IG - Operator Guide

Compact Controller for Stand-by and Parallel Operating Gen-sets
InteliGen
Modular Gen-set Controller
Operator guide for SPM, SSB, SPtM, MINT, MEXT
IG-CU
June 2005
Operator guide
Copyright 2004 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..............................................................................................................................................3
Description of the controller system (with all options)....................................................................................3
Conformity declaration ...................................................................................................................................4
!! Warnings !! ..................................................................................................................................................4
Operator Interface ..............................................................................................................................................5
Pushbuttons and LEDs ..................................................................................................................................5
Flow Chart of pushbutton Operation ..............................................................................................................8
Description of MEASUREMENT screens ......................................................................................................9
Password......................................................................................................................................................11
Mode and function description .........................................................................................................................12
OFF mode ....................................................................................................................................................12
MAN mode ...................................................................................................................................................12
AUT mode ....................................................................................................................................................12
TEST mode (SSB and SPtM only) ...............................................................................................................13
Alarm management ..........................................................................................................................................15
Warning (Wrn) ..............................................................................................................................................15
Shut down (Sd) ...........................................................................................................................................15
Slow stop (Stp) .............................................................................................................................................15
Electric protection (ElProt) ...........................................................................................................................15
Mains failure .................................................................................................................................................16
Remote control and data logging .....................................................................................................................17
Direct connection to the PC .........................................................................................................................17
PC software WinEdit .................................................................................................................................17
History file.....................................................................................................................................................17
Remote modem communication ..................................................................................................................17
Controller firmware and archive files............................................................................................................18
Technical data ..................................................................................................................................................19
InteliGen Operator guide, ComAp June 2005

IG-Operator guide. PDF
-2-
General guidelines
This manual provides general information on how to operate the InteliGen controller.
This manual is intended for everybody who is concerned with operation and maintenance of the gen-set.
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, earth fault protection 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.
Default applications
There are five default applications: SPM, SSB, SPtM, MINT, MEXT.
SPM
Single prime mover, no mains.
SSB
Single stand-by, no synchronizing, break transfer.
SPtM
Single stand-by, forward and reverse synchronizing, parallel operation, peak shaving, soft
load transfer.
MINT
Multiple parallel, forward synchronizing, load and VAR sharing, power management, soft
load transfer.
MEXT
Multiple parallel, external synchronizer and load sharer, power management,
Detail documentation
For more detail please refer to corresponding User guides (where x-x means software version):
SPM-SPM+IOM-x.x.pdf
SSB-SSB+IOM-x.x.pdf
SPtM-SPtM+IOM-x.x.pdf
MINT-MEXT+IOM-x.x.pdf
MEXT-MEXT+IOM-x.x.pdf
WinEdit-MultiEdit-x.x.pdf
Communiation guide-x.x.pdf
Application guide-x.x.pdf
Troubleshooting guide-x.x.pdf
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

-3-
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.
!! Warnings !!
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)!!!
Be aware that gen-set can automatically or remotely start when following
controller terminals are disconnected !!!
Mains voltage measuring

Binary outputs for MCB control
MCB feedback
and / or
and / or
Switch InteliGen to OFF mode and disconnect the Binary outputs Starter and Fuel to
avoid unexpected automatic start of gen-set and GCB closing.
!!! CAUTION !!!

Dangerous voltage
In no case touch the terminals for voltage and current measurement!
Always properly connect grounding terminals!
Take care when disconnecting In/Im3 terminals when the gen-set is stopped.
For safety connect parallel to controller In/Im3 terminals two anti parallel diodes 10A/100V.
In any case do not disconnect generator CT terminals when the gen-set is loaded.
Adjust set points

All setpoints are preadjusted to their typical values. But the setpoints 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 !!!
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.

-4-
Operator Interface
Pushbuttons and LEDs
3
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 OFFMAN AUT TEST.
MODE Cycle backward through gen-set operation modes OFFMAN AUTTEST.
HORN RESET
Deactivates the HORN (AUDIBLE ALARM).
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
Opens and closes (synchronizes) the Mains circuit breaker in MAN mode.
GCB ON/OFF
Opens and closes (synchronizes) the Generator circuit breaker in MAN
mode.
PAGE
Changes display function cyclically MEASUREMENTADJUSTMENTHISTORY.
Select the setpoint, select the screen, select history record or increase setpoint
value.
Select the setpoint, select the screen, select history record or decrease setpoint
value.
ENTER
Confirm setpoint value or move in within selected history record.

-5-
LEDs
13.
14.
15.
16.
17.
18.
MAINS VOLTAGE PRESENT: GREEN LED is on, if voltage on the mains terminals is present (in
SSB and SPtM). LED is not active in SPM, MINT, MEXT.
MAINS or BUS 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.
GEN VOLTAGE PRESENT: GREEN LED is on, if gen. voltage is present and within limits.
GEN-SET FAILURE: RED LED starts flashing when any 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).
GCB ON: GREEN LED is on, if GCB is closed. Flashes during synchronizing.
MCB ON: GREEN LED is on, if MCB is closed (binary input MCB feedback is closed). Flashes during
reverse synchronizing (synchronizing of the loaded gen-set back to the restored mains).
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 AUT or TEST.
Display menus
There are 3 display menus (functions) 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?

Use PAGE button to select the MEASUREMENT menu (if not already selected). Select the MEASUREMENT
screen. Use and to select the screen with requested data.
How to view and edit set points?

1.
2.
3.
4.
Use PAGE button to select the ADJUSTMENT menu (if is not already selected).
Use or to select requested set points group.
Press ENTER to confirm.
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 set password?

1.
2.
3.
4.
5.
6.
7.
8.
Use PAGE button to select the ADJUSTMENT menu

Use or to select Password.
Press ENTER to confirm.
Use or to select Enter password.
Press ENTER to edit.
Use or to modify the password.
Press ENTER to confirm the password.
Press PAGE to leave Password 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.
-6-
3. Use ENTER to select requested screen (record items) within displayed records
How to change the display contrast?

Press and hold ENTER and use or 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) InteliMains 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:
InteliMains
Hint:
Available from the main MEASUREMENT menu only.
How to find active alarms?

Active alarm list is available on the last screen in the MEASUREMENT menu.
Select MEASUREMENT menu. Press until 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 automatically when a new alarm comes up and Main
MEASUREMENT screen is active.
Hint:
Alarm list does not activate automatically if the display is switched to any other screen than the first one of
MEASUREMENT (the only one display screen that shows menu selector on the upper). The automatic jump
to the alarm list screen will not occur if you are listing through the measured values, parameters or history!
When to use GCB ON/OFF button?

The button is disabled in AUT mode.
In MAN mode is enabled, but before closing of the circuit beaker, generator voltage and frequency must be
within limits. InteliGen has internal protection to avoid the breaker closure without synchronizing.
The controller recongizes automatically:
if there is voltage on the bus and the gen-set shall be synchronized before closing the GCB
or there is no voltage on the bus and the GCB can be closed without synchronizing.
When to use MCB ON/OFF button?

The button is disabled in AUT mode.
Use this button in MAN mode to close or open the MCB. Be carefull while doing this, because you can
disconnect the load from the mains!!!

-7-

Next
Screen
Next
Screen
586
AUTO
1000
12345h
kW
14:23:15
MAN
500
Measure Screens
OFF
ENTER
PAGE
4. Press
Press
to cancel of editing mode
to write parameter into memory
buttons
to editing mode
3. Adjust parameter by
ENTER
buttons
RPM
ENTER
GEAR TEETH
150
150
NOM RPM
1500
1500
START RPM
30
30%
CRANK TIME
10s
10
PAGE
ENGINE BASIC
ENGINE PROT
GEN BASIC
GEN PROTECT
MAINS FAIL
1. Set cursor by
2. Press
PAGE
Par. Edit Screens
Parameter setting:
PAGE
PAGE
PAGE
Screen
History Screens
ENTER
ENTER
..... TO MEASURE SCREEN
ENTER
F
O
E Y
L
B OR
A
T IS T
H
Flow Chart of pushbutton Operation
-8-
Description of MEASUREMENT screens

Main measure screen
1
OFF MAN AUT
TEST
Ready
Mains Oper
cos
0.00
RPM
0
Tim er
0
7
5
8
6
1.
2.
3.
4.
5.
6.
7.
8.
Operation mode of the gen-set

Indication of active alarm
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.)
Following table contains an example of MINT and SPtM MEASUREMENT screens. Other applications can
be slightly different. Additional screens are visible when aig archive with external (IG-IOM or IGS-PTM)
module is used.
MINT
SPtM
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 PF
Actual value of PF
-9-
MINT
Generator
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)
SPtM
Generator
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)
Bus
EarthFaultCurr
Bus freq
Bus Vb1-2, Vb2-3, Vb3-1 ph-ph
Bus Vb1, Vb2, Vb3 ph-N (triple barograph)
Mains
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

AI1 Oil pressure
AI2 Water temperature
AI3 Fuel level
Battery voltage
IG-CU Analog inputs

AI1 Oil pressure
AI2 Water temperature
AI3 Fuel level
Battery voltage
(single barograph)
(single barograph)
(single barograph)
(single barograph)
(single barograph)
(single barograph)
(single barograph)
(single barograph)
IG-CU binary inputs 1/2

BI1 to BI5

BI1 to BI5

BI6 to BI9

BI6 to BI9
IG-CU binary outputs

BO1 to BO5
IG-CU binary outputs 1/2

BO1 to BO5

BO6 to BO9
Load shedding status

BO6 to BO9
Load shedding status
IG-PCLSM binary inputs

BI10 to BI13
IG-PCM binary inputs

BI10 to BI13
IG-PCLSM binary outputs

BO10 to BO13
IG-PCM binary outputs

BO10 to BO13
Gen-set power
Active power (total and per phase)
Power factor (total and per phase)
Reactive power kVAr (total and per phase)
Apparent power (total and per phase)
Gen-set power
Active power (total and per phase)
Power factor (total and per phase)
Reactive power kVAr (total and per phase)
Apparent power (total and per phase)
Statistic
Kilowatt-hours kWh
Active energy total
Reactive power hours kVArh Reactive
energy total
Run hours
Number of starts
NextServTime
Statistic
Kilowatt-hours kWh
Active energy total
Reactive power hours kVArh Reactive energy
total
Run hours
Number of starts
NextServTime

- 10 -
MINT
Synchroscope
Angle between V1g and V1m
Synchroscope
V1g Generator first phase voltage
V1m Mains first phase voltage
SPtM
Synchroscope
Angle between V1g and V1m
Synchroscope
V1g Generator first phase voltage
V1m Mains first phase voltage
SRO Speed regulator output indication in the

range 0 to 10,00V
VRO Voltage regulator output indication in
the range 0 to 100%.
SRO Speed regulator output indication in the

range 0 to 10,00V
VRO Voltage regulator output indication in the
range 0 to 100%.
Power management
Engine priority
Total available power (sum of Nominal
power)
Total run power (sum of Nominal power running)
Active reserve (single barograph)
CAN16 bus status address 1 to 16
(binary)
CAN23 bus status address 17 to 32
(binary)
Alarm list
Up to 8 items
Alarm list
Up to 8 items
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.
Even though one level may have been set from the front panel, the affected setpoints are not accessible
from WinEdit (direct or Modem) until this level 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 press enter.

- 11 -
Mode and function description

There are four gen-set operation modes: OFF - MAN AUT TEST in SSB and SPtM application. There are
three gen-set operation modes: OFF - MAN AUT in SPM and MINT application.
To select the mode use MODE or MODE.
OFF mode
No start of the gen-set is possible. Outputs STARTER, GCB CLOSE/OPEN and FUEL SOLENOID are
not energized.
No reaction if buttons START,STOP,GCB ON/OFF are pressed.
When power-cut comes, MCB CLOSE/OPEN opens. After mains returns, MCB CLOSE/OPEN closes
with MCB close del.
MAN mode
1) To start the gen-set press START.
2) When the generator voltage is within limits (adjusted in the setpoints group Generator protections)
GCB green LED on the front panel lights.
3) Press GCB ON/OFF to close the GCB. If the generator voltage is out of the limits, controller does not to
respond to the GCB ON/OFF .
a) If controller detects dead bus, immediately closes GCB OPEN/CLOSE output.
b) If controller detects voltage on the bus, starts synchronizing.
4) To stop the engine press STOP
a) controller unloads the gen-set, opens GCB CLOSE/OPEN. Unloading is active only when binary
input MCB feedback is closed or other gen-set is connected to bus. In other case GCB CLOSE/OPEN
opens immediately.
b) Gen-set is cooled and stopped.
Hint:
Controller does not respond to the binary input SYS START/STOP. The gen-set is fully in manual control;
there is no automatic way to stop it (except protections). The gen-set stays running until STOP button is
pressed.
Controller does not take place in Power management in MINT, MEXT application
AUT mode
AMF
1) Mains failure is recognized
a) Controller opens MCB (depends on setpoint AutoMains fail:MCB opens on setting)
b) After EmergStart del elapsed, InteliSys starts the gen-set
c) If mains recovers during the start-up process, Controller closes MCB again after MCB close del and
stops the gen-set.
2) When the gen-set is started and the generator voltage and frequency is within limits (adjusted in menu
Generator protections) Controller closes the GCB. If the generator voltage is out of the limits for
MaxStabil time, Controller indicates the failure and stops the gen-set.
3) After mains recovers:
a) After MainsReturn del the Controller starts synchronizing to mains, closes the MCB and starts
unloading.
b) After the Breakers overlap delay Controller opens the GCB.
c) The gen-set is cooled and stopped.
Remote start/stop
Genset starts automatically, when binary input REM START/STOP is closed and stops by opening it.
- 12 -
Peak shaving
Genset can start and stop automatically according to consumption from the mains (object).
If Mains import value exceeds for more than ProcessControl:PeakAutS/S del
ProcessControl:PeakLevelStart, engine starts automatically.
If Load consumption (Mains import + Genset power) drops for more than ProcessControl:PeakAutS/S del
below ProcessControl:PeakLevelStop, engine stops.
Hint:
Engine does not stop, if other condition for automatic starts are active.
Example: If peak stop condition occurs, but REMOTE START/STOP is active, engine stays running.
InteliSys does not respond to GCB ON/OFF , MCB ON/OFF , STOP, START buttons and corresponding
remote WinEdit or Modbus commands.
Set Basic setting: FltRes GoToMAN = ENABLED to avoid automatic engine start when pressing FAULT
RESET after Shut down or Slow stop alarm.
!!!!! VERY IMPORTANT !!!!!!
Engine can start automatically without warning when pressing FAULT RESET after shut down alarm.
TEST mode (SSB and SPtM only)

Use TEST mode for Gen-set start test if the Mains is OK or to short Blackout when Mains fail is announced
in advance.
The setpoint AutoMainsFail: 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 Return 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
The setpoint Ret from test = AUTO

While TEST mode is selected, gen-set is running unloaded.
When power cut comes InteliGen opens MCB.
After Return break elapses, InteliGen closes GCB.
When the mains recovers:
1. After the MainsReturn del InteliGen starts back synchronizing to mains and closes MCB.
2. 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.
- 13 -
Baseload
Process control: Load CTRL PTM = BASELOAD
Genset power is kept on value given by Baseload setpoint.
Internal Import export

ProcessControl: Load CTRL PTM = IMP/EXP
Process control: IE measurement = IM3 CT INPUT
Genset load is controlled to keep the import load at the level given by setpoint Process control: Import load
value.
Controller measures Import/Export value via current transformers connected to In/Im3 terminals.

- 14 -
Alarm management
Following alarms are available:
Binary alarms
No protection
Warning no action
Shutdown
Slow stop
Electric protection
History record
Analog alarms
None
Sensor fail
Wrn+shut down
Wrn+slow stop
Wrn+ElProt
Each active alarm is recorded to history and indicated on Alarm list screen. Detection of each binary input
alarm is fix 1 sec time delayed. Analog input Alarm detection is usually based on two levels (e.g. wrn and
sd). The Sensor fail activates or does not activate binary output common Alarm depends on configuration.
Use WinEdit to modify binary or analog inputs configuration.
Warning (Wrn)
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
Shut down (Sd)

When a shutdown occurs, InteliGen opens outputs GCB CLOSE/OPEN, FUEL SOLENOID, STARTER.
Possible shut-down alarms:
Over speed
Under speed
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 (Stp)

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.
When another gen-set is available to come on line, it will start and connect to the load before the unloading
function of the first set begins. If nothing else happens the set will unload when the Slow Stop Del is
exceeded.
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)
Electric protection (ElProt)

When the generator electric protection 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
- 15 -
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
BUS measurement error
Alarm inputs configured as unload ElProt protection
Mains failure
Mains failure detection depends on Auto mains failure setpoints (levels and delays) adjusting. When the
mains failure comes up, mains circuit breaker is opened.
Alarm time chart

Underspeed
Protection
delay
Engine running only, SD, Slow stop, Wrn

Gen>V, Gen<V, Gen>f, Gen<f,
Volt unbal, Curr unbal, Reverse power,
Unload protection
Cooling
Stop
Loaded
GCB opened
Loaded
Unloading
GCB closed
Synchronizing
Running
Min stab time
Idle
Starter OFF
Start
Ready
RPM=0 Cranking Starting
or
Max stab time
All the time & Overspeed protections & Ig IDMT, Ig unbal, IG short
Mains>V, Mains<V, Mains>f, Mains<f, MVolt unbal
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 measured value.
Alarms indication
There can be following actions when Alarm is active (depends on Alarm type and configuration):
Alarm list record
History list record
Active call (when is enabled and modem is installed)
Controller front panel LED indication
Binary output ALARM is closed when Alarm is active or when was deactivated and FAULT RESET
button was not pressed to confirm.
Binary output ALARM opens when Alarm was deactivated (no other Alarm is active) and FAULT RESET
button was pressed to confirm.
Binary output HORN is closed for adjustable time when any new Alarm occurs.
Corresponding value reading (binary input state, analog input value, generator voltage, .. ) is inverse
(e.g. 100 ) on InteliGen screen when value is out of limits (binary input protection is active).

- 16 -
Remote control and data logging

Direct connection to the PC
InteliGen can be connected directly with PC via RS232 interface.
Use the standard cross-wired cable RS232 to connect PC with InteliGen.
PC software WinEdit
ComAp software package WinEdit has to be installed on the PC (Windows 95 / 98 / 2000 / NT / XP) to
communicate with the controller via cable or modem
WinEdit enables:
Read the value
Adjust all set points
Read the history
Control the engine
Configure the controller
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 contains up to 110
records. When the history file is full, the oldest records are removed. History record structure depends
application archive.
Remote modem communication

Remote modem communication with controller is available when modem or GSM modem is connected to
controller. It is possible to read all values check or change setpoints, view history record and download aig
archive file.
Modem connection
Open WinEdit, Type connection = Modem. During modem connection are available all functions like from
direct connection.
Active calls
If the function is enabled and selected alarm comes up, the controller opens a connection to the remote PC
(selected phone number) automatically and send an aig archive file containing, among others the history file,
to the PC.
Active SMS message

If the function is enabled and selected alarm comes up, the controller sends a SMS to the selected phone
number. A GSM modem must be connected to the controller to enable this function. The SMS contains a
copy of the alarm list to help the operator to diagnose the situation.
Example of active SMS message:
#Gen-set name:AL=(Wrn PrimWater temp, !Emergency stop)

- 17 -
Controller firmware and archive files

There are only two types of software files in InteliGen:
Archive file aig (e.g. SPtM-SPtM+IOM-6.0.aig for SPtM application)
Firmware file mhx (e.g. IG-6.0.mhx)
Archives data structure

Following drawing (left side) describes which parts of InteliGen controller memory are stored in aig or ais
archive file.
FIRMWARE
FLASH
ig_5_x.mhx
Archive file
*.aig
Controller
configuration
EEPROM
RAM
NVRAM
history
setpoints
values
statistic
Controller memory
I/O, Setpoints
Names
HISTORY
Records
Values of
. SETPOINTS
.
Measured
VALUES
Statistic
VALUES
PC
Controller software modification

Controller software is distributed in
Complete installation pack on CD (include WinEdit, MultiEdit and detail user and application guides)
iwe pack for simple import of new SW version to corresponding WinEdit directories. Iwe sw pack
contains mhx file(s) and aig archives. Use WinEdit Options - Import firmware command to import iwe.
Controller application modification or change

WinEdit direct connection Controller Software configuration Select or Modify
Select = application change (e.g. from SSB to SPtM)
Modify = configuration change (Input, Outputs, protection, password setting, .. etc modification)
Controller firmware upgrade

WinEdit direct connection Controller Programming select required firmware version click Write to IG.

- 18 -
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 gen-set)
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
Vibration
Shocks
-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
Dimensions and weight

Dimensions
Weight
180x120x50mm
800g

- 19 -

IG - Operator Guide

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IG - Operator Guide

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

Copyright 2004 ComAp s.r.o.

ComAp, spol. s r.o.

InteliGen Operator guide, ComAp June 2005

Description of the controller system (with all options)

(Capital letters in the frame) buttons on the front panel

InteliGen Operator guide, ComAp June 2005

Mains voltage measuring

!!! CAUTION !!!

Adjust set points

InteliGen Operator guide, ComAp June 2005

InteliGen Operator guide, ComAp June 2005

How to select gen-set mode?

How to view measured data?

How to view and edit set points?

5. Set points marked * are password protected.

How to set password?

Use PAGE button to select the ADJUSTMENT menu

How to view the HISTORY menu?

How to change the display contrast?

How to check the serial number and software revision?

How to find active alarms?

When to use GCB ON/OFF button?

When to use MCB ON/OFF button?

InteliGen Operator guide, ComAp June 2005

InteliGen Operator guide, ComAp June 2005

to cancel of editing mode

to write parameter into memory

Par. Edit Screens

..... TO MEASURE SCREEN

Flow Chart of pushbutton Operation

Description of MEASUREMENT screens

OFF MAN AUT

Operation mode of the gen-set

InteliGen Operator guide, ComAp June 2005

Actual value of active power.

IG-CU Analog inputs

IG-CU Analog inputs

IG-CU binary inputs 1/2

IG-CU binary inputs 1/2

IG-CU binary inputs 2/2

IG-CU binary inputs 2/2

IG-CU binary outputs

IG-CU binary outputs 1/2

IG-CU binary outputs 2/2

IG-CU binary outputs 2/2

IG-PCLSM binary inputs

IG-PCM binary inputs

IG-PCLSM binary outputs

IG-PCM binary outputs

InteliGen Operator guide, ComAp June 2005

SRO Speed regulator output indication in the

SRO Speed regulator output indication in the

InteliGen Operator guide, ComAp June 2005

Mode and function description

TEST mode (SSB and SPtM only)

The setpoint Ret from test = MANUAL

The setpoint Ret from test = AUTO

Internal Import export

InteliGen Operator guide, ComAp June 2005

Shut down (Sd)

Slow stop (Stp)

Electric protection (ElProt)

Generator voltage unbalance