COMAP IGS NT 2.2 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 647E-mail: [email protected], www.comap.cz

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

mailto:[email protected]

http://www.comap.cz/

InteliGenNT, InteliSysNT, InteliMainsNT – Installation Guide, ©ComAp – December 2007 2 IGS-NT-2.2-Installation Guide.PDF

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


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


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 !!!


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 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 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 Generator protections Set point group 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.


Required and optional modules

Accessories Description Standard / Optional IG-EE IG-EEC IG-NT IG-NTC IM-NT

Controller Central Units with internal display

Standard

IS-NT-BB Controller Central Unit without internal display Standard IG-Display Additional display for IG-NT/NTC/EE/EEC, IM-NT Optional IS-Display Additional display for IS-NT-BB Optional IG-AVRI Controller AVR interface Optional IG-AVRi-TRANS/LV IG-AVRi-TRANS/100

Voltage transformer for supplying AVRi module Optional

AT LINK-CABLE 1,8m

RS232 (InteliMonitor, GenConfig) communication cable (It is not a part of controller delivery.)

Optional

IS-AIN8 (V2.4) External analog inputs unit Optional IS-BIN16/8 (V1.6) External binary I/O unit Optional I-LB (V1.0) I-LB+

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.

Optional

IG-IB (V2.1) Internet bridge Optional I-CB/CAT-Gas I-CB/CAT-Diesel I-CB/MTU I-CB/MTU-SIAM4000 I-CB/DeutzTEMe

Inteli - Communication Bridge: Interface unit for some types of engines with ECU (without J1939)

Optional

IGL-RA15 (V1.6) Remote annunciator Optional IGS-PTM (V8.0) External analog, binary I/O unit Optional I-AOUT8 (V1.0) 8 analog outputs unit Optional IG-MTU Voltage transformer unit to separate mains and

generator voltage measurement Optional

IG-MTU-2-1 Voltage transformer unit with voltage ratio 2:1 to separate mains and generator voltage measurement

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 Function No dongle for Single parallel to mains is required. IGS-NT-LSM+PMS Dongle for multiple applications MINT with Load sharing, Var sharing

and Power management function IGS-NT-miniCHP Enlarges the set of PLC functions for simple CHP applications (for

IG-NT and IG-EE controller types) IGS-NT-LSM+PMS-miniCHP

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.


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-NT-x.y-Application guide.pdf.


Terminals and dimensions IG-EE, IG-EEC, IG-NT, IG-NTC, IM-NT

170 (6,7")

185 (7,3")

123

(4,8

“) RS2

32

USB

68

2,7

“

Cutout for IG-XX/IM-NT113 x 175 mm

4,4 x 6,9”

123

(4,8

“)

110

(4,3

“)

IG-DISPLAY

170 (6,7")

185 (7,3")

Cutout for IG-DISPLAY113 x 175 mm

4,4 x 6,9”

123

(4,8

“)

110

(4,3

“)


IS-NT ~1

30 (5

,1“)

30

1,2“

176

(6,9

“)

290 (114,2")

280 (11")

98 (3

,9“)

30

1,2“

110

(4,3

“)

184

(72,

44“)

Cutout for IS-NT178 x 2827,0 x 11,1”

RS

232

US

B

170 (6,7")

68

2,7

“

IS-DISPLAY

30

1,2“

176

(6,9

“)

290 (114,2")

280 (11")

184

(72,

44“)

Cutout for IS-DISPLAY178 x 2827,0 x 11,1”


IS-NT-BB

170 (6,7")

194 (7,6")

123

(4,8

“) RS

232

USB

68

2,7

“

110

(4,3

“)

184 (7,3")

90 (3

,6")

4x o 4,3 35 (1,4") 2x M3

68 (2,7“)

194 (7,6")

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.

IG-AVRi + IG-AVRi TRANS

AVRi

-

AVRi

+

OUT1

OUT2 AC

1AC

2

OCOM

LB 5

Primary terminals 230-277 VAC / 400-480 VAC

0 - 18

43 (1,7”) 43 (1,7”)

36(1

,4”)

0 - 230/277 - 400/480

IG-AVRiTRANS/LV

Secondary terminals 18 VAC

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


IS-BIN16/8

45 (1,8")146 (5,7")

160

(6,3

") 40 (1,6")

25 (1,0")

IN1

-

RPM

+

IN 2

IN1

+

RPM

-

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


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

40 (15,7")

25 (9,8")

70 (27,5")

146 (57,5")

160

(63"

)

POWER8 - 36V DC

CO

M

CAN 1

H L

+

iS-AIN8

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-RA15-2.0-New features.pdf).


165 (6,5”)

38(1

,5”)

40(1

,6”)~75

(3,0

”)

~35

(1,4

”)

180 (7,1”)185 (7,3”)

106

(4,2

”)

44 (1,7”)54 (2,1”)

~25

(1,0

”)

120

(4,7

”)12

5(4

,9”)

Cutoutfor Remote Annunciator

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.


95 mm(3,7´´)

43 mm(1,7´´)

96 m

m (3

,8´´)COMPENSATION

GND

POWER

8-36V DC

BINARY OUTPUTS

BINARY INPUTS ANALOG INPUTS

AI4

BI8

BI7

BI6

BI5

BI4

BI3

BI2

BI1

0-20 mA ANALOG OUT

BO8

BO1

BO2

BO3

BO4

BO5

BO6

BO7

CAN

RxTx

CAN

LH

COM

LB 4

AO-

AO+

iGS-PTM

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

IG-IB Internet bridge

95 mm(3,7´´)

43 mm(1,7´´)

96 m

m (3

,8´´

)

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.


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). There are two versions of I-LB: Name Description Dimensions and terminals I-LB without

USB port

95 mm(3,7´´)

43 mm(1,7´´)

96 m

m (3

,8´´)

D1D2P1P2P3P4P5P6

P7120÷

120÷ RxD

TxD

RxC

TxC

I-LB+ with USB

port (speed ≈ 115200 bps)

95 mm(3,7´´)

43 mm(1,7´´)

96 m

m (3

,8´´)

D1D2P1P2P3P4P5P6

P7120

120 RxD

TxD

RxC

TxC

Tx

Rx

Indication LED: TxC, RxC Indicates data transfer on the CAN line. TxD, RxD Indicates data transfer on the RS232 line. Tx, Rx Indicates data transfer on USB RUN 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).

PWR Lights All the time when power supply is switched on.


I-CB Communication Bridge

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 n.o. 1 – 3 n.c.

1K

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.

POWER8-36V DC

COM

RS 23

2

LB 4i-CB

95 mm(3,7´´)

43 mm(1,7´´)

96 m

m (3

,8´´)


16X17

11 1 11 1 11

1 +X18

11 1 11 1 11

RE1

RE2

RE3

ER4

RE5

RE6

RE7

RE8

RE9

RE10

RE11

ER12

RE13

RE14

RE15

RE16

X3 X1X2X6 X4X5X8 X7X11 X9X10X14 X12X13X16 X15

9 + 8

16 X18 9 +View B

X18

8 X17 1 +

View B

3 X1 1

X1 X2 X3 X4 X5 X6 X7 X8 X9 X10 X11 X12 X13 X14 X15 X16

View A

3 X2 1 3 X3 1 3 X4 1 3 X5 1 3 X6 1 3 X7 1 3 X8 1 3 X9 1 3 X10 1 3 X11 1 3 X12 1 3 X13 1 3 X14 1 3 X15 1 3 X16 1

View A300

95

X17

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

I-CR CAN repeater 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´´)

96 m

m (3

,8´´

)


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.

95 mm (3,7´)43 mm(1,7´)

Powersupply

I-AOUT8ComApHW:SW:

ANALOG OUTPUTS

ANALOG OUTPUTS

CAN

U - I - p U - I - p U - I - p U - I - p

p - I - U p - I - U p - I - U p - I - U

1 2 Pwr

120 ohm

Functions Number of analog outputs 8, no galvanic separation Type of analog outputs (jumper selectable)

U I p

0 to 10VDC ± 1% , max 5 mA 0 to 20 mA ± 1% , max 500 ohms pwm 1200 Hz, 5V level, max 10 mA

Power supply 8 to 36 VDC Current consumption 100 ÷ 300 mA at 24 VDC Communication interface CAN1, with jumper selectable address 1 to 4

Jumper selectable terminating resistor 120 ohms. RS232 interface TTL, firmware upgrade via AT-link. Operating temperature range -40°C to +70°C Analog outputs refreshment Max. 300 ms


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 21 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.


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. Controllers which may be supplied from I-LBA module: Controller IG-NT/

IG-EE IG-NTC/ IG-EEC

IS-BB IS-NT IG-CU IS-CU IL-CU ID-DCU

Connection applicable

YES YES YES NO YES NO YES YES

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 IG-EE, IG-EEC, IG-NT, IG-NTC InteliGen – Remote Display IG-DISPLAY Available for applications SPI, SPTM, MINT, COX

AVRi

-

AVRi

+

OUT1

OUT2 AC

1AC

2

OCOM

LB 5


InteliMains NT controller InteliMains controller types IM-NT InteliMains – Remote Display IG-DISPLAY Available for applications MCB, MGCB

InteliSys NT controller, IS-DISPLAY InteliSys controller types IS-NT InteliSys – Remote Display IS-DISPLAY Available for applications SPI, SPTM, MINT, COX


IG-DISPLAY wiring

IS-D

ISP A1

COMR1B1

RS485Wire length: up to 1000 meters

IG-D

ISPL

AY

A1COMR1B1

POW

ER

8-36 VDC

0 VDC

POW

ER

0 VDC

RS2

32

MODEM / GSM

GenConfigInteliMonitor

BI: Alternative brightness

A1COMR1

B1

IG-NT IG- DISPLAY

IG-N

T

8-36 VDC


IS-DISPLAY wiring

IS-N

T-B

B

IS-D

ISPL

AY


IS-D

ISPL

AY

IS-D

ISP

A1COMR1

B1

IS-N

T-B

B

A1COMR1B1

POW

ER

POW

ER

0 VDC

POW

ER

8-36 VDC

0 VDCBI: Alternative brightness

A1COMR1

B1

IS-NT IS-DISPLAY

8-36 VDC

IS-NT-BB

IS-D

ISP A 1

COMR1B 1

IS-N

T-B

B


IS-D

ISPL

AY

IS-N

T-B

B

A1COMR1B1

POW

ER

8-36 VDC

0 VDC

POW

ER

0 VDC

USB

RS2

32U

SB

MODEM / GSM


BI:Alternative brightness

A1COMR1

B1

IS-DISPLAY

8-36 VDC


IS-NT- BB IS

-DIS

P A1COMR1

B1

IS- DISPLAYIS

-NT-

BB


POW

ER

0 VDC

USB

RS2

32U

SB

MODEM / GSM


POW

ER

8-36 VDC

0 VDC

IS-D

ISPL

A Y

A1COMR1B1

IS-D

ISPL

AY

IS-D

ISPL

AY

BI:Alternative brightness

8-36 VDC

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.y-Application guide.pdf.

InteliGenNT, InteliSysNT, InteliMainsNT

IGS-NT-2.2-Installation Guide.PDF

Recommended wiring

IG-EE

Basic module for Electronic engines

120 Ω Jumper

Back connectors

Side connectors

Side label

RS485 bias resistor jumpers

BOOT jumper (with long holder)

– Installation Guide, ©ComAp – December 2007 25


Interface Function Terminals Note Generator voltage L1,L2,L3, (N) 3x277 / 480 VAC (neutral not needed),

max 350 / 600VAC * Mains/Bus voltage L1,L2,L3, (N) 3x277 / 480 VAC (neutral not needed),

max 350 / 600VAC Generator current L1k,L1l, L2k,L2l, L3k,L3l 0 ÷ 5 Amps, max 10 A all time, 150 A for 2 sec Neutral/Mains current LNk,LNl 0 ÷ 5 Amps, max 10 A all time, 150 A for 2 sec IG-AVRi interface AVRI-OUT, AVRI-COM TTL (5V PWM) interface to IG-AVRi Power supply + , - 8 ÷ 36 VDC D+ D plus Inputs and output Binary inputs BI1 to BI6 Activation to minus power supply. Binary outputs BO1 to BO6 Load is connected to plus power supply. Analog inputs None Analog outputs None RPM None Communication interface RS232 (1) D SUB9 (male) PC: InteliMonitor, GenConfig or

Modem, GSM modem or ECU (e.g. Cummins ModBus)

RS232 (2) None RS485 (1) ** A1,B1,COMR1 IG-Display (Remote display) or

for PC (via RS485 converter) = redirected RS232 (1) see Basic settings: RS485(1)conv.

RS485 (2) None USB None CAN1 L1,H1,COMC1 Extension modules: IS-AIN, IS-BIN,IGS-PTM, IGL-

RA15, I-AOUT CAN2 L2,H2,CONC2 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.


IG-EEC

InteliGen – Basic module for Electronic Engines - option C

US

B

120 Ω Jumper

RS485 bias resistor jumpers

Boot JUMPER (with long holder)


Interface Function Terminals Note Generator voltage L1,L2,L3, (N) 3x120 / 277 Ph-N or 208 / 480 Ph-Ph VAC

(neutral not needed), max 350 / 600VAC * Mains/Bus voltage L1,L2,L3, (N) 3x120 / 277 Ph-N or 208 / 480 Ph-Ph VAC

(neutral not needed), max 350 / 600VAC Generator current L1k,L1l, L2k,L2l, L3k,L3l 0 ÷ 5 Amps, max 10 A all time, 150 A for 2 sec

0 ÷ 1 Amp, max 2 Amps all time Neutral/Mains current LNk,LNl 0 ÷ 5 Amps, max 10 A all time, 150 A for 2 sec

0 ÷ 1 Amp, max 2 Amps all time IG-AVRi interface AVRI-OUT, AVRI-COM TTL (5V PWM) interface to IG-AVRi Power supply + , - 8 ÷ 36 VDC D+ D plus Inputs and outputs Binary inputs BI1 to BI6 Activation to minus power supply. Binary outputs BO1 to BO6 Load is connected to plus power supply. Analog inputs None Analog outputs None RPM None Communication interface RS232 (1) D SUB9 (male) PC: InteliMonitor, GenConfig or


RS232 (2) D SUB9 (male) PC: InteliMonitor, GenConfig or Modem, GSM modem

RS485 (1) ** A1,B1,COMR1 IG-Display (Remote display) or for PC (via RS485 converter) = redirected RS232 (1) see Basic settings: RS485(1)conv.

RS485 (2) ** A2,B2,COMR2 Redirected RS232 (2) - see Basic settings: RS485(2)conv. PC: InteliMonitor, GenConfig or Modem, GSM modem

USB 2.0 slave PC: InteliMonitor CAN1 L1,H1,COMC1 Extension modules: IS-AIN, IS-BIN,IGS-PTM, IGL-




IG-NT

InteliGen – New Technology


Interface Function Terminals Note Generator voltage L1,L2,L3, (N) 3x 277 Ph-N or 480 Ph-Ph VAC

(neutral not needed), max 350 / 600VAC * Mains/Bus voltage L1,L2,L3, (N) 3x 277 Ph-N or 480 Ph-Ph VAC

(neutral not needed), max 350 / 600VAC Generator current L1k,L1l, L2k,L2l, L3k,L3l 0 ÷ 5 Amps, max 10 A all time, 150 A for 2 sec Neutral/Mains current LNk,LNl 0 ÷ 5 Amps, max 10 A all time, 150 A for 2 sec IG-AVRi interface AVRI-OUT, AVRI-COM TTL (5V PWM) interface to IG-AVRi Power supply + , - 8 ÷ 36 VDC D+ D plus Inputs and outputs Binary inputs BI1 ÷ BI6

BI7 ÷ BI12 Activation to minus power supply.

Binary outputs BO1 ÷ BO6 BO7 ÷ BO12

Load is connected to plus power supply.

Analog inputs AI1 ÷ AI3 Ohms, mA, Volts sensors Analog outputs SG-OUT, SG-COM Speed governor output interface (±10V / 5V

PWM; 500 – 3000Hz) RPM RPM-IN, RPM-COM Min 2 Vpk-pk (from 4 Hz to 4 kHz) Communication interface RS232 (1) D SUB9 (male) PC: InteliMonitor, GenConfig or


RS232 (2) None RS485 (1) ** A1,B1,COMR1 IG-Display (Remote display) or

for PC (via RS485 converter) = redirected RS232 (1) see Basic settings: RS485(1)conv.

RS485 (2) None CAN1 L1,H1,COMC1 Extension modules: IS-AIN, IS-BIN,IGS-PTM,

IGL-RA15, I-AOUT CAN2 L2,H2,CONC2 Intercontroller (Load&VAR sharing, Power



IG-NTC

InteliGen – New Technology – Option C

US

B






0 ÷ 1 Amp, max 2 Amps all time IG-AVRi interface AVRI-OUT, AVRI-COM TTL (5V PWM) interface to IG-AVRi Power supply + , - 8 ÷ 36 VDC D+ D plus Inputs and outputs Binary inputs BI1 ÷ BI6




Analog inputs AI1 ÷ AI3 Ohms, mA, Volts sensors Analog outputs SG-OUT, SG-COM Speed governor output interface (±10V / 5V PWM;

500 – 3000Hz) RPM RPM-IN, RPM-COM Min 2 Vpk-pk (from 4 Hz to 4 kHz) Communication interface RS232 (1) D SUB9 (male) PC: InteliMonitor, GenConfig or



RS485 (1) ** non isolated

A1,B1,COMR1 IG-Display (Remote display) or for PC (via RS485 converter) = redirected RS232 (1) see Basic settings: RS485(1)conv.

RS485 (2) ** isolated

A2,B2,COMR2 Redirected RS232 (2) - see Basic settings: RS485(2)conv. PC: InteliMonitor, GenConfig or Modem, GSM modem

USB 2.0 slave PC: InteliMonitor, GenConfig CAN1 L1,H1,COMC1 Extension modules: IS-AIN, IS-BIN,IGS-PTM, IGL-




IS-NT-BB

InteliSys – New Technology – Base Box






0 ÷ 1 Amp, max 2 Amps all time IG-AVRi interface AVRI-OUT, AVRI-COM TTL (5V PWM) interface to IG-AVRi Power supply + , - 8 ÷ 36 VDC D+ D plus Inputs and outputs Binary inputs BI1 ÷ BI6




Analog inputs AI1 ÷ AI4 Ohms, mA, Volts sensors Analog outputs SG-OUT, SG-COM

AOUT+, AOUT-COM Speed governor output interface (±10V / 5V PWM; 500 – 3000Hz) Configurable analog output, mA, V.

RPM RPM-IN, RPM-COM Min 2 Vpk-pk (from 4 Hz to 4 kHz) Communication interface RS232 (1) D SUB9 (male) PC: InteliMonitor, GenConfig or



RS485 (1) ** A1,B1,COMR1 IS-Display (Remote display)

RS485 (2) ** A2,B2,COMR2 Redirected RS232 (2) - see Basic settings: RS485(2)conv. PC: InteliMonitor, GenConfig or Modem, GSM modem

USB 2.0 slave PC: InteliMonitor, GenConfig CAN1 L1,H1,COMC1 Extension modules: IS-AIN, IS-BIN,IGS-PTM, IGL-




IM-NT

InteliMains – New Technology


Interface Function Terminals Note Mains voltage L1,L2,L3, (N) 3x120 / 277 Ph-N or 208 / 480 Ph-Ph VAC

(neutral not needed), max 350 / 600VAC Bus voltage L1,L2,L3, (N) 3x120 / 277 Ph-N or 208 / 480 Ph-Ph VAC

(neutral not needed), max 350 / 600VAC Mains current L1k,L1l, L2k,L2l, L3k,L3l 0 ÷ 5 Amps, max 10 A all time, 150 A for 2 sec

0 ÷ 1 Amp, max 2 Amps all time Aux current IAk,IAl 0 ÷ 5 Amps, max 10 A all time, 150 A for 2 sec

0 ÷ 1 Amp, max 2 Amps all time Power supply + , - 8 ÷ 36 VDC Inputs and outputs Binary inputs BI1 ÷ BI6 Activation to minus power supply. Binary outputs BO1 ÷ BO6 Load is connected to plus power supply. Communication interface RS232 (1) D SUB9 (male) PC: InteliMonitor, GenConfig or


RS232(2) None RS485 (1) ** non isolated

A1,B1,COMR1 IG-Display (Remote display) for PC (via RS485 converter) = redirected RS232 (1) see Basic settings: RS485(1)conv.

RS485 (2) None USB None CAN1 L1,H1,COMC1 Extension modules: IS-AIN8, IS-BIN16/8,IGS-PTM,

IGL-RA15, I-AOUT8 CAN2 L2,H2,CONC2 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.


Recommended wiring IG-NT – SPTM application


Recommended wiring IG-NT – SPI application


Recommended wiring IG-NT – MINT application


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).


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 Fuse Controller T1A orT2A IS-AIN8 T2A IS-BIN16/8 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.

+

-

12VDC+-

controllerT2A

Battery

Relays

I-LBA

+

-

+

-

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.


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.

GENERATORL1L2L3

N

L1L2L3

N

MAINSVOLTAGE

GENERATORVOLTAGE

L1 L2 L3 L3L2L1N

MCB GCBMAINS

LOAD

N

Voltage measurement Four-wire generator and mains or bus

Four-wire generator and three wire mains or bus

G

GENERATOR MAINS / BUSL3L2L1N L3L2L1N

L1

L2L3

N

Three-wire generator and mains or bus

G

GENERATOR MAINS / BUSL3L2L1N L3L2L1N

L1

L2L3


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

T 1 T2

0V

L1 L2 L3

VOLTAGE TERMINALS

0V 100V

100V

MAINS/BUSGENERATOR L1

L3L2

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

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 Three wire mains and three wire genset or electric

separation

T1 T3T2

L1

L3L2

L3

GENERATORL1 MAINS / BUSL2

400V

400V

400V

0V0V 0V

0V 0V0V40

0V

400V

400V

L1 L3

MAINS / BUS VOLTAGE

L2 L1 L2 L3

GENERATORVOLTAGE

N

IG-MTU

N

N

Ix-NT

T1 T3T2 T1 T3T2

L1

L3L2

L3

GENERATORL1

MAINS / BUS

L2

400V

400V

400V

L1 L3

MAINS / BUSVOLTAGE

L2

Ix- NT

L1 L2 L3

GENERATOR

VOLTAGE

N

IG- MTUIG- MTU

0 V 0 V

0 V

400V

400V

400V

0 V

0 V

0 V

400V

400V

400V

0 V

0 V

0 V

400V

400V

400V

0 V

0 V

0 V

N

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


L1

L2L3

N

G

I1k I1 l

K Lk l

I2k I2 l

K Lk l

I3k I3 l

K Lk l

Standard three CT connection

L1L2L3

G

I1k I1l

K Lk l

I2k I2l

K Lk l

I3k I3l

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

Mains power and PF measuring

G

GENERATOR

I3k I3l

L1L2L3

N

K Lk l

I1k I1l

K Lk l

I2k I2l

K Lk l

MAINS

Inl Ink

L Kl k

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.

G

I1k I1l I3k I3 lI2k I2 l

K Lk l

L1

L2L3

N

Ink In l

K Lk l K L

k l

L K

l k

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


GL1

L2L3

N

Ink In l

k lk lk l

k l

This arrangement covers earth faults in the load network only.

GL1

L2L3

N

Ink In l

L K

l k

k lk lk l

k l

K L

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.

GL1

L2L3

N

Ink In l

k lk lk l

k l

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.

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.


N L1 N L1

L1 MainsL3


Controller Binary inputs and outputs

Binary output via I-RB16

Wiring example 1


Wiring example 2

Wiring example 3

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


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.

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

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

BI 8 ( BI 16)COM 1 ( COM 2) +

8 - 36 V-

POWER -POWER +

+8 - 36 V

-

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

BI 8 ( BI 16)COM 1 ( COM 2)POWER +POWER -

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-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.

IS-B

IN16

/8

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.


Example of controller protection

IS-NT Jumpers Controller hardware jumpers: Function Jumper options Software configuration Analog inputs Current

Voltage Resistance

Required

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)

Not needed

Analog output 0 to 20 mA 0 to 10 VDC

Not needed

CAN or RS485 terminating resistors

Closed jumper connects 120Ω resistor to CAN1, CAN2, RS485-1, RS485-2

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


Speed governor output jumper

SG COMSG OUT

PWM

SG COMSG OUT

VoutR

SG COMSG OUTVout

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

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)


Resistive sensors (one wire)


Current sensors

Current and resistive sensors

Voltage and resistive sensors


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.

ABCD

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

ABCD

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

ABCD

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

ABCD

+ +24 VDC

0 VDCSensor

mA

ABCD

+

+24 VDC

0 VDC

SensormA

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

ABCD

+

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

ABCD

+

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


ABCD

+

R1

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.


CA

N1 H

COML

CA

N21.controller

Addr.: 1Addr.: 1

CA

N1

CA

N1

8.iS-AIN8Addr.: 8

6.iS-BIN16/8Addr.: in12

out6

CA

N1

CA

N1

1.iS-AIN8Addr.: 1

120

1.iS-BIN16/8Addr.: in1

out1

CA

N1

CA

N2

HCOM

L

HCOM

LH

COML

HCOM

L

HCOM

LH

COML

HCOM

L2.controllerAddr.: 2Addr.:

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 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.

CA

N1

CA

NH

CA

NL

CA

NL

CAN

HC

OM

CA

NL

CAN

HC

OM

CA

N1

CA

NL

CAN

HC

OM

CA

NL

CAN

HC

OM

CA

NL

CAN

HC

OM

CA

N1

CA

N2

CA

N1

CA

N2


Connection of ECU on CAN1

CAN1

CA

N1

CA

NL

CAN

HC

OM

CA

NL

CAN

HC

OM

CA

N1C

AN2

CA

N1C

AN2

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.

Status Tx Rx

Communication is OK Fast flashing – data transfer CAN bus is interrupted Continuous light Continuous lightShort 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

I-CB wiring and configuration

CAN H

CAN L

EngineControl Unit

120o

hm

Controller

CAN HCAN L

CA N L

CAN HC O M

CAN L

CAN HCO M

CAN H

CAN L

I-CB

CAN 1 CAN ECU

ECU

120o

hm

CAN

1C

AN 2

1. Configure I-CB using I-CBEdit software. Configured I-CB behaves like fictive IS-AIN and IS-BIN units. I-

CB configuration associates selected values (from ECU database) received from Engine Control Unit to selected CAN addressees (fictive IS-AIN, IS-BIN inputs and outputs).

2. Configure corresponding CONTROLLER CAN addresses and tick in PC configuration tool. 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.


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)

http://www.phoenixcontact.com/

http://www.saltek.cz/

http://www.belden.com/

http://www.phoenixcontact.com/

http://www.saltek.cz/



Picture 1 - shorter distances (all network components within one room) 120 Ω 120 Ω Picture 2 - longer distances (connection between rooms within one building)

CAN1 H

COML

CAN2

120

1.iS-CUAddr.: 1Addr.: 1

CAN1

CAN1

8.iS-AINAddr.: 8

7.iS-BINAddr.: in13

out7

CAN1

CAN1

1.iS-AINAddr.: 1

120

1.iS-BINAddr.: in1

out1

CAN1

CAN2

2.iS-CU

120

HCOM

L

HCOM

LH

COML

HCOM

L

HCOM

LH

COML

HCOM

L

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

H/A L/B COM

H/A L/B COM


Default sensors

Default characterisitics

CONTROLLER

VDO Temp VDO Press ohms 1°C 1°F ohms 1 bar psi

Primary Converted Converted Primary Converted Converted 29,0 51,0 69,0 95,0

135,0 195,0 290,0 440,0

700,00 1800,0 3200,0

110 90 80 70 60 50 40 30 20 0 -16

230 194 176 158 140 122 104 86 68 32

3

10,0 50,0 85,0

119,0 152,0 180,0

0,0 2,0 4,0 6,0 8,0

10,0

0 29 58 87

116145

Tristate sensor Resistance Considered as < 750Ω Inactive 750 - 2700Ω Active > 2700Ω Sensor failure (interrupted wire)

IS-AIN8 PT100 (IEC 571) PT1000 (IEC 571) Ni100 (IEC 43760) Ni1000 (IEC 43760)

0,1 Ù 0,1 °C 0,1 °F 0,1 Ù 0,1 °C 0,1 °F 0,1 Ù 0,1 °C 0,1 °F 0,1 Ù 0,1 °C 0,1 °F843, 922, 1000, 1078, 1155, 1232, 1309, 1385, 1461, 1536, 1610, 1685, 1758, 1832, 1905, 1977, 2049, 2120, 2191, 2262, 2332, 2401, 2470, 2539, 2607,

-400, -200, 0, 200, 400, 600, 800, 1000, 1200, 1400, 1600, 1800, 2000, 2200, 2400, 2600, 2800, 3000, 3200, 3400, 3600, 3800, 4000, 4200, 4400,

-400, -40, 320, 680, 1040, 1400, 1760, 2120, 2480, 2840, 3200, 3560, 3920, 4280, 4640, 5000, 5360, 5720, 6080, 6440, 6800, 7160, 7520, 7880, 8240,

7800, 8000, 8200, 8400, 8600, 8800, 9000, 9200, 9400, 9600, 9800, 10000, 10200, 10400, 10600, 10800, 11000, 11200, 11400, 11600, 1800, 12000, 12200, 12400, 12600,

-558, -508, -457, -407, -356, -306, -255, -204, -153, -102, -51, 0,

51, 103, 154, 205, 257, 308, 360, 412, 464, 516, 568, 620, 672,

-684, -594, -503, -413, -321, -231, -139, -47, 45, 136, 228, 320, 412, 505, 597, 689, 783, 874, 968,

1062, 1155, 1249, 1342, 1436, 1530,

695, 743, 791, 841, 893, 946,

1000, 1056, 1112, 1171, 1230, 1291, 1353, 1417, 1483, 1549, 1618, 1688, 1760, 1833, 1909, 1986, 2066, 2148, 2232,

-600, -500, -400, -300,-200, -100,

0, 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000,1100,1200,1300,1400,1500,1600,1700,1800,

-760, -580, -400, -220, -40, 140, 320, 500, 680, 860, 1040, 1220, 1400, 1580, 1760, 1940, 2120, 2300, 2480, 2660, 2840, 3020, 3200, 3380, 3560,

7909, 8107, 8308, 8512, 8717, 8925, 9135, 9347, 9562, 9780, 10000, 10223, 10448, 10676, 10907, 11140, 11376, 11615, 11857, 12102, 12350, 12601, 12854, 13111, 13371,

-500, -450, -400, -350, -300, -250, -200, -150, -100, -50, 0, 50, 100, 150, 200, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700,

-580, -490, -400, -310, -220, -130, -40, 50,

140, 230, 320, 410, 500, 590, 680, 770, 860, 950, 1040,1130,1220,1310,1400,1490,1580,


PT100 (IEC 571) PT1000 (IEC 571) Ni100 (IEC 43760) Ni1000 (IEC 43760) 0,1 Ù 0,1 °C 0,1 °F 0,1 Ù 0,1 °C 0,1 °F 0,1 Ù 0,1 °C 0,1 °F 0,1 Ù 0,1 °C 0,1 °F2675, 2742, 2809, 2875, 2941, 3006, 3072, 3136, 3200, 3264, 3327, 3389, 3451, 3513, 3574, 3635, 3695, 3755, 3815, 3874, 3903,

4600, 4800, 5000, 5200, 5400, 5600, 5800, 6000, 6200, 6400, 6600, 6800, 7000, 7200, 7400, 7600, 7800, 8000, 8200, 8400, 8500,

8600, 8960, 9320, 9680, 10040 10400 10760 11120 11480 11840 12200 12560 12920 13280 13640 14000 14360 14720 15080 15440 15620

12800, 13000, 13200, 13400, 13600, 13800, 14000, 14200, 14400, 14600, 14800, 15000, 15200, 15400, 15600, 15800, 16000, 16200, 16400, 16600, 16800, 17000, 17200, 17400, 17600, 17800, 18000, 18200, 18400, 18600, 18800, 19000, 19200, 19400, 19790,

724, 776, 829, 881, 934, 987,

1039, 1092, 1145, 1198, 1251, 1304, 1358, 1411, 1645, 1518, 1572, 1625, 1679, 1733, 1787, 1841, 1895, 1950, 2004, 2058, 2113, 2168, 2222, 2277, 2332, 2387, 2442, 2497, 2605,

1623, 1717, 1812, 1906, 2001, 2097, 2190, 2286, 2381, 2476, 2572, 2667, 2764, 2860, 3281, 3052, 3150, 3245, 3342, 3439, 3537, 3634, 3731, 3830, 3927, 4024, 4123, 4222, 4320, 4419, 4518, 4617, 4716, 4815, 5009,

2318, 2407, 2498, 2592, 2689, 2789,

1900,2000,2100,2200,2300,2400,

3740, 3920, 4100, 4280, 4460, 4640,

13635, 13901, 14171, 14444, 14720, 15000, 15283, 15570, 15860, 16154, 16451, 16752, 17056, 17365, 17677, 17993, 18312, 18636, 18964, 19295, 19631, 19970, 20314, 20662, 21013, 21370,

750, 800, 850, 900, 950, 1000, 1050, 1100, 1150, 1200, 1250, 1300, 1350, 1400, 1450, 1500, 1550, 1600, 1650, 1700, 1750, 1800, 1850, 1900, 1950, 2000,

1670,1760,1850,1940,2030,2120,2210,2300,2390,2480,2570,2660,2750,2840,2930,3020,3110,3200,3290,3380,3470,3560,3650,3740,3830,3920,

4-20mA/ 100

4-20mA/ 60

0-20mA/ 100-PTM

4-20mA/ 100-PTM

Primary Converted Converted Primary Converted Primary Converted170 200 230 280 330 390 460 560 690

0 13 25 38 50 63 75 88 100

0 8 15 23 30 38 45 53 60

0 38 57 77 96 116 135 155 174 194

0 20 30 40 50 60 70 80 90 100

38 57 77 96 116 135 155 174 194

0 12 25 37 50 62 75 87 100

100mV/100-PTM

Primary Converted 0

10 40 70

110 140 170 210 230 250

0 4

16 28 45 57 68 84 92 100

Sensor fail (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.


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.


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 Volvo TAD12 Standalone connector terminal Start output E Fuel output H

Comap controller CAN description Volvo TAD12 Data bus connector terminal CAN bus common Screen for the J1939 cable. CAN bus H 1(Hi) CAN bus L 2(Lo)

SCANIA S6 Comap controller binary output description Scania EMS B1 connector Start output connects directly to engine starter solenoid Fuel output 3 (ignition U15)

Comap controller CAN description Scania EMS B1 connector CAN bus common Screen for the J1939 cable. CAN bus H 9 CAN bus L 10

PERKINS 2800 series Comap controller binary output description Perkins Customer interface connector Start output connects directly to engine starter solenoid Fuel output 1,10,15,33,34

powers up ECU and enables the injectors


Comap controller CAN description Perkins Customer interface connector CAN bus common Screen for the J1939 cable. CAN bus H 31 CAN bus L 32

JOHN DEERE Comap controller binary output description John Deere 21 pin Deutsch connector Start output D Fuel output G (switched ECU power),J (ignition)

Comap controller CAN description John Deere 21 pin Deutsch connector CAN bus common Screen for the J1939 cable. CAN bus H V CAN bus L U

CUMMINS ISB/ISBE Comap controller binary output description Cummins ISB OEM Harness connector B Start output connects directly to engine starter solenoid Fuel output 39

Comap controller CAN description Cummins ISB 9 pin Deutsch connector CAN bus common SAE J1939 shield - screen for J1939 cable. CAN bus H SAE J1939 signal CAN bus L 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




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

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

Caterpillar

19SG COM

SG OUTPWM

Cat

erpi

llar

PEEC

9

Pay attention to the connector and jumper orientation.

CA

TER

PILL

AR

Sign

alco

nver

ter

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

Cummins

Cum

min

sEF

C

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 = 6,40 V SpeedRegChar = POSITIVE SpeedGovLowLim = 5V SpeedGovHiLim = 7,8V

SG COM

SG OUTVout

A 1

I 9

Cum

min

s EC

PG




SG COMSG OUT

VoutR

0V

5VCum

min

s O

NA

N



Barber Colman

SG COMSG OUT

VoutR

29

Bar

ber C

olm

anD

YNA

800

0


SG COMSG OUT

VoutR

2

Bar

ber C

olm

anD

YN1

1068

4

9


GAC

SG COMSG OUT

VoutR

GNG

AC

ESD

550

0

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

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

SG COMSG OUT

VoutR

225G

AC

EGS

104

B

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

WOODWARD

WO

OD

WA

RD

ProA

ctII

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






MTU

SG COM

SG OUTVout36

8 ( 0 to 10 VDC)

MTU

MD

EC

2000

, 40

00



DEUTZ

SG COM

SG OUTVout23 GND

24 (0, 5 to 4, 5 VDC)

DEU

TZBF

6M

2117

Opened for 0 % Droop

Plug F


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

PERKINS

SG COM

SG OUTVout

19 PER

KIN

S40

16 E6

1 TR

S

18




SG COM

SG OUTVout

PER

KIN

S23

00, 2

800

2024

122

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


SG COMSG OUT

VoutR

VBREF GNDRPS INPUT

PER

KIN

S13

00 E

Di


TOHO



AVR interface list Read carefully AVR instructions before connecting to controller! Basler: APR 63-5, AEC 63-7, KR-FX, KR-FFX

iG-

AVR

i

AVRi output is connected instead of external resistor for voltage adjusting.

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

Stamford SX 460

iG-

AVR

i

AVRi output is connected instead of external resistor for voltage adjusting.


STAMFORD SX 440, AS440, MX 321, SX 421

iG-

AVR

i

Turn trim on on MX 321 from zero position.


Leroy Sommer: R 438 LS, R448

iG-

AVR

i

AVRi output is connected instead Remote voltage trimmer 470 ohm to terminals ST4.


Leroy Sommer: R 449

iG-

AVR

i



Leroy Sommer: R 129

AVRi+

AVRi-

18VACFrom generator

OUT1

GND iG-

AVR

i

iG-AVRiTRANS

230/400VAC0VAC

AVRI COMAVRI OUT

J2

AVRi output is connected instead Remote voltage trimmer 470 ohm to terminal J2.


Mecc Alte Spa: S.R.7/2, U.V.R.6

iG-

AVR

i

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

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

Marelli: MX 341

iG-

AVR

i

Link pin 1 and 2 (no remote voltage trim) Disconnect Droop C/T (S1, S2)

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

Piller

AVRi output is connected instead Remote voltage trimmer 100Kohm.


Catterpillar VR6, VR3F

iG-

AVR

i

For VR3F link 4-7 has to be removed.


Catterpillar DVR

Pin 44 on DVR – PF regulation directly from DVR is not connected.

AVRi trim to 25% Volt/PF ctrl: AVR DCout bias = 50% VoltRegChar = POSITIVE


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


Technical data

Power supply Controller IS-Display IG-Display Voltage supply 8-36V DC 8-36V DC 8-36V DC Consumption depends on supply voltage 0,4A at 8VDC 0,3A at 8VDC 0,4A at 8VDC 0,15 A at 24VDC 0,1 A at 24VDC 0,14 A at 24VDC 0,1A at 36VDC 0,09A at 30VDC 0,12A at 30VDC Battery voltage measurement tolerance 2 % at 24V RTC battery life-cycle 10 year 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 -20..+70oC * Operating temperature IS-NT-BB -40..+70oC * Operating temperature (LT version) -40..+70oC * Storage temperature -30..+80oC Storage temperature IS-NT-BB -40..+80oC Flash memory data retention time 10 years Protection front panel IP65 Humidity 95% without condensation (complies with IEC/EN 60068-2-30) Standard conformity Low Voltage Directive EN 61010-1:95 +A1:97 Electromagnetic Compatibility 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) Vibration 5 - 25 Hz, ±1,6mm

25 - 100 Hz, a = 4 g Shocks a = 200 m/s2 Hint: * USB port should be used only above 0°C.

Dimensions and weight Dimensions 180x120x80mm Weight 950g

Mains and generator Nominal frequency 50-60Hz Frequency measurement tolerance 0,1Hz


Current inputs IG-xx IG-xxC / IS-NT-BB / IM-NT Nominal input current (from CT) 5 A 1 A / 5 A Load (CT output impedance) < 0,1 Ω < 0,1 Ω CT input burden < 0,2 VA per phase (Inom=5A) < 0,1 VA per phase (Inom=1A)

< 0,2 VA per phase (Inom=5A) Max. measured current from CT 10 A 2 A / 10 A Current measurement tolerance 2% from the Nominal current 2% from the Nominal current Max. peak current from CT 150 A / 1s 150 A / 1s Max. continuous current 12 A 2,4 A / 12 A

Voltage inputs – IG/IS-NT and modifications IG-xx IG-xxC / IS-NT-BB / IM-NT Nominal voltage (ph-N / ph-ph) 277/480 VAC 120/207 or 277/480 VAC Maximal measured/allowed voltage

346/600 VAC 150/260 or 346/600 VAC

Input resistance 0,6 MΩ phase to phase 0,6 MΩ phase to phase 0,3 MΩ phase to neutral 0,3 MΩ phase to neutral Voltage measurement tolerance 1 % from the Nominal voltage 1 % from the Nominal voltage Over voltage class III / 2 (EN61010) III / 2 (EN61010) Hint: kW and kWh measurement tolerance is 3%.

Binary inputs and outputs

Binary inputs IG-NT / IG-NTC IG-EE / IG-EEC / IM-NT IS-NT-BB Number of inputs 12 6 16 Input resistance 4,7 kΩ 4,7 kΩ 4,7 kΩ Input range 0-36 VDC 0-36 VDC 0-36 VDC Switching voltage level for close contact indication

0-2 V 0-2 V 0-2 V

Max voltage level for open contact indication

8-36 V

8-36 V

8-36 V

Binary open collector outputs IG-NT / IG-NTC IG-EE / IG-EEC / IM-NT IS-NT-BB Number of outputs 12 6 16 Maximum current 0,5 A 0,5 A 0,5 A Maximum switching voltage

36 VDC 36 VDC 36 VDC

Analog inputs Not electrically separated Number of inputs 3 / 0 / 4 unipolar ( IG-NT(x) / IG-EE(x), IM-NT / IS-NT-BB ) Resolution 10 bits Jumper selectable range V, ohm, mA Maximal resistance range 2500 Ω Maximal voltage range 5 V Maximal current range 0 – 20 mA Input impedance 180 Ω for mA measuring


Input impedance > 100 kΩ for V measuring Resistance measurement tolerance ± 2 % ± 2 Ω out of measured value Voltage measurement tolerance ± 1 % ± 1mV out of measured value Current measurement tolerance ± 1 % ± 0,5mA out of measured value

D+ function Max. D+ output current 300 mA Guaranteed level for signal Charging OK 80% of supply voltage

Speed pick-up input Type of sensor magnetic pick-up 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 0,2 %

Communication interface

RS232 interface Maximal distance 10m Speed up to 57.6kBd

RS485 interface Maximal distance 1000m Speed up to 57.6kBd

CAN bus interface Galvanically separated Maximal CAN bus length 200m Speed 250kBd Nominal impedance 120Ω Cable type 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


http://www.lappcable.com/


Analog outputs Speed governor output ± 10 V DC / 5 V PWM (500 – 3000Hz), max. 15 mA AVRi outputs PWM to IG-AVRi Current output 0 – 20 mA ± 0,3mA Voltage output 0 – 10 V DC, max. 15 mA Max load resistance 470R at 9,4V

IG-AVRi Power supply: 18V AC from IG-AVRi Trans/LV or IG-AVRi Trans/100 Absolutely maximum power supply range: 15 - 25 VAC or 20 - 35VDC Inputs: +AVR, -AVR (two wires, PWM from IG-CU) Outputs: OUT1, OUT2 floating (potential free) voltage source. AVRi output voltage range: potentiometer adjustable from +- 1V to +-10V DC. AVRi output current: max 15 mA. Mechanical dimensions: 96 x 27 x 43 mm , DIN rail (35 mm) mounted

IG-AVRi Trans/LV Primary voltage 1: 230-277 VAC Absolute low limit: 230 VAC – 20% Absolute high limit: 277 VAC + 20% Primary voltage 2: 400-480 VAC Absolute low limit: 400 VAC – 20% Absolute high limit: 480 VAC + 20% Frequency: 50 - 60 Hz Secondary voltage: 18 V AC, 5 VA Operating temperature -30..+70oC

IG-AVRi Trans/100 Primary voltage: 100 – 120 VAC Absolute low limit: 100 VAC – 20% Absolute high limit: 120 VAC + 20% Frequency: 50 - 60 Hz Secondary voltage: 18 V AC Operating temperature -30..+70oC

IGS-PTM Voltage supply 8-36V DC Consumption 0,1A depend on supply voltage Mechanical dimensions: 40 x 95 x 45 mm , DIN rail (35 mm) mounted Interface to controller CAN Operating temperature -30..+70oC 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 Maximal resistance range 0 – 250 Ω Maximal voltage range 0 – 100 mV Maximal current range 0 – 20 mA Resistance measurement tolerance 1 % ± 2 Ω out of measured value Voltage measurement tolerance 1,5 % ± 1mV out of measured value Current measurement tolerance 2,5 % ±0,5mA 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

IS-AIN8 Nominal power supply 24 VDC Power supply range 8 – 36 VDC Max. consumption 250 mA Mechanical dimensions: 150 x 160 x 50 mm ,

DIN rail (35 mm) mounted Connection to controller (galvanically separated) CAN1 Operating temperature -40..+70oC Storage temperature -40..+80oC Protection front panel IP 20 Humidity 95% without condensation Standard conformity Low Voltage Directive EN 61010-1:95 +A1:97 Electromagnetic Compatibility EN 50081-1:94, EN 50081-2:96 EN 50082-1:99, EN 50082-2:97

Analog inputs Nominal power supply 24 VDC Power supply range 8 – 36 VDC Number of inputs 8 Not galvanic separated Resolution 16 bits Each analog input can be software configured to: Measuring range Accuracy From to Resistance 0 Ω 2400 Ω ± 0,5 % 0 Ω 250 Ω ± 1,0 % Current Passive 0 / 4 mA 20 mA ± 0,5 % Active 4 mA 20 mA ± 0,5 % Active 0 mA ± 20 mA ± 0,5 % Voltage Thermocouples J, K, L type ± 0,2 % 0 mV 100 mV ± 0,2 % - 1000 mV + 1000 mV ± 0,5 % 0 mV 2500 mV ± 0,5 %


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 8-36V DC Consumption 0,1A depend on supply voltage Mechanical dimensions: 40 x 95 x 45 mm , 35 mm DIN rail mounted Interface to controller CAN Operating temperature -30..+70oC Number of analog outputs 8 (not electrically separated) Output range 0 to 10 VDC 0 to 20 mA PWM (1200 Hz)

IS-BIN16/8 Nominal power supply 24 VDC Power supply range 8 – 36 VDC Max. consumption 250 mA Mechanical dimensions: 150 x 160 x 50 mm ,

DIN rail (35 mm) mounted Connection to controller (galvanically separated) CAN1 Operating temperature -30..+70oC Storage temperature -40..+80oC Protection front panel IP 20 Humidity 95% without condensation Standard conformity Low Voltage Directive EN 61010-1:95 +A1:97 Electromagnetic Compatibility 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 8 + 8 Input resistance 3 kΩ Input voltage range 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) 8 Maximum current 0,5 A Maximum switching voltage 36 VDC

Frequency inputs Number of inputs 2 (RPM1, RPM2)

RPM1 Type of sensor magnetic pick-up


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

RPM2 Type of sensor Contact or Active sensor Minimal pulse width 10 ms, integration mode Maximum measured frequency 60 Hz, integration mode Note: RPM1, RPM2 are available from IS SW version 2.6

IGL-RA15

Power supply Voltage supply 8-36V DC Consumption 0,35-0,1A (+1A max horn output)

Depend on supply voltage

Operating conditions Operating temperature -20..+70oC Storage temperature -30..+80oC Protection front panel IP65

Dimensions and weight Dimensions 180x120x55mm Weight 950g

Horn output Maximum current 1 A Maximum switching voltage 36 VDC

I-CB, I-CR

Power supply Voltage input 8-36V DC Consumption 0.1A depend on power supply

Operating conditions Operating temperature -20 ÷ +70 °C Storage temperature -30 ÷ +80 °C Humidity 85% without condensation Protection IP20

Dimensions and weight Dimensions 95x96x43 mm, DIN rail (35 mm) mounted Weight 300g

CAN bus interface Galvanic separated Maximal CAN bus length 200m Speed up to 250kBd (depends on ECU type connected) Nominal impedance 120Ω


Cable type for iS connection twisted pair (shielded)

RS232 interface Maximal distance 10m Speed up to 19.2kbps (depends on ECU type connected)

I-LB Voltage supply 8-36V DC Consumption 0,1A depend on supply voltage Operating temperature -30..+70oC Mechanical dimensions: 95 x 96 x 43 mm , DIN rail (35 mm) mounted Interface to modem or PC RS232, RS422, RS485, (USB – I-LB+ version) Interface to controller CAN

IG-IB Voltage supply 8-36V DC Consumption 0,1A depend on supply voltage Mechanical dimensions: 95 x 96 x 43 mm , DIN rail (35 mm) mounted Interface to controller RS232 or CAN Interface to modem RS232 Interface to Ethernet RJ45 (10baseT) Operating temperature -30..+70oC Storage temperature -30..+70oC

I-RBxx Number of relays: 16 or 8 in sockets Nominal voltage: 24 VDC Voltage range: 16,8 – 36 VDC Relay opens at: 10% of nominal voltage Electric / mechanic cycles: 100 000 / 10 000 000 Operating temperature range: - 40°C to 70°C Maximal load: 6 A resistive load at 24VDC 4 A inductive load at 24 VDC (I-RBxx-231) 2 A at 231VAC Contacts protection: varistor 14DK390

IG-MTU Primary voltage Ph-Ph 3x400 VAC / 50Hz (3x480 VAC / 60 Hz) Secondary voltage Ph-N 3x 230 V AC ( 3x277 VAC / 60 Hz) , 5 VA Mechanical dimensions: 155 x 95 x 60 mm , DIN rail (35 mm) mounted Primary/secondary Phase shift < 1° Operating temperature -30..+70oC

IG-MTU-2-1 Primary voltage Ph-Ph 3x600 VAC / 50Hz (3x720 VAC / 60 Hz) Secondary voltage Ph-N 3x 173 V AC ( 3x208 VAC / 60 Hz) , 5 VA Mechanical dimensions: 155 x 95 x 60 mm , DIN rail (35 mm) mounted Primary/secondary Phase shift < 1° Operating temperature -30..+70oC

COMAP IGS NT 2.2 Installation Guide

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