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Manual 37471A easYgen-3000 Series - Genset Control Revision History Rev. Date Editor Changes NEW 10-05-05 Release based on 37417B 12-01-10 Minor changes Content 1. G ..................8 HAPTER ENERAL NFORMATION 2. B ................... 9 HAPTER ASIC PPLICATIONS Overview ..............................9 Application Mode {0} ..........................
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Manual 37471A easYgen-3000 Series - Genset Control Connecting a Landline Modem ......................39 Function ............................39 Preconditions for this Example ....................39 Connection ..........................40 easYgen Settings ........................40 ToolKit Settings ........................... 41 Phoenix Modem Settings ......................41 Wiring Self-Powered DIs........................43 Connecting Analog Inputs in Series (Multiple Devices) .................
Intended Use The unit must only be operated in the manner described by this manual. The prerequisite for a proper and safe operation of the product is correct transportation, storage, and installation as well as careful oper- ation and maintenance. What are the differences between the easYgen-3000 Series Package P1 & Package P2? easYgen-3000 Series Package P1...
Manual 37471A easYgen-3000 Series - Genset Control Chapter 2. Basic Applications Overview ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ NOTE Please refer to the Configuration Manual 37469 for selection of the application mode. Depending on the application, different application modes are possible. • Application mode {0} - [start/stop] - engine control - refer to page 10 - Measuring of engine/generator parameters (i.e.
Manual 37471A easYgen-3000 Series - Genset Control Application Mode {0} ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ This application mode may be used for isolated operation applications. In this case, the easYgen will function as an engine control. Current Voltage Analog/Digital Inputs Engine Start/Stop Figure 2-1: Application mode {0} The easYgen requires in all application modes the feedback reply from the circuit breakers.
Manual 37471A easYgen-3000 Series - Genset Control Application Mode {1o} ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ This application mode may be used for isolated operation applications. In this case, the easYgen will function as an engine control with generator and engine protection. The control unit can only open the GCB.
Manual 37471A easYgen-3000 Series - Genset Control Application Mode {1oc} ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ This application mode may be used in applications, where only the GCB is operated by the easYgen. If it is used for isolated or mains parallel operations, mains decoupling should be performed by the GCB or an external provi- sion.
Manual 37471A easYgen-3000 Series - Genset Control Application Mode {2oc} ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ This application mode may be used for mains parallel operation. In this case, the easYgen will function as an en- gine control with generator, mains and engine protection. The control unit can open and close the GCB and the MCB.
Manual 37471A easYgen-3000 Series - Genset Control Chapter 3. Multiple Genset Applications Overview ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ MCB Control LOAD optional GCB Control GCB Control GCB Control Current Current Current Voltage Voltage Voltage Dig./Analog Inputs Dig./Analog Inputs Dig./Analog Inputs Start/Stop Start/Stop Start/Stop Modbus...
Manual 37471A easYgen-3000 Series - Genset Control Configuration Example ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Mains Parallel Operation (mains interchange (import/export) power control) The following example describes the configuration of a typical mains parallel operation with import/export power control at the interchange point and load-dependent start/stop.
Manual 37471A easYgen-3000 Series - Genset Control Configuring Load-Dependent Start/Stop Isolated Operation Additional assumptions are valid for isolated operation (IOP), i.e. in case of an emergency operation: • A reserve power of 80 kW on the busbar shall be maintained, i.e. at least 2 generators are available in isolat- ed operation for redundancy because no supporting mains are present.
Manual 37471A easYgen-3000 Series - Genset Control Configuring Automatic Operation From the main screen on the unit select Parameter -> Configuration -> Configure application -> Configure auto- LogicsManager matic run and configure the function "Start req in AUTO" as shown in Figure 4-2 on page 20 to start the generator in Automatic operating mode if discrete input [DI 02] ("09.02 Discrete input 2") is energized...
Generator Excitation Protection ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ The easYgen-3000 Series provides the user with power factor monitoring. These monitoring functions permit for protection of the generator over- and under-excitation. The power factor monitoring consists of a warning alarm and/or a shutdown alarm when enabled. An alarm and the specified action will be initiated if the monitored pow- er factor surpasses the defined limits.
Manual 37471A easYgen-3000 Series - Genset Control Configuring a Set Point Control via Analog Input ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ The following example illustrates how to configure an easYgen for using an external load set point via analog in- put [AI 03]. The external set point may be enabled using a switch, wired to discrete input [DI 09]. An analog 0 to 20 mA input is to be used where 4 mA corresponds with 0 % power (0 MW), 12 mA corresponds with 50 % power (1 MW), and 20 mA corresponds with 100 % power (2 MW).
Manual 37471A easYgen-3000 Series - Genset Control LogicsManager Configure the function "Setp. 2 load" as shown in Figure 4-2 on page 20 to enable load setpoint 2 if discrete input [DI 09] is energized. Figure 4-2: Example - configuring load setpoint 2 for [DI 05] Viewing the Load Set Point on the easYgen After the unit is configured as described above, the "Setpoint"...
Manual 37471A easYgen-3000 Series - Genset Control Creating Self-Toggling (Pulsing) Relays Using LogicsManager ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Various functions are possible with the LogicsManager. This is a simple example of a relay output that toggles from energized to de-energized in automatic mode with adjustable on and off time. This pulsing relay may be combined with a flexible limit, which can be programmed with a function like low battery voltage to get a blink- ing warning light.
Manual 37471A easYgen-3000 Series - Genset Control Changing a Starter Battery Set Using LogicsManager ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Various functions are possible with the LogicsManager. The following programming example shows how two re- lay outputs are energized by turns when discrete input 9 is energized. At first time, discrete output 11 will be en- ergized, then, discrete output 12 will be energized, then discrete output 11 and so on.
Series - Genset Control Performing Remote Start/Stop and Acknowledgement ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ The easYgen-3000 Series controller may be configured to perform start/stop/acknowledgement functions remote- ly through the CAN bus or Modbus. The required procedure is detailed in the following steps. NOTE Refer to the operation manual 37470 for a detailed description of the navigation through the various display screens.
Setting Up a Test With or Without Load There are a lot of different opinions of the behavior of a proper test mode. The easYgen-3000 Series can support the following two modes: Test with load and test without load. Both modes work only in automatic mode. The correct test mode depends on your local specifications.
Manual 37471A easYgen-3000 Series - Genset Control Example for test without load: The engine shall start once a month and run for one hour without overtaking the load. The test day shall be every fifteenth of a month (with flag 2). A relay output can be configured that this test is running, e.g.
Manual 37471A easYgen-3000 Series - Genset Control Remote Start/Stop and Acknowledgement The easYgen may be started, stopped, or acknowledged with Modbus or CAN protocol via the interface. Two logical command variables are available for this in the LogicsManager: 04.13 Remote request 04.14...
Manual 37471A easYgen-3000 Series - Genset Control External Acknowledgement Navigate to the "Configure automatic run" screen by pressing the following softkeys in this sequence: Parameter -> Configuration -> Configure monitoring -> Miscellaneous Navigate to the entry "Ext. acknowledge" by using the softkeys and press to enter the "Ext.
Manual 37471A easYgen-3000 Series - Genset Control The following figure shows the reaction of the command variable on the various changes of the bits: Start bit Stop bit Com. var. 04.13 Remote request no reaction, stops, because because simultanous higher prioritized...
Connecting an IKD 1 on CAN Bus 1 ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ We recommend to connect external expansion boards, like the Woodward IKD 1 to CAN bus 2. This CAN bus offers preconfigured settings for operating several expansion boards including the IKD 1.
Manual 37471A easYgen-3000 Series - Genset Control Receive PDO The easYgen must be configured for receiving data on an RPDO. The data received on CAN ID 201h is inter- preted as object with the index 8011 (external DIs 1 to 8). For this, RPDO1 must be configured as follows:...
Manual 37471A easYgen-3000 Series - Genset Control Configuration for a Second IKD 1 If a second IKD 1 shall be connected to the easYgen, the following settings must be made to TPDO2 and RPDO2 in the easYgen: Figure 4-25: Configuration of the easYgen for a second IKD 1...
Manual 37471A easYgen-3000 Series - Genset Control Configuring a PWM Duty Cycle for a CAT ADEM Controller ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ If a PWM signal shall be used with a CAT ADEM speed controller, the duty cycle must be limited between 10% and 85%. For this, the following settings must be made to the respective analog output (the following parameter IDs and figures refer to analog output 1;...
Manual 37471A easYgen-3000 Series - Genset Control Connecting a GSM Modem ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ RS-232 INSYS Notebook with modem easYgen-3000 and Windows operating GSM Modem system 2000, XP, or Vista http://www.insys-tec.de and ToolKit application SW Figure 4-28: Connecting a GSM modem Function It is possible to establish a cellular connection to the system using a GSM modem.
Manual 37471A easYgen-3000 Series - Genset Control Connection It is possible to issue an active call in case of a malfunction using a relay of the relay manager. Connect the easYgen and the modem with the power supply as directed.
Manual 37471A easYgen-3000 Series - Genset Control ToolKit Settings In ToolKit, select Connect… from the Device menu to open the Communications window. Select the modem (this must be installed and configured under Windows) from the network list, enter the phone number and click the Connect button to establish a connection with the modem.
Manual 37471A easYgen-3000 Series - Genset Control Make the following settings on the Alarm/Output 1 tab. The phone number and the text can be set as required. Figure 4-32: Configuring alarm input 1 in the GSM modem software Make the following settings on the Alarm/Output 2 tab. The phone number and the text can be set as required.
Manual 37471A easYgen-3000 Series - Genset Control Connecting a Landline Modem ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ RS-232 Phoenix Notebook with modem and Windows operating landline modem system 2000, XP, or Vista with discrete input for dial up and ToolKit application SW Figure 4-34: Connecting a landline modem Function It is possible to establish a phone connection to the system using a modem.
Manual 37471A easYgen-3000 Series - Genset Control Connection It is possible to issue an active call in case of a malfunction using a relay of the relay manager. Connect the easYgen and the modem with the power supply as directed.
Manual 37471A easYgen-3000 Series - Genset Control ToolKit Settings In ToolKit, select Connect… from the Device menu to open the Communications window. Select the modem (this must be installed and configured under Windows) from the network list, enter the phone number and click the Connect button to establish a connection with the modem.
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Manual 37471A easYgen-3000 Series - Genset Control To configure the modem, proceed as follows. Configure the COM port The phone number and the text can be set as required. These settings configure the modem to accept an incoming call for remote configuration.
Manual 37471A easYgen-3000 Series - Genset Control Wiring Self-Powered DIs ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ In order to create self-powered discrete inputs, it is required to connect battery negative (B-) to ground and PE (terminal 61). Moreover, DI common (terminal 66) must be connected to Power supply 12/24 V (terminal 63, minimum wire size 0.5 mm²...
Connecting Analog Inputs in Series (Multiple Devices) ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ The analog inputs of the easYgen-3000 Series are galvanically isolated. This enables a series connection for up to 3 analog inputs. This connection allows for example to share a power setpoint for up to 3 devices.
Manual 37471A easYgen-3000 Series - Genset Control Possible Combinations The possible combinations of Phoenix modules are listed below. The parameters display the maximum extension. It is also possible to connect fewer modules. For example choose parameter ID 9941 (12AI 4AO) for connecting 10 AI and 1 AO.
Manual 37471A easYgen-3000 Series - Genset Control Setup Baud rate Set the Baud rate of CAN #2 in the easYgen and the Phoenix module to the same value. All members on the CAN bus need to have the same baud rate.
Manual 37471A easYgen-3000 Series - Genset Control Set the Node-ID Set the Node-ID for the configuration you are using. Figure 4-42: Enter the Phoenix Node-ID The node address is set using DIP switches 1 through 7. DIP switch 1 is the least significant digit of the node ad- dress and DIP switch 7 is the most.
Manual 37471A easYgen-3000 Series - Genset Control Confirm Your Changes Initialize the startup routine in the phoenix device. Set parameter ID 15134 "Configure external devices" to "yes" to confirm your changes in the easYgen. Figure 4-44: Confirming your changes Page 48/69...
Manual 37471A easYgen-3000 Series - Genset Control Configure External AI (easYgen-3000 Series Package P2 only) For getting an analog input to work, there are 3 major settings to adjust. The parameter numbers are examples for the first analog input, they are different for the second one.
RIGHT CONFIGURATION Table 4-15: Supported sender types Configure External AO (easYgen-3000 Series Package P2 only) By clicking the "Help" button, you get further information and examples regarding the format you need to choose. For a detailed description of all parameters see the configuration manual.
Manual 37471A easYgen-3000 Series - Genset Control Figure 4-49: Example - configure AO 1 Confirm Your Changes Set parameter ID 15134 "Configure external devices" to "yes" to confirm your changes in the easYgen. Figure 4-50: Confirming your changes Page 52/69...
We have tested the maximum number of gensets for the following common configurations. It is not important for the following configurations whether Woodward IKD 1 or Phoenix expansion boards are used for the discrete I/Os, the bus load remains the same.
Manual 37471A easYgen-3000 Series - Genset Control Example Configuration 1 (4 x easYgen-3100) ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Max. 4 Gensets CAN #1: - ToolKit - PLC CAN #2: - Maximum engine bus load - Remote panel Figure 5-1: Example configuration 1 Page 54/69...
Manual 37471A easYgen-3000 Series - Genset Control Example Configuration 7 (18 x easYgen-3200) ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Max. 18 Gensets CAN #1: - load sharing line only CAN #2: - Maximum engine bus load - ToolKit Figure 5-7: Example configuration 7 Page 60/69...
Manual 37471A easYgen-3000 Series - Genset Control Example Configuration 11 (12 x easYgen-3200) ≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡ Max. 12 Gensets CAN #1: - PLC CAN #2: - ECU - 32 discrete I/Os - 32 analog inputs Figure 5-11: Example configuration 11 Page 64/69...
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