-temperature environment
• RS485 communication port enabling remote control, remote measuring, remote
communication via ModBus protocol
• Equipped with CAN bus port to communicate with J1939 genset. Monitoring
frequently-used data such as water temperature, oil pressure, speed, fuel
consumption and so on of ECU machine, and additionally also control start, stop,
raising speed, and speed droop via CAN bus port
• Suitable for 3-phase 4-wire, 3-phase 3-wire, single phase 2-wire, and 2-phase 3-wire
systems with voltage 120/240 V and frequency 50/60 Hz
•easYgen-1600 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-600 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-1600 only: For Mains, controller has over and under voltage, over and
under frequency, loss of phase and phase sequence wrong detection functions
• For generator, controller has over and under voltage, over and under frequency, loss
of phase, phase sequence wrong, over and reverse power, over current functions
• 3 󰍓xed analog sensors: Engine temperature, oil pressure, and fuel level
•Precision measure and display parameters about Engine, Temp. (WT) °C/°F both be
displayed Oil pressure (OP) kPa/psi/bar all be displayed Fuel level (FL) %(unit) Speed
(SPD) r/min (unit) Battery Voltage (VB) V (unit) Charger Voltage (VD) V (unit) Hour
count (HC) can accumulate to max. 65535 hours. Start times can accumulate to
max. 65535 times
• Protection: automatic start/stop of the genset
•easYgen-1600 only: ATS (Auto Transfer Switch) control with perfect failure
indication and protection function
18 easYgen-600 B37698
2 System Overview
2.2 Features and Functions of both easYgen-600 and -1600
Released

• All output ports are relay-out
• Parameter setting: parameters can be modi󰍓ed and stored in internal FLASH
memory and cannot be lost even in case of power outage; most of them can be
adjusted using front panel of the controller and all of them can be modi󰍓ed using
ToolKit-SC con󰍓guration software on PC via USB or RS485 port
•More kinds of curves of temperature, oil pressure, fuel level can be used directly and
users can de󰍓ne the sensor curves by themselves
• Multiple crank disconnect conditions (generator frequency, speed sensor, oil
pressure) are optional
• Widely power supply range DC (8 to 35) V, suitable to di󰍒erent start battery voltage
environment
•Event log, real-time clock, scheduled start & stop generator (can be set as start
genset once a day/week/month whether with load or not)
• Logon wallpaper and display time are user-de󰍓ned
•Can be used on pumping units and as an indicating instrument (indicate and alarm
are enable only, relay is inhibited)
• With maintenance function. Actions (warning or shutdown) can be set when
maintenance time out
• All parameters are digital adjusted (instead of conventional analog modulation with
normal potentiometer) for more reliability and stability
• Waterproof security level IP55 due to rubber seal installed between the controller
enclosure and front panel
• Metal 󰍓xing clips enable perfect in high temperature environment
•Modular design, self-extinguishing ABS plastic enclosure, pluggable connection
terminals and embedded installation way; compact structure with easy mounting
• Users can reset total run time and total electric energy for convenience.
• Users can customize Start-up screen (text/image)
• Users can de󰍓ne HMI status screens (content) via drag-and-drop
2.3 Functions
• Protection: automatic start/stop of the genset, ATS (Auto Transfer Switch) control
with failure indication and protection function
• All output ports are relay-out
•Parameter settings: parameters can be modi󰍓ed and stored in internal FLASH
memory and cannot be lost even in case of a power outage; most of them can be
adjusted using front panel of the controller and all of them can be modi󰍓ed using
ToolKit-SC on a PC via USB or RS485 ports.
• Temperature, oil pressure and fuel level curves can be used directly and users can
de󰍓ne the sensor curves by themselves.
19easYgen-600B37698
2 System Overview
2.3 Functions
Released

• 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.
20 easYgen-600 B37698
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2.3 Functions
Released