Comprehensive Modular Genset Controller

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1 Inteligen Click Here To Learn More Comprehensive Modular Genset Controller

2 Brief Description The Inteligen is a comprehensive controller for single and multiple generating sets operating in standby or parallel mode. The Inteligen has the built in ability to provide complete transfer switch control including synchronizer and breaker control, if desired. A modular construction allows upgrades to different levels of complexity in order to provide best solutions for various customer applications. Built in synchronizer, isochronous load sharer, Mains and generator protections allow fully integrated solution for gensets in stand-by and parallel modes with multiple engine support. The Inteligen controller is equipped with a powerful 128 x 64 back-lit graphic display with icons, symbols and bar graphs for intuitive operation, which sets, together with high functionality, new standards in genset controls. At the heart of this controller beats a 16-bit micro-controller. Because of the offered software package together with the communications capabilities gives the customer many possible ways to communicate with the operating genset. There are three main ways one can connect with the Inteligen, via direct RS232, modem (land line or wireless), and Internet. Connecting through the modem one can enable the Inteligen to call out when any alarms are activated.

3 Features of the Inteligen Basic Features Large graphic back-lit LCD display 128x64 pixel resolution Automatic or manual engine starting and stopping Phase sequence supervision Automatic shutdown / alarm function Input frequency Hz Parameters adjustable via PC or ig keyboard Predefined and user definable configurations available. One configuration includes set of inputs/outputs and parameters. Adjustable parameters for each configuration. 6 LED indicators (Mains O.K., Gen C.B. ON, Mains C.B. ON, Engine Running / Alarm Push buttons for simple control 4 programmable outputs (out of 20 functions selection) 4 binary configurable inputs Lamp test during start up Real time clock Sealed membrane panel to IP x 113 mm front panel mounted case Metering Speed measurement from magnetic pickup Oil pressure measurement Coolant temperature measurement Battery volt measurement Fuel level measurement Running Hour Meter All Generator metering, kvar, kw, V1-V3, Hz, I1-I3, kwh, kvah Protection Fuel level low alarm Over Speed Protection Oil Pressure Alarm / Shutdown Coolant Temperature Alarm / Shutdown Battery Low Alarm Fuel Level Low Alarm Running Hour Meter All Generator metering, kvar, kw, V1-V3, Hz, I1-I3, kwh, kvah Generator Under / Over Voltage Alarm / Shutdown Generator Under / Over Frequency Alarm / Shutdown Over Current Alarm / Shutdown Engine Control Warm up and cooling functions Pre-lubrication function with timers Adjustable crank attempts Data Logging Back up history of the engine operation for back tracing up to 177 entries can be help Communications RS232 / Modbus communication support Modem communication support

4 Transfer Switch Control Generator C.B. control with feed-back Mains C.B. control with feed-back incl. mains return timer Active support of external load sharer and synchronizer 3 Phase AMF function - Over- /under frequency Over- /under voltage Voltage asymmetry

5 Modules Kit 1: ig-pcm, Power Control Module Automatic synchronizing Reverse synchronizing Speed / voltage control in standby operation Reverse power alarm/shutdown Load control incl. ramping 2 analog outputs (AVR incl. power factor control and speed control) 4 programmable outputs (selectable) 4 digital inputs (configurable) Import / export control Earth fault protection Kit 2: ig-vs, Vector Shift Protection, Software Mains vector shift protection Kit 3: ig-pclsm, Power Control and Load Sharing Module Power control module incl. analog isochronous load sharing line Kit 4: ig-com, Communication and Power Management Module CAN bus module including CAN communication interface Interconnection of several GNS3000 controllers and/or for interface to supervision system Optimizing the number of engines running in parallel Kit 5: ig-iom, I/O Extension Module 8 Extra binary configurable inputs 8 Extra binary programmable outputs 4 Extra configurable analog inputs 1 Analog output Kit 6: ig-mu, Modem Extension Controls several gensets in parallel via one Modem 1 CAN Bus interface and 1 RS232 interface with direct modem communication support Kit 7: ig-avri, Automatic Voltage Regulator Interface Matches to various AVR input

6 Functioning The Inteligen is a compact controller for complete management of gensets in standby or parallel running mode. The Inteligen automatically starts the gensets, closes the genset C.B. when all conditions are met, then stops the engine on external signal or by pushing stop push button. With upgrade kit s full criteria for isolated parallel and parallel with mains operation are met. Forward and reverse synchronizing, mains protection incl. vector surge, load and power factor control, earth fault control are the main functions. Power control for external load sharing modules provided. The key feature of Inteligen is its easy-to-use operation and installation. 16 predefined configurations for typical applications are available. 16 user-defined configurations are for special requirements. Configuration could be selected from the front panel or via Windows based Software WinEdit. The heart of the Inteligen controller is designed on the high performance 16bit micro-controller. The Inteligen is specially designed for high noise immunity and for considerable fluctuation of the power supply.

7 Inteligen System Overview

8 Inteligen Transfer Switch Control Overview

9 Features of Inteligen Central Unit LED indicators (Mains OK, Generator C.B. ON, Mains C.B. ON, Engine Running/Alarm) RPM input Battery voltage measurement Relay outputs 16 A (starter crank, fuel solenoid) Pre-configured digital inputs (Generator C.B. feedback, mains C.B. feedback, emergency stop, charger failure, remote start/stop) Configurable digital inputs Pre-configured digital outputs (general alarm, Generator C.B., mains C.B., Horn) Configurable digital outputs Pre-configured analog inputs (Engine oil pressure, Engine water temperature, fuel level) Mains voltage inputs Generator voltage inputs Generator current inputs RS232 and CAN interface Additional plug-in power control board (ig-pcm) 1 Output for voltage or power factor control (ig-avri) 1 Output for speed governor control 4 Digital inputs (configurable) 4 Open collector outputs (programmable) 1 Analog load sharing line (ig-pclsm) 1 CAN Bus Modem Extension Unit (ig-mu) 1 RS232 interface with direct modem communication support

10 Additional plug-in communication and power management (ig-com) 2 CAN bus interfaces Additional plug-in input/output board (ig-iom) 8 Digital inputs(configurable) 8 Digital outputs (programmable) 4 Analog inputs (configurable) 1 Analog output (programmable) Modem / PC Solution

11 Modem Parallel Operation Solution Load Sharing + Power Management + Import / Export Control G GOVERNOR G GOVERNOR G GOVERNOR IM-CU Load Sharing Line CAN Power Management Modem IG-MU *Note: Additional modules will be needed to accomplish the above-pictured tasks. Modules that may be needed include ig-pcm, ig-pclsm, ig-com, etc. PC

12 Panel Cutout and InteliGen Dimensions

13 Technical data Power supply Voltage supply 8-36V DC Consumption depends on supply voltage 0,4A at 8VDC; 0,1A at 36VDC Battery voltage measurement tolerance 2 % at 24V RTC battery live 1 0 year Operating conditions Operating temperature o C Storage temperature o C Protection front panel IP65 Humidity 85% without condensation Standard conformity Low Voltage Directive EN :95 +A1:97 Electromagnetic Compatibility EN :94, EN :96 EN :99, EN :97 Vibration 5-25 Hz, ±1,6mm Hz, a = 4 g Shocks a = 200 m/s 2 Dimensions and weight Dimensions Weight Mains and generator Nominal frequency Frequency measurement tolerance 180x120x50mm 800g 50-60Hz 0,1Hz Current inputs Nominal input current (from CT) Load (CT output impedance) CT input burden Max. measured current from CT Current measurement tolerance Max. peak current from CT Max. continuous current Voltage inputs Measuring voltage Maximal measured voltage Input resistance Voltage measurement tolerance 5 A < 0,1 Ω < 0,2 VA per phase (In=5A) 11 A 2% from the Nominal current 150 A / 1s 12 A 231VAC phase to neutral 400VAC phase to phase 290VAC phase to neutral 6 MΩ phase to phase 6 MΩ phase to neutral 2 % from the Nominal voltage

14 Overvoltage class III (EN61010) IG-MTU Primary voltage Ph-Ph Secondary voltage Ph-N Mechanical dimensions: Binary inputs and outputs 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 Binary inputs Number of inputs 9 Input resistance 4,7 kω Input range 0-36 VDC Switching voltage level for close contact indication 0-2 V Max voltage level for open contact indication 8-36 V Contact relay outputs Number of outputs 2 Electric life cycle min switching cycles Maximum current 12 A DC resistive load 4 A DC inductive load Maximum switching voltage 36 VDC Minimum load 24 V / 0,1 A Insulation voltage 500 Veff Binary open collector outputs Number of outputs 7 Maximum current 0,5 A Maximum switching voltage 36 VDC Analog inputs Not electrically separated Resolution Sensor resistance range Resistance measurement tolerance 10 bits 0 Ω-2,4 kω 4 % ± 2 Ω out of measured value Speed pick-up input Type of sensor magnetic pick-up (connection by shielded cable is recommended) Minimum input voltage 2 Vpk-pk (from 4 Hz to 4 khz) Maximum input voltage 50 Veff Minimum measured frequency 4 Hz Maximum measured frequency 10 khz (min. input voltage 6Vpk-pk) Frequency measurement tolerance 1,5 % RS232 interface Maximal distance Speed 10m 19.2kBd

15 Recommend external converter: ADVANTECH ADAM 4520: RS232 to RS422/485 converter, DIN rail, automatic RS485 bus supervision, no external data flow control signals, galvanic isolated. Recommended internal converter: ADVANTECH PCL-745B or PCL745S : Dual port RS422/485 Interface card, automatic RS485 bus supervision, no external data flow control signals, galvanic isolated. IG-IOM Voltage supply Consumption Mechanical dimensions: Connection to IG-CU Interface to modem or PC Interface to controller 8-36V DC 0,1A depend on supply voltage 40 x 95 x 45 mm, DIN rail (35 mm) mounted standard IOM cable 2 meters length, not galvanic separated RS232, RS422, RS485 CAN Binary inputs Number of inputs 8 Input resistance 4,7 kω Input range 0-36 VDC Switching voltage level for close contact indication 0-2 V Max voltage level for open contact indication 8-36 V Binary open collector outputs Number of outputs 8 Maximum current 0,5 A Maximum switching voltage 36 VDC Analog inputs Not electrically separated Number of inputs 4 Resolution 10 bits Sensor resistance range 0 Ω-2,4 kω Resistance measurement tolerance 4 % ± 2 Ω out of measured value Analog output Not electrically separated Number of inputs 1 Resolution 10 bits Output range 0 to 20 ma ± 0,33 ma IG-IB Voltage supply Consumption Mechanical dimensions: 8-36V DC 0,1A depend on supply voltage 40 x 95 x 45 mm, DIN rail (35 mm) mounted

16 Interface to controller Interface to modem Interface to Ethernet RS232 or CAN RS232 RJ45

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