Comap InteliDrive EM User Guide v.1.0

Copyright © 2011 ComAp s.r.o. Written by Jiří Ullsperger Prague, Czech Republic

ComAp, spol. s r.o. Kundratka 2359/17, 180 00 Praha 8, Czech Republic Tel: +420 2 66316661, Fax: +420 2 66316647 E-mail: [email protected], www.comap.cz

User guide

InteliDriveNT

InteliDrive EM Controller for Asynchronous Motors Powerful Controller for Asynchronous Motors with Protections, Remote Wireless Control and Simple Regulation (IL-NT MRS19 unit)

SW version 1.0, June 2011

mailto:[email protected]

http://www.comap.cz

InteliDrive EM, SW version 1.0, ©ComAp –Mai 2011 2

Table of Contents Table of Contents............................................................................................................................... 2 General guidelines ............................................................................................................................. 4

What describes this manual? ......................................................................................................... 4 !! Warnings !!.................................................................................................................................. 4 Text ............................................................................................................................................... 4

General description ............................................................................................................................ 6 Description of the controller system (with all options)...................................................................... 6 InteliDrive EM V1.0 brief description............................................................................................... 6 Direct connection of the controller to PC......................................................................................... 7 What Communication or Input / Output modules are supported? .................................................... 8 Remote annunciator IGL - RA15 .................................................................................................... 9

Controller Terminals and Dimensions ............................................................................................... 10 Terminals.................................................................................................................................... 10 Controller Dimensions.................................................................................................................. 10

Getting started ................................................................................................................................. 11 How to install ............................................................................................................................... 11 Three phase applications ............................................................................................................. 13 Single phase applications............................................................................................................. 14 Analog inputs............................................................................................................................... 15 Installing RS 232 Communication Module .................................................................................... 19

Inputs and outputs............................................................................................................................ 21 Binary inputs - default .................................................................................................................. 21 Logical Binary inputs.................................................................................................................... 21 Binary outputs - default ................................................................................................................ 23 Binary outputs - list....................................................................................................................... 24 Analog inputs............................................................................................................................... 26

Setpoints.......................................................................................................................................... 28 Password..................................................................................................................................... 28 Basic settings............................................................................................................................... 28 Communication Settings .............................................................................................................. 29 Motor Params .............................................................................................................................. 30 Motor Protect ............................................................................................................................... 30 Functions ..................................................................................................................................... 34 Extension I/O ............................................................................................................................... 34 Date/Time.................................................................................................................................... 35 Sensor spec................................................................................................................................. 37 SMS/E-mail.................................................................................................................................. 37 SMS messages............................................................................................................................ 37

Sensor specification ......................................................................................................................... 39 Background of the sensor calibration............................................................................................ 39 Default sensor settings................................................................................................................. 39

Operator interface ............................................................................................................................ 40 Pushbuttons and LEDs, MRS19 ................................................................................................... 40 How to start motor?...................................................................................................................... 41 How to select the gen-set mode? ................................................................................................. 41 Display menus ............................................................................................................................. 41 How to view measured data? ....................................................................................................... 41 How to view and edit set points? .................................................................................................. 41 How to find active alarms ? .......................................................................................................... 42 MEASUREMENT screens description .......................................................................................... 42

Function description ......................................................................................................................... 44 OFF mode ................................................................................................................................... 44 MAN mode................................................................................................................................... 44 AUT mode ................................................................................................................................... 44

Alarm management.......................................................................................................................... 45


Sensor fail (FLS) ......................................................................................................................... 45 Warning (WRN)............................................................................................................................ 45 Shut down (SD)............................................................................................................................ 45

Motor operation states...................................................................................................................... 46 List of possible alarms.................................................................................................................. 46 History file.................................................................................................................................... 47

Remote control and data logging...................................................................................................... 48 Direct connection to the PC.......................................................................................................... 48 PC software - LiteEdit .................................................................................................................. 48 Modbus protocol .......................................................................................................................... 48

Remote communication.................................................................................................................... 50 Internet connection....................................................................................................................... 50 Recommended ISDN modem....................................................................................................... 50 Recommended GSM modem ....................................................................................................... 50

Technical data.................................................................................................................................. 53 Power supply ............................................................................................................................... 53 Operating conditions .................................................................................................................... 53 Dimensions and weight ................................................................................................................ 53 Binary inputs and outputs............................................................................................................. 54 Analog inputs............................................................................................................................... 54 Speed pick-up input ..................................................................................................................... 54 CAN bus interface........................................................................................................................ 54 IL-NT RS232 interface.................................................................................................................. 55 IL-NT AOUT8 interface (optional card) ......................................................................................... 55

List of used abbreviations and expressions....................................................................................... 56


General guidelines

What describes this manual? This manual describes “InteliDrive EM 1.0” software, which is designed to control classical asynchronous motor three or single phase. The software is a firmware branch of standard IL-NT-MRS19 controller with additional and modified features. Standard controller documentation see in "IL-NT-VAutodetect 1.0.pdf”. Installation package: ID-EM-1.0.IWE (install into PC by double click and import to controller by

LiteEdit). Firmware: ID-EM-1.0.mhx Archive: ID-EM-1.0.ail

What is the purpose of the manual? This manual provides general information how to install and operate InteliDrive EM 1.0 controller. This manual is dedicated for - Service men and attendance of motor - Gen-set control panel builders - For everybody who is concerned with installation, operation and maintenance of the motor.

!! Warnings !!

Remote control InteliDrive EM controller can be remotely controlled. In case of the work on the motor or driven machine check, that nobody can remotely start the motor. To be sure: Disconnect power supply voltage of the controller, or ensure that all parameters described in this manual, which affects the remote control, are OFF, or disconnect power supply voltage of the motor. Because of large variety of InteliDrive EM parameters settings, it is not possible to describe all combinations. Some of InteliDrive EM 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 Motor protections (Bold) Set point group REMOTE START/STOP (Capital letters) binary inputs and outputs 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 any responsibility for its use unless otherwise expressly undertaken.


Note: SW and HW must be compatible (e.g. InteliDrive EM firmware and IL-NT MRS19 HW) otherwise the function will be disabled. If wrong software is downloaded, message HARDWARE INCOMPATIBLE appears on controller screen. In this case use Boot load (jumper) programming – close Boot jumper and follow instructions in LiteEdit, download correct software.

!!! CAUTION !!!

Dangerous voltage In no case touch the terminals for voltage and current measurement! Always connect grounding terminals! In any case do not disconnect InteliDrive EM CT terminals (if the CT is present) !

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.

!!! 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 !!!


General description

Description of the controller system (with all options) InteliDrive EM is a comprehensive controller to control electric asynchronous motor.

The controller is equipped with a powerful graphic display showing icons, symbols and bar-graphs for intuitive operation, which sets, together with high functionality, new standards in control of electric industrial motors. InteliDrive EM automatically starts the motor when all conditions are met, protects it and then stops him on external signal or by pressing push buttons.

The key feature of InteliDrive EM is its easy-to-use operation and installation. Are available predefined configurations for typical applications.

Hardware issues from IL-NT-MRS19 controller.

InteliDrive EM V1.0 brief description

Types of asynchronous motor and its wiring. The controller is designed to control the asynchronous motor with short-circuit armature. Nevertheless thanks to flexibility of the controller, other types of asynchronous motor are possible to use after changing settings and adapting the wiring. It is possible to control these motor kinds and wirings:

Motor Kind of Starting Current Transformer Comment Single phase Direct, SoftStarter without CT Single phase Direct, SoftStarter with CT CT allows to use

current protection, Low power protection, measure and record Current, Power and PF

Three phase Y/D, Direct, SoftStarter without three phase CT

Three phase Y/D, Direct, SoftStarter with three phase CT Like for Single phase, plus Y/D Starting optimization (v.1.1)

Motor Starting Modes It is possible to control single phase or three phase motors. These modes are available: § Direct starting – for smaller motors § Y-D starting – a most widespread starting of three phase asynchronous motors § Y-D optimized starting – function requires CT in power circuit (available since v.1.1). § Starting by Softstarter

To start the motor with SoftStarter, choose the option SoftStart and connect SoftStarter input to BOUT KM1.

§ Starting and speed regulation by frequency changer (available since v.1.1) Hint: To select your starting mode, use the setpoint “KindOfStarting”.


Direct connection of the controller to PC The simplest way to connect the controller to PC by IL-NT RS232 Communication module. All possibilities are : IL-NT RS232 is plug-in card (present in default configuration) to enable the controller for RS232 IL-NT S-USB Communication module, IB-Lite Internet / Ethernet Module Cards insert into expansion slot back on the controller. See more details in manuals for modules or User Guide InteliLite-NT-Vautodetect.

Remote Communication Plug-In module IL-NT GPRS allows to establish the wireless connection to the Internet or control the motor by SMS from the mobile phone. The connection to the Ethernet network (and so to Intranet or Internet) is possible establish with the plug-in module IB-Lite, with LiteEdit and monitor and control the motor at distance. Once the connection on Internet is established, it is possible to use WebSupervisor, a powerful tool for remote monitoring.

Protections Protections presented in the table bellow are implemented to protect the motor or/and the driven machine. Each group of protection is accompaigned by the explanation and by list of relative setpoints. Protection Description Relative

SetPoints Motor Voltage Overvoltage UnderVoltage

Protection against overvoltage and undervoltage of the motor power supply voltage.

Ove/UndVoltDel Voltage Unbalance Volt Unbalance Volt Unbal Del

Protection against the difference between phase voltages. Protection is inactive in the case of single phase motor. ConnectionType

Motor Overload Protection Protection against the current overloading. The Setpoint allows modifying the time constant, i.e. the reaction delay of the protection. To make operate this protection, connect the CT to the controller.

Amps IDMT Del

OverCurrent and torque OverCurrent Sd

The protection stops quickly the motor when Nominal Current corrected by percentage value ofSP OverCurrent Sd is overpassed. SP OverCurr Sd Del allows delaying the shutdown. This protects the motor against the sudden overcurrent, or the driven machine in the case of jamming etc. To make operate this protection, connect the CT to the controller.

OverCur Sd Del

Speed Overspeed Sd

The protection stops it when the speed passes under or over set zone. To make operate this protection, connect the speed sensor to the controller .

UnderSpeed Sd

Minimal Load The protection will stop the motor if the power LowLoadLimit


consumption underpasses the set level. The motor is stopped only when the condition lasts more than set delay. This function is usefull to survey the driven machine, e.g. if a pump does not lack the water in its inlet. To make operate this protection, connect the CT to the controller.

LowLoadLimDel

General Analog Protection AI1 AI1 Wrn AI1 Sd

The function surveys the value of analog input AI1. Two alarm limits are watched, one for warning only, the second one to stop the motor. To declare the alarm, the condition must last more than AIN1 Delay. The protection can be set in both increasing and decreasing trends. See more in the chapter Analog Inputs.

AI1 Del

General Analog Protection AI2 Analogical to General Analog Protection AI1 AI Wrn, AI2 Sd, AI2 Del

General Analog Protection AI3 Analogical to General Analog Protection AI1 AI Wrn, AI2 Sd, AI2 Del

Controller Power Supply Voltage DCVoltageOver

Protection against overvoltage and undervoltage of the controller power supply voltage. DCVoltageUnder

Maintenance Period WrnMaintenRun

The warning message is generated when one of the two following conditions are met:

- Motor Run Hours reached the level of SP WrnMaintenRun

- - the current date reached the date set in setpoint WrnMaintenAge. The options are to be used according to the maintenance rules and the motor requirements.

See more about Run Hours in the chapter MEASUREMENT screens description.

WrnMaintenAge

What Communication or Input / Output modules are supported? Unit or module Description Optional / Obligatory InteliDrive EM Central unit

(HW type IL-NT MRS19) Obligatory

Communication modules 1 IL-NT RS232 RS232 communication card Optional 2 IL-NT RS232-485 Communication module Optional 3 IL-NT S-USB USB communication module Optional 4 IL-NT GPRS GPRS communication module Optional 5 IB-Lite Internet / Ethernet Module including

Web Server Optional

6 IGL-RA15 Remote annunciator Optional Input output modules 7 IL-NT AIO 4 analog inputs and 1 analog output Optional 8 IL-NT AOUT8 8 analog outputs card Optional 9 IL-NT BIO8 8 input or output binary channels Optional 11 IL-NT IO1 4 analog outputs and 4 binary inputs Optional Hint: the module 1 or 2 or 3 or 5 is necessary for the comunication with LiteEdit


The cut-out for the Remote Annunciator is 167 x 108 mm.

Remote annunciator IGL - RA15 The remote annunciator IGL-RA15 can be connected to the controller via CAN bus. Any of the binary outputs can be configured (using LiteEdit software) to each LED diode on the RA15. The module can also be enabled or disabled using LiteEdit software. See the documentation of RA15 for the technical and function description.


Controller Terminals and Dimensions

Terminals

Controller Dimensions

Application InteliDrive EM


Getting started

How to install

General To ensure proper function:

Wiring for binary inputs and analog inputs must not be run with power cables. Analog and binary inputs should use shielded cables, especially when length >3m.

Power supply wiring To ensure proper function: Use min. power supply cable of 1.5mm2 Maximum continuous DC power supply voltage is 36VDC. Maximum allowable power supply voltage is 38VDC. The controller 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. Hint: The maximum allowable current through the controller’s negative terminal is 4A (this is dependent on binary output load). For the connections with 12VDC power supply, the controller includes internal capacitors that allow the controller to continue operation during cranking if the battery voltage dip occurs. If the voltage before dip is 10V, after 100ms the voltage recovers to 7 V, the controller continues operating. During this voltage dip the controller screen backlight can turn off and on but the controller keeps operating. It is possible to further support the controller by connecting the external capacitor and separating diode:

+-

12VDC+-

controllerT2A

Battery

+

D

C

Relays

Power supply fusing A fuse should be connected in-line with the battery positive terminal to the controller and modules. These items should never be connected directly to the power supply. Fuse value and type depends on number of connected devices and wire length. Recommended fuse (not fast) type - T1A – T2A. Not fast due to internal capacitors charging during power up.

Binary output wiring Do not connect binary outputs directly to DC relays without protection diodes, even if they are not connected directly to controller outputs.


+-

K1 K1K2 K2

24VDC+-

controllerT1A

Fuse

Fuse

Battery

DC relays

Binary input wiring The common pole of contacts is connected to (-) pole of power supply. It is preferable to choose the (-) pole of controller.

+

Battery

-

iL4k7 Ω

+ -PowerSupply

Controller


Magnetic pick-up Magnetic pick-up is a facultative option. The sensor is connected directly on the controller. To install the sensor brings the possibility to watch motor speed, record it in the history and use the protection activated when the speed goes off set limits. To ensure proper function, use a shielded cable.

Three phase applications

Current measurement The current measurement by means of current transformer is a facultative option. Installing the CT brings the possibility to measure current, record it in the history and use several protections starting with overcurrent protection until the protection against too low mechanical load (idle course). To ensure proper function:

§ Use cables of 2,5mm2

§ Use transformers to 5A § Connect CT according to following drawings


Current measurement

L1L2L3

N

G

COM L1l

K Lk l

L2l

K Lk l

L3l

K Lk l

Voltage measurement

G

GENERATORL3L2L1N

L1L2L3

NBUS

Hint: No separation transformers for three wires voltage connection are needed.

Single phase applications There is not a separate archive file for single-phase applications. Use standard ail archive and change the SetPoint TypeOfWiring.

Recommended wirings Mains single-phase voltage has to be connected to L1 voltage terminal and N terminal. Phase current has to be connected to L1 and COM terminals.

M

VOLTAGE

M

CURRENT 0-5A


Voltage measurement

G

GENERATOR

L3L2L1N

LN

Hint: Switchboard lightning strikes protection according standard regulation is expected!!!

Current measurement To ensure proper function

Use cables of 2,5mm2

Use transformers to 5A Connect CT according to following drawings. Terminals L2l and L3l are opened.

L1N

G

COM L1l

K Lk l

L2l L3l

Analog inputs Three analog inputs are available on the controller.

Configuration Each analog input can be configured by LiteEdit software following way.

Analog input item LiteEdit Possibility Not used Analog input isn’t used Type Type Alarm Analog input is used

Analog input name Name Up to 14 ASCII characters Analog Analog measuring in specified

range. Binary (not supp. by PTM)

Binary: open/close - threshold 750 Ω.

Config of input Config

Tri-state (not supp. by PTM) Three-state: open/close - threshold 750 Ω, Failure <10 Ω or > 2400 Ω

Physical dimension Dim bar,%,°C, … Up to 3 ASCII characters (Valid only for analog inputs)

Polarity Contact type

NC

Valid only for binary and three-state inputs

M

M

VOLTAGE

CURRENT 0-5A


NO Valid only for binary and three-state inputs

Over Overstep. Sensor fail does not activate protection.

Over+Fls Overstep and Sensor fail activates protection.

Under Under step. Sensor fail does not activate protection.

Protection direction Protection

Under+Fls Under step and Sensor fail activates protection.

Sensor characteristic Sensor Curve A Curve B Curve C PT 1000 NI 1000 VDO Temp VDO Press VDO Level 4-20mA/100 4-20mA/ 60 Pt100 Ni100 0-20mA/100 4-20mA/100 0-100mV/100

IL, IOM,PTM IL, IOM,PTM IL, IOM,PTM IL, IOM IL, IOM IL, IOM IL, IOM,PTM IL, IOM,PTM IL, IOM IL, IOM PTM PTM PTM PTM PTM

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 20mA/10.0Bar, ext. R 120 Ω 20mA/6.0Bar ext R 120 Ω 0-20mA/10.0Bar 4-20mA/10.0Bar

Decimal points Dec 0, 1, 2 Number of decimal points (Valid only for analog inputs)

User Curves 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 “Motor protect” group.

Default current sensor characteristic with external resistor 120 ohms 4-20mA/100 0-20mA/100 0-20mA/-20 - 120°C Primary Converted Note 1 Note 2 Note 3 Note 4 120 0 mA 0% -20°C 170 0 0% 4 mA 20% 8°C 200 13 22°C 230 25 25% 8 mA 40% 36°C 280 38 50°C 330 50 50% 12 mA 60% 64°C 390 63 78°C 460 75 75% 16 mA 80% 92°C 560 88 106°C 690 100 100% 20 mA 100% 120°C

Note 1 - % range for 4-20 mA input Note 2 - range 0-20 mA Note 3 - % range for 0-20 mA input Note 4 - characteristic 0-20 mA / -20 - +120 °C


Connection of the controller analog inputs

AI1

AI2

- PO

WER

3x RESISTIVESENSOR

AI3

Standard connection of three resistive sensors to analog inputs.

AI1

AI2

- PO

WER

+24V

3x SENSOR4 - 20 mA

AI3

GND

Three current output sensors connection to InteliLite. Set jumpers for current measurement

2x470

COM

-PO

WER

AI1

AI2

AI3

Mixed connection of InteliLite analog inputs: AI1 – binary input AI2 – three state input AI3 – analog resistive input

Analog inputs are designed for resistive sensors with resistance in range of 0Ω to 2,4kΩ. To ensure a proper function use shielded cables, especially for length over >3m. Shielding should be connected to the sensor body.

Current output transducers Analog inputs of the controller are mainly designed for resistor sensors. In special case transducers to 4-20mA output can be used for pressure measuring (10.0Bar or 6.0Bar). Use predefined 4-20mA/100 or 4-20mA/60 sensors. This method reduces the input resolution by less than 50%. Some types of transducers are not suitable for connection to InteliLite analog inputs because of influencing by InteliLite analog input.

As binary input Open, close state are detected, threshold level is 750Ω.

As three state input Open, close and failure state are detected. Threshold level is 750Ω, failure is detected when circuit resistance is <10Ω or > 2400Ω.


Unused analog inputs Configure Type = Not used

Example of analog input configuration Configure AIN1 input for measuring in Bar, VDO oil pressure sensor, range 0 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 – AIN1 (No.1 Not Used). Double-click on the text “Not Used” and set the configuration: Type: selection between Not used and Alarm “Not used” – analog input isn’t used ”Alarm” – analog input is used 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 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. 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 „####“ 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) „Pt1000“ – PT1000 sensor characteristic according to IEC 751 „Ni1000“ – Ni1000 sensor characteristic according to DIN 43 760 „VDO 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 „4-20mA/100“ – current output sensor characteristic – requires external resistor 120 ohms between Analog input and COM terminal Set to: VDO press Decimals: setting of number of decimal points of measured value. „0“ - e.g. 360 kPa, 100%, 50 °C „1“ - e.g. 3.6 Bar „2“ - e.g. 0.36 MPa „3“ - e.g. 0.366 MPa Set to: 1 When Analog input configuration is finished set the setpoints Wrn Oil press, Sd Oil press, Oil press del in Motor protection group.


Each Analog input has separate triplet of setpoints: Wrn level, Sd level, Anl Inp del. Number of decimal points of Wrn level1 and Sd level is the same as the configured number of decimal points of measured value.

Installing RS 232 Communication Module RS 232 Communication Module is chosen as example how to install a communication module. To install RS 232 communication module:

1. Insert a screwdriver into the slot of the cover.

2. Move the screwdriver to set apart the small cover. Be careful!

3. Remove the small cover. 4. Break apart the small cover into two pieces. Do not throw away the smaller part!


5. Take RS 232 communication module.

6. Plug RS 232 communication module into the slot of the controller. 7. Put back the small cover.


Inputs and outputs Hint: Any Binary input or output can be configured or changed to different function by LiteEdit software. There is fix 1 sec delay when any binary input is configured as protection.

Binary inputs - default

BI1 HornResButton

BI2 Access Lock

BI3 Emergency Stop

BI4 Remote AUT

BI5 Remote OFF

BI6 StopButton

BI7 Rem Start/Stop

Logical Binary inputs Each LBI can be configured to a physical binary input in LiteEdit PC program.

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 14 characters ASCII string NC Normally closed Contact type NO Normally opened Warning Alarm type Shut down All the time Alarm active Motor running only

Control:


HornResButton Binary input has the same function as Horn reset button on the InteliLite front panel.

Access lock If the input is closed, no setpoints can be adjusted from controller front panel and gen-set mode (OFF-MAN-AUT) cannot be changed. Hint: Access lock does not protect setpoints and mode changing from LiteEdit. To avoid unqualified changes the selected setpoints can be password protected.

Emergency stop If the input is opened, shut down is immediately activated. In default configuration, input is not inverted as it should be for safe function. If Emergency Stop function is required, it is recommended to Hint: In case of controller hardware or software fail, safe stop of the motor doesn’t have to be ensured. To back-up the Emergency stop function it is recommended to connect separate circuit for disconnection of KM1 contactor.

Sd Override When the input is active, the motor is not stopped even if a shut down appears. But if the shut down occurred before starting, the start is not allowed even if Sd Override active is active.

Remote AUT If the input is active, AUT mode is forced to the controller independently on the position of the MODE selector. If another of "remote“ inputs is active, then the REMOTE AUT input has the lowest priority.

Remote OFF If closed, the controller is switched to OFF mode (there are four modes OFF-MAN-AUT-TEST). When opens controller is switched back to previous mode.

Remote MAN If the input is active, MAN mode is forced to the controller independently on the position of the MODE selector.

StopButton Binary input has the same function as Stop button on the InteliLite front panel. It is active in MAN mode only.

Rem start/stop External request for motor run. AUT mode only.

Hint: Many other interne binary variables LBI (stands for Logical Binary Input) can be configured on physical binary inputs described here above. If 7 binary inputs of controller are not enough, connect one of auxiliary input / output modules. See chapter What Communication or Input / Output modules are supported?


StartButton Binary input has the same function as Start 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.

RemControlLock If the input is active, setpoints writing or command sending from the external terminal is disabled.

Emergency manual If the input is activated the controller behaves like when switched to OFF mode. Opens all binary outputs. Detection of "running" motor and subsequent alarm message "Sd Stop fail" is blocked. The controller shows “Emerg Man” state and the motor can not be started. Phase current and power measurement is active in this mode, regardless of the actual state of the motor. After the input is open again, the controller recovers to previous state and behaves according to the actual situation . Function is active in any controller mode.

BI-Timer1, 2 Strt The inputs activate internal timers. See more in chapter about Timer Function setpoint

ClearDayRHrsLd When this BIN is closed, the counter DayRunHrsLoad is reset to zero.

Lang Selection Selects one of two languages, which are predefined in the controller. The majority of texts changes. It is necessary to download the second language dictionary from LiteEdit. The controller is furnished with English dictionary only.

Binary outputs - default

BO1 KM1

BO2 KM2

BO3 KM3

BO4 Not used

BO5 Not used

BO6 Not used

BO7 Not used


Binary outputs - list

KM1 The output is to connect on the relay, which switch the contactor KM1 on. In the case of starting with SoftStarter (SetPoint KindOfStarting = SOFTSTART), this output is to be connected to the softstarter. In this case, see the format of softstarter input to ensure the correct cooperation.

KM2 The output is to connect on the relay which switch the contactor KM2 on, in the case of Y-D starting mode (SetPoint KindOfStarting = Y-D). When starting with SoftStarter (SetPoint KindOfStarting = SOFTSTART), this output is to be connected to the softstarter. In this case, see the format of softstarter input to ensure the correct cooperation.

KM3 The output is to connect on the relay which switch the contactor KM3 on, in the case of Y-D starting mode (SetPoint KindOfStarting = Y-D).

Not used Output has no function. The function can be assigned in LiteEdit, window Modify choosing one of interne variables (LBO).

CommonWrnSd The output closes if:

• any warning or shutdown comes up or • the motor malfunctions

The output opens if • FAULT RESET is pressed

The output closes again if a new fault comes up.

Horn The output closes if:

• any warning or shutdown comes up or • the motor malfunctions

The output opens if: • FAULT RESET is pressed or • HORN RESET is pressed or • Max time of HORN is exceeded (Horn timeout)

The output closes again if a new fault comes up.

Ready/Auto The output is closed if controller is ready in AUTO mode - no Shut down or Slow stop alarm is active.

Ready The output is closed if following conditions are fulfilled:

• Motor is not running and • No Shut down or Slow stop alarm is active • Controller is not in OFF mode

Not In Auto The output closes in OFF and MAN mode.

Running Output closes if the motor is in Running state.


Fault Reset

The output closes when the FAULT RESET is pressed.

Sd OverVolt Output closes when shut-down over voltage alarm appears.

Sd UnderVolt Output closes when shut-down under voltage alarm appears.

Overload Output closes, if the alarm of motor overload shutdown is activated. The output opens, if

• alarm is not active and • FAULT RESET is pressed

Wrn Overload Output closes if the current overload warning alarm activates.

Overspeed Output closes if the motor over speed alarm activates. The output opens, if


Underspeed Output closes if the motor under speed alarm activates. The output opens, if


Overcurrent Output closes if the

IDMT over current or current unbalance or short current alarm activates.

The output opens, if Alarm is not active and FAULT RESET is pressed

Common Wrn Output closes when any warning alarm appears. The output opens, if

• No warning alarm is active and • FAULT RESET is pressed

Common Sd Output closes when any shut-down alarm appears. The output opens, if

• No Sd alarm is active and • FAULT RESET is pressed


Common Fls Output closes when any sensor fail alarm appears. The output opens, if

• No warning alarm is active and • FAULT RESET is pressed • alarm is not active and • 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.

ServiceTime Output closes if the ServiceTime alarm activates. The output opens, if


BI1..7 – stat The outputs give information about the assigned binary input. In case the assigned binary input is configured to alarm type, then the output closes when the alarm activates. It opens if


In case the assigned binary input is configured to any control function, the output propagates the state of the input.

CtrlHeartBeat Output signalizes watchdog reset. In a healthy state it blinks at 500ms / 500ms rate. When watchdog reset occurs, it stops blinking.

ExercTimer1, 2 Output activates when Timer1 is active. Simultaneously, motor is started when is in AUT mode.

Sd LoadTooLow Protection is activated, indicated in Alarm list and recorded to History when active power is below Motor Protect: LowLoadLimit (no delay). Setpoint resolution depends on (Decimal – No Decimal) Power format setting in LiteEdit Units-Formats configuration. Hint: Many other intern binary variables LBO (stands for Logical Binary Output) can be configured on physical binary output described here below. If 7 binary inputs of controller are not enough, connect one of auxiliary input / output modules. See chapter What Communication or Input / Output modules are supported?

Analog inputs Three analog inputs are jumper configurable for resistive (default), voltage or current sensor.


It is possible to configure on each Analog input: • Sensor characteristics – from the list, or custom sensor curve • Value dimension (e.g. psi - bars, °F - °C, % - l) • Number of decimal points (0, 1, 2, …) Warning and shut-down limits are adjusted in Motor Protect group. The analog inputs are configurable. In Default configuration, the inputs are not configured. Use LiteEdit software to modify configuration. Hint: For further information about analog inputs’ configuration see the chapter Analog inputs.


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. There are 3 levels of passwords. Knowledge of higher password lets you to change setpoint protected by lower password.

ChangePassword Use ↑ or ↓ keys to set and ENTER key to change the password. Hint: At first the Password has to be entered before the new Password can be changed.

Basic settings

Motor name User defined name, used for InteliLite identification at remote phone or mobile connection. Motor name is max 14 characters long and have to be entered using LiteEdit software.

NomVolts Ph-N Mains nominal voltage between the phase and the neuter. Range: 80 – 6000V

Gear teeth [-] Number of teeth on the motor gear for the pick-up (impulse sensor of speed). When the motor is equipped by pick-up, it allows

- measure the speed - record the speed into history record - protect the motor or driven machine against underspeed (and against overspeed as well).

Set to zero, if no pick-up is used. Step: 1 Range: 0 – 500

Nominal RPM [RPM] Nominal motor speed. Step: 1RPM Range: 100 – 4000 RPM This SetPoint is usefull in combination with the sensor of speed. Set with this setpoint the nominal speed. The limits of speed protection are watched with respect to Nominal RPM. See also Group Motor Protect, SetPoints UnderSpeed and OverSpeed.

ControllerMode [OFF, MAN, AUT] Equivalent to Controller mode changes by MODE→ or ←MODE buttons. Hint: Controller Mode change can be separately password protected.


Connection Type Defines if the motor is single phase or three phases. 3f: for three phase motor 1f: for single phase motor

Communication Settings

ControllerAddr (1 .. 32) [-] Controller identification number. It is possible to set controller address different from the default value (1) so that more IL controllers can be interconnected (via RS485) and accessed e.g. from Modbus terminal. Hint: When opening connection to the controller its address has to correspond with the setting in PC tool. From LiteEdit it is only possible to connect to controllers with address 1.

COM1 Mode [DIRECT/MODEM/MODBUS] Communication protocol switch for the COM1 channel. DIRECT: LiteEdit communication protocol via direct cable. MODEM: LiteEdit communication protocol via modem. MODBUS: Modbus protocol. See detailed description in InteliCommunication guide.

COM2 Mode [DIRECT/MODBUS] Communication protocol switch for the COM2 channel, if dual communication module is plugged in. DIRECT: LiteEdit communication protocol via direct cable. MODBUS: Modbus protocol. See detailed description in InteliCommunication guide. Hint: For details on communication speed and other technical parameters please see chapter Technical Data. For detail description see chapter Modbus protocol. Controller supports register oriented Modbus. Hint: Modbus TCP protocol using IB-Lite communication module requires setting COM1 Mode = DIRECT and COM2 Mode = MODBUS.

ModemIniString If your modem needs some additional initialization AT commands (i.e. because of national telephony network differences), it can be entered here. Otherwise leave this setpoint blank.

ModbusComSpeed [9600,19200, 38400, 57600] If the Modbus mode is selected on COM1 or COM2 channels, the Modbus communication speed in bps can be adjusted here.

AirGate IP Name of AirGate account to which the controller is to be connected. Each user can create his own account. For details and other SetPoints, see the InteliLite-NT Communication Guide. Hint: To test the AirGate function, use the test ComAp account. Login name is comapdrive, password is comapdrive.


Motor Params

Nomin power [kW] Nominal power of the motor. Step: 0,1 kW Range: 0,6 – 120 kW

Nomin current [A] Nominal current of the motor (current in power supply lead). Step: 0,1 A Range: 0,1 – 180 A

KindOfStarting Must be set according to system of motor starting, i.e.

- direct starting. There is only one contactor driven by binary output KM1.

- Y-D Starting with 3 contactors. The starting delay (duration of Y regime) is defined by SP StarterDel.

- Softstarter. Is to be used in the case the softstarter is connected. The starter signal for softstarter is on binary output KM1.

Prestart delay [s] Allows delaying the start of motor with regard to the moment of start requirement. This is usefull for some application together with the mode AUT. Normally, the value should be 0. Step: 1s Range: 0 – 600 s

Motor Protect

CT Ratio [/5A] Motor phases current transformers ratio. Set up according to the type of used current transformer and according to the required range of current measurement. Step: 1 A Range: 1 – 5000 A / 5A Hint: The current inputs are over loadable by 90%.

Horn timeout [s] Max time limit of horn sounding. Set to zero if you want to leave the output HORN open. Horn timeout starts again from the beginning if a new alarm appears before previous Horn timeout has elapsed. Step: 1s Range: 0 – 600 s

Overspeed Sd [%] Threshold for over speed protection Step: 1% of nominal RPM Range: 90 – 150%

Underspeed Sd [%] Threshold for under speed protection Step: 1% of nominal RPM Range: 0 – 120%


AI1 Wrn [unit is adjustable in Modify window] Warning threshold level for ANALOG INPUT 1 Unit, step and range are adjustable in Modify window.

AI1 Sd [unit is adjustable in Modify window] Shutdown threshold level for ANALOG INPUT 1 Unit, step and range are adjustable in Modify window.

AI1 del [s] Delay for ANALOG INPUT 1 Step: 1s Range: 0 – 900s







DCVoltageOver [V] Warning threshold for high controller power supply voltage. Step: 0,1 V Range: 8– 40 V

DCVoltageUnder [V]

Batt volt del [s] Delay for low controller power supply voltage alarm. Step: 1 s Range: 0 – 600 s


LowLoadLimit Shutdown threshold for low power load. Example of use: controller stops the pump when the water runs out. Step: 0,1 kW Range: 0 – 1000 Hint: To make possible this protection, the wiring circuit must be equipped by current transformers.

LowLoadLimitDel Step: 1 s Range: 0 – 180 s

WrnMaintenRun [h] Counts down when motor is running. If reaches zero, a warning message appears. Step: 1h Range: 0 – 10000h

WrnMaintenAge [calendar date] If the current date reaches the setpoint value, a warning message appears. This is usefull for motors or driven machines, which don’t work a lot but it is necessary to make maintenance even though.

OverCurrent Sd [%] Threshold for motor overcurrent (in % of Nominal current). This protection is not temporarily dependant, i.e. The time of reaction depends on setpoint Overcur Sd Del only, not on size of overcurrent. Step: 1% of nominal current Range: 0 – 400% Tip: This protection can use to protect the driven machine in the case of a mechanical seizure etc.

OverCur Sd Del [s] Delay for motor overcurrent alarm. Step: 0.1s Range: 0 – 600.0 s

Amps IDMT Del [ s ] IDMT curve shape selection. Amps IDMT Del is Reaction time of IDMT protection for 200% overcurrent Igen = 2* Nomin Current. Step: 1 s Range: 1 - 60,0 s IDMT is “very inverse” over current protection. Reaction time is not constant but depends on over current level according following formula.

In the case of three phase wiring, Iph is maximal value of all measured phases of current.

Amps IDMT Del * Nomin Current Reaction time = Iph - Nomin Current


Hints: To simulate the breaker characteristic “C” according to the IEC EN 60255-3 standard, Amps IDMT Del must be at least 30. The bigger the value is, the slower the reaction of the protection is. Be careful to optimize well the ratio of the current transformer in order not to saturate the current inputs of the controller and in the same time not to decrease the measurement precision in the range of nominal values. See also setpoint CT Ratio.

Igen

Nominal Current Short Crct Sd

Amps IDMT Del

Maximal Reaction time

Reac

tion

time

OverVoltage [%] Threshold for mains overvoltage. All three phases are checked. Maximum out of three is used. Step: 1% of Nominal voltage Range: (UnderVoltage) – 200%

UnderVoltage [%] Threshold for mains undervoltage. Step: 1% of Nominal voltage Range: 0% - (OverVoltage)

Ove/UndVoltDel [s] Delay for mains undervoltage and overvoltage alarm Step: 0.1s Range: 0.0 – 600.0 s

Volt unbal [%] Threshold for phase voltage unbalance alarm. Step: 1% of Nominal voltage Range: 0 – 200% of Nominal voltage


Volt unbal del [s] Delay for voltage unbalance alarm. Step: 0.1s Range: 0.0 – 600.0 s

Functions

CtrlByAIN/BIN [BIN / BININV / CU:AIN1-3] BIN: The motor starts if Rem Start/Stop BIN is closed. This function (together with BININV)

allows starting and stopping the motor according to the status of a sensor with a binary output. Example: if the level of water overpasses the point where the sensor is, the pump is activated.

BININV: The inverse function to BIN. The motor starts if Rem Start/Stop BIN is open. AIN1-3: The motor starts when the value on the AINx meets the value of setpoint Start by AIN.

The motor stops when the value on the AINx meets the value of setpoint Stop by AIN. Hint: When an auxiliary module with analog inputs is connected to the controller, it is possible to use its inputs AIO AINx apart of CU: AINx.

Start by AIN [Computer Unit] For meaning, see CtrlByAIN/BIN Step: 1 Range: 0 – 10 000 CU Default value: 0 … means that the display lights all the time

Stop by AIN [Computer Unit] For meaning, see CtrlByAIN/BIN Step: 1 Range: 0 – 10 000 CU Default value: 0 … means that the display lights all the time

Extension I/O

AnlInAIO1 lev1 [CU] Warning threshold level for the first analog input of the auxiliary I/O module with analog inputs (when present). Unit, step and range are adjustable in Modify window. See also Alarm management chapter. Step: 1 Range: -100 +10000 computer unites Hint: Because control unit itself has three analog inputs, the value number of this first external input is 4, and so on.

AnlInAIO1 lev2 [CU] Shutdown threshold level for the first analog input of the auxiliary I/O module. See also Alarm management chapter. Step: 1 Range: -100 +10000 computer unites


AnlInAIO1 del [s] Delay for AnlInAIO1 Step: 1s Range: 0 – 180s

Calibr AIO1 [CU] Calibrating constant to adjust the zero of the measured analog inputs value. Physical dimension of calibrating constant is corresponding to Analog input. Step: 1 Range: -1000 +1000

AnlInAIO2, 3, 4 Like AnIInAIO 1 Hint: Calibration constants have to be adjusted when measured value is near the alarm level or when the connection to PC is not available. LiteEdit PC software offers more powerful curves that the user can set to accommodate the sensor characteristic to the analog input.

Date/Time

Time stamp per [min] Time interval for periodic history records. Step: 1 min Range: 0 – 240min

SummerTimeMod [DISABLED/WINTER/SUMMER,WINTER-S,SUMMER-S] DISABLED: Automatic switching between summer and wintertime is disabled. WINTER (SUMMER) : Automatic switching between summer and wintertime is enabled and it is set to winter (summer) season. WINTER-S (SUMMER-S) : Modification for southern hemisphere.

Time [HHMMSS] Actual real time

Date [DDMMYYYY] Actual date.

Timer1…2Function [No Func / AutoRun / Mode OFF] It is possible to choose out of 3 following Timer functions. Binary output Exerc Timer X is always activated when Timer is active regardless of chosen Timer function. Timer functions require controller running in AUT mode. No Func: There is no any other function, but binary output Timer1..2 activation. AutoRUN: When this option is chosen then the Timer output is also internally connected to the

Remote TEST binary input. Mode OFF: When this option is chosen then the Timer output is also internally connected to the

Remote OFF binary input.


Timer 1..2 Repeat [NONE/MONDAY/TUESDAY/WEDNESDAY/THURSDAY/WEDNESDAY/FRIDAY/SATURDAY/SUNDAY/MON-FRI/MON-SAT/MON-SUN/SAT-SUN] Determinates repetition of TIMER 1 activation. Binary output TIMER 1 is internally linked with Rem Start/Stop binary input. Refer to binary inputs for details. NONE: Timer function is disabled MONDAY, TUESDAY, WEDNESDAY, THURSDAY, WEDNESDAY, FRIDAY, SATURDAY, SUNDAY: Timer is activated on daily basis. MON-FRI, MON-SAT, SAT-SUN: Timer is activated on selected day interval.

Timer1..2 ON Time Day time when Timer output activates.

Timer1..2Duration Duration of Timer output is active. Step: 1 min Range: 1 – 1440 s

Timer Function Date/Time: Timer (1 and 2) Function: Auto Run Starts motor at Timer1 ON Time for Timer1Duration with Timer1 Repeat periodicity Mode OFF activates controller Remote OFF mode at Timer1 ON Time for Timer1Duration with

Timer1 Repeat periodicity. No Func See table below. Timer1Function Timer1 Repeat Timer1 ON Time Timer1 Duration Note No Func NONE Anything 5 min Note 1 Auto Run NONE Anything 5 min Note 2 Mode OFF NONE Anything 5 min Note 3 Note 1. Rising edge on binary input “BI-Timer1Strt” activates Binary output “ExcercTimer1” for 5 minutes in any OFF-MAN-AUT mode (with settings according table above). Note 2. Rising edge on binary input “BI-Timer1Strt” activates Binary output “ExcercTimer1” for 5 minutes and Starts the motor for 5 minutes in AUT mode. Note 3. Rising edge on binary input “BI-Timer1Strt” activates Binary output “ExcercTimer1” for 5 minutes and activates controller Remote OFF mode for 5 minutes. Timer 2 function is equal to the Timer1. Hint: Once running timer is reset only when delay is over or when controller is switched Off and On.


Sensor spec

AI1, AI2, AI3 Calibration [unit is adjustable in Modify window] Calibrating constant to adjust the zero of the measured analog inputs value. Physical dimension of calibrating constant is corresponding to Analog input. Step: 1 Range: -1000 – +1000 See also Sensor specification chapter. Hint: Calibration constants have to be adjusted when measured value is near the alarm level or when the connection to PC is not available. LiteEdit PC software offers more powerful curves that the user can set to accommodate the sensor characteristic to the analog input.

SMS/E-mail

Yel Alarm Msg When a Wrn message appears, the controller sends the message by SMS or e-mail. The destination depends on SP TelNo/Addr Ch1 and TelNo/Addr Ch2. Range: OFF, ON

Red Alarm Msg When a Sd event appears, the controller sends the message by SMS or e-mail. The destination depends on SP TelNo/Addr Ch1 and TelNo/Addr Ch2. Range: OFF, ON

MsgAfterStart When the setpoint is ON, a SMS massage or e-mail is sent after each start or stop of motor. Range: OFF, ON

TelNo/Addr Ch1 To put here the phone number or e-mail address. Format: character string

TelNo/Addr Ch2 To put here the phone number or e-mail address. Format: character string Hint: To allow the communication, the controller must be connected to a telephone modem or to internet. For connection, use ComAp auxiliary modules.

SMS messages To allow sending the Start / Stop messages, set the setpoint MsgAfterStart to ON. (The controller must be equipped with the auxiliary communication module IL-GPRS). Message example:

#IL-NT:STATUS=(System Started) #Run Hours: 46 #No. of starts: 45

#IL-NT:STATUS=(System Stopped) #Run Hours: 46 #No. of starts: 45


Motor Start Stop commands via SMS Command SMS Response Note Start #1:0 ,c1 #EL.MOTOR:c_ok

#EL.MOTOR:c_err Access code = 0, No password

#1:0 p0,c1 Access code = 0 Password = 0

Stop #1:0 ,c2 #EL.MOTOR:c_ok Access code = 0 No password

#1:0 p0,c1 Access code = 0 Password = 0

Note: The name “EL.MOTOR” in table above follows the Basic Settings: Motor Name setpoint.


Sensor specification

Background of the sensor calibration To correct measuring error of each analog input (pressure, temperature, level) calibrating constants within 10 % of measure range should be set. Three (seven) calibrating constants are set in physical units - bar, oC, %. From these constants are counted equivalent calibrating resistances, which are internally (in software), add to sensor resistance. At the moment of calibration (ENTER pressing) is calculated (and in memory saved) calibrating resistance (Ω). This value is added to measured sensor resistance before calculation of the AI1 (AI2 or AI3) value. Example: The display shows the temperature 70 °C and real value is 73 °C. After setting Calibr AI1 to +3 °C (and pressing ENTER) InteliLite calculates corresponding resistance (e.g.5Ω) and saves this value into the memory. The resistance is then added to all calculations (e.g. instead of 70°C -> 73°C, or e.g. instead of 5°C -> 6°C). Hint: The calibration must be done at the operational point of the analog input (e.g. 80°C, 4.0Bar etc.)

Default sensor settings Analog input 1: 6 points VDO characteristic, pressure measuring in bar Analog input 2: 10 points VDO characteristic, temperature measuring in °C Analog input 3: 2 points VDO fuel level sensor, 0% = 10Ω, 100% = 180Ω

VDO Temperature sensor

0

500

1000

1500

2000

32 68 86 104 122 140 158 176 194 230

Temperature [°F]

Res

ista

nce

[ohm

]

VDO Pressure sensor

0

50

100

150

200

0 29 58 87 116 145

Pressure [psi]

Res

ista

nce

[ohm

]

Temperature ºC/°F

Pt 1000 Ohm

Ni 1000 Ohm

-20/-4 -10/14 0/32 30/86 60/140 80/176 90/194 100/212 110/230 120/248

922 961 1000 1117 1232 1309 1347 1385 1423 1461

893 946 1000 1171 1353 1483 1549 1618 1688 1760

Hint: When measured value is 6% out of range the Sensor fail FLS is detected.


Operator interface

Pushbuttons and LEDs, MRS19

Pushbuttons 1. MODE→ - Cyclic forward selection the gen-set operation mode (OFF -> MAN -> AUT ) 2. ←MODE - Cyclic backward selection the gen-set operation mode (AUT -> MAN ->OFF ) 3. HORN RESET - Deactivates the HORN 4. FAULT RESET - Acknowledges faults and alarms 5. START - Start of the motor 6. STOP - Stop of the motor 7. PAGE - Cyclic selection of the display mode(MEASUREMENT->ADJUSTEMENT) 8. ↑ - Select the set point, select the screen or increase set point value 9. ↓ - Select the set point, select the screen or decrease set point value 10. ENTER - Confirm set point value

LEDs ALARM Indicates active or inactive, but still not reset shutdown alarm WARNING Indicates active or inactive, but still not reset warning alarm

3 2 1

4

5

6

7

8

9

10


How to start motor? Motor start can be activated: 1. Locally via panel Start , Stop buttons. 2. Remotely wired to Binary inputs StartButton, StopButton. 3. Remote Start button (BI-Timer1Strt) to run motor for preadjusted time: Motor stops automatically

after time is over. See Timer Function 4. Automatic Motor start based on internal “calendar” timer. 5. Remotely via serial line RS232 or RS485 – using PC software LiteEdit. 6. Remotely via SMS message. 7. Remotely via internet. Hint Any start/stop is recorded to History log and can be reported via SMS.

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 ↑ and ↓ to select the screen with requested data.

How to view and edit set points? 1. Use repeatedly PAGE button to select the ADJUSTMENT menu. 2. Use ↑ or ↓ to select requested set points group. 3. Press ENTER to confirm. 4. Use ↑ or ↓ to select requested set point. 5. Set points marked “*” are password protected. 6. Press ENTER to edit. 7. Use ↑ or ↓ to modify the set point. When ↑ or ↓ 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.

How to change the display contrast? Press ENTER and ↑ or ↓ at the same time to adjust the best display contrast Hint: Only in MEASUREMENT menu.

How to check the serial number and software revision? Press ENTER 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) InteliLite serial number (8 character number) 3) SW version: the first is the firmware version number, the second is configuration table

number. 4) Application: MRS19 5) Branch: ID-EM


Hint: Only in MEASUREMENT menu.

How to change language? Press ENTER and then PAGE to get to Serial number and software revision screen. Then press PAGE to enter Language selection screen. Use ↑ or ↓ to select desired langue and press ENTER to confirm selection. Hint: Before choosing a new language, this one must be loaded from PC by LiteEdit.

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. Three state alarms are introduced:

Description * Wrn Temperature Active not accepted alarm Wrn Temperature Active accepted alarm

* Wrn Temperature Inactive not accepted alarm Inactive accepted alarm

Press FAULT RESET 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. Hint: Alarm list does not activate when you are reviewing the values or setpoints. Second alarm list for ECU alarms is also available. It is displayed one screen above the standard alarm list on the controller display or under the standard alarm list in Control window of LiteEdit. If an alarm appears in this alarm list, it is signalized in the standard alarm list and by exclamation mark on the main measure screen. Control from the front panel:

↑↓ One screen up/down Enter Cursor move within the ECU alarm list

Enter + Fault reset ECU fault code reset

MEASUREMENT screens description

Main measure screen

1 2

3

4

7

6

5


1. Operation mode of the motor 2. Indication of: active access lock “L”, Remote communication “R” and alarm “!” 3. Status of the motor 4. RPM of the motor 5. Active power 6. Power factor 7. Timer - event’s counting time (e.g. “Y run” when the motor starts )

Mains screen L1-N, L2-N, L3-N L1-L2, L2-L3, L3-L1 Freq I (triple bargraph of phase currents)

Analog inputs screen Bargraph of controller power supply voltage is always present at bottom of screen. Other bargraphs according to the definition of analog inputs. See also Analog Input chapter.

Binary inputs BI1 to BI7

Binary outputs BO1 to BO7

Power screen Active power (total) Power factor (total) Mains voltage (per phase)

Statistic Run hours Number of starts DayRunHrsLoad TotalRunHrsLoad Energy kWh

Energy kVArh Maintenance (Next ServiceTime)

Counters can be cleared or set through LiteEdit Set statistics command in menu Controller. DayRunHrsLoad Automatic is cleared automatically at midnight 0:00 time or can be cleared by LBI ClearDayRHrsLd configured to Binary input.

Alarm list Alarm list Includes - Active unacknowledged alarms - Active acknowledged alarms - Inactive unacknowledged alarms See more in the chapter How to find active alarms?


Function description

OFF mode No start of the motor is possible. Outputs KM1, KM2 and KM3 are not energized. No reaction if buttons START,STOP are pressed.

MAN mode START - starts the motor. STOP stops the motor. Hint: The motor can run without load unlimited time. The controller does not automatically stop the running motor in MAN mode. The controller does not start the motor when binary input REM START/STOP is closed. The start and stop signals can be provided by extern pushbuttons connected to binary inputs Start Button and Stop Button. These two LBI must be configured to two physical binary inputs.

AUT mode The controller does not respond to buttons START, STOP Motor start/stop request is given by binary input REM START/STOP. Except Basic setting: STOPinAUT = ENABLED. See more in Basic setting or Start-stop sequence in MAN mode.


Alarm management Following alarms are available:

• Sensor fail • Warning • Shut down

Sensor fail (FLS) Sensor fail is detected when measured value is 6% out of selected sensor characteristic. Sensor fail is indicated by ##### symbol instead measured value.

Warning (WRN) When warning comes up, only alarm outputs and common warning output are closed. Information about warning event is also

Possible warnings: See List of possible events

Shut down (SD) When the shut-down alarm comes up, InteliLite opens outputs KM1, KM2 and KM3 to stop the motor immediately. Alarm outputs and common shutdown output are closed. Active or not reset protection disables start.

Possible shut-down alarms: See List of possible alarms.


Motor operation states Motor states Init Autotest during controller power on Not ready Motor is not ready to start Ready Motor is ready to run Starting Motor is under voltage in Y wiring (KM1 and KM2 contactors are ON) Loaded Starting is over, motor is running Stop Stop Shutdown Shut-down alarm activated EmergMan Emergency Manual motor operation

List of possible alarms

Events specification Protection type

Information on binary output available (See list of Binary outputs)

Description

Wrn “Name of analog input” WRN YES Level of AINx is smaller or higher (depends on parameter Direction in the window of this AINx in Modify menu) than setpoint AINx Wrn of Motor Protect Group. Nota: the text of alarm message takes the name of AIN (if AIN is renamed).

Sd “Name of analog input” SD YES Level of AINx is smaller or higher (depends on parameter Direction in the window of this AINx in Modify menu) than setpoint AINx Sd of Motor Protect Group.

Ubatt WRN YES Controller power supply voltage is out of limits given by DCVoltageUnder and DCVoltageOver setpoints.

Binary input Configu-rable

YES Configurable Warning/Shutdown alarms on the inputs of controller.

Start failed SD YES Motor start failed. ParamFail NONE NO Wrong checksum of parameters.

Happens typically after downloading new firmware or changing of the parameter. The controller stays in INIT mode. Check all parameters, write at least one new parameter.

Wrn Volt L1, 2, 3 Wrn YES The mains voltage is out of limits given by OverVoltage and UnderVoltage setpoints, the start of controller is not requested.

Sd Volt L1, 2, 3 Wrn YES The mains voltage is out of limits given by OverVoltage and UnderVoltage setpoints, the start of motor was requested or the motor was running.

Voltage unbl SD NO The mains voltage is unbalanced more than the value of Volt Unbalance setpoint.

OverCurrent SD YES The current is higher than the value given by OverCurrent setpoint.


Events specification Protection type

Information on binary output available (See list of Binary outputs)

Description

Overspeed SD YES The protection comes active if the speed is greater than Overspeed setpoint.

Underspeed SD YES The protection comes active if the speed is greater than Underspeed setpoint. Protection evaluation starts after reaching status Running.

EmergencyStop SD NO If the input Emergency stop is opened shutdown is immediately activated.

PickupFault SD NO Failure of magnetic pick-up sensor for speed measurement.

Stop fail SD YES Motor stop failed. WrnServiceTime WRN NO The period for servicing is set by the

NextServTime setpoint. The protection comes active if the running hours of the motor reach this value, or the current date reaches the date set by WrnMaintenAge setpoint.

Wrn RA15 fail WRN NO Warning alarm in case of lost connection to IGL-RA15 module.

Sd IOM fail SD NO Shutdown alarm in case of lost connection to auxiliary I/O modules IG-IOM/IGS-PTM.

Low BackupBatt WRN NO RTC backup battery is flat (battery inside of the controller)

History file The controller stores a record of each important event into the history file. The history file seats 117 records. When the history file is full, the oldest records are removed. Hint: To force history download in LiteEdit (direct, modem or Internet) open History window and select History | Read history command.


Remote control and data logging

Direct connection to the PC The controller can be connected directly with PC via optional IL-NT RS232 interface. Use the standard serial cable to connect PC with InteliLite. Hint: Make sure the grounding system on controller and PC – COM port (negative of the PC DC supply) are identical – before the first direct connection. There must not be any voltage between these two points otherwise the internal reversible fuse in controller burns out. The simple solution is to assure, that the PC supply 240/20V is ground free (GND terminal is not connected).

5 - GND

2 - RxD3 - TxD

PC

5 - GND

2 - RxD3 - TxD

RS2

32

RS2

32

230 VAC

0 VD

C

CONTROLLER

+-Battery

Required the samevoltage potentialbetween GND‘s

RS 232

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 motor • configure the controller • select software configuration • modify alarm inputs and outputs • modify password, commands protections • direct, modem or Internet communication

Modbus protocol The selection of the function of the controller serial port is done via the setpoint RS232 mode in Basic settings • 9600 bps, 8 data bits, 1 stop bit, no parity • Transfer mode RTU • Function 3 (Read Multiply Registers) • Function 6 (Write Single Register) • Function 16 (Write Multiply Registers) • The response to an incoming message is sent with minimum 4.096 ms delay after message

reception The complete description of Modbus communication protocol can be found in Modbus Protocol Reference Guide PI-MBUS-300 and Open Modbus Specification Release 1.0. Both documents are available from web site at http://www.modicon.com/openmbus/ .

http://www.modicon.com/openmbus/


Communication object vs. Register All the data intended for communication has its representation as communication objects in the controller. The communication object is represented by the n-byte array in the controller memory and identified by the unique 16-bit communication object number. The register, according to Modbus communication protocol, represents a two-byte data and in communication functions is referenced by 16-bit register address. Further in the description of communication functions the communication object number will always be used as a register address and length of the communication object will be expressed by number of registers. Just one communication object can be read or written by one communication function. Hint: To obtain communication object numbers it is possible to download the actual controller description on-line from controller or from (ail) archive and use “export data” function from LiteEdit software.


Remote communication Note: Refer to InteliCommunication guide for all additional information.

Internet connection The controller can be monitored from LiteEdit 4.5.4 over the Internet using - Internet Bridge (IG-IB) connected to the controller RS232 port or - IL-GPRS module

Recommended ISDN modem • Askey TAS-200E • ASUScom TA-220ST • Develo Microlink ISDN i

Recommended GSM modem • Siemens M20, TC35, TC35i, ES75, MC39 • Wavecom M1200/WMOD2 • Wavecom - Maestro 20, dual 900/1800MHz. • Wavecom – Fastrack M1306B, dual 900/1800 MHz (Fastrack M1206B is NOT recommended) • FALCOM A2D, dual 900/1800MHz.

GSM Modem setup

Run following program for proper GSM setup, before you start to work with GSM modem. Program writes all the necessary AT commands to configure the GSM modem properly for use with the controller.

This program runs independently on LiteEdit:

• Start MS Windows -> Start -> Program files -> LiteEdit -> Gm_setup.exe. • Select COM port • Select IGS-NT or IG-MU unit • Press Setup button • Follow commands in GSM Modem Setup window

Typical real baud rate for GSM data communication is 80 to 90 Bps. Hint: It is strongly recommended to use the same type of modem on the both sides (controller and PC) of connection.

Mobile SIM card setting • Adjust SIM card in GSM modem following way: • enable data connection (when required) • no PIN code

Analog modem

Analog modem

GSM modem

GSM modem or


Internet connection with IL-NT-GPRS module • Apart of the controller and IL-NT-GPRS module, antenna and SIM card with GPRS are

required. • Contact SIM card operator for getting GPRS APN name, username and password. • Make sure SIM card does not require PIN code. If it does, it is possible to disable it in every

common • mobile telephone. • Power up the ComAp controller. • Enter correct APN Name, APN UserName and APN UserPass in controller’s Comms Settings.

Set • COM1 Mode = DIRECT. • Switch off ComAp controller. • Place the SIM card into slot on IL-NT-GPRS card, plug in the IL-NT-GPRS card into

communication • slot on back side of ComAp controller. • Connect the antenna to designated SMA connector. • Connect power supply to IL-NT-GPRS module. It supports 8-36V DC voltage. • Power up the system. • Wait for approx 2 - 4 minutes for first connection of the system to AirGate. Then navigate to

last of measurement screens where you will find signal strength bar and AirGate ID value.

Once this AirGate ID is displayed, connection via AirGate was successful. This value will be needed for LiteEdit or WebSupervisor connection. AirGate Connection dialog in LiteEdit:


Add new dialog in WebSupervisor:

Should you encounter any troubles with connection, check the fault codes on the same screen and find detailed description in Diagnostic codes tables bellow. Open LiteEdit or enter your WebSupervisor account. Communication is ready to use. Table of Diagnostic Codes:

Code Description 1 Controller registered, waiting for authorization 2 Not possible to register, controller blacklisted 3 Not possible to register, server has no more capacity 4 Not possible to register, other reason 5 Controller registered and authorized


Technical data

Power supply Voltage supply 8-36V DC Consumption 40-430mA depend on supply voltage and temperature Consumption depends on supply voltage 0,104A at 8VDC 0,080A at 12VDC 0,051A at 24VDC 0,044A at 30VDC

0,040A at 36VDC Allowed supply voltage drop-out: 100ms from min. 10V return to min. 8V Battery voltage measurement tolerance 2 % at 24V

Operating conditions Operating temperature -40...+70oC Storage temperature -30...+80oC Protection front panel IP65 Humidity 95% 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/s2

Dimensions and weight Dimensions 180x120x55mm Weight 450g

Current inputs Nominal input current (from CT) 5 A Load (CT output impedance) < 0,1 Ω CT input burden < 0,2 VA per phase (In=5A) Max. measured current from CT 10 A Current measurement tolerance 2% from the Nominal current Max. peak current from CT 150 A / 1s Max. continuous current 12 A

Voltage inputs Measuring voltage range 0 – 277 VAC phase to neutral 0 – 480 VAC phase to phase Maximal measured voltage 340 VAC phase to neutral 600 VAC phase to phase Input resistance 0.6 MΩ phase to phase 0.3 MΩ phase to neutral Voltage measurement tolerance 2 % from the Nominal voltage Overvoltage class III / 2 (EN61010)


Binary inputs and outputs Binary inputs Number of inputs 7 Input resistance 4,2 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 7 Maximum current 0,5 A Maximum switching voltage 36 VDC

Analog inputs Not electrically separated Number of inputs 3 Resolution 10 bits Jumper selectable range V, Ohm(default), mA Maximal resistance range 2500 Ω Maximal voltage range 2.5 V Current range 0 – 20 mA Input impedance 180 Ω for mA measuring Input impedance > 100 kΩ for V measuring Resistance measurement tolerance ± 2 % ± 2 Ω out of measured value Voltage measurement tolerance ± 1 % ± 1mV out of measured value Current measurement tolerance ± 2.5 % ± 0,5mA 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 0,2 %

CAN bus interface Galvanically separated Maximal CAN bus length 200m Speed 250kBd Nominal impedance 120Ω Cable type twisted pair (shielded) Following dynamic cable parameters are important especially for maximal 200 meters CAN bus length and 32 IS-COM units connected: Nominal Velocity of Propagation min. 75% (max. 4,4 ns/m) Wire crosscut min.0,25 mm2 Maximal attenuation (at 1 MHz) 2 dB / 100m Recommended Industrial Automation & Process Control Cables: BELDEN (see http://www.belden.com):

• 3082A DeviceBus for Allen-Bradley DeviceNet • 3083A DeviceBus for Allen-Bradley DeviceNet • 3086A DeviceBus for Honeywell SDS

http://www.belden.com


• 3087A DeviceBus for Honeywell SDS • 3084A DeviceBus for Allen-Bradley DeviceNet • 3085A DeviceBus for Allen-Bradley DeviceNet • 3105A Paired EIA Industrial RS485 cable

LAPP CABLE (see http://www.lappcable.com)

• Unitronic BUS DeviceNet Trunk Cable • Unitronic BUS DeviceNet Drop Cable • Unitronic BUS CAN • Unitronic-FD BUS P CAN UL/CSA

IL-NT RS232 interface Maximal distance 10m Speed 19.2kBd (STD) 9.6kBd (MODBUS) 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

IL-NT AOUT8 interface (optional card) Plugs into IL-NT controller EXTENSION MODULE port. Number of PWM outputs 8 PWM frequency 250Hz Maximum current 0.5 A Maximum switching voltage 36 VDC Output resistance 1Ω Resolution 10 bits

http://www.lappcable.com


List of used abbreviations and expressions

AIN Analog Input BIN Binary Input

BOUT Binary Output CT Current Transformer CU Computer Unit = dimension of value without a physical meaning

ID EM InteliDrive EM LBI, LAI Logical Binary/Analog Input – an internal variable (memory) which can be assigned to

a physical Binary/Analog Input and afterwards can treated by the controller. LBO Logical Binary Output - an internal variable (memory) which can be assigned to a

physical Binary/Analog Output LiteEdit PC program to monitor and set up the controller

SP Set Point – parameter which can be modified in controller or by means of LiteEdit

Documents

Comap InteliDrive EM User Guide v.1.0