hsc – id-bf - applied power engineering€¦ · hsc - id-bf - operator guide ... - 28 - no...

Copyright © 2009 ComAp s.r.o. Written by Ladislav Kadaník, Jiří Patera Prague, Czech Republic

ComAp, spol. s r.o. Kundratka 2359/17, 180 00 Praha 8, Czech Republic Tel: +420 246 012 111, Fax: +420 266 316 647 E-mail: [email protected], www.comapsystems.com

Operator guide

InteliDrive

HSC – ID-BF High Speed Conversion Kit

Based on iD-BF Controller

High Speed Conversion Kit Operation

September 2009

HSC - iD-BF - Operator Guide, ©ComAp – September 2009 - 2 - ID-BF - Operator Guide r2.pdf

Table of Contents Table of Contents .......................................................................................................................................... - 2 -

Abbreviations............................................................................................................................................. - 4 - Conformity declaration .............................................................................................................................. - 6 - Adjust set points........................................................................................................................................ - 6 -

General description ....................................................................................................................................... - 7 - Basic operation.............................................................................................................................................. - 8 -

Bi-fuel conversion kit principles................................................................................................................. - 8 - Controls ................................................................................................................................................... - 10 - Gas Train................................................................................................................................................. - 13 - Conversion kit components..................................................................................................................... - 14 -

Principle of operation................................................................................................................................... - 18 - Gas throttle valve control ........................................................................................................................ - 18 - Conditions for Bi-fuel operation............................................................................................................... - 18 - Default Shutdown and Slow stop of the gas ........................................................................................... - 18 - Protections smoothly limiting the gas delivery ........................................................................................ - 19 -

Operator Interface ....................................................................................................................................... - 20 - Pushbuttons and LEDs ........................................................................................................................... - 20 - How to select engine mode ?.................................................................................................................. - 20 - Display menus......................................................................................................................................... - 21 - How to view measured data?.................................................................................................................. - 21 - How to view and edit set points? ............................................................................................................ - 21 - How to use the Fast- edit function? ........................................................................................................ - 21 - How to view the HISTORY menu?.......................................................................................................... - 21 - How to check the serial number and software revision? ........................................................................ - 21 - How to change the display contrast ? ..................................................................................................... - 21 - How to change the display backlight intensity ? ..................................................................................... - 22 - How to change controller language ? .................................................................................................... - 22 - How to find active alarms ? ..................................................................................................................... - 22 - Controller screens ................................................................................................................................... - 22 - Functions available from ID-BF front panel keys .................................................................................... - 25 -

Operation instructions.................................................................................................................................. - 27 - Operational modes.................................................................................................................................. - 27 - Manual operation mode - MAN ............................................................................................................... - 27 - Automatic operation mode - AUT............................................................................................................ - 27 -

Alarm management ..................................................................................................................................... - 28 - No protection........................................................................................................................................... - 28 - Warning ................................................................................................................................................... - 28 - Bi-fuel Shut down .................................................................................................................................... - 28 - Bi-fuel Slow stop ..................................................................................................................................... - 29 - Sensor fail detection................................................................................................................................ - 29 - Broken wire ............................................................................................................................................. - 29 - Exhaust temperatures protection principles............................................................................................ - 29 - Alarms indication..................................................................................................................................... - 30 -

iD-BF supervise and configuration (basic information) ............................................................................... - 31 - How to install PC SW?............................................................................................................................ - 31 - Upgrade of iD-BF firmware ..................................................................................................................... - 32 - Virtual COM Port driver (VCP) ................................................................................................................ - 33 - How to connect PC to ID-BF controller ? ................................................................................................ - 34 - How to start DriveMonitor ?..................................................................................................................... - 34 - How to open communication of DriveMonitor with ID-BF controller? ..................................................... - 34 - Information available in DriveMonitor...................................................................................................... - 35 - Control window........................................................................................................................................ - 36 - How to download ID-BF controller history and store the history file? ..................................................... - 37 - History window structure ......................................................................................................................... - 38 - Setpoints window .................................................................................................................................... - 39 - Password protection................................................................................................................................ - 39 -


Technical data ............................................................................................................................................. - 40 - ID-DCU.................................................................................................................................................... - 40 -


Abbreviations Aid Archive file extension for InteliDrive controller AIN Controller or extension module Analog input Alarm General term for any active engine protection Warning, Shutdown, … etc. Alarm list

Controller or PC DriveMonitor screen with list of active and unaccepted alarms detected from ID controller.

ECU Alarm list

Controller or PC DriveMonitor screen with list of active and unaccepted alarms detected from engine ECU.

AOUT Controller Analog OUTput or outputs group. Archive

Usually aid file that contains all controller data: configuration, setpoints setting and history records.

Bi-fuel Bi-fuel operation i.e. diesel fuel as ignition portion plus gas fuel as main fuel BI Controller binary input. BIN Controller binary inputs group. BO Controller binary output. BOUT Controller binary outputs group. CAN Control Area Network – serial data link. D+

Controller function for battery charging function check and/or engine running indication.

DC DriveConfig, PC software for InteliDrive configuration. DM DriveMonitor, PC software for InteliDrive monitoring. DriveConfig PC software for InteliDrive configuration. DriveMonitor PC software for InteliDrive monitoring. ECU Engine Electronic (injection) Control Unit. ECU alarm Alarm detected in engine electronic control unit that is received via J1939. Fls Controller sensor fail alarm. FMI Failure Mode Identifier. GSM modem Modem for Global System of Mobile communication History

List of alarms and operational states with Reason, Date and Time and adjustable values set that is stored in controller, can be listed from the screen or DriveMonitor.

I-AOUT8 Controller extension module with 8 analog outputs: 10V or 20mA. I-CB

Inteli – Communication bridge = controller interface for other electronic engines like MTU, CAT etc.. that are not supported yet.

ID InteliDrive controller. ID-COM

InteliDrive communication module with interface to J1939, J1587 and to other controllers.

ID-DCU InteliDrive – DieselControlUnit. ID-MCU InteliDrive – Industrial Controller Unit with Volvo Penta front panel modification.

IG-DFM Dual-Fuel Module = interface unit for InteliDrive controller (gas throttle valve servo, Diesel consumptiom measurement.

IG-IB InteliGen – Internet Bridge = controller interface for internet communication. IGL-RA15 Remote Anunciator = external 15 LED indication panel (three colors, configurable). IG-MU I-LB

InteliGen – Modem Unit = controller interface for multiple engines application – one point communication with group or one point modem connection.

IGS-PTM Controller extension module with 8 binary inputs and outputs and 4 analog inputs. I-RB Inteli Relay board = interface board with 16 free contact relays. I-RB16 Inteli Relay board = interface board with 16 free contact relays. I-RD

Inteli Remote Display (Remote Panel) = the same panel like on controller, all data received via CAN2 bus.

I-RD-CAN


I-RP


IS-AIN8 InteliSys – Analog input module = extension module with 8 analog inputs.


IS-BIN16/8

InteliSys – Binary input/output module = extension module with 16 binary inputs and 8 binary outputs.

J1587

The J1587 bus is mainly used for redundant signals; system diagnosis and software download on after market tools.

J1587/J1708 See J1587 J1939 The J1939 bus in mainly used for engine controls and engine monitoring. KWP2000 Scania Communication protocol. Mhx Extension for controller firmware (Motorola HeX file). MID Message Identification Assignments. OFF

Controller mode when power supply is switched on, but all binary outputs and start commands are disabled = engine start is blocked.

PID J1939 Parameter Identification Assignments. PPID J1939 Proprietary Parameter Identification Assignments. PCB Printed Circuit Board PSID J1939 Proprietary Parameter Identification Assignments. RS232

Standard serial data line for PC or Modem connection (controller programming or monitoring).

Sd Shut down Gas protection. SID J1939 Subsystem Identification Assignments. Stp Stop Gas protection Wrn Warning protection.


Conformity declaration

Following described machine complies with the appropriate basic safety and health requirement of the EC Low Voltage Directive No: 73/23 / EEC and EC Electromagnetic Compatibility Directive 89/336 / EEC based on its design and type, as brought into circulation by us.

!!! CAUTION !!! Always properly connect grounding terminals!

Adjust set points All parameters are preadjusted to their typical values. But the set points in the “Basic settings” settings group !!must!! be adjusted before the first startup of the gen-set.

!!! WRONG ADJUSTMENT OF BASIC PARAMETERS CAN DESTROY THE ENGINE !!!

The following instructions are for qualified personnel only.

To avoid personal injury do not perform any action not specified in the User guides for ID-DCU Marine or ID-DCU Industrial !!!

WARNING – VERY IMPORTANT !!!

Be aware that the binary outputs can change state during and after software reprogramming. Before the controller is used again ensure that the proper configuration and setpoint settings

are set in the controller.

Disconnect the Binary outputs to avoid unexpected automatic start during any work or maintenance on the engine or switchboard.

Note: ComAp believes that all information provided herein is correct and reliable and reserves the right to update at any time. ComAp does not assume any responsibility for its use unless otherwise expressly undertaken.


General description This guide provides general information on how to operate the InteliDrive controller. More detailed information is available in the User guides for ID-DCU Marine or ID-DCU Industrial. InteliDrive ID-BF is a specialized engine controller for high-speed Bi-fuel applications. It controls, monitors and protects the engine in bi-fuel operational mode. The controller can communicate with Engine Management System via the CAN serial line using standard J1939 or another (MODBUS) communication protocol.

InteliDrive controllers are equipped with a powerful graphic display with icons, symbols and bar-graphs for intuitive operation, which together with high functionality sets new standards in engine controls.

Engine functions • Engine bi-fuel operation sequencing and control • Engine monitoring and protections (2 or more level analog inputs protection, adjustable delays) • Running hours meter, count-down of maintenance perion • Configurable 14 Binary inputs and Outputs and 8 Analog inputs • Setpoints are adjustable via InteliDrive panel or via PC software • 3 level password protection • On screen Alarm and ECU Alarm indication • Event and time driven engine history for back tracing • Two or more languages selectable in controller Communication • RS232 / Modbus RTU • Analog or GSM modem • Internet • Engines with Engine Electronic Control Unit: J1939, MODBUS • Extension units for more I/O and Remote Display panel. Physical • 180x120 mm front panel mounted case • Graphic back-lit LCD display 128x64 pixel resolution with icons and bar graphs • LED status indicators / Lamp test

Conformity declaration

Following described machine complies with the appropriate basic safety and health requirement of the EC Low Voltage Directive No: 73/23 / EEC and EC Electromagnetic Compatibility Directive 89/336 / EEC based on its design and type, as brought into circulation by us.


Basic operation

Bi-fuel conversion kit principles

exhaust

pickup

SYSTEMANTIKNOCKING

current

diesel actuator

senzor

turbine

injection equipment

air filter

intercooler

senzorknocking

supercharger

blender

GAS TRAIN

water

gas

actuator

suction

BI-FUEL CONTROLSYSTEM

active

throttle bodygas filter

senzorpressure

Engine governor

flywheel

camshaft

safety-valvedouble

regulatorgas pressure

valvehand

pressuresenzor

senzortemperature

senzortemperature

2

3

4

5

6

7

89

10

1GENERATOR

SWITCHBOARD

Power transducer

InteliDrive

The Sensor/Actuator numbers are used in the text below to identify the Sender/Actuator. 1. Generator active power measurement Active power is one of the main entries into the regulation. Actual power of the generator is evaluated from voltage and current measured by common three-phase transducer.

2. Gas Pressure after Pressure Regulator This binary (contact) sensor is used for Shut down protection of engine in case of failure of Gas Pressure Regulator. Connect this sensor to controller binary input RegGasPress (see setpoint Diesel protect:RegGasPr del).

3. Boost Air Temperature


This PT100 sensor is used for two-stage protection of the engine. If too high temperature is measured, first warning and then gas shutdown is generated – see corresponding setpoints in Engine protect group.

4. Exhaust Gas Temperature (left and right) Those sensors are used for two-level protection of the engine. If too high temperature is measured, first warning and then gas shutdown is generated.

Increasing Exhaust temperature causes Gas throttle valve limitation (FLSR function) – see setpoints Diesel protect:Exhaust TmpLim, ExhaustTmpGain, ….

5. Gas Pressure before Gas Pressure Regulator This digital sensor is used for protection of engine in the case of gas drop during bi-fuel operation. If gas drop is detected, shutdown of gas occurs. Connect this sensor to controller binary input LowGasPress.

6. Knocking sensors (each cylinder) These sensors, together with the DENOX20 anti-knocking controller, are used for the protection of engine in case of knocking. Denox output 4 – 20mA must be connected to controller analog input.

7. Timing sensor (active pickup) on Camshaft DENOX20 anti-knocking controller uses this sensor.

8. Double gas safety valve On – Off valve is opened for bi-fuel engine operation, when all bi-fuel operation conditions are met. ID-BF controller controls valves by Binary output GAS OK.

9. Throttle body actuator This actuator is controlled by pulse width modulation signal (PWM) in the range 0% (fully closed) to 100% (fully opened) during Bi- fuel operation. The position of the Throttle valve defines the amount of gas delivered to the engine.

10. Diesel flow sensor This sensor measures the electrical current energising diesel actuator. Another solution is the measuring of the flow of the diesel fuel by an transducer with electric impulses output. By electronic engine the value is provided by ECM unit through communication channel. The purpose of the sensor is to keep the Diesel portion above the level that is necessary to ignite the gas-air mixture in the cylinder. There is two-stage protection: the first stage (Diesel protect:DieselLimMin, DieselLImGain) is smooth protection limiting the gas by gently closing the Throttle valve, the second stage (Diesel protect:DieselLimCls) is immediate gas shutdown.

The Bi-Fuel Kit delivers gas to the each cylinder through the standard engine air-intake system and air-gas mixture is ignited by a diesel. System automatically operates and adjusts the flow of natural gas.


Controls

A – HSC Panel The main part of the Bi-fuel conversion kit

1. iD-BF Controller iD-BF controller is the main controller of the Bi-fuel conversion kit. How to handle control pushbuttons of iD-BF controller is described in “Standard operating procedures” chapter.

2. STOP GAS (Emergency diesel) Emergent transition to diesel operation mode. The pushbutton starts the immediate transition to diesel operation mode while closing gas solenoid valves. Pushbutton with arrestment device spring.

Use this pushbutton only in emergent situation because the immediate transition to diesel operation mode produces generated power stress.

3. POWER 24VDC Switch The power supply switch ON/OFF of the of control panel.

A

2 1

3 4

5

6

7


The switching off the power supply of HSC panel during Bi-Fuel operation is very non cultured “emergent diesel” function. To close the gas immediately use pushbutton STOP GAS or EMERGENCY DIESEL mentioned above.

4. KNOCKING Lamp Knocking alarm lamp. The light is ON, while knocking detector DENOX detects significant value of detonations.

5. ALARM Lamp General Alarm lamp. Any warning and protection initiate this signalization. It is lightening until FAULT RESET pushbutton is pressed.

6. DIESEK OK The light is ON if genset is running & ready for Bi-Fuel operation. That means all conditions for transition and running in Bi-Fuel operation mode are fulfilled satisfied?.

7. GAS The light is ON if genset is operating in Bi-Fuel mode.

B – HSC Panel – inside view

5

4

3

2 1


1 Extensional unit of analogue values measuring 2 Knocking detector unit 3 Supply circuit breakers 4 Control relays 5 Sensors and interconnections terminal strip

B – HSC Panel – inside view of the door

1 Basic control unit iD-BF 2 Technology interface iG-DFM 3 The place for communication support unit iD-COM

1

2

3


Gas Train

6 5 9 7 4 3 8 2 1

1. Manual Ball valve Manual security ball valve gas in inlet to gas train. Security valve has to be closed while the bi-fuel operation is not possible (not allowed) for longer time.

2. Gas filter Standard dust filter. The filter must be periodically checked and cleaned.

3. Electromagnetic gas valves The cascade of two pieces is used for security reasons

4. Gas pressure regulator The gas pressure regulator controls the difference between gas pressure mixer inlet and air suction pressure. The difference must be constant and independent on the actual power to achieve the proper function of Gas actuator 5 – see bellow. Control value of air pressure is fed by hose 7 – see bellow.

5. Gas actuator Gas throttle valve and valve position feedback sensor. The gas portion is controlled by iD-BF through this actuator

6. Gas distributor The device distributes the gas to two turbocharger inlets to reach balanced work of left/right cylinder bank of engine.

7. Boost air pressure feedback The hose leads the feedback air pressure from suction manifold to gas pressure regulator.

8. Inlet gas pressure sensor Contact sensor. If the pressure of the fuel gas is to low then the bi-fuel operation is not allowed or it is abandoned


9. Gas pressure sensor measuring the pressure downstream gas pressure regulator

Contact security sensor. The sensor activation is token as Gas actuator failure. The bi-fuel operation is abandoned immediately.

Conversion kit components

Gas pressure sensors

There is one pressure switch installed on the gas train. One on the gas filter block, which has a function to inform us in the case of gas supply breakdown. The switching pressure value of the switch is minimal allowed value before gas train. Pressure level tuning is executed by adjustable bolt which is situated in the center of switch.

Boost air temperature sensor (Boost Air Tmp)

Its function is to measure temperature of boost air after intercooler. The thermoresistive element Pt100 should be mounted after the turbo-charger downstream aftercooler ( if engine has it ) before intake cylinders. Boost air temperature radically ipacted proper Bi-fuel system function


Exhaust Gas Temperature sensor (Exh Tmp)

Their function is to measure temperature of exhaust gases, which goes from each bank of cylinders, behind the turbines of turbochargers.

Denox sensor

Their function is to sense mechanical vibrations in the place which is competently close to the combustion chamber. By means of this signal following analyze is recognized whether detonating combustion occurs.

Camshaft Position Sensor


Its function is to send the information to control system that combustion process of some cylinder is in some phase just now. In the concrete, our effort is that this chosen mark will mean the compression top dead center of the first cylinder. (TDC of Cylinder No1)

Diesel Fuel Flowmeter

Their function is measure quantity of fuel consumption. The device is used if it is not posible to measure diesel actuator position.

Electromagnetic Gas Throttle-valve

Gas Pressure Regulator Outlet Pressure to Engine Gas regulator outlet pressure is the most important tuned parameter on the mechanical part of conversion kit. Gas mass flow depends directly on this pressure, it means final dual ratio also. Regulator spring compression indicates difference between regulator outlet pressure and reference pressure (underpressure after engine air filters). This is a way to set total pressure gradient to constant. Gas regulator outlet pressure has to be in according with proper throttle regulating range.


Gas Mixer

The function of gas mixer is to create a mixture, which is consists of natural gas and inletting air. By this arrangement it’s not necessary to make a homogenous mixture directly in the mixer, because these components will be intensively mix up during following passage thorough compressors of turbochargers.


Principle of operation

Gas throttle valve control

FLSRDieselLimMinDiesel GainDieselDecRmp

PWM

4 - 20 mA Detonation signalfrom DENOX

Engine power

Diesel actuator current

Gas throttlevalve position

GasRegulOffset

-

-

Engine power [ kW ]Gas

Thro

ttle

1-10

0 [ %

]

FLSRExhaustTmpLimExhaustTmpGainExhaustDecRmp

Exhaust Temperature

Convert Power

DetonationFromDetonation Lim

Gas Request

Gas Regul

Gas Valve

DieselLimCls

EngineShut down

Gas throttle valve position is controlled by BoostPress – GasThrottle setpoints (curve) when all conditions for Bi-fuel operation are OK.

Conditions for Bi-fuel operation • Mode MAN or AUT • Binary input GAS DISABLE is not activated (if configured) • Binary input GAS ENABLE is activated (if configured) • No unconfirmed and no active Shut down and/or Stop alarms present • Gen-set is running • Transition to bi-fuel operation mode is possible only if actual

Engine power > Diesel protect:Min Power. • The genset leaves the bi-fuel mode if

Diesel power < Diesel protect:DieselLimCls; • The genset leaves the bi-fuel mode if

Engine power < (Diesel protect:DieselLimCls + Diesel protect: Min Power)/2 • No knocking sensor “Sensor 6” failed • No DENOX fail • Previous bi-fuel operation mode was terminated more than 10secs ago.

Default Shutdown and Slow stop of the gas • Exhaust temperature (Left and Right on Vee engines); “Sensor 4” – analog signal, with two-stage

protection (warning and slow stop). If too high temperature is measured, gas slow stop is accomplished.

• Boost Air Temperature; “Sensor 3” – analog signal, with two-stage protection (warning and slow stop). If too high temperature is measured, gas slow stop is accomplished.


• Gas Pressure downstream the Gas Pressure Regulator; “Sensor 2” – binary signal used to protect the engine in case of failure of Gas Pressure Regulator. If too high pressure of gas is detected (and contact is activated), immediate gas shutdown is accomplished. The period of gas shut-off opening (Gas OK output) is spanned for Diesel protect:RegGasPrDel.

• Gas Pressure upstream the Pressure Regulator; “Sensor 5” – binary signal is used to protect the engine in the case of gas drop during bi-fuel operation. If gas drop is detected, shutdown of gas is accomplished.

• If diesel power decreases under Engine protect:DieselLimCls the immediate gas shutdown is generated. Bi-fuel operation is blocked for next 10 seconds.

• If another general protection alarm is activated Hint: Every shutdown and protection slow stop must be confirmed by operator to enable next Bi-fuel operation.

Protections smoothly limiting the gas delivery • Analog output from DENOX anti-knocking controller

If knocking is detected, DENOX analog output is rising and limiting the gas delivery by closing the Throttle valve. If knocking is not detected, DENOX analog output is slowly decreasing and the Throttle valve is opening again. When the system is running on the limit of knocking, the DENOX output is gently opening and closing the Throttle valve to keep the engine on the limit of knocking. If the DENOX output is higher than Detonation Lim, ID-BF binary output KNOCKING is activated – this indicates some problem with the system or with the engine, since normally only a few percent reduction is enough to remove knocking

• Low diesel actuator current - value Diesel When system is delivering gas to the engine, the diesel governor decreases the diesel portion to keep the engine power on the requested level. For reliable ignition of the gas-air mixture in the cylinder is necessary to keep the diesel portion above minimum level. If Diesel < Engine protect: DieselLimMin, iD-BF is gently closing the Throttle valve to decrease amount of gas and thus increase the diesel portion. The value Diesel is measured or counted depending on which configuration is selected (with IS-AIN8, I-CB or J1939).

• High exhaust temperature above the ExhaustTmpLim causes gently closing the Throttle valve to decrease amount of gas and thus increase the diesel portion.


Operator Interface

Pushbuttons and LEDs

Pushbuttons and LEDs: 1. MODE→ Cycle forward through engine operation modes OFF -> RUN -> AUT. 2. ←MODE Cycle backward through engine operation modes OFF <- RUN <- AUT. 3. HORN RESET Deactivates the HORN. 4. FAULT RESET Acknowledges faults and alarms. 5. START Starts the Bi-fuel operation in MAN mode. 6. STOP Smoothly stops the engine in Bi-fuel operation in MAN mode (hold time =1 sec). 7. GREEN = Engine OK. 8. RED = Engine fail. 9. PAGE Cycles through the display screens MEASUREMENT->SETPOINTS->HISTORY. 10. ↑ Select the set point, select the screen or increase set point value. 11. ↓ Select the set point, select the screen or decrease set point value. 12. ENTER Confirm set point value.

Hint: The 2nd (1 sec) push of the STOP button cancels the ‘Slow closing’ of the Bi-fuel and stops the Bi-fuel immediately.

How to select engine mode ? Use MODE→ or ←MODE to select requested engine operation mode. Hint: Switching to OFF mode is blocked on running engine.

3

9

10

11

12

2 1 4 5

6

7

8


Display menus There are 4 display menus available: MEASUREMENT, External measurement, SETPOINTS and HISTORY. Each menu consists of several screens. Pressing the PAGE button repeatedly will scroll the user through the menu screens.

How to view measured data? Pressing the PAGE button repeatedly will scroll the user through the menu screens. Select the MEASUREMENT screen. Use ↑ and ↓ to select the screen with requested data.

How to view and edit set points? 1. Pressing the PAGE button repeatedly will scroll the user through the menu screens. Select the

ADJUSTMENT screen. 2. Use ↑ or ↓ to select requested set points group. 3. Press ENTER to confirm. 4. Use ↑ or ↓ to select requested set point. 5. Set points marked “*” are password protected. 6. Press ENTER to edit. 7. Use ↑ or ↓ to modify the set point. When ↑ or ↓ is pressed for 2 sec, auto repeat function is

activated. 8. Press ENTER to confirm or PAGE to leave without change.

Press PAGE to leave selected set points group.

How to use the Fast- edit function? Hold Enter on Main screen for 3 sec to switch to Fast edit screen. Use Up/Dovn buttons to change the value. Press Enter to confirm value.

Hint: Use DriveConfig to redirect the Fast edit to another setpoint.

How to view the HISTORY menu? 1. Pressing the PAGE button repeatedly will scroll the user through the menu screens. Select the

HISTORY screen. 2. Use ↑ or ↓ to select a requested record. 3. Use ENTER to select requested screen (record items) within displayed records

How to check the serial number and software revision? Hold down the ENTER and the press PAGE. On the display you can see Controller INFO screen for 10 seconds: Controller name (see Basic setting group) Controller serial number (8 character number) SW version: the first is the firmware version number, the second is configuration table number. Application: ID Branch: InteliDrive Hint: Only in MEASUREMENT screen.

How to change the display contrast ? Press ENTER and ↑ or ↓ at the same time to adjust the best display contrast. Hint: Only in MEASUREMENT menu.


How to change the display backlight intensity ? Press ENTER and ↑ or ↓ at the same time to adjust the best display backlight. Hint: Only in INFO screen.

How to change controller language ? Press PAGE to go to Language screen. Select language ↑ or ↓ a press PAGE to confirm selection and exit window.

How to find active alarms ? Active alarm list and J1939 alarm list are the last two screens in the MEASUREMENT menu. Select MEASUREMENT menu. Press ↑ ( ↑ ) You will see the list of all active alarms with the number of alarms at the top-right corner. Inverted alarms are still active. Non-inverted alarms are not active, but not yet confirmed. Press FAULT RESET accepts alarms of active (visible screen). Non-active alarms immediately disappear from the list. Active alarm list appears on the screen when a new alarm comes up and Main MEASUREMENT screen is active. Hint: Alarm list does not activate when you are reviewing the values, parameters or history. The FAULT RESET button is inactive when controller screen is switched to any other than Alarm list or ECU Alarm list.

Main screen indication

1. Available mode 2. Active controller mode (inverse) 3. Controller Local mode indication 4. R = Remote connection indication (connection to DriveMonitor is opened) L = Access lock indication 5. Record in Alarm list 6. State machine indication 7. Dimension of measured Engine power 8. The total Engine power, Gas and Diesel fuel aliquot parts of the power 9. G/D aliquot parts (G+D=100% … total Engine power)

Controller screens There are three screen groups available on ID controller: Measuring – Setpoints – History. Measuring screen will be divided to more groups – ID-DCU, BIN/BOUT, AIN etc.

3 2 1 4 5

7

8 9

6


Measuring (instrument) screens Screen Content Hidden, but available by Key combination – see Function available from ID-DCU front panel keys Info screen: Fw and App. version, s.n., … Language list and switch. Language screen Fast edit screen Available using Up or Down front panel keys ECU diagnostics code list Alarm list 1 =Main screen

ID Mode, Engine state, G/D ratio, Engine power, Gas and Diesel fuel aliquot parts of the power Indication: Local, Alarm (in AL or ECU list), Remote data connection active, Access Lock

2 Physical analogue inputs of iD-BF Analog 1 to Analog 4 , 4x single barograph 3 Physical analogue inputs of iD-BF Analog 5 to Analog 8 , 4x single barograph while

congigured 4 Total Engine power, Diesel fuel aliquot part of power, Fuel rate, Gas Valve open position

bargraphs 5 Detonation, FLSR of Diesel fuel and Gas fuel, Gas Valve open position bargraphs 6 Offset, Diesel fuel actuator excitation, Gas request and real Gas Valve open position

bargraphs 7 Battery ID-DCU bargraph, maximal, average and minimal actual cylinders exhaust

temperature 8 ID-DCU BI 1 to 7 9 ID-DCU BI 8 to 14 10 ID-DCU BO 1 to 7 11 ID-DCU BO 8 to 14 12 Statistics: Run hours, Number of starts, Service time Following screens appears depend on configuration Opt Analog 1 to Analog 8, Name- value dimension, active alarm is negative (1x IS-AIN8) Opt IS-BIN BI indication 1 to 8 Opt IS-BIN BI indication 9 to 16 Opt IS-BIN BO indication 1 to 8 Opt ECU values I. Opt ECU values II. Setpoints screens correspond with Setpoint table above.

Alarm indication Possible Alarm list and History record prefixes

Prefix Meaning Wrn Warning Sd Bi-fuel Shutdown Stp Bi-fuel Slow Stop Bw Broken wire Fls Sensor fail

Three state Alarm list indication * Wrn Water temp Active not accepted alarm Wrn Water temp Active not accepted alarm * Wrn Water temp Inactive not accepted alarm Inactive accepted alarm

ECU Alarm list - SPN/FMI codes screen E n g O i L P r e s S W R N B o o s t P r e s s F L S E n g O i L T e m p F L S 6 2 9 F L S > C o n t r O l l e r # 1


E n G C o O l T e m P W R N F C : 1 1 0 O C : 7 F M I : 3

Info screen Info Comment CBH InteliDrive Product type ComAp 2003 – 2004 Company name

Customer’s DG

Controller name

Serial: 0200FFFF Controller serial number Sw ver: 1.0 Software version Appl: BF Application Branch: CCU BF Customer branch

Statistic values It is calculated: 1 Running hours Each finished 60 minutes when engine is running in bi-

fuel mode. 2 Maintenance time The rest of the time to required maintenance. Statistic values can be adjusted from DriveMonitor, password 3 level protected.

History records Following table does not contain Wrn, Sd and Fls messages from external units. Events specification Protection

type Information available on

binary output Alarms ID-BF Analog input 1 to 8 Configurable YES ID-BF Binary input 1 to 14 Configurable YES ID-DCU Battery voltage <, > WRN YES Battery flat WRN ParamFail NONE YES EmergencyStop SD YES WrnServiceTime WRN YES Local mode ON YES Local mode OFF YES Detonation WRN YES Detonation OK - YES Engine Power Flt SD YES Denox Fail SD YES RegGasPress SD YES DifCylTmp1 … DifCylTmp16 Stp YES Dx Trip SD YES DFM Fail SD YES Engine events Note Starts Button start Start from ID panel CAN control + Button start Start from ID RD RS232 control + Button start Start from DriveMonitor Remote start Start from BI Stops Button stop ID-DCU panel button CAN control + Engine stop Stop from ID RD RS232 control + Engine stop Stop from DriveMonitor


Remote stop ID-DCU binary input Other events Fault reset ID-DCU panel button Local mode ON ID-DCU panel button Local mode OFF ID-DCU panel button Gas Enable ID-DCU binary input Gas Disable ID-DCU binary input Emerg.man ON Emergency manual mode ON binary input Emerg.man OFF Emergency manual mode OFF binary

input Gas Open The begin of transition to Bi-fuel mode Gas Close The begin of transition to Diesel mode Gas Slow Close Smooth transition to Diesel mode Diesel Low Immediate transition to Dieseel mode due

to insufficient diesel portion RS232 control Start, Stop, Fault reset, On/Off button from

DriveMonitor or I-RD Modem control Start, Stop, Fault reset, On/Off from

Modem SMS control Received command from GSM modem CAN control Received command via CAN bus e.g. from

I-RD or I-LB ActCallCH1-OK Successful active call on channel 1 ActCallCH2-OK Successful active call on channel 2 ActCallCH3-OK Successful active call on channel 3 Switched on Controller supply was switched on Cfg loaded Configuration archive was changed FwLoaded Firmware upgrade Time stamp Depends on setpoint setting period Password set Any level from any terminal Password changed Any level from any terminal Access set Access code was set Access changed Access code was changed Watchdog Controller internal watchdog protection Param fail Setpoints checksum fail Bad SCADA Pswrd SCADA password differs ECU ECU communication failed ECU MODBUS ECU MODBUS communication failed RTC battery RTC battery fail Hint: Value name can’t exceed 11 characters to be recorded to History file with prefix (Wrn, Fls etc..). Longer names characters are canceled. Corresponding Sd BINx, Sd BOUTx or Sd AINx is indicated in Alarm list and history record when communication with any extension units (IS-BIN, IS-AIN, IGS-PTM) interrupted. Example: When IS-BIN16/8 is configured for addresses: Binary inputs = BIN1, BIN2 and Binary outputs = BOUT1, then three messages Sd BIN1, Sd BIN2, Sd BOUT1 are indicated after communication is interrupted. Hint: Any “State” information can be configured to any binary output by DriveConfig software.

Functions available from ID-BF front panel keys Function Key combination From where Contrast increase Enter – Up Contrast decrease Enter – Down Info screen Enter – Page Local mode ON Enter - Mode > (Right)

Main screen


Local mode OFF Enter - Mode < (Left) Fast edit Enter hold for 4 sec.

Fault code reset Fault reset Alarm list ECU fault code reset Fault reset ECU Alarm list Requested speed increase Up Requested speed decrease Down

Request confirmation and exit

Enter active when Engine params: EnLocalSpeed = ENABLED

Exit without confirmation Page

Fast edit screen

Backlight increase Enter – Up Backlight decrease Enter - Down Go to Language screen Page

Info screen exit Automatic after 10 sec to Main screen

Info screen

Language selection Up or Down key Language screen Language screen exit Enter

Note: Enter – Up means hold Enter and press Up The system supports following character sets: West European - Code page 1252 in Windows East European - Code page 1250 in Windows Russian - Code page 1251 in Windows Turkish - Code page 1254 in Windows Simplified Chinese - Code page 936 in Windows. Hint: If the configuration table has a code page, that is not supported in the display processor, “Unsupported code page” message appears on the ID screen. Press PAGE to return back to Language selection.


Operation instructions

Operational modes

OFF mode Solenoid valves are closed, gas is closed, the function of bi–fuel is disabled. The engine is not involved by conversion kit. The switching to OFF mode from MAN or AUT has the same effect like Emergent gas stop.

Firmware and controller configuration can be changed in OFF mode only.

MAN mode In MAN mode you have to use pushbuttons START / STOP to switch to / from bi-fuel operation.

AUT mode The function of the kit is fully automatic. If iD-BFis in AUT mode, it automatically opens gas and then slowly opens the throttle valve.

Manual operation mode - MAN

Start bi-fuel operating If you need to switch from diesel to bi-fuel operation and Conditions for Bi-fuel operations are satisfied, press the START button. System will slowly open the throttle valve and engine smoothly switches over to bi-fuel operation.

Finish bi–fuel operating If you need to switch from bi-fuel to diesel operation then press STOP button. System will slowly close the throttle valve and engine smoothly switches over to diesel operation. If the STOP button is pressed for the second time during closing of gas throttle valve, immediate gas close is effected.

Close gas inlet hand valve while bi-fuel mode will not be explored for longer time!

In emergent situation press emergency GAS STOP pushbutton on panel.

Hint: Do not use pushbutton STOP GAS for normal work because immediate close of gas valves cause a load drop on the engine. Use STOP button to switch to diesel operation.

Automatic operation mode - AUT Automatic run for bi-fuel starts immediately when conditions are fulfilled (see Conditions for Bi-fuel operations)

Automatic run stops the bi-fuel operation when one or more of Conditions for Bi-fuel operations is not fulfilled.

Hint: If you need to switch from bi-fuel to diesel operation, switch to MAN and press STOP button. (see MAN operating mode)

Hint: If you need immediately (emergency) to close safety valves and throttle valve press emergency GAS STOP pushbutton on panel.


Alarm management Following alarms and protections are available:

Prefix Meaning No protection

Wrn Warning Sd Bi-fuel Shutdown Stp Bi-fuel Slow Stop Fls Sensor fail Bw Broken wire

Alarm only HisRecOnly

There are output signals assigned to each type of protection (see chapter Inputs and outputs): • Common Warn • Common Diesel • Common EmeDiesel • Common SD • Common Fls

The additional output is Alarm, which is active while any of above named signals is active.

No protection If the Alarm protection is not configured then input measures normally. However if the analog input value exceeds the measuring range more than 6% then no Alarm and no Sensor fail is reported but the substituted text “####” is displayed instead of wrong value.

Warning When a warning comes up alarm message and Common Wrn output contact is closed. No other action is performed.

Typical reasons of alarm are: • Configured standard alarm Warning type or the Warning alarm as 1st level of next SD or Slow Stop

protections. • Exceeding of warning limit of cylinder temperature • Boost air temperature • Warning RG • HSC kit’s supply breaker is off • Low or high Battery voltage

When a Shut down comes up alarm outputs and common warning output are closed. No other action is performed.

Bi-fuel Shut down When a protection comes up alarm output signalization Comm SD contact is closed and a message occurs. Continuing protection disables the start of the genset even after FAULT RESET pushed. The status message is “Not ready”

Typical reasons of alarm are: • Configured standard Shut down protection. • Shut Down RG • Cylinders exhaust temperature • Low gas pressure on gas train inlet • High gas pressure downstream of gas pressure regulator


When a Shut down comes up alarm outputs and common warning output are closed. No other action is performed.

Bi-fuel Slow stop When a protection comes up alarm output signalization Comm Diesel contact is closed and a message occurs. Continuing protection disables the start of the genset even after FAULT RESET pushed. The status message is “Not ready”

Typical reasons of alarm are: • Configured standard Slow Stop protection. The protection can be assigned to iS-BF controller input • Cylinders exhaust temperature (MPS configuration) • Boost air temperature

When a Diesel protection comes up alarm outputs and common warning output are closed. No other action is performed.

Sensor fail detection Sensor fail Fls is detected when measured value is 6.2% out of range. The controller screen will display #### instead of the measured value. The reasons of alarm is:

• Configured standard Fls Alarm. This alarm is either alone standing warning or it is the reason of other protection (Warning, SD, Diesel). The level of the effect of the Fls Alarm is defined in process of configuration. The Fls Alarm can be assigned to iD-BF controller analogue input and/or to Programmable Logic Control functions – Force Protection.

When an alarm comes up alarm outputs and common signalization output are closed.

Broken wire Broken wire (BW) alarm is indicated on ID-RPU module only.

Exhaust temperatures protection principles Exhaust temperatures are protected in specific way which is selected during the configuration by Analog Inputs:AlarmType = Cylinder. High temperature exhaust temperatures protections in bi-fuel operation are accomplished by two methods in one moment. Each method evaluates the actual temperature in two levels of protection.

Absolute temperature protection Two levels of protective limits are defined by setpoints Engine Protect:MaxTcyl wrn and Engine Protect:MaxTcyl stp. If the temperature exceeds the limit of second level then the Diesel Protection is activated (MPS configuration) or Shut down respectively.(FCON configuration)

Differential temperature protection The principle of differential cylinder exhaust temperature from the average temperature is explained in the picture bellow. There is defined an double area round about average exhaust temperature of cylinders. Setpoints define the limits of both areas.

The first level of protection (Warning) is defined by setpoints Engine Protect:Max+ClDifPmin1, Engine Protect:Max-ClDifPmin1, Engine Protect:Max+ClDifPmax1, Engine Protect:Max-ClDifPmax1.

Setpoints Engine Protect:Max+ClDifPmin2, Engine Protect:Max-ClDifPmin2, Engine Protect:Max+ClDifPmax2, Engine Protect:Max-ClDifPmax2 defines the second level of protections. It means the Diesel Protection activated (MPS configuration) or Shut down (FCON configuration).


Gen-set power

Cyl

inde

r te

mpe

ratu

rede

viat

ion

from

ave

rage

Max+CylDifPmin

Max-CylDifPmin

Max+CylDifPnom

Nominal powerPminCylDifEval

Max-CylDifPnom

+

-

Average temperature

Alarms indication There can be following actions when Alarm is active (depends on Alarm type and configuration): • Alarm list record • History list record • Active call (when is enabled and modem is installed) • Controller front panel LED indication • Binary output ALARM is closed when Alarm is active or when was deactivated and FAULT RESET

button was not pressed to confirm. Binary output ALARM opens when Alarm was deactivated (no other Alarm is active) and FAULT RESET button was pressed to confirm.

• Binary output HORN is closed for adjustable time when any new Alarm occurs. • Corresponding value reading (binary input state, analog input value, generator voltage, .. ) is inverse on

InteliDrive screen when value is out of limits (binary input protection is active).

Three state Alarm list indication * Wrn Water temp Active not accepted alarm Wrn Water temp Active not accepted alarm * Wrn Water temp Inactive not accepted alarm Inactive accepted alarm


iD-BF supervise and configuration (basic information)

How to install PC SW? The SW package is applicable in Windows 2000/XP etc. operational systems.

Install the SW package ComAp PC Suite. The ComAp PC Suite is the set of software and supporting modules to monitor events, adjusting of setpoints, configure HW etc.

Follow instructions in the Setup – ComAp PC Suite window. Targeted installation is organized in the structure as follows:

a) Executive program modules are located in Root Folder Folder level No.2 Folder level No.3 Folder level No.4

DriveConfig DriveConfig.exe InteliDDE.exe DChelp.hlp

Program Files/ ComAp PC Suite/

DriveMonitor DriveMonitor.exe InteliDDE.exe


DMhelp.hlp Gm_setup gm_setup.exe Hasp hinstall.exe

hdinst_windows.dll haspds_windows.dll

IBConfig IBConfig.exe ICBEdit ICBEdit.exe IVProg IVProg.exe

CEService.dll

Tools

WinScope WinScope.exe b) Application data (database) are located in

Root Folder Folder level No.2

Folder level No.3 Folder level No.4

Database esf, esl, xml Index Files idx DriveConfig History, con, ini, cfg DriveMonitor History, con, ini, cfg

ICBEdit Database, def, xml IBConfig Ini

Documents and Settings/ All Users/ Application Data/ ComAp PC Suite/ Tools

WinScope Ini c) Firmware and archive files are located in

Root Folder Folder level No.2

Folder level No.3

Folder level No.4

Folder level No.5

Curves crv idf, mhx

Dict trn App

Displays idf, mhx Default aid, aim … others

DriveConfig

Archives

DriveMonitor aid, aim Help chm

Examples IG-NT

Examples IS-NT

IS-internet

Sites

IS-modem IBConfig Firmware bin ICBEdit Config icb IVProg ivp

Documents and Settings/ All Users/ Documents/ ComAp PC Suite/

Tools

WinScope Examples sdt, shn

Eventually previously installed ComAp SW is contained in C:\Program Files\ComAp\ … folder and the one is not modified during ComAp PC Suite installation procedure.

Upgrade of iD-BF firmware Experts which intend to download the upgraded firmware ( *.mhx file) and/or configuration ( *.aid file) into iD-BF controller should add to the just installed ComAp PC Suite the Bi-fuel application.

The specialized bi-fuel application software is available in iD-BF-1.2.idc and newer. To upgrade the firmware launch DriveConfig program and search for item Import firmware as follows:


The upgrade BF application come default like the others installed by ComAp PC Suite.

Virtual COM Port driver (VCP) As first it is recommended to install the application (ComAp PC Suite) – see above.

The PC communicates with the iD-BF controller logically via COM port but physically via USB port. That means it is necessary to install Virtual COM Port (VCP) mapped to USB.

If • the iD-BF controller is connected to PC by USB/RS232 cable and powered • and VCP driver is not installed

then the user is automatically prompted to install the driver. It is recommended to use the VCP driver previously downloaded and unzipped from http://www.ftdichip.com/Drivers/VCP.htm.

Another standard way is to install the driver “off-line” on request of the user.

http://www.ftdichip.com/Drivers/VCP.htm


How to connect PC to ID-BF controller ? Use the direct connection via RS232 AT link cable (CANNON 9, female connectors, crossed data cores) Maximal length of cable 10m.

How to start DriveMonitor ? Click DriveMonitor start icon.

How to open communication of DriveMonitor with ID-BF controller? Select Connection type – Open direct connection

Choose the correct communication port. That means the serial port COM which is connected to the controller. In the example below the port USB mapping the COM port (Convertor USB/RS232) is chosen.

Set the correct controller address and press the pushbutton OK.


Information available in DriveMonitor To visualize required type of the information push the corresponding icon as demonstrated:

Control window: displays all ID-DCU and I/O states, enables engine control.

ID-RPU window … not available in Industrial version

Setpoints: listing and adjusting

Values: reading of all I/O include external modules

History list: complete history list.


Control window

Description: 1. Buttons to deactivate Fault and Horn reset. 2. Buttons to switch-over the engine operation modes OFF, MAN and AUT 3. Buttons for Start or Stop of the Bi-fuel operation. 4. Controller operation state indication. 5. LED indication of engine state: GREEN = Engine OK, RED = Engine fail. 6. iD-BF Analog inputs list 7. iD-BF Binary inputs list 8. iD-BF Binary outputs list. 9. Alarm list 10. ECU Alarm list 11. Defined analog input bar graph – Generator Power. 12. ECU Alarm fault reset button. 13. G/D ratio measurement. 14. Bar graph of battery voltage. 15. Connection indication. 16. Archive type indication. 17. DDE Server indication.

1

9

10

13

14

2 3 4

7

8 11

12

15 16 17

5

6


Hint: More details of DriveMonitor software can be found in DriveMonitor User guide.

How to download ID-BF controller history and store the history file?

and thereby open standard MS window Save archive. The default folder is: C:\Program Files\ComAp\InteliDrive\Archives If more than one genset in installed on the site then we recommend to define folder tree according the number of gensets. The example see in the picture. Note the language of the saving window corresponds to the adjusted language of MS Windows operation system instead of DriveMonitor.


History window structure


Setpoints window Setpoins may be visualized by the press of Setpoints icon. All setpoints are divided into groups according to the logical meaning. The items which value is eventually gray backgrounded are actually protected by password. The appropriate level of the password must be passed to enable the modification of the value. Details see in the next article.

Password protection Password is a four-digit number. Only setpoints associated with the entered password level can be modified. There are three levels of password protection. 0. User level allows change of non-protected setpoints only 1. Operator level allows change of setpoints protected by Operator level 1. 2. Master level allows change of setpoints protected by Operator 1. and Master level 2. 3. Supervisor highest level allows all setpoints or configuration changes, firmware upgrade. There can be password protected: • Setpoints (depends on configuration) • Statistics values (Level 3 only) • Engine commands (depends on configuration)

Even though one level may have been set from the front panel, the affected setpoints are not accessible from DriveMonitor (direct or Modem) until this level is set in DriveMonitor (direct or Modem). Setpoints opened from front panel are automatically closed 15 minutes after the last key has been depressed or when wrong value of password is set. Password is a four-digit number. Only setpoints associated with the entered password level can be modified. Any password can be changed once that level password or higher has been entered.


Technical data

ID-DCU

Power supply Voltage range 8-36V DC Current consumption (depends on supply voltage) 0,34A at 8VDC

0,12A at 24VDC 0,09A at 36VDC

Battery voltage measurement tolerance 2 % at 24V RTC battery life-cycle 10 year Hint: RTC battery flat causes wrong Date&Time information only.

Operating conditions Operating temperature ID-DCU -20 to +70 °C Operating temperature ID-DCU-LT -40 to +70 °C Storage temperature -30 to +80 °C Humidity 95% without condensation Flash memory data retention time 10 years Protection front panel IP65 Standard conformity Low Voltage Directive EN 61010-1:95 +A1:97 Electromagnetic Compatibility EN 61000-6-2, October 2001

EN 61000-6-4, October 2001 IEC 60533, Ed. 2; 1999-11

Vibration 5 - 25 Hz, ±1,6mm 25 - 100 Hz, a = 4 g

Shocks a = 200 m/s2

Dimensions and weight Dimensions (183x123x47mm)

See chapter terminals and dimensions Weight 800g