COMAP IGS NT 2.2 Installation Guide

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

Inteli New Technology Modular Gen-set Controller IG-EE, IG-EEC, IG-NT, IG-NTC, IS-NT, IM-NT Software version IGS-NT-2.2, IM-NT-2.3, December 2007

INSTALLATION GUIDE

Copyright © 2005 ComAp s.r.o. ComAp, spol. s r.o. Světova 7, 180 00 Praha 8, Czech Republic Tel: +420 266 790 611, Fax: +420 266 316 647 E-mail: [email protected], www.comap.cz

Table of Contents Table of Contents .............................................................................................................................................. 2 General guidelines............................................................................................................................................. 4 What is described in this manual? ................................................................................................................ 4 WARNING ..................................................................................................................................................... 4 Dangerous voltage ........................................................................................................................................ 4 Adjust set points............................................................................................................................................ 4 Conformity declaration .................................................................................................................................. 5 Symbols......................................................................................................................................................... 5 Text ............................................................................................................................................................... 5 Required and optional modules .................................................................................................................... 6 Terminals and dimensions................................................................................................................................. 8 IS-BIN16/8................................................................................................................................................... 11 IS-AIN8........................................................................................................................................................ 12 IGL-RA15 Remote annunciator................................................................................................................... 12 IGS-PTM ..................................................................................................................................................... 13 IG-IB Internet bridge.................................................................................................................................... 14 I-LB Local Bridge......................................................................................................................................... 15 I-CB Communication Bridge....................................................................................................................... 16 I-RB16, I-RB16/231 relay board.................................................................................................................. 16 I-CR CAN repeater...................................................................................................................................... 17 I-AOUT8 ...................................................................................................................................................... 18 I-LBA ........................................................................................................................................................... 20 Front panels ................................................................................................................................................ 20 Recommended wiring...................................................................................................................................... 25 IG-EE........................................................................................................................................................... 25 IG-EEC ........................................................................................................................................................ 27 IG-NT........................................................................................................................................................... 29 IG-NTC ........................................................................................................................................................ 31 IS-NT-BB ..................................................................................................................................................... 33 IM-NT .......................................................................................................................................................... 35 Recommended wiring IG-NT – SPTM application ...................................................................................... 37 Recommended wiring IG-NT – SPI application .......................................................................................... 38 Recommended wiring IG-NT – MINT application ....................................................................................... 39 IS-DISPLAY................................................................................................................................................. 40 Wiring .......................................................................................................................................................... 40 Voltage measurement ................................................................................................................................. 42 Current measurement ................................................................................................................................. 43 Single phase applications ........................................................................................................................... 45 Controller Binary inputs and outputs........................................................................................................... 47 Binary inputs on IS-BIN16/8........................................................................................................................ 49 Binary outputs on IS-BIN16/8...................................................................................................................... 49 IS-NT Jumpers ............................................................................................................................................ 50 Analog inputs wiring examples.................................................................................................................... 51 Analog inputs on IS-AIN8............................................................................................................................ 54 External modules connection ...................................................................................................................... 55 I-CB wiring and configuration ...................................................................................................................... 57 Recommended CAN/RS485 connection..................................................................................................... 58 Default sensors................................................................................................................................................ 60 Default characterisitics ................................................................................................................................ 60 Sensor fail (Fls) ........................................................................................................................................ 61 Speed governor interface list........................................................................................................................... 63 Electronic engines interface ........................................................................................................................ 63 Speed governor interface............................................................................................................................ 64 AVR interface list ............................................................................................................................................. 69 InteliGenNT, InteliSysNT, InteliMainsNT – Installation Guide, ©ComAp – December 2007 IGS-NT-2.2-Installation Guide.PDF

2

Technical data ................................................................................................................................................. 72 Power supply............................................................................................................................................... 72 Operating conditions ................................................................................................................................... 72 Dimensions and weight ............................................................................................................................... 72 Mains and generator ................................................................................................................................... 72 Binary inputs and outputs............................................................................................................................ 73 Analog inputs............................................................................................................................................... 73 D+ function .................................................................................................................................................. 74 Speed pick-up input .................................................................................................................................... 74 Communication interface ............................................................................................................................ 74 Analog outputs ............................................................................................................................................ 75 IG-AVRi ....................................................................................................................................................... 75 IGS-PTM ..................................................................................................................................................... 75 IS-AIN8........................................................................................................................................................ 76 I-AOUT8 ...................................................................................................................................................... 77 IS-BIN16/8................................................................................................................................................... 77 IGL-RA15 .................................................................................................................................................... 78 I-CB, I-CR.................................................................................................................................................... 78 I-LB.............................................................................................................................................................. 79 IG-IB ............................................................................................................................................................ 79 I-RBxx.......................................................................................................................................................... 79 IG-MTU........................................................................................................................................................ 79 IG-MTU-2-1 ................................................................................................................................................. 79

InteliGenNT, InteliSysNT, InteliMainsNT – Installation Guide, ©ComAp – December 2007 IGS-NT-2.2-Installation Guide.PDF

3

General guidelines What is described in this manual? IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTION

- This manual contains important instructions for IGS-NT controllers

family that shall be followed during installation and maintenance of the Inteli NT genset controllers. It is intended for use by Gen-set control panel builders and for everybody who is concerned with installation, operation and maintenance of the gen-set.

WARNING Remote control The controller can be remotely controlled. In the event that maintenance needs to be done to the gen-set, check the following to ensure that the engine cannot be started. To be sure: Disconnect remote control via RS232 or another communication line Disconnect input REMOTE START/STOP or Disconnect output STARTER and outputs GCB CLOSE/OPEN and MCB CLOSE/OPEN. Be aware the unqualified manipulation can disconnect the object from the power supply source. The controller contains a large number of configurable setpoints, because of this it is impossible to describe all applications. Controller functions are subject to change from SW version to SW version. This manual only describes the product and is not guaranteed to be set for your application on arrival.

!!! CAUTION !!! Dangerous voltage The terminals for voltage and current measurement should never be touched. Properly connect the grounding terminals. Do not disconnect the Controller CT terminals for any reason.

Adjust set points All parameters are djusted 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 !!!


4

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 to disconnect following 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 controller to MAN mode and disconnect the Binary outputs Starter and Fuel or press EMERGENCY STOP button to avoid unexpected automatic start of gen-set and GCB closing during any work or maintenance on the gen-set or switchboard.

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.

Symbols Symbols used in this manual: Grounding point symbol

AC voltage symbol

DC voltage symbol

Text PAGE

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

Break Return

(Italic) set points Set point group

Generator protections

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.


5

Required and optional modules Accessories

Description

Standard / Optional

IG-EE IG-EEC IG-NT IG-NTC IM-NT IS-NT-BB IG-Display IS-Display IG-AVRI IG-AVRi-TRANS/LV IG-AVRi-TRANS/100 AT LINK-CABLE 1,8m IS-AIN8 (V2.4) IS-BIN16/8 (V1.6) I-LB (V1.0) I-LB+

Controller Central Units with internal display

Standard

Controller Central Unit without internal display Additional display for IG-NT/NTC/EE/EEC, IM-NT Additional display for IS-NT-BB Controller AVR interface Voltage transformer for supplying AVRi module

Standard Optional Optional Optional Optional

RS232 (InteliMonitor, GenConfig) communication cable (It is not a part of controller delivery.) External analog inputs unit External binary I/O unit Inteli-Local Bridge Option w/o USB replaces IG-MU (RS232/RS485 communication speed increased to 57600 bps); option “+” with USB allows higher communication speed with multiple controllers to a local PC. Internet bridge

Optional

IG-IB (V2.1) I-CB/CAT-Gas I-CB/CAT-Diesel I-CB/MTU I-CB/MTU-SIAM4000 I-CB/DeutzTEMe IGL-RA15 (V1.6) IGS-PTM (V8.0) I-AOUT8 (V1.0) IG-MTU IG-MTU-2-1

Optional Optional Optional

Optional Optional

Inteli - Communication Bridge: Interface unit for some types of engines with ECU (without J1939) Remote annunciator External analog, binary I/O unit 8 analog outputs unit Voltage transformer unit to separate mains and generator voltage measurement Voltage transformer unit with voltage ratio 2:1 to separate mains and generator voltage measurement

Optional Optional Optional Optional Optional

Controller central unit contains complete hardware for all applications. Number of inputs and outputs can be expanded by additional modules IS-AIN8, IS-BIN16/8, IGS-PTM, IGL-RA15, I-AOUT8.

Dongle overview Dongle IGS-NT-LSM+PMS IGS-NT-miniCHP IGS-NT-LSM+PMSminiCHP

Function No dongle for Single parallel to mains is required. Dongle for multiple applications MINT with Load sharing, Var sharing and Power management function Enlarges the set of PLC functions for simple CHP applications (for IG-NT and IG-EE controller types) Combined dongle for Load sharing and Power management and PLC functions enlargement for simple CHP applications (for IG-NT and IG-EE controller types)

Available PC software Name

Function

GenConfig

Common IGS-NT family configuration (off-line) tool.


6

InteliMonitor Common IGS-NT family monitoring (on-line) tool. WinScope Graphic monitoring-recording tool. Hint: For more information about controllers and modules (number of I/O, communication ports, …) see IGS-NTx.y-Application guide.pdf.


7

Terminals and dimensions

123 (4,8“)

110 (4,3“)

IG-EE, IG-EEC, IG-NT, IG-NTC, IM-NT

USB

Cutout for IG-XX/IM-NT 113 x 175 mm 4,4 x 6,9”

68 2,7“

RS232

123 (4,8“)

170 (6,7")

185 (7,3")

110 (4,3“)

123 (4,8“)

IG-DISPLAY

185 (7,3") 170 (6,7")

Cutout for IG-DISPLAY 113 x 175 mm 4,4 x 6,9”


8

184 (72,44“)

176 (6,9“)

110 (4,3“)

IS-NT

USB

Cutout for IS-NT 178 x 282 7,0 x 11,1” 30 1,2“

170 (6,7") 30 68 1,2“ 2,7“

98 (3,9“)

~130 (5,1“)

RS232

280 (11")

290 (114,2")

184 (72,44“)

176 (6,9“)

IS-DISPLAY

30 1,2“

280 (11")

290 (114,2")

Cutout for IS-DISPLAY 178 x 282 7,0 x 11,1”


9

4x

o

3 35 (1,4") 2x M

90 (3,6")

3 4,

194 (7,6") 184 (7,3")

110 (4,3“)

IS-NT-BB

68 (2,7“)

194 (7,6")

USB

68 2,7“

123 (4,8“)

RS232

170 (6,7")

Hint: In the environment rich on vibrations it is not recommended to fix IS-NT-BB on the DIN rail but to screw it down on to the switchboard rear side.

OUT2 AC1 AC2

OUT1 OCOM

IG-AVRi + IG-AVRi TRANS Primary terminals 230-277 VAC / 400-480 VAC

0 - 230/277 - 400/480

IG-AVRi TRANS/LV

36 (1,4”)

AVRi +

AVRi -

LB 5

0 - 18

43 (1,7”)

43 (1,7”)

Secondary terminals 18 VAC

IG-AVRi unit is DIN rail mount (35mm) IG-AVRi TRANS are DIN rail mount (35mm)


10

IS-BIN16/8 146 (5,7")

45 (1,8")

RPM -

IN 2

RPM +

IN1 +

IN1 -

160 (6,3")

40 (1,6")

25 (1,0")

IS-BIN16/8 unit is DIN railmount (35mm)


11

IS-AIN8 46, 4 (18,3")

40 (15,7")

CAN1 L

H

iS- AIN8

COM

160 (63")

146(57,5")

POWER 8 - 36V DC

+

25 (9,8")

70 (27,5")

IS-AIN8 unit is DIN rail mount (35mm)

IGL-RA15 Remote annunciator Remote (CAN bus, up to 200 meters) 15 LED states indicator. IGL-RA15 unit can be connected to controller via CAN as Binary output group with addresses 1+2 or 3+4 or 5+6 or 7+8. To configure IGL-RA15 use GenConfig -> Modules -> Available modules, select IGL-RA15 module and add it using + button. GenConfig automatically adds IGL-RA15 binary outputs to the configuration. For more information about IGL-RA15 consult manual (IGL-RA15-1.2.pdf) and New features list (IGL-RA152.0-New features.pdf).


12

~ 25 (1,0”)

106 (4,2”)

120 (4,7”) 125 (4,9”)

54 (2,1”) 44 (1,7”)

165 (6,5”)

~ 35 (1,4”) 38 (1,5”) 40 (1,6”)

~ 75 (3,0”)

Cutout for Remote Annunciator

180 (7,1”) 185 (7,3”)

167 x 108 mm (6,6 x 4,3)”

IGS-PTM IGS-PTM is I/O extension module with 8 binary I/O, four analog inputs configurable for range: • 0 – 250 Ω (suitable for Pt100, Ni100, VDO pressure, VDO level), • 0 – 100 mV (suitable for thermocouples), • 0 – 20 mA. and one analog output configurable for range • 0 to 20 mA. Detail descriptions see in IGS-PTM-7.0.pdf manual. Hint: The 0-100 mV inputs are only suitable for thermocouples galvanically separated from the frame – “isolated” type. For non-isolated type thermocouples use IS-AIN8 module. The 0-250Ω input is not possible to use for Pt1000, Ni1000 and VDO Temp sensors due to measurement range < 250Ω. For operation with IGS-NT controller it is necessary to close IGS jumper.


13

0-20 mA ANALOG OUT

CAN H COM L

iGS-PTM

Tx

CAN

Rx

COMPENSATION

LB 4

POWER BO8

BO7

BO6

BO5

BO4

BO3

BO2

BINARY OUTPUTS BO1

96 mm (3,8´´)

ANALOG INPUTS

AO-

AO+

AI4

GND

BI8

BI7

BI6

BI5

BI4

BI3

BI2

BI1

BINARY INPUTS

8-36V DC

43 mm (1,7´´)

95 mm (3,7´´)

IGS-PTM unit is DIN rail (35mm) mounted.

96 mm (3,8´´)

IG-IB Internet bridge

95 mm (3,7´´)

43 mm (1,7´´)

See InteliCommunicationGuide for further information. It is recommended to use IG-IB firmware version 2.0. IG-IB unit is DIN 35 mm rail mounted.


14

I-LB Local Bridge I-LB is a successor of the IG-MU unit designed to be used with IG/IS-NT controllers. It therefore provides additional communication port and higher communication speed. Speed for direct/modem connection can be up to 57600 bps (IG-MU only 19200 bps).

120÷

120÷

There are two versions of I-LB: Name Description Dimensions and terminals without I-LB USB port RxC

RxD P7

TxD

96 mm (3,8´´)

TxC

P6

P5

P4

P3

P2

P1

D2

D1

43 mm (1,7´´)

95 mm (3,7´´)

RxC

RxD

120

P7

TxC

TxD

96 mm (3,8´´)

with USB port (speed ≈ 115200 bps)

120

I-LB+

Tx Rx

P6

P5

P4

P3

P2

P1

D2

D1

95 mm (3,7´´)

Indication LED: TxC, RxC TxD, RxD Tx, Rx RUN PWR

43 mm (1,7´´)

Indicates data transfer on the CAN line. Indicates data transfer on the RS232 line. Indicates data transfer on USB Lights when at least one other unit is active on the CAN bus. Blinks when no unit is communicated on the CAN bus (during communication speed detection). Lights All the time when power supply is switched on.


15

I-CB Communication Bridge

RS 232

96 mm (3,8´´)

COM

i-CB

LB 4

POWER 8-36V DC

95 mm (3,7´´)

43 mm (1,7´´)

I-CB (Communication bridge) is CAN bus interface between Controller and Engine Control Unit (ECU) that has not standard J1939 communication (MTU, CAT etc.). Engine values (RPM, Oil pressure and other) are received from ECU via CAN and corresponding sensors are not needed on controller. Use ICBEdit software for I-CB configuration (included in installation package).

I-RB16, I-RB16/231 relay board Relay board contains 16 relays for binary (open collector) output separation. All relays are placed in sockets. Number relays: 16 in socket Nominal voltage: 24 VDC Voltage range: 16,8 – 36 VDC Relay opens at: 10% of nominal voltage Electric / mechanic cycles: 100 000 (when switching 16A) / 10 000 000 Operating temperature range: - 40°C to 70°C Maximal load: 16A resistive load 4A inductive load Contacts protection: varistor 14DK390 Relay-connector connection: 1–2 1–3

n.o. n.c.

K 1

2

3

I-RB16/231 board contains relays that can switch 231 VAC load.

Mechanical dimension I-RB16 is 35 mm DIN rail mounted. One unit contains two parts (separate PCB) 8 relays each on common plastic base. I-RB16 is 60mm high from DIN rail base.


16

View A

300

1

X7

1

X6

1

X5

X4

1

1

X18 9

16

16

1

X2

1

X1

X17 8

+

X18

X3

95

X8

RE1

1

RE2

X9

1

RE3

X10

ER4

1

RE5

X11

RE6

1

RE7

X12

RE8

1

RE9

X13

RE10

1

RE11

X14

ER12

1

RE13

X15

RE14

1

RE15

X16

RE16

1

9

View B

+

1

X17

8

X18

+

1

+

X17 View B

3 X1 1

X1

3 X2 1

X2

3 X3 1

X3

3 X4 1

X4

3 X5 1

X5

3 X6 1

X6

3 X7 1

X7

3 X8 1

X8

3 X9 1

X9

3 X10 1

3 X11 1

3 X12 1

3 X13 1

3 X14 1

3 X15 1

X10

X11

X12

X13

X14

X15

3 X16 1

X16

View A

Hint: I-RB contains two separate boards, 8 relay each. It can be ordered as I-RB8 as well.

I-CR CAN repeater

96 mm (3,8´´)

I-CR module enables to extend CAN bus line of - extension modules CAN1 to more than 200 meters - intercontroller CAN2 to more than 200/900 meters (in 32C/8C mode) More application details see in separate manual “Extending the CAN bus”.

95 mm (3,7´´)

43 mm (1,7´´)


17

I-AOUT8 I-AOUT8 is a new extension unit with 8 analog outputs. Each analog output can be switched by jumper for. - 0 to 20 mA - 0 to 10 VDC - PWM (Pulse With Modulation on 1,2 kHz) I-AOUT8 module is connected on IGS-NT CAN1 (peripheral) bus. The corresponding module Address 1 to 4 (default 1) must be set on module (by Adr.1 and Adr.2 jumpers) and in controller configuration. Communication fail is indicated in controller Alarm list and by binary output. Use GenConfig PC tool for controller configuration. It is possible to connect up to four I-AOUT8 units to one controller. Unit is 35 mm DIN rail mounted. CAN1 terminating 120 ohm resistor jumper is connected in default. AGND terminals are on the same potential.

120 ohm p-I-U

p-I-U

p-I-U

p-I-U

CAN

ANALOG OUTPUTS

I-AOUT8 ComAp HW: SW:

Power supply

ANALOG OUTPUTS

U-I-p

U-I-p

U-I-p

U-I-p 1 2 Pwr

95 mm (3,7´)

43 mm (1,7´)

Functions Number of analog outputs Type of analog outputs (jumper selectable) Power supply Current consumption Communication interface RS232 interface Operating temperature range Analog outputs refreshment

U I p

8, no galvanic separation 0 to 10VDC ± 1% , max 5 mA 0 to 20 mA ± 1% , max 500 ohms pwm 1200 Hz, 5V level, max 10 mA 8 to 36 VDC 100 ÷ 300 mA at 24 VDC CAN1, with jumper selectable address 1 to 4 Jumper selectable terminating resistor 120 ohms. TTL, firmware upgrade via AT-link. -40°C to +70°C Max. 300 ms


18

CAN address jumper setting Up to four modules can be connected to one controller. Set module CAN address corresponding to configuration according table below. CAN Address Jumper 1 Jumper 2 1 No No 2 Yes No 3 No Yes 4 Yes Yes

Analog output hardware modification Follow the p-I-I-U symbols on the module sticker. There are two equivalent positions for mA measuring. AOUT jumper

Symbol

Function

p

Pwm Pulse-Width-Modulation

I

0 to 20 mA

U

0 to 10 VDC

LED indication Green LED is located near the power supply connector. I-AOUT8 module state LED Pwr No power supply Dark Memory fail Fast blink (100/100 ms) Communication fail Slow blink (300/300 ms) OK Continuous light

Wiring and jumper setting example Voltage output 0 to 10 VDC Current output 0 to 20 mA Current output 0 to 20 mA Pwm output

Pwm output 1200 Hz Current output 0 to 20 mA Current output 0 to 20 mA Voltage output 0 to 10 VDC

Hint: Extension module communication fail can be configured in GenConfig to No protection, Warning, Shutdown.


19

I-LBA For the connections with 12VDC power supply an I-LBA module can be connected to controller power terminals in order to allow the controller to continue operation during cranking if the battery voltage dip occurs. IG-CU

IS-CU

IL-CU

ID-DCU

YES

NO

YES

YES

OUT2 AC1 AC2

OUT1 OCOM

Controllers which may be supplied from I-LBA module: Controller IG-NT/ IG-NTC/ IS-BB IS-NT IG-EE IG-EEC Connection YES YES YES NO applicable

AVRi +

AVRi -

LB 5

Hint: The I-LBA unit is intended to supply one controller unit only at the same time. It is not recommended to use +PWR BOUT outputs on thecontroller as a source for relays, as their consumption would exhaust I-LBA capacitors very fast. It is also not recommended to supply any kind of above controllers with LT (Low Temperature) display because of the high current consumption of the LT display. See also chapter Power supply fusing.

Front panels InteliGen NT controller, IG-DISPLAY InteliGen controller types InteliGen – Remote Display Available for applications

IG-EE, IG-EEC, IG-NT, IG-NTC IG-DISPLAY SPI, SPTM, MINT, COX


20

InteliMains NT controller InteliMains controller types InteliMains – Remote Display Available for applications

IM-NT IG-DISPLAY MCB, MGCB

InteliSys NT controller, IS-DISPLAY InteliSys controller types InteliSys – Remote Display Available for applications

IS-NT IS-DISPLAY SPI, SPTM, MINT, COX


21

IG-DISPLAY wiring

P

IG- DISPLAY

RS485

A1 COMR1 B1

POWER

8-36 VDC

0 VDC BI: Alternative brightness 0 VDC 8-36 VDC

POWER

RS232

Wire length: up to 1000 meters

IG-DISPLAY

A1 A1 COMR1 COMR1 B1 B1

IG-NT

IS-DIS

IG-NT

GenConfig InteliMonitor MODEM/ GSM


22

IS-DISPLAY wiring IS-NT

IS-DISPLAY

A1 COMR1 B1

RS485

IS-NT-BB


IS-DISP

A1 COMR1 B1

0 VDC 8-36 VDC

IS-DISPLAY

0 VDC BI : Alternative brightness

POWER

8-36 VDC

POWER

IS-DISPLAY

POWER

IS-NT-BB

A1 COMR1 B1

IS-DISPLAY

IS-NT-BB

P

A1 COMR 1 B1

USB

RS232

USB

A1 A1 COMR1 COMR1 B1 B1

0 VDC BI:Alternative brightness 8-36 VDC

POWER

0 VDC

IS-DISPLAY

8-36 VDC

POWER

IS-NT-BB

IS-DIS


IS-NT-BB

RS485

GenConfig InteliMonitor

MODEM/ GSM


23

IS-NT- BB

IS- DISPLAY RS485

A1 COMR1 B1

USB

RS232

USB

A1 COMR1 B1

IS-DISPLAY

0 VDC BI:Alternative brightness 8-36 VDC

IS-DISPLAY

0 VDC

POWER IS-DISPLAY

8-36 VDC

POWER

IS-NT-BB

IS-DISP


GenConfig InteliMonitor MODEM/ GSM

Hint: The state of BI Alternative brightness only influences the particular display. IS-NT-BB unit doesn’t include internal display. For IG/IS-NT hardware options consult IGS-NT-x.yApplication guide.pdf.


24

Recommended wiring IG-EE Basic module for Electronic engines

Side label Side connectors Back connectors 120 Ω Jumper RS485 bias resistor jumpers

BOOT jumper (with long holder)


25

Interface Function Generator voltage

Terminals L1,L2,L3, (N)

Mains/Bus voltage

L1,L2,L3, (N)

Generator current L1k,L1l, L2k,L2l, L3k,L3l Neutral/Mains current LNk,LNl IG-AVRi interface AVRI-OUT, AVRI-COM Power supply +,D+ Inputs and output Binary inputs BI1 to BI6 Binary outputs BO1 to BO6 Analog inputs None Analog outputs None RPM None Communication interface RS232 (1) D SUB9 (male) RS232 (2) RS485 (1) **

None A1,B1,COMR1

RS485 (2) USB CAN1

None None L1,H1,COMC1

CAN2

L2,H2,CONC2

Note 3x277 / 480 VAC (neutral not needed), max 350 / 600VAC * 3x277 / 480 VAC (neutral not needed), max 350 / 600VAC 0 ÷ 5 Amps, max 10 A all time, 150 A for 2 sec 0 ÷ 5 Amps, max 10 A all time, 150 A for 2 sec TTL (5V PWM) interface to IG-AVRi 8 ÷ 36 VDC D plus Activation to minus power supply. Load is connected to plus power supply.

PC: InteliMonitor, GenConfig or Modem, GSM modem or ECU (e.g. Cummins ModBus) IG-Display (Remote display) or for PC (via RS485 converter) = redirected RS232 (1) see Basic settings: RS485(1)conv. Extension modules: IS-AIN, IS-BIN,IGS-PTM, IGLRA15, I-AOUT Intercontroller (Load&VAR sharing, Power management) and monitoring (IG-IB, I-LB)

Hint: * IG-MTU or IG-MTU-2-1 can be used for three wire systems, systems with separated Neutral or when galvanic separation between generator or mains voltage and controller is required. ** When more devices connected to RS485 bias resistor jumpers should be closed only on one of them.


26

IG-EEC InteliGen – Basic module for Electronic Engines - option C

Boot JUMPER (with long holder) RS485 bias resistor jumpers

USB

120 Ω Jumper


27



Mains/Bus voltage

L1,L2,L3, (N)

Generator current

L1k,L1l, L2k,L2l, L3k,L3l

Neutral/Mains current

LNk,LNl

IG-AVRi interface AVRI-OUT, AVRI-COM Power supply +,D+ Inputs and outputs Binary inputs BI1 to BI6 Binary outputs BO1 to BO6 Analog inputs None Analog outputs None RPM None Communication interface RS232 (1) D SUB9 (male) RS232 (2)

D SUB9 (male)

RS485 (1) **

A1,B1,COMR1

RS485 (2) **

A2,B2,COMR2

USB CAN1

2.0 slave L1,H1,COMC1

CAN2

L2,H2,CONC2

Note 3x120 / 277 Ph-N or 208 / 480 Ph-Ph VAC (neutral not needed), max 350 / 600VAC * 3x120 / 277 Ph-N or 208 / 480 Ph-Ph VAC (neutral not needed), max 350 / 600VAC 0 ÷ 5 Amps, max 10 A all time, 150 A for 2 sec 0 ÷ 1 Amp, max 2 Amps all time 0 ÷ 5 Amps, max 10 A all time, 150 A for 2 sec 0 ÷ 1 Amp, max 2 Amps all time TTL (5V PWM) interface to IG-AVRi 8 ÷ 36 VDC D plus Activation to minus power supply. Load is connected to plus power supply.

PC: InteliMonitor, GenConfig or Modem, GSM modem or ECU (e.g. Cummins ModBus) PC: InteliMonitor, GenConfig or Modem, GSM modem IG-Display (Remote display) or for PC (via RS485 converter) = redirected RS232 (1) see Basic settings: RS485(1)conv. Redirected RS232 (2) - see Basic settings: RS485(2)conv. PC: InteliMonitor, GenConfig or Modem, GSM modem PC: InteliMonitor Extension modules: IS-AIN, IS-BIN,IGS-PTM, IGLRA15, I-AOUT Intercontroller (Load&VAR sharing, Power management) and monitoring (IG-IB, I-LB)



28

IG-NT InteliGen – New Technology


29



Mains/Bus voltage

L1,L2,L3, (N)

Generator current Neutral/Mains current IG-AVRi interface Power supply D+ Inputs and outputs Binary inputs

L1k,L1l, L2k,L2l, L3k,L3l LNk,LNl AVRI-OUT, AVRI-COM +,-

Binary outputs Analog inputs Analog outputs

BI1 ÷ BI6 BI7 ÷ BI12 BO1 ÷ BO6 BO7 ÷ BO12 AI1 ÷ AI3 SG-OUT, SG-COM

RPM RPM-IN, RPM-COM Communication interface RS232 (1) D SUB9 (male) RS232 (2) RS485 (1) **

None A1,B1,COMR1

RS485 (2) CAN1

None L1,H1,COMC1

CAN2

L2,H2,CONC2

Note 3x 277 Ph-N or 480 Ph-Ph VAC (neutral not needed), max 350 / 600VAC * 3x 277 Ph-N or 480 Ph-Ph VAC (neutral not needed), max 350 / 600VAC 0 ÷ 5 Amps, max 10 A all time, 150 A for 2 sec 0 ÷ 5 Amps, max 10 A all time, 150 A for 2 sec TTL (5V PWM) interface to IG-AVRi 8 ÷ 36 VDC D plus Activation to minus power supply. Load is connected to plus power supply. Ohms, mA, Volts sensors Speed governor output interface (±10V / 5V PWM; 500 – 3000Hz) Min 2 Vpk-pk (from 4 Hz to 4 kHz) PC: InteliMonitor, GenConfig or Modem, GSM modem or ECU (e.g. Cummins ModBus) IG-Display (Remote display) or for PC (via RS485 converter) = redirected RS232 (1) see Basic settings: RS485(1)conv. Extension modules: IS-AIN, IS-BIN,IGS-PTM, IGL-RA15, I-AOUT Intercontroller (Load&VAR sharing, Power management) and monitoring (IG-IB, I-LB)



30

IG-NTC

USB

InteliGen – New Technology – Option C


31



Mains/Bus voltage

L1,L2,L3, (N)

Generator current



LNk,LNl

IG-AVRi interface Power supply D+ Inputs and outputs Binary inputs

AVRI-OUT, AVRI-COM +,-


BI1 ÷ BI6 BI7 ÷ BI12 BO1 ÷ BO6 BO7 ÷ BO12 AI1 ÷ AI3 SG-OUT, SG-COM

RPM RPM-IN, RPM-COM Communication interface RS232 (1) D SUB9 (male) RS232 (2)

D SUB9 (male)

RS485 (1) ** non isolated

A1,B1,COMR1

RS485 (2) ** isolated

A2,B2,COMR2

USB CAN1


CAN2

L2,H2,CONC2

Note 3x120 / 277 Ph-N or 208 / 480 Ph-Ph VAC (neutral not needed), max 350 / 600VAC * 3x120 / 277 Ph-N or 208 / 480 Ph-Ph VAC (neutral not needed), max 350 / 600VAC 0 ÷ 5 Amps, max 10 A all time, 150 A for 2 sec 0 ÷ 1 Amp, max 2 Amps all time 0 ÷ 5 Amps, max 10 A all time, 150 A for 2 sec 0 ÷ 1 Amp, max 2 Amps all time TTL (5V PWM) interface to IG-AVRi 8 ÷ 36 VDC D plus Activation to minus power supply. Load is connected to plus power supply. Ohms, mA, Volts sensors Speed governor output interface (±10V / 5V PWM; 500 – 3000Hz) Min 2 Vpk-pk (from 4 Hz to 4 kHz) PC: InteliMonitor, GenConfig or Modem, GSM modem or ECU (e.g. Cummins ModBus) PC: InteliMonitor, GenConfig or Modem, GSM modem IG-Display (Remote display) or for PC (via RS485 converter) = redirected RS232 (1) see Basic settings: RS485(1)conv. Redirected RS232 (2) - see Basic settings: RS485(2)conv. PC: InteliMonitor, GenConfig or Modem, GSM modem PC: InteliMonitor, GenConfig Extension modules: IS-AIN, IS-BIN,IGS-PTM, IGLRA15, I-AOUT Intercontroller (Load&VAR sharing, Power management) and monitoring (IG-IB, I-LB)



32

IS-NT-BB InteliSys – New Technology – Base Box


33



Mains/Bus voltage

L1,L2,L3, (N)

Generator current



LNk,LNl

IG-AVRi interface Power supply D+ Inputs and outputs Binary inputs

AVRI-OUT, AVRI-COM +,-


BI1 ÷ BI6 BI7 ÷ BI16 BO1 ÷ BO6 BO7 ÷ BO16 AI1 ÷ AI4 SG-OUT, SG-COM AOUT+, AOUT-COM

RPM RPM-IN, RPM-COM Communication interface RS232 (1) D SUB9 (male) RS232 (2)

D SUB9 (male)

RS485 (1) **

A1,B1,COMR1

RS485 (2) **

A2,B2,COMR2

USB CAN1


CAN2

L2,H2,CONC2

Note 3x120 / 277 Ph-N or 208 / 480 Ph-Ph VAC (neutral not needed), max 350 / 600VAC * 3x120 / 277 Ph-N or 208 / 480 Ph-Ph VAC (neutral not needed), max 350 / 600VAC 0 ÷ 5 Amps, max 10 A all time, 150 A for 2 sec 0 ÷ 1 Amp, max 2 Amps all time 0 ÷ 5 Amps, max 10 A all time, 150 A for 2 sec 0 ÷ 1 Amp, max 2 Amps all time TTL (5V PWM) interface to IG-AVRi 8 ÷ 36 VDC D plus Activation to minus power supply. Load is connected to plus power supply. Ohms, mA, Volts sensors Speed governor output interface (±10V / 5V PWM; 500 – 3000Hz) Configurable analog output, mA, V. Min 2 Vpk-pk (from 4 Hz to 4 kHz) PC: InteliMonitor, GenConfig or Modem, GSM modem or ECU (e.g. Cummins ModBus) PC: InteliMonitor, GenConfig or Modem, GSM modem IS-Display (Remote display) Redirected RS232 (2) - see Basic settings: RS485(2)conv. PC: InteliMonitor, GenConfig or Modem, GSM modem PC: InteliMonitor, GenConfig Extension modules: IS-AIN, IS-BIN,IGS-PTM, IGLRA15, I-AOUT Intercontroller (Load&VAR sharing, Power management) and monitoring (IG-IB, I-LB)



34

IM-NT InteliMains – New Technology


35

Interface Function Mains voltage


Bus voltage

L1,L2,L3, (N)

Mains current


Aux current

IAk,IAl

Power supply +,Inputs and outputs Binary inputs BI1 ÷ BI6 Binary outputs BO1 ÷ BO6 Communication interface RS232 (1) D SUB9 (male) RS232(2) RS485 (1) ** non isolated

None A1,B1,COMR1

RS485 (2) USB CAN1

None None L1,H1,COMC1

CAN2

L2,H2,CONC2

Note 3x120 / 277 Ph-N or 208 / 480 Ph-Ph VAC (neutral not needed), max 350 / 600VAC 3x120 / 277 Ph-N or 208 / 480 Ph-Ph VAC (neutral not needed), max 350 / 600VAC 0 ÷ 5 Amps, max 10 A all time, 150 A for 2 sec 0 ÷ 1 Amp, max 2 Amps all time 0 ÷ 5 Amps, max 10 A all time, 150 A for 2 sec 0 ÷ 1 Amp, max 2 Amps all time 8 ÷ 36 VDC Activation to minus power supply. Load is connected to plus power supply. PC: InteliMonitor, GenConfig or Modem, GSM modem or ECU (e.g. Cummins ModBus) IG-Display (Remote display) for PC (via RS485 converter) = redirected RS232 (1) see Basic settings: RS485(1)conv. Extension modules: IS-AIN8, IS-BIN16/8,IGS-PTM, IGL-RA15, I-AOUT8 Intercontroller (Load&VAR sharing, Power management) and monitoring (IG-IB, I-LB)

Hint: ** When more devices connected to RS485 bias resistor jumpers should be closed only on one of them.


36

Recommended wiring IG-NT – SPTM application


37

Recommended wiring IG-NT – SPI application


38

Recommended wiring IG-NT – MINT application


39

IS-DISPLAY

Wiring General Tightening torque, allowable wire size and type, for the Field-Wiring Terminals: For Mains(Bus) Voltage and Generator Voltage terminals Specified tightening torque is 0,56Nm (5,0 In-lb) Use only diameter 2,0-0,5mm (12-24AWG) conductor, rated for 90°C minimum. For other controller field wiring terminals Specified tightening torque 0,79Nm (7,0 In-lb) Use only diameter 2,0-0,5mm (12-26AWG) conductor, rated for 75°C minimum. Use copper conductors only. To ensure proper function: Use grounding terminals. Cables for binary inputs and analogue inputs must not be placed along power cables. Analog and binary inputs should use shielded cables, especially when length exceeds 3m.

Power supply To ensure proper function: Use power supply cable min. 2,5mm2 Use fuse 1 amps for IG-EE, IG-EEC, IG-NT, IG-NTC 2 amps for IS-NT Maximal continuous DC power supply voltage is 36VDC. See chapter Technical data. Hint: Switchboard lightning strikes protection according standard regulation is expected !!! The maximum allowable current through the controller negative terminal is 3 to 8A (depends on controller type and binary output load). InteliGenNT, InteliSysNT, InteliMainsNT – Installation Guide, ©ComAp – December 2007 IGS-NT-2.2-Installation Guide.PDF

40

Power supply fusing A (2) respectively (1) amp fuse should be connected in-line with the power to the controller and modules, these items should never bee connected directly to the starting battery. Take care for proper controller, extension units and relays power supply fusing. Fuse value and type depends on number of connected devices and wire length. Recommended fuse (not fast) types:

Controller or unit Controller IS-AIN8 IS-BIN16/8

Fuse T1A orT2A T2A T1A

For more extension units use separate fusing according to the table above. Controller power supply should never be connected to starter terminals. For the connections with 12VDC power supply an I-LBA module can be connected to controller power terminals in order to allow the controller to continue operation during cranking if the battery voltage dip occurs. In this case, it is not recommended to use +PWR BOUT outputs on the controller as a source for relays, as their consumption would exhaust I-LBA capacitors very fast. Relays

controller + -

I-LBA

T2A

+

+

-

-

+ 12VDC Battery

Grounding To ensure proper function: The shortest possible piece of wire should be used for controller grounding. Use cable min. 2,5mm2 Brass M4x10 screw with star washer securing ring type grounding terminal shall be used. InteliGenNT, InteliSysNT, InteliMainsNT – Installation Guide, ©ComAp – December 2007 IGS-NT-2.2-Installation Guide.PDF

41

The negative battery terminal has to be properly grounded.

Magnetic pick-up To ensure proper function: Use a shielded cable Take care to interference signal when one common speed pick-up is used for both Speed governor and Controller. When some problems occur: - check grounding connection from pick-up to controllers, disconnect ground connection to one of them. - galvanically separate Controller RPM input using ComAp separation transformer RPM-ISO (1:1). - use separate pick-up for Speed governor and Controller. Controller indicates "Sd Underspeed" + "Pickup fault" after engine start when the pickup signal is good for start and low speed but too strong for higher speed (loss of signal due to RPM input saturation). Increase gap between pickup and engine flywheel or change pickup type.

Hint: If RPM is measured from the generator voltage (Gear teeth = 0), controller can detect RPM on no running gen-set when: • Controller generator voltage terminals are opened (e.g. due to opening of fuse switch) • Non zero RPM causes controller “Not ready” state and engine start is blocked. LOAD MAINS

MCB

GCB

GENERATOR L1 L2 L3

N

N

N L1 L2 L3

N L1 L2 L3

L1 L2 L3

MAINS VOLTAGE

GENERATOR VOLTAGE

Voltage measurement Four-wire generator and mains or bus

Four-wire generator and three wire mains or bus L1

G

L2 L3 N

N L1 L2 L3 GENERATOR

N L1 L2 MAINS / BUS

L3

Three-wire generator and mains or bus L1

G

L2 L3

N L1 L2 L3 G ENERATOR

N L1 L2 MAINS / BUS

L3


42

Hint: No separation transformers for three wires voltage connection (without N) are needed. Switchboard flash protection according standard regulation is expected! MAINS/ BUS GENERATOR

L1 L2 L3

Principle of two transformers measuring - typical wiring for high voltage application spare of one transformer.

100V

L3

L1

L2

0V

100V

0V

T2

T1

VOLTAGE TERMINALS

Voltage measurement separation For optional separation of Mains/bus and generator voltage from the controller (e.g. on ships) use IG-MTU.

IG MTU Connect one or two IG-MTU units to separate generator and Mains/bus voltage from controller. Three wire mains and three wire genset or electric separation

Ix-NT

0V

0V

L3

L2

L1

N

N

L3

IG- MTU

L2

L1

L3

L2

N

L1

N

L3

GENERATOR VOLTAGE

MAINS / BUS VOLTAGE

0V

400V

0V

400V

400V

0V

T3

IG- MTU L2

L1 L2 L3

400V

400V

400V

0V

400V

0V

T2

T1 0V

400V

T3 0V

400V

T2 0V

400V

400V

GENERATOR

0V

0V

0V

400V

T1

T3

IG- MTU L1

MAINS/ BUS

L1 L2 L3

0V

400V

0V

400V 400V

400V

0V

T2 0V

400V

T1

L1 L2 L3 N

0V

GENERATOR

MAINS / BUS

L1 L2 L3

400V

Three wire mains

GENERATOR

MAINS/ BUS VOLTAGE

VOLTAGE

Ix- NT

Current measurement To ensure proper function: • Use cables of 2,5 mm2 • Use 5A transformers • Connect CT according to following drawings


43

K k

G

L l

I1 k I1 l

K k

I1k I1l

K k

I2 k I2 l

K L k l

G

L1

L l

k

L1

K L k l

Two CT connection

L2 L3

Typical wiring for middle-high voltage application spare of one transformer.

I3k I3l

I2k I2l

l

Standard three CT connection

I3 k I3 l

Mains power and PF measuring K L k l K L

G

L2 L L3 l N

L1 L2 L3

K L k l

L l

K k

N

I1k I1l I2k I2l I3k I3l

Inl Ink MAINS

GENERATOR

Earth fault protection Earth fault current protection is active only when Process control: IE measurement = ANALOG INPUT or NONE. Connect separate current transformer to gen-set neutral. Adjust EarthFltCurrCT in Basic settings and EarthFaultCurr and EthFltCurr del limits in Generator protection group. K k

K k

L l

L1 K k

L2 L L3 l N

The simplest arrangement covers all zones from the generator windings to the final circuits in the load network.

L l

K k

G

L l

In k In l I1 k I1 l I2 k I2 l I3 k I3 l


44

L1

G

k

l

L2

k

l

L3

k

l

k

l

This arrangement covers earth faults in the load network only.

N

In k In l L

k

l

L2

k

l

L3

k

l

k

l

L1

N

This arrangement necessary for restricted earth fault protection. The location of the neutral earthing point in relation to the protection current transformers in the neutral conductor determines whether four or five current transformers are employed.

L l

K k

G

K

In k In l

L1

G

k

l

L2

k

l

L3

k

l

k

l

N

This arrangement necessary for restricted earth fault protection. The location of the neutral earthing point in relation to the protection current transformers in the neutral conductor determines whether four or five current transformers are employed.

In k In l

Single phase applications There is no special archive file or software for single phase applications. Use standard archive.

Recommended wiring 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. Adjust setpoint Gener protect:Gen I unbal to 200%. For single phase measurement of Mains import/export power connect L3 current transformer to Ink and Inl terminals of the controller. Measured power is internally multiplied by 3. Adjust correctly setpoints Basic settings:Im3/ErFlCurCTp and Im3/ErFlCurCTs.


45

N

L1

L1

N

L1

Mains L3


46

Controller Binary inputs and outputs Binary output via I-RB16

Wiring example 1


47

Wiring example 2

Wiring example 3

Hint: If +PWR BOUT are used, the controller consumption is increased by all relays connected. Therefore, an ILBA module cannot be used. Use maximum 2,5A fuses. Wiring of I/O is the same for IM-NT


48

Binary inputs on IS-BIN16/8 There are two groups of eight Binary inputs BI1 to BI8 and BI9 to BI16. Each group has a separate Common terminal COM1 and COM2. The Common terminal can be connected to positive or negative pole – see following drawing. Binary inputs are galvanically separated from IS-BIN16/8 power supply. A Binary inputs Common terminal is connected to positive supply terminal, Binary inputs contacts are closed to negative supply terminals. BI 1 ( BI 9) BI 2 ( BI 10) BI 3 ( BI 11)

BI 1 ( BI 9) BI 2 ( BI 10) BI 3 ( BI 11)

BI 8 ( BI 16) COM 1 ( COM2) POWER POWER +

Binary inputs common terminal is connected to negative supply terminal, Binary inputs contacts are closed to positive supply terminals.

BI 8 ( BI 16) + 8 - 36 V

COM 1 ( COM2) POWER + POWER -

+ 8 - 36 V

Input voltage range for opened contact is from 8 VDC to Power supply VDC. Input voltage range for closed contact is from 0 to 2 VDC. Voltage level is defined between Binary input and Binary input COM terminal and does not depend on “positive” or “negative” connection. Impulse inputs do not work with IGS-NT controller.

Binary outputs on IS-BIN16/8

IS-BIN 16/8

IS-BIN16/8 binary outputs are galvanically separated from IS-BIN16/8 power supply. It is necessary to connect plus 24 VDC (power supply ) to IS-BIN16/8 terminal according to following drawing. The maximum load values are 0.5 A / 36V for one output.

Binary output protections Controller inputs and outputs terminals are protected against transient disturbance. Protection capability is limited. Never use DC relays without protection diodes. Use protection diodes at all relays in the switchboard even if they are not connected directly to controller Binary outputs.


49

Example of controller protection

IS-NT Jumpers Controller hardware jumpers: Function Jumper options Analog inputs Current Voltage Resistance Speed governor output ± 10VDC voltage output (use SpdGovPWM rate = 1200 Hz) ± 10VDC voltage output via 10 kΩ resistor (use SpdGovPWM rate = 1200 Hz) PWM 500 – 3000Hz (SpdGovPWM rate setpoint) Analog output 0 to 20 mA 0 to 10 VDC CAN or RS485 Closed jumper connects 120Ω resistor to terminating resistors CAN1, CAN2, RS485-1, RS485-2

Software configuration Required Not needed

Not needed Not needed

Analog input jumpers

Current range: 0 to 25 mA (max) Voltage range: 0 to 5 VDC (max) Resistive range: 0 to 2400 Ω


50

Speed governor output jumper PWM

SG OUT SG COM

Pulse Width Modulation 1200 Hz / 5V / 10mA max V-outR range: ± 10 VDC via 10 kΩ

VoutR

Vout

SG OUT SG COM

V-out range: ± 10 VDC

SG OUT SG COM

SG COM is internally connected to controller 0VDC power supply.

Analog output jumper

Voltage range: 0 to 10 VDC Current range: 0 to 20 mA

AOUT COM is internally connected to controller 0 VDC power supply.

Analog inputs wiring examples Resistive sensors (two wires)


51

Resistive sensors (one wire)


52

Current sensors

Current and resistive sensors

Voltage and resistive sensors


53

Analog inputs on IS-AIN8 IS-AIN8 extension module analog inputs can be configured to • Resistor two wire input • Resistor three wire input • Current input • Thermocouple input • Voltage input Select sensor characteristic from the list or define user sensor characteristic in PC configuration tool.

Resistor sensor input – two wire connection. Range 0 to 2400 ohms. Pt100, Pt1000, Ni100, Ni1000 D terminal is shielding

A B C D

Resistor sensor input – three wire connection. Range 0 to 2400 ohms. Pt100, Pt1000, Ni100, Ni1000 – recomended. D terminal is shielding

A B C D

Passive current sensor (current source is in IS-AIN8) Range 0 to + 20 mA or 4 to + 20 mA

A B C D

A B C D

D terminal is shielding

+

mA

+24 VDC Sensor 0 VDC

Active current sensor (current source is in sensor) Range –20mA to +20 mA or 4 to + 20 mA D terminal is shielding

+24 VDC A B C D

A

+

B C D

Sensor 0 VDC

+

B C D

A

mA

Thermocouple J, K, L D terminal is shielding From IS-AIN8 hardware version 5.1 can be B terminal grounded to frame

+

Voltage input Range 0 to + 2500 mV. Voltage range is 0 to ± 1000 mV. D terminal is shielding


54

R1

A B C D

+

R2

For 10V input voltage range connect external resistors R1, R2 and select sensor characteristic 10V. R1=10 kohm, R2=2,7 kohm. D terminal is shielding

Hint Thermocouples connected to IS-AIN8 hardware versions below 5.0 must be galvanically separated from the frame. If the thermocouples are connected to IS-AIN8, appropriate jumpers must be removed (see rear sticker).

External modules connection IS-BIN16/8 is an extension module with 16 binary inputs and 8 binary outputs. IS-AIN8 is an extension module with 8 analog inputs. All I/O can be configured to any logical function or protection. It is possible to connect up to 10 IS-AIN8 and 4 IS-BIN16/8 external units to one CONTROLLER. External modules IS-BIN16/8 and IS-AIN8 are connected to CONTROLLER CAN1 bus. Controllers are connected to CONTROLLER CAN2 bus in multiple applications. To operate external modules • Connect all external modules to CAN1 bus line • On each module adjust I/O CAN1 address in the range of 1 to 7 for IS-BIN16/8 inputs, 1 to 4 for IS- BIN16/8 outputs (address 0 switches corresponding communication OFF) or 0 to 9 for IS-AIN8 (0 has address 10 meaning). • Input output address is displayed on the front panel LED’s • Use PC configuration tool to configure CONTROLLER according external modules setting IS-BIN16/8 module has two separate CAN1 addresses for binary inputs Group 1, Group 2 and binary outputs Group (total three addresses). The CAN1 address for BI Group 1 and for BO Group 2 can be adjusted on the IS-BIN16/8. The address for BI Group 2 is set automatically to the address following BI Group 1. Hint: CAN address 0 disables corresponding CAN message (Group data are not send).

IS-AIN8, IS-BIN8/16 address setting • • •

Press Address button during IS-AIN8 power supply on to switch to addressing mode. Then repeatedly press or keep pressed address button to adjust required address according to CONTROLLER configuration. After setting requested address, release the buttons and wait until the digits blink – it indicates write the changed address to EEPROM memory.

IS-AIN8, IS-BIN8/16 SW version check Let suppose IS-AIN8 of SW version 1.4. Shortly press address button. Following sequence appears on the display: number “1”, one second pause, number “4”, two second pause, number “1”, one second pause, number “4”, two second pause and finally IS-AIN8 actual address. Error message (e.g. SD BOUT2) appears on Controller screen when Binary input or output Address x is configured but corresponding unit is not recognized (no message is received from CAN bus). Check IS configuration and corresponding external IS-AIN, IS-BIN unit address setting.


55

Addr.: 2

H COM L

CAN1

CAN1

8.iS-AIN8

Addr.: 1

H COM L

CAN1

H COM L

H COM L

H COM L

Addr.: 8

H COM L

1.iS-BIN16/8 Addr.: in1 out1

6.iS-BIN16/8

120

2.controller

1.iS-AIN8

CAN1

CAN2 CAN1

Addr.: 1

CAN2 CAN1

1.controller

H COM L H COM L

Addr.: in12 out 6

Hint: CAN bus line has to be terminated by 120 ohm resistors on the both ends. For longer distances is recommended to connect CAN COM terminals between all controllers and cable shielding to the ground in one point. External units can be connected on the CAN bus line in any order, but line arrangement (no tails no star) is necessary. Recommended CAN bus data cables see in Chapter Technical data. IG-MU and IG-IB units are connected to CONTROLLER CAN2 bus.

IGS-PTM and IGL-RA15 module connection


CANL CO M CANH

CANL COM CANH

CAN L CO M CAN H

CAN L CO M CAN H

CAN2 CAN1

CAN H

CAN L

CAN L COM CAN H

CAN2 CAN1

CAN1

CAN1

It is possible to connect up to four IGS-PTM and one IGL-RA15 to one CONTROLLER. IGS-PTM can be connected to CONTROLLER like IS-AIN8 and IS-BIN16. IGS-PTM behaves like IS-AIN8 and IS-BIN16/8 modules in one unit. IGS-PTM and I-CB units contain internal jumper removable 120-ohm resistor.

56

CAN1 CAN L CO M CAN H

CAN L CO M CAN H

CAN2 CAN1

CAN2 CAN1

CAN1

Connection of ECU on CAN1

ECU communicating over the CAN bus are connected to CAN1 port of the controller and other ComAp modules can be connected to this CAN bus as well. For detailed description of connection of various ECUs refer to Comap Electronic Engines Support manual.

CAN bus Tx, Rx LED indication Tx and Rx LED is connected directly to Tx and Rx signal. Tx

Rx

Status Communication is OK

Fast flashing – data transfer

CAN bus is interrupted Continuous light Continuous light Short connection H – L Fine flashing Dark Short connection L – COM Dark Dark Short connection H – COM Fine flashing Dark Wrong connection H – H, L – L Synchro flashing

CA N L COM CAN H CAN L CO M CAN H

CAN 1

CAN ECU

CAN L

CAN L

CAN H

CAN H

I-CB

CAN L

120ohm

Controller

CAN 2 CAN 1

120ohm

I-CB wiring and configuration

CAN H

ECU

Engine Control Unit

1. Configure I-CB using I-CBEdit software. Configured I-CB behaves like fictive IS-AIN and IS-BIN units. ICB configuration associates selected values (from ECU database) received from Engine Control Unit to selected CAN addressees (fictive IS-AIN, IS-BIN inputs and outputs). in PC configuration tool. 2. Configure corresponding CONTROLLER CAN addresses and tick 3. Configure separate inputs and outputs in corresponding Analog, Binary inputs, outputs in PC configuration tool. Hint: In case of CAT engines, there is RS232 connection between I-CB and CCM.


57

Recommended CAN/RS485 connection CAN bus connection The bus has to be terminated by 120 Ohm resistors at both ends. External units can be connected on the CAN bus line in any order, but keeping line arrangement (no tails, no star) is necessary. Standard maximum bus length is 200m for 32C CAN BUS MODE and 900m for 8C CAN BUS MODE Shielded cable has to be used, shielding has to be connected to PE on one side (controller side). A) For shorter distances (all network components within one room) – picture 1 Interconnect H and L; shielding connect to PE on controller side B) For longer distances (connection between rooms within one building) – picture 2 Interconnect H, L, COM; shielding connect to PE in one point C) In case of surge hazard (connection out of building in case of storm etc.) – picture 3 We recommend to use following protections: - Phoenix Contact (http://www.phoenixcontact.com): PT 5-HF-12DC-ST with PT2x2-BE (base element) - Saltek (http://www.saltek.cz): DM-012/2 R DJ Recommended data cables: BELDEN (http://www.belden.com) A) For shorter distances: 3105A Paired - EIA Industrial RS-485 PLTC/CM (1x2 conductors) B) For longer distances: 3106A Paired - EIA Industrial RS-485 PLTC/CM (1x2+1 conductors) C) In case of surge hazard: 3106A Paired - EIA Industrial RS-485 PLTC/CM (1x2+1 conductors)

RS485 connection The line has to be terminated by 120 Ohm resistors at both ends. External units can be connected on the RS485 line in any order, but keeping line arrangement (no tails, no star) is necessary. Standard maximum link length is 1000m. Shielded cable has to be used, shielding has to be connected to PE on one side (controller side). A) For shorter distances (all network components within one room) – picture 1 interconnect A and B; shielding connect to PE on controller side B) For longer distances (connection between rooms within one building) – picture 2 interconnect A, B, COM; shielding connect to PE in one point C) In case of surge hazard (connection out of building in case of storm etc.) – picture 3 We recommend to use following protections: - Phoenix Contact (http://www.phoenixcontact.com): PT 5-HF-5DC-ST with PT2x2-BE (base element) (or MT-RS485-TTL) - Saltek (http://www.saltek.cz): DM-006/2 R DJ Recommended data cables: BELDEN (http://www.belden.com) A) For shorter distances: 3105A Paired - EIA Industrial RS-485 PLTC/CM (1x2 conductors) B) For longer distances: 3106A Paired - EIA Industrial RS-485 PLTC/CM (1x2+1 conductors) C) In case of surge hazard: 3106A Paired - EIA Industrial RS-485 PLTC/CM (1x2+1 conductors)


58

Picture 1 - shorter distances (all network components within one room) 120 Ω

120 Ω

H/A L/B COM

H/A L/B COM

Picture 2 - longer distances (connection between rooms within one building)

8.iS-AIN

Addr.: 1

CAN1

1.iS-AIN

H COM L

H COM L

CAN1

H COM L H COM L

CAN1

1.iS-CU Addr.: 1

CAN2 CAN1

120

H COM L

Addr.: 8

H COM L

1.iS-BIN Addr.: in1 out1

H COM L

7.iS-BIN 120

H COM L

CAN1

2.iS-CU

CAN2 CAN1

120

Addr.: in13 out7

Picture 3 - surge hazard (connection out of building in case of storm etc.) 120 Ω

120 Ω PT5-HF-12DC-ST (CAN) PT5-HF-5DC-ST (RS485)

H/A L/B COM


H/A L/B COM

59

Default sensors Default characterisitics CONTROLLER VDO Temp VDO Press ohms 1 bar psi ohms 1°F 1°C Primary Converted Converted Primary Converted Converted 0 0,0 10,0 230 110 29,0 29 2,0 50,0 194 90 51,0 58 4,0 85,0 176 80 69,0 87 6,0 119,0 158 70 95,0 116 8,0 152,0 140 60 135,0 145 10,0 180,0 122 50 195,0 104 40 290,0 86 30 440,0 68 20 700,00 32 0 1800,0 3 -16 3200,0

Tristate sensor Resistance < 750Ω 750 - 2700Ω > 2700Ω

Considered as Inactive Active Sensor failure (interrupted wire)

IS-AIN8 PT100 (IEC 571) 0,1 Ù 0,1 °C 0,1 °F -400, -400, 843, -40, 922, -200, 320, 1000, 0, 680, 1078, 200, 1040, 1155, 400, 1400, 1232, 600, 1760, 1309, 800, 1385, 1000, 2120, 1461, 1200, 2480, 1536, 1400, 2840, 1610, 1600, 3200, 1685, 1800, 3560, 1758, 2000, 3920, 1832, 2200, 4280, 1905, 2400, 4640, 1977, 2600, 5000, 2049, 2800, 5360, 2120, 3000, 5720, 2191, 3200, 6080, 2262, 3400, 6440, 2332, 3600, 6800, 2401, 3800, 7160, 2470, 4000, 7520, 2539, 4200, 7880, 2607, 4400, 8240,

PT1000 (IEC 571) 0,1 Ù 0,1 °C 0,1 °F -684, -558, 7800, -594, -508, 8000, -503, -457, 8200, -407, 8400, -413, -356, 8600, -321, -306, 8800, -231, -255, 9000, -139, -204, 9200, -47, -153, 9400, 45, -102, 9600, 136, -51, 9800, 228, 0, 10000, 320, 51, 10200, 412, 10400, 103, 505, 10600, 154, 597, 10800, 205, 689, 11000, 257, 783, 11200, 308, 874, 11400, 360, 968, 11600, 412, 1062, 464, 1800, 1155, 12000, 516, 1249, 12200, 568, 1342, 12400, 620, 1436, 12600, 672, 1530,

Ni100 (IEC 43760) 0,1 Ù 0,1 °C 0,1 °F -600, -760, 695, -500, -580, 743, -400, -400, 791, -300, -220, 841, -40, -200, 893, -100, 140, 946, 320, 0, 1000, 500, 100, 1056, 680, 200, 1112, 860, 300, 1171, 400, 1040, 1230, 500, 1220, 1291, 600, 1400, 1353, 700, 1580, 1417, 800, 1760, 1483, 900, 1940, 1549, 1000, 2120, 1618, 1100, 2300, 1688, 1200, 2480, 1760, 1300, 2660, 1833, 1400, 2840, 1909, 1500, 3020, 1986, 1600, 3200, 2066, 1700, 3380, 2148, 1800, 3560, 2232,

Ni1000 (IEC 43760) 0,1 Ù 0,1 °C 0,1 °F 7909, -500, -580, 8107, -450, -490, 8308, -400, -400, 8512, -350, -310, 8717, -300, -220, 8925, -250, -130, 9135, -200, -40, 9347, -150, 50, 9562, -100, 140, 9780, -50, 230, 10000, 0, 320, 10223, 50, 410, 10448, 100, 500, 10676, 150, 590, 10907, 200, 680, 11140, 250, 770, 11376, 300, 860, 11615, 350, 950, 11857, 400, 1040, 12102, 450, 1130, 12350, 500, 1220, 12601, 550, 1310, 12854, 600, 1400, 13111, 650, 1490, 13371, 700, 1580,


60

PT100 (IEC 571) 0,1 Ù 0,1 °C 0,1 °F 2675, 4600, 8600, 2742, 4800, 8960, 2809, 5000, 9320, 2875, 5200, 9680, 2941, 5400, 10040 3006, 5600, 10400 3072, 5800, 10760 3136, 6000, 11120 3200, 6200, 11480 3264, 6400, 11840 3327, 6600, 12200 3389, 6800, 12560 3451, 7000, 12920 3513, 7200, 13280 3574, 7400, 13640 3635, 7600, 14000 3695, 7800, 14360 3755, 8000, 14720 3815, 8200, 15080 3874, 8400, 15440 3903, 8500, 15620

PT1000 (IEC 571) 0,1 Ù 0,1 °C 0,1 °F 1623, 12800, 724, 1717, 13000, 776, 1812, 13200, 829, 1906, 13400, 881, 2001, 13600, 934, 2097, 13800, 987, 14000, 1039, 2190, 14200, 1092, 2286, 14400, 1145, 2381, 14600, 1198, 2476, 14800, 1251, 2572, 15000, 1304, 2667, 15200, 1358, 2764, 15400, 1411, 2860, 15600, 1645, 3281, 15800, 1518, 3052, 16000, 1572, 3150, 16200, 1625, 3245, 16400, 1679, 3342, 16600, 1733, 3439, 16800, 1787, 3537, 17000, 1841, 3634, 17200, 1895, 3731, 17400, 1950, 3830, 17600, 2004, 3927, 17800, 2058, 4024, 18000, 2113, 4123, 18200, 2168, 4222, 18400, 2222, 4320, 18600, 2277, 4419, 18800, 2332, 4518, 19000, 2387, 4617, 19200, 2442, 4716, 19400, 2497, 4815, 19790, 2605, 5009,

Ni100 (IEC 43760) 0,1 Ù 0,1 °C 0,1 °F 2318, 1900, 3740, 2407, 2000, 3920, 2498, 2100, 4100, 2592, 2200, 4280, 2689, 2300, 4460, 2789, 2400, 4640,

4-20mA/ 4-20mA/ 0-20mA/ 4-20mA/ 100 60 100-PTM 100-PTM Primary Converted Converted Primary Converted Primary Converted 0 38 0 0 0 0 170 12 57 20 38 8 13 200 25 77 30 57 15 25 230 37 96 40 77 23 38 280 50 116 50 96 30 50 330 62 135 60 116 38 63 390 75 155 70 135 45 75 460 87 174 80 155 53 88 560 100 194 90 174 60 100 690 100 194

Sensor fail

Ni1000 (IEC 43760) 0,1 Ù 0,1 °C 0,1 °F 1670, 13635, 750, 1760, 13901, 800, 1850, 14171, 850, 1940, 14444, 900, 2030, 14720, 950, 15000, 1000, 2120, 15283, 1050, 2210, 15570, 1100, 2300, 15860, 1150, 2390, 16154, 1200, 2480, 16451, 1250, 2570, 16752, 1300, 2660, 17056, 1350, 2750, 17365, 1400, 2840, 17677, 1450, 2930, 17993, 1500, 3020, 18312, 1550, 3110, 18636, 1600, 3200, 18964, 1650, 3290, 19295, 1700, 3380, 19631, 1750, 3470, 19970, 1800, 3560, 20314, 1850, 3650, 20662, 1900, 3740, 21013, 1950, 3830, 21370, 2000, 3920,

100mV/100-PTM Primary Converted 0 0 4 10 16 40 28 70 45 110 57 140 68 170 84 210 92 230 100 250

(Fls)

A sensor fail on the analog input is detected when Analog input value is +6% or – 6% out of range of selected characteristic. Hint: Sensor fail does not activate Binary output Alarm. InteliGenNT, InteliSysNT, InteliMainsNT – Installation Guide, ©ComAp – December 2007 IGS-NT-2.2-Installation Guide.PDF

61

If engine shutdown/stop is required when Fls appears, configure in GenConfig -> Inputs/Outputs -> Analog inputs -> Protection -> property “Active when” to Under/Over limit + Fls.


62

Speed governor interface list Hint: Read carefully Speed governor instructions before connecting controller Speed governor interface!

Electronic engines interface All below mentioned interface examples describes analog interface even if they are (in some cases) used for Electronic Control Units (Electronic engines) with CAN data bus. There are several possibilities to connect CAN bus interface between Electronic engine and ComAp controller. Please ask your local distributor for more details.

Controller ECU interface I-CB unit is an interface between Controller and Electronic engine. Following I-CB types are available: For more details see I-CB-ICBEdit-1.1.pdf manual. I-CB type Engine I-CB/MTU MTU I-CB/MTU-SIAM4000 MTU I-CB/CAT-Diesel CAT I-CB/CAT-Gas CAT I-CB/DeutzTEMe Deutz

J1939 interface The following tables show how to connect the engine control units to the controller:

VOLVO TAD12 Comap controller binary output description Start output Fuel output Comap controller CAN description CAN bus common CAN bus H CAN bus L

Volvo TAD12 Standalone connector terminal E H Volvo TAD12 Data bus connector terminal Screen for the J1939 cable. 1(Hi) 2(Lo)

SCANIA S6 Comap controller binary output description Start output Fuel output Comap controller CAN description CAN bus common CAN bus H CAN bus L

Scania EMS B1 connector connects directly to engine starter solenoid 3 (ignition U15) Scania EMS B1 connector Screen for the J1939 cable. 9 10

PERKINS 2800 series Comap controller binary output description Start output Fuel output

Perkins Customer interface connector connects directly to engine starter solenoid 1,10,15,33,34 powers up ECU and enables the injectors


63

Comap controller CAN description CAN bus common CAN bus H CAN bus L

Perkins Customer interface connector Screen for the J1939 cable. 31 32

JOHN DEERE Comap controller binary output description Start output Fuel output Comap controller CAN description CAN bus common CAN bus H CAN bus L

John Deere 21 pin Deutsch connector D G (switched ECU power),J (ignition) John Deere 21 pin Deutsch connector Screen for the J1939 cable. V U

CUMMINS ISB/ISBE Comap controller binary output description Start output Fuel output

Cummins ISB OEM Harness connector B connects directly to engine starter solenoid 39

Comap controller CAN description CAN bus common CAN bus H CAN bus L

Cummins ISB 9 pin Deutsch connector SAE J1939 shield - screen for J1939 cable. SAE J1939 signal SAE J1939 return

Speed governor interface Following chapter describes analog interface to engines with standard electronic speed governors.

Controller Speed reg out voltage limits Setpoints Sync/Ld ctrl: SpeedGovLowLim [0,01V] and SpeedGovHiLim [0,01V] limit low and high levels of output voltage. E.g. instead of full –10V to +10V Speed governor output range can be set SpeedGovLowLim = 0,00 V and SpeedGovHiLim = 5,00 V to reduce the output range from 0 to 5V. Heinzmann Sync/Load ctrl: Speed gov bias = 0,00 V SpeedRegChar = POSITIVE

Sync/Load ctrl: Speed gov bias = 5,00 V SpeedRegChar = POSITIVE


64


Sync/Load ctrl: Speed gov bias = 5V SpeedRegChar = POSITIVE SpeedGovLowLim = 0,8V (without resistor Speed gov bias = 2,5V SpeedGovLowLim = 0,4V)

Terminals A3 and B3 are on OEM 14-pin connector. Mounted on Perkins 40xx engines.

PWM

SG OUT

9

SG COM

19

Caterpillar PEEC

Caterpillar

CATERPILLAR Signal converter

Pay attention to the connector and jumper orientation.

Sync/Load ctrl: Speed gov bias = 5,10 V SpeedRegChar = POSITIVE SpeedGovLowLim = 0V SpeedGovHiLim = 10V

Cummins EFC

Cummins

Sync/Load ctrl: Speed gov bias = 6,40 V SpeedRegChar = POSITIVE SpeedGovLowLim = 5V SpeedGovHiLim = 7,8V

Vout

SG OUT

I9

SG COM

A1

Cummins ECPG

Spurious operation of the controller push buttons is caused by excessive interference from the speed controller when capacitor is not connected between power supply terminals 1 and 2. Sync/Load ctrl: Speed gov bias = 2,50 V SpeedRegChar = POSITIVE



65

Cummins ONAN

0V

SG COM SG OUT

5V

VoutR

Sync/Load ctrl: Speed gov bias = 2,50 V SpeedRegChar = POSITIVE SpeedGovLowLim = 0V SpeedGovHiLim = 5V Sync/Load ctrl: Speed gov bias = 5,00 V SpeedRegChar = POSITIVE

Barber Colman DYN1 10684

Barber Colman DYNA 8000

Barber Colman

2 9

SG COM SG OUT VoutR

2

9

SG COM SG OUT VoutR



GAC ESD 5500

GAC G N

SG COM SG OUT VoutR

Sync/Load ctrl: Speed gov bias = 5,00 V SpeedRegChar = NEGATIVE SpeedGovLowLim = 4V SpeedGovHiLim = 6V

GAC EGS 104B

Sync/Load ctrl: Speed gov bias = 5,00 V SpeedRegChar = NEGATIVE

2 25

SG COM SG OUT VoutR

Sync/Load ctrl: Speed gov bias = 5,00 V SpeedRegChar = NEGATIVE SpeedGovLowLim = 4V SpeedGovHiLim = 6V

WOODWARD ProAct II

WOODWARD Sync/Load ctrl: Speed gov bias = 0,00 V SpeedRegChar = POSITIVE SpeedGovLowLim = -2,5V SpeedGovHiLim = 2,5V


66





Vout

SG OUT

8 (0 to 10 VDC) 36

SG COM

MTU MDEC 2000, 4000

MTU Sync/Load ctrl: Speed gov bias = 4,90 V SpeedRegChar = POSITIVE SpeedGovLowLim = 0V SpeedGovHiLim = 10V

Pay attention to the connector and jumper orientation. DEUTZ Vout

SG OUT SG COM

24 (0, 5 to 4, 5 VDC) 23 GND 21 Opened for 17 0 % Droop

DEUTZ BF6M

Plug F

Sync/Load ctrl: Speed gov bias = 2,50 V SpeedRegChar = POSITIVE SpeedGovLowLim = 0,5V SpeedGovHiLim = 4,5V

Vout

SG OUT

18

SG COM

19

PERKINS 4016 E61 TRS

Pay attention to the connector and jumper orientation. PERKINS




67

SG OUT SG COM

PERKINS 2300, 2800

Vout

12 2 24 20


PERKINS 1300 EDi

Pay attention to the connector and jumper orientation. For external speed setting terminals 2 and 12 on ECM have to be interconnected. Above mentioned pin numbers refer to the Customer Interface Connector. The J1 connector on ECM has the following numbering: 20 = J1/3; 24 = J1/17; 12 = J1/18; 2 = J1/49 VBREF GND RPS INPUT

SG COM SG OUT VoutR


TOHO Sync/Load ctrl: Speed gov bias = 4,00 V SpeedRegChar = POSITIVE


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AVR interface list Read carefully AVR instructions before connecting to controller! Basler: APR 63-5, AEC 63-7, KR-FX, KR-FFX AVRi trim to minimum counterclockwise. iGAVRi

Volt/PF ctrl: AVR DCout bias = 50% VoltRegChar = POSITIVE

AVRi output is connected instead of external resistor for voltage adjusting. Stamford SX 460 AVRi trim to minimum counterclockwise. iGAVRi


AVRi output is connected instead of external resistor for voltage adjusting. STAMFORD SX 440, AS440, MX 321, SX 421 AVRi trim to minimum counterclockwise. iGAVRi


Turn trim on on MX 321 from zero position. Leroy Sommer: R 438 LS, R448 AVRi trim to minimum counterclockwise. iGAVRi


AVRi output is connected instead Remote voltage trimmer 470 ohm to terminals ST4. Leroy Sommer: R 449

iGAVRi

AVRi trim to minimum counterclockwise. Volt/PF ctrl: AVR DCout bias = 50% VoltRegChar = POSITIVE


69

Leroy Sommer: R 129

J2

GND

iG AVRi TRANS

230/400VAC 0VAC

iGAVRi

18VAC

OUT1

From generator

AVRi+

AVRI OUT AVRI COM

AVRi-


AVRi output is connected instead Remote voltage trimmer 470 ohm to terminal J2. Mecc Alte Spa: S.R.7/2, U.V.R.6

iGAVRi

AVRi trim to maximum clockwise. Volt/PF ctrl: AVR DCout bias = 75% VoltRegChar = NEGATIVE

AVRi output is connected instead Remote voltage trimmer 100Kohm (OUT1=top position wire and GND =second top position). Marelli: MX 341

iGAVRi

AVRi trimpot in middle position. Volt/PF ctrl: AVR DCout bias = 50% VoltRegChar = POSITIVE

Link pin 1 and 2 (no remote voltage trim) Disconnect Droop C/T (S1, S2) Piller AVRi trim to minimum counterclockwise. Volt/PF ctrl: AVR DCout bias = 39% VoltRegChar = POSITIVE AVRi output is connected instead Remote voltage trimmer 100Kohm. Catterpillar VR6, VR3F

iGAVRi


For VR3F link 4-7 has to be removed. Catterpillar DVR AVRi trim to 25% Volt/PF ctrl: AVR DCout bias = 50% VoltRegChar = POSITIVE Pin 44 on DVR – PF regulation directly from DVR is not connected.


70

AVK Newage MA330 AVRi trim to minimum counterclockwise Volt/PF ctrl: AVR DCout bias = 50% VoltRegChar = POSITIVE Marathon DVR2000E AVRi trim to 1/3 clockwise Volt/PF ctrl: AVR DCout bias = 50% VoltRegChar = POSITIVE


71

Technical data Power supply Voltage supply Consumption depends on supply voltage

Controller 8-36V DC 0,4A at 8VDC 0,15 A at 24VDC 0,1A at 36VDC 2 % at 24V 10 year

IS-Display 8-36V DC 0,3A at 8VDC 0,1 A at 24VDC 0,09A at 30VDC

IG-Display 8-36V DC 0,4A at 8VDC 0,14 A at 24VDC 0,12A at 30VDC

Battery voltage measurement tolerance RTC battery life-cycle Hint: When internal RTC battery becomes flat, controller function (e.g. Ready for stand by) does not change until controller power supply is switched off. Some time before the battery is completely exhausted, a warning message appears in Alarmlist: "RTCbatteryFlat". After the next power switch on (with flat battery already) controller: Stays in the INIT state (not possible to run genset) All History records disappear except of “System log: SetpointCS err” record Time and Date values are set to zero Statistics values are random

Operating conditions Operating temperature Operating temperature IS-NT-BB Operating temperature (LT version) Storage temperature Storage temperature IS-NT-BB Flash memory data retention time Protection front panel Humidity Standard conformity Low Voltage Directive Electromagnetic Compatibility

Vibration Shocks

-20..+70oC * -40..+70oC * -40..+70oC * -30..+80oC -40..+80oC 10 years IP65 95% without condensation (complies with IEC/EN 60068-2-30) 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

Hint: * USB port should be used only above 0°C.

Dimensions and weight Dimensions Weight

180x120x80mm 950g

Mains and generator Nominal frequency Frequency measurement tolerance

50-60Hz 0,1Hz


72

Current inputs Nominal input current (from CT) Load (CT output impedance) CT input burden

IG-xx 5A < 0,1 Ω < 0,2 VA per phase (Inom=5A)

Max. measured current from CT Current measurement tolerance Max. peak current from CT Max. continuous current

10 A 2% from the Nominal current 150 A / 1s 12 A

IG-xxC / IS-NT-BB / IM-NT 1A/5A < 0,1 Ω < 0,1 VA per phase (Inom=1A) < 0,2 VA per phase (Inom=5A) 2 A / 10 A 2% from the Nominal current 150 A / 1s 2,4 A / 12 A

Voltage inputs – IG/IS-NT and modifications IG-xx Nominal voltage (ph-N / ph-ph) Maximal measured/allowed voltage Input resistance Voltage measurement tolerance Over voltage class

277/480 VAC 346/600 VAC

IG-xxC / IS-NT-BB / IM-NT 120/207 or 277/480 VAC 150/260 or 346/600 VAC

0,6 MΩ phase to phase 0,3 MΩ phase to neutral 1 % from the Nominal voltage III / 2 (EN61010)

0,6 MΩ phase to phase 0,3 MΩ phase to neutral 1 % from the Nominal voltage III / 2 (EN61010)

Hint: kW and kWh measurement tolerance is 3%.

Binary inputs and outputs Binary inputs Number of inputs Input resistance Input range Switching voltage level for close contact indication Max voltage level for open contact indication

IG-NT / IG-NTC 12 4,7 kΩ 0-36 VDC 0-2 V

IG-EE / IG-EEC / IM-NT 6 4,7 kΩ 0-36 VDC 0-2 V

IS-NT-BB 16 4,7 kΩ 0-36 VDC 0-2 V

8-36 V

8-36 V

8-36 V

IG-EE / IG-EEC / IM-NT 6 0,5 A 36 VDC

IS-NT-BB 16 0,5 A 36 VDC

Binary open collector outputs Number of outputs Maximum current Maximum switching voltage

IG-NT / IG-NTC 12 0,5 A 36 VDC

Analog inputs Not electrically separated Number of inputs Resolution Jumper selectable range Maximal resistance range Maximal voltage range Maximal current range Input impedance

3 / 0 / 4 unipolar ( IG-NT(x) / IG-EE(x), IM-NT / IS-NT-BB ) 10 bits V, ohm, mA 2500 Ω 5V 0 – 20 mA 180 Ω for mA measuring


73

Input impedance Resistance measurement tolerance Voltage measurement tolerance Current measurement tolerance

> 100 kΩ for V measuring ± 2 % ± 2 Ω out of measured value ± 1 % ± 1mV out of measured value ± 1 % ± 0,5mA out of measured value

D+ function Max. D+ output current Guaranteed level for signal Charging OK

300 mA 80% of supply voltage

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 2 Vpk-pk (from 4 Hz to 4 kHz) 50 Veff 4 Hz 10 kHz (min. input voltage 6Vpk-pk) 0,2 %

Communication interface RS232 interface Maximal distance Speed

10m up to 57.6kBd

RS485 interface Maximal distance Speed

1000m up to 57.6kBd

CAN bus interface Galvanically separated Maximal CAN bus length Speed Nominal impedance Cable type

200m 250kBd 120Ω twisted pair (shielded)

Following dynamic cable parameters are important especially for maximal 200 meters CAN bus length and 32 iS-COM units connected: Nominal Velocity of Propagation min. 75% (max. 4,4 ns/m) Wire crosscut min.0,25 mm2 Maximal attenuation (at 1 MHz) 2 dB / 100m Recommended Industrial Automation & Process Control Cables: BELDEN (see http://www.belden.com): 3082A DeviceBus for Allen-Bradley DeviceNet 3083A DeviceBus for Allen-Bradley DeviceNet 3086A DeviceBus for Honeywell SDS 3087A DeviceBus for Honeywell SDS 3084A DeviceBus for Allen-Bradley DeviceNet 3085A DeviceBus for Allen-Bradley DeviceNet 3105A Paired EIA Industrial RS485 cable LAPP CABLE (see http://www.lappcable.com) Unitronic BUS DeviceNet Trunk Cable Unitronic BUS DeviceNet Drop Cable Unitronic BUS CAN Unitronic-FD BUS P CAN UL/CSA InteliGenNT, InteliSysNT, InteliMainsNT – Installation Guide, ©ComAp – December 2007 IGS-NT-2.2-Installation Guide.PDF

74

Analog outputs Speed governor output AVRi outputs Current output Voltage output Max load resistance

± 10 V DC / 5 V PWM (500 – 3000Hz), max. 15 mA PWM to IG-AVRi 0 – 20 mA ± 0,3mA 0 – 10 V DC, max. 15 mA 470R at 9,4V

IG-AVRi Power supply: Absolutely maximum power supply range:

18V AC from IG-AVRi Trans/LV or IG-AVRi Trans/100 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: Absolute low limit: Absolute high limit:

230-277 VAC 230 VAC – 20% 277 VAC + 20%

Primary voltage 2: Absolute low limit: Absolute high limit:

400-480 VAC 400 VAC – 20% 480 VAC + 20%

Frequency: Secondary voltage: Operating temperature

50 - 60 Hz 18 V AC, 5 VA -30..+70oC

IG-AVRi Trans/100 Primary voltage: Absolute low limit: Absolute high limit:

100 – 120 VAC 100 VAC – 20% 120 VAC + 20%

Frequency: Secondary voltage: Operating temperature

50 - 60 Hz 18 V AC -30..+70oC

IGS-PTM Voltage supply Consumption Mechanical dimensions: Interface to controller Operating temperature

8-36V DC 0,1A depend on supply voltage 40 x 95 x 45 mm , DIN rail (35 mm) mounted CAN -30..+70oC

Binary inputs Number of inputs Input resistance Input range Switching voltage level for close contact indication Max voltage level for open contact indication

8 4,7 kΩ 0 - 36 VDC 0-2V 8-36 V

Binary open collector outputs Number of outputs

8


75

Maximum current Maximum switching voltage

0,5 A 36 VDC

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 Ω 0 – 100 mV 0 – 20 mA 1 % ± 2 Ω out of measured value 1,5 % ± 1mV out of measured value 2,5 % ±0,5mA out of measured value

Analog output Not electrically separated Number of inputs Resolution Output range

1 10 bits 0 to 20 mA ± 0,33 mA

IS-AIN8 Nominal power supply Power supply range Max. consumption Mechanical dimensions: Connection to controller (galvanically separated) Operating temperature Storage temperature Protection front panel Humidity Standard conformity Low Voltage Directive Electromagnetic Compatibility

24 VDC 8 – 36 VDC 250 mA 150 x 160 x 50 mm , DIN rail (35 mm) mounted CAN1 -40..+70oC -40..+80oC IP 20 95% without condensation EN 61010-1:95 +A1:97 EN 50081-1:94, EN 50081-2:96 EN 50082-1:99, EN 50082-2:97

Analog inputs Nominal power supply Power supply range Number of inputs Not galvanic separated Resolution Each analog input can be software configured to:

Resistance Current Voltage

Passive Active Active Thermocouples J, K, L type

24 VDC 8 – 36 VDC 8 16 bits Measuring range Accuracy From to ± 0,5 % 2400 Ω 0 Ω ± 1,0 % 0 Ω 250 Ω 0 / 4 mA 20 mA ± 0,5 % 4 mA 20 mA ± 0,5 % 0 mA ± 20 mA ± 0,5 % ± 0,2 % 0 mV 100 mV ± 0,2 % - 1000 mV + 1000 mV ± 0,5 % 0 mV 2500 mV ± 0,5 %


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Hint: Sensors must be isolated from the engine body (except for thermocouples (since HW version 5.0)). Follow rear sticker description and remove the appropriate jumpers in case of thermocouples not isolated from the engine body. It's possible to connect voltage up to 10V to an analog input if an external volt box which is described on p.53 is used.

I-AOUT8 Voltage supply Consumption Mechanical dimensions: Interface to controller Operating temperature Number of analog outputs Output range

8-36V DC 0,1A depend on supply voltage 40 x 95 x 45 mm , 35 mm DIN rail mounted CAN -30..+70oC 8 (not electrically separated) 0 to 10 VDC 0 to 20 mA PWM (1200 Hz)

IS-BIN16/8 Nominal power supply Power supply range Max. consumption Mechanical dimensions: Connection to controller (galvanically separated) Operating temperature Storage temperature Protection front panel Humidity Standard conformity Low Voltage Directive Electromagnetic Compatibility

24 VDC 8 – 36 VDC 250 mA 150 x 160 x 50 mm , DIN rail (35 mm) mounted CAN1 -30..+70oC -40..+80oC IP 20 95% without condensation EN 61010-1:95 +A1:97 EN 50081-1:94, EN 50081-2:96 EN 50082-1:99, EN 50082-2:97

Binary inputs Galvanically separated two groups Number of inputs Input resistance Input voltage range

8+8 3 kΩ 0-36 VDC

Input voltage level for open contact 8 to Power supply VDC Input voltage level for close contact 0 to 2 VDC Voltage level is defined between Binary input and Binary input COM terminal.

Open collector outputs Number of outputs (galvanically separated) Maximum current Maximum switching voltage

8 0,5 A 36 VDC

Frequency inputs Number of inputs

2 (RPM1, RPM2)

RPM1 Type of sensor

magnetic pick-up


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Minimum input voltage Maximum input voltage Maximum measured frequency

2 Vpk-pk (from 4 Hz to 4 kHz) 50 Veff 8 kHz (min. input voltage 6Vpk-pk), frequency mode

RPM2 Type of sensor Minimal pulse width Maximum measured frequency Note:

Contact or Active sensor 10 ms, integration mode 60 Hz, integration mode

RPM1, RPM2 are available from IS SW version 2.6

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


180x120x55mm 950g

Horn output Maximum current Maximum switching voltage

1A 36 VDC

I-CB, I-CR Power supply Voltage input Consumption

8-36V DC 0.1A depend on power supply

Operating conditions Operating temperature Storage temperature Humidity Protection

-20 ÷ +70 °C -30 ÷ +80 °C 85% without condensation IP20


95x96x43 mm, DIN rail (35 mm) mounted 300g

CAN bus interface Galvanic separated Maximal CAN bus length Speed Nominal impedance

200m up to 250kBd (depends on ECU type connected) 120Ω


78

Cable type for iS connection

twisted pair (shielded)

RS232 interface Maximal distance Speed

10m up to 19.2kbps (depends on ECU type connected)

I-LB Voltage supply Consumption Operating temperature Mechanical dimensions: Interface to modem or PC Interface to controller

8-36V DC 0,1A depend on supply voltage -30..+70oC 95 x 96 x 43 mm , DIN rail (35 mm) mounted RS232, RS422, RS485, (USB – I-LB+ version) CAN

IG-IB Voltage supply Consumption Mechanical dimensions: Interface to controller Interface to modem Interface to Ethernet Operating temperature Storage temperature

8-36V DC 0,1A depend on supply voltage 95 x 96 x 43 mm , DIN rail (35 mm) mounted RS232 or CAN RS232 RJ45 (10baseT) -30..+70oC -30..+70oC

I-RBxx Number of relays: Nominal voltage: Voltage range: Relay opens at: Electric / mechanic cycles: Operating temperature range: Maximal load: (I-RBxx-231) Contacts protection:

16 or 8 in sockets 24 VDC 16,8 – 36 VDC 10% of nominal voltage 100 000 / 10 000 000 - 40°C to 70°C 6 A resistive load at 24VDC 4 A inductive load at 24 VDC 2 A at 231VAC varistor 14DK390

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-2-1 Primary voltage Ph-Ph Secondary voltage Ph-N Mechanical dimensions: Primary/secondary Phase shift Operating temperature

3x600 VAC / 50Hz (3x720 VAC / 60 Hz) 3x 173 V AC ( 3x208 VAC / 60 Hz) , 5 VA 155 x 95 x 60 mm , DIN rail (35 mm) mounted < 1° -30..+70oC


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COMAP IGS NT 2.2 Installation Guide

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