Woodward easYgen-400 Technical Manual
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Woodward easYgen-400 Technical Manual

Genset control
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easYgen-400
Technical Manual
Genset Control
easYgen-400
B37884A

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Summary of Contents for Woodward easYgen-400

  • Page 1 Technical Manual Genset Control easYgen-400 B37884A...
  • Page 2 Woodward GmbH Handwerkstr. 29 — 70565 Stuttgart — Germany Phone +49 (0) 711 789 54‑510 Fax +49 (0) 711 789 54‑101 stgt-info@woodward.com © 2019 Woodward GmbH easYgen-400 B37884A...
  • Page 3 Terminals 1 to 14: Power Supply, Fuel/Gas, Starter, D+, Relay 01 to04, AI 01 to 04 Terminals 15 to 17: Magnetic Pickup Terminals 18 to 20: CAN (J1939) interface The easYgen-400 is a control unit for engine-generator management applications. The control unit can be used in simple Start/Stop applications. Scope of delivery The following parts are included in the covering box.
  • Page 4 Brief Overview Configuration software and Technical Manual are available at Woodward website:http:// www.woodward.com/easYgen-400.aspx Sample application setup Fig. 2: Sample application setup easYgen-400 B37884A...
  • Page 5 • 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 ╚═▷ “Transition Procedures”. B37884A easYgen-400...

  • Page 6: Table Of Contents

    ................Features and Functions of both easYgen-400 and -1400 .
  • Page 7 ................Trouble Shooting B37884A easYgen-400...
  • Page 8 ................Index easYgen-400 B37884A...

  • Page 9: General Information

    ◦ 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;...

  • Page 10: Symbols Used In This Manual

    Safety instructions are marked with symbols. The safety instructions are always introduced by signal words that express the severity of the danger. DANGER! This combination of symbol and signal word indicates an immediately dangerous situation that can cause death or severe injuries if not avoided. easYgen-400 B37884A...
  • Page 11 [Screen xx / Screen xy / Menu path. Screen xz] ... 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. B37884A easYgen-400...

  • Page 12: Copyright And 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: •...

  • Page 13: Safety

    In addition, our employees are interested in any new information and experiences that arise from usage and could be valuable for improving our products. Warranty terms Please enquire about the terms of warranty from your nearest Woodward representative. To find your closest Customer Service representative, go to: ══▷ http:// www.woodward.com/Directory.aspx Safety 1.4.1...

  • Page 14: Personnel

    Be aware that the remote control of a system that is managing life-threatening engine- generator-electricity parts must be adapted to the local situation! The following safety notes cover both the device itself and basics of the overall genset system. The dedicated genset-system safety instruction must be considered, too! easYgen-400 B37884A...
  • Page 15 Failure to comply with this also poses the risk of personal injury or loss of life if 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. B37884A easYgen-400...

  • Page 16: System Overview

    For even higher challenges in genset control, the easYgen series offers further solutions encompassing complex and ambitious applications. For dedicated protection tasks, ask Woodward for its protection (relay) solutions. Operation Modes • See ╚═▷ “Operation Modes”...

  • Page 17: Features And Functions Of Both Easygen-400 And -1400

    For purposes of comparison and better differentiation, both are described below. easYgen-400 is intended to be used for single automation systems, auto start/stop of the unit is performed using a remote signal.
  • Page 18 Mains/Generator Line voltage (U , and U ), Phase voltage (U , and U • easYgen-400 only: Collects and shows 3-phase voltage, current, power parameter and frequency of generator. Generator Line voltage (U , and U ), Phase voltage (U , and U •...
  • Page 19 2 System Overview 2.2 Features and Functions of both easYgen-400 and -1400 • For generator, controller can detect overvoltage and undervoltage, overfrequency and underfrequency, loss of phase, incorrect phase sequence, overpower and reverse power, overcurrent. • 2 fixed analog sensors: Engine temperature and oil pressure.

  • Page 20: Functions

    • Accumulative total run time and total electric energy of A and B. The user can reset it to 0 and re-accumulate the value, which allows to count the total value. Intended Use of This Control easYgen-400 genset controllers are used for genset automation and monitor control system of single unit, offering: • automatic start/stop, •...

  • Page 21: Installation

    CUTOUT 116.5 mm 114 mm 137 mm 44 mm Fig. 4: easYgen-400 dimensions and cut-out Wiring General Notes Battery Voltage Input This controller can be used with batteries with a voltage range from 8 to 35 V The negative pole of the battery must be connected to the engine shell. The wire between the power supply and the battery must have a cross section above 2.5 mm...
  • Page 22 Shall be marked with AWG wire range and terminal torque rating. Installed in accordance with the NEC (United States) or the CEC (Canada). Current sense inputs shall be marked: “From Listed or R/C (XODW2.8) current transformers”. Connections shall be made with 75ºC rated wire minimum. easYgen-400 B37884A...
  • Page 23 3 Installation 3.2 Wiring Terminals Fig. 5: easYgen-400 Terminals Function Cable Remarks Size POWER SUPPLY − 2.5 mm² Connected to the negative pole of starter battery POWER SUPPLY + 2.5 mm² Connected to positive pole of starter battery. If the wire is longer than 30 m, use double wires in parallel.
  • Page 24 Ground connected is active (B-) Details see ╚═▷ Input 1 “Programmable Inputs” Configurable 1.0 mm² Ground connected is active (B-) Input 2 Configurable 1.0 mm² Ground connected is active (B-) Input 3 Sensor common 1.0 mm² Sensor common port easYgen-400 B37884A...
  • Page 25 Empty terminal Empty terminal CT A Phase 1.5 mm² Connect secondary coil, rated 5A Sensing Input CT B Phase 1.5 mm² Sensing Input CT C Phase 1.5 mm² Sensing Input CT Common port 1.5 mm² Refer to Installation description B37884A easYgen-400...

  • Page 26: Interfaces

    3 Installation 3.3 Interfaces Wiring typical applications Fig. 6: easYgen-400 wiring of a typical application Interfaces Interface Connections Fig. 7: Interface Connections easYgen-400 B37884A...

  • Page 27: Install Toolkit-Sc

    General notes ToolKit-SC is a software tool for configuration including configuration file management, monitoring, remote control, and custom language management. The ToolKit-SC.exe file is available as a download on the Woodward website and the device-specific download website. Please follow installation instruction.

  • Page 28: Configuration

    • USB connected PC/laptop using ToolKit-SC configuration software (full edit) The configuration software ToolKit-SC is part of the delivery and (latest edition) can be downloaded from our website Woodward.com. Search for "ToolKit-SC". Different digital/relay outputs can be configured with the same output type .
  • Page 29 4 Configuration 4.1 Access to the Control Fig. 8: easYgen-400 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.

  • Page 30: Front Panel Control

    WARNING! Users can change passwords. Please make note of the new password after changing it. If you forget the password, please contact Woodward services and send all device information on the “ABOUT” page of the controller for legitimation. 4.1.2...

  • Page 31: Hmi Screens Without Password Level

    • Home screen • Status • Engine • Generator • Load • Alarm • Home screen etc. The first screen includes: • Gen: voltage, frequency, current, active power, reactive power • Engine: speed, temperature, oil pressure, battery voltage B37884A easYgen-400...
  • Page 32 • power factor (positive and negative), average power factor (positive and negative), • accumulated energy, • earth current, • total electric energy A and B. Fig. 9: Power Factor Active power Reactive power easYgen-400 B37884A...
  • Page 33 Some screens are only visible in configuration mode. Press »Set/Confirm« button to switch to configuration mode. Screens in configuration mode: • 1 Set parameters • 2 Information • 3 Set language • 4 Event log • 5 ECU DM2 • 6 Maintenance B37884A easYgen-400...

  • Page 34: Configure Toolkit-Sc

    Russian, Portuguese, Turkish, Polish, French. The display language is changed once the configuration has been written to the device. If a menu is open on the device while you change the language in ToolKit, the new language will display after pressing a front panel button. easYgen-400 B37884A...

  • Page 35: Access Via Toolkit-Sc Configuration Tool

    The button on the lower right side lets you select the screen. ╺▶ To import your current ToolKit-SC configuration into the device, click on "Write config(W)" in the menu bar. Your are asked to enter a password. Additionally, the splash screen image can be selected. B37884A easYgen-400...

  • Page 36: Parameters

    Fig. 11: ToolKit-SC: write configuration The settings are transmitted to the device and immediately become active. Parameters 4.2.1 Parameter Menu Structure Parameter Menu Parameters of both HMI (front panel access) and ToolKit-SC are not presented in the same order. easYgen-400 B37884A...

  • Page 37: Parameter Settings Menu--Hmi Access

    4 Configuration 4.2 Parameters Fig. 12: Menu Structure easYgen-400 - overview 4.2.2 Parameter Settings Menu--HMI Access ╺▶ Press the »RIGHT« button. The main menu opens. ⇨ B37884A easYgen-400...

  • Page 38: Configure Measurement

    The editor screen is closed automatically after five minutes of inactivity. The setting process is aborted immediately when pushing the »Stop« button! 4.2.3 Configure Measurement Generator Settings [PARAMETER / Configure measurement / Generator] Items Parameters Defaults Description General generator settings Monitoring Monitoring is enabled. Monitoring is disabled. easYgen-400 B37884A...
  • Page 39 The measurement is performed line-line. 3: Single Phase, 2 VL12, VL23 and VL31 Wire (1Ph2W) 2 Phase, 3 Wire (2Ph3W) The measurement is performed line-neutral and line-line: VL12 VL1N and VL2N Single Phase, 2 Wire (1Ph2W) The measurement is performed line-neutral: VL1N B37884A easYgen-400...

  • Page 40: Configure Application

    Default of discrete input 5 level warn‐ Notes See chapter ╚═▷ “Programmable Inputs” for details Operation Close to activate Close to Close to activate (N.O.): The discrete input is analyzed as activate "enabled" by energizing the input (normally open). easYgen-400 B37884A...
  • Page 41 ╚═▷ “Programmable Outputs” for details 4.2.4.1.3 Configure Analog Inputs [PARAMETER / Configure application / Configure inputs/outputs / Configure analog inputs / ...] Items Parameters Defaults Description Temperature Type 00 to 14 08 SGX See chapter ╚═▷ “Programmable Sensors” B37884A easYgen-400...
  • Page 42 Reaction from the device if the high temperature alarm is Stop triggered. Cooling Down Immediate Stop: The GCB opens and the engine stops Warning immediately Cooling down: The GCB opens and the engine stops after the configured cooldown time. easYgen-400 B37884A...
  • Page 43 If a type (01 or higher) Curve can be Notes with curve is selected: For fuel level curve management and customization. loaded ..and/or edited (curve) Low limit shutdown 0 to 100 % Shut down when sensor value is below the threshold. B37884A easYgen-400...
  • Page 44 Select local temperature unit for display °F Pressure Select local pressure unit for display 4.2.4.1.4 Configure external LEDs 1 [Parameter / Configure application / Configure external outputs / Configure ext. 1 discrete LEDs] Fig. 15: ToolKit-SC: Configure external LEDs easYgen-400 B37884A...
  • Page 45 Label print Once the configuration of external LEDs is complete, the corresponding LED labels can be printed on paper by means of the “Label print” button in . The following screen opens: Fig. 16: Label print screen in ToolKit B37884A easYgen-400...

  • Page 46: Configure Engine

    Speed on Load 0 to 100 % Setting value is percentage of rated speed. Controller detects when it is ready to load. It won’t switch on when speed is under loading speed. Configure Start/Stop easYgen-400 B37884A...
  • Page 47 "start idle". Speed drop pulse 0 to 20 s 0.2 s The speed drop pulse time relates to the output "25 Speed lower pulse" and is active for the configured time after the stop sequence "stop idle". Crank disconnect B37884A easYgen-400...

  • Page 48: Configure Test Run

    1 to 31 »Monthly«: Select a week day Sunday, to Sunday »Weekly«: Select a week day Saturday Time (hour) 0 to 24 h 0 (o'clock) Define the start time (hour) Time (minute) 0 to 59 Define the start time (minute) easYgen-400 B37884A...

  • Page 49: Configure Breakers

    GCB as well. If the time is configured to "zero" the closing pulse acts as a steady pulse. Opening time 0.0 to 60.0 s 3.0 s Pulse width of generator switch OFF Notes This is the duration from the opening pulse for GCB as well. B37884A easYgen-400...

  • Page 50: Configure Monitoring

    »Multiply« defines the grade of reaction on the ratio of generator current to overcurrent setting. A low value means Multiply fast reaction (short delay time); the greater the value the slower reaction because longer delay time. Monitoring Power [PARAMETER / Configure monitoring / Generator / Power] easYgen-400 B37884A...

  • Page 51: Monitoring Breakers

    Release the alarm when the MPU speed is same or lower than this value. Loss of speed signal Delay 0 to 20 s Release the alarm when the speed signal (MPU) is not available for this period of time. B37884A easYgen-400...

  • Page 52: Other Monitoring

    Defines the alarm class if the maintenance is triggered. Warn Shutdown Interval 0 to 5000 h 250 h Maintenance interval based on operation hours. Time Push icon (current Maintenance based on internal time. date) 4.2.7 Configure Counters [PARAMETER / Configure counters] easYgen-400 B37884A...

  • Page 53: Configure Language / Clock

    Time sub module enable comfortable setting time value: time) hh:mm:ss Push button Write value to the easYgen device Use PC time Push button Write PC time to the easYgen device Current module Date (YYYY-MM- (actual Display device's value value) B37884A easYgen-400...

  • Page 54: Configure System Management

    Once you have created a theme, save it to file by hitting the save button. Load a theme from file by hitting the load button. Default reset Push button Reset theme to default settings Activate start-up logo Enabled/disabled Enabled Show customer's logo during start-up? easYgen-400 B37884A...

  • Page 55: Selectable Inputs/Outputs/Sensors

    Defined resistance range is (0 to 6) KΩ. 1 Custom Res Curve Default is »0 Not used«. 2 VDO 3 SGH 4 SGD 5 CURTIS 6 DATCON 7 VOLVO-EC 8 SGX 9 to 10 Reserved 11 CLOSED 12 OPEN 13 VDO 5 bar B37884A easYgen-400...

  • Page 56: Programmable Inputs

    If the signal is active after safety run on delay over, the genset will immediately activate a shutdown alarm. Low OP Alarm Auxiliary Alarm Only warning, no shutdown. Aux. Shutdown Alarm If the signal is active, genset will immediately alarm to shutdown. easYgen-400 B37884A...

  • Page 57: Programmable Outputs

    Pick-up when stop idle while disconnect when genset stop completely. Preglow Close before started and disconnect before powered on Close GCB When close time is set to 0 s, it is continuous closing Reserved B37884A easYgen-400...

  • Page 58: Status Menu

    HIGH for the pre-set »drop speed pulse time« after entering stop idling Reserved Status Menu General notes Both HMI and ToolKit-SC offer status information. 4.4.1 HMI Status Screens HMI displays the following status screens: • Status (home) • Generator • Load • Engine 1 easYgen-400 B37884A...

  • Page 59: Toolkit-Sc Status Screens

    (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 - B37884A easYgen-400...
  • Page 60 Module Info Model, Hardware Version, Software Version, Issue Date Event log Fixed view of: Event log report table. Showss the 99 No., Event type latest events. Columns "move behind" visible part of the screen: Event Item, Date, Time, easYgen-400 B37884A...
  • Page 61 (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) Read log Push buttons to manage logged data Clear Export to Txt B37884A easYgen-400...

  • Page 62: Operation

    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 easYgen-400 B37884A...

  • Page 63: Operation Mode Auto

    AUTO mode but without breaker control. Breakers can be opened and closed without taking care of load or genset state! CAUTION! Take care for genset and supply. 5.2.3 Operation Mode STOP General notes In operation mode STOP, the breaker is open and the engine is not running. B37884A easYgen-400...

  • Page 64: Start/Stop Operation

    The AUTO Start procedure is going through sub procedures with own timers. 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. easYgen-400 B37884A...

  • Page 65: Stop Engine

    5 Operation 5.3 START/STOP Operation Fig. 18: Engine start procedure 5.3.2 Stop engine The AUTO Stop procedure is going through sub procedures with own timers. B37884A easYgen-400...
  • Page 66 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. Fig. 19: Engine stop/stand-by procedure easYgen-400 B37884A...

  • Page 67: Manual Start/Stop

    When set to speed sensor, ensure that the number of flywheel teeth is the same as setting. Sensor not used? Make sure not to select a sensor that is not in use. Otherwise, an error message might occur. B37884A easYgen-400...
  • Page 68 HMI is using a table »Firing speed« instead: Setting description Gen frequency Speed sensor Speed sensor + Gen frequency Oil pressure Oil pressure + Gen frequency Oil pressure + Speed sensor Oil pressure + Speed sensor + Gen frequency easYgen-400 B37884A...

  • Page 69: Commissioning

    (if idle run be set). 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 connection according to this manual ╺▶ If there is any other question, please contact your local Woodward support B37884A easYgen-400...

  • Page 70: Interfaces And Protocols

    Connect to starter coil directly Terminals of controller 3 pins data link Remark connector CAN GND CAN communication shielding line(connect with ECU terminal only) CAN(H) Impedance 120 Ω connecting line is recommended. CAN(L) Impedance 120 Ω connecting line is recommended. easYgen-400 B37884A...
  • Page 71 Expand 30A relay; battery voltage of ECU is supplied by relay. Start relay output Connect to starter coil directly CAN GND CAN communication shielding line(connect with controller’s terminal only) CAN(H) CAN(H) Impedance 120 Ω connecting line is recommended. B37884A easYgen-400...
  • Page 72 Terminals of ADEC (X1port) Remark controller Fuel relay output X1 43 X1 Terminal 28 Connected to negative of battery Start relay output X1 37 X1 Terminal 22 Connected to negative of battery Terminals of controller SAM (X23 port) Remark easYgen-400 B37884A...
  • Page 73 Expand 30A relay; battery voltage of terminal 14 is supplied by relay. Fuse is 16A. Start relay output Connect to starter coil directly Connected to negative of battery CAN GND CAN communication shielding line(connect with controller’s terminal only) B37884A easYgen-400...
  • Page 74 Engine port Remark controller Fuel relay output 1,40 Connect to engine ignition lock 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. easYgen-400 B37884A...
  • Page 75 7 Interfaces and Protocols 7.1 J1939 Terminals of Engine port Remark controller CAN(L) 1,34 Impedance 120 Ω connecting line is recommended. B37884A easYgen-400...

  • Page 76: Technical Specifications

    Phase-phase: 100 .. 300 V：1%; 50 .. 100 V： 1.5 % (according to UL6200) Phase-neutral: 100 .. 360 V：1% 50 .. 100 V： 1.5 % Minimum frequency Generator: 10 Hz Maximum frequency Generator: 99.5 Hz Frequency resolution 0.1 Hz (10 .. 99 Hz) easYgen-400 B37884A...
  • Page 77 1 Adc 24 Vdc, resistive GP (according to UL 6200) Programmable Relay Output 02 1 Adc 24 Vdc, resistive GP Programmable Relay Output 03 1 Adc 24 Vdc, resistive GP Programmable Relay Output 04 1 Adc 24 Vdc, resistive GP B37884A easYgen-400...
  • Page 78 • CANbus port and can communicate with J1939 genset: ◦ Monitoring frequently-used data (such as water temperature, oil pressure, speed, fuel consumption and so on) of ECU ◦ Control START, STOP, raising speed, and speed droop Phase Configuration easYgen-400 B37884A...

  • Page 79: Measuring And Monitoring

    • Precision measure and display parameters about Engine: • Temp. (WT) °C/°F both be displayed • Oil pressure (OP) kPa/psi/bar all be displayed • Speed (SPD) r/min (unit) • Battery Voltage (VB) V (unit) • Charger Voltage (VD) V (unit) B37884A easYgen-400...
  • Page 80 8 Technical Specifications 8.1 Measuring and Monitoring • Hour count (HC) can accumulate to max. 65535 hours. • Start times can accumulate to max. 65535 times easYgen-400 B37884A...

  • Page 81: Alarms And Warnings

    When low coolant level input is active, controller will send warning alarm signal and it will be displayed in LCD. Temp. Sensor Open When sensor hasn’t connected to corresponding port, controller will send warning alarm signal and it will be displayed in LCD. B37884A easYgen-400...

  • Page 82: Shutdown Alarms

    When genset frequency is higher than set threshold, controller will send a stop alarm signal and it will be displayed on the LCD. Under Freq. Shutdown When genset frequency is lower than set threshold, controller will send a stop alarm signal and it will be displayed on the LCD. easYgen-400 B37884A...

  • Page 83: Trouble Shooting

    Check if the connections from the controller to the engine and the output ports settings are correct. ECU warning or shutdown Get information from the LCD of the alarm page; If there is a detailed alarm, check the respective engine. If there is no detailed alarm, please B37884A easYgen-400...
  • Page 84 9 Appendix 9.2 Trouble Shooting Symptoms Possible Solutions refer to the relevant section of the engine manual as specified in the SPN alarm code. easYgen-400 B37884A...
  • Page 85 OPEN requests or alarms. Somehow "waiting for next occurrence". Real power Part Number Power Factor Potential (Voltage) Transformer Reactive power Apparent power Serial Number Suspect Parameter Number Voltage B37884A easYgen-400...
  • Page 86 ................Personnel  14 easYgen-400 B37884A...
  • Page 87 ................Wiring  21 B37884A easYgen-400...
  • Page 88 Woodward GmbH Handwerkstraße 29 — 70565 Stuttgart — Germany Phone +49 (0) 711 789 54-510 +49 (0) 711 789 54-101 stgt-info@woodward.com...

This manual is also suitable for:

Easygen-1400

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