Woodward easYgen-800 Manual
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Woodward easYgen-800 Manual

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easYgen-800
Manual
Genset Control
easYgen-800
37691A

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  • Page 1 Manual Genset Control easYgen-800 37691A...
  • Page 2 This is no translation but the original Technical Manual in English. Designed in Germany and Poland; manufactured in China. Woodward GmbH Handwerkstrasse 29 70565 Stuttgart Germany Telephone: +49 (0) 711 789 54-510 Fax: +49 (0) 711 789 54-101 E-mail: stgt-info@woodward.com Internet: http://www.woodward.com © 2018 easYgen-800 | Genset Control 37691A...
  • Page 3 ETHERNET interface connector (RJ-45) 12 SD micro card slot Terminals 56 to 61: Analog inputs The easYgen-800 are control units for engine-generator system management applications. The control units can be used in applications such as: co-genera‐ tion, stand-by, AMF or distributed generation.
  • Page 4 In this case, the easYgen will function as an engine control with generator and engine protection. The control unit can open and close the circuit breaker . Transition procedures are described in chapter Ä Chapter 5.5 “Transition Procedures” on page 99. easYgen-800 | Genset Control 37691A...

  • Page 5: Table Of Contents

    2.2.1 Operation Mode AUTO......................16 2.2.2 Operation Mode MANual......................16 2.2.3 Operation Mode STOP......................17 Features and Functions of both easYgen-800 and -1800............17 Functions........................... 19 Intended Use of This Control..................... 20 Installation..........................21 Mounting............................ 21 Wiring............................21 Interfaces........................... 26 3.3.1...
  • Page 6 4.4.3.2 Digital Output Module WWDOUT16..................87 Operation..........................91 Front Panel: Operating and Display Elements................91 Warning/Alarm Signaling......................93 5.2.1 Alarm Acknowledgment......................93 Operation Modes........................94 5.3.1 Operation Mode AUTO......................94 5.3.2 Operation Mode MANual......................94 easYgen-800 | Genset Control 37691A...
  • Page 7 9.3.1.8 Error Handling......................... 124 9.3.2 Read Holding Registers 03_hex....................125 9.3.3 Force Single Coil 05H_hex...................... 147 9.3.4 Preset Single Register 06H_hex..................... 148 9.3.4.1 Generator Status........................148 9.3.4.2 Remote Start Status........................ 148 9.3.4.3 Breaker Status......................... 149 37691A easYgen-800 | Genset Control...
  • Page 8 Table of contents Glossary And List Of Abbreviations..................151 Index............................153 easYgen-800 | Genset Control 37691A...

  • Page 9: General Information

    This symbol indicates useful tips and recommen‐ dations as well as information for efficient and trouble-free operation. Additional markings To emphasize instructions, results, lists, references, and other ele‐ ments, the following markings are used in these instructions: 37691A easYgen-800 | Genset Control...

  • Page 10: General Information

    Woodward assumes no liability for dam‐ ages due to: Failure to comply with the instructions in this manual...

  • Page 11: Service And Warranty

    Intended use requires operation of the control unit within the written specifications. All permissible applications are outlined in Ä Chapter 6 “Appli‐ cation” on page 101 . Intended use includes compliance with all instructions and safety notes presented in this manual. 37691A easYgen-800 | Genset Control...

  • Page 12: Personnel

    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 usage location must be observed. easYgen-800 | Genset Control 37691A...

  • Page 13: General Safety Notes

    37691A easYgen-800 | Genset Control...
  • Page 14 General Information General Information > Safety > General Safety Notes easYgen-800 | Genset Control 37691A...

  • Page 15: System Overview

    For even higher challenges in genset control the easYgen series offers further solutions up to the most complex and ambitious applications. For dedicated protection tasks ask Woodward for its protection (relay) solutions. Display and Status Indicators General Notes HMI and the configuration software enable access to control, set‐...

  • Page 16: Operation Modes

    Depending on settings and application status, AUTO control can: supply load by generator start the engine stop the engine 2.2.2 Operation Mode MANual General notes In operation mode MANual both genset and breakers are inde‐ pendently from each other under easYgen control. easYgen-800 | Genset Control 37691A...

  • Page 17: Operation Mode Stop

    The easYgen-1800 is the device with more/higher functionality. For comparison and better differentiation both are described below. easYgen-800 is intended to be used for single automation sys‐ tems, auto start/stop of the unit are performed with the help of remote signal.
  • Page 18 ) Phase voltage (U , and U ) Phase voltage (U , and U easYgen-800 only: Collects and shows 3-phase voltage, cur‐ rent, power parameter and frequency of generator. Generator Line voltage (U , and U ) Line voltage (U...

  • Page 19: Functions

    Logon wallpaper and display time are user-defined Can be used on pumping units and as an indicating instrument (indicate and alarm are enable only, relay is inhibited) Maintenance function: Actions (warning or shutdown) can be set when maintenance time out 37691A easYgen-800 | Genset Control...

  • Page 20: Intended Use Of This Control

    B. User can reset it as 0 and re-accumulative the value which allows to count the total value user defined. Intended Use of This Control easYgen-800 genset controllers are used for genset automation and monitor control system of single unit to achieve...

  • Page 21: Installation

    Use clips included in delivery. Tighten strong but not with brute force to get best IP protection result! Fig. 4: easYgen-800/1800 cut-out Wiring General Notes Battery Voltage Input...
  • Page 22 WARNING! If there is a load current, open circuit of transform‐ er’s secondary side is not allowed! CAUTION! Withstand Voltage Test Disconnect all terminal connections before high voltage test of the installed controller. easYgen-800 | Genset Control 37691A...
  • Page 23 Installation Wiring Terminals Fig. 5: easYgen-800 Terminals Function Cable Size Remarks POWER SUPPLY + Connected with negative of starter battery 2.5 mm POWER SUPPLY - Connected with positive of starter battery. If wire length is over 30m, better to 2.5 mm double wires in parallel.
  • Page 24 1.5 mm 1.5 mm DI 08 Ground connected is active (B-). 1.0 mm Details see form 3. AI 05 Connected to temperature, oil pressure or level Details see 1.0 mm sensors AI 04 1.0 mm easYgen-800 | Genset Control 37691A...
  • Page 25 Connected to fuel level sensor 1.0 mm COMMON Common terminal of sensor, (B-) has already connected RS232 (GSM) Connected to GSM module 0.5 mm 0.5 mm 0.5 mm Wiring typical applications Fig. 6: easYgen-800 wiring of a typical application 37691A easYgen-800 | Genset Control...

  • Page 26: Interfaces

    For Ethernet network communication Micro SD card (slot) To store event logs 3.3.1 Ethernet Interface Connection Ethernet Port Terminals The terminals are: Name Description Transmit Data+ Transceiver Data- Receive Data+ Not connected Not connected Receive Data- easYgen-800 | Genset Control 37691A...

  • Page 27: Micro Sd Card Slot

    ToolKit-SC for the connected device with the SD card inside. At present the controllers support ≤ 8 GB Micro SD card. Location of the SD card: see Enabling SD card usage: see Ä Chapter 4.2.6 “Configure Interfaces” on page 59 37691A easYgen-800 | Genset Control...

  • Page 28: Install Toolkit-Sc

    ToolKit-SC is a software tool for configuration including configura‐ tion file management, monitoring, remote control, and custom lan‐ guage management. The ToolKit-SC.exe file is available via down‐ load from Woodward web page and device specific download web page. Please follow installation instruction.

  • Page 29: Configuration

    USB connected PC/laptop by ToolKit-SC configuration soft‐ ware (full edit) The configuration software ToolKit-SC is part of delivery and (latest edition) can be downloaded from our web site Woodward.com: search for "ToolKit-SC". Different Discrete Inputs can NOT use one and the same Input Type;...

  • Page 30: Access To The Control

    Press this key and controller enters into AUTO Mode) mode Mute "Horn"/ Press once: Alarming sound OFF Alarm acknowl‐ Second time pressing the button: edge Alarm is acknowledged Alarm LED changes from twinkling to perma‐ nently illuminated easYgen-800 | Genset Control 37691A...
  • Page 31 37691A easYgen-800 | Genset Control...

  • Page 32: Front Panel Control

    Access to the Control > Access Via The Front Panel > Front Panel Control WARNING! Passwords can be changed by user. Please clearly remember the password after changing. If you forget it, please contact Woodward services and send all device information of the controller page “ABOUT” for legitimation. 4.1.1.2...
  • Page 33 (positive and negative), reactive power (positive and negative), total reactive power (positive and negative), appa‐ rent power, total apparent power, power factor (positive and negative), average power factor (positive and negative), accumulated energy, earth current, total electric energy A and B. 37691A easYgen-800 | Genset Control...
  • Page 34 Records all start/stop events (shutdown alarm, trip and stop alarm, manual /auto start or stop) and the real time when alarm occurs. “Others” screen includes: Time and Date count down time for maintenance input/output ports status easYgen-800 | Genset Control 37691A...

  • Page 35: Configure Toolkit-Sc

    Open Config Strg+O” è “File Print the current configuration (to your default printer) with Print Config” è Configuration update between ToolKit-SC and the device (and vice versa) requests pushing the button “Read config” or “Write config” ! 37691A easYgen-800 | Genset Control...

  • Page 36: Configure Customized Language

    To write this customized language into the device - via USB con‐ “Write” (4) . To use this lan‐ nection, only - needs to push button “Other language” in menu guage data for display needs to select “PARAMETER è Configure language / clock è Language” . easYgen-800 | Genset Control 37691A...

  • Page 37: Access Via Toolkit-Sc Configuration Tool

    Accept to read device configuration ð ToolKit-SC presents the current device configuration set‐ tings and values Use the lower left area to select a screen/page to edit Work with the selected screen at (lower) right side 37691A easYgen-800 | Genset Control...

  • Page 38: Read/Write Configuration

    Fig. 12: ToolKit-SC: write configura‐ tion 4.1.3.1 Read/Write Configuration General notes Parameters 4.2.1 Parameter Menu Structure Parameter Menu Parameter presentation of both HMI (front panel access) and ToolKit-SC do not follow the same structure easYgen-800 | Genset Control 37691A...
  • Page 39 Configuration Parameters> Parameter Menu Structure Fig. 13: Menu Structure easYgen-800 - overview 37691A easYgen-800 | Genset Control...

  • Page 40: Parameter Settings Menu--Hmi Access

    ð Parameter is updated with the new setting immediately! Changing settings with ToolKit-SC needs to push “Write” button before device is updated! Editor screen is closed automatically after five minutes of inactivity! Setting is aborted immediately when pushing the “Stop” button! easYgen-800 | Genset Control 37691A...

  • Page 41: Configure Measurement

    The ratio of external CT rent Load rated current (5 to 6000) A 500 A Generator’s rated current, standard of load current Load rated active power (0 to 6000) kW 276 kW Generator’s rated power, standard of load power 37691A easYgen-800 | Genset Control...

  • Page 42: Configure Application

    ... for discrete inputs 1 to 3: (Map Programmable Input) 00 to 52 28 Start Default of discrete input 1 request in AUTO 26 High tem‐ Default of discrete input 2 perature 27 Low oil Default of discrete input 3 pressure easYgen-800 | Genset Control 37691A...
  • Page 43 ((empty with Customer specific output name ters note: Input output remark, as: Preheat)) (Adjust to logic) Output (N.O.) Output Select according to logic of the connected signal (normally open (N.O.) or normally connected) Output (N.C.) 37691A easYgen-800 | Genset Control...
  • Page 44 Ä Chapter 4.3.3 “Programmable Outputs” on page 72 for details Configure Custom Sequences & Combinations General note easYgen offers customer programmable logic "inside". Two setting types are available and described below: Engine flags Logic flags easYgen-800 | Genset Control 37691A...
  • Page 45 Outputs as logical OR and switch it ON/OFF by a third Program‐ mable Output in series. The result (Logical flag 1..6) is available as input for further control or output/relay directly: Logic Flag X = (S1 OR S2) AND S3 37691A easYgen-800 | Genset Control...
  • Page 46 Delay 0 to 3600 s The alarm status change must be valid for this period of time before it is released Engine heater control enabled/disabled disabled Notes “enabled” : The following related settings will be taken into account easYgen-800 | Genset Control 37691A...
  • Page 47 Release the alarm when sensor value is same or lower than this (14.94 psi, value and Delay time is over 1.03 bar) Delay 0 to 3600 s The alarm status change must be valid for this period of time before it is released 37691A easYgen-800 | Genset Control...
  • Page 48 Curve can be Notes curve is selected: loaded ... For fuel level curve management and customization..and/or edited (curve) Wire break alarm Warn Warn Alarm type to be released if wire break is detected Shutdown None easYgen-800 | Genset Control 37691A...
  • Page 49 The alarm status change must be valid for this period of time before it is released Items Parameters Defaults Description Displayed units Pressure Select local pressure unit for display Temperature °C °C Select local temperature unit for display °F 37691A easYgen-800 | Genset Control...
  • Page 50 Input delay 0.0 to 20.0 s 2.0 s The input status must be valid for this period of time before it is released (Description) Text field for 20 let‐ ((empty)) Customer specific sensor name ters easYgen-800 | Genset Control 37691A...

  • Page 51: Configure Engine

    Configure Start/Stop Start Attempts 1 to 10 times Max. number of crank attempts. When reaching this number, con‐ troller will send start failure signal. Start timers 37691A easYgen-800 | Genset Control...

  • Page 52: Configure Test Run

    “PARAMETER è Configure application è Configure TEST run” Items Parameters Defaults Description Scheduled run enabled/disabled disabled Notes “enabled” : The following related settings will be taken into account Run mode Off load Off load On load easYgen-800 | Genset Control 37691A...

  • Page 53: Configure Breakers

    "zero" the closing pulse acts as a steady pulse. Opening time 0.0 to 20.0 s 3.0 s Pulse width of generator switch OFF Notes This is the duration from the opening pulse for GCB as well. 37691A easYgen-800 | Genset Control...

  • Page 54: Configure Monitoring

    Release the alarm when sensor value is same or higher than this value and Delay time is over Return 0 to 200 % 108 % (54.0 Cancel the alarm when sensor value is same or lower than this value and Delay time is over easYgen-800 | Genset Control 37691A...
  • Page 55 A low value means fast reaction (short delay time); the greater the value the slower reaction because longer delay time. Enable generator phase enabled/disabled enabled rotation fail Enable generator voltage enabled/disabled enabled asymmetry 37691A easYgen-800 | Genset Control...
  • Page 56 Alarm type to be released if wire break is detected Shutdown Trip and Stop Trip Limit 0 to 200 % 110 % (303 Release the alarm when sensor value is same or higher than this value and Delay time is over easYgen-800 | Genset Control 37691A...

  • Page 57: Monitoring Breakers

    Loading speed 0 to 100 % 90 % (1350 In AUTO mode the GCB closes if the actual engine speed is r/min) higher than the configured loading speed. This function is only used if the MPU input is used. 37691A easYgen-800 | Genset Control...
  • Page 58 Time between ending of genset idle delay and stopped when delay “Stop solenoid Hold” is set as "0" or Time between ending of Stop solenoid hold delay and stopped when “Stop solenoid Hold” time is not "0". easYgen-800 | Genset Control 37691A...

  • Page 59: Other Monitoring

    The alarm status change must be valid for this period of time before it is released 4.2.6 Configure Interfaces “PARAMETER è Configure interfaces” Items Parameters Defaults Description Modbus slave ID Modbus slave ID 1 to 254 RS485 37691A easYgen-800 | Genset Control...

  • Page 60: Configure Gsm Module

    When controller detects an alarm, it will send short message to phone automatically (if enabled). All shutdown, trip and stop and trip alarms will be sent to the pre-set phone. Warnings are sent to the phone according to the settings. easYgen-800 | Genset Control 37691A...
  • Page 61 SMS INHIBIT START INHIBIT START OK Generator START will be inhibited. SMS PERMIT START PERMIT START OK Discharge the inhibit START signal. 37691A easYgen-800 | Genset Control...

  • Page 62: Configure Ethernet Interface

    The IP address must be in the same network segment as the IP address of monitoring equipment (e.g. PC). Example: Monitoring equipment IP address is 192.168.50.144, controller IP can be 192.168.50.146, sub network mask (for both) is 255.255.255.0 easYgen-800 | Genset Control 37691A...

  • Page 63: Configure Maintenance

    This Web Server mode is for visualization only - no parameter change access. With “Operate è Stop/Manual/Start/Auto” a basic remote control is accessible on the lower right corner. Fig. 22: Web Server mode 4.2.7 Configure Maintenance “PARAMETER è Configure maintenance” 37691A easYgen-800 | Genset Control...
  • Page 64 Warn Shutdown Indication Remaining time B 0 to 30000 h Select Action B No Action No Action Warn Shutdown Indication Maintenance due Display current time Overall Select Action No Action No Action Warn Shutdown Indication easYgen-800 | Genset Control 37691A...

  • Page 65: Configure Counters

    0 to 65534 hours 0 hours Preset value 0 to 59 min 0 min Preset value Set (push button) PUSH: Preset time is written to the connected easYgen Start counter 0 to 65534 Preset value: Number of starts 37691A easYgen-800 | Genset Control...

  • Page 66: Configure Switchable Parameter Set

    Description Language Simplified Chinese English With "Other" the customer specific (loaded) language (file) will be used for HMI display. English Notes Other To upload a customer specific language file, see ToolKit-SC “Language pack” menu Date/Time easYgen-800 | Genset Control 37691A...

  • Page 67: Configure System Management

    Defaults Description Mute buzzer enabled/disabled disabled Disabled: No acoustic signal with alarm/warning Activate status bar color enabled/disabled disabled HMI only: Use a contrast background color of information line area at the bottom of the display? 37691A easYgen-800 | Genset Control...
  • Page 68 Duration the user page picture is visible during device start-up. Set start-up logo Push button Push: Opens sub menu to select a picture file (480 x 27 pixels black/white) and transfer it into the device. easYgen-800 | Genset Control 37691A...

  • Page 69: Selectable Inputs/Outputs/Sensors

    15 Reserved Fuel Level Sensor 0 Not used Defined resistance range is (0 to 6) KΩ. “4 SGH sensor” . 1 Custom Res Curve Default is 2 Reserved 3 SGD 4 SGH 5 to 15 Reserved 37691A easYgen-800 | Genset Control...

  • Page 70: Programmable Inputs

    NO shutdown Shutdown alarm and shutdown immediately Trip and stop alarm generator unloads shutdown after hi-speed cooling Trip alarm generator unloads NO shutdown Release Condition Description Never input inactive Always input is active all the time easYgen-800 | Genset Control 37691A...
  • Page 71 Low oil pressure Connected sensor digital input Start request in AUTO In Auto mode, when input active, genset can be started automatically and take load after genset normal running; when input inactive, genset will stop automatically 37691A easYgen-800 | Genset Control...

  • Page 72: Programmable Outputs

    Rising edge: Decrease speed by one 4.3.3 Programmable Outputs Type Description Not Used Engine flag 1 Ä Chapter 4.2.4.1.2.3.1 “Engine Flags 1 For details please read to 6” on page 45 below. Engine flag 2 Engine flag 3 easYgen-800 | Genset Control 37691A...
  • Page 73 Action between the period from “stop idle” to “failed to stop” Stop solenoid Used for engines with ETS electromagnet. Close when stop idle is over and open when pre-set “Stop time of engine” is over 37691A easYgen-800 | Genset Control...
  • Page 74 Action when input port 4 is active Discrete input 5 active Action when input port 5 is active Discrete input 6 active Action when input port 6 is active Discrete input 7 active Action when input port 7 is active easYgen-800 | Genset Control 37691A...
  • Page 75 Gen. undervoltage shutdown Action when generator low voltage shutdown Gen. voltage asymmetry Action when generator loss phase Gen. phase rotation mismatch Action when generator reverse phase Reserved Overload Action when controller detects generator have over power 37691A easYgen-800 | Genset Control...

  • Page 76: Status Menu

    Action in Auto mode GCB closed Status message 235 to 299 Reserved Status Menu General notes Both HMI and ToolKit-SC offer status information. 4.4.1 HMI Status Screens HMI comes with status screens: Status Engine Gen(erator) Load Alarm easYgen-800 | Genset Control 37691A...

  • Page 77: Toolkit-Sc Status Screens

    1 Engine flag 1, 2 Idle control,3 Close GCB, 4 -, 5 Stop solenoid, 6 Cen‐ tralized alarm Fuel relay, Start relay Status Stop mode, Manual mode, Test mode, Auto mode, Gen available, Gen closed, Alarm indicator, Running indicator Current date and time Date (yyyy-mm-dd), Time (hh:mm:ss) 37691A easYgen-800 | Genset Control...
  • Page 78 Items Parameters Description Total A Run time, Starts, Total energy Total B Run time, Starts, Total energy SD card Status, Total capacity, Remain capacity Earth fault current Percent Next maintenance time Maintenance 1 to 3 easYgen-800 | Genset Control 37691A...

  • Page 79: Configure For Using Accessories

    Read and displayed events can be pre-selected by min and max number e.g. for better overview Read log Export to Txt List of current (selected) events can be saved as .TXT file 4.4.3 Configure For Using Accessories For configuration see Ä Chapter 4.2 “Parameters” on page 38. 37691A easYgen-800 | Genset Control...

  • Page 80: Digital Input Module Wwdin16

    Status Menu > Configure For Using Access... > Digital Input Module WWDIN... 4.4.3.1 Digital Input Module WWDIN16 General notes Fig. 25: WWDIN16 Woodward Digital Input Module (WWDIN16) is an expansion module which has 16 auxiliary digital input channels. WWDIN16 data is transmitted to the easYgen via CANBUS. 4.4.3.1.1 Technical Data...
  • Page 81 Users can set the parameters of WWDIN16 module via easYgen. Pressing and holding ENTER button for more than 3 seconds will enter the configuration menu, which allows users to set all WWDIN16 parameters, as follows: 37691A easYgen-800 | Genset Control...
  • Page 82 0 to 1 0：Close to activate WWDIN16 setting 31. Input 16 Set 0 to 50 0：Not used WWDIN16 setting 32. Input 16 Type 0 to 1 0：Close to activate WWDIN16 setting Table 2: Input Settings (easYgen) easYgen-800 | Genset Control 37691A...
  • Page 83 Override mode Places the generator into its override mode; in override mode only over‐ speed shutdown and emergency shutdown will stop the engine Emergency stop The controller shuts down the engine immediately and records occurrence time 37691A easYgen-800 | Genset Control...
  • Page 84 DC power supply negative input. 2.5 mm DC input B+ DC power supply positive input. 2.5 mm SCR (CANBUS) Connect CANbus communication port to expan‐ 0.5 mm sion CAN port of the easYgen. CAN(H) (CANBUS) 0.5 mm easYgen-800 | Genset Control 37691A...
  • Page 85 1.0 mm DIN 15 Digital input 1.0 mm DIN 16 Digital input 1.0 mm COM(B-) Connect to B- is allowed. 1.0 mm LED Indicator INPUT STATUS Active input(s): corresponding LED(s) illumi‐ nated Table 5: Terminals 37691A easYgen-800 | Genset Control...
  • Page 86 Configuration Status Menu > Configure For Using Access... > Digital Input Module WWDIN... 4.4.3.1.7 Typical Application Fig. 27: Typical application 4.4.3.1.8 DIN Rail Mounting Dimensions Fig. 28: WWDIN16A dimensions easYgen-800 | Genset Control 37691A...

  • Page 87: Digital Output Module Wwdout16

    Table 6: Troubleshooting 4.4.3.2 Digital Output Module WWDOUT16 General notes Fig. 29: WWDOUT16B Woodward Digital Output Module (WWDOUT16) is an expansion module which has 16 auxiliary digital output channels. WWDOUT16 data is transmitted via CANBUS from easYgen to WWDOUT16 output module. 4.4.3.2.1...
  • Page 88 30. Output 15 Type 0: Normally open Configurable output type. 31. Output 16 Set 0: Not used Configurable output port Function 32. Output 16 Type 0: Normally open Configurable output type. Table 8: Output Settings (easYgen) easYgen-800 | Genset Control 37691A...
  • Page 89 Voltage free output; rated current is 7 A. 1.0 mm Aux. output port 9 Voltage free output; rated current is 7 A. 1.0 mm Aux. output port 10 Voltage free output; rated current is 7 A. 1.0 mm 37691A easYgen-800 | Genset Control...
  • Page 90 Fig. 31: WWDOUT16 dimensions 4.4.3.2.5 Troubleshooting Problem Possible Solution No power indication Check controller connection wiring CANbus communication failure Check wiring No output from output port Check if output port settings are active Table 10: Troubleshooting easYgen-800 | Genset Control 37691A...

  • Page 91: Operation

    Mute "Horn"/ Press once: Alarming sound OFF Alarm acknowl‐ Second time pressing the button: edge Alarm is acknowledged Alarm LED changes from twinkling to perma‐ nently illuminated Close breaker MANual mode: Switch breaker ON/Close 37691A easYgen-800 | Genset Control...
  • Page 92 | Genset Control 37691A...

  • Page 93: Warning/Alarm Signaling

    Warning/Alarm Signaling > Alarm Acknowledgment WARNING! Passwords can be changed by user. Please clearly remember the password after changing. If you forget it, please contact Woodward services and send all device information of the controller page “ABOUT” for legitimation. Warning/Alarm Signaling The Alarm type and Warning are visualized with - combinations of - “Alarm”...

  • Page 94: Operation Modes

    5.3.3 Operation Mode STOP General notes In operation mode STOP breakers are open and engine is not run‐ ning. This is a configurable operation mode, only. This is NO emergency STOP! easYgen-800 | Genset Control 37691A...

  • Page 95: Start/Stop Operation

    The remaining time of each of the timers initiated is shown in the display. When started via “Remote Start (off Load)” input, start procedures is the same as described below but breaker close relay is deactivated. 37691A easYgen-800 | Genset Control...

  • Page 96: Stop Engine

    Operation START/STOP Operation > Stop engine Fig. 33: Engine start procedure 5.4.2 Stop engine The AUTO Stop procedure is going through sub procedures with own timers. easYgen-800 | Genset Control 37691A...
  • Page 97 The remaining time of each of the timers initiated is shown in the display. When started via “Remote Stop (off Load)” input, start procedures is the same as described below but breaker open relay is deactivated. 37691A easYgen-800 | Genset Control...
  • Page 98 Operation START/STOP Operation > Stop engine Fig. 34: Engine stop/stand-by procedure easYgen-800 | Genset Control 37691A...

  • Page 99: Manual Start/Stop

    Rotating speed displayed in controller is calculated by generator frequency and number of poles. If generator frequency ( “Firing speed Hz” ) is not selected: Relative power quantity will neither be collected not displayed (e.g. water pump applica‐ tion). 37691A easYgen-800 | Genset Control...

  • Page 100: Trouble Shooting

    ECU warning or shutdown Get information from LCD of alarm page; If there is detailed alarm, check engine according to description. If not, please refer to engine manual according to SPN alarm code. easYgen-800 | Genset Control 37691A...

  • Page 101: Application

    During this time, please watch for engine’s running situations and AC generator’s voltage and frequency. If abnormal, stop genset running and check all wires connec‐ tion according to this manual If there is any other question, please contact your local Woodward support 37691A easYgen-800 | Genset Control...
  • Page 102 Application Commissioning easYgen-800 | Genset Control 37691A...

  • Page 103: Interfaces And Protocols

    Remark Fuel relay output Oil spout switch Start relay output Connect to starter coil directly Terminals of controller 9 pins connector Remark CAN GND SAE J1939 shield-E CAN communication shielding line(connect with ECU terminal only) 37691A easYgen-800 | Genset Control...
  • Page 104 41 for 0.1s during high-speed warming of controller via external expansion relay. CAN GND CAN communication shielding line(connect with controller’s this terminal only) CAN(H) Impedance 120 Ω connecting line is recommended. CAN(L) Impedance 120 Ω connecting line is recommended. easYgen-800 | Genset Control 37691A...
  • Page 105 SMART (X4 port) Remark CAN GND X4 3 CAN communication shielding line(connect to controller’s this terminal only) CAN(H) X4 1 Impedance 120 Ω connecting line is recommended. CAN(L) X4 2 Impedance 120 Ω connecting line is recommended. 37691A easYgen-800 | Genset Control...
  • Page 106 Fuel relay output Start relay output Connect to starter coil directly CAN GND CAN communication shielding line(connect with controller’s terminal only) CAN(H) Impedance 120 Ω connecting line is recommended. CAN(L) Impedance 120 Ω connecting line is recommended. easYgen-800 | Genset Control 37691A...
  • Page 107 ECU stop Set Auxiliary output 1 as “ECU Stop” Auxiliary output 2 ECU power Set Auxiliary output 2 as “ECU power” Negative power Positive power CAN GND CAN communication shielding line(connect with controller’s terminal only) 37691A easYgen-800 | Genset Control...
  • Page 108 Start relay output 1,61 CAN GND CAN communication shielding line(connect to the controller at this end only) CAN(H) 1,35 Impedance 120 Ω connecting line is recommended. CAN(L) 1,34 Impedance 120 Ω connecting line is recommended. easYgen-800 | Genset Control 37691A...

  • Page 109: Technical Specifications

    Working Conditions Temperature: (-25 to +70) °C; Humidity: (20 to 93) %RH Storage Condition Temperature: (-25 to +70) °C Protection Level against water and Front: IP65 by using mounting material dust delivered with device Back: IP20 37691A easYgen-800 | Genset Control...
  • Page 110 480 x 272 TFT LCD with backlight, multilingual interface (including English, Chinese or other languages) which can be chosen at the site, making commissioning convenient for fac‐ tory personnel LCD wear-resistance and scratch resistance due to hard screen acrylic; easYgen-800 | Genset Control 37691A...

  • Page 111: Measuring And Monitoring

    Each phase and total active power kW Each phase and total reactive power kvar Each phase and total apparent power kVA Each phase and average power factor PF Accumulate total generator power kWh, kvarh, kVAh Earth current A 37691A easYgen-800 | Genset Control...
  • Page 112 Fuel level (FL) %(unit) Speed (SPD) r/min (unit) Battery Voltage (VB) V (unit) Charger Voltage (VD) V (unit) Hour count (HC) can accumulate to max. 65535 hours. Start times can accumulate to max. 65535 times easYgen-800 | Genset Control 37691A...

  • Page 113: Appendix

    When the controller detects that start battery voltage has exceeded the pre-set value, it will initiate a warning alarm. Maintenance due When count down time is 0 and the action select “Warn”, it will initiate a warning alarm. 37691A easYgen-800 | Genset Control...

  • Page 114: Shutdown Alarms

    “Warn”, it will initiate a warning alarm. 9.1.3 Shutdown Alarms When controller detects shutdown alarm, it will send signal to open breaker and shuts down generator. easYgen-800 | Genset Control 37691A...
  • Page 115 When the controller detects that the sensor 2 value has fallen below the pre-set value, it will initiate a shutdown alarm. Discrete input When digit input port is set as shutdown and the alarm is active, it will initiate a shut‐ down alarm. 37691A easYgen-800 | Genset Control...

  • Page 116: Trip And Stop Alarms

    If over power detection is enabled, when the controller detects that the over power value (power is positive) has exceeded the pre-set value and the action select “Trip”, it will ini‐ tiate a trip alarm. easYgen-800 | Genset Control 37691A...

  • Page 117: Trouble Shooting

    FIX, Synal) basing on PC (or IPC). 9.3.1 Modbus Basics All communication loops should follow the master-slave mode. If so, data can be transferred between a master (e.g. PC) and 32 slaves. No communication can start from slaves. 37691A easYgen-800 | Genset Control...

  • Page 118: Data Frame Format

    Information Frame Format Initiating Address Function Data field End struc‐ structure code code ture Delay 1 byte 8-bit 1 byte 8-bit N bytes 2 bytes 16- Delay (equivalent N*8-bit (equivalent to 4 bytes) to 4 bytes) easYgen-800 | Genset Control 37691A...

  • Page 119: Address Code

    For each register, the first byte contains the high order bits and the second contains the low order bits. The slave received command format is slave address, function code, data field and the CRC code. 37691A easYgen-800 | Genset Control...

  • Page 120: Data Field

    CRC code ensure the error information does not work to increase the sys‐ tem's safety and efficiency. When the CRC is appended to the message, the low-order byte is appended first, followed by the high-order byte. easYgen-800 | Genset Control 37691A...
  • Page 121 The calculating of CRC code starts from [slave address] and except for all bytes of [CRC code]. 37691A easYgen-800 | Genset Control...
  • Page 122 06 3 registers (total 6 bytes) Data 1 00 The content of address 0026_hex Data 2 00 The content of address 0027_hex Data 3 00 The content of address 0028_hex CRC code 91 CRC code which calculated by slave easYgen-800 | Genset Control 37691A...
  • Page 123 Slave address 01 Respond to the slave 01 Function code 05 Force Single Coli Starting address 00 Starting address is 0000_hex Data FF Set coil as 1 CRC code CD CRC code which calculated by slave 37691A easYgen-800 | Genset Control...

  • Page 124: Error Handling

    CRC error received from the master will be ignored by the device. The frame format of error code that responds by slave is as follows (CRC excluded): Address code 1 byte Function code 1 byte (MSB is 1) Error code 1 byte CRC code 2 bytes easYgen-800 | Genset Control 37691A...

  • Page 125: Read Holding Registers 03_Hex

    1 for active 1bit Loss of Speed Signal 1 for active 1bit Over Frequency 1 for active 1bit Under Frequency 1 for active 1bit Over Voltage 1 for active 1bit Under Voltage 1 for active 1bit 37691A easYgen-800 | Genset Control...
  • Page 126 1 for active 1bit Reserved 1 for active 1bit Input Module2 Cylinder Temp High 1 for active 1bit Input Module1 Com Fail 1 for active 1bit Input Module1 Venting Temp High 1 for active 1bit easYgen-800 | Genset Control 37691A...
  • Page 127 Input Module2 Com Fail Input Module2 Venting Temp High Input Module2Sensor15 Open Input Module2 Sensor15 High Input Module2 Sensor15 Low Input Module2 Sensor16 Open Input Module2 Sensor16 High Input Module2 Sensor16 Low Input Module2 Sensor17 Open 37691A easYgen-800 | Genset Control...
  • Page 128 1 for active 1bit Reserved 1 for active 1bit Reserved 1 for active 1bit Reserved 1 for active 1bit Reserved 1 for active 1bit Reserved 1 for active 1bit Reserved 1bit Reserved 1bit Reserved 1bit easYgen-800 | Genset Control 37691A...
  • Page 129 Expansion Switch Input5 Expansion Switch Input6 Expansion Switch Input7 Expansion Switch Input8 Expansion Switch Input9 Expansion Switch Input1 Expansion Switch Input11 Expansion Switch Input12 Expansion Switch Input13 Expansion Switch Input14 Expansion Switch Input15 Expansion Switch Input16 37691A easYgen-800 | Genset Control...
  • Page 130 1bit Reserved 1 for active 1bit Expansion Switch Input Com Fail 1 for active 1bit Expansion Switch Output Com Fail 1 for active 1bit Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved easYgen-800 | Genset Control 37691A...
  • Page 131 Expansion Switch Input1 Expansion Switch Input11 Expansion Switch Input12 Expansion Switch Input13 Expansion Switch Input14 Expansion Switch Input15 Expansion Switch Input16 Reserved Reserved Reserved Reserved Reserved Reserved Reserved Loss of Exciting Earth Fault Negative Seq Current 37691A easYgen-800 | Genset Control...
  • Page 132 PLC 6 PLC 7 PLC 8 PLC 9 PLC 10 PLC 11 PLC 12 PLC 13 PLC 14 PLC 15 PLC 16 PLC 17 PLC 18 PLC 19 PLC 20 Reserved Reserved Expansion Switch Input1 easYgen-800 | Genset Control 37691A...
  • Page 133 Charge Alt Fail Warn 1 for active 1bit Battery High Voltage Warn 1 for active 1bit Battery Low Voltage Warn 1 for active 1bit Maintenance Due Warn 1 for active 1bit Reverse Power Warn 1 for active 1bit 37691A easYgen-800 | Genset Control...
  • Page 134 Input Module2 Cylinder Temp High 1 for active 1bit Input Module1 Com Fail Input Module1 Venting Temp High Input Module1 Sensor15 Open Input Module1 Sensor15 High Input Module1 Sensor15 Low Input Module1 Sensor16 Open Input Module1 Sensor16 High easYgen-800 | Genset Control 37691A...
  • Page 135 Input Module2 Sensor15 High Input Module2 Sensor15 Low Input Module2 Sensor16 Open Input Module2 Sensor16 High Input Module2 Sensor16 Low Input Module2 Sensor17 Open Input Module2 Sensor17 High Input Module2 Sensor17 Low Input Module2 Sensor18 Open 37691A easYgen-800 | Genset Control...
  • Page 136 1 for active 1bit Expansion Switch Input11 1 for active 1bit Expansion Switch Input12 1 for active 1bit Expansion Switch Input13 1 for active 1bit Expansion Switch Input14 Expansion Switch Input15 Expansion Switch Input16 Reserved easYgen-800 | Genset Control 37691A...
  • Page 137 1bit Reserved 1bit Reserved 1bit Reserved 1bit Reserved 1bit Reserved 1bit Reserved 1bit Reserved 1bit Reserved 1bit Reserved 1bit Reserved 1bit Reserved 1bit Reserved 1bit Reserved 1bit Reserved 1bit Reserved 1bit Reserved 1bit Reserved 1bit 37691A easYgen-800 | Genset Control...
  • Page 138 1 for active 1bit Digital Output 6 Status 1 for active 1bit Reserved 1 for active 1bit Reserved 1 for active 1bit Reserved 1 for active 1bit Reserved 1 for active 1bit Reserved 1 for active 1bit easYgen-800 | Genset Control 37691A...
  • Page 139 Reserved 1 for active 1bit Reserved 1 for active 1bit Reserved 1 for active 1bit Reserved 1 for active 1bit Reserved 1 for active 1bit Reserved 1 for active 1bit Reserved 1 for active 1bit 37691A easYgen-800 | Genset Control...
  • Page 140 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes easYgen-800 | Genset Control 37691A...
  • Page 141 Signed (*10) 4Bytes 0107 0108 C-phase Active Power Signed (*10) 4Bytes 0109 0110 Total Active Power Signed (*10) 4Bytes 0111 0112 A-phase Reactive Power Signed (*10) 4Bytes 0113 0114 B-phase Reactive Power Signed (*10) 4Bytes 37691A easYgen-800 | Genset Control...
  • Page 142 Level Sensor Value Signed 2Bytes Config Sensor 1 Resistance Value Unsigned (*10) 2Bytes Config Sensor 1 Value Signed 2Bytes Config Sensor 2 Resistance Value Unsigned (*10) 2Bytes Config Sensor 2 Value Signed 2Bytes Reserved 2Bytes Reserved 2Bytes easYgen-800 | Genset Control 37691A...
  • Page 143 2Bytes Gen Status Generator Status Form 2Bytes Gen Delay 2Bytes Remote Start Status Remote Start Status Form 2Bytes Remote Start Delay 2Bytes Breaker Status Breaker Status Form 2Bytes Transfer Rest 2Bytes Reserved 2Bytes Reserved 2Bytes 37691A easYgen-800 | Genset Control...
  • Page 144 Controller Current Time (DD) 2Bytes Controller Current Time (Week) 2Bytes Controller Current Time (HH) 2Bytes Controller Current Time (MM) 2Bytes Controller Current Time (SS) 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes easYgen-800 | Genset Control 37691A...
  • Page 145 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes 37691A easYgen-800 | Genset Control...
  • Page 146 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes Reserved 2Bytes easYgen-800 | Genset Control 37691A...

  • Page 147: Force Single Coil 05H_Hex

    1 for active; 0 for inactive Remote Output 5 1 for active; 0 for inactive Remote Output 6 1 for active; 0 for inactive Reserved 1 for active Reserved 1 for active Reserved 1 for active Reserved 1 for active 37691A easYgen-800 | Genset Control...

  • Page 148: Preset Single Register 06H_Hex

    Stop Idle ETS Hold Wait for Stop After Stop Failed to Stop This status has no ―delay value 9.3.4.2 Remote Start Status Items Description No Delay This status has no ―delay value Start Delay Stop Delay easYgen-800 | Genset Control 37691A...

  • Page 149: Breaker Status

    This status has no ―delay value Opening Transfer Rest Reserved Closing Gen Wait for Opened This status has no ―delay value Wait for Gen Closed This status has no ―delay value Reserved This status has no ―delay value 37691A easYgen-800 | Genset Control...
  • Page 150 Appendix Data Telegrams > Preset Single Register 06H... > Breaker Status easYgen-800 | Genset Control 37691A...
  • Page 151 Engine Control Unit Failure Mode Indicator Graphical Application Programming (GAP™) Generator Circuit Breaker Woodward device series (Genset Control) - not preferred for new design! Generator Group Breaker (speed) Governor; rpm regulator Human Machine Interface e.g., a front panel with display and...
  • Page 152 Reactive power Apparent power Serial Number Sequencer A sequencer file is carrying specific settings e.g. to enable communication with and/or control of an expansion module. Such files can be prepared by Woodward. Suspect Parameter Number Voltage easYgen-800 | Genset Control 37691A...
  • Page 153 Use ....... . 11, 20 Warranty ....... 11 37691A easYgen-800 | Genset Control...
  • Page 154 | Genset Control 37691A...
  • Page 156 Designed in Europe Woodward GmbH Handwerkstrasse 29 70565 Stuttgart Germany Phone +49 (0) 711 789 54-510 Fax +49 (0) 711 789 54-101 Stgt-Doku@woodward.com...

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Easygen-1800

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