HT-Gas Engine Control System Product Features Benefits

HT-Gas Engine Control System
HUEGLI TECH Gas Engine Management System
The HT-Gas Engine Control System
is a comprehensive solution in a
modular concept, presently for gas
engines up to 25 liter displacement:
Three modules complete this
syst5em: IS-CU InteliSys, AF-2000
Lambda controller and RM-814 or
RM- 5 Mixer.
InteliSys is a top end expandable
controller for single and multiple
generating
sets
operating
in
standby or parallel modes.
Product Features
•
•
•
•
•
•
•
•
•
•
•
Can-Bus communication
CHP support (e.g. universal PID loops)
Automatic synchronising and power control
Automatic and Manual drive
Fast response on load transient
2 Individual Graphical display
2 Separate History records (400 events)
Password protection (3 level)
Language selection
Numerous I/O’s
Configurable In and Outputs
Benefits
•
•
•
•
•
•
Complete integrated gen-set and engine
solution - less wiring and components
Communication among all components
via CAN, RS485 and Internet
Many types of communication easy
supervision and servicing
Perfect price/performance ratio
Precise Lambda control
O2-Drift compensation
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The AF-2000 is a unique and
enhanced Lambda Control unit
combined with an I/O Module. A
modern control platform with a
powerful microprocessor and a
large memory unleashes numerous
features with great flexibility.
The RM 814 or 25 Mixer is an
enhanced sophisticated Air Gas
blender based on the approved ring
gap principal. Due to a precise
mechanical
gear
system
an
accurate Lambda control tolerance
smaller
than
+/0.01
is
guaranteed.
All
3
units
together
are
communicating among each other
via CAN Bus. Modularity results in
a perfect price / feature ratio and
allows reasonable expansion of
I/O’s at any time.
Contact our gas experts for more
information and application detail.
www.huegli-tech.com
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Page 1 of 17
HT-Gas Engine Control System
Integrated Protection
Generator
• All standard InteliSys gen-set and
engine protection
Engine
• Exhaust temperatures
• Turbocharger temperatures
• Mixture temperature
• Gas temperature
• Various pressures
Communication Extention
•
•
IG-IB
IG-MU
Software
•
•
•
•
WinEdit
MultiEdit
AF-2000-CFG
Easy Fire (Ignition software release
in 2007)
Extention Features
InteliSys
• All standard InteliSys extentions
• BCD Ignition communication
(2007)
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AF-2000 Lambda Control
Product Features
•
•
•
•
•
•
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•
•
•
Precise Lambda control
Can-Bus communication
Graphical display
History record (200 events)
Password protected (3 level)
Language selection
Key pad control
Numerous I/O’s
Configurable In and Outputs
Display sealed IP65
Advantage
•
•
•
•
•
•
Perfect price performance ratio
O2-Drift compensation
Remote access via IS-CU
Automatic set up for commissioning
Reduced wiring
Programmable vie key pad
The AF-2000 is a unique and
enhanced Lambda Control unit
combined with an I/O Module. A
modern control platform with a
powerful microprocessor and a
large memory unleashes numerous
features and flexibility. It is used in
all gas engine application such as
stochiometric and lean burn.
Mapping
power,
pressure,
temperature and other parameters
result in a very precise and fast
responding air fuel ratio control.
Monitoring combined with logic
functions allows the user a wide
combination and therefore the AF2000 can be adapted to any
application task.
CAN Bus communication to other
peripheries facilitate remote access
and wiring issues.
A powerful graphical display, icons
symbols and bar graph for intuitive
operation set a new standard for
the gas engine controls.
Making the most use out of the AF2000 is to combine it together with the
RM series Mixer. This enables more
features and is also cost saving for any
application. Additional I/O’s on the Mixer
PCB
prevent
from
using
costly
extensions.
Ask our gas experts for information.
www.huegli-tech.com
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AF-2000 Lambda Control
Technical Specifications
Control Unit
•
•
•
•
Supply Voltage:
Current consumption:
Communication Interface:
Display:
•
•
•
•
•
Keypad:
Housing:
Mounting hole:
Front Display:
Weight:
24 V DC (+/- 25%)
<0,6A
Can-Bus, RS 232 und RS 485
Graphical LC-Display, 120 x 16 Dots,
Background illuminated
4 System keys, 10 Function keys
electro plated housing 141 x 69 x 32 mm
137 x 65 mm
144 x 72 mm
0,4 kg
I/O Module
•
•
•
•
Supply Voltage:
Interface:
Digital Input:
Digital Out:
•
Analogue Input:
•
•
•
•
Frequency Input:
Analogue Output:
Dimensions:
Mounting:
24 V DC (+/- 25%)
Can-Bus
8 Input 24 V DC, Low threshold< 5 V, High threshold > 15 V
8 Output 24 V DC, max. 0,5 A,
Whereas 2 can be used for PWM
4 Input 0..10 V / 0..20 mAmp, 10 Bit
4 Input for Thermocouple Typ K, max. 900°C, 10 Bit
1 Input for Pt100, max. 120°C, 10 Bit
1 Input for Lambda sensor, 10 Bit
max. 10 kHz Sine-wave
2 Output 0..20 mAmp (0..10 V with Shunt), 10 Bit
183 x 72 mm
35 mm DIN Rail
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Page 4 of 17
RM-Series Gas Mixer
The RM Mixer is an enhanced
sophisticated Air Gas blender
based on the approved ring gap
principal. Due to a precise
mechanical gear system an
accurate
Lambda
control
tolerance smaller than +/- 0.01 is
guaranteed.
Engineering
and
design has achieved a level which
allows using the mixer for
Natural, Bio and other gas
application.
Robustness
and
environmental protection makes
this mixer unique and extremely
user friendly.
An integrated, well protected electronics’ PCB equipped with several Inputs and Outputs provides
monitoring features for all important parameter like, gas inlet, air filter clock up, exhaust
temperature etc. An analogue output can be used as a drive. CAN Bus communication allows
flexibility together with IS-CU and the AF-2000 control system and cost savings for additional
I/O’s.
Product Features
•
•
•
•
•
•
•
•
Accurate gas metering
Fast response to load transient
CAN Communication (combined with AF-200)
On board I/O’s
Automatic and Manual drive
RM-814 (4-14 litre engine displacement)
RM-25 (14-25 litre engine displacement)
Status indication
A brilliant combination of control
units is to use the mixer together
with the AF-2000 lambda controller
and IS-CU gen-set control system.
This unleashes pure control, logic
and monitoring power and allows
unbounded communication among all
peripheries.
Technical Specification
•
•
•
•
•
•
12 and 24 VDC
6 Analogue Input [VDC, mAmp, Ω]
1 Binary Input
1 Binary Output
1 Analogue Output [VDC]
IP-67 Protected
W:\DOKUMENTATION 2\Gas Motoren\Mischer Ringspalt\Leaflet\English\4011-V1.0-Product Marketing Information-Mixer-29-8-06-dh-en.doc
Ask us for information and talk to
our gas application experts.
www.huegli-tech.com
4011-V1.0 07.09.2006
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Page 5 of 17
RM-Series Gas Mixer
Dimensions
Engine side
RM-814
RM-25
Airfilter Side
Gas Pipe 2“
½“ for
pressure
regulator or
negative
pressure
sensor
½“
for
crank
case ventilation
½“
for
gas
pressure sensor
Gaspressure, manifoldpressure,
exhaust temperature, manifoldtemperature
and
other
parameters can be connected
directly to the mixer.
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Light Easy Fire LEF
Digital Ignition
System
The BCD Digital Ignition System
1. Description of Control Module
The BCD1-8 is a microprocessor controlled
ignition system that combines the advantage of
the inductive and the capacitive type ignition in
one product.
It can supply up to 8 Cylinders.
The BCD1-8 produces alternating current (AC)
sparks, which reduces the wear of the spark
plug.
The energy and the spark duration levels can be
controlled, for best combustion and longest spark
plug life.
Industrial Version
The energy mode is selectable either via RS232
Link, or by modulation of the spark reference
pulse in case of an engine control module (ECM).
Two spark energy modes exist: single strike
(primary is driven once) and double strike (primary is driven twice).
The timing signal to the BCD is taken either from a ferrous trigger wheel, running at half engine
speed (on the camshaft with one peg per cylinder plus one reference pulse), or it gets timing
information from the engine’s own ECM.
If a trigger wheel is used, a speed (rpm) related timing curve can be programmed. There is also
provision for a fixed or variable timing offset through the RS-232 link.
If more than eight coil outputs are needed, two control modules can be cascaded for up to sixteen
(16) coil outputs. The number of outputs is configurable in firmware. The sequence of firings
starts when the module receives either the spark reference pulse (ECM) or the additional index
pulse from the trigger wheel.
The control module firing order is primary coil 1 followed by coil 2, 3, 4, and up to the configured
number of coils. The firing starts when the first trigger pulse following the reference pulse is
received. When two modules are used in cascade mode the firing alternates between master (A)
and slave (B). The firing order in cascade mode is A1, B1, A2, B2, A3, B3, and up to the
configured number of coils.
Note: The combination of the AC spark with plug-mounted coils provides excellent combustion on
Natural gas engines up to 5 liter/Cylinder, 2 MW power operation at Lambda 1.6
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Light Easy Fire LEF
Digital Ignition
System
2. The BCD features & Specifications
2.1 Features
2.2 Specifications
•
•
•
•
•
•
Supply Voltage range:
Power consumption:
Trigger inputs:
•
•
•
•
•
Combination of capacitive/inductive
Alternating current spark (AC)
User programmable ignition curve
RS-232 communication link
Two programmable energy levels
Up to 8 cylinders. 12, or 16 cylinders
are possible in cascade mode
2 outputs sinking up to 1Amp. at
+25°C and up to 0.5 Amp. at +15°C
1 Sensor input 0-5V
2 general trigger inputs, VR (passive)
or Open collector (active)
Trigger signals from ½ engine speed
disc or from Engine control module
EMC
Overspeed shutdown
18 - 32 VDC
Max 3.6A RMS
Two separate with
automatic detection of
type of sensor: Variable
reluctance (passive) 0.3120V p-p or open
collector (active) 5V
logic, internal pull-up in
module
Analog sensor input:
One, 0-5 VDC
Output: (Not assigned yet)
Two, max. load
30W, 30V, 1 Amp.
Communication port:
One, RS 232
Ambient temperature range: -40 °C to +125 °C
Transient Voltage protection: ISO 7637/2 to ISO
7637/3
EMC:
CISPR 25-2004/104/EC
Vibration:
IEC68-2-35 Fda
Sealing:
IP6k9k
Weight:
1.7 kg
3. Dimensions
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Light Easy Fire LEF
Digital Ignition
System
4. CU2-05 High Tension Coil
Dimensions as per drawing K805 100 05 (last page).
The CU2-05 Coils consist of the upper part, which is the coil
itself, plus a screwed on extension that fits right on to the
spark plug. Hence, no separate high tension cables are
required.
The coil incorporates an integrated connector and two fixations
to be screwed to a common bracket.
Unique is the internal insulation, it is a synthetic ester based
insulating liquid, which does not restrict internal micro
expansions, and which provides a self healing effect.
A feedback signal is available that can be used for combustion
information and spark diagnostic.
Secondary voltage
Is defined as the absolute peak value of the voltage
during the first negative oscillation during discharge.
(Upeak in figure A).
10%
Rise time tr
Is defined as the time from that the secondary voltage
has reached 10% of Upeak to the time that the voltage
has reached 90% of Upeak without any load.
90%
U peak
tr
Figure A
4.1 Ignition Characteristics
Impedance characteristics
Ignition coil parameters
Name
Resistance (kOhm)
Secondary inductance (H)
Primary inductance (uH)
Min
7.5
8.5
800
Nom
7.7
9.2
920
Max
7.9
10
1000
Primary current characteristic
Characteristics of primary current with 1.5uF charge capacitor
Name
Peak primary current
Coil drive voltage
Min
350
Nom
22
370
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Max
400
Unit
A
V
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Light Easy Fire LEF
Digital Ignition
System
4.2 Spark Characteristic
Spark duration td
Is defined as either:
U
The time from that the current becomes greater than 1
mA to the time that the current becomes zero after the
voltage no longer is limited (see figure B).
Or
The time from that the current becomes greater than 1
mA to the first time that the current becomes zero and
then no longer reaches 1 mA.
I
Figure B
td
Spark characteristics for 370V charge voltage 1.5uF charge capacitor, double strike mode
Characteristic
Min
Nom
400
430
µs
Spark energy
24
28
mJ
Secondary voltage (load 500kΩ // 50 pF)
24
26
28
kV
Secondary voltage rise time (load 500kΩ // 50 pF)
18
20
22
µs
Spark duration
Max
Unit
4.3 Installation
Due to its internal synthetic ester insulation, the coil should always be installed vertically, with the
coil portion on top. The maximum inclination from the vertical line is 45° in either direction. See
drawing K805 100 05. If the coils had been stored in a horizontal position for sometime, it should
be left min 1 hour in its vertical operating position before the engine is started.
4.4 Protection
Each coil has a built in over voltage protection in case the spark return connection "C" to the
BCD1-8 control is lost.
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Light Easy Fire LEF
Digital Ignition
System
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Light Easy Fire LEF
Digital Ignition
System
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Selection Guide
Product selection guide and application hint
Selection of Mixer by engine parameter:
In order to select the correct ring gap mixer, there are a few issues to watch out for:
•
•
Engine capacity
Displacement
A basic table helps to select the appropriate mixer:
Engine Type Inline [I] or V
Engine Displacement [lt] Mixer Model
I
I
I or V
V (with 2 air filters)
V (with 1 air filter)
V (with 2 air filters)
4-8
8-14
14-25
28-50
28-60
50-85
RM-814-ZF
RM-814F
RM-25F
RM-25F
(RM-45) n.a.y
(RM-45) n.a.y
Quantity Load [kW]
1
1
1
2
1
2
~80
~200
~350
~600
~750
~1100
n.a.y = not available yet
Still there needs to be paid attention to the design between the air filter, mixer and turbo
charger.
Restrictions in the design of the piping will cause loss of velocity of the air stream, which
will decrease the efficiency of the mixer.
Hence, the suction piping needs to be as straight as possible.
See below drawing recommendation:
Recommendation of piping:
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Selection Guide
Not recommended piping:
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Selection Guide
Selection of Mixer by engine type:
Engine manufacturer
Engine model
N/A or TC
MAN
MAN
MAN
MAN
MAN
MAN
MAN
MAN
MAN
Liebherr
Jinan
Jinan
SCANIA
E0834 E 302
E0836 E 302
E0836 LE 202
E2876 E 302
E2876 TE 302
E2876 LE 302
E2848
E2842 E 312
E2842 LE 312
G926TI
4-190
8V-190
SGI 12 ST
NA
N/A
TC
N/A
TC
TC
TC
N/A
TC
TC
TC
TC
TC
Lambda
Stoichiometric
Stoichiometric
Lean Burn
Stoichiometric
Lean Burn
Lean Burn
Lean Burn
Stoichiometric
Lean Burn
Lean Burn
Lean Burn
Lean Burn
Lean Burn
Load [kW] Mixer
54
75
110
140
150
210
280
250
400
170
200
RM-814-ZF
RM-814-ZF
RM-814F
RM-814F
RM-814F
RM-814F
RM-25F
RM-25F
RM-25F
RM-814F
RM-25F
RM-45F
RM-814F
Quantity
1
1
1
1
1
1
1
1
1
1
1
1
1
Possible System Alignments:
Inline Engine Single Mixer and Single Throttle
Sensors to be used:
P Boost = Pressure Sensor: DMU-01 / 0-2.5 bar absolute (On Huegli Tech supply list)
T Mixture = Manifold Temperature: PT 100
T Exhaust Gas = Exhaust Temperature: T-2472-3000 (On Huegli Tech supply list)
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Selection Guide
V-Engine Single Mixer and Throttle
V-Engine Single Mixer and Twin-Throttle
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Selection Guide
V-Engine Twin-Mixer and Single-Throttle
V-Engine Twin-Mixer and Twin-Throttle
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