ComAp IG-NT User manual

Compact Controller for Stand-by and Parallel Operating Gen-sets
Inteli New Technology
Modular Gen-set Controller
Single Parallel to Mains – SW configuration SPtM
IG-NT, IG-NTC, IG-EE, IG-EEC, IS-NT
Software version IGS-NT-2.4, December 2009
REFERENCE GUIDE
Copyright © 2005 ComAp s.r.o.
ComAp, spol. s r.o.
Kundratka 2359/17, 180 00 Praha 8, Czech Republic
Tel: [phone], Fax: [phone]
Technical support hotline: [phone]
E-mail: [e-mail], www.comap.cz

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Table of Contents
Table of Contents...............................................................................................................................................2
General guidelines..............................................................................................................................................4
What is described in this manual?.................................................................................................................4
General description ............................................................................................................................................6
Description of the controller system (with all options)....................................................................................6
SPTM .............................................................................................................................................................6
Available related documentation....................................................................................................................6
Functions............................................................................................................................................................7
OFF-MAN-AUT-TEST mode..........................................................................................................................7
Active Power control modes in SPtM.............................................................................................................9
Power derating.............................................................................................................................................13
Engine states................................................................................................................................................14
PLC functions...............................................................................................................................................21
Multi language support.................................................................................................................................22
ECU interface customizing...........................................................................................................................22
Protections and Alarm management................................................................................................................23
Gen-set operation states..................................................................................................................................33
Inputs and Outputs...........................................................................................................................................34
Virtual and physical modules .......................................................................................................................34
Binary inputs – Control.................................................................................................................................34
Binary inputs – Status information...............................................................................................................42
Binary outputs ..............................................................................................................................................42
Binary outputs – Breaker control..................................................................................................................44
Binary outputs – Control loops.....................................................................................................................45
Binary outputs – Status information.............................................................................................................46
Binary outputs – Fixed protection outputs....................................................................................................49
Binary outputs – Configurable prog. States.................................................................................................53
Analog inputs................................................................................................................................................57
Analog outputs .............................................................................................................................................59
Values ..........................................................................................................................................................59
Statistics.......................................................................................................................................................60
Setpoints...........................................................................................................................................................61
ProcessControl.............................................................................................................................................61
Basic settings...............................................................................................................................................67
Comms settings ..........................................................................................................................................71
Engine params.............................................................................................................................................73
Engine protect..............................................................................................................................................77
Analog protect..............................................................................................................................................81
Gener protect...............................................................................................................................................82
Mains protect................................................................................................................................................87
AMF settings ................................................................................................................................................89
Sync/Load ctrl...............................................................................................................................................90
Sync/load control adjustment.......................................................................................................................93
Volt/PF ctrl....................................................................................................................................................95
Volt/PF control adjustment...........................................................................................................................97
Force value...................................................................................................................................................98
Load shedding..............................................................................................................................................99
PLC settings...............................................................................................................................................100
Timer settings.............................................................................................................................................100
Act. calls/SMS............................................................................................................................................101
Date/Time...................................................................................................................................................102
List of possible events....................................................................................................................................104
Controller configuration and monitoring .........................................................................................................105
Direct connection to the PC .......................................................................................................................105
GenConfig functions...................................................................................................................................105

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InteliMonitor................................................................................................................................................106
Modbus protocol.........................................................................................................................................106
Value and setpoint codes...........................................................................................................................106
Technical data............................................................................................................................................106
Language support......................................................................................................................................106

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General guidelines
What is described in this manual?
This manual describes Single parallel to Mains „SPtM“ software configuration. The software configuration is
designed for single set, parallel with mains applications.
What is the purpose of this manual?
This manual provides general information on how to configure and operate the controller.
This manual is intended for use by:
Operators of gen-sets
Gen-set control panel builders
For everybody who is concerned with installation, operation and maintenance of the gen-set
!! Warnings !!
The NT controller can be remotely controlled. In the event that maintenance needs to be done to the gen-set,
check the following to ensure that the engine cannot be started.
To be sure:
Disconnect remote control via RS232 line
Disconnect input REMOTE START/STOP
or Disconnect output STARTER and outputs GCB CLOSE/OPEN and MCB CLOSE/OPEN
The controller contains a large number of configurable setpoints, because of this it is impossible to describe
all of its functions. These are subject to change from SW version to SW version. This manual only describes
the product and is not guaranteed to be set for your application on arrival.
Text
ESC (Capital letters in the frame) buttons on the front panel
Break Return (Italic) set points
Generator protections (Bold) Set point group
Cyan background Valid for IS-NT only
Conformity declaration
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.
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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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 NT controller terminals:
•Mains voltage measuring and / or
•Binary output for MCB control and / or
•MCB feedback
Be aware that the MCB can be switched off and gen-set can start !!!
Switch the controller to MAN mode and disconnect the Binary outputs Starter and Fuel
to avoid unexpected automatic start of gen-set and GCB closing.
!!! CAUTION !!!
Dangerous voltage
The terminals for voltage and current measurement should never be touched.
Properly connect the grounding terminals.
Do not disconnect the CT terminals for any reason.
Adjust set points
All setpoints are preadjusted to their typical values. But the set points in the “Basic settings” settings
group !!must!! be adjusted before the first startup of the gen-set.
!!! WRONG ADJUSTMENT OF BASIC PARAMETERS
CAN DESTROY THE GEN-SET !!!
The following instructions are for qualified personnel only. To avoid personal injury do
not perform any action not specified in this User guide !!!

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General description
Description of the controller system (with all options)
NT Family controllers are comprehensive AMF-controllers for single and multiple generating sets operating
in stand-by or parallel modes.
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 the Mains operation is a standard feature. Isolated parallel and Power Management System
support are optional. Forward and reverse synchronizing, Generator protections, Mains protection including
vector shift, load and power factor control are the major functions provided. Interfacing to foreign
synchronizers and load sharers is supported. Regarding the measurement inputs, the controller provides
True RMS method for voltage, current and power measurement.
The key feature of the controller is its easy-to-use operation and installation. Predefined configurations for
typical applications are available as well as user-defined configurations for special applications.
SPTM
This manual describes "SPtM" application type, which is designed to control a single-operating genset in
long-term parallel mode as well as in emergency mode. The application provides following main
features:
•automatic start and stop sequences
•engine and generator protections
•two breakers control (MCB, GCB), both synchronized
•mains protections including vectorshift
•AMF function (autostart due to mais failure)
•parallel to mains operation, various load control modes (constant, import/export..)
•island operation
•no-break transfers from island to parallel and vice versa
Available related documentation
PDF files Description
IGS-NT-2.4-Application guide.pdf Application guide for IG/IS-NT
IGS-NT-2.4-Installation guide.pdf Installation guide for IG/IS-NT
IGS-NT-2.0-Operator guide.pdf Operator guide for IG/IS-NT
IGS-NT Communication Guide 12-2009.pdf Communication guide for IG/IS-NT controllers

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Functions
OFF-MAN-AUT-TEST mode
OFF mode
Outputs STARTER, GCB CLOSE/OPEN and FUEL SOLENOID are not energized.
Genset cannot be started. If START,STOP,GCB ON/OFF,MCB ON/OFF buttons are pressed the controller
will not respond.
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.
When the gen-set is running it is not possible to switch directly to OFF mode. First you have to stop the
engine.
MAN mode
1) START - starts the gen-set.
2) GCB ON/OFF
If generator voltage is out of the limits (adjusted in the set point group Gener protect) controller does
not respond to the GCB ON/OFF
a) controller closes GCB to dead bus.
b) controller starts GCB synchronizing when mains is OK and MCB is closed. Closes the GCB
when synchronized and stays running in parallel. Operational mode in parallel depends on
ProcessControl setting.
c) Unloads gen-set and opens the GCB if gen-set was running in parallel to the mains.
d) Opens GCB immediately if gen-set was running in island operation.
3) MCB ON/OFF
a) controller closes MCB to dead bus (even if the mains voltage is out of limits).
b) controller starts MCB synchronizing when gen-set is running and GCB is closed. Closes the
MCB when synchronized and stays running in parallel. Operational mode in parallel depends on
ProcessControl setting.
c) Unloads gen-set and opens the MCB if gen-set was running in parallel to the mains.
4) STOP
a) When gen-set is running in parallel: transfers load to the mains, opens GCB, goes into cooling
state and stops the engine.
b) When gen-set is running island (MCB is opened): opens GCB, goes into cooling state and stops
the engine.
c) When engine is running unloaded: activates cooling sequence and then stops the engine.
d) During cooling state causes immediate engine stop.
Hint:
The genset is permitted to run unloaded for unlimited time.
Controller does not automatically start the gen-set when power cut comes or REM START/STOP is closed.
Controller does not automatically change the MCB state depending on mains changes.
Load control in parallel depends on ProcessControl: Load ctrl PtM setpoint.
SEM
In SEM mode, pressing of START or STOP buttons performs a predefined sequence:
1) START – starts the engine, synchronizes and runs in parallel.
2) STOP – softly unloads the gen-set, opens GCB, provides cooldown and stops the engine.
3) In case of mains failure and Process control: MFStart enable set to YES, allows automatic start/stop
same as in AUT mode.

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AUT mode – (Stand-by)
Automatic mode is influenced by ProcessControl: Island enable, ParallelEnable, Synchro enable and
MFStart enable setpoints.
No. Island enable Parallel enable Synchro enable MFStart enable
Function
1 YES YES BOTH YES SPTM application, stand-by, soft load transfer
2 NO YES BOTH X SPTM – long parallel, no Stand-by
3 YES NO NO YES SSB with break transfer;
Gen-set start is blocked.
4 NO NO NO NO
NO NO BOTH NO
NO NO REV NO
NO YES REV NO
NO YES NO YES
NO NO X X
YES NO NO NO
YES NO NO NO
Gen-set start is blocked. Binary output
Ofl StartBlck indicates those states.
Following procedure corresponds to setting No.1 from table above.
1) Mains failure is recognized
Controller opens MCB when AMF settings: MCB opens on = MAINSFAIL.
a) After AMF settings:EmergStart del elapsed, Controller starts the gen-set. Controller opens MCB
after engine starts when AMF settings: MCB opens on = GENRUN.
b) If mains recovers during the start-up process, Controller closes MCB again after AMF settings:
MCB close del and stops the gen-set.
2) When the gen-set is above Underspeed level and the generator voltage is within limits (adjust in the set
point group Gener protect) Controller closes the GCB. If the generator voltage is out of the limits for
Engine params: Max stab time, Controller alarms the failure and stops the gen-set.
3) After mains recovers:
a) After AMF settings: Mains ret del Controller starts synchronizing to mains and closes the MCB and
unloads the gen-set.
b) After the AMF settings:BreakerOverlap delay Controller opens the GCB.
c) The gen-set is cooled down and stopped.
TEST mode
Use TEST mode for Gen-set start test if the Mains is OK or to transfer the load to the gen-set when Mains
fail is announced in advance.
Hint:
The controller does not respond to GCB ON/OFF , STOP, START in Return To mains = ENABLED.
Engine automatically starts, when TEST mode is selected.
Engine can start automatically without warning when pressing FAULT RESET after shut down alarm.
Mains parameters out of limits during synchronising
In case that mains parameters get out of permitted limits during synchronizing to mains (reverse or forward),
the regulation of gen-set speed and voltage according to mains frequency and voltage is interrupted. During
the state, when parameters reach out of limits, until “Mains fail” is issued, the engine speed and voltage
regulation output is kept on the last value.
Baseload
Process control: Load ctrl PtM = BASELOAD
Gen-set power is kept at value given by Process control:Base load setpoint.

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Internal Import export
ProcessControl: Load ctrl PtM = IMP/EXP
Process control: IE measurement = IM3 CT INPUT
Gen-set power is controlled to keep the import load at the level given by setpoint Process control: Import
load value.
Controller measures Import/Export value via the current transformer connected to In/Im3 terminal. The value
of L3 is then multiplied by 3 to give an estimation of the actual Imp/Exp.
Active Power control modes in SPtM
Mode Function Setpoints
Warming The controller limits gen-set power for
requested time or until the water
temperature reach the requested value.
After warming the gen-set goes to the
requested (e.g. Baseload) power.
Engine params: Warming load;
Warming temp; Max warm time
Baseload Genset power is constant - set by
Baseload setpoint. ProcessControl: Load ctrl PtM=BASELOAD;
Base load
ANEXT Baseload Gen-set power is set via Analog input. ProcessControl: Load ctrl ANEXT Baseload;
Analog input: LdCtrlAnextBld
Import / Export Import/Export value is constant – I/E
power is measured by controller. ProcessControl: Load ctrl PtM=IM/EX;
Import load; I/E Pm-meas = IM3 CT INPUT
ANEXT
Import / Export Import/Export value is constant – I/E power is measured via Analog input. ProcessControl: Load ctrl PtM=IM/EX;
Import load; I/E Pm-meas = ANALOG INPUT
Analog input: LdCtrl:I/E-Pm
Peak shaving Automatic gen-set start/stop based on
object (load) consumption. ProcessControl: PeakLevelStart;
PeakLevelStop; PeakAutS/S del
Export limit Limits export to the mains in the
Baseload mode. ProcessControl: Export limit = ENABLE

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Requested power
Actual power
Speed
governor
ProcessControl: Load ctrl PtM = ANEXT BASELOAD
LOAD
GCBMCB
Controller
SpeedGoverrnor
output
Speed
governor
LOAD
GCBMCB
Controller
LdCtrl:I/E-Pm
Analog input: Vmains
Imns 3
LoadCtrlPtm = IM / EX
I / E- Pm meas =
ANALOG INPUT
ProcessControl :
ProcessControl :
ProcessControl :
IM/ EX
Requested I/E power
Actual I/E power
SpeedGoverrnor
output
Speed
governor
LoadCtrlPtm= IM / EX
LOAD
GCBMCB
Controller
Vmains
Imains ph3
ProcessControl : IM/EX
ProcessControl : I/E - Pm meas = IM3 CT INPUT
ProcessControl :
Requested I/E power
Actual I/E power
PF control modes
Mode Function Setpoints
Base PF Genset PF is constant – set by
Base PF setpoint. ProcessControl: PF ctrl PtM=BASE PF; Base PF
PF Import / Export Constant Import/Export PF– I/E
PF is measured by controller. ProcessControl: PF ctrl PtM=IM/EX; Import PF;
I/E Qm-meas = IM3 CT input
Constant Import/Export PF– I/E
PF is measured via Analog
input.
ProcessControl: PF ctrl PtM=IM/EX; Import PF;
I/E Qm-meas = IM3 CT input
Analog input: PFctrl:I/E-Qm

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ProcessControl : Import PF
AVR
ProcessControl :
ProcessControl :
LOAD
GCBMCB
IG-AVRi
Controller
Vmains
Imains ph3
PF ctrl PtM = PF IM / EX
Actual I / E PF
Requested I /E PF
I / E - Qm meas = IM 3 CT INPUT
AV Ri ou t p u t
Import PF
AVRi output
AVR
LOAD
GCBMCB
Controller
IG-AVRi
PfCtrl:I/E-Qm
Analog input: Vmains
Imns 3
Actual I/E PF
Requested I/E PF
PF ctrl PtM = PF IM/EX ProcessControl :
ProcessControl :
ProcessControl : I/E- Qm meas = ANALOG INPUT
Load shedding
All LOAD SHED outputs are activated (closed) to trip the unessential load when gen-set goes to island:
a) When GCB is closed after mains fail and gen-set starts in SEM / AUT mode.
b) When MCB opens from parallel to mains operation in SEM / AUT mode.
c) Before MCB is opened in MAN mode by button.
The load shedding function is active in all controller modes except OFF.
Load shedding has three steps and each step is linked with its own Load shed x binary output. There is only
one load shed level and delay for all three steps as well as recon level and delay. Load shed can only move
from one step to the next, e.g. No LoadShed to LdShed S1 to LdShed S2 to LdShed S3 and vice versa.
If manual reconnection of the load is desired, the AutoLd recon setpoint needs to be disabled (AutoLd recon
=DISABLED) and the MAN load recon binary input needs to be configured.
Rising edge on this input resets the controller to a lower stage, but only if the load is under the Ld recon level
at that moment.
Hint:
If no Load Shedding outputs are configured, there is no record to history and no scrren timer indication of the
activity of this function.

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Load reconnection – automatic -> AutoLd recon = ENABLED
Gen-set power
Ld recon level
BO Load shed 3
BO Load shed 2
BO Load shed 1
opened
opened
opened
Ld recon del Ld recon delLd recon del
Load reconnection – manual -> AutoLd recon = DISABLED
Test on load – SPtM
Affects the behavior in TEST mode. Before the activation of this function
1. adjust setpoint AMF settings: ReturnTo mains = DISABLED
2. adjust Process control: MFStart enable = YES.
3. switch controller to Test on load mode (see drawing below)
Gen-set starts and goes to load (synchronizes to the mains, closes GCB and opens MCB) automatically
when this input is closed even if Mains is OK.

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Gen-set stays running in parallel with mains during the soft load transfer from the mains to the gen-set until
Import power = 0. When the load is bigger than Nominal power, MCB stays closed, BO WrnTstOnLdFail is
closed and warning message is issued (WrnTstOnLdFail). This message is issued also when GCB is closed
and Load Ramp timer is counted down.
When the controller is switched from Test on load mode (and Mains is OK), it synchronizes MCB, stays
running in parallel for BreakerOverlap time (soft load transfer), opens GCB, cools down and stops.
During the load transfer from the gen-set to the mains can be BreakerOverlap time shortened due to the
influence of: Load ramp, GCB open level, GCB open del setpoints.
Hint:
It is possible to configure both binary inputs (Remote TEST and Test on load) to only one controller physical
binary input internally.
Power derating
This function linearly decreases genset nominal power according to analog input value.
Gen-set power starts decreasing when temperature measured by Analog input PowerDeratingX exceeds
DeratingX strt value.
Gen-set power is at DeratedX pwr value when temperature measured by Analog input Power deratingX is
equal or higher than DeratingX end value.
Hint:
To use Power derating function configure at first Analog input PowerDeratingX to any IGS-NT or IS-AIN
analog input terminal by GenConfig.
When Power derating function is active the generator overload protection is based on the Derated power! ! !
Derated power value Pg derated is visible in the controller measure screen.
When derating function is not active the Derating power is equal to Nominal power.
Example :
Nomin power = 200 kW, Derating1 strt = 70 °C, Derating1 end = 100 °C, Derated1 pwr = 70 %.
Genset is running at Nominal power 200 kW. When temperature reached 70 °C the genset power starts
decreasing. When temperature reached 100 °C genset runs at 70 % of Nominal power = 140 kW. When
temperature increased above DeratingX end temperature level, gen-set power stays at DeratedX pwr level
140 kW.
Temperature derating function
decreases genset power depend
on setpoints DeratingX strt,
DeratingX end and DeratedX pwr.
Temperature derating starts at
DeratingX strt temperature.
At DeratingX end temperature runs
genset at DeratedX pwr level.
Above DeratingX end temperature
Genset runs at constant DeratedX
pwr.

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Engine states
Engine prelubrication
Engine params: PrelubrTime
PrelubrPause
Prelubr pump
Not lubricated
Hint:
To use Prelubrication, configure Binary output PRELUBR PUMP first.
Prelubrication is disabled in controller OFF mode or if Prelubr time is set to zero.
Binary output PRELUBR PUMP is opened when engine is running.
Prelubrication cycle starts with PrelubrPause after engine stop.
Prelubrication cycle starts immediately when controller power supply is switched on or when mode changes
from OFF to MAN or AUT or after Emergency stop was reset. An Alarmlist message “Not lubricated” is active
until this first lubrication cycle has been completed.
Engine cooling
Engine warming
Service time alarm
Engine starting procedures

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Engine starting procedure if Engine params:Fuel solenoid = DIESEL ENGINE with different setting of
FuelSol offset.
Engine starting procedure if Engine params: Fuel solenoid = GAS ENGINE
Engine starting procedure with own starting procedure:
Engine is started after Starting RPM reach starting leve or other condition. BO: Starter is deactivated only if
one of those condition is fulfilled.
Generator nominal voltage is 231V but during Cranking is forced to 1000V until engine in Idle state (at least
one of condition has to be fulfilled).

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Unsuccessful start – no Engine params: Starting RPM reached
MaxCrank time
BO: Fuel solenoid
RPM
BO: Starter
Start fail activated only if this
has been the last start attempt in
a series.
BO: Start fail
Starting RPM level not reached
and no other signs of running
engine is present.
Unsuccessful start – RPM disappeared before/after Underspeed protection got active:
RPM dropped under Starting RPM
level and Underspeed enabled
-> protection activated.
Underspeed unblocking
BO: Fuel solenoid
RPM
BO: Starter
Start fail activated because of
RPM loss.
BO: Start fail
level.Starting RPM
Underspeed protection is not yet
Active. Underspeed is detected
only if RPM <= 2 and other
signs of moving engine
present = „still engine“.
Underspeed protection unblocking if Idle time < 5s:
Underspeed protection unblocking if Idle time > 5s:

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Transition Idle -> Nominal RPM, protections unblocking:
Preventilation (if Fuel solenoid = GAS):

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Ventilation (if Fuel solenoid = GAS ENGINE):

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Engine stopping procedures
Normal engine stop:
Pick-up sensor fault – forced engine stop:
pick up signal
BO: Stop pulse
BO: Stop solenoid
BO: Fuel solenoid
actual RPM
Stop time
Moment of the pick -up
sensor fault – measured
RPM=0.
In this moment „still engine“
is detected. If pick-up sensor
failed, there may be other
signals determining if
engine is still moving or not.
1s
Normal engine stop, but Stop time is set too short:

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Unsuccessful engine stop:
BO: Stop pulse
5s
BO: Stop solenoid
Stop time
BO: Fuel solenoid
RPM + pick - up signal > 0
Stop command issued, but
no reaction.
The cyclic stop attempts
continue until the engine
actually stops.
Stop time
In this moment the Stop time
elapsed, but the engine is still
moving. „Sd Stop fail“ alarm
appears.
The fuel or stop valve probably
stucked in wrong position.
“Forced” stop in still state:
Spontaneous engine start-up: