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

...

ComAp a.s..

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

Tel: +420 266 790 611, Fax: +420 266 316 647

Technical support hotline: +420 266 790 666

E-mail: info@comap.cz, 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

MINT

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

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

Modified setpoints ........................................................................................................................................ 11

Controller modes .......................................................................................................................................... 12

Power management ..................................................................................................................................... 16

DeadBusStart function ................................................................................................................................. 20

Load shedding .............................................................................................................................................. 20

DROOP ........................................................................................................................................................ 22

Protection mode settings .............................................................................................................................. 24

External breaker control ............................................................................................................................... 24

Heavy consumers support ........................................................................................................................... 25

Variable speed support ................................................................................................................................ 26

Force value – step by step guide ................................................................................................................. 27

Values for continuous writing from external sources ................................................................................... 29

User Buttons................................................................................................................................................. 29

User Mask function ...................................................................................................................................... 30

Remote Control Function ............................................................................................................................. 31

Virtual Peripheral Inputs-Outputs (VPIO) module ........................................................................................ 32

Shared Inputs and Outputs .......................................................................................................................... 32

Distributed Binary Inputs and Outputs ......................................................................................................... 34

Modbus Reading and Writing ....................................................................................................................... 35

User MODBUS ............................................................................................................................................. 35

Modbus Switches ......................................................................................................................................... 36

Power Formats ............................................................................................................................................. 36

PLC functions ............................................................................................................................................... 36

Multi language support ................................................................................................................................. 37

ECU interface customizing ........................................................................................................................... 37

Volt/PF control adjustment ........................................................................................................................... 37

Sync/load control adjustment ....................................................................................................................... 39

Protections and Alarm management ................................................................................................................ 40

Gen-set operation states .................................................................................................................................. 47

SynchroScope mode ........................................................................................................................................ 48

Inputs and Outputs ........................................................................................................................................... 49

Virtual and physical modules ....................................................................................................................... 49

Analog outputs ............................................................................................................................................. 49

Setpoints ........................................................................................................................................................... 51

ProcessControl ............................................................................................................................................. 51

Basic settings ............................................................................................................................................... 57

Delays/Timers .............................................................................................................................................. 68

Analog protect .............................................................................................................................................. 71

Gener protect ............................................................................................................................................... 72

Pwr management ......................................................................................................................................... 79

HeavyConsumers ......................................................................................................................................... 84

Sync/Load ctrl............................................................................................................................................... 84

Sync/load control adjustment ....................................................................................................................... 84

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

Volt/PF ctrl .................................................................................................................................................... 89

Force value ................................................................................................................................................... 91

Load shedding .............................................................................................................................................. 92

Timer settings ............................................................................................................................................... 94

Act. calls/SMS .............................................................................................................................................. 94

Date/Time ..................................................................................................................................................... 96

Table of values ................................................................................................................................................. 98

Group: Engine values ................................................................................................................................... 98

Group: Gener values .................................................................................................................................... 99

Group: Bus values ...................................................................................................................................... 106

Group: Power management ....................................................................................................................... 109

Group: Sync/Load ctrl ................................................................................................................................ 112

Group: Volt/PF ctrl ...................................................................................................................................... 114

Group: Force value .................................................................................................................................... 114

Group: Load shedding ................................................................................................................................ 116

Group: Analog CU ...................................................................................................................................... 116

Group: Bin inputs CU ................................................................................................................................. 117

Group: Bin outputs CU ............................................................................................................................... 118

Group: Log Bout ......................................................................................................................................... 118

Group: Info ................................................................................................................................................. 122

Group: Statistics ......................................................................................................................................... 128

Table of binary input functions........................................................................................................................ 133

HeavyConsumers ....................................................................................................................................... 174

Table of analog input functions ...................................................................................................................... 175

Table of binary output functions ..................................................................................................................... 184

Controller configuration and monitoring ......................................................................................................... 221

Direct connection to the PC ....................................................................................................................... 221

GenConfig functions ................................................................................................................................... 221

InteliMonitor ................................................................................................................................................ 222

Modbus protocol ......................................................................................................................................... 222

Value and setpoint codes ........................................................................................................................... 222

Technical data ............................................................................................................................................ 222

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

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

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

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

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

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

IGS-NT Operator Guide 01-2014.pdf

Operator guide for IG/IS-NT

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

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

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

Functions

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

AUT

Process control

StartStopBtn

DISABLED

ENABLED

ProtectionMode

NOT ACTIVE/ACTIVE

ACTIVE

Sync/Load ctrl

Sync timeout

NO TIMEOUT

1-1800s

GCB open level

NO LEVEL

1-100%

GCB open del

NO TIMEOUT

1-1800s

For the IGS-NT-GeCon-MARINE is possible to use IGS-NT-LSM+PMS or IGS-NT-GeCon-LSM+PMS dongle which enables the Load sharing and Power management functions. (both types of dongles have the same function)

Modified setpoints

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

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

MAN mode

Stopped

Running

Loaded

BI:ReadyToLoad

BI:GCB feedback active

BI:GCB feedback

not active

BI:ReadyTo

Load - deact

BI:ReadyTo

Load - deact

IG-EE GeCon

MINT

MCU

GCB feedback

GCB

close/open

Vg, Ig, Vb

RS232 - PC

Speed control (Sync/Load ctrl)

GCB

START

STOP

(ReadyToLoad)

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

In MANual mode, the controller evaluates configured protections only(when LBI:ReadyToLoad=1 only). All regulation loops are disabled, not active. Controller’s state changes based on sensed signals ReadyToLoad and GCB feedback. In case of some active protection, this is signalized by appropriate binary outputs. Engine cannot be started from GeCon, GeCon cannot close the GCB, etc..,only opens GCB in cause SD alarm and Setpoint:Protection mode:ACTIVE.

Controller flow chart in MAN mode

HAND mode

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

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

AUT mode

Engine start or Power management is activated from GeCon BI: Sys start/stop

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 starts synchronizing and is loaded/unloaded automatically based on

o Power management setting o GeCon BI: Sys start/stop

GeCon will stop engine started from engine controller when BI Sys start/stop or due to Power management function. Controller flow chart in AUT mode:

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

Power management

Automatic gen-set start / stop function based on load changes and/or Running hours or Generator size. Following functions are available:

Power management in kW

Guarantees adjustable load reserve (load step) in kW. Suitable for load demand-based optimization. Activation: #Pwr mgmt mode = ABS (kW)

Power management in kVA

Guarantees adjustable load reserve (load step) in kVA. Suitable for generator- or busbar dimensioningbased optimization. Activation: #Pwr mgmt mode = ABS (kVA)

Relative power management in %

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

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

Reserve

Actual Reserve

Start condition

Stop condition

Absolute kW / kVA

ARstrt = ΣPg

Nom

– ΣPg

Act

ARstp = ΣPg*

Nom

– ΣPg

Act

ARstrt < #LdResStrt

ARstp > #LdResStp

Relative

RRstrt = (ΣPg

Nom

– ΣPg

Act

) / ΣPg

Nom

RRstp = (ΣPg*

Nom

– ΣPg

Act

) / ΣPg*

Nom

RRstrt < #%LdResStrt

RRstp > #%LdResStp ARstrt

Actual Absolute reserve in kW or kVA - for engine start calculation.

ARstp

Actual Absolute reserves in kW or kVA - for engine stop calculation.

RRstrt

Actual Relative reserve in % - for engine start calculation.

RRstp

Actual Relative reserves in % - for engine stop calculation.

ΣPg

Nom

Sum of Nominal power of all gen-sets on the bus.

ΣPg*

Nom

Sum of Nominal power of all gen-sets on the bus apart of the one, which is going to be stopped.

ΣPg

Act

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

Start/Stop conditions in Power management

Where

Hint:

Optional functions in absolute or relative Power management are:

- Running hours balancing (equalization),

- Load demand (different size) engines swap and

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

G1 G2 G3

LOAD

1.controller 2.controller 3.controller

Basic settings: Contr.addr = 1 Pwr management: #Pwr mgmt mode = RUN HOURS EQU Priority ctrl = MASTER RunHoursBase = 100 h #RunHrsMaxDiff = 10 h Control group = COMMON

Basic settings: Contr.addr = 2 Pwr management: #Pwr mgmt mode = RUN HOURS EQU Priority ctrl = SLAVE RunHoursBase = 200 h #RunHrsMaxDiff = 10 h Control group = COMMON

Basic settings: Contr.addr = 3 Pwr management: #Pwr mgmt mode = RUN HOURS EQU Priority ctrl = SLAVE RunHoursBase = 300 h #RunHrsMaxDiff = 10 h Control group = COMMON

- Power management of two or more gen-set groups (bus tie support).

CAUTION!

The function of the controller is designed to handle the maximum sum of nominal power at 32000kW (3200.0kW, 320.00MW depending on the power format in the controller). If the sum of nominal power of all gen-sets connected to the intercontroller CAN exceeds these values the power format needs to be changed accordingly.

Example: There are 20 gen-sets each with 2000kW of nominal power. The sum of the nominal power is 40000kW. Therefore the power format in kW cannot be used because the sum exceeds 32767. Therefore power format in MW needs to be chosen because the sum in MW is 40MW (it does not exceeds 320.00MW).

Running hours balancing

The gen-sets priorities are automatically swapped to balance engine running hours. Up to 32 controllers are supported. Activation: #PriorAutoSwap = RUN HOURS EQU Important setpoints: RunHoursBase , #RunHrsMaxDiff

Different sized engines (Load demand) swap

Three running engines (priorities) are swapped based on load demand (one “small” engine runs on “small” load and swaps to another one “big” engine that runs when load increases).

Activation: #PriorAutoSwap = LD DEMAND SWAP Important setpoints: #PwrBandContr1, #PwrBandContr2, #PwrBandContr3, #PwrBandContr4, #PwrBandChngDe.

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

G1 G2 G3

LOAD

1.controller 2.controller 3.controller

Basic settings: Contr.addr = 1 Pwr management: #Pwr mgmt mode = LD DEMAND SWAP Priority ctrl = MASTER #PwrBandContr1 = 1 #PwrBandContr2 = 2 #PwrBandContr3 = 2+3 #PwrBandChngDe = 10 s Control group = COMMON

Basic settings: Contr.addr = 2 Pwr management: #Pwr mgmt mode = LD DEMAND SWAP Priority ctrl = SLAVE #PwrBandContr1 = 1 #PwrBandContr2 = 2 #PwrBandContr3 = 2+3 #PwrBandChngDe = 10 s Control group = COMMON

Basic settings: Contr.addr = 3 Pwr management: #Pwr mgmt mode = LD DEMAND SWAP Priority ctrl = SLAVE #PwrBandContr1 = 1 #PwrBandContr2 = 2 #PwrBandContr3 = 2+3 #PwrBandChngDe = 10 s Control group = COMMON

G1 G2 G3 G4 G5

LOAD1 LOAD 2

Basic settings: Contr.addr = 1 Pwr management:

Control group = 1 GroupLinkLeft = 1 GroupLinkRight = 2

BTB

BI Group link

1.controller

2.controller

3.controller 4.controller 5.controller

Basic settings: Contr.addr = 2 Pwr management:

Control group = 1 GroupLinkLeft = C GroupLinkRight = C

Basic settings:

Contr.addr = 3

Pwr management:

Control group = 2 GroupLinkLeft = C GroupLinkRight = C

Basic settings:

Contr.addr = 4

Pwr management:

Control group = 2 GroupLinkLeft = C GroupLinkRight = C

Basic settings:

Contr.addr = 5

Pwr management:

Control group = 2 GroupLinkLeft = C GroupLinkRight = C

Control group 2.

Control group 1.

BTB feedback

Pwr management of splitted group

Important setpoints: Control group, GroupLinkLeft, GroupLinkRight When a Bus-tie disconnects the gen-set group the Power management and Load and Var share can operate separately on each of them. To enable the independent Pwr management, Load and Var sharing between the gensets, group of gensets splitted by bus tie breaker, configure the setpoints as depicted on this picture.

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

CurShedLev CurRecLev

FreqShedLvl FreqRecLvl

LdShed stage 1 LdShed stage 2

LdShed stage 10

ManualLdRecon

Load shedding:

Ld Shed delay Ld recon delay

DeadBusStart function

Function is determined for emergency incident - blackout on the power bus – on the ship.

Function is controlled by this setpoints/signals:

Setpoint:DeadBusStrt [ ENABLED / DISABLED ] Setpoint:DeadBusST del [ 0…600s ] LBO: DeadBusStart Alarm: DeadBusStart

Description:

When controler detects no voltage (any bus phase voltage is below 15 VAC) on the bus for the time „DeadBusSTdel”, then this function activates local start command, starts the gen-set, and connects it to the bus.

When the function Dead Bus Start is evaluated, LBO:Dead Bus Start is activated. When LBO:Dead Bus Start=1 then Power management system is internally DEACTIVATED – all gensets with active LBO:DeadBusStart are started and connected to the bus (and run in loadsharing).

Activation and deactivation of this function is written to the history. For deactivation of this function is necessary to switch to SEM mode and confirm the DeadBusStart alarm. DeadBusStart function works in AUT mode only. Function is available in MINT aplication.

Load shedding

Load shedding fiction 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.

Hint:

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

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

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

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

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

BO Load shed 2

Curr recon level

BO Load shed 3

BO Load shed 1

BI Man load recon

opened

no action

Gen-set current

ProcCrtlMulti: Reg kW/kVAr

STD

Standard isochronous Load Sharing and VAr Sharing are based on CAN intercontroller communication.

DROOP

Load Sharing and VAr Sharing regulations are based on droop. Requested power of each gen-set is calculated based on bus voltage and bus frequency.

EMERG DROOP

Load Sharing and VAr Sharing regulation are based on standard CAN intercontroller communication, but can be conditionally switched to droop. All controllers are continually checking the CAN16/CAN32 register (value in group “Info”) to see witch addresses are they in cooperation (use the LBI EmergDroopEnab to confirm the supervised constalation of addresses on CAN). In case of lost of any controller from CAN the regulations are automatically switched to droop (yellow alarm EmergDroop act appears in alarm list, message EmergDROOPon is writen in history). Load Sharing and VAr Sharing regulation are switched back to the standard mode 60 s after the constalation of addresses on CAN returns back to the original state (message EmergDROOPoff is written in history, alarm EmergDroop act has to be confirmed manually). The purpose of this function is protection against the cut off the CAN intercontroller line.

Sync/load ctrl: Load droop, LdDroopOffset

Load droop

This setpoint defines the slope of the load droop correlation. The slope is set as a droop of frequency in percentages of the requested frequency (Basic settings: Nominal freq + Nom frq offset) on the range of the requested power from 0 to 100% of

Basic settings: Nomin power.

LdDroopOffset

This setpoint defines the value of requested power on the requested frequency (Basic settings: Nominal freq + Nom frq offset). Allows to shift the droop correlation line up

or down.

DROOP

The droop regulation of kW/kVAr is the alternative to the isochronous Load Sharing and VAr Sharing. In the isochronous regulation are all information about the kW/kVAr shared via intercontroller communication line whereas in droop no intercontroller communication is needed. The droop regulation is based on voltage and frequency which are measured on the common bus. The requested kW/kVAr are calculated in each controller from the actual bus voltage and bus frequency. This principle of regulation needs the voltage and frequency beeing changing within defined limits. Type of regulation depends on settings of setpoint

ProcCrtlMulti: Reg kW/kVAr.

Load Sharing in droop

Characteristics of Load Sharing in droop are given by settings of these parameters:

50%

Preq

50Hz

49Hz

Load droop = 4% ˜ 2 Hz (1% ˜ 0,5 Hz)

51Hz

75% 100%

LdDroopOffset = 75%

LdDroopOffset = 50%

Nomin power

Sync/load ctrl: VAr droop, VArDroopOffset

VAr droop

This setpoint defines the slope of the VAr droop correlation. The slope is set as a droop of voltage in percentages of the generator nominal voltage (Basic settings: GenNomV) on the range of the requested reactive power from 0 to 100% of nominal reactive power (value of nominal reactive power is not given by setpoint but it is calculated from setpoint Nomin power whilst the PF=0,8).

VArDroopOffset

This setpoint defines the value of requested reactive power on the nominal voltage (Basic settings: GenNomV). Allows to shift the droop correlation line up or down.

50%

Qreq

230,0 V

225,4 V

VAr droop = 4% ˜ 9,2 V (1% ˜ 2,3 V)

234,6 V

75% 100%

VArDroopOffset = 75%

VArDroopOffset = 50%

Nomin reactive power

Example: Load droop = 4%, LdDroopOffset = 50% (75%)

VAr Sharing in droop

Characteristics of VAr Sharing in droop are given by settings of these parameters:

Example: VAr droop = 4%, VArDroopOffset = 50% (75%)

Hint:

Droop mode allows cooperation of gen-set equipped by ComAp control system with gen-set equipped by any third party control system. The steady bus voltage and bus frequency has to be regulated by this third party control system. Active and reactive power of gen-set equipped by ComAp controller is kept on values given by droop settings.

Note:

Over frequency and under frequency protections are active in droop. Be aware that the gen-set frequency in droop can cross the levels of these protections. The force value on the under/over frequency protection limits can be used if it is needed to set the different limits in droop.

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 opened (no actions). Exceptions are Emergency Stop and Sd override alarms type.

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.

Heavy consumers support

On ship are ussualy several heavy consumers which are connected to power bus only for limited time. Before connecting is necessary to start more genset or easily increase actual load reserve for covering the connection of heavy consumer.

Defining sizes of Heavy consumers:

Group: HeavyConsumers Setpoints: HeavyConsumer1..6

Request before connection of Heavy consumer:

LBI: HeavyConsumer1 (request for increasing load reserve before Heavy consumer connection)

Confirmation/feedback for Heavy consumer connection

LBO: HeavyCons fdb1 (after activation the Heavy consumer connection is possible)

How it works:

1) Before Heavy consumer connection – the request is activated (LBI: HeavyConsumer1)

2) When LBI: HeavyConsumer1 is activated then size of consumer (Setpoints: HeavyConsumer1) is added to actual load reserve.

3) When the load reserve is increased (Syst res OK is activated) then HeavyCons fdb1 is activated.

4) Based on the HeavyCons fdb1=1 the user can connect HeavyConsumer1 to bus.

CAUTION!

The user must ensure that each heavy consumer will have the same size over all controllers (it means that HeavyConsumer1 has the size in controller #1 and #2.) (these setpoints are not shared)

Each controller counts level for start and stop (in power management system) locally, so user must ensure correct activation of Heavy consumer inputs in all controllers (for example via Share Inputs/Outputs). Solution is shown on the picture:

G1 G2 G3 G4

1 2 3 4

Control group 1 Control group 2

BTB

SHBIN

SHBI1:HeavyCons 1 -> LBI: HeavyConsumer1 SHBI2:HeavyCons 2 -> LBI: HeavyConsumer2 SHBI3:HeavyCons 3

SHBI5:BTBfeedback

LBI:HeavyConsumer3

SHBI4:HeavyCons 4

SHBI5:BTBfeedback

LBI:HeavyConsumer4

SHBIN

SHBI3:HeavyCons 3 -> LBI: HeavyConsumer3 SHBI4:HeavyCons 4 -> LBI: HeavyConsumer4

SHBI1:HeavyCons 1

SHBI5:BTBfeedback

LBI:HeavyConsumer1

SHBI2:HeavyCons 2

SHBI5:BTBfeedback

LBI:HeavyConsumer2

Heavy

Consumer

Heavy

Consumer

Heavy

Consumer

Heavy

Consumer

Two kinds of Heavy consumers: Bow thruster

After connection of bow thruster to the bus it can be loaded from 0-100% variously acording to the current maneuvers of ship. In this case the request (increasing of actual Load reserve) must stay active (LBI: HeavyConsumer1=1) all the time during connection of bow thruster to bus

Compressor

Compressor usually work ON/OFF (with unchanging load) So after connection of compressor to the bus (and its activation) the load of Compressor is added to current load on the bus and the user can deactivated the request (LBI: HeavyConsumer1->0), because compressor has stable load which was currently connected.

Variable speed support

This fw contains variable speed support which is used on Hybrid ship (ship with DC bus). Variable speed control is usually used on ship where the gen-sets work in long term period on small load. By changing speed on genset is possible to achieve lower fuel consumption. Frequency (and Voltage) are usually control according to current load.

For variable speed is used:

Setpoints: Nominal freq 30..65 Hz (step 1 Hz) FV (Basic settings Group)

ForceBlock6Del 0-60s (step 0,1s) FV (Delays/Timers Group)

30Hz

50Hz

138V

230V

voltage

frequency

Magnetic flux =U/f ~konstant

GenNomV, BusNomV FV (Basic settings Group)

Voltage dependence on frequency

In generator is induced magnetic flux, which is almost constant in various RPM. It is necessary to change nominal frequency together with nominal voltage – due to their dependence.

Temporary blocking of fix frequency and voltage protections

Temporary blocking of frequency and voltage fix protections After submitting a request for change of nominal frequency and voltage the generator needs some

time for performing the changes. During this time the fix frequency and voltage protections (connected to nominal values) must be blocked. The time need for blocking of these protections is set by setpoint: ForceBlock6Del 0-60s (step 0,1s) FV (Delays/Timers Group)

HINT

With larger frequency range the regulation can be rougher, in this case the AC/DC inverter is expected.

WARNING!

Used generator should be designed for variable rotation. With frequency changes the nominal value of Voltage must be also changed.

Force value – step by step guide

In this chapter there is complete step by step guide which shows how to use Force value function of the controller.

Add or remove Force value

Change position of Force value functions (priority)

Change the name of the source setpoint

(available only for Force value 1-16 setpoints)

Select the value that should be forced (i.e.

the value of the particular setpoint)

Rename binary input that

triggers the forcing

ID of binary input

(1 for ForceValueIn 1 etc.)

Select source setpoint or value

Forcing of values is used to change particular setpoint temporarily by activation of related Binary Input. This is used to change function of controller under given conditions (e.g. there are two different periods during the day when Export limit given by distribution network is required or not).

WARNING!

Setpoints must not be written continuously (e.g. via Modbus connection)! If continuous change of setpoints is required, combination of External values and Force value function needs to be used. The memory that holds setpoints is designed for up to 105 writings. Than memory may be damaged!

Setpoints that are available for forcing may be identified by Force value button on the right side in GenConfig (see the figure below).

When the button is clicked, Force value dialog appears.

For example if we add Force value:Force value 1 to be forced to ProcessControl:Export limit as value 0 (DISABLED) by Binary Input FORCEVALUEIN 1 we can change the function of Export limit from ENABLED to DISABLED by activation of FORCEVALUEIN 1. It is possible to rename the setpoint to e.g. Force value:ExportDisabled and Binary Input as well to e.g. DISABLEEXPLIM. The function will not change (only the corresponding names).

It is possible to use several force value functions for one setpoint. If more than one forcing Binary Input is active, the one with the highest position (lowest number in the Force value dialog) is used.

It is possible as well to use one Binary Input to force multiple setpoints (e.g. in case of complex function change).

NOTE:

It is possible only to force value or setpoint in other setpoint if their dimension and range are the same (e.g. only value with dimension in hours and which is Integer 16 to a setpoint with dimension hours and which is as well Integer 16). You may use PLC block Convert to change the dimension and range if needed.

Values for continuous writing from external sources

This function is especially designed for continuous writing of setpoints from external sources (e.g. via Modbus connection).

WARNING!

It is possible to use up to four different External values for continuous writing from external sources. The values are adjusted by setpoints in Force value group. Default (also initial) value may be adjusted, rate of change of ExtValueX (by Binary Inputs EXTVALUEX UP and EXTVALUEX DOWN) can be adjusted as well as high and low limit of the value. There are two way, how to adjust External values. One is using Binary Inputs mentioned above. Second one is to write the value directly using e.g. Modbus. External values then may be converted using PLC block convert and force into setpoint which is then continuously forced (note: NOT WRITTEN) by the value of ExtValueX. This way internal memory is safe and no damage may occur. External values are reverted back to their default (initial) value (given by corresponding setpoint) when Binary Input for their reset is active (and they change to the previous value after Binary Input deactivates). When the Binary Input is active the External value cannot be changed by Modbus writing or by using Binary Inputs for up and down value.

NOTE:

External values are not available for external writing when any Binary Input (up, down or reset) related to them is active. Note also that when the controller is reset (powered down and up again), all external values are reverted back to their default (initial) values.

HINT

For information on how to write (or read) objects from controller via Modbus, please refer to the latest Communication guide for InteliGen and InteliSys.

User Buttons

There are several User Buttons available in the controller. It is possible to set them on Soft Buttons in InteliVision 5 or 8.

Selects which button is this function mapped to

(0 – first button, 1 – second button and so on)

Choose UserButton index and

its function (ON/OFF etc.)

Choose which colour will be

available for this button

Select which condition triggers

which coulour

Adjust text for the button

when it is active or inactive

Pressing the button changes the state of log. Binary Output USER BUTTON X to closed. When the output is closed and the button is pressed state is not changed.

OFF

Pressing the button changes the state of log. Binary Output USER BUTTON X to opened. When the output is opened and the button is pressed state is not changed.

ON/OFF

Pressing the button changes the state of log. Binary Output USER BUTTON X to opened or closed depending on previous state (it is changed to the opposite state).

PULSE ON

Pressing the button issues log. Binary Output USER BUTTON X to close for one second.

NOTE:

Repeated pressing of button during the closed period (one second) causes issuing other puls of length of one second to be generated from the moment of button pushing.

Available functions for soft buttons are listed in the following table.

HINT

It is possible to lock User Button with password (go to tab Commands in GenConfig). User Buttons 1-5, 6-8 and 9-16 can be locked separately. It is also possible to use User Buttons in SCADA diagrams.

User Mask function

In GenConfig you can easily set any object in Screen Editor to show or hide based on activation of particular Logical Binary Input available for users. Below, there is diagram showing the setup of User Mask function in Screen Editor.

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