Woodward easYlite-200 User manual

Manual
easYlite-200
LED Lamp Expansion Module
Software Version 3.0.1.2
B37903
easYgen Expansion Module

Woodward GmbH
Handwerkstr. 29 — 70565 Stuttgart — Germany
Phone [phone]‑510
Fax [phone]‑101
[email protected]
© 2019 Woodward GmbH
2 easYlite-200 B37903

3easYlite-200B37903

Brief Overview
Fig. 1: easYlite-200
1Con󰍓gurable LED lamps
2LED labels
3 Lamp test button
4 Acknowledge button
5 Communication status lamp
6USB interface port
7 Terminal strip
General information
The easYlite-200 LED lamp expansion module is a LED display module with 16
programmable alarm, warning and status lamps, for which three colors (red, green,
yellow) can be chosen. The data collected by easYgen series controllers are transmitted
to the easYlite-200 for processing via CANBUS or RS485 port.
Each easYgen series controller can connect with up to two easYlite-200 modules.
4 easYlite-200 B37903
Brief Overview

Schematic easYlite-200
Fig. 2: easYlite-200 – connectivity overview
Scope of delivery
The following parts are included in the scope of delivery. Please check prior to the
installation that all parts are present.
The following parts are included in the covering box. Please check prior to the installation
that all parts are present:
• easYlite 200 LED lamp expansion module
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/
easYlite-200)
Con󰍓guration software and Technical Manual are available at Woodward website:http://
www.woodward.com/easylite200.aspx
5easYlite-200B37903
Brief Overview

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Table of Contents
1 General information 7
1.1 About This Manual 7
1.1.1 Revision history 7
1.1.2 Depiction Of Notes And Instructions 7
1.2 Copyright And Disclaimer 8
1.3 Service And Warranty 9
1.4 Safety 10
1.4.1 Intended Use 10
1.4.2 Personnel 10
1.4.3 General Safety Notes 11
1.4.4 Protective Equipment And Tools 13
2 System overview 15
2.1 Function overview 15
2.2 Display and Status Indicators 15
3 Installation 16
3.1 Installation 18
3.2 Terminal allocation 20
3.3 Wiring diagram 22
3.4 Power Supply 23
3.5 Relay outputs 24
3.6 Interfaces 25
4Con󰍏guration 26
4.1 easYgen: LED Con󰍓guration and Labelling 27
4.2 ToolKit Con󰍓guration easYlite-200 30
4.2.1 Parameter Con󰍓guration 30
4.3 Interfaces 31
5 Operation 32
5.1 Front panel 32
5.2 Relay Output 33
6 Applications 34
7 Technical Data 37
8 Appendix 40
9 Index 46
6 easYlite-200 B37903
Table of Contents

1 General information
1.1 About This Manual
1.1.1 Revision history
Build Date Editor Changes
1.0 2018-12-07 PW Original release
Up to date documentation?
Please check Woodward web site for latest revision of this Technical Manual (search for
"37903") and if there is an Errata Sheet with latest information (search for: "37904").
1.1.2 Depiction Of Notes And Instructions
Safety 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 indicates an immediately-dangerous situation
that could cause death or severe injuries if not avoided.
WARNING!
This combination of symbol and signal word indicates a possibly-dangerous situation that
could cause death or severe injuries if it is not avoided.
CAUTION!
This combination of symbol and signal word indicates a possibly-dangerous situation that
could cause slight injuries if it is not avoided.
NOTICE!
This combination of symbol and signal word indicates a possibly-dangerous situation that
could cause property and environmental damage if it is not avoided.
7easYlite-200B37903
1 General information
1.1 About This Manual

Tips and recommendations
This symbol indicates useful tips and recommendations as well as information for e󰍕cient
and trouble-free operation.
Additional markings
To emphasize instructions, results, lists, references, and other elements, the following
markings are used in these instructions:
Marking Explanation
Step-by-step instructions
ð 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 in
ToolKit located as described here.
Some parameters/settings/screens are available only in
ToolKit.
Dimensions in Figures
All dimensions shown 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
damages due to:
• Failure to comply with the instructions in this manual
• Improper use / misuse
• Willful operation by non-authorized persons
8 easYlite-200 B37903
1 General information
1.2 Copyright And Disclaimer

• Unauthorized conversions or non-approved technical modi󰍓cations
• Use 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 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.
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
9easYlite-200B37903
1 General information
1.3 Service And Warranty

1.4 Safety
1.4.1 Intended Use
The easYlite-200 is designed for use with a dedicated easYgen device. All functions
described in this manual are only performable, if the correct easYgen are incorporated.
Please refer to Woodward for the correct easYgen device.
NOTICE!
Damage due to improper use!
Improper use of the genset control unit may cause damage to the control unit as well as
connected components.
Improper use includes, but is not limited to:
•Storage, transport, and operation outside the speci󰍓ed 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.
This manual speci󰍓es the personnel quali󰍓cations required for the di󰍒erent areas of work,
listed below:
• Well trained for electrical installations.
• Skilled and competent to be aware especially of the local safety regulations.
•Experienced in working on 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 usage location must be observed.
10 easYlite-200 B37903
1 General information
1.4 Safety

1.4.3 General Safety Notes
Electrical hazards
DANGER!
Life-threatening hazard from electric shock!
There is an imminent life-threatening hazard from electric shocks from live parts. Damage
to insulation or to speci󰍓c components can pose a life-threatening hazard.
• Only a quali󰍓ed electrician should perform work on the electrical equipment.
• Immediately switch o󰍒 the power supply and have it repaired if there is damage to
the insulation.
• Before beginning work at live parts of electrical systems and resources, cut the
electricity and ensure it remains o󰍒 for the duration of the work. Comply with the
󰍓ve safety rules in the process:
◦ cut electricity;
◦ safeguard against restart;
◦ ensure electricity is not 󰍔owing;
◦ earth and short-circuit; and
◦ cover or shield neighboring live parts.
• Never bypass a fuse or render it inoperable. Always use the correct amperage when
changing a fuse.
• Keep moisture away from live parts. Moisture can cause short circuits.
Prime mover safety
WARNING!
Hazards due to insu󰈢cient prime mover protection
The engine, turbine, or other type of prime mover should be equipped with an overspeed
(over-temperature, or over-pressure, where applicable) shutdown device(s), that operates
totally independently of the prime mover control device(s) to protect against runaway or
damage to the engine, turbine, or other type of prime mover with possible personal injury
or loss of life should the mechanical-hydraulic 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.
11easYlite-200B37903
1 General information
1.4 Safety

Protective
equipment:
╺▶
╺▶
Modi󰈠cations
WARNING!
Hazards due to unauthorized modi󰈠cations
Any unauthorized modi󰍓cations to 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 unauthorized modi󰍓cations:
•constitute "misuse" and/or "negligence" within the meaning of the product warranty
thereby excluding warranty coverage for any resulting damage
•invalidate product certi󰍓cations or listings.
Use of batteries/alternators
NOTICE!
Damage to the control system due to improper handling
Disconnecting a battery from a control system that uses an alternator or battery-charging
device whilst the charging device is still connected causes damage to the control system.
• Make sure the charging device is turned o󰍒 before disconnecting the battery from
the system.
Unit includes a lithium backup battery for Real Time Clock. Field replacement of the
battery is not allowed.
In case of battery replacement please contact your Woodward service partner.
Electrostatic discharge
• ESD wrist band
NOTICE!
Damage from electrostatic discharge
All electronic equipment sensitive to damage from electrostatic discharge, which can
cause the control unit to malfunction or fail.
• To protect electronic components from static damage, take the precautions listed
below.
Avoid build-up of static electricity on your body by not wearing clothing made of
synthetic materials. Wear cotton or cotton-blend materials as much as possible because
these do not store static electric charges as easily as synthetics.
12 easYlite-200 B37903
1 General information
1.4 Safety

╺▶
╺▶
╺▶
Before working on terminals on the control unit, ground yourself by touching and holding
a grounded metal object (pipes, cabinets, equipment, etc.) to discharge any static
electricity.
Alternatively wear an ESD wrist band connected to ground.
Before any maintenance work on the control unit, ground yourself by
touching and holding a grounded metal object (pipes, cabinets, equipment,
etc.) to discharge any static electricity.
Alternatively wear an ESD wrist band connected to ground.
Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam cups, cigarette
packages, cellophane wrappers, vinyl books or folders, plastic bottles, etc.) away from the
control unit, modules and work area.
Opening the control cover may void the unit warranty. Do not remove the printed circuit
board (PCB) from the control cabinet unless instructed by this manual.
If instructed by this manual to remove the PCB from the control cabinet, follow these
precautions:
• Ensure that the device is completely voltage-free (all connectors have to be
disconnected).
• Do not touch any part of the PCB except the edges.
• Do not touch the electrical conductors, connectors, or components with conductive
devices or with bare hands.
• When replacing a PCB, keep the new PCB in the plastic antistatic protective bag it
comes in until you are ready to install it. Immediately after removing the old PCB
from the control cabinet, place it in the antistatic protective bag.
For additional information on how to prevent damage to electronic components caused by
improper handling, read and observe the precautions in:
• "Woodward manual 82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules".
1.4.4 Protective Equipment And Tools
Protective gear
Personal protective equipment serves to protect risks to the safety and health of persons
as well as to protect delicate components during work.
Certain tasks presented in this manual require the personnel to wear protective
equipment. Speci󰍓c required equipment is listed in each individual set of instructions.
The cumulative required personal protective equipment is detailed below:
ESD wrist band
The ESD (electrostatic discharge) wrist band keeps the user's body set to ground
potential. This measure protects sensitive electronic components from damage due to
electrostatic discharge.
13easYlite-200B37903
1 General information
1.4 Safety

Tools
Use of the proper tools ensures successful and safe execution of tasks presented in this
manual.
Speci󰍓c required tools are listed in each individual set of instructions.
The cumulative required tools are detailed below:
Torque screwdriver
A torque-screwdriver allow fastening of screws to a precisely speci󰍓ed torque.
Note the required torque range individually speci󰍓ed in the tasks listed in this manual.
14 easYlite-200 B37903
1 General information
1.4 Safety

2 System overview
2.1 Function overview
Description
The easYlite-200 expansion module is able to display warning, alarm or status messages
of an easYgen Woodward genset controller remotely (for example in a remote control
station). Two easYlites-200 can be connected to one 100- or 1000-series easYgen via CAN
or RS-485 interfaces, over which genset control messages are transmitted for external
signalling. One easYlite-200 module is able to display 16 di󰍒erent warning, alarm or
status messages using LEDs, each freely con󰍓gurable from the easYgen genset controller
level.
In addition to this, the easYlite-200 has a relay output to connect an external signaling
device (horn). The signaling device indicates then an alarm at the genset and/or failure of
communication with its master easYgen device. When a warning, alarm or status
message is issued at the genset control, the horn bit of the genset control is enabled. If
the horn bit is assigned to an output relay of the easYgen, this relay will be energized, as
well as the output relay of the easYlite-200.
2.2 Display and Status Indicators
General information
All status indication is hardware-based and realized by the easyLite-200 device´s LEDs. In
addition to status display, the front panel contains two lamp control buttons.
For access to settings, con󰍓guration of device parameters and status/alarm indication,
use of the software tool ToolKit is necessary. See further details in ╚═▷ “4 General
information”.
15easYlite-200B37903
2 System overview
2.1 Function overview

16 easYlite-200 B37903
2 System overview

3 Installation
General notes
NOTICE!
Avoid electrostatic discharge!
Before working with terminals please read and follow the instructions of chapter ╚═▷
“1.4.3 Electrostatic discharge”.
For CAN and RS485 shielded cabling, no more than 25 mm wiring exposed without shield
coverage are allowed at terminal plug side.
NOTICE!
Malfunctions due to literal use of example values
All technical data and ratings indicated in this chapter are merely listed as examples.
Literal use of these values does not take into account all actual speci󰍓cations of the
control unit as delivered.
• For de󰍓nite values please refer to chapter ╚═▷ “Technical Data”.
Wire sizes
Field wiring shall be made with use of cables which have temperature rating not less than
90 °C.
AWG mm² AWG mm² AWG mm² AWG mm² AWG mm² AWG mm²
30 0.05 21 0.38 14 2.5 4 25 3/0 95 600MCM 300
28 0.08 20 0.5 12 4 2 35 4/0 120 750MCM 400
26 0.14 18 0.75 10 6 1 50 300MCM 150 1000MCM500
24 0.25 17 1.0 8 10 1/0 55 350MCM 185
22 0.34 16 1.5 6 16 2/0 70 500MCM 240
Tab. 1: Conversion chart - wire sizes
17easYlite-200B37903
3 Installation

╺▶
╺▶
╺▶
╺▶
╺▶
╺▶
3.1 Installation
Housing dimensions
The easYlite-200 module is to be mounted using the included clips.
╚═▷ Fig. 3 below shows the housing and cutout dimensions of the unit:
165.5 mm
185.5 mm
41.1 mm
168 mm
108 mm
125.5 mm 105.5 mm
9.5 mm
CUTOUT
33.9 mm
Fig. 3: Dimensions easYlite-200 housing
Proceed as follows to install the unit:
Panel cutout
Cut out the panel according to the dimensions in ╚═▷ Fig. 3.
Remove terminals
Loosen the wire connection terminal screws on the back of the unit and remove the wire
connection terminal strip if required.
Loosen clamping screws
Loosen the four clamping screws until they are almost 󰍔ush with the clamp inserts and tilt
the clamp inserts down by 45° to remove them from the housing. Do not completely
remove the screws from the clamp inserts.
Insert unit into the cutout
Insert the unit into the panel cutout. Verify that the unit 󰍓ts correctly in the cutout. If the
panel cutout is not big enough, enlarge it accordingly. Ensure that the gasket is placed
properly if used. Ensure that the paper strip is not pinched between gasket and panel to
maintain isolation.
Attach clamp inserts
Re-install the clamp inserts by tilting the insert to the angle of 45°. Insert the nose of the
insert into the slot on the side of the housing. Raise the clamp insert so that it is parallel
to the control panel.
Tighten clamping screws
18 easYlite-200 B37903
3 Installation
3.1 Installation

╺▶
Tighten the clamping screws until the control unit is secured to the control panel. Over
tightening of these screws may result in the clamp inserts or the housing breaking.
Reattach terminals
Reattach the wire connection terminal strip and secure with the side screws.
Tighten the clips (tightening torque 0.3 Nm [2.65 lb⋅in]) in order to achieve the IP65
degree of protection.
If the gasket is damaged, it needs to be replaced. Use only the original gasket kit (P/N
3050-1057) for replacement.
19easYlite-200B37903
3 Installation
3.1 Installation

3.2 Terminal allocation
The rear panel of easYlite-200 with its terminals can be seen in ╚═▷ Fig. 4 below:
Fig. 4: easYlite-200, rear side view
No. Function Cable Size Description
1 DC input B− 2.5 mm² DC power supply negative input.
2 DC input B+ 2.5 mm² DC power supply positive input.
3 GND 0.5 mm² Modbus RS-485.
Connect the RS-485 port to RS-485 port of
easYgen series controllers. It is recommended to
use a shield with the impedance of 120 Ω, with
one end grounded. The terminal provides
resistance of 120 Ω; if needed, short-circuit
terminals 3, 4.
4 A (+)
5 B (−)
6 GND 0.5 mm² CAN bus.
Connect the CAN bus port to CAN port of
easYgen series controllers. It is recommended to
use a shield with the impedance of 120 Ω, with
one end grounded. The terminal provides
7 CAN (L)
8 CAN (H)
20 easYlite-200 B37903
3 Installation
3.2 Terminal allocation