Troubleshooting guide
Contents
1. GM_SETUP EXE supported with WE to configure GSM only modem for operation with IG CU IS CU or iL CU Make sure the following GM setup tick is selected only when IG MU version below 1 8 is used M Modem will be used with old version iG MU below 1 8 After GSM setup check if baud rate was configured to 9600 bps in GSM Modem Setup window standard setting Modem communication of Inteli controllers IG MU and IG IB is based on full modem cable connection where all handshaking signal DCD RTS CTS are active and connected Inteli controllers and IG MU IG IB automatically detect modem connection via RS232 DSR Data Send Ready signal Controller detects modem when is DSR active and direct connection when passive or not connected Make sure all signals are connected and activated in modem when it is not possible to open connection How to set the telephone number and the Gen set name It is possible via WinEdit software only Troubleshooting Guide ComAp August 2005 15 IG 6 2 IS 3 4 Troubleshooting Guide pdf Z omap GSM modem connected warning call shut down slow down enabled Act calls enabled SMS enabled SMS function properly but modem data call to WE is not performed The phone number for data calls is not set correctly must be in international format or the SIM card in GSM modem has not allowed data transfer This special feature must be mostly activated by the provider separately Co2. Select WinEdit menu Controller gt Reset How to check the configuration of IG In measurement press ENTER together with PAGE to select the Info screen or Detail IG inputs and outputs configurations see in WinEdit e Select WinEdit menu Controller gt Software configuration gt Modify e The other way is to export data Controller gt Export data You can store the configuration as a Microsoft Excel XLS file How to check the configuration of IS In measurement press ENTER together with ALARM LIST buttons to select the Info screen Troubleshooting Guide ComAp August 2005 6 IG 6 2 IS 3 4 Troubleshooting Guide pdf Yeomac Controller Mode cannot be changed from OFF Check the binary input REMOTE OFF If closed the mode cannot be changed using buttons IMODE lt jor MODE gt Controller mode changes itself When only one common speed pickup is used for speed governor and controller take care of interference signal not disturbing IG functions When some problems occur e Check ground connection from pick up to the governor and controller alternatively disconnect ground connection of the governor or controller e When Cummins EFC speed governor is used connect 4u7 50V capacitor to EFC power supply terminals 1 2 e Galvanically separate G RPM input using separation transformer 1 1 e Use separate pick up for the speed governor and IG Cont
3. list and history file for Alarm reason When power cut comes gen set does not start Check if AUT mode is selected Check if REMOTE OFF binary input is activated close or open according to the configuration have lost the IG Password and or Access code Read on WinEdit Values group IG info the values of PasswordDecode and AccessCdDecode Please send these two values and the serial number of the unit to ComAp Troubleshooting Guide ComAp August 2005 7 IG 6 2 IS 3 4 Troubleshooting Guide pdf Z omap It is not possible to remove catches to take controller out from switchboard Carefully remove front panel rubber seal to extend the gap RPM measuring Pickup signal Controller indicates Sd Underspeed Pickup fault after engine start when the pickup signal is good for start and low speed but too big for higher speed lost of signal due to RPM input saturation Increase gap between pickup and engine flywheel or change type of pickup RPM measuring RPM input does not work IG displays RPM value 0 e ForRPM measuring from the speed pickup must be the setpoint Basic setting Gear teeth greater than 0 e The distance between the RPM sensor and teeth must not be too large follow the pickup specification e Check the speed pickup wiring Controller detects RPM on no running gen set e RPM is measured from the generator voltage Gear teeth 0 e Generator voltage terminals are opened e g due to open
4. AN ANNARRA En ARRAN NNAK RNA 13 Controller looks dead after interruption during reprogramming ccceeceececeeeeeeeeeeeneeeeseeeteeeeeenaeees 13 Unsuccessful IS programmMing ccccccceecceeeeeeeeneeeeeenneeeeeeeeeeeeaaeeeeeeaeeeeeeneeeeeeaeeeeseneeeeensnaeeeeeaes 13 History stops recording eee 13 Unsuccessful programming MCSSAQE eecceee cence ee etee eect eee eset eae ee ee taaeeeeeeaeeeeeeaaeeesseaeeeeesiaeeeeeeaes 13 How to open default archive in OFF line CONNECTION cccccceceeeeeceeceeeeeeeeeeteenaeaeeeeeeeeeeseesnaeeeeees 13 How to change PC COM port before opening CONNECTION ce cceeeeeee eee eeteee ee ttteee ee teeeeeetnteeeerene 13 How to open default archive in ON line connection ecceceececeeeeeeeceeeeeeeeeetetecaaaaeceeeeeeeseesncaeeeeees 13 can t open communication to gensets group cceeeceeeeeeeeeeeneeeeeeeeneeeeeeaeeeseeaeeeeesieeeeeeenieeeeseaas 13 When WinEdit is started from MultiEdit with entered password the password symbol is gray and no protected functions are enabled ccccccececeeeesecceeeeeeeeeeecaeeeeeeeeeeeescacaeeeeeeesesecsacaeeeeeeeeeeseesieeeeeees 14 In WinEdit Open connection window there are no Sites ViSiIDI ccccceeecceeceeeeeeeeeeeeceeeeeeeeeees 14 WinEdit History in on line connection does not correspond to the history in controller 0 06 14 The display shows Configuration t
5. Compact Controller for Stand by and Parallel Operating Gen sets ComA InteliGen p InteliSys Software version IG 6 2 IS 3 4 August 2005 Troubleshooting guide ComAp spol s r o Copyright 2005 ComAp s r o Sv tova 7 180 00 Praha 8 Czech Republic Written by Ladislav Kadanik Tel 420 2 66316661 Fax 420 2 66316647 Prague Czech Republic E mail info comap cz www comap cz Table of Contents Table Of Comte nts enner n tbaa etal a ets eg aa rea etapa ae ieee 2 TROUDIGS 2 fegeacthcsuatectvedacetiesdaeeSotaceg et dsuca etetbutieet blawae eon cated eirte dane eadadea ei aap et bcaet et tavdap eet te eeailap et eadat etd ieee ace 5 Interference and over voltage transient protections sssesesrsesssrnsseeennanrsnnantennannannaneennaanannantennaanannaaaenn 5 Power supply input could be damaged if cccccccceceeeeeeeececeeeeeeececeneaeceeeeeeeesesecaeaeeeeeeesetecneneeeeeeess 5 Binary Output could be overloaded if cceeeceeeecceceeeeeeeceeaeceeeeeeeeeececaaeaeeeeeeeseeecaeaeeeeeeeeeesecsneeeeeess 5 Binary Input could be burned if c cccccceeeseeeeecceceeeeeeceeeceaeeeeeeeeeseceaaaeaeeeeeeeseseceaeaeeeseeeeeeeenieeeeeeeess 5 Analogue Output could be overloaded if ccccccceeeeeeeeeeeceeeeeeeeeceaaeeeeeeeeeseceneaeeeeeeeeeseceaaeeeeeeeeeneees 5 Analogue Input could be disturbed if cccccccceceeeeeeene eect eeeeeeeeeceeaaeeeeeeeeeseceaeaeeeeee
6. E server messages Timeout continuous Connected IG controller does not answer to DDE server request Probable reasons e IG controller is not connected Wrong communication cable IG controller failure Different controller address in IG and DDE server is adjusted Wrong PC COM port adjusting Wrong setting of Basic settings RS232 mode setpoint Standard Modbus Damaged IG RS232 port check PC IG ground connection Timeout sometimes Occasional timeouts can be caused by your operating system It is recommended to use Windows NT instead of Windows 9x for industrial purposes TAPI requested modem not found Modem is not configured in Windows or it has not required parameters TAPI unavailable modem Communication port is engaged by other communication device TAPI Line unexpectedly closed Modem is configured in Windows but it is not connected or it is failed TAPI Can t create connection It is not possible to open connection Probable reasons e When ringing is audible during start of the connection o On the selected phone number is incompatible type of modem e When engaged tone is audible during start of connection o Selected phone number is engaged o DDE server is connecting to itself when call his own number e When no tone is audible Troubleshooting Guide ComAp August 2005 14 IG 6 2 IS 3 4 Troubleshooting Guide pdf Z omap o Phone line is not connected to the Modem Connected Modem d
7. Multiple gen set applications ececcceeccececeeeeececeae cece eee ee seca eaaeceeeeeeesecaaaeceeeeeeeeseeecaeaeeeeeeesesecaeeeeeeeeeetees 9 Temporary generator voltage increasing or decreasing ccceeeceeeeeeeeeeeeneeeeeteeeeeeeteeaeeeteeeaeeeteeaeeees 9 The IG and or IS and or InteliMains are reset continuously ececceeceeeee cence teens eeeeeeteeeeeseaeeeeeaeeees 9 What is the sequence of GCB closing when more engines starts at once to the dead bus 10 The system reserve does not correspond to the number of running engines ceeeeeeeeereees 10 Power and PF sharing does not operate Well cccececcceeeeeeteeeeeeneeeeeeeaeeeeeecaeeeeeeaeeeeeenaeeeeeeenaeeeeeeaas 10 Two or more engines starts and stops at the same tiME 0 ee cece eeeeeee ee eeeeeeeeteeeaeeeseeaeeeeeeeaaees 10 Setpoint replication does Not WOKK ccecccceceeeeeceeneceeeeeeeeeeceeaaeeeeeeeeesecccaaeceeeeeeesecseaeeeeeeeeeesnenaeess 10 Binary outputs SYSTEM READY and SYSTEM RES OK do not operate ccccesseeeeseeeteeeeees 10 How to check proper CAN bus CONNECTION ccccccceeceeeeeeeeceeceeeeeeeeecaeaeeeeeeesesecaeaeeeeeeesessnniaeeeeees 10 How to check actual IG MU SW Version ss seeesrrnidirnneeiii inneni isknnni iin nedei niin NEAN NENNEN AA AANKAN KANANEN REENEN 10 CAN bus connection problemS ceccececcece cece eeeeeeaaeeeeeeeeececeeaaeeeeeeee
8. able error ssssseeserrenssrnnreenndannnnaantennannannaneennaanannaaetnnaannannaneena 14 DDE servor MESSAGES ssronci trekini nni aR ETERNE AR O 14 Timeout GOMTIMUOUS keesissr riar N E tescanedeocnndeaebef eves 14 Timeout SOMOUIMES 2 522 ss eceectescceet Sec ee R E E R 14 TAPI requested modem not found 0 2 eect cette ee eeeeee eee teneeeeeteeeaeeeeeeeaeeeseeeaeeeseeeaeeeeeeaeeeeeeeaaees 14 TAPI Unavailable MOGeM wraiiccccccssaccuccereccacasaainaccetecdcccssaavaccatacedeasaadeasiedeadacevasuwanganhacenadeasadacensadecassancacs 14 TAPI Line unexpectedly closed 0 00 eee cecceeee cence ee eeeeeeeeeeeeeeeeeeeeeeeeseeaeeeeeeeaeeeseeeaeeeseeeaeeesenaeeeseeaeees 14 TAPI Can t create CONNECTION cecceeceececneceeete eee eeeeeeeeeeceeeeeeeceeeaeaeceeeeeeseseqeaeaeeeeeeeeesenencneeeeeeeeeees 14 Connected Modem does not operate ccccccceeceececeeeeeeeeeeceneaeeeeeeeeeseceacaeeeeeeeseeeecseceeeeeeeerseennaeess 15 Troubleshooting Guide ComAp August 2005 3 IG 6 2 IS 3 4 Troubleshooting Guide pdf ComAp Connected Terminal does not operate cccccceeccececeeeeeeeceeeaeceeeeeeeeseccaaeceeeeeeesecseceeeeeeeeeeeennnaeess 15 Wrong ACCESS COE ceceeeeeee scence ee eeeeeeeeeeeeeeeeeeee ees aeeeeeceeeeeeseaeeeeeeeeaeeeseeeaeeeseeeaeeeseeeaeeesnaeeeseeaeees 15 Multiple IG controllers CONNECTION ccccceeeeeeeeceeceeeeeeeeeeceacaeceeeeeeesecacaeeeeeeeseseccan
9. aeeeeeeeeeeseciaeeeeeess 15 NV RAM GMOT ccciteccseratvecscadukernessttuanvasuran ceesaean EA aaa E EAKA ETE AEE a r Ka a aaa arana aaae a eiA 15 It is not possible to open Active call connection ssssssesrrenssssrtrrrrtnsttesttttntnnsttttttnn tenent tt nnmnnn nennt 15 GSM Modem connection SMS ccceccceecceceeeeeeeeeeeaeceee cece seceaaaeceeeeeeescacaeeeeeeesesecsaaeeeeeeeeeeseesueeeeeees 15 It is not possible to get any connection data SMS with controller through GSM modem 15 How to set the telephone number and the Gen set NAME ccccceeesecceeeeeeeeeeeeceneaeeeeeeeeeteeeseaeees 15 GSM modem connected warning call shut down slow down enabled Act calls enabled SMS enabled SMS function properly but modem data call to WE is not performed c eeee 16 Controller does not respond to SMS messages eeseessssssseerresssnnanttnnaannnnnntennaanannaattnnaanaannaatennaanannaae 16 Troubleshooting Guide ComAp August 2005 4 IG 6 2 IS 3 4 Troubleshooting Guide pdf ComAp Troubles Term Controller in following text means InteliGen or InteliSys controller Interference and over voltage transient protections Protection is always an issue for sensitive electronic devices InteliGen and InteliSys controller has various protections against interferences according to to international standards If interferences are too high then the controller cou
10. antity is out of range tolerance as shown in the specs e 220 Vac voltage is appled directly to the terminals Analogue Output could be overloaded if e External voltage supply to the analogue output is connected Please refer to the manual the output load must be resistive Analogue Input could be disturbed if e Please refer to the manual the signal source must be a resistive or current sensor only RPM Input could be disturbed if e Induced interferences through RPM input coming from pickup signal Use RPM ISO or signal doubler MSP 6732 Please refer to the manual Load sharing line is not working e Use shielded and twisted wire as recommended in the specs e Connect only one shield from one cable to the terminals e Separate signal cable from power cable Troubleshooting Guide ComAp August 2005 5 IG 6 2 IS 3 4 Troubleshooting Guide pdf ComAp CAN Bus line is not working e Use shielded and twisted data cable as recommended in the specs e Connect CAN bus shielding in one point only e Terminate both ends with 120 Ohm resistors e Separate signal and data cables from power cables General IG controller works but displays fix strange code Front panel buttons are not active Upgrade IG firmware to version at least 5 3 or higher Often IG display refreshing The bar graph limits and displayed values are refreshed due to active Power derating function The controller display is
11. ceeceee cence eee eeee eect eeaeeeeeetaeeeeeeaeeeeeeeaas 8 Controller measures wrong values from current output SENSOM c ee eeeeeeeeeee eect eeteeeeeeeneeeeeenaeeeeeeaas 8 Power meas trih tecccncstedeinaacdenanieds ctneedadindeiacnediennds EEE AEN NEE A iA 9 Active and reactive power measurement shows unlikely valuesS ssssseesseerrssseerrssrrrrsserrrssrerrssreenn 9 Wrong mains or bus voltage and frequency measuring ccecceeeeeeeeeeeeeeeeeee teens ee taeeeee teaser tneeeeees 9 Controller does not measure generator current es sssssssserrsssssrnnstennantannnntennaanannaneennaanannaaeennadaaana anann 9 Maximal current of the analog output on IG IOM cannot reach 20 MA ee eeeeeeeeneeeeeeenteeeeeeneeeeeeaas 9 cannot find a neutral current measurement in SPtM ooo cece ee eeeeeeeeeeeeeeeeseeeeeeeeseeaeeeeeeaeeeeeeaaees 9 Generator overcurrent protection does not reQct ccccceeececceececeeeeeeeeceeeaeceeeeeeesecsacaeeeeeeeeeesetsenaneeeess 9 GS Stee re RIC se eae cpa acces sete cues E db aacens it sadecnevsgadeenesnces diuacecushbacenpasbade devia cedenta A 9 Troubleshooting Guide ComAp August 2005 2 IG 6 2 IS 3 4 Troubleshooting Guide pdf After MCB closes MCB fail is detected 0 ee eceeeeceeeeeeeeeeeeeeeeeeneeeeeeeneaeeeseneaeeeseneaeeeseneaeeeseeenaeeesaaeees 9 Although maximal current is adjust by pot IG displays low power ValUC ccceceeeeeeeeeenteeeeeeaees 9
12. dark Check the controller supply voltage connection level and polarity Supply is OK display is still dark Previous loading of firmware was aborted Start WinEdit Open the connection and follow instructions in WinEdit manual chapter Firmware upgrade Unsuccessful programming Low level programming When Low level programming does not work see Controller looks dead after interruption during reprogramming IG screens returns to the Main measure screen It is O K IG screen auto switch function activates 15 minutes after the last key press Controller works properly but display is empty When controller display is back illuminated the display contrast might be very low Wait at least 15 min from the last touch of any front panel button to be sure that controller returns to the Main measure screen Then press ENTER together with A button until you reach required contrast IS screen is dark Display back light is automatically switched off after 15 minutes after the last key press to prolong light source live Touch any button to light the display Unexpected behavior after firmware upgrade Check if firmware version application and SW configuration correspond to real Switchboard connection Check proper setpoints adjusting Controller remains in the Init state Setpoints checksum error was detected after switch on Change at least one setpoint e g Mode and switch IG off and on again or
13. ected Is ticked Connection via IG MU in Open connection window Are all Controller addresses correctly adjusted the same in WinEdit and in controllers Any wrong adjusted address blocks group communication Troubleshooting Guide ComAp August 2005 13 IG 6 2 IS 3 4 Troubleshooting Guide pdf Z oman When WinEdit is started from MultiEdit with entered password the password symbol is gray and no protected functions are enabled It can take up to one minute till the password is verified especially when WinEdit is started in the DDE Server Preparing state In WinEdit Open connection window there are no sites visible Check sites directory settings WinEdit Options Settings WinEdit History in on line connection does not correspond to the history in controller Open the WinEdit History window and force history re reading by selecting WinEdit menu History gt Read history The automatic history reading after opening connection can be activated by ticking check box Always read history after opening connection in WinEdit menu Options gt Setings gt History The display shows Configuration table error Previous loading of Software configuration application archive was aborted but IG controller is still able to communicate to DDE server Download application archive once more open the connection select WinEdit menu Controller gt Software configuration gt Select gt Write to IG DD
14. ed and it is not possible change it Some setpoints couples have consequent limits It is not possible to adjust setpoint when the second one is out of limits random value due to archive upgrade Use WinEdit function Setpoint Import alternative setpoints for default archive values import Not enough memory for InteliSys external modules configuration Remove default VDO sensor characteristics which are not used Some set points groups have a yellow background Yellow background indicates the setpoints which are out of limits Change these values to be within limits How find out the setpoints limits When cursor is placed on the setpoint value the limits appear on the bottom of the setpoints window It is not possible to configure IS Programmable functions Use PLUS application archive Controller malfunction after a new application download Check new configuration your configuration maybe differs from default archive Always save your archive before upgrading to the new one WinEdit MultiEdit Before the first direct connection 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 PTC protection activates and interrupts RS232 communication resistor in older types controller burns out The simple solution is to assure that the PC supply 240 20V i
15. eeeeeeeaeeeseneaeeeseeaaeeeseeaaeeeeeeaas 6 Controller remains in the Init State 2 cc cece ce eee eete ee erent eee erent ee eee aeee E A AE 6 How to check the configuration Of IG eee eeeere ee a EAE 6 How to check the configuration OF IS eee eesriie inan EEE REETA 6 Controller Mode cannot be changed from OFF esssesssssssseernasssnnasesnnaannnnantennannannaaednnaanannnaaeenndanannaaeen 7 Controller mode Changes Hel ois cc ssce se evedeveiedetensiasceteeenede ered E E EOE 7 Controller doesn t stop the engine on any alarm although it reports it in the Alarm list 7 No response on Start Stop KeyS ccccccceceeeeeeeeneeceeeeeeeeeceaaecaeeeeeeesesnaaeaeeeeesesesecaeaeeeeeeesessnniaeeeeeess 7 Controller is in the Not ready state and Alarm list is empty cceeeceeeeeeenteeeeeeeteeeeeeeaeeeeeetaeeeeeeeaas 7 MCB fail is reported although the MCB feedback iS OK c ce ceccceeeeeeeeeeeeecneeeeeenieeeeeeneeeentnaeeeeneaees 7 Controller does not close GCB in MAN or AUT mode eessesssssreseernasssnnaseennannannanetnnaanannnatennadnnannaaeen 7T Some setpoints cannot be Changed cccccccesescccceeeeccneeseseceeeeeeseaeeesnseneeesuseaeeeseseneaeeeneaaeeeeesensentecee 7 No Time stamp history record is written in the IG history occ cence center eeeeaeeeeeetaeeeeeenaeeeeeeeaas 7 IG front panel red LED on the gen set side lights or blinks 0 00 2 eceeeeeeeeeeeeeeeeeeeeeeeeeee
16. eeesecniaeeeeeeeeeneees 5 RPM Input could be disturbed if ccccceseseseseseseeeseseseseseseeeeeeseseseseeeseseseseseeseseeeseseseseseseeeeeeeeees 5 Load sharing line is not working oo eeeeeeeeeeeeee ee eeeeee ee eeee eter eeeeaeeeeeeaaaeeeeeeaaeeeeeeaaeeeeeeaeeeeeeceeeeseieeeseeaes 5 CAN Bus line is NOt working 0 eeceee eect eeette ee errr t ee errr ee ener eee ee erate entree ee ee naaeeeeeeaeeeesnaeeeeeenaes 6 GTN T A ase E as ce aceasta eae eee seh ee ee ee ee ee ed 6 IG controller works but displays fix strange code ceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeaeeeseeeeeeseeaeeeseeaaeees 6 Often IG display refreshing 0 cece nt rn ee eee err e ee etn ne ee ee nieee ee naeeeeeeaeeeeeecaeeeseeaas 6 The controller display iS dark 0 ccccceeceeeeeeeeeneee eee ee erties tutant ee eee Eu AAA EE ANAE ee teee ee eaeeeeesnieeeeesneeeeee 6 Supply is OK display is still Gark ccccccccceeeeeeeeeee cece cece eeeeeeaaeeeeeeeeececeaaaeceeeeeeesecaaaaeaeeeseetecsuaeeeeeess 6 IG screens returns to the Main measure Screen 00 0 cece cece ee eeeeeeeeeeeeeeeeeeneeeeeteneaeeeseeeeeeeeseeaeeeteenanens 6 Controller works properly but display is empty 0 ccceeeceeceeceeeeeeeeeeeeecaeceeeeeeeseccacaeeeeeeesesensiaeeeeeess 6 S screen 1S GaK recco corii iEn EEE NE EEEE EEEE AAEE AAEE EEE 6 Unexpected behavior after firmware upgrade cccceeeceeeceeeeeee sence eeeeeeee
17. ees 11 AVR output is at the end position 0 or 100 not only during the transients SPtM or MINT only 11 PF or PFS control does not operate welll c ccccccceeeceeececece cece ee teeeeceaeaeeeeeeeeeceneaneeeeeeeesetenesinaeeeees 11 Controller setting and CONFIQUIAtION 0 0 cette tenet eee ee ee te nian REENEN ENNEA ERENNERT EEEE ERES 11 IS configuration Impor eeina een aaa tiles NEEE wenden neue 11 What means InteliSys message SD BINx SD BOUTX SD AINX 0 0 eececeeceececeeee tree eeceeeeeeeteeeeeeneaes 12 It is not possible to change SetpOint cccccccccceeeeeeeeeeeaeeeeeee iai aaa aa a aA 12 Not enough memory for InteliSys external modules Configuration ceceeeeeeeeeeeeeeeeteeeeeeneeeeeeaes 12 Some set points groups have a yellow background 0 0 0 0 eeeeceeeeeeceeeeeeeeeeeeeeeeeeeeeeeeeseeeaeeeeeeaaeeeseeaaeees 12 How find out the Setpoints IMIS sinss nisihi a a EEA 12 It is not possible to configure IS Programmable functions eeeessssseesesreeseerreseerresernssrrtrnssrrrnssrnens 12 Controller malfunction after a new application download ccccceeeeeeeeceeceeeeeeeeeeeecaecaeeeeeeesetenaees 12 Win E Cite Multi EG its jascecesss eves ceca esa bes aaa dates geaesnteabeeeesd a ibe becenngbiddaaies AE a E aad 12 Before the first direct CONNECTION siss sionin a a a aaa 12 Communication via RS232 does not WOFK ccc eect eeeeee eee ee etne ee RAN
18. eeteeeeeeeeenaees 7 When power cut comes gen set does not Start ccccccceeeeeeeeceeceeeeeeeeeceecaeceeeeeeeeeesenneeeeeeeeneeesnnanees 7 have lost the IG Password and or ACCESS code 0 ccceccceecceeeeeeeeeaeeeceeeeceeeeesaeeeeaeeseneeeteeeeseneeenenees 7T It is not possible to remove catches to take controller out from switchboard 2 cseceeeeeeeeeeeees 8 RPM Measures lies eiabaieceeanageycavtadets sipaseetotcdeteeiadustentenged E EEE addinins 8 PiCkUp SIQNAl E ne ecieeeatecdaeeeeciadaayiceendaveees 8 RPM Measuring aiies E ies added to addi ates AEE EE Gada Pata sie 8 Controller detects RPM on no running Qen Set cece eeeeee eee eeenaeeeeeeaaeeeseeaaeeeeeeaaeeeeeeeaeeeeeenaeeeeas 8 Analog MEASUTING tc caiocsccedtie ccesee eds elnedists neds beineai diced le cde elds aad eel ce oe aeeciehe ded aadvedecdatens 8 IG does not measure analog ValUC cccec cies cgeetss aduteeeessdetel evaieies aasbe i aadeei naar eau daa 8 Why the Pt100 sensor cannot De USEG ascciinciiraishecerveoseiriesliveteentareecesarendtidsaendcusbescinanen ciel bass 8 Any of analog inputs does not measure COrrectly eee cee cette etree eet ee tenia eras eet aeennaeeeeeeeas 8 SENSO failure 1S METS CLE seas iicsesctudedtesesceckagswylucaeass dicts wblaneayiydavezad euaseze ATEA AA 8 Analogue input Value 1S XXXX sissien aaki aiea aak aai kia 8 Current output sensor influences resistor sensor MeaSUrINg
19. esecaaaeceeeeeeeseceecnisaeeeeeeesensnaeees 10 Sye Gad cont obererion a E E EAT EAEE EA E yatdeess dua uda AE O 10 IG PC LS M does not operate Properly sseesicsieeriinreniini ee rnanainne denii nnan Ninik ENANA AN NNE NANNE NESEN 10 InteliSys Sync Load control does not operate sessssssseerrenssnnnseennaasannaatennaaanannnntennaanannaattnnaaaannaaeennaa 10 Speed regulation does not hold the speed on the nominal speed level eseeeeeeeeeeeetteeeenee 10 IG PC LS M speed governor output is at the end position 10V or 10V not only during the transients SPIM or MINT ONY sseiiecten dedeecees seteceassheeetiecensteeethiaaeecenazeenesticeaenliee TAREE ORAE ENEA EEEE 11 Synchronizing operates well synchroscope indicates proper slip and angle but GCB or MCB does MOU COSC sc d5icesepegeias hides i Se ects E EE thdanectadseduasudsncaesgis ceuatadl A E a ENa 11 InteliMains doesn t start synchronizing after MCB is pressed cceeeeeeeseeeeeeeeeeeeeeeeneeeeeeneeeeeeaas 11 VOIUPF CONTO sac 2 cared ire bates cana cca steds ad docecaacesovagseasa te tach entaviedaa a ae aa E NE 11 IG AVRICOMMEGCUOM 235 ceciieies hate cia teeasiecdinkes E adel ete iaietuda E EA eee ler nein 11 Voltage regulation does not hold the voltage on the nominal voltage level eee eeeeeeeetteeeeeeees 11 Voltage regulation is at 0 position MINT cccceceeesceeeeeeeceeeeeeeaeeceeeeeceaeeeseaeeeeaeeseaeeeetaeeesneesea
20. etting in user manual e Check the setpoint AVR characteristics Check the setpoint Volt PF ctrl AVRReg char POSITIVE or NEGATIVE PF or PFS control does not operate well Increase PF or PFS gain Controller setting and configuration IS configuration import Use Cfglmport software to import configuration between different archives include programmable functions from e g IS MINT to default IS SPtM archive Cfglmport is part of WinEdit installation Start Programs WinEdit Cfglmport and can be used for IS controller only Check what from following can be removed from default IS archive configuration when there is insufficient memory to import configuration from another IS archive Troubleshooting Guide ComAp August 2005 11 IG 6 2 IS 3 4 Troubleshooting Guide pdf Z omap Removing of 1x BIN address saves 170B 1x BOUT address saves 160B 1x complete IS ANA8 Cylinders unit saves 450B 1x complete IS ANA8 unit saves 1000B One History item saves 10B One sensor curve saves 125B Configuration Analog inputs Sensors button VDO Press IS CU Remove What means InteliSys message SD BINx SD BOUTx SD AINx Error message e g SD BOUT2 appears on InteliSys screen when Binary input or output Address x is configured but no corresponding message is received Check IS configuration and corresponding external unit address setting It is not possible to change setpoint Setpoint is not password protect
21. he sequence of GCB closing when more engines starts at once to the dead bus The generator which reaches adjusted generator setpoints at first connects GCB to the dead bus Other gen sets have to synchronize to the bus The system reserve does not correspond to the number of running engines Check whether all IGs are in AUT mode and have the setpoint Pwr management Pwr management is set to ENABLED or EXTERNAL Power and PF sharing does not operate well Check the proper MCB feedback configuration must not be configured twice MCB feedback switches between parallel to the mains and isolated mode of the controller Two or more engines starts and stops at the same time They behave as one big engine Check the Pwr mangement Priority setpoints of these engines Priorities are probably set to the same value Setpoint replication does not work Check the CAN BUS STATUS status on IG measuring menu screen Each connected IG must have 1 on position of its address E g CAN BUS STATUS 1010000000000000 means that only IG s with controller addresses 1 and 3 are connected Binary outputs SYSTEM READY and SYSTEM RES OK do not operate Check whether all the IG s are in AUT mode and CAN bus is properly interconnected How to check proper CAN bus connection Check the CAN BUS STATUS status on IG measuring menu screen Each connected IG must have 1 on position of its address E g CAN BUS STATUS 1010000000000000 means that on
22. hx It is necessary to use corresponding files see ipt file When it is not possible to open direct communication use Boot load jumper programming It is possible to download display firmware by standard programming procedure when DDE server is running even if the IS display is dark History stops recording With WinEdit 5 3 and older DDE server 2 3 and older sometimes can happen that the history stops recording for some time hours days and later on resumes again In most cases the Read history command helps to re sync the controller and WinEdit history Workaround Install the latest available version of WinEdit 5 4 or later Unsuccessful programming message Check if controller is really switched to OFF mode Binary inputs Remote TEST or Remote MAN can block programming when closed How to open default archive in OFF line connection Select WinEdit menu Open connection gt OFF line Press Open archive button in Archives field and use standard Open file window Default archives are in directory C PROGRAM FILES COMAP WINEDIT APP DEFAULT How to change PC COM port before opening connection Select Connection Open In Open connection window select 5l button How to open default archive in ON line connection Selecting WinEdit menu Controller gt Software configuration gt Select opens window containing default archives can t open communication to gensets group Is IG MU proper conn
23. ing of fuse switch For proper voltage measuring should not be generator or mains voltage terminals unconnected Generator and or mains voltage terminals are to be connected to significant impedance Note No zero RPM causes controller Not ready state and engine start is blocked Analog measuring IG does not measure analog value Check proper sensor characteristic configuration and adjusting Why the Pt100 sensor cannot be used The analog input resolution is from 0 to 2400 ohms in one ohm steps Because of the Pt100 conversion ratio 0 3850 C is the temperature resolution very low 1 ohm 2 5 C steps Use Pt 1000 3 85 C or other type of higher conversion ratio sensor instead Any of analog inputs does not measure correctly Check appropriate setpoints Sensors spec Calibr Al x Sensor failure is detected The measured value is out of range check the sensor characteristic Change the Sensor spec Calibr An to one Enter and back to zero Enter Analogue input value is XXXX The measured value is out of range check the sensor characteristic or the input is set as Unused Current output sensor influences resistor sensor measuring When both resistor and current sensors are used connect Analog input COM terminal to G Minus power supply terminal Controller measures wrong values from current output sensor IG CU IS CU and IG IOM analog inputs are mainly designed for resistor sensors In special case t
24. ld be damaged Following chapter describes some of possible reasons on Power supply Binary Output Binary Input Analog Output and Analog Input controller terminals Power supply input could be damaged if e Relays without antiparallel protection diode over the coil are used When the inductive voltage is to high during switch over from on to off then the high inductive voltage peak could disturb damage the controller power supply protections e Jump load situation start the engine with a additional battery this is not recommended to do due the voltage peak is to high e Engine is running without battery but with alternator for battery charging In this situation the voltage increase and could disturb damage the controller Do not disconnect battery cable when the engine is running e Input voltage is higher than 36 Vdc Take care to this situation and avoid situation e Lightning strikes Use a galvanic separated power supply source e High harmonics distortion are induced Install G MTU transformer sets to separate mains and genset voltage inputs e Voltage peaks are disturbing the controller Install Schaffner Filter FN660 10 06 Binary Output could be overloaded if e Relays without antiparallel diode over the coil are used When the inductive voltage is to high during switch over from on to off then the high inductive voltage peak could disturb damage the output transistors Binary Input could be burned if e The voltage qu
25. ls are used for import export mains current measurement Generator overcurrent protection does not react Maximal measured current is 10A on the IG CT terminals Please check used CTs and CT ratio setting IG Starter kit After MCB closes MCB fail is detected The setpoint AutoMains fail MCB logic has to be set to CLOSE ON because of direct wire connection between binary output MCB CLOSE OPEN and input MCB FEEDBACK Although maximal current is adjust by pot IG displays low power value Setpoint Basic settings CT ratio has to be set to value higher than 3000 A 5A Multiple gen set applications Temporary generator voltage increasing or decreasing MINT application island mode Var Sharing single genset running loaded If a high load jump comes the AVR control loop may respond incorrectly by increasing or decreasing its output This leads to temporary increasing or decreasing of the generator voltage If the load changes are frequent periodic the result may be unstable voltage regulation Can occur in IG 5 0 6 0 IS 2 0 2 7 The IG and or IS and or InteliMains are reset continuously The software in controllers and or InteliMains is not compatible In standard software branch the compatible versions are IG 5 6 and later IS 2 7 and later IM5 1 and later For other sw branch please contact your distributor Troubleshooting Guide ComAp August 2005 9 IG 6 2 IS 3 4 Troubleshooting Guide pdf Z oman What is t
26. ly IG s with controller addresses 1 and 3 are connected How to check actual IG MU sw version Open MultiEdit direct or modem connection and select Help About item to open info panel CAN bus connection problems Check the CAN bus connection cable type and terminating 120Q resistors The CAN address of each IG must be unique throughout the system Right CAN bus structure in line Can bus length is max 200m Sync load control IG PC LS M does not operate properly e Check if IG PC LS M power supply terminals are connected to IG CU e Check if there is no mechanical obstacle to proper connector contact between IG CU and IG PC LS M module InteliSys Sync Load control does not operate Check if proper type of IS DONGLE hw key is connected Speed regulation does not hold the speed on the nominal speed level e SPM SSB MEXT No regulation is performed from IG Check your speed governor setting Troubleshooting Guide ComAp August 2005 10 IG 6 2 IS 3 4 Troubleshooting Guide pdf Z oman e SPtM MINT Start the set in MAN mode and follow the instructions in user manual for proper setting IG PC LS M speed governor output is at the end position 10V or 10V not only during the transients SPtM or MINT only e Start the gen set in MAN mode follow the instructions for speed governor output setting in user manual e Check the setpoint Sync load ctrl SoeedReg char POSITIVE or NEGATIVE Synchroni
27. ntroller does not respond to SMS messages SMS commands are not available in IG software version 6 0 On lover firmware version Wrong access code was set or modem is not connected to controller Troubleshooting Guide ComAp August 2005 16 IG 6 2 IS 3 4 Troubleshooting Guide pdf
28. oes not operate DSR signal from Modem is not active Using DSR signal IG controller detects modem connection from terminal connection and uses appropriate protocol Activate DSR signal by AT amp S0 command see Modem documentation Connected Terminal does not operate DSR signal from Modem is active Using DSR signal IG controller detects modem from terminal or RS232 485 converter and switches appropriate protocol Deactivate or disconnect DSR signal form terminal or RS232 485 converter Wrong Access code Check Access code or check connection between Controller and modem Multiple IG controllers connection To accelerate software loading to selected controller stop the communication to other controllers if possible in DDE server window NV RAM error Checksum of statistic values is wrong In version IG SW V4 0 and previous select WinEdit command Controller Clear statistic From IG SW V4 2 is NV RAM checksum automatically repaired while updating of any statistic value e g kWh It is not possible to open Active call connection When any modem is connected to single controller the Controller address has to be set to 1 When Controller address has different value than 1 Active call is not activated GSM Modem connection SMS It is not possible to get any connection data SMS with controller through GSM modem Controller has not found the modem due to wrong initial setting of the modem Use the utility
29. ransducers to 4 20mA output can be used for various measuring Some types of transducers are not suitable for connection to resistive analog inputs because of influencing by analog input Troubleshooting Guide ComAp August 2005 8 IG 6 2 IS 3 4 Troubleshooting Guide pdf Beomap In this case modify default 4 20mA 60 or 4 20mA 100 sensor characteristic to get proper reading Power measuring Active and reactive power measurement shows unlikely values Check the voltage and CT connection in all phases exactly according the drawings in Application manual Output leads from current transformers has to be shortened when disconnected from controller Wrong mains or bus voltage and frequency measuring Check neutral connection between mains bus and generator When it is required neutral separation use IG MTU separation transformers For proper voltage measuring should not be generator or mains voltage terminals unconnected Generator and or mains voltage terminals are to be connected to significant impedance Controller does not measure generator current Generator current is measured only when GCB is closed Maximal current of the analog output on IG IOM cannot reach 20 mA Check the supply voltage for IG IOM It must be in the range 8 to 36 Volts Check Basic settings AnOut kW 20mA setpoint which defines conversion ratio from kW to mA cannot find a neutral current measurement in SPtM The neutral current termina
30. roller doesn t stop the engine on any alarm although it reports it in the Alarm list Check the binary input SPRINKLER If closed no alarms except Overspeed and Emergency stop will stop the engine No response on Start Stop keys Check if controller is in the Ready state in MAN mode In AUT or OFF modes controller does not respond to Start Stop keys Controller is in the Not ready state and Alarm list is empty e Check RPM value on the main measure screen If the value is different from zero IG is in Not ready state e Check IG mode If you select the OFF mode IG is in the Not ready state MCB fail is reported although the MCB feedback is OK Check the setpoint AutoMains fail MCB logic your MCB logic can be converted Controller does not close GCB in MAN or AUT mode SPM application IG detects a voltage on the Mains terminals MINT application Measured bus voltage does not correspond to MCB feedback signal When MCB feedback is closed and the bus is dead IG wants to synchronize but cannot Some setpoints cannot be changed Password is not entered No Time stamp history record is written in the IG history IG IS Time stamp history record is written only when the engine is running InteliMains Time stamp record is written only when MCB is closed or bus voltage is present IG front panel red LED on the gen set side lights or blinks This LED indicates common gen set and engine alarms Check the Alarm
31. s ground free GND terminal is not connected see also the next point PC CONTROLLER 2 RxD Q 3 TxD RS 232 Hit 2 eat Required the same voltage potential between GND s Troubleshooting Guide ComAp August 2005 12 IG 6 2 IS 3 4 Troubleshooting Guide pdf Z omap Communication via RS232 does not work Controller looks dead after interruption during reprogramming The RS232 recoverable PTC ground protection is in InteliGen and InteliSys InteliLite controller Activation of PTC ground protection causes communication interruption and Supply is OK display is still dark see in the chapter General when it happens during firmware reprogramming Note the display gets a bit darker after controller supply switch on even if the firmware is not working due to previous download interruption In this case disconnect RS232 communication line and ensure one of following conditions for PC to controller connection 1 PC and controller ground are identical see Before the first direct connection 2 PC power supply is separated e g battery or insulated supply 3 Use RS232 isolator see in CommunicationGuide chapter Converters Isolator RS232 if item 1 or 2 is not possible PTC recovery time is at least 1 minute when RS232 line is disconnected Start controller Boot programming procedure after this time Unsuccessful IS programming InteliSys contains two firmware files application mhx and display m
32. zing operates well synchroscope indicates proper slip and angle but GCB or MCB does not close e Setpoint Sync load ctrl PhaseWindow is set to zero Set another value 2 5 is recommended e Check voltage difference in all three phases L12 L2 L3 and adjust properly Sync load ctrl Voltage window setpoint InteliMains doesn t start synchronizing after MCB is pressed Check the binary input SYNC DISABLE If closed InteliMains doesn t allow the synchronizing even if both mains and bus voltage are within limits Volt PF control IG AVRi connection When is IG AVRi is connected instead an external AVR resistor connect IG PC LS M AVRi outputs OUT1 GND or OUT2 GND When AVR module has a voltage input for the generator voltage adjusting connect floating IG PC LS M AVRi outputs OUT1 OUT2 Follow AVR documentation Use IG AVRi trim to adapt proper control range Follow IG SPtM or MINT documentation Voltage regulation does not hold the voltage on the nominal voltage level e SPM SSB MEXT No voltage regulation is performed from IG e SPtM MINT Start the set in MAN mode follow the instructions in user manual for proper setting Voltage regulation is at 0 position MINT e CAN bus between InteliGen InteliSys and InteliMains is interrupted check CAN status bits AVR output is at the end position 0 or 100 not only during the transients SPtM or MINT only e Start the set in MAN mode follow the instructions for AVR output s
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