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

InteliGenNT, InteliSysNT
Modular Gen-set Controller
Troubleshooting guide
IG-NT, IG-NTC, IG-EE, IG-EEC, IS-NT, IM-NT

Software version IGS-NT-2.1, IM-NT-2.0, February 2007

TROUBLESHOOTING GUIDE

Copyright © 2007 ComAp s.r.o.

ComAp, spol. s r.o.

Světova 7, 180 00 Praha 8, Czech Republic
Tel: +420 266 790 611, Fax: +420 266 316 647
E-mail: info@comap.cz, www.comap.cz
Table of Contents
Table of Contents .................................................................................................................................... 2
General guidelines................................................................................................................................... 3
Troubles................................................................................................................................................... 4
1) Communication........................................................................................................................... 4
2) Controller interface ..................................................................................................................... 4
3) External display problems .......................................................................................................... 5
4) Synchronizing, Load control ....................................................................................................... 5
5) PC software ................................................................................................................................ 6
6) Electrical measurement .............................................................................................................. 6
7) Other........................................................................................................................................... 6
How to … ................................................................................................................................................. 8
8) Special applications.................................................................................................................... 8

InteliGenNT, InteliSysNT – Troubleshooting guide,

SW version 2.1, ©ComAp – February 2007 2
IGS-NT-2.1-Troubleshooting guide.pdf
General guidelines
This manual provides a list of typical problems to solve when installing / operating the IG/IS-NT
controllers. It also incorporates the “How to...” section with examples of some non-standard or
interesting applications of these controllers.
This manual is intended for everybody who is concerned with operation and maintenance of the gen-
set.

InteliGenNT, InteliSysNT – Troubleshooting guide,

SW version 2.1, ©ComAp – February 2007 3
IGS-NT-2.1-Troubleshooting guide.pdf
Troubles
1) Communication
1.1 RS232(x) communication doesn’t work
Solution:
a) Setpoint RS232(x) mode set to different position than DIRECT – set to DIRECT.
b) Converter to RS485 is active at this communication channel – change setpoint RS485(x)conv.
to DISABLED position.
c) Earthing problem exists between the PC and the controller, i.e. the battery negative point is at
different levels in the two devices. The controller has a built-in protection which disconnects
the battery negative (GND) in the RS232 terminal. Re-activation takes some time (~ 1 min)
after you disconnect the cable (component cool down).
You can temporarily disconnect your laptop PC from the grid (e.g. if you intend to download
the configuration only). You can disconnect the earth wire from your PC (if allowed in your
country). The best solution is to use the RS232 galvanic separation device, e.g. the one
mentioned in the InteliCommunication guide, section Converters.

1.2 RS232(2) / RS485(2) / USB communication doesn’t work

Solution:
Relates to IG-NTC/EEC versions of IG-NT family and to IS-NT / IS-NT-BB. The controller FW version
is lower than 2.0 and/or the controller has been shipped from ComAp before September 2006. It is
necessary to download the FW into the communication sub-processor, which can be done by sending
the unit to ComAp or by downloading the latest version of Peripheral modules upgrade package and
following the procedure described there.

1.3 Problem accessing the controller via RS232(1) after configuration

programming error
Solution:
This can happen if the controller in normal condition has a modem connected to the RS232(1) port or
in general if other type of connection than DIRECT is set.
A remote programming attempt fails (e.g. due to bad phone line condition) and from that moment on
the controller reports on its display “CONTROLLER CONFIGURATION ERROR”. In this stage, even
with damaged cfg, the controller is still able to receive another phone call with another attempt to
program the configuration.
However, if the situation is to be solved locally (i.e. a local technician intends to re-program the
configuration), it is possible to switch the RS232(1) port back to DIRECT connection type by
simultaneous pressing up+left+right arrows on the controller.

2) Controller interface
2.1 The controller does not react on Mode <, > buttons pressing,
(some) setpoints cannot be changed
Solution:
a) Commands are password protected and password is not entered. Go to menu ->
Users/Password and log in. If your user profile has sufficient access rights, commands will be
unblocked. System administrator can also change the configuration to unblock the commands
from password protection.
b) Password is entered (= user logged in), but commands and/or (some) setpoints cannot be
changed. That means these are probably blocked by some higher protection level than the
current user has got. You need to log in as a user with sufficient access rights or contact the
system administrator to unblock the password protection for commands and/or some setpoints
you intend to change.
InteliGenNT, InteliSysNT – Troubleshooting guide,
SW version 2.1, ©ComAp – February 2007 4
IGS-NT-2.1-Troubleshooting guide.pdf
2.2 The controller does not react on Start, Stop, Fault & Horn reset,
GCB, MCB buttons
Solution:
a) Commands are password protected and password is not entered. Go to menu ->
Users/Password and log in. If your user profile has sufficient access rights, commands will be
unblocked. System administrator can also change the configuration to unblock the commands
from password protection.
b) Setpoint Basic settings: Local buttons is set to position EXTBUTTONS, which means only
the external control via binary inputs is enabled. Set this setpoint to position PANEL or BOTH.

2.3 Setpoint Controller mode cannot be changed

Solution:
a) The setpoint is password protected and password is not entered. Go to menu ->
Users/Password and log in. If your user profile has sufficient access rights, commands will be
unblocked. System administrator can also change the configuration to unblock the commands
from password protection.
b) Some forcing input for controller mode is active. Go to Measurement IO / Binary inputs and
check for Remote OFF, Remote MAN, Remote AUT, Remote TEST and similar inputs to be
active. If present and active (check also the input polarity using GenConfig – inputs can be
inverted), the controller mode cannot be changed from the mode selected by these inputs.
You probably have to disconnect the signals going to the controller.

2.4 Certain setpoints cannot be changed from the controller even if

correct password is entered
Solution:
These setpoints have probably configured the Force Value function on them. If the function is active
(i.e. alternative value is forced), the original value is not visible and cannot be changed. To modify the
original value, deactivate the Force value function(s) related to this setpoint first. Check the
configuration in GenConfig / Setpoints / Force value column to find out what is configured to a
particular setpoint.

3) External display problems

3.1 It is not possible to change any setpoints and to start/stop the
engine via IG/IS-Display module
Solution:
Access lock input is active for that particular terminal, therefore this terminal can only be used for
monitoring. You can check this by looking at the first measurement screen (Esc to menu and go to
Measurement CU) – “L” symbol (IG-Display) or “hand” symbol (IS-Display) is visible on the screen.
Following table assigns the signals and the terminals:
Binary input Display module
AccessLock int IG-NT/EE internal display, IS-Display address #1
AccessLock D#2 IG-Display, IS-Display address #2
AccessLock D#3 IS-Display address #3

4) Synchronizing, Load control

4.1 I have set the Sync/Load ctrl / Load ramp setpoint to a certain
value, but the controller stays in mains parallel for much shorter
time
Solution:
a) Setpoint AMF settings: BreakerOverlap is set to too short time for the controller to ramp down
the power. Set this setpoint to at least the same value like Sync/Load ctrl: Load ramp is set
to.

InteliGenNT, InteliSysNT – Troubleshooting guide,

SW version 2.1, ©ComAp – February 2007 5
IGS-NT-2.1-Troubleshooting guide.pdf
 b) Setpoint Sync/Load ctrl: GCB open del is set to too short time for the controller to ramp down
the power. Set this setpoint to at least the same value like Sync/Load ctrl: Load ramp is set
to.
c) Setpoint Sync/Load ctrl: GCB open level is set to too high value, so the GCB is switched off
with some power remaining on the generator. Set it to lower value.
d) The island load has been much lower than the gen-set nominal power is. The real time of load
ramp is Load ramp x Pinitial_island / Nomin power; the controller switches off the GCB
immediately (with 1s fix delay) if the power decreases under GCB open level.

4.2 Sync timeout occurring when synchronizing

Solution:
a) Setpoint Sync/Load ctrl: Sync timeout is set to too short time -> set it to longer time to allow
the controller to match all synchronizing conditions.
b) Improper setup of speed governor or AVR; SG or AVR don’t react (almost) anyhow on SRO or
VRO output change from the controller, or on the other hand the regulation is “hunting”. Check
control loop setpoints in the controller (Sync/Load ctrl and Volt/PF ctrl setpoint groups);
increase/reduce the range of analog output/input to SG/AVR. Check Installation guide for
proper interconnection between controller output and SG/AVR (if available for that type).

5) PC software
5.1 No history in ANT file received
Solution:
a) Archive saved by GenConfig tool with version lower than 2.1. The GenConfig is an offline tool
for configuration purposes, so the archives saved using this tool wouldn’t have the actual
history data. That’s why the history was not saved at all with this tool. Such an archive is very
poor help for technical support people as it often doesn’t bring the needed information.
Starting from version 2.1 of GenConfig, upon each archive saving, the history may be read out
from the controller and stored together with the rest of archive.
b) InteliMonitor / Settings / History – the Typical program usage is set to “Site monitored from this
computer only”. If this is not true, i.e. some other computer may be connected sometimes to
the site (controller), it may read out the history records and after this computer is connected
again, there appear to be no records in the archive. In such a case (especially can happen
with remote, e.g. modem connections), please switch to “Site monitored from more
computers”, which ensures proper history reading. The first option provides faster history
reading if there are only few new records, but with more computers accessing the same site
leads to the above mentioned behaviour.

6) Electrical measurement
6.1 The controller measures wrong generator/mains/bus voltages or
currents
Solution:
a) Setpoint Basic settings: CT ratio prim / Im3ErFlCurCTp / VT ratio / Vm VT ratio is set to
wrong value. The value does not correspond with CT / VT actually used. Change it to correct
value according to the information provided with the CT / VT.
b) For IS-NT-BB or IG-xxC HW types, the setpoint Basic settings: CT ratio sec /
Im3ErFlCurCTs / VgInpRangeSel / VmInpRangeSel is set to a wrong range. Set it to correct
range (5A or 1A, 120V or 277V).

7) Other
7.1 Statistic values contain weird numbers upon start-up
InteliGenNT, InteliSysNT – Troubleshooting guide,
SW version 2.1, ©ComAp – February 2007 6
IGS-NT-2.1-Troubleshooting guide.pdf
All NT controllers produced till March, 2007 (serial numbers 0703xxxx and lower) have undefined
values in statistics. The controllers produced later should have all statistics values initialized to 0.
Solution:
Should you meet a controller with undefined statistic values, run InteliMonitor, go to menu Monitor,
item Set statistics, and click on button “Clear all”. Wait until all numbers lose their bold form (writing in
process) and close the window.

7.2 After pressing Fault reset, the protection activity ends up some
later. The message in AlarmList however stays there as inactive.
Solution:
Setpoint Engine protect: ResetActAlarms is set to DISABLED. This is a new possibility compared to
IG/IS classic – you can disable the resetting of alarms that are currently active (Marine authorities
requirement). If you don’t need this functionality, switch the setpoint to ENABLED, which is the mode
compatible with IG/IS classic controllers.

7.3 No active call after some protection has been activated

Solution:
a) The setpoint that enables to initiate active calls for a particular protection type is not set to
enabled position. Check in Act. calls/SMS setpoint group.
b) Setpoint AcallCHx-Type is set to wrong position. E.g. it is set to SMS-GSM, while analog
modem is actually connected. You have to change this setpoint to such position to be
compatible with connection type used.
c) Phone number or e-mail address is wrong. Check the setting (Act. calls/SMS: AcallCHx-Addr
setpoints), including the prefix codes for local phone exchange or for intercity calls.

7.4 I forgot the password

Solution:
a) For all users except of the user 0 = administrator, the password can be reset by the
administrator. If administrator is logged in, he can reset the password to value “0” for a
particular user (from the controller display or from PC). Controller: log in as administrator, go
to Users/Password row in the menu and select the user for which you intend to reset the
password. You will see “Reset password” option on the screen, select it and press Esc until
you get back into the menu. Now that user has password = “0”. PC SW (InteliMonitor): log in
as administrator, go to menu Monitor / Admin users. A window opens where you can set up
the access rights etc. Select the user for which you intend to reset the password and press the
crossed lock icon. You can also reset passwords for all users at once.
b) If the highest (level 7) password of the administrator is lost, you have to provide your
distributor with the following information: controller serial number and PasswordDecode
number (in Values / Info group or visible at Info screens upon controller start-up). You will
receive your admin password in reply.

InteliGenNT, InteliSysNT – Troubleshooting guide,

SW version 2.1, ©ComAp – February 2007 7
IGS-NT-2.1-Troubleshooting guide.pdf
How to …
8) Special applications
8.1 Setup your controller to work as SSB application
SSB application is known from IG/IS classic controllers, but is no more present among NT
applications. So you have to modify the behaviour of SPtM application to achieve this. But typically,
this application type can be handled with IL-AMF controllers.
Start with default SPtM archive.
• In ProcessControl setpoint group, set the following setpoints:
• Island enable = YES (stand-by application needs to work in island when mains is gone)
• ParallelEnable = NO (no mains paralleling is allowed)
• SynchroEnable = NO (no synchronizing is allowed)
• MFStart enable = YES (the basic function of SSB application – to start upon mains failure)
If the mains is present, the controller shows Not ready state, as the engine start at that moment is not
possible – it can not go to parallel nor to start sync. You can monitor the readiness of the gen-set via
the output Stand-by ready, which should be on if there are no other problems with the gen-set.

8.2 Setup your controller to work as SPM application

SPM application is known from IG/IS classic controllers, but is no more present among NT
applications. So you have to modify the behaviour of MINT application to achieve this. but typically,
this application type can be handled with IL-MRS controllers.
Start with default MINT archive.
• In ProcessControl setpoint group, set the Synchro enable = NONE.
• In Pwr management setpoint group, set the Pwr management = DISABLED.
• The controller has to be single, i.e. no other controller may be connected via CAN bus 2.
Assuming that the above conditions are fulfilled, there should be no message in the Alarmlist “Dongle
incomp”. This message normally appears in MINT application as the LSM+PMS dongle is expected to
be present for normal purpose of this application. In this special case and providing the stated
conditions, the message is suppressed to allow work in SPM mode.

InteliGenNT, InteliSysNT – Troubleshooting guide,

SW version 2.1, ©ComAp – February 2007 8
IGS-NT-2.1-Troubleshooting guide.pdf