Controllers

overview

Single Genset Application

Agenda

› Controllers' introduction
› Basic Applications
› Controllers overview
› Additional Modules
› Remote Display
› Controller’s Modes
› Controller’s Alarms
› ComAp Webpage
Controllers Introduction
What is a ComAp controller?

› Front panel with buttons and rear panel with terminals

› Functions configurable via setpoints and PLC

› Hardware I/Os can be assigned to functions

› Device with predefined logical functions

› Front panel with terminals

Controllers Introduction
Controller performs various actions

› Protection

› Measurement

› Start and Stop

› Regulation

› Provide monitoring and

management interface
Basic Applications
Prime mover

Manual Remote Start (MRS)

› Manual or remote Start and Stop
› Genset monitoring and protection

Optional

GCB – Generator Circuit Breaker

Basic Applications
Prime mover

› Project is prepared for at El-

Katamy (Dubai, United Arab
Emirates), a rental company.

› InteliLite MRS 16 with CM-4G-

GPS are utilized.

› Monitoring and management of

controller is done via ComAp's
WebSupervisor and AirGate,

› Online monitoring of a rental fleet

Basic Applications
Dual MRS

› Consists of 2 Gen-sets

› Each controller measures its Gen-set

› Switching the Gen-sets in supplying of

load
› Genset failure
› Run-hours balancing

› Both Master-Slave controllers connected

via RS485 communication
Basic Applications
Standby

Automatic Mains Failure (AMF)

› Manual or remote Start and Stop
› Genset monitoring and protection
› Mains monitoring and protection

Optional

MCB – Mains Circuit GCB – Generator

Breaker Circuit Breaker
Basic Applications
Standby

› Control System at MotoGP

championship (Qatar)

› InteliLite NT AMF 25 are utilized.

› 44 generators (330 kVA each)

operate alongside with each other

› Lighting for the Qatar Motorcycle

Circuit
Basic Applications
Dual AMF

› Consists of 2 Gen-sets and 1 mains

› Each controller measures mains and its gen-set

› Switching the Gen-sets in supplying of load

› Genset failure
› Run-hours balancing

› Both Master-Slave controllers connected via RS485

communication
Basic Applications
Automatic Transfer Switch

Automatic Transfer Switch (ATS)

› Power source monitoring and protection

› Switching between two power sources

» Mains-to-Generator application
» Mains-to-Mains application
Basic Applications
Automatic Transfer Switch

Automatic Transfer Switch (ATS)

› Power source monitoring and protection

Optional

› Switching between two power sources

» Mains-to-Generator application
» Mains-to-Mains application

Optional
Basic Applications
Automatic Transfer Switch

› Control System at Kimberly-Clark

Corporation (USA)

› InteliCompact NT and InteliATS

are utilized.

› InteliATS is used to facilitate the

transition between generators and
the grid

› Backup Power System for a Kimbe

rly Clark Factory
InteliNano AMF5

› Single Gen-set controller for stand-by

and prime-power applications
› All-in-one intuitive and powerful PC tool
for configuration, monitoring and control,
locally or remotely
› Easy to install, configure, use and
monitor
InteliLite4

Advanced IL4
› AMF 25
› MRS 16
› AMF 20

Standard IL4
› AMF 9
› AMF 8
InteliLite4

More AINs
Extended PLC
Dual AMF
In-built RS485 port

USB Host
Two plug-in slots
InteliLite 4 Standard

› AMF and MRS applications in one unit

› Remote control and monitoring
› Strong security features
› Battery backup
› User-defined protections and setpoints
› Event-based history (up to 150 events)
› Multi-purpose schedulers
› Multilingual support and translator
option
› Zero power mode
 InteliLite 4 Advanced

› Event-based history log for easy troubleshooting

(up to 350 events)
› Extended PLC
› Inbuild RS485
› A larger number of controller terminals.
Hardware difference
IL4 vs IL3

› Dimensions
› Front fascia
› Terminals
» E-Stop
» +5 V output reference
» USB Host
» RS485
› Analog Inputs
› Extension modules
› Remote display
Dimensions

› The dimensions and the cut-out of the › The dimensions and the cut-out of the
InteliLite4 AMF 25 (AMF 20 and MRS 16) are InteliLite4 AMF 9 (AMF 8) are the same as in
the same as in the InteliLite3 AMF 25. the InteliLite9.
Front fascia

› The layout of buttons and design of the front fascia of InteliLite4 is the same as in the
previous generation of the controllers.
Terminals
InteliLite 4 Advanced

› The top row of terminals remains the same except for the numbering.
› The bottom row is equipped with additional +5V output ( ❻), a dedicated E-Stop input ( ❿),
USB host (⓮) and RS485 (⓬)

InteliLite4 AMF 25 InteliLite3 AMF 25

Analog Inputs

› InteliLite3:
» Resistive 0-2500 Ohm

› InteliLite4:
» Resistive 0-2500 Ohm
» Voltage 0-10 V
» Curent 0-20mA
Software difference

› Cyber security enhancments

› User Access Management

› PLC Editor / Interpreter

› User Protections and User

Setpoints

› Multi ECU
Cyber security enhancements – Zone model

› Trusted interfaces
» Less strict cybersecurity regulations are applicable.
» Login via UID and PIN possible.
» Locally used – PC, remote display etc.
» Implicit user logged in all the time – user can display measured values.
› Untrusted interfaces
» Strict cyber-security rules apply for this type of interface.
» The correct user account with password has to be used in order to connect to the controller
(valid also for displays).
User Access Management

› User accounts
» The total available number of accounts in the controller is 5
» 1 user with administrator access
» Administrator cannot manage users while logged in using User ID/PIN !!!
» Administrator default password = serial number of the unit
» User account has following properties:
Cyber security enhancments

› Account break protection

» Brute Force Protection (if a person attempting to login into the controller repeatedly provides
incorrect credentials)
» Wrn Brute Force Protection Active
» Password protection
» Wrn Default Password
» Recovery email
» Wrn Password reset e-mail addr is not set

› Production mode
» It is possible to perform any operation with the controller without any user needed to login
» Wrn Production Mode
AirGate 2.0

› Increasing reliability, Cyber Security

» All the traffic is fully encrypted
» Plug & play
» Related setpoints

› AirGate key
» a kind of "password" which must be defined in controller (e.g. via USB) prior to AirGate
connection can be established with that controller.
PLC

Model IL3 AMF 25 IL4 AMF8 IL4 AMF9 IL4 AMF20 IL4 MRS16 IL4 AMF25
OR / AND 16 8 16 16 64 64
XOR / RS 2 2 2 2 16 16
Comp Hyst 2 1 2 2 8 8
Comp Time 2 - 2 2 8 8
Comp Win - - - - 8 8
Delay 4 2 4 4 32 32
Timer 1 - 1 1 2 2
Math Fc. - - - - 4 4
Ana Switch 8 - - - - 4 4
Counter - - - - 4 4
Decomp. 4 - 4 4 4 4 4
Hold - - - - 2 2
Force Hist 2 - - - - -
Force Prot 2 - - - - -
User protections

› Controller allows
» Create
protections
» Edit created
protections
» Delete created
protections

› The maximum number of created protections is 64.

User Setpoints

› Controller allows
» Create
setpoints
» Edit created
setpoints
» Delete created
setpoints
» Chose location
of created
setpoints

› The maximum number of created setpoints is 128

Multi ECU

› InteliLite4 allows to configure, monitor and control multiple Electronic Control Units
connected over CAN (Engine Control Units, AVR modules, Breakers etc.) CAN.
› There are 2 connectors for ECU (are configured separately)
Model IL9 IL3 AMF25 IL4 AMF8 IL4 AMF9 IL4 AMF20 IL4 MRS16 IL4 AMF25
BINs 6+1 8 6+1 8+1 6+1 8+1 8+1
BOUTs 6 8 6 8 6 8 8
AIN (U/I/R) 3 (R) 4 (R) 3 (U/I/R) 3 (U/I/R) 3 (U/I/R) 4 (U/I/R) 4 (U/I/R)
Overview
Magnetic pick-up ● ● ● ● ● ● ●
RTC (incl. Battery backup) ● (no battery) ● ● ● ● ● ●
RS485 (on board) - - - - - ● ●
USB Host (on board) - - - - ● ● ●
USB Device (on board) ● ● ● ● ● ● ●
Plug-in modules 1x 2x 1x 1x 2x 2x 2x
CAN modules - 5 2 2 5 5 5
History records 150 350 150 150 350 350 350
Alternative configuration 3 3 3 3 3 3 3
Calendar/Scheduler 2 2 2 2 4 4 4
Dual AMF / MRS - ● - ● - ● ●
Remote display support ● ● ● ● ● ● ●
Load Shedding - - 2 2 5 5 5
Maintanance Timers 3 3 3 3 3 3 3
Analogue Switch - - - - - 4 4
PLC
User Setpoints - setpoints 64 64 128 128 128
User Protections - - 32 32 32 32 32
User Buttons - ● - - - 8 8
Gas Engine Support - ● - ● - ● ●
Dual Starter - - - ● - ● ●
Pulse Counter - ● - - - ● ●
Software
› InteliConfig
» Comissioning
» Service
» Short term monitoring
» New file extension for archives
*.ail4
›WebSupervisor
» Long term monitoring
» Cloud base service
» Fleet management
›InteliSCADA
» Long term monitoring
» Site control
›Winscope 1000
» Short term monitoring
» Archiving trends
InteliATS2 50

› Mains-to-Mains or Mains-to-Generator
application possibility
› Remote control and monitoring
› Strong security features
› Battery backup
› User-defined protections and setpoints
› Event-based history log (up to 150 records)
› Multi-purpose schedulers
› Multilingual support and translator option
› Elevator switch
 InteliATS2 70

› Event-based history log for easy troubleshooting

(up to 350 events)
› Extended PLC
› A larger number of controller terminals.
Additional modules

› According to the functionality of the

module
» Communication modules
» Extension modules

› Depending on the way of

interaction with the module
» Plug-in modules
» CAN modules
Plug-in modules overview

› 1-2 universal slots (A - B)

» Can be used for extension or communication

B A
Plug-in modules
› CM3-Ethernet (CM-Ethernet for IL3)
» Modbus TCP support,
» AirGate 2.0 technology for easy connection,
» Full SNMP support and active e-mail sending.
› CM2-4G-GPS (CM- for IL3)
» Active e-mail and SMS sending,
» AirGate 2.0 technology for easy connection,
» Tracking support.
› CM-RS232-485
» Modbus RTU support,
» RS232 interface,
» RS485 interface.
› EM-BIO8-EFCP
» Up to 8 configurable binary inputs or outputs,
» Wide measuring current range,
» One additional AC current Measuring for Earth Fault Current Protection.
CAN modules

› Inteli AIN8TC › Inteli IO8/8

» 8 analog input for measuring » Switchable configuration
temperature by thermocouples
between 8/8 and 16/0.

› Inteli AIO9/1 › Inteli AIN8

» 9 Analog Inputs » 8 Analog Inputs (R, U, I),
» 1 Analog Output (R).
Impulse/RPM sensor.

› IGS-PTM
› IGL-RA15
» 8 Binary Inputs
» 4 Analog Inputs (R, U, I), » Remote annunciator,
» 8 Binary Outputs » 15 programmable
» 1 Analog Output. and configurable LEDs,
» Customizable labels,
» Local horn output.
Remote display

› Remote display software

› Remote control
› Duplication of the controller’s screens, LED indications and
buttons
› Support following controllers:
» InteliLite4 family
» InteliGen4 200 family
» InteliATS2 family
› Connection to the master controller via RS232 or RS485
› Option to use a separate remote display on each serial link
channel
› Automatic detection of the connected master controller
Controllers Modes
OFF mode

› For programming purpose;

› No start of the gen-set is possible;

» No reaction if buttons START, STOP, GCB ON/OFF are pressed;
» Inputs STARTER, GCB CLOSE/OPEN and FUEL SOLENOID are not
energized;

› When genset is running, it is not possible to switch controller to OFF

mode;

› In case of AMF application, MCB remains closed;

Controllers Modes
MAN mode

› For commissioning purpose;

› All protection are active;

› Starting/Stopping genset and closing/opening breaker via buttons;

› Manual breaker operation;

Controllers Modes
AUTO mode

› Automatic predefined sequence

› The controller does not respond to buttons Start , Stop and GCB ON/OFF

› All protection are active;

Controllers Modes
AUTO mode

› Provides a test start of gen-set

› Genset runs unloaded

» When LBI Test on Load is activated, load is transferred to genset

› Modification of the AUT mode

› All protection are active;

Controllers Alarms

› Level 1 – Yellow alarm

› Level 2 – Red alarm

› Sensor failure detection (FLS)

› ECU alarm – Blue alarm

Controllers Alarms

Fault Reset button Horn Reset button

 Now is the ideal
time to clarify any
doubts
Revision

1. What is the difference between AMF and MRS applications?

› AMF application continuously monitors mains supply and automatically starts an engine and
switches load to a standby generator set in case of mains failure;
› MRS application provides only gen-set controlling, monitoring and protection.

2. What are the two sets of additional modules included in the ComAp portfolio to add-on
depending on the controller functional requirements?
› Extension (To expand the capabilities and flexibility of our control products, helping to
develop control systems according to individual project requirement).
› Communication (For easy connection to the controller to monitor and maintain your
equipment);
Revision

3. What is the main purpose of the ATS controller?

› Automatic Transfer Switch (ATS) controller is used for easy and fast switching between two
independent power sources.
› It continuously monitors the voltage and frequency of both the power sources (mains and
generators).
› If the connected power source fails, the ATS will transfer the circuit to the other source.

4. How does InteliLite 4 regulate speed and voltage?

The InteliLite type controller has no speed or voltage control function. It can only read the
value from the genset or mains and trigger the protection.
Revision

5. What modes are available in ComAp controllers?

› OFF mode (for programming purpose; Inputs STARTER, GCB CLOSE/OPEN and FUEL
SOLENOID are not energized; No reaction if buttons START,STOP,GCB ON/OFF are
pressed).
› MAN mode (for commissioning purpose; all protection is active; Starting/Stopping genset
and closing/opening breaker is done via buttons).
› AUT mode (Automatic predefined sequence; The controller does not respond to buttons
Start , Stop and GCB ON/OFF).
› TEST mode (modification of the AUT mode when the engine is started immediately and is
always running).
Revision

6. Let's imagine that we are a rental company that is looking for a suitable controller. The
requirements are as follows:
› Flexible solution:
» It can be a stand-alone genset or a mains backup power source, with effortless switching between
them
» Ability to customize controller functions and add new ones
› It should be possible to adjust maintenance schedule to continuously monitor genset status
› Ability to monitor, control and maintain rental equipment online
› 4 Analog Inputs on board
› Ability to update the configuration without connecting to PC

InteliLite 4 AMF 25 + communication module

ComAp Support

Hotline: +420 246 012 666

E-mail: support@[Link]
Website: [Link]

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