ComAp InteliGen: Models, Differences and Uses

What it is and where it is used

Short answer: the ComAp InteliGen is ComAp’s line of controllers for generator sets that run in parallel: it synchronizes one or several sets with each other and with the grid, shares active and reactive power, and protects the engine and the alternator. Its current version is the InteliGen 500 G2, successor to the InteliGen 500 and the InteliGen NT. For a single set with transfer on mains failure, ComAp offers the InteliLite.

The ComAp InteliGen, InteliLite and InteliMains controllers run generator sets: they start and stop the engine, protect it, measure the alternator and, depending on the model, transfer the load, synchronize and share power between several sets or with the grid. ComAp is a Czech manufacturer, and its equipment is common in emergency plants, continuous gas or diesel generation, cogeneration and hybrid installations.

They are found in transfer and paralleling panels of buildings, hospitals, data centers and industry, and in substation station service. For the whole picture see emergency diesel plant and, for paralleling with the grid, generator in parallel with the grid.

Variants: InteliLite 4 AMF 25, InteliGen 500, InteliGen NT, InteliSys and InteliMains 210

The exact part number (for example, IL4AMF25BAA) and the firmware version are read from the unit’s label and determine which functions it has.

Main features

• Automatic mains failure (AMF) transfer: starts the set when the mains fail and transfers the load; AMF stands for automatic mains failure.
• Paralleling: the InteliGen synchronizes, closes the set breaker and shares active and reactive power; with the InteliMains, the whole group runs in parallel with the grid.
• Built-in programmable logic for the interlocks and sequences specific to each installation.
• Set protection: engine and alternator. When the set runs in parallel with the grid, the utility also requires a relay at the point of connection.
• Event log for analyzing shutdowns and faults.

InteliGen 500 G2: what the ComAp datasheet says

The InteliGen 500 G2 datasheet (order code IG4500XXBAA, hardware 1.0.0, software 2.0.0, issued on May 5, 2023, in English) makes it possible to pin down what the current paralleling controller offers:

Other features the datasheet highlights:

• Dynamic spinning reserve, to avoid supply drops in island installations with renewable sources, and support for hybrid applications with the InteliSys NTC Hybrid.
• Earth fault current protection (EFCP) inside the controller itself.
• Cybersecurity compliance with ISA 62443 level 2 by design and access management with ten user accounts.
• Stage V and Tier 4 Final engines with aftertreatment system control through user-defined J1939 messages.
• Internal PLC interpreter with the ComAp PLC editor, remote access with AirGate 2.0 without a public or static IP address, WebSupervisor for fleets and InteliSCADA for plant monitoring.
• Module slots for 4G and GPS, an additional Ethernet port, RS232 or RS485 and additional binary inputs or outputs.
• Load sharing compatibility and power management with the InteliCompact NT, InteliGen and InteliSys NT families.

ComAp states on its page that the original InteliGen 500 is discontinued and that the G2 is the successor. It also states that the G2 is designed to replace the InteliGen NT and NTC controllers. This requires an extended-functions software key.

How to choose between the families

• One set, transfer on mains failure. InteliLite 4 AMF; transfer logic is the central issue.
• Several sets or paralleling with the grid. InteliGen 500 G2 or, in existing installations, InteliGen NT; load sharing and synchronization dominate.
• Bus tie or grid connection. InteliMains, which synchronizes the group with the grid.
• Hybridization with renewables or storage. InteliSys NTC Hybrid in that line.

Points to watch during commissioning

• Part number and firmware. The order code and the software version determine the functions; the versions of InteliConfig and of the ECU library must match them. A configuration created with one version does not always open in another.
• Replacement from NT generations. The G2 replaces the NT controllers, but the wiring, the scaling of the analog inputs and the custom logic must be reviewed and tested.
• Voltage and current measurement. The ratio of the instrument transformers is loaded into the controller; a wrong value upsets load sharing and the protections.
• Load sharing. The CAN lines need their 120 ohm termination resistor at both ends; a badly terminated network causes communication faults between controllers.
• Grid interconnection. Paralleling with the grid meets the utility’s conditions and requires interconnection protection; see generator synchronization and synchronism check 25.
• Transfer. The return-to-mains logic is tested with the real mains; see automatic transfer of sources.

Communications and integration

The InteliLite 4 AMF 25 comes with Modbus RTU and Modbus TCP, SNMP and J1939 toward the engine electronics. ComAp offers remote connection (AirGate) and cloud fleet monitoring (WebSupervisor). The InteliLite 4 line is configured with InteliConfig; the NT generations have their own communications guide. For SCADA integration see Modbus RTU and TCP and substation RTU and gateway.

Frequent technical questions

• Where is the InteliLite 4 AMF25 manual? Manuals and software are on the ComAp website, separated by model and version.
• The set does not synchronize: it is usually a voltage, frequency or angle difference outside the allowed window, or a missing closing permit. See synchronism check 25.
• Replacing a discontinued InteliLite AMF 25: the InteliLite 4 AMF 25 is the successor, but the configuration does not carry over by itself; it has to be redone and tested.

How we help

We do not sell controllers. At Tiza Group we configure the integration of the controller with the SCADA, review the transfer and paralleling logic and verify the protections of the set and of the point of connection, in substations and in industry. Remote work is done worldwide; field tests and commissioning are done in Colombia, or elsewhere on request. See control, protection and communications configuration and SCADA integration and gateways. To commission a paralleling system, see testing and commissioning. Write to us through the contact page.

Related guides

• Emergency diesel plant
• Synchronism check 25
• Modbus RTU and TCP

References

• ComAp, product pages for the InteliLite 4 AMF 25, AMF 8 and AMF 9, InteliLite AMF 25 (discontinued), InteliGen 500, InteliMains 210 G2 and InteliMains 510.
• ComAp, Parallel Gen-set Control Solutions brochure (2021).
• ISO 8528, reciprocating internal combustion engine driven alternating current generating sets.

Frequently asked questions