ComAp InteliDrive Lite Engine Controller for Pumps and Compressors

A single-engine controller for pumps and compressors (discontinued by ComAp)

The ComAp InteliDrive Lite (order code ID-FLX-LITE, listed by ComAp as InteliDrive FLX Lite) is an engine controller for pump and compressor drives. ComAp’s product page states that this product is discontinued and that availability should be checked with ComAp, so this page serves owners of installed units and projects that specify the model by name.

The datasheet describes a comprehensive controller for single engines with extended support for electronic engines and extension modules, a graphic display with icons, symbols and bar-graphs, control, monitoring and protection of mechanical and electronic diesel and gas engines, and automatic or manual start and stop. ECU support covers J1939 and Cummins Modbus. Features include smooth engine speed control, PLC functions (PID loop, comparators, timers), three password levels, two languages, a real time clock and an event history log. The datasheet was issued 2/20/2020 for hardware 1.6-SI and software 2.2.0.

Technical specifications

Plug-in modules

The datasheet lists the IL-NT-AOUT8 (8 analog outputs), IL-NT-BIO8 (8 binary I/O), IL-NT-IO1, IL-NT-AIO, IL-NT-RS232, IL-NT-RS232-485, IL-NT-S-USB, IB-Lite (Ethernet), IL-NT-GPRS, the IGL-RA15 annunciator, InternetBridge-NT and I-RB8 / I-RB16 relay boards. Panel mounting depth depends on the plug-in module fitted, from 74 to 128 mm.

Replacement and ordering notes

Because ComAp lists the product as discontinued, confirm what is available before committing a project, and ask for the successor that ComAp recommends for new installations. Send the engine make, ECU protocol, sensor types and the plug-in modules in use. Other ComAp controllers are listed under Diesel Generator Spare Parts; a current gen-set controller example is the InteliGen4 200.

Where the InteliDrive Lite fits on a pump or compressor skid

The InteliDrive Lite was designed around a single prime mover driving a mechanical load rather than a generator. That changes what the controller has to watch. Instead of voltage, frequency and breaker logic, the priorities are engine speed, oil pressure, coolant temperature, fuel level and the process value the engine is serving, such as discharge pressure on a fire or transfer pump or suction pressure on a gas compressor. The built-in PLC functions (PID loop, comparators and timers) let the speed of the engine follow a process signal, so the engine runs only as fast as the duty requires.

Because the controller supports both mechanical engines and electronic engines over J1939 or Cummins Modbus, it is often found on mixed fleets where older mechanically governed units sit next to newer ECU engines. On an electronic engine, many readings come from the ECU over the data link rather than from separate senders, which reduces field wiring on the skid.

Typical functions used in the field

• Automatic or manual start and stop, with start attempts and cranking logic configured in the controller.
• Engine protection shutdowns and warnings based on analog and binary inputs.
• Speed control loop following a process value from a transmitter.
• Event history with real time clock stamps, useful when investigating trips after the fact.
• Three password levels to separate operator, technician and engineering access.

Operating the controller in Oman and GCC conditions

Well-site pumps, pipeline booster stations and irrigation or dewatering sets in the region often run in direct sun and dusty air. The front panel is rated IP65 with IK04 impact protection, which suits a panel door, but the rear of the unit and its terminals still need a sealed enclosure. The datasheet operating range of –20 to +70 °C leaves margin for a hot panel, yet the internal temperature of a closed steel cabinet in summer can climb well above ambient, so sunshades, light-coloured enclosures and ventilation with filtered air are good practice.

The 8–36 V DC supply range covers 12 V and 24 V starting batteries, including the dip in voltage during cranking. Keep the battery and charger in good condition: a weak battery that drops below the supply range during cranking will reset the controller and can look like a controller fault.

Maintenance and replacement planning

Since ComAp lists this product as discontinued, owners of installed units should keep a record of the configuration file, firmware version and wiring diagram for each engine. Export the configuration with ComAp’s PC software while the unit is healthy, and store it with the panel documentation. If a direct replacement is not available, that file and the I/O list are the starting point for selecting and configuring a current ComAp controller.

• Check terminal tightness and connector seating during scheduled engine services; vibration loosens screw terminals over time.
• Verify sender readings against a calibrated gauge to catch drifting oil pressure or temperature senders.
• Test shutdown functions periodically rather than assuming they work.
• Review the event history for repeated warnings that point to a developing fault.

What to include in an RFQ

To help us source the correct unit or a suitable alternative, send the order code shown on the label (ID-FLX-LITE), the hardware and software versions if visible, the engine make and model, whether the engine is mechanical or ECU-controlled, the battery voltage, and a list of plug-in modules currently fitted. Photographs of the rating label and rear terminals are also helpful, as is the quantity required and the delivery location in Oman or elsewhere in the GCC.

Documents and quotation

The ComAp datasheet is attached. Seven Star LLC supplies ComAp products on request, subject to availability from the manufacturer and quoted by order code.