Woodward easYgen-3000 Installation Manual
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Woodward easYgen-3000 Installation Manual

Genset control
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37223A
easYgen-3000
Genset Control
Installation
Software Version 1.xxxx
Manual 37223A

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Summary of Contents for Woodward easYgen-3000

  • Page 1 37223A easYgen-3000 Genset Control Installation Software Version 1.xxxx Manual 37223A...
  • Page 2 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.

  • Page 3: Table Of Contents

    Manual 37223A easYgen-3000 Series - Genset Control Revision History Rev. Date Editor Changes NEW 06-11-23 Release 07-06-29 Minor corrections Content 1. G ..................7 HAPTER ENERAL NFORMATION 2. E .............8 HAPTER LECTROSTATIC ISCHARGE WARENESS 3. H .......................9 HAPTER OUSING Panel Cutout ............................9 Dimensions ............................10...
  • Page 4 Manual 37223A easYgen-3000 Series - Genset Control 8. A ......................51 HAPTER CCURACY A. U ..................52 PPENDIX SEFUL NFORMATION Suitable D-SUB Connector Housings....................52 CAN Bus Pin Assignments of Third-Party Units................... 52 D-SUB DE9 Connector....................... 52 RJ45/8P8C Connector ....................... 53 IDC / Header Connector......................
  • Page 5 Figures and Tables Figures Figure 3-1: Housing - panel-board cutout ..........................9 Figure 3-2: Housing easYgen-3000 - dimensions ........................10 Figure 3-3: easYgen-3200 - terminal arrangement - rear view ....................11 Figure 3-4: Housing - drill plan ............................... 13 Figure 4-1: Wiring diagram – overview........................... 14 Figure 5-1: Power supply.................................
  • Page 6 Manual 37223A easYgen-3000 Series - Genset Control Tables Table 1-1: Manual - overview..............................7 Table 3-1: Housing - panel cutout ............................. 9 Table 5-1: Conversion chart - wire size ........................... 16 Table 5-2: Power supply - terminal assignment........................17 Table 5-3: Charging alternator input/output - terminal assignment ..................18 Table 5-4: Voltage measuring (FlexRange) - terminal assignment - generator voltage............

  • Page 7: Chapter 1. General Information

    Manual 37223A easYgen-3000 Series - Genset Control Chapter 1. General Information Type English German easYgen-3000 Series easYgen-3000 - Installation this manual 37223 GR37223 easYgen-3000 - Configuration 37224 easYgen-3000 - Operation 37225 GR37225 easYgen-3000 - Application 37226 easYgen-3000 - Interfaces 37383 Table 1-1: Manual - overview Intended Use The unit must only be operated in the manner described by this manual.

  • Page 8: Chapter 2. Electrostatic Discharge Awareness

    CAUTION To prevent damage to electronic components caused by improper handling, read and observe the pre- cautions in Woodward manual 82715, Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules. NOTE The unit is capable to withstand an electrostatic powder coating process with a voltage of up to 85 kV and a current of up to 40 µA.

  • Page 9: Chapter 3. Housing

    Manual 37223A easYgen-3000 Series - Genset Control Chapter 3. Housing Panel Cutout ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ h' h H Figure 3-1: Housing - panel-board cutout Measure Description Tolerance Height Total 217 mm Panel cutout 183 mm + 1.0 mm Housing dimension 181 mm...

  • Page 10: Dimensions

    Manual 37223A easYgen-3000 Series - Genset Control Dimensions ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ 217 mm 181 mm 282 mm 247 mm 87 mm 99 mm Figure 3-2: Housing easYgen-3000 - dimensions Page 10/54 © Woodward...

  • Page 11: Terminal Arrangement

    Manual 37223A easYgen-3000 Series - Genset Control Terminal Arrangement ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 Discrete Inputs Relay Outputs Generator CT Analog Inputs Analog Outputs...

  • Page 12: Clamp Fastener Installation

    Manual 37223A easYgen-3000 Series - Genset Control Clamp Fastener Installation ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ For installation into a door panel with the fastening clamps, proceed as follows: Panel cut-out Cut out the panel according to the dimensions in Table 3-1. cut-out 138,0 Note: Don't drill the holes if you want to use the clamp fasteners.

  • Page 13: Screw Kit Installation

    Manual 37223A easYgen-3000 Series - Genset Control Screw Kit Installation ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ NOTE Don't drill the holes if you want to use the clamp fasteners. If the holes are drilled into the panel, the clamp fasteners cannot be used anymore! In order to enhance the protection to IP 66, it is possible to fasten the unit with a screw kit instead of the clamp fastener hardware.

  • Page 14: Chapter 4. Wiring Diagrams

    Manual 37223A easYgen-3000 Series - Genset Control Chapter 4. Wiring Diagrams [refer to next page for wiring diagram] Figure 4-1: Wiring diagram – overview Page 14/54 © Woodward...
  • Page 15 2: CAN-L Interface #3 Interface #4 3: GND 3: GND CAN bus #1 CAN bus #2 7: CAN-H 7: CAN-H Engine level (isolated) Guidance/system level (isolated) Subject to technical mocifications. 2007-06-28 | easYgen-3000 Wiring Diagram eYg3000ww-2607-ap.SKF © Woodward Page 15/54...

  • Page 16: Chapter 5. Connections

    Manual 37223A easYgen-3000 Series - Genset Control Chapter 5. Connections WARNING All technical data and ratings indicated in this chapter are not definite! Only the values indicated in Chapter 6: Technical Data on page 47 are valid! The following chart may be used to convert square millimeters [mm²] to AWG and vice versa: mm²...

  • Page 17: Power Supply

    [ms] Figure 5-2: Power supply - crank waveform at maximum load NOTE Woodward recommends to use one of the following slow-acting protective devices in the supply line to terminal 63: • Fuse NEOZED D01 6A or equivalent • Miniature Circuit Breaker 6A / Type C (for example: ABB type: S271C6 or equivalent) ©...

  • Page 18: Charging Alternator

    Manual 37223A easYgen-3000 Series - Genset Control Charging Alternator ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ 8 to 40 Vdc Auxiliary excitation Figure 5-3: Charging alternator input/output Terminal Description Battery B+ 2.5 mm² Auxiliary excitation output D+ 2.5 mm² Table 5-3: Charging alternator input/output - terminal assignment...

  • Page 19: Voltage Measuring (Flexrange)

    DO NOT use both sets of voltage measuring inputs. The control unit will not measure voltage correctly if the 100 V and 400 V inputs are utilized simultaneously. NOTE Woodward recommends protecting the voltage measuring inputs with slow-acting fuses rated for 2 to 6 A. Voltage Measuring: Generator...

  • Page 20: Figure 5-5: Voltage Measuring (Flexrange) -Generator, 3Ph 4W

    Manual 37223A easYgen-3000 Series - Genset Control Voltage Measuring: Generator, Parameter Setting '3Ph 4W' (3-phase, 4-wire) Figure 5-5: Voltage measuring (FlexRange) -generator, 3Ph 4W Wiring terminals Note 3Ph 4W Rated voltage (range) 100 Vac (50 to 130 V) 400 Vac (131 to 480 V) Measuring range (max.)

  • Page 21: Figure 5-6: Voltage Measuring (Flexrange) - Generator, 3Ph 3W

    Manual 37223A easYgen-3000 Series - Genset Control Voltage Measuring: Generator, Parameter Setting '3Ph 3W' (3-phase, 3-wire) Figure 5-6: Voltage measuring (FlexRange) - generator, 3Ph 3W Wiring terminals Note 3Ph 3W Rated voltage (range) 100 Vac (50 to 130 V) 400 Vac (131 to 480 V) Measuring range (max.)

  • Page 22: Figure 5-8: Voltage Measuring (Flexrange) - Generator, 1Ph 2W (Phase-Neutral)

    Manual 37223A easYgen-3000 Series - Genset Control Voltage Measuring: Generator, Parameter Setting '1Ph 2W' (1-phase, 2-wire) NOTE The 1-phase, 2-wire measurement may be performed phase-neutral or phase-phase. Please note to configure and wire the easYgen consistently. Refer to the Configuration Manual 37224 for more infor- mation.

  • Page 23: Voltage Measuring: Mains

    Manual 37223A easYgen-3000 Series - Genset Control Voltage Measuring: Mains 100 Vac 100 Vac L1 / Va 400 Vac 400 Vac 100 Vac 100 Vac L2 / Vb 400 Vac 400 Vac 100 Vac 100 Vac L3 / Vc 400 Vac...

  • Page 24: Figure 5-11: Voltage Measuring (Flexrange) - Mains, 3Ph 4W

    Manual 37223A easYgen-3000 Series - Genset Control Voltage Measuring: Mains, Parameter Setting '3Ph 4W' (3-phase, 4-wire) Figure 5-11: Voltage measuring (FlexRange) - mains, 3Ph 4W Wiring terminals Note 3Ph 4W Rated voltage (range) 100 Vac (50 to 130 V) 400 Vac (131 to 480 V) Measuring range (max.)

  • Page 25: Figure 5-12: Voltage Measuring (Flexrange) - Mains, 3Ph 3W

    Manual 37223A easYgen-3000 Series - Genset Control Voltage Measuring: Mains, Parameter Setting '3Ph 3W' (3-phase, 3-wire) Figure 5-12: Voltage measuring (FlexRange) - mains, 3Ph 3W Wiring terminals Note 3Ph 3W Rated voltage (range) 100 Vac (50 to 130 V) 400 Vac (131 to 480 V) Measuring range (max.)

  • Page 26: Figure 5-14: Voltage Measuring (Flexrange) - Mains, 1Ph 2W (Phase-Neutral)

    Manual 37223A easYgen-3000 Series - Genset Control Voltage Measuring: Mains, Parameter Setting '1Ph 2W' (1-phase, 2-wire) NOTE The 1-phase, 2-wire measurement may be performed phase-neutral or phase-phase. Please note to configure and wire the easYgen consistently. Refer to the Configuration Manual 37224 for more infor- mation.

  • Page 27: Voltage Measuring: Busbar (System 1) 1Ph 2W

    Manual 37223A easYgen-3000 Series - Genset Control Voltage Measuring: Busbar (System 1) 1Ph 2W 100 Vac 100 Vac 400 Vac 400 Vac 100 Vac 100 Vac 400 Vac 400 Vac Figure 5-16: Voltage measuring (FlexRange) - busbar (system 1) 1Ph 2W (phase-phase)

  • Page 28: Figure 5-17: Voltage Measuring (Flexrange) - Busbar, 1Ph 2W (Phase-Neutral)

    Manual 37223A easYgen-3000 Series - Genset Control Voltage Measuring: Busbar (System 1), Parameter Setting '1Ph 2W' (1-phase, 2-wire) NOTE The 1-phase, 2-wire measurement may be performed phase-neutral or phase-phase. Please note to configure and wire the easYgen consistently. Refer to the Configuration Manual 37224 for more infor- mation.

  • Page 29: Current Measuring

    Manual 37223A easYgen-3000 Series - Genset Control Current Measuring ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ CAUTION Before disconnecting the device, ensure that the current transformer/CT is short-circuited. Generator Current NOTE Generally, one line of the current transformers secondary is to be grounded close to the CT.

  • Page 30: Figure 5-20: Current Measuring - Generator, L1 L2 L3

    Manual 37223A easYgen-3000 Series - Genset Control Current Measuring: Generator, Parameter Setting 'L1 L2 Gen L1 Gen L2 Gen L3 Figure 5-20: Current measuring - generator, L1 L2 L3 Wiring terminals Notes L1 L2 L3 easYgen Phase s1 (k) L1...

  • Page 31: Mains Current 1-Phase

    Manual 37223A easYgen-3000 Series - Genset Control Mains Current 1-Phase NOTE Generally, one line of the current transformers secondary is to be grounded close to the PT. Detail: Connection of the transducers ../{x} A {x} = 1 or 5 s1 (k)

  • Page 32: Ground Current

    Manual 37223A easYgen-3000 Series - Genset Control Ground Current The mains current input can be configured to measure the mains current or ground current. Depending on how Parameter 'Input mains current as' is configured will determine if this input will measure the mains current (de- fault) or the ground current.

  • Page 33: Power Measuring

    Manual 37223A easYgen-3000 Series - Genset Control Power Measuring ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ If the unit's current transformers are wired according to the diagram shown, the following values are displayed. Parameter Description Sign displayed Generator real power Genset generating kW + Positive Generator real power...
  • Page 34 Manual 37223A easYgen-3000 Series - Genset Control Different power factor displays at the unit: i0.91 (inductive) c0.93 (capacitive) lg.91 (lagging) ld.93 (leading) Reactive power display at the unit: 70 kvar (positive) -60 kvar (negative) Output at the interface: + (positive)

  • Page 35: Mpu (Pickup)

    Manual 37223A easYgen-3000 Series - Genset Control MPU (Pickup) ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Rotating shaft Sensor Pickup input Figure 5-26: MPU - principle overview Shield 24 V MPU input (pickup) < 1,0 V Figure 5-27: MPU input Terminal Description MPU input - inductive/switching 2.5 mm²...

  • Page 36: Discrete Inputs

    Manual 37223A easYgen-3000 Series - Genset Control Discrete Inputs ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Discrete Inputs: Signal Polarity The discrete inputs are electrically isolated which permits the polarity of the connections to be either positive or negative. NOTE All discrete inputs must use the same polarity, either positive or negative signals, due to the common ground.

  • Page 37: Figure 5-30: Discrete Inputs - Alarm/Control Input - Negative Signal

    Manual 37223A easYgen-3000 Series - Genset Control Discrete Inputs: Negative Polarity Signal Power supply + (8 to 40 Vdc) Discrete input 1 Power supply - Discrete input 2 Power supply - Discrete input 3 Power supply - Discrete input 4...

  • Page 38: Discrete Inputs: Operation Logic

    Manual 37223A easYgen-3000 Series - Genset Control Discrete Inputs: Operation Logic Discrete inputs may be configured to normally open (N.O.) or normally closed (N.C.) states. In the state N.O., no potential is present during normal operation; if an alarm is issued or control operation is performed, the input is energized.

  • Page 39: Relay Outputs (Logicsmanager)

    Manual 37223A easYgen-3000 Series - Genset Control Relay Outputs (LogicsManager) ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ max. 250 Vac/dc Relay output external device Figure 5-32: Relay outputs Terminal Description Term. Com. Type Form A, N.O. make contact Ready for operation & Relay output [R 01] 2.5 mm²...

  • Page 40: Analog Inputs (Flexin)

    Manual 37223A easYgen-3000 Series - Genset Control Analog Inputs (FlexIn) ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ It is recommended to use two-pole analog senders. This ensures an accuracy of ≤ 1% for 0 to 500 Ohm inputs and ≤ 1.2% for 0 to 20 mA inputs.

  • Page 41: Wiring Single-Pole Senders

    Manual 37223A easYgen-3000 Series - Genset Control Wiring Single-Pole Senders An accuracy of ≤ 2.5% may be achieved when using single-pole senders. The specified accuracy of 2.5% for ≤ single-pole sensors can only be achieved if the differential voltage between the genset chassis ground and PE does not exceed +/- 2.5V.

  • Page 42: Wiring Single And Two-Pole Senders Simultaneously

    Manual 37223A easYgen-3000 Series - Genset Control Wiring Single and Two-Pole Senders Simultaneously An accuracy of ≤ 2.5% may be achieved when using single-pole senders. It is possible to combine single- and two-pole senders. The specified accuracy of 2.5% for single-pole sensors can only be achieved if the differen- ≤...

  • Page 43: Analog Outputs

    Manual 37223A easYgen-3000 Series - Genset Control Analog Outputs ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Controller configuration and an external jumper can change the multifunction controller bias output signals. Controller Wiring Speed / power controller Speed / power controller Speed / power controller Figure 5-36: Analog controller output - Wiring and external jumper setting...

  • Page 44: Interfaces

    Manual 37223A easYgen-3000 Series - Genset Control Interfaces ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ RS-485 Serial Interfaces RS-485 Serial Interface #1 (Serial Interface #2, Interface #2) Figure 5-37: RS-485 interface #1 - overview Terminal Description not connected not connected not connected not connected not connected...

  • Page 45: Rs-232 Serial Interface (Serial Interface #1, Interface #1)

    Manual 37223A easYgen-3000 Series - Genset Control RS-232 Serial Interface (Serial Interface #1, Interface #1) Figure 5-40: RS-232 interface - overview Terminal Description not connected RxD (receive data) TxD (transmit data) not connected GND (system ground) not connected RTS (request to send)

  • Page 46: Figure 5-43: Interfaces - Can Bus - Termination

    • The configured baud rate is to high for wiring length • The CAN bus cable is routed in close proximity with power cables Woodward recommends the use of shielded, twisted-pair cables for the CAN bus (i.e.: Lappkabel Unitronic LIYCY (TP) 2×2×0.25, UNITRONIC-Bus LD 2×2×0.22).

  • Page 47: Chapter 6. Technical Data

    Manual 37223A easYgen-3000 Series - Genset Control Chapter 6. Technical Data Nameplate ----------------------------------------------------------------------------------------------------- Serial number (numerical) Date of production (YYMM) Serial number (Barcode) Item number Item revision number Details Technical data Type Description (long) Type Description (short) Approval Approvals Measuring values, voltages ----------------------------------------------------------------------------- /Δ...
  • Page 48 Manual 37223A easYgen-3000 Series - Genset Control Discrete inputs ---------------------------------------------------------------------------------------isolated Input range (V )........Rated voltage 12/24 Vdc (8 to 40.0 Vdc) Cont, digital input Input resistance ....................approx. 20 kΩ Relay outputs ---------------------------------------------------------------------------------potential free Contact material ......................AgCdO General purpose (GP) (V Cont, relay output AC ...........2.00 Aac@250 Vac...
  • Page 49 Manual 37223A easYgen-3000 Series - Genset Control Interface -------------------------------------------------------------------------------------------------------- RS-232 interface ....................isolated Insulation voltage ....................1,000 Vdc Version ...................... RS-232 Standard Signal level ........................5V RS-485 interface ....................isolated Insulation voltage ....................1,000 Vdc Version ...................... RS-485 Standard Signal level ........................5V CAN bus interface ....................isolated Insulation voltage ....................1,500 Vdc...

  • Page 50: Chapter 7. Environmental Data

    Manual 37223A easYgen-3000 Series - Genset Control Chapter 7. Environmental Data Vibration -------------------------------------------------------------------------------------------------------- Frequency Range – Sine Sweep..............5Hz to 100Hz Acceleration ......................4G Frequency Range - Random................10Hz to 500Hz Power Intensity..................0.015G²/Hz RMS Value....................1.04 Grms Standards..........................EN 60255-21-1 (EN 60068-2-6, Fc) EN 60255-21-3 Lloyd’s Register, Vibration Test2...

  • Page 51: Chapter 8. Accuracy

    Manual 37223A easYgen-3000 Series - Genset Control Chapter 8. Accuracy Measuring value Display Accuracy Notes Frequency Generator 15.0 to 85.0 Hz 0.1 % Mains 40.0 to 85.0 Hz 0.1 % Voltage Generator 0 to 650 kV Transformer ratio selectable Mains...

  • Page 52: Appendix A. Useful Information

    Manual 37223A easYgen-3000 Series - Genset Control Appendix A. Useful Information Suitable D-SUB Connector Housings ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Some housings for D-Sub connectors are to wide to plug them into the unit properly. If your serial or CAN bus cable is equipped with a housing, which does not fit into the easYgen socket, you may replace the housing with...

  • Page 53: Rj45/8P8C Connector

    Manual 37223A easYgen-3000 Series - Genset Control RJ45/8P8C Connector male / plug female / socket Figure 8-2: CAN bus pin assignment - RJ45/8P8C connector Terminal Signal Description CAN_H CAN bus line (dominant high) CAN_L CAN bus line (dominant low) CAN_GND...
  • Page 54 Phone +49 (0) 711 789 54-0 • Fax +49 (0) 711 789 54-100 sales-stuttgart@woodward.com Homepage http://www.woodward.com/power 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).

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