WOODWARD easYgen-3000 Series (Package P1) Genset Control

WOODWARD easYgen-3000 Series (Package P1) Genset Control

Core positioning and basic information

The Woodward easyYgen-3000 series (Package P1) generator set controller is a multifunctional control unit designed for general and marine scenarios. Manual 37223E (software version 1.10xx) serves as an exclusive installation guide, focusing on hardware installation, wiring configuration, physical parameters, and safety specifications of the equipment, without involving parameter configuration and daily operation details. The product covers four core models (8440-1816/1817/1818/1831), which have undergone multiple revisions from A to E. The main focus is on optimizing the installation instructions and correcting details of the shell, ultimately forming a complete installation guidance system. Its core value lies in providing precise electrical parameter measurement, flexible input-output control, and reliable communication interconnection for generator sets, adapting to multi scenario application needs from ordinary computer rooms to ship decks.

Hardware structure and installation specifications

1. Shell type and core parameters

The product offers two differentiated shell designs, suitable for different installation scenarios:

Shell type corresponds to model, core feature size (W × H × D), protection level, installation method

Plastic shell easyYgen-3200 with graphic LCD display screen, supports local operation 282 × 217 × 99mm fixture fixing IP54; Screw kit IP66 panel embedded installation, hole size 249 × 183mm (tolerance+1.1/+1.0mm)

Metal shell easyYgen-3100 without display screen, focusing on integrated installation 249.6 × 227.4 × 84.1mm IP20 cabinet back installation, fixed with 4 M6 screws

2. Key installation requirements

Torque control: Plastic shell screws require 0.6Nm for fixation, fixtures require 0.1Nm for fixation; metal shell and terminal wiring require 0.5Nm to avoid damage to components due to over tightening

Wiring specification: Only 60/75 ℃ copper wire is allowed, with a maximum wire diameter of 2.5mm ² (14AWG), and the terminal load capacity needs to be matched

Static electricity protection: Before contacting the circuit board, it is necessary to release human static electricity to avoid synthetic materials from approaching the equipment; The PCB board should always be in anti-static packaging and only be operated with the edge in hand

Ship scene adaptation: The metal shell directly complies with LR/ABS classification society certification; The plastic shell needs to be fixed with 12 screws and an EMI filter (such as TIMONTA FSS2-65-4/3) should be installed in the bridge/deck area

3. Terminal layout and interface distribution

The back terminals of the device are designed according to functional zoning, including the power supply area (61-65 terminals), measurement area (1-40 terminals), input/output area (41-80 terminals), and communication area (independent interface). Among them:

The protective grounding (PE) terminal 61 is only effective on plastic shell models, and the metal shell needs to be grounded through the shell to achieve protection

Centralized layout of relay output and discrete input terminals for easy wiring organization; Separate partition of analog signal terminals to reduce interference

The communication interface (RS-232/RS-485/CAN) adopts standard D-SUB/IDC interface, with reserved shielding layer connection points to enhance anti-interference capability

Core Electrical Configuration and Wiring Guide

1. Power supply system configuration

Main power supply: Supports 12/24VDC wide voltage input (8-40Vdc), with a maximum power consumption of 17W. A 6A slow melting fuse (such as NEOZEN D01 6A) or a C-type miniature circuit breaker (such as ABB S271C6) needs to be connected in series in the power supply line

Auxiliary power supply: Terminal 65 provides pre excitation output (D+) for the charging generator, which excites the generator during startup and monitors the charging voltage during operation

Grounding requirements: The voltage difference between the negative terminal of the battery and the PE terminal shall not exceed 15V, and an isolated external power source shall be used if it exceeds this limit; Ship scenarios require additional access to independent safety protection devices that comply with classification society regulations

2. Measurement system wiring (voltage/current/power)

(1) Voltage measurement (FlexRange dual range)

Supports voltage measurement for generators, power grids, and busbars, covering various wiring methods such as 1Ph 2W/3W, 3Ph 3W/4W, etc. The core specifications are as follows:

Range selection: 100V range (50-130Veff) is suitable for low voltage scenarios, 400V range (131-480Veff) is suitable for high voltage scenarios, and it is strictly prohibited to connect two sets of ranges at the same time

Wiring requirements: The generator voltage is connected through terminals 29-36, the grid voltage is connected through terminals 21-28, and the bus voltage is connected through terminals 37-40; The N line needs to be wired separately to avoid measurement errors caused by different voltage systems sharing the N terminal

Protective measures: It is recommended to connect 2-6A slow melting fuses in series for all voltage inputs, and withstand surge voltages of 2.5kV at 100V and 4.0kV at 400V

(2) Current measurement (CT secondary side adaptation)

Support measurement of three-phase current for generators, single-phase current for power grids, and grounding current. Core specifications:

Rated input: compatible with 1A/5A CT secondary side signals, generator current is connected through terminals 3-8, and grid/ground current is connected through terminals 1-2

Wiring specification: The CT secondary side needs to be grounded at a single point (near the CT end), and the CT terminal must be short circuited before disconnecting the equipment to prevent high voltage caused by an open circuit

Measurement range: The linear measurement range of the generator current reaches 3 times the rated value, and the grid/ground current reaches 1.5 times the rated value, with an accuracy of Class 1

(3) Power and power factor measurement

Power measurement: Based on voltage/current signal derivation, the active power range is -2~2GW, the reactive power range is -2~2Gvar, and the accuracy is 2%. Zero crossing detection is required to ensure measurement accuracy

Power factor: defined from the perspective of a generator, the inductive load displays lag (lg) and the capacitive load displays lead (ld), which can be used as the basis for voltage regulation (capacitive overload outputs boost signal, inductive overload outputs buck signal)

3. Input/output interface configuration

(1) Discrete input (12 channels, terminals 66-78)

Electrical characteristics: Electrical isolation design, supporting positive/negative polarity signals, input resistance ≈ 20k Ω, working voltage 8-40Vdc

Pre allocation function: Core inputs such as DI01 (emergency stop signal), DI02 (automatic start), DI03 (low oil pressure alarm) have predefined functions, and DI07-DI08 are fixed as MCB/GCB feedback signals

Operation logic: Can be configured as normally open (N.O.)/normally closed (N.C.), energized when a fault occurs in the normally open state, and de energized when a fault occurs in the normally closed state

Safety reminder: DI01 is only an emergency stop signal input and cannot be directly used as an emergency stop execution function. It needs to independently implement the EN 60204 standard requirements externally

(2) Relay output (12 channels, terminals 41-60)

Hardware parameters: AgCdO contact material, universal load 2A@250Vac /24Vdc, PILOT load 1A@24Vdc Support long-term stable work

Pre allocation functions: R01 (ready to run), R04 (fuel solenoid valve), R05 (preheating), R07/R09 (GCB/MCB opening command), etc., supporting custom functions through LogicsManager software

Safety requirement: The "Ready to Run" output should be connected in series with the emergency stop function to ensure that the generator circuit breaker is disconnected and the engine stops in case of equipment failure

(4) Analog input/output

Analog input (3 channels, terminals 9-14): supports 0/4-20mA, 0-500 Ω, VDO sensor signals, bipolar wiring accuracy ≤ 1%, unipolar wiring accuracy ≤ 2.5%; Bipolar signal ground to PE, unipolar signal ground to engine ground (terminal 62)

Analog output (2 channels, terminals 15-20): Supports ± 10Vdc, ± 20mA, PWM signals, 20mA output maximum load of 500 Ω, resolution 11-12 bits, signal type can be switched through external jumpers

(5) MPU input (terminals 79-80)

Adaptive sensor: Magnetic electric speed sensor (MPU), input impedance ≥ 17k Ω, maximum input frequency 14kHz

Wiring requirements: The cable shielding layer is only grounded at a single point on the device end, and the MPU end is not grounded; Need to match the number of teeth and speed of the flywheel gear to ensure that the input frequency does not exceed the limit

4. Communication interface configuration

Interface Type Quantity Terminal/Interface Form Core Parameters Application Scenarios

RS-232 1-channel D-SUB DE9 electrical isolation, signal level ± 5V local debugging, point-to-point short-range communication

RS-485 1-channel D-SUB DE9 supports half duplex/full duplex, Modbus protocol for multi device networking and remote monitoring

CAN bus 2-channel D-SUB DE9/IDC electrical isolation, baud rate 10k-1Mbit/s industrial equipment interconnection, maximum distance 2500m (20kbit/s)

Key requirements for CAN bus: use shielded twisted pair cables (such as Lappkabel Unitronic LiyCY), with 120 Ω terminal resistors connected at both ends; Avoid parallel wiring with power cables to prevent electromagnetic interference

Environmental adaptability and compliance certification

1. Environmental tolerance

Temperature range: Operating -20 ℃~70 ℃, Storage -30 ℃~80 ℃, Supports low-temperature deck environment on ships

Vibration shock: sine vibration 5-100Hz (4G), random vibration 10-500Hz (1.04Grms), shock 40G (11ms sawtooth wave), in compliance with EN 60255 and MIL-STD 810F standards

Humidity protection: Stable operation for 5 days under 60 ℃ and 95% RH environment, meeting the requirements of high humidity environment for ships

2. Compliance and Certification

Basic certifications: CE, UL (for general locations), cUL (for easyYgen-3100 only), EMC compliant with EN related standards

Ship certification: LR (Lloyd's Register of Shipping), ABS (American Bureau of Shipping), suitable for ENV1-ENV4 Class 4 marine environment

Protection certification: Plastic shell IP66 (screw fixed) can withstand strong water spray, metal shell IP20 compatible for installation in cabinets

Safety regulations and precautions

Electrical safety: Protective grounding (PE) must be connected, with a wire diameter of ≥ 2.5mm ²; Insulation voltage lasts for 100Vac, test for 500Vac (1 second) to avoid leakage risk

Electrostatic protection: The equipment can withstand 85kV electrostatic spraying, but daily operation should avoid direct contact with PCB components; PCB replacement must be carried out in a voltage free environment, and both new and old boards require anti-static packaging protection

Wiring taboos: It is strictly prohibited to connect 100V and 400V voltage inputs simultaneously; CT secondary side cannot be open circuited, and voltage input cannot be short circuited; Separate wiring for different signal types (analog/digital) to reduce interference

Appendix Key Reference Information

CAN bus pin definition: Provides pin allocation for D-SUB DE9, RJ45/8P8C, and IDC interfaces, with CAN-H connected to 7-pin (D-SUB) and 1-pin (RJ45), and CAN-L connected to 2-pin (D-SUB) and 2-pin (RJ45) for easy interconnection of third-party devices

Wire diameter conversion table: including the correspondence between AWG and mm ² wire diameter (such as 14AWG=2.5mm ², 10AWG=6mm ²), for easy selection and matching

Compatible connectors: It is recommended to use narrow body D-SUB housings such as FCT (FKH1/FKC1G) and Wuerth Electronic (618009214622) to avoid interfaces that cannot be inserted