Woodward easYgen-1800 User manual

easYgen-1800
Operation Manual Genset Control
easYgen-1800
37690A

© 2017
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
37690AeasYgen-1800 | Genset Control2

Table of contents
1 General Information.................................................................................................................. 5
1.1 About This Manual...................................................................................................................... 5
1.1.1 Revision History.......................................................................................................................... 5
1.1.2 Depiction Of Notes And Instructions........................................................................................... 5
1.2 General Information..................................................................................................................... 6
1.2.1 Copyright And Disclaimer............................................................................................................ 6
1.2.2 Service And Warranty................................................................................................................. 7
1.2.3 Safety.......................................................................................................................................... 7
1.2.3.1 Intended Use............................................................................................................................... 7
1.2.3.2 Personnel.................................................................................................................................... 8
1.2.3.3 General Safety Notes.................................................................................................................. 9
2 System Overview..................................................................................................................... 11
2.1 Intended Use............................................................................................................................. 11
2.2 HMI Status Screens.................................................................................................................. 11
2.3 ToolKit-SC Status Screens........................................................................................................ 12
3 Operation................................................................................................................................. 15
3.1 Front Panel: Operating and Display Elements.......................................................................... 15
3.2 Warning/Alarm Signaling........................................................................................................... 17
3.2.1 Alarm Acknowledgment............................................................................................................. 17
3.3 Operation Modes....................................................................................................................... 18
3.3.1 Operation Mode AUTO.............................................................................................................. 18
3.3.2 Operation Mode MANual........................................................................................................... 18
3.3.3 Operation Mode STOP.............................................................................................................. 19
3.4 START/STOP Operation........................................................................................................... 19
3.4.1 Start engine to supply load........................................................................................................ 19
3.4.2 Stop engine after mains supplying load (again)........................................................................ 22
3.4.3 MANual START/STOP.............................................................................................................. 24
3.5 Transition Procedures............................................................................................................... 24
3.5.1 Disconnect during Cranking...................................................................................................... 24
3.5.2 Manual Breaker Transition........................................................................................................ 25
3.6 Trouble Shooting....................................................................................................................... 26
4 Appendix.................................................................................................................................. 27
4.1 Alarms and Warnings................................................................................................................ 27
4.1.1 Alarm Classes........................................................................................................................... 27
4.1.2 Warnings................................................................................................................................... 27
4.1.3 Shutdown Alarms...................................................................................................................... 28
4.1.4 Trip and Stop Alarms................................................................................................................. 30
Table of contents
37690A easYgen-1800 | Genset Control 3

4.1.5 Trip Alarms................................................................................................................................ 30
5 Glossary And List Of Abbreviations...................................................................................... 33
6 Index......................................................................................................................................... 35
Table of contents
37690AeasYgen-1800 | Genset Control4

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 1.8 and ToolKit-SC version 1.0
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...
37690A easYgen-1800 | Genset Control 5

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
37690AeasYgen-1800 | Genset Control6

Actions to the contrary will entitle us to claim compensation for
damages. We expressly reserve the right to raise any further
accessory claims.
1.2.2 Service And Warranty
By opening the device you will lose any warranty!
CAUTION!
Any unauthorized modifications or using this equip‐
ment outside its specified mechanical, electrical, or
other operating limits may cause personal injury
and/or property damage, including damage to the
equipment.
Any such unauthorized modifications
nconstitute "misuse" and/or "negligence" within the meaning of
the product warranty
nthereby excluding warranty coverage for any resulting damage,
and
ninvalidate product certifications or listings.
Our Customer Service is available for technical information.
Please see page 2 for the contact data.
In addition, our employees are constantly interested in new infor‐
mation and experiences that arise from usage and could be val‐
uable for the improvement of our products.
Please enquire about the terms of warranty from
your nearest Woodward representative.
For our contact search webpage please go to:
http://www.woodward.com/Directory.aspx
1.2.3 Safety
1.2.3.1 Intended Use
The easYgen unit has been designed and constructed solely for
the intended use described in this Operation Manual and--with
even more details-- in the Technical Manual.
nIntended use requires operation of the control unit within the
written specifications.
nIntended use includes compliance with all instructions and
safety notes presented in this manual.
nAny use which exceeds or differs from the intended use shall
be considered improper use.
nNo claims of any kind for damage will be entertained if such
claims result from improper use.
Warranty terms
General Information
General Information > Safety > Intended Use
37690A easYgen-1800 | Genset Control 7

NOTICE!
Damage due to improper use!
Improper use of the remote panel unit may cause
damage to the control unit as well as connected
components.
Improper use includes, but is not limited to:
– Operation outside the specified operation con‐
ditions.
1.2.3.2 Personnel
WARNING!
Hazards due to insufficiently qualified per‐
sonnel!
If unqualified 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 qualified personnel.
This manual specifies the personnel qualifications required for the
different areas of work, listed below:
nWell trained for electrical installations.
nSkilled and competent to be aware especially of the local
safety regulations.
nExperienced in working on electronic measuring and control
devices.
nAllowed 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.
General Information
General Information > Safety > Personnel
37690AeasYgen-1800 | Genset Control8

1.2.3.3 General Safety Notes
DANGER!
Moving parts and dangerous electricity!
Be aware that the remote control of a system that
is managing life dangerous engine-generator-elec‐
tricity parts needs attention for the local situation!
The following safety notes cover both the device
itself and basics of the overall genset system. The
dedicated genset-system related safety instruction
must be taken into account, too!
WARNING!
Hazards due to insufficient prime mover pro‐
tection
The engine, turbine, or other type of prime mover
should be equipped with an overspeed (over-tem‐
perature, or over-pressure, where applicable) shut‐
down 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 mecha‐
nism(s), the linkage(s), or the controlled device(s)
fail.
Hazards by system controlled
Prime mover safety
General Information
General Information > Safety > General Safety Notes
37690A easYgen-1800 | Genset Control 9

General Information
General Information > Safety > General Safety Notes
37690AeasYgen-1800 | Genset Control10

2 System Overview
The easYgen is a stand-alone genset controller with measuring,
monitoring, and breaker control functionality. It comes with a easy
mounting plastic housing covering a well tested electronic-electrical
system.
Display and buttons of the HMI offer both access to states and
values, and access to the application. Password protection enables
dedicated operation access levels. Remote control, monitoring, vis‐
ualization, and configuration are possible via integrated interfaces.
Communication between easYgens, with PLC control, or as a net‐
work member offers an enhanced system management range;
additionally supported by easy to implement accessories.
For even higher challenges in genset control the
easYgen series offers further solutions up to the
most complex and ambitious applications.
For dedicated protection tasks ask Woodward for
its protection (relay) solutions.
2.1 Intended Use
The easYgen unit has been designed and constructed solely for
the intended use described in this Operation Manual and--with
even more details-- in the Technical Manual.
nIntended use requires operation of the control unit within the
written specifications.
nIntended use includes compliance with all instructions and
safety notes presented in this manual.
nAny use which exceeds or differs from the intended use shall
be considered improper use.
nNo claims of any kind for damage will be entertained 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 connected
components.
Improper use includes, but is not limited to:
– Operation outside the specified operation con‐
ditions.
2.2 HMI Status Screens
HMI comes with status screens:
nStatus
nEngine
nGen(erator)
nLoad
nMains
General notes
System Overview
HMI Status Screens
37690A easYgen-1800 | Genset Control 11

nAlarm
nLog
nOthers
nAbout
n... and the home screen
in a loop
2.3 ToolKit-SC Status Screens
ToolKit-SC enables dedicated access to status information sum‐
marized into the following screens:
Fig. 1: easYgen-1800 status screens
Ext. analog inputs currently not used
“PARAMETER è STATUS MENU è Generator status”
Items Parameters Description
Engine/Sensor info Engine speed, Engine temp, Oil pressure, Fuel level, Battery volt, Charger
volt
More info Fuel temp, Inlet temp, Exhaust temp, Coolant pressure, Fuel pressure,
Turbo pressure, Total fuel consume, Coolant level, Oil temp
Selection of ECU data
via J1939.
Status and delay Gen status, Breaker status, Remote start, Mains status
Alarms Display of current
alarms and warnings
Digital inputs 1 start request in AUTO, 2 High temperature, 3 Low oil pressure, 4 User
defined, 5 User-defined, 6 User-defined, 7 Lamp test, 8 User defined,
Emergency stop
Accumulation Active power (kW), Reactive power (kvar), Apparent power (kVA)
Digital output 1 Engine flag 1, 2 Idle control,3 Close GCB, 4 Close MCB, 5 Stop sole‐
noid, 6 Centralized alarm
Fuel relay, Start relay
General notes
Generator Status
System Overview
ToolKit-SC Status Screens
37690AeasYgen-1800 | Genset Control12

Items Parameters Description
Status Stop mode, Manual mode, Test mode, Auto mode, Mains available, Mains
Closed, Gen available, Gen closed, Alarm indicator, Running indicator
Current date and time Date (yyyy-mm-dd), Time (hh:mm:ss)
“PARAMETER è STATUS MENU è Measured values”
Items Parameters Description
Electricity quantity
Mains L1, L2, L3, L1-2, L2-3, L3-1, L1Phase, L2Phase, L3Phase, Frequency
Generator L1, L2, L3, L1-2, L2-3, L3-1, L1Phase, L2Phase, L3Phase, Frequency
Current (A) L1, L2, L3
Active power (kW) L1, L2, L3, Total
Reactive power (kvar) L1, L2, L3, Total
Apparent power (kVA) L1, L2, L3, Total
Power factor L1, L2, L3, Avg
“PARAMETER è STATUS MENU è Ext. discrete inputs/outputs”
Items Parameters Description
Ext. discrete inputs 1-16
Input {X} (contact open/closed) {X}: 1 or 16
Ext. discrete outputs 1-16
Output {Y} (Hi/Low) {Y}: 1 or 16
“PARAMETER è STATUS MENU è Miscellaneous”
Items Parameters Description
Total A Run time, Starts, Total energy
Total B Run time, Starts, Total energy
SD card Status, Total capacity, Remain capacity
Earth fault current Percent
Next maintenance time Maintenance 1 to 3
Measured Values
Ext. Discrete Inputs/Outputs
Miscellaneous
System Overview
ToolKit-SC Status Screens
37690A easYgen-1800 | Genset Control 13

“PARAMETER è STATUS MENU è Event log and version”
Items Parameters Description
Module Info Model, Hardware Version, Software Version, Issue Date
Event log Fixed view of:
No., Event type
Columns "move behind" visible part of the screen:
Event Item, Date, Time,
Mains Uab (V) / Ubc (V) / Uca (V), Mains Ua (V), Mains Ub (V), Mains Uc
(V), Mains f (Hz),
Gens Uab (V) ..., Gens Ua (V) ..., Gens f(Hz),
Current Ia (A) ...,
Power (kW),
Speed (r/min),
Temp. (°C),
Press. (kPa),
Volt. (V)
Event log report table.
Showing the 99 latest
events or - with SD
card - the content of
the .DAT file(s)
Read log
Clear
Export to Txt
Push buttons to
manage logged data
(internal or SD card)
“PARAMETER è STATUS MENU è SD-Card”
The SD-Card stores the same information as
“Event log and version” but on the inserted SD
card in a .DAT file format.
Items Description
Read all log Event table is filled with all stored data
((number selection boxes))
Read log
Read and displayed events can be pre-selected by min and max number e.g. for better
overview
Export to Txt List of current (selected) events can be saved as .TXT file
Event Log and Version
SD-Card
System Overview
ToolKit-SC Status Screens
37690AeasYgen-1800 | Genset Control14

3 Operation
3.1 Front Panel: Operating and Display Elements
Fig. 2: HMI (front panel) easYgen-1800
Icons Keys Description
STOP Auto/Manual mode: Stop running generator
Stop mode: Reset alarm
Lamp test (press at least 3 seconds)
Notes
During stopping process, press this button again to
stop generator immediately.
I (START) MANual mode: Start genset
MAN (Manual
Mode)
Press this key and controller enters into MANual
mode
AUTO (Automatic
Mode)
Press this key and controller enters into AUTO
mode
Mute "Horn"/
Alarm acknowl‐
edge
Press once: Alarming sound OFF
Second time pressing the button:
nAlarm is acknowledged
nAlarm LED changes from twinkling to perma‐
nently illuminated
Operation
Front Panel: Operating and D...
37690A easYgen-1800 | Genset Control 15

Icons Keys Description
Gen Open/Close MANual mode: Switch Generator breaker ON or
OFF
Mains Open/
Close
MANual mode: Switch Mains breaker ON or OFF
Up/Increase 1) Screen scroll
2) Setting menu: Up cursor and increase value in
Down/Decrease 1) Screen scroll
2) Setting menu: Down cursor and decrease value
Left 1) Screen scroll
2) Setting menu: Left move cursor
Right 1) Screen scroll
2) Setting menu: Right move cursor
Set/Confirm Select viewing area
Exit 1) Returns to the main menu
2) In settings menu returns to the previous menu
Warning
Alarm
Running
Genset
Busbar
Mains
In MANual mode:
Pressing and (START) simultaneously will
force generator to crank. Successful start will not
be judged according to crank disconnect condi‐
tions, operator will have to crank the starter motor
manually; when operator decides that the engine
has fired, he/she should release the button and
start output will be deactivated, safety on delay will
start.
Operation
Front Panel: Operating and D...
37690AeasYgen-1800 | Genset Control16

WARNING!
Passwords can be changed by user. Please clearly
remember the password after changing. If you
forget it, please contact Woodward services and
send all device information of the controller page
“ABOUT” for legitimation.
3.2 Warning/Alarm Signaling
The Alarm type and Warning are visualized with - combinations of -
both LEDs “Alarm” and “Warning” located beside the display.
Alarm Indicator LED Warning Indicator LED Alarm Type
Slow flashing Slow flashing Warning
Fast flashing Off Shutdown or Trip Alarm
Fast flashing Slow flashing Shutdown or Trip Alarm
with Warning
ON (permanently illumi‐
nated)
Off Common Alarm,
acknowledged
ON (permanently illumi‐
nated)
ON (permanently illumi‐
nated)
Shutdown or Trip
Warning, Alarm acknowl‐
edged
3.2.1 Alarm Acknowledgment
The alarm acknowledge handling is valid for following alarm
classes
nWarning
nShutdown
nTrip/Stop
nTrip
Any new active alarm activates the horn and is visible with the
flashing “Alarm" LED.
After pressing the mute/acknowledge button the “horn” is deacti‐
vated and the “Alarm" LED changes from flashing to constant
active and stays active as long as any alarm is present. An addi‐
tional active alarm reactivates the horn and the “Alarm LED” starts
flashing again.
The operation mode automatically changes to STOP if a stopping
alarm is active ( “Shutdown” or “Trip/Stop” ).
The alarm reset is done with additional (2nd time) pressing the
mute/acknowledge button (Alarm LED is no longer flashing).
General notes
Mute Horn
Stop by alarm
Acknowledge alarm
Operation
Warning/Alarm Signaling > Alarm Acknowledgment
37690A easYgen-1800 | Genset Control 17

3.3 Operation Modes
The easYgen offers three operation modes:
nAUTO
nMANUAL (MAN)
nSTOP
n... and an internal (non) operating phase during starting the
device itself
The operation mode can be initiated - if current settings allow this
function:
ndirectly by pressing the according button at the front panel
ndirectly by click on the according button at the ToolKit-SC
remote screen
nvia discrete inputs
nvia interface
3.3.1 Operation Mode AUTO
In operation mode AUTO breakers and genset are under easYgen
control. Start and stop of the engine is managed automatically
together with open, close, and breaker transition.
Depending on settings and application status, AUTO control can:
nsupply load by mains
nsupply load by generator
ntransition load supply from mains to generator or from gener‐
ator to mains
nstart the engine
nstop the engine
Situation
nMains becomes abnormal because one or more of the parame‐
ters below misses its well defined working range:
–
“Overvoltage”
– “Undervoltage”
– “Overfrequency”
– “Underfrequency”
– “Mains voltage asymmetry”
– “Mains phase rotation fail”
Start procedure will include breaker handling, engine start, and sig‐
naling/warning.
All of the above listed parameters are (back) in normal range.
Stop procedure will include breaker handling, engine stand-by, and
signaling/warning.
3.3.2 Operation Mode MANual
In operation mode MANual both breakers and genset are inde‐
pendently from each other under easYgen control.
General notes
General notes
Load supply transition from mains
to genset
Load supply transition from genset
(back) to mains
General notes
Operation
Operation Modes > Operation Mode MANual
37690AeasYgen-1800 | Genset Control18

Start and stop of the engine is managed with the same procedure
as in AUTO mode but without breaker control. Breakers can be
opened and closed without taking care of load, genset, or mains
state!
WARNING!
MANual breaker open/close request can destroy
the genset and/or substantial damage mains.
Take care for genset and supply.
3.3.3 Operation Mode STOP
In operation mode STOP breakers are open and engine is not run‐
ning.
This is a configurable operation mode, only. This is
NO emergency STOP!
3.4 START/STOP Operation
3.4.1 Start engine to supply load
Mode Energy Breakers Genset
AUTO Mains is "normal" GCB is open Not running
Ready for operation
MCB is closed
Situation
nMains becomes abnormal because one or more of the
parameters below misses its well defined working range:
–
“Overvoltage”
– “Undervoltage”
– “Overfrequency”
– “Underfrequency”
– “Mains voltage asymmetry”
– “Mains phase rotation fail”
Pre-Condition
The AUTO Start procedure is going through sub procedures with
own timers.
General notes
General notes
Operation
START/STOP Operation > Start engine to supply load
37690A easYgen-1800 | Genset Control 19

If mains is back during the process, re-connecting
mains has priority.
The remaining time of each of the timers initiated is
shown in the display.
When started via “Remote Start (off Load)” input,
start procedures is the same as described below
but generator close relay is deactivated.
Because there is no mains control, only the part
"Start engine" (green background) is relevant.
Operation
START/STOP Operation > Start engine to supply load
37690AeasYgen-1800 | Genset Control20