InteliSysNTC

Hybrid
Firmware for
InteliSysNTC Hybrid

SW version 2.0.0
1 General information 2
2 New features 3
3 Abstract 4
4 Conditions 6
5 General installation structure 7
6 Required communication lines 8
7 Required data exchange 10
8 Configuration of InteliSysNTCHybrid for communication with UC-7112-LX Plus 13
9 Communication redundancy 15
10 Sharing the signals 17
11 Recommended settings for a hybrid site control 18
12 Related information 19

Copyright 2016 ComAp a.s.

Written by Petra Pclov
Prague, Czech Republic
ComAp a.s., U Uranie 1612/14a,
170 00 Prague 7, Czech Republic
Tel: +420 246 012 111
E-mail: [email protected], www.comap-control.com User Guide
1 General information
The IH-NT firmware is based on the last version of the InteliMains MCB application (IM-NT-3.4.0.)

InteliSys-NTC Hybrid 2.0.0 User Guide 2

2 New features
2.1 Changes in the version 2.0
All gen-set control functions have been removed
The InteliSysNTCHybrid 2.0 controller is superior controller which provides overall site control through
communication with gen-set controllers, PV inverters and battery management systems
Modbus master capability (ensured via UC-7112-LX Plus communication gateway)
The package of InteliSysNTCHybrid and the UC-7112-LX Plus communication gateway act as Modbus
RTU as well as TCP, which enables two direction information flow of defined values between the PV
inverters and gen-set controllers
Pre-defined communication interface to selected PV inverters
Pre-defined values mapped to adequate Modbus registers in selected PV inverters allow smooth set up
and configuration of the communication between the inverters, resp.cluster controllers od data
concentrators with the InteliSysNTCHybrid controller. Libraries will be released in April 2017
Comprehensive statistics of produced energy from the renewable energy resources and gen-sets was
added
Statistics of daily, weekly, monthly energy production of the PV power plant and gen-sets is provided

InteliSys-NTC Hybrid 2.0.0 User Guide 3

3 Abstract
This document will help you to successfully set up hybrid / microgrid project with InteliSys NTC Hybrid 2.0.0
master controller.
Note: Unlikely the InteliSys NTC Hybrid 1.0.0, InteliSys NTC Hybrid 2.0.0 is not gen-set controller, but it is
superior controller which interfaces with gen-set controllers, PV inverters, wind turbine switchgear, BMS, third
party SCADA, etc..

3.1 What is a Hybrid application?

Hybrid application combines conventional and non-conventional source for power generation. The most typical
application is with diesel gen-sets and photovoltaic plant as illustrated below.

Information about ComAp solution for hybrid applications can be found here: Hybrid power plant using ComAps
hybrid solution
For complete description of hybrid applications see our Hybrid Application Guide.

3.2 How do ComAp controllers support Hybrid

applications?
There are two different scenarios based on the position ComAp controllers are in master or slave. This
document refers to and provides assistance with the set up of applications where ComApInteliSys NTC Hybrid
2.0.0 controller works as a master controller providing interface to gen-set controllers, as well as to renewable

InteliSys-NTC Hybrid 2.0.0 User Guide 4

 energy source, and as such provides overall control of the hybrid application. Power management is provided by
slave InteliSys and InteliGen gen-set controllers with the IGS-NT-Hybrid 1.2.0 firmware, which receives
required value of Dynamic Spinning Reserve from the InteliSys NTC Hybrid2.0.0
Information about suitable genset controllers for hybrid applications and instructions for setup can be found in
the IGS-NT-Hybrid User guide.

3.3 How the InteliSys NTC Hybrid controller works?

The main duty of the IS-NTC-Hybrid 2.0.0 is to collect information from the PV inverters (status, actual PV
output, statics, etc.), calculate accordingly the required DSR and share it with the other ComAp genset
controllers over CAN bus. The gen-set controllers are then responsible for optimum power management of the
gen-sets with respect to the renewable energy source, which output utilization must be maximized, and only in
case the gen-sets face the thread of being underloaded, the IS-NTC-Hybrid would curtail the output from the PV
plant. The limitation of the renewable energy source is based on a calculation considering the minimum allowed
genset loading level (Min GS Power setpoint) to prevent the gen-sets from underloading, resp. to protect the
wind turbine in high wind speeds.

InteliSys-NTC Hybrid 2.0.0 User Guide 5

4 Conditions
To ensure flawless communication between the IS NTC Hybrid, PV inverters and ComAp gen-set controllers,
certain conditions must be met:
The InteliSysNTCHybrid controller must be used with the UC-7112-LX Plus communication gateway for
data exchange with PV inverters
The communication between InteliSysNTCHybrid and UC-7112-LX Plus is must be wired through the
RS485 port (communication over Modbus RTU)
The communication between UC-7112-LX Plus and the PV inverters can be wired through RS485 port or
Ethernet (communication over Modbus RTU or TCP)
The Modbus UC-7112-LX Plus supports communication with maximum 16 inverters, resp. the number of
values communicated with the PV inverters is 200
All the gen-set controllers that are used in hybrid/microgrid application must be ComAp InteliSys or InteliGen
versions equipped with IGS-NT-Hybrid firmware (for full list of supported gen-set controllers and instructions
how to configure them see IGS-NT-Hybrid User guide)
The power format in gen-set controllers must be set to 1 kW, kVAr, KVA, kX, V to be supported. Due to this
fact, the maximum installed power of gen-sets will be limited to 32,567 MW
The Dynamic Spinning Reserve (DSR) setpoint must be enabled in the InteliSysNTCHybrid as well as in the
gen-set controllers (folder Setpoints Pwr management Group)
IV5, IV8 and IV17T displays are supported in the InteliSysNTCHybrid controller, however the configuration
of the displays must be done by the user through image pack import.

InteliSys-NTC Hybrid 2.0.0 User Guide 6

5 General installation structure
There can be up to 321 ComAp genset controllers (InteliSysNTC BaseBox or InteliGenNTC BaseBox with the
IGS-NT-Hybrid firmware) connected together and performing power management.
Each gen-set must be equipped with generator circuit breaker controlled by ComAp controller. There needs to
be a circuit breaker for each group of RE sources and this circuit breaker should be controlled by the PV inverter,
wind inverter or by InteliMainsNT/C BaseBox. Optionally there can be Mains Circuit Breaker and Master
Generator Circuit Breaker controlled by ComAp controllers.

1If FUEL SAVE mode is active, only up to 11 gen-sets can be operated in power management

InteliSys-NTC Hybrid 2.0.0 User Guide 7

6 Required communication lines
There are several options how to communicate between the master hybrid controller InteliSysNTC Hybrid and
PV/wind inverter. Use one of the options below to ensure correct function of the system.

6.1 Connection via Modbus RTU/TCP through

communication gateway
ComAp gen-set controllers communicate always as Modbus Slave. In cases where ComAp InteliSysNTC
Hybrid controller should act as Modbus master, extension UC-7112-LX Plus communication gateway/Modbus
module must be used.

In this case there is a single Modbus line used for communication between the InteliSys NTC Hybrid controller
and the PV/wind inverter. The data among ComAp controllers, including InteliSysNTC Hybrid, is shared via
CAN2. There could be up to 32 slaves on the Modbus line, however it is recommended to communicate through
a cluster controller if there is a number of inverters, which collects and distributes all data from and to all the
inverters and communicates with the InteliSysNTC Hybrid over one communication line only.
See chapters Sharing the signals (page 17) for more details.
Note: It is also possible to use RS232 connection for Modbus. But RS232 port is not electrically isolated and
without any additional isolation therefore it should be used only for very short connection.

InteliSys-NTC Hybrid 2.0.0 User Guide 8

6.2 Communication via binary signals
Number of binary outputs can be used to switch between individual power bands in PV inverters.

6.3 Communication via analog signal

An analog output (4-20mA) from the InteliSys NTC Hybrid master controller can be used for PV output reduction
either through direct wired connection to the inverters or through a cluster controller.

InteliSys-NTC Hybrid 2.0.0 User Guide 9

7 Required data exchange
The UC-7112-LX Plus works as data concentrator which collects all required data from the PV inverters and
gen-set controllers, and provide them to the InteliSysNTCHybrid controller in specified dataset as per the
following table

Data Purpose Direction

From the
Total nominal power Information for InteliSysNTCHybrid for calculation of the inverters to
of the RE source Dynamic Spinning Reserve InteliSys
NTCHybrid

From the
Actual active power Information for InteliSysNTCHybrid for calculation of the inverters to
from the RE source Dynamic Spinning Reserve InteliSys
NTCHybrid

From
Requested active
InteliSys
power from the RE Request to adjust RE source output NTCHybrid to
source
the inverter
From
InteliSysNTC
Dynamic Spinning Information for ComAp controllers to provide sufficient load
Hybrid to
Reserve reserve to cover RE output fluctuations
ComAp genset
controllers
From ComAp
genset
Total running gensets
For the purpose to limit RE power output controllers to
actual power
InteliSysNTC
Hybrid
From ComAp
genset
Total running gensets
For the purpose to limit RE power output controllers to
nominal power
InteliSysNTC
Hybrid
Source: This Value is received from the Concentrator. The
From the
Concentrator reads the "Inverter P Actual" from each Inverter.
PV P actual Concentrator
This value is a summ of all P Actual of the inverters behind the
to the HMC
Concentrator
Source: This Value is received from the Concentrator.
From the
Concentrator reads the "Inverter Q Actual" from each Inverter.
PV Q actual Concentrator
This value is a summ of all Q Actual of the inverters behind the
to the HMC
concentrator
PV Nomin power Source: This Value is received from the Concentrator. From the

InteliSys-NTC Hybrid 2.0.0 User Guide 10

 Concentrator reads the "Inverter Nominal Powerl" from each
Inverter. This value is a summ of all "Inverter Nominal Power "of
Concentrator
the inverters behind the concentrator. The Inverter can contribute
to the HMC
to the value of total PV nominal power only if its Grid Relay is
connected and Communication Status is OK
Source: This Value is received from the Concentrator. The
concentrator reads the "Inverter kWh" from each inverter and From the
PV kWh keep the last value in the buffer even the inverter is not available. Concentrator
This value is a summ of kWh produced by all inverters behind the to the HMC
concentrator
Source: This Value is received from the Concentrator. Status
register. Each bit represents the information about the status of
From the
the grid relay of each inverter. "1" = Relay closed. HSB = Inverter
PV GridRelStat Concentrator
1, LSB = Inverter 16. The value of the representative bit is equal
to the HMC
to zero if no communication with the inverter is detected
(however it is in charge of the concentrator to ensure it
Source: This Value is received from the Concentrator. Status
register. Each bit represents the information about the
From the
communication status of each inverter. "1" = Comm OK. HSB =
PV CommStatus Concentrator
Inverter 1, LSB = Inverter 16. The communication OK is
to the HMC
evaluated by the concentrator as communication Timeout if
communication dropped for 1000 ms
Source: This Value is received from the Concentrator. This value From the
PV Aux BIN is for general use. Each bit is available in the configuration of the Concentrator
Controller as the LBO PV Aux Bin 1..16 LSB = PV Aux Bin 16 to the HMC
Source: This Value is received from the Concentrator. Set of 16 From the
PV Aux Value1 .. PV
auxiliary values. Concentrator can create up to 16 general values Concentrator
Aux Value16
which can be sent to HMC and processed in there. to the HMC
Source: This Value is calculated in the HMC and it is read by the
From the HMC
Concentrator via modbus. This is the absolute value of the PV
PV kW req to the
Power request. The concentrator recalculate this value to relative
Concentrator
value and distributes this value towards all inverters
From the HMC
Source: This Value is calculated in the HMC and it is read by the
PV kVAr req to the
Concentrator via modbus.
Concentrator

Note: HMC = HYBRID MASTER CONTROLLER

7.1 Data exchange between the PV inverters and

the InteliSysNTCHybrid
The InteliSysNTCHybrid collects data from the PV inverters to curtail the PV output when necessary and to
provide statistics to the user.

InteliSys-NTC Hybrid 2.0.0 User Guide 11

7.1.1 Statistics
Statistic data provided by the InteliSysNTCHybrid controller is based on data collection from the PV inverters
and gen-set controllers. PV values can be found in folder Value Group PV values. The statistics provide the
following values:
PV Annual kWh (collected data from 1st January to 31st December)
PV Monthly kWh (collected data from 1st to last day each month)
PV Weekly kWh (collected data from Monday (Sunday midnight) to Sunday midnight)
PV Daily kWh (collected data from midnight to midnight)

7.1.2 PV power output curtailment

PV power output curtailment is applied in off-grid and on-grid applications with zero-export.
In case that the gen-set minimum loading limit is reached, the InteliSysNTCHybrid controller requests decrease
of the PV power output. The required value (PV kW req) is calculated in the PLC with respect to the Min GS
Power settings (Setpoints Group ProcessControl).

7.2 Data exchange between the gen-sets and the

InteliSysNTCHybrid
7.2.1 Statistics
Statistics about gen-set energy production and fuel consumption can be found in folder Value Group Gen-sets
and are following:
GS Annual kWh (collected data from 1st January to 31st December)
GS Monthly kWh (collected data from 1st to last day each month)
GS Weekly kWh (collected data from Monday (Sunday midnight) to Sunday midnight)
GS Daily kWh (collected data from midnight to midnight)
GS Annual Fuel (collected data from 1st January to 31st December)
GS Monthly Fuel (collected data from 1st to last day each month)
GS Weekly Fuel (collected data from Monday (Sunday midnight) to Sunday midnight)
GS Daily Fuel (collected data from midnight to midnight)

IMPORTANT: All values are set to zero after each time interval (day, week, month, year). Change of
the time settings in the controller will reset the statistics! Switching of the controller does not reset
the statistics, unless it is switched on again after certain period within which some of the time
intervals elapsed (typically daily statistics).

InteliSys-NTC Hybrid 2.0.0 User Guide 12

8 Configuration of
InteliSysNTCHybrid for
communication with UC-7112-LX
Plus
8.1 Communication with PV inverters
For reading values from PV inverters, is necessary to use UC-7112-LX Plus gateway (Order code:
CM17112LBGB). The gateway is connected to InteliSysNTCHybrid via RS485(2) connector. For connection is
recommended to use cable enclosed with the gateway.
Setpoints in InteliSysNTCHybrid should be set to this values:

Setpoints Value
Comms settings/RS232(2) mode MODBUS-DIRECT
Comms settings/RS232(2) MBCSpd 57600 bps
Comms settings/Contr. address 1

For setting the gateway please follow UC-7112-LX Plus Operator guide

Connection between gateway and PV inverter can be via RS485 (Modbus RTU) or via ethernet (Modbus TCP).
At website www.comap-control.com. you can find settings for PV inverters. If you need connect PV inverter
which is not available, please contact technical support ([email protected]) or your local distributor.
Note: It is possible to communicate with up to 16 inverters with one gateway

8.2 Reading values from PV inverters

PV values are always in controller, but they are unmarked with disconnected UC-7112. With connected UC-
7112, are values correctly filled. Values can be visible on screen or uploaded to the built-in PLC.
Communication with WebSupervisor is without any special setting.
Values for performance reduction are always present in controller, UC-7112 reads values automatically. More
information you can see in chapter Communication with PV inverters (page 13).

InteliSys-NTC Hybrid 2.0.0 User Guide 13

8.3 Writing values to inverters
In order to scale the PV output to the desired value, the InteliSys NTC controller must be able to write the
required value to the particular Modbus register. To ensure smooth communication between the controller and
the PV inverter, Modbus registers mapping must be completed.

InteliSys-NTC Hybrid 2.0.0 User Guide 14

9 Communication redundancy
From a safety point of view it is absolutely necessary to ensure full control of a hybrid site, to prevent from any
malfunction and potential safety threat. Therefore it is important that the InteliSysNTC Hybrid controller has data
from all the other interlinked devices all the time and also, the controller itself has a backup redundant
controller which takes over in the unlikely case of the primary controller failure. It is recommended to connect
the PV inverter to the main bus through a circuit breaker which can be disconnected in case of a communication
failure, when the master controller is not able to derate the PV output. If there are more than one InteliSysNTC
Hybrid controller to communicate with the PV/wind inverters, there need to be changes in the configuration to
support this redundancy.

9.1 Monitoring of the status of communication with

the inverter and CAN2 communication
9.1.1 Option 1 - Heartbeat
There are 32 so called Modbus Switches (MS) in the controller. These MS can be used to write binary
information via Modbus. Use one of the switches to write heartbeat to the InteliSysNTC Hybrid controller to
monitor Modbus communication status. The heartbeat should have length based on the communication traffic
(longer pulses should be used when there is higher traffic on Modbus line).
Write this heartbeat using the following command

The following response will be received when the writing was successful: 01 06 18 C0 00 01 4F D7

9.1.2 Option 2 - Shared signals

The Modbus Switch can be also used in the configuration for indication of healthy Modbus reading. This signal
should be shared via CAN2 using SHBOUT virtual module to the other backup controller. It will serve as
Modbus and CAN2 communication status indicator.
In this example there are two controllers receiving the actual PV output request from the PV inverter. One of
them is set to share this value over CAN2 using SHAOUT1-1 output (this value is received in all other
controllers on SHAIN1-1 input). The other one shares the value over SHAOUT2-1 output and this signal is used
only when the main Modbus communication is not working properly.
The following configuration should be used in all the controllers (including the two receiving controllers).

InteliSys-NTC Hybrid 2.0.0 User Guide 15

 Use Delay PLCblock and select Pulse on Edge option. The Up and Down values should be higher than the
pulse duration of the heartbeat (e.g. heartbeat is 1s up and 1s down and the Delay is set to 2s and 2s). When the
output of this block goes to log 0 there is a problem with Modbus communication. This signal should be sent via
CAN2 using SHBOUT virtual module to all other controllers. It will serve as Modbus and CAN2 communication
status.
When the primary Modbus connection is healthy, the output of the Delay block is activated and the Analog
Switch block forwards the second input (DynSpRes MAIN). When the primary connection is down, the Modbus
Healthy signal goes to log 0 and the first input on the Analog Switch is forwarded (DynSpRes SEC).
Don't forget to connect LAI DynSpinResReq to the output of the Analog Switch block.
Note: For full specification of the Modbus communication redundancyplease refer to the chapter
Communication redundancy in the Reference guide.

InteliSys-NTC Hybrid 2.0.0 User Guide 16

10 Sharing the signals
The value of requested Dynamic Spinning Reserve can be shared via CAN among all ComAp genset controllers
and therefore not all the gen-set controllers need to be connected directly to the InteliSysNTC Hybrid controller.
The setting is illustrated in the following diagram.

The source of DSR in InteliSys NTC Hybrid would be PLC AOUT (PLC Analog Output; the name of the PLC
AOUT can be named arbitrarily by the user, e.g.DSR)
This DSR value then needs to be linked to the Logical Analog Function DynSpinResReq; .-click on LAI tab in
GenConfig and select Logical Analog Function DynSpinResReq. On the right side you can see Source value
selection, as shown below on the picture. Navigate to PLC group and select DSR.

The DSR value must be then shared to the other gen-set controllers using SHAOUT1-1 output (this value is
received in all other controllers on SHAIN1-1 input). G o to tab Modules, click on Extension modules Virtual
Shared, select SHAOUT and click on Insert. Then navigate to tab I/O, click on analog outputsSHAOUT
(1) and click on e.g. AOUT1. On the right side from PLCselect the configured PLC-AOUT 1 (DSR).

InteliSys-NTC Hybrid 2.0.0 User Guide 17

11 Recommended settings for a
hybrid site control
11.1 Limitation of the PV source
In general generators are not built to run at very low power for long periods of time. The minimum gen-set loading
is usually indicated by the generator manufacturer and may be given in percentage of nominal power.
To prevent the system from running at very low power, when the power delivered by the Renewable Energy
source is peaking and large Dynamic Spinning Reserve is required, the power output of Renewable Energy
source needs to be limited.
ComAp gen-set controllers provide all the information needed to prevent from violation of the minimum genset
loading. Each controller contains values that show total power delivered by the running gen-sets and also value
showing total nominal power available at the moment. From these two values it is possible to calculate the
relative load of the gen-set group. If this load gets below the given limit (Min GS Power), the InteliSysNTC Hybrid
controller should limit the RE source output to let the gen-set run at least at minimum required power (this
calculation can be done in ComAp controllers as well using ComAp's built-in PLC functions).
The following table shows you what data should be read from the controller.

Value in the controller Value in the calculation scheme above

TotRunPactP Total Delivered Power
netPgnomPh Total Nominal Power of running gen-sets

In the case that Mains is also a source of power for the system the function needs to be modified accordingly
(depending on various settings).
Example: A load of 800kW is partially supplied from a PV (600kW) and partially from a running gen-set
(200kW). However the minumim gen-set loading prescribes at least 300kW. Therefore the difference of
100kW of load which are currently supplied by the PV inverter but should be supplied from the gen-set. As a
result power produced by the PV must be cut by 100kW and thus the InteliSysNTC Hybrid controller will write
the requested power cut to the PV inverter. When the PV output is lowered, the minimum gen-set loading
level is not violated.

InteliSys-NTC Hybrid 2.0.0 User Guide 18

12 Related information
Firmware (*.mhx)
For InteliSysNTC Hybrid
IH-NT2.0.0.mhx

Table 11.1 Available firmware

Archives (*.ant)
For InteliSysNTC Hybrid
IH-SPTM-1.0.0.ant
IH-SPI-1.0.0.ant
IH-MINT-1.0.0.ant
IH-Combi-1.0.0.ant
IH-MCB-2.0.0.ant
IH-MGCB-2.0.0.ant

Table 11.2 Available archives

12.1 Available related documentation

Documents Description
IM-NT Reference General description, how to operate the InteliMains NT controllers and it is intended for
Guide.pdf everybody who is concerned with operation and maintenance of the controller.
IGS-NT
Troubleshooting How to solve most common troubles with InteliGen NT and InteliSys NT controllers.
Guide 08- Including the list of alarm massages.
2014.pdf
IG/IS-NT
Operator Guide for all hardware variation of InteliGen NT and InteliSys NT, InteliVision
Operator Guide
5 and InteliVision 8.
01-2014.pdf
IGS-NT
Thorough description of installation and technical information about InteliGen NT ,
Installation Guide
InteliSys NT , InteliMains NT and related accessories.
08-2014.pdf
IG/IS-NT
Communication Thorough description of connectivity and communication for InteliGen NT , InteliSys
Guide 09- NT , InteliMains NT and related accessories.
2014.pdf
Available as standard part of the installation package. Available in GenConfig and
Context help
InteliMonitor.

Table 11.3 Available documentation

InteliSys-NTC Hybrid 2.0.0 User Guide 19