IGMINTMINTIOM6.1

Copyright © 2004 ComAp s.r.o. Written by Ladislav Kadanik Prague, Czech Republic

ComAp, spol. s r.o. Světova 7, 180 00 Praha 8, Czech Republic Tel: +420 2 66316661, Fax: +420 2 66316647 E-mail: [email protected], www.comap.cz

Compact Controller for Stand-by and Parallel Operating Gen-sets

InteliGen®

Modular Gen-set Controller Multiple Internal Software Configuration - MINT

IG-CU + IG-PCLSM + IG-AVRi

Software version IG-6.1, May 2004

User guide

InteliGen – MINT, SW version 6.1, ©ComAp – May 2004 2 - IG-MINT-MINT+IOM-6.1.PDF

Table of Contents Table of Contents ...............................................................................................................................................2 General guidelines..............................................................................................................................................5

What is described in this manual? .................................................................................................................5 !! Warnings !! ..................................................................................................................................................5 Text ................................................................................................................................................................5 Conformity declaration ...................................................................................................................................5

General description ............................................................................................................................................7 Description of the controller system (with all options)....................................................................................7 MINT - required and optional modules...........................................................................................................7

Terminals and Dimensions.................................................................................................................................8 IG-CU Terminals ............................................................................................................................................8 Dimensions...................................................................................................................................................11 IGL-RA15 Remote annunciator....................................................................................................................14 IG-IB Internet bridge.....................................................................................................................................15

Recommended wirings .....................................................................................................................................16 IG-IOM Wiring ..............................................................................................................................................18 IG-MU Wiring................................................................................................................................................18

Multiple sets application ...................................................................................................................................20 MPM: Multiple Prime mover .........................................................................................................................20 MSB: Multiple Stand-by................................................................................................................................22 Multiple Parallel to mains, Stand-by, no MCB synchronization ...................................................................24 Multiple Parallel to mains, Stand-by, MCB synchronized, short time parallel..............................................25 Multiple Parallel to mains, Stand-by, MCB synchronized, Import-Export power or Base load control in parallel to mains + Stand-by ........................................................................................................................28

Getting started ..................................................................................................................................................30 How to install ................................................................................................................................................30 Analog inputs - configuration........................................................................................................................36 Hardware connection ...................................................................................................................................38 Extension modules (CAN bus) connection ..................................................................................................43

Inputs and outputs ............................................................................................................................................45 Binary inputs IG–CU + IG-PCLSM default ..............................................................................................45 Binary inputs IG-IOM, IGS-PTM default....................................................................................................45 Binary inputs – list ........................................................................................................................................46 Binary outputs IG-CU+IG-PCLSM default...................................................................................................49 Binary outputs IG-IOM, IGS-PTM ...............................................................................................................49 Binary outputs – list......................................................................................................................................49 Analog inputs IG-CU (+IG-IOM or IGS-PTM)...............................................................................................56 Analog output IG-IOM, IGS-PTM ................................................................................................................56

Setpoints...........................................................................................................................................................57 Password......................................................................................................................................................57 Process control ............................................................................................................................................58 Basic settings ...............................................................................................................................................58 Engine params .............................................................................................................................................60 Engine protect ..............................................................................................................................................63 Gener protect ...............................................................................................................................................66 Pwr management .........................................................................................................................................70 Sync/Ld ctrl...................................................................................................................................................74 Volt/PF ctrl....................................................................................................................................................77 Act. calls/SMS ..............................................................................................................................................79 Load Shedding .............................................................................................................................................80 Date and time...............................................................................................................................................80 Sensor spec .................................................................................................................................................81

IM - IG MINT setpoints adjustment...................................................................................................................82 Active and reactive power terminology ........................................................................................................82 Steps of InteliGen MINT set points adjustment............................................................................................83


Steps of InteliMains set points adjustment...................................................................................................88 Sensor specification .........................................................................................................................................92

Sensor calibration ........................................................................................................................................92 Default sensor settings.................................................................................................................................92

Operator Interface ............................................................................................................................................94 Pushbuttons and LEDs ................................................................................................................................94 How to select gen-set mode ?......................................................................................................................95 When to use GCB ON/OFF button ? .........................................................................................................95 Display menus..............................................................................................................................................95 How to view measured data?.......................................................................................................................95 How to view and edit set points? .................................................................................................................95 How to view the HISTORY menu?...............................................................................................................96 How to find active alarms ? ..........................................................................................................................96 Description of MEASUREMENT screens ....................................................................................................96 Flow Chart of pushbutton Operation ............................................................................................................99

Mode description ............................................................................................................................................101 OFF mode ..................................................................................................................................................101 MAN mode .................................................................................................................................................101 AUT mode ..................................................................................................................................................101 Load surge protection ................................................................................................................................102 Load shedding............................................................................................................................................102

Alarm management ........................................................................................................................................105 Warning ......................................................................................................................................................105 Unload ........................................................................................................................................................105 Slow stop....................................................................................................................................................105 Shut down ..................................................................................................................................................106 Voltage phase sequence detection............................................................................................................106

Setpoint replication management...................................................................................................................110 How to adjust setpoints ..............................................................................................................................110 Setpoints consistency ................................................................................................................................110

Gen-set operation states ................................................................................................................................111 Start-stop sequence ...................................................................................................................................111 Unsuccessful start ......................................................................................................................................112

Remote control and data logging ...................................................................................................................113 Direct connection to the PC .......................................................................................................................113 PC software - WinEdit ................................................................................................................................113 History file...................................................................................................................................................113

Remote and mobile communication ...............................................................................................................117 Modbus protocol.........................................................................................................................................117 Recommended ISDN modem ....................................................................................................................117 Recommended GSM modem.....................................................................................................................117 SIM card setting .........................................................................................................................................118 Active SMS message .................................................................................................................................118 IG-IB Internet communication ...................................................................................................................119

Value and setpoints codes .............................................................................................................................120 Technical data ................................................................................................................................................126

Power supply..............................................................................................................................................126 Operating conditions ..................................................................................................................................126 Dimensions and weight ..............................................................................................................................126 Bus and generator......................................................................................................................................126 IG-MTU.......................................................................................................................................................127 IG-MTU-C...................................................................................................................................................127 Binary inputs and outputs...........................................................................................................................127 Analog inputs..............................................................................................................................................127 Speed pick-up input ...................................................................................................................................128 CAN bus interface ......................................................................................................................................128 IG-PCLSM..................................................................................................................................................129 IG-AVRi ......................................................................................................................................................129 IG-IOM........................................................................................................................................................129 IG-MU.........................................................................................................................................................130 IG-IB ...........................................................................................................................................................130


IGS-PTM ....................................................................................................................................................130 IGL-RA15 ...................................................................................................................................................131 InteliGen Low Temperature modification ..................................................................................................131


General guidelines

What is described in this manual? This manual describes „MINT“ software configuration. The software configuration is designed for multiple sets applications with InteliGen internal load sharer and synchronizer (IG-PCLSM interface). What is the purpoase of this manual? This manual provides general information on how to install and operate the InteliGen controller. This manual is intended for use by:

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 the event that maintenance needs to be done to the gen-set, check the following to ensure that the engine cannot be started. To be sure:

Disconnect remote control via RS232 line Disconnect input REMOTE START/STOP

or Disconnect output STARTER and output GCB CLOSE/OPEN

The InteliGen contains a large number of configurable setpoints, because of this it is impossible to describe all applications. InteliGens functions are subject to change from SW version to SW version. This manual only describes the product and is not guaranteed to be set for your application on arrival.

Text PAGE (Capital letters in the frame) buttons on the front panel Break Return (Italic) set points Generator protections (Bold) Set point group REMOTE START/STOP (Capital letters) binary inputs and outputs

Conformity declaration

Following described machine complies with the appropriate basic safety and health requirement of the EC Low Voltage Directive No: 73/23 / EEC and EC Electromagnetic Compatibility Directive 89/336 / EEC based on its design and type, as brought into circulation by us.


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 binary outputs can change state during and after software reprogramming (before the controller is used again ensure that the proper

configuration and setpoint settings are set in the controller)!!!

Be aware that gen-set can automatically or remotely start !!!

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 The terminals for voltage and current measurement should never be touched. Properly connect the grounding terminals. Do not disconnect the InteliGens CT terminals for any reason.

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 !!!


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 the best solution for various customer applications. Optional synchronizer, isochronous load sharer, Mains and Generator protections allows for a 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 Gen-set controls. The InteliGen automatically starts the gen-set, 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.

MINT - required and optional modules Accessories Description Standard / Optional IG-CU InteliGen central unit Standard IG-PCLSM InteliGen power control and load sharing module Standard AT LINK-CABLE 1,8m

RS232 (WinEdit) communication cable Optional

IG-MTU IG-MTU-C

InteliGen voltage transformer unit to separate mains and generator voltage measurement (C = with filter)

Optional

IG-AVRI InteliGen AVR interface Optional IG-AVRi-TRANS InteliGen voltage transformer for supplying AVRi

module Optional

IG-COM InteliGen communication unit Optional IG-MU InteliGen – Modem Unit Optional IG-IB Internet bridge Optional IGL-RA15 Remote annunciator Optional IGS-PTM or IG-IOM

External analog, binary I/O unit. Connecting 3m cable is part of module delivery.

Optional

InteliGen display software description Serial number Description xx1xxxxx Standard character set: part of ASCII code (less than 128) xx2xxxxx Standard character set: + West European languages* xx3xxxxx Standard character set: + Chinese characters xx4xxxxx Standard character set: + West & East European languages incl. Russian xx5xxxxx Standard character set: + West & East European languages incl. Turkish


Terminals and Dimensions

IG-CU Terminals

RPM Grounding Terminal

Grounding Terminal

ANALOG INPUTS

BINARY INPUTS

BINARY OUTPUTSRPM

BO1

(STA

RT)

BO2

(FUE

L) POWER8 - 36 V DC

EXTE

NSIO

N MO

DULE

SiG

-PCM

/ iG-

PCLS

M

RS 23

2

GENERATOR CURRENT0 - 5 A

GENERATOR VOLTAGE 3 x 230 / 400 V

LB 5

BOOT JUMPER

EXTE

NSIO

N MO

DULE

SiG

-COM

/ iG-

IOM

+ -InlIn

(Im L3

)CU

RREN

TInk CO

MAI

1 (OI

L)

AI2 (

TEMP

)

AI3 (

FUEL

)

RPM

IN

RPM

GND

BO3

BO7

BO8

BO9

BO4

BO5

BO6

BI1

BI2

BI3 BI4

BI5

BI6

BI8

BI7

BI9

L1

L2

L3N L1

L2

L3

L3k

L3l

L2k

L2l

L1k

L1l

iG-CU

Drawing text translation Grounding Terminal RPM Grounding Terminal

IG-PCLSM Terminals

BINARY INPUTS

BINARY OUTPUTS

POWER8 - 36 V DC

BI10

BI11

BI12 BI13

BO1

0

BO1

1

BO1

2

BO13 + -

LOAD SHARING

Shie

ld

LSM

-

LSM

+

AVRi

AVRi

+

AVRi

-

SPEED GOVERNOR

Vout

R

GND

Vout

LB 4

Warning !!! Switch IG-CU off before connecting IG-PCLSM !


IG-AVRi Terminals

AVRi -

AVRi +

OUT1

OUT2AC1AC2

GND

LB 4

IG-COM Terminals There is different wiring of IG-COM CAN connectors from hardware version 4.0.

The IG-COM label is from side.

EXTENSION MODULE CAN 1H

LCOM

CAN 2

H

LCOM

LB 4

iG-COM

CAN R 120Ω Green CAN connectors are separated:

CAN2 CAN1 CAN2 = inter-controller CAN, - galvanically separated - internal resistor 120 ohm via jumper

CAN1 = for extension modules - IG-IOM, IGS-PTM, IGL-RA15, … - connection to Extension module 9 pin connector: CAN H = pin 5 CAN L = pin 9

IG-MU Terminals

iG-MU

RS 422 LB 6

RS 485

POWER8-36V DC

CAN CAN

RS 48

5 / R

S 42

2

RS 23

2RS

232

TxB

L HCO

M L HCO

M

TxA

RxB

RxA

COM

Indication LED: TxCAN, RxCAN Indicates data transfer on the CAN2 line. TxD, RxD Indicates data transfer on the RS232 line. RUN Lights when at least one other unit is active on the CAN2 bus.

Blinks when no unit is communicated on the CAN2 bus.


PWR Lights All time when power supply is switched on. Hint: It is recommended to use IG-MU software 2.2 for IG-6.1. Internal IG-MU jumpers

P1 P2 P3

P4

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

IG IOM, IGS-PTM terminals IGS-PTM is modification of standard IG-IOM module with four analog inputs, which can be configured for range:

• 0 – 250 Ω (suitable for Pt100, Ni100), • 0 – 100 mV (suitable for thermocouples), • 0 – 20 mA.

IGS-PTM can be connected to IG-CU or IS-CU. Detail description see in IGS-PTM manual.

POWER

8-36V DC

BINARY OUTPUTS

BINARY INPUTS ANALOG INPUTS ANALOG OUT

BO8

BI8

BI7

BI6

BI5

BI4

BI3

BI2

CO

M AI4

BI1

BO1

BO2

BO3

BO4

BO5

BO6

BO7

IG-C

U

RS23

2

iG-IOM

Hint: IG-IOM, IGS-PTM power supply indication LED :

lights when power supply is in the range


blinks when there is no communication between IG-CU and IG-IOM, IGS-PTM

Dimensions

IG-CU + IG-COM + IG-PCLSM

iG-PCLSM

iG-CU

iG-COM

185 (7,3")

80 (3

,1")

42,5

(1,7

")24 (0,9

")

45 (1

,8")~

110

(4,3

")

170 (8,87")

21

123

(4,8

")

~ 130 (5,1")

130

(5,1

") 113

(4,4

")2

1

1. RS 232 Cable must be ordered separately, order code: AT LINK-CABLE 1,8m. 2. IG-IOM or IGS-PTM (3m) cable is part of module delivery. Cutout for InteliGen 113 x 175 mm (4,4 x 6,9”).

IG-AVRi, IG-AVRi TRANS/LV

AVRi

-

AVRi

+

OUT1

OUT2 AC

1AC

2

GND

LB 4

Primary terminals 50 / 60 Hz Secondary terminals

0 - 18

43 (1,7”) 43 (1,7”)

36 (1

,4”)

0 - 230/277 - 400/480

iG-AVRiTRANS/LV


IG-AVRi unit is DIN rail mount (35mm) IG-AVRi TRANS are DIN rail mount (35mm)

IG-MU

95 mm(3,7´´)

43 mm(1,7´´)

96 m

m (3

,8´´

)

IG-MU unit is DIN 35 mm rail mounted.

IG-IOM

95 mm(3,7´´)

43 mm(1,7´´)

96 m

m (3

,8´´)

POWER 8-36V DC

BINARY OUTPUTS

BINARY INPUTS ANALOG INPUTS ANALOG OUT

BO8

BI8

BI7

BI6

BI5

BI4

BI3

BI2

CO

M AI4

BI1

BO1

BO2

BO3

BO4

BO5

BO6

BO7

IG-C

U

RS23

2

iG-IOM

IG-IOM unit is DIN 35 mm rail mounted.


IGS-PTM

COMPENSATION

GND

POWER

8-36V DC

BINARY OUTPUTS

BINARY INPUTS ANALOG INPUTS

AI4

BI8

BI7

BI6

BI5

BI4

BI3

BI2

BI1

0-20 mA ANALOG OUT

BO8

BO1

BO2

BO3

BO4

BO5

BO6

BO7

CAN

RxTx

CAN

LH

COM

LB 4

AO-

AO+

iGS-PTM

95 mm(3,7´´)

43 mm(1,7´´)

96 m

m (3

,8´´)

IGS-PTM unit is DIN 35 mm rail mounted.

IG-IOM, IGS-PTM is DIN rail mount (35mm). IG-IOM, IGS-PTM is connected to IG-CU by standard IOM cable (3 meters length). Wiring between IGS-PTM or IG-IOM and IG-CU:


IGL-RA15 Remote annunciator Remote (CAN bus, up 200 meters) 15 LED states indicator. One iGL-RA15 unit can be connected to IS-CU via CAN as Binary output address 13 and 14. Detail descriptions see in iGL-RA15.pdf user guide.

165 (6,5”)

38 (1

,5”)

40 (1

,6”)~75

(3,0

”)

~35

(1,4

”)

180 (7,1”)185 (7,3”)

106

(4,2

”)

44 (1,7”)54 (2,1”)

~25

(1,0

”)

120

(4,7

”)12

5 (4

,9”)

Cutout for Remote Annunciator 167 x 108 mm (6,6 x 4,3”)

IG-MTU, IG-MTU-C IG-MTU Separation transformers unit for InteliGen controller. It is used for three wire system, system with

separated Neutral or when galvanic separation between generator or mains voltage and controller is required.

IG-MTU-C Separation transformers unit with additional filter for controller. It is used like IG-MTU in special cases of extreme distortion of generator voltage by higher harmonics due to inverters etc..

60 (2,36")

95 (3

,74"

)

N L1 L2 L3

iG-MTU

155(6,10")

LB 3

Hint: IG-MTU-C phase shift is 6°. Use two IG-MTU-C units for both generator and bus voltage measuring or set Sync/Load ctrl: GtoB angle Req setpoint (-6° when IG-MTU-C is connected to Vg terminals). IG-MTU and IG-MTU-C units are the same dimension and DIN 35 mm rail mounted.


IG-IB Internet bridge

ETHERNETRJ 45

MODE

M / IB

CON

FIG

IG-C

U / D

ONGL

E

LB 5

POWER 8 - 36 V DCCOM LH CAN

1 2

3 4 5 6

iG-IB

95 mm(3,7´´)

43 mm(1,7´´)

96 m

m (3

,8´´

)

It is recommended to use IG-IB firmware version 2.0 IG-IB unit is DIN 35 mm rail mounted. See Internet communication


Recommended wirings

WATERTEMP

FUELLEVEL

STAR

TER

BATT

ERY

-+

FUELSOLENOID

EMERGSTOP

SYSTSTART/STOP

SYSTEMSTART/STOP

CONT

RO

LSI

GN

ALS

GENC.B.FEED-BACK

LOADRESERVE

DIES

EL/G

ASEN

GINE

RPM

CAN

OILPRESSURE

GENE

RATO

R

GG

UNLOAD

HORN

+24V

BIN

ARY

OU

TPU

TSFI

XCO

NFIG

URAB

LE

LOADRES.OK

GENC.B.

STARTER

FUELSOLENOID

RS-

232C

Inte

rfac

e

L1 L2 L3 N

Gen

erat

orC

.B.

LOAD

Mode

mor

PC

SDWATERTEMPSDFUELLEVEL

SDOILPRESSACCESSLOCK

PRESTARTSYNCHRONISESYSTREADY

PE

MG

CB

-iG

CU

Il nIknAN

ALO

GIN

PUTS

BINA

RYIN

PUTS

BINA

RYIN

PUTS

BIN

ARY

OU

TPUT

SRP

M

RPMIN

COM

BO3

BO7

BO8

BO9

BO4BO5

BO6

BO1START

BO2FUEL

AI1OIL

AI2TEMP

AI3FUEL

RPMGND

POW

ER8

-36

VDC

+-

EXTENSIONMODULESiG-COM/iG-IOM

EXTENSIONMODULESiG-PCM/iG-PCLSM

RS232

GEN

ERAT

OR

CUR

REN

T0

-5A

GEN

ERAT

OR

VOLT

AG

E3

x23

0V

N

L1

L2

L3

L1

L2

L3

BI1

BI2

BI3

BI4BI5

BI6

BI8BI7

BI9

L3kL3l

L2kL2l

L1kL1l

Seria

lNo.

EXTENSIONMODULE

iG-COMSerialNo.

CAN

H

LCOM

CAN

H

LCOM

Hint: Maximal inductive load of contact relay outputs BO1 and BO2 is 4 Amps. Use external relays for higher load. Drawing text translation Diesel / Gas engine Generator


Load

IG-PCLSM

-G

PCLS

Mi

Seria

l No.

BI1

0 B

I11

BI1

2B

I13

BINARY INPUTS

BO

10 B

O11

BO

12B

O13

BINARY OUTPUTS

POWER8 - 36 V DC

+ -

LOAD SHARING

Shie

ldLS

M-

LSM

+

AVRi

AVR

i+

AVR

i-

Vout

R

SPEED GOVERNOR

GN

D

Vout

LB 2

AU

TOM

ATIC

VO

LTA

GE

RE

GU

LATO

R

FROM

GEN

ERAT

OR

LOAD

SHA

RING

PAR

ALLE

L LIN

E

-+

SPEE

DG

OVE

RN

OR

230/4

00 V

18 V

AC

0 V D C

0 V D C

CONFIGURABLE

230/

400

V

18 V

iG-A

VRi

TRAN

S

Drawing text translation Speed Governor Automatic Voltage Control


Load sharing parallel line Configurable

IG-IOM Wiring

0 V D C

0-2 0 mA

0 V D C

8 - 36 V DC

POWER

8-36V DC

BINARY OUTPUTS

BINARY INPUTS ANALOG INPUTS

ANALOG OUT

BO8

BI8

BI7

BI6

BI5

BI4

BI3

BI2

CO

M AI4

BI1

BO1

BO2

BO3

BO4

BO5

BO6

BO7

IG-C

U

RS23

2

iG-IOM

Hint: Analog inputs COM terminal has to be connected to minus power supply.

IG-MU Wiring

RS485 / RS 422 connection BA

IG-MU

TxBTxARxBRxA

RS485

IG-MU

TxBTxARxBRxA

RS422


More IG-MU on CAN bus It is possible to connect two IG-MU units for MultiEdit, WinEdit connection (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.


Multiple sets application

MPM: Multiple Prime mover

G1

iG-CU

Vout

AVRi

3x

GCB1

3x

iG-CU

3x

SYS START/STOPMASTER SELECT

G2

MASTER SELECTOR


LOAD

3xU

B

3xU

G

3xI G

3xU

B

3xU

G

3xI G

GCB2

START/STOP

CAN

iG-P

CLS

M

SPEEDGOVERNOR

AVRiOUT

AVRiG-AVRi

CAN

Vout

AVRi

SPEEDGOVERNOR

AVRi

AVRiG-AVRi

LSM

LSM

OUT

LOAD SHARING LINEiG

-CO

MiG

-CO

M

iG-P

CLS

M

G1

iG-CU

3x

GCB1

3x

iG-CU

3x


G2

MASTER SELECTOR


LOAD

CAN

GCB23x

MGCB

LOAD RESERVE 2

LOAD RESERVE 2

MGCB

RE

S.O

K.(

2)

RE

S.O

K.(

1)

MG

CB

START/STOP

3x

3xU

B

3xU

G

3xI G

3xU

B

3xU

G

3xI G

MGCB

CAN

Vout

AVRi

SPEEDGOVERNOR

AVRi

AVRiG-AVRi

OUT

Vout

AVRi

SPEEDGOVERNOR

AVRi

iG-AVRi

OUT

LSM

LSM

AVR

LOAD SHARING LINE

iG-C

OM

iG-C

OM

iG-P

CLS

MiG

-PC

LSM


Drawing text translation Load Speed governor MGCB GCB Load sharing line Sys Start/Stop Master select Load reserve 2 Master selector Start/Stop CAN Res. OK

Specification • MGCB support • Gen-sets unload in island parallel • Power management (if IG-COMs are installed)

Hardware requirements nx IG-CU nx IG-COM (Optional) nx IG-PCLSM nx IG-AVRi, IG-AVRi-TRANS (Optional)

Description without MGCB 1) Start/Stop switch starts engines in Power management mode by closing of SYS START/STOP input. 2) MASTER SELECT selects the gen-set priority regardless of the Priority setpoint, if needed.

Description with MGCB 1) Start/Stop switch starts engines in Power management mode by closing of SYS START/STOP input. 2) LOAD RESERVE 2 is controlled by MGCB, to differentiate the load reserve necessary before closing of

MGCB (setpoints LoadRes Strt 2 and LoadRes Stp 2), and load reserve when system is loaded (setpoints LoadRes Strt 1 and LoadRes Stp 1).

3) MGCB is closed by LOAD RES OK of 1st or 2nd gen-set and then held by MGCB feedback. Loss of voltage at the bus opens MGCB.

4) MASTER SELECT selects the gen-set priority regardless of the Priority setpoint, if needed. Hint: Set SysAMFstrt del and SysAMFstp del setpoints at 1s for fast response Input MCB FEEDBACK should not be configured


MSB: Multiple Stand-by

G1

iG-CU

3x

GCB1

3x

iG-CU

3x


G2

MASTER SELECTOR


LOAD

3xU

B

3xU

G

3xI G

GCB2

MCB3x

KA

MGC

U,f

T 3x

3x

(3.PH.RELAY)

MCB

U,f

U,f

3xU

B

3xU

G

3xI G

3x

KA

iG-C

OM

CAN

iG-P

CLS

M

SPEEDGOVERNOR

AVRiOUT

AVRiG-AVRi

CAN

Vout

AVRi

SPEEDGOVERNOR

AVRi

AVRiG-AVRi

OUT

LSM

LSM

Vout

AVRi

LOAD SHARING LINE

iG-C

OM

iG-P

CLS

M

RE

S.O

K.(

2)

RE

S.O

K.(

1)

MG

CB

G1

iG-CU

3x

GCB1

3x

iG-CU


G2

MASTER SELECTOR


LOAD

3xU

B

3xU

G

3xI G

3xU

B

3xU

G

3xI G

GCB2

MCB3x

MGCB

U,f

T 3x

MCB

U,f

MGCB

MC

B

3x 3x

3x

MGCB

LOAD RESERVE 2

LOAD RESERVE 2

U,f

3x

CAN

SPEEDGOVERNOR

AVRiOUT

AVRiG-AVRi

CAN

Vout

AVRi

SPEEDGOVERNOR

AVRi

AVRiG-AVRi

OUT

LOAD SHARING LINE

LSMVout

AVRi

LSM

MGCB

iG-C

OM

iG-P

CLS

M

iG-C

OM

iG-P

CLS

M

Drawing text translation Load Speed governor


MCB MGCB GCB Load sharing line Sys Start/Stop Master select Load reserve 2 Master selector CAN 3.PH.RELAY Res. OK

Specification • Automatic start-up when the mains fails • Reclosing MCB after mains returns • MGCB support • Gen-sets unload in island parallel • Power management (if IG-COMs are installed)

Hardware requirements 1x Uf↑↓ relay (Mains decoupling relay) unit + MCB control nx IG-CU nx IG-COM (Optional) nx IG-PCLSM nx IG-AVRi, IG-AVRi-TRANS (Optional)

Description without MGCB 1) The Uf↑↓ relay opens MCB after the mains fails. At the same time the Uf↑↓ relay starts Power

management by closing of SYS START/STOP input 2) When mains returns, Uf↑↓ relay opens SYS START/STOP and GCBs are opened. 3) Bus 3 phase voltage relay detects no voltage and with its time delay closes MCB 4) MASTER SELECT selects the gen-set priority regardless of the Priority setpoint, if needed.

Description with MGCB 1) The Uf↑↓ relay opens MCB after the mains fails. At the same time the Uf↑↓ relay starts Power

management by closing of SYS START/STOP input. 2) LOAD RESERVE 2 is controlled by MGCB, to differentiate the load reserve necessary before closing of

MGCB (setpoints LoadRes Strt 2 and LoadRes Stp 2), and load reserve while system is loaded (setpoints LoadRes Strt 1 and LoadRes Stp 1).

3) MGCB is closed by LOAD RES OK of 1st or 2nd gen-set and then held by MGCB feedback. 4) When mains returns, Uf↑↓ relay opens SYS START/STOP. Loss of voltage at the bus opens MGCB. 5) Bus 3 phase voltage relay detects no voltage and with its time delay closes MCB. 6) MASTER SELECT selects the gen-set priority regardless of the Priority setpoint, if needed. Hint: Setpoint SysAMFstrt del is used for engines start delay after the mains fails. It is similar to setpoint EmergStart del in Single Stand-by. Setpoint SysAMFstp del is used for GCB opening after the mains returns. It is similar to setpoint Mains Ret del in Single Stand-by. Input MCB FEEDBACK should not be configured


Multiple Parallel to mains, Stand-by, no MCB synchronization

G1

iG-CU

GCB1

3x

iG-CU

3x


G2

MASTER SELECTOR


LOAD

CAN

3xU

B

3xU

G

3xI G

GCB2

MCB3x

KA

MCB

U,f

T 3x

3x

(3.PH.RELAY)

MCB

U,f

U,f3x

UB

3xU

G

3xI G

KA

CAN

LSMMAINS

3x

LOAD SHARINGLINE

MCB

PARALL.TO MAINSREQUIRED

MCBMCB FEEDBACK

MCB FEEDBACK

G2

SPEEDGOVERNOR

AVRiOUT

AVRiG-AVRi

Vout

AVRi

SPEEDGOVERNOR

AVRi

AVRiG-AVRi

LSM

LSM

OUT

LOAD SHARING LINE

Vout

AVRi

iG-P

CLS

MiG

-CO

MiG

-PC

LSM

iG-C

OM

Drawing text translation LSM MAINS Load Speed governor MCB GCB Load sharing line Sys Start/Stop Master select MCB feedback Master selector CAN 3.PH.RELAY Parall. to mains required

Specification • Synchronize gen-sets to mains • Import-Export or Base load power control • Automatic start-up when mains fails • After mains returns GCBs opening, reclosing MCB and synchronizing gen-sets to mains • Gen-sets unload • Power management (if IG-COMs are installed)

Hardware requirements 1x Uf↑↓ relay unit (Mains decoupling relay) + MCB control 1x External Mains Load sharing module for Import-Export power control or Base load power control on

local Load sharing modules nx IG-CU


nx IG-COM (Optional) nx IG-PCLSM nx IG-AVRi, IG-AVRi-TRANS (Optional)

Description 1) The system is started by the Uf↑↓ relay or by the switch “Parallel to mains required”. 2) The Uf↑↓ relay opens MCB after the mains fails. At the same time the Uf↑↓ relay starts Power

management by closing of SYS START/STOP input, if the gen-sets had not run in parallel to mains before.

3) When mains returns, Uf↑↓ relay opens SYS START/STOP, and GCBs are opened. 4) Bus 3 phase voltage relay detects no voltage and with its time delay closes MCB 5) If the switch “Parallel to mains required” is closed, gen-sets are again synchronized to the bus. 6) To stop the gen-sets while running in parallel to mains open the switch “Parallel to mains required”. 7) While stopping in parallel to mains, active MCB FEEDBACK ensures gen-sets soft unload 8) MASTER SELECT selects the gen-set priority regardless of the Priority setpoint, if needed. Hint: Setpoint SysAMFstrt del is used for engines start delay after the mains fails. It is similar to setpoint EmergStart del in Single Stand-by. If the input MCB FEEDBACK is active, the delay is 1s. Setpoint SysAMFstp del is used for GCB opening after the mains returns. It is similar to setpoint Mains Ret del in Single Stand-by. If the input MCB FEEDBACK is active, the delay for unloading is 1s.

Multiple Parallel to mains, Stand-by, MCB synchronized, short time parallel

G1

iG-CU

3xGCB1

3x

iG-CU

3x


G2

MASTER SELECTOR


LOAD

CAN

3xU

B

3xU

G

3xI G

GCB2

MCB3x

KA

MCB

U,f

T 3x

3x

(3.PH.RELAY)

MCB

U,f

MCB

3xU

B

3xU

G

3xI G

EXT.SYN Kt

3x

MCB FEEDBACK

MCBMCB FEEDBACK

KA Kt

MCB

SYN.ENABLED

EXT.SYN

KA

CAN

CAN

Vout

AVRi

SPEEDGOVERNOR

AVRi

AVRiG-AVRi

OUT

Vout

AVRi

SPEEDGOVERNOR

AVRi

iG-AVRi

OUT

AVR

LSM

LSM

LOAD SHARING LINE

iG-P

CLS

MiG

-CO

MiG

-PC

LSM

iG-C

OM


G1

iG-CU

3xGCB1

3x

iG-CU


G2

MASTER SELECTOR


LOAD

CAN

3xU

B

3xU

G

3xI G

GCB2

MCB3x

KA

MCB

U,f

T 3x

MCB

U,f

MCB

3xU

B

3xU

G

3xI G

EXT.SYN Kt

3x

MCB FEEDBACK

MCBMCB FEEDBACK

KA

MCB

SYN.ENABLED

EXT.SYN

MGCBLOAD RESERVE 2

LOAD RESERVE 2

3x

3x

(3.PH.RELAY)

3x

MGCB

MGCBR

ES

.OK

(1)

RE

S.O

K(2

)

MG

CB

KC

GC

B1

GC

B2

KC

KA

Kt

CAN

Vout

AVRi

SPEEDGOVERNOR

AVRi

AVRiG-AVRi

OUT

Vout

AVRi

SPEEDGOVERNOR

AVRi

iG-AVRi

OUT

LSM

LSM

AVR

LOAD SHARING LINE

iG-P

CLS

MiG

-CO

MiG

-PC

LSM

iG-C

OM

Drawing text translation Load Speed governor MGCB MCB GCB Load sharing line Sys Start/Stop Master select Load reserve 2 MCB feedback Master selector CAN Ext. syn Syn. enabled 3.PH.RELAY Res. OK

Specification • Automatic start-up when mains fails • After mains returns MCB synchronizing • One interrupt only stand-by • MGCB support • Gen-sets unload • Power management (if IG-COMs are installed)

Hardware requirements 1x Uf↑↓ relay unit (Mains decoupling relay) + MCB control 1x External MCB Synchronizer nx IG-CU nx IG-COM (Optional) nx IG-PCLSM nx IG-AVRi, IG-AVRi-TRANS (Optional)


Description without MGCB 1) The Uf↑↓ relay opens MCB after the mains fails. At the same time the Uf↑↓ relay starts Power

management by closing of SYS START/STOP input. 2) When mains returns, external synchronizer synchronizes gen-sets to the mains 3) Closing of MCB stops the gen-sets by opening of SYS START/STOP. 4) While stopping in parallel to mains, active MCB FEEDBACK ensures gen-sets soft unload 5) MASTER SELECT selects the gen-set priority regardless of the Priority setpoint, if needed.

Description with MGCB 1) The Uf↑↓ relay opens MCB after the mains fails. At the same time the Uf↑↓ relay starts Power

management by closing of SYS START/STOP input. 2) LOAD RESERVE 2 is controlled by MGCB, to differentiate the load reserve necessary before closing

of MGCB (setpoints LoadRes Strt 2 and LoadRes Stp 2), and load reserve while system is loaded (setpoints LoadRes Strt 1 and LoadRes Stp 1).

3) MGCB is closed by LOAD RES OK of 1st or 2nd gen-set and then hold by MGCB feedback. 4) When mains returns, external synchronizer synchronizes gen-sets to the mains. 5) Closing of MCB stops the gen-sets by opening of SYS START/STOP. Both GCBs are opened and

consequently KC relay opens also MGCB. 6) While stopping in parallel to mains, active MCB FEEDBACK ensures gen-sets soft unload 7) MASTER SELECT selects the gen-set priority regardless of the Priority setpoint, if needed.

Hint: Setpoint SysAMFstrt del is used for engines start delay after the mains fails. It is similar to setpoint EmergStart del in Single Stand-by. Time relay Kt is used for beginning of MCB synchronization after the mains returns. It is similar to setpoint Mains Ret del in Single Parallel to Mains (SPtM) application. Setpoint SysAMFstp del is not used in this case.


Multiple Parallel to mains, Stand-by, MCB synchronized, Import-Export power or Base load control in parallel to mains + Stand-by

G1

iG-CU

GCB1

3x

iG-CU

3x


G2

MASTER SELECTOR


LOAD

CAN

3xU

B

3xU

G

3xI G

GCB2

MCB3x

T 3x

3x

(3.PH.RELAY)

U,f

3xU

B

3xU

G

3xI G

KA

CAN

LSMMAINS

3x

LOAD SHARINGLINE

PARALL.TO MAINSREQUIRED

MCB

MCB FEEDBACK

MCB FEEDBACK

G2

SPEEDGOVERNOR

AVRiOUT

AVRiG-AVRi

Vout

AVRi

SPEEDGOVERNOR

AVRi

AVRiG-AVRi

LSM

LSM

OUT

LOAD SHARING LINE

Vout

AVRi

KA

MCB

U,f

MCB

EXT.SYN Kt

KA Kt

MCB

SYN.ENABLED

EXT.SYN

MCB

iG-P

CLS

MiG

-CO

MiG

-PC

LSM

iG-C

OM

Drawing text translation LSM MAINS Load Speed governor MCB GCB Load sharing line Sys Start/Stop Master select MCB feedback Master selector CAN Ext. syn Syn. enabled 3.PH.RELAY Parall. to mains required

Specification • Synchronize gen-sets to mains • Import-Export or Base load power control • Uninterruptible stand-by • After mains returns MCB synchronizing • Automatic stand-by with Short time parallel to mains • Gen-sets unload • Power management (if IG-COMs are installed)


Hardware requirements 1x Uf↑↓ relay unit (Mains decoupling relay) + MCB control 1x External Mains Load sharing module for Import-Export power control or Base load power control on

local Load sharing modules 1x External MCB Synchronizer nx IG-CU nx IG-COM (Optional) nx IG-PCLSM nx IG-AVRi, IG-AVRi-TRANS (Optional)

Description 1) The system is started by the Uf↑↓ relay or by the switch “Parallel to mains required”. 2) The Uf↑↓ relay opens MCB after the mains fails. At the same time the Uf↑↓ relay starts Power

management by closing of SYS START/STOP input, if the gen-sets had not run before. 3) When mains returns, external synchronizer synchronizes gen-sets to the mains. 4) To stop the gen-sets while running in parallel to mains open the switch “Parallel to mains required”. 5) While stopping in parallel to mains, active MCB FEEDBACK ensures gen-sets soft unload 6) MASTER SELECT selects the gen-set priority regardless of the Priority setpoint, if needed. Hint: Setpoint SysAMFstrt del is used for engines start delay after the mains fails. It is similar to setpoint EmergStart del in Single Stand-by. Time relay Kt is used for beginning of MCB synchronization after the mains returns. It is similar to setpoint Mains Ret del in Single Parallel to Mains (SPtM) application. After MCB closing, the delay for gen-sets unloading is 1s (MCB FEEDBACK is closed). Setpoint SysAMFstp del is not used in this case.


Getting started

How to install

General To ensure proper function:

Use grounding terminals. Wiring for binary inputs and analog inputs must not be run with power cables. Analog and binary inputs should use shielded cables, especially when length >3m.

Power supply To ensure proper function: Use min. power supply cable of 1.5mm2

Power supply of IG-PCLSM module should be directly connected to IG-CU. Maximum continuous DC power supply voltage is 36VDC. Maximum allowable power supply voltage is 39VCD. The InteliGen power supply terminal is protected against large pulse power disturbances. When there is a potential risk of the controller being subjected to conditions outside its capabilities, an outside protection devise should be used. Hint: The InteliGen controller should be grounded properly in order to protect against lighting strikes!! The maximum allowable current through the controller’s negative terminal is 4A (this is dependent on binary output load). Sometimes can occur starting problems due to low capacity (low temperature) 12VDC starting battery even if the controller power supply voltage range is from 8 VDC. In this case connect external capacitor + separating diode or I-LBA - Low Battery Adaptor module to allow the controller to continue operation during engine cranking.

+-

12VDC+-

controllerT2A

Battery

+

D

C

Relays

+

-

12VDC+-

controllerT2A

Battery

Relays

I-LBA

+

-

+

-

The 5 000 micro Farad capacitor ensures the 50ms voltage dip under following conditions: Voltage before dip is 12V and after 50ms the voltage recovers to min. controller allowed voltage, i.e. 8V. The capacitor size depends on required time, i.e. for 100ms dip 10 000 micro Farad is needed for the same conditions.

The I-LBA module ensures the 100ms voltage dip under following conditions: Voltage before dip is 12V and after 100ms the voltage recovers to min. allowed voltage 5V, IG-PCLSM and IG-COM modules are connected to IG (modules disconnecting increases voltage dip up to 200ms). The I-LBA enables controller operation from 5VDC (for 10 to 30 sec). The wiring resistance from battery should be up to 0.1 Ohm for I-LBA proper function.

Drawing text translation


Battery Controller Relays I-LBA

+

+

+

Battery

-

-

-

-iG-CU

iG-PC(LS)M

HUGELOADS

STARTER

T1A

Drawing text translation Battery Huge Loads Starter

Power supply fusing A one-amp fuse should be connected in-line with the battery positive terminal to the controller and modules. These items should never be connected directly to the starting battery. Fuse value and type depends on number of connected devices and wire length. Recommended fuse (not fast) type - T1A. Not fast due to internal capacitors charging during power up.

Binary output protections Do not connect binary outputs directly to DC relays without protection diodes, even if they are not connected directly to controller outputs.

+-

K1 K1K2 K2

24VDC+-

IG controllerT1A

Fuse

Fuse

Battery

DC relays

Example of InteliGen controller protection

Drawing text translation Fuse Battery IG controller


DC relays

Grounding To ensure proper function:

The shortest possible piece of wire should be used when grounding the controller. Use cable min. 2,5mm2 . 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

+

Battery

-

iG-CU

GACSpeed Control Unit

ESD 5500

MAGNETICPICK-UP

CDSignal

Signal

+

+-

-PowerSupply

PowerSupply

GND

RPM-IN

iS-CU

Drawing text translation Magnetic Pick-Up GAC Speed Control Unit Signal Power Supply Battery Be aware of interference signal from Speed governor when one speed pick-up is used. If engine will not start:

- 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

Controller indicates "Sd Underspeed" + "Pickup fault" after engine start when the pickup signal is good for start and low speed but too big for higher speed (lost of signal due to RPM input saturation). Increase gap between pickup and engine flywheel or change type of pickup. Hint: In some cases the controller will measure a RPM value even though the gen-set is not running:


RPM is measured from the generator voltage (Gear teeth = 0) IG is measuring some voltage value on input terminals due to open fusing. If RPM > 0 the controller will be put into a Not ready state and the engine will not be allowed to start.

GENERATORL1L2L3

N

L1L2L3

N

MAINSVOLTAGE

GENERATORVOLTAGE

L1 L2 L3

IG-CU SSB, SPtML3L2L1N

MCB GCBMAINS

LOAD

Drawing text translation Load Generator Mains Mains Voltage Generator Voltage

Current measurement To ensure proper function:

Use cables of 2,5mm2

Use transformers to 5A Connect CT according to following drawings

L1

L2L3

N

G

I1k I1 l

K Lk l

I2k I2 l

K Lk l

I3k I3 l

K Lk l

Standard three CT conenction

Single stand-by

Short time parallel

L1L2L3

G

I1k I1l

K Lk l

I2k I2l

K Lk l

I3k I3l

Two CT connection


Earth fault protection

G

I1k I1 l I3k I3 lI2k I2l

K Lk l

L1

L2L3

N

Ink In l

K Lk l K L

k l

L K

l k

The simplest arrangement covers all zones from the generator windings to the final circuits in the load network.

GL1

L2L3

N

Ink In l

k lk lk l

k l

This arrangement covers earth faults in the load network only.

GL1

L2L3

N

Ink In l

L K

l k

k lk lk l

k l

K L

This arrangement is necessary for restricted earth fault protection. The location of the neutral earthing point in relation to the protection current transformers in the neutral conductor determines whether four or five current transformers are employed.

GL1

L2L3

N

Ink In l

k lk lk l

k l

This arrangement is necessary for restricted earth fault protection. The location of the neutral earthing point in relation to the protection current transformers in the neutral conductor determines whether four or five current transformers are employed.

Connect separate current transformer to gen-set neutral. Adjust EarthFltCurrCT in Basic settings and EarthFaultCurr and EthFltCurr del limits in Generator protection group.

Voltage measurement

G

GENERATOR MAINSL3L2L1N LL2L1

L1

L2L3

N

3

Drawing text translation Generator Mains


Hint: Switchboard lighting strikes protection according standard regulation is expected !!! Mains / bus voltage neutral must be connected to the generator voltage N terminal.

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-C is separation transformers unit with additional filter for controller voltage measuring. It is used like IG-MTU in special cases of extreme distortion of generator voltage by higher harmonics due to inverters etc..

IG MTU Connect one or two IG-MTU or MTU-C units to separe generator and mains voltage from controller. IG-MTU-C is usually connected to Vg terminals to protect against higher voltage harmonics. Four wire mains and four-pole circuit breaker or three wire mains

Three wire mains and three wire genset or electric separation

T1 T3T2

L1

L3L2

L3

GENERATORL1 MAINS / BUSL2

400V

400V

400V

0V0V 0V

0V 0V0V40

0V

400V

400V

L1 L3

MAINS / BUSVOLTAGE

L2 L1 L2 L3

GENERATORVOLTAGE

N

IG-MTU

NN

T1 T3T2 T1 T3T2

L1

L3L2

L3

GENERATORL1 MAINS / BUS

L2

400V

400V

400V

0V0V 0V

0V 0V0V 0V 0V 0V

0V 0V 0V400

V

400

V

400

V

400V

400V

400V

400

V

400

V

400

V

L1 L3

MAINS / BUSVOLTAGE

L2

IG-CU

L1 L2 L3

GENERATORVOLTAGE

N

IG-MTUIG-MTU

T1 T2

L1

L3L2

0V

L1 L2 L3

VOLTAGE TERMINALS

N

0V 100V

100V

3x R

GENERATORMAINS / BUS

Principle of two transformers measuring. R = 120 kΩ, 2W

Drawing text translation Mains/Bus Generator Mains/Bus voltage Generator voltage Voltage terminals


Analog inputs - configuration Three analog inputs AI1, AI2, AI3 are available on the IG-CU. Additional four analog inputs AIM1, AIM2, AIM3, AIM4 are available on external IG-IOM or IGS-PTM unit. Before IG-IOM, IGS-PTM unit connection load +IOM aig archive. Each analog input AI1, AI2, AI3 can be configured by WinEdit software in the following way.

Analog input item WinEdit Possibility Analog input name Name Up to 14 ASCII characters Abbreviation Abbr Up to 4 characters Sensor type Sensor

type Analog Binary Tri-state

Analog measuring in specified range. Binary: open/close - threshold 750 Ω.Tri-state: open/close - threshold 750 Ω, Failure <10 Ω or > 2400 Ω

Physical dimension Dim bar,%,°C, … Up to 3 ASCII characters Active Active Under

Under + Fls Over Over + Fls

Protection is active under limit. … under or sensor fail. Protection is active over limit.. … over or sensor fail.

Polarity Inverted Open to activate Close to activate

Valid only for binary and three-state inputs

Alarm type Alarm type None Sensor fail Warning Wrn+Shutdown Wrn+Slowstop Wrn+ElProt

No protection Only sensor fail indication Wrn on both levels Level1+level2 protection Level1+level2 protection Level1+level2 protection

Alarm activity Alarm active

All the time Engine running only

Alarm check conditions

Sensor characteristic Sensor Not used Curve A Curve B Curve C Pt100/°C Pt1000/°C Ni100/°C Ni1000/°C VDO Temp/°C VDO Press bar VDO Level 0-20mA/100 4-20mA/100 0-20mA/100-PTM 4-20mA/100-PTM 100mV/100-PTM

Unused analog input set-points adjusted curve A set-points adjusted curve B set-points adjusted curve C Available on IGS-PTM IEC 751, range -20 to 120 °C Available on IGS-PTM DIN 43760, range -20 to 120 °C See chapter sensor specification See chapter sensor specification See chapter sensor specification No external resistor !!! No external resistor !!! Available on IGS-PTM Available on IGS-PTM Available on IGS-PTM

Decimal points Decimals 0, 1, 2 Number of decimal points Measurement type Meas type Resistance

Current Jumper on pins 1-2 Jumper on pins 2-3

Sensor characteristics - Curve A, B, C are adjusted in Sensor specification group – set points: 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 Engine protection group.

IG-CU Analog inputs hardware configuration Configure Analog inputs connection by jumpers AI1-AI3 on PCB (remove cover). This feature is available from IG-CU of hardware version 5. Previous IG-CU hw versions are fix switched to Resistance measurement.

• Resistance measurement – jumper on 1-2, • Current measurement – jumper on 2-3,


• Voltage measurement – no jumper.

AI1

AI2

AI3

123

RPM Grounding Terminal

Grounding Terminal

ANALOG INPUTS

BINARY INPUTS

BINARY OUTPUTSRPMBO

1(S

TART

)

BO2

(FUE

L) POWER8 - 36 V DC

EXTE

NSIO

N MO

DULE

SiG

-PCM

/ iG-

PCLS

M

RS 23

2

GENERATOR CURRENT0 - 5 A

GENERATOR VOLTAGE 3 x 230 / 400 V

LB 5

BOOT JUMPER

EXTE

NSIO

N MO

DULE

SiG

-COM

/ iG-

IOM

+ -InlIn

(Im L3

)CU

RREN

TInk CO

MAI

1 (OI

L)

AI2 (

TEMP

)

AI3 (

FUEL

)

RPM

IN

RPM

GND

BO3

BO7

BO8

BO9

BO4

BO5

BO6

BI1

BI2

BI3 BI4

BI5

BI6

BI8

BI7

BI9

L1

L2

L3N L1

L2

L3

L3k

L3l

L2k

L2l

L1k

L1l

iG-CU

Jumpers setting

1

2

3

Resistance measurement – jumper on pins 1-2. Default settings.

1

2

3

Current measurement – jumper on pins 2-3.

1

2

3

Voltage measurement – no jumper connected.

0/4 to 20mA measuring Customer Curve A, B, C examples for IG-CU current measuring (available only from IG hardware version 5): Analog input jumper = 2-3 (current) WinEdit configuration = Current (linear)

0-20mA/600

No. Primary Converted1 0 0 2 2000 600

0-20mA/1000

No. Primary Converted 1 0 0 2 2000 1000

4-20mA/600

No. Primary Converted1 400 0 2 2000 600

4-20mA/1000



0 to 4VDC measuring Default characteristics Customer characteristics

A,B,C example No analog input jumper = (voltage) WinEdit configuration = Current (linear)

0-20mA/100

0-4V/1000


Hint: Without external resistors is maximal Voltage measuring range 4 VDC. Connect external resistors ( divider) to extend input voltage range.

Default characteristics Following table describes how to use default characteristics.

IG-CU IGS-PTM Sensor

Jumper on

WinEdit cfg: Meas type=

Jumper on

WinEdit cfg: Meas type =

PT100/°C NI 100/°C

Not possible on IG-CU 1-2, Resistance Resistance

PT1000/°C NI 1000/°C

Resistance Pins 1-2

Resistance

VDO Temp VDO Press VDO Level

Resistance Pins 1-2

Resistance

0-20mA/100 4-20mA/100

Current (linear) Pins 2-3

Resistance

Not possible on IGS-PTM

0-20mA/100-PTM 4-20mA/100-PTM

Pins 2-3, Current

Resistance

100mV/100-PTM

Not possible on IG-CU

No jumper, Voltage

Resistance

Hint: External resistors 120 ohm for 20mA current measuring are not needed for IG hardware version 5 and above when analog input jumper is set to 2-3. IGS PTM resistor measuring range is 0 to 250 ohms.

Hardware connection Connection of IG-CU analog inputs

IG-CU

AI3

CO

MAI

1AI

2

-PO

WER

3x RESISTIVESENSOR

Standard connection of three resistive sensors to analog inputs AI1, AI2, AI3. Example of connection of “one wire” (grounded to frame) sensors. COM terminal is Analog input measuring reference. -POWER terminal supplies sensor.


IG-CU

AI3

CO

MAI

1AI

2

-PO

WER

3x RESISTIVESENSOR

Standard connection of three resistive sensors to analog inputs AI1, AI2, AI3. Example of connection of “two wire” sensors. Common point of resistive sensors is connected to COM terminal for more accurate measuring. COM terminal is Analog input measuring reference. -POWER terminal supplies sensor.

IG-CU

AI3CO

MAI

1AI

2

-PO

WE

R

+24V

3x SENSORS4 - 20 mA

Three current output sensors connection to InteliGen. Configuration jumper must be in 2-3 position for this type of measurement. WinEdit configuration = Current (linear). Example of connection of “two wire” sensors. Analog input common terminal COM has to be connected to IG minus Power supply terminal.

IG-CU

AI3CO

MA

I1A

I2- PO

WE

R

AI1 CURRENT SENSORAI2 RESISTIVE SENSORAI3 BINARY INPUT

+24V

Mixed connection of InteliGen analog inputs: AI1 – current sensor AI2 – resistive sensor. AI3 – binary input Analog input common terminal COM has to be connected to IG minus Power supply terminal.

2x 470 ohms

IG-CU

AI3CO

MA

I1A

I2- P

OW

ER

AI1 RESISTIVE SENSORAI2 BINARY INPUTAI3 THREE STATE INPUT

Mixed connection of InteliGen analog inputs: AI1 – resistive sensor AI2 – binary input AI3 – three state input Analog input common terminal COM has to be connected to IG minus Power supply terminal.

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


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

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

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 the following configurable items: 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. Set to: Analog Dim: Physical dimension of measured value (°C, %, Bar, ..) . Maximum length is three characters. Set to: Bar Active: setting of polarity: Set to: under (alarm is active when Oil pressure goes low) Alarm type: selection between different types of alarms. Set to: Wrn+Shutdown (lubrication is necessary for engine health) Alarm active Set to: Engine running only – Alarm detection is active only when engine is running, Engine protections: Protection del [s] after the BO starter is off, (RPM reached Start RPM). Sensor selection of sensor characteristic Set to: VDO press Decimals: setting of number of decimal points of measured value. Set to: 1 Meas type: Analog input hardware jumper position Set to: Resistance 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 fixed and 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

iG-CU

4k7 Ω

+ -PowerSupply

T1A

24VDC+ -

Battery

Binary outputs

iG-CU

LOAD

+ -PowerSupply

24VDC+ -

BatteryT1A

Drawing text translation Battery Power supply


IG-COM Wiring


LCOM

CAN 2

H

LCOM


LCOM

CAN 2

H

LCOM

ETHERNETRJ 45

MO

DEM

/IB

CONF

IG

IG-C

U/D

ONG

LE

LB 4

POWER 8 - 36 V DCCOM LH CAN2

1 2

3 4 5 6

iG-MU

iG-IB

120

120

2 2

There is different wiring of CAN connectors from IG-COM hardware version 4.0 Green CAN connectors are separated: CAN1 = for extension modules - IG-IOM, IGS-PTM, IGL-RA15, … - connection to Extension module 9 pin connector: CAN H = pin 5 CAN L = pin 9 CAN2 = inter-controller CAN, - galvanically separated - internal resistor 120 ohm via jumper No internal resistor 120 ohm is available on IG-MU. No internal resistor 120 ohm is available on IG-IB.

Hint: For CAN cables details see chapter Technical data – Communication interface. CAN bus must be connected in series, from one unit to the next, (no star, no branches) both ends must by the 120-ohm resistor terminated. For longer distances it is recommended to connect COM terminals between IG-COM units

120 Ω


EXTE

NS

ION

MO

DU

LE

Seri

al N

o.

CA

NHL

CO

M

CA

N

H LCO

M

EXTE

NS

ION

MO

DU

LE

Seri

al N

o.

CA

NHL

CO

M

CA

N

H LCO

M

RS

232

RS

232

RS

422

RS 422CAN CAN

--

iG-MUSerial No.

L L

CO

M

CO

MH H

TxB

TxA

RxB

RxA

POWER8-36V DC

CAN bus

Extension modules (CAN bus) connection

EXTENSION MODULESiG-COM / iG-IOM

CONNECTOR

120o

hm

CAN HCAN L

IGL-RA15 (optional)

CAN HCAN L

5

9

or

CAN

LCA

NH

COM

IGS-PTM (optional)

CAN

LCA

NH

COM

IG-IOM (optional)

59 CAN

LCA

NH

120 ohm

IG-CU 120o

hm

Drawing text translation Extension modules Connector Optional


Connection rules CAN bus line must be connected in series, from one unit to the next (no star, no cable stubs, no branches) both ends must by the 120-ohm (internal or external) resistor terminated. Maximal CAN bus length is up to 200 meters when Basic settings: CAN bus mode = 32C or up to 900 meters when Basic settings: CAN bus mode = 8C. For CAN data cables details see chapter Technical data – Communication interface. CAN cable shielding connect to IG-CU case. IG-CU contains internal fix 120-ohm resistor. Use D SUB9 male connector: CAN H = 5, CAN L = 9, COMMON = 3 and 8. IG-CU must be on the CAN bus end. New IG-IOM and IGS-PTM units contain internal jumper removable 120-ohm resistor (in older IOM types are fix resistors). To be sure check resistor presence by ohmmeter. Unit with internal resistor connect to the end of CAN line. Following connections are supported (IOM, PTM, RA15 order is not important).

IG-CU – IG-IOM IG-CU – IGS-PTM IG-CU – IGL-RA15 IG-CU – IG-IOM – IGL-RA15 IG-CU – IGS-PTM – IGL-RA15

It is possible to connect only one IG-IOM or IGS-PTM and one IGL-RA15 to IG-CU.


Inputs and outputs Hint: Any Binary input or output can be configured to any IG-CU controller or IG-IOM, IGS-PTM terminal or changed to different function by WinEdit software. There is fixed 1 sec delay when any binary input is configured as protection. Note that Binary inputs and outputs configured on IG-CU (and IG-PC(LS)M ) have much faster response against IG-IOM, IGS-PTM. It is recommended to configure function inputs like Emergency stop, GCB feedback, MCB feedback and others … exclusively to IS-CU.

Binary inputs IG–CU + IG-PCLSM default

Hint: When remove IG-PCLSM module from IG-CU configured binary IG-PCLSM alarms are not active. There is no indication of disconnected IG-PCLSM module.

Binary inputs IG-IOM, IGS-PTM default

Hint: Before connection of IG-IOM or IGS-PTM use +IOM aig archive. Use WinEdit to configure these binary inputs. Any binary input can be configured as a warning, unload, slow stop, shutdown – see chapter Alarm Management. WARNING: When the data cable between the IG-CU and the IG-IOM, IGS-PTM is disconnected, a SD alarm is activated. IG-IOM, IGS-PTM power supply LED blinks when the data bus is dead between the IG-IOM, IGS-PTM and IG-CU.


Binary inputs – list

Alarm If the input is closed (or opened) selected alarm is activated. Binary Alarm configuration items

Name 14 characters ASCII string Close to activate Inverted Open to activate Warning Slow stop Shut down Unloading

Alarm type

HistoryRecord, No warning All the time Alarm active Engine running only

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

GCB feedback Use this input to detect, 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 indicate, whether the gen-sets group operates in parallel to mains (MCB FEEDBACK is closed) or parallel isolated (MCB FEEDBACK is open) . Hint: MCB feedback must be connected to all controllers operating in Power management group when operating in parallel to the mains.

Emergency stop If the input is opened, shut down is immediately activated. Input is inverted (normally closed).

Sprinkler If the input is closed all alarms are disabled except the binary input EMERGENCY STOP and "engine overspeed 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 (OFF-MAN-AUT-TEST) cannot be changed. Hint: Access lock does not protect setpoints and mode changing from WinEdit. To avoid unqualified changes the selected setpoints, use password protection.

Sys start/stop If the input closes InteliGen starts the Pwr management (in AUT mode only). If the input opens, InteliGen inactivates Pwr management process and stops the gen-set.


Remote OFF If closed, iG is in OFF mode (there are three modes OFF-MAN-AUT). When opened, controller is switched back to previous mode. Hint: Remote OFF will switch controller to OFF mode even if the Access code is active or Controller mode is password protected. Binary input can be connected to timer switch, to avoid start of engine.

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

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

Load reserve 4 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 selected the same Load reserves.

MinRun power 1 (Minimal running power 1)

MinRun power 2 (Minimal running power 2)

MinRun power 3 (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 is closed. When not configured or not active, minimal running power is 0.

Master select 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 (Priority switch 1)



PrioritySwtch4 (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.

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.

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

Remote MAN When closed Controller is switched to MAN Mode. When opened controller is switched to previous mode.

RemControl lock Locks command writing and setpoint changing from all remote terminals.

GCB disable Active input blocks in AUT (not in MAN) mode closing GCB.

ForwSyncDisab Active input blocks forward GCB synchronizing.

Oil press Behavior for Inverted = Close to activate configuration: Binary input must be closed when engine is not running and opened when is running. "Sd Oil press B" is activated when input is opened on not running engine or when stays closed Engine params: Protection del after engine start. "Sd Oil press B" protection is not active when input is not configured.

Emerg. manual The controller behaves like when switched to OFF mode if input is closed. Opens all binary outputs Fuel solenoid, Cooling pump signals, etc... except:

Stop solenoid output does not close. Detection of "running" engine and subsequent alarm message "Sd Stop fail" is blocked. The controller shows "Emerg Man" state and the engine can not be started. Generator current and power (energy) measurement is active in this mode, regardless of actual state of the engine. After the binary input "Emerg. manual" is open again, the controller recovers to previous mode and behaves according to the actual situation (e.g. should the engine run, it tries to stop it). Function is active in any controller mode and activation of this input is written to history.


Binary outputs IG-CU+IG-PCLSM default

Hint: Maximal inductive load of contact relay outputs BO1 and BO2 is 4 Amps. Use external relays for higher load.

Binary outputs IG-IOM, IGS-PTM

Hint: Before connection of IG-IOM or IGS-PTM use +IOM aig archive. Use WinEdit to configure these binary outputs. WARNING: When the data cable between the IG-CU and the IG-IOM, IGS-PTM is disconnected, IG-IOM, IGS-PTM alarms are not active, only common IOM alarm appears.

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.

Idle/Nominal The output closes during engine start, after Idle time elapses. The output opens again in Cooling state. Hint: Connect Binary output IDLE / NOMINAL 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.

GCB ON coil

GCB OFF coil

GCB UV coil

GCB close/open

GCB closing GCB opening

2 s 2 s

Drawing text translation GCB closing GCB opening GCB close/open GCB ON coil GCB OFF coil GCB UV coil Hint: GCB UV coil automatically opens when GCB is closed spontaneously not from controller except Synchronization state.


Syst ready The output closes if the system load reserve could be achieved.

PBNom + PRNom > PAkt + Reserve PBNom Sum of the nominal power of all gen-sets on the bus PRNom Sum of the nominal power of all gen-sets ready to take the load i.e. starting, cooling or ready

to start) PAkt System load Reserve 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 Remote start/stop is closed. Use this output as an alarm indication.

Syst res OK The output closes when selected system load reserve is achieved.

PBNom > PAkt + Reserve PBNom Sum of the nominal power of all gen-sets on the bus PAkt System load Reserve 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..

Syst res1 OK The output closes when Load reserve 1 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 no Sd or Unload 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.

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

Unload The output is closed during unloading of genset.

Synchro The output is closed during genset forward and reverse synchronizing and opens when GCB or MCB is closed.

NotReadyAuto The output is closed in

• OFF, MAN, TEST mode or in • AUT mode when a failure blocking automatic operation is detected.

The output is opened only in AUT mode, when no failure blocking the engine operation is active and genset is ready to take the load or it is already running loaded. Hint: Use this input for external indication that genset is not ready for automatic or stand-by function.

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


Overload Output closes if the generator overload alarm activates. The output opens, if



Reverse power Output closes if the generator reverse power alarm activates. The output opens, if


Overspeed Output closes if the gen-set overspeed alarm activates. The output opens, if


Underspeed Output closes if the gen-set under speed alarm activates. The output opens, if


Start fail Output closes after the gen-set start-up fails. The output opens, if


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

Earth fault Output closes when Earth fault protection is active. Output opens when protection is not active and FAULT RESET is pressed.

Batt volts Output closes when battery over/under voltage warning appears. The output opens, if


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. 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 IG-AVRi module is not connected. Hint: The Alarm “Wrn VoltRegLim” is blocked when binary output AVR up and AVR down are configured.

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 Alarm “Wrn SpdRegLim” is blocked when binary output AVR up and AVT down are configured. 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. Min pulse duration 0,15 sec, max pulse duration 10 sec.

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


AIM 1

AIM 2

AIM 3

AIM 4 Output closes when IG-IOM, IGS-PTM Analog input 1, 2, 3, 4 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 Engine params: Stop time (default 60 s) in any case and 5 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.

CommonSdStpUnl Output closes when any Shut-down or Stop or Unload alarm appears. The output opens, if

• No from above alarms are active and • FAULT RESET is pressed

BI6 – stat, .. BI9 – stat (IG-CU Binary input status) When corresponding binary input (BI6 to BI9) is configured as Alarm and this Alarm is active (or inactive but not accepted by Fault reset button) then output is closed. When corresponding binary input (BI6 to BI9) is configured as function (e.g. GCB feedback) then output follows input state.

IOM BI5– stat, .. IOM BI8 – stat (IG-IOM or PTM Binary input status) When corresponding binary input (BIM5 to BIM8) is configured as Alarm and this Alarm is active (or inactive but not accepted by Fault reset button) then output is closed. When corresponding binary input (BIM5 to BIM8) is configured as function (e.g. GCB feedback) then output follows input state.


Analog inputs IG-CU (+IG-IOM or IGS-PTM)

Default setting of IG-IOM or IGS-PTM analog inputs is Not used.

Analog output IG-IOM, IGS-PTM

AOM1 Gen-set power Not configurable output of generator power in the range 0 to 20 mA. Hint: Adjust AnOut set point in kW/20mA to set analog output range.


Setpoints Password There are three levels of password protection. 0. User level allows change of non-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 a setpoint name (on controller screen) if the setpoint is password protected. The asterisk mark is removed only when the password is set from controller front panel. The asterisk mark is still visible on controller screen even if the password is set from WinEdit. When password is set from the controller front panel only the affected setpoints are not accessible from WinEdit (direct or Modem) until password is set in WinEdit (direct or Modem). Setpoints opened from front panel are automatically closed 15 minutes after the last key has been depressed or when wrong value of password is set. It is possible to protect remote Start, Stop, GCB and MCB commands from WinEdit, MultiEdit as well. This three level command protection can be configured from WinEdit.

EnterPassword Password is a four-digit number. Only setpoints associated with the entered password level can be modified. Use ↑ or ↓ to select the desired password and then hit enter.

ChangePassword 1

ChangePassword 2

ChangePassword 3 Hint: Any password can be changed once that level password or higher has been entered. To set password protection from WinEdit:

Open WinEdit Select Controller – Software configuration – Modify Select Setpoints window Set desired protection level: 0 or 1 or 2 or 3

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 – due to Internet

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. To set commands protection from WinEdit:

Open WinEdit Select Controller – Software configuration – Modify


Select Setpoints window Set Commands = 0 (no protection) or level 1 or 2 or 3

Process control Hint: The first character of replicated setpoints name is #.

#SystLdCtrl PtM [BASELOAD / LDSHARING] BASELOAD: Gen-sets group operating in parallel to mains is loaded at preadjusted level (SystBaseLoad). LDSHARING: Gen-sets load is controlled by load sharing line. Total group load is shared between connected gen-sets.

#SysPFCtrl PtM [ BASEPF / V SHARING ] BASEPF: gen-set is loaded at preadjusted level Process control: SysPwrFactor. V SHARING: power factor is shared with other engines.

#SystBaseLoad [kW] Total required power of gen-sets group operating in parallel to mains (MCB feedback closed). Step: 1 Range: 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

DetectOtherCAN [ DISABLED / ENABLED ] ENABLED: Message WrnCANbusEmpty is recorded to Alarm list and History when no other controller is on the CAN bus. DISABLED: No message.

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 [kW] Nominal power of the generator Step: 1 kW Range: 1 – 3000 kW

Nomin current [ A ] This is the current limit for the generator. IDMT over current and short current protection are set based on this setpoint. See Generator protections: 2Inom del, Ishort setpoints. Nominal current can be different from generator rated current value. Step: 1 A Range: 1 - 5000 A

!!! VERY IMPORTANT !!! • The maximum input range of the InteliGen current terminals are 11 Amps. Anything over this

value is displayed as measured limit, e.g. 15 Amps from CT is measured and displayed as 11 Amps.


• Take special care when selecting CT’s. All available 5 Amp CT’s do not have a range up to 11 Amps.

CT Ratio [/5A] Generator current transformer ratio. Step: 1 A/5A Range: 1 – 10000 A/5A Hint: When …/1A CT is used (e.g. 100A/1A) then set CT Ratio five times higher (500/5A). …/1A CT is not recommended because only 20% of measuring range is used.

PT ratio [/1] Gen-set potential transformers ratio. Step: 0,1 V / V Range: 0,1 – 500,0 V / V

Vb PT Ratio [/1] Bus potential transformers ratio. Step: 0,1 V / V Range: 0,1 – 500,0 V / V

AnOut-kW/20mA [kW/20mA] Conversion coefficient from gen-set power to IG-IOM, IGS-PTM analog output – in kW to full output scale 20 mA. Step: 1 kW / 20mA Range: 1 - 32000 kW / 20mA Hint: Available only for IG-IOM, IGS-PTM configuration.

EarthFltCurrCT [/5A] Earth fault protection CT ratio. Step: 1 A/5A Range: 1 – 5000 A/5A

Gen nom V [V] Nominal generator voltage (phase to neutral). Step: 1V Range: 80 – 30000 V

Bus nom V [V] Nominal bus voltage (phase to neutral). Step: 1V Range: 80 – 30000 V Hint: Both Gen and Mains nominal voltages must be set to the same value when no PT is used.

Nominal RPM [RPM] Nominal speed of the engine. Step: 1RPM Range: 100 – 4000 RPM The following table shows the relationship between frequency and nominal RPM due to generator poles.

Generator poles 50 Hz 60 Hz 2 3000 3600 4 1500 1800


6 1000 1200 Hint: Generator frequency can be used (for RPM measuring) only when generator voltage (min 5V) is present before reaching of the firing speed (Start RPM) after start. When pick-up cut (fail) comes, InteliGen detects under speed and stops the engine.

Nominal freq [Hz] Nominal generator frequency (usually 50 or 60 Hz). Step: 1Hz Range: 45 – 65 Hz

Gear teeth [-] Number of teeth on the engines flywheel for 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

FltRes GoToMAN [ DISABLED / ENABLED ] DISABLED: Controller stays in AUT mode after Fault reset . ENABLED: Automatic switch from AUT (or SEMI or TEST) to MAN mode after Fault reset to avoid automatic engine start. This function is active for all protections (Shut down, Slow stop, Unload, Off-load) except Warning protection. Hint: It is not possible reset Fault when Binary input Remote TEST is closed. Set to ENABLED to avoid automatic engine start when Fault reset button is pressed after shut down in automatic mode.

ControllerMode [ OFF, MAN, AUT ] Equivalent to Controller mode changes by MODE→ or ←MODE buttons. Hint: Mode change can be separately password protected.

Contr. addr (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 selection. Standard: InteliGen (WinEdit/MultiEdit) communication protocol. Modbus: InteliGen Modbus protocol. Hint: Detail description see in InteliGen Communication guide.

CAN bus mode [ 32C / 8C ] CAN bus speed selection. 32C: High speed CAN (250 kbps) applicable up to 32 controllers, CAN bus limited up to 200 meters. 8C: Low speed CAN (50 kbps) applicable up to 8 controllers, CAN bus limited up to 900 meters. Hint: Low speed use for long distance connection only. Set all connected controllers to the same speed.

Engine params

Prestart time [s] This is the time the binary output PRE-START is active for prior to 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

Starting RPM [%] “Firing” speed when controller stops cranking. Under speed limit when engine is running. Step: 1 % of Nominal speed Range: 1 – 50 %

MaxCrank time [s] Amount of time the iG will crank the engine in an attempt to start. Step: 1s Range: 1 – 60 s Hint: When digital output Fuel Solenoid is configured as gas, the engine will crank 25% longer on the last unsuccessful attempt in order to ventilate the remaining gas. The InteliGen will not continue cranking the engine after three seconds of RPM = 0. It will continue CrankFail pause.

CrankFail pause [s] Pause between crank attempts Step: 1s Range: 1 – 60 s

Crank attempts [-] Max number of crank attempts Step: 1 Range: 1 - 10 Hint: The starter will disengage when digital output starter is engaged for 2 sec. and RPM equals zero. The setpoint Gear teeth has to be set greater than zero. A pick-up fail shutdown is activated when digital output starter is closed and generator voltage is higher than 5 V and RPM equals zero.

Idle time [s] Idle time delay starts when RPM exceeds Start RPM. A start fail is detected if the RPM drops below 30 and the InteliGen is still in the Idle state. 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: 1 s Range: 1 – 300 s

Start RPMRPM

BO Starter

BO IDLE/RATED

RPM = 30RPM

Start Fail

Idle time Min stab timeElectric protectionsactive

Drawing text translation Start RPM Start Fail


BO Starter BO IDLE/RATED Idle time Min stab time Electric protections active Hint: Pressing START button in MAN mode skips the Idle time and switch to running state. Hint: Pressing START button in MAN mode skips the Idle time and switch to running state. Idle function Outputs and Setpoints overview:

Engine params:

Idle time [ s ]Idle/Nominal

binary output

Drawing text translation Engine params Idle time Idle/Nominal Binary output

Min stab time [s] This is the minimum time the iG will wait, after the RPM has come up to nominal RPM, to close the GCB. Step: 1s Range: 0 – Max stab time

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 does not reach defined limits ( see Generator protection group) within Max stab time the unload alarm is activated, genset cools and stops. History and Alarm list record contains Alarm reason (e.g. Vg<).

Cooling time [s] Runtime of the unloaded gen-set to cool the engine before stop. Engine stays on Nominal RPM during cooling. Step: 1s Range: 0 – 3600 s

AfterCool time [s] Runtime of engine after cooling pump. Binary output COOLING PUMP is closed when the engine starts and closes AfterCool 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.

Stop time [ s ] Stop time value means the minimum time for which Stop solenoid will be closed. If the engine stopping procedure will take longer time, the Stop solenoid stays closed until all signs of moving engine have disappeared (RPM, Vg, fg) + 5 seconds more to have some safety overlap. After Stop time has elapsed and the engine is still moving, the alarm "Sd Stop fail" is produced. However, this is not a normal situation and should be solved by increasing the Stop time setpoint.


The “StopValve" countdown timer will be displayed on IG screen. Step: 1s Range: 0 – 240 s

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.

If the engine is unsuccessful in starting the Fuel Solenoid output will stay energized 25% longer in order to vent the remaining gas. Example of FUEL SOLENOID output behavior during unsuccessful start.

Start RPM

BO Starter

RPM

BO Ignition

RPM < Start RPM

MaxCrank time

closed

on

opened

off

RPM > 30RPM < 3 RPM =0

the last cranking

RPM > 30RPM =0

MaxCrank time + 25 %

on

RPM < Start RPM

RPM < 3

closed opened+1sec

closed opened

+1sec

BO Fuelsolenoid=Diesel closed opened closed opened

ventilation

BO Fuelsolenoid=Gas

Drawing text translation BO Starter BO Fuel BO Ignition Start RPM Solenoid=Diesel Solenoid=Gas Closed Opened MaxCrank time The last cranking Ventilation

Engine protect

NextServTime [h] This is the amount of time that will elapse till service on the gen-set is required. When the countdown is complete:

• Service alarm is detected • Alarm list is recorded


Step: 1 h Range: 0 – 65535 h Hint: Once the service time has elapsed the NextServTime will have to be reset to clear the alarm and begin a new countdown.

Horn timeout [s] The maximum amount of time the horn will sound. If it desired to have the horn sound until the alarm is cleared then set to zero. Step: 1s Range: 0 – 600 s

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 setting is oil pressure warning. Step: 0,1 bar (psi) Range: -100 – 10000

Anl Inp1 level2 [ ] The second threshold level for ANALOG INPUT 1 alarm detection. Default setting is oil pressure shut down. Step: 0,1 bar (psi) Range: -100 – 10000

Anl Inp1 del [s] Delay for ANALOG INPUT 1 alarm. Step: 1 s Range: 0 – 180 s

Anl Inp2 level1 [ ] The first threshold level for ANALOG INPUT 2 alarm detection. Default setting is water temperature warning. Step: 1 °C (°F) Range: -100 – 10000

Anl Inp2 level2 [ ] The second threshold level for ANALOG INPUT 2 alarm detection. Default setting is water temperature shut down. Step: 1 °C (°F) Range: -100 – 10000

Anl Inp2 del [s] Delay for ANALOG INPUT 2 alarm.


Step: 1 s Range: 0 – 180 s

Anl Inp3 level1 [ ] The first threshold level for ANALOG INPUT 3 alarm detection. Default setting is fuel level warning. 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. Step: 1 % Range: -100 – 10000

Anl Inp3 del [s] Delay for ANALOG INPUT 3 alarm. Step: 1 s Range: 0 – 180 s

Batt >V [V] Warning level for battery over voltage. 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. Following AIM set points are available only when IG-IOM, IGS-PTM is configured.

AnlInIOM1 lev1 [ ] The level for IOM ANALOG INPUT 1 alarm detection. Step: 1 Range: -100 - +10000


AnlInIOM1 del [s] Delay for IOM ANALOG INPUT 1 alarm. Step: 1 s Range: 0 - 180 s










AnlInIOM4 del [s] Delay for IOM ANALOG INPUT 4 alarm. Step: 1 s Range: 0 - 180 s Hint: The analog input del is still enabled even if these inputs are configured as binary inputs contrary to standard Binary inputs B1 to BI9 which have fix 1 sec delay for activation.

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: Overload wrn – 300% Protection: Unload (GCB open), Cooling, Stop.


Overload wrn [%] Threshold for generator overload warning alarm (in % of Nominal power) Step: 1% of Nominal power Range: 50 – Overload Protection: Warning

Overload del [s] Delay for generator overload Step: 0.1s Range: 0 – 60.0 s

Ishort [ % ] Ishort is a percentage over nominal current, that when reached the GCB Close/Open, GCB UV coil, and the GCB Off coil are immediately opened, the event is recorded in the alarm and history list, and the engine will cool down and stop if the Fault reset button is not depressed. Step: 1 % of Nominal current Range: 100 - 500 % Protection: Unload (GCB open), Cooling, Stop.

Ishort del [s] Delay for generator short current protection. Step: 0.02 s Range: 0.00 – 10.00 s

2Inom del [ s ] IDMT curve shape selection. 2Inom del is the reaction time of IDMT protection for 200% overcurrent

Igen = 2* Nominal current. Step: 0,1 s Range: 0 - 60 s Protection: Unload (GCB open), Cooling, Stop. IDMT is inversely proportional to the generators overcurrent. The higher the overcurrent gets the less time will elapse before the alarm is activated. When the IDMT protection is activated the GCB is opened, the event is recorded in the alarm and history list, and the engine will cool down and stop if the fault reset button is not depressed.

2Inom del * Nomin current Reaction time = Igen - Nomin current

Where Reaction time is the amount of time from IDMT detection to the opening of the GCB.


Igen

Nominal current Ishort

2Inom del

Maximal Reaction timeRe

actio

ntim

e

Drawing text translation Ishort Reaction time Nominal current Maximal Reaction time Igen 2lnom del Hint: The maximum allowable Reaction time is 900 sec or 15 min. Where Igen is the maximum current of the three phases of generator current. EXAMPLE of Reaction time for different over current levels. Values in column 200% are equal 2Inom del.

Overcurrent 200 % =

2Inom del ≤ 100 % 101 % 110 %

0,2 s No action 20 s 2 s 2 s No action 200 s 20 s

Reaction time

20 s No action No action (time > 900 s)

200 s

!!! VERY IMPORTANT !!!

• The maximum input range of the InteliGen current terminals are 11 Amps. Anything over this value is displayed as measured limit, e.g. 15 Amps from CT is measured and displayed as 11 Amps.

• Take special care when selecting CT’s. All available 5 Amp CT’s do not have a range up to 11 Amps.

Curr unbal [%] Threshold for generator current unbalance. Step: 1% of Nominal current Range: 1 – 200% Protection: Unload (GCB open), Cooling, Stop.


Curr unbal del [s] Delay for generator current unbalance. Step: 0.1 s Range: 0 – 60.0 s

EarthFaultCurr [%] Threshold for generator Earth fault protection. Step: 1 % of Nominal current Range: 1 – 300 % Protection: Unload (GCB open), Cooling, Stop.

EthFltCurr del [s] Delay for generator Earth fault protection. Step: 0.1 s Range: 0– 60.0 s

Gen >V Sd [%] Threshold for generator over voltage Shut down protection. Step: 1% of Nominal voltage Range: 50 – 150% of Nominal voltage Protection: GCB opening and engine shut down.

Gen >V Unl [%] Threshold for generator over voltage. Step: 1% of Nominal voltage Range: Gen <V – 150% of Nominal voltage Protection: Unload (GCB opening), Cooling, Stop.

Gen <V Unl [%] Threshold for generator under voltage. Step: 1% of Nominal voltage Range: 50 – Gen >V Protection: Unload (GCB opening), Cooling, Stop. Hint: All three phases are checked for generator voltage protection. Minimum or maximum out of three is used.

Gen V del [s] Delay for generator under voltage and over voltage Unload and Shut down protection. Step: 0.1s Range: 0 – 600 s Protection: Unload (GCB opening), Cooling, Stop.

Volt unbal [%] Threshold for generator voltage unbalance. Step: 1% of Nominal voltage Range: 1 – 150% Protection: Unload (GCB open), Cooling, Stop.

Volt unbal del [s] Delay for generator voltage unbalance. Step: 0.1s Range: 0 – 60.0 s

Gen >f [%] Threshold for generator phase L3 over frequency. Step: 0.1% of Nominal frequency


Range: Gen < f - 200,0 % of Nominal frequency Protection: Unload (GCB open), Cooling, Stop.

Gen <f [%] Threshold for generator phase L3 under frequency. Step: 0.1% of Nominal frequency Range: 0.0 – Gen > f Protection: Unload (GCB open), Cooling, Stop.

Gen f del [s] Delay for generator under frequency and over frequency Step: 0.1s Range: 0 – 60.0 s

Pwr management 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 (ENABLED / DISABLED / EXTERNAL) [-] DISABLED: 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. 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.

Pwr mgmt mode [ ABS (kW) / REL (%)] ABS (kW): Load reserves for start LoadResStrt and for stop LoadResStp are set in absolute values in

kW (the same Pwr management procedure like before). REL (%): Load level for start LoadResStrt and for stop LoadResStp are set in relative values in %.

Then % means maximum allowable power of all running gensets in % of Nominal power. Following see examples for five gensets 100 kW each. Compare genset-starting sequence for setting Pwr mgmt mode = ABS (kW) or REL (%) during Actual power increasing.

1. Genset2. Genset

3. Genset

4. Genset

5. Genset

running

running

running

runningrunning

60 k

W

160

kW

260

kW

360

kW

Actual power

Pwr mgmt mode = ABS (kW)LoadResStrt = 40 kW

0 kW

100

kW

200

kW

300

kW

400

kW

500

kW


100

kW

200

kW

300

kW

400

kW

500

kW

1. Genset2. Genset

3. Genset

4. Genset

5. Genset

running

running

running

running

running

40%

100

kW

260

kW

360

kW

Actual power

Pwr mgmt mode = REL (%)LoadResStrt = 40 %

40%

200

kW40kW

80kW

120kW

40%

300

kW

40%

of40

0kW

0kW

160kW

ofofof

Drawing text translation Pwr mgmt mode = ABSOLUTE (RELATIVE) LoadResStrt Actual power Genset running

Priority (1..32) [-] Adjusts the priority of the gen-sets. Based on this 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 AutoMainsFail starting delay, Power management activation delay). Delay between mains failure and the emergency start of the gen-sets when Binary input SYS START/STOP is closed – e.g. controlled by mains decoupling relay. Island operation, MCB FEEDBACK is opened. If the MCB FEEDBACK is closed Power management activates with 1s delay after SYS START/STOP - parallel operation with the mains. Step: 1 s Range: 0 – 600 s

#SysAMFstpDel [s] (System AutoMainsFail stopping delay) Delay between Binary input SYS START/STOP opening and GCB opening in island mode when Binary input MCB FEEDBACK is opened. Delay between mains return to start of genset unloading when binary input SYS START/STOP is controlled from mains decoupling relay. If the MCB FEEDBACK is closed, the delay between Binary input SYS START/STOP opening and start of genset unloading in parallel to the mains is fixed to 1s. Step: 1 s 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 Sum of the nominal power of all gen-sets on the bus apart of the one, which is going to be

stoped. PAkt System load Reserve LoadRes Stp 1 or LoadRes Stp 2 Step: 1 kW% Range: 0 – 32000 kW% Hint: The engine will be stopped only when #MinRun power level stays running. !!! IMPORTANT !!! LoadRes Stp has to be higher than corresponding LoadRes Strt for Pwrmgm mode = ABS (kW) LoadRes Stp has to be lover than corresponding LoadRes Strt for Pwrmgm mode = REL (%)

1st gen-set 200

2nd gen-set 400

2nd gen-set

1st gen-set Y

N N N

Y

Y

Y

Y

Y

Y

Y

Y

Y Y

Load Res Stp 60 kW

Load Res Strt 40 kW

250 170

100 150 170

150 100


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

#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: 1 s 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:


Pwr management:

Priority

#LoadResStrt1#LoadResStp1#LoadResStrt2#LoadResStp2#LoadResStrt3#LoadResStp3#LoadResStrt4#LoadResStp4

#MinRun power1#MinRun power2#MinRun power3

Master select

Syst res OK

Syst ready

PrioritySwtch 4PrioritySwtch 3PrioritySwtch 2PrioritySwtch 1

Load reserve 2Load reserve 3Load reserve 4

MinRun power 1MinRun power 2MinRun power 3

Syst res1 OKSyst res2 OKSyst res3 OKSyst res4 OK

#SysAMFstsrtDel#SysAMFstpDel#NextStart del#OverldNextDel#NextStop del#SlowStop del

Binary inputs Binary outputs

Drawing text translation Binary inputs Binary inputs Master select Master select PrioritySwtch PrioritySwtch Load reserve Sys Start/Stop MinRun power MinRun power Pwr management Pwr management Priority Priority #LoadResStrt #LoadResStrt #LoadResStp #LoadResStp #MinRun power #MinRun power #SysAMFstsrtDel #SysAMFstsrtDel #SysAMFstpDel #SysAMFstpDel #NextStart del #NextStart del #OverldNextDel #OverldNextDel #NextStop del #NextStop del #SlowStop del #SlowStop del Binary outputs Binary outputs Syst ready Syst ready Syst res OK Syst res OK

Sync/Ld ctrl Hint: Adjusting procedure of Sync/load and Volt/PFcontrol loops see in chapter IM - IG MINT setpoints adjustment. SpeedRegChar [POSITIVE / NEGATIVE ] Switch between isochronous speed governor characteristic. 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.

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°

GtoB AngleReq [°] Phase difference between generator and mains voltage. Use this setpoint for phase correction of potential transformers for forward synchronizing. Step: 1° Range: -30° to +30° Following is an example of Controller connection to Middle voltage system. T1 shifts phase +30° and no shift is on T2. GtoM AngleReq = +30° for this example.

iG -CU

BUS

GCB

4

Vb GCB

3x10 kV 3x230/400VAC

Vg Ig

L1, L2, L3, NG

4

T1T2

3

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

Freq gain [%] Slip frequency control loop gain during synchronizing when GCB is still opened. Step: 0.1 % Range: 0 to +200.0 %

Freq int [%] Relative integration factor of slip frequency control loop. Step: 1 % Range: 0 % – 100 %

Freq der [%] Relative stability factor of slip frequency control loop. Step: 1% Range: 0 % – 100 %

Freq reg loop [ GCB OPEN / SYNC ONLY ] GCB OPEN: Frequency control is active when running unloaded and synchronizing. SYNC ONLY: Frequency control is active during synchronizing only.


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: 1 s Range: 0 – 600 s

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 GCB’s 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 isn’t reached GCB opens after GCB open del time. Step: 1 % of Nominal power Range: 0 to 100 %

GCB open del [s] Maximum time to unload the gen-set. Step: 1 s Range: 0 – 600s

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: GCB’s are closed and MCB is opened. Process control: SysLdCtrlPtM = LdSharing. Parallel to mains: GCB’s 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.

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

Volt/PF ctrl AVRRegChar [POSITIVE / NEGATIVE ] Switch between AVR characteristic. 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 %

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 AVR 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 [DISABLED / ENABLED] Enables or disables active calls/SMS to selected phone or mobile numbers when a warning alarm occurs.

Unload call [DISABLED / ENABLED] Enables or disables active calls/SMS to selected phone or mobile numbers when a unload alarm occurs.

Slow stop call [DISABLED / ENABLED] Enables or disables active calls/SMS to selected phone or mobile numbers when a slow stop alarm occurs.

Shut down call [DISABLED / ENABLED] Enables or disables active calls to selected phone or mobile numbers when a shut down alarm occurs.

AcallCH1..3-Type Up to three separate channels are available for any one of the following types of messages: 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. Each above message type has either a number or an e-mail address associated to it. For more details see WinEdit-MultiEdit guide chapter IG-IB Internet communication. Hint: 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 the time the iG is trying to send an active call type, incoming calls are blocked.


Load Shedding The load shedding function is available in all applications SPM, SSB, SPtM, MINT, MEXT and is active in all iG modes except OFF. Load shedding has three steps and each step is linked with its own LOAD SHED digital output. There is only one load shed level and delay for all three steps as well as recon level and delay. Load shed can only move from one step to the next, e.g. No LoadShed to LdShed S1 to LdShed S2 to LdShed S3 and vise versa. If manual reconnection of the load is desired the AutoLd recon setpoint needs to be disabled and the MAN LOAD RECON digital input needs to be configured. Digital input MAN LOAD RECON resets iG to lower stage of load shed only if the load is under Ld Recon Level. All LOAD SHED outputs are activated (closed) to trip unessential load before genset goes to island (MCB opens) from parallel to mains:

a) After Mains fail before genset starts to island in AUT mode. b) Before MCB is opened in MAN mode by button.

Ld shed level [%] When gen-set load exceeds this level for more than LD Shed delay , 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 [s] Time delay for LD shed level limit. Step: 0.1 s Range: 1 - 1800 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 [s] The amount of time that the load has to exceed Ld shed level before the next load shed level is activated. Step: 1 s Range: 1 - 1800 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.

#Time [HHMMSS] Real time clock adjustment.


#Date [DDMMYY] Actual date adjustment. Hint: #Time and #Date setpoints are synchronized via CAN bus each hour with the lowest address controller. #Time or #Date change in any controller changes Time or Date in all controllers on CAN bus.

Sensor spec

Calibr AI1 (AI2, AI3) […]

Calibr AIM1 (AIM2, AIM3, AIM4) […] Calibrating constant to adjust the measured value of IG-CU and IG-IOM, IGS-PTM (when configured) analog inputs. The units of the calibration constant are the same as the associated analog input, e.g. If entering 5 for Calibr AI1, and AI1 is oil pressure in psi’s then it would be 5 psi’s. 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.

InteliGen – MINT, SWIG-MINT-MINT+IOM-6

IM - IG MINT setpoints adjustment

Active and reactive power terminology

MAINS GEN

LOAD

MAINS LOAD GEN P > 0 ImpoQ> 0 Impo

Cos < 0 L Export P Import Q

Cos < 0 C Export P Export Q

Cos > Import Export

Cos > Import Import

Q

Mains Exported active poweImported active power When reactive power control: SysImportLdWhen reactive power Process control: Sys

Load Active power consumeWhen reactive power When reactive power

Genset Generated active powWhen reactive power When reactive power

version 6.1, ©ComAp – May 2004 .1.PDF

rt P > 0 Consumption rt Q> 0 Consumption

Cos > 0 C Consumption P Capacitive LOAD

Cos > 0 L Consumption P Inductive LOAD

P

Q

0 C P Q

0 L P Q

P

CoCoGe

CoCoCo

r is supplied to the mains. It is displayed in nega is consumed from the mains. It is displayed in p

is imported (>0) InteliMains displays L (inductivChr = L-Im kVAr. is exported (<0) InteliMains displays C (capacitiImportLdChr = C-Ex kVAr.

d by Load is displayed in positive numbers e.g.is positive (>0) InteliMains displays L (inductiveis negative (<0) InteliMains displays C (capacitiv

er is displayed in positive numbers e.g. 20kW. is positive (>0) InteliGen displays L (inductive) cis negative (<0) InteliGen displays C (capacitive

82 -

P> 0 Generation Q> 0 Generation

s < 0 L nsumption P neration Q

s < 0 C nsumption P nsumption Q

Cos > 0 C Generation P Consumption Q

Cos > 0 L Generation P Generation Q

P

Q

tive numbers e.g. –20kW. ositive numbers e.g. +20kW.

e) character of the load. Process

ve) character of the load.

20kW. ) character of the load. e) character of the load.

haracter of the load. ) character of the load.


Steps of InteliGen MINT set points adjustment Following chapters contain recommended procedure of InteliGen – MINT set points set up. At first refer to InteliGen - MINT Users guide, chapters Sync/load and Volt/PF set points. The first step is speed and AVR loop sensitivity adjusting. The second step is InteliGen - MINT set points adjusting.

1. IG-PCLSM Speed governor output Hint:

No droop Speed governor is expected for controller connection. Two wire shielded connection from IG-PCLSM SPEED GOVERNOR output (GND, Volt or VoltR) to Speed governor auxiliary input is recommended.

IG-PCLSM SPEED GOVERNOR output sensitivity should ±10V to ± 5% of Nominal generator frequency (see drawing below).

IMPORTATNT

Speed governor has to be adjusted for optimum performance before controller Sync / load control adjusting. Check generator phase sequence before the first GCB connection.

Example of Speed governor out sensitivity:

Speed gov bias Genset RPM -10 V 1425 RPM Nominal – 5% 0 V 1500 RPM = Nominal 10 V 1575 RPM Nominal + 5%

Check Speed gov bias when genset is idle running. When is speed characteristic negative (increasing Speed gov bias decreases RPM) set SpeedRegChar = NEGATIVE (All speed gain setpoints are positive).

RPMRPM

Volt [V] Volt [V]0 V +10 V- 10 V

Speed governorvoltage output1500 0 V

- 10 V1500

+10 V

Speed governorvoltage output

+ 5 % of nominal+ 5 % of nominal

- 5 % of nominal - 5 % of nominal SpeedRegChar = POSITIVE SpeedRegChar = NEGATIVE

Drawing text translation Speed governor voltage output RPM of nominal

Check Speed gov bias when genset is idle running. When is speed characteristic negative (increasing Speed gov bias decreases RPM) set SpeedRegChar = NEGATIVE (All speed gain setpoints are positive). To decrease Speed governor out sensitivity use IG-PCLSM VoutR output and connect external resistor R2 in parallel to output. VoutR output voltage is in this case R2 / (R1+R2) = 1 / 11 = 0.09 times off Vout voltage.


R2=1kR1=10k

GND

VoutR

SpeedgovernorIG-PCLSM

AUX input

GND

Vout range: -10.0 V to +10.0 V

VoutR range: depends onresistor R2 value

Drawing text translation Speed governor GND VoutR AUX input VoutR range: depends on resistor value Vout range

Each genset in the group should have the same speed governor out sensitivity. Speed governor characteristics difference unbalances Load sharing during synchronizing of loaded gensets group to the mains.

2. IG-PCLSM AVRi output Hint:No droop AVR unit is expected for standard controller connection. IG-AVRi-TRANS (AC power supply for AVRi) have to be supplied from gen-set voltage. AVRi outputs can be connected: OUT1-OUT2 or unsymmetrical OUT1-GND or OUT2-GND. To check AVR DCout bias range set Voltage gain = 0. 1) Potentiometer on the AVRi defines maximal OUT1, OUT2 voltage range 2) When AVRi is connected to AVR auxiliary voltage input use OUT1,OUT2 AVRi outputs 3) When AVRi replaces AVR external potentiometer use unsymmetrical output. 4) AVRi output voltage should change generator voltage max in range ± 10 % of Nominal voltage.

100.0 %

10 V

0 VAVR DCout bias0 %

AVRi pot set to minimum2 VAVRi pot set to maximum

Out1 - GND [V]

100.0 %

10 V

0 VAVR DCout bias0 %

AVRi pot set to minimum2 V

AVRi pot set to maximum

Out2 - GND [V]

AVRi Out1 or Out 2 to GND output voltage depends on AVRi trim setting


[V]

100.0 %

AVRi pot

=maxim

um

AVR DCout bias

10 VOut1 to Out2

0 V0 %

-10 V

AVRi pot = minimum

50 %

AVRi output voltage Out1 - GND Out2 - GND Out1 – Out2Bias \ Pot Min Max Min Max Min Max

0 % 0 0 2 10 - 2 V -10 V50 % 1 5 1 5 0 V 0 V

100 % 2 10 0 0 + 2 V 10 V

AVRi Out1 to Out 2 output voltage Drawing text translation AVR DCout bias Out

Example of AVRi out sensitivity: AVR DCout bias Generator voltage

0 % 210 V = Nominal –9% 50 % 230 V = Nominal 100 % 250 V = Nominal +9%

Adjust AVR and AVRi to keep Nominal genset voltage at AVR DCout bias = 50%. To decrease AVRi output voltage sensitivity turn AVRi trim ccw. When the AVR characteristic is negative (increasing AVRi output decreases generator voltage) set AVRChar = NEGATIVE (All AVR gain setpoints are positive).

Each genset should have the same AVRi out sensitivity. AVR characteristics difference unbalances PF sharing during synchronizing of loaded gensets group to the mains.

3. Voltage control Conditions: running single gen-set, analog Volt/PF control using IG-AVRi module. Adjust Voltage control set points of each gen-set separately : MINT - Volt/PF control: AVR DCout bias, Voltage gain, Voltage int, Voltage der.

Hint:Simulate voltage steps by changing of Nominal voltage setpoint and check stable Voltage control.

Voltage gainVoltage intVoltage der

Vbus AVRianalog output

Vgen

Voltage matching

InteliGen - MINT

+

+

AVR DCout bias

Drawing text translation


Voltage matching Vbus Vgen Voltage gain Voltage int Voltage der AVRi analog output AVR DCout bias

4. Forward synchronizing Conditions: two running gen-sets, one is connected in MAN mode to dead bus, on the second genset press in MAN mode GCB close/open button to start synchronising to the bus. Adjust Sync control set points of each gen-set separately. Check InteliGen-MINT synchroscope screen. IG - Sync/Load control: Voltage window, Phase window, Dwell time, Speed gov bias, Slip freq gain, Slip freq int, Slip freq der and Angle gain, Angle der.

Hint:At first set Phase window = 0 to avoid GCB closing. Simulate speed steps by changing of Speed gov bias setpoint or press repeatedly GCB close/open button to start – stop synchronizing and check stability of synchronizing.

Slip freq gainSlip freq intSlip freg derAngle gainAngle der

InteliGen - MINTfbus

SPEED GOVERNORanalog output

+-10 V

fgen

Speed gov bias

+

+

Drawing text translation fbus fgen Slip freq gain Slip freq int Slip freq der Angle gain Angle der Speed gov bias SPEED GOVERNOR analog output

5. Load sharing Conditions: two gensets are running in isolated parallel (MCB is opened). In the first step no load, then apply full load. When all gensets are running idle voltage of Load sharing line is zero V. When all gensets are running at Nominal power voltage of Load sharing is 7,5V.

In parallel isolated mode (MCB is opened) adjust following Load sharing set points. When genset is loaded, unloaded, loading, unloading check the Load sharing. Check if Speed governor analog output does not reach limits below –10V or over 10V of the range. IG - Sync/Load control: Load ramp, LS gain, LS int, LS der,

GCB open level, GCB open del Hint:When one genset is running loaded in MAN mode press GCB close/open button of the second genset to synchronize and load. Then press STOP button to unload genset and open GCB. Pressing of the START button returns IG controller back from Cooling to Idle state.


LS gainLS intLS der

1.InteliGen - MINT 2.InteliGen - MINT

LS line: 0 to +7,5 V +

+


+-10 V

Load sharingisolated parallelSPEED GOVERNOR

analog output+-10 V LS gain

LS intLS der

Speed gov bias Speed gov bias

++

Drawing text translation Load sharing isolated parallel SPEED GOVERNOR analog output Speed gov bias LS gain LS int LS der LS line

6. VAR sharing Conditions: are the same as in step 5 – Load sharing. In isolated parallel mode (MCB is opened) adjust following VAR sharing set points. When loaded, unloaded, loading, unloading check the PF sharing. Check if AVR analog output does not reach limits below 0% or over 100% of the range. IG - Volt/VAR control: VS gain, VS int, VS der

Hint:When one genset is running loaded in MAN mode press GCB close/open button of the second genset to synchronize and load. Then press STOP button to unload genset and open GCB. Pressing of the START button returns IG controller back from Cooling to Idle state.

VS gainVS intVS der

VS gainVS intVS der

CAN bus +

+

AVRianalog output

PF sharingAVRianalog output

AVR DCout bias AVR DCout bias

1.InteliGen - MINT 2.InteliGen - MINT

++

Drawing text translation PF sharing AVRi analog output AVR DCout bias VS gain VS int VS der CAN bus

Hint:Check output values of Sync/Load and Volt/PF control loops at InteliGen MINT Synchro screen. SRO - SpeedRegOut indicates IG-PCLSM Speed governor output in the range from –10.0V to +10.0V. VRO - VoltRegOut indicates IG-PCLSM AVRi output in the range from 0% to 100%.


Steps of InteliMains set points adjustment Hint:Set point which name begins # character (e.g. #SysLdCtrl PtM) is replicated from InteliMains controller to all InteliGen controllers and vice versa.

1. Back (reverse) synchronizing of multiple gensets Conditions: gen-sets group is running in isolated parallel (MCB is opened). Synchronize group to the mains. Group of gensets is running loaded, Load and PF is shared between gensets. Load and VAR sharing can be unbalanced during synchronizing when different sizes of gensets (or different adjusting of speed governors) are running in parallel.

Adjust following InteliMains synchronizing set points, check InteliMains synchroscope screen. IM - Sync/Load control: Voltage window, Phase window, Dwell time,

Slip freq gain, Slip freq int, Slip freq der and Angle gain, Angle der. Hint:Press repeatedly MCB close/open button on InteliMains controller (in MAN mode) to start /stop synchronizing and check IM synchroscope screen. At first set Phase window = 0 to avoid MCB closing.

Slip freq gainSlip freq intSlip freg derAngle gainAngle der

InteliMains InteliGen - MINT

LS line: +- 10 V

fbus

fmains

+

+


+-10 V

Back synchronizing

LS gainLS intLS der

Speed gov bias

Drawing text translation Back synchronizing fbus fmains Slip freq gain Slip freq int Slip freq der Angle gain Angle der LS line LS gain LS int LS der Speed gov bias SPEED GOVERNOR analog output

2. Voltage matching of multiple gensets Conditions: gen-sets group is running in isolated parallel (MCB is opened). Synchronize group to the mains. Group of gensets is running loaded, Load and PF is shared between gensets. Load and PF sharing can be unbalanced during synchronizing when different sizes of gensets (or different adjusting of speed governors) are running in parallel.

During synchronizing (Volt matching is active) adjust following Voltage control set points: IM - Volt/PF control: Volt gain, Volt int, Volt der.


Hint:At first set Phase window = 0 to avoid MCB closing. Press repeatedly MCB close/open button on InteliMains controller (in MAN mode) to start /stop synchronizing and check IM synchroscope screen. For test, adjust Nominal voltage of gensets group to different value from the mains voltage (e.g.210V).

VS gain VS int VS der

Voltage gainVoltage intVoltage der

CAN bus

Vbus

Vmains

+

+

AVRianalog output

Voltage matchingInteliMains InteliGen - MINT

AVR DCout bias

Drawing text translation Voltage matching Vbus Vmains Voltage gain Voltage int Voltage der CAN bus VS gain VS int VS der AVR DCout bias AVRi analog output

3. Parallel to the mains – Baseload mode Baseload set points adjusting Conditions: Bus (load) is connected to the mains - MCB is closed. IG or IM - Process control: #SysLdCtrl PtM = BASELOAD, #SysBaseLoad = …

Adjust following InteliGen – MINT Load and PF control set points and check forward synchronizing, stable load/unload and PF control.

IG - Sync/Load control: Load gain, Load int, Load der, Load ramp. IG - Volt/PF control: PF gain, PF int, PF der.

Hint:When mains is connected to the bus in MAN mode press the GCB close/open button of IG-MINT controller to start synchronizing to the mains, loading at the #SysBaseLoad value. Then press the STOP button to unload genset and open GCB. Pressing of the START button returns controller back from Cooling to Running state.


+

+

AVRianalog output

InteliGen - MINT

+

+


+-10 V

Gensetpower

Required part of#SysBaseLoad

#SysBasePF

Genset PF

PF gainPF intPF der

Load gainLoad intLoad der

InteliGen - MINT

Speed gov bias

AVR DCout bias

Drawing text translation Required part of #SysBaseLoad Genset power Load gain Load int Load der Speed gov bias SPEED GOVERNOR analog output #SysBasePF Genset PF PF gain PF int PF der AVR DCout bias AVRi analog output

4. Parallel to the mains – Import/Export mode Import/Export load and Import/Export PF set points adjusting. Conditions: Bus (load) is connected to the mains - MCB is closed. IM - Process control: #SysLdCtrl PtM = PWR-IM/EX, SysImport load = …

Adjust following InteliMains Load and PF control set points and check forward synchronizing, stable load/unload and IM/EX Load and PF control. IM - Sync/Load control: Load gain, Load int, Load der, Load ramp. IM - Volt/PF control: PF gain, PF int, PF der.

Hint: Forward synchronizing test When mains is connected to the bus in MAN mode press the GCB close/open button of IG-MINT controller to start forward synchronizing and voltage matching of single genset to the mains. InteliMains via LS line and CAN bus controls SysImport load and SysImport PF value which is shared between gensets in the group. When the STOP button of IG-MINT controller is pressed, genset unloads, opens GCB and steps to Cooling state. Pressing of the START button returns controller back from Cooling to Running state.


Reverse synchronizing test When gensets are running in parallel isolated (MCB is opened) in MAN mode press the InteliMains MCB close/open button to start reverse synchronising and voltage matching of loaded gensets to the mains.

Load gainLoad intLoad der

InteliMains InteliGen - MINT

LS line: +7,5 V

SysImport load

Actualmainspower

+

+


+-10 V

Load control

LS gainLS intLS der

Speed gov bias

VS gain VS int VS der

PF gainPF intPF der

CAN bus

ActualMains

PF

SysImportPF

+

+

AVRianalog output

PF controlInteliMains InteliGen - MINT

AVR DCout bias Drawing text translation Load control Actual mains power SysImport load Load gain Load int Load der LS line LS gain LS int LS der Speed gov bias SPEED GOVERNOR analog output PF control Actual Mains PF SysImport PF PF gain PF int PF der CAN bus VS gain VS int VS der AVR DCout bias AVRi analog output

Hint:Output values of Sync/Load and Volt/PF control loops check at InteliMains synchroscope screen. LSO indicates IM-PCLSM load sharing output in the range from –10.0V to +10.0V. VVO indicates IM Volt/PF output to CAN bus in the range from -1000 to +1000.


Sensor specification

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 - °C, %, psi, °F, bar, etc. From these constants equivalent calibrating resistances are calculated and are internally (in software) added to the sensors resistance. Once the calibration value is entered (enter is pressed) the calibrating resistance is calculated and saved in memory. This value is then added to measured sensor resistance before the value is displayed. 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.5Ω) and saves this value into the memory. The resistance is then added to all calculations (e.g. instead of 70°C -> 73°C, or e.g. instead of 5°C -> 6°C).

Default sensor settings Analog input 1: 10 points VDO characteristic, pressure measuring in bar Analog input 2: 6 points VDO characteristic, temperature measuring in °C Analog input3: 2 points VDO characteristic, fuel level measuring in % Curve A – VDO pressure Curve B – VDO temperature Curve C – VDO Fuel level

Primary ohms Converted 0,1 bar

Primary ohms Converted °C

Primary ohms Converted %

PT 100 PT 1000 NI 100 NI 1000

Primary Converted Primary Converted Primary Converted Primary Converted

92 100 108 116 123 131 139 146 154 169

-205 0

205 413 595 803

1013 1197 1411 1814

922 961

1000 1117 1232 1309 1347 1385 1423 1461

-20 -10

0 30 60 80 90

100 110 120

83 90 97

105 113 121 130 139 148 169

-206

-8 189 403 605 795

1000 1200 1392 1793

893

946 1000 1171 1353 1483 1549 1618 1688 1760

-20 -10

0 30 60 80 90

100 110 120

VDO Temp VDO Press VDO Level

Primary Converted Primary Converted Primary Converted

3900 1525 700 440 290

-20

0 20 30 40

10 50 85

119 152

0

20 40 60 80

10 180

0 100


195 135 95 69 38

50 60 70 80

100

180

100

4-20mA/100 4-20mA/60 0-20mA/100-PTM 4-20mA/100-PTM Primary Converted Converted Primary Converted Primary Converted

170 200 230 280 330 390 460 560 690

0

13 25 38 50 63 75 88

100

0 8

15 23 30 38 45 53 60

0 38 57 77 96

116 135 155 174 194

0 20 30 40 50 60 70 80 90 100

38 57 77 96

116 135 155 174 194

0 12 25 37 50 62 75 87

100

100mV/100-PTM Primary Converted

mV0100R

0 10 40 70

110 140 170 210 230 250

mV0100Out

0 4

16 28 45 57 68 84 92

100


Operator Interface

Pushbuttons and LEDs

3

9

10

11

12

2 1 4 5

6

14 13 7 18 8 17

15

16

Pushbuttons: 1. MODE→ Cycle forward through gen-set operation modes OFF -> MAN -> AUT. 2. ←MODE Cycle backward through gen-set operation modes OFF -> MAN -> AUT. 3. HORN RESET Deactivates the HORN. 4. FAULT RESET Acknowledges faults and alarms. 5. START Starts the gen-set in MAN mode. 6. STOP Stops the gen-set in MAN mode. 7. MCB ON/OFF Has no affect in MINT application. 8. GCB ON/OFF When in MAN mode opens and closes (synchronizes) the Generator

circuit breaker. 9. PAGE Cycles through the display screens MEASUREMENT->ADJUSTEMENT->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.


LEDs 13. BUS VOLTAGE PRESENT: GREEN LED is on, if voltage on the bus is present. 14. BUS FAILURE: RED LED starts flashing when the bus failure occurs. 15. GEN VOLTAGE PRESENT: GREEN LED is on, if gen. voltage is present and within limits. 16. 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).

17. GCB ON: GREEN LED is on, if GCB is closed. Flashes during gen-set synchronizing. 18. MCB ON: GREEN LED is on, if MCB is closed (binary input MCB feedback is closed).

How to select gen-set mode ? Use MODE→ or ←MODE to select requested gen-set operation mode OFF – MAN – AUT. It is not possible to go directly from OFF to AUT.

When to use GCB ON/OFF button ? 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. iG has internal protection to avoid the breaker closure without synchronizing.

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. Pressing the PAGE button repeatedly will scroll the user through the menu screens.

How to view measured data? Pressing the PAGE button repeatedly will scroll the user through the menu screens. Select the MEASUREMENT screen. Use ↑ and ↓ to select the screen with requested data.

How to view and edit set points? 1. Pressing the PAGE button repeatedly will scroll the user through the menu screens. Select the

ADJUSTMENT screen. 2. Use ↑ or ↓ to select requested set points group. 3. Press ENTER to confirm. 4. Use ↑ or ↓ to select requested set point. 5. Set points marked “*” are password protected. 6. Press ENTER to edit. 7. 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.


How to view the HISTORY menu? 1. Pressing the PAGE button repeatedly will scroll the user through the menu screens. Select the

HISTORY screen. 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? Hold down the ENTER and the press 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) InteliMains serial number (8 character number) 3) SW version: the first is the firmware version number, the second is configuration table number. 4) Application: IM 5) Branch: InteliMains

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.

Description of MEASUREMENT screens

Main measure screen

1 2

6

3

4

7

5

8

OFF MAN AUT TESTReadyMains Opercos 0.00RPM 0Timer 0

1. Operation mode of the gen-set 2. Indication of active alarm “!”or active Remote control “R”


3. Status of the gen-set 4. Actual condition 5. RPM of the gen-set 6. Active power 7. Power factor 8. Timer - event s counting time (e.g. prestart, cooling, etc.)

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)

Bus screen EarthFaultCurr Bus freq Bus Vb1-2, Vb2-3, Vb3-1 ph-ph Bus Vb1, Vb2, Vb3 ph-N (tripple bargraph)

IG-CU Analog inputs screen AI1 Oil pressure (single barograph) AI2 Water temperature (single barograph) AI3 Fuel level (single barograph) Battery voltage (single barograph)

IG-IOM, IGS-PTM Analog inputs screen (if configured) (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 Hint: IG-IOM, IGS-PTM binary inputs are visible only when is IG-IOM, IGS-PTM is configured.


IG-IOM, IGS-PTM binary inputs 1 / 2 (if configured) BI1 to BI4

IG-IOM, IGS-PTM binary inputs 2 / 2 (if configured) BI5 to BI8

IG-IOM, IGS-PTM binary outputs 1 / 2 (if configured) BO1 to BO4

IG-IOM, IGS-PTM binary outputs 2 / 2 (if configured) BO5 to BO8

Gen-set power screen Active power (total and per phase) Power factor (total and per phase) Reactive power kVAr (total and per phase) Apparent power (total and per phase)

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

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


Flow Chart of pushbutton Operation

Mea

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Scr

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GEA

R T

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1

50

-

NO

M R

PM15

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15

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RPM

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RPM

30

30%

CR

AN

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10

10s

PAGE

PAGE

PAGE

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1000 14

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PAGE

Drawing text translation Page Measure Screens Par. Edit Screens History Screens Next Screen


Engine Basic Engine Prot Gen Basic Gen Protect Mains Fail Gear Teeth Nom RPM Start RPM Crank Time Parameter setting Set cursor by “-“ buttons Press “-“ to editing mode Adjust parameter by “-“ buttons Press “-“ to write parameter into memory Press “-“ to cancel of editing mode Table of history To measure screen


Mode description There are three modes of the gen-set: OFF - MAN - AUT. To select the mode use MODE→ or ←MODE.

OFF mode Outputs STARTER, GCB CLOSE/OPEN and FUEL SOLENOID are not energized. Genset cannot be started. If START,STOP,GCB ON/OFF buttons is pressed the iG will not respond.

MAN mode 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 binary input SYS START/STOP. The genset is permitted to run for an unlimited amount of time. 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 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. 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 gen-sets. 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 when Basic setting: FltRes GoToMAN is set to DISABLED..

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

Ld shed del Ld shed del Ld shed del

BO Load shed 1

BO Load shed 2

BO Load shed 3

Ld shed level

Gen-set power

closed

closed

closed

Load reconnection – automatic AutoLd recon = ENABLED


Ld recon del Ld recon delLd recon del

BO Load shed 2

Ld recon level

Gen-set power

BO Load shed 3

BO Load shed 1

opened

opened

opened

Load reconnection – manual AutoLd recon = DISABLED

BO Load shed 2

Ld recon level Gen-set power

BO Load shed 3

BO Load shed 1

BI Man load recon

opened

opened

opened

no action

Drawing text translation Gen-set power Ld shed level Ld recon level BO Load shed BI Man load recon Ld shed del Ld recon del closed opened no action

Load sheeding Inputs, Outputs and Setpoints overview:


Ig

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

[ ENABLED /DISABLED ]

Man load recon

VgLoad shed 1Load shed 2Load shed 3

Drawing text translation Vg Ig Man load recon Load shedding Ld shed level Ld shed delay Ld recon level Ld recon del AutoLd recon [ENABLED / DISABLED] Load shed


Alarm management Following alarms are available: Binary alarms Analog alarms

Hint: The alarm can be configured for any IG-CU, IG-PCLSM and IG-IOM, IGS-PTM binary input. When warning comes up it is displayed on the Alarm list screen and the selected entries are written to the History record. Detection of each binary input alarm is fix 1 sec time delayed. Analog input Alarms have usually two levels - e.g. wrn and sd. Use WinEdit to modify binary or analog inputs protections. Sensor fail does not activate binary output common Alarm.

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.

InteliGen – MINT, SW version 6.1, ©ComAp –IG-MINT-MINT+IOM-6.1.PDF

When another genset is available to come on line, it will start and connect to the load before the unloading function of the first set begins. If nothing else happens the set will unload when the Slow Stop Del is exceeded. Binary inputs configured as Slow stop (alarms are displayed and stored under configured name) Analog inputs configured as Slow stop (alarms are displayed and stored under configured name)

Shut down When a shutdown occurs, InteliGen opens outputs GCB CLOSE/OPEN, FUEL SOLENOID, STARTER. Possible shut-down alarms Overspeed Underspeed

Start fail IG-IOM, IGS-PTM 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

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Max

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Gen>V, Gen<V, Gen>f, Gen<f, Volt unbal, Curr unbal, Reverse power,

Underspeed

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

Protection

Unload protection

delay

Ready RPM=0 Cranking Starting Running Loaded Loaded

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Syn

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Voltage phase sequence detecInteliGen controller detects phase sequence oprotection is important after controller installatalarms can be detected:

Wrong phase sequence There is fix defined phase sequence in InteliGdifferent order (e.g. L1,L3,L2 or L2,L1,L3) follo

G ph opposed = wrong generator phaB ph opposed = wrong bus phase seq

May 2004 106 -

tion n both generator and mains/bus voltage terminals. This ion to avoid wrong voltage phases connection. Following

en controller L1, L2, L3. When the phases are connected in wing alarms are detected: se sequence uence


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 the BO GCB close/open (MCB close/open) in steady state and GCB feedback (MCB feedback) is changed the GCB fail (MCB fail) is detected immediately (no delay).

Alarm: GCB fail

BO GCB close/open

BI GCB feedback

Alarm detection:immediatelly

active

closed

opened

Alarm: GCB fail

BI GCB feedback

BO GCB close/open

Alarm detection:immediatelly

active

opened

closed

When BO GCB close/open (MCB close/open) opens there is 2 sec delay for the breaker to respond before a GCB fail (MCB fail) will be detected.

Alarm: GCB fail

BO GCB close/open

BI GCB feedback

active

opened

opened

Time delay

5 sec

When BO GCB close/open (MCB close/open) closes, there is following delay for the breaker to respond before a GCB fail (MCB fail) will be detected:

• 2 sec when synchronizing SPtM, MINT, MEXT (parallel modes) • 5 sec in stand-by – SSB (island modes)


Alarm: GCB fail

BO GCB close/open

BI GCB feedback

active

closed

closed

Time delay5 or 2 sec

Drawing text translation BO GCB close/open BI GCB feedback Alarm: GCB fail Opened Closed Active Alarm detection: immediatelly Time delay

Sensor fail detection Sensor fail Fls is detected when measured value is 6,2 percent out of range. The controller screen will display #### instead of the correct measured value.

R1

R2

R3

R4R5

Range of sensor

-6% +6Range of measurement 100%

Sensor Failure

Senso% rFailure

Drawing text translation Range of sensor

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 +9,8V or –-9,8V for more than 2 sec the warning SpdRegLim is detected on the Alarm list. When AVRi output stays on <2% or >98% for more than 2 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. Hint: Corresponding warning is blocked when Binary outputs SPEED up,SPEED down or AVR up, AVR down are configured.


Bus voltage error detection Bus measure error is detected in MINT / MEXT application when: Voltage on IG bus terminals is out of limits 20 seconds after:

a) GCB (own) was closed in MAN or AUT mode b) MCB (feedback) was closed in AUT mode c) Any other GCB in power management group (on CAN bus) was closed. The alarm is activated after

20 s, however the GCB (own) closing is blocked immediately from safety reasons. Protection type is Unload, written to History and Alarm list. Protection from reason: a), c) − must be confirmed by FAULT RESET button Protection from any reason: a), b), c) − is recorded in Alarm list and History file - „Unl BusMeasError“ message.


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 Pwr management Date and Time #SystLoadCtrl #Syst start del #Time #SystPFControl #Syst stop del #Date #SystBaseLoad #LoadRes Strt 1 #SystPwrFactor #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


Gen-set operation states Gen-set can operate in following states: Not ready Gen-set is not ready to start Init After IG power supply switch on Ready Gen-set is ready to run Prestart Prestart sequence in process.

Prestart output is closed Cranking Engine is cranking Pause Pause between start attempts Starting START RPM (”firing speed”) is reached. Unl Alarm Gen-set is unloaded due to electric protection Loaded Gen-set is running loaded Stop Stop Shut down Shut down alarm Cooling Gen-set is cooling before stop Running Waiting for GCB connection Unloading Gen-set is unloading External gen-set conditions : MainsOper Mains (or Bus) is present MainsFlt Mains (or Bus) cut off – immediate state ValidFlt Mains (or Bus) cut off – takes EmergStart del IslandOper Island operation MainsRet Mains (or Bus) recover Brks Off GCB, MCB opened Synchro Synchronizing is active Paral Oper Parallel operation with mains UnlProt Unload protection Multi Oper Island, Mains operation

Start-stop sequence MODE = MAN

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


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

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

Unsuccessful start

Crank attempts=3 State Closed outputs Condition of next transition Ready Start request Prestart PRESTART Prestart time Cranking PRESTART,STARTER,FUEL SOLENOID MaxCrank time Crank pause

PRESTART CrankFail paus

Cranking PRESTART,STARTER,FUEL SOLENOID MaxCrank time Crank pause

PRESTART CrankFail paus

Cranking PRESTART,STARTER,FUEL SOLENOID MaxCrank time Not ready HORN, GENERAL FAULT FAULT RESET Ready >>>>


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. Hint: Make sure the grounding system on controller and PC – COM port (negative of the PC DC supply) are identical – before the first direct connection. There must not be any voltage between these two points otherwise the internal resistor in controller burns out. The simple solution is to assure, that the PC supply 240/20V is ground free (GND terminal is not connected).

5 - GND

2 - RxD3 - TxD

PC

5 - GND

2 - RxD3 - TxD

RS2

32

RS2

32

230 VAC

0 VD

C

CONTROLLER

+-Battery

Required the samevoltage potentialbetween GND‘s

RS 232

PC software - WinEdit On the PC (for direct or modem connection) has to be installed the ComAp’s 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 Historical Value No. Number of historical event Reason Event specification Date Date of historical event in format DD/MM/YY Time Time of historical event in format HH:MM:SS Pwr Generator active power PF Generator PF LChr Character of the load Spd Engine speed


Gfrq Generator frequency Vg1 Generator voltage L1 Vg2 Generator voltage L2 Vg3 Generator voltage L3 Ig1 Generator current L1 Ig2 Generator current L2 Ig3 Generator current L3 Im3 Mains current L3 Bfrq Bus frequency Vb1 Bus voltage L1 Vb2 Bus voltage L2 Vb3 Bus voltage L3 Batt Battery voltage OilP IG-CU Analog input 1 value (default Oil pressure) Wtmp IG-CU Analog input 2 value (default Water temperature) Flev IG-CU Analog input 3 value (default Fuel level) AIM1 IG-IOM, IGS-PTM Analog input 1 value (when configured

IG-IOM, IGS-PTM) AIM2 IG-IOM, IGS-PTM Analog input 2 value (when configured

IG-IOM, IGS-PTM) BInp Binary inputs IG-CU BIPC Binary inputs IG-PCLSM BIM IG-IOM, IGS-PTM Binary inputs (when configured IG-IOM,

IGS-PTM) Bout Binary outputs IG-CU BOPC Binary outputs IG-PCLSM BOM IG-IOM, IGS-PTM Binary outputs (when configured IG-

IOM, IGS-PTM) Mode Mode IG - OFF, MAN AUT

List of possible events Zero signed events are not displayed or stored. Events specification Alarm History Active call Configurable Analog inputs IG-CU alarms YES YES YES Analog inputs IG-IOM, IGS-PTM alarms

YES YES YES

Binary inputs IG-CU alarms YES YES YES Binary inputs IG-PC(LS)M alarms YES YES YES Binary inputs IG-IOM, IGS-PTM alarms YES YES YES Events info InteliGen switched on 0 Switched On 0 Periodic history record 0 Time stamp 0 Starting sequence begins 0 Gen set start 0 Gen set stopped 0 Gen set stop 0 Generator circuit breaker closed 0 GCB closed 0 Generator circuit breaker opened 0 GCB opened 0 Mains circuit breaker closed 0 MCB closed 0 Mains circuit breaker opened 0 MCB opened 0 Password was set from any terminal 0 Password set 0 Password was changed from any terminal

0 Password chngd 0

Binary input Remote OFF was closed 0 Remote OFF set 0 Binary input Sprinkler was closed 0 Sprinkler set 0 Service time expired WrnService Time 0 wrn Speed regulator out was limited Wrn SpdRegLim 0 Wrn Volt regulator out was limited Wrn VoltRegLim 0 wrn Load shedding 0 Load shed 0


Events specification Alarm History Active call Load reconnection 0 Load recon 0 Some GCB in group was opened (MINT, MEXT)

0 Other GCB trip 0

No other controller on CAN bus (MINT, MEXT)

WrnCANbus Empty WrnCANbus Empty wrn

Engine Gen set start fail Sd Start Fail Sd Start Fail sd Gen set over speed Sd Overspeed Sd Overspeed sd Gen set under speed Sd Underspeed Sd Underspeed sd Emergency stop Emergency stop Emergency stop Sd RPM pickup fail SdPickupFail SdPickupFail sd Battery voltage – warning Wrn Batt volt Wrn Batt volt wrn Battery is discharged Sd Batt flat 0 sd Start info AMF start 0 GenSetMF start 0 AMF stop 0 GenSetMF stop 0 Remote start by binary input (SPM,SPtM)

0 GenSetRemStart 0

Remote stop by binary input (SPM,SPtM)

0 GenSetRemStop 0

System start by binary input (MINT,MEXT)

0 GenSetSysStart 0

System stop by binary input (MINT,MEXT)

0 GenSetSysStop 0

Peak start (SPtM) 0 GenSet PKstart 0 Peak stop (SPtM) 0 GenSet PKstop 0 Generator Generator phase 1 over voltage Unl Vg1 Over Unl Vg1 Over unl Generator phase 1 under voltage Unl Vg1 Under Unl Vg1 Under unl Generator phase 2 over voltage Unl Vg2 Over Unl Vg2 Over unl Generator phase 2 under voltage Unl Vg2 Under Unl Vg2 Under unl Generator phase 3 over voltage Unl Vg3 Over Unl Vg3 Over unl Generator phase 3 under voltage Unl Vg3 Under Unl Vg3 Under unl Generator over frequency Unl Fgen Over Unl Fgen Over unl Generator under frequency Unl Fgen Under Unl Fgen Under unl Generator voltage unbalance Unl Vgen Unbal Unl Vgen Unbal unl Generator overload warning Wrn Overload Wrn Overload 0 Generator overload UnlGen Overload UnlGen Overload unl Load surge protection LoadSurge LoadSurge Unl Reverse power Unl Rev Pwr Unl Rev Pwr unl Synchronization timeout Stp SyncTO Stp SyncTO Stp Reverse sync timeout Wrn RevSyncTO Wrn RevSyncTO Wrn Earth fault protection Unl EarthFltC Unl EarthFltC Unl Failure of generator circuit breaker GCB fail GCB fail unl Generator short current protection Unl Short Igen Unl Short Igen unl Generator IDMT protection Unl IDMT Unl IDMT unl Generator current unbalance Unl Igen Unbal Unl Igen Unbal unl Voltage on mains terminals (SPM) UnlCounterVolt UnlCounterVolt unl Bus voltage error (MINT) Unl BusMeasErr Unl BusMeasErr Unl Mains/bus Mains phase 1 over voltage 0 Vm1 Over 0 Mains phase 1 under voltage 0 Vm1 Under 0 Mains phase 2 over voltage 0 Vm2 Over 0 Mains phase 2 under voltage 0 Vm2 Under 0


Events specification Alarm History Active call Mains phase 3 over voltage 0 Vm3 Over 0 Mains phase 3 under voltage 0 Vm3 Under 0 Mains over frequency 0 Fmains Over 0 Mains under frequency 0 Fmains Under 0 Mains voltage unbalance 0 Vmains Unbal 0 Failure of mains circuit breaker MCB fail MCB fail wrn External Mains failure relay 0 Ext MF Relay 0 System info Wrong params checksum 0 Wrong params 0 Watchdog reset 0 Watchdog rst 0 Application loaded 0 Appl.loaded 0 Firmware loaded 0 Firmw.loaded 0 IG-IOM, IGS-PTM module fail Sd IOM fail Sd IOM fail sd IG-PC(LS)M module fail (SPtM, MINT) WrnPC(LS)Mfail 0 wrn Warning RA15 external module fail Wrn RA15 fail Wrn RA15 fail wrn Modem RS232 control command 0 RemControlUART 0 MODEM control command 0 RemControlMOD 0 CAN bus control command 0 RemControlCAN 0 ActCallCH1-OK 0 ActCallCH1-OK 0 ActCallCH2-OK 0 ActCallCH2-OK 0 ActCallCH3-OK 0 ActCallCH3-OK 0 ActCallCH1-Fail ActCallCH1-Fail ActCallCH1-Fail 0 ActCallCH2-Fail ActCallCH2-Fail ActCallCH2-Fail 0 ActCallCH3-Fail ActCallCH3-Fail ActCallCH3-Fail 0 Phase sequence Inverted polarity of gen phase L1 GEN L1 neg 0 0 Inverted polarity of gen phase L2 GEN L2 neg 0 0 Inverted polarity of gen phase L3 GEN L3 neg 0 0 Bad gen phase sequence G ph opposed 0 0 Bad gen phase sequence and polarity L1 G ph + L1 neg 0 0 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 mains phase L1 M L1 neg 0 0 Inverted polarity of mains phase L2 M L2 neg 0 0 Inverted polarity of mains phase L3 M L3 neg 0 0 Wrong mains phase sequence M ph opposed 0 0 Wrong mains phase sequence and polarity L1

M ph + L1 neg 0 0

Wrong mains phase sequence and polarity L2

M ph + L2 neg 0 0

Wrong mains phase sequence and polarity L3

M ph + L3 neg 0 0

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.

SD stop fail is detected when Engine params: Stop time after engine stop (when BO Fuel solenoid is opened or Stop solenoid is closed) the RPM is still > 30.

Note


Remote and mobile communication Modbus protocol • Direct connection: RS232, RS422, RS485

• Transfer mode RTU • Function 3 (Read Multiply Registers)

• 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/

• Modem connection • 9600 bps, 8 data bits, 1 stop bit, no parity

• Function 6 (Write Single 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.

Communication object vs. Register

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 M1200/WMOD2, dual 900/1800MHz (baud rate 9600 bps). • Wavecom - Maestro 20, dual 900/1800MHz. • Siemens M20, supports only 900MHz network. For modem configuration use GM setup program. • Siemens TC35

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

GSM modem

GSM modem or

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. Both SIM cards must have DATA setting when communication from controller to PC via two GSM modems.

How to check SIM card DATA setting • Move SIM card from controller GSM modem to Mobile phone. • Call from WinEdit to this Mobile phone and check (on Mobil phone) DATA call indication of incoming

call. • If phone does not indicate DATA - solve this with your GSM operator.

SMS commands Are not available from IG sw version 6.0.

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)


IG-IB Internet communication

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.

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

IG-C

U D

ON

GLE

MO

DEM

IB C

ON

FIG

POWERCAN

iG-IB iG-CU(iS-CU)

RS232

LED 1 2

LED 3 4 5 6 LED

IG-IB interface • Modem / IB config RS232 interface for IG-IB configuration or Modem connection

• CAN bus interface to group of controllers •

• IG-CU / Dongle RS232 interface for one controller connection or for Dongle for multiple controllers communication.

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.

Connect IG-IB Modem interface to PC and run “IB-cfg” software. Adjust items in IB configuration window IP address etc.

Active calls: E-mail or SMS via Internet.

IG-IB configuration

IG-IB0 Dongle IG-IB Dongle limits number of accessible controllers. Hint: For more detail see Communication guide – chapter IG-IB Internet communication.


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 Sw configuration Date Sw conf. ver. Ser. num. Filename

13.5.2004 6,1 4100096

Batt volt 8227

40 8228 Integer 16 Engine Fuel level

8978 Engine AnInIOM 2 Integer 16

SRO V

Act power kW Integer 16

0 0

React pwr kVAr 8203 React pwr L1 8527

React pwr L3 0 8529 Integer 16

8530 0 Integer 16

Appar pwr L3 0 8532 Generator 8204 Generator Generator

8535

Generator Generator

InteliGen MINT Group Name Value Dimension Com. obj. Data type Engine Engine speed 0 RPM 8209 Unsigned 16Engine 24,7 V 8213 Integer 16 Engine Oil press 5,7 bar Integer 16 Engine Water temp °C

16 % 8229 Integer 16 Engine AnInIOM 1 ##### U4 Integer 16

##### U5 8759 Engine AnInIOM 3 ##### U6 8760 Integer 16 Engine AnInIOM 4 ##### U7 8761 Integer 16 Engine 0 9052 Integer 16 Generator ##### kW 9678 Integer 16 Generator Act pwr L1 0 8524 Generator Act pwr L2 kW 8525 Integer 16 Generator Act pwr L3 kW 8526 Integer 16 Generator 0 Integer 16 Generator 0 Integer 16 Generator React pwr L2 0 8528 Integer 16 Generator Generator Appar pwr 0 kVA 8565 Integer 16 Generator Appar pwr L1 0 kVA Integer 16 Generator Appar pwr L2 kVA 8531 Generator kVA Integer 16

Pwr factor 0 Integer 8 Pwr factor L1 0 8533 Integer 8 Pwr factor L2 0 8534 Integer 8

Generator Pwr factor L3 0 Integer 8 Generator Load char 8395 Char Generator Load char 1 8626 Char Generator Load char 2 8627 Char Generator Load char 3 8628 Char Generator Gen freq 50 Hz 8210 Unsigned 16Generator Gen V L1-N 215 V 8192 Unsigned 16Generator Gen V L2-N 216 V 8193 Unsigned 16Generator Gen V L3-N 215 V 8194 Unsigned 16

Gen V L1-L2 0 V 9628 Unsigned 16Gen V L2-L3 0 V 9629 Unsigned 16

Generator Gen V L3-L1 0 V 9630 Unsigned 16Generator Gen curr L1 0 A 8198 Unsigned 16Generator Gen curr L2 0 A 8199 Unsigned 16Generator Gen curr L3 0 A 8200 Unsigned 16Generator EarthFaultCurr 2 A 8208 Unsigned 16


Integer 16

VRO % 9053

Bus freq 50

228 Unsigned 16Bus Bus V L1-L2 9631 Bus 0

Bus Act LoadSurge 9582 Integer 16

BInpIG 0

BInpIOM 8239

BOutPCLSM

BOutRA15 Binary 16

Pwr management 8498 Integer 16

kW 8499 0

ActReserve Unsigned 16

0

Info

3565275

Filename

BASE LOAD 0 String list

ProcessControl #SysPFCtrl PtM BASE PF

Generator Slip freq 0 Hz 8224 Generator Angle 0 ° 8225 Integer 16 Generator 50 Integer 16

Bus Hz 8211 Unsigned 16Bus Bus V L1-N 228 V 8195 Unsigned 16Bus Bus V L2-N 228 V 8196 Unsigned 16Bus Bus V L3-N V 8197

0 V Unsigned 16Bus V L2-L3 V 9632 Unsigned 16

Bus Bus V L3-L1 0 V 9633 Unsigned 160 P/s Integer 16

Bus Max LoadSurge 0 P/s 9583 Binary I/O 10100000 8235 Binary 16 Binary I/O BInpPCLSM 8601 Binary 8 Binary I/O 0 8602 Binary 16 Binary I/O BOutIG 0 Binary 16 Binary I/O 0 8603 Binary 8 Binary I/O BOutIOM 0 8604 Binary 16 Binary I/O ##### 9849

EnginePriority 1 8624 Unsigned 8 Pwr management TotAvlbPnom 0 kW Pwr management TotRunPnom 0 Integer 16 Pwr management TotRunPact kW 8496 Integer 16 Pwr management 0 kW% 8625 Integer 16 Pwr management LoadRes Start 200 kW% 8622 Pwr management LoadRes Stop 250 kW% 8623 Unsigned 16 Statistics kWhours 0 8205 Integer 32 Statistics kVArhours 0 8539 Integer 32 Statistics NumStarts 8207 Unsigned 16Statistics RunHours 0 h 8206 Integer 32 Statistics NextServTime ##### h 9648 Unsigned 16 Info LdShed state NextStart 9089 Unsigned 16Info TimerText MainsOper 8954 Unsigned 16Info TimerValue 0 s 8955 Integer 16 Info SW version 6,1 8393 Unsigned 8

SW branch 1 8707 Unsigned 8 Info Application 254 8480 Unsigned 8 Info ControllerMode OFF 9651 Unsigned 8 Info IOM SW ver. 3 9022 Unsigned 8 Info CAN16 1E+15 8546 Binary 16 Info CAN32 0 8827 Binary 16 Info PasswordDecode 9090 Unsigned 32

Setpoints Name Sw configuration Date Sw conf. ver. Ser. num. InteliGen MINT 13.5.2004 6,1 4100096 Group Name Value Dimension Password Com. obj. Low limit High limit Data type ProcessControl #SysLdCtrl PtM 8774

0 8779 String list


0 0,6

Basic settings 0,1

30 0 3600 Engine params s 0

60 s 9100

0 -100

ProcessControl #SysBaseLoad 200 kW 0 8775 30000 Unsigned 16ProcessControl #SysPwrFactor 0,95 0 8776 1 Integer 16 ProcessControl DetectOtherCAN DISABLED 0 9921 String list Basic settings Gen-set name InteliGen 0 8637 Short string Basic settings Nomin power 200 kW 0 8276 1 3000 Unsigned 16Basic settings Nomin current 288 A 0 8275 1 5000 Unsigned 16Basic settings CT ratio 400 /5A 0 8274 1 10000 Unsigned 16

PT ratio 1 /1 0 9579 500 Unsigned 16Basic settings Vb PT ratio 1 /1 0 9580 0,1 500 Unsigned 16Basic settings AnOut-kW/20mA 200 0 9019 1 32000 Integer 16 Basic settings EarthFltCurrCT 400 /5A 0 8566 1 8000 Unsigned 16Basic settings Gen nom V 231 V 0 8277 80 30000 Unsigned 16Basic settings Bus nom V 231 V 0 9888 80 30000 Unsigned 16Basic settings Nominal RPM 1500 RPM 0 8253 100 4000 Unsigned 16Basic settings Nominal freq 50 Hz 0 8278 45 65 Unsigned 16Basic settings Gear teeth 120 0 8252 0 500 Unsigned 16Basic settings FltRes GoToMAN DISABLED 0 9983 String list Basic settings ControllerMode OFF 0 8315 String list Basic settings Contr. addr 1 3 24537 1 32 Unsigned 8 Basic settings RS232 mode STANDARD 3 24522 String list Basic settings CAN bus mode 32C 3 24499 String list Engine params Prestart time 2 s 0 8394 0 600 Unsigned 16Engine params Starting RPM 25 % 0 8254 1 50 Unsigned 8 Engine params MaxCrank time 5 s 0 8256 1 60 Unsigned 8 Engine params CrnkFail pause 8 s 0 8257 5 60 Unsigned 8 Engine params Crank attempts 3 0 8255 1 10 Unsigned 8 Engine params Idle time 10 s 0 9097 0 3600 Unsigned 16Engine params Min stab time 2 s 0 8259 0 10 Unsigned 16Engine params Max stab time 10 s 0 8313 2 300 Unsigned 16Engine params Cooling time s 8258 0 Unsigned 16

AfterCool time 30 0 8662 3600 Unsigned 16Engine params Stop time 0 9815 0 240 Unsigned 16Engine params Fuel solenoid DIESEL 0 String list Engine protect NextServTime 65535 h 0 9648 0 65535 Unsigned 16Engine protect Horn timeout 10 s 0 8264 0 600 Unsigned 16Engine protect Overspeed 115 % 0 8263 100 150 Unsigned 16Engine protect Protection del 5 s 0 8262 0 300 Unsigned 16Engine protect AnlInp1 level1 2 bar 0 8369 -10 1000 Integer 16 Engine protect AnlInp1 level2 1 bar 0 8370 -10 1000 Integer 16 Engine protect AnlInp1 del 3 s 0 8365 0 180 Unsigned 16Engine protect AnlInp2 level1 80 °C 0 8375 -100 10000 Integer 16 Engine protect AnlInp2 level2 90 °C 0 8376 -100 10000 Integer 16 Engine protect AnlInp2 del 5 s 0 8371 0 180 Unsigned 16Engine protect AnlInp3 level1 10 % 0 8381 -100 10000 Integer 16 Engine protect AnlInp3 level2 3 % 0 8382 -100 10000 Integer 16 Engine protect AnlInp3 del 15 s 0 8377 0 180 Unsigned 16Engine protect Batt >V 36 V 0 9587 18 40 Integer 16 Engine protect Batt <V 18 V 0 8387 8 36 Integer 16 Engine protect Batt V del 5 s 0 8383 0 600 Unsigned 16Engine protect AnlInIOM1 lev1 0 U4 0 8762 -100 10000 Integer 16 Engine protect AnlInIOM1 lev2 100 U4 0 8766 -100 10000 Integer 16 Engine protect AnlInIOM1 del 5 s 8770 0 180 Unsigned 16Engine protect AnlInIOM2 lev1 0 U5 0 8763 10000 Integer 16 Engine protect AnlInIOM2 lev2 100 U5 0 8767 -100 10000 Integer 16


-100 Engine protect

Gener protect

150 Gener protect % 50

3 8288 150

Gener protect s 0

600

0 Pwr management

Voltage window

Engine protect AnlInIOM2 del 5 s 0 8771 0 180 Unsigned 16Engine protect AnlInIOM3 lev1 0 U6 0 8764 -100 10000 Integer 16 Engine protect AnlInIOM3 lev2 100 U6 0 8768 -100 10000 Integer 16 Engine protect AnlInIOM3 del 5 s 0 8772 0 180 Unsigned 16Engine protect AnlInIOM4 lev1 0 U7 0 8765 -100 10000 Integer 16 Engine protect AnlInIOM4 lev2 100 U7 0 8769 10000 Integer 16

AnlInIOM4 del 5 s 0 8773 0 180 Unsigned 16 Gener protect Overload 120 % 0 8280 110 300 Unsigned 16Gener protect Overload Wrn 110 % 0 9685 0 120 Unsigned 16

Overload del 5 s 0 8281 0 600 Unsigned 16Gener protect Ishort 200 % 0 8282 100 500 Unsigned 16Gener protect Ishort del 0 s 0 9991 0 10 Unsigned 16Gener protect 2Inom del 4 s 0 8283 0 60 Unsigned 16Gener protect Curr unbal 50 % 0 8284 1 200 Unsigned 16Gener protect Curr unbal del 5 s 0 8285 0 600 Unsigned 16Gener protect EarthFaultCurr 30 % 0 8286 1 300 Unsigned 16Gener protect EthFltCurr del 10 s 0 8287 0 600 Unsigned 16Gener protect Gen >V Sd 120 % 0 10013 85 150 Unsigned 16Gener protect Gen >V Unl 110 % 0 8291 85 Unsigned 16

Gen <V Unl 85 0 8293 110 Unsigned 16Gener protect Gen V del s 0 8292 0 600 Unsigned 16Gener protect Volt unbal 10 % 0 1 Unsigned 16

Volt unbal del 3 0 8289 600 Unsigned 16Gener protect Gen >f 110 % 0 8296 85 150 Unsigned 16Gener protect Gen <f 85 % 0 8298 50 110 Unsigned 16Gener protect Gen f del 3 s 0 8297 0 600 Unsigned 16Gener protect Reverse power 15 % 0 8486 0 50 Unsigned 8 Gener protect ReversePwr del 0,5 s 0 8552 0 600 Unsigned 16Gener protect Max load surge 50 P/s 0 9581 0 60 Unsigned 16 Pwr management Pwr management ENABLED 0 8551 String list Pwr management #Pwr mgmt mode ABS(kW) 0 9874 String list Pwr management Priority 1 0 8488 1 32 Unsigned 8 Pwr management #SysAMFstrtDel 5 s 0 8549 0 600 Unsigned 16Pwr management #SysAMFstpDel 10 s 0 8550 0 600 Unsigned 16Pwr management #LoadResStrt 1 100 kW% 0 8489 0 32000 Unsigned 16Pwr management #LoadResStp 1 150 kW% 0 8491 0 32000 Unsigned 16Pwr management #LoadResStrt 2 200 kW% 0 8490 0 32000 Unsigned 16Pwr management #LoadResStp 2 250 kW% 0 8633 0 32000 Unsigned 16Pwr management #LoadResStrt 3 300 kW% 0 8831 0 32000 Unsigned 16Pwr management #LoadResStp 3 350 kW% 0 8833 0 32000 Unsigned 16Pwr management #LoadResStrt 4 400 kW% 0 8832 0 32000 Unsigned 16Pwr management #LoadResStp 4 450 kW% 0 8834 0 32000 Unsigned 16Pwr management #NextStrtDel 5 s 0 8492 0 600 Unsigned 16Pwr management #OverldNextDel 2 s 0 8493 0 Unsigned 16Pwr management #NextStopDel 10 s 0 8494 0 600 Unsigned 16Pwr management #SlowStopDel 30 s 0 8495 0 600 Unsigned 16Pwr management #MinRunPower 1 100 kW 9584 0 60000 Unsigned 16

#MinRunPower 2 200 kW 0 9585 0 60000 Unsigned 16Pwr management #MinRunPower 3 300 kW 0 9586 0 60000 Unsigned 16 Sync/Load ctrl SpeedRegChar NEGATIVE 0 9054 String list Sync/Load ctrl GtoB AngleReq 0 ° 0 9578 -30 30 Integer 16 Sync/Load ctrl 3 % 0 8650 0 100 Unsigned 16Sync/Load ctrl Phase window 5 ° 0 8652 0 90 Unsigned 16Sync/Load ctrl Dwell time 1 s 0 8653 0 25 Unsigned 16


0 Sync/Load ctrl

Voltage int 0

0 #Time #Date

0

-1000

Sync/Load ctrl Freq gain 20 % 0 8715 0 200 Integer 16 Sync/Load ctrl Freq int 50 % 0 8716 0 100 Integer 16 Sync/Load ctrl Freq der 10 % 0 8717 0 100 Integer 16 Sync/Load ctrl Freq reg loop SYNC ONLY 0 9891 String list Sync/Load ctrl Angle gain 50 % 0 8718 0 200 Integer 16 Sync/Load ctrl Angle der 10 % 0 8719 0 100 Integer 16 Sync/Load ctrl Speed gov bias 0 V 0 8656 -10 10 Integer 16 Sync/Load ctrl Load ramp 60 s 8658 0 600 Unsigned 16

Load gain 20 % 0 8659 0 200 Integer 16 Sync/Load ctrl Load int 100 % 0 8713 0 100 Integer 16 Sync/Load ctrl Load der 10 % 0 8714 0 100 Integer 16 Sync/Load ctrl GCB open level 5 % 0 8547 0 100 Unsigned 16Sync/Load ctrl GCB open del 60 s 0 8548 0 600 Unsigned 16Sync/Load ctrl LS gain 20 % 0 8725 0 200 Integer 16 Sync/Load ctrl LS int 100 % 0 9035 0 100 Integer 16 Sync/Load ctrl LS der 20 % 0 8726 0 100 Integer 16 Sync/Load ctrl Sync timeout 60 s 0 8657 0 1800 Unsigned 16 Volt/PF ctrl AVRRegChar POSITIVE 0 9055 String list Volt/PF ctrl Voltage gain 20 % 0 8501 0 200 Integer 16 Volt/PF ctrl 20 % 0 8720 0 100 Integer 16 Volt/PF ctrl Voltage der 10 % 0 8502 100 Integer 16 Volt/PF ctrl PF gain 20 % 0 8503 0 200 Integer 16 Volt/PF ctrl PF int 20 % 0 8721 0 100 Integer 16 Volt/PF ctrl PF der 10 % 0 8504 0 100 Integer 16 Volt/PF ctrl VS gain 15 % 0 8777 0 200 Integer 16 Volt/PF ctrl VS int 15 % 0 9036 0 100 Integer 16 Volt/PF ctrl VS der 10 % 0 8778 0 100 Unsigned 16Volt/PF ctrl AVR DCout bias 50 % 0 8500 0 100 Integer 16 Act. calls/SMS Warning call DISABLED 0 8482 String list Act. calls/SMS Unload call DISABLED 0 8483 String list Act. calls/SMS Slow stop call DISABLED 0 8485 String list Act. calls/SMS Shut down call DISABLED 0 8484 String list Act. calls/SMS AcallCH1-Type DISABLED 0 9594 String list Act. calls/SMS AcallCH1-Addr 0 9597 Long string Act. calls/SMS AcallCH2-Type DISABLED 0 9595 String list Act. calls/SMS AcallCH2-Addr 0 9598 Long string Act. calls/SMS AcallCH3-Type DISABLED 0 9596 String list Act. calls/SMS AcallCH3-Addr 0 9599 Long string Act. calls/SMS NumberRings AA 3 3 24512 1 30 Unsigned 8 Act. calls/SMS A.c.multiplier 1 3 24505 1 250 Unsigned 8 Load shedding Ld shed level 90 % 0 8884 50 200 Integer 16 Load shedding Ld shed del 2 s 0 8887 0 1800 Unsigned 16Load shedding Ld recon level 50 % 0 8890 0 90 Integer 16 Load shedding Ld recon del 5 s 0 8893 0 1800 Unsigned 16Load shedding AutoLd recon ENABLED 0 9649 String list Date/Time Time stamp per 60 min 8979 0 240 Unsigned 8 Date/Time 17:04:02 0 24554 Time Date/Time 23.10.2002 0 24553 Date

Sensors spec Calibr AI 1 bar 0 8431 -100 100 Integer 16 Sensors spec Calibr AI 2 0 °C 0 8407 1000 Integer 16 Sensors spec Calibr AI 3 0 % 0 8467 -1000 1000 Integer 16 Sensors spec Calibr AI 4 0 U4 0 8793 -1000 1000 Integer 16


U7 -1000

Sensors spec Calibr AI 5 0 U5 0 8794 -1000 1000 Integer 16 Sensors spec Calibr AI 6 0 U6 0 8795 -1000 1000 Integer 16 Sensors spec Calibr AI 7 0 0 8796 1000 Integer 16


Technical data Power supply Voltage supply 8-36V DC Consumption depends on supply voltage 0,34A at 8VDC 0,12A at 24VDC

0,09A at 36VDC Battery voltage measurement tolerance 2 % at 24V RTC battery life-cycle 10 year Hint: When internal RTC battery becomes flat 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 IG-CU -20..+70oC Operating temperature IG-CU-LT -30..+70oC Storage temperature -30..+80oC

Standard conformity

Flash memory data retention time 10 years Protection front panel IP65 Humidity 95% without condensation

(From IG serial number xxxx0900)

Low Voltage Directive EN 61010-1:95 +A1:97 Electromagnetic Compatibility EN 50081-1:94, EN 50081-2:96 EN 50082-1:99, EN 50082-2:97 Vibration 5 - 25 Hz, ±1,6mm

25 - 100 Hz, a = 4 g Shocks a = 200 m/s2

Dimensions and weight Dimensions 180x120x50mm Weight 800g

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

Current inputs Nominal input current (from CT) 5 A Load (CT output impedance) < 0,1 Ω CT input burden < 0,2 VA per phase (In=5A) Max. measured current from CT 11 A

Max. peak current from CT 150 A / 1s Current measurement tolerance 2% from the Nominal current

Max. continuous current 12 A

Voltage inputs IG-CU Nominal voltage 231/400 VAC


Maximal measured/allowed voltage (short time) 290/500 VAC Input resistance 6 MΩ phase to phase 6 MΩ phase to neutral Voltage measurement tolerance 2 % from the Nominal voltage Overvoltage class III / 2 (EN61010)

Voltage inputs IG-CU/600 Nominal voltage 277/480 VAC Maximal measured/allowed voltage (short time) 346/600 VAC Input resistance 6 MΩ phase to phase 6 MΩ phase to neutral Voltage measurement tolerance 2 % from the Nominal voltage Overvoltage class III / 2 (EN61010)

IG-MTU Primary voltage Ph-Ph 3x400 VAC / 50Hz (3x480 VAC / 60 Hz) Secondary voltage Ph-N 3x 230 V AC ( 3x277 VAC / 60 Hz) , 5 VA Mechanical dimensions: 155 x 95 x 60 mm , DIN rail (35 mm) mounted Primary/secondary Phase shift < 1° Operating temperature -30..+70oC

IG-MTU-C Primary voltage Ph-Ph 3x400 VAC / 50Hz (3x480 VAC / 60 Hz) Secondary voltage Ph-N 3x 230 V AC ( 3x277 VAC / 60 Hz) , 5 VA Mechanical dimensions: 155 x 95 x 60 mm , DIN rail (35 mm) mounted Primary/secondary Phase shift 6° Operating temperature -30..+70oC

Binary inputs and outputs Binary inputs Number of inputs 9 Input resistance 4,7 kΩ 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 2 Electric life cycle min 100.000 switching cycles Maximum current 12 A DC resistive load

Binary open collector outputs

Maximum current 0,5 A Maximum switching voltage 36 VDC

4 A DC inductive load Maximum switching voltage 36 VDC Minimum load 24 V / 0,1 A Insulation voltage 500 Veff

Number of outputs 7

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


Speed pick-up input Type of sensor magnetic pick-up (connection by shielded cable is recommended)

Frequency measurement tolerance 1,5 %

Speed 19.2kBd

Recommended internal converter:

Minimum input voltage 2 Vpk-pk (from 4 Hz to 4 kHz) Maximum input voltage 50 Veff Minimum measured frequency 4 Hz Maximum measured frequency 10 kHz (min. input voltage 6Vpk-pk)

RS232 interface Maximal distance 10m

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.

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 Basic setting: CAN bus mode = 32C 200m Basic setting: CAN bus mode = 8C 900m Speed 250kBd Nominal impedance 120Ω Cable type twisted pair (shielded) Following dynamic cable parameters are important especially for maximal 200 meters CAN bus length and 32 IG-COM units connected: Nominal Velocity of Propagation min. 75% (max. 4,4 ns/m) Wire crosscut min.0,25 mm2 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

• 3086A DeviceBus for Honeywell SDS


LAPP CABLE (see http://www.lappcable.com


• 3087A DeviceBus for Honeywell SDS • 3084A DeviceBus for Allen-Bradley DeviceNet

• 3105A Paired EIA Industrial RS485 cable

)

• Unitronic BUS CAN

Hint:

• Unitronic BUS DeviceNet Trunk Cable • Unitronic BUS DeviceNet Drop Cable

• Unitronic-FD BUS P CAN UL/CSA

When use double pair cable, use data pair for CAN bus and Power supply DC pair for Load sharing line connection.

http://www.belden.com/


IG-PCLSM Power supply: 8 – 36 V DC Consumption: 100 mA Binary inputs Number of inputs 4 Input resistance 4,7 kΩ Input range 0-36 VDC Switching voltage level for close contact indication 0-2 V

Open collector outputs

Speed governor output: ± 10 V DC , max.15 mA

Max voltage level for open contact indication 8-36 V

Number of outputs 4 Maximum current 0,5 A Maximum switching voltage 36 VDC

AVRi outputs: PWM to IG-AVRi LS output: max 10 V / 15 mA

IG-AVRi Power supply: 18V AC from IG-AVRi Trans/LV or IG-AVRi Trans/100 Absolutely maximum power supply range: 15 - 25 VAC or 20 - 35VDC Operating temperature -30..+70oC

AVRi output current: max 15 mA.

IG-AVRi Trans/LV

Absolute high limit: 277 VAC + 20%

Absolute high limit: 480 VAC + 20%

Secondary voltage: 18 V AC, 5 VA

IG-AVRi Trans/100

Operating temperature -30..+70oC

Inputs: +AVR, -AVR (two wires, PWM from IG-CU) Outputs: OUT1, OUT2 floating (potential free) voltage source. AVRi output voltage range: potentiometer adjustable from +- 1V to +-10V DC.

Mechanical dimensions: 96 x 27 x 43 mm , DIN rail (35 mm) mounted

Primary voltage 1: 230-277 VAC Absolute low limit: 230 VAC – 20%

Primary voltage 2: 400-480 VAC Absolute low limit: 400 VAC – 20%

Frequency: 50 - 60 Hz


Primary voltage: 100 – 120 VAC Absolute low limit: 100 VAC – 20% Absolute high limit: 120 VAC + 20% Frequency: 50 - 60 Hz Secondary voltage: 18 V AC

IG-IOM Voltage supply 8-36V DC Consumption 0,1A depend on supply voltage

Connection to IG-CU standard IOM cable 2 meters length, not galvanic separated Mechanical dimensions: 40 x 95 x 45 mm , DIN rail (35 mm) mounted



Number of inputs 4

Not electrically separated

Output range 0 to 20 mA ± 0,33 mA

IG-MU

Binary inputs Number of inputs 8 Input resistance 4,7 kΩ 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

Binary open collector outputs Number of outputs 8 Maximum current 0,5 A Maximum switching voltage 36 VDC

Analog inputs Not electrically separated

Resolution 10 bits Sensor resistance range 0 Ω-2,4 kΩ Resistance measurement tolerance 4 % ± 2 Ω out of measured value

Analog output

Number of outputs 1 Resolution 10 bits

Voltage supply 8-36V DC Consumption 0,1A depend on supply voltage Operating temperature -30..+70oC

Interface to modem or PC RS232, RS422, RS485 Mechanical dimensions: 40 x 95 x 45 mm , DIN rail (35 mm) mounted

Interface to controller CAN

IG-IB Voltage supply 8-36V DC

Interface to controller RS232 or CAN

IGS-PTM

Consumption 0,1A depend on supply voltage Operating temperature -30..+70oC Mechanical dimensions: 40 x 95 x 45 mm , DIN rail (35 mm) mounted

Interface to modem RS232 Interface to Ethernet RJ45

Voltage supply 8-36V DC Consumption 0,1A depend on supply voltage Operating temperature -30..+70oC Mechanical dimensions: 40 x 95 x 45 mm , DIN rail (35 mm) mounted Interface to controller CAN Binary inputs and outputs see IG-IOM Analog output see IG-IOM

Number of inputs 4

Analog inputs Not electrically separated


IGL-RA15

Resolution 10 bits Maximal resistance range 0 – 250 Ω Maximal voltage range 0 – 100 mV Maximal current range 0 – 20 mA Resistance measurement tolerance 1 % ± 2 Ω out of measured value Voltage measurement tolerance 1,5 % ± 1mV out of measured value Current measurement tolerance 2,5 % ±0,5mA out of measured value

Power supply Voltage supply 8-36V DC

Operating conditions

Horn output

Consumption 0,35-0,1A (+1A max horn output) Depend on supply voltage

Operating temperature -20..+70oC Storage temperature -30..+80oC Protection front panel IP65

Dimensions and weight Dimensions 180x120x55mm Weight 950g

Maximum current 1 A Maximum switching voltage 36 VDC

InteliGen Low Temperature modification LCD display limits controller operating temperature range to –20 oC - + 70 oC even if the other electronic components work in wider temperature range. Internal preheating foil is mounted in InteliGen LT to extend display operational temperature range. Preheating starts at temperature below 5 oC and preheating power depends on temperature and power supply voltage.

Technical data IG-CU, IL-CU Standard IG-LT, IL-LT

Operating temperature -20 oC..+70oC -30 oC..+70oC Storage temperature -30 oC..+80oC -30 oC..+80oC

Preheating foil increases controller current consumption

Preheating at ambient temperature Controller consumption at

No preheating 0 oC -15 oC -30 oC

12VDC 360 mA +50 mA +180 mA +300 mA 24VDC 230 mA +25 mA +85 mA +150 mA 36VDC 100 mA +20 mA +65 mA +100 mA

InteliGen LT work immediately after switch on at -30 oC and display becomes visible after a few minutes. Short-term voltage drops (e.g. during the engine cranking) do not affect the operation at all.


Order codes There are two types of preheating foil to cover full temperature and controller power supply range.

Order code Controller Nominal power supply IG-CU-LT/12 12 VDC IG-CU-LT/24

InteliGen 24 VDC

IL-CU-LT/12 12 VDC IL-CU-LT/24

InteliLite 24 VDC

IGMINTMINTIOM6.1

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Transcript of IGMINTMINTIOM6.1