AC03 2.

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InteliLite NT AC03
Modular Gen-set Contro ller
Compact Controller for Stand-by Operating Gen-sets

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SW version 2.0, June 2010

# Reference Guide
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Copyright © 2008 ComAp s.r.o. ComAp, spol. s r.o.

Written by Petr Novák Kundratka 2359/17, 180 00 Praha 8, Czech Republic
Customized by František Poupě Tel: +420 2 66316661, Fax: +420 2 66316647
Prague, Czech Republic E-mail: [email protected], www.comap.cz

Table of Contents
Table of Contents .................................................................................................................................... 2
General Guidelines.................................................................................................................................. 5
What describes this manual?.............................................................................................................. 5
!! Warnings !! ....................................................................................................................................... 5
Text ..................................................................................................................................................... 5
General Description................................................................................................................................. 7
Description of the controller system (with all options)......................................................................... 7
What is in the package?...................................................................................................................... 7
IL-NT RS232 Communication module ................................................................................................ 7
IL-NT RS232-485 Communication module ....................................................................................... 11
IL-NT S-USB Service USB communication module.......................................................................... 11
IB-Lite Ethernet communication plug-in card .................................................................................... 12
IL-NT-AOUT8 Gauge driver module ................................................................................................. 13
IL-NT RD Remote display software .................................................................................................. 14
IL-NT-EFCPM.................................................................................................................................... 14
IL-NT-EFCPM2 ................................................................................................................................. 15
Remote announciator IGL-RA15....................................................................................................... 15
IG-IOM/PTM module......................................................................................................................... 16
IG-IB Internet bridge.......................................................................................................................... 17
IL-NT Terminals and front fascia........................................................................................................... 18
IL-NT terminals and front fascia........................................................................................................ 18
Recommended Wiring........................................................................................................................... 19
AMF - Wiring Diagram....................................................................................................................... 19
Stand-by Applications............................................................................................................................ 20
Contactors (set point MCB Logic = “CLOSE-OFF”).......................................................................... 20
ATS with two stable positions (set point MCB Logic = “CLOSE-ON”) .............................................. 20
ATS with three stable positions (set point MCB Logic = “CLOSE-OFF”).......................................... 21
Getting Started ...................................................................................................................................... 22
How to install ..................................................................................................................................... 22
Current measurement ....................................................................................................................... 25
Earth Fault measurement (module) .................................................................................................. 26
Voltage measurement and generator connection types ................................................................... 28
Analog inputs..................................................................................................................................... 31
Extension modules (CAN bus) connection ....................................................................................... 34
Inputs and Outputs ................................................................................................................................ 36
Binary inputs IL-NT - default ............................................................................................................ 36
Binary inputs - list.............................................................................................................................. 36
Binary outputs IL-NT - default .......................................................................................................... 41
Binary outputs - list............................................................................................................................ 41
Analog inputs..................................................................................................................................... 52
Setpoints................................................................................................................................................ 53
Password........................................................................................................................................... 53
Basic Settings.................................................................................................................................... 53
Engine Params.................................................................................................................................. 57
Engine Protect................................................................................................................................... 62
Gener Protect.................................................................................................................................... 64
AMF Settings..................................................................................................................................... 67
Date/Time.......................................................................................................................................... 71
Sensors Spec.................................................................................................................................... 73
Extension I/O..................................................................................................................................... 73
SMS/E-Mail ....................................................................................................................................... 74
Man Operations................................................................................................................................. 76
Alternate Cfg ..................................................................................................................................... 77
ECU-controlled engine support ............................................................................................................. 79
Values read from ECU ...................................................................................................................... 80

NT
InteliLite AC03, SW version 2.0, ©ComAp – June 2010 2
AC03-2.0 Reference Guide.pdf

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Diagnostic messages read from ECU............................................................................................... 80

Analog inputs..................................................................................................................................... 81
Connection description...................................................................................................................... 81
Sensor Specification.............................................................................................................................. 84
Background of the sensor calibration................................................................................................ 84
Default sensor curves ....................................................................................................................... 84
Function Description.............................................................................................................................. 85
OFF Mode ......................................................................................................................................... 85
MAN Mode ........................................................................................................................................ 85
AUT Mode ......................................................................................................................................... 87
TEST mode ....................................................................................................................................... 87
Circuit breakers timing ...................................................................................................................... 88
Alarm Management ............................................................................................................................... 90
Sensor Fail (FLS) ............................................................................................................................. 90
Warning (WRN)................................................................................................................................. 90
Breaker open and cooling (BOC)...................................................................................................... 90
Shut down (SD)................................................................................................................................. 90
Mains failure (MF) ............................................................................................................................. 90
Voltage phase sequence detection................................................................................................... 91
Gen-set Operation States...................................................................................................................... 93
List of possible events....................................................................................................................... 93
History file.......................................................................................................................................... 96
User Interface ........................................................................................................................................ 97
Operator Interface AMF......................................................................................................................... 98
Display Screens and Pages Structure ............................................................................................ 100
Alarms ............................................................................................................................................. 101
Browsing ECU Alarms..................................................................................................................... 101
Earth Fault Protection Test ............................................................................................................. 101
Setpoint Change ............................................................................................................................. 102
Entering the Password .................................................................................................................... 102
Controller Information Screen ......................................................................................................... 103
Display Contrast Adjustment........................................................................................................... 103
Remote Control and Data Logging...................................................................................................... 104
Direct connection to the PC ............................................................................................................ 104
PC software - LiteEdit ..................................................................................................................... 104
Modbus protocol.............................................................................................................................. 104
Remote Communication ...................................................................................................................... 112
Internet connection.......................................................................................................................... 112
SMS Message Control .................................................................................................................... 112
Recommended ISDN modem ......................................................................................................... 117
Recommended GSM modem.......................................................................................................... 117
Mobile SIM card setting................................................................................................................... 117
IL-NT-RD Remote display software..................................................................................................... 118
General description......................................................................................................................... 118
Warning ! ......................................................................................................................................... 118
IL-NT-RD Software installation........................................................................................................ 118
IL-NT-RD Wiring.............................................................................................................................. 119
Function description........................................................................................................................ 121
SW compatibility.............................................................................................................................. 121
Maintenance ........................................................................................................................................ 122
Backup battery replacement ........................................................................................................... 122
Technical Data..................................................................................................................................... 124
Inputs/Outputs overview.................................................................................................................. 124
Generator protections ..................................................................................................................... 124
Power supply................................................................................................................................... 125
Operating conditions ....................................................................................................................... 125
Dimensions and weight ................................................................................................................... 125
Mains and generator ....................................................................................................................... 125
Binary inputs and outputs................................................................................................................ 126
Analog inputs................................................................................................................................... 126

NT
InteliLite AC03, SW version 2.0, ©ComAp – June 2010 3
AC03-2.0 Reference Guide.pdf

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Speed pick-up input ........................................................................................................................ 126

D+ Function..................................................................................................................................... 126
CAN bus interface ........................................................................................................................... 126
IL-NT RS232 interface (optional card) ............................................................................................ 127
IL-NT RS232-485 interface (optional card) ..................................................................................... 127
IL-NT S-USB interface (optional card) ............................................................................................ 128
IL-NT-AOUT8 interface (optional card)........................................................................................... 128
IL-NT-EFCPM interface (optional card) .......................................................................................... 128
IL-NT-EFCPM2 interface (optional card) ........................................................................................ 128
IGS-PTM ......................................................................................................................................... 129
IGL-RA15 ........................................................................................................................................ 129
IG-IB ................................................................................................................................................ 130

NT
InteliLite AC03, SW version 2.0, ©ComAp – June 2010 4
AC03-2.0 Reference Guide.pdf

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supplies
Solution for your business

Varieties of nominal output voltage with

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General Guidelines
What describ es this manual?

This manual describes „AC03“ software, which is designed for single set, stand-by applications.
What is the purpose of the manual?
This manual provides general information how to install and operate InteliLite NT AC03 controller.
This manual is dedicated for
Operators of gen-sets
Gen-set control panel builders
For everybody who is concerned with installation, operation and maintenance of the gen-set

!! Warnings ! !

Remote contro l
InteliLite controller can be remotely controlled. In case of the work on the gen-set check, that nobody
can remotely start the engine.
To be sure:
Disconnect remote control via RS232 line
Disconnect input REM START/STOP
or
Disconnect output STARTER and outputs GCB CLOSE/OPEN and MCB CLOSE/OPEN
NT
Because of large variety of InteliLite parameters settings, it is not possible to describe any
combination. Some of InteliLite functions are subject of changes depend on SW version. The data in
this manual only describes the product and are not warranty of performance or characteristic.

Text

PAGE (Capital letters in the frame) buttons on the front panel

Break Return (Italic) set points
Generator protections (Bold) Set point group
REMOTE START/STOP (Capital letters) binary inputs and outputs
IL-NT-EFCPM2 (Yellow background) new features and text changed from version 1.0

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 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.

NT
InteliLite AC03, SW version 2.0, ©ComAp – June 2010 5
AC03-2.0 Reference Guide.pdf

WARNING – VERY IMPORTANT !! !

Every time you want disconnect following InteliLiteNT controller terminals:

! Mains voltage measuring and / or

! Binary output for MCB control and / or
! MCB Feedback

Switch InteliLite to MAN or OFF Mode or disconnect the Binary outputs Starter and
Fuel to avoid unexpected automatic start of gen-set and GCB closing.

!!! CAUTION !!!

Dangerous voltage
In no case touch the terminals for voltage and current measurement!
Always connect grounding terminals!
NT
In any case do not disconnect InteliLite CT terminals !

Ad ju st set poin ts
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 follow ing instr uctions are for qualified personnel only. To avoid personal injury do
not perform any action not specified in this User guide !!!

NT
InteliLite AC03, SW version 2.0, ©ComAp – June 2010 6
AC03-2.0 Reference Guide.pdf

General Description
Description o f the contr oller system (with all opt ions)
NT
InteliLite AC03 is a comprehensive AMF-controller for single generating sets operating in stand-by

$
mode. IL-NT AC03 features extended support of electronic engines and extension modules.

Download now
NT
InteliLite controllers are equipped with a powerful graphic display showing icons, symbols and bar-
graphs for intuitive operation, which sets, together with high functionality, new standards in Gen-set
controls.
NT
InteliLite automatically starts the Gen-set, closes the Gen-set C.B. when all conditions are met, then
stops the engine on external signal or by pressing push buttons.
NT
InteliLite provides gas engine support without ventilation.
NT
The key feature of InteliLite is its easy-to-use operation and installation. Predefined configurations
for typical applications are available as well as user-defined configurations for special applications.

What is in the package?

Accessories Description Optional / Obligatory

NT
IL-NT-AC03 InteliLite central unit Obligatory
IL-NT-RS232 RS232 communication card Optional for AC03
IL-NT-RS232-485 RS232 and RS485 communication card Optional for AC03
IL-NT-S-USB Service USB communication card Optional for AC03
**IB-Lite Ethernet communication card Optional for AC03
**IL-NT-AOUT8 Gauge driver plug-in card Optional for AC03
*IL-NT RD Remote display software Optional for AC03
IL-NT-EFCPM Earth Fault Current Protection Module Optional for AC03
**IL-NT-EFCPM2 Earth Fault Current Protection Module Optional for AC03
IGL-RA15 Remote annunciator Optional for AC03
IG-IOM/PTM I/O extension module Optional for AC03
IG-IB Internet communication bridge Optional for AC03
AT-LINK-CONV Service programming RS232 interface Optional for AC03
AT-LINK-CABLE Serial RS232 communication cable 1,8m Optional for AC03

*Remote display for IL-NT controllers uses standard IL-NT controller with Remote display software.
**Supported from version IL-NT-AMF26-P-2.0.

Hint:
For detailed information about extension modules used with IL-NT controllers, please see the IL-NT-
Accessory Modules manual.

IL-NT RS232 Communication module

NT
IL-NT RS232 is optional plug-in card to enable InteliLite for RS232 communication. This is required
for computer or Modbus connecting. Card inserts into expansion slot back on the controller.
To insert the module, you must open the cover first (use screwdriver to open) and then insert the
module into slot. Once you have insert it, the module will snap under plastic teeth. It is supposed to be
installed permanently. Should you need to remove it, the safest way is to remove whole back cover
and then remove module manually.

NT
InteliLite AC03, SW version 2.0, ©ComAp – June 2010 7
AC03-2.0 Reference Guide.pdf

How to install RS 232 communication module:

Hint:
The following procedure is analogic also for other communication modules.

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.

NT
InteliLite AC03, SW version 2.0, ©ComAp – June 2010 8
AC03-2.0 Reference Guide.pdf

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

5. Take RS 232 communication module.

NT
InteliLite AC03, SW version 2.0, ©ComAp – June 2010 9
AC03-2.0 Reference Guide.pdf

6. Plug RS 232 communication module into the slot of the controller.

7. Put back the small cover.

Hint:
When you insert RS 232 communication module, the boot jumper is hidden. For that reason we
recommend to use RS 232 communication module with the boot jumper placed on it. See pictures
below:

RS 232 communication module with the boot jumper.

NT
InteliLite AC03, SW version 2.0, ©ComAp – June 2010 10
AC03-2.0 Reference Guide.pdf

IL-NT RS232-485 Commun icati on mod ule

NT
IL-NT RS232-485 is optional plug-in card to enable InteliLite the RS232 and RS485 communication.
This is required for computer or Modbus connection. Card inserts into expansion slot back on the
controller. The IL-NT RS232-485 is a dual port module with RS232 and RS485 interfaces at
independent COM channels. The RS232 is connected to COM1 and RS485 to COM2.

To insert the module, please follow the instructions for IL-NT RS232 module, procedure is analogous.
You must open the cover first (use screwdriver to open) and then insert the module into slot. Once you
have inserted it, the module will snap under plastic teeth. It is supposed to be installed permanently.
Should you need to remove it, the safest way is to remove whole back cover and than remove module
manually.

RS485 RS232

Boot jumper
RS485 Terminator jumper

IL-NT S-USB Service USB communication module

NT
IL-NT S-USB is optional plug-in card to enable InteliLite communication via USB port. This is
required for computer or Modbus connecting. Card inserts into expansion slot back on the controller.
To insert the module, please follow the instructions for IL-NT RS232 module, procedure is analogous.
You must open the cover first (use screwdriver to open) and then insert the module into slot. Once you
have inserted it, part of the module will remain over plastic box. It is supposed to be used as a service
tool. When you need to remove it, grab module in cutouts and pull it up manually.

NT
InteliLite AC03, SW version 2.0, ©ComAp – June 2010 11
AC03-2.0 Reference Guide.pdf

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Hint:
Use the shielded USB A-B cable with this module! Recommended is ComAp cable – Order code:
“USB-LINK CABLE 1.8M”.

IB-Lite Ethernet communication plug-in card

IB-Lite is a plug-in card with Ethernet 10/100 Mbit interface in RJ45 connector. The card is internally
connected to both COM1 and COM2 serial channels and provides an interface for connecting a PC
with LiteEdit or InteliMonitor through ethernet/internet network, for sending active e-mails and for
integration of the controller into a building management (Modbus TCP protocol).
This card also enables to monitor and control the genset over web browser from any location with
internet access using appropriate security measures.

Card inserts into “extension module” slot back on the controller. To insert the module, please follow
the instructions for IL-NT RS232 module, procedure is analogical.

Use Ethernet UTP cable with RJ45 connector for connection of the module into your ethernet network.
The module can be also connected directly to a PC using cross-wired UTP cable.

NT
InteliLite AC03, SW version 2.0, ©ComAp – June 2010 12
AC03-2.0 Reference Guide.pdf

Hint:
Modbus TCP protocol using IB-Lite communication module requires setting COM1 Mode = DIRECT
and COM2 Mode = MODBUS.

Hint:
The module requires some settings before initial usage. See IB-Lite-1.2-Reference Guide.pdf for more
details about IB-Lite communication plug-in card.

IL-NT-AOUT8 Gauge dri ver module

IL-NT-AOUT8 is optional plug-in card. Through this card controller can drive up to 8 VDO style
industrial/automotive gauges. Noncompensated gauges like 0-10V or 0-20mA are not supported.
Gauge type and value are configured in LiteEdit software. Any analog value from controller may be
shown in that way.

To insert the module, you must open the cover first (use screwdriver to open) and then insert the
module into slot. Once you have insert it, the module will snap under plastic teeth. It is supposed to be
installed permanently. Should you need to remove it, the safest way is to remove whole back cover
and than remove module manually.
Installing IL-NT-AOUT8 module is similar to installing RS 232 module. The difference is that IL-NT-
AOUT8 fits to “extension module” slot and after installing IL-NT-AOUT8 you do not put back the small
cover.

PC Installation Suite consist a set of prepared converting curves for basic usage of PWM outputs with
automotive gauges.

IL-NT-AOUT8 module:

NT
InteliLite AC03, SW version 2.0, ©ComAp – June 2010 13
AC03-2.0 Reference Guide.pdf