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Woodward GmbH
Handwerkstraße 29 — 70565 Stuttgart — Germany
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+49 (0) 711 789 54-510
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Summary of Contents for easYgen-400

Page 1: ...Technical Manual easYgen 400 Genset Control easYgen 400 Version 2 1 0 7 Document ID B37884A Revision F Build 51656 Released...

Page 2: ...igned in Germany and Poland manufactured in China Woodward GmbH Handwerkstr 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...

Page 3: ...l 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 Please check p...

Page 4: ...uration software and Technical Manual are available at Woodward website http wwdmanuals com easygen 400 Sample application setup Fig 2 Sample application setup 4 easYgen 400 B37884A Brief Overview Rel...

Page 5: ...gle genset application 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 ar...

Page 6: ...s and Functions of both easYgen 400 and 1400 18 2 3 Functions 21 2 4 Intended Use of This Control 21 3 Installation 22 3 1 Mounting 22 3 2 Wiring 22 3 3 Interfaces 27 3 4 Install ToolKit SC 28 4 Confi...

Page 7: ...ng Breakers 53 4 2 5 3 Monitoring Engine 54 4 2 5 4 Other Monitoring 54 4 2 6 Configure Maintenance 55 4 2 7 Configure Counters 55 4 2 8 Configure Language Clock 56 4 2 9 Configure System Management 5...

Page 8: ...s 70 5 4 1 Disconnect during cranking 70 6 Commissioning 72 7 Interfaces and Protocols 73 7 1 J1939 73 8 Technical Specifications 79 8 1 Measuring and Monitoring 82 9 Appendix 84 9 1 Alarms and Warnin...

Page 9: ...ports 27 Preheat until safety 28 Preheat until warming 29 Preheat until cranking Corrections Repairs None D 2020 11 TM NEW Software Version 2 1 0 6 needed ToolKit SC Version 1 5 1 3 or higher NEW feat...

Page 10: ...ker page Horn Alarm Acknowledge Alarm reset function Traditional Chinese implemented changed name easYgen400 easYgen1400 to easYgen 400 easYgen 1400 in controller information page status LED not turni...

Page 11: ...us Technical Manual In 3 2 Wiring terminal ratings and descriptions updated in Table corrections in Fig 6 Chapter 4 2 4 1 Configure Inputs and Outputs supplemented with an external LED module Minor ad...

Page 12: ...ous situation that can cause slight injuries if it is not avoided NOTICE This combination of symbol and signal word indicates a possibly dangerous situation that can cause property and environmental d...

Page 13: ...o comply with the instructions in this manual Improper use misuse Willful operation by non authorized persons Unauthorized conversions or non approved technical modifications Use of non approved spare...

Page 14: ...nformation 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...

Page 15: ...d in working with electronic measuring and control devices Allowed to manage the controlled engine generator system The workforce must only consist of persons who can be expected to carry out their wo...

Page 16: ...ntly of the prime mover control device s to protect from runaway or damage to the engine turbine or any other type of prime mover Failure to comply with this also poses the risk of personal injury or...

Page 17: ...ies 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 protect...

Page 18: ...intended to be used for single automation systems auto start stop of the unit is performed using a remote signal easYgen 1400 has all the functions of the easYgen 400 as well as automatic mains failu...

Page 19: ...raising speed and speed droop via CAN bus port Suitable for 3 phase 4 wire 3 phase 3 wire single phase 2 wire and 2 phase 3 wire systems with voltage 120 240 V and frequency 50 60 Hz easYgen 1400 onl...

Page 20: ...generator frequency speed sensor oil pressure are available Wide power supply range DC 8 to 35 V suitable for different start battery voltage environment Event log real time clock scheduled start stop...

Page 21: ...nce function Actions warning or shutdown can be set when maintenance time out Instead of conventional analog modulation with a potentiometer all parameters use digital adjustment for more reliability...

Page 22: ...his controller can be used with batteries with a voltage range from 8 to 35 VDC The negative pole of the battery must be connected to the engine shell The wire between the power supply and the battery...

Page 23: ...age Test Disconnect all terminal connections before performing a high voltage test of the installed controller CAUTION All inputs and outputs besides the Generator Voltage and Mains Voltage terminals...

Page 24: ...24 Vdc circuits is recommended 3 FUEL Relay Output 1 5 mm Relay is supplied by terminal 2 Rated 5 Adc 24 Vdc supply output Rated 2 Adc 24 Vdc inductive according to UL 6200 4 Start Relay Output 1 5 mm...

Page 25: ...put 1 0 mm Connect to oil pressure resistance type sensor Details see 4 3 2 Programmable Inputs 15 MPU 0 5 mm Connected with speed sensor Note If no MPU is installed parameter Firing speed RPM PARAMET...

Page 26: ...ensing Input 1 0 mm Connect to W phase output 2 A fuse is recommended 28 Generator N2 Input 1 0 mm Connect to generator N wire 29 NC Empty terminal 30 NC Empty terminal 31 NC Empty terminal 32 NC Empt...

Page 27: ...ring typical applications Fig 6 easYgen 400 wiring of a typical application 3 3 Interfaces Interface Connections Fig 7 Interface Connections 27 easYgen 400 B37884A 3 Installation 3 3 Interfaces Releas...

Page 28: ...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 Remove old so...

Page 29: ...relay outputs can be configured with the same output type E g Contents Setting of Flexible Output Port 1 is Output Type 18 Horn So 18 Horn can still be used for other Output ports too Input the senso...

Page 30: ...genset MAN Manual Mode Press this key and the controller enters into MAN mode AUTO Automatic Mode Press this key and the controller enters into AUTO mode Open Close breaker Release breaker control in...

Page 31: ...be deactivated safety on delay will start 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...

Page 32: ...test input was entered 7 Go back to the upper level using the Right Set Confirm button 8 Repeat step 7 as often as required until you reach the main menu screen 4 1 2 1 HMI Screens Without Password Le...

Page 33: ...mperature turbo pressure fuel consumption total fuel consumption and so on Different engine with different parameters 4th screen includes Phase voltage line voltage frequency phase sequence 5th screen...

Page 34: ...isplay all alarm information e g warning alarm shutdown alarm trip alarm and trip and stop alarm ECU alarms and shutdown alarms If the alarm information is displayed check the engine otherwise please...

Page 35: ...configuration into ToolKit SC with File Open Config Strg O Print the current configuration to your default printer with File Print Config Refresh config A configuration update between ToolKit SC and...

Page 36: ...device configuration ToolKit SC displays the current device configuration settings and values 3 Use the lower left area to select a screen page to edit 4 The button on the lower right side lets you s...

Page 37: ...ted to the device and immediately become active 4 2 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 orde...

Page 38: ...Fig 12 Menu Structure easYgen 400 overview 4 2 2 Parameter Settings Menu HMI Access 1 Press the RIGHT button 38 easYgen 400 B37884A 4 Configuration 4 2 2 Parameter Settings Menu HMI Access Released...

Page 39: ...itor 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 Co...

Page 40: ...ge Power kW Power kVA Power kW Selects the reference for the Load value in Home Screen General Measurement Settings PARAMETER Configure measurement General Measurement settings Items Parameters Defaul...

Page 41: ...tdown Default of discrete input 1 02 Low oil pressure shutdown Default of discrete input 2 10 Start request in AUTO Default of discrete input 3 11 Fuel level warning Default of discrete input 4 12 Coo...

Page 42: ...nfigure discrete outputs Notes For discrete outputs 1 to 4 Map Programmable Output 00 to 26 02 Stop solenoid Default of discrete output 1 03 Idle control Default of discrete output 2 05 Close GCB Defa...

Page 43: ...he following related settings will be taken into account On 0 to 300 C 50 C 122 F The engine heater control is switched on if the actual temperature is lower than the configured threshold Off 0 to 300...

Page 44: ...hen the sensor value is below the threshold Fuel pump control On 0 to 100 25 Release the alarm when sensor value is identical to or below this value and the delay time is over Off 0 to 100 80 Cancel t...

Page 45: ...alue is below the threshold Items Parameters Defaults Description Displayed units Temperature C F C Select local temperature unit for display Pressure kPa psi bar kPa Select local pressure unit for di...

Page 46: ...utdown Warning Alarm type to be released if wire break is detected Mute button TX enable enabled disabled enabled Allows the external LED signalling module to mute the horn signal Adjust to logic Outp...

Page 47: ...ns of the Font and Font color buttons and previewed Further buttons allow to adjust the printout page parameters Page setting and configure the printer Printer setup Finally the actual appearance of l...

Page 48: ...ith an additional parameter the speed variation can be adjusted Inc Dec step 1 to 20 rpm but the overall offset is limited to 10 from rated speed The speed offset is active as long as the engine is in...

Page 49: ...regular stop to standby Activated once the fail to stop delay time e g crank disconnect conditions contain oil pressure and oil pressure drops quite slowly if genset stops is reached Pulse time Speed...

Page 50: ...Off load On load Off load Schedule period Monthly Weekly Daily Custom weekly Monthly Notes Custom weekly A table with16 x setting blocks displays each with Start time weekly to select a week day Star...

Page 51: ...ng of the breaker in MAN mode Key switch Opens closes breaker with the buttons Auto switch The controller logic is used to open close the breaker and the related buttons are disabled Closing time 0 0...

Page 52: ...Alarm type to be released if limit is exceeded Monitoring Frequency PARAMETER Configure monitoring Generator Frequency Items Parameters Defaults Description Overfrequency Limit 0 0 to 75 Hz 57 0 Hz R...

Page 53: ...ire break is detected There is no wire breaker for this protection Limit 0 to 6000 kW 304 kW Release the alarm when sensor value is same or higher than this value and Delay time is over Return 0 to 60...

Page 54: ...Battery Voltage PARAMETER Configure monitoring Engine Other monitoring Battery voltage Items Parameters Defaults Description Overvoltage Limit 12 0 to 40 0 V 33 0 V Release the alarm when sensor valu...

Page 55: ...interval based on operation hours Time Push icon current date Maintenance based on internal time PARAMETER Configure maintenance interval to reset Items Parameters Defaults Description Maintenance in...

Page 56: ...2 8 Configure Language Clock PARAMETER Configure language clock Items Parameters Defaults Description Language English Chinese Spanish Russian Portuguese Turkish Polish French English One of the lang...

Page 57: ...recommended and upload it to the device Select Default theme OEM plant theme Terminal users theme Select pre defined theme or user defined HMI theme Theme configuration is disabled in Default theme mo...

Page 58: ...o 10 Reserved 11 DIGITAL CLOSED 12 DIGITAL OPEN 13 to 14 Reserved Defined resistance range is 0 to 6 K Default is 0 Not used Pressure Sensor 0 Not used 1 Custom Res Curve 2 VDO 3 SGH 4 SGD 5 CURTIS 6...

Page 59: ...sor curve values the X value resistor must be in sequence from small to large otherwise mistakes can occur If you select the option None under sensor type the sensor curve does not work If the corresp...

Page 60: ...rm output when input is active 20 Idle mode Under voltage frequency speed protection is inactive 21 Enable 60Hz Set System rated frequency to default of 60 Hz e g used for CANBUS engine 22 Raise speed...

Page 61: ...uel Action when genset is starting and disconnect when stop is completed 18 Starter Genset output in start output status and open in other status 19 ECU Stop Used for ECU engine and control its stop 2...

Page 62: ...it SC lets you access status information via the following screens Fig 17 easYgen x400 status screens Generator Status PARAMETER STATUS MENU Generator status Items Parameters Description Engine info E...

Page 63: ...ance time Time Engine hours Time Generator status Gen status Module info will be moved to Event log page Measured Values PARAMETER STATUS MENU Measured values Items Parameters Description Electricity...

Page 64: ...Event Item Date Time Mains control is not supported by this model so all Mains values are 0 Mains Uab V Ubc V Uca V Mains Ua V Mains Ub V Mains Uc V Mains f Hz Gens Uab V Gens Ua V Gens f Hz Current I...

Page 65: ...ute Horn Any new active alarm activates the horn and is made visible by the flashing Alarm LED After pressing the Down Decrease button the horn is deactivated and the Alarm LED changes from flashing t...

Page 66: ...engine is managed automatically along with opening closing the breaker supply load by generator start the engine stop the engine 5 2 2 Operation Mode MANual General notes In operation mode MANual both...

Page 67: ...tart 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...

Page 68: ...Fig 18 Engine start procedure 5 3 2 Stop engine The AUTO Stop procedure is going through sub procedures with own timers 68 easYgen 400 B37884A 5 Operation 5 3 2 Stop engine Released...

Page 69: ...s 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 69 easYge...

Page 70: ...ribed above 5 4 Transition Procedures 5 4 1 Disconnect during cranking There are three conditions under control to abort the starting of the engine speed sensor generator frequency engine oil pressure...

Page 71: ...be registrated nor displayed e g water pump application HMI only In ToolKit SC frequency speed and oil pressure can be enabled disabled separately HMI is using a table Firing speed instead No Setting...

Page 72: ...manual mode and controller will executive routine 5 Set controller under manual mode press start button genset will start After the setting times as setting controller will send signal of Start Fail t...

Page 73: ...39 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 CAN H...

Page 74: ...mins QSZ13 Common J1939 Terminals of controller OEM connector of engine Remark Fuel relay output 45 Start relay output Connect to starter coil directly Auxiliary output 1 16 41 Setting to idle speed c...

Page 75: ...0 connecting line is recommended John Deere Terminals of controller 21 pins connector Remark Fuel relay output G J Start relay output D CAN GND CAN communication shielding line connect with controller...

Page 76: ...to starter coil directly CAN GND CAN communication shielding line connect with controller s terminal only CAN H 9 Impedance 120 connecting line is recommended CAN L 10 Impedance 120 connecting line is...

Page 77: ...ry output 1 6 ECU stop Set Auxiliary output 1 as ECU Stop Auxiliary output 2 5 ECU power Set Auxiliary output 2 as ECU power 3 Negative power 4 Positive power CAN GND CAN communication shielding line...

Page 78: ...ne 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 connecting line is recommended CAN L 1 34 Impedanc...

Page 79: ...Battery voltage measurement Accuracy 1 12 V 24 V Alternator Input Range 3 Phase 4 Wire 15 Vac 173 Vac ph N according to UL6200 3 Phase 3 Wire 30 Vac 620 Vac ph ph 3 Phase 3 Wire 30 Vac 300 Vac ph ph a...

Page 80: ...ity max 93 non condensing Storage Condition Temperature 25 to 70 C Protection Level against water and dust Front IP65 by using mounting material delivered with device Back IP20 Net Weight 0 3 kg Input...

Page 81: ...cklight multilingual interface including English Chinese or other languages which can be chosen at the site making commissioning convenient for factory personnel LCD wear resistance and scratch resist...

Page 82: ...ce Frequency Hz For generator controller has over and under voltage over and under frequency loss of phase phase sequence wrong over and reverse power over current functions Load Current IA IB IC Each...

Page 83: ...y 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 83 easYgen 400 B37884A 8 Technical Specifications 8 1 Measur...

Page 84: ...will be displayed in LCD 2 Genset Over Current When the current of genset is higher than threshold and setting over current delay is 0 controller will send warning alarm signal and it will be display...

Page 85: ...reaker and shuts down generator No Items Description 2 High Temp Shutdown When the temperature of water cylinder is higher than set threshold controller will send a stop alarm signal and it will be di...

Page 86: ...Fail If the module does not detect the ECU data it will initiate a shutdown alarm 9 2 Trouble Shooting Symptoms Possible Solutions Controller has no power Check starting batteries Check controller con...

Page 87: ...Symptoms Possible Solutions refer to the relevant section of the engine manual as specified in the SPN alarm code 87 easYgen 400 B37884A 9 Appendix 9 2 Trouble Shooting Released...

Page 88: ...Pickup Unit N C Normally Closed break contact N O Normally Open make contact NC Neutral Contactor OC Occurrence Count Operation In general operation State when the genset is running according to the...

Page 89: ...C Commissioning 72 Configuration 29 Contact person 14 Customer Service 14 F Front Panel 29 Functions 17 H HMI 57 I Installation 22 Intended use 14 21 Interfaces 27 73 K Keys 30 L Language 35 M Mounti...

Page 90: ...sonnel 15 Protocols 73 S Service 14 Symbols in the instructions 12 System Overview 17 T Technical Specifications 79 ToolKit SC 28 35 Trouble Shooting 86 U Use 14 21 W Warnings 84 Warranty 14 Wiring 22...

Page 91: ...Woodward GmbH Handwerkstra e 29 70565 Stuttgart Germany Phone Fax stgt info woodward com 49 0 711 789 54 510 49 0 711 789 54 101 Released...

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