ICS-100 Operations Manual Understanding the hardware and safety features of the unit and how to perform basic operations of the controller unit Copyright, 2000

Engineering Concepts Unlimited Inc. 8950 Technology Drive

Fishers, IN 46038 The New Standard of Safety in Generator Controls

ICS-100

Volume

1

C O R P O R A T E G R A P H I C S A N D C O M M U N I C A T I O N S

All specifications subject to change without notice

Engineering Concepts Unlimited Inc. 8950 Technology Drive

Fishers, IN 46038

Table of Contents Safety First 2 Self Powered for ultimate safety 3 Epoxy Encapsulation 4 Module Enclosures 5 Premium Components rated for temperature 5 Description of the basic controls and readouts 6 Philosophy of operation 7 How to Operate the Unit 8 To manually start the unit 8 To stop the unit 8 To place unit in auto standby mode 8 To reset unit after fault shutdown 8 To acknowledge alarms 8 Specifications 10 Shutdown Faults 11 Shutdowns continued 12 Pre-Alarms 13 Pre-Alarms Continued… 14

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Chapter

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Understanding the ICS-100 Design Philosophy This product is a departure from the normal and designed to last.

he most important aspect of the design of this product is safety. From the first pencil sketch we knew that this product would be required to function in an unfriendly environment. The final installation locations are

open fields, forests, third world countries, irrigation projects and the like. What is most important however is the lack of operator training. The unit is designed to work with almost no operator training. In order to reduce any chance of the operator coming into contact with live AC generator output the unit is divided into two sections. One section is the generator control and display. A second unit that is electrically isolated from the display unit is the AC data measurement module. This module provides NO DIRECT AC ELECTRICAL PATH CONNECTION to the main unit.

Safety First afety is achieved by separating the AC data measurement module from the main generator control unit. By using internationally certified components the units are kept at a high voltage standoff number. The wires do connect between units but the components that they connect to do not electrically connect to the

circuitry of the AC module. This is the primary safety barrier between the two units.

More Safety ll the components in the AC measurement unit are oversized for both voltage and power rating. In addition multiple parts must fail to achieve any dangerous potentials to the main circuit area. In the unlikely event this should

happen we still are behind the main standoff barrier between boards. This means that dangerous voltage still cannot bridge the main user interface control.

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Self Powered for ultimate safety he AC board is not powered by the battery. Powering from the battery means direct connection of the battery ( and all of the engine switches, relays etc) directly to a module that is connected to the AC Generator output. Any

potential short would then cause all of the engine wiring and devices to attempt to go to voltages to above 500 VAC in some cases. Any personnel around the generator would be unaware of this situation and could cause bodily harm or even death.

The generator control is shown with its accompanying AC measurement module.

By connecting the AC modules on board power transformer to either 120VAC or 240VAC taps off the generator the unit is now self-powered. A common question that arises is if the generator is not running how does the AC module work? The answer is the generator control expects and measures the voltage only if the engine is in the run mode. If the AC voltage module stops working the unit detects a low AC voltage event and stops the engine. In the off mode or auto standby the system ignores the low AC values. By mounting the AC measurement module near (and away from) the generator unit cost savings can be realized. Wiring close to the generator connections allows less wire length and less cable ties. Less wire length also means less interference with other electronic modules such as governors and voltage regulators.

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Long Term Reliability n order to achieve long term physical reliability the units are built with 25 year tested manufacturing techniques. In house automation assures that the majority of components are not touched by human hands thus eliminating errors and

contamination of the components. The assembly techniques are not enough to assure long term ruggedness. A durable and stable physical system must be applied to keep the electronic parts in the proper orientation. The unit must withstand moisture, diesel fuel and vibration.

Epoxy Encapsulation n order to meet the rugged requirements of this industry epoxy encapsulation is a necessity. Though difficult to design in and apply, epoxy gives long-term stability to the physical package. At present there are tens of thousands of electronic

modules with encapsulation that are running in some cases in excess of 25 years. Many of these are in the oil industry on offshore petroleum production platforms. This particular application is among the worst that can be found.

Views of pre-encapsulated product shows the vulnerability of open circuit boards

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Module Enclosures hen larger modules are used in applications involving mechanical stresses it becomes necessary to use metal enclosures to support against resonant nodes occurring during vibration. Both the AC and Generator controls use

metal surrounds to do this. In the case of the AC module a zinc casting is used. On the generator control a metal frame is used with bond outs. This yields an outstanding mechanical package. The metal frames also allow for the removal of waste thermal energy.

View of AC zinc measurement module enclosure

Premium Components rated for temperature ll the components specified have been evaluated for wide temperature range operation. Derating charts are applied to all the components to assure satisfactory operation over the temperature range. Only parts with nearly

indefinite lifetimes are used in the construction of the unit. NO ELECTROLYTIC CAPACITORS are used in any of the measurement, power supplies or communications systems. This type of capacitor can potentially freeze under extreme temperatures and lose capacitance.

The Vacuum Fluorescent Display is rated for –40 to +85C operation, no freeze ups or temperature related problems. All other components are of premium grade.

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Description of the basic controls and readouts

1. Not In Auto Lamp – If the unit is not in auto this lamp will flash continuously

2. No Modem Connection Lamp – If the auto button is pushed a modem check will occur. In the event that the modem check fails this lamp will flash.

3. Cranking Cycle Lamp – When the starter is engaged this lamp will light.

4. Major Fault Lamp – Certain faults such as engine shutdowns will cause this lamp to light. The not in auto condition also lights this lamp.

5. Minor Fault Lamp – Pre-alarms will cause this lamp to light. 6. Generator on line lamp – Detects voltage on the bus terminals 7. Auto Button – When pressed does both a modem check and

arms the remote start contacts for engine start. Lamp above displays status.

8. Off Reset Button – Will stop the engine and reset the control. Lamp above indicates status.

9. Manual Button – When pressed the engine will start and run immediately. Lamp above indicates status.

10. Phase Select Button - Causes the phase display to scroll.

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11. Scroll Recall Button – Depending on the programming of the unit this causes alternate displays to be shown

12. Lamp Test Alarm Silence – Causes the lamps to blink and the horn to be silenced after a fault has registered. You may have to press this multiple times until all faults have been acknowledged.

13. Alarm Horn – Marine grade horn that sounds on various faults. It

is silenced by pressing the Lamp Test Alarm Silence button repeatedly until the horn silences.

14. Main Alphanumeric Display – Presents data in a multi-line format.

The section to the left on the primary display shows the AC information and Engine gauge information. The message center area shows 16 x 2 character messages about the status of the engine. If no faults are shown the KW/KVA screen is shown. If faults are active the active faults will display. If more than one fault is active and all have been acknowledged by pressing the Lamp Test Alarm Silence Button then the fault message area will automatically scroll showing all current faults in progress.

Philosophy of operation he unit is comprised of several sections working together to deliver all of the performance required. When looked at from a simplified standpoint it works as a system of several blocks. .

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How to Operate the Unit Be sure power is on the unit. If the unit is powered up the display will look similar to the picture on page 5.

To manually start the unit Press the manual button. Within a short pause the engine will begin cranking. Upon detection of proper crank disconnect speed the engine starting relay will be released and the engine will throttle up. At this point all the voltages should be increasing and oil pressure should begin to read.

To stop the unit Press the OFF button. The engine should stop and readings should begin to lower in value.

To place unit in auto standby mode Press the AUTO button. This will cause the modem check to occur and place the unit in auto mode. In the even the remote start signal is detected the engine will crank and run. It is important to post warning signs that the engine will start without notice if you are using it in this mode.

To reset unit after fault shutdown Press the OFF button. This will reset the fault system for another run operation.

To acknowledge alarms During run operation certain conditions may arise such as a pre-low fuel alarm. In the event this happens the system will turn on the alarm horn and indicate the fault condition in the message center window ( the 16 x 2 character section of the display to the right). To acknowledge and silence the alarm press the lamp test alarm silence

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button. If there is only one pre-alarm on then the horn will clear. If there are more alarms still in progress it may be necessary to repeat the lamp test alarm silence until they are all silenced. At this point the display will scroll the current alarms in progress. If alarms clear on their own then the horn will silence automatically.

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Specifications AC Specifications

AC Volts 1-2,2-3,3-1,BUS 70 to 525 VAC AC Volts 1-N,2-N,3-N 70 to 525 VAC AC Amps per phase 1,2,3 0 to 9999 AMPS (0-5Amp

CTS) AC Power Factor ph 1,2,3 0 to .5PF LAG AC Frequency 0 to 99.9 HZ AC Frequency (optional) 0 to 999 HZ AC KW meter phase 1,2,3 0 to 2000 KW AC total KW phase 1+2+3 0 to 5000 KW AC KVA meter phase 1,2,3 0 to 2000 KVA AC KVA total phase 1+2+3 0 to 5000 KVA AC KW HOUR meter 0 to 65000 MWH

DC Specifications Crank Time 0 to 100 Secs Rest Time 0 to 100 Secs Crank Cycles 1 to 20 Low Oil Pressure Shutdown Any resistive to GND

sender Low Oil Pressure Pre-Alarm Derived from above

sender High Engine Temperature Shutdown

Any resistive to GND sender

High Engine Temperature Pre-Alarm

Derived from above sender

Fuel Shutdown Any resistive to GND sender

Fuel Low Level Pre-Alarm Derived from above sender

Speed Sensing of Magnetic Pickup

0 to 8500 HZ 0 to 10VRMS

Loss of pickup detect YES DC Voltage range 9 to 30VDC

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Shutdown Faults

Name Low limit

High limit OFF/ON Delay

Low Oil Pressure 5 psi

High Engine Temperature

210 F

Overcrank 10 cranks

Overspeed 2000 rpm

Low Fuel Shutdown 5%

Emergency Stop

AC overvoltage Ph1-N 525 VAC YES 2 to 14 SECS

AC overvoltage Ph2-N 525 VAC YES 2 to 14 SECS

AC overvoltage Ph3-N 525 VAC YES 2 to 14 SECS

AC overvoltage Ph 1-2 525 VAC YES 2 to 14 SECS

AC overvoltage Ph 2-3 525 VAC YES 2 to 14 SECS

AC overvoltage Ph 3-1 525 VAC YES 2 to 14 SECS

AC undervoltage Ph1-N 80VAC YES 2 to 14 SECS

AC undervoltage Ph2-N 80VAC YES 2 to 14 SECS

AC undervoltage Ph3-N 80VAC YES 2 to 14 SECS

AC overvoltage Ph 1-2 80VAC YES 2 to 14 SECS

AC overvoltage Ph 2-3 80VAC YES 2 to 14 SECS

AC overvoltage Ph 3-1 80VAC YES 2 to 14 SECS

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Shutdowns continued

Name Low limit

High limit OFF/ON Delay

High AC AMPS Ph 1 Per CT YES 2 to 14 SECS

High AC AMPS Ph 2 Per CT YES 2 to 14 SECS

High AC AMPS Ph 3 Per CT YES 2 to 14 SECS

High KW Ph1 2000 KW YES 2 to 14 SECS

High KW Ph2 2000 KW YES 2 to 14 SECS

High KW Ph3 2000 KW YES 2 to 14 SECS

High Total KW 5000 KVA YES 2 to 14 SECS

High KVA Ph1 2000 KVA YES 2 to 14 SECS

High KVA Ph2 2000 KVA YES 2 to 14 SECS

High KVA Ph3 2000 KVA YES 2 to 14 SECS

High Total KVA 5000 KVA YES 2 to 14 SECS

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Pre-Alarms

Name Low limit High limit OFF/ON Delay

Pre Low Oil Pressure 30 psi

Pre High Engine Temp. 200 F

Pre Low Fuel Level 10%

Low Power Factor Ph 1 .5 YES

Low Power Factor Ph 2 .5 YES

Low Power Factor Ph 3 .5 YES

Ruptured Basin

Low Coolant Level

Emergency Stop

Loss of Commercial Power

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Pre-Alarms Continued…

Name Low limit

High limit OFF/ON Delay

Pre Low Oil Pressure 30 psi

Pre High Engine Temp. 200 F

Pre Low Fuel Level 10%

Low Power Factor Ph 1 .5 YES

Low Power Factor Ph 2 .5 YES

Low Power Factor Ph 3 .5 YES

Ruptured Basin

Low Coolant Level

Emergency Stop

Loss of Commercial Power