igmintmintiom6.1

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

ComAp, spol. s r.o. Svtova 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 IGCU + 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 DCEX

TENS

ION

MODU

LES

iG-P

CM / i

G-PC

LSM

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 120 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 (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 nIknA

NA

LOG

INPU

TS

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

G2MASTER 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


G2MASTER 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


G2MASTER 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


G2MASTER 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


G2MASTER 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


G2MASTER 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


G2MASTER 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


G2MASTER 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 1.5mm2Power 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 controllers 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 0

V0V 0V

0V400V

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 0

V

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 k, 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 .Tri-state: open/close - threshold 750 , Failure 2400

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 0 to 2,4k. To ensure a proper function use shielded cables, especially for length over >3m.


Binary input Open, close state are detected, threshold level is 750 . Three state input Open, close and failure state are detected. Threshold level is 750 , failure is detected when circuit resistance is 2400 . 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

+ -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


EXTE

NS

ION

MO

DU

LE

Seri

al N

o.

CA

NHL

CO

M

CA

N

H LCOM

EXTE

NS

ION

MO

DU

LE

Seri

al N

o.

CA

NHL

CO

M

CA

N

H LCOM

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 120oh

m

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 IGCU + 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

H

igmintmintiom6.1

Documents

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