Woodward easYgen-3400 P1 User manual

easYgen-3000 Series
Manual Genset Control
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The easYgen-3000 Series 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, peak shaving, import/export or distributed
generation.
The easYgen-3000 Series is also applicable for island, island par‐
allel, mains parallel and multiple unit mains parallel operations.
The easYgen-3400/3500 offer a wider range of functionality and
applications than the lower numbered easYgens and are preferred
for communcation with Woodwards LS-5 synchronizers and load
share controllers.
Fig. 1: Sample application setup: Mains parallel operation
The easYgen will function as an engine control with generator,
mains and engine protection.
The control unit can open and close the generator circuit
breaker (GCB) and the mains circuit breaker (MCB).
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For a listing of additional application modes and setups
please refer to chapter ª Chapter 6 “Application”
on page 451.
The following parts are included in the scope of delivery. Please
check prior to the installation that all parts are present.
Fig. 2: Scope of delivery - schematic
A easYgen-3400/3500 genset control (plastic or
sheet metal housing) including terminal plug/
jack
B Product CD (configuration software and manual)
C Installation material (plastic housing only): 4x
clamp fastener
D Installation material (plastic housing only): 12x
Screw kit
The easYgen-3400/3500 controllers are available in different pack‐
ages. The major differences are listed below.
In this manual the package specific information is
marked with P1-only or P2-only .
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Discrete Inputs 12 23
Relay Outputs 12 22
Sinking Outputs (Transistors) 0 2
Analog Inputs (0 - 20 mA/0 - 10 V) 0 3
Analog Inputs (0 - 250 Ohms/0 - 2500 Ohms) 0 4
Analog Outputs (0 - 20 mA) 0 3
External discrete inputs / outputs via CANopen (maximum) 32 / 32 16 / 16
External analog inputs / outputs via CANopen (maximum) 16 / 4 0 / 0
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Fig. 3: easYgen-3400/3500 P1 Series (housing variants)
A1 easYgen-3500 P1 (plastic housing with dis‐
play)
A2 easYgen-3400 P1 (sheet metal housing)
1 Mains/generator/busbar PT terminal
2 Analog inputs/outputs and generator CT ter‐
minal
3 CAN bus interface connector #1
4 CAN bus interface connector #2
5 CAN bus interface connector #3
6 Discret inputs terminal
7 Relay outputs terminal
8 RS-232 interface connector
9 RS-485 interface connector
Fig. 4: easYgen-3400-3500 P2 Series (housing variants)
A1 easYgen-3500 P2 (plastic housing with dis‐
play)
A2 easYgen-3400 P2 (sheet metal housing)
1 Mains/generator/busbar PT terminal
2 Analog inputs/outpouts
3 Analog inputs/outputs and generator CT ter‐
minal
4 Analog inputs/outpouts
5 CAN bus interface connector #2
6 CAN bus interface connector #1
7 Discrete inputs and sinking output terminal
8 Discret inputs, power supply, and MPU ter‐
minal
9 Relay outputs terminal
10 Relay outputs terminal
11 CAN bus interface connector #3
12 RS-232 interface connector
13 RS-485 interface connector
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1.1 About This Manual.................................................................................................................... 19
1.1.1 Revision History........................................................................................................................ 19
1.1.2 Depiction Of Notes And Instructions......................................................................................... 24
1.2 Copyright And Disclaimer.......................................................................................................... 25
1.3 Service And Warranty............................................................................................................... 26
1.4 Safety........................................................................................................................................ 26
1.4.1 Intended Use............................................................................................................................. 26
1.4.2 Personnel.................................................................................................................................. 27
1.4.3 General Safety Notes................................................................................................................ 28
1.4.4 Protective Equipment And Tools............................................................................................... 31
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2.1 Display And Status Indicators................................................................................................... 33
2.2 Hardware Interfaces (Terminals)............................................................................................... 34
2.3 Application Modes Overview..................................................................................................... 36
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3.1 Mount Unit (Sheet Metal Housing)............................................................................................39
3.2 Mount Unit (Plastic Housing)..................................................................................................... 41
3.2.1 Clamp Fastener Installation....................................................................................................... 42
3.2.2 Screw Kit Installation................................................................................................................. 43
3.3 Setup Connections.................................................................................................................... 45
3.3.1 Terminal Allocation.................................................................................................................... 45
3.3.2 Wiring Diagram.......................................................................................................................... 46
3.3.3 Power Supply............................................................................................................................ 51
3.3.4 Charging Alternator................................................................................................................... 52
3.3.5 Voltage Measuring.................................................................................................................... 53
3.3.5.1 Generator Voltage..................................................................................................................... 53
3.3.5.2 Mains Voltage............................................................................................................................ 60
3.3.5.3 Busbar Voltage.......................................................................................................................... 66
3.3.6 Current Measuring..................................................................................................................... 69
3.3.6.1 Generator Current..................................................................................................................... 69
3.3.6.2 Mains Current............................................................................................................................ 71
3.3.6.3 Ground Current......................................................................................................................... 72
3.3.7 Power Measuring...................................................................................................................... 73
3.3.8 Power Factor Definition............................................................................................................. 74
3.3.9 Magnetic Pickup Unit (MPU)..................................................................................................... 75
3.3.10 Discrete Inputs.......................................................................................................................... 76
3.3.11 Relay Outputs (LogicsManager)................................................................................................ 78
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3.3.12 Analog Inputs............................................................................................................................ 80
3.3.12.1 Analog Inputs (0 to 500 Ohm | 0/4 to 20 mA)............................................................................80
3.3.12.2 Analog Inputs (0/4 to 20 mA / 0 to 10 V).......................................................................... 83
3.3.12.3 Analog Inputs (0 to 250 Ohms / 0 to 2500 Ohms)............................................................ 85
3.3.13 Analog Outputs.......................................................................................................................... 86
3.3.13.1 Analog Outputs (±20 mA, ± 10 V, PWM).................................................................................. 86
3.3.13.2 Analog Outputs 4 to 6 (0/4 to 20 mA)............................................................................... 87
3.3.14 Transistor Outputs............................................................................................................87
3.3.15 Serial Interfaces........................................................................................................................ 88
3.3.15.1 RS-485 Interface....................................................................................................................... 88
3.3.15.2 RS-232 Interface....................................................................................................................... 89
3.4 CAN Bus Interfaces................................................................................................................... 90
3.5 Connecting 24 V Relays............................................................................................................ 92
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4.1 Basic Setup............................................................................................................................... 95
4.1.1 Configure Language/Clock........................................................................................................ 95
4.1.2 Configure Display...................................................................................................................... 99
4.1.3 Lamp Test................................................................................................................................. 99
4.1.4 Enter Password......................................................................................................................... 99
4.1.5 System Management.............................................................................................................. 102
4.1.6 Password System.................................................................................................................... 103
4.2 Configure Measurement.......................................................................................................... 104
4.2.1 Configure Transformer............................................................................................................ 109
4.2.2 External Mains Active Power................................................................................................... 112
4.2.3 External Mains Reactive Power.............................................................................................. 113
4.3 Function Of Inputs And Outputs..............................................................................................113
4.3.1 Discrete Inputs........................................................................................................................ 113
4.3.2 Discrete Outputs...................................................................................................................... 116
4.4 Configure Monitoring............................................................................................................... 120
4.4.1 Generator................................................................................................................................ 120
4.4.1.1 Generator Operating Voltage / Frequency.............................................................................. 120
4.4.1.2 Generator Overfrequency (Level 1 & 2) ANSI# 81O............................................................... 121
4.4.1.3 Generator Underfrequency (Level 1 & 2) ANSI# 81U............................................................. 122
4.4.1.4 Generator Overvoltage (Level 1 & 2) ANSI# 59...................................................................... 124
4.4.1.5 Generator Undervoltage (Level 1 & 2) ANSI# 27.................................................................... 125
4.4.1.6 Generator Time-Overcurrent (Level 1, 2 & 3) ANSI# 50/51.................................................... 127
4.4.1.7 Generator Reverse/Reduced Power (Level 1 & 2) ANSI# 32R/F............................................ 128
4.4.1.8 Generator Overload IOP (Level 1 & 2) ANSI# 32.................................................................... 130
4.4.1.9 Generator Overload MOP (Level 1 & 2) ANSI# 32.................................................................. 132
4.4.1.10 Generator Unbalanced Load (Level 1 & 2) ANSI# 46............................................................. 133
4.4.1.11 Generator Voltage Asymmetry................................................................................................ 135
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4.4.1.12 Generator Ground Fault (Level 1 & 2)..................................................................................... 137
4.4.1.13 Generator Phase Rotation....................................................................................................... 140
4.4.1.14 Generator Inverse Time-Overcurrent ANSI# IEC 255............................................................. 142
4.4.1.15 Generator Lagging Power Factor (Level 1 & 2)....................................................................... 145
4.4.1.16 Generator Leading Power Factor (Level 1 & 2)....................................................................... 147
4.4.1.17 Generator Voltage Restrained Overcurrent Monitoring - ANSI #51........................................ 149
4.4.2 Mains....................................................................................................................................... 150
4.4.2.1 Mains Operating Voltage / Frequency.....................................................................................151
4.4.2.2 Mains Decoupling.................................................................................................................... 152
4.4.2.3 Mains Overfrequency (Level 1 & 2) ANSI# 81O...................................................................... 159
4.4.2.4 Mains Underfrequency (Level 1 & 2) ANSI# 81U.................................................................... 160
4.4.2.5 Mains Overvoltage (Level 1 & 2) ANSI# 59............................................................................. 162
4.4.2.6 Mains Undervoltage (Level 1 & 2) ANSI# 27........................................................................... 163
4.4.2.7 Mains Voltage Increase........................................................................................................... 165
4.4.2.8 Mains Time-Dependent Voltage.............................................................................................. 167
4.4.2.9 QV Monitoring......................................................................................................................... 170
4.4.2.10 Change Of Frequency............................................................................................................. 172
4.4.2.11 Mains Voltage Phase Rotation................................................................................................ 176
4.4.2.12 Mains Import Power (Level 1 & 2)........................................................................................... 177
4.4.2.13 Mains Export Power (Level 1 & 2)........................................................................................... 179
4.4.2.14 Mains Lagging Power Factor (Level 1 & 2)............................................................................. 180
4.4.2.15 Mains Leading Power Factor (Level 1 & 2)............................................................................. 182
4.4.2.16 Blocking of Mains Protection................................................................................................... 183
4.4.3 Engine..................................................................................................................................... 184
4.4.3.1 Engine Overspeed (Level 1 & 2) ANSI# 12............................................................................. 184
4.4.3.2 Engine Underspeed (Level 1 & 2)........................................................................................... 185
4.4.3.3 Engine/Generator Speed Detection........................................................................................ 186
4.4.3.4 Engine/Generator Active Power Mismatch.............................................................................. 188
4.4.3.5 Engine/Mains Active Power Mismatch.................................................................................... 189
4.4.3.6 Engine/Generator Unloading Mismatch.................................................................................. 190
4.4.3.7 Engine Start Failure................................................................................................................. 191
4.4.3.8 Engine Shutdown Malfunction ................................................................................................ 192
4.4.3.9 Engine Unintended Stop ........................................................................................................ 192
4.4.3.10 Engine Operating Range Failure............................................................................................. 193
4.4.3.11 Engine Charge Alternator (D+)................................................................................................ 195
4.4.3.12 Cylinder Temperature.............................................................................................................. 196
4.4.4 Breaker.................................................................................................................................... 202
4.4.4.1 Configure GCB........................................................................................................................ 202
4.4.4.2 Synchronization GCB ............................................................................................................. 203
4.4.4.3 Configure GGB........................................................................................................................ 204
4.4.4.4 Synchronization GGB ............................................................................................................. 205
4.4.4.5 Configure MCB........................................................................................................................ 206
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4.4.4.6 Synchronization MCB ............................................................................................................. 208
4.4.4.7 Generator/Busbar/Mains Phase Rotation................................................................................ 209
4.4.5 Flexible Limits.......................................................................................................................... 210
4.4.6 Miscellaneous.......................................................................................................................... 215
4.4.6.1 Alarm Acknowledgement......................................................................................................... 215
4.4.6.2 Free Configurable Alarms....................................................................................................... 216
4.4.6.3 CAN Bus Overload.................................................................................................................. 217
4.4.6.4 CAN Interface 1....................................................................................................................... 218
4.4.6.5 CAN Interface 2....................................................................................................................... 219
4.4.6.6 CAN Interface 2 - J1939 Interface........................................................................................... 220
4.4.6.7 J1939 Interface - Red Stop Alarm........................................................................................... 221
4.4.6.8 J1939 Interface - Amber Warning Alarm................................................................................. 222
4.4.6.9 Battery Overvoltage (Level 1 & 2)........................................................................................... 223
4.4.6.10 Battery Undervoltage (Level 1 & 2)......................................................................................... 224
4.4.6.11 Multi-Unit Parameter Alignment.............................................................................................. 225
4.4.6.12 Multi-Unit Missing Members.................................................................................................... 227
4.4.6.13 Neutral Interlocking................................................................................................................. 228
4.5 Configure Application.............................................................................................................. 228
4.5.1 Configure Breakers................................................................................................................. 228
4.5.1.1 Dead Bus Closing GCB........................................................................................................... 230
4.5.1.2 Synchronization GCB/MCB..................................................................................................... 231
4.5.1.3 Dead Bus Closing MCB........................................................................................................... 232
4.5.1.4 Open GCB............................................................................................................................... 233
4.5.1.5 Open MCB............................................................................................................................... 234
4.5.1.6 Transition Modes (Breaker Logic)........................................................................................... 234
4.5.1.7 Parameters.............................................................................................................................. 239
4.5.1.8 Breakers GCB......................................................................................................................... 242
4.5.1.9 Breakers GGB......................................................................................................................... 246
4.5.1.10 Breakers MCB......................................................................................................................... 249
4.5.1.11 Synchronization....................................................................................................................... 253
4.5.1.12 Neutral Interlocking................................................................................................................. 255
4.5.2 Inputs And Outputs.................................................................................................................. 255
4.5.2.1 Analog Inputs.......................................................................................................................... 255
4.5.2.2 External Analog Inputs............................................................................................................ 270
4.5.3 Discrete Inputs........................................................................................................................ 273
4.5.4 External Discrete Inputs.......................................................................................................... 278
4.5.5 Discrete Outputs (LogicsManager)..........................................................................................279
4.5.6 External Discrete Outputs....................................................................................................... 282
4.5.7 Analog Outputs........................................................................................................................ 283
4.5.7.1 Analog Outputs 1 and 2........................................................................................................... 283
4.5.7.2 Analog Outputs 4 to 6..................................................................................................... 287
4.5.8 External Analog Outputs......................................................................................................... 289
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