Woodward easYgen-400 Operation Manual Genset Control

easYgen-400

Operation Manual

Genset Control

Rev. Date Editor Changes

F 2023-08 MK NEW Software Version 2.1.0.8

•Suitable for new LCD display •

E 2021-06 MK NEW Software Version 2.1.0.7

•needed ToolKit-SC Version 1.5.1.5 or higher •

NEW features & functions

•Added output ports: 27 Preheat until safety, 28 Preheat until •

warming, 29 Preheat until cranking

Corrections/Repairs

•None •

D 2020-11 TM NEW Software Version 2.1.0.6

•needed ToolKit-SC Version 1.5.1.3 or higher •

NEW features & functions

•Support for HATZ ECU •

Corrections/Repairs

•None •

C 2020-11 TM NEW Software Version 2.1.0.5

NEW features & functions

• ID 835 Enumeration “emergency shutdown” function for discrete •

inputs

• ID 846 Action (alarm class) from analog inputs monitoring is now •

configurable

• ID 1099 Additional logic for maintenance counters •

• ID 1098 Semi-Auto mode for AMF start •

• ID 1103 Unbalanced load alarm •

Corrections/Repairs

• ID 837 Breaker logic “constant” de-energizes with breaker alarm •

• ID 931 Corrected Volvo ECU 50/60 Hz selection

Rev. Date Editor Changes

• ID 1000 Reference values for rated “active power” and “reactive •

power”

B 2019-05 PW NEW Software Revision 2.0.0.1 and ToolKit-SC version 1.5.0.4

Corrections/Repairs

•Fixed the following in HMI software: •

◦fixed the version name to 4 digits; ◦

◦possibility to close GCB when engine not running; ◦

◦kvar spelling; ◦

◦ impossibility to mute the horn with easYlite-200; ◦

◦HMI user defined sensor curves displaying messy codes in ◦

other languages

◦after gen closed, if changed breaker close delay by Toolkit-◦

sc, 6550 countdown error occurred in HMI;

◦when change to OEM plant theme and Terminal users ◦

theme, press close/open button in manual mode, error

occurred in breaker page;

◦Horn/Alarm Acknowledge / Alarm reset function ◦

◦”Traditional Chinese” implemented ◦

◦changed name easYgen400/easYgen1400 to easYgen-400/ ◦

easYgen-1400 in controller information page;

◦status LED not turning on if the “Conventional Engine” was ◦

selected, easYgen and genset in STOP condition, START

button pressed;

◦maintenance counter resetting ◦

◦Polish translation errors ◦

◦modified configuration of auto test mode, including number ◦

of input ports, LED display order, and level sensor changed

from flexible sensor to resistor type sensor;

◦ J1939 standard and setpoint idle ◦

◦Volvo EMS2 50/60Hz rated speed selection ◦

◦overload monitoring not using the “return” value; ◦

◦Volvo EMS2 rated frequency selection and rated speed ◦

modification;

◦mains breaker warning in MAN mode; ◦

◦operation mode changing from MAN with closed GCB to ◦

MCB;

◦breaker status in MAN mode; ◦

◦removed all ECU types with Modbus; ◦

◦removed “Baud rate and Modbus slave ID” parameters; ◦

◦parameter naming change: in order to align with ToolKit, ◦

changed “Current” to “Limit” and “Low fuel level” to “Fuel

level warning” in HMI parameter config screen;

•Fixed the following in ToolKit-SC

Rev. Date Editor Changes

◦fixed the version name of 2 digits displayed on ToolKit to 4 ◦

digits;

◦removed WWDMODEM-3G related parameters; ◦

◦removed “emergency stop input”; ◦

◦removed “Baud rate and Modbus slave ID”parameters; ◦

◦removed all ECU types with Modbus. ◦

A 2018-11 PC Describes device implemented software version 1.8 and

ToolKit-SC version 1.4.0.2

Additional markings

To highlight instructions, results, lists, references, and other elements, the following

markings are used in these instructions:

Marking Explanation

__▶ Step-by-step instructions

⇨ Results of action steps

╚═▷ References to sections of these instructions and to other

relevant documents

• Listing without fixed sequence

»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

the HMI screen or ToolKit located as described here.

Some parameters/settings/screens are available only

either in ToolKit or on the HMI/display

1.2 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 modifications •

•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

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

1.3

Service And Warranty

Opening the device will nullify any warranty

Any such unauthorized modifications

• constitute “misuse” and/or “negligence” as per the product warranty

• thereby exclude warranty coverage for any resulting damage, and

• invalidate product certifications or listings.

Our Customer Service is available for technical information. Please see page 2 for contact

details.

In addition, our employees are interested in any new information and experiences that

arise from usage and could be valuable for improving our products.

1.4

1.4.1

Safety

Intended Use

The easYgen unit has been designed and constructed solely for the intended use

described in this Operation Manual and – with even more details – in the Technical

Manual.

• Intended use requires operation of the control unit within the range outlined in the

written specifications.

Steps to be taken for commissioning are outlined in the Technical Manual. •

• Intended use includes compliance with all instructions and safety notes presented in •

this manual.

•Any use which exceeds or differs from the intended use shall be considered improper •

use.

•No claims for any kind for damage will be considered if such claims result from •

improper use.

1.4.2 Personnel

This manual specifies the personnel qualifications required for the different areas of work,

listed below:

•Well trained for electrical installations. •

•Aware of the local safety regulations. •

•Experienced in working with electronic measuring and control devices. •

•Allowed to manage the controlled (engine/generator) system. •

The workforce must only consist of persons who can be expected to carry out their work

reliably. Persons with impaired reactions due to, for example, the consumption of drugs,

alcohol, or medication are prohibited.

When selecting personnel, the age-related and occupation-related regulations governing

the operating location must be observed

System Overview

General notes

The easYgen is a stand-alone genset controller with measuring, monitoring, and breaker

control functionality. It comes with an easily mountable plastic housing covering a

thoroughly tested electronic-electrical system.

Display and buttons of the HMI offer access to states and values, as well as access to the

application. Password protection enables the assignment of multiple operation access

levels. Remote access, monitoring, visualization, and configuration are possible via

integrated interfaces. Communication between easYgens using PLC control or as a

network member offers an enhanced system management range; additionally supported

by easy to implement accessories

2.1

2.2

HMI Status Screens

HMI displays the following status screens:

•

• Status (home)

•

• Generator

•

• Load

•

• Engine 1

•

• Engine 2

•

• Status

•

• Alarm

•

• home screen etc.

 

ToolKit-SC Status Screens

General notes

ToolKit-SC lets you access status information via the following screens

Items Parameters Description

Engine info Engine speed, Battery volt, Charger volt D+

Sensor info Engine temp, Oil pressure, Fuel level Selection of ECU

data via J1939.

More info Coolant pressure, Coolant level,Fuel pressure, Fuel

temp, Turbo pressure, Oil temp, Inlet temp, Fuel

consume, Exhaust temp, Total consume

Alarms Current Alarms and Warning Lists of current

alarms and

warnings

(Digital )Inputs 01 High temperature shutdown, 02 Low oil pressure

shutdown, 10 Start request in AUTO, 11 Fuel level

warning, 12 Coolant level warning

(Digital) Outputs 02 Stop solenoid, 03 Idle control, 05 Close GCB, 06

Fuel relay, Start relay

Accumulation (run) Time, Starts

Next maintenance

time

Time

Engine hours Time

Generator status Gen status

Module info will be moved to Event log page

Items Parameters Description

Electricity quantity

Mains-/

Generator L1. L2. L3. L1-2. L2-3. L3-1. L1Phase, L2Phase, L3Phase, Frequency

Current (A) L1. L2. L3

Active power (kW) L1. L2. L3. Total

Reactive power (kvar) L1. L2. L3. Total

Apparent power (kVA) L1. L2. L3. Total

Power factor L1. L2. L3. Avg

Ext. Analog Inputs

[PARAMETER / STATUS MENU / Ext. analog inputs]

Items Parameters Description

Expansion AIN24 {X} {X}: 1 or 2

Cylinder Temp {Y} (in °C and °F) {Y}: 1 or 22

Exhaust Temp {Z} (in °C and °F) {Z}: 1 or 2

Sensor {N} {N}: 15 or 24

Event Log and Version

[PARAMETER / STATUS MENU / Event log and version]

Items Parameters Description

Module Info Model, Hardware Version, Software Version, Issue Date

Event log Fixed view of:

No., Event type

Columns “move behind” visible part of the screen:

Event Item, Date, Time,

((Mains control is not supported by this model, so all “Mains” values

are”0″:))

Mains Uab (V) / Ubc (V) / Uca (V), Mains Ua (V), Mains Ub (V), Mains

Uc (V), Mains f (Hz),

Gens Uab (V) …, Gens Ua (V) …, Gens f(Hz),

Current Ia (A) …,

Power (kW),

Speed (r/min),

Temp. (°C),

Press. (kPa),

Volt. (V)

Event log report

table. Showss the

99 latest events

Icons Keys Description

STOP Auto/Manual mode: Stops running generator

Stop mode: Resets alarm

Lamp test (press at least 3 seconds)

Notes

During stopping process, press this button again to stop generator

immediately.

I (START) MANual mode: Start genset

MAN (Manual Mode) Press this key and the controller enters into MAN mode

AUTO (Automatic Mode) Press this key and the controller enters into AUTO mode

Open/Close breaker Release breaker control in MAN mode.

The navigation button “Up/Increase” is used to close the GCB

3.2.1

3.3

Alarm Acknowledgment

General notes

The alarm acknowledge handling is valid for following alarm classes

•

• Shutdown

•

• Trip/Stop

•

• Trip

Mute Horn

Any new active alarm activates the horn and is made visible by the flashing Alarm LED.

After pressing the “Down/Decrease” button, the horn is deactivated and the Alarm LED

changes from flashing to constantly active and stays active as long as any alarm is

present. An additional active alarm reactivates the horn and the Alarm LED starts flashing

again.

Stop by alarm

The operation mode automatically changes to STOP if a stopping alarm is active

(»Shutdown« or »Trip/Stop«).

Acknowledge alarm

In case of alarm condition, pressing the STOP button will reset the alarm.

Operation Modes

General notes

The easYgen offers three operation modes:

•

• AUTO

•

• MANUAL (MAN)

•

• STOP

•

• … and an internal (non) operating phase during the start of the device itself

The operation mode can be initiated – provided the current settings allow for this

function:

•

• directly by pressing the respective button on the front panel

•

• directly by click on the respective button on the ToolKit-SC remote screen

•

• via discrete inputs

•

• via interface

3.3.1

General notes

In operation mode AUTO, both genset and breaker are under easYgen control. The start

and stopping of the engine is managed automatically, along with opening/closing the

breaker.

•

• supply load by generator

•

• start the engine

•

• stop the engine

3.3.2

Operation Mode MANual

General notes

In operation mode MANual, both genset and breakers are independent of each other

under easYgen control.

The starting and stopping of the engine are managed using the same procedure as in

AUTO mode but without breaker control. Breakers can be opened and closed without

taking care of load or genset state!

3.3.3

Operation Mode STOP

General notes

In operation mode STOP, the breaker is open and the engine is not running.

3.4

3.4.1

START/STOP Operation

Start engine to supply load

The AUTO Start procedure is going through sub procedures with own timers

3.5

Pressing

can stop the running generator as described above.

Transition Procedures

3.5.1

Disconnect during cranking

There are three conditions under control to abort the starting of the engine:

•

• speed sensor

•

• generator frequency

•

• engine oil pressure

They can be used separately or in combinations.

We recommend selecting all three at the same time: engine oil pressure together with

speed sensor, and generator frequency. This allows for an immediate separation of the

starter motor from the engine. Additionally, crank disconnect can be checked exactly.

When set to speed sensor, ensure that the number of flywheel teeth is the same as

setting.

5 Glossary and List of Abbreviations

CB Circuit Breaker

CT Current Transformer

DI Discrete Input

DO Discrete (Relay) Output

ECU Engine Control Unit

FMI Failure Mode Indicator

GCB Generator Circuit Breaker

GOV (speed) Governor; rpm regulator

HMI Human Machine Interface e.g., a front panel with display and

buttons for interaction

I Current

MCB Mains Circuit Breaker

MPU Magnetic Pickup Unit

N.C. Normally Closed (break) contact

N.O. Normally Open (make) contact

NC Neutral Contactor

OC Occurrence Count

Operation In (general) operation.

State when the genset is running according to the selected

mode, all parameters are in allowed values and ranges, and

without OPEN requests or alarms. Somehow “waiting for next

occurrence”.

P Real power

P/N Part Number

PF Power Factor

PT Potential (Voltage) Transformer

Q Reactive power

S Apparent power

S/N Serial Number

SPN Suspect Parameter Number

V Voltage

 

Index

A

Alarms

Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  25█

Shutdown Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  26█

C

Contact person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9█

Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9█

F

Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  12█

I

Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9█

K

Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  16█

O

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  16█

Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  18█

P

Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10█

S

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9█

Symbols

in the instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7█

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  12█

29 easYgen-400 B37890A

Index

Released

T

Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  24█

U

Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9█

W

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  25█

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .