ComAp InteliLite MRS10, InteliLite MRS11, InteliLite MRS15, InteliLite MRS16 User Manual

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InteliLite

InteliLite® MRS

Modular Gen-set Controller

Compact Controller for Single Operating Gen-sets

(IL-CU MRS10/11/15/16 unit)

SW version 2.2, November 2004

User guide

ComAp, spol. s r.o.

Světova 7, 180 00 Praha 8, Czech Republic Tel: +420 2 66316661, Fax: +420 2 66316647 E-mail: info@comap.cz, www.comap.cz

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Table of Contents

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

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

What describes this manual?.............................................................................................................. 4

!! Warnings !! ....................................................................................................................................... 4

Text ..................................................................................................................................................... 4

General description ................................................................................................................................. 6

Description of the controller system (with all options)......................................................................... 6

What is in the package?...................................................................................................................... 6

Remote announciator iGL - RA15....................................................................................................... 6

iG IOM/PTM module ........................................................................................................................... 6

Terminals and dimensions....................................................................................................................... 7

IL-CU Terminals .................................................................................................................................. 7

Dimensions.......................................................................................................................................... 8

Recommended wiring.............................................................................................................................. 9

MRS – Wiring Diagram ....................................................................................................................... 9

Getting started ....................................................................................................................................... 10

How to install..................................................................................................................................... 10

Single phase applications ................................................................................................................. 14

Analog inputs..................................................................................................................................... 14

Extension modules (CAN bus) connection ....................................................................................... 19

Inputs and outputs ................................................................................................................................. 20

Binary inputs IL-CU - default............................................................................................................ 20

Binary inputs – list ............................................................................................................................. 20

Binary outputs IL-CU - default.......................................................................................................... 22

Binary outputs - list............................................................................................................................ 22

Analog inputs..................................................................................................................................... 27

Setpoints................................................................................................................................................ 28

Password........................................................................................................................................... 28

Basic settings .................................................................................................................................... 28

Engine params .................................................................................................................................. 29

Engine protect ................................................................................................................................... 32

Gener protect .................................................................................................................................... 33

Sensor spec ...................................................................................................................................... 36

*IOM module ..................................................................................................................................... 36

*ECU-controlled engine support............................................................................................................ 38

Values read from ECU ...................................................................................................................... 39

Diagnostic messages read from ECU............................................................................................... 39

Analog inputs..................................................................................................................................... 40

J1939 connection description............................................................................................................ 41

Sensor specification .............................................................................................................................. 43

Default sensor settings...................................................................................................................... 43

Operator interface.................................................................................................................................. 44

Pushbuttons and LEDs, MRS10/11/15/16 ........................................................................................ 44

How to select the gen-set mode ?..................................................................................................... 45

^When to use buttons GCB ON/OFF?.............................................................................................. 45

Display menus................................................................................................................................... 45

How to view measured data?............................................................................................................ 45

How to view and edit set points? ...................................................................................................... 45

How to find active alarms ?............................................................................................................... 45

MEASUREMENT screens description .............................................................................................. 46

Chart guide to menus and pushbutton’s operation ........................................................................... 49

Function description .............................................................................................................................. 50

OFF mode ......................................................................................................................................... 50

MAN mode ........................................................................................................................................ 50

AUT mode ......................................................................................................................................... 51

InteliLite – MRS10/11/15/16, SW version 2.2, ©ComAp – November 2004 2 IL-MRS-2.2.pdf

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Alarm management ............................................................................................................................... 52

Sensor fail (FLS) .............................................................................................................................. 52

Warning (WRN)................................................................................................................................. 52

Shut down (SD)................................................................................................................................. 52

Voltage phase sequence detection................................................................................................... 53

Gen-set operation states ....................................................................................................................... 54

List of possible alarms....................................................................................................................... 54

Remote control and data logging .......................................................................................................... 56

Direct connection to the PC .............................................................................................................. 56

PC software - LiteEdit ....................................................................................................................... 56

Modbus protocol................................................................................................................................56

Remote communication......................................................................................................................... 62

*Recommended ISDN modem.......................................................................................................... 62

*Recommended GSM modem .......................................................................................................... 62

*Mobile SIM card setting ................................................................................................................... 62

Technical data ....................................................................................................................................... 63

Power supply..................................................................................................................................... 63

Operating conditions ......................................................................................................................... 63

Low Temperature modification ........................................................................................................ 63

Dimensions and weight..................................................................................................................... 64

Generator .......................................................................................................................................... 64

Binary inputs and outputs.................................................................................................................. 64

Analog inputs..................................................................................................................................... 64

Speed pick-up input .......................................................................................................................... 65

*RS232 interface ............................................................................................................................... 65

*CAN bus interface............................................................................................................................ 65

InteliLite – MRS10/11/15/16, SW version 2.2, ©ComAp – November 2004 3 IL-MRS-2.2.pdf

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General guidelines

What describes this manual?

This manual describes „MRS 10/11/15/16“ software, which is designed for single set applications. What is the purpose of the manual? This manual provides general information how to install and operate InteliLite MRS controller.

This manual is dedicated for

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

!! Warnings !!

Remote control

InteliLite controller can be remotely controlled. In case of the work on the gen-set check, that nobody can remotely start the engine. To be sure:

Disconnect remote control via RS232 line Disconnect input REMOTE START/STOP

Disconnect output STARTER and outputs GCB CLOSE/OPEN

Because of large variety of InteliLite parameters settings, it is not possible to describe any combination. Some of InteliLite functions are subject of changes depend on SW version. The data in this manual only describes the product and are not warranty of performance or characteristic.

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 *Something (Symbol * before text) valid only for iL MRS 15/16 ^Something (Symbol ^ before text) valid only for iL MRS 11/16

InteliLite – MRS10/11/15/16, SW version 2.2, ©ComAp – November 2004 4 IL-MRS-2.2.pdf

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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.

Note:

SW and HW must be compatible (MRS10 firmware and MRS10 HW) otherwise the function wil be disabled. If wrong software is downloaded, message HARDWARE INCOMPATIBLE appears on controller screen. In this case use Boot load (jumper) programming – close Boot jumper and follow instructions in LiteEdit, download correct software. Similarly use only Chinese HW together with Chinese SW.

!!! CAUTION !!!

Dangerous voltage

In no case touch the terminals for voltage and current measurement! Always connect grounding terminals! In any case do not disconnect InteliLite CT terminals !

djust set points

All parameters are preadjusted to their typical values. But the set points in the “Basic settings” settings group !!must!! be adjusted before the first startup of the gen-set.

!!! WRONG ADJUSTMENT OF BASIC PARAMETERS

CAN DESTROY THE GEN-SET !!!

The following instructions are for qualified personnel only. To avoid personal injury do

not perform any action not specified in this User guide !!!

InteliLite – MRS10/11/15/16, SW version 2.2, ©ComAp – November 2004 5 IL-MRS-2.2.pdf

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General description

Description of the controller system (with all options)

InteliLite iL-MRS is a comprehensive controller for single generating sets. IL-MRS 15/16 features extended support of electronic engines. InteliLite controllers are equipped with a powerful graphic display showing icons, symbols and bargraphs for intuitive operation, which sets, together with high functionality, new standards in Gen-set controls. InteliLite automatically starts the Gen-set, closes the Gen-set C.B. when all conditions are met, then stops the engine on external signal or by pressing push buttons. InteliLite provides gas engine support without ventilation. The key feature of InteliLite is its easy-to-use operation and installation. Predefined configurations for typical applications are available as well as user-defined configurations for special applications.

What is in the package?

Accessories Description Optional / Obligatory IL – MRS InteliLite central unit Obligatory iGL -RA15 Remote announciator Optional for MRS15/16 iG-IOM/PTM I/O extension module Optional for MRS15/16 AT-LINK-CONV External RS232 interface Optional for MRS10/11

Remote announciator iGL - RA15

The remote announciator iGL-RA15 can be connected to the MRS15/16 unit via CAN bus. Any of the binary outputs can be configured (using LiteEdit software) to each LED diode on the RA15. The module can be also enabled or disabled using LiteEdit software.

See the documentation of RA15 for the technical and function description.

iG IOM/PTM module

iG-IOM and iGS-PTM modules are I/O extension modules equipped with 8 binary inputs, 8 binary outputs, 4 analogue inputs and one analogue output. The module can be used for MRS15/16 only.

 Binary inputs and outputs are configurable the same way like inputs and outputs on iL.  Analogue inputs are configurable like iL with the limitation that the binary and tristate mode

can not be used on PTM module.

 The protection of analogue IOM/PTM inputs is activated by overcrossing the limits, active only

when the engine is running.

 iG-IOM analogue inputs are resistive (the same parameters like iL) 0 Ω-2,4 kΩ.

The module

IOM is designed for especially VDO resistive sensors.

 iGS-PTM analogue inputs are configurable by jumpers to ranges 0-250Ω, 0-100mV, 0-20mA.

The module can be used especially for Pt100 sensors and current sensors.

The module PTM

is not suitable for VDO temperature sensor.

See the documentation of iGS-PTM for the technical and function description.

InteliLite – MRS10/11/15/16, SW version 2.2, ©ComAp – November 2004 6 IL-MRS-2.2.pdf

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Terminals and dimensions

IL-CU Terminals

RPM Grounding Terminal

Grounding Terminal

POWER

8 - 36 V DC

RS 232

D+

BOOT JUMPER

BO3

BO4

BO5

BO6

BO1

(START)

BO2

(FUEL)

BINARY

OUTPUTS

ANALOG INPUTS

RPM

COM

AI1 OIL

AI2 TEMP

AI3 FUEL

RPM IN

RPM GND

BINARY INPUTSGEN. CURRENT

0 - 5 A

GENERATOR VOLTAGE

3 x 230 / 400 V

BI1

BI2

BI3

BI4

BI5

BI6

LB 16

L1L2L3

L3l

L2l

L1l

COM

EXTENSION MODULE

iL-MRS 15

Hint:

EXTENSION MODULE and TEST PORT serves for Extension IGS-PTM or IG-IOM and IGL-RA15 CAN bus connection only. This port is used for production tests as well.

InteliLite – MRS10/11/15/16, SW version 2.2, ©ComAp – November 2004 7 IL-MRS-2.2.pdf

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Dimensions

IL-CU

185 (7,3")

170 (8,87")

4 2 , 5 ( 1 , 7 " )

4 5 ( 1 , 8 " )

1 3 0 ( 5 , 1 " )

1 2 3 ( 4 , 8 " )

1 1 3 ( 4 , 4 " )

Cutout

for InteliL ite

113 x 175 mm

(4.4 x 6,9“)

Only for service purpose

IL-MRS 10, 11

IL-MRS 15, 16

AT-LINK-CONV

InteliLite MRS 15

185 (7,3")

170 (8,8 7")

4 2 , 5 ( 1 , 7 " )

4 5 ( 1 , 8 " )

~ 1 1 0 ( 4 , 3 " )

RS 232 Cable

Extension module via CAN bus

1 3 0 ( 5 , 1 " )

1 2 3 ( 4 , 8 " )

1 1 3 ( 4 , 4 " )

InteliLite – MRS10/11/15/16, SW version 2.2, ©ComAp – November 2004 8 IL-MRS-2.2.pdf

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Recommended wiring

MRS – Wiring Diagram

LOAD

EMERGENCY STOP ACCESS LOCK

CONTROL

SIGNALS

REMOTE S/S

DIESEL/GAS ENGINE

RPM

OIL PRESSURE

WATER TEMP

FUEL LEVEL

STARTER

BATTERY

FUEL SOLE NOID

GENERATOR

Generator C.B.

SPRINKLER REMOTE OFF

RS-232C

Interface

Modem or PC

CONTROL

SIGNALS

NOT USED

+24 V

BINARY OUTPUTS

GEN C.B.

STARTER

FUEL SOLENOID

PRESTART

ALARM

READY TO LOAD

D+

CHRG

ALTERNATOR

POWER

8 - 36 V DC

RS 232

D+

BOOT JUMPER

BO3

BO4

BO5

BO6

BO1

(START

)

BO2

(FUEL

)

BINARY

OUTPUTS

ANALOG INPUTS

RPM

COM

AI1 OIL

AI2 TEMP

AI3 FUEL

RPM IN RPM GND

BINARY INPUTSGEN. CURRENT

0 - 5 A

GENERATOR VOLTAGE

3 x 230 / 400 V

BI1

BI2

BI3

BI4

BI5

BI6

LB 16

L3l L2l L1l

COM

EXTENSION MODULE

iL-MRS 15

ECU

Hint:

From IL-2.1 it is possible to start Volvo and Scania engines via CAN bus. See Engines started via

CAN bus.

InteliLite – MRS10/11/15/16, SW version 2.2, ©ComAp – November 2004 9 IL-MRS-2.2.pdf

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Getting started

How to install

General

To ensure proper function:

Use grounding terminals. Wiring for binary inputs and analog inputs must not be run with power cables. Analog and binary inputs should use shielded cables, especially when length >3m.

Power supply

To ensure proper function: Use min. power supply cable of 1.5mm

Maximum continuous DC power supply voltage is 36VDC. Maximum allowable power supply voltage is 39VCD. The InteliLite’s power supply terminals are protected against large pulse power disturbances. When there is a potential risk of the controller being subjected to conditions outside its capabilities, an outside protection devise should be used.

Hint:

The InteliLite controller should be grounded properly in order to protect against lighting strikes!! The maximum allowable current through the controller’s negative terminal is 4A (this is dependent on binary output load).

For the connections with 12VDC power supply, the InteliLite includes internal capacitors that allow the controller to continue operation during cranking if the battery voltage dip occurs. If the voltage before dip is 10V, after 50ms the voltage recovers to 7 V, the controller continues operating. During this voltage dip the controller screen backlight can turn off and on but the controller keeps operating. It is possible to further support the controller by connecting the external capacitor and separating diode:

12VDC

controller

T2A

Battery

Relays

The capacitor size depends on required time. It shall be approximately thousands of microFarads. Or by connecting special I-LBA module:

12VDC

controller

T2A

Battery

Relays

I-LBA

InteliLite – MRS10/11/15/16, SW version 2.2, ©ComAp – November 2004 10 IL-MRS-2.2.pdf

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Power supply fusing

A one-amp fuse should be connected in-line with the battery positive terminal to the controller and modules. These items should never be connected directly to the starting battery. Fuse value and type depends on number of connected devices and wire length. Recommended fuse (not fast) type - T1A. Not fast due to internal capacitors charging during power up.

12VDC

Battery

iL-CU

HUGE

LOADS

STARTER

T1A

Binary output protections

Do not connect binary outputs directly to DC relays without protection diodes, even if they are not connected directly to controller outputs.

K1K2K2

24VDC

controller

T1A

Fuse

Battery

DC relays

Grounding

To ensure proper function: Use as short as possible cable to the grounding point on the switchboard Use cable min. 2,5mm

The “-“ terminal of the battery has to be properly grounded

InteliLite – MRS10/11/15/16, SW version 2.2, ©ComAp – November 2004 11 IL-MRS-2.2.pdf

s short

as possible

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InteliLite – MRS10/11/15/16, SW version 2.2, ©ComAp – November 2004 12 IL-MRS-2.2.pdf

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Magnetic pick-up

To ensure proper function: Use a shielded cable

Battery

GAC

Speed Control Unit

ESD 5500

MAGNETIC

PICK-UP

Signal

Power Supply

Current measurement

To ensure proper function Use cables of 2,5mm

Use transformers to 5A Connect CT according to following drawings

L2 L3

COM L1l

K L k l

L2l

K L k l

L3l

K L k l

Voltage measurement

GENERATOR MAINS

L3L2L1N

L2 L3

L3L2L1N

Hint:

Switchboard lighting strikes protection according standard regulation is expected !!!

InteliLite – MRS10/11/15/16, SW version 2.2, ©ComAp – November 2004 13 IL-MRS-2.2.pdf

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Single phase applications

There is not a separate archive file for single-phase applications. Use standard ail archives.

Recommended wirings

Generator (and mains) single-phase voltage has to be connected to all three-voltage terminals L1, L2 and L3. Generator current has to be connected to L1l and COM terminals only.

Voltage measurement

GENERATOR MAINS

L3L2L1N

L N

L3L2L1N

Hint:

Switchboard lighting strikes protection according standard regulation is expected !!!

Current measurement

To ensure proper function

Use cables of 2,5mm

Use transformers to 5A

Connect CT according to following drawings. Terminals L2l and L3l are opened.

COM L1l

K L

k l

L2l L3l

Set points adjustment

To run a single-phase application, the following set points have to be set:

Gener protect: Curr unbal to 200 % Gener protect: Curr unbal del to 60,0 s

Hint:

In version 1.4 and lower increase Basic setting: Nomin current to avoid activation of current unbalance protection after 1 minute full load running. (Current unbalance limit is 100% of Nomin current in IL version 1.4 and lower.)

Analog inputs

Three analog inputs are available on the IL-CU

Configuration

Each analog input can be configured by LiteEdit software following way.

InteliLite – MRS10/11/15/16, SW version 2.2, ©ComAp – November 2004 14 IL-MRS-2.2.pdf

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Analog input item LiteEdit Possibility

Type Type Not used

Alarm

Analog input isn’t used

Analog input name Name Up to 14 ASCII characters Config of input Config Analog

Binary (not supp. by PTM) Tri-state (not supp. by PTM)

Analog measuring in specified range. Binary: open/close - threshold 750 Ω. Three-state: open/close threshold 750 Ω, Failure <10 Ω or > 2400 Ω

Physical dimension Dim bar,%,°C, … Up to 3 ASCII characters

(Valid only for analog inputs)

Polarity Contact

type

Valid only for binary and threestate inputs Valid only for binary and threestate inputs

Over Overstep. Sensor fail does not

activate protection.

Over+Fls Overstep and Sensor fail

activates protection.

Under Under step. Sensor fail does

not activate protection.

Protection direction Protection

Under+Fls Under step and Sensor fail

activates protection.

Sensor characteristic Sensor Curve A

Curve B Curve C

PT 1000 NI 1000 VDO Temp VDO Press VDO Level 4-20mA/100 4-20mA/ 60 Pt100 Ni100 0-20mA/100 4-20mA/100 0-100mV/100

iL, IOM,PTM iL, IOM,PTM iL, IOM,PTM

iL, IOM iL, IOM iL, IOM iL, IOM,PTM iL, IOM,PTM iL, IOM iL, IOM PTM PTM PTM PTM PTM

User curve A User curve B User curve C

IEC 751, range -20 to 120 °C DIN 43760, range -20 to 120 °C See chapter sensor specification 20mA/10.0Bar, ext. R 120 Ω 20mA/6.0Bar ext R 120 Ω

0-20mA/10.0Bar 4-20mA/10.0Bar

Decimal points Dec 0, 1, 2 Number of decimal points

(Valid only for analog inputs)

User Curve A, B, C are adjustable in LiteEdit. Each Analog input has separate set points for two level alarm setting. Analog input alarm levels and

delay adjust in Protection or Engine protection group.

InteliLite – MRS10/11/15/16, SW version 2.2, ©ComAp – November 2004 15 IL-MRS-2.2.pdf

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Connection of IL-CU analog inputs

COM

AI1

AI2

-POWER

3x RESISTIVE

SENSOR

AI3

Standard connection of three resistive sensors to analog inputs.

Common point of resistive sensors is connected to COM terminal for accurate measuring.

COM

AI1

AI2

-POWER

+24V

3x 120 ohm

2x SENSOR

4 - 20 mA

AI3

Three current output sensors connection to InteliLite.

External resistors 120 ohms each are connected between minus power supply terminal of IL-CU and analog inputs.

Current sensor connecting reduces the analog input resolution by less than 50% against resistive sensor. Analog input common terminal COM has to be connected to IL minus Power supply terminal.

2x 470

COM

-POWER

AI1

AI2

AI3

Mixed connection of InteliLite analog inputs:

AI1 – binary input AI2 – three state input AI3 – analog resistive input

Common point of IL-CU analog inputs is connected to COM terminal.

Analog inputs are designed for resistive sensors with resistance in range of 0Ω to 2,4kΩ. To ensure a proper function use shielded cables, especially for length over >3m.

Current output transducers

IL-CU analog inputs are mainly designed for resistor sensors.

In special case transducers to 4-20mA output can be used for oil measuring (10.0Bar or 6.0Bar). Use predefined 4-20mA/100 or 4-20mA/60 sensors.

This method reduces the input resolution by less than 50%. Some types of transducers are not

suitable for connection to InteliLite analog inputs because of influencing by InteliLite analog input.

As binary input

Open, close state are detected, threshold level is 750 Ω.

As three state input

Open, close and failure state are detected. Threshold level is 750 Ω, failure is detected when circuit resistance is <10 Ω or > 2400 Ω.

InteliLite – MRS10/11/15/16, SW version 2.2, ©ComAp – November 2004 16 IL-MRS-2.2.pdf

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Hint:

Protections on binary and three state inputs are following:

IL-CU: AI1 Shutdown IG-IOM: AI1 Shutdown

AI2 Shutdown AI2 Shutdown AI3 Warning AI3 Shutdown AI4 Shutdown

Unused analog inputs

Configure Type = Not used

Example of analog input configuration

Configure Oil press input for measuring in Bar, VDO oil pressure sensor, range 0 to 10.0 bars. Alarm protection level set to 3.5 bars, shut down level 1.2 bars. Start LiteEdit and select – Controller - Configuration – Modify – Oil Press. Set configuration for Oil Press analog input:

Type: selection between Not used and Alarm

“Not used” – analog input isn’t used ”Alarm” – analog input is used Set to: Alarm

Config: selection between Analog, Binary Tri-state input.

“Analog” – resistor sensor is connected to Analog input. “Binary” – open/close contact is connected between Analog input and COM terminal of Analog inputs. Analog input detects only open/close state. “Tri-state” – open/close contact is connected parallel to one of two serial resistors between Analog input and COM terminal of Analog inputs. Set to: Analog

Dim: Physical dimension of measured value (°C, %, Bar, ..) Maximal dimension length is three

characters. Set to: Bar

Contact type: selection of polarity only when analog input is configured as Binary or Tri-state. When

is analog input configured as analog this setting has no sense. „NC“ – polarity of binary or tri-state input „NO“ – polarity of binary or tri-state input

Sensor: selection of sensor characteristic

„Unused input“ - when Analog input is not used. On the InteliLite screen is displayed „####“ value, no alarm is detected. „Curve A“ – User curve A is defined in LiteEdit (default VDO temperature sensor) „Curve B“ – User curve B is defined in LiteEdit (default VDO pressure sensor) „Curve C“ – User curve C is defined in LiteEdit (default VDO fuel level sensor) „Pt1000“ – PT1000 sensor characteristic according to IEC 751 „Ni1000“ – Ni1000 sensor characteristic according to DIN 43 760 „VDO temp“ – VDO temperature sensor „VDO press“ – VDO pressure sensor „VDO level“ – VDO level sensor „4-20mA/60“ – current output sensor characteristic – requires external resistor 120 ohms between Analog input and COM terminal of Analog inputs „4-20mA/100“ – current output sensor characteristic – requires external resistor 120 ohms between Analog input and COM terminal of Analog inputs Set to: VDO press

Decimals: setting of number of decimal points of measured value. „0“ - e.g. 360 kPa, 100%, 50 °C

„1“ – e.g. 3.6 Bar

InteliLite – MRS10/11/15/16, SW version 2.2, ©ComAp – November 2004 17 IL-MRS-2.2.pdf

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„2“- e.g. 0.36 MPa „3“ - e.g. 0.366 MPa Set to: 1

When Analog input configuration is finished set the setpoints Wrn Oil press, Sd Oil press, Oil press del in Engine protection group. Each Analog input has separate triplet of setpoints: Wrn level, Sd level, Anl Inp del. Names of these

setpoints are fix defined

Number of decimal points of Wrn level1 and Sd level is the same as the configured number of

decimal points of measured value.

Binary inputs

Binary outputs

Battery

4k7

Ω

Power

Supply

Battery

LOAD

Power

Supply

InteliLite – MRS10/11/15/16, SW version 2.2, ©ComAp – November 2004 18 IL-MRS-2.2.pdf

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Extension modules (CAN bus) connection

CAN H

CAN L

IGL-RA15 (optional)

CAN H

CAN L

CAN H

COM

IGS-PTM (optional)

CAN L

CAN H

COM

IG-IOM (optional)

CAN L

CAN H

120 ohm

EXTENSION MODULES

IL-CU

120 ohm

10 ohm

15nF

COM

Connection rules

CAN bus line must be connected in series, from one unit to the next (no star, no cable stubs, no branches) both ends must by the 120-ohm (internal or external) resistor terminated. Maximal CAN bus length is up to 200 meters.

For CAN data cables details see chapter Technical data – Communication interface. CAN cable shielding connect to IL-CU COM terminal.

IL-CU contains internal fix 120-ohm resistor and must be located on the CAN bus end.

New IG-IOM and IGS-PTM units contain internal jumper removable 120-ohm resistor (in older IOM types are fix resistors). To be sure check resistor presence by ohmmeter. Unit with internal resistor connect to the end of CAN line.

Following connections are supported (IOM, PTM, ECU order is not important).

IL-CU – IG-IOM IL-CU – IGS-PTM IL-CU – IGL-RA15 IL-CU – IG-IOM – IGL-RA15 IL-CU – IGS-PTM – IGL-RA15

It is possible to connect only one IG-IOM or IGS-PTM and one IGL-RA15 to IL-CU.

InteliLite – MRS10/11/15/16, SW version 2.2, ©ComAp – November 2004 19 IL-MRS-2.2.pdf

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Inputs and outputs

Hint:

Any Binary input or output can be configured to any IL-CU controller terminal or changed to different function by LiteEdit software. There is fix 1 sec delay when any binary input is configured as protection.

Binary inputs IL-CU - default

BI1 Rem ote Start/stop BI2 Access lock BI3 Emergency stop BI4 Rem ote OFF BI5 Sprinkler BI6 Not used

Binary inputs – list

Not used

Binary input has no function. Use this configuration when Binary input is not connected.

Alarm

If the input is closed (or opened) selected alarm is activated. Binary Alarm configuration items

Name 14 chararcters ASCII string

NC Normally closed Contact type NO Normally opened Warning Alarm type

Shut down All the time Alarm active Engine running only

Rem start/stop

External request for engine run. AUT mode only.

Emergency stop

If the input is opened, shut down is immediately activated. Input is inverted (normally closed) in default configuration.

Hint:

In case of controller hardware or software fail, safe stop of the engine doesn’t have to be ensured. To back-up the Emergency stop function it is recommended to connect separate circuit for disconnection of Fuel solenoid and Starter signals.

Sprinkler

If the input is closed all alarms are disabled except the binary input EMERGENCY STOP and "engine overspeed protection".

InteliLite – MRS10/11/15/16, SW version 2.2, ©ComAp – November 2004 20 IL-MRS-2.2.pdf

Page 21

• all IL alarms are detected,

• IL front panel gen-set RED LED blinks or lights,

• alarm is recorded on the IL alarm list screen,

• BUT gen-set remains running.

Hint:

Warning SprinklActive is indicated in the AlarmList if sprinkler mode active to inform the operator that

the engine is not protected.

Access lock

If the input is closed, no setpoints can be adjusted from controller front panel and gen-set mode (OFFMAN-AUT-TEST) cannot be changed.

Hint:

Access lock does not protect setpoints and mode changing from LiteEdit. To avoid unqualified changes the selected setpoints can be password protected.

Remote OFF

If closed, iL is switched to OFF mode (there are four modes OFF-MAN-AUT-TEST). When opens controller is switched back to previous mode.

Hint:

This binary input should be connected to schedule timer switch, to avoid start of engine.

StartButton

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

StopButton

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

FaultResButton

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

HornResButton

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

^GCB button

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

RemControlLock

If the input is active, setpoints writing or command sending from the external terminal is disabled.

Emergency manual

If the input is activated the controller behaves like when switched to OFF mode. Opens all binary outputs. There is one exception – Stop solenoid doesn’t activate on this transition.

Detection of "running" engine and subsequent alarm message "Sd Stop fail" is blocked. The controller shows “Emerg Man” state and the engine can not be started. Generator current and power measurement is active in this mode, regardless of the actual state of the engine.

After the input is open again, the controller recovers to previous state and behaves according to the actual situation .

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Unction is active in any controller mode and activation of the input is written to history.

Remote man

If the input is active, MAN mode is forced to the controller independently on the position of the MODE

selector. If another of „remote“ inputs is active, then the Remote MAN input has the lowest priority.

Binary outputs IL-CU - default

BO1 Starter (relay output) BO2 Fuel solenoid (relay output) BO3 GCB Close/Open BO4 Prestart BO5 Ready to Load BO6 Alarm

Binary outputs - list

Not used

Output has no function.

Starter

The closed relay energizes the starter motor. The relay opens if:

• the “firing” speed is reached or

• maximum time of cranking is exceeded or

• request to stop comes up

Fuel solenoid

Closed output opens the fuel solenoid and enables the engine start. The output opens if:

Emergency stop comes or Cooled gen-set is stopped or in pause between repeated starts

Ignition

The output closes after reaching value of CrankRPM, fixed 30RPM. Opens after stopping of the engine or in pause during repeated start.

Prestart

The output closes prior to the engine start (Prestart) and opens when START RPM speed is reached.

During repeated crank attempts the output is closed too. The output could be used for pre-glow, pre-heat or prelubrication.

Idle/Nominal

The output Idle/Nominal closes after the timer Idle time elapses. The Idle time counter starts to countdown when Start speed reached. The Underspeed protection is not evaluated during idle period. A Start fail protection occurs if the RPM drop below 2RPM during idle.

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GCB Close/Open

MRS11, 16: The output controls the generator circuit breaker. MRS10 and 15 (GCB no GCB button):

The output closes automatically (in MAN or AUT mode) after engine is started,

MinStabtime elapsed, and generator voltage and frequency is in limits.

GCB on coil

The output activates Generator Circuit Breaker coil.

GCB off coil

The output deactivates Generator Circuit Breaker coil.

GCB UV coil

The output controls Generator Circuit Breaker coil after voltage drop-out.

*AnInIOM1..4 Wrn

Output closes if warning alarm on the appropriate IOM/PTM analog input activates. The output opens, if

• alarm is not active and

• FAULT RESET is pressed

*AnInIOM1..4 Sd

Output closes if shutdown alarm on the appropriate IOM/PTM analog input activates. The output opens, if

• alarm is not active and

FAULT RESET is pressed

Air valves

Closes together with Prestart. Opens after the engine is stopped. Stopped engine conditions: RPM = 0, Engine params: Starting Poil, D+ (when enabled).

GenParamsOK

The output is copy of generator status LED on iL front panel. The output is closed if genset is running and all genset electric values are in limits.

Alarm

The output closes if :

• any warning or shutdown comes up or

• the gen-set malfunctions

The output opens if

• FAULT RESET is pressed

The output closes again if a new fault comes up.

Horn

The output closes if:

• any warning or shutdown comes up or

• the gen-set malfunctions

The output opens if:

• FAULT RESET is pressed or

• HORN RESET is pressed or

• Max time of HORN is exceeded (Horn timeout)

The output closes again if a new fault comes up.

Ready

The output is closed if following conditions are fulfilled:

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• Gen-set is not running and

• No Shut down or Slow stop alarm is active

• Controller is not in OFF mode

Ready to load

The output is closed if genset is running and all electric values are in limits no alarm is active - it is possible to close GCB or it is already closed. The output opens during cooling state.

Stop solenoid

The closed output energizes stop solenoid to stop the engine. The output opens again 10 s after

RPM < 2 and Generator voltage < 10 VAC and

Oil pressure < Engine params: Starting oil.

MainsParams OK

The output is copy of mains status LED on IL front panel. The output is closed if mains voltage and frequency are within limits.

ChrgAlternFail

Output closes if gen-set is running and D+ input not energized. The output opens, if

• alarm is not active and

• FAULT RESET is pressed

Hint:

Treshhold level for D+ input is 80% supply voltage.

Vgen failed

The output closes if the generator over/under voltage shutdown alarm or voltage asymmetry shutdown alarm activates. The output opens, if

• alarm is not active and

• FAULT RESET is pressed

fgen failed

Output closes if the generator over/under frequency shutdown alarm activates. The output opens, if

• alarm is not active and

• FAULT RESET is pressed

Overload

Output closes if the generator overload shutdown alarm activates. The output opens, if

• alarm is not active and

• FAULT RESET is pressed

Stop failed

Output closes when the engine has to be stopped, but speed or frequency or voltage or oil pressure is detected. This protection goes active 60s after stop command. The output opens, if

• alarm is not active and

• FAULT RESET is pressed

Overspeed

Output closes if the gen-set over speed alarm activates. The output opens, if

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• alarm is not active and

• FAULT RESET is pressed

Underspeed

Output closes if the gen-set under speed alarm activates. The output opens, if

• alarm is not active and

• FAULT RESET is pressed

Start failed

Output closes after the gen-set start-up fails. The output opens, if

• alarm is not active and

• FAULT RESET is pressed

Overcurrent

Output closes if the generator

*IDMT over current or current unbalance or

short current alarm activates. The output opens, if Alarm is not active and FAULT RESET is pressed

Battery flat

Output closes when iL performs reset during start procedure (probably due to weak battery). The output opens, if

• alarm is not active and

• FAULT RESET is pressed

V batt failed

Output closes when battery over/under voltage warning appears. The output opens, if

• alarm is not active and

• FAULT RESET is pressed

Common Wrn

Output closes when any warning alarm appears. The output opens, if

• No warning alarm is active and

• FAULT RESET is pressed

Common Sd

Output closes when any shut-down alarm appears. The output opens, if

• No sd alarm is active and

• FAULT RESET is pressed

Common Fls

Output closes when any sensor fail alarm appears. The output opens, if

• No warning alarm is active and

• FAULT RESET is pressed

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Oil Press

Output closes if the oil pressure shutdown alarm activates. The output opens, if

• alarm is not active and

• FAULT RESET is pressed

Oil Press Wrn

Output closes if the oil pressure warning alarm activates. The output opens, if

• alarm is not active and

• FAULT RESET is pressed

Water Temp

Output closes if the water temperature shutdown alarm activates. The output opens, if

• alarm is not active and

• FAULT RESET is pressed

Water Temp Wrn

Output closes if the water temperature warning alarm activates. The output opens, if

• alarm is not active and

• FAULT RESET is pressed

OFF mode

The output is closed, if OFF mode is selected.

MAN mode

The output is closed, if MAN mode is selected.

AUT mode

The output is closed, if AUT mode is selected.

FuelLevel

Output closes if the Fuel level shutdown alarm activates.

FuelLevelWrn

Output closes if the Fuel level warning alarm activates.

Running

Output closes if the engine is in Running state.

ServiceTime

Output closes if the ServiceTime alarm activates. The output opens, if

• alarm is not active and

• FAULT RESET is pressed

BI1..6 – stat *BI1..8IOM - stat

The outputs give an information about the assigned binary input. In case the assigned binary input is configured to alarm type, then the output closes when the alarm activates. It opens if

• alarm is not active and

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• FAULT RESET is pressed

In case the assigned binary input is configured to any control function, the output propagates the state of the input.

ECU CommOK

If the ECU is not communicating and all values from ECU show #### the output is not active. If the ECU communicates the output is active.

ECU PwrRelay

The output closes at the beginning of prestart and opens if the engine shall be stopped.

ECU YellowLamp

The output copies warning information from ECU.

ECU RedLamp

The output copies shutdown information from ECU.

CtrlHeartBeat

Output signalizes watchdog reset. In a healthy state it blinks at 500ms : 500ms rate. When watchdog reset occurs, it stops blinking.

Stop Pulse

Output is active for 1 second after Stop solenoid output activation. This signal is sent to ECU in case

of engine stop request.

ECU CommError

The output is an inversion of binary output ECU CommOK, i.e. the output is closed when ECU is not

communicating and all values from ECU show #####. Communication error causes stop of the engine.

Analog inputs

Three analog inputs for resistive sensor 0 to 2400 Ω measuring. Each analog input can be adjusted to convert resistor measured value to displayed value in bar, °C (°F) or %. Warning and shut-down limits are adjusted in Engine protection group. Since version 2.0 the analog inputs are configurable. Default configuration is:

Oil press

Oil pressure analog input. Default VDO sensor in range 0 to 10.0 bars.

Water temp

Water temperature analog input. Default VDO sensor in range 0 to 100 °C.

Fuel level

Fuel level analog input. Default VDO sensor 0-180R = 0-100%

Hint:

For further information about analog inputs’ configuration see Analog inputs.

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Setpoints

Password

EnterPassword

Password is a four-digit number. Password enables change of relevant protected set points Use ↑ or ↓ keys to set and ENTER key to enter the password.

ChangePassword

Use ↑ or ↓ keys to set and ENTER key to change the password.

Hint:

At first the Password has to be entered before the new Password can be changed.

Basic settings

Gen-set name

User defined name, used for InteliLite identification at remote phone or mobile connection.

Gen-set name is max 14 characters long and have to be entered using LiteEdit software.

Nomin power [kW]

Nominal power of the generator Step: 1kW Range: 1 – 4000 kW

Nominal current [ A ]

It is current limit for generator *IDMT over current and short current protection and means maximal

continuous generator current. See Generator protections: *2Inom del, Ishort setpoints. Nominal current can be different from generator rated current value.

Step: 1 A Range: 1 - 5000 A

CT Ratio [/5A]

Gen-set phases current transformers ratio. Step: 1 A Range: 1 – 5000 A / 5A

*PT ratio [/1]

Gen-set potential transformers ratio. Step: 0,1 V / V Range: 0,1 – 500,0 V / V

Nomin voltage [V]

Nominal generator voltage (phase to neutral) Step: 1V Range: 100 – 300 V

Nominal freq [Hz]

Nominal generator frequency (usually 50 or 60 Hz ) Step: 1Hz Range: 45 – 65 Hz

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Gear teeth [-]

Number of teeth on the engine gear for the pick-up. Set to zero, if no pick-up is used. Engine speed is counted from the generator frequency. Step: 1 Range: 0 – 500

Hint:

Generator frequency can be used only when generator voltage (min 5V) is present before reaching of

the firing speed (Starting RPM) after start.

Nominal RPM [RPM]

Nominal engine speed. Step: 1RPM Range: 100 – 4000 RPM

FltRes GoToMAN [ENABLED/DISABLED]

DISABLED: Controller stays in AUT mode after Fault reset . ENABLED: Automatic switch from AUT (or TEST) to MAN mode after Fault reset to avoid

automatic engine start. This function is active for Shut down protection only.

DispBaklightTO [min]

Timeout after which the display backlight is switched off. Step: 1 min Range: 0 – 60 min Default value: 0 … means that the display lights all the time

ControllerMode [ OFF, MAN, AUT ]

Equivalent to Controller mode changes by MODE→ or ←MODE buttons.

Hint:

Controller Mode change can be separately password protected.

* RS232 mode [STANDARD/MODBUS/CumminsMB]

Communication protocol switch. Standard: LiteEdit communication protocol. Modbus: Modbus protocol. CumminsMB: Protocol for communication with Cummins engines via Modbus.

Hint:

For detail description see chapter Modbus protocol.

*NumberRings AA [ - ]

Number of rings prior to open modem connection. Step: 1 Range: 1 – 30

Hint: NumberRings AA change is not activated immedatelly. It is activated after controller is switched on or

when modem is connected to controller.

Engine params

Start RPM [%]

“Firing” speed when iL controller stops cranking (starter goes OFF). Step: 1% of nominal RPM Range: 5 – 50 %

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Starting POil [Bar]

When reached controller stops cranking (starter goes OFF). Step: 0,1 bar Range: -10,0 – 1000,0

Hint:

There are three conditions for stop cranking: Starting RPM, StartingPOil and D+ (when enabled). Starter goes off when any of these conditions is vaid.

Prestart time [s]

Time of closing of the PRE-START output prior to the engine start. Set to zero if you want to leave the output PRE-START open. Step: 1s Range: 0 – 600 s

MaxCrank time [s]

Maximum time limit of cranking. Step: 1s Range: 1 – 60 s

CrnkFail pause [s]

Pause between crank attempts. Step: 1s Range: 5 – 60 s

Crank attemps [-]

Max number of crank attempts. Step: 1 Range: 1 – 10

Idle time [s]

Idle time delay starts when RPM exceeds Start RPM . Start fail is detected when during Idle state

RPM decreases below 2.

During the Idle time timer running the binary output IDLE/NOMINAL is opened, when it elapses the

IDLE/NOMINAL output closes. Binary output IDLE/NOMINAL opens during Cooling period again. Step: 1 s Range: 0 – 600 s

Start RPM

BO Starter

BO IDLE/RATED

RPM = 2

Start Fail

Idle time Min stab time

Electric protections active

Hint:

If the IDLE function not supported on the governor, set the Idle time nevertheless to minimum 5s to avoid Underspeed possibly caused by instability of the engine short after start.

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Min stab time [s]

Minimum time after reaching of defined level of RPM to the closing GCB. Step: 1s Range: 0 – 300 s

Max stab time [s]

Maximum time after start to get proper voltage level of the generator. Step: 1s Range: 0 – 300 s

Hint:

When generator voltage within Max stab time does not reach defined limits (Generator protection

group) , an alarm occurs and the genset will shut down.

Stop time [s]

Under normal conditions the engine must certainly stop within this period. The period starts by issuing stop command. Step: 1s Range: 0 – 600 s

Hint:

Stop of engine is detected when all following conditions are met: RPM =0, Oil pressure < StartingPOil

and Generator voltage < 10 VAC. Stop fail is detected when is difference between those conditions, e.g RPM=O and Generator voltage > 10V.

Cooling time [s]

Runtime of the unloaded gen-set to cool the engine before stop. Step: 1s Range: 0 – 3600 s

Cooling speed [ NOMINAL / IDLE ]

Selects the function of the Binary output IDLE/NOMINAL during engine Cooling state. NOMINAL : Cooling is executed at Nominal speed and generator protections are active. IDLE: Cooling is executed at Idle speed and generator protections are switched off.

Hint:

Binary output IDLE/NOMINAL must be configured and connected to speed governor. Engine Idle speed must be adjusted on speed governor.

Fuel solenoid [ DIESEL / GAS ]

Determines behavior of the Binary output FUEL SOLENOID. DIESEL: Output closes 1 sec before Binary output STARTER.

The output opens if Emergency stop comes or Cooled gen-set is stopped and in pause

between repeated starts.

GAS: Output closes together with Binary output IGNITION if RPM is over the 30 RPM (fix value).

Output opens after stop command or in pause between repeated start.

D+ function [ENABLED/CHRGFAIL/DISABLED]

ENABLED: The D+ terminal is used for both functions – “running engine” detection and charge fail detection. CHRGFAIL: The D+ terminal is used for charge fail detection only DISABLED: The D+ terminal is not used.

Hint:

The magnetization current is provided independently on this setpoint value.

The D+ charge fail protection becomes active after Engine params:Idle time reaches zero.

ECU FreqSelect [PRIMARY/SECONDARY/DEFAULT]

This setpoint should be used only for Volvo and Scania engines.

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Volvo – “Volvo-MarineD12 Aux” is selected in ECU configuration: Primary or secondary engine speed is set by Frequency select bits in VP Status frame.

Scania – “Scania S6 Singlespeed” is selected in ECU configuration:

Nominal engine speed is chosen by Nominal speed switch 1 and 2 from DLN1 frame when the engine is running on nominal speed, i.e. binary output Idle/Nominal is active. When the output is not active (engine is running on Idle speed), the setpoint ECU FreqSelect is not taken into account.

Engine protect

Eng prot del [s]

During the start of the gen-set, some engine protections have to be blocked (e.g. Oil pressure).

The protections are unblocked after the Protection del time. The time starts after reaching Start RPM.

Step: 1s Range: 0 – 300 s

Horn timeout [s]

Max time limit of horn sounding. Set to zero if you want to leave the output HORN open. Step: 1s Range: 0 – 600 s

Overspeed [%]

Threshold for over speed protection Step: 1% of nominal RPM Range: 100 – 150%

AnlInp1 level1 [ Bar]

Warning threshold level for ANALOG INPUT 1 Step: 0,1 bar Range: AnlInp1 level2 – 10000

AnlInp1 level2 [ Bar]

Shutdown threshold level for ANALOG INPUT 1 Step: 0,1 bar Range: -100 – AnlInp1 level1

AnlInp1 del [s]

Delay for ANALOG INPUT 1 Step: 1 s Range: 0 – 180 s

AnlInp2 level1 [ ]

Warning threshold level for ANALOG INPUT 2 Step: 1 °C Range: -100 – Anlinp2 level2

AnlInp2 level2 [ ]

Shutdown threshold level for ANALOG INPUT 2 Step: 1 °C Range: AnlInp2 level1 – 10000

AnlInp2 del [s]

Delay for ANALOG INPUT 2 alarm. Step: 1 s

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Range: 0 – 180 s

AnlInp3 level1 [ ]

Warning threshold level for ANALOG INPUT 3 Step: 1 % Range: AnlInp3 level2 – 10000

AnlInp3 level2 [ ]

Shutdown threshold level for ANALOG INPUT 3 Step: 1 % Range: -100 – AnlInp3 level1

AnlInp3 del [s]

Delay for ANALOG INPUT 3 Step: 1 s Range: 0 – 180 s

Batt undervolt [V]

Warning threshold for low battery voltage. Step: 0,1 V Range: 8V – Batt overvolt

Batt overvolt [V]

Warning threshold for high battery voltage. Step: 0,1 V Range: Batt undervolt – 40 V

Batt volt del [s]

Delay for low battery voltage alarm. Step: 1s Range: 0 – 600 s

NextServTime [h]

Counts down when engine running. If reaches zero, an alarm appears. Step: 1h Range: 0 – 65535h

Gener protect

Hint:

All electric protections when activated result in shutdown.

Overload [%]

Threshold for generator overload (in % of Nominal power) Step: 1% of Nominal power Range: 0 – 200%

Overload del [s]

Delay for generator overload alarm. Step: 0.1s Range: 0 – 60.0 s

Ishort [ % ]

Shutdown occurs when short circuit limit Ishort limit is reached. Step: 1 % of Nominal current

Range: 100 - 500 %

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*2Inom del [ s ]

IDMT curve shape selection. 2Inom del is Reaction time of IDMT protection for 200% overcurrent Igen = 2* Nominal current.

Step: 0,1 s Range: 0,1 - 20 s IDMT is “very inverse” generator over current protection. Reaction time is not constant but depends on generator over current level according following formula.

2Inom del * Nomin current

Reaction time = Igen

- Nomin current

Hint:

Reaction time is limited up to 900 sec = 15 minutes. IDMT protection is not active for Reaction time values longer than 15 minutes.

Igen is maximal value of all measured phases of generator current.

EXAMPLE of Reaction time for different over current levels. Values in column 200% are 2Inom del.

Overcurrent

200 % =

2Inom del

≤ 100 % 101 % 110 %

0,2 s

No action 20 s 2 s

2 s

No action 200 s 20 s

Reaction time

20 s

No action No action

(time > 900 s)

200 s

Igen

Nominal current

Ishort

2Inom del

Maximal Reaction time

R ea c tio ntime

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Curr unbal [%]

Threshold for generator current asymmetric (unbalance). Step: 1% of Nominal current Range: 1 – 200% of Nominal current

Curr unbal del [s]

Delay for generator current assymetry Step: 0.1 s Range: 0 – 60.0 s

Gen >V Sd [%]

Shutdown level for generator overvoltage. All three phases are checked. Maximum out of three is used. Step: 1% of Nominal voltage Range: Gen <V – 200%

Gen <V Sd [%]

Shutdown level for generator undervoltage. All three phases are checked. Minimum out of three is used.

Step: 1% of Nominal voltage Range: 0% – Gen >V

Gen V del [s]

Delay for generator undervoltage and overvoltage alarm Step: 0.1s Range: 0 – 60 s

Volt unbal [%]

Threshold for generator voltage unbalance alarm. Step: 1% of Nominal voltage Range: 0 – 100% of Nominal voltage

Volt unbal del [s]

Delay for generator voltage unbalance alarm. Step: 0.1s Range: 0 – 60.0 s

Gen >f [%]

Shutdown level for generator overfrequency. Step: 0.1% of Nominal frequency Range: Gen <f – 200.0%

Gen <f [%]

Shutdown level for generator underfrequency. Step: 0.1% of Nominal frequency Range: 0.0 – Gen >f

Gen f del [s]

Delay for generator underfrequency and overfrequency alarm. Step: 0.1s Range: 0 – 60.0 s

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Sensor spec

Calibr AI1,AI2,A3 […]

Calibrating constant to adjust the measured value of IL analog inputs. Physical dimension of calibrating constant is corresponding to Analog input. Step: 1 Range: -1000 – +1000

Hint:

Calibration constants have to be adjusted when measured value is near the alarm level. User curves A, B, C can be defined by LiteEdit software.

*IOM module

AnOut-kW/20mA [kW/20mA]

Conversion coefficient from gen-set power to IG-IOM, IGS-PTM analog output – in kW to full output scale 20 mA. Step: 1 kW / 20mA Range: 1 - 32000 kW / 20mA

AnlInIOM1 lev1 [ ]

The level for IOM ANALOG INPUT 1 alarm detection. Step: 1 Range: -100 - +10000

AnlInIOM1 lev2 [ ]

The level for IOM ANALOG INPUT 1 alarm detection. Step: 1 Range: -100 - +10000

AnlInIOM1 del [s]

Delay for IOM ANALOG INPUT 1 alarm. Step: 1 s Range: 0 - 180 s

AnlInIOM2 lev1 [ ]

The level for IOM ANALOG INPUT 2 alarm detection. Step: 1 Range: -100 - +10000

AnlInIOM2 lev2 [ ]

The level for IOM ANALOG INPUT 2 alarm detection. Step: 1 Range: -100 - +10000

AnlInIOM2 del [s]

Delay for IOM ANALOG INPUT 2 alarm. Step: 1 s Range: 0 - 180 s

AnlInIOM3 lev1 [ ]

The level for IOM ANALOG INPUT 3 alarm detection. Step: 1 Range: -100 - +10000

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AnlInIOM3 lev2 [ ]

The level for IOM ANALOG INPUT 3 alarm detection. Step: 1 Range: -100 - +10000

AnlInIOM3 del [s]

Delay for IOM ANALOG INPUT 3 alarm. Step: 1 s Range: 0 - 180 s

AnlInIOM4 lev1 [ ]

The level for IOM ANALOG INPUT 4 alarm detection. Step: 1 Range: -100 - +10000

AnlInIOM4 lev2 [ ]

The level for IOM ANALOG INPUT 4 alarm detection. Step: 1 Range: -100 - +10000

AnlInIOM4 del [s]

Delay for IOM ANALOG INPUT 4 alarm. Step: 1 s Range: 0 - 180 s

The protection of IOM/PTM inputs is activated by overcrossing the limits.

CalibrAInIOM 1,2,3,4 […]

Calibrating constant to adjust the measured value of IOM/PTM analog inputs. Physical dimension of calibrating constant is corresponding to Analog input. Step: 1 Range: -1000 – +1000

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*ECU-controlled engine support

There exists only one firmware branch for both standard and electronic controlled (monitored) engines.

Presence of the ECU on the CAN bus/RS232 is configured via LiteEdit like other peripheries (iG-IOM,

iGL-RA15). Pressing the

button in Configuration window of LiteEdit (version 2.0 and higher), opens ECU dialog window where the appropriate engine/ECU type should be selected. There are three groups of engine/ECU types:

• Standard J1939 engines

• Scania S6

• Cummins-MODBUS

If the connected engine is Cummins communicating via RS232, it is necessary to set the setpoint

Basic settings:RS232 mode = CUMMINSMB.

Loss of communication causes shutdown of the running engine. On the contrary, the ECU can be switched off at quiescent engine, that means not-communicating ECU is in that moment normal

situation. All values from ECU shall show ####, but no alarm is displayed. The output ECU CommOK

follows the real situation, that means it is not active anytime when the ECU does not communicate.

The output ECU PwrRelay closes at the beginning of prestart and opens if the engine shall be

stopped.

The engine is started via standard contact output or via CAN bus (for Volvo and Scania engines). For other engines J1939 is used for monitoring only.

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Values read from ECU

Standard J1939 engines and Scania

When “Standard J1939 engines” and “Scania S6” options are selected, following values are read from standard J1939 frames:

 5.2.1.9 Engine speed (frame 5.3.7 EEC1)  5.2.5.28 Engine oil pressure (frame 5.3.29 Engine Fluid Level/Pressure)  5.2.5.5 Engine coolant temperature (frame 5.3.28 Engine Temperature)  5.2.5.61 Total engine hours (frame 5.3.19 Engine Hours, Revolutions)  5.2.1.7 Percent load at current speed (frame 5.3.6 EEC2)  5.2.5.63 Fuel rate (frame 5.3.32 Fuel Economy)  5.2.5.36 Boost pressure (frame 5.3.36 Inlet/Exhaust Conditions)  5.2.5.4 Intake manifold 1 temperature (frame 5.3.36 Inlet/Exhaust Conditions)

Cummins MODBUS

When “Cummins-Modbus” option is selected, following values are read from Modbus Register Data (for QSX15,QSK45, QSK60):

 Engine Speed (Register Address:30001)  Oil Pressure (Register Address:30003)  Coolant Temperature (Register Address:30002)  Engine Running Time (Register Address:30008-30009)  Fuel Consumption Rate (Register Address:30018)  Intake Manifold Absolute Pressure (Register Address:30530 (QSK45, QSK60 only))  Intake Manifold Temperature (Register Address:30531 (QSK45, QSK60 only))

Diagnostic messages read from ECU

Diagnostic messages are read and displayed in extra ECU Alarm list. For Standard J1939 SPN (Suspect Parameter Number), FMI (Failure Mode Identifier) and OC (Occurrence Counter) are shown together with verbal description if available. One SPN (Suspect Parameter Number) / FMI (Failure Mode Identify) couple describes one fail information. If FMI is equal to 0 or 1, WRN is displayed in the ECU Alarm list. For any other FMI values, FLS is displayed. Detail SPM/FMI code specification see in:

• SAE Truck and Bus Control and Communications Network Standards Manual, SAE HS-1939

Publication

• Or refer to corresponding engine manufacturer’s ECU error codes list.

Following messages are displayed with the description:

 SPN:100 EngOil Press  SPN:102 Boost Press  SPN:105 Intake Temp  SPN:110 EngCool Temp  SPN:175 EngOil Temp  SPN:629 Controller#1  SPN:636 PositionSensor  SPN:637 TimingSensor  SPN:651 InjectorCyl#1  SPN:652 InjectorCyl#2  SPN:653 InjectorCyl#3  SPN:654 InjectorCyl#4  SPN:655 InjectorCyl#5  SPN:656 InjectorCyl#6  SPN:677 EngStartRelay  SPN:1485 ECU MainRelay

For Scania Fault codes (FC) are displayed. Following messages are available for particular groups of Fault codes:

 FC:1000-1001 Overspeed  FC:1100-1107 EngSpdSensor1

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Page 40

 FC:1200-1207 EngSpdSensor2  FC:2000-2002 WtrTempSensor  FC:2100-2102 ChrgAirTmpSens  FC:2200-2202 ChrgAirPrsSens  FC:2400-2403 OilPressSensor  FC:2600-2601 SensorSupply1  FC:2700-2701 SensorSupply2  FC:2800-2802 ExtrAnalogInp  FC:3200-3205 BatteryVoltage  FC:4300-4303 HW Watchdog  FC:6200-6201 FanActuator  FC:6400-6401 WasteGateAct  FC:6600-6601 StarterActuatr  FC:6A00-6A01 ExhaustBrkAct  FC:B000-B001 OilPressProt  FC:B100-B101 CoolantLevProt  FC:B200 OverheatCoolWt  FC:B300 EmergencyStop  FC:C000-C006 PDEInjctorCyl1  FC:C100-C106 PDEInjctorCyl2  FC:C200-C206 PDEInjctorCyl3  FC:C300-C306 PDEInjctorCyl4  FC:C400-C406 PDEInjctorCyl5  FC:C500-C506 PDEInjctorCyl6  FC:C600-C606 PDEInjctorCyl7  FC:C700-C706 PDEInjctorCyl8  FC:E200 OverheatProt  FC:E600 CoordEmergStop

Analog inputs

Reading of mentioned values from ECU enables to use analog inputs of the unit for other purposes, e.g. measuring, displaying and alarm activation related to various quantities. The configuration thus allows to use three analog inputs on the central unit and four analog inputs on IG-IOM/IGS-PTM module if connected. If the engine without ECU is controlled by InteliLite, the first analog input is permanently configured to Oil pressure, other analog inputs remain freely configurable.

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J1939 connection description

The following diagrams show how to connect the engine control unit to the InteliLite controller:

Engines started via CAN bus

VOLVO PENTA engines (EMS I, EMS II, EDC III units)

8 7 6 5 4 3 2 1

8-pin

Deutsch

connector

POWER D+

IL-MRS15/16

BINARY BO2

OUTPUTS (FUEL)

BO1

(ECU CommOK)

EXTENSION L

MODULE COM

SCANIA S6

1 2 3 4 5 6 7 8 9

+24 V DC

10-pin

EMS B1

connector

GND

POWER D+

IL-MRS15/16

BINARY BO2

OUTPUTS (FUEL)

BO1

(ECU CommOK)

EXTENSION L

MODULE COM

Engines not started via CAN bus

PERKINS 2800 series

IL-CU binary output description Perkins Customer interface connector Start output connects directly to engine starter solenoid Fuel output 1,10,15,33,34

powers up ECU and enables the injectors

IL-CU CAN description Perkins Customer interface connector CAN bus common Screen for the J1939 cable. CAN bus H 31 CAN bus L 32

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JOHN DEERE

IL-CU binary output description John Deere 21 pin Deutsch connector Start output D Fuel output G (switched ECU power),J (ignition)

IL-CU CAN description John Deere 21 pin Deutsch connector CAN bus common Screen for the J1939 cable. CAN bus H V CAN bus L U

CUMMINS ISB/ISBE

IL-CU binary output description Cummins ISB OEM Harness connector B Start output connects directly to engine starter solenoid Fuel output 39

IL-CU CAN description Cummins ISB 9 pin Deutsch connector CAN bus common SAE J1939 shield - screen for J1939 cable. CAN bus H SAE J1939 signal CAN bus L SAE J1939 return

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Sensor specification

To correct measuring error of each analog input (pressure, temperature, level) calibrating constants within 10 % of measure range should be set. Three calibrating constants are set in physical units - bar,

C, % . From these constants are counted equivalent calibrating resistance which are internally (in software) add to sensor resistance. At the moment of calibration (ENTER pressing) is calculated (and in memory saved) calibrating resistance (in Ω). This value is added to measured sensor resistance before calculation of the AI1 (AI2) value.

Example: iL-CU display Temperature 70 °C and real value is 73 °C. After setting Calibr AI1 to +3 °C (and pressing ENTER) InteliLite calculates corresponding resistance (e.g.5Ω) and saves this value into the memory. The resistance is then added to all calculations (e.g. instead of 70°C -> 73°C, or e.g. instead of 5°C -> 6°C).

Note: The calibration must be done at the operational point of the analog input (e.g. 80°C, 4.0Bar etc..)

Default sensor settings

Analog input 1: 6 points VDO characteristic, pressure measuring in bar Analog input 2: 10 points VDO characteristic, temperature measuring in °C Analog input 3: 2 points VDO fuel level sensor, 0% = 10Ω, 100% = 180Ω

For VDO sensor characteristic see chapter Value and set points codes.

VDO Temperature sensor

500

1000

1500

2000

0 2030405060708090110

Temperature [ C]

Resistance [ohm]

VDO Pressure sensor

100

150

200

0246810

Pressure [bar]

Resistance [ohm]

Temperature ºC

Pt 1000 ohm

Ni 1000

ohm

-20

-10 0 30 60 80 90 100 110 120 0

922 961 1000 1117 1232 1309 1347 1385 1423 1461

-1

893

946 1000 1171 1353 1483 1549 1618 1688 1760

-1

Hint:

When measured value is 6% out of range the Sensor fail FLS is detected.

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Page 44

Operator interface

Pushbuttons and LEDs, MRS10/11/15/16

Pushbuttons

1 4

1. MODE→ Cyclic forward selection the gen-set operation mode (OFF -> MAN -> AUT )

2. ←MODE Cyclic backward selection the gen-set operation mode (AUT -> MAN ->OFF )

3. HORN RESET Deactivates the HORN

4. FAULT RESET Acknowledges faults and alarms

5. START Start of the gen-set

6. STOP Stop of the gen-set

8. GCB ON/OFF ^Manual open/close of the Generator circuit breaker

9. PAGE Cyclic selection of the display mode(MEASUREMENT->ADJUSTEMENT)

10. Select the set point, select the screen or increase set point value

11. Select the set point, select the screen or decrease set point value

12. ENTER Confirm set point value

LEDs

13.

14.

15. GEN VOLTAGE PRESENT: GREEN LED is on, if gen. voltage is present and within limits

16. GEN-SET FAILURE: RED LED starts flashing when gen-set failure occurs. After FAULT RESET

button is pressed, goes to steady light (if an alarm is still active) or is off (if no alarm is active)

17. ^GCB ON: GREEN LED is on, if GCB is closed. Driven by GCB CLOSE/OPEN output.

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How to select the gen-set mode ?

Use MODE→ or ←MODE to select requested gen-set operation mode (OFF – MAN – AUT)

^When to use buttons GCB ON/OFF?

In AUT mode these buttons are disabled. In MAN mode are enabled, but before closing of any circuit beaker, voltage must be within limits. Internal protection against closing of both circuit breakers is implemented.

Display menus

There are 2 display menus available: MEASUREMENT and ADJUSTMENT Each menu consists of several screens. Press repeatedly PAGE button to select requested menu.

How to view measured data?

1. Use repeatedly PAGE button to select the MEASUREMENT menu.

2. Use ↑ and ↓ to select the screen with requested data.

How to view and edit set points?

1. Use repeatedly PAGE button to select the ADJUSTMENT menu.

2. Use ↑ or ↓ to select requested set points group.

3. Press ENTER to confirm.

4. Use ↑ or ↓ to select requested set point.

5. Set points marked “*” are password protected.

6. Press ENTER to edit.

7. Use ↑ or ↓ to modify the set point. When ↑ or ↓ is pressed for 2 sec, auto repeat function is

activated.

8. Press ENTER to confirm or PAGE to leave without change.

9. Press PAGE to leave selected set points group.

How to change the display contrast ?

Press ENTER and ↑ or ↓ at the same time to adjust the best display contrast

Hint:

Only in MEASUREMENT menu.

How to check the serial number and software revision?

Press ENTER and then PAGE. On the display you can see InteliLite INFO screen for 10 seconds. InteliLite INFO screen contains :

1) Controller name (see Basic setting group)

2) InteliLite serial number (8 character number)

3) SW version: the first is the firmware version number, the second is configuration table number.

4) Application: MRS16

5) Branch: Standard

Hint:

Only in MEASUREMENT menu.

How to find active alarms ?

Active alarm list is the last screen in the MEASUREMENT menu.

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Select MEASUREMENT menu. Press ↑ You will see the list of all active alarms with the number of alarms at the top-right corner Three state alarms are introduced:

Versions 1.4 and lower Version 2.0 and higher Description

Wrn Water temp * Wrn Water temp Active not accepted alarm Wrn Water temp Wrn Water temp Active accepted alarm

Wrn Water temp * Wrn Water temp Inactive not accepted alarm Inactive accepted alarm

Press FAULT RESET accepts all alarms. Non-active alarms immediately disappear from the list. Active alarm list appears on the screen when a new alarm comes up and Main MEASUREMENT screen is active.

Hint:

Alarm list does not activate when you are reviewing the values or setpoints.

In AMF25 since version 2.0 second alarm list for ECU alarms is added. It is displayed one screen above the standard alarm list on the controller display or under the standard alarm list in Control window of LiteEdit (also since version 2.0). If an alarm appears in this alarm list, it is signalized in the standard alarm list and by exclamation mark on the main measure screen. Control from the front panel:

↑↓

One screen up/down

Enter Cursor move within the ECU alarm list

Enter + Fault reset ECU fault code reset

MEASUREMENT screens description

Main measure screen

OFF MAN AUT TEST

Ready Mains Oper cos 0.00

RPM 0

Timer 0

1. Operation mode of the gen-set

2. Indication of active access lock, Remote OFF or Remote TEST

L and alarm !

3. Status of the gen-set

5. RPM of the gen-set

6. Active power

7. Power factor

8. Timer - event s counting time (e.g. prestart, cooling, etc.)

Generator screen

Gen freq Gen V1-2, V2-3, V3-1 ph-ph

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Gen V1, V2, V3 ph-N (triple bargraph) Gen I1, I2, I3 (triple bargraph)

IL-CU Analog inputs screen

Oil pressure (single bargraph) Water temperature (single bargraph) Fuel level (single bargraph) Battery voltage (single bargraph)

IL-CU binary inputs

BI1 to BI6

IL-CU binary outputs

BO1 to BO6

ECU state

ECU YellowLamp ECU RedLamp

WaitToStart

Hint:

This screen is shown/hidden depending on whether the ECU is configured or not.

*ECUValues

Oil press Water temp PercLoadAtCS Boost pressure ManifoldTemp

Fuel rate

Hint:

This screen is shown/hidden depending on whether the ECU is configured or not.

Gen-set power screen

Active power (total and per phase) Power factor (total and per phase) React power (total and per phase) Appar power (total and per phase)

Statistic

Run hours Number of starts

*Kilowatt-hours kWh (total) *Reactive power hours kVAh (total only)

NextServTime

*ECU AlarmList

Diagnostic messages are read from ECU and displayed in this second alarm list. For Standard J1939 engines SPN (Suspect Parameter Number), FMI (Failure Mode Identifier) and OC (Occurrence Counter) are shown together with verbal description if available.

Following image shows displaying of ECU alarms in the second alarm list. The additional information for the row selected by cursor is on the last row (SPN, OC and FMI codes). If the verbal description of alarm is not available, the SPN (decimal and hexadecimal) is displayed.

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EngOilPress WRN BoostPress FLS EngOilTemp FLS 629(275h) FLS Controller#1 EngCoolTemp WRN _____________________ SPN:110 OC:7 FMI:3

Hint:

For FMI = 0 and 1, WRN is displayed. For other FMI codes, FLS is displayed.

Alarm list

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Page 49

Chart guide to menus and pushbutton’s operation

Measure Screens

GEAR TEETH › 150 150 NOM RPM 1500 1500 RPM START RPM 30 30% CRANK TIME 10 10s

PAGE

Par. Edit Screens

› ENGINE BASIC ENGINE PROT GEN BASIC GEN PROTECT MAINS FAIL

ENTER

PAGE

Screen

OFF

586

500

1000

14:23:15

12345h

MAN

AUTO

ENTER

Parameter setting:

1. Set cursor by buttons

2. Press to editing mode

3. Adjust parameter by buttons

4. Press to write parameter into memory

Press to cancel of editing mode

PAGE

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Page 50

Function description

OFF mode

No start of the gen-set is possible. Outputs STARTER, GCB CLOSE/OPEN and FUEL SOLENOID are not energized. No reaction if buttons START,STOP,^GCB ON/OFF are pressed.

MAN mode

START. - starts the gen-set. ^GCB ON/OFF

• The controller closes GCB.

• The controller opens GCB when closed.

• If the generator voltage is out of the limits, the controller does not to respond to the GCB

ON/OFF

STOP stops the gen-set.

Hint:

The engine can run without load unlimited time. The controller does not automatically stop the running gen-set in MAN mode.

The controller does not start the gen-set when binary input REM START/STOP is closed.

Start-stop sequence (simplified)

MODE = MAN (Engine start/stop request is given by pressing buttons START and STOP ) MODE = AUT (Engine start/stop request is given by binary input REM START/STOP)

State Condition of the transition Action Next state

Start request PRESTART on

Prestart time counter

started

Prestart

RPM > 2 or Oil pressure detected or Gen voltage > 10V

Stop (Stop fail)

Ready

OFF mode selected or Shut down alarm active

Not Ready

Not Ready RPM < 2, Oil pressure not detected, Vgen

< 10V, no shutdown alarm active, other than OFF mode selected

Ready

Prestart

Prestart time elapsed

STARTER on FUEL SOLENOID on

MaxCrank time counter

started

Cranking

RPM> Start RPM

STARTER off PRESTART off

Starting

Cranking

D+ input activated or oil pressure detected or Gen voltage > 25% Vgnom

STARTER off PRESTART off

Cranking

Page 51

State Condition of the transition Action Next state

MaxCrank time elapsed, 1st attempt

STARTER off FUEL SOLENOID off STOP SOLENOID on CrankFail pause timer

started

Crank pause

MaxCrank time

elapsed, last attempt

STARTER off PRESTART off

Shutdown (Start fail)

Crank pause

CrankFail pause elapsed

STARTER on FUEL SOLENOID on

STOP SOLENOID off MaxCrank time counter

started

Cranking

80% Nominal speed reached

READY TO LOAD on

Min, MaxStabTime

counter started

Running

RPM = 0 or any other shutdown condition FUEL SOLENOID off

STOP SOLENOID on

Shutdown

Starting

60 sec. Elapsed

FUEL SOLENOID off STOP SOLENOID on

Shutdown (Start fail)

Stop request READY TO LOAD off

Cooling time timer started

Cooling

RPM = 0 or any other shutdown condition READY TO LOAD off

FUEL SOLENOID off

Shutdown

Running

GCB CLOSE/OPEN

closed

Loaded

GCB CLOSE/OPEN opened

Running

Loaded

RPM = 0 or any other shutdown condition FUEL SOLENOID off

STOP SOLENOID on READY TO LOAD off

Shutdown

Cooling time elapsed

FUEL SOLENOID off STOP SOLENOID on

Stop

RPM = 0 or any other shutdown condition FUEL SOLENOID off

STOP SOLENOID on

Shutdown

Cooling

Start request READY TO LOAD on

Running

RPM = 0, Oil pressure not detected, Vgen <

10V

Ready

Stop

60 sec.

Elapsed

Stop (Stop fail)

if all generator parameters OK and MinStab Time elapsed, indicates that GCB is possible to close.

In AUT mode closes in this moment GCB automatically.

If GCB output used GCB opens automatically

The start-up sequence can be interrupted in any time by comming stop request

Fuel solenoid is switched on with time advance of 1s fixed before starter motor is switched on.

Hint:

Treshhold level for D+ input is 80% supply voltage, activation delay is 1s (to override short firings during during cranking – for example in cold conditions).

AUT mode

The controller does not respond to buttons START, STOP, MCB ON/OFF, GCB ON/OFF. Engine start/stop request is given by binary input REM START/STOP.

Page 52

Alarm management

Following alarms are available:

Sensor fail Warning Shut down

Sensor fail (FLS)

Sensor fail is detected when measured value is 6% out of selected sensor characteristic. Sensor fail is indicated by ##### symbol instead measured value.

Warning (WRN)

When warning comes up, only alarm outputs and common warning output are closed.

Possible warnings:

See List of possible events

Shut down (SD)

When the shut-down alarm comes up, InteliLite opens outputs GCB CLOSE/OPEN, FUEL SOLENOID, STARTER and PRESTART to stop the engine immediately. Alarm outputs and common shutdown output are closed. Active or not reset protection disables start.

Possible shut-down alarms:

See List of possible events

Alarm time chart

"All the time" c onfigured protections, I >, I >>, RP M > >, m ains failure detection

GCB opened

"Engine running only" protections, engine

water temperature luboil pressure

Underspeed

Stop

Start

Starter OFF

Protec tion

delay

Switched to

nominal speed

Min stab t ime

GCB closed

Max stab time

Gen >U, <U, >f, <f

Idle time

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Voltage phase sequence detection

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

Wrong phase sequence

There is fix defined phase sequence in InteliLite controller L1, L2, L3. When the phases are connected in different order (e.g. L1,L3,L2 or L2,L1,L3) following alarms are detected:

G ph opposed = wrong generator phase sequence

Inverted phase polarity

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

GEN L1 neg = generator phase L1 is inverted GEN L2 neg = generator phase L2 is inverted GEN L3 neg = generator phase L3 is inverted

Wrong phase sequence and inverted polarity

It is combination of both previous alarms G ph+L1 neg = wrong generator phase sequence and phase L1 is inverted G ph+L2 neg = wrong generator phase sequence and phase L2 is inverted G ph+L3 neg = wrong generator phase sequence and phase L3 is inverted

Hint:

Phase sequence detection is active when voltage in all three phases is >50VAC and all phases angles are in the range 120° ± 20. Phase sequence alarm detection is 1 sec delayed to avoid transient effects.

Sensor fail detection

Sensor fail Fls is detected when measured value is 6,2 percent out of range. Controller screen displays in this case string #### instead measured value.

Sensor Failure

Range of sensor

-6%

Range of measurement

100%

+6%

Sensor Failure

Page 54

Gen-set operation states

Engine state machine

Init Autotest during controller power on Not ready Genset is not ready to start Prestart Prestart sequence in process, Prestart output is closed Cranking Engine is cranking Pause Pause between start attempts

Starting Starting speed is reached and the Idle timer is running

Running Genset is running at nominal speed Loaded Genset is running at nominal speed and GCB OPEN/CLOSE is closed Stop Stop Shutdown Shut-down alarm activated Ready Genset is ready to run Cooling Genset is cooling before stop

List of possible alarms

Events specification Protection

type

Information on binary

output available (See list

of Binary outputs)

Description

Oil Press Wrn WRN YES Oil pressure is smaller than

Wrn Oil press setpoint.

Oil Press Sd SD NO Oil pressure is smaller than Sd

Oil press

setpoint.

Water Temp Wrn WRN YES Water temperature is greater

than

Wrn Water temp setpoint.

Water Temp Sd SD NO Water temperature is greater

than

Sd Water temp setpoint.

Fuel Level Wrn WRN YES Fuel level is smaller than Wrn

Fuel Level

setpoint.

Fuel Level Sd SD NO Fuel level is smaller than Sd

Fuel Level

setpoint.

Analog inp IOM/PTM - Wrn WRN YES Warning alarm configurable on

the input of IG-IOM/IGS-PTM.

Analog inp IOM/PTM - Sd SD YES Shutdown alarm configurable

on the input of IG-IOM/IGSPTM.

Binary input Configurabl

YES Configurable

Warning/Shutdown alarms on the inputs of IL-CU.

Battery voltage <, > WRN YES Battery voltage is out of limits

given by

Batt overvolt and Batt

undervolt

setpoints.

Battery flat SD YES If the controller switches off

during starting sequence due to bad battery condition it doesn’t try to start again and

activates this protection. Start failed SD YES Gen-set start failed. ParamFail NONE NO Wrong checksum of

parameters. Happends

Page 55

Events specification Protection

type

Information on binary

output available (See list

of Binary outputs)

Description

typically after downloading

new firmware or changing of

the parameter. The controller

stays in INIT mode. Check all

parameters, write at least one

new parameter. Vgen <, > SD YES The generator voltage is out of

limits given by

Gen <V and

Gen >V setpoints.

Vgen unbl SD NO The generator voltage is

unbalanced more than the

value of

Volt unbal setpoint.

Fgen <,> SD YES The generator frequency is out

of limits given by

Gen >f and

Gen <f setpoints.

Igen unbl SD NO The generator current is

unbalanced. Overload SD YES The load is greater than the

value given by

Overload

setpoint. Overspeed SD YES The protection comes active if

the speed is greater than

Overspeed setpoint.

Underspeed SD YES During starting of the engine

when the RPM reache the

value of

Start RPM setpoint

the starter is switched off and

the speed of the engine can

drop under

Start RPM again.

Than the Underspeed

protection comes active.

EmergencyStop SD NO If the input Emergency stop is

opened shutdown is

immediately activated. PickupFault SD NO Failure of magnetic pick-up

sensor for speed

measurement. Stop fail SD YES Gen-set stop failed. WrnServiceTime WRN NO The period for servicing is set

by the

NextServTime setpoint.

The protection comes active if

the running hours of the

engine reach this value. ChrgAlternFail WRN YES Failure of alternator for

charging the battery. SprinklActive WRN NO The protection is active if the

output

Sprinkler is closed.

*Wrn RA15 fail WRN NO Warning alarm in case of lost

connection to IGL-RA15

module. *Sd IOM fail SD NO Shutdown alarm in case of lost

connection to IG-IOM/IGS-

PTM module. Wrn ECU Alarm WRN NO ECU alarm list is not empty

Page 56

Remote control and data logging

Direct connection to the PC

InteliLite can be connected directly with PC via RS232 interface.

• iL MRS15/16 is equpped built-in RS232 interface

• iL MRS10/11 needs external RS232 interface AT-LINK-CONV (ordered separately)

Use the standard serial cable to connect PC with InteliLite.

Hint:

Make sure the grounding system on controller and PC – COM port (negative of the PC DC supply) are identical – before the first direct connection. There must not be any voltage between these two points otherwise the internal resistor in controller burns out. The simple solution is to assure, that the PC supply 240/20V is ground free (GND terminal is not connected).

5 - GND

2 - RxD 3 - TxD

5 - GND

2 - RxD

3 - TxD

RS232

230 VAC

0 VDC

CONTROLLER

Battery

Required the same

voltage potential

between GND‘s

RS 232

PC software - LiteEdit

On the PC (for direct or modem connection) has to be installed the ComAp’s software package LiteEdit. (based on Windows 95 or newer platform) LiteEdit enables: read the quantities adjust all set points control the engine configure the controller select software configuration modify alarm inputs and outputs modify password, commands protections direct or *modem communication

Modbus protocol

The selection of the function of iL serial port is done via the setpoint

RS232 mode in Basic settings

•

9600 bps, 8 data bits, 1 stop bit, no parity

• Transfer mode RTU

• Function 3 (Read Multiply Registers)

• Function 6 (Write Single Register)

• Function 16 (Write Multiply Registers)

• The response to an incoming message is sent with minimum 4.096 ms delay after message

reception

Page 57

The complete description of Modbus communication protocol can be found in

Modbus Protocol

Reference Guide PI-MBUS-300

and Open Modbus Specification Release 1.0. Both documents are

available from web site at

http://www.modicon.com/openmbus/ .

Communication object vs. Register

All the data intended for communication has its representation as communication objects in the controller. The communication object is represented by the n-byte array in the controller memory and identified by the unique 16-bit communication object number. The register, according to Modbus communication protocol, represents a two-byte data and in communication functions is referenced by 16-bit register address. Further in the description of communication functions

the communication

object number will always be used as a register address

and length of the communication object

will be expressed by number of registers.

Just one communication object can be read or written

by one communication function.

Hint:

To obtain communication object numbers it is possible to download the Actual IL controller description on-line from controller or from (ail) archive and use “export data” function from LiteEdit software.

Communication object list (exported from default archive)

Setpoints (MRS10/11/15/16):

Name Firmware ver. Application Date App. ver. Ser. num. Filename

InteliLite IL-2.1

R:10.11.2004

MRS16 30.11.2004 2,1 0200FFFF MRS16-

2.1.ail

Group Name Value Dimension Password Com. obj. Low limit High

limit

Data type

Basic settings Gen-set name InteliLite No 8637 Short string

Basic settings Nomin power 200 kW No 8276 1 4000 Unsigned

Basic settings Nomin current 350 A No 8275 1 5000 Unsigned

Basic settings CT ratio 2000/5A No 8274 1 5000 Unsigned

Basic settings PT ratio 1,0 /1 No 9579 0,1 500,0 Unsigned

Basic settings Nomin voltage 231 V No 8277 100 22000 Unsigned

Basic settings Nominal freq 50 Hz No 8278 45 65 Unsigned

Basic settings Gear teeth 120 No 8252 0 500 Unsigned

Basic settings Nominal RPM 1500 RPM No 8253 100 4000 Unsigned

Basic settings FltResGoToMAN DISABLED No 9983 String list

Basic settings DispBaklightTO 0 min No 10121 0 60 Unsigned 8

Basic settings ControllerMode OFF No 8315 String list

Basic settings RS232 mode STANDARD Yes 24522 String list

Basic settings NumberRings AA 3 Yes 24512 1 30 Unsigned 8

Engine params Starting RPM 25 % No 8254 5 50 Unsigned 8

Engine params Starting POil 4,5 Bar No 9681 -10,0 1000,0 Integer 16

Engine params Prestart time 2 s No 8394 0 600 Unsigned

Page 58

Engine params MaxCrank time 5 s No 8256 1 60 Unsigned 8

Engine params CrnkFail pause 8 s No 8257 5 60 Unsigned 8

Engine params Crank attempts 3 No 8255 1 10 Unsigned 8

Engine params Idle time 12 s No 9097 0 600 Unsigned

Engine params Min stab time 2 s No 8259 0 300 Unsigned

Engine params Max stab time 10 s No 8313 0 300 Unsigned

Engine params Stop time 60 s No 9815 0 600 Unsigned

Engine params Cooling time 30 s No 8258 0 3600 Unsigned

Engine params Cooling speed IDLE No 10046 String list

Engine params Fuel solenoid DIESEL No 9100 String list

Engine params D+ function DISABLED No 9683 String list

Engine params ECU FreqSelect PRIMARY No 10266 String list

Engine protect Eng prot del 5 s No 8262 0 300 Unsigned

Engine protect Horn timeout 10 s No 8264 0 600 Unsigned

Engine protect Overspeed 115 % No 8263 50 150 Unsigned

Engine protect AnlInp1 level1 2,0 Bar No 8369 1,0 1000,0 Integer 16

Engine protect AnlInp1 level2 1,0 Bar No 8370 -10,0 2,0 Integer 16

Engine protect AnlInp1 del 3 s No 8365 0 180 Unsigned

Engine protect AnlInp2 level1 80 °C No 8375 -100 90 Integer 16

Engine protect AnlInp2 level2 90 °C No 8376 80 10000 Integer 16

Engine protect AnlInp2 del 5 s No 8371 0 180 Unsigned

Engine protect AnlInp3 level1 20 % No 8381 10 10000 Integer 16

Engine protect AnlInp3 level2 10 % No 8382 -100 20 Integer 16

Engine protect AnlInp3 del 10 s No 8377 0 180 Unsigned

Engine protect Batt overvolt 36,0 V No 9587 18,0 40,0 Integer 16

Engine protect Batt undervolt 18,0 V No 8387 8,0 36,0 Integer 16

Engine protect Batt volt del 5 s No 8383 0 600 Unsigned

Engine protect NextServTime 65534 h No 9648 0 65535 Unsigned

Gener protect Overload 120 % No 8280 0 200 Unsigned

Gener protect Overload del 5,0 s No 8281 0,0 60,0 Unsigned

Gener protect Ishort 250 % No 8282 100 500 Unsigned

Gener protect 2Inom del 4,0 s No 8283 0,1 20,0 Unsigned

Gener protect Curr unbal 50 % No 8284 1 200 Unsigned

Page 59

Gener protect Curr unbal del 5,0 s No 8285 0,0 60,0 Unsigned

Gener protect Gen >V Sd 110 % No 8291 70 200 Unsigned

Gener protect Gen <V Sd 70 % No 8293 0 110 Unsigned

Gener protect Gen V del 3,0 s No 8292 0,0 60,0 Unsigned

Gener protect Volt unbal 10 % No 8288 1 100 Unsigned

Gener protect Volt unbal del 3,0 s No 8289 0,0 60,0 Unsigned

Gener protect Gen >f 110,0 % No 8296 85,0 200,0 Unsigned

Gener protect Gen <f 85,0 % No 8298 0,0 110,0 Unsigned

Gener protect Gen f del 3,0 s No 8297 0,0 60,0 Unsigned

Sensors spec Calibr AI 1 0,0 Bar No 8431 -100,0 100,0 Integer 16

Sensors spec Calibr AI 2 0 °C No 8407 -1000 1000 Integer 16

Sensors spec Calibr AI 3 0 % No 8467 -1000 1000 Integer 16

IOM/PTM module

AnOut-kW/20mA 200 No 9019 1 32000 Integer 16

IOM/PTM module

AnlInIOM1 lev1 0 U4 No 8762 -100 10000 Integer 16

IOM/PTM module

AnlInIOM1 lev2 0 U4 No 8766 -100 10000 Integer 16

IOM/PTM module

AnlInIOM1 del 0 s No 8770 0 180 Unsigned

IOM/PTM module

AnlInIOM2 lev1 0 U5 No 8763 -100 10000 Integer 16

IOM/PTM module

AnlInIOM2 lev2 0 U5 No 8767 -100 10000 Integer 16

IOM/PTM module

AnlInIOM2 del 0 s No 8771 0 180 Unsigned

IOM/PTM module

AnlInIOM3 lev1 0 U6 No 8764 -100 10000 Integer 16

IOM/PTM module

AnlInIOM3 lev2 0 U6 No 8768 -100 10000 Integer 16

IOM/PTM module

AnlInIOM3 del 0 s No 8772 0 180 Unsigned

IOM/PTM module

AnlInIOM4 lev1 0 U7 No 8765 -100 10000 Integer 16

IOM/PTM module

AnlInIOM4 lev2 0 U7 No 8769 -100 10000 Integer 16

IOM/PTM module

AnlInIOM4 del 0 s No 8773 0 180 Unsigned

IOM/PTM module

CalibrAInIOM 1 0 U4 No 8793 -1000 1000 Integer 16

IOM/PTM module

CalibrAInIOM 2 0 U5 No 8794 -1000 1000 Integer 16

IOM/PTM module

CalibrAInIOM 3 0 U6 No 8795 -1000 1000 Integer 16

IOM/PTM module

CalibrAInIOM 4 0 U7 No 8796 -1000 1000 Integer 16

Values (MRS10/11/15/16):

Name Firmware ver. Application Date App. ver. Ser. num.

Page 60

InteliLite IL-2.1 R:10.11.2004 MRS16 30.11.2004 2,1 0200FFFF

Group Name Value Dimension Com. obj. Data type

Engine params Engine Speed 0 RPM 8209 Unsigned 16

Engine params ECU State 000 10034 Binary 8

Analog Batt volt 27,0 V 8213 Integer 16

Analog Oil press 3,6 Bar 8227 Integer 16

Analog Water temp 15 °C 8228 Integer 16

Analog Fuel level ##### % 8229 Integer 16

Generator Act power 0 kW 8202 Integer 16

Generator Act pwr L1 0 kW 8524 Integer 16

Generator Act pwr L2 0 kW 8525 Integer 16

Generator Act pwr L3 0 kW 8526 Integer 16

Generator React pwr kVAr 0 8203 Integer 16

Generator React pwr L1 0 8527 Integer 16

Generator React pwr L2 0 8528 Integer 16

Generator React pwr L3 0 8529 Integer 16

Generator Appar pwr 0 kVA 8565 Integer 16

Generator Appar pwr L1 0 kVA 8530 Integer 16

Generator Appar pwr L2 0 kVA 8531 Integer 16

Generator Appar pwr L3 0 kVA 8532 Integer 16

Generator Pwr factor 0,00 8204 Integer 8

Generator Pwr factor L1 0,00 8533 Integer 8

Generator Pwr factor L2 0,00 8534 Integer 8

Generator Pwr factor L3 0,00 8535 Integer 8

Generator Load char 8395 Char

Generator Load char 1 8626 Char

Generator Load char 2 8627 Char

Generator Load char 3 8628 Char

Generator Gen freq 0,0 Hz 8210 Unsigned 16

Generator Gen V L1-N 0 V 8192 Unsigned 16

Generator Gen V L2-N 0 V 8193 Unsigned 16

Generator Gen V L3-N 0 V 8194 Unsigned 16

Generator Gen V L1-L2 0 V 9628 Unsigned 16

Generator Gen V L2-L3 0 V 9629 Unsigned 16

Generator Gen V L3-L1 0 V 9630 Unsigned 16

Generator Gen curr L1 0 A 8198 Unsigned 16

Generator Gen curr L2 0 A 8199 Unsigned 16

Page 61

Generator Gen curr L3 0 A 8200 Unsigned 16

Binary I/O BInpIL 001000 8235 Binary 16

Binary I/O BOutIL 000001 8239 Binary 16

Statistics kWhours 0 8205 Integer 32

Statistics kVArhours 0 8539 Integer 32

Statistics NumStarts 0 8207 Unsigned 16

Statistics RunHours 0 h 8206 Integer 32

Statistics NextServTime 65534 h 9648 Unsigned 16

IL info TimerText Ready 8954 Unsigned 16

IL info TimerValue 0 s 8955 Unsigned 16

IL info SW version 2,1 8393 Unsigned 8

IL info SW branch 1 8707 Unsigned 8

IL info Application 4 8480 Unsigned 8

IL info ControllerMode 0 9651 Unsigned 8

IL info DiagData 0 10050 Unsigned 32

IL info PasswordDecode 2481875985 9090 Unsigned 32

RA15 module BOutRA15 000000000000000 9849 Binary 16

IOM/PTM module AnInIOM 1 0 U4 8978 Integer 16

IOM/PTM module AnInIOM 2 0 U5 8759 Integer 16

IOM/PTM module AnInIOM 3 0 U6 8760 Integer 16

IOM/PTM module AnInIOM 4 0 U7 8761 Integer 16

IOM/PTM module BInpIOM 00000000 8602 Binary 16

IOM/PTM module BOutIOM 00000000 8604 Binary 16

ECU Fuel rate ##### L/h 9860 Unsigned 16

ECU Water temp ##### °C 9855 Integer 16

ECU ManifoldTemp ##### °C 9878 Integer 16

ECU Oil press ##### Bar 9929 Unsigned 16

ECU Boost pressure 0,0 Bar 9877 Unsigned 8

ECU PercLoadAtCS 0 % 9925 Unsigned 8

In case of software malfunction DiagData shows the value that enables to locate possible bug in

software. Include this number when reporting a software problem.

Page 62

Remote communication

*Recommended ISDN modem

• Askey TAS-200E

• ASUScom TA-220ST

*Recommended GSM modem

• Wavecom M1200 (previously WMOD2; baud rate to 9600 bps)

• Siemens M20

• Siemens TC35

• FALCOM A2D

GSM Modem setup

Prior to start work with GSM modem run following program for GSM proper setup. Program writes all the necessary AT commands to configure the GSM modem properly for use with ILCU. This program runs independent on LiteEdit:

• Start MS Windows-Start-Program files - LiteEdit –Gm_setup.exe.

• Select COM port

• Select iG-CU (=IS-CU) or iG-MU unit

• Press Setup button

• Follow commands in GSM Modem Setup window

Typical baud rate for GSM data communication is 80 to 90 Bps.

Hint:

It is strongly recommended to use the same type of modem on the both sides (IL and PC) of connection.

Analog modem

GSM modem

Analog modem

*Mobile SIM card setting

Adjust SIM card in GSM modem following way: enable data connection (when required) no PIN code

Page 63

Technical data

Power supply

Voltage supply 8-36V DC Consumption 0,5-0,1A depend on supply voltage Allowed supply voltage drop-out: 50ms from min. 10V, return to min. 8V

(valid for InteliLite of hardware version 3.2 and higher)

Battery voltage measurement tolerance 2 % at 24V

Hint:

For the supply voltage less than 7V the backlight of the display is switched off.

Operating conditions

Operating temperature IL-CU -20..+70oC Operating temperature IL-CU-LT

-30..+70oC

Storage temperature -30..+80

C Protection front panel IP65 Humidity 95% without condensation Standard conformity Low Voltage Directive EN 61010-1:95 +A1:97 Electromagnetic Compatibility EN 50081-1:94, EN 50081-2:96 EN 50082-1:99, EN 50082-2:97 Vibration 5 - 25 Hz, ±1,6mm

25 - 100 Hz, a = 4 g

Shocks a = 200 m/s

Low Temperature modification

LCD display limits controller operating temperature range to –20

C - + 70 oC even if the other

electronic components work in wider temperature range.

Internal preheating foil is mounted in InteliLite LT to extend display operational temperature range.

Preheating starts at temperature below 5

C and preheating power depends on temperature and

power supply voltage.

Technical data

IL-CU Standard Order code:IL-CU-LT

Operating temperature -20 oC..+70oC -30 oC..+70oC Storage temperature -30 oC..+80oC -30 oC..+80oC

Preheating foil increases controller current consumption

Preheating at ambient temperature Controller

consumption at

No preheating

C -15

C -30 oC

12VDC 360 mA +50 mA +180 mA +300 mA 24VDC 230 mA +25 mA +85 mA +150 mA 36VDC 100 mA +20 mA +65 mA +100 mA

InteliLite LT works immediately after switch on at -30

C and display becomes visible after a few

minutes.

Page 64

Short-term voltage drops (e.g. during the engine cranking) do not affect the operation at all.

Dimensions and weight

Dimensions 180x120x55mm Weight 800g

Generator

Nominal frequency 50-60Hz Frequency measurement tolerance 0,2%

Current inputs

Nominal input current (from CT) 5 A Load (CT output impedance) < 0,1

Ω

CT input burden < 0,2 VA per phase (In=5A) Max. measured current from CT 10 A Current measurement tolerance 2% from the Nominal current Max. peak current from CT 150 A / 1s Max. continuous current 12 A

Voltage inputs

Measuring voltage 231VAC phase to neutral 400VAC phase to phase Maximal measured voltage 290VAC phase to neutral Input resistance 0,6 M

Ω phase to phase

0,3 M

Ω phase to neutral

Voltage measurement tolerance 2 % from the Nominal voltage Overvoltage class III (EN61010)

Binary inputs and outputs

Binary inputs

Number of inputs 6 Input resistance 4,7 k

Ω

Input range 0-36 VDC Switching voltage level for close contact indication 0-2 V Max voltage level for open contact indication 8-36 V

Contact relay outputs

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

Binary open collector outputs

Number of outputs 4 Maximum current 0,5 A Maximum switching voltage 36 VDC

Analog inputs

Not electrically separated Resolution 10 bits Sensor resistance range 0

Ω-2,4 kΩ

Resistance measurement tolerance 4 %

± 2 Ω out of measured value

Page 65

Speed pick-up input

Type of sensor magnetic pick-up (connection by shielded cable is recommended) Minimum input voltage 2 Vpk-pk (from 4 Hz to 4 kHz) Maximum input voltage 50 Veff Minimum measured frequency 4 Hz Maximum measured frequency 10 kHz (min. input voltage 6Vpk-pk) Frequency measurement tolerance 0,2 %

*RS232 interface

Maximal distance 10m Speed 19.2kBd (STD) 9.6kBd (MODBUS)

Recommend external converter: ADVANTECH – ADAM 4520: RS232 to RS422/485 converter, DIN rail, automatic RS485 bus supervision, no external data flow control signals, galvanic isolated.

Recommended internal converter: ADVANTECH – PCL-745B or PCL745S : Dual port RS422/485 Interface card, automatic RS485 bus supervision, no external data flow control signals, galvanic isolated

*CAN bus interface

Galvanically separated Maximal CAN bus length 200m Speed 250kBd Nominal impedance 120

Ω

Cable type twisted pair (shielded)

Following dynamic cable parameters are important especially for maximal 200 meters CAN bus length and 32 iS-COM units connected: Nominal Velocity of Propagation min. 75% (max. 4,4 ns/m) Wire crosscut min.0,25 mm

Maximal attenuation (at 1 MHz) 2 dB / 100m

Recommended Industrial Automation & Process Control Cables: BELDEN (see

http://www.belden.com):

• 3082A DeviceBus for Allen-Bradley DeviceNet

• 3083A DeviceBus for Allen-Bradley DeviceNet

• 3086A DeviceBus for Honeywell SDS

• 3087A DeviceBus for Honeywell SDS

• 3084A DeviceBus for Allen-Bradley DeviceNet

• 3085A DeviceBus for Allen-Bradley DeviceNet

• 3105A Paired EIA Industrial RS485 cable

LAPP CABLE (see

http://www.lappcable.com)

• Unitronic BUS DeviceNet Trunk Cable

• Unitronic BUS DeviceNet Drop Cable

• Unitronic BUS CAN

• Unitronic-FD BUS P CAN UL/CSA