id dcu industrial

Copyright 2004-2014 ComAp s.r.o. Written by LK, RJZD Prague, Czech Republic

ComAp, spol. a.s. Kundratka 2359/17, 180 00 Praha 8, Czech Republic Tel: +420 246 012 111, Fax: +420 266 316 647 E-mail: [email protected], www.comap.cz

REFERENCE GUIDE

InteliDrive

IDDCU Industrial Expandable engine controller

with electronic engines support

Single speed applications SS All speed applications AS

SW version 2.8, April 2014

ID-DCU-Industrial-2.8, ComAp - April 2014 - 2 - ID-DCU-Industrial-2.8r2.pdf

Table of Contents

Table of Contents ....................................................................................................................................... - 2 - Abbreviations .......................................................................................................................................... - 4 -

General description ..................................................................................................................................... - 6 - Physical component and interface Descriptions .................................................................................... - 7 -

Terminal and dimensions............................................................................................................................ - 8 - ID-DCU ................................................................................................................................................... - 8 - ID-DCU terminals ................................................................................................................................... - 9 - ID-COM terminals ................................................................................................................................. - 10 - ID-SCM Speed control module............................................................................................................. - 10 - InteliVision 8 ......................................................................................................................................... - 12 - InteliVision 5 ......................................................................................................................................... - 13 - Communication lines wiring .................................................................................................................. - 15 - InteliDrive Remote Display (Remote Panel) ......................................................................................... - 15 - ID DCU dimensions .............................................................................................................................. - 20 - I-RB.. technical description ................................................................................................................... - 20 - IS-BIN16/8 ............................................................................................................................................ - 21 - IS-AIN8 ................................................................................................................................................. - 22 - IGL-RA15 Remote annunciator ............................................................................................................ - 23 - IGS-PTM ............................................................................................................................................... - 24 - I-AOUT8 ............................................................................................................................................... - 25 - IG-LB, I-LB+ ......................................................................................................................................... - 26 - IG-IB Internet bridge ............................................................................................................................. - 27 - I-CB communication bridge ................................................................................................................. - 27 -

Recommended wiring ............................................................................................................................... - 28 - Wiring example ..................................................................................................................................... - 28 - Engine without ECU (mechanical engine) ............................................................................................ - 28 - Scania S6 wiring example .................................................................................................................... - 29 - Bus/Communication architecture ......................................................................................................... - 29 - I-CB wiring and configuration ............................................................................................................... - 30 -

Getting started .......................................................................................................................................... - 31 - How to install ........................................................................................................................................ - 31 - ID-DCU Analog inputs hardware configuration .................................................................................... - 33 - ID-DCU Analog inputs software configuration ...................................................................................... - 34 - Hardware connection ........................................................................................................................... - 38 - Analog inputs on IS-AIN8 ..................................................................................................................... - 39 - Binary inputs / outputs on ID-DCU ....................................................................................................... - 41 - Binary inputs on IS-BIN16/8 ................................................................................................................. - 41 - Binary outputs on IS-BIN16/8 ............................................................................................................... - 42 -

Binary Inputs ............................................................................................................................................. - 45 - Binary inputs from J1939 configuration ................................................................................................ - 50 - Binary inputs protection ........................................................................................................................ - 50 -

Binary outputs ........................................................................................................................................... - 52 - Source Log Bout ............................................................................................................................... - 52 - Source Prg.states ............................................................................................................................. - 58 - Source Ana protections ..................................................................................................................... - 60 - Source Bin protections ...................................................................................................................... - 60 - Source Binary Inputs CU ................................................................................................................... - 60 - Source Binary Inputs ......................................................................................................................... - 60 - Source J1939 .................................................................................................................................... - 61 - Binary output to J1939 configuration: Source-Value ........................................................................... - 61 -

Logical analog inputs list........................................................................................................................... - 62 - Obligatory J1939 items ......................................................................................................................... - 64 - Analog inputs from J1939 configuration ............................................................................................... - 64 - Analog inputs protection ....................................................................................................................... - 65 -

Analog outputs .......................................................................................................................................... - 72 - InteliDrive Engine ECU communication................................................................................................. - 73 -


Setpoints ................................................................................................................................................... - 74 - Password .............................................................................................................................................. - 74 - Basic settings ....................................................................................................................................... - 75 - Engine params ..................................................................................................................................... - 78 - Engine protect ...................................................................................................................................... - 83 - Load sharing (AS only) ....................................................................................................................... - 86 - Analog inputs ........................................................................................................................................ - 88 - Active call/SMS .................................................................................................................................... - 89 - Date and time ....................................................................................................................................... - 90 - SCM unit (visible when ID-SCM or ID-SCM1 is configured) .............................................................. - 90 - Protections............................................................................................................................................ - 91 -

Operator Interface ..................................................................................................................................... - 92 - Pushbuttons and LEDs ......................................................................................................................... - 92 - How to select engine mode ? ............................................................................................................... - 93 - Display menus ...................................................................................................................................... - 93 - How to view measured data? ............................................................................................................... - 93 - How to view and edit set points? .......................................................................................................... - 93 - How to use the Fast- edit function? ...................................................................................................... - 93 - How to view the HISTORY menu? ....................................................................................................... - 93 - How to check the serial number and software revision? ...................................................................... - 94 - How to find active alarms ? .................................................................................................................. - 94 - Controller screens ................................................................................................................................ - 95 - Functions available from ID-DCU front panel keys .............................................................................. - 98 -

ID-DCU functions ...................................................................................................................................... - 99 - Default archives .................................................................................................................................... - 99 - Operational modes ............................................................................................................................... - 99 - Function description details ................................................................................................................ - 100 - Universal states .................................................................................................................................. - 104 -

PLC toolbar functions ............................................................................................................................. - 105 - PLC blocks ......................................................................................................................................... - 110 -

Controller configuration and monitoring .................................................................................................. - 149 - Direct connection to the PC ................................................................................................................ - 149 - DriveConfig ......................................................................................................................................... - 149 - Configuration steps ............................................................................................................................ - 150 - Configuration lock ............................................................................................................................... - 151 - DriveMonitor ....................................................................................................................................... - 151 - Password protection ........................................................................................................................... - 152 - Modbus communication ..................................................................................................................... - 152 -

Technical data ........................................................................................................................................ - 154 - ID-DCU ............................................................................................................................................... - 154 - I-RD-CAN ........................................................................................................................................... - 156 - ID-SCM ............................................................................................................................................... - 156 - CAN bus interface .............................................................................................................................. - 157 - IS-BIN16/8, IS-AIN8 ........................................................................................................................... - 157 - IS-BIN16/8 .......................................................................................................................................... - 157 - IS-AIN8 ............................................................................................................................................... - 158 - IGL-RA15............................................................................................................................................ - 158 - IGS-PTM ............................................................................................................................................. - 159 - I-AOUT8 ............................................................................................................................................. - 160 - I-LB ..................................................................................................................................................... - 160 - IG-IB ................................................................................................................................................... - 160 -


Abbreviations

aid Archive file extension for InteliDrive controller

AIN Controller or extension module Analog input

Alarm General term for any active engine protection Warning, Shutdown, etc.

Alarm list

Controller or PC DriveMonitor screen with list of active and unaccepted alarms detected from ID controller.

ECU Alarm list

Controller or PC DriveMonitor screen with list of active and unaccepted alarms detected from engine ECU.

AOUT Controller Analog OUTput or outputs group.

Archive

Usually aid file that contains all controller data: configuration, setpoints setting and history records.

AUX Controller application (archive, operational mode) for Auxiliary engines.

BI Controller binary input.

BIN Controller binary inputs group.

BO Controller binary output.

BOUT Controller binary outputs group.

CAN Control Area Network serial data link.

Cd Cool down protection, cooling period is included before engine stops.

CMB Controller Combined mode.

D+

Controller function for battery charging function check and/or engine running indication.

DC DriveConfig, PC software for InteliDrive configuration.

DM DriveMonitor, PC software for InteliDrive monitoring.

DriveConfig PC software for InteliDrive configuration.

DriveMonitor PC software for InteliDrive monitoring.

ECU Engine Electronic (injection) Control Unit.

ECU alarm Alarm detected in engine electronic control unit that is received via J1939.

EME InteliDrive Emergency operational mode.

EMS I. Electronic Management System version I.

EMS II. Electronic Management System version II.

Fls Controller sensor fail alarm.

FMI Failure Mode Identifier.

GSM modem Modem for Global System of Mobile communication

History

List of alarms and operational states with Reason, Date and Time and adjustable values set that is stored in controller, can be listed from the screen or DriveMonitor.

HRB Controller Harbor mode.

I-AOUT8 Controller extension module with 8 analog outputs: 10V or 20mA.

I-CB

Inteli Communication bridge = controller interface for other electronic engines like MTU, CAT etc.. that are not supported yet.

ID InteliDrive controller.

ID-COM

InteliDrive communication module with interface to J1939, J1587 and to other controllers.

ID-DCU InteliDrive DieselControlUnit.

ID-MCU InteliDrive Industrial Controller Unit with Volvo Penta front panel modification.

ID-RPU

InteliDrive Redundancy Protection Unit = ID backup unit for Over speed and Emergency stop protection in Marine applications.

ID-SCM ID-SCM1 InteliDrive Speed Control Module = interface unit for InteliDrive controller.

IG-IB Internet Bridge = controller interface for internet communication.

IGL-RA15 Remote Anunciator = external 15 LED indication panel (three colors, configurable).

IG-MU I-LB

Modem Unit = controller interface for multiple engines application one point communication with group or one point modem connection.

IGS-PTM Controller extension module with 8 binary inputs and outputs and 4 analog inputs.


I-RB Inteli Relay board = interface board with 16 free contact relays.

I-RB16 Inteli Relay board = interface board with 16 free contact relays.

I-RD

Inteli Remote Display (Remote Panel) = the same panel like on controller, all data received via CAN2 bus.

I-RD-CAN


I-RP


IS-AIN8 InteliSys Analog input module = extension module with 8 analog inputs.

IS-BIN16/8

InteliSys Binary input/output module = extension module with 16 binary inputs and 8 binary outputs.

J1587

The J1587 bus is mainly used for redundant signals; system diagnosis and software download on after market tools.

J1587/J1708 See J1587

J1939 The J1939 bus in mainly used for engine controls and engine monitoring.

KWP2000 Scania Communication protocol.

mhx Extension for controller firmware (Motorola HeX file).

MID Message Identification Assignments.

OFF

Controller mode when power supply is switched on, but all binary outputs and start commands are disabled = engine start is blocked.

PID J1939 Parameter Identification Assignments.

PPID J1939 Proprietary Parameter Identification Assignments.

RPM Engine Revolution Per Minute engine speed.

PCB Printed Circuit Board

PSID J1939 Proprietary Parameter Identification Assignments.

RS232

Standard serial data line for PC or Modem connection (controller programming or monitoring).

Sd Shut down protection.

SID J1939 Subsystem Identification Assignments.

Wrn Warning protection.


General description

InteliDrive ID-DCU Industrial is a specialized engine controller for Industrial applications. It controls, monitors and protects the engine in single or variable speed operational modes. The controller can communicate with Engine Management System via the CAN serial line using standard J1939 or another (KWP2000) communication protocol.

InteliDrive controllers are equipped with a powerful graphic display with icons, symbols and bar-graphs for intuitive operation, which together with high functionality sets new standards in engine controls.

Engine functions

Engine sequencing and control (start/stop, warm-up and cool-down, pre-lubrication etc.)

Engine monitoring and protections (2 or more level analog inputs protection, adjustable delays)

Speed measurement from magnetic pick-up or from ECU

Running hours meter, number of starts counter, fuel counter

Configurable 14 Binary inputs and Outputs and 8 Analog inputs

Setpoints are adjustable via InteliDrive panel or via PC software

3 level password protection

On screen Alarm and ECU Alarm indication

Event and time driven engine history for back tracing

Two or more languages selectable in controller

Communication

RS232 / Modbus RTU

Analog or GSM modem - with I-LB+ interface

Internet - with IG-IB interface

Engines with Engine Electronic Control Unit: J1939, J1587, KWP2000

Extension units for more I/O and Remote Display panel.

InteliVision5 and InteliVision8 color displays support

Physical

180x120 mm front panel mounted case

Graphic back-lit LCD display 128x64 pixel resolution with icons and bar graphs

LED status indicators / Lamp test

Multifunctional panel buttons

Conformity declaration

Following described machine complies with the appropriate basic safety and health requirement of the EC Low Voltage Directive No: 73/23 / EEC and EC Electromagnetic Compatibility Directive 89/336 / EEC based on its design and type, as brought into circulation by us.

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.


Physical component and interface Descriptions

Module

ID-DCU Central unit InteliDrive central unit: 14 BIN, 14BOUT, 8 AIN, 1xRS232, 1xCAN1 (full), 1xCAN2 (TTL), 1x Sync.Data line (TTL)

ID-SCM Interface Controller interface with two RPM inputs, two impulse inputs, two analog outputs and one Sped governor (V, mA or pwm) output.

ID-SCM1 Interface Controller interface with one Sped governor (V, mA) output.

ID-COM Communication interface

InteliDrive Communication interface for inter-controller or Remote display CAN2 line and for Redundancy synchronous J1708/1587 data line.

I-RB16 Relay board 16 relays with free NO/NC contacts 24VDC for binary outputs separation

I-RB8 Relay board 8 relays with free NO/NC contacts 24VDC for binary outputs separation

I-RB16-231 Relay board 16 relays with free NO/NC contacts 231VDC for binary outputs separation

I-RB8-231 Relay board 8 relays with free NO/NC contacts 231VDC for binary outputs separation

I-RD-CAN Remote display InteliDrive Remote display (Slave panel), CAN or RS232 interface

InteliVision5-CAN

Color display Remote color display 5 with CAN interface

InteliVision8 Color display Remote color display 8 with CAN or RS232 interface. I/O extension

IS-AIN8 8 analog inputs Configurable for VDO, PT100, PT1000, Thermocouples, mA, Volts

IS-BIN16/8 Extension module

16 Binary inputs, 8 Binary outputs

IGS-PTM Extension module

8 BIN, 8 BOUT, 4 AIN, 1 AOUT

I-AOUT8 Extension module

8 Analog outputs selectable to 10VDC, 20 mA, pwm (2,4kHz)

IGL-RA15 External LED indication panel

Configurable 15 LED and Horn signal.

Communication modules

I-LB, I-LB+ Multiple engines modem interface.

IG-IB Internet interface

I-CB ECU communication interface

I-CR CAN repeater

Hint: IG-IOM extension unit is not compatible with ID-DCU controller.


Terminal and dimensions

ID-DCU

The front panel of the InteliDrive controller is intended for installation in an overall enclosure rubber seal for IP 65 - see chapter Technical data.

Front panel LED

Right RED Active alarm indication Blinks when new alarm is activated. Steady lights after Fault reset confirmation - when alarm is still active. Disappears after Fault reset confirmation when alarm is inactive.

Right GREEN Engine running indication Lights when engine is running.

Left GREEN Indication of Binary output Close load state

Lights when output is Closed.


ID-DCU terminals

Grounding

Terminal

BOOT

JUMPER

BINARY INPUTSRP

M

BINARY INPUTSANALOG

INPUTS

BINARY

OUTPUTS

POWE

R8 - 36 V DC

EX

TE

NS

ION

MO

DU

LE

ID-R

PU

RS

232

LB

1

EX

TE

NS

ION

MO

DU

LE

ID-C

OM

+ -RPMG

ND

RP

MIN

BI1

BI2

BI3

BI4

BI5

SH

IEL

D

CO

M

D+

BO

1

BO

2

BO

3

BO

4

BO

5

BO

8

BO

6

BO

12

BO

13

BO

14

BO

9

BO

7

BO

10

BO

11

AIN

1

AIN

2

AIN

3

AIN

4

AIN

6+

AIN

5+

AIN

8+

AIN

8-

AIN

6-

AIN

5-

AIN

7+

AIN

7-

BI6

BI7

BI8

BI9

BI1

0

BI1

1

BI1

3

BI1

2

BI1

4

ID-DCU-Industrial

RPM Primary RPM

BI1 to BI14 Binary inputs, active when closed to minus power supply

BO1 to BO14 Binary outputs; Low side switch; 0,5 Amps each;

D+ D plus terminal

AIN1 to AIN4 Analog inputs group 1 AIN5+, AIN5- AIN6+, AIN6- AIN7+, AIN7- AIN8+, AIN8-

Analog inputs group 2

ID-DCU xx -LT version with display preheating LT is an option for extending of operating temperature range from -20 to -40 C. Heating foil is not part of standard ID-DCU and ID-MCU (without -LT extension).

Board temperature

+5 C- 40 C

Pre

heating

3,5 W

The only one low temperature sensitive part is the controller display. ID-DCU-Industrial-LT version contains a preheating foil on the display activated below +5C (measured on the PCB). Heating is switched off when controller power supply is below 10VDC (together with display backlight).


ID-COM terminals

Communication interface. ID-COM is mounted directly to ID-DCU box.

CAN1 Extension modules: EMS, IS-AIN8, IS-BIN16/8, IGS-PTM, IGL-RA15

CAN2 Intercontroller: I-RD-CAN, IG-MU, I-LB, I-LB+, IG-IB, others ID-DCU

ID-DCU ID-COM

INTERFACE

INTERFACE

INTERFACE

CAN1

J1939

J1587

CAN2

PR

OC

ES

SO

R

TTL

TTL

TTL

120 ohms

120 ohms

Hint:

Put jumper to connect the internal 120 ohms terminating resistor for CAN2 interface. ID-COM module is not required when inter-controller CAN2 and J1587 lines are not used. In this case connect Extension modules CAN1 directly to Extension modules port ID-COM on ID-DCU (9-pin connector: 5=H, 9=L).

ID-SCM Speed control module

ID-SCM module is interface module for InteliDrive controller application. Module is mounted directly to ID-DCU controller case. Module power supply: 8 to 36VDC.

Inputs RPM1, RPM2: Two inputs for frequency (e.g. flow) measuring. Expected sensor is magnetic pickup with maximal frequency range up to 8 kHz. The output values SCM Freq1, SCM Freq2 calculation use setpoints FreqRate1 and FreqRate2 - see below. Closed jumper divides input frequency by 16 - recommended for higher frequency (>1000Hz) measuring. Jumper position does not influence output value range.

Jumper RPM input nominal frequency range

Closed > 1000 Hz

Closed or Opened 500 1000 Hz Opened < 500 Hz

IMP1, IMP2: Two impulse inputs for integral (e.g. consumption) measuring. It is expected NPN open collector (active) impulse sensor with maximal frequency range up to 60 Hz. Minimal pulse duration is 1ms. The output values SCM Imp1, SCM Imp2 calculation use setpoints TransferRate1 and TransferRate2 - see below. ID-SCM inputs wiring example


RPM IN

RPM GND

Magnetic pickup

RPM1, RPM2

Magnetic pickup wiring to RPM1 and RPM2 inputs.

PWR

INGND

Contact

IMP1, IMP2

Contact sensor wiring to IMP1 and IMP2 inputs.

Active NPN

sensor

+24VDC

GND

IMP1, IMP2

PWR

IN

GND

Active NPN sensor wiring to IMP1 and IMP2 inputs.

Outputs

AOUT1, AOUT2: Two general-configurable analog outputs for indication or any loop control. Outputs are jumper adjustable between 0 to 10VDC and 0 to 20 mA. Speed governor: Analog interface to engine speed governor for engine speed control by voltage (engine without ECU). Output is jumper selectable between 10VDC or 10VDC via 10kohms or PWM (1600Hz / 5Volts, 10 mA max). The Speed governor output can be also configured by DriveConfig as the AOUT3 analog output if needed. Default jumpers setting: AOUT1 and AOUT2 ~ 0-10VDC; Speed governor ~ 10VDC; RPM1 and RPM2 ~ opened jumper (divides input frequency by 1).

r

ID-SCM1

Cost effective version of ID-SCM with just one Speed governor output. ID-SCM1 module has one analog output module for InteliDrive industrial or marine applications. Module is mounted directly to ID-DCU controller case. Technical data

Power supply: internal supply from ID-DCU (8 to 36 VDC) Operating temperature range: -40C to +70C


Number of analog outputs: 1, no galvanic separation Analog output refreshment: 100 ms

Analog output options a) pwm 1600 Hz (fix), 5V level, max 10 mA b) 0 to 10VDC 1%, 10 kiloohms output resistance c) 0 to 10VDC 1%, max 5 mA (voltage output)

Configuration in DriveConfig a) Modules = SCM b) I/O Analog outputs SCM active AOUT1 only!

a. Source b. Convert c. Low limit (value corresponding to 0V output) d. Hi limit (value corresponding to 10V output)

InteliVision 8

InteliVision 8 is 8 color TFT display with powerful functions ( For more details see InteliVision-1.2.2-Reference Guide r1.doc) 1. InteliVision 8 can be used as additional remote display for ID-DCU Industrial or ID-DCU Marine. Technical parameters:

8" color TFT display, 800 600 pixels

Operating temperature: -20 + 75C Front IP 65 / Rear IP 20

CAN bus interface; RS485, RS232

Plug and Play structure following controller configuration

Power supply: 8 -36 VDC

Terminals and Dimension


Back side of InteliVision 8

InteliVision 5

5 inch color display.

245 (9.7")

16

4

(6.5

")

282820

170 (6.7")

11

0

(4.3

")

InteliVision5 ComAp

Fixing clips

Connector

Power


170 (6.7")

110 (4

.3")

InteliVision5CAN connector wiring

1 GND 5 UBatt

2 A/B IN 6 CAN-L

3 BO-A 7 COM

4 BO-B 8 CAN-H

1-5: Power supply 8 36VDC 6-8: CAN2 (with galvanic separation) to ID-DCU or ID-Mobile. 3-4: Binary output fix configured for Horn function. It is Solid State Relay with galvanic separation max 36VDC/0,5A (like free contact). 2-1: Analog/Binary Input for display and buttons backlit control.

Connect resistive pot for continuous backlit change: 0 = 0%; 2400 (and more) = 100% OR just contact to switch between 0% and 100%. Note: It is possible to connect up to three InteliVision 5 or InteliVision 8 displays to common CAN2 bus. The display addresses must be different in this case.


Communication lines wiring

InteliDrive Remote Display (Remote Panel)


Hint: The ID-DCU-Industrial controller can be used as a I-RD-CAN remote display after uploading of the I-RD-CAN firmware

Remote Display I-RD-CAN (Remote Panel) works as a remote control panel for the ID-DCU master controller.

All panel buttons works the same way as corresponding buttons on master controller. All LEDs displays the same state as corresponding LEDs on master controller.

Start, Stop buttons and setpoint changes are not active when master ID-DCU controller is in Local mode.

I-RD-CAN screen listing does not influence screen on master controller.

Interruption of the serial line between master device and I-RD-CAN will have no effect to the engine. Master device will always be able to work without connected Remote display.

I-RD-CAN displays the same screens as its master controller and can be switched to the same languages. The user interface is identical as the master controller.

I-RD-CAN is the same mechanical and electronic design (the same box but some electronic components were removed). No inputs and outputs are available on I-RD-CAN only.

It is possible to connect I-RD-CAN to ID-DCU via RS232 (38,4kbps) or via CAN bus (50 or 250 kbps).

I-RD-CAN automatically downloads new configuration table from master controller if the CRC doesn t match the CRC of the stored configuration table.

I-RD-CAN uses separate mhx firmware different from controller firmware compatible with both ID-DCU-Industrial and ID-VP-Industrial.

I-RD-CAN firmware can be reprogrammed via Boot load procedure only.

I-RD-CAN backlight can be switched to full intensity when middle power supply terminal (D+ in DCU) is closed to + power supply.

I-RD-CAN wiring

RS232 interface: three wire cable (2-3, 3-2, 5-5), max. cable length up 10 meters.

ID-CU I-RDRS232 RS232

Contr.addr 1

CAN addr. 1

Contr.addr 1

Using converters to RS485 or RS422 increases distance up to 1000 meters. 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, baud rate 38400 bps.

BL

Jumper (under cover) to connect I-RD-CAN internal 120 resistor for CAN bus line terminating

I-RD-CAN


ID-CU I-RDRS232 RS232RS232 /

RS422/485

RS232 /

RS422/485

RS422/485Converter Converter

Contr.addr 1

CAN addr. 1

Contr.addr 1

CAN bus connection requires ID-COM module on ID-DCU. Use I-RD-CAN Central unit 9-pin connector (5=CAN H, 9=CAN L) to connect CAN bus. Put jumper to connect I-RD-CAN internal 120-ohm resistor for CAN bus line terminating.

ID-CUCAN2

ID-C

OM

I-RD

Contr.addr 1

CAN addr. 1

Contr.addr 1

5 - CAN H

9 = CAN L

120 o

hm

I-RD-CAN can monitor any ID-DCU controller on the CAN2 bus based on I-RD-CAN Contr. address setting.

1.ID-CUCAN2

ID-C

OM

I-RD

2.ID-CU

ID-C

OM

`

`

Contr.addr 1

Contr.addr 2

CAN addr. 1

Contr.addr 2

5 - CAN H

9 = CAN L

12

0 o

hm

It is possible to connect up to two I-RD-CAN to common CAN2 bus. The I-RD-CAN address must be different in this case.

1.ID-CUCAN2

ID-C

OM

I-RD

2.ID-CU

ID-C

OM

I-RD

CAN addr. 1

CAN addr. 2

Contr.addr 1

Contr.addr 2

Contr.addr 1

Contr.addr 2

5 - CAN H

9 = CAN L

12

0 o

hm

12

0 o

hm

Hint: There is no connection between ID-DCU and Remote panel during ID-DCU controller programming and in INIT state.

Rules for InteliVision 5/8, I-RD-CAN, I-LB and IG-IB CAN2 address setting There are only 2 addresses on the CAN2 bus, that are shared between IG-IB, I-RD-CAN and I-LB, I-LB+ (IG-MU) - when used for direct cable connection. That means only two of these modules can be used at the same time on the same bus. The I-LB (IG-MU) can be connected as third device when is used for modem connection. The following CAN addresses are used for modules connected to CAN2 (intercontroller CAN bus). There cannot be more modules using the same address connected at the same time. Address can be changed using jumpers, configuration program or from the display - refer to the corresponding chapter or reference guide for detailed description.


Real CAN2

Address IG-MU I-LB

I-LB (modem)

I-LB+ IG-IB

(IBConfig 1.5)

IG-IB (IBConfig

1.6) IV 5, IV 8 I-RD-CAN

121

122 addr. 2

123 addr. 2 addr. 2 addr. 1 addr. 1 addr. 2 addr. 2 addr. 2

124 addr. 1 addr.1 addr. 2 addr. 2 addr. 1 addr. 1 addr. 1

125 modem addr. 1 addr. 3 *1

addr. 3 *1

Hint: *1

- address 3 can be in the controller enabled or disabled for InteliVision 5 CAN, InteliVision 8 or I-RD-CAN utilization by 5thRemPan setpoint value. ENABLED ~ address 3 is available for InteliVision 5 CAN (or InteliVision 8 or I-RD-CAN), DISABLED ~ address 3 is not available for displays but it is dedicated for modem. Hint: Please note that USB port is using its CAN address only if an external device is connected to the USB port of I-LB+. Make sure that other device (e.g. IG-IB) is not using the same CAN address as USB port of an I-LB+, because using USB port could interrupt CAN communication. Hint: Please note that addresses 1 and 2 (123, 124) are exchanged in versions IBConfig 1.5 and IBConfig 1.6 (see the table above).

IG-MU, I-LB address is set by Jumper

IG-IB address is set during configuration by IBConfig PC software.

InteliVision 8 and I-RD-CAN address can be set from I-RD-CAN keyboard during initialization.

How to establish ID-DCU to I-RD-CAN connection

Following screen appears after I-RD-CAN power supply is switched on and there is no connection to ID-DCU established.

Screen rows Meaning / selection range I-RD front panel button to change

I-RD-Industrial 1.x I-RD firmware branch and version

ComAp 2004 Copyright

SN: xxxxxxxx Controller serial number

Contr. Addr: 1 Controller address: 1 to 32 Up, Down

Connection: CAN addr.1 Connection: CAN addr.1, CAN addr.2, RS232

Page

NO CONNECTION TRYING. , PROGRAMMING I-RD status during Init state.

1. Connect selected communication line between ID-DCU controller and I-RD-CAN panel. 2. Switch ID-DCU and I-RD-CAN power supply on. 3. After I-RD-CAN Initialization screen appears: Use front panel Up/Down buttons to change

Controller address in the range 1 to 32. This I-RD-CAN Controller address must correspond to connected ID-DCU Basic setting: Controller address setpoint.

4. Use Page button to set I-RD-CAN connection: CAN addr.1, CAN addr.2 or RS232. 5. Then press Enter button to start data download. Message TRAYING appears on the I-RD-CAN

screen. Unsuccessful attempt to read data is repeated each 15 sec. 6. The Programming bargraph appears on I-RD-CAN screen after connection is opened. 7. Standard ID-DCU screen appears after complete configuration is loaded to I-RD-CAN.

Hint: To switch to Init screen press Page button for more than 2 sec when CFG table error message appears on the I-RD-CAN screen.


I-RD-CAN backlight-brightness intensity change (the same procedure for ID-DCU and I-RD-CAN) 1. Enter+Page buttons = switch to Info screen and then 2. Enter+Up/Down button increases/decreases the display backlight (it is stored - until the next change). 3. The setpoint Basic setting: LightTimeOff in I-RD works locally for I-RD (this is only exception) and it is not transferred to the central unit. Backlight is after this time switched off from current level. Any key touch activates the backlight. That means it is possible to set I-RD backlight level and LightTimeOff independent to ID-DCU. From I-RD firmware version 1.2 and hardware version 2.0 from s.n. xxxx0006 is possible to change Remote panel display backlight between adjustable and full level via external switch see drawing below.

POWER

8-36VDC

+ -

POWER

SUPPLY

BACKLITE

SWITCH

REMOTE PANEL

Opened switch = Backlight is adjustable by Enter-Up/Enter-Down panel keys from INFO screen (Enter-Page)

Closed switch = full backlight like in ID-DCU

Hint: It is not possible to control I-RD backlight continuously via analog input like on ID-DCU.

BL


ID DCU dimensions

ID-COM and ID-SCM are mounted directly to ID-DCU case. I-RD Industrial (Slave panel) has the same dimensions.

ID-SCM

ID-DCU

ID-COM

183 (7,2")

80

(3,1

")

42,5

(1,7

")24

(0,9

")

47

(1,8

")

~11

0(4

,3")

170 (8,87")

RS232

123

(4,8

")110

(4,4

")

Cutout

for InteliDrive

113 x 175 mm

(4.4 x 6,9)

ID-DCU box is fixed using four screw clips.

I-RB.. technical description

Relay board contains 16 or 8 relays for ID-DCU binary (open collector) output separation. All relays are placed in sockets. Product options

I-RB16 16 relays, load 24 VDC

I-RB8 8 relays, load 24 VDC

I-RB16-231 16 relays, load 231 VAC

I-RB8-231 8 relays, load 231 VAC

Number relays: 16 or 8 in sockets Nominal voltage: 24 VDC Voltage range: 16,8 36 VDC Relay opens at: 10% of nominal voltage Electric / mechanic cycles: 100 000 / 10 000 000 Operating temperature range: - 40C to 70C Maximal load: 6 A resistive load at 24VDC 4 A inductive load at 24 VDC 2 A at 231VAC Contacts protection: varistor 14DK390

1

K

2 3

1-2 n.o. 1-3 n.c.

113 (4,43)

180 (7,06)

170 (6,67)


Mechanical dimension I-RB16 is 35 mm DIN rail mounted. One unit contains two parts (separate PCB) 8 relays each on common plastic base. I-RB16, I-RB8 is 60mm high from DIN rail base.

16

X17

11 1 11 1 11

1 +

X18

11 1 11 1 11

RE

1

RE

2

RE

3

ER

4

RE

5

RE

6

RE

7

RE

8

RE

9

RE

10

RE

11

ER

12

RE

13

RE

14

RE

15

RE

16

X3 X1X2X6 X4X5X8 X7X11 X9X10X14 X12X13X16 X15

9 + 8

16 X18 9 +View B

X18

8 X17 1 +

View B

3 X1 1

X1 X2 X3 X4 X5 X6 X7 X8 X9 X10 X11 X12 X13 X14 X15 X16

View A

3 X2 1 3 X3 1 3 X4 1 3 X5 1 3 X6 1 3 X7 1 3 X8 1 3 X9 1 3 X10 1 3 X11 1 3 X12 1 3 X13 1 3 X14 1 3 X15 1 3 X16 1

View A

300

95

X17

Hint: I-RB16 contains two separate boards, 8 relay each.

IS-BIN16/8

Extension module with 16 binary inputs and 8 binary outputs. All I/O can be configured to any logical function or protection - see chapter Binary inputs and Binary outputs. RPM1 and RPM2 inputs are not supported in InteliDrive. IS-BIN16/8 module is connected on InteliDrive CAN1 bus. The corresponding module Address must be set on module and in controller configuration. Communication fail is indicated in controller Alarm list and by binary outputs Comm BIN fail, Comm BOUT fail. Use DriveConfig PC tool for controller configuration. The Binary I/O specification see in chapter Technical data.


45 (1,8")146 (5,7")1

60

(6,3

") 40 (1,6")

25 (1,0")

IN1

-

RPM

+

IN 2

IN1

+

RPM

-

IS-BIN16/8 unit is DIN rail mount (35mm)

IS-AIN8

Extension module with 8 analog inputs. All inputs can be configured to any logical function or protection - see chapter Analog inputs. IS-AIN8 module is connected on InteliDrive CAN1 bus. The corresponding module Address must be set on module and in controller configuration. Communication fail is indicated in controller Alarm list and by binary output Comm AIN fail. Use DriveConfig PC tool for controller configuration. The analog inputs specification see in chapter Technical data.


46,4 (18,3")

40 (15,7")

25 (9,8")

70 (27,5")

146 (57,5")

160

(63

")

POWER8 - 36V DC

CO

M

CO

M

CAN CAN

RS 232

H HL L

+

iS-AIN8

IS-AIN8 unit is DIN rail mount (35mm)

IGL-RA15 Remote annunciator

Remote (CAN1 bus, up to 200 meters) 15 LED states indicator. One iGL-RA15 unit can be connected to ID-DCU via CAN1 as Binary output group of addresses 5 and 6. Detail descriptions see in IGL-RA15.pdf user guide. Communication fail is indicated in controller Alarm list and by binary outputs Comm BOUT fail. Use DriveConfig PC tool for controller configuration.


165 (6,5)

38

(1,5

)

40

(1,6

)~7

5(3

,0)

~3

5(1

,4)

180 (7,1)

185 (7,3)

10

6(4

,2)

44 (1,7)

54 (2,1)

~2

5(1

,0)

12

0(4

,7)

12

5(4

,9)

Cutoutfor Remote Annunciator

167 x 108 mm(6,6 x 4,3)

IGS-PTM

Extension module with 4 analog inputs, 8 Binary I/O. All I/O can be configured to any logical function or protection - see chapter Binary inputs, Binary outputs and Analog inputs. IGS-PTM module is connected on InteliDrive CAN1 bus. The corresponding module Address (1 to 4) must be set on module and in controller configuration. Communication fail is indicated in controller Alarm list and by binary output CommBIN fail, CommBOUT fail, CommAIN fail. Use DriveConfig PC tool for controller configuration. Any analog input can be configured for range:

0 250 (suitable for Pt100, Ni100), 0 100 mV (suitable for thermocouples), 0 20 mA.

Detail description see in IGS-PTM-1.0.pdf manual.


95 mm(3,7)

43 mm(1,7)

96 m

m (

3,8

)

COMPENSATION

GN

D

POWER

8-36V DC

BINARY OUTPUTS

BINARY INPUTS ANALOG INPUTS

AI4

BI8

BI7

BI6

BI5

BI4

BI3

BI2

BI1

0-20 mA ANALOG OUT

BO

8

BO

1

BO

2

BO

3

BO

4

BO

5

BO

6

BO

7

CA

N

Rx

Tx

CA

N

LH

CO

M

LB 4

AO

-

AO

+

iGS-PTM

IGS-PTM unit is DIN rail (35mm) mounted.

I-AOUT8

Extension module with 8 analog outputs. All outputs can be configured to any logical function - see chapter Analog outputs. I-AOUT8 module is connected on InteliDrive CAN1 bus. The corresponding module Address 1 to 4 (default 1) must be set on module and in controller configuration. Communication fail is indicated in controller Alarm list and by binary output Comm AOUT fail. Use DriveConfig PC tool for controller configuration. Each analog output can be switched by jumper for.

- 0 to 20 mA - 0 to 10 VDC (default) - Pwm (Pulse With Modulation on 1,2 kHz)

Module is 35 mm DIN rail mounted. CAN1 terminating 120 ohm resistor jumper is connected in default.

95 mm (3,7)43 mm(1,7)

96

mm

(3,8

')

Power

supply

I-AOUT8ComAp

HW:

SW:

+ 8

-36 V

DC

GN

D

AG

ND

AO

UT

5

AG

ND

AO

UT

6

AG

ND

AO

UT

7

AG

ND

AO

UT

8

ANALOG OUTPUTS

AO

UT

1

AG

ND

AO

UT

2

AG

ND

AO

UT

3

AG

ND

AO

UT

4

AG

ND

ANALOG OUTPUTS

CA

NL

CC

OM

CA

NH

CAN

U - I - p U - I - p U - I - p U - I - p

p - I - U p - I - U p - I - U p - I - U

1 2 Pwr

120 ohm

Hint: Extension module communication fail can be configured in DriveConfig to No protection, Warning, Shutdown.


IG-LB, I-LB+

Modem interface unit for multiple engines with more separate internal channels for controller connection: - Local connection 1 (I-LB local address 1) - Local connection 2 (I-LB local address 2) - Modem connection 1 (I-LB modem address 1) - Modem connection 2 (I-LB modem address 2)

It is necessary to select which connection type(s) a particular I-LB is using. In I-LB+ version, there is additional USB slave port, which can be used as a local connection only, together with RS232-modem connection. See more details in Inteli Communication Guide.

Jumper selection tree ComAp / ModBus selects between ComAp PC tools (InteliMonitor, WinScope, ...) and third party PC SW for monitoring: - ComAp

o Direct / Modem selects between direct connection (via RS232 or RS485) and modem connection type DIRECT

RS232 / RS485 selection of serial communication type

ADR1 / ADR2 selection between two available local communication channels; if I-LB+ is used, the USB communication automatically occupies the other channel

MODEM HW / SW control selection between modems with full interface ADR1 / ADR2 selection between two available modem communication channels;

IG/IS-NT controllers only, in ID the secondary modem channel not available

Setting RS232 / RS485 jumper to RS232 position is obligatory - ModBus (not available at USB port of I-LB+, USB port always works in ComAp mode)

o Direct / Modem selects between direct connection (via RS232 or RS485) and modem connection type

DIRECT RS232 / RS485 selection of serial communication type

ADR1 / ADR2 selection between two available local communication channels; if I-LB+ is used, the USB communication automatically occupies the other channel

MODEM ADR1 / ADR2 selection between two available modem communication channels;

IG/IS-NT controllers only, in ID the secondary modem channel not available

Setting HW / SW control has no influence; a modem with HW control is always expected in this mode

o ModBus Rate (9600 / 19200 / 38400 / 57600 bps) selects the communication speed when ModBus protocol is selected, no matter if in Direct or Modem mode


IG-IB Internet bridge

Internet interface unit for single or multiple engines.

95 mm(3,7)

43 mm(1,7)

96

mm

(3

,8

)

See Internet communication It is recommended to use IG-IB firmware version 2.0 IG-IB unit is DIN 35 mm rail mounted.

I-CB communication bridge

I-CB (Communication bridge) is programmable CAN1 bus interface between InteliDrive and Engine Control Units (like MTU, CAT etc.) without standard J1939 communication protocol. Engine values from ECU (RPM, Oil pressure and other) are converted to standard InteliDrive I/O protocol. Use ICBEdit software for I-CB configuration.

POWER8-36V DC

COM

RS

23

2

LB 4i-CB

95 mm(3,7)

43 mm(1,7)

96 m

m (

3,8

)


Recommended wiring

Wiring example

14

L H

H

-

A

B

12345678

H

L

A

B

CAN2

CAN1

ID-COM

+

L

J15

87

J19

39

K17 K18

I-RB16

9 9

1 2 3

16x

K1-K16

120 ohm

12

0 o

hm

CAN2

59

HL

IS-BIN

LH

IS-AIN

LH

IGS-PTM

LH

12

0 o

hm

+ -POWER

+ -POWER

+ -POWER

120 ohm

IG-IBIG-MU

+ -POWER

+ -POWER

L HL H

12

0 o

hm

Engine without ECU (mechanical engine)

14

K17 K18

I-RB16

9 9

1 2 3

16x

K1-K16

12

0 o

hm

CAN1

59

HL

IS-BIN

LH

IS-AIN

LH

IGS-PTM

LH

12

0 o

hm

+ -POWER

+ -POWER

+ -POWER

120 ohm

-+


Scania S6 wiring example

CAN L

CAN H

STARTER LOCK

KEY

+24V

GND

+24VStarter

relay

STARTER LOCK KEY B1-3 pin can be used for engine Emergency stop. Function in ID-DCU operational mode: engine Start/Stop is processed via J1939 CAN bus and STARTER KEY LOCK is all time on +24 volts (CPU ready on Fuel solenoid output is still closed). The starter must be operated via A1-6 pin according drawing above when EDC control unit is configured to start engine via J1939 CAN bus.

Bus/Communication architecture

RS232 One of following possibilities is available:

PC software interface (DriveConfig, DriveMonitor). Modbus protocol option for SCADA systems. Analog or GSM Modem interface. IG-IB internet interface.

CAN1 / J1939 / KWP2000

CAN1 is data line for controller Inputs/Outputs extension. It is possible to connect following extension modules:

ECU (Engine Control Unit), IGS-PTM (8 BI, 8BO, 4AI, 1AO), IS-AIN (8AI), IS-BIN (16BI, 8BO).


Full physical CAN interface on ID-DCU is available, no ID-COM interface needed. Maximal CAN bus length is up to 200m.

CAN2

Inter-controller CAN for multiple engines applications. ID-COM module is necessary. It is possible to connect

ID-DCU controllers and/or I-LB, I-LB+, IG-MU (Direct cable, analog modem or GSM modem interface) and/or IG-IB (Internet interface) and/or I-RD Industrial remote display (Slave panel).

There are some limits for number of modules connected to CAN2 see Rules for I-RD, IG-MU and IG-IB CAN address setting. The data rate is selectable in two levels: 250 kbd for 200 meters line and 62 kbd for 900 meters line.

Redundancy line (e.g.J1708)

There are 2 datalinks in the system, one CAN SAE J1939 datalink and one SAE J1708/J1587 datalink. The J1939 datalink is used for control and monitoring data. The J1708/J1587 datalink is used for redundancy control and monitoring. The ID-COM interface is necessary to use for synchronous J1708/1587 data line.

CAN bus Connection rules

CAN bus line must be connected in series, from one unit to the next (no star, no cable stubs, no branches) both ends must by the 120-ohm (internal or external) resistor terminated. Maximal CAN2 bus length is up to 200 meters when Basic settings: CAN bus mode = 32C or up to 900 meters when Basic settings: CAN bus mode = 8C. For CAN data cables details see chapter Technical data Communication interface. CAN cable shielding connect to ID-DCU case. ID-DCU contains internal fix 120-ohm resistor on CAN1 bus. Use D SUB9 male connector: CAN H = 5, CAN L = 9, COMMON = 3 and 8. ID-DCU must be on the CAN bus end. IGS-PTM units contains internal jumper-removable 120 ohm resistor. To be sure check resistor presence by ohmmeter. Unit with internal resistor should be connected to the end of CAN2 line.

I-CB wiring and configuration

CAN H

CAN L

EngineControl Unit

120

Ohm

Controller

CAN H

CAN LCA N L

CA N HC O M

CA N L

CAN HC O M

CAN H

CAN L

I-CB

CAN 1 CAN ECU

ECU

120

ohm

CA

N 1

CA

N 2

1. Configure I-CB using I-CBEdit software. Configured I-CB behaves like fictive IS-AIN and IS-BIN units. I-

CB configuration associates selected values (from ECU database) received from Engine Control Unit to selected CAN addressees (fictive IS-AIN, IS-BIN inputs and outputs).

2. Configure corresponding CONTROLLER CAN addresses in PC configuration tool. 3. Configure separate inputs and outputs in corresponding Analog, Binary inputs, outputs in PC

configuration tool. Hint: In case of CAT engines, there is RS232 connection between I-CB and CCM.


Getting started

How to install

Hint: All components shall be used within marked electrical ratings see chapter Technical data.

General

To ensure proper function: Use grounding terminals. Wiring for binary inputs and analog inputs must not be lead parallel with high voltage/current cables. Analog and binary inputs should be provided with shielded cables, especially when length >3m.

Power supply Use min. power supply cable of 1.5 mm

2 to ensure proper function.

Maximum continuous DC power supply voltage is 36VDC. Maximum allowable power supply voltage is 39VDC see chapter Technical data. Hint: The InteliDrive controller should be grounded properly in order to protect against atmospheric discharges !! Install separate conductors for signal and power inputs. Allow for conductor voltage drop when determining conductor size. All power supplies must have common ground.

+

+

Battery

-

-

controller

and load

HUGE

LOADS

STARTER

T2,5 A

Power supply fusing

T2,5 Amp fuse (depends on load size) should be connected in-line with the battery positive terminal to the controller and modules. Controller and I/O modules should never be connected directly to the starting battery. Fuse value and type depends on number of connected devices and wire length. Recommended fuse (not fast) type - due to internal capacitors charging during power up.

Binary output protections Do not connect binary outputs directly to DC relays without protection diodes. Use protection diodes even if the relays are not connected directly to controller outputs. Use a fast recovery 3A / 50V diodes.


+

-

K1K1

K2K2

24VDC+-

controller

Fuse

Fuse

Battery

DC relays

Fuse

Example of controller protection

Grounding

To ensure proper function: The shortest possible piece of wire should be used when grounding the controller. Use cable min. 2,5mm

2 .

The - terminal of the battery has to be properly grounded.

Magnetic pick-up

To ensure proper function use a shielded cable.

+

Battery

-

GACSpeed Control Unit

ESD 5500

MAGNETICPICK-UP

CD

Signal

Signal

+

+-

-

PowerSupply

PowerSupply

GND

RPM-IN

controller

Be aware of interference signal from Speed governor when one speed pick-up is used.


ID-DCU Analog inputs hardware configuration

Configure Analog inputs AI1-AI8 connection by jumpers on PCB (remove cover).

Grounding Terminal

BOOT JUMPER

BINARY INPUTSRPM

BINARY INPUTSANALOG INPUTS

BINARY OUTPUTS POWER8 - 36 V DC

EX

TE

NS

ION

MO

DU

LE

ID-R

PU

RS

232

LB

1

EX

TE

NS

ION

MO

DU

LE

ID-C

OM

+ -RPMG

ND

RP

MIN

BI1

BI2

BI3

BI4

BI5

SH

IEL

D

CO

M

D+

BO

1

BO

2

BO

3

BO

4

BO

5

BO

8

BO

6

BO

12

BO

13

BO

14

BO

9

BO

7

BO

10

BO

11

AIN

1

AIN

2

AIN

3

AIN

4

AIN

6+

AIN

5+

AIN

8+

AIN

8-

AIN

6-

AIN

5-

AIN

7+

AIN

7-

BI6

BI7

BI8

BI9

BI1

0

BI1

1

BI1

3

BI1

2

BI1

4

1234

AI1

AI2

AI3

AI4

1234 A

I5+

AI6

+

AI7

+

AI8

+

Jumpers setting

1234

Current Measurement jumper on pins 1-2.

1234

Voltage (thermocouples AI5-AI8) measurement jumper on pins 2-3.

1234

Resistance measurement - jumper on pins 3-4.

Hint: Maximal voltage on controller Differential analog inputs AI5 to AI8 is in the range 2 to +5 VDC against minus power supply terminal !


Controller default jumper setting from production

AI1 to AI4 Current sensor

AI5 to AI8 Resistance sensor

ID-DCU Analog inputs software configuration

See table below Hint: ID-DCU hardware jumper must correspond with software configuration.

Configuration

See drawing above.

Property Value

Name Value name is displayed on the screens and in the Alarm list and History record. Enter up to 14 ASCII characters. Name is automatically set to Function name if function is selected from the Logical function list see Function item.

Dim Dimension is displayed on the screens. Select dimension from the list or add a new one.

Sensor Select sensor from the list or create a customer sensor characteristics in User sensor window. There must be corresponding analog input hardware jumper setting in InteliDrive controller. See Sensor availability table below.

Resolution Output value (reading) resolution. DriveConfig indicates when Resolution is out of the value range.

Sensor range Full output value (reading) range for 20 mA (current), 250 , 2400 (resistive), 1 V, 100 mV (voltage) sensor.

Protection type Select from the list. Configure two levels protection as standard or more levels (window) protection in Expert mode.

Active when Configure direction Over or Under limit when protection is activated.

Block type Configure protection activity: All the time or Engine running with three different adjustable delays when protection is active after engine start (RPM > Starting RPM).

Bargraph 100% Value for bargarph full scale.

Function Select from the list if function is required or leave free if input is a protection only.

Protections:

No protection

Warning

Sensor fail

Colldown

Shutdown

Alarm only

HistRecord only

Protections:

No protection

Warning

Sensor fail

Colldown

Shutdown

Alarm only

HistRecord only

Protections:

No protection

Warning

Sensor fail

Colldown

Shutdown

Alarm only

HistRecord only

Sensor

characteristics

+

RI

Analog input

Protections:

No protection

Warning

Sensor fail

Colldown

Shutdown

Alarm only

HistRecord only

Logical analog

input list

Analog output

Binary outputs

State machine

Hardware

jumper

ID-DCUV

alu

e

Bargraph20mA = 10,0 Bar


Sensors availability

Sensors available on ID-DCU AI1 AI4 Resolution Sensor range HW jumper Pt1000/C, Ni1000/C, Pt1000/F, Ni1000/F

Fix, not configurable Resistance: 3-4

4-20 mA active, 20 mA active (measures + only)

See Hint below

For 20 mA input Current: 1-2

0-250 , 0-2400 For 250 or 2400 Input

Resistance: 3-4

0 4V Voltage

Sensors available on ID-DCU AI5 AI8 Resolution Sensor range HW jumper Pt100/C, Pt1000/C, Ni100/C, Ni1000/C, Pt100/F, Pt1000/F, Ni100/F, Ni1000/F Fix, not configurable Resistance: 3-4

Thermocpl J/C, Th. K/C, ThL/C, Thermocpl J/F, Th. K/F, ThL/F Fix, not configurable Voltage: 2-3

4-20 mA active, 20 mA active See Hint below

For 20 mA input Current: 1-2

0-250 , 0-2400 For 250 or 2400 input

Resistance: 3-4

1 V, 0-100mV , 0 5V For 1V or 100mV Voltage: 2-3

Configuration examples

Conversion from 4-20mA to 6,0 Bar Oil pressure sensor (Wrn+Sd protection and Oil pressure function)

Conversion from 1V input to engine speed request 0 to 100%


Step 1. Create new User sensor Hint: HW configuration: CU 0-1V can be used for characteristics 1V, but this characteristics can be configured to AI5 to AI8 inputs only ! Sensor range (gray background) automatically follows the User sensor characteristics (zero value in drawing above is not important).

Conversion from 20mA to 100% request

Re

quest

[%]

-20 m

A

20 m

A

+100%

mA

0 m

A

-100%

Sensor

fail

Sen

sor

fail

Bargraph

0% +100%

Sensor characteristics 20mA works in full range on ID-DCU AI5 to AI8 only. ID-DCU AI1 to AI4 measures 0 to 20 mA range only. Default sensor characteristics creates conversion to 100%. Bargraph indicates only positive values 0 to +100%.


Conversion from 20mA to +100% request with User sensor

-20

mA

20

mA

+100%

mA

0 m

A0%

+50%R

equ

est

[%]

Se

nso

r fa

il

Se

nso

r fa

ilBargraph indication

0% 100%

Sensor characteristics 20mA works in full range on ID-DCU AI5 to AI8 only. ID-DCU AI1 to AI4 measures 0 to 20 mA range only. Step 1. Create User sensor like below. Step 2. Configure user sensor instead default 20mA sensor. Step 3. Configure Bargraph 100% to correspond User sensor. Bargraph indicates full 0 to 100% range in this case.

1. Step: Create User sensor like below.

2. Step: Configure user sensor instead default 20mA sensor.

User sensor examples

Availability Configuration

AI1 to AI4 AI5 to AI8 Analog input jumper = 1-2 (current)

0 - 20mA / 600

AI1 to AI4 AI5 to AI8

4 - 20mA / 100,0

AI5 to AI8 Analog input jumper = 2-3

0 1V / 10,000


(voltage)

AI5 to AI8

0 - 100mV / 100,00

AI1 to AI4 AI5 to AI8 Analog input jumper = 3-4 (resistance)

0 1200 ohm / 100

Hint:

It is possible to set up to 30 points non-linear sensor characteristics. Connect external resistors (voltage divider) to extend input voltage range.

Hardware connection

Connection of ID-DCU analog inputs

ID-CU

CO

M-

PO

WE

R

AI4

AI3

AI2

AI1

AI6

-A

I6+

AI5

-A

I5+

AI8

-A

I8+

AI7

-A

I7+

All jumpers in position (3-4)

Standard connection of resistive sensors to ID-DCU analog inputs AI1 to AI8. The COM terminal must be always connected to the negative power terminal.

v

+

v

+

-

CO

M-

PO

WE

R

AI1

(3

-4)

AI4

AI3

(2

-3)

AI2

(1

-2)

AI6

-A

I6+

AI5

-A

I5+

AI8

-A

I8+

AI7

-A

I7+

(3-4

)

(1-2

)

(1-2

)

(2-3

)

+

Different sensors connection to ID-DCU. AI configuration jumpers must be in corresponding position and corresponding DriveConfig configuration according to used sensor. Analog input common terminal COM has to be connected to ID minus Power supply terminal. Mixed connection of ID-DCU analog inputs: AI2, AI7 current sensor AI1, AI5 resistive sensor AI3, AI8 voltage input AI6 thermocouple (voltage) AI4 Not used


ID-CUC

OM

- P

OW

ER

AI4

AI3

AI2

AI1

AI6

-A

I6+

AI5

-A

I5+

AI8

-A

I8+

AI7

-A

I7+

All jumpers in position (3-4)

2x 4

70 o

hm

s

2x 4

70 o

hm

s

Mixed connection of ID-DCU analog inputs: AI1, AI2, AI5, AI6 resistive sensor AI3, AI7 binary input AI4, AI8 three state input Analog input common terminal COM has to be connected to ID minus Power supply terminal.

To ensure a proper function use shielded cables, especially for length over >3m.

Analog inputs on IS-AIN8

IS-AIN8 analog inputs can be configured to

Resistor two wire input

Resistor three wire input

Current input

Thermocouple input

Voltage input Select sensor characteristic from the list or define user sensor characteristic in DriveConfig.

A

B

C

D

Resistor sensor input two wire connection. Range 0 to 2400 ohms. Pt100, Pt1000, Ni100, Ni1000 D terminal is shielding

A

B

C

D

Resistor sensor input three wire connection. Range 0 to 2400 ohms. Pt100, Pt1000, Ni100, Ni1000 recommended. D terminal is shielding

A

B

C

D

Passive current sensor (current source is in IS-AIN8) Range 0 to + 20 mA or 4 to + 20 mA D terminal is shielding

A

B

C

D

+ +24 VDC

0 VDC

Sensor

mA

A

B

C

D

+

+24 VDC

0 VDC

SensormA

Active current sensor (current source is in sensor) Range 20mA to +20 mA or 4 to + 20 mA D terminal is shielding


A

B

C

D

+

Thermocouple J, K, L D terminal is shielding From IS-AIN8 hardware version 5.1 can be B thermocouple terminal connected to frame.

A

B

C

D

+

Voltage input Range 0 to + 2500 mV. Voltage range is 0 to 1000 mV. D terminal is shielding

A

B

C

D

+

R1

R2

For 10V input voltage range connect external resistors R1, R2 and select sensor characteristic 10V. R1=10 Kohm, R2=2,7 Kohm. D terminal is shielding

Hint Thermocouples connected to IS-AIN8 hardware versions below 5.0 must be galvanically separated from the frame. If the thermocouples are connected to IS-AIN8, appropriate jumpers must be removed (see rear sticker).

Analog Sensor availability Table of supported sensors on various modules. Do not configure sensors, that are not supported on the input.

ID AI1-4 ID AI5-8 IGS-PTM IS-AIN8

PT100/C Y Y Y PT1000/C Y Y Y NI100/C Y Y Y NI1000/C Y Y Y PT100/F Y Y Y PT1000/F Y Y Y NI100/F Y Y Y NI1000/F Y Y Y Thermo J/C Y Y Thermo K/C Y Y Thermo L/C Y Y Thermo J/F Y Y Thermo K/F Y Y Thermo L/F Y Y 4-20mA passive Y

4-20mA active Y Y Y Y

0-20mA passive Y

+-20mA active Y Y Y Y

0-250ohm Y Y Y Y

0-2400ohm Y Y Y

0-4V Y Y

+-1V Y Y

0-10V Y

0-100mV Y Y Y

Tristate Y Y


Hint: Fahrenheit sensors are supported from IS-AIN8 of sw version 2.2 only.

Analog as Binary input

To use Analog input as binary configure following characteristics:

Primary Converted

0 0

1000 1

Analog as three state (tristate) binary input

Open, close and failure (broken wire, short wire) states are detected. Threshold level is 750 , failure is

detected when circuit resistance is 2400 .

Binary inputs / outputs on ID-DCU

Use wiring cables min. of 1.0 mm2 to ensure proper function.

+24V

DC

0 V

DC

BI 1

BI 2

BI 3

BI 4

BI 5

BI 6

BI 7

BI 8

BI 9

BI 10

BI 12

BI 13

BI 14

BI 11

+ -

BO

7

BO

8

BO

9

BO

10

BO

12

BO

13

BO

14

BO

11

ID-DCU

BO

1

BO

2

BO

3

BO

4

BO

5

BO

6

Hint: Incorrect polarity of the binary output connection may cause a damage of the binary outputs.

Binary inputs on IS-BIN16/8

There are two groups of eight Binary inputs BI1 to BI8 and BI9 to BI16. Each group has a separate Common terminal COM1 and COM2. The Common terminal can be connected to positive or negative pole see following drawing. Binary inputs are galvanically separated from IS-BIN16/8 power supply. A Binary inputs Common terminal is connected to positive supply terminal, Binary inputs contacts are closed to negative supply terminals.

Binary inputs common terminal is connected to negative supply terminal, Binary inputs contacts are closed to positive supply terminals.


BI 1 (BI 9)

BI 2 (BI 10)

BI 3 (BI 11)

BI 8 (BI 16)

COM 1 (COM 2) +

8 - 36 V

-

IS-B

IN 1

6/8

+

8 - 36 V

-

BI 1 (BI 9)

BI 2 (BI 10)

BI 3 (BI 11)

BI 8 (BI 16)

COM 1 (COM 2)

IS-B

IN 1

6/8

Input voltage range for opened contact is from 8 VDC to Power supply VDC. Input voltage range for closed contact is from 0 to 2 VDC. Voltage level is defined between Binary input and Binary input COM terminal and does not depend on positive or negative connection. Hint:

It is recommended to separate inputs by diodes when two or more binary inputs are connected in parallel to avoid wrong input activation when one controller is switched off.

controller

BIBI

controller

Binary outputs on IS-BIN16/8

IS-BIN16/8 binary outputs are galvanically separated from IS-BIN16/8 power supply. It is necessary to connect plus 24 VDC (power supply ) to IS-BIN16/8 terminal according to following drawing. The maximum load values are 0.5 A / 36V for one output.

IS-B

IN 1

6/8

BO 1

BO 8

0 V DC

24 V DC

BO 2

+

8 - 36 V

-

Binary output separation

In some special cases e.g. when Relays plus terminal is disconnected via EMERGENCY STOP contact, the binary outputs must be separated using diodes to avoid false Binary output LED indication. In the Example below when EMERGENCY STOP contact is opened, the BO3 LED should light (without separating diode SD3) even if the BO3 output is opened.


+

BO 3

BO 4

BO x

- POWER SUPPLY

EMERGENCY

STOP

+24VDC

0 VDC

iS-CUiS-BINiGS-PTM

iG-IOM

SD3

SD4

IS-AIN8, IS-BIN8/16 address setting

Press Address button during IS-AIN8 power supply on to switch to addressing mode.

Then repeatedly press or keep pressed address button to adjust required address according to IS-CU configuration.

After setting requested address, release the buttons and wait until the digits blink it indicates write the changed address to EEPROM memory.

Hint: CAN address 0 disables corresponding CAN message (Group data are not send).

IS-AIN8, IS-BIN8/16 SW version check

Let suppose IS-AIN8 of SW version 1.4. Shortly press address button. Following sequence appears on the display: number 1, one second pause, number 4, two second pause, number 1, one second pause, number 4, two second pause and finally IS-AIN8 actual address. Table of recommended CAN1 address setting on IS-AIN8 and IS-BIN16/8

CAN 1 Address CAN1 Address

1. iS-AIN8 1 Inputs Outputs

2. iS-AIN8 2 1. iS-BIN16/8 1 1

3. iS-AIN8 3 2. iS-BIN16/8 3 2

4. iS-AIN8 4 3. iS-BIN16/8 5 3

4. iS-BIN16/8 7 4

Table of corresponding address setting in DriveConfig during ID-DCU configuration.

Address Address

1. iS-AIN8 1 Inputs Outputs

2. iS-AIN8 2 1. iS-BIN16/8 1, 2 1

3. iS-AIN8 3 2. iS-BIN16/8 3. 4 2

4. iS-AIN8 4 3. iS-BIN16/8 5, 6 3

4. iS-BIN16/8 7, 8 4

Hint: IS-BIN16/8 module has separate CAN1 addresses for binary inputs Group 1, Group 2 and binary outputs Group (total three addresses). The CAN1 address for BI Group 1 and for BO Group can be adjusted on the iS-BIN16/8. The address for BI Group 2 is set automatically to the address following after BI Group 1. CAN bus line has to be terminated by 120 ohm resistors on the both ends. For longer distances is recommended to connect CAN COM terminals between all controllers and cable shielding to the ground in one point. External units can be connected on the CAN bus line in any order, but line arrangement (no tails no star) is necessary. Recommended CAN bus data cables see in Chapter Technical data. I-LB, I-LB+, IG-MU and IG-IB units are connected to CAN2 bus.


IGS-PTM and IGL-RA15 module connection It is possible to connect up to four IGS-PTM and one IGL-RA15 to one controller. IGS-PTM behaves like IS-AIN and IS-BIN modules in one unit. IGS-PTM and IGL-RA15units contain internal jumper removable 120-ohm resistor. Hint: Only IGS-PTM from hardware version 2.0 and software version 4.0 is compatible with InteliDrive.


Binary Inputs

Any InteliDrive controller extension physical binary input can be configured as function or protection. Following chapter contains Logical binary inputs list that can be configured to any physical input. ID-DCU binary inputs Remote start, Remote stop, Rem start/stop are not active in LOC mode. Hint: Minimal input pulse duration is 120 ms to be detected as valid (binary inputs sampling rate is 100 ms). Adjustable delay can be configured to any binary input when is used as a protection: Standard = 0,5 sec or one of BinInp delay 1, 2, 3 that can be adjusted by corresponding Setpoint BinInp delay 1, 2, 3.

Input

BI delay configuration

Setpoint

Standard (0,5s)

BinInp delay 1 BinInp delay 1



See setpoints BinInp delay 1 [s] etc

Access Lock If the input is closed

o Panel buttons START, STOP are inactive o No setpoints can be adjusted from controller front panel o Controller mode (e.g. OFF-RUN) cannot be changed o Fault reset (screen sensitive), Horn reset buttons are still active o It is possible to list Values, Setpoints and History o Binary inputs function is without change

Active Access lock is indicated by L in the upper right corner of controller screen. Hint: Access lock does not protect Setpoints change, Mode change and START, STOP commands from Drive Monitor (direct or modem). To avoid unqualified changes of the selected setpoints or commands use password protection.

Remote Lock

If the input is closed following commands via serial line (e.g. from DriveMonitor or from remote display) are inactive:

o Remote engine start, stop commands o Fault reset and horn reset o Setpoints change

Engine can be started, stopped via Binary inputs (e.g. Remote start) or via front panel buttons. InteliDrive local / remote commands blocking overview Y = available; N = blocked

Device Command Access lock Remote lock Local mode

ID-DCU panel START N Y Y

STOP N Y Y

FLT RES Y Y Y

HORN RES Y Y Y

Setpoint change N Y Y

Mode change N Y Y

ID-DCU Bin Inputs Remote start Y Y N

Remote st

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