Compact Controller for Stand-by and Parallel Operating Gen-sets

InteliSys®
Modular Gen-set Controller
Operator guide for SPM, SSB, SPtM, SPI, MINT

IS-CU

June 2005

Operator guide

ComAp, spol. s r.o.

Copyright © 2004 ComAp s.r.o. Světova 7, 180 00 Praha 8, Czech Republic
Written by Ladislav Kadanik Tel: +420 2 66316661, Fax: +420 2 66316647
Prague, Czech Republic E-mail: info@comap.cz, www.comap.cz
Table of Contents
Table of Contents ...............................................................................................................................................2
General guidelines..............................................................................................................................................3
Description of the controller system (with all options)....................................................................................3
Conformity declaration ...................................................................................................................................4
Operator interface...............................................................................................................................................5
Pushbuttons and LEDs ..................................................................................................................................5
Description of MEASUREMENT screens ......................................................................................................8
Mode and function description .........................................................................................................................11
OFF mode ....................................................................................................................................................11
MAN mode ...................................................................................................................................................11
SEM mode....................................................................................................................................................11
AUT mode ....................................................................................................................................................12
TEST mode (SSB and SPtM only) ...............................................................................................................12
Load control modes in parallel to mains ......................................................................................................13
Genset warming ...........................................................................................................................................14
Power derating .............................................................................................................................................14
Alarm management ..........................................................................................................................................15
Warning (Wrn) ..............................................................................................................................................15
Shut down (Sd) ............................................................................................................................................15
Slow stop (Stp) .............................................................................................................................................15
Electric protection (ElProt) ...........................................................................................................................15
Off load.........................................................................................................................................................15
Mains failure .................................................................................................................................................16
Remote control and data logging .....................................................................................................................17
Direct connection to the PC .........................................................................................................................17
PC software - WinEdit ..................................................................................................................................17
History file.....................................................................................................................................................17
Remote modem communication ..................................................................................................................17
Controller firmware and archive files............................................................................................................17
Technical data ..................................................................................................................................................19

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General guidelines
This guide provides general information on how to operate the InteliSys controller.
This guide is intended for everybody who is concerned with operation and maintenance of the gen-set.

Description of the controller system (with all options)

InteliSys IS-CU is a comprehensive gen-set controller for single and multiple generating sets operating in
stand-by or parallel modes with CHP support. A modular construction allows upgrades to different levels of
complexity in order to provide the best solutions for various customer applications. Optional synchronizer,
isochronous load sharer, Mains and Generator protection allows for a total integrated solution for gen-sets in
stand-by and parallel modes with single engine support.
IS-CU analog and binary inputs and binary outputs can be expanded by additional modules IS-AIN8, IS-
BIN16/8, IGS-PTM and IGL-RA15.
The InteliSys controllers are equipped with a powerful graphic display showing icons, symbols and bar-
graphs for intuitive operation, which sets, together with high functionality, new standards in gen-set controls.
The InteliSys automatically starts the gen-sets, closes the Gen-set C.B. when all conditions are met, then
stops the engine on external signal or by pressing push buttons.
The key feature of InteliSys is its easy-to-use installation and operation. Predefined configurations for typical
applications are available as well as user-defined configurations for special applications.

The additional programmable functions are available in each application:

• Programmable logic and timing functions
• Temp by power control loop
• Overheat protection
• Cylinders difference measuring and protection
• Additional setpoints
With hardware keys DONGLE, Island parallel and parallel to Mains operation can be achieved. Forward and
reverse synchronizing, mains protection, load and power factor control, earth fault protection are the major
functions provided.

Default applications
There are five default applications: SPM, SSB, SPtM, MINT, MEXT.
SPM Single prime mover, no mains.
SSB Single stand-by, no synchronizing, break transfer.
SPtM Single stand-by, forward and reverse synchronizing, parallel operation, peak shaving, soft
load transfer.
SPI Single stand-by, no MCB control, forward synchronizing, parallel operation, peak shaving,
soft load transfer.
MINT Multiple parallel, forward synchronizing, load and VAR sharing, power management, soft
load transfer.

Detail documentation
For more detail please refer to corresponding User guides (where –x-x means software version):

IS-SPM-x.x.pdf WinEdit-MultiEdit-x.x.pdf
IS-SSB-x.x.pdf Communiation guide-x.x.pdf
IS-SPtM-x.x.pdf Application guide-x.x.pdf
IS-SPI-x.x.pdf Troubleshooting guide-x.x.pdf
IS-MINT-x.x.pdf

Text
PAGE (Capital letters in the frame) buttons on the front panel

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Break Return (Italic) set points
Generator protections (Bold) Set point group
REMOTE START/STOP (Capital letters) binary inputs and outputs

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.

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)!!!

Be aware that gen-set can automatically or remotely start when following

controller terminals are disconnected !!!
• Mains voltage measuring and / or
• Binary outputs for MCB control and / or
• MCB feedback

Switch controller to OFF mode and disconnect the Binary outputs Starter and Fuel to
avoid unexpected automatic start of gen-set and GCB closing.

!!! CAUTION !!!

Dangerous voltage
In no case touch the terminals for voltage and current measurement!
Always properly connect grounding terminals!

Take care when disconnecting In/Im3 terminals when the gen-set is stopped.
For safety connect parallel to InteliSys In/Im3 terminals two anti parallel diodes 10A/100V.

In any case do not disconnect generator CT terminals when the gen-set is loaded.

Adjust set points

All setpoints are preadjusted to their typical values. But the setpoints 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 !!!

Note:
ComAp believes that all information provided herein is correct and reliable and reserves the right to update
at any time. ComAp does not assume any responsibility for its use unless otherwise expressly undertaken.

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Operator interface
Pushbuttons and LEDs

10

8 7 6 5

16 15 14 13 12 11
Pushbuttons
1. Numeric keyboard for setpoints values adjusting, measure screen fast select
2. CLEAR Clears character left from the cursor (Back Space), Exit from MENU
3. ENTER Value confirmation (function is equal to 7.)
4. MODE→ forward through gen-set operation modes OFF -> MAN-> SEM -> AUT->TEST.
←MODE backward through gen-set operation modes OFF<- MAN<- SEM <-AUT<-TEST.
FAULT RESET Acknowledges faults and alarms.
START Starts the gen-set in MAN and SEM mode.
STOP Stops the gen-set in MAN and SEM mode.
5. GCB ON/OFF When in MAN mode, opens and closes the GCB.
6. MCB ON/OFF When in MAN mode, opens and closes the MCB.

Display handling
7. ENTER Menu, value item confirmation (function is equal to 3.)
8. MENU Switch to the InteliSys Menu screen
9. ↑, ↓,<, > Select the InteliSys Menu item
10. ALARM LIST Switch to the InteliSys Alarm screen

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LEDs
11. Engine status LED
12. Generator status LED
13. GCB status LED corresponds with Binary input GCB feedback.
14. LOAD status LED
15. MCB status LED
16. Mains status LED

Three color LED status: green = operation, orange = warning, red = fail

How to select gen-set mode ?

Use MODE→ or ←MODE to select requested gen-set operation mode OFF – MAN – AUT– TEST. It is not
possible to go directly from OFF to AUT or TEST.

Display menus
There are 3 display menus available: Measurements, Params and History
Each menu consists of several groups of screens, except of history.

How to view measured data?

Select MENU - Measurement screen.
Use ↑ and ↓ to select the group of screen with requested data and press ENTER .
Use ↑ and ↓ and < and > to select the screen with requested data.
Use short measure screen selection – e.g. pressing of 1 and 1 switches to first group – first screen.
Number of InteliSys measuring screens changes (appears, disappears) depend on number of external
modules IS-AIN, IS-BIN16/8 configuration.

How to view and edit set points?

Select MENU - Params screen.
Use ↑ and ↓ to select setpoints group and press ENTER .
Use ↑ and ↓ to select the requested setpoint.. Use < and > like PgDn and PgUp buttons. Long hold of
< and > buttons is like Home/End.
Select Set points item from the InteliSys menu.
Password protected setpoints are marked by LOCK symbol.

How to set password?

Press . button to Password entering and editing window.
Password is a four-digit number. Only setpoints associated with the entered password level can be modified.
Use ↑ or ↓ to select the desired password and then press enter.

How to view the HISTORY menu?

Select MENU - History screen - Showhist and press ENTER .
Use ↑ and ↓ and < and > buttons to list all stored values.
± button switches between PgUp / PgDown and RowUp / RowDown history listing.
Hint:
For jump to selected record write record number and press ENTER .

How to change the display contrast ?

Press ENTER and ↑ or ↓ at the same time to adjust the best display contrast.
Only in MEASUREMENT menu.

How to check the serial number and software version?

Hold down ENTER and press ALARM LIST . On the display you can see InteliSys INFO screen for 10
seconds.
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InteliSys INFO screen contains:
1) Controller name (see Basic setting group)
2) InteliSys serial number (8 character number)
3) SW version: firmware and configuration table number
4) Application: e.g. SPtM
5) Branch: InteliSys …
6) Firmware release identification: IS-3.0 R: 01.10.2003
7) Terminal version:
8) Screen definition:
9) Encoding: used characters set
Hint:
Only in MEASUREMENT menu.
Press 1 to switch to HELP screen.
Press 2 to switch to DONGLE features description.

How to check dongle type

Go to info screen - hold down ENTER and press ALARM LIST then press 2 to Dongle screen.
There is information describing software branch and application.
Example:
Dongle: Standard
1. IS-PCLSM

How to find active alarms ?

Press ALARM LIST to switch to Alarm screen.
Inverted alarms are still active. Non-inverted alarms are not active, but not yet confirmed.
Press FAULT RESET to accept all alarms. Non-active alarms immediately disappear from the list.
Press ALARM LIST to return to previous screen.
New Alarm list record is indicated by ! symbol on status screen.
Hint:
Automatic jump to Alarm list is active only when the first measurement screen is active.

When to use GCB ON/OFF and MCB ON/OFF buttons ?

In SEM and AUT mode these buttons are disabled.
In MAN mode are enabled, but before closing of GCB, generator voltage must be within limits. Internal
protection against unsynchronized closing of both circuit breakers is implemented.
In TEST mode it is possible by pressing of these buttons to transfer the load from the mains to the gen-set.

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Description of MEASUREMENT screens
1 2

[1-1] Generator 1/5

Act power Engine speed

6

kW RPM
0 0
3

11 Pwr factor 0.00

OFF MAN SEM AUT TEST Date 24.11.04
Time 10:51:35 ! ± 4
10 Timer 0
Not ready Speed= 0 RPM
MainsOper ODEBL Pgen= 0 (####) kW
9
8 7 6 5

1. Remote communication indication.

Access lock indication. Symbol is visible when Access lock is active.
2. Measuring screen indication
[1–1] Generator 1/5
[1–1] Measure screen address.
For jump to selected screen set this address from numeric keyboard.
Generator Measure screen group name
1/5 The first screen from five in group.
3. Alarm list indication. Exclamation mark indicates the Alarm list is not empty. Flashing means new
item appeared in Alarm list.
4. Indication of Password access from controller keyboard.
Closed lock No password is set.
Opened lock Password is set. Password level is visible in open lock.
5. Required gen-set power.
#### When ProcessControl:#SysLdCtrl PtM = LDSHARING
Number When ProcessControl:#SysLdCtrl PtM = BASE LOAD
6. Actual gen-set power.
7. Indication of current gen-set power control or power limitation (why is the power reduced).
Power limitation due to warming procedure is not indicated.
O Overheat protection
D Power derating
E Export protection
B Base load
L Loadsharing
8. Electric Machine state indication.
9. Engine Machine state indication.
10. Timer – events counting time (e.g. prestart, cooling etc.).
11. Controller mode indication. Black background indicates active mode (OFF in example above).

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 Mode in frame ( AUT in example above ) indicates where will mode return after binary input Remote
OFF will be opened.

Measuring screen list

Screen structure is different in different applications.
[1-1] Generator 1/5 [3-1] Synchronizing 1/1
Slip freq 0,00 Hz
Act power Engine speed Angle 0,0 °
Gen V L1-N 0 V
Mns V L1-N 0 V

Volt match 123

kW RPM 000
0 0 SpdRegOut 0,00 V
Pwr factor 0,00 VoltRegOut 0,0 %
[1-2] Generator 2/5 [4-1] Anl inputs 1/1
Gen freq 0,0 Hz IS-CU Anl input 1 0,0 °C
Gen V Ph-Ph 0 0 0V AI1……│…….…│… Bargraph………..……..
Gen V Ph-N 0 0 0V IS-CU Anl input 2 0,0 °C
Gen V Ph-N ….…│…….…│… Bargraph…….. AI2……│…….…│…Bargraph………………..
IS-CU Anl input 3 0,0 °C
Gen current 0 0 0A AI3……│…….…│…Bargraph………………..
Gen current …………………… Bargraph ..│.. IS-CU Anl input 4 0,0 bar
AI4……│…….…│…Bargraph………………..
Max load surge 0,00 P/s Batt volt 24,0 V
Act load surge 0,00 P/s Batt volt .…│…….…│… Bargraph……...…..

[1-3] Generator 3/5 [5-1] Bin inputs CU 1/1

Act power 0 kW BI1 ………….. 0 BI9 ……..……….. 0
per phase 0 0 0 kW BI2 ………….. 0 BI10 …………….. 0
React Pwr 0 kVAr BI3 ………….. 0 BI11 …………….. 0
per phase 0 0 0 kVAr BI4 ………….. 0 BI12 …………….. 0
Appar pwr 0 kVA BI5 ………….. 0 BI13 …………….. 0
per phase 0 0 0 kVA BI6 ………….. 0 BI14 …………….. 0
Pwr factor 0,00 BI7 ………….. 0 BI15 …………….. 0
per phase 0,00 0,00 0,00 BI8 ………….. 0 BI16 ………..….. 0
Pg derated 0 kW

[1-4] Generator 4/5 [6-1] Bin outputs CU 1/1

StatusLdShed NoLdShed BO1 ………….. 0 BO9 ……..……….. 0
EarthFaultCurr 0A BO2 ………….. 0 BO10 …………….. 0
BO3 ………….. 0 BO11 …………….. 0
iCB string BO4 ………….. 0 BO12 …………….. 0
BO5 ………….. 0 BO13 …………….. 0
BO6 ………….. 0 BO14 …………….. 0
BO7 ………….. 0 BO15 …………….. 0
BO8 ………….. 0 BO16 ………..….. 0
[1-5] Generator 5/5 [7-1] Pwr management 1/1
kWhours 0 Engine priority 1
kVArhours 0 TotAvlbPnom 0 kW
NumStarts 0 TotRunPnom 0 kW
RunHours 0h TotRunPact 0 kW
NextServTime 0h
ActRes/%Load 0 kW%
ActRes/%Load…│………│.. Bargraph……….

CAN16 1000000000000000
CAN32 0000000000000000
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[2-1] Bus 1/1 [8-1] Bin inputs 1/1
Bus freq 0,0 Hz BI1 ………….. 0 BI9 ……..……….. 0
BI2 ………….. 0 BI10 …………….. 0
Bus V Ph-Ph 0 0 0V BI3 ………….. 0 BI11 …………….. 0
BI4 ………….. 0 BI12 …………….. 0
Bus V Ph-N……│…….…│… Bargraph………. BI5 ………….. 0 BI13 …………….. 0
BI6 ………….. 0 BI14 …………….. 0
BI7 ………….. 0 BI15 …………….. 0
BI8 ………….. 0 BI16 ………..….. 0
[9-1] Bin outputs 1/1
BO1 ………….. 0
BO2 ………….. 0
BO3 ………….. 0
BO4 ………….. 0
BO5 ………….. 0
BO6 ………….. 0
BO7 ………….. 0
BO8 ………….. 0
[10-1] Analog inputs 1/1
Analog input 1………………… ………….. 0 °C
Analog input 2………………… ………….. 0 °C
Analog input 3………………… ………….. 0 °C
Analog input 4………………… ………….. 0 °C
Analog input 5………………… ………….. 0 °C
Analog input 6………………… ………….. 0 °C
Analog input 7………………… ………….. 0 °C
Analog input 8………………… ………….. 0 °C
[9-1] Cylinder temps 1/2
I.
400
350
400
450
400
350
400
450
T Cyl I. Aver 400 °C
[9-2] Cylinder temps 2/2
I.
0
-50
0
50
0
-50
0
50
T Cyl I. Aver 400 °C

Hint:
Additional screens are automatically generated when external units are configured.
Screens [8.1] up to [8.7] are inputs of extension units IS-BIN16/8.
Screens [9.1] up to [9.4] are outputs of extension units IS-BIN16/8.
Screens [10.1] up to [10.8] are analog inputs of extension units IS-AIN8.
Screens [9.1] up to [9.4] are cylinder temperature indication based on IS-AIN8 analog inputs.

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Mode and function description
There are four gen-set operation modes: OFF - MAN – AUT – TEST in SSB and SPtM application. There are
three gen-set operation modes: OFF - MAN – AUT in SPM and MINT application.
To select the mode use MODE→ or ←MODE.

OFF mode
• No start of the gen-set is possible. Outputs STARTER, GCB CLOSE/OPEN and FUEL SOLENOID are
not energized.
• No reaction if buttons START,STOP,GCB ON/OFF are pressed.
• When power-cut comes, MCB CLOSE/OPEN opens. After mains returns, MCB CLOSE/OPEN closes
with MCB close del.

MAN mode
1) To start the gen-set press START.
2) When the generator voltage is within limits (adjusted in the setpoints group Generator protections)
GCB green LED on the front panel lights.
3) Press GCB ON/OFF to close the GCB. If the generator voltage is out of the limits, controller does not to
respond to the GCB ON/OFF .
a) If controller detects dead bus, immediately closes GCB OPEN/CLOSE output.
b) If controller detects voltage on the bus, starts synchronizing.
4) To stop the engine press STOP
a) controller unloads the gen-set, opens GCB CLOSE/OPEN. Unloading is active only when binary
input MCB feedback is closed or other gen-set is connected to bus. In other case GCB CLOSE/OPEN
opens immediately.
b) Gen-set is cooled and stopped.
Hint:
Controller does not respond to the binary input SYS START/STOP. The gen-set is fully in manual control;
there is no automatic way to stop it (except protections). The gen-set stays running until STOP button is
pressed.
Controller does not take place in Power management in MINT, MEXT application

SEM mode
START. button starts the gen-set.
• Controller closes GCB to dead bus.
When Mains is within limits and MCB is ON, Controller starts synchronizing and closes GCB when
synchronizing conditions are met. Gen-set remains running in parallel.
• When Mains failure is recognized during parallel operation - Controller opens MCB.
• After mains recovers Controller synchronizes MCB and returns to parallel operation

STOP stops the gen-set.

In case of mains failure the gen-set starts automatically. After mains recovery stops automatically (MCB
synchro, soft transfer). This AMF function is the same as described below in AUT mode.
Other automatic starts/stops (peak start/stop, binary input Rem Start/stop) are not active.
Load control options are the same as in AUT mode.
Hint:
InteliSys does not respond to GCB ON/OFF , MCB ON/OFF buttons.

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AUT mode
AMF
1) Mains failure is recognized
a) InteliSys opens MCB (depends on setpoint AutoMains fail:MCB opens on setting)
b) After EmergStart del elapsed, InteliSys starts the gen-set
c) If mains recovers during the start-up process, InteliSys closes MCB again after MCB close del and
stops the gen-set.
2) When the gen-set is started and the generator voltage and frequency is within limits (adjusted in menu
Generator protections) InteliSys closes the GCB. If the generator voltage is out of the limits for MaxStabil
time, InteliSys alarms the failure and stops the gen-set.
3) After mains recovers:
a) After MainsReturn del InteliSys starts synchronizing to mains, closes the MCB and starts unloading.
b) After the Breakers overlap delay InteliSys opens the GCB.
c) The gen-set is cooled and stopped.

Remote start/stop
Genset starts automatically, when binary input REM START/STOP is closed and stops by opening it.

Peak shaving
Genset can start and stop automatically according to consumption from the mains (object). IE measurement
must not be set to NONE and ProcessControl:PeakAutS/S del must be greater than 0.
If Mains import value exceeds for more than ProcessControl:PeakAutS/S del
ProcessControl:PeakLevelStart, engine starts automatically.
If Load consumption (Mains import + Genset power) drops for more than ProcessControl:PeakAutS/S del
below ProcessControl:PeakLevelStop, engine stops.
Hint:
Engine does not stop, if other condition for automatic starts are active.
Example: If peak stop condition occurs, but REMOTE START/STOP is active, engine stays running.

InteliSys does not respond to GCB ON/OFF , MCB ON/OFF , STOP, START buttons and corresponding
remote WinEdit or Modbus commands.

Set Basic setting: FltRes GoToMAN = ENABLED to avoid automatic engine start when pressing FAULT
RESET after Shut down or Slow stop alarm.

!!!!! VERY IMPORTANT !!!!!!

Engine can start automatically without warning when pressing FAULT RESET after shut down alarm.

TEST mode (SSB and SPtM only)

The setpoint Ret from test influences the behavior of TEST mode.
Caution: The gen-set starts automatically and is always running in TEST mode!

The setpoint Ret from test = MANUAL

1. While TEST mode is selected, gen-set automatically starts and is running unloaded.
2. To load the gen-set with load supply interruption
a. Power cut comes or
b. MCB ON/OFF button is pressed
When power cut or MCB ON/OFF : InteliSys opens MCB, after Return break elapses, InteliSys closes
GCB.
When the mains recovers gen-set remains island running !

3. To load the gen-set without load supply interruption

a. GCB ON/OFF is pressed
b. Binary input TEST ON LOAD is closed
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 In this case InteliSys synchronizes gen-set to mains, closes GCB, Breaker overlap time runs in parallel
and then opens MCB.
When the mains recovers gen-set remains island running !
4. To stop the gen-set select other mode than TEST
While TEST mode is selected, gen-set is running unloaded.
When power cut comes InteliSys opens MCB.
After Return break elapses, InteliSys closes GCB.
When the mains recovers:
1. After the MainsReturn del InteliSys starts back synchronizing to mains and closes MCB.
2. The gen-set remains running in parallel for BreakerOverlap time, opens GCB and remain running
unloaded.
To stop the gen-set select other mode than TEST
Hint:
InteliSys does not respond to GCB ON/OFF , STOP, START in Ret from test = AUTO.
Engine automatically starts, when TEST mode is selected.
Engine can start automatically without warning when pressing FAULT RESET after shut down alarm.

Load control modes in parallel to mains

Baseload
Process control: Load CTRL PTM = BASELOAD
Genset power is kept on value given by Baseload setpoint.

Internal Import export

ProcessControl: Load CTRL PTM = IMP/EXP
Process control: IE measurement = IM3 CT INPUT
Genset load is controlled to keep the import load at the level given by setpoint Process control: Import load
value.
InteliSys measures Import/Export value via CT connected to In/Im3 terminals.

External Import export

Process control: Load CTRL PTM = IMP/EXP
Process control: IE measurement = ANALOG INPUT
Genset load is controlled to keep the import load at the level given by setpoint Process control: Import load
value.
Real I/E power value is measured from the Analog input LdCTRL:ExtI/E.

Temperature control by gen-set power

Genset load is changed to keep required temperature TempByPwr Treq on analog input LdCtrl:TByPwr.
If the temperature measured from analog input “LdCtrl:TbyPwr” exceeds value TbyPwr Treq the gen-set
power is decreased gradually to Min Power PtM. If the temperature drops below TbyPwr Treq the gen-set
increases the power gradually up to Nominal power
Hint:
Sampling time of Temperature by power control loop is 20 seconds.
Requested power value ActReqPower is visible on the controller measure screen. Decreasing of Requested
gen-set power according to TbyPwr control (does not decrease Nominal power value) has no influence on
generator protection limits (different from Power derating function).

Overheat protection
Function is active when ProcessControl:Overheat prot = ENABLED
Analog input: LdCtrl:TbyPwr
Setpoints: Same as described in previous paragraph ( temperature by power control)
The function is similar to the Temp by Power. But in this case the requested load can vary between Mim
Power PtM and Baseload (if Load control = BASELOAD).

Hint:
Requested temperature should be set a bit higher as operational temperature.
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Export protection
Function is active when ProcessControl:Export prot = ENABLED.
Process control: IE measurement must not be set to NONE!
This function limits the requested gen-set power to keep Import power higher or equal to the setpoint
Import load.

Genset warming
Engine warming period starts after GCB is closed to parallel operation. The required gen-set load (e.g.
Baseload) is reduced to Engine params: Warming load.
Engine warming is finished when Engine params: Warming temp is reached but latest after Engine
params: Max warm time. Warming temperature is measured on Analog input Warming temp.
Genset Load is increased to Baseload (or to different value due to Import/Export function) after Warming is
finished.

Power derating
This function linearly decreases gen-set nominal power according to analog input value.
Gen-set power starts decreasing when temperature measured by Analog input Derating temp exceeds
DeratingStart value.
Gen-set power is at DeratedPower value when temperature measured by Analog input Derating temp is
equal or higher than DeratingEnd value.

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Alarm management
Following alarms are available:
Binary alarms Analog alarms Block type
Alarm type Active
No protection
Warning None Over All the time
Shutdown Wrn+shut down Over + Fls Run only group 1
Slow stop Wrn+Slow stop Under Run only group 2
Electric protection Wrn+El.protection Under + Fls Run only group 3
Off load Cylinder

Each active alarm is recorded to history and indicated on Alarm list screen. Detection of each binary input
alarm is fix 1 sec time delayed. Analog input Alarm detection is usually based on two levels (e.g. wrn and
sd). The Sensor fail activates or does not activate binary output common Alarm depends on configuration.
Use WinEdit to modify binary or analog inputs configuration.

Warning (Wrn)
When a warning occurs, only alarm outputs and common warning output are closed, no other action is
performed.
See List of possible events in chapter Remote control and data logging

Shut down (Sd)

When a shut-down alarm occurs, InteliSys opens outputs GCB CLOSE/OPEN, FUEL SOLENOID,
STARTER to stop the engine immediately. Alarm outputs and common shutdown output are closed. Active
or not reset protection disables start.
See List of possible events in chapter Remote control and data logging.

Slow stop (Stp)

When a slow stop protection occurs, the behavior of the gen-set is similar like Stop button pressing
(unloading, GCB open, cooling, stop). Alarm outputs and common slow stop output are closed.
Active or not reset protection disables start.
See List of possible events in chapter Remote control and data logging

Electric protection (ElProt)

In case of this alarm GCB is opened immediately and the engine goes to cooling. Alarm outputs and
common unl output are closed. Active or not reset protection disables start resp. GCB closing.
See List of possible events in chapter Remote control and data logging

Off load
When Off load protection is active GCB is opened immediately but the engine does not go to cooling state –
stays running for 60 second and then, if in AUT mode, the gen-set is stopped. Alarm outputs and common
unl output are closed. Active Off load protection disables start respectively GCB closing.

When Off load protection is not active (Binary input is opened) the gen-set starts again and GCB closes
again without Fault reset (in AUT, if a request for run – e.g. REM START/STOP – is still active).

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Mains failure
Mains failure detection depends on Auto mains failure setpoints (levels and delays) adjusting. When the
mains failure comes up, mains circuit breaker is opened.
Hint:
Only the first mains failure reason is written to history.
Mains failure is not written to alarm list!

Alarm time chart

Underspeed

Protection
delay Engine running only, SD, Slow stop, Wrn
Gen>V, Gen<V, Gen>f, Gen<f,
Volt unbal, Curr unbal, Reverse
power, Unload protection, Load surge

All the time & Overspeed protections & Ig IDMT, Ig unbal, IG short
Mains >V, Mains <V, Mains >f, Mains <f, MVolt unbal

Ready
Cranking Starting Running Loaded Loaded
RPM=0

GCB opened
Starter OFF

Min stab time

GCB closed

Max stab time

Synchronizing

Unloading

Cooling
Start

Stop
Idle

or

GCB, MCB fail detection

MCB or GCB fail detection is based on breaker command comparing with binary input breaker feedback.

Sensor fail detection

Sensor fail Fls is detected when measured value is 6 percent out of selected characteristic range. The
controller screen will display #### instead of the measured value.

Alarms indication
There can be following actions when Alarm is active (depends on Alarm type and configuration):
• Alarm list record
• History list record
• Active call (when is enabled and modem is installed)
• Controller front panel LED indication
• Binary output ALARM is closed when Alarm is active or when was deactivated and FAULT RESET
button was not pressed to confirm.
Binary output ALARM opens when Alarm was deactivated (no other Alarm is active) and FAULT RESET
button was pressed to confirm.
• Binary output HORN is closed for adjustable time when any new Alarm occurs.
• Corresponding value reading (binary input state, analog input value, generator voltage, .. ) is inverse
(e.g. 100 ) on Controller screen when value is out of limits (binary input protection is active).

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Remote control and data logging
Direct connection to the PC
InteliSys can be connected directly to the PC via the RS232 interface.
Use the standard RS232 null modem cable to connect PC with InteliSys.

PC software - WinEdit
On the PC (for direct or modem connection) has to be installed the ComAp’s software package WinEdit.
(based on Windows 95 or newer platform)
WinEdit enables:
read the quantities,
adjust all set points,
read the history,
control the engine,
configure the controller,
select software configuration,
modify alarm inputs and outputs,
direct or modem communication,
receive active calls.

History file
InteliSys stores a record of each important event into the history file. The history file contains several
hunderds records. When the history file is full, the oldest records are removed. History record structure
depends on local configuration.

Remote modem communication

Remote modem communication with controller is available when modem or GSM modem is connected to
controller. It is possible to read all values check or change setpoints, view history record and download aig
archive file.

Modem connection
Open WinEdit, Type connection = Modem. During modem connection are available all functions like from
direct connection.

Active calls
If the function is enabled and selected alarm comes up, the controller opens a connection to the remote PC
(selected phone number) automatically and send an aig archive file containing, among others the history file,
to the PC.

Active SMS message

If the function is enabled and selected alarm comes up, the controller sends a SMS to the selected phone
number. A GSM modem must be connected to the controller to enable this function. The SMS contains a
copy of the alarm list to help the operator to diagnose the situation.

Example of active SMS message:

#Gen-set name:AL=(Wrn PrimWater temp, !Emergency stop)

Controller firmware and archive files

There are only two types of software files in InteliSys:

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 Archive file ais (e.g. SPtM-3.3.aig for SPtM application)
Firmware file mhx (e.g. IS-3.3.mhx)

Controller software modification

Controller software is distributed in
Complete installation pack on CD (include WinEdit, MultiEdit and detail user and application guides)
iwe pack for simple import of new SW version to corresponding WinEdit directories. Iwe sw pack
contains mhx file(s) and aig archives. Use WinEdit Options - Import firmware command to import iwe.

Controller application modification or change

WinEdit direct connection – Controller – Software configuration – Select or Modify
Select = application change (e.g. from SSB to SPtM)
Modify = configuration change (Input, Outputs, protection, password setting, .. etc modification)

Controller firmware upgrade

WinEdit direct connection – Controller – Programming – select required firmware version – click Write to IG.

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Technical data
Power supply
Voltage supply 8-36V DC
Consumption 0,22 A for 24V supply
0,17A for 36V supply
0,69A for 8V supply
Battery voltage measurement tolerance 2 % at 24V

RTC battery life-cycle 10 year

Hint:
When internal RTC battery becomes flat InteliSys function (e.g. Ready for stand by) does not change until
controller power supply is switched off.
After the next power switch on controller:
Stays in the INIT state (not possible to run gen-set)
All History records disappear except Wrong params record
Alarm list is empty
Time and Date values are set to zero
Statistics values are random

Operating conditions
Operating temperature -10..+60oC
Storage temperature -30..+80oC
Flash memory data retention time 10 years
Protection front panel IP65
Humidity 95% without condensation
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

Dimensions and weight IS-CU

Dimensions 290 x 190 x 60 mm
Weight 1000g

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