ComAp InteliGen IG-NTC Modules — Gen-Set Controller InteliGen IG-NTC HW Version 1.3-TO

Technical Dossier

Product Details And Specifications

ComAp InteliGen Series: Comprehensive Module Range and Technical Overview

The ComAp InteliGen (IG) series is a purpose-built gen-set controller platform deployed across heavy industrial sectors including petrochemical plants, nuclear power facilities, offshore platforms, and large-scale data centers. Manufactured in the Czech Republic, InteliGen controllers are engineered for parallel operation of multiple generator sets, providing synchronization, load sharing, and protection functions in island and mains-parallel modes. The platform's modular architecture — separating the base controller from expansion I/O and communication modules — has made it a standard reference design in critical power infrastructure globally. Installed base spans hundreds of thousands of units across Europe, Asia-Pacific, the Middle East, and the Americas, with active deployments in facilities requiring 24/7 uptime and IEC 60255-compliant protection relay integration.

The Evolution of InteliGen Architecture

The InteliGen platform originated in the early 2000s as ComAp's response to the growing demand for networked, multi-genset control in industrial standby and prime power applications. The first-generation IG-NT controllers introduced a 32-bit processor core, a backlit LCD operator interface, and a proprietary CAN-based inter-module bus (IB-Lite). Hardware revision milestones are significant for compatibility: HW version 1.x units use a specific backplane connector pinout and firmware branch (FW 1.x) that is not forward-compatible with HW 2.x firmware. The IG-NTC variant (the C denoting the compact or cost-optimized configuration) was introduced to address mid-range applications where the full IG-NT feature set was not required, while retaining the same physical form factor and communication bus. The HW version 1.3-TO designation indicates a specific board revision with a terminal output (TO) configuration, relevant for replacement sourcing. Later generations — InteliGen 200, InteliGen 500, and the current InteliGen NT GPRS/4G variants — introduced Ethernet, USB, and cellular connectivity, but retain backward-compatible I/O expansion slots for IG-IOM and IG-BIO modules. Understanding hardware revision compatibility is critical when sourcing replacement units: a HW 2.x controller cannot directly substitute a HW 1.x unit without firmware reconfiguration and potential I/O remapping.

InteliGen Full Catalog & Functionalities (SKU List)

The following SKUs represent the verified InteliGen series module range, classified by functional category.

Controllers (Base Units)

• IG-NTC HW 1.3-TO: Compact gen-set controller, terminal output, HW rev 1.3, single-unit operation.
• IG-NTC HW 1.4-TO: Compact controller, updated relay driver circuit, terminal output variant.
• IG-NTC HW 2.0: Revised compact controller, enhanced EMC compliance, updated CAN transceiver.
• IG-NT HW 2.x: Full-featured gen-set controller, parallel operation, CAN bus, LCD display.
• IG-NT GPRS: Gen-set controller with integrated GPRS modem for remote monitoring.
• IG-NT 4G: Gen-set controller with integrated 4G/LTE cellular modem, current production.
• IG-200: Second-generation InteliGen controller, Ethernet + USB, enhanced protection relay functions.
• IG-500: High-end InteliGen controller, dual Ethernet, extended I/O, IEC 61850 support.
• IG-NTC-BB: Compact controller variant with battery-backed RTC and extended temperature range.
• IG-NTC-SW: Software-only license variant for virtual controller deployment in SCADA environments.

I/O Expansion Modules

• IG-IOM: I/O expansion module, 8 DI / 8 DO / 4 AI, IB-Lite bus interface.
• IG-IOM-B: Extended I/O module, 16 DI / 8 DO, for high-density input applications.
• IG-BIO: Binary I/O module, 8 DI / 8 DO, plug-in to IG-NT backplane slot.
• IG-AIO: Analog I/O module, 4 AI (0-20 mA / 0-10 V) / 2 AO, for sensor integration.

Communication & Adapter Modules

• IG-COM: RS-232 / RS-485 communication module, Modbus RTU master/slave.
• IG-ETHERNET: Ethernet adapter module, 10/100 Mbps, Modbus TCP, SNMP support.
• IG-CANOPEN: CANopen gateway module, DS301 profile, for integration with CANopen field devices.
• IG-PROFIBUS: PROFIBUS DP slave adapter, for integration into Siemens and ABB DCS environments.

Power Supply Modules

• IG-PSU-24: 24 VDC auxiliary power supply module, 5 A output, DIN rail mount.
• IG-PSU-12: 12 VDC auxiliary power supply module, for battery-backed panel installations.

Sourcing Hard-to-Find & Obsolete InteliGen Parts

The InteliGen IG-NTC HW 1.x series has reached end-of-active-production status. ComAp no longer manufactures HW 1.x board revisions, and firmware support for FW 1.x branches has been discontinued. For operators maintaining legacy installations — particularly in facilities where a full controller platform migration is not operationally feasible — sourcing verified replacement units from specialist distributors is the primary lifecycle extension strategy. DriveKNMS maintains a dedicated inventory of tested, pull-out, and refurbished InteliGen IG-NTC and IG-NT HW 1.x units sourced from decommissioned panels and controlled dismantling projects. Each unit is cross-referenced against the original hardware revision label and firmware version before dispatch. For facilities requiring long-term maintenance agreements covering InteliGen spare parts, DriveKNMS provides multi-year supply contracts with guaranteed stock reservation. Inquiries for bulk quantities, specific HW revision matching, or firmware-locked units should be directed to the sales team with the full nameplate data from the installed unit.

Quality Control for the InteliGen Range

InteliGen controllers integrate a multi-layer communication architecture — the IB-Lite CAN bus, the operator LCD interface bus, and the protection relay output bus — each of which requires independent verification during refurbishment. DriveKNMS applies the following test protocol to all InteliGen units prior to dispatch: (1) Visual inspection of the PCB for capacitor bulge, corrosion on the backplane connector, and relay contact wear. (2) Power-on functional test at rated supply voltage (8-36 VDC for IG-NTC), verifying LCD initialization, firmware version display, and CAN bus enumeration. (3) I/O functional test: all digital inputs verified with a calibrated signal source; all digital outputs verified under resistive load. (4) Communication port test: RS-232 and RS-485 ports verified with a Modbus RTU loopback test. (5) Protection relay output test: all configurable relay outputs cycled through their full operating range. Units that fail any stage are quarantined and not dispatched. Test records are retained for 24 months and available on request.