Woodward easyYgen LS-6XT Circuit Breaker Control Unit: Technical Characteristics, Installation and Application Guide

Woodward easyYgen LS-6XT Circuit Breaker Control Unit: Technical Characteristics, Installation and Application Guide

Introduction

In the field of modern generator system management and power distribution, intelligent circuit breaker control units play a crucial role. The easyYgen LS-6XT series launched by Woodward is a high-performance control unit designed to meet this demand. As an industrial grade product designed in Germany, LS-6XT not only has excellent reliability, but also provides flexible configuration options and wide application compatibility. This article will delve into the technical characteristics, installation requirements, configuration methods, and practical application scenarios of the device, providing a comprehensive reference guide for engineers and technicians.

Product Overview and Technical Features

1.1 Product positioning and functions

The Woodward easyYgen LS-6XT series is a circuit breaker control unit designed specifically for engine generator system management. This device can be used as an independent unit or combined with Woodward easyYgen-3400/3500XT generator control unit and/or easyYgen | GC-3400XT to form a complete power management system.

The core functions of LS-6XT include:

Dual circuit breaker control (CBA and CBB modes)

System synchronization check and grid connection function

Real time monitoring of power parameters (voltage, current, frequency, power, power factor)

Advanced protection functions (overvoltage, undervoltage, overclocking, underflocking, etc.)

Multiple communication interface support (CAN, Ethernet, RS-485, USB)

Programmable Logic Manager ™） Analog Manager ™）

1.2 Technical Specifications Highlights

According to Chapter 8 "Technical Specifications" of the technical manual, LS-6XT has the following key characteristics:

Measurement performance:

Voltage measurement range: 0-690V AC (phase voltage)

Current measurement range: compatible with 1A/5A CT

Frequency measurement range: 0-75Hz

Power measurement accuracy: ± 0.5% of rated value

Real time clock battery: lithium battery backup

Environmental adaptability:

Working temperature: -25 ° C to+70 ° C

Storage temperature: -40 ° C to+85 ° C

Protection level: Complies with UL standards and is suitable for Type 1 enclosures

Humidity range: 5% to 95% relative humidity (non condensing)

Interface capability:

3 Ethernet ports (10/100Base-T)

CAN bus interface (supporting CANopen protocol)

RS-485 serial interface

USB 2.0 service port

12 digital inputs/12 relay outputs

3 analog inputs/2 analog outputs

1.3 Hardware Configuration and Packaging Content

The standard delivery scope includes:

EasyYgen LS-6XT equipment body

All pluggable terminal connectors

Installation Program Supplemental Instructions (IPS) and Printed QR Code Labels (2 copies)

Configuration files and technical manuals stored in the internal memory of the device

It is worth noting that the documents stored inside the device are in "delivery status" and may not be the latest version. The latest version needs to be obtained from Woodward's official website.

Safety regulations and installation requirements

2.1 Safety precautions

Section 1.3 of the technical manual emphasizes the important safety regulations that must be followed when using LS-6XT:

Personnel qualification requirements:

Electrical work must be carried out by qualified electricians

Operators need to receive relevant training and be familiar with all applicable regulations

Prohibit personnel under the influence of alcohol and drugs from operating equipment

Electrical safety measures:

Ensure that the system is powered off and prevent accidental restarts before operation

Voltage measurement input requires 2-6A slow melting fuse

One end of the CT secondary side must be grounded nearby

The power line requires the use of cables with a temperature rating of not less than 90 ° C

Anti static protection:

Release static electricity by touching grounded metal objects before operation

Suggest using an ESD wristband

Avoid wearing synthetic fiber clothing

Keep plastic and vinyl materials away from the work area

2.2 Mechanical Installation

For the sheet metal shell model (LS-612XT-P1), installation should follow the following steps:

Hole positioning: Drill installation holes according to the hole spacing of 42.45 × 96.2mm

Equipment fixation: Use screws with a maximum diameter of 6mm (M6) for fixation

Torque control: Tighten according to the required torque of the screw quality grade

Wiring space: Ensure sufficient operating space above and below the terminals

Key installation dimensions:

Equipment width: 250mm

Installation hole spacing: horizontal 42.45mm, vertical 96.2mm

Maximum wire diameter: The terminal supports a maximum of 2.5mm ² wire

2.3 Electrical Connections

Power connection:

Power range: 8-40V DC (nominal 12/24V)

Positive terminal connected to terminal 63, negative terminal connected to terminal 64

Protective grounding (PE) connected to the bottom center of the sheet metal shell

Suggest using 6A fuses or C-type miniature circuit breakers for protection

Voltage measurement connection:

System A voltage: terminals 30-36

System B voltage: terminals 22-28

Auxiliary voltage: terminals 38-40

Supports multiple wiring configurations: 3-phase 4-wire, 3-phase 3-wire, 1-phase 3-wire, 1-phase 2-wire

Current measurement connection:

System A current: terminals 3-8 (L1, L2, L3 phases)

System B current: terminals 1-2 (single-phase)

The CT direction should be based on the software version. Note that version 2.10-0 points to system A, while version 2.10-1 and above points to system B

Power measurement configuration:

CBA mode: measuring power flow between system A and system B

CBA/BBB mode: Simultaneously monitor the power status of two circuit breakers

The definition of power factor follows international standards (inductive load is positive, capacitive load is negative)

System configuration and parameter settings

3.1 Access Level and Password System

LS-6XT adopts a multi-level password protection system, providing 5 access levels:

Basic level (CL01): Restricted viewing permission, no configuration permission

Temporary debugging level (AC02): Algorithm code access, expires after session ends

Debugging Level (CL03): General Debugging Parameter Access

Temporary Super Debugging Level (AC04): Algorithm Code Access Advanced Features

Super Debugging Level (CL05): Almost Full Access (except for calibration and super user items)

Access channels include:

Local HMI of the device (basic code input)

USB connection ToolKit (user account login)

Ethernet remote panel (user account login)

Third party devices use Modbus TCP/CANopen/RS-485

3.2 HMI Operation and Navigation

The main screen of the device is divided into five main areas:

Numerical display area: real-time data such as voltage, current, frequency, power, etc

Status message area: operating mode, device status

Alarm message area: Latest unconfirmed alarm

Single line diagram area: visualization of circuit breaker status and power flow direction

Soft key function area: Navigation and operation control

Special function screen:

Customer customized screen: up to 18 customizable monitoring values can be configured

Synchronous oscilloscope: visually display the phase difference between system A and B

Logic Manager: Visualize Logic Conditions and Variable States

Event history: system event records with timestamps

3.3 Key parameter configuration

Language and clock settings:

Supports English, German, and one reserved language

Real time clock with configurable time zone and daylight saving time rules

Network time can be synchronized through SNTP protocol

Measurement configuration:

Voltage Transformer Ratio Setting (Parameters 1800, 1803, 1812)

Current Transformer Ratio and Direction Configuration

Definition of power measurement symbols (based on CT installation direction)

Circuit breaker configuration:

Operation mode selection: manual/automatic

Synchronization parameters: frequency difference, voltage difference, phase angle, dwell time

Dead bus closure condition setting

Logical Command Configuration (AMF Function)

Monitoring function configuration:

System A/B protection: overvoltage, undervoltage, overclocking, underfrequency, voltage asymmetry, etc

Circuit breaker monitoring: closing transition monitoring, unloading mismatch detection

Communication monitoring: CAN, Ethernet, multi unit system status

Application Mode and Advanced Features

4.1 Application layer architecture

LS-6XT supports a two-tier application architecture:

Layer 1: Generator Unit Layer

Communicate with easyYgen-3000XT and other LS-6XT

Support CBA or CBA/BBB circuit breaker modes

Special application modes: L-MCB, L-GGB, L-MCB/GGB

Main power failure detection and main power decoupling

Layer 3: Power Station Layer

Communicate with group controller (GC) and other LS-6XT

Support CBA or CBA/BBB circuit breaker modes

Main power fault detection and decoupling (GCB)

4.2 Synchronization check function

As a redundancy check function, synchronous inspection enhances system security:

Available command variables:

02.29 Synchronization conditions: dependent on voltage, frequency, and phase angle

02.30 Dead bus closure condition: depends on system A/B voltage and dead bus configuration

02.28 Synchronization check relay: Triggered when any of the above conditions are met

Key parameters:

Positive/Negative Frequency Difference CBA (5711/5712)

Voltage difference CBA (5710)

Maximum positive/negative phase angle CBA (5713/5714)

Phase matching dwell time CBA (5717)

4.3 Expansion of External I/O Modules

External I/O modules can be connected via CAN1 bus:

IKD1: Up to 2, providing 16DI/16DO

IKD-IN-16:1, providing 16DI

IKD-OUT-16:1, providing 16DO

The configuration tool can be accessed through ToolKit and supports flexible digital input monitoring and relay output control.

4.4 Communication and Protocol Support

CAN interface:

CAN1 interface supports CANopen protocol

Support Process Data Objects (PDO) and Service Data Objects (SDO)

Configurable load balancing communication parameters

Ethernet interface:

Three independent 10/100Base-T ports

Supports Modbus TCP/IP protocol

Remote Panel Access (RP-3000XT)

System interconnection function (new feature)

Serial interface:

RS-485 supports half duplex/full duplex operation

Modbus RTU protocol

USB 2.0 Device Interface (ToolKit Connection)

Load balancing:

Broadcast messages via CAN bus or UDP (Ethernet)

Configurable transmission rate and timeout period

Support redundant communication paths

Maintenance and troubleshooting

5.1 Daily Maintenance

Indicator light test:

Through the HMI "LAMPTEST" button or logical command variable 04.04

Test all panel LED indicator lights

System restart:

Both ToolKit and HMI provide restart function

Wait up to 20 seconds after parameter changes to ensure saving

Event and alarm management:

The alarm is divided into 6 levels (A-F)

Event history with timestamp

Alarm can be confirmed locally or remotely

5.2 Common problem handling

Communication fault inspection:

Verify that all devices have consistent baud rates

Check the terminal resistance of the CAN bus (120 Ω at both ends)

Confirm that the bus length does not exceed the speed limit

Check if the cable is close to the power cord

Measurement abnormality troubleshooting:

Confirm that the CT/PT ratio setting is correct

Check the wiring phase sequence

Verify voltage/current measurement range configuration

Check if the grounding connection is good

Circuit breaker operation issues:

Confirm operating mode (manual/automatic)

Check the status of the enable signal

Verify if the synchronization conditions are met

Check the configuration of the logic manager

5.3 Software Update

Get the latest files:

Accessing the complete product documentation through QR code

Download the latest configuration file from Woodward's official website

Use ToolKit 7.0.1 or higher version

Update precautions:

Hardware compatibility check (some hardware is incompatible with older software versions)

Backup the current configuration before updating

Perform updates at the super debug level (CL05)

Practical application case analysis

6.1 Independent Application Mode (A01)

In independent operation mode, LS-6XT can manage a single circuit breaker (CBA mode) or dual circuit breakers (CBA/BBB mode). Typical applications include:

Basic main power source - generator set switching:

System A serves as the main power source, while System B serves as the generator set

Automatically switch to the generator set when the main power supply fails

Automatically synchronize and switch back to the main power supply after the main power supply is restored

Key configuration parameters:

Main power decoupling threshold setting

Generator start-up delay

Synchronization check parameter optimization

6.2 Integrated application with easyYgen (A03/A04)

When LS-6XT is used in conjunction with easyYgen-3400XT/3500XT, a complete generator control system can be formed:

Parallel operation of multiple generator sets:

An externally operated main circuit breaker (MCB)

Multiple generator sets are connected in parallel through generator busbar circuit breakers (GGBs)

Load balancing and frequency/voltage modulation control

H configuration system:

Two incoming main power supplies with connecting circuit breakers

Multiple generator sets support

Complex logic interlocking and priority management

6.3 Special Application Configuration

Digital input monitoring (CBA response):

Can be configured as normally open or normally closed

Response signal timeout detection

Circuit breaker fault alarm

Ethernet interconnection function:

Multi device data synchronization

Remote configuration and monitoring

System redundancy and fault switching

Technological Development Trends and Suggestions

7.1 Software Function Enhancement

According to the revision history, LS-6XT continues to add new features:

Ethernet interconnection function (version 2.14-0)

External reactive power measurement

Modbus master station function

Logical command support (AMF function)

System rationality monitoring

7.2 Hardware compatibility considerations

Important precautions:

Software versions above 2.13-0 require hardware adjustments

Old hardware may not be compatible with new software

Before upgrading, it is necessary to check the hardware version

7.3 Best Practice Recommendations

Installation phase:

Carefully plan the wiring to avoid interference

Ensure proper cable shielding and grounding

Reserve sufficient maintenance space

Configuration phase:

Starting from default settings, gradually adjust

Record all parameter changes

Conduct comprehensive testing before putting it into operation

Operation phase:

Regularly check event logs

Monitor communication status

Keep software and documentation updated