InteliDrive Nano. Reference Guide. Engine Controller. InteliDrive Nano. Compact Controller for Industrial Engines. SW version 1.

Transcription

1 InteliDrive Nano InteliDrive Nano Engine Controller Compact Controller for Industrial Engines SW version 1.3, October 2012 Reference Guide Copyright 2012 ComAp s.r.o. ComAp, spol. s r.o. Kundratka 17, Praha 8, Czech Republic Tel: , Fax: info@comap.cz,

2 Table of contents Table of contents... 2 General Guidelines... 3 What describes this manual?... 3!! Warnings!!... 3 Text... 3 System Overview... 4 General description... 4 Configurability... 4 Application examples... 5 Engine Speed control in MAN mode... 6 Control loop in AUT mode... 7 Installation and wiring... 9 Terminals diagram Wiring hints Operator interface Setup mode Inputs and Outputs Logical Binary outputs Logical Binary and Analog inputs Setpoints Setpoint overview B - Basic Settings E - Engine and Protection Parameters R RPM Control Alarm and History Management Events Warnings Shutdowns ECU Messages Technical data Power supply Operating conditions Binary inputs and outputs Analog inputs Speed pick-up input D+ function InteliDrive Nano, SW version 1.3, ComAp October

3 General Guidelines What describes this manual? IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTION - This manual contains important instructions for InteliDrive Nano controller that shall be followed during installation and maintenance. The manual describes also software, which is designed for single engine applications. What is the purpose of the manual? Provides general information how to install and operate InteliDrive Nano controller. This manual is dedicated for Engine operators Engine control panel builders For everybody who is concerned with installation, operation and maintenance of the industrial engines with InteliDrive Nano.!! Warnings!! Remote control InteliDrive Nano controller can be controlled remotely. In case of any work on the engine make sure that nobody can start it remotely. To be sure make the following steps: Disconnect input REM START/STOP or Disconnect output STARTER Because of large variety of InteliDrive Nano parameters setting, it is not possible to describe all combinations. Some of InteliDrive Nano functions are subject of changes depending on SW version. The data in this manual describes the product and are not warranty of performance or characteristic. Text PAGE Break Return Generator protections REMOTE START/STOP Capital letters in the frame buttons on the front panel Italic set points Bold Set point group Capital letters binary inputs and outputs Note: ComAp believes that all information provided herein is correct and reliable ComAp however reserves the right to update it at any time. ComAp does not assume any responsibility for its use unless otherwise expressly undertaken. Note: SW and HW must be compatible otherwise some functions will be disabled. InteliDrive Nano, SW version 1.3, ComAp October

4 System Overview General description InteliDrive Nano is a comprehensive controller for single industrial engines including the electronic EFI engines. InteliDrive Nano controller is equipped with a powerful graphic display showing icons and symbols without texts for its intuitive operation, which sets, together with high functionality, new standards in engine control. InteliDrive Nano can operate an engine in MANual or AUTomatic modes. The key feature of InteliDrive Nano is its easy-to-use operation and installation. Predefined configurations of typical applications are available as well as user-defined configurations for special applications. Configurability One of the key features of the controller is its high level of adaptability based on the needs of every particular application. The way, how to achieve this, is the configuration. NOTE: Use DriveEdit PC software to the read configuration from the controller or disk, view it, modify it and write the configuration to controller or disk. The firmware contains a number of binary inputs and outputs needed for all necessary functions available in the firmware. However not all functions are required at the same time. Configuration task is mapping of "logical" firmware inputs and outputs to the "physical" hardware input and output terminals and some setpoints modification. Configuration parts: 1. Mapping of logical binary and analog inputs (functions) to physical binary input terminals 2. Mapping of logical binary outputs (functions) to physical binary output terminals 3. Assigning sensor characteristics 4. Selecting of ECU type if an ECU is connected 5. Setpoints modification The controller is delivered with a default configuration, which should suit to most standard applications. This default configuration can be changed either directly from controller s front panel or by using PC with DriveEdit software. NOTE: For connection to PC please use the USB interface. Controller can be powered directly from USB communication port. In this case LCD backlight is turned off and all outputs are open. Configuration of InteliDrive Nano controller can be stored in an ain file for later use or for its modification in DriveEdit PC software. Such file is called archive. The archive contains full image of the controller at the moment of saving. Besides the configuration there is also recorded actual adjustment of all setpoints as well as all measured values and history logs. The archive can be simply used for preparing controllers with identical configuration and settings. InteliDrive Nano, SW version 1.3, ComAp October

5 Application examples Application example 1 Engine type Mechanical engine, constant speed Functions Start to Nominal RPM Protections Overspeed, Oil Pressure, Cooling Temperature, Fuel level Application example 2 Engine type Mechanical engine, variable speed Functions Start to Idle then Nominal RPM, manual speed adjusting Protections Overspeed, Oil Pressure, Cooling Temperature, Fuel level MAN mode Manual: manual speed adjustment ramping function AUT mode Automatic start/stop, automatic speed adjustment Application example 3 Engine type Functions Protections MAN mode AUT mode Electronic engine, constant or variable speed, simple wiring Start to Idle then Nominal RPM Overspeed, Oil Pressure, Cooling Temperature, Fuel level Manual: manual speed adjustment ramp function Automatic start/stop, automatic speed adjustment CAN - J1939 BO ECU relay ECU Diesel Engine - + Battery InteliDrive Nano, SW version 1.3, ComAp October

6 Application example 4 Engine type Electronic engine, constant or variable speed, simple wiring Functions Start to Idle then Nominal RPM Protections Overspeed, Oil Pressure, Cooling Temperature, Fuel level MAN mode Manual: manual speed adjustment ramp function AUT mode Automatic start/stop, automatic control loop Application example 5 Engine type Electronic engine, constant or variable speed, simple wiring Functions Start to Idle then Nominal RPM Protections Overspeed, Fuel level, ECU Alarms indication MAN mode Manual: manual speed adjustment ramp function AUT mode Automatic start/stop, automatic speed adjustment Engine Speed control in MAN mode R05-Speed Ramp Engine starts to R02-Idle Speed, increases after Idle time to the R03-Operational Speed that can be changed by panel Up/Down buttons, switched by Binary input I-28 Speed Switch to another R04- Speed Switch value that can be again changed by panel Up/Down buttons and returns to previous value of R03-Operational Speed. InteliDrive Nano, SW version 1.3, ComAp October

7 All RPM changes are accepted within R15-Max and R16-Min Speed Limits. Operational and Speed Switch change (by Up/Down buttons) is remembered in case of switching by Binary input Speed Switch for all time engine is running. After Engine Start are R03-Operational Speed and R04-Speed Switch actualized to default R03, R04 setpoint values. Up/Down buttons function Up/Down button 1x pressed 2x pressed Press and hold for 3s Speed request step + / - 1 RPM + / - R05 / see Note below Follow the R05-Speed Ramp Note: (R05-Speed Ramp / 2 + 1) = 100/2+1 = 51RPM. when R05 = 100 RPM/s. RPM MAN Control loop in AUT mode Pressure sensor is connected to T22 AIN4, converted to Bars by T22-AI4 curve, compared with R11 Request, processed in PI block. Speed request is limited by R15, R16 and transferred to CAN J1939 and converted via R07, R08 to T29 Analog output 1. Control Loop I/O Function Terminal Mnemo Type Conversion Control Loop In T22 AIN4 0/4-20mA T22 AI4 Obligatory Loop Dislabled T25 BIN7 BIN HiSide n.a. Optional Speed Request T29 AO1 0 5VDC R07, R08 Optional Loop In Indication T30 AO2 0 5VDC R13, R14 Optional CAN InteliDrive Nano, SW version 1.3, ComAp October

8 CAN interface EFI engine Engine Compressor ECU Pressure Sensor CAN J1939 T22 (-I50) AIN4 0/4-20mA Control Loop In Speed Request R15-Min Speed Limit R16-Max Speed Limit ID-Nano AUT mode PI block R09-Control Loop Gain R10-Control Loop Int R12-Control Loop Bias Curve 4 Bar Curve 4 10,0 0,0 4mA 20mA R11-Control Loop Request R13-Control Loop In 0% R14-Control Loop In 100% + VBatt T25 (-I27) BI7 LoopDisabled Control Loop In Indication T30 AO2 0-5VDC External gauge Analog interface Mechanical engine Engine Speed Governor Compressor Pressure Sensor T29 AO1 0-5VDC T22 (-I50) AIN4 0/4-20mA Control Loop In R15-Min Speed Limit R16-Max Speed Limit Speed Request R07-Speed request 0% R08-Speed Request 100% ID-Nano AUT mode PI block R09-Control Loop Gain R10-Control Loop Int Curve 4 Bar Curve 4 10,0 0,0 4mA 20mA R11-Control Loop Request InteliDrive Nano, SW version 1.3, ComAp October

9 Installation and wiring Mounting The controller is to be mounted into the switchboard door. Requested cut-out size is 96x96mm. Use the screw holders delivered with the controller to fix the controller into the door as described on pictures below. Package contents Accessories Description Optional / Obligatory InteliDrive Nano InteliDrive Nano controller unit Obligatory Short Guide InteliDrive Nano brief overview Obligatory Holders Two controller holders Obligatory InteliDrive Nano, SW version 1.3, ComAp October

10 Terminals diagram Default configuration T15 AIN1-R / BIN1 Wrn/Cd - Coolant Wrn/Cd Protection 2 AIN8: 0-10V T16 User curve 8 T14 AIN2-R / BIN2 Wrn/Sd - Oil Press GND T17 T13 AIN3-R / BIN3 Wrn/Cd - Fuel level Speed Request User curve 7 AIN7: Ω T18 T12 BIN4 Hi-side Emergency Stop GND T19 T11 BIN5 Hi-side Remote Start/Stop Wrn/Cd Protection 1 AIN6: 0/4-20mA T20 User curve 6 T10 IN-COM Level Start/Stop User curve 5 AIN5: 0/4-20mA T21 T09 BO3 / 0,5A Hi-side Close Load Ctrl Loop In AIN4: 0/4-20mA T22 User curve 4 T08 BO4 / 0,5A Hi-side Alarm GND T23 T07 FUEL / 10A Relay FUEL /ECU /STOP Speed Switch BIN6 Hi-side T24 T06 FUEL / 10A Relay FUEL /ECU /STOP Loop Disabled BIN7 Hi-side T25 T05 Starter / 10A Relay STARTER Pick-up RPM - GND T26 T04 Starter / 10A Relay STARTER RPM T27 T03 SUPPLY+ (+VBAtt) 8 to 36 VDC GND T28 T02 D+ Connect to T03 Speed Request AO1: 0 5V T29 when not used!!! T01 SUPPLY - (0VBatt) AIN4 Ctrl Loop In AO2: 0 5V T30 User curves for Resistive measuring AIN7 Ohm Conversion curve 1000ohm / RPM 1 0, , ,0 means 1000 ohms; 2500 means RPM User curves for ma measuring AIN4 Ctrl Loop In, AIN5 Level Start Stop, AIN6 Wrn/Cd Protection1 Ohm Conversion curve 20mA / 20,0 1 0, , ,0 means 20 ma User curves for Voltage measuring AIN8 Ohm Conversion curve 10V / 10,00 1 0, , ,0 means 10 V InteliDrive Nano, SW version 1.3, ComAp October

11 Sensor fail is indicated below ½ of low and over +12% of high limit of sensor characteristic. Wiring hints To ensure proper function: Use min. power supply cable of 2.5mm 2 Maximum continuous DC power supply voltage is 36 VDC. Maximum allowable power supply voltage is 39VDC. The InteliDrive Nano power supply terminals are protected against large pulse power disturbances. When there is a potential risk of the controller being subjected to conditions outside its capabilities an outside protection devise should be used. For the connections with 12VDC power supply, the InteliDrive Nano includes internal capacitors that allow the controller to continue operation during cranking if the battery voltage dip occurs. If the voltage before drop is 10V, after 100ms the voltage recovers to 5 V, the controller continues operating. During this voltage drop the controller screen backlight can turn off and on but the controller keeps operating. Power supply fusing Controller should never be connected directly to the starting battery. App 6 amp fuse should be connected in-line with the battery positive terminal to the controller. Fuse value and type depends on number of connected devices and wire length. Recommended fuse (not fast) type - T1A. Not fast due to internal capacitors charging during power up. The capacitor size should be µf to withstand 150ms voltage dip under following conditions: Voltage before the drop is 12V, after 150ms the voltage recovers to min. allowed voltage, i.e. 8V. D + C F Motor starter Motor starter D+ Charging alternator D+ output is on terminal T02. Hint: Do not leave it opened. If not used connect T02 D+ terminal to battery positive T03. InteliDrive Nano, SW version 1.3, ComAp October

12 Binary outputs Use minimally 1 mm 2 cables for wiring of all binary outputs. CAUTION! Controller Binary outputs are high side type (connecting +VBatt on output terminal)! Never connect any analog sensor to this output to avoid sensor damage. All outputs are short circuit protected. Use suppression diodes on all relays and other inductive loads! CPU + - Analog inputs Analog inputs are designed for resistive automotive type sensors like VDO or DATCON. The sensors are connected either by one wire (the second pole is sensor body) or by two wires. In case of grounded sensors connect the terminal T10 to the engine body as near from the sensors as possible. In case of isolated sensors connect the terminal T10 to the negative power supply terminal of the controller as well as the opposite poles of the sensors. NOTE: Symbol #### is displayed when measured value is out of range or sensor s wire is broken. Analog Sensors wiring GROUNDED SENSORS ISOLATED SENSORS ID Nano InteliDrive Nano, SW version 1.3, ComAp October

13 Operator interface Stop button Stop button 0,5s delay, no auto repeat. Dual Up/Down keys function Menu enables to change the Up - and Down - keys function between Screen listing or Speed Up/Down command (indicated by + - bar). Screen listing mode RPM adjustment mode Switch screen Up Switch screen Down Speed Up Speed Down Menu selection Press Menu button to modify following functions below. Use Up/down to select item and press Start button to change mode or Enter Runtime setpoints. Use Stop button to escape back to menu, press Menu to return back to previous measuring screen. Adjust PID setpoints - Change Up/Down buttons function - Switch between MAN AUT mode Screen Icons START button function Switch to Runtime Ctrl Loop - setpoints screen Change of Up/Down buttons function between Screen listing mode and RPM adjustment mode Switching between MAN and AUTO mode Press Menu button to return back to measuring screen. It is not possible to change screens when Up/Down keys are in Speed Up/down mode i.e. enter Menu from screen what you want to see after. Runtime setpoints Only below setpoints are available to modify on running engine. Select requested item by Up/Down, press Start to edit, Use Up/Down to modify, Enter to confirm, Stop to return to Menu. R09 Ctrl Loop Gain R10 Ctrl Loop Int R11 Ctrl Loop Request R12 Ctrl Loop Bias R13 LoopReq 0% R14 Loop Req 100% InteliDrive Nano, SW version 1.3, ComAp October

14 Press Stop to return to Menu, press Menu to return back to Measuring screen. Measuring screens 1-st measuring screen 1800 RPM 1800 RPM 5,0 Bar 5,0 Bar Engine RPM Engine state and Timers Running hours Status 2-nd measuring screen Oil pressure T14 AIN2 Cooling temperature T15 AIN1 Fuel level T13 AIN3 Battery voltage 3-rd RPM control screen Engine RPM Actual (T26-T27) Engine RPM Requested Control loop Actual value T22 AIN4 Control loop Requested value The 3-rd screen disappears when B01 Basic settings: Application = SingleSpeed 4-th measuring screen Level Start/Stop T21 AIN5 Wrn/Cd Protection 1 T20 AIN6 Wrn/Cd Protection 2 T16 AIN8 free line Not configured value is displayed as The 4-th screen disappears when all AIN5, AIN6, AIN8 values are not configured. Alarm-History (10 items screen) Alarm-History (10 items screen) Status icons Active LBI Remote Start/Stop (T11 BIN5) Active LBI Access Lock Active function Level Start/Stop AUT mode, AIN5 configured, Active Control Loop AUT mode, AIN4 configured, No Loop block Remote AUT Active Speed Switch (T24 BI6) InteliDrive Nano, SW version 1.3, ComAp October

15 Reserve Active Alarm State machines indication 1st Measuring screen - 2nd line Ready Starting Running Loaded Cooling Not Ready Data from ECU The analog measuring T14 Oil Pressure and T15-Coolant Temperature has to be configured as Not used (function code I00) to display those ECU values on the second screen when ECU is configured. Engine RPM is switched to ECU source automatically. The ECU Fault codes are reported in the Alarm-History Screen as well as the ECU communication fail. Setup mode Setup mode is available when: Engine is not running, Controller is in MAN mode, Panel Up/Dn keys are switched to Screen listing mode. The Setup mode is blocked by the binary function Access lock as well as the Menu button. To enter Setup mode press and hold then press shortly button and then and then. Setup mode enables partial controller configuration (I/O function modification and setpoints setting) using just panel buttons without PC tool. NOTE: The controller will automatically switch to Setup mode when there is some problem with checksum (i.e. memory integrity) or when there is incompatibility between firmware and archive version. This situation can occur when you upgrade a firmware. If this happen just check and set all setpoints properly. InteliDrive Nano, SW version 1.3, ComAp October

16 Setup mode icons Outputs settings RPM control Inputs settings ECU setting Basic settings Info Engine parameters and protections For move in menu use and buttons. Press Start button to select choice or Stop button for exit. Supported ECU InteliDrive Nano, SW version 1.3, ComAp October

17 Inputs and Outputs In the table below you can see which logical function can be assigned to physical binary or analog input or binary output. Each logical input or output function has unique code. Input code s firs letter is I output code s letter is O. Summary of all logical input function is in chapter Logical binary and analog inputs, summary of logical output function is in Logical binary outputs. Each logical binary input and output can be configured as Normally Open (NO) or Normally Close (NC). Physical Inputs Terminal Type Direction Input function assignment T11 binary input I00, I02-NO, I30 T12 binary input I00, I01-NC, I10, I16, I29, I30 T13 binary/analog input I00, I20, I21-ch1 T14 binary/analog input I00, I22, I23-ch2 T15 binary/analog input I00, I24, I25-ch3 T16 Analog input I00, I54 T18 Analog input I00, I52 T20 Analog input I00, I53 T21 Analog input I00, I51 T22 Analog input I00, I50 T24 Binary input I00, I04, I10, I16, I28-NO, I30 T25 Binary input I00, I04, I10, I16, I27-NO, I30 Default configuration is in bold e.g. I02-NO = function 02 Normally Opened; I21-ch1 = I21 with sensor characteristics 1. Physical Outputs Terminal Type Direction Input function assignment T04-T05 binary output O00,O01-NO, O04, O07, O08, O09, O10, O 11 T06-T07 binary output O00, O02-NO, O03, O04, O07, O08, O09, O10, O11 T08 binary output O00, O04-NO, O07, O08, O09, O10, O11 T09 binary output O00, O04, O07, O08, O09, O10, O11-NO T29 Analog Output Speed request - fix T30 Analog Output AIN4 indication output fix Normally Open contact Normally Open contact no voltage on output terminal or no passing current from/to binary input terminal. When the contact is opened controller read logical 0 (L) on binary input when is closed controller read logical 1 (H). In case of output logical 0 (L) means 0V on binary output and logical 1 (H) means battery positive voltage on output. Normally Open contact output Normally Closed contact output Normally Open contact input button Normally Closed contact input button InteliDrive Nano, SW version 1.3, ComAp October

18 Normally Closed contact Normally Close contact (inverted) represents close contact positive voltage on output terminal or passing current from/to binary input terminal. When the contact is opened controller read logical 1 (H) on binary input when is closed controller read logical 0 (L). In case of output logical 1 (H) means 0V on binary output and logical 0 (L) means battery positive voltage on output. Logical Binary outputs Output code Output name Type Terminal assignment O00 Not Used binary T04-5, T06-7, T08, T09 O01 Starter binary T04 O02 Fuel Solenoid binary T06 O03 Stop Solenoid binary T06 O04 Alarm binary T04-5, T06-7, T08, T09 O07 Ready To Load binary T04-5, T06-7, T08, T09 O08 Prestart binary T04-5, T06-7, T08, T09 O09 ECU Power Relay binary T04-5, T06-7, T08, T09 O10 Cooling Pump Binary T04-5, T06-7, T08, T09 O11 Close Load binary T04-5, T06-7, T08, T09 For outputs configuration use PC software DriveEdit or switch controller to Setup mode. On the picture below is example how to configure binary output via front controller s screen. At first you have to select output terminal. For move use and buttons for choice press Start button and Stop button for return. Then pick out logical function (O00-O09) and select contact type (Normally Open contact or Normally Closed contact) and confirm change. InteliDrive Nano, SW version 1.3, ComAp October

19 InteliDrive Nano, SW version 1.3, ComAp October

20 O00 Not Used Output has no function. Use this configuration when output is not connected. O01 Starter This output is dedicated for starter motor control. Corresponding setpoints: E01-Prestart Time, E02-MaxCrankTime. O02 Fuel Solenoid This output is dedicated to control the fuel solenoid (valve). The output is closed in the same time as Starter output and remains closed all the time the engine runs. O03 Stop Solenoid This output is dedicated to control the stop solenoid (valve). The output is closed in the moment when the engine shall stop and remains active until is stopped, but at least for 60s. The engine is stopped if: RPM < 2 and Oil pressure < 4,5 Bar. O04 Alarm The output is designed to be used as external alarm indication like a red bulb in the control room etc. The output is active when at least one unconfirmed alarm is present in the event log. O07 Ready To Load The output is activated when engine is running, idle is over and no shutdown or cool down alarms are active. The output opens during cooling state or when emergency stop or any shutdown / cool down alarm is active. O08 Prestart The output is activated prior to the engine start and deactivated when 25% of Nominal RPM speed is reached. During crank attempts the output is activated too. The output could be used for pre-glow, pre-heat or pre-lubrication. O09 ECU Power Relay This output is to be used for control of "keyswitch" input or power supply (over relay) of an ECU. If the particular ECU does not have keyswitch or similar input, it can be used for control of DC power for the ECU. The output closes together with O08 Prestart and remains closed all the time the engine shall be running. It is opened in the moment the engine shall stop (i.e. together with the O02 Fuel Solenoid ). InteliDrive Nano, SW version 1.3, ComAp October

21 NOTE: The controller does not evaluate the communication failure alarm during the period when this output is not active +1 second after Prestart activation. O10 Cooling Pump The output is activated prior to the engine start and deactivated when Aftercool time is over. The output could be used for engine cooling after stop. O11 Close Load The output is activated when the START button is closed in Running state. Output is disconnected when panel STOP button is pressed or any shut-down or cool-down alarm occurs. The output could be used for any kind of load (clutch) activation. Logical Binary and Analog inputs Input code Input name Type Terminal assignment I00 Not Used Binary Analog T11,T12,T13,T14,T15,T16,T18,T20, T21,T22,T24,T25 I01 Emergency Stop Binary T12 I02 Remote Start/Stop Binary T11 I04 Access Lock Binary T24, T25 I10 External Warning 1 Binary T12, T24, T25 I15 External Cooldown 1 Binary T12, T24, T25 I20 Low Fuel Level Binary T13 I21 Fuel Level Analog Analog T13 I22 Low Oil Pressure Binary T14 I23 Oil Pressure Analog Analog T14 I24 High Coolant Temperature Binary T15 I25 Coolant Temperature Analog Analog T15 I27 Loop Disabled Binary T25 I28 Speed Switch Binary T24 I29 SD Override Binary T12, T24, T25 I30 Remote AUT Binary T12, T24, T25 Analog inputs Input code Input name Type Terminal assignment I50 Control Loop AIN Analog T22 I51 Start/Stop Level Analog T21 I52 Speed Request Analog T18 I53 Wrn/Cd Protection 1 High Analog T20 I54 Wrn/Cd Protection 2 High Analog T16 For inputs configuration use PC software DriveEdit or switch controller to Setup mode. On the picture below is example how to configure binary inputs via front controller s screen. At first you have to select input terminal. For move use and buttons for choice press Start button and Stop button for return. Then pick out logical function (I00-I20, I22 and I24) and select contact type (Normally Open contact or Normally Closed contact) and confirm change. InteliDrive Nano, SW version 1.3, ComAp October

22 3x 3x InteliDrive Nano, SW version 1.3, ComAp October

23 I00 Not Used Input has no function. Use this configuration when binary or analog input is not connected. I01 Emergency Stop This input will activate the built-in Emergency Stop alarm. It is recommended to use Normally Closed button for this input because of safety reasons. If this binary input is activated left red LED above Stop button starts blinking, general shutdown symbol is displayed on LCD s upper right corner, Emergency Stop symbol is displayed on event log with running hours stamp and shut down procedure will occur. I02 Remote Start/Stop External request for engine start active in Auto mode only. NOTE: The Remote Start/stop can be configured only on terminal T11 for reason awaking controller from Zero Power mode. I04 Access Lock If the input is closed the controller Menu button, Setup mode and Engine Start and Stop buttons are blocked. No setpoints no I/O function can be adjusted from controller s front panel and mode (Manual - Auto) cannot be changed. Access Lock does not protect setpoints and mode changing from DriveEdit. Also history is accessible. Access Lock is also functionless in case that the controller is in Setup mode. I10 External Warning 1 If this binary input is activated the Alarm red LED above Stop button will start blinking, general warning symbol will be displayed on LCD s upper right corner and External Warning 1 symbol will be displayed on event log with running hours stamp. This alarm is only warning. I16 External Cooldown 1 If this binary input is activated the Alarm red LED above Stop button will start blinking, general shutdown symbol will be displayed on LCD, External Shutdown 1 symbol will be displayed on event log with running hours stamp and Cool down procedure will occur. I20 Low Fuel Level If this binary input is activated the Alarm red LED above Stop button will start blinking, general warning symbol will be displayed on LCD s upper right corner and Low Fuel Level symbol will be displayed on event log with running hours stamp. This alarm is only warning. NOTE: Input has 10s delay. InteliDrive Nano, SW version 1.3, ComAp October

24 I21 Fuel Level Analog Analog input for fuel level measurement. When measured value exceed preset threshold left red LED above Stop button will start blinking, general warning symbol will be displayed on LCD s upper right corner and fuel level symbol will be displayed on event log with running hours stamp. This alarm is only warning. You can choice one from two preset resistive sensors (VDO, Datcon) or you can create your own sensor curve. NOTE: Input has 10s delay. I22 Low Oil Pressure If this binary input is activated the Alarm red LED above Stop button will start blinking, general shutdown symbol will be displayed on LCD s upper right corner, oil pressure symbol will be displayed on event log with running hours stamp and shut down procedure will occur. I23 Oil Pressure Analog Analog input for oil pressure measurement. When measured value exceed preset threshold the red LED above Stop button will start blinking, general shutdown symbol will be displayed on LCD s upper right corner and oil pressure symbol will be displayed on event log with running hours stamp and shut down procedure will occur. You can choice one from five default resistive sensors (VDO, Datcon) or you can create your own sensor curve. You can setup shutdown threshold (E04 Oil Pressure Shutdown) in Engine parameters and protection group. NOTE: Input has 3s delay. I24 High Coolant Temperature If this external binary input is activated the red LED above Stop button will start blinking, general shutdown symbol will be displayed on LCD s upper right corner, Coolant Temperature symbol will be displayed on event log with running hours stamp and shut down procedure will occur. I25 Coolant Temperature Analog Analog input for coolant temperature measurement. When measured value exceed preset threshold the red LED above Stop button will start blinking, general shutdown symbol will be displayed on LCD s upper right corner and coolant temperature symbol will be displayed on event log with running hours stamp and shut down procedure will occur. Default threshold is 90 C. You can choose one from four default resistive sensors (VDO, Datcon) or you can create your own sensor curve. You can setup shutdown threshold (E05 Coolant Temperature Shutdown) in Engine parameters and protection group. InteliDrive Nano, SW version 1.3, ComAp October

25 NOTE: Input has 5s delay. I27 Loop Disabled Active input deactivates the Control loop and switch the Speed Request output to R12 Control Loop Bias. I28 Speed Switch Active input switch the Speed request from R03-Operational Speed to R04-Speed Switch in MAN mode. I29 Shut-down Override Active input blocks the engine Cool-down and stop except the Overspeed protection and Emergency stop. All alarm indications and History records stays active. I30 Remote AUT Active input switch controller mode from MAN to AUT and returns back to MAN when is inactive. AUT mode is indicated by panel LED AUTO and by symbol A on first screen dashboard - position 5-th. Active input blocks Menu setting to MAN. Remote AUT is available on T11-BIN5, T12-BIN4, T24-BIN6, T25-BIN7. I50 Control Loop AIN Input for value that can be controlled by engine RPM. Available on AIN4 (4-20mA) on T22 terminal. Corresponding RPM control setpoints: Ctrl Loop Gain-R09, Ctrl Loop Int-R10, Ctrl Loop Request-R11, Ctrl Loop Bias-R12, Loop Request 0%-R13, Loop Request 100%-R14. I51 Start/Stop Level Analog input for Automatic Engine Start Stop function in AUT mode based on analog value e.g. level signal. Available on AIN5 (4-20mA) on T21 terminal. AIN5 sensor fail activates the engine stop. Corresponding setpoints: Level Start-E09, Level Stop E10, Level Delay-E11. I52 Speed Request Analog Input for Engine speed request in MAN mode using external potentiometer. Available on AIN7 (0-2400ohm) on terminal T18. InteliDrive Nano, SW version 1.3, ComAp October

26 I53 Warning / Cool down Protection 1 General AIN6 (4-20mA) T20 Analog input protection - type of Running only. Corresponding setpoints: Warning Protection1-E12, Cool down Protection1-E13, Protection1 Delay-E14, Protection1 Run Del E23. The protection type Over/Under depends on Wrn/Cd limits setting it is: "Over" when E12 (Wrn limit) is lower then E13 (Cd limit) "Under" when E12 (Wrn limit) is higher then E13 (Cd limit) I54 Warning / Cool down Protection 2 General AIN8 (10V) T16 Analog input protection type of All time. Corresponding setpoints: Warning Protection 2-E15, Cool down Protection 2-E16, Protection 2 Delay-E17 The protection type Over/Under depends on Wrn/Cd limits setting it is: "Over" when E15 (Wrn limit) is lower then E16 (Cd limit) "Under" when E15 (Wrn limit) is higher then E16 (Cd limit) Hint: The I53 and I54 protections type Over/Under depends on corresponding Warning and Cooldown limits. Limits Protection type Wrn limit < Cd limit Over Wrn limit > Cd limit Under InteliDrive Nano, SW version 1.3, ComAp October

27 Setpoints Setpoints are analog, binary or special data objects that are used for adjusting the controller to the specific environment. Setpoints are collected to groups according to their meaning. Setpoints can be adjusted from the controller s front panel or PC. On the picture below is example how to change setpoint via controller s front panel. InteliDrive Nano, SW version 1.3, ComAp October

28 Setpoint overview Basic settings Range / default B03 Gear Teeth / 120 B04 Nominal RPM / 2200RPM B05 Units Format 1 = Metric; 2 = US / 1 B07 Zero Power Mode min / 10min B08 Application 1 = SS; 2 = VS / 2 B09 RPMbyWterminal 0,05 2,00 / 1,00 Engine and Protection Parameters Range / default E01 Prestart Time / 2s E02 Maximum Cranking Time 0-60 / 5s E03 Cooling Time / 30s E04 Oil Pressure Shut Down 0 10,0 / 1,0bar E05 Coolant Temperature Cool Down / 90 C E06 Battery Under voltage Warning 8 36,0 / 22,0V E07 Warning Maintenance / 9999h E08 Running Timer / 0min E09 Level Start / 0% E10 Level Stop / 0% E11 Level Delay / 5s E12 Warning Protection 1 ± / 0 E13 Cool Down Protection 1 ± / 0 E14 Protection 1 Delay 0 60 / 5s E15 Warning Protection 2 ± / 0 E16 Cool down Protection 2 ± / 0 E17 Protection 2 Delay 0 60 / 5s E18 After Cooling Time / 30s E19 Oil Pressure Warning 0 10,0 / 2,0bar (fix delay 3s) E20 Coolant Temperature Warning / 90 C (fix delay 5s) E21 Fuel Level Warning / 10% (fix delay 20s) E22 Fuel Level Cool Down / 5% (fix delay 20s) E23 Protection1 Run Delay s / 10s E24 Starting RPM / 350 RPM RPM control R01 Idle Time / 5s R02 Idle Speed / 800RPM R03 Operational Speed / 2200RPM R04 Speed Switch / 1500RPM R05 Speed Ramp / 400RPM/s R06 Speed Request in MAN mode 1 = BIN - 2 = AIN / 1 R07 Speed Request 0% / 800RPM InteliDrive Nano, SW version 1.3, ComAp October

29 R08 Speed Request 100% / 2200RPM R09 Control Loop Gain ±100,00 / 10, 00% R10 Control Loop Int ±100,0 / 10, 0% R11 Control Loop Request ±32000 / 0 R12 Control Loop Bias / 0 R13 Control Loop In 0% / 0 R14 Ctrl Loop In 100% / 1000 R15 Max Speed Limit / 800RPM R16 Min Speed Limit / 2200RPM RunTime setpoints R09, R10, R11, R12 can be changed on running engine from Menu -. B - Basic Settings B03 Gear Teeth Units: Range: Default value: 120 Number of teeth on the engine gear for the pick-up sensor. The setpoint is ignored when ECU is configured. B04 Nominal RPM Units: RPM Range: Default value: 2200 RPM base for Overspeed (fix 115%) protection. To increase Overspeed limit increase the B04- Nominal voltage. B05 Units Format Units: Step: Range: Metric = 1, US = 2; Default value: Metric Converts dimension of values coming from ECU. 1. METRIC = C, bar, l/h 2. US = F, psi, gallon/h B07 Zero Power Mode Delay Units: min Range: 0 to 360 Default value: 10 The controller is switched to Zero Power Mode when there is no user interaction with the controller for the preset time. Zero Power Mode is disabled in AMF automatic mode. Value 0 also disables this function. For the controller wake up press button Start or activate input T11. The controller will not switch to Zero Power Mode if any alarm is active. InteliDrive Nano, SW version 1.3, ComAp October

30 B08 Application Units: Step: Range: SS = 1, VS = 2; SS= Single (constant) speed; VS = Variable speed engine. Default value: VS=2 Selection to hide RPM ctrl setpoints group and 3-rd measuring screen when not needed. B09 RPMbyWterminal Units: Step: 0,01 Range: 0,05 2,00 Default value: 1,00 Coefficient for RPM calculation when RPM input is connected to charging alternator - W terminal instead to magnetic pick-up. E - Engine and Protection Parameters E01 Prestart Time Units: seconds [s] Step: 1s Range: 0-600s Default value: 2 Time of closing of the O08 Prestart output prior to the engine start. Set to zero if you want to leave the output O08 Prestart open. E02 Maximum Cranking Time Alternative name: MaxCrank Time Units: seconds [s] Step: 1s Range: 0-60s Default value: 5 Maximum duration when the starter motor is energized. E03 Cooling Time Units: seconds [s] Step: 1s Range: s Default value: 30 Runtime of the unloaded to cool the engine before stop. E04 Oil Pressure Shutdown Units: Bar [Bar] InteliDrive Nano, SW version 1.3, ComAp October

31 Step: 0,1 Range: 0-10 Default value: 1 Delay: 3 s Shutdown threshold level for I23 Oil Pressure Analog input. E05 Coolant Temperature Cooldown Units: degree Celsius [ C] Range: Default value: 90 Delay: 5 s Shutdown threshold level for I25 Coolant Temperature Analog input. E06 Battery Undervoltage Warning Units: Volts [V] Step: 0,1 Range: 8 40 Default value: 22 Delay: 30 s Warning threshold for Low Battery voltage. E07 Warning Maintenance Units: hours [h] Step: 1 h Range: h Default value: 9999 h Counts down when engine running. If reaches zero, an alarm will appear. When the value is set, than the Maintenance function is disabled and counter does not count. Counter value disappear in controllers statistics. Maximum value for running countdown is Warning Maintenance will appear when counter elapsed. E08 Running timer Units: minutes [min] Range: Default value: 0 Engine will stop in MAN mode when Running timer is over. E09 Level Start Units: % [ % ] Range: InteliDrive Nano, SW version 1.3, ComAp October

32 Default value: 0 Engine start level in AUT mode for Analog input AIN5. Value over or below this level activates the engine start. The function depends on relation between Start and Stop Level: StartLevel > Stop Level: engine starts over Start and Stops below Stop. StartLevel < Stop Level: engine starts over Stop and Stops below Start. E10 Level Stop Units: % [ % ] Range: Default value: 0 Stop level in AUT mode for Analog input AIN5. E11 Level Delay Units: s [ s ] Range: Default value: 5 Delay for Level Start or Level Stop activation in AUT mode time to be level out of limit. E12 Warning Protection 1 Units: [ - ] Range: ± Default value: 0 Warning limit for protection 1. E13 Cool down Protection 1 Units: [ - ] Range: ± Default value: 0 Cooldown limit for protection 1. E14 Protection 1 Delay Units: s [ s ] Range: 0 60 Default value: 5 Delay for protection 1. InteliDrive Nano, SW version 1.3, ComAp October

33 E15 Warning Protection 2 Units: [ - ] Range: ± Default value: 0 Warning limit for general protection 1. E16 Cd Protection 2 Units: [ - ] Range: ± Default value: 0 Cooldown limit for engine protection 1. E17 Protection 2 Delay Units: s [ s ] Range: 0 60 Default value: 5 Delay for Engine protection 2. E18 After Cooling Time Units: seconds [s] Step: 1s Range: s Default value: 30 Runtime of the cooling pump to cool the engine after stop. E19 Oil Pressure Warning Units: Bar [Bar] Step: 0,1 Range: 0-10 Default value: 2 Delay: 3 s Shutdown threshold level for I23 Oil Pressure Analog input. E20 Coolant Temperature Warning Units: degree Celsius [ C] Range: Default value: 90 InteliDrive Nano, SW version 1.3, ComAp October

34 Delay: 5 s Shutdown threshold level for I25 Coolant Temperature Analog input. E21 Fuel Level Warning Units: % [%] Range: Default value: 10 Delay: 20 s Shutdown threshold level for I21 Coolant Temperature Analog input. E22 Fuel Level Cooldown Units: % [%] Range: Default value: 5 Delay: 20 s Shutdown threshold level for I21 Coolant Temperature Analog input. E23 Protection 1 Run Delay Units: s [s] Range: Default value: 5 Running delay for I53-Wrn/Cd Protection 1 Runing only type delay. R RPM Control R01 Idle Time Units: s [ s ] Range: Default value: 5 Time when engine Speed request = Idle Speed-R02 and Binary output Close load can t be activated. R02 Idle Speed Units: RPM [ RPM ] Range: Default value: 800 InteliDrive Nano, SW version 1.3, ComAp October

35 Speed request after engine start for Idle Time-R01. R03 Operational Speed Units: RPM [ RPM ] Range: Default value: 2200 Requested speed in Running state when Idle time-r01 is over and Binary input Speed Switch-I28 is not active. R04 Speed Switch Units: RPM [ RPM ] Range: Default value: 1500 Active input changes Speed request from setpoint OperationalSpeed-R03 to SpeedSwitch-R04. The Speed request change is done by SpeedRamp-R05. R05 Speed Ramp Units: RPM/s [ R/s ] Range: Default value: 400 Setpoint limits the engine Speed request changes when changed from Speed Up / Speed Down buttons or from AIN7-T18 by potentiometer. R06 Speed Request in MAN mode Units: Step: Range: BIN = 1; AIN = 2 Default value: BIN = 1 Speed request source selection in MAN mode: 1. BIN: Speed Up / Speed Down panel buttons, Binary input Speed Switch -I AIN: AIN7-T18 (potentiometer). R07 Speed Request 0% Units: RPM [ RPM ] Range: Default value: 800 Setting of voltage output characteristics for Analog interface to Speed governor AOUT1 (5V) -T29. Default setting means AOUT1 = 0V at 800RPM (and less). R08 Speed Request 100% Units: RPM [ RPM ] InteliDrive Nano, SW version 1.3, ComAp October

36 Range: Default value: 2200 Setting of voltage output characteristics for Analog interface to Speed governor AOUT1 (5V) -T29. Default setting means AOUT1 = 5V at 2200RPM (and more). R09 Control Loop Gain Units: % [ % ] Step: 0,01 Range: ± 100,00 Default value: 10 Control loop gain factor. Loop is active in AUT mode; BI7-Loop Disable-T25 disables the loop and set Speed Request = CtrlLoopBias-R12. Loop input: AIN4 (4-20mA)-T22; Loop output: Speed request; R10 Control Loop Int Units: % [ % ] Range: Default value: 10 Control loop Integration factor. Loop input: AIN4 (4-20mA)-T22; Loop output: Speed request; Loop active in AUT mode; BI7-T25 disables the loop and set the CtrlLoopBias-R12 on the output. R11 Control Loop Request Units: Range: ± Default value: 10 Control loop Requested value. Loop input: AIN4 (4-20mA)-T22; Loop output: Speed request; Loop active in AUT mode; BI7-T25 disables the loop and set the CtrlLoopBias-R12 on the output. R12 Control Loop Bias Units: % [ % ] Range: Default value: 10 Control loop Integration factor. Loop input: AIN4 (4-20mA)-T22; Loop output: Speed request; Loop active in AUT mode; BI7-T25 disables the loop and set the CtrlLoopBias-R12 on the output. R13 Control Loop In 0% Units: Range: Default value: 0 AOUT2-T30 setting of voltage output characteristics for actual value gauge conversion from T22 AIN4. InteliDrive Nano, SW version 1.3, ComAp October

37 R14 Control Loop In 100% Units: Range: Default value: 0 AOUT2-T30 setting of voltage output characteristics for actual value gauge conversion from T22 AIN4. R15 Max Speed Limit Units: RPM [ RPM ] Range: Default value: 800 The Speed request from any source ( in any mode) cant get over those limits. R16 Min Speed Limit Units: RPM [ RPM ] Range: Default value: 2200 The Speed request from any source ( in any mode) cant get over those limits. InteliDrive Nano, SW version 1.3, ComAp October

38 Alarm and History Management On the screen can be displayed maximally four records. Total capacity is 10 records. Controller will stop writing records to the history when the shutdown alarm will occur. ^ press OK 1800 RPM 9 s 26,3 h! ˇ press ^ press ˇ press ^ press 1800 RPM 1800 RPM 5,0 bar 5,0 bar ˇ press ^ press ˇ press and hold 3s ^ press and hold 3s ˇ press ˇ press ^ press ^ press and hold 3s Following alarms and records are available: Event Warnings Shutdowns ECU Messages InteliDrive Nano, SW version 1.3, ComAp October

39 Events Every event listed in table below is saved in history with running hours stamp see picture below. Possible Events Manual Start Engine was manually started by pressing button Start in Manual mode. Remote Start Engine was remotely started via input terminal s function I02 Remote Start/Stop. Controller is in Auto mode. Level Start Engine was started in AUT mode crossing the Start level limit. Manual Stop Engine was manually stopped by pressing button Stop in Manual mode. Remote Stop Engine was remotely stopped via input terminal s function I02 Remote Start/Stop. Controller is in Auto mode. Level Stop Engine was stopped in AUT mode by crossing the Stop level limit. Run Time Stop Engine was stopped by Runtime function. Auto On AUTO mode turned on. Man On MAN mode turned on. Power On Controller is turned on. InteliDrive Nano, SW version 1.3, ComAp October

40 Warnings Active warning When warning comes up, only O04 Alarm output is closed, red LED above Stop button will start blinking. Warning symbol will start blinking on up-and-right LCD corner and proper warning symbol is displayed in history with running hours stamp. Active warning can t be confirmed. See list of possible warnings. Non-active warning When warning became non-active, O04 Alarm output is opened and red LED above Stop button stop blinking and the warning symbol on main screen goes out. Possible warnings Warning Maintenance The period for servicing is set by the WrnMaintenance setpoint. The protection comes active if the running hours of the engine reach this value. Watchdog Software timer that triggers a system reset or other corrective action if the main program, due to some fault condition, such as a hang, neglects to regularly service the watchdog. The intention is to bring the system back from the unresponsive state into normal operation. Low Battery This warning comes up if the battery voltage is lower than preset Battery Undervoltage limit for longer than 30s. Fuel Level This warning occurs when analog input Fuel Level is below 20% or binary input Fuel Level is closed longer than 10s. External Warning 1 Indication of active Binary input I15 - External Cool Down 1. If the input is closed external warning 1 is activated. External Cool Down 1 Indication of active Binary input I15 - External Cool Down 1. If the input is closed external warning 1 is activated. InteliDrive Nano, SW version 1.3, ComAp October

41 ECU Communication Error The warning is activated when ECU if configured is not communicating and all values from ECU show #####. Shutdowns Shutdown procedure InteliDrive Nano controller opens outputs O01 Starter, O08 Prestart and O02 Fuel Solenoid or close O03 Stop Solenoid to stop the engine immediately. O04 Alarm output is closed. Active or not confirmed protection disables start. Active unconfirmed shutdown When shutdown comes up, Shutdown procedure will start, red LED above Stop button starts blinking. Shutdown symbol will start blinking on up-and-right LCD corner and proper shutdown symbol is displayed in history with running hours stamp. The record in history is negative, see picture below. See list of Possible shutdown alarms. For shutdown alarm confirmation press Stop button Active confirmed shutdown When active shutdown is confirmed the red LED above the Stop button stops blinking. The record in history stays negative with confirmation symbol at the end. O04 Alarm output endures closed. Inactive unconfirmed shutdown O04 Alarm output is closed, red LED above Stop button is shining. Shutdown symbol is displayed on right up LCD corner and proper warning symbol is displayed in history with running hours stamp, see picture below. See list of possible shutdown alarms. For shutdown alarm confirmation press Stop button Inactive confirmed shutdown O04 Alarm output is opened. It is possible to start engine when all shutdowns are inactive and confirmed. Possible shutdown alarms Emergency Stop The binary input Emergency Stop was activated. Overspeed The protection comes active if the speed is greater than 115% of nominal engine RPM InteliDrive Nano, SW version 1.3, ComAp October

42 which are derived from frequency. Underspeed Low engine RPM. This alarm will be issued when the is running and then stops by itself, i.e. the RPM drops under the nominal engine RPM. The underspeed alarm starts to be evaluated 5 sec after successful start and is being evaluated all the time the fuel solenoid is on. Low Oil Pressure Engine will stop when oil pressure declined to or less than 1 bar or binary input I22 Low Oil Pressure is active. High Coolant temperature Engine will stop when temperature of coolant exceed Coolant Temperature Shutdown threshold. External Shutdown 1 Start Fail start failed. Stop Fail stop failed. Battery Flat If the controller switches off during starting sequence due to bad battery condition it doesn t try to start again and activates this protection. ECU Messages ECU Message Diagnostic messages are read and displayed in history behind ECU Warning symbol. For Standard J1939 SPN (Suspect Parameter Number) and FMI (Failure Mode Identifier) are shown. Detail SPN/FMI code specification see in: SAE Truck and Bus Control and Communications Network Standards Manual, SAE HS-1939 Publication Or refer to corresponding engine manufacturer s ECU error codes list. Complete list of text diagnostic messages for each ECU can be found in ComAp Electronic Engines Support manual. InteliDrive Nano, SW version 1.3, ComAp October