Woodward easYgen-800 User manual

easYgen-800
Manual Genset Control
easYgen-800
37691A

© 2018
This is no translation but the original Technical Manual in English.
Designed in Germany and Poland; manufactured in China.
Woodward GmbH
Handwerkstrasse 29
70565 Stuttgart
Germany
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
Internet: http://www.woodward.com
37691AeasYgen-800 | Genset Control2

Brief Overview
Fig. 1: easYgen-800
1 Terminals 1 to 22: Power supply, relays, discrete
inputs, MPU, D+, ...
2 Terminals 23 to 26: CAN (J1939)
3 Terminals 33 to 35: RS-485 interface
4 USB service port for PC/laptop with ToolKit-SC
5 Terminals 62 to 64: RS-232 interface
6 ETHERNET interface connector (RJ-45)
7 Terminals 56 to 61: Analog inputs
8 Terminals 49 to 55 (screwable): Generator and
Ground current
9 Terminals 45 to 48: Generator voltage
10 Terminals 41 to 44: Intentionally not imple‐
mented
11 Terminals 36 to 40: Relay outputs
12 SD micro card slot
The easYgen-800 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 or distributed generation.
The following parts are included in the covering box. Please check
prior to the installation that all parts are present:
nDevice easYgen genset control
All screwable terminal connectors are delivered with plug and
jack
nClamp fastener installation material (4x)
n
“Installation Procedure Supplement” paper with links to the
latest edition of Technical Documentation and software for
download:
(http://www.wwdmanuals.com/easYgen-800)
Configuration software and Technical Manual are
available at Woodward web site:
http://www.woodward.com/easYgen-800.aspx
Scope of delivery
Brief Overview
37691A easYgen-800 | Genset Control 3

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.
nIn this case, the easYgen will function as an engine control with
generator and engine protection.
nThe control unit can open and close the circuit breaker .
Transition procedures are described in chapter
Ä Chapter 5.5 “Transition Procedures”
on page 99.
Sample application setup
Brief Overview
37691AeasYgen-800 | Genset Control4

Table of contents
1 General Information.................................................................................................................. 9
1.1 About This Manual...................................................................................................................... 9
1.1.1 Revision History.......................................................................................................................... 9
1.1.2 Depiction Of Notes And Instructions........................................................................................... 9
1.2 General Information................................................................................................................... 10
1.2.1 Copyright And Disclaimer.......................................................................................................... 10
1.2.2 Service And Warranty............................................................................................................... 11
1.2.3 Safety........................................................................................................................................ 11
1.2.3.1 Intended Use............................................................................................................................. 11
1.2.3.2 Personnel.................................................................................................................................. 12
1.2.3.3 General Safety Notes................................................................................................................ 13
2 System Overview..................................................................................................................... 15
2.1 Display and Status Indicators.................................................................................................... 15
2.2 Operation Modes....................................................................................................................... 16
2.2.1 Operation Mode AUTO.............................................................................................................. 16
2.2.2 Operation Mode MANual........................................................................................................... 16
2.2.3 Operation Mode STOP.............................................................................................................. 17
2.3 Features and Functions of both easYgen-800 and -1800......................................................... 17
2.4 Functions................................................................................................................................... 19
2.5 Intended Use of This Control..................................................................................................... 20
3 Installation............................................................................................................................... 21
3.1 Mounting.................................................................................................................................... 21
3.2 Wiring........................................................................................................................................ 21
3.3 Interfaces................................................................................................................................... 26
3.3.1 Ethernet Interface Connection................................................................................................... 26
3.4 Micro SD Card Slot.................................................................................................................... 27
3.5 Install ToolKit-SC....................................................................................................................... 28
4 Configuration........................................................................................................................... 29
4.1 Access to the Control................................................................................................................ 30
4.1.1 Access Via The Front Panel...................................................................................................... 30
4.1.1.1 Front Panel: Operating and Display Elements.......................................................................... 30
4.1.1.2 Front Panel Control................................................................................................................... 32
4.1.2 Configure ToolKit-SC................................................................................................................ 35
4.1.2.1 Configure Communication......................................................................................................... 35
4.1.2.2 Manage Configuration Data...................................................................................................... 35
4.1.2.3 Configure Customized Language.............................................................................................. 36
4.1.3 Access via ToolKit-SC Configuration Tool................................................................................ 37
Table of contents
37691A easYgen-800 | Genset Control 5

4.1.3.1 Read/Write Configuration.......................................................................................................... 38
4.2 Parameters................................................................................................................................ 38
4.2.1 Parameter Menu Structure........................................................................................................ 38
4.2.2 Parameter Settings Menu--HMI Access.................................................................................... 40
4.2.3 Configure Measurement............................................................................................................ 41
4.2.4 Configure Application................................................................................................................ 42
4.2.4.1 Configure Inputs and Outputs................................................................................................... 42
4.2.4.2 Configure Engine....................................................................................................................... 51
4.2.4.3 Configure TEST Run................................................................................................................. 52
4.2.4.4 Configure Breakers................................................................................................................... 53
4.2.5 Configure Monitoring................................................................................................................. 54
4.2.5.1 Monitoring Generator ............................................................................................................... 54
4.2.5.2 Monitoring Breakers.................................................................................................................. 57
4.2.5.3 Monitoring Engine..................................................................................................................... 57
4.2.5.4 Other Monitoring........................................................................................................................ 59
4.2.6 Configure Interfaces.................................................................................................................. 59
4.2.6.1 Configure GSM Module............................................................................................................. 60
4.2.6.2 Configure Ethernet Interface..................................................................................................... 62
4.2.7 Configure Maintenance............................................................................................................. 63
4.2.8 Configure Counters................................................................................................................... 65
4.2.9 Configure Switchable Parameter Set........................................................................................ 66
4.2.10 Configure Language / Clock...................................................................................................... 66
4.2.11 Configure System Management................................................................................................ 67
4.2.12 Configure HMI........................................................................................................................... 67
4.3 Selectable Inputs/Outputs/Sensors........................................................................................... 69
4.3.1 Programmable Sensors............................................................................................................. 69
4.3.2 Programmable Inputs................................................................................................................ 70
4.3.3 Programmable Outputs............................................................................................................. 72
4.4 Status Menu.............................................................................................................................. 76
4.4.1 HMI Status Screens.................................................................................................................. 76
4.4.2 ToolKit-SC Status Screens........................................................................................................ 77
4.4.3 Configure For Using Accessories.............................................................................................. 79
4.4.3.1 Digital Input Module WWDIN16................................................................................................. 80
4.4.3.2 Digital Output Module WWDOUT16.......................................................................................... 87
5 Operation................................................................................................................................. 91
5.1 Front Panel: Operating and Display Elements.......................................................................... 91
5.2 Warning/Alarm Signaling........................................................................................................... 93
5.2.1 Alarm Acknowledgment............................................................................................................. 93
5.3 Operation Modes....................................................................................................................... 94
5.3.1 Operation Mode AUTO.............................................................................................................. 94
5.3.2 Operation Mode MANual........................................................................................................... 94
Table of contents
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5.3.3 Operation Mode STOP.............................................................................................................. 94
5.4 START/STOP Operation........................................................................................................... 95
5.4.1 Start engine to supply load........................................................................................................ 95
5.4.2 Stop engine............................................................................................................................... 96
5.4.3 MANual START/STOP.............................................................................................................. 99
5.5 Transition Procedures............................................................................................................... 99
5.5.1 Disconnect during Cranking...................................................................................................... 99
5.6 Trouble Shooting..................................................................................................................... 100
6 Application............................................................................................................................. 101
6.1 Commissioning........................................................................................................................ 101
7 Interfaces and Protocols...................................................................................................... 103
7.1 J1939....................................................................................................................................... 103
8 Technical Specifications...................................................................................................... 109
8.1 Measuring and Monitoring....................................................................................................... 111
9 Appendix................................................................................................................................ 113
9.1 Alarms and Warnings.............................................................................................................. 113
9.1.1 Alarm Classes......................................................................................................................... 113
9.1.2 Warnings................................................................................................................................. 113
9.1.3 Shutdown Alarms.................................................................................................................... 114
9.1.4 Trip and Stop Alarms............................................................................................................... 116
9.1.5 Trip Alarms.............................................................................................................................. 116
9.2 Trouble Shooting..................................................................................................................... 117
9.3 Data Telegrams....................................................................................................................... 117
9.3.1 Modbus Basics........................................................................................................................ 117
9.3.1.1 Data Frame Format................................................................................................................. 118
9.3.1.2 Modbus Communication Protocol........................................................................................... 118
9.3.1.3 Information Frame Format....................................................................................................... 118
9.3.1.4 Address Code.......................................................................................................................... 119
9.3.1.5 Function Code......................................................................................................................... 119
9.3.1.6 Data Field................................................................................................................................ 120
9.3.1.7 Error Check Code (CRC)........................................................................................................ 120
9.3.1.8 Error Handling......................................................................................................................... 124
9.3.2 Read Holding Registers 03_hex.............................................................................................. 125
9.3.3 Force Single Coil 05H_hex...................................................................................................... 147
9.3.4 Preset Single Register 06H_hex............................................................................................. 148
9.3.4.1 Generator Status..................................................................................................................... 148
9.3.4.2 Remote Start Status................................................................................................................ 148
9.3.4.3 Breaker Status......................................................................................................................... 149
Table of contents
37691A easYgen-800 | Genset Control 7

10 Glossary And List Of Abbreviations.................................................................................... 151
11 Index....................................................................................................................................... 153
Table of contents
37691AeasYgen-800 | Genset Control8

1 General Information
1.1 About This Manual
1.1.1 Revision History
Rev. Date Editor Changes
NEW 2018-03 GG Describes device implemented software version 2.x and ToolKit-SC version 1.1.x.x
Technical Manual
nRelease = 1st issue
1.1.2 Depiction Of Notes And Instructions
Safety instructions are marked with symbols in these instructions.
The safety instructions are always introduced by signal words that
express the extent of the danger.
DANGER!
This combination of symbol and signal word indi‐
cates an immediately-dangerous situation that
could cause death or severe injuries if not avoided.
WARNING!
This combination of symbol and signal word indi‐
cates a possibly-dangerous situation that could
cause death or severe injuries if it is not avoided.
CAUTION!
This combination of symbol and signal word indi‐
cates a possibly-dangerous situation that could
cause slight injuries if it is not avoided.
NOTICE!
This combination of symbol and signal word indi‐
cates a possibly-dangerous situation that could
cause property and environmental damage if it is
not avoided.
This symbol indicates useful tips and recommen‐
dations as well as information for efficient and
trouble-free operation.
To emphasize instructions, results, lists, references, and other ele‐
ments, the following markings are used in these instructions:
Safety instructions
Tips and recommendations
Additional markings
General Information
About This Manual > Depiction Of Notes And Ins...
37691A easYgen-800 | Genset Control 9

Marking Explanation
Step-by-step instructions
ðResults of action steps
References to sections of these instructions and to
other relevant documents
Listing without fixed sequence
[Buttons] Operating elements (e.g. buttons, switches), display
elements (e.g. signal lamps)
“Display” Screen elements (e.g. buttons, programming of func‐
tion keys)
“Screen xx è Screen xy
è Screen xz” ...
Menu path.
The following information and setting refer to a page
on HMI screen or ToolKit located as described here.
Some parameters/settings/screens are available only
either in ToolKit or in HMI/display.
Dimensions in Figures
All dimensions shown with no units specified are in
mm.
1.2 General Information
1.2.1 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 dam‐
ages due to:
nFailure to comply with the instructions in this manual
nImproper use / misuse
nWillful operation by non-authorized persons
nUnauthorized conversions or non-approved technical modifica‐
tions
nUse of non-approved spare parts
The originator is solely liable to the full extent for damages caused
by such conduct. The agreed upon obligations in the delivery con‐
tract, the general terms and conditions, the manufacturer’s delivery
conditions, and the statutory regulations valid at the time the con‐
tract 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.
General Information
General Information > Copyright And Disclaimer
37691AeasYgen-800 | Genset Control10