Comap Igs Nt Mint 2.2 Reference Guide

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Copyright 2005 ComAp s.r.o.

ComAp, spol. s r.o.Kundratka 2359/17, 180 00 Praha 8, Czech Republic

Tel: +420 266 012 111, Fax: +420 266 316 647Technical support hotline: +420 266 012 666

E-mail: [email protected], www.comap.cz

REFERENCE GUIDE

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

Inteli New Technology

Modular Gen-set ControllerMultiple Internal engines application SW configuration

MINT

IG-NT, IG-NTC, IG-EE, IG-EEC, IS-NT

Software version IGS-NT-2.2, December 2007


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Inteli NT MINT, SW Version 2.2, ComAp December 2007IGS-NT-MINT-2.2-Reference Guide.PDF

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Table of Contents

Table of Contents ...............................................................................................................................................2

General guidelines..............................................................................................................................................4What is described in this manual? .................................................................................................................4

General description ............................................................................................................................................6Description of the controller system (with all options)....................................................................................6Available related documentation....................................................................................................................6

Functions............................................................................................................................................................7OFF-MAN-AUT mode ....................................................................................................................................7Power management.......................................................................................................................................9Engine states................................................................................................................................................14PLC functions ...............................................................................................................................................20Multi language support.................................................................................................................................20ECU interface customizing...........................................................................................................................20

Protections and Alarm management................................................................................................................21

Gen-set operation states..................................................................................................................................30Inputs and Outputs ...........................................................................................................................................31

Virtual and physical modules .......................................................................................................................31Binary Inputs - Control .................................................................................................................................31Binary inputs Status information ...............................................................................................................39Binary outputs Engine control ...................................................................................................................40Binary outputs Breaker control..................................................................................................................41Binary outputs Control loops .....................................................................................................................42Binary outputs Status information.............................................................................................................43Binary outputs Fixed protection outputs....................................................................................................46Binary outputs Configurable prog. States .................................................................................................49Binary outputs Power management..........................................................................................................53Analog inputs................................................................................................................................................53

Analog outputs .............................................................................................................................................54Analog values...............................................................................................................................................54

Setpoints...........................................................................................................................................................56ProcessControl.............................................................................................................................................56Basic settings ...............................................................................................................................................61Comms settings ...........................................................................................................................................65Engine params.............................................................................................................................................67Engine protect ..............................................................................................................................................71Analog protect ..............................................................................................................................................76Gener protect ...............................................................................................................................................76Pwr management .........................................................................................................................................81Sync/Load ctrl...............................................................................................................................................86Sync/load control adjustment.......................................................................................................................90

Volt/PF ctrl....................................................................................................................................................92Volt/PF control adjustment...........................................................................................................................93

Force value...................................................................................................................................................94Load shedding..............................................................................................................................................96PLC settings .................................................................................................................................................96Timer settings...............................................................................................................................................97Act. calls/SMS..............................................................................................................................................97Date/Time.....................................................................................................................................................99

List of possible events ....................................................................................................................................100Controller configuration and monitoring .........................................................................................................101

Direct connection to the PC .......................................................................................................................101GenConfig functions...................................................................................................................................101InteliMonitor................................................................................................................................................102

Modbus protocol.........................................................................................................................................102Value and setpoint codes...........................................................................................................................102


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Technical data............................................................................................................................................102


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4

General guidelines

What is described in this manual?

This manual describes MINT software configuration. The software configuration is designed for multiplesets applications with internal load sharer and synchronizer.

What is the purpose of this manual?This manual provides general information on how to configure and operate the controller.This manual is intended for use by:

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

!! Warnings !!

Remote controlThe NT controller can be remotely controlled. In case 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 lineDisconnect input REMOTE START/STOP

orDisconnect output STARTER and output GCB CLOSE/OPEN

The controller contains a large number of configurable setpoints, because of this it is impossible to describeall of its functions. These are subject to change from SW version to SW version. This manual only describesthe product and is not guaranteed to be set for your application on arrival.

Text

ESC (Capital letters in the frame) buttons on the front panel

Break Return (Italic) set pointsGenerator protections (Bold) Set point groupREMOTE START/STOP (Capital letters) binary inputs and outputsCyan background Valid for IS-NT only

Conformity declaration

Following described machine complies with the appropriate basic safety and healthrequirement of the EC Low Voltage Directive No: 73/23 / EEC and ECElectromagnetic 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 updateat any time. ComAp does not assume any responsibility for its use unless otherwise expressly undertaken.


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WARNING VERY IMPORTANT !! !

Be aware that the binary outputs can change state during and after sof twarereprogramming (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 the controller to MAN mode and disconnect the Binary outputs Starter and Fuelto avoid unexpected automatic start of gen-set 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 CT terminals for any reason.

Adjust set points

All setpoints 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 inst ructions 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

Descript ion of the control ler system (with all options)

NT Family controllers are comprehensive AMF-controllers for single and multiple generating sets operatingin stand-by or parallel modes. A modular construction allow upgrades to different levels of complexity inorder to provide the best solution for various customer applications.NT Family controllers are equipped with a powerful graphic display showing icons, symbols and bar-graphsfor intuitive operation, which sets, together with high functionality, new standards in Gen-set controls.The controller automatically starts the gen-set, closes the Gen-set C.B. when all conditions are met, thenstops the engine on external signal or by pressing push buttons.Parallel to the Mains operation is a standard feature. Isolated parallel and Power Management Systemsupport are optional. Forward and reverse synchronizing, Generator protections, Mains protection includingvector shift, load and power factor control are the major functions provided. Interfacing to foreignsynchronizers and load sharers is supported. Regarding the measurement inputs, the controller providesTrue RMS method for voltage, current and power measurement.

The key feature of the controller is its easy-to-use operation and installation. Predefined configurations fortypical applications are available as well as user-defined configurations for special applications.

Available related documentation

PDF files Description

IGS-NT-2.2-Application guide.pdf Application guide for IG/IS-NT

IGS-NT-2.2-Installation guide.pdf Installation guide for IG/IS-NT

IGS-NT-2.2-Operator guide.pdf Operator guide for IG/IS-NT

InteliCommunicationGuide December07.pdf Communication guide for IG/IS-NT, ID and Il controllers


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Functions

OFF-MAN-AUT mode

OFF modeOutputs STARTER, GCB CLOSE/OPEN and FUEL SOLENOID are not energized.

Gen-set cannot be started. If START,STOP,GCB ON/OFF buttons are pressed the controller will not

respond.When the gen-set is running it is not possible to switch directly to OFF mode. First you have to stop theengine.

MAN mode

1) START - starts the gen-set.

2) GCB ON/OFF

If generator voltage is out of the limits (adjusted in the set point group Gener protect) controller doesnot respond to the GCB ON/OFF

a) controller closes GCB to dead bus.b) controller starts GCB synchronizing when bus voltage is OK and MCB is closed or when other

gen-set(s) provide healthy voltage to the bus. Closes the GCB when synchronized and staysrunning in parallel (island or mains parallel).

c) Unloads gen-set and opens the GCB if gen-set was running in parallel to the mains or to othergen-set(s).

3) STOP

a) When gen-set is running in parallel: transfers the load to the mains or to other gen-set(s), opensGCB, goes into cooling state and stops the engine.

b) When gen-set is running in single island (or in general there is no mains and no other gen-set(s)to transfer the load to): opens GCB, goes into cooling state and stops the engine.

c) When engine is running unloaded: activates cooling sequence and then stops the engine.d) During cooling state causes immediate engine stop.

Hint:The gen-set is permitted to run unloaded for unlimited time.Controller does not automatically start the gen-set when SYS START/STOP input is closed.Load control type in mains parallel depends on ProcessControl: #SysLdCtrlPtM= BASELOAD orLDSHARING setpoint.

SEM

In SEM mode, pressing of START or STOP buttons performs a predefined sequence:

1) START starts the engine, synchronizes and runs in parallel.

2) STOP softly unloads the gen-set, opens GCB, provides cooldown and stops the engine.

AUT mode1) All gen-sets necessary to cover selected LoadRes strt are started when binary input SYS START/STOP

is closed and Pwr managementis ENABLED. Power management can be based on kW, kVA or onrelative % reserve.a) 1 sec delayed when MCB FEEDBACK binary input is closed (mains parallel)b) delayed #SysAMFstrt delwhen MCB FEEDBACK binary input is opened start to island parallel

(multi AMF) situation2) The first gen-set closes the GCB to the dead bus, the rest are synchronized to the bus.3) When all necessary gen-sets are connected to the bus and LoadRes strt is achieved, SYST RES OK

output is closed. Output could be used to close the MGCB (Master GCB).4) Total load and power factor are shared between parallel operating gen-sets.5) Close input LOAD RESERVE 2 (or 3 or 4) and use setpoint LoadRes strt2(or 3 or 4) to switch to another

load reserve setting. E.g. high load reserve during system start to be able to switch-on big devices, thenduring normal operation lower reserve to save engines (and fuel).


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6) If total load increases and selected LoadRes strt is no more fulfilled, after a Next start del next readygen-set with the highest priority (lowest priority number) is started and synchronized to the bus.

7) If load decreases and selected LoadRes stp is exceeded, after a Next stop del the running gen-set withthe lowest priority is unloaded, got off line, cooled and stopped.

8) Complete gen-sets group stops when binary input SYS START/STOP opens. If the input MCBFEEDBACK is closed (gen-sets are in parallel to mains) controllers softly transfer the load to the mains.When gen-set is unloaded (see GCB open levelor GCB open del) opens the output GCB

CLOSE/OPEN.9) The Running hours balancing or Load demand engines swap can be activated in power management.Hint:

Controller does not respond to GCB ON/OFF , STOP, START buttons and corresponding remote

InteliMonitor or Modbus commands in AUT mode.

Set Basic setting: FltRes GoToMAN= ENABLED to avoid automatic engine start when pressing FAULT

RESET after any 2nd

level alarm (Shutdown, Slow stop, Breaker Open&Cooldown).


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Relative power management in %Guarantees that the engines be not continuously loaded more than to a certain level, leaving less thanselected relative load reserve. Suitable for engine life-based optimization.Activation: #Pwr mgmt mode= REL (%)

Start/Stop conditions in Power management

Reserve Actual Reserve Start condition Stop conditionAbsolutekW / kVA

ARstrt = PgNom PgActARstp = Pg*Nom PgAct

ARstrt < #LdResStrt ARstp > #LdResStp

Relative%

RRstrt = [(PgNom PgAct) / PgNom].100%RRstp = [(Pg*Nom PgAct) / Pg*Nom].100%

RRstrt < #%LdResStrt RRstp > #%LdResStp

WhereARstrt Actual Absolute reserve in kW or kVA - for engine start calculation.ARstp Actual Absolute reserves in kW or kVA - for engine stop calculation.RRstrt Actual Relative reserve in % - for engine start calculation.RRstp Actual Relative reserves in % - for engine stop calculation.PgNom Sum of Nominal power of all gen-sets on the bus.Pg*Nom Sum of Nominal power of all gen-sets on the bus apart from the one, which is going to be

stopped.PgAct Sum of Actual power of all gen-sets on the bus = system load.


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Hint:Optional functions in absolute or relative Power management are:

- Running hours balancing (equalization),- Load demand (different size) engines swap and- Power management of two or more gen-set groups (bus tie support).

Running hours balancingThe gen-sets priorities are automatically swapped to balance engine running hours. Up to 32 controllers aresupported.Activation: #PriorAutoSwap= RUN HOURS EQUImportant setpoints: RunHoursBase, #RunHrsMaxDiff

Different sized engines (Load demand) swapThree running engines (priorities) are swapped based on load demand (one small engine runs on smallload and swaps to another one big engine that runs when load increases).Activation: #PriorAutoSwap= LD DEMAND SWAPImportant setpoints: #PwrBandContr1, #PwrBandContr2, #PwrBandContr3, #PwrBandContr4,#PwrBandChngDe.


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Pwr management of splitted groupImportant setpoints: Control group, GroupLinkLeft, GroupLinkRightWhen a Bus-tie disconnects the gen-set group the Power management can operate separately on each ofthem.

G1 G2 G3 G4 G5

LOAD1 LOAD 2

Basic settings:

Contr.addr= 1

Pwr management:

Control group= 1GroupLinkLeft= 1

GroupLinkRight= 2

BTB

BIGrouplink

1.controller 2.controller 3.controller 4.controller 5.controller

Basic settings:

Contr.addr= 2

Pwr management:Control group= 1

GroupLinkLeft= CGroupLinkRight= C

Basic settings:

Contr.addr= 3


GroupLinkLeft= CGroupLinkRight = C

Basic settings:

Contr.addr= 4



Basic settings:

Contr.addr= 5



Control group 2.Control group 1.

BTB feedback

Load sheddingAll LOAD SHED outputs are activated (closed) to trip the unessential load when gen-set goes to island:

a) When GCB is closed after mains fail and gen-set starts in SEM / AUT mode.b) When MCB opens from parallel to mains operation in SEM / AUT mode.c) Before MCB is opened in MAN mode by button.

The load shedding function is active in all controller modes except OFF.Load shedding has three steps and each step is linked with its own Load shed x binary output. There is onlyone load shed level and delay for all three steps as well as recon level and delay. Load shed can only movefrom one step to the next, e.g. No LoadShed to LdShed S1 to LdShed S2 to LdShed S3 and vice versa.If manual reconnection of the load is desired, the AutoLd recon setpoint needs to be disabled (AutoLd recon=DISABLED) and the MAN load recon binary input needs to be configured.Rising edge on this input resets the controller to a lower stage, but only if the load is under the Ld recon levelat that moment.

Hint:If no Load Shedding outputs are configured, there is no record to history and no scrren timer indication of theactivity of this function.


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Load reconnection automatic ->AutoLd recon =ENABLED

Ld recon del Ld recon delLd recon del

BO Load shed 2

Ld recon level

Gen-set power

BO Load shed 3

BO Load shed 1

opened

opened

opened

Load reconnection manual ->AutoLd recon =DISABLED

System Base loadGen-set group is controlled on constant (or adjustable) power. The Baseload value can by changed bysetpoint or via analog input.Important setpoints: ProcessControl: #SysLdCtrlPtM= BASELOAD; #SysBaseload; SysBaseLdMode.

Local BaseloadSelected gen-set from island or mains parallel running group can be loaded to constant LocalBaseloadvalue. This engine is taken out from Load sharing and Power management. LocalBaseloadvalue is reducedonly when common group (actual) load is lower than this value. The gen-sets in the group will try to matchtheir LocalBaseloads (when more than one) based on their controller addresses, so the first limited would bethe one with the highest CAN address. I.e. this function will switch-off automatically in one or more

controllers if there is not enough load to cover all the requested LocalBaseloads.Important setpoints: ProcessControl: LocalBaseload.


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System Base power factorGen-set group is controlled in mains parallel to keep a constant (or adjustable) power factor.Important setpoints: ProcessControl: #SysPFCtrlPtM= BASEPF; #SysPwrFactor.

Import-ExportGen-set group is controlled to keep constant (or adjustable) Import or Export value. The external controller

InteliMains NT must be connected on the CAN2 to control gen-set group kW I/E.Important setpoints: ProcessControl: #SysLdCtrlPtM= LDSHARING.

Import/Export power factorGen-set group is controlled to keep constant (or adjustable) Import or Export power factor.Important setpoints: ProcessControl: #SysLdCtrlPtM= VSHARING.The external InteliMains NT controllermust be connected on the CAN2 to control gen-set group PF I/E.

Engine states

Engine prelubrication

Engine params: PrelubrTime

PrelubrPause

Prelubr pump

Not lubricated

Hint:To use Prelubrication, configure Binary output PRELUBR PUMP first.Prelubrication is disabled in controller OFF mode or if Prelubr time is set to zero.Binary output PRELUBR PUMP is opened when engine is running.Prelubrication cycle starts with PrelubrPauseafter engine stop.Prelubrication cycle starts immediately when controller power supply is switched on or when mode changesfrom OFF to MAN or AUT or after Emergency stop was reset. An Alarmlist message Not lubricated is activeuntil this first lubrication cycle has been completed.

Engine cooling

Engine warming

Service time alarm


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Engine starting procedures

Engine starting procedure if Engine params:Fuel solenoid= DIESEL ENGINE with different setting ofFuelSol offset.

Engine starting procedure if Engine params: Fuel solenoid= GAS ENGINE


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Unsuccessful start no Engine params: Starting RPMreached

Unsuccessful start RPM disappeared before/after Underspeed protection got active:

RPM dropped under Starting RPM

level and Underspeed enabled

-> protection activated.

Underspeed unblocking

BO: Fuel solenoid

RPM

BO: Starter

Start fail activated because of

RPM loss.

BO: Start fail

Starting RPM level.

Underspeed protection is not yet

Active. Underspeed is detected

only if RPM 5s:


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Transition Idle -> Nominal RPM, protections unblocking:

= 5s

Max stab time

ProtDel GroupX

Idle time

BO: Idle/Nominal

RPM

BO: Starter

Transition Idle - > Nominal RPM.

Starter switched off.

Underspeed protection

unblocked.

Electrical protections enabled.

Engine running only

protections of group X (=1 -3)

enabled.

Underspeed unblocking

Preventilation (if Fuel solenoid= GAS ENGINE):

Ventilation (if Fuel solenoid= GAS ENGINE):


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Engine stopping proceduresNormal engine stop:

1s

BO: Stop pulse

BO: Stop solenoid Stop time

BO: Fuel solenoid

RPM + pick - up signal

Typical engine stop time

Correct setting Stop time

setpoint is set to longer

time than typical engine

stop time.

Pick-up sensor fault forced engine stop:

Normal engine stop, but Stop timeis set too short:


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Unsuccessful engine stop:

BO: Stop pulse

5s

BO: Stop solenoid

Stop time

BO: Fuel solenoid

RPM + pick - up signal > 0

Stop command issued, but

no reaction.

The cyclic stop attempts

continue until the engine

actually stops.Stop time

In this moment the Stop time

elapsed, but the engine is still

moving. Sd Stop fail alarm

appears.The fuel or stop valve probably

stucked in wrong position.

Forced stop in still state:

BO: Stop pulse

BO: Stop solenoid

= Stop time

BO: Fuel solenoid

measured RPM = 0Stop bu tton pressed (MAN

mode).

Stop solenoid activated for

Stop time period.

Stop pulse activated for 1s.

Spontaneous engine start-up:

B) BO: Stop solenoid

= 2+5s

A) BO: Stop solenoid

Stop time

BO: Fuel solenoid

measured RPM

Engine running condition

detected. Alarm Sd Stop fail

appears.

Still engine condition

achieved.

Stop time A) Stop time long enough to

stop the engine.

B) Stop time too short,

additional Stop solenoid

activation needed.

The overlay is 2+5s since still

engine condition achieved.

Engine started conditions- Engine speed (RPM) > Starting RPMor- AI: Oil press > Starting POilor- D+ terminal active for minimum 1s or- BI: RunIndication 1 or 2 or 3 = active or- Generator voltage > 25% of GenNomV(any phase)


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Engine running conditions- RPM > Engine params: Starting RPMor- Analog input Oil pressure > Engine params: Starting POilor- D+ terminal active and Engine params: D+ function= ENABLED or- Active Binary input Run indication1 or- Active Binary input Run indication2 or

- Active Binary input Run indication3 or- Vgen > 15 V (any phase).

Still engine conditions- Engine speed (RPM) = 0 and- AI: Oil press < Starting POiland- D+ terminal not active and- BI: RunIndication 1 and 2 and 3 = not active and- Generator voltage < 15V (all phases) and- Generator frequency = 0 Hz and- if all above conditions are fulfilled, additional 2s delay is necessary to confirm still engine

Note:If any of the functions not used (e.g. BI RunIndication3 not configured), its state is omitted in the evaluation.This is not valid for RPM comparisons, this condition is always active.

PLC functions

For PLC functions description see IGS-NT-2.2-Application guide.pdf.

Multi language support

NT Family controllers support up to five Languages that is possible to switch during controller duty. Everyterminal (i.e. Remote display or PC-InteliMonitor) can be switched to different language. Use PC-GenConfig- Translator tool to translate texts to another language.Default application archives contain all texts in English only.

ECU interface customizing

The list of available ECU interfaces can be found in GenConfig / Modules / ECU list.

Binary selectorThis function enables to change the following CAN values transmitted to ECU via J1939 or binary outputonly. The change can be provided by setpoint or via Binary input. There are four Bin selector channelsavailable.

J1939 value ECU command

Governor mode Isochronous - Droop

Idle Speed select Idle NominalFrequency select 1500 1800

Preheat request Yes No

Protection override Yes No


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Protections and Alarm management

Protection groupsThere are two groups of protections in the controller: fix and customer configurable.

Setpoint group

Analog protections Configurable Analog protect

Generator protections Configurable Gener protect

Mains protectionsshould not be used inMINT application

Configurable Mains protect

Fix protections Fix Engine params,Gener protect,Analog protect

Protection typesLev. Protection

typesAbbr. Gen-set action Record Horn

activeLED

*)

1 Historyrecord

Hst None History only no no

1 Alarm only Al None (Alarm disappears whenbecomes inactive and Fault Resetbutton is pressed.)

Alarmlist only yes Y

1 Warning Wrn None (Alarm disappears whenbecomes inactive and Fault Resetbutton is pressed.)

Alarmlist andHistory

yes Y

1 ALindication

ALI None (Alarm disappearsautomatically, when becomesinactive.)

Alarmlist only no no

1 A+Hindication

AHI None (Alarm disappearsautomatically, when becomesinactive.)


no no

2 Low power LoP Load is ramped-down to Generprotect: Min power PtM. Afterprotection becomes inactive, thepower limitation is automaticallyterminated (no fault resetnecessary).


no no

2 Off load OfL SEM, AUT modes:Controller opens GCB without soft

unloading, gen-set runs 1 minute atNominal RPM. Gen-set statechanges to Cooling and Stop 1minute after Off load activation.Controller starts automatically GCBsynchronizing (or closes GCB)when Off load is deactivated (nofault reset necessary).MAN mode:Controller opens GCB without softunloading and the gen-set runswithout load until operatorintervention.

All generator protections are activeduring Off load duty.


no no


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2 BreakerOpen &Cool-down

BOC Controller opens GCB without softunloading, gen-set state changes toCooling and Stop. Fault reset mustbe activated for next start.


yes R

1 Mainsprotection

MP Controller opens GCB, gen-setstays running.

History only no no

2 Slow stop Stp Soft unloading then the GCBopens, the gen-set state changes toCooling and Stop.


yes R

2 Shutdown Sd Controller opens GCB without softunloading and stops the gen-setwithout Cooling state.


yes R

X Sensor fail Fls Can be indicated when Analoginput value is 6% out of sensorcharacteristic range.To allow sensor fail to activatecorresponding (e.g. Sd) Analoginput protection, set the protectionin GenConfig -> Inputs/Outputs ->

Analoginputs -> Protection -> propertyActive when to Under/Over limit +Fls.


no no

*) Yellow color of Gen-set indication LED is available only in IS-NT. In IG-NT, Y indication of LED meansthat both red and green LEDs are on.

Default protections in MINT

Fix firmware based

Engine: Protection Corresponding setpoints

Overspeed Sd Engine protections: Overspeed

Underspeed Sd Engine params: Starting RPM

Generator: Corresponding setpoints

IDMT overcurrent BOC Basic settings: Nomin current;Gener protect:2Inom del

IDMT Active power BOC Gener protect: OverldStrtEval; 2POvrldStrtEvDel

Shortcurrent BOC Gener protect: Ishort; Ishort del

Generator voltage: Ug1>, Ug1, Ug2, Ug3V BOC; Gen >,Ug2>>, Ug3>>

Sd Gener protect: Gen >V Sd; Gen V del.

Generator frequency: fg BOC Gener protect: Gen >f; Gen V BOC; Gen f; Gen V; Batt


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Bus vo ltage and frequency protections - limits and indications

Basic settings:

VoltProtSelect = PHASE-NEUTRAL

Gener protect: Gen >V BOC

Gen V Sd Gen V del

Gen >f

Gen V BOC

Gen V Sd

Gen V del Gen >f

Gen V BOC

Gen f

Gen V BOC

Gen f Gen


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- Underspeed (only if Fuel solenoid= GAS ENGINE)

Alarm time chart

Ready

RPM=0

LoadedCranking Starting Running

All the time & Overspeed protections & Ig IDMT, Ig unbal, IG short

Mains >V, Mains f, Mains V, Genf, Gen


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Possible CB sequences:

CB close command:

2s

BO: CB status

BI: CB fdb neg

BI: CB fdb

BO: CB ON coil

1s

BO: CB close/open

BO: CB UV coil minimum 1s from UV switching on,together with MinStab time elapsing isnecessary before the CB is allowed toclose

When closing the CB, the CB status LBOswitches over only when both feedbacksare in correct position


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Repeated CB close command:

CB fail fdb mismatch:

2s

2s1s

BO: CB OFF coil

2s

BO: CB status

BI: CB fdb ne

BI: CB fdb

BO: CB ON coil

1s

BO: CB close/o en

BO: CB UV coil

If the CB is not closed afterthe first attempt, it is only resetby OFF pulse and no CB fail isissued. This would be issuedafter the second unsuccessfullattempt.

BO: CB status = 0

BI: CB fdb ne = 1

BI: CB fdb = 0

BO: CB fail

ON pulse has finished and CBstatus is not =1. CB fail isissued immediatelly

2s

BO: CB OFF coil

BO: CB fail

500 ms


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CB open command:

Transition closing -> opening (opening command is issued during clos ing pulse):

2sBO: CB OFF coil

BI: CB fdb neg

BI: CB fdb

BO: CB close/open

BO: CB UV coil

During CB opening the CB statusLBO is deactivated with change ofthe first feddback status

Further behavior of UV outputdepends on the system status. In

case of transition to cooling staysoff, if the Cb was opened manuallyand the engine keeps running, itactivates again after timeoutelapses.

BO: CB status


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Transition opening -> closing (closing command is issued during opening pulse)

MCB opens on = GENRUN:

2s

2s

BO: CB OFF coil

BI: CB fdb neg

BI: CB fdb

BO: CB close/open

BO: CB UV coil

BO: CB status

BO: CB ON coil

OFF a UV pulse is always activated forthe full time. manual control (= CBbutton) is deactivated during opening

pulse.

Here starts the standard closingsequence see CB close command.

In this moment, the reason for closing theCB is activated again (e.g. RemoteStart/Stop is activated)

BO: MCB UV coil

FwRet break

RPM / fg / UgEmergStart del

2s

BO: MCB OFF coil

BI: MCB fdb neg

BI: MCB fdb

BO: Mains OK

BO: MCB status

BO: Fuel solenoid

FwRet break dealy is between MCBstatus deactivation and command forGCB closing.

BO: MCB close/open

Generator voltage is within limits

BO: GCB close/open

BO: GCB ON coil

If mains returns in this moment,starting sequence is interruptedand MCB stays closed. It is validuntil the moment when generatorvoltage is within limits.


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Other CB fail reasons:

When the BO CB close/open is in steady state and CB feedback is changed, the CB fail is detectedimmediately (no delay).

Alar m: GC B f ail

BO G CB close/open

BI GCB feedback

Alarm detect ion:

immediatelly

active

closed

opened

Alarm: G CB fail

BI GCB feedback

BO G CB c lose/open

Alarm detection:

immediatelly

active

opened

closed

When the BO CB close/open opens, there is 5 resp. 2 sec delay for the breaker to respond before a CBfail is detected. In such case, if CB OFF coil is used for opening the CB and CB fail occurs duringopening the CB, the signal CB OFF coil is automatically extended until the breaker opening is detected(evaluated as CB status).

2 sec when the CB is used for synchronizing

5 sec in other cases

Alarm: G CB fail

BO G CB close/open

BI GCB feedback

active

opened

opened

Time delay

5 sec

In case that CB fail is detected after switching the controller on (CB is closed), the CB OFF coil output isactivated immediatelly.


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Gen-set operation states

Gen-set can operate in following states

Not ready Gen-set is not ready to start

Init After controller power supply switch on

Ready Gen-set is ready to run

Prestart Prestart sequence in process.From closing of Prestartoutput to closing of Starteroutput.

Cranking Engine is cranking; Starteroutput is closed

Pause Pause between start attempts

Starting Engine params:Starting RPMis reached

Running Waiting for GCB connection

Warming After GCB is closed to parallel operation, gen-set load is reduced Engineparams:Warming load

Soft load Gen-set power is ramping up

Loaded Gen-set is loaded

Soft unld Gen-set power is ramping down

Cooling Gen-set is cooling before stop

Stop Stop

Shutdown Shutdown alarm activated

Ventil Gas engine ventilation of unburned fuel when stop command comes duringcranking with gas

SDVentil Gas engine ventilation of unburned fuel after unsuccessful start attempt

Off load GCB is opened, gen-set keeps running on nominal RPM

Emerg man Emergency manual state see Emerg. manualBI description

External gen-set conditions :

MainsOper Mains is present (MCB is closed, GCB is opened)

Brks Off GCB, MCB opened

Synchro Gen-set is synchronizing (bus voltage OK, GCB isopen)

MultIslOp Multiple Island - gen-set is running loaded in islandparallel mode (MCB is open, GCB is closed)

MultParOp Multiple Parallel gen-set is running loaded inmains parallel mode (MCB is closed, GCB isclosed)


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Inputs and Outputs

Virtual and physical modules

Number of I/O can be extended and project wiring can be reduced using the following extension and virtualmodules.

Module name

BIN

BOUT

AIN

AOUT

Note

IGS-NT cont roller x x x x Number of I/O depends on type.

IGS-PTM 8 8 4 1 Standard I/O extension module.

IS-AIN8 - - 8 - Standard I/O extension module.

IS-BIN16/8 16 8 - - Standard I/O extension module.

I-CB x x x x Configurable communication bridge.

IGL-RA15 - 15 - - 15 Green, Red, Yellow LED panel.I-AOUT8 - - - 8 8 Analog outputs

VPIO 8 8 - - Virtual periphery I/O module.

SHBIN 8 - - - SHared (virtual) Binary INput module

SHBOUT - 8 - - SHared (virtual) Binary OUTput module

SHAIN - - 8 - Shared (virtual) Analog INput module

SHAOUT - - - 8 Shared (virtual) Analog OUTput module

PLC x x x x Programmable (internal) logic module.

Hint:For more details about Virtual peripherals (Shared and Internal virtual I/O periphery and PLC) see IGS-NT-Application guide-2.2.pdf.

Binary Inputs - Control

Sys start/stopIf the input closes, the controller may start the engine (in AUT mode only). Request to start depends on stateof setpoint Pwr management:Pwr managementstate and, if ENABLED, on the actual need of load reserve.I.e. all controllers in the system should have their Sys start/stop inputs active, but it doesnt mean that allengines are running.If Pwr management:Pwr managementis DISABLED, the closed input requests the engine to startregardless of the load reserves.Gen-set is running both in mains parallel or island parallel (depends on mains condition). Reaction on input

state change is delayed by setpoints #SysAMFStrtDel/ #SysAMFStopDelin island mode, by 1 sec in mainsparallel mode (= input MCB feedback active).

Emergency stopIf the input is activated, engine shutdown is immediately issued. It has a character of a Shutdown -protection type, however some special behaviour follows in the case of its activation:

- Outputs Ignition, Ventilation, Cooling pump, Prelubr pump are switched off, regardless of the enginestate.

- This input cannot be overridden with the input Sd override.Hint:Alarm type is set to No protection, as this input itself creates the shutdown protection.Input is inverted (= normally closed) in default configuration to achieve maximum security (broken wire).


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Nominal speedIf the input is closed, the controller forces the engine immediately to the Running state, bypassing the Idletimesetting and shortening the start-up procedure.

Hint:

Use this input if you want to shorten the start-up procedure in an AMF situation.

PrestartBypassIf the input is closd, the controller bypasses the Prestart timeand activates the Starter output immediately.Hint:Use this input to bypass the pre-glow / prelubrication time in the case that the engine has run a short timebefore.

Oil pressBehavior for Inverted = Open to activate configuration:Binary input must be closed when engine is not running and opened when it is running. "Sd Oil press B" isactivated when input is opened on not running engine (still engine condition) or when stays closed for time

period set by Engine protect: RunOnlyBlkDel1after engine start. "Sd Oil press B" protection is not activewhen input is not configured.

Sd overrideIf the input is closed, all 2

ndlevel protections are disabled to allow engine run in an emergency situation, e.g.

sprinkler devices power supply.All protections are shown in Alarmlist and recorded into History, but the controller doesnt stop the enginedue to their occurence. If the input is deactivated and some protections are still active or not yet reset, thecontroller starts to take these protections into account and consequently stops the engine.Hint:All 2

ndlevel protections are locked out, except of:

- Emergency stop- Overspeed

- Underspeed (only if Fuel solenoid= GAS ENGINE)

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

Stop solenoid output does not close.The output terminals that are configured with inversion are closed.

Detection of "running engine" condition and subsequent alarm message "Sd Stop fail" is blocked. Thecontroller shows "Emerg Man" state and the engine can not be started. Generator current and power(energy) measurement is active in this mode, regardless of the actual state of the engine.After the binary input EMERG. MANUAL is open again, the controller recovers to previous mode and

behaves according to the actual situation. Should the engine run and any of the conditions to start the enginewas active, it will keep the engine running.Function is active in any controller mode and activation of this input is written to history.Hint:The function is intended especially for Marine gen-sets which are supposed to be started manually while thecontroller has no power supply. To recover successfully from this state, only the signals Stop solenoid, GCBON/OFF coil should be used for engine and breaker control, as the other outputs are continuous activeduring engine run (e.g. Fuel solenoid) and it is not possible to switch them between more control sources.


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RunIndication1

RunIndication 2

RunIndication 3Any of three binary inputs can be used for engine running indication e.g. via Oil pressure contact. Active

Running indication blocks engine start (to avoid starter damage).

AccessLock intIf the input is closed, no setpoints can be adjusted and no commands can be issued from the controller frontpanel.Hint:As the controller mode (OFF-MAN-AUT-TEST) is one of the setpoints, not even that can be changed.The START, STOP, FAULT RESET and other control buttons are disabled as well.

AccessLock D#2If the input is closed, no setpoints can be adjusted and no commands can be issued from IG/IS-Display #2.

AccessLock D#3If the input is closed, no setpoints can be adjusted and no commands can be issued from IS-Display #3.

AccessLock extIf the input is closed, no setpoints can be adjusted and no commands can be issued from any externalterminal = via direct/modem/internet connection to the controller.Hint:Use these inputs to lock out the selected terminals for setpoint changes and commands. Such a terminal canonly be used for monitoring.

Remote OFFActive binary input forces the controller mode to OFF. When opened the controller is switched to previousmode.If the engine is running, the active input has no effect. The controller switches to OFF mode only after theengine has been stopped.Hint:Use this input to block the engine start during service.

Remote MANActive binary input forces the controller mode to MAN.

Remote AUTActive binary input forces the controller mode to AUT.Hint:Use this input to switch the controller to automatic operation, e.g. using the external key switch.

Force block 1

Force block 2

Force block 3Three binary inputs for user-specific blocking of programmable protections. If the particular input is active, allthe protections with the corresponding Force block X block type are blocked.


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Load res 2

Load res 3

Load res 4If the input LOAD RES X is closed, the setpoint set Pwr management:#LoadResStrt X+ #LoadResStop X

(#%LdResStrt X+ #%LdResStop X)will be selected. Higher index has higher priority when more thesebinary inputs are closed together. When not configured or not active, setpoint set #LoadResStrt 1+#LoadResStop 1(#%LdResStrt 1+ #%LdResStop 1)is used.Hint:All controllers operating in Power management must have the same Load reserves selected.It is possible to use Virtual periphery to share the signals between more controllers on the CAN bus. In suchcase one controller is a server which physically has the signals connected and other controllers get thesesignals via CAN bus.Setpoint set selection depends on the #Pwr mgmt mode if set to ABS (kW or kVA), #LoadResStrt Xtypesetpoints are active, if set to REL (%), #%LdResStrt Xtype setpoints are active.

MinRun power 1

MinRun power 2

MinRun power 3When binary input MinRun power 1 or 2 or 3 is closed, the corresponding setpoint Pwr management:#MinRun power 1or 2or 3is selected. Higher index has higher priority when more these binary inputs areclosed together. When not configured or not active, minimal running power is 0, i.e. the system works onlybased on Load reserves.Hint:All controllers operating in Power management must have selected the same MinRun power input.It is possible to use Virtual periphery to share the signals between more controllers on the CAN bus. In thiscase one controller is a server which physically has the signals connected and other controllers get thesesignals via CAN bus.

Priority sw A (Priority switch A)

Priority sw B (Priority switch B)

Priority sw C (Prior ity switch C)

Priority sw D (Prior ity switch D)

Binary inputs for priority selection.

Priority value Priority 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Priority sw A 0 or nc 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1Priority sw B 0 or nc 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1

Priority sw C 0 or nc 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1

Priority sw D 0 or nc 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1

Hint:Priority value is defined by setpoint Priority when all Priority switches are opened or not configured.The priority value defined by a combination of binary inputs Priority sw X is accepted with 1s delay. So if achange is made to more inputs simultaneously, it is accepted 1s after the last change sensed.

GroupLinkIf the input is configured, the group linking function is active, i.e. this controller becomes the status server fortwo groups of gen-sets and informs them about the BTB status.If this input is closed, the controller reports BTB status as closed, if open, the controller reports open BTBstatus.


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StartButton

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

and when setpoint Basic settings-> Local Buttonis set to EXTBUTTONS or BOTH.

StopButton

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

and when setpoint Basic settings-> Local Buttonis set to EXTBUTTONS or BOTH.

FaultResButton

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

To enable this function, set the setpoint Basic settings-> Local Buttonto EXTBUTTONS or BOTH.

HornResButton

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

GCBButton

Binary input has the same function as GCB button on the controller front panel. It is active in MAN and

TEST modes only. In TEST mode in some special cases only (see description of the TEST mode in chapterMode and functions description).Hint:All Binary inputs, which simulate controller front panel buttons, are edge (no level) sensitive, and they reacton the rising edge only. Minimal input pulse duration is 0,2 seconds.

ManualLdReconThe rising edge on this input switches the controller to the lower Load Shedding stage when Loadshedding:AutoLd recon=DISABLED and the load is under Load shedding:Ld recon level.

GCB disableThe input blocks the GCB closing, even if all other conditions (e.g. during synchronizing) for its closing are

fulfilled. Valid in all modes.Hint:If you want to lock out the GCB (or MCB) closing during synchronizing loop test, set Sync/Load ctr l:Phasewindow= 0. This allows the control loop to be tested while actual GCB (or MCB) closing is blocked.Conditions for closing:

1) voltage only on generator side of GCB (or MCB)2) voltage on both sides of GCB (or MCB) and all synchronizing conditions fulfilled.

Al t brightnessActive binary input switches controller display backlight to the alternative setting. Alternative intensity of thebacklight can be set independently using the controller panel buttons.Hint:

Input available in IG-NT/EE and modifications only. For IG-Display and IS-Display modules, this binary inputis located in the Power connector and its function is fixed (not configurable).

IssueActCallC1

IssueActCallC2

IssueActCallC3Rising edge on these binary inputs forces an active call to be issued via the corresponding channel.Hint:Can be used to send e.g. SMS in the case of a mains failure to report that the engine has successfullystarted (linked from the output Gen params OK) and later on to report that the engine has stopped again(linked from the inverted output Fuel solenoid).


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ECUComFailBlckThe input blocks the issuing of the alarm in case of ECU communication failure.

StartblockingThe input blocks the engine start. If active, NotReady state is shown on the controller screen and a messageappears in the Alarmlist. As soon as input is deactivated, engine start is enabled again.

Hint:Use this input for cooperation with external supervisory device, such as PLC. It can prevent the engine to bestarted because of some reasons not known to the controller.

ECU StoppedEngEngine stop was activated in ECU, not from controller. The controller reflects this situation and also goes toStop to avoid an Underspeed alarm (and record in the Alarm list).

CtrlHBeat sensBI "CtrlHBeat sens"should be assigned to the output "CtrlHeartBeat" from the other controller. If input signaldoes not correspond to right form (log 1 / log 0 - 500 ms / 500 ms; +/- 100 ms), BO: "CtrlHBeat FD" (FailDetect) is activated. This BO can be used for primary controller blocking (switching to Emerg. manual,

disconnecting BO, ...) and mainly for disconnecting of BI "Emerg. manual" of this controller. What means thatthe backup controller assumes engine control.

Force value 1 16If any of the particular 16 input s is active, the Force value function on that corresponding channel getsactive, forcing an alternative value to the selected setpoint.

CylDifEvalBlkIf the signal is active, the protection based on the difference amongst cylinder temperatures is blocked. Aftersignal deactivation, the protection is unblocked immediately.

ExtValue1 up

ExtValue2 up

ExtValue3 up

ExtValue4 upActive binary input causes increasing of the corresponding ExtValueXvalue. The rate of change is given bythe setpoint ExtValueX rate. If the ExtValueXreaches the ExtValueXHiLim, the further input request isignored.

CylDifEvalDel

Internal prot activity

CylDif evaluates deviation

BI: CylDifEvalBlk

CylDif Prot activeFault reset


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ExtValue1 down

ExtValue2 down

ExtValue3 down

ExtValue4 downActive binary input causes decreasing of the corresponding ExtValueXvalue. The rate of change is given bythe setpoint ExtValueX rate. If the ExtValueXreaches the ExtValueXLoLim, the further input request isignored.Hint:If at least one of the inputs (ExtValueX up/ ExtValueX down) is configured for the particular ExtValueX, theexternal set commands to the same value are ignored.

ExtValue1reset

ExtValue2reset

ExtValue3reset

ExtValue4resetActive binary input causes ExtValueXto be reset and held at its default value, given by the setpointExtValueXdeflt.Hint:These inputs, if configured, do not block the external set commands (in contrast to ExtValueX up/ ExtValueXdown inputs). However, if the reset input is activated, the corresponding ExtValueXis reset to its default(ExtValueXdeflt) value. This default value is kept in ExtValueXuntil the reset input is deactivated, and theexternal set commands received meanwhile are ignored.

PulseCounter 1PulseCounter 2

PulseCounter 3

PulseCounter 4The inputs are linked with corresponding counters, which integrate the pulses sensed at these inputs. Eachrising edge of the signal at input increases the internal counter value.Hint:Pulse width (both high/low levels) must be at least 100 ms in order to be correctly sensed!Conversion ratio can be selected using the setpoints ConvCoefPulseX. The converted values are visible instatistics values PulseCounter X. These values can be reset using Statistics window in InteliMonitor.

Timer block 1

Timer block 2

Timer block 3

Timer block 4

Timer block 5

Timer block 6

Timer block 7


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Timer block 8

Timer block 9

Timer block 10

Timer block 11

Timer block 12

Timer block 13

Timer block 14

Timer block 15

Timer block 16

Blocking inputs for particular timer module channels. The input can lock out its assigned channel if thisinput is active, the channel wont activate its output (Timer active X) to e.g. start the engine.

Lang sel int A

Lang sel int B

Lang sel int CSet of binary inputs for forcing alternative languages. This set of inputs is switching the controllers internalterminal for IG-based controllers the front panel, for IS-based controllers the IS-Display with address #1.

Encoding of binary inputs combinations:

Language index -> given by display setting 1 2 3 4 5 6 7

Lang sel int A 0 1 0 1 0 1 0 1

Lang sel int B 0 0 1 1 0 0 1 1

Lang sel int C 0 0 0 0 1 1 1 1

Hint:Warning each language change causes the restart of the respective display (not the whole controller), sothe displays control panel wont react until the restart has finished (~ 5s).Value 0 in the table denotes that the corresponding input is not active or not configured.If more than 7 languages are present in the controller, it is not possible to force languages with index higherthan 7 using these binary inputs.The reaction on BI combination change is 1s delayed not to react on transient combinations if a rotaryselector switch is used.

Lang sel D#2 ALang sel D#2 B

Lang sel D#2 CSet of binary inputs for forcing alternative languages. This set of inputs is switching the controllers externalterminal with address #2 for IG-based controllers the IG-Display, for IS-based controllers the IS-Displaywith address #2.



Lang sel D#2 A 0 1 0 1 0 1 0 1

Lang sel D#2 B 0 0 1 1 0 0 1 1

Lang sel D#2 C 0 0 0 0 1 1 1 1


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Hint:Warning each language change causes the restart of the respective display (not the whole controller), sothe displays control panel wont react until the restart has finished (~ 5s).Value 0 in the table denotes that the corresponding input is not active or not configured.If more than 7 languages are present in the controller, it is not possible to force languages with index higherthan 7 using these binary inputs.The reaction on BI combination change is 1s delayed not to react on transient combinations if a rotary

selector switch is used.

Lang sel D#3 A

Lang sel D#3 B

Lang sel D#3 CSet of binary inputs for forcing alternative languages. This set of inputs is switching the IS-Display withaddress #3.



Lang sel D#3 A 0 1 0 1 0 1 0 1Lang sel D#3 B 0 0 1 1 0 0 1 1

Lang sel D#3 C 0 0 0 0 1 1 1 1

Hint:Warning each language change causes the restart of the respective display (not the whole controller), sothe displays control panel wont react until the restart has finished (~ 5s).Value 0 in the table denotes that the corresponding input is not active or not configured.If more than 7 languages are present in the controller, it is not possible to force languages with index higherthan 7 using these binary inputs.The reaction on BI combination change is 1s delayed not to react on transient combinations if a rotaryselector switch is used.

Binary inputs Status information

GCB feedbackGenerator Circuit Breaker positive feedback input (closed if GCB is closed). This is a primary source for thecontroller about the status of the GCB.

GCB fdb negGenerator Circuit Breaker negative feedback input (closed if GCB is open). Additional signal, can be used ifboth positive and negative feedback signals are available from the breaker.Hint:If both feedbacks are used and there is a mismatch between these signals, longer than 500 ms, a GCB fail

alarm is activated.

MCB feedbackMains Circuit Breaker positive feedback input (closed if MCB is closed). This is a primary source for thecontroller about the status of the MCB.Hint:The controller decides based on this signal whether the gen-set is running in mains parallel or islandoperation.

MCB fdb negMains Circuit Breaker negative feedback input (closed if MCB is open). Additional signal, can be used if bothpositive and negative feedback signals are available from the breaker.


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Hint:If both feedbacks are used and there is a mismatch between these signals, longer than 500 ms, a MCB failalarm is activated.

NeutralCB fdbUse this input to detect, whether the Neutral circuit breaker is open or closed. See also setpoint Process

control:#Neutral cont.and binary output Neutral CB C/O.

Binary outputs Engine control

StarterThe output is intended to energize the starter motor during start sequence. The output opens ifthe Engine params:Starting RPMlevel is reached or maximum time of cranking is exceeded.Hint:If setpoint Engine params:Fuel solenoid= GAS ENGINE, the Starter output is active during Preventilationand Ventilation states as well to clean the engine off the unburned gas.

Fuel solenoidThe output controls the engine fuel valve. The setpoint Engine params: Fuel solenoidselects the outputbehaviour DIESEL or GAS ENGINE.

Stop solenoidThe output closes to activate the stop valve which interrupts the fuel input to the engine. The output isalways closed until the engine reaches 0 RPM and other engine running conditions disappear as well +additional 5s.The minimum time of activation is given by the Engine params:Stop timesetpoint, so even if all enginerunning conditions would disappear before, the Stop solenoid stays closed for that time.Hint:The output also closes if the engine begins to rotate spontaneously. It stays closed until still enginecondition is achieved + additional 5s.

Intended only for diesel engines, especially marine ones.

Stop pulse1s pulse for engine stop command, intended for ECU connection.

PrestartThe output closes prior to the engine start (time defined by Engine params:Prestart timesetpoint) andopens when Starter output opens the last time during starting sequence. During repeated crank attempts theoutput is constantly closed.The output can be used for pre-glow, pre-heat or prelubrication.

IgnitionIntended to activate the ignition unit of gas engines. The output closes immediately as engine runningcondition is detected and opens after the engine stop (still engine condition). The function is independenton other conditions, i.e. always if engine running is detected, the output activates.The output opens immediately when BI EMERGENCY STOP gets active.Hint:In case of repeated start:a) the output is switched on when RPM = 30 (it is fixed value)b) the output is switched off during Crank pause, but not until RPM fell down to 0c) the output is switched off by STOP command when RPM=0

VentilationIntended for the engine ventilator control. The output closes together with Prestart output and opens after the

engine stop (still engine condition).The output opens immediately when BI EMERGENCY STOP gets active or in OFF mode.


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Idle/NominalThe output closes with transition from Starting (Idle) to Running state. It opens either with transition toCooling state (if Engine params:Cooling speed= IDLE), or after the command to stop the engine (if Engineparams:Cooling speed= NOMINAL).The closed output means that Nominal RPM are requested.Hint:

Connect this output to the speed governor to switch the requested speed: opened = IDLE RPM,closed=Nominal RPM.

Cooling pumpThe output closes when gen-set starts (engine started condition) and opens AfterCoolTimedelayed afterthe engine stop (still engine condition).The output opens immediately when BI EMERGENCY STOP gets active or in OFF mode.

Prelubr pumpIf engine is not running, the output closes with period Engine params:Prelubr pausefor Engine params:Prelubr time.The output opens immediately when BI EMERGENCY STOP gets active or in OFF mode.

Not lubricatedOutput indicates the lubrication cycle (PrelubrTime) is not finished after controller Switch-on or return fromOFF mode or deactivation of Emergency stop signal.

Binary outputs Breaker control

Hint:Controllers are protected against simultaneoous closing of two or more GCBs to dead bus by means ofhand-shake signals on CAN bus communication.

GCB close/open

The output controls the generator circuit breaker. It is intended for contactors provides a continual activesignal if GCB should be closed.

GCB ON coilThe pulse output for GCB closing. If GCB synchronizing is enabled, the pulse length is 2s, if not, pulse lengthis 5s.Hint:ON coil can only be closed if UV coil is already active for at least 1s and MinStab timehas elapsed.

GCB OFF coilThe pulse output for GCB opening. If GCB synchronizing is enabled, the pulse length is 2s, if not, pulselength is 5s.


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GCB UV coilGCB undervoltage coil. Output is closed if generator values are within limits and GCB is ready to be closed.It is opened if GCB should be open, and then closed again if generator electric values are in limits. If GCBsynchronizing is enabled, the opening pulse length is 2s, if not, pulse length is 5s.Hint:UV coil automatically opens and OFF coil closes if GCB is closed spontaneously, not from controllers

activity. This state lasts until the GCB status has been deactivated.The only exception is during synchronization state, as an external device is allowed to close the GCB.

GCB statusIndicates breaker state expected by controller (based on gen-set state, controller commands and breakerfeedback). Can be used for external indication of breaker status according to controllers information.

MCB statusIndicates breaker state expected by controller (based on gen-set state, controller commands and breakerfeedback). Can be used for external indication of breaker status according to controllers information.

Neutral CB C/O

Neutral circuit breaker close /open output controls the generator Neutral circuit breaker. It is intended forcontactors provides a continual active signal if NCB should be closed. See also setpoint Neutral cont.

LdShed stage 1

LdShed stage 2

LdShed stage 3Load shedding outputs for partial load switching.

Binary outputs Control loops

AVR up

AVR dnBinary outputs for Volt / PF control by motorized or electronic potentiometer.

Speed up

Speed dnBinary outputs for Synchronizing and Load control. Outputs can be used instead of analog Speed governoroutput for older engine types. Minimum pulse duration is 0,15 sec. Maximum pulse duration is 10,0 sec.

Binary outputs UP nad DOWN of a PID regulator produce pulses, whose length correspond to derivation ofthe analog output (further AOUT) of the same regulator. In other words:

1. If there is no change of the AOUT, no pulses are produced2. If the AOUT is increasing, pulses are generated on the UP output. Pulse length depends on speed of

the increase.3. If the AOUT is decreasing, pulses are generated on the DOWN output. Pulse length depends on

speed of the decrease.4. Long pulses on the same output can merge5. If the calculated pulse in each particular cycle is too short, it is not copied to the output, but is only

buffered. When the buffered pulse exceeds minimal pulse length, pulse is generated to appropriateoutput.

The pulses are generated even if the analog regulator output is already at limit value. As for speed and

voltage regulation, this kind of regulation is good for droop-based systems. At isochronous system, it cancause stability problems, because it is slower.


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Hint:When Speed governor output stays near to the limit value (SpeedGovLowLim+0,2 V or SpeedGovHiLim-0,2V) for more than 2 sec, the Wrn SpdRegLim message is displayed in the Alarm list and recorded to History.When AVRi output stays on 98% for more than 2 sec, the Wrn VoltRegLim is displayed in theAlarm list and recorded to History.Corresponding warning is blocked when Binary outputs Speed Up, Speed Dn or AVR up, AVR dn are

configured to a physical BO or VPIO.It is not recommended to process these signals via the internal PLC, as the precise signal timing would bedistorted.

RemoteControl1

RemoteControl2

RemoteControl3

RemoteControl4

RemoteControl5

RemoteControl6

RemoteControl7

RemoteControl8These outputs are controlled remotely from InteliMonitor or other tool. The user selects the requested stateof these outputs via the buttons in this program.Hint:Outputs can be used to switch on/off some auxiliary devices in the control panel.

Binary outputs Status information

Ready for loadThe output closes when the engine is running, no 2

ndlevel protection is active and the GCB is already closed

or is able to be closed (i.e. all generator parameters are within limits).

Gen-set activeThe output closes together with Prestart output and opens together with achieving still engine conditionafter the stop command. If the start sequence finishes with Start fail, the output opens after the lastunsuccessful start attempt.

Hint:The output also closes if the engine begins to rotate spontaneously. It stays closed until still enginecondition is achieved.

OperationalThe output is closed when no protection is active and the gen-set is ready for operation or is currently inoperation.

ReadyThe output is closed, if following conditions are fulfilled:- Gen-set is not running and- No 2

ndlevel protection is active (or not yet reset)

- The controller has no engine running indication from any source- The controller is not in OFF mode


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Not readyThe output is closed, if following conditions are fulfilled:- The controller in OFF mode or- Any 2

ndlevel alarm is active or not yet reset

CrankProcedure

The output closes together with the first Starter activation and opens with the last Starter deactivation (eitherengine running state achieved, or Start fail). During crank pauses, the output stays closed.

CrankingIndication of cranking procedure.

StartingThe output closes together with Prestart output and opens with transition from Idle to Running state or withStart fail output activation. During crank pauses, the output stays closed.

Idle run

The output closes if engine started condition is detected after start and opens with Starting to Runningtransition.

RunningThe output closes with transition from Starting to Running state. It opens with transition to Cooling state or ifany 2

ndlevel protection gets active. It stays closed if the engine is loaded.

ForwardSynchroThe output is closed during forward synchronizing and opens when GCB status gets active (= GCB wasclosed). The output can be used for external synchronizing module control.

Warming

The output is closed during warming procedure the gen-set power is kept at Warming loadlevel in thisperiod.

Soft loadThe output is closed during gen-set soft loading state the gen-set power is ramping up, i.e. since GCB wasclosed until the end of the ramp.

LoadedThe output is closed when gen-set is loaded GCB is closed and no load ramp is active.

Soft unloadThe output is closed during gen-set soft unloading state gen-set power is ramping down.

CoolingThe output closes during engine Cooling state, i.e. from GCB opening to stop command.

StoppingThe output closes after the command to stop has been issued. It opens if still engine conditions are fulfilled.The output also closes if the engine begins to rotate spontaneously. It stays closed until still enginecondition is achieved.

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


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

Sem modeThe output is closed, if SEM mode is selected.

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

Gen params OKThe output is copy of generator status LED on controller front panel. The output is closed if gen-set isrunning and all generator electric values are in limits and no 2

ndlevel alarm is active (when only 1

stlevel

alarm is active, the output is closed).Hint:Use this output for switching on of auxiliary device (e.g. cooling pump) driven from generator voltageindependently on the GCB status.

Bus params OKThe output is copy of bus status LED on controller front panel. The output is closed if bus electric values arein limits.

In synchronismThe output closes during synchronizing if all matching conditions are fulfilled. It opens if correspondingbreaker is closed (xCB status output get active).Hint:Synchronizing matching conditions:

- Slip frequency < 0,25 Hz- Gen to Mains/Bus voltage phase shift within Sync/Load ctrl :Phase window- Gen and Mains/Bus voltages within Sync/Load ctr l:Voltage window- Sync/Load c trl:Dwell timeelapsed

StartButnEcho

StopButnEcho

FltResButnEcho

HrnResButnEcho

GCBButnEchoThese outputs are active for 1s if the corresponding button is pressed or binary input gets active or remotecommand is issued (from PC software, SMS, ...).

CtrlHeartBeatThe output signalizes watchdog reset. In a healthy state it flashes at 500ms : 500ms rate. It stops flashingwhen the unit reset occurs and the new controller start-up fails.

Bin selector 1-4The outputs are active according to the corresponding setpoints Engine params:Bin selector X.These areused for particular ECU settings.

Logical 0Constant value that can be configured to any output.


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Logical 1Constant value that can be configured to any output.

Al lAvailGS runThe output gets closed if all gen-sets available to take part in PMS are running and loaded. All gen-setshaving the same logical group (Pwr management: Control group) as this controller has are considered +

gen-sets from other logical groups if those are currently linked with controllers logical group (usingGroupLink feature).

InMainsParalThis LBO indicates that controller (or logical group, which the controller is member of) is connected to themains. It means that there exists a way across MCB (IM-NT-MCB application) or MCB+MGCB (IM-NT-MGCB application) to the controller. It is possible to configure this signal as MCB feedback of the controller,what can be useful for complicated applications with higher amount of mains.Hint:This signal works correctly only if IM-NT is used as the MCB/MGCB control device.

TimerAct 1-4

TimerAct 5-8

TimerAct 9-12

TimerAct 13-16These outputs are active if at least one of their assigned timer module channels gets active. Timer modulechannels are organized into groups of four.

TimerActiveComThis output is a logical OR (Com = Common) of the outputs TimerAct 1-4, 5-8, 9-12, 13-16. It gets active ifany timer module channel is active.

kWh pulseThe output generates 1 sec pulse in case that the kWh value increases.

Engines swappedThe output generates 100 ms pulse in case that two gen-sets exchange their priorities due to differencebetween Maximal running hours and Minimal running hours value (active when Pwr management:#PriorAutoSwapset to RUN HOURS EQU).

Binary outputs Fixed protection outputs

AlarmThe output closes if any alarm comes up. It opens if FAULT RESET is pressed. The output closes again if a

new fault comes up.

Alarm flash ingIf any alarm comes up, the output starts periodic closing/opening with period 1s/1s. It opens and stays open

if FAULT RESET is pressed.

Horn

The output closes if any alarm comes up. It opens if FAULT RESET or HORN RESET is pressed or if

Engine protect:Horn timeouthas elapsed. The output closes again if a new fault comes up.


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Horn flashingIf any alarm comes up, the output starts periodic closing/opening with period 1s/1s. It opens and stays open

if FAULT RESET or HORN RESET is pressed or if Engine protect:Horn timeouthas elapsed.

Common HstThe output closes if any History record-type alarm appears. The output opens after 1s.

Common LoPThe output closes if any Low power-type alarm appears. The output opens, if no Low power-type alarm is

active. No FAULT RESET needed.

Common AlThe output closes if any Alarm only-type alarm appears. The output opens, if no Alarm only-type alarm is

active and FAULT RESET has been pressed.

Common WrnThe output closes if any Warning-type alarm appears. The output opens, if no Warning-type alarm is


CommonActLev 1The output is a logical OR of Common Al and Common Wrn outputs.

CommonAlLev 1The output is active if at least one of the 1

stlevel alarms (Al, Wrn) is active or not yet confirmed.

Hint:See picture below with signal behaviour description. The same behaviour like for Warning-type alarm wouldbe for Alarm only.The same behaviour, but with signals CommonActLev 2 and CommonAlLev 2 would be forBreakerOpen&Cool-down, Slow stop and Shutdown-type alarms

Common OfL

The output closes if any Off load-type alarm appears. The output opens, if no Off load-type alarm isactive. No FAULT RESET needed.


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Common BOCThe output closes if any Breaker Open & Cool-down-type alarm appears. The output opens, if no Breaker

Open & Cool-down-type alarm is active and FAULT RESET has been pressed.

Common StpThe output closes if any Slow stop-type alarm appears. The output opens, if no Slow stop-type alarm is


Common SdThe output closes if any Shutdown-type alarm appears. The output opens, if no Shutdown-type alarm is


CommonActLev 2The output is a logical OR of Common BOC, Common Stp and Common Sd outputs.

CommonAlLev 2The output is active if at least one of the 2

ndlevel alarms (BOC, Stp, Sd) is active or not yet confirmed.

Common FlsThe output closes if any Fail sensor-type alarm appears. The output opens, if no Fail sensor-type alarm is


T cyl differOutput closes when engine cylinder temperature difference warning is active.

Vgen The output closes if the generator over/under voltage alarm activates.

Vbus The output closes if the bus over/under voltage is detected.

OvercurrentThe output closes if the generator IDMT Overcurrent or Shortcurrent alarm activates. The output opens, if

none of these alarms is active and FAULT RESET has been pressed.

ECU comm errorOutput closes if there is an error in the communication with ECU. It doesnt matter how the ECU isconnected J1939 link or RS232 line.

PeriphCommErr

Output closes if there is an error in the communication with any peripheral unit (e.g. IS-AIN8, IGS-PTM, ...).

CtrlHBeat FDBI "CtrlHBeat sens"should be assigned to the output "CtrlHeartBeat" from the other controller. If input signaldoes not correspond to right form (log 1 / log 0 - 500 ms / 500 ms; +/- 100 ms), BO: "CtrlHBeat FD" (FailDetect) is activated. This BO can be used for primary controller blocking (switching to Emerg. manual,disconnecting BO, ...) and mainly for disconnecting of BI "Emerg. manual" of this controller. What means thatthe backup controller assumes engine control.

CAN2 bus emptyThe output closes if the controller doesnt see any other controllers on the CAN2 bus. The output activationcan be blocked by setpoint Basic settings:CAN2emptDetect(So it should be DISABLED for single

applications.)


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Bus meas errorThe output closes when bus measurement protection is activated according to description of Generprotect:BusMeasErrorsetpoint.

Binary outputs Configurable prog. States

J1939Indication of J1939 communication fail (configurable between Nop protection, Warning or Shutdown).

KWP2000Indication of KWP2000 communication fail.

SHBinCfGErrShared Binary module configuration error i.e. more than one source was configured (is on the CAN2 bus

Comap Igs Nt Mint 2.2 Reference Guide

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