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InteliGen

, InteliSys

, InteliMains

– Troubleshooting Guide,

SW version IGS-NT-3.1.0, IM-NT-3.1.0, ©ComAp

– August 2018

IGS-NT Troubleshooting Guide.pdf

List of Abbreviations

AMF

Auto Mains Failure (controller starts automatically on mains failure)

Analog Input

Analog Output

ATS

Automatic Transfer Switch (switches load to supplied bus (by mains or generators))

AVR

Automatic Voltage Regulator

Binary Input

Binary Output

BOC

Breaker Open & Cool-down - protection type (see application manual for details)

BTB

Bus-Tie Breaker

CAN1

CAN bus for ComAp extension modules (e.g. IGS-PTM) and engine ECU
connection

CAN2

CAN bus for communication between ComAp controllers and communication
modules connection (e.g. I-LB+)

COX

Application for Complex Systems where actions are taken by a PLC and controller
only follows orders => needs an external driver (cox)

Current Transformer

ECU

engine Electronic Control Unit

ESF

Engine Specific File

Forward synchronisation

Synchronisation of unloaded genset to mains (GCB closing process)

FMI

Failure Mode Identifier

Graphical Characters - option for additional support of one "graphical" language

GCB

Generator Circuit Breaker

CHP

Combined Heat & Power - cogeneration application, usually with gas engine

I-AOUT8

Extension module with 8 AO

I-CB

Communication Bridge - interfaces IS, IG/IS-NT, ID controllers and non-standard
engine ECU

IG-AVRi

IG Automatic Voltage Regulator interface

IG-EE

InteliGen for Electronic Engines (HW optimized for connection to an engine
equipped with ECU)

IG-EEC

InteliGen EE controller with extended communication possibi switchable
sensing ranges of AC voltages and currents

IG-IB

IG-Internet Bridge - for internet/ethernet communication

IGL-RA15

Indication panel with LEDs signalizing state of 15 BO

IG-NT

InteliGen New Technology gen-set controller

IG-NTC

InteliGen NT controller with extended communication possibi switchable
sensing ranges of AC voltages and currents

IGS-NT-LSM+PMS

Dongle for IG-XX and IS-NT to enable Load Sharing and VAr sharing control loops
and PMS

IGS-PTM

Extension module with 8 BI/BO, 4 AI and 1 AO

I-LB

Local Bridge

– for direct and modem monitoring and control of multiple gen-sets

IM-NT

InteliMains New Technology - Mains supervision controller; the same controller with
a different SW configuration can work as a bus-tie synchronizer

I-RB

Relay Board

IS-AIN8

Extension module with 8 AI.

IS-BIN8/16

Extension module with 8 BO and 16 BI.

Содержание InteliGen NT

Страница 1: ...1 Fax 266 31 66 47 E mail info comap control com www comap control com TROUBLESHOOTING GUIDE Compact Controller for Stand by and Parallel Operating Gen sets InteliGenNT InteliSysNT InteliMainsNT Modular Controller Troubleshooting guide IG NT IG NTC IG NT BB IG NTC BB IS NT BB IS NTC BB IM NT IM NT BB IM NTC BB Software version IGS NT 3 1 0 IM NT 3 1 0 August 2018 ...

Страница 2: ...pushing command buttons or setting adjustments 12 InteliVision InteliVision 8 and image retention 13 Synchronizing Load control 14 Gen set voltage is increasing decreasing over under the limits during synchronization 14 GCB is opened before the Load ramp time is over 14 Sync fail alarm is issued 14 MGCB is not closed even all conditions are fulfilled 14 IM NT BTB connects dead buses together 15 Po...

Страница 3: ...uide SW version IGS NT 3 1 0 IM NT 3 1 0 ComAp August 2018 3 IGS NT Troubleshooting Guide pdf Setup your controller to work as the SSB application 23 Setup your controller to work as the SPM application 23 List of Abbreviations 24 List of Possible Events 27 ...

Страница 4: ...come across when installing operating the IG IS IM NT controllers It also incorporates the How to section with examples of some non standard or interesting applications of these controllers List of Abbreviations and List of Possible Events which contains information about alarm messages which can be displayed by a controller This manual is intended for everyone who is concerned with operation and ...

Страница 5: ...TM SPI and MINT mode powermanagement list of all Setpoints Values Logical Binary Inputs and Logical Binary Output IGS NT COX 3 1 0 Reference Guide pdf General description of COX applications for InteliGen NT and InteliSys NT Contains description of engine and generator control powermanagement list of all Setpoints Values Logical Binary Inputs and Logical Binary Output IGS NT Application Guide 05 2...

Страница 6: ...p before September 2006 It is necessary to download new FW into the communication sub processor It can be done by sending unit to ComAp or by downloading the latest version of Peripheral modules upgrade package and following procedure described in the attached documet Problem accessing controller after configuration programming error Problem It can happen that remote configuration programming atte...

Страница 7: ... or remote connection drop out If controller firmware programming was not successful it is not possible to open connection to a controller it does not respond and controller screen is blank In such case you need to use this procedure for controller programming 1 Close connection to controller and start GenConfig 2 Check communication port setting in GenConfig Go to Options Select connection and se...

Страница 8: ...gs looks like this if you are checking strings on controller with Comms setting Contr address set to 1 and controller does not communicate with any other controllers via CAN2 CAN16 I000000000000000 CAN32 0000000000000000 Strings looks like this if you are checking strings on controller with Comms setting Contr address set to 1 and controller communicates with controllers with Contr address set to ...

Страница 9: ...ake sure that the terminating resistor jumper is closed only in devices which are at the ends of a CAN line b Check if each device connected to a CAN bus has a unique CAN address In case of the CAN 2 bus it means that Comms settings Contr address setpoint has to be set to a unique number in each controller which is connected to the CAN2 bus See Addresses of Modules on CAN2 chapter in Inteli Commun...

Страница 10: ...buttons does not work in the AUT mode b There are active alarms in controller alarm list Button function can not be performed because of an alarm activity Get rid of an alarm first and use a button again c Setpoint Basic settings Local buttons is set to position EXTBUTTONS which means that only external control using binary inputs is enabled Set this setpoint to position PANEL or BOTH to be able t...

Страница 11: ...n to find and alarm text and match it with the default English text Check PLC functions Force protect setting and customized protections see card Protections in GenConfig to find alarm messages which are not listed in the List of Possible Events Wrong display HW message Problem WRONG DISPLAY HW message is displayed if wrong display hardware is detected Solution It is necessary to send IS Display I...

Страница 12: ...er controller reset Reason of the problem are either incorrectly set setpoints or flat RTC battery Solution a A new firmware containing new setpoints was uploaded into a controller Use InteliMonitor online connected to the controller to check all setpoints and fix setting of those which are set in a wrong way You have to change at least one setpoint setting If all setpoints are correct change one ...

Страница 13: ...crystal molecules from returning to their normal relaxed state Image retention reversing burn in can be observed during using InteliVision when retention of the main screen which is displayed for most of the time is strongly visible also on other screens This image retention is not permanent change After some time it fades Solution DECREESE BRIGHTNESS of screen to approx 50 60 This solution helps ...

Страница 14: ... before the Load ramp time is over Problem After reverse synchronization and during generator unloading is GCB opened before the Load ramp time is over Solution a AMF settings BreakerOverlap time is shorter than the Sync Load ctrl Load ramp time setting Set Breaker overlap to the same or longer time than Load ramp setpoint b GCB is opened during generator unloading as soon as generator power level...

Страница 15: ...ng and Power management Fof rmore details see chapter Local Baseload in IGS NT MINT x y Reference Guide Running Hours Equalization does not work properly Problem Gensets priority switching based on engine running hours Pwr management PriorAutoSwap is set to RUN HOURS EQU does not work properly and some or all gensets has the same priority It means that gensets with the same priority behaves as one...

Страница 16: ...uld run in parallel with mains Check state of the Syst res OK signal in InteliMonitor go to Values Log Bout LogBout 4 to see if Act Reserve is evaluated by IM NT as sufficient enough condition for MGCB closing is ActReserve LoadResStrt x Solution a Check if setpoint Pwr management Pwr management is set to ENABLED in genset controllers there is no such setpoint in IM NT itself Act Reserve value PBN...

Страница 17: ... only few new records but with more computers accessing the same site leads to the above mentioned behaviour b Archive was saved with GenConfig tool with version lower than 2 1 GenConfig is offline tool for configuration purposes so archives saved using this tool does not contain actual history data That s why history is not saved at all with this tool Starting from version 2 1 GenConfig is able t...

Страница 18: ... or even zero Power Factor PF value is incorrect too and there is a big difference in PF between phases e g phase L1 power factor is 0 9 and in phase L2 power factor is 0 2 Solution Solution is to adjust CTs connection it means changing polarity of CTs and or swapping their order Correct voltage and current measurement connection Imagine that a generator is loaded with a load bank which burns 100 ...

Страница 19: ...tion is as follows UL1 UL2 UL3 400 V IL1 IL2 IL3 250 A PFL1 1 PFL2 PFL3 0 5 PL1 UL1xIL1xPFL1 400x250x1 100 kW PL2 PL3 UL2xIL2xPFL2 50 kW PTOT PL1 PL2 PL3 100 50 50 0 kW Example of incorrect connection with wrong CT polarity in phase L2 In this case 100 kW is still burned in each load bank phase but PF in phase L2 is not 1 from controller point of view PF in phase L2 is 1 because current goes in th...

Страница 20: ...rollers are powered down time change does not occur due to previous error fixed in 2 6 3 2 9 1 but time is not desynchronized Wrn addr error occurs when updating to new FW Problem Wrn addr error is issued Controller address cannot be changed This may occur after changing CANnegotiation setpoint to AUT and restarting the controller or after update to the new FW version e g IM NT 2 9 to IM NT 2 9 1 ...

Страница 21: ...roller panel log in as administrator default user name of the administrator is U0 go to Users Password in the menu and select user for which you intend to reset the password You will see Reset password option on the screen select it press Enter to confirm your choice and press Esc to get back into the menu Now that user has password set to 0 and it can be set to any value PC SW InteliMonitor log i...

Страница 22: ...binary inputs are evaluated immediately after switching controller on It takes some additional time to run PLC or establish remote communication via CAN virtual periphery SHBIN or with a standard extension module e g IGS PTM Breaker feedback is very important signal for correct controller function and it is strongly recommended to connect it directly to binary input of a controller itself b Check ...

Страница 23: ...ollers but it is no more present among NT applications So you have to modify behaviour of the MINT application to achieve that This type of application can be handled with IL NT MRS controllers Start with the default MINT archive and follow these instructions The controller with MINT COX or Combi in MINT archive can work without Dongle LSM PMS if all following conditions are fulfilled o The power ...

Страница 24: ...cal language GCB Generator Circuit Breaker CHP Combined Heat Power cogeneration application usually with gas engine I AOUT8 Extension module with 8 AO I CB Communication Bridge interfaces IS IG IS NT ID controllers and non standard engine ECU IG AVRi IG Automatic Voltage Regulator interface IG EE InteliGen for Electronic Engines HW optimized for connection to an engine equipped with ECU IG EEC Int...

Страница 25: ...C Occurrence Count number of fault occurrances transmitted in diagnostic frame from ECU OfL Off load protection type see application manual for details PF Power Factor PGN Parameter Group Number refer to SAE J1939 71 PMS Power Management System ensures optimization of running gen sets on sites with multiple gen sets based on kW kVA spinning reserve or on relative load no master system ensures high...

Страница 26: ...InteliGenNT InteliSysNT InteliMainsNT Troubleshooting Guide SW version IGS NT 3 1 0 IM NT 3 1 0 ComAp August 2018 26 IGS NT Troubleshooting Guide pdf controllers via intercontroller CAN2 ...

Страница 27: ...heck module communication activity look at the Tx and Rx LEDs of the CAN bus port Fast flashing means that communication is OK ANA 1 101 A H Indication of error in communication with analog inputs extension module Check if the unit with corresponding CAN address is powered up address of the module is set correctly see Modules card in GenConfig and an extension module manual correctly connected and...

Страница 28: ...nnection powered up terminating resistors are properly connected the CAN bus Low and High wires are not swapped SHBIN 1 41 A H Indication of error in communication with SHBOUT 1 4 module Check that one of the controllers on site is configured as a SOURCE controller has SHBOUT x module configured the SOURCE controller is powered up TARGET and SOURCE controllers are connected to the CAN2 bus and Tx ...

Страница 29: ... alarms are not displayed and considered by controller and this alarm is the setting notification Wrong config A H Wrong controller configuration indication Indicates that controller hardware doesn t support PLC used in configuration In case DISTBIN DISTBOUT is configured and the IS AFC LSM PMS dongle is not used alarm message Wrong config is issued DISTBIN and DISTBOUT function is conditioned by ...

Страница 30: ...tage unbalance is calculated as a maximum difference between phase voltages BusL V unbal Left bus voltage unbalance alarm is based on BusL protect BusL V unbal and BusL V unb del setpoints The voltage unbalance is calculated as a maximum difference between phase voltages BusR V unbal Right bus voltage unbalance alarm is based on BusR protect BusR V unbal and BusR V unb del setpoints The voltage un...

Страница 31: ... params Starting RPM or AI Oil press Starting POil or D terminal active this condition is used only if Engine params D function ENABLED or BI RunIndication 1 or 2 or 3 is active or Generator voltage 15V in any phase See Speed pick up input section in the Technical data chapter in IGS NT x y Installation Guide manual for information about requested pick up signal parametres Sd BatteryFlat A H Alarm...

Страница 32: ...ication genset or group of gensets was not synchronized to mains within Sync Load ctrl Sync timeout time Check setting of setpoints in the Sync Load ctrl and Volt PF ctrl groups Frequency regulation loop Angle regulation loop and Voltage regulation loop are active during synchronisation and you may need to adjust their setting Actual state of synchronization is visible on the controller measuremen...

Страница 33: ... It means that Basic settings FixVoltProtSel is set to PHASE NEUTRAL 19 BOC L12 L23 or L31 under A H Generator L12 L23 or L31 voltage was under the Gen V BOC limit for Gen V del time Undervoltage protections are based on Gener protect Gen V BOC and Gen V del setpoints This alarm is issued if voltage protections are based on phase to phase voltages It means that Basic settings FixVoltProtSel is set...

Страница 34: ...P and Mains V del setpoints This alarm is issued if voltage protections are based on phase to phase voltages It means that Basic settings FixVoltProtSel is set to PHASE PHASE Mains Avg x V A H If the value of 10 min average mains voltage of any phase Mains Avg V1 Mains Avg V2 Mains Avg V3 exceed value given by setpoint Mains Avg V MP Mains protect group the MCB is opened and message Mains Avg x V ...

Страница 35: ...ion this condition applies only if BusL Volt prot is set to ENABLED This alarm is issued if voltage protections are based on phase to phase voltages It means that Basic settings FixVoltProtSel is set to PHASE PHASE BusL L12 L23 or L31 over H Left bus L12 L23 or L31 voltage was over the BusLeft V limit for the BusLeft V del time Information about that is recorded into controller history Setpoint Bu...

Страница 36: ...otSel is set to PHASE PHASE BusR L12 L23 or L31 over H Right bus L12 L23 or L31 voltage was over the BusRight V limit for the BusRight V del time Information about that is recorded into controller history Setpoint BusR protect BusR Volt prot has to be set to ENABLED if healthy bus voltage detection and history record are requested Voltage has to be below the BusRight V limit if BTB synchronisation...

Страница 37: ...limit for Bus f del time Under frequency protection is based on Bus protect Bus f and Bus f del setpoints f bus over H Bus frequency was over the Bus f limit for Bus f del time Over frequency protection is based on Bus protect Bus f and Bus f del setpoints Bus meas error A H Bus measurement error is issued if bus voltage is out of limits For details see description of the Gener protect BusMeasErro...

Страница 38: ...eas low overcurrent means longer reaction time This protection is active if the BusL2Inom prot setpoint is set to ENABLED Protection is based on setpoints BusL protect BusL2Inom del and Basic settings Nomin current BOC ShortCurr A H Generator short current protection was activated Generator current was over Generator protect Ishort level for Ishort del time BOC Overload A H Indicates overload IDMT...

Страница 39: ...vernor output value is within SpeedGovLowLim 0 2V range or SpeedGovHiLim 0 2V range This alarm gives you information that engine speed governor is either connected in a wrong way or one of the speed control related regulation loops6 is set in a wrong way Warning is blocked if binary output functions SPEED up and SPEED down are configured Refer also to Sync load control adjustment chapter in an IGS...

Страница 40: ...3 ActCallCH1Fail CH2Fail CH3Fail A H Indication of unsuccessful active call 1 3 See Inteli Communication Guide for information about active calls See an IGS NT x y Reference Guide for description of setpoints which are part of the Act calls SMS group and are used for active call setup Switched On H Controller was switched on Watchdog H Indication of internal watchdog Send controller archive with h...

Страница 41: ...hanged Alias changed Terminal H External terminal was either connected or disconnected BinaryUnstable H Unstable binary input this problem is usually caused by floating binary input ground Check controller grounding to fix the problem ForceValue H Indication of any configured ForceValue state Force value ON and OFF records are done TimeModeChange H Indication of TimeModeChange summer winter Setpoi...

Страница 42: ...tion See setpoints Mains protect VectorS prot and VectorS limit Other CB trip H Other CB on bus was tripped This information is available for breakers which are controlled by a ComAp controller IG IS NT or IM NT GCB opened H GCB was opened GCB closed H GCB was closed MCB opened H MCB was opened MCB opened ext H MCB was opened externally MCB closed H MCB was closed MGCB opened H MGCB was opened MGC...

Страница 43: ...splayed as Wrn or Sd alarm type Alarm type depends on Protection upon module failure setting in Modules card in GenConfig Available settings are No Protection Warning and Shutdown 2 See setting of Force Protect functions on the PLC card in GenConfig to find out what PLC State x texts were changed to 3 Hold Enter and push Esc to enter the Info screen 1 Push the right arrow to enter Info screen 2 to...

Страница 44: ...ue Go to Monitor and Set statistics to do that 17 It happens if 12V battery is used as power supply and voltage drops during engine starting due to high starter current Use the I LBA module to avoid this problem 18 See the How to check that communication between controllers works chapter for more information 19 Check if generator voltage regulation works properly if this alarm is issued See Volt P...

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