Woodward Easy Gen 3200 - 2

easYgen-3200 Overview
Genset Control for Multiple Unit Operation
- marked
CERTIFICATE of
Design Assessment
by ABS
-
Proprietary Information
American Bureau of Shipping & Affiliated Companies
Current and Future Part Numbers P2
easYgen-3000 Terminal Comm. 1A CT 5A CT 1A CT 5A CT
Platform Blocks Ports P2 P2
RP-3000 2 1 No No No No
(Remote Panel)
easYgen-3100 80 4 8440-1819 8440-1817 8440-1844 8440-1845
easYgen-3200 80 4 8440-1816 8440-1831 8440-1842 8440-1843

easYgen-3400 80+ 4+ 8440-xxxx 8440-xxxx 8440-xxxx 8440-xxxx
easYgen-3500 80+ 4+ 8440-xxxx 8440-xxxx 8440-xxxx 8440-xxxx
RP-3000 easYgen-3100 easYgen-3200 Proprietary Information

Market
Genset Applications:
• Diesel and gas engines.
• Synchronous Generators
• Single unit island/mains parallel operation
• Multiple unit island/mains parallel operation
Typical Field Applications:

• Emergency mode - AMF (Automatic Mains Failure)
• Stand-by application
• Cogeneration – CHP (Combined Heat and Power)
• Peak shaving
• Prime mover application
• Export/Import control
• Load or process dependend start/stop for single/multiple
units
Application
Single Unit Mains Parallel
• Engine start / stop
• Generator protection
• AMF (auto mains failure)
• Generator control
• Frequency / active power
• Voltage / power factor
• Parallel to mains
• Full Generator Breaker Control
• Full Mains Breaker Control
Application
No external mains
breaker control module
required. Mains CT and
PT will connected to all
easYgen-3000.
 Redundant Multiple Unit Mains Parallel nd
protection/control over la
is
the Mains Breaker. in allel
n its par
2 u s
3 ain
to m
Up and ps.
ap
Terminology Overview
• FlexAppTM Multiple breaker operation application setups in one unit:
No breaker, GCB o/, GCB o/c, GCB & MCB o/c*
• FlexRangeTM Allows for the control to operate on a wide range
of PT voltage inputs and CT configurations
• FlexInTM The controller analog inputs are compatible with both
resistive and mA signals permitting the use of a wide range of sending
units
• LogicsManagerTM Configurations, operating sequences, and operating
modes can be modified through the use of logical operators,
timers, internal and external status
• Analog ManagerTM Analog signals can be monitored and sent to an output
(metered values, bias signals for control purposes)
• FlexLimitsTM Free running and programmable analog limit switches
extend the quantity of trip levels or actuation triggers
• FlexCANTM Utilizes CANopen and J1939 protocols
* o/ = open; o/c = open/synch./close
Features Overview
Engine control Protection
• Diesel or gas engines • Engine protection
• Start/Stop management • Generator protection
• ECU interconnection • Mains monitoring
• Breaker monitoring
Breaker control
 GCB
Customization
 MCB
• High flexibility via LogicsManager
 No breaker application
• Multiple languages
Power Management • Customized front foils/face panels

• kW-,kVAr-, f-, V-, PF-Control
• kW-, kvar-, Sharing
Features – Engine Control
• Stop, Manual, Automatic modes • Crank control and
protection
• Start / stop by
discrete inputs, interface, frontpanel, • Aux. excitation for
analog inputs ... alternator via D+
• ECU J1939 CAN connection for termimal
 Monitoring • Aux. services for pre-
 Visualization and postrun
 Control
• Counters for running
• Override mode for critical operation hours , service
• Speed sensing/monitoring via MPU requests,...
• Redundant relay outputs for safety
considerations (breaker, gas
valves,...) via LogicsManager
Features – Engine Control
Start-Stop-Management
Load-Dependent Start/Stop (LDSS) up to 32 generator sets based on:

-Fuel efficiency
-System spinning reserve power
-Service hours
-Multiple sized engines/generators
Fault conditions on generator “#” in the network (Next generator starts)
Process data: e.g. temperature, fuel level, or any other measured state
Loss of mains detection for supplying emergency power
Features – Breaker
Breaker Synchronization Modes
 No breaker, GCB, MCB  Phase matching
 Slip frequency synch.
Breaker modes  Synch. check option
 Parallel
 Open transition Protection
 Closed transition  Synch Time Out
 Interchange (Soft transfer)  Close Time Out
 External (No breaker ops.)  Open Time Out
 Field rotation monitoring
Droop can be
Features – Controllers
activated/deactivated
via LogicsManager
AVR and Governor Control Signals
output status
Frequency Two setpoints for each controller
 Load sharing  Internal setpoints
 Isochronous  Interface
 Droop  Discrete Inputs (discrete raise/lower)
Voltage  Analog inputs (by mA, by potentiometer)
 Reactive (var) sharing Bias outputs (for AVR & Governor)
 Isochronous  Adjustable analog bias signal between
 Droop +/-20 mA or +/-10 V
 PWM output
Load control
 Relay outputs raise/lower (3-step-Logic)
 Baseload
 Analog bias and raise/lower outputs are
 Export/Import separately configurable for V, var, f and
Power Factor kW. (=> dual fuel capability)
 Constant
Features - LogicsManagerTM
Configuration and modification of sequences and operation modes by
using logical operators, timers, internal and external status conditions.
Digital Signals Relay Outputs

Discrete inputs Assignment Operate freely
Relay status configurable outputs
External discrete inputs With timer ON-delay and OFF-delay
External relays
16 additional/internal flags or logical
Control messages
operations
via CAN/Modbus
Internal Conditions Internal Conditions

Conditions Start/stop engine
- CB status Change operation mode
- operating mode
- engine status Acknowledge of alarms
Alarms Inhibit emergency mode
- warning alarm Creating internal flags for
- shutdown alarm cascading logic with
Time / Date multiple variables
Discrete Inputs / Outputs
12 x Relay Outputs Expansion with external DI/DO boards
• Alarm and control • Maximum 16 DI/16 DO
• 6 single-pole contacts • Woodward IKD 1
• 6 two-pole contacts • Phoenix
• Max 2A @ 24Vdc/250Vac
12 x Discrete Inputs
• Alarm and control (isolated)
• Configurables: Timers, alarm
classes, text
Analog Inputs / Outputs
3 x Analog Inputs 1 x Battery Voltage
• 0 to 500 Ohm or 0/4 to 20 mA • Monitoring of power supply 8 to 40 Vdc
• Change between different
senders via parameter
P2 External analog input module
• 1- and 2-wire senders
compatibility
supported
• 11 bit resolution
• Configurables: Timers,
alarm classes, text
1 x Magnetic Pickup Unit

(MPU)
• Switching or inductive
• Configurable for number of
teeth
Analog Inputs / Outputs
2 x Analog Outputs
• Maximum +/- 20 mA or +/- 10 V or PWM (500 kHz)
• Preconfigured for speed and voltage bias or configurable as
scalable output for measured values (kW) (ext. analog meters)
• Change between voltage and current by installing jumpers
• 11/12 bit resolution
1 x Auxiliary Excitation D+
• Input: Sensing and monitoring of
excitation voltage
• Output: Supplying excitation
voltage (via internal shunt
resistor)
Voltage Sensing - Generator and Mains
3Ph4W (3phase, 4wire) 3Ph3W (3phase, 3wire)
1-, 2- and 3-phase CT arrangement possible & configurable for each phase
FlexRangeTM
1Ph3W (1phase, 3wire) 1Ph2W (1phase, 2wire)
only 2-phase CT possible only 1-phase CT possible
AC Generator sensing
True RMS Voltage Sensing True RMS Current Sensing
• 4-phase (L1, L2, L3, Neutral) • 3-phase
• 100 and 400 V input • Non-returning slave pointer
• Frequency measurement • 1% accuracy
• Field rotation detection
• 1% accuracy
Power Sensing
• Phase-to-Phase measurement • 2% accuracy
• Phase-to-Neutral measurement • True RMS power measuring
• 3ph3w, 3ph4w, 1ph2w, or 2ph3w • Real and reactive power
• Power factor
True RMS Auxilliary Current Sensing
• Energy counters Wh and varh
• Configurable as mains CT or
Generator ground fault CT Proprietary Information
AC Mains Sensing
True RMS Voltage Sensing True RMS Current Sensing
• 4-phase (L1, L2, L3, Neutral) • Non-returning slave pointer
• 100 and 400 V inputs • Class 1 accuracy
• Frequency measurement
• Field rotation detection
• Class 1 accuracy
• Phase-to-Phase measurement
• Phase-to-Neutral measurement
• 3ph3w, 3ph4w, 1ph2w, or 2ph3w
Power Sensing
• Real, reactive, and apparent
power
AC Bus Sensing
True RMS Voltage Sensing

• 2-phase sensing (L1-L2 or L1-to-N)
• Phase angle between mains / bus and generator / bus
• Dead bus detection
DynamicsLCDTM
Multiple languages – 10 standard
English Turkish
German Portuguese
Italian Russian
French Chinese
Spanish Japanese
Polish
DynamicsLCDTM
Italian
French
Spanish
Turkish
Portuguese
DynamicsLCDTM
Chinese
Russian
Japanese
DynamicsLCDTM
The 320x240 pixel graphic interactive LC display provides soft keys with
changing functionality depending on application (see FlexAppTM) and operation.
Delta / Wye Alarm Screen

Voltage
Configure
Automatic mode Parameter
Manual mode Additional

measured values
STOP mode
Acknowledge/
reset centralized
Change operation alarm
modes
Engine start / stop Breaker control
DynamicsLCDTM
The display sections:
Last alarm
Current operation
i.e. cranking, loading,
start pause, etc.
Single line diagram

and operation mode
DynamicsLCDTM
Operating modes
Automatic mode
Manual mode
Stop mode
DynamicsLCDTM
Symbols in the Single Line Diagram
Acceptable Volt/Freq detected
Field rotation clockwise (CW)
Field rotation counterclockwise (CCW)
Import/export mains power
Engine monitoring delay expired
Engine speed detected
DynamicsLCDTM
Stop command issued
Start/run command issued
Unit attempting to close the breaker
Unit attempting to open the breaker

DynamicsLCDTM
Examples of Measuring Screens
DynamicsLCDTM
Alarm screen Event History
• Active alarms visible • In-/ out coming events (+ / -)
• Date and time stamped • Date and time stamp
• 16 entries displayed • 300 entries (FIFO)
Alarms will stay active until acknowledged, even if power is cycled.
Alarm Classes
Alarm Classes are configurable for almost all protection functions
Class Action Result
Display
AB
Warning
Display and Horn Warning
C Display and Horn Unload Gen. and open GCB Cool down Shut down
D Display and Horn Open GCB immediate Cool down Shut down
E Display and Horn Unload Gen. and open GCB Immediate Stop Shut down
F Display and Horn Open GCB immediate Immediate Stop Shut down
Control
For control purposes via LogicsManager to
change/modify sequencing or discrete outputs internal
Generator Protection
# of Trip Levels ANSI Code
Over-/undervoltage 2/2 [59/27]
Voltage asymmetry 1 [47]
Over-/underfrequency 2/2 [81O/U]
Overload (IOP/MOP) 2 [32]
Reverse/reduced power 2 [32R/F]
Unbalanced load 2 [46 measured]
Definite time-overcurrent 3 [50/51]
Inverse time-overcurrent 1 [IEC 255]
Overspeed (MPU) 2 [12]
Measured ground current 2 [50G]
Calculated ground current 2
Power factor (PF) lagging 2
PF leading – loss of excitation 2 [40Q]
Phase rotation field CW/CCW 1
Psetpoint  Pactual mismatch 1 Controller*
Unload mismatch (time out monitoring) 1 Controller*
Operating range failed 1 Controller*
* plausibility monitoring features
Engine Protection
• Maintenance days exceeded
• Maintenance hours exceeded
• Over-/Underspeed (MPU)
• Unintended Stop
• Engine Stop malfunction
• Speed/frequency mismatch
• Start failure
• Charge alternator low voltage
• Red stop lamp (J1939)
• Amber warning lamp (J1939)
• Battery over-/undervoltage
Mains Monitoring and Decoupling
 Over-/undervoltage 2/2 [59/27 ]
 Over-/underfrequency 2/2 [81O/U]
 Import/Export power 2 [32]
 Power factor leading 2 [55]
 Power factor lagging 2
 Phase shift 1ph/3ph [78 ]
 Phase rotation
Miscellaneous Monitoring
• GCB / MCB fail to close
• GCB / MCB fail to open
• Synch. Time Out GCB / MCB
• Phase rotation mismatch generator / busbar / mains
• Mains decoupling
• CAN bus communications monitoring (J1939, CANopen)
• Parameter alignment (multiple units)
• Missing members (multiple units)
• EEPROM failure (internal CPU)
• Wire break analog inputs
• Discrete inputs
• FlexLimitsTM for analog values
Interfaces
• ToolKit
• Load share
• Modbus
• CANopen
Serial 1
CAN 1 RS-232
Serial 2
CAN 2
RS-485
• Extension cards • Modbus
(IKD 1,
Phoenix)
• J1939 ECU
All interfaces are galvanically isolated!

CAN Interface Overview
Guidance level
Up to 32 units
• Load share
• CANopen
PLC
CAN 1
Digital expansion modules

CAN 2
Engine level
• J1939 (ECU) 2x IKD 1 Phoenix
• Extension cards
Analog expansion modules
ECU
ECU
GATEWAY
G ATEW AY
P2
E N G IN E G EN ER ATO R
- Engine - Generator Proprietary Information
Phoenix J1939
Serial Interface Overview
Serial RS-232 • ToolKit

• Modbus
Modem
PC • Peer-to-peer
Ethernet
Serial 1
Serial RS-232
RS-232
Serial RS-485
Serial 2
PLC RS-485
Profibus
• Modbus
• Multiple units
PC
Configuration via ToolKit
RS-232 or CAN
Serial 1
RS-232
Miscellaneous
CE marked
UL listed
IP54 (NEMA 2) from front with clamp fasteners
IP66 (NEMA 4) from front with screw kit
- marked
IP20 from back
Operating temperature range –20 to +70°C
Weight approx. 4.1lbs/1.85 kg
Lloyds Register (LR) Marine Approval
Certificate of Design Assessment by ABS CERTIFICATE of
Design Assessment
by ABS
Complete Product Package
easYgen-3200-5 (5A CT Model)
12 x Screws for IP66 front panel mounting (8923-1262)
4 x clamping brackets for IP56 front panel mounting (8923-1263)
1 x CD with
 Woodward ToolKit v3.0 configuration program
 ToolKit *.WTOOL files (English and German)
 ToolKit *.SID files (English and German)
 Manuals
Remote Panel 3000
Remote Panel RP-3000
• CANopen connected panel to all easYgen-3000 controls
• Point-to-point connection
• Same look and feel as easYgen-3200
easYgen-3000 controls
CANopen
RP-3000
easYgen-3100
easYgen-3100 (1A CT and 5A CT model)
• Metal housing: no display, HMI via interfaces and DI
• Same functionality as easYgen-3200
easYgen-3000/P2 Features
Extended I/O Via External Terminals
P2
only
P2
only
Extended I/O Via External Terminals
48 x Analog Inputs
- 32 x Inputs via predefined J1939 engine messages in 10 languages
- 16 x Inputs via CANopen terminals
4 x Analog Outputs (CANopen, scalable, 0-20 mA or 0-10V)
16 x Discrete Inputs (CANopen terminals) additional  32 total
16 x Discrete Outputs (CANopen terminals) additional  32 total
Some terminals I/O will be mapped to act like a central terminal (single
point connection and message broadcast to every control e.g.: room
temperature, common fuel tank level, gas leakage detection, etc.)
The J1939 terminals need to be configured using the terminal
manufacturers software tools
The CANopen terminals may be configured via ToolKit directly
P2
only
Free Running PID Loops
3 x Independent freely programmable PID control loops
• Configurable as Analog Outputs (0-20 mA) or 3-step-outputs
(Relay Outputs)
• Proportional, Integral, and Derivative adjustment
• Programmable for activation/deactivation via LogicsManager
• External and internal set points can be used
Usable for water heat cycle control, dual-fuel control, room
temperature control …
3rd Party Accessories
P2
Accessories easYgen-3000/P2 only
CANopen Bus Coupler
IL CAN BK-TC-PAC [#2718701] (max 3 possible)
Analog Inputs
IB IL AI 2/SF-PAC [#2861302] 2x analog (0-20 mA, 4-20 mA, ±20 mA, 0-10 V, ±10 V)
IB IL TEMP 2 UTH-PAC [#2861386] 2x thermocouples
IB IL TEMP 2 RTD-PAC [#2861328] 2x RTDs, resistive senders
Analog Outputs
IB IL AO 2/SF-PAC [#2863083] 2x analog outputs (0-20 mA, 4-20 mA, 0-10 V)
Phoenix part numbers in brackets
P2
Accessories easYgen-3000/P2
only
J1939 Analog Inputs
TC 4 [#AXTC4] 4x thermocouples
TC 20[#TC20] 20x thermocouples
Analog input 10 [#AX030100] freely configurable, for advanced J1939 users only
Axiomatic part numbers in brackets
Accessories
Accessories easYgen-3000 All Versions
IKD 1 Digital Expansion Card

[P/N 8440-1041]
Terminal Strip Kit – Plug Set

[P/N 8923-1314]
Accessories easYgen-3000 all types
CANopen bus coupler
IL CAN BK-TC-PAC [#2718701] (max 3 possible)
Discrete inputs / outputs
IB IL 24/230 DOR4/W [#2836421] 4x discrete output, PDT (5-253V, 3 A)
IB IL 24 DO2-2A-PAC [#2861263] 2x discrete output, (24V, 2A)
Supports IB IL 24 DO 8; IB IL 24 DO 16 and IB IL 24 DO 32 types
IB IL24 DI 2-PAC [#2861221] 2x discrete input (24V)
Supports IB IL24 DI 4; IB IL24 DI 8; IB IL24 DI 16 and IB IL24 DI 32 types
Phoenix part numbers in brackets
Product Documentation
Product Specification
[P/N 37258]
Package 1 Manuals Package 2 Manuals
Installation Manual Installation Manual
[P/N 37223] [P/N 37414]
Configuration Manual Configuration Manual

[P/N 37224] [P/N 37415]
Operation Manual Operation Manual

[P/N 37225] [P/N 37416]
Interface Manual Interface Manual
[P/N 37383] [P/N 37417]
Application Manual Application Manual

[P/N 37226] [P/N 37418]
End of Section 1
1 Overview 6 LogicsManager
2 Hardware and I/O 7 Analog Manager
3 Operational Modes 8 Controller
4 Configuration and ToolKit 9 Synchronization and Breaker
5 Communication 10 Application
11 Sequencing
Note:
Information contained herein is intended for and appropriate to the purposes of this publication/presentation.
Woodward reserves the right to update or otherwise revise any portion of this publication at any time. Technical data
and detailed information is available in Woodward product specs. Specific reliance should be given only to information
contained in purchase order(s), other contractual document(s), or information otherwise expressly represented in
writing by Woodward as correct and accurate for the specific facts, circumstances and applications.
easYgen-3200 Training
Section 2 – Hardware and I/O
marked
CERTIFICATE of
Design Assessment
by ABS
Contents
Introduction slide 3
Power Supply 4
MPU Input 5
FlexRangeTM 6
Discrete Inputs 20
Discrete Outputs 22
FlexInTM 25
Analog Outputs 29
Auxiliary Excitation D+ 31
Technical Data 32
Introduction
Introduction
FlexRangeTM
Power Supply
The voltage measuring inputs of the easYgen-3000 permit the user to
MPU Input
customize the controller for use with a wide range of voltage potential
FlexRangeTM transformers and system configurations. Each control has two sets of PT
Discrete Inputs inputs (100 Vac and 400 Vac), with configurable ranges.
Discrete Outputs The CT inputs may be configured for any combination of monitoring and
FlexInTM protection schemes to provide the highest level of flexibility possible for
Analog Outputs
the user.
Aux Excitation
D+
Technical Data
FlexInTM
Programming created by Woodward that permits the user to configure the
analog inputs of the easYgen-3000 series to work with a wide range of
resistive and/or current (mA) senders.
55
Power supply
Introduction
Power Supply • 12/24 Vdc (8 to 40 Vdc)

MPU Input power supply – able to
FlexRangeTM
withstand power
dropouts up to 10ms
Discrete Inputs
Discrete Outputs
FlexInTM
• Recommend installing a
Analog Outputs
slow blow fuse on the
power input
Aux Excitation
D+
Technical Data
i.e. NEOZED D01 6A or
miniature 6A /type C circuit
breaker
56
Pickup Input MPU
Introduction The MPU input (Magnetic Pickup Unit) measures the engine
Power Supply
speed by counting the teeth of the flywheel.
MPU Input
• The number of teeth is adjustable
FlexRangeTM • Switching or inductive senders may be used
Discrete Inputs
Discrete Outputs
FlexInTM
Analog Outputs
Aux Excitation
D+
Technical Data
57
Flex Range
Measuring
Introduction
True RMS measurement of the generator, mains and busbar voltage
Power Supply
measuring inputs
MPU Input
- Rated 100 Vac (max. 150 Vac) and
FlexRangeTM - Rated 400 Vac (max. 600 Vac)
Discrete Inputs
Discrete Outputs Generator Mains Busbar

FlexInTM
Analog Outputs
Aux Excitation
D+
Technical Data
58
Flex Range - 3Ph4W
3Ph4W (3phase, 4wire)
Introduction 1- or 3-phase voltage measurement possible
Power Supply
MPU Input
FlexRangeTM
Discrete Inputs
Discrete Outputs
FlexInTM
Analog Outputs
Aux Excitation
D+ Generator voltage measurement 3PH4W
Technical Data
Mains voltage measurement 3PH4W
“Busbar” 1PH2W voltage measurement
Phase – Phase L1 - L2 or
Phase – Neutral L1 - N
59
Flex Range - 3Ph4W
Introduction
L1 L2 L3 N
Power Supply
MPU Input
FlexRangeTM
Discrete Inputs
Discrete Outputs
FlexInTM
Analog Outputs
Aux Excitation
D+
Technical Data
G
60
Flex Range - 3Ph4W
Introduction 1- or 3-phase current measurement possible
Power Supply
MPU Input
FlexRangeTM
Discrete Inputs
Discrete Outputs
FlexInTM
Analog Outputs
Aux Excitation
D+ Generator current measuring L1 L2 L3 or
Technical Data
L1 or L2 or L3
Mains current measuring L1 or L2 or L3
61
Flex Range - 3Ph4W
Introduction Measured values in the display
Power Supply
MPU Input
FlexRangeTM
Discrete Inputs
Discrete Outputs
FlexInTM
Analog Outputs
Aux Excitation
D+
Technical Data
62
Flex Range - 3Ph3W
Introduction 1- or 3-phase voltage measurement possible
Power Supply
MPU Input
FlexRangeTM
Discrete Inputs
Discrete Outputs
FlexInTM
Analog Outputs
Aux Excitation
Technical Data
Phase – Phase L1 – L2
63
Flex Range - 3Ph3W
Introduction
L1 L2 L3
Power Supply
MPU Input
FlexRangeTM
Discrete Inputs
Discrete Outputs
FlexInTM
Analog Outputs
Aux Excitation
D+
Technical Data
G
64
Flex Range - 3Ph3W
Introduction 1- or 3-phase current measurement possible
Power Supply
MPU Input
FlexRangeTM
Discrete Inputs
Discrete Outputs
FlexInTM
Analog Outputs
Aux Excitation
D+ Generator current measuring L1 L2 L3 or
Technical Data
L1 or L3
Mains current measuring L1 or L3
65
Flex Range - 3Ph3W
Power Supply
MPU Input
FlexRangeTM
Discrete Inputs
Discrete Outputs
FlexInTM
Analog Outputs
Aux Excitation
D+
Technical Data
66
Flex Range - 1Ph3W
Introduction only 2-phase voltage measurement possible
Power Supply
MPU Input
FlexRangeTM
jumper
Discrete Inputs
Discrete Outputs
FlexInTM
Analog Outputs
Aux Excitation
Technical Data
67
Flex Range - 1Ph3W
Introduction only 1- or 2-phase current measurement possible
Power Supply
MPU Input
FlexRangeTM
Discrete Inputs
Discrete Outputs
FlexInTM
Analog Outputs
Aux Excitation
D+ Generator current measuring L1 L3 or
Technical Data
L1 or L3
Mains current measuring L1 or L3
68
Flex Range - 1Ph3W
Power Supply
MPU Input
FlexRangeTM
Discrete Inputs
Discrete Outputs
FlexInTM
Analog Outputs
Aux Excitation
D+
Technical Data
69
Flex Range - 1Ph2W
Introduction only 1-phase voltage measurement possible
Power Supply
MPU Input
FlexRangeTM
jumper
Discrete Inputs
Discrete Outputs
FlexInTM
Analog Outputs
Aux Excitation
Technical Data
70
Flex Range - 1Ph2W
Introduction only 1-phase current measurement possible
Power Supply
MPU Input
FlexRangeTM
Discrete Inputs
Discrete Outputs
FlexInTM
Analog Outputs
Aux Excitation
D+ Generator current measuring L1
Technical Data
Mains current measuring L1
71
Flex Range - Ground current
Parameter: Mains current input = Ground current
Introduction
Power Supply
MPU Input
FlexRangeTM
Discrete Inputs
Examples
Discrete Outputs
FlexInTM
Analog Outputs
Aux Excitation
D+
Technical Data
72
Discrete Inputs
Introduction
Discrete I/O
 12 discrete inputs (alarm and control)
Power Supply
MPU Input
 Expansion with external boards
FlexRangeTM
- 2x Woodward (IKD) or
Discrete Inputs - 1x Phoenix
Discrete Outputs
FlexInTM
Analog Outputs
Aux Excitation
D+
Technical Data
73
Discrete Inputs
Common for DI 1 – 12
May use either + or – polarity
DI is energized if voltage is measured between
Introduction
the input terminal and terminal 66
Power Supply
1 Emergency Stop
MPU Input
2 Start in Auto
FlexRange TM
3 Low oil pressure

Discrete Inputs
4 Coolant temp.
Discrete Outputs
5 Ext. acknowledge
FlexInTM
6 Release MCB
Analog Outputs 7 Reply MCB is open
Aux Excitation 8 Reply GCB is open
D+
Technical Data 9 Discrete input
10 Discrete input
11 Discrete input
12 Discrete input
74 N.C. normally closed

Preconfigured for: Alarm Control
Discrete Outputs
Max 250 V AC/DC
Discrete outputs 1 through 5
Introduction
Max 2 A each contact

Power Supply
MPU Input
FlexRangeTM
Device ok
Discrete Inputs
Horn
Discrete Outputs
Crank
FlexInTM
Analog Outputs
Fuel valve
Aux Excitation
D+
Technical Data
Preglow
75
Discrete Outputs
Max 250 V AC/DC
Introduction
Power Supply
MPU Input
FlexRangeTM
Discrete Inputs GCB close

Discrete Outputs
FlexInTM
GCB open
Analog Outputs
Aux Excitation
D+
Technical Data MCB close
MCB open
76
Discrete Outputs
Introduction
Power Supply
Lube pump
MPU Input
Warning signal
FlexRangeTM
Discrete Inputs
Shutdown signal
Discrete Outputs
FlexInTM
Analog Outputs
Aux Excitation
D+
Technical Data
Max 250 V AC/DC
77
FlexInTM
Analog inputs
Introduction
3 analog inputs
Power Supply
• programmable as 0 to 500 Ohm or 0/4 to 20 mA
MPU Input
FlexRangeTM
VDO / resistive input (0 to 500 Ohm) 1- or 2-pole sender
Discrete Inputs • 0 to 5 bar (0 to 75.5 psi)
Discrete Outputs • 0 to 10 bar (0 to 145 psi)
FlexInTM
• 40 to 120 °C (104 to 248 °F)
• 50 to 150 °C (122 to 302 °F)
Analog Outputs
• Linear 2-point, adjustable min/max value
Aux Excitation
D+ • User defined – 9-point curve
Technical Data
0/4 to 20 mA (freely configurable)

• Linear 2-point, adjustable min/max value
• User defined – 9-point curve
78
FlexInTM
Wiring single- and two-pole senders
Introduction
Power Supply
MPU Input
FlexRangeTM
Discrete Inputs
Discrete Outputs
FlexInTM
Analog Outputs
Aux Excitation
D+
Technical Data
79
FlexInTM
Introduction
Power Supply Battery voltage with

MPU Input
bar graph
FlexRangeTM
Discrete Inputs
Discrete Outputs
FlexInTM
Analog Outputs Bar graph disappears if

Aux Excitation
input is switched OFF
D+
Technical Data
80
FlexInTM
Introduction
Actual measured value

Power Supply
Numeric and graphical

MPU Input
FlexRangeTM
Text for input
Discrete Inputs description is
Discrete Outputs
configurable
FlexInTM Bar graph
Analog Outputs min / max value
Aux Excitation
D+
Technical Data
81
Analog Outputs
Introduction
Two analog outputs
Power Supply
• +/- 20mA or
+/-20mA
MPU Input • +/- 10V or
FlexRangeTM • PWM (500 Hz)
Discrete Inputs
Discrete Outputs
FlexInTM
Output signals +/-10V
Analog Outputs • speed bias (governor)

Aux Excitation
D+
• voltage bias (AVR) jumper
Technical Data
• measured values
– Generator kW PWM
– Power factor
82
Analog Outputs
11/12 bit resolution =
Signal Options:
Introduction 102.4 steps / mA or
• OFF
204.8 steps / V
Power Supply • User defined (maximum +/- 20mA and +/- 10V)
MPU Input
• 0-10mA / 0-5V
• 0-20mA / 0-10V
FlexRangeTM
• 4-20mA
Discrete Inputs • 0.5-4.5V
• 10-0mA / 5-0V
Discrete Outputs
• 20-0mA / 10-0V
FlexInTM
• 20-4mA
Analog Outputs • 4.5-0.5V
Aux Excitation
• +/-1 V
D+
• +/- 2.5
Technical Data
Actual output signal
• +/- 3V
• +/-10mA / +/-5V % in relation to the
• +/-20mA +/-10V configured range
• Resolution 11/12 bit

83
Auxiliary Excitation D+
Introduction The D+ is an input and an output
Power Supply
MPU Input • Provides an auxiliary excitation voltage during the cranking of

FlexRangeTM the engine
Discrete Inputs • Measures the D+ voltage after startup of the engine
Discrete Outputs
FlexInTM
Analog Outputs
Aux Excitation D+
Technical Data
84
Technical Data
Technical specifications can be found in the “Installation” manual
Introduction
Power Supply
MPU Input
FlexRangeTM
Discrete Inputs
Discrete Outputs
FlexInTM
Analog Outputs
Aux Excitation
D+
Technical Data
85
Technical Data
Introduction
Power Supply
MPU Input
FlexRangeTM
Discrete Inputs
Discrete Outputs
FlexInTM
Analog Outputs
Aux Excitation
D+
Technical Data
86
Technical Data
Introduction
Power Supply
MPU Input
FlexRangeTM
Discrete Inputs
Discrete Outputs
FlexInTM
Analog Outputs
Aux Excitation
D+
Technical Data
87
Technical Data
Introduction
Power Supply
MPU Input
FlexRangeTM
Discrete Inputs
Discrete Outputs
FlexInTM
Analog Outputs
Aux Excitation
D+
Technical Data
88
End of Section 2
11 Sequencing
Note:
89
Section 3 - Operational Modes
marked
CERTIFICATE of
Design Assessment
by ABS
Contents
DynamicsLCDTM slide 3
Status Menu 6
Parameter Menu 14
Password Protection 18
Operation Modes (Auto, Manual, Stop) 24
Start / Stop 27
FlexAppTM 31
FAQ 37
DynamicsLCDTM
The 320x240 pixel graphic interactive LC display provides soft keys
DynamicsLCDTM
whose functionality changes depending on application (see FlexAppTM)
and operation.
Status Menu
Parameter Menu
Password Delta / Wye Alarm screen

Voltage
Operation Configure
Automatic Mode parameter
Start / Stop
FlexAppTM Manual Mode Additional

measured values
FAQ
Stop Mode
Acknowledge
centralized alarm
Change operation
modes
Manual engine start / stop Manual breaker control
92
DynamicsLCDTM
The Display Topography:
DynamicsLCDTM
Status Menu Last alarm

Parameter Menu
Password
Current operation
Operation i.e. Cranking, loading,
Start / Stop
start pause, etc.
FlexAppTM
FAQ
Single line diagram

and operation mode
93
Status Menu
Screen Navigation – Measured Values
DynamicsLCDTM
Status Menu Advance to Next Screen

Parameter Menu
Select Subdirectory
Password
Operation
Start / Stop
FlexAppTM
FAQ
Screen Name
94
Status Menu
DynamicsLCDTM
Status Menu
Parameter Menu
Password
Operation
Start / Stop
FlexAppTM
FAQ
Set Points
95
Status Menu
DynamicsLCDTM
Status Menu
Parameter Menu
Password
Operation
Start / Stop
FlexAppTM
FAQ
Counters and Service
96
Status Menu
DynamicsLCDTM
Status Menu
Parameter Menu
Password
Operation
Start / Stop
FlexAppTM
FAQ
Measured Values
97
Status Menu
DynamicsLCDTM
Status Menu
Parameter Menu
Password
Operation
Start / Stop
FlexAppTM
FAQ Online
Diagram
Visible
98
Parameter Menu
Screen Navigation – Parameter Screens
DynamicsLCDTM
Press “Parameter” Soft key
Status Menu
Parameter Menu
Password
Select Subdirectory
Operation
Start / Stop
FlexAppTM
FAQ
Screen Name
99
Parameter Menu
DynamicsLCDTM System Overview Parameter
Status Menu
Parameter Menu
Password
Operation
Start / Stop
FlexAppTM
FAQ
Screen Name
Pathway to
this screen
100
Parameter Menu
Change a Parameter
DynamicsLCDTM
Status Menu
Move black cursor
line up and down
Parameter Menu
Password
Operation
Start / Stop
FlexAppTM
FAQ
Press “Enter” soft key to select
parameter to be changed
101
Password Protection
Three levels of password protection enable multiple users
DynamicsLCDTM with varying degrees of access
Status Menu
Parameter Menu
Password protection valid for 2 hours
Password
Level 1/End user 0001
Operation
Level 2/Temporary commissioning (random
Start / Stop
number+200)*3
Level 3/Commissioning 0003
FlexAppTM
FAQ
102
Password Protection
DynamicsLCDTM Toolkit.lnk
Status Menu
Possible ways to access a parameter:
Parameter Menu
Hardware Enter Password for:
Password
HMI Pushbuttons Display
Operation
Start / Stop
RS-232 ToolKit No password required
FlexAppTM
RS-232 Modbus Serial 1 (RS-232)
FAQ RS-485 Modbus Serial 2 (RS-485)
CAN 1 CANopen CAN 1
103
Password Protection
DynamicsLCDTM System Overview Parameter
Status Menu
Parameter Menu
Password
Operation
Start / Stop
FlexAppTM
FAQ
Password Screen
104
Password Protection
DynamicsLCDTM
Level 1/End user 0001
Status Menu Level 2/Temporary commissioning (random
number+200)*3
Parameter Menu
Level 3/Commissioning 0003
Password
Randomly generated number
Operation
Start / Stop
Current level of access
FlexAppTM
FAQ
To access to this
communication port,
enter code here
105
Password Protection
Individual parameters cannot be viewed or edited if
DynamicsLCDTM the password has not been entered or has expired.
Status Menu
Parameter Menu
Password Names for submenus are always

Operation
displayed
Start / Stop
FlexAppTM
FAQ
106
Password Protection
New version shows that parameters are locked Version
DynamicsLCDTM 1.12
Status Menu
Parameter Menu
Password Lock open, with active password

Operation
level
Start / Stop
FlexAppTM
FAQ
107
Operation Modes
Shutdown alarms will change the operating mode to STOP
DynamicsLCDTM
AB
Status Menu
Parameter Menu
Password
Operation
C
Start / Stop
FlexAppTM
FAQ
D
E
F
108
Operation Modes
DynamicsLCDTM Changing the operation mode via HMI soft keys

Status Menu
Parameter Menu
Password
Operation
Start / Stop AUTOMATIC

FlexAppTM
FAQ
MANUAL
STOP
109
Start / Stop in Auto
Generator:
DynamicsLCDTM
Start conditions Stop conditions
Status Menu
 LM: Start in auto is “true”  LM: Start conditions are “false”
Parameter Menu may be used with load dependent start/stop function  Alarm class C-F detected
 LM: Start w/o load is “true”  LM: Stop in auto
Password
 LM: Critical mode is “true”
Operation
 Loss of mains {GCB/MCB} (Emergency mode)  LM: Inhibit emergency mode
Mains voltage/frequency out of operating range
Start / Stop Mains rotation field wrong
FlexAppTM
“Fail to close MCB” (if parameter is enabled)
FAQ
Mains:
Close MCB: Open MCB:
 Mains are within accepted limits  Dependent upon breaker logic
 DI7 is de-energized (MCB is open)  For mains decoupling
 LM: Enable MCB is “true” (default DI6)
 Conditions for synchronization or
dead bus closing are met
110
Start / Stop Logic
Diesel engine
DynamicsLCDTM
- Pre-glow function
Status Menu
- Fuel or Stop solenoid activation
Parameter Menu
- Crank/start circuit control
Password
Gas engine
Operation
- Ignition
Start / Stop
- Gas valve
FlexApp TM

FAQ
External logic - Fuel solenoid as a start
request to external controllers
- External control must take care of start sequence – no start failure
111
FlexAppTM
DynamicsLCDTM There are four application modes available:

Status Menu
Parameter name: Product spec application:

Parameter Menu
Password
Operation
[GCB/MCB] [GCB/MCB open/close {2oc}]
Start / Stop
[GCB] [GCB open/close {1oc}]
FlexAppTM
[GCB open] [GCB open {1o}]
FAQ
[none] [0-CB-Mode {0}]
112
FlexAppTM – Breaker Application – [GCB/MCB]
Two breaker mode
DynamicsLCDTM • Mains/utility breaker (MCB) and generator breaker (GCB)
Status Menu
• Generator protection for shutdown and GCB open command
Parameter Menu
• Single or multiple genset operation
Password
• GCB & MCB open close command
Operation
• Automatic mains failure (AMF) / emergency mode
Start / Stop
FlexAppTM
FAQ
Fixed Input Fixed Output

DI 8 reply GCB (B contacts) DO 6/7 GCB close / open
DI 7 reply MCB (B contacts) DO 8/9 MCB close / open
113
FlexAppTM – Breaker Application – [GCB]
One breaker mode
DynamicsLCDTM • Generator breaker (GCB) control
Status Menu
Parameter Menu
Password
• GCB open/close command Grey= breaker status only:
Operation
MCB control is external
Start / Stop
FlexAppTM
FAQ

DI 8 reply GCB (B contacts) DO 6/7 GCB close / open
DI 7 reply mains parallel
114
FlexAppTM
It is possible to not
DynamicsLCDTM display mains data…
Status Menu Application [GCB]
Parameter Menu
Password
Operation Application [GCB/MCB]

Start / Stop
FlexAppTM
FAQ
115
FlexAppTM – Breaker Application – [GCB open]
Breaker open mode
DynamicsLCDTM • Generator breaker open only
Status Menu
Parameter Menu
Password
• GCB open command (shunt trip)
Operation
Start / Stop
FlexAppTM
FAQ

DI 8 reply GCB (B contact) DO 7 GCB open
116
DI 7 reply MCB (mains parallel)
FlexAppTM – Breaker Application – [none]
Base mode
DynamicsLCDTM • No breaker control
Status Menu
Parameter Menu
• Generator and engine protection
Password
• All breaker control is external
Operation
Start / Stop
FlexAppTM
FAQ
Fixed Input
DI 8 reply GCB (B contact)
DI 7 reply MCB (mains parallel)
117
Frequently Asked Questions
DynamicsLCDTM
• How do I set my password?
Status Menu
Parameter Menu • How long is my password access active?

Password
• How do I change my password?

Operation
Start / Stop
• Must the Easygen have starter sequence control?
FlexAppTM
FAQ • Can I use switches to control MANUAL operation?
• Can I use my PLC to close the circuit breakers?
118
FAQ
• How do I set my password?
• How long is my password access active?
High light the password to be set, then enter with the button .
DynamicsLCDTM
Use the right arrow and +/- buttons to set your password, then enter with the button.
Status Menu
The new code level will now display. Your password is active for 2 hours.
Parameter Menu
Password
Operation
Start / Stop
FlexAppTM
FAQ
119
DynamicsLCDTM
Status Menu
Parameter Menu
• How do I reset the maintenance counter?
Password
Operation
Start / Stop • How can I define the loss of mains condition

FlexAppTM in order to activate the emergency mode?
FAQ
120
FAQ
How do I reset the maintenance counter?
DynamicsLCDTM The maintenance hours counter decreases as the operation hours counter increases.
Status Menu The maintenance days counter decreases as the Internal calendar clock increases.
Parameter Menu When a count down timer reaches “0” an alarm is issued. The reset procedure is as follows:
Password Step 1:
Operation
Start / Stop
FlexAppTM
FAQ
121 Enter password (see config. manual)

FAQ
DynamicsLCDTM
Status Menu
Step 2:
Parameter Menu
Password
Operation
Symbol appears only if the
required password is active
Start / Stop
FlexAppTM
FAQ
Press “Next Page”  “Counters and

service” buttons to get to counters screen.
122
Proprietary Information Next, press the “Tool” symbol button.
FAQ
DynamicsLCDTM
Status Menu
Step 3: Step 4:
Parameter Menu
Password
Operation
Start / Stop
FlexAppTM
FAQ
Select counter to reset. Press enter, select YES, press enter.

Now the alarm may be acknowledged in
the alarm list.
123
FAQ
How can I define the loss of mains condition, in order to activate the
DynamicsLCDTM
emergency mode?
The operating range defines the loss of mains conditions.
Status Menu
The thresholds from the mains monitoring are used for protection
Parameter Menu
purpose, not for the loss of mains detection!
Password Adjust the “Operating range
Operation voltage / frequency” of the mains
Start / Stop
FlexAppTM
FAQ
124
End of Section 3
11 Sequencing
Note:
125
Section 4 - Configuration via ToolKit
Contents
Installing ToolKit 4
Connect 11
Status Menu 16
Configuration 24
Settings Menu 26
FAQ 38
Introduction
Introduction
Installation The easYgen-3000 may be configured using Woodward’s ToolKit

Connect
software. All future Woodward products will use ToolKit for
configuration, communications and HMI functionality.
Status Menu
Configuration
Settings
FAQ
Toolkit.lnk
128
Installing ToolKit
Introduction ToolKit 3.x
Installation The executable file for ToolKit may be found on the CD-ROM, which
Connect
comes with the control, or on the Woodward website.
Status Menu
http://www.woodward.com/software/Download/SWProductDetail.cfm?FileID=165
Configuration
Settings Menu
FAQ
129
Installing ToolKit
Introduction Install ToolKit 3.x
Installation
Follow the webpage directions for downloading ToolKit.
Connect
Install Microsoft .net Framework first!
Status Menu
Configuration
Settings Menu
FAQ
Click the Run button to start installing ToolKit
130
Installing ToolKit
Introduction Click the Next button on the ToolKit Setup Wizard dialog box
Installation
Connect
Status Menu
Configuration
Settings Menu
FAQ
The installation will start after accepting Licensing Agreement

131
Installing ToolKit
Introduction When the installation is complete, click on the close button to exit
Installation
Connect
Status Menu
Configuration
Settings Menu
FAQ
132
Installing ToolKit
Introduction
Configure the ToolKit directories
Installation
ToolKit requires that controller specific files be installed in a separate folder
Connect
than the ToolKit folder in order to enable communications between the PC
Status Menu
and the easYgen. Refer to the configuration manual for an example.
Configuration
Settings Menu
ToolKit Files
FAQ
ToolKit uses the following files:

*.WTOOL
8440-1831-D_US_5418-2752-NEW_32.WTOOL
*.SID
5418-2752-D.SID
*.WSET
User defined name.WSET
133
Installing ToolKit
Introduction
Get the config files
Installation
Load the config files from the easYgen-3000 page on the internet
Connect
http://www.woodward.com/power/easygen-3000.cfm?
Status Menu
Configuration
Copy the files to the previously defined ToolKit directories
Settings Menu
Part number of the program

FAQ
5418-2752-D.SID software
8440-1831-D_US_5418-2752-D_32.WTOOL
# of gensets to be displayed
Part number of the
control Language ID
US = English
DE = German
134
Installing ToolKit
Introduction Selecting a Communication Port
Installation
The default COM port settings of ToolKit may be configured by selecting
Connect Tools  Options from the toolbar.
Status Menu
The options window will be displayed permitting you to select the desired default
COM port and the default path for the configuration files.
Configuration
Settings Menu
FAQ
135
Connect
Introduction
Open the *.wtool file
Installation
Connect
After the ToolKit application has been started, select what control to
communicate with. Open the proper *.wtool file.
Status Menu
File  Open Tool

Configuration
Or the symbol in the tool bar

Settings Menu
FAQ
136
Connect
Introduction
Serial Connection
Installation
• Connect to the serial COM port
Connect
• Use a Null Modem Cable
Status Menu
(crossover)
Configuration
Settings Menu
FAQ
RS-232
Serial 1
RS-232
ToolKit
137
Connect
Introduction
Initialize communication between the PC and the controller
Installation
Device  Connect
Connect
Status Menu
Configuration Press the Connect icon

Settings Menu
FAQ
138
Connect
Introduction
Installation
Check “Device -> Communications” if no measured values are displayed.
Connect
It should read “ToolConfigurator” for connecting via the RS-232 port.
Status Menu
Configuration
Settings Menu
FAQ
139
Status Menus
Introduction
Installation
Connect
Status Menu
Configuration
Settings Menu
FAQ
Measured values
140
Status Menus
Introduction
Installation
Connect
Status Menu
Use push buttons to
navigate between screens
Configuration
Settings Menu
FAQ
Navigate with arrows

or select with mouse
141
Status Menus
Introduction
Installation
Active alarms Can not be reset if
Connect
active flag = TRUE
Status Menu
Configuration
Settings Menu
FAQ
142
Status Menus
Introduction
Installation
Connect
Active alarm classes

Status Menu
Configuration
Settings Menu
FAQ
Reset alarms online
143
Status Menus
Use EXPORT to create HTML
Introduction
file of the active alarms
Installation
Connect
Status Menu
Configuration
Settings Menu
FAQ
144
Configuration
Introduction
Installation
Connect
Status Menu
Configuration
Settings Menu
FAQ
145
Configuration
Changes are written directly to
Introduction
the controller!
Installation
Connect
Status Menu
Go to the desired screen
Configuration
Settings Menu Unique parameter number

FAQ Select value to be editted
Min/ max values
146
Settings Menu
Introduction
The settings menu is used to save configuration files from the
Installation controller, edit saved files offline, load a saved file into additional
Connect
controllers, and identifies differences in settings of two different files.
Status Menu
Configuration
Settings Menu
FAQ
147
Settings Menu
Introduction
Installation
Connect • Saves the settings from an easYgen control to the computer for use
Status Menu as a historical record or to be transfered to additional controllers.
Configuration
Settings Menu
FAQ
• Click the Browse...

button to create or
enter a file name
148
Settings Menu
Introduction
Installation
Connect
• Select COM port to be used
Status Menu
Configuration
Settings Menu • Monitor progress

FAQ
• Enter notes if desired
149
Settings Menu
Introduction
Installation
Connect
Status Menu
Edit settings file permits changing of
set points without being connected to
Configuration
a controller.
Settings Menu
FAQ
150
Settings Menu
Introduction
Installation
Connect
Status Menu
Configuration
Settings Menu
FAQ
151
Settings Menu
Introduction
Installation
Connect
Status Menu
Configuration
Settings Menu
FAQ
152
Settings Menu
Introduction
Installation
Connect
1) Warning
Status Menu
Configuration
Settings Menu
FAQ
Load the setting files only if the controller is in Stop mode!
153
Settings Menu
Introduction
Installation
Connect
2) Select file with
Status Menu Browse button
Configuration
Settings Menu
FAQ
3) Monitor
progress
154
Settings Menu
Introduction
Installation
Connect • Select the two files to compare

Status Menu
Configuration
Settings Menu
FAQ
155
Settings Menu
Introduction
Installation
Connect
Status Menu
• Any
Configuration
differences
are displayed
Settings Menu
as a
FAQ spreadsheet
156
Settings Menu
Introduction
Installation
Connect
LogicsManager
Status Menu results
Configuration
Settings Menu
FAQ
157
Introduction
Installation
• How do I find specific parameters?
Connect
Status Menu • How do I use the “Trend” function?

• What other connection types are available?
Configuration
Settings Menu
FAQ • How do I work with multiple configuration files

that are in different languages?
• How do I install the v2.xx and v3.xx drivers for the
IXXAT USB-to-CAN compact converter?
158
FAQ
Introduction How do I find certain parameters?
Installation
Use the search function in ToolKit
Connect
• Starting with version V2.3
Status Menu
Configuration
Double-click on
Settings Menu
the result will
FAQ open the page
159
FAQ
Introduction
How do I use the “Trend” function?
Installation
Mark any measured value with the right mouse button.
Connect
Select “Add to trend”.
Status Menu
Configuration
Settings Menu
FAQ
160
FAQ - Trend function
Introduction
Installation
Connect
Adjust trend scaling with “Properties...”
Status Menu
Configuration
Settings Menu
FAQ
161
FAQ - Trend function
Introduction Export as screenshot or *.csv file (only values in display, no storage)
Installation
Connect
Status Menu
Configuration
Settings Menu
FAQ
162
FAQ
Introduction
What other connection types are available?
Installation
A) Multiple units via CANopen
Connect
Status Menu
Use a USB-to-CAN converter (from IXXAT)
Configuration
Settings Menu VCI driver 3.0 or higher needed

FAQ
CAN 1
Change the parameter

ToolKit IXXAT USB-to-CAN CAN 1
“8950 Node-ID CAN-Bus 1”
to #2, #3,....
163
Proprietary Information http://www.ixxat.com
FAQ – Multiple units on CAN #1
Introduction
Select the CAN hardware in the Network menu
Installation
Select the device with Tool Device  Tool Configurator
Connect
Change the baud rate from
Status Menu “Autodetect” to 250kBd if there are
Configuration
less than 3 members on the CAN bus
Settings Menu
FAQ
164
FAQ – Multiple units on CAN #1
Introduction
Display of multiple units in the “Plant page” screen
Installation
Connect
Status Menu
Configuration
Settings Menu
FAQ
165
FAQ
Introduction
Installation
B) Remote access via modem connection
Connect
Status Menu
Configuration
Settings Menu
FAQ
RS-232
Serial 1
RS-232
Industrial modem
ToolKit
with discrete input for dial up
166
FAQ - Modem
Introduction Select the modem from the “Network” and enter the number to
Installation
be dialed.
Connect
Status Menu
Configuration
Settings Menu
FAQ
167
FAQ
Introduction
Installation
C) Remote access via Ethernet connection
Connect
Status Menu
The Anybus converter provides a virtual COM port.

Configuration
The ToolKit software must connect to this port via the LAN
Settings Menu
FAQ
RS-232 Ethernet
Serial 1
RS-232
Anybus ToolKit
http://www.anybus.com/products/abxss.shtml
168
FAQ
Introduction
How do I work with multiple configuration files with
Installation
different languages?
Connect
Use language specific folders
Status Menu
• The English and German *.SID files are named identically
Configuration
• The *.SID file contains language information and must not be renamed
Settings Menu
• Opening the *.WTOOL file means ToolKit looks for the *.SID file in the specified
FAQ folder
• Assign different file paths for different languages
169
FAQ
Introduction
How do I work with multiple configuration files that
Installation
are in different languages?
Connect
Status Menu
Red indicates
Configuration
an incorrect
Settings Menu
SID- selection
FAQ
170
FAQ
Introduction
How do I install the v2.xx and v3.xxdrivers for the
Installation
Connect
Status Menu
Configuration
Settings Menu
FAQ
Open the Device Manager window and right click on the VCI3
171 Interface and select Update Driver.
FAQ
Introduction
Installation
Connect
Status Menu
Configuration
Settings Menu
FAQ
The Hardware Update Wizard dialog window will open. Select

172 Install from a list or specific location and then click on Next.
FAQ
Introduction
Installation
Connect
Status Menu
Configuration
Settings Menu
FAQ
Select “Don’t search. I will choose the driver to install.” and click
173 the Next button.
FAQ
Introduction
Installation
Connect
Status Menu
Configuration
Settings Menu
FAQ
The Hardware Update Wizard will show both sets of drivers.

Select the driver required by the controller and configuration tool
and click the Next button.
174
FAQ
Introduction
Installation
Connect
Status Menu
Configuration
Settings Menu
FAQ
The Hardware Update Wizard will install the desired drivers.

175
FAQ
Introduction
Installation
Connect
Status Menu
Configuration
Settings Menu
FAQ
Click on Finish to complete the installation of the driver.

176
FAQ
Introduction
Installation
Connect
Status Menu
Configuration
Settings Menu
FAQ
The results of the installation process can be viewed in the Device

177 Manager window.
End of Section 4
11 Sequencing
Note:
Note:
Information
and detailedcontained herein
information is intended
is available for and appropriate
in Woodward to the
product specs. purposes
Specific of this
reliance publication/presentation.
should be given only to information
Woodward
contained in purchase order(s), other contractual document(s), or information otherwise at
reserves the right to update or otherwise revise any portion of this publication any time.
expressly Technical data
represented in
and detailed information is available in Woodward product specs. Specific reliance should be
writing by Woodward as correct and accurate for the specific facts, circumstances and applications.given only to information
178 writing by Woodward as correct and accurate for the specific facts, circumstances and applications.
Section 5 - Communication
marked
CERTIFICATE of
Design Assessment
by ABS
Contents
Communication Ports 4
Serial Port Communication 5
CAN bus Communications 13
Password Protection 25
FAQ 27
Introduction
Introduction
Comm Ports
Serial Comms
CANbus Comms The easYgen-3200 has four communication ports. The functionality of
Password these ports are varied and may be utilize multiple protocols. These
FAQ
functions range from load dependent start/stop, load-sharing, reading
ECU data, configuration, and remote monitoring and control via an HMI.
181
Communication Ports
Introduction
Comm Ports
• Load-sharing • ToolKit
Serial Comms
• CANopen • Modbus
CANbus Comms
Serial 1
Password CAN 1 RS-232
FAQ
Serial 2
CAN 2
RS-485
• Extension cards • Modbus
(IKD 1,
Phoenix)
• J1939
messaging
All interfaces are galvanically (electrically) isolated
182
Serial Port Communications
Introduction
Comm Ports
Serial RS-232 • ToolKit
Serial Comms
• Modbus
CANbus Comms Modem
PC • Peer-to-peer
Password
FAQ
Ethernet
Serial 1
Serial RS-232 RS-232
Serial RS-485
Serial 2
PLC
Profibus RS-485
• Modbus
• Multiple units
PC
183
Serial 1: ToolKit via RS-232
Introduction
RS-232
Comm Ports
Serial Comms
CANbus Comms
Serial 1
Password RS-232
FAQ
184
Serial 1: GSM Modem via RS-232
Introduction
Comm Ports
Serial Comms
CANbus Comms
Password RS-232
FAQ
INSYS ToolKit
Serial 1 GSM Modem Modbus
RS-232 http://www.insys-tec.de
185
Serial 1: Landline Modem via DPC
Introduction
Comm Ports
Serial Comms
CANbus Comms
Password RS-232
FAQ
Phoenix ToolKit
Serial 1 landline modem Modbus
RS-232 with discrete input for dial up
186
Serial 1: Ethernet to RS-232 converter
Introduction
Comm Ports
Serial Comms
CANbus Comms
Password RS-232 Ethernet

FAQ
Anybus ToolKit
Serial 1 Modbus
RS-232
The Anybus converter provides a virtual COM port.
The Toolkit software must connect to this port to
receive the data
http://www.anybus.com/products/abxss.shtml
187
Serial 1: Modbus on RS-232
Introduction • For point to point communications easYgen-3000 to the Master
Comm Ports
Serial Comms
CANbus Comms
Password Modbus
Serial 1
FAQ
RS-232
PLC
Slave ID = 1 Modbus Master
188
Introduction Baud rate
Comm Ports
Serial Comms
CANbus Comms
Password
FAQ
189 Do not disable, required for ToolKit!

Introduction • Multi-drop communications for several easYgen-3000s to one Master
Comm Ports • Full- and Half Duplex- communications supported
Serial Comms
• Acquire visualization data from different IDs
CANbus Comms
Password
FAQ
Modbus
Serial 2
RS-485
PLC
Slave ID = 1 Slave ID = 2 Slave ID = 3 Modbus Master
190
Introduction • Wiring of Half Duplex- communications
Comm Ports
Serial Comms
CANbus Comms
Password
FAQ
• Wiring of Full Duplex- communications
191
Serial 2: Modbus to Profibus
Introduction
Comm Ports
Serial Comms SPS

CANbus Comms
Password RS-485 Profibus

FAQ
Profibus-Master
Anybus X-gateway
Serial 2
RS-485 Modbus Master to Profibus DP Slave converter.
Must be programmed separately.
http://www.anybus.de/products/prodindex.shtml
192
Serial 2: Parameters
Introduction
Comm Ports
Serial Comms
CANbus Comms
Password
FAQ
193 Enter a longer delay for slower PLCs

CAN Bus Communications
Introduction Guidance level
32 units max
Comm Ports • Load sharing
Serial Comms • CANopen
CANbus Comms
Password CAN 1
FAQ
Digital expansion modules
CAN 2
Engine level
2x IKD 1 Phoenix
• J1939 (ECU)
• Extension cards
Analog expansion modules
P2
ECU
ECU
GATEWAY
G ATEW AY
Engine Generator
194
Proprietary Information Phoenix J1939
CAN 1: PC
Introduction
Comm Ports
CAN 1 IXXAT USB-to-CAN
Serial Comms converter ToolKit
http://www.ixxat.com CANopen
CANbus Comms
software tool
Password Connection to a PC via CAN-to-USB
interface transducer, e.g. IXXAT
FAQ
Use the PC tool to watch CAN traffic
195
CAN 1: Load Sharing
Introduction
Comm Ports CAN 1

Serial Comms
CANbus Comms
Password
FAQ
196
CAN 1: CANopen to PLC
Introduction
Comm Ports CAN 1

Serial Comms PLC
CANbus Comms
Password
FAQ
Use the CANopen PDO parameters to adjust to your system.

The easYgen is delivered with a CANopen *.eds file for the PLC.
197
CAN 1: Parameters
Introduction
For load share

Comm Ports
Serial Comms
CANbus Comms
Password
FAQ
198
CAN 1: Parameters
Introduction
For CANopen
Comm Ports
Serial Comms
CANbus Comms
Password
FAQ
199
CAN 2: ECU and IKD
Introduction
Parameters in the easYgen
Comm Ports CAN interface 2 IKD
Serial Comms
Function for RPDO 1 = 1st IKD
CANbus Comms Parameters in IKD 1 IKD2
Function for RPDO 2 = 2nd IKD
Password
FAQ
CAN 2
2x IKD 1
extension card
ECU
ECU
GATEWAY
G ATEW AY
Engine Generator
200
CAN 2: ECU and Phoenix
Introduction
Parameters in the easYgen
Comm Ports CAN interface 2 Phoenix
Serial Comms
Function for RPDO 1 = BK 16DIDO
CANbus Comms
Function for RPDO 2 = Off
Password
FAQ
Parameter in the Phoenix card

Node ID =2
CAN 2
Phoenix
extension card
ECU
ECU
GATEWAY
G ATEW AY
Engine Generator
201
CAN 2: Visualization of a J1939 ECU
Introduction The easYgen reads & displays ECU values:
Comm Ports
Serial Comms Alarms (failure code, blink code)

CANbus Comms Pressure
Password
Temperature
FAQ
Other measured values
Visualization
J1939
ECU
ECU
GATEWAY
G ATEW AY
Engine Generator
202
CAN 2: Monitoring of a J1939 ECU
Introduction The easYgen reacts to ECU messages with an alarm:
Comm Ports
Serial Comms
• Amber warning lamp

CANbus Comms
Password
• Red stop lamp
FAQ
Adjustable alarm class for each bit
Warning / Alarm lamp
J1939
ECU
ECU
GATEWAY
G ATE W AY
Engine Generator
203
CAN 2: P1 J1939 ECU Values
Introduction
Comm Ports
• Throttle position (SPN91) • Air inlet temperature (SPN172)
Serial Comms
• % Load at current speed (SPN92) • Exhaust gas temperature (SPN173)
CANbus Comms
• Engine oil level (SPN98) • Fuel temperature (SPN174)
Password
• Engine oil pressure (SPN100) • Engine oil temperature (SPN175)
FAQ
• Boost pressure (SPN102) • Fuel rate (SPN183)
• Intake manifold temperature • Engine speed (SPN190)
(SPN105) • Total engine hours (SPN247)
• Barometric pressure (SPN108) • Actual engine torque (SPN513)
• Engine coolant temperature
(SPN110)
• Coolant level (SPN111)
204
Introduction
Comm Ports
• Engine Intercooler Temp (SPN52) • Transmission Oil Temperature
• Fuel Delivery Pressure (SPN94) (SPN177)
Serial Comms
• Auxiliary Temperature 1 (SPN441)
CANbus Comms
• Fuel Filter Differential Pressure
(SPN95) • Auxiliary Temperature 2 (SPN442)
Password
• Crankcase Pressure (SPN101) • Actual Engine Torque (SPN513)
FAQ
• Turbo Air Inlet Pressure (SPN106) • Alternator Bear. 1 Temperature
• Air Filter 1 Differential Pressure (SPN1122)
(SPN107) • Alternator Bear. 2 Temperature
• Coolant Pressure (SPN109) (SPN1123)
• Transmission Oil Pressure (SPN127)

• Fuel Rail Pressure (SPN157)
Version
• Ambient Air Temperature (SPN171) 1.12
• Turbo Oil Temperature (SPN176)
205
Introduction
Comm Ports
• Engine Intercooler Temp (SPN52) • Fuel Rail Pressure (SPN157)
Serial Comms
• Fuel Delivery Pressure (SPN94) • Ambient Air Temperature (SPN171)
CANbus Comms
• Fuel Filter Differential Pressure • Turbo Oil Temperature (SPN176)
(SPN95) • Transmission Oil Temperature
Password
• Crankcase Pressure (SPN101) (SPN177)
FAQ
• Turbo Air Inlet Pressure (SPN106) • Auxiliary Temperature 1 (SPN441)
• Air Filter 1 Differential Pressure • Auxiliary Temperature 2 (SPN442)
(SPN107) • Actual Engine Torque (SPN513)
• Coolant Pressure (SPN109)
• Transmission Oil Pressure (SPN127)
Version
1.12
206
Introduction
Comm Ports
• Alternator Bearing 1 Temperature • Main Bearing 1-11 Temperatures
(SPN1122) (SPN1157-1167)
Serial Comms
• Alternator Bearing 2 Temperature • Turbo 1-4 Compressor Inlet
CANbus Comms
(SPN1123) Temperatures (SPN1172-1175)
Password
• Alternator Winding 1,2,3 Temperature • Turbo 1-4 Turbine Inlet Pressures
FAQ (SPN1124-1126) (SPN1176-1179)
• Intake Manifold 2,3,4 Temperature • Turbo 1-4 Turbine Inlet Temperatures
(SPN1131-1133) (SPN1180-1183)
• Engine Thermostat (SPN1134)
• Engine Oil Temperature 2 (SPN1135)
• Engine ECU Temperature (SPN1136)
• Exhaust Gas Port 1-20 Temperatures Version
(SPN1137-1156) 1.12
207
Introduction
Comm Ports
• Turbo 1-4 Turbine Outlet • Battery 1 Temperature (SPN1800)
Temperature (SPN1184-1187) • Battery 2 Temperature (SPN1801)
Serial Comms
• Engine Aux. Coolant Pressure • Intake Manifold 5 Temperature
CANbus Comms
(SPN1203) (SPN1802)
Password
• Pre-filter Oil Pressure (SPN1208) • Intake Manifold 6 Temperature
FAQ
• Engine Aux. Coolant Temperature (SPN1803)
(SPN1212) • Right Exhaust Gas Temperature
• Fuel Filter Differential Pressure (SPN2433)
(SPN1382) • Left Exhaust Gas Temperature
(SPN2434)
Version
1.12
208
CAN 2: Control of a J1939 ECU
Introduction The easYgen sends commands to the ECU:
Comm Ports
Serial Comms
Start/Stop
CANbus Comms
Request Alarms Speed offset
Password
(failure code,
- blink code)
Droop
FAQ Reset blink code
(only Scania) Idle
Acknowledge Control – if supported by

ECU
J1939
ECU
ECU
GATEWAY
G ATEW AY
E N G IN E G ENER ATO R
Engine Generator
209
Deutz
Introduction Volvo MAN SISU
Woodward S6 EMR2/ Volvo MTU
EMS1/ MFR/ EEM2/ SAE
EGS Scania Volvo EMS2 ADEC
Comm Ports EDC3 EDC7 EEM3
EDC4
Serial Comms 15102
EGS S6 EMR2 EMS2 EMS2 ADEC MAN SISU Std.
Device type
CANbus Comms
Engine
No Yes No Yes Yes Yes Yes Yes No
Password
Start
Engine
Yes Yes No Yes Yes Yes Yes Yes Yes
FAQ Stop
Droop
Yes Yes No Yes Yes Yes Yes Yes Yes
Mode
Idle Mode No Yes No Yes Yes No No No No
50/60Hz
Yes Yes No Yes No Yes No No No
Switch
Yes Yes Yes Yes Yes Yes
Speed Bias Yes Yes Yes
offset set point offset set point set point set point
Preglow No No No Yes Yes No No No No
Override
ECU No Yes No No No Yes No No Yes
Alarms
210
CAN 2: Coupling to Woodward E3
Introduction Gas Mixer
Comm Ports
Serial Comms Gas Engine Control
Start / Stop KW feedback

CANbus Comms
Password Knock
Detection
FAQ
Power
Management
Controls - Throttle
Integrated
Spark - Engine Control
Throttle Bodies
Ignition Plugs
By-pass /
Coils Waste gate
High Energy TecJet
Ignition Control Gas Control

211 Valve
The easYgen reads & displays EGS values via CAN
Introduction
Comm Ports
Serial Comms Visualization Coming up:

CANbus Comms
Engine Speed
Alarms
Engine Load %
Password
Speed setting
Amber warning
FAQ lamp > Warning
Engine Hours
Coolant temperature
Fuel temperature Red stop lamp
Boost pressure CAN > Shutdown
Manifold Absolute Temperature J1939
212
The easYgen sends CAN commands to the EGS
Introduction
Comm Ports
Serial Comms
CAN Commands
CANbus Comms Start / stop
Password Shutdown
FAQ Speed setpoint
Genset breaker status
CAN
J1939 Load setpoint
Alarm Reset
Real power
Rated speed
213
Introduction
CAN 2
Comm Ports ECU
GATEWAY
E C U
G ATE W AY
E N G IN E G E N E R ATO R
Serial Comms
Engine Generator
CANbus Comms
Password Control signals provided by the easYgen:

FAQ
Engine Start LogicsManager 03.02. "Starter"
Engine Stop LogicsManager 03.27. "Stopping solenoid"
Droop mode LogicsManager 00.25 "Frequency droop active"
Idle Mode LogicsManager 04.15. "Idle run active"
50/60 Hz switch If the parameter "1750 Rated system frequency" is
changed within the easYgen
Speed bias Refer to parameter 5537 in the Config. Manual
Preglow LogicsManager 03.04. "Preglow/Ignition"
Override LogicsManager 04.27. "Critical mode"
Version Reset Alarms LogicsManager 00.15. "LM: External acknowledge”
1.12
214
NOT every ECU supports all signals, see interface manual for details
Introduction
CAN 2
Comm Ports ECU
GATEWAY
E C U
G ATE W AY
E N G IN E G E N E R ATO R
Serial Comms
Engine Generator
CANbus Comms
Password Parameters
FAQ Setting Device type J1939 Device Engine control SPN Version Comment
ECU (ID 15102) address address (ID 15103)
(ID 15106) (ID 15107)
Woodward E3 EGS 234 0 n/a
MTU ADEC ADEC MTU 1 128 n/a Connection:
easYgen  SAM via CAN2
SAM  ADEC using MTU bus
Deutz EMR2 EMR2 Deutz 3 0 Version 1

Volvo EDC4
Volvo EMS2 EMS2 Volvo 17 0 n/a The rated speed of the EMS1 and
Volvo EMS1 EDC3 cannot be switched via the
Volvo EDC3 easYgen.
Scania S6 S6 Scania 39 0 n/a
Version MAN MFR/EDC7 MAN 253 0 n/a Connection:
1.12 easYgen  MFR via CAN2
MFR  EDC7 using MAN bus
215
Proprietary Information SAE ECUs Standard 234 0 n/a
CAN 2: Parameters
Expansion boards
Introduction
Comm Ports
Serial Comms
CANbus Comms
Password
FAQ
Enter ECU protocol

216
P2
only CAN 2: Analog expansion boards
Introduction
Comm Ports
Serial Comms
CANbus Comms
Password
FAQ
- ECU
217
P2
only CAN 2: Parameters
Expansion boards – refer to applications manual for details
Introduction
Comm Ports
Serial Comms
CANbus Comms
Password
FAQ
218
Password Protection
Introduction
Comm Ports
Level 1/end user 0001
Serial Comms Level 2/temporary commissioning (random
number+200)*3
CANbus Comms
Level 3/commissioning 0003
Password
Possible ways to change a parameter:
FAQ
Hardware Access Method/Protocol Enter Password for:
HMI Push-buttons Display
RS-232 ToolKit No password required
CAN 1 CANopen CAN 1
219
Password Protection
Introduction
Comm Ports
Level 1/end user 0001
Serial Comms Level 2/temporary commissioning (random
number+200)*3
CANbus Comms
Level 3/commissioning 0003
Password
Randomly generated number
FAQ
Current level of access
To access to this interface,

Enter code here
220
FAQ
Introduction
How can I make a start / stop / acknowledge via the interface?
Comm Ports
Serial Comms
CANbus Comms 1) Configure the start / acknowledge

Password commands in the easYgen
FAQ 2) Send the start/ stop commands via
interface
3) Change to automatic mode and
check the function
221
FAQ
Introduction
How can I make a start / stop / acknowledge via interface?
Comm Ports
Serial Comms
1) Config device
CANbus Comms
Password
FAQ
Acknowledge:
Enter input command variable “04.14 Remote acknowledge” in the
“Ext.Acknowledge” LogicsManager output.
When data bit 4 “Remote acknowledge” changes from false to true, the
“Ext.Acknowledge” LogicsManager output is enabled.
Data bit 4 “Remote acknowledge” must change back to false in order to reset the
222 “Ext.Acknowledge” LogicsManager output.
FAQ
Introduction
Comm Ports
Serial Comms
1) Config device
CANbus Comms
Password
FAQ
Start/Stop:
Enter input command variable “04.13 Remote request ” in the “Start request in
AUTO” LogicsManager output.
When data bit 0 “Start request” changes from false to true, the “Start request
in AUTO” LogicsManager output is enabled.
When data bit 1 “Stop request” changes from false to true, “Start request in
223 AUTO” LogicsManager output is disabled.
FAQ
Introduction
Comm Ports
Serial Comms
2) Send start bit
CANbus Comms
Password
Remote control
FAQ Parameter ID 503
224
FAQ
Introduction
Comm Ports
2) Send start bit:
Serial Comms
All interface protocols write utilizing the same LogicsManagerTM commands:
CANbus Comms
Password
FAQ
04.13 Remote request
RS-232 CAN bus 1
Modbus 04.14 Remote acknowledge CANopen
Modbus
RS-485
225
FAQ
Introduction
Comm Ports
2) Send start / stop bits
Serial Comms
CANbus Comms Via interface RS-232 or RS-485, Modbus protocol address 503
Password
Start/Stop
FAQ Engine starts when the “Remote Start” data bit is true/high
Engine stops when the “Remote Stop” data bit is true/high
Start
Stop
226
Note: Software ModScan32 adds internally +1 to the address (504 instead of 503)
FAQ
Introduction
Comm Ports
2) Send acknowledge bit
Serial Comms
CANbus Comms Via interface RS-232 or RS-485, Modbus protocol address 503
Password Acknowledge:
FAQ Bit must be reset by the Modbus master
Acknowledge
227
Note: Software ModScan32 adds internally +1 to the address (504 instead of 503)
FAQ
Introduction
Comm Ports
2) Send start / stop / acknowledge bits
Serial Comms
CANbus Comms Via CANbus interface – two methods possible

(Refer to the Interface manual 37383 for more details)
Password
FAQ
228
FAQ
Introduction
Comm Ports
2) Send start / stop bits
Serial Comms
CANbus Comms Start/Stop:

Password
FAQ
Start bit #0
Stop bit #1
04.13 Remote
start request
229
FAQ
Introduction
Comm Ports
2) The acknowledge sequence requires two “rising edges”
Serial Comms
CANbus Comms
Password 1st edge acknowledges

alarm, clearing
FAQ Acknowledge #4
centralized alarm (horn)
2nd edge clears all

inactive alarms
04.14 Ext.
Acknowledge
230
FAQ
Introduction
Comm Ports
3) Monitor result
Serial Comms
Engine will perform a start sequence
CANbus Comms
Password
FAQ
231
End of Section 5
11 Sequencing
Note:
232
Section 6 - LogicsManager
marked
CERTIFICATE of
Design Assessment
by ABS
Contents
Screen Description 5
Input Command Variables 6
Signs 11
Operators 13
Time delay 17
Logical Outputs 18
Programming 24
Exercise 26
Introduction
Introduction The LogicsManagerTM permits the easYgen-3000 operating logic to
Description be customized to the individual application. The status of discrete
Input Commands
inputs, discrete outputs, internal conditions, alarms, and measured
values may be combined into logical functions. These logical
Signs
functions may be used to initiate numerous operational functions,
Operators
such as starting the generator in the automatic mode.
Time Delay
Logical Outputs
Woodward’s LogicsManagerTM has been developed to give the user
Programming
complete control for flexible configuration and operation.
Exercise
235
Introduction - LogicsManagerTM
Introduction
Description
Input Commands
Digital Signals Relay Outputs
Discrete inputs Assignment Operate freely
Signs Relay status configurable outputs
External discrete inputs With timer ON-delay and OFF-delay
Operators
External relays
16 additional/internal flags or logical
Control via
Time Delay operations
interface
Logical Outputs
Internal Conditions Internal Conditions
Programming Conditions Start/stop engine
- CB status
Exercise Change operation mode
- operating mode
- engine status Acknowledge of alarms
Alarms Inhibit emergency mode
- warning alarm Creating internal flags for
- shutdown alarm cascading logic with
Time / Date multiple variables
236
Screen Description
Introduction
Components of a Boolean Logic equation:
Description
Input Commands Logical Output Sign Delay ON

Signs Delay OFF
Operators
Time Delay
Command
Logical Outputs
Programming Operator 01
Exercise
Operator 02
237
Input Command Variables
Introduction
The following groups are available:
Description
Input Commands
00 Flags condition (results of 08 System related alarms
LogicsManager outputs)
Signs 09 Discrete inputs
01 Alarm system (active
Operators alarm classes) 10 Analog inputs
(wire break)
Time Delay 02 System condition
11 Clock and timer
Logical Outputs 03 Engine control
12 External DIs
Programming 04 Applications condition
13 Discrete outputs
Exercise 05 Engine related alarms
14 External DOs
06 Generator related alarms
15 Flexible limits
07 Mains related alarms
18 Transistor outputs
(external excitation 12V/24V)
238
Introduction
Viewing the state of the inputs in ToolKit:
Description
Input Commands
Signs
Operators
Time Delay
Logical Outputs
Programming
Exercise
239
Introduction
Viewing the state of the inputs in the HMI:
Description
Input Commands
Signs
Operators
Time Delay
Logical Outputs
Programming
Exercise
240
Introduction
Internal clock and timer functions:
Description
Input Commands
Signs
Operators
Time Delay
Logical Outputs
Programming
Exercise
241
Introduction If a discrete input or alarm threshold is to
Description
be used as an input command to the
LogicsManager, the alarm class must be
Input Commands
configured as “Control”.
Signs
Operators
Time Delay
Logical Outputs
Programming
Exercise
242
Signs
Introduction
The sign defines if the input is enable and how it will be used
Description
Direct Command value
Input Commands - The command variable input
is
Signs
passed directly to the
Operators operator.
Time Delay
Logical Outputs NOT Command value

- The command variable input
Programming
status is inverted and then
Exercise passed to the operator.
Hard False
is ignored and this logic path is
always FALSE.
Hard True
243 is ignored and this logic path is
always TRUE.
Signs
Introduction
Description
Input Commands
Command input:
Grey if sign = TRUE or FALSE
Signs
Operators
Time Delay
Logical Outputs
Programming
Exercise
244
Operators
Introduction
Operator 01 and 02
Description
Input Commands
Signs
Operators
Time Delay
Logical Outputs
Programming
Exercise
245
Operators
Introduction
Truth Tables
Description
AND OR NAND
Input Commands
x1 x1
Signs
x1 x2
Operators x2
x2
Time Delay
Logical Outputs
Programming
Exercise
x1 x2 y x1 x2 y x1 x2 y
0 0 0 0 0 0 0 0 1
0 1 0 0 1 1 0 1 1
1 0 0 1 0 1 1 0 1
1 1 1 1 1 1 1 1 0
246
Operators
Introduction
Truth Tables
Description
NOR NXOR XOR
Input Commands
x1 x1
OFF OFF
ON ON
Signs
x1 x2
x2 x2
Operators OFF ON
ON OFF
Time Delay
Logical Outputs
Programming
Exercise
x1 x2 y x1 x2 y x1 x2 y
0 0 1 0 0 1 0 0 0
0 1 0 0 1 0 0 1 1
1 0 0 1 0 0 1 0 1
1 1 0 1 1 1 1 1 0
247
Operators
Introduction
The “Help” screen gives a description of the logical outputs.
Description
Input Commands
Signs
Press soft key
Operators
Time Delay
Logical Outputs
Programming
Exercise
248
Time Delay
Introduction
Delay ON Delay OFF
Description The amount of time that the logical The amount of time that the logical
output state is delayed before changing output state is delayed before changing
Input Commands
to true to false
Signs
Operators
Time Delay
Logical Outputs
Programming
Exercise
Delay ON Delay OFF
249
Logical Outputs
Introduction
There are three types available:
Description
Input Commands
Signs Relay outputs Any discrete output that are freely configurable
Operators
Time Delay
Internal functions and conditions such as “Start

Logical Outputs Logical Functions
request in AUTO” or “Firing speed reached”
Programming
Exercise
Additional Boolean equations which can be used

Internal Flags whenever three input command variables are not
enough or time delayed signals are required
250
Logical Outputs
Relay output 1 Ready for operation OFF
Introduction
Relay outputs
Relays 2 to 12 Depending on configuration
Description
Input Commands
External relays 1-16 via expansion board
Signs
May be used as additional flags if not utilized
Operators
Time Delay
Logical Outputs
Programming
Exercise
251
Logical Outputs
Introduction
Internal Flags Internal flags 1 through 16
Description
Flag 1: used as placeholder – use caution when
Input Commands
employing it for other purposes
Internal flag 8:
Signs
Flag 8: Timer function
Operators Timer1: 08:00.00
Time Delay
Timer2:
17:00.00
Logical Outputs
Programming
Active weekday:
Monday: Yes
Exercise
…..
Friday: Yes
Saturday: No
Sunday: No
252
Logical Outputs
Introduction
Logical Functions
Description
Input Commands
Start request in AUTO
Signs Stop request in AUTO
Operators Load dependent (LD) start stop
Time Delay Start w/o load
Logical Outputs Critical mode
Programming Inhibit emergency
Exercise External acknowledge
Undelayed close GCB
External mains decoupling requested
Enable MCB
Firing speed reached
253
Logical Outputs
Introduction
Logical Functions
Description
Setpoint 2 power
Input Commands
Setpoint 2 power factor
Signs
Setpoint 2 frequency
Operators
Setpoint 2 voltage
Time Delay Frequency droop active
Logical Outputs Voltage droop active
Programming Discrete f/P + (raise)
Exercise
Discrete f/P – (lower)
Discrete V/PF + (raise)
Discrete V/PF – (lower)
RUN synchronization mode
CHECK synchronization mode
PERMISSIVE synchronization mode
254
Logical Outputs
Introduction
Logical Functions
Description
Input Commands
Signs Constant idle run

Operators Auto idle mode
Time Delay
Logical Outputs AUTO operation mode

Programming MANUAL operation mode
Exercise STOP operation mode
255
Programming
Introduction
Select component to change with arrows
Description
Input Commands
Signs Change value with + and -
Operators
Time Delay
Go to next input command group
Logical Outputs
Programming
Exercise
Select from list in ToolKit
256
Programming
Introduction
Remote start:
Description
Input Commands
Start req. in Auto:
Signs Discrete input 2 (Alarm class = control)
Operators Internal flag 8 (Timer)
Time Delay Remote request (activated via interface)
Internal flag 8:
Logical Outputs
Programming
Timer1: 08:00.00 Timer2:
Exercise 17:00.00
Active weekday:
Monday: Yes …..
Friday: Yes
Saturday: No Sunday:
No
257
Version
1.12 Programming
Introduction
New version shows the active/inactive status of the
Description
input command variables
Input Commands
Signs
Operators
Time Delay
Logical Outputs
Programming
Exercise
258
Exercise
Introduction
Your customer needs a relay output to cause a
Description
warning light to flash if the operator puts an
easYgen-3200 into the MANUAL operation mode.
Input Commands
Signs
Operators
Time Delay
Logical Outputs
Programming
Exercise
259
Exercise
Introduction
Create pulsing relays output
Description
 Use as many flags as necessary
Input Commands
 The relay shall only pulse in operating mode MANUAL
Signs
 Use relay 11 as pulse relay
Operators
 Change the pulse / pause ratio
Time Delay
Logical Outputs
Programming
Exercise
260
Exercise
Introduction
Solution: Create pulsing relay output.
Description
Can be used as a simple process controller if combined with Flexible Limits
Input Commands (alarm class = control). Only digital PID possible with multiple Flexible Limits
Signs and different pulse / pause ratios.
Operators
Pause time Pulse time
Time Delay
Logical Outputs
Programming
Exercise
261
End of Section 6
11 Sequencing
Note:
262
Section 7 – Analog Manager
marked
CERTIFICATE of
Design Assessment
by ABS
Contents
Data Sources 6
Flexible Limits 13
Source Format 18
Analog Output 21
Exercises 29
Introduction
Introduction
Analog ManagerTM
Data Sources
The Analog Manager permits measured or internal analog values, such as
Flexible Limits
speed or voltage bias signals, to be utilized for the following
Source Format functionalities:
Analog Outputs • Monitoring via FlexLimitsTM for alarm and control purposes
Exercises
• Sources for the analog bias signals output
• Sources for the set point references to external controllers
265
Introduction
Introduction
The easYgen offers the ability to measure multiple values:
Data Sources
• Voltage • Active Power
Flexible Limits
• Current • Reactive Power
Source Format
• Speed / Frequency • Apparent Power
Analog Outputs
Exercises
• Analog Input
The Analog Manager utilizes these values for additional tasks.

• Flexible Limits
• Analog Outputs
• Controller Set Points
266
Data Sources
Introduction
Possible data sources
Data Sources
00 Internal values
Flexible Limits
01 Generator values
Source Format 02 Mains values
Analog Outputs 03 Busbar
Exercises
05 Controller set points
06 Analog inputs
08 External analog inputs
07 Engine values (ECU)

Version
1.12
Change data source with + and -

267
Data Sources
Introduction Group 00 Internal values
Data Sources
Flexible Limits
Source Format
Analog Outputs
Exercises
268
Data Sources
Introduction Group 01 Generator values
Data Sources
Analog Analog variable Reference value
Flexible Limits
input #
Source Format
01.01 Gen. aver.ph-n volt Generator rated voltage
Analog Outputs
01.02 Gen voltage L1-N Generator rated voltage
Exercises
01.09 Gen. frequency Rated frequency
01.13 Gen. current average Generator rated current
01.20 Gen. power factor Power factor 1
01.24 Gen. total real power Generator rated real power
01.28 Gen.total react. power Generator rated reactive power
01.32 Gen. total apparent power Gen. rated real and reactive power
269
And many more detailed values
Data Sources
Group 02 Mains values
Introduction
Data Sources
Flexible Limits
Source Format
Analog Outputs
Exercises
270
Data Sources
Introduction Group 05 Controller setpoints
Data Sources
Flexible Limits
Source Format
Analog Outputs
Exercises
Refer to the controller

section for additional
information
271
Data Sources
Introduction Group 03 Busbar values
Data Sources
Flexible Limits
Source Format
Analog Outputs
Exercises
Group 06 Analog inputs
272
Data Sources
Group 07 ECU Engine values (J1939) Version
1.12
Introduction
Number # Datenquelle
Data Sources
Flexible Limits
07.07 SPN 100: Engine Oil Pressure
Source Format 07.15 SPN 110: Engine Coolant Temperature
Analog Outputs
07.16 SPN 190: Coolant Level
Exercises
07.27 SPN 190: Engine Speed
Group 08 External Analog inputs

Number # Datenquelle Referenzwert
08.01 External Analog Input 1 Display value

273
And many more detailed values
Flexible Limits
Introduction
Data Sources
Flexible Limits
Description of the
Source Format parameters
Analog Outputs
Exercises
274
Flexible Limits
Introduction Description of the parameters
Data Sources
Flexible Limits Enter text to be displayed in

alarm list and event log if the
Source Format
FlexLimit is not configured as
Analog Outputs a control.
Exercises
Enter alarm class

Available:
A
B
C
D
E
F
Control
275
Flexible Limits
Data Sources
Enable flexible limit
Flexible Limits (disabled by default)
Source Format
Analog Outputs
Exercises
Enter delay time
276
Flexible Limits
Data Sources
Flexible Limits
Source Format
Analog Outputs
Exercises
If the alarm class is

configured as
control these
parameters are
ignored
277
Flexible Limits
Data Sources
Flexible Limits
Select monitored data
Source Format source from list
Analog Outputs
Exercises
Limit defines the

threshold that an action
is initiated
Hysteresis defines the
level below the limit that
the condition no longer
exists
278
Source Format
Introduction
Format of the values:
Data Sources
Flexible Limits
The data range of these values is +/- 32000 (+/- 320.00%)
Source Format
There are two types of values
Analog Outputs
• with reference i.e. voltages, refer to rated voltage, entered as 000.00%
Exercises
• without reference i.e. analog inputs entered in the displayed format without a
decimal
% - Values Display values

12000 = 120.00% 45 = 4.5bar
279
Voltage Analog input
Source Format
Introduction
The format is needed for the following parameters:
Data Sources
Flexible Limits
Flexible limits Parameter: Limit
Hysteresis
Source Format
Analog Outputs Analog outputs Parameter: Source value at minimum output

Exercises Source value at maximum output
280
Source Format
Introduction
Examples:
Data Sources
Flexible Limits
Source Format
Analog Outputs
Exercises
281
Analog Output
Introduction
Description of the
Data Sources parameters
Flexible Limits
Source Format
Analog Outputs
Exercises
282
Analog Output
Introduction
Description of the analog output parameters
Data Sources
Flexible Limits
Source Format
Analog Outputs
Data source:
Exercises
select from list
283
Analog Output
Introduction
Data Sources
Flexible Limits
Source Format
Analog Outputs
Exercises
Define the upper and

lower limits of the
signal as a percentage
284
Analog Output
Introduction
Data Sources
Flexible Limits
Source Format Select desired signal

type and range
Analog Outputs
Exercises • User defined (max.

+/- 20mA/ +/- 10V)
• 0-10mA / 0-5V
• 0-20mA / 0-10V
• 20-4mA
• 4.5-0.5V
• +/-1 V
• +/- 2.5
• And many more…
285
Analog Output
Introduction
Data Sources
Flexible Limits
Source Format
Analog Outputs
Only for hardware type:
Exercises
User defined
For output signal 4 to 20mA:

Range: 0-100% = -20 to 20mA
Min output: 60.00% = 4mA
Max output: 100.00% = 20mA
286
Analog Output
Introduction
Data Sources
Flexible Limits
Source Format
Ensure hardware is configured
for +/-10V or 0-10V if using
Analog Outputs PWM signal
Exercises
Only for PWM

signal
287
Analog Output
Introduction
Examples for analog output parameters from the Configuration manual
Data Sources
Flexible Limits
Source Format
Analog Outputs
Exercises
288
Analog Outputs: Status Screen
Introduction
Signal Options: Analog outputs
Data Sources
 OFF 2 analog outputs
 User defined (max. +/- 20mA and +/- 10V)
Flexible Limits
 0-10mA / 0-5V
Configurable as a
Source Format  0-20mA / 0-10V voltage, current, or
 4-20mA PWM signal
Analog Outputs
Actual output
 0.5-4.5V Preconfigured for speed and
Exercises
 10-0mA / 5-0V
signal
voltage bias
 20-0mA / 10-0V % in relation to
 20-4mA the configured
 4.5-0.5V
range
 +/-1 V
 +/- 2.5
 +/- 3V
 +/-10mA / +/-5V
 +/-20mA +/-10V
289
Exercises
Introduction
A: 1) Configure the analog input 1 for a VDO fuel tank level sender.
Data Sources 2) Additional task: What would you have to change to view the tank
Flexible Limits
level in liters?
Source Format
B: Configure the analog output manager:
Analog Outputs
Generator real power for an analog meter (rated power 200 KW).
Exercises
C: Configure the analog output manager:

Speed bias signal for analog output 1 range: 3 – 7 Vdc
D: Use the flexible limits and activate a fuel transfer pump with the fuel
tank levels from the analog input (refer to section 2, exercise A).
290
Exercises: Task A
Introduction
1) Configure the Analog input 1 for a VDO fuel tank level sensor.
Data Sources
Sender Type:
Flexible Limits
Resistive range: 0 to 180 Ohm linear= 0 to 100% Fuel

Source Format
level, 2-wire / two-pole sender
Analog Outputs
Exercises
2) Additional task: What would you have to change to see the fuel
tank level in liters?
100% = 6000 liters
291
Exercises: Task A
Introduction
Data Sources
Change parameters in the analog input screen
Flexible Limits
Source Format
Analog Outputs
Exercises
292
Exercises: Solution A
Introduction
Data Sources
Flexible Limits
Source Format
Analog Outputs
Exercises
Enter name to be displayed
293
Introduction
Data Sources
Select Type “linear” from list
Flexible Limits
Source Format
Analog Outputs
Exercises
Verify sender hardware type 0-500 Ohm
294
Introduction
Data Sources
Flexible Limits
Source Format
Analog Outputs
Exercises
Select wire break

(Not in this example)
295
Introduction
Data Sources
Flexible Limits
Enter value to be displayed
Source Format
Analog Outputs
Exercises
Format displayed value

Limit hardware range to 1000 = 100.0%
0-180 Ohm
(all “0” are overwritten with
(180Ω/500Ω=36.00%)
296 measured value)
Introduction
Data Sources
Enter resistance offset if

Flexible Limits
any contact resistance
Source Format exists in the circuit
Analog Outputs
Configure sending unit
Exercises
connection type to match the
installed two-wire sender
297
Introduction
Data Sources
Flexible Limits
Check result in the display
Source Format
Analog Outputs
Exercises
298
Introduction
2) Additional task: What would you have to change to view the fuel
Data Sources tank level in liters?
Enter the value to be displayed
Flexible Limits
100% = 6000 liters at 100% = 6000l
Source Format
Analog Outputs
Exercises
Change the format and the

bar graph range
299
Exercises: Task B
Introduction
Configure the analog output manager to operate
Data Sources an analog meter that will display the generator real power.
Flexible Limits
The generator is rated at 200 kW.
The range on the meter display is from –62.5 kW to 250 kW.
Source Format
Analog Outputs
Exercises 0mA -62.5 KW

4mA 0 KW
20mA 250 KW
KW
250
-62.5
300
Exercises: Solution B
Introduction
Configure the analog output manager
Data Sources Generator real power for an analog meter (rated power 200 KW)
Flexible Limits
0mA -62.5 KW -31.25% from rated power
Source Format
4mA 0 KW
Analog Outputs
20mA 250 KW 125.00% from rated power
Exercises
301
Exercises: Task C
Introduction
Data Sources Speed bias signal for analog output 1 range: 3 – 7 V.
Flexible Limits
Source Format
Analog Outputs
Exercises
302
Exercises: Solution C
Introduction
Data Sources Speed bias signal for analog output 1 range: 3 – 7 V.
Flexible Limits
Hardware type “user defined” with min. / max. configuration
complete output range is +/- 20mA (+/- 10V)
Source Format
3V 65.00% min. value
Analog Outputs
7V 85.00% max. value -10V 0V 10V
3 7
Exercises
303
Exercises: Task D
Introduction
Fuel Transfer Pump Operation
Data Sources The flexible limits are to be used to activate a fuel pump when the fuel level
in the day tank falls below 20% capacity and shut off the fuel pump when the
Flexible Limits
fuel level in the day tank exceeds 90% capacity. The flexible limits interpret
Source Format the fuel level from an analog input. (refer to section 2, exercise A)
Analog Outputs
100% = 6000 l 90% = 5400 l20% = 1200 l
Exercises
Fuel
Fuel pump OFF
90%
20% Fuel pump ON

304
Exercises: Solution D
Introduction
Data Sources Two flexible limits are required for turning on and off a fuel pump. Flexible
limit 5 defines the fuel pump on limit and flexible limit 6 defines the fuel
Flexible Limits
pump off limit.
Source Format
Analog Outputs
Exercises
305
Exercises: Solution D
Introduction
Data Sources The LogicsManager for a single discrete output is used to operate the fuel
transfer pump for the day tank.
Flexible Limits
Source Format
Analog Outputs
Exercises
Flexible limit 5 (20% capacity) activates the fuel pump and the relay
remains energized until flexible limit 6 is reached (90% capacity).
Discrete Output 10 (13.10) is used as self-holding contact for turning the
306
fuel pump on and off.
End of Section 7
11 Sequencing
Note:
307
Section 8 - Controller
marked
CERTIFICATE of
Design Assessment
by ABS
Contents
slide 3
Introduction
4
Controller
13
Set Points
17
Load Sharing
24
FAQ
30
Exercises
Introduction
Introduction The easYgen-3200 provides the user with a selection of bias signals
Controller to operate numerous speed controls and voltage regulators. The
easYgen-3200 may be configured to use analog voltage and/or
Set Points
current signals, PWM signals, or raise/lower contacts to increase or
Load Sharing
decrease the speed and voltage reference point.
FAQ
Exercises
310
What does “control” mean?
Introduction
• Measure the actual state
Controller -
Set Points • Compare with reference value

-
Load Sharing
FAQ • Make correction

Exercises
311
Controller
Introduction
Analog / PWM Controller
Controller Proportional Gain
Set Points Integral Gain
Load Sharing Derivative ratio
FAQ
Frequency / power controller and voltage / power factor controller

Exercises
Adjustable bias signal (+/-20mA / +/- 10V) or

500 Hz PWM (duty cycle signal)
Example:
-10V - 3 10V
7
312
Controller
Introduction
P (Proportional Gain)
Controller The proportional gain indicates the closed-loop control system gain. By
Set Points increasing the gain, the response is increased to permit larger
corrections to the variable to be controlled. The further out of tolerance
Load Sharing
the process is the larger the response action to return the process to
FAQ the control set point. If the gain is configured too high, the result is
Exercises
excessive overshoot/undershoot of the desired value.
313
Controller
Introduction
I (Integral Gain)
Controller The integral gain represents the I-component of the PID controller. The
Set Points integral corrects for any offset (between set point and process variable)
automatically over time by shifting the proportioning band. Integral gain
Load Sharing
automatically changes the output requirements until the process
FAQ variable and the set point are the same. This parameter permits the
Exercises
user to adjust how quickly the integral attempts to correct for any offset.
314
Controller
Introduction
D (Derivative Ratio)
Controller The derivative represents the D-component of the PID controller. By
Set Points increasing this parameter, the stability of the system is increased. The
controller will attempt to slow down the action of the throttle in an
Load Sharing
attempt to prevent excessive overshoot or undershoot. Essentially,
FAQ derivative acts as the brake for the process.
Exercises
315
Controller
Introduction
63
FR EQ U EN C Y
Controller
62
Set Points 61
Load Sharing
60
59
FAQ
58
Exercises 57
T IM E
316
Controller
Analog / PWM Controller Bias Signal
Introduction
The analog outputs are used for the bias signals

Controller
Set Points
Speed bias (F/P control)
Load Sharing Voltage bias (V/PF control)
FAQ
Exercises
317
Controller
Introduction
Three Step Controller (Raise/Lower/Off)
Controller
- Time pulse (minimum energize time)
Set Points
- Gain factor
Load Sharing
- Dead-band adjustment
FAQ
Exercises
- Expand dead-band function
Frequency / power controller and Voltage / power factor controller

(raise / lower) are possible through configuration of the LogicsManager.
318
Controller
Introduction
Three Step Controller
Controller
The time interval between the raise / lower pulse depends on the actual
Set Points difference between set point and actual value.
Load Sharing
Raise/lower pulse
FAQ
Time delay
Exercises
Difference between setpoint and real value
1 2 3 4 5 6 7 8
319
Controller
Introduction
Controller Tuning
Controller
The analog and three-step controllers should ramp in a similar manner as
Set Points shown below when properly tuned.
Load Sharing
FAQ
- 120
Exercises Volts
- 90
Volts
- Ramp of Voltage
Controller is
determined by the
- 30 Gain
Volts
- Point at which
Controller takes
control
- 0
Volt
320 s
Set Points
Introduction “AUTOMATIC” operation mode
Controller External Set points
Set Points Frequency set point
Load Sharing
Voltage set point
FAQ
Power set point
Exercises
Power factor set point
Analog inputs
0/4 to 20 mA or 0 to 500 Ohm
Discrete inputs
Raise/lower set point via momentary switch
Interface
CANopen or Modbus
321
Set Points
Introduction
Analog Inputs
Controller
Set Points
Load Sharing
FAQ
Exercises
User defined is in relation to the

Rated power (in %).
0 Min. value ( 0% of rated)

Max. value (100.00 %)
322
Set Points
Introduction
Discrete Input for Raise/Lower
Controller
Set Points
Load Sharing
FAQ
Exercises
The power ramp always starts at the current measured value. If the
breaker is opened this set point automatically resets to 0 kW.
323
Set Points
Interface Power Set Point
Introduction
Controller
Set Points
Load Sharing
FAQ
Exercises
324
Load Sharing
Introduction
Load sharing over the CAN bus
Controller
Real load sharing is performed as a utilization factor.
Set Points (Generators compare measured load:generator rating)
Load Sharing
Reactive load sharing is performed as a utilization factor.
FAQ (Generators compare measured reactive load:generator rating)
Exercises
Maximum of 32 units can load-share
Split bus applications are possible with up to four bus bars
(different segment numbers)
Load sharing with GCP-30 series is not possible !
325
Load Sharing
Introduction
Interconnection of Units via CAN 1
Controller
Set Points
Load Sharing
The units require unique
device numbers
FAQ
CAN 1
Exercises
Generator 1
CAN 1
326
More units
Proprietary Information Generator 2
Load Sharing
Introduction
Active Power Load Sharing
Controller
Maintain frequency / maintain power utilization factor
Set Points
Weighting factor may be applied to load sharing
Load Sharing
(> 50% more frequency, < 50% more power utilization)
FAQ
Exercises
Reactive Power Load Sharing

Maintain voltage / maintain reactive power utilization factor
Weighting factor may be applied to reactive load sharing
(> 50% more voltage, < 50% more reactive power utilization)
327
Load Sharing
Segment numbering for multiple common busses
Introduction
General segment definition
Controller
Alternative segment groups for use with bus tie breakers
Set Points
Only the generator connected to the same segment number may load
Load Sharing
share with each other
FAQ
Exercises
328
Load Sharing
Introduction
Controller
Segment 1
Set Points Load

Load Sharing
FAQ
Exercises
Segment 2
Load
Segment 3
329 Load
Load Sharing
Introduction
Controller
Segment 1
Set Points Load

Load Sharing
Segment #2 TRUE
FAQ
Exercises
Segment 2
Load
Segment 3
330 Load
Load Sharing
Introduction
Controller
Segment 1
Set Points Load

Load Sharing
FAQ
Exercises
Segment 2
Load
Segment #2 TRUE
Segment 3
331 Load
FAQ
Introduction
• How can I configure my controller bias signal output?
Controller
Set Points
Load Sharing
FAQ • How can I limit the generator load when the cooling water
Exercises temperature is below a desired threshold?
332
FAQ
Introduction
How can I configure my controller bias signal output?
Controller
Set Points There are two possible types:

Load Sharing
FAQ - Three step controller (raise / lower outputs)

Exercises
 Relays via LogicsManager
- Analog controller (bias signals) / PWM  Analog output
333
FAQ
Introduction
Controller
Three step controller (raise / lower outputs)  LogicsManager
Set Points
Parameters for frequency control
Load Sharing
FAQ
Exercises
Select freely configurable relay
LogicsManager input commands:

03.20 Governor raise 03.22 AVR raise
334
03.21 Governor lower 03.23 AVR lower
FAQ
Introduction
Controller
Analog controller (bias signals)  Analog output
Set Points
Parameters for frequency control Configure analog output
Load Sharing
FAQ
Exercises
Data source:
00.02 Voltage bias
00.03 Speed bias
Test controller range

335 with initial state
FAQ
How can I limit the generator load when the cooling water
Introduction
temperature is below a desired threshold?
Controller
Set Points Use the “warm up limit” of the active load controller
The easYgen controls the warm up load limit (in % of rated power)
Load Sharing
whenever the measured value of the analog
FAQ input drops below the
Exercises threshold.
336
FAQ
How can I limit the generator load when the cooling water
Introduction
temperature is below a desired threshold?
Controller
Set Points
The warm up load limit permits a partial load warm up with a lower set point
whenever the generator runs parallel to mains.
Load Sharing
FAQ
Exercises
337
Exercise:
Introduction Configure the analog output manager (FlexOut)
Controller Speed bias signal for analog output 1 range: 3–7V

Set Points
Load Sharing
FAQ
Exercises
338
End of Section 8
11 Sequencing
Note:
339
Section 9 - Synchronization and Breaker Logic
marked
CERTIFICATE of
Design Assessment
by ABS
Contents
Introduction Slide 3
Synchronization 4
Breaker Logic 9
FAQ 31
Exercises 32
Introduction
Introduction
The easYgen-3200 is able to perform synchronization of the generator
Synchronization across the generator circuit breaker to a common bus as well as
Breaker Logic
synchronizing the common bus to a utility across the mains circuit
breaker. It is possible to configure the easYgen-3200 for either slip or
FAQ
phase matching synchronization and the acceptable breaker closure
Exercise
window.
By adding SPM-D/10 synchronizers to the system, up to four generator

common busses and three tie breakers may be operated.
342
Synchronization
Introduction
The easYgen-3200 has a synchroscope in the HMI
Synchronization
Breaker Logic
Bus/mains Bus/mains
FAQ voltages frequencies
Exercise
Voltage/
frequency Phase
differential angle L1
343
Synchronization
Introduction
Slip Synchronization
Configurable frequency window
o
Synchronization 0
Breaker Logic Configurable voltage window o o
-9 0 +90
FAQ Configurable synch. frequency differential
Exercise Configurable breaker closing time o
180
Used to calculate when breaker close pulse is issued
 Formula for calculating phase angle at closing command

Phase angle = 360o * (Frequency differential) * (breaker closing time)
Example:
Phase angle = 360o * (0.3 Hz) * (0.2 sec) = 21.6°
344
Synchronization
Introduction
Slip Synchronization
o
Synchronization 0
Breaker Logic Define close pulse duration o o
-9 0 +90
FAQ Define stable timer [3415 Generator stable time]
Exercise Define maximum voltage differential o
180
345
Synchronization
Introduction
Phase Matching
Synchronization
Breaker Logic Select “Configure MCB or GCB”

• Define stable timer
o o
-9 0 +90
FAQ
Exercise
• Define voltage differential window
• Define positive and negative phase angle window limits
o
180
• Define dwell time
346
Synchronization
Introduction
Multiple Synchronization Modes
Synchronization
Breaker Logic RUN

FAQ
Active synchronization is performed. Bias signals to the -9 0
o
+90
o
governor and voltage regulator are active and breaker

Exercise
close commands are issued. 180
o
PERMISSIVE
Passive synchronization performed. Bias signals to the
governor and voltage regulator are not active but breaker
close commands are issued.
CHECK
Active synchronization is simulated. Bias signals to the
governor and voltage regulator are active but breaker close
commands are not issued.
OFF
The synchronization can be disabled
347
Proprietary Information The synchronization modes can be changed via a LogicsManager output
Breaker Logic
Introduction
The following MCB/GCB transition modes are available:
Synchronization
1 Parallel 3 Closed transition

Breaker Logic
FAQ Base load or import / export Make before break

Exercise Soft load / unload Block loading / unloading
2 Interchange 4 Open transition

Parallel for a limited time Break before make
Soft load transfer Only dead busbar closing
5 External
External breaker control (PLC)
348
Only “open” commands issued
Breaker Logic
Introduction
Synchronization
Breaker Logic
FAQ
Exercise
Only if application mode =

GCB/MCB
Breaker logic may

be changed via the
LogicsManager
349
Breaker Logic
Introduction
1. Parallel {2oc} {1oc} {1o} {external}
Synchronization
Parallel breaker logic must be selected for the following operation modes:
Breaker Logic • Isolated operation
FAQ
• Mains parallel operation
Exercise In the event of an engine start request the following occurs:

• The GCB is synchronized and closed
• The generator assumes load and the adjusted real power or reactive
power set points are controlled
Following the stop request the following occurs:

• The generator sheds load until real power has reached the "Unload
limit" (parameter 3125)
• The generator power factor is controlled to "1.00" (unity)
• The GCB is opened
• The engine is shut down following the configured cool down period
350
Breaker Logic
2. Interchange {2oc}
Introduction
For this breaker logic to function correctly, the mains power measurement must be
Synchronization connected properly. The following applies for the power display:
• Positive mains power = export power
Breaker Logic
• Negative mains power = import power
FAQ
Exercise In the event of a start request, a change is made from mains to generator supply.
The following occurs:
• The generator assumes load until the imported mains interchange
real power has reached 3 % of the "Generator rated active power”
• The MCB is opened
When a stop request has been issued, a change is made from generator to
mains supply. The following occurs:
• The MCB is synchronized and closed
• The generator sheds load until real power has reached the "Unload
limit" (parameter 3125)
• The generator power factor is controlled to "1.00" (unity)
351 • The GCB is opened
Breaker Logic
Introduction
3. CLOSED TRANSIT {2oc}
Synchronization
The circuit breakers are opened irrespective of the power.

Breaker Logic
Maximum closed transit time is 500 msec.
FAQ
Exercise In the event of an engine start request, a change is made from mains to
generator supply. The following occurs:
• The MCB is opened and the generator assumes all loads
After the engine stop request has been issued, a change is made from generator
to mains supply. The following occurs:
• The MCB is synchronized and closed
• The GCB is opened and the mains assume all loads
352
Breaker Logic
Introduction
4. OPEN TRANSIT {2oc}
Synchronization
In the event of an engine start request, a change is made from mains to
Breaker Logic generator supply. The following occurs:
FAQ
• The MCB is opened
• The GCB is closed after the time configured in "Transfer
Exercise
time GCB<->MCB" (parameter 3400) has expired
After the engine stop request has been issued, a change is made from generator
to mains supply. The following occurs:
• The GCB is opened
• The MCB is closed after the time configured in "Transfer
time GCB<->MCB“ has expired
353
Breaker Logic
Introduction
5. External
Synchronization
Breaker Logic
All breaker control must be carried out via master controller (i.e. PLC).
FAQ
Exercise The easYgen controller always issues the breaker open command
under fault conditions and in the breaker unloading states (Unloading
GCB) if the stop request is active.
354
Breaker Logic
Introduction
The MCB operates only if “Enable MCB = TRUE”
Synchronization
The default configuration is as follows:
Breaker Logic
FAQ
Exercise
Closure prevented if
alarm occurs
Closure prevented if
field rotation is wrong
355
FAQ
Introduction
How do I define the operating ranges for synchronization ?
Synchronization
The operating ranges are utilized for permitting breaker closures and defining when
Breaker Logic an emergency mode should be initiated.
FAQ
Exercise
- Generator Mains
356
Exercise
Introduction
Configure the following application:
Synchronization
1. You are commissioning an emergency standby generator for a manufacturing
Breaker Logic plant. Select a “breaker logic” for the test run where the generator assumes
the entire plant load and then separates from the utility. The test mode must be
FAQ
initiated via a discrete input.
Exercise
2. A second “breaker logic” mode is desired where the generator assumes the
entire plant load but still remains paralleled with the utility.
Load
357
Solution
Introduction
1) Test mode with the generator running isolated from mains
Synchronization
Configure the alarm class for DI 10 as “control”

Breaker Logic
FAQ
Exercise
358
Solution
Introduction
Synchronization
Select transition mode “Interchange” to open the breaker at zero power
Breaker Logic
FAQ
Exercise
Mains CT required!
359
Solution
Introduction
Synchronization
Use discrete input 10 also as start command via “Start in Auto”
Breaker Logic
FAQ
Exercise
360
Solution
Introduction
2) Test mode with the generator running parallel to mains
Synchronization
Select “Parallel” transition mode and configure the “Load set point” to Import 0 kW
Breaker Logic
FAQ
Exercise
361
Solution
Introduction
2) Test mode with the generator running parallel to mains
Synchronization
Use discrete input 10 also as start command via “Start in Auto”
Breaker Logic
FAQ
Exercise
362
End of Section 9
11 Sequencing
Note:
363
Section 10 - Application
marked
CERTIFICATE of
Design Assessment
by ABS
Contents
Introduction Slide 3
Start / Stop in Auto 4
Logical Outputs 6
Start / Stop 10
Alarm Classes 14
Protection 15
FAQ 23
Introduction
Introduction
Start / Stop Auto
Logical Outputs
This section is a quick review of
previous sections as well as a more
Start / Stop
detailed description of software
Alarm Classes
ehancements.
Protection
FAQ
366
Introduction Generator:
Start /Stop AutoStart conditions Stop conditions

Logical Outputs
LM: Start in auto is “true”
 LM: Start conditions are “false”
Start / Stop may be used with load dependent start/stop function

 Alarm class C-F detected
LM: Start w/o load is “true”

 LM: Stop in auto
Alarm Classes
LM: Critical mode is “true”
Protection Loss of mains {GCB/MCB} (Emergency mode)  LM: Inhibit emergency mode
FAQ
Mains voltage/frequency out of operating range
Mains rotation field wrong
“Fail to close MCB” (if parameter is enabled)
Mains:
Close MCB: Open MCB:
Mains are within accepted limits  Dependent upon breaker logic

DI8 is de-energized (MCB is open)  For mains decoupling
LM: Enable MCB is “true” (default DI6)
Conditions for synchronization or
367 dead bus closing are met
Introduction
Start /Stop Auto
Logical Outputs
Start / Stop
Alarm Classes
Protection
FAQ
368
Logical Outputs
Introduction
Hierarchy of Logical Outputs:
Start /Stop Auto
Logical Outputs
Start
Start / Stop
Start, breaker depending
Alarm Classes
on parameter
Protection
No start
FAQ
Open breaker
Close breaker
Close breaker with pause
No start
Open breaker
369
Logical Outputs
Introduction
Start /Stop Auto

Changing the operation
Logical Outputs mode via LogicsManager
Start / Stop
Alarm Classes
Protection
FAQ
370
Start / Stop Logic
Introduction
Diesel Engine
Start /Stop Auto
- Pre-glow function
Logical Outputs
- Fuel or Stop solenoid activation
Start / Stop
Alarm Classes
Gas Engine
Protection
- Ignition
FAQ
- Gas valve
External Logic
- Fuel solenoid as a start request to external controllers
- External control must take care of start sequence – no start failure
371
Start / Stop Sequence
Introduction Diesel Engine
Start /Stop Auto
Logical Outputs
Start / Stop
Alarm Classes
Protection
FAQ
372
Start / Stop Sequence
Introduction Gas Engine
Start /Stop Auto
Logical Outputs
Start / Stop
Alarm Classes
Protection
FAQ
373
Alarm Classes
Class Action Result
Introduction
Start /Stop Auto
Warning
AB
Display
Logical Outputs
Start / Stop
Display and Horn Warning
Alarm Classes
C
Protection
Display and Horn Unlaod Gen. And open GCB Cool down Shut down
FAQ
D Display and Horn Open GCB immediate Cool down Shut down
E Display and Horn Unlaod Gen. And open GCB Immediate Stop Shut down
F Display and Horn Open GCB immediate Immediate Stop Shut down
Control
For control purposes via LogicsManager to
change/modify sequencing or discrete outputs internal
374
Introduction # of Trip Levels ANSI Code
Over-/undervoltage 2/2 [59/27]
Start /Stop Auto
Voltage asymmetry 1 [47]
Logical Outputs
Over-/underfrequency 2/2 [81O/U]
Start / Stop Overload (IOP/MOP) 2 [32]
Alarm Classes Reverse/reduced power 2 [32R/F]
Unbalanced load 2 [46 measured]
Protection
Definite time-overcurrent 3 [50/51]
FAQ
Inverse time-overcurrent 1 [IEC 255]
Overspeed (MPU) 2 [12]
Measured ground current 2 [50G]
Calculated ground current 2
375
Introduction
Start /Stop Auto
Power factor (PF) lagging 2
Logical Outputs PF leading – loss of excitation 2 [40Q]
Start / Stop Phase rotation field CW/CCW 1
Alarm Classes
Psetpoint  Pactual mismatch 1 Controller*
Unload mismatch (time out monitoring) 1 Controller*
Protection
Operating range failed 1 Controller*
FAQ
* plausibility monitoring features
376
Engine Protection
Introduction
Maintenance days exceeded
Start /Stop Auto
Maintenance hours exceeded
Logical Outputs
Start / Stop
Over-/Underspeed (MPU)
Alarm Classes Unintended Stop
Protection Engine Stop malfunction
FAQ
Speed/frequency mismatch
Start failure
Charge alternator low voltage
Red stop lamp (J1939)
Amber warning lamp (J1939)
Battery over-/undervoltage
377
Mains Monitoring and Decoupling
Introduction
Over-/undervoltage 2/2 [59/27 ]
Start /Stop Auto
Over-/underfrequency 2/2 [81O/U]
Logical Outputs Import/Export power 2 [32]
Start / Stop
Power factor leading 2
Power factor lagging 2
Alarm Classes
Phase shift 1ph/3ph [78 ]
Protection
Field rotation
FAQ
378
Miscellaneous Monitoring
Introduction
GCB / MCB fail to close
Start /Stop Auto

GCB / MCB fail to open
Logical Outputs Synch. Time Out GCB / MCB
Start / Stop Phase rotation mismatch generator / busbar / mains
Alarm Classes
Mains decoupling
Protection
CAN bus communications monitoring (J1939, CANopen)
FAQ
Parameter alignment (multiple units)
Missing members (multiple units)
EEPROM failure (internal CPU)
Wire break analog inputs
Discrete inputs
FlexLimitsTM for analog values
379
Software Enhancements Version
1.12
Introduction Password for ToolKit required
Display hibernation / backlight shutdown
Start /Stop Auto
Logical Outputs
Start / Stop Daylight saving time implemented, fully adjustable

LogicsManager: Status display of input command
Alarm Classes
Protection
FAQ
variables
Display password level
380
1.12
Introduction
Start /Stop Auto

ECU J1939 Features
Logical Outputs
Start / Stop
• J1939 CAN values from engine may be used in
Alarm Classes Analog Manager
Protection
• New MAN MFR/EDC7 ECU (J1939) coupling
FAQ
• ECU alarm messages now in event list

• HMI populates only with J1939 messages
broadcast by ECU
• Alarm reset message (DM 11) is sent to J1939
members
381
1.12
Introduction
Start /Stop Auto

Controller Functions
Logical Outputs
Start / Stop
• Multiple set points now available via Analog Manager
Alarm Classes (ramped values, without ramp) for external use
Protection
• Import / export power control set point performed via
FAQ
ramp
• Droop tracking: frequency does not drop off when
droop is being activated
• LM “Discrete +/-” of set points now also active in
MANUAL mode
382
FAQ Version
1.12
Introduction How can I adjust the daylight saving time?
Start /Stop Auto
Each region has its specific parameters. Possible options are:
Logical Outputs
Start / Stop European Union (Germany)

Alarm Classes Start: End:
Last Sunday of March Last Sunday of October
Protection 01:00 GMT (+1) 01:00 GMT (+1)
FAQ March 30, 2008 October 26, 2008
2008
March 29, 2009 October 25, 2008
2009
USA, Canada
Start: End:
Second Sunday of March First Sunday of
02:00 a.m. November
02:00 a.m.
2008 March 09, 2008 November 02, 2009
383
2009 March 08, 2009 November 01, 2009
FAQ Version
1.12
Introduction How can I adjust the daylight saving time?
Start /Stop Auto
Available parameters, example for Germany:
Logical Outputs
Start / Stop
Alarm Classes
Protection
FAQ
384
End of Section 10
11 Sequencing
Note:
385
Section 11 - Sequencing
marked
CERTIFICATE of
Design Assessment
by ABS
Contents
Getting Started 5
Start/Stop 10
Calculation 17
Exercises 40
Introduction
Introduction Multiple easYgen-3000s may be configured to sequence generators
Getting started on- and offline in order to supply the power required while operating
Start/Stop
the power plant with a high degree of efficiency. This sequencing is
performed automatically through a Load Dependant Start/Stop
Calculation
(LDSS) calculation in the easYgen software according to the
Exercises
thresholds configured by the user.
This LDSS calculation may be utilized in utility parallel operation as

well as for isolated operations.
388
Introduction
Introduction
Isolated and mains parallel operations
Getting Started
Start/Stop
• Different size engine ratings possible
Calculation
• Reserve power or generator load calculation

Exercises
• Multiple choice start/stop priority selection

• Emergency mode start with “start all” or “sequencing”
389
Getting Started
Introduction
Connection between the units via CAN 1
Getting Started
Start/Stop CAN 1
Calculation
Exercises
390
Getting Started
Introduction
Enable LDSS Sequencing
Getting Started
Start/Stop
Calculation
Exercises
391
Getting started
Introduction
Enable LDSS Sequencing
Getting Started
Only generators on the same bus segment can be sequenced.
Start/Stop
Calculation
Exercises
bus 1 Load
bus 2
392 Load
Getting Started
Introduction
Status Screen
Getting Started
- Operation mode and breaker feedback status
Start/Stop
- Add on/off condition
Calculation
- Measured values
Exercises
393
Getting Started
Introduction
Status Screen
Getting Started
Start/Stop
Calculation
Exercises
394
Start/Stop Mode
Load-dependent start/stop may either be performed according to a system
Introduction
reserve power or the generator load depending on the configuration of the
Getting Started "Start stop mode“.
Start/Stop Reserve power
Load-dependent start/stop is performed so a configured minimum reserve power
Calculation
is maintained in the system. This provides enough reserve power for load swings
Exercises regardless of the generator load. The actual reserve power in the system is the
total rated power of all gensets minus the actual total generator real power. This
provides high system reliability and is intended for applications that require a
dedicated reserve power on the load bus, independent of the number of gensets.
Generator load
Load-dependent start/stop is performed so the next genset will be started if all
gensets in operation reach the maximum generator load percentage of the rated
power. A generator will be stopped when the load of all gensets in operation fall
below the configured minimum generator percentage of the rated power.
An additional Dynamic parameter prevents the gensets from being started and
stopped continusously if only a few gensets are in operation. The Dynamic is only
395 considered for the start sequence if "Fit size of engines" is enabled.
Dead Bus Start Mode
Introduction (Loss of Mains Condition)
Getting Started
Start/Stop
All
Calculation
All available engines will start and supply the load. If the minimum
Exercises
running time is expired the LDSS sequencing calculates how many
engines will be required to supply power to the load and sequences
generators offline.
LDSS
Only one generator is started and closed to the busbar. The LDSS
sequencing calculates if additional units are required and additional
generators are sequenced online accordingly. Load sequencing
schemes are typically used with this type of dead bus starting to
prevent overloading the generator.
396
Start/Stop Priority
Multiple Start/Stop Priority Selections are Available
Introduction
Getting Started
1 Assigned generator priority
If a genset is to be started, the genset with the highest priority configured will
Start/Stop
be started. If a genset is to be stopped, the genset with the lowest priority
Calculation configured will be stopped.
Exercises 2 Efficiency, fit size of engine
If all gensets have the same priority, the next genset is selected according to
the size of engine, i.e. the genset combination, which allows an optimum
efficiency will be used.
3 Service Hours, based on maintenance hours or change of
engines according to run time
If all gensets have the same rated load or this parameter is disabled, the
remaining hours until the next maintenance are considered.
4 Assigned generator number (device number)
If all else are equal, the genset with the lowest generator number will be
started first or stopped last.
397
Start/Stop Priority
Introduction
1
1. Base or Alternative Priority Sequencing
Getting Started
- Lowest number has the highest priority
Start/Stop
- Generator assigned priority
Calculation
Exercises
 Base priority
 Three alternate priorities (LogicsManager)
398
Start/Stop Priority
Introduction
2
2. Fit Size of Engine Sequencing
Getting Started
- For use with multiple engine sizes
Start/Stop
- Calculation for optimal efficiency
Calculation
- Start/Stop of multiple engines is possible
Exercises
Works only if the Base or LogicsManager Priorities are equal
399
Start/Stop Priority
Introduction
3
3. Fit Service Hours Sequencing
Getting Started
Equal – maintenance at the same time
Start/Stop
 Start unit with the highest service hours remaining
Calculation
Exercises
 Stop unit with the lowest service hours remaining
Staggered – different maintenance time
 Start unit with the lowest service hours remaining
 Stop unit with the highest service hours remaining
Works only if the Base or LogicsManager Priority and Fit of Engine are
equal
400
Start/Stop Priority
Introduction
4. Change of Engines when Fit Service Hours is Equal
3
Getting Started
The easYgen-3000 divides the time remaining on the maintenance hours
Start/Stop
counter by the service hours group (32/64/128h) to determine the
Calculation individual unit’s time group.
Exercises
Example:
Unit 1: 254 h  254 / 64 = 3.96  Time group 3
Unit 2: 325 h  325 / 64 = 5.07  Time group
Unit 3: 284 h  284/ 64 = 4.44  Time group 4
The unit 2 is the next unit to start
Higher calculated time group
401
Start/Stop Priority
Introduction
3 Change of Engines when Fit Service Hours is Staggered
Getting Started
The easYgen-3000 divides the time remaining on the maintenance hours
Start/Stop
counter by the service hours group (32/64/128h) to determine the
Calculation individual unit’s time group.
Exercises
Example:
Unit 1: 254 h  254 / 64 = 3.96  Time group 3
Unit 2: 325 h  325 / 64 = 5.07  Time group 5
Unit 3: 284 h  284/ 64 = 4.44  Time group 4
The unit 1 is the next unit to start
Lower calculated time group
402
Start/Stop Priority
Introduction
2. Generator Number
4
Getting Started
Lowest device number -> highest priority
Start/Stop
Calculation
Exercises
403
Calculation
Introduction
System Reserve Power
Getting Started
Generators are sequenced on and off to maintain a spinning reserve for
Start/Stop
the plant. This reserve power threshold is used to calculate when
Calculation additional generators are required to be started or shutdown.
Exercises
• Utilized for system requiring high degree of reliability

• Ensures that reserve is always available
• Reserve power must match the largest load step
• Most efficient when more generators are online
404
Calculation
Introduction
System Reserve Power – Mains Parallel
Getting Started
Start/Stop
Calculation Power set point Import 50 kW Minimum

Exercises power 20 kW Reserve
50 kW power 30 kW Hysteresis
20 kW 10 kW
Start of the first engine
Actual mains power > power set point +

generator min. load
70 kW Actual mains power > 50
kW + 20 kW = 70 kW
P rated =
200 kW
405
Load
Calculation
Introduction
Getting Started
Start/Stop
30 kW Power set point Import 50 kW Minimum

Calculation 170 kW
10 kW
Start of the second engine
Actual total generator power >

Total rated power – reserve power
220 kW Actual total generator power >
200 kW - 30 kW = 170 kW
P rated =
200 kW
406
Load
Calculation
Introduction
Getting Started
Start/Stop
Calculation
15 kW 185 kW Power set point Import 50 kW
Exercises Minimum power 20 kW
50 kW Reserve power 30 kW
15 kW
185 kW Hysteresis 10 kW
Start of the third engine
Actual total generator power >

Total rated power – reserve power
420 kW Actual total generator power >
(200 kW + 200 kW) - 30 kW = 370 kW
P rated =
200 kW
407
Load
Calculation
Introduction
Getting Started
Start/Stop
Calculation
Exercises
220 kW 420 kW 620 kW

Second engine starts Third engine starts Three units at max power
600
500
400 Mains power

300
Generator power
200
100
Reserve power
0
408
Calculation
Introduction
Getting Started
Start/Stop
Calculation
15 kW+5 kW 120 kW Power set point Import 50 kW Minimum
15 kW+5 kW 120 kW 10 kW
Stop of the third engine
120 kW Actual total generator power <

Total rated power (n-1) – reserve power -
410 kW hysteresis
Actual total generator power <

P rated =
(200 kW + 200 kW) - 30 kW – 10 kW
200 kW
= 360 kW
409
Load
Calculation
Introduction
Getting Started
Start/Stop
30 kW+10 kW Power set point Import 50 kW Minimum

Calculation 80 kW
80 kW 10 kW
Stop of the second engine

Total rated power (n-1) – reserve power -
210 kW hysteresis

P rated =
200 kW - 30 kW – 10 kW = 160 kW
200 kW
410
Load
Calculation
Introduction
Getting Started
Start/Stop
Calculation 10 kW Power set point Import 50 kW Minimum

10 kW
Stop of the last engine

Minimum power - hysteresis
60 kW Actual total generator power <
20 kW – 10 kW = 10 kW
P rated =
200 kW
411
Load
Calculation
Introduction
Getting Started
Start/Stop
Calculation
Exercises
410 kW 210 kW 60 kW
Third engine stops Second engine stops Last engine stops
600
500
400 Mains power

300
Generator power
200
100
Reserve power
0
412
Calculation
Introduction
System Reserve Power – Isolated Operation
Getting Started
Start condition
Start/Stop
First unit immediately
Calculation
Exercises
The following unit uses the same formula like mains parallel
Actual total generator power > total rated power – reserve power
Stop condition
The same formula like mains parallel
Actual total generator power < total rated power (n-1) –
reserve power - hysteresis
Last unit keeps running
413
Calculation
Introduction
Generator Load Capacity
Getting Started
Generators are sequenced on and off based on configured values for
Start/Stop
minimum and maximum percent of rated load. This permits online
Calculation generators to be loaded to the maximum limit before the next generator is
Exercises
started. When connected load reduces to the minimum load limit, then a
generator is removed and shutdown.
An additional Dynamic parameter prevents the gensets from being started

and stopped continuously when only a few gensets of different sizes are in
operation. The Dynamic is only considered if "Fit size of engines" is
enabled.
• Simplified generator sequencing

• Most efficient when few generators are online
414
Calculation
Introduction
Generator Load – Mains Parallel
Getting Started
Start/Stop

Exercises power 20 kW Max. load
50 kW 80%
20 kW Min. load 40%
Start of the first engine

generator min. load
70 kW Actual mains power > 50
kW + 20 kW = 70 kW
P rated =
200 kW
415
Load
Calculation
Introduction
Getting Started
Start/Stop
40 kW Power set point Import 50 kW

Calculation 160 kW
Max. load 80%

Min. load 40%
Start of the second engine
Actual generator power > max. load

210 kW
Actual generator power >
P rated = 200 kW * (0.8) = 160 kW
200 kW
416
Load
Calculation
Introduction
Getting started
Start/Stop
Calculation
40 kW 160 kW Max. load 80%
Min. load 40%
Start of the third engine

370 kW Actual generator power >
(200 kW + 200 kW) * (0.8) = 320 kW
P rated =
200 kW
417
Load
Calculation
Introduction
Getting Started
Start/Stop
Calculation
Exercises
210 kW 370 kW 530 kW

Second engine starts Third engine starts Three units at max. load
600
500
400 Mains power

300
Generator power
200
100
Reserve power
0
418
Calculation
Introduction
Getting Started
Start/Stop
Calculation
Minimum power 20 kW
Exercises
Hysteresis 5 kW
50 kW
120 kW Max. load 80%
80 kW
Min. load 40%

80 kW
Actual generator power < min. load
290 kW Actual generator power <

(200 kW * 3 ) * (0.4) = 240 kW
P rated =
200 kW
419
Load
Calculation
Introduction
Getting Started
Start/Stop

Calculation 80 kW
50 kW Hysteresis 5 kW Max.
80 kW load 80%
Min. load 40% !!!
Stop of the second engine

(200 kW * 2 ) * (0.4) = 160 kW !!!
P rated =
200 kW
420
Load
Calculation
Introduction
Getting Started
Start/Stop

Calculation 15 kW
Max. load 80%
Min. load 40%
Stop of last engine
Actual generator power < gen. min load

65 kW [5767] - hysteresis [5769]
Actual generator power <

P rated =
20 kW – 5 kW = 15 kW
200 kW
421
Load
Calculation
Introduction
Getting Started
Start/Stop

Exercises power 20 kW Hysteresis
15 kW Min. load 40%
Mains load
Actual mains power < power set point +

generator min. load - hysteresis
65 kW Actual mains power < 50
kW + 20 kW – 5 kW = 65 kW
P rated =
200 kW
422
Load
Calculation
Introduction
Getting Started
Start/Stop
Calculation
Exercises
290 kW 210 kW 65 kW
Third engine stops Second engine stops Last engine stops
600
500
400 Mains power

300
Generator power
200
100
Reserve power
0
423
Calculation
Generator Rated Load Capacity
Introduction
Calculating dynamic power
Getting Started
Dynamic characteristic= (min power %) + [(max power % – min power %) * dynamic%]
Start/Stop Dynamic power level = (required power) / (dynamic characteristic)
Calculation
100%
Exercises Constants:
80%
Low dynamic = 25%
MAX
Moderate dynamic = 50% 75%
HIGH
High dynamic = 75%
50%
MOD
Example for Moderate:
25%
Dynamic characteristic= (40%) + [(80% – 40%) * 50%] = 60% LOW
Dynamic power level = 200 kW / 60% = 333 kW
20%
MIN
0%
424
Calculation
Introduction
Generator Load (differing sizes) – Mains Parallel
Getting Started
Start/Stop

Exercises power 20 kW Hysteresis
P rated = 200 kW
20 kW Min. load 40%
Dynamic Moderate (50%)
P rated = 100 kW Start of the first engine

70 kW generator min. load
P rated = 50 kW
Actual mains power > 50
kW + 20 kW = 70 kW
425
Load
Calculation
Introduction Generator Load (differing sizes) – Mains Parallel
Getting Started
50 kW genset: Min 50 kW * 0.40 = 20 kW, Max 50 kW * 0.70 = 35 kW
Start/Stop
Calculation
Exercises 200 kW genset: Min 200 kW * 0.40 = 80 kW, Max 200 kW * 0.70 = 140 kW
Required RATED Power : 20 kW / [0.40 + (0.70-0.40)*0.50] = 36.4 kW
The 50 kW genset will be started.
426
Calculation
Introduction
Getting Started
Start/Stop
Calculation Power set point Import 50 kW

Max. load 70%

Min. load 40%
15 kW Start of the second engine
35 kW
85 kW
Actual generator power >
50 kW * (0.7) = 35 kW
427
Load
Calculation
Getting Started
Start/Stop
Calculation
The 100 kW genset will be started and the 50 kW genset removed.
428
Calculation
Introduction
All Gensets connected and load drops to 190 kW.
Getting Started
Start/Stop

Calculation
Minimum power 20 kW
Exercises
Hysteresis 5 kW
50 kW
70 kW Max. load 70%
40 kW
Min. load 40%

30 kW 20 kW

(50+100+200 kW) * (0.4) = 140 kW
P rated total=
350 kW
429
Load
Calculation
Getting Started
Start/Stop
Calculation
The 50 kW genset will be removed.
430
Calculation
Introduction
Getting Started
Start/Stop

Calculation 93 kW
50 kW Hysteresis 5 kW Max.
53 kW 47 kW load 70%
Min. load 40%
Third engine stopped
Actual generator power > min. load

190 kW Actual generator power < max. load
431
Load
Calculation
Introduction
Getting Started
Start/Stop
Calculation Power set point Import 50 kW

Max. load 70%
Min. load 40%
35 kW Stop of last engine

15 kW
Actual generator power < gen. min load
65 kW [5767] - hysteresis [5769]
Actual generator power <

20 kW – 5 kW = 15 kW
432
Load
Exercise: Reserve Power
Configure the load dependent start/stop for a mains parallel application with
Introduction two 100kW peak shaving generators with reserve power sequencing. Facility
Getting Started
sees common load shift of 10-15 kW with occasional 20 kW pump operation.
Start/Stop
Calculations and configurations:
Calculation
1. Mains interchange power set point Import 50 kW
Exercises 2. Determine an acceptable hysteresis
3. Set minimum running load for generators at 25 kW
4. Determine at what import power will the first generator
initiate start
5. Determine an acceptable reserve power value
6. Determine at what facility power will the second
generator initiate start
7. Determine at what facility power will the second
generator shut down
8. Determine at what facility power will the first generator
shut down
433
Exercise: Solution 1
Introduction
two 100kW peak shaving generators with reserve power sequencing. Facility
Getting Started sees common load shift of 10-15 kW with occasional 20 kW pump operation.
Start/Stop Mains interchange power set point Import 50 kW
Calculation Parameter
Exercises  Configuration
 Configure application
 Configure controller
 Configure load control
 Load set point 1 or 2 source  (5539) Internal pwr. setp.1
 Load set point 1 or 2  (5526) Import
 Int. load control set point 1 or 2  (5520) 50 kW
434
Getting Started
Start/Stop
Determine an acceptable hysteresis
Calculation
Parameter
 Configure automatic run
 Load dependent start/stop
 Mains parallel operation
Determine hysteresis based on facility loads. Hysteresis needs to be larger than the
common load swings. At 15 kW shifts, assume a hysteresis of 20 kW.
MOP Hysteresis [5769] 20 kW
435
Introduction
Getting Started sees common load shift of 10-15 kW with occasional 20 kW pump operation.
Start/Stop
Set minimum running load for generators at 25 kW
Calculation
Parameter
Minimum running load = MOP min (starting) load [5767] – MOP Hysteresis [5769]
25 kW= MOP Min Load – 20 kW, MOP Min Load = 25 kW + 20 kW
MOP Minimum load [5767] 45 kW
436
Getting Started
Start/Stop Determine at what import power will the first generator initiate start
Import load set point + MOP min load = Import power level
50 kW + 45 kW = 95 kW
437
Introduction
Getting Started sees common load shift of 10-15 kW with occasional 20 kW pump operation
Start/Stop
Determine an acceptable reserve power value
Calculation
Parameter
MOP Reserve Power [5768] = Value greater than maximum anticipated added load
above normal operation (20 kW pump). Assume reserve of 25 kW
MOP Reserve Power [5768] 25 kW
438
Introduction
Start/Stop Determine at what facility power will the second generator initiate start
Import load set point + (Gen 1 rated – reserve) = facility power level
50 kW + (100 kW – 25 kW) = 125 kW
439
Introduction
Start/Stop
Determine at what facility power will the second generator shut down
Calculation
Parameter
Exercises
 Configuration
Import load set point + Gen 1 MOP Min Load + Gen 2 MOP Min load – MOP
Hysteresis = facility power level for Gen 2 shut down
50 kW + 45 kW + 45 kW – 20 kW = 120 kW
440
Introduction
Start/Stop
Determine at what facility power will the first generator shut down
Calculation
Parameter
Exercises
 Configuration
Import load set point + Gen 1 MOP Min Load – MOP Hysteresis = facility power
level for Gen 1 shut down
50 kW + 45 kW– 20 kW = 75 kW
441
Exercise: Generator Load
Configure the load dependent start/stop for an isolated plant with three
Introduction generators (1-100kW, 1-200kW, 1-300kW) with generator load sequencing.
Getting Started
The 100kW gen is the first on the bus. Assume a Moderate (50%) dynamic,
equal priority, best fit selected
Start/Stop
Generator load calculation :

Calculation
1. Set maximum generator operating load

Exercises
2. Set minimum generator load

3. Determine at what power level does the next generator start
4. Determine which generator(s) is on line with 100 kW facility load
5. Determine at what power level does the third generator start
6. Given exercise 5, which generators would be left connected
with a High Dynamic
442
Introduction
generators (1-100kW, 1-200kW, 1-300kW) with generator load sequencing.
Getting Started The 100kW gen is the first on the bus. Assume a Moderate (50%) dynamic,
Start/Stop
Calculation Set maximum generator operating load.

Exercises Parameter
 Configuration
 Isolated operation
 IOP Max. generator load [5762]  85%
443
Introduction
Start/Stop
Calculation Set minimum generator load.

Exercises Parameter
 Configuration
 Isolated operation
 IOP Min. generator load [5763]  35%
NOTE: actual minimum operating load will be lower and dependent on the
dynamic configuration
444
Introduction
Start/Stop
Calculation
Determine at what power level does the next generator start
Exercises
In General, the next start occurs when:
Plant load > Sum of rated powers of the generators online * IOP max
generator load [5762]
100 kW * 0.85 = 85 kW for Next to start
445
Introduction
Start/Stop
Determine which generator(s) is on line with 100 kW facility load

Calculation
Exercises Determine Dynamic Power Level

100 kW / [0.35+(0.85-0.35)*0.5) = 167 kW required genset power
The 200 kW generator is the best fit.
If the 100 kW gen was on the bus as load increased, then the 200 kW gen
would be added. With the increasing load settling at 100 kW, then the 100 kW
generator would be unloaded and removed.
Check
The 200 kW generator has a min load of 200*0.35 = 70 kW and a max load of
200*0.85 = 170 kW.
The 100 kW gen has a max load of 85 kW. The 300 kW gen has a min load of
105 kW.
446
Introduction
Getting Started The 100kW and 300kW gensets are on the bus. Assume a Moderate (50%)
dynamic, equal priority, best fit selected
Start/Stop
Calculation
Determine at what power level does the third (200kW) generator start
Exercises
(100 kW + 300 kW) * 0.85 = 340 kW for third to start
Determine Dynamic Power Level

If power remained at 340 kW, then all three generators would remain
connected.
447
Introduction
Getting Started The 100kW and 300kW gensets are on the bus. Assume a High (75%)
dynamic, equal priority, best fit selected
Start/Stop
Calculation
Determine at what power level does the third (200kW) generator start
Exercises
(100 kW + 300 kW) * 0.85 = 340 kW for third to start
Determine Dynamic Power Level

If power remained at 340 kW, then the 200kW and 300kW generators would
remain connected and the 100kW generator would be removed.
448
End of Presentation
11 Sequencing
Thank you for your attention

Note:
449

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easYgen-3200 Overview

Genset Control for Multiple Unit Operation

easYgen-3100 80 4 8440-1819 8440-1817 8440-1844 8440-1845

easYgen-3200 80 4 8440-1816 8440-1831 8440-1842 8440-1843

RP-3000 easYgen-3100 easYgen-3200 Proprietary Information

Typical Field Applications:

Power Management • Customized front foils/face panels

Load-Dependent Start/Stop (LDSS) up to 32 generator sets based on:

Digital Signals Relay Outputs

Internal Conditions Internal Conditions

1 x Magnetic Pickup Unit

True RMS Voltage Sensing

Delta / Wye Alarm Screen

Manual mode Additional

Engine start / stop Breaker control

Single line diagram

Acceptable Volt/Freq detected

Field rotation clockwise (CW)

Field rotation counterclockwise (CCW)

Import/export mains power

Engine monitoring delay expired

Engine speed detected

Stop command issued

Start/run command issued

Unit attempting to close the breaker

Unit attempting to open the breaker

Alarms will stay active until acknowledged, even if power is cycled.

Display and Horn Warning

* plausibility monitoring features

All interfaces are galvanically isolated!

Digital expansion modules

Serial RS-232 • ToolKit

4 x clamping brackets for IP56 front panel mounting (8923-1263)

Accessories easYgen-3000 All Versions

IKD 1 Digital Expansion Card

Terminal Strip Kit – Plug Set

Configuration Manual Configuration Manual

Operation Manual Operation Manual

Application Manual Application Manual

Power Supply • 12/24 Vdc (8 to 40 Vdc)

Discrete Outputs Generator Mains Busbar

Mains current measuring L1 or L2 or L3

Mains current measuring L1 or L3

Mains current measuring L1 or L3

Mains current measuring L1

3 Low oil pressure

Technical Data 9 Discrete input

74 N.C. normally closed

Max 2 A each contact

Discrete Inputs GCB close

Technical Data MCB close

Max 250 V AC/DC

0/4 to 20 mA (freely configurable)

Power Supply Battery voltage with

Analog Outputs Bar graph disappears if

Actual measured value

Numeric and graphical

Analog Outputs • speed bias (governor)

• Resolution 11/12 bit

MPU Input • Provides an auxiliary excitation voltage during the cranking of

2 Hardware and I/O 7 Analog Manager

3 Operational Modes 8 Controller

4 Configuration and ToolKit 9 Synchronization and Breaker