Gen-set Controller

InteliGenNT
Starter Kit

February 2008

Getting Started Guide

ComAp, spol. s r.o.

Copyright 2008 ComAp s.r.o. Kundratka 2359/17, 180 00 Praha 8, Czech Republic
Written by Vladimir Zubak Tel: +420 246 012 111, Fax: +420 246 316 647
Prague, Czech Republic E-mail: info@comap.cz, www.comap.cz
Table of Contents
Introduction.............................................................................................................................................. 3
Useful to Know .................................................................................................................................... 3
What Is in the Package ....................................................................................................................... 3
Available Related Documentation ....................................................................................................... 4
Starter Kit Description.............................................................................................................................. 5
Starter Kit Layout ................................................................................................................................ 5
Starter Kit Connection ......................................................................................................................... 6
Functional Diagram......................................................................................................................... 6
Binary Inputs ................................................................................................................................... 7
Binary Outputs ................................................................................................................................ 7
Analog Inputs .................................................................................................................................. 8
Analog Outputs ............................................................................................................................... 8
Engine Simulator............................................................................................................................. 8
Mains and Generator Simulator...................................................................................................... 9
CAN Connector............................................................................................................................... 9
IG-NT Terminals................................................................................................................................ 10
InteliGen New Technology......................................................................................................... 10
Interface ........................................................................................................................................ 11
Cable Connection.............................................................................................................................. 11
Controller Inputs and Outputs ........................................................................................................... 12
Binary Inputs ................................................................................................................................. 12
Binary Outputs .............................................................................................................................. 13
Analog Inputs ................................................................................................................................ 13
Analog Outputs ............................................................................................................................. 13
Genset Simulator .............................................................................................................................. 13
Mains and generator simulator.......................................................................................................... 13
Engine simulator ............................................................................................................................... 13
Mains and Generator Simulator.................................................................................................... 13
Engine Simulator........................................................................................................................... 14
Controller Buttons ............................................................................................................................. 14
Abbreviations Used in this Manual.................................................................................................... 14

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Introduction
Congratulations to your purchase of ComAp controller. The purpose of this document is to help you
with the first contact with the IG-NT controller using the InteliGen NT Starter Kit (thereinafter the
Starter Kit).

The InteliGen NT Starter Kit is a tool which allows you to simulate operation of a genset.
You can simulate and test for instance:
starting and stopping sequence
failure and operating conditions
mains failure and AMF function
genset synchronization to mains
remote start/stop function
controller PLC functions

Useful to Know
Please note that there are some limitations of the Starter Kit, because the InteliGen NT Starter
Kit does not contain complete genset simulator.

Therefore engine speed is not controlled by the IG-NT, potentiometer called RPM is used for the
engine simulator speed regulation. Potentiometer Ugen is used for generator voltage control and
potentiometer Igen controls generator current.

Mains simulation is limited, too. It is possible to control mains voltage only (using potentiometer Um
and Um switch), mains current measurement is not available in the kit.

InteliGen NT Starter Kit allows you to write to controller any firmware or application (SPtM, MINT etc.)
which was designed for the IG-NT or the IM-NT controller. However, dongle may be necessary for
controller proper function. For example the IGS-NT-LSM+PMS dongle is necessary for Load Sharing
and Power Management functions testing. The IGS-NT-miniCHP dongle is necessary to make all PLC
functions available.

Warning: Please note that line voltage is connected to the Generator voltage and the Mains
voltage controller terminals. Therefore do not manipulate with the controller and its terminals if
power supply is switched on, although power supply circuits of the Starter Kit are isolated.

What Is in the Package

InteliGen NT Starter Kit contains:

one InteliGen NT controller

genset simulator
power supply cable
null modem cable
12 switches connected to controller binary inputs
12 LEDs connected to controller binary outputs
4 potentiometres connected to controller analog inputs
gauge connected to controller analog outputs

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Available Related Documentation
PDF files
IG/IS-NT Getting started
IGS-NT-2.0-Operator guide.pdf
InteliCommunicationGuide July 07.pdf
Description
Guide for those who are starting with IG/IS-NT controllers
Operator guide for IG/IS-NT controllers
Communication guide for IG/IS-NT, ID and IL controllers

All mentioned manuals are available on our webpage, you may find useful the following link:
http://www.comap.cz/index.php?idpg=28&IDprod=126

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Starter Kit Description
Starter Kit Layout

1. Controller IG-NT
2. Binary outputs LEDs
3. Binary inputs
4. D+ function
5. Power supply switch
6. CAN1, CAN2 and RS232(1) connectors
7. Gauge
8. Switch and potentiometers for mains, engine and generator simulators control
9. Analog inputs potentiometers

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Starter Kit Connection
Functional Diagram

The IG-NT controller terminals connected to the Starter Kit:

1 Generator current terminals

2 Generator voltage terminals
3 Mains (bus) voltage terminals
4 Binary outputs BO1 (Starter) and BO2 (Fuel solenoid)
5 RPM IN and RPM COM terminals
6 Binary outputs terminals
7 Binary inputs terminals
8 Binary outputs BO3 (GCB close/open) and BO4 (MCB close/open)
9 Analog inputs terminals
10 AVRI OUT and AVRI COM terminals
11 Speed governor terminals

See the IG-NT Terminals chapter for information about position of terminals on the controller.

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Binary Inputs
For detailed information about controller binary inputs connection see Binary inputs.

Binary Outputs
For detailed information about controller binary outputs connection see Binary outputs.

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Analog Inputs
You can change analog inputs configuration according to your needs. See Analog inputs for details.

Analog Outputs
Analog outputs are fixed, configurable analog outputs are not available in the IG-NT controller. It is
possible to use either module IS-AOUT 8 or IGS-PTM, if configurable analog outputs are requested.
See Analog outputs for details.

Engine Simulator
For details about simulator function see Engine simulator.

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Mains and Generator Simulator
Mains and generator simulator connection. For function description see Mains and generator
simulator.

CAN Connector
Connection of pins of the CAN1/CAN2 connector.

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IG-NT Terminals
InteliGen New Technology

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Interface
Function Terminals Note
Generator voltage L1,L2,L3, (N) 3x 277 Ph-N or 480 Ph-Ph VAC
(neutral not needed), max 350 / 600VAC *
Mains/Bus voltage L1,L2,L3, (N) 3x 277 Ph-N or 480 Ph-Ph VAC
(neutral not needed), max 350 / 600VAC
Generator current L1k,L1l, L2k,L2l, L3k,L3l 0 5 Amps, max 10 A all time, 150 A for 2 sec
Neutral/Mains current LNk,LNl 0 5 Amps, max 10 A all time, 150 A for 2 sec
IG-AVRi interface AVRI-OUT, AVRI-COM TTL (5V PWM) interface to IG-AVRi
Power supply +,- 8 36 VDC
D+ D+ D plus
Inputs and outputs
Binary inputs BI1 BI6 Activation to minus power supply.
BI7 BI12
Binary outputs BO1 BO6 Load is connected to plus power supply.
BO7 BO12
Analog inputs AI1 AI3 Ohms, mA, Volts sensors
Analog outputs SG-OUT, SG-COM Speed governor output interface (10V / 5V
PWM; 500 3000Hz)
RPM RPM-IN, RPM-COM Min 2 Vpk-pk (from 4 Hz to 4 kHz)
Communication interface
RS232 (1) D SUB9 (male) PC: InteliMonitor, GenConfig or
Modem, GSM modem or
ECU (e.g. Cummins ModBus)
RS232 (2) None
RS485 (1) A1,B1,COMR1 IG-Display (Remote display) or
for PC (via RS485 converter) = redirected RS232
(1)
see Basic settings: RS485(1)conv.
RS485 (2) None
CAN1 L1,H1,COMC1 Extension modules: IS-AIN, IS-BIN,IGS-PTM,
IGL-RA15, I-AOUT
CAN2 L2,H2,CONC2 Intercontroller (Load&VAR sharing, Power
management) and monitoring (IG-IB, I-LB)

Cable Connection
Several connectors are available on the InteliGen NT Starter Kit:

Power Supply
Use this connector for power supply connection using enclosed cable. Power supply 230V, 50/60Hz
should be used. It is possible to switch the Starter Kit over to power supply 110V, 50/60Hz using
enclosed instruction sheet.

Do not connect 230V power supply to the Starter Kit, if the Starter Kit was switched over to
110V. It is strongly recommended to put warning label on the Starter Kit, if power supply
voltage was changed to 110V.

RS 232(1)
Use this connector for direct connection to a computer, modem connection, an ECU connection or
Modbus communication. For details see information about the setpoint RS232(1) mode on page 67 of
the IGS-NT-SPtM-2.2-Reference Guide (this information is available in the other application reference
guides, too).

It is necessary to use an USB/RS232 converter for direct PC connection, if RS 232 connector is

not available on your PC. See InteliCommunicationGuide for information about recommended
converters, the latest version is available on this webpage:
http://www.comap.cz/index.php?idpg=28&IDprod=126

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Use the enclosed null modem cable for the RS 232 (1) interface.

CAN 1
Use this connector for CAN bus connection of ComAp external modules (e.g. IGS-PTM) and/or engine
ECU.

CAN 2
Use this connector for CAN bus connection of other ComAp controllers, communication modules (I-LB
or IG-IB) and a PLC / external SCADA terminal.

You can find information about proper CAN bus connection in the manual IGS-NT-2.2-Installation
Guide, which is available on this webpage:
http://www.comap.cz/index.php?idpg=28&IDprod=126

See CAN connector for information about pins connection of the CAN 1 and the CAN 2 connectors.

Controller Inputs and Outputs

Description of binary inputs and outputs on the Starter Kit is valid for default archive (IG-SPtM-
StarterKit).

You can change function of inputs and outputs according to your needs. However, there are
exceptions related to the engine simulator and the breakers simulators (GCB and MCB):

The engine simulator for proper function needs:

BO 1 function is set to Starter
BO 2 function is set to Fuel Solenoid

The GCB breaker simulator for proper function needs:

BI 1 function is set to GCB feedback
BO 3 function is set to GCB close/open

The MCB breaker simulator for proper function needs:

BI 2 function is set to MCB feedback
BO 4 function is set to MCB close/open

For description of BI/BO functions see for instance the IGS-NT-SPtM-2.2-Reference Guide, which is
available on this webpage:
http://www.comap.cz/index.php?idpg=28&IDprod=126

Binary Inputs
Two types of binary inputs are available on the Starter Kit:

1. Breaker simulator (BI1 and BI2)

Three positions of a breaker switch are available:
ON the breaker simulator is forced to ON state
AUT state of the breaker simulator is given by state of BO3/BO4 (GCB/MCB) of the controller
OFF the breaker simulator is forced to OFF state

2. Switch (BI3 BI12, D+)

Two positions of a switch are available:
OPEN the switch is opened if lever is down and LED is dark
CLOSE the switch is closed if lever is up and LED is shining

You can configure binary inputs 3-12 according to your needs.

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Binary Outputs

Every binary output can be in two states:

OPEN - output is opened and LED is dark
CLOSE - output is closed and LED is shining

Three groups of binary outputs are available:

1. Engine simulator
BO1 and BO2 are hardwired to the engine simulator.

2. Breakers simulator
BO3 and BO4 are hardwired to the breakers simulator (MCB and GCB).

3. General outputs
BO5 BO12 are connected to signal LED only.

You can configure binary outputs 5-12 according to your needs.

Analog Inputs

Three analog inputs are available on the IG-NT controller. Controller inputs are connected to the group
of potentiometers ANALOG INPUTS in this order:
AIN1 OIL PRESS
AIN2 WATER TEMP
AIN3 FUEL LEVEL

Analog Outputs

There are no user-configurable analog outputs available on the IG-NT controller, but it is possible to
display some analog values on the gauge, which is available on the Starter Kit. Available values are:

AVRi output voltage regulator output value is displayed on the gauge, if switch is set to position 3
Speed governor speed governor output value is displayed on the gauge, if switch is set to position 4

For switching between position 3 and 4 use switch which is labeled as 1 2 3 4.

Properties of all types of the IG-NT controller inputs and outputs are described in the manual
IGS-NT-2.2-Installation Guide, which is available on this webpage:
http://www.comap.cz/index.php?idpg=28&IDprod=126

Genset Simulator
Genset simulator contains two main parts:
Mains and generator simulator
Engine simulator

Mains and Generator Simulator

The Mains simulator is used for the mains voltage simulation. Frequency of the mains voltage is fixed
and it is based on frequency of the power supply. The mains voltage can be adjusted using:

Um switch - switching the mains voltage on/off

Um potentiometer the mains voltage regulation

Please note that mains current is not provided by the Mains simulator. It is not possible to
simulate mains power Export/Import for example. Be aware of this limitation.

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The Generator simulator is used for simulation of the generator voltage and current. Generator
frequency is provided by the Engine simulator.

Generator simulator outputs can be adjusted using:

Ugen potentiometer for generator voltage regulation
Igen potentiometer for generator current regulation

Engine Simulator
The Engine simulator is source of variable generator frequency and magnetic pick-up signal
(connected to controller terminal RPM IN).

Relation between engine RPM and generator frequency is given by controller setpoints Gear teeth and
Nominal RPM. Recommended setting of the setpoints for the Starter Kit is:
Gear teeth = 256
Nominal RPM = 1500/1800 (frequency 50/60Hz)

It is possible to set Gear teeth = 0 and engine RPM measurement is based on frequency of the
generator voltage then.

Engine simulator outputs (RPM and generator frequency) can be adjusted using:
RPM potentiometer for engine RPM regulation

Controller Buttons
For information about the IG-NT controller buttons function and information displayed on the controller
screen see the IG/IS-NT Operator guide 2.0, which is available on this webpage:
http://www.comap.cz/index.php?idpg=28&IDprod=126

Abbreviations Used in this Manual

MCB Mains circuit breaker
GCB Generator circuit breaker
BI Binary input
BO Binary output
AI Analog input
AO Analog output
RPM Revolutions
VRO Voltage regulator output
SRO Speed regulator output

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