ComAp InteliSys NT, InteliGen NT, InteliMains NT Troubleshooting Manual
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Managemant System
ISO 1348 5:20 03
ComAp a.s.
U Uranie 1612/14a, 170 00 Praha 7, Czech Republic
Tel: +420 246 012 111, Fax: +266 31 66 47
E-mail: info@comap-control.com, www.comap-control.com
TROUBLESHOOTING GUIDE
Compact Controller for Stand-by and Parallel Operating Gen-sets
InteliGenNT, InteliSysNT,
InteliMainsNT
Modular Controller
Troubleshooting guide
IG-NT, IG-NTC, IG-NT-BB, IG-NTC-BB, IS-NT-BB, IS-NTC-BB,
IM-NT, IM-NT-BB, IM-NTC-BB
Software version IGS-NT-3.1.0, IM-NT-3.1.0, August 2018
InteliGenNT, InteliSysNT, InteliMainsNT – Troubleshooting Guide,
SW version IGS-NT-3.1.0, IM-NT-3.1.0, ©ComAp – August 2018 2
IGS-NT Troubleshooting Guide.pdf
Table of Contents
Table of Contents .................................................................................................................................... 2
General guidelines ................................................................................................................................... 4
Available related documentation ............................................................................................................. 5
Troubleshooting ....................................................................................................................................... 6
Communication ................................................................................................................................... 6
RS232(x) communication doesn’t work .......................................................................................... 6
RS232(2) / RS485(2) / USB communication doesn’t work ............................................................. 6
Problem accessing controller after configuration programming error ............................................ 6
Modem TC35i does not respond to SMS commands ..................................................................... 6
Unsuccessful controller programming ............................................................................................ 7
How to check that CAN communication between controllers works .............................................. 8
CAN communication does not work................................................................................................ 9
Controller interface ............................................................................................................................ 10
Setpoints setting cannot be changed............................................................................................ 10
Controller does not react to buttons pushing ................................................................................ 10
Controller mode cannot be changed............................................................................................. 10
Some setpoints cannot be changed even if correct password is used ......................................... 11
Unknown alarm is displayed ......................................................................................................... 11
Wrong display HW message ........................................................................................................ 11
Configuration table error ............................................................................................................... 11
Display is blank and LEDs are neither blinking nor glowing ......................................................... 12
Display is blank, but backlight works ............................................................................................ 12
Display is showing “Unsupported code page” .............................................................................. 12
INIT is displayed and controller mode cannot be changed .......................................................... 12
External display problems ................................................................................................................. 12
No reaction to pushing command buttons or setting adjustments ............................................... 12
InteliVision/InteliVision 8 and image retention .............................................................................. 13
Synchronizing, Load control .............................................................................................................. 14
Gen-set voltage is increasing/decreasing over/under the limits during synchronization .............. 14
GCB is opened before the Load ramp time is over ...................................................................... 14
Sync fail alarm is issued ............................................................................................................... 14
MGCB is not closed even all conditions are fulfilled ..................................................................... 14
IM-NT BTB connects dead buses together .................................................................................. 15
Power management .......................................................................................................................... 15
Gen-set doesn't share load with other gen-sets ........................................................................... 15
Running Hours Equalization does not work properly.................................................................... 15
Load shedding is active although not all gensets are loaded ....................................................... 15
MGCB is not closed although gensets are running ...................................................................... 16
PC software ....................................................................................................................................... 17
There is no history in .ant file ........................................................................................................ 17
History is not complete ................................................................................................................. 17
Electrical measurement ..................................................................................................................... 17
Controller measures wrong generator/mains/bus voltages or currents ........................................ 17
Power measurement does not work ............................................................................................. 18
Other ................................................................................................................................................. 20
SummerTime Mode causing time rollback and time desynchronization ...................................... 20
Wrn addr error occurs when updating to new FW ........................................................................ 20
Statistic values window contains strange numbers upon start-up ................................................ 20
Alarms stays in Alarm list even though Fault reset was used to acknowledge them ................... 21
No active call after some protection has been activated .............................................................. 21
Forgotten controller password ..................................................................................................... 21
PID regulator doesn't work in the same way as in IS-CU ............................................................. 21
MCB fail / GCB fail alarm is issued after switching controller on .................................................. 21
How to … ............................................................................................................................................... 23
Special applications .......................................................................................................................... 23
InteliGenNT, InteliSysNT, InteliMainsNT – Troubleshooting Guide,
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Setup your controller to work as the SSB application ................................................................... 23
Setup your controller to work as the SPM application .................................................................. 23
List of Abbreviations .............................................................................................................................. 24
List of Possible Events .......................................................................................................................... 27
InteliGenNT, InteliSysNT, InteliMainsNT – Troubleshooting Guide,
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General guidelines
This manual provides list of typical problems you may come across when installing / operating the
IG/IS/IM-NT controllers. It also incorporates the “How to...” section with examples of some nonstandard or interesting applications of these controllers, List of Abbreviations and List of Possible
Events which contains information about alarm messages which can be displayed by a controller.
This manual is intended for everyone who is concerned with operation and maintenance of gen-sets.
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Available related documentation
PDF files
Description
IGS-NT-SPTM-3.1.0 Reference Guide.pdf
General description of SPtM applications for
InteliGen NT and InteliSys NT. Contains
description of engine and generator control,
control of power in parallel to mains operation,
list of all Setpoints, Values, Logical Binary
Inputs and Logical Binary Output.
IGS-NT-SPI-3.1.0 Reference Guide.pdf
General description of SPI applications for
InteliGen NT and InteliSys NT. Contains
description of engine and generator control,
control of power in parallel to mains operation,
list of all Setpoints, Values, Logical Binary
Inputs and Logical Binary Output.
IGS-NT-MINT-3.1.0 Reference Guide.pdf
General description of MINT applications for
InteliGen NT and InteliSys NT. Contains
description of engine and generator control,
powermanagement, list of all Setpoints, Values,
Logical Binary Inputs and Logical Binary Output.
IGS-NT-Combi-3.1.0 Reference Guide.pdf
General description of Combi applications for
InteliGen NT and InteliSys NT. Contains
description of engine, and generator control in
SPTM, SPI and MINT mode,
powermanagement, list of all Setpoints, Values,
Logical Binary Inputs and Logical Binary Output.
IGS-NT-COX-3.1.0 Reference Guide.pdf
General description of COX applications for
InteliGen NT and InteliSys NT. Contains
description of engine and generator control,
powermanagement, list of all Setpoints, Values,
Logical Binary Inputs and Logical Binary Output.
IGS-NT Application Guide 05-2013.pdf
Applications of InteliGen NT, InteliSys NT and
InteliMains NT, examples of connection,
description of PLC functions, Virtual and Shared
peripheries.
IGS-NT Operator Guide 01-2014.pdf
Operator Guide for all hardware variation of
InteliGen NT and InteliSys NT, InteliVision 5 and
InteliVision 8.
IGS-NT Installation Guide 08-2014.pdf
Thorough description of installation and
technical information about InteliGen NT,
InteliSys NT and InteliMains NT and related
accessories.
IGS-NT Communication Guide 05-2013.pdf
Thorough description of connectivity and
communication for InteliGen NT, InteliSys NT
and InteliMains NT and related accessories.
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 & ID-DCU Accessory Modules 07-2014.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.
InteliGenNT, InteliSysNT, InteliMainsNT – Troubleshooting Guide,
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Troubleshooting
Communication
RS232(x) communication doesn’t work
Solution:
a) Setpoint RS232(x) mode is set to different setting than DIRECT – change its setting to
DIRECT.
b) Converter to RS485 is active at this communication channel – change setpoint RS485(x)conv.
to DISABLED position.
c) Earthing problem exists between the PC and the controller, i.e. the battery negative potential
has different levels in the two devices. IG/IS/IM-NT controllers has a built-in protection which
disconnects battery negative (GND) from the RS232 terminal. Re-activation takes some time
(~ 1 min) after you disconnect the cable (component cools down).
You can temporarily disconnect your laptop PC from the grid (e.g. if you intend to download
controller configuration only). You can disconnect the earth wire from your PC. The best
solution is to use the RS232 galvanic separation device, e.g. one of those which are
mentioned in the InteliCommunication Guide, section Converters.
RS232(2) / RS485(2) / USB communication doesn’t work
Solution:
Relates to IG-NTC/EEC versions of IG-NT family and to IS-NT / IS-NT-BB. Controller FW
version is lower than 2.0 and/or controller was shipped from ComAp before September 2006.
It is necessary to download new FW into the communication sub-processor. It can be done by
sending unit to ComAp or by downloading the latest version of Peripheral modules upgrade
package and following procedure described in the attached documet.
Problem accessing controller after configuration programming error
Problem:
It can happen that remote configuration programming attempt fails (e.g. due to bad phone line
condition) and from that moment on controller shows on its display “CONTROLLER
CONFIGURATION ERROR”.
Solution:
In this stage, even with damaged configuration, controller is still able to receive another phone
call with another attempt to program configuration.
However, if the situation is to be solved locally (i.e. a local technician intends to re-program the
configuration), it is possible to switch the RS232(1) port back to the DIRECT connection mode
by simultaneous pressing up+left+right arrows on the controller.
It is strongly recommended not to upgrade controller firmware using a remote connection,
because in case of programming failure problem has to be solved locally using boot jumper
programming procedure. See Unsuccessful controller programming chapter for information
about this procedure.
Modem TC35i does not respond to SMS commands
Solution:
Do the following:
1. Send AT+CPMS="MT","MT","MT" command via hyperterminal or using the
RS232()MdmIni parameter.
2. Send AT+CPMS="SM","SM","SM" command via hyperterminal or using the
RS232()MdmIni parameter.
3. Restart the modem.
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Unsuccessful controller programming
Procedure which is described in this chapter is part of the Boot Jumper Programming video which you
can watch here:
http://www.comap.cz/support/training/training-videos
It is necessary to use the boot jumper for controller programming in case of unsuccessful controller
firmware programming. It may for instance happen due to an accidental cable disconnection,
computer failure or remote connection drop out. If controller firmware programming was not
successful, it is not possible to open connection to a controller, it does not respond and controller
screen is blank. In such case you need to use this procedure for controller programming:
1. Close connection to controller and start GenConfig
2. Check communication port setting in GenConfig. Go to Options – Select connection and select
the right communication port. It is necessary to use the RS232 (1) controller interface, boot jumper
programming does not work with the RS232 (2) or USB controller interface.
3. Go to File – Firmware upgrade and Cloning… – FW upgrade (default configuration)… and select
firmware you would like to upload into a controller.
4. Follow instructions in the notification window:
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Opened BOOT LOADER jumper is marked on the picture (there are three different possibilities):
IG-NTC and IS-NT IG-NT IGS-NT(C)-BB
Close the jumper for programming.
5. Follow instructions in the notification window after programming:
It is possible to configure and program controller in the standard way after this procedure is done.
How to check that CAN communication between controllers works
Check strings CAN16 and CAN32 to see if controller communicates with other controllers via the
CAN2 bus (Intercontroller&Monitoring CAN2). Use InteliMonitor, go to Values - Info to check state of
the strings. These strings contains information about addresses of other controllers which
communicates with a particular controller. Position of each controller in the strings is given by setpoint
Comms setting: Contr. address.
Strings looks like this if you are checking strings on controller with Comms setting: Contr. address set
to 1 and controller does not communicate with any other controllers via CAN2:
CAN16 I000000000000000
CAN32 0000000000000000
Strings looks like this if you are checking strings on controller with Comms setting: Contr. address set
to 1 and controller communicates with controllers with Contr. address set to 2, 16 and 31:
CAN16 I I 0000000000000 I
CAN32 00000000000000 I 0
Strings Reg16 and Reg32 are available directly on controller screens if MINT, Combi or COX
application is used in controller. These strings contains information about addresses of controllers
which belongs into the same logical group as controller which displays this information. Strings Reg16
and Reg32 contains the similar information, however the symbol “I” is displayed only for controllers,
that belong to the same logical group as this controller.
For more information about logical groups see description of Pwr management: Control group,
GroupLinkLeft and GroupLinkRight setpoints (these setpoints are part of the ProcessControl group in
the COX application) in a relevant IGS-NT-xy-Reference Guide.
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CAN communication does not work
Problem:
CAN communication (either via CAN1 or CAN2 interface) does not work.
Solution:
a) Check if CAN bus is properly terminated. Measure resistance between the H and L CAN
terminals when all devices connected to a CAN bus are switched off. Resistance between the
H and L should be about 60 Ω, because two 120 Ω resistors has to be used to terminate CAN
bus at the both ends of a CAN line. See External modules connection chapter in IGS-NTInstallation Guide for information about CAN bus connection.
Be aware that some ComAp devices has a built in 120 Ω resistor which is connected to a CAN
bus if jumper next to a CAN interface is closed! Make sure that the terminating resistor jumper
is closed only in devices which are at the ends of a CAN line.
b) Check if each device connected to a CAN bus has a unique CAN address.
In case of the CAN 2 bus it means that Comms settings: Contr. address setpoint has to be
set to a unique number in each controller which is connected to the CAN2 bus. See Addresses
of Modules on CAN2 chapter in Inteli Communication Guide for information about setting of
CAN addresses in ComAp communication modules and InteliVision to avoid conflict between
addresses.
In case of devices connected to the CAN 1 bus make sure that addresses are set according to
instructions which are displayed upon module configuration on the GenConfig card Modules.
On the picture is example of information which is displayed about IGS-PTM module jumpers
setting. Similar information is displayed for all extension modules.
c) Check wiring topology of the whole CAN bus cable. The topology must be linear (straight), not
“star type” and must not contain any loops.
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Controller interface
Setpoints setting cannot be changed
Solution:
a) Setpoints are password protected and password is not entered. Go to menu ->
Users/Password and log in. If your user profile has sufficient access rights, setpoints editing
will be unblocked. System administrator can change controller configuration to give you
access to setpoints.
b) Password is entered (= user is logged in), but setpoints cannot be changed. That means these
are probably blocked by some higher protection level than the current user has got. You need
to log in as a user with sufficient access rights or contact system administrator to give you
access to setpoints.
c) Access lock function is active. Switch the Access lock function off.
Controller does not react to buttons pushing
Problem:
Controller does not react to Start, Stop, Fault & Horn reset, GCB, MCB, MGCB or controller
mode ←,→ buttons pushing.
Solution:
a) Controller is not in MAN or SEM (IS-NT only) mode, switch it to one of these modes. See
OFF-MAN-AUT-TEST mode chapter in IGS-NT-x.y-Reference Guide for information which
buttons works in a particular mode. For example GCB, MCB, Start and Stop buttons does not
work in the AUT mode.
b) There are active alarms in controller alarm list. Button function can not be performed because
of an alarm activity. Get rid of an alarm first and use a button again.
c) Setpoint Basic settings: Local buttons is set to position EXTBUTTONS, which means that
only external control using binary inputs is enabled. Set this setpoint to position PANEL or
BOTH to be able to control genset using its panel buttons.
d) Access lock function is active. Switch the Access lock function off.
Controller mode cannot be changed
Problem:
Controller mode cannot be changed,
Solution:
a) The Basic settings: ControllerMode setpoint is password protected and password is not
entered. Go to menu -> Users/Password and log in. If your user profile has sufficient access
rights, setpoint will be unblocked. System administrator can change controller configuration to
give you access to commands and setpoints.
b) Function for controller mode forcing is active. Go to Measurement IO / Binary inputs and
check if binary input with Remote OFF, Remote MAN, Remote AUT or Remote TEST function
is active. If present and active (check also input polarity using GenConfig – input function can
be inverted), controller mode cannot be changed from mode selected with a binary input
function. It is necessary to change binary input state or disconnect binary inputs from
controller to be able to change controller mode. There may not be binary input with one of the
above mentioned functions.
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Check the LBI card in GenConfig to see if e.g. PLC output is used to force controller into a particular
mode:
Some setpoints cannot be changed even if correct password is used
Solution:
Force value function is probably configured to a setpoint and activated. If the function is active
(i.e. alternative value is forced), the original value is not visible and cannot be changed. To
modify the original value, deactivate the Force value function(s) related to this setpoint first.
Letter F is displayed next to a setpoint if its setting is changed using the Force value function.
You can check in GenConfig if Force value is configured to a setpoint which can not be
changed and how it is activated.
Unknown alarm is displayed
Problem:
Alarm which can not be found in this guide or a Reference Guide is displayed by controller.
Solution:
All texts which are displayed by controller can be changed using Trasnlator in GenConfig.
Try to find an alarm text on the Translator card, use the Ctrl+F function to find and alarm text
and match it with the default English text. Check PLC functions Force protect setting and
customized protections (see card Protections in GenConfig) to find alarm messages which are
not listed in the List of Possible Events.
Wrong display HW message
Problem:
“WRONG DISPLAY HW” message is displayed if wrong display hardware is detected.
Solution:
It is necessary to send IS-Display/IG-Display to ComAp for repair if the message is displayed.
Configuration table error
Problem:
“Configuration table error” message is displayed by controller. There are two possible reason:
1. Controller configuration upload was not done properly (typical reason is cable disconnection
during configuration upload)
2. Controller was set up incorrectly during production
Solution:
Try to upload your configuration into controller again. Use one of default configuration files if it
does not help (in case that the original configuration is corrupted).
In case that configuration uploads does not help, connect InteliMonitor to the controller and
check if it is in the INIT state. It is necessary to send controller to ComAp for repair if the
message is displayed and controller is in the INIT state. In case that InteliVision is used, these
two messages has the same meaning as “Configuration table error“:
Comm. error (24492:080000F7)
Timeout (24571:080000BC)
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Display is blank and LEDs are neither blinking nor glowing
Problem:
There is nothing displayed by controller, display backlight is off and LEDs are not flashing or
glowing.
Solution:
a) There is no power supply voltage. Check the power supply voltage.
b) Boot jumper is closed, switch controller off, open the jumper and switch controller on.
Display is blank, but backlight works
Problem:
There is nothing displayed by controller, but display backlight is on.
Solution:
a) Previous controller programming failed, follow instructions in the Unsuccessful controller
programming section.
b) IG-NT, IG-Display: Display contrast is set to an extremely low value. Hold Enter and push the
arrow up ↑ button then to increase contrast.
Display is showing “Unsupported code page”
Problem:
The following message is shown on the display: Unsupported code page
Solution:
The language used in the controller is not supported in the display (unsupported languages
with graphical characters). In this case, change the language of the controller and contact
ComAp to get more information about supported graphical languages (by default Chinese and
Korean).
INIT is displayed and controller mode cannot be changed
Problem:
The unit shows "INIT" and does not work, controller mode can not be changed. This situation
occurs after controller reset. Reason of the problem are either incorrectly set setpoints or flat
RTC battery.
Solution:
a) A new firmware containing new setpoints was uploaded into a controller. Use InteliMonitor
online connected to the controller to check all setpoints and fix setting of those which are set in
a wrong way. You have to change at least one setpoint setting. If all setpoints are correct,
change one of them and put it back to the original value to recalculate the checksum. It may
be necessary to switch controller off and on after changing setpoints setting. You can tick
Reset from Init state function in Options in GenConfig to avoid repeating of this problem (Init
state reset is done automatically by GenConfig if this function is active).
b) The RTC backup battery is flat. Send a controller to your distributor for battery exchange if the
RTCbatteryFlat message is displayed4.
External display problems
No reaction to pushing command buttons or setting adjustments
Problem:
It is not possible to adjust any setpoint setting and issue any command using IG-NT panel,
IG/IS-Display module or InteliVision (IV).
Solution:
Access lock input is active for that particular terminal, therefore this terminal can be used only
for monitoring. You can check this by looking on the first measurement screen (press Esc to
enter menu and select Measurement).
These symbols are displayed if access lock is active:
IS-Display – “crossed hand” symbol is displayed in the upper left corner
IG-Display and IG-NT – lock symbol is displayed in the upper right corner
InteliVision – “crossed hand” symbol is displayed in the upper right corner of the Status bar
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part of measurement screens (see Operator Interface chapter in an InteliVision
Reference Guide for information about the Status bar part of measurement
screens)
Binary input
function
Locked display module
AccessLock int
IG-NT/EE internal display, IS-Display and IV with Terminal address = 1
AccessLock D#2
IG-Display, IS-Display and IV with Terminal address = 2
AccessLock D#3
IS-Display and IV with Terminal address = 3
InteliVision/InteliVision 8 and image retention
Problem:
In general LCD screens are susceptible to image retention at varying degrees. Image
retention is caused by a parasitic capacitance build up within the LCD cell, which prevents the
liquid crystal molecules from returning to their normal relaxed state.
Image retention (reversing burn-in) can be observed during using InteliVision, when retention
of the main screen, which is displayed for most of the time, is strongly visible also on other
screens. This image retention is not permanent change. After some time it fades.
Solution:
DECREESE BRIGHTNESS of screen to approx. 50-60%.
This solution helps to decrease recovery time of a screen to less than 2 minutes, when an
image retention fades (the time can be longer if is used IV in too hot or too cold environment).
There are two brightness settings available:
• Day mode
• Night mode (especially for Marine applications)
Changing the modes can be done by holding the ESC button for 1 second.
Display brightness can be adjusted in range from 0 % to 100 % in both modes. Brightness of
the display can be increased/decreased by holding Esc button and repeated pushing .
See the picture below:
Push ESC + PgUp buttons or ESC + PgDn buttons to select mode which should be adjusted.
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Synchronizing, Load control
Gen-set voltage is increasing/decreasing over/under the limits during
synchronization
Problem:
When gen-set is synchronizing to the Bus/Mains its voltage goes out of limits and GCB is
opened due to over/undervoltage protection.
Solution:
a) Check setpoints GenNomV or GenNomVph-ph if they are adjusted to proper value.
b) If the voltage is adjusted properly check if the same value is in MainsNomV/BusNomV or
MainsNomVph-ph/BusNomVph-ph. These values need to be adjusted to the same value
even if nominal voltages of gen-set and Bus/Mains are different!
c) See the example below for proper adjustment of system with different nominal voltages on
Mains/Bus and gen-set.
Example:
Both setpoints GenNomV or GenNomVph-ph and MainsNomV/BusNomV or MainsNomVph-
ph/BusNomVph-ph must be adjusted to the same values according to the value of actual
generator nominal voltage. E.g. gen-set nominal is 231 V but Bus/Mains nominal is 240 V.
- In this case both setpoints need to be adjusted to 231 V and setpoints of corresponding
protections for Bus/Mains need to be set assymetrically.
- For 240 V on Bus/Mains it is typical to open MCB when voltage reaches 254 V or 225 V.
- Since the setpoint for Mains/Bus nominal voltage is adjusted to 231 V corresponding
protection setpoints need to be adjusted to Mains >V/Bus >V = 106% and Mains <V/Bus
<V = 97 % (hence the desired values are reached).
GCB is opened before the Load ramp time is over
Problem:
After reverse synchronization and during generator unloading is GCB opened before the Load
ramp time is over.
Solution:
a) AMF settings: BreakerOverlap time is shorter than the Sync/Load ctrl: Load ramp time
setting. Set Breaker overlap to the same or longer time than Load ramp setpoint.
b) GCB is opened during generator unloading as soon as generator power level given by
setpoint Sync/Load ctrl: GCB open level is reached. Decrease the GCB open level setting to
avoid premature GCB opening.
c) Load in island was much lower than gen-set nominal power. The real time of load ramp is
Load ramp x Pinitial_island / Nomin power; controller switches off GCB immediately (with 1s
delay) as soon as generator power gets below the GCB open level.
Sync fail alarm is issued
Solution:
a) Setpoint Sync/Load ctrl: Sync timeout is set to too short time -> set it to a longer time to allow
controller to match all synchronizing conditions.
b) Speed governor or AVR control is not setup correctly. See chapters Speed Governor Interface
List and AVR Interface List in IGS-NT Installation Guide for information about proper
connection of a speed governor and AVR. See Sync/load control adjustment and Volt/PF
control adjustment chapters in an IGS-NT Reference Guide for information how to setup
controller speed and voltage regulation loops correctly.
MGCB is not closed even all conditions are fulfilled
Solution:
a) IM-NT Bus protect: Bus >V Hst, Bus <V Hst, Bus >f, Bus <f do not have the same settings as
IG/IS-NT generator control unit (use the same settings for generator and mains control unit).
b) IM-NT and other gen-sets are not in the same logical group. See setpoints Pwr Management:
Control group (Controller cannot see each other via CAN bus).
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