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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

Proprietary Information
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

Proprietary Information
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

Proprietary Information
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

Proprietary Information
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

Proprietary Information
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

Proprietary Information
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

Proprietary Information
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

Proprietary Information
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
Proprietary Information
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

Proprietary Information
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

Proprietary Information
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
Proprietary Information
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)

Proprietary Information
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

Proprietary Information
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

Proprietary Information
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

Proprietary Information
DynamicsLCDTM
Multiple languages – 10 standard
English Turkish
German Portuguese
Italian Russian
French Chinese
Spanish Japanese
Polish

Proprietary Information
DynamicsLCDTM
Italian
French
Spanish

Turkish
Portuguese

Proprietary Information
DynamicsLCDTM
Chinese
Russian

Japanese

Proprietary Information
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

Proprietary Information
DynamicsLCDTM
The display sections:

Last alarm

Current operation
i.e. cranking, loading,
start pause, etc.

Single line diagram


and operation mode

Proprietary Information
DynamicsLCDTM
Operating modes

Automatic mode

Manual mode

Stop mode
Proprietary Information
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

Proprietary Information
DynamicsLCDTM

Stop command issued

Start/run command issued

Unit attempting to close the breaker

Unit attempting to open the breaker


Proprietary Information
DynamicsLCDTM
Examples of Measuring Screens

Proprietary Information
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.

Proprietary Information
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
Proprietary Information
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

Proprietary Information
Generator Protection
# of Trip Levels ANSI Code
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

Proprietary Information
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

Proprietary Information
Mains Monitoring and Decoupling
# of Trip Levels ANSI Code
 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

Proprietary Information
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
Proprietary Information
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!


Proprietary Information
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
Proprietary Information
Configuration via ToolKit

RS-232 or CAN

Serial 1
RS-232

Proprietary Information
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
Proprietary Information
American Bureau of Shipping & Affiliated Companies
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

Proprietary Information
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

Proprietary Information
easYgen-3100
easYgen-3100 (1A CT and 5A CT model)
• Metal housing: no display, HMI via interfaces and DI
• Same functionality as easYgen-3200

Proprietary Information
easYgen-3000/P2 Features
Extended I/O Via External Terminals
P2
only

Proprietary Information
easYgen-3000/P2 Features
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

Proprietary Information
easYgen-3000/P2 Features
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 …

Proprietary Information
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

Proprietary Information
3rd Party Accessories
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

Proprietary Information
Accessories

Accessories easYgen-3000 All Versions

IKD 1 Digital Expansion Card


[P/N 8440-1041]

Terminal Strip Kit – Plug Set


[P/N 8923-1314]

Proprietary Information
3rd Party Accessories
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

Proprietary Information
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]

Proprietary Information
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.
Proprietary Information
easYgen-3200 Training
Section 2 – Hardware and I/O

marked

CERTIFICATE of
Design Assessment
by ABS
American Bureau of Shipping & Affiliated Companies

Proprietary Information
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

Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
Flex Range - 3Ph4W
3Ph4W (3phase, 4wire)
Introduction
L1 L2 L3 N
Power Supply

MPU Input

FlexRangeTM

Discrete Inputs

Discrete Outputs

FlexInTM

Analog Outputs

Aux Excitation
D+

Technical Data

G
60
Proprietary Information
Flex Range - 3Ph4W
3Ph4W (3phase, 4wire)
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
Proprietary Information
Flex Range - 3Ph4W
3Ph4W (3phase, 4wire)
Introduction Measured values in the display
Power Supply

MPU Input

FlexRangeTM

Discrete Inputs

Discrete Outputs

FlexInTM

Analog Outputs

Aux Excitation
D+

Technical Data

62
Proprietary Information
Flex Range - 3Ph3W
3Ph3W (3phase, 3wire)
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 3PH3W
Technical Data
Mains voltage measurement 3PH3W
“Busbar” 1PH2W voltage measurement
Phase – Phase L1 – L2

63
Proprietary Information
Flex Range - 3Ph3W
3Ph3W (3phase, 3wire)
Introduction
L1 L2 L3
Power Supply

MPU Input

FlexRangeTM

Discrete Inputs

Discrete Outputs

FlexInTM

Analog Outputs

Aux Excitation
D+

Technical Data

G
64
Proprietary Information
Flex Range - 3Ph3W
3Ph3W (3phase, 3wire)
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
Proprietary Information
Flex Range - 3Ph3W
3Ph3W (3phase, 3wire)
Introduction Measured values in the display
Power Supply

MPU Input

FlexRangeTM

Discrete Inputs

Discrete Outputs

FlexInTM

Analog Outputs

Aux Excitation
D+

Technical Data

66
Proprietary Information
Flex Range - 1Ph3W
1Ph3W (1phase, 3wire)
Introduction only 2-phase voltage measurement possible
Power Supply

MPU Input

FlexRangeTM
jumper
Discrete Inputs

Discrete Outputs

FlexInTM

Analog Outputs

Aux Excitation
D+ Generator voltage measurement 1PH3W
Technical Data
Mains voltage measurement 1PH3W
“Busbar” 1PH2W voltage measurement
Phase – Neutral L1 - N

67
Proprietary Information
Flex Range - 1Ph3W
1Ph3W (1phase, 3wire)
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
Proprietary Information
Flex Range - 1Ph3W
1Ph3W (1phase, 3wire)
Introduction Measured values in the display
Power Supply

MPU Input

FlexRangeTM

Discrete Inputs

Discrete Outputs

FlexInTM

Analog Outputs

Aux Excitation
D+

Technical Data

69
Proprietary Information
Flex Range - 1Ph2W
1Ph2W (1phase, 2wire)
Introduction only 1-phase voltage measurement possible
Power Supply

MPU Input

FlexRangeTM
jumper
Discrete Inputs

Discrete Outputs

FlexInTM

Analog Outputs

Aux Excitation
D+ Generator voltage measurement 1PH2W
Technical Data
Mains voltage measurement 1PH2W
“Busbar” 1PH2W voltage measurement
Phase – Neutral L1 - N

70
Proprietary Information
Flex Range - 1Ph2W
1Ph2W (1phase, 2wire)
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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


Proprietary Information
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
Proprietary Information
Discrete Outputs
Max 250 V AC/DC
Discrete outputs 6 through 9
Introduction

Power Supply
Max 2 A each contact

MPU Input

FlexRangeTM

Discrete Inputs GCB close


Discrete Outputs

FlexInTM
GCB open
Analog Outputs

Aux Excitation
D+

Technical Data MCB close

MCB open

76
Proprietary Information
Discrete Outputs
Discrete outputs 10 through 12
Introduction

Power Supply
Lube pump
MPU Input

Warning signal
FlexRangeTM

Discrete Inputs
Shutdown signal

Discrete Outputs

FlexInTM

Analog Outputs
Max 2 A each contact
Aux Excitation
D+

Technical Data

Max 250 V AC/DC

77
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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

86
Proprietary Information
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

87
Proprietary Information
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

88
Proprietary Information
End of Section 2

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.
89
Proprietary Information
easYgen-3200 Training
Section 3 - Operational Modes

marked

CERTIFICATE of
Design Assessment
by ABS
American Bureau of Shipping & Affiliated Companies

Proprietary Information
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

Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
Status Menu

DynamicsLCDTM

Status Menu

Parameter Menu

Password

Operation

Start / Stop

FlexAppTM

FAQ

Set Points

95
Proprietary Information
Status Menu

DynamicsLCDTM

Status Menu

Parameter Menu

Password

Operation

Start / Stop

FlexAppTM

FAQ

Counters and Service

96
Proprietary Information
Status Menu

DynamicsLCDTM

Status Menu

Parameter Menu

Password

Operation

Start / Stop

FlexAppTM

FAQ

Measured Values

97
Proprietary Information
Status Menu

DynamicsLCDTM

Status Menu

Parameter Menu

Password

Operation

Start / Stop

FlexAppTM

FAQ Online
Diagram
Visible

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Proprietary Information
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
Proprietary Information
Parameter Menu
Screen Navigation – Parameter Screens
DynamicsLCDTM System Overview Parameter
Status Menu

Parameter Menu

Password

Operation

Start / Stop

FlexAppTM

FAQ

Screen Name

Pathway to
this screen

100
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
Password Protection
Screen Navigation – Parameter Screens
DynamicsLCDTM System Overview Parameter
Status Menu

Parameter Menu

Password

Operation

Start / Stop

FlexAppTM

FAQ

Password Screen

104
Proprietary Information
Password Protection
Password protection valid for 2 hours
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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

- Crank/start circuit control


FAQ
External logic - Fuel solenoid as a start
request to external controllers
- External control must take care of start sequence – no start failure

111
Proprietary Information
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
Proprietary Information
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
Proprietary Information
FlexAppTM – Breaker Application – [GCB]
One breaker mode
DynamicsLCDTM • Generator breaker (GCB) control
Status Menu
• Generator protection for shutdown and GCB open command
Parameter Menu
• Single or multiple genset operation
Password
• GCB open/close command Grey= breaker status only:
Operation
MCB control is external
Start / Stop

FlexAppTM

FAQ

Fixed Input Fixed Output


DI 8 reply GCB (B contacts) DO 6/7 GCB close / open
DI 7 reply mains parallel
114
Proprietary Information
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
Proprietary Information
FlexAppTM – Breaker Application – [GCB open]
Breaker open mode
DynamicsLCDTM • Generator breaker open only
Status Menu
• Generator protection for shutdown and GCB open command
Parameter Menu
• Single or multiple genset operation
Password
• GCB open command (shunt trip)
Operation

Start / Stop

FlexAppTM

FAQ

Fixed Input Fixed Output


DI 8 reply GCB (B contact) DO 7 GCB open
116
Proprietary Information
DI 7 reply MCB (mains parallel)
FlexAppTM – Breaker Application – [none]
Base mode
DynamicsLCDTM • No breaker control
Status Menu
• Single or multiple genset operation
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
Frequently Asked Questions

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
Proprietary Information
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)


Proprietary Information
FAQ
How do I reset the maintenance counter?
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
How do I reset the maintenance counter?
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
Proprietary Information
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
Proprietary Information
End of Section 3

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.
125
Proprietary Information
easYgen-3200 Training
Section 4 - Configuration via ToolKit

Proprietary Information
Contents
Introduction slide 3
Installing ToolKit 4
Connect 11
Status Menu 16
Configuration 24
Settings Menu 26
FAQ 38

Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
Installing ToolKit
Introduction When the installation is complete, click on the close button to exit
Installation

Connect

Status Menu

Configuration

Settings Menu

FAQ

132
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
Status Menus
Introduction

Installation

Connect

Status Menu

Configuration

Settings Menu

FAQ

Measured values
140
Proprietary Information
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
Proprietary Information
Status Menus
Introduction

Installation
Active alarms Can not be reset if
Connect
active flag = TRUE
Status Menu

Configuration

Settings Menu

FAQ

142
Proprietary Information
Status Menus
Introduction

Installation

Connect

Active alarm classes


Status Menu

Configuration

Settings Menu

FAQ

Reset alarms online

143
Proprietary Information
Status Menus
Use EXPORT to create HTML
Introduction
file of the active alarms
Installation

Connect

Status Menu

Configuration

Settings Menu

FAQ

144
Proprietary Information
Configuration
Introduction

Installation

Connect

Status Menu

Configuration

Settings Menu

FAQ

145
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
Settings Menu
Introduction

Installation

Connect
• Select COM port to be used
Status Menu

Configuration

Settings Menu • Monitor progress


FAQ
• Enter notes if desired

149
Proprietary Information
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
Proprietary Information
Settings Menu
Introduction

Installation

Connect

Status Menu

Configuration

Settings Menu

FAQ

151
Proprietary Information
Settings Menu
Introduction

Installation

Connect

Status Menu

Configuration

Settings Menu

FAQ

152
Proprietary Information
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
Proprietary Information
Settings Menu
Introduction

Installation

Connect
2) Select file with
Status Menu Browse button
Configuration

Settings Menu

FAQ

3) Monitor
progress

154
Proprietary Information
Settings Menu
Introduction

Installation

Connect • Select the two files to compare


Status Menu

Configuration

Settings Menu

FAQ

155
Proprietary Information
Settings Menu
Introduction

Installation

Connect

Status Menu
• Any
Configuration
differences
are displayed
Settings Menu
as a
FAQ spreadsheet

156
Proprietary Information
Settings Menu
Introduction

Installation

Connect
LogicsManager
Status Menu results
Configuration

Settings Menu

FAQ

157
Proprietary Information
Frequently Asked Questions
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
FAQ - Trend function
Introduction

Installation

Connect
Adjust trend scaling with “Properties...”
Status Menu

Configuration

Settings Menu

FAQ

161
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
FAQ
Introduction
What other connection types are available?
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
Proprietary Information
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
Proprietary Information
FAQ
Introduction
What other connection types are available?
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
FAQ
Introduction
How do I install the v2.xx and v3.xxdrivers for the
Installation
IXXAT USB-to-CAN compact converter?
Connect

Status Menu

Configuration

Settings Menu

FAQ

Open the Device Manager window and right click on the VCI3
171 Interface and select Update Driver.
Proprietary Information
FAQ
Introduction
How do I install the v2.xx and v3.xxdrivers for the
Installation
IXXAT USB-to-CAN compact converter?
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.
Proprietary Information
FAQ
Introduction
How do I install the v2.xx and v3.xxdrivers for the
Installation
IXXAT USB-to-CAN compact converter?
Connect

Status Menu

Configuration

Settings Menu

FAQ

Select “Don’t search. I will choose the driver to install.” and click
173 the Next button.
Proprietary Information
FAQ
Introduction
How do I install the v2.xx and v3.xxdrivers for the
Installation
IXXAT USB-to-CAN compact converter?
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
Proprietary Information
FAQ
Introduction
How do I install the v2.xx and v3.xxdrivers for the
Installation
IXXAT USB-to-CAN compact converter?
Connect

Status Menu

Configuration

Settings Menu

FAQ

The Hardware Update Wizard will install the desired drivers.


175
Proprietary Information
FAQ
Introduction
How do I install the v2.xx and v3.xxdrivers for the
Installation
IXXAT USB-to-CAN compact converter?
Connect

Status Menu

Configuration

Settings Menu

FAQ

Click on Finish to complete the installation of the driver.


176
Proprietary Information
FAQ
Introduction
How do I install the v2.xx and v3.xxdrivers for the
Installation
IXXAT USB-to-CAN compact converter?
Connect

Status Menu

Configuration

Settings Menu

FAQ

The results of the installation process can be viewed in the Device


177 Manager window.
Proprietary Information
End of Section 4

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:
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
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
contained in purchase order(s), other contractual document(s), or information otherwise expressly represented in
178 writing by Woodward as correct and accurate for the specific facts, circumstances and applications.
Proprietary Information
easYgen-3200 Training
Section 5 - Communication

marked

CERTIFICATE of
Design Assessment
by ABS
American Bureau of Shipping & Affiliated Companies

Proprietary Information
Contents
Introduction slide 3
Communication Ports 4
Serial Port Communication 5
CAN bus Communications 13
Password Protection 25
FAQ 27

Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
Serial 1: ToolKit via RS-232
Introduction

RS-232
Comm Ports

Serial Comms

CANbus Comms
Serial 1
Password RS-232
FAQ

184
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
Serial 1: Modbus on RS-232
Introduction Baud rate
Comm Ports

Serial Comms

CANbus Comms

Password

FAQ

189 Do not disable, required for ToolKit!


Proprietary Information
Serial 2: Modbus on RS-485
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
Proprietary Information
Serial 2: Modbus on RS-485
Introduction • Wiring of Half Duplex- communications
Comm Ports

Serial Comms

CANbus Comms

Password

FAQ

• Wiring of Full Duplex- communications

191
Proprietary Information
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
Proprietary Information
Serial 2: Parameters
Introduction

Comm Ports

Serial Comms

CANbus Comms

Password

FAQ

193 Enter a longer delay for slower PLCs


Proprietary Information
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

E N G IN E G EN ER ATO R

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
Proprietary Information
CAN 1: Load Sharing
Introduction

Comm Ports CAN 1


Serial Comms

CANbus Comms

Password

FAQ

196
Proprietary Information
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
Proprietary Information
CAN 1: Parameters
Introduction

For load share


Comm Ports

Serial Comms

CANbus Comms

Password

FAQ

198
Proprietary Information
CAN 1: Parameters
Introduction
For CANopen
Comm Ports

Serial Comms

CANbus Comms

Password

FAQ

199
Proprietary Information
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

E N G IN E G EN ER ATO R

Engine Generator
200
Proprietary Information
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

E N G IN E G EN ER ATO R

Engine Generator
201
Proprietary Information
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

E N G IN E G EN ER ATO R

Engine Generator
202
Proprietary Information
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

E N G IN E G EN ER ATO R

Engine Generator
203
Proprietary Information
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
Proprietary Information
CAN 2: P2 J1939 ECU Values
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
Proprietary Information
CAN 2: P2 J1939 ECU Values
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
Proprietary Information
CAN 2: P2 J1939 ECU Values
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
Proprietary Information
CAN 2: P2 J1939 ECU Values
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
Proprietary Information
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
Proprietary Information
CAN 2: Control of a J1939 ECU
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
Proprietary Information
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
Proprietary Information
CAN 2: Coupling to Woodward E3
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
Proprietary Information
CAN 2: Coupling to Woodward E3
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
Proprietary Information
CAN 2: Control of a J1939 ECU
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
Proprietary Information
NOT every ECU supports all signals, see interface manual for details
CAN 2: Control of a J1939 ECU
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
Proprietary Information
P2
only CAN 2: Analog expansion boards
Introduction

Comm Ports

Serial Comms

CANbus Comms

Password

FAQ

- ECU

217
Proprietary Information
P2
only CAN 2: Parameters
Expansion boards – refer to applications manual for details
Introduction

Comm Ports

Serial Comms

CANbus Comms

Password

FAQ

218
Proprietary Information
Password Protection
Introduction
Password protection valid for 2 hours
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

RS-232 Modbus Serial 1 (RS-232)

RS-485 Modbus Serial 2 (RS-485)

CAN 1 CANopen CAN 1

219
Proprietary Information
Password Protection
Introduction
Password protection valid for 2 hours
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
Proprietary Information
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
Proprietary Information
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.
Proprietary Information
FAQ
Introduction
How can I make a start / stop / acknowledge via interface?
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.
Proprietary Information
FAQ
Introduction
How can I make a start / stop / acknowledge via interface?
Comm Ports

Serial Comms
2) Send start bit
CANbus Comms

Password
Remote control
FAQ Parameter ID 503

224
Proprietary Information
FAQ
Introduction
How can I make a start / stop / acknowledge via interface?
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
Proprietary Information
FAQ
Introduction
How can I make a start / stop / acknowledge via interface?
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
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Note: Software ModScan32 adds internally +1 to the address (504 instead of 503)
FAQ
Introduction
How can I make a start / stop / acknowledge via interface?
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
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Note: Software ModScan32 adds internally +1 to the address (504 instead of 503)
FAQ
Introduction
How can I make a start / stop / acknowledge via interface?
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
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FAQ
Introduction
How can I make a start / stop / acknowledge via interface?
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
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FAQ
Introduction
How can I make a start / stop / acknowledge via interface?
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
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FAQ
Introduction
How can I make a start / stop / acknowledge via interface?
Comm Ports
3) Monitor result
Serial Comms
Engine will perform a start sequence
CANbus Comms

Password

FAQ

231
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End of Section 5

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.
232
Proprietary Information
easYgen-3200 Training
Section 6 - LogicsManager

marked

CERTIFICATE of
Design Assessment
by ABS
American Bureau of Shipping & Affiliated Companies

Proprietary Information
Contents
Introduction slide 3
Screen Description 5
Input Command Variables 6
Signs 11
Operators 13
Time delay 17
Logical Outputs 18
Programming 24
Exercise 26

Proprietary Information
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
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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

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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

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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)

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Input Command Variables
Introduction
Viewing the state of the inputs in ToolKit:
Description

Input Commands

Signs

Operators

Time Delay

Logical Outputs

Programming

Exercise

239
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Input Command Variables
Introduction
Viewing the state of the inputs in the HMI:
Description

Input Commands

Signs

Operators

Time Delay

Logical Outputs

Programming

Exercise

240
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Input Command Variables
Introduction
Internal clock and timer functions:
Description

Input Commands

Signs

Operators

Time Delay

Logical Outputs

Programming

Exercise

241
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Input Command Variables
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
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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
- The command variable input
is ignored and this logic path is
always FALSE.

Hard True
- The command variable input
243 is ignored and this logic path is
Proprietary Information
always TRUE.
Signs
Introduction

Description

Input Commands
Command input:
Grey if sign = TRUE or FALSE
Signs

Operators

Time Delay

Logical Outputs

Programming

Exercise

244
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Operators
Introduction
Operator 01 and 02
Description

Input Commands

Signs

Operators

Time Delay

Logical Outputs

Programming

Exercise

245
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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

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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

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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
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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

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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

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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
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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

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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

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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
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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

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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

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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

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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
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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
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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

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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

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End of Section 6

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.
262
Proprietary Information
easYgen-3200 Training
Section 7 – Analog Manager

marked

CERTIFICATE of
Design Assessment
by ABS
American Bureau of Shipping & Affiliated Companies

Proprietary Information
Contents
Introduction slide 3
Data Sources 6
Flexible Limits 13
Source Format 18
Analog Output 21
Exercises 29

Proprietary Information
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

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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

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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 -


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Data Sources
Introduction Group 00 Internal values
Data Sources

Flexible Limits

Source Format

Analog Outputs

Exercises

268
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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
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Data Sources
Group 02 Mains values
Introduction

Data Sources

Flexible Limits

Source Format

Analog Outputs

Exercises

270
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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
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Data Sources
Introduction Group 03 Busbar values
Data Sources

Flexible Limits

Source Format

Analog Outputs

Exercises

Group 06 Analog inputs

272
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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


08.02 External Analog Input 2 Display value
08.09 External Analog Input 3 Display value

273
And many more detailed values
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Flexible Limits
Introduction

Data Sources

Flexible Limits
Description of the
Source Format parameters
Analog Outputs

Exercises

274
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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
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Flexible Limits
Introduction Description of the parameters
Data Sources
Enable flexible limit
Flexible Limits (disabled by default)
Source Format

Analog Outputs

Exercises

Enter delay time

276
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Flexible Limits
Introduction Description of the parameters
Data Sources

Flexible Limits

Source Format

Analog Outputs

Exercises

If the alarm class is


configured as
control these
parameters are
ignored

277
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Flexible Limits
Introduction Description of the parameters
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

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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

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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
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Source Format
Introduction
Examples:
Data Sources

Flexible Limits

Source Format

Analog Outputs

Exercises

281
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Analog Output
Introduction
Description of the
Data Sources parameters
Flexible Limits

Source Format

Analog Outputs

Exercises

282
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Analog Output
Introduction
Description of the analog output parameters
Data Sources

Flexible Limits

Source Format

Analog Outputs
Data source:

Exercises
select from list

283
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Analog Output
Introduction
Description of the analog output parameters
Data Sources

Flexible Limits

Source Format

Analog Outputs

Exercises

Define the upper and


lower limits of the
signal as a percentage

284
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Analog Output
Introduction
Description of the analog output parameters
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…

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Analog Output
Introduction
Description of the analog output parameters
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

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Analog Output
Introduction
Description of the analog output parameters
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

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Analog Output
Introduction
Examples for analog output parameters from the Configuration manual
Data Sources

Flexible Limits

Source Format

Analog Outputs

Exercises

288
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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
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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
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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
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Exercises: Task A
Introduction
1) Configure the Analog input 1 for a VDO fuel tank level sensor.
Data Sources
Change parameters in the analog input screen
Flexible Limits

Source Format

Analog Outputs

Exercises

292
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Exercises: Solution A
Introduction
1) Configure the Analog input 1 for a VDO fuel tank level sensor.
Data Sources

Flexible Limits

Source Format

Analog Outputs

Exercises

Enter name to be displayed

293
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Exercises: Solution A
Introduction
1) Configure the Analog input 1 for a VDO fuel tank level sensor.
Data Sources
Select Type “linear” from list
Flexible Limits

Source Format

Analog Outputs

Exercises

Verify sender hardware type 0-500 Ohm

294
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Exercises: Solution A
Introduction
1) Configure the Analog input 1 for a VDO fuel tank level sensor.
Data Sources

Flexible Limits

Source Format

Analog Outputs

Exercises

Select wire break


(Not in this example)

295
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Exercises: Solution A
Introduction
1) Configure the Analog input 1 for a VDO fuel tank level sensor.
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)
Proprietary Information
Exercises: Solution A
Introduction
1) Configure the Analog input 1 for a VDO fuel tank level sensor.
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
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Exercises: Solution A
Introduction
1) Configure the Analog input 1 for a VDO fuel tank level sensor.
Data Sources

Flexible Limits
Check result in the display
Source Format

Analog Outputs

Exercises

298
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Exercises: Solution A
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
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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
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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
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Exercises: Task C
Introduction
Configure the analog output manager
Data Sources Speed bias signal for analog output 1 range: 3 – 7 V.
Flexible Limits

Source Format

Analog Outputs

Exercises

302
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Exercises: Solution C
Introduction
Configure the analog output manager
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
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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
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Exercises: Solution D
Introduction
Fuel Transfer Pump Operation
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

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Exercises: Solution D
Introduction
Fuel Transfer Pump Operation
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
Proprietary Information
fuel pump on and off.
End of Section 7

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.
307
Proprietary Information
easYgen-3200 Training
Section 8 - Controller

marked

CERTIFICATE of
Design Assessment
by ABS
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Proprietary Information
Contents
slide 3
Introduction
4
Controller
13
Set Points
17
Load Sharing
24
FAQ
30
Exercises

Proprietary Information
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
Proprietary Information
What does “control” mean?
Introduction
• Measure the actual state
Controller -

Set Points • Compare with reference value


-
Load Sharing

FAQ • Make correction


Exercises

311
Proprietary Information
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

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Proprietary Information
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.

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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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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.

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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
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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
Proprietary Information
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
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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 %)

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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.
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Proprietary Information
Set Points
Interface Power Set Point
Introduction

Controller

Set Points

Load Sharing

FAQ

Exercises

324
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
Load Sharing
Introduction

Controller
Segment 1

Set Points Load


Load Sharing

FAQ

Exercises

Segment 2
Load

Segment 3
329 Load
Proprietary Information
Load Sharing
Introduction

Controller
Segment 1

Set Points Load


Load Sharing
Segment #2 TRUE
FAQ

Exercises

Segment 2
Load

Segment 3
330 Load
Proprietary Information
Load Sharing
Introduction

Controller
Segment 1

Set Points Load


Load Sharing

FAQ

Exercises

Segment 2
Load
Segment #2 TRUE

Segment 3
331 Load
Proprietary Information
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
Proprietary Information
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

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Proprietary Information
FAQ
Introduction
How can I configure my controller bias signal output?
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
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Proprietary Information
03.21 Governor lower 03.23 AVR lower
FAQ
Introduction
How can I configure my controller bias signal output?
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
Proprietary Information
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
Proprietary Information
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

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Proprietary Information
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

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Proprietary Information
End of Section 8

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.
339
Proprietary Information
easYgen-3200 Training
Section 9 - Synchronization and Breaker Logic

marked

CERTIFICATE of
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American Bureau of Shipping & Affiliated Companies

Proprietary Information
Contents
Introduction Slide 3
Synchronization 4
Breaker Logic 9
FAQ 31
Exercises 32

Proprietary Information
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
Proprietary Information
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
Proprietary Information
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°

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Proprietary Information
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

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Proprietary Information
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

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Proprietary Information
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
Proprietary Information
Breaker Logic
Introduction

Synchronization

Breaker Logic

FAQ

Exercise

Only if application mode =


GCB/MCB

Breaker logic may


be changed via the
LogicsManager

349
Proprietary Information
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
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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 GCB is synchronized and closed
• 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
Proprietary Information
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 GCB is synchronized and closed
• 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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
Solution
Introduction
1) Test mode with the generator running isolated from mains
Synchronization
Select transition mode “Interchange” to open the breaker at zero power
Breaker Logic

FAQ

Exercise

Mains CT required!

359
Proprietary Information
Solution
Introduction
1) Test mode with the generator running isolated from mains
Synchronization
Use discrete input 10 also as start command via “Start in Auto”
Breaker Logic

FAQ

Exercise

360
Proprietary Information
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
Proprietary Information
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
Proprietary Information
End of Section 9

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.
363
Proprietary Information
easYgen-3200 Training
Section 10 - Application

marked

CERTIFICATE of
Design Assessment
by ABS
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Proprietary Information
Contents
Introduction Slide 3
Start / Stop in Auto 4
Logical Outputs 6
Start / Stop 10
Alarm Classes 14
Protection 15
FAQ 23

Proprietary Information
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
Proprietary Information
Start / Stop in Auto
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
Proprietary Information
Start / Stop in Auto
Introduction

Start /Stop Auto

Logical Outputs

Start / Stop

Alarm Classes

Protection

FAQ

368
Proprietary Information
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
Proprietary Information
Logical Outputs
Introduction

Start /Stop Auto


Changing the operation
Logical Outputs mode via LogicsManager
Start / Stop

Alarm Classes

Protection

FAQ

370
Proprietary Information
Start / Stop Logic
Introduction
Diesel Engine
Start /Stop Auto
- Pre-glow function
Logical Outputs
- Fuel or Stop solenoid activation
Start / Stop
- Crank/start circuit control
Alarm Classes
Gas Engine
Protection
- Ignition
FAQ
- Gas valve
- Crank/start circuit control

External Logic
- Fuel solenoid as a start request to external controllers
- External control must take care of start sequence – no start failure

371
Proprietary Information
Start / Stop Sequence
Introduction Diesel Engine
Start /Stop Auto

Logical Outputs

Start / Stop

Alarm Classes

Protection

FAQ

372
Proprietary Information
Start / Stop Sequence
Introduction Gas Engine
Start /Stop Auto

Logical Outputs

Start / Stop

Alarm Classes

Protection

FAQ

373
Proprietary Information
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
Proprietary Information
Generator Protection
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
Proprietary Information
Generator Protection
Introduction
# of Trip Levels ANSI Code
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
Proprietary Information
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
Proprietary Information
Mains Monitoring and Decoupling
# of Trip Levels ANSI Code
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
Software Enhancements Version
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
Proprietary Information
Software Enhancements Version
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
End of Section 10

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.
385
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easYgen-3200 Training
Section 11 - Sequencing

marked

CERTIFICATE of
Design Assessment
by ABS
American Bureau of Shipping & Affiliated Companies

Proprietary Information
Contents
Introduction slide 3
Getting Started 5
Start/Stop 10
Calculation 17
Exercises 40

Proprietary Information
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
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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
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Getting Started
Introduction
Connection between the units via CAN 1
Getting Started

Start/Stop CAN 1
Calculation

Exercises

390
Proprietary Information
Getting Started
Introduction
Enable LDSS Sequencing
Getting Started

Start/Stop

Calculation

Exercises

391
Proprietary Information
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
Proprietary Information
Getting Started
Introduction
Status Screen
Getting Started
- Operation mode and breaker feedback status
Start/Stop
- Add on/off condition
Calculation
- Measured values
Exercises

393
Proprietary Information
Getting Started
Introduction
Status Screen
Getting Started

Start/Stop

Calculation

Exercises

394
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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.
Proprietary Information
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
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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.

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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
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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
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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
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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
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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
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Start/Stop Priority
Introduction
2. Generator Number
4
Getting Started
Lowest device number -> highest priority
Start/Stop

Calculation

Exercises

403
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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
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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
Proprietary Information
Calculation
Introduction
System Reserve Power – Mains Parallel
Getting Started

Start/Stop

30 kW Power set point Import 50 kW Minimum


Calculation 170 kW
Exercises power 20 kW Reserve
50 kW power 30 kW Hysteresis
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
Proprietary Information
Calculation
Introduction
System Reserve Power – Mains Parallel
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
Proprietary Information
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
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Calculation
Introduction
System Reserve Power – Mains Parallel
Getting Started

Start/Stop

Calculation
15 kW+5 kW 120 kW Power set point Import 50 kW Minimum
Exercises power 20 kW Reserve
50 kW power 30 kW Hysteresis
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
Proprietary Information
Calculation
Introduction
System Reserve Power – Mains Parallel
Getting Started

Start/Stop

30 kW+10 kW Power set point Import 50 kW Minimum


Calculation 80 kW
Exercises power 20 kW Reserve
50 kW power 30 kW Hysteresis
80 kW 10 kW

Stop of the second engine

Actual total generator power <


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

Actual total generator power <


P rated =
200 kW - 30 kW – 10 kW = 160 kW
200 kW
410
Load
Proprietary Information
Calculation
Introduction
System Reserve Power – Mains Parallel
Getting Started

Start/Stop

Calculation 10 kW Power set point Import 50 kW Minimum


Exercises power 20 kW Reserve
50 kW power 30 kW Hysteresis
10 kW

Stop of the last engine

Actual total generator power <


Minimum power - hysteresis
60 kW Actual total generator power <
20 kW – 10 kW = 10 kW
P rated =
200 kW
411
Load
Proprietary Information
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
Proprietary Information
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
Proprietary Information
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
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Calculation
Introduction
Generator Load – Mains Parallel
Getting Started

Start/Stop

Calculation Power set point Import 50 kW Minimum


Exercises power 20 kW Max. load
50 kW 80%
20 kW Min. load 40%

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
415
Load
Proprietary Information
Calculation
Introduction
Generator Load – Mains Parallel
Getting Started

Start/Stop

40 kW Power set point Import 50 kW


Calculation 160 kW
Exercises Minimum power 20 kW
50 kW Hysteresis 5 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
Proprietary Information
Calculation
Introduction
Generator Load – Mains Parallel
Getting started

Start/Stop

Calculation
40 kW 160 kW Power set point Import 50 kW
Exercises Minimum power 20 kW
50 kW Hysteresis 5 kW
40 kW 160 kW Max. load 80%
Min. load 40%

Start of the third engine

Actual generator power > max. load


370 kW Actual generator power >
(200 kW + 200 kW) * (0.8) = 320 kW
P rated =
200 kW
417
Load
Proprietary Information
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
Proprietary Information
Calculation
Introduction
Generator Load – Mains Parallel
Getting Started

Start/Stop

Calculation
120 kW 80 kW Power set point Import 50 kW
Minimum power 20 kW
Exercises
Hysteresis 5 kW
50 kW
120 kW Max. load 80%
80 kW
Min. load 40%

Stop of the third engine


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
Proprietary Information
Calculation
Introduction
Generator Load – Mains Parallel
Getting Started

Start/Stop

120 kW Power set point Import 50 kW


Calculation 80 kW
Exercises Minimum power 20 kW
50 kW Hysteresis 5 kW Max.
80 kW load 80%
Min. load 40% !!!

Stop of the second engine

Actual generator power < min. load


210 kW Actual generator power <
(200 kW * 2 ) * (0.4) = 160 kW !!!
P rated =
200 kW
420
Load
Proprietary Information
Calculation
Introduction
Generator Load – Mains Parallel
Getting Started

Start/Stop

185 kW Power set point Import 50 kW


Calculation 15 kW
Exercises Minimum power 20 kW
50 kW Hysteresis 5 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
Proprietary Information
Calculation
Introduction
Generator Load – Mains Parallel
Getting Started

Start/Stop

Calculation Power set point Import 50 kW Minimum


Exercises power 20 kW Hysteresis
50 kW 5 kW Max. load 80%
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
Proprietary Information
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
Proprietary Information
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
Proprietary Information
Calculation
Introduction
Generator Load (differing sizes) – Mains Parallel
Getting Started

Start/Stop

Calculation Power set point Import 50 kW Minimum


Exercises power 20 kW Hysteresis
P rated = 200 kW
50 kW 5 kW Max. load 70%
20 kW Min. load 40%
Dynamic Moderate (50%)
P rated = 100 kW Start of the first engine

Actual mains power > power set point +


70 kW generator min. load
P rated = 50 kW
Actual mains power > 50
kW + 20 kW = 70 kW

425
Load
Proprietary Information
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
100 kW genset: Min 100 kW * 0.40 = 40 kW, Max 100 kW * 0.70 = 70 kW

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
Proprietary Information
Calculation
Introduction
Generator Load – Mains Parallel
Getting Started

Start/Stop

Calculation Power set point Import 50 kW


Exercises Minimum power 20 kW
50 kW Hysteresis 5 kW

Max. load 70%


Min. load 40%
15 kW Start of the second engine
35 kW
Actual generator power > max. load
85 kW
Actual generator power >
50 kW * (0.7) = 35 kW

427
Load
Proprietary Information
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
100 kW genset: Min 100 kW * 0.40 = 40 kW, Max 100 kW * 0.70 = 70 kW

Exercises 200 kW genset: Min 200 kW * 0.40 = 80 kW, Max 200 kW * 0.70 = 140 kW

Required RATED Power : 35 kW / [0.40 + (0.70-0.40)*0.50] = 63.6 kW

The 100 kW genset will be started and the 50 kW genset removed.

428
Proprietary Information
Calculation
Introduction
Generator Load (differing sizes) – Mains Parallel
All Gensets connected and load drops to 190 kW.
Getting Started

Start/Stop

120 kW 80 kW Power set point Import 50 kW


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

Stop of the third engine


30 kW 20 kW
Actual generator power < min. load

190 kW Actual generator power <


(50+100+200 kW) * (0.4) = 140 kW
P rated total=
350 kW
429
Load
Proprietary Information
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
100 kW genset: Min 100 kW * 0.40 = 40 kW, Max 100 kW * 0.70 = 70 kW

Exercises 200 kW genset: Min 200 kW * 0.40 = 80 kW, Max 200 kW * 0.70 = 140 kW

Required RATED Power : 140 kW / [0.40 + (0.70-0.40)*0.50] = 254.5 kW

The 50 kW genset will be removed.

430
Proprietary Information
Calculation
Introduction
Generator Load (differing sizes) – Mains Parallel
Getting Started

Start/Stop

107 kW Power set point Import 50 kW


Calculation 93 kW
Exercises Minimum power 20 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
Proprietary Information
Calculation
Introduction
Generator Load (differing sizes) – Mains Parallel
Getting Started

Start/Stop

Calculation Power set point Import 50 kW


Exercises Minimum power 20 kW
50 kW Hysteresis 5 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
Proprietary Information
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
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Exercise: Solution 1
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 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
Proprietary Information
Exercise: Solution 2
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
Determine an acceptable hysteresis
Calculation
Parameter
Exercises  Configuration
 Configure application
 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
Proprietary Information
Exercise: Solution 3
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
Set minimum running load for generators at 25 kW
Calculation
Parameter
Exercises  Configuration
 Configure application
 Configure automatic run
 Load dependent start/stop
 Mains parallel operation
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
Proprietary Information
Exercise: Solution 4
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 Determine at what import power will the first generator initiate start
Calculation Parameter
Exercises  Configuration
 Configure application
 Configure automatic run
 Load dependent start/stop
 Mains parallel operation
Import load set point + MOP min load = Import power level
50 kW + 45 kW = 95 kW

437
Proprietary Information
Exercise: Solution 5
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
Determine an acceptable reserve power value
Calculation
Parameter
Exercises  Configuration
 Configure application
 Configure automatic run
 Load dependent start/stop
 Mains parallel operation
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
Proprietary Information
Exercise: Solution 6
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 Determine at what facility power will the second generator initiate start
Calculation Parameter
Exercises  Configuration
 Configure application
 Configure automatic run
 Load dependent start/stop
 Mains parallel operation
Import load set point + (Gen 1 rated – reserve) = facility power level
50 kW + (100 kW – 25 kW) = 125 kW

439
Proprietary Information
Exercise: Solution 7
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
Determine at what facility power will the second generator shut down
Calculation
Parameter
Exercises
 Configuration
 Configure application
 Configure automatic run
 Load dependent start/stop
 Mains parallel operation
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

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Exercise: Solution 8
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
Determine at what facility power will the first generator shut down
Calculation
Parameter
Exercises
 Configuration
 Configure application
 Configure automatic run
 Load dependent start/stop
 Mains parallel operation
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

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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

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Exercise: Solution 1
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

Calculation Set maximum generator operating load.


Exercises Parameter
 Configuration
 Configure application
 Configure automatic run
 Load dependent start/stop
 Isolated operation
 IOP Max. generator load [5762]  85%

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Exercise: Solution 2
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

Calculation Set minimum generator load.


Exercises Parameter
 Configuration
 Configure application
 Configure automatic run
 Load dependent start/stop
 Isolated operation
 IOP Min. generator load [5763]  35%
NOTE: actual minimum operating load will be lower and dependent on the
dynamic configuration

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Exercise: Solution 3
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

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

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Exercise: Solution 4
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

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.
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Exercise: Solution 5
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 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
In General, the next start occurs when:
Plant load > Sum of rated powers of the generators online * IOP max
generator load [5762]
(100 kW + 300 kW) * 0.85 = 340 kW for third to start

Determine Dynamic Power Level


340 kW / [0.35+(0.85-0.35)*0.5) = 567 kW required genset power
If power remained at 340 kW, then all three generators would remain
connected.

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Exercise: Solution 6
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 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
In General, the next start occurs when:
Plant load > Sum of rated powers of the generators online * IOP max
generator load [5762]
(100 kW + 300 kW) * 0.85 = 340 kW for third to start

Determine Dynamic Power Level


340 kW / [0.35+(0.85-0.35)*0.75) = 469 kW required genset power
If power remained at 340 kW, then the 200kW and 300kW generators would
remain connected and the 100kW generator would be removed.

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End of Presentation

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

Thank you for your attention


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