ComAp InteliMains NT IM-NT-BB, InteliMains NT IM-NTC-BB, InteliMains NT IM-NT Reference Manual
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Reference Guide
InteliMains
NT
®
Mains Circuit Breaker and Master Generator
Circuit Breaker Applications
IM-NT-BB, IM-NTC-BB, IM-NT
SW version 3.2.0, September 2015
Copyright ©2015 ComAp a.s.
ComAp a.s.
Kundratka 17, 180 00 Praha 8, Czech Republic
Tel: +420 246 012 111, Fax: +420 266 316 647
E-mail:info@comap.cz, www.comap.cz
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Table of contents
1 Document information ................................................................................................................... 6
1.1 Available Related Documentation .............................................................................................. 7
1.2 Clarification of notation ............................................................................................................... 8
1.3 Conformity Declaration ............................................................................................................... 8
2 System overview ............................................................................................................................ 9
2.1 General description .................................................................................................................... 9
2.2 Configurability and monitoring .................................................................................................. 10
2.2.1 GenConfig ........................................................................................................................ 10
2.2.2 InteliMonitor ..................................................................................................................... 10
2.2.3 WinScope ......................................................................................................................... 11
2.2.4 WebSupervisor ................................................................................................................ 11
2.3 Applications overview ............................................................................................................... 11
3 Installation .................................................................................................................................... 12
3.1 IM-NT Installation instructions .................................................................................................. 13
3.1.1 Mounting .......................................................................................................................... 13
3.1.2 Terminal diagram, Dimensions ........................................................................................ 14
3.1.3 Package contents ............................................................................................................ 15
3.1.4 Jumper settings................................................................................................................ 15
3.2 IM-NT-BB and IM-NTC-BB Installation instructions ................................................................. 15
3.2.1 Mounting .......................................................................................................................... 16
3.2.2 Terminal diagram, Dimensions ........................................................................................ 18
3.2.3 Package contents ............................................................................................................ 19
3.2.4 Jumper settings................................................................................................................ 19
3.3 Wiring (general) ........................................................................................................................ 19
3.4 Grounding (general) ................................................................................................................. 20
3.5 Power supply (general)............................................................................................................. 20
3.6 Power supply fusing (general) .................................................................................................. 20
3.7 Voltage and current inputs (general) ........................................................................................ 21
3.8 Binary Input wiring (general) .................................................................................................... 22
3.9 Binary Output wiring ................................................................................................................. 22
3.9.1 IM-NT ............................................................................................................................... 22
3.9.2 IM-NT-BB and IM-NTC-BB .............................................................................................. 23
3.10 Analog Input and Output wiring ................................................................................................ 24
3.11 CAN and RS485 bus wiring ...................................................................................................... 26
3.11.1 Wiring examples .............................................................................................................. 27
3.12 Extension modules (general) .................................................................................................... 28
4 Putting it into operation ............................................................................................................... 29
4.1 Connection to a controller using PC ......................................................................................... 29
4.1.1 Direct connection ............................................................................................................. 29
4.1.2 Modem connection .......................................................................................................... 30
4.1.3 Internet connection .......................................................................................................... 31
4.1.4 Airgate connection ........................................................................................................... 32
4.1.5 Connection to multiple controllers.................................................................................... 33
4.2 Modification of configuration, setpoints etc. ............................................................................. 34
4.3 Programming of a controller ..................................................................................................... 35
4.3.1 Standard programming .................................................................................................... 35
4.3.2 Programming of non-responsive controller ...................................................................... 35
4.4 Changing the language ............................................................................................................ 38
4.4.1 Selection of the language in InteliMains-NT GC .............................................................. 38
4.4.2 Selection of the language in InteliMains-NT(C)-BaseBox ............................................... 38
4.5 Password management ............................................................................................................ 39
4.5.1 User administration .......................................................................................................... 39
4.5.2 Access group setting in GenConfig ................................................................................. 40
4.5.3 Password break protection .............................................................................................. 40
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4.6 Related tools ............................................................................................................................. 42
5 Operator guide .............................................................................................................................. 43
5.1 IM-NT ........................................................................................................................................ 43
5.2 Systems with InteliVision displays ............................................................................................ 43
6 Firmware and Archives ................................................................................................................ 44
6.1 BaseBox type controllers .......................................................................................................... 44
6.2 Graphical Character type controllers ........................................................................................ 44
7 Function description .................................................................................................................... 45
7.1 Overview ................................................................................................................................... 45
7.2 Modes ....................................................................................................................................... 57
7.2.1 OFF mode ........................................................................................................................ 57
7.2.2 MAN mode ....................................................................................................................... 57
7.2.3 AUT mode ........................................................................................................................ 57
7.2.4 TEST mode ...................................................................................................................... 57
7.3 Process Limitation .................................................................................................................... 61
7.3.1 MGCB .............................................................................................................................. 61
7.3.2 MCB ................................................................................................................................. 64
7.4 System start .............................................................................................................................. 65
7.5 StartUpSynchronization ............................................................................................................ 66
7.6 Power management ................................................................................................................. 66
7.6.1 Power management limitations ........................................................................................ 66
7.6.2 Basic Power management ............................................................................................... 67
7.6.3 Automatic priority swapping ............................................................................................. 80
7.6.4 Minimum Running Power ................................................................................................. 96
7.6.5 Control Groups................................................................................................................. 98
7.6.6 Load shedding based on active power ............................................................................ 99
7.6.7 Load shedding based on frequency .............................................................................. 100
7.6.8 Peak shaving based on Active and Apparent Power .................................................... 102
7.7 Remote Alarm Messaging ...................................................................................................... 102
7.7.1 Communication Types for Remote Alarm Messaging ................................................... 102
7.7.2 Example of setting ......................................................................................................... 103
7.8 Controller Redundancy ........................................................................................................... 103
7.8.1 Redundant systems using binary signals ...................................................................... 104
7.8.2 Redundant systems using CAN bus .............................................................................. 104
7.9 System load control modes .................................................................................................... 106
7.9.1 SYSBLD->LS ................................................................................................................. 106
7.9.2 ANEXSYSBLD->LS ....................................................................................................... 106
7.9.3 IMP/EXP ........................................................................................................................ 107
7.9.4 ANEXT IMP/EXP ........................................................................................................... 107
7.9.5 T BY PWR ...................................................................................................................... 107
7.9.6 Managing system load control modes ........................................................................... 108
7.10 System PF control modes ...................................................................................................... 113
7.10.1 PF IMP/EXP ................................................................................................................... 113
7.10.2 PF ANEXT IMP/EXP ...................................................................................................... 113
7.11 Automatic Mains Failure function ........................................................................................... 113
7.12 Regulation loops ..................................................................................................................... 115
7.12.1 PI regulation adjustment ................................................................................................ 116
7.13 Force value – step by step guide ........................................................................................... 117
7.14 Values for continuous writing from external sources .............................................................. 118
7.15 General Purpose Timers ........................................................................................................ 119
7.15.1 Timer modes .................................................................................................................. 119
7.16 History Related functions........................................................................................................ 120
7.16.1 History Records Adjustment .......................................................................................... 120
7.16.2 Time Stamp function ...................................................................................................... 121
7.16.3 Time and Date Intercontroller Sharing ........................................................................... 121
7.16.4 Summer Time Mode ...................................................................................................... 121
7.17 User Buttons ........................................................................................................................... 121
7.18 Remote Control Function........................................................................................................ 122
7.19 Virtual Peripheral Inputs-Outputs (VPIO) module .................................................................. 123
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7.20 Shared Inputs and Outputs .................................................................................................... 123
7.21 Distributed Binary Inputs and Outputs .................................................................................... 125
7.22 Modbus Reading and Writing ................................................................................................. 126
7.23 User MODBUS ....................................................................................................................... 127
7.24 Modbus Switches ................................................................................................................... 127
7.25 Analog Input Sensors and User Sensors ............................................................................... 128
7.26 Languages and Translator tool in GenConfig ........................................................................ 129
7.27 Power Formats ....................................................................................................................... 129
7.28 System Start/Stop ................................................................................................................... 129
7.29 Soft Unload with support of I Aux measurement .................................................................... 130
7.30 System Isolated ...................................................................................................................... 132
7.31 User Mask function ................................................................................................................. 132
7.32 Switchable Current measurement ratio .................................................................................. 134
7.33 PLC functions ......................................................................................................................... 134
7.34 Multi language support ........................................................................................................... 134
8 Protections and Alarm management........................................................................................ 135
8.1.1 Protection groups ........................................................................................................... 135
8.1.2 Protection types ............................................................................................................. 135
8.1.3 Default protections in MCB/MGCB applications ............................................................ 136
8.1.4 Mains voltage and frequency protections - limits and indications ................................. 137
8.1.5 Bus voltage and frequency protections - limits and indications ..................................... 137
8.1.6 User configurable protections ........................................................................................ 138
8.1.7 Reset Actual Alarms selection ....................................................................................... 140
8.1.8 Bus Measurement Error detection ................................................................................. 140
8.1.9 Peripheral Modules Error detection ............................................................................... 141
9 Circuit breakers operation sequence, MGCB/MCB fail detection ........................................ 142
9.1 MCB fail Information ............................................................................................................... 142
9.2 General Information ................................................................................................................ 143
9.2.1 Related binary inputs: .................................................................................................... 143
9.2.2 Related binary outputs: .................................................................................................. 143
9.2.3 Following graphs depict possible CB sequences: ......................................................... 144
9.2.4 Follow function for breaker control in AUT mode .......................................................... 147
9.2.5 Follow function for breaker control in MAN mode .......................................................... 148
10 Controller operation states ................................................................................................. 149
APPENDIX .......................................................................................................................................... 150
11 Setpoints ............................................................................................................................... 151
11.1 Password Protection ............................................................................................................... 151
11.2 Table of setpoints ................................................................................................................... 151
11.2.1 Group: ProcessControl .................................................................................................. 151
11.2.2 Group: Basic settings ..................................................................................................... 175
11.2.3 Group: Comms settings ................................................................................................. 191
11.2.4 Group: ComProtSetting ................................................................................................. 206
11.2.5 Group: Analog protect .................................................................................................... 209
11.2.6 Group: Mains protect ..................................................................................................... 210
11.2.7 Group: Bus protect ......................................................................................................... 219
11.2.8 Group: AMF settings ...................................................................................................... 224
11.2.9 Group: Pwr management ............................................................................................... 229
11.2.10 Group: Sync/Load ctrl .................................................................................................... 248
11.2.11 Group: Volt/PF ctrl ......................................................................................................... 256
11.2.12 Group: Force value ........................................................................................................ 258
11.2.13 Group: Load shedding ................................................................................................... 271
11.2.14 Group: Timer settings .................................................................................................... 281
11.2.15 Group: Act. calls/SMS .................................................................................................... 286
11.2.16 Group: Date/Time .......................................................................................................... 292
12 Values .................................................................................................................................... 295
12.1 Table of values ....................................................................................................................... 295
12.1.1 Group: Mains values ...................................................................................................... 295
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12.1.2 Group: Bus values ......................................................................................................... 305
12.1.3 Group: Object values ..................................................................................................... 308
12.1.4 Group: Gen-sets ............................................................................................................ 309
12.1.5 Group: Control loops ...................................................................................................... 319
12.1.6 Group: Mains protect ..................................................................................................... 319
12.1.7 Group: Power management ........................................................................................... 320
12.1.8 Group: Sync/Load ctrl .................................................................................................... 323
12.1.9 Group: Volt/PF ctrl ......................................................................................................... 323
12.1.10 Group: Force value ........................................................................................................ 324
12.1.11 Group: Load shedding ................................................................................................... 326
12.1.12 Group: Analog CU ......................................................................................................... 326
12.1.13 Group: Bin inputs CU ..................................................................................................... 327
12.1.14 Group: Bin outputs CU ................................................................................................... 328
12.1.15 Group: Log Bout ............................................................................................................ 328
12.1.16 Group: Info ..................................................................................................................... 333
12.1.17 Group: Statistics............................................................................................................. 341
13 Binary input functions ......................................................................................................... 345
13.1 Virtual and physical modules .................................................................................................. 345
13.2 Table of binary input functions ............................................................................................... 346
14 Binary output functions ....................................................................................................... 392
14.1 Virtual and physical modules .................................................................................................. 392
14.2 Table of binary output functions ............................................................................................. 393
15 Analog Input functions ........................................................................................................ 430
15.1 Virtual and physical modules .................................................................................................. 430
15.2 Table of analog input functions .............................................................................................. 431
16 User Notes ............................................................................................................................. 435
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1 Document information
REVISION NUMBER
RELATED SW. VERSION
DATE
1
3.0
27.5.2013
2
3.1.0
1.9.2014
3
3.2.0
30.3.2015
Pressing F1 in the GenConfig and InteliMonitor setpoint, values or configuration window
will open the help with the context of currently selected setpoint, value and binary input
or output function.
InteliMains-NT® – MGCB/MCB Reference guide
Written by: Tomáš Vydra
©2015 ComAp a.s.
Kundratka 17, Praha 8, Czech Republic
Phone: +420 246 012 111, Fax: +420 266 316 647
Web: HTTP://WWW.COMAP.CZ, e-mail: info@comap.cz
DOCUMENT HISTORY
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1.1 Available Related Documentation
PDF files
Description
IM-NT-MCB-MGCB-3.2.0 Reference
Guide.pdf
General description of MCB and MGCB applications
for InteliMains. Contains general information about
installation and related PC software.
IM-NT-BTB-3.2.0 Reference Guide.pdf
General description of BTB applications for
InteliMains. Contains general information about
installation and related PC software.
IM-NT-FDR-3.2.0 Reference Guide.pdf
General description of FDR applications for
InteliMains. Contains general information about
installation and related PC software.
IG/IS-NT Installation Guide 08-2014.pdf
Thorough description of installation and technical
information about InteliGen NT, InteliSys NT,
InteliMains NT and related accessories.
IG/IS-NT Communication Guide 09-2014.pdf
Thorough description of connectivity and
communication for InteliGen NT, InteliSys NT,
InteliMains NT and related accessories.
IG/IS-NT Operator Guide 01-2014.pdf
Operator Guide for BaseBox controllers using
InteliVision 5 and/or 8.
IG/IS-NT-Application Guide 05-2013.pdf
Application Guide for InteliGen NT, InteliSys NT and
InteliMains NT systems
IG/IS-NT Troubleshooting Guide 08-2014.pdf
Troubleshooting guide for InteliGen NT, InteliSys NT,
InteliMains NT and related accessories
InteliMainsNT, SW version 3.2.0
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1.2 Clarification of notation
TYPE
TEXT NOTATION
Setpoints in the text
SetpointGroup:SetpointName
Values in the text
ValueGroup:ValueName
Logical Binary/Analog Input/Output functions in the text
LOGICALFUNCTION
Setpoint setting option
OPTION
The following described machine complies with the appropriate basic safety and
health requirement of the EC Low Voltage Directive No: 73/23 / EEC and EC
Electromagnetic Compatibility Directive 89/336 / EEC based on its design and type, as
brought into circulation by us.
HINT
This type of paragraph points out details to help user installation/configuration.
NOTE:
This type of paragraph calls readers’ attention to a notice or related theme.
CAUTION!
This type of paragraph highlights a procedure, adjustment, etc. which may cause damage or improper
functioning of the equipment if not carried out correctly and may not be clear at first sight.
WARNING!
This type of paragraph indicates things, procedures, adjustments, etc. which demand a high level of
attention, otherwise personal injury or death may occur.
EXAMPLE:
This type of paragraph indicates examples of usage for illustrational purposes.
1.3 Conformity Declaration
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2 System overview
2.1 General description
InteliMains-NT controller is comprehensive mains supervision controller for multiple generating sets
operating in parallel to the Mains. A modular construction allows upgrades to different levels of
complexity in order to provide the best solution for various customer applications.
NT Family controllers are equipped with a powerful graphic display showing icons, symbols and bargraphs for intuitive operation, which sets, together with high functionality, new standards in Gen-set
controls.
BaseBox versions of InteliMains controllers are now available. This version features controller without
built-in monochromatic display and can be combined with new and powerful display units InteliVision-8
and InteliVision-5. For more information on these products, please go to comap.cz web pages.
The controller automatically connects the group of gen-sets to the Mains. It features mains failure
detection using integrated Mains protections, MCB and MGCB synchronization, configuration level
switches based on Mains import or object consumption.
The controller provides easy-to-use operation and installation. Predefined configurations for typical
applications are available as well as user-defined configurations for special applications.
NOTE:
In versions below 2.6 the IM-NT controller does not accept an external bus supply (bus supply which
is not controlled by a ComAp controller).
Gensets have to be in AUT mode to ensure proper MGCB function.
The key features are:
Automatic gen-set start when the mains fails (BI SYS START/STOP is closed)
MCB controlled by InteliMains-NT
Break transfer on mains failure
MCB synchronizing after mains return
Power management (load dependent start and stop)
Gen-set priority can be defined manually or automatically based on running hours equalization
or load demand (most efficient combination)
Load sharing and VAR sharing
Gen-sets soft loading and unloading
Voltage matching
Reverse power protection
Full PLC logic included
Support of redundancy controller
MGCB support
Group Link function
Active calls and SMS
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2.2 Configurability and monitoring
One of the key features of the controller is the system’s high level of adaptability to the needs of each
individual application and wide possibilities for monitoring. This can be achieved by configuring and
using the powerful ComAp PC/mobile tools.
Supported configuration and monitoring tools:
GenConfig – complete configuration and firmware upgrade
InteliMonitor – multiple site monitoring and setpoint setting
WinScope – special graphical monitoring software
WebSupervisor – web-based system for monitoring and controlling
o WebSupervisor mobile – supporting application for smartphones
NOTE:
Use the GenConfig PC software to read, view and modify configuration from the controller or disk and
write the new configuration to the controller or disk.
2.2.1 GenConfig
Configuration and monitoring tool for InteliMainsNT,
InteliGenNT and other controllers. See more in
GenConfig Reference Guide.
This tool provides the following functions:
Direct, modem or internet communication with
the controller
Offline or online controller configuration
Controller firmware upgrade
Reading/writing/adjustment of setpoints
Binary/Analog Inputs and Outputs logical functions adjustments
Exporting data into a XLS file
Controller language translation
Screen Editor for editing InteliVision 5 a 8 screens
PLC Editor for editing built-in PLC functions
Updating and configuration of InteliVision 8 firmware
User Protections, User sensor curves, password protection and history management
2.2.2 InteliMonitor
PC Monitoring tool for Inteli controllers. See more in the
InteliMonitor Reference Guide.
This tool provides the following functions:
Online monitoring of a controller or whole site
Fully customizable SCADA diagram
Reading/writing/adjustment of setpoints
Reading of measured values
Browsing of controller history records
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2.2.3 WinScope
Special graphical controller monitoring software. See
more in the WinScope Reference guide.
This tool provides the following functions:
Monitoring and archiving of ComAp controller’s
parameters and values
View of actual/historic trends in controller
On-line change of controllers’ parameters for
easy regulator setup
2.2.4 WebSupervisor
Web-based system for monitoring and controlling ComAp controllers. See more at the WebSupervisor
webpage.
This tool provides the following functions:
Site and fleet monitoring
Reading of measured values
Browsing of controller history records
On-line notification of alarms
E-mail notification
Also available as a smartphone application
2.3 Applications overview
For detailed description of several possible applications using InteliMainsNT please refer to the
IGS-NT-Application Guide.
NOTE:
It is necessary to use power formats in MX when the sum of nominal power of gen-sets or any power
in the system (e.g. power imported from Mains) is expected to be above 32000 kW.
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3 Installation
CONTROLLER TYPE
HARDWARE FEATURES
IM-NT
6 Binary Outputs
6 Binary Inputs
Mains and Bus Voltage measurement (3-phase)
Mains Current measurement (3-phase)
Auxiliary Current measurement (1-phase)
RS485 Communication port for universal use
RS232 Communication port
CAN1 Communication port (for extension modules)
CAN2 Communication port (for intercontroller
communication and monitoring)
IM-NT-BB
12 Binary Outputs
12 Binary Inputs
3 Analog Inputs
1 Analog Output
Mains and Bus Voltage measurement (3-phase)
Mains Current measurement (3-phase)
Auxiliary Current measurement (1-phase)
RS485 Communication port dedicated for display
RS232 Communication port
CAN1 Communication port (for extension modules)
CAN2 Communication port (for intercontroller
communication and monitoring)
IM-NTC-BB
12 Binary Outputs
12 Binary Inputs
3 Analog Inputs
1 Analog Output
Mains and Bus Voltage measurement (3-phase)
Mains Current measurement (3-phase)
Auxiliary Current measurement (1-phase)
RS485 Communication port dedicated for display
RS485 Communication port for universal use with galvanic
separation
RS232 Communication port
CAN1 Communication port (for extension modules)
CAN2 Communication port (for intercontroller
communication and monitoring)
USB Communication port
RJ45 (Ethernet) Communication port
There are currently three HW versions of InteliMainsNT controller. Please refer to the corresponding
portion of this chapter for installation instruction for your particular controller type. Chapters relevant
for both HW configurations are marked as “(general)”.
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3.1 IM-NT Installation instructions
This portion of Instalation instructions is dedicated to the
InteliMains-NT-GC controller with built-in display. If you have
BaseBox type of the controller (without the built-in display), please
refer to the section 3.2.
Prepare the screw holders
Locate four sockets for screw holders
Insert the unit into cut-out in a switchboard and
insert all four screw holders accordingly to their
positions
Tighten as required to fix the controller in the
position
3.1.1 Mounting
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3.1.2 Terminal diagram, Dimensions
Mains Bus
Voltage measurement
Binary inputs
RS232
Current measurement
Mains Aux
Binary outputs
N/A
+PWR BOUT
Grounding
RS485
CAN1
Extension
CAN2
Intercontroller
170 (6,7")
185 (7,3")
123 (4,8“)
RS232
USB
68
2,7“
Cutout for IG-XX/IM-NT
113 x 175 mm
4,4 x 6,9”
123 (4,8“)
110 (4,3“)
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3.1.3 Package contents
Voltage measurement
RS232
120 Ω
terminators
Pull up
Pull down
This portion of Instalation instructions is dedicated to the
InteliMains-NT-BaseBox and InteliMains-NTC-BaseBox
controllers without built-in display. If you have version with built-in
display of the controller, please refer to the section 3.1.
Boot jumper location
The package contains:
Controller
Mounting holders
Terminal blocks
3.1.4 Jumper settings
There are several jumpers available on the unit. Their location and purpose is described below.
Use boot jumper if controller is not responding to communication (e.g. due to faulty programming
sequence). Take off the rubber cover using screwdriver to acces boot jumper next to dongle slot.
Use 120 Ω terminators at the end of CAN1, CAN2 or RS485 buses. Do not use these terminators on
units that are not terminating the bus.
Use pull up and pull down resitors on RS485 to bias the line when no device is active on the bus to
prevent noise from undriven line to be interpreted as data.
3.2 IM-NT-BB and IM-NTC-BB Installation instructions
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3.2.1 Mounting
Locate two plastic holders on the back side of the
controller
Make sure both holders are in open position (right
image). If not (left image) open them by pulling
them slightly out
Mount the unit on the DIN rail and secure by
pressing two plastic holder until they click and fix
the unit into position
Mount InteliVision 5 into the switchboard cut-out
(for more information on InteliVision 5 mounting
please refer to the InteliVision 5 Reference
Guide)
Use the rail provided on the back side of
InteliVision 5 and mount the controller to it while
following the same steps when mounting on
standard rail (rail openings on InteliVision 5 are
fixed so there is only one possible way how to
mount the controller to it)
BaseBox units are prepared for mounting on DIN rain mount (35mm).
BaseBox units may also be mounted on InteliVision 5 and together with it mounted into cut-out
in a switchboard.
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Locate four screw holes on the front of the
controller
Insert provided screws and use them to secure
the controller mounted to InteliVision 5 (screws fit
into InteliVision 5 holder pieces)
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3.2.2 Terminal diagram, Dimensions
Mains Bus
Voltage measurement
Binary inputs
1-6
7-12
RS485
Display only
CAN1
Extension
modules
CAN2
Intercontroller
and
monitoring
RS232
USB
(NTC only)
Ethernet
(NTC only)
RS485
Universal
use
(NTC only)
Current measurement
Mains Aux
Binary outputs
1-8
9-12 + -
Binary outputs
Binary inputs
Power
Analog inputs
1-3
AI COM
Analog output
AOUT COM
AOUT -
RS232
56.5
223
110
RS 232
USBRJ 45
68.5
142
166
IM-NTC-BB only
IM-NTC-BB only
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3.2.3 Package contents
Mains Bus
Voltage measurement
Binary inputs
1-6
120 Ω
terminators
RS232
USB
(NTC only)
Ethernet
(NTC only)
Current measurement
Mains Aux
Binary outputs
1-8
Power
AI COM
Analog output
AOUT COM
AOUT -
Pull upPull down
Pull up
Pull down
(NTC only)
Voltage
output
0-10V
Current
output
0-20mA
Voltage input
0-5 VDC
Current input
0-25 mA
Resistance input
0-2400 Ω
120 Ω
terminator
Boot jumper location
The package contains:
Controller
Screws for optional screw mounting
Terminal blocks
3.2.4 Jumper settings
There are several jumpers available on the unit. Their location and purpose is described below.
Use boot jumper if controller is not responding to communication (e.g. due to faulty programming
sequence). Take off the rubber cover using screwdriver to acces boot jumper next to dongle slot.
Use 120 Ω terminators at the end of CAN1, CAN2 or RS485 buses. Do not use these terminators on
units that are not terminating the bus.
Use pull up and pull down resitors on RS485 to bias the line when no device is active on the bus to
prevent noise from undriven line to be interpreted as data.
3.3 Wiring (general)
To ensure proper function:
Tightening torque, allowable wire size and type, for the Field-Wiring Terminals:
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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 the length is more than
3 m.
For Mains(Bus) Voltage, Generator Voltage a Current terminals
o Specified tightening torque is 0,56Nm (5,0 In-lb)
o Use only diameter 2,0-0,5mm (12-26AWG) conductor, rated for 90°C
minimum.
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For other controller field wiring terminals
Binary outputs
Battery 24V DC
- +
IM-NT
IM-NT-BB
or
IM-NTC-BB
Extension module
T1A or T2A
T2A
T1A
o Specified tightening torque 0,79Nm (7,0 In-lb)
o Use only diameter 2,0-0,5mm (12-26AWG) conductor, rated for
75°C minimum.
o Use copper conductors only.
3.4 Grounding (general)
The shortest possible piece of wire should be used for controller grounding. Use cable min. 2.5 mm2.
A brass M4x10 screw with star washer securing ring type grounding terminal shall be used.
The negative “-” battery terminal must be properly grounded.
Switchboard and engine must be grounded at a common point. Use as short a cable as
possible to the grounding point.
3.5 Power supply (general)
To ensure proper function:
Use power supply cable min. 2,5mm2
Use fuse
o 1 amp for IM-NT
o 2 amps for IM-NT-BB or IM-NTC-BB
Maximal continuous DC power supply voltage is 36VDC.
CAUTION!
Switchboard lightning strikes protection according standard regulation is expected!!!
The maximum allowable current through the controller negative terminal is 3 to 8A (depends on the
controller type and binary output load).
HINT
For more information on technical data regarding supply, inputs, outputs etc. please refer to
IGS-NT-Instalation Guide.
3.6 Power supply fusing (general)
Always use according fuse (1Amp or 2Amps) when
connection controller, extension modules or relays to
a power source.
See the diagram for proper fusing.
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3.7 Voltage and current inputs (general)
A) B)
L1
L2
L3
N
N L3L2L1
MAINS
N L3L2L1
BUS
L1
L2
L3
N L3L2L1
MAINS
N L3L2L1
BUS
A) B)
K
L
k
l
K
L
k
l
K
L
k
l
I1k I1l I2k I2l I3k I3l
K
L
k
l
K
L
k
l
I1k I1l I2k I2l I3k I3l
WARNING!
Risk of personal injury due to electric shock when manipulating voltage terminals under voltage! Be
sure the terminals are not under voltage before touching them.
WARNING!
Do not open the secondary circuit of current transformers when the primary circuit is closed!!! Open
the primary circuit first!
Use 1.5 mm2 cables for voltage connection and 2.5 mm2 for current transformers connection.
Adjust nominal voltage, nominal current, CT ratio and PT ratio by appropriate setpoints in the Basic
Settings group.
VOLTAGE MEASUREMENT WIRING
CURRENT MEASUREMENT WIRING
CAUTION!
Check measurement connections carefully! Failure is possible if phases are connected in wrong order
(WrongPhSequence detected by the controller) but this is not detected if the phases are just rotated
(i.e. instead of phase sequence L1, L2, L3, phase sequence is e.g. L2, L3, L1.
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3.8 Binary Input wiring (general)
IM-NT-BB IM-NT
This portion of Instalation instructions is dedicated to the
InteliMains-NT-GC controller with built-in display. If you have
BaseBox type of the controller (without the built-in display), please
refer to the section 3.8.2.
Controller
Battery 24V
DC
+ -
Controller
Battery 24V
DC
+ -
+PWR BOUT
Battery 24V
DC
+ -
Controller
Internal
4k7
To microprocessor
Use min. 1 mm2 cables for wiring of binary inputs.
NOTE:
The name and function or alarm type for each binary input have to
be assigned during the configuration. Binary inputs may be used in
built-in PLC as well. Please refer to the manual of GenConfig for
more information.
It is recommended to use separation diodes when multiple binary
input terminals are connected together to prevent unwanted
activation of binary input when one of the controllers is switched off.
3.9 Binary Output wiring
3.9.1 IM-NT
Correct wiring for Binary output is shown in the diagram below. On the left +PWR BOUT is not used,
on the right +PWR BOUT is used. If Binary outputs are connected directly to the power source,
additional fuse should be used.
NOTE:
If +PWR BOUT is used, it increases power consumption of the controller.
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3.9.2 IM-NT-BB and IM-NTC-BB
This portion of Instalation instructions is dedicated to the
InteliMains-NT-BaseBox and InteliMains-NTC-BaseBox
controllers without built-in display. If you have version with built-in
display of the controller, please refer to the section 3.8.1.
Binary outputs
+ -
BO1
Battery 24V
DC
+ -
From
microprocessor
Internal
Binary outputs
+ -
BO1
Battery 24V
DC
+ -
From
microprocessor
Internal
It is possible to use binary outputs as low side switch or high side switch in BaseBox type of controller.
For correct wiring in both cases please refer to the following diagrams.
Low side switch High side switch
CAUTION!
Both power supply sockets for binary outputs need to be connected to ensure proper function of binary
outputs.
Never use DC relays without protection diods!
Low side or High side function of binary outputs can be chosen in configuration tool GenConfig in
Modules tab. This configuration is used for all binary inputs available on the controller.
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3.10 Analog Input and Output wiring
This portion of Instalation instructions is dedicated to the
InteliMains-NT-BaseBox and InteliMains-NTC-BaseBox
controllers without built-in display. Analog inputs and output are not
available in InteliMains-NT-GC.
Resistive sensor on Analog input 3 and Analog
output wiring
Battery 24V
DC
+ -
AI3
AI COM
Internal
AOUT
COM
AOUT +
Resistive sensor with grounding on Analog input
3 and Analog output wiring. Note, that battery
should be also grounded to common ground
in all cases!
Battery 24V
DC
+ -
AI3
AI COM
Internal
AOUT
COM
AOUT +
HINT
For more information on technical data regarding supply, inputs, outputs etc. please refer to
For jumper setting of Analog inputs please refer to the section 3.2.4 Jumper settings.
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Passive Current sensor on Analog input 3 and
Active Current sensor on ANalog input 2
Battery 24V
DC
+ -
AI3
AI COM
Internal
AOUT
COM
AOUT +
AI2
Voltage sensors on Analog input 1 and 3
Battery 24V
DC
+ -
AI3
AI COM
Internal
AOUT
COM
AOUT +
AI1
10K
10K
Tristate sensor (binary sensor with fail detection)
on Analog input 3
Below 750Ω = Inactive
Between 750Ω and 2400Ω = Active
Below 10 Ω or Over 2400Ω = sensor failure
(wire shorted or interrupted)
Battery 24V
DC
+ -
AI3
AI COM
Internal
AOUT
COM
AOUT +
P
100R
1k5
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3.11 CAN and RS485 bus wiring
Cable type
Shielded twisted pair
Impedance
120 Ω
Propagation velocity
75% (delay 4.4 ns/m)
Wire crosscut
0.25 mm2
Attenuation (@1MHz)
2dB/100 m
The wiring of the CAN bus communication should be provided in such a way that the following rules
are observed:
The maximum length of the CAN bus depends on the communication speed. For a speed of
250 kbps, which is used on the CAN1 bus (extension modules, ECU) and CAN2 bus if it is
switched to 32C mode, the maximum length is 200 m. If the CAN2 bus is switched to 8C mode
the speed is 50 kbps and the maximum length is 800 m.
The maximum length of the RS485 bus is 1000 m
The bus (CAN and RS485) must be wired in linear form with termination resistors at both
ends. No nodes are allowed except on the controller terminals.
NOTE:
A termination resistors at the CAN and RS485 are already implemented on the PCB. For
connecting, close the jumper near the appropriate CAN or RS485 terminal. For more
information on jumper settings please refer to the section 3.1.4 Jumper setting.
Use a cable with following parameters:
CAN AND RS485 BUS TOPOLOGY
NOTE:
See the website www.can-cia.org for information about the CAN bus, specifications, etc.
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3.11.1 Wiring examples
1. For shorter distances (all network components within one room) – picture 1
interconnect A and B; shielding connect to PE on controller side
2. For longer distances (connection between rooms within one building) – picture 2
interconnect A, B, COM; shielding connect to PE at one point
3. In case of surge hazard (connection out of building in case of storm etc.) – picture 3
We recommend using the following protections:
Phoenix Contact (http://www.phoenixcontact.com): PT 5-HF-5DC-ST with PT2x2-BE
(base element)(or MT-RS485-TTL)
Saltek (http://www.saltek.cz): DM-006/2 R DJ
Recommended data cables: BELDEN (http://www.belden.com)
1. For shorter distances: 3105A Paired – EIA Industrial RS-485 PLTC/CM (1x2 conductors)
2. For shorter distances: 3105A Paired – EIA Industrial RS-485 PLTC/CM (1x2 conductors)
3. In case of surge hazard: 3106A Paired – EIA Industrial RS-485 PLTC/CM (1x2+1 conductors)
PICTURE 1 – SHORTER DISTANCES (ALL NETWORK COMPONENTS WITHIN ONE ROOM)
PICTURE 2 – LONGER DISTANCES (CONNECTION BETWEEN ROOMS WITHIN ONE BUILDING)
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PICTURE 3 – SURGE HAZARD (CONNECTION OUT OF BUILDING IN CASE OF STORM ETC.)
3.12 Extension modules (general)
For detailed description of several available extension modules for InteliMainsNT please refer to the
IGS-NT-Instalation Guide.
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4 Putting it into operation
GenConfig
InteliMonitor
In this section brief introduction how to
connect to a controller,
modify various settings,
program controller and reprogram non-responsive controller,
manage passwords and password protections and
operate related tools (ScreenEditor, PLC Editor etc.)
is presented.
4.1 Connection to a controller using PC
There are several available ways to connect to controller using PC for monitoring, control or
configuration/programming. For more information on related PC tools please refer to the section
2.2 Configurability and monitoring.
4.1.1 Direct connection
A direct connection can be realized by RS232 connection or USB connection (available on NTC
BaseBox only). Figures below illustrate the connection setting in GenConfig and InteliMonitor.
Select according COM port, adjust CAN address and enter password (optional for locked
configuration).
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4.1.2 Modem connection
GenConfig
InteliMonitor
A modem connection can be realized by suitable modem connected to the controller. Figures below
illustrate the connection setting in GenConfig and InteliMonitor.
Select connected modem, adjust Phone number and enter CAN address and enter correct
Access Code for remote connection. Enter password (optional for locked configuration).
It is possible to adjust number of rings before the controller accepts the connection from modem – use
Comms settings:NumberRings AA.
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4.1.3 Internet connection
GenConfig
InteliMonitor
Internet (Ethernet) connection can be used directly in NTC BaseBox version of the controller. For
connection to other versions, use IntenetBridge-NT device. Figures below illustrate the connection
setting in GenConfig and InteliMonitor.
Adjust IP address of the controller (InternetBridge) you want to connect to. Select CAN address of the
controller. Enter Access Code for remote connection. Enter password (optional for locked
configuration).
NOTE:
The controller must have public IP address or it must be reachable for connection in the specific
network.
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4.1.4 Airgate connection
GenConfig
InteliMonitor
AirGate connection can be used directly in NTC BaseBox version of the controller. For connection to
other versions, use IntenetBridge-NT device. Figures below illustrate the connection setting in
GenConfig and InteliMonitor.
Enter AirGate address of a server with AirGate service (currently airgate.comap.cz). Select CAN
address of the controller you want to connect to. Enter AirGate ID of the controller (InternetBridge) you
want to connect to (AirGate ID is assigned automatically if the controller is properly connected to the
Internet and corresponding AirGate setting is enabled. You can find AirGate ID in controller values.).
Enter Access Code for remote connection. Enter password (optional for locked configuration).
NOTE:
What is AirGate service? AirGate is a service provided for free by
ComAp which allows users to connect to controllers even though they
are not assigned public IP address or if there are behind corporate
firewalls. Controller connects to the AirGate server (secure and fast
server located in Central Europe) and obtains AirGate ID (used in the
connection, see above). Then it communicates with the server on a
secure line and any user that know AirGate ID and access code for
that particular controller can connect from anywhere (Internet access
needed) to the controller and monitor and control it.
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4.1.5 Connection to multiple controllers
Direct multiple connection
Internet multiple connection (use Internet Bridges IPs for connection to NTC BaseBox
controllers as well
Airgate multiple connection (fill in AirGate IDs for each controller, when using InternetBridge
fill in InternetBridge AirGate ID for each controller)
Connection to multiple controller is available in InteliMonitor. It is possible to connect to multiple
controller using Direct connection to I-LB+, using Internet connection to NTC BaseBox controllers or to
InternetBridge, using modem connection capable of multiple connections or AirGate connection to
multiple NTC BaseBox controllers or to IntenetBridge.
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4.2 Modification of configuration, setpoints etc.
For full configuration of controller configuration use GenConfig. You may open archive prepared for
specific application and upload it to the controller. You may also change:
Controller type (Modules tab)
Extension modules (Modules tab)
Binary Input and Output logical functions and protections (I/O tab)
Analog input sensor type, logical functions and protections (I/O tab)
Analog output function, conversion, normalization, resolution (I/O tab)
Setpoints and password level for particular setpoint (Setpoints tab)
Commands password protection (Commands tab)
Prepare custom protections (Protections tab)
Modify History data selection (History tab)
Prepare custom user sensor characteristics (User Sensor tab)
Modify languages settings (Languages tab)
Translate corresponding names to other language prepared in Languages tab (Translator tab)
Prepare complex logical functions with built-in PLC functions (PLC Editor tab)
Modify screens for InteliVision 5 and 8 (Screen Editor tab)
Review and modify assigned logical binary functions (LBI tab)
Review and modify assigned logical analog functions (LAI tab)
Select power format, rename Pulse counters and Remote switches (Miscellaneous tab)
CAUTION!
Do not forget that changes in GenConfig are not sent to the controller unless you write them to the
controller.
In InteliMonitor it is possible to configure:
Setpoints (multiple setpoint configuration in several controllers at once)
Set/Reset statistics
Administrate users and their rights
CAUTION!
Do not forget that all changes in InteliMonitor are sent to the connected controller and controller
immediately acts on it. Do not change CAN address of the controller or connection is lost and need to
be re-established with new CAN address.
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4.3 Programming of a controller
4.3.1 Standard programming
For programming GenConfig is used. Select correct connection mode and then select the following
option:
You may use “FW upgrade (from default configuration)” (this will overwrite all of the settings in the
controller with default settings. If you need to upgrade firmware from existing configuration, select “FW
upgrade (from existing configuration)”. This function will automatically open wizard which will help you
update the existing configuration to be compatible with the newly selected firmware.
4.3.2 Programming of non-responsive controller
If the controller does not contain valid firmware, new firmware cannot be programmed in the standard
way. This situation can occur if the connection between the PC and the controller was interrupted e.g.
during a previous firmware upgrade. In such case the controller may have a blank display or
connection to InteliVision may not be established and it does not communicate with the PC. The bootjumper must be used to get valid firmware into the controller.
Connect proper cable for programming (use RS232 port).
Open GenConfig and select “FW upgrade (default configuration)”
From the following table select FW that is required or click open and browse your files to find
firmware in non-default location
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Click OK
Wait until the connection times out and following dialog appears
Follow the instructions and then click OK (information regarding the location of boot jumper
can be found in section 3.1.4 (IM-NT-GC) or 3.2.4 (IM-NT-BB and IM-NTC-BB)
Programming starts momentarily
When the programming is done following dialog appears
Follow the instructions and press OK. Following diagram will appear and programming is done
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Additional dialog warns you that the setpoints may have improper values. Change the
configuration in normal way.
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4.4 Changing the language
This portion of instructions is dedicated to the InteliMains-NT-GC
controller with built-in display. If you have BaseBox type of the
controller (without the built-in display), please refer to the section
4.4.2.
This portion of instructions is dedicated to the InteliMains-NT-
BaseBox and InteliMains-NTC-BaseBox controllers without built-in
display. If you have version with built-in display of the controller,
please refer to the section 4.4.2.
There is step-by-step guide in GenConfig help available for the Languages and Translator tabs which
contains all the information on how to prepare new languages in the configuration (press F1 in
Languages or Translator tab or go to Help->GenConfig Help and locate corresponding chapters).
4.4.1 Selection of the language in InteliMains-NT GC
Selection of the language can be either done by Binary Input selection (please refer to the section
Functions description) or by selecting the language through the menu of built-in display. To select the
language go to main menu and scroll down. Select “Languages” by pressing Enter. There is complete
selection of languages configured in the controller. Using arrows select the preferred language and
press Enter to confirm. Display reboots (controller itself remains fully functional) and new language is
used.
HINT
If you need to use graphical language you may need to upload correct set of characters into the
controller. By default Chinese character set is uploaded in the controller. If you need to use for
example Korean characters (Hangul), in GenConfig select following menu while connected to the
controller: File -> Firmware upgrade and Cloning -> Display GC font change / FW upgrade. GenConfig
connects to the controller and new fonts may be uploaded to the controller as well as new firmware for
the built-in display.
NOTE
If you are using InteliVision 5, InteliVision 8 or InteliVision 17 Touch with the GC type of the controller
please refer also to the chapter 4.4.2 for more information on how to change language in the
InteliVision.
4.4.2 Selection of the language in InteliMains-NT(C)-BaseBox
If using BaseBox version of the controller you may use InteliVision 5, InteliVision 8 or InteliVision 17
Touch. If you need to use for some reason IG or IS-Display please refer to the chapter 4.4.1 for the
instructions regarding built-in display which works the same as the external displays.
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For InteliVision 5 an 8 go to main menu and select Help/Others and Languages. Scroll up and down
and select preferred langugue. Confirm by pressing enter.
If you are using InteliVision 17, it is running standard InteliMonitor software. Please refer to the manual
of InteliMonitor how to change fonts in InteliMonitor and in custom SCADA.
HINT
If you need to use graphical language you may need to upload correct set of characters into the
InteliVision via controller. By default Chinese character set is uploaded in the controller. If you need to
use for example Korean characters (Hangul), in GenConfig select following menu while connected to
the controller: File -> Firmware upgrade and Cloning -> Display GC font change / FW upgrade.
GenConfig connects to the controller and new fonts may be uploaded to the controller as well as new
firmware for the built-in display.
4.5 Password management
Password management requires InteliMonitor for user names, passwords and rights modification. It
also requires GenConfig for assigning corresponding setpoints and command to correct right groups.
4.5.1 User administration
User administration is available only when logged in as an
Administrator. Once logged in select “Admin users…” as shown on
the right.
Following dialog is displayed:
Enable or disable users. Change user names and by double clicking change the access groups that
are accessible by particular user. Hold CTRL and click separate access groups to select only several
of them with no access to lower groups.
Log in as a different user to change password for that particular user.
NOTE:
Newly enabled user has always default password “0”.
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4.5.2 Access group setting in GenConfig
To assign particular setpoint to access group use the following function in GenConfig (by clicking
select the correct access group).
NOTE:
Each setpoint may be assigned to only one access group. This setpoint can be changed by all users
with activated corresponding access rights.
To assign particular command to access group use the following function in GenConfig (by clicking
select the correct access group).
NOTE:
Each command may be assigned to only one access group. This command can be used by all users
with activated corresponding access rights.
4.5.3 Password break protection
Password break protection (PBP) can be adjusted to ENABLED or DISABLE by a tick box in
password management in InteliMonitor (see the figure below). Default value is ENABLED.
Warning “PassInsertBlck” is displayed in alarm list during the blocking period.
Controller does not accept attempts to insert correct or incorrect password during the blocking
period. In case of this attempt there is a message displayed in InteliMonitor, GenConfig and
InteliVision 5 and 8 which states the remaining time of blocking.
Controller is blocked for 5 minutes if there were 6 attempts to insert incorrect password. In case of
another six failed attempts (after the period of blocking elapses) the blocking period is 30, 60, 120 and
240 minutes long respectively.
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History record “Incorrect password” is written after the 6
th
failed attempt to enter password (i.e. this
record is written once the PBP is activated). During the blocking no history records of inserting
incorrect or correct password are written.
Entering of passwords during the blocking period does not prolong the blocking period (passwords are
not actually entered because they are rejected by the controller at all).
When the controller is switched OFF and ON again (i.e. power down and up again) during the blocking
period, the blocking period is reset back to the full length of currently active PBP (e.g. if there is 24
minutes remaining out of 30 minutes after the controller reset there will be again 30 minutes
remaining).
After the correct password is inserted the PBP blocking period for next 6 failed attempts is reverted
back to 5 minutes.
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4.6 Related tools
There are two tools available for user regarding the configuration of the controller:
Screen Editor – it can be used to modify screens in InteliVision 5 and 8
PLC Editor – it can be used to create and modify built-in PLC functions
HINT
For more information on Screen Editor use help in GenConfig (Help -> Screen Editor Help).
For more information on PLC Editor use GenConfig Reference Guide.
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5 Operator guide
This portion of instructions is dedicated to the InteliMains-NT-GC
controller with built-in display. If you have BaseBox type of the
controller (without the built-in display) or you are using also
InteliVision with InteliMains-NT -GC, please refer to the section 5.2.
This portion of instructions is dedicated to the all
three types of controller with connected InteliVision
5 or 8. If you have InteliMains-NT-GC and you are
not using InteliVision 5 or 8 please refer to the
section 5.1.
5.1 IM-NT
For extensive information regarding operator control use operator guide for IM-NT.
5.2 Systems with InteliVision displays
For extensive information regarding operator control use operator guide for IGS-NT since general
functions of InteliVision displays are the same for InteliGen, InteliSys and InteliMains.
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6 Firmware and Archives
InteliMains-NT-BaseBox and InteliMains-NTC-BaseBox
InteliMains-NT-GC
Since the version 3.0, controller firmware was differentiated for BaseBox type controllers and GC
(Graphical Character, with built-in display) controllers. These firmwares are compatible but their
functions differ slightly. It is not possible to upload BaseBox type firmware to GC controller and vice
versa.
6.1 BaseBox type controllers
The firmware for these controllers has specific functions available which are not available in Graphical
Character type controllers. The list of BaseBox-exclusive function is as follows:
Peak Shaving based on kVA
Distributed Binary Inputs and Outputs
User MODBUS
6.2 Graphical Character type controllers
The firmware for GC controllers do not support functions described above, although it can still be used
in combination with BaseBox type controllers.
NOTE:
It is possible to use specialized InteliMains-NT firmware for InteliSys controllers. This firmware
supports all the functions mentioned above.
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7 Function description
FUNCTION NAME
(ALPHABETICAL
ORDER)
BRIEF DESCRIPTION
RELATED SETPOINTS, INPUTS AND
OUTPUTS
Access locking
from various
sources
There are vast options regarding
access restrictions in the controller. It
is possible to lock:
Buttons for various commands
on the terminal.
External buttons for various
commands on binary inputs.
Built-in terminal or terminal #1 to
monitoring mode only.
External local terminal or
terminal #2 to monitoring mode
only.
All external remote terminals (PC
connection, displays on all buses
except on RS485 dedicated
port).
Local buttons
ACCESSLOCK INT
ACCESSLOCK D#2
ACCESSLOCK D#3
ACCESSLOCK EXT
FAULTRESBUTTON
HORNRESBUTTON
STOPBUTTON
STARTBUTTON
MCBBUTTON
MGCBBUTTON
Active call,
emailing and
SMS service
AA
This function allows user to choose
under which conditions active emailing
happens, what is the type of the
message and separate addresses or
numbers. Learn more about these
functions in a separate chapter.
History record
Alarm only
Warning
Mains protect
MainsP w/Reset
AcallCH1-Type
AcallCH2-Type
AcallCH3-Type
AcallCH4-Type
AcallCH5-Type
AcallCH1-Addr
AcallCH2-Addr
AcallCH3-Addr
AcallCH4-Addr
AcallCH5-Addr
ActCallAttempt
Acall+SMS lang
ISSUEACTCALLC1
ISSUEACTCALLC2
ISSUEACTCALLC3
ISSUEACTCALLC4
ISSUEACTCALLC5
SMTP authent
SMTP user name
SMTP password
SMTP address
Contr mailbox
Time zone
Alternative
brightness for
built-in
InteliGen
display.
It is possible to choose two different
levels of brightness and switch them with
logical binary input.
Alt brightness
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7.1 Overview
HINT
There are numerous built-in functions in the controller that can be modified or combined to produce
new functions for specific uses. Note that it is not possible to describe all the combinations or
modifications in detail in this manual. Users are encouraged to find new way of how to use existing
functions to their benefit.
Click this symbol at the functions for more information on particular complex function.
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FUNCTION NAME
(ALPHABETICAL
ORDER)
BRIEF DESCRIPTION
RELATED SETPOINTS, INPUTS AND
OUTPUTS
Automatic CAN
address
assignement
It is possible to leave the assignement of
CAN addresses on controllers
themselves. If the function is activated
controllers will look for possible collisions
of CAN bus communication and they will
change their addresses accordingly. This
function need to be activated or
deactivated in all controllers on CAN bus.
It is available only in some applications.
CANnegotiation
Automatic
display
backlight
timeout
It is possible to adjust timeout for
backlight of built-in display of the
controller. When using InteliVision
display the backlight timeout is adjusted
separately in the the display.
DispBaklightTO
Automatic
Mains Failure
function
AA
This is a complex function that ensures
correct reaction of the system to detected
Mains Failure. For more information
please refer to a separate chapter.
MFStart enable
EmergStart del
FwRet break
MCB close del
MCB opens on
ReturnWithIntr
BreakerOverlap
RetFromIsland
ReturnTo mains
Mains ret del
MGCB Close del
Automatic
synchronization
AA
Controller automatically performs
synchronization sequence including
corresponding regulations to achieve
correct phase and voltage on both
synchronized sides. It possible to set
phase shift caused by transformers to be
taken into acount during synchronization.
Synchronization automatically closes
corresponding breaker if the voltages on
both sides do not differ more than
Voltage window and their phases do not
differ more than Phase window for time
equal to Dwell time. For regulation loops
functions please refer to a separate
chapter.
Voltage window
BtoM AngleReq
Phase window
Dwell time
Sync timeout
FORWARDSYNCHRO
REVERSESYNCHRO
IN SYNCHRONISM
Basic Voltage
and Current
settings
AA
In the controller there are many
parameters that are used for entering of
nominal values of Mains and Bus
characteristics. It also allows users to set
measurement transformers ratio and
select range of voltage measurement. All
of these parameters are crucial for the
right function of the controlle since
regulations, protections and other
function are directly dependant of these
settings. For additional information on
protections please refer to separate
chapter Protections and Alarm
Management.
Vm VT ratio
Vm InpRangeSel
Bus VT ratio
BusInpRangeSel
MainsNomV
MainsNomVph-ph
BusNomV
BusNomVph-ph
Nomin current
NominMainsImp
MainsCTprim
MainsCTsec
AuxCurrCTprim
AuxCurrCTsec
Nominal freq
Nom frq offset
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FUNCTION NAME
(ALPHABETICAL
ORDER)
BRIEF DESCRIPTION
RELATED SETPOINTS, INPUTS AND
OUTPUTS
CAN bus
communication
mode
It is possible to change speed of
communication on CAN2 bus
(Intercontroller and Monitoring) to lower
(longer distance, limited to 8 controllers)
or to higher (shorter distance, limited to
32 controllers).
CAN bus mode
Circuit Breaker
control
AA
Circuit Breaker control depends on many
various parameters. Please refer to a
separate chapter.
MCB CLOSE/OPEN
MCB ON COIL
MCB OFF COIL
MCB UV COIL
MCB STATUS
MGCB CLOSE/OPEN
MGCB ON COIL
MGCB OFF COIL
MGCB UV COIL
MGCB STATUS
Circuit breaker
feedback
sensing
AA
Lear more about circuit breaker feedback
sensing in a separate chapter.
MGCB FEEDBACK
MGCB FDB NEG
MCB FEEDBACK
MCB FDB NEG
Communication
log in controller
history
It is possible to log communication
events into the controller history (e.g.
opened new communication,
communication closed etc.).
LB/UART Log
Controller
modes of
operation
AA
Controller can be switched to several
modes of operation. It is possible to
switch modes using buttons on terminal,
using buttons in InteliMonitor, changing
of a setpoint or activation of binary inputs
for remote change of the mode of
operation. For more information on
modes of operation please refer to a
separate chapter.
ControllerMode
REMOTE OFF
REMOTE MAN
REMOTE AUT
REMOTE TEST
OFF MODE
MAN MODE
AUT MODE
TEST MODE
Controller
Redundancy
AA
It is possible to use redundant controller
which is in monitoring mode only unless
the primary controller fails. This is a
complex function and it is described in a
separate chapter.
Watched Contr
CTRLHEARTBEAT
CTRLHBEAT FD
EMERG. MANUAL
CTRLHBEAT SENS
Detection of
communication
error of
peripheral
modules
Controller detects any problems in
communication with extension modules
(it is possible to adjust corresponding
level of protection in GenConfig) and
issues alarm based on it.
PeriphCommErr
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FUNCTION NAME
(ALPHABETICAL
ORDER)
BRIEF DESCRIPTION
RELATED SETPOINTS, INPUTS AND
OUTPUTS
Detection of
empty CAN bus
This function can be used to detect failed
communication via CAN2 bus. If no other
controllers are found on CAN2 bus,
alarm is issued.
CAN2emptDetect
Disable Circuit
breaker
function
It is possible to disable one or both
breakers via InteliMains. Disabled circuit
breaker opens (if previously closed) and
InteliMains keeps it open under any
conditions.
MGCB DISABLE
MCB DISABLE
MGCB OPEN
Evaluation of
CAN2
communication
collision
Controller automatically detects possible
collisions on CAN2 bus (e.g. same
shared binary outputs are broadcasted
by two controllers on one CAN bus).
SHxOcol detect
External values
available for
repeated writing
AA
It is not possible to repeatedly write
setpoints from external device (although
it is possible to repeatedly force different
values or continuously changing values
into setpoint because forced value is not
stored in the memory) because of
possible memory damage. If continuous
writing of some value into a setpoint from
external device is needed, External
values should be used and their value
should be subsequently forced to the
setpoint for safe operation. For detailed
guide to the usage of external value
please refer to a separate chapter.
ExtValue1deflt
ExtValue2deflt
ExtValue3deflt
ExtValue4deflt
ExtValue1LoLim
ExtValue2LoLim
ExtValue3LoLim
ExtValue4LoLim
ExtValue1HiLim
ExtValue2HiLim
ExtValue3HiLim
ExtValue4HiLim
ExtValue1 rate
ExtValue2 rate
ExtValue3 rate
ExtValue4 rate
EXTVALUE1 UP
EXTVALUE2 UP
EXTVALUE3 UP
EXTVALUE4 UP
EXTVALUE1 DOWN
EXTVALUE2 DOWN
EXTVALUE3 DOWN
EXTVALUE4 DOWN
EXTVALUE1RESET
EXTVALUE2RESET
EXTVALUE3RESET
EXTVALUE4RESET
Forcing of a
value to the
setpoint
AA
It is possible to force up to 16 different
values to one setpoint to change various
functions of the controller. Any suitable
setpoint or value can be forced into the
setpoint provided that this setpoint is
forcable. There are 16 Force value
setpoints designed just for forcing (if
correct value for forcing is not available
in any other setpoint or value). For
detailed step-by-step instruction on how
to use value forcing please refer to a
separate chapter.
Force value 1
Force value 2
Force value 3
Force value 4
Force value 5
Force value 6
Force value 7
Force value 8
Force value 9
Force value 10
Force value 11
Force value 12
Force value 13
Force value 14
Force value 15
Force value 16
FORCEVALUEIN 1
FORCEVALUEIN 2
FORCEVALUEIN 3
FORCEVALUEIN 4
FORCEVALUEIN 5
FORCEVALUEIN 6
FORCEVALUEIN 7
FORCEVALUEIN 8
FORCEVALUEIN 9
FORCEVALUEIN 10
FORCEVALUEIN 11
FORCEVALUEIN 12
FORCEVALUEIN 13
FORCEVALUEIN 14
FORCEVALUEIN 15
FORCEVALUEIN 16
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FUNCTION NAME
(ALPHABETICAL
ORDER)
BRIEF DESCRIPTION
RELATED SETPOINTS, INPUTS AND
OUTPUTS
Group Link
function for
complex
installations
(Bus Tie
Breaker)
AA
Group Link function enables ComAp
controllers to work independently or
together dependent on the state of a Bus
Tie Breaker. For more information refer
to the chapter Power management.
GROUPLINK
Control group
GroupLinkLeft
GroupLinkRight
History related
functions
AA
It is possible to modify history records
layout and set periodic time stamping in
history. Controller has adjustable time
and date setpoints (time is update each
second) and there is inbuilt summer time
mode function. Read about history layout
modification in separate chapter.
Time stamp act
Time Stamp Per
#SummerTimeMod
#Time
#Date
TIME STAMP ACT
Internet related
communication
functions
AA
It is possible to connect controllers to
Internet. AirGate function is also
available when Internet connection is
established. Active emails may be sent
upon various reasons. For more
information on these functions please
refer to a separate chapter.
IP Addr mode
IP address
Net mask
Gateway IP
ComApProtoPort
AirGate
AirGate IP
DNS IP
NumberRings AA
Language
selection
InteliMains can change language in its
built-in display as well as in attached
displayes by activation of binary inputs.
LANG SEL INT A
LANG SEL INT B
LANG SEL INT C
LANG SEL D#2 A
LANG SEL D#2 B
LANG SEL D#2 C
LANG SEL D#3 A
LANG SEL D#3 B
LANG SEL D#3 C
Load shedding
function
AA
Complex load shedding and
reconnection function is available in the
controller. It is described in the separate
chapter.
Ld shed active
LdShedBased on
Ld shed mode
Ld shedStages
Ld shedLevel1
Ld shedLevel2
Ld shedLevel3
Ld shed f lvl1
Ld shed f lvl2
Ld shed f lvl3
Ld shedDelay1
Ld shedDelay2
Ld shedDelay3
Ld reconLevel1
Ld reconLevel2
Ld reconLevel3
LdRecon f lvl1
LdRecon f lvl2
LdRecon f lvl3
Ld reconDelay1
Ld reconDelay2
Ld reconDelay3
AutoLd recon
LDSHED STAGE 1
LDSHED STAGE 2
LDSHED STAGE 3
MANUALLDRECON
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FUNCTION NAME
(ALPHABETICAL
ORDER)
BRIEF DESCRIPTION
RELATED SETPOINTS, INPUTS AND
OUTPUTS
Mains Coupling
This function defines if Mains Coupling is
enabled via controller breakers. It should
be enabled only if two or more Mains
incommers are in phase and it is allowed
by local authorities.
Mains coupling
Measurement of
P and Q
selection
You may select the source of Mains
current measurement or disable this
measurement.
I/E-Pm meas
I/E-Qm meas
MLC:I/E-PM
MPF:I/E-QM
Minimum
required power
in parallel to
Mains operation
This function sets minimal power
produced by gen-set group in parallel to
Mains operation in % of nominal power of
each gen-set regardless of Import/Export
limit. This function is active only if
InteliMains plays active role in load
sharing.
Min Power PtM
Modbus
switches
AA
There are two Modbus registers
containing 16 bits each that can be easily
written using Modbus. Their values are
available in the form of a Value
(BINARY) and in the form of logical
binary ouputs that can be used further in
the configuration.
MODBUSSW1-32
ModbusSw1
ModbusSw2
Overheat
Protection
AA
This function is used to protect system
from overheating. If the temperature rises
above given limit, mode of load control is
changed to prevent overheating. When
temperature returns back the previous
mode of load control is restored. For
exact function of Temperature By Power
control see separate chapter System
Load Control.
Overheat prot
TempByPwr Treq
MLC:TBYPWR
Peak Shaving
function
AA
Peak Shaving function can be based on
active power (kW) or reactive power
(kVA). It is described in a separate
chapter.
PeakLevelStart
PeakLevelStop
PeakAutS/S del
Peak kVA Start
Peak kVA Stop
PeakKVAS/S del
Permanent
logical 0 or 1
outputs
It is possible to use permanent logical
binary function that is always logical 0 or
logical 1. It may used for various
purposes.
LOGICAL 0
LOGICAL 1
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FUNCTION NAME
(ALPHABETICAL
ORDER)
BRIEF DESCRIPTION
RELATED SETPOINTS, INPUTS AND
OUTPUTS
Power
Management
AA
Power management is a very complex
function with many settings that is used if
the gen-sets are in AUT mode of
operation (and other requirements are
fulfilled) to start and stop engines
accordingly to set parameters for more
efficient function of the system. Part of
Power Management consists of
automatic priority swapping for extended
efficiency of the system. For complete
information of all Power Management
function please refer to a separate
chapter.
#Pwr mgmt mode
#PriorAutoSwap
Priority ctrl
#SysAMFstrtDel
#SysAMFstopDel
LoadResStrt 1
LoadResStop 1
LoadResStrt 2
LoadResStop 2
LoadResStrt 3
LoadResStop 3
LoadResStrt 4
LoadResStop 4
%LdResStrt 1
%LdResStop 1
%LdResStrt 2
%LdResStop 2
%LdResStrt 3
%LdResStop 3
%LdResStrt 4
%LdResStop 4
NextStrt Del
OverldNext Del
NextStopDel
SlowStopDel
MinRunPower 1
MinRunPower 2
MinRunPower 3
RunHrsMaxDiff
PwrBandContr 1
PwrBandContr 2
PwrBandContr 3
PwrBandContr 4
PwrBnChngDlUp
PwrBnChngDlDn
LOAD RES 2
LOAD RES 3
LOAD RES 4
SYSTREADY
SYST RES OK
SYST RES 1 OK
SYST RES 2 OK
SYST RES 3 OK
SYST RES 4 OK
ALLAVAILGS RUN
ENGINES SWAPPED
Process
limitation
control
AA
This function is used to limit process (e.g.
parallel operation is not allowed). This
function is complex and it is described in
a separate chapter.
Island enable
ParallelEnable
Synchro enable
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FUNCTION NAME
(ALPHABETICAL
ORDER)
BRIEF DESCRIPTION
RELATED SETPOINTS, INPUTS AND
OUTPUTS
Protections
AA
Protections in the controller are very
complex function with many settings.
Please refer to a separate chapter for
more information about protection
functions in InteliMains.
Horn Timeout
BinInp delay 1
BinInp delay 2
BinInp delay 3
ForceBlockDel1
ForceBlockDel2
ForceBlockDel3
ResetActAlarms
Force block 1
Force block 2
Force block 3
VMAINS <>
VMAINS <>
FMAINS <>
FBUS <>
MAINS FAIL
BUS FAIL
VECTORSHIFTTRP
VMAINS <>
HORN
ALARM
HORN FLASHING
ALARM FLASHING
COMMON WRN
COMMON MPR
COMMON FLS
COMMON MP
COMMON AL
COMMON HST
COMMONACTLEV 1
COMMONALLEV 1
COMMONACTLEV 2
COMMONALLEV 2
Mns2POvrldProt
OverldStrtEval
2POvrldStEvDel
Mns2Inom prot
Mains2Inom del
Mains >V MP
Mains <V MP
Mains V del
Mains Avg>V MP
Mains >f
Mains <f
Mains f del
VectorS prot
VectorS CB sel
VectorS limit
ROCOF Win
ROCOF df/dt
Bus >V
Bus <V
Bus V del
Bus >f
Bus <f
Bus f del
BusMeasError
Pulse Counters
The controller offers up to 4 pulse
counters that can count incomming
pulses of at least 100 ms (high and low)
length with various conversion. The
counted value is stored in the controller
and can be displayed.
ConvCoefPulse1
ConvCoefPulse2
ConvCoefPulse3
ConvCoefPulse4
PULSECOUNTER 1
PULSECOUNTER 2
PULSECOUNTER 3
PULSECOUNTER 4
Regulation
functions
AA
There is whole variaty of regulation
functions in the controller. Please refer to
a separate chapter to find out more.
Freq gain
Freq int
Angle Gain
Load Ramp
Load gain
Load int
Voltage gain
Voltage Int
PF gain
PF int
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FUNCTION NAME
(ALPHABETICAL
ORDER)
BRIEF DESCRIPTION
RELATED SETPOINTS, INPUTS AND
OUTPUTS
Remote Control
Function
AA
This particular function enables user to
close or open binary output assigned to
RemoteControl function from
InteliMonitor or via Modbus commands.
For more information please refer to a
separate chapter.
REMOTECONTROL1
REMOTECONTROL2
REMOTECONTROL3
REMOTECONTROL4
REMOTECONTROL5
REMOTECONTROL6
REMOTECONTROL7
REMOTECONTROL8
Remote start
and stop of the
system
System controlled by InteliMains can be
started and stopped based on
activation/deactivation of binary input
Rem start/stop. Behavior of the system
then depends on load control mode,
power management, process control and
other factors.
REM START/STOP
RS232 and
RS485
communication
functions
The controller has several settings
regarding RS232 and RS485 functions. It
is possible to set mode of communication
on particular port, speed of
communication and AT commands for
modem connection.
RS232(1) mode
RS232(2) mode
RS232(1)MBCSpd
RS232(2)MBCSpd
RS232(1)MdmIni
RS232(2)MdmIni
RS485(1) conv.
RS485(2) conv.
Soft unloading
and Soft
unloading
based on
Auxiliary
measurement
AA
Soft unloading can be performed in the
standard way or it can be performed
based on actual current to the load or
through MGCB measurement to prevent
sudden overloading of gen-sets because
of other loads on bus. This function is
using Auxiliary current measurement to
ensure that soft unloading is performed
correctly in case of complex installations
(e.g. two Mains incommers).
Soft Unload
AuxCurrCTprim
AuxCurrCTsec
MGCB open lev
MGCB open del
Start Blocked
indication
The controller indicates blocked start of
the gen-set group based on process
limitation setpoints by activation of logical
binary output START BLOCKED (previously
it was indicated by alarm list message).
START BLOCKED
StartUpSynchro
nization
AA
StartUpSynchronization is now supported
in InteliMainsNT controllers.
MultiSoftStart
Synchronization
of separate gensets directly to
the Mains
voltage
This function enables or disables the
direct synchronization of each gen-set to
Mains voltage. This is beneficial for faster
system reaction time after startup.
Moreover, you can use this function to
distribute Mains voltage along bus even if
no gen-set is running.
MGCBparalClose
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FUNCTION NAME
(ALPHABETICAL
ORDER)
BRIEF DESCRIPTION
RELATED SETPOINTS, INPUTS AND
OUTPUTS
System Isolated
AA
There are two logical binary inputs that
can be used for secondary CB
feedbacks. When these binary inputs get
activated the corresponding breakers are
considered opened no matter what is the
position of feedbacks of MCB or MGCB.
MCBISOLATED
MGCBISOLATED
System Load
Control
AA
System Load is a complex function and it
is described in a separate chapter.
SysBaseLoad
SysPwrFactor
SysLdCtrl PtM
SysPFCtrl PtM
Import load
Import PF
MLoad ctrl PtM
PF ctrl PtM
Export limit
TempByPwr Treq
TempByPwr gain
TempByPwr int
MLC:ANEXSYSBLD
MLC:ANEXI/E
MLC:TBYPWR
MPF:ANEXI/E
System starting
impuls
AA
This is multipurpose starting impulse
which serves as a starting input for gen-
set controllers in the system.
SYS START/STOP
Switchable
Current
measurement
ratio
Using force value function on
MainsCTprim, the controller can
effectively switch the ratio of the current
measurement on the fly (if the
measurement transformers can switch
their amplification).
MainsCTprim
Test on load
and Test on
load with break
AA
InteliMains can perform controlled test on
load in TEST mode. For detailed
description of Test on load please refer
to a separate chapter.
TEST ON LOAD
Parallel enable
Synchro enable
Island enable
FwRet break
ReturnWithIntr
BreakerOverlap
RetFromIsland
ReturnTo Mains
Time
synchronization
and GPS
positioning with
InternetBridgeNT
InteliMains obtains data about precise
time and GPS position from
InternetBridge-NT-2.0 (and higher)
connected to the CAN. Time is
broadcasted to all the controllers on CAN
bus. Position is available for monitoring
and for WebSupervisor.
Latitude
Longitude
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FUNCTION NAME
(ALPHABETICAL
ORDER)
BRIEF DESCRIPTION
RELATED SETPOINTS, INPUTS AND
OUTPUTS
Timers
AA
Up to 16 timers are provided in the
controller (with 4 combined outputs).
They can be used to trigger various
internal functions as well as external
devices. Please refer to a separate
chapter for detailed information.
Timer channel 1
Timer channel 2
Timer channel 3
Timer channel 4
Timer channel 5
Timer channel 6
Timer channel 7
Timer channel 8
Timer channel 9
Timer channel 10
Timer channel 11
Timer channel 12
Timer channel 13
Timer channel 14
Timer channel 15
Timer channel 16
TIMERACT 1-4
TIMERACT 5-8
TIMERACT 9-12
TIMERACT 13-16
TIMERACTIVECOM
TIMER BLOCK 1
TIMER BLOCK 2
TIMER BLOCK 3
TIMER BLOCK 4
TIMER BLOCK 5
TIMER BLOCK 6
TIMER BLOCK 7
TIMER BLOCK 8
TIMER BLOCK 9
TIMER BLOCK 10
TIMER BLOCK 11
TIMER BLOCK 12
TIMER BLOCK 13
TIMER BLOCK 14
TIMER BLOCK 15
TIMER BLOCK 16
User Buttons
AA
It is possible to use up to 16 user
buttons. User buttons can be for example
assigned to software buttons in
InteliVision displays. Pressing of
corresponding button then activates the
output with function that is chosen in the
configuration. For more information on
how to use User Buttons please refer to
a separate chapter.
UserBtn pulse
USER BUTTON 1
USER BUTTON 2
USER BUTTON 3
USER BUTTON 4
USER BUTTON 5
USER BUTTON 6
USER BUTTON 7
USER BUTTON 8
USER BUTTON 9
USER BUTTON 10
USER BUTTON 11
USER BUTTON 12
USER BUTTON 13
USER BUTTON 14
USER BUTTON 15
USER BUTTON 16
User
Configurable
protections
AA
There are several prepared user
configurable protections in default
archive. Please refer to a separate
chapter for complex step-by-step
instructions on user configurable
protections.
Batt >V
Batt <V
Batt volt del
Mains I unbal
Mains Iunb del
Mains V unbal
Mains Vunb del
Bus V unbal
Bus Vunb del
User Mask
AA
It is possible to use four separate Logical
Binary Inputs to show or hide particular
objects in InteliVision 5 and 8. It is
possible to use these inputs to show
particular screens in InteliVision 5. For
more information on this function please
refer to the separate chapter.
USER MASK 1
USER MASK 2
USER MASK 3
USER MASK 4
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FUNCTION NAME
(ALPHABETICAL
ORDER)
BRIEF DESCRIPTION
RELATED SETPOINTS, INPUTS AND
OUTPUTS
User MODBUS
AA
Modbus registers (up to 128) can be
defined for every value and setpoint in
the controller. This can be used to
prevent shift of Modbus numbers, to
standardize Modbus communication for
several applications or to make Batch
reading and writing much more user
friendly. For more information on Modbus
please refer to the Communication Guide
or to the context help in GenConfig.
Variable
connection of
devices on CAN
bus
It is possible to select number and type
of devices connected on CAN2 bus
(MODEM: I-LB+ or OTHER: InteliVision,
I-RD). CAN addresses 123 and 124 are
always dedicated to connection of
OTHER devices (e.g. InteliVision 5
CAN). Using two setpoints dedicated to
this function, it is possible to choose if
addresses 122 and 125 are used for
communication by OTHER devices or in
MODEM mode (i.e. prepared for I-LB+ or
IB-NT connection).
CANAddrSwitch1
CANAddrSwitch2
Voltage
protections
mode Ph-N or
Ph-Ph
AA
In the controller it is possible to select
whether fixed protections are based on
measured Ph-N voltage or on measured
Ph-Ph voltage. For more information of
fixed protections please refer to the
separate chapter Protections and Alarm
management.
FixVoltProtSelect
Wrong Phases
sequence
Controller automatically detects if phases
measurement is connected in wrong
sequence (note that the wrong sequence
is not detected if the phases are just
rotated, i.e. L2-L3-L1)
WRONGPHSEQ
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7.2 Modes
7.2.1 OFF mode
InteliMains NT has no influence at gen-set group.
If mains voltage is within limits and no mains alarm is active, MCB is closed after
AMF settings:MCB close del if AMF settings:MCB opens on = MAINS FAIL.
If AMF settings:MCB opens on = GEN RUNNING, MCB stays closed all the time, regardless of the
mains condition.
MCB application - if the controller is switched to OFF mode while the gen-sets are running and there
is voltage on the bus, MCB is not closed before bus voltage disappears.
MGCB application – if the controller is switched to OFF mode while the gen-sets are running and
there is voltage on the bus, MGCB is opened and after AMF settings:FwRet break MCB is closed (if
there is Mains voltage).
Binary output SYS START/STOP is not active.
7.2.2 MAN mode
It is possible to close/open breakers manually under supervision of IM-NT controller which doesn’t
allow to close simultaneously breakers without synchronizing (e.g. MCB and MGCB).
If the Mains fails, controller opens MCB if AMF settings:MCB opens on = MAINS FAIL. After the
Mains returns, MCB stays opened. Otherwise MCB is controlled manually by pressing MCB ON/OFF
button or closing MCBBUTTON binary input.
MGCB application – if the Mains fails and group of gen-sets is started and there is voltage on the
bus, then MGCB can be closed anytime by pressing MGCB ON/OFF button.
Pressing of Start/Stop buttons closes/opens binary output SYS START/STOP, i.e. cause start/stop of the
gen-set group.
7.2.3 AUT mode
Controller performs automatically sequences after Mains failure, closing/opening MCB and MGCB,
Peak shaving function, closing of SYS START/STOP binary output.
MCB is opened according to setpoint AMF settings:MCB opens on after Mains failure or after the
gen-sets are running.
MGCB is closed after the start of gen-set group as soon as an appropriate load reserve is achieved
(SYST RES OK binary output closed). If Mains fails and MCB is opened then MGCB stays closed
unless voltage on the bus goes out of the limits.
Controller reacts on binary input REM START/STOP – if this input is closed, controller activates binary
output SYS START/STOP in order to start gen-set group. In MGCB application, MGCB can be closed
before the output activation (see also setpoint Process control:MGCBparalClose).
7.2.4 TEST mode
7.2.4.1 MCB application
In TEST mode gen-sets are automatically started (activation of binary output SYS START/STOP) and
connect to the bus. System goes to parallel to Mains operation and remains there. The group required
power is given by currently selected mode of Load control.
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7.2.4.2 Test on Load in MCB application
TEST mode
activated
Binary
InputTest
on Load
switched on
Test on Load
cannot be done
Test on Load with
synchronization
Test on Load
with Break
Parallel enable =
ANY SETTING
Synchro enable =
NONE or REVERSE
Gen-sets
start
Setpoint Island
enable
DISABLED
ENABLED
Setpoints Parallel
enable and Synchro
enable
Parallel enable =
ENABLED
Synchro enable =
BOTH or FORWARD
Synchronization
Passed
Failed
Alarm and load
remains on
Mains
Mains unload
Load in Island
Parallel enable =
DISABLED
Synchro enable =
ANY SETTING
MCB opens
FwResBreak
MGCB closes
Load in Island
Activation diagram
This function is activated when TEST ON LOAD Binary Input is activated and gets deactivated when the
Binary Input is deactivated. The load is taken over by gen-sets and MCB is opened. If the Mains fails
during the test, load is transferred to the gen-sets. If there are not enough gen-sets (running with GCB
closed) to cover the actual load, alarm is issued WrnTstOnLdFail and MCB stays closed. If the load
goes down alarm is then deactivated and MCB is opened.
NOTE:
The settings of the controller must allow the Test on Load function to transfer the load to the gen-set
group. If this is not allowed (e.g. SysBaseLoad is 0 kW), the system will not transfer the load.
7.2.4.3 MGCB application
Gen-sets are started and synchronized on generator bus. If the ProcessControl:MGCBParalClose is
set to MCB CLOSED, MGCB is opened when switching to TEST mode. If
ProcessControl:MCB opens on is set to MAINSFAIL, MGCB is opened immediately after switching to
TEST mode. If ProcessControl:MCB opens on is set to GEN RUNNING, MGCB is opened when the
first gen-set reaches Running state.
7.2.4.4 Test on Load in MGCB application
This function may be initiated by activation of Binary Input TEST ON LOAD or by pushing of MCB or
MGCB button.
Activation and Deactivation by TEST ON LOAD Binary Input. Red area is Test on Load with
synchronization. Blue area is Test on Load with break.
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EXAMPLE:
Test on Load
deactivation
Parallel enable =
ENABLED
Synchro enable =
BOTH or REVERSE
Return with
Synchronization
Soft Unload
Load on Mains
MCB closes
FwRetBreak
Setpoints Parallel
enable and Synchro
enable
Synchronization
Passed
Failed
Synchronization
Warning
Setpoint
ReturnWithIntr
ENABLED
DISABLED
Load remains
in Island
Parallel enable =
ANY SETTING
Synchro enable =
NONE or FORWARD
Parallel enable =
DISABLED
Synchro enable =
ANY SETTING
Return with Break
Load on Mains
ReturnTo
Mains
DISABLED
ENABLED
Load remains
in Island
ReturnTo
Mains
MGCB opens
DISABLED
ENABLED
Deactivation diagram
This is an example of Test on Load function when: ProcessControl:Island enable = ENABLED,
ProcessControl:Parallel enable = DISABLED and ProcessControl:Synchro enable = NONE.
Controller mode is changed to TEST mode. Gen-sets are started by SYS START/STOP activation.
Logical Binary Input TEST ON LOAD is activated. Because Island operation is enabled, but Parallel
operation is disabled, controller will perform Test on Load with Break. See the figure below for detailed
path.
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EXAMPLE:
TEST mode
activated
Gen-sets
start
Setpoint Island
enable
Test on Load
cannot be done
DISABLED
ENABLED
Setpoints Parallel
enable and Synchro
enable
Button
pushed
MGCB
MCB
Setpoint Island
enable
DISABLED
ENABLED
Test on Load
with Break
MCB opens
FwResBreak
MGCB closes
Load in Island
Parallel enable =
ENABLED
Synchro enable =
BOTH or FORWARD
Test on Load with
synchronization
Synchronization
Passed
Failed
Alarm and load
remains on
Mains
Mains unload
Load in Island
Parallel enable =
DISABLED
Synchro enable =
ANY SETTING
Parallel enable =
ANY SETTING
Synchro enable =
NONE or REVERSE
Test on Load
cannot be done
Setpoint
ReturnTo
Mains
ENABLED
DISABLED
CB Buttons not
active in TEST
This is an example of return from Test on Load function when the same setting are applied as in
previous example and AMF setting:ReturnTo Mains = ENABLED.
Logical Binary Input TEST ON LOAD is deactivated. Because Parallel operation is not allowed controller
performs return with break. Because return to Mains is enabled, controller opens MGCB, waits for
AMF Settings:FwRetBreak and closed MCB. See the figure below for detailed path.
Activation by pushing MCB or MGCB button. This is available only if
AMF settings:ReturnTo mains is set to DISABLED.
- MGCB button: Gen-sets are synchronized to Mains via MGCB and MGCB closes. If there are not
enough gen-sets (running with GCB closed) to cover the actual load, alarm is issued WrnTstOnLdFail
and MCB stays closed. If the load goes down alarm is then deactivated and MCB is opened.
- MCB button: MCB is opened and MGCB is closed after FwRetBreak if there is enough running gensets to support actual selected reserve for start.
Return to Mains after using buttons to initiate Test on Load function may be performed by changing or
forcing to ENABLED value to AMF settings:ReturnTo mains or by changing into different mode (e.g.
AUT mode). If the controller is switched to another mode, it behaves accordingly to that mode and the
current situation.
EXAMPLE:
Test on Load was performed by pushing MCB button. ProcessControl:Parallel enable = DISABLED
and ProcessControl:Synchro enable = NONE. Load is on gen-sets and the system is in Island
operation. Mode is changed to AUT. Controller counts down AMF settings:Mains ret del and if
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AMF settings:RetFromIsland = AUTO, it starts break transfer of the load back to Mains if it is enabled
ISLAND
ENABLE
PARALLEL
ENABLE
SYNCHRO
ENABLE
MFSTART
MGCBPARALCLOSE
SHORT DESCRIPTION
YES
YES
BOTH
YES
NO
- Island and Parallel operations are possible.
- Transfer with synchronization from Island to
Parallel and from Mains to Parallel are enabled
- Gen-sets will be started when the Mains fails.
- Gen-sets will first synchronize on the bus before
synchronizing via MGCB
YES
YES
BOTH
NO
NO
- Island and Parallel operations are possible.
- Transfer with synchronization from Island to
Parallel and from Mains to Parallel are enabled
- Gen-sets will not be started when the Mains
fails.
- Gen-sets will first synchronize on the bus before
synchronizing via MGCB
YES
YES
FORWARD
YES
NO
- Island and Parallel operations are possible.
- Transfer with synchronization from Mains to
Parallel is enabled (Island to Parallel N/A)
- Gen-sets will be started when the Mains fails.
- Gen-sets will first synchronize on the bus before
synchronizing via MGCB
YES
YES
FORWARD
NO
NO
- Island and Parallel operations are possible.
- Transfer with synchronization from Mains to
Parallel is enabled (Island to Parallel N/A)
- Gen-sets will not be started when the Mains
fails.
- Gen-sets will first synchronize on the bus before
synchronizing via MGCB
YES
YES
NONE
YES
YES
- Island and Parallel operations are possible.
- Transfer with synchronization via InteliMains is
not available
- Gen-sets will be started when the Mains fails.
- Gen-sets will synchronize directly to the Mains
(MGCB already closed) , i.e. synchronization
transfer from Island to Parallel
by the setpoint AMF settings:ReturnWithIntr.
NOTE:
The settings of the controller must allow the Test on Load function to transfer the load to the gen-set
group. If this is not allowed (e.g. SysBaseLoad is 0 kW), the system will not transfer the load.
7.3 Process Limitation
This chapter brings overview of process limitations in AUT mode (whole system in AUT mode, if there
are e.g. gen-set controllers in MAN mode, other settings conbinations may be used). There are many
possibilities how to set the setpoints related to the process limitation, nonetheless there are several
recommended settings (for whole system in AUT) that are shown the table below with short
description of the function.
7.3.1 MGCB
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ISLAND
ENABLE
PARALLEL
ENABLE
SYNCHRO
ENABLE
MFSTART
MGCBPARALCLOSE
SHORT DESCRIPTION
YES
YES
NONE
NO
YES
- Island and Parallel operations are possible.
- Transfer with synchronization via InteliMains is
not available
- Gen-sets will not be started when the Mains
fails.
- Gen-sets will synchronize directly to the Mains
(MGCB already closed) , i.e. synchronization
transfer from Island to Parallel
YES
YES
NONE
YES
MCB CLOSED
- Island and Parallel operations are possible.
- Transfer with synchronization via InteliMains is
not available
- Gen-sets will be started when the Mains fails.
- Gen-sets will synchronize directly to the Mains
(MGCB already closed) , i.e. synchronization
transfer from Island to Parallel
- MGCB will be closed if the MCB is closed
YES
YES
NONE
NO
MCB CLOSED
- Island and Parallel operations are possible.
- Transfer with synchronization via InteliMains is
not available
- Gen-sets will not be started when the Mains
fails.
- Gen-sets will synchronize directly to the Mains
(MGCB already closed) , i.e. synchronization
transfer from Island to Parallel
- MGCB will be closed if the MCB is closed
YES
YES
REVERSE
YES
YES
- Island and Parallel operations are possible.
- Transfer with synchronization from Island to
Parallel is enabled
- Gen-sets will be started when the Mains fails.
- Gen-sets will synchronize directly to the Mains
(MGCB already closed), i.e. synchronization
transfer from Mains to Parallel
YES
YES
REVERSE
YES
NO
- Island and Parallel operations are possible.
- Transfer with synchronization from Island to
Parallel is enabled (Mains to Parallel N/A)
- Gen-sets will be started when the Mains fails.
YES
YES
REVERSE
NO
YES
- Island and Parallel operations are possible.
- Transfer with synchronization from Island to
Parallel is enabled
- Gen-sets will not be started when the Mains
fails.
- Gen-sets will synchronize directly to the Mains
(MGCB already closed), i.e. synchronization
transfer from Mains to Parallel
YES
YES
REVERSE
NO
NO
- Island and Parallel operations are possible.
- Transfer with synchronization from Island to
Parallel is enabled (Mains to Parallel N/A)
- Gen-sets will not be started when the Mains
fails.
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ISLAND
ENABLE
PARALLEL
ENABLE
SYNCHRO
ENABLE
MFSTART
MGCBPARALCLOSE
SHORT DESCRIPTION
YES
YES
REVERSE
YES
MCB CLOSED
- Island and Parallel operations are possible.
- Transfer with synchronization from Island to
Parallel is enabled
- Gen-sets will be started when the Mains fails.
- Gen-sets will synchronize directly to the Mains
(MGCB already closed), i.e. synchronization
transfer from Mains to Parallel
- MGCB will be closed if the MCB is closed
YES
YES
REVERSE
NO
MCB CLOSED
- Island and Parallel operations are possible.
- Transfer with synchronization from Island to
Parallel is enabled
- Gen-sets will not be started when the Mains
fails.
- Gen-sets will synchronize directly to the Mains
(MGCB already closed), i.e. synchronization
transfer from Mains to Parallel
- MGCB will be closed if the MCB is closed
YES
NO
NONE
YES
NO
- Island operation is possible.
- Transfer with synchronization is N/A
- Gen-sets will be started when the Mains fails.
YES
NO
NONE
NO
NO
- Island operation is possible.
- Transfer with synchronization is N/A
- Gen-sets will not be started when the Mains
fails.
YES
NO
NONE
YES
MCB CLOSED
- Island operation is possible.
- Transfer with synchronization is N/A
- Gen-sets will be started when the Mains fails.
- MGCB will be closed if the MCB is closed
YES
NO
NONE
NO
MCB CLOSED
- Island operation is possible.
- Transfer with synchronization is N/A
- Gen-sets will not be started when the Mains
fails.
- MGCB will be closed if the MCB is closed
NO
YES
FORWARD
NO
NO
- Parallel operation is possible.
- Transfer with synchronization from Mains to
Parallel is enabled
- Gen-sets will not be started when the Mains
fails.
- Gen-sets will first synchronize on the bus before
synchronizing via MGCB
NO
YES
NONE
NO
YES
- Parallel operation is possible.
- Transfer with synchronization via InteliMains is
N/A
- Gen-sets will not be started when the Mains
fails.
- Gen-sets will synchronize directly to the Mains
(MGCB already closed), i.e. synchronization
transfer from Mains to Parallel
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ISLAND
ENABLE
PARALLEL
ENABLE
SYNCHRO
ENABLE
MFSTART
MGCBPARALCLOSE
SHORT DESCRIPTION
NO
YES
NONE
NO
MCB CLOSED
- Parallel operation is possible.
- Transfer with synchronization via InteliMains is
N/A
- Gen-sets will not be started when the Mains
fails.
- Gen-sets will synchronize directly to the Mains
(MGCB already closed), i.e. synchronization
transfer from Mains to Parallel
- MGCB will be closed if the MCB is closed
7.3.2 MCB
ISLAND ENABLE
PARALLELENABLE
SYNCHRO ENABLE
MFSTART
SHORT DESCRIPTION
YES
YES
REVERSE
YES
Island and Parallel operation is
possible.
Transfer with synchronization via
InteliMains is possible
Gen-sets will be started when the
Mains fails.
YES
YES
REVERSE
NO
Island and Parallel operation is
possible.
Transfer with synchronization via
InteliMains is possible
Gen-sets will not be started when the
Mains fails.
YES
YES
NONE
YES
Island and Parallel operation is
possible. (Controller can transfer to
Parallel operation from Mains
operation.)
Transfer with synchronization via
InteliMains is not possible
Gen-sets will be started when the
Mains fails.
YES
YES
NONE
NO
Island and Parallel operation is
possible. (Controller can transfer to
Parallel operation from Mains
operation.)
Transfer with synchronization via
InteliMains is not possible
Gen-sets will not be started when the
Mains fails.
YES
NO
NONE
YES
Island operation is possible.
Transfer with synchronization via
InteliMains is not possible
Gen-sets will be started when the
Mains fails.
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ISLAND ENABLE
PARALLELENABLE
SYNCHRO ENABLE
MFSTART
SHORT DESCRIPTION
YES
NO
NONE
NO
Island operation is possible.
Transfer with synchronization via
InteliMains is not possible
Gen-sets will not be started when the
Mains fails.
NO
YES
REVERSE
NO
Parallel operation is possible.
Transfer with synchronization via
InteliMains is possible
Gen-sets will not be started when the
Mains fails.
NO
YES
NONE
NO
Parallel operation is possible.
(Controller can transfer to Parallel
operation from Mains operation.)
Transfer with synchronization via
InteliMains is not possible
Gen-sets will not be started when the
Mains fails.
7.4 System start
There may be several reasons for system start. The most common are: pressing of Start button in
MAN mode, activation of BI REM START/STOP in AUT mode, AMF in MAN or AUT mode, activation of BI
TEST ON LOAD in TEST mode, power management in AUT mode and other reasons. Below there is
description of power management initiated start of the system.
In the following section there is a description of system with several gen-sets and IM-NT controlling
MCB and MGCB (see the lower diagram on the page 6). All gensets are taking part in power
management (Pwr management:Pwr management = ENABLED)
Power management is set to Abs(kW) – for Abs(kVA) same setpoints are used, for Rel(%)
setpoints Pwr management:#%LdResStrt and Pwr management:#%LdResStop are used.
In Island operation IM-NT will not close MGCB untill sufficient nominal power (given by
formula below) is reached (i.e. untill sufficient number of gen-sets with according nominal
powers are running).
EXAMPLE:
First set of Pwr management:#LoadResStrt/Stop setpoints is used -
Pwr management:#LoadResStrt 1 = 300, Pwr management:#LoadResStop 1 = 500
There are 4 gensets, all with nominal power 100 kW. When Mains failure occurs (i.e. system
goes to the Island operation mode) SYSTEM START/STOP is activated for all gensets and all
gensets are starting because they need to fullfill load reserve 300 kW (supposing non zero
load, such reserve is fullfiled only when all four gensets are running).
If Pwr management:#LoadResStrt 1 is set to 299, only three gensets will be started when
Mains failure occurs before MGCB closes. The formula which determines how many gensets
will be started is show below:
After MGCB closing power management is functioning accordingly to the description below.
Different load reserve sets may be used for starting of the system and for its usual run (e.g.
selection of second load reserve set may be conditioned by MGCB FEEDBACK). It is particularly
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beneficial in combination with load shedding after Mains failure occurs (i.e. part of the load is
supplied immediately and other parts are connected as other gensets start).
NOTE:
System starting sequences may be very different due to their complexity (i.e. gensets which do not
take part in power management, various nominal powers etc.). Each system should be considered
individually.
7.5 StartUpSynchronization
InteliMainsNT now supports StartUpSynchronization function which is available in standard firmware
for InteliGenNT and InteliSysNT from version 3.1.0.
BusMeasError function was changed so it does not signalize Bus measurement error when there are
gen-sets starting in start up synchronization with their closed GCB and there is no voltage on the bus.
In MGCB application there is a support for closing of MGCB in Island mode (MCB must be opened)
when at lest one gen-set in the same control group indicates that it starts in SUS. This can be used for
soft start on big transformers connected behind MGCB and therefore preventing dangerous
magnetization currents. This behaviour is changed by setpoint ProcessControl:MultiSoftStart.
7.6 Power management
It is important to note that InteliMainsNT in MCB or MGCB applications is not directly controlling the
power management. The power management is decentralized system and it is resolved individually in
each InteliGenNT or InteliSysNT running in MINT application (this system synchronizes setpoints so it is
resolved based on the same rules in all controllers and the system is more robust because it does not
depend on a single master). InteliMainsNT controller plays crucial role in the system in the control of
required load in parallel to Mains operation (see the chapter 7.9) and also it can be switched to
MASTER in Automatic priority swap function (see the chapter 7.6.2).
The Power management function decides how many gen-sets should run and selects particular gensets to run. The power management is applicable in cases multiple gen-sets run in parallel to mains or
in the island operation. The function is based on the load evaluation in order to provide enough of
available running power. Since it allows the system to start and stop gen-sets based on the load
demand, it can vastly improve the system fuel efficiency. In other words, an additional gen-set starts
when the load of the system rises above certain level. The additional gen-set stops, when the load of
the system drops down below a certain level. The process of determining gen-set start and stop is
done in each controller; there is no "master slave" system. Therefore, the system is very robust and
resistant to failures of any unit in the system. Each of the controllers can be switched off without
influencing the whole system. Except the situation the respective gen-set is not available for the power
management.
The power management evaluates so called load reserve. The load reserve is calculated as difference
between actual load and nominal power of running gen-sets. The reserve is calculated as absolute
value (in kW / kVA) or relatively to the nominal power of gen-set(s) (in %). The setpoint
Pwr management: #Pwr mgmt mode is used to select the absolute or relative mode.
The automatic priority swapping function focuses on efficient run of gen-set in regards to running
hours and gen-set size.
7.6.1 Power management limitations
WARNING!
This section contains important information regarding power management function that are crucial for
the correct function of power management.
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The function of the controller is designed to handle the maximum sum of nominal power at 32000kW
(3200.0kW, 320.00MW depending on the power format in the controller). If the sum of nominal power
of all gen-sets connected to the intercontroller CAN exceeds these values the power format needs to
be changed accordingly.
EXAMPLE:
There are 20 gen-sets each with 2000kW of nominal power. The sum of the nominal power is
40000kW. Therefore the power format in kW cannot be used because the sum exceeds 32767.
Therefore power format in MW needs to be chosen because the sum in MW is 40MW (it does not
exceeds 320.00MW).
7.6.2 Basic Power management
The setpoint Pwr management: Pwr management enables and disables the gen-set to be active
within the power management and makes automatic load dependent starts and stops. If the power
management is disabled, the start and stop of the gen-set do not depend on the load of the group. If
the gen-set remains in AUT mode, the running condition depends only on the binary input Sys
start/stop.
The binary input Sys start/stop requests the gen-set to start or stop. If the input is not active, the genset stops with delay Pwr management: #SysAMFstopDel after the input has been deactivated and
will not start again if in AUT mode. If the input is activated again, the delay Pwr management:
#SysAMFstrtDel starts to count down. Once the delay elapsed (+0.5s because of compatibility
reasons with Load Demand Swapping), the gen-set is activated and can be started by the power
management. In other words, the power management is activated only if the binary input Sys
start/stop is activated, the option of setpoint Pwr management: Pwr management = ENABLED and
the AUT mode are selected.
NOTE:
The gen-set takes part of the power management (= is active) only if the controller is in AUT mode!
NOTE:
The gen-set performs load and VAR sharing whenever it is connected to the bus bar i.e. it is
independent on whether the controller is in AUT or MAN mode or whether the power management is
active or not. Do not confuse power management with load sharing.
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7.6.2.1 Principles of Power management
System activation
System deactivation
Sys start/stop activation
in AUT mode
SysAMFstrtDel
Start of the whole system is
delayed by this time
NextStrt del / OverldNext del
Start of individual gen-set is
delayed by this time
NextStop del
Start of an individuel gen-set is
delayed by this time
Gen-set
started based
on Reserves
Gen-set
stopped
based on
Reserves
YES
NO
YES
NO
Sys start/stop deactivation
in AUT mode
SysAMFstopDel
Stop of the whole system is
delayed by this time
Stopping sequence of all gen-
sets in AUT mode
Internal conditions based on remaining load reserves and priorities are evaluated once a delay is
elapsed. If the load reserve is insufficient the gen-set is started after delay given by the setpoint
Pwr management: #NextStrt del is elapsed. Once the gen-set runs the controller evaluates stopping
conditions based on load reserves and priorities. If the reserve is sufficient enough to stop a particular
gen-set, it is stopped after delay given by the setpoint Pwr management: #NextStopDel is elapsed.
All the time the system stop condition – i.e. the binary input Sys start/stop deactivated – is evaluated
as well. Once the delay given by the setpoint Pwr management: #SysAMFstopDel has elapsed all
gen-sets in AUT mode are stopped. Following figure depicts the system activation and deactivation
logic.
NOTE:
The setpoint Pwr management: OverldNext del is used in the case gen-sets are running at 90% or
more of their nominal power. The setpoint Pwr management: OverldNext del should be generally
shorter than the setpoint Pwr management: NextStrt del. The shorter time always applies in such a
case (counting in that part of NextStrt del may have already been elapsed).
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7.6.2.2 Load reserve
Reserve
Actual Reserve
Start condition
Stop condition
Absolute
kW / kVA
ARstrt = ΣPg
Nom
– ΣPg
Act
ARstp = ΣPg*
Nom
– ΣPg
Act
ARstrt < #LoadResStrt
ARstp > #LoadResStop
Relative
%
RRstrt = [(ΣPg
Nom
– ΣPg
Act
) / ΣPg
Nom
].100%
RRstp = [(ΣPg*
Nom
– ΣPg
Act
) / ΣPg*
Nom
].100%
RRstrt < #%LdResStrt
RRstp > #%LdResStop
Reserve
Actual Reserve
Start condition
Stop condition
Absolute
kW / kVA
ARstrt = ΣPg
Nom
– BaseLd
ARstp = ΣPg*
Nom
– BaseLd
ARstrt < #LoadResStrt
ARstp > #LoadResStop
Relative
%
RRstrt = [(ΣPg
Nom
– BaseLd) / ΣPg
Nom
].100%
RRstp = [(ΣPg*
Nom
– BaseLd) / ΣPg*
Nom
].100%
RRstrt < #%LdResStrt
RRstp > #%LdResStop
ARstrt
Actual Absolute reserve in kW or kVA - for engine start calculation.
ARstp
Actual Absolute reserves in kW or kVA - for engine stop calculation.
RRstrt
Actual Relative reserve in % - for engine start calculation.
RRstp
Actual Relative reserves in % - for engine stop calculation.
ΣPg
Nom
Sum of Nominal power of all gen-sets on the bus.
ΣPg*
Nom
Sum of Nominal power of all gen-sets on the bus apart of the one, which is going to be
stopped.
ΣPg
Act
BaseLd
Sum of Actual power of all gen-sets on the bus = system load.
Baseload is given by the setpoint ProcessControl: #SysBaseLoad
The power management is based on the load reserve concept. The load reserve is defined as
a difference of the running nominal power of the group within power management and the total load of
the system. There are two ways how to determine the load reserve. The absolute power management
allows the system to keep the load reserve higher or equal to value in kW or kVA given by a relevant
setpoint. The relative power management assures that load reserve is kept higher or equal to relative
portion in % of the nominal power of group (i.e. running gen-sets active in power management) given
by a relevant set-point. Depending of the situation, load reserves are calculated differently in two
cases:
Case #1:
island operation
or parallel to mains operation, ProcessControl: #SysLdCtrl PtM = LDSHARING
Case #2:
parallel to mains operation, ProcessControl: #SysLdCtrl PtM = BASELOAD
Where
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NOTE:
Power [kW]
Sum of available nominal
power – running gen-sets
in PM
Total Load of
the system
Level to start another gen-set
Nom Pwr in PM - #LoadResStrtX
Nom G1
Time
Nom
G1+G2
Time
Gen 2 Ready
#NextStrt del
Start
Stabilization
Synchronization
GCB closed
Soft loading
Loaded
Running
Gen 1
BO Syst res OK
System starting sequences may be very different due to their complexity (i.e. gen-sets which do not
take part in power management, various nominal powers etc.). Each system should be considered
individually. Optional functions in absolute or relative Power management are:
- Running hours balancing (equalization) – in absolute or relative pwr mgmnt
- Load demand (different size) engines swap – in absolute pwr mgmnt only
- Power management of two or more gen-set groups (bus tie support) – in absolute or relative
power management
NOTE:
The parallel operation to the mains of multiple gen-sets requires use of the InteliMains controller. The
InteliMains controller supervises the mains. For further information, please refer to the IM-NT-MCB-
MGCB 3.0 Reference Guide or newer version of the guide.
7.6.2.2.1 Starting sequence
As written above, the power management is based on the load evaluation in order to provide enough
of available running power. An additional gen-set starts when the load of the system raises above
certain level to keep the load reserve big enough. Following figure depicts the situation when
an additional gen-set is requested to join the already running gen-set(s) to the bus.
Figure: Starting sequence
As shown above, the load of the system has increased above the level defined by the start condition –
i.e. the load reserve is not sufficient as required by the setpoint Pwr management: #LoadResStrt.
Further explication is provided in chapters Absolute Power Management and Relative Power
Management
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The level is illustrated by the green dashed line. If the load reserve keeps insufficient for longer time
than defined by the setpoint Pwr management: #NextStrt del, the next gen-set is actually started.
The standard starting sequence follows. Please refer to the chapter Engine states for further
information. Once the synchronization procedure is done, the GCB breaker is closed and the gen-set
power is ramping up. Once loaded, the system load reserve is raised and becomes sufficient again.
Please note the sum of nominal power of all gen-sets on the bus is increased by the nominal power of
the additional gen-set.
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7.6.2.2.2 Stopping sequence
Power [kW]
Sum of available nominal
power – running gen-sets
in PM
Total Load of
the system
Level to stop additional gen-set
Nom Pwr in PM - #LoadResStop X
Nom G1
Time
Nom
G1+G2
Time
Gen 2
#NextStop del
Soft unloading
GCB opened
Loaded
Gen 1
BO Syst res OK
Stopped and ready to PM
Cooling
Running Running
As it is written above, the power management is based on the load evaluation in order to provide
enough of available running power. An additional gen-set stops when the load of the system drops
below certain level to avoid inefficient run of the gen-set. Following figure depicts the situation when
a gen-set is requested to stop due to the power management.
Figure: Stopping sequence
As shown above, the system load has decreased below the level defined by the stop condition –
i.e. the load reserve is over a limit given by the setpoint Pwr management: #LoadResStop. Further
explication is provided in chapters Absolute Power Management and Relative Power Management
The level is illustrated by the red dashed line. If the load reserve keeps over this limit for longer time
than defined by setpoint Pwr management: #NextStopDel del, the next gen-set is actually requested
to stop. Once the gen-set is unloaded, the GCB breaker is opened. Please note the sum of nominal
power of all gen-sets on the bus is decreased by the nominal power of the stopped gen-set.
The cooling sequence follows before the gen-set is actually stopped. The gen-set is ready to be
started if the system load increases again.
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7.6.2.2.3 Absolute Power Management
Sum of available nominal power
– running gen-sets in PM
Total Load of the system Starting sequence Stopping sequence
Gen1
Priority 1
Gen2
Priority 2
Gen3
Priority 3
Gen 1 Running, loaded
Gen 2
#LoadResStrt1
#LoadResStrt1
Starting
sequence
Running, loaded
Gen 3
Running, loaded
#LoadResStop1
Stopping
sequence
#LoadResStop1
Actual power [ kW or kVA ]
BO Syst res OK
#LoadResStrt1
Time
Stopping
sequence
Time
Starting
sequence
Stopped and ready
to PM
Stopped and
ready to PM
The power management based on absolute load reserves can be successfuly used in cases the load
portions are similar to the gen-set capacity or even bigger. The goal of the absolute reserve mode is to
provide the same load reserve all the time independently on how many gen-sets are currently running.
The mode perfectly fits for industrial plants with large loads.
The absolute power management guarantees adjustable load reserve in kVA or kW.
Activation:
Pwr management: #Pwr mgmt mode = ABS (kW) - Based on active power load reserve.
Suitable for load demand-based optimization
Pwr management: #Pwr mgmt mode = ABS (kVA) - Based on apparent power load reserve.
Suitable for generator or busbar
dimensioning-based optimization.
Figure: Power management based on absolute load reserve
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An example of absolute power management is shown on the figure below. There are three gen-sets
Setpoint group
Basic settings
Pwr management
Setpoint
Nomin power
Pwr management
#Pwr mgmt mode
Priority
#PriorityAuto Swap
#LoadRes Strt X
#LoadRes Stop X
Gen-set #1
200 kW
ENABLED
ABS (kW)
1
DISABLED
100 kW
125 kW
Gen-set #2
500 kW
ENABLED
ABS (kW)
2
DISABLED
100 kW
125 kW
Gen-set #3
1 000 kW
ENABLED
ABS (kW)
3
DISABLED
100 kW
125 kW
Power [kW]
Sum of available nominal
power – running gen-sets
in PM
Total Load of
the system
Level to start additional gen-set
Nom Pwr in PM - #LoadResStrt X
75
575
100
600
200
700
1700
Time
Time
Starting
sequence
Gen 1
Gen 2
Running, loaded
BO Syst res OK
Gen 3
Start sequence
Stop sequence
Stopped and ready
Starting
sequence
Stopped and ready
Stopping
sequence
Stopping
sequence
Level to stop additional gen-set
Nom Pwr in PM - #LoadResStop X
Running, loaded
Running, loaded
with following choice of setpoints:
NOTE:
Gen-set #1 means that the CAN address of the controller is set to 1. The relevant setpoint is adjusted
by Comms settings: Contr. address.
Figure: Absolute Power management example
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As it is shown on both figures above, the addional gen-set is added once the actual load reserve is
SHBIN
BI n
SHBINSHBOUT
Power
management
Power
management
Power
management
BO n
BI n
Controller 1 Controller 2 Controller 3
Switch for
activation of load
reserve set #2
BI n
CAN 2
LBI: LoadRes 2
LBI: LoadRes 2 LBI: LoadRes 2
below the level given by the setpoint Pwr management: #LoadResStrt X. The addional gen-set is
removed once the actual load reserve is above the level set by Pwr management: #LoadResStop X.
The green dashed line depicts the value of load at which the additional gen-set is requested to start.
This value of the load value is linked with the setpoint Pwr management: #LoadResStrt X in following
way:
Sum of Nominal power - #LoadResStrt X = Value of load when additional gen-set requested to start
E.g.: 700 kW – 100 kW = 600 kW
The red dashed line depicts the value of load at which the additional gen-set is requested to stop. This
value of the load value is linked with the setpoint Pwr management: #LoadRes Stop X in following
way:
Sum of Nominal power - #LoadResStop X = Value of load when additional gen-set requested to stop
E.g.: 700 kW – 125 kW = 575 kW
There are 4 levels for starting and stoping gen-sets.
#LoadResStrt 1 / #LoadResStop 1 considered by default.
#LoadResStrt 2 / #LoadResStop 2 considered if LBI: Load res 2 activated
#LoadResStrt 3 / #LoadResStop 3 considered if LBI: Load res 3 activated
#LoadResStrt 4 / #LoadResStop 4 considered if LBI: Load res 4 activated
The option of switching the load reserves by LBI may be usefull in cases appliances with important
power consumption are expected to be connected to the bus.
NOTE:
All controllers cooperating together in Power management must have the same load reserve set
selected.
It is possible to use virtual shared peripheries for distribution of the binary signal to activate LBI Load
res 2,3 or 4 among controllers over the CAN bus. For further information, please refer to the chapter
Shared Inputs and Outputs.
Figure: Example of using virtual shared peripheries for signal distribution
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7.6.2.2.4 Relative Power Management
Sum of available nominal power
– running gen-sets in PM
Total Load of the
system
Starting sequence Stopping sequence
Gen1
Priority 1
Gen2
Priority 2
Gen3
Priority 3
Gen 1 Running, loaded
Gen 2
#LoadResStrt1
= 25%
#LoadResStrt1
= 25%
Starting
sequence
Running, loaded
Gen 3
Running, loaded
#LoadResStop1
= 37%
Stopped and
ready
Stopped and ready
#LoadResStop1
= 37%
Actual power [ kW or kVA ]
BO Syst res OK
#LoadResStrt1
= 25%
Time
Time
Starting
sequence
Stopping
sequence
Stopping
sequence
Ready
Ready
The power management based on relative load reserves perfectly fits to those applications with such
load portions connected to the group at once are much lower than the gen-set nominal power. This
mode helps to achieve the maximal lifetime of the gen-sets, as they can be operated within optimal
load range. The maximal size of the load connected at once depends on number of actually working
gen-sets. The more gen-sets are connected to the busbar the bigger load portion can be connected at
once.
The relative power management guarantees that the engines are not continuously loaded more than
to a certain level.
Activation: Pwr management:#Pwr mgmt mode = REL (%)
Suitable for engine life-based optimization.
Figure: Power management based on relative load reserve
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Setpoint group
Basic settings
Pwr management
Setpoint
Nomin power
Pwr management
#Pwr mgmt mode
Priority
#PriorityAuto Swap
#%LdRes Strt X
#%LdRes Stop X
Gen-set #1
200 kW
ENABLED
REL (%)
1
DISABLED
35 %
40 %
Gen-set #2
500 kW
ENABLED
REL (%)
2
DISABLED
35 %
40 %
Gen-set #3
1 000 kW
ENABLED
REL (%)
3
DISABLED
35 %
40 %
Power [% / kW]
Sum of available nominal
power – running gen-sets
in PM
Total Load of the system
Level to start additional gen-set
Nom Pwr - #%LdResStrt X
Level to stop additional gen-set
Nom Pwr - #%LdResStop X
60% 120
60% 420
65% 130
65% 455
100% 700
1700
Time
Time
Starting
sequence
Gen 1
Gen 2
Running, loaded
BO Syst res OK
Gen 3
Starting sequence
Stopping sequence
Stopped and
ready
Stopped and
ready
100% 200
Starting
sequence
Stopping
sequence
Stopping
sequence
Running, loaded
Running, loaded
Ready
Ready
An example of relative power management is shown on the figure below. There are three gen-sets
with following choice of setpoints:
NOTE:
Gen-set #1 means that the CAN address of the controller is set to 1. The relevant setpoint is adjusted
by Comms settings: Contr. address.
Figure: Relative Power management example
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As it is shown on both figures above, the addional gen-set is added once the actual load reserve is
SHBIN
BI n
SHBINSHBOUT
Power
management
Power
management
Power
management
BO n
BI n
Controller 1 Controller 2 Controller 3
Switch for
activation of load
reserve set #2
BI n
CAN 2
LBI: LoadRes 2
LBI: LoadRes 2 LBI: LoadRes 2
below the level given by the setpoint Pwr management: #%LdResStrt X. The addional gen-set is
removed once the actual load reserve is above the level set by Pwr management: #%LdResStop X.
The green dashed line depicts the value of load at which the additional gen-set is requested to start.
This value of the load value is linked with the setpoint Pwr management: #%LdResStrt X in following
way:
(100 % - #%LdResStrt X) * Sum of Nominal power = Value of load when additional gen-set requested
to start in kW (in % of nominal power)
E.g.: (100 % – 35 %) * 700 kW = 455 kW (65 % of nominal power)
The red dashed line depicts the value of load at which the additional gen-set is requested to stop. This
value of the load value is linked with the setpoint Pwr management: #LoadRes Stop X in following
way:
(100 % - #%LdResStop X) * Sum of Nominal power = Value of load when additional gen-set requested
to stop in kW (in % of nominal power)
E.g.: (100 % – 40 %) * 700 kW = 420 kW (60 % of nominal power)
There are 4 levels for starting and stoping gen-sets.
#%LdResStrt 1 / #%LdResStop 1 considered by default.
#%LdResStrt 2 / #%LdResStop 2 considered if LBI: Load res 2 activated
#%LdResStrt 3 / #%LdResStop 3 considered if LBI: Load res 3 activated
#%LdResStrt 4 / #%LdResStop 4 considered if LBI: Load res 4 activated
NOTE:
All controllers cooperating together in Power management must have the same load reserve set
selected.
It is possible to use virtual shared peripheries for distribution of the binary signal to activate LBI Load
res 2,3 or 4 among controllers over the CAN bus.
Figure: Example of using virtual shared peripheries for signal distribution
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7.6.2.3 Priorities
Setpoint
group
Basic
settings
Pwr management
Setpoint
Nomin
power
Pwr
management
#Pwr mgmt
mode
Priority
#PriorityAutoS
wap
#LoadResStr
t X
#LoadResStop
X
Gen-set #1
200 kW
ENABLED
ABS (kW)
4
DISABLED
50 kW
70 kW
Gen-set #2
200 kW
ENABLED
ABS (kW)
3
DISABLED
50 kW
70 kW
Gen-set #3
200 kW
ENABLED
ABS (kW)
2
DISABLED
50 kW
70 kW
Gen-set #4
200 kW
ENABLED
ABS (kW)
1
DISABLED
50 kW
70 kW
Power [% / kW]
Sum of available nominal
power – running gen-sets
in PM
Total load of the system
Level to start additional gen-
set Nom Pwr - #LoadResStrt X
Level to stop additional gen-set
Nom Pwr - #LoadResStop X
130
330
150
350
400
Time
Time
Starting
sequence
Gen #4 Priority = 1
Gen #3 Priority = 2
Gen #2 Priority = 3
Starting sequence
Stopping sequence
200
330
350
400
800
Gen #1 Priority = 4
Starting
sequence
Starting
sequence
Stopping
sequence
Stopping
sequence
Stopping
sequence
The priority of the gen-set within the group is given by the setpoint Pwr management: Priority. Lower
number represents "higher" priority, i.e. a gen-set with lower number starts before another one with
higher number. In other words, the setpoint Pwr management: Priority means order in which gen-sets
are started and connected to the bus. An example is shown on the figure below. There are four gensets with following choice of setpoints:
Figure: Power management example - Priorities
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NOTE:
Gen-set #1 means that the CAN address of the controller is set to 1. The relevant setpoint is adjusted
by Comms settings: Contr. address.
By choosing the setpoint Pwr management: Priority = 1, the gen-set #4 is running all the time in the
example shown on the figure above (AUT mode selected, Pwr management enabled and LBI Sys
start/stop activated).
The priority can be also adjusted by a set of logical binary inputs Priority sw A, Priority sw B, Priority
sw C and Priority sw D. If at least one of these inputs is closed, the priority adjusted by the setpoint as
mentioned above is overridden by the priority given by the combination (binary code) of the Priority
SW inputs.
NOTE:
The inputs are intended for adjusting the priority by a rotary switch.
The force value function can be used to force priority 0 into the setpoint Pwr management: Priority.
Priority 0 is the "highest" one, which means the gen-set will be running all the time while the power
management is switched on.
If more than one gen-set have the same priority, they will act as "one big" gen-set. There are methods
of automatic optimization of the priorities to achieve specific behavior of the group such as equalizing
engine hours of the gen-sets or selection of optimal gen-sets to run according to their size and current
load demand.
7.6.3 Automatic priority swapping
As stated in the chapter Priorities, the operator is able to select the order of gen-set starting. There is
also the option of automatic priority selection. The controllers are sharing data concerning the running
hours and all important information relevant to the actual load. Thanks to the Automatic priority
swapping function the controllers choose the gen-set(s) to be running with consideration of their
running hours and the actual load. The Running hours equalization (RHE) function keeps a constant
maximal difference of gen-sets’ running hours. The Load demand swap (LDS) function keeps running
only the gen-sets with suitable nominal power to avoid inefficient fuel consumption or gen-set
overload.
At least one gen-set in the group must be set as the master for priority optimization
(Pwr Management: Priority ctrl = MASTER). It is possible to have more than one master, the one with
lowest CAN address will play the role of the master and if it is switched off the next one will take the
master role.
Important setpoint: Pwr management: #PriorAutoSwap
The Automatic priority swapping function does not change the setpoint Pwr management: Priority.
The function sets the order of gen-sets by virtual values “engine priority”.
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MCB MGCB
GCB1
GCB2
GCB3
GCBn
InteliMains
Comms settings:
Contr. Addr = 4
Pwr management:
#PriorAutoSwap = RUN
HOURS EQU
Priority ctrl = MASTER
#RunHrsMaxDiff = 10h
Control group =
COMMON
Comms settings:
Contr. Addr = 1
Pwr management:
#PriorAutoSwap = RUN
HOURS EQU
Priority ctrl = SLAVE
RunHoursBase = 100h
#RunHrsMaxDiff = 10h
Control group =
COMMON
Comms settings:
Contr. Addr = 2
Pwr management:
#PriorAutoSwap = RUN
HOURS EQU
Priority ctrl = SLAVE
RunHoursBase = 200h
#RunHrsMaxDiff = 10h
Control group =
COMMON
Comms settings:
Contr. Addr = 3
Pwr management:
#PriorAutoSwap = RUN
HOURS EQU
Priority ctrl = SLAVE
RunHoursBase = 300h
#RunHrsMaxDiff = 10h
Control group =
COMMON
Comms settings:
Contr. Addr = n
Pwr management:
#PriorAutoSwap = RUN
HOURS EQU
Priority ctrl = SLAVE
RunHoursBase =0h
#RunHrsMaxDiff = 10h
Control group =
COMMON
CAN
n321
7.6.3.1 Running hours equalization (RHE)
The gen-sets “engine priorities” are automatically swapped to balance engine running hours. In other
words, the controllers compare Run hours of each gen-set and select gen-set(s) to run in order to
maintain constant maximal difference of running hours. Up to 32 controllers are supported.
Activation: Pwr management: #PriorAutoSwap = RUN HOURS EQU
Important setpoints: RunHoursBase, #RunHrsMaxDiff, Priority ctrl, Control group
The actual values to be considered by the Running Hours Equalization are calculated from the
following formula:
RHEi = Runhoursi - RunHoursBasei,
where RHE is considered value for Running hours equalization, i stands for a particular gen-set,
Runhours is a cumulative sum of run hours available in statistic values of the controller,
RunHoursBase is a setpoint. This setpoint may be used in the case of gen-sets with different runs
hours are intended to be set at the same initial point (e.g. a new gen-set and a used gen-set after
retrofit maintenance inspection).
The Running hours equalization function compares RHE value of each controller in the group. Once
the difference between RHE of individual controllers is higher than #RunHrsMaxDiff
(i.e. #RunHrsMaxDiff + 1), the gen-set(s) with the lowest is/are started.
InteliMainsNT, SW version 3.2.0
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Figure: Running Hours Equalization example
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EXAMPLE:
Run hours
#RunHoursBase
RHE
Gen-set #1
250
150
100
Gen-set #2
450
250
200
The system structure is shown on the figure above. The InteliMains controller assumes the role of
master in priority swapping and swaps priority of the engines based on their running hours.
3 cases are considered:
Case #1: 2 gen-gets available
Case #2: 3 gen-gets available with same initial RHE.
Case #3: 3 gen-gets available with different initial RHE.
Case #1:
Gen-set 1 running hours = 250 -> running hours considered in RHE = 100 (150-RunHoursBase)
Gen-set 2 running hours = 450 -> running hours considered in RHE = 200 (250-RunHoursBase)
Both gen-sets have the same nominal power of 700 kW. Originally, priority of gen-sets was G1 = 2,
G2 = 1. Load demand in this example is constant and it is 500 kW (i.e. only one engine is running at
any time). In this case, the InteliMains controller sets the engine priority of the gen-set 1 to 1 because
it has the lowest considered RHE and the difference between RHE2 (i.e. considered RHE of gen-set
2) and RHE1 is higher than #RunHrsMaxDiff that is set to 10h.
The gen-set 1 runs for 100 hours to equalize the RHE of both gen-sets. The gen-set 1 keeps running
until the difference between RHE1 and RHE2 exceeds #RunHrsMaxDiff (i.e. 10h). The gen-set 1 runs
100 + #RunHrsMaxDiff + 1 = 100 + 10 + 1 = 111 hours. After 111 hours the gen-sets 2 has the lowest
RHE and the difference between RHE1 and RHE2 is higher than #RunHrsMaxDiff. The gen-set 2 runs
11 hours to equalize the RHE of both gen-sets and then additional #RunHrsMaxDiff + 1 hours (i.e. 11
+ 10 + 1 = 22 hours). The evolution of RHE1 and RHE2 is shown on the figure below.
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170
180
190
200
210
220
230
240
250
260
RHE
Step
1 2 3 4 5
step
0 1 2 3 4
5
RHE1
100
211
211
233
233
255
RHE2
200
200
222
222
244
244
Run G1 (ΔRHE1)
0
111 0 22 0 22
Run G2 (Δ RHE2)
0 0 22 0 22
0
Figure: Running Hours Equalization example, 2 gen-sets
From the example of the case #1, it can be concluded that the gen-sets are swapped after the
duration determined by following formula:
SwapTime = Second lowest considered running hours – Current lowest considered running
hours + #RunHrsMaxDiff +1
Case #2:
Gen-set 1 running hours = 0 -> running hours considered in RHE = 0 (0-RunHoursBase)
Gen-set 2 running hours = 0 -> running hours considered in RHE = 0 (0-RunHoursBase)
Gen-set 3 running hours = 0 -> running hours considered in RHE = 0 (0-RunHoursBase)
Each gen-set has the same RHE = 0 h. By applying the SwapTime formula, we get the run time of
gen-set 1 before next swapping:
SwapTimeG1 = 0 – 0 + 10 + 1 = 11
Similar way, we get the run time of gen-set 2 before next swapping:
SwapTimeG2 = 11 – 11 + 10 + 1 = 11
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0
10
20
30
40
50
60
70
80
90
RHE
Step
1 2 3 4 5 6 7 8 9 10 11 12 13
step
0 1 2 3 4 5 6 7 8 9 10
11
12
13
RHE1
0
11
11
11
11
33
33
33
33
55
55
55
55
77
RHE2
0 0 11
11
22
22
33
33
44
44
55
55
66
66
RHE3
0 0 0
22
22
22
22
44
44
44
44
66
66
66
Run G1 (Δ RHE1)
0
11 0 0 0 22 0 0 0 22 0 0 0 22
Run G2 (Δ RHE2)
0 0 11 0 11 0 11 0 11 0 11 0 11 0 Run G3 (Δ RHE3)
0 0 0
22 0 0 0 22 0 0 0 22 0 0
Finally, we get the run time of gen-set 3 before next swapping:
SwapTimeG2 = 11 – 0 + 10 + 1 = 22
Please refer to figure below to understand the evolution of RHE of gen-sets in this particular case.
Figure: Running Hours Equalization example, 3 gen-sets with same initial RHE
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Case #3:
240
250
260
270
280
290
300
310
RHE
Step
1 2 3 4 5 6 7 8 9 10 11 12 13
step
0 1 2 3 4 5 6 7 8 9 10
11
12
13
RHE1
100
211
211
233
233
255
255
255
272
272
272
288
288
288
RHE2
200
200
222
222
244
244
261
261
261
277
277
277
294
294
RHE3
250
250
250
250
250
250
250
266
266
266
283
283
283
299
Run G1 (Δ RHE1)
0
111 0 22 0 22 0 0
17 0 0
16 0 0
Run G2 (Δ RHE2)
0 0 22 0 22 0 17 0 0
16 0 0
17 0 Run G3 (Δ RHE3)
0 0 0 0 0 0 0
16 0 0
17 0 0
16
Gen-set 1 running hours = 250 -> running hours considered in RHE = 100 (150-RunHoursBase)
Gen-set 2 running hours = 450 -> running hours considered in RHE = 200 (250-RunHoursBase)
Gen-set 3 running hours = 750 -> running hours considered in RHE = 250 (500-RunHoursBase)
The gen-set 1 has the lowest RHE1 = 100 h. By applying the SwapTime formula, we get the run time
of gen-set 2 before next swapping:
SwapTimeG1 = 200 – 100 + 10 + 1 = 111
Till the step 5, the evolution of the gen-set swapping is the same as in the case #1, just gen-set 1 and
gen-set 2 involve. In the step 6 the gen-set 2 can run only 17 hours (previously 22 hours) because the
gen-set 3 involves. The evolution of RHE1, RHE2 and RHE3 is shown on the figure below.
NOTE:
Setting Pwr management: #RunHrsMaxDiff = 5 does not mean that gen-sets swap every 5 hours.
The Swap time is determined by the formula stated above. Please read the entire chapter Running
hours equalization for better understanding.
In the case Pwr management: #RunHrsMaxDiff is set to 0 and all gen-set in the group are at the
same initial point (RHE are equal), the gen-set swapping happens every hour.
NOTE:
InteliMainsNT, SW version 3.2.0
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Figure: Running Hours Equalization example, 3 gen-sets with different initial RHE
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Core power management is still fully functional.
Priority setpoints are not actually changed. Virtual values “engine priority” are used. If changing of
priority setpoints is required, they need to be changed and RHE needs to disabled and enabled again
for the changes to take place.
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7.6.3.2 Load demand swap (LDS) – different sized engines
If there are gen-sets of different size at the site, it may be required always to run such gen-sets that
best fit to the actual load demand. The Load demand swap function is intended for this purpose and
can control up to 3 gen-sets (priorities). Up to three running engines (priorities) can be swapped based
on load demand (e.g. one “small” engine may run on “small” load and swaps to another one, “big”
engine that runs when load increases). This function is available only in combination with absolute
power management.
Activation: Pwr management:#PriorAutoSwap = LD DEMAND SWAP
Important setpoints: #PwrBandContr1, #PwrBandContr2, #PwrBandContr3, #PwrBandContr4,
#PwrBandChngDlUp, #PwrBandChngDlDn, Load reserve setpoints (depending on selected load
reserve set), Priority ctrl, Control group.
The gen-sets must have addresses 1, 2 and 3. There are four power bands; each of them has
adjusted specific combination of gen-sets that run within it. Power bands are adjusted by setpoints
#PwrBandContr1, #PwrBandContr2, #PwrBandContr3 and #PwrBandContr4. The load levels of
the power bands are defined by sum of nominal powers of gen-sets that are adjusted to run in each
particular power band, and the load reserve for start. The combinations of gen-sets must be created in
the way the total nominal power of the Power band #1 < #2 < #3 < #4. If the load demand is above the
power band #4 then all gen-sets are ordered to run. In fact there is power band #5, which has fixedly
selected all the gen-sets to run.
The currently active power band is given by the actual load demand. If the load demand changes and
gets out from the current power band, the next/previous power band is activated with delay
Pwr management: #PwrBnChngDlUp or Pwr management: #PwrBnChngDlDn depending on
the direction of the change. The gen-sets which are included in the current power band get engine
priority 1, the others get priority 32. The setpoint Pwr management: Priority is not influenced by this
function. Virtual values “engine priority” are used.
NOTE:
If the power band change delays (i.e. Pwr management: #PwrBnChngDlUp and
Pwr management: #PwrBnChngDlDn) are adjusted to higher values than
Pwr management: #NextStrt del and Pwr management: #OverldNextDel setpoints then it may occur,
that also the gen-sets not belonging to the current power band will start. This is normal and it prevents
the system from overloading. Priority setpoints are not actually changed. Virtual values “engine
priority” are used.
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7.6.3.2.1 Handover UP Swap sequence
Power [kW]
Sum of available nominal
power – running gen-sets
in PM
Load
Level of Load reserve start
Setpoint #LoadResStrt X
Nom G1
Time
Nom
G1+G2
Gen 2 Ready
#NextStrt del
Start
Stabilization
Synchronization
Soft loading
Loaded
Running
Gen 1
BO Syst res OK
Loaded
Soft unloading
GCB opened
#NextStop Del
Stopped and ready to PM
Nom G2
#PwrBnChngDlUp
#NextStop Del*
Sum of available nominal power – running gen-sets in PM*
Cooling
Time
*Soft unloading
GCB opened
*Cooling
As explain above, the automatic priority swapping evaluates the load of the system and assigns the
most appropriate power band. The handover UP sequence describes the situation the gen-set with
lower nominal power is swapped by the gen-set with higher nominal power. The gen-set with lower
nominal capacity is stopped once the sequence is over. The stopped gen-set is in ready state and
keeps available in power management.
NOTE:
If the power band change delay Pwr management: #PwrBnChngDlUp is adjusted to that longer value
than total time requiring start of other gen-set, stabilization, synchronization, GCB closing and soft
loading, it postpones the soft unloading of the gen-set to be stopped. This delay is depicted by the
dashed orange line. Consequently, the handover up swap sequence is postponed by this delay.
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Power [kW]
Sum of available nominal
power – running gen-sets
in PM
Load
Level of Load reserve stop
Setpoint #LoadResStop X
Nom G1
Time
Nom
G1+G2
Time
Gen 2
#NextStop del
Start
Stabilization
Synchronization
Soft loading
Gen 1
BO Syst res OK
Ready
Soft unloading
GCB opened
Loaded
Nom G2
#PwrBnChngDlDn
#NextStrt del
*Cooling
#NextStop del*
Sum of available nominal power – running gen-sets in PM*
*Soft unloading
GCB opened
7.6.3.2.2 Handover DOWN Swap sequence
The handover DOWN sequence describes the opposite situation. The gen-set with higher nominal
power is swapped by the gen-set with lower nominal power. The gen-set with higher nominal capacity
is stopped once the sequence is over. The stopped gen-set is in ready state and keeps available in
power management.
NOTE:
If the power band change delay Pwr management: #PwrBnChngDlDn is adjusted to that longer value
than total time requiring start of other gen-set, stabilization, synchronization, GCB closing and soft
loading, it postpones the soft unloading of the gen-set to be stopped. This delay is depicted by the
dashed orange line. Consequently, the handover down swap sequence is postponed by this delay.
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EXAMPLE:
MCB MGCB
GCB1
InteliMains
CAN
2
3
1
Basic settings:
Contr. Addr = 4
Pwr management:
#PriorAutoSwap = LD
DEMAND SWAP
Priority ctrl = MASTER
#PwrBandContr1 = 1
#PwrBandContr2= 2
#PwrBandContr3 = 3
#PwrBandContr4 = 2+3
#PwrBandChngDlUp = 10s
#PwrBandChngDlDn = 10s
Control group = COMMON
Basic settings:
Contr. Addr = 1
Pwr management:
#PriorAutoSwap = LD
DEMAND SWAP
Priority ctrl = SLAVE
#PwrBandContr1 = 1
#PwrBandContr2= 2
#PwrBandContr3 = 3
#PwrBandContr4 = 2+3
#PwrBandChngDlUp = 10s
#PwrBandChngDlDn = 10s
Control group = COMMON
Basic settings:
Contr. Addr = 2
Pwr management:
#PriorAutoSwap = LD
DEMAND SWAP
Priority ctrl = SLAVE
#PwrBandContr1 = 1
#PwrBandContr2= 2
#PwrBandContr3 = 3
#PwrBandContr4 = 2+3
#PwrBandChngDlUp = 10s
#PwrBandChngDlDn = 10s
Control group = COMMON
Basic settings:
Contr. Addr = 3
Pwr management:
#PriorAutoSwap = LD
DEMAND SWAP
Priority ctrl = SLAVE
#PwrBandContr1 = 1
#PwrBandContr2= 2
#PwrBandContr3 = 3
#PwrBandContr4 = 2+3
#PwrBandChngDlUp = 10s
#PwrBandChngDlDn = 10s
Control group = COMMON
GCB2
GCB3
Gen-sets
Nominal power [kW]
Power band [kW]
G1
200
0 .. 150
G2
500
151 .. 450
The system is shown in previous figure. The InteliMains controller assumes the role of master in
priority swapping and swaps engine priority based on user defined power bands. There are 4 available
customizable power bands. The power band #5 is fixed – all available gen-set in power gen-set are
running.
Power bands are changed up if:
(Nominal power of all gen-sets in a particular band - Total generated power by gen-sets in power
management) < Reserve for start
or down if:
(Nominal power of all gen-sets in next lower band - Total generated power by gen-sets in power
management) > Reserve for stop
The site contains 3 gen-sets, G1 is 200kW, G2 is 500kW and G3 is 1000kW. The reserve for start is
adjusted to 50kW and for stop to 70kW. Following table describes available power bands:
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Figure: Load Demand Swapping example
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G1+G2
700
451 .. 650
G3
1000
651 .. 950
G1+G3
1200
951 .. 1150
G2+G3
1500
1151 .. 1450
G1+G2+G3
1700
>1450
Power band
Gen-sets
Nominal power [kW]
Power band range [kW]
#PwrBandContr1
G1
200
0 .. 150
#PwrBandContr2
G2
500
151 .. 450
#PwrBandContr3
G3
1000
451 .. 950
#PwrBandContr4
G2+G3
1500
951 .. 1450
Fixed power band #5
G1+G2+G3
1700
>1450
Following table describes selected power bands:
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Following figure illustrates the power bands swapping in function of load evolution.
130
430
930
1430
150
450
950
1450
200
500
1000
1500
Gen 1
Gen 2
Gen 3
1700
t1 t2 t3 t4 t5
t6
t7
t8 t9
Power [kW]
Time
Sum of available nominal power – running gensets in PM
Total Load of
the system
Level to start additional gen-set
Nom Pwr - #LoadResStrt X
Level to stop additional gen-set
Nom Pwr - #LoadResStop X
Handover Up Swap sequence Starting sequence Stopping sequence
Handover DOWN Swap sequence
Time
step t1
t1
->
t2
t2 t2->
t3
t3
t3
->
t4
t4
t4
->
t5
t5
t5
->
t6
t6
t6
->
t7
t7
t7
->
t8
t8
t8
->
t9
t9
Gen#1
200
kW
LOADED
handover UP
READY
handover UP
READY
starting of gen#2
READY
starting of gen#1
LOADED
stopping of gen#1
READY
stopping of gen#2
READY
handover DOWN
READY
handover DOWN
LOADED
Gen#2
500
kW
READY
LOADED
READY
LOADED
LOADED
LOADED
READY
LOADED
READY
Gen#3
1 000
kW
READY
READY
LOADED
LOADED
LOADED
LOADED
LOADED
READY
READY
Figure: Load Demand Swapping example
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7.6.3.3 Efficiency
MCB MGCB
CAN
1
Comms settings:
Contr. Addr = 1
Basic settings:
Nomin power =
300 kW
Pwr management:
#PriorAutoSwap =
EFFICIENCY
Priority ctrl = SLAVE
#RunHrsMaxDiff = 9h
RunHoursBase = 0 h
Control group =
COMMON
Comms settings:
Contr. Addr = 2
Basic settings:
Nomin power =
200 kW
Pwr management:
#PriorAutoSwap =
EFFICIENCY
Priority ctrl = SLAVE
#RunHrsMaxDiff = 9h
RunHoursBase = 0
Control group =
COMMON
Values: Statistics
Run hours = 0
Comms settings:
Contr. Addr = 3
Comms settings:
Nomin power =
200 kW
Pwr management:
#PriorAutoSwap =
EFFICIENCY
Priority ctrl = SLAVE
#RunHrsMaxDiff = 9h
RunHoursBase = 0 h
Control group =
COMMON
Values: Statistics
Run hours = 10 h
Comms settings:
Contr. Addr = 4
Comms settings:
Nomin power =
200 kW
Pwr management:
#PriorAutoSwap =
EFFICIENCY
Priority ctrl = SLAVE
#RunHrsMaxDiff = 9h
RunHoursBase = 0 h
Control group =
COMMON
Values: Statistics
Run hours = 20 h
Comms settings:
Contr. Addr = 5
Comms settings:
Nomin power =
100 kW
Pwr management:
#PriorAutoSwap =
EFFICIENCY
Priority ctrl = SLAVE
RunHoursBase = 0 h
Control group =
COMMON
2 3 4 5
GCB1
GCB2
GCB3
GCB4
GCB5
InteliMains
Comms settings:
Contr. Addr = 6
Pwr management:
#PriorAutoSwap =
EFFICIENCY
Priority ctrl = MASTER
Control group =
COMMON
Setpoint group
Basic settings
Pwr management
Setpoint
Nomin power / RHE
Pwr management
#Pwr mgmt mode
Priority
#PriorityAutoSwap
#LoadResStrt X
#LoadResStop X
Gen-set #1
300 kW
ENABLED
ABS (kW)
1
EFFICIENCY
20 kW
30 kW
Gen-set #2
200 kW / 0 h
ENABLED
ABS (kW)
2
EFFICIENCY
Gen-set #3
200 kW / 10 h
ENABLED
ABS (kW)
3
EFFICIENCY
Gen-set #4
200 kW / 20 h
ENABLED
ABS (kW)
4
EFFICIENCY
Gen-set #5
100 kW
ENABLED
ABS (kW)
5
EFFICIENCY
The Efficiency mode is a combination of Running Hours Equalization and Load Demand Swap priority
optimization modes. Please refer to chapters 7.6.3.1 and 7.6.3.2 for further information about RHE
and LDS priority optimization function.
In the first step, the controller sorts the gen-sets according to their nominal power.
In the second step, the controller sorts the gen-sets with the same nominal power according to
their RHE.
The gen-set(s) their nominal power fits the most are chosen. From those with same nominal
power, the gen-set(s) with lowest RHE are chosen.
EXAMPLE:
NOTE:
Gen-set #1 means that the CAN address of the controller is set to 1. The relevant setpoint is adjusted
by Comms settings: Contr. address.
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Following table provide an example of gen-set selection in function of system load evolution. The table
System Load
[kW]
Running gen-sets
Description
Total Running
power within PM
[kW]
Relative load of
gen-sets [%]
40
100
40%
60
100
60%
80
[0h]
start
stop
LDS Swap
300
26%
100
[10h]
200
50%
120
[20h]
200
60%
120
[30h] [10h]
Start
stop
RHE Swap
400
30%
120
[20h]
200
60%
140
[30h]
200
70%
180
[40h]
Start
stop
LDS Swap
500
36%
200
300
67%
240
300
80%
280
Start
Gen#5 joins
(LDS)
400
70%
340
400
85%
380
[20h]
start
stop
LDS + RHE
Swap
600
63%
400
500
80%
440
500
88%
480
start
Gen#5 joins
(LDS)
600
80%
540
600
90%
580
[30h]
start
stop
LDS Swap
800
73%
600
700
86%
640
700
91%
680
start
Gen#5 joins
(LDS)
800
85%
740
800
93%
780
[40h]
start
stop
LDS Swap
1000
78%
800
900
89%
840
900
93%
880
start
Gen#5 joins
1000
88%
is an example of Efficiency priority optimization function.
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(LDS)
940
1000
94%
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7.6.4 Minimum Running Power
Power [kW]
Sum of available nominal
power – running gen-sets in
PM
Total Load of the
system
Level to start additional gen-set
Nom Pwr in PM - #LoadResStrt X
75
575
100
600
200
700
1700
Time
Time
Starting
sequence
Gen 1
Gen 2
Running
Gen 3
Start sequence
Stop sequence
Stopped
and ready
Starting
sequence
Stopped and ready
Stopping
sequence
Stopping
sequence
Level to stop additional gen-set
Nom Pwr in PM - #LoadResStop X
400
MinRun
Pwr
LBI:MinRunPwr 1
Minimal available
nominal power in PM if
LBI: MinRunPWR 1
activated
Minimum Running Power function is used to adjust a minimum value of the sum of nominal power of
all running gen-sets. If the function is active, then the gen-sets would not be stopped, although the
reserve for stop is fulfilled.
EXAMPLE:
The setpoint Pwr management: #MinRunPower 1 is adjusted to 400 kW. Once the LBI: MinRunPwr 1
is activated, the available nominal running power has to be equal or higher to 400 kW. Even if the load
reserve is big enough to stop the gen-set #2 (nominal power 500 kW), the gen-set keeps running as at
least 400 kW has to be available. The gen-set#1 (nominal power 200 kW) is not enough.
There are 3 different MinRunPower setpoints.
InteliMainsNT, SW version 3.2.0
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#MinRunPower 1 considered if LBI MinRun power 1 activated
#MinRunPower 2 considered if LBI MinRun power 2 activated
#MinRunPower 3 considered if LBI MinRun power 3 activated
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NOTE:
Virtual I/O
BI n
Virtual I/OVirtual I/O
Power
management
Power
management
Power
management
BO n
BI n
#Controller 1 #Controller 2 #Controller 3
Switch for activation
of MiniRun power
set #2
BI n
CAN 2
LBI: MiniRun Power 2
LBI: MiniRun Power 2 LBI: MiniRun Power 2
If more than one binary input for MinRunPower activation is closed MinRunPower setpoint with higher
number is used (i.e. binary inputs with higher number have higher priority). When no binary input is
closed, then minimal running power is 0.
NOTE:
All controllers cooperating together in Power management must have the same Minimal Running
Power set selected.
It is possible to use virtual shared peripheries for distribution of the binary signal activating LBI MinRun
Power 1,2 or 3 among controllers over the CAN bus.
Figure: Example of using virtual shared peripheries for signal distribution
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7.6.5 Control Groups
BTB
CAN
1 2
Controller Controller
Control group: 2
GroupLinkLeft: COMMON
GroupLinkRight: COMMON
BI Group link: NC
Control group: 2
GroupLinkLeft: 2
GroupLinkRight: 3
Group link: BTB feedb.
Control group: 3
GroupLinkLeft: 2
GroupLinkRight: 3
Group link: BTB feedb.
Control group: 3
GroupLinkLeft: COMMON
GroupLinkRight: COMMON
BI Group link: NC
Controller Controller
BI Goup
link
3 4
The physical group of the gen-sets (i.e. the site) can be separated into smaller logical groups, which
can work independently even if they are interconnected by the CAN2 bus. The logical groups are
intended to reflect the real topology of the site when the site is divided into smaller gen-set groups
separated from each other by bus-tie breakers. If the bus-tie breakers are closed the sub-groups have
to work as one large group and if the bus-tie breakers are open, the sub-groups have to work
independently.
The group which the particular controller belongs to is adjusted by the setpoint
Pwr management: Control group. If there is only one group in the site, adjust the setpoint to 1
(=COMMON).
The information which groups are currently linked together is being distributed via the CAN.
Each controller can provide information about one BTB breaker. The breaker position is
detected by the input GroupLink (i.e. this input is to be connected to the breaker feedback).
The two groups which are connected together by the BTB breaker mentioned above are
adjusted by setpoints Pwr management: GroupLinkLeft and
Pwr management: GroupLinkRight.
NOTE:
The "group link" function is independent on the group, where the controller itself belongs to.
The controller can provide "group link" information about any two groups.
If the "group link" is opened the two groups act as two separated groups. If it is closed the
roups act as one large group.
The picture below shows an example of a site with 4 gen-sets separated by a BTB breaker into two
groups of 2. The BTB position is detected by the controllers 2 and 3. The reason, why there are 2
controllers used for detection of the BTB position, is to have a backup source of the group link
information if the primary source (controller) is switched off.
Figure: Example of control groups
Once the BTB breaker is closed, the control group 2 and 3 become new group 2+3. The closed BTB
and the group link function influence the load reserve (i.e. increased by added gen-set of added gensets). Load sharing applies for all gen-sets.
InteliMainsNT, SW version 3.2.0
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7.6.6 Load shedding based on active power
Load shedding is a function that automatically disconnects and reconnects various loads depending
on several user defined parameters. The load shedding based on active power is activated by setting
the setpoint Ld shed mode to PWR ONLY.
Important setpoints: all setpoints in group Load shedding
The load shedding function is active in all controller modes except OFF. Load shedding works based
on mains import value or the total gen-set group active power (setpoint Load shedding:LdShedBased
on).
Load shedding has three steps and each step is linked with its own Load shed binary output
(LDSHED STAGE X). There are three load shed levels and delays for all three steps as well as recon
levels and delays (setpoints in Load shedding group Ld shedLevel1-3, Ld shedDelay1-3, Ld
reconLevel1-3, Ld reconDelay1-3). Load shed can only move from one step to the next, e.g. “No
LoadShed” to “LdShed stage 1” to “LdShed stage 2” to “LdShed stage 3” and vice versa.
If manual reconnection of the load is desired, the Load shedding:AutoLd recon setpoint needs to be
disabled (DISABLED) and the MANUALLDRECON binary input needs to be configured.
Rising edge on this input resets the controller to a lower stage, but only if the load is under the Ld
recon level for Ld recon delay at that moment.
Depending on Load shedding:Ld shed active setting load shedding is active never (DISABLE), during
island operation (ISLAND ONLY), during island operation with special function when transition to
island operation occurs (ISL + TRIP PARAL) or all the time (ALL THE TIME)
EXAMPLE:
When Ld shed active = ISL + TRIP PARAL, all load shed outputs are activated (closed) to trip the
unessential load when gen-set group goes to island:
a) Immediately when MGCB closes after mains fail and gen-set group is instructed to start in
AUT mode (MGCB application only).
b) After EmergStart del elapses when mains fail and gen-set group is instructed to start in AUT
mode (MCB application only).
c) Immediately when MGCB is closed in MAN mode by button (transit to island from parallel
operation).
NOTE:
If no Load Shedding outputs are configured, there is no record to history and no screen timer
indication of the activity of this function.
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Ld shed delay
Ld shed delay
Ld shed delay
BO LdShed stage 1
BO LdShed stage 2
BO LdShed stage 3
Ld shed level
Mains import or
gen-sets power
Time
Ld recon delay
Ld recon delay
Ld recon delay
BO LdShed stage 1
BO LdShed stage 2
BO LdShed stage 3
Ld recon level
Time
Mains import or
gen-sets power
Ld recon delay
Ld recon delay
Ld recon delay
BO LdShed stage 1
BO LdShed stage 2
BO LdShed stage 3
Ld recon level
Mains import or
gen-sets power
Time
BI ManualLdRecon
Figure: Examples of load shedding and load reconnection (load shed, load recon, manual load recon)
7.6.7 Load shedding based on frequency
Load shedding is a function that automatically disconnects and reconnects various loads depending
on several user defined parameters. The load shedding based on frequency is activated by setting the
setpoint Ld shed mode to FREQ ONLY.
Important setpoints: all setpoints in group Load shedding
The load shedding function is active in all controller modes except OFF. Load shedding works based
on Mains frequency or Bus frequency based on setting LdShedBase on (MAINS IMPORT is Mains
frequency, GEN-SETS means Bus frequency).
Load shedding has three steps and each step is linked with its own Load shed binary output
(LDSHED STAGE X). There are three load shed levels and delays for all three steps as well as recon
levels and delays (setpoints in Load shedding group Ld shed f lvl1-3, Ld shedDelay1-3,
LdRecon f lvl1-3, Ld reconDelay1-3). Load shed can only move from one step to the next, e.g. “No
LoadShed” to “LdShed stage 1” to “LdShed stage 2” to “LdShed stage 3” and vice versa.
If manual reconnection of the load is desired, the Load shedding:AutoLd recon setpoint needs to be
disabled (DISABLED) and the MANUALLDRECON binary input needs to be configured.
InteliMainsNT, SW version 3.2.0
InteliMains-NT-MCB-MGCB-3.2.0-Reference Guide.pdf, ©ComAp – April 2015
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