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Woodward easYgen-3500XT - User Manual

Woodward easYgen-3500XT
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Products: Genset Controllers
Device Series: easYgen-3000XT
Devices: easYgen-3100XT/3200XT/3400XT/3500XT
37630 easYgen-3000XT Flash Instruction
w w w . w o o d w a r d . c o m
1
EASYGEN-3000XT FLASH INSTRUCTION #37630
Flashing a Woodward easYgen-3000XT device for full or partial update
For trained personnel only!
Updating the device software needs expert level. Otherwise, the device
can become unusable or even cause error function that can lead into
dangerous situation with genset.
DO NOT switch off the device
until the flash procedure is explicitly mentioned as
completely finished as described below
If the device to be updated is installed into a running genset system, it
is mandatory that a genset control expert guarantees trouble free
system setup during update process.
If firmware update process is however interrupted before it has finished,
due to lost or switched off power supply, your device may be no longer
able to operate.
Note that you perform firmware update at your own risk.
What to do?
The updating process comes with conditions, which need certain preparations, ask for step-by-step procedure,
and will be closed with some final preparations.
First, read this instruction manual completely and carefully, before you start updating your device.
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Summary

Getting Started with Firmware Update

Firmware Update Preconditions

Preparing for Firmware Update

Using the Woodward Toolkit

Detailed steps and guidance for utilizing the Woodward Toolkit software during the preparation phase.

Step-by-Step Firmware Update Procedure

Verifying Firmware Version

Finalizing the Firmware Update

Reverting Safety Preparations

Instructions for undoing temporary safety measures and restoring normal interface connections post-update.

Confirmation of Update Completion

Final confirmation that the device update is complete and the unit is ready for operation.

Summary

Getting Started with Firmware Update

Firmware Update Preconditions

Preparing for Firmware Update

Using the Woodward Toolkit

Detailed steps and guidance for utilizing the Woodward Toolkit software during the preparation phase.

Step-by-Step Firmware Update Procedure

Verifying Firmware Version

Finalizing the Firmware Update

Reverting Safety Preparations

Instructions for undoing temporary safety measures and restoring normal interface connections post-update.

Confirmation of Update Completion

Final confirmation that the device update is complete and the unit is ready for operation.

Overview

The Woodward easYgen-3000XT is a series of genset controllers designed for managing and monitoring generator sets. This device series, including models like the easYgen-3100XT, easYgen-3200XT, easYgen-3400XT, and easYgen-3500XT, is primarily used for controlling the operation of gensets, ensuring their reliable and safe performance.

Function Description

The core function of the easYgen-3000XT series is to provide comprehensive control over genset operations. This includes starting and stopping the genset, monitoring various parameters, and managing power output. The controllers are equipped to handle both full and partial updates, allowing for software enhancements and bug fixes to be applied efficiently.

A critical aspect of its functionality involves the update process, which is detailed in the provided instructions. This process ensures that the device's software remains current, incorporating the latest features and improvements. During an update, the device undergoes a controlled shutdown and reboot sequence, with status indicators (display or LEDs) providing feedback on the progress. The controller is designed to prevent data loss by allowing users to save current settings before an update and restore them afterward.

The easYgen-3000XT can operate in various modes, including a "STOP" mode, which is crucial for safe maintenance and update procedures. In this mode, the device ensures that no genset control operations are active, preventing unintended actions during critical tasks. It also supports communication with a PC or laptop via USB or Ethernet interfaces, enabling configuration, monitoring, and software updates through Woodward's ToolKit software.

The device is capable of identifying and managing different application files (.scp files) tailored for specific interfaces (USB or Ethernet), ensuring compatibility and proper functionality during updates. It also incorporates security features, requiring a specific code level (Code Level 5) for login to perform sensitive operations like software updates, thereby preventing unauthorized access and modifications.

Usage Features

The easYgen-3000XT offers several features that enhance its usability and operational flexibility:

  • User Interface: Depending on the variant, the device may feature an HMI (Human Machine Interface) with a display or rely on LEDs for status indication. The HMI variant provides a visual interface for monitoring and configuration, displaying information such as the home screen and firmware version. For variants with LEDs, these indicators (e.g., Communication, Operation, Alarm) provide essential status feedback, changing colors (red, green, blinking) to signify different operational states or during update processes.
  • ToolKit Software Integration: The device is designed to work seamlessly with Woodward's ToolKit software. This PC-based application allows users to connect to the easYgen-3000XT, open configuration files (.wtool), save current settings (.wset), and perform software updates. The ToolKit provides a structured interface for selecting network connections (COM ports, TCP/IP, USB-to-CAN), managing baud rates, and logging into the device with appropriate security credentials.
  • Flexible Update Options: Users can update the device via either a USB or Ethernet interface. The instructions recommend using the Ethernet variant for its potentially faster transfer times (6-9 minutes compared to 15-18 minutes for USB). This flexibility allows users to choose the most convenient and efficient method based on their setup.
  • Configuration Management: Before any update, users are advised to save their current settings as a .wset file. This feature is crucial for maintaining the device's specific configuration and ensuring that these settings can be reloaded after the update, preventing the need for manual re-configuration. The "Restore Settings" option during the update process further aids in this, allowing users to choose whether to restore current settings or start fresh.
  • Safety Warnings and Procedures: The device's operation, especially during updates, is guided by clear safety warnings. These emphasize the importance of having trained personnel, not switching off the device during updates, and ensuring the genset system is in a safe state. These warnings are integrated into the ToolKit's update prompts, ensuring users are aware of potential risks.
  • Error Handling: The system provides feedback for various error conditions, such as "Failed" messages if the security level is insufficient or "Production Identifier Mismatch" if an incorrect application file is selected. These messages guide users to troubleshoot and resolve issues during the update process.

Maintenance Features

The easYgen-3000XT incorporates features that facilitate its maintenance and ensure its long-term reliability:

  • Software Update Mechanism: The primary maintenance feature is its robust software update mechanism. Regular updates are essential for incorporating new functionalities, improving performance, and addressing security vulnerabilities. The step-by-step instructions provided ensure that even complex updates can be performed systematically.
  • Version Verification: After an update, the device allows for verification of the installed software versions (Application, HMI, Bitmap, Language) through both the ToolKit's "STATUS MENU" and the HMI's "Diagnostic" screen. This ensures that all components have been updated correctly and are compatible. Any discrepancies are highlighted with an exclamation mark, prompting further investigation.
  • Troubleshooting Support: In cases of persistent issues or version discrepancies, the manual directs users to contact their sales support partner and provides a reference to an application note (#37573) for further product support options, including returning equipment for repair. This structured support system aids in resolving complex maintenance challenges.
  • Temporary Safety Preparations: For maintenance involving software updates, specific safety preparations are outlined, such as selecting "STOP" mode, ensuring other gensets are controlled, and removing unnecessary interface connections. These steps minimize risks during maintenance activities.
  • Post-Update Procedures: After a successful update, the device guides users through essential post-update steps, including ensuring the latest (saved) settings are loaded and re-connecting all interface connections. These steps ensure the device returns to its normal operational state efficiently and safely.
  • Clear Status Indicators: During critical maintenance operations like software updates, the device provides clear status indicators, whether through the HMI display or LEDs. For instance, the display showing "Updating: Please do not switch off the device!" or LEDs blinking/turning red provides crucial information to the user, preventing premature power-offs that could damage the device.

In summary, the Woodward easYgen-3000XT series is a sophisticated genset controller designed for robust performance, ease of use, and maintainability, with a strong emphasis on safe and systematic software management.

Woodward easYgen-3500XT Specifications

General IconGeneral
Frequency50/60 Hz
OutputsRelay outputs, analog outputs
CertificationsCE, UL
AC SystemSingle-phase or three-phase
Operating Temperature-20 to +70 °C
CommunicationEthernet, RS-232, RS-485
DisplayGraphical LCD
ProtectionOver/under voltage, over/under frequency
Control Functionsload sharing
Power Supply24 VDC, 18-36 VDC
InputsDigital and analog inputs

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