Unclassed Base Panel User Manual
Contents
1. VDO Temperature sensor VDO Pressure sensor 2000 200 1800 E 1600 E 6 1400 9 150 o 1200 Py 1000 e 100 S 800 s 9 A E 400 e 200 0 0 0 20 30 40 50 60 70 80 90 110 0 2 4 6 8 10 Temperature C Pressure bar Hint When measured value is 6 out of range the Sensor fail FLS is detected InteliLite DCU SW version 1 0 OComAp October 2002 25 IL DCU 1 0 pdf Operator interface Pushbuttons and LEDs Pushbuttons HORN FAULT o Dq XX PAGE EOS ENTER gt MODE Cyclic forward selection the gen set operation mode OFF gt MAN gt AUT lt MODE Cyclic backward selection the gen set operation mode AUT gt MAN gt OFF ORN RESET Deactivates the HORN AULT RESET Acknowledges faults and alarms Start of the gen set TOP Stop of the gen set not used not used PAGE Cyclic selection of the display mode MEASUREMENT gt ADJUSTEMENT gt HISTORY 10 Select the set point select the screen or increase set point value 11 Select the set point select the screen or decrease set point value 0 NO O1 BR D 0 Se gt A ge D 12 ENTER Confirm set point value LEDs 13 not used 14 not used 15 ENGINE RUNNING NO ALARM GREEN LED is on 16 ENGINE FAILURE RED LED starts flashing when gen set failure occurs After button is pressed goes to steady light if an alarm is still active or is off if no alarm i2. As short as possible InteliLite DCU SW version 1 0 OComAp October 2002 10 IL DCU 1 0 pdf Magnetic pick up To ensure proper function Use a shielded cable MAGNETIC PICK UP Ee GAC Speed Control Unit ESD 5500 a Battery Hint Switchboard flash protection according standard regulation is expected Analog inputs Two analog inputs Oil Press and Water Temp are available on the IL CU Configuration Each analog input can be configured by LiteEdit software following way Analog input item LiteEdit Type Type Not used Alarm Config of input Config Analog Binary Tri state Physical dimension bar C Polarity Contact NC type NO Sensor characteristic Sensor Curve A Curve B Curve C PT 1000 NI 1000 VDO Temp Possibility Analog input isn t used Analog measuring in specified range Binary open close threshold 750 Q Three state open close threshold 750 Q Failure lt 10 Q or gt 2400 Q Up to 3 ASCII characters Valid only for analog inputs Valid only for binary and three state inputs Valid only for binary and three state inputs User curve A User curve B User curve C IEC 751 range 20 to 120 C DIN 43760 range 20 to 120 C See chapter sensor specification InteliLite DCU SW version 1 0 ComAp October 2002
3. nyi sio E nl lt U 2 D SSSS Sa NI nda ONE Ndi nao GION310S TINA y o x sena YSLYVLS A mi D o IES 9 a a D NOT USED p dW31 ZIV 110 LIV WOD SNS OO ANALOG INPUTS NOT USED a3sn LON WATER PUMP Doo Gas a O DIESEL GAS ENGINE JANSSIAA 110 dW31 431VM 1 M GIONINOS DI E STARTER Ee N po BATTERY CHRG ALTERNATOR InteliLite DCU SW version 1 0 OComAp October 2002 9 IL DCU 1 0 pdf Getting started How to install General To ensure proper function Use grounding terminals Cables for binary inputs and analog inputs must not be placed along power cables Analog and binary inputs should use shielded cables especially when length gt 3m Power supply To ensure proper function Use min power supply cable 1 5mm Hint Max current of power minus terminal is 4A and it depends on binary outputs load For 12VDC power supply connect external capacitor and separating diode to support controller supplying during cranking HUGE LOADS Battery STARTER Grounding To ensure proper function Use as short as possible cable to the grounding point on the switchboard Use cable min 2 5mm The terminal of the battery has to be properly grounded
4. Water Temp Output closes if the water temperature shutdown alarm activates The output opens if e alarm is not active and e FAULT RESET is pressed Water Temp Wrn Output closes if the water temperature warning alarm activates The output opens if e alarm is not active and e FAULT RESET is pressed OFF mode The output is closed if OFF mode is selected MAN mode The output is closed if MAN mode is selected AUT mode The output is closed if AUT mode is selected Running Output closes if the engine is in Running state ServiceTime Output closes if the ServiceTime alarm activates The output opens if e alarm is not active and e FAULT RESET is pressed Analog inputs Two analog inputs for resistive sensor O to 2400 Q measuring Each analog input can be adjusted to convert resistor measured value to displayed value in bar C or Warning and shut down limits are adjusted in Engine protection group Oil press Oil pressure analog input Default range O to 10 0 bars Water temp Water temperature analog input Default range O to 100 C InteliLite DCU SW version 1 0 OComAp October 2002 IL DCU 1 0 pdf 20 Setpoints Password EnterPassword Password is a four digit number Password enables change of relevant protected set points Use or keys to set and ENTER key to enter the password ChangePassword Use i or keys to set and ENTER key to change the password Hint At first
5. Analog input Step 1 Range 1000 1000 Hints Calibration constants have to be adjusted when measured value is near the alarm level User curves A B C can be defined by LiteEdit software InteliLite DCU SW version 1 0 OComAp October 2002 24 IL DCU 1 0 pdf Sensor specification To correct measuring error of each analog input pressure temperature level calibrating constants within 10 of measure range should be set Three calibrating constants are set in physical units bar C From these constants are counted equivalent calibrating resistance which are internally in software add to sensor resistance At the moment of calibration ENTER pressing is calculated and in memory saved calibrating resistance in Q This value is added to measured sensor resistance before calculation of the Al Al2 value Example iL CU display Temperature 70 C and real value is 73 C After setting Calibr AIT to 3 C and pressing ENTER InteliLite calculates corresponding resistance e g 5Q and saves this value into the memory The resistance is then added to all calculations e g instead of 70 C gt 73 C or e g instead of 5 C gt 6 C Default sensor settings Analog input 1 10 points VDO characteristic pressure measuring in bar Analog input 2 6 points VDO characteristic temperature measuring in C For VDO sensor characteristic see chapter Value and set points codes
6. closed iL is switched to OFF mode there are four modes OFF MAN AUT TEST When opens controller is switched back to previous mode Hints This binary input should be connected to schedule timer switch to avoid start of engine StartButton Binary input has the same function as Start button on the InteliLite front panel It is active in MAN mode only StopButton Binary input has the same function as button on the InteliLite front panel It is active in MAN mode only FaultResButton Binary input has the same function as Fault reset button on the InteliLite front panel HornResButton Binary input has the same function as button on the InteliLite front panel Binary outputs IL CU default BO1 Starter relay output BO2 Fuel solenoid relay output BO3 Prestart BO4 Alarm BO5 Horn BO6 Not used Binary outputs list Not used Output has no function Starter The closed relay energizes the starter motor The relay opens if e the firing speed is reached or InteliLite DCU SW version 1 0 OComAp October 2002 17 IL DCU 1 0 pdf e maximum time of cranking is exceeded or e request to stop comes up Fuel solenoid Closed output opens the fuel solenoid and enables the engine start The output opens if Emergency stop comes or Cooled gen set is stopped or in pause between repeated starts Prestart The output closes prior to the engine start Prestart and opens when START RPM speed is reached
7. zero if you want to leave the output HORN open Step 1s Range O 600 s Overspeed Yo Threshold for over speed protection Step 1 of nominal RPM Range 100 150 Wrn Oil press Bar Warning threshold level for ANALOG INPUT 1 Step 0 1 bar Range Sd Oil press 10000 Sd Oil press Bar Shutdown threshold level for ANALOG INPUT 1 Step 0 1 bar Range 100 Wrn Oil press Oil press del s Delay for ANALOG INPUT 1 Step 1s Range 0 180s Wrn Water temp C Warning threshold level for ANALOG INPUT 2 Step 1 C Range 100 Sd Water temp Sd Water temp C Shutdown threshold level for ANALOG INPUT 2 Step 1 C Range Wrn Water temp 10000 Water temp del s Delay for ANALOG INPUT 2 alarm Step 1s Range 0 180s Batt undervolt V Warning threshold for low battery voltage Step 0 1 V Range 8V Batt overvolt Batt overvolt V Warning threshold for high battery voltage Step 0 1 V Range Batt undervolt 40 V Batt volt del s Delay for low battery voltage alarm Step 1s InteliLite DCU SW version 1 0 OComAp October 2002 23 IL DCU 1 0 pdf Range O 600 s NextServTime h Counts down when engine running If reaches zero an alarm appears Step 1h Range 0 65535h Sensor spec Calibr Al1 A12 Calibrating constant to adjust the measured value of IL analog inputs Physical dimension of calibrating constant is corresponding to
8. 1 0 pdf Alarm management Following alarms are available Warning Shut down Warning WRN When warning comes up only alarm outputs and common warning output are closed Possible warnings See List of possible events Shut down SD When the shut down alarm comes up InteliLite opens outputs FUEL SOLENOID STARTER and PRESTART to stop the engine immediately Alarm outputs and common shutdown output are closed Active or not reset protection disables start Possible shut down alarms See List of possible events Sensor fail detection Sensor fail Fls is detected when measured value is 6 2 percent out of range Controller screen displays in this case string instead measured value Sensor 6 Range of measurement 6 Sensor Failure Kg Failure Range of sensor InteliLite DCU SW version 1 0 OComAp October 2002 32 IL DCU 1 0 pdf Gen set operation states Engine state machine Init Not ready Pause between start attempts Starting Starting speed is reached and 80 Nominal RPM not reached Engine is running at nominal speed Stop Shut down alarm activated Engine is ready to run Engine is cooling before stop List of possible alarms Events specification Protection Information on binary output type available See list of Binary outputs YES AA YES InteliLite DCU SW version 1 0 OComAp October 2002 33 IL DCU 1 0 pdf Remote control and data logging Direct connection to the P
9. 11 IL DCU 1 0 pdf VDO Press VDO Level 4 20mA 100 4 20mA 60 external R 120 Q external R 120 Q only for analog inputs User Curve A B C are adjustable in LiteEdit Each Analog input has separate set points for two level alarm setting Analog input alarm levels and delay adjust in Protection or Engine protection group Hardware connection Connection of IL CU analog inputs 2x RESISTIVE SENSOR 2x 470 ohms Al1 BINARY INPUT Al2 THREE STATE INPUT 2x SENSOR 4 20mA 24V Standard connection of two resistive sensors to analog inputs Oil Press and Water Temp Common point of resistive sensors is connected to COM terminal for accurate measuring Three current output sensors connection to InteliLite External resistors 120 ohms each are connected between minus power supply terminal of IL CU and analog inputs Current sensor connecting reduces the analog input resolution by less than 50 against resistive sensor Analog input common terminal COM has to be connected to IL minus Power supply terminal Mixed connection of InteliLite analog inputs Oil Press binary input Water Temp three state input Common point of IL CU analog inputs is connected to COM terminal Analog inputs are designed for resistive sensors with resistance in range of 0Q to 2 4kQ To ensure a proper function use shielded cables especially for length over gt 3m InteliLite DCU SW version 1 0 OComA
10. C InteliLite can be connected directly with PC via RS232 interface Use the standard cable RS232 cable to connect PC with InteliLite PC software LiteEdit On the PC for direct or modem connection has to be installed the ComAp s software package LiteEdit based on Windows 95 or newer platform LiteEdit enables read the quantities adjust all set points control the engine configure the controller select software configuration modify alarm inputs and outputs modify password commands protections InteliLite DCU SW version 1 0 OComAp October 2002 34 IL DCU 1 0 pdf Technical data Power supply Voltage supply Consumption Battery voltage measurement tolerance Operating conditions Operating temperature Storage temperature Protection front panel Humidity Standard conformity Low Voltage Directive Electromagnetic Compatibility Vibration Shocks Dimensions and weight Dimensions Weight Binary inputs and outputs Binary inputs Number of inputs Input resistance Input range Switching voltage level for close contact indication Max voltage level for open contact indication Contact relay outputs Number of outputs Electric life cycle Maximum current Maximum switching voltage Minimum load Insulation voltage Binary open collector outputs Number of outputs Maximum current Maximum switching voltage Analog inputs Not electrically separated Resolution Sensor resistance range Resista
11. Compact Controller for Single Operating Gen sets InteliLite Modular Controller IL MRS 15 DCU Diesel Control Unit for engine driven pump or fan Software version 1 0 October 2002 Prague Czech Republic Copyright 2002 Com p s r o Written by Ales Krumphanzl and Ladislav Kadanik ComAp s r o Svetova 7 180 00 Praha 8 Czech Republic Tel 420 2 6679 0611 Fax 420 2 6631 6647 WWW http www comap cz E mail info comap cz mg IT P R GUID USE Table of Contents PIANOS OP CONES odioso ee 2 Gani tooo totor olor occiso lada 4 What describes this manual ii danoise ete semis den cites scie 4 RR ate QU GT A A 4 OX EEE EEE 4 Core o AA A ne ren saca dcas Sr eo ni mien 6 Description of the controller system with all options 6 VV al 1S nine package EE 6 Lemmas ANA den Ee ee 7 DECU WE nl ct SR de lata a a AA ce Gy a 7 DIM SS Tei E O A di UT De 8 RECOMMENASO WA a e dd a E e a ra til den 9 ESB Mina Diada ns o a de A tao la 9 Can A A NOPE ne Ease e 10 OWN LOS Mita docu DC ner Re ee ee eee ae 10 PUAN Blue UU de sg as Geo ae Gene Ge a Le tee 11 E OFAN NAO e dl ee 11 Hardware ed Ee EE 12 DOUS ie Ke UNIS no dae sola oca es cl circa 16 Binary Inputs LC UE densa 16 ESTAR IDPS S ostra A ostia 16 Binary Outputs IL CU COT AUN UA o eu ad 17 Bar OUPS SUIS tada A A 17 AMIGO INDI Wa A AA WA 20 e ai azi 21 Pas WO lara iaa iaa 21 See a ados 21 ENGINE DA NAM ada a 21 ENGINES DI da es 22 A SPEC taste ee
12. During repeated crank attempts the output is closed too The output could be used for pre glow pre heat or prelubrication Alarm The output closes if e any alarm comes up or e the gen set malfunctions The output opens if e FAULT RESET is pressed The output closes again if a new fault comes up Horn The output closes if e any alarm comes up or e the gen set malfunctions The output opens if e FAULT RESET is pressed or e HORN RESET is pressed or e Max time of HORN is exceeded Horn timeout The output closes again if a new fault comes up Ready The output is closed if following conditions are fulfilled e Gen set is not running and e No Shut down or Slow stop alarm is active e Controller is not in OFF mode Stop solenoid The closed output energized stop solenoid to stop the engine The output opens again if RPM 0 with delay 10s and min time 40s elapsed ChrgAlternFail Output closes if gen set is running and D input not energized The output opens if e alarm is not active and e FAULT RESET is pressed Hint Treshhold level for D input is 80 supply voltage Stop failed Output closes when the engine have to be stopped but speed or frequency or voltage or oil pressure is detected This protection goes active 60s after stop command With start goes this protection inactive The output opens if InteliLite DCU SW version 1 0 OComAp October 2002 18 IL DCU 1 0 pdf e alarm is not active an
13. EE gt saga E ooo tod InteliLite DCU SW version 1 0 OComAp October 2002 6 IL DCU 1 0 pdf Terminals and dimensions IL DCU Terminals Grounding Terminal NOT USED NOT USED BINARY INPUTS en iL MRS 15 DCU CE D W Ka 2 ke O zZ BOOT JUMPER ANALOG INPUTS POWER 8 36 V DC COM Al OIL Al2 TEMP RPM Grounding Terminal Hint IL DCU hardware is based on IL MRS15 controller There can be small differences in front panel design and back label InteliLite DCU SW version 1 0 OComAp October 2002 7 IL DCU 1 0 pdf Dimensions IL DCU TateliLite wre 15 Con D START HORN FAULT Dl XX 130 5 1 170 8 87 Cutout for InteliLite 113x 175 mm 4 4 x 6 9 1 RS 232 Cable InteliLite DCU SW version 1 0 OComAp October 2002 8 IL DCU 1 0 pdf Recommended wiring IL DCU Wiring Diagram Li pre lin LU an 98 i os H N H p g SS y o ga xo GI 2 gt 8 SE o 2s DI N d3sn LON E O OU a YS DINI g a Z 440 3 038 E E dQLS AONSOYSN E z a D N 2 1907 88300V S SE 2 e E S S 310 38 de lt a E m2 i 9 notte cit P S
14. IN 43 760 DO temp VDO temperature sensor VDO press VDO pressure sensor VDO level VDO level sensor 4 20MA 60 current output sensor characteristic requires external resistor 120 ohms between Analog input and COM terminal of Analog inputs 4 20mMmA 100 current output sensor characteristic requires external resistor 120 ohms between Analog input and COM terminal of Analog inputs Set to VDO press Decimals setting of number of decimal points of measured value 0 eg 360 kPa 100 50 C l eg 3 6 Bar A e g 0 36 MPa wo eg 0 866 MPa Set to 1 When Analog input configuration is finished set the setpoints Wrn Oil press Sd Oil press Oil press del in Engine protection group Each Analog input has separate triplet of setpoints Wrn level Sd level An Inp del Names of these setpoints are fix defined Number of decimal points of Wrn levelf and Sd level is the same as the configured number of decimal points of measured value Binary inputs Power Supply 8 E Battery InteliLite DCU SW version 1 0 OComAp October 2002 14 IL DCU 1 0 pdf Binary outputs O gt D Ve ME Q Battery InteliLite DCU SW version 1 0 OComAp October 2002 IL DCU 1 0 pdf 15 Inputs and outputs Hint Any Binary input or output can be configured to any IL CU controller terminal or changed to different function by LiteEdit software There is
15. Set to Alarm Config selection between Analog Binary Tri state input Analog resistor sensor is connected to Analog input Binary open close contact is connected between Analog input and COM terminal of Analog inputs Analog input detects only open close state Tri state open close contact is connected parallel to one of two serial resistors between Analog input and COM terminal of Analog inputs Set to Analog Dim Physical dimension of measured value C Bar Maximal dimension length is three characters Set to Bar Contact type selection of polarity only when analog input is configured as Binary or Tri state When is analog input configured as analog this setting has no sense NC polarity of binary or tri state input NO polarity of binary or tri state input Sensor selection of sensor characteristic Unused input when Analog input is not used On the InteliLite screen is displayed HHHH value no alarm is detected Curve A User curve A is defined in LiteEdit default VDO temperature sensor Curve B User curve B is defined in LiteEdit default VDO pressure sensor Curve C User curve C is defined in LiteEdit default VDO fuel level sensor InteliLite DCU SW version 1 0 OComAp October 2002 13 IL DCU 1 0 pdf Pt1000 PT1000 sensor characteristic according to IEC 751 Ni1000 Ni1000 sensor characteristic according to D
16. be 24 Sensor special a ld esta 25 DSTA SENSOR sei Sci cock deat aa 25 Operator IMIG ACC se ii E 26 FUSNDUTIONS ANA LEDS ii scene A A IA EE O 26 How to select the gen Set mode 21 DISPLAY MENUS ESS te ga a iii 27 HOW to VIEW measured dala tuna iia 27 How to view and edit set points 27 HOW TO MHE EE 27 MEASUREMENT screens description iiiiiiiseiieneseeeereeernn 28 Chart guide to menus and pushbutton S operation 29 FUN CIO NASI SU ii iaa ac 30 OFE MOGE E eege 30 MANOS lana a an omic 30 A A I NAT Ue ee ee AS cred pair Mere ty ttre Mere Te 31 AITIWA Inte LO mA sf LS DRA RR EDP ery Tee RO RR O Aion ou eine Men mee Con eter APAE eer etre Mere mre 32 Ee ORNE e O ewe a O Ru ol 32 SRP GON ES D riso ipa rte Ameren te Se a ag RS E Sc eens 32 Gen set operation States A 33 LISTOTPOSSIDIS ne EE 33 Remote control and data logging sise 34 Direct connection to the PC Aaa aaa 34 PC Sotware Dn EE 34 E ene Uer 35 POWER SUD sra lili 35 InteliLite DCU SW version 1 0 OComAp October 2002 2 IL DCU 1 0 pdf Operan AA nl a adan 35 DIMEnSIONS And WEI Mn a 35 Binary InpuIS AMG ei e a dat dd a 35 ANO UNO US anos dra Beta dor Ges dE pd ka aa 35 EE 36 InteliLite DCU SW version 1 0 OComAp October 2002 3 IL DCU 1 0 pdf General guidelines What describes this manual This manual describes IL DCU software which is designed for single engine driven applications like pump or fan no generator IL DCU software is based on sta
17. d e FAULT RESET is pressed Overspeed Output closes if the gen set overspeed alarm activates The output opens if e alarm is not active and e FAULT RESET is pressed Underspeed Output closes if the gen set underspeed alarm activates The output opens if e alarm is not active and e FAULT RESET is pressed Start failed Output closes after the gen set start up fails The output opens if e alarm is not active and e FAULT RESET is pressed Battery flat Output closes when iL preforms reset during start procedure probably due to weak battery The output opens if e alarm is not active and e FAULT RESET is pressed V batt failed Output closes when battery over under voltage warning appears The output opens if e alarm is not active and e FAULT RESET is pressed Common Wrn Output closes when any warning alarm appears The output opens if e No warning alarm is active and e FAULT RESET is pressed Common Sd Output closes when any shut down alarm appears The output opens if e No sd alarm is active and e FAULT RESET is pressed Oil Press Output closes if the oil pressure shutdown alarm activates The output opens if e alarm is not active and e FAULT RESET is pressed Oil Press Wrn Output closes if the oil pressure warning alarm activates The output opens if e alarm is not active and InteliLite DCU SW version 1 0 OComAp October 2002 19 IL DCU 1 0 pdf e FAULT RESET is pressed
18. eliLite serial number 8 character number 3 SW version the first is the firmware version number the second is configuration table number 4 Application MRS16 5 Branch Standard Hints Only in MEASUREMENT menu How to find active alarms Active alarm list is the last screen in the MEASUREMENT menu Select MEASUREMENT menu Press You will see the list of all active alarms with the number of alarms at the top right corner Inverted alarms are still active Non inverted alarms are not active but not yet confirmed Press accepts all alarms Non active alarms immediately disappear from the list Active alarm list appears on the screen when a new alarm comes up and Main MEASUREMENT screen is active Hints Alarm list does not activate when you are reviewing the values parameters or history InteliLite DCU SW version 1 0 OComAp October 2002 27 IL DCU 1 0 pdf MEASUREMENT screens description Main measure screen 1500 RPM Timer 1 Operation mode of the gen set Indication of active access lock Remote OFF or Remote TEST symbol means some records in Alarm list L symbol means Binary input Access lock is active 3 Status of the engine set 4 RPM of the engine 5 Timer event s counting time e g prestart cooling etc IL CU Analog inputs screen Oil pressure single bargraph Water temperature single bargraph Battery voltage single bargraph IL CU binary inputs BI1 to BI6 IL CU binary out
19. fix 1 sec delay when any binary input is configured as protection Binary inputs IL CU default BI1 Remote Start stop BI2 Access lock BI3 Emergency stop BI4 Remote OFF BI5 Sprinkler BI6 Not used Binary inputs list Not used Binary input has no function Use this configuration when Binary input is not connected Alarm If the input is closed or opened selected alarm is activated Binary Alarm configuration items Name ooo 14chararcters ASCII string Contact type Normally closed Normally opened Shut down Alarm active Wb Engine running only SSS Emergency stop If the input is opened shut down is immediately activated Input is inverted normally closed Sprinkler If the input is closed all alarms are disabled except the binary input EMERGENCY STOP and engine overspeed protection e all IL alarms are detected e IL front panel gen set RED LED blinks or lights e alarm is recorded on the IL alarm list screen e BUT gen set remains running InteliLite DCU SW version 1 0 OComAp October 2002 16 IL DCU 1 0 pdf Access lock If the input is closed no setpoints can be adjusted from controller front panel and gen set mode OFF MAN AUT TEST cannot be changed Access lock does not protect setpoints and mode changing from LiteEdit To avoid unqualified changes the selected setpoints can be password protected Rem start stop External request for engine run AUT mode only Remote OFF If
20. nce measurement tolerance 8 36V DC 0 5 0 1A depend on supply voltage 2 at 24V 20 70 C 30 80 C IP65 85 EN 61010 1 95 A1 97 EN 50081 1 94 EN 50081 2 96 EN 50082 1 99 EN 50082 2 97 5 25 Hz 1 6mm 25 100 Hz a 4g a 200 m s 180x120x50mm 8009 6 4 7 KQ 0 36 VDC 0 2 V 8 36 V 2 min 100 000 switching cycles 12 A DC resistive load 4 A DC inductive load 36 VDC 24V 0 1A 500 Veff 0 5 A 36 VDC 10 bits 0 0 24 KQ 4 2 Q out of measured value InteliLite DCU SW version 1 0 OComAp October 2002 35 IL DCU 1 0 pdf 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 10m Speed 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 InteliLite DCU SW version 1 0 OComAp October 2002 36 IL DCU 1 0 pdf
21. ndard InteliLite MRS 15 application where all electric generator setpoints inputs outputs protections and measuring are removed What is the purpose of the manual This manual provides general information how to install and operate InteliLite DCU controller This manual is dedicated for Operators of engine sets Engines control panel builders For everybody who is concerned with installation operation and maintenance of the engine set Warnings Remote control InteliLite controller can be remotely controlled In case of the work on the engine set check that nobody can remotely start the engine To be sure Disconnect remote control via RS232 line Disconnect input REMOTE START STOP or Disconnect output STARTER Because of large variety of InteliLite parameters settings it is not possible to describe any combination Some of InteliLite functions are subject of changes depend on SW version The data in this manual only describes the product and are not warranty of performance or characteristic Text PAGE Capital letters in the frame buttons on the front panel Break Return Italic set points Generator protections Bold Set point group REMOTE START STOP Capital letters binary inputs and outputs InteliLite DCU SW version 1 0 OComAp October 2002 4 IL DCU 1 0 pdf 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 a
22. ny responsibility for its use unless otherwise expressly undertaken HH CAUTION HH Adjust set points All parameters are preadjusted to their typical values But the set points in the Basic settings settings group must be adjusted before the first startup of the gen set IT 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 InteliLite DCU SW version 1 0 OComAp October 2002 5 IL DCU 1 0 pdf General description Description of the controller system with all options InteliLite L DCU is a comprehensive controller for single engine sets InteliLite DCU 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 Engine set controls InteliLite DCU automatically starts stops the engine on external signal or by pressing push buttons InteliLite DCU automatically checks engine conditions and protects against out limit operation The key feature of InteliLite is its easy to use operation and installation Predefined configurations for typical applications are available as well as user defined configurations for special applications What is in the package Optional Obligatory Obligatory o IL DCU InteliLite central unit Obligatory
23. p October 2002 12 IL DCU 1 0 pdf Current output sensors connection To connect the current output sensor external parallel resistor 120 2 has to be added The input sensor characteristic has to be configured to 4 20mA 100 or 4 20mA 60 sensor This method reduces the input resolution by less than 50 Current output transducers IL CU analog inputs are mainly designed for resistor sensors In special case transducers to 4 20mA output can be used for various measuring Some types of transducers are not suitable for connection to InteliLite analog inputs because of influencing by InteliLite analog input In this case change default 4 20mA 60 or 4 20mA 100 sensor characteristic to get proper reading Binary input Open close state are detected threshold level is 750 2 Three state input Open close and failure state are detected Threshold level is 750 2 failure is detected when circuit resistance is lt 10 Q or gt 2400 Q Unused analog inputs Configure Type Not used Example of analog input configuration Configure Oil press input for measuring in Bar VDO oil pressure sensor range O to 10 0 bars Alarm protection level set to 3 5 bars shut down level 1 2 bars Start LiteEdit and select Controller Configuration Modify Oil Press Set configuration for Oil Press analog input Type selection between Not used and Alarm Not used analog input isn t used Alarm analog input is used
24. puts BO1 to BO6 Statistic Run hours Number of starts NextServTime Alarm list InteliLite DCU SW version 1 0 OComAp October 2002 IL DCU 1 0 pdf 28 Chart guide to menus and pushbutton s operation OFF MAN ENGINE BASIC ENGINE PROT GEN BASIC GEN PROTECT MAINS FAIL GEAR TEETH 150 o CRANK TIME 10 10s Parameter setting A y 1 Set cursor ya buttons 2 Press ws to editing mode 3 Adjust parameter ya buttons 4 Press to write parameter into memory Press eee to cancel of editing mode InteliLite DCU SW version 1 0 OComAp October 2002 29 IL DCU 1 0 pdf Function description OFF mode No start of the gen set is possible Outputs STARTER and FUEL SOLENOID are not energized No reaction if buttons START STOP are pressed MAN mode START starts the gen set STOP stops the gen set Hints The engine can run without load unlimited time The controller does not automatically stop the running gen set in MAN mode The controller does not start the gen set when binary input REM START STOP is closed Start stop sequence simplified MODE MAN Engine start stop request is given by pressing buttons START and STOP MODE AUT Engine start stop request is given by binary input REM START STOP Condition of the transition Next state Ready Start request PRESTART on Prestart started q AO k ngen E AA IS active Not Ready RPM lt 2 Oil pressure lt Star
25. s active 17 not used 18 not used InteliLite DCU SW version 1 0 OComAp October 2002 26 IL DCU 1 0 pdf How to select the gen set mode Use MODE or MODE to select requested gen set operation mode OFF MAN AUT Display menus There are 2 display menus available MEASUREMENT and ADJUSTMENT Each menu consists of several screens Press repeatedly PAGE button to select requested menu How to view measured data 1 Use repeatedly PAGE button to select the MEASUREMENT menu 2 Use land to select the screen with requested data How to view and edit set points Use repeatedly PAGE button to select the ADJUSTMENT menu Use I or W to select requested set points group Press to confirm Use or Mto select requested set point Set points marked are password protected Press ENTER to edit Use or 4 to modify the set point When I or W is pressed for 2 sec auto repeat function is activated 8 Press ENTER to confirm or PAGE to leave without change 9 Press PAGE to leave selected set points group de o Keng How to change the display contrast Press ENTER and I or Nat the same time to adjust the best display contrast Hints Only in MEASUREMENT menu How to check the serial number and software revision Press and then PAGE On the display you can see InteliLite INFO screen for 10 seconds InteliLite INFO screen contains 1 Controller name see Basic setting group 2 Int
26. the Password has to be entered before the new Password can be changed Basic settings Gen set name User defined name used for InteliLite identification at remote phone or mobile connection Gen set name is max 14 characters long and have to be entered using LiteEdit software Gear teeth Number of teeth on the engine gear for the pick up Step 1 Range 1 500 Nominal RPM RPM Nominal engine speed Step 1RPM Range 100 4000 RPM Mode IL OFF MAN AUT Equivalent to Controller mode changes by MODE or k MODE buttons Hint Controller Mode change can be separately password protected Num rings AA Number of rings prior to open modem connection Step 1 Range 1 30 NumberRings AA change is not activated immedatelly It is activated after controller is switched on or when modem is connected to controller Engine params Starting RPM Yo Firing speed when iL controller stops cranking starter goes OFF Step 1 of nominal RPM Range 5 50 Yo InteliLite DCU SW version 1 0 OComAp October 2002 21 IL DCU 1 0 pdf Starting POIl Bar When reached controller stops cranking starter goes OFF Step 0 1 bar Range 100 10000 Hint There are three conditions for stop cranking Starting RPM StartingP Oil and D when enabled Starter goes off when any of these conditions is vaid Prestart time s Time of closing of the PRE START output prior to the engine start Set to
27. tingPOil no Ready shutdown alarm active other than OFF mode selected Prestart Prestart time elapsed STARTER on Cranking FUEL SOLENOID on MaxCrank time counter started Cranking RPM gt Start RPM STARTER off Starting PRESTART off D input activated or oil pressure detected STARTER off Cranking or Gen voltage gt 25 Vgnom PRESTART off MaxCrank time elapsed 1st attempt STARTER off Crank pause FUEL SOLENOID off STOP SOLENOID on CrankFail pause timer started MaxCrank time elapsed last attempt STARTER off Shutdown Start fail PRESTART off CrankFail pause elapsed STARTER on Cranking FUEL SOLENOID on STOP SOLENOID off MaxCrank time counter started InteliLite DCU SW version 1 0 OComAp October 2002 30 IL DCU 1 0 pdf Starting 80 Nominal speed reached READY TO LOAD on Running Min MaxStab Time counter started STOP SOLENOID on STOP SOLENOID on Cooling time timer started RPM 0 or any other shutdown condition READY TO LOAD off Shutdown FUEL SOLENOID off ANA MARES PER STOP SOLENOID on STOP SOLENOID on Start request READY TO LOAD on Stop RPM 0 Oil pressure lt StartingPOil po Ready 60 sec Elapsed Co Stop Stop fai A O EN NN Hint Treshhold level for D input is 80 supply voltage AUT mode The controller does not respond to buttons START STOPI Engine start stop request is given by binary input REM START STOP InteliLite DCU SW version 1 0 OComAp October 2002 31 IL DCU
28. zero if you want to leave the output PRE START open Step 1s Range O 600 s MaxCrank time s Maximum time limit of cranking Step 1s Range 1 60s CrnkFail pause s Pause between crank attempts Step 1s Range 5 60s Crank attemps Max number of crank attempts Step 1 Range 1 10 MinStpValvTime s Binary output Stop solenoid closes when stop sequence begins and closes at least for MinStpValvTime Example MinStpValvTime 20 sec a When engine stops RPM 0 in 10 seconds Binary output Stop solenoid still stays closed for 10 sec b When engine stops in 30 seconds Binary output Stop solenoid opens 10 seconds after RPM 0 and Oil pressure lt StartingP Oil Those 10 sec is fix time for safe stop Step 1s Range O 180s Hint Stop of engine is detected when all following conditions are met RPM 0 Oil pressure lt StartingPOil Cooling time s Runtime of the unloaded gen set to cool the engine before stop Step 1s Range 0 3600s D function ENABLED DISABLED Enable or disable D function Engine protect Eng prot del s During the start of the gen set some engine protections have to be blocked e g Oil pressure The protections are unblocked after the Protection del time The time starts after reaching Start RPM InteliLite DCU SW version 1 0 OComAp October 2002 22 IL DCU 1 0 pdf Step 1s Range 0 300 s Horn timeout s Max time limit of horn sounding Set to
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