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

InteliSysNT
AFR Gen-set Controller
Air Fuel Ratio controller for Lean burn
systems with SPI, SPtM, MINT, COX
Software version IS-NT-AFR-1.6, August 2009

AFR CONTROL GUIDE

Copyright 2009 ComAp s.r.o.

ComAp, spol. s r.o.


Kundratka 2359/17, 180 00 Praha 8, Czech Republic
Tel: +420 246 012 111, Fax: +420 266 316 647
E-mail: info@comap.cz, www.comap.cz
Table of Contents
Table of Contents .................................................................................................................................... 2
General guidelines................................................................................................................................... 3
Description of the controller system.................................................................................................... 3
Available documentation ......................................................................................................................... 4
Inteli NT general manuals ................................................................................................................... 4
Inteli NT application manuals .............................................................................................................. 4
Inteli NT PC tools manuals.................................................................................................................. 5
Inteli common manuals ....................................................................................................................... 5
Conformity declaration ........................................................................................................................ 5
!! Warnings !! ....................................................................................................................................... 6
Mode and function description ................................................................................................................ 7
OFF mode ........................................................................................................................................... 7
MAN mode .......................................................................................................................................... 7
SEM mode........................................................................................................................................... 7
AUT mode ........................................................................................................................................... 7
ISNT Air Fuel Ratio control software ..................................................................................................... 9
Hardware........................................................................................................................................... 10
Virtual and physical modules ............................................................................................................ 12
Maximum number of configured I/O modules ................................................................................... 12
Binary inputs...................................................................................................................................... 13
Binary outputs ................................................................................................................................... 14
Analogue inputs ................................................................................................................................ 15
Logical analogue values.................................................................................................................... 16
Statistics values ................................................................................................................................ 16
Setpoints Engine protect ................................................................................................................ 17
Setpoints Mains protect (SPI, SPtM archives) .................................................................................. 19
Setpoints AFR control .................................................................................................................... 22
AFR control chart .............................................................................................................................. 27
Protections ........................................................................................................................................ 28
History and Alarm list records ........................................................................................................... 30
PLC functions .................................................................................................................................... 30
Abbreviation list ..................................................................................................................................... 33

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General guidelines
This manual provides general information on how to operate the IS-NT-AFR controller. IS-NT-AFR sw
is a special branch dedicated for control of lean burn gas engines.
This manual is intended for everybody who is concerned with operation and maintenance of the IS-NT
AFR control system

Description of the controller system


NT family controllers are comprehensive AMF-controllers for single and multiple generating sets
operating in stand-by or parallel modes. Synchronizer, isochronous load sharer, Mains and Generator
protections allow for a total integrated solution for gen-sets in stand-by and parallel modes with
multiple engine support.
NT family 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 controller 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.
Parallel to Mains operation can be achieved without additional HW. Forward and reverse
synchronizing, Mains protection including vector shift, 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 NT family controllers is their easy-to-use installation and operation. Predefined
configurations for typical applications are available as well as user-defined configurations for special
applications.

Default applications
There are four default applications: SPI, SPtM, MINT and COX.

SPI Single Parallel Island application - for single gen-sets in parallel with mains or in island
operation; suitable for CHP application; no MCB control
SPtM Single Parallel to Mains application - for single gen-sets in parallel with mains or in island
operation, with AMF support; both MCB and GCB controlled
MINT Multiple application with INTernal control loops - for multiple gen-sets in island parallel or
mains parallel operation; Load Sharing and VAr Sharing controlled internally; PMS
available
COX A special application intended for COoperation with an eXternal supervisory control
system, e.g. PLC. Most internal control sequencies are removed or reduced, all major
actions (synchronizing, load control type) are initiated via binary inputs to the NT controller.

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Available documentation
Inteli NT general manuals
IGS-NT-2.2-Application guide.pdf
Dedicated to gen-set control panel builders and project designers.
Covers above all following items:
IG/IS-NT hardware options
Comparison of number of I/O and communication ports in different HW modifications
Order codes overview
Applications overview purpose, connection recommendations, function description
PLC functions description
Virtual peripherals principle and usage

IGS-NT-2.3-Installation guide.pdf
Dedicated to gen-set control panel builders and everybody concerned with installation of the gen-set.
Includes information about following topics:
Terminals and dimensions of all controllers and peripheral modules
Recommended wirings
Controllers interface options
Default sensors
Speed governor interfaces
AVR interfaces
Technical data

IGS-NT-2.0-Operator guide.pdf
Dedicated to everybody concerned with operation and maintenance of the gen-set.
It describes
Operator interface
Measurement screens of the NT family controllers
Modes and function of the controller.
IG/IS-NT Available documentation list

IGS-NT-2.2-Troubleshooting guide.pdf
Includes description of possible troubles during configuration, adjustment and operation of the
controller.
Consists of two parts:
List of troubles and their solution
How to section with recommended procedures in some typical situations

Inteli NT application manuals


For each application an appropriate manual is available:

IGS-NT-SPTM-2.2 Reference guide.pdf


IGS-NT-SPI-2.2 Reference guide.pdf
IGS-NT-MINT-2.2 Reference guide.pdf
IGS-NT-COX-2.2 Reference guide.pdf
They include these sections:

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Modes description (OFF, MAN, AUT, )
Functions description (e.g. Load shedding, Power management, Start/Stop sequences)
Protections and alarm management
Gen-set operation states
Inputs and outputs
Setpoints
List of abbreviations

Inteli NT PC tools manuals


InteliMonitor-2.3.pdf
This manual describes InteliMonitor monitoring PC tool in the following chapters:
Connection to the controller (Direct, Modem, Internet)
InteliDDE Server
Menus description
Password and access code

GenConfig-2.4.pdf
This manual describes GenConfig configuration PC tool in the following chapters:
Connection to the controller (Direct, Modem, Internet)
InteliDDE Server
Menus description
Controller configuration steps (Modules, I/O, Setpoints, Protections, History,)

Inteli common manuals


InteliCommunicationGuide June 08.pdf
This manual covers communication topics not only regarding IG/IS-NT controllers but also InteliLite
and InteliDrive controllers. It applies to communication between the controller and superior service or
monitoring system but not to communication among the controllers or between the controller and its
peripherals (extension modules, ECU).
It is divided into following chapters:
Local connection
Remote connection
Modem connection
Internet connection
Active call, SMS, email
Modbus description
I-LB, IG-IB communication units
Modem recommendations
Recommended converters

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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!! 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 and / or
Binary outputs for MCB control and / or
MCB feedback

Switch InteliSysNT 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.

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Mode and function description
There are four gen-set operation modes: OFF - MAN SEM AUT in SPI, SPtM and MINT
application. There are three gen-set operation modes: OFF MAN AUT in COX application.
To select the mode use MODE or MODE buttons.

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.
MCB behavior depends on AMF settings: MCB opens on setpoint:
MAINSFAIL: When power-cut comes, MCB opens. After Mains returns, MCB closes with MCB
close del.
GEN RUNNING:When power-cut comes, MCB stays closed until the gen-set starts and
produces voltage within limits.

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 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) If synchronization is successful, the voltage and mains/bus voltage is within the voltage window,
and the phase angle between generator and mains voltage is within parameter: Phase angle for
time: Dwell time, command to close the GCB is sent. In case of non successful synchronization
the Sync Timeout elapsed; the engine is shut down generating message: Sd SyncFail.
5) 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 down and stopped.
Hint:
Controller does not respond to external signals and/or conditions. 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 application

SEM mode
In SEM mode, pressing of START or STOP buttons performs a predefined sequence:
START starts the engine, synchronizes and runs in parallel.
STOP softly unloads the gen-set, opens GCB, provides cooldown and stops the engine.
In case of mains failure and Process control: MFStart enable set to YES, allows automatic start/stop
same as in AUT mode.

AUT mode
Gen-set is controlled based on external signals (Rem start/stop, Sys start/stop) or conditions (AMF,
Peak shaving, Power management system, ).

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Hint:
Engine does not stop, if other condition for automatic starts is active.
Example: If peak stop condition occurs, but REMOTE START/STOP is active, engine stays running.

Controller does not respond to GCB ON/OFF , MCB ON/OFF, STOP, START buttons and
corresponding remote InteliMonitor or Modbus commands.

!!!!! VERY IMPORTANT !!!!!!

Set Basic setting: FltRes GoToMAN = ENABLED to avoid automatic engine start when pressing
FAULT RESET after Shut down or Slow stop alarm.
Engine can start automatically without warning when pressing FAULT RESET after shut down alarm.

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ISNT Air Fuel Ratio control software
IS-NT-AFR-1.6 is based on standard InteliSys-NT software of version 2.3 and IS AFR 1.5 sw
(classic IS controller).
Corresponding IS-NT-AFR dongle activates AFR function. Following document describes differences
against standard IS-NT functions only. For standard InteliSys functions description see corresponding
(SPTM, SPI, MINT) user guides.

Main changes against the IGS-NT standard sw:


1. AFR sw branch is dedicated for gas engines only, special AFR dongle is required
2. special setpoint group AFR control was added
3. different start procedure Ventilation time before each cranking attempt to blow out the non
burn gas from the engine pipe system
4. Overspeed during engine start is automatically reset and another start attempt is initiated
5. message Wrn:SpdRegLimit is neither recorded into Alarm list nor into History
6. System cooperates with more extension modules connected on the CAN bus (knocking
detection, speed governor, stepper control) and their parameters are accessible from main
unit
7. Offload protection (Ofl) has different behaviour then in std IGS-NT, see below.

Main changes against the classic IS-AFR-1.5


1. New setpoint limit Engine protect: StartOverspeed [ % ]
2. New setpoint Engine protect: StartBlockDel [ s ]
3. New setpoint Engine protect: ServiceTime Sd [ h ]
4. New Logical binary output kWh pulses and corresponding setpoint AFR control: kWh pulse [
kWh ]
5. Removed message Wrn SpeedRegLimit in alarm list and in History record.
6. Removed Stop fail indication

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Hardware
Im
Vm Vb 1 Gas valves
2 ZPR
3 Gas-Air mixer
Vg
Ig
4 Extension Ana in
5 Mixture compressor
6 Mixture cooler
7 Speed governor
8 MAP, MAT sense
BO
9 Ignition system
on/off 10 Misfiring detection
BI
11 Knocking detection
knocking Knocking 12 Gas engine
13 Generator
14 IS-NT controller
15 AFR dongle
BI
Misfiring

BO
Ignition

EXHAUST
Water pressure
Oil temp
Oil press Analog inputs
Water temp
Timing pickup
RPM
RPM

MAT
MAP

Sync/Load control

water

Mixer feedback
CAN
control

AOUT

GAS on/off BO
GAS on/off

Valve check

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IS-NT-AFR Dongles option

Single parallel SPtM / SPI Multiple+power management MINT


IGS-NT-AFR-PCM IGS-NT-AFR-LSM+PMS

Wiring example of binary and analogue I/O


IS-NT
GCB feedback Starter
BI1 BO1
MCB feedback Idle/Nominal
BI2 BO2
Rem start stop Fuel solenoid = GAS
BI3 BO3
Emergency stop Fuel solenoid = GAS
BI4 BO4
Access lock GCB close/open
BI5 BO5
Remote OFF MCB close/open
BI6 BO6
ShutDown Alarm
BI7 BO7
Warning Horn
BI8 BO8

Shut down Ready


BI9 BO9
reserve Prelubr pump
BI10 BO10
reserve Cooling pump
BI11 BO11
reserve Ignition
BI12 BO12
GasVTest OK GasVTest run
BI13 BO13
GasSelection Common warning
BI14 BO14
DxLoadReduct MAP ctrl fail
BI15 BO15
Misfiring Common shut down
BI16 BO16
Water temperature
AI1
Oil pressure
AI2
Oil temperature
AI3
Water pressure Mixer position
AI4 AO Mixer

IS-AIN8
MAP 4/20 mA Mixer feedback
AI2 AI1
MAT Pt100
AI3
Ana CH4
AI4
reserve
AI5
reserve
AI6
reserve
AI7
reserve
AI8

Wiring example of IS-NT speed governor and AVR interface


More details see in Application guide.
AC2
AC1

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Virtual and physical modules
Number of I/O can be extended and project wiring can be reduced using the following extension and
virtual modules.

BOUT

AOUT
Module name Note
BIN

AIN
IS-NT controller 16 16 4 1 For more details check the IGS-NT Installation guide
IGS-PTM 8 8 4 1 Standard I/O extension module.
IS-AIN8 - - 8 - Standard I/O extension module.
IS-BIN16/8 16 8 - - Standard I/O extension module.
I-CB x x x x Configurable communication bridge.
IGL-RA15 - 15 - - 15 Green, Red, Yellow LED panel.
I-AOUT8 - - - 8 8 Analogue outputs
VPIO 8 8 - - Virtual periphery I/O module.
SHBIN 8 - - - SHared (virtual) Binary INput module
SHBOUT - 8 - - SHared (virtual) Binary OUTput module
SHAIN - - 4 - Shared (virtual) Analogue INput module
SHAOUT - - - 4 Shared (virtual) Analogue OUTput module
PLC x x x x Programmable (internal) logic module.

Maximum number of configured I/O modules


Module Maximum
Note
name number
Address of the module can be only 1-4. Configuration of this module decrease
IGS-PTM 4 the maximum number of IS-AIN8 and IS-BIN16/8 and I-AOUT8 which can be
additionally configured to IGS-NT controller
In case there is connected any IGS-PTM (address 1-4) the maximum number of IS-
IS-AIN8 10
AIN8 is reduced by this number
In case there is connected any IGS-PTM (address 1-4) the maximum number of IS-
IS-
6 BIN16/8 is reduced by this number. In case, there is connected any IGL-RA15
BIN16/8
module, then one IGL-RA15 means loose of possibility to configure 2 IS-BIN16/8
I-CB 1 Address of any I-CB module must be 1
Configuration of this module decrease the maximum number of IS-BIN16/8 which
IGL-RA15 4
can be additionally configured to IGS-NT controller
Configuration of this module decrease the maximum number of IGS-PTM which can
I-AOUT8 4
be additionally configured to IGS-NT controller
VPIO 4
SHBIN 6
Take in account that each controller which has configured SHBOUT module should
have configured this module with different address, otherwise there will be
SHBOUT 6
mismatch of SHBOUT modules on CAN line and Shared outputs will not work
correctly
SHAIN 2
Take in account that each controller which has configured SHAOUT module should
have configured this module with different address, otherwise there will be
SHAOUT 2
mismatch of SHAOUT modules on CAN line and Shared outputs will not work
correctly
Hint:
For more details about Virtual peripherals (Shared and Internal virtual I/O periphery and PLC) see
IGS-NT-Application guide-2.2.pdf.

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Binary inputs
Hint:
Following list contains inputs/outputs related to Air Fuel Ratio control only. For standard I/O list please
see standard IGS-NT Reference guide.

Gas selection
Binary input changes set of mixer fixed position for engine start, run and low power condition, see
AFR control chart

Misfiring
Misfiring binary input activates IS-NT-AFR engine misfiring protection. Misfiring is detected from
external misfiring unit. Protection is active only when gen-set power is above MAP1 power.
When binary input is active:
- Immediately reduces required MAP value by setpoint AFR control: MisfMAP reduct
- Starts engine unloading after AFR control: MisfLdRed del with rate Sync/Load ctrl: Load
ramp to value Gener protect: Min Power PtM.
- Activates Engine Slow stop (Cool down) after AFR control: Misfiring del.

The engine shut down is activated when Misfiring unload protection is activated 5 times in one hour
(Alarm list and History record Sd Misfiring). The internal (modulo 5) counter is reset after one hour
without Misfiring activation or after engine Stop.

BI Misfiring

MAP reduction
Genset load
MisfLdRed del
Lo
ad Misfiring del
ra
m Min Power PtM
p

GCB
opened
Engine
Slow stop

DxLoad reduct
Input activates IS-AFR engine knocking protection. Knocking is detected from external unit. Protection
is active only when gen-set power is above MAP1 power.
When is closed:
- Immediately starts engine unloading with rate Sync/Load ctrl: Load ramp to value Gener protect:
Min Power PtM.
- Activates Engine shut down after AFR control: Knocking del.

The engine shut down is activated when binary input DxLoad reduct is activated 5 times in one hour
(Alarm list and History record Sd Knocking). The internal (modulo 5) counter is reset after one hour
without Knocking activation or after engine Stop.

GasVTest OK
Binary input from Gas valve test unit that indicates OK result of Gas valve test.

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Binary outputs
IS-AFR Timer Active output was replaced by standard IS-NT timer function.

MAP ctrl fail


Binary output is closed when MAP characteristic is out of control range, MAP requested and MAP
actual differ more then parameter MAP difference for longer then MAP timeout. See protection MAP
control fail.

Mixer up
Output for binary Up Mixer control. This output is result of PID control, so its pulse length is not fixed.

Mixer down
Output for binary Down Mixer control. This output is result of PID control, so its pulse length is not
fixed.
MAP

+Mixer BO hyst
MAP required
ual
P act -Mixer BO hyst
MA

Binary output Mixer up on off


on
Binary output Mixer down off on off
Hint:
Binary outputs Mixer up and Mixer down are not active when analogue input Mixer feedback is not
configured.

GasVTest run
Output for Gas valve test activation. Configure this output in case you want to run the Gas valve check
before each start of engine.

kWh pulses
Based on AFR control: kWh pulses setpoint, this output generates 1 sec pulse. kWh value starts
calculating from setpoint change.

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Analogue inputs
MAT
Analogue input for Manifold mixture temperature.
Engine Slow stop (Cool down) is activated when MAT sensor fail is detected.

MAP
Analogue input for Manifold mixture pressure recommended resolution of sensor characteristics is
0,001 Bar. Engine Shut down is activated when MAP sensor fail is detected.

Ana CH4
Gas content influences Mixer position during engine start and running unloaded state when setpoint
AFR control: Ana CH4 = ENABLED. In this case the setpoints StartPosition1, RunPosition1,
StartPosition2, RunPosition2 are ignored.
Use this input in case of landfill applications, when the gas quality varies significantly and fixed mixer
position for start and run condition cannot be used.
Hint:
StartPosition1 and RunPosition1 setpoints are used when Ana CH4 sensor fail is detected (sensor
value is out of range).
Connect external gas analyzer to analogue input Ana CH4 and configure corresponding sensor
characteristics with respect to 0 to 100% Mixer control output range.

Configuration example

Mixer fdb
Analogue input for mixer feedback position. Mixer feedback is used for binary mixer position control
only and it is not used for mixer control via analogue output (indication only). Mixer feedback sensor
characteristics must be configured in the range 0,00 to 100,00% to be the same dimension as Mixer
position output.

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Logical analogue values
Mixer position [ 0,00 to 100,00%]
Configure this output to IS-NT physical analogue output 0 10V (0 20 mA) for mixer control.
IS-NT Mixer position output conversion to IS-NT physical analogue output

Mixer feedback [ 0,00 to 100,00%]


Actual value based on Mixer feedback input.

MAP required [ 0,000 to 10,000 bar]


Final MAP required including temperature correction, see AFR control chart.

MAP actual [ 0,000 to 10,000 bar]


actual MAP based on MAP analogue input.

Statistics values
Following statistics value is additional against to standard InteliSys NT software.

Day kWhours
Visible on Generator [1-5] screen or in InteliMonitor - Value screen
It is automatically set to zero each midnight (24:00:00) when controller is switched on

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Setpoints Engine protect
The only Air Fuel Ratio specific setpoints are listed below. For other setpoints list and description refer
to standard IGS-NT Reference guides.

Overspeed [%]
Threshold for engine over speed protection active all time.
Step: 1% of Nominal RPM
Range: 0 200%

StartOverspeed [%]
RPM limit without delay, which is evaluated during start procedure only:
During the starting procedure: stops the engine and initiates new starting attempt (without Fault)
reset until reaches the Engine params: Cranking attempts number.
Initiate Engine shut down after engine is running.
Step: 1% of Nominal RPM
Range: 0 200%

StartBlockDel [s]
Time limit within the next (automatic or manual) engine start is blocked after engine was stopped. No
block when set to zero.
Step: 1s
Range: 0 to 60000 s

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ServiceTime Sd [h]
Engine will stop (cooldown) after this value counts down to zero.
Step: 1h
Range: 0 to 65535 h

BoOvrSpdReset [NO / YES]


Breaker Open OverSpeed Reset is a setpoint which defines behaviour in case of active Off load
protection.
YES: possible overspeed after breaker open as a consequence of Off load protection is automatically
reset and genset is started again.
NO: possible overspeed after breaker open as a consequence of Off load protection is not reset
internally.

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Setpoints Mains protect (SPI, SPtM archives)
Mains >V MP [ % ] (FV)
Threshold for mains over voltage.
Step: 1%
Range: Mains<V MP 150 % of MainsNomV or MainsNomVph-ph respectively
Protection: Mains protection.
Force value possibility: Yes

Mains >V del [s]


Delay time for Mains over voltage protection evaluation.
Step: 0,02s
Range: 0,00 600,00 s
Force value possibility: NO

Mains <V MP [ % ] (FV)


Threshold for mains under voltage.
Step: 1%
Range: 50 Mains>V MP % of MainsNomV or MainsNomVph-ph respectively
Protection: Mains protection.
Force value possibility: Yes

Hint:
All three phases are checked for mains voltage protection. Minimum or maximum out of three is used.
For high voltage applications, the MainsNomVph-ph can be used for nominal voltage setting.

Mains <V del [s]


Delay for mains under voltage protection.
Step: 0,02 s
Range: 0,00 600,00 s

Mains >f [%] (FV)


Threshold for mains over frequency in % of nominal frequency.
Step: 0,1%
Range: Mains<f - 150,0 % of Nominal freq
Protection: Mains protection.
Force value possibility: Yes

Mains >f del [s]


Delay time for Mains over frequency protection evaluation.
Step: 0,02s
Range: 0,00 600,00 s
Force value possibility: NO

Mains <f [%] (FV)


Threshold for mains under frequency in % of nominal frequency.
Step: 0,1%
Range: 50,0 - Mains>f % of Nominal freq
Protection: Mains protection.
Force value possibility: Yes

Hint:
The mains frequency is evaluated from the L3 phase.

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Mains <f del [s]
Delay for mains under frequency protection.
Step: 0,02 s
Range: 0,00 600,00 s
Force value possibility: NO

FwRet break >U [s]


Delay between the Mains comes back and reverse synchronization process is initiated. During this
time the mains is evaluated if it is healthy. This time is taken in account in case the Mains over voltage
protection was activated.
Step: 0,1 s
Range: 0,0 800,0 s
Force value possibility: NO

FwRet break <U [s]


Delay between the Mains comes back and reverse synchronization process is initiated. During this
time the mains is evaluated if it is healthy. This time is taken in account in case the Mains under
voltage protection was activated.
Step: 0,1 s
Range: 0,0 800,0 s
Force value possibility: NO

FwRet break >f [s]


Delay between the Mains comes back and reverse synchronization process is initiated. During this
time the mains is evaluated if it is healthy. This time is taken in account in case the Mains over
frequency protection was activated.
Step: 0,1 s
Range: 0,0 800,0 s
Force value possibility: NO

FwRet break <f [s]


Delay between the Mains comes back and reverse synchronization process is initiated. During this
time the mains is evaluated if it is healthy. This time is taken in account in case the Mains under
frequency protection was activated.
Step: 0,1 s
Range: 0,0 800,0 s
Force value possibility: NO

FwRet break VS [s]


Delay between the Mains comes back and reverse synchronization process is initiated. During this
time the mains is evaluated if it is healthy. This time is taken in account in case the Mains vector shift
protection was activated.
Step: 0,1 s
Range: 0,0 800,0 s
Force value possibility: NO

AfMainsFlRun [s]
When the Mains protection is evaluated and an OffLoad protection is configured (e.g. on
LBO:MainsParams OK) the GCB is tripped together with MCB (in SPtM) but genset is not stopped. In
case during the time AfMainsFlRun (After Mains Fail Run) the Mains recovers, the FwRet break xx is
count down and reverse synchronization is initiated.
If the Mains does not return within the parameter AfMainsFlRun, the genset is stopped. Genset will be
started as soon as the mains recovers back.

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This setpoint influences the behaviour in AUT mode only.

VectorS prot [ DISABLED / PARALLEL ONLY / ENABLED ] (FV)


DISABLED: Vector shift protection is disabled.
PARALLEL ONLY: Vector shift protection is enabled only if the gen-set is running in parallel with
mains (= MCB+GCB status active).
ENABLED: Vector shift protection is enabled if MCB status is active.
Force value possibility: Yes
Hint:
If ENABLED is selected, it is likely that Vector shift protection will trip the MCB before other mains
protections. It senses the fast changes in mains voltage angle position, which occur with every mains
failure, even if the gen-set is not running in parallel with mains.

VectorS CB sel [ MCB / GCB ] (FV)


MCB: MCB is tripped if Vector shift protection gets active.
GCB: GCB is tripped if Vector shift protection gets active.
Force value possibility: Yes
Hint:
If GCB is selected and mains failure comes up, it is likely that MCB trips as well later on because of
other mains protections.
This setpoint is in SPtM archive only

VectorS limit []
Vector shift protection threshold level.
Step: 1
Range: 1 45
Hint:
To be sure of proper adjusting of VectorS limit, check Max VectorS value on the controller or PC
software screen. Max VectorS value is set to zero when transiting to parallel, and then accumulates
the maximum reached value (positive only) during parallel operation. Thus, during the normal
operation, only the background noise is accumulated (usually max 3), and the protection level
should be set to approximately twice the value of this noise.

Mains V unbal [%]


Threshold for mains voltage unbalance alarm in % of nominal voltage. The voltage unbalance is
calculated as a maximum difference between phase voltages.
Step: 1%
Range: 0 200% of MainsNomV or MainsNomVph-ph respectively

Mains Vunb del [s]


Delay for mains voltage unbalance alarm.
Step: 0,1s
Range: 0 600,0 s
Protection: Mains protection

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Setpoints AFR control
GasVTEST [ ENABLE / DISABLE ]
ENABLE: Binary output GasVTest run (Gas valve test) is activated before each engine start by:
Binary input Rem start/stop in AUT mode,
START button in MAN and SEM mode,
DISABLE: Engine starts after start command without Gas valve test.
Hint:
Gas Valve TEST procedure is skipped during Automatic Mains Fail gen-set start to short black-out
time.
Active sprinkler function enables engine start even if the Gas valve test is negative.

GasVTest del [s]


Binary output GasVTest run starts Gas valve test procedure and timer GasV TEST del.
Engine starts when Binary input GasVTest OK (test feedback) is activated (closed) during GasVTest
del.
Engine shut down protection is activated when no GasVTest feedback is detected during GasVTest
del.
Step: 1s
Range: 0 to 300 s
Start Engine
command shut down

BO GasVTest run
GasVTest del
BI GasVTest OK opened

Starter opened

BinaryInput BinaryOutput Gas valve


GasVTest OK IS-NT GasVTest run test unit Start
Engine start
command

BO GasVTest run
GasVTest del
BI GasVTest OK
OK
Prestart
. Starting procedure

StartPosition1 [%]
Mixer fix position for Engine start when Binary input GasSelection is opened or not configured.
Step: 0,01 %
Range: 0,00 to 100,00 %

RunPosition1 [%]
Mixer fix position after engine reaches Nominal RPM when GCB is opened. Position is active when
Binary input GasSelection is opened or not configured.
Step: 0,01 %
Range: 0,00 to 100,00 %

LoPwrPosition1 [%]
Mixer low power fix position after GCB is closed until gen-set reaches Low MAP power. Position is
active when Binary input GasSelection is opened or not configured.
Step: 0,01 %
Range: 0,00 to 100,00 %

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StartPosition2 [%]
Mixer fix position for Engine start when Binary input GasSelection is active.
Step: 0,01 %
Range: 0,00 to 100,00 %

RunPosition2 [%]
Mixer fix position after engine reaches Nominal RPM when GCB is opened. Position is active when
Binary input GasSelection is active.
Step: 0,01 %
Range: 0,00 to 100,00 %

LoPwrPosition2 [%]
Mixer low power fix position after GCB is closed until gen-set reaches Low MAP power. Position is
active when Binary input GasSelection is active.
Step: 0,01 %
Range: 0,00 to 100,00 %

MxPos40%CH4, MxPos60%CH4 [%]


Setpoints for transformation from CH4 content to Mixer position output. This function is active when
Ana CH4 = ENABLED.
Step: 0,1 %
Range: 0,0 to 100,0 %
Mix pos CH4

% CH4 %
MxPos60%CH4
Ana CH4

MxPos40%CH4
40% 60%
4 - 20 mA Ana CH4
Example:
Setting MxPos40%CH4 = 40% and MxPos6%CH4 = 60% means linear 1:1 transformation between
CH4 input and Mixer position.

Ana CH4 [ DISABLED / ENA-FIX / ENA-STEP ]


DISABLED Mixer position for engine start and running unloaded (< Low MAP power) is defined
by setpoint AFR control: StartPosition1 or 2 and RunPosition1 or 2 and Lo Pwr
position 1 or 2.
ENA-FIX Mixer position for engine start, running unloaded ((< Low MAP power) is defined by
analogue input Ana CH4 (via configured characteristic MxPos40%CH4,
MxPos60%CH4).
ENA-STEP Mixer output = ENA-FIX + corresponding difference between active (depends on
Binary input Gas selection) StartPosition, RunPosition and LoPwr position.
see table below

Ana CH4: Start Run < Lo MAP power > Lo MAP power
DISABLE StartPosition1 RunPosition1 LoPwr postion1 PID control
StartPosition2 RunPosition2 LoPwr postion2
ENA-FIX The mixer output depends on AnaCH4 input (corresponding PID control
sensor characteristics) and setting of MxPos40%CH4 and
MxPos60%CH4
ENA-STEP = ENA-FIX = ENA-FIX + Dif1 = ENA-FIX + Dif2 PID control

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Dif1 and Dif2 depends on Binary input Gas selection - see below
Binary input = opened = closed
Gas selection
Dif1 = RunPosition1 - StartPosition1 RunPosition2 - StartPosition2
Dif2 = LoPwr position1 - StartPosition1 LoPwr position2 - StartPosition2

MAP1 power [ kW ]
The first MAP characteristic specification: gen-set power for MAP1 value and kW power limit for AFR
PID Mixer control loop activation.
Step: 1 kW
Range: 0 to MAP2 power

MAP1 [ Bar ]
MAP characteristic specification: MAP value at MAP1 power.
Step: 0,001 Bar
Range: 0,000 to 10,000 Bar

MAP2 power [ kW ]
The second MAP characteristic specification: gen-set power for MAP2 value
Step: 1 kW
Range: MAP1 power to MAP3 power

MAP2 [ Bar ]
MAP characteristic specification: MAP value at MAP2 power.
Step: 0,001 Bar
Range: 0,000 to 10,000 Bar

MAP3 power [ kW ]
The third MAP characteristic specification: gen-set power for MAP3 value
Step: 1 kW
Range: MAP2 power to MAP4 power

MAP3 [ Bar ]
MAP characteristic specification: MAP value at MAP3 power.
Step: 0,001 Bar
Range: 0,000 to 10,000 Bar

MAP4 power [ kW ]
The fourth MAP characteristic specification: gen-set power for MAP4 value
Step: 1 kW
Range: MAP3 power to MAP5 power

MAP4 [ Bar ]
MAP characteristic specification: MAP value at MAP4 power.
Step: 0,001 Bar
Range: 0,000 to 10,000 Bar

MAP5 power [ kW ]
The third MAP characteristic specification: gen-set power for MAP3 value
Step: 1 kW
Range: MAP4 power to Nominal power

MAP5 [ Bar ]
MAP characteristic specification: MAP value at MAP5 power.
Step: 0,001 Bar
Range: 0,000 to 10,000 Bar

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Hint:
However the MAP curve has 5 points, you can use less of them if necessary. Just put any of MAP x
(x>2) to 0 value and these points are not calculated into the curve. The first 2 points: MAP1 power,
MAP 1 and MAP2 power, MAP2 must be configured every time.

Mixer MODE [MANUAL / AUTOMATIC / AUT-PAR ]


MANUAL Mixer position is defined only by setpoint Mixer position in all engine states.
AUTOMATIC Automatic mixer control that activated after GCB is closed and gen-set load above
Low MAP power (in island and parallel to mains mode).
AUT-PAR Automatic Mixer control only in parallel to mains (MCB is closed)

Mixer position [%]


Mixer position when Mixer MODE = MANUAL.
Step: 0,01 %
Range: 0,00 to 100,00 %

Mixer BO hyst [%]


Hysteresis for Mixer binary control via Binary outputs Speed up, Speed down. See chapter Binary
outputs.
Step: 0,01 %
Range: 0,00 to 100,00 %

AFR gain [%]


Gain for AFR control loop. AFR gain sign defines the direction of regulation.

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Step: 0,1 %
Range: -200,0 to +200,0 %

AFR int [%]


Integration factor for AFR control loop.
Step: 1 %
Range: 0 to 100 %

Rough calculation of speed of Mixer position output change in % per 1 minute

%/min = - {sign(AFR gain)}(AFR int * ) / 500


Where:
AFR int = setpoint 0 to 100%
= difference in mBar between requested and actual MAP - see table below.

MAP requested MAP actual


1,000 Bar 0,900 Bar 100

Example: AFR int = 50%; = 100; %/min = - 50 * 100 / 500 = - 10 %/min.


Mixer position output speed does not depend on AFR gain setting.

AFR der [%]


Derivative factor for AFR control loop.
Step: 1 %
Range: 0 to 100 %

MisfMAP reduct [ Bar ]


Required MAP value is immediately reduced by this value when binary input Misfiring is active.
Step: 0,001 Bar
Range: -1,000 to 1,000 Bar

MisfLdRed del [s]


The engine load is reduced after MisfLdRed del when binary input Misfiring is activated.
Step: 1s
Range: 0 to Misfiring del s

Misfiring del [s]


Engine cool down protection is activated when binary input Misfiring is activated for Misfiring del.
Step: 1s
Range: MisfLdRed del to 600 s

Knocking del [s]


Engine shut down protection is activated when binary input DxLdReduct is activated for Knocking del.
Step: 1s
Range: 0 to 600 s

MAP difference [ Bar ]


Allowed difference from MAP characteristic (Low MAP, High MAP).
Step: 0,001 Bar
Range: 0,000 to 1,000 Bar

MAP timeout [s]


Engine shut down is activated when actual MAP is out of characteristics (MAP difference) for MAP
timeout.
Step: 1s
Range: 0 to 600 s

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kWh pulse [ kWh ]
Number of kWh per one 1 sec pulse on Logical binary output kWh pulse. Pulse calculation starts
from setpoint change.
Step: 1 kWh
Range: 0 to 65535 kWh

AFR control chart


Corresponds to software version 1.6

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Timing chart

fix position Mixer regulation fix position

Start position Start position


Run position Run position
LoPWR position LoPWR ...

Engine states

AFR control stays active during short (up to 1 sec) engine power drop out (no jump to LoPwr position).

kW
Lo Pwr position

1 sec
time
AFR control

Protections
MAP control fail
Engine shut down is detected and Binary output MAP ctrl fail is closed when actual MAP value is out
of range. See setpoints AFR control: MAP difference, MAP timeout. Protection is active when genset
power > Low MAP power.

MAP control fls


Engine Slow stop (Cool down) is activated when MAP or MAT sensor fail is detected or MAP / MAT
function is not configured.

Misfiring
External Misfiring detection unit output is supposed to be connected to InteliSys binary input Misfiring.

Knocking
External Knocking detection unit (e.g. DetCon) output must be connected to InteliSys binary input
DxLoad reduct.
Hint:
MAP control fail, Misfiring, Knocking, Oxygen range protections are activated from MAP1 power.

Not configured MAP or MAT analogue input indicates sensor fail alarm.

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Gas Valve test procedure
Test is based on the external automatic unit that put pressure between two closed Gas valves and
measures pressure value stability. Test is activated prior to engine start by InteliSys Binary output
GasVTest run. InteliSys waits for adjustable delay for test result - Binary input GasVTest OK must be
closed within this time. Engine starts at any time during Gas valve test procedure when Binary input
GasVTest OK is closed. Engine shut down is detected (Sd GasVTest message in AL and HST) when
no positive feedback (GasVTest OK) is received during adjustable delay GasVTest del. Gas Valve
TEST procedure is skipped during Automatic Mains Fail gen-set start to short black-out time.

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History and Alarm list records
Record Reason
MAPControlFls MAP or MAT not configured or sensor fail
Stp O2 limit O2 is out of range when gen-set power > Low MAP power
Sd MAPCtrlFail MAP is out of range during active AFR control
Wrn Misfire Active BI Misfiring
Sd Misfire Misfiring protection was active 6x in one hour
Sd MisfireTO After Misfiring timeout
Wrn Knocking Active BI Knocking
Sd KnockingTO After Knocking timeout
Sd Knocking Knocking protection was active 6x in one hour
Sd GasVTest Gas valve test shut down
Dongle incomp Corresponding AFR dongle is missing

PLC functions

Config item Selection IG- IG-NT/EE IS-NT Note*


Available NT/EE IGS-NT -
miniCHP-

Log Func I. 16 16 64 AND, OR


2 to 8 inputs
Binary output

Log Func II. 2 2 16 XOR, RS (flip-flop)


2 inputs
Binary output

Comp Hyst 2 4 16 Analogue input


Two limits
Binary output

Comp Time 0 4 8 Analogue input


One limit + delay
Binary output

Ana Switch 0 2 16 Two analogue inputs


Analogue output
Binary input as selector

Math Func 0 2 16 ADD, SUB, ABS, AVG, MAX,


MIN
Two analogue inputs
Analogue output
Analogue input, Analogue
Mov Avg 0 1 2 output
Performs averaging (filtering)
of the input value with
selectable weight and period

InterpolFunc 0 1 2 Linear interpolation


Analogue input
Analogue output

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ForceHistory 0 4 4 Binary input causes history
record when changes from 0 to
1

ForceProtect 0 4 4 Adjustable protection levels,


based on PLC evaluation

PID Bin 0 2 4 PID control loop with binary


output

Counter 0 1 4 Edges counter


One limit
Binary output

Timer 0 1 4 Periodic signal generator


Binary output
Analogue input

Delay 4 8 16 Adjustable rising and falling


edge delay

PID - Analogue output jumps to


PID Ana B 0 2 4 adjustable Bias value when
Gate input is active (instead
zero as before) and starts from
Bias.
Math functions with
Ext. Math. 0 2 8 expandable number of inputs
up to 8.
Selectable: ADD, AVG, MAX,
MIN
8 analogue inputs, 1 analogue
output.
Window comparator
Comp.Win. 2 4 16 Analogue input, two limits,
analogue output. Binary output
is active when input is within
limits.
Ramp - Analogue input,
Ramp 0 2 4 analogue output.
Two setpoints for Ramp-up and
down speed (in number of units
per second). Enable-Up,
Enable-Down: Ena/Disables
the ramp.
Analogue output changing
Up/Down 0 2 4 within 2 limits (by defined rate
of change - ramp) when
Up/Down input is active.
Binary input Ena / Disables
jump over the selected
number of the next following
Jump 0 0 4 PLC blocks.
Jumps to the last one when
number of blocks is

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higher than existing. Jump size
is fix, adjustable
during the configuration
procedure only.

Analogue output (internal


register) can be Increased /
Decreased by one with rising
edge of binary input
Inc / Dec in range from 0 to
adjustable limit
(max 65535).
Register is Inc / Decreased
over zero when "Cycle"
option is ticked.
Register stops on 0 even other
Dec pulses come
(or on Max for Inc pulses)
Increment/Decrement 0 0 2 when "Cycle" option is
not ticked.
Example of "Cycle" when Max
= 5:
1-2-3-4-5-0-1-... or ...4-3-2-1-0-
5-4- ...
Example of "No-Cycle" when
Max = 5:
1-2-3-4-5-5-5-... or ...4-3-2-1-0-
0-0- ...
Binary input "Reset" switch the
Analogue output to
adjustable Default value.

Table (conversion) can contain


up to 30 items. Input
Multiplexer constant 0 0 4 can be connected to (above)
Inc/Dec function.

Selected part of Analogue input


can be decomposed
Decomposer 0 0 4 (decoded) to four binary
outputs.

Converts any "Short" and


"Long" analogue value format
to (signed) Integer format
compatible with all PLC
Convert 0 0 4 analogue inputs. The invalid
Analogue output is indicated
(####) when Analogue input
value is out of Integer
range.
* Note: For detailed PLC functions description see IGS-NT-2.1-Application guide.pdf

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Abbreviation list
AMF Auto Mains Failure (controller starts automatically on mains failure)
AI Analogue Input
AO Analogue Output
ATS Automatic Transfer Switch (switches the load to actually supplied bus (by mains or generators))
AVR Automatic Voltage Regulator
BI Binary Input
BO Binary Output
BOC Breaker Open & Cool-down - protection type (see application manual for details)
BTB Bus-Tie Breaker
CAN1 CAN bus for extension modules connection (e.g. IGS-PTM, IS-BIN8/16, IS-AIN8, I-AOUT8, I-
CB, IGL-RA15)
CAN2 CAN bus for intercontroller communication (in multiple applications) and monitoring (connection
of I-LB, IG-IB)
COX Application for Complex Systems where actions are taken by a PLC and the controller only
follows the orders => needs an external driver (cox)
ESF Engine Specific File
FMI Failure Mode Identifier
GC Graphical Characters - option for additional support of one "graphical" language
GCB Generator Circuit Breaker
CHP Combined Heat & Power - cogeneration application, usually with gas engine
I-AOUT8 Extension module with 8 AO
I-CB Communication Bridge - interfaces IS, IG/IS-NT, ID controllers and non-standard engine ECU
IG-AVRi IG Automatic Voltage Regulator interface
IG-EE InteliGen for Electronic Engines (HW optimized for connection to an engine equipped with
ECU)
IG-EEC InteliGen EE controller with extended communication possibilities + switchable sensing ranges
of AC voltages and currents
IG-IB IG Internet Bridge - for internet/ethernet communication
IGL-RA15 Indication panel with LEDs signalizing state of 15 BO
IG-NT InteliGen New Technology gen-set controller
IG-NTC InteliGen NT controller with extended communication possibilities + switchable sensing ranges
of AC voltages and currents
IGS-NT-
LSM+PMS Dongle for IG-XX and IS-NT to enable Load Sharing control loops and PMS
IGS-PTM Extension module with 8 BI/BO, 4 AI and 1 AO
I-LB Local Bridge for direct and modem monitoring and control of multiple gen-sets
IM-NT InteliMains New Technology - Mains supervision controller; the same controller in a different
SW configuration can work as a bus-tie synchronizer
I-RB Relay Board
IS-AIN8 Extension module with 8 AI.
IS-BIN8/16 Extension module with 8 BO and 16 BI.
IS-NT InteliSys New technology gen-set controller
IS-NT-BB InteliSys New Technology Basic Box (without display)
KWP2000 Key Word Protocol of Scania S6 unit (for engine diagnostics)
LS Load Sharing - analogue load sharing line to interconnect the gen-sets on the site (for isolated
parallel or mains parallel of multiple gen-sets); IG/IS-NT controllers use digital Load Sharing via

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CAN2 bus
LSM Load Sharing Module
LT Option for Low Temperature modification (display equipped with heating foil)
MCB Mains Circuit Breaker
MGCB Master Generator Circuit Breaker (sometimes used with multiple gen-sets in island parallel or
mains parallel operation)
MINT Multiple application with INTernal control loops - for multiple gen-sets in island parallel or mains
parallel operation; Load Sharing and VAr Sharing controlled internally; PMS available
MP Mains protection
NPU Mains protection relay (voltage, frequency, vector shift protections)
OC Occurrence Count (number of fault occurrances transmitted in diagnostic frame from ECU)
OfL Off load - protection type (see application manual for details)
PGN Parameter Group Number (refer to SAE J1939-71)
PMS Power Management System - ensures optimization of running gen-sets on the site with multiple
gen-sets; based on kW/kVA spinning reserve or on relative (%) load; no-master system
ensures high reliability
SHAIN Shared (virtual) Analogue INput module
SHAOUT Shared (virtual) Analogue OUTput module
SHBIN SHared (virtual) Binary INput module
SHBOUT SHared (virtual) Binary OUTput module
SPI Single Parallel Island application - for single gen-sets in parallel with mains or in island
operation; suitable for CHP application; no MCB control
SPM Single Prime Mover application - for single gen-sets without mains
SPN Suspect Parameter Number (refer to SAE J1939-71)
SPtM Single Parallel to Mains application - for single gen-sets in parallel with mains or in island
operation, with AMF support; both MCB and GCB controlled
SSB Single Stand-By application - for single gen-sets with mains and break transfer gen-set to
mains
VPIO Virtual periphery I/O module internal SW wires linking binary outputs to inputs
VS VAr Sharing - ensures VAr sharing between the gen-sets on the site via CAN bus (for isolated
parallel or mains parallel of multiple gen-sets)

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