Woodward easYgen-3000 Instruction Manual

37225B
Operation
Software Version 1.xxxx
Manual 37225B
easYgen-3000
Genset Control

Manual 37225B easYgen-3000 - Genset Control
Page 2/51 © Woodward
WARNING
Read this entire manual and all other publications pertaining to the work to be performed before install-
ing, operating, or servicing this equipment. Practice all plant and safety instructions and precautions.
Failure to follow instructions can cause personal injury and/or property damage.
The engine, turbine, or other type of prime mover should be equipped with an overspeed (overtempera-
ture, or overpressure, 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 gov-
ernor(s) or electric control(s), the actuator(s), fuel control(s), the driving mechanism(s), the linkage(s),
or the controlled device(s) fail.
Any unauthorized modifications to or use of this equipment 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: (i) constitute "misuse" and/or "negligence" within
the meaning of the product warranty thereby excluding warranty coverage for any resulting damage,
and (ii) invalidate product certifications or listings.
CAUTION
To prevent damage to a control system that uses an alternator or battery-charging device, make sure
the charging device is turned off before disconnecting the battery from the system.
Electronic controls contain static-sensitive parts. Observe the following precautions to prevent dam-
age to these parts.
•Discharge body static before handling the control (with power to the control turned off, contact a
grounded surface and maintain contact while handling the control).
•Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around printed circuit boards.
•Do not touch the components or conductors on a printed circuit board with your hands or with
conductive devices.
OUT-OF-DATE PUBLICATION
This publication may have been revised or updated since this copy was produced. To verify that you
have the latest revision, be sure to check the Woodward website:
http://www.woodward.com/pubs/current.pdf
The revision level is shown at the bottom of the front cover after the publication number. The latest
version of most publications is available at:
http://www.woodward.com/publications
If your publication is not there, please contact your customer service representative to get the latest
copy.
Important definitions
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation that, if not avoided, could result in damage to equipment.
NOTE
Provides other helpful information that does not fall under the warning or caution categories.
Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be
correct and reliable. However, Woodward assumes no responsibility unless otherwise expressly undertaken.
© Woodward
All Rights Reserved.

Manual 37225B easYgen-3000 - Genset Control
© Woodward Page 3/51
Revision History
Rev. Date Editor Changes
NEW 06-11-23 TP Release
A 07-06-29 TP Minor corrections and update to reflect the new functionality
B 08-02-07 TP Minor corrections; easYgen-3100 description added; message IDs added
Content
CHAPTER 1. GENERAL INFORMATION.........................................................................................5
Document Overview................................................................................................................................5
Short Description.....................................................................................................................................6
CHAPTER 2. EASYGEN-3200 NAVIGATION / OPERATION.............................................................7
Navigation ...............................................................................................................................................8
Operation ..............................................................................................................................................24
Display........................................................................................................................................26
Mode...........................................................................................................................................27
Operation....................................................................................................................................28
LogicsManager ...........................................................................................................................29
CHAPTER 3. EASYGEN-3100 LEDS.........................................................................................30
CHAPTER 4. FUNCTIONAL DESCRIPTION ..................................................................................31
Overview ...............................................................................................................................................31
Application Modes.................................................................................................................................32
Application Mode {0} – Start/Stop...............................................................................................32
Application Mode {1o} – Open GCB...........................................................................................32
Application Mode {1oc} – Open/Close GCB...............................................................................32
Application Mode {2oc} – Open/Close GCB/MCB......................................................................32
Operating Modes...................................................................................................................................33
Operating Mode STOP...............................................................................................................33
Operating Mode MANUAL..........................................................................................................34
Operating Mode AUTOMATIC....................................................................................................35
CHAPTER 5. EASYGEN-3200 CONFIGURATION .........................................................................37
Structure of the Parameters..................................................................................................................37
Parameters............................................................................................................................................39
Language....................................................................................................................................39
Real-Time Clock - Time..............................................................................................................39
Real-Time Clock - Date ..............................................................................................................40
Display Contrast .........................................................................................................................40
Password....................................................................................................................................41
Deactivate Horn..........................................................................................................................41
Factory (Default) Values.............................................................................................................41
APPENDIX A. DISPLAY MESSAGES ..........................................................................................42
Status Messages...................................................................................................................................42
Alarm Messages ...................................................................................................................................44
APPENDIX B. RESTORING A LANGUAGE SETTING .....................................................................50

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Figures And Tables
Figures
Figure 2-1: Front panel and display...........................................................................................................................................7
Figure 2-2: Screen - Level overview........................................................................................................................................24
Figure 3-1: Position of the LEDs.............................................................................................................................................30
Figure 5-1: Configuration screens (overview).........................................................................................................................37
Figure 5-2: Front panel and display.........................................................................................................................................50
Tables
Table 1-1: Manual - Overview...................................................................................................................................................5
Table 2-1: Display - Measuring values....................................................................................................................................26
Table 4-1: Functional description - Overview.........................................................................................................................31
Table 4-2: Functional description - AMF conditions...............................................................................................................35
Table 5-1: Message IDs for analog inputs ...............................................................................................................................49
Table 5-2: Message IDs for discrete inputs..............................................................................................................................49
Table 5-3: Message IDs for external discrete inputs................................................................................................................49
Table 5-4: Message IDs for flexible limits ..............................................................................................................................49

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Chapter 1.
General Information
Document Overview
≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Type English German
easYgen-3000 Series
easYgen-3000 - Installation 37223 GR37223
easYgen-3000 - Configuration 37224 GR37224
easYgen-3000 - Operation this manual Ö37225 GR37225
easYgen-3000 - Application 37226 -
easYgen-3000 - Interfaces 37383 -
easYgen-3200 - Brief Operation Information 37399 GR37399
easYgen-3100 - Brief Operation Information 37409 -
Table 1-1: Manual - Overview
Intended Use The unit must only be operated as described in this manual. The prerequisite for a proper and safe
operation of the product is correct transportation, storage, and installation as well as careful operation and main-
tenance.
NOTE
This manual has been developed for a unit equipped with all available options. Inputs/outputs, func-
tions, configuration screens, and other details described which do not exist on your unit may be ig-
nored.
The present manual has been prepared to enable the installation and commissioning of the unit. Be-
cause of the large variety of parameter settings, it is not possible to cover every combination. The
manual is therefore only a guide. In case of incorrect entries or a total loss of functions, the default set-
tings may be taken from the list of parameters in the configuration manual 37224 or from ToolKit and
the respective *.SID file.

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Short Description
≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
The easYgen-3000 Series generator set controllers provide the following functions:
• Genset control
• Engine, mains and generator protection
• Engine data measurement -
o oil pressure and temperature, coolant temperature, battery voltage, speed,
service hours, etc.
• Generator and mains data measurement -
o voltage, current, power, kvar, kW, kWh, etc.
• Load/var sharing for up to 32 participants
• Load-dependent start/stop
• Automatic, Manual, and Stop operating modes
• Application modes -
o no CB operation
o open GCB
o open/close GCB
o open/close GCB/MCB
• LogicsManager for processing measured values, discrete inputs, and internal states
• Engine starter sequencing
• Alarm display with circuit breaker trip and engine shutdown
• AMF (automatic mains failure) standby genset control, with automatic engine start on a mains failure
detection and open transition breaker control
• Critical mode operation
• Synchronizing (phase matching and slip frequency) and mains parallel operation
• External frequency, voltage, power, and power factor set point control via analog input or interface
• FIFO event history with 300 entries
• Multilingual user interface (English, German, French, Spanish, Italian, Portuguese, Turkish, Russian,
Chinese, Japanese)
• ECU data visualization via J1939
• CAN bus communication to engine controllers, plant management systems, expansion boards, and
ToolKit configuration and visualization software
• RS-485 Modbus communication with plant management systems
• RS-232 Modbus communication with plant management systems and ToolKit configuration and visu-
alization software
Type designation is as follows:
easYgen -xxxx- 5
CTs, current transformers, secondary
[1] = ../1 A
[5] = ../5 A
Model
[-3100] = Model '3100' for switch cabinet back mounting
[-3200] = Model '3200' for front-panel flush-mounting
Type
Examples:
EASYGEN-3200-5 (easYgen-3200, 100 & 400 Vac inputs, ../5 A measuring inputs, front panel flush-mounting)
EASYGEN-3100-1 (easYgen-3100, 100 & 400 Vac inputs, ../1 A measuring inputs, cabinet back mounting)

Manual 37225B easYgen-3000 - Genset Control
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Chapter 2.
easYgen-3200 Navigation / Operation
3
1
2
3
4
13 910 11 14
5
6
7
8
12
Figure 2-1: Front panel and display
Figure 2-1 illustrates the front panel/display of the easYgen-3200 with push buttons, LEDs and Liquid Crystal
display (LC display). A short description of the front panel is given below.
NOTE
This push button is always active and will stop the engine when pressed, except the op-
erating modes are selected externally. In this case, the AUTO and MAN Mode push but-
tons are also disabled.
Function blocks
Buttons that have the same function within one screen are grouped into function blocks. The
function blocks are defined as:
Display.........Change the method of voltage and power calculations displayed (page 24).
Mode............Change the mode of operation (page 27).
Operation....Used to perform manual operation of the genset and the breakers (page 28).
Navigation...Navigation between system and configuration screens, and alarm list (page 28).
1 2 3 5
6 7 8 9
10 11
Push buttons
The push buttons on the front panel are assigned to softkeys on the display. Each softkey is as-
signed to a function depending on the mode of operation.
12
Liquid Crystal Display (LC display)
The display contains softkey characters, measuring values, modes of operation, and alarms. The
functionality of the display screens as well as the description of the functions is detailed in the
"Navigation" section (page 8).
13
14
LED
The left LED
13
indicates that the unit is in STOP mode. The right LED
14
indicates that alarm
messages are active / present in the control unit.

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Navigation
≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
Individual display screens are listed in the following text. All softkeys, which are available in the individual
screens are described with their function.
Screen "Operating values - overview" / "Starting screen" [all application modes]
This screen appears upon startup of the unit.
Toggle between delta/wye voltage display. The index of the
"V" symbol indicates whether delta or wye voltage is dis-
played and which phases are displayed.
Change into AUTOMATIC operating mode.
Change into MANUAL operating mode.
Change into STOP operating mode.
Display the alarm list (unacknowledged alarms).
Display the configuration menu screen.
Display the indication menu screen.
This softkey is only displayed in front of the mains symbol
if the Alarm LED is flashing (An alarm is present, which
has not yet been acknowledged as 'Seen'). This softkey re-
sets the horn and acknowledges the alarm as 'Seen'.
Operating mode MANUAL: start/stop engine.
Operating mode MANUAL: open GCB/MCB.
Operating mode MANUAL: close GCB/MCB.
STOP operating mode:
AUTOMATIC operating mode:
MANUAL operating mode:
NOTE
If the mains data display is disabled (refer to Configuration Manual 37224), above screens will only
show generator data with bigger digits.

Manual 37225B easYgen-3000 - Genset Control
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Screen "Alarm list" [all application modes]
This screen appears after pressing the "Alarm" softkey in the start-
ing screen. All alarm messages, which have not been acknowledged
and cleared, are displayed. Each alarm is displayed with the alarm
message and the date and time of the alarm occurred in the format
yy-mon-dd hh:mm:ss.ss. Please note, that self-acknowledging
alarm messages get a new timestamp when initializing the unit
(switching on). The symbol indicates that this alarm condition is
still present. A maximum of 16 alarm messages can be displayed. If
16 alarm messages are already displayed and further alarm mes-
sages occur, these will not be displayed before displayed alarm
messages are acknowledged and thus deleted from the list. The "!"
following the letter symbols A through E indicate whether an alarm
class is present or not .
Return to the starting screen.
Scroll up to next alarm message.
Scroll down to next alarm message.
The selected alarm message (displayed inverted) will be ac-
knowledged. This is only possible, if the alarm condition is
no longer present. If the Alarm LED is still flashing (an
alarm is present, which has not yet been acknowledged as
'Seen'), this softkey resets the horn and acknowledges the
alarm as 'Seen'.
Screen "Next Page" [all application modes]
This screen appears after pressing the "Next Page" softkey.
Return to the starting screen.
Setpoints
Display the setpoints screen.
Synchroscope
Display the synchroscope screen.
Sequencing
Display the sequencing screen.
Counters and service
Display the counters and service screen.
Measured values
Display the measured values screen.
Diagnostic
Display the diagonstic screen.

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Screen "Setpoints" [all application modes]
This screen appears after pressing the "Setpoints" softkey in the
"Next page" screen. The set point is displayed on the left and the
actual value is displayed on the right half of the screen. The symbol
indicates the mains power and indicates the generator power.
The figures 1 or 2 indicate whether set point 1 or set point 2 is used
in AUTOMATIC operation. The source, which is used for set point
1 or set point 2, is displayed with the respective LogicsManager
function number.
Return to "Next page" screen.
Change into AUTOMATIC operating mode.
Change into MANUAL operating mode.
Scroll up one set point.
Scroll down one set point.
Raise the selected set point.
Lower the selected set point.
MANUAL operating mode:
AUTOMATIC operating mode:
P.......Real power
Constant = fixed generator load control
Import = fixed import power control
Export = fixed export power control
PF.....Power factor
V.......Voltage
f........Frequency

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Screen "Synchroscope" [all application modes]
This screen appears after pressing the "Synchroscope" softkey in
the "Next page" screen.
Return to "Next page" screen.
Synchroscope generator/busbar
Display the generator / busbar synchroscope screen.
Synchroscope busbar/mains
Display the busbar / mains synchroscope screen.
Screen "Synchroscope generator / busbar" [all application modes]
This screen appears after pressing the "Synchroscope Gen. / Bus-
bar" softkey in the "Synchroscope" screen. The square symbol
indicates the actual phase angle between busbar and generator. The
12 o'clock position on the top means 0° and the 6 o'clock position
on the bottom means 180°. The frequency and voltage differences
are indicated in the center of the circle.
Return to "Synchroscope" screen.
Change into AUTOMATIC operating mode.
Change into MANUAL operating mode.
Change into STOP operating mode.
Operating mode MANUAL: Raise voltage/frequency.
Operating mode MANUAL: Lower voltage/frequency.
Operating mode MANUAL: start/stop engine.
Operating mode MANUAL: open GCB/MCB.
Display detail:
Operating mode MANUAL: close GCB/MCB.

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Screen "Synchroscope busbar / mains" [all application modes]
This screen appears after pressing the "Synchroscope Busbar /
Mains" softkey in the "Synchroscope" screen. The square symbol
indicates the actual phase angle between busbar and mains. The 12
o'clock position on the top means 0° and the 6 o'clock position on
the bottom means 180°. The frequency and voltage differences are
indicated in the center of the circle.
Return to "Synchroscope" screen.
Change into AUTOMATIC operating mode.
Change into MANUAL operating mode.
Change into STOP operating mode.
Operating mode MANUAL: Raise voltage/frequency.
Operating mode MANUAL: Lower voltage/frequency.
Operating mode MANUAL: start/stop engine.
Operating mode MANUAL: open GCB/MCB.
Display detail:
Operating mode MANUAL: close GCB/MCB.

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Screen "Sequencing" [all application modes]
This screen appears after pressing the "Sequencing" softkey in the
"Next page" screen. The sequencing screen shows all gensets par-
ticipating in load sharing. The operation mode of each genset as
well as the state of its GCB is shown on this screen. The symbol
above the generator number indicates AUTOMATIC operating
mode, indicates MANUAL, and indicates STOP. The field
below shows whether the respective GCB is closed ( ) or open
(). The bottom field displays the actual load sharing values. If
this device is not participating in load sharing, "LD start stop Off"
is displayed here.
Return to "Next page" screen.
Scroll down to genset 17 through 32 display.
Scroll up to genset 1 through 16 display.
Change into AUTOMATIC operating mode.
Change into MANUAL operating mode.
Change into STOP operating mode.

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Screen "Counters and service" [all application modes]
This screen appears after pressing the "Counters and service" soft-
key in the "Next page" screen.
Return to "Next page" screen.
Scroll down to the energy counter display screen.
Scroll up to the operating hours counter display screen.
Change into AUTOMATIC operating mode.
Change into MANUAL operating mode.
Change into STOP operating mode.
Operating mode MANUAL: start/stop engine.
Operating mode MANUAL: open GCB/MCB.
Operating mode MANUAL: close GCB/MCB.
Hours of operation 0.00h - Operating hours counter
0.00h = Total operating hours (hours in operation,
the decimals are hundredths of an hour)
Number of starts 00 - Start counter
00 = Total number of starts
Hours until maintenance 000h - Maintenance counter
000h = Hours until next maintenance
Days until maintenance 000h - Maintenance counter
000h = Days until next maintenance
Gen. positive active energy 0.00 MWh - Generator posi-
tive active energy
0.00MWh = Total generator positive active energy
Gen. positive reactive energy 0.00 Mvarh - Generator
positive reactive energy
0.00Mvarh = Total generator positive reactive en-
ergy
Gen. negative reactive energy 0.00 Mvarh - Generator
negative reactive energy
0.00Mvarh = Total generator negative reactive en-
ergy
NOTE
Further information about resetting or setting the counters may be found in the Configuration Manual
37224.

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Screen "Measured values" [all application modes]
This screen appears after pressing the "Measured values" softkey in
the "Next page" screen.
Return to the "Next page" screen.
J1939 interface
Display the J1939 interface indication screen.
Analog inputs/outputs
Display the analog inputs and outputs indication screen.
Discrete inputs/outputs
Display the discrete inputs and outputs indication screen.
Generator
Display the generator indication screen.
Busbar
Display the busbar indication screen.
Mains
Display the mains indication screen.
Screen "J1939 interface" [all application modes]
This screen appears after pressing the "J1939 interface" softkey in
the "Measured Values" screen. The values transmitted by the ECU
are displayed here. If a value is not transmitted, "Missing" will be
displayed.
Return to "Measured Values" screen.
Scroll up display screen.
Scroll down display screen.

Manual 37225B easYgen-3000 - Genset Control
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Screen "Analog inputs/outputs" [all application modes]
These screens appear after pressing the "Analog inputs/outputs"
softkey in the "Measured values" screen. The analog inputs and
outputs are displayed. The analog outputs are displayed as a per-
centage of the selected hardware range, i.e. 50 % of a 0 to 20 mA
output refer to 10 mA.
Return to "Measured Values" screen.
Scroll down to the "Analog outputs" screen.
Scroll up to the "Analog inputs" screen.
Change into AUTOMATIC operating mode.
Change into MANUAL operating mode.
Change into STOP operating mode.
Operating mode MANUAL: start/stop engine.
Operating mode MANUAL: open GCB/MCB.
Operating mode MANUAL: close GCB/MCB.
"Analog inputs" screen:
"Analog outputs" screen:

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Screen "Discrete inputs/outputs" [all application modes]
This screen appears after pressing the "Discrete inputs/outputs"
softkey in the "Measured values" screen. Discrete input and dis-
crete output status are displayed.
Return to "Measured Values" screen.
Scroll down display screen to external discrete IOs.
Scroll up display screen to internal discrete IOs.
Change into AUTOMATIC operating mode.
Change into MANUAL operating mode.
Change into STOP operating mode.
Operating mode MANUAL: start/stop engine.
Operating mode MANUAL: open GCB/MCB.
Operating mode MANUAL: close GCB/MCB.
Status display of the discrete inputs and discrete outputs.
(Note: The configured logic for the discrete input
"N.O./N.C." will determine how the easYgen reacts to the
state of the discrete input. If the respective DI is config-
ured to N.O, the unit reacts on the energized state ( ); if it
is configured to N.C., it reacts on the de-energized state .)
Discrete input: energized
de-energized
Discrete output: relay activated
relay de-activated

Manual 37225B easYgen-3000 - Genset Control
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Screen "Generator" [all application modes]
This screen appears after pressing the "Generator" softkey in the
"Measured values" screen. All measured generator values are dis-
played in this screen.
Return to "Measured values" screen.
Scroll down display screen to additional generator values.
Scroll up display screen to main generator values.
Reset the maximum value display.
Change into AUTOMATIC operating mode.
Change into MANUAL operating mode.
Change into STOP operating mode.
Operating mode MANUAL: start/stop engine.
Operating mode MANUAL: open GCB/MCB.
Operating mode MANUAL: close GCB/MCB.
V.......Voltage
I........Current
P.......Real power
Q.......Reactive power
S........Apparent power
PF.....Power factor
Screen "Busbar" [all application modes]
This screen appears after pressing the "Busbar" softkey in the
"Measured values" screen. All measured busbar values are dis-
played in this screen.
Return to "Measured values" screen.
Change into AUTOMATIC operating mode.
Change into MANUAL operating mode.
Change into STOP operating mode.
Operating mode MANUAL: start/stop engine.
Operating mode MANUAL: open GCB/MCB.
Operating mode MANUAL: close GCB/MCB.

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Screen "Mains" [all application modes]
This screen appears after pressing the "Mains" softkey in the
"Measured values" screen. All measured generator values are dis-
played in this screen.
Return to "Measured values" screen.
Scroll down display screen to additional mains values.
Scroll up display screen to main mains values.
Reset the maximum value display.
Change into AUTOMATIC operating mode.
Change into MANUAL operating mode.
Change into STOP operating mode.
Operating mode MANUAL: start/stop engine.
Operating mode MANUAL: open GCB/MCB.
Operating mode MANUAL: close GCB/MCB.
V...... Voltage
I........ Current
P....... Real power
Q...... Reactive power
S....... Apparent power
PF .... Power factor
Screen "Diagnostic" [all application modes]
This screen appears after pressing the "Diagnostic" softkey in the
"Next page" screen.
Return to the "Next page" screen.
LogicsManager conditions
Display the LogicsManager conditions screen.
Actual date and time
Display the actual date and time screen.
Event History
Display the event history screen.
Version
Display the version screen.

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Screen "LogicsManager conditions" [all application modes]
This screen appears after pressing the "LogicsManager conditions"
softkey in the "Diagnostic" screen. You are able to display the con-
ditions of all LogicsManager command variables, which are lo-
cated in their respective groups.
Return to "Diagnostic" screen.
Scroll up one group / command variable.
Scroll down one group / command variable.
Select the highlighted command variable group and display
the state of the command variables in this group.
Command variables of group 4 (ex.):
Status display of the command variables:
The command variables is TRUE
The command variables is FALSE
Screen "Actual date and time" [all application modes]
This screen appears after pressing the "Actual date and time" soft-
key in the "Diagnostic" screen. This screen displays the actual date
and time.
Return to "Diagnostic" screen.
Change into AUTOMATIC operating mode.
Change into MANUAL operating mode.
Change into STOP operating mode.
Operating mode MANUAL: start/stop engine.
Operating mode MANUAL: open GCB/MCB.
Operating mode MANUAL: close GCB/MCB.
xxxx-yyy-zz - Date
xxxx = Year
yyy = Month
zz = Day
xx:yy:zz - Time
xx = Hour
yy = Minute
zz = Second