Comap InteliDrive EM User Guide v.1.0

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
User guide
Copyright 2011 ComAp s.r.o. Written by Ji 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: info@comap.cz, www.comap.cz
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 InteliDrive EM, SW version 1.0, ComAp Mai 2011 2
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
InteliDrive EM, SW version 1.0, ComAp Mai 2011
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: Firmware: Archive:
ID-EM-1.0.IWE (install into PC by double click and import to controller by LiteEdit). ID-EM-1.0.mhx 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 Break Return Motor protections REMOTE START/STOP (Capital letters in the frame) buttons on the front panel (Italic) set points (Bold) Set point group (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 Single phase Single phase Kind of Starting Direct, SoftStarter Direct, SoftStarter Current Transformer without CT with CT Comment CT allows to use current protection, Low power protection, measure and record Current, Power and PF
Three phase Three phase
Y/D, Direct, SoftStarter Y/D, Direct, SoftStarter
without three phase CT 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 Motor Voltage Description Relative SetPoints Protection against overvoltage and undervoltage Overvoltage of the motor power supply voltage. UnderVoltage Ove/UndVoltDel Voltage Unbalance Protection against the difference between phase Volt Unbalance voltages. Volt Unbal Del Protection is inactive in the case of single phase ConnectionType motor. Protection against the current overloading. The Amps IDMT Del 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. The protection stops quickly the motor when OverCurrent Sd Nominal Current corrected by percentage value of OverCur Sd Del SP 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. The protection stops it when the speed passes Overspeed Sd under or over set zone. UnderSpeed Sd To make operate this protection, connect the speed sensor to the controller . The protection will stop the motor if the power LowLoadLimit
Motor Overload Protection
OverCurrent and torque
Speed
Minimal Load
General Analog Protection AI1
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. 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. Analogical to General Analog Protection AI1
LowLoadLimDel
AI1 Wrn AI1 Sd AI1 Del
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 Protection against overvoltage and undervoltage DCVoltageOver of the controller power supply voltage. DCVoltageUnder General Analog Protection AI2 Maintenance Period The warning message is generated when one of WrnMaintenRun the two following conditions are met: WrnMaintenAge - 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.
What Communication or Input / Output modules are supported?

Unit or module InteliDrive EM Communication modules 1 IL-NT RS232 2 IL-NT RS232-485 3 IL-NT S-USB 4 IL-NT GPRS 5 IB-Lite Description Central unit (HW type IL-NT MRS19) RS232 communication card Communication module USB communication module GPRS communication module Internet / Ethernet Module including Web Server Remote annunciator Optional / Obligatory Obligatory
Optional Optional Optional Optional Optional
6 IGL-RA15 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
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 The cut-out for the Remote Annunciator is 167 x 108 mm. RA15 for the technical and function description.
Controller Terminals and Dimensions

Terminals
Controller Dimensions
Application InteliDrive EM
10
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 controllers 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:
Relays
T2A
D
+
controller + -
+ 12VDC Battery
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.
11
Fuse Fuse
K1 K2
K1
K2
controller T1A + DC relays + 24VDC
Battery
Binary input wiring

The common pole of contacts is connected to (-) pole of power supply. It is preferable to choose the (-) pole of controller.
4k7
Controller
iL
+ Power Supply
+
Battery
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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
13
Current measurement
K L k l L1 K L k l L2 K L L3 k l N
M G
COM L1l
L2l
CURRENT 0-5A
L3l
Voltage measurement
L1
M G
L2 L3 N BUS
L1 L2 L3 GENERATOR VOLTAGE
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.
14
Voltage measurement
M G
L N
L1
L2
L3
VOLTAGE GENERATOR 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.
M G
K L k l
L1 N
COM L1l L2l

CURRENT 0-5A
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 Type Analog input name Config of input LiteEdit Type Name Config Possibility Analog input isnt used Analog input is used Up to 14 ASCII characters Analog measuring in specified range. Binary: open/close - threshold 750 . Three-state: open/close threshold 750 , Failure <10 or > 2400 Up to 3 ASCII characters (Valid only for analog inputs) Valid only for binary and threestate inputs 15
Not used Alarm Analog Binary (not supp. by PTM)
Tri-state (not supp. by PTM)
Physical dimension Polarity
Dim Contact type
bar,%,C, NC
NO Protection direction Protection Over Over+Fls Under Under+Fls 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 0, 1, 2 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
Valid only for binary and threestate inputs Overstep. Sensor fail does not activate protection. Overstep and Sensor fail activates protection. Under step. Sensor fail does not activate protection. Under step and Sensor fail activates protection. 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 20mA/6.0Bar ext R 120 0-20mA/10.0Bar 4-20mA/10.0Bar Number of decimal points (Valid only for analog inputs)
Decimal points
Dec
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

Primary 120 170 200 230 280 330 390 460 560 690 4-20mA/100 Converted 0 13 25 38 50 63 75 88 100 Note 1 0% 25% 50% 75% 100% 0-20mA/100 Note 2 0 mA 4 mA 8 mA 12 mA 16 mA 20 mA Note 3 0% 20% 40% 60% 80% 100% 0-20mA/-20 - 120C Note 4 -20C 8C 22C 36C 50C 64C 78C 92C 106C 120C
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
16
Connection of the controller analog inputs

- POWER
Standard connection of three resistive sensors to analog inputs.
3x RESISTIVE SENSOR
- POWER
AI1 AI2 AI3
Three current output sensors connection to InteliLite.
AI1 AI2 AI3
Set jumpers for current measurement
GND
3x SENSOR 4 - 20 mA +24V
- POWER COM AI1 AI2
Mixed connection of InteliLite analog inputs: AI1 binary input AI2 three state input AI3 analog resistive input
2x 470
Analog inputs are designed for resistive sensors with resistance in range of 0 to 2,4k. 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 750.
As three state input

Open, close and failure state are detected. Threshold level is 750, failure is detected when circuit resistance is <10 or > 2400. InteliDrive EM, SW version 1.0, ComAp Mai 2011 17
AI3
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 isnt 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.
18
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! InteliDrive EM, SW version 1.0, ComAp Mai 2011 19
5. Take RS 232 communication module.
6. Plug RS 232 communication module into the slot of the controller. 7. Put back the small cover.
20
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 Contact type NC NO Alarm type Warning Shut down Alarm active All the time Motor running only
14 characters ASCII string Normally closed Normally opened
Control:
21
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 (OFFMAN-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 doesnt 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?
22
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 BO2 BO3 BO4 BO5 BO6 BO7
KM1 KM2 KM3 Not used Not used Not used Not used
23
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.
24
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 alarm is not active and FAULT RESET is pressed
Underspeed
Output closes if the motor under speed alarm activates. The output opens, if alarm is not active and FAULT RESET is pressed
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
25
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 alarm is not active and FAULT RESET is pressed
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 alarm is not active and FAULT RESET is pressed 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.
26
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.
27
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.
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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.
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Motor Params
Nomin power
Nominal power of the motor. Step: 0,1 kW Range: 0,6 120 kW
[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: 1A 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%
[%]
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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
Shutdown threshold level for ANALOG INPUT 1 Unit, step and range are adjustable in Modify window.
AI1 del
Delay for ANALOG INPUT 1 Step: 1s Range: 0 900s
[s]
AI2 Wrn
AI2 Sd
AI2 del
[s]
AI3 Wrn
AI3 Sd
AI3 del
[s]
DCVoltageOver
[V]
Warning threshold for high controller power supply voltage. Step: 0,1 V Range: 8 40 V
DCVoltageUnder Batt volt del
[V] [s]
Delay for low controller power supply voltage alarm. Step: 1s Range: 0 600 s
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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: Range: 1s 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 dont 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
Delay for motor overcurrent alarm. Step: 0.1s Range: 0 600.0 s
[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: 1s 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. Amps IDMT Del * Nomin Current Reaction time = Iph Nomin Current
In the case of three phase wiring, Iph is maximal value of all measured phases of current.
32
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.
Reaction time
Maximal Reaction time
Amps IDMT Del
Igen Nominal Current Short Crct Sd
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
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Volt unbal del

Delay for voltage unbalance alarm. Step: 0.1s Range: 0.0 600.0 s
[s]
Functions
CtrlByAIN/BIN
BIN:
[BIN / BININV / CU:AIN1-3]
BININV: AIN1-3:
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. The inverse function to BIN. The motor starts if Rem Start/Stop BIN is open. 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
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AnlInAIO1 del
Delay for AnlInAIO1 Step: 1s Range: 0 180s
[s]
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
Actual real time
[HHMMSS] [DDMMYYYY]
Date
Actual date.
Timer12Function [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: AutoRUN: Mode OFF: There is no any other function, but binary output Timer1..2 activation. When this option is chosen then the Timer output is also internally connected to the Remote TEST binary input. When this option is chosen then the Timer output is also internally connected to the Remote OFF binary input.
35
Timer 1..2 Repeat [NONE/MONDAY/TUESDAY/WEDNESDAY/THURSDAY/WEDNESDAY/FRI DAY/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 Mode OFF No Func Starts motor at Timer1 ON Time for Timer1Duration with Timer1 Repeat periodicity activates controller Remote OFF mode at Timer1 ON Time for Timer1Duration with Timer1 Repeat periodicity. See table below.
Timer1Function No Func Auto Run Mode OFF
Timer1 Repeat NONE NONE NONE
Timer1 ON Time Anything Anything Anything
Timer1 Duration 5 min 5 min 5 min
Note Note 1 Note 2 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.
36
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
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Motor Start Stop commands via SMS

Command Start SMS #1:0 ,c1 #1:0 p0,c1 Stop #1:0 ,c2 #1:0 p0,c1 #EL.MOTOR:c_ok Response #EL.MOTOR:c_ok #EL.MOTOR:c_err Note Access code = 0, No password Access code = 0 Password = 0 Access code = 0 No password Access code = 0 Password = 0
Note: The name EL.MOTOR in table above follows the Basic Settings: Motor Name setpoint.
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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 (). 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.5) and saves this value into the memory. The resistance is then added to all calculations (e.g. instead of 70C -> 73C, or e.g. instead of 5C -> 6C). Hint: The calibration must be done at the operational point of the analog input (e.g. 80C, 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% = 10, 100% = 180
VDO Temperature sensor

2000 1500 1000 500 0 32 68 86 104 122 140 158 176 194 230 Temperature [F] 200 150 100 50 0 0
VDO Pressure sensor
Resistance [ohm]
Resistance [ohm]
29
58
87
116
145
Pressure [psi]
Temperature C/F -20/-4 -10/14 0/32 30/86 60/140 80/176 90/194 100/212 110/230 120/248
Pt 1000 Ohm 922 961 1000 1117 1232 1309 1347 1385 1423 1461
Ni 1000 Ohm 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.
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Operator interface
Pushbuttons and LEDs, MRS19
Pushbuttons
3 2 1
5 7 6
10
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
MODE - Cyclic forward selection the gen-set operation mode (OFF -> MAN -> AUT ) MODE - Cyclic backward selection the gen-set operation mode (AUT -> MAN ->OFF ) HORN RESET - Deactivates the HORN FAULT RESET - Acknowledges faults and alarms START - Start of the motor STOP - Stop of the motor PAGE - Cyclic selection of the display mode(MEASUREMENT->ADJUSTEMENT) - Select the set point, select the screen or increase set point value - Select the set point, select the screen or decrease set point value ENTER - Confirm set point value
LEDs
ALARM WARNING Indicates active or inactive, but still not reset shutdown alarm Indicates active or inactive, but still not reset warning alarm
40
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. 2. 3. 4. 5. 6. 7. Use repeatedly PAGE button to select the ADJUSTMENT menu. Use or to select requested set points group. Press ENTER to confirm. Use or to select requested set point. Set points marked * are password protected. Press ENTER to edit. 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 InteliDrive EM, SW version 1.0, ComAp Mai 2011 41
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 Active not accepted alarm Active accepted alarm Inactive not accepted alarm Inactive accepted alarm
* Wrn Temperature Wrn Temperature * Wrn Temperature
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: Enter Enter + Fault reset One screen up/down Cursor move within the ECU alarm list ECU fault code reset
MEASUREMENT screens description

Main measure screen
2 1 3 6 4 5 7 InteliDrive EM, SW version 1.0, ComAp Mai 2011 42
1. 2. 3. 4. 5. 6. 7.
Operation mode of the motor Indication of: active access lock L, Remote communication R and alarm ! Status of the motor RPM of the motor Active power Power factor Timer - events 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 Power factor Mains voltage (total) (total) (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?
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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.
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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.
45
Motor operation states

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

Events specification Wrn Name of analog input Protection type WRN Information on binary output available (See Description list of Binary outputs) 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
Ubatt
WRN
YES
Binary input Start failed ParamFail
Configurable SD NONE
YES YES NO
Wrn Volt L1, 2, 3
Wrn
YES
Sd Volt L1, 2, 3
Wrn
YES
Voltage unbl
SD
NO
OverCurrent
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. Controller power supply voltage is out of limits given by DCVoltageUnder and DCVoltageOver setpoints. Configurable Warning/Shutdown alarms on the inputs of controller. Motor start failed. 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. The mains voltage is out of limits given by OverVoltage and UnderVoltage setpoints, the start of controller is not requested. The mains voltage is out of limits given by OverVoltage and UnderVoltage setpoints, the start of motor was requested or the motor was running. The mains voltage is unbalanced more than the value of Volt Unbalance setpoint. The current is higher than the value given by OverCurrent setpoint.
46
Events specification Overspeed
Protection type SD
Underspeed
SD
EmergencyStop PickupFault Stop fail WrnServiceTime
SD SD SD WRN
Wrn RA15 fail Sd IOM fail
WRN SD
Low BackupBatt
WRN
Information on binary output available (See Description list of Binary outputs) YES The protection comes active if the speed is greater than Overspeed setpoint. YES The protection comes active if the speed is greater than Underspeed setpoint. Protection evaluation starts after reaching status Running. If the input Emergency stop is opened NO shutdown is immediately activated. NO Failure of magnetic pick-up sensor for speed measurement. YES Motor stop failed. 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. NO Warning alarm in case of lost connection to IGL-RA15 module. NO Shutdown alarm in case of lost connection to auxiliary I/O modules IGIOM/IGS-PTM. 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.
47
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).
PC CONTROLLER
RS232
RS 232
Required the same voltage potential between GNDs
230 VAC
RS232
2 - RxD 3 - TxD 5 - GND
2 - RxD 3 - TxD 5 - GND
Battery
0 VDC
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/ . InteliDrive EM, SW version 1.0, ComAp Mai 2011 48
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.
49
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.
Analog modem
Analog modem
or
GSM modem
GSM modem
Mobile SIM card setting

Adjust SIM card in GSM modem following way: enable data connection (when required) no PIN code 50
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 controllers 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:
51
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
52
Technical data
Power supply
Voltage supply Consumption Consumption depends on supply voltage 8-36V DC 40-430mA depend on supply voltage and temperature 0,104A at 8VDC 0,080A at 12VDC 0,051A at 24VDC 0,044A at 30VDC 0,040A at 36VDC 100ms from min. 10V return to min. 8V 2 % at 24V
Allowed supply voltage drop-out: Battery voltage measurement tolerance
Operating conditions
Operating temperature Storage temperature Protection front panel Humidity Standard conformity Low Voltage Directive Electromagnetic Compatibility Vibration Shocks -40...+70oC -30...+80oC IP65 95% without condensation EN 61010-1:95 +A1:97 EN 50081-1:94, EN 50081-2:96 EN 50082-1:99, EN 50082-2:97 5 - 25 Hz, 1,6mm 25 - 100 Hz, a = 4 g a = 200 m/s2
Dimensions and weight

Dimensions Weight 180x120x55mm 450g
Current inputs
Nominal input current (from CT) Load (CT output impedance) CT input burden Max. measured current from CT Current measurement tolerance Max. peak current from CT Max. continuous current 5A < 0,1 < 0,2 VA per phase (In=5A) 10 A 2% from the Nominal current 150 A / 1s 12 A
Voltage inputs
Measuring voltage range Maximal measured voltage Input resistance Voltage measurement tolerance Overvoltage class 0 277 VAC phase to neutral 0 480 VAC phase to phase 340 VAC phase to neutral 600 VAC phase to phase 0.6 M phase to phase 0.3 M phase to neutral 2 % from the Nominal voltage III / 2 (EN61010)
53
Binary inputs and outputs

Binary inputs
Number of inputs Input resistance Input range Switching voltage level for close contact indication Max voltage level for open contact indication 7 4,2 k 0-36 VDC 0-2 V 8-36 V
Binary open collector outputs

Number of outputs Maximum current Maximum switching voltage 7 0,5 A 36 VDC
Analog inputs
Not electrically separated Number of inputs Resolution Jumper selectable range Maximal resistance range Maximal voltage range Current range Input impedance Input impedance Resistance measurement tolerance Voltage measurement tolerance Current measurement tolerance 3 10 bits V, Ohm(default), mA 2500 2.5 V 0 20 mA 180 for mA measuring > 100 k for V measuring 2 % 2 out of measured value 1 % 1mV out of measured value 2.5 % 0,5mA out of measured value
Speed pick-up input

Type of sensor Minimum input voltage Maximum input voltage Minimum measured frequency Maximum measured frequency Frequency measurement tolerance magnetic pick-up (connection by shielded cable is recommended) 2 Vpk-pk (from 4 Hz to 4 kHz) 50 Veff 4 Hz 10 kHz (min. input voltage 6Vpk-pk) 0,2 %
CAN bus interface

Galvanically separated Maximal CAN bus length Speed Nominal impedance Cable type 200m 250kBd 120 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 InteliDrive EM, SW version 1.0, ComAp Mai 2011 54
3087A 3084A 3085A 3105A
DeviceBus for Honeywell SDS DeviceBus for Allen-Bradley DeviceNet DeviceBus for Allen-Bradley DeviceNet 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 Speed 10m 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 PWM frequency Maximum current Maximum switching voltage Output resistance Resolution 8 250Hz 0.5 A 36 VDC 1 10 bits
55
List of used abbreviations and expressions

AIN BIN BOUT CT CU ID EM LBI, LAI LBO LiteEdit SP Analog Input Binary Input Binary Output Current Transformer Computer Unit = dimension of value without a physical meaning InteliDrive EM 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. Logical Binary Output - an internal variable (memory) which can be assigned to a physical Binary/Analog Output PC program to monitor and set up the controller Set Point parameter which can be modified in controller or by means of LiteEdit
56

Comap InteliDrive EM User Guide v.1.0

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InteliDriveNT

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

InteliDrive EM, SW version 1.0, ComAp Mai 2011

Installation package: Firmware: Archive:

What is the purpose of the manual?

InteliDrive EM, SW version 1.0, ComAp Mai 2011

!!! CAUTION !!!

Adjust set points

InteliDrive EM, SW version 1.0, ComAp Mai 2011

InteliDrive EM V1.0 brief description

Three phase Three phase

Y/D, Direct, SoftStarter Y/D, Direct, SoftStarter

without three phase CT with three phase CT

Like for Single phase, plus Y/D Starting optimization (v.1.1)

Motor Starting Modes

InteliDrive EM, SW version 1.0, ComAp Mai 2011

Direct connection of the controller to PC

Motor Overload Protection

OverCurrent and torque

InteliDrive EM, SW version 1.0, ComAp Mai 2011

General Analog Protection AI1

AI1 Wrn AI1 Sd AI1 Del

What Communication or Input / Output modules are supported?

Optional Optional Optional Optional Optional

InteliDrive EM, SW version 1.0, ComAp Mai 2011

Remote annunciator IGL - RA15

InteliDrive EM, SW version 1.0, ComAp Mai 2011

Controller Terminals and Dimensions

InteliDrive EM, SW version 1.0, ComAp Mai 2011

Power supply wiring

Power supply fusing

Binary output wiring

InteliDrive EM, SW version 1.0, ComAp Mai 2011

controller T1A + DC relays + 24VDC

Binary input wiring

InteliDrive EM, SW version 1.0, ComAp Mai 2011

Three phase applications

InteliDrive EM, SW version 1.0, ComAp Mai 2011

Single phase applications

InteliDrive EM, SW version 1.0, ComAp Mai 2011

COM L1l L2l

Not used Alarm Analog Binary (not supp. by PTM)

Tri-state (not supp. by PTM)

Physical dimension Polarity

Dim Contact type

InteliDrive EM, SW version 1.0, ComAp Mai 2011

Default current sensor characteristic with external resistor 120 ohms

InteliDrive EM, SW version 1.0, ComAp Mai 2011

Connection of the controller analog inputs

AI1 AI2 AI3

Three current output sensors connection to InteliLite.

AI1 AI2 AI3

Set jumpers for current measurement

- POWER COM AI1 AI2

Current output transducers

As three state input

Unused analog inputs

Example of analog input configuration

InteliDrive EM, SW version 1.0, ComAp Mai 2011

Installing RS 232 Communication Module

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

5. Take RS 232 communication module.

InteliDrive EM, SW version 1.0, ComAp Mai 2011

Inputs and outputs