PANTALLA

InteliLite
AMF25
Controller for single gen-set
applications
SW version 1.9.0
1 Document information 6
2 System overview 11
3 Applications overview 20
4 Installation and wiring 22
5 Controller setup 61
6 Communication 153
7 Technical data 180
8 Appendix 182
Copyright © 2018 ComAp a.s.

Written by Michal Slavata
Prague, Czech Republic
ComAp a.s., U Uranie 1612/14a,
Global Guide
170 00 Prague 7, Czech Republic
Tel: +420 246 012 111
E-mail: [email protected], www.comap-control.com
Table of contents
1 Document information 6
1.1 Clarification of notation 6
1.2 About this Global Guide 6
1.3 Legal notice 6
1.4 General warnings 8
1.4.1 Remote control and programing 8
1.4.2 SW and HW versions compatibility 8
1.4.3 Dangerous voltage 8
1.4.4 Adjust the setpoints 8
1.5 Certifications and standards 9
1.6 Document history 9
1.7 Symbols in this manual 10
2 System overview 11
2.1 General description 11
2.1.1 The key features of InteliLite 11
2.2 True RMS measurement 11
2.3 Configurability and monitoring 11
2.3.1 Supported configuration and monitoring tools 12
2.3.2 Configuration parts 12
2.4 PC Tools 13
2.4.1 InteliConfig 13
2.4.2 WebSupervisor 13
2.4.3 WinScope 14
2.5 Plug-in Modules 14
2.5.1 CM-Ethernet 14
2.5.2 CM-4G-GPS 15
2.5.3 CM-GPRS 15
2.5.4 CM-RS232-485 15
2.5.5 EM-BIO8-EFCP 16
2.6 CAN modules 16
2.6.1 Inteli IO8/8 16
2.6.2 Inteli AIN8 17
2.6.3 Inteli AIN8TC 17
2.6.4 Inteli AIO9/1 18
2.6.5 IGS-PTM 18
2.6.6 IGL-RA15 19
InteliLite Global Guide 2

3 Applications overview 20
3.1 AMF - Automatic Mains Failure Start 20
3.2 MRS - Manual Remote Start 20
4 Installation and wiring 22

4.1 Package content 22
4.2 Controller installation 23
4.2.1 Dimensions 23
4.2.2 Mounting 23
4.3 Terminal Diagram 25
4.4 Recommended wiring 26
4.4.1 General 27
4.4.2 Grounding 27
4.4.3 Power supply 27
4.4.4 Measurement wiring 29
4.4.5 Magnetic pick-up 46
4.4.6 Binary inputs 47
4.4.7 Binary Outputs 48
4.4.8 Emergency stop 49
4.4.9 Analog inputs 49
4.4.10 CAN bus and RS485 wiring 54
4.4.11 USB 57
4.4.12 Example of AMF Wiring 57
4.4.13 Example of MRS Wiring 58
4.5 Plug-in module installation 58
4.5.1 Installation 58
4.6 Maintenance 60
4.6.1 Backup battery replacement 60
5 Controller setup 61
5.1 Default configuration 61
5.1.1 Binary inputs 61
5.1.2 Binary outputs 61
5.1.3 Analog inputs 62
5.2 Controller configuration and PC tools connection 62
5.2.1 USB 62
5.2.2 RS232/RS485 63
5.2.3 Ethernet 64
5.3 Operator Guide 69
5.3.1 Front panel elements 69

5.3.2 Display screens and pages structure 71
5.3.3 Browsing alarms 84
5.3.4 Password 85
5.3.5 Information screen 91
5.3.6 Language selection 92
5.3.7 Display contrast adjustment 93
5.4 Remote Display 93
5.4.1 General description 94
5.4.2 IL3-RD Firmware installation 94
5.4.3 Wiring 94
5.4.4 Interconnection variants 95
5.4.5 Connection process 96
5.4.6 Connection troubleshooting 96
5.4.7 Function description 97
5.4.8 Firmware compatibility 97
5.5 Functions 98
5.5.1 Start-stop sequence 98
5.5.2 AMF sequence 100
5.5.3 Operating Modes 101
5.5.4 Engine start 102
5.5.5 Stabilization 107
5.5.6 Connecting to load 107
5.5.7 MRS operation 107
5.5.8 AMF operation 107
5.5.9 Dual Operation 109
5.5.10 Engine cool down and stop 112
5.5.11 Alarm management 112
5.5.12 History log 118
5.5.13 Breaker control 120
5.5.14 Exercise timers 123
5.5.15 Rental Timers 129
5.5.16 Service timers 130
5.5.17 Analog switches 130
5.5.18 Additional running engine indications 132
5.5.19 Voltage phase sequence detection 132
5.5.20 Gen-set operation states 133
5.5.21 Sensor curves 135
5.5.22 PLC 137
5.5.23 Geo-fencing 144

5.5.24 Tier 4 Final 144
5.5.25 Alternate configuration 147
5.5.26 ECU Frequency selection 148
5.5.27 Cybernetic security 148
6 Communication 153
6.1 PC 153
6.1.1 Direct communication 153
6.1.2 Remote communication 155
6.2 Connection to 3rd party systems 166
6.2.1 SNMP 166
6.2.2 MODBUS-RTU, MODBUS/TCP 168
7 Technical data 180
8 Appendix 182
8.1 Controller objects 183
8.1.1 Setpoints 184
8.1.2 Values 475
8.1.3 Logical binary inputs 523
8.1.4 Logical binary outputs 567
8.1.5 Logical analog inputs 638
8.1.6 PLC 670
8.2 Alarms 683
8.2.1 Alarms level 1 683
8.2.2 Alarms level 2 709
8.2.3 Fail sensor and other types 728
8.3 Modules 730
8.3.1 Plug-In modules 731
8.3.2 CAN modules 746

1 Document information
1.1 Clarification of notation 6
1.2 About this Global Guide 6
1.3 Legal notice 6
1.4 General warnings 8
1.5 Certifications and standards 9
1.6 Document history 9
1.7 Symbols in this manual 10
back to Table of contents
1.1 Clarification of notation

Note: This type of paragraph calls readers attention to a notice or related theme.
IMPORTANT: This type of paragraph highlights a procedure, adjustment etc., which can cause a
damage or unproper 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.
1.2 About this Global Guide

This manual contains important instructions for InteliLite controllers family that shall be followed during
installation and maintenance of the controllers.
This manual provides general information how to install and operate InteliLite controllers.
This manual is dedicated for:
Operators of gen-sets
Gen-set control panel builders
For everybody who is concerned with installation, operation and maintenance of the gen-set
1.3 Legal notice

This End User's Guide /Manual as part of the Documentation is an inseparable part of ComAp’s Product and
may be used exclusively according to the conditions defined in the “USER or Distributor LICENSE
AGREEMENT CONDITIONS– COMAP CONTROL SYSTEMS SOFTWARE” (License Agreement) and in the
“ComAp a.s. Standard Terms for sale of Products and provision of Services” (Standard Terms)
ComAp’s License Agreement is governed by the Czech Authorship Act 121/2000 Col., by international treaties
and by other relevant legal documents regulating protection of the intellectual properties (TRIPS).
The End User and/or ComAp’s Distributor shall only be permitted to use this End User's Guide /Manual with
ComAp Control System Registered Products. The Documentation is not intended and applicable for any other
purpose.

ComAp reserves the right to update this End User's Guide /Manual at any time. ComAp does not assume any
responsibility for its use outside of the scope of the Standard Terms and the License Agreement.
Licensed End User is entitled to make only necessary number of copies of the End User's Guide /Manual. Any
translation of this End User's Guide /Manual without the prior written consent of ComAp is expressly prohibited!
Even if the prior written consent from ComAp is acquired, ComAp does not take any responsibility for the
content and quality of any such translation. ComAp will deem a translation equal to this End User's
Guide/Manual only if it agrees to verify such a translation. The terms and conditions of such verification must be
included in the written consent.
For more details relating to the Ownership, Extent of Permitted Reproductions Term of Use of the
Documentation and to the Confidentiality rules please review and comply with the ComAp’s END
USER or Distributor LICENSE AGREEMENT CONDITIONS– COMAP CONTROL SYSTEMS
SOFTWARE and STANDARD TERMS FOR SALE OF PRODUCTS AND PROVISION OF SERVICES
available on the www.comap-control.com.
Security Risk Disclaimer
Pay attention to the following recommendations and measures to increase the level of security of ComAp
products and services.
Please note that possible cyber-attacks cannot be fully avoided by the below mentioned recommendations and
set of measures already performed by ComAp, but by following them the cyber-attacks can be considerably
reduced and thereby to reduce the risk of damage. ComAp does not take any responsibility for the actions of
persons responsible for cyber-attacks, nor for any damage caused by the cyber-attack. However, ComAp is
prepared to provide technical support to resolve problems arising from such actions, including but not limited to
restoring settings prior to the cyber-attacks, backing up data, recommending other preventive measures against
any further attacks.
Warning: Some forms of technical support may be provided against payment. There is no legal or factual
entitlement for technical services provided in connection to resolving problems arising from cyber-attack or
other unauthorized accesses to ComAp's Products or Services.
General security recommendations and set of measures
1. AccessCode
• Change the AccessCode BEFORE the device is connected to a network.
• Use a secure AccessCode – ideally a random string of 8 characters containing lowercase, uppercase letters
and digits.
• For each device use a different AccessCode.
2. Password
• Change the password BEFORE the device enters a regular operation.
• Do not leave displays or PC tools unattended if an user, especially administrator, is logged in.
3. Controller Web interface
• The controller web interface at port TCP/80 is based on http, not https, and thus it is intended to be used only
in closed private network infrastructures.
• Avoid exposing the port TCP/80 to the public Internet.
4. MODBUS/TCP
• The MODBUS/TCP protocol (port TCP/502) is an instrumentation protocol designed to exchange data
between locally connected devices like sensors, I/O modules, controllers etc. From it’s nature it does not
contain any kind of security – neither encryption nor authentication. Thus it is intended to be used only in closed
private network infrastructures.

• Avoid exposing the port TCP/502 to the public Internet.
5. SNMP
• The SNMP protocol (port UDP/161) version 1,2 is not encrypted. Thus it is intended to be used only in closed
private network infrastructures.
• Avoid exposing the port UDP/161 to the public Internet.
Used Open Source Software: mBed-TLS
https://www.mbed.com/en/development/software/mbed-tls/
http://www.apache.org/licenses/LICENSE-2.0
Used Font: zpix-pixel-font
WEBLINK to the license conditions: https://github.com/SolidZORO/zpix-pixel-font
Copyright (c) [2019] [Jason Fung]
1.4 General warnings

1.4.1 Remote control and programing
Controller can be remotely controlled. In the event that maintenance of gen-set has to be done, or controller has
to be programmed, check the following points to ensure that the engine cannot be started or any other parts of
the system cannot be effected.
To be sure:
Disconnect remote control
Disconnect binary outputs
1.4.2 SW and HW versions compatibility

Be aware to use proper combination of SW and HW versions.
1.4.3 Dangerous voltage

In no case touch the terminals for voltage and current measurement!
Always connect grounding terminals!
In any case do not disconnect controller CT terminals!
1.4.4 Adjust the setpoints

All parameters are adjusted to their typical values. However the setpoints has to be checked and adjusted to
their real values before the first starting of the gen-set.
IMPORTANT: Wrong adjustment of setpoints can destroy the gen-set.
Note: The controller contains a large number of configurable setpoints, because of this it is impossible to
describe all of its functions. Some functions can be changed or have different behavior in different SW versions.
Always check the Global guide and New feature list for SW version which is used in controller. This manual
only describes the product and is not guaranteed to be set for your application.

IMPORTANT: Be aware that the binary outputs can change state during and after software
reprogramming (before the controller is used again ensure that the proper configuration and
setpoint settings are set in the controller).
The following instructions are for qualified personnel only. To avoid personal injury do not perform any action not
specified in related guides for product.
1.5 Certifications and standards

EN 61000-6-2
EN 61000-6-4
EN 61010-1
EN 60068-2-1 (-20 °C/16 h for std, -40 °C/16 h for LT version)
EN 60068-2-2 (70 °C/16 h)
EN 60068-2-6 (2÷25 Hz / ±1,6 mm; 25÷100 Hz / 4,0 g)

EN 60068-2-27 (a=500 m/s2; T=6 ms)
EN 60068-2-30:2005 25/55°C, RH 95%, 48hours
EN 60529 (front panel IP65, back side IP20)
1.6 Document history

Revision number Related sw. version Date Author
11 1.9.0 23.9.2019 Michal Slavata
10 1.8.0 21.5.2019 Michal Slavata
9 1.7.0 22.8.2018 Michal Slavata

1.7 Symbols in this manual
Connector - Resistor
3 x Phases Grounding
male adjustable
Active Resistive
current Contact GSM sensor
sensor RPTC
GSM RS 232
Contactor
AirGate modem male
Controller RS 232
IG-AVRi
Alternating simplified female
current
Module IG-AVRi
Starter
Analog simplified TRANS
modem
Switch -
Current
Jumper manually
measuring
Battery operated
Current
Load Transformer
Binary measuring
output
USB type B
Diode Mains male
Breaker
contact
Ethernet USB type B
Mains female
Breaker male
contact
Voltage
Ethernet Mobile
measuring
female provider
Breaker
Passive Wifi / WAN /
Fuel
current LAN
solenoid
Breaker sensor back to Document
information
Fuse Pick - up
Breaker
Fuse switch Relay coil

Capacitor
Relay coil of
Generator slow-
Coil
operating
Generator
Connector - schematic Resistor
female

2 System overview
2.1 General description 11
2.2 True RMS measurement 11
2.3 Configurability and monitoring 11
2.4 PC Tools 13
2.5 Plug-in Modules 14
2.6 CAN modules 16
2.1 General description

InteliLite Family controllers are comprehensive gen-set controllers for single gen-sets operating in stand-by
(MRS) or back-up (AMF) applications. A modular construction allows upgrades to different levels of complexity
in order to provide the best solution for various customer applications. The controllers are equipped with a
powerful graphic display showing icons, symbols and bar graphs for intuitive operation, which, together with its
high level of functionality, sets new standards in Gen-set controls.
2.1.1 The key features of InteliLite

Easy-to-use operation and installation. The factory default configuration covers most applications
Various customizations are possible thanks to its configurability
Excellent remote communication capabilities
High level of support for EFI engines (most world producers)
High reliability
2.2 True RMS measurement

This controller measures AC values based on True RMS principle. This principle corresponds exactly to the
physical definition of alternating voltage effective values. Under normal circumstances the mains voltage
should have a pure sinusoidal waveform. However some nonlinear elements connected to the mains produce
harmonic waveforms with frequencies of multiplies of the basic mains frequency and this may result in
deformation of the voltage waveforms. The True RMS measurement gives accurate readings of effective values
not only for pure sinusoidal waveforms, but also for deformed waveforms.
2.3 Configurability and monitoring

One of the key features of the controller is the system’s high level of adaptability to the needs of each individual
application and wide possibilities for monitoring. This can be achieved by configuring and using the powerful
PC/mobile tools.

2.3.1 Supported configuration and monitoring tools
InteliConfig - complete configuration and single gen-set monitoring
WebSupervisor - web-based system for monitoring and controlling
WebSupervisor mobile - supporting application for smart-phones
WinScope - special graphical monitoring software
Note: Use the InteliConfig PC software to read, view and modify configuration from the controller or disk and
write the new configuration to the controller or disk.
The firmware of controller contains a large number of binary inputs and outputs needed for all necessary
functions available. However, not all functions are required at the same time on the same gen-set and also the
controller hardware does not have so many input and output terminals. One of the main tasks of the
configuration is mapping of “logical” firmware inputs and outputs to the “physical” hardware inputs and outputs.
2.3.2 Configuration parts

Mapping of logical binary inputs (functions) or assigning alarms to physical binary input terminals
Mapping of logical binary outputs (functions) to physical binary output terminals
Assigning sensor characteristics (curves) and alarms to analog inputs
Selection of peripheral modules, which are connected to the controller, and doing the same (as mentioned
above) for them
Selection of ECU type, if an ECU is connected
Changing the language of the controller interface
Image 2.1 Principle of binary inputs and outputs configuration

The controller is shipped with a default configuration, which should be suitable for most standard applications.
This default configuration can be changed only by using a PC with the InteliConfig software. See InteliConfig
documentation for details.
Once the configuration is modified, it can be saved to a file for later usage with another controller or for backup
purposes. The file is called archive and has the file extension .ail3. An archive contains a full image of the
controller at the time of saving (if the controller is online for the PC) except the firmware. Besides configuration it
also contains current adjustment of all setpoints, all measured values, a copy of the history log and a copy of the
alarm list.
The archive can be simply used for cloning controllers, i.e. preparing controllers with identical configuration and
settings.
2.4 PC Tools
2.4.1 InteliConfig
Configuration and monitoring tool for InteliLite controllers. See more in InteliConfig Reference Guide.
This tool provides the following functions:

Direct or internet communication with the
controller
Offline or online controller configuration
Controller firmware upgrade
Reading/writing/adjustment of setpoints
Reading of measured values
Browsing of controller history records
Exporting data into a XLS file
Controller language translation
2.4.2 WebSupervisor
Web-based system for monitoring and controlling of controllers. See more at the WebSupervisor webpage.

Site and fleet monitoring
Reading of measured values
Browsing of controller history records
On-line notification of alarms
Email notification
Also available as a smart-phone application
WebSupervisor available at: www.websupervisor.net

Demo account:
Login: comaptest
Password: ComAp123

2.4.3 WinScope
Special graphical controller monitoring software used mainly for commissioning and gen-set troubleshooting.
See more in the WinScope Reference guide.

Monitoring and archiving of ComAp controller’s
parameters and values
View of actual / historical trends in controller
On-line change of controllers’ parameters for
easy regulator setup
2.5 Plug-in Modules

2.5.1 CM-Ethernet
Internet/Ethernet module including web server.
10/100 Mbit ethernet interface in RJ45 socket
Web interface for monitoring and adjustment of
the controller
Direct IP and/or AirGate connection for remote
access from InteliConfig
MODBUS/TCP and SNMP protocols for
integration of the controller into building
management systems or other remote
monitoring purposes
Sending of active emails
Simply connection via AirGate

2.5.2 CM-4G-GPS
GSM/4G Internet module and GPS locator
Wireless integrated solution
Quick and easy installation
Support of WebSupervisor
Instant alarm SMS notification
System control over SMS
Quad Band GPRS/EDGE modem,
850/900/1800/1900 MHz, FDD LTE: Band 1,
Band 2, Band 3, Band 4, Band 5, Band 7, Band
8, Band 20, all bands with diversity,
WCDMA/HSDPA/HSUPA/HSPA+: Band 1,
Band 2, Band 5, Band 8, all bands with diversity
GPRS multi-slot class 10
TCP/IP communication over GPRS
2.5.3 CM-GPRS
GSM/GPRS Internet module
Wireless integrated solution
Quick and easy installation
Support of WebSupervisor
Instant alarm SMS notification
System control over SMS
Quad Band GPRS/EDGE modem,
850/900/1800/1900 MHz
GPRS multi-slot class 10
TCP/IP communication over GPRS
2.5.4 CM-RS232-485
Communication module with two communication ports.
RS232 and RS485 interface
MODBUS
Serial connection to InteliConfig

2.5.5 EM-BIO8-EFCP
Hybrid current input and binary input/output extension module.
One additional AC current (CT) measuring for
Earth Fault Current protection (EFCP)
Wide range of measured current - one input for
1A and 1 input for 5A
Up to 8 additional configurable binary inputs or
outputs
2.6 CAN modules

2.6.1 Inteli IO8/8
The unit offers the user the flexibility to configure the unit to have 8 binary inputs, 8 binary outputs, and 2 analog
outputs, or 16 binary inputs, 0 binary outputs and 2 analog outputs via switches inside the controller.
Configuration 8/8
8 Binary inputs (options: pull up or pull down
logic)
8 Binary outputs (options: Low side switch (LSS)
or High side switch (HSS))
2 Analog outputs (options: voltage (0-10V),
current (0-20mA) and PWM (5V, adjustable
frequency 200Hz-2,4kHz))
Configuration 16/0
16 Binary inputs (options: pull up or pull down
logic)
0 Binary outputs
2 Analog outputs (options: voltage (0-10V),
current (0-20mA) and PWM (5V, adjustable
frequency 200Hz-2,4kHz))

2.6.2 Inteli AIN8
The unit offers the user the flexibility to configure the unit to have 8 analog inputs.
Supported sensors:
Resistor 3-wire input
Common resistor: 0-250Ω, 0-2400Ω, 0-10kΩ
Temperature sensor: Pt100, Pt1000, Ni100,
Ni1000
Current (active or passive sensors)
±20mA , 0-20mA, 4-20mA
Voltage
±1V, 0-2,4V, 0-5V, 0-10V
Lambda probes
Thermocouples are not supported (the
measuring loop was designed for lambda
probes, what caused non-support of
thermocouples)
2.6.3 Inteli AIN8TC

8 Analog Channels Module
8 analog input channels for measuring
temperature by thermocouples

2.6.4 Inteli AIO9/1
9 Analog Inputs and 1 Analog Output Module
4× differential voltage inputs for measurement in
range of 0 - 65 V or -65 V – 0 V
4× shielded, galvanically separated ±75 mV
inputs
Resistance analog input 0 – 2500 ohm
One analog output
2.6.5 IGS-PTM
The unit offers the user the flexibility to configure the unit to have 8 binary inputs, 8 binary outputs, 4 analog
inputs and 1 analog outputs.
Configurable 8 binary and 4 analog inputs
Configurable 8 binary and 1 analog output
LEDs indicate the state of binary inputs/outputs
Measures values from Pt100 and Ni100 sensors
Analog inputs (resistance range 0-250 Ohms,
voltage range 0-100mV, current range 0-20mA -
selectable via jumper)
UL certified

2.6.6 IGL-RA15
Remote annunciator.
15 programmable LEDs with configurable colors
red-green-yellow
Lamp test function with status LED
Customizable labels
Local horn output
Maximal distance 200 m from the controller
Up to 4 units can be connected to the controller
UL certified
back to System overview

3 Applications overview
3.1 AMF - Automatic Mains Failure Start 20
3.2 MRS - Manual Remote Start 20
3.1 AMF - Automatic Mains Failure Start

The typical scheme of Automatic Mains Failure Start application is shown below. The controller controls two
breakers – a mains breaker and a generator breaker. Feedback from both breakers isn’t necessary. InteliLite
controllers can also work without breaker feedbacks.
Image 3.1 AMF application overview
3.2 MRS - Manual Remote Start

The typical scheme of Manual Remote Start application is shown below. The controller controls one breaker – a
generator breaker. Feedback from breaker isn’t necessary. InteliLite controllers can also work without breaker
feedback.

Image 3.2 MRS application overview
back to Applications overview

4 Installation and wiring
4.1 Package content 22
4.2 Controller installation 23
4.3 Terminal Diagram 25
4.4 Recommended wiring 26
4.5 Plug-in module installation 58
4.6 Maintenance 60
4.1 Package content

The package contains:
Controller
Mounting holders
Terminal blocks
Note: The package does not contain a communication or extension modules. The required modules should be
ordered separately.

4.2 Controller installation
4.2.1 Dimensions
① Plug-in module
Note: Dimension x depends on plug-in module
Note: Dimensions are in millimeters.
Note: Cutout is in millimeters.
4.2.2 Mounting
The controller is to be mounted onto the switchboard door. Requested cutout size is 187 x 132 mm. Use the
screw holders delivered with the controller to fix the controller into the door as described on pictures
below.Recommended torque for holders is 0.15 N·m.

Panel door mounting
Note: Enclosure Type rating with mounting instruction - For use on a Flat surface of a type 1 enclosure.

4.3 Terminal Diagram
GENERATOR GENERATOR MAINS VOLTAGE BINARY INPUTS
CURRENT VOLTAGE MEASUREMENT
MEASUREMENT MEASUREMENT
T28 COM T35 N T39 N T43 BIN1
T29 L1 T36 L1 T40 L1 T44 BIN2
T30 L2 T37 L2 T41 L2 T45 BIN3
T31 L3 T38 L3 T42 L3 T46 BIN4
T47 BIN5
T48 BIN6
T49 BIN7
T50 BIN8
Image 4.1 Terminal diagram for InteliLite AMF25
CAN1 ANALOG INPUTS BINARY OUTPUTS POWER SUPPLY,

D+
T25 L T15 RPM GND T04 BOUT1 T01 BATT -
T26 COM T16 RPM IN T05 BOUT2 T02 D+
T27 H T17 A COM T06 BOUT3 T03 BATT +
T18 A01 T07 BOUT4
T19 A02 T08 BOUT5
T20 A03 T09 BOUT6
T21 A04 T10 BOUT7
T11 BOUT8

4.4 Recommended wiring
Current inputs 28 - 31 Current measurement wiring (page 30)
Voltage measurement AMF wiring (page 32)

Generator voltage inputs 35 - 38
Voltage measurement MRS wiring (page 39)
Mains voltage inputs 39 - 42 Voltage measurement AMF wiring (page 32)
Binary inputs 43 - 50 Binary inputs (page 47)
CAN bus and RS485 H, COM, L CAN bus and RS485 wiring (page 54)
Analog inputs 15 - 21 Analog inputs (page 49)
Binary outputs 04 - 11 Binary Outputs (page 48)
Power supply "+", D, "-" Power supply (page 27)
USB USB (page 57)
Note: Wiring terminal markings to included tightening torque: 0,5 N-m (4,5 lb-in)., and wire size: 2 mm2 (12-
26AWG).

4.4.1 General
To ensure proper function:
Use grounding terminals.
Wiring for binary inputs and analog inputs must not be run with power cables.
Analog and binary inputs should use shielded cables, especially when the length is more than 3 m.
Tightening torque, allowable wire size and type, for the Field-Wiring Terminals:
For Mains(Bus) Voltage, Generator Voltage and Current terminals
Specified tightening torque is 0,56 Nm (5,0 In-lbs)
use only diameter 2,0 - 0,5 mm (12 - 26 AWG) conductor,

rated for 90°C minimum.
For other controller field wiring terminals
Specified tightening torque 0,79 nm (7,0 In-lb)
Use only diameter 2,0 - 0,5 mm (12 - 26 AWG) conductor,

rated for 75°C minimum.
use copper conductors only
4.4.2 Grounding
The shortest possible length of wire should be used for controller grounding. Use cable min 2.5 mm2.
The negative " - " battery terminal must be properly grounded.
Switchboard and engine must be grounded at common point. Use as short cable as possible to the grounding
point.
4.4.3 Power supply

Use power supply cable min. 1.5 mm2
Maximum continuous DC power supply voltage is 36 V DC. The controller’s power supply terminals are
protected against large pulse power disturbances. When there is a potential risk of the controller being subjected
to conditions outside its capabilities, an outside protection device should be used.

It is necessary to ensure that potential difference between generator current COM terminal and battery “ - ”
terminal is maximally ± 2 V. Therefore is strongly recommended to interconnect these two terminals together.
Note: The controller should be grounded properly in order to protect against lighting strikes. The maximum
allowable current through the controller’s negative terminal is 4 A (this is dependent on binary output load).
For the connections with 12 V DC power supply, the controller includes internal capacitors that allow the
controller to continue in operation during cranking if the batter voltage dip occurs. If the voltage dip goes during
cranking to 0 V and after 50 ms it recovers to 4 V, the controller continues operating. This cycle can repeat
several times. During this voltage dip the controller screen backlight can turn off.
Note: Recommended fusing is 3 A fuse.
Note: In case of the dip to 0 V the high-side binary outputs will be temporarily switched off and after recovering
to 4 V back on.
IMPORTANT: When the controller is power up only by USB and the USB is disconnected then the
actual statistics can be lost.
Note: Suitable conductor protection shall be provided in accordance with NFPA 70, Article 240.
Note: Low voltage circuits (35 volts or less) shall be supplied from the engine starting battery or an isolated
secondary circuit.
Note: It is also possible to further support the controller by connecting the external capacitor and separating
diode. The capacitor size depends on required time. It shall be approximately thousands of μF. The capacitor
size should be 5 000 μF to withstand 150 ms voltage dip under following conditions: Voltage before dip is 12 V,
after 150 ms the voltage recovers to min. allowed voltage, i.e. 8 V.
Power supply fusing

A 3 A fuse should be connected in-line with the battery positive terminal to the controller and modules. These
items should never be connected directly to the starting battery. Fuse value and type depends on number of
connected devices and wire length. Recommended fuse (not fast) type - T3 A. Not fast due to internal
capacitors charging during power up.

Note: Recommended fusing is 3 A fuse.
IMPORTANT: 3 A fuse is calculated without BOUT consumption nor extension modules. Real value
of fuse depends on consumption of binary outputs and modules.
Example: Maximal consumption of binary outputs can be 22 A

2 x 10 A on high current outputs (for 10 seconds)
2 A on all others binary outputs
4.4.4 Measurement wiring

Use 1.5 mm2 cables for voltage connection and 2.5 mm2 for current transformers connection. Adjust
Connection type (page 193), Nominal Voltage Ph-N (page 195), Nominal Voltage Ph-Ph (page 195),
Nominal Current (page 191), PT Ratio (page 195), Vm PT Ratio (page 196) and CT Ratio (page 192) by
appropriate setpoints in the Basic Settings group.
IMPORTANT: Risk of personal injury due to electric shock when manipulating voltage terminals
under voltage. Be sure the terminals are not under voltage before touching them.
Do not open the secondary circuit of current transformers when the primary circuit is closed. Open
the primary circuit first.
CT Location
Image 4.2 CT Location
There are two options of CT location.

a) Load

b) Gen-Set
Note: The current measurement protections are active only when the Gen-set is running.
If the CT Location is set to Load the Short Circuit BOC (page 243) protection is enabled only when GCB is
closed.
Current measurement wiring

The number of CT’s is automatically selected based on selected value of setpoint Connection type (page 193)
[3Ph4Wire / High Leg D / 3Ph3Wire / Split Ph / Mono Ph].
Generator currents and power measurement is suppressed if current level is bellow <1 % of CT range.
Use cables of 2.5 mm2
Use transformers to 5 A
Connect CT according to following drawings:
3 phase application:
Image 4.3 3 phase application
IMPORTANT: It is necessary to ensure that potential difference between current COM terminal and
power supply “-” terminal is maximally ± 2 V. There are 2 options how to ensure this:
"Red" option - properly ground both terminals
"Blue" option - interconnect these two terminals
Always apply only one option. Never realize both options on one installation.

Split phase application:
Image 4.4 Split phase application
IMPORTANT: The second phase of split phase connection is connected to the terminal, where is
normally connected the third phase.

Mono phase application:
Connect CT according to following drawings. Terminals phase 2 and phase 3 are opened.
Image 4.5 Mono phase application
Voltage measurement AMF wiring

There are 4 voltage measurement Connection Type (setpoint Connection type (page 193) [3Ph4Wire
/3Ph3Wire / Split Ph / Mono Ph]) options, every type matches to corresponding generator connection type.
Note: For fusing of voltage measurement input use T1A or T2A fuse.
The generator protections are evaluated from different voltages based on Connection type (page 193) setting:
3Ph 4W – Ph-Ph voltage, Ph-N voltage
3Ph 3W – Ph-Ph voltage
SplPhL1L2 – Ph-N voltage
Mono Ph – Ph-N voltage

ConnectionType: 3 Phase 4 Wires
Image 4.6 3 phase application with neutral
Image 4.7 Typical 3 Phase 4 Wires generator wiring

ConnectionType: High Leg D
Image 4.8 High Leg Delta application
Table 4.1 Typical High Leg D generator wiring

Image 4.9 3 phase application without neutral

ConnectionType: SplPhL1L2
Image 4.11 Split phase L1L2 application

Image 4.12 Typical Split Phase generator wiring
usually connected the third phase.


ConnectionType: Mono Phase
Image 4.16 Typical Mono Phase generator wiring
Voltage measurement MRS wiring

There are 4 voltage measurement Connection Type (setpoint Connection type (page 193) [3Ph4Wire
/3Ph3Wire / Split Ph / Mono Ph]) options, every type matches to corresponding generator connection type.
Note: For fusing of voltage measurement input use T1A or T2A fuse.
The generator protections are evaluated from different voltages based on Connection type (page 193) setting:
3Ph 4W – Ph-Ph voltage, Ph-N voltage
3Ph 3W – Ph-Ph voltage
Mono Ph – Ph-N voltage

Image 4.17 3 phase application with neutral

ConnectionType: High Leg D
Image 4.19 High Leg Delta application
Image 4.20 Typical High Leg D generator wiring

Image 4.21 3 phase application without neutral


usually connected the third phase.


ConnectionType: Mono Phase
Image 4.28 Typical Mono Phase generator wiring
4.4.5 Magnetic pick-up

A magnetic speed sensor (pickup) is the most common method of engine speed measurement. To use this
method, mount the pickup opposite to the engine flywheel, connect the cable to the controller as shown on the
picture below and adjust the setpoint Gear Teeth (page 197) according to the number of teeth on the flywheel.
For the details about the pick-up input parameters see Technical data on page 180
IMPORTANT: To ensure proper function use a shielded cable.

If engine will not start:
Check ground connection from pick-up to controllers, eventually disconnect ground connection to one of
them.
Note: In some cases the controller will measure a RPM value even though the gen-set is not running: RPM is
measured from the generator voltage (Gear Teeth = 0). Controller is measuring some voltage value on input
terminals due to open fusing. If RPM > 0 the controller will be put into a Not ready state and the engine will not
be allowed to start.
4.4.6 Binary inputs

Use minimally 1 mm2 cables for wiring of Binary inputs.
Image 4.29 Wiring binary inputs
Note: The name and function or alarm type for each binary input have to be assigned during the configuration.

4.4.7 Binary Outputs
Use min. 1 mm2 cables for wiring of binary outputs. Use external relays as indicated on the schematic below for
all outputs except those where low-current loads are connected (signalization etc...).
IMPORTANT: Use suppression diodes on all relays and other inductive loads!
Note: Every single low current binary output can provide up to 0,5 A of steady current.
Note: Binary output 1 (terminal 4) and binary output 2 (terminal 5) are high current outputs (5 A for long term).
IMPORTANT: When operating temperature is higher than 60 °C it is strongly recommended to limit

output current of high current binary outputs (terminal 4 and terminal 5) to 4 A (each).

4.4.8 Emergency stop
The Emergency Stop function can be made in two ways:
Connecting a normally closed “mushroom-type” button to the binary input . This is a purely software solution.
A hard-wired solution, where the button also disconnects the power supply from the controller outputs.
Image 4.30 Hard-wired emergency stop
IMPORTANT: Suppression diodes are not indicated, but required.
4.4.9 Analog inputs

The analog inputs are designed for resistive automotive type sensors like VDO or DATCON. The sensors are
connected either by one wire (the second pole is the sensor body) or by two wires.
In the case of grounded sensors, connect the AI COM terminal to the engine body as near to the sensors as
possible.
In the case of isolated sensors, connect the AI COM terminal to the negative power supply terminal of the
controller as well as one pole of each sensor.

Analog inputs are typically used for: Oil Pressure, Coolant Temperature and Fuel Level. All of these parameters
are connected with relevant protections.
Image 4.31 Grounded sensors Image 4.32 Isolated sensors
Note: Schemes show only analog input connection overview, not actual wiring.
Note: The name, sensor characteristic and alarm types for each analog input have to be assigned during
configuration.
Analog inputs with voltage & current sensors

On each analog input, there is a possibility to connect voltage or current output sensor instead of resistive one.
Recommended wiring connection for these measurements and recommended curves are bellow.
Voltage sensors
Sensor’s output
R1 (Ω) R2 (Ω)
range (V)
0 - 10 390 100
0 - 30 1500 100
0 - 70 3300 100

Image 4.33 Wiring of analog input with voltage sensor
Tables for HW versions 1.1 and lower.
0 - 10 V
V 0 1 2 3 4 5 6 7 8 9 10
Ω 81 145 219 306 409 539 685 887 1125 1458 1933
0 - 30 V
V 0 2 4 6 8 10 12 14
Ω 95 134 177 223 274 330 395 465
V 16 18 20 22 24 26 28 30
Ω 543 633 735 853 993 1154 1350 1589
0 - 70 V
V 0 2 4 6 8 10 12 14 16 18 20 22
Ω 99 117 137 155 175 196 219 242 266 291 318 346
V 24 26 28 30 32 34 36 38 40 42 44 46
Ω 375 406 439 473 510 549 589 633 679 729 781 838
V 48 50 52 54 56 58 60 62 64 66 68 70
Ω 873 963 1033 1110 1193 1283 1383 1492 1612 1748 1896 2065
Tables for HW versions 1.2 and higher.
0 - 10 V
V 0 1 2 3 4 5 6 7 8 9 10
Ω 80 98 119 143 172 208 251 306 378 474 611

0 - 30 V
V 0 2 4 6 8 10 12 14
Ω 94 105 118 131 147 163 182 202
V 16 18 20 22 24 26 28 30
Ω 226 252 282 317 358 405 463 533
0 - 70 V
V 0 2 4 6 8 10 12 14 16 18 20 22
Ω 97 102 108 114 120 126 133 140 147 154 162 170
V 24 26 28 30 32 34 36 38 40 42 44 46
Ω 179 188 198 208 219 231 243 256 269 284 300 316
V 48 50 52 54 56 58 60 62 64 66 68 70
Ω 334 354 375 398 422 449 479 511 547 587 631 681
Note: This is a conversion of voltage from voltage sensor to appropriate resistance value. Use resistance
values in InteliConfig to create your specific curve. These values should be used in "Ohm" column.
Current sensors
Sensor’s output
R (Ω)
range (mA)
0-20 100
Image 4.34 Wiring of analog input with current sensor

Table for HW versions 1.1 and lower.
0 - 22 mA
mA 0 1 2 3 4 5 6 7 8 9 10 11
Ω 100 131 164 200 238 280 325 374 427 485 550 621
mA 12 13 14 15 16 17 18 19 20 21 22
Ω 700 788 887 1000 1128 1276 1450 1654 1900 2200 2575
Table for HW versions 1.2 and higher.
0 - 22 mA
mA 0 1 2 3 4 5 6 7 8 9 10 11
Ω 100 110 120 130 141 154 168 182 198 216 235 256
mA 12 13 14 15 16 17 18 19 20 21 22
Ω 280 306 336 370 409 453 505 566 640 730 842
Note: This is a conversion of current from current sensor to appropriate resistance value. Use resistance
values in InteliConfig to create your specific curve. These values should be used in "Ohm" column.
Analog as binary or tristate inputs

Analog inputs can be used also as binary or tri-state, i.e. for contact sensors without or with circuit check. The
threshold level is 750 Ω. In the case of tri-state, values lower than 10 Ω and values over 2400 Ω are evaluated as
sensor failure (short or open circuit).
Image 4.35 Analog inputs as tristate Image 4.36 Analog inputs as binary
Note: The name, sensor characteristic and alarm types for each analog input have to be assigned during
configuration.
Note: Tristate and binary sensors are not suitable for Analog Switch functions.

4.4.10 CAN bus and RS485 wiring
CAN bus wiring
The wiring of the CAN bus should be provided in such a way that the following rules are observed:
The maximum length of the CAN bus depends on the communication speed. For a speed of 250 kbps, which
is used on the CAN1 bus (extension modules, ECU), the maximum length is 200 m.
The bus must be wired in linear form with termination resistors at both ends. No nodes are allowed except on
the controller terminals.
Shielded cable1 has to be used, shielding has to be connected to the terminal T01 (Grounding).
External units can be connected on the CAN bus line in any order, but keeping line arrangement (no tails, no
star) is necessary.
The CAN bus has to be terminated by 120 Ohm resistors at both ends use a cable with following
parameters:
Cable type Shielded twisted pair

Impedance 120 Ω
Propagation velocity ≥ 75% (delay ≤ 4,4 ns/m)
Wire crosscut ≥ 0,25 mm2
Attenuation (@1MHz) ≤ 2 dB/100 m
Note: Communication circuits shall be connected to communication circuits of Listed equipment.
Note: A termination resistor at the CAN (120 Ω) is already implemented on the PCB. For connecting, close the
jumper near the appropriate CAN terminal.
Image 4.37 CAN bus topology
1Recommended data cables: BELDEN (http://www.belden.com) - for shorter distances: 3105A Paired - EIA
Industrial RS-485 PLTC/CM (1x2 conductors); for longer distances: 3106A Paired - EIA Industrial RS-485
PLTC/CM (1x2+1 conductors)

For shorter distances (connection within one building)
Image 4.38 CAN bus wiring for shorter distances
Note: Shielding shall be grounded at one end only. Shielding shall not be connected to CAN COM terminal
For longer distances or in case of surge hazard (connection out of building, in case of storm etc.)
Image 4.39 CAN bus wiring for longer distances
① Recommended PT5-HF-12DC-ST1
RS485 wiring
The wiring of the RS485 communication should be provided in such a way that the following rules are observed:
Note: A termination resistor at the RS485 (120Ω) is already implemented on the PCB. For connecting, close
the jumper near the appropriate RS485 terminal.
Standard maximum bus length is 1000 m.

Shielded cable2 has to be used, shielding has to be connected to the terminal T01 (Grounding).
External units can be connected on the RS485 line in any order, but keeping line arrangement (no tails, no
star) is necessary.
The line has to be terminated by 120 Ohm resistors at both ends.
1Protections recommended: Phoenix Contact (http://www.phoenixcontact.com): PT 5-HF-12DC-ST with PT2x2-

BE (base element) or Saltek (http://www.saltek.cz): DM-012/2 R DJ
2Recommended data cables: BELDEN (http://www.belden.com) - for shorter distances: 3105A Paired - EIA
Industrial RS-485 PLTC/CM (1x2 conductors); for longer distances: 3106A Paired - EIA Industrial RS-485
PLTC/CM (1x2+1 conductors)

For shorter distances (connection within one building)
Image 4.40 RS485 wiring for shorter distances
For longer distances or in case of surge hazard (connection out of building, in case of storm etc.)
Image 4.41 RS485 wiring for longer distances
① Recommended PT5HF-5DC-ST1
Note: Communication circuits shall be connected to communication circuits of Listed equipment.
1Recommended protections: Phoenix Contact (http://www.phoenixcontact.com): PT 5-HF-5DC-ST with PT2x2-

BE (base element)(or MT-RS485-TTL) or Saltek (http://www.saltek.cz): DM-006/2 R DJ

4.4.11 USB
This is required for computer connection. Use the shielded USB A-B cable.
Image 4.42 USB connection
Controller can by also power by USB (only for service purpose like a uploading firmware, change of
configuration etc.).
IMPORTANT: Power supply by USB is only for service purpose. Binary inputs and outputs are in
logical 0. Also plug-in modules are not working.
4.4.12 Example of AMF Wiring

4.4.13 Example of MRS Wiring
back to Recommended wiring
4.5 Plug-in module installation

4.5.1 Installation
Remove the back cover. To do this, press four holders which are located in corners.

After removing back cover insert the plug-in module. Plug-in module has to be inserted under holders. Start with
holders marked by symbol 1. On the controller are also arrows for better navigation. After inserting plug-in
module under holders 1 press it down to holders marked by symbol 2 which locks the module.
Insert the plug-in module under holders marked by symbol 1.
After locking the plug-in module into holders, place back the back cover (small cover for connectors has to be
removed from back cover). Finally insert the small cover for connectors. Small covers are unique for each plug-
in module.

4.6 Maintenance
4.6.1 Backup battery replacement
The internal backup battery lifetime is approx. 6 years. If replacement of backup batter is needed, follow these
instructions:
Connect the controller to a PC and save an archive for backup purposes (not necessary but recommended).
Disconnect all terminals from the controller and remove the controller from the switchboard.
Remove the back cover and all plug-in modules.
Release the rear cover using a flat screwdriver or another suitable tool.
The battery is located in a holder on the circuit board. Remove the old battery with a small sharp screwdriver
and push with a finger the new battery into the holder.
Put the rear cover back. Use slight pressure to lock the snaps into the housing. Pay attention that the cover
is in correct position and not upside down!
Put back the plugin modules and back cover.
Power the controller on, adjust date and time and check all setpoints.
back to Installation and wiring

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InteliLite

Copyright © 2018 ComAp a.s.

InteliLite Global Guide 2

4 Installation and wiring 22

InteliLite Global Guide 3

InteliLite Global Guide 4

7 Technical data 180

InteliLite Global Guide 5

back to Table of contents

1.1 Clarification of notation

1.2 About this Global Guide

1.3 Legal notice

InteliLite Global Guide 6

InteliLite Global Guide 7

1.4 General warnings

1.4.2 SW and HW versions compatibility

1.4.3 Dangerous voltage

1.4.4 Adjust the setpoints

InteliLite Global Guide 8

1.5 Certifications and standards

EN 60068-2-6 (2÷25 Hz / ±1,6 mm; 25÷100 Hz / 4,0 g)

1.6 Document history

InteliLite Global Guide 9

Fuse switch Relay coil

InteliLite Global Guide 10

back to Table of contents

2.1 General description

2.1.1 The key features of InteliLite

2.2 True RMS measurement

2.3 Configurability and monitoring

InteliLite Global Guide 11

2.3.2 Configuration parts

Image 2.1 Principle of binary inputs and outputs configuration

InteliLite Global Guide 12

This tool provides the following functions:

This tool provides the following functions:

WebSupervisor available at: www.websupervisor.net

InteliLite Global Guide 13

This tool provides the following functions:

2.5 Plug-in Modules

InteliLite Global Guide 14

InteliLite Global Guide 15

2.6 CAN modules

InteliLite Global Guide 16

2.6.3 Inteli AIN8TC

InteliLite Global Guide 17

InteliLite Global Guide 18

back to System overview

InteliLite Global Guide 19

back to Table of contents

3.1 AMF - Automatic Mains Failure Start

Image 3.1 AMF application overview

3.2 MRS - Manual Remote Start

InteliLite Global Guide 20

back to Applications overview

InteliLite Global Guide 21

back to Table of contents

4.1 Package content

InteliLite Global Guide 22

Note: Dimensions are in millimeters.