Compact Bi-fuel Governor/Controller€¦ · InteliGen BF, SW Version 2.4, ComAp – June 2005 - 10 – IG-BF-2.4.pdf . Principle of operation Gas throttle valve control FLSR DieselLimMin

ComAp, spol. s r.o. Světova 7, 180 00 Praha 8, Czech Republic Tel: +420 2 66316661, Fax: +420 2 66316647 E-mail: [email protected], www.comap.cz

Software version 2.4, June 2005 Prague, Czech Republic Copyright © 2003-2005 ComAp s.r.o. Written by Ales Prochazka, Jiří Patara

User guide

Compact Governor/Controller for Bi-fuel Conversion Kit

InteliGen®

Compact Bi-fuel Governor/Controller Conversion Kit Software Configuration

IG-BF unit + IG-DFM module

Table of content Table of content ............................................................................................................................................ 2 General description....................................................................................................................................... 3 Terminals and Dimensions ........................................................................................................................... 4

IG-BF Terminals ....................................................................................................................................... 4 DENOX terminals ..................................................................................................................................... 5 IG –BF Dimensions ............................................................................................................................... 6 IS-AIN8 Dimensions .............................................................................................................................. 7 I-CB Dimensions ...................................................................................................................................... 8

Functional description................................................................................................................................... 9 Sensors and Actuators location ............................................................................................................... 9 Principle of operation.............................................................................................................................. 11

Inputs and outputs ...................................................................................................................................... 13 Binary inputs – IG-BF – default .............................................................................................................. 13 Binary inputs – list .................................................................................................................................. 13 Binary outputs – IG-BF - default............................................................................................................. 14 Binary outputs – list ................................................................................................................................ 15 Analog inputs IG-BF ............................................................................................................................... 16 Analog input / output of IG-DFM interface.............................................................................................. 17 Analog inputs IS-AIN8 ............................................................................................................................ 17 IS-AIN8 analog inputs configuration....................................................................................................... 18 Gas regulation values............................................................................................................................. 19

Setpoints..................................................................................................................................................... 21 Password................................................................................................................................................ 21 Basic settings ......................................................................................................................................... 22 Diesel protect ......................................................................................................................................... 24 Engine protect ........................................................................................................................................ 27 Convert Power........................................................................................................................................ 32 Convert Diesel ........................................................................................................................................ 32 Act. calls/SMS ........................................................................................................................................ 33 Date and time ......................................................................................................................................... 34 Analog Config......................................................................................................................................... 34 Specials .................................................................................................................................................. 35

Operator Interface....................................................................................................................................... 36 Pushbuttons and LEDs........................................................................................................................... 36 How to select the system mode? ........................................................................................................... 37 Display menus........................................................................................................................................ 37 How to view measured data?................................................................................................................. 37 How to view and edit set points?............................................................................................................ 37 How to handle the HISTORY menu? ..................................................................................................... 37 How to find active alarms? ..................................................................................................................... 38 Chart guide to menus and pushbutton’s operation ................................................................................ 41

Instructions for operation ............................................................................................................................ 42 Remote control and data logging................................................................................................................ 43

History file............................................................................................................................................... 43 IG-BF controller operational states ........................................................................................................ 44

Technical data ............................................................................................................................................ 46 Power supply.......................................................................................................................................... 46 Operating conditions .............................................................................................................................. 46 Dimensions and weight .......................................................................................................................... 46 Binary inputs and outputs....................................................................................................................... 46 Analog inputs.......................................................................................................................................... 47 RS232 interface...................................................................................................................................... 47 IG-BFM................................................................................................................................................... 47 IS-AIN8................................................................................................................................................... 47 I-CB ........................................................................................................................................................ 48

InteliGen BF, SW Version 2.4, ComAp – June 2005 - 2 – IG-BF-2.4.pdf

General description High Speed engine Control - HSC panel contains following components for engine bi-fuel conversion. Unit Description Standard/Optional IG-BF controller central unit Standard IG-DFM controller extension module Standard DENOX CAN engine knocking protection unit Standard IS-AIN8 extension module – 8 analog inputs Optional I-CB communication bridge Optional IG-COM communication unit Optional IG-MU modem unit Optional IG-IB internet bridge Optional IGL-RA15 remote annunciator Optional Hint: IG-BF-2.2 software is not compatible with standard IG-CU hardware. Detail connections see in project documentation drawing No. 03.0178_011. IG-BF controller is programmable unit designed for bi-fuel operation. Controller measures several important values of pressure, temperature and diesel actuator current and controls throttle and gas safety valves according to customer adjustable characteristics. Extension modules IG-BFM, DENOX CAN and IS-AIN8 or I-CB contain all necessary inputs and outputs for engine protection and control. There are several adjustable protections that prevent engine bi-fuel operation from unacceptable states. IG-BF controller is equipped with a powerful graphic display showing icons, symbols and bar graphs for intuitive operation. IG-BF controller stores all important operation fail states for maintenance purpose. Available application archives and corresponding hardware: Archive Description Hardware BF+ANA-2.2 Archive with external IS-AIN8 extension module IG-BF + IS-AIN8 BF+ICB-2.2 Archive with external communication bridge module I-CB/CAT IG-BF+ I-CB/CAT DieselBF+J1939-2.2 Archive without external unit for engines with J1939 support IG-BF Hint: For further information on I-CB and PC configuration tool ICBEdit, please, refer to I-CB-ICBEdit-1.1.pdf and I-CB-ICBEdit-1.1-New features.pdf.


Terminals and Dimensions

IG-BF Terminals

ANALOG INPUTS

BINARY INPUTS

BINARY OUTPUTSRPM

BO1

BO2

POWER8 - 36 V DC

EXTE

NSIO

N MO

DULE

iG-D

FM

RS 23

2

LB 3

BOOT JUMPER

iG-BF

+ -Inl

Ink

COM

AI1

AI2

AI3

RPM

IN

RPM

GND

BO3

BO7

BO8

BO9

BO4

BO5

BO6

BI1

BI2

BI3 BI4

BI5

BI6

BI8

BI7

BI9

L1

L2

L3N L1

L2

L3

L3k

L3l

L2k

L2l

L1k

L1l

EXTE

NSIO

N MO

DULE

SiG

-COM

/ iG-

IOM

RPM Grounding Terminal

Grounding Terminal

IG-DFM Terminals


DENOX terminals

IGNITIONPULSE KNOCKING

SENSORS

POWERSUPPLY

INARYBOUTPUTS

TIMING REDUCTIONANALOG OUTPUTS

LB 6

CANTx Rx

DF

Standard

8

16

Sens

or#2

Sens

or#1

Sens

or#3

Sens

or#4

Sens

or#5

Sens

or#6

Sens

or#7

Sens

or#8

Sens

or#9

Sens

or#1

0

Sens

or#1

2

Sens

or#1

3

Sens

or#1

4

Sens

or#1

5

Sens

or#1

6

SERVICECONNECTOR

ISU

/bla

ck

ISU

/bro

wn

Shie

ldin

g ShieldAB

LB 6

4

9-36V DC

+ - Com

mon

Engi

nekn

ocki

ng

Load

redu

ctio

n

Trip 0

V

0-5

V D

C

+5

V D

C

4-20

mA

-

4-20

mA

+RS 232

LB 6


IG –BF Dimensions

IG-BF + IG-DFM+ IG-COM

iG-BFM

iG-CU

iG-COM

185 (7,3")

80 (3

,1")

42,5

(1,7

")24 (0,9

")

45 (1

,8")~

110

(4,3

")

170 (8,87")

21

123

(4,8

")

~ 130 (5,1")

130

(5,1

") 113

(4,4

")2

1

1

2

Cutout for InteliGen

113 x 175 mm (4.4 x 6,9“)

RS 232 CableIOM Cable


IS-AIN8 Dimensions 46,4 (18,3")

40 (15,7")

25 (9,8")

70 (27,5")

146 (57,5")

160

(63"

)

POWER8 - 36V DC

CO

M

CO

M

CAN CAN

RS 232

H HL L

+

Hint: IS-AIN8 configuration description see in the chapter IS-AIN8 configuration.


I-CB Dimensions

POWER8-36V DC

RS 422 COM

RS 23

2RS 485

TxB

TxA

RxB

RxA

LB 4

95 mm(3,7´´)

43 mm(1,7´´)

96 m

m (3

,8´´

)

I-CB unit is DIN rail (35mm) mounted Hint: I-CB configuration description see in the chapter I-CB configuration.


Functional description

Sensors and Actuators location

exhaust

pickup

SYSTEMANTIKNOCKING

current

diesel actuator

senzor

turbine

injection equipment

air filter

intercooler

senzorknocking

supercharger

blender

GAS TRAIN

water

gas

actuator

suction

ENGINE CONTROLSYSTEM

throttle bodygas filter

active

(2x)

senzorpressure

Engine governor

flywheel

camshaft

safety-valvedouble

regulatorgas pressure

valvehand

pressuresenzor

senzortemperature

(2x)

senzortemperature

2

3

4

5

6

7

89

10

1GENERATOR

SWITCHBOARD

generatorvoltage

generatorcurrent

Note: The Sensor/Actuator numbers are used in the text below to identify the Sender/Actuator.


1. Generator voltage and current measurement Actual power of the generator is evaluated from voltage and current measured by IG-BF. These values are visible in WinEdit in Values -> Specials. Optionally it can be obtained by Power-current transducer connected to second analog input (see setpoint Basic settings: PwrMeasType). Power is one of the main entries into the regulation.

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. Default configuration is on the third channel of the extension unit, Pt100 sensor, temperature reading is in °C.

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, …. Default configuration is on the first and second analog input of the extension unit, Thermocouples type “J”, temperature reading is in °C.

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 DENOX anti-knocking controller, are used for the protection of engine in case of knocking. Denox output 4 – 20 mA must be connected to controller analog input AI1.

7. Timing sensor (active pickup) on Camshaft DENOX 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. IG-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 measuring the electrical current energising diesel valve is used if the BF+ANA-2.2.aig archive is used. Another solution is the measuring of the flow of the diesel by an transducer with electric current or 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.


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 • No sensor fail for AI1 DETONATION; “Sensor 6” • Correct measurement of generator voltage and current to obtain total “electric” power (when

Basic settings: PwrMeasType = 1 PHASE or 3 PHASE) If Basic settings: PwrMeasType = 4-20mA then the AIN2 input is checked.

• Position of diesel actuator -> Diesel protect: DieselLimCls; “Sensor 10“ • No DENOX fail • Gen-set is running • Binary input GASDISABLE is open (if configured) • Binary input GASENABLE is closed • No unconfirmed shut down alarms are active

Hint: If you do not use binary inputs GASDISABLE or GASENABLE, configure them to any free binary input and set the correct polarity to enable bi-fuel operation.


Default Shutdown and Slow stop signals • 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 generated.

• 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 generated.

• Gas Pressure after the Pressure Regulator; “Sensor 2” – binary signal used for protection of engine in case of failure of Gas Pressure Regulator. If too high pressure of gas is detected (and contact is closed), immediate gas shutdown is generated and is blocked for Diesel protect:RegGasPr del after valve opening (GasOK). Binary Gas pressure sensor is configured to logical Binary input “RegGasPress”. The delay is necessary, since there is a pressure peak after opening of Double gas safety valve.

• Gas Pressure before the Pressure Regulator; “Sensor 5” – binary signal used for protection of engine in the case of gas drop during bi-fuel operation. If gas drop is detected, shutdown of gas is detected. Can be configured as standard alarm input

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

Hint: Every shutdown and protection slow stop must be confirmed by operator to enable Bi- fuel operation and the delivery of the gas. Protection signals may vary with the type of converted engine, check actual software configuration.

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, IG-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, InteliGen 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.


Inputs and outputs Hint: Binary inputs or outputs can be configured to any IG-BF terminal or can be changed to different function by WinEdit software. There is fix 1 sec delay when any binary input is configured as protection. No binary inputs and outputs are available on IS-AIN8 even if they are visible in WinEdit !!!

Binary inputs – IG-BF – default Input Name Alarm configuration BI1 Gas Enable BI2 Alarm 2 BI3 LowGasPress Alarm: Close to activate, Shutdown, All the time BI4 RegGasPress BI5 Alarm 5 BI6 Alarm 6 BI7 Alarm 7 BI8 Dx Trip Signal from DENOX BI9 Dx LdReduct Alarm: Close to activate, Warning, All the time

Binary inputs – list

Alarm If the input is closed (or opened) selected alarm is activated. Binary Alarm configuration items

Name 14 characters ASCII string Close to activate Inverted Open to activate Warning Shut down Stops gas operation immediately Slow stop Stops gas operation slowly

Alarm type

HistoryRecord No warning All the time Alarm active Engine running only When gas is opened

Not used Binary input has no function. Use this configuration when Binary input is not connected.

Emergency stop If the input is closed the safety valve and throttle valve are immediately closed: IG-BF Binary output Gas is opened (Gas Shut Off is closed) and IG-BFM pwm output is opened.

Access lock If the input is closed, no setpoints can be adjusted from controller front panel and gen-set mode (OFF-RUN) cannot be changed. Hint: Access lock does not protect setpoints and mode changing from WinEdit. To avoid unqualified changes the selected setpoints can be password protected.


FaultResButton Binary input has the same function as Fault reset button on the InteliGen front panel.

HornResButton Binary input has the same function as Horn reset button on the InteliGen front panel.

Gas Enable Binary input enables Bi- fuel operation when is closed.

Gas Disable Binary input disables Bi- fuel operation when is closed.

Gas Enable Gas Disable Bi- fuel operationclosed opened Enabled closed closed Disabled opened opened Disabled opened closed Disabled

Dx Trip DENOX activates this signal if it is receiving pulses from sensor on camshaft, “Sensor 7”. This signal must be active to enable bi-fuel operation. The timing of failure activation to improve the noise immunity and thus to avoid false alarms. If the binary input „Dx Trip“ is not configured then iG-BF supposes the DENOX device is not included in the control system.

RegGas Press Input indicates Gas pressure regulator fail when closed. Gas shutdown is activated immediately and is blocked for Diesel protect:RegGasPr del after valve opening (GasOK).

Manual Reg The binary input is used to stop the generator power stabilization.The activation of binary input results the abatement of stabilization procedure. The stabilization procedure does not continue till the end of increasing/decreasing ramp(s) of the gas independently on the state of MANUAL REG signal.

Binary outputs – IG-BF - default IG-BF outputs are configurable – see binary outputs list.

Output Name BO1 Not used BIO Not used BO3 Gas OK BO4 Not used BO5 Not used BO6 Not used BO7 Knocking BO8 Diesel OK BO9 Gas OK


Binary outputs – list

Not used

Common Alarm The output closes if :

• any alarm comes up or • the gen-set malfunctions

The output opens if • FAULT RESET is pressed

The output closes again if a new fault comes up.

Horn The output closes if:

• any alarm comes up or • the gen-set malfunctions

The output opens if: • FAULT RESET is pressed or • HORN RESET is pressed or • Max time of HORN is exceeded (Horn timeout)

The output closes again if a new fault comes up.

Batt volt Output closes when battery over/under voltage warning appears. The output opens, if

• alarm is not active and • FAULT RESET is pressed

Common Wrn Output closes when any warning alarm appears. The output opens, if

• No warning alarm is active and • FAULT RESET is pressed

Common Stp Output closes when any slow stop alarm appears. The output opens, if

• No slow stop alarm is active and • FAULT RESET is pressed

Common Sd Output closes when any shut-down alarm appears. The output opens, if

• No sd alarm is active and • FAULT RESET is pressed

Common Fls Output closes when any sensor fail alarm appears. The output opens, if no Sensor fail is active and Fault reset button is pressed.

OFF mode The output is closed, if OFF mode is selected.


Service time Output closes when gen-set count down timer Service time reaches zero.

Knocking Output is closed and History record is activated when DENOX output signal is higher than Diesel protect: DetonationLim. Another OK History record is activated when DENOX output signal is back below DetonatioLim.

Diesel Low Output is closed when Diesel Actuator current is less than Diesel protect: DieselLimMin +10%.

Diesel OK Binary output DIESEL OK (light indicator „DIESEL OK“) indicates all conditions for genset in bi-fuel operation.

Gas OK Output controls Gas safety valve. Gas safety valve is opened when output is closed.

Gas Shut Off Indication output is closed when gas is closed.

Denox Error Output is closed when is difference between DENOX binary output Knocking and DENOX output (current) signal. Output indicates DENOX fail. In version 2.0 and higher extended for the case when the signal Dx Trip from Denox doesn’t correspond to the value Diesel (indicates running engine when > 2.0%) for more than 60 seconds.

Power UP, Power DOWN Binary outputs used to generator power stabilization during the gas-ramping after start of the bi-fuel work and/or before the stop of the one.

Service time Output closes when gen-set count down timer Service time reaches zero.

Analog inputs IG-BF In IG-BF application are the first two analog inputs fix defined for 4 to 20 mA sensors measuring only. It is not possible to change configuration of AI1 and AI2. AI1 and AI2 analog reading range

0 mA ###### 4 mA 0,0 % 20 mA 100,0 %

The jumpers for mA measuring must be closed in IG-BF unit. Default Analog inputs configuration is as follows:

AI1 Denox signal (Detonations) Input for external engine detonation unit signal. This 4 – 20 mA analog input is not configurable; 20mA corresponds to 100% output value “Detonation” in % that is visible on controller screen or in WinEdit. See chapter Gas regulation values. This value is compared to setpoints Detonation Lim


AI2 Total power Input for power from diesel measuring. This 4 – 20 mA input is not configurable. Power for full 20mA is adjusted by setpoint Basic settings:Power range. It is possible to set e.g. 20mA = 23 kW. This input is active only if Basic settings:PwrMeasType is set to 4-20mA.

AI3 Offset Analog input for simulation of convert power table or offset the curve on the one. This input is mainly used for installation and testing.

AI4 Valve FDB The voltage from back-feed sensor mounted on the gas butterfly valve. The sensor transmits actual position (angle) of opening of butterfly valve.

Analog input / output of IG-DFM interface

Current sense (input) Three terminals for Diesel actuator current (fuel) measuring are available for range up to:

8 Amps, 0,2 Amps, 0,02 Amps.

Full range for each selected input is meant as 100,0% (e.g. 8 Amps = 100%, 0,2 Amps = 100% , etc.).

Actuator (output) Pulse width modulation for gas throttle valve control. Maximal output current is 5 Amps.

Actuator position (input) The input is available only on IG-DFM 1.1 HW module and next versions. There are three terminals for Gas throttle valve back feed sensor and the supply of the sensor. Analog position input is used only when the Gas throttle valve is equipped by position sensor. That is used for regulation of the required position by servoregulator. If servoregulation is not required then connect the jumper on the printed circuit board inside of IG-DFM 1.1 module to position more distant from the edge and vice versa. Actuator position and servopositioning is disabled. Then the function of IG-DFM 1.1 HW module is the same like the older IG-DFM 1.0 HW module.

Analog inputs IS-AIN8

AIN1 – AIN8 default configuration (IS-AIN8)

Name Abbr. Type Dim Active Alarm Activity Sensor Dec1.IOM ExhTmpLeft ExTL Analog °F Over Wrn+Sd All the time Curve B 0 2.IOM ExhTmpRight ExTR Analog °F Over Wrn+Sd All the time Curve B 0 3.IOM BoostAirTmp BATm Analog °F Over Wrn+Sd All the time Curve A 1 4.IOM AnInAna-4 Ana4 Analog - Over Wrn+Sd All the time Unused input 0 AIN 5 AnInAna-5 Ana5 Analog - Over Wrn+Sd All the time 0 AIN 6 AnInAna-6 Ana6 Analog - Over Wrn+Sd All the time 0 AIN 7 AnInAna-7 Ana7 Analog - Over Wrn+Sd All the time 0 AIN 8 AnInAna-8 Ana8 Analog - Over Wrn+Sd All the time 0

AIN5 to AIN8 is not visible in WinEdit!


IS-AIN8 Analog inputs AIN 1-4 can be configured from WinEdit.

IS-AIN8 analog inputs configuration It is possible to connect only one external analog module IS-AIN8 to IG-BF controller. IS-AIN8 has to be configured with address 1. There are two steps of IS-AIN8 analog inputs configuration: Input Hardware configuration (measuring type and range) and Software configuration (Name, Dimension, sensor characterisitics… ) Following table describes relations between WinEdit and Setpoints configuration. Analog inputs WinEdit sensor configuration

Sensor (from list) Curve A, B, C ANA PT, NI, Thermo, VDO ANA mA ANA ohms

AIN1, AIN2, AIN3, AIN4,

Configurable: NAME, Dimension, Protection, … .. standard function

ANA V, mV

AIN5, AIN6, AIN7, AIN8.

Inputs are not configurable (invisible in WE): Name, Abbr, Dimension, Protection, …= fix.

IS-AIN8 analog inputs are divided into two parts:

Analog inputs 1- 4 • Hardware configuration is selected by setpoints Analog Config: Ana-1 HWCfg to Ana-4 HWCfg

(must be set for customer curves A, B, C, not needed for other curves). • Output value range is selected by setpoints Analog Config: Ana-1 Range to Ana-4 Range (e.g.20

mA = 100,0). • Inputs AIN1 to AIN4 can be fully configured in WinEdit like IG-IOM module inputs (1.IOM .. 4.IOM):

o Name, o Abbreviation (name of column of history record), o Sensor type, o Dimension, o Active – reaction on under / over adjusted levels by setpoints Engine protect: AnInAna-x lev

1,2 with delay AnInAna-x del, o Alarm type – Sensor Fail, Warning, Wrn+Shutdown, Wrn+SlowStop, o Alarm active – All the time, Engine running only, o Sensor – Unused input, Curve A, B, C, ANA xxxx, o Decimal points.

• As sensor can be selected – Unused input, User curves A, B, C or fix curves ANA xxxx only. Any other sensor is detected as sensor fail.

Analog inputs 5- 8 • AIN5 to AIN8 inputs are not visible in WinEdit and can be configured only by setpoints in

Analog Config group. • Type of sensor (fix curve) for inputs AIN5 to AIN8 is configured by setpoints Analog Config:

Ana-(5-8) Sensor. • Default configuration is Over, Wrn+Sd, Allthe time and can’t be changed include the Input

name. Those inputs can be used for two level protections – see setpoints group Engine protection.


• AIN5 to AIN8 Names and abbreviation can be modified by WinEdit - translator function. Hint: Change of configuration analog inputs by setpoints takes effect after new IG-BF or IS-AIN8 module power up. Analog inputs sensors for Exhaust temperature protection (see Diesel protect: ExhTempSense 1 and 2) must be configured without decimal point (see AIN1 and AIN2).

Gas regulation values

Engine power [kW] Total power gained from both diesel and gas.

G/D Ratio [%] The topical percentual saving of the diesel fuel is evaluated.

Gas power [kW] Power gained from gas.

Diesel power [kW] Power gained from diesel.

Gas Valve [%] Output value for Gas valve control.

Gas Request [%] Gas valve request is output value from conversion between Engine power and Gas Throttle position. See setpoints group Convert power and drawing in the chapter Principle of operation.

Gas Regul [%] It is Gas valve request reduced by Diesel and Exhaust FLSR value and value of detonations from DENOX.

FLSR Diesel [ % ] Fast Limit Slow Release block for protection against reducing of diesel fuel below DieselLimMin setpoint. Diesel FLSR value is substracted from Gas valve position. Gas valve position is not reduced when is FLSR = 0.

FLSR Exhaust [ % ] Fast Limit Slow Release block for protection against Exhaust overheating over ExhaustTmpLim setpoint. Exhaust FLSR value is substracted from Gas valve position. Gas valve position is not reduced when is FLSR = 0.

Detonation [ % ] Value in % measured on InteliGen analog input AI1: Denox signal (100% = 20 mA).

Diesel [%] This value indicates the portion of diesel that is used. For IS-AIN8 connected: Evaluated from diesel actuator sensor connected to analog input of IG-BF through IG-BFM module. For I-CB connected:


ackLimitEffectiveRackEffectiveRDiesel 1000×

= where Effective Rack and Effective Rack Limit are parameters read

from CCM (configured on AI5 and AI6 of fictive IS-AIN8). For J1939: Diesel = Percent Load at Current Speed x 10 where parameter Percent Load at Current Speed is read from the engine with J1939 support.

Offset [%] Analog input for simulation of convert power table or offset the curve on the one. This input is mainly used for installation and testing.

Fuel rate [L/h] Evaluation and visualization of the topical diesel rate.

FuelCons [L] Total consumption of the diesel fuel. This feature is active only if BF+ANA-2.2.aig archive. The consumption of the diesel is measured by the flowmeter equipped with impulse output. (The value of Basic settings – DieselMeasMode should be equal to FLOWMTR)


Setpoints Password There are three levels of password protection. 0. User level allows change of not protected setpoints only 1. Operator level allows change of setpoints protected by Operator level 2. Master level allows change of setpoints protected by Operator and Master level 3. Supervisor highest level allows all setpoints or configuration changes, firmware upgrade. Hint: The asterisk mark “*“ appears before setpoint name (on controller screen) when is setpoint password protected. Asterisk mark is removed only when password is set from controller front panel. Asterisk mark is still visible on controller screen even if the password is set from WinEdit. There are separate accesses to controller from Front panel, from WinEdit, from Modem or from Internet. Setpoints which are opened e.g. from WinEdit are still closed from Front panel. Setpoints opened from front panel are automatically closed 15 minutes after the last key touch or when wrong password is set. It is possible to protect remote Start, Stop, GCB, MCB commands from WinEdit, MultiEdit as well. This three level command protection can be configured from WinEdit.

EnterPassword Password is a four-digit number. Password enables change of relevant protected set points depends on configured Password level. Use ↑ or ↓ to modify the set the password.

ChangePassword 1 Hint: At first the old Password 1 has to be entered before the new Password 1 can be changed.

ChangePassword 2 Hint: At first the old Password 2 has to be entered before the new Password 2 can be changed.

ChangePassword 3 Hint: At first the old Password 3 has to be entered before the new Password 3 or Password 2 or Password 1 can be changed.

Access code • Can be changed from WinEdit software only. • Has to be set before remote modem or SMS connection is opened. • Can be up to 16 ASCII characters

At first the Password3 has to be entered before the new Access code can be changed.

Commands protection Commands password protection protects following commands from WinEdit / MultiEdit direct, modem or GSM modem connection:

Start, Stop, Horn reset, Fault reset, GCB close/open, MCB close/open. Selected Command password level 0, 1, 2, 3 is valid for all commands. Selected level is in RED color.


Basic settings

Gen-set name User defined name, used for InteliGen identification at remote phone or mobile connection. Gen-set name is max 14 characters long and have to be entered manually using WinEdit software. Hint:Gen-set name is not changed when new archive is loaded. Check Gen-set name after firmware upgrade.

Mode IG [OFF, MAN, AUT] Setting this setpoint is equivalent to Controller mode changes by MODE→ or ←MODE buttons. Hint: Mode change can be separately password protected.

Power range [kW] Power range of electric power (measured on analog input AI2 if external sensor with current output 4-20mA used). Determines which power corresponds to full range 20 mA (e.g. 20 mA = 2000 kW). Step: 1 kW Range: 0 – 3000 kW

CT Ratio [/5A] Generator current transformer ratio. Step: 1 A/5A Range: 1 – 10000 A/5A

PT ratio [/1] Gen-set potential transformers ratio. Step: 0,1 V / V Range: 0,1 – 500,0 V / V

PwrMeasType [1 PHASE,3 PHASE,4-20mA] Type of power measuring: 1 PHASE: one-phase measuring (In) 3 PHASE: three-phase measuring (L1, L2, L3) 4-20mA: measuring using external sensor with current output 4-20mA

AuxConsumption [kW] Estimated electric power needed to no load run of the genset. This setpoint is used to evaluate the topical percentual saving of the diesel fuel. Step: 1 kW Range: 0 – 255 kW

DieselMeasMode [POSACT, FLOWMTR] Modes of diesel portion measuring: POSACT: Diesel portion is evaluated by measuring of actuator position (current led into iG-DFM) or by communication with ECU FLOWMTR: Diesel portion is evaluated by flow/frequency converter connected to RPM iG-BF’s terminals Default setting: POSACT

Gear teeth [-] Measuring coefficient of the flowmeter flywheel. Appropriate value is adjusted, if the diesel value is less then 100,0% on nominal power of diesel run.


Step: 1 Range: 1 – 500

FuelConsCoeff [1/ltr] The parameter is available only in BF+ANA-2.2.aig archive. While the diesel rate is measured by the flowmeter equipped with the impulse output then the total diesel consumption is counted. Set the setpoint value to number of impulses per 1 volume unit (usually litres) Step: 1 1/ltr Range: 1 – 500 1/ltr Hint: The consumption is counted both in diesel and bi-fuel work.

GasValveLoLim [%] The gas throttle valve range is stretched. The feature is suitable when/because the threshold of Gas throttle valve opening is set off zero point. This parameter together with Basic Settings – GasValveHiLim allows to use the full range (0 – 100%) of Convert Power – GasThrottle corresponding with full mechanical range of throttle valve. The effect is the clarity of Convert power map adjusting.

The 0% level of Convert Power - GasThrottle x is set off to GasValveLoLim what is the output value from iG-DFM driver module needed for the begin of the gas’s throttle valve opening. Step: 0.1 % Range: 0.0 - GasValveHiLim % Hint: Adjusting procedure of GasValveLoLim and GasValveHiLim: Set GasValveLoLim to 0% and GasValveHiLim to 100,0%. Switch the operation mode to OFF and the Diesel protect – GasRegulOffset’s value set to VALVETEST. Turn potentiometer Offset and check when the gas throttle valve reaches positions: 1. throttle begins to move from closed position 2. throttle reaches the mechanical limit of opening. Read both limit values Gas valve % and use then for the setting of GasValveLoLim (the begin of opening) and GasValveHiLim (the end of opening).

GasValveHiLim [%] See explanations in the Basic Settings – GasValveLoLim.. The 100% level of Convert Power - GasThrottle x is set off to GasValveHiLim what is the output value from iG-DFM driver module needed for the full mechanical opening of the gas throttle valve. Step: 0.1 % Range: GasValveLoLim - 100.0 %


NextServTime [h] This is the amount of time that will elapse till service on the gen-set is required. When the countdown is complete:

• Service alarm is detected • Alarm list is recorded

Step: 1 h Range: 0 – 65535 h Hint: Once the service time has elapsed the NextServTime will have to be reset to clear the alarm and begin a new countdown. Running hours and Service time is calculated when Gas is opened only.

Horn timeout [s] Binary output Horn automatically opens (without Horn reset button) after Horn timeout. Set to zero if you want to leave the output HORN open. Step: 1s Range: 0 – 600 s

Contr. adr (1 … 32) [-] Controller identification number. Each gen-set in the group on CAN bus has to have its own unique number. Default value is 1. Hint: When opening Direct or Modem connection to single InteliGen, the InteliGen Controller address must correspond to WinEdit communication setup setting.

RS232 mode [Standard / Modbus] Communication protocol switch. Standard: InteliGen (WinEdit/MultiEdit) communication protocol. Modbus: InteliGen Modbus protocol. Hint: Detail descriptions see in InteliGen Communication guide.

Diesel protect

DieselLimMin [kW] When Diesel Actuator current (fuel) is less than DieselLimMin the gas throttle valve (9) starts closing down (GasDecRamp). The gas throttle valve closing speed is set by Diesel Gain. Step: 0 kW Range: 0 – 100(Min Power) kW

DieselLimCls [kW] The Gas (all outputs for gas safety valve (8) and throttle valve(9)) are closed when Diesel power (fuel) is less than DieselLimCls. Bi-fuel operation is again enabled after 10 seconds delay. Step: 0 kW Range: 0 – 3000 kW

Diesel Gain (Diesel increasing) [-] Setpoint influences the gas throttle valve closing speed (and diesel increasing rate) when Diesel actuator current Id (fuel) is less than DieselLimMin. Throttle valve closing speed (increasing output from FLSR module –see Principle of operation) is proportional to difference between actual Diesel actuator current and DieselLimMin according to following formula:

FLSR = (DieselLimMin – Id) * Diesel Gain, when Id < MinDieselLim


Step: 0,1 Range: 0,0 – 100,0

DieselDecRmp (Diesel decreasing ramp) [%/s] Setpoint influences the gas throttle valve opening speed when Diesel actuator current (fuel) is higher than DieselLimMin. Step: 0,1 %/s Range: 0,0 – 200,0 %/s

Detonation Lim (Detonation limit) [%] The Knocking warning alarm is indicated when DENOX output (controller AI1 4 – 20 mA signal) is over this limit. Step: 0,1 % Range: 0,0 – 100,0 %

DetonationFrom [ % ] Limit for DENOX output (controller AI1 4 – 20 mA signal) from which is gas output reducing loop active. Difference above this limit is subtracted from required Gas level. Example: DetonationFrom = 2,0%, actual Detonation value = 2,5%. Then 0,5% is subtracted from Gas valve position. Step: 0,1 % Range: 0,0 – 10,0 % (Detonation Lim)

Min Power [kW] Bi- fuel operation (gas throttle valve and emergency valve) is activated only when Engine power surpassed this limit. Gas is closed when actual engine power is below limit

2inDieselLimMMinPower +

.

Step: 1 kW Range: DieselLimMin – 3000 kW

RegGasPr del [s] Delay during which bi-fuel operation SD RegGasPress is blocked after opening of gas valve (output GasOK). Step: 1 s Range: 0 – 60 s

Gas Dec Ramp (Gas decreasing ramp) [%/s] Gas throttle valve closing speed for SlowClose procedure. Step: 0,001 %/s Range: 0,000 – 3,000 %/s

Gas Ramp (Gas increasing ramp) [%/s] Speed of Gas throttle valve opening during start (first gas open). Step: 0,001 %/s Range: 0,000 – 3,000 %/s

Gas Ramp Start [%] Initial gas throttle valve position. When all gas conditions are OK after engine start gas throttle valve jumps to this position and continues ramping. Step: 0,1 % Range: 0,0 – 100,0 %


Gas ramp

Gas Ramp Start

Conditions for gasthrottle valve opening

SlowCloseactive

GasRegulOffset [DISABLE/ENABLE/VALVETEST] Gas throttle valve offset that enables connect change throttle valve position from AIN3 analog input. This function was designed mainly for testing of optimal valve characteristic setting. The characteristic of selected analog input is defined by Curve “C”.

DISABLE: Offset is switched off. ENABLE: Offset is switched on. VALVETEST: Offset is directly used to open the Gas throttle valve. The value is accepted only in OFF operational mode if the genset is stopped. This choice is used to calibrate the positioning of the Gas throttle valve. See also Basic settings - GasValveLoLim and Basic settings - GasValveHiLim setpoints

Hint: The value of Offset potentiometer is directly being added to requested Gas throttle valve position!

ExhaustTmpLim [ °C ] Enters the FLSR function according to formula described bellow. Step: 1 °C Range: 300 to 1300 °C Hint: This setpoint defines limit for restraining of fuel. Limits for Warning and Shutdown are Engine protect:ExTmp… wrn and ExTmp… sd.

ExhaustTmpGain [ - ] Rate of Gas solenoid position reduction. Fast Limit Slow Rate function operates according to following formula FLSR value is subtraced from the required Throttle valve position. Gas reduction formula:

FLSR = [FLSR + (ExhaustTemperature(t0)-ExhaustTemperature(t-1))*ExhaustTmpGain – (ExhaustTemperature(t0) - ExhaustTmpLim) *ExhaustTmpInt]

Gas increasing formula: FLSR = FLSR – ExhaustDecRmp

Step: 0,1 Range: 0,0 to 100,0

ExhaustTmpInt [-] Integration constant for PI regulator of Gas solenoid position reduction described above. Step: 0,1 Range: 0,0 to 100,0

ExhaustDecRmp [ %/s ] Rate of Gas solenoid return to required position after Exhaust temperature is lower than ExhaustTmpLim. Step: 0,01 %/s Range: 0,00 to 10,00 %/s


Diesel PI regulator While the gas butterfly valve position is ramped then the actual generator power is stabilized by Diesel PI regulator. The regulation is abandoned by activation of MANUAL REG or by finish of the ramping gas butterfly valve.

Inputs OutputsMANUAL REG

GAS VALVE RAMP

Dsl Power GainDsl Power IntDsl PI PeriodDsl PI TauAct

POWER UP

POWER DN

binary

analogue

Analog input: GAS VALVE RAMP Binary input: MANUAL REG Outputs: POWER UP POWER DN Setpoints: Dsl Power Gain Dsl Power Int Dsl PI Period Dsl PI TauAct

How to use power stabilizing regulator: Example: MANUAL REG = BI6, Outputs = BO4, BO5 1. Configure: MANU REG to iG-BF BI6 2. Configure: POWER UP to iG-BF BO4 3. Configure: POWER DN to iG-BF BO5 4. Adjust setpoints in Prog function group

Dsl Power Gain [ % ] The Gain for programmable PI active power stabilizer. Step: 0.01 % Range: -100.00 to +100.00 %

Dsl Power Int [ % ] The Integration factor for programmable PI active power stabilizer. Step: 0.01 % Range: 0.00 to +100.00 %

Dsl PI Period [ s ] Regulation period. For slow responding regulated systems set this time longer. Step: 0.1 s Range: 1.0 to +600.0 s

Dsl PI TauAct [ s ] Time constant of actuator. Example: Adjust 5 sec when time from open to close valve is 5 sec. Step: 0.1 s Range: 0.1 to +60.0 s

Engine protect

Batt >V [V] Warning level for battery over voltage. Step: 0,1V Range: 9 – 40 V


Batt <V [V] Warning level for low battery voltage. Step: 0,1V Range: 8 – 30 V

Batt V del [s] Delay for battery voltage alarms. Step: 1s Range: 0 – 600 s Valid for BF+ANA-2.x.aig archive:

ExTmpLeft wrn [ °C ] The level for IS-AIN8 analog input 1 alarm detection. Step: 1 Range: -32000 - +32000

ExTmpLeft sd [ °C ] The level for IS-AIN8 analog input 1 alarm detection. Step: 1 Range: -32000 - +32000

ExTmpLeft del [s] Delay for IS-AIN8 analog input 1 alarm. Step: 1s Range: 0 - 180s

ExTmpRight wrn [ °C ] The level for IS-AIN8 analog input 2 alarm detection. Step: 1 Range: -32000 - +32000

ExTmpRight sd [ °C ] The level for IS-AIN8 analog input 2 alarm detection. Step: 1 Range: -32000 - +32000

ExTmpRight del [s] Delay for IS-AIN8 analog input 2 alarm. Step: 1s Range: 0 - 180s

BoostAirT wrn [ °C ] The level for IS-AIN8 analog input 3 alarm detection. Step: 1 Range: -32000 - +32000

BoostAirT sd [ °C ] The level for IS-AIN8 analog input 3 alarm detection. Step: 1 Range: -32000 - +32000


BoostAirT del [s] Delay for IS-AIN8 analog input 3 alarm. Step: 1s Range: 0 - 180s

AnInAna- (4 .. 8) lev1 [ °C ] The level for IS-AIN ANALOG INPUT 4-8 alarm detection. Step: 1 Range: -32000 - +32000

AnInAna- (4 .. 8) lev2 [ °C ] The level for IS-AIN8 ANALOG INPUT 4-8 alarm detection. Step: 1 Range: -32000 - +32000

AnInAna- (4 .. 8) del [s] Delay for IS-AIN8 ANALOG INPUT 4-8 alarm. Step: 1 s Range: 0 - 180 s Valid for BF+ICB-2.x.aig archive:

ExTmpLeft wrn [ °C ] The level for mapped IS-AIN8 analog input 1 alarm detection. Step: 1 Range: -32000 - +32000

ExTmpLeft sd [ °C ] The level for mapped IS-AIN8 analog input 1 alarm detection. Step: 1 Range: -32000 - +32000

ExTmpLeft del [s] Delay for mapped IS-AIN8 analog input 1 alarm. Step: 1s Range: 0 - 180s

ExTmpRight wrn [ °C ] The level for mapped IS-AIN8 analog input 2 alarm detection. Step: 1 Range: -32000 - +32000

ExTmpRight sd [ °C ] The level for mapped IS-AIN8 analog input 2 alarm detection. Step: 1 Range: -32000 - +32000

ExTmpRight del [s] Delay for mapped IS-AIN8 analog input 2 alarm. Step: 1s Range: 0 - 180s


BoostAirT wrn [ °C ] The level for mapped IS-AIN8 analog input 3 alarm detection. Step: 0,1 Range: -3200,0 - +3200,0

BoostAirT sd [ °C ] The level for mapped IS-AIN8 analog input 3 alarm detection. Step: 0,1 Range: -3200,0 - +3200,0

BoostAirT del [s] Delay for mapped IS-AIN8 analog input 3 alarm. Step: 1s Range: 0 - 180s

Fuel rate wrn [ L/h ] The level for mapped IS-AIN8 analog input 4 alarm detection. Step: 0,1 Range: -3200,0 - +3200,0

Fuel rate sd [ L/h ] The level for mapped IS-AIN8 analog input 4 alarm detection. Step: 0,1 Range: -3200,0 - +3200,0

Fuel rate del [s] Delay for mapped IS-AIN8 analog input 4 alarm. Step: 1s Range: 0 - 180s

Rack wrn [ mm ] The level for mapped IS-AIN8 analog input 4 alarm detection. Step: 0,01 Range: -320,00 - +320,00

Rack sd [ mm] The level for mapped IS-AIN8 analog input 4 alarm detection. Step: 0,01 Range: -320,00 - +320,00

Rack del [s] Delay for mapped IS-AIN8 analog input 4 alarm. Step: 1s Range: 0 - 180s

Rack limit wrn [ mm ] The level for mapped IS-AIN8 analog input 5 alarm detection. Step: 0,01 Range: -320,00 - +320,00

Rack limit sd [ mm] The level for mapped IS-AIN8 analog input 5 alarm detection. Step: 0,01


Range: -320,00 - +320,00

Rack limit del [s] Delay for mapped IS-AIN8 analog input 5 alarm. Step: 1s Range: 0 - 180s

AnInAna- (7 .. 8) lev1 [ °C ] The level for mapped IS-AIN ANALOG INPUT 4-8 alarm detection. Step: 1 Range: -32000 - +32000

AnInAna- (7 .. 8) lev2 [ °C ] The level for mapped IS-AIN8 ANALOG INPUT 7-8 alarm detection. Step: 1 Range: -32000 - +32000

AnInAna- (7 .. 8) del [s] Delay for mapped IS-AIN8 ANALOG INPUT 7-8 alarm. Step: 1 s Range: 0 - 180 s Valid for BF+J1939-2.2.aig archive:

ExTmp wrn [ °C ] The level for mapped IS-AIN8 analog input 1 alarm detection. Step: 1 Range: -32000 - +32000

ExTmp sd [ °C ] The level for mapped IS-AIN8 analog input 1 alarm detection. Step: 1 Range: -32000 - +32000

ExTmpt del [s] Delay for mapped IS-AIN8 analog input 1 alarm. Step: 1s Range: 0 - 180s

BoostAirT wrn [ °C ] The level for mapped IS-AIN8 analog input 2 alarm detection. Step: 0,1 Range: -3200,0 - +3200,0

BoostAirT sd [ °C ] The level for mapped IS-AIN8 analog input 2 alarm detection. Step: 0,1 Range: -3200,0 - +3200,0

BoostAirT del [s] Delay for mapped IS-AIN8 analog input 2 alarm. Step: 1s Range: 0 - 180s


Hint: The adjustable analog input delay is still active when analog inputs are configured as binary.

Convert Power This setpoint group contains conversion characteristics between Engine power and required level of gas throttle valve opening. Default setting (for information only)

Engine power [ kW ]Gas

Thro

ttle

1-10

0 [ %

]

Engine power

[kW] GasThrottle

[%] 1 100 0,0 % 2 200 35,5 % 3 300 35,5 % 4 400 35,5 % 5 500 35,5 % 6 600 35,5 % 7 700 34,0 % 8 800 33,0 % 9 900 28,0 % 10 1000 0,0 %

EnginePower 1 [kW] Step: 1 kW Range: 0 – 3000 kW

GasThrottle 1 [%] Step: 0,1 % Range: 0,0 – 100,0 %

EnginePower 10 [kW] Step: 1 kW Range: 0 – 3000 kW

GasThrottle 10 [%] Step: 0,1 % Range: 0,0 – 100,0 %

Convert Diesel This setpoint group contains conversion characteristics between Diesel value (position of diesel actuator) and engine power gained from diesel. Diesel value is measured or counted depending on selected

configuration. Diesel [ % ]

Die

sel p

ower

[ kW

]

The Fuel rate of the diesel fuel is available in this group of setpoints in BF+ANA-2.2.aig archive only


Diesel 1..10 [%] Step: 0,1 % Range: 0,0 to 100,0 %

DieselPwr 1..10 [kW] Step: 1 kW Range: 0 to 3000 kW

Fuel rate 1..10 [L/h] Step: 0.1 % Range: 0.0 – 600.0 L/h

Act. calls/SMS

Warning call [DISABLED / ENABLED] Enables or disables active calls/SMS to selected phone or mobile when the warning alarm occurs.

Shut Off call [DISABLED / ENABLED] Enables or disables active calls to selected phone or mobile when the shut down alarm occurs.

AcallCH1 .. 3 - Type There are three separate channels for active calls. If is set each channel sends data or SMS to phone number or e-mail to address, which is set in following AcallCH1…3 Addr setpoint. DISABLED: Channel is disabled. DATA: Standard analog, GSM or ISDN modem connection to WinEdit. SMS: Channel sends SMS message. Only when is GSM modem connected. E-MAIL: Channel sends E-mail. Only when is IG-IB connected. EML-SMS: Channel sends E-mail with short SMS. Only when is IG-IB connected. Email contains

- header with serial number and application info. - Alarm list - 20 History records (reason, date, time)

Example of EML-SMS: AL=(Sd Water Temp,Wrn Water Temp,!Emerg Stop,ActCallCH1Fail)

AcallCH1..3Addr Address for channel 1...3 active call. Practically it means phone number or e-mail address. For more details see WinEdit-MultiEdit guide chapter IG-IB Internet communication. Hint: To receive active call run WinEdit – Type of connection = Active call. WinEdit Active call window contains list of received AIG or AIS files. Each list item contains Gen-set name, Date, Time, IS serial number.

NumberRings AA [ - ] Number of rings prior to open modem connection from PC to controller. Step: 1 Range: 1 – 30 Hint: NumberRings AA change is not accepted immedatelly but after controller is switched on or when modem is connected to controller.


A.c.multiplier [1 to 250] When active call is activated, controller tries five times to open the connection when A.c.multiplier = 1 (e.g. when the phone line is engaged). There are ten attempts when A.c.multiplier = 2, etc.. Step: 1 Range: 1 to 250 Hint: There are 5 attempts for any active call. Timeout for connection is 90 sec and after 120 sec controller starts the next attempt. During that time response for incoming call is blocked.

Date and time

TimeStamp per Time interval for history record. Time base is based on number of minutes since midnight. Step: 1 min Range: 0 - 240 min Hint: No history is recorded when TimeStamp Per = 0. Time stamps are stored to history when Gas is open (output GasOk is closed).

SummerTimeMode [DISABLED / WINTER / SUMMER,

WINTER-S, SUMMER-S] DISABLED: Automatic switching between summer and wintertime is disabled. WINTER (SUMMER): Automatic switching between summer and wintertime is enabled and it is set

to winter (summer) season. WINTER-S (SUMMER-S): Modification for southern hemisphere.

Time [HHMMSS] Real time clock adjustment

Date [DDMMYY] Actual date adjustment

Analog Config Note: Only in BF+ANA-2.x.aig and BF+ICB-2.x.aig.

Ana-(1- 4) HWCfg [ possible HW configuration ] This setpoint selects Hardware configuration of IS-AIN8 analog inputs (=measuring type). Possible HW configuration of IS-AIN8 analog inputs 1 – 4:

• ±100mV, • ±1V, • 0-2.5V, • 0-10V, • 0-2500Ω, • 0-2500Ω 3w (3-wire sensor connection), • ±20mA active, • 0-20mA passive.

Ana-(5-8) Sensor [ list of fix curves IS-AIN8 ] Configuration of sensors on analog inputs IS-AIN8 module.


Possible HW configuration of analog inputs 5 – 8 is: • PT100, • PT1000, • NI100, • NI1000, • ThermoJ, • ThermoK, • ThermoL, • 4 – 20 mApas, • 4 – 20 mAact, • 0 – 20 mA pas, • ± 20 mAact, • 0 – 250 ohm, • 0 – 2400 ohm, • 0 – 2,4 V, • ± 1 V, • ± 10 V, • ± 100 mV, • PT100 F, (value in Fahrenheits) • PT1000 F, • NI100 F, • NI1000 F, • ThermoJ F, • ThermoK F, • ThermoL F.

Ana-(1-8) Range [-] Range of inputs in case of fix curves with linear sensor. This values is used for maximum of linear sensor. Example: - Analog input is configured for sensor 0-250Ω.

- Range for this input is set to 100. - When resistance on analog input is 250Ω, IG-BF shows value 100.

Specials

FRP delay [s] Determines range of time interval of power skips evaluation from which the DieselLim SD is evaluated. Step: 0,1 s Range: 0,0 – 4,0 s


Operator Interface

Pushbuttons and LEDs

1 4

12

11

6

5 2

9

10

8

7

3

Pushbuttons: 1. MODE→ Selection the system operation mode (OFF -> MAN -> AUT) 2. ←MODE Selection the system operation mode (AUT -> MAN -> OFF) 3. HORN RESET Deactivates the HORN 4. FAULT RESET Acknowledges faults and alarms 5. START Start of bi-fuel operation. The pushbutton is active only in MAN mode 6. STOP Slow close of the gas. The throttle valve is slowly closed and then system

changes operational state to Diesel. If the STOP button is pressed for the second time during Slow stop, immediate gas close is effected. The pushbutton is active only in MAN mode.

7. PAGE Cyclic selection of the display mode (MEASUREMENT->SETPOINTS->HISTORY)

8. ↑ Select the set point, select the screen or increase set point value 9. ↓ Select the set point, select the screen or decrease set point value 10. ENTER Confirm set point value


LEDs 11. ENGINE OK No warning or shutdown is reported on engine and gas train 12. ENGINE FAILURE LED starts flashing when engine or gas train failure occurs.

After FAULT RESET button is pressed, goes to steady light (if an alarm is still active) or is off (if no alarm is active)

How to select the system mode? For transition from OFF to MAN or AUT use MODE→ button. Button MODE→ is active only if the switch OFF MAN AUT is visible on the display. Transition from OFF to AUT is possible at any time, if no shutdown is reported. During this transition gas throttle valve slowly opens and thus is accomplished smooth transition from diesel to bi-fuel operation. There are two possible ways how to make transition from AUT/MAN to OFF:

- Use STOP button in MAN operational mode for smooth transition to Diesel operation. During this transition gas throttle slowly closes and thus is accomplished smooth transition from bi-fuel to diesel operation. Subsequently use ←MODE for transition from MAN/AUT to OFF.

- Use ←MODE for immediate transition from AUT/MAN to OFF. During this transition gas throttle valve and double safety valves are immediately closed and thus the delivery of gas is cut. Pressing STOP button twice provides the same function.

Warning: If the engine diesel governor is not properly set, immediate close of gas valves may cause a load drop on the engine. Use STOP button for normal switch over to diesel operation.

Display menus There are 3 display menus available: MEASUREMENT, SETPOINTS and HISTORY Each menu consists of several screens. Press repeatedly PAGE button to select requested menu.

How to view measured data? 1. Use repeatedly PAGE button to select the MEASUREMENT menu. 2. Use ↑ and ↓ to select the screen with requested data.

How to view and edit set points? 1. Use repeatedly PAGE button to select the SETPOINTS menu. 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. 9. Press PAGE to leave selected set points group.

How to handle the HISTORY menu? 1. Use repeatedly PAGE to select the HISTORY menu. 2. Use ↑ or ↓ to select a requested record.


3. Use ENTER to select requested screen (record items) within displayed records

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 check the serial number and software revision? Press ENTER and then PAGE. On the display you can see InteliGen INFO screen for 10 seconds. InteliGen INFO screen contains :

1) Controller name (see Basic setting group) 2) InteliGens serial number (8 character number) 3) SW version: the first is the firmware version number; the second is configuration table number. 4) Application: IG-BF 5) Branch: IG-BF

Hint: Only in MEASUREMENT menu.

How to find active alarms? Active alarm list is the last screen 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 all alarms. 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.

Main measure screen 1 2

!OFF MAN AUT 1. InteliGen mode

% 35

Gas Open kW

Tot 200Gas 70Dsl 130

2. Indication of active alarm 33. State of engine

4. Total power and power gained from gas and diesel

4 5. Ratio of power gained from gas and total power:

AuxTot

DslTotD+

−=

100*)(/G

5

Power screen Engine power [kW] Diesel power [kW] Fuel rate [%] - only in BF+ANA-2.2.aig archive available Gas Valve [%]


Regulation screen Detonation [%] FLSR Diesel [%] FLSR Exhaust [%] Gas Valve [%]

Gas screen Offset [%] Gas Request [%] Gas Valve [%]

Engine values

BF+ANA-2.x BF+ICB-2.x BF+J1939-2.x ExhTmpLeft [°C] ExhTmpLeft [°C] ExhTmp [°C] ExhTmpRight [°C] ExhTmpRight [°C] BoostAirTmp [°C] BoostAirTmp [°C] BoostAirTmp [°C] Fuel rate [L/h] AnInAna-4 Fuel rate [L/h]

Note: The symbol “x” means numbers 1, 2, 3, …

Extended analog inputs

BF+ANA-2.x BF+ICB-2.x BF+J1939-2.x AnInAna-5 Rack [mm] AnInAna-6 Rack limit [mm] AnInAna-7 AnInAna-7 AnInAna-8 AnInAna-8

Note: The symbol “x” means numbers 1, 2, 3, …

IG-BF binary inputs 1 / 2 BI1 to BI5

IG-BF binary inputs 2 / 2 BI6 to BI9

IG-BF binary outputs 1 / 2 BO1 to BO5

IG-BF binary outputs 2 / 2 BO6 to BO9

Statistics RunHours [h] NextServTime [h] Fuel consumption [L] - active only if diesel fuel consumption is counted by flowmeter

equipped with impulse output Diesel [%]

Batt Volt [V]

Group Specials The values Group Specials listed bellow are visible only in WinEdit SW.


Act pwr 1, Act pwr 2, Act pwr 3

– active power in phases L1, L2, L3

Pwr factor - power factor of generator

Pwr factor1, Pwr factor2, Pwr factor3 – power factor in phases L1, L2, L3

Load char - Load character of generator

Load char1, Load char2, Load char3 – load character in phases L1, L2, L3

Mains PF ¨ – generator power factor if used alternative (mains) measuring terminals

MainsLoadChr – generator load character if used alternative (mains) measuring terminals

MapDieselPwr – The value MapDieselPwr is evaluated from the map in the setpoints group Diesel Convert. MapDieselPwr is the value Diesel Convert:Diesel Power corresponding to actual value DIESEL%.

Alarm list Hint: Running hours are incremented only during bi-fuel operation. Service time is decremented both during diesel and bi-fuel operation.


Chart guide to menus and pushbutton’s operation

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Instructions for operation The function of the kit is fully automatic. If InteliGen is in AUT mode, it automatically opens the safety valves and then slowly opens the throttle valve. By slow opening of throttle valve smooth transition from diesel to bi-fuel operation is accomplished. If you need to switch from bi-fuel to diesel operation, switch to operational mode MAN and 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 Slow stop, immediate gas closing is effected (active only in MAN mode). If you need to immediately close safety valves and throttle valve, press ←MODE button to reach the OFF operational state. This button is active only if the OFF – switch is visible on the display. It is also possible to press STOP button for the second time during Slow stop with the same result. Warning: If the engine diesel governor is not properly set, immediate close of gas valves may cause a load drop on the engine. Use STOP button for normal switch over to diesel operation. If you need to switch from diesel to bi-fuel operation, press the START button in operation mode MAN. System will slowly open the throttle valve and engine smoothly switches over to bi-fuel operation.

Conditions for bi-fuel operation • Mode MAN, AUT • No sensor fail for AI1 Detonation • No sensor fail for selected type of Engine power measuring • Gen-set is running and the topical power is higher than Diesel protect - Min Power • No DENOX fail • Binary input GASDISABLE is open (if configured) • Binary input GASENABLE is closed • No unconfirmed shut down alarms are active • The period minimum10secs elapsed from the last closing of the gas valve.


Remote control and data logging

History file Record structure Abbreviation Value Reason Date Time Pwr Total power G/D Gas/Diesel ratio PwrG Power gained from Gas PwrD Power gained from Diesel Vout Gas throttle valve output % GsRq GasRegul in % FLSD Fast Limit Slow Release – Diesel protection FLSE Fast Limit Slow Release – Exhaust overheating protection Knck Signal from DENOX – knocking indication IG-BF Analog input 1 Offs IG-BF analog input 3: Offset Binp Binary inputs IG – BF Bout Binary outputs IG – BF Mode OFF – MAN – AUT Batt Battery voltage ExTL IS-AIN8 Analog input 1 ExTmpLeft ExTR IS-AIN8 Analog input 2 ExTmpRight BATm IS-AIN8 Analog input 3 BoostAirTmp FuRa IS-AIN8 Analog input 4 (e.g Fuel rate - BF+ICB-2.x.aig configuration) Rck IS-AIN8 Analog input 5 (e.g. Rack - BF+ICB-2.x.aig configuration) RckL IS-AIN8 Analog input 6 (e.g. Rack limit - BF+ICB-2.x.aig configuration) Ana7 IS-AIN8 Analog input 7 Ana8 IS-AIN8 Analog input 8 Note: The symbol “x” means numbers 1, 2, 3, …

List of possible events Zero signed events are not displayed or stored. Events specification Alarm History Active call Configurable Analog inputs IG-BF alarms YES YES YES Analog inputs iG-IOM or IS-AIN alarms YES YES YES Binary inputs IG-BF alarms YES YES YES Binary inputs iG-IOM or IS-AIN alarms YES YES YES Events info InteliGen switched on 0 Switched On 0 Gas open 0 GasOpen 0 Gas closed 0 GasClose 0 Gas enable Gas enable Gas enable 0 RegGasPress 0 RegGasPress 0 Detonation OK 0 Detonation OK 0 Detonation Detonation Detonation 0 Denox Knocking Dx Knocking Dx Knocking 0 Denox Trip Dx Trip Dx Trip 0


Events specification Alarm History Active call Denox load reduction Dx LdReduct Dx LdReduct 0 GasSlowClose 0 GasSlowClose 0 Periodic history record 0 Time stamp 0 Time mode was changed 0 TimeModeChngd 0 Password was set from any terminal 0 Password set 0 Password was changed from any terminal

0 Password chngd 0

Service time expired WrnService Time 0 Wrn Engine Emergency stop closed EmergencyClose EmergencyClose Sd Battery voltage Wrn Batt volt Wrn Batt volt Wrn Battery is discharged Sd Batt flat 0 Sd External Temperature Left (AI1) ExTmpLeft ExTmpLeft Wrn/sd/stp External Temperature Right (AI2) ExTmpRight ExTmpRight Wrn/sd/stp Offset (AI3) Offset Offset Wrn/sd/stp Boost air temperature (AI4) BoostAirTmp BoostAirTmp Wrn/sd/stp Boost sensor fail Fls Boost Fls Boost Fls Low gas peressure (BI) Sd LowGasPress Sd LowGasPress Sd DieselLow Sd DieselLow Sd DieselLow Sd Sd Denox Fail Sd Denox Fail Sd Denox Fail Sd Sd BFM Fail Sd BFM Fail 0 Sd Sd Gas Low Sd Gas Low 0 Sd Sd Reg gas pressure Sd RegGasPress Sd RegGasPress Sd System info Wrong params checksum 0 Wrong params 0 Watchdog reset 0 Watchdog rst 0 Application archive loaded 0 Appl.loaded 0 Firmware loaded 0 Firmw.loaded 0 IS-AIN8 module fail Sd ANA fail Sd ANA fail Warning RA15 fail Wrn RA15 fail Wrn RA15 fail Modem RS232 control command 0 RS232 control 0 MODEM control command 0 MODEM control 0 SMS control command 0 SMS control 0 Modem Bridge control command 0 MB control 0 Local Brigde control command 0 LB control 0 Internet Bridge control command 0 IB control 0 Active call from CH1 successfully sent 0 ActCallCH1 –OK 0 Active call from CH2 successfully sent 0 ActCallCH2 –OK 0 Active call from CH3 successfully sent 0 ActCallCH3 –OK 0 Unsuccessful active call from CH1 ActCallCH1Fail ActCallCH1Fail 0 Unsuccessful active call from CH2 ActCallCH2 Fail ActCallCH2 Fail 0 Unsuccessful active call from CH3 ActCallCH3 Fail ActCallCH3 Fail 0 Hint: Binary and analog inputs alarm events are recorded and displayed under a user name.

IG-BF controller operational states Abbreviation Meaning Init Controller initialization Not ready Not ready: OFF mode, Gas disabled, sensor fail (Detonation, Boost), active Binary

input SD Ready Gas enable, DENOX Trip disable, Low Boost pressure Diesel Gas enable, DENOX Trip enable, Low Boost pressure


Gas Open Bi fuel operation Restrict Gas throttle valve is limited (by FLSR or Detonation protection) SlowClose Gas programmable closing procedure FLSR = Fast Limit Slow Release


Technical data

Power supply Voltage supply 8-36V DC Consumption depends on supply voltage 0,4A at 8VDC; 0,1A at 36VDC Battery voltage measurement tolerance 2 % at 24V RTC battery live 10 year Hint: When internal RTC battery becomes empty InteliGen function (e.g. Ready for stand by) does not change until controller power supply is switched off. After the next power switch on controller: Stays in the INIT state (not possible to run genset) All History records disappear except Wrong setpoint record Alarm list is empty Time and Date values are set to zero Statistics values are random

Operating conditions Operating temperature -20..+70oC Storage temperature -30..+80oC Protection front panel IP65 Humidity 95% without condensation Standard conformity Low Voltage Directive EN 61010-1:95 +A1:97 Electromagnetic Compatibility EN 50081-1:94, EN 50081-2:96 EN 50082-1:99, EN 50082-2:97 Vibration 5 - 25 Hz, ±1,6mm

25 - 100 Hz, a = 4 g Shocks a = 200 m/s2

Dimensions and weight Dimensions 180x120x50mm Weight 800g

Binary inputs and outputs Binary inputs Number of inputs 9 Input resistance 4,7 kΩ Input range 0-36 VDC Switching voltage level for close contact indication 0-2 V Max voltage level for open contact indication 8-36 V

Contact relay outputs Number of outputs 2 Electric life cycle min 100.000 switching cycles Maximum current 12 A DC resistive load 4 A DC inductive load Maximum switching voltage 36 VDC Minimum load 24 V / 0,1 A Insulation voltage 500 Veff


Binary open collector outputs Number of outputs 7 Maximum current 0,5 A Maximum switching voltage 36 VDC

Analog inputs Not electrically separated Resolution 10 bits Sensor resistance range 0 Ω-2,4 kΩ Resistance measurement tolerance 4 % ± 2 Ω out of measured value

RS232 interface Maximal distance 10m Speed 19.2kBd Recommend external converter: ADVANTECH – ADAM 4520: RS232 to RS422/485 converter, DIN rail, automatic RS485 bus supervision, no external data flow control signals, galvanic isolated. Recommended internal converter: ADVANTECH – PCL-745B or PCL745S : Dual port RS422/485 Interface card, automatic RS485 bus supervision, no external data flow control signals, galvanic isolated.

IG-BFM Power supply 8 – 36 V DC Operating temperature -20 ÷ +70 °C Humidity 95% without condensation

Analog input Galvanically separated One input with three ranges: 0 – 0,02 A 0 – 0,2 A

0 – 8 A

PWM output (for gas throttle valve control) Maximal output current 5 A

IS-AIN8 Power supply: 8 - 36 V DC Consumption (depends on supply voltage and configuration) 100 - 300mA Mechanical dimensions: 150 x 160 x 50 mm ,

DIN rail (35 mm) mounted Connection to IS-CU (galvanically separated) CAN1 Operating temperature -10..+60 o C Storage temperature -40..+80 o C Protection front panel IP 20 Humidity 95% without condensation Standard conformity Low Voltage Directive EN 61010-1:95 +A1:97 Electromagnetic Compatibility EN 50081-1:94, EN 50081-2:96


EN 50082-1:99, EN 50082-2:97

I-CB Power supply: 8 – 36 V DC Consumption: 0.1A depend on power supply Operating temperature -20 ÷ +70 °C Storage temperature -30 ÷ +80 °C Humidity 85% without condensation Protection IP20 Dimensions 95x96x43 mm, DIN rail (35 mm) mounted Weight 300g


Compact Bi-fuel Governor/Controller€¦ · InteliGen BF, SW Version 2.4, ComAp – June 2005 - 10 – IG-BF-2.4.pdf . Principle of operation Gas throttle valve control FLSR DieselLimMin

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