Igmintmintiom6 1

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
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: info@comap.cz, www.comap.cz
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 InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 2-
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 InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 3-
IGS-PTM ....................................................................................................................................................130 IGL-RA15 ...................................................................................................................................................131 InteliGen Low Temperature modification ..................................................................................................131
InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF
4-
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 genset, 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 Break Return Generator protections REMOTE START/STOP (Capital letters in the frame) buttons on the front panel (Italic) set points (Bold) Set point group (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.
5-
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 !!!
6-
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 IG-CU IG-PCLSM AT LINK-CABLE 1,8m IG-MTU IG-MTU-C IG-AVRI IG-AVRi-TRANS IG-COM IG-MU IG-IB IGL-RA15 IGS-PTM or IG-IOM Description InteliGen central unit InteliGen power control and load sharing module RS232 (WinEdit) communication cable InteliGen voltage transformer unit to separate mains and generator voltage measurement (C = with filter) InteliGen AVR interface InteliGen voltage transformer for supplying AVRi module InteliGen communication unit InteliGen Modem Unit Internet bridge Remote annunciator External analog, binary I/O unit. Connecting 3m cable is part of module delivery. Standard / Optional Standard Standard Optional Optional
Optional Optional Optional Optional Optional Optional Optional
InteliGen display software description

Serial number xx1xxxxx xx2xxxxx xx3xxxxx xx4xxxxx xx5xxxxx Description Standard character set: part of ASCII code (less than 128) Standard character set: + West European languages* Standard character set: + Chinese characters Standard character set: + West & East European languages incl. Russian Standard character set: + West & East European languages incl. Turkish
7-
Terminals and Dimensions

IG-CU Terminals
Grounding T erminal
BI1
BI6
BI7
BI8 RS 232
BI4
L1k L1l
L2k L2l
L3k L3l
L1
L2
L1
L2
L3
L3
BI2
GENERATOR CURRENT 0-5A
GENERATOR VOLTAGE 3 x 230 / 400 V
BI3
BINARY INPUTS
LB 5
EXTENSION MODULES iG-COM / iG-IOM
BOOT JUMPER BO1 (START) ANALOG INPUTS AI2 (TEMP) AI3 (FUEL) AI1 (OIL) RPM RPM GND RPM IN BINARY OUTPUTS POWER 8 - 36 V DC
Inl In (Im L3) Ink CURRENT
COM
BO2 (FUEL)
EXTENSION MODULES iG-PCM / iG-PCLSM
iG-CU
+ -
BO3
BO4
BO5
BO6
BO7
BO8
RP M Grounding T erminal
Drawing text translation Grounding Terminal RPM Grounding Terminal
IG-PCLSM Terminals
BO9
Shield
AVRi+
LSM+
GND
AVRi-
LSM-
BI9
BI5
VoutR
LOAD SHARING
SPEED GOVERNOR
Vout
AVRi
BINARY INPUTS BO10 BI10 BI12 BI11 BI13
BINARY OUTPUTS BO12 BO11 BO13
POWER 8 - 36 V DC
+ -
Warning !!! Switch IG-CU off before connecting IG-PCLSM !
LB 4
8-
IG-AVRi Terminals
AVRi OUT1 GND OUT2 AC1 AC2
LB 4
AVRi +
IG-COM Terminals
There is different wiring of IG-COM CAN connectors from hardware version 4.0.
The IG-COM label is from side.

LB 4
LB 6
H COM L CAN 2 CAN R 120 EXTENSION MODULE
L COM H CAN 1
iG-COM
Green CAN connectors are separated: CAN2
CAN1
CAN2 = inter-controller CAN, CAN1 = for extension modules - galvanically separated - IG-IOM, IGS-PTM, IGL-RA15, - internal resistor 120 ohm via jumper - connection to Extension module 9 pin connector: CAN H = pin 5 CAN L = pin 9
IG-MU Terminals
COM
COM
RS 422 TxB TxA RxB RxA COM RS 485 / RS 422 RS 232 RS 232 POWER 8-36V DC
CAN
CAN
RS 485
iG-MU
Indication LED: TxCAN, RxCAN TxD, RxD RUN
Indicates data transfer on the CAN2 line. Indicates data transfer on the RS232 line. Lights when at least one other unit is active on the CAN2 bus. Blinks when no unit is communicated on the CAN2 bus.
9-
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
P4
P3 P1 P2
P1 P2 P3 P4
2-nd local bridge Modbus jumper Boot jumper 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.
BINARY INPUTS
C OM
BI1
BI2
BI3
BI4
BI5
BI6
BI7
BI8
ANALOG INPUTS
AI4 ANALO G O UT RS232 PO WER 8-36V DC
iG-IOM
IG -C U BINARY OUTPUTS BO1 BO2 BO3 BO4 BO5 BO6 BO7 BO8
Hint: IG-IOM, IGS-PTM power supply indication LED : lights when power supply is in the range InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 10 -
blinks when there is no communication between IG-CU and IG-IOM, IGS-PTM
Dimensions
IG-CU + IG-COM + IG-PCLSM
1
130 (5,1") 113 (4,4")
~ 130 (5,1")
170 (8,87")
2 1
~ 110 (4,3")
80 (3,1")
iG-PCLSM
iG-COM
42,5 (1,7")
24 (0,9")
iG-CU
185 (7,3")
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

Primary terminals 50 / 60 Hz
OUT1 GND OUT2 AC1 AC2
45 (1,8")
0 - 230/277 - 400/480
LB 4
AVRi +
AVRi -
iG-AVRi TRANS/LV
0 - 18
43 (1,7)
36 (1,4)
43 (1,7)
Secondary terminals
123 (4,8")
11 -
IG-AVRi unit is DIN rail mount (35mm) IG-AVRi TRANS are DIN rail mount (35mm)
IG-MU
96 mm (3,8)
95 mm (3,7)
43 mm (1,7)
IG-MU unit is DIN 35 mm rail mounted.
IG-IOM
B INARY INPUT S
COM
BI1
BI2
BI3
BI4
BI5
BI6
BI7
BI8
ANAL OG INPUT S
AI4 ANAL OG OUT
IG-CU
iG-IOM
RS232
B INARY OUT PUT S B O1 B O2 B O3 B O4 B O5 B O6 B O7 B O8
POWER 8-36V DC
96 mm (3,8)
95 mm (3,7)
43 mm (1,7)
IG-IOM unit is DIN 35 mm rail mounted.
12 -
IGS-PTM
GND
AO+
BI1
BI2
BI3
BI4
BI5
BI6
BI7
BI8
AI4
BINARY INPUTS
ANALOG INPUTS COMPENSATION
0-20 mA ANALOG OUT
AO-
Tx
CAN H COM L
CAN
iGS-PTM
LB 4
BINARY OUTPUTS BO1 BO2 BO3 BO4 BO5 BO6 BO7 BO8
POWER 8-36V DC
96 mm (3,8)
Rx
95 mm (3,7)
43 mm (1,7)
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:
13 -
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.
54 (2,1) 44 (1,7)
106 (4,2)
165 (6,5)
~ 75 (3,0)
180 (7,1) 185 (7,3)
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..
~ 35 (1,4) 38 (1,5) 40 (1,6)
LB 3
~ 25 (1,0)
iG-MTU
N L1 L2 L3
155(6,10")
95 (3,74")
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.
120 (4,7) 125 (4,9)
60 (2,36")
14 -
IG-IB Internet bridge
ETHERNET RJ 45 1 2
LB 5
4 H COM L CAN POWER 8 - 36 V DC
IG-CU / DONGLE
iG-IB
96 mm (3,8)
MODEM / IB CONFIG
95 mm (3,7)
43 mm (1,7)
It is recommended to use IG-IB firmware version 2.0 IG-IB unit is DIN 35 mm rail mounted. See Internet communication
15 -
FUEL SOLENOID
FUEL LEVEL WATER TEMP

OIL PRESSURE
RPM
H
COM
L
COM
CAN
CAN
CAN
EXTENSION MODULE
GENERATOR
iG-COM
Serial No.
Inl Ink COM AI1 OIL AI2 TEMP AI3 FUEL RPM GND RPM IN
L1k L1l L2k L2l L3k L3l
ANALOG INPUTS
Serial No.
N L1 L2 L3 L1 L2 L3
iG-CU
STARTER FUEL SOLENOID GEN C.B.

FIX
CONFIGURABLE
+24V
Generator C.B.
BO1 START BO2 FUEL BO3 BO4 BO5 BO6 BO7 BO8 BO9
LOAD RES. OK UNLOAD

BI1 BI2 BI3 BI4 BI5 BI6 BI7 BI8 BI9
GEN C.B. FEED-BACK LOAD RESERVE
HORN
PRESTART SYNCHRONISE SYST READY
BINARY OUTPUTS
SYST START / STOP EMERG STOP
BINARY INPUTS
ACCESS LOCK SD OIL PRESS SD WATER TEMP SD FUEL LEVEL

CONTROL SIGNALS
Recommended wirings
POWER 8 - 36 V DC
+ -
RS 232
MGCB
TO SYSTE P T/ S MSTAR
Drawing text translation Diesel / Gas engine Generator Hint: Maximal inductive load of contact relay outputs BO1 and BO2 is 4 Amps. Use external relays for higher load.
+ BATTERY STARTER

DIESEL/GAS ENGINE
GENERATOR VOLTAGE 3 x 230 V RPM
16 BINARY OUTPUTS
L2
L3
L1
RS-232C Interface
PE
Modem or PC
LOAD
Load
IG-PCLSM
SPEED GOVERNOR AUTOMATIC VOLTAGE REGULATOR
FROM GENERATOR
iG-AVRi TRANS
LOAD SHARING PARALLEL LINE + -
Shield
LSM+
LSM-
VoutR Vout
GND
AVRi+
AVRi-
iG-PCLSM
LOAD SHARING
SPEED GOVERNOR
AVRi
Serial No.
BINARY INPUTS BI10 BI12 BI11 BI13
BINARY OUTPUTS BO10 BO12 BO13 BO11
POWER 8 - 36 V DC
+ 0 V DC
0 V DC CONFIGURABLE
Drawing text translation Speed Governor Automatic Voltage Control InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 17 -
LB 2
18 V AC
230/400 V
18 V
230/400 V
Load sharing parallel line Configurable
IG-IOM Wiring
0 V DC
0- 2 0 m A
COM
BI2
BI3
BI4
BI5
BI6
BI7
BI1
BI8
AI4 ANALOG OUT RS232 POWER 8-36V DC
BINARY INPUTS
ANALOG INPUTS
BINARY OUTPUTS
IG-CU
iG-IOM
BO1
BO2
BO3
BO4
BO5
BO6
BO7
BO8
0 V DC 8 - 36 V D C
Hint: Analog inputs COM terminal has to be connected to minus power supply.
IG-MU Wiring
RS485 / RS 422 connection
TxB TxA RxB RxA
B A
IG-MU
RS485
IG-MU
TxB TxA RxB RxA
RS422
18 -
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.
19 -
Multiple sets application

MPM: Multiple Prime mover
LOAD
GCB1
3x 3x
G1
3xU G 3xU B CAN 3xIG
iG-AVRi iG-PCLSM iG-COM

AVRi O UT AVRi
AVR
iG-CU
Vout LSM
SPEED GOVERNOR
LO AD SHARING LINE
SYS START/STO P MASTER SELECT
GCB2
MASTER SELECTO R
3x
G2
3xU B 3xU G 3xIG CAN

AVRi O UT AVRi
AVR
iG-CU
Vout LSM
SPEED GOVERNOR
SYS START/STO P START/STO P MASTER SELECT
LOAD
3x
MGCB
3x
GCB1
3x
G1
RES.O K.(1)
RES.O K.(2)
MG CB
MGCB

AVRi AVRi O UT
AVR
iG-CU
Vout LSM
SPEED GOVERNOR
LO AD SHARING LINE
SYS START/STO P MASTER SELECT LO AD RESERVE 2

MG CB
GCB2
3x
MASTER SELECTO R
3x
G2
3xU G 3xU B CAN 3xIG
iG-AVRi iG-COM iG-PCLSM

AVRi AVRi O UT
AVR
iG-CU
Vout LSM
SPEED GOVERNOR
SYS START/STO P START/STO P MASTER SELECT LO AD RESERVE 2
20 -
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 nx nx nx IG-CU IG-COM (Optional) IG-PCLSM 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
21 -
MSB: Multiple Stand-by

LOAD
U,f
T
3x 3x
MCB
3x
GCB1
3x 3x
G1
3xU B 3xU G CAN 3xIG
U,f
3x
(3.PH.RELAY)

AVRi AVRi O UT
AVR
KA KA
iG-CU
MCB
M GC SYS START/STO P M ASTER SELECT
Vout
LSM
SPEED GOVERNOR
LO AD SHARING LINE
GCB2
M ASTER SELECTOR
3x
G2

AVRi AVRi O UT
AVR
iG-CU
LSM
Vout
SPEED GOVERNOR
U,f
SYS START/STO P M ASTER SELECT
LOAD
U,f
T
3x
3x
MCB
3x
3x
MGCB
3x
GCB1
3x
G1
RES.O K.(1)
RES.O K.(2)
U,f
MG CB
MGCB

AVRi AVRi O UT
AVR
MG CB M CB
iG-CU
MCB
Vout LSM
SPEED GOVERNOR
SYS START/STOP M ASTER SELECT LO AD RESERVE 2

MG CB
LOAD SHARING LINE
GCB2
3x
MASTER SELECTO R
3x
G2
3xU G 3xU B 3xIG CAN

AVRi AVRi O UT
AVR
iG-CU
Vout
LSM
SPEED GOVERNOR
U,f
SYS START/STOP M ASTER SELECT LO AD RESERVE 2
Drawing text translation Load Speed governor InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 22 -
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)
1x nx nx nx nx Uf relay (Mains decoupling relay) unit + MCB control IG-CU IG-COM (Optional) IG-PCLSM IG-AVRi, IG-AVRi-TRANS (Optional)

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.

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
23 -
Multiple Parallel to mains, Stand-by, no MCB synchronization

LSM MAINS
LOAD
U,f LOAD SHARING LINE
T
3x 3x
MCB
3x
GCB1
3x
G1
U,f
3x
(3.PH.RELAY)

AVRi AVRi O UT
AVR
KA KA
iG-CU
MCB
M CB SYS START/STOP M ASTER SELECT M CB FEEDBACK
Vout LSM
SPEED GOVERNOR
LOAD SHARING LINE
GCB2
MASTER SELECTO R
3x
G2
3xU G 3xU B 3xIG CAN

AVRi AVRi O UT
AVR
PARALL. TO M AINS REQ UIRED M CB U,f M CB SYS START/STO P M ASTER SELECT M CB FEEDBACK
iG-CU
Vout LSM
SPEED GOVERNOR
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)
1x 1x nx Uf relay unit (Mains decoupling relay) + MCB control External Mains Load sharing module for Import-Export power control or Base load power control on local Load sharing modules IG-CU 24 -
nx nx nx
IG-COM (Optional) IG-PCLSM 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
LOAD
U,f
T
3x 3x
MCB
3x
3x
GCB1
3x
G1
U,f
3x

AVRi AVRi O UT
AVR
KA KA
(3.PH.RELAY)
iG-CU
MCB
M CB
EX T.SYN
LSM
Vout
SPEED GOVERNOR
LO AD SHARING LINE
Kt
SYS START/STO P M ASTER SELECT M CB FEEDBACK MASTER SELECTO R
GCB2
3x
KA
EX T. SYN
Kt 3xU B 3xU G M CB
G2
3xIG CAN
SYN.ENABLED

AVRi AVRi O UT
AVR
iG-CU
Vout LSM
SPEED GOVERNOR
M CB
SYS START/STO P M ASTER SELECT M CB FEEDBACK
M CB
25 -
LOAD
U,f
T
3x 3x
MCB
3x
MGCB
3x
GCB1
3x
G1
3x
U,f
(3.PH.RELAY)
KA
G CB1 G CB2
KC

AVRi AVRi O UT
AVR
RES.O K(1)
RES.O K(2)
MCB
M CB
EX T.SYN
M G CB
KA
iG-CU
KC
LSM
Vout
SPEED GOVERNOR
Kt
MGCB
MG CB
SYS START/STO P MASTER SELECT LOAD RESERVE 2 MCB FEEDBACK
LO AD SHARING LINE
M ASTER SELECTO R KA
EX T. SYN
3x
GCB2
3x
Kt M CB
G2
SYN.ENABLED

AVRi AVRi O UT
AVR
iG-CU
Vout LSM
SPEED GOVERNOR
SYS START/STO P M CB M ASTER SELECT LOAD RESERVE 2 M CB FEEDBACK MCB
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)
1x 1x nx nx nx nx Uf relay unit (Mains decoupling relay) + MCB control External MCB Synchronizer IG-CU IG-COM (Optional) IG-PCLSM IG-AVRi, IG-AVRi-TRANS (Optional) 26 -

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.

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.
27 -
Multiple Parallel to mains, Stand-by, MCB synchronized, Import-Export power or Base load control in parallel to mains + Stand-by
LSM MAINS
LOAD
U,f LO AD SHARING LINE
T
3x 3x
MCB
3x
GCB1
3x
G1
U,f
3x
(3.PH.RELAY)

AVRi AVRi O UT
AVR
KA KA
iG-CU
MCB
MCB
EXT.SYN
Vout LSM
SPEED GOVERNOR
LOAD SHARING LINE
Kt
SYS START/STOP M ASTER SELECT M CB FEEDBACK
GCB2
MASTER SELECTO R KA
EX T. SYN 3x
Kt 3xU G 3xU B MCB
G2
CAN 3xIG
SYN.ENABLED

AVRi AVRi O UT
AVR
PARALL. TO M AINS REQ UIRED
iG-CU
Vout LSM
SPEED GOVERNOR
M CB M CB
SYS START/STO P M ASTER SELECT M CB FEEDBACK
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)
28 -
1x 1x 1x nx nx nx nx Uf relay unit (Mains decoupling relay) + MCB control External Mains Load sharing module for Import-Export power control or Base load power control on local Load sharing modules External MCB Synchronizer IG-CU IG-COM (Optional) IG-PCLSM 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.
29 -
Getting started
How to install
General
To ensure proper function: Use grounding terminals. Wiring for binary inputs and analog inputs must not be run with power cables. Analog and binary inputs should use shielded cables, especially when length >3m.
Power supply
To ensure proper function: Use min. power supply cable of 1.5mm2 Power supply of IG-PCLSM module should be directly connected to IG-CU. Maximum continuous DC power supply voltage is 36VDC. Maximum allowable power supply voltage is 39VCD. The InteliGen power supply terminal is protected against large pulse power disturbances. When there is a potential risk of the controller being subjected to conditions outside its capabilities, an outside protection devise should be used. Hint: The InteliGen controller should be grounded properly in order to protect against lighting strikes!! The maximum allowable current through the 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.
Relays
Relays
T2A
D
+
controller
I-LBA
+ -
T2A
controller
+ + -
+ -
+ 12VDC Battery
+ 12VDC Battery
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.
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.
Drawing text translation
30 -
Battery Controller Relays I-LBA
T1A
+ + -
iG-CU iG-PC(LS)M
+
Battery
HUGE LOADS STARTER
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.
Fuse Fuse
K1 K2
K1
K2
T1A
IG controller
+ DC relays
+ 24VDC
Battery
Example of InteliGen controller protection
Drawing text translation Fuse Battery IG controller
31 -
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
iG-CU iS-CU
Signal
RPM-IN GND
MAGNETIC PICK-UP
C Signal
GAC Speed Control Unit ESD 5500

+ Power Supply Power Supply
+
Battery
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:
32 -
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.
LOAD MAINS
L1 L2 L3 N
MCB
GCB
G ENERATOR
L1 L2 L3 N
L1
L2
L3
L1
L2
MAINS VOLTAG E
G ENERATO R VOLTAGE
IG-CU
SSB, SPtM
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
K k L l L1 K k L l L2 K k L L3 l N
L3
Standard three CT conenction Single stand-by Short time parallel
I1 k I1 l
I2 k I2 l
I3 k I3 l
K L k l
L1
K L k l
L2 L3
Two CT connection
I1k I1l
I2k I2l
I3k I3l
33 -
Earth fault protection

G
K k K k L l L1 K k L l K k L2 L L3 l N
The simplest arrangement covers all zones from the generator windings to the final circuits in the load network.
L l
In k In l I1 k I1 l I2 k I2 l I3 k I3 l
L1
k k k k
l l l l
L2 L3 N
This arrangement covers earth faults in the load network only.
In k In l
K L
L1 L2 L3 N
k k k k
l l l 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.
L l
K k
In k In l
L1
k k k k
l l l l
L2 L3 N
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.
In k In l
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
L1
L2 L3 N
L1 L2 L3 G ENERATO R
L1 L2 L 3 MAINS
Drawing text translation Generator Mains InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 34 -
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-MTUC is usually connected to Vg terminals to protect against higher voltage harmonics. Four wire mains and four-pole circuit breaker or Three wire mains and three wire genset or electric three wire mains separation
L1 L2 L3 MAINS / BUS GENERATOR L1 L2 L3 N
L1 L2 L3 M AINS / BUS G E NERATO R L1 L2 L3
400V
400V
400V
400 V
400V
400 V
0V
0V
400 V
0V
0V
0V
400V
400V
0V
0V
0V
400V
400V
400V
0V
0V
T1
400V
T2
400V
T3
400V
T1
0V
T2
T3
0V
T1
400 V 0V
T2
400 V 0V
T3
400 V 0V
0V
0V
IG-MTU
IG -M T U
L1 L2
IG -M T U
L2 L3 L3 N
L1
L2
L3
L1
L2
L3
L1
MAINS / BUS VOLTAGE
GENERATOR VOLTAGE
M AINS / BUS VO LTAG E
G ENERATO R VO LTAG E
IG-CU
MAINS / BUS GENERATOR
L1 L2 L3
Principle of two transformers measuring.

T1
100V 0V
T2
100V
R = 120 k, 2W
0V
3x R
L1
L2
VOLTAGE TERMINALS
Drawing text translation Mains/Bus Generator Mains/Bus voltage Generator voltage Voltage terminals
L3
0V
35 -
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 Analog Analog measuring in specified range. type Binary Binary: open/close - threshold 750 . Tri-state Tri-state: open/close - threshold 750 , Failure <10 or > 2400 Physical dimension Dim bar,%,C, Up to 3 ASCII characters Active Active Under Protection is active under limit. Under + Fls under or sensor fail. Over Protection is active over limit.. Over + Fls over or sensor fail. Polarity Inverted Open to activate Valid only for binary and three-state inputs Close to activate Alarm type Alarm type None No protection Sensor fail Only sensor fail indication Warning Wrn on both levels Wrn+Shutdown Level1+level2 protection Wrn+Slowstop Level1+level2 protection Wrn+ElProt Level1+level2 protection Alarm activity Alarm All the time active Engine running Alarm check conditions only Unused analog input Sensor characteristic Sensor Not used set-points adjusted curve A Curve A set-points adjusted curve B Curve B set-points adjusted curve C Curve C Available on IGS-PTM Pt100/C Pt1000/C IEC 751, range -20 to 120 C Ni100/C Available on IGS-PTM Ni1000/C DIN 43760, range -20 to 120 C VDO Temp/C See chapter sensor specification VDO Press bar See chapter sensor specification VDO Level See chapter sensor specification 0-20mA/100 No external resistor !!! 4-20mA/100 No external resistor !!! 0-20mA/100-PTM Available on IGS-PTM 4-20mA/100-PTM Available on IGS-PTM 100mV/100-PTM Available on IGS-PTM Decimal points Decimals 0, 1, 2 Number of decimal points Measurement type Meas type Resistance Jumper on pins 1-2 Current 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, InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 36 -
Voltage measurement
no jumper.
Grounding T erminal
BI1
BI6
BI7
BI8
BI4
BI2
L1k L1l
L2k L2l
L3k L3l
L1
L2
L1
L2
L3
L3
GENERATOR VOLTAGE 3 x 230 / 400 V
BI3
BINARY INPUTS
LB 5
iG-CU
BOOT JUMPER
Inl In (Im L3) Ink CURRENT
BO1 (START)
AI2 (TEMP)
AI3 (FUEL)
RPM GND
AI1 (OIL)
RPM IN
COM
BO2 (FUEL)
ANALOG INPUTS
RPM
BINARY OUTPUTS
POWER 8 - 36 V DC
BO9
BO3
BO4
BO5
BO6
BO7
BO8
RS 232
RPM Grounding T erminal
BI9
BI5
3 2 1
Jumpers setting
AI1 AI2 AI3
3 2 1
3 2 1
Resistance measurement jumper on pins 1-2. Default settings. Current measurement jumper on pins 2-3.
3 2 1
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 Converted 1 0 0 2 2000 600 4-20mA/600 No. Primary Converted 1 400 0 2 2000 600 0-20mA/1000 No. Primary Converted 1 0 0 2 2000 1000 4-20mA/1000 No. Primary Converted 1 400 0 2 2000 1000
37 -
0 to 4VDC measuring
Default characteristics No analog input jumper = (voltage) WinEdit configuration = Current (linear) 0-20mA/100 Customer characteristics A,B,C example 0-4V/1000 No. Primary Converted 1 0 0 2 2000 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 WinEdit cfg: Sensor Jumper on Meas type= PT100/C Not possible on IG-CU NI 100/C PT1000/C Resistance Resistance NI 1000/C Pins 1-2 VDO Temp Resistance Resistance VDO Press Pins 1-2 VDO Level 0-20mA/100 Current (linear) Resistance 4-20mA/100 Pins 2-3 0-20mA/100-PTM Not possible on IG-CU 4-20mA/100-PTM 100mV/100-PTM IGS-PTM WinEdit cfg: Jumper on Meas type = 1-2, Resistance Resistance
Not possible on IGS-PTM
Pins 2-3, Current No jumper, Voltage
Resistance 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
- POWER COM AI1 AI2 AI3
IG-CU
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.
3x RESISTIVE SENSOR
38 -
IG-CU
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.
3x RESISTIVE SENSOR
IG-CU
Three current output sensors connection to InteliGen. Configuration jumper must be in 2-3 position for this type of measurement. WinEdit configuration = Current (linear).
3x SENSORS 4 - 20 mA +24V
Example of connection of two wire sensors. Analog input common terminal COM has to be connected to IG minus Power supply terminal.
IG-CU
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.
+24V AI1 CURRENT SENSOR AI2 RESISTIVE SENSOR AI3 BINARY INPUT
- PO W ER COM AI1 AI2 AI3
IG-CU
Mixed connection of InteliGen analog inputs: AI1 resistive sensor AI2 binary input AI3 three state input
2x 470 ohm s
Analog input common terminal COM has to be connected to IG minus Power supply terminal.
AI1 RESISTIVE SENSO R AI2 BINARY INPUT AI3 THREE STATE INPUT
Analog inputs are designed for resistive sensors with resistance in range of 0 to 2,4k. To ensure a proper function use shielded cables, especially for length over >3m.
39 -
Binary input
Open, close state are detected, threshold level is 750 .
Three state input

Open, close and failure state are detected. Threshold level is 750 , failure is detected when circuit resistance is <10 or > 2400 .
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.
40 -
Binary inputs
4k7
iG-CU
+
Power Supply
T1A
+ 24VDC Battery
Binary outputs
LOAD
iG-CU
+
Power Supply
T1A
+ 24VDC Battery
Drawing text translation Battery Power supply
41 -
IG-COM Wiring
120
H COM L CAN 2 EXTENSION MODULE L COM H CAN 1
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
H COM L CAN 2 EXTENSION MODULE
L COM H CAN 1
No internal resistor 120 ohm is available on IG-MU.
iG-MU
ETHERNET RJ 45 1 2
LB 4
No internal resistor 120 ohm is available on IG-IB.
MODEM / IB CONFIG
iG-IB
4 H COM L CAN2 POWER 8 - 36 V DC
IG-CU / DONGLE
5
120
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
42 -
CAN bus
RxB
COM
COM
CAN
CAN
CAN
CAN
RS 422
COM
COM
RxA
TxB TxA
EXTENSION MODULE
EXTENSION MODULE
iG-MU
Se rial No.
RS 422
RS 232
RS 232
Serial No.
Serial No.
POWER 8-36V DC
--
COM
COM
CAN
Extension modules (CAN bus) connection

5
120ohm
CAN H CAN L
CAN H CAN L
CAN
IG-CU
9
CANL COM CANH
CANL CANH
EXTENSION MODULES iG-COM / iG-IOM CONNECTOR
IGS-PTM (optional)
or
IGL-RA15 (optional)
120 ohm
IG-IOM (optional)
Drawing text translation Extension modules Connector Optional
CANL COM CANH
120ohm
43 -
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.
44 -
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.
45 -
Binary inputs list

Alarm
If the input is closed (or opened) selected alarm is activated. Binary Alarm configuration items Name 14 characters ASCII string Inverted Close to activate Open to activate Alarm type Warning Slow stop Shut down Unloading HistoryRecord, No warning Alarm active All the time 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-MANAUT-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. InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 46 -
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) PrioritySwtch2 (Priority switch 2) PrioritySwtch3 (Priority switch 3) PrioritySwtch4 (Priority switch 4)
Binary inputs for external genset priority selection. Priority selection is important in Power management. Higher Priority gensets starts sooner. The range from of Priority setting is 1 to 15. Priority value Priority 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PrioritySwtch1 0 or nc 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 PrioritySwtch2 0 or nc 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 PrioritySwtch3 0 or nc 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 PrioritySwtch4 0 or nc 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 Hint: Priority value is defined by setpoint Power management: Priority when all Priority switches are opened or not configured.
Man load recon (Manual load reconnection)

Rising edge on MAN LOAD RECON input resets IG controller to the lower step of Load shedding when AutoLd recon = DISABLED and Generator actual load is under Ld Recon level. InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 47 -
Ld recon del is not important in manual reconnection by binary input . Principle of Load shedding is described in the chapter Function description Load shedding.
Start button
Binary input has the same function as Start button on the InteliGen front panel. It is active in MAN mode only.
Stop button
Binary input has the same function as Stop button on the InteliGen front panel. It is active in MAN mode only.
FaultResButton
Binary input has the same function as Fault reset button on the InteliGen front panel.
HornResButton
Binary input has the same function as Horn reset button on the InteliGen front panel.
Gen CB button
Binary input has the same function as GCB button on the InteliGen front panel. It is active in MAN mode only.
Remote MAN
When closed Controller is switched to MAN Mode. When opened controller is switched to previous mode.
RemControl lock
Locks command writing and setpoint changing from all remote terminals.
GCB disable
Active input blocks in AUT (not in MAN) mode closing GCB.
ForwSyncDisab
Active input blocks forward GCB synchronizing.
Oil press
Behavior for Inverted = Close to activate configuration: Binary input must be closed when engine is not running and opened when is running. "Sd Oil press B" is activated when input is opened on not running engine or when stays closed Engine params: Protection del after engine start. "Sd Oil press B" protection is not active when input is not configured.
Emerg. manual
The controller behaves like when switched to OFF mode if input is closed. Opens all binary outputs Fuel solenoid, Cooling pump signals, etc... except: Stop solenoid output does not close. Detection of "running" engine and subsequent alarm message "Sd Stop fail" is blocked. The controller shows "Emerg Man" state and the engine can not be started. Generator current and power (energy) measurement is active in this mode, regardless of actual state of the engine. After the binary input "Emerg. manual" is open again, the controller recovers to previous mode and behaves according to the actual situation (e.g. should the engine run, it tries to stop it). Function is active in any controller mode and activation of this input is written to history.
48 -
Binary outputs IG-CU+IG-PCLSM default
Hint: Maximal inductive load of contact relay outputs BO1 and BO2 is 4 Amps. Use external relays for higher load.
Binary outputs IG-IOM, IGS-PTM
Hint: Before connection of IG-IOM or IGS-PTM use +IOM aig archive. Use WinEdit to configure these binary outputs. WARNING: When the data cable between the IG-CU and the IG-IOM, IGS-PTM is disconnected, IG-IOM, IGS-PTM alarms are not active, only common IOM alarm appears.
Binary outputs list

Starter The closed relay energizes the starter motor. The relay opens if: the Start RPM speed is reached or maximum time of cranking is exceeded or request to stop comes up
Fuel solenoid
The setpoint Engine params: Fuel solenoid selects the output function: DIESEL, GAS.Fuel solenoid (DIESEL / GAS)
49 -
Ignition
The closed output switches on the ignition. The output closes if: RPM > 30. The output opens if: RPM < 3.
Pre-start
The output closes prior to the engine start (Prestart) and opens when START RPM speed is reached. During repeated crank attempts the output is closed too. The output could be used for pre-glow, pre-heat or prelubrication.
Cooling pump
The output closes when gen-set starts and opens AfterCoolTime delayed after stop the engine.
Idle/Nominal
The output closes during engine start, after Idle time elapses. The output opens again in Cooling state. Hint: Connect Binary output IDLE / NOMINAL to speed governor to switch the speed: opened = IDLE, closed=RATED.
GCB close/open
The output controls the generator circuit breaker. Hint: Supposed time to close (reaction time) of GCB is 0,1 sec.
GCB ON coil
Pulse output for GCB closing.
GCB OFF coil

Pulse output for GCB opening.
GCB UV coil
GCB undervoltage coil.
GCB closing GCB close/open GCB ON coil GCB OFF coil GCB UV coil
2s 2s
GCB opening
Drawing text translation GCB closing GCB opening GCB close/open GCB ON coil GCB OFF coil GCB UV coil
Hint: GCB UV coil automatically opens when GCB is closed spontaneously not from controller except Synchronization state.
50 -
Syst ready
The output closes if the system load reserve could be achieved. PBNom + PRNom > PAkt + Reserve PBNom PRNom PAkt Reserve Sum of the nominal power of all gen-sets on the bus Sum of the nominal power of all gen-sets ready to take the load i.e. starting, cooling or ready to start) System load adjusted setpoint LoadRes strt 1 or LoadRes strt 2
Hint: Gen-sets have to be included in Power management by closing of input SYS START/STOP Is ready to take the load when is in AUT mode and no shut down alarm is active and accepted, Setpoint Power management = ENABLED or EXTERNAL, BI Remote start/stop is closed. Use this output as an alarm indication.
Syst res OK
The output closes when selected system load reserve is achieved. PBNom > PAkt + Reserve PBNom PAkt Reserve Sum of the nominal power of all gen-sets on the bus System load selected setpoint LoadRes strt 1 or LoadRes strt 2
The output can be used for closing of MGCB (Master generator circuit breaker) Hint: Gen-set has to be included in Power management by closing of input SYS START/STOP Gen-set has to be in AUT mode Setpoint Power management has to be ENABLED or EXTERNAL..
Syst res1 OK
The output closes when Load reserve 1 is achieved. It is not important which reserve is selected.
Syst res2 OK
Syst res3 OK
Syst res4 OK
GenParamsOK
The output is copy of generator status LED on IG front panel. The output is closed if genset is running and all genset electric values are in limits and no no Sd or Unload alarm is active. Hint: Use this output for switching of auxiliary device (e.g. cooling pump) driven from generator independently on the GCB.
Alarm
The output closes if : any alarm comes up or the gen-set malfunctions The output opens if FAULT RESET is pressed InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 51 -
The output closes again if a new fault comes up.
Horn
The output closes if: any alarm comes up or the gen-set malfunctions The output opens if: FAULT RESET is pressed or HORN RESET is pressed or Max time of HORN is exceeded (Horn timeout) The output closes again if a new fault comes up.
Full load
The output closes if the gen-set is fully loaded and there is no reserve in engine power. The output can be used for load shedding. The output closes when the load >= 0.9 * Nomin power for more than 3sec. The output opens when the load < 0.9 * Nomin power.
Ready to load
The output is closed if genset is running and all electric values are in limits no alarm is active. The GCB is already closed or is able to be closed. The output opens during cooling state.
Unload
The output is closed during unloading of genset.
Synchro
The output is closed during genset forward and reverse synchronizing and opens when GCB or MCB is closed.
NotReadyAuto
The output is closed in OFF, MAN, TEST mode or in AUT mode when a failure blocking automatic operation is detected. The output is opened only in AUT mode, when no failure blocking the engine operation is active and genset is ready to take the load or it is already running loaded. Hint: Use this input for external indication that genset is not ready for automatic or stand-by function.
Vg fail
The output closes if the generator over/under voltage alarm or voltage asymmetry alarm activates. The output opens, if alarm is not active and FAULT RESET is pressed
fg fail
Output closes if the generator over/under frequency alarm activates. The output opens, if alarm is not active and FAULT RESET is pressed
Overload
Output closes if the generator overload alarm activates. The output opens, if alarm is not active and FAULT RESET is pressed
52 -
Reverse power
Output closes if the generator reverse power alarm activates. The output opens, if alarm is not active and FAULT RESET is pressed
Overspeed
Output closes if the gen-set overspeed alarm activates. The output opens, if alarm is not active and FAULT RESET is pressed
Underspeed
Output closes if the gen-set under speed alarm activates. The output opens, if alarm is not active and FAULT RESET is pressed
Start fail
Output closes after the gen-set start-up fails. The output opens, if alarm is not active and FAULT RESET is pressed
Overcurrent
Output closes if the generator IDMT over current or current unbalance or short current alarm activates. The output opens, if Alarm is not active and FAULT RESET is pressed
Earth fault
Output closes when Earth fault protection is active. Output opens when protection is not active and FAULT RESET is pressed.
Batt volts
Output closes when battery over/under voltage warning appears. The output opens, if alarm is not active and FAULT RESET is pressed
Common Wrn
Output closes when any warning alarm appears. The output opens, if No warning alarm is active and FAULT RESET is pressed
Common Stp
Output closes when any slow stop alarm appears. The output opens, if No slow stop alarm is active and FAULT RESET is pressed
53 -
Common Sd
Output closes when any shut-down alarm appears. The output opens, if No sd alarm is active and FAULT RESET is pressed
Common Unl
Output closes when any unload alarm appears. The output opens, if No unload alarm is active and FAULT RESET is pressed
Common Fls
Output closes when any sensor fail alarm appears. The output opens, if no Sensor fail is active and Fault reset button is pressed.
AVR up AVR down

Binary outputs for Volt / PF control by motorized potentiometer. Outputs should be used when IG-AVRi module is not connected. Hint: The Alarm Wrn VoltRegLim is blocked when binary output AVR up and AVR down are configured.
SPEED up SPEED down

Binary outputs for Sync / Load control by motorized potentiometer. Minimal pulse duration is 0,15 sec. Maximal pulse duration is 10,0 sec. Hint: The Alarm Wrn SpdRegLim is blocked when binary output AVR up and AVT down are configured. The response of SPEED UP and SPEED DOWN binary outputs is very fast and frequent to make control process more precise. It is supposed direct connection to electronic speed governor without mechanical elements like relays, motorized potentiometer or servo. Min pulse duration 0,15 sec, max pulse duration 10 sec.
OFF mode
The output is closed, if OFF mode is selected.
MAN mode
The output is closed, if MAN mode is selected.
AUT mode
The output is closed, if AUT mode is selected.
AIn 1 , AIn 2, AIn 3

Output closes when IG-CU Analog input 1, 2, 3 Level1 or Level2 (e.g. warning or shutdown) alarm appears. The output opens, if Alarm is not active and FAULT RESET is pressed
54 -
AIM 1 AIM 2 AIM 3 AIM 4

Output closes when IG-IOM, IGS-PTM Analog input 1, 2, 3, 4 Level1 or Level2 (e.g. warning or shutdown) alarm appears. The output opens, if Alarm is not active and FAULT RESET is pressed
Load shedd 1 (2, 3)

Output closes when gen-set power exceeds Ld shed level limit for Ld shed del time. Output opens automatically when AutoLd recon = ENABLED or manually by rising edge of Binary input MAN LOAD RECON. One edge moves only one stage. Principle of Load shedding is described in the chapter Function description Load shedding.
Stop solenoid
Output closes when is active stop command. Output activates as well when engine moves spontaneously, not from starter sequence. Output is closed for minimal Engine params: Stop time (default 60 s) in any case and 5 sec after RPM=0.
Service time
Output closes when gen-set Service count down timer Service time reaches zero.
Cooling
Output closes when gen-set is in Cooling state.
CommonSdStpUnl
Output closes when any Shut-down or Stop or Unload alarm appears. The output opens, if No from above alarms are active and FAULT RESET is pressed
BI6 stat, .. BI9 stat
(IG-CU Binary input status)
When corresponding binary input (BI6 to BI9) is configured as Alarm and this Alarm is active (or inactive but not accepted by Fault reset button) then output is closed. When corresponding binary input (BI6 to BI9) is configured as function (e.g. GCB feedback) then output follows input state.
IOM BI5 stat, .. IOM BI8 stat
(IG-IOM or PTM Binary input status)
When corresponding binary input (BIM5 to BIM8) is configured as Alarm and this Alarm is active (or inactive but not accepted by Fault reset button) then output is closed. When corresponding binary input (BIM5 to BIM8) is configured as function (e.g. GCB feedback) then output follows input state.
55 -
Analog inputs IG-CU (+IG-IOM or IGS-PTM)
Default setting of IG-IOM or IGS-PTM analog inputs is Not used.
Analog output IG-IOM, IGS-PTM

AOM1 Gen-set power
Not configurable output of generator power in the range 0 to 20 mA. Hint: Adjust AnOut set point in kW/20mA to set analog output range.
56 -
Setpoints
Password
There are three levels of password protection. 0. User level allows change of non-protected setpoints only 1. Operator level allows change of setpoints protected by Operator level 2. Master level allows change of setpoints protected by Operator and Master level 3. Supervisor highest level allows all setpoints or configuration changes, firmware upgrade. Hint: The asterisk mark * appears before a setpoint name (on controller screen) if the setpoint is password protected. The asterisk mark is removed only when the password is set from controller front panel. The asterisk mark is still visible on controller screen even if the password is set from WinEdit. When password is set from the controller front panel only the affected setpoints are not accessible from WinEdit (direct or Modem) until password is set in WinEdit (direct or Modem). Setpoints opened from front panel are automatically closed 15 minutes after the last key has been depressed or when wrong value of password is set. It is possible to protect remote Start, Stop, GCB and MCB commands from WinEdit, MultiEdit as well. This three level command protection can be configured from WinEdit.
EnterPassword
Password is a four-digit number. Only setpoints associated with the entered password level can be modified. Use or to select the desired password and then hit enter.
ChangePassword 1 ChangePassword 2 ChangePassword 3

Hint: Any password can be changed once that level password or higher has been entered. To set password protection from WinEdit: Open WinEdit Select Controller Software configuration Modify Select Setpoints window Set desired protection level: 0 or 1 or 2 or 3
Access code
Can be changed from WinEdit software only. Has to be set before remote modem or SMS connection is opened. Can be up to 16 ASCII characters due to Internet At first the Password3 has to be entered before the new Access code can be changed.
Commands protection
Commands password protection protects following commands from WinEdit / MultiEdit direct, modem or GSM modem connection: Start, Stop, Horn reset, Fault reset, GCB close/open, MCB close/open. Selected Command password level 0, 1, 2, 3 is valid for all commands. Selected level is in RED color. To set commands protection from WinEdit: Open WinEdit Select Controller Software configuration Modify InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 57 -
Select Setpoints window Set Commands = 0 (no protection) or level 1 or 2 or 3
Process control
Hint: The first character of replicated setpoints name is #.
#SystLdCtrl PtM
[BASELOAD / LDSHARING]
BASELOAD: Gen-sets group operating in parallel to mains is loaded at preadjusted level (SystBaseLoad). LDSHARING: Gen-sets load is controlled by load sharing line. Total group load is shared between connected gen-sets.
#SysPFCtrl PtM
BASEPF: V SHARING:
[ BASEPF / V SHARING ]
gen-set is loaded at preadjusted level Process control: SysPwrFactor. power factor is shared with other engines.
#SystBaseLoad
[kW]
Total required power of gen-sets group operating in parallel to mains (MCB feedback closed). Step: 1 Range: 0 +30000 kW
#SystPwrFactor
[-]
The required power factor of gen-sets group operating in parallel to mains. Step: 0,01 Range: 0,60 1,00
DetectOtherCAN
[ DISABLED / ENABLED ]
ENABLED: Message WrnCANbusEmpty is recorded to Alarm list and History when no other controller is on the CAN bus. DISABLED: No message.
Basic settings
Gen-set name
User defined name, used for InteliGen identification at remote phone or mobile connection. Gen-set name is max 14 characters long and have to be entered manually using WinEdit software. Hint: Gen-set name is not changed when new archive is loaded. Check Gen-set name after firmware upgrade.
Nomin power
Nominal power of the generator Step: 1 kW Range: 1 3000 kW
[kW]
Nomin current
[A]
This is the current limit for the generator. IDMT over current and short current protection are set based on this setpoint. See Generator protections: 2Inom del, Ishort setpoints. Nominal current can be different from generator rated current value. Step: 1A Range: 1 - 5000 A !!! VERY IMPORTANT !!! The maximum input range of the InteliGen current terminals are 11 Amps. Anything over this value is displayed as measured limit, e.g. 15 Amps from CT is measured and displayed as 11 Amps. InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 58 -
Take special care when selecting CTs. All available 5 Amp CTs do not have a range up to 11 Amps.
CT Ratio
[/5A]
Generator current transformer ratio. Step: 1 A/5A Range: 1 10000 A/5A Hint: When /1A CT is used (e.g. 100A/1A) then set CT Ratio five times higher (500/5A). /1A CT is not recommended because only 20% of measuring range is used.
PT ratio
Gen-set potential transformers ratio. Step: 0,1 V / V Range: 0,1 500,0 V / V
[/1]
Vb PT Ratio
Bus potential transformers ratio. Step: 0,1 V / V Range: 0,1 500,0 V / V
[/1]
AnOut-kW/20mA
[kW/20mA]
Conversion coefficient from gen-set power to IG-IOM, IGS-PTM analog output in kW to full output scale 20 mA. Step: 1 kW / 20mA Range: 1 - 32000 kW / 20mA Hint: Available only for IG-IOM, IGS-PTM configuration.
EarthFltCurrCT
Earth fault protection CT ratio. Step: 1 A/5A Range: 1 5000 A/5A
[/5A]
Gen nom V
Nominal generator voltage (phase to neutral). Step: 1V Range: 80 30000 V
[V]
Bus nom V
[V]
Nominal bus voltage (phase to neutral). Step: 1V Range: 80 30000 V Hint: Both Gen and Mains nominal voltages must be set to the same value when no PT is used.
Nominal RPM
Nominal speed of the engine. Step: 1RPM Range: 100 4000 RPM
[RPM]
The following table shows the relationship between frequency and nominal RPM due to generator poles. Generator poles 2 4 50 Hz 3000 1500 60 Hz 3600 1800 59 -
6 1000 1200 Hint: Generator frequency can be used (for RPM measuring) only when generator voltage (min 5V) is present before reaching of the firing speed (Start RPM) after start. When pick-up cut (fail) comes, InteliGen detects under speed and stops the engine.
Nominal freq
[Hz]
Nominal generator frequency (usually 50 or 60 Hz). Step: 1Hz Range: 45 65 Hz
Gear teeth
[-]
Number of teeth on the engines flywheel for for the pick-up. Set to zero, if no pick-up is used. Engine speed is calculated from the generator frequency. Step: 1 Range: 0 500
FltRes GoToMAN
[ DISABLED / ENABLED ]
DISABLED: Controller stays in AUT mode after Fault reset . ENABLED: Automatic switch from AUT (or SEMI or TEST) to MAN mode after Fault reset to avoid automatic engine start. This function is active for all protections (Shut down, Slow stop, Unload, Off-load) except Warning protection. Hint: It is not possible reset Fault when Binary input Remote TEST is closed. Set to ENABLED to avoid automatic engine start when Fault reset button is pressed after shut down in automatic mode.
ControllerMode
[ OFF, MAN, AUT ]
Equivalent to Controller mode changes by MODE or MODE buttons. Hint: Mode change can be separately password protected.
Contr. addr (1 .. 32)
[-]
Controller identification number. Each gen-set in the group has to have its own unique number. Default value is 1. Hint: When opening Direct or Modem connection to single InteliGen, the InteliGen Controller address has to be set to 1 and must correspond to WinEdit communication setup setting.
RS232 mode
[ Standard / Modbus ]
Communication protocol selection. Standard: InteliGen (WinEdit/MultiEdit) communication protocol. Modbus: InteliGen Modbus protocol. Hint: Detail description see in InteliGen Communication guide.
CAN bus mode
[ 32C / 8C ]
CAN bus speed selection. 32C: High speed CAN (250 kbps) applicable up to 32 controllers, CAN bus limited up to 200 meters. 8C: Low speed CAN (50 kbps) applicable up to 8 controllers, CAN bus limited up to 900 meters. Hint: Low speed use for long distance connection only. Set all connected controllers to the same speed.
Engine params
Prestart time [s]
60 This is the time the binary output PRE-START is active for prior to engine start. InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF
Set to zero if you want to leave the output PRE-START open. RPM must be zero during Prestart time. Step: 1s Range: 0 600 s
Starting RPM
[%]
Firing speed when controller stops cranking. Under speed limit when engine is running. Step: 1 % of Nominal speed Range: 1 50 %
MaxCrank time
[s]
Amount of time the iG will crank the engine in an attempt to start. Step: 1s Range: 1 60 s Hint: When digital output Fuel Solenoid is configured as gas, the engine will crank 25% longer on the last unsuccessful attempt in order to ventilate the remaining gas. The InteliGen will not continue cranking the engine after three seconds of RPM = 0. It will continue CrankFail pause.
CrankFail pause
Pause between crank attempts Step: 1s Range: 1 60 s
[s]
Crank attempts
[-]
Max number of crank attempts Step: 1 Range: 1 - 10 Hint: The starter will disengage when digital output starter is engaged for 2 sec. and RPM equals zero. The setpoint Gear teeth has to be set greater than zero. A pick-up fail shutdown is activated when digital output starter is closed and generator voltage is higher than 5 V and RPM equals zero.
Idle time
[s]
Idle time delay starts when RPM exceeds Start RPM. A start fail is detected if the RPM drops below 30 and the InteliGen is still in the Idle state. During the Idle time is Binary output IDLE/NOMINAL opened, when expires IDLE/NOMINAL output closes. Binary output IDLE/NOMINAL opens during Cooling period again. Step: 1s Range: 1 300 s
RP M
Start RPM RPM = 30 BO Starter
RP
BO IDLE/RATED Idle time Start Fail Min stab time Electric protections active
Drawing text translation Start RPM Start Fail

InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 61 -
BO Starter BO IDLE/RATED Idle time Min stab time Electric protections active Hint: Pressing START button in MAN mode skips the Idle time and switch to running state. Hint: Pressing START button in MAN mode skips the Idle time and switch to running state. Idle function Outputs and Setpoints overview:
Engine params: Idle time [s]
Idle/Nominal
binary output
Drawing text translation Engine params Idle time Idle/Nominal Binary output
Min stab time
[s]
This is the minimum time the iG will wait, after the RPM has come up to nominal RPM, to close the GCB. Step: 1s Range: 0 Max stab time
Max stab time
[s]
Maximum time after reaching of defined level of RPM to get proper voltage level of the generator. Step: 1s Range: Min stab time 300 s Hint: When generator voltage does not reach defined limits ( see Generator protection group) within Max stab time the unload alarm is activated, genset cools and stops. History and Alarm list record contains Alarm reason (e.g. Vg<).
Cooling time
[s]
Runtime of the unloaded gen-set to cool the engine before stop. Engine stays on Nominal RPM during cooling. Step: 1s Range: 0 3600 s
AfterCool time
[s]
Runtime of engine after cooling pump. Binary output COOLING PUMP is closed when the engine starts and closes AfterCool time delayed after gen-set stops. Step: 1s Range: 0 3600 s Hint: If the engine After cooling function is needed the binary output COOLING PUMP should be configured.
Stop time
[s]
Stop time value means the minimum time for which Stop solenoid will be closed. If the engine stopping procedure will take longer time, the Stop solenoid stays closed until all signs of moving engine have disappeared (RPM, Vg, fg) + 5 seconds more to have some safety overlap. After Stop time has elapsed and the engine is still moving, the alarm "Sd Stop fail" is produced. However, this is not a normal situation and should be solved by increasing the Stop time setpoint.
62 -
The StopValve" countdown timer will be displayed on IG screen. Step: 1s Range: 0 240 s
Fuel solenoid
(DIESEL / GAS)
[-]
Selecting of FUEL SOLENOID output function. DIESEL: closed output opens the fuel solenoid and enables the engine start. The output opens if: Emergency stop comes or Cooled gen-set is stopped or In pause between repeated starts GAS: closed output energizes the gas valve. The output closes if RPM > 30 with 1s delay. The output opens if: Emergency stop comes or The cooled gen-set is stopped or In pause between repeated starts. If the engine is unsuccessful in starting the Fuel Solenoid output will stay energized 25% longer in order to vent the remaining gas. Example of FUEL SOLENOID output behavior during unsuccessful start.
the last cranking
BO Starter Start RPM RPM
closed
opened
ventilation
M axCrank tim e
RPM < Start RPM RPM < 3 RPM > 30 RPM =0 RPM > 30 RPM < Start RPM
+ 25 %
RPM < 3
RPM =0
M axCrank time BO Fuel solenoid=Diesel BO Fuel +1sec solenoid=G as BO Ignition

closed opened closed opened
+1sec
closed opened closed opened
on
off
on
Drawing text translation BO Starter BO Fuel BO Ignition Start RPM Solenoid=Diesel Solenoid=Gas Closed Opened MaxCrank time The last cranking Ventilation
Engine protect
NextServTime [h]
This is the amount of time that will elapse till service on the gen-set is required. When the countdown is complete: Service alarm is detected Alarm list is recorded InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 63 -
Step: Range:
1h 0 65535 h
Hint: Once the service time has elapsed the NextServTime will have to be reset to clear the alarm and begin a new countdown.
Horn timeout
[s]
The maximum amount of time the horn will sound. If it desired to have the horn sound until the alarm is cleared then set to zero. Step: 1s Range: 0 600 s
Overspeed
[%]
Threshold for over speed protection Step: 1% of nominal RPM Range: 50 150% Hint: Engine params: Start RPM value is checked as underspeed level.
Protection del
[s]
During the start of the gen-set, some engine protections have to be blocked (e.g. Oil pressure). The protections are unblocked after the Protection del time. The time starts after reaching Start RPM. Step: 1s Range: 0 300 s
Anl Inp1 level1
[]
The first threshold level for ANALOG INPUT 1 alarm detection. Default setting is setting is oil pressure warning. Step: 0,1 bar (psi) Range: -100 10000
Anl Inp1 level2
[]
The second threshold level for ANALOG INPUT 1 alarm detection. Default setting is oil pressure shut down. Step: 0,1 bar (psi) Range: -100 10000
Anl Inp1 del

Delay for ANALOG INPUT 1 alarm. Step: 1s Range: 0 180 s
[s]
Anl Inp2 level1
[]
The first threshold level for ANALOG INPUT 2 alarm detection. Default setting is water temperature warning. Step: 1 C (F) Range: -100 10000
Anl Inp2 level2
[]
The second threshold level for ANALOG INPUT 2 alarm detection. Default setting is water temperature shut down. Step: 1 C (F) Range: -100 10000
Anl Inp2 del

Delay for ANALOG INPUT 2 alarm.
[s]
64 -
Step: Range:
1s 0 180 s
Anl Inp3 level1
[]
The first threshold level for ANALOG INPUT 3 alarm detection. Default setting is fuel level warning. Step: 1% Range: -100 10000
Anl Inp3 level2
[]
The second threshold level for ANALOG INPUT 3 alarm detection. Default setting is fuel level shut down. Step: 1% Range: -100 10000
Anl Inp3 del

Delay for ANALOG INPUT 3 alarm. Step: 1s Range: 0 180 s
[s]
Batt >V
[V]
Warning level for battery over voltage. Step: 0,1V Range: 10 40 V
Batt <V
[V]
Warning level for low battery voltage. Step: 0,1V Range: 8 30 V
Batt V del
[s]
Delay for battery voltage alarms. Step: 1s Range: 0 600 s Hint: SD battery flat is detected when controller is switched off during cranking. The next start is blocked. Following AIM set points are available only when IG-IOM, IGS-PTM is configured.
AnlInIOM1 lev1
[]
The level for IOM ANALOG INPUT 1 alarm detection. Step: 1 Range: -100 - +10000
AnlInIOM1 lev2
[]
AnlInIOM1 del
[s]
Delay for IOM ANALOG INPUT 1 alarm. Step: 1 s Range: 0 - 180 s
AnlInIOM2 lev1
[]
The level for IOM ANALOG INPUT 2 alarm detection. Step: 1 Range: -100 - +10000 InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 65 -
AnlInIOM2 lev2
[]
AnlInIOM2 del
[s]
AnlInIOM3 lev1
[]
AnlInIOM3 lev2
[]
AnlInIOM3 del
[s]
AnlInIOM4 lev1
[]
AnlInIOM4 lev2
[]
AnlInIOM4 del
[s]
Hint: The analog input del is still enabled even if these inputs are configured as binary inputs contrary to standard Binary inputs B1 to BI9 which have fix 1 sec delay for activation.
Gener protect
Hint: All Alarm limits are the last acceptable values. Alarm detection starts when measured value is over the alarm limit.
Overload
[%]
Threshold for generator overload (in % of Nominal power) triggers when exceeded. Step: 1% of Nominal power Range: Overload wrn 300% Protection: Unload (GCB open), Cooling, Stop. InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 66 -
Overload wrn
[%]
Threshold for generator overload warning alarm (in % of Nominal power) Step: 1% of Nominal power Range: 50 Overload Protection: Warning
Overload del
Delay for generator overload Step: 0.1s Range: 0 60.0 s
[s]
Ishort
[%]
Ishort is a percentage over nominal current, that when reached the GCB Close/Open, GCB UV coil, and the GCB Off coil are immediately opened, the event is recorded in the alarm and history list, and the engine will cool down and stop if the Fault reset button is not depressed. Step: 1 % of Nominal current Range: 100 - 500 % Protection: Unload (GCB open), Cooling, Stop.
Ishort del
[s]
Delay for generator short current protection. Step: 0.02 s Range: 0.00 10.00 s
2Inom del
[s]
IDMT curve shape selection. 2Inom del is the reaction time of IDMT protection for 200% overcurrent Igen = 2* Nominal current. Step: 0,1 s Range: 0 - 60 s Protection: Unload (GCB open), Cooling, Stop. IDMT is inversely proportional to the generators overcurrent. The higher the overcurrent gets the less time will elapse before the alarm is activated. When the IDMT protection is activated the GCB is opened, the event is recorded in the alarm and history list, and the engine will cool down and stop if the fault reset button is not depressed.
2Inom del * Nomin current
Reaction time = Igen Nomin current
Where Reaction time is the amount of time from IDMT detection to the opening of the GCB.
67 -
Reaction time
Maximal Reaction time
2Inom del
Igen
Nominal current
Drawing text translation Ishort Reaction time Nominal current Maximal Reaction time Igen 2lnom del Hint: The maximum allowable Reaction time is 900 sec or 15 min.
Where Igen is the maximum current of the three phases of generator current. EXAMPLE of Reaction time for different over current levels. Values in column 200% are equal 2Inom del. 200 % = 2Inom del 0,2 s 2s 20 s Overcurrent 100 % 101 % No action No action No action 20 s 200 s No action (time > 900 s) 110 % 2s 20 s 200 s
Ishort
Reaction time
!!! VERY IMPORTANT !!! The maximum input range of the InteliGen current terminals are 11 Amps. Anything over this value is displayed as measured limit, e.g. 15 Amps from CT is measured and displayed as 11 Amps. Take special care when selecting CTs. All available 5 Amp CTs do not have a range up to 11 Amps.
Curr unbal
[%]
Threshold for generator current unbalance. Step: 1% of Nominal current Range: 1 200% Protection: Unload (GCB open), Cooling, Stop.
68 -
Curr unbal del

Delay for generator current unbalance. Step: 0.1 s Range: 0 60.0 s
[s]
EarthFaultCurr
[%]
Threshold for generator Earth fault protection. Step: 1 % of Nominal current Range: 1 300 % Protection: Unload (GCB open), Cooling, Stop.
EthFltCurr del
[s]
Delay for generator Earth fault protection. Step: 0.1 s Range: 0 60.0 s
Gen >V Sd
[%]
Threshold for generator over voltage Shut down protection. Step: 1% of Nominal voltage Range: 50 150% of Nominal voltage Protection: GCB opening and engine shut down.
Gen >V Unl
[%]
Threshold for generator over voltage. Step: 1% of Nominal voltage Range: Gen <V 150% of Nominal voltage Protection: Unload (GCB opening), Cooling, Stop.
Gen <V Unl
[%]
Threshold for generator under voltage. Step: 1% of Nominal voltage Range: 50 Gen >V Protection: Unload (GCB opening), Cooling, Stop. Hint: All three phases are checked for generator voltage protection. Minimum or maximum out of three is used.
Gen V del
[s]
Delay for generator under voltage and over voltage Unload and Shut down protection. Step: 0.1s Range: 0 600 s Protection: Unload (GCB opening), Cooling, Stop.
Volt unbal
[%]
Threshold for generator voltage unbalance. Step: 1% of Nominal voltage Range: 1 150% Protection: Unload (GCB open), Cooling, Stop.
Volt unbal del

Delay for generator voltage unbalance. Step: 0.1s Range: 0 60.0 s
[s]
Gen >f
[%]
Threshold for generator phase L3 over frequency. Step: 0.1% of Nominal frequency InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 69 -
Range: Protection:
Gen < f - 200,0 % of Nominal frequency Unload (GCB open), Cooling, Stop.
Gen <f
[%]
Threshold for generator phase L3 under frequency. Step: 0.1% of Nominal frequency Range: 0.0 Gen > f Protection: Unload (GCB open), Cooling, Stop.
Gen f del
[s]
Delay for generator under frequency and over frequency Step: 0.1s Range: 0 60.0 s
Pwr management
Hint All parameters in the Power management group except Power management, Priority have to be equal throughout all the controllers and are automatically replicated from one controller into the other connected controllers. The first character of all replicated setpoint names is #. It is visible on InteliGen screen and in WinEdit.
Pwr management (ENABLED / DISABLED / EXTERNAL) [-]

DISABLED: Each engine starts / stops when Binary input Sys start/stop is closed / opened independent on other gen-sets. CAN bus line is necessary for VAR sharing. ENABLED: Gen-sets operate in Pwr management. Binary input Sys start/stop the engine to take place in power management. EXTERNAL : Same as ENABLED, but pwr management values(Priority, number of currently active Reserve, number of currently active MinRunPower) are controlled externally via CAN bus.
Pwr mgmt mode

ABS (kW): REL (%):
[ ABS (kW) / REL (%)]
Load reserves for start LoadResStrt and for stop LoadResStp are set in absolute values in kW (the same Pwr management procedure like before). Load level for start LoadResStrt and for stop LoadResStp are set in relative values in %. Then % means maximum allowable power of all running gensets in % of Nominal power.
Following see examples for five gensets 100 kW each. Compare genset-starting sequence for setting Pwr mgmt mode = ABS (kW) or REL (%) during Actual power increasing.
Pwr mgmt mode = ABS (kW) LoadResStrt = 40 kW
200 kW 300 kW 400 kW 100 kW 500 kW
0 kW
160 kW
260 kW
360 kW
60 kW
Actual power
1. Genset 2. Genset 3. Genset 4. Genset 5. Genset
running running running running running
70 -
Pwr mgmt mode = REL (%) LoadResStrt = 40 %

40 % of 100 kW 40 % of 200 kW 40 % of 300 kW
40 % of 400 kW
400 kW
100 kW
200 kW
260 kW
300 kW
360 kW
500 kW
0 kW
Actual power
40 kW
80 kW
120 kW
160 kW
1. Genset 2. Genset 3. Genset 4. Genset 5. Genset
running running running running running
Drawing text translation Pwr mgmt mode = ABSOLUTE (RELATIVE) LoadResStrt Actual power Genset running
Priority (1..32)
[-]
Adjusts the priority of the gen-sets. Based on this priorities gen-sets are started. Priority 1 is the highest, Priority 32 is the lowest. Step: 1 Range: 1 32 Hint: Two or more gen-sets can have the same priority. In that case they behave as one big gen-set with the sum of gen-sets Nominal power. When one of them has closed Binary input Master select behaves as higher priority engine.
#SysAMFstrtDel
[s]
(System AutoMainsFail starting delay, Power management activation delay). Delay between mains failure and the emergency start of the gen-sets when Binary input SYS START/STOP is closed e.g. controlled by mains decoupling relay. Island operation, MCB FEEDBACK is opened. If the MCB FEEDBACK is closed Power management activates with 1s delay after SYS START/STOP parallel operation with the mains. Step: 1s Range: 0 600 s
#SysAMFstpDel
[s]
(System AutoMainsFail stopping delay) Delay between Binary input SYS START/STOP opening and GCB opening in island mode when Binary input MCB FEEDBACK is opened. Delay between mains return to start of genset unloading when binary input SYS START/STOP is controlled from mains decoupling relay. If the MCB FEEDBACK is closed, the delay between Binary input SYS START/STOP opening and start of genset unloading in parallel to the mains is fixed to 1s. Step: 1s Range: 0 600 s
#LoadResStrt 1 (2, 3, 4)
[kW%]
Required system load reserve, or in the other words load reserve defines the maximum allowable load jump. One of the load reserves 1, 2, 3, 4 is by binary input LOAD RESERVE 2, 3, 4 selectable. When the required load reserve is not achieved, another gen-set is started. Step: 1 kW% Range: 1 32000 kW%
71 -
Hint: Use load reserves to separate minimum initial power for start-up and necessary reserve in steady running conditions.
#LoadResStp 1 (2, 3, 4)
[kW%]
One of the load reserves 1, 2, 3, 4 is by binary input LOAD RESERVE 2, 3, 4 selectable. When LoadRes Stp 1 (2, 3, 4) level is achieved, the gen-set with the lowest priority (highest setpoint Priority ) is stopped. Next gen-set is stopped when: PBNom > PAkt + LoadRes stp PBNom PAkt Reserve Step: Range: Sum of the nominal power of all gen-sets on the bus apart of the one, which is going to be stoped. System load LoadRes Stp 1 or LoadRes Stp 2 1 kW% 0 32000 kW%
Hint: The engine will be stopped only when #MinRun power level stays running.
!!! IMPORTANT !!!

LoadRes Stp has to be higher than corresponding LoadRes Strt for Pwrmgm mode = ABS (kW) LoadRes Stp has to be lover than corresponding LoadRes Strt for Pwrmgm mode = REL (%)
2nd gen-set 400 Load Res Stp 60 kW
Load Res Strt 40 kW
1st gen-set 200
100
150 170
250
170
150
100
1st gen-set 2nd gen-set
Y N
Y N
Y Y
Y Y
Y Y
Y Y
Y N
72 -
#Next start del
[s]
The delay before next gen-set start-up in Power management. Delay is not used, when the first gen-set(s) starts. Step: 1s Range: 0 600 s
#Overld NextDel
[s]
The delay before next gen-set start-up in Power management when the system load is equal or higher then nominal power of all gen-sets on the bus. Delay is not used, when the first gen-set(s) starts. Step: 1s Range: 0 600 s
#Next stop del
[s]
The delay before next gen-set stopping in Power management. When delay is elapsed, the gen-set starts unloading, gets off line and stops. Step: 1s Range: 0 600 s
#Slow stop del
[s]
Waiting to next gen-set start before gen-set slow stop procedure. Gen-set stops when Slow stop del expires even if next gen-set does not start. When there it is not next gen set available slow stop procedure begins immediately. Step: 1s Range: 0 600 s
#MinRun power 1 (2, 3)
[ kW ]
It is minimal required power of gen-set group (sum of Nominal power of running gensets). When Binary input SYS START STOP is closed starts and stays running such number of gensets to keep #MinRunPower value independent on load value. When Binary inputs MIN RUN POWER 1 (or MIN RUN POWER 2 or MIN RUN POWER 3) is closed different value of #MinRun power 1 (or 2 or 3) is selected. When more binary inputs MIN RUN POWERx is closed the higher number has higher priority. When no input closed, no #MinRun power is selected and minimum running power is zero. Step: 1 kW Range: 0 60000 kW Hint: The engine will be stopped only when #MinRun power level stays running. Power management Inputs, Outputs and Setpoints overview:
73 -
Binary inputs
Binary outputs
Master select
Pwr management:
PrioritySwtch 1 PrioritySwtch 2 PrioritySwtch 3 PrioritySwtch 4
Load reserve 2 Load reserve 3 Load reserve 4
#SysAMFstsrtDel #SysAMFstpDel #NextStart del #OverldNextDel #NextStop del #SlowStop del
Priority
Syst ready
#LoadResStrt1 #LoadResStp1 #LoadResStrt2 #LoadResStp2 #LoadResStrt3 #LoadResStp3 #LoadResStrt4 #LoadResStp4 #MinRun power1 #MinRun power2 #MinRun power3
Syst res OK
Syst res1 OK Syst res2 OK Syst res3 OK Syst res4 OK
MinRun power 1 MinRun power 2 MinRun power 3
Drawing text translation Binary inputs Master select PrioritySwtch Load reserve MinRun power Pwr management Priority #LoadResStrt #LoadResStp #MinRun power #SysAMFstsrtDel #SysAMFstpDel #NextStart del #OverldNextDel #NextStop del #SlowStop del Binary outputs Syst ready Syst res OK
Binary inputs Master select PrioritySwtch Sys Start/Stop MinRun power Pwr management Priority #LoadResStrt #LoadResStp #MinRun power #SysAMFstsrtDel #SysAMFstpDel #NextStart del #OverldNextDel #NextStop del #SlowStop del Binary outputs Syst ready Syst res OK
Sync/Ld ctrl
Hint: Adjusting procedure of Sync/load and Volt/PFcontrol loops see in chapter IM - IG MINT setpoints adjustment.
SpeedRegChar
[POSITIVE / NEGATIVE ]
Switch between isochronous speed governor characteristic. POSITIVE: When controller Speed governor output voltage increases engine speed increases. NEGATIVE: When controller Speed governor output voltage decreases engine speed increases. Hint: All corresponding set points Slip freq gain, Angle gain and Load gain are positive. When set to NEGATIVE Binary outputs SPEED UP and SPEED DOWN works in opposite way.
Voltage window
[%]
74 -
Maximum difference between generator and bus voltage.
Step: Range:
0.1 % of Nominal voltage 0.0 100.0 %
Phase window
[]
Maximum phase angle difference between generator and bus. Step: 1 Range: 0 90
GtoB AngleReq
[]
Phase difference between generator and mains voltage. Use this setpoint for phase correction of potential transformers for forward synchronizing. Step: 1 Range: -30 to +30 Following is an example of Controller connection to Middle voltage system. T1 shifts phase +30 and no shift is on T2. GtoM AngleReq = +30 for this example.
BUS
T2
T1
GCB
3x230/400VAC
3x10 kV
4
4
L1, L2, L3, N
Vb
GCB
Vg Ig
iG -CU
Dwell time
[s]
The period of time that the phase angle must be within Phase window and Voltage difference within voltage window before GCB closing. Step: 0.1 s Range: 0.0 25.0 s
Freq gain
[%]
Slip frequency control loop gain during synchronizing when GCB is still opened. Step: 0.1 % Range: 0 to +200.0 %
Freq int
[%]
Relative integration factor of slip frequency control loop. Step: 1% Range: 0 % 100 %
Freq der
[%]
Relative stability factor of slip frequency control loop. Step: 1% Range: 0 % 100 %
Freq reg loop

GCB OPEN: SYNC ONLY:
[ GCB OPEN / SYNC ONLY ]
Frequency control is active when running unloaded and synchronizing. Frequency control is active during synchronizing only.
75 -
Angle gain
[%]
Gain of angle control loop when slip frequency is near zero and GCB is still opened. Step: 0.1% Range: 0 % to +200.0 %
Angle der
[%]
Relative stability factor of angle control loop. Step: 0.1% Range: 0 % to +100.0 % Hint: Setpoints Slip freq gain, Slip freq int, Slip freq der, Angle gain, Angle der adjusts speed (are active) during synchronizing only when GCB is opened.
Speed gov bias
[V]
Speed control DC output bias level of SPEED GOVERNOR voltage output. Step: 0.01 V Range: -10.00 to +10.00 V
Load ramp
[s]
Increasing or decreasing load rate. In seconds / nominal power. Step: 1s Range: 0 600 s
Load gain
[%]
Gain of power control loop, when GCB and MCB are closed. Step: 0.1 % Range: 0 to +200.0 %
Load int
[%]
Relative integration factor of power control loop. Step: 1% Range: 0 100 %
Load der
[%]
Relative stability factor of power control loop. Step: 1% Range: 0 100 % Hint: Load gain, Load int and Load der setpoints are active only when gensets group operates in parallel to the mains, when GCBs and MCB are closed and Process control: SysLdCtrlPtM = Baseload. Load control operates via IG-PCLSM load sharing line, where 7,5 VDC value means requirement of Nominal genset power.
GCB open level
[%]
Power level for getting offline while unloading. If this level isnt reached GCB opens after GCB open del time. Step: 1 % of Nominal power Range: 0 to 100 %
GCB open del

Maximum time to unload the gen-set. Step: 1s Range: 0 600s
[s]
LS gain
Gain of load sharing power control loop.
[%]
76 -
Step: Range:
0.1% 0 to +200.0 %
LS int
[%]
Integratio factor of load sharing power control loop. Step: 1% Range: 0 100 %
LS der
[%]
Relative stability factor of load sharing power control loop. Step: 1% Range: 0 100 % Hint: LS gain, LS int and LS der setpoints are active when gensets group operates in Island parallel: GCBs are closed and MCB is opened. Process control: SysLdCtrlPtM = LdSharing. Parallel to mains: GCBs and MCB are closed. Process control: SysLdCtrlPtM = LdSharing. Load control operates via IG-PCLSM load sharing line, where 7,5 VDC value means requirement of Nominal genset power.
Sync timeout
[s]
Maximal allowed time for forward or reverse synchronization. When Sync timeout is expired Sync alarm is detected. Step: 1s Range: 0 1800 s Hint: When any gain setpoint is set to zero corresponding control loop is switched OFF.
Volt/PF ctrl
AVRRegChar [POSITIVE / NEGATIVE ]
Switch between AVR characteristic. POSITIVE: When controller and AVRi output voltage increases generator voltage increases. NEGATIVE: When controller and AVRi output voltage decreases generator voltage increases. Hint: All corresponding set points Voltage gain and PF gain are positive. When set to NEGATIVE Binary outputs AVR UP and AVR DOWN works in opposite way.
Voltage gain
Gain of voltage control loop. Step: 0.1 % Range: 0 to +200.0 %
[%]
Voltage int
[%]
Relative integration factor of voltage control loop. Increasing of integration value causes quicker response. Step: 1% Range: 0 100 %
Voltage der
[%]
Relative stability factor of voltage control loop. Step: 1% Range: 0 100 % Hint: Voltage gain, Voltage int andVoltage der setpoints are active (adjusts AVR) only when GCB is open to maintain Nominal voltage or to match voltage during synchronizing. Voltage loop operates as well when GCB is closed and MCB opened. InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 77 -
PF gain
[%]
Gain of power factor control loop. Step: 0.1 % Range: 0 to +200.0 % Hint: When any gain setpoint is set to zero corresponding control loop is switched OFF.
PF int
[%]
Relative integration factor of power factor control loop. Increasing of integration value causes quicker response. Step: 1% Range: 0 100 %
PF der
[%]
Relative stability factor of power factor control loop. Step: 1% Range: 0 100 % Hint: PF gain, PF int and PF der setpoints are active only when is gen-set parallel to mains.
VS gain
[%]
Gain of VAR (power factor) sharing control loop. Step: 0.1 % Range: 0 to +200.0 %
VS int
[%]
Relative integration factor of of VAR (power factor) sharing control loop. Step: 1% Range: 0 100 % Hint: VS (PF) int in fact hides two setpoints: - VS int to keep the the reactive power precisely shared - maintain system voltage at nominal. This is very slow additional voltage control loop (only integrative control). Its power is about 10times weaker than real VS int. Primary voltage control should be done by AVR governor.
VS der
[%]
Relative stability factor of of VAR (power factor) sharing control loop. Step: 1% Range: 0 100 % Hint: VS gain, VS int and VS der setpoints adjusts AVR only when GCB closed and MCB open or GCB closed and MCB closed and the Setpoint SysLdcrtlPtM is set to Loadsharing) to adjust PF (VAR sharing) and maintain system voltage at nominal.
AVR DCout bias
[%]
AVRi voltage output bias level. Step: 0.1 % Range: 0 100.0 % Hint: Real voltage level depends on AVRi outputs connection and output level potentiometer setting. Maximum output range is 10 V.
78 -
Act. calls/SMS
Warning call Unload call Slow stop call Shut down call AcallCH1..3-Type
Up to three separate channels are available for any one of the following types of messages: DISABLED: Channel is disabled. DATA: Standard analog, GSM or ISDN modem connection to WinEdit. SMS: Channel sends SMS message. Only when is GSM modem connected. E-MAIL: Channel sends E-mail. Only when is IG-IB connected. EML-SMS: Channel sends E-mail with short SMS. Only when is IG-IB connected. Email contains - header with serial number and application info. - Alarm list - 20 History records (reason, date, time) Example of EML-SMS: AL=(Sd Water Temp,Wrn Water Temp,!Emerg Stop,ActCallCH1Fail)
[DISABLED / ENABLED] [DISABLED / ENABLED] [DISABLED / ENABLED] [DISABLED / ENABLED]
Enables or disables active calls/SMS to selected phone or mobile numbers when a warning alarm occurs.
Enables or disables active calls/SMS to selected phone or mobile numbers when a unload alarm occurs.
Enables or disables active calls/SMS to selected phone or mobile numbers when a slow stop alarm occurs.
Enables or disables active calls to selected phone or mobile numbers when a shut down alarm occurs.
AcallCH1..3Addr
Address for channel 1...3 active call. Each above message type has either a number or an e-mail address associated to it. For more details see WinEdit-MultiEdit guide chapter IG-IB Internet communication. Hint: To receive active call run WinEdit Type of connection = Active call. WinEdit Active call window contains list of received AIG or AIS files. Each list item contains Gen-set name, Date, Time, IS serial number.
NumberRings AA
[-]
Number of rings prior to open modem connection from PC to controller. Step: 1 Range: 1 30 Hint: NumberRings AA change is not accepted immedatelly but after controller is switched on or when modem is connected to controller.
A.c.multiplier
[ 1 to 250 ]
When active call is activated, controller tries five times to open the connection when A.c.multiplier = 1 (e.g. when the phone line is engaged). There are ten attempts when A.c.multiplier = 2, etc.. Step: 1 Range: 1 to 250 Hint: There are 5 attempts for any active call. Timeout for connection is 90 sec and after 120 sec controller starts the next attempt. During the time the iG is trying to send an active call type, incoming calls are blocked.
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Load Shedding
The load shedding function is available in all applications SPM, SSB, SPtM, MINT, MEXT and is active in all iG modes except OFF. Load shedding has three steps and each step is linked with its own LOAD SHED digital output. There is only one load shed level and delay for all three steps as well as recon level and delay. Load shed can only move from one step to the next, e.g. No LoadShed to LdShed S1 to LdShed S2 to LdShed S3 and vise versa. If manual reconnection of the load is desired the AutoLd recon setpoint needs to be disabled and the MAN LOAD RECON digital input needs to be configured. Digital input MAN LOAD RECON resets iG to lower stage of load shed only if the load is under Ld Recon Level. All LOAD SHED outputs are activated (closed) to trip unessential load before genset goes to island (MCB opens) from parallel to mains: a) After Mains fail before genset starts to island in AUT mode. b) Before MCB is opened in MAN mode by button.
Ld shed level
[%]
When gen-set load exceeds this level for more than LD Shed delay , iG controller proceeds to the next Load shedding stage - the next binary output LOAD SHED x is closed. Step: 1 % of Nominal power Range: from Ld Recon level to 200 % of Nominal power
Ld shed del
[s]
Time delay for LD shed level limit. Step: 0.1 s Range: 1 - 1800 s
Ld recon level
[%]
When gen-set load drops under this level for more than LD recon delay time, IS/IG controller proceeds to the lower Load shedding stage. The binary output for higher stage is opened (LOAD SHED x). Automatic load reconnection works only when AutoLd recon = ENABLED. Step: 1 % of Nominal power Range: from 0 - Ld shed level
Ld recon del
[s]
The amount of time that the load has to exceed Ld shed level before the next load shed level is activated. Step: 1s Range: 1 - 1800 s
AutoLd recon (DISABLED / ENABLED) [-]

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

TimeStamp per
Time interval for history record. Time base is based on number of minutes since midnight. Step: 1 min Range: 0 - 240 min Hint: No history is recorded when TimeStamp Per = 0.
#Time [HHMMSS]
Real time clock adjustment.
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#Date [DDMMYY]
Actual date adjustment. Hint: #Time and #Date setpoints are synchronized via CAN bus each hour with the lowest address controller. #Time or #Date change in any controller changes Time or Date in all controllers on CAN bus.
Sensor spec
Calibr AI1 (AI2, AI3) Calibr AIM1 (AIM2, AIM3, AIM4) [] []
Calibrating constant to adjust the measured value of IG-CU and IG-IOM, IGS-PTM (when configured) analog inputs. The units of the calibration constant are the same as the associated analog input, e.g. If entering 5 for Calibr AI1, and AI1 is oil pressure in psis then it would be 5 psis. Step: 1 Range: -1000 +1000 Hint: Calibr AI1, Calibr AI1, Calibr AI3 have to be adjusted when measured value is near the alarm level. Customer adjustable characteristics Curve A, Curve B, Curve C adjust in WinEdit.
81 -
IM - IG MINT setpoints adjustment

Active and reactive power terminology
LOAD
MAINS
GEN
MAINS P > 0 Import Q> 0 Import Q Cos < 0 L Export P Import Q Cos < 0 C Export P Export Q Cos > 0 L Import P Import Q Cos > 0 C Import P Export Q P
P>0 Q> 0 Q
LOAD Consumption Consumption
P> 0 Q> 0
GEN Generation Generation Q
Cos > 0 L Consumption P Inductive LOAD Cos > 0 C Consumption P Capacitive LOAD
Cos < 0 L Consumption P Generation Q P Cos < 0 C Consumption P Consumption Q
Cos > 0 L Generation P Generation Q P Cos > 0 C Generation P Consumption Q
Mains
Exported active power is supplied to the mains. It is displayed in negative numbers e.g. 20kW. Imported active power is consumed from the mains. It is displayed in positive numbers e.g. +20kW. When reactive power is imported (>0) InteliMains displays L (inductive) character of the load. Process control: SysImportLdChr = L-Im kVAr. When reactive power is exported (<0) InteliMains displays C (capacitive) character of the load. Process control: SysImportLdChr = C-Ex kVAr.
Load
Active power consumed by Load is displayed in positive numbers e.g. 20kW. When reactive power is positive (>0) InteliMains displays L (inductive) character of the load. When reactive power is negative (<0) InteliMains displays C (capacitive) character of the load.
Genset
Generated active power is displayed in positive numbers e.g. 20kW. When reactive power is positive (>0) InteliGen displays L (inductive) character of the load. When reactive power is negative (<0) InteliGen displays C (capacitive) character of the load.
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Steps of InteliGen MINT set points adjustment

Following chapters contain recommended procedure of InteliGen MINT set points set up. At first refer to InteliGen - MINT Users guide, chapters Sync/load and Volt/PF set points. The first step is speed and AVR loop sensitivity adjusting. The second step is InteliGen - MINT set points adjusting.
1. IG-PCLSM Speed governor output

Hint: No droop Speed governor is expected for controller connection. Two wire shielded connection from IG-PCLSM SPEED GOVERNOR output (GND, Volt or VoltR) to Speed governor auxiliary input is recommended. IG-PCLSM SPEED GOVERNOR output sensitivity should 10V to 5% of Nominal generator frequency (see drawing below). IMPORTATNT Speed governor has to be adjusted for optimum performance before controller Sync / load control adjusting. Check generator phase sequence before the first GCB connection. Example of Speed governor out sensitivity: Genset RPM Speed gov bias -10 V 1425 RPM 0V 1500 RPM = Nominal 10 V 1575 RPM
Nominal 5% Nominal + 5%
Check Speed gov bias when genset is idle running. When is speed characteristic negative (increasing Speed gov bias decreases RPM) set SpeedRegChar = NEGATIVE (All speed gain setpoints are positive). RPM RPM + 5 % of nominal + 5 % of nominal
1500 - 10 V 0V
Speed governor voltage output +10 V
1500 - 10 V
0V
Volt [V]
Speed governor voltage output +10 V
Volt [V]
- 5 % of nominal SpeedRegChar = POSITIVE
- 5 % of nominal SpeedRegChar = NEGATIVE
Drawing text translation Speed governor voltage output RPM of nominal

Check Speed gov bias when genset is idle running. When is speed characteristic negative (increasing Speed gov bias decreases RPM) set SpeedRegChar = NEGATIVE (All speed gain setpoints are positive). To decrease Speed governor out sensitivity use IG-PCLSM VoutR output and connect external resistor R2 in parallel to output. VoutR output voltage is in this case R2 / (R1+R2) = 1 / 11 = 0.09 times off Vout voltage.
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IG-PCLSM
G ND
VoutR range: depends on resistor R2 value
Speed governor
G ND
R2=1k R1=10k VoutR AUX input
Vout range: -10.0 V to +10.0 V
Drawing text translation Speed governor GND VoutR AUX input VoutR range: depends on resistor value Vout range
Each genset in the group should have the same speed governor out sensitivity. Speed governor characteristics difference unbalances Load sharing during synchronizing of loaded gensets group to the mains.
2. IG-PCLSM AVRi output

Hint: No droop AVR unit is expected for standard controller connection. IG-AVRi-TRANS (AC power supply for AVRi) have to be supplied from gen-set voltage. AVRi outputs can be connected: OUT1-OUT2 or unsymmetrical OUT1-GND or OUT2-GND. To check AVR DCout bias range set Voltage gain = 0. 1) 2) 3) 4) Potentiometer on the AVRi defines maximal OUT1, OUT2 voltage range When AVRi is connected to AVR auxiliary voltage input use OUT1,OUT2 AVRi outputs When AVRi replaces AVR external potentiometer use unsymmetrical output. AVRi output voltage should change generator voltage max in range 10 % of Nominal voltage.
Out1 - GND [V]
10 V
10 V
Out2 - GND [V]

um xim ma
AV Ri pot set to
2V 0V
AVRi pot
t to t se i po R AV
2V 0V
in set to m AVRi pot
imum
ma xim um
set to m inimum
0%
AVR DCout bias
100.0 %
0%
AVR DCout bias
100.0 %
AVRi Out1 or Out 2 to GND output voltage depends on AVRi trim setting
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[V]
10 V
Out1 to Out2
um im ax m
0V 0%
= m ot imu min ip R ot = p i V A AVR

50 %
AVR DCout bias
100.0 %
AVRi output voltage Out1 - GND Out2 - GND Out1 Out2 Bias \ Pot Min Max Min Max Min Max 0% 0 0 2 10 - 2 V -10 V 50 % 1 5 1 5 0V 0V 100 % 2 10 0 0 + 2 V 10 V
-10 V
AVRi Out1 to Out 2 output voltage
Drawing text translation AVR DCout bias Out

Example of AVRi out sensitivity: AVR DCout bias Generator voltage 0% 210 V 50 % 230 V = Nominal 100 % 250 V
= Nominal 9% = Nominal +9%
Adjust AVR and AVRi to keep Nominal genset voltage at AVR DCout bias = 50%. To decrease AVRi output voltage sensitivity turn AVRi trim ccw. When the AVR characteristic is negative (increasing AVRi output decreases generator voltage) set AVRChar = NEGATIVE (All AVR gain setpoints are positive). Each genset should have the same AVRi out sensitivity. AVR characteristics difference unbalances PF sharing during synchronizing of loaded gensets group to the mains.
3. Voltage control
Conditions: running single gen-set, analog Volt/PF control using IG-AVRi module. Adjust Voltage control set points of each gen-set separately : MINT - Volt/PF control: AVR DCout bias, Voltage gain, Voltage int, Voltage der. Hint: Simulate voltage steps by changing of Nominal voltage setpoint and check stable Voltage control.
Voltage matching
Vbus
InteliGen - MINT
Voltage gain Voltage int Voltage der
AVRi analog output + +
Vgen AVR DCout bias
Drawing text translation

InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 85 -
Voltage matching Vbus Vgen Voltage gain Voltage int Voltage der AVRi analog output AVR DCout bias
4. Forward synchronizing
Conditions: two running gen-sets, one is connected in MAN mode to dead bus, on the second genset press in MAN mode GCB close/open button to start synchronising to the bus. Adjust Sync control set points of each gen-set separately. Check InteliGen-MINT synchroscope screen. IG - Sync/Load control: Voltage window, Phase window, Dwell time, Speed gov bias, Slip freq gain, Slip freq int, Slip freq der and Angle gain, Angle der. Hint: At first set Phase window = 0 to avoid GCB closing. Simulate speed steps by changing of Speed gov bias setpoint or press repeatedly GCB close/open button to start stop synchronizing and check stability of synchronizing.
InteliGen - MINT
fbus Slip freq gain Slip freq int Slip freg der Angle gain Angle der +
SPEED GOVERNOR analog output +-10 V
fgen Speed gov bias
Drawing text translation fbus fgen Slip freq gain Slip freq int Slip freq der Angle gain Angle der Speed gov bias SPEED GOVERNOR analog output
5. Load sharing
Conditions: two gensets are running in isolated parallel (MCB is opened). In the first step no load, then apply full load. When all gensets are running idle voltage of Load sharing line is zero V. When all gensets are running at Nominal power voltage of Load sharing is 7,5V. In parallel isolated mode (MCB is opened) adjust following Load sharing set points. When genset is loaded, unloaded, loading, unloading check the Load sharing. Check if Speed governor analog output does not reach limits below 10V or over 10V of the range. IG - Sync/Load control: Load ramp, LS gain, LS int, LS der, GCB open level, GCB open del Hint: When one genset is running loaded in MAN mode press GCB close/open button of the second genset to synchronize and load. Then press STOP button to unload genset and open GCB. Pressing of the START button returns IG controller back from Cooling to Idle state. InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 86 -
SPEED G OVERNO R analog output +-10 V + +
1.InteliGen - MINT
LS gain LS int LS der
Load sharing isolated parallel

LS line: 0 to +7,5 V
2.InteliGen - MINT SPEED G OVERNOR

LS gain LS int LS der + analog output +-10 V +
Speed gov bias
Speed gov bias
Drawing text translation Load sharing isolated parallel SPEED GOVERNOR analog output Speed gov bias LS gain LS int LS der LS line
6. VAR sharing
Conditions: are the same as in step 5 Load sharing. In isolated parallel mode (MCB is opened) adjust following VAR sharing set points. When loaded, unloaded, loading, unloading check the PF sharing. Check if AVR analog output does not reach limits below 0% or over 100% of the range. IG - Volt/VAR control: VS gain, VS int, VS der
Hint: When one genset is running loaded in MAN mode press GCB close/open button of the second genset to synchronize and load. Then press STOP button to unload genset and open GCB. Pressing of the START button returns IG controller back from Cooling to Idle state.
AVRi analog output +
1.InteliGen - MINT
VS gain VS int VS der
PF sharing
CAN bus
2.InteliGen - MINT
VS gain VS int VS der AVR DCout bias
AVRi analog output + +
AVR DCout bias
Drawing text translation PF sharing AVRi analog output AVR DCout bias VS gain VS int VS der CAN bus
Hint: Check output values of Sync/Load and Volt/PF control loops at InteliGen MINT Synchro screen. SRO - SpeedRegOut indicates IG-PCLSM Speed governor output in the range from 10.0V to +10.0V. VRO - VoltRegOut indicates IG-PCLSM AVRi output in the range from 0% to 100%. InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 87 -
Steps of InteliMains set points adjustment

Hint: Set point which name begins # character (e.g. #SysLdCtrl PtM) is replicated from InteliMains controller to all InteliGen controllers and vice versa.
1. Back (reverse) synchronizing of multiple gensets

Conditions: gen-sets group is running in isolated parallel (MCB is opened). Synchronize group to the mains. Group of gensets is running loaded, Load and PF is shared between gensets. Load and VAR sharing can be unbalanced during synchronizing when different sizes of gensets (or different adjusting of speed governors) are running in parallel. Adjust following InteliMains synchronizing set points, check InteliMains synchroscope screen. IM - Sync/Load control: Voltage window, Phase window, Dwell time, Slip freq gain, Slip freq int, Slip freq der and Angle gain, Angle der. Hint: Press repeatedly MCB close/open button on InteliMains controller (in MAN mode) to start /stop synchronizing and check IM synchroscope screen. At first set Phase window = 0 to avoid MCB closing.
InteliMains
fbus Slip freq gain Slip freq int Slip freg der Angle gain Angle der
Back synchronizing
InteliGen - MINT
LS gain LS int LS der + +
LS line: +- 10 V
SPEED G OVERNO R analog output +-10 V
fmains
Speed gov bias
Drawing text translation Back synchronizing fbus fmains Slip freq gain Slip freq int Slip freq der Angle gain Angle der LS line LS gain LS int LS der Speed gov bias SPEED GOVERNOR analog output
2. Voltage matching of multiple gensets

Conditions: gen-sets group is running in isolated parallel (MCB is opened). Synchronize group to the mains. Group of gensets is running loaded, Load and PF is shared between gensets. Load and PF sharing can be unbalanced during synchronizing when different sizes of gensets (or different adjusting of speed governors) are running in parallel. During synchronizing (Volt matching is active) adjust following Voltage control set points: IM - Volt/PF control: Volt gain, Volt int, Volt der.
88 -
Hint: At first set Phase window = 0 to avoid MCB closing. Press repeatedly MCB close/open button on InteliMains controller (in MAN mode) to start /stop synchronizing and check IM synchroscope screen. For test, adjust Nominal voltage of gensets group to different value from the mains voltage (e.g.210V). Voltage matching Vbus InteliMains InteliGen - MINT
Voltage gain Voltage int Voltage der Vm ains AVR DCout bias CAN bus VS gain VS int VS der + +
AVRi analog output
Drawing text translation Voltage matching Vbus Vmains Voltage gain Voltage int Voltage der CAN bus VS gain VS int VS der AVR DCout bias AVRi analog output
3. Parallel to the mains Baseload mode

Baseload set points adjusting Conditions: Bus (load) is connected to the mains - MCB is closed. IG or IM - Process control: #SysLdCtrl PtM = BASELOAD, #SysBaseLoad = Adjust following InteliGen MINT Load and PF control set points and check forward synchronizing, stable load/unload and PF control. IG - Sync/Load control: Load gain, Load int, Load der, Load ramp. IG - Volt/PF control: PF gain, PF int, PF der. Hint: When mains is connected to the bus in MAN mode press the GCB close/open button of IG-MINT controller to start synchronizing to the mains, loading at the #SysBaseLoad value. Then press the STOP button to unload genset and open GCB. Pressing of the START button returns controller back from Cooling to Running state.
89 -
Required part of #SysBaseLoad
InteliGen - MINT
Load gain Load int Load der SPEED GOVERNOR analog output +-10 V + +
Genset power Speed gov bias
#SysBasePF
InteliGen - MINT
PF gain PF int PF der + + AVRi analog output
Genset PF AVR DCout bias
Drawing text translation Required part of #SysBaseLoad Genset power Load gain Load int Load der Speed gov bias SPEED GOVERNOR analog output #SysBasePF Genset PF PF gain PF int PF der AVR DCout bias AVRi analog output
4. Parallel to the mains Import/Export mode

Import/Export load and Import/Export PF set points adjusting. Conditions: Bus (load) is connected to the mains - MCB is closed. IM - Process control: #SysLdCtrl PtM = PWR-IM/EX, SysImport load = Adjust following InteliMains Load and PF control set points and check forward synchronizing, stable load/unload and IM/EX Load and PF control. IM - Sync/Load control: Load gain, Load int, Load der, Load ramp. IM - Volt/PF control: PF gain, PF int, PF der. Hint: Forward synchronizing test When mains is connected to the bus in MAN mode press the GCB close/open button of IG-MINT controller to start forward synchronizing and voltage matching of single genset to the mains. InteliMains via LS line and CAN bus controls SysImport load and SysImport PF value which is shared between gensets in the group. When the STOP button of IG-MINT controller is pressed, genset unloads, opens GCB and steps to Cooling state. Pressing of the START button returns controller back from Cooling to Running state.
90 -
Reverse synchronizing test When gensets are running in parallel isolated (MCB is opened) in MAN mode press the InteliMains MCB close/open button to start reverse synchronising and voltage matching of loaded gensets to the mains.
Actual m ains power
InteliMains
Load gain Load int Load der
Load control
InteliGen - MINT
LS gain LS int LS der + +
LS line: +7,5 V
SPEED GOVERNOR analog output +-10 V
SysImport load
Speed gov bias
Actual Mains PF
InteliMains
PF gain PF int PF der
PF control
CAN bus
InteliGen - MINT
VS gain VS int VS der + +
AVRi analog output
SysImport PF
AVR DCout bias
Drawing text translation Load control Actual mains power SysImport load Load gain Load int Load der LS line LS gain LS int LS der Speed gov bias SPEED GOVERNOR analog output PF control Actual Mains PF SysImport PF PF gain PF int PF der CAN bus VS gain VS int VS der AVR DCout bias AVRi analog output
Hint: Output values of Sync/Load and Volt/PF control loops check at InteliMains synchroscope screen. LSO indicates IM-PCLSM load sharing output in the range from 10.0V to +10.0V. VVO indicates IM Volt/PF output to CAN bus in the range from -1000 to +1000.
91 -
Sensor specification
Sensor calibration
To correct measuring error of each analog input (pressure, temperature, level) calibrating constants within 10 % of measure range should be set. Three calibrating constants are set in physical units - C, %, psi, F, bar, etc. From these constants equivalent calibrating resistances are calculated and are internally (in software) added to the sensors resistance. Once the calibration value is entered (enter is pressed) the calibrating resistance is calculated and saved in memory. This value is then added to measured sensor resistance before the value is displayed. Example: IG-CU display Temperature 70 C and real value is 73 C. After setting Calibr AI1 to +3 C (and pressing ENTER) InteliGen calculates corresponding resistance (e.g.5) and saves this value into the memory. The resistance is then added to all calculations (e.g. instead of 70C -> 73C, or e.g. instead of 5C -> 6C).
Default sensor settings

Analog input 1: 10 points VDO characteristic, pressure measuring in bar Analog input 2: 6 points VDO characteristic, temperature measuring in C Analog input3: 2 points VDO characteristic, fuel level measuring in % Curve A VDO pressure Curve B VDO temperature Curve C VDO Fuel level
Primary ohms Converted 0,1 bar
Primary ohms Converted C
Primary ohms Converted %
PT 100 PT 1000 NI 100 NI 1000 Primary Converted Primary Converted Primary Converted Primary Converted 92 100 108 116 123 131 139 146 154 169 -205 0 205 413 595 803 1013 1197 1411 1814 922 961 1000 1117 1232 1309 1347 1385 1423 1461 -20 -10 0 30 60 80 90 100 110 120 83 90 97 105 113 121 130 139 148 169 -206 -8 189 403 605 795 1000 1200 1392 1793 893 946 1000 1171 1353 1483 1549 1618 1688 1760 -20 -10 0 30 60 80 90 100 110 120
VDO Temp VDO Press VDO Level Primary Converted Primary Converted Primary Converted 3900 1525 700 440 290 -20 0 20 30 40 10 50 85 119 152 0 20 40 60 80 10 180 0 100
92 -
195 135 95 69 38
50 60 70 80 100
180
100
Primary 170 200 230 280 330 390 460 560 690
4-20mA/100 4-20mA/60 0-20mA/100-PTM 4-20mA/100-PTM Converted Converted Primary Converted Primary Converted 0 13 25 38 50 63 75 88 100 0 8 15 23 30 38 45 53 60 0 38 57 77 96 116 135 155 174 194 0 20 30 40 50 60 70 80 90 100 38 57 77 96 116 135 155 174 194 0 12 25 37 50 62 75 87 100
100mV/100-PTM Primary Converted mV0100R mV0100Out 0 10 40 70 110 140 170 210 230 250 0 4 16 28 45 57 68 84 92 100
93 -
Operator Interface
Pushbuttons and LEDs
3 2 1 4 5
15
10
16
11
12
14
13
18
17
Pushbuttons:
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. MODE Cycle forward through gen-set operation modes OFF -> MAN -> AUT. MODE Cycle backward through gen-set operation modes OFF -> MAN -> AUT. HORN RESET Deactivates the HORN. FAULT RESET Acknowledges faults and alarms. START Starts the gen-set in MAN mode. STOP Stops the gen-set in MAN mode. MCB ON/OFF Has no affect in MINT application. GCB ON/OFF When in MAN mode opens and closes (synchronizes) the Generator circuit breaker. PAGE Cycles through the display screens MEASUREMENT->ADJUSTEMENT->HISTORY. Select the setpoint, select the screen or increase setpoint value. Select the setpoint, select the screen or decrease setpoint value. ENTER Confirm setpoint value.
94 -
LEDs
13. 14. 15. 16. BUS VOLTAGE PRESENT: GREEN LED is on, if voltage on the bus is present. BUS FAILURE: RED LED starts flashing when the bus failure occurs. GEN VOLTAGE PRESENT: GREEN LED is on, if gen. voltage is present and within limits. GEN-SET FAILURE: RED LED starts flashing when gen-set failure occurs. After FAULT RESET button is pressed, goes to steady light (if an alarm is still active) or is off (if no alarm is active). 17. GCB ON: GREEN LED is on, if GCB is closed. Flashes during gen-set synchronizing. 18. MCB ON: GREEN LED is on, if MCB is closed (binary input MCB feedback is closed).
How to select gen-set mode ?

Use MODE or MODE to select requested gen-set operation mode OFF MAN AUT. It is not possible to go directly from OFF to AUT.
When to use GCB ON/OFF button ?

In AUT mode the button is disabled. In MAN mode is enabled, but before closing of the circuit beaker, generator voltage must be within limits. iG has internal protection to avoid the breaker closure without synchronizing.
Closing to dead bus

When no voltage is detected on the bus, the GCB is immediately closed.
Synchronizing
When voltage is detected on the bus (within Voltage window) InteliGen starts synchronizing and waits for closing of GCB.
Display menus
There are 3 display menus available: MEASUREMENT, ADJUSTMENT and HISTORY Each menu consists of several screens. Pressing the PAGE button repeatedly will scroll the user through the menu screens.
How to view measured data?

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

1. Pressing the PAGE button repeatedly will scroll the user through the menu screens. Select the ADJUSTMENT screen. 2. Use or to select requested set points group. 3. Press ENTER to confirm. 4. Use or to select requested set point. 5. Set points marked * are password protected. 6. Press ENTER to edit. 7. Use or to modify the set point. When or is pressed for 2 sec, auto repeat function is activated. 8. Press ENTER to confirm or PAGE to leave without change. 9. Press PAGE to leave selected set points group.
95 -
How to view the HISTORY menu?

1. Pressing the PAGE button repeatedly will scroll the user through the menu screens. Select the HISTORY screen. 2. Use or to select a requested record. 3. Use ENTER to select requested screen (record items) within displayed records
How to change the display contrast ?

Press ENTER and or at the same time to adjust the best display contrast Hint: Only in MEASUREMENT menu
How to check the serial number and software revision?

Hold down the ENTER and the press PAGE. On the display you can see InteliGen INFO screen for 10 seconds. InteliGen INFO screen contains : 1) Controller name (see Basic setting group) 2) InteliMains serial number (8 character number) 3) SW version: the first is the firmware version number, the second is configuration table number. 4) Application: IM 5) Branch: InteliMains Hint: Only in MEASUREMENT menu.
How to find active alarms ?

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

Main measure screen
1 2
OFF MAN AUT
TEST
3 4 7 5 8
Ready Mains Oper cos 0.00 RPM 0 Tim er 0
6
1. Operation mode of the gen-set 2. Indication of active alarm !or active Remote control R InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 96 -
3. 4. 5. 6. 7. 8.
Status of the gen-set Actual condition RPM of the gen-set Active power Power factor Timer - event s counting time (e.g. prestart, cooling, etc.)
Generator screen
Load surge maximal value Load surge actual value Gen freq Gen V1-2, V2-3, V3-1 ph-ph Gen V1, V2, V3 ph-N (triple barograph) Gen I1, I2, I3 (triple barograph)
Bus screen
EarthFaultCurr Bus freq Bus Vb1-2, Vb2-3, Vb3-1 ph-ph Bus Vb1, Vb2, Vb3 ph-N (tripple bargraph)
IG-CU Analog inputs screen

AI1 Oil pressure AI2 Water temperature AI3 Fuel level Battery voltage (single barograph) (single barograph) (single barograph) (single barograph)
IG-IOM, IGS-PTM Analog inputs screen (if configured)

(single barograph) (single barograph) (single barograph) (single barograph)
IG-CU binary inputs 1/2

BI1 to BI5
IG-CU binary inputs 2/2

BI6 to BI9
IG-CU binary outputs 1/2

BO1 to BO5
IG-CU binary outputs 2/2

BO6 to BO9 Load shedding status
IG-PCLSM binary inputs

BI10 BI13
IG-PCLSM binary outputs

BO10 BO13 Hint: IG-IOM, IGS-PTM binary inputs are visible only when is IG-IOM, IGS-PTM is configured. InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 97 -
IG-IOM, IGS-PTM binary inputs 1 / 2 (if configured)

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

BI5 to BI8
IG-IOM, IGS-PTM binary outputs 1 / 2 (if configured)

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

BO5 to BO8
Gen-set power screen

Active power Power factor Reactive power kVAr Apparent power (total and per phase) (total and per phase) (total and per phase) (total and per phase)
Statistic
Kilowatt-hours kWh Active energy Reactive power hours kVArh Reactive energy Run hours Number of starts NextServTime total total
Synchroscope
Angle between V1g and V1m V1g Generator first phase voltage V1m Mains first phase voltage (synchroscope)
SRO Speed regulator output indication in the range 0 to 10,00V VRO Voltage regulator output indication in the range 0 to 100%.
Power management
Engine priority Total available power (sum of Nominal power) Total run power (sum of Nominal power - running) Active reserve (single barograph) CAN16 bus status address 1 to 16 (binary) CAN23 bus status address 17 to 32 (binary)
Alarm list
98 -
PAGE PAGE
PAGE
Measure Screens Par. Edit Screens
History Screens
OFF
ENGINE BASIC ENGINE PROT GEN BASIC GEN PROTECT MAINS FAIL
MAN 500
AUTO
1000
Screen
Drawing text translation Page Measure Screens Par. Edit Screens History Screens Next Screen
PAGE ENTER
RPM GEAR TEETH 150 150 NOM RPM 1500 1500 START RPM 30 30% CRANK TIME 10s 10
Flow Chart of pushbutton Operation
586
kW
12345h 14:23:15
Next Screen
Parameter setting: 1. Set cursor by 2. Press
ENTER
F O E Y L B OR A T IST H
buttons
to editing mode buttons
3. Adjust parameter by 4. Press

ENTER
to write parameter into memory to cancel of editing mode

ENTER ENTER
Next Screen
Press
PAGE
ENTER
99 -
PAGE
..... TO MEASURE SCREEN
Engine Basic Engine Prot Gen Basic Gen Protect Mains Fail Gear Teeth Nom RPM Start RPM Crank Time Parameter setting Set cursor by - buttons Press - to editing mode Adjust parameter by - buttons Press - to write parameter into memory Press - to cancel of editing mode Table of history To measure screen
100 -
Mode description
There are three modes of the gen-set: OFF - MAN - AUT. To select the mode use MODE or MODE.
OFF mode
Outputs STARTER, GCB CLOSE/OPEN and FUEL SOLENOID are not energized. Genset cannot be started. If START,STOP,GCB ON/OFF buttons is pressed the iG will not respond.
MAN mode
1) To start the gen-set press START. 2) When the generator voltage is within limits (adjusted in the setpoints group Generator protections) GCB green LED on the front panel lights. 3) Press GCB ON/OFF to close the GCB. If the generator voltage is out of the limits, InteliGen does not to respond to the GCB ON/OFF . a) If InteliGen detects dead bus, immediately closes GCB OPEN/CLOSE output. b) If InteliGen detects voltage (Voltage window) on the bus, starts synchronizing. 4) To stop the engine press STOP a) InteliGen unloads the gen-set. When the gen-set load reaches GCB Open level, (but max. GCB open del), iG opens GCB CLOSE/OPEN. Unloading is active only when binary input MCB feedback is closed or other gen-set is connected to bus. In other case GCB CLOSE/OPEN opens immediately. b) Gen-set is cooled and stopped. Hint: InteliGen does not respond to the binary input SYS START/STOP. The genset is permitted to run for an unlimited amount of time. InteliGen is disconnected from Power management Load and power factor sharing in parallel isolated group are active only when Load sharing line and CAN bus between all gen-sets are connected.
AUT mode
1) All gen-sets necessary to cover selected LoadRes strt are started a) immediately when SYS START/STOP binary input is closed b) delayed SysAMFstrt del when MCB FEEDBACK binary input is opened mains failure comes 2) The first gen-set closes to the dead bus, the rest are synchronized to the bus. 3) When all necessary gen-sets are connected to the bus and LoadRes strt is achieved, SYST RES OK output is closed. Output could be used to close the MGCB. 4) Gen-sets get loaded and total active and reactive load are shared between parallel operating gen-sets. 5) Close input LOAD RESERVE 2 (or 3 or 4) and use setpoint LoadRes strt, if necessary. 6) If load increases and selected LoadRes strt is not achieved, after a Next start del next gen-set with the highest priority is started and synchronized to the bus. 7) If load decreases and selected LoadRes stp is exceeded, after a Next stop del the running gen-set with the lowest priority is unloaded, got off line, cooled and stopped. 8) Gen-sets group stops when binary input SYS START/STOP opens. If the input MCB FEEDBACK is closed (gen-sets are in parallel to mains) InteliGen unloads the gen-sets. When gen-set is unloaded (see GCB open level or GCB open del) opens SYST RES OK and opens GCB CLOSE/OPEN. Hint: InteliGen does not respond to GCB ON/OFF InteliGen does not respond to START and STOP
!!!!! VERY IMPORTANT !!!!!!
101 -
Engine can start automatically without warning when pressing FAULT RESET after shut down alarm when Basic setting: FltRes GoToMAN is set to DISABLED..
Load surge protection

Load surge protection is fast Mains failure protection. It detects sudden generator load changes during parallel operation with the mains. Due to Mains failure can be generator immediately fully unloaded or heavy overloaded. Load surge protection in this case opens MCB or GCB depends on controller application. Load surge protection becomes active 3 sec delayed after entering to parallel (synchronizing). Values visible on the iG screen and in WinEdit
Max load surge
[Pnom/s]
It is maximal value of Act load surge (maxi meter). When genset enters the parallel mode, the Max load surge value is reseted to zero. Hint: Max load surge is visible on iG generator screen and in WinEdit.
Load shedding
G en-set power Ld shed level
closed
BO Load shed 1
closed
BO Load shed 2
closed
BO Load shed 3
Ld shed del
Ld shed del
Ld shed del
Load reconnection automatic

AutoLd recon = ENABLED
102 -
G en-set power Ld recon level
BO Load shed 3 BO Load shed 2 BO Load shed 1
opened
opened
opened
Ld recon del
Ld recon del
Ld recon del
Load reconnection manual

AutoLd recon = DISABLED
Ld recon level
G en -set po w er
BO Load shed 3 BO Load shed 2 BO Load shed 1
opened
opened
opened
BI Man load recon

no action
Drawing text translation Gen-set power Ld shed level Ld recon level BO Load shed BI Man load recon Ld shed del Ld recon del closed opened no action
Load sheeding Inputs, Outputs and Setpoints overview:
103 -
Vg Ig
Man load recon
Load shedding: Ld shed level [%] Ld shed delay [s] Ld recon level [%] Ld recon del [s] AutoLd recon [ ENABLED / DISABLED ]
Load shed 1 Load shed 2 Load shed 3
Drawing text translation Vg Ig Man load recon Load shedding Ld shed level Ld shed delay Ld recon level Ld recon del AutoLd recon [ENABLED / DISABLED] Load shed
104 -
Alarm management
Following alarms are available: Binary alarms Analog alarms
Hint: The alarm can be configured for any IG-CU, IG-PCLSM and IG-IOM, IGS-PTM binary input. When warning comes up it is displayed on the Alarm list screen and the selected entries are written to the History record. Detection of each binary input alarm is fix 1 sec time delayed. Analog input Alarms have usually two levels - e.g. wrn and sd. Use WinEdit to modify binary or analog inputs protections. Sensor fail does not activate binary output common Alarm.
Warning
When warning comes up, only alarm outputs are closed. Possible warnings: Binary inputs configured as Warning (alarms are displayed and stored under configured name) Analog inputs configured as Warning (alarms are displayed and stored under configured name) Battery voltage alarm level
Unload
When the generator protection comes up, InteliGen opens the output GCB CLOSE/OPEN In MAN and AUT mode engine is cooled and stopped. Possible unload alarms GCB failure Overload IDMT Overcurrent (all three phases are checked) Short current (all three phases are checked) Current unbalance Generator voltage unbalance Generator over/under voltage (all three phases are checked) Generator over/under frequency (all three phases are checked) Reverse power Earth fault BUS measurement error Alarm inputs configured as unload protection
Slow stop
When the slow stop alarm comes up InteliGen unloads gen-set, opens output GCB CLOSE/OPEN, waits for Cooling time and opens FUEL SOLENOID output. InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 105 -
When another genset is available to come on line, it will start and connect to the load before the unloading function of the first set begins. If nothing else happens the set will unload when the Slow Stop Del is exceeded. Binary inputs configured as Slow stop (alarms are displayed and stored under configured name) Analog inputs configured as Slow stop (alarms are displayed and stored under configured name)
Shut down
When a shutdown occurs, InteliGen opens outputs GCB CLOSE/OPEN, FUEL SOLENOID, STARTER. Possible shut-down alarms Overspeed Underspeed Start fail IG-IOM, IGS-PTM fail Binary inputs configured as Shut down (alarms are displayed and stored under configured name) Analog inputs configured as Shut down (alarms are displayed and stored under configured name)
Alarm time chart

Underspeed Protection delay Engine running only, SD, Slow stop, Wrn Gen>V, Gen<V, Gen>f, Gen<f, Volt unbal, Curr unbal, Reverse power, Unload protection All the time & Overspeed protections & Ig IDMT, Ig unbal, IG short Mains>V, Mains<V, Mains>f, Mains<f, MVolt unbal
Ready RPM=0 Cranking Starting Starter OFF Start Idle
Running Synchronizing Min stab time GCB closed
Loaded or Max stab time
Loaded GCB opened Unloading Cooling Stop 106 -
Voltage phase sequence detection

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

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

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

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

MCB or GCB fail detection is based on binary output CB close/open comparing with binary input CB feedback. There are three different time delays for CB fail detection see following diagrams. When the BO GCB close/open (MCB close/open) in steady state and GCB feedback (MCB feedback) is changed the GCB fail (MCB fail) is detected immediately (no delay).
closed
BO G CB close/open opened closed BI G CB feedback active Alarm: G CB fail Alarm detection: immediatelly
BO G CB close/open
BI G CB feedback
opened active
Alarm: G CB fail
Alarm detection: immediatelly
When BO GCB close/open (MCB close/open) opens there is 2 sec delay for the breaker to respond before a GCB fail (MCB fail) will be detected.
BO G CB close/open opened
BI G CB feedback
T ime delay 5 sec
opened active
Alarm: G CB fail
When BO GCB close/open (MCB close/open) closes, there is following delay for the breaker to respond before a GCB fail (MCB fail) will be detected: 2 sec when synchronizing SPtM, MINT, MEXT (parallel modes) 5 sec in stand-by SSB (island modes) InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 107 -
closed BO G CB close/open T ime delay BI G CB feedback 5 or 2 sec active Alarm: G CB fail closed
Drawing text translation BO GCB close/open BI GCB feedback Alarm: GCB fail Opened Closed Active Alarm detection: immediatelly Time delay
Sensor fail detection

Sensor fail Fls is detected when measured value is 6,2 percent out of range. The controller screen will display #### instead of the correct measured value.
R1
R2 R3 R4 R5
Sensor Failure
-6%
Range of measurement +6% Sensor 100%
Range of sensor
Failure
Drawing text translation Range of sensor
IG-PC(LS)M module fail

Fail is detected when controller is switched on only. Fail is not detected during operation state.
Speed regulator and Volt regulator limit warning

There are two control loops in controller: Sync/Load control and Volt/PF control. During operation state it is detected when regulator output reached limit value i.e.: When Speed governor output stays on +9,8V or -9,8V for more than 2 sec the warning SpdRegLim is detected on the Alarm list. When AVRi output stays on <2% or >98% for more than 2 sec the warning VoltRegLim is detected on the Alarm list. This warning indicates only (no other action) wrong connection or adjusting of control loop. Control loops should operate within range. Hint: Corresponding warning is blocked when Binary outputs SPEED up,SPEED down or AVR up, AVR down are configured.
108 -
Bus voltage error detection

Bus measure error is detected in MINT / MEXT application when: Voltage on IG bus terminals is out of limits 20 seconds after: a) GCB (own) was closed in MAN or AUT mode b) MCB (feedback) was closed in AUT mode c) Any other GCB in power management group (on CAN bus) was closed. The alarm is activated after 20 s, however the GCB (own) closing is blocked immediately from safety reasons. Protection type is Unload, written to History and Alarm list. Protection from reason: a), c) must be confirmed by FAULT RESET button Protection from any reason: a), b), c) is recorded in Alarm list and History file - Unl BusMeasError message.
109 -
Setpoint replication management

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

1) Switch on all InteliGens in the network 2) Select any InteliGen and adjust setpoints in the ProcessControl group or in Power management group 3) Replication management immediately updates modified setpoint in each InteliGen in the network (except Priority) 4) Any new powered InteliGen automatically updates all setpoints from InteliGen with lowest Controller Adr number.
Setpoints consistency
Any changes of following setpoints in the ProcessControl group and in Power management group (except Priority) done in one InteliGen are automatically replicated in all other connecting InteliGens. ProcessControl Pwr management Date and Time #SystLoadCtrl #Syst start del #Time #SystPFControl #Syst stop del #Date #SystBaseLoad #LoadRes Strt 1 #SystPwrFactor #LoadRes Strt 2 #LoadRes Strt 3 #LoadRes Strt 4 #LoadRes Stp 1 #LoadRes Stp 2 #LoadRes Stp 3 #LoadRes Stp 4 #Next start del #Ovrld NextDel #Next stop del #Slow stop del Any new powered InteliGen receive automatically all replicated parameters from InteliGen with the lowest Controller adr
110 -
Gen-set operation states

Gen-set can operate in following states: Not ready Init Ready Prestart Cranking Pause Starting Unl Alarm Loaded Stop Shut down Cooling Running Unloading Gen-set is not ready to start After IG power supply switch on Gen-set is ready to run Prestart sequence in process. Prestart output is closed Engine is cranking Pause between start attempts START RPM (firing speed) is reached. Gen-set is unloaded due to electric protection Gen-set is running loaded Stop Shut down alarm Gen-set is cooling before stop Waiting for GCB connection Gen-set is unloading
External gen-set conditions : MainsOper MainsFlt ValidFlt IslandOper MainsRet Brks Off Synchro Paral Oper UnlProt Multi Oper Mains (or Bus) is present Mains (or Bus) cut off immediate state Mains (or Bus) cut off takes EmergStart del Island operation Mains (or Bus) recover GCB, MCB opened Synchronizing is active Parallel operation with mains Unload protection Island, Mains operation
Start-stop sequence
MODE = MAN
Engine stop by using GCB ON/OFF and STOP

State Ready Prestart Cranking Starting Running Loaded Unloading Stop Ready Closed outputs PRESTART PRESTART,STARTER,FUEL SOLENOID FUEL SOLENOID FUEL SOLENOID FUEL SOLENOID, GCB CLOSE/OPEN FUEL SOLENOID Condition of next transition START request Prestart time=0 RPM> Start RPM RPM>(Nominal speed-Nominal speed/16) GCB ON/OFF GCB ON/OFF STOP RPM=0 >>>>
111 -
Engine stop by using STOP

State Ready Prestart Cranking Starting Running Loaded Cooling Stop Ready Closed outputs PRESTART PRESTART,STARTER,FUEL SOLENOID FUEL SOLENOID FUEL SOLENOID FUEL SOLENOID, GCB CLOSE/OPEN FUEL SOLENOID Condition of next transition START request Prestart time=0 RPM> Start RPM RPM>(15/16 of Nominal speed) GCB ON/OFF STOP Cooling time=0 RPM=0 >>>>
Hint: Gen-set stops immediately when button STOP is pressed during Cooling procedure.
Unsuccessful start
Crank attempts=3
State Ready Prestart Cranking Crank pause Cranking Crank pause Cranking Not ready Ready Closed outputs PRESTART PRESTART,STARTER,FUEL SOLENOID PRESTART PRESTART,STARTER,FUEL SOLENOID PRESTART PRESTART,STARTER,FUEL SOLENOID HORN, GENERAL FAULT Condition of next transition Start request Prestart time MaxCrank time CrankFail paus MaxCrank time CrankFail paus MaxCrank time FAULT RESET >>>>
112 -
Remote control and data logging

Direct connection to the PC
InteliGen can be connected directly with PC via RS232 interface. Use the standard cable RS232 cable to connect PC with InteliGen. Hint: Make sure the grounding system on controller and PC COM port (negative of the PC DC supply) are identical before the first direct connection. There must not be any voltage between these two points otherwise the internal resistor in controller burns out. The simple solution is to assure, that the PC supply 240/20V is ground free (GND terminal is not connected).
PC
CONTROLLER
230 VAC
RS232
RS 232
Required the same voltage potential between GNDs
RS232
2 - RxD 3 - TxD 5 - GND
2 - RxD 3 - TxD 5 - GND
Battery
0 VDC
PC software - WinEdit
On the PC (for direct or modem connection) has to be installed the ComAps software package WinEdit. (based on Windows 95 or newer platform) WinEdit enables: read the quantities, adjust all set points, read the history control the engine configure the controller select software configuration modify alarm inputs and outputs modify password, commands protections, direct or modem communication receive active calls
History file
InteliGen stores a record of each important event into the history file. The history file seats 117 records. When the history file is full, the oldest records are removed. Hint: To force history download in WinEdit (direct or modem) open History window and select History | Read history command.
Record structure
Abbreviation No. Reason Date Time Pwr PF LChr Spd Historical Value Number of historical event Event specification Date of historical event in format DD/MM/YY Time of historical event in format HH:MM:SS Generator active power Generator PF Character of the load Engine speed
113 -
Gfrq Vg1 Vg2 Vg3 Ig1 Ig2 Ig3 Im3 Bfrq Vb1 Vb2 Vb3 Batt OilP Wtmp Flev AIM1 AIM2 BInp BIPC BIM Bout BOPC BOM Mode
Generator frequency Generator voltage L1 Generator voltage L2 Generator voltage L3 Generator current L1 Generator current L2 Generator current L3 Mains current L3 Bus frequency Bus voltage L1 Bus voltage L2 Bus voltage L3 Battery voltage IG-CU Analog input 1 value (default Oil pressure) IG-CU Analog input 2 value (default Water temperature) IG-CU Analog input 3 value (default Fuel level) IG-IOM, IGS-PTM Analog input 1 value (when configured IG-IOM, IGS-PTM) IG-IOM, IGS-PTM Analog input 2 value (when configured IG-IOM, IGS-PTM) Binary inputs IG-CU Binary inputs IG-PCLSM IG-IOM, IGS-PTM Binary inputs (when configured IG-IOM, IGS-PTM) Binary outputs IG-CU Binary outputs IG-PCLSM IG-IOM, IGS-PTM Binary outputs (when configured IGIOM, IGS-PTM) Mode IG - OFF, MAN AUT
List of possible events

Zero signed events are not displayed or stored. Events specification Alarm Configurable Analog inputs IG-CU alarms YES Analog inputs IG-IOM, IGS-PTM YES alarms Binary inputs IG-CU alarms YES Binary inputs IG-PC(LS)M alarms YES Binary inputs IG-IOM, IGS-PTM alarms YES Events info InteliGen switched on 0 Periodic history record 0 Starting sequence begins 0 Gen set stopped 0 Generator circuit breaker closed 0 Generator circuit breaker opened 0 Mains circuit breaker closed 0 Mains circuit breaker opened 0 Password was set from any terminal 0 Password was changed from any 0 terminal Binary input Remote OFF was closed 0 Binary input Sprinkler was closed 0 Service time expired WrnService Time Speed regulator out was limited Wrn SpdRegLim Volt regulator out was limited Wrn VoltRegLim Load shedding 0 InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF History YES YES YES YES YES Switched On Time stamp Gen set start Gen set stop GCB closed GCB opened MCB closed MCB opened Password set Password chngd Remote OFF set Sprinkler set 0 0 0 Load shed Active call YES YES YES YES YES 0 0 0 0 0 0 0 0 0 0 0 0 wrn Wrn wrn 0 114 -
Events specification Load reconnection Some GCB in group was opened (MINT, MEXT) No other controller on CAN bus (MINT, MEXT) Engine Gen set start fail Gen set over speed Gen set under speed Emergency stop RPM pickup fail Battery voltage warning Battery is discharged Start info AMF start AMF stop Remote start by binary input (SPM,SPtM) Remote stop by binary input (SPM,SPtM) System start by binary input (MINT,MEXT) System stop by binary input (MINT,MEXT) Peak start (SPtM) Peak stop (SPtM) Generator Generator phase 1 over voltage Generator phase 1 under voltage Generator phase 2 over voltage Generator phase 2 under voltage Generator phase 3 over voltage Generator phase 3 under voltage Generator over frequency Generator under frequency Generator voltage unbalance Generator overload warning Generator overload Load surge protection Reverse power Synchronization timeout Reverse sync timeout Earth fault protection Failure of generator circuit breaker Generator short current protection Generator IDMT protection Generator current unbalance Voltage on mains terminals (SPM) Bus voltage error (MINT) Mains/bus Mains phase 1 over voltage Mains phase 1 under voltage Mains phase 2 over voltage Mains phase 2 under voltage
Alarm 0 0
History Load recon Other GCB trip
Active call 0 0
WrnCANbus Empty WrnCANbus Empty wrn Sd Start Fail Sd Overspeed Sd Underspeed Emergency stop SdPickupFail Wrn Batt volt Sd Batt flat 0 0 0 0 0 0 0 0 Unl Vg1 Over Unl Vg1 Under Unl Vg2 Over Unl Vg2 Under Unl Vg3 Over Unl Vg3 Under Unl Fgen Over Unl Fgen Under Unl Vgen Unbal Wrn Overload UnlGen Overload LoadSurge Unl Rev Pwr Stp SyncTO Wrn RevSyncTO Unl EarthFltC GCB fail Unl Short Igen Unl IDMT Unl Igen Unbal UnlCounterVolt Unl BusMeasErr 0 0 0 0 Sd Start Fail Sd Overspeed Sd Underspeed Emergency stop SdPickupFail Wrn Batt volt 0 GenSetMF start GenSetMF stop GenSetRemStart GenSetRemStop GenSetSysStart GenSetSysStop GenSet PKstart GenSet PKstop Unl Vg1 Over Unl Vg1 Under Unl Vg2 Over Unl Vg2 Under Unl Vg3 Over Unl Vg3 Under Unl Fgen Over Unl Fgen Under Unl Vgen Unbal Wrn Overload UnlGen Overload LoadSurge Unl Rev Pwr Stp SyncTO Wrn RevSyncTO Unl EarthFltC GCB fail Unl Short Igen Unl IDMT Unl Igen Unbal UnlCounterVolt Unl BusMeasErr Vm1 Over Vm1 Under Vm2 Over Vm2 Under sd sd sd Sd sd wrn sd 0 0 0 0 0 0 0 0 unl unl unl unl unl unl unl unl unl 0 unl Unl unl Stp Wrn Unl unl unl unl unl unl Unl 0 0 0 0 115 -
Events specification Alarm Mains phase 3 over voltage 0 Mains phase 3 under voltage 0 Mains over frequency 0 Mains under frequency 0 Mains voltage unbalance 0 Failure of mains circuit breaker MCB fail External Mains failure relay 0 System info Wrong params checksum 0 Watchdog reset 0 Application loaded 0 Firmware loaded 0 IG-IOM, IGS-PTM module fail Sd IOM fail IG-PC(LS)M module fail (SPtM, MINT) WrnPC(LS)Mfail Warning RA15 external module fail Wrn RA15 fail Modem RS232 control command 0 MODEM control command 0 CAN bus control command 0 ActCallCH1-OK 0 ActCallCH2-OK 0 ActCallCH3-OK 0 ActCallCH1-Fail ActCallCH1-Fail ActCallCH2-Fail ActCallCH2-Fail ActCallCH3-Fail ActCallCH3-Fail Phase sequence Inverted polarity of gen phase L1 GEN L1 neg Inverted polarity of gen phase L2 GEN L2 neg Inverted polarity of gen phase L3 GEN L3 neg Bad gen phase sequence G ph opposed Bad gen phase sequence and polarity L1 G ph + L1 neg Bad gen phase sequence and polarity L2 G ph + L2 neg Bad gen phase sequence and polarity L3 G ph + L3 neg Inverted polarity of mains phase L1 M L1 neg Inverted polarity of mains phase L2 M L2 neg Inverted polarity of mains phase L3 M L3 neg Wrong mains phase sequence M ph opposed Wrong mains phase sequence and M ph + L1 neg polarity L1 Wrong mains phase sequence and M ph + L2 neg polarity L2 Wrong mains phase sequence and M ph + L3 neg polarity L3
History Vm3 Over Vm3 Under Fmains Over Fmains Under Vmains Unbal MCB fail Ext MF Relay Wrong params Watchdog rst Appl.loaded Firmw.loaded Sd IOM fail 0 Wrn RA15 fail RemControlUART RemControlMOD RemControlCAN ActCallCH1-OK ActCallCH2-OK ActCallCH3-OK ActCallCH1-Fail ActCallCH2-Fail ActCallCH3-Fail 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Active call 0 0 0 0 0 wrn 0 0 0 0 0 sd wrn wrn 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Hint: Binary and analog inputs alarm events are recorded and displayed under a user name. Modem Bridge (MB) is IG-MU connected to modem. Local Bridge (LB) is IG-MU connected to PC. Note SD stop fail is detected when Engine params: Stop time after engine stop (when BO Fuel solenoid is opened or Stop solenoid is closed) the RPM is still > 30.
116 -
Remote and mobile communication

Modbus protocol
Direct connection: RS232, RS422, RS485 Modem connection 9600 bps, 8 data bits, 1 stop bit, no parity Transfer mode RTU Function 3 (Read Multiply Registers) Function 6 (Write Single Register) Function 16 (Write Multiply Registers) The response to an incoming message is sent with minimum 4.096 ms delay after message reception
The complete description of Modbus communication protocol can be found in Modbus Protocol Reference Guide PI-MBUS-300 and Open Modbus Specification Release 1.0. Both documents are available from web site at http://www.modicon.com/openmbus/ .
Communication object vs. Register

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

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

Askey TAS-200E
Modem unit IG-MU

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

Wavecom M1200/WMOD2, dual 900/1800MHz (baud rate 9600 bps). Wavecom - Maestro 20, dual 900/1800MHz. Siemens M20, supports only 900MHz network. For modem configuration use GM setup program. Siemens TC35
Hint: Any Modem goes to init procedure in following cases InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 117 -
after controller reset (when modem is already connected) whenever is modem connected to controller each 20 minutes when is no connection when connection is closed when data transmit error occurs
GSM Modem setup

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

Adjust SIM card on GSM modem in the following way: Enable data communication (it could be done by your local GSM operator), Set phone number SMS service center SC (recommended in international format in case of roaming), Set no PIN code required. Hint: All SMS on SIM card will be erased during GSM modem initialization. Valid SMS on SIM card will be served except adjusting and gen-set control command. Both SIM cards must have DATA setting when communication from controller to PC via two GSM modems.
How to check SIM card DATA setting

Move SIM card from controller GSM modem to Mobile phone. Call from WinEdit to this Mobile phone and check (on Mobil phone) DATA call indication of incoming call. If phone does not indicate DATA - solve this with your GSM operator.
SMS commands
Are not available from IG sw version 6.0.
Active SMS message

Active SMS message is invoked by controller request. Active SMS message is sending to GSM phone number specified in setpoints group Act. Calls/SMS on InteliGen/InteliSys. Specified phone number must be in international format +cccyyyxxxxxx where ccc is country code, yyy is operator prefix and xxxxxx is local phone number. Active message contains items of actual Alarm list (most eight items). Example of active SMS message: #Gen-set name:AL=(Wrn PrimWater temp, !Emergency stop)
118 -
Modbus protocol
There are three possibility of Modbus connection to InteliGen / InteliSys via IG-MU direct via RS232, RS485/422 or via modem. Modbus protocol on IG-MU must be activated by switch P2.
IG-IB Internet communication

IG-IB Internet bridge is interface for Internet communication between one or more controllers and PC. Internet Bridge be can currently connected to internet only via via LAN (Ethernet connector). In future it will be possible to use also Modem connection (wired line MODEM connector) Hint: Contact local IT manager in any case before using IG-IB. Hint: Do not use IG firmware older than 5.2 and IS firmware older than 2.2 for full functionality of internet connection. Hint: Company LAN connected to the Internet is probably configured to enable access to the servers located on the Internet, but to disable access in the reverse direction. If IG-IB has to be visible from the Internet, then your LAN administrator should create a communication channel on the Internet access server. The IG-IB uses the TCP-communication and listen on the port 23 (known as Telnet port).
One controller - RS232/Ethernet connection

In this case no dongle is necessary. One unit could be also connected via CAN interface.
INTERNET
ETHERNET LED 1 2 MODEM IB CONFIG IG-CU DONGLE RS232
iG-IB
iG-CU (iS-CU)
LED
3 4 CAN
5 6 POWER
LED
IG-IB interface
Modem / IB config RS232 interface for IG-IB configuration or Modem connection IG-CU / Dongle RS232 interface for one controller connection or for Dongle for multiple controllers communication. CAN bus interface to group of controllers Ethernet to LAN interface to company net See IG-IB Internet bridge
Connection types
Internet or Modem (wired line) remote connection from WinEdit or MultiEdit software. Active calls: E-mail or SMS via Internet.
IG-IB configuration
Connect IG-IB Modem interface to PC and run IB-cfg software. Adjust items in IB configuration window IP address etc.
IG-IB0 Dongle
IG-IB Dongle limits number of accessible controllers. Hint: For more detail see Communication guide chapter IG-IB Internet communication. InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 119 -
Value and setpoints codes

Hint: Actual values, setpoints and configuration (in XLS or DOC) file is possible to export on-line from controller or off-line from archive using WinEdit Controller Export data command.
Values
Name InteliGen Group Engine Engine Engine Engine Engine Engine Engine Engine Engine Engine Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Sw configuration MINT Name Engine speed Batt volt Oil press Water temp Fuel level AnInIOM 1 AnInIOM 2 AnInIOM 3 AnInIOM 4 SRO Act power Act pwr L1 Act pwr L2 Act pwr L3 React pwr kVAr React pwr L1 React pwr L2 React pwr L3 Appar pwr Appar pwr L1 Appar pwr L2 Appar pwr L3 Pwr factor Pwr factor L1 Pwr factor L2 Pwr factor L3 Load char Load char 1 Load char 2 Load char 3 Gen freq Gen V L1-N Gen V L2-N Gen V L3-N Gen V L1-L2 Gen V L2-L3 Gen V L3-L1 Gen curr L1 Gen curr L2 Gen curr L3 EarthFaultCurr 50 215 216 215 0 0 0 0 0 0 2 Hz V V V V V V A A A A Date 13.5.2004 Value 0 24,7 5,7 40 16 ##### ##### ##### ##### 0 ##### 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 kVA kVA kVA kVA Sw conf. ver. Ser. num. Filename 6,1 Dimension RPM V bar C % U4 U5 U6 U7 V kW kW kW kW 4100096 Com. obj. Data type 8209 8213 8227 8228 8229 8978 8759 8760 8761 9052 9678 8524 8525 8526 8203 8527 8528 8529 8565 8530 8531 8532 8204 8533 8534 8535 8395 8626 8627 8628 8210 8192 8193 8194 9628 9629 9630 8198 8199 8200 8208 Unsigned 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 8 Integer 8 Integer 8 Integer 8 Char Char Char Char Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16
120 -
Generator Generator Generator Bus Bus Bus Bus Bus Bus Bus Bus Bus Binary I/O Binary I/O Binary I/O Binary I/O Binary I/O Binary I/O Binary I/O
Slip freq Angle VRO Bus freq Bus V L1-N Bus V L2-N Bus V L3-N Bus V L1-L2 Bus V L2-L3 Bus V L3-L1 Act LoadSurge Max LoadSurge BInpIG BInpPCLSM BInpIOM BOutIG BOutPCLSM BOutIOM BOutRA15
0 0 50 50 228 228 228 0 0 0 0 0 10100000 0 0 0 0 0 ##### 1 0 0 0 0 200 250 0 0 0 0 ##### NextStart MainsOper 0 6,1 1 254 OFF 3 1E+15 0 3565275
Hz % Hz V V V V V V P/s P/s
8224 8225 9053 8211 8195 8196 8197 9631 9632 9633 9582 9583 8235 8601 8602 8239 8603 8604 9849 8624
Integer 16 Integer 16 Integer 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Integer 16 Integer 16 Binary 16 Binary 8 Binary 16 Binary 16 Binary 8 Binary 16 Binary 16 Unsigned 8 Integer 16 Integer 16 Integer 16 Integer 16 Unsigned 16 Unsigned 16 Integer 32 Integer 32 Unsigned 16 Integer 32 Unsigned 16 Unsigned 16 Unsigned 16 Integer 16 Unsigned 8 Unsigned 8 Unsigned 8 Unsigned 8 Unsigned 8 Binary 16 Binary 16 Unsigned 32
Pwr management EnginePriority Pwr management TotAvlbPnom Pwr management TotRunPnom Pwr management TotRunPact Pwr management ActReserve Pwr management LoadRes Start Pwr management LoadRes Stop Statistics Statistics Statistics Statistics Statistics Info Info Info Info Info Info Info Info Info Info Info kWhours kVArhours NumStarts RunHours NextServTime LdShed state TimerText TimerValue SW version SW branch Application ControllerMode IOM SW ver. CAN16 CAN32 PasswordDecode
kW kW kW kW% kW% kW%
8498 8499 8496 8625 8622 8623 8205 8539 8207
h h
8206 9648 9089 8954
8955 8393 8707 8480 9651 9022 8546 8827 9090
Setpoints
Name InteliGen Group ProcessControl ProcessControl Sw configuration MINT Name #SysLdCtrl PtM #SysPFCtrl PtM Date 13.5.2004 Value BASE LOAD BASE PF Sw conf. ver. 6,1 Dimension Ser. num. Filename 4100096 Password Com. obj. Low limit High limit Data type 0 0 8774 8779 String list String list
121 -
ProcessControl ProcessControl ProcessControl Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Engine params Engine params Engine params Engine params Engine params Engine params Engine params Engine params Engine params Engine params Engine params Engine params Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect
#SysBaseLoad #SysPwrFactor DetectOtherCAN Gen-set name Nomin power Nomin current CT ratio PT ratio Vb PT ratio AnOut-kW/20mA EarthFltCurrCT Gen nom V Bus nom V Nominal RPM Nominal freq Gear teeth FltRes GoToMAN ControllerMode Contr. addr RS232 mode CAN bus mode Prestart time Starting RPM MaxCrank time CrnkFail pause Crank attempts Idle time Min stab time Max stab time Cooling time AfterCool time Stop time Fuel solenoid NextServTime Horn timeout Overspeed Protection del AnlInp1 level1 AnlInp1 level2 AnlInp1 del AnlInp2 level1 AnlInp2 level2 AnlInp2 del AnlInp3 level1 AnlInp3 level2 AnlInp3 del Batt >V Batt <V Batt V del AnlInIOM1 lev1 AnlInIOM1 lev2 AnlInIOM1 del AnlInIOM2 lev1 AnlInIOM2 lev2
200 0,95 DISABLED InteliGen 200 288 400 1 1 200 400 231 231 1500 50 120 DISABLED OFF 1 STANDARD 32C 2 25 5 8 3 10 2 10 30 30 60 DIESEL 65535 10 115 5 2 1 3 80 90 5 10 3 15 36 18 5 0 100 5 0 100
kW
0 0 0 0
8775 8776 9921 8637 8276 8275 8274 9579 9580 9019 8566 8277 9888 8253 8278 8252 9983 8315 24537 24522 24499 8394 8254 8256 8257 8255 9097 8259 8313 8258 8662 9815 9100 9648 8264 8263 8262 8369 8370 8365 8375 8376 8371 8381 8382 8377 9587 8387 8383 8762 8766 8770 8763 8767
0 0,6
30000 Unsigned 16 1 Integer 16 String list Short string
kW A /5A /1 /1 /5A V V RPM Hz
0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 3 3
1 1 1 0,1 0,1 1 1 80 80 100 45 0
3000 Unsigned 16 5000 Unsigned 16 10000 Unsigned 16 500 Unsigned 16 500 Unsigned 16 32000 Integer 16 8000 Unsigned 16 30000 Unsigned 16 30000 Unsigned 16 4000 Unsigned 16 65 Unsigned 16 500 Unsigned 16 String list String list
32 Unsigned 8 String list String list
s % s s s s s s s s
0 0 0 0 0 0 0 0 0 0 0 0
0 1 1 5 1 0 0 2 0 0 0
600 Unsigned 16 50 Unsigned 8 60 Unsigned 8 60 Unsigned 8 10 Unsigned 8 3600 Unsigned 16 10 Unsigned 16 300 Unsigned 16 3600 Unsigned 16 3600 Unsigned 16 240 Unsigned 16 String list
h s % s bar bar s C C s % % s V V s U4 U4 s U5 U5
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 100 0 -10 -10 0 -100 -100 0 -100 -100 0 18 8 0 -100 -100 0 -100 -100
65535 Unsigned 16 600 Unsigned 16 150 Unsigned 16 300 Unsigned 16 1000 Integer 16 1000 Integer 16 180 Unsigned 16 10000 Integer 16 10000 Integer 16 180 Unsigned 16 10000 Integer 16 10000 Integer 16 180 Unsigned 16 40 Integer 16 36 Integer 16 600 Unsigned 16 10000 Integer 16 10000 Integer 16 180 Unsigned 16 10000 Integer 16 10000 Integer 16
122 -
Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect
AnlInIOM2 del AnlInIOM3 lev1 AnlInIOM3 lev2 AnlInIOM3 del AnlInIOM4 lev1 AnlInIOM4 lev2 AnlInIOM4 del Overload Overload Wrn Overload del Ishort Ishort del 2Inom del Curr unbal Curr unbal del EarthFaultCurr EthFltCurr del Gen >V Sd Gen >V Unl Gen <V Unl Gen V del Volt unbal Volt unbal del Gen >f Gen <f Gen f del Reverse power ReversePwr del Max load surge
5 0 100 5 0 100 5 120 110 5 200 0 4 50 5 30 10 120 110 85 3 10 3 110 85 3 15 0,5 50 ENABLED ABS(kW) 1 5 10 100 150 200 250 300 350 400 450 5 2 10 30 100 200 300 NEGATIVE 0 3 5 1
s U6 U6 s U7 U7 s % % s % s s % s % s % % % s % s % % s % s P/s
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
8771 8764 8768 8772 8765 8769 8773 8280 9685 8281 8282 9991 8283 8284 8285 8286 8287 10013 8291 8293 8292 8288 8289 8296 8298 8297 8486 8552 9581 8551 9874 8488 8549 8550 8489 8491 8490 8633 8831 8833 8832 8834 8492 8493 8494 8495 9584 9585 9586 9054 9578 8650 8652 8653
0 -100 -100 0 -100 -100 0 110 0 0 100 0 0 1 0 1 0 85 85 50 0 1 0 85 50 0 0 0 0
180 Unsigned 16 10000 Integer 16 10000 Integer 16 180 Unsigned 16 10000 Integer 16 10000 Integer 16 180 Unsigned 16 300 Unsigned 16 120 Unsigned 16 600 Unsigned 16 500 Unsigned 16 10 Unsigned 16 60 Unsigned 16 200 Unsigned 16 600 Unsigned 16 300 Unsigned 16 600 Unsigned 16 150 Unsigned 16 150 Unsigned 16 110 Unsigned 16 600 Unsigned 16 150 Unsigned 16 600 Unsigned 16 150 Unsigned 16 110 Unsigned 16 600 Unsigned 16 50 Unsigned 8 600 Unsigned 16 60 Unsigned 16 String list String list
Pwr management Pwr management Pwr management #Pwr mgmt mode Pwr management Priority Pwr management #SysAMFstrtDel Pwr management #SysAMFstpDel Pwr management #LoadResStrt 1 Pwr management #LoadResStp 1 Pwr management #LoadResStrt 2 Pwr management #LoadResStp 2 Pwr management #LoadResStrt 3 Pwr management #LoadResStp 3 Pwr management #LoadResStrt 4 Pwr management #LoadResStp 4 Pwr management #NextStrtDel Pwr management #OverldNextDel Pwr management #NextStopDel Pwr management #SlowStopDel Pwr management #MinRunPower 1 Pwr management #MinRunPower 2 Pwr management #MinRunPower 3 Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl SpeedRegChar GtoB AngleReq Voltage window Phase window Dwell time
1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
32 Unsigned 8 600 Unsigned 16 600 Unsigned 16 32000 Unsigned 16 32000 Unsigned 16 32000 Unsigned 16 32000 Unsigned 16 32000 Unsigned 16 32000 Unsigned 16 32000 Unsigned 16 32000 Unsigned 16 600 Unsigned 16 600 Unsigned 16 600 Unsigned 16 600 Unsigned 16 60000 Unsigned 16 60000 Unsigned 16 60000 Unsigned 16 String list
s s kW% kW% kW% kW% kW% kW% kW% kW% s s s s kW kW kW
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
% s
0 0 0 0
-30 0 0 0
30 Integer 16 100 Unsigned 16 90 Unsigned 16 25 Unsigned 16
123 -
Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Volt/PF ctrl Volt/PF ctrl Volt/PF ctrl Volt/PF ctrl Volt/PF ctrl Volt/PF ctrl Volt/PF ctrl Volt/PF ctrl Volt/PF ctrl Volt/PF ctrl Volt/PF ctrl Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Load shedding Load shedding Load shedding Load shedding Load shedding Date/Time Date/Time Date/Time Sensors spec Sensors spec Sensors spec Sensors spec
Freq gain Freq int Freq der Freq reg loop Angle gain Angle der Speed gov bias Load ramp Load gain Load int Load der GCB open level GCB open del LS gain LS int LS der Sync timeout AVRRegChar Voltage gain Voltage int Voltage der PF gain PF int PF der VS gain VS int VS der AVR DCout bias Warning call Unload call Slow stop call Shut down call AcallCH1-Type AcallCH1-Addr AcallCH2-Type AcallCH2-Addr AcallCH3-Type AcallCH3-Addr NumberRings AA A.c.multiplier Ld shed level Ld shed del Ld recon level Ld recon del AutoLd recon Time stamp per #Time #Date Calibr AI 1 Calibr AI 2 Calibr AI 3 Calibr AI 4
20 50 10 SYNC ONLY 50 10 0 60 20 100 10 5 60 20 100 20 60 POSITIVE 20 20 10 20 20 10 15 15 10 50 DISABLED DISABLED DISABLED DISABLED DISABLED DISABLED DISABLED 3 1 90 2 50 5 ENABLED 60 17:04:02 23.10.2002 0 0 0 0
% % % % % V s % % % % s % % % s
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
8715 8716 8717 9891 8718 8719 8656 8658 8659 8713 8714 8547 8548 8725 9035 8726 8657 9055 8501 8720 8502 8503 8721 8504 8777 9036 8778 8500 8482 8483 8485 8484 9594 9597 9595 9598 9596 9599 24512 24505 8884 8887 8890 8893 9649 8979 24554 24553 8431 8407 8467 8793
0 0 0 0 0 -10 0 0 0 0 0 0 0 0 0 0
200 Integer 16 100 Integer 16 100 Integer 16 String list 200 Integer 16 100 Integer 16 10 Integer 16 600 Unsigned 16 200 Integer 16 100 Integer 16 100 Integer 16 100 Unsigned 16 600 Unsigned 16 200 Integer 16 100 Integer 16 100 Integer 16 1800 Unsigned 16 String list
% % % % % % % % % %
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 3
0 0 0 0 0 0 0 0 0 0
200 Integer 16 100 Integer 16 100 Integer 16 200 Integer 16 100 Integer 16 100 Integer 16 200 Integer 16 100 Integer 16 100 Unsigned 16 100 Integer 16 String list String list String list String list String list Long string String list Long string String list Long string
1 1 50 0 0 0
30 Unsigned 8 250 Unsigned 8 200 Integer 16 1800 Unsigned 16 90 Integer 16 1800 Unsigned 16 String list
% s % s
0 0 0 0 0
min
0 0 0
240 Unsigned 8 Time Date
bar C % U4
0 0 0 0
-100 -1000 -1000 -1000
100 Integer 16 1000 Integer 16 1000 Integer 16 1000 Integer 16
124 -
Sensors spec Sensors spec Sensors spec
Calibr AI 5 Calibr AI 6 Calibr AI 7
0 0 0
U5 U6 U7
0 0 0
8794 8795 8796
-1000 -1000 -1000
1000 Integer 16 1000 Integer 16 1000 Integer 16
125 -
Technical data
Power supply
Voltage supply Consumption depends on supply voltage 8-36V DC 0,34A at 8VDC 0,12A at 24VDC 0,09A at 36VDC 2 % at 24V 10 year
Battery voltage measurement tolerance RTC battery life-cycle Hint: When internal RTC battery becomes flat InteliGen function (e.g. Ready for stand by) does not change until controller power supply is switched off. After the next power switch on controller: Stays in the INIT state (not possible to run genset) All History records disappear except Wrong params record Alarm list is empty Time and Date values are set to zero Statistics values are random
Operating conditions
Operating temperature IG-CU Operating temperature IG-CU-LT Storage temperature Flash memory data retention time Protection front panel Humidity Standard conformity Low Voltage Directive Electromagnetic Compatibility Vibration Shocks -20..+70oC -30..+70oC -30..+80oC 10 years IP65 95% without condensation (From IG serial number xxxx0900) EN 61010-1:95 +A1:97 EN 50081-1:94, EN 50081-2:96 EN 50082-1:99, EN 50082-2:97 5 - 25 Hz, 1,6mm 25 - 100 Hz, a = 4 g a = 200 m/s2
Dimensions and weight

Dimensions Weight 180x120x50mm 800g
Bus and generator

Nominal frequency Frequency measurement tolerance 50-60Hz 0,1Hz
Current inputs
Nominal input current (from CT) Load (CT output impedance) CT input burden Max. measured current from CT Current measurement tolerance Max. peak current from CT Max. continuous current 5A < 0,1 < 0,2 VA per phase (In=5A) 11 A 2% from the Nominal current 150 A / 1s 12 A 231/400 VAC 126 -
Voltage inputs
Nominal voltage
IG-CU
Maximal measured/allowed voltage (short time) 290/500 VAC Input resistance 6 M phase to phase 6 M phase to neutral Voltage measurement tolerance 2 % from the Nominal voltage Overvoltage class III / 2 (EN61010)
Voltage inputs
IG-CU/600
Nominal voltage 277/480 VAC Maximal measured/allowed voltage (short time) 346/600 VAC Input resistance 6 M phase to phase 6 M phase to neutral Voltage measurement tolerance 2 % from the Nominal voltage Overvoltage class III / 2 (EN61010)
IG-MTU
Primary voltage Ph-Ph Secondary voltage Ph-N Mechanical dimensions: Primary/secondary Phase shift Operating temperature 3x400 VAC / 50Hz (3x480 VAC / 60 Hz) 3x 230 V AC ( 3x277 VAC / 60 Hz) , 5 VA 155 x 95 x 60 mm , DIN rail (35 mm) mounted < 1 -30..+70oC
IG-MTU-C
Primary voltage Ph-Ph Secondary voltage Ph-N Mechanical dimensions: Primary/secondary Phase shift Operating temperature 3x400 VAC / 50Hz (3x480 VAC / 60 Hz) 3x 230 V AC ( 3x277 VAC / 60 Hz) , 5 VA 155 x 95 x 60 mm , DIN rail (35 mm) mounted 6 -30..+70oC
Binary inputs and outputs

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

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

Number of outputs Maximum current Maximum switching voltage 7 0,5 A 36 VDC
Analog inputs
Not electrically separated Resolution Sensor resistance range Resistance measurement tolerance 10 bits 0 -2,4 k 4 % 2 out of measured value 127 -
Speed pick-up input

Type of sensor Minimum input voltage Maximum input voltage Minimum measured frequency Maximum measured frequency Frequency measurement tolerance magnetic pick-up (connection by shielded cable is recommended) 2 Vpk-pk (from 4 Hz to 4 kHz) 50 Veff 4 Hz 10 kHz (min. input voltage 6Vpk-pk) 1,5 %
RS232 interface
Maximal distance Speed 10m 19.2kBd
Recommend external converter: ADVANTECH ADAM 4520: RS232 to RS422/485 converter, DIN rail, automatic RS485 bus supervision, no external data flow control signals, galvanic isolated. Recommended internal converter: ADVANTECH PCL-745B or PCL745S : Dual port RS422/485 Interface card, automatic RS485 bus supervision, no external data flow control signals, galvanic isolated.
CAN bus interface

Galvanically separated Maximal CAN bus length Basic setting: CAN bus mode = 32C Basic setting: CAN bus mode = 8C Speed Nominal impedance Cable type 200m 900m 250kBd 120 twisted pair (shielded)
Following dynamic cable parameters are important especially for maximal 200 meters CAN bus length and 32 IG-COM units connected: Nominal Velocity of Propagation min. 75% (max. 4,4 ns/m) Wire crosscut min.0,25 mm2 Maximal attenuation (at 1 MHz) 2 dB / 100m Recommended Industrial Automation & Process Control Cables: BELDEN (see http://www.belden.com): 3082A DeviceBus for Allen-Bradley DeviceNet 3083A DeviceBus for Allen-Bradley DeviceNet 3086A DeviceBus for Honeywell SDS 3087A DeviceBus for Honeywell SDS 3084A DeviceBus for Allen-Bradley DeviceNet 3085A DeviceBus for Allen-Bradley DeviceNet 3105A Paired EIA Industrial RS485 cable LAPP CABLE (see http://www.lappcable.com) Unitronic BUS DeviceNet Trunk Cable Unitronic BUS DeviceNet Drop Cable Unitronic BUS CAN Unitronic-FD BUS P CAN UL/CSA Hint: When use double pair cable, use data pair for CAN bus and Power supply DC pair for Load sharing line connection.
128 -
IG-PCLSM
Power supply: Consumption: 8 36 V DC 100 mA 4 4,7 k 0-36 VDC 0-2 V 8-36 V
Binary inputs
Number of inputs Input resistance Input range Switching voltage level for close contact indication Max voltage level for open contact indication
Open collector outputs

Number of outputs Maximum current Maximum switching voltage Speed governor output: AVRi outputs: LS output: 4 0,5 A 36 VDC 10 V DC , max.15 mA PWM to IG-AVRi max 10 V / 15 mA
IG-AVRi
Power supply: 18V AC from IG-AVRi Trans/LV or IG-AVRi Trans/100 Absolutely maximum power supply range: 15 - 25 VAC or 20 - 35VDC Operating temperature -30..+70oC Inputs: Outputs: AVRi output voltage range: AVRi output current: Mechanical dimensions: +AVR, -AVR (two wires, PWM from IG-CU) OUT1, OUT2 floating (potential free) voltage source. potentiometer adjustable from +- 1V to +-10V DC. max 15 mA. 96 x 27 x 43 mm , DIN rail (35 mm) mounted
IG-AVRi Trans/LV
Primary voltage 1: Absolute low limit: Absolute high limit: Primary voltage 2: Absolute low limit: Absolute high limit: Frequency: Secondary voltage: Operating temperature 230-277 VAC 230 VAC 20% 277 VAC + 20% 400-480 VAC 400 VAC 20% 480 VAC + 20% 50 - 60 Hz 18 V AC, 5 VA -30..+70oC
IG-AVRi Trans/100
Primary voltage: Absolute low limit: Absolute high limit: Frequency: Secondary voltage: Operating temperature 100 120 VAC 100 VAC 20% 120 VAC + 20% 50 - 60 Hz 18 V AC -30..+70oC
IG-IOM
Voltage supply Consumption Mechanical dimensions: Connection to IG-CU 8-36V DC 0,1A depend on supply voltage 40 x 95 x 45 mm , DIN rail (35 mm) mounted standard IOM cable 2 meters length, not galvanic separated 129 -
Operating temperature
-30..+70oC 8 4,7 k 0 - 36 VDC 0-2V 8-36 V
Binary inputs
Number of inputs Input resistance Input range Switching voltage level for close contact indication Max voltage level for open contact indication
Binary open collector outputs

Number of outputs Maximum current Maximum switching voltage 8 0,5 A 36 VDC
Analog inputs
Not electrically separated Number of inputs Resolution Sensor resistance range Resistance measurement tolerance 4 10 bits 0 -2,4 k 4 % 2 out of measured value
Analog output
Not electrically separated Number of outputs Resolution Output range 1 10 bits 0 to 20 mA 0,33 mA
IG-MU
Voltage supply Consumption Operating temperature Mechanical dimensions: Interface to modem or PC Interface to controller 8-36V DC 0,1A depend on supply voltage -30..+70oC 40 x 95 x 45 mm , DIN rail (35 mm) mounted RS232, RS422, RS485 CAN
IG-IB
Voltage supply Consumption Operating temperature Mechanical dimensions: Interface to controller Interface to modem Interface to Ethernet 8-36V DC 0,1A depend on supply voltage -30..+70oC 40 x 95 x 45 mm , DIN rail (35 mm) mounted RS232 or CAN RS232 RJ45
IGS-PTM
Voltage supply Consumption Operating temperature Mechanical dimensions: Interface to controller Binary inputs and outputs Analog output 8-36V DC 0,1A depend on supply voltage -30..+70oC 40 x 95 x 45 mm , DIN rail (35 mm) mounted CAN see IG-IOM see IG-IOM
Analog inputs
Not electrically separated Number of inputs InteliGen MINT, SW version 6.1, ComAp May 2004 IG-MINT-MINT+IOM-6.1.PDF 4 130 -
Resolution Maximal resistance range Maximal voltage range Maximal current range Resistance measurement tolerance Voltage measurement tolerance Current measurement tolerance
10 bits 0 250 0 100 mV 0 20 mA 1 % 2 out of measured value 1,5 % 1mV out of measured value 2,5 % 0,5mA out of measured value
IGL-RA15
Power supply
Voltage supply Consumption 8-36V DC 0,35-0,1A (+1A max horn output) Depend on supply voltage
Operating conditions
Operating temperature Storage temperature Protection front panel -20..+70oC -30..+80oC IP65
Dimensions and weight

Dimensions Weight 180x120x55mm 950g
Horn output
Maximum current Maximum switching voltage 1A 36 VDC
InteliGen Low Temperature modification

LCD display limits controller operating temperature range to 20 oC - + 70 oC even if the other electronic components work in wider temperature range. Internal preheating foil is mounted in InteliGen LT to extend display operational temperature range. Preheating starts at temperature below 5 oC and preheating power depends on temperature and power supply voltage.
Technical data
Operating temperature Storage temperature
IG-CU, IL-CU Standard -20 oC..+70oC -30 oC..+80oC
IG-LT, IL-LT -30 oC..+70oC -30 oC..+80oC
Preheating foil increases controller current consumption
Controller consumption at 12VDC 24VDC 36VDC
No preheating Preheating at ambient temperature 0 oC -15 oC -30 oC 360 mA +50 mA +180 mA +300 mA 230 mA +25 mA +85 mA +150 mA 100 mA +20 mA +65 mA +100 mA
InteliGen LT work immediately after switch on at -30 oC and display becomes visible after a few minutes.
Short-term voltage drops (e.g. during the engine cranking) do not affect the operation at all.
131 -
Order codes
There are two types of preheating foil to cover full temperature and controller power supply range.
Order code IG-CU-LT/12 IG-CU-LT/24 IL-CU-LT/12 IL-CU-LT/24
Controller InteliGen
InteliLite
Nominal power supply 12 VDC 24 VDC 12 VDC 24 VDC
132 -

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

InteliGen Modular Gen-set Controller

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

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

WARNING VERY IMPORTANT !!!

!!! CAUTION !!!

Adjust set points

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

MINT - required and optional modules

Optional Optional Optional Optional Optional Optional Optional

InteliGen display software description

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

Terminals and Dimensions

GENERATOR CURRENT 0-5A

GENERATOR VOLTAGE 3 x 230 / 400 V

EXTENSION MODULES iG-COM / iG-IOM

Inl In (Im L3) Ink CURRENT

EXTENSION MODULES iG-PCM / iG-PCLSM

Drawing text translation Grounding Terminal RPM Grounding Terminal

BINARY INPUTS BO10 BI10 BI12 BI11 BI13

BINARY OUTPUTS BO12 BO11 BO13

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

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

The IG-COM label is from side.

H COM L CAN 2 CAN R 120 EXTENSION MODULE

Green CAN connectors are separated: CAN2

Indication LED: TxCAN, RxCAN TxD, RxD RUN

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

IG IOM, IGS-PTM terminals

AI4 ANALO G O UT RS232 PO WER 8-36V DC

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

IG-AVRi, IG-AVRi TRANS/LV

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

IG-MU unit is DIN 35 mm rail mounted.

AI4 ANAL OG OUT

B INARY OUT PUT S B O1 B O2 B O3 B O4 B O5 B O6 B O7 B O8

IG-IOM unit is DIN 35 mm rail mounted.

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

ANALOG INPUTS COMPENSATION

0-20 mA ANALOG OUT

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

IGL-RA15 Remote annunciator

180 (7,1) 185 (7,3)

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

~ 35 (1,4) 38 (1,5) 40 (1,6)

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

120 (4,7) 125 (4,9)

IG-IB Internet bridge

4 H COM L CAN POWER 8 - 36 V DC

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

FUEL LEVEL WATER TEMP

L1k L1l L2k L2l L3k L3l

GENERATOR CURRENT 0-5A

EXTENSION MODULES iG-COM / iG-IOM

STARTER FUEL SOLENOID GEN C.B.

LOAD RES. OK UNLOAD

EXTENSION MODULES iG-PCM / iG-PCLSM

GEN C.B. FEED-BACK LOAD RESERVE

SYST START / STOP EMERG STOP

ACCESS LOCK SD OIL PRESS SD WATER TEMP SD FUEL LEVEL

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

LOAD SHARING PARALLEL LINE + -

BINARY INPUTS BI10 BI12 BI11 BI13