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 congurable 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/rmware 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.

Benets:
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 exibility 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, landll gas, coal gas, propane gas, biogas and others Excellent remote monitoring features backed by sophisticated PC programs which are especially suited for eet owners

All key algorithms are eld 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 misring 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 CU controller meets several forcing counter standards (EN, UL, CSA, NFPA) Internal congurable PLC functions

Congurable 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 InteliBifuel CU (ID-RPU) binary outputs separation Each channel has both n.o. and n.c. contacts available LED state indication

Extension modules 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

InternetBridge-NT (Communication Module with Cellular/Ethernet Connection) I-LB+ (Local Bridge) I-CB (ECU Communication Bridge) DriveMonitor (PC Monitoring Tool) WinScope (Special Graphical Controllers Monitoring Software) DriveCong (PC Conguration Tool)

Benets:
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 conguration 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 InternetBridge-NT and/or I-LB+ (Local Bridge)

Bifuel Control System

Elements of the system

InteliBifuel DENOX 2
Anti knocking device Field proven solution for 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 congured for single cylinder or for the monitoring of neighbouring cylinders Suitable for all inline engines up to a maximum of 6 cylinders

InteliBifuel DENOX 20
Anti knocking device Field proven solution for 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 congured 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.comap.cz

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

E SERVIC CENTER
RS 232C E AC INTERF CAN1 Inter ge-N netBrid T

Y LAN FACTOR

S OUTPUT BINARY URABLE CONFIG

I
ifuel InteliB DFM
INPUTS ANALOG URABLE CONFIG

fuel C nteliBi

CAN2

I-RD-CA

L CONTRO ROOM

ID-COM
I-LB+

4-20mA

I P
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 X 20 or NO DE 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 LOAD
LE ROTT GAS TH LVE VA

I-CB+

AS MIN G RE SU PRES OR SENS

VALUES J1939

+ 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 X 20 or el DENO ifu liB 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 Type Type DG DG set set Output Output 500 500 kW600 kW600 kW kW all all outputs outputs 400 400 kW kW 440 440 kW kW

Cummins Cummins VTA VTA series series Deutz Deutz MAN MAN TBD TBD series series D2842LE201 D2842LE201

Mercedes Mercedes OM444LA/12183TB83 OM444LA/12183TB83 Perkins Perkins SCANIA SCANIA Volvo Volvo

2000, 2000, 3000, 3000, 4000 4000 series series 580 all kW outputs DC DC series series TAD TAD series series 225 225 kW520 kW520 kW kW all all outputs 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 efcient 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 Training

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 benet 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 a.s.
Czech Republic Phone: + 420 246 012 111 Fax: + 420 266 316 647 E-mail: info@comap.cz Internet: www.comap.cz

Customer satisfaction is our mission. We continuously develop our people to be the best to succeed in our mission.
ComAp. Features and specication are subject to change without prior notice.

2013-03/CPLEBFCS