Woodward easYgen exciter-10 User manual

Technical Manual
Generator Excitation Driver Module
easYgen | exciter-10
Software Version 1.01
Document ID: B37910, Revision B - Build 50683
easYgen Expansion Module

Manual (original)
This is no translation but the original Technical Manual in English.
Designed in Germany.
Woodward GmbH
Handwerkstr. 29
70565 Stuttgart
Germany
Telephone: [phone]‑510
Fax: [phone]‑101
E-mail: [email protected]
Internet: http://www.woodward.com
© 2020 Woodward GmbH. All rights reserved.
2 easYgen | exciter-10 B37910

Brief Overview
General information
The ”easYgen | exciter-10“ (= ”EX-10“) is a generator excitation driver module designed
for operation together with the genset control unit ”easYgen 3400/3500XT“ (release 1.16
or higher). The controller function is inherent to the easYgen. The easYgen measures the
generator values like voltage, power factor etc. and compares it with the valid set point.
According to the deviation, the easYgen controls an ”Excitation command“, which is fed
to the ”easYgen | exciter-10“ as a PMW signal. The ”easYgen | exciter-10“ then provides
the generator 󰍓eld excitation current according to the PWM signal.
The excitation power supply can be from shunt, auxiliary winding or permanent magnet
(PMG) type with either single phase or three phase.
Generator
Voltage & Current
Excitation
Excitation
Excitation
easYgen Genset control
Active Voltage Regulator
with AVR logic
Sensing
current
module
command
Fig. 1: Overview ”easYgen 3500XT“ with ”easYgen | exciter-10“
The easYgen | exciter-10 is equipped with temperature protection, to prevent failure and
damage caused by overheating. In occurrence of overheating, the exciter will shut-down
until normal operating temperature is reached then automatically restarts operation
Features:
In conjunction with easYgen-3400/3500XT genset controls, the active voltage regulator
system o󰍒ers:
• Automatic Voltage Regulation (AVR)•
• Soft start functionality•
•Under frequency regulation (Volt/Hz) de󰍓ned by a con󰍓gurable 5-point characteristic •
and activated by LogicsManager
• Line drop compensation via AnalogManager•
• Power factor and kvar control•
• Voltage droop compensation•
• Fault Ride Through (FRT) support•
• Setpoint con󰍓guration and AVR status overview on the easYgen screen and on•
Woodward ToolKit Service Tool
3easYgen | exciter-10B37910
Brief Overview

Protection:
• Current limitation – limit can be adjusted via a potentiometer (IEXC.)•
• Over-temperature protection – as the heat sink temperature crosses a•
threshold ”EX-10“ output shuts-o󰍒
• Short-circuit protection – when transient current output exceeds a threshold,•
the ”EX-10 decreases“ the excitation output to below 0.2A until shutdown
Scope of delivery
The following parts are included in the scope of delivery. Please check prior to the
installation that all parts are present.
Fig. 2: Dimension ”easYgen 3500XT“ with ”easYgen | exciter-10“
The following parts are included in the covering box. Please check prior to the installation
that all parts are present:
• exciter-10 module•
• »Installation Procedure Supplement« paper with links to the latest edition of•
Technical Documentation and software for download:══▷ B37912_ISP_exciter-10_A
•Screw kit installation material •
4 easYgen | exciter-10 B37910
Brief Overview

For the wiring 9 󰍔at plug receptacles 6.35 mm (0.25") are needed which are not included.
QR Code
To get access to the complete product documentation, please scan this QR code or use
the following link: ══▷ http://wwdmanuals.com/easygenexciter-10.
5easYgen | exciter-10B37910
Brief Overview

Table of Contents
1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7█
1.1 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7█
1.2 Depiction Of Notes And Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7█
1.2.1 Copyright And Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8█
1.2.2 Service And Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9█
1.3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9█
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10█
2.1 Mount unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11█
2.2 Setup Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11█
2.2.1 Wiring ”easYgen | exciter-10“ / ”easYgen“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13█
2.2.2 PMG power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14█
2.2.3 Shunt power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15█
2.2.4 Auxiliary winding power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16█
3Con󰍏guration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17█
3.1 Con󰍓guration via easYgen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17█
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21█
4.1 Current limitation (”IEXC.“) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21█
4.2 LED Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21█
4.3 Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22█
5 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23█
5.1 Product label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23█
5.2 Mechanical drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24█
5.3 Technical parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25█
5.4 Maximum continuous 󰍓eld current output CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25█
5.5 Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26█
6 Glossary And List Of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27█
7 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29█
6 easYgen | exciter-10 B37910
Table of Contents

1 General information
1.1 Revision History
Rev. Date Editor Changes
B 2020-12 BL Corrections/Repairs
• Threshold of overtemperature changed. Refer to ╚═▷ “Temperature (Over-•
temperature) Protection”
• Manual updated according to UL and CE maximum continuous 󰍓eld current.•
A 2020-08 BL First release
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.
Tips and recommendations
This symbol indicates useful tips and recommendations as well as information for
e󰍕cient and trouble-free operation.
7easYgen | exciter-10B37910
1 General information
1.1 Revision History

Additional markings
To emphasize instructions, results, lists, references, and other elements, the following
markings are used in these instructions:
Marking Explanation
⚙Start of a procedure list
>Prerequisite for a procedure list
▷Step-by-step instructions
▶Results of action steps
╚═▷ References to sections of these instructions and to other relevant
documents
• Listing without 󰍓xed sequence
☼ Example
»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 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 speci󰍓ed are in mm.
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
any damages due to:
• Failure to comply with the instructions in this manual•
• Improper use / misuse•
•Willful operation by non-authorized persons •
• Unauthorized conversions or non-approved technical modi󰍓cations•
• Use of non-approved spare parts•
The originator is solely liable for the full extent for damages caused by such conduct. The
obligations agreed-upon 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
8 easYgen | exciter-10 B37910
1 General information
1.2.1 Copyright And Disclaimer

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.
1.2.2 Service And Warranty
Our Customer Service is available for technical information.
For regional support, please refer to: ══▷ http://www.woodward.com/Support_pgd.aspx.
In addition, our employees are constantly interested in new information and experiences
that arise from usage and could be valuable for the improvement of our products.
Warranty terms
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
1.3 Special Tools
•Torque screwdriver •
A torque-screwdriver allow fastening of screws to a precisely speci󰍓ed torque.
• Crimping tool for the 󰍔at plug receptacles•
9easYgen | exciter-10B37910
1 General information
1.2.2 Service And Warranty

2 Installation
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 ╚═▷ “5 Technical Data”.•
NOTICE!
Recommended mounting position
The easYgen | exciter-10 shall be mounted in such a way that optimal convection through
the heat sink is ensured.
DANGER!
To avoid damages in case of a voltage control loop failure ensure that the engine will
stop immediately and GCB is opened immediately e.g. by including the “Ready for
operation relay” of the easYgen.
Make sure that the various generator monitoring functions e.g. overvoltage,
undervoltage, overfrequency, underfrequency, power factor etc. are set correctly.
Additionally it is strongly recommended to use a MPU for speed monitoring if no speed
governor is installed.
10 easYgen | exciter-10 B37910
2 Installation

2.1 Mount unit
The module must be 󰍓xed with 4 screws. The torque must be 1.1-1.3 Nm.
Take care for su󰍕cient air convection. For good heat dissipation we recommend
landscape orientation.
X1
Z1
X2
Z2
F
F+
PWM
PWM+
Shield
Fuse1 (X1,X2)
IEXC. Operation Protection
Fuse2 (Z1,Z2)
140 [5.51"]
175 [6.89"]
200 [7.87"]
115 [4.53"]
60 [2.36"]
19 [0.75"]
Unit : mm [inch]
6.5 [0.26"]
PART NO: 10-012-909
REV: A Made in Taiwan
Fig. 3: Dimension ”easYgen 3500XT“ with ”easYgen | exciter-10“
2.2 Setup Connections
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 1000MCM 500
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
Table 1: Conversion chart - wire sizes
11easYgen | exciter-10B37910
2 Installation
2.1 Mount unit

Terminal allocation and function
X1
Z1
X2
Z2
F−
F+
PWM−
PWM+
Shield
Fuse1 (X1,X2)
IEXC. Operation Protection
Fuse2 (Z1,Z2)
PART NO: 10-012-909
REV: A Made in Taiwan
easYgen | exciter-10
Fig. 4: Terminals ”easYgen | exciter 10“
The 9 terminals are designed as 󰍔at plugs 6.35 mm (0.25"). Therefore the wiring must be
done with 9 󰍔at plug receptacles.
Terminal label Function Notes
X1, X2, Z1, Z2 Power supply:
-PMG input,
-Shunt input or
-Auxilary winding input
40 … 250 Vac, 40 ... 500 Hz
Note for Shunt and Auxiliary
winding supply: If the build up
voltage is below 20Vac, a reliable
start up of the start voltage cannot
be guaranteed.
F+ Field excitation positive output
F− Field excitation negative output
PWM− PWM negative input 500 Hz PWM duty cycle 0 ... 100%
Pulse Voltage 5 ... 20 Vdc, < 20 mA
(5 Vdc recommended)
If the easYgen is con󰍓gured to use
analog output 2 for AVR, this
12 easYgen | exciter-10 B37910
2 Installation
2.2 Setup Connections

Terminal label Function Notes
terminal must be connected to
terminal 20 of the easYgen.
PWM+ PWM positive input If the easYgen is con󰍓gured to use
analog output 2 for AVR, this
terminal must be connected to
terminal 19 of the easYgen.
Shield Shield Connect to the common Protective
Earth (PE)
2.2.1 Wiring ”easYgen | exciter-10“ / ”easYgen“
The 󰍓gure below shows a typical wiring between the ”easYgen | exciter-10“ and
the ”easYgen“. In this example analog output 2 of the easYgen is con󰍓gured for AVR.
(Power supply is PMG in this example.)
easYgen easYgen | exciter-10
Excitation
F(−)
F(+)
PWM
20
19
Power supply
X1
Z1
X2
Z2
PMG
G
Generator
current and voltage
PWM (−)
PWM (+)
AO2
Fig. 5: Wiring ”easYgen“ / ”easYgen | exciter-10“
13easYgen | exciter-10B37910
2 Installation
2.2.1 Wiring ”easYgen | exciter-10“ / ”easYgen“

2.2.2 PMG power supply
The 󰍓gure below shows the wiring for ”PMG“ power supply.
PMG Configuration
Stator (12 - wire) Marked T1 to T12
Z2 X1 Z1 X2 F+ F−
PMG
F+
F−
T2 T3
T4 T5 T6
T7 T8 T9
T10 T11 T12
T1
Fig. 6: Wiring for ”PMG“ power supply
14 easYgen | exciter-10 B37910
2 Installation
2.2.2 PMG power supply

2.2.3 Shunt power supply
If the build up voltage is below 20Vac, a reliable start up of the start voltage cannot be
guaranteed.
The 󰍓gure below shows the wiring for ”Shunt“ power supply.
Stator (12 - wire) Marked T1 to
Shunt Configuration
Z2 X1 Z1 X2 F+ F−
T4 T5 T6T10 T11 T12
F−
F+
T1 T2 T3 T7 T8 T9
Fig. 7: Wiring for ”Shunt“ power supply
15easYgen | exciter-10B37910
2 Installation
2.2.3 Shunt power supply

2.2.4 Auxiliary winding power supply
If the build up voltage is below 20Vac, a reliable start up of the start voltage cannot be
guaranteed.
The 󰍓gure below shows the wiring for ”Auxiliary Winding“ power supply.
AUX Windings Configuration
Z2 X1 Z1 X2 F+ F−
Stator (12 - wire) Marked T1 to T12
F+
F−
T4 T5 T6T10 T11 T12
T1 T2 T3 T7 T8 T9
Fig. 8: Wiring for ”Auxiliary Winding“ power supply
16 easYgen | exciter-10 B37910
2 Installation
2.2.4 Auxiliary winding power supply

3Con󰍏guration
General information
Since the ”easYgen | exciter-10“ itself has no controller function, the con󰍓guration is done
via the easYgen in which the controller function is integrated.
The easYgen can be con󰍓gured via the PC tool ToolKit or, depending on the model, via the
HMI.
Only the current limitation adjustment must be done via the potentiometer ”IEXC.“ at the
exciter itself. Take care to adjust this potentiometer according to the excitation current of
the generator. Refer to chapter operation: ╚═▷ “4.1 Current limitation (”IEXC.“)”)
3.1 Con󰍏guration via easYgen
This document contains only two screenshots of important AVR parameters.
For detailed description of the con󰍓guration refer to the easYgen manuals.
(Chapters: ”Voltage Control“, ”AVR FRT Adjustments”)
══▷ EG3500XTP1
══▷ EG3500XTP2
Also make sure that the various generator monitoring functions e.g. overvoltage,
undervoltage, overfrequency, underfrequency, power factor etc. are set correctly.
(easYgen manuals chapter ”Con󰍓gure Generator Monitoring“)
For operation with ”easYgen | exciter-10“ parameter 5607 Voltage control must be
con󰍓gured to ”AVR“ like in the screenshot below:
17easYgen | exciter-10B37910
3 Con󰍓guration

Fig. 9: Main con󰈠guration sheet for ”Voltage control“ of ToolKit
If you click on the AVR button in the lower left corner you will get to the AVR page below.
There are some indications of actual values and the parameters for:
•Voltage 󰍓lter time •
• Start behavior•
• V(f) characteristic•
18 easYgen | exciter-10 B37910
3 Con󰍓guration
3.1 Con󰍓guration via easYgen

Fig. 10: Con󰈠guration sheet for AVR ”easYgen | exciter 10“ of ToolKit
Usually analogue output 2 is used to control the exciter. The following screenshot shows
an example of how to con󰍓gure AO2.
Note: The hardware and source level settings in󰍔uence the excitation range and control
behaviour.
19easYgen | exciter-10B37910
3 Con󰍓guration
3.1 Con󰍓guration via easYgen

Fig. 11: Con󰈠guration Analog Output 2 for AVR operation
20 easYgen | exciter-10 B37910
3 Con󰍓guration
3.1 Con󰍓guration via easYgen