InteliGen 500 G2

Controller for multiple gen-set

applications

SW version 2.3.0
1 General information 2
2 Changes in the version 2.3.0 3
3 Changes in the version 2.2.0 5
4 Changes in the version 2.1.1 8
5 Changes in the version 2.1.0 9
6 Notes 13

Copyright © 2023 ComAp a.s.

Written by Petr Chvojka
Prague, Czech Republic
ComAp a.s., U Uranie 1612/14a,
170 00 Prague 7, Czech Republic
Tel: +420 246 012 111
E-mail: [email protected], www.comap-control.com New Features List
1 General information
1.1 Version information
Major firmware version supporting integration of PVs in SPTM applications, improved ECU support and
several bug fixes.

1.2 Clarification of Notation

Note: This type of paragraph calls the reader’s attention to a notice or related theme.

IMPORTANT: This type of paragraph highlights a procedure, adjustment etc., which can cause a
damage or improper function of the equipment if not performed correctly and may not be clear at
first sight.

WARNING: This type of paragraph highlights a procedure, adjustment etc., which can cause a
damage or improper function of the equipment if not performed correctly and may not be clear at
first sight.

Example: This type of paragraph contains information that is used to illustrate how a specific function
works.

InteliGen 500 G2 2.3.0 New Features List 2

2 Changes in the version 2.3.0
ULC 6200:2019 Certified, Not witness tested
IMPORTANT: FW version of integrated color display (ICD) 2.3.0.8 or newer is required.

2.1 New features

The support of new applications for small hybrid microgrid (HMG) sites consisting of a single genset,
mains incomer and photovoltaics (PVs) while controlling
Standard SPtM application
All the breakers (GCB, MCB, PVCB)
PV inverters via integrated Modbus Client (TCP or RTU including Sunspec protocol)
2 registers are for free (i.e., without a need for a SW key) for the Modbus Client function testing
Archive upgrade from the GC to AGC is supported in InteliConfig version 2.50 and newer
Power management in kVA mode (works only in absolute units) is supported
New setpoints defining a controller address
Setpoint CAN Controller Address for inter-controller communication over CAN2 terminal
Setpoint Terminal Comm Address for remote communication with other terminals such as display,
SCADA, InteliConfig over ethernet or RS485
Completely new screen for Maintenance and Rental timers is available on the integrated color display
New setpoint Modbus Server Address used for setting the address of a controller for communication over
rd
Modbus with 3 party systems
New setpoint Modbus/TCP Master link for the selection of the communication port for the Modbus Client
function (either in-built ethernet or via plug-in module CM3-Ethernet)
Modbus ECUs are supported by a control unit (ECU library 8.6 and newer is required)
Waukesha ESM and ESM2
Cummins GCS
Support of communication using multiplexed signals when communicating with several ECUs
simultaneously
Universal hours counters
The counter increments its value when appropriate LBI is active
Actual value of timer is visible in statistics
2 counters available (LBIs UNIVERSAL HOURS COUNTER 1 and UNIVERSAL HOURS COUNTER 2)
In default, all roles have rights to edit all the setpoints
New LAIs DYNAMIC SPINNING RESERVE and DYNAMIC SPINNING RESERVE OFFSET
Modification of PLC block Comp Hyst
Input Enable enabling of output of comparator was added
When input is not configured, output is enabled all the time
New PLC block Analog Change Monitor
The block monitors decreasing/increasing change of any analog value
Improvement of PLC blocks Ramp and Up/Down
New parameter for setting a time units for ramping (s/min)

InteliGen 500 G2 2.3.0 New Features List 3

 Subgroup Load Transfer was moved to Process Control setpoint group
New setpoint Bus Meas Error Delay
The setpoint adjusts delay for bus measurement error protection
Default values for the setpoints Mains Measurement P and Mains Measurement Q changed to Mains CT
Reverse power protection is newly evaluated regardless of a GCB state (GCB feedback)
Remote alarm messaging improvement
There are setpoints for each type of alarm in controller enabling or disabling remote alarm messaging
for each alarm type
Modem IMEI value of a 4G plug-in module visible in the Values

2.2 New features - AGC version only

All the upgrades are similar for both GC and AGC archives

2.3 Repairs
Resolution of RPM regulation for Cummins CM2358 was increased
Previous resolution was ±15 RPM
It was not possible to change the language of a controller without a logged-in user
During SUS, electrical protections were evaluated already after Minimal Stabilization Time and not after
Maximal Stabilization Time
Behavior of the LBO SOFT LOAD during a single genset operation in parallel to Mains was fixed
Improved communication with ECU MAN MFR
When an antenna for calculating a GPS position was disconnected from a controlelr, no alarm was issued
LBOs STOP SOLENOID and STOP PULSE were not activated during acranking fail pause
Switching of Modbus communicationbaud rate was not processed even when the setpoint was changed
Only when CM-RS232-485 was used
LBOs for ECU fault codes were active for only 1-2 s even if the alarm was still active
Power format was evaluated incorrectly when active power was negative
Next Engine Stop Delay was not applied and a genset went directly to a cooling phase
nd
Only after 2 and each following Remote Start/Stop signal
In MAN mode during the Idle time period, it was not possible to skip to the Running phase by pressing the
Start button
Evaluation of ECU BOUTs was incorrect when
One ECU with more than 32 BOUTs was configured
5 ECUs with at least 1 BOUT were configured
The Total Fuel Consumption of Doosan G2 EDC17 was incorrect
The decimal point was shifted by one place
Protection Starting Overspeed Sd was not evaluated accordingly if the level was set higher than for the
protection Overspeed Sd
LBOs ROCOF ACTIVE and VECTOR SHIFT ACTIVE were not activated during active ROCOF and Vector
Shift protections, respectively

InteliGen 500 G2 2.3.0 New Features List 4

3 Changes in the version 2.2.0
ULC 6200:2019 Certified, Not witness tested
IMPORTANT: Due to the new user access management, FW version of integrated color display
(ICD) 2.3.0.8 or newer is required.

3.1 New features

User defined groups and subgroups of setpoints within User Setpoints management
The number of groups/subgroups is different in the GC and AGC archives
GC: 2 groups, 5 subgroups

AGC: 5 groups, 5 subgroups

Modbus Client (Master) function
The function allows a controller to initiate the communication with 3rd party devices over Modbus RTU
or TCP
A number of devices that can be added into a configuration is limited (excluding modbus ECUs such
as Waukesha ESM and ESM2, Cummins GCS) based on an archive:
GC: 4 modbus devices

AGC: 5 modbus devices

The function needs to be activated by a SW key
Support of 32 bit values read from ECU or Modbus devices
Sunset/Sunrise function
The function calculates the sunrise and sunset based on GPS coordinates and activates a dedicated
LBO and/or start/stop a genset
Increased size of PLC, the following number of blocks was added
OR/AND: 16
XOR/RS: 10
Comp Hyst: 4
Math Fc.: 2
AxB/C±D: 2
Ana Switch: 2
Ana Switch8: 2
Convert: 2
Decomp. 4: 2
Integration: 2
Comp Time PLC block was replaced by improved Comp Delay block
During a configuration upgrade the Comp Time block will be replaced automatically
New PLC block Integration enabling to calculate an analog value during timefor instance, the PLC block
calculates produced energy in kWh based on generated power in kW)

InteliGen 500 G2 2.3.0 New Features List 5

 It is possible to rename default names of existing objects in the configuration, for instance:
Maintenance Timers
Pulse/Hours Counters
User Buttons
Timers and Rental Timers
Voltage protections can be evaluated based on the phase-phase, phase-neutral or both voltages using
new setpoint Evaluated Voltage Protections
Modbus ECUs are supported within an ECU Library (8.5 and newer)
Cummins GCS
Waukesha ESM and ESM2
Improved method for calculation of fuel consumption
Improved support of an engine regeneration
New LBI ATT FORCE REGEN ALT is added allowing a user to run a regeneration process manually
Without evaluation of undervoltage and underfrequency protections

At a specific RPM given by new setpoint DPF Regeneration RPM

Improved user access management - access level based was replaced by a role-based system
Individual user accounts can be assigned to individual roles
Role 0: administrator

Role 1-7: configurable roles

Role 8: Modbus

Role 9: SNMP
Extended range of the selected setpoints up to 32 000 kW
Nominal power
Nominal power split phase
Extended range of the setpoint Earth Fault CT Ratio for a BIO8 module up to 10 000 A
Extended range of the setpoint Cranking Attempts up to 20
The setpoint group Loss of Mains Protections (Vector shift and ROCOF protections) is visible and
configurable also in MINT
Default value of the setpoint MCB Open Window is changed to 1%
Values from LAIs OIL PRESSURE, COOLANT TEMPERATURE and FUEL LEVEL are visible in Values
New temperature sensors are supported
PT100 (°C)
PT1000 (°C)
NI100 (°C)
NI1000 (°C)
PT100 (°F)
PT1000 (°F)
NI100 (°F)
NI1000 (°F)

InteliGen 500 G2 2.3.0 New Features List 6

3.2 New features - AGC version only
Configuration Lock function to lock and protect a configuration by a password
A number of Modbus devices in a configuration: 5
User defined groups and subgroups of setpoints within User Setpoints management
5 groups, 5 subgroups
Increased size of PLC, the following number of blocks was added
XOR/RS: 8
Comp Hyst: 4
Comp Delay (previously Comp Time): 14
Delay: 8
Timer: 2
Math Fc.: 12
AxB/C±D: 14
Interpolation8: 4
Up/Down: 2
Ana Switch: 6
Ana Switch8: 2
Convert: 2
Decomp. 4: 4
Integration: 6

3.3 Repairs
SNMP trap identifiers for protections
Value Mains Load Character is displayed correctly
Improved stability of communication over in-built ethernet port
Wrn MCB Fail to Open alarm handling
The alarm becomes inactive when Mains gets healthy and MCB is closed ang GCB is open
Setpoint AirGate Connection is not affected by history or vice-versa
Improved email notifications
Improved Modbus communication
MCB keeps closing/opening in case of open transfer in SPtM applications when a setpoint Open Transfer
Min Break > 3 s
Incorrect display of a controller mode on a display when using LBI SWITCH TO OFF/MAN/AUTO
AMF procedure is interrupted in case the Mains gets healthy again before the load is supplied by gensets

InteliGen 500 G2 2.3.0 New Features List 7

4 Changes in the version 2.1.1
ULC 6200:2019 Certified, Not witness tested

4.1 Repairs
User UID - incorrect visibility in InteliConfig
Ethernet communication improvment

InteliGen 500 G2 2.3.0 New Features List 8

5 Changes in the version 2.1.0
ULC 6200:2019 Certified, Not witness tested

5.1 New features

Default value of setpoint MCB Close Delay
New default value is 5s
Renaming of Aftertreatment screen to ECU Lamps screen
Activation of ECU for diagnostic purposes in OFF mode - setpoint Manual ECU Activation Timeout
Disabling of Phase Rotation protection
setpoint Phase Rotation Protection added
Implementation of LBI: FORCE IDLE. Gen-set is switched by operator to manual idle state to save fuel or to
prolong Idle time e.g. when an engine is cold.

Force Idle
Related FW 2.1.0 Related applications MINT, SPTM
Description
This LBI activates Force Idle function.
A breaker control was improved.
Amount of attempts to close breaker – Setpoint Attempts To Close Breaker
The delay between the attempts – Setpoint Delay Between Closing Attempts
Waiting time for breaker feedback - Setpoint Waiting for breaker Feedback

Attempts To Close Breaker

Setpoint Group Process Control Force value no
Range 1..5
Default Value 2 Step 1
Description
This setpoint adjusts the amount of attempts the controller performs when a breaker is requested to be
closed. If the breaker feedback is not received at the end of the attempt, an alarm is not issued, unless it
was the last attempt to close the breaker.

Delay Between Closing Attempts

Setpoint Group Process Control Force value no
Range 2..60 s
Default Value 2 Step 1
Description
This setpoint adjusts the delay between breaker closing attempts the controller performs when a
breaker is requested to be closed. Delay is one second longer than you set here due to breaker's
safety.
Example: If this setpoint is set to 10 seconds, the delay between another attempt to close the
breaker will be 11 seconds.

InteliGen 500 G2 2.3.0 New Features List 9

 Waiting For Breaker Feedback
Setpoint group Process Control Force value YES
Range [units] 1 .. 60 [s]
Default value 2 [s] Step 1 [s]
Description
This setpoint adjusts the length of breaker closing attempt.
SNMP improvement
support of SNMP v3
SNMP v3 is supported on plug-in module CM3-Ethernet and on on-board ethernet
FW 1.1.0.7 or newer of CM3-Ethernet plug-in module is required
ROCOF and Vector Shift protections are evaluated also in MAN mode
LBI Idle Bypass

Idle Bypass
Description
When this LBI is active, controller will skip Idle phase.
LBI is active before Idle Time - controller goes directly to Stabilization phase
LBI is activated during Idle Time - Idle Time is skipped and controller goes to Stabilization phase

Alarm type for Maintenance Timers was change to Slow Stop type
Support of predefined linear sensors
Modbus communication was improved
Setpoint Modbus Mode was implemented
Modbus RTU Timing was fixed
Setpoint Nominal Frequency has 1 decimal place
Support of 8C and 16C communication modes on CAN2 line - setpoint CAN Intercontroller Comm Mode
User keys
LBOs User Key X State - LBO is active when user key (gray buttons on controller front facia) is pushed
Actual values of exercise timers are visible
Support of Leroy Sommer D500 series protocol
LBO History Record Indication Pulse added - This LBO triggers 1s pulse when new history record is
created in history log.
A function detecting a number of controllers on CAN2 line added

#CAN2 Units Missing Protection

Communication
Setpoint Group Force value no
Settings
Range HistRecOnly/Wrn/Sd/BOC
Default Value Wrn Step -
Description
This setpoint adjusts type of protection for CAN2 Units Missing alarm.

InteliGen 500 G2 2.3.0 New Features List 10

 #Number Of Units On CAN2 Check
Communication
Setpoint Group Force value no
Settings
Range Enabled/Disabled
Default Value Disabled Step -
Description
When number of detected unit is lower than value adjusted by setpoint #Number Of Units On CAN2, alarm
Wrn CAN 2 Units Missing or Sd CAN 2 Units Missing is activated. Type of alarm is adjusted via setpoint
#CAN2 Units Missing Protection

#Number Of Units On CAN2

Communication
Setpoint Group Force value no
Settings
Range 1..32
Default Value 1 Step 1
Description
This setpoint defines the minimum number of units supposed to be connected to CAN2.
Values for actual voltage and current unbalance added
New LBIs Switch To OFF, Switch To MAN and Switch To AUTO
Update of PLC block Convert
Possibility of disabling of user logging history records - new setpoint User Logging Record
Conditioned Run Hours counters are not connected with running engine condition - there is only 1
condition for these counters - appropriate LBI
Statistic value Genset kVAh added
Reference for frequency protection - it is possible to select between fixed references (50Hz and 60Hz) and
actual value of setpoint Nominal Frequency - setpoint Frequency Protection Reference
Universal values for modbus interface added
RemoteControl 2B
RemoteControl 4B
RemoteCOntrol Bin
LBI Droop Unload Disable is replaced by LBI Soft Unload Enable

5.2 New features - AGC version only

LBIs for force disabling of protections
Force Protection Disabled 2 and Force Protection Disabled 3
It is possible to use force values for following setpoints:
Generator Overfrequency BOC
Generator Overfrequency Wrn
Generator Underfrequency BOC
Generator Underfrequency Wrn
LBI for disabling of synchronization

InteliGen 500 G2 2.3.0 New Features List 11

 Synchronization Disabled
Description
This binary input is used to disable the forward and reverse synchronization process so the controller
won't attempt to close breaker(s) if synchronization would be needed. This LBI is useful if user want to
set the additional condition for start of the synchronization.
LBI for Voltage Droop

Voltage Droop
Description
If this LBI is active, Voltage regulation is forced to Droop regardless of the setpoint Load/VAr Sharing
Regulation Type.

5.3 Repairs
SNMP Traps
correct text for SNMP traps generated from universal binary and analog protections
correct OID for SNMP traps generated from universal binary and analog protections
Airgate Status incorrectly displayed on ICD
Incorerct default value of setpoint Airgate Port
Change of setpoints Time and Date was not written into history
Detected voltage in function Voltage Autodetect was not used for Mains/Bus side
Alarm Stp Request under Minimal PTM was disabled
Mains Power Factor and Mains Import S were not calculated when using Analog Input measurement

InteliGen 500 G2 2.3.0 New Features List 12

6 Notes
6.1 Document history
Revision number Related sw. version Date Author
3 2.2.0 22.3.2024 Petr Chvojka
2 2.1.1 15.12.2023 Michal Slavata
1 2.1.0 27.10.2023 Michal Slavata

InteliGen 500 G2 2.3.0 New Features List 13