The ComAp InteliDrive FLX Lite is an engine controller designed for pumps and compressors, offering a comprehensive solution for single engine applications, including extended support for electronic engines and plug-in modules. It features an intuitive graphic display with icons, symbols, and bar-graphs for easy operation. The controller also supports gas engines without ventilation.
Function Description:
The InteliDrive FLX Lite serves as a central control unit for engine applications, managing start-stop sequences, engine speed, and various protections. It can be configured and monitored using the LiteEdit software, InteliMonitor, or remotely via a web browser, WebSupervisor, or Web Server when equipped with communication modules. The controller supports both single-speed and all-speed engines, including popular brands like Cummins, Volvo, and John Deere. Its process logic enables active engine control, history logging, and configuration without requiring programming.
Important Technical Specifications:
Power Supply:
- Range: 8-36 V DC
- Drop-out immunity: 100 ms from min. 10 V return to min. 8 V
- Consumption: 40-440 mA (depends on supply voltage and temperature)
- 0.104 A / 8 V DC
- 0.080 A / 12 V DC
- 0.051 A / 24 V DC
- 0.044 A / 30 V DC
- 0.040 A / 36 V DC
- Battery voltage measurement tolerance: 2 % at 24 V
- Maximum continuous DC power supply voltage: 36 VDC
- Maximum allowable DC power supply voltage: 39 VDC
- Fusing: Recommended T1A (not fast) fuse for battery positive terminal.
Operating Conditions:
- Operating temperature: -20 °C to +70 °C
- Storage temperature: -30 °C to +80 °C
- Protection front panel: IP65
- Humidity: 95 % w/o condensation
- Electromagnetic Compatibility: EN 50081-1:94, EN 50081-2:96, EN 50082-1:99, EN 50082-2:97
- Vibration: 5-25 Hz, ±1.6 mm; 25-100 Hz, a = 4 g
- Shocks: a = 200 m/s²
Dimensions and Weight:
- Dimensions: 180 × 120 × 55 mm
- Weight: 450 g
- Number of inputs: 7
- Input resistance: 4.2 kΩ
- Input range: 0-36 V DC
- Switching voltage level for close/open contact indication: 0-2 V DC close contact; 8-36 V DC open contact
Binary Outputs:
- Number of outputs: 7
- Maximum current: 0.5 A
- Max switching voltage: 36 V DC
- Number of inputs: 9 (3 resistive and 6 voltage)
- Resolution: 10 bits
- Wiring selectable range: V, Ω, mA
- Maximal resistance range: 2400 Ω
- Maximal voltage range: 0-10 V (0-40 V for AIN4+5)
- Resistance measurement tolerance: ±2 % ±2 Ω
- Voltage accuracy: 1 %, ±100 mV (±400 mV for AIN4-5)
- Resistance accuracy: 4 % ±5 Ω
- Minimum input voltage: 2 Vpk-pk (from 4 Hz to 4 kHz)
- Maximum input voltage: 50 Veff
- Measured frequency: 4 Hz to 10 kHz
- Frequency measurement tolerance: 0.2 %
D+ Function:
- Max. D+ output current: 300 mA
- Guaranteed level for signal: 80 % of supply voltage
CAN Bus Interface:
- Max CAN bus length: 200 m
- Speed: 250 kBd
- Nominal impedance: 120 Ω
- Cable type: twisted pair (shielded)
- Nominal Velocity: min. 75 % (max. 4.4 ns/m)
- Wire crosscut: min. 0.25 mm²
- Maximal attenuation (at 1 MHz): 2 dB / 100 m
Extension Plug-in Modules:
- IL-NT AOUT8: 8 AOUT Gauge driver card (PWM signal at 1200 Hz, 0.5 A max current, 36 V DC max switching voltage, 1 Ω output resistance, 10 bits resolution).
- IL-NT AIO: 4× AIN + 1× AOUT (10 bits resolution, 2400 Ω max resistance range, 4 V max voltage range, 0-20 mA current range, 180 Ω input impedance for current, >68 kΩ for voltage).
- IL-NT IO1: 4× BIN + 4× AOUT (0 to +VBatt ±1 V analog output range, 4 binary inputs).
- IL-NT BIO8: 8× BIN or BOUT (0.4 A max one binary output current, 2.5 A max total current per module).
Communication Modules:
- IL-NT RS232: RS232 communication card (10 m max distance, 19.2 kBd STD, 9.6 kBd MODBUS).
- IL-NT RS232-485: Combined RS232/RS485 communication card (10 m RS232, 1200 m RS485 max distance, up to 57.6 kBd DIRECT, 38.4 kBd Analog modem, 9.6 kBd digital modem, 57.6 kBd MODBUS).
- IL-NT S-USB: USB communication card (5 m max distance, up to 57.6 kBd DIRECT, 38.4 kBd Analog modem, 9.6 kBd digital modem, 57.6 kBd MODBUS).
- IB-Lite: Ethernet/Internet interface (10/100 Mbps Ethernet in RJ45 socket).
- IL-NT GPRS: GSM/GPRS modem (Quad Band 850/900/1800/1900 MHz, GPRS multi-slot class 10, CSD up to 14.4 kbps, TCP/IP over GPRS, 8-36 V DC voltage supply).
Remote Modules:
- IL-NT RD (SW): Remote display software for the controller.
- IGL-RA15: Remote annunciator (0.35-0.1 A consumption, 950 g weight).
- IB-NT: Communication module (3G, Ethernet).
Usage Features:
- Mounting: Designed for switchboard door mounting with a cutout size of 17 × 112 mm.
- User Interface: Features a graphic display with intuitive icons and bar-graphs. Supports multiple languages (English, Chinese, Greek, Turkish, Hebrew, Russian, East European languages).
- Operating Modes: OFF, MAN (Manual), AUT (Automatic) modes for engine control.
- Engine Speed Control: Various options for engine RPM control in MAN mode, including constant speed, idle speed, ramp to nominal RPM, three-step switching via binary inputs, continuous change via analog input (potentiometer), and automatic regulation in AUT mode.
- Load Limitation: Functions for engine load limitation using PI loops and hysteresis comparators, with inputs from ECU (Engine Load or RPM) or analog inputs.
- Display Menus: MEASUREMENT, ADJUSTMENT, and HISTORY menus are available in Engineer interface, while only MEASUREMENT is available in User interface.
- Setpoint Configuration: Setpoints can be adjusted via panel buttons or the LiteEdit PC tool, with password protection for critical settings.
- Remote Monitoring and Control: Supports remote control via RS232, web browser, WebSupervisor, AirGate, and cellular network.
- ECU Support: Compatible with various electronic engine units (ECUs) via CAN J1939 interface, allowing reading of diagnostic messages and engine values like fuel rate, coolant temp, oil pressure, and boost pressure.
- Tier 4 Diagnostic Codes: Displays supplementary values related to DPF status for configured Tier 4 ECUs.
- Timers: Includes engine running timer and two identical timers for auto start and stop functions with different conditions.
Maintenance Features:
- Alarm Management: Detects and signals various alarms including Sensor fail (Fls), Warning (Wrn), Cooldown (Cd), and Shut down (Sd). Alarms are displayed on the controller screen and recorded in the history file.
- History File: Stores up to 255 records of important events, including event specification, date, time, engine speed, battery voltage, and analog input values.
- Troubleshooting: Provides diagnostic messages read from the ECU, including SPN, FMI, and OC codes for J1939 engines, and specific fault codes for Scania and Volvo engines.
- Firmware Updates: Firmware can be updated using LiteEdit, with a boot jumper programming option for recovery from software failures.
- Calibration: Analog input calibration constants can be adjusted to ensure accurate measurements.
- Service Time Alarm: Activates an alarm when the engine's running hours reach a predefined service time.
- Fuel Theft Protection: Monitors fuel level changes to detect leakage or theft.
- Security: Recommendations include changing default AccessCode and password, avoiding exposure of TCP/80 and TCP/502 ports to the public Internet, and using shielded USB cables.
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