Generator brands · Controllers
ComAp Generator Controller Repairs and Setup
We repair ComAp generator controllers on site across Gauteng, from InteliLite modules on single standby sets to InteliGen and InteliSys controllers running sets in parallel. We find whether the fault is in the controller, its settings, or the sensors, breakers and links around it, and fix it there. A replacement controller is configured to match your installation and proved by testing.
Established 2006
20 years of experience
24/7 operations
We Arrive Within 1–2 Hours
(usually within 1 hour)
Free callouts and quotations
One-year warranty
Qualified and certified technicians
We Service & Repair All Generator Brands
All generator makes and models
1 kVA–20,000 kVA capability
Which ComAp family runs your installation?
| Family | What it controls | What we look at first |
|---|---|---|
| InteliLite | What it controlsOne set, remote start or automatic mains failure (AMF) | What we look at firstMode, mains sensing, start and fuel outputs, senders |
| InteliGen | What it controlsSets in parallel with each other or with the mains | What we look at firstSynchronising, breaker feedback, load sharing |
| InteliSys | What it controlsLarge or complex plants with custom control logic | What we look at firstThe programmed logic and its inputs |
| InteliMains | What it controlsThe mains side of a paralleled plant | What we look at firstMains breaker control and mains protection |
A photo of the controller front is enough to identify it. Other sets carry Deep Sea Electronics or SmartGen modules, which we also repair.
Where ComAp is used
From one standby set to a paralleled plant
On a single standby set, an InteliLite set up for automatic mains failure starts, stops and protects the engine, senses the mains and drives the changeover. During load shedding that can happen several times a day, so a weak battery, charger or contactor shows up quickly: a display that resets while cranking, a fail-to-start alarm, or a load that never transfers.
Where sets run together, each controller matches voltage, frequency and phase to the live busbar before closing its breaker, then trims the governor and the AVR on a Stamford or similar alternator so each set carries its share of real and reactive power.
The photo shows a large set beside its switchgear in a plant room, the scale of installation where more capable controllers are found. It is an example of the type of equipment and is not presented as a ComAp installation.
The settings and the history log come first
A ComAp controller holds more of the installation’s behaviour in its settings than in its wiring: start conditions, timers, protection limits, breaker logic and load-sharing gains. Those settings sit behind passwords at different access levels, so a saved copy of the configuration and the person who holds the passwords are worth having on hand.
The history log records each alarm with the readings at that moment, which usually shows whether a shutdown came from the engine, the alternator, a breaker or a sensor before a single wire is disconnected.
How a ComAp controller grades a protection
| Protection type | What happens | What to do |
|---|---|---|
| Warning | What happensThe alarm shows; the set keeps running | What to doArrange a check |
| Breaker open and cool-down | What happensThe breaker opens; the engine cools unloaded, then stops | What to doFind the cause before reloading |
| Shutdown | What happensThe breaker opens and the engine stops at once | What to doDo not restart until it is found |
| Sensor failure | What happensA reading is outside the sender’s possible range | What to doCheck the sender and wiring |
Our guide to controller alarms explains what the common alarm names point to.
Paralleled plants
Faults we trace when sets run together
Will not synchronise: Surging and hunting
The set runs but never closes onto the bus: speed or voltage matching, a governor interface or a wiring error.
Breaker will not close: ATS and changeover problems
A failed auxiliary contact, closing coil or undervoltage release stops the breaker closing or reporting its position.
Uneven load sharing: Voltage problems
One set carries more than its share, from settings, a governor or AVR interface fault, or a weaker engine.
Lost communication
Paralleled controllers talk over a CAN bus; a damaged cable or missing terminating resistor stops them cooperating.
Reverse power trips
A set drawing power from the bus instead of supplying it trips on reverse power, usually from a fuel or governor fault.
Before a replacement ComAp controller goes into service
Controllers fail with age, water, heat or a surge. Before handover we confirm that:
- The old configuration was saved, if the unit still communicates
- Speed control, AVR interface, breakers and current transformers are on the right terminals
- Limits, timers and load-sharing settings suit the engine, alternator and site
- A full start, synchronise or transfer, load and stop sequence has run
- Each protection that can be tested safely has been proved
On a paralleled plant, load bank testing is a practical way to prove load sharing.
Independent service
We Service & Repair All Generator Brands
Onsite Generator Repairs is an independent generator specialist. We repair, service and maintain ComAp equipment as part of our work on every make of generator.
Manufacturer warranty claims go through the manufacturer’s own network. If your generator is still under warranty, check the warranty terms before arranging work by anyone else.
Brand names and trademarks belong to their respective owners. Onsite Generator Repairs is an independent service and repair company.
Service areas
Where we work in Gauteng
FAQ
Frequently asked questions
We have lost the ComAp password. What now?
Readings and history can usually be viewed without it, but protected settings need the right access level. Recovering access may need the original installer or the maker’s own support process.
Our InteliLite set did not start in a power cut. Why?
Often it was left out of auto (AUT) mode after a test, an earlier alarm was never reset, or the battery is flat. A blown mains sensing fuse usually does the opposite and starts the set with the mains still on. Photograph the screen and see our changeover guide, or call us.
Why does one paralleled set carry more load than the other?
Usually load-sharing settings, a governor or AVR interface fault, or different speed droop. The sets are checked together; see control panel repairs.
What should we have ready for a visit?
The controller model, photos of the alarm and history screens, the set’s make, model and kVA, and any configuration file or single-line drawing.
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Who we work for
Need a generator technician?
- 24/7 operations
- We Arrive Within 1–2 Hours (usually within 1 hour)
- Free callouts and quotations