Bifuel control system

BIFUEL MANAGEMENTSOLUTION PACKAGESINTELIBIFUEL 2 & INTELIBIFUEL 20

Description:

The InteliBifuel 2 and InteliBifuel 20 control system packages from ComAp are a comprehensive Bifuel (dual fuel) control solution for all diesel powered engines.

The two packages share a range of common features with the option of being used with any engine:

� InteliBifuel 2 (up to 6 cylinders in line) � InteliBifuel 20 (engines above

6 cylinders)

Both control packages feature: � InteliBifuel CU – a highly configurable

expandable Bifuel control unit with built-in PLC functions

� InteliBifuel DENOX – an anti-knocking system with multiple channels (2 for InteliBifuel 2 or 20 for InteliBifuel 20)

� InteliBifuel DFM – a Dual Fuel Module for fuel control and monitoring

� Software/firmware and documentation

The control modules can be fully integrated via CAN bus. Key parameters from all modules are accessible via the main display on InteliBifuel CU.

All key algorithms are field proven on many installations:

� The gas throttle valve control algorithm automatically increases and decreases the gas quantity dynamically across the engine loading range without any requirement for manual or regular adjustment from the operator, this feature ensures maximization of the gas usage safely.

� Knocking and misfiring detections protect the engine from any damage when the possibility of the gas quality exceeding the expected limits, or should combustion become unreliable due to an engine defect

� Diesel Fuel savings – substitute up to 80% of diesel consumption with gas

� Extending run times without refueling � Possible emission reductions

compared to original 100% diesel operation:• CO2

• NOx

• SOx

• Particulate emissions � Fuel flexibility and smooth transition

between diesel and Bifuel operations � Fully automatic and dynamic solution

mainly concerned with engine safety

and the safe control and modulation of the gas quantity to maximize the substituted gas

� Fully integrated system – all parts and parameters are monitored and accessible from a single point

� Solution for various types of gases – natural gas, well gas, landfill gas, coal gas, propane gas, biogas and others.

� Excellent remote monitoring features backed by sophisticated PC programs which are especially suited for fleet owners

Benefits:

Benefits: � Integrated solution with hardwired

safety functions – less wiring and components

� Full communication support of engines with ECU – simpler wiring, access to information from ECU via Modbus

� Event driven History recording, easy backtracking and problem solving

� Load sharing for propulsion engines – better power utilization of installed engines

� Slave panels available – economical solution for remote control

� Integrated clutch control – less wiring and components

� Many types of communication – easy supervision and servicing

� Perfect price/performance ratio � Built-in PLC-integrated control

of technology

Features � Bifuel system monitoring and

engine protection � 14 binary inputs, 14 binary outputs,

8 analog inputs � RS232/Modem/Modbus/Internet

communication � Engine measurement from sensors or

via J1939 � Input/output and J1939 configuration � Bifuel running hour meter � Graphic back-lit LCD display with

icons and bar graphs � Sealed membrane panel to IP65 � 180 × 120 mm front panel mounted case

� Operating temperature:• -20 to +70 °C regular unit• -40 to +70 °C low temperature unit

� 3 level password protection � InteliBifuel controller meets several

forcing counter standards (EN, UL, CSA, NFPA)

� Internal – configurable PLC functions

Configurable PLC functions � Logical functions: AND, OR, XOR, RS � Comparators with delay or

with hysteresis � Analog switch from two inputs to

one output � Mathematical functions: ADD, SUB,

MAX, MIN, AVG � Linear interpolation, Moving average � PID loops with analog or

binary outputs � Counters, Timers, Delay functions � History and protection forcing � Ramp Up/Down, Inc/Dec, Jump, � Programmable switches and others

Relay board I-RB8 / I-RB16 � 8 or 16 relays for ID-DCU (ID-RPU)

binary outputs separation � Each channel has both n.o. and n.c.

contacts available � LED state indication

Extension module and remote display possibilities

� up to 1× I-AOUT8 (Analog Outputs Extension Module)

� up to 4× IGL-RA15 (Remote Annunciator)

� up to 4× IGS-PTM (Input/Output Module)

� up to 4× IS-AIN8 (Analogue Input Module)

� up to 3× IS-BIN16/8 (Binary Input/Output Module)

� up to 2× I-RD-CAN (Remote Display with CAN Bus Interface)

Communication modules and PC tools

� IG-IB (Internet Bridge) � I-LB+ (Local Bridge) � I-CB (ECU Communication Bridge) � DriveMonitor (PC Monitoring Tool) � WinScope (Special Graphical

Controllers’ Monitoring Software) � DriveConfig (PC Configuration Tool)

Communication interface ID-COM

� Multi-controller and/or Remote display and IG-IB and/or I-LB+ (Local Bridge)

InteliBifuel CUDescription:

The InteliBifuel CU is the highly flexible main control unit of the ComAp fully featured InteliBifuel solution. This sophisticated Bifuel (dual fuel) controller has outstanding monitoring, protection and control features including allocation for J1939 or sensors or used for the conversion of any type of diesel engine to Bifuel operation.

The InteliBifuel CU protects the engine during Bifuel operation by controlling the gas throttle valve and gas shut off safety solenoid valves preventing the engine from exceeding any critical safety parameters.

This advanced controller is designed to communicate through both standard and proprietary CAN J1939 communication protocols to a wide range of EFI engines including: Caterpillar, Cummins, Detroit Diesel, Deutz, GM, Isuzu, Iveco, John Deere, MAN, MTU, Perkins, Scania, Sisu, Volvo Penta and others.

Designed to be highly flexible and versatile, the extended InteliBifuel product family offers a range of engine specific versions suitable for any type of Bifuel application.Tailored control requirements for specific applications can be met by means of available additional modules which offer multiple input and output configurations and possibilities.

A set of PLC (analog and binary) functions enable the customer to control and regulate any additional components and functions as may be required.

Bifuel Control System

Elements of the system

InteliBifuel DENOX 2 � Anti knocking device � Field proven solution of knocking detection � Integration with InteliBifuel CU controller via Analog and

Binary outputs � Parameters for adjustment accessible via

DenEdit software � 2 monitoring channels � Each channel can be configured for single cylinder

monitoring or for the monitoring of neighbouring cylinder � Suitable for all inline engines up to a maximum of 6 cylinders

InteliBifuel DFM � Dual-Fuel Module - interface unit for InteliBifuel CU

controller with Speed governor and Diesel actuator � Gas throttle valve servo control loop � Diesel consumption measurement via current loop

InteliBifuel DENOX 20 � Anti knocking device � Field proven solution of knocking detection � Integration with InteliBifuel CU controller via Analog and

Binary outputs � Parameters for adjustment accessible via

DenEdit software � Up to 20 monitoring channels � Each channel can be configured for single cylinder

monitoring up to 20 cylinders � Suitable for engine up 20 cylinders

Bifuel Control System

Package Order code

InteliBifuel 2InteliBifuel CUInteliBifuel DENOX 2 InteliBifuel DFMSoftware and documentation

IBF-2

InteliBifuel 20InteliBifuel CUInteliBifuel DENOX 20InteliBifuel DFMSoftware and documentation

IBF-20

You can get more information on

www.comapsystems.com

Elements of the system

Order codes

1ph/3ph

IS-AIN8

IS-BIN16/8

PC MODEM

InteliBifuel CU

BINARY INPUTS

CONFIGURABLE

BINARY OUTPUTS

CONFIGURABLE

RS 232C

485/232

INTERFACE

POWER SUPPLY

8 TO 36 VDC+ -

ID-COM

CAN1IG-IB

I-AOUT8

IGS-PTM

IGL-RA15

I-CB+

INTELIVISION 8

GENERATOR

DIESEL ENGINE

ECM

ANALOG INPUTS

CONFIGURABLE

I-RD-CAN

I-LB+

Engine knocking

sensors 2-20

J1939VALUES + Fault code

POWER SUPPLY

8 TO 36 VDC

+-

InteliBifuel DENOX 2

orInteliBifuel DENOX 20

TO OTHER ENGINES

FACTORY LAN

FIREWALL

CONTROLROOM

SERVICE

CENTER

INTELISUPERVISOR

INTERNET

CAN2

GAS THROTTLE

VALVE

PRESSURE

GOVERNORCLOSING

VALVESGASFILTERGAS

INLET

MIN GAS

PRESSURE

SENSOR

MAX GAS

PRESSURE

SENSOR

Engines operation parameters

Camshaft

position

Gas throttle valve Control line

4-20mA

IP

LOAD

MAINS

InteliBifuel DFM

IS-AIN8

IS-BIN16/8

InteliBifuel CU

BINARY INPUTS

CONFIGURABLE

BINARY OUTPUTS

CONFIGURABLE

RS 232C

485/232

INTERFACE

EX MODUL

POWER SUPPLY

8 TO 36 VDC+ -

HYDRAULIC PUMP

DIESEL ENGINE

ANALOG INPUTS

CONFIGURABLE

RPM

Engine knocking

sensors 2-20

J1939VALUES + Fault code

POWER SUPPLY

8 TO 36 VDC

+-

InteliBifuel DENOX 2

orInteliBifuel DENOX 20

GAS THROTTLE

VALVE

PRESSURE

GOVERNORCLOSING

VALVESGASFILTERGAS

INLET

MIN GAS

PRESSURE

SENSOR

MAX GAS

PRESSURE

SENSOR

Engines operation parameters

Camshaft

position

Gas throttle valve Control line

PRESSURE

InteliBifuel DFM

ECU

Bifuel Control System

Schematic diagrams

GEN-SET APPLICATION

PUMPS APPLICATION

Bifuel Control System

“Our company has installed over 60 ComAp Bi-Fuel kits to many different types of engines. The ComAp Bifuel solution technologies are without doubt the safest, most reliable and efficient systems in the world.

Our company is proud to promote a high quality product like ComAp Bifuel equipment and we have no hesitation to recommend this solution for Bifuel operation!”

Alex Hintz, Power Service Co.

Customer feedback

Brand Type DG set Output

Cummins VTA series 500 kW–600 kW

Deutz TBD series all outputs

MAN D2842LE201 400 kW

Mercedes OM444LA/12183TB83 440 kW

Perkins 2000, 3000, 4000 series 580 kW

SCANIA DC series 225 kW–520 kW

Volvo TAD series all outputs

Brand Type DG set Output

Caterpillar 3300 series 150 kW–220 kW

Caterpillar 3400 series 200 kW–650 kW

Caterpillar 3500 series 700 kW–2000 kW

Caterpillar C series 200 kW–1500 kW

Cummins KTA series 400 kW–1200 kW

Cummins QSK series 1100 kW–1800 kW

Cummins QST series 650 kW–800 kW

Brand Type DG set Output

Cummins VTA series 500 kW–600 kW

Deutz TBD series all outputs

MAN D2842LE201 400 kW

Mercedes OM444LA/12183TB83 440 kW

Perkins 2000, 3000, 4000 series all outputs

SCANIA DC series 225 kW–520 kW

Volvo TAD series all outputs

Examples of converted high speed engines

� Many other engine brands and models – for details please contact ComAp

References

Czech Republic Russia

� Phoenix Zeppelin Czech Republic � CAT C15, BOOMEL®250 DUAL � CHP power plant – Prime power operation � Bio Diesel + Bio Gas / Natural Gas

� ADD � 3× Perkins 4006-23TAG3A � Prime power operation � Raw Natural gas (well gas) � Extreme conditions – Siberia

bifuel.support@comap.czFor more information and Bifuel support contact us at:

Customer satisfaction is our mission. We continuously develop the best people to succeed in our mission.

© ComAp. Features and specification are subject to change without prior notice 2012-01/CSLEBFCS

ComAp, spol. s r.o.

Phone: + 420 246 012 111Fax: + 420 266 316 647E-mail: info@comap.czInternet: www.comapsystems.com

MANUFACTURER: LOCAL DISTRIBUTOR / PARTNER:

ComAp Bifuel Trainings

Practical and informative training on ComAp’s Bifuel range of products. Learn more about ComAp Bifuel products system solution.

Hands-on practical training is designed to help and to benefit all customers’ types of ComAp from a comprehensive practical learning experience. The training is delivered by experienced product specialists who are capable of demonstrating all of the functions of ComAp products.

Group or individual hands-on practical training sessions are held in our new vocational training centre which is equipped with a Bifuel engine.

Learn more about ComAp’s tailored solution and master valuable Bifuel know-how.

Master valuable know-how