comap ig combi 1.0

8/13/2019 Comap Ig Combi 1.0

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Comp act Control ler forStandby and Parallel Operating Gen-sets

InteliGen Mod ular Gen-set Con trol ler

Softw are branch Com bi Bin ary inpu ts selectable Single-Multiple

SSB , SPtM, MINT app licatio n(iG-CU + iG-COM + iG-PCLS M + iG-AVRi )

Software version 1.0, March 2003

Prague, Czech Republic

Copyright ! 2003 ComAp s.r.o.

Written by: Tomas Zahradnik, Ladislav Kadanik

ComAp s.r.o. Svetova 7, 180 00 Praha 8, Czech RepublicTel: +420-2-6631 6661, Fax: +420-2-6631 6647

WWW: http://www.comap.czE-mail:[email protected]


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

2

Table of Contents

Table of Contents .................................................................................................................................... 2 General guidelines................................................................................................................................... 4

What describes this manual? .............................................................................................................. 4 !! Warnings !! ....................................................................................................................................... 4 Text ..................................................................................................................................................... 5

General description ................................................................................................................................. 6 Description of the controller system (with all options)......................................................................... 6 What is in the package? ...................................................................................................................... 6

Terminals and Dimensions ...................................................................................................................... 7 IG-CU Terminals ................................................................................................................................. 7 Dimensions.......................................................................................................................................... 9 IG-IB Internet bridge.......................................................................................................................... 11

Recommended wirings .......................................................................................................................... 12 Single application SSB, SPtM (or SPM) ........................................................................................... 12 Manual fuse synchronizing................................................................................................................ 13 Multiple application MINT.................................................................................................................. 13 Multiple application MINT+ InteliMains ............................................................................................. 14 IG-MU Wiring..................................................................................................................................... 16

Getting started ....................................................................................................................................... 17 How to install ..................................................................................................................................... 17

Analog inputs..................................................................................................................................... 21 Configuration ..................................................................................................................................... 21 Hardware connection ........................................................................................................................ 22

Inputs and outputs ................................................................................................................................. 28 Binary inputs IG-CU default ........................................................................................................ 28 Binary inputs - IG-PCM - default ....................................................................................................... 28 Binary inputs list ............................................................................................................................. 28 Binary outputs IG-CU - default ....................................................................................................... 32 Binary outputs IG-PCM - default .................................................................................................... 32 Binary outputs list........................................................................................................................... 33

Analog inputs IG-CU ......................................................................................................................... 39 Setpoints ................................................................................................................................................ 40

Password........................................................................................................................................... 40 ProcCtrlSingle (S ) ................................................................................................................................ 41 ProcCtrlMulti (M) .................................................................................................................................. 42 Basic settings .................................................................................................................................... 43 Engine params .................................................................................................................................. 45 Engine protect ................................................................................................................................... 47 Gener protect .................................................................................................................................... 49

Auto Mains Fail.................................................................................................................................. 52 Pwr management (M)........................................................................................................................... 54 Sync/Ld ctrl........................................................................................................................................ 57 Volt/PF ctrl ......................................................................................................................................... 60

Act. calls/SMS ................................................................................................................................... 61 Load Shedding .................................................................................................................................. 62 Date and time .................................................................................................................................... 63 Sensor spec ...................................................................................................................................... 64

Sensor specification .............................................................................................................................. 65 Background of the sensor calibration................................................................................................ 65 Default sensor settings...................................................................................................................... 65

Operator Interface ................................................................................................................................. 66 Pushbuttons and LEDs ..................................................................................................................... 66

How to select the gen-set mode?...................................................................................................... 67

When to use button GCB ON/OFF? ................................................................................................. 67 Display menus................................................................................................................................... 67


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How to view measured data?............................................................................................................ 67 How to view and edit set points?....................................................................................................... 67 How to handle the HISTORY menu? ................................................................................................ 68 How to find active alarms?................................................................................................................ 68 MEASUREMENT screens description .............................................................................................. 68 Chart guide to menus and pushbuttons operation ........................................................................... 71

Function description .............................................................................................................................. 72 OFF mode ......................................................................................................................................... 72 MAN mode ........................................................................................................................................ 72

AUT mode ......................................................................................................................................... 72 Manual fuse synchronizing................................................................................................................ 73 Two setpoint set switch ..................................................................................................................... 73 SSB SPtM switch ........................................................................................................................... 73 Baseload change by Binary inputs.................................................................................................... 73 Single / Multiple application switch.................................................................................................... 74 Load surge protection ....................................................................................................................... 74 Load shedding................................................................................................................................... 74

Alarm management ............................................................................................................................... 76 Warning ............................................................................................................................................. 76

Unload ............................................................................................................................................... 76 Slow stop........................................................................................................................................... 76 Shut down ......................................................................................................................................... 77 Voltage phase sequence detection ................................................................................................... 77

Setpoint replication management .......................................................................................................... 80 How to adjust setpoints ..................................................................................................................... 80 Setpoints consistency ....................................................................................................................... 80

Gen-set operation states ....................................................................................................................... 81 Start-stop sequence .......................................................................................................................... 81 Unsuccessful start ............................................................................................................................. 82

Remote control and data logging .......................................................................................................... 83 Direct connection to the PC .............................................................................................................. 83 PC software - WinEdit ....................................................................................................................... 83

History file.......................................................................................................................................... 83 Remote and mobile communication ...................................................................................................... 87

Modbus protocol................................................................................................................................ 87 Recommended ISDN modem ........................................................................................................... 87 Recommended GSM modem............................................................................................................ 87 Mobile SIM card setting..................................................................................................................... 88 SMS message format........................................................................................................................ 88

Active SMS message ........................................................................................................................ 92 IG-IB Internet communication ........................................................................................................... 93

Value and setpoints codes .................................................................................................................... 94 Technical data ....................................................................................................................................... 99

Power supply..................................................................................................................................... 99 Operating conditions ......................................................................................................................... 99

Dimensions and weight ..................................................................................................................... 99 Bus and generator ............................................................................................................................. 99 IG-MTU............................................................................................................................................ 100 Binary inputs and outputs................................................................................................................ 100

Analog inputs................................................................................................................................... 100 Speed pick-up input ........................................................................................................................ 100 CAN bus interface ........................................................................................................................... 101 IG-PCLSM ....................................................................................................................................... 101 IG-AVRi ........................................................................................................................................... 102 IG-MU.............................................................................................................................................. 102 IG-IB ................................................................................................................................................ 102


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4

General guidelines

What descr ibes th is manual?This manual describes IG Combi software configuration, which was designed especially for rentalgensets. IG Combi software is based on standard IG software version 5.5.There are available two setpoint sets and three Application modes selectable by Binary inputs withoutsoftware download.

IG-Combi functions

Selection between two Nominal setpoints sets (e.g. 230/1500/50Hz and 277/1800/60Hz) by Binaryinput.

Set No.1 Set No.2Nominal voltage 1

Nominal RPM 1Nominal frequency 1

Nominal voltage 2

Nominal RPM 2Nominal frequency 2

VAC Ph-N

RPMHz

Genset automatic Mains Fail start disabling by setpoint. Switch between SSB and SPtM Application mode by Binary input. Increase and decrease Baseload value in Parallel to mains by Binary inputs. Manual fuse synchronizing function (MCB). Change from Single (SPtM) to Multiple (MINT) Application mode by Binary input.

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

What is the purpose of the manual?This manual provides general information how to install and operate InteliGen controller.This manual is dedicated for

Operators of gen-setsGen-set control panel buildersFor everybody who is concerned with installation, operation and maintenance of the gen-set

!! Warnings !!

Remote controlInteliGen controller can be remotely controlled. In case of the work on the gen-set check, that nobodycan remotely start the engine.To be sure:

Disconnect remote control via RS232 / CAN lineDisconnect input REMOTE START/STOP

orDisconnect output STARTER and outputs GCB CLOSE/OPEN and MCB CLOSE/OPEN

Because of large variety of InteliGen parameters settings, it is not possible to describe anycombination. Some of InteliGen functions are subject of changes depend on SW version.The data in this manual only describes the product and are not warranty of performance orcharacteristic.


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TextPAGE (Capital letters in the frame) buttons on the front panelBreak Return (Italic) set pointsGenerator protections (Bold) Set point groupREMOTE START/STOP (Capital letters) binary inputs and outputs

Inputs and setpoints marked (M) have meaning in Multiple applications only.Inputs and setpoints marked (S) have meaning in Single application only.

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

WARNING VERY IMPORTANT !!!Be aware that the controller can change Binary outputs states during and aftersoftware reprogramming (before is finished proper configuration and Setpoints

setting) !!!

Switch InteliGen to MAN mode and disconnect the Binary outputs Starter and Fuel toavoid unexpected automatic start of genset and GCB closing .

!!! CAUTION !!!Dangerous voltageIn no case touch the terminals for voltage and current measurement!

Always connect grounding terminals!In any case do not disconnect InteliGen CT terminals !

Adjust set points All parameters are preadjusted to their typical values. But the set points in the Basic settings settingsgroup !!must!! be adjusted before the first startup of the gen-set.

!!! WRONG ADJUSTMENT OF BASIC PARAMETERSCAN DESTROY THE GEN-SET !!!

The following instructions are for qualified personnel only. To avoid personal injury donot perform any action not specified in this User guide !!!


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General description

Descr ipt ion of th e control ler sys tem (wi th a l l opt ions)InteliGen iG-CU is a comprehensive AMF-controller for single and multiple generating sets operatingin stand-by or parallel modes. A modular construction allows upgrades to different levels of complexityin order to provide best solutions for various customer applications. Optional synchronizer,isochronous load sharer, Mains and Generator protections allows total integrated solution for Gen-setsin stand-by and parallel modes with multiple engine support.

InteliGen controllers are equipped with a powerful graphic display showing icons, symbols andbar-graphs for intuitive operation, which sets, together with high functionality, new standards in Gen-set controls.

InteliGen automatically starts the Gen-sets, closes the Gen-set C.B. when all conditions aremet, 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. Forwardand reverse synchronizing, Mains protection including load surge, load and power factor control, earthfault protection are the major functions provided. Interfacing to foreign synchronizers and load sharersis supported.

The key feature of InteliGen is its easy-to-use operation and installation. Predefinedconfigurations for typical applications are available as well as user-defined configurations for specialapplications.

What is in the package? Accessories Description Optional / ObligatoryIG-CU InteliGen central unit Obligatory

IG-PCLSM InteliGen power control and loadsharing module Obligatory

IG-MTU InteliGen voltage transformer unitto separate mains and generatorvoltage measurement

Optional

IG-AVRI InteliGen AVR interface OptionalIG-AVRi-TRANS InteliGen voltage transformer for

supplying AVRi moduleOptional

IG-COM InteliGen communication unit OptionalIG-MU InteliGen Modem Unit OptionalIG-IB Internet bridge Optional


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Terminals and Dimensions

IG-CU Term inals

RPM Grounding Terminal

Grounding Terminal

BINARY INPUTSGENERATORCURRENT

0 - 5 A

GENERATORVOLTAGE

3 x 230 / 400 V

In(Im L3)

CURRENT

ANALOG INPUTS BINARY OUTPUTSRPM

IG-PCLSM Terminals

i G - P

C L S M

SerialNo.

BI10

BI11

BI12

BI13

BINARYINPUTS

BO10

BO11

BO12

BO13

BINARYOUTPUTS

POWER8 - 36 V DC

+ -

LOADSHARING

Shield

LSM-

LSM+

AVRi

AVRi+

AVRi-

VoutR

SPEEDGOVERNOR

GND

Vout


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IG-AVRi Terminals

IG-COM Terminals

EXTENSION MODULE

iG-COM Serial No.

CAN

H

LCOM

CAN

H

LCOM

IG-MU Terminals

P1 P2

P3

P4


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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")

2

1

123(4,8")

~ 130 (5,1")

130(5,1")

113(4,4")

2

1

1

2

Cutoutfor InteliGen

113 x 175 mm(4.4 x 6,9)

RS 232 CableIOM Cable IG-AVRi, IG-AVRi TRANS

Secondary terminals0 x 18VAC

230/400 V

43 (1,7) 43 (1,7)

3 6 ( 1

, 4 )

18 V

iG-AVRiTRANS

Primary terminals0230480 VAC


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There are two types of AVRi available

Primary voltage Secondary voltage

230 and 400 VAC 18 VAC277 VAC 18 VAC

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)

9 6 m m

( 3

, 8 )

IG-MU unit is DIN railmount (35mm)

IG-MTU

60 (2,36")

9 5 ( 3

, 7 4 " )

N L1 L2 L3

iG-MTU

Serial No.

LB 1

155(6,10")


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IG-IB Intern et bridg e

95 mm(3,7)

43 mm(1,7)

9 6 m m

( 3

, 8 )

ETHERNETRJ 45

M O D E M

/ I B C O N F I G

I G - C

U / D O N G L E

LB 4

POWER 8 - 36 V DCCOM LH CAN

1 2

3 4 5 6


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Recommended wirings

Single app licat ion SSB , SPtM (or SPM)

MCB

LOAD

MAINSGCB

G1

Vg

33

Ig

Engine

1

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

I m 3

Emergency stop S t a r t e r

F u e

l

S p e e d g o v e r n o r

A V R i

G C B f e e d b a c

k

G C B c l o s e / o p e n

M C B f e e d b a c

k

M C B c l o s e / o p e n

R P M

3

V m /

V b Sys start/stop

Nominal switch

Synchro EnableRevSync Enable

BINARY INPUTS

BaseLoad IncBaseLoad Dec

NN

SSB, SPTMBinary input Nominal switch selects between two setpoints sets ( Nominal voltage , Nominal RPM ,Nominal freq ).Single application mode is active when Binary input: MultipleEnable is not configured or opened.Binary input: Synchro Enable enables GCB synchronizing - selects between SSB (when opened) and

SPtM (when closed) Application mode. Change of this binary input is accepted only in OFF mode.Binary input: RevSync Enable enables reverse (MCB) synchronizing.Binary inputs: BaseLoad Inc and BaseLoad Dec inc/decreases ActReqPower (Active requiredgenerator power value) that is in principle Baseload value. ActReqPower is visible on IG screen.Speed of Baseload change is adjusted by ProcCtrlSingle : BaseloadChange.

SPMBinary input MCB feedback must be opened or not configuredSetpoint AutoMainsFail: MF StartEnable = DISABLEDMains Voltage measuring terminals must be connected to ground.


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Manual fuse synchroniz ing

Manualfuse switch

LOAD

MAINSGCB

G1

Vg

33

Ig

Engine

1

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

I m 3 Emergency stop

S t a r t e r

F u e l


A V R i

G C B f e e d

b a c k


M C B f e e d

b a c k

R P M

3

V m

/ V b Sys start/stop

Nominal switch

Synchro EnableRevSync Enable

BINARY INPUTS

3

In synchronism

BINARY OUTPUT

NN

Manual

Sync/Load ctrl : ManualFuseSync = ENABLED

Important !!!

Fulfillment synchronization conditions are indicated by Binary output In synchronism.Manual fuse switches can be closed only when Binary output: In synchronism is closed!!!

There is no timeout for fuse switch closing ( Sync/Load ctrl : Sync timeout is not active).Binary input: MCB feedback can be closed after all Manual fuse switches are closed.MCB feedback activates Load control function.

Multip le applic at ion MINT

BUS GCB1G1

Vg

33

Ig

Engine

IG-CU Combi+ IG-PCLSM

+ IG-COM


F u e l


A V R i

G C B f e e d

b a c k


M C B f e e d

b a c k

R P M

V m

/ V b

Sys start/stop

Nominal switch

Synchro Enable

BINARY INPUTS

3

LOAD

C A N b u s

B U S

L S l i n e

To another gensets

MGCB

MultipleEnable


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

Multip le applicat ion MINT+ Intel iMains

BUS GCB1G1

Vg

33

Ig

Engine

IG-CU Combi+ IG-PCLSM

+ IG-COM


F u e l


A V R i

G C B f e e d

b a c k

G C B

c l o s e / o p e n

M C B f e e d

b a c k

R P M

V m

/ V b

Sys start/stop

Nominal switch

Synchro Enable

BINARY INPUTS

3

LOAD

C A N b u s

B U S

L S l i n e

To another gensets

MultipleEnable

MCB

MAINS

3

I m

3

V m

M

C B f e e d

b a c k

M C B c l o s e / o p e n

InteliMains+IM-PCLSM

+IG-COM

MGCB

3

V b

CAN bus

M C B f e e d

b a c k

LS line

More application details see in InteliGen standard software V5.5 user guides:

IG-SSB-SSB+IOM-5.5.pdfIG-SPtM-SPtM+IOM-5.5.pdfIG-MINT-MINT+IOM-5.5.pdfIM-IM+IOM-5.0.pdfIG5.5-IS2.7-ApplicationGuide.pdf


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IG-PCLSM connection

- G P C L S M

i

S e r i a

l N o .

B I 1 0

B I 1 1

B I 1 2

B I 1 3

BINARYINPUTS

B O 1 0

B O 1 1

B O 1 2

B O 1 3

BINARYOUTPUTS

POWER8 - 36 V DC

+ -

LOADSHARING

S h i e l d

L S M -

L S M +

AVRi

A V R i +

A V R i -

V o u

t R

SPEEDGOVERNOR

G N D

V o u

t

L B 2

A U T O M

A T I C

V O L T A G E

R E G U L A T O R

O M G

O

L O A D S H A R I N G P A R A L L E L L I N E

- +

S P E E D

G O V E R

N O R

2 3 0 / 4 0 0 V

1 8 V A C

0 V DC

0 V DC

CONFIGURABLE

2 3 0 / 4 0 0 V

1 8 V

i G - A

V R i

T R A N S


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IG-MU Wiring

RS485 / RS 422 connection

B A

IG-MU

TxBTxARxBRxA

RS485

IG-MU

TxBTxARxBRxA

RS422

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

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

P1 P2

P3

P4

Jumpers position:P1 2-nd local bridgeP2 Modbus jumperP3 Boot jumperP4 Switch between RS232 and RS485/RS422


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Getting started

How to ins ta l lGeneralTo ensure proper function:

Use grounding terminals.Cables for binary inputs and analog inputs must not be placed along power cables.

Analog and binary inputs should use shielded cables, especially when length >3m.

Power supplyTo ensure proper function:

Use min. power supply cable 1,5mm 2 Power supply of IG-PCLSM module should be directly connected to IG-CU.

Maximum continuous DC power supply voltage is 36VDC. Absolute maximum peak power supplyvoltage is 39VCD. Controller has fast protection against peak pulse power disturbances on powersupply terminals. When is risk of overstep of standard controller supply conditions use externalprotection device.

Hint:Switchboard flash protection according standard regulation is expected !!!Max current of power minus terminal can be up to 4A (depends on binary outputs load).For 12VDC power supply, connect external capacitor and separating diode to support controllersupplying during cranking.

+

+

+

Battery

-

-

-

-iG-CU

iG-PC(LS)M

HUGELOADS

STARTER

T1A

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


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Binary output protectionsIn any case do not connect DC relays without protection diodes even if they are not connected directlyto controllers outputs.

+-

K1 K1K2 K2

24VDC+-

IG controller T1A

Fuse

Fuse

Battery

DC relays

Example of InteliGen controller protection

GroundingTo ensure proper function:

Use as short as possible cable to the grounding point on the switchboardUse cable min. 2,5mm 2 The - terminal of the battery has to be properly grounded

Magnetic pick-upTo ensure proper function:Use a shielded cable

As shortas possible


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+

Battery

-

iG-CU

GACSpeed Control Unit

ESD 5500

MAGNETICPICK-UP

CD

Signal

Signal

+

+-

-Power Supply

Power Supply

GND

RPM-IN

iS-CU

Be aware of interference signal from Speed governor when one speed pick-up is used.When some problems occur:

- Check ground connection from pick-up to controllers, eventually disconnect ground connection

to one of them,- Galvanically separate Inteligen RPM input using ComAp separation transformer RPM-ISO

(1:1)- use separate pick-up for Speed governor and InteliGen

Hint:Controller can detect RPM on no running gen-set when:

RPM is measured from the generator voltage (Gear teeth = 0) IG Generator voltage terminals are opened (e.g. due to opening of fuse disconnector)

No zero RPM causes controller Not ready state and engine start is blocked.

GENERATORL1L2L3

N

L1L2L3

N

MAINSVOLTAGE

GENERATORVOLTAGE

L 1

L 2 L

3

IG-CU SSB, SPtM

L 3

L 2

L 1 N

MCB GCBMAINS

LOAD

Earth fault protectionIt is not available in this software application.


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Voltage measurement

G

GENERATOR MAINSL3L2L1N L3L2L1

L1

L2

L3

N

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

Mains and gen-set neutral separationIf required mains and gen-set neutral separation (four pole breakers) IG-MTU have to be addedbetween mains and controller terminals.

IG MTUConnect two IG-MTU units for separation of generator and bus voltage from controller when is:a) 3wire mains/bus and generatorb) 4wire mains/bus and generator, separated neutral

T1 T3T2 T1 T3T2

L1

L3L2

L3

GENERATORL1 MAINS / BUS

L2

4 0 0 V

4 0 0 V

4 0 0 V

0 V

0 V

0 V

0 V

0 V

0 V

0 V

0 V 0

V

0 V

0 V

0 V

4 0 0 V

4 0 0 V

4 0 0 V

4 0 0 V

4 0 0 V

4 0 0 V

4 0 0 V

4 0 0 V

4 0 0 V

L 1

L 3

MAINS / BUSVOLTAGE

L 2

IG-CU

L 1

L 2

L 3

GENERATORVOLTAGE

N

IG-MTUIG-MTU


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Connect one IG-MTU unit for separation of generator and bus voltage from controller when is 3wiremains/bus and 4wire generator.

T1 T3T2

L1

L3L2

L3

GENERATORL1 MAINS / BUS

L2

4 0 0 V

4 0 0 V

4 0 0 V

0 V

0 V 0 V

0 V 0 V

0 V 4 0 0 V

4 0 0 V

4 0 0 V

L 1

L 3

MAINS / BUSVOLTAGE

L 2 L

1 L 2

L 3

GENERATORVOLTAGE

N

IG-MTU

NN

IG-CU

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

Configurat ionEach analog input AI1, AI2, AI3 can be configured by WinEdit software following way.

Analog input item WinEdit Possibility Analog input name Name Up to 14 ASCII charactersType of input Type Analog

BinaryTri-state

Analog measuring in specified range.Binary: open/close - threshold 750 .Three-state: open/close - threshold 750 , Failure 2400

Physical dimension Dim bar,%,C, Up to 3 ASCII charactersPolarity Inverted Open to activate

Close to activateValid only for binary and three-state inputsValid only for binary and three-state inputs

Alarm type Alarm type WarningShut down

Protection Anl Inp level1 is reachedProtection Anl Inp level 2 is reached

Alarm activity Alarmactivity All the timeEngine runningonly

Alarm is check condition

Sensor characteristic Sensor NoneCurve ACurve BCurve C

PT 1000NI 1000VDO TempVDO PressVDO Level

4-20mA/1004-20mA/ 60

unused analog inputUser curve AUser curve BUser curve C

IEC 751, range -20 to 120 CDIN 43760, range -20 to 120 CSee chapter sensor specification

external R=120 external R=120


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Active Active OverUnder

Alarm active when over Alarm active when under

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

Hardware conn ect ion

Connection of IG-CU analog inputs

IG-CU

A I 3

C O M

A I 1

A I 2

- P O W E R

3x RESISTIVESENSOR

Standard connection of three resistive sensorsto analog inputs AI1, AI2, AI3.

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

IG-CU

A I 3

C O M

A I 1

A I 2

- P O W E R

+24V3x 120 ohm

3x SENSOR4 - 20 mA

Three current output sensors connection toInteliGen.

External resistors 120 ohms each are

connected between minus power supplyterminal of IG-CU and AI1, AI2, AI3.

Current sensor connecting reduces the analoginput resolution by less than 50% againstresistive sensor.


IG-CU

A I 3

C O M

A I 1

A I 2

- P O W E R

+24V

1 2 0 o

h m

AI1 CUR REN T SE NS OR AI2 RES ISTIV E SE NS OR AI3 BINAR Y INPU T

Mixed connection of InteliGen analog inputs:

AI1 current sensor with external 120 ohms

resistor AI2 resistive sensor. AI3 binary input



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2x 470 ohms

IG-CU

A I 3

C O M

A I 1

A I 2

- P O W E R

AI1 RE SIST IVE SE NS OR AI2 BINA RY INPU T AI3 TH RE E ST AT E INPU T

Mixed connection of InteliGen analog inputs:

AI1 resistive sensor AI2 binary input AI3 three state input


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

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

Current output transducersIG-CU analog inputs are mainly designed for resistor sensors.In special case transducers to 4-20mA output can be used for various measuring.

Some types of transducers are not suitable for connection to InteliGen analog inputs because ofinfluencing by InteliGen analog input. In this case change default 4-20mA/60 or 4-20mA/100 sensorcharacteristic to get proper reading.

Binary inputOpen, close state are detected, threshold level is 750 .

Three state inputOpen, close and failure state are detected. Threshold level is 750 , failure is detected when circuitresistance is 2400 .

Unused analog inputsConfigure Sensor = Unused input

Example of analog input configurationConfigure Analog input 1 for Oil press measuring in Bar, VDO oil pressure sensor, range 0 to 10.0bars. Alarm protection level set to 3.5 bars, shut down level 1.2 bars.Start WinEdit and select Controller - Software configuration Modify - Analog inputs.There are following configuration items. Set configuration for selected analog input (rows 1 to 7):

Name : Change the name of analog input; maximal length is 11 charactersSet to: Oil Press

Abbr : Abbreviation is used in history record for column labeling; maximal length is 4characters.Set to: OilP

Type : selection between Analog, Binary Tri-state input.Analog resistor sensor is connected to Analog input.


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Binary open/close contact is connected between Analog input and COM terminal of Analog inputs. Analog input detects only open/close state.Tri-state open/close contact is connected parallel to one of two serial resistors between Analoginput and COM terminal of Analog inputs.Set to: Analog

Dim : Physical dimension of measured value ( C, %, Bar, ..) Maximal dimension length is threecharacters.Set to: Bar

Active : setting of polarity:over alarm is active when analog input value is over the Analog input limits (setpoints Anl Inp level1 or Anl Inp level2 in Engine protection group).under - alarm is active when analog input value is under the Analog input limits.Set to: under (alarm is active when Oil pressure goes low)

Inverted : selection of polarity only when analog input is configured as Binary or Tri-state. When isanalog input configured as analog this setting has no sense.Open to activate polarity of binary or tri-state input

Close to activate polarity of binary or tri-state input

Alarm type : selection between different types of alarms.Sensor fail sensor value is 20% out of selected sensor range. Use when analog input is used formeasuring only, not for protections.Warning Anl Inp level1 is warning level, Anl Inp level2 is not usedWrn+Shutdown - Anl Inp level1 is warning, Anl Inp level 2 is shutdown levelWrn+Slowstop - Anl Inp level1 is warning, Anl Inp level 2 is slowstop levelWrn+Unload - Anl Inp level1 is warning, Anl Inp level 2 is unload levelSet to: Wrn+Shutdown (lubrication is necessary for engine health)

Alarm active : selection betweenAll the time no limited alarm detection

Engine running only alarm detection is activated Engine protections : Protection del [s] after theBO starter is off, (RPM reached Start RPM).

Sensor : selection of sensor characteristicUnused input - when Analog input is not used. On the InteliGen screen is displayed #### value,no alarm is detected.Curve A User curve A is defined in WInEdit (default VDO temperature sensor)Curve B User curve B is defined in WInEdit (default VDO pressure sensor)Curve C User curve C is defined in WInEdit (default VDO fuel level sensor)Pt1000 PT1000 sensor characteristic according to IEC 751Ni1000 Ni1000 sensor characteristic according to DIN 43 760VDO temp VDO temperature sensorVDO press VDO pressure sensorVDO level VDO level sensor4-20mA/60 current output sensor characteristic requires external resistor 120 ohms between

Analog input and COM terminal of Analog inputs4-20mA/100 current output sensor characteristic requires external resistor 120 ohms between

Analog input and COM terminal of Analog inputsSet to: VDO press

Decimals : setting of number of decimal points of measured value.0 - e.g. 360 kPa, 100%, 50 C1 e.g. 3.6 Bar2- e.g. 0.36 MPa3 - e.g. 0.366 MPaSet to: 1


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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 . Namesof these setpoints are fix defined do not depend on the name of measured value which can bechanged.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

+ -Power Supply

T1A

24VDC+ -

Battery

Binary outputs

iG-CU

LOAD

+ -Power Supply

24VDC+ -

BatteryT1A

IG-COM Wiring


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EXTENSION MODULE

Serial No.

CAN

H

LCOM

CAN

H

LCOM

EXTENSION MODULE

Serial No.

CAN

H

LCOM

CAN

H

LCOM

EXTENSION MODULE

Serial No.

CAN

H

LCOM

CAN

H

LCOM

Hint:For CAN cables details see chapter Technical data Communication interface.

CAN bus have to be to line connected, both end by the 120 ohm resistor terminated.For longer distances is recommended to connect COM terminals between iG-COM units.

CAN bus connection

CAN bus is internaly connected

C A N L

iG-COM

0 C A N

C A N L

C A N L

0 C A N

120 ohm terminator

Twisted pair data cable

0 C A N

C A N H

C A N H

0 C A N

C A N H

iG-COM

C A N H

C A N L

CAN bus is internaly connected

CAN bus to next unit

120

120


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EXTENSIONMODULE

SerialNo.

CAN

HLCOM

C A N

H LCOM

EXTENSIONMODULE

SerialNo.

CAN

HLCOM

CAN

H LCOM

RS232

RS232

RS422

RS 422CAN CAN

--

iG-MU

SerialNo.

L L

COM

COMH H

TxB

TxA

RxB

RxA

POWER8-36V DC

CAN bus


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Inputs and outputsHint:

Any Binary input or output can be configured to any IG-CU controller terminal or changed to differentfunction by WinEdit software. There is fix 1 sec delay when any binary input is configured asprotection.

B in ary in pu ts IG-CU def aul t

BI1 GCB feedback

BI2 MCB feedback

BI3 Sys start/stop

BI4 Emergency stopBI5 MultipleEnable

BI6 Access lock

BI7 NominalSwitch

BI8 Alarm 8If the input is closed, selected alarm type is activated. Default configuration Close to activate, Shutdown, Engine running only.

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

Bin ary inp uts - IG-PCM - default

BI1 Synchro Enable

BI2 RevSync Enable

BI3 BaseLoad Inc

BI4 BaseLoad Dec

B inary i np uts listInputs marked (M) have meaning in multiple application only.Inputs marked (S ) have meaning in single application only.

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

Name 14 characters ASCII string

Close to activateInvertedOpen to activate


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WarningSlow stopShut downUnloading

Alarm type

HistoryRecord No warning, All the time Alarm activeEngine running only

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

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

MCB feedbackUse this input for indication, whether the mains circuit breaker is open or closed.

This input indicates, whether the gen-set operates in parallel to mains (MCB FEEDBACK is closed) orisolated (MCB FEEDBACK is open).

Emergency stopIf the input is active shut down is immediately activated.

SprinklerIf the input is closed all alarms are disabled except the binary input EMERGENCY STOP and

"engine over speed protection".

all IG alarms are detected, enabled Active calls remains active,

IG front panel gen-set RED LED blinks or lights, alarm is recorded on the IG alarm list screen, alarm is recorded into history, BUT gen-set remains running.

Access lockIf the input is closed, no setpoints can be adjusted from controller front panel and gen-set mode (OFF-MAN-AUT) cannot be changed.Hint:

Access lock does not protect setpoints and mode changing from WinEdit. To avoid unqualifiedchanges the selected setpoints can be password protected.

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

Sys start/stopSingle parallel application (SPtM):

If the input closes, InteliGen starts the engine (in AUT mode only). Genset isrunning in parallel (base load power level) or island (depends on Mains state).If the input opens and gen-set runs in island, gen-set keeps running until mainsrecovers. After mains recovery InteliGen opens GCB, cools and stops theengine.

Single application (SSB): no action .Multiple Application: If the input closes InteliGen starts the Pwr management (in AUT mode only).


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

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

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

Load reserve 4 (M) If the input LOAD RESERVE 4 is closed the setpoint LoadRes strt 4, LoadRes stp 4 will be selected.Hint:When more than one Load reserve binary inputs are closed, the higher number has higher priority.

All controllers operating in Power management group have to select the same Load reserves.

MinRun power 1 (M) (Minimal running power 1)

MinRun power 2 (M) (Minimal running power 2)

MinRun power 3 (M) (Minimal running power 3)When binary input MinRun power 1 or 2 or 3 is closed the corresponding setpoints MinRun power 1 or2 or 3 is selected. Higher index has higher priority when more binary inputs are closed. When notconfigured or not active, minimal running power is 0.

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

PrioritySwtch1 (M) (Priority switch 1)



PrioritySwtch4 (M) (Priority switch 4)Binary inputs for external genset priority selection. Priority selection is important in Powermanagement. Higher Priority gensets starts sooner.The range from of Priority setting is 1 to 15.

Priority value Prior i ty 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15PrioritySwtch1 0 or nc 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1PrioritySwtch2 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 1PrioritySwtch4 0 or nc 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1Hint:Priority value is defined by setpoint Power management : Priority when all Priority switches areopened 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 sheddingwhen

Auto Ld recon = DISABLED andGenerator actual load is under Ld Recon level .

Ld recon del is not important in manual reconnection by binary input.Principle of Load shedding is described in the chapter Function description Load shedding .


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Start buttonBinary input has the same function as Start button on the InteliGen front panel. It is active in MANmode only.

Stop button

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

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

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

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

mode only.

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

MultipleEnableWhen binary input is closed, multiple application is selected and InteliGen behave as in MINTapplication.When binary input is opened (or not configured), single application is selected and InteliGen behaveas in SPtM or SSB application.

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

NominalSwitchThis binary input select one of the nominal setpoints from Basic settings group.

NominalSwitch Selected setpoints from Basic set t ings Open (or not configured) Nomin voltage 1, Nominal PRM 1, Nominal freq 1Closed Nomin voltage 2, Nominal PRM 2, Nominal freq 2

Synchro Enable (S ) When closed, enables forward Synchronization (of GCB) and SPtM behavior of InteliGen is selectedwhen MultipleEnable is opened.When opens, disable forward Synchronization and SSB behavior of InteliGen is selected whenMultipleEnable is opened.

Binary input SSB SPtM MINTSynchro Enable Opened Closed ClosedReverseSync Enable Opened Opened or

ClosedX

Multiple Enable Opened Opened ClosedX = no influence

Hint:

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


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

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

BaseLoad Dec (S ) When closed, actual required power is decreased by BaseLoadChange percent of Nominal power persecond.Hint:Baseload change is available in SPtM - parallel to the mains only - Binary input MultipleEnable =OPENED.Process control Baseload setpoint does not change

Actual required power is displayed on the first InteliGens screen in brackets or in WinEdit.

B inary ou tpu ts IG-CU - defaultIG-CU outputs are configurable see binary outputs list.

BO1 Starter (relay output)

BO2 Fuel solenoid (relay output)

BO3 GCB close/open

BO4 MCB close/open

BO5 AlarmBO6 Horn

BO7 Pre-start

BO8 In synchronism

BO9 Cooling pump

B inary ou tpu ts IG-PCM - defaultIG-PCLSM outputs are configurable see binary outputs extension.

BO10 AVR up

BO11 AVR down

BO12 SPEED up

BO13 SPEED down


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Bin ary ou tpu ts l is t

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

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

Pre-startThe 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 pumpThe output closes when gen-set starts and opens AfterCoolTime delayed after stop the engine.

Prelubr pumpThe output periodically closes / opens Prelubrication time / PrelubricationPause .

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

GCB close/openThe output controls the generator circuit breaker.

Hint:Supposed time to close (reaction time) of GCB is 0,1 sec.

GCB ON coilPulse output for GCB closing.

GCB OFF coilPulse output for GCB opening.

GCB UV coilGCB undervoltage coil.

MCB close/openThe output controls the mains circuit breaker.Hint:Supposed time to closed (reaction time) of MCB is 0,1 sec.


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MCB ON coilPulse output for MCB closing.

MCB OFF coilPulse output for MCB opening.

MCB UV coilMCB undervoltage coil.

GCB ON coil

GCB OFF coil

GCB UV coil

GCB close/open

GCB closing GCB opening

2 s 2 s

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

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

P BNom + P RNom > P Akt + Reserve

P BNom Sum of the nominal power of all gen-sets on the busP RNom Sum of the nominal power of all gen-sets ready to take the load i.e. starting, cooling or

ready to start)P Akt System loadReserve 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/STOPIs ready to take the load when is in AUT mode and no shut down alarm is active and accepted,Setpoint Power management = ENABLED or EXTERNAL, BI Sys start/stop is closed.Use this output as an alarm indication.

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

P BNom > P Akt + Reserve

P BNom Sum of the nominal power of all gen-sets on the busP Akt System loadReserve 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/STOPGen-set has to be in AUT modeSetpoint Power management has to be ENABLED or EXTERNAL.


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Syst res1 OK (M) The output closes when Load reserve 1 is achieved. It is not important which reserve is selected.




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

AlarmThe 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.

HornThe 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 loadThe output closes if the gen-set is fully loaded and there is no reserve in engine power. The outputcan be used for load shedding. The output closes when the load >= 0.9 * Nomin power for more than3sec. The output opens when the load < 0.9 * Nomin power.

StandBy ready (S ) The output is closed if following conditions are fulfilled:

Gen-set is not running and InteliGen is in AUT mode No Shut down or Slow stop alarm is active

Ready to runThe output is closed if following conditions are fulfilled:

Gen-set is not running and No Shut down or Slow stop alarm is active Controller is not in OFF mode


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

Unload

The output is closed during unloading of genset.

SynchronizeThe output is closed during genset synchronizing and opens when GCB is closed.

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

Vg failThe 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 failOutput closes if the generator over/under frequency alarm activates.The output opens, if


Vm failThe output closes if the mains over/under voltage alarm or voltage asymmetry alarm activates.The output opens, if


fm failOutput closes if the mains over/under frequency alarm activates.The output opens, if


Overload

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

Reverse powerOutput 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

alarm is not active and


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FAULT RESET is pressed

UnderspeedOutput closes if the gen-set underspeed alarm activates.The output opens, if


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


OvercurrentOutput closes if the generator

IDMT over current or

current unbalance or short current alarm activates.The output opens, if

Alarm is not active and FAULT RESET is pressed

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


Common WrnOutput closes when any warning alarm appears.The output opens, if

No warning alarm is active and FAULT RESET is pressed

Common StpOutput closes when any slow stop alarm appears.The output opens, if

No slow stop alarm is active and FAULT RESET is pressed

Common SdOutput closes when any shut-down alarm appears.The output opens, if

No sd alarm is active and FAULT RESET is pressed

Common UnlOutput closes when any unload alarm appears.The output opens, if

No unload alarm is active and FAULT RESET is pressed

Common FlsOutput closes when any sensor fail alarm appears.


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

AVR up

AVR downBinary outputs for Volt / PF control by motorized potentiometer. Outputs should be used when iG-

AVRi module is not connected.

SPEED up

SPEED downBinary outputs for Sync / Load control by motorized potentiometer. Minimal pulse duration is 0,15 sec.Maximal pulse duration is 10,0 sec.Hint:The response of SPEED UP and SPEED DOWN binary outputs is very fast and frequent to makecontrol process more precise. It is supposed direct connection to electronic speed governor withoutmechanical elements like relays, motorized potentiometer or servo.

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

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

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

AIn 1

AIn 2AIn 3Output closes when

IG-CU Analog input 1, 2, 3 Level1 or Level2 (e.g. warning or shutdown) alarm appears.The output opens, if

Alarm is not active and FAULT RESET is pressed

Load shedd 1 (2, 3)Output closes when gen-set power exceeds Ld shed level limit for Ld shed del time.Output opens automatically when Auto Ld 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 solenoidOutput closes when is active stop command.Output activates as well when engine moves spontaneously, not from starter sequence.Output is closed for minimal 40 seconds in any case and minimal 10 sec after RPM=0.

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

CoolingOutput closes when gen-set is in Cooling state.


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

An alog inp uts IG-CUThree analog inputs for resistive sensor 0 to 2400 measuring. Each analog input can be adjustedto convert resistor measured value to displayed value in bar, C or %. Warning and shut-down limitsare adjusted in Engine protection group.

AI1Oil pressure analog input. Default range 0 to 10.0 bars.

AI2Water temperature analog input. Default range 0 to 100 C.

AI3Fuel level analog input. Default range 0 to 100 %.


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SetpointsPasswordThere are three levels of password protection.0. User level allows change of not protected setpoints only1. Operator level allows change of setpoints protected by Operator level2. Master level allows change of setpoints protected by Operator and Master level3. Supervisor highest level allows all setpoints or configuration changes, firmware upgrade.Hint:The asterisk mark * appears before setpoint name (on controller screen) when is setpoint passwordprotected.

Asterisk mark is removed only when password is set from controller front panel. Asterisk mark is still visible on controller screen even if the password is set from WinEdit.

There are separate accesses to controller from Front panel, from WinEdit, from Modem or from

Internet. Setpoints which are opened e.g. from WinEdit are still closed from Front panel.Setpoints opened from front panel are automatically closed 15 minutes after the last key touch orwhen wrong password is set.

It is possible to protect remote Start, Stop, GCB, MCB commands from WinEdit, MultiEdit as well. Thisthree level command protection can be configured from WinEdit.

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

ChangePassword 1Hint:

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


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


At first the old Password 3 has to be entered before the new Password 3 or Password 2 or Password1 can be changed.

Access code Can be changed from WinEdit software only. Has to be set before remote modem or SMS connection is opened. Can be up to 16 ASCII characters

At first the Password3 has to be entered before the new Access code can be changed.

Commands protectionCommands password protection protects following commands from WinEdit / MultiEdit direct, modemor GSM modem connection:

Start, Stop, Horn reset, Fault reset, GCB close/open, MCB close/open.Selected Command password level 0, 1, 2, 3 is valid for all commands. Selected level is in RED color.


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ProcCtr lSingle ( S )

Load control [BASELOAD, IMP/EXP]Control mode selection for parallel to mains operation.BASELOAD: gen-set is loaded at preadjusted level ( Base load ).

IMP/EXP: gen-set load is changed according to import/export value ( Import load, Import PF ).Setpoint is available in parallel to mains only.

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

Baseload [kW]Required gen-set load when Load control = BASELOAD.Step: 1 kWRange: 0 Nominal Power

BaseloadChange [% / s] Amount of required gen-set load change changed per second. Change is activated by binary inputsBaseLoad Inc/Dec per one second.Step: 1 % of Nominal PowerRange: 0 100%

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

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

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

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

PeakLevelStop [kW]Load power level when gen-set stops ( PeakAutStart = ENABLED). Genset stop is 5 sec delayed afterPeakLevelStop limit is reached.When gen-set is running the load power is calculated (no directly measured) from the differencebetween gen-set and mains power.

When e.g. gen-set actual power is 100 kW (Pg=+100) and gen-set exports to the mains 60 kW(Pm= - 60) load power is Pg + Pm=40 kW.When e.g. gen-set actual power is 100 kW (Pg=+100) and gen-set imports from the mains 60kW (Pm= + 60) load power is Pg + Pm=160 kW.


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Step: 1 kWRange: 0 3200 kW

Export limit [ENABLED, DISABLED]Protection against power export to the mains when is adjusted Load control = BASELOAD. Exportpower is limited to not exceed Import load value.ENABLED: When export power exceeds Import load value Load control is automatically switched

to IMP/EXP mode to keep Import load value.DISABLED: No protection is active.Hint:To protect genset against power export adjust ExportLimit = ENABLED and Import load = 0. Export limit function Outputs and Setpoints overview:

Process control :

Load ctrl PtM = BASELOAD

Export limit = ENABLED

Required gensetpower

Export limitation

Internal value

Export limit function behaviour:

Mains I/E

Load

Gen

0

Baseload

Load

Gen

Mains I/E+

-

Import

Export

Baseload

0

Baseload

+

-DISABLED

Import

Export

Baseload

ENABLED

ProcCtr lMul t i (M) 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.

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


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Step: 1Range: 0 +30000 kW

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

Basic se t t ings

Gen-set nameUser 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 generatorStep: 1kWRange: 1 3000 kW

Nomin current [A]It is current limit for generator IDMT over current and short current protection and means maximalcontinuous generator current. See Generator protections : 2Inom del, Ishort setpoints .Nominal current can be different from generator rated current value.Step: 1 ARange: 1 - 5000 A

!!! VERY IMPORTANT !!! Maximal input range of InteliGen and InteliSys current terminals is up to 11 amps. Over thisvalue is measured value limited, e.g. 15amps from CT is still measured as 11 amps!

Take care about CT selection. Not every 5Amps CT has the output range to 11 amps!

CT Ratio [/5A]Gen-set phases current transformers ratio.Step: 1 ARange: 1 5000 A / 5A

Im3 CT Ratio [/5A]Mains current transformer ratio for single phase Import / Export power and PF measuring. Singlephase power value is multiplied by three.Step: 1 ARange: 1 5000 A / 5AHint:Im3 has to be connect to mains L3 phase !!!Balanced mains power is expected.

Nomin voltage 1 [V]Nominal generator voltage (phase to neutral). Setpoint set 1 is selected when Binary inputNominalSwitch is opened .

Step: 1 VRange: 80 300 V


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Nominal RPM 1 [RPM]Nominal speed of the engineStep: 1 RPMRange: 100 4000 RPMFollowing table contains relation between Nominal frequency and Nominal RPM for different kind ofgenerators. Typical is four pole generator which has 50 Hz / 1500 RPM.

Generator poles 50 Hz 60 Hz2 3000 36004 1500 18006 1000 1200

Setpoint set 1 is selected when Binary input NominalSwitch is opened .

Nominal freq 1 [Hz]Nominal generator frequency (usually 50 or 60 Hz). Setpoint set 1 is selected when Binary inputNominalSwitch is opened . Step: 1HzRange: 45 65 Hz

Nomin voltage 2 [V]Nominal generator voltage (phase to neutral). Setpoint set 2 is selected when Binary inputNominalSwitch is closed . Step: 1 VRange: 80 300 V

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

Nominal freq 2 [Hz]Nominal generator frequency (usually 50 or 60 Hz). Setpoint set 2 is selected when Binary inputNominalSwitch is closed . Step: 1HzRange: 45 65 Hz

NominalSwitch = opened NominalSwitch = closedNomin voltage 1 Nomin voltage 2Nominal RPM 1 Nominal RPM 2

Nomin freq 1 Nomin freq 2

Hint:Binary input NominalSwitch is active all the time.

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

Mode IG [ OFF, MAN, AUT]

Equivalent to Controller mode changes by MODE or MODE buttons.Hint:Mode change can be separately password protected.


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Contr. adr (1 32) [-]Controller identification number. Each gen-set in the group has to have its own unique number. Defaultvalue is 1.Hint:When opening Direct or Modem connection to single InteliGen, the InteliGen Controller address has tobe set to 1 and must correspond to WinEdit communication setup setting.

RS232 mode [Standard / Modbus]Communication protocol switch.Standard: InteliGen (WinEdit/MultiEdit) communication protocol.Modbus: InteliGen Modbus protocol.Hint:Detail descriptions see in InteliGen Communication guide.

Engine param s

Prestart time [s]

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

Prelubr time [s]Time of closing of the PRELUBR PUMP binary output. Function is active all the time the engine is notrunning. Prelubrication is periodically repeated.Step: 1sRange: 0 600 s

Prelubr pause [min]

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

Start RPM [%]Firing speed. iG stops cranking. Underspeed limit when engine is running.Step: 1 % of nominal speedRange: 1 50 %

MaxCrank time [s]Maximum time limit of crankingStep: 1sRange: 1 60 sHint: The last cranking of unsucessfull start is 25% longer for gas ventilation when the Binary output FUELSOLENOID is configured to GAS.Cranking stops when RPM = 0 within 3 seconds. Continues CrankFail pause.

CrankFail pause [s]Pause between crank attempts


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Step: 1sRange: 1 60 s

Crank attempts [-]Max number of crank attemptsStep: 1Range: 1 - 10

Idle time [s]Idle time delay starts when RPM exceeds Start RPM . Start fail is detected when during Idle state RPMdecreases below 30.During the Idle time is Binary output IDLE/NOMINAL opened, when expires IDLE/NOMINAL outputcloses. Binary output IDLE/NOMINAL opens during Cooling period again.Step: 1 sRange: 1 300 s

Start RPM R P

M

BO Starter

BO IDLE/RATED

RPM = 30 R P M

Start Fail

Idle time Min stab timeElectric protectionsactive

Idle function Outputs and Setpoints overview:

Engine params :

Idle time [ s ]

Idle/Nominalbinary output

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

activated.

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

Cooling time [s]

Runtime of the unloaded gen-set to cool the engine before stop.Step: 1sRange: 0 3600 s


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AfterCoolTime [s]Runtime of engine after cooling pump. Binary output COOLING PUMP is closed when the enginestarts and closes Cooling time delayed after gen-set stops.Step: 1sRange: 0 3600 sHint:If the engine After cooling function is needed the binary output COOLING PUMP should beconfigured.

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 orCooled gen-set is stopped orin 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 orthe cooled gen-set is stopped orin pause between repeated starts.

The last cranking during unsuccessful start is 25% longer due to ventilation.

Example of FUEL SOLENOID output behavior during unsuccessful start.

Start RPM

BO Starter

RP M

BO Ignition

RPM < Start RPM

MaxCrank time

closed

on

opened

off

RPM > 30

RPM < 3 RPM =0

the last cranking

RPM > 30

RPM =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

Engine protect

NextServTime [h] Adjusted value is counted down. When zero is reached

Service alarm is detected Alarm list is recorded

Step: 1 hRange: 0 65535 h

Horn timeout [s]Max time limit of horn sounding. Set to zero if you want to leave the output HORN open.

Step: 1sRange: 0 600 s


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Overspeed [%]Threshold for over speed protectionStep: 1% of nominal RPMRange: 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: 1sRange: 0 300 s

Anl Inp1 level1 [ ]The first threshold level for ANALOG INPUT 1 alarm detection. Default setting is oil pressure warningin 0,1 bars.Step: 0,1 barRange: -100 10000

Anl Inp1 level2 [ ]The second threshold level for ANALOG INPUT 1 alarm detection. Default setting is oil pressure shutdown in 0,1 bars.Step: 0,1 barRange: -100 10000

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

Anl Inp2 level1 [ ]The first threshold level for ANALOG INPUT 2 alarm detection. Default setting is water temperaturewarning in C.Step: 1 CRange: -100 10000

Anl Inp2 level2 [ ]The second threshold level for ANALOG INPUT 2 alarm detection. Defaul

comap ig combi 1.0

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