37471

easYgen-3000 Series
Genset Control

Application
Software Version: 1.15xx or higher

Manual 37471

Manual 37471

easYgen-3000 Series - Genset Control

WARNING
Read this entire manual and all other publications pertaining to the work to be performed before installing, operating, or servicing this equipment. Practice all plant and safety instructions and precautions.
Failure to follow instructions can cause personal injury and/or property damage.
The engine, turbine, or other type of prime mover should be equipped with an overspeed (overtemperature, or overpressure, where applicable) shutdown device(s), that operates totally independently of the
prime mover control device(s) to protect against runaway or damage to the engine, turbine, or other
type of prime mover with possible personal injury or loss of life should the mechanical-hydraulic governor(s) or electric control(s), the actuator(s), fuel control(s), the driving mechanism(s), the linkage(s),
or the controlled device(s) fail.
Any unauthorized modifications to or use of this equipment outside its specified mechanical, electrical,
or other operating limits may cause personal injury and/or property damage, including damage to the
equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or "negligence" within
the meaning of the product warranty thereby excluding warranty coverage for any resulting damage,
and (ii) invalidate product certifications or listings.

CAUTION
To prevent damage to a control system that uses an alternator or battery-charging device, make sure
the charging device is turned off before disconnecting the battery from the system.
Electronic controls contain static-sensitive parts. Observe the following precautions to prevent damage to these parts.

Discharge body static before handling the control (with power to the control turned off, contact a
grounded surface and maintain contact while handling the control).

Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around printed circuit boards.

Do not touch the components or conductors on a printed circuit board with your hands or with
conductive devices.

OUT-OF-DATE PUBLICATION
This publication may have been revised or updated since this copy was produced. To verify that you
have the latest revision, be sure to check the Woodward website:
http://www.woodward.com/pubs/current.pdf
The revision level is shown at the bottom of the front cover after the publication number. The latest
version of most publications is available at:
http://www.woodward.com/publications
If your publication is not there, please contact your customer service representative to get the latest
copy.

Important definitions
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION
Indicates a potentially hazardous situation that, if not avoided, could result in damage to equipment.

NOTE
Provides other helpful information that does not fall under the warning or caution categories.
Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be
correct and reliable. However, Woodward assumes no responsibility unless otherwise expressly undertaken.

Woodward
All Rights Reserved.

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Revision History
Rev. Date
NEW 10-05-05

Editor
TE

Changes
Release based on 37417B

Content

CHAPTER 1. GENERAL INFORMATION ....................................................................................... 8

CHAPTER 2. BASIC APPLICATIONS ........................................................................................... 9
Overview .................................................................................................................................................. 9
Application Mode {0} .............................................................................................................................. 10
Application Mode {1o} ............................................................................................................................ 11
Application Mode {1oc} .......................................................................................................................... 12
Application Mode {2oc} .......................................................................................................................... 13

CHAPTER 3. MULTIPLE GENSET APPLICATIONS ...................................................................... 14

Overview ................................................................................................................................................ 14
Configuration Example ........................................................................................................................... 15
Mains Parallel Operation (mains interchange (import/export) power control) ............................. 15

CHAPTER 4. SPECIAL APPLICATION EXAMPLES ...................................................................... 18

Generator Excitation Protection ............................................................................................................. 18
Configuring a Set Point Control via Analog Input .................................................................................. 19
Configuring the Rated Generator Power ..................................................................................... 19
Configuring the Analog Input for Real Power Set Point............................................................... 19
Configuring the Load Controller ................................................................................................... 19
Viewing the Load Set Point on the easYgen ............................................................................... 20
Creating Self-Toggling (Pulsing) Relays Using LogicsManager ............................................................ 21
Changing a Starter Battery Set Using LogicsManager .......................................................................... 22
Performing Remote Start/Stop and Acknowledgement ......................................................................... 24
Preliminary Conditions ................................................................................................................. 24
Operating Modes ......................................................................................................................... 24
Setting Up a Test With or Without Load ...................................................................................... 25
Remote Start/Stop and Acknowledgement .................................................................................. 27
Bit Enabling via Modbus Protocol and RS-485 Interface............................................................. 29
Bit Enabling via CANopen Protocol and CAN Interface 1 ........................................................... 29
Connecting an IKD 1 on CAN Bus 1 ...................................................................................................... 30
easYgen Configuration ................................................................................................................ 30
IKD 1 Configuration...................................................................................................................... 31
Baudrate Configuration ................................................................................................................ 32
Configuration for a Second IKD 1 ................................................................................................ 33
Configuring a PWM Duty Cycle for a CAT ADEM Controller ................................................................. 34
Connecting a GSM Modem .................................................................................................................... 35
Function ....................................................................................................................................... 35
Preconditions for this Example .................................................................................................... 35
Connection ................................................................................................................................... 36
easYgen Settings ......................................................................................................................... 36
ToolKit Settings ............................................................................................................................ 37
GSM Modem Settings .................................................................................................................. 37

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Connecting a Landline Modem .............................................................................................................. 39

Function ....................................................................................................................................... 39
Preconditions for this Example .................................................................................................... 39
Connection .................................................................................................................................. 40
easYgen Settings ........................................................................................................................ 40
ToolKit Settings ........................................................................................................................... 41
Phoenix Modem Settings ............................................................................................................ 41
Wiring Self-Powered DIs........................................................................................................................ 43
Connecting Analog Inputs in Series (Multiple Devices) ......................................................................... 44
Phoenix Expansion Modules ................................................................................................................. 44
Supported Phoenix Modules ....................................................................................................... 44
Possible Combinations ................................................................................................................ 45
Setup ........................................................................................................................................... 46
Configure External Inputs/Outputs .............................................................................................. 49

CHAPTER 5. EXAMPLES FOR LOAD SHARING APPLICATIONS.................................................... 53

General Information ............................................................................................................................... 53
Example Configuration 1 (4 x easYgen-3100) ...................................................................................... 54
Example Configuration 2 (4 x easYgen-3100) ...................................................................................... 55
Example Configuration 3 (4 x easYgen-3200) ...................................................................................... 56
Example Configuration 4 (8 x easYgen-3200) ...................................................................................... 57
Example Configuration 5 (10 x easYgen-3200) .................................................................................... 58
Example Configuration 6 (5 x easYgen-3200) ...................................................................................... 59
Example Configuration 7 (18 x easYgen-3200) .................................................................................... 60
Example Configuration 8 (20 x easYgen-3200) .................................................................................... 61
Example Configuration 9 (5 x easYgen-3200) ...................................................................................... 62
Example Configuration 10 (10 x easYgen-3200) .................................................................................. 63
Example Configuration 11 (12 x easYgen-3200) .................................................................................. 64
Example Configuration 12 (12 x easYgen-3200) .................................................................................. 65
Example Configuration 13 (15 x easYgen-3200) .................................................................................. 66
Example Configuration 14 (30 x easYgen-3200) .................................................................................. 67
Example Configuration 15 (32 x easYgen-3200) .................................................................................. 68

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Figures and Tables

Figures
Figure 2-1: Application mode {0} ............................................................................................................................................ 10
Figure 2-2: Application mode {1o} .......................................................................................................................................... 11
Figure 2-3: Application mode {1oc} ......................................................................................................................................... 12
Figure 2-4: Application mode {2oc} ......................................................................................................................................... 13
Figure 3-1: Multiple genset application mode........................................................................................................................... 14
Figure 3-2: Example - configuring load-dependent start stop (LM).......................................................................................... 15
Figure 3-3: Example - configuring Start in Auto (LM) ............................................................................................................. 17
Figure 4-1: Example - generator excitation protection .............................................................................................................. 18
Figure 4-2: Example - configuring load setpoint 2 for [DI 05] ................................................................................................. 20
Figure 4-3: Example - Setpoints screen .................................................................................................................................... 20
Figure 4-4: Example - Analog inputs screen ............................................................................................................................. 20
Figure 4-5: Example - configuring Flag 5 for a pulsing relay ................................................................................................... 21
Figure 4-6: Example - configuring Relay 2 for a pulsing relay ................................................................................................. 21
Figure 4-7: Example - configuring Relay 11 for a battery change logic ................................................................................... 22
Figure 4-8: Example - configuring Relay 12 for a battery change logic ................................................................................... 22
Figure 4-9: Example - configuring Flag 2 for a battery change logic ....................................................................................... 22
Figure 4-10: Example - configuring Flag 3 for a battery change logic...................................................................................... 23
Figure 4-11: Example - configuring Flag 4 for a battery change logic...................................................................................... 23
Figure 4-12: Example - configuring Flag 5 for a battery change logic...................................................................................... 23
Figure 4-13: Configuration - Operat. mode AUTO ................................................................................................................... 24
Figure 4-14: Configuration - Operat. mode AUTO ................................................................................................................... 25
Figure 4-15: Configuration - Operat. mode STOP .................................................................................................................... 25
Figure 4-16: Configuration Flag 2 (timer).............................................................................................................................. 26
Figure 4-17: Configuration - Start w/o load .............................................................................................................................. 26
Figure 4-18: Example - remote start request ............................................................................................................................. 27
Figure 4-19: Example - remote acknowledgement.................................................................................................................... 28
Figure 4-20: Example - command variable ............................................................................................................................... 29
Figure 4-21: Configuration of TPDO1 for an IKD 1................................................................................................................. 30
Figure 4-22: Configuration of RPDO1 for an IKD 1 ................................................................................................................ 31
Figure 4-23: Configuration of the IKD 1 .................................................................................................................................. 31
Figure 4-24: Configuration of the baud rate .............................................................................................................................. 32
Figure 4-25: Configuration of the easYgen for a second IKD 1 ............................................................................................... 33
Figure 4-26: Configuration of the second IKD 1 ...................................................................................................................... 33
Figure 4-27: Configuring a PWM duty cycle for a CAT ADEM controller.............................................................................. 34
Figure 4-28: Connecting a GSM modem .................................................................................................................................. 35
Figure 4-29: GSM modem connection ...................................................................................................................................... 36
Figure 4-30: Connecting ToolKit with a GSM modem ............................................................................................................. 37
Figure 4-31: Configuring the GSM modem software................................................................................................................ 37
Figure 4-32: Configuring alarm input 1 in the GSM modem software ..................................................................................... 38
Figure 4-33: Configuring alarm input 2 in the GSM modem software ..................................................................................... 38
Figure 4-34: Connecting a landline modem .............................................................................................................................. 39
Figure 4-35: Landline modem connection ................................................................................................................................ 40
Figure 4-36: Connecting ToolKit with a landline modem......................................................................................................... 41
Figure 4-37: Wiring self-powered DIs ...................................................................................................................................... 43
Figure 4-38: Example connecting analog inputs in series ...................................................................................................... 44
Figure 4-39: Configuring the Phoenix modules ........................................................................................................................ 45
Figure 4-40: Configuring the interface baud rate ...................................................................................................................... 46
Figure 4-41: Set the Phoenix baud rate ..................................................................................................................................... 46
Figure 4-42: Enter the Phoenix Node-ID .................................................................................................................................. 47
Figure 4-43: Set the Phoenix Node-ID ...................................................................................................................................... 47
Figure 4-44: Confirming your changes ..................................................................................................................................... 48
Figure 4-45: Configure external DI ........................................................................................................................................... 49
Figure 4-46: Configure external DO ......................................................................................................................................... 49
Figure 4-47: Configure the input condition ............................................................................................................................... 49
Figure 4-48: Configure external AI ........................................................................................................................................... 50
Figure 4-49: Example - configure AO 1 ................................................................................................................................... 52
Figure 4-50: Confirming your changes ..................................................................................................................................... 52
Figure 5-1: Example configuration 1 ........................................................................................................................................ 54
Figure 5-2: Example configuration 2 ........................................................................................................................................ 55
Figure 5-3: Example configuration 3 ........................................................................................................................................ 56
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Figure 5-4: Example configuration 4 ........................................................................................................................................ 57

Figure 5-5: Example configuration 5 ........................................................................................................................................ 58
Figure 5-6: Example configuration 6 ........................................................................................................................................ 59
Figure 5-7: Example configuration 7 ........................................................................................................................................ 60
Figure 5-8: Example configuration 8 ........................................................................................................................................ 61
Figure 5-9: Example configuration 9 ........................................................................................................................................ 62
Figure 5-10: Example configuration 10 .................................................................................................................................... 63
Figure 5-11: Example configuration 11 .................................................................................................................................... 64
Figure 5-12: Example configuration 12 .................................................................................................................................... 65
Figure 5-13: Example configuration 13 .................................................................................................................................... 66
Figure 5-14: Example configuration 14 .................................................................................................................................... 67
Figure 5-15: Example configuration 15 .................................................................................................................................... 68

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Tables
Table 1-1: Manual - overview ..................................................................................................................................................... 8
Table 3-1: Configuration of load-dependent start/stop.............................................................................................................. 15
Table 3-2: Configuration of load-dependent start/stop IOP ...................................................................................................... 16
Table 3-3: Configuration of load-dependent start/stop MOP .................................................................................................... 16
Table 3-4: Configuration of emergency operation .................................................................................................................... 17
Table 3-5: Configuration of import/export power control......................................................................................................... 17
Table 4-1: Example - generator excitation protection ............................................................................................................... 18
Table 4-2: Configuration of the rated generator power ............................................................................................................. 19
Table 4-3: Configuration of the analog input for real power set point ...................................................................................... 19
Table 4-4: Configuration of the analog input for real power set point - ToolKit only parameters ............................................ 19
Table 4-5: Configuration of the load controller ........................................................................................................................ 19
Table 4-6: Timer configuration ................................................................................................................................................. 26
Table 4-7: Configuration of TPDO1 for an IKD 1 .................................................................................................................... 30
Table 4-8: Configuration of RPDO1 for an IKD 1.................................................................................................................... 31
Table 4-9: Configuration of the IKD 1 ...................................................................................................................................... 31
Table 4-10: Configuring a PWM duty cycle for a CAT ADEM controller ............................................................................... 34
Table 4-11: Configuring the easYgen for GSM modem connection ......................................................................................... 36
Table 4-12: Configuring the easYgen for landline modem connection ..................................................................................... 40
Table 4-13: Supported Phoenix Modules .................................................................................................................................. 44
*1 easYgen-3000 Series (Package P2) only............................................................................................................................... 44
Table 4-14: Possible combinations of Phoenix modules ........................................................................................................... 45
*1 easYgen-3000 Series (Package P2) only............................................................................................................................... 45
Table 4-15: Supported sender types .......................................................................................................................................... 51
Table 5-1: IKD 1 - Possible Phoenix usage combinations ........................................................................................................ 53

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easYgen-3000 Series - Genset Control

Chapter 1.
General Information
Type
easYgen-3000 Series
easYgen-3000 Series - Installation
easYgen-3000 Series - Configuration
easYgen-3000 Series - Operation
easYgen-3000 Series - Application
easYgen-3000 Series - Interfaces
easYgen-3000 Series - Parameter List
easYgen-3200 - Brief Operation Information
easYgen-3100 - Brief Operation Information
RP-3000 Remote Panel

this manual

English

German

37468
37469
37470
37471
37472
37473
37399
37474
37413

DE37468
DE37469
DE37470
DE37473
GR37399
-

Table 1-1: Manual - overview

Intended Use The unit must only be operated in the manner described by this manual. The prerequisite for a
proper and safe operation of the product is correct transportation, storage, and installation as well as careful operation and maintenance.
What are the differences between the easYgen-3000 Series Package P1 & Package P2?
easYgen-3000 Series
Freely configurable PID controllers
External discrete inputs / outputs via CANopen (maximum)
External analog inputs / outputs via CANopen (maximum)

Package P1
16 / 16
-

Package P2
3
32 / 32
16 / 4

NOTE
This manual has been developed for a unit fitted with all available options. Inputs/outputs, functions,
configuration screens, and other details described, which do not exist on your unit, may be ignored.
The present manual has been prepared to enable the installation and commissioning of the unit. Due to
the large variety of parameter settings, it is not possible to cover every combination. The manual is
therefore only a guide. In case of incorrect entries or a total loss of functions, the default settings may
be taken from the list of parameters enclosed in the configuration manual 37469 or from ToolKit and
the respective *.SID file.

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Chapter 2.
Basic Applications
Overview

NOTE
Please refer to the Configuration Manual 37469 for selection of the application mode. Depending on the
application, different application modes are possible.

Application mode {0} - [start/stop] - engine control - refer to page 10

- Measuring of engine/generator parameters (i.e. voltage, frequency, current, power, coolant temperature, oil
pressure, etc.)
- Engine start/stop
Application mode {1o} - [open GCB] - protection - refer to page 11
- Measuring of engine/generator parameters (i.e. voltage, frequency, current, power, coolant temperature, oil
pressure, etc.)
- Engine start/stop
- Engine/generator protection (relay output to open GCB)
Application mode {1oc} - [open/close GCB] - 1-CB control - refer to page 12
- Measuring of engine/generator parameters (i.e. voltage, frequency, current, power, coolant temperature, oil
pressure, etc.)
- Engine start/stop
- Engine/generator protection (relay output to open GCB)
- GCB operation (relay output to close GCB)
Application mode {2oc} - [open/close GCB/MCB] - 2-CB control - refer to page 13
- Measuring of engine/generator/mains parameters (i.e. voltage, frequency, current, power, coolant temperature, oil pressure, etc.)
- Engine start/stop
- Engine/generator protection (relay output to open GCB)
- GCB operation (relay output to close GCB)
- MCB operation (relay output to open and close the MCB)
- Mains failure detection (AMF auto mains failure operation) and automatic engine start/stop

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Application Mode {0}

Relay (& pulse) outputs

LOAD

CAN bus / Modbus / (Ethernet)

This application mode may be used for isolated operation applications. In this case, the easYgen will function as
an engine control.

Current
Voltage

G
MPU
Analog/Digital Inputs
Engine Start/Stop

Figure 2-1: Application mode {0}

The easYgen requires in all application modes the feedback reply from the circuit breakers. These replies are
used to define, whether it controls frequency, shares the load with other gensets, or performs active load control.
The following feedback signals are used in this application mode and fixed to the respective discrete inputs:
DI 7 "Reply MCB" (mains parallel)
DI 8 "Reply GCB" (normally closed (break) contact)

NOTE
If the easYgen is intended to be operated in parallel with the mains, the mains voltage measuring inputs must be connected. If an external mains decoupling is performed, jumpers between busbar and
mains voltage measuring inputs may be installed.

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Application Mode {1o}

Relay (& pulse) outputs

Voltage

CAN bus / Modbus / (Ethernet)

LOAD

This application mode may be used for isolated operation applications. In this case, the easYgen will function as
an engine control with generator and engine protection. The control unit can only open the GCB.

GCB open
Current
Voltage

G
MPU
Analog/Digital Inputs
Engine Start/Stop

Figure 2-2: Application mode {1o}

The easYgen requires in all application modes the feedback reply from the circuit breakers. These replies are
used to define, whether it controls frequency, shares the load with other gensets, or performs active load control.
The following feedback signals and commands are used in this application mode and fixed to the respective discrete inputs and outputs:
DI 7 "Reply MCB" (mains parallel)
DI 8 "Reply GCB" (normally closed (break) contact)
DO 7 "Command: GCB open"

NOTE
If the easYgen is intended to be operated in parallel with the mains, the mains voltage measuring inputs must be connected. If an external mains decoupling is performed, jumpers between busbar and
mains voltage measuring inputs may be installed.

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easYgen-3000 Series - Genset Control

Application Mode {1oc}

Relay (& pulse) outputs

Voltage

CAN bus / Modbus / (Ethernet)

LOAD

This application mode may be used in applications, where only the GCB is operated by the easYgen. If it is used
for isolated or mains parallel operations, mains decoupling should be performed by the GCB or an external provision. The easYgen will function as an engine control with generator and engine protection. The control unit can
open and close the GCB.

GCB Control
Current
Voltage

G
MPU
Analog/Digital Inputs
Engine Start/Stop

Figure 2-3: Application mode {1oc}

The easYgen requires in all application modes the feedback reply from the circuit breakers. These replies are
used to define, whether it controls frequency, shares the load with other gensets, or performs active load control.
The following feedback signals and commands are used in this application mode and fixed to the respective discrete inputs and outputs:

DI 7 "Reply MCB" (mains parallel)

DI 8 "Reply GCB" (normally closed (break) contact)
DO 6 "Command: GCB close"
DO 7 "Command: GCB open"

NOTE
If the easYgen is intended to be operated in parallel with the mains, the mains voltage measuring inputs must be connected. If an external mains decoupling is performed, jumpers between busbar and
mains voltage measuring inputs may be installed.

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Application Mode {2oc}

MCB Control

LOAD

Relay (& pulse) outputs

Current
Voltage

CAN bus / Modbus / (Ethernet)

This application mode may be used for mains parallel operation. In this case, the easYgen will function as an engine control with generator, mains and engine protection. The control unit can open and close the GCB and the
MCB.
An emergency mode (AMF operation) is only possible in this application mode.

Voltage
GCB Control
Current
Voltage

G
MPU
Analog/Digital Inputs
Engine Start/Stop

Figure 2-4: Application mode {2oc}

The easYgen requires in all application modes the feedback reply from the circuit breakers. These replies are
used to define, whether it controls frequency, shares the load with other gensets, or performs active load control.
The following feedback signals and commands are used in this application mode and fixed to the respective discrete inputs and outputs:

DI 7 "Reply MCB" (mains parallel)

DI 8 "Reply GCB" (normally closed (break) contact)
DO 6 "Command: GCB close"
DO 7 "Command: GCB open"
DO 8 "Command: MCB close"
DO 9 "Command: MCB open"

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Chapter 3.
Multiple Genset Applications
Overview

Current
Voltage

Current
Voltage

G
MPU
Dig./Analog Inputs
Start/Stop

Current

Voltage
GCB Control

GCB Control

Current
Voltage

Voltage

Open/Close

Current

Voltage

Voltage
GCB Control

Voltage

Open/Close

LOAD

optional
PLC

Current

Open/Close

MCB Control

Voltage

MPU

MPU
Dig./Analog Inputs

Dig./Analog Inputs
Start/Stop

Start/Stop

Modbus
CAN bus
Figure 3-1: Multiple genset application mode

In a multiple-unit mains parallel application, all easYgens need the same signals for:
- mains voltage and current
- reply and release signal of the MCB
The open and close contacts from all controls must be wired in parallel.

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Configuration Example

Mains Parallel Operation (mains interchange (import/export) power control)

The following example describes the configuration of a typical mains parallel operation with import/export power
control at the interchange point and load-dependent start/stop.
Multiple generators are to be operated in parallel to the mains maintaining a stable power at the interchange
point. The generators shall be started depending on the momentary load at the plant. An emergency operation in
case of a mains failure is also intended. The load dependent start/stop function (LDSS) shall be enabled with a
remote start request and during emergency operation. LDSS shall depend on the reserve power on the busbar. In
case of a dead busbar (caused by a mains failure) all capable generators shall be started and operated with their
minimum running time. No generator priority is considered. Generator selection shall be performed depending on
the operating hours.
The following assumptions are valid for this example:
3 generators, each with 80 kW rated power, are available.
The recommended minimum load for the generators is 40 kW.
The minimum running time is 180 s.
Configuring Load-Dependent Start/Stop
From the main screen on the unit select Parameter -> Configuration -> Configure application -> Configure automatic run -> Load dependent start/stop and configure the following parameters:
ID
5752
5753
5751
5754
5755
5756
5759

Parameter
Start stop mode
Dead busbar start mode
Base priority
Fit size of engine
Fit service hours
Changes of engines
Minimum running time

Value
Reserve power
All
5
No
Equal
Off
180 s

Comment
The reserve power at the interchange point is to be considered for LDSS
All generators shall start in case of a dead busbar (mains failure)
The base priority for the genset is 5
The generator rated power is not considered for LDSS
The remaining hours until next service are considered for LDSS
No engine change will be performed
The minimum running time is 180 seconds
Table 3-1: Configuration of load-dependent start/stop

Configure the LogicsManager function "LD start stop" as shown in Figure 4-2 on page 20 to enable LDSS if a
start request in automatic operating mode or emergency mode are enabled.

Figure 3-2: Example - configuring load-dependent start stop (LM)

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Configuring Load-Dependent Start/Stop Isolated Operation

Additional assumptions are valid for isolated operation (IOP), i.e. in case of an emergency operation:
A reserve power of 80 kW on the busbar shall be maintained, i.e. at least 2 generators are available in isolated operation for redundancy because no supporting mains are present.
A hysteresis of 20 kW is required to avoid frequent starts and stops.
The delay for adding another generator shall be 10 seconds.
The delay for adding another generator shall be reduced to 3 seconds if a generator at the busbar is operating
above its rated load (accelerated start of the next generator).
The delay for removing a generator from the busbar shall be 180 seconds.
From the main screen on the unit select Parameter -> Configuration -> Configure application -> Configure automatic run -> Load dependent start/stop -> Isolated operation and configure the following parameters:
ID
5760
5761
5764
5765
5766

Parameter
IOP Reserve power
IOP Hysteresis
IOP Add on delay
IOP Add on delay at rated load
IOP Add off delay

Value
80 kW
20 kW
10 s
3s
180 s

Comment
The reserve power in isolated operation is 80 kW
The reserve power hysteresis in isolated operation is 20 kW
The add on delay in isolated operation is 10 seconds
The add on delay at rated load in isolated operation is 3 seconds
The add off delay in isolated operation is 180 seconds
Table 3-2: Configuration of load-dependent start/stop IOP

Configuring Load-Dependent Start/Stop Mains Parallel Operation

Additional assumptions are valid for mains parallel operation (MOP):
The first generator is only started if it is able to operate at a minimum load of 40 kW.
A hysteresis of 20 kW is required to avoid frequent starts and stops.
A reserve power of 10 kW on the busbar shall be maintained, i.e. at least 10 kW of generator capacity are
available for short load peaks. Higher load peaks are supported by the mains.
The delay for adding another generator shall be 30 seconds.
The delay for adding another generator shall be reduced to 10 seconds if a generator at the busbar is operating above its rated load (accelerated start of the next generator).
The delay for removing a generator from the busbar shall be 60 seconds.
From the main screen on the unit select Parameter -> Configuration -> Configure application -> Configure automatic run -> Load dependent start/stop -> Mains parallel operation and configure the following parameters:
ID
5767
5769
5768
5772
5773
5774

Parameter
MOP Minimum load
MOP Hysteresis
MOP Reserve power
MOP Add on delay
MOP Add on delay at rated load
MOP Add off delay

Value
40 kW
20 kW
10 kW
30 s
10 s
60 s

Comment
The minimum load in mains parallel operation is 40 kW
The reserve power hysteresis in mains parallel operation is 20 kW
The reserve power in mains parallel operation is 10 kW
The add on delay in mains parallel operation is 20 seconds
The add on delay at rated load in mains parallel operation is 10 seconds
The add off delay in mains parallel operation is 60 seconds
Table 3-3: Configuration of load-dependent start/stop MOP

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Configuring Automatic Operation

From the main screen on the unit select Parameter -> Configuration -> Configure application -> Configure automatic run and configure the LogicsManager function "Start req in AUTO" as shown in Figure 4-2 on page 20 to
start the generator in Automatic operating mode if discrete input [DI 02] ("09.02 Discrete input 2") is energized
or a remote start request ("04.13 Remote request" = start via interface) is issued.

Figure 3-3: Example - configuring Start in Auto (LM)

Configuring Emergency Operation

The emergency operation is to be configured that it is initiated if the mains fail for at least 3 seconds or the MCB
cannot be closed.
From the main screen on the unit select Parameter -> Configuration -> Configure application -> Configure emergency run and configure the following parameters:
ID
2802
2800
3408

Parameter
On/Off
Mains fail delay time
Emerg. start with MCB failure

Value
On
3.00 s
Yes

Comment
Emergency operation is enabled
Emergency operation is initiated if the mains fail for a t least 3 seconds
Emergency operation is initiated if the MCB fails to close
Table 3-4: Configuration of emergency operation

Configuring Import/Export Power Control

The power controller is to be configured to use the internal power set point 1, which is to be configured to 0 kW
import power.
From the main screen on the unit select Parameter -> Configuration -> Configure application -> Configure controller -> Configure load control and configure the following parameters:
ID
5539
5526
5520

Parameter
Load setpoint 1 source
Load setpoint 1
Int. load control setpoint 1

Value
05.04. Internal pwr. setp.1
Import
0 kW

Comment
The internal power set point 1 is used as load set point 1
The internal power set point 1 is a import power value
The internal power set point 1 is configured to 0 kW
Table 3-5: Configuration of import/export power control

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Chapter 4.
Special Application Examples
Generator Excitation Protection

The easYgen-3000 Series provides the user with power factor monitoring. These monitoring functions permit for
protection of the generator over- and under-excitation. The power factor monitoring consists of a warning alarm
and/or a shutdown alarm when enabled. An alarm and the specified action will be initiated if the monitored power factor surpasses the defined limits. Typically the generator is monitored for loss of excitation and/or over excitation in a mains parallel application. When a generator plant is paralleled against a utility, it is possible to control
the power factor at a desired reference. When the plant is operated in an island mode or isolated parallel application, it is not possible to control the power factor. The load will dictate what the power factor is due to the reactive nature of the load.
Figure 4-1 shows a typical power factor (generator excitation) protection range, where the desired range of operation (green area) is from 0.7 lagging (capacitive) to 0.8 leading (inductive). When the power factor exceeds either
of these limits by entering the yellow shaded areas starting at 0.7 lagging or 0.8 leading for more than 30 seconds,
a class B warning alarm is initiated. If the power factor exceeds the desired range further and enters the red
shaded areas starting at 0.5 lagging or 0.6 leading for 1 second, a class E alarm is initiated and the generator is
shut down.
Shut down: Power Factor < 0.5 Lagging

Warning: Power Factor < 0.8 Leading

Shut down: Power Factor < 0.6 Leading

Warning: Power Factor < 0.7 Lagging

- 0.5

- 0.75

1.00

0.75

0.5

Figure 4-1: Example - generator excitation protection

In order to achieve the described protection, the power factor monitoring parameters (refer to Configuration Manual 37469 for more information) have to be configured according to Table 1-1: Manual - overview.
Generator power factor lagging level 1
ID
Text
Setting
2325
Monitoring
ON
2329
Limit
+0.700
2330
Delay
30.00 s
2326
Alarm class
B
2327
Self acknowledge
NO
2328
Delayed by engine speed YES

Generator power factor lagging level 2

ID
Text
Setting
2331
Monitoring
ON
2335
Limit
+0.500
2336
Delay
1.00 s
2332
Alarm class
E
2333
Self acknowledge
NO
2334
Delayed by engine speed YES

Generator power factor leading level 1

ID
Text
Setting
2375
Monitoring
ON
2379
Limit
-0.800
2380
Delay
30.00 s
2376
Alarm class
B
2377
Self acknowledge
NO
2378
Delayed by engine speed YES

Generator power factor leading level 2

ID
Text
Setting
2381
Monitoring
ON
2385
Limit
-0.600
2386
Delay
1.00 s
2382
Alarm class
E
2383
Self acknowledge
NO
2384
Delayed by engine speed YES
Table 4-1: Example - generator excitation protection

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Configuring a Set Point Control via Analog Input

The following example illustrates how to configure an easYgen for using an external load set point via analog input [AI 03]. The external set point may be enabled using a switch, wired to discrete input [DI 09]. An analog
0 to 20 mA input is to be used where 4 mA corresponds with 0 % power (0 MW), 12 mA corresponds with 50 %
power (1 MW), and 20 mA corresponds with 100 % power (2 MW).

Configuring the Rated Generator Power

From the main screen on the unit select Parameter -> Configuration -> Configure measurement and configure the
following parameter:
ID
1752

Parameter
Gen. rated active power [kW]

Value
2000

Comment
Generator rated power of 2 MW
Table 4-2: Configuration of the rated generator power

Configuring the Analog Input for Real Power Set Point

From the main screen on the unit select Parameter -> Configuration -> Configure application -> Configure inputs/outputs -> Configure analog inputs -> Analog input 3 and configure the following parameters:
ID
1100
1101
1102
1139
1140
1120
1103
1104
1105
10116
3636
3637

Parameter
Type
User defined min display value
User defined min display value
Sender value at display min.
Sender value at display max.
Sender type
Monitoring wire break
Wire break alarm class
Self acknowledge wire break
Filter time constant
Bargraph minimum
Bargraph maximum

Value
Linear
+00000
+10000
020.00%
100.00%
0 - 20mA
Low
Class B
No
Off
+00000
+10000

Comment
A user-defined linear characteristic curve is to be used
A value of 000.00 % is displayed at the minimum of the input range
A value of 100.00 % is displayed at the maximum of the input range
The sender value at minimum display is 20 % i.e. 4 mA
The sender value at maximum display is 100 % i.e. 20 mA
A 0 to 20 mA sender is used on the analog input
If the analog signal falls below 2 mA, a wire break is indicated
An alarm of class B will be issued in case of a wire break
A wire break is not automatically cleared after it has been repaired
No filter time constant is applied to the analog signal
The start value for the bargraph display of the analog input is 00000
The end value for the bargraph display of the analog input is 10000
Table 4-3: Configuration of the analog input for real power set point

The following parameters may only be changed using ToolKit and serve for a more detailed display of the analog
value:
ID
1125
1135

Parameter
Description
Value format

Value
ActivePower SP (%)
000.00%

Comment
Analog input [AI 03] is labeled with "ActivePower SP (%)" on the display
The value format of the bargraph display of the analog input is "000.00%"

Table 4-4: Configuration of the analog input for real power set point - ToolKit only parameters

Configuring the Load Controller

The load controller is to be configured that it uses a fixed load setpoint 1 of 2 MW unless a switch energizes discrete input [DI 09] for enabling a variable load setpoint 2, which is controlled by analog input [AI 03].
From the main screen on the unit select Parameter -> Configuration -> Configure application -> Configure controller -> Configure load control and configure the following parameters:
ID
5539
5526
5520
5540
5527

Parameter
Load setpoint 1 source
Load setpoint 1
Int. load control setpoint 1
Load setpoint 2 source
Load setpoint 2

Value
05.04 Internal pwr. setp.1
Constant
02000.0kW
06.03 Analog input 3
Constant

Comment
Internal power setpoint 1 is used as setpoint 1
A constant load is to be controlled for setpoint 1
A constant load of 2 MW is to be used for internal setpoint 1
Analog input 3 is used as setpoint 2
A constant load is to be controlled for setpoint 2
Table 4-5: Configuration of the load controller

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Configure the LogicsManager function "Setp. 2 load" as shown in Figure 4-2 on page 20 to enable load setpoint 2
if discrete input [DI 09] is energized.

Figure 4-2: Example - configuring load setpoint 2 for [DI 05]

Viewing the Load Set Point on the easYgen

After the unit is configured as described above, the "Setpoint" screen may be viewed from the main screen by selecting Next page -> Setpoints.
Figure 4-3 shows the "Setpoint" screen with enabled load setpoint 2 ([DI 09] is energized). This is indicated by
the figure "2" in fromt of the load setpoint section. A generator load of approx. 1 MW (~50 % or 12 mA) is displayed.

Figure 4-3: Example - Setpoints screen

The "Analog inputs" screen may be viewed from the main screen by selecting Next page -> Measured values ->
Analog inputs/outputs.
Figure 4-3 shows the "Analog inputs" screen with the display of analog input [AI 03] at the bottom (labeled "ActivePower SP"). Analog input [AI 03] is displayed with an input signal of approx. 50 % (~12 mA or 1 MW).

Figure 4-4: Example - Analog inputs screen

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Creating Self-Toggling (Pulsing) Relays Using LogicsManager

Various functions are possible with the LogicsManager. This is a simple example of a relay output that toggles
from energized to de-energized in automatic mode with adjustable on and off time. This pulsing relay may be
combined with a flexible limit, which can be programmed with a function like low battery voltage to get a blinking warning light.
Relay 2 is the discrete output (DO 2) and Flag 5 is used as an auxiliary flag. Relay 2 will be ON (energized) for 2
seconds and then OFF (de-energized) for 2 seconds as long as the easYgen is in automatic mode.

Figure 4-5: Example - configuring Flag 5 for a pulsing relay

In this example is the Delay ON time in the LogicsManager of Flag 5 indicates how long the pause is. The Delay
OFF time of Relay 2 is the pulse duration.

Figure 4-6: Example - configuring Relay 2 for a pulsing relay

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Changing a Starter Battery Set Using LogicsManager

Various functions are possible with the LogicsManager. The following programming example shows how two relay outputs are energized by turns when discrete input 9 is energized. At first time, discrete output 11 will be
energized, then, discrete output 12 will be energized, then discrete output 11 and so on.
This logic may be used to change between two starter battery sets for each starting cycle.
Configure Relay 11 and Relay 12 as well as the Flags 2, 3, 4, and 5 as shown in the following example. You may
also use the discrete input, which starts the engine by default (DI 2) or any other input command instead of discrete input 9; for example the command variable 03.06 "Engine released".

Figure 4-7: Example - configuring Relay 11 for a battery change logic

Figure 4-8: Example - configuring Relay 12 for a battery change logic

Figure 4-9: Example - configuring Flag 2 for a battery change logic

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Figure 4-10: Example - configuring Flag 3 for a battery change logic

Figure 4-11: Example - configuring Flag 4 for a battery change logic

Figure 4-12: Example - configuring Flag 5 for a battery change logic

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Performing Remote Start/Stop and Acknowledgement

The easYgen-3000 Series controller may be configured to perform start/stop/acknowledgement functions remotely through the CAN bus or Modbus. The required procedure is detailed in the following steps.

NOTE
Refer to the operation manual 37470 for a detailed description of the navigation through the various
display screens. A detailed description of the individual parameters may be found in the configuration
manual 37469.
Be sure to enter the password for code level 2 or higher to be able to access the required configuration
screens.
Refer to the configuration manual 37469 for a description of the installation, configuration and usage of
the ToolKit visualization and configuration application.

Preliminary Conditions
We recommend to reset the unit to factory settings before proceeding. Refer to the System Management section
of the Parameters chapter in the configuration manual 37469 for reference. The LogicsManager factory settings
are shown in the Factory Settings section of the LogicsManager appendix of the configuration manual 37469.

Operating Modes
Two operating modes may be used with remote control:
1.
2.

STOP
AUTOMATIC

It is possible to fix the operating mode using the LogicsManager function 00.16 "Operat. mode AUTO" (parameter ID 12510).
The Operat. mode AUTO LogicsManager function (parameter ID 12510) can be configured as shown in Figure
4-13. AUTOMATIC operation mode is always enabled.

Figure 4-13: Configuration - Operat. mode AUTO

If an alarm of alarm class C through F occurs in AUTOMATIC operating mode, the control does not return to
STOP operating mode if the alarm is cleared after acknowledgement and a restart is initiated.

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It is also possible to configure a discrete input for controlling the operating mode using the LogicsManager function 00.16 "Operat. mode AUTO" (parameter ID 12510) and 00.18 "Operat. mode AUTO" (parameter ID 12530).
The Operat. mode AUTO LogicsManager function (parameter ID 12510) can be configured as shown in Figure
4-13. AUTOMATIC operation mode is enabled as soon as discrete input 9 is energized.

Figure 4-14: Configuration - Operat. mode AUTO

The Operat. mode STOP LogicsManager function (parameter ID 12530) can be configured as shown in Figure
4-13. STOP operation mode is enabled as soon as discrete input 9 is de-energized.

Figure 4-15: Configuration - Operat. mode STOP

Setting Up a Test With or Without Load

There are a lot of different opinions of the behavior of a proper test mode. The easYgen-3000 Series can support
the following two modes: Test with load and test without load. Both modes work only in automatic mode. The
correct test mode depends on your local specifications.
Test With Load
This is the LogicsManager function "Start req. in AUTO" (parameter 12120). No special message appears on the
display. If the mains fail during start in auto, the unit keeps running until the mains return and the mains settling
time is expired or the conditions for "Start req. in AUTO" are FALSE again. It depends on which is longer active.
Test Without Load
This is the LogicsManager function "Start w/o load" (parameter 12540). If the conditions for this LogicsManager
function are TRUE, the engine will provide an automatic starting sequence and keep the generator running until
this function is FALSE again. Then the unit will perform an automatic stop sequence and remain stand by in auto
mode. The message "Start w/o load" is displayed during the test without load. If the mains fails during test without load and the emergency mode is enabled, the unit will take over the load.
It will open the MCB and close the GCB. When the mains return, it will transfer the load back to the mains according to the configured breaker transition mode after the mains settling timer has expired. The engine will keep
running until the conditions for "Start w/o load" are FALSE again.

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Example for test without load: The engine shall start once a month and run for one hour without overtaking the
load. The test day shall be every fifteenth of a month (with flag 2). A relay output can be configured that this test
is running, e.g. for a signal lamp.
The following settings are to be made for the timer:
ID
1663
1662

Parameter
Active day
Active hour

Value
15
10

Comment
The active day is enabled every fifteenth of the month
The active hour is enabled between 10:00 and 11:00 am every day
Table 4-6: Timer configuration

The LogicsManager function Flag 2 (parameter ID 12240) can be configured as shown in Figure 4-16. Flag 2 becomes TRUE as soon as the configured active day and active time is reached.

Figure 4-16: Configuration Flag 2 (timer)

The Start without load LogicsManager function (parameter ID 12540) can be configured as shown in Figure
4-17. Start without load mode is enabled as soon as Flag 2 becomes TRUE.

Figure 4-17: Configuration - Start w/o load

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Remote Start/Stop and Acknowledgement

The easYgen may be started, stopped, or acknowledged with Modbus or CAN protocol via the interface. Two
logical command variables are available for this in the LogicsManager:
04.13
04.14

Remote request
Remote acknowledge

Configuration of the LogicsManager Functions via HMI and/or ToolKit

Start Request in AUTOMATIC Operating Mode
Navigate to the "Configure automatic run" screen by pressing the following softkeys in this sequence:
Parameter -> Configuration -> Configure application -> Configure automatic run
Navigate to the entry "Start req in AUTO" by using the
AUTO" LogicsManager screen.

and

softkeys and press

to enter the "Start req in

Figure 4-18: Example - remote start request

Configure the "Start req in AUTO" LogicsManager function as above using the
softkeys and Confirm the change by pressing the

and

as well as

and

softkey:

With this setting, the "Start req in AUTO" LogicsManager output becomes TRUE as soon as the remote request
signal is enabled.
Press

until you return to the start screen.

NOTE
The LogicsManager commands 2 and 3 may be used to configure additional conditions like discrete
inputs, which must be energized to be able to issue the remote start request.

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External Acknowledgement
Navigate to the "Configure automatic run" screen by pressing the following softkeys in this sequence:
Parameter -> Configuration -> Configure monitoring -> Miscellaneous
Navigate to the entry "Ext. acknowledge" by using the
knowledge" LogicsManager screen.

and

softkeys and press

to enter the "Ext. ac-

Figure 4-19: Example - remote acknowledgement

Configure the "Ext. acknowledge" LogicsManager function as above using the

softkeys and Confirm the change by pressing the

and

as well as

and

softkey:

With this setting, the "Ext. acknowledge" LogicsManager output becomes TRUE as soon as the remote acknowledge signal is enabled.

NOTE
The LogicsManager commands 2 and 3 may be used to configure additional conditions like discrete
inputs, which must be energized to be able to issue the remote acknowledge command.

Please refer to the Interface Manual 37472 for a description of how to configure the LogicsManager functions via
Modbus.

NOTE
All interfaces access to the same bits. The command variable "04.13 Remote request" remains enabled
in the easYgen until a new command is sent or the power supply failed or is removed.

Remote start: The command variable "04.13 Remote request" changes to "1" (high) if the start bit (ID 503, bit 0)
changes from "0" to "1". The command variable "04.13 Remote request" changes to "0" (low) if the stop bit
(ID 503, bit 1) changes from "0" to "1" (refer to Figure 4-20 on page 29).
Acknowledgement: The command variable "04.14 Remote acknowledge" reflects the acknowledgement bit
(ID 503, bit 4).
An acknowledgement is generally performed twice:
1st change of the logical output "External acknowledge" from "0" to "1": Silence horn
2nd change of the logical output "External acknowledge" from "0" to "1": Acknowledges all inactive alarms

ATTENTION
The easYgen does NOT react on the disabling of the start bit, but only on the enabling of the stop bit.
This has the advantage that it is not required to maintain the connection established for the whole time
in case of a remote start.

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The following figure shows the reaction of the command variable on the various changes of the bits:
Start bit

Stop bit

Com. var. 04.13

Remote request
no reaction,
because simultanous

stops, because
higher prioritized

Figure 4-20: Example - command variable

Enabling the bits may be performed with several methods:

Bit Enabling via Modbus Protocol and RS-485 Interface

The parameter Modbus Slave ID must be configured. The control bits are sent on address 503 for a start via
Modbus.
Bit 0
Bit 1
Bit 4

Start
Stop
Acknowledgement

Bits 2 and 3 must be "0" (for the watchdog).

Please refer to the Interface Manual 37472 for a description of how to enable control bits via Modbus.

Bit Enabling via CANopen Protocol and CAN Interface 1

Protocol CANopen:

For further information refer to the interface manual 37472 and the CANopen file *.eds,
which is delivered with the unit.

Please refer to the Interface Manual 37472 for a description of how to enable control bits via CAN bus.

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Connecting an IKD 1 on CAN Bus 1

We recommend to connect external expansion boards, like the Woodward IKD 1 to CAN bus 2. This CAN bus
offers preconfigured settings for operating several expansion boards including the IKD 1.
However, it is also possible to connect an IKD 1 to CAN bus 1. Proceed as follows for this.

easYgen Configuration
Refer to the easYgen-3000 Series Configuration Manual 37469 for the configuration of the unit and the parameters concerned. Refer also to the easYgen-3000 Series Interface Manual 37472 for a description of the data objects.
The easYgen may either be configured directly using the display screens or using the ToolKit software. The following screenshots show both options.
Transmit PDO
The easYgen must be configured for sending objects with the index 8001 (external DOs 1 to 8) and 3 x 8000 on
CAN ID 181 (hex) every 20 ms on TPDO1. This is used to send messages to an external device. For this, TPDO1
must be configured as follows:
ID
9600
9602
9604
8962

Parameter
COB-ID
Transmission type
Event timer
Selected Data Protocol

Value
181 (hex) / 385 (dec)
255
20ms
65000

Comment
The COB-ID is configured to 181 (hex) or 385 (dec)
Data is automatically broadcasted (transmission type 255)
The event timer is configured to 20 ms
Data protocol 65000 is selected
Table 4-7: Configuration of TPDO1 for an IKD 1

Figure 4-21: Configuration of TPDO1 for an IKD 1

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Receive PDO
The easYgen must be configured for receiving data on an RPDO. The data received on CAN ID 201h is interpreted as object with the index 8011 (external DIs 1 to 8). For this, RPDO1 must be configured as follows:
ID
9300
9121
8970

Parameter
COB-ID
Event timer
Selected Data Protocol

Value
201 (hex) / 513 (dec)
2000ms
65000

Comment
The COB-ID is configured to 201 (hex) or 513 (dec)
The event timer is configured to 2000 ms
Data protocol 65000 is selected
Table 4-8: Configuration of RPDO1 for an IKD 1

Figure 4-22: Configuration of RPDO1 for an IKD 1

IKD 1 Configuration
Refer to the IKD 1 Manual 37135 for the configuration of the unit and the parameters concerned. Please note that
the DPC cable (P/N 5417-557) together with the LeoPC1 software is required to configure the IKD 1.
The IKD 1 must be configured as follows to communicate with an easYgen:
ID
-

Parameter
CAN Node ID
CAN ID receive data
CAN ID send data
Physical state only

Value
0
385 (dec)
513 (dec)
Yes

Comment
The CAN node ID is configured to 0
The CAN ID for receive data is configured to 385 (dec)
The CAN ID for send data is configured to 513 (dec)
Only the physical state of the IKD 1 inputs is evaluated
Table 4-9: Configuration of the IKD 1

Figure 4-23: Configuration of the IKD 1

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Baudrate Configuration
The baud rate must be configured identical in the easYgen and the IKD 1. The following example shows the configuration of both units to 250 kBd:

Figure 4-24: Configuration of the baud rate

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Configuration for a Second IKD 1

If a second IKD 1 shall be connected to the easYgen, the following settings must be made to TPDO2 and RPDO2
in the easYgen:

Figure 4-25: Configuration of the easYgen for a second IKD 1

The second IKD 1 must be configured as follows to communicate with an easYgen:

Figure 4-26: Configuration of the second IKD 1

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Configuring a PWM Duty Cycle for a CAT ADEM Controller

If a PWM signal shall be used with a CAT ADEM speed controller, the duty cycle must be limited between 10%
and 85%. For this, the following settings must be made to the respective analog output (the following parameter
IDs and figures refer to analog output 1; however, another analog output may also be used):
ID
5200
5201
5208
5209
5202
5210

Parameter
Data source
Selected hardware type
User defined min. output value
User defined max. output value
PWM signal
PWM output level

Value
[00.03] Speed bias
User defined
10.00%
85.00%
On
10.00V

Comment
A speed signal will be output
A user-defined hardware type will be used
The minimum output value of the user-defined hardware type is 10%
The minimum output value of the user-defined hardware type is 85%
The PWM signal is enabled
The PWM output level is configured to 10 V
Table 4-10: Configuring a PWM duty cycle for a CAT ADEM controller

Figure 4-27: Configuring a PWM duty cycle for a CAT ADEM controller

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Connecting a GSM Modem

RS-232

easYgen-3000

INSYS
GSM Modem
http://www.insys-tec.de

Notebook with modem

and Windows operating
system 2000, XP, or Vista
and ToolKit application SW
Figure 4-28: Connecting a GSM modem

Function
It is possible to establish a cellular connection to the system using a GSM modem. This application is intended
for mobile use. It is also interesting to trigger a call in case of an alarm with this application. The GSM modem
provides a discrete input for this, which can trigger e.g. a short message (SMS) (depending on the network provider, it can also be possible to send a fax message).
Different actions can be performed 'online' using the ToolKit application software, which is delivered on the CDROM with the control. These actions include:
Configuration
Visualization
Transfer settings to and from the hard drive

Preconditions for this Example

easYgen-3000
Straight serial cable for connecting the easYgen with the GSM modem
Wireless modem INSYS GSM 4.2 with antenna (http://www.insys-tec.de)
SIM card with data transfer enabled (to be enabled by the GSM provider)
PC or notebook with Windows OS 2000, XP, or Vista with modem (we recommend to use the Windows
standard driver for older modems (e.g. ELSA Microlink 56k) if the dedicated driver does not work)
Application software ToolKit version 2.2 or higher
Configuration files available (*.sid, *.wtool)
FAX/SMS receiver for receiving alarm messages

NOTE
If a SIM card is used, which is enabled to send SMS messages, an SMS can be sent by the GSM modem. To establish a data connection, data transfer has to be enabled by the network provider.

NOTE
The INSYS GSM Modem 4.2 has two discrete inputs, which can be used to send two different alarm
messages. One relay of the easYgen is required for each alarm message.

NOTE
The easYgen does not send AT commands to the connected modem. The dispatch of an alarm message is performed by the modem after energizing a discrete input.
If a different modem is used, this has to accept incoming calls automatically and establish a connection between calling PC and easYgen.

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Connection

RS-232

Serial 1

RS-232

It is possible to issue an active call in case of a malfunction using a relay of the relay manager. Connect the easYgen and the modem with the power supply as directed.

8
7

DO

12/24 V
easYgen-3000

Alarm input 1

63
64
INSYS GSM 4.2

Figure 4-29: GSM modem connection

NOTE
Use the straight RS-232 cable delivered with the GSM modem for connecting the easYgen with the modem.
When commissioning the system, use a null modem cable to configure the easYgen via a PC with
ToolKit.

easYgen Settings
Configure the following setting in the easYgen (refer to the Configuration Manual 37469) to connect to the modem for configuration purposes (the same settings must be configured in the modem):
ID
3163
3161
3162
7901

Parameter
Baudrate
Parity
Stop bits
Enable ServLink protocol

Value
9600 Bd
No
One
Yes

Comment
The baud rate is set to 9600 Baud
The transmission protocol is configured without parity
The transmission protocol is configured with one stop bit
The ServLink protocol is enabled
Table 4-11: Configuring the easYgen for GSM modem connection

NOTE
If the transmission quality of the phone line is poor, the baud rate should be lowered since no data flow
control is performed between easYgen and modem.
Generally, the connection via modem is a bit slower than a direct connection of PC and easYgen.

Configure the relay(s) connected with the modem using the easYgen LogicsManager (refer to the Configuration
Manual 37469).

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ToolKit Settings
In ToolKit, select Connect from the Device menu to open the Communications window. Select the modem
(this must be installed and configured under Windows) from the network list, enter the phone number and click
the Connect button to establish a connection with the modem.

Figure 4-30: Connecting ToolKit with a GSM modem

GSM Modem Settings

INSYS Microelectronics provides the application software HS-COMM to configure the GSM modem for the application. Refer to the operation manual of the modem for detailed information.
The following settings show an example for sending an alarm message as a short message.
Descriptions of the individual parameters can be taken from the operation manual of the modem.
Settings Using the Configuration Software
Make the following settings on the Basic Settings tab. These settings configure the modem to accept an incoming
call for remote configuration. The phone number and text can be configured as required.

Figure 4-31: Configuring the GSM modem software

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Make the following settings on the Alarm/Output 1 tab. The phone number and the text can be set as required.

Figure 4-32: Configuring alarm input 1 in the GSM modem software

Make the following settings on the Alarm/Output 2 tab. The phone number and the text can be set as required.

Figure 4-33: Configuring alarm input 2 in the GSM modem software

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Connecting a Landline Modem

RS-232

Phoenix
landline modem
with discrete input for dial up

Notebook with modem

and Windows operating
system 2000, XP, or Vista
and ToolKit application SW
Figure 4-34: Connecting a landline modem

Function
It is possible to establish a phone connection to the system using a modem. This application is intended for stationary use, where a steady remote control is required.
It is also interesting to trigger a call in case of an alarm with this application. The Phoenix modem provides a discrete input for this, which can trigger e.g. a call or a fax message.
Different actions can be performed 'online' using the ToolKit application software, which is delivered on the CDROM with the control. These actions include:
Configuration
Visualization
Transfer settings to and from the hard drive

Preconditions for this Example

easYgen-3000
Straight serial cable for connecting the easYgen with the modem
Phoenix PSI data/fax modem/RS232 (www.phoenixcontact.com)
PC or notebook with Windows OS 2000, XP, or Vista with modem (we recommend to use the Windows
standard driver for older modems (e.g. ELSA Microlink 56k) if the dedicated driver does not work)
Application software ToolKit version 2.2 or higher
Configuration files available (*.sid, *.wtool)
FAX/SMS receiver for receiving alarm messages

NOTE
Sending an SMS via the fixed-network line may be enabled by the network provider.

NOTE
The Phoenix PSI-Data/Fax-Modem/RS232 has one discrete input, which can be used to send an alarm
message. One relay of the easYgen is required for the alarm message. It is also possible to use the
switch output of the modem to operate a discrete input of the easYgen, for example for a remote start.

NOTE
The easYgen does not send AT commands to the connected modem. The dispatch of an alarm message is performed by the modem after energizing a discrete input.
If a different modem is used, this has to accept incoming calls automatically and establish a connection between calling PC and easYgen.

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Connection

RS-232

Serial 1

RS-232

It is possible to issue an active call in case of a malfunction using a relay of the relay manager. Connect the easYgen and the modem with the power supply as directed.

i+
i-

DO

12/24 V
easYgen-3000

63
64

Alarm input

Phoenix Modem
PSI-DATA/RS232

Figure 4-35: Landline modem connection

NOTE
Use a straight RS-232 cable (not delivered with the modem) for connecting the easYgen with the modem.
When commissioning the system, use a null modem cable to configure the easYgen via a PC with
ToolKit.

easYgen Settings
Configure the following setting in the easYgen (refer to the Configuration Manual 37469) to connect to the modem for configuration purposes (the same settings must be configured in the modem):
ID
3163
3161
3162
7901

Parameter
Baudrate
Parity
Stop bits
Enable ServLink protocol

Value
4800 Bd
No
One
Yes

Comment
The baud rate is set to 4800 Baud
The transmission protocol is configured without parity
The transmission protocol is configured with one stop bit
The ServLink protocol is enabled
Table 4-12: Configuring the easYgen for landline modem connection

NOTE
If the transmission quality of the phone line is poor, the baud rate should be lowered since no data flow
control is performed between easYgen and modem.
Generally, the connection via modem is a bit slower than a direct connection of PC and easYgen.
The maximum baud rate depends on the used modem. The easYgen supports the following baud rates:
2400, 4800, 9600, 14400, 19200, 38400, 65000, and 11500 Bauds.

Configure the relay(s) connected with the modem using the easYgen LogicsManager (refer to the Configuration
Manual 37469).

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ToolKit Settings
In ToolKit, select Connect from the Device menu to open the Communications window. Select the modem
(this must be installed and configured under Windows) from the network list, enter the phone number and click
the Connect button to establish a connection with the modem.

Figure 4-36: Connecting ToolKit with a landline modem

Phoenix Modem Settings

The settings refer to an example for sending an alarm message via fax.
Descriptions of the individual parameters can be taken from the operation manual of the modem.
DIP Switches
All DIP switches are set to OFF (default state).
Settings using the configuration software
Phoenix provides an application software to configure the modem for the application. Refer to the operation manual of the device for detailed information.
The following settings form an example for sending an alarm message via fax.
Descriptions of the individual parameters can be taken from the operation manual of the modem.

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To configure the modem, proceed as follows.

Configure the COM port

The phone number and the text can be

set as required.

These settings configure the modem to

accept an incoming call for remote
configuration.

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Wiring Self-Powered DIs

Discrete input [DI 12]

Discrete input [DI 11]
Discrete input [DI 10]
Discrete input [DI 9]
Discrete input [DI 8]
Discrete input [DI 7]
Discrete input [DI 6]
Discrete input [DI 5]
Discrete input [DI 4]
Discrete input [DI 3]
Discrete input [DI 2]
Discrete input [DI 1]

Power supply 12/24 V

63 64

Protective Earth PE

61

Common (terminals 67 to 78)

66 67 68 69 70 71 72 73 74 75 76 77 78

In order to create self-powered discrete inputs, it is required to connect battery negative (B-) to ground and PE
(terminal 61). Moreover, DI common (terminal 66) must be connected to Power supply 12/24 V (terminal 63,
minimum wire size 0.5 mm (20 AWG)).
Now, it is possible to energize the discrete inputs against ground.

Power supply 0 V

B+

B-

Figure 4-37: Wiring self-powered DIs

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Connecting Analog Inputs in Series (Multiple Devices)

The analog inputs of the easYgen-3000 Series are galvanically isolated. This enables a series connection for up to
3 analog inputs. This connection allows for example to share a power setpoint for up to 3 devices.
The example shows the terminal numbers for the analog input #3, but in principle it works for all analog inputs
which support a 0-20 mA signal.
easYgen-3000 Series

Source
0-20 mA

14

13

easYgen-3000 Series

Analog input 3

14

13

easYgen-3000 Series

Analog input 3

14

13

Analog input 3

Figure 4-38: Example connecting analog inputs in series

Phoenix Expansion Modules

Supported Phoenix Modules

Bus coupler

Discrete outputs

Discrete inputs

Analog outputs

Analog inputs

IL CAN BK

IB IL 24 DO 2

IB IL 24 DI 2

IB IL AO 2/SF *1

IB IL AI 2/SF *1

IB IL 24 DI 4

IB IL TEMP 2 UTH *1

IB IL 24 DO 16 *

IB IL 24 DI 8

IB IL TEMP 2 RTD *1

IB IL 24 DO 32 *1

IB IL 24 DI 16

IB IL 24/230 DOR4/W

IB IL 24 DI 32

IB IL 24 DO 8
1

Table 4-13: Supported Phoenix Modules

1

* easYgen-3000 Series (Package P2) only

NOTE
Phoenix module ILB CO 24 DI 16 DO 16 is not supported.

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Possible Combinations
The possible combinations of Phoenix modules are listed below. The parameters display the maximum extension.
It is also possible to connect fewer modules. For example choose parameter ID 9941 (12AI 4AO) for connecting
10 AI and 1 AO. It is possible to use multiple Phoenix modules with one bus coupler. Each single value in the
marked screenshot can be handled by one bus coupler.

x
x
x
x

x
x
x
x

x
x
x

Phoenix 16AI 4AO DI/DO 1..32

x
x
x

Phoenix 12AI 4AO DI/DO 1..32

Phoenix 16AI 4AO

x
x
x

Phoenix 8AI 4AO DI/DO 1..32

Phoenix 12AI 4AO

x
x
x

Phoenix 4AI 4AO DI/DO 1..32

Phoenix 8AI 4AO

Phoenix Di/DO 1..32

x
x

Phoenix 4AI 4AO

Phoenix Di/DO 1..16

Phoenix Di/DO 17..32 *1
Phoenix Di/DO 1..32 *1
Phoenix 4AI 4AO *1
Phoenix 8AI 4AO *1
Phoenix 12AI 4AO *1
Phoenix 16AI 4AO *1
Phoenix 4AI 4AO DI/DO 1..32 *1
Phoenix 8AI 4AO DI/DO 1..32 *1
Phoenix 12AI 4AO DI/DO 1..32 *1
Phoenix 16AI 4AO DI/DO 1..32 *1

Phoenix Di/DO 17..32

Phoenix Di/DO 1..16

Figure 4-39: Configuring the Phoenix modules

x
x
x
x

Table 4-14: Possible combinations of Phoenix modules

*1 easYgen-3000 Series (Package P2) only

NOTE
There is a maximum of three bus couplers on the CAN bus. There is also a maximum of 16AI 4AO
DI/DO 1..32, which must not exceeded in all possible combinations.
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Setup
Baud rate
Set the Baud rate of CAN #2 in the easYgen and the Phoenix module to the same value. All members on the
CAN bus need to have the same baud rate.

Figure 4-40: Configuring the interface baud rate

Each bus coupler has 10 DIP switches. These switches are located on the left side of the CANopen bus coupler.
DIP switches 1 through 7 are used to set the node address and DIP switches 8 to 10 are used to set the baud rate.

Figure 4-41: Set the Phoenix baud rate

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Set the Node-ID

Set the Node-ID for the configuration you are using.

Figure 4-42: Enter the Phoenix Node-ID

The node address is set using DIP switches 1 through 7. DIP switch 1 is the least significant digit of the node address and DIP switch 7 is the most. Valid node address settings range from 1 to 127. Note that the UL power will
need to be cycled in order to implement any changes to the node address. Node address 0 is reserved, and used to
auto-configure the I/O attached to the module. The unit will not go online at address 0.

Figure 4-43: Set the Phoenix Node-ID

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Confirm Your Changes

Initialize the startup routine in the phoenix device. Set parameter ID 15134 "Configure external devices" to "yes"
to confirm your changes in the easYgen.

Figure 4-44: Confirming your changes

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Configure External Inputs/Outputs

Configure External DI

Figure 4-45: Configure external DI

Configure External DO
Click "Edit" Button to enter the LogicsManager.

Figure 4-46: Configure external DO

Figure 4-47: Configure the input condition

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Configure External AI (easYgen-3000 Series Package P2 only)

For getting an analog input to work, there are 3 major settings to adjust. The parameter numbers are examples for
the first analog input, they are different for the second one.
Parameter ID 5851 "Type" defines the characteristic curve of the sensor.
Parameter ID 5856 "Sender Type" defines the sensor hardware (be sure that this value matches with the
wired and connected extension board).
Parameter ID 5859 "Sender connection type" defines the wiring of the sensor.

Figure 4-48: Configure external AI

The following table shows the possible configuration combination of the "Type" settings (parameter ID 5851)
and the "Sender type" setting (parameter ID 5856).

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R0=300

R0=400

R0=500

R0=1000

R0=1500

R0=2000

R0=3000

X
X
X
X

R0=240

X
X
X
X

R0=200

X
X
X
X

R0=150

X
X
X
X

R0=50

X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X

R0=120

X
X
X

R0=30

X
X
X

R0=20

X
X
X

R0=10

X
X
X

R0=100

4 - 20mA

X
X
X

Thermocouple

20mA

X
X
X

0 - 400 Ohm

0 - 20mA

X
X
X

0 - 4000 Ohm

10V

OFF
Linear
Table A
Table B
Thermo couple type K
Thermo couple type J
Thermo couple type E
Thermo couple type R
Thermo couple type S
Thermo couple type T
Thermo couple type B
Thermo couple type N
Thermo couple type U
Thermo couple type L
Thermo couple type C
Thermo couple type W
Thermo couple type HK
Pt DIN(R0)
Pt SAMA(R0)
Ni DIN(R0)
Ni SAMA(R0)
Cu10
Cu50
Cu53
Ni 1000(Landis)
Ni 500(Viessm.)
KTY 81-110
KTY 84

0 - 10V

Parameter
Type

Sender Type

0500

X
X
X
X

X
X
X
X

X
X
X
X

X
X
X
X

X
X
X
X

X
X
X
X

X
X
X
X

X
X
X
X

X
X
X
X

X
X
X
X

X
X
X
X

X
X
X
X

Configuration of sender type is not used

NOT ALLOWED
RIGHT CONFIGURATION

Table 4-15: Supported sender types

Configure External AO (easYgen-3000 Series Package P2 only)

By clicking the "Help" button, you get further information and examples regarding the format you need to
choose. For a detailed description of all parameters see the configuration manual.

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Figure 4-49: Example - configure AO 1

Confirm Your Changes

Set parameter ID 15134 "Configure external devices" to "yes" to confirm your changes in the easYgen.

Figure 4-50: Confirming your changes

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Chapter 5.
Examples for Load Sharing Applications
General Information

The following examples show different suggested configurations for load sharing applications. The number of
gensets in a load sharing application is limited by the maximum CAN bus load. The CAN bus load again depends
on the number of messages sent on the bus, i.e. the number of connected peripheral devices. We have tested the
maximum number of gensets for the following common configurations.
It is not important for the following configurations whether Woodward IKD 1 or Phoenix expansion boards are
used for the discrete I/Os, the bus load remains the same.
Any combination of Phoenix expansion boards of the Inline Modular (IL) series and Woodward IKD 1 DI/DO
expansion boards is possible with the following restrictions:
The total number of inputs and outputs must not exceed:
o 32 discrete inputs
o 32 discrete outputs
o 16 analog inputs
o 4 analog outputs
A maximum of three CANopen bus couplers IL CAN BK-TC-PAC (Phoenix order no. 2718701) can be used
Not all IKD 1 / Phoenix DI/O combinations are possible; Table 5-1 shows some possible combinations (the
Phoenix DI/Os may be composed of any combinations of terminal blocks with 2, 4, 8, 16, or 32 inputs/outputs):
DIs 1 to 8
DIs 9 to 16
IKD 1 #1
IKD 1 #2
IKD 1 #1
IKD 1 #2
4 Phoenix DI/Os
IKD 1 #1
IKD 1 #1
16 Phoenix DI/Os
-

DIs 17 to 24
DIs 25 to 32
IKD 1 #3
IKD 1 #4
16 Phoenix DI/Os
IKD 1 #3
8 Phoenix DI/Os
IKD 1 #3
16 Phoenix DI/Os
IKD 1 #3
IKD 1 #4

Table 5-1: IKD 1 - Possible Phoenix usage combinations

Only the following Phoenix analog input terminal blocks may be used:
o IB IL AI 2/SF-PAC (Phoenix order no. 2861302) for connecting 2 analog sources (0-20 mA, 4-20 mA,
20 mA, 0-10 V, 10 V)
o IB IL TEMP 2 UTH-PAC (Phoenix order no. 2861386) for connecting 2 thermocouples
o IB IL TEMP 2 RTD-PAC (Phoenix order no. 2861328) for connecting 2 RTDs
Only the following Phoenix analog output terminal block may be used:
o IB IL AO 2/SF-PAC (Phoenix order no. 2863083) for 2 analog outputs (0-20 mA, 4-20 mA, 0-10 V)
The J1939 analog inputs have been tested with Axiomatic analog input modules

NOTE
The instructions in the Phoenix Contact manuals must be observed.
TPDOs may be used to transmit signals of an external board, which is connected to CAN bus 2, on
CAN bus 1.

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Example Configuration 1 (4 x easYgen-3100)

Max. 4 Gensets
CAN #1:
- ToolKit
- PLC
CAN #2:
- Maximum engine bus load
- Remote panel

Figure 5-1: Example configuration 1

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Example Configuration 2 (4 x easYgen-3100)

Max. 4 Gensets
CAN #1:
- ToolKit
CAN #2:
- Maximum engine bus load
- Remote panel

Figure 5-2: Example configuration 2

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Example Configuration 3 (4 x easYgen-3200)

Max. 4 Gensets
CAN #1:
- ToolKit
- PLC
CAN #2:
- Maximum engine bus load

Figure 5-3: Example configuration 3

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Example Configuration 4 (8 x easYgen-3200)

Max. 8 Gensets
CAN #1:
- PLC
CAN #2:
- Maximum engine bus load
- ToolKit

Figure 5-4: Example configuration 4

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Example Configuration 5 (10 x easYgen-3200)

Max. 10 Gensets
CAN #1:
- PLC
CAN #2:
- Maximum engine bus load

Figure 5-5: Example configuration 5

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Example Configuration 6 (5 x easYgen-3200)

Max. 5 Gensets
CAN #1:
- ToolKit
CAN #2:
- Maximum engine bus load

Figure 5-6: Example configuration 6

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Example Configuration 7 (18 x easYgen-3200)

Max. 18 Gensets
CAN #1:
- load sharing line only
CAN #2:
- Maximum engine bus load
- ToolKit

Figure 5-7: Example configuration 7

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Example Configuration 8 (20 x easYgen-3200)

Max. 20 Gensets
CAN #1:
- load sharing line only
CAN #2:
- Maximum engine bus load

Figure 5-8: Example configuration 8

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Example Configuration 9 (5 x easYgen-3200)

Max. 5 Gensets
CAN #1:
- ToolKit
- PLC
CAN #2:
- ECU
- 32 discrete I/Os
- 32 analog inputs

Figure 5-9: Example configuration 9

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Example Configuration 10 (10 x easYgen-3200)

Max. 10 Gensets
CAN #1:
- PLC
CAN #2:
- ToolKit
- ECU
- 32 discrete I/Os
- 32 analog inputs

Figure 5-10: Example configuration 10

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Example Configuration 11 (12 x easYgen-3200)

Max. 12 Gensets
CAN #1:
- PLC
CAN #2:
- ECU
- 32 discrete I/Os
- 32 analog inputs

Figure 5-11: Example configuration 11

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Example Configuration 12 (12 x easYgen-3200)

Max. 12 Gensets
CAN #1:
- PLC
CAN #2:
- ToolKit
- ECU
- 32 analog inputs

Figure 5-12: Example configuration 12

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Example Configuration 13 (15 x easYgen-3200)

Max. 15 Gensets
CAN #1:
- PLC
CAN #2:
- not used

Figure 5-13: Example configuration 13

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Example Configuration 14 (30 x easYgen-3200)

Max. 30 Gensets
CAN #1:
- load sharing line only
CAN #2:
- ToolKit

Figure 5-14: Example configuration 14

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Example Configuration 15 (32 x easYgen-3200)

Max. 32 Gensets
CAN #1:
- load sharing line only
CAN #2:
- not used

Figure 5-15: Example configuration 15

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We appreciate your comments about the content of our publications.

Please send comments to: stgt-documentation@woodward.com
Please include the manual number from the front cover of this publication.

Woodward GmbH
Handwerkstrasse 29 - 70565 Stuttgart - Germany
Phone +49 (0) 711 789 54-0 Fax +49 (0) 711 789 54-100
stgt-info@woodward.com
Homepage
http://www.woodward.com/power

Woodward has company-owned plants, subsidiaries, and branches, as well as authorized

distributors and other authorized service and sales facilities throughout the world.
Complete address/phone/fax/e-mail information
for all locations is available on our website (www.woodward.com).

2010/05/Stuttgart