ComAp - InteliGen 500 G2

InteliGen 500 G2

Order code: IG4500XXBAA

Upcoming training: 23.1.2025. Find out more.

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.

This product is a direct successor of our InteliGen 500, InteliGen NT GC and InteliGen NTC GC controllers.

Stage V & Tier4Final
Cybersecurity by design
Multi ECU support
Start-up synchronisation
Forced values
Signal sharing across units*
Dynamic spinning reserve
Controller redundancy*
Modbus Client controlling 3rd party devices*

InteliGen 500 G2 Datasheet

English (19 Dec 2024)

Manuals

5 files

English (5 Dec 2024)

English (26 Sep 2024)

English (9 Mar 2023)

Software

4 files

English (5 Dec 2024)

English (4 Dec 2024)

English (4 Oct 2024)

English (26 Sep 2024)

EU Declaration of Conformity

English (3 Sep 2024)

English (9 Mar 2023)

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Overview
Related products
Extended features
Resources
Training

Overview
Related products
Extended features
Resources
Training

InteliGen 500 G2

The InteliGen 500 G2 offers:

Support for installations with the option for cooperation with up to 32 gen-sets/mains/tie controllers
Keeping your business and data as safe as possible, meeting the ISA 62443 level 2 - level 3 security requirements
StageV and Tier4Final-ready by default
Multi ECU (Electronic Control Unit) enabling communication with more independent J1939 devices such as Engine Control Units, AVR modules, Breakers, etc.
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 minimum possible delay
PV control supporting small hybrid microgrid(HMG) sites consisting of a grid connection and a single genset and photovoltaic (PV) inverters*
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
Faster and cost-effective operations with signal sharing over a CAN bus across a group of control units*
Controller redundancyRedundancy in critical backup power systems is essential to ensure that the power is never compromised. Our controllers allow for installing a second controller to continuously monitor for potential failure. minimising solution downtime and ensuring the power isn’t compromised*
Modbus Client which can initiate Modbus communication and control 3rd party devices*
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
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. 2.0 for easy connection to your equipment remotely, without worrying about your asset’s IP address
User-defined protections and setpoints on top of default parameters
Remote control and monitoring of your gen-set operations with WebSupervisor, our cloud-based fleet management tool
Secure user management
Compatible load/Var sharing and power management with other ComAp solutions
Droop regulation allowing load sharing and Var sharing when inter-controller’s communication is lost
Plug-in modules to easily extend the functionality of the product
Possibility to have a mains application in a gen-set controller with firmware upload functions
One hardware for more applications, enabling an easy switch between MINT and SPtM (or MCB and MGCB)
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**
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.
Event-based history for fast and easy troubleshooting
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
Clear visualisation and overview of all important information on the built-in colour display

* Features available with a software key.

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

Extended features applicable to this controller with a software key:

Alternative products

InteliGen 1000

InteliGen 1000 is the most advanced ComAp gen-set controller for multiple gen-sets with paralleling operations, with or without connection to the mains or other source. Intended primarily for switchgear applications, this high-end controller will help you control and monitor demanding projects with critical infrastructures such as datacentres, hospitals and banks.

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.

InteliMains 1010

InteliMains 1010 is the most advanced ComAp mains/utility/tie-breaker supervision controller for complex applications. Designed following top IT security standards to protect your operations, the InteliMains 1010 acts as a relay for mains protection and helps synchronise your gen-sets to the mains/utility for switchgear applications and critical infrastructure installations, such as datacentres, hospitals or banks.

InteliMains 510

InteliMains 510 is the mains supervision controller used for synchronising set of gensets to the Mains/Utility or bus-tie-breaker operations, primarily intended for switchgear and targeting advanced and more complex applications.

Extended Feature - IG500 G2 Suite

A bundle of features for the InteliGen 500 G2 paralleling controller that significantly improves the performance of a controller, making it suitable even for more complex and demanding applications. The IG 500 G2 Suite will enable you without changing the control system to build advanced logic with enhanced PLC capacity, save physical wiring transmitting signals over CAN line or create a back-up unit in case the primary controller fails, helping to minimise power downtime and increase system reliability.

Accessories

CM3-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.

EM-BIO8-EFCP

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

InteliVision 18Touch G2

Easy to install, configure and use, the InteliVision 18Touch G2 provides comprehensive overview and monitoring of your complex installations. A new generation of our InteliVision 18Touch, this display will support your control and monitoring needs for sites with multiple controllers and complex installations, such as CHP or Hybrid that need to monitor a large number of values. The product comes with embedded InteliSCADA software, ComAp's PC monitoring and management tool, enabling easy screen configuration, history check and change of setpoints from a single location.

CM2-4G-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.

I-CR

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

InteliVision 10Touch

Intuitive and easy to use, the InteliVision 10Touch is a high-quality PC panel designed for a broad range of ComAp’s paralleling and single gen-set controllers for various applications. This 10.1” multi-touch display comes with embedded InteliScada display, our signature PC monitoring tool, enabling easy monitoring and simple screen configuration to meet your needs.

I-CR-R

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

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.

InteliSCADA

InteliSCADA is an intuitive software tool that enables quick and simple creation and monitoring of complex Supervisory Control and Data Acquisition (SCADA) systems for controlling industrial processes. The tool can be used to monitor locally both simple and advanced paralleling sites, regardless of the type of application.

Substitute of

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 500

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.

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.

Extended Features

Extended Feature - IG500 G2 Suite

Extended Feature - Modbus client

Providing direct access to the Modbus Client (primary) functionality, this extended feature eliminates the need for an external gateway for the controller to communicate with different devices. With this built-in capability, the controller can seamlessly take on the role of the initiator in Modbus TCP/RTU communication. This enables efficiently requesting and issuing commands to 3rd party devices, which operate as Modbus Servers.

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 G2

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Frequently Asked Questions

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About InteliGen 500 G2 Video

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