IG SPTM SPtMIOM 6.2

Compact Controller for Stand-by and Parallel Operating Gen-sets
InteliGen Modular Gen-set Controller

Single Parallel to Mains Configuration - SPtM
IG-CU + PCM + IG-AVRi units Software version IG-6.2, August 2005
User guide
Copyright 2005 ComAp s.r.o. Written by Ladislav Kadanik Prague, Czech Republic
ComAp, spol. s r.o. Svtova 7, 180 00 Praha 8, Czech Republic Tel: +420 2 66316661, Fax: +420 2 66316647 E-mail: info@comap.cz, www.comap.cz
Table of Contents
Table of Contents ...............................................................................................................................................2 General guidelines..............................................................................................................................................4 What is described in this manual? .................................................................................................................4 !! Warnings !! ..................................................................................................................................................4 Text ................................................................................................................................................................4 Conformity declaration ...................................................................................................................................4 General description ............................................................................................................................................6 Description of the controller system (with all options)....................................................................................6 SPtM - required and optional modules...........................................................................................................6 Terminals and dimensions..................................................................................................................................7 IG-CU Terminals ............................................................................................................................................7 Dimensions.....................................................................................................................................................9 IGL-RA15 Remote annunciator....................................................................................................................12 IG-IB Internet bridge.....................................................................................................................................13 I-CR CAN repeater.......................................................................................................................................13 Recommended wiring.......................................................................................................................................14 Single Parallel to Mains applications................................................................................................................17 Getting started ..................................................................................................................................................18 How to install ................................................................................................................................................18 Single phase applications ............................................................................................................................23 Analog inputs - configuration........................................................................................................................24 Hardware connection ...................................................................................................................................27 Extension modules (CAN1 bus) connection ................................................................................................31 Inputs and outputs ............................................................................................................................................32 Binary inputs IG-CU + IG-PCM default ....................................................................................................32 Binary inputs IG-IOM, IGS-PTM default..............................................................................................32 Binary inputs list ........................................................................................................................................33 Binary outputs IG-CU + IG- PCM default..............................................................................................36 Binary outputs IG-IOM, IGS-PTM ...............................................................................................................36 Binary outputs list......................................................................................................................................36 Analog inputs IG-CU (+IG-IOM or IGS-PTM)...............................................................................................43 Analog output IG-IOM, IGS-PTM ................................................................................................................43 Setpoints...........................................................................................................................................................44 Password......................................................................................................................................................44 ProcessControl.............................................................................................................................................45 Basic settings ...............................................................................................................................................47 Engine params .............................................................................................................................................49 Engine protect ..............................................................................................................................................52 Gener protect ...............................................................................................................................................55 Auto Mains Fail ............................................................................................................................................58 Sync/Load ctrl...............................................................................................................................................62 Sync/Load control adjustment......................................................................................................................65 Volt/PF ctrl....................................................................................................................................................66 Volt/PF control adjustment ...........................................................................................................................67 Act. calls/SMS ..............................................................................................................................................69 Date and time ...............................................................................................................................................70 Sensor spec .................................................................................................................................................70 Load Shedding .............................................................................................................................................70 Sensor specification .........................................................................................................................................72 Sensor calibration ........................................................................................................................................72 Default sensor settings.................................................................................................................................72 Operator Interface ............................................................................................................................................74 Pushbuttons and LEDs ................................................................................................................................74 How to select gen-set mode ?......................................................................................................................75 When to use GCB ON/OFF and MCB ON/OFF buttons ? ........................................................................75 InteliGen SPtM, SW Version 6.2, ComAp August 2005 -2 IG-SPTM-SPTM+IOM-6.2.PDF
Display menus..............................................................................................................................................75 How to view measured data?.......................................................................................................................75 How to view and edit set points? .................................................................................................................75 How to view the HISTORY menu?...............................................................................................................75 How to find active alarms ? ..........................................................................................................................76 Description of MEASUREMENT screens ....................................................................................................76 Flow Chart of pushbutton Operation ............................................................................................................79 Mode description ..............................................................................................................................................81 OFF mode ....................................................................................................................................................81 MAN mode ...................................................................................................................................................81 AUT mode ....................................................................................................................................................81 TEST mode ..................................................................................................................................................82 Load surge protection ..................................................................................................................................85 Load shedding..............................................................................................................................................85 Alarm management ..........................................................................................................................................88 Sensor fail (Fls) .........................................................................................................................................88 Warning ........................................................................................................................................................88 Shut down ....................................................................................................................................................88 Slow stop......................................................................................................................................................88 ElProt............................................................................................................................................................89 Mains failure .................................................................................................................................................89 HistoryRecord...............................................................................................................................................89 Voltage phase sequence detection..............................................................................................................90 Gen-set operation states ..................................................................................................................................93 Start-stop sequence .....................................................................................................................................93 Unsuccessful start........................................................................................................................................94 Remote control and data logging .....................................................................................................................95 Direct connection to the PC .........................................................................................................................95 PC software - WinEdit ..................................................................................................................................95 History file.....................................................................................................................................................95 Remote and mobile communication .................................................................................................................99 Modbus protocol...........................................................................................................................................99 Recommended ISDN modem ......................................................................................................................99 Recommended GSM modem.......................................................................................................................99 SIM card setting .........................................................................................................................................100 Active SMS message .................................................................................................................................100 IG-IB Internet communication ...................................................................................................................101 Value and setpoints codes .............................................................................................................................102 Technical data ................................................................................................................................................107 Power supply..............................................................................................................................................107 Operating conditions ..................................................................................................................................107 Dimensions and weight ..............................................................................................................................107 Mains and generator ..................................................................................................................................107 IG-MTU.......................................................................................................................................................108 IG-MTU-C...................................................................................................................................................108 Binary inputs and outputs...........................................................................................................................108 Analog inputs..............................................................................................................................................108 Speed pick-up input ...................................................................................................................................109 IG-PCM ......................................................................................................................................................109 IG-AVRi ......................................................................................................................................................109 IG-IOM........................................................................................................................................................110 IGS-PTM ....................................................................................................................................................110 IG-IB ...........................................................................................................................................................111 IGL-RA15 ...................................................................................................................................................111 InteliGen Low Temperature modification ..................................................................................................111
InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF
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General guidelines
What is described in this manual?
This manual describes Single parallel to Mains SPtM software configuration. The software configuration is designed for single set, parallel with mains applications. What is the purpose of this manual? This manual provides general information on how to install and operate the InteliGen 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 !!
Remote control
InteliGen controller can be remotely controlled. In the event that maintenance needs to be done to the genset, check the following to ensure that the engine cannot be started. To be sure: Disconnect remote control via RS232 line Disconnect input REMOTE START/STOP or Disconnect output STARTER and outputs GCB CLOSE/OPEN and MCB CLOSE/OPEN The InteliGen contains a large number of configurable setpoints, because of this it is impossible to describe all applications. InteliGen functions are subject to change from SW version to SW version. This manual only describes the product and is not guarantee to be set for your application on arrival.
Text
PAGE Break Return Generator protections REMOTE START/STOP (Capital letters in the frame) buttons on the front panel (Italic) set points (Bold) Set point group (Capital letters) binary inputs and outputs
Conformity declaration
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.
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Note: ComAp believes that all information provided herein is correct and reliable and reserves the right to update at any time. ComAp does not assume any responsibility for its use unless otherwise expressly undertaken.
WARNING VERY IMPORTANT !!!
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 disconnect following InteliGen controller terminals: Mains voltage measuring Binary output for MCB control MCB feedback and / or and / or
Be aware that the MCB can be switched off and gen-set can start !!! Switch InteliGen to MAN mode and disconnect the Binary outputs Starter and Fuel to avoid unexpected automatic start of genset 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 InteliGens CT terminals for any reason.
Adjust set points

All parameters are preadjusted to their typical values. But the set points in the Basic settings settings group !!must!! be adjusted before the first startup of the gen-set. !!! WRONG ADJUSTMENT OF BASIC PARAMETERS CAN DESTROY THE GEN-SET !!! The following instructions are for qualified personnel only. To avoid personal injury do not perform any action not specified in this User guide !!!
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General description
Description of the controller system (with all options)
InteliGen IG-CU is a comprehensive AMF-controller for single and multiple generating sets operating in stand-by or parallel modes. A modular construction allows upgrades to different levels of complexity in order to provide the best solution for various customer applications. Optional synchronizer, isochronous load sharer, Mains and Generator protections allows for a total integrated solution for Gen-sets in stand-by and parallel modes with multiple engine support. InteliGen controllers are equipped with a powerful graphic display showing icons, symbols and bar-graphs for intuitive operation, which sets, together with high functionality, new standards in Gen-set controls. The InteliGen automatically starts the gen-set, closes the Gen-set C.B. when all conditions are met, then stops the engine on external signal or by pressing push buttons. With upgrade kits, isolated parallel and parallel to Mains operation can be achieved. Forward and reverse synchronizing, Mains protection including load surge, load and power factor control are the major functions provided. Interfacing to foreign synchronizers and load sharers is supported. The key feature of InteliGen is its easy-to-use operation and installation. Predefined configurations for typical applications are available as well as user-defined configurations for special applications.
SPtM - required and optional modules

Accessories IG-CU IG-PCM AT LINK-CABLE 1,8m IG-MTU IG-COM IG-AVRI IG-AVRi-TRANS IG-IB IGL-RA15 IGS-PTM or IG-IOM Description InteliGen central unit InteliGen power control module RS232 (WinEdit) communication cable InteliGen voltage transformer unit to separate mains and generator voltage measurement InteliGen communication unit InteliGen AVR interface InteliGen voltage transformer for supplying AVRi module Internet bridge Remote annunciator External analog, binary I/O unit. Connecting 3m cable is part of module delivery. Standard / Optional Standard Standard Optional Optional Optional Standard Standard Optional Optional Optional
InteliGen display software description

Serial number xx1xxxxx xx2xxxxx xx3xxxxx xx4xxxxx xx5xxxxx Description Standard character set: part of ASCII code (less than 128) Standard character set: + West European languages* Standard character set: + Chinese characters Standard character set: + West & East European languages incl. Russian Standard character set: + West & East European languages incl. Turkish
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Terminals and dimensions

IG-CU Terminals
Grounding Terminal
BI1
BI6
BI7
BI8 RS 232
BI4
L1k L1l
L2k L2l
L3k L3l
L1
L2
L1
L2
L3
L3
BI2
GENERATOR CURRENT 0-5A
GENERATOR VOLTAGE 3 x 230 / 400 V
BI3
BINARY INPUTS
LB 5
EXTENSION MODULES iG-COM / iG-IOM
BOOT JUMPER BO1 (START) ANALOG INPUTS AI2 (TEMP) AI3 (FUEL) AI1 (OIL) RPM RPM GND RPM IN BINARY OUTPUTS POWER 8 - 36 V DC
Inl In (Im L3) Ink CURRENT
COM
BO2 (FUEL)
EXTENSION MODULES iG-PCM / iG-PCLSM
iG-CU
+ -
BO3
BO4
BO5
BO6
BO7
BO8
RPM Grounding Terminal
Drawing text translation Grounding Terminal RPM Grounding Terminal
PCM Terminals
BO9
VoutR
AVRi+
GND
SPEED GOVERNOR
BINARY INPUTS
BINARY OUTPUTS
BO10
BO12
BO13
BO11
+ -
BI10
Warning !!! Switch IG-CU off before connecting IG-PCM !
BI12
BI11
BI13
AVRi-
Vout
AVRi
POWER 8 - 36 V DC
LB 4
BI9
BI5
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IG-MU Terminals
COM
COM
RS 422 TxB TxA RxB RxA COM
LB 6
CAN
CAN
RS 485
RS 485 / RS 422
RS 232
iG-MU
RS 232 POWER 8-36V DC
Indication LED: TxCAN, RxCAN TxD, RxD RUN PWR
Indicates data transfer on the CAN2 line. Indicates data transfer on the RS232 line. Lights when at least one other unit is active on the CAN2 bus. Blinks when no unit is communicated on the CAN2 bus. Lights All time when power supply is switched on.
Hint: It is recommended to use IG-MU software 2.2 for IG-6.1. Internal IG-MU jumpers
P4
P3 P1 P2
P1 P2 P3 P4
2-nd local bridge Modbus jumper Boot jumper Switch between RS232 and RS485/RS422
IG- IOM, IGS-PTM terminals

IGS-PTM is modification of standard IG-IOM module with four analog inputs, which can be configured for range: 0 250 (suitable for Pt100, Ni100), 0 100 mV (suitable for thermocouples), 0 20 mA. IGS-PTM can be connected to IG-CU or IS-CU. Detail description see in IGS-PTM manual. InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF -8
BINARY INPUTS
COM
BI1
BI2
BI3
BI4
BI5
BI6
BI7
BI8
ANALOG INPUTS
AI4 ANALOG OUT RS232 POWER 8-36V DC
iG-IOM
IG-CU BINARY OUTPUTS BO1 BO2 BO3 BO4 BO5 BO6 BO7 BO8
Hint: IG-IOM, IGS-PTM power supply indication LED: lights when power supply is in the range blinks when there is no communication between IG-CU and IG-IOM, IGS-PTM
Dimensions
IG-CU + IG-PCM
1
113 (4,4")
130 (5,1")
~ 110 (5,1")
170 (8,87")
~ 110 (4,3")
80 (3,1")
iG-PCM
42,5 (1,7")
24 (0,9")
iG-CU
185 (7,3")
1. RS 232 Cable must be ordered separately, order code: AT LINK-CABLE 1,8m. 2. IG-IOM or IGS-PTM (3m) cable is part of module delivery. Cutout for InteliGen 113 x 175 mm (4,4 x 6,9).
45 (1,8")
123 (4,8")
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IG-AVRi, IG-AVRi TRANS/LV

Primary terminals 50 / 60 Hz
OUT1 OCOM OUT2 AC1 AC2
0 - 230/277 - 400/480
LB 5
AVRi +
AVRi -
iG-AVRi TRANS/LV
0 - 18
43 (1,7)
36 (1,4)
43 (1,7)
Secondary terminals
IG-AVRi unit is DIN rail mount (35mm) IG-AVRi TRANS are DIN rail mount (35mm)
IG-MU
96 mm (3,8)
95 mm (3,7)
43 mm (1,7)
IG-MU unit is DIN railmount (35mm)
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IG-IOM
IG-IOM is extension module with 8 binary inputs, 8 binary outputs and 4 analog inputs for resistive sensors.
COM BI2 BI3 BI4 BI5 BI6 BI7 BI1 BI8 AI4 ANALOG OUT
BINARY INPUTS
ANALOG INPUTS
iG-IOM
RS232 IG-CU
BINARY OUTPUTS BO1 BO2 BO3 BO4 BO5 BO6 BO7 BO8
POWER 8-36V DC
96 mm (3,8)
95 mm (3,7)
43 mm (1,7)
IGS-PTM
GND AO+ BI1 BI2 BI3 BI4 BI5 BI6 BI7 BI8 AI4 AO-
BINARY INPUTS
ANALOG INPUTS COMPENSATION
0-20 mA ANALOG OUT
Tx
CAN H COM L
CAN
iGS-PTM
LB 4
BINARY OUTPUTS BO1 BO2 BO3 BO4 BO5 BO6 BO7 BO8
POWER 8-36V DC
96 mm (3,8)
Rx
95 mm (3,7)
43 mm (1,7)
IG-IOM, IGS-PTM is DIN rail mount (35mm). IG-IOM, IGS-PTM is connected to IG-CU by standard IOM cable (3 meters length). Wiring between IGS-PTM or IG-IOM and IG-CU:
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IGL-RA15 Remote annunciator

Remote (CAN bus, up 200 meters) 15 LED states indicator. To configure IGL-RA15 use WinEdit Controller configuration - Binary outputs (left bottom) button.
54 (2,1) 44 (1,7)
106 (4,2)
165 (6,5)
~75 (3,0)
180 (7,1) 185 (7,3)
Cutout for Remote Annunciator 167 x 108 mm (6,6 x 4,3) IGS-PTM unit is DIN rail (35mm) mounted.
IG-MTU, IG-MTU-C
IG-MTU Separation transformers unit for InteliGen controller. It is used for three wire system, system with separated Neutral or when galvanic separation between generator or mains voltage and controller is required. IG-MTU-C Separation transformers unit with additional filter for InteliGen controller. It is used like IG-MTU in special cases of extreme distortion of generator voltage by higher harmonics due to inverters etc..
~35 (1,4) 38 (1,5) 40 (1,6)
LB 3
~25 (1,0)
iG-MTU
N L1 L2 L3
155(6,10")
95 (3,74")
Hint: IG-MTU-C phase shift is 6. Use two IG-MTU-C units for both generator and bus voltage measuring or set Sync/Load ctrl: GtoM angle Req setpoint (-6 when IG-MTU-C is connected to Vg terminals). InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF - 12
120 (4,7) 125 (4,9)
60 (2,36")
IG-MTU and IG-MTU-C units are the same dimension and DIN 35 mm rail mounted.
IG-IB Internet bridge
ETHERNET RJ 45 1 2
LB 5
4 H COM L CAN POWER 8 - 36 V DC
IG-CU / DONGLE
iG-IB
96 mm (3,8)
MODEM / IB CONFIG
95 mm (3,7)
43 mm (1,7)
It is recommended to use IG-IB firmware version 2.0 IG-IB unit is DIN 35 mm rail mounted. See Internet communication
I-CR CAN repeater

I-CR module enables to extend CAN bus line of - extension modules CAN1 to more than 200 meters - intercontroller CAN2 to more than 900 meters (in 8C mode) More application details see in separate manual Extending the CAN bus.
96 mm (3,8)
95 mm (3,7)
43 mm (1,7)
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Inl Ink COM AI1 OIL AI2 TEMP AI3 FUEL RPM GND RPM IN
STARTER
iG-CU
BO1 START BO2 FUEL BO3 BO4 BO5 BO6 BO7 BO8 BO9
Generator C.B.
FUEL SOLENOID
GEN C.B.
FIX
MAINS C.B. ALARM

BI1 BI2 BI3 BI4 BI5 BI6 BI7 BI8 BI9
CONTROL SIGNALS
HORN
PRESTART FULL LOAD STAND-BY READY
Recommended wiring
POWER 8 - 36 V DC
+ -
RS 232

+ BATTERY STARTER
FUEL SOLENOID FUEL LEVEL WATER TEMP
Hint: Maximal inductive load of contact relay outputs BO1 and BO2 is 4 Amps. Use external relays for higher load. Drawing text translation Diesel / Gas engine Generator Load
DIESEL/GAS ENGINE
OIL PRESSURE RPM
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ANALOG INPUTS RPM BINARY OUTPUTS
Serial No.
BINARY OUTPUTS
CONFIGURABLE
+24 V
GENERATOR
L1k L1l L2k L2l L3k L3l
N L1 L2 L3 L1 L2 L3
GENERATOR VOLTAGE 3 x 230 V BINARY INPUTS
GEN C.B. FEED-BACK MAINS C.B. FEED-BACK
REMOTE OFF EMERGENCY STOP

ACCESS LOCK OIL PRESSURE WATER TEMP FUEL LEVEL
Mains C.B.
LOAD
PE
L2
L3
L1
RS-232C Interface
Modem or PC
SPEED GOVERNOR
AUTOMATIC VOLTAGE CONTROL
iG-AVRi TRANS
LB 5
AVRi+
GND
VoutR
SPEED GOVERNOR
BINARY INPUTS
BO10
BINARY OUTPUTS BO12 BO13 BO11
+ 0 V DC
BI10
BI12
0 V DC CONFIGURABLE
Drawing text translation Speed Governor Automatic Voltage Control Configurable InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF - 15
BI11
BI13
AVRi-
Vout
AVRi
POWER 8 - 36 V DC
LB 5
18 V AC
230/400 V
18 V
230/400 V
Hint: Im3 CT Current transformer for Mains current measuring has to be connected to Mains L3 phase. IG-PCM Power supply connect direct from IG-CU Speed governor output connect to speed governor by shielded wire. IG-AVRi Power supply 230 VAC connect to gen-set phase voltage. Voltage outputs OUT1 and OUT2 can be connected as floating (potential free) or as unsymmetrical OUT1 (or OUT2) to GND. Output can be connected to auxiliary voltage AVR input or instead of external AVR potentiometer by shielded wire. Warning !!! Do not ground any AVRi output OUT1,OUT2 or the transformer (18V AC) output !!! Do not power more AVRi units from common AVRi trans !!!
IG-IOM
0 V DC
0- 2 0 m A
COM
BI1
BI2
BI3
BI4
BI5
BI6
BI7
BI8
AI4 ANALOG OUT RS232 POWER 8-36V DC
BINARY INPUTS
ANALOG INPUTS
BINARY OUTPUTS
BO1
BO2
BO3
BO4
BO5
IG-CU
iG-IOM
BO6
BO7
BO8
0 V DC 8 - 36 V D C
Hint: Analog inputs COM terminal has to be connected to minus power supply.
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Single Parallel to Mains applications

LOAD
MCB
GCB
AVR
T
MCB
G~
GCB
3x U
1x I
K4
K3
0V
EXT.S/S
3x I
3x U
MCB
GCB
iG-AVRi
Ig
In
Um
BI
Ug
OUT
AVRi
AVRi
iG_CU
FUEL
iG_PCM
VoutR GND
AC
MCB
BO
GCB
iG_AVR-TRANS
230V / 18VAC
0V
K2
K3
K4
N
+24V
F
K2
+24V
ESD5500
230V AC
Drawing text translation Load Fuel
!!! CAUTION !!!

Dangerous voltage
In no case touch the terminals for voltage and current measurement! Always connect grounding terminals! In any case do not disconnect Im3 terminals even if the gen-set is stopped.. For safety connect parallel to Inteligen Im3 terminals two anti parallel diodes 10A/100V. In any case do not disconnect InteliGen generator CT terminals when the gen-set is loaded.
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Getting started
How to install
General
To ensure proper function: Use grounding terminals. Wiring for binary inputs and analog inputs must not be run with power cables. Analog and binary inputs should use shielded cables, especially when length >3m.
Power supply
To ensure proper function: Use min. power supply cable of 1.5mm2 Power supply of IG-PCLSM module should be directly connected to IG-CU. Maximum continuous DC power supply voltage is 36VDC. Maximum allowable power supply voltage is 39VCD. The InteliGens power supply terminals are protected against large pulse power disturbances. When there is a potential risk of the controller being subjected to conditions outside its capabilities, an outside protection devise should be used. Hint: The InteliGen controller should be grounded properly in order to protect against lighting strikes!! The maximum allowable current through the controllers negative terminal is 4A (this is dependent on binary output load). Sometimes can occur starting problems due to low capacity (low temperature) 12VDC starting battery even if the controller power supply voltage range is from 8 VDC. In this case connect external capacitor + separating diode or I-LBA - Low Battery Adaptor module to allow the controller to continue operation during engine cranking.
Relays
Relays
T2A
D
+
controller
I-LBA
+ -
T2A
controller
+ + -
+ -
+ 12VDC Battery
+ 12VDC Battery
The I-LBA module ensures the 100ms voltage dip under following conditions: Voltage before dip is 12V and after 100ms the voltage recovers to min. allowed voltage 5V, IG-PCLSM and IG-COM modules are connected to IG (modules disconnecting increases voltage dip up to 200ms). The I-LBA enables controller operation from 5VDC (for 10 to 30 sec). The wiring resistance from battery should be up to 0.1 Ohm for I-LBA proper function.
The 5 000 micro Farad capacitor ensures the 50ms voltage dip under following conditions: Voltage before dip is 12V and after 50ms the voltage recovers to min. controller allowed voltage, i.e. 8V. The capacitor size depends on required time, i.e. for 100ms dip 10 000 micro Farad is needed for the same conditions.
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Drawing text translation Battery Controller Relays I-LBA
T1A
+ + -
iG-CU iG-PC(LS)M
+
Battery
HUGE LOADS STARTER
Drawing text translation Battery Huge Loads Starter
Power supply fusing

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

Do not connect binary outputs directly to DC relays without protection diodes, even if they are not connected directly to controller outputs.
Fuse Fuse
K1 K2
K1
K2
T1A
IG controller
+ DC relays
+ 24VDC
Battery
Example of InteliGen controller protection
Drawing text translation Fuse Battery InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF
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IG controller DC relays
Grounding
To ensure proper function: The shortest possible piece of wire should be used when grounding the controller. Use cable min. 2,5mm2 . The - terminal of the battery has to be properly grounded.
As short as possible
Magnetic pick-up
To ensure proper function: Use a shielded cable
iG-CU iS-CU
Signal
RPM-IN GND
MAGNETIC PICK-UP
C Signal
GAC Speed Control Unit ESD 5500

+ Power Supply Power Supply
+
Battery
Drawing text translation Magnetic Pick-Up GAC Speed Control Unit Signal Power Supply Battery Be aware of interference signal from Speed governor when one speed pick-up is used. If engine will not start: - check ground connection from pick-up to controllers, eventually disconnect ground connection to one of them - galvanically separate InteliGen RPM input using ComAp separation transformer RPM-ISO (1:1) - use separate pick-up for Speed governor and InteliGen Controller indicates "Sd Underspeed" + "Pickup fault" after engine start when the pickup signal is good for start and low speed but too big for higher speed (lost of signal due to RPM input saturation). Increase gap between pickup and engine flywheel or change type of pickup.
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Hint: In some cases the controller will measure a RPM value even though the gen-set is not running: RPM is measured from the generator voltage (Gear teeth = 0) IG is measuring some voltage value on input terminals due to open fusing. If RPM > 0 the controller will be put into a Not ready state and the engine will not be allowed to start.
LOAD MAINS
L1 L2 L3 N
MCB
GCB
G ENERATOR
L1 L2 L3 N
L1
L2
L3
L1
L2
MAINS VOLTAG E
G ENERATO R VOLTAGE
IG-CU
SSB, SPtM
Drawing text translation Load Generator Mains Mains Voltage Generator Voltage
Current measurement
To ensure proper function: Use cables of 2,5mm2 Use transformers to 5A Connect CT according to following drawings
K k
L l
L1 K k L l L2 K k L L3 l N
L3
Standard three CT connection Single stand-by Short time parallel
I1 k I1 l
I2 k I2 l
I3 k I3 l
K L k l
L1
K L k l
L2 L3
Two CT connection. Typical wiring for middle-high voltage application spare of one transformer.
I1k I1l
I2k I2l
I3k I3l
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Mains power and PF measuring K L k l K L
L1 L2 L3 N
L l K k
K L k l
I1k I1l I2k I2l I3k I3l
Inl Ink MAINS
GENERATOR Adjust Basic settings: Im3 CT ratio.
!!! ATTENTION DANGEROUS VOLTAGE !!! Hint: Mains voltage neutral must be connected to the generator voltage neutral connector.
Voltage measurement
L1
L2 L3 N
L1 L2 L3 G ENERATO R
L1 L2 L 3 MAINS
Drawing text translation Generator Mains Hint: Switchboard lighting strikes protection according standard regulation is expected !!! Mains (load) voltage neutral must be connected to the generator voltage N terminal.
Mains and gen-set neutral separation

If required mains and gen-set neutral separation (four pole breakers) IG-MTU have to be added between mains and controller terminals. IG-MTU-C is separation transformers unit with additional filter for controller voltage measuring. It is used like IG-MTU in special cases of extreme distortion of generator voltage by higher harmonics due to inverters etc..
IG MTU
Connect one or two IG-MTU or MTU-C units to separe generator and mains voltage from controller. IG-MTUC is usually connected to Vg terminals to protect against higher voltage harmonics. Four wire mains and four-pole circuit breaker or three wire mains Three wire mains and three wire genset or electric separation
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L1 L2 L3
MAINS / BUS
GENERATOR
L1 L2 L3 N
L1 L2 L3
MAINS / BUS
GENERATOR
L1 L2 L3
400V
400V
400V
400V
400V
400V
0V
0V
0V
0V
0V
400V
400V
400V
0V
0V
0V
400V
400V
400V
T1
400V
0V
T2
400V
0V
T3
400V
0V
T1
0V
T2
0V
T3
0V
T1
400V 0V
T2
400V 0V
T3
400V 0V
IG-MTU
IG-MTU
L1
L2
L1
L2
L1
L2
L3
L3
L1
L2
L3
MAINS / BUS VOLTAGE
GENERATOR VOLTAGE
MAINS / BUS VOLTAGE
IG-CU
GENERATOR VOLTAGE
Drawing text translation Mains/Bus Generator Mains/Bus voltage Generator voltage MAINS / BUS GENERATOR
L1 L2 L3
Principle of two transformers measuring.

T1
100V 0V
T2
100V
R = 120 k, 2W
0V
3x R
Typical wiring for middle-high voltage application spare of one transformer.
L1
L2
VOLTAGE TERMINALS
Drawing text translation Voltage terminals
Single phase applications

There is not a separate archive file for single phase applications. Use standard aig archive.
Recommended wirings
Generator (mains) single-phase voltage has to be connected to all three-voltage terminals L1, L2, L3. Generator current has to be connected to L1k, L1l terminals only.
L1 N L1
L1
L2
L3
L3
L1
L2
MAINS VOLTAGE
GENERATOR VOLTAGE
L3
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L3
0V
IG-MTU
Drawing text translation Generator voltage Mains voltage
Set points adjusting

To run a single-phase application, the following set points have to be changed: Gener protect: Curr unbal to 200 %
Analog inputs - configuration

Three analog inputs AI1, AI2, AI3 are available on the IG-CU. Additional four analog inputs AIM1, AIM2, AIM3, AIM4 are available on external IG-IOM or IGS-PTM unit. Before IG-IOM, IGS-PTM unit connection load +IOM aig archive. Each analog input AI1, AI2, AI3 can be configured by WinEdit software in the following way. Analog input item WinEdit Possibility Analog input name Name Up to 14 ASCII characters Abbreviation Abbr Up to 4 characters Sensor type Sensor Analog Analog measuring in specified range. type Binary Binary: open/close - threshold 750 . Tri-state Tri-state: open/close - threshold 750 , Failure <10 or > 2400 Physical dimension Dim bar,%,C, Up to 3 ASCII characters Active Active Under Protection is active under limit. Under + Fls under or sensor fail. Over Protection is active over limit.. Over + Fls over or sensor fail. Polarity Inverted Open to activate Valid only for binary and three-state Close to activate inputs Alarm type Alarm type None No protection Sensor fail Only sensor fail indication Warning Wrn on both levels Wrn+Shutdown Level1+level2 protection Wrn+Slowstop Level1+level2 protection Wrn+ElProt Level1+level2 protection Alarm activity Alarm All the time active Engine running Alarm check conditions only Unused analog input Sensor characteristic Sensor Not used set-points adjusted curve A Curve A set-points adjusted curve B Curve B set-points adjusted curve C Curve C Available on IGS-PTM Pt100/C Pt1000/C IEC 751, range -20 to 120 C Ni100/C Available on IGS-PTM Ni1000/C DIN 43760, range -20 to 120 C VDO Temp/C See chapter sensor specification VDO Press bar See chapter sensor specification VDO Level See chapter sensor specification 0-20mA/100 No external resistor !!! 4-20mA/100 No external resistor !!! 0-20mA/100-PTM Available on IGS-PTM 4-20mA/100-PTM Available on IGS-PTM 100mV/100-PTM Available on IGS-PTM Decimal points Decimals 0, 1, 2 Number of decimal points Measurement type Meas type Resistance Jumper on pins 1-2 Current Jumper on pins 2-3 InteliGen SPtM, SW Version 6.2, ComAp August 2005 - 24 IG-SPTM-SPTM+IOM-6.2.PDF
Sensor characteristics - Curve A, B, C are adjusted in Sensor specification group set points: Each Analog input has separate set points for two level alarm setting. Analog input alarm levels Anl Inp level1, Anl Inp level2 and delay Anl Inp del adjust in Engine protection group.
IG-CU Analog inputs hardware configuration

Configure Analog inputs connection by jumpers AI1-AI3 on PCB (remove cover). This feature is available from IG-CU of hardware version 5. Previous IG-CU hw versions are fix switched to Resistance measurement. Resistance measurement jumper on 1-2, Current measurement jumper on 2-3, Voltage measurement no jumper.
Grounding Terminal
Jumpers setting
3 2
LB 5
GENERATOR VOLTAGE 3 x 230 / 400 V
BINARY INPUTS
iG-CU
3 2 1
BOOT JUMPER
Resistance measurement jumper on pins 1-2. Default settings. Current measurement jumper on pins 2-3.
BI6
BI7
BI8
BI1
BI4
BI2
L1k L1l
L2k L2l
L3k L3l
L1
L2
L2
L3
L1
L3
BI3
Inl In (Im L3) Ink CURRENT
BO1 (START)
AI2 (TEMP)
AI3 (FUEL)
BO2 (FUEL)
ANALOG INPUTS
AI1 (OIL)
RPM
RPM GND RPM IN
BINARY OUTPUTS
POWER 8 - 36 V DC
BO9
RS 232
BI9
BI5
3 2 1
Voltage measurement no jumper connected.
COM
BO3
BO4
BO5
BO6
BO7
RPM Grounding Terminal
3 2 1
AI1 AI2 AI3
BO8
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0/4 to 20mA measuring

Customer Curve A, B, C examples for IG-CU current measuring (available only from IG hardware version 5): Analog input jumper = 2-3 (current) WinEdit configuration = Current (linear) 0-20mA/600 No. Primary Converted 1 0 0 2 2000 600 4-20mA/600 No. Primary Converted 1 400 0 2 2000 600 0-20mA/1000 No. Primary Converted 1 0 0 2 2000 1000 4-20mA/1000 No. Primary Converted 1 400 0 2 2000 1000
0 to 4VDC measuring
Default characteristics No analog input jumper = (voltage) WinEdit configuration = Current (linear) 0-20mA/100 Customer characteristics A,B,C example 0-4V/1000 No. Primary Converted 1 0 0 2 2000 1000
Hint: Without external resistors is maximal Voltage measuring range 4 VDC. Connect external resistors ( divider) to extend input voltage range.
Default characteristics
Following table describes how to use default characteristics. IG-CU WinEdit cfg: Sensor Jumper on Meas type= PT100/C Not possible on IG-CU NI 100/C PT1000/C Resistance Resistance NI 1000/C Pins 1-2 VDO Temp Resistance Resistance VDO Press Pins 1-2 VDO Level 0-20mA/100 Current (linear) Current (linear) 4-20mA/100 Pins 2-3 0-20mA/100-PTM 4-20mA/100-PTM Not possible on IG-CU 100mV/100-PTM IGS-PTM WinEdit cfg: Jumper on Meas type = 1-2, Resistance Resistance
Not possible on IGS-PTM
Pins 2-3, Current No jumper, Voltage
Resistance Resistance
Hint: External resistors 120 ohm for 20mA current measuring are not needed for IG hardware version 5 and above when analog input jumper is set to 2-3. IGS PTM resistor measuring range is 0 to 250 ohms.
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Hardware connection
Connection of IG-CU analog inputs
- POWER COM AI1 AI2 AI3
IG-CU
Possible connection of three resistive sensors to analog inputs AI1, AI2, AI3. Example of connection of one wire (grounded to engine frame) sensors. COM terminal is Analog input measuring reference. -POWER terminal supplies sensor.
Engine frame
3x RESISTIVE SENSOR
Battery
IG-CU
As above but with better accuracy.
Engine frame
3x RESISTIVE SENSOR
Battery
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- PO WER COM
IG-CU
Standard connection of three resistive sensors to analog inputs AI1, AI2, AI3. Example of connection of two wire sensors. Common point of resistive sensors is connected to COM terminal for more accurate measuring. COM terminal is Analog input measuring reference. -POWER terminal supplies sensor.
Battery
3x RESISTIVE SENSOR
IG-CU
AI 1 AI 2 AI 3
Three current output sensors connection to InteliGen. Configuration jumper must be in 2-3 position for this type of measurement. WinEdit configuration = Current (linear).
3x SENSORS 4 - 20 mA +24V
Example of connection of two wire sensors. Analog input common terminal COM has to be connected to IG minus Power supply terminal.
IG-CU
Mixed connection of InteliGen analog inputs: AI1 current sensor AI2 resistive sensor. AI3 binary input Analog input common terminal COM has to be connected to IG minus Power supply terminal.
+24V AI1 CURRENT SENSOR AI2 RESISTIVE SENSOR AI3 BINARY INPUT
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- PO W ER COM AI 1 AI 2 AI3
IG-CU
Mixed connection of InteliGen analog inputs: AI1 resistive sensor AI2 binary input AI3 three state input
2x 470 ohm s
Analog input common terminal COM has to be connected to IG minus Power supply terminal.
AI1 R ESIS TIVE SENSO R AI2 BINARY INPUT AI3 THREE STAT E INPUT
Analog inputs are designed for resistive sensors with resistance in range of 0 to 2,4k. To ensure a proper function use shielded cables, especially for length over >3m.
Binary input
Open, close state are detected, threshold level is 750 .
Three state input

Open, close and failure state are detected. Threshold level is 750 , failure is detected when circuit resistance is <10 or > 2400 .
Example of analog input configuration

Configure Analog input 1 for Oil press measuring in Bar, VDO oil pressure sensor, range 0 to 10.0 bars. Alarm protection level set to 3.5 bars, shut down level 1.2 bars. Start WinEdit and select Controller - Software configuration Modify - Analog inputs. There are the following configurable items: Name: Change the name of analog input maximal length is 11 characters Set to: Oil Press Abbr: Abbreviation is used in history record for column labeling, maximal length is 4characters. Set to: OilP Type: selection between Analog, Binary, Tri-state input. Set to: Analog Dim: Physical dimension of measured value (C, %, Bar, ..) . Maximum length is three characters. Set to: Bar Active: setting of polarity: Set to: under (alarm is active when Oil pressure goes low) Alarm type: selection between different types of alarms. Set to: Wrn+Shutdown (lubrication is necessary for engine health) Alarm active Set to: Engine running only Alarm detection is active only when engine is running, Engine protections: Protection del [s] after the BO starter is off, (RPM reached Start RPM). Sensor selection of sensor characteristic Set to: VDO press Decimals: setting of number of decimal points of measured value. Set to: 1 InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF - 29
Meas type: Analog input hardware jumper position Set to: Resistance When Analog input configuration is finished set the setpoints Anl Inp level1, Anl Inp level2, Anl Inp del in Engine protection group. Each Analog input has separate triplet of setpoints: Anl Inp level1, Anl Inp level2, Anl Inp del. Names of these setpoints are are fixed and do not depend on the name of measured value which can be changed. Number of decimal points of Anl Inp level1 and Anl Inp level2 is the same as the configured number of decimal points of measured value.
Binary inputs
4k7
iG-CU
+
Power Supply
T1A
+ 24VDC Battery
Binary outputs
LOAD
iG-CU
+
Power Supply
T1A
+ 24VDC Battery
Drawing text translation Battery Power supply
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Extension modules (CAN1 bus) connection

5
120ohm
CAN H CAN L
CAN H CAN L
IG-CU
9
CANL COM CANH
CANL CANH
EXTENSION MODULES iG-COM / iG-IOM CONNECTOR
IGS-PTM (optional)
or
IGL-RA15 (optional)
120 ohm
IG-IOM (optional)
Drawing text translation Extension modules Connector Optional
Connection rules
CAN bus line must be connected in series, from one unit to the next (no star, no cable stubs, no branches) both ends must by the 120-ohm (internal or external) resistor terminated. Maximal CAN bus length is up to 200 meters when Basic settings: CAN bus mode = 32C or up to 900 meters when Basic settings: CAN bus mode = 8C. For CAN data cables details see chapter Technical data Communication interface. CAN cable shielding connect to IG-CU case. IG-CU contains internal fix 120-ohm resistor. Use D SUB9 male connector: CAN H = 5, CAN L = 9, COMMON = 3 and 8. IG-CU must be on the CAN bus end. New IG-IOM and IGS-PTM units contain internal jumper removable 120-ohm resistor (in older IOM types are fix resistors). To be sure check resistor presence by ohmmeter. Unit with internal resistor connect to the end of CAN line. Following connections are supported (IOM, PTM, RA15 order is not important). IG-CU IG-IOM IG-CU IGS-PTM IG-CU IGL-RA15 IG-CU IG-IOM IGL-RA15 IG-CU IGS-PTM IGL-RA15 It is possible to connect only one IG-IOM or IGS-PTM and one IGL-RA15 to IG-CU.
CANL COM CANH
120ohm
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Inputs and outputs

Hint: Any Binary input or output can be configured to any IG-CU controller or IG-IOM, IGS-PTM terminal or changed to different function by WinEdit software. There is fixed 1 sec delay when any binary input is configured as protection. Note that Binary inputs and outputs configured on IG-CU (and IG-PC(LS)M ) have much faster response against IG-IOM, IGS-PTM. It is recommended to configure function inputs like Emergency stop, GCB feedback, MCB feedback and others exclusively to IG-CU.
Binary inputs IG-CU + IG-PCM default
Hint: When remove IG-PCM module from IG-CU configured binary IG-PCM alarms are not active. There is no indication of disconnected IG-PCM module.
Binary inputs
IG-IOM, IGS-PTM default
Hint: Before connection of IG-IOM or IGS-PTM use +IOM aig archive. Use WinEdit to configure these binary inputs. Any binary input can be configured as a warning, unload, slow stop, shutdown see chapter Alarm Management. WARNING: When the data cable between the IG-CU and the IG-IOM, IGS-PTM is disconnected, a SD alarm is activated. IG-IOM, IGS-PTM power supply LED blinks when the data bus is dead between the IG-IOM, IGS-PTM and IG-CU. InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF - 32
Binary inputs list

Alarm
If the input is closed (or opened) selected alarm is activated. Binary Alarm configuration items Name 14 characters ASCII string Inverted Close to activate Open to activate Alarm type Warning Slow stop Shut down Unloading HistoryRecord, No warning Alarm active All the time Engine running only
Not used
Binary input has no function. Use this configuration when Binary input is not connected.
GCB feedback
Use this input to detect, whether the generator circuit breaker is open or closed. If the feedback is not used, connect this input to the output GCB CLOSE/OPEN
MCB feedback
Use this input for indication, whether the mains circuit breaker is open or closed. This input indicates, whether the gen-set operates in parallel to mains (MCB FEEDBACK is closed) or isolated (MCB FEEDBACK is open).
Emergency stop
Input immediately activates the engine shut down. Emergency stop is not blocked by Sprinkler function see below. Emergency stop is indicated in Alarm list and is recorded in History. When Emergency stop is activated the Binary outputs: - Fuel solenoid, Ignition and GCB close/open opens, - Binary output Stop solenoid closes. Hint: From safety reasons (broken wire) is recommended to configure Emergency stop as Open to activate. The Emergency stop input should not stop the engine in the case of controller fail. In such case can the second Emergency stop button contact e.g. disconnect the Fuel solenoid or Speed governor supply (or activate Stop solenoid, etc..).
Sprinkler
If the input is closed all alarms are disabled except the binary input EMERGENCY STOP and "engine overspeed protection". all IG alarms are detected, enabled Active calls remains active, IG front panel gen-set RED LED blinks or lights, alarm is recorded on the IG alarm list screen, alarm is recorded into history, BUT gen-set remains running.
Access lock
If the input is closed, no setpoints can be adjusted from controller front panel and gen-set mode (OFF-MANAUT-TEST) cannot be changed. Hint: InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF - 33
Access lock does not protect setpoints and mode changing from WinEdit. To avoid unqualified changes the selected setpoints, use password protection.
Rem start/stop
If the input closes, InteliGen starts the engine (in AUT mode only). Genset is running in parallel (base load power level) or island (depends on Mains state). If the input opens and gen-set runs in island, gen-set keeps running until mains recovers. After mains recovery InteliGen opens GCB, cools and stops the engine.
Remote OFF
If closed, iG is switched to OFF mode (there are four modes OFF-MAN-AUT-TEST). When opened, controller is switched back to previous mode. Hint: Remote OFF will switch controller to OFF mode even if the Access code is active or Controller mode is password protected. Binary input can be connected to timer switch, to avoid start of engine.
Remote TEST
If closed, iG is switched to TEST mode (there are four modes OFF-MAN-AUT-TEST). When opens controller is switched back to previous mode. Hint: Binary input Remote OFF has higher priority than Remote TEST.
Man load recon (Manual load reconnection)

Pulse signal (rising edge) on MAN LOAD RECON input resets IG controller to the lower step of Load shedding when AutoLd recon = DISABLED and Generator actual load is under Ld Recon level. Ld recon del is not important in manual reconnection by binary input . Principle of Load shedding is described in the chapter Function description Load shedding.
TestOnLoad
Affects the behavior in TEST. When input is closed, the GenSet goes to load automatically. To activate this function switch controller to TEST mode and adjust setpoint AutoMainFail: Ret from test = MANUAL.. Related setpoints which influence load transfer: Load ramp, GCB Open level, GCB open del, Breaker overlap.
Start button
Binary input has the same function as Start button on the InteliGen front panel. It is active in MAN mode only.
Stop button
Binary input has the same function as Stop button on the InteliGen front panel. It is active in MAN mode only.
FaultResButton
Binary input has the same function as Fault reset button on the InteliGen front panel.
HornResButton
Binary input has the same function as Horn reset button on the InteliGen front panel.
Gen CB button
Binary input has the same function as GCB button on the InteliGen front panel. It is active in MAN mode only. InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF - 34
MainsCB button
Binary input has the same function as MCB button on the InteliGen front panel. It is active in MAN mode only.
Remote MAN
When closed Controller is switched to MAN Mode. When opened controller is switched to previous mode.
RemControl lock
Locks command writing and setpoint changing from all remote terminals.
Ext MF relay
Input should be configured, if external MF relay is used for detection of Mains failure. If the input is active, the mains is evaluated as failed even if the voltage/frequency at the controller mains voltage terminals is within limits.
GCB disable
Active input blocks in AUT (not in MAN) mode closing GCB.
ForwSyncDisab
Active input blocks forward GCB synchronizing. Load is transferred with break MCB is opened and then GCB closed.
RevSync Disab
Active input blocks reverse MCB synchronizing.
Oil press
Behavior for Inverted = Open to activate configuration: Binary input must be closed when engine is not running and opened when is running. "Sd Oil press B" is activated when input is opened on not running engine or when stays closed Engine params: Protection del after engine start. "Sd Oil press B" protection is not active when input is not configured.
Emerg. manual
The controller behaves like when switched to OFF mode if input is closed. Opens all binary outputs Fuel solenoid, Cooling pump signals, etc... except: Stop solenoid output does not close. MCB close open output depends on AutoMainsFAil: MCB logic is opened when MCB logic = CLOSE-ON is closed when MCB logic = CLOSE-OFF Detection of "running" engine and subsequent alarm message "Sd Stop fail" is blocked. The controller shows "Emerg Man" state and the engine can not be started. Generator current and power (energy) measurement is active in this mode, regardless of actual state of the engine. After the binary input "Emerg. manual" is open again, the controller recovers to previous mode and behaves according to the actual situation (e.g. should the engine run, it tries to stop it). Function is active in any controller mode and activation of this input is written to history.
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Binary outputs IG-CU + IG- PCM default
Hint: Maximal inductive load of contact relay outputs BO1 and BO2 is 4 Amps. Use external relays for higher load.
Binary outputs IG-IOM, IGS-PTM
Hint: Before connection of IG-IOM or IGS-PTM use +IOM aig archive. Use WinEdit to configure these binary outputs. WARNING: When the data cable between the IG-CU and the IG-IOM, IGS-PTM is disconnected, IG-IOM, IGS-PTM alarms are not active, only common IOM alarm appears.
Binary outputs list

Starter
The closed relay energizes the starter motor. The relay opens if: the Start RPM speed is reached or maximum time of cranking is exceeded or request to stop comes up
Fuel solenoid
The setpoint Engine params: Fuel solenoid selects the output function: DIESEL, GAS. Fuel solenoid (DIESEL / GAS) InteliGen SPtM, SW Version 6.2, ComAp August 2005 - 36 IG-SPTM-SPTM+IOM-6.2.PDF
Ignition
The closed output switches on the ignition. The output closes if: RPM > 30. The output opens if: RPM < 3.
Pre-start
The output closes prior to the engine start (Prestart) and opens when START RPM speed is reached. During repeated crank attempts the output is closed too. The output could be used for pre-glow, pre-heat or prelubrication.
Cooling pump
The output closes when gen-set starts and opens AfterCoolTime delayed after stop the engine.
Idle/Nominal
The output closes during engine start, after Idle time elapses. The output opens after engine has stopped. Hint: Connect Binary output IDLE / NOMINAL to speed governor to switch the speed: opened = IDLE, closed=RATED.
GCB close/open
The output controls the generator circuit breaker. Hint: Supposed time to close (reaction time) of GCB is 0,1 sec.
GCB ON coil
Pulse output for GCB closing.
GCB OFF coil

Pulse output for GCB opening.
GCB UV coil
GCB undervoltage coil.
MCB close/open
The output controls the mains circuit breaker. Hint: Supposed time to closed (reaction time) of MCB is 0,1 sec.
MCB ON coil
Pulse output for MCB closing.
MCB OFF coil

Pulse output for MCB opening.
MCB UV coil
MCB undervoltage coil.
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GCB closing GCB close/open GCB ON coil GCB OFF coil GCB UV coil
2s
GCB opening
2s
Drawing text translation GCB closing GCB opening GCB close/open GCB ON coil GCB OFF coil GCB UV coil Hint: GCB UV coil automatically opens when GCB is closed spontaneously not from controller except Synchronization state.
GenParamsOK
The output is copy of generator status LED on IG front panel. The output is closed if genset is running and all genset electric values are in limits and no Sd or Unload alarm is active. Hint: Use this output for switching of auxiliary device (e.g. cooling pump) driven from generator independently on the GCB.
Alarm
The output closes if : any alarm comes up or the gen-set malfunctions The output opens if FAULT RESET is pressed The output closes again if a new fault comes up.
Horn
The output closes if: any alarm comes up or the gen-set malfunctions The output opens if: FAULT RESET is pressed or HORN RESET is pressed or Max time of HORN is exceeded (Horn timeout) The output closes again if a new fault comes up.
Full load
The output closes if the gen-set is fully loaded and there is no reserve in engine power. The output can be used for load shedding. The output closes when the load >= 0.9 * Nomin power for more than 3sec. The output opens when the load < 0.9 * Nomin power.
StandBy ready
The output is closed if following conditions are fulfilled:
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Gen-set is not running and InteliGen is in AUT mode No Shut down or Slow stop alarm is active
Ready to run
The output is closed if following conditions are fulfilled: Gen-set is not running and No Shut down or Slow stop alarm is active Controller is not in OFF mode
Ready to load
The output is closed if genset is running and all electric values are in limits no alarm is active. The GCB is already closed or is able to be closed. The output opens during cooling state.
Unload
The output is closed during unloading of genset.
Synchro
The output is closed during genset forward and reverse synchronizing and opens when GCB or MCB is closed.
NotReadyAuto
The output is closed in OFF, MAN, TEST mode or in AUT mode when a failure blocking automatic operation is detected. The output is opened only in AUT mode, when no failure blocking the engine operation is active and genset is ready to take the load or it is already running loaded. Hint: Use this input for external indication that genset is not ready for automatic or stand-by function.
Vg fail
The output closes if the generator over/under voltage alarm or voltage asymmetry alarm activates. The output opens, if alarm is not active and FAULT RESET is pressed
fg fail
Output closes if the generator over/under frequency alarm activates. The output opens, if alarm is not active and FAULT RESET is pressed
Vm fail
The output closes if the mains over/under voltage alarm or voltage asymmetry alarm activates. The output opens, if alarm is not active and FAULT RESET is pressed
fm fail
Output closes if the mains over/under frequency alarm activates. The output opens, if alarm is not active and FAULT RESET is pressed
- 39
Overload
Output closes if the generator overload alarm activates. The output opens, if alarm is not active and FAULT RESET is pressed
Reverse power
Output closes if the generator reverse power alarm activates. The output opens, if alarm is not active and FAULT RESET is pressed
Overspeed
Output closes if the gen-set overspeed alarm activates. The output opens, if alarm is not active and FAULT RESET is pressed
Underspeed
Output closes if the gen-set underspeed alarm activates. The output opens, if alarm is not active and FAULT RESET is pressed
Start fail
Output closes after the gen-set start-up fails. The output opens, if alarm is not active and FAULT RESET is pressed
Overcurrent
Output closes if the generator IDMT over current or current unbalance or short current alarm activates. The output opens, if Alarm is not active and FAULT RESET is pressed
Batt volts
Output closes when battery over/under voltage warning appears. The output opens, if alarm is not active and FAULT RESET is pressed
Common Wrn
Output closes when any warning alarm appears. The output opens, if No warning alarm is active and FAULT RESET is pressed
Common Stp
Output closes when any slow stop alarm appears. The output opens, if No slow stop alarm is active and InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF - 40
FAULT RESET is pressed
Common Sd
Output closes when any shut-down alarm appears. The output opens, if No sd alarm is active and FAULT RESET is pressed
Common Unl
Output closes when any unload alarm appears. The output opens, if No unload alarm is active and FAULT RESET is pressed
Common Fls
Output closes when any sensor fail alarm appears. The output opens, if no Sensor fail is active and Fault reset button is pressed.
AVR up AVR down

Binary outputs for Volt / PF control by motorized potentiometer. Outputs should be used when IG-AVRi module is not connected. Hint: The Alarm Wrn VoltRegLim is blocked when binary output AVR up and AVR down are configured.
SPEED up SPEED down

Binary outputs for Sync / Load control by motorized potentiometer. Minimal pulse duration is 0,15 sec. Maximal pulse duration is 10,0 sec. Hint: The Alarm Wrn SpdRegLim is blocked when binary output AVR up and AVT down are configured. Hint: The response of SPEED UP and SPEED DOWN binary outputs is very fast and frequent to make control process more precise. It is supposed direct connection to electronic speed governor without mechanical elements like relays, motorized potentiometer or servo.
OFF mode
The output is closed, if OFF mode is selected.
MAN mode
The output is closed, if MAN mode is selected.
AUT mode
The output is closed, if AUT mode is selected.
TEST mode
The output is closed, if TEST mode is selected.
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AIn 1 AIn 2 AIn 3

Output closes when IG-CU Analog input 1, 2, 3 Level1 or Level2 (e.g. warning or shutdown) alarm appears. The output opens, if Alarm is not active and FAULT RESET is pressed
AIM 1 AIM 2 AIM 3 AIM 4

Output closes when IG-IOM, IGS-PTM Analog input 1, 2, 3, 4 Level1 or Level2 (e.g. warning or shutdown) alarm appears. The output opens, if Alarm is not active and FAULT RESET is pressed
Load shedd 1 (2, 3)

Output closes when gen-set power exceeds Ld shed level limit for Ld shed del time. Output opens automatically when AutoLd recon = ENABLED or manually by rising edge of Binary input MAN LOAD RECON. One edge moves only one stage. Principle of Load shedding is described in the chapter Function description Load shedding.
Stop solenoid
Output closes when is active stop command. Output activates as well when engine moves spontaneously, not from starter sequence. Output is closed for minimal Engine params: Stop time (default 60 s) in any case and 5 sec after RPM=0.
Service time
Output closes when gen-set Service count down timer Service time reaches zero.
Cooling
Output closes when gen-set is in Cooling state.
CommonSdStpUnl
Output closes when any Shut-down or Stop or Unload alarm appears. The output opens, if No from above alarms are active and FAULT RESET is pressed
BI6 stat, .. BI9 stat
(IG-CU Binary input status)
When corresponding binary input (BI6 to BI9) is configured as Alarm and this Alarm is active (or inactive but not accepted by Fault reset button) then output is closed. When corresponding binary input (BI6 to BI9) is configured as function (e.g. GCB feedback) then output follows input state.
- 42
IOM BI6 stat, .. IOM BI8 stat
(IG-IOM or PTM Binary input status)
When corresponding binary input (BIM5 to BIM8) is configured as Alarm and this Alarm is active (or inactive but not accepted by Fault reset button) then output is closed. When corresponding binary input (BIM5 to BIM8) is configured as function (e.g. GCB feedback) then output follows input state.
MainsParams OK
The output is copy of mains status LED on IG front panel. The output is closed if mains electric values are in limits, load surge protection is not active and Ext MF relay binary input is not active.
Analog inputs IG-CU (+IG-IOM or IGS-PTM)
Default setting of IG-IOM or IGS-PTM analog inputs is Not used.
Analog output IG-IOM, IGS-PTM

AOM1 Gen-set power
Not configurable output of generator power in the range 0 to 20 mA. Hint: Adjust AnOut set point in kW/20mA to set analog output range.
- 43
Setpoints
Password
There are three levels of password protection. 0. User level allows change of non-protected setpoints only 1. Operator level allows change of setpoints protected by Operator level 2. Master level allows change of setpoints protected by Operator and Master level 3. Supervisor highest level allows all setpoints or configuration changes, firmware upgrade. Hint: The asterisk mark * appears before a setpoint name (on controller screen) if the setpoint is password protected. The asterisk mark is removed only when the password is set from controllers front panel. The asterisk mark is still visible on controller screen even if the password is set from WinEdit. When password is set from the controller front panel only the affected setpoints are not accessible from WinEdit (direct or Modem) until password is set in WinEdit (direct or Modem). Setpoints opened from front panel are automatically closed 15 minutes after the last key has been depressed or when wrong value of password is set. It is possible to protect remote Start, Stop, GCB and MCB commands from WinEdit, MultiEdit as well. This three level command protection can be configured from WinEdit.
EnterPassword
Password is a four-digit number. Only setpoints associated with the entered password level can be modified. Use or to select the desired password and then hit enter.
ChangePassword 1 ChangePassword 2 ChangePassword 3

Hint: Any password can be changed once that level password or higher has been entered. To set password protection from WinEdit: Open WinEdit Select Controller Software configuration Modify Select Setpoints window Set desired protection level: 0 or 1 or 2 or 3
Access code
Can be changed from WinEdit software only. Has to be set before remote modem or SMS connection is opened. Can be up to 16 ASCII characters due to Internet At first the Password3 has to be entered before the new Access code can be changed.
Commands protection
Commands password protection protects following commands from WinEdit / MultiEdit direct, modem or GSM modem connection: Start, Stop, Horn reset, Fault reset, GCB close/open, MCB close/open. Selected Command password level 0, 1, 2, 3 is valid for all commands. Selected level is in RED color. To set commands protection from WinEdit: Open WinEdit InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF - 44
Select Controller Software configuration Modify Select Setpoints window Set Commands = 0 (no protection) or level 1 or 2 or 3
ProcessControl
Load ctrl PtM [BASELOAD, IMP/EXP]
Control mode selection for parallel to mains operation. BASELOAD: gen-set is loaded at preadjusted level (Base load). IMP/EXP: gen-set load is changed according to import/export value (Import load, Import PF). Available in parallel to mains only.
Base load
[kW]
Required gen-set load when Load control = Base load. Step: 1 kW Range: 0 3200 kW
Base PF
[-]
Required inductive (leading) power factor when Load control = Base load. Step: 0.01 Range: 0.60 to 1.00
Import load
[kW]
Required power from / to mains when Load control = Import export. Import load > 0 is consumption from the mains, when Import load < 0 the power is exported to the mains. Step: 1 kW Range: -3200kW to +3200 kW
Import PF
[-]
Required inductive (leading) power factor of the mains when Load control = Import export Step: 0.01 Range: 0.60 to 1.00
PeakLevelStart
[kW]
Load power level when gen-set starts (PeakAutS/S del > 0). Load value is measured and calculated from mains current phase Im3, L3 before start. It is supposed balanced load. Genset start is PeakAutS/S del delayed after PeakLevelStart limit is reached. Step: 1 kW Range: 0 3200 kW
PeakLevelStop
[kW]
Load power level when gen-set stops (PeakAutS/S del > 0). Genset stop is PeakAutS/S del delayed after PeakLevelStop limit is reached. When is gen-set running the load power is calculated (no directly measured) from the difference between gen-set and mains power. When e.g. gen-set actual power is 100 kW (Pg=+100) and gen-set exports to the mains 60 kW (Pm= - 60) load power is Pg + Pm=40 kW. When e.g. gen-set actual power is 100 kW (Pg=+100) and gen-set imports from the mains 60 kW (Pm= + 60) load power is Pg + Pm=160 kW. Step: 1 kW Range: 0 3200 kW
PeakAutS/S del
[s]
Instead of setpoint PeakAutStart [ ENABLED/DISABLED] allows selectable delay for Peak Start/Stop function. Value 0 turns Peak Start/Stop function off. Step: 1s InteliGen SPtM, SW Version 6.2, ComAp August 2005 - 45 IG-SPTM-SPTM+IOM-6.2.PDF
Range:
0 3200 s
Export limit
[ ENABLED, DISABLED ]
Protection against power export to the mains when is adjusted Load control = BASELOAD. Export power is limited to not exceed Import load value. ENABLED: When export power exceeds Import load value Load control is automatically switched to IMP/EXP mode to keep Import load value. DISABLED: No protection is active. Hint: To protect genset against power export adjust ExportLimit = ENABLED and Import load = 0. Export limit function Outputs and Setpoints overview: Export limitation
Process control: Load ctrl PtM = BASELOAD Export limit = ENABLED Required genset power
Internal value
Drawing text translation Export limitation Process control Load ctrl PtM BASELOAD Export limit ENABLED Required genset power Internal value Export limit function behaviour:
Load Mains I/E Gen
Load
Baseload
Baseload
Gen Baseload Baseload
+ Mains I/E 0
+ Import 0 Export
Export Import
DISABLED
ENABLED
Drawing text translation Disabled Enabled Load Gen Mains I/E
- 46
Baseload Import Export
Basic settings
Gen-set name
User defined name, used for InteliGen identification at remote phone or mobile connection. Gen-set name is max 14 characters long and have to be entered manually using WinEdit software. Hint: Gen-set name is not changed when new archive is loaded. Check Gen-set name after firmware upgrade.
Nomin power
Nominal power of the generator Step: 1kW Range: 1 3000 kW
[kW]
Nomin current
[A]
This is the current limit for the generator. IDMT over current and short current protection are set based on this setpoint. See Generator protections: 2Inom del, Ishort setpoints. Nominal current can be different from generator rated current value. Step: 1A Range: 1 - 5000 A !!! VERY IMPORTANT !!! The maximum input range of the InteliGen current terminals are 11 Amps. Anything over this value is displayed as measured limit, e.g. 15 Amps from CT is measured and displayed as 11 Amps. Take special care when selecting CTs. All available 5 Amp CTs do not have a range up to 11 Amps.
CT Ratio
[/5A]
Gen-set phases current transformers ratio. Step: 1A Range: 1 10000 A/5A Hint: When /1A CT is used (e.g. 100A/1A) then set CT Ratio five times higher (500/5A). /1A CT is not recommended because only 20% of measuring range is used.
PT ratio
Gen-set potential transformers ratio. Step: 0,1 V / V Range: 0,1 500,0 V / V
[/1]
Vm PT ratio
Mains potential transformers ratio. Step: 0,1 V / V Range: 0,1 500,0 V / V
[/1]
AnOut-kW/20mA
[kW/20mA]
Conversion coefficient from gen-set power to IG-IOM, IGS-PTM analog output in kW to full output scale 20 mA. Step: 1 kW / 20mA Range: 1 - 32000 kW / 20mA InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF - 47
Hint: Available only for IG-IOM, IGS-PTM configuration.
Im3 CT Ratio
[/5A]
Mains current transformer ratio for single phase Import / Export power and PF measuring. Single phase power value is multiplied by three. Step: 1A Range: 1 5000 A / 5A Hint: Im3 has to be connect to mains L3 phase !!! Balanced mains power is expected.
Gen nom V
Nominal generator voltage (phase to neutral). Step: 1V Range: 80 30000 V
[V]
Mains nom V
[V]
Nominal mains voltage (phase to neutral). Step: 1V Range: 80 30000 V Hint: Both Gen and Mains nominal voltages must be set to the same value when no PT is used.
Nominal RPM
Nominal speed of the engine Step: 1RPM Range: 100 4000 RPM
[RPM]
The following table shows the relationship between frequency and nominal RPM due to generator poles. Generator poles 50 Hz 60 Hz 2 3000 3600 4 1500 1800 6 1000 1200 Hint: Generator frequency can be used (for RPM measuring) only when generator voltage (min 5V) is present before reaching of the firing speed (Start RPM) after start. When pick-up cut (fail) comes, InteliGen detects underspeed and stops the engine.
Nominal freq
[Hz]
Nominal generator frequency (usually 50 or 60 Hz ) Step: 1Hz Range: 45 65 Hz
Gear teeth
[-]
Number of teeth on the engines flywheel for for the pick-up. Set to zero, if no pick-up is used. Engine speed is calculated from the generator frequency. Step: 1 Range: 0 500
FltRes GoToMAN
[ DISABLED / ENABLED ]
DISABLED: Controller stays in AUT mode after Fault reset . ENABLED: Automatic switch from AUT (or SEMI or TEST) to MAN mode after Fault reset to avoid automatic engine start. This function is active for all protections (Shut down, Slow stop, Unload, Off-load) except Warning protection. Hint: It is not possible reset Fault when Binary input Remote TEST is closed. InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF - 48
Set to ENABLED to avoid automatic engine start when Fault reset button is pressed after shut down in automatic mode.
ControllerMode
[ OFF, MAN, AUT, TEST ]
Equivalent to Controller mode changes by MODE or MODE buttons. Hint: Mode change can be separately password protected.
Contr. addr (1 .. 32)
[-]
Controller identification number. Each gen-set in the group has to have its own unique number. Default value is 1. Hint: When opening Direct or Modem connection to single InteliGen, the InteliGen Controller address has to be set to 1 and must correspond to WinEdit communication setup setting.
RS232 mode
[ Standard / Modbus ]
Communication protocol selection. Standard: InteliGen (WinEdit/MultiEdit) communication protocol. Modbus: InteliGen Modbus protocol. Hint: Detail description see in InteliGen Communication guide.
CAN bus mode
[ 32C / 8C ]
CAN bus speed selection. 32C: High speed CAN (250 kbps) applicable up to 32 controllers, CAN bus limited up to 200 meters. 8C: Low speed CAN (50 kbps) applicable up to 8 controllers, CAN bus limited up to 900 meters. Hint: Low speed use for long distance connection only. Set all connected controllers to the same speed.
Engine params
Prestart time [s]
This is the time the binary output PRE-START is active for prior to engine start. Set to zero if you want to leave the output PRE-START open. RPM must be zero during Prestart time. Step: 1s Range: 0 600 s
Starting RPM
[%]
Firing speed when controller stops cranking. Under speed limit when engine is running. Step: 1 % of Nominal speed Range: 1 50 %
MaxCrank time
[s]
Amount of time the iG will crank the engine in an attempt to start. Step: 1s Range: 1 60 s Hint: When digital output Fuel Solenoid is configured as gas, the engine will crank 25% longer on the last unsuccessful attempt in order to ventilate the remaining gas. The InteliGen will not continue cranking the engine after three seconds of RPM = 0. It will continue CrankFail pause.
CrankFail pause
Pause between crank attempts Step: 1s Range: 1 60 s
[s]
- 49
Crank attempts
[-]
Max number of crank attempts Step: 1 Range: 1 - 10 Hint: The starter will disengage when digital output starter is engaged for 2 sec. and RPM equals zero. The setpoint Gear teeth has to be set greater than zero. A pick-up fail shutdown is activated when digital output starter is closed and generator voltage is higher than 5 V and RPM equals zero.
Idle time
[s]
Idle time delay starts when RPM exceeds Start RPM. A start fail is detected if the RPM drops below 30 and the InteliGen is still in the Idle state. Binary output IDLE/NOMINAL is opened During the Idle time and closes when Idle time expires. Binary output IDLE/NOMINAL opens after the engine has stopped. Step: 1s Range: 1 300 s
Start RPM
M RP
RPM = 30
RPM
BO Starter BO IDLE/NOMINAL
Idle time
Min stab time
Start Fail
Electric protections active
Drawing text translation Start RPM Start Fail BO Starter BO IDLE/NOMINAL Idle time Min stab time Electric protections active Hint: Pressing START button in MAN mode skips the Idle time and switch to running state. Idle function Outputs and Setpoints overview:
Engine params: Idle time [s]
Idle/Nominal
binary output
Drawing text translation Engine params Idle time Idle/Nominal Binary output
Min stab time
[s]
- 50
This is the minimum time the iG will wait, after the RPM has come up to nominal RPM, to close the GCB.
Step: Range:
1s 0 Max stab time
Max stab time
[s]
Maximum time after reaching of defined level of RPM to get proper voltage level of the generator. Step: 1s Range: Min stab time 300 s Hint: When generator voltage does not reach defined limits ( see Generator protection group) within Max stab time the unload alarm is activated, genset cools and stops. History and Alarm list record contains Alarm reason (e.g. Vg<).
Cooling time
[s]
Runtime of the unloaded gen-set to cool the engine before stop. Engine stays on Nominal RPM during cooling. Step: 1s Range: 0 3600 s
AfterCool time
[s]
Runtime of engine after cooling pump. Binary output COOLING PUMP is closed when the engine starts and closes AfterCool time delayed after gen-set stops. Step: 1s Range: 0 3600 s Hint: If the engine After cooling function is needed the binary output COOLING PUMP should be configured.
Stop time
[s]
Stop time value means the minimum time for which Stop solenoid will be closed. If the engine stopping procedure will take longer time, the Stop solenoid stays closed until all signs of moving engine have disappeared (RPM, Vg, fg) + 5 seconds more to have some safety overlap. After Stop time has elapsed and the engine is still moving, the alarm "Sd Stop fail" is produced. However, this is not a normal situation and should be solved by increasing the Stop time setpoint. The StopValve" countdown timer will be displayed on IG screen. Step: 1s Range: 0 240 s
Fuel solenoid
(DIESEL / GAS)
[-]
Selecting of FUEL SOLENOID output function. DIESEL: closed output opens the fuel solenoid and enables the engine start. The output opens if: Emergency stop comes or Cooled gen-set is stopped or in pause between repeated starts GAS: closed output energizes the gas valve. The output closes if RPM > 30 with 1s delay. The output opens if: emergency stop comes or the cooled gen-set is stopped or in pause between repeated starts. If the engine is unsuccessful in starting the Fuel Solenoid output will stay energized 25% longer in order to vent the remaining gas. Example of FUEL SOLENOID output behavior during unsuccessful start.
- 51
the last cranking
BO Starter Start RPM RPM
closed
opened
ventilation
M axCrank tim e
RPM < Start RPM RPM < 3 RPM > 30 RPM =0 RPM > 30 RPM < Start RPM
+ 25 %
RPM < 3
RPM =0
M axCrank time BO Fuel solenoid=Diesel BO Fuel +1sec solenoid=G as BO Ignition

closed opened closed opened
+1sec
closed opened closed opened
on
off
on
Drawing text translation BO Starter BO Fuel BO Ignition Start RPM Solenoid=Diesel Solenoid=Gas Closed Opened MaxCrank time The last cranking Ventilation
Engine protect
NextServTime [h]
This is the amount of time that will elapse till service on the gen-set is required. When the countdown is complete: Service alarm is detected Alarm list is recorded Step: 1h Range: 0 65535 h Hint: Once the service time has elapsed the NextServTime will have to be reset to clear the alarm and begin a new countdown.
Horn timeout
[s]
The maximum amount of time the horn will sound. If it desired to have the horn sound until the alarm is cleared then set to zero. Step: 1s Range: 0 600 s
Overspeed
[%]
Threshold for over speed protection Step: 1% of nominal RPM Range: 50 150% Hint: Engine params: Start RPM value is checked as underspeed level.
Protection del
[s]
- 52
During the start of the gen-set, some engine protections have to be blocked (e.g. Oil pressure). InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF
The protections are unblocked after the Protection del time. The time starts after reaching Start RPM. Step: 1s Range: 0 300 s
Anl Inp1 level1
[]
The first threshold level for ANALOG INPUT 1 alarm detection. Default setting is oil pressure warning. Step: 0,1 bar (psi) Range: -100 10000
Anl Inp1 level2
[]
The second threshold level for ANALOG INPUT 1 alarm detection. Default setting is oil pressure shut down. Step: 0,1 bar (psi) Range: -100 10000
Anl Inp1 del

Delay for ANALOG INPUT 1 alarm. Step: 1s Range: 0 180 s
[s]
Anl Inp2 level1
[]
The first threshold level for ANALOG INPUT 2 alarm detection. Default setting is water temperature warning. Step: 1 C (F) Range: -100 10000
Anl Inp2 level2
[]
The second threshold level for ANALOG INPUT 2 alarm detection. Default setting is water temperature shut down. Step: 1 C (F) Range: -100 10000
Anl Inp2 del

[s]
Anl Inp3 level1
[]
The first threshold level for ANALOG INPUT 3 alarm detection. Default setting is fuel level warning. Step: 1% Range: -100 10000
Anl Inp3 level2
[]
The second threshold level for ANALOG INPUT 3 alarm detection. Default setting is fuel level shut down. Step: 1% Range: -100 10000
Anl Inp3 del

[s]
Batt >V
[V]
Warning level for battery overvoltage. Step: 0,1V Range: 10 40 V
- 53
Batt <V
[V]
Warning level for low battery voltage. Step: 0,1V Range: 8 30 V
Batt V del
[s]
Delay for battery voltage alarms. Step: 1s Range: 0 600 s Hint: SD battery flat is detected when controller is switched off during cranking. The next start is blocked. Following AIM set points are available only when IG-IOM, IGS-PTM is configured.
AnlInIOM1 lev1
[]
The level for IOM ANALOG INPUT 1 alarm detection. Step: 1 Range: -100 - +10000
AnlInIOM1 lev2
[]
AnlInIOM1 del
[s]
Delay for IOM ANALOG INPUT 1 alarm. Step: 1 s Range: 0 - 180 s
AnlInIOM2 lev1
[]
AnlInIOM2 lev2
[]
AnlInIOM2 del
[s]
AnlInIOM3 lev1
[]
AnlInIOM3 lev2
[]
- 54
AnlInIOM3 del
[s]
AnlInIOM4 lev1
[]
AnlInIOM4 lev2
[]
AnlInIOM4 del
[s]
Delay for IOM ANALOG INPUT 4 alarm. Step: 1 s Range: 0 - 180 s Hint: The analog input del is still enabled even if these inputs are configured as binary inputs contrary to standard Binary inputs B1 to BI9 which have fix 1 sec delay for activation.
Gener protect
Hint: All Alarm limits are the last acceptable values. Alarm detection starts when measured value is over the alarm limit.
Overload
[%]
Threshold for generator overload (in % of Nominal power) triggers when exceeded. Step: 1% of Nominal power Range: Overload wrn 300% Protection: Unload (GCB open), Cooling, Stop.
Overload wrn
[%]
Threshold for generator overload warning alarm (in % of Nominal power) Step: 1% of Nominal power Range: 50 Overload Protection: Warning
Overload del
Delay for generator overload Step: 0.1s Range: 0 60.0 s
[s]
Ishort
[%]
Ishort is a percentage over nominal current, that when reached the GCB Close/Open, GCB UV coil, and the GCB Off coil are immediately opened, the event is recorded in the alarm and history list, and the engine will cool down and stop if the Fault reset button is not depressed. Step: 1 % of Nominal current Range: 100 - 500 % Protection: Unload (GCB open), Cooling, Stop.
- 55
Ishort del
[s]
Delay for generator short current protection. Step: 0.02 s Range: 0.00 10.00 s
2Inom del
[s]
IDMT curve shape selection. 2Inom del is the reaction time of IDMT protection for 200% overcurrent Igen = 2* Nominal current. Step: 0,1 s Range: 0 - 60 s Protection: Unload (GCB open), Cooling, Stop. IDMT is inversely proportional to the generators overcurrent. The higher the overcurrent gets the less time will elapse before the alarm is activated. When the IDMT protection is activated the GCB is opened, the event is recorded in the alarm and history list, and the engine will cool down and stop if the fault reset button is not depressed.
2Inom del * Nomin current Reaction time = Igen Nomin current
Where Reaction time is the amount of time from IDMT detection to the opening of the GCB.
Reaction time
Maximal Reaction time
2Inom del
Igen
Nominal current
Drawing text translation Ishort Reaction time Nominal current Maximal Reaction time Igen 2lnom del Hint: The maximum allowable Reaction time is 900 sec or 15 min. InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF
Ishort
- 56
It is typical to allow genset to operate for 110% for one hour in 24 hours. In this case the setpoint Nominal current should be set to 110% of the genset nominal current. Where Igen is the maximum current of the three phases of generator current. EXAMPLE of Reaction time for different over current levels. Values in column 200% are equal 2Inom del. 200 % = 2Inom del 0,2 s 2s 20 s Overcurrent 100 % 101 % No action No action No action 20 s 200 s No action (time > 900 s) 110 % 2s 20 s 200 s
Reaction time
!!! VERY IMPORTANT !!! The maximum input range of the InteliGen current terminals are 11 Amps. Anything over this value is displayed as measured limit, e.g. 15 Amps from CT is measured and displayed as 11 Amps. Take special care when selecting CTs. All available 5 Amp CTs do not have a range up to 11 Amps.
Curr unbal
[%]
Threshold for generator current unbalance. The current unbalance is calculated as a maximum difference among of phase currents. Step: 1% of Nominal current Range: 1 200% Protection: Unload (GCB open), Cooling, Stop.
Curr unbal del

Delay for generator current unbalance. Step: 0.1 s Range: 0 600.0 s
[s]
Gen >V Sd
[%]
Threshold for generator over voltage Shut down protection. Step: 1% of Nominal voltage Range: 50 150% of Nominal voltage Protection: GCB opening and engine shut down.
Gen >V Unl
[%]
Threshold for generator over voltage. Step: 1% of Nominal voltage Range: Gen <V 150% of Nominal voltage Protection: Unload (GCB opening), Cooling, Stop.
Gen <V Unl
[%]
Threshold for generator under voltage. Step: 1% of Nominal voltage Range: 50 Gen >V Protection: Unload (GCB opening), Cooling, Stop. Hint: All three phases are checked for generator voltage protection. Minimum or maximum out of three is used.
Gen V del
[s]
Delay for generator under voltage and over voltage Unload and Shut down protection. Step: 0.1s Range: 0 600.0 s InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF - 57
Protection:
Unload (GCB opening), Cooling, Stop.
Volt unbal
[%]
Threshold for generator voltage unbalance. The voltage unbalance is calculated as a maximum difference among of phase voltages. Step: 1% of Nominal voltage Range: 1 150% Protection: Unload (GCB open), Cooling, Stop.
Volt unbal del

Delay for generator voltage unbalance. Step: 0.1s Range: 0 600.0 s
[s]
Gen >f
[%]
Threshold for generator phase L3 over frequency. Step: 0.1% of Nominal frequency Range: Gen < f - 200,0 % of Nominal frequency Protection: Unload (GCB open), Cooling, Stop.
Gen <f
[%]
Threshold for generator phase L3 under frequency. Step: 0.1% of Nominal frequency Range: 0.0 Gen > f Protection: Unload (GCB open), Cooling, Stop.
Gen f del
[s]
Delay for generator under frequency and over frequency Step: 0.1s Range: 0 600.0 s
Reverse power
[%]
Threshold for generator reverse (back) power alarm. Step: 1 % of Nominal power Range: 0 200 % of Nominal power
ReversePwr del
[s]
Delay for generator back (reverse) power alarm. Step: 0.1 s Range: 0 600.0 s Protection: Unload (GCB open), Cooling, Stop.
Auto Mains Fail

EmergStart del [s]
Delay after the mains failure to the emergency start of the gen-set Step: 1s Range: 0 300 s
Mains ret del
[s]
Delay after the mains return to start of MCB reverse synchronizing. Step: 1s Range: 1 3600 s
FwRet break
[s]
- 58
Delay between GCB opening and MCB closing during the return procedure (in SSB). InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF
Delay between MCB opening and GCB closing in TEST Mode when power cut comes. Step: 0,1s Range: 0 60,0 s The time charts below show recommended setting of AutoMains fail:FwRet break setpoint: MCB close/open MCB feedback MCB close/open MCB feedback MCB opening FwRet break GCB close/open MCB opening GCB close/open del
FwRet break
If the FwRet break setpoint is set shorter than the time required for opening of the circuit breaker, the controller closes GCB close/open output straight away (100 ms) after the MCB feedback input deactivates.
If some delay between MCB feedback deactivation and closing of GCB close/open output is required, then the FwRet break must be set to MCB opening + del time.
MCB close del
[s]
Delay after mains returns to MCB closing, if gen-set is not running and GCB is opened. E.g. genset is in OFF mode or in start-up procedure. Step: 0,1s Range: 0 60,0 s
Mains >V
[%]
Threshold for mains over voltage. All three phases are checked. Maximum out of three is used. Step: 1% of Nominal voltage Range: 100 150%
Mains <V
[%]
Threshold for mains under voltage. All three phases are checked. Maximum out of three is used. Step: 1% of Nominal voltage Range: 50 100%
Mains V del
[s]
Delay for mains under voltage and over voltage. Step: 0,1 s Range: 0 60,0 s
MVolt unbal
Threshold for mains voltage unbalance Step: 1% of Nominal voltage Range: 1 150%
[%]
MVoltUnbal del
[s]
Delay for mains voltage unbalance Step: 0,1 s Range: 0- 60,0 s InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF
- 59
Mains >f
[%]
Threshold for mains phase L3 over frequency. Step: 0,1% of Nominal frequency Range: 100,0 150,0%
Mains <f
[%]
Threshold for mains phase L3 under frequency. Step: 0,1% of Nominal frequency Range: 50,0 100,0%
Mains f del
[s]
Delay for mains under frequency and over frequency Step: 0,1s Range: 0 60,0 s
BreakerOverlap
[s]
BreakerOverlap defines max time of running in parallel with mains during mains return procedure. During this time soft transfer of load is activated. BreakerOverlap time is used in AUT and TEST (Ret from test = AUTO) modes. Step: 0,1s Range: 0 600,0 s Hint: For correct soft load transfer procedure check corresponding setpoints setting in Sync/Load ctrl: Load ramp, GCB open level, GCB open del.
Max load surge
[P/s]
This is the limit for the change in load per second the generator will accept. If this limit is exceeded the MCB opens immediately. Protection is active only in parallel to the mains. When reached opens immediately (no delay) MCB in SPtM GCB in MINT, MEXT When Load surge protection becomes active the Alarm list and History record UnlLoadSurge appears. See Load surge protection Step: P / 1 sec , where P is Nominal power Range: 0 60 P / 1 sec , where P is Nominal power Example: Suppose Nominal power = 100 kW and Max load surge = 1 P/s. Then is genset protected against power step 100 kW/1sec. Hint: Wrong setting of Max load surge level can cause unnecessary transfer to island even if is the mains OK. To be sure for proper adjusting of Max load surge check Act load surge and Max load surge values on the controller or WinEdit screen. Zero switches Load surge protection OFF.
ReturnWithIntr
ENABLED: DISABLED:
[ ENABLED / DISABLED ]
Enables break transfer of the load to the mains when is reverse synchronizing unsuccessful = opens GCB and after FwRet break delay closes MCB. Genset stays running loaded when reverse synchronizing is unsuccessful, even if mains is OK.
MCB opens on
[ MAINSFAIL / GENRUN ]
Adjusting of condition when MCB opens after Mains fail: MAINSFAIL: Controller activates corresponding binary output when Mains fail is detected. GEN RUN: Controller activates corresponding binary output after genset is running. InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF - 60
MCB logic (CLOSE-ON / CLOSE - OFF) [-]

The setpoint influences the behavior of the output MCB CLOSE/OPEN CLOSE-ON: When the output MCB CLOSE/OPEN is closed MCB should be closed. CLOSE-OFF: When the output MCB CLOSE/OPEN is closed MCB should be opened. Following diagram shows difference between MCB CLOSE/OPEN output behaviors when InteliGen is switched ON. Hint: In case MCB logic = CLOSE-OFF it is necessary to change externally the polarity of the output signal
iG OFF
Mains O.K.
iG ON
Mains O.K.
MCB logic = CLOSE-ON
Mains Failure
MCB logic = CLOSE-OFF
Signal after external inverted relay
Drawing text translation Signal after external inverted relay MCB logic CLOSE-ON CLOSE-OFF Mains O.K. Mains Failure
iG-CU
DO 4
AUX. INVERTING RELAY
MCB
Battery
Drawing text translation Battery Aux. inverting relay
Ret from test
[MANUAL / AUTO]
The setpoint influences the behavior of the TEST mode. MANUAL: Select TEST. InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF - 61
Gen-set starts and runs unloaded. To synchronize gen-set to mains press GCB ON/OFF or close binary input TEST ON LOAD. InteliGen closes GCB, for Breaker overlap time runs parallel to mains and then opens MCB soft transfer. Load can be switched to the genset by pressing of MCB ON/OFF instead GCB. In this case InteliGen opens MCB at first and then closes GCB. Genset remains island running. To stop the gen-set select a different mode than TEST. AUTO: Select TEST. Gen-sets starts and runs unloaded. To transfer load from mains to the gen-set wait for the power-cut. InteliGen does not response for MCB ON/OFF , GCB ON/OFF buttons. When power cut comes MCB opens and after FwRet break delay GCB closes. When the mains recovers InteliGen synchronize gen-set to mains and closes MCB. The gen-set remains running parallel to mains for BreakerOverlap time, opens GCB. The gen-set remains running without load. To stop the gen-set select a different mode than TEST.
Ret fromIsland
[ MANUAL, AUTO ]
MANUAL: Controller is automatically switched to MAN mode when transiting to Island (GCB closes after Mains fail). Load transfer then must be activated by switching back to AUT mode. AUTO: Load is automatically transferred in AUT mode after Mains return. Hint: Select Ret fromIsland = MANUAL when you want to start the reverse transfer to the mains manually.
Sync/Load ctrl
SpeedRegChar [POSITIVE / NEGATIVE ]
Switch between isochronous speed governor characteristic. POSITIVE: When controller Speed governor output voltage increases engine speed increases. NEGATIVE: When controller Speed governor output voltage decreases engine speed increases. Hint: All corresponding set points Slip freq gain, Angle gain and Load gain are positive. When set to NEGATIVE Binary outputs SPEED UP and SPEED DOWN works in opposite way.
GtoM AngleReq
[]
Phase difference between generator and mains voltage. Use this setpoint for phase correction of potential transformers for forward synchronizing. Step: 1 Range: -30 to +30 Following is an example of Controller connection to Middle or High voltage system. T1 shifts phase +30 and no shift is on T2. GtoM AngleReq = +30 for this example.
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LOAD
MCB
T1
3x10 kV
3x230/400VAC
GCB
3
T2
4
4
L1, L2, L3, N
Vm
Im
MCB
GCB
Vg Ig
iG -CU
Voltage window
[%]
Maximum difference between generator and mains voltage. Step: 0,1 % of Nominal voltage Range: 0.0 100.0 %
Phase window
[]
Maximum phase angle difference between generator and mains. Step: 1 Range: 0 90
Dwell time
[s]
The period of time that the phase angle must be within Phase window and Voltage difference within voltage window before GCB closing. Step: 0.1 s Range: 0.0 25.0 s
Freq gain
[%]
Slip frequency control loop gain during synchronizing when GCB is still opened. Step: 0.1 % Range: -200.0 to +200.0 %
Freq int
[%]
Relative integration factor of slip frequency control loop. Step: 1% Range: 0 % 100 %
Freq der
[%]
Relative stability factor of slip frequency control loop. Step: 1% Range: 0 % 100 %
Freq reg loop
[ ALWAYS / SYNC ONLY ]
ALWAYS: Frequency control is active in island operation, running unloaded period and synchronizing. SYNC ONLY: Frequency control is active during synchronizing only.
Angle gain
[%]
Gain of angle control loop when slip frequency is near zero and GCB is still opened. Step: 0,1% Range: 0 % to +200.0 %
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Angle der
[%]
Relative stability factor of angle control loop. Step: 0,1% Range: 0 % to +100.0 % Hint: Setpoints Slip freq gain, Slip freq int, Slip freq der, Angle gain, Angle der adjusts speed (are active) during synchronizing only when GCB is opened.
Speed gov bias
[V]
Speed control DC output bias level of SPEED GOVERNOR voltage output. Step: 0.01 V Range: -10.00 to +10.00 V
Load ramp
[s]
Increasing or decreasing load rate. In seconds / nominal power. Step: 1s Range: 0 600 s
Load gain
[%]
Gain of power control loop, when GCB and MCB are closed. Step: 0,1 % Range: 0.0 200.0 %
Load int
[%]
Relative integration factor of power control loop. Step: 1% Range: 0 100 %
Load der
[%]
Relative stability factor of power control loop. Step: 1% Range: 0 100 % Hint: Load gain, Load int and Load der setpoints are active only when gensets group operates in parallel to the mains, when GCBs and MCB are closed and Process control: SysLdCtrlPtM = Baseload or Imp/Exp. SpeedRegOut behavior Operation mode Genset state Running GCB opened Island Loaded island GCB closed MCB opened Output value = Speed gov bias Parallel Synchronizing Loaded in parallel GCB closed Active loop: Freq gain, int, der; Angle gain, der Active loop: Load control or Load sharing
Sync/Load ctrl: Freq reg loop =SYNC ONLY Sync/Load ctrl: Freq reg loop = ALL THE TIME
Active loop: Freq gain, int, der;
GCB open level
[%]
Power level for getting offline while unloading. If this level isnt reached GCB opens after GCB open del time. Step: % of Nominal power Range: 0 to 100 %
GCB open del
[s]
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Maximum time to unload the gen-set. Step: 1s InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF
Range:
0 600 s
Sync timeout
[s]
Maximal allowed time for forward or reverse synchronization. Step: 1s Range: 0 1800 s Hint: When any gain setpoint is set to zero corresponding control loop is switched OFF.
Sync/Load control adjustment

Hint: No droop Speed governor is expected for controller connection. Two wire shielded connection from IG-PCM SPEED GOVERNOR output (GND, Volt or VoltR) to Speed governor auxiliary input is recommended. IG-PCM SPEED GOVERNOR output sensitivity should be less then 10V to 5% of Nominal generator frequency (see drawing below). IMPORTATNT Speed governor has to be adjusted for optimum performance before controller Sync / load control adjusting. Check generator phase sequence before the first GCB connection. RPM RPM + 5 % of nominal + 5 % of nominal
1500 - 10 V 0V
Speed governor voltage output +10 V
1500 - 10 V
0V
Volt [V]
Speed governor voltage output +10 V
Volt [V]
- 5 % of nominal SpeedRegChar = POSITIVE
- 5 % of nominal SpeedRegChar = NEGATIVE
Drawing text translation Speed governor voltage output RPM of nominal

Hint: To decrease sensitivity of the speed governor auxiliary input (e.g.1:11) use IG-PCM VoutR output and connect external resistor R2. Output resistance of VoutR is 10 kohm.
Speed governor
G ND
IS-CU
G ND
VoutR range: depends on resistor value
R2=1k R1=10k VoutR AUX input
Vout range: -10.0 V to +10.0 V
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Drawing text translation Speed governor GND VoutR AUX input VoutR range: depends on resistor value Vout range
Before optimal Sync/load setpoints adjusting disconnect GCB OPEN/CLOSE output to avoid paralleling.
Synchronizer adjustment
Start the engine in MAN Mode. Set the engine RPM by speed trim on speed governor or by Speed gov bias to Nominal frequency. To start synchronizing press GCB ON/OFF button. GCB LED starts flash to indicate synchronization. To stop synchronization press again GCB ON/OFF . Slip control adjusting: 4) Adjust Slip freq gain (care to sign) to unstable speed control and decrease value by 30 % to insure stable performance. 5) Adjust Slip freq int, Slip freq der to stable (fast and smooth) slip control. Syncroscope on the controller measure screen should move slow down and stop (in any position, because Angle control is off). Angle control adjusting: 6) Set Angle gain and Angle der. Synroscope on the controller measure screen should move slow down and stop in up position. Set Angle gain to unstable value (syncroscope swings) and decrease value by 30 % to insure stable performance. Then set Angle der to improve stability. 1) 2) 3)
Load control adjustment

1) 2) zero. 3) mains. 4) When is GCB closed, gen-set load slowly increases to Base load value. Check that gen-set power is positive (CT polarity !). 5) Increase Load gain to unstable load control and decrease value by 30 % to insure stable performance. When Load int factor is set to zero gen-set load can differ from required baseload. 6) To adjust and optimize Load int and Load der change several times Base load between 30 and 70 % of nominal power. 7) When gen-set is running full load check if a. IG-PCM voltage value is not limited (not exceed 10V) b. Speed governor actuator output isnt mechanically limited or operates in small section of throttle range. Start the gen-set in MAN Mode, press GCB ON/OFF button to synchronize and close gen-set to Set Process control = Baseload, set Baseload value to 30 % of nominal load. Set Load gain to the same value and sign (polarity) as Slip freq gain. Set Load int and Load der to
Volt/PF ctrl
AVRRegChar [POSITIVE / NEGATIVE ]
Switch between AVR characteristics. POSITIVE: When IG-CU and AVRi output voltage increases generator voltage increases. NEGATIVE: When IG-CU and AVRi output voltage decreases generator voltage increases. Hint: All corresponding set points Voltage gain and PF gain are positive. When set to NEGATIVE Binary outputs AVR UP and AVR DOWN works in opposite way.
Voltage gain
[%]
Gain of voltage control loop. Step: 0,1 % Range: -200.0 to +200.0 % Hint: When any gain setpoint is set to zero corresponding control loop is switched OFF. InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF - 66
Voltage int
[%]
Relative integration factor of voltage control loop. Increasing of integration value causes quicker response. Step: 1% Range: 0 100 %
Voltage der
[%]
Relative stability factor of voltage control loop. Step: 1% Range: 0 100 % Hint: Voltage gain, Voltage int and Voltage der setpoints are active (adjusts AVR) only when GCB is open to maintain Nominal voltage or to match voltage during synchronizing. Voltage loop operates as well when GCB is closed and MCB opened.
PF gain
Gain of power factor control loop. Step: 0,1 % Range: -200.0 200.0 %
[%]
PF int
[%]
Relative integration factor of power factor control loop. Increasing of integration value causes quicker response. Step: 1% Range: 0 100 %
PF der
[%]
Relative stability factor of power factor control loop. Step: 1% Range: 0 100 % Hint: PF gain, PF int and PF der setpoints are active (adjusts AVR) only in parallel to the mains when GCB and MCB are closed.
AVR DCout bias
[%]
AVRi voltage output bias level. Step: 0,1 % Range: 0 100.0 % Hint: Real voltage level depends on AVRi outputs connection and output level potentiometer setting. Maximum range is 10 V. VoltRegOut behavior Operation mode Genset state Running, GCB opened Island Loaded island GCB closed MCB opened Active loop: Active loop: Volt gain, int, der; Volt gain, int, der; Parallel Loaded in parallel GCB closed Active loop: PF control
Synchronizing
Active loop: Volt gain, int, der;
Volt/PF control adjustment

Hint: No droop AVR unit is expected for standard controller connection.
IG-AVRi output connection

IG-AVRi-TRANS (AC power supply for AVRi) have to be supplied from gen-set voltage. AVRi outputs can be connected: OUT1-OUT2 or unsymmetrical OUT1-GND or OUT2-GND. InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF - 67
1) 2) 3) 4)
Potentiometer on the AVRi defines maximal OUT1, OUT2 voltage range When AVRi is connected to AVR auxiliary voltage input use OUT1,OUT2 AVRi outputs When AVRi replaces AVR external potentiometer use unsymmetrical output. AVRi output voltage should change generator voltage max in range 10 % of Nominal voltage.
Out1 - GND [V]
Out2 - GND [V]
10 V
10 V
2V 0V
m mu axi to m t t se i po VR A inimum set to m AVRi pot

0% AVR DCout bias
AV Ri pot set to
2V 0V
AVRi pot
ma xim um
set to m inimum
100.0 %
0%
AVR DCout bias
100.0 %
AVRi Out1 or Out 2 to GND output voltage depends on AVRi trim setting [V] Out1 to Out2
10 V
0V 0%
= um ot inim ip =m R pot AV AVRi

50 %
um im ax m
AVR DCout bias
100.0 %
AVRi output voltage Out1 - GND Out2 - GND Out1 Out2 Bias \ Pot Min Max Min Max Min Max 0% 0 0 2 10 - 2 V -10 V 50 % 1 5 1 5 0V 0V 100 % 2 10 0 0 + 2 V 10 V
-10 V
AVRi Out1 to Out 2 output voltage
Drawing text translation AVR DCout bias Out
Voltage control adjustment

1) 2) 3) 4) Set Voltage gain, Voltage int, Voltage der to zero and AVR DCout bias = 50%. Start the gen-set in MAN Mode to nominal speed. Adjust generator voltage to nominal value. When gen-set is running without load increase careful Voltage gain to unstable point and then decrease value by 30 % to insure stable performance. 5) Adjust Voltage int and Voltage der. Hint: To judge optimal adjusting induce generator voltage jumps by AVR DCout bias change or by Nominal voltage change.
PF control adjustment
Prior to PF adjustment should be Sync/load and Volt control adjusted ! The genset should be 30 % loaded. 1) Set the same values PF gain, PF int and PF der as in voltage control loop. 2) Set Process control = Baseload, set Baseload to 30 % of nominal load, PF reference to 1.0. 3) Start and synchronize the gen-set in MAN Mode by pressing GCB ON/OFF 4) When running in parallel 30% loaded increase slowly PF gain to unstable point and then decrease value by 30 % to insure stable performance.
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5) Adjust PF int and PF der. Hint: To judge optimal adjusting induce generator power jumps by Baseload change or by soft changes of AVR DCout bias.
Act. calls/SMS
Warning call Unload call Slow stop call Shut down call AcallCH1..3-Type
Up to three separate channels are available for any one of the following types of messages: DISABLED: Channel is disabled. DATA: Standard analog, GSM or ISDN modem connection to WinEdit. SMS: Channel sends SMS message. Only when is GSM modem connected. E-MAIL: Channel sends E-mail. Only when is IG-IB connected. EML-SMS: Channel sends E-mail with short SMS. Only when is IG-IB connected. Email contains - header with serial number and application info. - Alarm list - 20 History records (reason, date, time) Example of EML-SMS: AL=(Sd Water Temp,Wrn Water Temp,!Emerg Stop,ActCallCH1Fail)
[DISABLED / ENABLED] [DISABLED / ENABLED] [DISABLED / ENABLED] [DISABLED / ENABLED]
Enables or disables active calls/SMS to selected phone or mobile numbers when a warning alarm occurs.
Enables or disables active calls/SMS to selected phone or mobile numbers when a unload alarm occurs.
Enables or disables active calls/SMS to selected phone or mobile numbers when a slow stop alarm occurs.
Enables or disables active calls to selected phone or mobile numbers when a shut down alarm occurs.
AcallCH1..3Addr
Address for channel 1...3 active call. Each above message type has either a number or an e-mail address associated to it. For more details see WinEdit-MultiEdit guide chapter IG-IB Internet communication. Hint: To receive active call run WinEdit Type of connection = Active call. WinEdit Active call window contains list of received AIG or AIS files. Each list item contains Gen-set name, Date, Time, controller serial number.
Num rings AA
[-]
Number of rings prior to open modem connection. Step: 1 Range: 1 30 Hint: NumberRings AA change is not activated immediately. It is activated after controller is switched on or when modem is connected to controller.
A.c.multiplier
[-]
When active call is activated, controller tries A.c.multiplier times to open the connection. Step: 1 Range: 1 to 250 InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF
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Hint: Timeout for connection is 90 sec and after 120 sec controller starts the next attempt. Incoming calls are blocked when controller tries to send an active call.
Date and time

TimeStamp per
Time interval for history record. Time base is based on number of minutes since midnight. Step: 1 min Range: 0 - 240 min Hint: No history is recorded when TimeStamp per = 0.
#Time [HHMMSS]
Real time clock adjustment
#Date [DDMMYY]
Actual date adjustment Hint: #Time and #Date setpoints are synchronized via CAN bus each hour with the lowest address controller. #Time or #Date change in any controller changes Time or Date in all controllers on CAN bus.
Sensor spec
Calibr AI1 (AI2, AI3) Calibr AIM1 (AIM2, AIM3, AIM4) [] []
Calibrating constant to adjust the measured value of IG-CU and IG-IOM, IGS-PTM (when configured) analog inputs. The units of the calibration constant are the same as the associated analog input, e.g. If entering 5 for Calibr AI1, and AI1 is oil pressure in psis then it would be 5 psis. Step: 1 Range: -1000 +1000 Hint: Calibr AI1, Calibr AI1, Calibr AI3 have to be adjusted when measured value is near the alarm level. User curves A, B, C can be defined by WinEdit software.
Load Shedding
The load shedding function is available in all applications SPM, SSB, SPtM, MINT, MEXT and is active in all iG modes except OFF. Load shedding has three steps and each step is linked with its own LOAD SHED digital 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 vise versa. If manual reconnection of the load is desired the AutoLd recon setpoint needs to be disabled and the MAN LOAD RECON digital input needs to be configured. Digital input MAN LOAD RECON resets iG to lower stage of load shed only if the load is under Ld Recon Level. All LOAD SHED outputs are activated (closed) to trip unessential load before genset goes to island (MCB opens) from parallel to mains: a) After Mains fail before genset starts to island in AUT mode. b) Before MCB is opened in MAN mode by button.
Ld shed level
[%]
When gen-set load exceeds this level for more than LD Shed delay , iG controller proceeds to the next Load shedding stage - the next binary output LOAD SHED x is closed. InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF - 70
Step: Range:
1 % of Nominal power from Ld Recon level to 200 % of Nominal power
Ld shed delay
[s]
Time delay for LD shed level limit. Step: 0,1 s Range: 1 - 1800 s
Ld recon level
[%]
When gen-set load drops under this level for more than LD recon delay time, IS/IG controller proceeds to the lower Load shedding stage. The binary output for higher stage is opened (LOAD SHED x). Automatic load reconnection works only when AutoLd recon = ENABLED. Step: 1 % of Nominal power Range: from 0 - Ld shed level
Ld recon del
[s]
Time delay for LD recon level limit. Step: 1s Range: 1 - 1800 s
AutoLd recon (DISABLED / ENABLED) [-]

Enables automatic reconnection of shedded load. If enabled, binary input MAN LOAD RECON has no function.
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Sensor specification
Sensor calibration
To correct measuring error of each analog input (pressure, temperature, level) calibrating constants within 10 % of measure range should be set. Three calibrating constants are set in physical units - C, %, psi, F, bar, etc. From these constants equivalent calibrating resistances are calculated and are internally (in software) added to the sensors resistance. Once the calibration value is entered (enter is pressed) the calibrating resistance is calculated and saved in memory. This value is then added to measured sensor resistance before the value is displayed. Example: IG-CU display Temperature 70 C and real value is 73 C. After setting Calibr AI1 to +3 C (and pressing ENTER) InteliGen calculates corresponding resistance (e.g.5) and saves this value into the memory. The resistance is then added to all calculations (e.g. instead of 70C -> 73C, or e.g. instead of 5C -> 6C).
Default sensor settings

Analog input 1: 10 points VDO characteristic, pressure measuring in bar Analog input 2: 6 points VDO characteristic, temperature measuring in C Analog input3: 2 points VDO characteristic, fuel level measuring in % Curve A VDO pressure Curve B VDO temperature Curve C VDO Fuel level
Primary ohms Converted 0,1 bar
Primary ohms Converted C
Primary ohms Converted %
PT 100 PT 1000 NI 100 NI 1000 IEC 751 IEC 751 IEC 43760 IEC 43760 Primary Converted Primary Converted Primary Converted Primary Converted 0,1 C C C C 92 100 108 116 123 131 139 146 154 169 -205 0 205 413 595 803 1013 1197 1411 1814 922 961 1000 1117 1232 1309 1347 1385 1423 1461 -20 -10 0 30 60 80 90 100 110 120 89 95 100 117 135 148 155 162 167 176 -20 -10 0 30 60 80 90 100 110 120 893 946 1000 1171 1353 1483 1549 1618 1688 1760 -20 -10 0 30 60 80 90 100 110 120
VDO Temp VDO Press VDO Level Primary Converted Primary Converted Primary Converted 3900 1525 -20 0 10 50 0 20 10 180 0 100
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700 440 290 195 135 95 69 38
20 30 40 50 60 70 80 100
85 119 152 180
40 60 80 100
Primary 170 200 230 280 330 390 460 560 690
4-20mA/100 4-20mA/60 0-20mA/100-PTM 4-20mA/100-PTM Converted Converted Primary Converted Primary Converted 0 13 25 38 50 63 75 88 100 0 8 15 23 30 38 45 53 60 0 38 57 77 96 116 135 155 174 194 0 20 30 40 50 60 70 80 90 100 38 57 77 96 116 135 155 174 194 0 12 25 37 50 62 75 87 100
100mV/100-PTM Primary Converted mV0100R mV0100Out 0 10 40 70 110 140 170 210 230 250 0 4 16 28 45 57 68 84 92 100
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Operator Interface
Pushbuttons and LEDs
3 2 1 4 5
15
10
16
11
12
14
13
18
17
Pushbuttons:
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. MODE Cycle forward through gen-set operation modes OFF -> MAN-> AUT -> TEST. MODE Cycle backward through gen-set operation modes OFF-> MAN->AUT-> TEST. HORN RESET Deactivates the HORN. FAULT RESET Acknowledges faults and alarms. START Starts the gen-set in MAN mode. STOP Stops the gen-set in MAN mode. MCB ON/OFF When in MAN mode, opens and closes (synchronizes) the Mains circuit breaker. GCB ON/OFF When in MAN mode, opens and closes (synchronizes) the Generator circuit breaker. PAGE Cycles through the display screens MEASUREMENT->ADJUSTEMENT->HISTORY. Select the setpoint, select the screen or increase setpoint value. Select the setpoint, select the screen or decrease setpoint value. ENTER Confirm setpoint value.
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LEDs
13. MAINS PRESENT: GREEN LED is on, if mains is present and within limits. 14. MAINS FAILURE: RED LED starts flashing when the mains failure occurs and gen-set does not run, goes to steady light when the gen-set starts and goes off when the mains restores. 15. GEN VOLTAGE PRESENT: GREEN LED is on, if gen. voltage is present and within limits. 16. GEN-SET FAILURE: RED LED starts flashing when gen-set failure occurs. After FAULT RESET button is pressed, goes to steady light (if an alarm is still active) or is off (if no alarm is active). 17. GCB ON: GREEN LED is on, if GCB is closed. Flashes during gen-set synchronizing. 18. MCB ON: GREEN LED is on, if MCB is closed. Flashes during gen-set synchronizing.
How to select gen-set mode ?

Use MODE or MODE to select requested gen-set operation mode OFF MAN AUT TEST. It is not possible to go directly from OFF to TEST.
When to use GCB ON/OFF and MCB ON/OFF buttons ?

In AUT mode these buttons are disabled. In MAN mode are enabled, but before closing of any circuit beaker, voltage must be within limits. iG has internal protection to avoid the closure of both breakers at once without synchronizing. In TEST mode MCB ON/OFF is enabled, to allow test with load.
Display menus
There are 3 display menus available: MEASUREMENT, ADJUSTMENT and HISTORY Each menu consists of several screens. Pressing the PAGE button repeatedly will scroll the user through the menu screens.
How to view measured data?

Pressing the PAGE button repeatedly will scroll the user through the menu screens. Select the MEASUREMENT screen. Use and to select the screen with requested data.
How to view and edit set points?

1. Pressing the PAGE button repeatedly will scroll the user through the menu screens. Select the ADJUSTMENT screen. 2. Use or to select requested set points group. 3. Press ENTER to confirm. 4. Use or to select requested set point. 5. Set points marked * are password protected. 6. Press ENTER to edit. 7. Use or to modify the set point. When or is pressed for 2 sec, auto repeat function is activated. 8. Press ENTER to confirm or PAGE to leave without change. 9. Press PAGE to leave selected set points group.
How to view the HISTORY menu?

1. Pressing the PAGE button repeatedly will scroll the user through the menu screens. Select the HISTORY screen. 2. Use or to select a requested record. 3. Use ENTER to select requested screen (record items) within displayed records InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF - 75
How to change the display contrast ?

Press ENTER and or at the same time to adjust the best display contrast Hint: Only in MEASUREMENT menu
How to check the serial number and software revision?

Hold down the ENTER and the press PAGE. On the display you can see InteliGen INFO screen for 10 seconds. InteliGen INFO screen contains : 1) Controller name (see Basic setting group) 2) InteliGen serial number (8 character number) 3) SW version: the first is the firmware version number, the second is configuration table number. 4) Application: IM 5) Branch: standard Hint: Only in MEASUREMENT menu.
How to find active alarms ?

Active alarm list is the last screen in the MEASUREMENT menu. Select MEASUREMENT menu. Press You will see the list of all active alarms with the number of alarms at the top-right corner. Inverted alarms are still active. Non-inverted alarms are not active, but not yet confirmed. Press FAULT RESET to accept all alarms. Non-active alarms immediately disappear from the list. Active alarm list appears on the screen when a new alarm comes up and Main MEASUREMENT screen is active. Hint: Alarm list does not activate when you are reviewing the values, parameters or history.
Description of MEASUREMENT screens

Main measure screen
1 2
OFF MAN AUT
TEST
3 4 7 5 8
Ready Mains Oper cos 0.00 RPM 0 Tim er 0
6
1. 2. 3. 4. 5. 6. 7. 8. Operation mode of the gen-set Indication of active alarm !or active Remote control R Status of the gen-set Actual condition RPM of the gen-set Active power Power factor Timer - event s counting time (e.g. prestart, cooling, etc.) - 76
Total power screen

PWR I/E -20 10kW 0.90L
20kW 30kW 1.00R 0.90C Left up corner: Actual power control mode Off or Base or Imp/Exp and required power values.
Load: Mains: Genset:
Actual value of active power. Actual value of PF Actual value of active power. Actual value of PF Actual value of active power. Actual value of PF
Generator screen
Load surge maximal value Load surge actual value Gen freq Gen V1-2, V2-3, V3-1 ph-ph Gen V1, V2, V3 ph-N (triple barograph) Gen I1, I2, I3 (triple barograph)
Actual value of PFMains screen

Mains Curr L3 P mains Q mains Mains Power Factor Mains freq Mains V1-2, V2-3, V3-1 ph-ph Mains V1, V2, V3 ph-N (triple barograph)
IG-CU Analog inputs screen

AI1 Oil pressure AI2 Water temperature AI3 Fuel level Battery voltage (single barograph) (single barograph) (single barograph) (single barograph)
IG-IOM, IGS-PTM Analog inputs screen (if configured)

(single barograph) (single barograph) (single barograph) (single barograph)
IG-CU binary inputs 1 / 2

BI1 to BI5
IG-CU binary inputs 2 / 2

BI6 to BI9
IG-CU binary outputs 1 / 2

BO1 to BO5
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IG-CU binary outputs 2 / 2

BO6 to BO9 Load shedding status
IG_PCM binary inputs

BI10 to BI13
IG_PCM binary outputs

BO10 to BO13
IG-IOM, IGS-PTM binary inputs 1 / 2 (if configured)

BI1 to BI4
IG-IOM, IGS-PTM binary inputs 2 / 2 (if configured)

BI5 to BI8
IG-IOM, IGS-PTM binary outputs 1 / 2 (if configured)

BO1 to BO4
IG-IOM, IGS-PTM binary outputs 2 / 2 (if configured)

BO5 to BO8
Gen-set power screen

Active power Power factor Reactive power kVAr Apparent power (total and per phase) (total and per phase) (total and per phase) (total and per phase)
Statistic
Kilowatt-hours kWh Active energy Reactive power hours kVArh Reactive energy Run hours Number of starts NextServTime total total
Synchronizing
Angle between V1g and V1m V1g Generator first phase voltage V1m Mains first phase voltage (synchroscope)
SRO Speed regulator output indication in the range 10,00V to 10,00V VRO Voltage regulator output indication in the range 0 to 100%.
Alarm list
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PAGE PAGE
PAGE
Measure Screens Par. Edit Screens
History Screens
OFF
ENGINE BASIC ENGINE PROT GEN BASIC GEN PROTECT MAINS FAIL
MAN 500
AUTO
1000
Screen
Drawing text translation Page Measure Screens Par. Edit Screens

PAGE ENTER
RPM GEAR TEETH 150 150 NOM RPM 1500 1500 START RPM 30 30% CRANK TIME 10s 10
Flow Chart of pushbutton Operation
586
kW
12345h 14:23:15
Next Screen
Parameter setting: 1. Set cursor by 2. Press
ENTER
OF LE RY B TA ISTO H
buttons
to editing mode buttons
3. Adjust parameter by 4. Press

ENTER
to write parameter into memory to cancel of editing mode

ENTER ENTER
Next Screen
Press
PAGE
ENTER
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PAGE
..... TO MEASURE SCREEN
History Screens Next Screen Engine Basic Engine Prot Gen Basic Gen Protect Mains Fail Gear Teeth Nom RPM Start RPM Crank Time Parameter setting Set cursor by - buttons Press - to editing mode Adjust parameter by - buttons Press - to write parameter into memory Press - to cancel of editing mode Table of history To measure screen
- 80
Mode description
There are three modes of the gen-set: OFF - MAN AUT - TEST. To select the mode press MODE or MODE
OFF mode
Outputs STARTER, GCB CLOSE/OPEN and FUEL SOLENOID are not energized. Genset cannot be started. If START,STOP,GCB ON/OFF buttons is pressed the iG will not respond. MCB behavior depends on AutoMains fail: MCB opens on setpoint: MAINSFAIL: When power-cut comes, MCB opens. After mains returns, MCB closes with MCB close del. GENRUN: When power-cut comes, MCB stays closed.
MAN mode
1) START. - starts the gen-set. 2) GCB ON/OFF If the GCB if generator voltage is out of the limits (adjusted in the set point group Generator protections) InteliGen does not to respond to the GCB ON/OFF a) IG closes GCB to dead bus. b) IG starts synchronizing. When synchronized closes the GCB and stays running in parallel. c) Opens the GCB if it was closed with soft unloading to the mains. 3) MCB ON/OFF a) IG closes MCB to dead bus (even if mains the voltage is out of limits). b) IG starts synchronizing. When synchronized closes the MCB and stays running in parallel. c) Opens the MCB if it is closed with soft unloading. 4) STOP a) When running in parallel transfers load to the mains, opens GCB, goes into cooling state and stops the engine. b) When engine is running unloaded activates cooling sequence and then stops the engine. c) During cooling state causes immediate engine stop. Hint: The genset is permitted to run unloaded for an unlimited amount of time. When power cut comes or REM START/STOP is closed InteliGen does not start the gen-set. Load control in parallel depends on Process control: Load control = BASELOAD or IMP/EXP setpoint.
AUT mode
AMF
1) Mains failure is recognized InteliGen opens MCB when AutoMains fail: MCB opens on = MAINSFAIL. a) After EmergStart del elapsed, InteliGen starts the gen-set. InteliGen opens MCB after engine starts when AutoMains fail: MCB opens on = GENRUN. b) If mains recovers during the start-up process, InteliGen closes MCB again after MCB close del and stops the gen-set. 2) When the gen-set reaches Underspeed level and the generator voltage is within limits (adjust in the set point group Generator protections) InteliGen closes the GCB. If the generator voltage is out of the limits for MaxStabil time, InteliGen alarms the failure and stops the gen-set. 3) After mains recovers: a) After MainsReturn del InteliGen starts synchronizing to mains and closes the MCB and unloads genset. b) After the Breakers overlap delay InteliGen opens the GCB. c) The gen-set is cooled and stopped. InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF - 81
Baseload
ProcessControl = Base load 1) InteliGen starts the gen-set when a) binary input REM START/STOP is closed. b) PeakAutStart = ENABLED and Load power exceeds PeakLevelStart. 2) InteliGen synchronizes gen-set to mains, closes GCB and increase load (Load ramp) 3) Gen-set remains running parallel to mains at Base load gen-set power. 4) InteliGen stops the gen-set when a) binary input REM START/STOP is opened. b) PeakAutStart = ENABLED and Load power decreases below PeakLevelStop. 5) The gen-set is unloaded, InteliGen opens GCB 6) The gen-set is cooled and stopped.
Import export
ProcessControl = Imp/Exp 1) InteliGen starts the gen-set when a) binary input REM START/STOP is closed. b) PeakAutStart = ENABLED and Load power exceeds PeakLevelStart. 2) InteliGen synchronizes gen-set to mains, closes GCB and increase load (Load ramp) 3) Gen-set remains running parallel to mains at Import load mains power. 4) InteliGen stops the gen-set when a. binary input REM START/STOP is opened. b. PeakAutStart = ENABLED and Load power decreases below PeakLevelStop. 5) The gen-set is unloaded, InteliGen opens GCB 6) The gen-set is cooled and stopped. Hint: InteliGen does not respond to GCB ON/OFF , MCB ON/OFF , STOP, START
!!!!! VERY IMPORTANT !!!!!!
Engine can start automatically without warning when pressing FAULT RESET after shut down alarm when Basic setting: FltRes GoToMAN is set to DISABLED.
TEST mode
The setpoint Ret from test influences the behavior of TEST mode.
The setpoint Ret from test = MANUAL

1. While TEST mode is selected, gen-set automatically starts and is running unloaded. 2. To load the gen-set with load supply interruption a) Power cut comes or b) MCB ON/OFF button is pressed When power cut or MCB ON/OFF : InteliGen opens MCB, after FwRet break elapses, InteliGen closes GCB. When the mains recovers gen-set remains island running! 3. To load the gen-set without load supply interruption a) GCB ON/OFF is pressed b) Binary input TEST ON LOAD is closed In this case InteliGen synchronizes gen-set to mains, closes GCB, Breaker overlap time runs in parallel and then opens MCB. When the mains recovers gen-set remains island running ! 4) To stop the gen-set select other mode than TEST InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF - 82
The setpoint Ret from test = AUTO

While TEST mode is selected, gen-set is running unloaded. When power cut comes InteliGen opens MCB. After FwRet break elapses, InteliGen closes GCB. When the mains recovers: a) After the MainsReturn del InteliGen starts back synchronizing to mains and closes MCB. b) The gen-set remains running in parallel for BreakerOverlap time, opens GCB and remain running unloaded. To stop the gen-set select other mode than TEST Hint: InteliGen does not respond to GCB ON/OFF , STOP, START in Ret from test = AUTO. Engine automatically starts, when TEST mode is selected. Engine can start automatically without warning when pressing FAULT RESET after shut down alarm.
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Switch to TEST Mode
Gen-set starts running unloaded
Mains failure
Mains
OK
See description 2a) See description 2b)
= MANUAL MCB ON/OFF button or Mains failure Return from TEST GCB ON/OFF button
= AUTO
Action
See description 3a)
INTERRUPTION MCB opens waits FwRet break time GCB closes
NO INTERRUPTION Synchronizing GCB closes Breaker overlap time runs in parallel MCB opens
Gen-set is loaded island running
Mains failure
Mains
OK
= MANUAL Return from TEST
= AUTO
Setpoints mentioned in chart are from AutoMains Fail group
Mains return del waits MCB Synchronizing Breaker overlap time runs in parallel GCB opens
Gen-set is running unloaded
To change switch InteliGen to AUT or MAN or OFF mode.
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On load test
It is possible to transfer the load to genset when mains is OK. Configure Binary inputs TestOnLoad and Remote TEST and adjust Return from test = MANUAL. Related setpoints which influences load transfer: Load ramp, GCB Open level, GCB open del, Breaker overlap.
O V batt
TestOnLoad
Remote TEST
IG-CU
Auto Main Fail: Return from test = MANUAL
Drawing text translation TestOnLoad Remote TEST Auto Main Fail: Return from test = MANUAL
Load surge protection

Load surge protection is fast Mains failure protection. It detects sudden generator load changes during parallel operation with the mains. Due to Mains failure can be generator immediately fully unloaded or heavy overloaded. Load surge protection in this case opens MCB or GCB depends on controller application. Load surge protection becomes active 3 sec delayed after entering to parallel (synchronizing). Values visible on the iG screen and in WinEdit
Max load surge
[P/s]
It is maximal value of Act load surge (maxi meter). When genset enters the parallel mode, the Max load surge value is reseted to zero. Hint: Max load surge is visible on iG generator screen and in WinEdit.
Load shedding
G en-set power Ld shed level
closed
BO Load shed 1
closed
BO Load shed 2
closed
BO Load shed 3
Ld shed del
Ld shed del
Ld shed del
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Load reconnection automatic

AutoLd recon = ENABLED
G en-set power Ld recon level
BO Load shed 3 BO Load shed 2 BO Load shed 1
opened
opened
opened
Ld recon del
Ld recon del
Ld recon del
Load reconnection manual

AutoLd recon = DISABLED
Ld recon level
G en -set po w er
BO Load shed 3 BO Load shed 2 BO Load shed 1
opened
opened
opened
BI Man load recon

no action
Drawing text translation Gen-set power Ld shed level Ld recon level BO Load shed BI Man load recon Ld shed del Ld recon del closed opened no action
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Load sheeding Inputs, Outputs and Setpoints overview:
Vg Ig
Man load recon
Load shedding: Ld shed level [%] Ld shed delay [s] Ld recon level [%] Ld recon del [s] AutoLd recon [ ENABLED / DISABLED ]
Load shed 1 Load shed 2 Load shed 3
Drawing text translation Vg Ig Man load recon Load shedding Ld shed level Ld shed delay Ld recon level Ld recon del AutoLd recon [ENABLED / DISABLED] Load shed
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Alarm management
Following alarms are available: Binary alarms Analog alarms
Hint: The alarm can be configured for any IG-CU, IG-PCLSM and IG-IOM, IGS-PTM binary input. When warning comes up it is displayed on the Alarm list screen and the selected entries are written to the History record. Detection of each binary input alarm is fix 1 sec time delayed. Analog input Alarms have usually two levels - e.g. wrn and sd. Use WinEdit to modify binary or analog inputs protections. Sensor fail does not activate binary output common Alarm.
Sensor fail
(Fls)
A sensor fail on the analog input is detected when Analog input value is +6% or 6% out of range of selected characteristic.
Warning
When warning comes up, only alarm outputs are closed. Possible warnings: Binary inputs configured as Warning (alarms are displayed and stored under configured name) Analog inputs configured as Warning (alarms are displayed and stored under configured name) Battery voltage alarm level MCB failure (when is difference between output and feedback signal)Unload
Shut down
When a shutdown occurs, InteliGen opens outputs GCB CLOSE/OPEN, FUEL SOLENOID, STARTER and PRESTART. Possible shut-down alarms Overspeed Underspeed Start fail IG-IOM, IGS-PTM fail Binary inputs configured as Shut down (alarms are displayed and stored under configured name) Analog inputs configured as Shut down (alarms are displayed and stored under configured name)
Slow stop
When the slow stop alarm comes up InteliGen unloads gen-set, opens output GCB CLOSE/OPEN, waits for Cooling time and opens FUEL SOLENOID output soft load transfer. InteliGen SPtM, SW Version 6.2, ComAp August 2005 - 88 IG-SPTM-SPTM+IOM-6.2.PDF
Binary inputs configured as Slow stop (alarms are displayed and stored under configured name) Analog inputs configured as Slow stop (alarms are displayed and stored under configured name)
ElProt
When the Electric generator protection (Unload) comes up, InteliGen opens the output GCB CLOSE/OPEN In MAN and AUT mode engine is cooled and stopped. Possible unload alarms GCB failure Overload IDMT Overcurrent (all three phases are checked) Short current (all three phases are checked) Current unbalance Generator voltage unbalance Generator over/under voltage (all three phases are checked) Generator over/under frequency (all three phases are checked) Reverse power Earth fault Alarm inputs configured as unload protection
Mains failure
Mains failure detection depends on Auto mains failure setpoints (levels and delays) adjusting. When mains failure comes up, mains circuit breaker is opened.
Possible mains failure alarms:

Mains over/under voltage (all three phases are checked) Mains over/under frequency (all three phases are checked) Mains voltage unbalance MCB Failure
HistoryRecord
History record protection activates history record only.
Alarm time chart

Protection delay
Underspeed Engine running only, SD, Slow stop, Wrn Gen>V, Gen<V, Gen>f, Gen<f, Volt unbal, Curr unbal, Reverse power, Unload protection, Load surge
All the time & Overspeed protections & Ig IDMT, Ig unbal, IG short Mains>V, Mains<V, Mains>f, Mains<f, MVolt unbal
Ready RPM=0 Cranking Starting Starter OFF Min stab time Start Idle
Running GCB closed Synchronizing
Loaded or Max stab time
Loaded GCB opened Unloading Cooling Stop - 89
Voltage phase sequence detection

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

There is fix defined phase sequence in InteliGen controller L1, L2, L3. When the phases are connected in different order (e.g. L1,L3,L2 or L2,L1,L3) following alarms are detected: G ph opposed = wrong generator phase sequence M ph opposed = wrong mains phase sequence B ph opposed = wrong bus phase sequence
Inverted phase polarity

inverted phase polarity can be detected due to wrong connection of separation transformers between controller and generator / mains / bus voltage. Phase sequence is OK but some phase(s) is connected in opposite way (180 shift). Following alarms can be detected: GEN L1 neg = generator phase L1 is inverted GEN L2 neg = generator phase L2 is inverted GEN L3 neg = generator phase L3 is inverted M L1 neg = mains phase L1 is inverted M L2 neg = mains phase L2 is inverted M L3 neg = mains phase L3 is inverted
Wrong phase sequence and inverted polarity

It is combination of both previous alarms G ph+L1 neg = wrong generator phase sequence and phase L1 is inverted G ph+L2 neg = wrong generator phase sequence and phase L2 is inverted G ph+L3 neg = wrong generator phase sequence and phase L3 is inverted M ph+L1 neg = wrong mains phase sequence and phase L1 is inverted M ph+L2 neg = wrong mains phase sequence and phase L2 is inverted M ph+L3 neg = wrong mains phase sequence and phase L3 is inverted Hint: Phase sequence detection is active when voltage in all three phases is >50VAC and all phases angles are in the range 120 20. Phase sequence alarm detection is 1 sec delayed to avoid transient effects. B (=BUS) alarms are detected in MINT, MEXT applications instead M. (=MAINS) alarms.
GCB fail detection

GCB fail detection is based on binary output CB close/open comparing with binary input CB feedback. There are three different time delays for CB fail detection see following diagrams. When the BO GCB close/open in steady state and GCB feedback is changed the GCB fail is detected immediately (no delay).
closed
BO G CB close/open opened closed BI G CB feedback active Alarm: G CB fail Alarm detection: immediatelly
BO G CB close/open
BI G CB feedback
opened active
Alarm: G CB fail
Alarm detection: immediatelly
There is different behavior of MCB No fail is detected when MCB is opened externally a) Controller synchronizes MCB when Mains is OK InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF - 90
b) MCB stays opened when Mains is out of limits c) Closed binary input Ext MF relay activates the same action like Mains fail. When BO GCB close/open (MCB close/open) opens there is 5 sec delay for the breaker to respond before a GCB fail (MCB fail) will be detected.
BO G CB close/open opened
BI G CB feedback
T ime delay 5 sec
opened active
Alarm: G CB fail
When BO GCB close/open (MCB close/open) closes, there is following delay for the breaker to respond before a GCB fail (MCB fail) will be detected: 2 sec when synchronizing - SPtM, MINT, MEXT (parallel modes) 5 sec in stand-by - SSB (island modes)
closed BO G CB close/open T ime delay BI G CB feedback 5 or 2 sec active Alarm: G CB fail closed
Drawing text translation BO GCB close/open BI GCB feedback Alarm: GCB fail Opened Closed Active Alarm detection: immediatelly Time delay
Sensor fail detection

Sensor fail Fls is detected when measured value is 6,2 percent out of range. The controller screen will display #### instead of the correct measured value.
R1
R2 R3 R4 R5
Sensor Failure
-6%
Range of measurement +6% Sensor 100%
Range of sensor
Failure
Drawing text translation Range of sensor

InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF - 91
IG-PC(LS)M module fail

Fail is detected when controller is switched on only. Fail is not detected during operation state.
Speed regulator and Volt regulator limit warning

There are two control loops in controller: Sync/Load control and Volt/PF control. During operation state it is detected when regulator output reached limit value i.e.: When Speed governor output stays on +9,8V or -9,8V for more than 2 sec the warning SpdRegLim is detected on the Alarm list. When AVRi output stays on <2% or >98% for more than 2 sec the warning VoltRegLim is detected on the Alarm list. This warning indicates only (no other action) wrong connection or adjusting of control loop. Control loops should operate within range. Hint: Corresponding warning is blocked when Binary outputs SPEED up,SPEED down or AVR up, AVR down are configured.
Power export protection

Protection against power export to the mains when Load control = BASELOAD. Export power is limited to not exceed Import load value. When export power exceeds Import load value Load control is automatically switched to IMP/EXP mode to keep Import load value. To protect genset against power export adjust ExportLimit = ENABLED and Import load = 0.
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Gen-set operation states

Gen-set can operate in following states Not ready Init Ready Prestart Cranking Pause Starting Unl Alarm Loaded Unloading Stop Shutdown Cooling Running Gen-set is not ready to start After IG power supply switch on Gen-set is ready to run Prestart sequence in process. Prestart output is closed Engine is cranking Pause between start attempts START RPM (firing speed) is reached. Gen electric protection unload is active Gen-set is running loaded Gen-set is unloading Stop Shut down alarm Gen-set is cooling before stop Waiting for GCB connection
External gen-set conditions : MainsOper Mains is present MainsFlt Mains cut off ValidFlt Mains cut off stay more than EmergStart del IslOper Island operation MainsRet Mains recover Brks Off GCB, MCB opened Synchro Gen-set is synchronizing ParalOper Gen-set is in parallel with mains UnlProt Unload protection
Start-stop sequence
MODE = MAN
Engine stop by using GCB ON/OFF and STOP

State Ready Prestart Cranking Starting Running Loaded Unloading Stop Ready Closed outputs PRESTART PRESTART,STARTER,FUEL SOLENOID FUEL SOLENOID FUEL SOLENOID FUEL SOLENOID, GCB CLOSE/OPEN FUEL SOLENOID Condition of next transition START request Prestart time=0 RPM> Start RPM RPM>(Nominal speed-Nominal speed/16) GCB ON/OFF GCB ON/OFF STOP RPM=0 >>>>
- 93
Engine stop by using STOP

State Ready Prestart Cranking Starting Running Loaded Cooling Stop Ready Closed outputs PRESTART PRESTART,STARTER,FUEL SOLENOID FUEL SOLENOID FUEL SOLENOID FUEL SOLENOID, GCB CLOSE/OPEN FUEL SOLENOID Condition of next transition START request Prestart time=0 RPM> Start RPM RPM>(15/16 of Nominal speed) GCB ON/OFF STOP Cooling time=0 RPM=0 >>>>
Hint: Gen-set stops immediately when button STOP is pressed during Cooling procedure.
Unsuccessful start
Crank attempts=3
State Ready Prestart Cranking Crank pause Cranking Crank pause Cranking Not ready Ready Closed outputs PRESTART PRESTART,STARTER,FUEL SOLENOID PRESTART PRESTART,STARTER,FUEL SOLENOID PRESTART PRESTART,STARTER,FUEL SOLENOID HORN, GENERAL FAULT Condition of next transition Start request Prestart time MaxCrank time CrankFail paus MaxCrank time CrankFail paus MaxCrank time FAULT RESET >>>>
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Remote control and data logging

Direct connection to the PC
InteliGen can be connected directly with PC via RS232 interface. Use the standard cable RS232 cable to connect PC with InteliGen. Hint: Make sure the grounding system on controller and PC COM port (negative of the PC DC supply) are identical before the first direct connection. There must not be any voltage between these two points otherwise the internal resistor in controller burns out. The simple solution is to assure, that the PC supply 240/20V is ground free (GND terminal is not connected).
PC
CONTROLLER
230 VAC
RS232
RS 232
Required the same voltage potential between GNDs
RS232
2 - RxD 3 - TxD 5 - GND
2 - RxD 3 - TxD 5 - GND
Battery
0 VDC
PC software - WinEdit
On the PC (for direct or modem connection) has to be installed the ComAps software package WinEdit. (based on Windows 95 or newer platform) WinEdit enables: read the quantities, adjust all set points, read the history control the engine configure the controller select software configuration modify alarm inputs and outputs modify password, commands protections, direct or modem communication receive active calls
History file
InteliGen stores a record of each important event into the history file. The history file seats 117 records. When the history file is full, the oldest records are removed. Hint: To force history download in WinEdit (direct or modem) open History window and select History | Read history command.
Record structure
Abbreviation Historical Value No. Number of historical event Reason Event specification Date Date of historical event in format DD/MM/YY Time Time of historical event in format HH:MM:SS Pwr Generator active power PF Generator PF LChr Character of the load Spd Engine speed InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF
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Gfrq Vg1 Vg2 Vg3 Ig1 Ig2 Ig3 Im3 Mfrq Vm1 Vm2 Vm3 Pmns MPF MLChr Batt OilP Wtmp Flev AIM1 AIM2 BInp BIPC BIM Bout BOPC BOM Mode
Generator frequency Generator voltage L1 Generator voltage L2 Generator voltage L3 Generator current L1 Generator current L2 Generator current L3 Mains current L3 Mains frequency Mains voltage L1 Mains voltage L2 Mains voltage L3 Mains active Imp/Exp power Mains PF Mains load character Battery voltage IG-CU Analog input 1 value ( default Oil pressure) IG-CU Analog input 2 value ( default Water temperature) IG-CU Analog input 3 value ( default Fuel level) IG-IOM, IGS-PTM Analog input 1 value (when configured IG-IOM, IGS-PTM) IG-IOM, IGS-PTM Analog input 2 value (when configured IG-IOM, IGS-PTM) Binary inputs IG-CU Binary inputs IG-PCM IG-IOM, IGS-PTM Binary inputs (when configured IG-IOM, IGS-PTM) Binary outputs IG-CU Binary outputs IG-PCM IG-IOM, IGS-PTM Binary outputs (when configured IGIOM, IGS-PTM) Mode IG - OFF, MAN AUT, TEST
List of possible events

Zero signed events are not displayed or stored. Events specification Alarm Configurable Analog inputs IG-CU alarms YES Analog inputs IG-IOM, IGS-PTM YES alarms Binary inputs IG-CU alarms YES Binary inputs IG-PC(LS)M alarms YES Binary inputs IG-IOM, IGS-PTM alarms YES Events info InteliGen switched on 0 Periodic history record 0 Starting sequence begins 0 Gen set stopped 0 Generator circuit breaker closed 0 Generator circuit breaker opened 0 Mains circuit breaker closed 0 Mains circuit breaker opened 0 Password was set from any terminal 0 Password was changed from any 0 terminal InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF History YES YES YES YES YES Switched On Time stamp Gen set start Gen set stop GCB closed GCB opened MCB closed MCB opened Password set Password chngd Active call YES YES YES YES YES 0 0 0 0 0 0 0 0 0 0 - 96
Events specification Binary input Remote OFF was closed Binary input Sprinkler was closed Service time expired Speed regulator out was limited Volt regulator out was limited Load shedding Load reconnection Some GCB in group was opened (MINT, MEXT) No other controller on CAN bus (MINT, MEXT) Engine Gen set start fail Gen set over speed Gen set under speed Emergency stop RPM pickup fail Battery voltage warning Battery is discharged Start info AMF start AMF stop Remote start by binary input (SPM,SPtM) Remote stop by binary input (SPM,SPtM) System start by binary input (MINT,MEXT) System stop by binary input (MINT,MEXT) Peak start (SPtM) Peak stop (SPtM) Generator Generator phase 1 over voltage Generator phase 1 under voltage Generator phase 2 over voltage Generator phase 2 under voltage Generator phase 3 over voltage Generator phase 3 under voltage Generator over frequency Generator under frequency Generator voltage unbalance Generator overload warning Generator overload Load surge protection Reverse power Synchronization timeout Reverse sync timeout Earth fault protection Failure of generator circuit breaker Generator short current protection Generator IDMT protection Generator current unbalance
Alarm 0 0 WrnService Time Wrn SpdRegLim Wrn VoltRegLim 0 0 0
History Remote OFF set Sprinkler set 0 0 0 Load shed Load recon Other GCB trip
Active call 0 0 wrn Wrn wrn 0 0 0
WrnCANbus Empty WrnCANbus Empty wrn Sd Start Fail Sd Overspeed Sd Underspeed Emergency stop SdPickupFail Wrn Batt volt Sd Batt flat 0 0 0 0 0 0 0 0 Unl Vg1 Over Unl Vg1 Under Unl Vg2 Over Unl Vg2 Under Unl Vg3 Over Unl Vg3 Under Unl Fgen Over Unl Fgen Under Unl Vgen Unbal Wrn Overload UnlGen Overload LoadSurge Unl Rev Pwr Stp SyncTO Wrn RevSyncTO Unl EarthFltC GCB fail Unl Short Igen Unl IDMT Unl Igen Unbal Sd Start Fail Sd Overspeed Sd Underspeed Emergency stop SdPickupFail Wrn Batt volt 0 GenSetMF start GenSetMF stop GenSetRemStart GenSetRemStop GenSetSysStart GenSetSysStop GenSet PKstart GenSet PKstop Unl Vg1 Over Unl Vg1 Under Unl Vg2 Over Unl Vg2 Under Unl Vg3 Over Unl Vg3 Under Unl Fgen Over Unl Fgen Under Unl Vgen Unbal Wrn Overload UnlGen Overload LoadSurge Unl Rev Pwr Stp SyncTO Wrn RevSyncTO Unl EarthFltC GCB fail Unl Short Igen Unl IDMT Unl Igen Unbal sd sd sd Sd sd wrn sd 0 0 0 0 0 0 0 0 unl unl unl unl unl unl unl unl unl 0 unl Unl unl Stp Wrn Unl unl unl unl unl - 97
Events specification
Alarm
History
Active call
Voltage on mains terminals (SPM) UnlCounterVolt UnlCounterVolt unl Bus voltage error (MINT) Unl BusMeasErr Unl BusMeasErr Unl Mains/bus Mains phase 1 over voltage 0 Vm1 Over 0 Mains phase 1 under voltage 0 Vm1 Under 0 Mains phase 2 over voltage 0 Vm2 Over 0 Mains phase 2 under voltage 0 Vm2 Under 0 Mains phase 3 over voltage 0 Vm3 Over 0 Mains phase 3 under voltage 0 Vm3 Under 0 Mains over frequency 0 Fmains Over 0 Mains under frequency 0 Fmains Under 0 Mains voltage unbalance 0 Vmains Unbal 0 Failure of mains circuit breaker MCB fail MCB fail wrn External Mains failure relay 0 Ext MF Relay 0 System info Wrong params checksum 0 Wrong params 0 Watchdog reset 0 Watchdog rst 0 Application loaded 0 Appl.loaded 0 Firmware loaded 0 Firmw.loaded 0 IG-IOM, IGS-PTM module fail Sd IOM fail Sd IOM fail sd IG-PC(LS)M module fail (SPtM, MINT) WrnPC(LS)Mfail 0 wrn Warning RA15 external module fail Wrn RA15 fail Wrn RA15 fail wrn Modem RS232 control command 0 RemControlUART 0 MODEM control command 0 RemControlMOD 0 CAN bus control command 0 RemControlCAN 0 ActCallCH1-OK 0 ActCallCH1-OK 0 ActCallCH2-OK 0 ActCallCH2-OK 0 ActCallCH3-OK 0 ActCallCH3-OK 0 ActCallCH1-Fail ActCallCH1-Fail ActCallCH1-Fail 0 ActCallCH2-Fail ActCallCH2-Fail ActCallCH2-Fail 0 ActCallCH3-Fail ActCallCH3-Fail ActCallCH3-Fail 0 Phase sequence Inverted polarity of gen phase L1 GEN L1 neg 0 0 Inverted polarity of gen phase L2 GEN L2 neg 0 0 Inverted polarity of gen phase L3 GEN L3 neg 0 0 Bad gen phase sequence G ph opposed 0 0 Bad gen phase sequence and polarity L1 G ph + L1 neg 0 0 Bad gen phase sequence and polarity L2 G ph + L2 neg 0 0 Bad gen phase sequence and polarity L3 G ph + L3 neg 0 0 Inverted polarity of mains phase L1 M L1 neg 0 0 Inverted polarity of mains phase L2 M L2 neg 0 0 Inverted polarity of mains phase L3 M L3 neg 0 0 Wrong mains phase sequence M ph opposed 0 0 Wrong mains phase sequence and M ph + L1 neg 0 0 polarity L1 Wrong mains phase sequence and M ph + L2 neg 0 0 polarity L2 Wrong mains phase sequence and M ph + L3 neg 0 0 polarity L3 Hint: Binary and analog inputs alarm events are recorded and displayed under a user name. Note SD stop fail is detected when Engine params: Stop time after engine stop (when BO Fuel solenoid is opened or Stop solenoid is closed) the RPM is still > 30. - 98
Remote and mobile communication

Modbus protocol
Direct connection: RS232, RS422, RS485 Modem connection 9600 bps, 8 data bits, 1 stop bit, no parity Transfer mode RTU Function 3 (Read Multiply Registers) Function 6 (Write Single Register) Function 16 (Write Multiply Registers) The response to an incoming message is sent with minimum 4.096 ms delay after message reception
The complete description of Modbus communication protocol can be found in Modbus Protocol Reference Guide PI-MBUS-300 and Open Modbus Specification Release 1.0. Both documents are available from web site at http://www.modicon.com/openmbus/ .
Communication object vs. Register

All the data intended for communication has its representation as communication objects in the controller. The communication object is represented by the n-byte array in the controller memory and identified by the unique 16-bit communication object number. The register, according to Modbus communication protocol, represents a two-byte data and in communication functions is referenced by 16-bit register address. Further in the description of communication functions the communication object number will always be used as a register address and length of the communication object will be expressed by number of registers. Just one communication object can be read or written by one communication function. Hint: It is possible to download the Actual IG or IS controller description from on-line controller or from (aig or ais) archive. Use ..\ Program files \ ComAp \ WinEdit \ Tools \ Cfg_img \ Cfg_img.exe software.
IG-MU modbus communication

Modbus protocol communication is supported from IG-MU SW version 1.9. In this case is necessary to use IG SW version at least 5.2 or IS SW V 2.2. Place Modbus jumper in unit before IG-MU Modbus communication.
Recommended ISDN modem

Askey TAS-200E ASUScom TA-220ST
Modem unit IG-MU

SW version up to 1.6 supports GSM data communication, not SMS. SW Version up to 1.6 does not support Modbus protocol, ISDN data and RS485 communication. Number of rings is default fix configured to 3, not depends on Act.call/SMS: Num rings AA setpoint.
Recommended GSM modem

Wavecom M1200/WMOD2, dual 900/1800MHz (baud rate 9600 bps). Wavecom - Maestro 20, dual 900/1800MHz. Siemens M20, supports only 900MHz network. For modem configuration use GM setup program. Siemens TC35 Hint: Any Modem goes to init procedure in following cases InteliGen SPtM, SW Version 6.2, ComAp August 2005 - 99 IG-SPTM-SPTM+IOM-6.2.PDF
after controller reset (when modem is already connected) whenever is modem connected to controller each 20 minutes when is no connection when connection is closed when data transmit error occurs
GSM Modem setup

Prior to start work with GSM modem run following program for GSM proper setup. Program writes all the necessary AT commands to configure the GSM modem properly for use with IG-CU or IS-CU. This program runs independent on WinEdit: Start MS Windows-Start-Program files - WinEdit Gm_setup.exe. Select COM port Select IG-CU (=IS-CU) or IG-MU unit Press Setup button Follow commands in GSM Modem Setup window Hint: It is strongly recommended to use the same type of modem on the both sides (IG and PC) of connection.
Analog modem
Analog modem
or
GSM modem
GSM modem
SIM card setting

Adjust SIM card on GSM modem in the following way: Enable data communication (it could be done by your local GSM operator), Set phone number SMS service center SC (recommended in international format in case of roaming), Set no PIN code required. Hint: All SMS on SIM card will be erased during GSM modem initialization. Valid SMS on SIM card will be served except adjusting and gen-set control command. Both SIM cards must have DATA setting when communication from controller to PC via two GSM modems.
How to check SIM card DATA setting

Move SIM card from controller GSM modem to Mobile phone. Call from WinEdit to this Mobile phone and check (on Mobil phone) DATA call indication of incoming call. If phone does not indicate DATA - solve this with your GSM operator.
SMS commands
Are not available from IG sw version 6.0.
Active SMS message

Active SMS message is invoked by controller request. Active SMS message is sending to GSM phone number specified in setpoints group Act. Calls/SMS on InteliGen/InteliSys. Specified phone number must be in international format +cccyyyxxxxxx where ccc is country code, yyy is operator prefix and xxxxxx is local phone number. Active message contains items of actual Alarm list (most eight items). Example of active SMS message: #Gen-set name:AL=(Wrn PrimWater temp, !Emergency stop) InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF - 100
Modbus protocol
There are three possibility of Modbus connection to InteliGen / InteliSys via IG-MU direct via RS232, RS485/422 or via modem. Modbus protocol on IG-MU must be activated by switch P2.
IG-IB Internet communication

IG-IB Internet bridge is interface for Internet communication between one or more controllers and PC. There are two possibilities of Internet connection: via LAN Ethernet or via Modem (wired line) For more details see Communication guide. Before IG-IB using contact company IT manager in any case. Hint: Company LAN connected to the Internet is probably configured to enable access to the servers located on the Internet, but to disable access in the reverse direction. If IG-IB has to be visible from the Internet, then your LAN administrator should create a communication channel on the Internet access server. The IG-IB uses the TCP-communication and listen on the port 23 (known as Telnet port).
PC
ETHERNET
MODEM IB CONFIG
IG-CU DONGLE
iG-IB
RS232
iG-CU
CAN
POWER
IG-CU
RS232
IG-IB
RS232
MODEM
RS232
MODEM
PC
IG-IB interface
Modem / IB config RS232 interface for IG-IB configuration or Modem connection IG-CU / Dongle RS232 interface for one controller connection or for Dongle for multiple controllers communication. CAN bus interface to group of controllers Ethernet to LAN interface to company net See IG-IB Internet bridge
Connection types
Internet or Modem (wired line) remote connection from WinEdit or MultiEdit software. Active calls: E-mail or SMS via Internet.
IG-IB configuration
Connect IG-IB Modem interface to PC and run IB-cfg software. Adjust items in IB configuration window IP address etc.
IG-IB Dongle
IG-IB Dongle limits number of accessible controllers. Hint: For more detail see Communication guide chapter IG-IB Internet communication. InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF
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Value and setpoints codes

Hint: Actual values, setpoints and configuration (in XLS or DOC) file is possible to export on-line from controller or off-line from archive using WinEdit Controller Export data command.
Values
Name InteliGen Group Sw configuration SPtM Name Date 13.5.2004 Value 0 0 0 2 WaitStop 0 26 9,4 35 39 ##### ##### ##### ##### 0 ##### 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 kVA kVA kVA kVA RPM V bar C % U4 U5 U6 U7 V kW kW kW kW kW Sw conf. ver. Ser. num. Filename 6,1 Dimension kW 4100096 Com. obj. Data type 8663 9032 9033 9025 9026 9240 9030 8209 8213 8227 8228 8229 8978 8759 8760 8761 9052 9678 8524 8525 8526 8203 8527 8528 8529 8565 8530 8531 8532 8204 8533 8534 8535 8395 8626 8627 8628 50 217 217 Hz V V 8210 8192 8193 Integer 16 Integer 8 Char Integer 8 Char Integer 16 Unsigned 16 Unsigned 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 16 Integer 8 Integer 8 Integer 8 Integer 8 Char Char Char Char Unsigned 16 Unsigned 16 Unsigned 16
ProcessControl ActReqPower ProcessControl ActReqPf ProcessControl ActReqLdChar ProcessControl Object PF ProcessControl Obj Load Char ProcessControl Object Consump ProcessControl LoadControl Engine Engine Engine Engine Engine Engine Engine Engine Engine Engine Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Engine speed Batt volt Oil press Water temp Fuel level AnInIOM 1 AnInIOM 2 AnInIOM 3 AnInIOM 4 SRO Act power Act pwr L1 Act pwr L2 Act pwr L3 React pwr kVAr React pwr L1 React pwr L2 React pwr L3 Appar pwr Appar pwr L1 Appar pwr L2 Appar pwr L3 Pwr factor Pwr factor L1 Pwr factor L2 Pwr factor L3 Load char Load char 1 Load char 2 Load char 3 Gen freq Gen V L1-N Gen V L2-N
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Generator Generator Generator Generator Generator Generator Generator Generator Generator Generator Mains Mains Mains Mains Mains Mains Mains Mains Mains Mains Mains Mains Mains Mains Binary I/O Binary I/O Binary I/O Binary I/O Binary I/O Binary I/O Binary I/O Statistics Statistics Statistics Statistics Statistics Info Info Info Info Info Info Info Info Info Info Info
Gen V L3-N Gen V L1-L2 Gen V L2-L3 Gen V L3-L1 Gen curr L1 Gen curr L2 Gen curr L3 Slip freq Angle VRO Mains Curr L3 Mains freq Mns V L1-N Mns V L2-N Mns V L3-N Mns V L1-L2 Mns V L2-L3 Mns V L3-L1 P mains Q mains kVAr Mains PF MainsLoadChr Act LoadSurge Max LoadSurge BInpIG BInpPCM BInpIOM BOutIG BOutPCM BOutIOM BOutRA15 kWhours kVArhours NumStarts RunHours NextServTime LdShed state TimerText TimerValue SW version SW branch Application ControllerMode IOM SW ver. CAN16 CAN32 PasswordDecode
218 0 0 0 0 0 0 0 0 50 3 50 232 232 232 0 0 0 2 0 1 R 0 0 10100000 0 0 0 0 0 ##### 0 0 0 0 ##### BrkOvrlap MainsFlt 0 6,1 1 3 OFF 3 1E+15 0 3565275
V V V V A A A Hz % A Hz V V V V V V kW
8194 9628 9629 9630 8198 8199 8200 8224 8225 9053 8208 8211 8195 8196 8197 9631 9632 9633 8703 8704 8705 8709
Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Integer 16 Integer 16 Integer 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Unsigned 16 Integer 16 Integer 16 Integer 8 Char Integer 16 Integer 16 Binary 16 Binary 8 Binary 16 Binary 16 Binary 8 Binary 16 Binary 16 Integer 32 Integer 32 Unsigned 16 Integer 32 Unsigned 16 Unsigned 16 Unsigned 16 Integer 16 Unsigned 8 Unsigned 8 Unsigned 8 Unsigned 8 Unsigned 8 Binary 16 Binary 16 Unsigned 32
P/s P/s
9582 9583 8235 8601 8602 8239 8603 8604 9849 8205 8539 8207
h h
8206 9648 9089 8954
8955 8393 8707 8480 9651 9022 8546 8827 9090
Setpoints
Name InteliGen Sw configuration SPtM Date 13.5.2004 Sw conf. ver. 6,1 Ser. num. Filename 4100096
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Group
Name
Value BASE LOAD 180 0,95 0 0,95 50 20 0 DISABLED InteliGen 200 288 400 1 1 200 400 231 231 1500 50 120 DISABLED OFF 1 STANDARD 32C 2 25 5 8 3 10 2 10 30 30 60 DIESEL 65535 10 115 5 2 1 3 80 90 5 10 3 15 36
Dimension kW kW kW kW s
Password Com. obj. Low limit High limit Data type 0 0 0 0 0 0 0 0 0 0 8638 8639 8640 8641 8642 8643 8644 9989 9592 8637 8276 8275 8274 9579 9580 9019 8566 8277 9888 8253 8278 8252 9983 8315 24537 24522 24499 8394 8254 8256 8257 8255 9097 8259 8313 8258 8662 9815 9100 9648 8264 8263 8262 8369 8370 8365 8375 8376 8371 8381 8382 8377 9587 0 0 100 0 -10 -10 0 -100 -100 0 -100 -100 0 18 0 1 1 5 1 0 0 2 0 0 0 1 1 1 1 0,1 0,1 1 1 80 80 100 45 0 0 0,6 -3200 0,6 0 0 0 String list 200 Integer 16 1 Integer 16 3200 Integer 16 1 Integer 16 3200 Integer 16 3200 Integer 16 3200 Unsigned 16 String list Short string 3000 Unsigned 16 5000 Unsigned 16 10000 Unsigned 16 500 Unsigned 16 500 Unsigned 16 32000 Integer 16 8000 Unsigned 16 30000 Unsigned 16 30000 Unsigned 16 4000 Unsigned 16 65 Unsigned 16 500 Unsigned 16 String list String list 32 Unsigned 8 String list String list 600 Unsigned 16 50 Unsigned 8 60 Unsigned 8 60 Unsigned 8 10 Unsigned 8 3600 Unsigned 16 10 Unsigned 16 300 Unsigned 16 3600 Unsigned 16 3600 Unsigned 16 240 Unsigned 16 String list 65535 Unsigned 16 600 Unsigned 16 150 Unsigned 16 300 Unsigned 16 1000 Integer 16 1000 Integer 16 180 Unsigned 16 10000 Integer 16 10000 Integer 16 180 Unsigned 16 10000 Integer 16 10000 Integer 16 180 Unsigned 16 40 Integer 16
ProcessControl Load ctrl PtM ProcessControl Base load ProcessControl Base PF ProcessControl Import load ProcessControl Import PF ProcessControl PeakLevelStart ProcessControl PeakLevelStop ProcessControl PeakAutS/S del ProcessControl Export limit Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Basic settings Gen-set name Nomin power Nomin current CT ratio PT ratio Vm PT ratio AnOut-kW/20mA Im3 CT ratio Gen nom V Mains nom V Nominal RPM Nominal freq Gear teeth FltRes GoToMAN ControllerMode Contr. addr RS232 mode CAN bus mode
kW A /5A /1 /1 /5A V V RPM Hz
0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 3 3
Engine params Prestart time Engine params Starting RPM Engine params MaxCrank time Engine params CrnkFail pause Engine params Crank attempts Engine params Idle time Engine params Min stab time Engine params Max stab time Engine params Cooling time Engine params AfterCool time Engine params Stop time Engine params Fuel solenoid Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect NextServTime Horn timeout Overspeed Protection del AnlInp1 level1 AnlInp1 level2 AnlInp1 del AnlInp2 level1 AnlInp2 level2 AnlInp2 del AnlInp3 level1 AnlInp3 level2 AnlInp3 del Batt >V
s % s s s s s s s s
0 0 0 0 0 0 0 0 0 0 0 0
h s % s bar bar s C C s % % s V
0 0 0 0 0 0 0 0 0 0 0 0 0 0
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Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Engine protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect Gener protect AutoMains fail AutoMains fail AutoMains fail AutoMains fail AutoMains fail AutoMains fail AutoMains fail AutoMains fail AutoMains fail AutoMains fail AutoMains fail AutoMains fail AutoMains fail AutoMains fail AutoMains fail AutoMains fail AutoMains fail AutoMains fail AutoMains fail Sync/Load ctrl Sync/Load ctrl
Batt <V Batt V del AnlInIOM1 lev1 AnlInIOM1 lev2 AnlInIOM1 del AnlInIOM2 lev1 AnlInIOM2 lev2 AnlInIOM2 del AnlInIOM3 lev1 AnlInIOM3 lev2 AnlInIOM3 del AnlInIOM4 lev1 AnlInIOM4 lev2 AnlInIOM4 del Overload Overload Wrn Overload del Ishort Ishort del 2Inom del Curr unbal Curr unbal del Gen >V Sd Gen >V Unl Gen <V Unl Gen V del Volt unbal Volt unbal del Gen >f Gen <f Gen f del Reverse power ReversePwr del EmergStart del Mains ret del FwRet break MCB close del Mains >V Mains <V Mains V del MVolt unbal MVoltUnbal del Mains >f Mains <f Mains f del BreakerOverlap Max load surge ReturnWithIntr MCB opens on MCB logic Ret from test Ret fromIsland SpeedRegChar GtoM AngleReq
18 5 0 100 5 0 100 5 0 100 5 0 100 5 120 110 5 200 0 4 50 5 120 110 85 3 10 3 110 85 3 15 0,5 5 20 1 1 110 90 2 10 2 102 98 0,5 3 50 DISABLED MAINSFAIL CLOSE-OFF MANUAL AUTO NEGATIVE 0
V s U4 U4 s U5 U5 s U6 U6 s U7 U7 s % % s % s s % s % % % s % s % % s % s s s s s % % s % s % % s s P/s
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
8387 8383 8762 8766 8770 8763 8767 8771 8764 8768 8772 8765 8769 8773 8280 9685 8281 8282 9991 8283 8284 8285 10013 8291 8293 8292 8288 8289 8296 8298 8297 8486 8552 8301 8302 8303 8389 8305 8307 8306 8446 8447 8310 8312 8311 8661 9581 9862 9850 8444 8618 9590 9054 9578
8 0 -100 -100 0 -100 -100 0 -100 -100 0 -100 -100 0 110 0 0 100 0 0 1 0 85 85 50 0 1 0 85 50 0 0 0 0 0 0 0 90 50 0 1 0 98 50 0 0 0
36 Integer 16 600 Unsigned 16 10000 Integer 16 10000 Integer 16 180 Unsigned 16 10000 Integer 16 10000 Integer 16 180 Unsigned 16 10000 Integer 16 10000 Integer 16 180 Unsigned 16 10000 Integer 16 10000 Integer 16 180 Unsigned 16 300 Unsigned 16 120 Unsigned 16 600 Unsigned 16 500 Unsigned 16 10 Unsigned 16 60 Unsigned 16 200 Unsigned 16 600 Unsigned 16 150 Unsigned 16 150 Unsigned 16 110 Unsigned 16 600 Unsigned 16 150 Unsigned 16 600 Unsigned 16 150 Unsigned 16 110 Unsigned 16 600 Unsigned 16 50 Unsigned 8 600 Unsigned 16 600 Unsigned 16 3600 Unsigned 16 60 Unsigned 16 60 Unsigned 16 150 Unsigned 16 110 Unsigned 16 600 Unsigned 16 150 Unsigned 16 600 Unsigned 16 150 Unsigned 16 102 Unsigned 16 600 Unsigned 16 600 Unsigned 16 60 Unsigned 16 String list String list String list String list String list String list
-30
30 Integer 16
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Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Sync/Load ctrl Volt/PF ctrl Volt/PF ctrl Volt/PF ctrl Volt/PF ctrl Volt/PF ctrl Volt/PF ctrl Volt/PF ctrl Volt/PF ctrl Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Act. calls/SMS Load shedding Load shedding Load shedding Load shedding Load shedding Date/Time Date/Time Date/Time Sensors spec Sensors spec Sensors spec Sensors spec Sensors spec Sensors spec Sensors spec
Voltage window Phase window Dwell time Freq gain Freq int Freq der Freq reg loop Angle gain Angle der Speed gov bias Load ramp Load gain Load int Load der GCB open level GCB open del Sync timeout AVRRegChar Voltage gain Voltage int Voltage der PF gain PF int PF der AVR DCout bias Warning call Unload call Slow stop call Shut down call AcallCH1-Type AcallCH1-Addr AcallCH2-Type AcallCH2-Addr AcallCH3-Type AcallCH3-Addr NumberRings AA A.c.multiplier Ld shed level Ld shed del Ld recon level Ld recon del AutoLd recon Time stamp per #Time #Date Calibr AI 1 Calibr AI 2 Calibr AI 3 Calibr AI 4 Calibr AI 5 Calibr AI 6 Calibr AI 7
3 5 1 20 50 10 SYNC ONLY 50 10 0 60 20 100 10 5 60 60 POSITIVE 20 20 10 20 20 10 50 DISABLED DISABLED DISABLED DISABLED DISABLED DISABLED DISABLED 3 1 90 2 50 5 ENABLED 60 16:25:19 11.7.2002 0 0 0 0 0 0 0
% s % % % % % V s % % % % s s
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
8650 8652 8653 8715 8716 8717 9891 8718 8719 8656 8658 8659 8713 8714 8547 8548 8657 9055 8501 8720 8502 8503 8721 8504 8500 8482 8483 8485 8484 9594 9597 9595 9598 9596 9599 24512 24505 8884 8887 8890 8893 9649 8979 24554 24553 8431 8407 8467 8793 8794 8795 8796
0 0 0 0 0 0 0 0 -10 0 0 0 0 0 0 0
100 Unsigned 16 90 Unsigned 16 25 Unsigned 16 200 Integer 16 100 Integer 16 100 Integer 16 String list 200 Integer 16 100 Integer 16 10 Integer 16 600 Unsigned 16 200 Integer 16 100 Integer 16 100 Integer 16 100 Unsigned 16 600 Unsigned 16 1800 Unsigned 16 String list
% % % % % % %
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 3
0 0 0 0 0 0 0
200 Integer 16 100 Integer 16 100 Integer 16 200 Integer 16 100 Integer 16 100 Integer 16 100 Integer 16 String list String list String list String list String list Long string String list Long string String list Long string
1 1 50 0 0 0
30 Unsigned 8 250 Unsigned 8 200 Integer 16 1800 Unsigned 16 90 Integer 16 1800 Unsigned 16 String list
% s % s
0 0 0 0 0
min
0 0 0
240 Unsigned 8 Time Date
bar C % U4 U5 U6 U7
0 0 0 0 0 0 0
-100 -1000 -1000 -1000 -1000 -1000 -1000
100 Integer 16 1000 Integer 16 1000 Integer 16 1000 Integer 16 1000 Integer 16 1000 Integer 16 1000 Integer 16
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Technical data
Power supply
Voltage supply Consumption depends on supply voltage 8-36V DC 0,34A at 8VDC 0,12A at 24VDC 0,09A at 36VDC 2 % at 24V 10 year
Battery voltage measurement tolerance RTC battery life-cycle Hint: When internal RTC battery becomes flat InteliGen function (e.g. Ready for stand by) does not change until controller power supply is switched off. After the next power switch on controller: Stays in the INIT state (not possible to run genset) All History records disappear except Wrong params record Alarm list is empty Time and Date values are set to zero Statistics values are random
Operating conditions
Operating temperature IG-CU Operating temperature IG-CU-LT Storage temperature Flash memory data retention time Protection front panel Humidity Standard conformity Low Voltage Directive Electromagnetic Compatibility -20..+70oC -30..+70oC -30..+80oC 10 years IP65 95% without condensation (From IG serial number xxxx0900) EN 61010-1:95 +A1:97 EN 50081-1:94 (EN 61000-6-3) EN 50081-2:96 (EN 61000-6-4) EN 50082-1:99 (EN 61000-6-1) EN 50082-2:97 (EN 61000-6-2) 5 - 25 Hz, 1,6mm 25 - 100 Hz, a = 4 g a = 200 m/s2
Vibration Shocks
Dimensions and weight

Dimensions Weight 180x120x50mm 800g
Mains and generator

Nominal frequency Frequency measurement tolerance 50-60Hz 0,1Hz
Current inputs
Nominal input current (from CT) 5A Load (CT output impedance) < 0,1 CT input burden < 0,2 VA per phase (In=5A) Max. measured current from CT 11 A Current measurement tolerance 2% from the Nominal current Max. peak current from CT 150 A / 1s Max. continuous current 12 A InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF
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Voltage inputs
IG-CU
Nominal voltage 231/400 VAC Maximal measured/allowed voltage (short time) 290/500 VAC Input resistance 6 M phase to phase 6 M phase to neutral Voltage measurement tolerance 2 % from the Nominal voltage Over voltage class III / 2 (EN61010)
Voltage inputs
IG-CU/600
Nominal voltage 277/480 VAC Maximal measured/allowed voltage (short time) 346/600 VAC Input resistance 6 M phase to phase 6 M phase to neutral Voltage measurement tolerance 2 % from the Nominal voltage Over voltage class III / 2 (EN61010)
IG-MTU
Primary voltage Ph-Ph Secondary voltage Ph-N Mechanical dimensions: Primary/secondary Phase shift Operating temperature 3x400 VAC / 50Hz (3x480 VAC / 60 Hz) 3x 230 V AC ( 3x277 VAC / 60 Hz) , 5 VA 155 x 95 x 60 mm , DIN rail (35 mm) mounted < 1 -30..+70oC
IG-MTU-C
Primary voltage Ph-Ph Secondary voltage Ph-N Mechanical dimensions: Primary/secondary Phase shift Operating temperature 3x400 VAC / 50Hz (3x480 VAC / 60 Hz) 3x 230 V AC ( 3x277 VAC / 60 Hz) , 5 VA 155 x 95 x 60 mm , DIN rail (35 mm) mounted 6 -30..+70oC
Binary inputs and outputs

Binary inputs
Number of inputs 9 Input resistance 4,7 k Input range 0-36 VDC Switching voltage level for close contact indication 0-2 V Max voltage level for open contact indication 8-36 V
Contact relay outputs

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

Number of outputs Maximum current Maximum switching voltage 7 0,5 A 36 VDC
Analog inputs
Not electrically separated Resolution 10 bits InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF - 108
Sensor resistance range Resistance measurement tolerance
0 -2,4 k 4 % 2 out of measured value
Speed pick-up input

Type of sensor Minimum input voltage Maximum input voltage Minimum measured frequency Maximum measured frequency Frequency measurement tolerance magnetic pick-up (connection by shielded cable is recommended) 2 Vpk-pk (from 4 Hz to 4 kHz) 50 Veff 4 Hz 10 kHz (min. input voltage 6Vpk-pk) 1,5 %
RS232 interface
Maximal distance Speed 10m 19.2kBd
Recommend external converter: ADVANTECH ADAM 4520: RS232 to RS422/485 converter, DIN rail, automatic RS485 bus supervision, no external data flow control signals, galvanic isolated. Recommended internal converter: ADVANTECH PCL-745B or PCL745S : Dual port RS422/485 Interface card, automatic RS485 bus supervision, no external data flow control signals, galvanic isolated.
IG-PCM
Power supply: Consumption: 8 36 V DC 100 mA 4 4,7 k 0-36 VDC 0-2 V 8-36 V
Binary inputs
Number of inputs Input resistance Input range Switching voltage level for close contact indication Max voltage level for open contact indication
Open collector outputs

Number of outputs Maximum current Maximum switching voltage Speed governor output AVRi outputs: 4 0,5 A 36 VDC 10 V DC , max.15 mA PWM to IG-AVRi
IG-AVRi
Power supply: 18V AC from IG-AVRi Trans/LV or IG-AVRi Trans/100 Absolutely maximum power supply range: 15 - 25 VAC or 20 - 35VDC Inputs: Outputs: AVRi output voltage range: AVRi output current: Mechanical dimensions: +AVR, -AVR (two wires, PWM from IG-CU) OUT1, OUT2 floating (potential free) voltage source. potentiometer adjustable from +- 1V to +-10V DC. max 15 mA. 96 x 27 x 43 mm , DIN rail (35 mm) mounted
IG-AVRi Trans/LV
Primary voltage 1: 230-277 VAC Absolute low limit: 230 VAC 20% Absolute high limit: 277 VAC + 20% InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF
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Primary voltage 2: Absolute low limit: Absolute high limit: Frequency: Secondary voltage: Operating temperature
400-480 VAC 400 VAC 20% 480 VAC + 20% 50 - 60 Hz 18 V AC, 5 VA -30..+70oC
IG-AVRi Trans/100
Primary voltage: Absolute low limit: Absolute high limit: Frequency: Secondary voltage: Operating temperature 100 120 VAC 100 VAC 20% 120 VAC + 20% 50 - 60 Hz 18 V AC -30..+70oC
IG-IOM
Voltage supply Consumption Mechanical dimensions: Connection to IG-CU Operating temperature 8-36V DC 0,1A depend on supply voltage 40 x 95 x 45 mm , DIN rail (35 mm) mounted standard IOM cable 3 meters length, not galvanic separated -30..+70oC 8 4,7 k 0 - 36 VDC 0-2V 8-36 V
Binary inputs
Number of inputs Input resistance Input range Switching voltage level for close contact indication Max voltage level for open contact indication
Binary open collector outputs

Number of outputs Maximum current Maximum switching voltage 8 0,5 A 36 VDC
Analog inputs
Not electrically separated Number of inputs Resolution Sensor resistance range Resistance measurement tolerance 4 10 bits 0 -2,4 k 4 % 2 out of measured value
Analog output
Not electrically separated Number of i outputs Resolution Output range 1 10 bits 0 to 20 mA 0,33 mA
IGS-PTM
Voltage supply 8-36V DC Consumption 0,1A depend on supply voltage Mechanical dimensions: 40 x 95 x 45 mm , DIN rail (35 mm) mounted Interface to controller CAN Binary inputs and outputs see IG-IOM Analog output see IG-IOM InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF
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Operating temperature
-30..+70oC
Analog inputs
Not electrically separated Number of inputs Resolution Maximal resistance range Maximal voltage range Maximal current range Resistance measurement tolerance Voltage measurement tolerance Current measurement tolerance 4 10 bits 0 250 0 100 mV 0 20 mA 1 % 2 out of measured value 1,5 % 1mV out of measured value 2,5 % 0,5mA out of measured value
IG-IB
Voltage supply Consumption Mechanical dimensions: Interface to controller Interface to modem Interface to Ethernet Operating temperature 8-36V DC 0,1A depend on supply voltage 40 x 95 x 45 mm , DIN rail (35 mm) mounted RS232 or CAN RS232 RJ45 -30..+70oC
IGL-RA15
Power supply
Voltage supply Consumption 8-36V DC 0,35-0,1A (+1A max horn output) Depend on supply voltage
Operating conditions
Operating temperature Storage temperature Protection front panel -20..+70oC -30..+80oC IP65
Dimensions and weight

Dimensions Weight 180x120x55mm 950g
Horn output
Maximum current Maximum switching voltage 1A 36 VDC
InteliGen Low Temperature modification

LCD display limits controller operating temperature range to 20 oC - + 70 oC even if the other electronic components work in wider temperature range. Internal preheating foil is mounted in InteliGen LT to extend display operational temperature range. Preheating starts at temperature below 5 oC and preheating power depends on temperature and power supply voltage.
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Technical data
Operating temperature Storage temperature
IG-CU Standard -20 oC..+70oC -30 oC..+80oC
IG-LT -30 oC..+70oC -30 oC..+80oC
Preheating foil increases controller current consumption
Controller consumption at 12VDC 24VDC 36VDC
No preheating Preheating at ambient temperature 0 oC -15 oC -30 oC 360 mA +50 mA +180 mA +300 mA 230 mA +25 mA +85 mA +150 mA 100 mA +20 mA +65 mA +100 mA
InteliGen LT work immediately after switch on at -30 oC and display becomes visible after a few minutes.
Short-term voltage drops (e.g. during the engine cranking) do not affect the operation at all.
Order codes
There are two types of preheating foil to cover full temperature and controller power supply range.
Order code IG-CU-LT/12 IG-CU-LT/24
Controller InteliGen
Nominal power supply 12 VDC 24 VDC
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IG SPTM SPtMIOM 6.2

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IG SPTM SPtMIOM 6.2

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Compact Controller for Stand-by and Parallel Operating Gen-sets

InteliGen Modular Gen-set Controller

InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF

InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF

WARNING VERY IMPORTANT !!!

!!! CAUTION !!!

Adjust set points

InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF

SPtM - required and optional modules

InteliGen display software description

InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF

Terminals and dimensions

GENERATOR CURRENT 0-5A

GENERATOR VOLTAGE 3 x 230 / 400 V

EXTENSION MODULES iG-COM / iG-IOM

Inl In (Im L3) Ink CURRENT

EXTENSION MODULES iG-PCM / iG-PCLSM

RPM Grounding Terminal

Drawing text translation Grounding Terminal RPM Grounding Terminal

Warning !!! Switch IG-CU off before connecting IG-PCM !

InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF

RS 422 TxB TxA RxB RxA COM

RS 232 POWER 8-36V DC

Indication LED: TxCAN, RxCAN TxD, RxD RUN PWR

IG- IOM, IGS-PTM terminals

AI4 ANALOG OUT RS232 POWER 8-36V DC

InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF

IG-AVRi, IG-AVRi TRANS/LV

IG-MU unit is DIN railmount (35mm)

InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF

ANALOG INPUTS COMPENSATION

0-20 mA ANALOG OUT

InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF

IGL-RA15 Remote annunciator

180 (7,1) 185 (7,3)

~35 (1,4) 38 (1,5) 40 (1,6)

120 (4,7) 125 (4,9)

IG-IB Internet bridge

4 H COM L CAN POWER 8 - 36 V DC

I-CR CAN repeater

InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF

GENERATOR CURRENT 0-5A

EXTENSION MODULES iG-COM / iG-IOM

MAINS C.B. ALARM

EXTENSION MODULES iG-PCM / iG-PCLSM

InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF

L1k L1l L2k L2l L3k L3l

GENERATOR VOLTAGE 3 x 230 V BINARY INPUTS

GEN C.B. FEED-BACK MAINS C.B. FEED-BACK

REMOTE OFF EMERGENCY STOP

AUTOMATIC VOLTAGE CONTROL

BINARY OUTPUTS BO12 BO13 BO11

AI4 ANALOG OUT RS232 POWER 8-36V DC

InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF

Single Parallel to Mains applications

Drawing text translation Load Fuel

!!! CAUTION !!!

InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF

InteliGen SPtM, SW Version 6.2, ComAp August 2005 IG-SPTM-SPTM+IOM-6.2.PDF

Drawing text translation Battery Controller Relays I-LBA

HUGE LOADS STARTER

Drawing text translation Battery Huge Loads Starter