The Supra Control System Integrates
- Engine Control
- Alternator Voltage Regulation
- Auxiliary Power Inputs
- Operator Interface
- Remote Site Monitoring and Communications
The Supra Model 250 System is a highly integrated control solution that will improve the reliability, serviceability, and remote controllability of DC generator power systems. The Supra Controller can control power to DC loads and serve as a fuel based programmable battery charging system.
Supra’s high level of circuit integration eliminates separate and independent control modules, simplifying the wire harness and eliminating the typical conflicts between modules integrated from different manufactures.
The Supra Controller based DC generator system can be: remotely controlled, monitored, calibrated, and tested, through an industrial modem, cell phone modem, or Ethernet. Communication is accessible locally with a PC Laptop or remotely through the Internet to facilitate site support and reduce costly visits to the site.
The Supra provides a complete log of alarms and operating parameters at the completion of a charge cycle or shutdown due to a fault condition. Alarms can be reset and the generator exercised remotely to help identify potential problems before scheduling a site visit. If an unscheduled maintenance is required, the technician can arrive at the site prepared, reducing the need for a second visit.
The Supra facilitates Hybrid Systems incorporating other sources of power including solar, wind, hydro, and utility.
All connections to the controllers are through Amp/Tyco Circular C type connectors facilitating onsite repair through controller swapping (plug and play).
The controller circuits were designed to meet the most stringent Military and Telecommunications requirements for EMI, EMP, and Ripple.
The Supra Controller can meet the requirements of any type of grounding requirement: negative, positive, or float.
Supra Advantages
1. Optically isolated RS 232 and CAN bus communications allow the generator to be controlled (locally or remotely) through a PC computer with Polar’s GUI or the customer’s own CAN bus.
2. Precision battery charging using control of both the voltage and current output. Battery charging using a single parameter of voltage control is insufficient because small milli-volt changes can cause undesirable, large current fluctuations
3. User configurable battery charging algorithms for different battery technologies. User configurable: current limit in bulk charge, temperature compensation curves, differentiation of load current and battery charge, and float voltages.
4. Control of Engine: RPM, starter motor, glow plugs, choke, fuel racks, fuel and engine block heaters, and cooling fans. Accurate monitoring of temperatures, pressures, coolant, and fuel levels.
5. Digitally controlled variable parameters: Digital control allows the generators, voltages, currents, engine speeds, and sensor calibrations to be remotely calibrated. All potentiometers were eliminated
6. Set points and recalibration can be performed remotely through the Internet, RS 232, Ethernet, or Cell Phone Modem using Polar’s GUI interface.
7. Software is field upgradeable.
8. 10 bit A/D converters and optically isolated linear amplifiers provide accurate voltage, current, fuel level, oil pressure, temperature, and engine speed measurements.
9. Sensor and communications ports are isolated, so the failure of an input sensor or communications port will not contribute to system conflicts and issues.
10. High immunity to electrical noise. Sources of noise include the starter motor, spark plugs, lightning, coupling of AC sources, cell phone transmissions, microwave, and radar transmissions.
11. Very low conductance and radiation of EMI: A clean DC Power Source is incorporated for the provisioning of sensors, field coils, and actuators with a resultant effect of a reduced EMI source. This is unlike other controller manufacturers, who typically use an unfiltered PWM source of power. Polar Power also increases EMI suppression by housing the three models 250, 290 and 320 in sealed Aluminum enclosures.
12. Polar’s unique circuit provides reliable operation in floating, positive, or negative ground systems. Polar uses switching power supplies to isolate both the positive and negative inputs. Most other controllers use a lower cost 3-pin voltage regulator that creates problems when moving between positive and negative ground systems.
13. The power supplies input and output signals and is fully isolated for up to 1500 Volts, via opto and galvanic couplers. The Supra Control System can tolerate most Hipot testing with controls connected in place.
14. Superior high voltage and current surge immunity from lightning, alternator surges, and load dumps with active voltage clipping circuits.
15. Supra’s microprocessor and relays are able to operate under low voltage conditions during engine cranking with a starting battery in poor condition.
16. AMP / Tyco Circular C type connectors are used to maintain a high degree of reliability and provide ease of field service. Signal pins are gold plated and power pins are silver plated, providing low maintenance operation in high humidity, salt fog, and sandy environments.
17. Model 250 and 290 enclosures are gasket sealed to IP64.
18. Conformally coated circuit boards: all components are soldered in place, except for fuses in the Model 290 module.
Supra Control System
The advantages of Polar's highly integrated control system:
-
- No conflicts with Reference/Calibrations
- Wiring harness is very simple
- One vendor is responsible for the configuration management of hardware and software
- Plug-and-play for troubleshooting and repair
- All electronic components have extended temperature performance
- Lower-cost for a completely configured system
Competitor/Old
Disadvantages with multiple modules from various manufacturers in the same generator system:
- Reference/Calibrations (i.e. voltage, current, engine speed) will be different from module to module
- Connector systems will be different
- Wiring harnesses are larger and more complicated
- Configuration control is limited as various vendors make changes to their product
- Component and assembly costs are significantly higher
- For repairs and troubleshooting changing wires on terminal strips in the field presents problems as there is always the possibility of reversing wires
Supra MCS 2020
Master Control and Monitoring System
Site Monitoring and Control
The Supra2020 controller is a Master Controller that manages and controls one or many Polar Power generators and other connected 3rd party devices.
Advantages
| • Site / System monitoring • Integrated Calibration and Control Settings • Green Priority – Solar over generator • Generator runtime scheduling • Generator rotation scheduling • CAN and MODBUS device monitoring • Battery BMS • Solar Controller • CAN and MODBUS device integration • History Tracking and Export | • SMS and E-mail Alerts • Maintenance • Warnings • Critical • Site Logs • NOC Integration • User Accounts with Change Log • Backup and Restore functions • -40° to 55° C operational range |
Design Performance
• Supports all system voltage ranges
• Gives charging priority to Alternative Power
• Runs independently
• Works with all carriers
• Limited data usage
Supra 2020 Controller Features
The Supra 2020 controller integrates a hybrid system using the following features.
Site and System Monitoring and Control
• Our unique controller allows system monitoring and integration with multiple Polar Power generators and 3rd party devices, such as batteries and solar systems.
• Perform all settings and calibration within the web interface, accessible from anywhere
when connected to an internet-connected router.
• Controller runs independently and allows generator controllers to also run independently
as a backup to the Supra 2020. If there is ever a problem with the controller or communication
between the controller and the generators, the generators will run themselves as required.
• A touchscreen display can be used with the controller for local control and operation.
• History data, including charts, can be viewed and generated. The data from the
charts can be downloaded for further analysis.
• Settings and data are automatically backed up daily and can be used to restore the system or
make a duplicate of the system settings.
• Settings can be imported and exported for easy duplication from system to system.
• An overview page makes it simple to see that the system is functioning properly and time remaining for required maintenance.
Generator Runtime Scheduling
• Generator charging and exercise / equalize profiles can be scheduled daily/weekly/monthly.
• Scheduling is integrated with solar controllers to give charging priority to the solar controller when
available.
NOC Integration
• An API allows server requests for specific site information. All pertinent information about the system can be polled from the controller.
• API allows settings to be updated for any or all connected controllers.
• API allows for user management.
• Software updates can be pushed out to any or all controllers.
• Subscriptions are available for API access.
Optional Devices
GPIO Board
Adds switch inputs and relay outputs to the Supra2020. Utilizes common
connectors for ease of install.
Available in various configurations. Standard config has:
• 8 Digital Inputs
• 6 Relay Outputs
• 2 CAN Channels
Supra2020 w/ GPIO
Multifunction Interface Board (MFIB)
Adds analog inputs and outputs and switch inputs. Provides a sealed enclosure
(available) with common connectors.
Includes:
• 8 Analog Inputs (Current 4x, Temp 4x, Voltage 2X)
• 4 Digital Inputs
• 4 Relay Outputs
• 1 PWM Output
• 1 CAN Communication
• 1 RS232 Communication
MFIB
UI Features
Quickly view historical runtimes and pertinent data on the Overview Page
View the status of each generator
Create a customized run schedule
Add external devices
Product Comparison
Polar’s Supra2020 vs Supra Controller
Supra 2020 Controller
• Allows integrated control of up to 2 Polar gensets.
• Integrates with 3rd party devices
• Remote monitoring and control for entire system
• Provides history data
• E-mail and text alerts
• Provides complete fault history logs.
• API for NOC integration
Supra Controller
• Controls 1 Polar genset
• Does not integrate with 3rd party devices
• Remote monitoring for individual genset
• System log information for starts, stops, and faults
• No e-mail or text alerts
• Cogeneration and CHP
• Limited fault information other than critical faults
• Generator information only available through GUI
• Lower cost
When to add the Supra 2020 Controller
• Auto Rotation between 2 gensets
• Connecting multiple DC gen outputs
• Interfacing with 3rd party controllers
• NOC integration
• Datalogging system
• E-mail or Text alerts
Preferred applications for Supra 2020
• Dual gen applications
• Multi-site applications
• Renewable hybrid power systems
• Battery charging applications
Limited Warranty - Refer to website for details.
Remote CMCS
Centralized Master Control System
Overview
Polar’s CMCS (Centralized Remote Control and Monitoring) Software provides the means to collect data and alarm information from a few sites to thousands of sites. The CMCS polls the data from each SUPRA MCS (Master Control System) in the field. It can function as a complete NOC center or provide API data/alarms into an established NOC. Increasing the monitoring aspects of the site and having it convenient greatly improves
the site maintenance and reliability.
The SUPRA MCS controller monitors and controls the Supra 250, while monitoring other devices on the site, including the battery BMS, solar MPPT, site temperatures, etc. The SUPRA MCS is an industrial computer operating on Linux.
The CMCS interfaces with all SUPRA MCS’s installed on each site then captures the data locally and presents the data, alarms, and analytics to a
dashboard to view.
Existing NOC Centers can send API requests to the SUPRA MCS’s at the sites, thereby greatly increasing its ability to site monitor.
This solution is different from the competition for many reasons, including the changing of performance settings, diagnostics, direct access to the SUPRA MCS, manage Remote Software Updates, and more. CMCS does not require an IOT platform and can be directly integrated into the company’s server. Data retrieved by the NOC can be stored locally or in the IOT.
Polar Power provides a usable interface that can perform most common functions. The interface can be easily updated to include additional features and information. Data retrieved by the CMCS can be stored locally or in the IOT. Source code is supplied to enable modifications to the interface and to direct the data output to the desired source.
The SUPRA MCS controller monitors and controls the Supra 250, while monitoring other devices on the site, including the battery BMS, solar MPPT, site temperatures, etc. The SUPRA MCS is an industrial computer operating on Linux.
The CMCS interfaces with all SUPRA MCS’s installed on each site then captures the data locally and presents the data, alarms, and analytics to a
dashboard to view.
Existing NOC Centers can send API requests to the SUPRA MCS’s at the sites, thereby greatly increasing its ability to site monitor.
This solution is different from the competition for many reasons, including the changing of performance settings, diagnostics, direct access to the SUPRA MCS, manage Remote Software Updates, and more. CMCS does not require an IOT platform and can be directly integrated into the company’s server. Data retrieved by the NOC can be stored locally or in the IOT.
Polar Power provides a usable interface that can perform most common functions. The interface can be easily updated to include additional features and information. Data retrieved by the CMCS can be stored locally or in the IOT. Source code is supplied to enable modifications to the interface and to direct the data output to the desired source.
Capabilities and Use-Cases
The CMCS can monitor multiple sites concurrently. It gathers real-time snapshots of most data linked to the SUPRA MCS.
The included sample interface features a sortable and customizable information table and an expanded view of all data.
The API which powers the CMCS can access most of the settings and information inside the SUPRA MCS, including adding, editing, and disabling user accounts, as well as setting Alert Triggers and working with Digital I/O (GPIO) devices.
The following are specific uses of the NOC and API software:
• Multi-generator sites
• Centralized bulk user administration
• Real-time performance monitoring
• Real-time fault/alert management
• Remote updating of SUPRA MCS software
• Remotely Backup, Export, and Restore data
• Remotely download configuration file(s)
• Remotely trigger a system reboot
Customizing the dashboard view columns
Site Settings
Fetching all settings
Add a Site
Import System Settings
Import Schedule Settings
Security
Security is a primary consideration of Polar’s development team. The API supports a user-specific API key and full logging of all actions. All queries are performed via secure HTTP/POST connections and gain permission from the Polar Power server. All communication between the CMCS and the Supra MCS units is secured by an encrypted HMAC signature to prevent unauthorized access to the private Supra MCS API. All data stored on the SUPRA MCS hardware is fully encrypted.
Future Development
Future Development
Development focus is on converting all existing functions of the SUPRA MCS software to API-compatible formats. Upon completion, a 3rd party application will be able to change all system settings and activate all live controls. Customers will be able to fully integrate Polar Power devices into their own custom software solutions.
With the high levels of past and ongoing data collection AI can be applied to a great number of tasks including:
Troubleshooting
Site problems down to the component levels within the generator, battery banks, solar MPPT controls,
Solar PV modules, circuit breaker status, site maintenance and other accessories.
AI Optimization
Energy usage by analyzing patterns and suggesting adjustments to improve efficiency and extend the lifespan
of batteries. Polar DC gensets offer the most efficient generators for powering a site. These gensets are
programmable and can be further optimized by AI.
Preventative AI analytics
Identify specific issues, such as malfunctioning components or connectivity problems, and provide actionable insights for quick resolution. Receive notice well in advance of a potential issue. This gives enough time to get replacement parts to a site.
AI predictive maintenance
By leveraging machine learning algorithms, AI can predict potential failures before they occur, enabling proactive maintenance and reducing downtime.
AI analysis of faults
Use AI to determine when and why a fault occurred. Integration with remote access tools allows technicians to diagnose and address issues without physically visiting the site.
Feature Summary
Included Features
- Network connectivity Status: Specific description of online or cause of no connectivity.
- Summary of unit(s) being managed by controller: Quickly view which sites are setup and being managed by the SUPRA MCS and which sites are configured
properly for backup control. - Fetch live operational data from unit(s): See any data that is available in the SUPRA MCS and connected 3rd party devices.
- Access all system data: All data for Polar gensets and 3rd party devices is available when attached to the SUPRA MCS. This includes Fuel Level, Maintenance Interval, etc.
- Directly connect to a site: Select any site and jump right to the SUPRA MCS control interface for advanced monitoring and control features, as well as historical plots ranging back years.
- Configure custom dashboard to track operational data: Create live charts quickly for any combination of data. Pin the charts to the dashboard.
- Export and Import Data: Data retrieved by the NOC Center is stored in memory. It can be exported for analysis and imported for quickly viewing a combination of charts with past data.
- E-mail and Text Notifications: Define which users receive Maintenance, Warnings, Critical Alerts alert levels. Apply settings across all or selected sites.
- View and Edit control settings: All system control settings can be viewed and modified from the Polar NOC Center. Quickly see all settings in a table and identify sites with incorrect settings. Change settings for any or all sites at once.
- Clone Settings across sites: Select a site with the settings to be cloned and apply the settings to any or all the sites at once.
- Backup and Restore unit data/settings: Backup and restore the entire SUPRA MCS database, or specific tables from the database, including Generator Settings, SUPRA MCS Settings, System Settings, Alert Triggers, Devices, and Factory Constraints.
- Manage user accounts on all or selected unit(s): Add, Modify, or Disable user accounts on any or all sites at once.
- Manage scheduler: Enable or Disable the scheduler for any or all sites. Clone a complete schedule across any or all sites.
- Install updates to unit(s): All SUPRA MCS software updates can be applied at any time to connected sites. Choose when to apply updates and always have the latest SUPRA MCS features and updates.
- Reboot unit(s): SUPRA MCS units at any or all sites can be rebooted from the NOC Center.
- IOT not required: Uses API requests and responds with the data table. Data can be stored locally or sent to the IOT.
- Access diagnostic data (Know what's wrong before going to site): See all data and make an informed decision on which test equipment or replacement system equipment will be needed before traveling to the site. Control settings can also be modified for immediate response to a component failure.
Planned Features
Ongoing development of new and requested features
