Easy 3000 Installation Manual
Easy 3000 Installation Manual
Easy 3000 Installation Manual
easYgen-3000
Genset Control
Installation
Software Version 1.0xxx
Manual 37223
Manual 37223
WARNING
Read this entire manual and all other publications pertaining to the work to be performed before installing, operating, or servicing this equipment. Practice all plant and safety instructions and precautions.
Failure to follow instructions can cause personal injury and/or property damage.
The engine, turbine, or other type of prime mover should be equipped with an overspeed (overtemperature, or overpressure, where applicable) shutdown device(s), that operates totally independently of the
prime mover control device(s) to protect against runaway or damage to the engine, turbine, or other
type of prime mover with possible personal injury or loss of life should 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.
Any unauthorized modifications to or use of this equipment outside its specified mechanical, electrical,
or other operating limits may cause personal injury and/or property damage, including damage to the
equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or "negligence" within
the meaning of the product warranty thereby excluding warranty coverage for any resulting damage,
and (ii) invalidate product certifications or listings.
CAUTION
To prevent damage to a control system that uses an alternator or battery-charging device, make sure
the charging device is turned off before disconnecting the battery from the system.
Electronic controls contain static-sensitive parts. Observe the following precautions to prevent damage to these parts.
Discharge body static before handling the control (with power to the control turned off, contact a
grounded surface and maintain contact while handling the control).
Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around printed circuit boards.
Do not touch the components or conductors on a printed circuit board with your hands or with
conductive devices.
OUT-OF-DATE PUBLICATION
This publication may have been revised or updated since this copy was produced. To verify that you
have the latest revision, be sure to check the Woodward website:
http://www.woodward.com/pubs/current.pdf
The revision level is shown at the bottom of the front cover after the publication number. The latest
version of most publications is available at:
http://www.woodward.com/publications
If your publication is not there, please contact your customer service representative to get the latest
copy.
Important definitions
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation that, if not avoided, could result in damage to equipment.
NOTE
Provides other helpful information that does not fall under the warning or caution categories.
Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be
correct and reliable. However, Woodward assumes no responsibility unless otherwise expressly undertaken.
Woodward
All Rights Reserved.
Page 2/52
Woodward
Manual 37223
Revision History
Rev. Date
NEW 06-11-23
Editor
TP
Changes
Release
Content
CHAPTER 1. GENERAL INFORMATION.........................................................................................7
CHAPTER 2. ELECTROSTATIC DISCHARGE AWARENESS .............................................................8
CHAPTER 3. HOUSING ...............................................................................................................9
Panel Cutout ...........................................................................................................................................9
Dimensions ...........................................................................................................................................10
Terminal Arrangement ..........................................................................................................................11
Clamp Fastener Installation ..................................................................................................................12
Screw Kit Installation.............................................................................................................................13
Page 3/52
Manual 37223
Page 4/52
Woodward
Manual 37223
Woodward
Page 5/52
Manual 37223
Tables
Table 1-1: Manual - overview.................................................................................................................................................... 7
Table 3-1: Housing - panel cutout ............................................................................................................................................. 9
Table 5-1: Conversion chart - wire size ................................................................................................................................... 15
Table 5-2: Power supply - terminal assignment....................................................................................................................... 16
Table 5-3: Charging alternator input/output - terminal assignment ......................................................................................... 17
Table 5-4: Voltage measuring (FlexRange) - terminal assignment - generator voltage.......................................................... 18
Table 5-5: Voltage measuring (FlexRange) - terminal assignment - generator, 3Ph 4W......................................................... 19
Table 5-6: Voltage measuring (FlexRange) - terminal assignment - generator, 3Ph 3W......................................................... 20
Table 5-7: Voltage measuring (FlexRange) - terminal assignment - generator, 1Ph 3W......................................................... 20
Table 5-8: Voltage measuring (FlexRange) - terminal assignment - generator, 1Ph 2W (phase-phase).................................. 21
Table 5-9: Voltage measuring (FlexRange) - terminal assignment - mains voltage ............................................................... 22
Table 5-10: Voltage measuring (FlexRange) - terminal assignment - mains, 3Ph 4W ............................................................ 23
Table 5-11: Voltage measuring (FlexRange) - terminal assignment - mains, 3Ph 3W ............................................................ 24
Table 5-12: Voltage measuring (FlexRange) - terminal assignment - mains, 1Ph 3W ............................................................ 24
Table 5-13: Voltage measuring (FlexRange) - terminal assignment - mains, 1Ph 2W (phase-phase) ..................................... 25
Table 5-14: Voltage measuring (FlexRange) - terminal assignment - busbar (system 1) 1Ph 2W (phase-phase)................... 26
Table 5-15: Current measuring - terminal assignment - generator current .............................................................................. 27
Table 5-16: Current measuring - terminal assignment - generator, L1 L2 L3 ......................................................................... 28
Table 5-17: Current measuring - terminal assignment - generator, phase Lx .......................................................................... 28
Table 5-18: Current measuring - terminal assignment - mains current .................................................................................... 29
Table 5-19: current measuring - terminal assignment - mains, phase Lx................................................................................. 29
Table 5-20: Current measuring - terminal assignment - ground current .................................................................................. 30
Table 5-21: MPU - terminal assignment.................................................................................................................................. 33
Table 5-22: Discrete input - terminal assignment .................................................................................................................... 35
Table 5-23: Relay outputs - terminal assignment .................................................................................................................... 37
Table 5-24: Analog inputs (FlexIn) - terminal assignment - wiring two-pole senders............................................................ 38
Table 5-25: Analog inputs (FlexIn) - terminal assignment - wiring single-pole senders ........................................................ 39
Table 5-26: Analog inputs (FlexIn) - terminal assignment - wiring single- and two-pole senders ......................................... 40
Table 5-27: Bias signal outputs - analog or PWM ................................................................................................................... 41
Table 5-28: RS-232 interface - pin assignment........................................................................................................................ 42
Table 5-29: RS-485/RS-422 interface #1 - pin assignment...................................................................................................... 42
Table 5-30: CAN bus #1 - pin assignment............................................................................................................................... 43
Table 5-31: CAN bus #2 - pin assignment............................................................................................................................... 43
Table 5-32: Maximum CAN bus length................................................................................................................................... 44
Table 8-1: CAN bus pin assignment - D-SUB DE9 connector ................................................................................................ 50
Table 8-2: CAN bus pin assignment - RJ45/8P8C connector .................................................................................................. 50
Table 8-3: CAN bus pin assignment - IDC / Header ............................................................................................................... 51
Page 6/52
Woodward
Manual 37223
Chapter 1.
General Information
Type
easYgen-3000 Series
easYgen-3000 - Installation
easYgen-3000 - Configuration
easYgen-3000 - Operation
easYgen-3000 - Application
easYgen-3000 - Interfaces
this manual
English
German
37223
37224
37225
37226
37383
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 operation and maintenance.
NOTE
This manual has been developed for a unit fitted with all available options. Inputs/outputs, functions,
configuration screens, and other details described, which do not exist on your unit, may be ignored.
The present manual has been prepared to enable the installation and commissioning of the unit. Due to
the large variety of parameter settings, it is not possible to cover every combination. The manual is
therefore only a guide. In case of incorrect entries or a total loss of functions, the default settings may
be taken from the list of parameters enclosed in the configuration manual 37224 or from ToolKit and
the respective *.SID file.
Woodward
Page 7/52
Manual 37223
Chapter 2.
Electrostatic Discharge Awareness
All electronic equipment is static-sensitive, some components more than others. To protect these components
from static damage, you must take special precautions to minimize or eliminate electrostatic discharges.
Follow these precautions when working with or near the control.
1.
Before doing maintenance on the electronic control, discharge the static electricity on your body to
ground by touching and holding a grounded metal object (pipes, cabinets, equipment, etc.).
2.
Avoid the build-up of static electricity on your body by not wearing clothing made of synthetic materials.
Wear cotton or cotton-blend materials as much as possible because these do not store static electric charges as easily as synthetics.
3.
Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam cups, cigarette packages, cellophane wrappers, vinyl books or folders, plastic bottles, etc.) away from the control, modules, and work
area as much as possible.
4.
CAUTION
To prevent damage to electronic components caused by improper handling, read and observe the precautions in Woodward manual 82715, Guide for Handling and Protection of Electronic Controls, Printed
Circuit Boards, and Modules.
Page 8/52
Woodward
Manual 37223
Chapter 3.
Housing
Panel Cutout
B
b
b'
h' h H
Description
Height
Width
Depth
Total
Panel cutout
Housing dimension
Total
Panel cutout
Housing dimension
Total
217 mm
183 mm
181 mm
282 mm
249 mm
247 mm
99 mm
Tolerance
--+ 1.0 mm
--+ 1.1 mm
---
Woodward
Page 9/52
Manual 37223
Dimensions
217 mm
181 mm
282 mm
247 mm
87 mm
99 mm
Page 10/52
Woodward
Manual 37223
Terminal Arrangement
L3 AI 01 AI 02 AI 03 AO 01
AO 02
L2
Analog Outputs
+/-10 Vdc
+/- 20 mA
PWM
L1
Analog Inputs
0 to 500 Ohm
0/4 to 20 mA
Mains PT
L1
L2
L3
RS-232
Relay R01
Common
Relay R04
Relay R03
Relay R02
Relay R05
Relay R06
Generator PT
L1
L2
L3
Busbar PT
L1 L2/N
100 V
400 V
100 V
400 V
100 V
400 V
100 V
400 V
100 V
400 V
100 V
400 V
100 V
400 V
100 V
400 V
100 V
400 V
100 V
400 V
Generator CT
Relay Outputs
RS-485 / RS-422
Discrete Inputs
Relay R07
Relay R08
Relay R09
Common
Relay R12
Relay R11
Relay R10
MPU MPU +
DI 12
DI 11
DI 10
DI 09
DI 08
DI 07
DI 06
DI 05
DI 04
DI 03
DI 02
DI 01
DI Common
Auxiliary excitation D+
24 V Power supply
24 V +
Engine ground
Protective earth PE
Pickup
Ground/Mains CT
CAN bus #2
CAN bus #1
80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41
Out
L1
PWM
PWM
s2 s1 s2 s1 s2 s1 s2 s1
V
V
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Out
Woodward
Page 11/52
Manual 37223
For installation into a door panel with the fastening clamps, proceed as follows:
1.
Panel cut-out
Cut out the panel according to the dimensions in Table 3-1.
cut-out
138,0
Rmax: R 3,5
186,0
2.
Remove terminals
Loosen the wire connection terminal screws on the back of the unit and
remove the wire connection terminal strip if required (1).
3.
4.
5.
6.
7.
Reattach terminals
Reattach the wire connection terminal strip (1) and secure them with the
side screws.
Page 12/52
2
1
1
2
Woodward
Manual 37223
In order to enhance the protection to IP 66, it is possible to fasten the unit with a screw kit instead of the clamp
fastener hardware.
Proceed as follows to install the unit using the screw kit:
1. Cut out the panel and drill the holes according to the dimensions in Figure 3-4.
2. Insert the unit into the panel cutout. Verify that the unit fits correctly in the cutout. If the panel cutout is not
big enough, enlarge it accordingly.
3. Insert the screws and tighten to 0.6 Nm (5.3 pound inches) of torque. Tighten the screws with a crosswise
pattern to ensure even pressure distribution.
NOTE
If the thickness of the panel sheet exceeds 2.5 mm, be sure to use screws with a length of the panel
sheet thickness + 4 mm.
259.0
5.7
12 x 4.5
183.0
194.4
161.5
91.5
224.5
124.5
21.5
24.5
5.0
254.0
249.0
Cutout dimension:
249mm (+1.1mm) x 183mm (+1.0mm)
Woodward
Page 13/52
Manual 37223
400 Vac
9-pin male
submin-D-connector
Interface #1
RS-232 (isolated)
Serial #1
2: RxD
3: TxD
5: GND
7: RTS
8: CTS
[R 01]
[R 02]
100 Vac
[R 03]
400 Vac
[R 04]
Generator voltage L3
[R 05]
Generator voltage L2
Generator voltage L1
400 Vac
FlexRange
100 Vac
Generator voltage N
100 Vac
400 Vac
FlexRange
400 Vac
100 Vac
400 Vac
100 Vac
400 Vac
FlexRange
[R 07]
[R 08]
Mains voltage L3
[R 09]
[R 10]
400 Vac
400 Vac
[R 06]
Mains voltage N
100 Vac
100 Vac
LogicsManager
100 Vac
Mains voltage L2
100 Vac
[R 11]
400 Vac
[R 12]
Mains voltage L1
100 Vac
PE
Analog output [AO 02]
(+/-10Vdc / +/-20mA / PWM)
(isolated)
+
+
+
+
-
L3
Generator current
(isolated)
L2
L1
s2
s1
Ground current
(or mains current)
(isolated)
L1
s2
2: CAN-L
3: GND
7: CAN-H
Interface #4
CAN bus #2
Engine level (isolated)
[DI 01]
[DI 02]
[DI 03]
[DI 04]
[DI 05]
[DI 06]
[DI 07]
[DI 08]
[DI 09]
[DI 10]
[DI 11]
[DI 12]
+
-
MPU (pickup)
FlexCAN
FlexIn
s2
s1
s2
s1
+
-
Power supply
isolated, 8 to 40 Vdc
Analog output [AO 01]
(+/-10Vdc / +/-20mA / PWM)
(isolated)
s1
Engine ground
FlexOut
+
-
Interface #3
CAN bus #1
Guidance/system level (isolated)
2: CAN-L
3: GND
7: CAN-H
80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41
Interface #2
RS-485/RS-422 (isolated) #1
Serial #2
9-pin male
submin-D-connector
2: B
4: B'
7: A
9: A'
FlexCAN
9-pin male
submin-D-connector
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
DC
voltage
DC
current
GND
VOut GND
N/C
GND
VOut GND
N/C
IA
PWM GND
IA
PWM GND
PWM
9-pin male
submin-D-connector
Chapter 4.
Wiring Diagrams
Woodward
Manual 37223
Chapter 5.
Connections
WARNING
All technical data and ratings indicated in this chapter are not definite! Only the values indicated in
Chapter 6: Technical Data on page 45 are valid!
The following chart may be used to convert square millimeters [mm] to AWG and vice versa:
AWG
30
28
26
24
22
mm
0.05
0.08
0.14
0.25
0.34
AWG
21
20
18
17
16
mm
0.38
0.5
0.75
1.0
1.5
AWG
14
12
10
8
6
mm
2.5
4
6
10
16
AWG
4
2
1
1/0
2/0
mm
25
35
50
55
70
AWG
3/0
4/0
300MCM
350MCM
500MCM
mm
95
120
150
185
240
AWG
600MCM
750MCM
1000MCM
mm
300
400
500
Woodward
Page 15/52
Manual 37223
Power Supply
61 PE
Power supply
63 8 to 40.0 Vdc
64 0 Vdc
Description
PE (protection earth)
12/24Vdc (8 to 40.0 Vdc)
0 Vdc
Amax
2.5 mm
2.5 mm
2.5 mm
Power Supply
[V]
12.0
11.0
Continuous voltage range =
8.0 to 40.0 Vdc
10.0
Continuous voltage = min. 8.0 Vdc
9.0
8.0
7.0
6.0
5.0
4.0
3.0
2.0
Time
1.0
0.0
-50
50
100
150
200
250
300
350
[ms]
NOTE
Woodward recommends to use one of the following slow-acting protective devices in the supply line to
terminal 63:
Fuse NEOZED D01 6A or equivalent
or
Miniature Circuit Breaker 6A / Type C (for example: ABB type: S271C6 or equivalent)
Page 16/52
Woodward
Manual 37223
Charging Alternator
63 8 to 40 Vdc
B+
+
-
G~
D+
Auxiliary excitation
65 D+
Description
Battery B+
Auxiliary excitation output D+
Amax
2.5 mm
2.5 mm
NOTE
The charging alternator D+ acts as an output for pre-exciting the charging alternator during engine
start-up only. During regular operation, it acts as an input for monitoring the charging voltage.
Woodward
Page 17/52
Manual 37223
NOTE
DO NOT use both sets of voltage measuring inputs. The control unit will not measure voltage correctly
if the 100 V and 400 V inputs are utilized simultaneously.
NOTE
Woodward recommends protecting the voltage measuring inputs with slow-acting fuses rated for 2 to
6 A.
GCB
L1
L2
3~
L3
N
29 100 Vac
400 Vac
30 400 Vac
100 Vac
31 100 Vac
400 Vac
32 400 Vac
100 Vac
33 100 Vac
400 Vac
34 400 Vac
100 Vac
35 100 Vac
400 Vac
36 400 Vac
L1 / Va
L2 / Vb
L3 / Vc
Generator voltage
(phase voltage)
100 Vac
N / Vcom
Description
Generator voltage - phase L1 / Va
Generator voltage - phase L2 / Vb
Generator voltage - phase L3 / Vc
Generator voltage - phase N / Vcom
100 Vac
400 Vac
100 Vac
400 Vac
100 Vac
400 Vac
100 Vac
400 Vac
Amax
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
Page 18/52
Woodward
Manual 37223
L1
L1
A1
A1
A2
A2
A5
A6
N
C2
C6
C1
B1
B5
C2
B2
C1
L2
B1
L3
L3
A2
A6
C2
B6
B5
B2
C5
A2
C1
C6
A1
C5
N
C2
L1
A
C6
A5
L2
L1
A1
N B6
C5
B2
C1
B1
A5
L2
A6
B
B6
B5
B2
B1
L2
L3
L3
3Ph 4W
Rated voltage
Range (max.)
easYgen
Phase
Wiring terminals
29
L1
100 Vac
0 to 150 Vac
31
33
L2
L3
35
N
30
L1
Note
400 Vac
0 to 600 Vac
32
34
L2
L3
1
36
N
For different voltage systems, different wiring terminals have to be used. Incorrect measurements are possible if both voltage systems use
the same N terminal.
Woodward
Page 19/52
Manual 37223
L1
L1
A
C6
A1
C5
C2
A2
A1
A2
C1
C2
A5
C1
B2
L2
B1
A6
B6
B5
B2
B1
L2
L3
L3
Wiring terminals
3Ph 3W
Rated voltage
Range (max.)
easYgen
Phase
100 Vac
0 to 150 Vac
31
33
L2
L3
29
L1
35
---
Note
400 Vac
0 to 600 Vac
32
34
L2
L3
30
L1
2
36
---
B5
C2
B6
B1
C1
L1
A1
A5
A2
A6
C6
B2
B6
C5
B5
B2
B1
C2
C
A1
A2
A5
A6
C1
L3
N
C6
C5
L3
N
L1
1Ph 3W
Rated voltage
Range (max.)
easYgen
Phase
Wiring terminals
29
L1
100 Vac
0 to 150 Vac
31
33
N
L3
35
N
30
L1
Note
400 Vac
0 to 600 Vac
32
34
N
L3
3
36
N
2
3
Page 20/52
Woodward
Manual 37223
B
A1
A2
A5
A6
A1
B5
A2
B6
L1
L2
L1
L2
1Ph 2W
Rated voltage
Range (max.)
easYgen
Phase
Wiring terminals
29
L1
100 Vac
0 to 150 Vac
31
33
L2
---
35
---
30
L1
Note
400 Vac
0 to 600 Vac
32
34
L2
---
4
36
---
Table 5-8: Voltage measuring (FlexRange) - terminal assignment - generator, 1Ph 2W (phase-phase)
For different voltage systems, different wiring terminals have to be used. Incorrect measurements are possible if both voltage systems use
the same N terminal.
Woodward
Page 21/52
Manual 37223
MCB
L1
L2
L3
N
21 100 Vac
400 Vac
22 400 Vac
100 Vac
23 100 Vac
400 Vac
24 400 Vac
100 Vac
25 100 Vac
400 Vac
26 400 Vac
100 Vac
27 100 Vac
400 Vac
28 400 Vac
L1 / Va
L2 / Vb
L3 / Vc
Mains voltage
(phase voltage)
100 Vac
N / Vcom
Description
Mains voltage - phase L1 / Va
Mains voltage - phase L2 / Vb
Mains voltage - phase L3 / Vc
Mains voltage - phase N / Vcom
100 Vac
400 Vac
100 Vac
400 Vac
100 Vac
400 Vac
100 Vac
400 Vac
Amax
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
Page 22/52
Woodward
Manual 37223
L1
L1
A1
A1
A2
A2
A5
A6
N
C2
C6
C1
B1
B5
C2
B2
B1
C1
L2
L3
L3
A2
A6
C2
B6
B5
B2
C5
A2
C1
C6
A1
C5
N
C2
L1
A
C6
A5
L2
L1
A1
N B6
C5
B2
C1
B1
A5
L2
A6
B
B6
B5
B2
B1
L2
L3
L3
3Ph 4W
Rated voltage
Range (max.)
easYgen
Phase
Wiring terminals
21
L1
100 Vac
0 to 150 Vac
23
25
L2
L3
27
N
22
L1
Note
400 Vac
0 to 600 Vac
24
26
L2
L3
5
28
N
For different voltage systems, different wiring terminals have to be used. Incorrect measurements are possible if both voltage systems use
the same N terminal.
Woodward
Page 23/52
Manual 37223
L1
L1
A
C6
A1
C5
C2
A2
A1
A2
C1
C2
A5
C1
B2
L2
B1
A6
B6
B5
B2
B1
L3
L2
L3
Wiring terminals
3Ph 3W
Rated voltage
Range (max.)
easYgen
Phase
100 Vac
0 to 150 Vac
23
25
L2
L3
21
L1
27
---
Note
400 Vac
0 to 600 Vac
24
26
L2
L3
22
L1
6
28
---
B5
C2
B6
B1
C1
L1
A1
A5
A2
A6
C6
B2
B6
C5
B5
B2
B1
C2
C
A1
A2
A5
A6
C1
L3
N
C6
C5
L3
N
L1
1Ph 3W
Rated voltages
Range (max.)
easYgen
Phase
Wiring terminals
21
L1
100 Vac
0 to 150 Vac
23
25
N
L3
27
N
22
L1
Note
400 Vac
0 to 600 Vac
24
26
N
L3
7
28
N
6
7
Page 24/52
Woodward
Manual 37223
B
A1
A2
A5
A6
A1
B5
A2
B6
L1
L2
L1
L2
1Ph 2W
Rated voltage
Range (max.)
easYgen
Phase
Wiring terminals
21
L1
100 Vac
0 to 150 Vac
23
25
L2
---
27
---
22
L1
Note
400 Vac
0 to 600 Vac
24
26
L2
---
8
28
---
Table 5-13: Voltage measuring (FlexRange) - terminal assignment - mains, 1Ph 2W (phase-phase)
For different voltage systems, different wiring terminals have to be used. Incorrect measurements are possible if both voltage systems use
the same N terminal.
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Manual 37223
GCB
MCB
L1
L2
L3
100 Vac
37 100 Vac
400 Vac
38 400 Vac
100 Vac
39 100 Vac
400 Vac
40 400 Vac
L1
L2
Busbar
voltage
(phase
voltage)
Description
Busbar voltage (system 1) - phase L1
Busbar voltage (system 1) - phase L2
100 Vac
400 Vac
100 Vac
400 Vac
Amax
2.5 mm
2.5 mm
2.5 mm
2.5 mm
Table 5-14: Voltage measuring (FlexRange) - terminal assignment - busbar (system 1) 1Ph 2W (phase-phase)
Page 26/52
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Manual 37223
Current Measuring
CAUTION
Before disconnecting the device, ensure that the current transformer/CT is short-circuited.
Generator Current
NOTE
Generally, one line of the current transformers secondary is to be grounded close to the CT.
GCB
L1
L2
3~
L3
S1
s2
s1
G
..
S2
s1 (k)
..
L..
s2 (l)
L..
8 ../{x} A
s1 (k) - L3
7 ../{x} A
s2 (l) - L3
6 ../{x} A
s1 (k) - L2
5 ../{x} A
s2 (l) - L2
4 ../{x} A
s1 (k) - L1
3 ../{x} A
s2 (l) - L1
Generator current
(phase current)
Detail:
Connection of the transducers
../{x} A - {x} = 1 or 5
Description
Generator current - phase L3 - transformer terminal s1 (k)
Generator current - phase L3 - transformer terminal s2 (l)
Generator current - phase L2 - transformer terminal s1 (k)
Generator current - phase L2 - transformer terminal s2 (l)
Generator current - phase L1 - transformer terminal s1 (k)
Generator current - phase L1 - transformer terminal s2 (l)
Amax
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
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Manual 37223
G
3~
L2
L3
N
Wiring terminals
5
6
s1 (k) L2
s2 (l) L2
L1 L2 L3
easYgen
Phase
3
s1 (k) L1
4
s2 (l) L1
Notes
7
s1 (k) L3
8
s2 (l) L3
Current Measuring: Generator, Parameter Setting 'Phase L1', 'Phase L2' & 'Phase L3'
IGen L1
IGen L2
L1
G
3~
L2
L3
N
IGen L3
L1
G
3~
L2
L3
N
L1
G
3~
L2
L3
N
Phase L1
Phase L2
Phase L3
Figure 5-17: Current measuring - Generator, phase Lx
Wiring terminals
Notes
Phase L1
easYgen
Phase
3
s1 (k) L1
4
s2 (l) L1
5
---
6
---
7
---
8
---
easYgen
Phase
3
---
4
---
5
s1 (k) L2
6
s2 (l) L2
7
---
8
---
easYgen
Phase
Phase L1 and L3
easYgen
Phase
3
---
4
---
5
---
6
---
7
s1 (k) L3
8
s2 (l) L3
3
s1 (k) L1
4
s2 (l) L1
5
---
6
---
7
s1 (k) L3
8
s2 (l) L3
Phase L2
Phase L3
This is valid if the generator voltage measurement is configured to 1Ph 3W (refer to Voltage Measuring: Generator, Parameter Setting
'1Ph 3W' (1-phase, 3-wire) on page 20).
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Manual 37223
MCB
L1
L2
L3
N
Detail:
Connection of the transducers
L..
s1 (k)
s2 (l)
../{x} A
{x} = 1 or 5
L..
2 ../{x} A
s1 (k)
1 ../{x} A
s2 (l)
Mains
current
s1
..
S1
s2
..
S2
Description
Mains current - transformer terminal s1 (k)
Mains current - transformer terminal s2 (l)
Amax
2.5 mm
2.5 mm
Current Measuring: Mains, Parameter Setting 'Phase L1', 'Phase L2' & 'Phase L3'
IMains L1
IMains L2
IMains L3
L1
L1
L1
L2
L2
L2
L3
L3
L3
Phase L1
Phase L2
Phase L3
Figure 5-19: Current measuring - mains, phase Lx
Wiring terminals
Notes
Phase L1
easYgen
Phase
1
s2 (l) - L1
2
s1 (k) - L1
easYgen
Phase
1
s2 (l) - L2
2
s1 (k) - L2
easYgen
Phase
1
s2 (l) - L3
2
s1 (k) - L3
Phase L2
Phase L3
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Manual 37223
Ground Current
The mains current input can be configured to measure the mains current or ground current. Depending on how
Parameter 'Input mains current as' is configured will determine if this input will measure the mains current (default) or the ground current. Refer to configuration manual 37224 for more information.
NOTE
Generally, one line of the current transformers secondary is to be grounded.
Holmgreen
connection
G
3~
Cable-type current
transformer
L1
L3
L1
L2
L2
3~
L3
3~
R
L1
L1
L1
L2
L2
L2
L3
L3
L3
s1 (k)
s2 (l)
Ground current
Description
Ground current - transformer terminal s1 (k)
Ground current - transformer terminal s2 (l)
Amax
2.5 mm
2.5 mm
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Manual 37223
Power Measuring
If the unit's current transformers are wired according to the diagram shown, the following values are displayed.
Parameter
Generator real power
Generator real power
Generator power factor (cos )
Generator power factor (cos )
Mains real power
Mains real power
Mains power factor (cos )
Mains power factor (cos )
Description
Genset generating kW
Genset in reverse power
Inductive / lagging
Capacitive / leading
Plant exporting kW +
Plant importing kW Inductive / lagging
Capacitive / leading
Sign displayed
+ Positive
- Negative
+ Positive
- Negative
+ Positive
- Negative
+ Positive
- Negative
MAINS
MCB
mains circuit breaker
s2 (l)
S2 (L)
1
2
s1 (k)
S1 (K)
P
pos
Real power
display positive
Q
ind
Reacitive power
display inductive
easYgen
BUSBAR
GCB
generator circuit breaker
s2 (l)
S2 (L)
5
6
s1 (k)
S1 (K)
P
pos
Real power
display positive
Q
ind
Reacitive power
display inductive
GENERATOR
G
Figure 5-21: Power measuring - direction of power
The phasor diagram is used from the generator's view. Power factor is defined as follows.
Power Factor is defined as a ratio of the real power to apparent power. In a purely resistive circuit, the voltage
and current waveforms are instep resulting in a ratio or power factor of 1.00 (often referred to as unity). In an inductive circuit the current lags behind the voltage waveform resulting in usable power (real power) and unusable
power (reactive power). This results in a positive ratio or lagging power factor (i.e. 0.85lagging). In a capacitive
circuit the current waveform leads the voltage waveform resulting in usable power (real power) and unusable
power (reactive power). This results in a negative ratio or a leading power factor (i.e. 0.85leading).
Inductive: Electrical load whose current waveform lags
the voltage waveform thus having a lagging power factor. Some inductive loads such as electric motors have
a large startup current requirement resulting in lagging
power factors.
Woodward
Manual 37223
c0.93 (capacitive)
ld.93 (leading)
- (negative)
leading
The generator is
over excited
under excited
Control: If the control unit is equipped with a power factor controller while in parallel with the utility:
A voltage lower "-" signal is output as long as the
measured value is "more inductive" than the reference
set point
Example: measured = i0.91; set point = i0.95
Phasor diagram:
inductive
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capacitive
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Manual 37223
MPU (Pickup)
Rotating shaft
Sensor
to
Pickup
input
24 V
< 1,0 V
79
80
Description
MPU input - inductive/switching
MPU input - GND
Amax
2.5 mm
2.5 mm
Table 5-21: MPU - terminal assignment
NOTE
The shield of the MPU (Magnetic Pickup Unit) connection cable must be connected to a single point
ground terminal near the easYgen. The shield must not be connected at the MPU side of the cable.
NOTE
The number of teeth on the flywheel reference gear and the flywheel speed must be configured so that
the magnetic pickup input frequency does not exceed 14kHz.
12000
[mVrms]
10000
8000
6000
4000
2000
[kHz]
0
0,1
10
100
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Manual 37223
Discrete Inputs
NOTE
All discrete inputs must use the same polarity, either positive or negative signals, due to the common
ground.
66
68
69
70
71
72
73
74
75
76
77
78
67
Discrete input 1
Discrete input 2
Discrete input 3
Discrete input 4
Discrete input 5
Discrete input 6
Discrete input 7
Discrete input 8
Discrete input 9
Discrete input 10
Discrete input 11
Discrete input 12
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Manual 37223
66
67
Power supply -
68
Power supply -
69
Power supply -
70
Power supply -
71
Power supply -
72
Power supply -
73
Power supply -
74
Power supply -
75
Power supply -
76
Power supply -
77
Power supply -
78
Discrete input 1
Discrete input 2
Discrete input 3
Discrete input 4
Discrete input 5
Discrete input 6
Discrete input 7
Discrete input 8
Discrete input 9
Discrete input 10
Discrete input 11
Discrete input 12
Description
Discrete inputs - GND (common ground)
Discrete input [DI 01]; pre-assigned to 'Emergency stop'
Discrete input [DI 02]; pre-assigned to 'Start in AUTO'
Discrete input [DI 03]; pre-assigned to 'Low oil pressure'
Discrete input [DI 04]; pre-assigned to 'Coolant temperature'
Discrete input [DI 05]; pre-assigned to 'External alarm acknowledgement'
Discrete input [DI 06]; pre-assigned to 'Enable MCB'
Discrete input [DI 07]; fixed to 'Reply MCB'
Discrete input [DI 08]; fixed to 'Reply GCB'
Discrete input [DI 09]
Discrete input [DI 10]
Discrete input [DI 11]
Discrete input [DI 12]
Amax
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
WARNING
Discrete Input DI01 "Emergency Stop" is only a signaling input. This input may only be used to signal
that an external emergency stop button has been actuated. According to EN 60204, this input is not
approved to be used as the emergency stop function. The emergency stop function must be implemented external to the control and cannot rely on the control to function properly.
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Manual 37223
Vdc (GND)
GND (Vdc)
Page 36/52
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Manual 37223
Relay Outputs
(LogicsManager)
B A
2A
external device
N/
Relay output
Description
Amax
42
41
{all}
{all}
{all}
{all}
{all}
43
44
46
45
48
47
50
49
52
51
54
53
56
55
57
58
59
60
{0}
{1o}
{1oc}
{2oc}
{0}
{1o}
{1oc}
{2oc}
{0}
{1o}
{1oc}
{2oc}
{0}
{1o}
{1oc}
{2oc}
{all}
{all}
{all}
Type
Ready for operation &
N.O.
LogicsManager
Centralized alarm or
SW
LogicsManager
Starter or
SW
LogicsManager
Fuel solenoid / gas valve or
SW
LogicsManager
Preglow or
SW
LogicsManager
LogicsManager
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
SW
2.5 mm
Command: close GCB
LogicsManager
Command: open GCB
LogicsManager
Command: close MCB
LogicsManager
Command: open MCB
Auxiliary services or
LogicsManager
Alarm class A and B or
LogicsManager
Alarm class C, D, E, F or
LogicsManager
N.O.
SW
N.O.
SW
2.5 mm
2.5 mm
N.O.
SW
2.5 mm
N.O.
SW
2.5 mm
SW
2.5 mm
SW
2.5 mm
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Manual 37223
It is recommended to use two-pole analog senders. This ensures an accuracy of 1% for 0 to 500 Ohm inputs
and 1.2% for 0/4 to 20 mA inputs.
NOTE
The return wires (GND) should be connected to PE (terminal 61; for two-pole senders) or engine
ground (terminal 62; for single-pole senders) as close to the easYgen terminals as possible.
0/4 to 20 mA
PE
+
Protective Earth
[AI 03]
Resistive / VDO
0/4 to 20 mA
61
9 10 11 12 13 14
To ensure accurate system measurements, all VDO sending units must utilize insulated wires that are
connected to the easYgen analog input ground (terminals 9/11/13). Terminals 9/11/13 must have jumper
wires connected to the PE connection (terminal 61).
Analog input
[AI 02]
0/4 to 20 mA
[AI 01]
Resistive / VDO
Description
Analog input [AI 01] ground, connected with PE
Analog input [AI 01]
Analog input [AI 02] ground, connected with PE
Analog input [AI 02]
Analog input [AI 03] ground, connected with PE
Analog input [AI 03]
Amax
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
Table 5-24: Analog inputs (FlexIn) - terminal assignment - wiring two-pole senders
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Manual 37223
0/4 to 20 mA
[AI 03]
Resistive / VDO
0/4 to 20 mA
62 61
PE
9 10 11 12 13 14
An accuracy of 2.5% may be achieved when using single-pole senders. The specified accuracy of 2.5% for
single-pole sensors can only be achieved if the differential voltage between the genset chassis ground and PE
does not exceed +/- 2.5V.
Protective Earth
Engine ground
Engine ground
+
+
-
Analog input
[AI 02]
Resistive / VDO
0/4 to 20 mA
[AI 01]
Resistive / VDO
Description
Analog input [AI 01] ground, connected with engine ground
Analog input [AI 01]
Analog input [AI 02] ground, connected with engine ground
Analog input [AI 02]
Analog input [AI 03] ground, connected with engine ground
Analog input [AI 03]
Amax
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
Table 5-25: Analog inputs (FlexIn) - terminal assignment - wiring single-pole senders
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Manual 37223
0/4 to 20 mA
PE
+
Protective Earth
[AI 03]
Resistive / VDO
+
-
+
-
Analog input
[AI 02]
62
0/4 to 20 mA
61
9 10 11 12 13 14
An accuracy of 2.5% may be achieved when using single-pole senders. It is possible to combine single- and
two-pole senders. The specified accuracy of 2.5% for single-pole sensors can only be achieved if the differential voltage between the genset chassis ground and PE does not exceed +/- 2.5V.
Engine ground
Engine ground
Resistive / VDO
[AI 01]
Resistive / VDO
Figure 5-31: Analog inputs (FlexIn) - wiring single- and two-pole senders
Terminal
9
10
11
12
13
14
Description
Analog input [AI 01] ground, connected with PE / engine ground
Analog input [AI 01]
Analog input [AI 02] ground, connected with PE / engine ground
Analog input [AI 02]
Analog input [AI 03] ground, connected with PE / engine ground
Analog input [AI 03]
Amax
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
Table 5-26: Analog inputs (FlexIn) - terminal assignment - wiring single- and two-pole senders
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Manual 37223
Controller configuration and an external jumper can change the multifunction controller bias output signals.
PWM
Current
GND
VA
B
A IA
C GND
B VA
Voltage
Speed
Governor
GND
IA
C GND
N/C
C GND
B PWM
PWM
Speed
Governor
GND
Speed
Governor
Controller Wiring
Speed / power
controller
Speed / power
controller
Speed / power
controller
Figure 5-32: Analog controller output - Wiring and external jumper setting
Type
I
Current
V
Voltage
PWM
I
Current
V
Voltage
PWM
A
B
C
A
B
C
A
B
C
A
B
C
A
B
C
A
B
C
Terminal
15
IA
16
17
GND
15
16
VA
17
GND
15
16 PWM
17
GND
18
IA
19
20
GND
18
19
VA
20
GND
18
19 PWM
20
GND
Description
Analog output AO 01
Analog output AO 02
Amax
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
2.5 mm
Table 5-27: Bias signal outputs - analog or PWM
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Manual 37223
Interfaces
Description
not connected
RxD (receive data)
TxD (transmit data)
not connected
GND (system ground)
not connected
RTS (request to send)
CTS (clear to send)
not connected
Amax
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Table 5-28: RS-232 interface - pin assignment
Description
not connected
B
not connected
B'
not connected
not connected
A
not connected
A'
Amax
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Table 5-29: RS-485/RS-422 interface #1 - pin assignment
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Manual 37223
Description
not connected
CAN-L
GND
not connected
not connected
not connected
CAN-H
not connected
not connected
Amax
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Table 5-30: CAN bus #1 - pin assignment
Description
not connected
CAN-L
GND
not connected
not connected
not connected
CAN-H
not connected
not connected
Amax
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Table 5-31: CAN bus #2 - pin assignment
NOTE
Refer to Appendix A: CAN Bus Pin Assignments on page 50 for general information about CAN bus pin
assignments.
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Manual 37223
NOTE
Please note that the CAN bus must be terminated with a resistor, which corresponds to the impedance
of the cable (e.g. 120 Ohms, 1/4 W) at both ends. The termination resistor is connected between CAN-H
and CAN-L.
Note:
We recommend for very critical EMC
conditions (many noise sources with
high noise levels) and high transmission
rates to use the "Split Termination
Concept", i.e. dividing the termination
resistor into 2x60 Ohms with a center tap
connected to ground via a capacitor
of 10 - 100 nF.
GND
CAN-L
Termination
resistor
CAN-H
GND
CAN-L
CAN-H
GND
~60 Ohms
CAN-L
Termination
resistor
CAN-H
~60 Ohms
10 ~ 100 nF
Note:
The termination has to be
performed with a resisitance,
which corresponds to the
impedance of the used cable
(e.g 120 Ohms)
CAN bus
CAN bus
CAN bus
Max. length
25 m
50 m
100 m
250 m
1000 m
2500 m
The maximum specified length for the communication bus wiring might not be achieved if poor quality wire is
utilized, there is high contact resistance, or other conditions exist. Reducing the baud rate may overcome these issues.
Page 44/52
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Manual 37223
Chapter 6.
Technical Data
Nameplate ----------------------------------------------------------------------------------------------------1
1
2
3
4
5
6
7
8
9
S/N
S/N
S/N
P/N
REV
Details
Type
Type
Approval
Accuracy.................................................................................................................... Class 1
Linear measuring range
Generator..........................................................3.0 Irated
Mains/ground current......................... approx. 1.5 Irated
Maximum power consumption per path ...............................................................< 0.15 VA
Rated short-time current (1 s)
[1]...................................................................50.0 Irated
[5].................................................................. 10.0 Irated
Ambient variables -------------------------------------------------------------------------------------------- Power supply .............................................................................. 12/24 Vdc (8 to 40.0 Vdc)
Intrinsic consumption
2 PCB hardware ............................................ max. 17 W
- Degree of pollution..............................................................................................................2
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Manual 37223
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Manual 37223
Interface --------------------------------------------------------------------------------------------------------
RS-232 interface
Version ...................................................................................................... RS-232 Standard
Signal level .......................................................................................................................5V
RS-485/RS-422 interface
Version ...................................................................................................... RS-485 Standard
Signal level .......................................................................................................................5V
Type....................................................................................................................... easYpack
Dimensions (W H D) .................................................................282 217 67/99 mm
Front cutout (W H)............................................................... 249 [+1.1] 183 [+1.0] mm
Wiring................................................................................... screw-plug-terminals 2.5 mm
Recommended locked torque .......................................................... 4 inch pounds / 0.5 Nm
use 60/75 C copper wire only
use class 1 wire only or equivalent
Weight ......................................................................................................... approx. 1,850 g
Protection ------------------------------------------------------------------------------------------------------
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Manual 37223
Chapter 7.
Environmental Data
Page 48/52
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Manual 37223
Chapter 8.
Accuracy
Measuring value
Display
Accuracy
Notes
15.0 to 85.0 Hz
40.0 to 85.0 Hz
0.1 %
0.1 %
0 to 650 kV
0 to 650 kV
1%
1%
0 to 32,000 A
0 to 32,000 A
0 to 32,000 A
1%
1%
1%
Slave pointer
-
-2 to 2 GW
2%
-2 to 2 Gvar
2%
lag0.00 to 1.00
to lead0.00
2%
Frequency
Generator
Mains
Voltage
Generator
Mains
Current
Generator
Max. value
Mains/ground current
Real power
Current total real power value
Reactive power
Current value in L1, L2, L3
Power factor
Current value power factor L1
Miscellaneous
Real energy
Operating hours
Maintenance call hours
Maintenance call days
Start counter
Battery voltage
Pickup speed
0 to 4,200 GWh
4109 h
0 to 9,999 h
0 to 999 d
0 to 65,535
8 to 40 V
fn +/- 40 %
1%
not calibrated
-
Analog inputs
0 to 180 Ohms
freely scaleable
*
for VDO sensors
0 to 360 Ohms
freely scaleable
*
for VDO sensors
0 to 500 Ohms
freely scaleable
*
for resistive sensor
0/4 to 20 mA
freely scaleable
**
*
1% for two-pole senders; 2.5% for single-pole senders and a combination of single- and two-pole sensors
** 1.2% for two-pole senders; 2.5% for single-pole senders and a combination of single- and two-pole sensors
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Manual 37223
Appendix A.
Useful Information
CAN Bus Pin Assignments of Third-Party Units
female / socket
Description
Reserved
CAN Bus Signal (dominant low)
CAN ground
Reserved
Optional shield
Optional CAN ground
CAN Bus Signal (dominant high)
Reserved
Optional external voltage supply Vcc
Table 8-1: CAN bus pin assignment - D-SUB DE9 connector
RJ45/8P8C Connector
male / plug
female / socket
Description
CAN bus line (dominant high)
CAN bus line (dominant low)
Ground / 0 V / VReserved
Reserved
Optional CAN Shield
Ground / 0 V / VOptional external voltage supply Vcc
Table 8-2: CAN bus pin assignment - RJ45/8P8C connector
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Manual 37223
Signal
(GND)
CAN_L
CAN_H
CAN_GND
(CAN_V+)
(CAN_SHLD)
-
Description
Reserved
Optional CAN ground
CAN bus line (dominant low)
CAN bus line (dominant high)
CAN ground
Reserved
Reserved
Optional external voltage supply Vcc
Optional shield
Not connected
Table 8-3: CAN bus pin assignment - IDC / Header
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Woodward GmbH
Handwerkstrasse 29 - 70565 Stuttgart - Germany
Phone +49 (0) 711 789 54-0 Fax +49 (0) 711 789 54-100
[email protected]
Homepage
http://www.woodward.com/power
06/12/S