Bifuel control system

BIFUEL MANAGEMENT SOLUTION PACKAGES INTELIBIFUEL 2 & INTELIBIFUEL 20

Description:
The InteliBifuel 2 and InteliBifuel20 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.

Benefits:
 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

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

Elements of the system

 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

InteliBifuel CU
Description:
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.

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)

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

Communication interface ID-COM

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

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 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

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

Order codes
Package InteliBifuel 2 InteliBifuel CU InteliBifuel DENOX 2 InteliBifuel DFM Software and documentation InteliBifuel 20 InteliBifuel CU InteliBifuel DENOX 20 InteliBifuel DFM Software and documentation Order code IBF-2

You can get more information on

www.comapsystems.com

IBF-20

Bifuel Control System

Schematic diagrams
GEN-SET APPLICATION
ER TO OTH
M MODE
INTELIV ISION 8

ENGIN

ES

INTELIS

UPERVIS

OR

INTERN

ET

ALL FIREW

PC SUPPLY POWER VDC 8 TO 36 + INPUTS BINARY URABLE CONFIG

485/232

RS 232C E AC INTERF

CAN1

E SERVIC CENTER
IG-IB

Y LAN FACTOR

S OUTPUT BINARY URABLE CONFIG

ifuel InteliB

DFM
INPUTS ANALOG URABLE CONFIG

fuel C nteliBi

U
4-20mA

CAN2

I-RD-CA

L CONTRO ROOM

ID-COM

I-LB+

I
Engines operati on para meters

I-AOUT8 IS-BIN 16/8

1ph

SUPPLY POWER VDC 8 TO 36

GAS INLET

PUMPS APPLICATION
485/232 SUPPLY POWER VDC 8 TO 36 + INPUTS BINARY URABLE CONFIG

SUPPLY POWER VDC 8 TO 36

GAS INLET

Bifuel Control System

/3ph

ft Camsha position

X2 el DENO InteliBifu 20 or DENOX el InteliBifu

IS-AIN g knockin Engine s 2-20 sensor 8

IGS-PT

ECM

GENER

ATOR

IGL-RA

15

DIESE

L ENG

INE

MAINS
AS MIN G RE SU PRES OR SENS LE ROTT GAS TH LVE VA

I-CB+

LOAD
J1939 VALUES + Fa

ult code

GAS FILTER

NG CLOSI VALVES

SURE PRES RNOR GOVE

AS MAX G RE SU PRES OR SENS

Gas th

rottle va

lve Co

ntrol lin

RS 232C E AC INTERF

S OUTPUT BINARY URABLE CONFIG

InteliB

ifuel D

FM

InteliB
INPUTS ANALOG URABLE CONFIG

ifuel C
RPM

EX MO

DUL

PRESSU
Engines operati

RE
s

meter on para

ft Camsha position

IS-BIN

16/8

X2 el DENO InteliBifu 20 or DENOX liBifuel Inte

IS-AIN g knockin Engine s 2-20 sensor J1939 VALUES 8

ECU
ULIC P UMP

L ENG DIESE

INE

HYDRA

+ Fault

code

AS MIN G RE SU PRES OR SENS

LE ROTT GAS TH LVE VA

GAS FILTER

NG CLOSI VALVES

SURE PRES RNOR GOVE

AS MAX G RE SU PRES OR SENS

Gas th

rottle va

lve Co

ntrol lin

Examples of converted high speed engines

Brand Caterpillar Caterpillar Caterpillar Caterpillar Cummins Cummins Cummins Type 3300 series 3400 series 3500 series C series KTA series QSK series QST series DG set Output 150 kW220 kW 200 kW650 kW 700 kW2000 kW 200 kW1500 kW 400 kW1200 kW 1100 kW1800 kW 650 kW800 kW Brand Brand Cummins Cummins Deutz Deutz MAN MAN Type Type VTAVTA series series TBDTBD series series D2842LE201 D2842LE201 DG DG set Output set Output 500 500 kW600 kW kW600 kW all outputs all outputs 400 400 kW kW

Mercedes OM444LA/12183TB83 Mercedes OM444LA/12183TB83 440 440 kW kW Perkins Perkins SCANIA SCANIA Volvo Volvo 2000, 3000, 4000 series 580 all outputs 2000, 3000, 4000 series kW DC series DC series TADTAD series series 225 225 kW520 kW kW520 kW all outputs all outputs

 Many other engine brands and models for details please contact ComAp

Customer feedback

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.

References Czech Republic Russia

   

Phoenix Zeppelin Czech Republic CAT C15, BOOMEL250 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 Control System

ComAp Bifuel Trainings

Master valuable know-how

Practical and informative training on ComAps 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 ComAps tailored solution and master valuable Bifuel know-how.

bifuel.support@comap.cz
MANUFACTURER: LOCAL DISTRIBUTOR / PARTNER:

For more information and Bifuel support contact us at:

ComAp, spol. s r.o.

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

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