easYgen-2500

OPERATORS MANUAL

Document:

easYgen Operators Manual

Part Number

371-0193

371-0193

Contents
1.
2.

introduction

Safety
6
2.1 General . .............................................................................................................................................................................6
2.2 Personal Protective Equipment..................................................................................................................................6
2.3 Fire and Explosion ..........................................................................................................................................................7
2.4 Mechanical.........................................................................................................................................................................7
2.5 Chemical . ..........................................................................................................................................................................7
2.6 Noise ...................................................................................................................................................................................7
2.7 Electrical ............................................................................................................................................................................8
2.8 First Aid For Electric Shock ..........................................................................................................................................8

3. CONTROL SYSTEM overview

10
3.1 Control System Description and Identification...................................................................................................10
3.1.1 Panel Equipment: . ....................................................................................................................................................10
3.2 Operational Overview of the easYgen-2500 Control System..........................................................................12
3.3 Operational Display Area............................................................................................................................................13
4. Functional Description easYgen-2500 Control Systems
14
4.1 Application Modes........................................................................................................................................................14
4.1.1 Multiple generating sets, Prime Power..............................................................................................................14
4.1.2 Multiple Generating sets, Auto Utility Failure with Intelligent ATS..........................................................14
4.1.3 Automatic Synchronising (up to 16 generating sets): .................................................................................15
4.1.4 Protective Circuits: . ..................................................................................................................................................16
4.2 Control System Options and Upgrades.................................................................................................................17
4.2.1 Battery Trickle Chargers: ........................................................................................................................................17
4.2.2 Heaters: .......................................................................................................................................................................17
4.2.3 Electric Fuel Transfer Pumps: .............................................................................................................................17
4.2.4 Remote Control and Monitoring Via a PC (NetBiter): . ................................................................................17
5.

OPERATION
18
5.1 General..............................................................................................................................................................................18
5.2 Pre-Start Checks.............................................................................................................................................................18
5.3 Operation of easYgen-2500 Control Panel (Multiple Generating Sets, No Parallel with Mains)..........19
5.3.1 Engine Start/Stop.....................................................................................................................................................19
5.3.2 Circuit Breaker Open/Close...................................................................................................................................19
5.3.3 Automatic Start-up/Shutdown of the easYgen-2500 Control Panel (AMF Variant): ........................19
5.4 Operation ....................................................................................................................................................................... 20
5.4.1 Operating Mode MANUAL................................................................................................................................... 20
5.4.2 Operating Mode STOP...........................................................................................................................................21
5.4.3 Operating Mode AUTO..........................................................................................................................................21
5.5 Sequencing..................................................................................................................................................................... 22

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6.

Navigation
23
6.1 Operating mode........................................................................................................................................................... 23
6.2 Alarm/Shut down list................................................................................................................................................... 24
6.3 Main menu...................................................................................................................................................................... 24
6.4 Screen Setpoints......................................................................................................................................................... 25
6.5 Screen Synchroscope................................................................................................................................................ 26
6.6 Screen Sequencing ................................................................................................................................................... 27
6.7 Screen Counters and Service.................................................................................................................................. 27
6.8 Screen Measured Values.......................................................................................................................................... 28
6.9 Screen Generator........................................................................................................................................................ 28
6.10 Screen J1939 Status.................................................................................................................................................... 29
6.11 Screen J1939 Active Diag. Trbl. Codes.................................................................................................................. 29
6.12 Screen J1939 Previous Diag. Trbl. Codes............................................................................................................. 29
6.13 Screen Analog Inputs/Outputs.............................................................................................................................. 30
6.14 Screen Discrete Inputs/Outputs............................................................................................................................ 30
6.15 Screen Diagnostic........................................................................................................................................................31
6.16 Screen Actual Date and Time..................................................................................................................................31
6.17 Screen Event History................................................................................................................................................. 32
6.18 Screen Parameter....................................................................................................................................................... 32
6.19 Screen Language/Clock Configuration............................................................................................................... 33
6.20 Screen Display Configuration................................................................................................................................. 33
6.21 Screen Enter Password.............................................................................................................................................. 33
6.22 Screen System Management.................................................................................................................................. 34

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1. introduction
The easYgen-2500 advanced electronic control system has been designed and installed to control and monitor the
generating set.
This control system consists of two major components working together a control panel and an alternator output circuit
breaker.
The control panel provides a means of starting and stopping the generating set, monitoring its operation and output and
automatically shutting down the generating set in the event of a critical condition arising, such as low oil pressure or high
engine coolant temperature.
The power output circuit breaker serves to protect the alternator by automatically disconnecting the load in the event of
overload or short circuit. It also provides a means of switching the generating set output.
The easYgen-2500 control system incorporates a microprocessor based complete load control and engine management
system and carries out all the functions necessary for engine control, synchronising, real (kW) control, reactive (kVAR) control
and automatic generating set sequencing. Protection is provided by the control system against various fault conditions.

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2. Safety
2.1 General
The generating set is designed to be safe when used in the correct manner. Responsibility for safety, however, rests with the
personnel who use the generating set. Before performing any procedure or operating technique, it is the users responsibility
to ensure that it is safe to do so.
Warning:
II Read and understand all safety precautions and warnings before operating the generating set.
II Failure to follow the instructions, procedures and safety precautions in this manual may increase the possibility
of accidents and injuries.
II Never start the generating set unless it is safe to do so.
II Do not attempt to operate the generating set with a known unsafe condition.
II If the generating set is unsafe, fit danger notices and disconnect the battery negative () lead so that it cannot
be started until the condition is corrected.
II Disconnect the battery negative () lead prior to attempting installation, repairs or cleaning on the generating
set.
II Install and operate this generating set only in full compliance with relevant National, Local or Federal Codes,
Standards or other requirements.

2.2 Personal Protective Equipment

Figure 2a Typical PPE to be worn by an Operator

Wear a hard hat, protective glasses and other protective equipment, as required.

When work is performed around an engine that is operating, wear protective devices for ears in order to help prevent
damage to hearing.

Do not wear loose clothing or jewellery that can snag on controls or on other parts of the engine.

Ensure that all protective guards and all covers are secured in place on the engine.

Never put maintenance fluids into glass containers. Glass containers can break.

Use all cleaning solutions with care.

Report all necessary repairs.

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Unless other instructions are provided, perform the maintenance under the following conditions:

The engine is stopped. Ensure that the engine cannot be started.

Disconnect the batteries when maintenance is performed or when the electrical system is serviced. Disconnect the
battery ground leads. Tape the leads in order to help prevent sparks.

Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment that is damaged or
repair the equipment.

2.3 Fire and Explosion

Fuels and fumes associated with generating sets can be flammable and potentially explosive.
Proper care in handling these materials can dramatically limit the risk of fire or explosion.
However, safety dictates that fully charged BC and ABC fire extinguishers are kept on hand.
Personnel must know how to operate them.
Warning:
II Ensure the generating set room is properly ventilated.
II Keep the room, the floor and the generating set clean. When spills of fuel, oil, battery
electrolyte or coolant occur, they should be cleaned up immediately.
II Never store flammable liquids near the engine.
II Store oily rags in covered metal containers.
II Do not smoke or allow sparks, flames or other sources of ignition around fuel or batteries. Fuel vapours are
explosive. Hydrogen gas generated by charging batteries is also explosive.
II Avoid refilling the fuel tank while the engine is running.
II Do not attempt to operate the generating set with any known leaks in the fuel system.

2.4 Mechanical
The generating set is designed with guards for protection from moving parts. Care must still be taken to protect personnel
and equipment from other mechanical hazards when working around the generating set.
Warning:
II Do not attempt to operate the generating set with safety guards removed. While the generating set is running
do not attempt to reach under or around the guards for any reason.
II Keep hands, arms, long hair, loose clothing and jewellery away from pulleys, belts and other moving parts.

Some moving parts can not be seen clearly when the generating set is running.

II Keep access doors on enclosures, if equipped, closed and locked when not required to be open.
II Avoid contact with hot oil, hot coolant, hot exhaust gases, hot surfaces, sharp edges and corners.
II Wear protective clothing including gloves and hat when working around the generating set.

2.5 Chemical
Fuels, oils, coolants, lubricants and battery electrolyte used in this generating set are typical of the industry. However, they
can be hazardous to personnel if not treated properly. The disposal of fuels, oils, coolants, lubricants, battery electrolyte and
batteries should be carried out in accordance with local government laws and regulations.
Warning:
II Do not swallow or have skin contact with fuel, oil, coolant, lubricants or battery electrolyte. If swallowed, seek
medical treatment immediately. Do not induce vomiting if fuel is swallowed. For skin contact, wash with soap
and water.
II Do not wear clothing that has been contaminated by fuel or lube oil.

2.6 Noise
Warning:
II Prolonged exposure to noise levels above 80 dBA is hazardous to hearing.
II Ear protection must be worn when operating or working around an operating generating set.
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2.7 Electrical
Safe and efficient operation of electrical equipment can be achieved only if the equipment is correctly operated and
maintained.
Warning:
II Ensure the generating set, including a mobile set, is effectively grounded/earthed prior to operation.
II Do not touch electrically energised parts of the generating set and/or interconnecting cables or conductors with
any part of the body or with any non insulated conductive object.
II Use only Class BC or Class ABC extinguishers on electrical fires.

2.8 First Aid For Electric Shock

Warning:
II Do not touch the victims skin with bare hands until the source of electricity has been turned off.
II Switch off the power, if possible.
II Otherwise pull the plug or pull the cable away from the victim.
II If this is not possible, stand on dry insulating material and pull the victim clear of the conductor, preferably using
insulated material such as dry wood.
II If victim is breathing, turn the victim into the recovery position.
II If victim is unconscious, perform resuscitation as required:
OPEN THE AIRWAY:
1. Tilt the victims head back and lift the chin upwards.
2. Remove objects from the mouth or throat (including false teeth, tobacco or chewing gum).
BREATHING:
1. Check that the victim is breathing by looking, listening and feeling for the breath.
CIRCULATION:
1. Check for pulse in the victims neck.
IF NO BREATHING BUT PULSE IS PRESENT:
1. Pinch the victims nose firmly.
2. Take a deep breath and seal your lips around the victims lips.
3. Blow slowly into the mouth watching for the chest to rise. Let the chest fall completely.
Give breaths at a rate of 10 per minute.
4. If the victim must be left to get help, give 10 breaths first and then return
quickly and continue.
5. Check for pulse after every 10 breaths.
6. When breathing restarts, place the victim into the recovery position described
later in this section.

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IF NO BREATHING AND NO PULSE:

1. Call or telephone for medical help.
2. Give two breaths and start chest compression as follows:
3. Place heel of hand 2 fingers breadth above ribcage/breastbone junction.
4. Place other hand on top and interlock fingers.
5. Keeping arms straight, press down 45 cm (1.52 inch) 30 times at a rate of 100 per minute.
There should be equal timing between chest compression and release.
6. Repeat cycle (2 breaths, 30 compressions) until medical help takes over.
7. If condition improves, confirm pulse and continue with breaths. Check for pulse after
every 10 breaths.
8. When breathing restarts, place the victim into the recovery position.

Warning:
II Do not apply pressure over the ribs, lower tip of the victims breastbone or the abdomen.

RECOVERY POSITION:
1. Turn the victim onto the side.
2. Keep the head tilted with the jaw forward to maintain the open airway.
3. Make sure the victim cannot roll forwards or backwards.
4. Check for breathing and pulse regularly. If either stops, proceed as above.
Warning:
II Do not give liquids until victim is conscious.

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3. CONTROL SYSTEM overview

3.1 Control System Description and Identification
3.1.1 Panel Equipment:
Before starting or running the generating set, the operator should become fully acquainted with the display screen, menus
and controls. The various screens should be observed from time to time while the generating set is running so that any
abnormal readings can be detected before problems arise.
Figures 3a and 3b show typical diagrams of the easYgen-2500 Control Panel. Addition of optional equipment will add
items to the panel so the panel fitted on the generating set may be slightly different from the one shown. The following
descriptions explain the function of each item on both the panel and controller and each display screen menu on the panels:
1. Push Buttons on the front panel are assigned to softkeys on the display. Each softkey is assigned to a function
depending on the mode of operation.
2. Display contains softkey characters, measuring values, modes of operation and alarms.
3. Stop LED indicates that the unit is in STOP mode.
4. Alarm LED indicates that alarm messages are active in the controller.
5. Woodward easYgen-2500 Controller.
6. Emergency Stop Push button A red lock-down Push button that immediately shuts down the generating set and will
inhibit start until the Push button has been released by turning it clockwise and clearing the alarm in the alarm list.
7. Audible Alarm Buzzer that sounds on sensing of a fault condition depending on fault handling description.
8. Breaker Closed Light to indicate generating set breaker closed.

4
3
5
8
6
7

Figure 3a Diagram of easYgen-2500 Control Panel

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1
2

Figure 3b Diagram of inside of easYgen-2500 Control Panel

1. Miniature Circuit Breakers
2. Battery Charger
3. Relays
4. Terminals

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3.2 Operational Overview of the easYgen-2500 Control System

1

10

Figure 3c Diagram of Operating Values Overview / Starting Screen

1. Delta/Wye Voltage Changes the generating set voltage displays from Phase to Phase or Phase to Neutral.
2. Automatic Places the system into automatic mode so that starts/stops, breaker control and commands will be all carried
out automatically. When in auto mode a circular arrow will be displayed.
3. Manual All start/stops of the generating set must be done using the Engine start/stop button. The breakers must also
be controlled via the breaker control soft keys. When in manual mode a Hand will be displayed were the auto and stop
modes are displayed.
4. Stop
5. Alarm Screen Allows user to view Alarm Log/History Active/Inactive aults and details the level of alarm/shutdown.
6. Configure Parameter Within this menu the user can alter every aspect of the controller in terms of preferences to
monitoring/control setpoints that are password protected.
7. Additional Measured Values All real time values such as generating set voltage, current, kW, kVar, frequency, r.p.m.
busbar voltage/frequency, analog inputs/outputs and discrete inputs/outputs are found within this menu.
8. Acknowledge/Reset Centralised Alarm
9. Engine Start/Stop
10. Breaker Control

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3.3 Operational Display Area

The display is partitioned into different areas to give an over view of the displayed area

1 Values
2. Operation State & Alarm Message
3. Operation
4. Softkeys

The values section of the screen illustrates all measured power

related information including voltages, currents, frequencies,
power and power factor values.

The operation state & alarm message section of the screen shows
the actual operating information.

The operation section of the screen has a single line diagram of

the system application showing current status of the engine and
power circuit breaker.
This level is also used for manual operation of the generating set.

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4. Functional Description easYgen-2500 Control Systems

This section provides a more detailed description of the control system function in each of the application modes.

4.1 Application Modes

This list is not exhaustive but highlights the main, intended, applications covered by the easYgen-2500 panel.

4.1.1 Multiple generating sets, Prime Power

4.1.2 Multiple Generating sets, Auto Utility Failure with Intelligent ATS

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4.1.3 Automatic Synchronising (up to 16 generating sets):

The generating sets can parallel with other similarly equipped generating sets (up to a total of 16 generating sets). In a group
of generating sets, each is given its own identifying number (1 - 16). There are two operational variants, Prime Power and
Automatic Mains Failure (AMF).
Depending on the configuration setup, the generating sets can be started manually or automatically. Automatic starting can
be initiated on a failure of the mains supply by a signal from the mains monitoring system in the case of the AMF variant. For
both variants, automatic starting can be initiated according to load demand (load dependant start / stop sequencing).
(i) Prime Power For prime power, generating sets should be in AUTO mode with the link across the start signal. This
will bring all generating sets online, supplying the load and will allow the easYgen-2500 control system to initialise Load
Dependant Start / Stop (LDSS). With LDSS, the load dictates how many generating sets run, i.e. as the load increases the
number of generating sets increases and vice versa. The order in which the generating sets start can be can be configured
based on an assigned priority number, service hours or engine run time.
When the generating set reaches rated speed and voltage the system checks if there are any generating sets online. If there
are no other generating sets supplying the load the generating set connects immediately to the load. If there are other
generating sets on load then the generating set automatically synchronises, connects to the load and then shares the load in
proportion to its output capability.
(ii) Automatic Mains Failure (AMF) In this mode of operation an external changeover system must be used in conjunction
with the easYgen Control System to handle all mains sensing and load transfer functions. All generating sets would normally
be placed in the AUTO mode. The generating set would then wait for an external starting signal.
On receipt of an external start signal, the generating set start sequence is initiated. If the engine fails to start after 3 attempts
then the start sequence is disabled. A visual and audible alarm is enabled and the exact fault shown on the LCD display while
viewing the ALARM/EVENT LOG. Refer to a qualified generating set technician to determine the cause of the start failure. Restarting of the generating set will be inhibited until the fault is acknowledged and reset in the ALARM/EVENT LOG.
When each generating set reaches rated speed and voltage the system checks if there are already any generating sets on line
supplying the local bus. If there are no other machines supplying the local bus the generating set is connected immediately
to the bus. If there are other machines already supplying the local bus then the generator automatically synchronises to
the supply, connects to the local bus and then shares any bus load, in proportion to its output capability, with the other
generating sets.
When the generating sets have connected to the local bus the disconnection of the mains from the load and connection of
the generating system to the load is handled by the separate changeover system.
At this point the generators will operate in load dependant sequencing mode where the load dictates how many generating
sets run. As the load increases then the number of sets increase and vice versa. The generating sets have a pre-set starting
priority as the load increases. As the load decreases they stop in reverse order. The starting and stopping order sequence can
be changed by the operator at any time. Another feature in the automatic mode is that if a generating set stops because of
a fault then the next generating set in the sequence starts up and synchronises automatically to the load. When the faulty
generating set is repaired it will automatically take its place back in the running sequence.
Note:

To ensure the correct operation of external switchgear, if any generating set is to be taken out of service ensure that
the generating set DC supply is removed.

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4.1.4 Protective Circuits:

Fault conditions on the easYgen-2500 control panel are set as classes

Figure 6a - Alarm Class Table

All alarms are logged with a timestamp in the ALARM / EVENT LOG. These settings are intrinsic to the generating set-up
parameters in the software and can only be changed with suitable security clearance. When a class E or F fault is sensed, the
alarm lamp illuminates, the audible alarm is energised and the generating set is automatically shut down immediately. The
audible alarm will remain energised until the alarm is acknowledged. The engine remains locked out until the fault has been
acknowledged. The possible fault conditions available for sensing are dependant on the particular operating mode of the
generating set. These may include:

Overspeed

High Engine Coolant Temperature

Low Engine Temperature

High Oil Temperature

Low Oil Pressure

Battery Voltage High

Battery Voltage Low

Overcurrent

Reverse Power

Loss Of Excitation

Generator Voltage High

Generator Voltage Low

Generator Frequency High

Generator Frequency Low

Load High Limit

Load Low Limit.

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4.2 Control System Options and Upgrades

A large variety of options may be fitted to customise the control system to a specific installation. The following sections cover
the use and operation of some of these options.

4.2.1 Battery Trickle Chargers:

These chargers are designed to ensure that the starter batteries maintain their charge even if the generating set is not
operated for long periods.

4.2.2 Heaters:
Two types of heater may be fitted on the generating set:
1. Immersion type heaters (engine heaters) may be fitted in the engine coolant system to ensure that the engine is easy to
start and able to take load more quickly.
2. Alternator anti-condensation heaters (alternator heaters) may be fitted to the alternator stator winding to keep them dry in
humid conditions, the heaters are automatically disconnected on engine start-up.

4.2.3 Electric Fuel Transfer Pumps:

Fuel transfer pumps are required when fuel must be transferred from a bulk storage tank to the generating set day tank.
The controls consist of two illuminated Push buttons on the fuel transfer control panel door. The red button is a combined
trip lamp and stop buton. The green button is a run lamp and manual start Push button.
To operate the pump manually, ensure the red Push button is in the ON position (pulled out). Press and hold the green Push
button to manually run the pump. The pump will only run in the manual mode while the green button is held in.
To operate the pump in automatic mode, just ensure that the red Push button is in the ON position (pulled out). The pump
will start running automatically when the fuel level is low and will illuminate the green run lamp. When the tank is full, the
pump is turned off and the green lamp is extinguished.
The red lamp will illuminate if there has been an electrical overload.
Care must be taken to ensure that the pump is primed with fuel prior to operation to lubricate the seals. Also, the pump
should never be run when the bulk tanks are empty or when valves on the fuel fill lines are closed.

4.2.4 Remote Control and Monitoring Via a PC (NetBiter):

A software package is available to remotely control and monitor the generating set either directly with a PC or over a phone/
internet/internal line using a modem.

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5. OPERATION
5.1 General
The generating set is equipped with an easYgen-2500 electronic control system.
This control system allows the operator to manually or automatically control the generating set. It has protection circuits to
sound an alarm and even shut down the generating set if problems occur.
The following procedures detail the steps required to prepare the generating set for operation and start and stop it normally.
A qualified generating set technician should start the generating set for the first time after installation or after the generating
set has been out of service for a time for maintenance purposes.
Warning:
II If at any time one of the generating sets stops because of a fault, the fault should be rectified before trying to
restart the generator.

5.2 Pre-Start Checks

The following checks should be performed prior to starting the generating set:
Warning:
II As generating sets with autostart control panels can be remotely started without warning, always ensure the
control panel is switched off before carrying out any checks.
1. Ensure the Controller is in STOP mode
Warning:
II Do not remove the radiator cap when the coolant is hot. Do not add large amounts of cold coolant to a hot
system as serious damage could result.
2. Check the engine oil and coolant levels replenish as necessary.
Note:

Diesel engines normally consume lube oil at a rate of 0.25% to 1% of the fuel consumption.

When adding coolant to the radiator system, always pour slowly to help prevent air from becoming trapped in the
engine.
Warning:

II When filling the fuel tank, do not smoke or use an open flame in the vicinity.
3. Check the fuel level - fill as necessary.
Warning:
II Before tightening the fan belts, disconnect the battery negative () lead to ensure the engine cannot be
accidentally started.
4. Check the condition and tension of the fan and engine alternator belts tighten as necessary.
5. Check all hoses for loose connections or deterioration tighten or replace as necessary.
6. Check the battery terminals for corrosion clean as necessary.
Warning:
II When working with the batteries, do not smoke or use an open flame in the vicinity. Hydrogen gas from
batteries is explosive.
II Do not short the positive and negative terminals together.
7. Check the battery electrolyte level fill with distilled water as necessary.
8. Check the control panel and the generating set for heavy accumulation of dust and dirt clean as necessary. These can
pose an electrical hazard or give rise to cooling problems.
9. Check the air filter restriction indicator, if fitted replace the filter as necessary.
10. Clear the area around the generating set of any insecure items that could inhibit operation or cause injury. Ensure cooling
air ventilation screens are clear.

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11. Visually check the entire generating set for signs of leaks from the fuel system, cooling system or lubrication seals.
12. Periodically drain exhaust system condensate traps, if equipped.
13. Ensure the Alternator Output Circuit Breaker is in the OFF position.

5.3 Operation of easYgen-2500 Control Panel (Multiple Generating Sets, No Parallel with Mains)
This section covers the Start-up/Shutdown procedure for the easYgen-2500 Control Panel. There are two main variants, Prime
Power and Automatic Mains Failure (AMF). With the AMF variant an external load transfer panel must be used. This can be
any Load Transfer Panel designed to sense a mains failure and handle all load transfer and re-transfer functions.

5.3.1 Engine Start/Stop

Starting process: By pressing this softkey the engine is started in manual mode.

Successful: If the starting process was successful, the circular arrow indicates that speed
is detected and the engine is running. The symbol indicates that the engine delayed
monitoring has expired and the monitoring functions are enabled.

Unsuccessful: No change in the display until the start failure message appears.

Stop process: Pressing the softkey again will stop the engine.
and the

symbol

Successful: If the stop process was successful, the circular arrow

disappear.

Unsuccessful: No change in the display until the stop failure message appears.

5.3.2 Circuit Breaker Open/Close

Close: By pressing the softkey under the desired circuit breaker, it is closed.

Successful: If the closing process was successful, the breaker symbol turns horizontal.

Unsuccessful: If the closing process was not successful, the breaker symbol remains vertical.

Open: To open this breaker this softkey is pressed while the breaker symbol is horizontal. The
arrows and the Open GCB messages indicate the open command.

Successful: If the opening process was successful, the breaker symbol turns vertical.

Unsuccessful: If the opening process was not successful, the breaker symbol remains
horizontal and the arrows will remain within the softkey character until the control is able to
open the breaker.

5.3.3 Automatic Start-up/Shutdown of the easYgen-2500 Control Panel (AMF Variant):

The following procedure should be used for preparing a generating set equipped with an easYgen-2500 Control System to be
started automatically. This section only applies to the AMF variant.
Note:

The generating set may be stopped at any time by pushing the Emergency Stop Push button.

The engine will not start if the Alarm lamp is illuminated. Reset the control system by acknowledging the alarm in the
Alarm/Event Log screen. Ensure the faults have been corrected prior to attempting to start the generating set.

1. Automatic Start: Ensure the Emergency Stop Push button and any Remote Stop Push buttons are released. Set the
operation mode to AUTO.
The generating set is now ready to automatically start when an external start signal is received.
Note:

A transfer panel manual should be used along with this manual to allow a change over.

Complete periodic maintenance checks as given in Diesel Operators Manual.

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5.4 Operation
5.4.1 Operating Mode MANUAL
To start the generating set in manual, place the controller in MANUAL, then using the gen start/stop button, press once to
place a 1 in the engine LCD display. In manual mode the generator breaker has to be closed manually.
In the MANUAL operating mode (softkey MAN) the engine and the power circuit breakers are
operated via the push buttons along the bottom of the display (softkeys). All elements that may be
operated via the softkeys have a black frame. All other elements cannot be operated. The single line
diagram in the lowest line will change according to the application mode.
The single line diagrams are displayed as follows:
Single line diagram for application mode {0} No breaker control
When MANUAL operating mode is selected a black frame softkey character
will appear around the engine to indicate that the push buttons below this
softkey character may be used to start and stop the engine. This is shown below
highlighted for the following functions.
Examples for the single line diagrams

Start the engine

Stop the engine

Single line diagram for application mode {1o} Generating set breaker open
control.
For a {1o} application both the engine and the GCB softkey characters appear
with the following functions. The X symbol indicates that a breaker open
command is issued or a closure of the breaker is blocked. The dotted breaker line
indicates no defined breaker state.
Examples for the single line diagrams

Start the engine

Stop the engine

Open the GCB

Single line diagram for application mode {1oc} Generating set breaker
open/close.
For a {1oc} application both the engine and the GCB softkey characters appear
with the following functions.

Start the engine

Stop the engine

Open the GCB

Close the GCB

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Examples for the single line diagrams

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5.4.2 Operating Mode STOP

Note:

Selecting the operation mode STOP is not the same as an EMERGENCY STOP. In some cases the easYgen will perform
additional logic functions, such as an engine cool down period before the engine is stopped.
In the STOP operating mode neither the engine nor the GCB can be operated. Dependent on the
application mode the power circuit breakers cannot be operated. If the operating mode STOP has
been selected while:
the engine was already stopped

The GCB will not be closed

The fuel solenoid relay will not be enabled

The discrete inputs and bus commands are ignored

The start push buttons (softkeys) are disabled (depending on the previous operating mode)

The engine/generator monitoring remains de-activated (exception: all monitoring that is not
delayed by the engine speed monitoring)

the engine was running

The GCB is opened

Requirements:

The easYgen-2500 is at least in application mode {1o} and

the GCB is closed

An engine cool down will be performed (the STOP LED is flashing)

The fuel solenoid relay will be disabled

The engine/generator monitoring will be de-activated (exception: all monitoring that is

delayed by the engine speed monitoring)

The control unit screen will display the operations as they are performed

the engine performs a cool down

 ressing the STOP button again causes an immediate stop of the cool down and stops the
P
engine

5.4.3 Operating Mode AUTO

To place the controller in AUTO mode, select the relevant soft key on the display. When in automatic, the easYgen-2500 panel
will be subject to all automatic scenarios which may cause the generating set to start/stop, operate breakers, contacts and
raise/lower setpoints at any given time, without the need for user interaction.
In the AUTOMATIC operating mode, all engine, GCB functions are operated via an interface.
The function of the easYgen depends on the configuration of the unit and how the external
signals are used. The start/stop sequence of the engine is described in more detail in manual
37427.
Start engine

A Start in Auto requires.

Remote start
The engine is started via a remote start signal.

The AUTOMATIC operating mode is enabled.

The function Start req. in AUTO is assigned via the LogicsManager to a discrete input
and the conditions are fulfilled (TRUE).

No alarms or shutdowns are active

The engine is ready for operation.

The GCB is open.

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5.5 Sequencing
Communication between the controllers is required for load sharing To verify that the required number of controllers are on
the network then go to Sequencing screen. This will show each generating sets current status (visible at any controller on the
network) and system load and the reserve load of the system.

a Total kW available
b kW in reserve
c kW on load
d Percentage on load

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6. Navigation
6.1 Operating mode
This screen appears on startup of the unit
Toggle between delta/wye voltage display. The index of the V
symbol indicates whether delta or wye voltage is displayed and
which phases are displayed.
Change into AUTOMATIC operating mode.

Change into MANUAL operating mode.

Change into STOP operating mode.

Display the alarm list (unacknowledged alarms).

Display the Parameter screen.

Scroll down to Measured values screen.

This softkey is only displayed in front of the mains symbol if the
Alarm LED is flashing (An alarm is present, which has not yet
been acknowledged as Seen). This softkey resets the horn and
acknowledges the alarm as Seen.
Operating mode MANUAL: start/stop engine.

Operating mode MANUAL: open GCB.

Operating mode MANUAL: close GCB.

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6.2 Alarm/Shut down list

This screen appears after pressing the Alarm softkey in the starting screen. All
alarm messages, which have not been acknowledged and cleared, are displayed.
Each alarm is displayed with the alarm message and the date and time of
the alarm occurred in the format yy-mon-dd hh:mm:ss. Please note, that selfacknowledging alarm messages get a new timestamp when initializing the unit
(switching on). The symbol indicates that this alarm condition is still present.
A maximum of 16 alarm messages can be displayed. If 16 alarm messages are
already displayed and further alarm messages occur, these will not be displayed
before displayed alarm messages are acknowledged and thus deleted from the
list.
Return to the starting screen.

Scroll up to next alarm message.

Scroll down to next alarm message.

The selected alarm message (displayed inverted) will be
acknowledged. This is only possible, if the alarm condition is
no longer present. If the Alarm LED is still flashing (an alarm is
present, which has not yet been acknowledged as Seen), this
softkey resets the horn and acknowledges the alarm as Seen.

6.3 Main menu

This screen appears after pressing the

softkey two times.

Return to the starting screen.

Scroll up to next menu item.
Scroll down to next menu item.
Enter menu item.
Measured
Values

Display the measured values screen.

Setpoints

Display the generating setpoints screen.

Synchroscope

Display the synchroscope screen.

Sequencing

Display the sequencing screen.

Counters and
Service

Display the counters and service screen.

Diagnostic

Display the diagonstic screen.

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6.4 Screen Setpoints

Manual Operating Mode

Automatic Operating Mode

This screen appears after pressing the Setpoints softkey in the Main menu
screen. The set point is displayed on the left and the actual value is displayed on
the right half of the screen. The symbol indicates the generator power. The
figures 1 or 2 indicate whether set point 1 or set point 2 is used in AUTOMATIC
operation. The source, which is used for set point 1 or set point 2, is displayed
with the respective LogicsManager function number.
The set points may only be adjusted if the respective controller is enabled.
Frequency and voltage may be adjusted within the configured operating limits.
Active power may be adjusted between 0 and the configured load control
setpoint maximum.
Return to Main menu screen.
Change into AUTOMATIC operating mode.
Change into MANUAL operating mode.
Scroll up one set point.
Scroll down one set point.
Raise the selected set point.
Lower the selected set point.
P Real power
Constant = fixed generator load control
Import = fixed import power control
PF Power factor
V Voltage
f Frequency

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6.5 Screen Synchroscope (only applicable to multiple sets)

This screen appears after pressing the Synchroscope softkey in the Main menu
screen. The square symbol indicates the actual phase angle between bus and
generating. A complete left position of the square symbol means -180 and
complete right position means +180. The frequency and voltage differences are
indicated on the top of the display.
Return to Main menu screen.
Change into AUTOMATIC operating mode.
Change into MANUAL operating mode.
Change into STOP operating mode.
Operating mode MANUAL: Raise voltage/frequency.
Operating mode MANUAL: Lower voltage/frequency.
Operating mode MANUAL: start/stop engine.
Operating mode MANUAL: open GCB.
Operating mode MANUAL: close GCB.

RUN
Active synchronization is performed. Bias signals to the governor and voltage regulator are active and breaker close
commands are issued.
PERMISSIVE
Passive synchronization performed. Bias signals to the governor and voltage regulator are not active but breaker close
commands are issued.
CHECK
Active synchronization is simulated. Bias signals to the governor and voltage regulator are active but breaker close commands
are not issued.
Note:

When doing an initial sync. Check, place the controller in Check mode and also as a second measure remove the BCR
relay within the panel. This will allow the engineer to view the Synchroscope display on the controller check voltages
across phase to phase.

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6.6 Screen Sequencing (only applicable to multiple sets)

This screen appears after pressing the Sequencing softkey in the Main menu
screen. The sequencing screen shows all generating sets participating in load
sharing and load dependent start/stop. The operation mode of each generating
set as well as the state of its GCB is shown on this screen. The symbol above
the generator number indicates AUTOMATIC operating mode, indicates
MANUAL and indicates STOP. The field below shows whether the respective
GCB is closed ( ) or open ( ). The bottom field displays the actual load
dependent start/stop values. If this device is not participating in load dependent
start/stop, LD start stop Off is displayed here.
Return to Main menu screen.
Scroll down to generating set 09 through 16 display.
Scroll up to generating set 1 through 08 display.
Display the second screen on the left hand side.

6.7 Screen Counters and Service

This screen appears after pressing the Counters and Service softkey in the Main
menu screen.
Return to Main menu screen.
Scroll down to next page.
Scroll up to previous page.
Display the Maintenance reset screen.
Enter menu item.
Hours of operation 0.00h Operating hours counter
0.00h = Total operating hours (hours in operation, the
decimals are hundredths of an hour)
Number of starts 00 Start counter
00 = Total number of starts
Gen. positive active energy 0.00 MWh Generator
positive active energy
0.00MWh = Total generator positive active energy
Hours until maintenance 000h Maintenance counter
000h = Hours until next maintenance
Days until maintenance 000h Maintenance counter
000h = Days until next maintenance
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6.8 Screen Measured Values

This screen appears after pressing the Measured values softkey in the Main menu
screen.
Return to Main menu screen.
Scroll up to next menu item.
Scroll down to next menu item.
Enter menu item.
Generator
Display the generator indication screen.
Engine (J1939)
Display the Engine (J1939) interface screen.
Analog inputs/outputs
Display the analog inputs and outputs indication screen.
Discrete inputs/outputs
Display the discrete inputs and outputs indication screen.
Electronic Engines
In the Measured Values menu, scroll down to Engine
(J1939) - Press Enter
J1939 Analog Values1 - press Enter
Note: Engine must be running to see these values
Mechanical Engines
In the measured Values menu, scroll down to Analog
Inputs/Outputs - Press Enter
Scroll down to Analog Input 1 for Oil Pressure or
Analog Input 2 for Engine Temperature

6.9 Screen Generator

This screen appears after pressing the Generator softkey in the Measured values
screen. All measured generator values are displayed in this screen.
Return to Measured values screen.
Scroll down display screen to additional generator values.
Scroll up display screen to main generator values.
Reset the maximum value display.
V = Voltage
A = Current
kW = Real power
Kvar = Reactive power
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6.10 Screen J1939 Status (only applicable to electronic engines)

This screen appears after pressing the Engine (J1939) softkey in the J1939
interface screen. The status of the J1939 interface is displayed here.
Return to J1939 interface screen.
Scroll up to next menu item.
Scroll down to next menu item.

6.11 Screen J1939 Active Diag. Trbl. Codes (only applicable to electronic engines)
This screen appears after pressing the J1939 Active diag. trbl.codes softkey in the
Engine (J1939) screen. The active J1939 diagnosis trouble codes are displayed
here.
SPN = Suspect Parameter Number
FMI = Failure Mode Indicator
OC = Occurrence Count
Return to Engine (J1939) screen.
Scroll up display screen.
Scroll down display screen.

6.12 Screen J1939 Previous Diag. Trbl. Codes (only applicable to electronic engines)
This screen appears after pressing the J1939 Previous diag. trbl codes softkey in
the Engine (J1939) screen. The previously active J1939 diagnosis trouble codes
are displayed here.
SPN = Suspect Parameter Number
FMI = Failure Mode Indicator
OC = Occurrence Count
Return to Engine (J1939) screen.
Scroll up display screen.
Scroll down display screen.

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6.13 Screen Analog Inputs/Outputs

This screen appears after pressing the Analog inputs/outputs softkey in the
Measured values screen. All measured generator values are displayed in this
screen.
Return to Measured values screen.
Scroll up display screen.
Scroll down display screen.

6.14 Screen Discrete Inputs/Outputs

This screen appears after pressing the Discrete inputs/outputs softkey in the
Measured values screen. Discrete input and discrete output status are displayed.
Return to Measured Values screen.
Scroll down to external DIs/DOs.
Scroll up to discrete inputs/outputs.
Status display of the discrete inputs and discrete outputs.
(Note: The configured logic for the discrete input N.O./
N.C. will determine how the easYgen reacts to the state
of the discrete input. If the respective DI is configured
to N.O, the unit reacts on the energized state ( ); if it is
configured to N.C., it reacts on the de-energized state
(

30

).

Discrete input:

energized

de-energized

Discrete output:

relay activated

relay de-activated

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6.15 Screen Diagnostic

This screen appears after pressing the Diagnostic softkey in the Main menu
screen.
Return to the Main menu screen.
Scroll up to next menu item.
Scroll down to next menu item.
Enter menu item.
LogicsManager Conditions
Display the LogicsManager conditions screen.
Actual Date and Time
Display the actual date and time screen.
Version
Display the version screen.
Event History
Display the event history screen.
Miscellaneous
Display the miscellaneous screen.

6.16 Screen Actual Date and Time

This screen appears after pressing the Actual date and time softkey in the
Diagnostic screen. This screen displays the actual date and time.
Return to Diagnostic screen.

31

xxxx-yyy-zz = Date

xxxx = Year

yyy = Month

zz = Day

xx:yy:zz = Time

xx = Hour

yy = Minute

zz = Second

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6.17 Screen Event History

This screen appears after pressing the Event History softkey in the Diagnostic
screen. A date/time stamp is added to each entry. Additional characters (+ and )
indicate the state of the event. The + character indicates an condition that is still
active. If the condition is no longer present anymore, it will be displayed again,
but with a indication.
Return to Diagnostic screen.
Scroll up one event.
Scroll down one event.

6.18 Screen Parameter

This screen appears after pressing the

softkey in the starting screen.

Return to the starting screen.

Scroll up to next menu item.
Scroll down to next menu item.
Enter menu item.
Code Level Display
Displays the code level.
Configuration
Display the configuration menu screen.
Language / Clock Configuration
Display the language / clock configuration.
Display Configuration
Display the display configuration.
Enter Password
Display the password entry screen.
System Management
Display the system management configuration screen.

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6.19 Screen Language/Clock Configuration

This screen appears after pressing the Language / clock configuration softkey in
the Parameter screen.
Return to the Parameter screen.
Scroll up one parameter.
Scroll down one parameter.
Select the parameter to be configured with this softkey.
Change the parameter using the softkey. Confirm
the change with the softkey or exit parameter
configuration without any changes using the softkey.

6.20 Screen Display Configuration

This screen appears after pressing the Display configuration softkey in the
Parameter screen. The contrast and brightness of the display may be configured
here.
Return to the Parameter screen.
Increase contrast/brightness.
Decrease contrast/brightness.
Lamp test.
Pressing and holding the STOP button for at least 10
seconds restores the default settings for contrast and
brightness in case the generating settings have been
adjusted in a way that the display cant be read anymore.

6.21 Screen Enter Password

This screen appears after pressing the Enter password softkey in the Parameter
screen. Only the password may be entered using this screen. The code levels are
only displayed depending on the entered password.
Return to the Parameter screen.
Scroll up one parameter.
Scroll down one parameter.
Select the parameter to be configured with this button.
Change the parameter using the softkey. Confirm the
change with the softkey or exit parameter configuration
without any changes using the softkey.

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Code level CL0 (User Level) Standard password = none

This code level permits for monitoring of the system and limited access to the parameters. Configuration of the control is not
permitted. Only the parameters for setting the language, date, time and the horn reset time are accessible. The unit powers
up in this code level.
Code level CL1 (Service Level) Standard Password = 0 0 0 1
This code level entitles the user to change selected non critical parameters, such as getting the parameters accessible in CL0
plus bar / PSI, C / F. The user may also change the password for level CL1. Access granted by this password expires two
hours after the password has been entered and the user is returned to the CL0 level.
Note:

Passwords are used to protect crucial sets points and are therefore only available to trained technicians, please contact
your local dealer.

6.22 Screen System Management

This screen appears after pressing the System management softkey in the
Parameter screen.
Return to the Parameter screen.
Scroll up one parameter.
Scroll down one parameter.
Select the parameter to be configured with this button.
Change the parameter using the softkey. Confirm
the change with the softkey or exit parameter
configuration without any changes using the softkey.

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