Version 2.0
2.0.598 (1 October 2026) (2.0 Update 3)
Bug fixes for IntelliGen
Added recording of uplink packets to the SD card. This makes it possible to see the commands sent to the IntelliGen when reviewing SD card data. IntelliGen HP only.
Improved calibration of peak voltage detection circuit by accounting for the diode drop. Accounted for the peak voltage measurement in the wear tracking. IntelliGen HP only.
When reading an older thermal calibration packet (created before version 2 software and therefore does not contain the FET current limits) the low side FET current limit will default to 250A instead of 200A.
Added new oscilloscope trigger option: “Crank Start”. Using this option the oscilloscope buffer can be filled starting the moment cranking begins, providing a detailed look at the cranking processing.
Changed thermistor constants used in IntelliGen HP FET and regulator temperature measurements. The new constants reflect the updated thermistor part number used in production versions of the IntelliGen HP.
Bug fixes for IntelliGen Display
- During high-speed replay, if the auto-pause on error feature was enabled, some errors could be missed if the replay rate was faster than the user interface could process. This has been fixed.
New features for IntelliGen Display
For the oscilloscope, reserved bits in the oscilloscope setup packet are now used to downlink the configured pole-pairs. The oscilloscope display software uses this value to construct a back-emf and hall rpm measurement which can be added to the oscilloscope chart.
For the oscilloscope, added a least-squares linear regression of the hall and back-emf rpm to compute and plot the hall and back-emf acceleration. The regression computes the acceleration using all the rpm measurements from the previous electrical cycle.
Added computation of acceleration using rpm telemetry to plot acceleration. The acceleration is computed using the most recent 50 milliseconds of rpm data.
New features for IntelliGen Communications Standard Developers Kit
- Added a new SDK example application: “gensdkreplaylogger”. This command-line application gives an example of replaying a .gentel file and generating text outputs for telemetry. The application is included with the standard software installation and can be used as-is for automated data processing tasks. The IntelliGen Display software has been written to use the logging example code - so the outputs from IntelliGen Display will be the same as the outputs from the logging example.
2.0.595 (11 September 2026) (2.0 Update 2)
Bug fixes for IntelliGen
When using fractional hall shifts, if the system transitions from back-emf to hall sense driven commutation, the fractional shift was not applied for the first commutation output. This has been fixed.
When doing commutation testing or static align testing, if the hall sensors were invalid, the commutation outputs would be interrupted by hall error logic. This has been fixed so that the error processing is not applied in commutation testing modes.
For spinning hall alignment, the computation of the voltage constant has been improved by using the average rpm during the test time, rather than the instantaneous rpm at the end of the test.
For saturated current measurements where the saturated current is estimated using the generator model the filtering has been improved.
When moving in the reverse direction the step counter was not tracked correctly. This only affected the step counter telemetry.
Changed step counter logic: steps during backing up are now counted down, this makes it possible to see the rotor movement during the backing up operation as well as cranking acceleration. The step counter in telemetry can now be a negative number.
For the IntelliGen HP, improved the peak voltage reporting so the reported value is the highest value during the telemetry epoch, rather than the most recent peak measurement.
Bug fixes for IntelliGen Display
Fixed the recording of error bit fields in csv log files: previously the order of the bits in the resulting 32-bit word was not guaranteed to match the order of the bits in the binary packet, now it is.
When capturing a chart as a pdf file the default name of the file has been set correctly to match the name of the chart.
Fixed bug caused by renaming of telemetry files to include the serial number: the file rename operation was discarding any data already written to the file.
2.0.591 (30 August 2026) (2.0 Update 1)
Bug fixes for IntelliGen
Fix to fixed duty cycle reversing when beeping was enabled. A bug in the beep tone generation prevented the correct duty cycle output, preventing the reverse operation from working.
Fix to reversing using stepping logic: hall sensors were not being corrected according to configured flip and shift, so stepping would only succeed for hall sensors that needed no corrections.
Fix to direction error detection: previously it was possible to get a direction error during propeller reversing due variously to micro-stepping, engine compression, or winding cogging torque. Direction errors are now explicitly ignored during beeping and reversing prior to crank.
Improved computation of phase resistance during static hall alignment. Previously the resistance was computed using all the data of the static align, now the resistance is computed using only the whole steps of the static align. This improves the accuracy of the resistance since the motor inductance reduces the current when half-stepping.
Improved computation of phase resistance during static hall alignment by using the phase current measurements rather than the DC current measurements if possible (IntelliGen HP only).
Fixed missing slow telemetry packet in SD card recordings on IntelliGen HP.
Fixed missing trigger for SD card recording when crank command is received, this way the recording includes the cranking details before the rpm becomes non-zero.
Fixed hall sensor error reporting at zero speed, errors were not cleared until a hall sensor change occurred.
Updated phase resistance comparison during reverse stepping: because reverse stepping is typically done using half-steps the measured resistance is higher than truth, and this could cause the comparison to fail when it should pass.
Fixed the telemetry variable “steps since start” to count correctly from the initiation of cranking. Previously this variable would be zeroed at the wrong time, causing the reported value to be off by 6 steps.
Fixed the battery low voltage warning when cranking from the backup battery. During backup battery cranking it is expected that the battery voltage will sag below the low warning limit, so the warning is masked in that condition.
New features for IntelliGen
Added fractional hall shift. Previously the hall shift parameter could only adjust by whole steps, from 0 to 5. However, some hall sensor installations could be incorrect by fractional values (commonly half a step). The new hall shift value can range from -0.5 to 5.495, which represents a whole number shift plus a fractional shift. A shift of 1.75 is equivalent to a whole shift of 2 and a fractional shift of -0.25. The whole number shift works as before; however, if the speed is non-zero, the fraction is used to time shift the hall triggered commutation to affect the fraction shift. This dramatically improves hall-driven commutation for installations that have large hall errors. Note that the fractional shift can only be applied when the speed is non-zero, so it cannot improve cranking torque.
Added the ability for the static hall alignment logic to compute a half-step shift.
Added the ability for the spinning hall alignment logic to compute the fractional shift.
Added accounting of fractional hall shift in stepping reverse logic: if stepping is activated the step will be done using either whole or half-steps, depending on the amount of the fractional shift in the hall sensors.
Added optional crank stall checking. When enabled the crank operation will be aborted if, after the median hall period indicates more than 240 rpm, the most recent hall period becomes more than 2x greater than the median period (indicating a rapid deceleration), or the hall sensors indicate a reverse step. This feature is intended to perform a rapid shutdown of commutation during cranking if the software thinks the engine compression is going to stop the rotation. For windings with very low resistance failing to shut down commutation quickly enough could cause a catastrophic over current event. The ability to rapidly detect failure of crank acceleration depends on the winding and hall sensor details - this check may not be appropriate for all windings.
Added 80% voltage sag limit to the cranking current computation: if the source voltage falls to less than 80% of the value before cranking the voltage used to compute the current will be limited to the 80% value. This will prevent cranking current commands from collapsing a battery.
Added a new crank abort check: if the voltage sags below 50% of the value before cranking the crank will be aborted and the system disabled.
If SD card recording is active the minimum recording rate is increased to 250Hz for fast telemetry and 5Hz for slow telemetry during cranking mode (IntelliGen HP only).
Added ability to perform commutation testing brake mode, where all phases are enabled at the same pwm value (IntelliGen HP only).
When cranking the duty cycle is updated to account for FET control dead time. For low resistance windings the duty cycle represented by the dead time could be a significant part of the desired control output.
Added improved handling of saturated current sensing. When the HV current sense (or the backup battery current sense during cranking with backup battery) are saturated, the system will use the winding power model (total resistance and voltage constant) to estimate the current that should be flowing based on the duty cycle and DC voltage. If the estimated current is greater than what is indicated by the saturated sensor the sensor result is replaced with the estimate. This makes it possible (though not necessarily a good idea) to use starting power greater than can be measured by the hardware.
Updated default generator and control configuration parameters: peak power to 2000W, power feed forward to 100%, sensing to prefer back-emf, minimum back-emf rpm to 2500, fault power to 2500W. These changes only apply if the configuration is set to defaults.
Bug fixes for IntelliGen Display
Fixed problem with resetting log files, the known configuration data were not being written automatically to the new file.
Fixed limitation on SD card recording rate configuration - the UI was incorrectly limiting the rate configuration to 127Hz.
Fixed simulated engine cranking with the backup battery - the simulator was not correctly computing the backup battery voltage during cranking.
New features for IntelliGen Display
Added locally computed power telemetry as options to display alongside the currents. Updated the default charts to use the power telemetry.
Added better reporting of simulation states to strip charts. Added variables include simulation shaft angle, simulation speed, acceleration, average commutation angle error and maximum commutation angle error. This makes it easier to understand the impact of compression torque on the commutation accuracy of the simulated system.
Added tooltip to the replay toolbar to display what file is being replayed.
Changed the name of the log and sd files to include the serial number and device type. Previously the names were of the form “gentel-date-time.gentel”. Now they are “IntelliGen_X_date-time.gentel”, or “IntelliGenHP_X_date-time.gentel”, in which X is the device serial number.
2.0.586 (27 July 2026) (2.0 First Release)
New features for IntelliGen
Support for the IntelliGen HP. IntelliGen HP is a new higher power/voltage hardware. The support comes in the form of a new device enumeration value and a new firmware image specific to the HP:
Support for SD card recording and data transfer (which required increasing the maximum IntelliGen packet size from 255 to 512 bytes).
Support for low voltage regulator voltage selection (6V or 12V).
Support for selection of CAN bus termination on or off.
Support for pre-charge control of the HV switch and Switched output switches.
Support for dedicated peak-voltage detection circuit.
Support for phase current measurements.
Changes to the IntelliGen ICD (shared by standard and HP IntelliGen) to accommodate the new capabilities.
Added control configuration option “Bootup Disabled”. When selected this option causes IntelliGen to turn all user controllable enables off at system bootup (excluding quick restarts). This feature is useful for development work when the system configuration is not yet stable and enabling devices automatically could cause problems.
Added control configuration option “Errors Prevent Commutation”. When selected this option causes IntelliGen to operate in passive mode (no commutation) if there is any shaft sensor error, including angular mismatch between hall and back-emf sensors.
Changed error reporting ICD to provide direction error indication specific sensorless or hall shaft sensing. Also added an error to indicate if commutation is being prevented by a shaft sensor error.
Added user enable/disable of low voltage A and B regulator enable. Previously the enable status of the low voltage regulators was controllable only via configuration, now the configured enable status can be disabled with the user enable packet, like the main regulator.
Changed generator configuration limits to be specified in power rather than current. This reflects that the true limits on the generator are with respect to phase current, which is proportional to power, rather than DC current.
Changed current feedback control law to be power feedback. This makes it easier to accommodate a wider range of voltages, and to manage pack voltage sag under load.
Changed power feedback control law to use new gain scaling and feedforward logic that more accurately models the duty cycle to power relationship. This provides higher power control fidelity over a wider range of voltages and speeds.
Added new thermal limits: low-side and high-side FET current limits. These limits apply to the estimated phase current (not the DC current). They are used in the power feedback control law to prevent exceeding the FET continuous current limit. The limits are also used in the crank fault detection logic to catch an overcurrent condition. The thermal limits are set at the factory and cannot be altered by the user.
Added support for non-standard main regulator voltage setpoints (for example 48V instead of 28.5V or 25.0V). The regulator setpoints are now recorded in configuration set at the factory.
Changed voltage feedback control law to use the desired bridge voltage as the scaling reference rather than a fixed 75V as before. This change allows the same gains to work over a wider range of bridge voltages.
Added new crank configuration parameter: initial crank power. This value is used to set the initial output of the rpm control law and the current control law at the moment cranking begins. This makes it possible to use less aggressive feedback gains and still achieve a strong initial response to cranking.
Changed time telemetry packet, instead of reporting number of revolutions since the engine started it now reports number of commutation steps. This makes it possible to see the acceleration for engine starting in more detail. The generator wear packet continues to track total revolutions.
Changed variables in the fast telemetry packet to be unfiltered when the generator mode is cranking. During the cranking mode the voltage, current, duty cycle, rpm are the most recent values, rather than the average value over the fast telemetry interval.
Added new backup before crank option: power mode control. Power mode control replaces the fixed backup duty cycle with a duty computed by the power feedback control law. Setting the backup power to 0 preserves the fixed duty cycle behavior.
Added new backup before crank option: stepping. Stepping works by slowly stepping the commutation outputs in reverse, and forward if necessary, to validate the hall sensors and to position the engine against the reverse compression stop. In addition to hall sensor validation stepping mode also validates that all the phases have approximately the same resistance which matches the configured resistance. Stepping can be done using a fixed duty cycle or power feedback. Stepping can be disabled to get the old (maximum torque) backup behavior.
Changed regulator enable control: previously if the regulator was marked “batteryless” it would be forced to be on. This logic has been removed; the regulator will now only come on if explicitly configured to do so.
Added configuration control of the automatic PWM frequency scaling, including the ability to specify minimum and maximum frequencies, and a desired scaling term given as the desired number of PWM periods per commutation step.
Removed the minimum duty cycle configuration parameter.
Changed the maximum value of the duty cycle rate limit. Previously the maximum configurable value was 2550 %/s. Now it can be up to 25500 %/s. This can be helpful for achieving the desired initial crank power.
Removed option to enable advanced hall error detection - this feature is now always on.
Changed power configuration to specify the generation and HV limits in power rather than current.
Updated back-emf decoder logic to handle higher frequency commutation (for higher pole count generators) in which the expected commutation switch may occur before the filtered phase voltage has crossed zero.
Removed estimation of demag time in back emf decoding.
Added configuration parameter specifying the time delay to use for back-emf demagnetization compensation.
Improved estimate of phase voltage filter delay. The actual filter delay is different for IntelliGen versus IntelliGen HP.
Added configuration parameter “max sensorless rpm”, which can be used to indicate the system should revert to hall sensors at higher speeds.
Changed logic associated with storing configuration and generator wear information to flash: if the electrical speed is more than 700Hz the flash write is not done until the speed returns to zero.
Added rotor position estimates along with an estimate of the difference between the hall and back-emf position estimates.
Added password control and lock/unlock of configuration categories. This includes the ability to mark configuration items as read only or hidden when the system is unlocked without the correct password.
Redesigned the oscilloscope to support new features of version 2 software, including space vector pwm, phase current measurements, and rotor position estimates.
Improved static hall align in test mode: a successful static hall alignment test will now compute and record the total resistance value in the generator configuration. In addition, static hall align will test for and warn if the alignment has a half step error. Previously a half step error (hall sensors shifted by 30 electrical degrees) would fail the static alignment test.
Improved spinning hall align in test mode: a successful spinning hall alignment test will now compute and record the voltage constant in the generator configuration.
Improved tracking of interrupt cpu time by including the time of the phase voltage processing loop. Changed the CPU telemetry message to increase the maximum reportable interrupt time to 51% from 25.5%.
Changed CAN bit timing details to put the sample point at exactly 87.5% of the bit time, which is the optimal sampling point according to the CAN industry. This is changed from the previous configuration which had the sample point at 67%.
Changed BOR (brown out reset) voltage monitor level. Previously the BOR was at the default 1.8V level, now it is at 3.0V (the processor runs at 3.3V). This helps prevent cases during bootup when the processor begins running before other ICs on the board are functioning.
Updated the compiler used for the firmware from “gnu-tools-for-stm32.12.3.rel1” to “gnu-tools-for-stm32.14.3.rel1”.
New features for IntelliGen Display
Moved the status bar (which displays communications status and messages) into a dedicated toolbar. This allows it to sit alongside the logging toolbar, reducing the total amount of vertical space required for the application. It also makes it possible to turn the status bar off if desired.
Improved chart axis selection when using the mouse to drag a chart axis.
Added tooltip variable descriptions to the chart signal selection dropdown.
Reorganized display of software and hardware version information.
Added Interrupts window which can be used to see the details of the microprocessor interrupts.
Improved simulator fidelity to more accurately account for engine details; including the torque of compression and the friction. The simulator now has parameters to adjust the engine size, compression ratio, and inertia.
Updated Qt to version 6.11.
Changed the compiler for Windows from mingw to llvm-mingw (17.0.6).
Added menu driven interface for selecting the theme, background color, and text color. This allows the display to be customized as desired. The customization is stored by project so you can have projects with different appearances.
Version 1.4
1.4.429 (23 June 2026) (1.4 Update 9)
Bug fixes for IntelliGen
- During the cranking mode IntelliGen would automatically turn off the switched output to reduce load on the battery system. This has been changed such that the switched output is only turned off if the cranking battery is the backup battery. When cranking from the HV battery the switched output is allowed to remain on.
New features for IntelliGen
Added “hall offset” telemetry item to the slow2 telemetry packet, using a previously reserved byte. This telemetry item reports the average electrical angle difference between the back-emf sensors and the hall sensors. This can be used to measure the accuracy of the hall sensor installation.
Added a new control configuration item, the “mismatch threshold”, using previously reserved bits. The threshold can be used to adjust the amount of alignment error between hall and back-emf sensors that triggers the mismatch error. The default alignment error threshold is 30 electrical degrees.
1.4.428 (24 April 2026) (1.4 Update 8)
Bug fixes for IntelliGen
Added filtering to rpm measurement used for determining generation power limits. This improves the system at lower speeds where the intra-cycle engine torque variation can cause significant rpm change. Power generation is now based on rpm computed from two mechanical revolutions worth of shaft sensor measurements. The filtered rpm is also used as the input to the telemetry that is transmitted to the user.
Added filtering to back-emf crossing detection. A successful crossing detection will produce a back-emf period which is averaged with the median period. This reduces noise in the back-emf crossing detection.
Changed back-emf estimate to be based on median shaft sensor period rather than most recent period. This adds a small amount of latency in trade for resilience against a poor period detection.
Bug fixes for IntelliGen Display
Improved chart axis selection when using the mouse to drag a chart axis.
Improved oscilloscope chart logic to make sure the chart time window matches the scope capture time window.
Added more detailed descriptions to the packet log display, this makes it easier when replaying files to see what configuration data was changed.
1.4.427 (15 October 2025) (1.4 Update 7)
Bug fixes for IntelliGen
Fixed bug on maximum HV voltage. The value set in OTP (during manufacturing) was not read correctly. For 16S units with part numbers 11350 or 11377 the max HV voltage is correct, but other part numbers would read a max HV voltage of 14S when it should be 16S. This has been fixed so that the max HV voltage will match what was set in OTP during manufacturing.
Fixed case where, if crank command was being sent repeatedly over the communications interface, it was possible to re-initiate a crank attempt before the previous one had stopped.
Fixed case where it was possible to command a crank from the user disabled state when the rpm was non-zero. Crank command from the user disabled state is still accepted (since the enable packet that commands crank can also set user enable), but only if the rpm is zero.
Changed required available peak time to accept a non-emergency crank command. Previously crank command was accepted if the remaining peak time was more than 50% of the maximum. This has been changed such that the available peak time must be 100%. This will increase the amount of time required between crank attempts to allow the peak time integrator to wind down completely. It also reduces the maximum peak time required in configuration since each crank attempt will begin with 100% peak time available.
Increased the required voltage on the HV or backup battery input to allow a crank command. Previous thresholds were 12V, and the new thresholds are 32V (HV) and 22V (backup).
Fixed bug on io start command signal processing. Previous logic required this signal to be inactive before an active input would command crank. Accepting a crank command would reset the arming state, requiring the command signal to go inactive again before it can be used to command a crank. The updated logic clears the arm state whether the crank command was accepted or not. This protects against the case where some other condition was preventing cranking, for example if the user had disabled the IntelliGen, and then upon clearing that condition the io start command would immediately command a crank. The new logic prevents this by always requiring the io start command signal to be inactive before going active, even if the previous io start command was not accepted.
Added a fixed 5 second delay following a crank before a new non-emergency crank can be commanded.
Fixed bug on sensorless direction error reporting, the sensorless error bit would be set when the hall sensors indicated direction error rather than when the sensorless decoder indicated direction error.
Improved logic on bridge voltage control when the HV switch is closed. Previously the HV switch would open (and control logic would switch to voltage control) if the HV voltage exceeded limits, this could happen if, for example, the HV battery became disconnected and therefore current could not flow to the battery. Now the logic has been updated to open the switch and revert to voltage control if either the HV voltage or the bridge voltage exceeds the voltage limits. This protects against the case where the HV switch itself is faulty and is acting as a diode.
Bug fixes for IntelliGen Display
- Changed generator configuration label: winding “resistance” to “impedance” to more properly reflect that this term is not the DC resistance of the winding, but the impedance at PWM frequency.
1.4.423 (21 August 2025) (1.4 Update 6)
New features for IntelliGen
Added feature to report in a debug message the reason for a crank abort.
Added new control configuration parameter for engine starting: crank fault current limit. This value is used to stop a crank attempt if too much current is measured for too long. The feature can be used to catch otherwise catastrophic crank failures such as a hard stop or overly aggressive current feedback control gains.
Added new control configuration parameter for engine starting: crank fault time. This value is used in two places: it is the amount of time that current is allowed to exceed the crank fault limit, and it is the amount of time that the system will wait before evaluating rpm and aborting the crank if the rpm is less than 50.
Added new test mode feature to energize a phase at an arbitrary duty cycle. This is an advanced test which can consume significant current and should only be used by competent test personnel.
Bug fixes for IntelliGen
Added a 2 second reverse error blanking window: when RPM falls through 500 the blanking window is armed, and for the next two seconds a reverse error is not reported to the user. This prevents spurious error reports that are caused by the engine bouncing off compression when it stops.
Reduced the timeout for low rpm failed crank from 2.5 seconds to the value configured by the crank fault time.
Changed analog sampling to reduce the time delay from phase voltage ADC measurement to processing. This is the same change that would automatically happen anytime the PWM frequency went above 44kHz.
Improved sensor sampling logic that manages current sensor saturation. Previously a saturated HV current sensor (or backup battery current sense if backup battery was cranking) would be replaced by an equivalent estimate constructed from the generator current measurement. However, the generator current measurement can be corrupted by ground bounce from some larger windings. The new logic will only replace the saturated sensor measurement if the replacement signal is larger in magnitude. Further, if the replacement signal is not larger in magnitude the software will estimate the generator current from the motor constants and use if it is larger in magnitude than the saturated sensor.
Fixed bug in combined current control law that simultaneously manages generator and HV current. When switching between limiting conditions (generator or HV) the feedforward term of the control output could jump slightly. This has been fixed so feedforward term remains consistent whether the generator or the HV current is the limiting factor.
Fixed bug in current control telemetry output: the fields
genCurrentControlActiveandhvCurrentControlActivewere never set making it difficult to observe which current limit was in effect.Fixed bug in current control telemetry output: the HV current command did not reflect the augmentation current when in augmentation mode.
Improved reporting of rectifier faults: previously some rectifier faults would be reported when the motor control IC was first energized, these are now suppressed. Only sustained faults, signaled when commutation is active, are reported as errors.
Changed HV current threshold used to set errors. Previously the error threshold limit was 1.5 Amps, now it is 10% of the generator current limit, or 1.5 Amps, whichever is larger. This reduces the likelihood of spurious HV current errors that can occur when the generator system is large, but the HV charge and/or discharge current limit is small.
1.4.417 (30 April 2025) (1.4 Update 5)
Bug fixes for IntelliGen
Fixed bug with the “spinning hall align” feature of test mode. Previously, if the hall order needed to go from not-flipped to flipped, the hall align feature would do this, but it would not do the reverse. Now, if the hall alignment needs to go from flipped to not-flipped the spinning hall align will do this.
Improved sensorless mismatch detection. Previously it was assumed that the back-emf crossing detection would occur before the corresponding hall sensor transition (the hall sensor transition should happen 30 electrical degrees after the zero crossing). However, if the hall sensors are slightly mis-aligned and there is sufficient noise on the back emf signal, this assumption could lead to a spurious sensorless mismatch error. The logic has been improved to account for the case where the hall transition happens earlier than the zero-crossing detection, reducing the chance of spurious mismatch detection. In addition, the threshold for successive mismatches before displaying an error has been increased.
Bug fixes for IntelliGen Display
- Fixed bug in the simulator which was not obeying the automatic PWM frequency scaling logic. This could result in simulated PWM events happening too slowly and a corresponding problem with the back emf decoder in simulation.
1.4.415 (23 January 2025) (1.4 Update 4)
Bug fixes for IntelliGen
Fixed bug that indicated engine crank was not available if the generator peak current limit was configured the same as the continuous limit.
Improved enable indication of main regulator status. The main regulator status indication is based on voltage feedback; however, a discharged backup battery could drag the voltage below the status threshold - even when the regulator is working correctly. The new logic detects this case and indicates the regulator status is good if the regulator is supply current greater than 90% of the limit.
Improved detection of hall sensor failure. Previously a hall sensor failure would only be detected upon a hall sensor transition - which might not happen for several electrical steps. Now a hall sensor failure will also be asserted if no transition has occurred after 166% of the expected interval. This detection is intended to disable hall sensor commutation before a failed sensor can produce a mis-commutation event which might damage hardware. This error detection only applies after the cranking state, and must be enabled in the control configuration.
Suppressed the sensorless mismatch error if the hall sensors have an error in the recent past.
Bug fixes for IntelliGen Display
Fixed switched output load in the simulator.
Updated SDK to include the files gencompareutil.cpp/hpp and genprintutil.cpp/hpp. These provide functions for generating and reading human readable text descriptions of IntelliGen packets.
Fixed bug with windows 11 theme light mode which made it hard to see the presence of checkbox checkmarks.
1.4.411 (11 November 2024) (1.4 Update 3)
Bug fixes for IntelliGen
- Changed default power configuration setting so that the main regulator and HV switch are enabled during the disabled state.
Bug fixes for IntelliGen Display
Updated average button tooltip to indicate when averaging is not available because no variables have been selected to log.
Updated Datasheet to reflect 16S versions of IntelliGen.
Fixed problem with Windows 11 theme and allowed Windows 11 theme to be used.
Updated to support Dark mode on both Windows 11 and macOS. Dark mode is not supported on Windows 10.
1.4.406 (4 October 2024) (1.4 Update 2)
Bug fixes for IntelliGen
Changed frequency of regulator current limit pwm control signal from 2kHz to 24kHz. This significantly reduces the noise on the current limit control signal.
Fixed bug in test mode caused by timer overflow for tests longer than 357 seconds.
Bug fixes for IntelliGen Display
Improved display variable selection.
Added improved command line processing. Use command line –help to see the options.
1.4.405 (22 August 2024) (1.4 Update 1)
Bug fixes for IntelliGen
Fixed bug in handling of back emf decoder failure: The decoder was not properly coasting through a detection miss when commutating with hall sensors.
Suppressed sensorless pattern warning when back emf decoder misses while commutating with hall sensors. When commutating with hall sensors the back emf decoder is more likely to have errors due to hall sensor alignment.
Improved sensor choice when both back emf and hall sensors are working, and both have recent errors. Previously the sensors with the oldest error would be chosen, but now, if the hall sensor error is less than 10 seconds old the back emf sensor will be chosen. This change improves the sensor choice because any hall sensor error (while commutating with hall sensors) will typically trigger a back emf sensor error; but the reverse is not true.
Improved handling of test mode commanded back emf failure. The improved implementation more closely models a real failure.
Test mode can now assert multiple hall and back emf sensors simultaneously.
Added logic to exit generating or augmenting mode (going to passive mode) if both hall and back emf sensors are invalid.
Added logic to stay in passive mode until at least one of the available sensor sources (hall and back emf) has gone at least 10 seconds without an error.
Bug fixes for IntelliGen Display
Fixed Qt user interface problem on Windows 11 which does not allocate enough space for spin box controls. If Windows 11 is detected, and no UI theme is specified in the global ini file or the command line, the theme will be explicitly set to “windowsvista” which will cause the display to look like it does on Windows 10.
Unified the global ini file settings with command line inputs. Use –help on the command line to see documentation.
Added option to fail a hall sensor in the simulator. A failed hall sensor always reads 1 and won’t trigger a simulated hall sensor interrupt.
Changed simulator to use simulated CAN interface instead of simulated UART interface.
1.4.404 (16 August 2024) (1.4 First Release)
New features for IntelliGen
Improved the regulator current limit control law. The new control law should better manage calibration errors, respond faster, and work better at light loads.
Removed the feature “regulator limit follows loads”. This feature was not often used and complicated the regulator current limit control law.
Changed the interpretation of CAN setting “No Config”. Previously only command inputs and telemetry outputs were allowed. Now you can request settings using the GEN_PKT_REQUEST packet; this makes it possible to discover why it is not possible to alter configuration over the CAN bus once this setting is on.
Extended the Nack packet to report a new nack cause: “genNackCANConfigDisabled” which indicates that the configuration packet was rejected due to the “No Config” option being set in CAN settings.
Improved the back emf estimation when commutation is off (passive mode). The old method simply used the speed and voltage constant. The new method uses line-to-line phase voltage measurements. This improves the transition from non-commutating to commutating modes when the configured generator voltage constant was incorrect.
Added fast telemetry reporting of current control error. This is useful for tuning the current feedback law.
Added fast telemetry reporting of raw generator current. Generator current is normally constructed from other current measurements, which improves accuracy. Adding the raw generator current measurement makes it easier to diagnose problems in the current measurement.
Changed logic for transitioning from cranking state to generating state. Previously, if the cranking time elapsed and the rpm was not above the “generating on” threshold IntelliGen would transition to the passive state, waiting until the rpm increased before going to the generating state. Now, if the crank timer elapses and the rpm is above the “generating off” threshold IntelliGen will transition to the generating state.
Changed logic for derating the 28V regulator for low input voltage. Previously the derating was done using hysteresis, so the derated current was hard to predict within the hysteresis limits. Now the logic is simpler, the derated current limit is computed linearly based on the input voltage, using the same limits as the previous hysteresis computation.
Added new static hall alignment features. This feature runs the generator slowly, stepping through fixed commutation steps and measuring the hall sensor pattern to determine the corrections needed. This is easier than the previously automatic alignment that was based on back emf sensing and required the generator to be spinning at high speed.
Added new storage command that can be used to set a specific configuration category to default values.
Changed logic for io start command: previously if both the io start command and io start enable were active the IntelliGen would crank the engine for start. Now the IntelliGen will not crank the engine until the io start command is first inactive and then active.
Removed generator voltage limit configuration value. The voltage limit is now hard-coded at 75V (the previous default value) for the stock IntelliGen, and 75V is used as the reference voltage for gain scaling in the generator voltage control law.
Removed power configuration value for the HV close threshold. The close threshold is now hard-coded at 0.5V (the previous default value).
Added logic to limit the HV maximum voltage based on factory configuration data.
New features for IntelliGen Display
Added the ability to select which variables are written to the csv log files. If no variables are selected the csv file is not written at all (the binary .gentel file is always recorded so the .csv can easily be recreated through replay).
Improved the macos version of IntelliGen Display.
Added the ability to change the display background and text colors via “IntelliGen Display.ini” file.
Added feature to specify the HV battery cell count, when IntelliGen is configured with “HV is battery”. Specifying the HV battery cell count automatically sets the HV charge voltage, HV max voltage, and sets the HV enable in generating mode; simplifying setup. This is a UI only feature, the configuration packet and embedded logic have not changed.
Added configuration warning feature which will warn the user if their configuration is not consistent: for example if the maximum generator power is insufficient to supply the main regulator.
Version 1.3
1.3.351 (18 June 2024) (1.3 Update 4)
Bug fixes for IntelliGen
Improved logic affecting the close/open of the HV switch while in the passive mode of operation (generator spinning, but commutation off).
Added logic to open the HV switch when in the disabled state if the generator voltage is too high. This is needed because it is possible to be spinning at high speed while in the disabled state.
Bug fixes for IntelliGen Display
Fixed issue when saving IntelliGen configuration: if the file already existed the display software was not confirming the user wanted to update the data in the existing file.
Fixed issue that would flag a configuration as modified when the configuration was only requested, which is not a modification. This would cause unnecessary requests to save configuration to a file when closing the display.
Improved the process for adding variables to the gauges or variables toolbar.
Added tooltip descriptions to variables in the gauges and variables toolbar.
1.3.349 (5 April 2024) (1.3 Update 3)
Bug fixes for IntelliGen
Updated the determination of “start available” bit in telemetry. Previously start available would be false if the system was disabled by the user, or the generator was disabled. Now, those disables do not clear start available, because the same enable packet which engages the crank command can also clear those disables.
If the cranking power source is the HV connection, and the HV switch is disabled by the user, the cranking command is rejected; previously it was not. Note that if the HV switch is open due to configuration (not user enable), the crank command will cause the switch to close and the cranking operation will proceed.
1.3.348 (18 March 2024) (1.3 Update 2)
Bug fixes for IntelliGen
Removed the ability to send an augment command when the generator was not already spinning. Now the only way to apply current to the generator before it is spinning is to use the crank command.
Fixed issue with sensorless decoding: a failure to find a zero crossing should not generate a sensorless decode error unless the failure repeated. However, when commutating with hall sensors the coast logic did not work - leading to a sensorless error indication that would not clear.
Fixed issue with sensorless mismatch error warning: previously if the step difference between the sensorless and hall sensors was only 1 the error would not be set. Now the error will be set even if the difference is only 1 step. However it will take several successive mismatches to set the error.
During the cranking state, if the source of cranking current was removed while the engine was making torque, the current feedback law could cause an overvoltage condition that would damage the IntelliGen hardware. Software now checks for the overvoltage and ends the cranking state to protect the hardware. Other operational states already had overvoltage protection.
New features for IntelliGen
Added support for the “Device Enumeration” concept introduced with the latest bootloader. Device enumeration prevents users from loading firmware that does not match the type of device (for example, installing IntelliJect firmware on IntelliGen).
Changed computation of sensorless crossing to improve the ability to measure the zero crossing when the back emf wave form is not linear. This improves the crossing detection at high boost ratios.
Changed sensorless guess rules: the sensorless decoder is now only allowed to generate a guess crossing once every four commutation intervals (instead of every other). In other words, if the decoder has to guess a crossing time it must correctly find the next three crossings before it is allowed to guess again, otherwise a sensorless error will be generated.
Improved the reporting of the max voltage telemetry value, which is the maximum voltage measured at the generator, phases, or high voltage connection. Previously the instantaneous phase voltages used by the sensorless decoder did not participate in the determination of the max voltage, now they do. This will better capture short voltage transients that can happen at the commutation switch.
Changed the ICD for the unlock packet. The new packet has the same structure, but the minimum size has been increased. This forces packet, when traveling over CAN bus, to use the packet-over-CAN schema, which includes sending the entire packet header and CRC. This change prevents a random unlucky CAN frame from unlocking the configuration. Older versions of the display software will not be able to unlock this version of the IntelliGen firmware.
Bug fixes for IntelliGen Display
Improved auto-pause feature for replay: previously the pause signal was only obeyed when the replay had caught up to the desired time stamp. Now the pause signal will exit the replay loop as soon as a packet is decoded which caused the pause. This improves the time accuracy of the automatic pause.
Fixed display of units on charts: previously all units were displayed on the left axis of the chart, now they are correctly displayed on the left or right axis depending on the relevant chart data.
Added logic to automatically select oscilloscope traces if no signals are selected when scope data is received. This will also force the scope x-axis to move as needed to make sure the data is displayed.
1.3.346 (9 January 2024) (1.3 Update 1)
Bug fixes for IntelliGen
Increased the minimum number of pwm periods per commutation interval from 5 to 8. This affects the automatic PWM frequency scaling, which increases PWM frequency as needed for higher motor speeds. The change improves the ability of the sensorless back-emf decoder to work at high speeds.
Changed process of saving configuration data to non-volatile storage. Previously the save to storage was not allowed if the generator was spinning and enabled. Now it is. If the nonvolatile storage location is full (i.e. it must be erased) the save is still not allowed, however this will happen infrequently.
Added backup nonvolatile storage capability. Anytime the wear storage sector must be erased a backup copy of the wear information will temporarily be written to configuration storage before the erase is performed. Similarly, anytime the configuration storage must be erased a backup copy of the configuration will be temporarily written to wear storage. If power is lost during the erase operation the backup copy will be used to reinitialize the system upon reboot.
Changed frequency of the duty cycle control of the switched output from 2000Hz to 200Hz. This better aligns with the worst case turn on and turn off time of the switch.
Removed brownout logic that reduced switched output duty cycle when battery voltage fell more than half a volt below regulator setpoint.
Added automatic fix to erroneous regulator duty cycle limit calibration that was present in some rev 4.0 boards.
Bug fixes for IntelliGen Display
Fixed bug that prevented changing communications configuration when the “Set All to Defaults” option was checked.
Improved strip chart control to provide fine control of the chart replay position in cases where the amount of buffered data is very large.
Three variables from the “Current Control” telemetry packet were not available to chart, they have been added to the variable list: “Gen Current Control Active”, “HV current control active”, and “HV charge override active”.
New features for IntelliGen Display
Increased throughput for the TouCAN USB-CAN module if the module reports its firmware as 1.0 or greater. Older TouCAN firmware contained a bug that prevented the device from reaching its full speed potential.
Added the ability specify details of the simulated generator and batteries. This makes the simulator useful for exploring the performance of different generator system designs.
1.3.338 (31 October 2023) (1.3 First Release)
New features for IntelliGen
Added support for factory configurable regulator max current limit. Previously it was assumed the regulator maximum current output was 14 Amps. The max value is now configurable at the factory. This change anticipates future versions of IntelliGen with increased regulator performance.
Updated the communications protocol to API3. This adds support for higher currents from the regulator and system current measurements, expanded generator wear information, peak voltage and current measurements, peak charge integrator status reporting, and more details about rectifier faults.
Added option to enable integral feedback of the high voltage to the hv current command (for hv is battery cases). This allows the IntelliGen to send current to the HV rail even when the HV voltage is at the setpoint, which is needed to support continuous loads on the HV rail.
Changed the name of the “SPINNING” mode of operation to “PASSIVE”. This reflects the ability of the IntelliGen to passively commutate power during the spinning/passive state.
Added logic to the “PASSIVE” state of operation to control the current consumed or produced by the high voltage rail and the main regulator. The logic is similar to that used in the generating state, but accounts for the inability to regulate the voltage and current of the generator using active commutation.
Added thermal protection logic which can derate the generator current limit and the regulator current limit to protect the temperature of the IntelliGen commutator and main regulator respectively. The thermal limits are configured at the factory.
Added input voltage protection logic which can derate the regulator current limit to protect regulator at low input voltage. The voltage derate limits are configured at the factory.
Changed the cutoff frequency on the low pass filter used for FET and Regulator temperature measurements. Previously the filter was 0.2Hz, now it is 5Hz. This provides faster response for the derating system.
Changed the way error bits are set: the data used to indicate a sensor error are now set using telemetry data, as the telemetry are computed. Since telemetry are averaged for the telemetry period (fast or slow) this mitigates spurious error indication caused by analog noise. Errors that are not related to sensor readings (i.e. fault indications) are unchanged: they are set immediately upon fault detection.
Split the user’s guide into two documents: a Users Guide and a Datasheet. The Datasheet contains the mechanical and electrical ICD. Both documents are included in the IntelliGen Display software.
Changed the names of some variables in the user interface and SDK to be more consistent with hardware labels.
Added new information to the wear packet: the integral of the absolute values of the generator current, hv current, and regulator current (the backup battery already had such an integral). Also added two new time trackers: the amount of time the system was running with the generator hot, and the amount of time the system was running with the IntelliGen rectifier or regulator hot.
Changed the telemetry output timing: the wear information was previously sent with slow telemetry. Now it is sent at 1/10th of the slow telemetry rate. This saves bandwidth since the wear information does not change quickly.
Changed logic in the generator current controller: if the commanded cranking current is greater than 1/4th of the max generator current the measurement used for feedback is unfiltered. This allows the controller to respond more quickly to handle large current transients.
Added feedforward term to generator current control law.
Added protection logic to reject a crank command if the generator is too hot, the IntelliGen is too hot, or the peak charge integrator (which enables or disables the peak current limit) is more than 50% exhausted. New “Nack” causes were also added to indicate each of these cases.
Added augmented enable packet that includes an extra bit which can be used to command an “emergency” crank. When the emergency bit is set the new protection logic is bypassed, the generator thermal derating is temporarily disabled, the peak charge integrator is zeroed, and the audible portion of the crank process is skipped. The emergency crank command should only be used if the engine must be started, even if doing so will risk damage to the generator.
New features for IntelliGen display
- Updated the default charts to specify 6 charts: “Generator”, “Regulator”, “Power”, “Control”, “Thermal”, “Faults”. The first three charts are visible by default.
Version 1.2
1.2.307 (30 September 2023) (1.2 Update 5)
Bug fixes for IntelliGen
Fixed bug in application of pwm duty cycle rate limit. The configured rate limit was not being enforced.
Fixed bug in sensorless phase voltage processing. A timing value could be corrupted in an interrupt, causing the sensorless decoder to fail.
1.2.306 (27 June 2023) (1.2 Update 4)
Bug fixes for IntelliGen
IntelliGen was waiting for a hall sensor interrupt before testing the hall sensor pattern for validity. If all hall sensors were bad this would never happen, and the hall sensor error would not be indicated even though the hall sensors were bad. This has been fixed.
Corrected start available indication in the fast telemetry packet to account for user disable of the high voltage switch, and presence of the high voltage or main battery.
Fixed bug in starting with the main battery: the start command would be rejected based on the status of the high voltage switch, even though high voltage was not used in this case.
New features for IntelliGen
Added a new packet that can be used to command an override to the HV charge current command. The override can only reduce the charge current (down to zero) from the configured value. The override has a timeout associated with it such that the user must continuously send the override packet to keep the override in effect.
Added the ability to change the hall sensor order in software. Changing the order may be needed to fix some types of mis-wiring. The order change is done by logically swapping the U and W hall sensors so that “UVW” becomes “WVU”. Hall sensor order, plus the hall sensor shift option, should allow any combination of hall sensor wiring to be accounted for.
1.2.301 (20 April 2023) (1.2 Update 3)
Bug fixes for IntelliGen display
Removed the ability for end users to change the current calibration configuration data.
Changed labels of low voltage regulators for Lv1 and Lv2 to LvA and LvB.
Changed “heater” toolbar to “switched” toolbar.
Bug fixes for IntelliGen
Changed implementation of reverse operation to reduce the chance of errors when changing direction.
Improved selection of commutation source when both sources are in an error state. This improves the handling of the backup process prior to cranking.
Increased the number of reverse step detections required to signal a direction error from 3 to 6. This improves the backup and cranking process which can see reverse indications as the engine bounces off compression.
Added automatic pwm frequency increases: the PWM frequency is stepped up at intervals of 2kHz to maintain at least 5 pwm cycles per commutation interval. The configured pwm frequency is the minimum frequency.
Added testmode feature for automatically determining the hall shift and direction.
Changed watchdog time reporting to be in units of microseconds rather than clock ticks.
Removed the “zero current” command - this feature was not useful.
Removed heater current limit setting - the switched output is now just directly commanded with no current feedback.
Suppressed sensorless commutation error reporting when the “hall only” mode of operation is selected.
Supressed regulator faults (Main, LvA, LvB) for 0.25 second after the regulator is enabled, since the fault condition is often reported before the regulators have had a chance to stabilize.
Changed interpretation of the “batteryless” power configuration flag. If “batteryless” is selected the main regulator is forced into the maximum current limit state, since browning out the regulator cannot be tolerated without battery backup.
If “batteryless” is configured in the power configuration the user is not allowed to disable the regulator via command unless IntelliGen is unlocked.
Applied 50 microsecond time delay compensation to sensorless decoding of phase voltage measurements to account for delay due to low pass filters.
Changed current feedback control law to incorporate feedforward voltage term.
Changed the implementation of the feedforward voltage term, for both the current and voltage control laws, to allow high speed (on every period measurement) adjustment of the pwm duty cycle to compensate for ripple due to intra-cycle engine speed variation.
Changed the application of pwm limits for the cranking case so the minimum pwm limit can be violated during the cranking case.
Limited the user setting for minimum pwm duty cycle, it can not be set less than 5%.
Added generator current correction: to improve generator current measurement the generator current is constructed from the other currents if possible.
1.2.285 (28 February 2023) (1.2 Update 2)
New features for IntelliGen display
Added alarm for regulator, powerboard, and battery temperature measurements
Added preliminary support for TouCAN USB to CAN module from Currawong Engineering.
1.2.283 (22 February 2023) (1.2 Update 1)
Bug fixes for IntelliGen
Changed the system current scaling in the communications ICD from 0.1 Amps per bit to 0.2 Amps per bit. This is needed to accommodate larger currents than were originally anticipated.
Updated the transfer function from regulator current limit duty cycle to current limit. This transfer function is used to bound the limits of the regulator current limit feedback loop.
Increased the gains of the regulator current limit feedback loop to get faster response.
Updated the rules required to close the HV switch. The HV switch cannot be closed unless at least 20 Volts as already present on the HV terminal. This prevents the case where the switch is closed before a battery is connected - which can lead to large current surge in the input capacitors. This change affects the disabled state, which previously had no protection, and the states prior to cranking, which previously required 24V to close the switch, but now only require 20V. States from cranking to later (including generating) are unchanged).
New features for IntelliGen
- Added a new current limit value: the main battery charge current limit. When set to non-zero this current limit is used to limit the main regulator current output to prevent overcharging the main (28V/25V) battery.
Bug fixes for IntelliGen display
- Corrected timestamp handling of chart comments, for cases where time goes backwards (i.e. when IntelliGen is power-cycled).
New features for IntelliGen display
Added the ability the capture any window to pdf, or to capture the entire IntelliGen display, including all docked and floating windows.
Change the name of the display variable “Main Current” to “Regulator Current”, this reflects that the current in question is the output of the main regulator.
1.2.278 (20 January 2023) (1.2 First release)
New features for IntelliGen
Support for new analog signals in revision 3: external HV battery temperature sensor, regulator temperature, and current reference voltage.
Support for new digital signals in revision 3: the ability to programmatically select regulator voltage to match either 8S LiFePO4 battery or 6s LiIon.
Removed power5fault indicator and added regulator and HV batter temperature faults.
Updated the “faults” telemetry packet to include the new analog signals and renamed the packet to be “slow telemetry 2”.
New features for IntelliGen Display
User interface support for revision 3: new telemetry variables in the log and new configuration data for the external HV battery temperature sensor.
Added logic to update the communications settings when opening a project.
Version 1.1
1.1.272 (7 December 2022) (1.1 First release)
New features for IntelliGen
Removed the configuration option for maximum HV voltage deviation. HV voltage is now allowed to vary between 24V and the configurable maximum.
Added a HV battery charge model based on three numbers: the maximum HV output current, the HV charge voltage, and the HV battery resistance. These are used to compute a desired charge current (which can be negative if the battery voltage is too high).
Changed HV control architecture for the “HV is battery” case: if the switch is closed the generator PWM is controlled to manage the current in the generator, or the HV battery, whichever limit is lower. In this way the generator will charge the HV battery unless such charging exceeds the generator current limit.
Changed the current limit telemetry packet to remove the “bridge adjust voltage” (which no longer exists) and add the HV charge current command.
Changed regulator current limit logic for the not spinning case, such that the regulator output limit is set according to the amount of HV input (discharge) current allowed.
Removed the option for “HV follows load”, this logic is superseded by the HV battery charge logic.
Added configurable options to control the state of the LV1 and LV2 regulators, the main regulator, and the HV switch status when the system is disabled. This makes it possible to keep these devices enabled when the IntelliGen is disabled, allowing downstream devices to remain powered while IntelliGen is disabled.
Added feedback control for the main regulator current limit. Previously the current limit was set by a hard-coded transfer function between the desired limit (in Amps) and the duty cycle sent to the regulator. Now the duty cycle is adjusted using current feedback. The duty cycle sent to the regulator current limit circuit is now included in the current control telemetry.
Changed regulator feedback control such that when the HV switch is open the control feedback is based on the regulator current and the generator current. This enforces the generator current limit if it is less than the regulator limit. When the hv switch is closed the regulator current feedback is based on the regulator current and the hv discharge current, to enforce the hv discharge limit.
Changed energy used telemetry from Joules to kilo-Joules.
Changed the sign convention on the battery current. All current measurements now have the following conventions: positive indicates current flowing away from the generator, and negative indicates current flowing towards the generator. Hence when cranking the engine with the generator the generator current is negative, as is the HV or main battery current (whichever is used for cranking).
Added rectifier fault counter. Previously the rectifier fault signal was sampled at 500Hz, but faults can be indicated for very brief times; causing software to miss them. This new feature traps and counts every fault indication during the slow telemetry reporting interval, reporting the fault count in the telemetry.
Added current control loop for the heater switch control. The current control loop is enabled by setting a non-zero maximum heater current in the power configuration. In that case heater commands are interpreted as a percentage of that current, and a feedback loop is used to determine the heater duty cycle that achieves the commanded current. Heater current is not directly measured, it is computed as the sum of the regulator and battery current. The computed current may be more than the actual heater current if other loads are consuming power - which will result in less heater current than desired.
Added heater switch logic: if the main voltage (nominally 28V) browns out below the setpoint the heater command is ramped down, such that at 4.5V below the setpoint the heater command is 0. If the voltage falls below 18V the heater is turned off. If the heater is on, and the engine is commanded to crank, the heater duty cycle is set to 0% while the engine is cranking.
Updated engine starting logic: previously the cranking state exited when positive (generating) current was measured. Now the current command used for engine speed control is limited to 1 Amp in the generating direction, and the system remains in the cranking state until the crank timeout elapses, or the rpm exceeds the generator on threshold. This makes it possible for the IntelliGen to keep cranking an engine which is running intermittently as it starts up. The control configuration packet now specifies crank time in resolution of 0.5 seconds with a maximum of 127.5 seconds.
Added test mode feature for error injection and testing.
Added the option to configure the system to crank from both main battery and high voltage battery. When both options are selected the system will use the power source with the highest voltage.
New features for IntelliGen Display
Added replay option: “Auto Pause”. When enabled this feature will automatically pause the replay when a new sticky error is occurs, when a user comment is occurs, or when a scope capture occurs.
Added heater control toolbar which makes it possible to command different heater values and timeouts. Removed the simple heater on/off button from the main toolbar.
Added option to save configuration comparison results to a text file.
Version 1.0
1.0.244 (4 August 2022) (1.0 Update 1)
New features for IntelliGen firmware
- Removed the previous generation limits as a function of rpm and replaced with a table. The table makes it possible to reduce the generator current limit at higher speeds to unload the engine. The first entry of the table defines the rpm below which the system will leave the generating state. The second entry of the table defines the rpm above which the system will go the generating state. The table must have at least 3 entries.
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