Woodward EPU-100 User manual

37561
Technical Manual 37561
EPU-100 „Electronic Pickup Unit“
Remanence Voltage Converter
for Asynchronous Generators
Technical Manual
Version 1.0

Manual 37561 Remanence Voltage Converter - EPU-100
Page 2/20 © Woodward
WARNING
Read this entire manual and all other publications pertaining to the work to be performed
before installing, 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
(overtemperature, 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 governor(s) or electric control(s), the actuator(s),
fuel control(s), the driving mechanism(s), the linkage(s), or the controlled device(s) fail.
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 damage 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.
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 37561 Remanence Voltage Converter - EPU-100
© Woodward Page 3/20
Revision History
Rev. Date Editor Changes
NEW 2014-02-27 GG Release
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.
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.
Content
GENERAL INFORMATION ..........................................................................................................5
Introduction...............................................................................................................................................5
Safety Precautions ...................................................................................................................................5
Intended Use............................................................................................................................................6
ELECTROSTATIC DISCHARGE AWARENESS ...............................................................................7
INSTALLATION.........................................................................................................................8
Mounting and Removal ............................................................................................................................8
Wiring.......................................................................................................................................................9
Terminal and Interface .............................................................................................................................9
FUNCTIONAL DESCRIPTION ....................................................................................................10
Display....................................................................................................................................................10
Signal Conversion..................................................................................................................................10
CONFIGURATION ...................................................................................................................11
Configure easYgen series genset controller for EPU-100 input ..................................................11
OPERATION...........................................................................................................................12
Application..............................................................................................................................................13
Setup of the easYgen controller...................................................................................................13
Application Setup of EPU and easYgen.......................................................................................13

Manual 37561 Remanence Voltage Converter - EPU-100
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TROUBLE-SHOOTING .............................................................................................................14
SERVICE ...............................................................................................................................16
Product Service Options........................................................................................................................ 16
Returning Equipment for Repair ............................................................................................................ 16
Due to the fact that the EPU-100 is a low cost one PCB solution, replacement will be prioritized
before repair. Warranty conditions are not affected. Anyway please send the repair candidate
back for analysis reasons. Packing A Control............................................................................. 16
Packing A Control........................................................................................................................ 17
Return Authorization Number RAN ............................................................................................. 17
Replacement Parts ................................................................................................................................ 17
Further Information................................................................................................................................ 17
How to contact Woodward..................................................................................................................... 18
Technical Assistance............................................................................................................................. 19
Parts of Delivery
Please check delivery before starting installation.
This product comes with:
Piece(s) Name Remarks
1
EPU-100
Remanence Voltage Converter
1 Mini CD-ROM
Containing the EPU-100 Technical Manual (this manual), the Product
Specification and further information
1 Packaging -/-
The DIN rail is not(!) part of delivery
Table 1. Parts of delivery

Manual 37561 Remanence Voltage Converter - EPU-100
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General Information
CAUTION
Only qualified workers should install this equipment. Such work should be performed only
after reading this entire set of instructions.
Apply appropriate personal protective equipment and follow safe electrical practices.
The successful operation of this equipment depends upon proper handling, installation, and
operation. Neglecting fundamental installation requirements may lead to personal injury as
well as damage to electrical equipment or other property.
Failure to follow these instructions will result in death or serious injury!
Introduction
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EPU means Electronic Pickup Unit. It converts the Remanence Voltage of the connected
Asynchronous Generator into a digital signal with a rotational frequency according to the number of
revolutions.
No adjustment needed.
In combination with Woodward’s easYgen devices installation and configuration becomes very easy.
EPU-100 input and supply power is already available. Configuration is just one parameter setting away.
EPU-100 is preferred especially for small gensets.
NOTE
The present manual has been prepared to enable the installation and commissioning of the
unit.
Due to the large variety of applications, it is not possible to cover every combination. The
manual is therefore only a guide.
Safety Precautions
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•Don’t use EPU-100 in hazardous area.
•Don’t use EPU-100 for medical devices.
•Installation by trained personnel only.

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Intended Use
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The unit must only be operated in the manner described by 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 maintenance with respect to its technical data.
EPU-100 …
•is prepared for DIN rail mounting.
•converts even the low Remanence Voltage output of an asynchronous generator without load
into a rectangle speed/frequency related input for synchronization of closing breaker(s).
•is intended to be used with gensets only.
Woodward offers kits for asynchronous genset control that cover both EPU-100 together and easYgen-
2000 or easYgen-3000. An Application Note describes the best practice implementation and use of this
kit.
NOTE
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: constitute
"misuse" and/or "negligence" within the meaning of the product warranty thereby excluding
warranty coverage for any resulting damage and invalidate product certifications or listings.
Don’t use EPU-100 for speed regulation.

Manual 37561 Remanence Voltage Converter - EPU-100
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Electrostatic Discharge Awareness
All electronic equipment is static-sensitive, some components more than others. To protect these
components from static damage, you must take special precautions to minimize or eliminate
electrostatic discharges.
Follow these precautions when working with or near the control.
1. Before doing maintenance on the electronic control, discharge the static electricity on your body
to ground by touching and holding a grounded metal object (pipes, cabinets, equipment, etc.).
2. Avoid the build-up of static electricity on your body by not wearing clothing made of synthetic
materials. Wear cotton or cotton-blend materials as much as possible because these do not
store static electric charges as easily as synthetics.
3. Keep plastic, vinyl and Styrofoam materials (such as plastic or Styrofoam cups, cigarette
packages, cellophane wrappers, vinyl books or folders, plastic bottles, etc.) away from the
control, modules and work area as much as possible.
4. Opening the control cover may void the unit warranty!
Do not remove the printed circuit board (PCB) from the housing unless absolutely necessary. If
you must remove the PCB from the housing, follow these precautions:
•Ensure that the device is completely voltage-free (all connectors have to be disconnected).
•Do not touch any part of the PCB except the edges.
•Do not touch the electrical conductors, connectors or components with conductive devices or
with bare hands.
•When replacing a PCB, keep the new PCB in the plastic antistatic protective bag it comes in
until you are ready to install it. Immediately after removing the old PCB from the control
cabinet, place it in the antistatic protective bag.
CAUTION
To prevent damage to electronic components caused by improper handling, read and
observe the precautions in Woodward manual 82715, Guide for Handling and Protection of
Electronic Controls, Printed Circuit Boards and Modules.

Manual 37561 Remanence Voltage Converter - EPU-100
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Installation
Mounting and Removal
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EPU-100 is prepared for DIN rail mounting:
•Attach the upper snap-on guide to the DIN rail
•Press the EPU-100 down onto the DIN rail until it locks into position
Drawing 1: Housing with circuit diagram and terminals

Manual 37561 Remanence Voltage Converter - EPU-100
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Wiring
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Drawing 2: Connection Diagram
NOTE
Inductances must be provided with a suitable interference suppressor.
Terminal and Interface
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WARNING
Danger For Life! Connection only at generator standstill!
Take care for safety instructions!
Contact Signal Name
Wire size Amax
„inflexible“
„flexible“
1
Remanence voltage IN
L1 – L2
Phase, VRem. IN
0.2 .. 4 mm² 0.2 .. 2.5 mm²
2 Phase, VRem. IN 0.2 .. 4 mm² 0.2 .. 2.5 mm²
3
EPU OUT
“MPU-signal”
-VMPU OUT
0.2 .. 4 mm² 0.2 .. 2.5 mm²
4 +VMPU OUT 0.2 .. 4 mm² 0.2 .. 2.5 mm²
5
(Power supply)
–UBatt. ; 0 V reference
0.2 .. 4 mm² 0.2 .. 2.5 mm²
6 +UBatt. 0.2 .. 4 mm² 0.2 .. 2.5 mm²
Table 2. Terminal wiring
For use with Woodward easYgen please connect MPU OUT of the EPU-100 with easYgen terminal for
MPU input.
MPU
input

Manual 37561 Remanence Voltage Converter - EPU-100
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Functional Description
Display
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LED function: LED is …
•illuminated if supply voltage is in range,
and
•toggling with incoming Remanence Voltage signal.
The LED’s blinking frequency is 4 times lower than the genset rotation frequency to be visible.
Signal Conversion
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The output frequency VMPU of the EPU-100 is 8 times higher than the frequency of the input voltage
VRem.

Manual 37561 Remanence Voltage Converter - EPU-100
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Configuration
CAUTION
Configuration only if system is off.
No configuration for EPU-100. Configuration has to be done at genset controller side!
NOTE
There is no standard for the MPU signal defined.
EPU-100 working together with easYgen series genset controllers just needs configuration
as described below.
Using EPU-100 with other genset controllers like Woodward’s easYgen
this genset controllers need specific setup.
Configure easYgen series genset controller for EPU-100 input
EPU input will be configured like MPU input with the
•number of teeth of the Pickup sensor or the
•number of impulses of the sensor
per one turn.
easYgen series Technical Manuals contain conversion tables for speed measurement related to the
number of teeth (easYgen parameter ID 1602) and nominal speed in rpm (easYgen parameter ID
1601).
easYgen settings at 50 Hz mains frequency:
rpm
Parameter ID 1601 500 750 1000 1500 3000
Number of teeth
Parameter ID 1602
Terminal 79/80 48 32 24 16 8
Table 3. Overview rpm / number of teeth

Manual 37561 Remanence Voltage Converter - EPU-100
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Operation
WARNING – HIGH VOLTAGE
Please follow the safety regulation – especially for working with high voltage! Take care to be
well instructed for first aid caused by electrical accidents. Don’t contact hazardous parts:
DANGER TO LIFE
CAUTION
Commissioning by qualified personnel only.
CAUTION
Check phase correct connections before commissioning.
Missing or wrong connected (measuring) wiring can lead to malfunctions, which in turn can
lead to damaged equipment or even accidents!

Manual 37561 Remanence Voltage Converter - EPU-100
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Application
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This application describes the setup of an easYgen-2000/-3000 series to run an asynchronous
generator in combination with an EPU-100.
Setup of the easYgen controller
1. Set parameter 235 (Generator Type) to “Asynchron”. The parameter can be found in “Configure
measurement” menu:
2. To be able to measure the rpm of the engine, when the generator is in island mode the settings
for the MPU need to be adjusted:
1. Parameter 1600 (MPU input) need to be configured to “On”
2. Parameter 15155 (Engine speed source) need to be configured to “Internal)
3. Parameter 1601 (Engine rated speed) according to the engine value
4. Parameter 1602 (Fly wheel teeth) need to be set to the value corresponding to the
matching value listed on page 11 e.g.,:
After this software setup the easYgen can interprete the MPU signal coming from the EPU-100.
Application Setup of EPU and easYgen
1. Connect EPU-100 as described with chapter Installation on page 8.
2. Check polarity of MPU-signal at easYgen terminal!
3. Connect 12/24 VDC power supply
The application setup is complete.
EPU-100 LED is …
•Illuminated: supply power in range
•Toggling: Remanence voltage input signal VREM is valid

Manual 37561 Remanence Voltage Converter - EPU-100
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Trouble-Shooting
Problem Reason Why Solution
LED off
No supply voltage
or
supply voltage polarity
mismatch
Check supply voltage
LED toggling all the time
(with mains frequency)
Input with open connection
works like antenna for mains
Check shielding
or
connect inputs 1 and 2
separately and both together
to ground
No MPU-signal No input signal detected
Check EPU outputs 3 and 4
with a multimeter VDC:
2 .. 3 V = output is valid
EPU input is OK, but
easYgen is detecting
no MPU-signal
Wrong polarity at easYgen
MPU input
Check polarity at easYgen MPU
input
Table 4. Trouble-Shooting

Manual 37561 Remanence Voltage Converter - EPU-100
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Appendix 1.
Technical Data
Attribute Unit Value Remarks
Remanence Voltage input
VAC
0.5 .. 600
L1 – L2
Input impedance
kΩ
> 240
Input frequency range
Hz
16 .. 85
Output frequency range Hz 128 .. 680 8 times higher than input
frequency
accuracy
%
5
For 40 .. 60 Hz
MPU Output Signal “MPU-signal”
VDC
4.5 .. 5.5
Reaction time
ms
< 400
Tracking time
LED frequency Hz ca. 4 .. 21 4 times lower than input
frequency
Supply voltage
V
DC
8 .. 42
Vnom = 24 V
Supply current
ADC
< 0.02
Wire size
mm
2
0.2 .. 4
“inflexible”
mm
2
0.2 .. 2.5
“flexible”
Cable length to MPU-signal
receiving end
m < 10 shielded
Cable length to power supply
m
< 30
Cable mains/load
-
-
shielded
Absolute altitude
m
up to 4,000
Ambient temperature
“operation”
°C -40 .. +70
Storage temperature
°C
-40 .. +100
Dimensions
mm
30 x 75 x 55
W x D x H
Standards, approvals,
approbations
DIN EN 61010-1, CE
(UL on request)
CAT II 300-600 V acc. to
DIN EN 61010-1
Table 5. Technical data

Manual 37561 Remanence Voltage Converter - EPU-100
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Service
Product Service Options
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The following factory options are available for servicing Woodward equipment, based on the standard
Woodward Product and Service Warranty (5-01-1205) that is in effect at the time the product is
purchased from Woodward or the service is performed. If you are experiencing problems with
installation or unsatisfactory performance of an installed system, the following options are available:
•Consult the troubleshooting guide in the manual.
•Contact Woodward technical assistance (see "How to Contact Woodward" later in this chapter) and
discuss your problem. In most cases, your problem can be resolved over the phone. If not, you can
select which course of action you wish to pursue based on the available services listed in this
section.
Returning Equipment for Repair
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If a control (or any part of an electronic control) is to be returned to Woodward for repair, please contact
Woodward in advance to obtain a Return Authorization Number. When shipping the unit(s), attach a tag
with the following information:
•Name and location where the control is installed
•Name and phone number of contact person
•Complete Woodward part numbers (P/N) and serial number (S/N)
•Description of the problem
•Instructions describing the desired type of repair
CAUTION
To prevent damage to electronic components caused by improper handling, read and observe
the precautions in Woodward manual 82715, Guide for Handling and Protection of Electronic
Controls, Printed Circuit Boards and Modules.
Due to the fact that the EPU-100 is a low cost one PCB solution, replacement
will be prioritized before repair. Warranty conditions are not affected.
Anyway please send the repair candidate back for analysis reasons.

Manual 37561 Remanence Voltage Converter - EPU-100
© Woodward Page 17/20
Packing A Control
Use the following materials when returning a complete control:
•Antistatic protective bags on all electronic modules
•Packing materials that will not damage the surface of the unit
•A packing carton with double walls
Return Authorization Number RAN
When returning equipment to Woodward, please telephone and ask for the Customer Service
Department in Stuttgart [[phone]]. They will help expedite the processing of your order
through our distributors or local service facility. To expedite the repair process, contact Woodward in
advance to obtain a Return Authorization Number and arrange for issue of a purchase order for the
unit(s) to be repaired. No work can be started until a purchase order is received.
NOTE
We highly recommend that you make arrangement in advance for return shipments.
Contact a Woodward customer service representative at [phone] for
instructions and for a Return Authorization Number.
Replacement Parts
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When ordering replacement parts for controls, include the following information:
•The part numbers P/N (XXXX-XXXX) that is on the enclosure nameplate.
•The unit serial number S/N, which is also on the nameplate.
Further Information
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Woodward device Product Specification # Technical Manual #
Asynchronous Kit with
EPU-100 and easYgen-2500
37568 37535 and 37561
Asynchronous Kit with
EPU-100 and easYgen-3500
37528 and 37561
easYgen-1000 series 37180 37476 .. 37480
easYgen-2000 series 37548 37535
easYgen-3100/3200 37258 37532
easYgen-3400/3500 37523 37528
easYgen-3400/3500 Marine 37533 37531
DSLC-2 37493 37443
Table 6. Further Information

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How to contact Woodward
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Please contact following address if you have questions or if you want to send a product for repair:
Woodward GmbH
Handwerkstrasse 29
70565 Stuttgart - Germany
Phone: [phone] (8.00 - 16.30 German time)
Fax: [phone]
eMail: stgt-[email protected]
For assistance outside Germany, call one of the international Woodward facilities to obtain the address
and phone number of the facility nearest your location where you will be able to get information and
service.
You can also contact the Woodward Customer Service Department or consult our worldwide directory
on Woodward’s website (www.woodward.com) for the name of your nearest Woodward distributor or
service facility.
For worldwide directory information, go to
www.woodward.com/ic/locations.

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Technical Assistance
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If you need to telephone for technical assistance, you will need to provide the following information.
Please write it down here before phoning:
Contact
Your company _____________________________________________
Your name ________________________________________________
Phone number _____________________________________________
Fax number _______________________________________________
Product (see name plate)
Unit no. and revision: P/N: _________________ REV: ___________
Unit type EPU-100 _______________________________
Serial number S/N: __________________________________
Description of your problem
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
If applicable, please have a list of all parameters available. You can print this e.g., using ToolKit.
Additionally you can save the complete set of parameters (standard values) and send them to our
Service department.

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We appreciate your comments about the content of our publications.
Please send comments to: stgt-[email protected]
Please include the manual number from the front cover of this publication.
Woodward GmbH
Handwerkstrasse 29 - 70565 Stuttgart - Germany
Phone [phone] •Fax [phone]
stgt-i[email protected]
Homepage
http://www.woodward.com
Woodward has company-owned plants, subsidiaries, and branches, as well as authorized
distributors and other authorized service and sales facilities throughout the world.
Complete address/phone/fax/e-mail information
for all locations is available on our website (www.woodward.com).
.
2014/5/Stuttgart