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.

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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.

Manual 37561 Remanence Voltage Converter - EPU-100
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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

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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.