Inteligen Learn More Comprehensive Modular Genset Controller
Brief Description The Inteligen is a comprehensive controller for single and multiple generating sets operating in standby or parallel to the utility. The Inteligen has the built in ability to provide complete transfer switch control including synchronizer and breaker control, if desired. A modular construction allows upgrades to different levels of complexity in order to provide best solutions for various customer applications. Built in synchronizer, isochronous load sharer, Mains and generator protections allow fully integrated solution for multiple gensets in stand-by and parallel to the utility. The igl-ra15, a fifteen led remote annunciator, is offered as an add on module in order to meet NFPA110 applications. The InteliGen s software allows the user to change the generator connection / configuration without changing setpoints within the controller. The software automatically detects the reconfiguration of the generator at start up and automatically reconfigures itself for proper protection. The Inteligen controller is equipped with a powerful 128 x 64 back-lit graphic display with icons, symbols and bar graphs for intuitive operation, which sets, together with high functionality, new standards in genset controls. At the heart of this controller beats a 16-bit micro-controller. Because of the offered software package together with the communications capabilities gives the customer many possible ways to communicate with the operating genset. There are multiple ways one can connect with the Inteligen, via direct RS232, modem (land line or wireless), through a company network, and Internet. Connecting through the modem one can enable the Inteligen to call out when any alarms are activated. The InteliGen is NFPA110 compliant, UL recognized, CSA approved and CE compliant. The Multiple Transfer Switch function allows the InteliGen to control the connection of five separate loads to one set.
Features of the Inteligen Basic Features Large graphic back-lit LCD display 128x64 pixel resolution Automatic or manual engine starting and stopping Phase sequence supervision Automatic shutdown / warning function Input frequency 50-60 Hz Parameters adjustable via PC or ig keyboard Predefined and user definable configurations available. One configuration includes set of inputs/outputs and parameters. Adjustable parameters for each configuration. 6 LED indicators (Mains O.K., Gen C.B. ON, Mains C.B. ON, Engine Running / Alarm Push buttons for simple control 7 programmable digital outputs (out of 20 functions selection) 9 digital configurable inputs Lamp test during start up Real time clock Sealed membrane panel to IP65 113 x 175 mm front panel mounted case Metering Speed measurement from magnetic pickup Oil pressure measurement Coolant temperature measurement Battery volt measurement Fuel level measurement Running Hour Meter All Generator metering, kvar, kw, V1-V3, Hz, I1-I3, kwh, kvah Protection Fuel level low Warning / Shutdown Over Speed Protection Oil Pressure Warning / Shutdown Coolant Temperature (high and low) Warning Coolant Temperature (high) Shutdown Battery Voltage Over / Under Warning Running Hour Meter All Generator metering, kvar, kw, V1-V3, Hz, I1-I3, kwh, kvah Generator Under / Over Voltage Warning / Shutdown Generator Under / Over Frequency Warning / Shutdown Over Current Warning / Shutdown Engine Control Preheat and aftercool functions Pre-lubrication function with timers Adjustable crank attempts Data Logging Back up history of the engine operation for back tracing up to 177 entries can be help Communications RS232 / Modbus communication support Modem communication support
Transfer Switch Control Generator C.B. control with feed-back Mains C.B. control with feed-back incl. mains return timer Active support of external load sharer and synchronizer 3 Phase AMF function - Over- /under frequency Over- /under voltage Voltage asymmetry
Modules Kit 1: ig-pcm, Power Control Module Automatic synchronizing Reverse synchronizing Speed / voltage control in standby operation Reverse power alarm/shutdown Load control incl. ramping 2 analog outputs (AVR incl. power factor control and speed control) 4 programmable digital outputs (selectable) 4 digital inputs (configurable) Import / export control Earth fault protection Kit 3: ig-pclsm, Power Control and Load Sharing Module Same as (PCM) power control module including an analog isochronous load sharing line Kit 4: ig-com, Communication and Power Management Module CAN bus module including CAN communication interface Interconnection of several ig-cua controllers and/or interface to supervision system Optimizing the number of sets running in parallel Kit 5: ig-iom, I/O Extension Module 8 Extra digital configurable inputs 8 Extra digital programmable outputs 1 Analog output 4 Extra configurable resistive analog inputs Kit 5: ig-ptm, I/O Extension Module 8 Extra digital configurable inputs 8 Extra digital programmable outputs 1 Analog output 4 Extra configurable analog inputs (Thermocouples, 0-100mV, 0-20mA, 0-250 ohms) Kit 6: ig-mu, Modem Extension
Enables the control and monitoring of several gensets in parallel via one Modem or RS232 connection. 1 CAN Bus interface and 1 RS232 interface with direct modem communication support Kit 6: ig-ib(m), Internet Extension Enables the ability to control and monitor one (IB) or several gensets (IBM) in parallel via one Ethernet / Internet / Modem connection. 1 CAN Bus interface, 1 RS232 interface with direct modem communication support, and 1 Ethernet connection. Kit 7: ig-avri, Automatic Voltage Regulator Interface An accessory that allows VAR and Power Factor control by influencing the AVR through a -/+ 10 DC V swing. Kit 1: igl-ra15, Remote Annunciation Module 15 three-color LEDS User definable labeling LED color is determined using the front panel buttons(r/g/y) CAN Bus connection to unit 1 connection for siren Horn reset and lamp test keys Max. Distance is 200m
Functioning The Inteligen is a compact controller for complete management of gensets in standby or parallel to the utility applications. The Inteligen automatically starts the genset, closes the genset circuit breaker when all conditions are accebtable, then stops the engine on external signal or by pushing the stop push button. With upgrade kits full criteria for isolated parallel and parallel with the utility operation are met. Forward and reverse synchronizing, utility protection incl. vector surge, load and power factor control, earth fault protection are the main functions. Power control for external load sharing modules provided. The key feature of Inteligen is its easy-to-use operation and installation. 16 predefined configurations for typical applications are available. 16 user-defined configurations are for special requirements. Configuration could be selected from the front panel or via the Windows based Software, WinEdit. The heart of the Inteligen controller is designed on the high performance 16bit micro-controller. The Inteligen is specially designed for high noise immunity and for considerable fluctuation of the power supply.
Inteligen System Overview
Inteligen Transfer Switch Control Overview
Features of Inteligen Central Unit 6 1 1 2 5 4 4 3 3 3 3 3 1 LED indicators (Mains OK, Generator C.B. ON, Mains C.B. ON, Engine Running/Alarm) RPM input Battery voltage measurement Relay outputs 16 A (starter crank, fuel solenoid) Pre-configured digital inputs (Generator C.B. feedback, mains C.B. feedback, emergency stop, charger failure, remote start/stop) Configurable digital inputs Pre-configured digital outputs (general alarm, Generator C.B., mains C.B., Horn) Configurable digital outputs Pre-configured analog inputs (Engine oil pressure, Engine water temperature, fuel level) Mains voltage inputs Generator voltage inputs Generator current inputs RS232 and CAN interface Additional plug-in power control board (ig-pcm) 1 Output for voltage or power factor control (ig-avri) 1 Output for speed governor control 4 Digital inputs (configurable) 4 Open collector outputs (programmable) 1 Analog load sharing line (ig-pclsm) 1 CAN Bus Modem Extension Unit (ig-mu) 1 RS232 interface with direct modem communication support Internet Module (ig-ib(m)) 1 Ethernet port for network communications 1 CAN bus interface for multiple set applications (ig-ibm only) 1 RS232 interface for ig-cua connection (ig-ib only) 1 RS232 interface with direct modem communication support
Additional plug-in communication and power management (ig-com) 2 CAN bus interfaces Additional plug-in input/output board (ig-iom) 8 Digital inputs(configurable) 8 Digital outputs (programmable) 4 Resistive analog inputs (configurable) 1 Analog output (programmable) Additional plug-in input/output board (ig-ptm) 8 Digital inputs(configurable) 8 Digital outputs (programmable) 4 Analog inputs (Thermocouples, 0-100mV, 0-20mA, 0-250 ohm) (configurable) 1 Analog output (programmable) Remote Annunciator Expansion Module (igl-ra15) 1 Output for a 1 amp max auxiliary horn 1 CAN bus interface for connection to the controller. 1 8-36 V DC power input 15 Three color LED s color and function is configurable 2 Buttons for Horn Rest and Lamp Test Modem / PC Solution
Modem Parallel Operation Solution Load Sharing + Power Management + Import / Export Control G GOVERNOR G GOVERNOR G GOVERNOR IM-CU Load Sharing Line CAN Power Management Modem IG-MU PC *Note: Additional modules will be needed to accomplish the above-pictured tasks. Modules that may be needed include ig-pcm, ig-pclsm, ig-com, etc.
Panel Cutout and InteliGen Dimensions
Technical Data Power supply Voltage supply Consumption depends on supply voltage Battery voltage measurement tolerance RTC battery live Operating conditions 8-36V DC 0.4A at 8VDC; 0.1A at 36VDC 2 % at 24V 10 year Operating temperature -40 - +158 o F Storage temperature -65 - +160 o F Protection front panel IP65 Humidity 85% 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 Vibration 5-25 Hz, ±1,6mm 25-100 Hz, a = 4 g Shocks a = 200 m/s 2 Standards NFPA110, UL, CSA, CE Dimensions and weight Dimensions Weight Mains and generator Nominal frequency Frequency measurement tolerance 180x120x50mm 800g 50-60Hz 0.1Hz Current inputs Nominal input current (from CT) Load (CT output impedance) CT input burden Max. measured current from CT Current measurement tolerance Max. peak current from CT Max. continuous current Voltage inputs Measuring voltage Maximal measured voltage Input resistance 5 A < 0,1 Ω < 0,2 VA per phase (In=5A) 11 A 2% from the Nominal current 150 A / 1s 12 A 277VAC phase to neutral 480VAC phase to phase 300VAC phase to neutral 6 MΩ phase to phase 6 MΩ phase to neutral
Voltage measurement tolerance Overvoltage class 2 % from the Nominal voltage III (EN61010) IG-MTU Primary voltage Ph-Ph 3x480 VAC / 60 Hz (3x400 VAC / 50Hz ) Secondary voltage Ph-N 3x277 VAC / 60 Hz (3x 230 VAC ), 5 VA Mechanical dimensions: 155 x 95 x 60 mm, DIN rail (35 mm) mounted Binary inputs and outputs Binary inputs Number of inputs 9 Input resistance 4.7 kω Input range 0-36 VDC Switching voltage level for close contact indication 0-2 V Max voltage level for open contact indication 8-36 V Contact relay outputs Number of outputs 2 Electric life cycle min 100.000 switching cycles Maximum current 12 A DC resistive load 4 A DC inductive load Maximum switching voltage 36 VDC Minimum load 24 V / 0.1 A Insulation voltage 500 Veff Binary open collector outputs Number of outputs 7 Maximum current 0.5 A Maximum switching voltage 36 VDC Analog inputs Not electrically separated Resolution Sensor resistance range Resistance measurement tolerance 10 bits 0 Ω-2,4 kω 4 % ± 2 Ω out of measured value Speed pick-up input Type of sensor magnetic pick-up (connection by shielded cable is recommended) Minimum input voltage 2 Vpk-pk (from 4 Hz to 4 khz) Maximum input voltage 50 Veff Minimum measured frequency 4 Hz Maximum measured frequency 10 khz (min. input voltage 6Vpk-pk) Frequency measurement tolerance 1.5 %
RS232 interface Maximal distance Speed 10m 19.2kBd Recommend external converter: ADVANTECH ADAM 4520: RS232 to RS422/485 converter, DIN rail, automatic RS485 bus supervision, no external data flow control signals, galvanic isolated. Recommended internal converter: ADVANTECH PCL-745B or PCL745S : Dual port RS422/485 Interface card, automatic RS485 bus supervision, no external data flow control signals, galvanic isolated. IG-IOM Voltage supply Consumption Mechanical dimensions: Connection to IG-CU Interface to modem or PC Interface to controller 8-36V DC 0.1A depend on supply voltage 40 x 95 x 45 mm, DIN rail (35 mm) mounted standard IOM cable 2 meters length, not galvanic separated RS232, RS422, RS485 CAN Binary inputs Number of inputs 8 Input resistance 4.7 kω Input range 0-36 VDC Switching voltage level for close contact indication 0-2 V Max voltage level for open contact indication 8-36 V Binary open collector outputs Number of outputs 8 Maximum current 0.5 A Maximum switching voltage 36 VDC Analog inputs Not electrically separated Number of inputs 4 Resolution 10 bits Sensor resistance range 0 Ω-2.4 kω Resistance measurement tolerance 4 % ± 2 Ω out of measured value Analog output Not electrically separated Number of inputs 1 Resolution 10 bits Output range 0 to 20 ma ± 0,33 ma
IG-IB Voltage supply Consumption Mechanical dimensions: Interface to controller Interface to modem Interface to Ethernet 8-36V DC 0.1A depend on supply voltage 40 x 95 x 45 mm, DIN rail (35 mm) mounted RS232 or CAN RS232 RJ45