ComAp IG-NT, IG-NTC, IS-NT, IG-EEC, IG-NT-BB Reference Manual
...
Copyright © 2005 ComAp s.r.o.
ComAp, spol. s r.o.
Kundratka 2359/17, 180 00 Praha 8, Czech Republic
Tel: +420 266 012 111, Fax: +420 266 316 647
Technical support hotline: +420 266 012 666
E-mail: info@comap.cz, www.comap.cz
Compact Controller for Stand-by and Parallel Operating Gen-sets
Inteli New Technology
Modular Gen-set Controller
Multiple Internal engines application – SW configuration
MINT
IG-NT, IG-NTC, IG-EE, IG-EEC, IS-NT,IG-NT-BB, IG-NTC-BB, IS-NTC-BB
Software version IGS-NT-3.0, May 2013
REFERENCE GUIDE
2
Table of Contents
Table of Contents ............................................................................................................................................... 2
Document information ........................................................................................................................................ 4
Available related documentation ........................................................................................................................ 5
General guidelines .............................................................................................................................................. 6
What is described in this manual? ................................................................................................................. 6
Dangerous voltage ......................................................................................................................................... 7
Adjust set points ............................................................................................................................................. 7
Clarification of notation ................................................................................................................................... 8
Available Firmware and Archive sets ................................................................................................................. 9
General description .......................................................................................................................................... 10
Basic description of MINT application .......................................................................................................... 10
Functions .......................................................................................................................................................... 11
OFF-MAN-AUT mode .................................................................................................................................. 11
Active and Reactive Power control modes in MINT ..................................................................................... 12
Power management ..................................................................................................................................... 12
Load shedding .............................................................................................................................................. 17
Engine states................................................................................................................................................ 18
Circuit breakers operation sequence, GCB/MCB fail detection ................................................................... 26
Remote Alarm Messaging ............................................................................................................................ 32
Controller Redundancy ................................................................................................................................ 33
Force value – step by step guide ................................................................................................................. 34
Values for continuous writing from external sources ................................................................................... 36
General Purpose Timers .............................................................................................................................. 36
History Related functions ............................................................................................................................. 37
User Buttons................................................................................................................................................. 39
Remote Control Function ............................................................................................................................. 39
Virtual Peripheral Inputs-Outputs (VPIO) module ........................................................................................ 40
Shared Inputs and Outputs .......................................................................................................................... 40
Distributed Binary Inputs and Outputs ......................................................................................................... 42
Modbus Reading and Writing ....................................................................................................................... 43
User MODBUS ............................................................................................................................................. 44
Analog Input Sensors and User Sensors ..................................................................................................... 44
Languages and Translator tool in GenConfig .............................................................................................. 45
Power Formats ............................................................................................................................................. 45
System Start/Stop ........................................................................................................................................ 46
User Mask function ...................................................................................................................................... 47
PLC functions ............................................................................................................................................... 47
Multi language support ................................................................................................................................. 47
ECU interface customizing ........................................................................................................................... 47
Protections and Alarm management ................................................................................................................ 49
Configuration of User configurable protections in GenConfig ...................................................................... 55
Gen-set operation states .................................................................................................................................. 58
Inputs and Outputs ........................................................................................................................................... 60
Virtual and physical modules ....................................................................................................................... 60
Setpoints ........................................................................................................................................................... 61
List of possible events ...................................................................................................................................... 62
Controller configuration and monitoring ........................................................................................................... 63
Direct connection to the PC ......................................................................................................................... 63
GenConfig functions ..................................................................................................................................... 63
InteliMonitor .................................................................................................................................................. 64
Modbus protocol ........................................................................................................................................... 64
Value and setpoint codes ............................................................................................................................. 64
Technical data .............................................................................................................................................. 64
Language support ........................................................................................................................................ 64
Setpoint groups ................................................................................................................................................ 67
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Setpoints - SMS/E-Mail ................................................................................................................................ 67
Setpoints - Analog protect ............................................................................................................................ 67
Setpoints - Basic Settings ............................................................................................................................ 68
Setpoints - Comms settings ......................................................................................................................... 68
Setpoints - Date/Time .................................................................................................................................. 69
Setpoints - Engine Params .......................................................................................................................... 69
Setpoints - Engine Protect ........................................................................................................................... 69
Setpoints - Force value ................................................................................................................................ 70
Setpoints - Gener Protect ............................................................................................................................. 70
Setpoints - Load shedding ........................................................................................................................... 71
Setpoints - Power Management ................................................................................................................... 71
Setpoints - Process Control ......................................................................................................................... 72
Setpoints - Sync/load Ctrl ............................................................................................................................. 72
Setpoints - Timer settings ............................................................................................................................ 73
Setpoints - Volt/PF Control ........................................................................................................................... 73
Value groups .................................................................................................................................................... 74
Values group - Analog CU ........................................................................................................................... 74
Values group - Bin inputs CU ....................................................................................................................... 74
Values group - Bin outputs CU ..................................................................................................................... 74
Values group - Engine values ...................................................................................................................... 74
Values group - Force value .......................................................................................................................... 74
Values group - Gener values ....................................................................................................................... 75
Values group - Info ....................................................................................................................................... 75
Values group - Log Bout .............................................................................................................................. 76
Values group - Load shedding ..................................................................................................................... 76
Values group - Bus values ........................................................................................................................... 76
Values group - Power management ............................................................................................................ 76
Values group - Statistics .............................................................................................................................. 76
Values group - Sync/Load ctrl ...................................................................................................................... 77
Values group - Volt/PF ctrl ........................................................................................................................... 77
Binary input functions ....................................................................................................................................... 78
Analog input functions ...................................................................................................................................... 80
Binary output functions ..................................................................................................................................... 81
Common functions ....................................................................................................................................... 81
Breaker control ............................................................................................................................................. 81
Control loops ................................................................................................................................................ 81
Power management ..................................................................................................................................... 81
Status information ........................................................................................................................................ 82
Fixed protections output ............................................................................................................................... 82
Configurable protections output ................................................................................................................... 83
Table of setpoints ......................................................................................................................................... 84
Table of values ........................................................................................................................................... 196
Table of binary input functions ................................................................................................................... 230
Table of analog input functions .................................................................................................................. 275
Table of binary output functions ................................................................................................................. 284
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Document information
REVISION NUMBER
RELATED SW. VERSION
DATE
1
3.0
31.5.2013
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.
IGS-NT® – MINT Reference guide
Written by: Pavel Mareš
©2013 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
Inteli NT MINT, SW Version 3.0, ©ComAp –May 2013
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Available related documentation
PDF files
Description
IGS-NT-SPTM-3.0 Reference Guide.pdf
General description of SPtM applications for
InteliGen-NT and InetliSys-NT. Contains
description of engine and generator control, control
of power in parallel to mains operation, list of all
Setpoints, Values, Logical Binary Inputs and
Logical Binary Output.
IGS-NT-SPI-3.0 Reference Guide.pdf
General description of SPI applications for
InteliGen-NT and InetliSys-NT. Contains
description of engine and generator control, control
of power in parallel to mains operation, list of all
Setpoints, Values, Logical Binary Inputs and
Logical Binary Output.
IGS-NT-MINT-3.0 Reference Guide.pdf
General description of MINT applications for
InteliGen NT and InetliSys NT. Contains
description of engine and generator control,
powermanagement, list of all Setpoints, Values,
Logical Binary Inputs and Logical Binary Output.
IGS-NT-Combi-3.0 Reference Guide.pdf
General description of Combi applications for
InteliGen-NT and InetliSys-NT. Contains
description of engine, and generator control in
SPTM, SPI and MINT mode, powermanagement,
list of all Setpoints, Values, Logical Binary Inputs
and Logical Binary Output.
IGS-NT-COX-3.0 Reference Guide.pdf
General description of COX applications for
InteliGen NT and InetliSys NT. Contains
description of engine and generator control,
powermanagement, list of all Setpoints, Values,
Logical Binary Inputs and Logical Binary Output.
IGS-NT Application Guide 05-2013.pdf
Applications of InteliGen NT, InetliSys NT and
InteliMains NT, examples of connection,
description of PLC functions, Virtual and Shared
peripheries.
IGS-NT Operator Guide 05-2013.pdf
Operator Guide for all hardware variation of
InteliGen NT and InetliSys NT, InteliVision 5 and
InteliVision 8.
IGS-NT Installation Guide 05-2013.pdf
Thorough description of installation and technical
information about InteliGen NT, InetliSys NT and
InteliMains NT and related accessories.
IGS-NT Communication Guide 05-2013.pdf
Thorough description of connectivity and
communication for InteliGen NT, InetliSys NT and
InteliMains NT and related accessories.
IGS-NT Troubleshooting Guide 05-2013.pdf
How to solve most common troubles with
InteliGen NT and InetliSys NT controllers. Including
the list of alarm massages.
IGS-NT & ID-DCU Accessory Modules 05-2013.pdf
Thorough description of accessory modules for
IGS-NT family, technical data, information about
installation of the modules, how to connect them to
controller and set them properly.
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General guidelines
Following described machine complies with the appropriate basic safety and health
requirement of the EC Low Voltage Directive No: 73/23 / EEC and EC
Electromagnetic Compatibility Directive 89/336 / EEC based on its design and type,
as brought into circulation by us.
What is described in this manual?
This manual describes „MINT“ software configuration. The software configuration is designed for multiple
sets applications with internal load sharer and synchronizer.
What is the purpose of this manual?
This manual provides general information on how to configure and operate the controller.
This manual is intended for use by:
Operators of gen-sets
Gen-set control panel builders
For everybody who is concerned with installation, operation and maintenance of the gen-set
!! Warnings !!
The NT controller can be remotely controlled. In the event that maintenance needs to be done to the gen-set,
check the following to ensure that the engine cannot be started.
To be sure:
Disconnect remote control via RS232 line
Disconnect input REMOTE START/STOP
or
Disconnect output STARTER and outputs GCB CLOSE/OPEN and MCB CLOSE/OPEN
The controller contains a large number of configurable setpoints, because of this it is impossible to describe
all of its functions. These are subject to change from SW version to SW version. This manual only describes
the product and is not guaranteed to be set for your application on arrival.
Text
ESC (Capital letters in the frame) buttons on the front panel
Break Return (Italic) set points
Generator protections (Bold) Set point group
Cyan background Valid for IS-NT only
Conformity declaration
Note:
ComAp believes that all information provided herein is correct and reliable and reserves the right to update
at any time. ComAp does not assume any responsibility for its use unless otherwise expressly undertaken.
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Be aware that the binary outputs can change state during and after software
reprogramming (before the controller is used again ensure that the proper
configuration and setpoint settings are set in the controller).
Every time you want to disconnect following NT controller terminals:
Mains voltage measuring and / or
Binary output for MCB control and / or
MCB feedback
Be aware that the MCB can be switched off and gen-set can start !!!
Switch the controller to MAN mode and disconnect the Binary outputs Starter and Fuel
to avoid unexpected automatic start of gen-set and GCB closing.
!!! CAUTION !!!
Dangerous voltage
The terminals for voltage and current measurement should never be touched.
Properly connect the grounding terminals.
Do not disconnect the CT terminals for any reason.
Adjust set points
All setpoints are preadjusted to their typical values. But the set points in the “Basic settings” settings
group !!must!! be adjusted before the first startup of the gen-set.
!!! WRONG ADJUSTMENT OF BASIC PARAMETERS
CAN DESTROY THE GEN-SET !!!
The following instructions are for qualified personnel only. To avoid personal injury do
not perform any action not specified in this User guide !!!
WARNING – VERY IMPORTANT !!!
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Clarification of notation
HINT
This type of paragraph points out details to help user installation/configuration.
NOTE:
This type of paragraph calls readers’ attention to a notice or related theme.
CAUTION!
This type of paragraph highlights a procedure, adjustment, etc. which may cause damage or improper
functioning of the equipment if not carried out correctly and may not be clear at first sight.
WARNING!
This type of paragraph indicates things, procedures, adjustments, etc. which demand a high level of
attention, otherwise personal injury or death may occur.
EXAMPLE:
This type of paragraph indicates examples of usage for illustrational purposes.
Inteli NT MINT, SW Version 3.0, ©ComAp –May 2013
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Available Firmware and Archive sets
For IG-NT-GC and IG-NTC-GC
For IG-NT-BB and IG-NTC-BB
For IS-NT-BB and IS-NTC-BB
IG-NT-GC-3.0
IG-NT-BB-3.0
IS-NT-3.0
For IG-NT(C) GC
For IG-NT-BB and IG-NTC-BB
For IS-NT-BB and IS-NTC-BB
IG-GC-SPTM-3.0
IG-BB-SPTM-3.0
IS-SPTM-3.0
IG-GC-SPI-3.0
IG-BB-SPI-3.0
IS-SPI-3.0
IG-GC-MINT-3.0
IG-BB-MINT-3.0
IS-MINT-3.0
IG-GC-COMBI-3.0
IG-BB-COMBI-3.0
IS-COMBI-3.0
IG-GC-COX-3.0
IG-BB-COX-3.0
IS-COX-3.0
IG-GC-MINT-Marine-3.0
IS-MINT-Marine-3.0
Since version 3.0 of IGS-NT Standard firmware is the Firmware differentiated for InteliGen-NT GC and
InteliGen-NT BaseBox type controllers. For suitable firmware for your controller please consult this table:
Firmware (*.mhx)
Archives (*.ant)
Some features are available only in InteliGen-NT Basebox, InteliGen-NTC Basebox and InteliSys. These
features are highlighted by green background.
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General description
Basic description of MINT application
The MINT application is intended for sites where up to 32 gen-sets cooperate with each one. It includes
following main features:
Automatic startup and stop sequences with adjustable timing
Wide range of generator and engine protections, additional freely configurable protections
Multiple island operation with digital active and reactive load sharing
Parallel to the mains operation
One breaker control (GCB) including synchronizing to the busbar.
Soft loading and unloading
Power management - automatic starting and stopping of gen-sets according to the load demand,
running hours equalization and other optimalization features
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Functions
OFF-MAN-AUT mode
OFF mode
Outputs STARTER, GCB CLOSE/OPEN and FUEL SOLENOID are not energized.
Gen-set cannot be started. If START,STOP,GCB ON/OFF buttons are pressed the controller will not
respond.
When the gen-set is running it is not possible to switch directly to OFF mode. First you have to stop the
engine.
MAN mode
1) START - starts the gen-set.
2) GCB ON/OFF
If generator voltage is out of the limits (adjusted in the set point group Gener protect) controller does
not respond to the GCB ON/OFF
a) controller closes GCB to dead bus.
b) controller starts GCB synchronizing when bus voltage is OK and MCB is closed or when other
gen-set(s) provide healthy voltage to the bus. Closes the GCB when synchronized and stays
running in parallel (island or mains parallel).
c) Unloads gen-set and opens the GCB if gen-set was running in parallel to the mains or to other
gen-set(s).
3) STOP
a) When gen-set is running in parallel: transfers the load to the mains or to other gen-set(s), opens
GCB, goes into cooling state and stops the engine.
b) When gen-set is running in single island (or in general there is no mains and no other gen-set(s)
to transfer the load to): opens GCB, goes into cooling state and stops the engine.
c) When engine is running unloaded: activates cooling sequence and then stops the engine.
d) During cooling state causes immediate engine stop.
HINT
The gen-set is permitted to run unloaded for unlimited time.
Controller does not automatically start the gen-set when SYS START/STOP input is closed.
Load control type in mains parallel depends on ProcessControl: #SysLdCtrlPtM = BASELOAD or
LDSHARING setpoint.
SEM
In SEM mode, pressing of START or STOP buttons performs a predefined sequence:
1) START – starts the engine, synchronizes and runs in parallel.
2) STOP – softly unloads the gen-set, opens GCB, provides cooldown and stops the engine.
AUT mode
1) All gen-sets necessary to cover selected LoadRes strt are started when binary input SYS START/STOP
is closed and Pwr management is ENABLED. Power management can be based on kW, kVA or on
relative % reserve.
a) 1 sec delayed when MCB FEEDBACK binary input is closed (mains parallel)
b) delayed #SysAMFstrt del when MCB FEEDBACK binary input is opened – start to island parallel
(multi AMF) situation
2) The first gen-set closes the GCB to the dead bus, the rest are synchronized to the bus.
3) When all necessary gen-sets are connected to the bus and LoadRes strt is achieved, SYST RES OK
output is closed. Output could be used to close the MGCB (Master GCB).
4) Total load and power factor are shared between parallel operating gen-sets.
5) Close input LOAD RESERVE 2 (or 3 or 4) and use setpoint LoadRes strt2(or 3 or 4) to switch to another
load reserve setting. E.g. high load reserve during system start to be able to switch-on big devices, then
during normal operation lower reserve to save engines (and fuel).
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6) If total load increases and selected LoadRes strt is no more fulfilled, after a Next start del next ready
gen-set with the highest priority (lowest priority number) is started and synchronized to the bus.
7) If load decreases and selected LoadRes stp is exceeded, after a Next stop del the running gen-set with
the lowest priority is unloaded, got off line, cooled and stopped.
8) Complete gen-sets group stops when binary input SYS START/STOP opens. If the input MCB
FEEDBACK is closed (gen-sets are in parallel to mains) controllers softly transfer the load to the mains.
When gen-set is unloaded (see GCB open level or GCB open del) opens the output GCB
CLOSE/OPEN.
9) The Running hours balancing or Load demand engines swap can be activated in power management.
HINT
Controller does not respond to GCB ON/OFF , STOP, START buttons and corresponding remote
InteliMonitor or Modbus commands in AUT mode.
Set Basic setting: FltRes GoToMAN = ENABLED to avoid automatic engine start when pressing FAULT
RESET after any 2nd level alarm (Shutdown, Slow stop, Breaker Open&Cooldown).
Active and Reactive Power control modes in MINT
System Base load
Gen-set group is controlled on constant (or adjustable) power. The Baseload value can by changed by
setpoint or via analog input.
Important setpoints: ProcessControl: #SysLdCtrlPtM = BASELOAD; #SysBaseload; SysBaseLdMode.
Local Baseload
Selected gen-set from island or mains parallel running group can be loaded to constant LocalBaseload
value. This engine is taken out from Load sharing and Power management. LocalBaseload value is reduced
only when common group (actual) load is lower than this value. The gen-sets in the group will try to match
their LocalBaseloads (when more than one) based on their controller addresses, so the first limited would be
the one with the highest CAN address. I.e. this function will switch-off automatically in one or more
controllers if there is not enough load to cover all the requested LocalBaseloads.
Important setpoints: ProcessControl: LocalBaseload.
System Base power factor
Gen-set group is controlled in mains parallel to keep a constant (or adjustable) power factor.
Important setpoints: ProcessControl: #SysPFCtrlPtM = BASEPF; #SysPwrFactor.
Import-Export
Gen-set group is controlled to keep constant (or adjustable) Import or Export value. The external controller
InteliMains NT must be connected on the CAN2 to control gen-set group kW I/E.
Important setpoints: ProcessControl: #SysLdCtrlPtM = LDSHARING.
Import/Export power factor
Gen-set group is controlled to keep constant (or adjustable) Import or Export power factor.
Important setpoints: ProcessControl: #SysLdCtrlPtM = VSHARING. The external InteliMains NT controller
must be connected on the CAN2 to control gen-set group PF I/E.
Power management
Automatic gen-set start / stop function based on load changes and/or Running hours or Engine size.
Following functions are available:
Power management in kW
Guarantees adjustable load reserve (load step) in kW. Suitable for load demand-based optimization.
Activation: Pwr management:#Pwr mgmt mode = ABS (kW)
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Power management in kVA
Gen1
Priority 1
Gen2
Priority 2
Gen3
Priority 3
Gen 1 = Running, Loaded
Gen 2
#LdResStrt1
#LdResStrt1
#NextStrt del
Running
Gen 3
#NextStrt del
Running
#LdResStp1
#NextStp del
Unloading / Cooling
#NextStp del
Unloading / Cooling
#LdResStp1
Actual power [ kW or kVA ]
Time
BO Syst res OK
#LdResStrt1
Figure: Power management function in absolute mode
Guarantees adjustable load reserve (load step) in kVA. Suitable for generator- or busbar dimensioningbased optimization.
Activation: Pwr management:#Pwr mgmt mode = ABS (kVA)
Relative power management in %
Guarantees that the engines are not continuously loaded more than to a certain level. Suitable for engine
life-based optimization.
Activation: Pwr management:#Pwr mgmt mode = REL (%)
Inteli NT MINT, SW Version 3.0, ©ComAp –May 2013
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Gen1
Priority 1
Gen2
Priority 2
Gen3
Priority 3
Gen 1 = Running, Loaded
Gen 2
#%LdResStrt1
= 25%
#%LdResStrt1
= 25%
#NextStrt del
Running
Gen 3
#NextStrt del
Running
#%LdResStp1
=37%
#NextStp del
Unloading / Cooling
#NextStp del
Unloading / Cooling
#%LdResStp1
=37%
Actual power [ kW or kVA ]
Time
BO Syst res OK
#%LdResStrt1
= 25%
Reserve
Actual Reserve
Start condition
Stop condition
Absolute
kW / kVA
ARstrt = ΣPg
Nom
– ΣPg
Act
ARstp = ΣPg*
Nom
– ΣPg
Act
ARstrt < #LdResStrt
ARstp > #LdResStp
Relative
%
RRstrt = [(ΣPg
Nom
– ΣPg
Act
) / ΣPg
Nom
].100%
RRstp = [(ΣPg*
Nom
– ΣPg
Act
) / ΣPg*
Nom
].100%
RRstrt < #%LdResStrt
RRstp > #%LdResStp
ARstrt
Actual Absolute reserve in kW or kVA - for engine start calculation.
ARstp
Actual Absolute reserves in kW or kVA - for engine stop calculation.
RRstrt
Actual Relative reserve in % - for engine start calculation.
RRstp
Actual Relative reserves in % - for engine stop calculation.
ΣPg
Nom
Sum of Nominal power of all gen-sets on the bus.
Figure: Power management function in relative mode
art/Stop conditions in Power management
St
Where
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Second lowest considered running hours –
Current lowest considered running hours +
#RunHrsMaxDiff
450 – 250 + 10 = 210 hours
ΣPg*
Nom
Sum of Nominal power of all gen-sets on the bus apart of the one, which is going to be
stopped.
ΣPg
Act
Sum of Actual power of all gen-sets on the bus = system load.
NOTE:
G1 G2 G3
Basic settings:
Contr. Addr = 2
Pwr management:
#PriorAutoSwap = RUN HOURS EQU
Priority ctrl = SLAVE
RunHoursBase = 200h
#RunHrsMaxDiff = 10h
Control group = COMMON
Basic settings:
Contr. Addr = 1
Pwr management:
#PriorAutoSwap = RUN HOURS EQU
Priority ctrl = SLAVE
RunHoursBase = 100h
#RunHrsMaxDiff = 10h
Control group = COMMON
Basic settings:
Contr. Addr = 3
Pwr management:
#PriorAutoSwap = RUN HOURS EQU
Priority ctrl = SLAVE
RunHoursBase = 300h
#RunHrsMaxDiff = 10h
Control group = COMMON
Basic settings:
Contr. Addr = 4
Pwr management:
#PriorAutoSwap = RUN HOURS EQU
Priority ctrl = MASTER
#RunHrsMaxDiff = 10h
Control group = COMMON
InteliMains
CAN
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.
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
pwr mgmnt
Running hours equalization (RHE)
The gen-sets priorities are automatically swapped to balance engine running hours. Up to 32 controllers are
supported.
Activation: Pwr management:#PriorAutoSwap = RUN HOURS EQU
Important setpoints: RunHoursBase, #RunHrsMaxDiff, Priority ctrl, Control group
Figure: Running Hours Equalization example
EXAMPLE:
In this example the system is shown in previous figure. InteliMains assumes the role of master in priority
swapping and swappes priority of the engines based on their running hours.
Gen-set 1 running hours = 250 -> running hours considered in RHE = 150 (250-RunHoursBase)
Gen-set 2 running hours = 450 -> running hours considered in RHE = 250 (450-RunHoursBase)
Gen-set 3 running hours = 750 -> running hours considered in RHE = 450 (750-RunHoursBase)
All the engines have the same nominal power which is 700 kW. Originally priority of gen-sets was G1 = 3, G2
= 2, G3 = 1. Load demand in this example is constant and it is 500 kW (so only one engine is running at any
time).
InteliMains will change priority of gen-set 1 to 1 because it has the lowest considered running hours and genset 1 will run for 210 hours.
After 210 hours, situation will change. Gen-set 2 will
now have the lowest considered running hours
(Gen-set 1 = 460, Gen-set 2 = 450, Gen-set 3 =
750). Gen-set 2 will now have priority 1 and it will run
for 20 hours. Then Gen-set 1 will run again for 20
hours. This will continue until both engines will have
running hours 770. Then the third engine will run. At that point engines will be swapping with period of 20
hours (2 x Pwr management:#RunHrsMaxDiff).
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G1 G2 G3
Basic settings:
Contr. Addr = 2
Pwr management:
#PriorAutoSwap = LD DEMAND SWAP
Priority ctrl = SLAVE
#PwrBandContr1 = 1
#PwrBandContr2 = 2
#PwrBandContr3 = 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 = 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 = 2+3
#PwrBandChngDlUp = 10s
#PwrBandChngDlDn = 10s
Control group = COMMON
Basic settings:
Contr. Addr = 4
Pwr management:
#PriorAutoSwap = LD DEMAND SWAP
Priority ctrl = MASTER
#PwrBandContr1 = 1
#PwrBandContr2 = 2
#PwrBandContr3 = 2+3
#PwrBandChngDlUp = 10s
#PwrBandChngDlDn = 10s
Control group = COMMON
InteliMains
CAN
NOTE:
Core power management is still fully functional.
Priority setpoints are not actually changed. Virtual values 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
Different sized engines (Load demand) swap (LDS)
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
availatible 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.
EXAMPLE:
In this example the system is shown in previous figure. InteliMains assumes the role of master in priority
swapping and swappes priority of the engines based on user defined power bands. In power band 1, gen-set
with CAN address 1 will be running, in power band 2, gen-set with CAN address 2 will be running and in
power band 3, gen-sets with address 2 and 3 will be running.
Power bands are changed up if:
or down if:
Power management using control groups
When a Bus-tie separates the gen-set groups, they can operate separately (power management, load
control, mode of function etc.). When GROUPLINK is active, all the gen-sets in according groups are controlled
by InteliMains with lower CAN address only.
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Figure: Load Demand Swapping example
(Nominal power of all gen-sets in a particular band - Total generated power by gen-sets in power
management) < Reserve for start
(Nominal power of all gen-sets in next lower band - Total generated power by gen-sets in power
management) > Reserve for stop
17
G1 G2 G3
Basic settings:
Contr. Addr = 2
Pwr management:
Control group = COMMON
Basic settings:
Contr. Addr = 1
Pwr management:
Control group = COMMON
Basic settings:
Contr. Addr = 3
Pwr management:
Control group = COMMON
GroupLinkLeft = COMMON
GroupLinkRight = 2
BTBfeedback = GroupLink
Basic settings:
Contr. Addr = 6
Pwr management:
Control group = COMMON
InteliMains
CAN
G4 G5
InteliMains
Basic settings:
Contr. Addr = 4
Pwr management:
Control group = 2
Basic settings:
Contr. Addr = 5
Pwr management:
Control group = 2
Basic settings:
Contr. Addr = 7
Pwr management:
Control group = 2
Load shedding: Ld shed level
Ld shed delay
Ld recon level
Ld recon delay
AutoLd recon
LdShed stage 1
LdShed stage 2
LdShed stage 3
ManualLdRecon
Important setpoints: Control group, GroupLinkLeft, GroupLinkRight
Figure: Power management using control groups
EXAMPLE:
In the example above, bus tie breaker separates gen-sets into two groups. BTB is operated manually in this
example. If BTB is opened, each control group is working independently. If the BTB closes, controller
number 3 sends signal via CAN bus and groups COMMON and 2 are connected together. One InteliMains
(the one with lower CAN address) takes over and controls both groups. It is not possible to use both
InteliMains parallel to the Mains when BTB is closed and InteliMains with lower CAN address takes over the
control. In this case gen-sets are controlled only by this InteliMains and the second InteliMains does not have
any means to control its parallel function.
Load shedding
All LOAD SHED outputs are activated (closed) to trip the unessential load when gen-set goes to island:
a) When GCB is closed after mains fail and gen-set starts in SEM / AUT mode.
b) When MCB opens from parallel to mains operation in SEM / AUT mode.
c) Before MCB is opened in MAN mode by button.
The load shedding function is active in all controller modes except OFF.
Load shedding has three steps and each step is linked with its own Load shed x binary output. There is only
one load shed level and delay for all three steps as well as recon level and delay. Load shed can only move
from one step to the next, e.g. No LoadShed to LdShed S1 to LdShed S2 to LdShed S3 and vice versa.
If manual reconnection of the load is desired, the AutoLd recon setpoint needs to be disabled (AutoLd recon
= DISABLED) and the MAN load recon binary input needs to be configured.
Rising edge on this input resets the controller to a lower stage, but only if the load is under the Ld recon level
at that moment.
HINT
If no Load Shedding outputs are configured, there is no record to history and no scrren timer indication of the
activity of this function.
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Ld shed del
Ld shed del
Ld shed del
BO Load shed 1
BO Load shed 2
BO Load shed 3
Ld shed level
Gen-set power
closed
closed
closed
Ld recon del Ld recon delLd recon del
BO Load shed 2
Ld recon level
Gen-set power
BO Load shed 3
BO Load shed 1
opened
opened
opened
BO Load shed 2
Ld recon level
G
e
n
-
s
e
t
p
o
w
e
r
BO Load shed 3
BO Load shed 1
BI Man load recon
opened
opened
opened
no action
Engine params: PrelubrTime
PrelubrPause
Prelubr pump
Not lubricated
Load reconnection – automatic -> AutoLd recon = ENABLED
Load reconnection – manual -> AutoLd recon = DISABLED
Engine states
Engine prelubrication
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Engine params: Cooling speed
Cooling time
Cooldown optim
AfterCoolTime
Cooling pump
Cooling
Engine params: Warming load
Warming temp
Max warm time
Reduces
requested load
Warming
Warming temp
Analog input
Engine protect: Service time 1
Service time 2
Service time 3
Service time 4
WrnServiceT3+4
WrnServiceT1+2
Engine params: Starting RPM
Prestart time
MaxCrank time
CrnkFail pause
Crank attempts
Idle time
Fuel solenoid
Starting
Stop solenoid
Starter
Prestart
Cranking
Crank procedure
Idle/Nominal
Idle run
Ignition
Operational
HINT
To use Prelubrication, configure Binary output PRELUBR PUMP first.
Prelubrication is disabled in controller OFF mode or if Prelubr time is set to zero.
Binary output PRELUBR PUMP is opened when engine is running.
Prelubrication cycle starts with PrelubrPause after engine stop.
Prelubrication cycle starts immediately when controller power supply is switched on or when mode changes
from OFF to MAN or AUT or after Emergency stop was reset. An Alarmlist message “Not lubricated” is active
until this first lubrication cycle has been completed.
Engine cooling
Engine warming
Service time alarm
Engine starting procedures
Engine starting procedure if Engine params: Fuel solenoid = DIESEL ENGINE with different setting of
FuelSol offset.
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-5s
BO: Fuel solenoid
RPM
BO: Starter
Negative values possible only
with DIESEL setting.
BO: Fuel solenoid
BO: Fuel solenoid
0 s offset means that Fuel
solenoid is activated together
with Starter.
FuelSol offset
+5s
RPM > Starting RPM or
Oil pressure > Starting POil or
RunIndication1,2,3 = 1
BO: Fuel solenoid
BO: Fuel solenoid
RPM > 30
BO: Starter
0 s FuelSol offset
activates
the Fuel solenoid
immediately if RPM > 30.
FuelSol ofset countdown is
started if RPM > 30.
Max up to 5s
Fuel solenoid activation
FuelSol offset
+5s
= 231 V
Idle run
BI: Sys Start /stop
BO: Starter
BO: Fuel solenoid
RPM
GenNomV
< Starting RPM
= 1000 V
Cranking
GenNomV is forced during
BO: Starter is deactivated
Starting RPM > 1000
cranking untill
Engine starting procedure if Engine params: Fuel solenoid = GAS ENGINE
Engine starting procedure with own starting procedure:
Engine is started after Starting RPM reach starting leve or other condition. BO: Starter is deactivated only if
one of those condition is fulfilled.
Generator nominal voltage is 231V but during Cranking is forced to 1000V until engine in Idle state (at least
one of condition has to be fulfilled).
Unsuccessful start – no Engine params: Starting RPM reached
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21
MaxCrank time
BO: Fuel solenoid
RPM
BO: Starter
Start fail activated only if this
has been the last start attempt in
a series.
BO: Start fail
Starting RPM level not reached
and no other signs of running
engine is present.
RPM dropped under Starting RPM
level and Underspeed enabled
-> protection activated.
Underspeed unblocking
BO: Fuel solenoid
RPM
BO: Starter
Start fail activated because of
RPM loss.
BO: Start fail
Starting RPM level.
Underspeed protection is not yet
Active. Underspeed is detected
only if RPM <= 2 and other
signs of moving engine
present = „still engine“.
= 5s
BO: Idle/Nominal
RPM
BO: Starter
Transition Idle - > Nominal RPM.
Idle time <5s
Starter switched off after
reaching Starting RPM or other
engine „running“ condition.
Underspeed protection
unblocked
Unsuccessful start – RPM disappeared before/after Underspeed protection got active:
Underspeed protection unblocking if Idle time < 5s:
Underspeed protection unblocking if Idle time > 5s:
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Idle time > 5s
= 5s
BO: Idle/Nominal
RPM
BO: Starter
Transition Idle - > Nominal RPM.
Starter switched off after
reaching Starting RPM or other
„running“ condition.
Underspeed protection
unblocked.
= 5s
Max stab time
ProtDel GroupX
Idle time
BO: Idle/Nominal
RPM
BO: Starter
Transition Idle - > Nominal RPM.
Starter switched off.
Underspeed protection
unblocked.
Electrical protections enabled.
„Engine running only“
protections of group X (=1 -3)
enabled.
Underspeed unblocking
PreVentil time
BO: Fuel solenoid
RPM
BO: Starter
Last unsuccessful start attempt or
engine Shutdown.
Starter activated, but Fuel solenoid
delayed for PreVentil time because:
last start attempt wasn‘t successful or
engine Shutdown or
this is the first start attempt after the
controller switch -on.
Additional Fuel solenoid activation
delay can be caused by
FuelSol offset setting.
Transition Idle -> Nominal RPM, protections unblocking:
Preventilation (if Fuel solenoid = GAS):
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+25%
= MaxCrank time
BO: Fuel solenoid
RPM
BO: Starter
( CrankAttempts - 1) the attempt
The last crank attempt is extended by
25% of MaxCrank time, with Fuel
solenoid closed, to ventilate the gas
from the engine.
Fuel solenoid activation delay can
be set using FuelSol offset.
1s
BO: Stop pulse
BO: Stop solenoid
Stop time
BO: Fuel solenoid
RPM + pick - up signal
Typical engine stop time
Correct setting – Stop time
setpoint is set to longer
time than typical engine
stop time.
pick up signal
BO: Stop pulse
BO: Stop solenoid
Stop time
BO: Fuel solenoid
actual RPM
Moment of the pick -up
sensor fault – measured
RPM=0.
In this moment „still engine“
is detected. If pick-up sensor
failed, there may be other
signals determining if
engine is still moving or not.
1s
Ventilation (if Fuel solenoid = GAS ENGINE):
Engine stopping procedures
Normal engine stop:
Pick-up sensor fault – forced engine stop:
Normal engine stop, but Stop time is set too short:
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2s
5s
BO: Stop solenoid
Stop time
BO: Fuel solenoid
RPM + pick - up signal
Stop command issued.
In this moment „still engine“
is detected.
In this moment the Stop time
elapsed, but the engine is still
moving. „Sd Stop fail“ alarm
appears.
„Still engine“ confirmed.
Additional 5s delay elapsed,
Stop solenoid deactivated.
BO: Stop pulse
5s
BO: Stop solenoid
Stop time
BO: Fuel solenoid
RPM + pick - up signal > 0
Stop command issued, but
no reaction.
The cyclic stop attempts
continue until the engine
actually stops.
Stop time
In this moment the Stop time
elapsed, but the engine is still
moving. „Sd Stop fail“ alarm
appears.
The fuel or stop valve probably
stucked in wrong position.
BO: Stop pulse
BO: Stop solenoid
= Stop time
BO: Fuel solenoid
measured RPM = 0
Stop button pressed (MAN
mode).
Stop solenoid activated for
Stop time period.
Stop pulse activated for 1s.
Unsuccessful engine stop:
“Forced” stop in still state:
Spontaneous engine start-up:
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B) BO: Stop solenoid
=2+10s
A) BO: Stop solenoid
Stop time
BO: Fuel solenoid
measured RPM
„Engine running“ condition
detected. Alarm „Sd Stop fail“
appears.
„Still engine“ condition
achieved.
Stop time
A) Stop time long enough to
stop the engine.
B) Stop time too short,
additional Stop solenoid
activation needed.
The overlay is 2+10s since „still
engine“ condition achieved.
Gen V > 25% Generator Nominal
D+ terminal active for minimum 1s
Idle run
> Starting RPM
> 25% GenNomV
Cranking
Oil press > Starting POil
AI: Oil press function
Voltage (any phase)
RPM > Starting RPM
RunIndication 1,2,3 active
Oil Press
D+ indication
RPM
GenNomV
BI: RunIndication 1,2,3
BO: Fuel solenoid
or
or
or
or
Starting
“Engine started” conditions
- Engine speed (RPM) > Starting RPM or
- AI: Oil press > Starting POil or
- D+ terminal active for minimum 1s or
- BI: RunIndication 1 or 2 or 3 = active or
- Generator voltage > 25% of GenNomV (any phase)
-
“Engine running” conditions
- RPM > Engine params: Starting RPM or
- Analog input Oil pressure > Engine params: Starting POil or
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- D+ terminal active and Engine params: D+ function = ENABLED or
- Active Binary input RunIndication1 or
26
- Active Binary input RunIndication2 or
- Active Binary input RunIndication3 or
- Vgen > 15 V (any phase).
“Still engine” conditions
- Engine speed (RPM) = 0 and
- AI: Oil press < Starting POil and
- D+ terminal not active and
- BI: RunIndication 1 and 2 and 3 = not active and
- Generator voltage < 15V (all phases) and
- Generator frequency = 0 Hz and
- if all above conditions are fulfilled, additional 2s delay is necessary to confirm “still engine”
NOTE:
If any of the functions not used (e.g. BI RunIndication3 not configured), it’s state is omitted in the evaluation.
This is not valid for RPM comparisons, this condition is always active.
Circuit breakers operation sequence, GCB/MCB fail detection
NOTE:
In the following text, “CB” abbreviation is used for MCB or GCB respectively.
Related binary inputs:
- CB fdb – CB feedback binary input
- CB fdb neg – negative CB feedback binary input. Used for increasing the reliability of CB status
evaluated by the controller. In case that it is not configured, negative value of CB fdb is calculated
internally within the controller.
Related binary outputs:
- CB close/open – output for circuit breaker. Equals to 1 during the time when CB is requested o be
closed.
- CB ON coil – output for closing coil of the CB. 2s pulse (5s if synchronising is not provided by the
particuilar CB) is used for closing the CB.
- CB OFF coil – output for opening coil of the CB. 2s pulse (5s if synchronising is not provided by the
particuilar CB) is used for opening the CB.
- CB UV coil – output for undervoltage coil of the CB. Permanently active, 2s negative pulse (5s if
synchronising is not provided by the particuilar CB) is used for CB opening request
- CB status – output indicating CB status as evaluated by the controller. This signal is used for lighting
LEDs on the panel, switching the regulations, CB fail evaluation, etc.
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Possible CB sequences:
2s
BO: CB status
BI: CB fdb neg
BI: CB fdb
BO: CB ON coil
1s
BO: CB close/open
BO: CB UV coil
minimum 1s from UV switching on,
together with MinStab time elapsing is
necessary before the CB is allowed to
close
When closing the CB, the CB status LBO
switches over only when both feedbacks
are in correct position
CB close command:
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2s
2s
1s
BO: CB OFF coil
2s
BO: CB status
BI: CB fdb neg
BI: CB fdb
BO: CB ON coil
1s
BO: CB close/open
BO: CB UV coil
If the CB is not closed after
the first attempt, it is only reset
by OFF pulse and no CB fail is
issued. This would be issued
after the second unsuccessfull
attempt.
BO: CB status = 0
BI: CB fdb neg = 1
BI: CB fdb = 0
BO: CB fail
ON pulse has finished and CB
status is not =1. CB fail is
issued immediatelly
Repeated CB close command:
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2s
BO: CB OFF coil
BO: CB fail
500 ms
<2s
BO: CB status = 0
BI: CB fdb neg = 1
BI: CB fdb
BO: CB ON coil
1s
BO: CB close/open
BO: CB UV coil
CB fail – If any inconsistence between
the two feedback signals is detected, CB
fail is issued.
ON pulse is shortened/interrupted
and replaced by UV and OFF pulse
OFF pulse is activated until both
feedbacks return to the correct
position +2 seconds.
2s
BO: CB OFF coil
BI: CB fdb neg
BI: CB fdb
BO: CB close/open
BO: CB UV coil
During CB opening the CB status
LBO is deactivated with change of
the first feddback status
Further behavior of UV output
depends on the system status. In
case of transition to cooling stays
off, if the Cb was opened manually
and the engine keeps running, it
activates again after timeout
elapses.
BO: CB status
CB fail – fdb mismatch:
CB open command:
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Transition closing -> opening (opening command is issued during closing pulse):
<2s
2s
BO: CB OFF coil
BI: CB fdb neg
BI: CB fdb
BO: CB close/open
BO: CB UV coil
BO: CB status
BO: CB ON coil
Closing pulse is shortened, opening
sequence is started immediatelly
CB opening by protection or manual
command (button pressed)
2s
2s
BO: CB OFF coil
BI: CB fdb neg
BI: CB fdb
BO: CB close/open
BO: CB UV coil
BO: CB status
BO: CB ON coil
OFF a UV pulse is always activated for
the full time. manual control (= CB
button) is deactivated during opening
pulse.
Here starts the standard closing
sequence – see CB close command.
In this moment, the reason for closing the
CB is activated again (e.g. Remote
Start/Stop is activated)
Transition opening -> closing (closing command is issued during opening pulse)
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