ComAp IG-NT GC, IS-NTC-BB, IG-NTC GC, IS-NT, IG-NT-BB Reference Manual

Copyright © 2015 ComAp a.s.

ComAp a.s..

Kundratka 2359/17, 180 00 Praha 8, Czech Republic

Tel: [phone], Fax: [phone]

Technical support hotline: [phone]

E-mail: [e-mail], www.comap.cz

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

Inteli New Technology

Modular Generator Controller

Multiple Internal engines application – SW configuration

SPI

IG-NT GC, IG-NTC GC, IS-NT, IG-NT-BB, IG-NTC-BB, IS-NTC-BB

Software version IGS-NT-GeCon-MARINE-3.2, July 2015

REFERENCE GUIDE

2

Table of Contents

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

General guidelines .............................................................................................................................................. 4

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

Dangerous voltage ......................................................................................................................................... 5

Adjust set points ............................................................................................................................................. 5

Clarification of notation ................................................................................................................................... 5

Available Firmware and Archive sets ................................................................................................................. 6

General description ............................................................................................................................................ 7

Description of the controller system (with all options) .................................................................................... 7

Comparing of IGS-NT-GeCon-MARINE 3.2 with standard gen-set fw .......................................................... 7

Available documentation ................................................................................................................................ 7

Example of interconnection GeCon x Engine controller ..................................................................................... 9

Functions .......................................................................................................................................................... 11

Basic description of SPI application ............................................................................................................. 11

Modified setpoints ........................................................................................................................................ 12

Controller modes .......................................................................................................................................... 13

Mains parameters out of limits during synchronising ................................................................................... 17

Active Power control modes in SPI .............................................................................................................. 17

PF control modes ......................................................................................................................................... 18

Load shedding .............................................................................................................................................. 19

Test on load – SPtM ..................................................................................................................................... 21

Power derating ............................................................................................................................................. 22

Protection mode settings .............................................................................................................................. 22

Circuit breakers operation sequence, GCB/MCB fail detection ................................................................... 23

External breaker control ............................................................................................................................... 29

Peak shaving based on Active and Apparent power ................................................................................... 29

Remote Alarm Messaging ............................................................................................................................ 30

Variable speed support ................................................................................................................................ 31

Force value – step by step guide ................................................................................................................. 32

Values for continuous writing from external sources ................................................................................... 34

User Buttons................................................................................................................................................. 34

User Mask function ...................................................................................................................................... 35

Remote Control Function ............................................................................................................................. 36

Virtual Peripheral Inputs-Outputs (VPIO) module ........................................................................................ 37

Shared Inputs and Outputs .......................................................................................................................... 37

Distributed Binary Inputs and Outputs ......................................................................................................... 39

Modbus Reading and Writing ....................................................................................................................... 40

User MODBUS ............................................................................................................................................. 40

Modbus Switches ......................................................................................................................................... 41

Power Formats ............................................................................................................................................. 41

PLC functions ............................................................................................................................................... 41

Multi language support ................................................................................................................................. 42

ECU interface customizing ........................................................................................................................... 42

Volt/PF control adjustment ........................................................................................................................... 42

Sync/load control adjustment ....................................................................................................................... 44

Protections and Alarm management ................................................................................................................ 47

Gen-set operation states .................................................................................................................................. 57

Inputs and Outputs ........................................................................................................................................... 58

Virtual and physical modules ....................................................................................................................... 58

Analog outputs ............................................................................................................................................. 58

Setpoints ........................................................................................................................................................... 60

ProcessControl ............................................................................................................................................. 60

Basic settings ............................................................................................................................................... 67

Comms settings............................................................................................................................................ 72

Delays/Timers .............................................................................................................................................. 78

Analog protect .............................................................................................................................................. 81

Inteli NT GeCon-MARINE SPI, SW Version 3.2, ©ComAp – July 2015
IGS-NT-GeCon-MARINE-SPI-3.2.PDF

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Gener protect ............................................................................................................................................... 83

Mains protect ................................................................................................................................................ 90

AMF settings ................................................................................................................................................ 92

Sync/Load ctrl............................................................................................................................................... 93

Volt/PF ctrl .................................................................................................................................................... 97

Force value ................................................................................................................................................... 99

Load shedding ............................................................................................................................................ 101

Timer settings ............................................................................................................................................. 103

Act. calls/SMS ............................................................................................................................................ 104

Date/Time ................................................................................................................................................... 107

Table of values ............................................................................................................................................... 108

Group: Gener values .................................................................................................................................. 108

Group: Mains values .................................................................................................................................. 115

Group: Sync/Load ctrl ................................................................................................................................ 120

Group: Volt/PF ctrl ...................................................................................................................................... 121

Group: Force value .................................................................................................................................... 121

Group: Load shedding ................................................................................................................................ 123

Group: Analog CU ...................................................................................................................................... 123

Group: Bin inputs CU ................................................................................................................................. 125

Group: Bin outputs CU ............................................................................................................................... 125

Group: Log Bout ......................................................................................................................................... 125

Group: Info ................................................................................................................................................. 129

Group: Statistics ......................................................................................................................................... 136

Table of binary input functions........................................................................................................................ 140

Table of analog input functions ...................................................................................................................... 177

Table of binary output functions ..................................................................................................................... 187

Controller configuration and monitoring ......................................................................................................... 222

Direct connection to the PC ....................................................................................................................... 222

GenConfig functions ................................................................................................................................... 222

InteliMonitor ................................................................................................................................................ 223

Modbus protocol ......................................................................................................................................... 223

Value and setpoint codes ........................................................................................................................... 223

Technical data ............................................................................................................................................ 223

Inteli NT GeCon-MARINE SPI, SW Version 3.2, ©ComAp – July 2015
IGS-NT-GeCon-MARINE-SPI-3.2.PDF

4

General guidelines

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.

What is described in this manual?

This manual describes IGS-NT -GeCon-MARINE- „MINT“ software configuration. The Generator controller
software configuration is designed for multiple sets applications with internal load sharer and synchronizer.

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

Operators of gen-sets/generators
Gen-set/generator control panel builders
For everybody who is concerned with installation, operation and maintenance of the gen­set/generator

!! Warnings !!
Remote control

The IGS-NT controller can be remotely controlled. In case 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 controller contains a large number of configurable setpoints, because of this it is impossible to describe
all of its functions. These are subject to change from SW version to SW version. This manual only describes
the product and is not guaranteed to be set for your application on arrival.

Text

PAGE (Capital letters in the frame) buttons on the front panel
Break Return (Italic) set points
Generator protections (Bold) Set point group
REMOTE START/STOP (Capital letters) binary inputs and outputs
Cyan background Valid for IS-NT only

Conformity declaration

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.

Inteli NT GeCon-MARINE SPI, SW Version 3.2, ©ComAp – July 2015
IGS-NT-GeCon-MARINE-SPI-3.2.PDF

5

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 the controller to SEM mode and disconnect the Binary outputs Starter and Fuel

to avoid unexpected automatic start of gen-set and GCB closing.

!!! CAUTION !!!

Dangerous voltage

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

Adjust set points

All setpoints are preadjusted to their typical values. But the set points in the “Basic settings” 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 !!!

WARNING – VERY IMPORTANT !!!

Clarification of notation

HINT

This type of paragraph points out details to help user installation/configuration.

NOTE:

This type of paragraph calls readers’ attention to a notice or related theme.

CAUTION!

This type of paragraph highlights a procedure, adjustment, etc. which may cause damage or improper
functioning of the equipment if not carried out correctly and may not be clear at first sight.

WARNING!

This type of paragraph indicates things, procedures, adjustments, etc. which demand a high level of
attention, otherwise personal injury or death may occur.

EXAMPLE:

This type of paragraph indicates examples of usage for illustrational purposes.

Inteli NT GeCon-MARINE SPI, SW Version 3.2, ©ComAp – July 2015
IGS-NT-GeCon-MARINE-SPI-3.2.PDF

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Available Firmware and Archive sets

InteliGen NT GC

InteliGen NTC GC

InteliGen NT BaseBox

InteliGen NTC BaseBox

InteliSys NT BaseBox

InteliSys NTC BaseBox

IG-NT-GC-GeCon-MARINE-3.2

IG-NT-BB-GeCon-MARINE-3.2

IS-NT-GeCon-MARINE-3.2

InteliGen NT GC

InteliGen NTC GC

InteliGen NT BaseBox

InteliGen NTC BaseBox

InteliSys NT BaseBox

InteliSys NTC BaseBox

IG-GC-GeCon-MARINE -SPTM-

3.2

IG-BB-GeCon-MARINE -SPTM-

3.2

IS- GeCon-MARINE-SPTM-3.2

IG-GC-GeCon-MARINE -SPI-

3.2

IG-BB-GeCon-MARINE -SPI-3.2

IS- GeCon-MARINE-SPI-3.2

IG-GC-GeCon-MARINE -MINT-

3.2

IG-BB-GeCon-MARINE -MINT-

3.2

IS- GeCon-MARINE-MINT-3.2

IG-GC-GeCon-MARINE -

COMBI-3.2

IG-BB-GeCon-MARINE -

COMBI-3.2

IS- GeCon-MARINE-COMBI-3.2

For suitable firmware for your controller please consult this table:

Firmware (*.mhx)

Archives (*.ant)

Some features are available only in InteliGen NT Basebox, InteliGen NTC Basebox and InteliSys NT. These
features are highlighted by green background.

Features which are not available in InteliGenNT GC controller:
User MODBUS

Distributed Binary Inputs and Outputs

Inteli NT GeCon-MARINE SPI, SW Version 3.2, ©ComAp – July 2015
IGS-NT-GeCon-MARINE-SPI-3.2.PDF

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General description

PDF FILE

DESCRIPTION

IGS-NT & ID-DCU Accessory Modules 02-

2015.pdf

Thorough description of accessory modules for IGS-NT
family, technical data, information about installation of the
modules, how to connect them to controller and set them
properly.

IGS-NT Troubleshooting Guide 08-2014.pdf

How to solve most common troubles with InteliGen NT and
InteliSys NT controllers. Including the list of alarm massages.

IGS-NT Communication Guide 09-2014.pdf

Communication guide for IG/IS-NT controllers. It contains
information how to connect control unit and all
communication features descriptions

IGS-NT Installation Guide 08-2014.pdf

Installation guide for IG/IS-NT controllers. It contains
technical information about controler and extension modules

IGS-NT Application Guide 05-2013.pdf

Application guide for IG/IS-NT controllers. It refers to
application and typical installation settings and sites
structures

Description of the controller system (with all options)

NT Family controllers are comprehensive AMF-controllers 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.
NT Family 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 controller automatically starts the gen-set, closes the Gen-set C.B. when all conditions are met, then
stops the engine* (* sw GeCon opens GCB only, not stops the engine) on external signal or by pressing
push buttons.
Parallel to the Mains operation is a standard feature. Isolated parallel and Power Management System
support are optional. Forward and reverse synchronizing, Generator protections, Mains protection including
vector shift, load and power factor control are the major functions provided. Interfacing to foreign
synchronizers and load sharers is supported.
The key feature of the controller is its easy-to-use operation and installation. Predefined configurations for
typical applications are available as well as user-defined configurations for special applications.

Comparing of IGS-NT-GeCon-MARINE 3.2 with standard gen-set fw

GeCon does not take care of Engine control
GeCon accepts in SEM mode external control of GCB and Engine
GeCon can control the engine via Binary start/stop output signals only – see below. The independent Engine
controller (e.g. ID-DCU) is expected.
Synchronizing and unloading timeouts can be disabled by setpoint setting (or Force value function)
All regulations (load, VAr sharing, frequency, voltage) can be disabled by setpoint change or by Force value.
Interface GeCon to engine controller is provided by I/O wires no by communication line.

Available documentation

Inteli NT GeCon-MARINE SPI, SW Version 3.2, ©ComAp – July 2015
IGS-NT-GeCon-MARINE-SPI-3.2.PDF

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IGS-NT Operator Guide 01-2014.pdf

Operator guide for IG/IS-NT

Inteli NT GeCon-MARINE SPI, SW Version 3.2, ©ComAp – July 2015
IGS-NT-GeCon-MARINE-SPI-3.2.PDF

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Example of interconnection

GeCon x Engine controller

Schematic wiring:

Important signals/ interconnections:

From GeCon side:

BO: Start pulse, Stop pulse - for sending Start and Stop signals
Speed control (during synchronisation, regulation):
BO: Speed Up, Speed Down or Aout SG out

Inteli NT GeCon-MARINE SPI, SW Version 3.2, ©ComAp – July 2015
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BI: ReadyToLoad – signal from Engine unit – it means that Engine is ready (speed is ok, no 2nd level
alarms) and can be loaded.

Other signals:

- Information about Warnings / SD in one unit can be sent to second unit.

- ECU – in case of Ecu communicating via CAN bus J1939 – GeCon can be connected to CAN1 for
showing ECU values on the display

- Interconnection on CAN2:

o For Time and Date synchronisation only- in case of IGS-NT and ID-DCU
o In case of connection IB-NT or I-LB+ - you can monitor both kind of units (IGS-NT, ID-DCU)
o In case of connection display – you can switch between both kind of units (IGS-NT, ID-DCU)

Inteli NT GeCon-MARINE SPI, SW Version 3.2, ©ComAp – July 2015
IGS-NT-GeCon-MARINE-SPI-3.2.PDF

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Functions

Basic description of SPI application

The SPI application is intended for single gen-sets and includes following main features:

 Automatic startup and stop sequences with adjustable timing
 Wide range of generator and engine protections, additional freely configurable protections
 Parallel to the mains operation, many different load control modes (baseload, import/export control

and other)

 Island operation
 Integrated mains protection (mains decoupling relay) including vector shift
 One breaker control (GCB) including synchronizing
 MCB position sensing
 Soft loading and unloading

Inteli NT GeCon-MARINE SPI, SW Version 3.2, ©ComAp – July 2015
IGS-NT-GeCon-MARINE-SPI-3.2.PDF

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Modified setpoints

Group

Setpoint

Option

Function

Process control

StartStopBtn

ENABLED
DISABLED

Standard panel Start/Stop buttons function.
Panel Start/Stop buttons are disabled.

ProtectionMode

ACTIVE
NOT ACTIVE

ACTIVE:
2-nd level protections are evaluated, GCB
or MCB is controlled.
NOT ACTIVE:
2-nd level protections are evaluated, GCB
or MCB is NOT opened.
Exceptions are Emerg Stop and alarms
types Sdoverride.

Sync/Load ctrl

Sync timeout

1-1800s
NO TIMEOUT

Standard MINT function.
Unlimited synchronizing time.

GCB open level

1-100%
NO LEVEL

Standard MINT function.
No generator power open level detection.

GCB open del

1-1800s
NO TIMEOUT

Standard MINT function.
Unlimited unloading procedure.

“HAND”

SEM

AUT

Basic setting

ControllerMode

SEM

SEM

AUT

Process control

StartStopBtn

DISABLED

ENABLED

ENABLED

ProtectionMode

NOT ACTIVE
/ACTIVE

ACTIVE

ACTIVE

Sync/Load ctrl

Sync timeout

NO TIMEOUT

1-1800s

1-1800s

GCB open level

NO LEVEL

1-100%

1-100%

GCB open del

NO TIMEOUT

1-1800s

1-1800s

Below mentioned are GeCon specific setpoints only.

Hint:

All above mentioned setpoints can be Forced by Binary input(s) to another value (or switched between
ENABLED and DISABLED).

Based on setpoint settings there are three possible operational modes HAND – SEM - AUT:

Hint:

It is possible to configure (Force value) “HAND” – SEM switching via Binary input.

Inteli NT GeCon-MARINE SPI, SW Version 3.2, ©ComAp – July 2015
IGS-NT-GeCon-MARINE-SPI-3.2.PDF

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Controller modes

OFF mode

Use OFF mode to block controller functions (even if is power on). OFF mode is used for controller firmware
or configuration change.
Binary outputs (e.g. GCB CLOSE/OPEN) are not energized, all closed Binary outputs are opened when
controller is switched to OFF mode.
Gen-set cannot be started and operated from IGS-NT-GeCon controller – no response for panel buttons and
Binary input commands.

Hint:

Switching to OFF mode is blocked on running engine to avoid accidental engine stop by mode change or by
firmware or configuration programming.

Inteli NT GeCon-MARINE SPI, SW Version 3.2, ©ComAp – July 2015
IGS-NT-GeCon-MARINE-SPI-3.2.PDF

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SEM mode

Engine start can be activated from

o Engine controller (e.g. ID-DCU, ID-MCU)
o GeCon panel – Start button
o GeCon BI: StartButton
o Remotely e.g. from InteliMonitor

GeCon BI: ReadyToLoad initiates GeCon “Running” state” - activates Gener protect: Min stab time a Max
stab time within the generator electric protections are activated.

Gen-set is loaded/unloaded from

o GeCon panel – GCB button
o GeCon BI: GCBButton
o Direct GCB “hand” control
o Remotely e.g. from InteliMonitor
o LBI: Gen unload

GCB closing from controller can be blocked by BI: GCB disable (does not block synchronization process)

Controller flow chart in SEM mode:

Inteli NT GeCon-MARINE SPI, SW Version 3.2, ©ComAp – July 2015
IGS-NT-GeCon-MARINE-SPI-3.2.PDF

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HAND mode

IG-EE GeCon

MINT

MCU

GCB feedback

GCB

close/open

Vg, Ig, Vb

RS232 - PC

Speed control
(Sync/Load ctrl)

GCB

START

STOP

(ReadyToLoad)

G

G

External Engine

Start / Stop

External GCB

Close / Open

generator
measuring

Process control: StartStopBtn = DISABLED
ProtectionMode = NOT ACTIVE
Sync/Load ctrl: Sync timeout = NO TIMEOUT
GCB open level = NO LEVEL
GCB open del = NO TIMEOUT

MCU

Hand mode is a special type of SEM mode. In Hand mode, the panel Start, Stop buttons are not working,
GCB is supposed to be controlled externally. The Hand mode is achieved by setpoints adjustment - see the
following picture.

Inteli NT GeCon-MARINE SPI, SW Version 3.2, ©ComAp – July 2015
IGS-NT-GeCon-MARINE-SPI-3.2.PDF

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AUT mode

No.

Island

enable

Parallel

enable

Synchro

enable

Function
1

YES

YES

FORWARD

Basic SPI application

2

YES

NO

NO

SPM application

3

NO

YES

FORWARD

SPI application, no island (stand-by) operation
allowed

4

NO

NO

NO

Gen-set start is blocked. Binary output
StartBlocked indicates those states.
NO

NO

FORWARD

NO

YES

NO

Automatic mode is influenced by ProcessControl: Island enable, ParallelEnable, Synchro enable setpoints.

Following procedure corresponds to setting No.1 from table above.

1) After the input Rem start/stop is energized, controller starts the gen-set. If MCB feedack is active, the
controller will synchronize the gen-set to mains and ramp up the load, depending on the ProcessControl
set points adjustment.

2) If a mains failure is recognized, the controller will open the GCB to separate the failed mains from the
generator. After the mains breaker has been open (MCB feedback is de-energized), the controller will
close the GCB again to the island (stand-by) operation.

3) If mains recovers again, the GCB is open again to allow the MCB to be closed (manually or in general
not with a command from the controller). After both mains is present and MCB closed, the controller will
synchronize again with the healthy mains and close the GCB.

4) If input Rem start/stop is de-energized, controller will softly unload the gen-set back to the mains, then
open the GCB, cool down and stop the gen-set.

TEST mode

Use TEST mode for Gen-set start test if the Mains is OK or to transfer the load to the gen-set when Mains
fail is announced in advance.

HINT

The controller does not respond to GCB ON/OFF , STOP, START in Return To mains = ENABLED.
Gen-set automatically starts, when TEST mode is selected.

Inteli NT GeCon-MARINE SPI, SW Version 3.2, ©ComAp – July 2015
IGS-NT-GeCon-MARINE-SPI-3.2.PDF

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ProcessControl: Load ctrl PtM

Mode

Function

Related Setpoints – LBI – LBO - LAI

BASELOAD

Gen-set power is regulated to value
given by Base load setpoint.

ProcessControl: Base load

IM/EX

Gen-set load is controlled so, that the
mains import is maintained constant at
the level given by Import load setpoint –
I/E power is measured by controller on
auxiliary CT input or by analog input.

ProcessControl: Import load, I/E Pm­meas

ANEXT BASELOAD

Gen-set power is set by analog input.

Analog input: LdCtrlAnextBld

ANEXT IM/EX

Gen-set load is controlled so, that the
mains import is maintained constant at
the level given by the analog input
LdCtrl:AnExI/E – I/E power is measured
by controller on auxiliary CT input or by
analog input.

ProcessControl: I/E Pm-meas, Analog
input: PFCtrl:AnExI/E

T BY PWR

Gen-set power is controlled to keep the
required temperature, that is measured
via an analog input.

ProcessControl: TempByPwr Treq,
TempByPwr gain, TempByPwr int,

Analog input: LdCtrl:TByPwr

Another modes of active power control

Mode

Function

Related Setpoints – LBI – LBO - LAI

Export limit

Limits export to the mains in the
baseload mode. If the function is
enabled, the gen-set power is limited so
that mains import is always higher or
equal to the setpoint Import Load.

ProcessControl: Export limit = ENABLE,
Import load

Warming

The controller limits gen-set power for
requested time or until the water
temperature reach the requested value.
After warming the gen-set goes to the
requested (e.g. Baseload) power.

ProcessControl: Warming load;
Warming temp; Max warm time

Peak shaving

Automatic gen-set start/stop based on
object (load) consumption. Can be
based on measured kW or kVA.

ProcessControl: PeakLevelStart;
PeakLevelStop; PeakAutS/S del, Peak
kVA Start, Peak kVA Stop, PeakKVAS/S
del, LBO: PeakShaveAct

Mains parameters out of limits during synchronising

In case that mains parameters get out of permitted limits during synchronizing to mains (reverse or forward),
the regulation of gen-set speed and voltage according to mains frequency and voltage is interrupted. During

the state, when parameters reach out of limits, until “Mains fail” is issued, the engine speed and voltage

regulation output is kept on the last value.

Active Power control modes in SPI

Inteli NT GeCon-MARINE SPI, SW Version 3.2, ©ComAp – July 2015
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Requested power

Actual power

Vgen

Igen

SpeedGoverrnor

output

Speed

governor

ProcessControl: Load ctrl PtM = ANEXT BASELOAD

LOAD

GCBMCB

Controller

LdCtrl:AnExtBld

Analog input:

Requested power

Actual power

ProcessControl: Baseload

Vgen

Igen

SpeedGoverrnor

output

Speed

governor

ProcessControl: Load ctrl PtM = BASELOAD

LOAD

GCBMCB

Controller

SpeedGoverrnor

output

Speed

governor

LOAD

GCBMCB

Controller

LdCtrl:I/E-Pm

Analog input:

Vmains

Imns 3

LoadCtrlPtm = IM / EX
I / E- Pm meas =

ANALOG INPUT

ProcessControl :
ProcessControl :

ProcessControl :

IM/ EX

Requested I/E power

Actual I/ E power

SpeedGoverrnor

output

Speed

governor

LoadCtrlPtm = IM / EX

LOAD

GCBMCB

Controller

Vmains

Imains ph3

ProcessControl :

IM/EX

ProcessControl :

I/E -Pm meas = IM3 CT INPUT

ProcessControl :

Requested I/

E power

Actual I/ E power

ProcCtrlSingle: PF ctrl PtM

Mode

Function

Setpoints

BASEPF

Gen-set power factor is maintained at
constant level adjusted by the setpoint
Base PF.

ProcCtrlSingle: PF ctrl PtM

PF-IM/EX

Gen-set power factor is controlled so, that the
mains power factor is maintained constant at
the level adjusted by setpoint Import PF

ProcCtrlSingle: Import PF,
I/E Qm-meas

ANEXT BASEPF

Gen-set power factor is maintained at
constant level given by the analog input
PFCtrl:AnExBPF

Analog input: PFCtrl:AnExBPF

ANEXT PF-IM/EX

Gen-set load is controlled so, that the mains
power factor is maintained constant at the
level given by the analog input PFCtrl:AnExI/E
– I/E power factor is measured by controller
on auxiliary CT input or by analog input.

ProcCtrlSingle: I/E Qm-meas
Analog input: PFCtrl:AnExI/E

PF control modes

Inteli NT GeCon-MARINE SPI, SW Version 3.2, ©ComAp – July 2015
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Requested PF

Actual PF

ProcessControl: Base PF

Vgen

Igen

AVRi output

AVR

ProcessControl: PF ctrl PtM = BASEPF

LOAD

GCBMCB

Controller

IG-AVRi

ProcessControl :

Import PF

AVR

ProcessControl :
ProcessControl :

LOAD

GCBMCB

Controller

IG-AVRi

Vmains

Imains ph3

PF ctrl PtM = PF IM/ EX

Actual I/ E PF

Requested I /E PF

I / E- Qm meas = IM3 CT INPUT

AVRiout pu t

Import PF

AVRi output

AVR

LOAD

GCBMCB

Controller

IG-AVRi

PfCtrl:I/E-Qm

Analog input:

Vmains

Imns 3

Actual I/E PF

Requested I/E PF

PF ctrl PtM = PF IM/EX

ProcessControl :

ProcessControl :

ProcessControl : I/E- Qm meas

= ANALOG INPUT

Load shedding

Load shedding function is dedicated for tripping of non-essential load in case of high generator current, or
drop of generator frequency above/below preadjusted limits, for preadjusted time.
All LOAD SHED outputs are activated (closed) to trip the unessential load when gen-set goes to island:

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

The load shedding function is active in all controller modes except OFF and MAN.
Load shedding has ten steps and each step is linked with its own Load shed x binary output. The non
essential load shedding is based on generator current and generator frequency. There is only one level for
current load shedding and one level for frequency load shedding for all 10 steps, as well for reconnection
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 S10 and vice versa.
If manual reconnection of the load is desired, the AutoLd recon setpoint needs to be disabled (AutoLd recon
= DISABLED) and the MAN load recon binary input needs to be configured.
Rising edge on this input resets the controller to a lower stage, but only if the load is under the Ld recon level
at that moment.
The current load shedding can be activated in case any of phase current exceeds the adjusted limit. The
reconnection is able only in case all of the current values are below reconnection level.

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CurShedLev
CurRecLev

FreqShedLvl
FreqRecLvl

LdShed stage 1
LdShed stage 2

LdShed stage 10

ManualLdRecon

Load shedding:

Ld Shed delay
Ld recon delay

Ld shed

del

Ld shed

del

Ld shed

del

BO Load shed 1

BO Load shed 2

BO Load shed 3

Curr shed level

Gen-set current

closed

closed

closed

Ld recon del Ld recon delLd recon del

BO Load shed 2

Curr recon level

Gen-set current

BO Load shed 3

BO Load shed 1

opened

opened

opened

Hint:

If no Load Shedding outputs are configured, there is no record to history and no screen timer indication of
the activity of this function.

On the following pictures, the generator current load shedding is depicted. The current is evaluated from all 3
phases, each phase can activate the load shedding. On the picture, due to transparency, only 3 load shed
outputs are depicted, not all 10.
The generator frequency based load shedding is in fact the same, but fall below preadjusted limit is watched,
instead of exceeding of the limit as in case of current load shedding.

Load reconnection – automatic -> AutoLd recon = ENABLED

Load reconnection – manual -> AutoLd recon = DISABLED

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BO Load shed 2

Curr recon level

BO Load shed 3

BO Load shed 1

BI Man load recon

opened

opened

opened

no action

Gen-set current

0 V batt

Test on load
Remote TEST

AMF settings:
ReturnTo mains = DISABLED

WrnTstOnLdFail

Test on load – SPtM

Affects the behavior in TEST mode. Before the activation of this function

1. adjust setpoint AMF settings: ReturnTo mains = DISABLED

2. adjust Process control: MFStart enable = YES.

3. switch controller to Test on load mode (see drawing below)

Gen-set starts and goes to load (synchronizes to the mains, closes GCB and opens MCB) automatically
when this input is closed even if Mains is OK.

Transmition of power from mains to generator

Behaviour of function depends on settings of setpoint ProcessControl:I/E-Pm meas. If the mains import is
measured (ProcessControl:I/E-Pm meas = IM3 CT INPUT or ANALO INPUT) then there is no time
limitation for unloading and opening of MCB. The MCB is opened when the Import/Export goes below 0 ± 5%
of Basic settings: Nomin power. If the setpoint ProcessControl:I/E-Pm meas = NONE then the MCB is
opened after delay given by setpoint AMF settings: BreakerOverlap.

Transmition of power from generator back to mains

GCB is opened when the power on gen-set is drops under level given by setpoint Sync/Load ctrl: GCB
open level at the least after delay given by setpoint AMF settings: BreakerOverlap.

Test on load with break (interruption)

The transfer of the load in TEST mode can be performed with interruption in case that the parallel to mains
operation is undesirable. Set setpoints ProcessControl:Parallel enable = NO or ProcessControl:Synchro
enable = NONE or REVERSE, ProcessControl:Island enable = YES: If the LBI Test on Load gets active the
load is passed from the mains to the gen-set with interruption. Controller opens MCB and closes GCB after
delay given by AMF settings:FwRet break. After deactivation of LBI Test on Load GCB is opened and and
MCB Is closed after delay given by AMF settings:FwRet break.

HINT

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Temperature derating function
decreases genset power depend
on setpoints DeratingX strt,
DeratingX end and DeratedX pwr.

Temperature derating starts at
DeratingX strt temperature.

At DeratingX end temperature runs
genset at DeratedX pwr level.

Above DeratingX end temperature
Genset runs at constant DeratedX
pwr.

It is possible to configure both binary inputs (Remote TEST and Test on load) to only one controller physical
binary input internally.

Power derating

This function linearly decreases genset nominal power according to analog input value.
Gen-set power starts decreasing when temperature measured by Analog input PowerDeratingX exceeds
DeratingX strt value.
Gen-set power is at DeratedX pwr value when temperature measured by Analog input Power deratingX is
equal or higher than DeratingX end value.

Hint:

To use Power derating function configure at first Analog input PowerDeratingX to any IGS-NT or IS-AIN
analog input terminal by GenConfig.

When Power derating function is active the generator overload protection is based on the Derated power! ! !
Derated power value Pg derated is visible in the controller measure screen.
When derating function is not active the Derating power is equal to Nominal power.
Example :

Nomin power = 200 kW, Derating1 strt = 70 °C, Derating1 end = 100 °C, Derated1 pwr = 70 %.

Genset is running at Nominal power 200 kW. When temperature reached 70 °C the genset power starts

decreasing. When temperature reached 100 °C genset runs at 70 % of Nominal power = 140 kW. When
temperature increased above DeratingX end temperature level, gen-set power stays at DeratedX pwr level
140 kW.

Protection mode settings

Protections in this application are affected by Setpoint ProtectionMode (group ProcessControl).
This setpoint is active in MAN,SEM and AUT mode.

Setpoint ProtectionMode has 2 options of settings:

ACTIVE:

Standard setting – all protections are active, in case of 2nd level alarm the breaker is opened/controlled.
(2-nd level alarms are evaluated, GCB or MCB is controlled)

NOT ACTIVE:

2-nd level alarms are evaluated only , but GCB or MCB are NOT controlled (no actions).
Exceptions are Emergency Stop and Sd override alarms type.

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Circuit breakers operation sequence, GCB/MCB fail detection

2s

BO: CB status

BI: CB fdb neg

BI: CB fdb

BO: CB ON coil

1s

BO: CB close/open

BO: CB UV coil

minimum 1s from UV switching on,
together with MinStab time elapsing is
necessary before the CB is allowed to
close

When closing the CB, the CB status LBO
switches over only when both feedbacks
are in correct position

NOTE:

In the following text, “CB” abbreviation is used for MCB or GCB respectively.

Related binary inputs:

- CB fdb – CB feedback binary input

- CB fdb neg – negative CB feedback binary input. Used for increasing the reliability of CB status

evaluated by the controller. In case that it is not configured, negative value of CB fdb is calculated
internally within the controller.

Related binary outputs:

- CB close/open – output for circuit breaker. Equals to 1 during the time when CB is requested o be

closed.

- CB ON coil – output for closing coil of the CB. 2s pulse (5s if synchronising is not provided by the

particuilar CB) is used for closing the CB.

- CB OFF coil – output for opening coil of the CB. 2s pulse (5s if synchronising is not provided by the

particuilar CB) is used for opening the CB.

- CB UV coil – output for undervoltage coil of the CB. Permanently active, 2s negative pulse (5s if

synchronising is not provided by the particuilar CB) is used for CB opening request

- CB status – output indicating CB status as evaluated by the controller. This signal is used for lighting

LEDs on the panel, switching the regulations, CB fail evaluation, etc.

Possible CB sequences:

CB close command:

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2s

2s

1s

BO: CB OFF coil

2s

BO: CB status

BI: CB fdb neg

BI: CB fdb

BO: CB ON coil

1s

BO: CB close/open

BO: CB UV coil

If the CB is not closed after
the first attempt, it is only reset
by OFF pulse and no CB fail is
issued. This would be issued
after the second unsuccessfull
attempt.

BO: CB status = 0

BI: CB fdb neg = 1

BI: CB fdb = 0

BO: CB fail

ON pulse has finished and CB
status is not =1. CB fail is
issued immediatelly

Repeated CB close command:

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2s

BO: CB OFF coil

BO: CB fail

500 ms

<2s

BO: CB status = 0

BI: CB fdb neg = 1

BI: CB fdb

BO: CB ON coil

1s

BO: CB close/open

BO: CB UV coil

CB fail – If any inconsistence between
the two feedback signals is detected, CB
fail is issued.

ON pulse is shortened/interrupted
and replaced by UV and OFF pulse

OFF pulse is activated until both
feedbacks return to the correct
position +2 seconds.

2s

BO: CB OFF coil

BI: CB fdb neg

BI: CB fdb

BO: CB close/open

BO: CB UV coil

During CB opening the CB status
LBO is deactivated with change of
the first feddback status

Further behavior of UV output
depends on the system status. In
case of transition to cooling stays
off, if the Cb was opened manually
and the engine keeps running, it
activates again after timeout
elapses.

BO: CB status

CB fail – fdb mismatch:

CB open command:

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

<2s

2s

BO: CB OFF coil

BI: CB fdb neg

BI: CB fdb

BO: CB close/open

BO: CB UV coil

BO: CB status

BO: CB ON coil

Closing pulse is shortened, opening
sequence is started immediatelly

CB opening by protection or manual
command (button pressed)

2s

2s

BO: CB OFF coil

BI: CB fdb neg

BI: CB fdb

BO: CB close/open

BO: CB UV coil

BO: CB status

BO: CB ON coil

OFF a UV pulse is always activated for
the full time. manual control (= CB
button) is deactivated during opening
pulse.

Here starts the standard closing
sequence – see CB close command.

In this moment, the reason for closing the
CB is activated again (e.g. Remote
Start/Stop is activated)

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

Inteli NT GeCon-MARINE SPI, SW Version 3.2, ©ComAp – July 2015
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Alarm: GCB fail

BO GCB close/open

BI GCB feedback

Alarm detection:

immediatelly

active

closed

opened

Alarm: GCB fail

BI GCB feedback

BO GCB close/open

Alarm detection:

immediatelly

active

opened

closed

BO: MCB UV coil

FwRet break

RPM / fg / Ug

EmergStart del

2s

BO: MCB OFF coil

BI: MCB fdb neg

BI: MCB fdb

BO: Mains OK

BO: MCB status

BO: Fuel solenoid

FwRet break dealy is between MCB
status deactivation and command for
GCB closing.

BO: MCB close/open

Generator voltage is within limits
BO: GCB close/open

BO: GCB ON coil

If mains returns in this moment,
starting sequence is interrupted
and MCB stays closed. It is valid
until the moment when generator
voltage is within limits.

MCB opens on = GENRUN:

Other CB fail reasons:

 When the BO CB close/open is in steady state and CB feedback is changed, the CB fail is detected

immediately (no delay).

 When the BO CB close/open opens, there is 5 resp. 2 sec delay for the breaker to respond before a CB

fail is detected. In such case, if CB OFF coil is used for opening the CB and CB fail occurs during
opening the CB, the signal CB OFF coil is automatically extended until the breaker opening is detected
(evaluated as CB status).

 2 sec when the CB is used for synchronizing
 5 sec in other cases

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Alarm: GCB fail

BO GCB close/open

BI GCB feedback

active

opened

opened

Time delay

5 sec

Rename the VPIO to suitable name
(e.g. L2 MCB fail, which indicates that it is
Level 2 alarm)

Choose Wrn MCB fail from Prg. States group on
any VPIO output

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

activated immediatelly.

NOTE:

If the MCB or GCB feedback gets active during synchronization the breaker is imediately closed.

CAUTION!

In case that MCB feedback is active (MCB is expected as closed) and “MCB fail” is reported due to previous

incorrect manipulation of MCB, in the moment of Fault reset, the MCB fail is cleared and the controller

internally goes to “closed” state. I.e. MCB fdb status is confirmed and the output MCB close/open is

energized.

MCB fail Information

Opening of the MCB externally is allowed because external protection device may open it based on its
protections. The controller will try to reclose the breaker if Mains protect type protection is not configured
accordingly (e.g. external protection device/relay does not allow user to send this type of signal or such
wiring is impractical). After failed attempt to close the breaker, the controller issues standard alarm and in
AUT mode starts the engine and consequently closes GCB breaker.

Warning!

In this case, if the supposed opening of the MCB is caused merely by MCB feedback failure and
the actual position of the MCB is still closed, the controller will close GCB to the Mains voltage
directly without synchronizing because it cannot be distinguished what exactly happened. This
situation can be possibly harmful to the personnel or the equipment. Should this be the case, the
following solution is proposed:

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Adjust the delay if required (since the start of the engine
can take up considerable time, 0.5s should be sufficient)

Toggle on the protection for the interconnected VPIO input
(e.g. BI VPIO-1 1 is interconnected with BO VPIO-1 1)

Set the type of the
protection to Off load

External breaker control

This application accepts external breaker control in these situations:
MINT application:

Mode:MAN, SEM
External breaker control is accepted only when LBI:ReadyToLoad=1

Exceptions:
If the BUS voltage is >15V and GCBfdb=1 and LBI:ReadyToLoad=0 then BO GCB Fail and History record
are performed

SPtM application:
Mode:SEM
External MCB control is accepted
External GCB control is accepted only when LBI:ReadyToLoad=1

Exceptions:
If the Mains parameters are out of limits (voltage and frequency) and GCB and MCB are closed and
LBI:ReadyToLoad=1 – external control is not accepted – Wrn MCB fail and Wrn GCB fail are evaluated.

If the Mains voltage is > 15V and MCBfdb=1 and GCBfdb=1 and LBI:ReadyToLoad=0 then BO GCB Fail
and History record are performed.

SPI application:
Mode: SEM
External GCB control is accepted only when LBI:ReadyToLoad=1

Exceptions:
If the Mains parameters are out of limits (voltage and frequency) and GCB and MCB are closed and
LBI:ReadyToLoad=1 – external control is not accepted – Wrn MCB fail and Wrn GCB fail are evaluated.

If the Mains voltage is > 15V and MCBfdb=1 and GCBfdb=1 and LBI:ReadyToLoad=0 then BO GCB Fail
and History record are performed.

Peak shaving based on Active and Apparent power

The Peak shaving function is active only in AUT mode in parallel to Mains operation. Peak shaving is based
on Object P or Object Q (consumption of load). If load consumption increases over
ProcessControl:PeakLevelStart or ProcessControl:PeakKVAStart for period longer than

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PeakLevelStart

PeakAutS/S del

Actual power [ kW

]

Time

PeakLevelStop

PeakAutS/S del

Sys start/stop

ProcessControl:PeakAutS/S or ProcessControl:PeakKVAS/S del the gen-set is started (BO Sys start/stop
is activated). If load consumption decreases below ProcessControl:PeakLevelStop or

ProcessControl:PeakKVAStop for period longer than ProcessControl:PeakAutS/S del or
ProcessControl:PeakKVAS/S del the gen-set is stopped. Both Peak shaving based on kW and kVA can

work simultaneously (SYS START/STOP is activated if at least one condition is fulfilled). Peak shaving based on
Apparent power is available in InteliGen-NT Basebox, InteliGen-NTC Basebox and InteliSys-NT only.

Figure: Example of peak shaving function based on Active power (the same function for Reactive power)

NOTE:

Function Peak Shaving based on Apparent power is not available for IG-NT-GC controller.

Remote Alarm Messaging

It is possible to use up to five channels for Active Call, Email and SMS upon defined type of Alarm. It is
possible to define protection type for all ENABLED channels to react. All the possibilities in the controller are:
History record, Alarm only, Warning, Mains protect and Mains protect with Reset. Find more information
about alarm types in the chapter Protections and alarm management.

Communication Types for Remote Alarm Messaging

Below there all types of communication available for each Active Call channel.
DATA-ANA: This option sends a complete archive to the recipient's PC via analog modem. An analog
modem must be connected either to one of controller COM ports or to one of I-LB modules connected to the
controller via CAN2 bus. The channel address must contain complete telephone number of the recipient's
PC where InteliMonitor is running in Active call receiving mode.
DATA-GSM: This option sends a complete archive to the recipient's PC via GSM modem. A GSM modem
with activated CSD data transfers must be connected either to one of controller COM ports or to one of I-LB
modules connected to the controller via CAN2 bus. The channel address must contain complete telephone
number of the recipient's PC where InteliMonitor is running in Active call receiving mode.
DATA-ISDN: This option sends a complete archive to the recipient's PC via ISDN modem. An ISDN modem
must be connected either to one of controller COM ports or to one of I-LB modules connected to the
controller via CAN2 bus. The channel address must contain complete telephone number of the recipient's
PC where InteliMonitor is running in Active call receiving mode.
DATA-CDMA: This option sends a complete archive to the recipient's PC via CDMA modem. A CDMA
modem must be connected either to one of controller COM ports or to one of I-LB modules connected to the
controller via CAN2 bus. The local CDMA network must allow point-to-point data transfers. The channel
address must contain complete telephone number of the recipient's PC where InteliMonitor is running in
Active call receiving mode.
SMS-GSM: This option sends a short text message (SMS) containing the actual Alarmlist contents to the
recipient's mobile phone via the GSM modem. The channel address must contain complete telephone
number of the recipient's mobile phone.
SMS-CDMA: This option sends a short text message (SMS) containing the actual Alarmlist contents to the
recipient's mobile phone via the CDMA modem. The channel address must contain complete telephone
number of the recipient's mobile phone.

Inteli NT GeCon-MARINE SPI, SW Version 3.2, ©ComAp – July 2015
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