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Compact Controller for Standby and Parallel Operating Gen-sets

InteliGen Modular Gen-set Controller


Software branch Combi Binary inputs selectable Single-Multiple SSB, SPtM, MINT application (iG-CU + iG-COM + iG-PCLSM + iG-AVRi)

Software version 1.0, March 2003 Prague, Czech Republic Copyright ! 2003 ComAp s.r.o. Written by: Tomas Zahradnik, Ladislav Kadanik

ComAp s.r.o. Svetova 7, 180 00 Praha 8, Czech Republic Tel: +420-2-6631 6661, Fax: +420-2-6631 6647 WWW: http://www.comap.cz E-mail:info@comap.cz

Table of Contents
Table of Contents .................................................................................................................................... 2 General guidelines................................................................................................................................... 4 What describes this manual? .............................................................................................................. 4 !! Warnings !! ....................................................................................................................................... 4 Text ..................................................................................................................................................... 5 General description ................................................................................................................................. 6 Description of the controller system (with all options)......................................................................... 6 What is in the package?...................................................................................................................... 6 Terminals and Dimensions ...................................................................................................................... 7 IG-CU Terminals ................................................................................................................................. 7 Dimensions.......................................................................................................................................... 9 IG-IB Internet bridge.......................................................................................................................... 11 Recommended wirings .......................................................................................................................... 12 Single application SSB, SPtM (or SPM) ........................................................................................... 12 Manual fuse synchronizing................................................................................................................ 13 Multiple application MINT.................................................................................................................. 13 Multiple application MINT+ InteliMains ............................................................................................. 14 IG-MU Wiring..................................................................................................................................... 16 Getting started ....................................................................................................................................... 17 How to install ..................................................................................................................................... 17 Analog inputs..................................................................................................................................... 21 Configuration ..................................................................................................................................... 21 Hardware connection ........................................................................................................................ 22 Inputs and outputs ................................................................................................................................. 28 Binary inputs IG-CU default ........................................................................................................ 28 Binary inputs - IG-PCM - default ....................................................................................................... 28 Binary inputs list ............................................................................................................................. 28 Binary outputs IG-CU - default ....................................................................................................... 32 Binary outputs IG-PCM - default .................................................................................................... 32 Binary outputs list ........................................................................................................................... 33 Analog inputs IG-CU ......................................................................................................................... 39 Setpoints................................................................................................................................................ 40 Password........................................................................................................................................... 40 ProcCtrlSingle(S) ................................................................................................................................ 41 ProcCtrlMulti(M) .................................................................................................................................. 42 Basic settings .................................................................................................................................... 43 Engine params .................................................................................................................................. 45 Engine protect ................................................................................................................................... 47 Gener protect .................................................................................................................................... 49 Auto Mains Fail.................................................................................................................................. 52 Pwr management(M)........................................................................................................................... 54 Sync/Ld ctrl........................................................................................................................................ 57 Volt/PF ctrl......................................................................................................................................... 60 Act. calls/SMS ................................................................................................................................... 61 Load Shedding .................................................................................................................................. 62 Date and time .................................................................................................................................... 63 Sensor spec ...................................................................................................................................... 64 Sensor specification .............................................................................................................................. 65 Background of the sensor calibration................................................................................................ 65 Default sensor settings...................................................................................................................... 65 Operator Interface ................................................................................................................................. 66 Pushbuttons and LEDs ..................................................................................................................... 66 How to select the gen-set mode?...................................................................................................... 67 When to use button GCB ON/OFF? ................................................................................................. 67 Display menus................................................................................................................................... 67 InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf 2

How to view measured data?............................................................................................................ 67 How to view and edit set points?....................................................................................................... 67 How to handle the HISTORY menu? ................................................................................................ 68 How to find active alarms? ................................................................................................................ 68 MEASUREMENT screens description .............................................................................................. 68 Chart guide to menus and pushbuttons operation ........................................................................... 71 Function description .............................................................................................................................. 72 OFF mode ......................................................................................................................................... 72 MAN mode ........................................................................................................................................ 72 AUT mode ......................................................................................................................................... 72 Manual fuse synchronizing................................................................................................................ 73 Two setpoint set switch ..................................................................................................................... 73 SSB SPtM switch ........................................................................................................................... 73 Baseload change by Binary inputs.................................................................................................... 73 Single / Multiple application switch.................................................................................................... 74 Load surge protection ....................................................................................................................... 74 Load shedding................................................................................................................................... 74 Alarm management ............................................................................................................................... 76 Warning ............................................................................................................................................. 76 Unload ............................................................................................................................................... 76 Slow stop........................................................................................................................................... 76 Shut down ......................................................................................................................................... 77 Voltage phase sequence detection ................................................................................................... 77 Setpoint replication management.......................................................................................................... 80 How to adjust setpoints ..................................................................................................................... 80 Setpoints consistency ....................................................................................................................... 80 Gen-set operation states ....................................................................................................................... 81 Start-stop sequence .......................................................................................................................... 81 Unsuccessful start ............................................................................................................................. 82 Remote control and data logging .......................................................................................................... 83 Direct connection to the PC .............................................................................................................. 83 PC software - WinEdit ....................................................................................................................... 83 History file.......................................................................................................................................... 83 Remote and mobile communication ...................................................................................................... 87 Modbus protocol................................................................................................................................ 87 Recommended ISDN modem ........................................................................................................... 87 Recommended GSM modem............................................................................................................ 87 Mobile SIM card setting..................................................................................................................... 88 SMS message format........................................................................................................................ 88 Active SMS message ........................................................................................................................ 92 IG-IB Internet communication ........................................................................................................... 93 Value and setpoints codes .................................................................................................................... 94 Technical data ....................................................................................................................................... 99 Power supply..................................................................................................................................... 99 Operating conditions ......................................................................................................................... 99 Dimensions and weight ..................................................................................................................... 99 Bus and generator............................................................................................................................. 99 IG-MTU............................................................................................................................................ 100 Binary inputs and outputs................................................................................................................ 100 Analog inputs................................................................................................................................... 100 Speed pick-up input ........................................................................................................................ 100 CAN bus interface ........................................................................................................................... 101 IG-PCLSM ....................................................................................................................................... 101 IG-AVRi ........................................................................................................................................... 102 IG-MU.............................................................................................................................................. 102 IG-IB ................................................................................................................................................ 102

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

General guidelines
What describes this manual?
This manual describes IG Combi software configuration, which was designed especially for rental gensets. IG Combi software is based on standard IG software version 5.5. There are available two setpoint sets and three Application modes selectable by Binary inputs without software download.

IG-Combi functions
Selection between two Nominal setpoints sets (e.g. 230/1500/50Hz and 277/1800/60Hz) by Binary input. Set No.1 Set No.2 VAC Ph-N Nominal voltage 2 Nominal voltage 1 RPM Nominal RPM 2 Nominal RPM 1 Hz Nominal frequency 2 Nominal frequency 1 Genset automatic Mains Fail start disabling by setpoint. Switch between SSB and SPtM Application mode by Binary input. Increase and decrease Baseload value in Parallel to mains by Binary inputs. Manual fuse synchronizing function (MCB). Change from Single (SPtM) to Multiple (MINT) Application mode by Binary input.

Hint: IG-Combi software does not support IG-IOM or IGS-PTM module.

What is the purpose of the manual?


This manual provides general information how to install and operate InteliGen controller. This manual is dedicated for Operators of gen-sets Gen-set control panel builders For everybody who is concerned with installation, operation and maintenance of the gen-set

!! Warnings !!
Remote control
InteliGen controller can be remotely controlled. In case of the work on the gen-set check, that nobody can remotely start the engine. To be sure: Disconnect remote control via RS232 / CAN line Disconnect input REMOTE START/STOP or Disconnect output STARTER and outputs GCB CLOSE/OPEN and MCB CLOSE/OPEN Because of large variety of InteliGen parameters settings, it is not possible to describe any combination. Some of InteliGen functions are subject of changes depend on SW version. The data in this manual only describes the product and are not warranty of performance or characteristic.

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

Text
PAGE Break Return Generator protections REMOTE START/STOP Inputs and setpoints marked Inputs and setpoints marked
(M) (S)

(Capital letters in the frame) buttons on the front panel (Italic) set points (Bold) Set point group (Capital letters) binary inputs and outputs have meaning in Multiple applications only. have meaning in Single application only.

Note: ComAp believes that all information provided herein is correct and reliable and reserves the right to update at any time. ComAp does not assume any responsibility for its use unless otherwise expressly undertaken.

WARNING VERY IMPORTANT !!!

Be aware that the controller can change Binary outputs states during and after software reprogramming (before is finished proper configuration and Setpoints setting) !!! Switch InteliGen to MAN mode and disconnect the Binary outputs Starter and Fuel to avoid unexpected automatic start of genset and GCB closing.

!!! CAUTION !!!


Dangerous voltage
In no case touch the terminals for voltage and current measurement! Always connect grounding terminals! In any case do not disconnect InteliGen CT terminals !

Adjust set points


All parameters are preadjusted to their typical values. But the set points in the Basic settings settings group !!must!! be adjusted before the first startup of the gen-set. !!! WRONG ADJUSTMENT OF BASIC PARAMETERS CAN DESTROY THE GEN-SET !!! The following instructions are for qualified personnel only. To avoid personal injury do not perform any action not specified in this User guide !!!

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

General description
Description of the controller system (with all options)
InteliGen iG-CU is a comprehensive AMF-controller for single and multiple generating sets operating in stand-by or parallel modes. A modular construction allows upgrades to different levels of complexity in order to provide best solutions for various customer applications. Optional synchronizer, isochronous load sharer, Mains and Generator protections allows total integrated solution for Gen-sets in stand-by and parallel modes with multiple engine support. InteliGen controllers are equipped with a powerful graphic display showing icons, symbols and bar-graphs for intuitive operation, which sets, together with high functionality, new standards in Genset controls. InteliGen automatically starts the Gen-sets, closes the Gen-set C.B. when all conditions are met, then stops the engine on external signal or by pressing push buttons. With upgrade kits, isolated parallel and parallel to Mains operation can be achieved. Forward and reverse synchronizing, Mains protection including load surge, load and power factor control, earth fault protection are the major functions provided. Interfacing to foreign synchronizers and load sharers is supported. The key feature of InteliGen is its easy-to-use operation and installation. Predefined configurations for typical applications are available as well as user-defined configurations for special applications.

What is in the package?


Accessories IG-CU IG-PCLSM IG-MTU Description InteliGen central unit InteliGen power control and load sharing module InteliGen voltage transformer unit to separate mains and generator voltage measurement InteliGen AVR interface InteliGen voltage transformer for supplying AVRi module InteliGen communication unit InteliGen Modem Unit Internet bridge Optional / Obligatory Obligatory Obligatory Optional

IG-AVRI IG-AVRi-TRANS IG-COM IG-MU IG-IB

Optional Optional Optional Optional Optional

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

Terminals and Dimensions


IG-CU Terminals
Grounding Terminal

GENERATOR CURRENT 0-5A

GENERATOR VOLTAGE 3 x 230 / 400 V

BINARY INPUTS

In (Im L3) CURRENT

ANALOG INPUTS

RPM

BINARY OUTPUTS

RPM Grounding Terminal

IG-PCLSM Terminals

Shield

LSM+

LSM-

GND

VoutR

iG-PCLSM

LOAD SHARING

SPEED GOVERNOR

AVRi

Serial No.

BINARY INPUTS

BINARY OUTPUTS

POWER 8 - 36 V DC

BO10

BI13

BO11

BI11

BO12

BI12

BO13

BI10

+ -

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

AVRi+

Vout

AVRi-

IG-AVRi Terminals

IG-COM Terminals
H
COM

L
COM

CAN

EXTENSION MODULE

CAN

iG-COM
IG-MU Terminals

Serial No.

P4

P3 P1 P2

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

Dimensions
IG-CU + IG-COM + IG-PCLSM
1
130 (5,1") 113 (4,4")

~ 130 (5,1")

170 (8,87")

2 1

~ 110 (4,3")

80 (3,1")

iG-PCLSM

iG-COM

Cutout for InteliGen


45 (1,8")

42,5 (1,7")

24 (0,9")

iG-CU

113 x 175 mm (4.4 x 6,9)

185 (7,3")

1 2

RS 232 Cable IOM Cable


Secondary terminals 0 x 18VAC

IG-AVRi, IG-AVRi TRANS

18 V

iG-AVRi TRANS
230/400 V

43 (1,7)

36 (1,4)

43 (1,7)

Primary terminals 0230480 VAC

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

123 (4,8")

There are two types of AVRi available Primary voltage 230 and 400 VAC 277 VAC IG-AVRi unit is DIN rail mount (35mm) IG-AVRi TRANS are DIN rail mount (35mm) Secondary voltage 18 VAC 18 VAC

IG-MU

96 mm (3,8)

95 mm (3,7)

43 mm (1,7)

IG-MU unit is DIN railmount (35mm)

IG-MTU
LB 1

iG-MTU
Serial No.

N L1 L2 L3

155(6,10")

95 (3,74")

60 (2,36")

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

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IG-IB Internet bridge

ETHERNET RJ 45 1 2

LB 4

4 H COM L CAN POWER 8 - 36 V DC

96 mm (3,8)

MODEM / IB CONFIG

IG-CU / DONGLE

95 mm (3,7)

43 mm (1,7)

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

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Recommended wirings
Single application SSB, SPtM (or SPM)
LOAD

MAINS N 3 1

MCB N

GCB
G1

Engine

3 BINARY INPUTS

GCB feedback GCB close/open

AVRi RPM Speed governor

Fuel Starter

MCB feedback MCB close/open

Vm / Vb

Vg Ig

IG-CU Combi + IG-PCLSM (+ IG-COM)

Sys start/stop Emergency stop Nominal switch Synchro Enable RevSync Enable BaseLoad Inc BaseLoad Dec

SSB, SPTM Binary input Nominal switch selects between two setpoints sets (Nominal voltage, Nominal RPM, Nominal freq). Single application mode is active when Binary input: MultipleEnable is not configured or opened. Binary input: Synchro Enable enables GCB synchronizing - selects between SSB (when opened) and SPtM (when closed) Application mode. Change of this binary input is accepted only in OFF mode. Binary input: RevSync Enable enables reverse (MCB) synchronizing. Binary inputs: BaseLoad Inc and BaseLoad Dec inc/decreases ActReqPower (Active required generator power value) that is in principle Baseload value. ActReqPower is visible on IG screen. Speed of Baseload change is adjusted by ProcCtrlSingle: BaseloadChange. SPM Binary input MCB feedback must be opened or not configured Setpoint AutoMainsFail: MF StartEnable = DISABLED Mains Voltage measuring terminals must be connected to ground.

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

Im3

12

Manual fuse synchronizing


LOAD Manual fuse switch 3 N 3 1 Manual N 3 3 BINARY INPUTS Sys start/stop Emergency stop Nominal switch Synchro Enable RevSync Enable BINARY OUTPUT In synchronism GCB
G1

MAINS

Engine

GCB feedback GCB close/open

AVRi RPM Speed governor


3 3

MCB feedback

Vm / Vb

IG-CU Combi + IG-PCLSM (+ IG-COM)

Sync/Load ctrl: ManualFuseSync = ENABLED Important !!! Fulfillment synchronization conditions are indicated by Binary output In synchronism. Manual fuse switches can be closed only when Binary output: In synchronism is closed!!! There is no timeout for fuse switch closing (Sync/Load ctrl: Sync timeout is not active). Binary input: MCB feedback can be closed after all Manual fuse switches are closed. MCB feedback activates Load control function.

Multiple application MINT


LOAD

MGCB BUS GCB1


G1

Fuel Starter
Engine

Vg Ig

Im3

GCB feedback GCB close/open

AVRi RPM Speed governor

Vm / Vb

MCB feedback

Fuel Starter

Vg Ig

BINARY INPUTS Sys start/stop Emergency stop Nominal switch MultipleEnable Synchro Enable

IG-CU Combi + IG-PCLSM + IG-COM

BUS

CAN bus

To another gensets

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

LS line

13

MINT: Binary input: MultipleEnable is closed to switch to multiple Application mode. Single/Multiple application mode change is possible in InteliGen OFF mode only. System behavior in Multiple applications is like standard IG-MINT.

Multiple application MINT+ InteliMains


MAINS MCB

LOAD MGCB CAN bus LS line

InteliMains +IM-PCLSM +IG-COM

BUS

GCB1
G1

MCB feedback MCB close/open


3

Vb

3 3

Im Vm
Engine

GCB feedback GCB close/open

AVRi RPM Speed governor

Vm / Vb

MCB feedback

Fuel Starter

Vg Ig

BINARY INPUTS Sys start/stop Emergency stop Nominal switch MultipleEnable Synchro Enable

BUS MCB feedback CAN bus

IG-CU Combi + IG-PCLSM + IG-COM

To another gensets

More application details see in InteliGen standard software V5.5 user guides: IG-SSB-SSB+IOM-5.5.pdf IG-SPtM-SPtM+IOM-5.5.pdf IG-MINT-MINT+IOM-5.5.pdf IM-IM+IOM-5.0.pdf IG5.5-IS2.7-ApplicationGuide.pdf

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

LS line

14

IG-PCLSM connection

0 V DC
iG-PCLSM

LOAD SHARING PARALLEL LINE + -

Serial No.

BI10 Shield LSMLSM+ BINARY INPUTS GND VoutR Vout SPEED GOVERNOR BINARY OUTPUTS

BI11

LOAD SHARING

BI12

BI13

SPEED GOVERNOR

BO10

BO11

CONFIGURABLE
AVRi AVRiAVRi+
LB 2

BO12

BO13

POWER 8 - 36 V DC

+ -

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

AUTOMATIC VOLTAGE REGULATOR


18 V AC
18 V

iG-AVRi TRANS
230/400 V

0 V DC

230/400 V FROM GENERATOR

15

IG-MU Wiring
RS485 / RS 422 connection
TxB TxA RxB RxA B A

IG-MU

RS485

IG-MU

TxB TxA RxB RxA

RS422

More IG-MU on CAN bus


It is possible to connect two IG-MU units for direct connection to MultiEdit, WinEdit (local bridge) and one IG-MU for modem connection (=maximal three IG-MU) to CAN bus at once. Internal address setting jumper must be placed when two local bridges are connected to CAN bus. IG-MU automatically detects modem connection.

Modbus communication
Place Modbus jumper in unit before IG-MU Modbus communication. IG-MU jumpers setting

P4

P3 P1 P2

Jumpers position: P1 2-nd local bridge P2 Modbus jumper P3 Boot jumper P4 Switch between RS232 and RS485/RS422

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

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Getting started
How to install
General
To ensure proper function: Use grounding terminals. Cables for binary inputs and analog inputs must not be placed along power cables. Analog and binary inputs should use shielded cables, especially when length >3m.

Power supply
To ensure proper function: 2 Use min. power supply cable 1,5mm Power supply of IG-PCLSM module should be directly connected to IG-CU. Maximum continuous DC power supply voltage is 36VDC. Absolute maximum peak power supply voltage is 39VCD. Controller has fast protection against peak pulse power disturbances on power supply terminals. When is risk of overstep of standard controller supply conditions use external protection device. Hint: Switchboard flash protection according standard regulation is expected !!! Max current of power minus terminal can be up to 4A (depends on binary outputs load). For 12VDC power supply, connect external capacitor and separating diode to support controller supplying during cranking.

T1A

+ + -

iG-CU iG-PC(LS)M

+
Battery

HUGE LOADS STARTER

Power supply fusing


In any case do not connect controller and extension units power supply directly to starting battery. Take care for proper controller, extension units and relays power supply fusing. Fuse value and type depends on number of connected devices and wire length. Recommended fuse (not fast) type - T1A.

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

17

Binary output protections


In any case do not connect DC relays without protection diodes even if they are not connected directly to controllers outputs.

Fuse Fuse
K1 K1 K2

K2

T1A

IG controller + DC relays

+ 24VDC

Battery
Example of InteliGen controller protection

Grounding
To ensure proper function: Use as short as possible cable to the grounding point on the switchboard 2 Use cable min. 2,5mm The - terminal of the battery has to be properly grounded

As short as possible

Magnetic pick-up
To ensure proper function: Use a shielded cable

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

18

iG-CU iS-CU

Signal

RPM-IN GND

MAGNETIC PICK-UP

C Signal

GAC Speed Control Unit ESD 5500


+ Power Supply Power Supply +

+
Battery

Be aware of interference signal from Speed governor when one speed pick-up is used. When some problems occur: - Check ground connection from pick-up to controllers, eventually disconnect ground connection to one of them, - Galvanically separate Inteligen RPM input using ComAp separation transformer RPM-ISO (1:1) - use separate pick-up for Speed governor and InteliGen Hint: Controller can detect RPM on no running gen-set when: RPM is measured from the generator voltage (Gear teeth = 0) IG Generator voltage terminals are opened (e.g. due to opening of fuse disconnector) No zero RPM causes controller Not ready state and engine start is blocked.
LO AD MAINS
L1 L2 L3 N

MCB

GCB

GENERATO R
L1 L2 L3 N

L1

L2

L3

L1

L2

MAINS VO LTAGE

GENERATOR VO LTAGE

IG-CU

SSB, SPtM

Earth fault protection


It is not available in this software application.

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

L3

19

Voltage measurement
L1

L2 L3 N

L1 L2 L3 G ENERATO R

L1 L2 L3 MAINS

Hint: Switchboard flash protection according standard regulation is expected!!! Mains / bus voltage neutral must be connected to the generator voltage neutral connector.

Mains and gen-set neutral separation


If required mains and gen-set neutral separation (four pole breakers) IG-MTU have to be added between mains and controller terminals.

IG MTU
Connect two IG-MTU units for separation of generator and bus voltage from controller when is: a) 3wire mains/bus and generator b) 4wire mains/bus and generator, separated neutral
L1 L2 L3 M AINS / BUS G ENERAT O R L1 L2 L3

400V

400V

400V

400 V

400 V

0V

0V

400 V

0V

0V

0V

T1
400V 0V

T2
400V 0V

T3
400V 0V

T1
400 V 0V

T2
400 V 0V

T3
400 V 0V

IG-M T U
L1 L2 L1 L2 L3 L3 N

IG -MT U

M AINS / BUS VO LT AG E

G ENERATO R VO LTAG E

IG-CU

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

0V

20

Connect one IG-MTU unit for separation of generator and bus voltage from controller when is 3wire mains/bus and 4wire generator.
L1 L2 L3 MAINS / BUS GENERATOR L1 L2 L3 N

400V

400V

400V

T1
400V 0V

0V

T2
400V 0V

0V

T3
400V 0V

IG-MTU

0V

L1

L2

L1

L2

L3

MAINS / BUS VOLTAGE

GENERATOR VOLTAGE

IG-CU

Analog inputs
Three analog inputs AI1, AI2, AI3 are available on the IG-CU.

Configuration
Each analog input AI1, AI2, AI3 can be configured by WinEdit software following way. Analog input item Analog input name Type of input WinEdit Name Type Possibility Up to 14 ASCII characters Analog measuring in specified range. Analog Binary: open/close - threshold 750 . Binary Three-state: open/close - threshold 750 , Tri-state Failure <10 or > 2400 bar,%,C, Up to 3 ASCII characters Open to activate Valid only for binary and three-state inputs Close to activate Valid only for binary and three-state inputs Protection Anl Inp level1 is reached Warning Protection Anl Inp level2 is reached Shut down Alarm is check condition All the time Engine running only unused analog input None User curve A Curve A User curve B Curve B User curve C Curve C PT 1000 NI 1000 VDO Temp VDO Press VDO Level 4-20mA/100 4-20mA/ 60 IEC 751, range -20 to 120 C DIN 43760, range -20 to 120 C See chapter sensor specification external R=120 external R=120 21

Physical dimension Polarity Alarm type Alarm activity Sensor characteristic

Dim Inverted Alarm type Alarm activity Sensor

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

L3

Over Alarm active when over Under Alarm active when under Decimal points Dec 0, 1, 2 Number of decimal points User Curve A, B, C are adjustable in WinEdit. Each Analog input has separate set points for two level alarm setting. Analog input alarm levels Anl Inp level1, Anl Inp level2 and delay Anl Inp del adjust in Protection or Engine protection group.

Active

Active

Hardware connection
Connection of IG-CU analog inputs
- PO W ER CO M AI1 AI2 AI3

IG-CU

Standard connection of three resistive sensors to analog inputs AI1, AI2, AI3. Analog input common terminal COM has to be connected to IG minus Power supply terminal.

3x RESISTIVE SENSO R
- PO W ER CO M AI1 AI2 AI3

IG-CU

Three current output sensors connection to InteliGen. External resistors 120 ohms each are connected between minus power supply terminal of IG-CU and AI1, AI2, AI3.
3x SENSO R 4 - 20 mA

3x 120 ohm

+24V

Current sensor connecting reduces the analog input resolution by less than 50% against resistive sensor. Analog input common terminal COM has to be connected to IG minus Power supply terminal. Mixed connection of InteliGen analog inputs: AI1 current sensor with external 120 ohms resistor AI2 resistive sensor. AI3 binary input Analog input common terminal COM has to be connected to IG minus Power supply terminal.

120 ohm

- POW ER COM AI1 AI2 AI3

IG-CU

+24V AI1 CURRENT SENSOR AI2 RESISTIVE SENSOR AI3 BINARY INPUT

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

22

- PO W ER CO M AI1 AI2 AI3

IG-CU

Mixed connection of InteliGen analog inputs: AI1 resistive sensor AI2 binary input AI3 three state input

2x 470 ohm s

Analog input common terminal COM has to be connected to IG minus Power supply terminal.

AI1 RESISTIVE SENSO R AI2 BINARY INPUT AI3 THREE STATE INPUT

Analog inputs are designed for resistive sensors with resistance in range of 0 to 2,4k. To ensure a proper function use shielded cables, especially for length over >3m.

Current output sensors connection


To connect the current output sensor, external parallel resistor 120 has to be added. The input sensor characteristic has to be configured to 4-20mA/100 or 4-20mA/60 sensor. This method reduces the input resolution by less than 50%.

Current output transducers


IG-CU analog inputs are mainly designed for resistor sensors. In special case transducers to 4-20mA output can be used for various measuring. Some types of transducers are not suitable for connection to InteliGen analog inputs because of influencing by InteliGen analog input. In this case change default 4-20mA/60 or 4-20mA/100 sensor characteristic to get proper reading.

Binary input
Open, close state are detected, threshold level is 750 .

Three state input


Open, close and failure state are detected. Threshold level is 750 , failure is detected when circuit resistance is <10 or > 2400 .

Unused analog inputs


Configure Sensor = Unused input

Example of analog input configuration


Configure Analog input 1 for Oil press measuring in Bar, VDO oil pressure sensor, range 0 to 10.0 bars. Alarm protection level set to 3.5 bars, shut down level 1.2 bars. Start WinEdit and select Controller - Software configuration Modify - Analog inputs. There are following configuration items. Set configuration for selected analog input (rows 1 to 7): Name: Change the name of analog input; maximal length is 11 characters Set to: Oil Press Abbr: Abbreviation is used in history record for column labeling; maximal length is 4characters. Set to: OilP Type: selection between Analog, Binary Tri-state input. Analog resistor sensor is connected to Analog input.

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23

Binary open/close contact is connected between Analog input and COM terminal of Analog inputs. Analog input detects only open/close state. Tri-state open/close contact is connected parallel to one of two serial resistors between Analog input and COM terminal of Analog inputs. Set to: Analog Dim: Physical dimension of measured value (C, %, Bar, ..) Maximal dimension length is three characters. Set to: Bar Active: setting of polarity: over alarm is active when analog input value is over the Analog input limits (setpoints Anl Inp level1 or Anl Inp level2 in Engine protection group). under - alarm is active when analog input value is under the Analog input limits. Set to: under (alarm is active when Oil pressure goes low) Inverted: selection of polarity only when analog input is configured as Binary or Tri-state. When is analog input configured as analog this setting has no sense. Open to activate polarity of binary or tri-state input Close to activate polarity of binary or tri-state input Alarm type: selection between different types of alarms. Sensor fail sensor value is 20% out of selected sensor range. Use when analog input is used for measuring only, not for protections. Warning Anl Inp level1 is warning level, Anl Inp level2 is not used Wrn+Shutdown - Anl Inp level1 is warning, Anl Inp level 2 is shutdown level Wrn+Slowstop - Anl Inp level1 is warning, Anl Inp level 2 is slowstop level Wrn+Unload - Anl Inp level1 is warning, Anl Inp level 2 is unload level Set to: Wrn+Shutdown (lubrication is necessary for engine health) Alarm active: selection between All the time no limited alarm detection Engine running only alarm detection is activated Engine protections: Protection del [s] after the BO starter is off, (RPM reached Start RPM). Sensor: selection of sensor characteristic Unused input - when Analog input is not used. On the InteliGen screen is displayed #### value, no alarm is detected. Curve A User curve A is defined in WInEdit (default VDO temperature sensor) Curve B User curve B is defined in WInEdit (default VDO pressure sensor) Curve C User curve C is defined in WInEdit (default VDO fuel level sensor) Pt1000 PT1000 sensor characteristic according to IEC 751 Ni1000 Ni1000 sensor characteristic according to DIN 43 760 VDO temp VDO temperature sensor VDO press VDO pressure sensor VDO level VDO level sensor 4-20mA/60 current output sensor characteristic requires external resistor 120 ohms between Analog input and COM terminal of Analog inputs 4-20mA/100 current output sensor characteristic requires external resistor 120 ohms between Analog input and COM terminal of Analog inputs Set to: VDO press Decimals: setting of number of decimal points of measured value. 0 e.g. 360 kPa, 100%, 50 C 1 e.g. 3.6 Bar 2e.g. 0.36 MPa 3 e.g. 0.366 MPa Set to: 1

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24

When Analog input configuration is finished set the setpoints Anl Inp level1, Anl Inp level2, Anl Inp del in Engine protection group. Each Analog input has separate triplet of setpoints: Anl Inp level1, Anl Inp level2, Anl Inp del. Names of these setpoints are fix defined do not depend on the name of measured value which can be changed. Number of decimal points of Anl Inp level1 and Anl Inp level2 is the same as the configured number of decimal points of measured value.

Binary inputs
4k7

iG-CU

+ Power Supply

T1A

+ 24VDC Battery

Binary outputs
LOAD

iG-CU

+ Power Supply

T1A

+ 24VDC Battery

IG-COM Wiring

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25

120
CAN

H
COM

L
COM

EXTENSION MODULE

CAN

Serial No.

H
COM

L
COM

CAN

EXTENSION MODULE

CAN

Serial No.

H
COM

L
COM

120
CAN

CAN

EXTENSION MODULE

Serial No.

Hint: For CAN cables details see chapter Technical data Communication interface. CAN bus have to be to line connected, both end by the 120 ohm resistor terminated. For longer distances is recommended to connect COM terminals between iG-COM units.

CAN bus connection


120 ohm terminator

CANL 0CAN CANH

CANL 0CAN CANH

CANL 0CAN CANH

CAN bus is internaly connected

CAN bus is internaly connected

iG-COM

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

CANL 0CAN CANH

Twisted pair data cable

CAN bus to next unit

iG-COM

26

H
COM COM

L H

CAN

EXTENSION MODULE CAN

Serial No.

H
COM COM

L H

CAN

EXTENSION MODULE

CAN

CAN bus

Serial No.

L
CAN

COM H L
CAN

Se rial No.

COM

iG-MU

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf


H TxB TxA
RS 422

RxB RS 422 RS 232 RS 232 RxA

POWER 8- 36V DC

--

27

Inputs and outputs


Hint: Any Binary input or output can be configured to any IG-CU controller terminal or changed to different function by WinEdit software. There is fix 1 sec delay when any binary input is configured as protection.

Binary inputs IG-CU default


BI1 GCB feedback BI2 MCB feedback BI3 Sys start/stop BI4 Emergency stop BI5 MultipleEnable BI6 Access lock BI7 NominalSwitch BI8 Alarm 8
If the input is closed, selected alarm type is activated. Default configuration Close to activate, Shut down, Engine running only.

BI9 Alarm 9
If the input is closed, selected alarm type is activated. Default configuration Close to activate, Slow stop, All the time.

Binary inputs - IG-PCM - default


BI1 Synchro Enable BI2 RevSync Enable BI3 BaseLoad Inc BI4 BaseLoad Dec

Binary inputs list


Inputs marked Inputs marked
(M) (S)

have meaning in multiple application only. have meaning in single application only.

Alarm
If the input is closed (or opened) selected alarm is activated. Binary Alarm configuration items Name 14 characters ASCII string Inverted Close to activate Open to activate InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf 28

Alarm type

Alarm active

Warning Slow stop Shut down Unloading HistoryRecord All the time Engine running only

No warning,

Not used
Binary input has no function. Use this configuration when Binary input is not connected.

GCB feedback
Use this input for indication, whether the generator circuit breaker is open or closed. If the feedback is not used, connect this input to the output GCB CLOSE/OPEN

MCB feedback
Use this input for indication, whether the mains circuit breaker is open or closed. This input indicates, whether the gen-set operates in parallel to mains (MCB FEEDBACK is closed) or isolated (MCB FEEDBACK is open).

Emergency stop
If the input is active shut down is immediately activated.

Sprinkler
If the input is closed all alarms are disabled except the binary input EMERGENCY STOP and "engine over speed protection". all IG alarms are detected, enabled Active calls remains active, IG front panel gen-set RED LED blinks or lights, alarm is recorded on the IG alarm list screen, alarm is recorded into history, BUT gen-set remains running.

Access lock
If the input is closed, no setpoints can be adjusted from controller front panel and gen-set mode (OFFMAN-AUT) cannot be changed. Hint: Access lock does not protect setpoints and mode changing from WinEdit. To avoid unqualified changes the selected setpoints can be password protected.

Remote OFF
If closed, iG is switched to OFF mode (there are three modes OFF-MAN-AUT). When opens controller is switched back to previous mode. Hint: This binary input can be connected to timer switch, to avoid start of engine.

Sys start/stop
Single parallel application (SPtM): If the input closes, InteliGen starts the engine (in AUT mode only). Genset is running in parallel (base load power level) or island (depends on Mains state). If the input opens and gen-set runs in island, gen-set keeps running until mains recovers. After mains recovery InteliGen opens GCB, cools and stops the engine. Single application (SSB): no action . Multiple Application: If the input closes InteliGen starts the Pwr management (in AUT mode only). InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf 29

If the input opens, InteliGen inactivates Pwr management process and stops the gen-set.

Load reserve 2(M)


If the input LOAD RESERVE 2 is closed the setpoints LoadRes strt 2, LoadRes stp 2 will be selected.

Load reserve 3(M)


If the input LOAD RESERVE 3 is closed the setpoint LoadRes strt 3, LoadRes stp 3 will be selected.

Load reserve 4(M)


If the input LOAD RESERVE 4 is closed the setpoint LoadRes strt 4, LoadRes stp 4 will be selected. Hint: When more than one Load reserve binary inputs are closed, the higher number has higher priority. All controllers operating in Power management group have to select the same Load reserves.

MinRun power 1(M) (Minimal running power 1) MinRun power 2(M) (Minimal running power 2) MinRun power 3(M) (Minimal running power 3)
When binary input MinRun power 1 or 2 or 3 is closed the corresponding setpoints MinRun power 1 or 2 or 3 is selected. Higher index has higher priority when more binary inputs are closed. When not configured or not active, minimal running power is 0.

Master select(M)
If the input is closed, the gen-set has the highest priority (Priority = 0) in Power management regardless of the value of the setpoint Priority.

PrioritySwtch1(M) (Priority switch 1) PrioritySwtch2(M) (Priority switch 2) PrioritySwtch3(M) (Priority switch 3) PrioritySwtch4(M) (Priority switch 4)
Binary inputs for external genset priority selection. Priority selection is important in Power management. Higher Priority gensets starts sooner. The range from of Priority setting is 1 to 15. Priority value Priority 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PrioritySwtch1 0 or nc 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 PrioritySwtch2 0 or nc 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 PrioritySwtch3 0 or nc 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 PrioritySwtch4 0 or nc 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 Hint: Priority value is defined by setpoint Power management: Priority when all Priority switches are opened or not configured.

Man load recon (Manual load reconnection)


Rising edge on MAN LOAD RECON input resets IG controller to the lower step of Load shedding when AutoLd recon = DISABLED and Generator actual load is under Ld Recon level. Ld recon del is not important in manual reconnection by binary input. Principle of Load shedding is described in the chapter Function description Load shedding.

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30

Start button
Binary input has the same function as Start button on the InteliGen front panel. It is active in MAN mode only.

Stop button
Binary input has the same function as Stop button on the InteliGen front panel. It is active in MAN mode only.

FaultResButton
Binary input has the same function as Fault reset button on the InteliGen front panel.

HornResButton
Binary input has the same function as Horn reset button on the InteliGen front panel.

GenCB button
Binary input has the same function as GCB button on the InteliGen front panel. It is active in MAN mode only.

MainsCB button(S)
Binary input has the same function as MCB button on the InteliGen front panel. It is active in MAN mode only.

MultipleEnable
When binary input is closed, multiple application is selected and InteliGen behave as in MINT application. When binary input is opened (or not configured), single application is selected and InteliGen behave as in SPtM or SSB application. Hint: This binary input could be changed only in controllers OFF mode or after IG switch on.

NominalSwitch
This binary input select one of the nominal setpoints from Basic settings group. NominalSwitch Selected setpoints from Basic settings Open (or not configured) Nomin voltage 1, Nominal PRM 1, Nominal freq 1 Nomin voltage 2, Nominal PRM 2, Nominal freq 2 Closed

Synchro Enable(S)
When closed, enables forward Synchronization (of GCB) and SPtM behavior of InteliGen is selected when MultipleEnable is opened. When opens, disable forward Synchronization and SSB behavior of InteliGen is selected when MultipleEnable is opened. Binary input Synchro Enable ReverseSync Enable Multiple Enable X = no influence SSB Opened Opened Opened SPtM Closed Opened or Closed Opened MINT Closed X Closed

Hint: This binary input could be changed only in controllers OFF mode or after IG switch on.

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31

RevSync Enable(S)
When closed, enables reverse MCB Synchronization in SPtM. Hint: For reverse synchronization enabling the binary input Synchro Enable must be closed too.

BaseLoad Inc(S)
When closed, actual required power is increased by BaseLoadChange percent of Nominal power per second. Upper value of actual requested power is limited by Nominal power setpoint.

BaseLoad Dec(S)
When closed, actual required power is decreased by BaseLoadChange percent of Nominal power per second. Hint: Baseload change is available in SPtM - parallel to the mains only - Binary input MultipleEnable = OPENED. Process control Baseload setpoint does not change Actual required power is displayed on the first InteliGens screen in brackets or in WinEdit.

Binary outputs IG-CU - default


IG-CU outputs are configurable see binary outputs list.

BO1 BO2 BO3 BO4 BO5 BO6 BO7 BO8 BO9

Starter (relay output) Fuel solenoid (relay output) GCB close/open MCB close/open Alarm Horn Pre-start In synchronism Cooling pump

Binary outputs IG-PCM - default


IG-PCLSM outputs are configurable see binary outputs extension.

BO10 BO11 BO12 BO13

AVR up AVR down SPEED up SPEED down

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32

Binary outputs list


Starter
The closed relay energizes the starter motor. The relay opens if: The Start RPM speed is reached or, Maximum time of cranking is exceeded or, Request to stop comes up.

Fuel solenoid
The setpoint Engine params: Fuel solenoid selects the output function: DIESEL, GAS. Fuel solenoid (DIESEL / GAS)

Ignition
The closed output switches on the ignition. The output closes if: RPM > 30. The output opens if: RPM < 3.

Pre-start
The output closes prior to the engine start (Prestart) and opens when START RPM speed is reached. During repeated crank attempts the output is closed too. The output could be used for pre-glow, pre-heat or prelubrication.

Cooling pump
The output closes when gen-set starts and opens AfterCoolTime delayed after stop the engine.

Prelubr pump
The output periodically closes / opens Prelubrication time / PrelubricationPause.

Idle/Nominal
The output closes when rated RPM are requested, after Idle time elapses. The output opens again in Cooling state. Hint: Connect Binary output IDLE RATED to speed governor to switch the speed: opened = IDLE, closed=RATED.

GCB close/open
The output controls the generator circuit breaker. Hint: Supposed time to close (reaction time) of GCB is 0,1 sec.

GCB ON coil
Pulse output for GCB closing.

GCB OFF coil


Pulse output for GCB opening.

GCB UV coil
GCB undervoltage coil.

MCB close/open
The output controls the mains circuit breaker. Hint: Supposed time to closed (reaction time) of MCB is 0,1 sec. InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf 33

MCB ON coil
Pulse output for MCB closing.

MCB OFF coil


Pulse output for MCB opening.

MCB UV coil
MCB undervoltage coil.
GCB closing GCB close/open GCB ON coil GCB OFF coil GCB UV coil 2s 2s GCB opening

Hint: GCB UV coil automatically opens when GCB is closed spontaneously not from controller except Synchronization state.

Syst ready(M)
The output closes if the system load reserve could be achieved. PBNom + PRNom > PAkt + Reserve PBNom PRNom PAkt Reserve Sum of the nominal power of all gen-sets on the bus Sum of the nominal power of all gen-sets ready to take the load i.e. starting, cooling or ready to start) System load adjusted setpoint LoadRes strt 1 or LoadRes strt 2

Hint: Gen-sets have to be included in Power management by closing of input SYS START/STOP Is ready to take the load when is in AUT mode and no shut down alarm is active and accepted, Setpoint Power management = ENABLED or EXTERNAL, BI Sys start/stop is closed. Use this output as an alarm indication.

Syst res OK(M)


The output closes when selected system load reserve is achieved. PBNom > PAkt + Reserve PBNom PAkt Reserve Sum of the nominal power of all gen-sets on the bus System load selected setpoint LoadRes strt 1 or LoadRes strt 2

The output can be used for closing of MGCB (Master generator circuit breaker) Hint: Gen-set has to be included in Power management by closing of input SYS START/STOP Gen-set has to be in AUT mode Setpoint Power management has to be ENABLED or EXTERNAL.

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34

Syst res1 OK(M)


The output closes when Load reserve 1 is achieved. It is not important which reserve is selected.

Syst res2 OK(M)


The output closes when Load reserve 2 is achieved. It is not important which reserve is selected.

Syst res3 OK(M)


The output closes when Load reserve 3 is achieved. It is not important which reserve is selected.

Syst res4 OK(M)


The output closes when Load reserve 4 is achieved. It is not important which reserve is selected.

GenParamsOK
The output is copy of generator status LED on IG front panel. The output is closed if genset is running and all genset electric values are in limits and no alarm is active. Hint: Use this output for switching of auxiliary device (e.g. cooling pump) driven from generator independently on the GCB.

Alarm
The output closes if: any alarm comes up or, the gen-set malfunctions The output opens if : FAULT RESET is pressed The output closes again if a new fault comes up.

Horn
The output closes if: any alarm comes up or the gen-set malfunctions The output opens if: FAULT RESET is pressed or HORN RESET is pressed or Max time of HORN is exceeded (Horn timeout) The output closes again if a new fault comes up.

Full load
The output closes if the gen-set is fully loaded and there is no reserve in engine power. The output can be used for load shedding. The output closes when the load >= 0.9 * Nomin power for more than 3sec. The output opens when the load < 0.9 * Nomin power.

StandBy ready(S)
The output is closed if following conditions are fulfilled: Gen-set is not running and InteliGen is in AUT mode No Shut down or Slow stop alarm is active

Ready to run
The output is closed if following conditions are fulfilled: Gen-set is not running and No Shut down or Slow stop alarm is active Controller is not in OFF mode

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35

Ready to load
The output is closed if genset is running and all electric values are in limits no alarm is active - it is possible to close GCB or it is already closed. The output opens during cooling state.

Unload
The output is closed during unloading of genset.

Synchronize
The output is closed during genset synchronizing and opens when GCB is closed.

NotReadyAuto
The output is opened only in AUT mode, when no failure blocking the engine operation is pending genset is ready to take the load (or running loaded). In all other modes (OFF, MAN) and in case of failure blocking the engine operation the output is closed.

Vg fail
The output closes if the generator over/under voltage alarm or voltage asymmetry alarm activates. The output opens, if alarm is not active and FAULT RESET is pressed

fg fail
Output closes if the generator over/under frequency alarm activates. The output opens, if alarm is not active and FAULT RESET is pressed

Vm fail
The output closes if the mains over/under voltage alarm or voltage asymmetry alarm activates. The output opens, if alarm is not active and FAULT RESET is pressed

fm fail
Output closes if the mains over/under frequency alarm activates. The output opens, if alarm is not active and FAULT RESET is pressed

Overload
Output closes if the generator overload alarm activates. The output opens, if alarm is not active and FAULT RESET is pressed

Reverse power
Output closes if the generator reverse power alarm activates. The output opens, if alarm is not active and FAULT RESET is pressed

Overspeed
Output closes if the gen-set overspeed alarm activates. The output opens, if alarm is not active and InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf 36

FAULT RESET is pressed

Underspeed
Output closes if the gen-set underspeed alarm activates. The output opens, if alarm is not active and FAULT RESET is pressed

Start fail
Output closes after the gen-set start-up fails. The output opens, if alarm is not active and FAULT RESET is pressed

Overcurrent
Output closes if the generator IDMT over current or current unbalance or short current alarm activates. The output opens, if Alarm is not active and FAULT RESET is pressed

Batt volts
Output closes when battery over/under voltage warning appears. The output opens, if alarm is not active and FAULT RESET is pressed

Common Wrn
Output closes when any warning alarm appears. The output opens, if No warning alarm is active and FAULT RESET is pressed

Common Stp
Output closes when any slow stop alarm appears. The output opens, if No slow stop alarm is active and FAULT RESET is pressed

Common Sd
Output closes when any shut-down alarm appears. The output opens, if No sd alarm is active and FAULT RESET is pressed

Common Unl
Output closes when any unload alarm appears. The output opens, if No unload alarm is active and FAULT RESET is pressed

Common Fls
Output closes when any sensor fail alarm appears. InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf 37

The output opens, if no Sensor fail is active and Fault reset button is pressed.

AVR up AVR down


Binary outputs for Volt / PF control by motorized potentiometer. Outputs should be used when iGAVRi module is not connected.

SPEED up SPEED down


Binary outputs for Sync / Load control by motorized potentiometer. Minimal pulse duration is 0,15 sec. Maximal pulse duration is 10,0 sec. Hint: The response of SPEED UP and SPEED DOWN binary outputs is very fast and frequent to make control process more precise. It is supposed direct connection to electronic speed governor without mechanical elements like relays, motorized potentiometer or servo.

OFF mode
The output is closed, if OFF mode is selected.

MAN mode
The output is closed, if MAN mode is selected.

AUT mode
The output is closed, if AUT mode is selected.

AIn 1 AIn 2 AIn 3


Output closes when IG-CU Analog input 1, 2, 3 Level1 or Level2 (e.g. warning or shutdown) alarm appears. The output opens, if Alarm is not active and FAULT RESET is pressed

Load shedd 1 (2, 3)


Output closes when gen-set power exceeds Ld shed level limit for Ld shed del time. Output opens automatically when AutoLd recon = ENABLED or manually by rising edge of Binary input MAN LOAD RECON. One edge moves only one stage. Principle of Load shedding is described in the chapter Function description Load shedding.

Stop solenoid
Output closes when is active stop command. Output activates as well when engine moves spontaneously, not from starter sequence. Output is closed for minimal 40 seconds in any case and minimal 10 sec after RPM=0.

Service time
Output closes when gen-set Service count down timer Service time reaches zero.

Cooling
Output closes when gen-set is in Cooling state.

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38

In synchronism
Output closes when conditions for MCB close are achieve. This output is used as signalization when Manual Fuse Synchronize is used (see. setpoint ManualFuseSync in Sync/Load ctrl group).

Analog inputs IG-CU


Three analog inputs for resistive sensor 0 to 2400 measuring. Each analog input can be adjusted to convert resistor measured value to displayed value in bar, C or %. Warning and shut-down limits are adjusted in Engine protection group.

AI1
Oil pressure analog input. Default range 0 to 10.0 bars.

AI2
Water temperature analog input. Default range 0 to 100 C.

AI3
Fuel level analog input. Default range 0 to 100 %.

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39

Setpoints
Password
There are three levels of password protection. 0. User level allows change of not protected setpoints only 1. Operator level allows change of setpoints protected by Operator level 2. Master level allows change of setpoints protected by Operator and Master level 3. Supervisor highest level allows all setpoints or configuration changes, firmware upgrade. Hint: The asterisk mark * appears before setpoint name (on controller screen) when is setpoint password protected. Asterisk mark is removed only when password is set from controller front panel. Asterisk mark is still visible on controller screen even if the password is set from WinEdit. There are separate accesses to controller from Front panel, from WinEdit, from Modem or from Internet. Setpoints which are opened e.g. from WinEdit are still closed from Front panel. Setpoints opened from front panel are automatically closed 15 minutes after the last key touch or when wrong password is set. It is possible to protect remote Start, Stop, GCB, MCB commands from WinEdit, MultiEdit as well. This three level command protection can be configured from WinEdit.

EnterPassword
Password is a four-digit number. Password enables change of relevant protected set points depends on configured Password level. Use or to modify the set the password.

ChangePassword 1
Hint: At first the old Password 1 has to be entered before the new Password 1 can be changed.

ChangePassword 2
Hint: At first the old Password 2 has to be entered before the new Password 2 can be changed.

ChangePassword 3
Hint: At first the old Password 3 has to be entered before the new Password 3 or Password 2 or Password 1 can be changed.

Access code
Can be changed from WinEdit software only. Has to be set before remote modem or SMS connection is opened. Can be up to 16 ASCII characters At first the Password3 has to be entered before the new Access code can be changed.

Commands protection
Commands password protection protects following commands from WinEdit / MultiEdit direct, modem or GSM modem connection: Start, Stop, Horn reset, Fault reset, GCB close/open, MCB close/open. Selected Command password level 0, 1, 2, 3 is valid for all commands. Selected level is in RED color.

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40

ProcCtrlSingle(S)
Load control [BASELOAD, IMP/EXP]
Control mode selection for parallel to mains operation. BASELOAD: gen-set is loaded at preadjusted level (Base load). IMP/EXP: gen-set load is changed according to import/export value (Import load, Import PF). Setpoint is available in parallel to mains only.

PeakAutStart

[DISABLED / ENABLED]

Automatic starts and stops of gen-set based on increasing / decreasing level of import load (PeakLevelStart, PeakLevelStop).

Baseload

[kW]

Required gen-set load when Load control = BASELOAD. Step: 1 kW Range: 0 Nominal Power

BaseloadChange

[% / s]

Amount of required gen-set load change changed per second. Change is activated by binary inputs BaseLoad Inc/Dec per one second. Step: 1 % of Nominal Power Range: 0 100%

PF reference

[-]

Required inductive (leading) power factor when Load control = Base load. Step: 0.01 Range: 0.60 to 1.00

Import load

[kW]

Required power from / to mains when Load control = Import export. Import load > 0 is consumption from the mains, when Import load < 0 the power is exported to the mains. Step: 1 kW Range: -3200kW to +3200 kW

Import PF

[-]

Required inductive (leading) power factor of the mains when Load control = Import export Step: 0.01 Range: 0.60 to 1.00

PeakLevelStart

[kW]

Load power level when gen-set starts (PeakAutStart = ENABLED). Load value is measured and calculated from mains current phase Im3, L3 before start. It is supposed balanced load. Genset start is 5 sec delayed after PeakLevelStart limit is reached. Step: 1 kW Range: 0 3200 kW

PeakLevelStop

[kW]

Load power level when gen-set stops (PeakAutStart = ENABLED). Genset stop is 5 sec delayed after PeakLevelStop limit is reached. When gen-set is running the load power is calculated (no directly measured) from the difference between gen-set and mains power. When e.g. gen-set actual power is 100 kW (Pg=+100) and gen-set exports to the mains 60 kW (Pm= - 60) load power is Pg + Pm=40 kW. When e.g. gen-set actual power is 100 kW (Pg=+100) and gen-set imports from the mains 60 kW (Pm= + 60) load power is Pg + Pm=160 kW. InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf 41

Step: Range:

1 kW 0 3200 kW

Export limit

[ENABLED, DISABLED]

Protection against power export to the mains when is adjusted Load control = BASELOAD. Export power is limited to not exceed Import load value. ENABLED: When export power exceeds Import load value Load control is automatically switched to IMP/EXP mode to keep Import load value. DISABLED: No protection is active. Hint: To protect genset against power export adjust ExportLimit = ENABLED and Import load = 0. Export limit function Outputs and Setpoints overview: Export limitation
Process control: Load ctrl PtM = BASELOAD Export limit = ENABLED Required genset power
Internal value

Export limit function behaviour:


Load Mains I/E Gen

Load

Baseload

Baseload

Gen Baseload Baseload

+ Mains I/E 0

+ Import 0 Export Export Import

DISABLED

ENABLED

ProcCtrlMulti(M)
Hint: The first character of replicated setpoints name is #.

#SystLdCtrl PtM
BASELOAD: LDSHARING:

[BASELOAD / LDSHARING]

Gen-sets group operating in parallel to mains is loaded at preadjusted level (SystBaseLoad). Gen-sets load is controlled by load sharing line. Total group load is shared between connected gen-sets.

#SystBaseLoad

[kW]
42

Total required power of gen-sets group operating in parallel to mains (MCB feedback closed). InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

Step: Range:

1 0 +30000 kW

#SystPwrFactor

[-]

The required power factor of gen-sets group operating in parallel to mains. Step: 0,01 Range: 0,60 1,00

Basic settings
Gen-set name
User defined name, used for InteliGen identification at remote phone or mobile connection. Gen-set name is max 14 characters long and have to be entered manually using WinEdit software. Hint: Gen-set name is not changed when new archive is loaded. Check Gen-set name after firmware upgrade.

Nomin power
Nominal power of the generator Step: 1kW Range: 1 3000 kW

[kW]

Nomin current

[A]

It is current limit for generator IDMT over current and short current protection and means maximal continuous generator current. See Generator protections: 2Inom del, Ishort setpoints. Nominal current can be different from generator rated current value. Step: 1A Range: 1 - 5000 A !!! VERY IMPORTANT !!! Maximal input range of InteliGen and InteliSys current terminals is up to 11 amps. Over this value is measured value limited, e.g. 15amps from CT is still measured as 11 amps! Take care about CT selection. Not every 5Amps CT has the output range to 11 amps!

CT Ratio

[/5A]

Gen-set phases current transformers ratio. Step: 1A Range: 1 5000 A / 5A

Im3 CT Ratio

[/5A]

Mains current transformer ratio for single phase Import / Export power and PF measuring. Single phase power value is multiplied by three. Step: 1A Range: 1 5000 A / 5A Hint: Im3 has to be connect to mains L3 phase !!! Balanced mains power is expected.

Nomin voltage 1

[V]

Nominal generator voltage (phase to neutral). Setpoint set 1 is selected when Binary input NominalSwitch is opened. Step: 1V Range: 80 300 V

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

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Nominal RPM 1

[RPM]

Nominal speed of the engine Step: 1 RPM Range: 100 4000 RPM Following table contains relation between Nominal frequency and Nominal RPM for different kind of generators. Typical is four pole generator which has 50 Hz / 1500 RPM. Generator poles 50 Hz 60 Hz 2 3000 3600 4 1500 1800 6 1000 1200 Setpoint set 1 is selected when Binary input NominalSwitch is opened.

Nominal freq 1

[Hz]

Nominal generator frequency (usually 50 or 60 Hz). Setpoint set 1 is selected when Binary input NominalSwitch is opened. Step: 1Hz Range: 45 65 Hz

Nomin voltage 2

[V]

Nominal generator voltage (phase to neutral). Setpoint set 2 is selected when Binary input NominalSwitch is closed. Step: 1V Range: 80 300 V

Nominal RPM 2

[RPM]

Nominal speed of the engine. Setpoint set 2 is selected when Binary input NominalSwitch is closed. Step: 1 RPM Range: 100 4000 RPM

Nominal freq 2

[Hz]

Nominal generator frequency (usually 50 or 60 Hz). Setpoint set 2 is selected when Binary input NominalSwitch is closed. Step: 1Hz Range: 45 65 Hz NominalSwitch = opened Nomin voltage 1 Nominal RPM 1 Nomin freq 1 NominalSwitch = closed Nomin voltage 2 Nominal RPM 2 Nomin freq 2

Hint: Binary input NominalSwitch is active all the time.

Gear teeth

[-]

Number of teeth on the engine gear for the pick-up. Set to zero, if no pick-up is used. Engine speed is calculated from the generator frequency. Step: 1 Range: 0 500 Hints Generator frequency can be used only when generator voltage (min 5V) is present before reaching of the firing speed (Start RPM) after start. When pick-up cut comes, InteliGen detects underspeed and stops the engine.

Mode IG

[ OFF, MAN, AUT]

Equivalent to Controller mode changes by MODE or MODE buttons. Hint: Mode change can be separately password protected. InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf 44

Contr. adr (1 32)

[-]

Controller identification number. Each gen-set in the group has to have its own unique number. Default value is 1. Hint: When opening Direct or Modem connection to single InteliGen, the InteliGen Controller address has to be set to 1 and must correspond to WinEdit communication setup setting.

RS232 mode

[Standard / Modbus]

Communication protocol switch. Standard: InteliGen (WinEdit/MultiEdit) communication protocol. Modbus: InteliGen Modbus protocol. Hint: Detail descriptions see in InteliGen Communication guide.

Engine params
Prestart time [s]
Time of closing of the PRE-START output prior to the engine start. Set to zero if you want to leave the output PRE-START open. RPM must be zero during Prestart time. Step: 1s Range: 0 600 s

Prelubr time

[s]

Time of closing of the PRELUBR PUMP binary output. Function is active all the time the engine is not running. Prelubrication is periodically repeated. Step: 1s Range: 0 600 s

Prelubr pause

[min]

Interval between prelubrication. Step: 1 minute Range: 1 1000 min Hint: To use Prelubrication configure Binary output PRELUBRICATION PUMP at first. Prelubrication is disabled in InteliGen OFF mode or when is Prelubr time set to zero. When engine is running PRELUBR PUMP binary output is opened. Prelubrication starts Prelubr pause after engine stops. Prelubrication starts immediately when InteliGen power supply turns on or when mode changes from OFF to MAN or AUT.

Start RPM

[%]

Firing speed. iG stops cranking. Underspeed limit when engine is running. Step: 1 % of nominal speed Range: 1 50 %

MaxCrank time

[s]

Maximum time limit of cranking Step: 1s Range: 1 60 s Hint: The last cranking of unsucessfull start is 25% longer for gas ventilation when the Binary output FUEL SOLENOID is configured to GAS. Cranking stops when RPM = 0 within 3 seconds. Continues CrankFail pause.

CrankFail pause
Pause between crank attempts

[s]

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

45

Step: Range:

1s 1 60 s

Crank attempts
Max number of crank attempts Step: 1 Range: 1 - 10

[-]

Idle time

[s]

Idle time delay starts when RPM exceeds Start RPM. Start fail is detected when during Idle state RPM decreases below 30. During the Idle time is Binary output IDLE/NOMINAL opened, when expires IDLE/NOMINAL output closes. Binary output IDLE/NOMINAL opens during Cooling period again. Step: 1s Range: 1 300 s
RP M

Start RPM RPM = 30 BO Starter

RP

BO IDLE/RATED Idle time Start Fail Min stab time Electric protections active

Idle function Outputs and Setpoints overview:


Engine params: Idle time [s]

Idle/Nominal
binary output

Min stab time

[s]

Minimum time after reaching of nominal RPM to the closing GCB. Step: 1s Range: 0 Max stab time Hint: When engine RPM within 30 sec does not reach defined level of RPM Shut down start fail alarm is activated.

Max stab time

[s]

Maximum time after reaching of defined level of RPM to get proper voltage level of the generator. Step: 1s Range: Min stab time 300 s Hint: When generator voltage within Max stab time does not reach defined limits (Generator protection group) Unload alarm is activated, genset cools and stops. History and Alarm list record contains Alarm reason corresponding to active protection.

Cooling time

[s]

Runtime of the unloaded gen-set to cool the engine before stop. Step: 1s Range: 0 3600 s InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf 46

AfterCoolTime

[s]

Runtime of engine after cooling pump. Binary output COOLING PUMP is closed when the engine starts and closes Cooling time delayed after gen-set stops. Step: 1s Range: 0 3600 s Hint: If the engine After cooling function is needed the binary output COOLING PUMP should be configured.

Fuel solenoid

(DIESEL / GAS)

[-]

Selecting of FUEL SOLENOID output function. DIESEL: closed output opens the fuel solenoid and enables the engine start. The output opens if: Emergency stop comes or Cooled gen-set is stopped or in pause between repeated starts GAS: closed output energizes the gas valve. The output closes if RPM > 30 with 1s delay. The output opens if: emergency stop comes or the cooled gen-set is stopped or in pause between repeated starts. The last cranking during unsuccessful start is 25% longer due to ventilation. Example of FUEL SOLENOID output behavior during unsuccessful start.
the last cranking

BO Starter Start RPM RPM

closed

opened

ventilation

M axCrank tim e
RPM < Start RPM RPM < 3 RPM > 30 RPM =0 RPM > 30 RPM < Start RPM

+ 25 %

RPM < 3

RPM =0

M axCrank tim e BO Fuel solenoid=Diesel BO Fuel +1sec solenoid=G as BO Ignition


closed opened closed opened

+1sec
closed opened closed opened

on

off

on

Engine protect
NextServTime [h]
Adjusted value is counted down. When zero is reached Service alarm is detected Alarm list is recorded Step: Range: 1h 0 65535 h

Horn timeout

[s]

Max time limit of horn sounding. Set to zero if you want to leave the output HORN open. Step: 1s Range: 0 600 s

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

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Overspeed

[%]

Threshold for over speed protection Step: 1% of nominal RPM Range: 50 150% Hint: Engine params: Start RPM value is checked as underspeed level.

Protection del

[s]

During the start of the gen-set, some engine protections have to be blocked (e.g. Oil pressure). The protections are unblocked after the Protection del time. The time starts after reaching Start RPM. Step: 1s Range: 0 300 s

Anl Inp1 level1

[]

The first threshold level for ANALOG INPUT 1 alarm detection. Default setting is oil pressure warning in 0,1 bars. Step: 0,1 bar Range: -100 10000

Anl Inp1 level2

[]

The second threshold level for ANALOG INPUT 1 alarm detection. Default setting is oil pressure shut down in 0,1 bars. Step: 0,1 bar Range: -100 10000

Anl Inp1 del


Delay for ANALOG INPUT 1 alarm. Step: 1s Range: 0 180 s

[s]

Anl Inp2 level1

[]

The first threshold level for ANALOG INPUT 2 alarm detection. Default setting is water temperature warning in C. Step: 1 C Range: -100 10000

Anl Inp2 level2

[]

The second threshold level for ANALOG INPUT 2 alarm detection. Default setting is water temperature shut down in C. Step: 1 C Range: -100 10000

Anl Inp2 del


Delay for ANALOG INPUT 2 alarm. Step: 1s Range: 0 180 s

[s]

Anl Inp3 level1

[]

The first threshold level for ANALOG INPUT 3 alarm detection. Default setting is fuel level warning in %. Step: 1% Range: -100 10000

Anl Inp3 level2

[]

The second threshold level for ANALOG INPUT 3 alarm detection. Default setting is fuel level shut down in %. InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf 48

Step: Range:

1% -100 10000

Anl Inp3 del


Delay for ANALOG INPUT 3 alarm. Step: 1s Range: 0 180 s

[s]

Batt >V

[V]

Warning level for battery overvoltage. Step: 0,1V Range: 10 40 V

Batt <V

[V]

Warning level for low battery voltage. Step: 0,1V Range: 8 30 V

Batt V del

[s]

Delay for battery voltage alarms. Step: 1s Range: 0 600 s Hint: SD battery flat is detected when controller is switched off during cranking. The next start is blocked.

Gener protect
Hint: All Alarm limits are the last acceptable values. Alarm detection starts when measured value is over the alarm limit.

Overload

[%]

Threshold for generator overload (in % of Nominal power) triggers when exceeded. Step: 1% of Nominal power Range: 50 300%

Overload del

[s]

Delay for generator overload alarm. Step: 0.1s Range: 0 60.0 s

Ishort

[%]

When Short circuit limit Ishort limit is reached Short circuit alarm is detected and the binary outputs GCB CLOS/OPEN is immediately opened GCB UV coil is immediately opened GCB OFF coil is immediately closed. Short circuit alarm is recorded to Alarm list and History. The engine goes to cooling and stops down when, Fault reset button is not pressed. Step: 1 % of Nominal current Range: 100 - 500 %

2Inom del

[s]

IDMT curve shape selection. 2Inom del is Reaction time of IDMT protection for 200% overcurrent Igen = 2* Nominal current. Step: 0,1 s Range: 0 - 60 s InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf 49

IDMT is very inverse generator over current protection. Reaction time is not constant but depends on generator over current level according following formula. IDMT protection opens Binary output GCB CLOSE/OPEN when becomes active. IDMT protection is recorded to Alarm list and History. The engine cools down and stops when Fault reset button is not pressed. 2Inom del * Nomin current Reaction time = Igen

- Nomin current

Where Reaction time is time from IDMT over current detection to GCB CLOSE/OPEN opening. Igen is maximal value of all measured phases of generator current. Hint: Reaction time is limited up to 900 sec = 15 minutes. IDMT protection is not active for Reaction time values longer than 15 minutes. EXAMPLE of Reaction time for different over current levels. Values in column 200% are 2Inom del. 200 % = 2Inom del 0,2 s 2s 20 s Overcurrent ! 100 % 101 % No action No action No action 20 s 200 s No action (time > 900 s) 110 % 2s 20 s 200 s

Reaction time

Reaction tim e

Maxim al Reaction tim e

2Inom del

Igen Nom inal current Ishort

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

50

Curr unbal

[%]

Threshold for generator current unbalance Step: 1% of Nominal current Range: 1 200%

Curr unbal del


Delay for generator current unbalance Step: 0.1 s Range: 0 60.0 s

[s]

Gen >V

[%]

Threshold for generator overvoltage. All three phases are checked. Maximum out of three is used. Step: 1% of Nominal voltage Range: Gen <V 200% of Nominal voltage

Gen <V

[%]

Threshold for generator undervoltage. All three phases are checked. Minimum out of three is used. Step: 1% of Nominal voltage Range: 0 Gen >V

Gen V del

[s]

Delay for generator undervoltage and overvoltage alarm Step: 0.1s Range: 0 60 s

Volt unbal

[%]

Threshold for generator voltage unbalance alarm Step: 1% of Nominal voltage Range: 1 150%

Volt unbal del

[s]

Delay for generator voltage unbalance alarm. Step: 0.1s Range: 0 60.0 s

Gen >f

[%]

Threshold for generator phase L3 overfrequency. Step: 0.1% of Nominal frequency Range: Gen < f - 200,0 % of Nominal frequency

Gen <f

[%]

Threshold for generator phase L3 underfrequency. Step: 0.1% of Nominal frequency Range: 0.0 Gen > f

Gen f del

[s]

Delay for generator underfrequency and overfrequency alarm Step: 0.1s Range: 0 60.0 s

Reverse power

[%]

Threshold for generator reverse power alarm. Step: 1 % of Nominal power Range: 0 50 %

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

51

Rev. power del

[s]

Delay for generator reverse power alarm. Unload alarm is detected when is Reverse power protection activated. Step: 0.1 s Range: 0 60.0 s

Auto Mains Fail


EmergStart del [s]
Delay after the mains failure to the emergency start of the gen-set Step: 1s Range: 0 300 s

Mains ret del

[s]

Delay after the mains return to start of MCB reverse synchronizing. Step: 1s Range: 1 3600 s

Return break

[s]

Delay after GCB opening to MCB closing during the return procedure (in SSB). Step: 0,1s Range: 0 60,0 s

MCB close del

[s]

Delay after mains returns to MCB closing, if gen-set is not running and GCB is opened. E.g. genset is in OFF mode or in start-up procedure. Step: 0,1s Range: 0 60,0 s

Mains >V

[%]

Threshold for mains over voltage. All three phases are checked. Maximum out of three is used. Step: 1% of Nominal voltage Range: 100 150%

Mains <V

[%]

Threshold for mains under voltage. All three phases are checked. Minimum out of three is used. Step: 1% of Nominal voltage Range: 50 100%

Mains V del

[s]

Delay for mains under voltage and over voltage. Step: 0,1 s Range: 0 60,0 s

MVolt unbal
Threshold for mains voltage unbalance. Step: 1% of Nominal voltage Range: 1 150%

[%]

MVolt unb del


Delay for mains voltage unbalance. Step: 0,1 s Range: 0- 60,0 s

[s]

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

52

Mains >f

[%]

Threshold for mains phase L3 over frequency. Step: 0,1% of Nominal frequency Range: 100,0 150,0%

Mains <f

[%]

Threshold for mains phase L3 under frequency. Step: 0,1% of Nominal frequency Range: 50,0 100,0%

Mains f del

[s]

Delay for mains under frequency and over frequency. Step: 0,1s Range: 0 60,0 s

BreakerOverlap

[s]

When limited time of running in parallel with mains is required, BreakerOverlap defines max time of running in parallel with mains. During this time soft transfer of load is activated. It is used in AUT mode. Step: 0,1s Range: 0 600,0 s Hint: To proper soft transfer of load check corresponding setpoints in Sync/Load ctrl: Load ramp, GCB open level, GCB open del.

Max load surge

[P/s]

Limit for fast generator load changes in parallel to mains. The MCB opens immediately (no delay) when Max load surge limit is reached. Load change is detected from period to period. P means Basic setting: Nominal power value. Load surge protection becomes active 3 sec delayed after entering to parallel (synchronizing). For proper adjusting in real conditions see following values on IG generator measure screen or in WinEdit Values Mains window: ActLoadSurge is actual value load changes in P/s. MaxLoadSurge is maximal value of load changes in P/s. Value is cleared when genset enters the parallel mode. Step: 1 P/s , where P is Nominal power Range: 0 60 P/s , where P is Nominal power Example: Suppose Nominal power = 100kW. Then Max lod surge = 10 P/s is protection limit against load change faster then 10*100=1000 kW per second. Hint: Wrong setting of Max load surge level can cause unnecessary transfer to island even if is the mains OK. To be sure for proper adjusting of Max load surge check Act load surge and Max load surge values on the controller or WinEdit screen. Zero switches Load surge protection OFF.

MCB logic

[CLOSE-ON / CLOSE OFF]

The setpoint influences the behavior of the output MCB CLOSE/OPEN. CLOSE-ON: When the output MCB CLOSE/OPEN is closed MCB should be closed. CLOSE-OFF: When the output MCB CLOSE/OPEN is closed MCB should be opened. Following diagram shows difference between MCB CLOSE/OPEN output behaviors when InteliGen is switched ON. Hint: In case MCB logic = CLOSE-OFF it is necessary to change externally the polarity of the output signal

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

53

iG OFF

Mains O.K.

iG ON

Mains O.K.

MCB logic = CLOSE-ON

Mains Failure

MCB logic = CLOSE-OFF

Signal after external inverted relay

iG-CU
DO 4

AUX. INVERTING RELAY

MCB

Battery

Ret fromIsland

[MANUAL, AUTO]

MANUAL: Controller is automatically switched to MAN mode when Mains returns. Load transfer then must be confirmed by MCB pressing. AUTO: Load is automatically transferred in AUT mode after Mains return. Hint: Select Ret fromIsland = MANUAL when is important in which time is load transferred back to the mains.

MF StartEnable

[ENABLE, DISABLE]

ENABLE: Controller automatically starts engine when AUT mode is selected and Mains Fail. DISABLE: Controller doesnt do any automatic engine start in AUT mode when Mains Fail.

Pwr management (M)


Hint All parameters in the Power management group except Power management, Priority have to be equal throughout all the controllers and are automatically replicated from one controller into the other connected controllers. The first character of all replicated setpoint names is #. It is visible on InteliGen screen and in WinEdit.

Pwr management
DISABLED:

[ENABLED / DISABLED / EXTERNAL]

Each engine starts / stops when Binary input Sys start/stop is closed / opened independent on other gen-sets. CAN bus line is necessary for VAR sharing. 54

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

ENABLED:

Gen-sets operate in Pwr management. Binary input Sys start/stop the engine to take place in power management. EXTERNAL: Same as ENABLED, but pwr management values (Priority, number of currently active Reserve, number of currently active MinRunPower) are controlled externally via CAN bus.

Priority (1...32)

[-]

Adjusts the priority of the gen-sets. Based on these priorities gen-sets are started. Priority 1 is the highest. Priority 32 is the lowest. Step: 1 Range: 1 32 Hint: Two or more gen-sets can have the same priority. In that case they behave as one big gen-set with the sum of gen-sets Nominal power. When one of them has closed Binary input Master select behaves as higher priority engine.

#SysAMFstrtDel

[s]

System start delay between SYS START/STOP closing and start of Power management. When SYS START/STOP is controlled by mains decoupling relay, delay after the mains failure to the emergency start of the gen-sets. If the MCB FEEDBACK is closed, Power management is starts with 1s delay. Step: 1s Range: 0 600 s

#SysAMFstpDel

[s]

System stop delay between SYS START/STOP opening and GCB opening if the MCB FEEDBACK is closed. When SYS START/STOP is controlled by mains decoupling relay, delay after the end of mains failure to opening of GCB. If the MCB FEEDBACK is closed, gen-sets are unloaded to mains prior to GCB opening. Step: 1s Range: 0 600 s

#LoadResStrt 1 (2, 3, 4)

[kW]

Required system load reserve, or in the other words load reserve defines the maximum allowable load jump. One of the load reserves 1, 2, 3, 4 is by binary input LOAD RESERVE 2, 3, 4 selectable. When the required load reserve is not achieved, another gen-set is started. Step: 1 kW Range: 1 32000 kW Hint: Use load reserves to separate minimum initial power for start-up and necessary reserve in steady running conditions.

#LoadResStp 1 (2, 3, 4)

[kW]

One of the load reserves 1, 2, 3, 4 is by binary input LOAD RESERVE 2, 3, 4 selectable. When LoadRes Stp 1 (2, 3, 4) level is achieved, the gen-set with the lowest priority (highest setpoint Priority) is stopped. Next gen-set is stopped when: PBNom > PAkt + LoadRes stp PBNom PAkt Reserve Step: Range: Hint: InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf 55 Sum of the nominal power of all gen-sets on the bus apart of the one, which is going to be stoped. System load LoadRes Stp 1 or LoadRes Stp 2 1 kW 0 32000 kW

The engine will be stopped only when #MinRun power level stays running.

!!! IMPORTANT !!!


LoadRes Stp has to be higher than corresponding LoadRes Strt !

2nd gen-set 400 Load Res Stp 60 kW

Load Res Strt 40 kW

1st gen-set 200

100

150 170

250

170

150

100

1st gen-set 2nd gen-set

Y N

Y N

Y Y

Y Y

Y Y

Y Y

Y N

#Next start del

[s]

The delay before next gen-set start-up in Power management. Delay is not used, when the first genset(s) starts. Step: 1s Range: 0 600 s

#Overld NextDel

[s]

The delay before next gen-set start-up in Power management when the system load is equal or higher then nominal power of all gen-sets on the bus. Delay is not used, when the first gen-set(s) starts. Step: 1s Range: 0 600 s

#Next stop del

[s]

The delay before next gen-set stopping in Power management. When delay is elapsed, the gen-set starts unloading, gets off line and stops. Step: 1s Range: 0 600 s InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf 56

#Slow stop del

[s]

Waiting to next gen-set start before gen-set slow stop procedure. Gen-set stops when Slow stop del expires even if next gen-set does not start. When there it is not next gen set available slow stop procedure begins immediately. Step: 1s Range: 0 600 s

#MinRun power 1 (2, 3)

[ kW ]

It is minimal required power of gen-set group (sum of Nominal power of running gensets). When Binary input SYS START STOP is closed starts and stays running such number of gensets to keep #MinRunPower value independent on load value. When Binary inputs MIN RUN POWER 1 (or MIN RUN POWER 2 or MIN RUN POWER 3) is closed different value of #MinRun power 1 (or 2 or 3) is selected. When more binary inputs MIN RUN POWERx is closed the higher number has higher priority. When no input closed, no #MinRun power is selected and minimum running power is zero. Step: 1 kW Range: 0 60000 kW Hint: The engine will be stopped only when #MinRun power level stays running. Power management Inputs, Outputs and Setpoints overview:
Binary inputs Binary outputs

Master select Pwr management: PrioritySwtch 1 PrioritySwtch 2 PrioritySwtch 3 PrioritySwtch 4 Load reserve 2 Load reserve 3 Load reserve 4 #SysAMFstsrtDel #SysAMFstpDel #NextStart del #OverldNextDel #NextStop del #SlowStop del

Priority

Syst ready

#LoadResStrt1 #LoadResStp1 #LoadResStrt2 #LoadResStp2 #LoadResStrt3 #LoadResStp3 #LoadResStrt4 #LoadResStp4 #MinRun power1 #MinRun power2 #MinRun power3

Syst res OK Syst res1 OK Syst res2 OK Syst res3 OK Syst res4 OK

MinRun power 1 MinRun power 2 MinRun power 3

Sync/Ld ctrl
SpeedRegChar [POSITIVE / NEGATIVE]
Switch between isochronous speed governor characteristics. POSITIVE: When controller Speed governor output voltage increases engine speed increases. NEGATIVE: When controller Speed governor output voltage decreases engine speed increases. Hint: All corresponding set points Slip freq gain, Angle gain and Load gain are positive. When set to NEGATIVE Binary outputs SPEED UP and SPEED DOWN works in opposite way.

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

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Voltage window

[%]

Maximum difference between generator and bus voltage. Step: 0.1 % of Nominal voltage Range: 0.0 100.0 %

Phase window

[]

Maximum phase angle difference between generator and bus. Step: 1 Range: 0 90

Dwell time

[s]

The period of time that the phase angle must be within Phase window and Voltage difference within voltage window before GCB closing. Step: 0.1 s Range: 0.0 25.0 s

Slip freq gain

[%]

Gain of slip frequency control loop when GCB is still opened. Step: 0.1 % Range: 0 to +200.0 %

Slip freq int

[%]

Relative integration factor of slip frequency control loop. Step: 1% Range: 0 % 100 %

Slip freq der

[%]

Relative stability factor of slip frequency control loop. Step: 1% Range: 0 % 100 %

Angle gain

[%]

Gain of angle control loop when slip frequency is near zero and GCB is still opened. Step: 0.1% Range: 0 % to +200.0 %

Angle der

[%]

Relative stability factor of angle control loop. Step: 0.1% Range: 0 % to +100.0 % Hint: Setpoints Slip freq gain, Slip freq int, Slip freq der, Angle gain, Angle der adjusts speed (are active) during synchronizing only when GCB is opened.

Speed gov bias

[V]

Speed control DC output bias level of SPEED GOVERNOR voltage output. Step: 0.01 V Range: -10.00 to +10.00 V

Load ramp

[s]

Increasing or decreasing load rate. In seconds / nominal power. Step: 1s Range: 0 600 s

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

58

Load gain

[%]

Gain of power control loop, when GCB and MCB are closed. Step: 0.1 % Range: 0 to +200.0 %

Load int

[%]

Relative integration factor of power control loop. Step: 1% Range: 0 100 %

Load der

[%]

Relative stability factor of power control loop. Step: 1% Range: 0 100 % Hint: Load gain, Load int and Load der setpoints are active only when gensets group operates in parallel to the mains, when GCBs and MCB are closed and Process control: SysLdCtrlPtM = Baseload. Load control operates via IG-PCLSM load sharing line, where 7,5 VDC value means requirement of Nominal genset power.

GCB open level

[%]

Power level for getting offline while unloading. If this level isnt reached GCB opens after GCB open del time. Step: 1 % of Nominal power Range: 0 to 100 %

GCB open del


Maximum time to unload the gen-set. Step: 1s Range: 0 600s

[s]

LS gain
Gain of load sharing power control loop. Step: 0.1% Range: 0 to +200.0 %

[%]

LS int

[%]

Integratio factor of load sharing power control loop. Step: 1% Range: 0 100 %

LS der

[%]

Relative stability factor of load sharing power control loop. Step: 1% Range: 0 100 % Hint: LS gain, LS int and LS der setpoints are active when gensets group operates in Island parallel: GCBs are closed and MCB is opened. Process control: SysLdCtrlPtM = LdSharing. Parallel to mains: GCBs and MCB are closed. Process control: SysLdCtrlPtM = LdSharing. Load control operates via IG-PCLSM load sharing line, where 7,5 VDC value means requirement of Nominal genset power.

Sync timeout

[s]

Maximal allowed time for forward or reverse synchronization. When Sync timeout is expired Sync alarm is detected. InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf 59

Step: 1s Range: 0 1800 s Hint: When any gain setpoint is set to zero corresponding control loop is switched OFF.

ManualFuseSync

[ENABLED, DISABLED]

Select controlling of MCB output when reverse synchronization is in process. ENABLE: InteliGen controls MCB output. DISABLE: External device controls connecting of MCB during unlimited timeout. Hint: Reverse synchronization is allowed only when binary inputs Synchro Enable and RevSync Enabled are closed.

Volt/PF ctrl
AVRRegChar [POSITIVE / NEGATIVE]
Switch between AVR characteristics. POSITIVE: When controller and AVRi output voltage increases generator voltage increases. NEGATIVE: When controller and AVRi output voltage decreases generator voltage increases. Hint: All corresponding set points Voltage gain and PF gain are positive. When set to NEGATIVE Binary outputs AVR UP and AVR DOWN works in opposite way.

Voltage gain
Gain of voltage control loop. Step: 0.1 % Range: 0 to +200.0 %

[%]

Voltage int

[%]

Relative integration factor of voltage control loop. Increasing of integration value causes quicker response. Step: 1% Range: 0 100 %

Voltage der

[%]

Relative stability factor of voltage control loop. Step: 1% Range: 0 100 % Hint: Voltage gain, Voltage int andVoltage der setpoints are active (adjusts AVR) only when GCB is open to maintain Nominal voltage or to match voltage during synchronizing. Voltage loop operates as well when GCB is closed and MCB opened.

PF gain

[%]

Gain of power factor control loop. Step: 0.1 % Range: 0 to +200.0 % Hint: When any gain setpoint is set to zero corresponding control loop is switched OFF.

PF int

[%]

Relative integration factor of power factor control loop. Increasing of integration value causes quicker response. Step: 1% Range: 0 100 %

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PF der

[%]

Relative stability factor of power factor control loop. Step: 1% Range: 0 100 % Hint: PF gain, PF int and PF der setpoints are active only when is gen-set parallel to mains.

VS gain

[%]

Gain of VAR (power factor) sharing control loop. Step: 0.1 % Range: 0 to +200.0 %

VS int

[%]

Relative integration factor of of VAR (power factor) sharing control loop. Step: 1% Range: 0 100 % Hint: VS (PF) int in fact hides two setpoints: - VS int to keep the the reactive power precisely shared - maintain system voltage at nominal. This is very slow additional voltage control loop (only integrative control). Its power is about 10times weaker than real VS int. Primary voltage control should be done by speed governor.

VS der

[%]

Relative stability factor of of VAR (power factor) sharing control loop. Step: 1% Range: 0 100 % Hint: VS gain, VS int and VS der setpoints adjusts AVR only when GCB closed and MCB open or GCB closed and MCB closed and the Setpoint SysLdcrtlPtM is set to Loadsharing) to adjust PF (VAR sharing) and maintain system voltage at nominal.

AVR DCout bias

[%]

AVRi voltage output bias level. Step: 0.1 % Range: 0 100.0 % Hint: Real voltage level depends on AVRi outputs connection and output level potentiometer setting. Maximum output range is 10 V.

Act. calls/SMS
Warning call Unload call Slow stop call Shut down call [DISABLED / ENABLED] [DISABLED / ENABLED] [DISABLED / ENABLED] [DISABLED / ENABLED]
Enables or disables active calls/SMS to selected phone or mobile when the warning alarm occurs.

Enables or disables active calls/SMS to selected phone or mobile when the unload alarm occurs.

Enables or disables active calls/SMS to selected phone or mobile when the slow down alarm occurs.

Enables or disables active calls to selected phone or mobile when the shut down alarm occurs.

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There are three separate channels for active calls. If is set each channel sends data or SMS to phone number or e-mail to address, which is set in following AcallCH13 Addr setpoint. DISABLED: Channel is disabled. DATA: Standard analog, GSM or ISDN modem connection to WinEdit. SMS: Channel sends SMS message. Only when is GSM modem connected. E-MAIL: Channel sends E-mail. Only when is IG-IB connected. EML-SMS: Channel sends E-mail with short SMS. Only when is IG-IB connected. Email contains - header with serial number and application info. - Alarm list - 20 History records (reason, date, time) Example of EML-SMS: AL=(Sd Water Temp,Wrn Water Temp,!Emerg Stop,ActCallCH1Fail)

AcallCH1..3Addr
Address for channel 1...3 active call. Practically it means phone number or e-mail address. For more details see WinEdit-MultiEdit guide chapter IG-IB Internet communication. Hint: When any modem is connected to single controller the Controller address has to be set to 1!!! When Controller address has different value than 1 Active call is not activated. To receive active call run WinEdit Type of connection = Active call. WinEdit Active call window contains list of received AIG or AIS files. Each list item contains Gen-set name, Date, Time, IS serial number.

NumberRings AA

[-]

Number of rings prior to open modem connection from PC to controller. Step: 1 Range: 1 30 Hint: NumberRings AA change is not accepted immedatelly but after controller is switched on or when modem is connected to controller.

A.c.multiplier

[1 to 250]

When active call is activated, controller tries five times to open the connection when A.c.multiplier = 1 (e.g. when the phone line is engaged). There are ten attempts when A.c.multiplier = 2, etc.. Step: 1 Range: 1 to 250 Hint: There are 5 attempts for any active call. Timeout for connection is 90 sec and after 120 sec controller starts the next attempt. During that time response for incoming call is blocked.

Load Shedding
Load shedding function is available in all applications like SPM, SSB, SPtM, MINT and is active in all IS/IG controller modes except OFF mode. Load shedding has three steps (stages), each one linked with Binary output LOAD SHED 1, LOAD SHED 2, LOAD SHED 3. Only transition to the next stage is possible, e.g. from No LdShed to LdShed S1, to LdShed S2, to LdShed S3 and vice versa. There is only one load limit and delay for three Load shedding steps and one limit and delay for automatic Load reconnection steps. One binary input MAN LOAD RECON is available for manual reconnection of shedded load when setpoint AutoLd recon = DISABLED. Rising edge on this input resets IS/IG controller to the lower stage, but only if the load is under the Ld Recon level. Principle of Load shedding is described in the chapter Function description Load shedding.

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Ld shed level

[%]

When gen-set load exceeds this level for more than LD Shed delay time, IS/IG controller proceeds to the next Load shedding stage - the next binary output LOAD SHED x is closed. Step: 1 % of Nominal power Range: from Ld Recon level to 200 % of Nominal power

Ld shed del
Time delay for LD shed level limit. Step: 0.1 s Range: 1 - 1800 s

[s]

Ld recon level

[%]

When gen-set load drops under this level for more than LD recon delay time, IS/IG controller proceeds to the lower Load shedding stage. The binary output for higher stage is opened (LOAD SHED x). Automatic load reconnection works only when AutoLd recon = ENABLED. Step: 1 % of Nominal power Range: from 0 - Ld shed level

Ld recon del
Time delay for LD Recon level limit. Step: 1s Range: 1 - 1800 s

[s]

AutoLd recon

[DISABLED / ENABLED]

Enables automatic reconnection of shedded load. If enabled, binary input MAN LOAD RECON has no function.

Date and time


TimeStamp per
Time interval for history record. Time base is based on number of minutes since midnight. Step: 1 min Range: 0 - 240 min Hint: No history is recorded when TimeStamp Per = 0.

SummerTimeMode [DISABLED / WINTER / SUMMER, WINTER-S, SUMMER-S]


DISABLED: WINTER (SUMMER): Automatic switching between summer and wintertime is disabled. Automatic switching between summer and wintertime is enabled and it is set to winter (summer) season. WINTER-S (SUMMER-S): Modification for southern hemisphere.

Time [HHMMSS]
Real time clock adjustment

Date [DDMMYY]
Actual date adjustment

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Sensor spec
Calibr AI1 (AI2, AI3) []
Calibrating constant to adjust the measured value of IG-CU analog inputs. Physical dimension of calibrating constant is corresponding to Analog input. Step: 1 Range: -1000 +1000 Hint: Calibr AI1, Calibr AI1, Calibr AI3 have to be adjusted when measured value is near the alarm level. Customer adjustable characteristics Curve A, Curve B, Curve C adjust in WinEdit.

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Sensor specification
Background of the sensor calibration
To correct measuring error of each analog input (pressure, temperature, level), calibrating constants within 10 % of measure range should be set. Three calibrating constants are set in physical units - bar, o C, % . From these constants are calculated equivalent calibrating resistances which are internally (in software) add to sensor resistance. At the moment of calibration (ENTER pressing) is calculated (and in memory saved) calibrating resistance (in ). This value is added to measured sensor resistance before calculation of the AI1 (AI2 or AI3) value. Example: iG-CU display Temperature 70 C and real value is 73 C. After setting Calibr AI1 to +3 C (and pressing ENTER) InteliGen calculates corresponding resistance (e.g.5) and saves this value into the memory. The resistance is then added to all calculations (e.g. instead of 70C -> 73C, or e.g. instead of 5C -> 6C).

Default sensor settings


Analog input 1: Analog input 2: Analog input 3: 10 points VDO characteristic, pressure measuring 6 points VDO characteristic, temperature measuring 2 points VDO characteristic, fuel level measuring in bar in C in %

For VDO sensor characteristic see chapter Value and set points codes.
VDO Temperature sensor
2000 1800 1600 1400 1200 1000 800 600 400 200 0 0 20 30 40 50 60 70 80 90 110

VDO Pressure sensor


200 Resistance [ohm] 150 100 50 0 0 2 4 6 8 10

Resistance [ohm]

Temperature [ C]

Pressure [bar]

Temperature C -20 -10 0 30 60 80 90 100 110 120 0

Pt 1000 ohm 922 961 1000 1117 1232 1309 1347 1385 1423 1461 -1

Ni 1000 ohm 893 946 1000 1171 1353 1483 1549 1618 1688 1760 -1

Hint: When measured value is 6% out of range the Sensor fail FLS is detected.

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Operator Interface
Pushbuttons and LEDs
3 2 1 4 5

15

10

16

11

12

14

13

18

17

Pushbuttons:
MODE Cyclic forward selection the gen-set operation mode (OFF -> MAN -> AUT) MODE Cyclic backward selection the gen-set operation mode (AUT -> MAN -> OFF) HORN RESET Deactivates the HORN FAULT RESET Acknowledges faults and alarms START Start of the gen-set STOP Stop of the gen-set MCB ON/OFF Has no affect in this application GCB ON/OFF Manual open/close (synchronies) of the Generator circuit breaker PAGE Cyclic selection of the display mode (MEASUREMENT -> ADJUSTMENT -> HISTORY) 10. Select the setpoint, select the screen or increase setpoint value 11. Select the setpoint, select the screen or decrease setpoint value 12. ENTER Confirm setpoint value 1. 2. 3. 4. 5. 6. 7. 8. 9.

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LEDs
13. BUS VOLTAGE PRESENT: 14. BUS FAILURE: 15. 16. 17. 18. GREEN LED is on, if voltage on the bus is present RED LED starts flashing when the mains failure occurs and gen-set does not run, goes to steady light when the gen-set starts and goes off when the mains restores. GEN VOLTAGE PRESENT: GREEN LED is on, if gen. voltage is present and within limits GEN-SET FAILURE: RED LED starts flashing when gen-set failure occurs. After FAULT RESET button is pressed, goes to steady light (if an alarm is still active) or is off (if no alarm is active) GCB ON GREEN LED is on, if GCB is closed. Flashes during gen-set synchronizing. MCB ON GREEN LED is on, if MCB is closed (binary input MCB feedback is closed) .

How to select the gen-set mode?


Use MODE or MODE to select requested gen-set operation mode (OFF MAN AUT)

When to use button GCB ON/OFF?


In AUT mode the button is disabled. In MAN mode is enabled, but before closing of the circuit beaker, generator voltage must be within limits.

Closing to dead bus


When no voltage is detected on the bus, the GCB is immediately closed.

Synchronizing
When voltage is detected on the bus (within Voltage window) InteliGen starts synchronizing and waits for closing of GCB.

Display menus
There are 3 display menus available: MEASUREMENT, ADJUSTMENT and HISTORY Each menu consists of several screens. Press repeatedly PAGE button to select requested menu.

How to view measured data?


1. Use repeatedly PAGE button to select the MEASUREMENT menu. 2. Use and to select the screen with requested data.

How to view and edit set points?


1. 2. 3. 4. 5. 6. 7. Use repeatedly PAGE button to select the ADJUSTMENT menu. Use or to select requested set points group. Press ENTER to confirm. Use or to select requested set point. Set points marked * are password protected. Press ENTER to edit. Use or to modify the set point. When or is pressed for 2 sec, auto repeat function is activated. 8. Press ENTER to confirm or PAGE to leave without change. 9. Press PAGE to leave selected set points group.

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How to handle the HISTORY menu?


1. Use repeatedly PAGE to select the HISTORY menu. 2. Use or to select a requested record. 3. Use ENTER to select requested screen (record items) within displayed records

How to change the display contrast ?


Press ENTER and or at the same time to adjust the best display contrast Hint: Only in MEASUREMENT menu

How to check the serial number and software revision?


Press ENTER and then PAGE. On the display you can see InteliGen INFO screen for 10 seconds. InteliGen INFO screen contains: 1) Controller name (see Basic setting group) 2) InteliGen serial number (8 character number) 3) SW version: the first is the firmware version number; the second is configuration table number. 4) Application: IG-Combi 5) Branch: InteliGen Hint: Only in MEASUREMENT menu.

How to find active alarms?


Active alarm list is the last screen in the MEASUREMENT menu. Select MEASUREMENT menu. Press You will see the list of all active alarms with the number of alarms at the top-right corner. Inverted alarms are still active. Non-inverted alarms are not active, but not yet confirmed. Press FAULT RESET accepts all alarms. Non-active alarms immediately disappear from the list. Active alarm list appears on the screen when a new alarm comes up and Main MEASUREMENT screen is active. Hint: Alarm list does not activate when you are reviewing the values, parameters or history.

MEASUREMENT screens description


Main measure screen
1 2

OFF MAN AUT

TEST

3 4 7 5 8

Ready Mains Oper cos 0.00 RPM 0 Tim er 0

6
1. Operation mode of the gen-set (OFF-MAN-AUT) 2. Indication of active alarm InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf 68

3. 4. 5. 6. 7. 8. 9. 10.

Status of the gen-set Actual condition RPM of the gen-set Active power Power factor Timer - event s counting time (e.g. prestart, cooling, etc.) Actual required power displayed in brackets. Application operation actual application mode [Single = SSB, SinglePar = SPtM, Multi=MINT]

Generator screen
Load surge maximal value Load surge actual value Gen freq Gen V1-2, V2-3, V3-1 ph-ph Gen V1, V2, V3 ph-N (triple barograph) Gen I1, I2, I3 (triple barograph)

Mains/Bus screen
Mains Current L3 Active Mains power Reactive Mains power Mains/Bus Power factor Mains/Bus freq Mains/Bus Vb1-2, Vb2-3, Vb3-1 ph-ph Mains/Bus Vb1, Vb2, Vb3 ph-N (tripple bargraph)

IG-CU Analog inputs screen


AI1 Oil pressure AI2 Water temperature AI3 Fuel level Battery voltage (single barograph) (single barograph) (single barograph) (single barograph)

IG-CU binary inputs 1/2


BI1 to BI5

IG-CU binary inputs 2/2


BI6 to BI9

IG-CU binary outputs 1/2


BO1 to BO5

IG-CU binary outputs 2/2


BO6 to BO9 Load shedding status

IG-PCLSM binary inputs


BI10 BI13

IG-PCLSM binary outputs


BO10 BO13

Gen-set power screen


Active power Power factor (total and per phase) (total and per phase) 69

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Reactive power kVAr Apparent power

(total and per phase) (total and per phase)

Statistic
Kilowatt-hours kWh Active energy Reactive power hours kVArh Reactive energy Run hours Number of starts NextServTime total total

Synchroscope
Slip frequency Angle between V1g and V1m V1g Generator first phase voltage V1m Mains first phase voltage (synchroscope)

SRO Speed regulator output indication in the range 0 to 10,00V VRO Voltage regulator output indication in the range 0 to 100%.

Power management
Engine priority Total available power (sum of Nominal power) Total run power (sum of Nominal power - running) Active reserve (single barograph) CAN16 bus status address 1 to 16 (binary) CAN23 bus status address 17 to 32 (binary)

Alarm list

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PAGE PAGE

PAGE

Measure Screens Par. Edit Screens

History Screens

OFF
ENGINE BASIC ENGINE PROT GEN BASIC GEN PROTECT MAINS FAIL

MAN 500

AUTO

1000

Screen

586

kW

12345h 14:23:15

PAGE

ENTER

RPM

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GEAR TEETH 150 150 NOM RPM 1500 1500 START RPM 30% 30 CRANK TIME 10s 10

Next Screen
Parameter setting: 1. Set cursor by 2. Press
ENTER

F O E Y L B OR A T IST H

buttons

Chart guide to menus and pushbuttons operation

to editing mode buttons

3. Adjust parameter by 4. Press


ENTER

to write parameter into memory to cancel of editing mode


ENTER ENTER

Next Screen
Press
PAGE

ENTER

71

PAGE

..... TO MEASURE SCREEN

Function description
There are three modes of the gen-set: OFF - MAN - AUT. To select the mode use MODE and MODE.

OFF mode
No start of the gen/set is possible. Outputs STARTER, GCB CLOSE/OPEN and FUEL SOLENOID are not energized. No reaction if buttons START, STOP, GCB ON/OFF are pressed. In OFF mode only is activated switching between: SSB SPtM via Binary input: Synchro Enable. Multiple and Single mode by Binary input: Multiple Enable.

MAN mode
In MAN mode genset can be controlled by IG front panel buttons. Button reaction can be different depends on selected Application mode. See Binary inputs: Synchro Enable, RevSync Enable, Multiple Enable, which in principle switch Application mode between SSB, SPtM and MINT. 1) To start the gen-set press START. 2) When the generator voltage is within limits (adjusted in the setpoints group Generator protections) GCB green LED on the front panel lights. 3) Press GCB ON/OFF to close the GCB. If the generator voltage is out of the limits, InteliGen does not to respond to the GCB ON/OFF. a) If InteliGen detects dead bus, immediately closes GCB OPEN/CLOSE output. b) If InteliGen detects voltage (Voltage window) on the bus, starts synchronizing. 4) To stop the engine press STOP a) InteliGen unloads the gen-set. When the gen-set load reaches GCB Open level, (but max. GCB open del), iG opens GCB CLOSE/OPEN. Unloading is active only when binary input MCB feedback is closed or other gen-set is connected to bus. In other case GCB CLOSE/OPEN opens immediately. b) Gen-set is cooled and stopped. Hint: InteliGen does not respond to the SYS START/STOP input. InteliGen is disconnected from Power management. Load and power factor sharing in parallel isolated group are active only when Load sharing line and CAN bus between all gen-sets are connected.

AUT mode
In AUT mode genset cant be controlled by IG front panel buttons. Controller function can be different depends on selected Application mode. See Binary inputs: Synchro Enable, RevSync Enable, Multiple Enable, which in principle switch Application mode between SSB, SPtM and MINT. Binary input Synchro Enable Multiple Enable SSB Opened Opened SPtM Closed Opened MINT Closed Closed

Following description corresponds with MINT Application mode. 1) All gen-sets necessary to cover selected LoadRes strt are started a) Immediately when SYS START/STOP binary input is closed b) Delayed SysAMFstrt del when MCB FEEDBACK binary input is opened mains failure comes 2) The first gen-set closes to the dead bus, the rest are synchronized to the bus. InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf 72

3) When all necessary gen-sets are connected to the bus and LoadRes strt is achieved, SYST RES OK output is closed. Output could be used to close the MGCB. 4) Gen-sets get loaded and total active and reactive load are shared between parallel operating gensets. 5) Close input LOAD RESERVE 2 (or 3 or 4) and use setpoint LoadRes strt, if necessary. 6) If load increases and selected LoadRes strt is not achieved, after a Next start del next gen-set with the highest priority is started and synchronized to the bus. 7) If load decreases and selected LoadRes stp is exceeded, after a Next stop del the running gen-set with the lowest priority is unloaded, got off line, cooled and stopped. 8) Gen-sets group stops when binary input SYS START/STOP opens. If the input MCB FEEDBACK is closed (gen-sets are in parallel to mains) InteliGen unloads the gen-sets. When gen-set is unloaded (see GCB open level or GCB open del) opens SYST RES OK and opens GCB CLOSE/OPEN. Hint: InteliGen does not respond to GCB ON/OFF InteliGen does not respond to START and STOP !!!!! VERY IMPORTANT !!!!!!

Engine can start automatically without warning when pressing FAULT RESET after shut down alarm.

Manual fuse synchronizing


Function is enabled or disabled by setpoint ManualFuseSync [ENABLED, DISABLED]. Setpoint select binary MCB output function when reverse synchronization is in process. ENABLE: InteliGen controls MCB output. DISABLE: External device controls connecting of MCB during unlimited timeout. Synchro state is indicated by Binary output In synchronism. Manual fuse switches can be closed only when Binary output: In synchronism is closed. There is no timeout for fuse switch closing (Sync/Load ctrl: Sync timeout is not active). Binary input: MCB feedback can be closed after all Manual fuse switches are closed. MCB feedback activates Load control function.

Two setpoint set switch


Binary input Nominal switch selects between two setpoints sets (Nominal voltage, Nominal RPM, Nominal freq).

SSB SPtM switch


Binary input: Synchro Enable enables GCB synchronizing - selects between SSB (when opened) and SPtM (when closed) Application mode. Binary input: RevSync Enable enables reverse (MCB) synchronizing.

Baseload change by Binary inputs


Function is available in SPtM Application mode in parallel to the mains only. Binary inputs: BaseLoad Inc and BaseLoad Dec inc/decreases ActReqPower (Active required generator power value) that is in principle Baseload value. ActReqPower is visible on IG screen. Speed of Baseload change is adjusted by ProcCtrlSingle: BaseloadChange.

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Single / Multiple application switch


Single application mode is active when Binary input: MultipleEnable is not configured or opened. Multiple application mode is active when Binary input: MultipleEnable is closed. Single/Multiple application mode change is possible in InteliGen OFF mode only. System behavior is like in standard IG-MINT.

Load surge protection


Load surge protection is fast Mains failure protection. It detects sudden generator load changes during parallel operation with the mains. Due to Mains failure can be generator immediately fully unloaded or heavy overloaded. Load surge protection in this case opens MCB or GCB depends on controller application. Load surge protection becomes active 3 sec delayed after entering to parallel (synchronizing). Values visible on the iG screen and in WinEdit

Max load surge

[Pnom/s]

It is maximal value of Act load surge (maxi meter). When genset enters the parallel mode, the Max load surge value is reseted to zero. Hint: Max load surge is visible on iG generator screen and in WinEdit.

Load shedding
G en-set power Ld shed level

closed

BO Load shed 1
closed

BO Load shed 2
closed

BO Load shed 3

Ld shed del

Ld shed del

Ld shed del

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Load reconnection automatic


AutoLd recon = ENABLED
G en-set power Ld recon level

BO Load shed 3 BO Load shed 2 BO Load shed 1

opened

opened

opened

Ld recon del

Ld recon del

Ld recon del

Load reconnection manual


AutoLd recon = DISABLED
Ld recon level
G en -s et p ow er

BO Load shed 3 BO Load shed 2 BO Load shed 1

opened

opened

opened

BI Man load recon


no action

Load sheeding Inputs, Outputs and Setpoints overview:


Load shedding: Ld shed level [%] Ld shed delay [s] Ld recon level [%] Ld recon del [s] AutoLd recon [ ENABLED / DISABLED ]

Vg Ig

Load shed 1 Load shed 2 Load shed 3

Man load recon

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Alarm management
Following alarms are available: Fls Warning Unload Slow stop Shut down History record sensor fail only warning, no action GCB opening unload and cooling before stop immediately stops no Alarm, no action

Hint: The alarm can be configured for any IG-CU, IG-PCLSM binary input. When warning comes up it is displayed on the Alarm list screen and (selected ones) are written to History record. Detection of each binary input alarm is fix 1 sec time delayed. Alarms detected on IG-CU analog inputs are two levels (e.g. wrn and sd). Use WinEdit to modify binary or analog inputs.

Warning
When warning comes up, only alarm outputs are closed. Possible warnings: Binary inputs configured as Warning (alarms are displayed and stored under configured name) Analog inputs configured as Warning (alarms are displayed and stored under configured name) Battery voltage alarm level

Unload
When the generator protection comes up, InteliGen opens the output GCB CLOSE/OPEN In MAN and AUT mode engine is cooled and stopped. Possible unload alarms GCB failure Overload IDMT Overcurrent (all three phases are checked) Short current (all three phases are checked) Current unbalance Generator voltage unbalance Generator over/under voltage (all three phases are checked) Generator over/under frequency (all three phases are checked) Reverse power Earth fault BUS measurement error Alarm inputs configured as unload protection

Slow stop
When the slow stop alarm comes up InteliGen unloads gen-set, opens output GCB CLOSE/OPEN, waits for Cooling time and opens FUEL SOLENOID output. When other gen-set is ready to run it starts and connects to load before unload function activates. Unload activates at the latest when Slow stop del exceeds. Binary inputs configured as Slow stop (alarms are displayed and stored under configured name)

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Analog inputs configured as Slow stop (alarms are displayed and stored under configured name)

Shut down
When the shut-down alarm comes up, InteliGen opens outputs GCB CLOSE/OPEN, FUEL SOLENOID, STARTER. Possible shut-down alarms Overspeed Underspeed Start fail Binary inputs configured as Shut down (alarms are displayed and stored under configured name) Analog inputs configured as Shut down (alarms are displayed and stored under configured name)

Alarm time chart


Underspeed Protection delay

Engine running only, SD, Slow stop, Wrn Gen>V, Gen<V, Gen>f, Gen<f, Volt unbal, Curr unbal, Reverse power, Unload protection

All the time & Overspeed protections & Ig IDMT, Ig unbal, IG short Mains >V, Mains <V, Mains >f, Mains <f, MVolt unbal

Ready Cranking RPM=0

Starting

Running

Loaded

Loaded

Min stab time

Synchronizing

or Max stab time

Voltage phase sequence detection


InteliGen controller detects phase sequence on both generator and mains/bus voltage terminals. This protection is important after controller installation to avoid wrong voltage phases connection. Following alarms can be detected:

Wrong phase sequence


There is fix defined phase sequence in InteliGen controller L1, L2, L3. When the phases are connected in different order (e.g. L1, L3, L2 or L2, L1, L3) following alarms are detected: G ph opposed = wrong generator phase sequence B ph opposed = wrong bus phase sequence

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GCB opened Cooling Stop

Starter OFF

GCB closed

Unloading

Start

Idle

77

Inverted phase polarity


Inverted phase polarity can be detected due to wrong connection of separation transformers between controller and generator / mains / bus voltage. Phase sequence is OK but some phase(s) is connected in opposite way (180 shift). Following alarms can be detected: GEN L1 neg = generator phase L1 is inverted GEN L2 neg = generator phase L2 is inverted GEN L3 neg = generator phase L3 is inverted B L1 neg = mains phase L1 is inverted B L2 neg = mains phase L2 is inverted B L3 neg = mains phase L3 is inverted

Wrong phase sequence and inverted polarity


It is combination of both previous alarms G ph+L1 neg = wrong generator phase sequence and phase L1 is inverted G ph+L2 neg = wrong generator phase sequence and phase L2 is inverted G ph+L3 neg = wrong generator phase sequence and phase L3 is inverted B ph+L1 neg = wrong mains phase sequence and phase L1 is inverted B ph+L2 neg = wrong mains phase sequence and phase L2 is inverted B ph+L3 neg = wrong mains phase sequence and phase L3 is inverted Hint: Phase sequence detection is active when voltage in all three phases is >50VAC and all phases angles are in the range 120 20. Phase sequence alarm detection is 1 sec delayed to avoid transient effects. B (=BUS) alarms are detected in MINT, MEXT applications instead M. (=MAINS) alarms.

GCB, MCB fail detection


MCB or GCB fail detection is based on binary output CB close/open comparing with binary input CB feedback. There are three different time delays for CB fail detection see following diagrams. When is BO GCB close/open (MCB close/open) in steady state and GCB feedback (MCB feedback) is changed the GCB fail is detected immediately (no delay).
closed BO G CB close/open opened closed BI G CB feedback active Alarm: G CB fail Alarm detection: immediatelly Alarm: G CB fail BI G CB feedback opened active Alarm detection: immediatelly BO G CB close/open

When BO GCB close/open (MCB close/open) opens there is 2 sec delay for GCB fail (MCB fail) detection.
BO G CB close/open opened

BI G CB feedback

T ime delay 5 sec

opened active

Alarm: G CB fail

When BO GCB close/open (MCB close/open) closes, there is following delay for GCB fail (MCB fail) detection: 2 sec when synchronizing (parallel modes) InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf 78

5 sec in stand-by (island modes)


closed BO G CB close/open T ime delay BI G CB feedback 5 or 2 sec active Alarm: G CB fail closed

Sensor fail detection


Sensor fail Fls is detected when measured value is 6,2 percent out of range. Controller screen displays in this case string #### instead measured value.
R1

R2 R3 R4 R5

Sensor -6% Failure

Range of measurement +6% Sensor 100%

Range of sensor

Failure

IG-PC(LS)M module fail


Fail is detected when controller is switched on only. Fail is not detected during operation state.

Speed regulator and Volt regulator limit warning


There are two control loops in controller: Sync/Load control and Volt/PF control. During operation state it is detected when regulator output reached limit value i.e.: When Speed governor output stays on +10V or 10V for more than 5 sec the warning SpdRegLim is detected on the Alarm list. When AVRi output stays on 0% or 100% for more than 5 sec the warning VoltRegLim is detected on the Alarm list. This warning indicates only (no other action) wrong connection or adjusting of control loop. Control loops should operate within range.

Bus voltage error detection


BusMeasError is detected when: AUT mode: binary input MCB feedback is closed and BUS parameters are out of limits GCB is closed, generator parameters are OK, but BUS V>, V<, f>, f< parameters are out of limits. Detection delay: fix 20 sec, Type of protection: unload, auto quitted (without Fault reset)

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Setpoint replication management


All setpoints in the Power management group except: Priority have to be equal in every InteliGen connected to the network. InteliGen has built in automatic replication procedure to ensure that. Hint: When group of InteliGens are not interconnected by CAN digital line, each gen-set operate separately. In this case is recommended to adjust the equal setpoints in all InteliGens manually.

How to adjust setpoints


1) Switch on all InteliGens in the network 2) Select any InteliGen and adjust setpoints in the ProcessControl group or in Power management group 3) Replication management immediately updates modified setpoint in each InteliGen in the network (except Priority) 4) Any new powered InteliGen automatically updates all setpoints from InteliGen with lowest Controller Adr number.

Setpoints consistency
Any changes of following setpoints in the ProcessControl group and in Power management group (except Priority) done in one InteliGen are automatically replicated in all other connecting InteliGens. ProcessControl #SystLoadCtrl #SystPFControl #SystBaseLoad #SystPwrFactor Pwr management #Syst start del #Syst stop del #LoadRes Strt 1 #LoadRes Strt 2 #LoadRes Strt 3 #LoadRes Strt 4 #LoadRes Stp 1 #LoadRes Stp 2 #LoadRes Stp 3 #LoadRes Stp 4 #Next start del #Ovrld NextDel #Next stop del #Slow stop del

Any new powered InteliGen receive automatically all replicated parameters from InteliGen with the lowest Controller adr

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Gen-set operation states


Gen-set can operate in following states: Not ready Init Ready Prestart Cranking Pause Starting Unl Alarm Loaded Stop Shut down Cooling Running RPM fail Unloading Gen-set is not ready to start After IG power supply switch on Gen-set is ready to run Prestart sequence in process. Prestart output is closed Engine is cranking Pause between start attempts START RPM (firing speed) is reached. Gen-set is unloaded due to electric protection Gen-set is running loaded Stop Shut down alarm Gen-set is cooling before stop Waiting for GCB connection Engine Over or Under speed Gen-set is unloading

External gen-set conditions: MainsOper MainsFlt ValidFlt IslandOper MainsRet Brks Off Synchro Paral Oper UnlProt Multi Oper RetTransf Mains (or Bus) is present Mains (or Bus) cut off immediate state Mains (or Bus) cut off takes EmergStart del Island operation Mains (or Bus) recover GCB, MCB opened Synchronizing is active Parallel operation with mains Unload protection Island, Mains operation Waiting to mains stabilization

Start-stop sequence
MODE = MAN

Engine stop by using GCB ON/OFF and STOP


State Ready Prestart Cranking Starting Running Loaded Unloading Stop Ready Closed outputs PRESTART PRESTART,STARTER, FUEL SOLENOID FUEL SOLENOID FUEL SOLENOID FUEL SOLENOID, GCB CLOSE/OPEN FUEL SOLENOID Condition of next transition START request Prestart time=0 RPM> Start RPM RPM>(Nominal speed-Nominal speed/16) GCB ON/OFF GCB ON/OFF STOP RPM=0 >>>>

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Engine stop by using STOP


State Ready Prestart Cranking Starting Running Loaded Cooling Stop Ready Closed outputs PRESTART PRESTART, STARTER, FUEL SOLENOID FUEL SOLENOID FUEL SOLENOID FUEL SOLENOID, GCB CLOSE/OPEN FUEL SOLENOID Condition of next transition START request Prestart time=0 RPM> Start RPM RPM>(15/16 of Nominal speed) GCB ON/OFF STOP Cooling time=0 RPM=0 >>>>

Hint: Gen-set stops immediately when button STOP is pressed during Cooling procedure.

Unsuccessful start
Crank attempts=3
State Ready Prestart Cranking Crank pause Cranking Crank pause Cranking Not ready Ready Closed outputs PRESTART PRESTART, STARTER, FUEL SOLENOID PRESTART PRESTART, STARTER, FUEL SOLENOID PRESTART PRESTART, STARTER, FUEL SOLENOID HORN, GENERAL FAULT Condition of next transition Start request Prestart time MaxCrank time CrankFail paus MaxCrank time CrankFail paus MaxCrank time FAULT RESET >>>>

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Remote control and data logging


Direct connection to the PC
InteliGen can be connected directly with PC via RS232 interface. Use the standard cable RS232 cable to connect PC with InteliGen.

PC software - WinEdit
On the PC (for direct or modem connection) has to be installed the ComAps software package WinEdit. (based on Windows 95 or newer platform) WinEdit enables: read the quantities, adjust all set points, read the history control the engine configure the controller select software configuration modify alarm inputs and outputs modify password, commands protections, direct or modem communication receive active calls

History file
InteliGen stores a record of each important event into the history file. The history file seats 117 records. When the history file is full, the oldest records are removed. Hint: To force history download in WinEdit (direct or modem) open History window and select History | Read history command.

Record structure
Abbreviation No. Reason Time Date Pwr Cos LChr Spd Gfrq Vg1 Vg2 Vg3 Bfrq Vb1 Vb2 Vb3 Ig1 Ig2 Ig3 Batt AI1 (Oil) AI2 (Temp) Historical Value Number of historical event Event specification Time of historical event in format HH:MM:SS Date of historical event in format DD/MM/YY Generator power Generator cos Character of the load Engine speed Generator frequency Generator voltage L1 Generator voltage L2 Generator voltage L3 Bus frequency Bus voltage L1 Bus voltage L2 Bus voltage L3 Generator current L1 Generator current L2 Generator current L3 Battery voltage IG-CU Analog input 1 value (default Oil pressure) IG-CU Analog input 2 value (default Water temperature) 83

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

AI3 (Fuel) BInp BIPC BOut BOPC

IG-CU Analog input 3 value ( default Fuel level) IG-CU Binary inputs IG-PCLSM Binary inputs IG-CU Binary outputs IG-PCLSM Binary outputs

List of possible events


Zero signed events are not displayed or stored. Events specification Alarm Configurable Analog inputs IG-CU alarms YES Binary inputs IG-CU alarms YES Binary inputs IG-PC(LS)M alarms YES Events info InteliGen switched on 0 Periodic history record 0 Starting sequence begins 0 Gen set stopped 0 Generator circuit breaker closed 0 Generator circuit breaker opened 0 Other GCB (in MINT) trip 0 Mains circuit breaker closed 0 Mains circuit breaker opened 0 Time mode was changed 0 Password was set from any terminal 0 Password was changed from any 0 terminal Binary input Remote OFF was closed 0 Binary input Sprinkler was closed 0 Service time expired WrnService Time Speed regulator out was limited Wrn SpdRegLim Volt regulator out was limited Wrn VoltRegLim Engine Gen set start fail Sd Start Fail Gen set overspeed Sd Overspeed Gen set underspeed Sd Underspeed SD stop fail see Note 1. Sd StopFail Emergency stop Emergency stop RPM pickup fail Sd PickupFail Battery voltage warning Wrn Batt volt Battery is discharged Sd Batt flat Start info AMF start 0 AMF stop 0 Remote start by binary input 0 (SPM,SPtM) Remote stop by binary input 0 (SPM,SPtM) System start by binary input 0 (MINT,MEXT) System stop by binary input 0 (MINT,MEXT) Peak start (SPtM) 0 Peak stop (SPtM) 0 Generator Generator phase 1 overvoltage Unl Vg1 Over Generator phase 1 undervoltage Unl Vg1 Under Generator phase 2 overvoltage Unl Vg2 Over InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf History YES YES YES Switched On Time stamp Gen set start Gen set stop GCB closed GCB opened OtherGCBtrip MCB closed MCB opened TimeModeChngd Password set Password chngd Remote OFF set Sprinkler set 0 0 0 Sd Start Fail Sd Overspeed Sd Underspeed Sd StopFail Emergency stop Sd PickupFail Wrn Batt volt 0 MF start MF stop GenSetRemStart GenSetRemStop GenSetSysStart GenSetSysStop GenSet PKstart GenSet PKstop Unl Vg1 Over Unl Vg1 Under Unl Vg2 Over Active call YES YES YES 0 0 0 0 0 0 0 0 0 0 0 0 0 0 wrn Wrn wrn sd sd sd sd Sd sd wrn sd 0 0 0 0 0 0 0 0 unl unl unl 84

Events specification Generator phase 2 undervoltage Generator phase 3 overvoltage Generator phase 3 undervoltage Generator overfrequency Generator underfrequency Generator voltage unbalance Generator overload Load surge protection Reverse power Synchronization timeout Earth fault protection Failure of generator circuit breaker Generator short current protection Generator IDMT protection Generator current unbalance Voltage on mains terminals (SPM) Bus voltage error (MINT) Mains/bus Bus phase 1 overvoltage Bus phase 1 undervoltage Bus phase 2 overvoltage Bus phase 2 undervoltage Bus phase 3 overvoltage Bus phase 3 undervoltage Bus overfrequency Bus underfrequency Bus voltage unbalance

Alarm Unl Vg2 Under Unl Vg3 Over Unl Vg3 Under Unl Fgen Over Unl Fgen Under Unl Vgen Unbal UnlGen Overload LoadSurge Unl Rev PWR Stp SyncTO Unl EarthFltC GCB fail Unl Short Igen Unl IDMT Unl Igen Unbal UnlCounterVolt Unl BusMeasErr 0 0 0 0 0 0 0 0 0

History Unl Vg2 Under Unl Vg3 Over Unl Vg3 Under Unl Fgen Over Unl Fgen Under Unl Vgen Unbal UnlGen Overload LoadSurge Unl Rev PWR Stp SyncTO Unl EarthFltC GCB fail Unl Short Igen Unl IDMT Unl Igen Unbal UnlCounterVolt Unl BusMeasErr Vb1 Over Vb1 Under Vb2 Over Vb2 Under Vb3 Over Vb3 Under Fbus Over Fbus Under Vbus Unbal Wrong params Watchdog rst Appl.loaded Firmw.loaded 0 RS232 control MODEM control SMS control MB control LB control IB control ActCallCH1 sent ActCallCH2 sent ActCallCH3 sent ActCH1 failed ActCH2 failed ActCH3 failed 0 0 0 0 0

Active call unl unl unl unl unl unl unl unl unl Stp Unl wrn unl unl unl unl Unl 0 0 0 0 0 0 0 0 0 0 0 0 0 wrn 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 85

System info Wrong params checksum 0 Watchdog reset 0 Application loaded 0 Firmware loaded 0 IG-PC(LS)M module fail (SPtM, MINT) WrnPC(LS)Mfail Modem RS232 control command 0 MODEM control command 0 SMS control command 0 Modem Bridge control command 0 Local Brigde control command 0 Internet Bridge control command 0 Active call from CH1 sucessfully sent 0 Active call from CH2 sucessfully sent 0 Active call from CH3 sucessfully sent 0 Unsuccesfull active call from CH1 ActCH1 failed Unsuccesfull active call from CH2 ActCH2 failed Unsuccesfull active call from CH3 ActCH3 failed Phase sequence Inverted polarity of gen phase L1 GEN L1 neg Inverted polarity of gen phase L2 GEN L2 neg Inverted polarity of gen phase L3 GEN L3 neg Bad gen phase sequence G ph opposed Bad gen phase sequence and polarity L1 G ph + L1 neg InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

Events specification Alarm History Active call Bad gen phase sequence and polarity L2 G ph + L2 neg 0 0 Bad gen phase sequence and polarity L3 G ph + L3 neg 0 0 Inverted polarity of bus phase L1 B L1 neg 0 0 Inverted polarity of bus phase L2 B L2 neg 0 0 Inverted polarity of bus phase L3 B L3 neg 0 0 Wrong bus phase sequence B ph opposed 0 0 Wrong bus phase sequence and polarity B ph + L1 neg 0 0 L1 Wrong bus phase sequence and polarity B ph + L2 neg 0 0 L2 Wrong bus phase sequence and polarity B ph + L3 neg 0 0 L3 Hint: Binary and analog inputs alarm events are recorded and displayed under a user name. Modem Bridge (MB) is IG-MU connected to modem. Local Bridge (LB) is IG-MU connected to PC. Note 1 SD stop fail is detected when 60 sec after engine stop (BO Fuel = opened or Styop solenoid is closed) RPM > 30.

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Remote and mobile communication


Modbus protocol
Direct connection: RS232, RS422, RS485 Modem connection 9600 bps, 8 data bits, 1 stop bit, no parity Transfer mode RTU Function 3 (Read Multiply Registers) Function 6 (Write Single Register) Function 16 (Write Multiply Registers) The response to an incoming message is sent with minimum 4.096 ms delay after message reception

The complete description of Modbus communication protocol can be found in Modbus Protocol Reference Guide PI-MBUS-300 and Open Modbus Specification Release 1.0. Both documents are available from web site at http://www.modicon.com/openmbus/ .

Communication object vs. Register


All the data intended for communication has its representation as communication objects in the controller. The communication object is represented by the n-byte array in the controller memory and identified by the unique 16-bit communication object number. The register, according to Modbus communication protocol, represents a two-byte data and in communication functions is referenced by 16-bit register address. Further in the description of communication functions the communication object number will always be used as a register address and length of the communication object will be expressed by number of registers. Just one communication object can be read or written by one communication function. Hint: It is possible to download the Actual IG or IS controller description from on-line controller or from (aig or ais) archive. Use ..\ Program files \ ComAp \ WinEdit \ Tools \ Cfg_img \ Cfg_img.exe software.

IG-MU modbus communication


Modbus protocol communication is supported from IG-MU SW version 1.9. In this case is necessary to use IG SW version at least 5.2 or IS SW V 2.2. Place Modbus jumper in unit before IG-MU Modbus communication.

Recommended ISDN modem


Askey TAS-200E

Modem unit IG-MU


SW version up to 1.6 supports GSM data communication, not SMS. SW Version up to 1.6 does not support Modbus protocol, ISDN data and RS485 communication. Number of rings is default fix configured to 3, not depends on Act.call/SMS: Num rings AA setpoint.

Recommended GSM modem


Wavecom WMOD2, dual 900/1800MHz (baud rate 9600 bps). Siemens M20, supports only 900MHz network. For modem configuration use GM setup program.

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Hint: Any Modem goes to init procedure in following cases - after controller reset (when modem is already connected) - whenever is modem connected to controller - each 20 minutes when is no connection - when connection is closed - when data transmit error occurs

GSM Modem setup


Prior to start work with GSM modem run following program for GSM proper setup. Program writes all the necessary AT commands to configure the GSM modem properly for use with IG-CU or IS-CU. This program runs independent on WinEdit: Start MS Windows-Start-Program files - WinEdit Gm_setup.exe. Select COM port Select iG-CU (=IS-CU) or iG-MU unit Press Setup button Follow commands in GSM Modem Setup window Hint: It is strongly recommended to use the same type of modem on the both sides (IG and PC) of connection.

Analog modem

Analog modem

or

GSM modem

GSM modem

Mobile SIM card setting


Adjust SIM card on GSM modem in the following way: Enable data communication (it could be done by your local GSM operator), Set phone number SMS service center SC (recommended in international format in case of roaming), Set no PIN code required. Hint: All SMS on SIM card will be erased during GSM modem initialization. Valid SMS on SIM card will be served except adjusting and gen-set control command.

SMS message format


IG-MU serves and answers only SMS in valid format addressed to controller IG 5.2 / IS 2.2 or above. SMS message format: Start with # character, followed controller address, followed colon character and access code, Commands are comma separated, Commands are not case sensitive, Maximum message length is limited up to 160 characters, IG-MU answers only message with valid Access code, Answer exceeds 160 characters is separated to more messages.

SMS message header


Every SMS must start with header in format: #address:access command1, command2 where address is controller address 1 to 32 88

InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf

access # :

is valid access code set-up by WinEdit (up to 15 characters length), character indicated beginning of message, character separated controller address and access code

Hint: For direct communication to one controller is possible skip address setting.

SMS message commands


Hint: SMS commands are available for IG-MU from software version 1.9. 1. Controller address Controller address is unique controller identification number located in setpoint group Basic setting : Contr addr [1 to 32]. Syntax: Example: #XX XX controller address [1 to 32] #5 Message is addressed to controller with address 5.

2. Access code InteliGen / InteliSys Access code is 15 characters length string. Access code is separated from controller address by column. Syntax: Example: #5:X X controller access code up to 15 characters length #5:accesscode Message is addressed to controller with address 5 and its access code is set to value accesscode.

3. Read value or setpoint Command for reading of selected value or setpoint. Return value is in appropriate numerical or string format. Syntax: r XXXX (or rXXXX) r command XXXX value or setpoint code #5:accesscode r 8252 Reading of setpoint 8252 (8252 = Gear teeth)

Example:

4. Adjust setpoint Command for adjusting of selected setpoint. Answer message contains only confirmation of successful adjusting or appropriate error. Syntax: w XXXX YYYY (or wXXXX YYYY) w command XXXX setpoint code YYYY value of setpoint in appropriate format #5:accesscode w 8252 144 Adjusting of setpoint 8252 to value 144 (8252 = Gear teeth). ok w_err er_pass er_old adjusting setpoint was correct adjusting setpoint was not successful adjusting setpoint required enter valid password command for adjusting was read out from SMS during GSM modem initialization in this case command will not be served.

Example: Return code:

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5. Enter password Password setting command. Password has to be set before adjusting of protected setpoint or calling protected gen-set control command. Setting password command is not necessary before every adjusting. Password is four digit number in range 0 to 9999. Syntax: p PPPP (or pPPPP) p command PPPP password #5:accesscode p 1234, w 8252 144 Setting password before adjusting protected setpoint. ok er_pass setting password was successful setting password is not valid

Example: Return code:

6. Gen-set control SMS command for invoking gen-set control command as Start, Stop, Fault reset etc. Syntax: c Y (or cY) c command Y type of operation
Y Type of operation 1 Start 2 Stop 3 Horn Reset 4 Fault Reset 5 GCB ON 6 GCB OFF Y Type of operation 7 MCB ON 8 MCB OFF 9 GCB ON/OFF 10 MCB ON/OFF 11 Next Mode 12 Previous Mode

Example:

#5:accesscode p 1234, c1 This SMS command invoke gen-set command Start. Password setting is needed in case of gen-set command protection. ok er_pass c? c_er invoking gen-set command was successful invoking gen-set command require setting valid password unknown gen-set command invoking gen-set command is not allowed in actual state (e.g. attempt invoke gen-set start command in OFF mode). command was read out from SMS during GSM modem initialization in this case command will not be served.

Return code:

er_old 7. Read Alarm list Read actual Alarm list. Syntax: Example: Return code:

a a command #5:accesscode a Request of actual Alarm list. AL=(items of alarm list) comma separated items of Alarm list. Exclamation mark in front of Alarm list item indicates inverse record (still active alarm). 1. Answer message contains most eight items of Alarm list. 2. Full Alarm list is sent in one message only.

Note:

8. Time delay Insert time delay before serving next SMS command. InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf 90

Syntax:

Example: Return code:

d T d command T time delay in sec (in range 1 to 600) #5:accesscode d 10 Request 10 sec delay before serving next SMS command. d_ok d_over time delay was successful performed requested time delay is out of range (1 to 600 sec)

Note:

Any other SMS messages are not served during time delay!

9. Help Request for list of supported SMS command. Syntax: Example: Return code: Note: ? #5:accesscode ? ?=(p passwd,r comm_obj,w com_obj val,c cmd_num,d sec,a,?) list of supported SMS commands Return code is not separated to more message.

10. Answer message Answer message start with # character followed Gen-set name. Colon separate this head form return codes of SMS commands. Answer message is generated during serving received message and is sending in case of acquirement 160 characters or end of received message. Answer message is sending to the originator phone number. Tree dots at the end of message indicate separation and next following message. Example: #5:accesscode r8252,w8252 100,r8252 answer message #Gensetname: 144,ok,100

11. Examples of SMS commands Here is following several examples of SMS messages addresses to controller InteliGen" with address 5, named Gen-set name. Access code in this controller is set to accesscode and password is 1234. In examples are used setpoints and values 8276 Nomin.power, 8209 RPM, 8315 Controller Mode, 8235 binary inputs, 8296 Gen > f. Example 1 reading value SMS: #5:accesscode r8276 Answer: #Gen-set name:100 Example 2 adjusting setpoint SMS: #5:accesscode r8276,w8276 110,r8276 Answer: #Gen-set name:100,ok,110

read value 8276

read value 8276, write 110, read value 8276 read value of 8276 is 100, writing to 8276 was ok, new value of 8276 is 110

Example 3 Gen-set control and delay time SMS: #5:accesscode r8276,c1,d30,r8209 START, Answer: #Gen-set name:110,ok,d_ok,1499 was ok,

read value 8276, invoke gen-set command delay 30 sec, read value 8209 read value of 8276 is 110, Gen-set command START confirm delay command, read value of 8209 is 1499

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Example 4 adjusting special setpoint SMS: #5:accesscode r8315,w8315 0,r8315 type), Answer: #Gen-set name:MAN,ok,OFF string,

read value 8315, write 1 (index of stringlist read value 8315 read value of 8315 as writing was ok, read new value of 8315 as string

Hint: Setpoints Stringlist type (e.g. Controller Mode) is read as string and adjust as index of string item in string list. e.g. Controller Mode: Read value [as string] OFF MAN SEM AUT TEST Write value [as index] 0 1 2 3 4 Note

IS only Standard IG

Example 5 reading and writing other type SMS: #5:accesscode r8235,w8296 110.2 point Answer: #Gen-set name:OIIIOOIIO,ok value),

read value 8235, write 110.2 with decimal read value of 8235 (binary writing was ok

Note:

1. Writing binary setpoint is not supported. 2. Writing setpoint with decimal point is automatically complement in appropriate number of decimal places.

Example 6 reading actual Alarm list read actual Alarm list SMS: #5:accesscode a Actual Alarm list contains Answer: #Gen-set name:AL=(!Wrn PrimWater temp, !Wrn SecWater temp, three items. Batt volt)

Active SMS message


Active SMS message is invoked by controller request. Active SMS message is sending to GSM phone number specified in setpoints group Act. Calls/SMS on InteliGen /InteliSys . Specified phone number must be in international format +cccyyyxxxxxx where ccc is country code, yyy is operator prefix and xxxxxx is local phone number. Active message contains items of actual Alarm list (most eight items). Example of active SMS message: #Gen-set name:AL=(Wrn PrimWater temp, !Emergency stop)

Modbus protocol
There are three possibility of Modbus connection to InteliGen / InteliSys via IG-MU direct via RS232, RS485/422 or via modem. Modbus protocol on IG-MU must be activated by switch P2. InteliGen Combi, SW version 1.0, ComAp March 2003 IG-Combi-1.0.pdf 92

IG-IB Internet communication


iG-IB Internet bridge is interface for Internet communication between one or more controllers and PC. Internet Bridge be can currently connected to internet only via via LAN (Ethernet connector). In future it will be possible to use also Modem connection (wired line MODEM connector) Hint: Contact local IT manager in any case before using iG-IB. Hint: Do not use IG firmware older than 5.2 and IS firmware older than 2.2 for full functionality of internet connection. Hint: Company LAN connected to the Internet is probably configured to enable access to the servers located on the Internet, but to disable access in the reverse direction. If iG-IB has to be visible from the Internet, then your LAN administrator should create a communication channel on the Internet access server. The iG-IB uses the TCP-communication and listen on the port 23 (known as Telnet port).

One controller - RS232/Ethernet connection


In this case no dongle is necessary. One unit could be also connected via CAN interface.

INTERNET

ETHERNET LED 1 2 MODEM IB CONFIG IG-CU DONGLE RS232

iG-IB

iG-CU (iS-CU)

LED

3 4 CAN

5 6 POWER

LED

IG-IB interface
Modem / IB config RS232 interface for IG-IB configuration or Modem connection IG-CU / Dongle RS232 interface for one controller connection or for Dongle for multiple controllers communication. CAN bus interface to group of controllers Ethernet to LAN interface to company net See IG-IB Internet bridge

Connection types
Internet or Modem (wired line) remote connection from WinEdit or MultiEdit software. Active calls: E-mail or SMS via Internet. Hint: For more detail see WinEdit5.3-MultiEdit5.3 user guide from October 2002 chapter IG-IB Internet communication.

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Value and setpoints codes


Hint: Actual values, setpoints and configuration (in XLS or DOC) file is possible to export on-line from controller or off-line from archive using WinEdit Controller Export data command.

Values
Name IG-Combi Group ProcCtrlSingle Engine Engine Engine Engine Engine Engine Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Sw configuration COMBI Name ActReqPower Engine Speed Batt Volt Oil Press Water Temp Fuel Level SRO Act power Act pwr L1 Act pwr L2 Act pwr L3 React pwr kVAr React pwr L1 React pwr L2 React pwr L3 Appar pwr Appar pwr L1 Appar pwr L2 Appar pwr L3 Pwr factor Pwr factor L1 Pwr factor L2 Pwr factor L3 Load char Load char 1 Load char 2 Load char 3 Gen freq Gen V act nom Gen V L1-N Gen V L2-N Gen V L3-N Gen V L1-L2 Gen V L2-L3 Gen V L3-L1 Gen curr L1 Gen curr L2 Gen curr L3 Mains Curr L3 Slip freq Date 19.3.2003 Value 200 1519 26,5 3,8 22 16 -10 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 0,95 Sw conf. ver. Ser. num. 1 0811056D Dimension kW RPM V Bar C % V kW kW kW kW Com. obj. 8663 8209 8213 8227 8228 8229 9052 8202 8524 8525 8526 8203 8527 8528 8529 8565 8530 8531 8532 8204 8533 8534 8535 8395 8626 8627 8628 8210 9917 8192 8193 8194 9628 9629 9630 8198 8199 8200 8208 8224 Filename

Data type Integer 16 Unsigned 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 8 Integer 8 Integer 8 Integer 8 Char Char Char Char Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Integer 16

kVA kVA kVA kVA

50 230 231 231 231 0 0 0 0 1 0 0 0

Hz V V V V V V V A A A A Hz

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Generator Generator Mains/Bus Mains/Bus Mains/Bus Mains/Bus Mains/Bus Mains/Bus Mains/Bus Mains/Bus Mains/Bus Mains/Bus Mains/Bus Mains/Bus Mains/Bus Binary I/O Binary I/O Binary I/O Binary I/O Pwr management Pwr management Pwr management Pwr management Pwr management Pwr management Pwr management Statistics Statistics Statistics Statistics Statistics IG info IG info IG info IG info IG info IG info IG info IG info IG info IG info IG info

Angle VRO Mains freq Mns V L1-N Mns V L2-N Mns V L3-N Mns V L1-L2 Mns V L2-L3 Mns V L3-L1 P mains Q mains kVAr Mains PF MainsLoadChr Act LoadSurge Max LoadSurge BInpIG BInpPCLSM BOutIG BOutPCM EnginePriority TotAvlbPnom TotRunPnom TotRunPact ActReserve LoadRes Start LoadRes Stop kWhours kVArhours NumStarts RunHours NextServTime

0 99,7 50 232 232 232 0 0 0 0 0 0,14 0,04 0,21 111110000 0 11100001 1 1 200 200 0 200 100 150 52 -82 235 21 65534

% Hz V V V V V V kW

8225 9053 8211 8195 8196 8197 9631 9632 9633 8703 8704 8705 8709 9582 9583 8235 8601 8239 8603 8624 8498 8499 8496 8625 8622 8623 8205 8539 8207 8206 9648 9089 8954 8955 8393 8707 8480 9651 9910 8546 8827 9090

Integer 16 Integer 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Integer 16 Integer 16 Integer 8 Char Integer 16 Integer 16 Binary 16 Binary 8 Binary 16 Binary 8 Unsigned 8 Integer 16 Integer 16 Integer 16 Integer 16 Unsigned 16 Unsigned 16 Integer 32 Integer 32 Unsigned 16 Integer 32 Unsigned 16 Unsigned 16 Unsigned 16 Integer 16 Unsigned 8 Unsigned 8 Unsigned 8 Unsigned 8 Unsigned 16 Binary 16 Binary 16 Unsigned 32

P/s P/s

kW kW kW kW kW kW

h h

LdShed state No LdShed TimerText No Timer TimerValue 0 SW version 1 SW branch 21 Application 248 IG Mode MAN ApplOper Multi CAN16 1E+15 CAN32 0 PasswordDecode 4018494723

Setpoints
Name IG-Combi Group ProcCtrlSingle ProcCtrlSingle ProcCtrlSingle ProcCtrlSingle Sw configuration COMBI Name Date 19.3.2003 Value Sw conf. ver. Ser. num. Filename 1 0811056D Dimension Password Com. obj. Low limit High limit 0 0 0 0 8638 8711 8639 9909 Data type String list String list Integer 16 Unsigned 8

Load control BASELOAD PeakAutStart DISABLED Baseload 180 BaseloadChange 10

kW %/s

0 0

200 100

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ProcCtrlSingle ProcCtrlSingle ProcCtrlSingle ProcCtrlSingle ProcCtrlSingle ProcCtrlSingle ProcCtrlMulti ProcCtrlMulti ProcCtrlMulti Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Engine params Engine params Engine params Engine params Engine params Engine params Engine params Engine params Engine params Engine params Engine params Engine params Engine params Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect

PF reference Import load Import PF PeakLevelStart PeakLevelStop ExportLimit #SysLdCtrl PtM #SysBaseLoad #SysPwrFactor Gen-set name Nomin power Nomin current CT ratio Im3 CT ratio Nomin voltage1 Nomin voltage2 Nominal RPM 1 Nominal RPM 2 Nominal freq 1 Nominal freq 2 Gear teeth Mode iG Contr. addr RS232 mode Prestart time Prelubr time Prelubr pause Start RPM MaxCrank time CrnkFail pause Crank attemps Idle time Min stab time Max stab time Cooling time AfterCoolTime Fuel solenoid NextServTime Horn timeout Overspeed Protection del AnlInp1 level1 AnlInp1 level2 AnlInp1 del AnlInp2 level1 AnlInp2 level2 AnlInp2 del AnlInp3 level1 AnlInp3 level2 AnlInp3 del Batt >V Batt <V Batt V del

0,95 0 0,95 50 20 DISABLED BASELOAD 200 0,95 IG-Combi 200 288 400 400 230 120 1500 1200 50 60 120 MAN 1 STANDARD 2 0 1 25 5 8 3 10 2 10 30 30 DIESEL 65534 10 115 5 2 1 3 80 90 5 10 3 15 36 18 5

kW kW kW

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

8640 8641 8642 8643 8644 9592 8774 8775 8776 8637 8276 8275 8274 8566 9911 9912 9915 9916 9913 9914 8252 8315 24537 24522 8394 8780 8781 8254 8256 8257 8255 9097 8259 8313 8258 8662 9100 9648 8264 8263 8262 8369 8370 8365 8375 8376 8371 8381 8382 8377 9587 8387 8383

0,6 -3200 0,6 0 0

1 3200 1 3200 3200

Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 String list String list Unsigned 16 Integer 16 Short string Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 String list Unsigned 8 String list Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 8 Unsigned 8 Unsigned 8 Unsigned 8 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 String list Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Integer 16 Integer 16 Unsigned 16 Integer 16 Integer 16 Unsigned 16 Integer 16 Integer 16 Unsigned 16 Integer 16 Integer 16 Unsigned 16

kW

0 0,6

30000 1

kW A /5A /5A V V RPM RPM Hz Hz

1 1 1 1 80 80 100 100 45 45 0 1

3000 5000 5000 5000 300 300 4000 4000 65 65 500 32

s s min % s s s s s s s

0 0 1 1 1 5 1 0 0 2 0 0

600 600 1000 50 60 60 10 3600 10 300 3600 3600

h s % s Bar Bar s C C s % % s V V s

0 0 100 0 -10 -10 0 -100 -100 0 -100 -100 0 18 8 0

65535 600 150 300 1000 1000 180 10000 10000 180 10000 10000 180 40 36 600

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Gener Gener Gener Gener Gener Gener Gener Gener Gener Gener Gener Gener Gener Gener Gener Gener

protect protect protect protect protect protect protect protect protect protect protect protect protect protect protect protect

Overload Overload del Ishort 2Inom del Curr unbal Curr unbal del Gen >V Gen <V Gen V del Volt unbal Volt unbal del Gen >f Gen <f Gen f del Reverse power Rev. power del EmergStart del Mains ret del Return break MCB close del Mains >V Mains <V Mains V del MVolt unbal MVolt unb del Mains >f Mains <f Mains f del BreakerOverlap Max load surge MCB Logic Ret fromIsland MF StartEnable Pwr management Priority #SysAMFstrtDel #SysAMFstpDel #LoadResStrt 1 #LoadResStp 1 #LoadResStrt 2 #LoadResStp 2 #LoadResStrt 3 #LoadResStp 3 #LoadResStrt 4 #LoadResStp 4 #NextStrtDel #OverldNextDel #NextStopDel #SlowStopDel #MinRunPower 1 #MinRunPower 2 #MinRunPower 3 SpeedRegChar Voltage window Phase window

120 5 200 4 50 5 110 85 3 10 3 110 85 3 15 0,5 5 20 1 1 110 90 2 10 2 102 98 0,5 3 50 CLOSE-OFF AUTO DISABLED ENABLED 1 5 10 100 150 200 250 300 350 400 450 5 2 10 30 100 200 300 NEGATIVE 3 5

% s % s % s % % s % s % % s % s s s s s % % s % s % % s s P/s

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

8280 8281 8282 8283 8284 8285 8291 8293 8292 8288 8289 8296 8298 8297 8486 8552 8301 8302 8303 8389 8305 8307 8306 8446 8447 8310 8312 8311 8661 9581 8444 9590 9238 8551 8488 8549 8550 8489 8491 8490 8633 8831 8833 8832 8834 8492 8493 8494 8495 9584 9585 9586 9054 8650 8652

50 0 100 0 1 0 85 50 0 1 0 85 50 0 0 0 0 0 0 0 90 50 0 1 0 98 50 0 0 0

300 60 500 60 200 60 150 110 60 150 60 150 110 60 50 60 300 3600 60 60 150 110 60 150 60 150 102 60 600 60

Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 8 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 String list String list String list String list Unsigned 8 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 String list Unsigned 16 Unsigned 16

AutoMains Fail AutoMains Fail AutoMains Fail AutoMains Fail AutoMains Fail AutoMains Fail AutoMains Fail AutoMains Fail AutoMains Fail AutoMains Fail AutoMains Fail AutoMains Fail AutoMains Fail AutoMains Fail AutoMains Fail AutoMains Fail AutoMains Fail Pwr management Pwr management Pwr management Pwr management Pwr management Pwr management Pwr management Pwr management Pwr management Pwr management Pwr management Pwr management Pwr management Pwr management Pwr management Pwr management Pwr management Pwr management Pwr management Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl

s s kW kW kW kW kW kW kW kW s s s s kW kW kW

1 0 0 0 100 0 200 0 300 0 400 0 0 0 0 0 0 0

32 600 600 150 32000 250 32000 350 32000 450 32000 600 600 600 600 60000 60000 60000

0 0

100 90

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Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Volt/PF ctrl Volt/PF ctrl Volt/PF ctrl Volt/PF ctrl Volt/PF ctrl Volt/PF ctrl Volt/PF ctrl Volt/PF ctrl Volt/PF ctrl Volt/PF ctrl Volt/PF ctrl Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Load shedding Load shedding Load shedding Load shedding Load shedding Date/Time Date/Time Date/Time Date/Time Sensors spec Sensors spec Sensors spec

Dwell time Slip freq gain Slip freq int Slip freq der Angle gain Angle der Speed gov bias Load ramp Load gain Load int Load der GCB open level GCB open del Sync timeout ManualFuseSync LS gain LS int LS der AVRRegChar Voltage gain Voltage int Voltage der PF gain PF int PF der VS gain VS int VS der AVR DCout bias Warning call Unload call Slow stop call Shut down call AcallCH1-Type AcallCH1-Addr AcallCH2-Type AcallCH2-Addr AcallCH3-Type AcallCH3-Addr Num rings AA A.c.multiplier Ld shed level Ld shed del Ld recon level Ld recon del AutoLd recon

1 20 50 10 50 10 0 60 20 100 10 5 60 60 DISABLED 20 100 20 POSITIVE 20 20 10 20 20 10 15 15 10 50 DISABLED DISABLED DISABLED DISABLED DISABLED DISABLED DISABLED 3 1 90 2 50 5 ENABLED

s % % % % % V s % % % % s s % % %

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 3

8653 8715 8716 8717 8718 8719 8656 8658 8659 8713 8714 8547 8548 8657 9906 8725 9035 8726 9055 8501 8720 8502 8503 8721 8504 8777 9036 8778 8500 8482 8483 8485 8484 9594 9597 9595 9598 9596 9599 24512 24505 8884 8887 8890 8893 9649 8979 8727 24554 24553 8431 8407 8467

0 0 0 0 0 0 -10 0 0 0 0 0 0 0 0 0 0

25 200 100 100 200 100 10 600 200 100 100 100 600 1800 200 100 100

Unsigned 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Unsigned 16 Integer 16 Integer 16 Integer 16 Unsigned 16 Unsigned 16 Unsigned 16 String list Integer 16 Integer 16 Integer 16 String list Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Unsigned 16 Integer 16 String list String list String list String list String list Long string String list Long string String list Long string Unsigned 8 Unsigned 8 Integer 16 Unsigned 16 Integer 16 Unsigned 16 String list Unsigned 8 String list Time Date Integer 16 Integer 16 Integer 16

% % % % % % % % % %

0 0 0 0 0 0 0 0 0 0

200 100 100 200 100 100 200 100 100 100

1 1 50 0 0 0

30 250 200 1800 90 1800

% s % s

0 0 0 0 0 0 0 0 0 0 0 0

TimeStamp Per 60 SummerTimeMode DISABLED Time 10:32:52 Date 19.3.2003 Calibr AI 1 Calibr AI 2 Calibr AI 3 0 0 0

min

240

Bar C %

-100 -1000 -1000

100 1000 1000

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Technical data
Power supply
Voltage supply 8-36V DC Consumption depends on supply voltage 0,4A at 8VDC; 0,1A at 36VDC Battery voltage measurement tolerance 2 % at 24V RTC battery live 10 year Hint: When internal RTC battery becomes empty InteliGen function (e.g. Ready for stand by) does not change until controller power supply is switched off. After the next power switch on controller: Stays in the INIT state (not possible to run genset) All History records disappear except Wrong params record Alarm list is empty Time and Date values are set to zero Statistics values are random

Operating conditions
Operating temperature Storage temperature Protection front panel Humidity Standard conformity Low Voltage Directive Electromagnetic Compatibility Vibration Shocks -20..+70 C o -30..+80 C IP65 85% without condensation EN 61010-1:95 +A1:97 EN 50081-1:94, EN 50081-2:96 EN 50082-1:99, EN 50082-2:97 5 - 25 Hz, 1,6mm 25 - 100 Hz, a = 4 g 2 a = 200 m/s
o

Dimensions and weight


Dimensions Weight 180x120x50mm 800g

Bus and generator


Nominal frequency Frequency measurement tolerance 50-60Hz 0,1Hz

Current inputs
Nominal input current (from CT) Load (CT output impedance) CT input burden Max. measured current from CT Current measurement tolerance Max. peak current from CT Max. continuous current 5A < 0,1 < 0,2 VA per phase (In=5A) 11 A 2% from the Nominal current 150 A / 1s 12 A 231VAC phase to neutral 400VAC phase to phase 290VAC phase to neutral 6 M phase to phase 6 M phase to neutral 99

Voltage inputs
Measuring voltage Maximal measured voltage Input resistance

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Voltage measurement tolerance Overvoltage class

2 % from the Nominal voltage III (EN61010)

IG-MTU
Primary voltage Ph-Ph Secondary voltage Ph-N Mechanical dimensions: 3x400 VAC / 50Hz (3x480 VAC / 60 Hz) 3x 230 V AC ( 3x277 VAC / 60 Hz) , 5 VA 155 x 95 x 60 mm , DIN rail (35 mm) mounted

Binary inputs and outputs


Binary inputs
Number of inputs 9 Input resistance 4,7 k Input range 0-36 VDC Switching voltage level for close contact indication 0-2 V Max voltage level for open contact indication 8-36 V

Contact relay outputs


Number of outputs Electric life cycle Maximum current Maximum switching voltage Minimum load Insulation voltage 2 min 100.000 switching cycles 12 A DC resistive load 4 A DC inductive load 36 VDC 24 V / 0,1 A 500 Veff

Binary open collector outputs


Number of outputs Maximum current Maximum switching voltage 7 0,5 A 36 VDC

Analog inputs
Not electrically separated Resolution Sensor resistance range Resistance measurement tolerance 10 bits 0 -2,4 k 4 % 2 out of measured value

Speed pick-up input


Type of sensor Minimum input voltage Maximum input voltage Minimum measured frequency Maximum measured frequency Frequency measurement tolerance magnetic pick-up (connection by shielded cable is recommended) 2 Vpk-pk (from 4 Hz to 4 kHz) 50 Veff 4 Hz 10 kHz (min. input voltage 6Vpk-pk) 1,5 %

RS232 interface
Maximal distance Speed 10m 19.2kBd

Recommend external converter: ADVANTECH ADAM 4520: RS232 to RS422/485 converter, DIN rail, automatic RS485 bus supervision, no external data flow control signals, galvanic isolated. Recommended internal converter:

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ADVANTECH PCL-745B or PCL745S : Dual port RS422/485 Interface card, automatic RS485 bus supervision, no external data flow control signals, galvanic isolated.

CAN bus interface


Galvanically separated Maximal CAN bus length Speed Nominal impedance Cable type 200m 250kBd 120 twisted pair (shielded)

Following dynamic cable parameters are important especially for maximal 200 meters CAN bus length and 32 iS-COM units connected: Nominal Velocity of Propagation min. 75% (max. 4,4 ns/m) 2 Wire crosscut min.0,25 mm Maximal attenuation (at 1 MHz) 2 dB / 100m Recommended Industrial Automation & Process Control Cables: BELDEN (see http://www.belden.com): 3082A DeviceBus for Allen-Bradley DeviceNet 3083A DeviceBus for Allen-Bradley DeviceNet 3086A DeviceBus for Honeywell SDS 3087A DeviceBus for Honeywell SDS 3084A DeviceBus for Allen-Bradley DeviceNet 3085A DeviceBus for Allen-Bradley DeviceNet 3105A Paired EIA Industrial RS485 cable LAPP CABLE (see http://www.lappcable.com) Unitronic BUS DeviceNet Trunk Cable Unitronic BUS DeviceNet Drop Cable Unitronic BUS CAN Unitronic-FD BUS P CAN UL/CSA Hint: When use double pair cable, use data pair for CAN bus and Power supply DC pair for Load sharing line connection.

IG-PCLSM
Power supply: Consumption: 8 36 V DC 100 mA 4 4,7 k 0-36 VDC 0-2 V 8-36 V

Binary inputs
Number of inputs Input resistance Input range Switching voltage level for close contact indication Max voltage level for open contact indication

Open collector outputs


Number of outputs Maximum current Maximum switching voltage Speed governor output: AVRi outputs: LS output: 4 0,5 A 36 VDC 10 V DC , max.15 mA PWM to IG-AVRi max 10 V / 15 mA

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IG-AVRi
Power supply: 18V AC from AVRi trans (230, 400 / 18V, 5VA) Absolutely maximum power supply range: 15 - 25 VAC or DC voltage 20 - 35VDC Inputs: +AVR, -AVR (two wires, PWM from IS-CU) Outputs: OUT1, OUT2 floating (potential free) voltage source. AVRi output voltage range: potentiometer adjustable from +- 1V to +-10V DC. AVRi output current: max 15 mA. Mechanical dimensions: 96 x 27 x 43 mm , DIN rail (35 mm) mounted

IG-AVRi trans
Primary voltage: Secondary voltage: 230/400 V AC ( 30V) / 50 Hz 18 V AC, 5 VA

IG-AVRi trans/277
Primary voltage: Secondary voltage: 277 V AC ( 30V) / 60 Hz 18 V AC, 5 VA

IG-MU
Voltage supply Consumption Mechanical dimensions: Interface to modem or PC Interface to controller 8-36V DC 0,1A depend on supply voltage 40 x 95 x 45 mm , DIN rail (35 mm) mounted RS232, RS422, RS485 CAN

IG-IB
Voltage supply Consumption Mechanical dimensions: Interface to controller Interface to modem Interface to Ethernet 8-36V DC 0,1A depend on supply voltage 40 x 95 x 45 mm , DIN rail (35 mm) mounted RS232 or CAN RS232 RJ45

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