ComAp InteliSys COX Control Manual Download

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InteliSys

-AFR-Abstract, SW version 1.0, ©ComAp – December 2006 34

IS-NT-AFR-1.0-Abstract.pdf

AFR control chart

… corresponds to software version 1.5

Pgen [ kW ]

MAP

Sensor characteristic-y

ANALOG INPUT

MAT

Sensor characteristic-z

ANALOG INPUT

MAP

Gen-set power kW

Required

MAP

AFR gain
AFR int
AFR der

Mixer PID control

LowM

wer

AUTOMATIC

Mixer position

Low MAP
High MAP
MAT reference
MAT correction

Low MAP power

High MAP power

MisfMAP reduct

BINARY INPUT

Misfiring

MisfLdRed del
Misfiring del

Actual

MAP

MAP difference
MAP timeout

MAP range protection

Engine

Shut down

Load

Sensor characteristic-v

ANALOG INPUT

UEGO

Diff O2
Diff O2 del

Sensor characteristic-w

ANALOG INPUT

Mixer feedback

Indication

History record

Knocking del

Knocking protection

BINARY INPUT

DxLoad reduct

Engine

Shut down

Oxygen range protection

Mixer BO hyst

Mixer Up/Down

control

Mixer feedback

Mixer up

Mixer down

Mixer position

BINARY OUTPUTS

Sensor characteristic-x

ANALOG INPUT

Ana CH4

Start, Run, LoPwrPosition

Mixer

MODE

MANUAL

Mixer position

LowMAP

power

ANALOG

OUTPUT

%CH4

DISABLED

ENA-FIX

Ana CH4

GCB closed

opened

closed

RunPosition

RunPosition2

BINARY INPUT

Force value

opened

closed

BINARY INPUT

EngineRunning

StartPosition

StartPosition2

opened

closed

opened

closed

MxPos40%CH4
MxPos60%CH4

%MxPosition

LoPwrPosition

LoPwrPosition2

Timing chart

w MAP

LoPWR position

Engine states

fix position

Run position

Start position

Sta

B cl

osed

Mixer regulation

Run position

ngi

ne s

top

Start position

fix position

LoPWR ...

Summary of Contents for InteliSys COX

Page 1: ...90 611 Fax 420 266 316 647 E mail 40Hinfo comap cz 41Hwww comap cz AFR CONTROL GUIDE Compact Controller for Stand by and Parallel Operating Gen sets InteliSysNT AFR Gen set Controller Air Fuel Ratio controller for Lean burn systems with SPI SPtM MINT COX Software version IS NT AFR 1 0 December 2006 ...

Page 2: ... Operator interface 7 InteliSysNT pushbuttons and LEDs 7 Description of InteliSysNT MEASUREMENT screens 12 Users and Passwords 18 Mode and function description 19 OFF mode 19 MAN mode 19 AUT mode 19 TEST mode SPtM only 20 IS NT Air Fuel Ratio control software 21 Hardware 22 Binary inputs 24 Binary outputs 25 Analog inputs 25 Logical analog values 26 Statistics values 27 Setpoints Timers setting 28...

Page 3: ...onal HW Forward and reverse synchronizing Mains protection including vector shift load and power factor control earth fault protection are the major functions provided Interfacing to foreign synchronizers and load sharers is supported The key feature of NT family controllers is their easy to use installation and operation Predefined configurations for typical applications are available as well as ...

Page 4: ...nd everybody concerned with installation of the gen set Includes information about following topics Terminals and dimensions of all controllers and peripheral modules Recommended wirings Controllers interface options Default sensors Speed governor interfaces AVR interfaces Technical data IGS NT 2 0 Operator guide pdf Dedicated to everybody concerned with operation and maintenance of the gen set It...

Page 5: ...on Password and access code GenConfig 2 0 pdf This manual describes GenConfig configuration PC tool in the following chapters Connection to the controller Direct Modem Internet InteliDDE Server Menus description Controller configuration steps Modules I O Setpoints Protections History Inteli common manuals InteliCommunicationGuide September 06 pdf This manual covers communication topics not only re...

Page 6: ...nd Fuel to avoid unexpected automatic start of gen set and GCB closing 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 CAUTION Dangerous voltage In no case touch the terminals for voltage and current measurement Always properly con...

Page 7: ...creen Go to selected display group directly Measurement screens Go to another screen directly Language screen Select language directly History screen If pressed button a symbol appears on the display bottom right corner and it is possible to move by one page of records using arrow buttons 2 Clear Clears character on the left side of the cursor exits from menu 3 Enter 1 2 3 4 5 6 7 8 9 24 23 10 22 ...

Page 8: ...t language 14 Select the setpoint setpoint group select the screen select history record decrease setpoint value edit stringlist value select language 15 In AlarmList screen shift the Alarm list page down if more than 7 items moves history record displayed columns to the right 16 In AlarmList screen shift the Alarm list page up if more than 7 items moves history record displayed columns to the lef...

Page 9: ...ne and table of characters See picture on the right How to view Alarm list 1 Select the ALARMLIST menu item and press ENTER or press in measurements screens to go directly to the Alarm list How to view measured data 1 Select the MEASUREMENT CU menu item and press ENTER 2 Use and to select the screen with requested data How to view IO values 1 Select the MEASUREMENT IO menu item and press ENTER 2 U...

Page 10: ... 1 Lang sel xxx C 0 0 0 0 1 1 1 1 How to change the display contrast Press and hold ENTER and use or to adjust the best display contrast Hint Available from the MEASUREMENT screens only How to check the serial number and software revision Hold down the ENTER and then press ESC On the display you can see controller INFO screen for 10 seconds InteliGenNT InteliSysNT Controller INFO screen contains 1...

Page 11: ...accept all alarms an asterix mark disappears when an alarm is accepted by FAULT RESET Non active alarms immediately disappear from the list Active alarm list appears on the screen automatically when a new alarm comes up and Main MEASUREMENT screen was selected Hint Alarm list does not activate automatically if the display is switched to any other screen than the first one of MEASUREMENT typically ...

Page 12: ... machine state indication 7 Actual gen set power requested gen set power 8 Actual RPM 9 Indication of access level from the controller panel Closed lock No password set Opened lock Password is set Password level is visible in opened lock 10 Controller date and time Can be set in Date Time group of setpoints 1 Alarm list 1 Details of the alarm from ECU indicated by the cursor are displayed at the b...

Page 13: ... BaseLd BldEmLm PwrI E TbyPwr 2 PF control mode Island BasePF PF I E 3 Required power value 4 Required PF value 5 Actual Mains active power and PF values 6 Actual load active power and PF values 7 Actual gen set active power and PF values 1 Generator frequency 2 Generator voltage phase phase 3 Generator voltage phase neutral triple bargraph 4 Generator current triple bargraph 1 Mains frequency 2 M...

Page 14: ...hase voltage 5 Mains first phase voltage 6 Voltage match of all three ph 0 doesn t match 1 OK 7 SRO Speed Regulator Output indication in the range SpeedGovLowLim SpeedGovHiLim 8 VRO Voltage Regulator Output indication in the range 0 100 Statistics 1 Total engine running hours 2 Total number of starts 3 Total number of unsuccessful starts 4 Service times set in Engine protect group of setpoints 5 T...

Page 15: ...TimerAct T1 4 TimerAct T5 8 TimerAct T9 12 TimerAct T13 16 11 11 AFR control Mixer position Mixer feedback MAP required MAP actual MAT actual O2 actual Mixer mode Measurement IO SPtM Screens Description IS NT analog inputs 1 Analog input 1 e g Oil pressure 2 Analog input 2 e g Primary water temperature 3 Analog input 3 e g Fuel level 4 analog input 4 e g Secondary water temperature 1 2 4 3 ...

Page 16: ...mAp December 2006 16 IS NT AFR 1 0 Abstract pdf IS NT binary inputs indication IS NT binary outputs indication If the temperatures of cylinders are configured measured it is possible to see bargraphs of these temperatures on the separate screen ...

Page 17: ...res from the average temperature Further screens are automatically added if I O extension modules or ECU are connected to the controller History 1 Bottom lines show record number reason date and time even if other columns are actually displayed Users Password This screen shows list of users To enter or change password of selected user press Enter 1 ...

Page 18: ... even if the password is set from different terminal Even though one level may have been set from the front panel the affected set points are not accessible from InteliMonitor direct or Modem until this level is set in InteliMonitor direct or Modem Set point screen opened from front panel is automatically closed 15 minutes after the last key has been pressed It is possible to protect remote Start ...

Page 19: ...OSE output b If controller detects voltage on the bus starts synchronizing 4 To stop the engine press STOP a controller unloads the gen set opens GCB CLOSE OPEN Unloading is active only when binary input MCB feedback is closed or other gen set is connected to bus In other case GCB CLOSE OPEN opens immediately b Gen set is cooled down and stopped Hint Controller does not respond to external signals...

Page 20: ...t automatically without warning when pressing FAULT RESET after shut down alarm Baseload Process control Load ctrl PtM BASELOAD Gen set power is kept at value given by Process control Base load setpoint 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 co...

Page 21: ...ault sensors ENG_CHN trn Eng_esp trn China Dictionary Spain dictionary 10_134_1_5 IDX Index file Available documentation PDF files Description IS NT AFR 1 0 Abstract pdf AFR functions description GenConfig 2 0 pdf Manual for PC configuration tool InteliMonitor 2 0 pdf Manual for PC monitoring tool Related documents IGS NT MINT 2 0 pdf Manual for standard IG IS NT Multiple INTernal application IGS ...

Page 22: ...InteliSysNT AFR Abstract SW version 1 0 ComAp December 2006 22 IS NT AFR 1 0 Abstract pdf Hardware ...

Page 23: ...emperature Water pressure BI1 BI2 BI3 BI4 BI5 BI6 BI7 BI8 BI9 BI10 BI11 BI12 BI13 BI14 BI15 BI16 AI1 AI2 AI3 AI4 Voltage output AO IS CU IS AIN Mixer GCB close open MCB close open Alarm Horn Idle Nominal relay Prelubr pump GasVTest run Ignition Cooling pump Common warning Common shut down MAP ctrl fail BO1 BO2 BO3 BO4 BO5 BO6 BO7 BO8 BO9 BO10 BO11 BO12 BO13 BO14 BO15 BO16 Starter relay Fuel soleno...

Page 24: ...oad ctrl Load ramp to value Gener protect Min Power PtM Activates Engine Slow stop Cool down after AFR control Misfiring del The engine shut down is activated when Misfiring unload protection is activated 5 times in one hour Alarm list and History record Sd Misfiring The internal modulo 5 counter is reset after one hour without Misfiring activation or after engine Stop BI Misfiring Engine Genset l...

Page 25: ...etpoint this output generates 1 sec pulse kWh value starts calculating from setpoint change Analog inputs MAT Analog input for Manifold mixture temperature Engine Slow stop Cool down is activated when MAT sensor fail is detected MAP Analog input for Manifold mixture pressure recommended resolution of sensor characteristics is 0 1 Bar Engine Shut down is activated when MAP sensor fail is detected A...

Page 26: ...figure sensor characteristics with one decimal point i e format 10 0 Mixer fdb Analog input for mixer feedback position Mixer feedback is used for binary mixer position control only and it is not used for mixer control via analog output indication only Mixer feedback sensor characteristics must be configured in the range 0 0 to 100 0 to be the same dimension as Mixer position output Logical analog...

Page 27: ...vice time has elapsed the corresponding Service time X setpoint must be adjusted again to a konzero value to clear the alarm and begin a new countdown You can rename the particular timers using Translator to indicate specific service intervals e g OilChange time SparkPlug time PulseCounter 1 PulseCounter 2 PulseCounter 3 PulseCounter 4 The inputs are linked with corresponding counters which integr...

Page 28: ...oller is switched from MAN to AUT mode or when controller is switched ON in AUT mode when Timer is active Baseload FastEdit It is possible to change setpoint ProcessControl Base load from controller panel instead from Process control setpoint group 1 Press button on controller numeric keyboard to open Fast Edit screen There is actual value and limits 2 Change Baseload value using UP DOWN 1 increme...

Page 29: ...unts down to zero Step 1 h Range 0 to 65535 h Setpoints AFR control GasVTEST ENABLE DISABLE ENABLE Binary output GasVTest run Gas valve test is activated before each engine start by Binary input Rem start stop in AUT mode START button in MAN and SEM mode In TEST mode when is not Mains fail DISABLE Engine starts after start command without Gas valve test Hint Gas Valve TEST procedure is skipped dur...

Page 30: ... RunPosition Mixer fix position after engine reaches Nominal RPM when GCB is opened Position is active when Binary input GasSelection is opened Step 0 1 Range 0 0 to 100 0 LoPwrPosition Mixer low power fix position after GCB is closed until gen set reaches Low MAP power Position is active when Binary input GasSelection is opened Step 0 1 Range 0 0 to 100 0 Hint Use Force value function to force di...

Page 31: ...ing sensor characteristics and setting of MxPos40 CH4 and MxPos60 CH4 PID control ENA STEP ENA FIX ENA FIX Dif1 ENA FIX Dif2 PID control Dif1 and Dif2 depends on Binary input Gas selection see below Binary input Gas selection opened closed Dif1 RunPosition1 StartPosition1 RunPosition2 StartPosition2 Dif2 LoPwr position1 StartPosition1 LoPwr position2 StartPosition2 Low MAP power kW MAP characteris...

Page 32: ...mains MCB is closed Mixer position Mixer position when Mixer MODE TEST Step 0 1 Range 0 0 to 100 0 Mixer BO hyst Hysteresis for Mixer binary control via Binary outputs Speed up Speed down See chapter Binary outputs Step 0 1 Range 0 0 to 100 0 AFR gain Gain for AFR control loop Step 0 1 Range 0 0 to 200 0 AFR int Integration factor for AFR control loop Step 1 Range 0 to 100 Rough calculation of spe...

Page 33: ...ry input Misfiring is activated for Misfiring del Step 1 s Range MisfLdRed del to 600 s Knocking del s Engine shut down protection is activated when binary input DxLdReduct is activated for Knocking del Step 1 s Range 0 to 600 s MAP difference Bar Allowed difference from MAP characteristic Low MAP High MAP Step 0 001 Bar Range 0 000 to 1 000 Bar MAP timeout s Engine shut down is activated when act...

Page 34: ...ixer feedback Indication History record Knocking del Knocking protection BINARY INPUT DxLoad reduct Engine Shut down Oxygen range protection Mixer BO hyst Mixer Up Down control Mixer feedback Mixer up Mixer down Mixer position BINARY OUTPUTS Sensor characteristic x ANALOG INPUT Ana CH4 Start Run LoPwrPosition Mixer MODE MANUAL Mixer position LowMAP power ANALOG OUTPUT CH4 DISABLED ENA FIX Ana CH4 ...

Page 35: ...ions are activated from Low MAP power Active Sprinkler function blocks engine stop due to MAP control fail Misfiring Knocking and Oxygen protection engine stays running even if any from those protections is active Sprinkler protection does not block MAP and MAT sensor fail detection engine will stop when MAP or MAT sensor fail is detected even if BI Sprinkler is active Not configured MAP or MAT an...

Page 36: ...st Gas valve test shut down Dongle incomp Corresponding AFR dongle is missing Number of programmable functions of IS NT AFR branch Config item Selection available IS NT Note Log Func I 64 AND OR 2 to 8 inputs Binary output Log Func II 16 XOR RS flip flop 2 inputs Binary output Comp Hyst 16 Analog input Two limits Binary output Comp Time 8 Analog input One limit delay Binary output Ana Switch 16 Tw...

Page 37: ...falling edge delay PID control with Analog output and adjustable Bias 4 PID Analog output jumps to adjustable Bias value when Gate input is active instead zero as before and starts from Bias Ext Math 8 Math functions with expandable number of inputs up to 8 Selectable ADD AVG MAX MIN Eight analog inputs one analog output Comp Win 16 Window comparator Analog input two limits analog output Binary ou...

Page 38: ...f independent device e g cooling pump Use PLC function Timer as minute marks time base Connect Binary input Run to measured signal e g cooling pump output Analog input reload set to constant value 300 i e period 1 minute PLC Timer output connect internally to Logical Binary input Pulse counter 1 Renamed Force value 3 Default LoPwrPosition 1 setting Name of binary input switch Renamed from Force va...

Page 39: ...tomatic Voltage Regulator interface IG EE InteliGen for Electronic Engines HW optimized for connection to an engine equipped with ECU IG EEC InteliGen EE controller with extended communication possibilities switchable sensing ranges of AC voltages and currents IG IB IG Internet Bridge for internet ethernet communication IGL RA15 Indication panel with LEDs signalizing state of 15 BO IG NT InteliGen...

Page 40: ...ization of running gen sets on the site with multiple gen sets based on kW kVA spinning reserve or on relative load no master system ensures high reliability SHAIN Shared virtual Analog INput module SHAOUT Shared virtual Analog OUTput module SHBIN SHared virtual Binary INput module SHBOUT SHared virtual Binary OUTput module SPI Single Parallel Island application for single gen sets in parallel wit...

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