ComAp - InteliGen 500

InteliGen 500

Order code: IG3500XXBAA

This product is obsolete, availability might be limited. Check out its successor, InteliGen 500 G2

Upcoming training: 23.1.2025. Find out more.

InteliGen 500 is a paralleling controller with 5" colour display for advanced diesel gen-set applications, supporting both single and multiple gen-sets running in grid-tied or island operations.

Remote connection & monitoring
Start-up synchronisation
Dynamic spinning reserve
Built-in colour display
Built-in Ethernet port

InteliGen 500 Datasheet

English (25 Jan 2023)

English 25 Jan 2023

Polish 25 Jan 2023

Manuals

6 files

English (5 Dec 2024)

English (25 Jan 2023)

English (16 Aug 2024)

English (25 Jan 2023)

Software

3 files

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English (4 Dec 2024)

English (16 Aug 2024)

EU Declaration of Conformity

English (3 Sep 2024)

English (25 Jan 2023)

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Overview
Related products
Extended features
Resources
Training

Overview
Related products
Extended features
Resources
Training

InteliGen 500

The InteliGen 500 offers:

Support for installations with the option for cooperation with up to 32 gen-sets/mains/tie controllers
AirGateComAp’s controllers incorporate AirGate connection technology to make access to the internet as simple as possible. AirGate enables our controllers to connect to the internet using the existing network infrastructure, negotiating firewalls and VPN systems and removing the requirement for static and public IP addresses. for easy connection to your equipment remotely, without worrying about your asset’s IP address
Start-up synchronisationComAp’s Start-up synchronisation eliminates any blackout time, and the start-up time is the same for sites running 2, 10, or even 30 gen-sets. To avoid delaying availability of the system due to slow-starting generators or other problems, any engines that fail to reach running speed with a specified time are rejected from the scheme and, if able, are left to perform traditional synchronising after the majority of sets have become available. to minimise the paralleling start sequence time and get the gen-set system up and running with the minimum possible delay
Dynamic spinning reserveDynamic Spinning Reserve allows the system to react flexibly to changes in power produced by renewable energy sources. ComAp controllers can react to requested spinning reserve and keep the sufficient amount of gen-sets running to cover the drop-in output of the renewable source (e.g. when cloud cover is heavier). helping to deliver maximum amount of available energy from photovoltaics
Clear visualisation and overview of all important information on the built-in colour display
Built-in PLCComAp has integrated Programable Logic Controller tightly with our standard line of controllers. This helps our customers to cut costs, minimise points of failure for advanced systems, and overcome any challenge that may occur. interpreter with the use of ComAp's free PLC Editor
StageV and Tier4Final-ready
Remote control and monitoring of your gen-set operations with WebSupervisor, our cloud-based fleet management tool
Compatible load/Var sharing and power management with other ComAp solutions
Droop regulation allowing load sharing and Var sharing when the inter-controller’s communication is lost
Plug-in modules to easily extend the functionality of the controller
Possibility to have a mains application in a gen-set controller
One hardware for more applications, enabling an easy switch between MINT and SPtM applications
Optional geofencingA geographical area can be defined in the controller and, with the aid of our GPS module, a selectable protection can be activated when the gen-set leaves the defined area. Prevent your gen-set to be used in a location different to the one agreed upon. Taking your equipment to a different location without your consent is not only breach of contract but also it might deteriorate your gen-set. feature helping with efficient unit tracking and theft prevention*
Event-based history for fast and easy troubleshooting
Increased site efficiency and reduced operational costs through effective power managementOur system allows for up to 32 generators running in parallel, regardless of whether the generators are of different sizes, power outputs, and from different manufactures. The system is highly adaptive and can create up to 4 different schemes of power management that can be switched with a simple switch.
Automatic Mains Failure that ensures automatic start of gen-sets and minimises downtime
Peak shaving for limiting the import from the mains (e.g. due to higher prices)
Load shedding ensuring the most important loads are running even when there is a lack of power

* Feature available with a CM2-4G-GPS plug-in card.

Accessories

CM-4G-GPS

An easy-to-use and highly efficient solution for connecting gen-set controllers online via 4G network. Enables remote monitoring and tracking of the gen-set’s exact position, helping to optimise its uptime and reduce maintenance costs.

CM-RS232-485

Communication module enabling integration of genset controller into the local monitoring system over Modbus RTU and a quick connection to ComAp software tools for configuration and monitoring InteliConfig and InteliSCADA.

WinScope

WinScope is a high-performance PC tool used for monitoring and archiving trends. The tool enables quick and easy adjusting of setpoints to achieve optimal functionality and maximum performance of your gen-set. WinScope 1000 is available and can work in demo mode, free basic mode or paid advanced version, which can monitor up to 32 controllers and channels. WinScope 1000 is the newest generation of our WinScope tool.

I-CR-R

CAN redundancy module for inter-controller CAN, helping to increase controller communication reliability on sites with large footprint.

EM-BIO8-EFCP

Binary I/O plug-in module with earth fault current protection measurement.

CM-Ethernet

An easy-to-use communication solution to help connect gen-set controllers online via wired connection. This plug-in communication module enables remote monitoring and control for the gen-set controllers and provides access to various gen-set values - engine values, generator, load and Mains electrical values - alarms and history from anywhere.

IGL-RA15

Upgraded version of Remote Annunciator with new ComAp design and full NFPA 110 compliance. Designed as an extension signaling unit for ComAp products.

IGS-PTM

Analogue/binary Input/Output module.

Inteli AIN8

Module with 8 analogue Input channels and 1 RPM/Impulse Input.

InteliVision 5.2

InteliVision 5.2 is an easy-to-use remote colour display for ComAp controllers, for monitoring and control of single gen-set for various applications. This intuitive plug&play solution provides comprehensive visual overview of all engine data, monitoring information and trend history.

I-CB/MTU

ECU communication interface for MTU engines with ADEC and MDEC ECUs.

CM-GPRS

An easy-to-use communication solution to help connect single and paralleling gen-set controllers online via GPRS and GSM communication.

Inteli AIN8TC

Peripheral module, extension module - 8 thermocouples inputs.

Inteli IO8/8

Binary Inputs/Outputs and analogue Outputs module.

I-CR

CAN repeater module for inter-controller CAN, helping to increase controller communication reliability on sites with large footprint.

Alternative products

InteliGen NT

InteliGen NT GC is a controller for single or multiple diesel gen-sets operating in stand-by or parallel mode. This controller will help you control, monitor and ensure the back-up power for medium sized sites, as well as rental applications. The InteliGen NT GC is an earlier generation controller of our InteliGen 500 G2.

InteliGen 200

InteliGen 200 is a gen-set control unit for common paralleling applications, supporting both single and multiple gensets running in grid-tied or island operations.

InteliGen NTC

InteliGen NTC GC is a controller with a broad range of communication capabilities for single or multiple diesel gen-sets operating in stand-by or parallel mode. This product will help you ensure the back-up power for medium sized sites, as well as rental applications. The InteliGen NTC GC is an earlier generation of our InteliGen 500 G2 controller.

InteliGen4 200

InteliGen4 200 is a diesel gen-set control unit for common paralleling applications supporting both single and multiple gen-sets running in grid-tied or island operations.

InteliMains 210

InteliMains 210 is a secure mains supervision controller for synchronising sets of gen-sets to the mains/utility source. The controller can also be used for tie-breaker operation and is compatible for switchgear and standard applications.

Substitute of

InteliGen 500 G2

InteliGen 500 G2 is a paralleling controller with 5" colour display for advanced and more complex diesel gen-set applications, supporting both single and multiple gen-sets running in grid-tied or island operations.

Extended Features

Extended Feature - InteliGen 500 Microgrid

InteliGen 500 Microgrid is a new solution for complete microgrid control. The system ensures full control of the energy resources in your microgrid, efficient energy management and remote monitoring. The solution is a combination of the InteliGen 500 gen-set controller, a custom microgrid ComAp firmware upgrade activated by a software key and an InteliFieldbus Gateway for interaction with third-party products, including solar inverters.

Frequently Asked Questions

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Can I unlock my controller?

If you have forgotten your controller password, it can be found using the password decode function.

You will need the following information about your device:

serial number
"password decode" number

Both numbers can be obtained through the monitoring software relevant to the device.

Serial number is available in Controller info
Password decode number is available in Values / Info

You can also show these numbers on your device's display. Typically, this requires a sequence or combination of buttons to be pressed. Details can be found typically in the device Operator guide.

Once you have these numbers, please contact your ComAp distributor and they will help you get your password back.

I cannot program my controller, it looks dead. How do I restore a controller with broken firmware?

The controller firmware does not usually break by itself however it can be damaged during controller programming, typically if power is lost during the process. If there does not seem to be a hardware issue with the controller there is an option to restore the controller using a process called ‘Boot Jumper’ programming.

This can be described as a sequence of steps you need to perform to allow the configuration tool to write new firmware into the device.

The steps typically are:

Physically connect the controller to your PC.
Power the controller on and initiate connection and firmware programming from the software tool menu.
The software will ask you to switch the device off, close the Boot Jumper and switch the device back on.
The programming will then proceed and you will receive further instructions during the process.

The boot jumper can be found either on the communication module (where plug-in modules are used) or on the device itself, typically under a rubber grommet, next to the dongle slot.

The description above is not enough? Try our Booot jumper training video.

How do I connect to my ComAp controller? What types of connections are supported?

ComAp offers a wide range of options to connect to your controller:

RS232 / RS485
USB - USB A<->B (usually a printer cable)
Internet connection - LAN, GPRS, 3G, 4G

Note that some connection types require you to use a communication module (plug-in eg a RS232 card) or communication bridge (external device eg Internet Bridge NT).

Each ComAp device usually allows for multiple ways of connection. The simplest one supported by the majority of our devices is the RS232 (serial) connection. For this, you need an RS232 cable (null modem) and if your PC is not equipped with an RS232 port you need a USB<->RS232 converter.
USB connections are very common. Almost all ComAp devices support connection using simple USB A<->B cable (printer cable) for easy configuration. Some devices can be powered from the USB port for programming to allow easy configuration right on your desk.
Other connection types: Internet connection (LAN, GPRS, 3G, 4G), Modbus RTU, Modbus TCP, SNMP, AirGate, Modem.
Note that some connection types require you to use a communication module (plug-in eg a RS232 card) or communication bridge (external device eg Internet Bridge NT). Not all types of connection are possible on each device. You can find all the details related to this topic in your device's Comprehensive guide or Communication guide.

Detailed information about connection to:
InteliLite NT, InteliATS NT, InteliCompact NT is available IL-NT, IA-NT, IC-NT Communication Guide (page 21)
InteliGen-NT, InteliSys-NT, InteliMains-NT is available in IGS-NT Communication Guide (page 19)
InteliLite is available in Global Guide InteliLite AMF25 Global Guide (page 126)

I cannot connect to my controller using the Internet or AirGate connection, why?

Usually connecting to the controller over the internet is straightforward and works out of the box. However, there are a few parameters that need to be set correctly.

Make sure you have the latest firmware in the controller itself but also in all the communication modules (plug-in, built-in or external).
- Communication modules that supports connection via the internet
  - CM-4G-GPS
  - CM-Ethernet
  - CM-GPRS
  - InternetBridge-NT 4G
  - InternetBridge-NT
  - IB-Lite
  - IB-COM (Built-in communication module for NTC controllers)
  - IL-NT GPRS

Ensure the communication interface is configured correctly.
- CM-4G-GPS, CM-Ethernet, CM-GPRS - Can be set in the controllers setpoints on the unit itself or using InteliConfig configuration software.
- IB-COM, IB-Lite - Use web interface - just connect to http://<controller-ip-address>/sp_index.htm using your favourite web browser.
- InternetBridge-NT 4G, InternetBridge-NT - Requires a software tool called IBNTConfig(https://www.comap-control.com/products/detail/ib-nt-config) and an USB A<->B cable for configuration. This way you can also enable MODBUS, SNMP etc.

Make sure there is no firewall blocking your connection. Consult your IT specialist or ISP if not sure. If you use a firewall, make sure the following ports are open for communication:
- The device must be able to send data to the AirGate server at UDP port 6127 and TCP port 23. The TCP port can be changed in the module setup to 21 if needed.
- TCP port 44445 is required for WebSupervisor connection.
- Port 80 is used for accessing the communication module web interface.
- Port 502 is used for Modbus TCP communication (enabled by default).
- Port 161 is used for SNMP (needs to be enabled).

How do I change the controller firmware? Where can I get the latest firmware?

You can download the latest firmware package on the webpage of the device. You can easily navigate there through the ‘Products’ section or just use the Search function. If you cannot find the firmware on the website or if you require different than the offered version do not hesitate to contact our support team.

The firmware upgrade itself is easy to perform. You need the appropriate configuration software and a connection to the controller (preferably a direct connection). Prior to initiating the update process, we strongly recommend you to save a complete backup of your device.

It usually consists of several steps:

Create a controller back up.
Update the device firmware. It will contain default Configuration Archive and default Application.
Change the Application (SPtM, MiNT, MCB, MGCB, BTB, etc) to the required type (by programming appropriate default archive to the controller).
Use the Import Configuration Wizard to restore your previous configuration. In some cases manual interventions might be needed during this step.
Optional: Update the connected display firmware or device communication module firmware.

Should you be unsuccessful in programming the new version, the rollback procedure is to install previous firmware version and use your back up to restore the controller to its original state before the firmware upgrade was attempted.

InteliGen 500

Accessories

Alternative products

Substitute of

Extended Features

Frequently Asked Questions

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