ComAp InteliLite MRS16 User manual

Copyright © 2016 ComAp a.s.
Written by Michal Slavata
Prague, Czech Republic
ComAp a.s., Kundratka 2359/17,
180 00 Praha 8, Czech Republic
Tel: [phone]
E-mail: i[email protected], www.comap.cz Global Guide
InteliLite
MRS16
Controller for single gen-set
applications
SW version 1.2.1
Table of contents 2
1 Document information 6
2 System overview 10
3 Applications overview 17
4 Installation and wiring 18
5 Controller setup 44
6 Communication 118
7 Technical data 145
8 Appendix 147

InteliLite Global Guide 2
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 7
1.4.1 Remote control and programing 7
1.4.2 SW and HW versions compatibility 7
1.4.3 Dangerous voltage 7
1.4.4 Adjust the setpoints 7
1.5 Certifications and standards 8
1.6 Document history 8
1.7 Symbols in this manual 9
2 System overview 10
2.1 General description 10
2.1.1 The key features of InteliLite 10
2.2 True RMS measurement 10
2.3 Configuration And Monitoring 10
2.3.1 Supported configuration and monitoring tools 11
2.3.2 Configuration parts 11
2.4 PC Tools 12
2.4.1 LiteEdit2015 12
2.4.2 WebSupervisor 12
2.4.3 WinScope 13
2.5 Plug-in Modules 13
2.5.1 CM-Ethernet 13
2.5.2 CM-4G-GPS 13
2.5.3 CM-GPRS 14
2.5.4 CM-RS232-485 14
2.5.5 EM-BIO8-EFCP 14
2.6 CAN modules 15
2.6.1 Inteli AIN8 15
2.6.2 Inteli IO8/8 15
2.6.3 IGL-RA15 16
2.6.4 I-LB+ 16
3 Applications overview 17

InteliLite Global Guide 3
3.1 MRS - Manual Remote Start 17
4 Installation and wiring 18
4.1 Package content 18
4.2 Controller installation 19
4.2.1 Dimensions 19
4.2.2 Mounting 19
4.3 Terminal Diagram 21
4.4 Recommended wiring 22
4.4.1 General 23
4.4.2 Grounding 23
4.4.3 Power supply 23
4.4.4 Measurement wiring 25
4.4.5 Magnetic pick-up 30
4.4.6 Binary inputs 31
4.4.7 Binary Outputs 32
4.4.8 Emergency stop 33
4.4.9 Analog inputs 33
4.4.10 CAN bus and RS485 wiring 36
4.4.11 USB 39
4.4.12 Example of MRS Wiring 40
4.5 Plug-in module installation 41
4.6 Maintenance 42
4.6.1 Backup battery replacement 42
5 Controller setup 44
5.1 Default configuration 44
5.1.1 Binary inputs 44
5.1.2 Binary outputs 44
5.1.3 Analog inputs 44
5.2 Controller configuration and PC tools connection 45
5.2.1 USB 45
5.2.2 RS232 46
5.2.3 Ethernet 47
5.3 Operator Guide 52
5.3.1 Front panel elements 52
5.3.2 Display screens and pages structure 54
5.3.3 Browsing alarms 65
5.3.4 Password 66
5.3.5 Information screen 70

InteliLite Global Guide 4
5.3.6 Language selection 71
5.3.7 Display contrast adjustment 73
5.4 Functions 73
5.4.1 Start-stop sequence 74
5.4.2 Operating Modes 75
5.4.3 Engine start 76
5.4.4 Stabilization 81
5.4.5 Connecting to load 81
5.4.6 MRS operation 81
5.4.7 Engine cool down and stop 81
5.4.8 Alarm management 82
5.4.9 History log 88
5.4.10 Breaker control 89
5.4.11 Exercise timers 92
5.4.12 Rental Timers 99
5.4.13 Service timers 100
5.4.14 Analog switches 100
5.4.15 Flowchart 102
5.4.16 Additional running engine indications 103
5.4.17 Voltage phase sequence detection 103
5.4.18 Gen-set operation states 103
5.4.19 Sensor curves 105
5.4.20 PLC 107
5.4.21 Geo-fencing 113
5.4.22 Tier 4 Final 113
5.4.23 Alternate configuration 116
6 Communication 118
6.1 PC 118
6.1.1 Direct communication 118
6.1.2 Remote communication 120
6.2 Connection to 3rd party systems 131
6.2.1 SNMP 131
6.2.2 MODBUS-RTU, MODBUS/TCP 133
7 Technical data 145
8 Appendix 147
8.1 Controller objects 148
8.1.1 Setpoints 149

InteliLite Global Guide 5
8.1.2 Values 404
8.1.3 Logical binary inputs 448
8.1.4 Logical binary outputs 462
8.1.5 Logical analog inputs 514
8.1.6 PLC 546
8.2 Alarms 559
8.2.1 Alarms level 1 559
8.2.2 Alarms level 2 581
8.2.3 Fail sensor and other types 599
8.3 Modules 601
8.3.1 Plug-In modules 602
8.3.2 CAN modules 616

InteliLite Global Guide 6
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 7
1.5 Certifications and standards 8
1.6 Document history 8
1.7 Symbols in this manual 9
6back 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.

InteliLite Global Guide 7
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.cz.
Used Open Source Software: mBed-TLS
https://www.mbed.com/en/development/software/mbed-tls/
http://www.apache.org/licenses/LICENSE-2.0
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
Disconnected 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.

InteliLite Global Guide 8
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
Certificates and standards
EN 61000-6-2
EN 61000-6-4
EN 61010-1
EN 61000-2-1 (-20 °C/16 h for std, -40 °C/16 h for LT version)
EN 61000-2-2 (70 °C/16 h)
EN 61000-2-6 (2÷25 Hz / ±1,6 mm; 25÷100 Hz / 4,0 g)
EN 61000-2-27 (a=500 m/s2; T=6 ms)
EN 61000-2-30
EN 60529 (front panel IP65, back side IP20)
1.6 Document history
Revision number Related sw. version Date Author
4 1.2.1 5.12.2016 Michal Slavata
3 1.1.0 23.5.2016 Michal Slavata
2 1.1.0 6.3.2016 Michal Slavata
1 1.0.0 15.7.2016 Michal Slavata

1.7 Symbols in this manual
3 x Phases
Active
current
sensor
AirGate
Alternating
current
Analog
modem
Battery
Binary
output
Breaker
contact
Breaker
contact
Breaker
Breaker
Breaker
Capacitor
Coil
Connector -
female
Connector -
male
Contact
Contactor
Controller
simplified
Module
simplified
Current
measuring
Current
measuring
Diode
Ethernet
male
Ethernet
female
Fuel
solenoid
Fuse
Fuse switch
Generator
Generator
schematic
Grounding
GSM
GSM
modem
IG-AVRi
IG-AVRi
TRANS
Jumper
Load
Mains
Mains
Mobile
provider
Passive
current
sensor
Pick - up
Relay coil
Relay coil of
slow-
operating
Resistor
Resistor
adjustable
Resistive
sensor
RPTC
RS232
male
RS232
female
Starter
Switch -
manually
operated
Transformer
USB type B
male
USBtype B
female
Voltage
measuring
Wifi / WAN /
LAN
6back to Document
information
InteliLite Global Guide 9

InteliLite Global Guide 10
2 System overview
2.1 General description 10
2.2 True RMS measurement 10
2.3 Configuration And Monitoring 10
2.4 PC Tools 12
2.5 Plug-in Modules 13
2.6 CAN modules 15
6back to Table of contents
2.1 General description
InteliLite Family controllers are comprehensive gen-set controllers for single generating sets operating in stand-
by or parallel modes. 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 Configuration 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.

InteliLite Global Guide 11
2.3.1 Supported configuration and monitoring tools
LiteEdit2015 - 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 LiteEdit2015 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

InteliLite Global Guide 12
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 LiteEdit2015 software. See LiteEdit2015
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 .aic. 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 LiteEdit2015
Configuration and monitoring tool for InteliLite controllers. See more in LiteEdit2015 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.
This tool provides the following functions:
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:http://websupervisor.comap.cz/
Demo account:
Login: comaptest
Password: comaptest

InteliLite Global Guide 13
2.4.3 WinScope
Special graphical controller monitoring software used mainly for commissioning and gen-set troubleshooting.
See more in the WinScope Reference guide.
This tool provides the following functions:
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 LiteEdit2015
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
GPRS multi-slot class 10
TCP/IP communication over GPRS

InteliLite Global Guide 14
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, ECU link support
Serial connection to LiteEdit2015
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

InteliLite Global Guide 15
2.6 CAN modules
2.6.1 Inteli AIN8
The extension module Inteli AIN8 offers users more analog inputs and outputs for controllers. 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)
2.6.2 Inteli IO8/8
The extension module Inteli IO8/8 offers users more binary inputs and outputs for controllers. 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))

InteliLite Global Guide 16
2.6.3 IGL-RA15
Remote annunciator.
15 programmable LEDs with configurable colors
red-green-yellow
Customizable labels
Local horn output
Lamp test function
Maximal distance 200 m from the controller
UL certified
2.6.4 I-LB+
Local Bridge.
Communication bridge for sites with multiple
controllers for local or remote monitoring and
control
Direct (RS232,RS485), modem, Modbus or
USB connection to multiple controllers
Communication speed up to 57600 bps
(including Modbus mode)
Analog / GSM / ISDN / CDMA modem support
6back to System overview

InteliLite Global Guide 17
3 Applications overview
3.1 MRS - Manual Remote Start 17
6back to Table of contents
InteliLite controllers are designed for single applications.
3.1 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 3.1 MRS application overview
6back to Applications overview

InteliLite Global Guide 18
4 Installation and wiring
4.1 Package content 18
4.2 Controller installation 19
4.3 Terminal Diagram 21
4.4 Recommended wiring 22
4.5 Plug-in module installation 41
4.6 Maintenance 42
6back to Table of contents
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.

InteliLite Global Guide 19
4.2 Controller installation
4.2.1 Dimensions
①Plug-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 Nm.
Panel door mounting Overview of parameter x

InteliLite Global Guide 20
Plug-in module Parameter x [mm]
CM-RS232-485 105 @ RS232 / 62 @ RS485
CM-Ethernet 95
USB 85
CM-GPRS Depends on connector of
antenna
EM-BIO8 62
CM-4G-GPS Depends on connector of
antenna
Note: The controller is to be mounted into panel doors as a standalone unit using provided metal holders. The
requested cut-out size is 187x132 mm. Use the screw holders delivered with the controller to fix the controller
into the door.
Note: Enclosure Type rating with mounting instruction - For use on a Flat surface of a type 1 enclosure.