Technical Documents

8808 Series Genset Control Panel Manual

1. Brief description

The 8808 system is well designed and has strong power. Besides the basic Gen-set
remote function, a good deal of powerful functions are also provided: 32 Gen-sets
synchronization, parallel connection of Gen-sets and Mains, automatic realization of the
sharing of active power and reactive power load per rata and Standard computer
communication interface. Via PC or common telephone net remote dialing connection,
we can supervise the multiple Gen-sets synchronizing system.

Generator control and protect function

1. Manual and auto control of single Gen0sjet and output air switch;
2. Wide LCD screen display;
Engine parameters: oil pressure, water temperature, batter voltage, run hours;
Generator parameters; phase voltage, wire voltage, frequency, power factor, active
power, reactive power, degree;
Synchronizing parameters: parallel connected Mains bus voltage, Mains bus voltage,
alternator voltage, frequency, potential difference.
3. Protect stop:
Low oil pressure, High temperature, Over speed, Over frequency, Lose of speed signal,
Start fail, Over current, High/Low voltage, Back power, Differential protection;
4. Failure warning:
Charge fail, High temperature, Low oil pressure, Low battery voltage, Sensor failure.
5. HISTORY record (like the black box).
6. Authorization control of Parameter settings
7. Convenient function extend
Synchronization control
1. Automatic synchronization, automatic realization of the sharing of active power and
reactive power load pro rata, automatic connection and disconnection of Gen-sets
according to load’s fluctuation.
2. Realization of load diversion without power cut.
3. The setting of LoadResStrt ensures stable power supplying when load fluctuates.
4. Start priority can be programmed.
5. Via CAN industrial controller high speed BUS the Gen-sets’ communication can be
realized.
6. With input/output programming interface.
7. Single manual Gen-set can be easily extended to Multiple Gen-set supervising and
synchronizing system.
8. Synchronizing units can be enlarged to 32 Gen-sets

Remote control function

1. Standard RS232 communication interface;
2. With one communication interface, Multiple Gen-sets can be supervised.
3. Provide open communication protocol.
4. Provide superior control computer software free charge.
5. On the interface of the supervising software, we can observe all the Gen-sets’ operate
status and control Gen-sets’ running, load and enact the Gen-sets’ settings.

Composing of the system

Gen-sets for synchronization must be equipped with an electro-velometer and an automatic
voltage adjustor (AVR), each synchronized Gen-set is a unit, when the load is enlarged, we can
add synchronizing unit as required. Every unit includes:
1. 8808 high voltage control panel
The 8808 panel adopts advanced Main controller, provides basic functions such as Gen-
sets’ control and protection, automatic synchronization, sharing of active power and
reactive power load, communication, etc.
2. Automatic breaker
 The synchronizing Gen-sets must be equipped with an auto-high voltage-breaker, and its
rated current depends on gen-sets’ output current, all the Gen-sets’ output wires are
connected to a common BUS and consist a synchronizing system.
3. Conflux high voltage output tank
Conflux high voltage output tank can control the synchronized Gen-sets’ output conflux
and brake’s ON/OFF state.
4. Automatic source diversion tank (ATS)
(equipment selectable)
ATS can realize automatic diversion between Mains and Gen-set.

2. Means of operation
Operation interface
Pushbuttons
2.1 MODE  Cyclic forward selection the Gen-set operation mode (OFF – MAN – AUT)
2.2  MODE Cyclic forward selection the Gen-set operation mode (AUT – MAN – OFF)
2.3 Horn reset Deactivates the HORN
2.4 Fault reset Acknowledges faults and alarms
2.5 Start In MAN mode these button are disabled.
1) When Gen-set is static, press MAN to open the fuel valve and start the start-motor to
crank, after the Gen-set getting right, the start motor will be out of use. If the first start
fails, after an enacted time, it will try to start again automatically. If it fails for the third
time, a fail signal will be sent out, and the fuel valve will close.
2) When Gen-set is cooling state, press MAN, the cooling time will be canceled, then the
Gen-set can supply power (with load).
2.6 Unload/Stop
In MAN mode these buttons are disabled.
1) When the Gen-set runs with load, press MAN, and he Gen-set switch will open, the
Gen-set will begin cooling delay, after the cooling time, Gen-set will stop
automatically.
2) When the Gen-set is in the cooling state press MAN, the cooling delay will be canceled,
and the Gen-set will stop immediately.
Hint: When Gen-set is in normal operation, if emergency cases occur, press MAN twice, this
motion equals to the emergency stop; in normal case, the MAN bottom should be pressed only
once, so that the Gen-set be shutdown after the cooling delay.
2.7 MCB ON/OFF During Multiple operation (MINT), MAN bottom have no effect.
2.8 GCB ON/OFF Manual Open/Close the brake (if Mains have power, press MAN and
the controller with combine and synchronize multiple Gen-sets).
2.9 PAGE Cyclic selection of the display mode
(MEASUREMENT – ADJUSTMENT – HISTORY – ALARMS)
2.10  Select the setpoint, select the screen or increase setpoint value
2.11  Select the setpoint, select the screen or decrease setpoint value
2.12 ENTER Confirm setpoint value
LEDs
2.13 MAINS PRESENT If the Mains’ voltage s present and within limits, the green lights.
2.14 MAINS FAILURE Has no affect in this application.
2.15 GEN VOLTAGE PRESENT LED is on, if gen. voltage is present and within limits
2.16 GEN-SET FAILURE LED starts flashing when gen-set failure occurs. After FAULT
RESET button is pressed, goes to steady light (if an alarm is still active) or is off (if no alarm
is active)
2.17 GCB ON LED is on, if GCB is closed. Flashes when GCB FEEDBACK does not
correspond to GCB CLOSE/OPEN.
2.18 MCB ON not active.
How to select the Gen-set mode?
In AUT mode these buttons are disabled.
In MAN mode are enabled, but before closing of any circuit breaker, voltage must be
within limits.
Closing to dead bus
When no voltage is detected on the bus, the GCB is immediately closed.
Synchronizing
Under AUT mode. When voltage is detected on the bus (within voltage window)
InteliGen starts synchronizing and waits for closing of GCB.
Display menus
 There are 3 display menus available: MEASUREMENT, ADJUSTMENT and HISTORY
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  or  to select the screen with requested data.
Hot to view and edit set points?
1. Use repeatedly PAGE button to select the ADJUSTMENT menu.
2. Use  or  to select requested set points group.
3. Press ENTER to confirm.
4. Use  or  to select requested set point.
5. Set points marked “*” are password protected.
6. Press ENTER to edit.
7. 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.
Statistics
Kilowatthours kWh (total and per phases)
Apparent power hours kVAh (total only)
Run hours
Number of starts
How to handle the HISTORY menu?
1. Use repeatedly PAGE to select the HISTORY menu.
2. Use  or  to select a requested record.
3. Use ENTER to select requested screen (record items) within displayed records
How to change the display contrast?
Press ENTER and  or  at the same time to adjust the best display contrast.
How to check the serial number and software revision?
Press ENTER and then PAGE. On the display you can see InteliGen INFO screen for 10
seconds.
 InteliGen INFO screen contains:
1) Controller name (see Basic setting group)
2) InteliMains serial number (8 character number)
3) SW version: the first is the firmware version number, the second is configuration
table number.
4) Application: IM
5) Branch: InteliMains
How to fin active alarms?
Active alarm list is the last screen in the MEASUREMENT menu.
Select the MEASUREMENT menu. Press  . You will see the list of all active alarms
with the number of alarms at the top-right corner. Inverted alarms are still active.
Non-inverted alarms are not active, but not yet confirmed.
Press FAULT RESET accepts all alarms. Non-active alarms immediately disappear from
the list.
Active alarm list appears on the screen hen a new alarm comes up and Main
MEASUREMENT screen is active.
Main measure screen
InteliGen Mode
Gen-set power – meter
Gen-set states
Power Factor, load character
Generator screen
Gen-set states
Engine speed (single bargraph)
Gen freq
Gen V1, V2, V3 (triple bargraph)
Gen I1, I2, I3 (triple bargraph)
Bus screen
Neutral current
Bus frequency
Gen V1, V2, V3 (triple bargraph)
Analog sensors screen
Oil pressure (AI1) (single bargraph)
Water temperature (AI2) (single bargraph)
Fuel level (AI3) (single bargraph)
Gen-set power screen
Active power (total and per phase)
Power factor (total and per phase)
Reactive power (total and per phase)
Power factor (total and per phase)
Statistics
Kilowatthours kWh (total and per phase)
Apparent power houurs kVAh (total only)
Run hours
Number of starts
Sychroscope
Angle (between U1 and U1m)
Slip (between U1g and U1m)
U1g [V]
U1m [V]
Sequencing
Engine priority
Total available power (sum of Nominal power)
Total run power (sum of Nominal power-running)
Active reserve (single bar graph)
CAN bus status (binary)
Alarm list
Gen-set operation state prompting messages:
English Meaning English Meaning
Not ready Gen-set do not get ready Loaded Gen-set is loaded
Init Controller initializing Stop Gen-set’s stopped
Ready Gen-set get ready Shut down Shutdown failure
Prestart Valid prestart output Cooling Gen-set’s getting cold
Cranking Valid start motor output, cranking Idle Gen-set’s getting heat
Over/low speed shut
Pause Cranking pause RPM fail
down
Over/low voltage
Starting Start motor exited, Gen-set speed up AVR fail
during loading
Unl alarm Unload failure Unloading Gen-set’s unloading

HISTORY
When operations are done to install/upgrade software, start/stop the engine, open/close the brake
or warning and failure shutdown arise, the controller will automatically record all the running
parameters of the time, and this will benefit the checking and solving of failures.
In start course, the controller will timely (adjustable) record Gen-set’s parameters. 100 pieces of
records can be deposited in the HISTORY bar. When there are more records, the oldest one will
be covered.
English English
for Meaning for Meaning
short short
Voltage of the mains first phase
No Record’s serial number Vb1
when event occurs
Voltage of the mains second phase
Reason Event description Vb2
when event occurs
Voltage of the mains third phase
Time Time Vb3
when event occurs
Current of the mains first phase
Date Date Ig1
when event occurs
Gen-set’s output power when Current of the mains second phase
Pwr Ig2
event occurs when event occurs
Gen-set’s power factor when event Current of the mains third phase
Cos Ig3
occurs when event occurs
Gen-set’s load property when
Lchar In Neutral current when event occurs
event occurs
En-set’s rotation speed when event
Spd Batt Battery voltage when event occurs
occurs
Gen-set’s frequency when event
Gfreq Oil Oil pressure when event occurs
occurs
Voltage of the alternator’s first Water temperature when event
Vg1 Temp
phase when event occurs occurs
Voltage of the alternator’s second
Vg2 Fuel Fuel level when event occurs
phase when the event occurs
Voltage of the alternator’s third Binary input state when event
Vg3 BinInp
phase when the event occurs occurs
Mains’ frequency when event Binary output state when event
Bfreq BinOut
occurs occurs
Warning message
English for English for
Meaning Meaning
short short
Unl Gen
Wrn Oil Press Low oil pressure warning Alternator’s overload
Overload
Sd Oil Press Low oil pressure shutdown Unl Inueatral Nueatral overcurrent
Fls Oil Press Oil pressure sensor failure Sd AVR Fail AVR failure
Wrn Water Sd
High temperature warning Over speed shutdown
Temp Overspeed
Sd Water High water temperature Sd
Low speed shutdown
Temp shutdown Underspeed
Fls Water Water temperature sensor
Sd Start Fail Start fail
Temp failure
Wrn Fuel
Low fuel level warning GCB Fail Alternator GCB failure
Level
Sd Fuel Level Low fuel level shutdown MCB Fail Mains’ switch (MCB) failure
Fls Fuel Level Fuel level sensor failure Gen set sart Gen-set starts
Low battery voltage
Wrn Batt Volt Gen set stop Gen-set stop
warning
Unl Back Back power failure
Emerg Stop Emergency stop
Power
Wrn Charg Sequence fault of the
Charger fail warning GEN L1 neg
Fail alternator’s first phase
Gen Sequence fault of the
Gen-set low voltage GEN L2 neg
Undervolt alternator’s second phase
Over voltage of the Sequence fault of the
Unl Vg1 Over GEN L3 neg
alternator’s first phase alternator’s third phase
Unl Vg1 Low voltage of the G ph Sequence fault of the
Under alternator’s first phase opposed alternator’s phase
Over voltage of the
Unl Vg2 Over G ph+L1 neg
alternator’s second phase
 Unl Vg2 Low voltage of the
G ph+L2 neg
Under alternator’s second phase
Over voltage of the
Unl Vg3 Over G phase Ang
alternator’s third phase
Unl Vg3 Low voltage of the
Active call Failure call
Under alternator’s third phase
Unl Fgen Bad active
Over frequency of alternator
Over call
Unl Fgen
Low frequency of alternator SyncTimeout Synchronizing timeout
Under
Unl Igen Unbalance voltage of R
Synchronizing timeout
Unbal alternator’s phase SyncTimeout
Unl Vgen Unbalance voltage of
Appl loaded Controller’s initialized
Unbal alternator’s phase
Over current of the Firmw
Unl Ig1 Over
alternator’s first phase loaded
Over current of the
Unl Ig2 Over
alternator’s second phase
Over current of the
Unl Ig3 Over
alternator’s third phase

How to set the parameters of Sequencing page

The SEQUENCING’s settings mainly controls the Gen-set’s operation state according to the
change of load.
In one parallel system, all the Sequencing’s parameters must be the same, except Priority,
Controller adr, GCB open level, GCB open del. The controller can copy the Sequencing’s
parameters automatically.
Hint: If Gen-sets are not combined with CAN bus, then each Gen-set work individually and the
auto-copy function has no effect, the manual operation is necessary.
Function description
There are three modes of the gen-set: OFF – MAN – AUT.
To select the mode press MODE  and  MODE

OFF Mode
No start to the gen-set is possible. Output STARTER, GCB CLOSE/OPEN and FUEL
SOLENOID are not energized. No reaction if buttons START, STOP, GCB ON/OFF are
presented.
1. START
1) To start the Gen-set: press START
2) When the generator voltage is within limits, the corresponding light flashes.
3) Press GCB ON/OFF to close the GCB. If the generator voltage is out of the limits,
InteliGen does not respond to the GCB ON/OFF.
4) If the Bus’s voltage cannot detected by controller, GCB ON/OFF will close. If the
generator voltage is in the limits, then the Gen-sets will began to synchronize.
2. STOP
1) Press STOP.
2) If Gen-sets are still supplying power, unload is the first step. When the supplying
level reaches GCB open level, GCBB will open automatically; if no parallel Gen-
sets, GCB off immediately.
3) Engine will stop after the cooling delay.
Hint: Only with load delivery wires active power can be delivered, only when combining to
CAN bus, reactive power can be delivered.

AUT Mode
1. Set a 3 phases Mains inductor to both of the two Mains circuits, when failures arises to
one route of Mains, such as power cut or lack phase or grounding or other unusual cases,
the inductor will send a signal to the Gen-set stand-by system.
2. When both of the two Mains work right, Gen-set will stand by.
3. When failure arises to one route of Mains, such as power cut or lack of phase or
grounding or other unusual cases, a preferential Gen-set which can supply enough reserve
power will start after a delay.
 4. A first get stabled Gen-set will be put into use, and the others will combine to the bus one
by one according the sequence of stable time.
5. But the stand by system will not control ATS to switch to the Gen-set side or close brake,
the Gen-set keeps in heat stand-by state.
6. When the Gen-set keeps in heat stand-by state, if the another Main also gets abnormal,
the stand-by system will control ATS to switch to Gen-set side or close the brake, stand
by Gen-set will supplying power immediately.
7. When both of the Mains fail, the stand-by Gen-set will start without delay immediately.
Stand-by system control ATS to switch to Gen-set side or close the output brake, that is,
Gen-set will supplying power to load.
8. Based on the Gen-set’s rated power, active and reactive power will be delivered pro rata.
9. When the load increases to such a degree that the required power is greater than the total
power of the parallel connected Gen-sets. After a delay (Next start del), a Gen-set with
priority 1 will start and synchronized automatically; if the load decreases to such a degree
that the supplied power is greater than the required, the Gen-set with priority 1 will
upload and stop after a cooling delay.
10. When one of the Mains gets right, the Gen-set will run with load for 2 minutes
(adjustable 1 to 20 minutes), and then the system control ATS to switch to the Mains side
or open the output brake, and keeps running for stand-by.
11. When both of the two Mains get right, if Gen-sets are in heat stand-by state, they will
stop after 10 minutes cooling delay (adjustable 1 to 10 minutes); if the Gen-sets are
supplying power, they will run with load for 2 minutes (adjustable 2 to 20 minutes) and
then control ATS to switch to Mains side or open the brake and stop the engine after 10
minutes’ cooling delay (adjustable 1 to 10 minutes).
Communication Module
Direct connection to PC
Use the standard cable RS232 cable to connect PC with 8808 high voltage control panel
Remote dialing connection with MODEM
Use MODEM to connect PC with 8808 high voltage control panel
PC software
N the PC (for direct or modem connection) has to be installed the Comap’s software package
(Based on Windows (% or newer platform)
The software enables:
1. Read the quantities
2. Adjust all set points
3. Read the history
4. Control the engine
5. Configure the controller
6. Select software configuration
7. Modify alarm inputs and outputs
8. Direct or modem communication
9. Receive active calls
Description of the warning page
The 8808 control panel provides warning messages as flows: Warning, Unload, Shutdown with
cooling delay or shutdown.
Hints: Every binary input interface can be enacted as a warning message by superior control unit
and every warning messages will display on the warning page, and write in the HISTORY
record.
Warnings
As a warning failure happens, controller will only send a signal to the warning binary output
without any other motion. Warning failures:
1. Warning binary input
2. Warning analog input
3. Sensor failure
4. Over battery voltage
5. Order of phase fault (Gen-set)
6. Order of phase faults (Mains)
7. Brake failure
Unload failures:
When this kind of failure arises, controller will open the brake automatically with a cooling
delay. Listed as follows:
 1. Verload
2. Over current (3 phases to be checked)
3. Current unbalance (3 phases to be checked)
4. Voltage unbalance (3 phases)
5. Alternator over/low voltage (3 phases to be checked)
6. Alternator over/low frequency (3 phases to be checked)
7. Back power
8. Protect motion
9. Unload failure warning input interface
Slow stop failure (with cooling delay)
When slow stop failure occurs, unload firstly and then open the brake, and stop after a cooling
delay; if there are still other gen-sets in the system, they will start and synchronize and load
automatically. The failed gen-set will stop after cooling delay (if after slow stop delay the load
still not delivered, the controller will control to open the brake and stop). Slow stop failures:
1. Neutral over current
2. Over speed
3. Low speed
4. Protect motion
5. Emergency stop binary input
6. Emergency stop analog input
Synchronizing
1. Manual synchronizing
1) Start Gen-set #1
2) Close the electro-air switch 1BK by hand, and the indicator lights
3) Start Gen-set #2
4) Press the ON button on #2 Gen-set’s main control panel, and the related indicator
will began to flash, showing that Gen-sets are synchronizing. When all is right,
the 2BK indicator flashes.
5) Load the Gen-set
6) Cut off 1BK and 2BK by hand
7) Stop gen-set by hand
2. Auto synchronizing
A. Single Gen-set start module without Mains power:
1) Analogize Mains power cut
2) Reserve start (load ResStrt 1) activated. When the reserve start power value
equals to the Gen-set’s capacity, according to the PRI’s sequence, #1 Gen-set
will start, after a delay, 1BK will close automatically and the related indicator
flashes (if #1 Gen-set fails to start for 3 minutes, #2 Gen-set will start instead).
3) Gen-set output switch (in the low voltage control panel) close, and the Gen-set
began to supply power to load. The signal will be feedback to 8808 panel, and
then the Load ResStrt 2 will be activated.
4) Add total load step by step up to 696KW (75% single Gen-set rated power),
696KW (load) + 186KW (Load ResStrt) = 882KW < 928KW (#1 capacity),
#2 Gen-set will not start.
5) Add total load step by step to more than 789KW (85% rated power), 789KW
(load) + 186KW (Load ResStrt) = 975KW > 928KW (#1 capacity), after a
delay #2 Gen-set will start and synchronize automatically, 50% of #1 Gen-
set’s load will be steadily passed to #2 gen-set.
6) Reduce the total load step by step to less than 696KW (75% rated power)
696KW (load) + 278KW (Load ResStp) = 974KW>928KW (#1 capacity), #2
Gen-set will not draw out.
7) Reduce the total load step by step to less than 464KW (50% rated power)
464KW (load) + 278KW (Load ResStp) = 742KW<928KW (#1 capacity), #2
Gen-set’s load will be steadily passed to #2 Gen-set exit from the parallel
connection and stop after cooling delay.
8) Analogize #1 Gen-set’s failure, and #2 Gen-set will start and load
automatically, they act double stand-by system.
9) When Mains get right, after the Mains return delay #1 Gen-set will draw out
and stop after cooling delay.
B. When the mains’ power cut the two Gen-sets will start the synchronizing pattern