ID – BF - Applied Power · PDF fileIS-AIN8 ... - 128 - IS-AIN8 ... PPID J1939...

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

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

Reference guide

InteliDrive

ID – BF Expandable Bi-fuel Governor/Controller

with electronic engines support

Conversion Kit Software Configuration

SW version 1.2, June 2009

ID-BF-1.2, ©ComAp – June 2009 - 2 - ID-BF-1.2 - Reference Guide.pdf

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

Abbreviations............................................................................................................................................. - 5 - General description ....................................................................................................................................... - 7 -

Physical component and interface Descriptions ....................................................................................... - 8 - Corresponding documentation.................................................................................................................. - 8 -

Terminal and dimensions .............................................................................................................................. - 9 - ID-BF ......................................................................................................................................................... - 9 - ID-DCU terminals .................................................................................................................................... - 10 - IG-DFM Terminals................................................................................................................................... - 11 - ID-COM terminals ................................................................................................................................... - 12 - ID-DCU / IG-DFM / ID-COM dimensions ................................................................................................ - 13 - IS-BIN16/8............................................................................................................................................... - 14 - IS-AIN8.................................................................................................................................................... - 15 - IGS-PTM ................................................................................................................................................. - 16 - I-AOUT8 .................................................................................................................................................. - 17 - I-CB communication bridge..................................................................................................................... - 18 - I-RD-CAN (Remote Panel)...................................................................................................................... - 19 - I-LB, I-LB+ ............................................................................................................................................... - 22 - IG-IB Internet bridge................................................................................................................................ - 23 - Rules for I-RD-CAN, I-LB and IG-IB – CAN2 address setting ................................................................ - 23 - I-RB.. technical description ..................................................................................................................... - 24 -

Recommended wiring.................................................................................................................................. - 25 - Wiring example ....................................................................................................................................... - 25 - Electronic engine without redundancy line.............................................................................................. - 26 - Engine without ECU (mechanical engine) .............................................................................................. - 26 - Communication architecture ................................................................................................................... - 27 - I-CB wiring and configuration.................................................................................................................. - 28 -

Getting started ............................................................................................................................................. - 29 - How to install ........................................................................................................................................... - 29 - ID-DCU Analog inputs hardware configuration....................................................................................... - 30 - Examples of ID-DCU analog inputs connection...................................................................................... - 31 - ID-DCU Analog inputs software configuration ........................................................................................ - 32 - Analog inputs on IS-AIN8........................................................................................................................ - 38 - Analog Sensor availability ....................................................................................................................... - 39 - Binary inputs / outputs on ID-DCU.......................................................................................................... - 40 - Binary inputs on IS-BIN16/8.................................................................................................................... - 40 - Binary outputs on IS-BIN16/8.................................................................................................................. - 41 -

Logical Binary Inputs List............................................................................................................................. - 43 - Binary inputs assigned to CAT EMCP3, ICB (CAT CCM) and J1939 (CAT) configurations .................. - 47 - Binary inputs protection........................................................................................................................... - 47 -

Logical Binary outputs List........................................................................................................................... - 49 - Source – Log Bout .................................................................................................................................. - 49 - Source – Info........................................................................................................................................... - 52 - Source – Prg.states................................................................................................................................. - 52 - Source – Ana protections........................................................................................................................ - 53 - Source – Bin protections ......................................................................................................................... - 54 - Source – Binary Inputs CU...................................................................................................................... - 54 - Source – Binary Inputs............................................................................................................................ - 54 - Binary outputs assigned to CAT EMCP3, ICB (CAT CCM) and J1939 (CAT) configurations................ - 54 -

Logical analog inputs list ............................................................................................................................. - 55 - Analog inputs assigned to CAT EMCP3, ICB (CAT CCM) and J1939 (CAT) configurations ................. - 55 - Analog inputs from J1939 configuration.................................................................................................. - 56 - Analog inputs protection.......................................................................................................................... - 56 -

Analog outputs............................................................................................................................................. - 64 - InteliDrive – Engine ECU communication ................................................................................................... - 66 - Setpoints...................................................................................................................................................... - 67 -


Password................................................................................................................................................. - 67 - Basic settings .......................................................................................................................................... - 68 - Diesel protect .......................................................................................................................................... - 73 - Engine protect ......................................................................................................................................... - 76 - Convert Power......................................................................................................................................... - 80 - Convert Diesel......................................................................................................................................... - 81 - Analog Inputs .......................................................................................................................................... - 81 - Active call/SMS ....................................................................................................................................... - 81 - Date and time.......................................................................................................................................... - 82 - Protections .............................................................................................................................................. - 82 -

PLC - programmable functions.................................................................................................................... - 83 - PLC functions description ....................................................................................................................... - 86 - PLC configuration example ..................................................................................................................... - 96 -

Function details notices ............................................................................................................................. - 101 - Protections ............................................................................................................................................ - 101 - Universal states..................................................................................................................................... - 104 -

Alarm management ................................................................................................................................... - 105 - No protection......................................................................................................................................... - 105 - Warning ................................................................................................................................................. - 105 - Bi-fuel Shut down .................................................................................................................................. - 105 - Bi-fuel Slow stop ................................................................................................................................... - 106 - Sensor fail detection.............................................................................................................................. - 106 - Broken wire ........................................................................................................................................... - 106 - Exhaust temperatures protection principles.......................................................................................... - 106 - Alarms indication................................................................................................................................... - 107 -

Bi-fuel conversion kit principles ................................................................................................................. - 108 - Sensors and Actuators location ............................................................................................................ - 108 - Principle of operation ............................................................................................................................ - 110 -

Operator Interface ..................................................................................................................................... - 112 - Pushbuttons and LEDs ......................................................................................................................... - 112 - How to select engine mode ?................................................................................................................ - 112 - Display menus....................................................................................................................................... - 113 - How to view measured data?................................................................................................................ - 113 - How to view and edit set points? .......................................................................................................... - 113 - How to use the Fast- edit function? ...................................................................................................... - 113 - How to view the HISTORY menu?........................................................................................................ - 113 - How to check the serial number and software revision? ...................................................................... - 113 - How to change the display contrast ? ................................................................................................... - 113 - How to change the display backlight intensity ? ................................................................................... - 114 - How to change controller language ? .................................................................................................. - 114 - How to find active alarms ? ................................................................................................................... - 114 - Controller screens ................................................................................................................................. - 114 - Functions available from ID-DCU front panel keys............................................................................... - 117 -

Operation instructions................................................................................................................................ - 119 - Operational modes................................................................................................................................ - 119 - Manual operation mode - MAN ............................................................................................................. - 119 - Automatic operation mode - AUT.......................................................................................................... - 119 -

Controller configuration and monitoring .................................................................................................... - 120 - Direct connection to the PC .................................................................................................................. - 120 - Default archive ...................................................................................................................................... - 120 - DriveConfig............................................................................................................................................ - 120 - Configuration steps ............................................................................................................................... - 121 - Configuration lock ................................................................................................................................. - 122 - DriveMonitor .......................................................................................................................................... - 122 - Password protection.............................................................................................................................. - 123 - Modbus communication ........................................................................................................................ - 123 -

Technical data ........................................................................................................................................... - 125 - ID-DCU.................................................................................................................................................. - 125 - I-RD-CAN .............................................................................................................................................. - 126 - IG-DFM.................................................................................................................................................. - 127 - CAN bus interface ................................................................................................................................. - 127 - IS-BIN16/8, IS-AIN8 .............................................................................................................................. - 127 -


IS-BIN16/8............................................................................................................................................. - 128 - IS-AIN8.................................................................................................................................................. - 128 - IGL-RA15 .............................................................................................................................................. - 129 - IGS-PTM ............................................................................................................................................... - 129 - I-AOUT8 ................................................................................................................................................ - 130 - I-RBxx.................................................................................................................................................... - 130 - I-LB........................................................................................................................................................ - 130 - IG-IB ...................................................................................................................................................... - 130 -


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

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

ECU Alarm list

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

AOUT Controller Analog OUTput or outputs group. Archive

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

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

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

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

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

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

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

ID InteliDrive controller. ID-COM

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

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

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

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

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

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

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

I-RD-CAN


I-RP



IS-AIN8 InteliSys – Analog input module = extension module with 8 analog inputs. IS-BIN16/8

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

J1587

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

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

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

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

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

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


General description InteliDrive ID-BF is a specialized engine controller for high-speed Bi-fuel applications. It controls, monitors and protects the engine in bi-fuel operational mode. The controller can communicate with Engine Management System via the CAN serial line using standard J1939 or another (MODBUS) communication protocol.

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

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

Conformity declaration

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

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


Physical component and interface Descriptions Module ID-BF Central unit InteliDrive central unit:

14 BIN, 14BOUT, 8 AIN, 1xRS232, 1xCAN1 (full), 1xCAN2 (TTL), 1x Sync.Data line (TTL)

IG-DFM Interface Controller interface with Speed governor and Diesel actuator and Gas throttle valve servo-control loop.

ID-COM Communication interface

InteliDrive Communication interface for inter-controller or Remote display CAN1 line and for Redundancy synchronous J1708/1587 data line.

I-RB16 Relay board 16 relays with free NO/NC contacts 24VDC for binary outputs separation

I-RB8 Relay board 8 relays with free NO/NC contacts 24VDC for binary outputs separation

I-RB16-231 Relay board 16 relays with free NO/NC contacts 231VDC for binary outputs separation

I-RB8-231 Relay board 8 relays with free NO/NC contacts 231VDC for binary outputs separation

I-RD-CAN Remote display InteliDrive Remote display (Slave panel), CAN or RS232 interface I/O extension IS-AIN8 8 analog inputs Configurable for

VDO, PT100, PT1000, Thermocouples, mA, Volts IS-BIN16/8 Extension

module 16 Binary inputs, 8 Binary outputs

IGS-PTM Extension module

8 BIN, 8 BOUT, 4 AIN, 1 AOUT

I-AOUT8 Extension module

8 Analog outputs selectable to 10VDC, 20 mA, pwm (2,4kHz)

Communication I-LB, I-LB+ IG-MU

Multiple engines modem interface.

IG-IB Internet interface I-CB ECU communication interface Hint: IG-IOM extension unit is not compatible with ID-DCU controller.

Corresponding documentation PDF files Description 1 iD-BF-1.0 OperatorGuide.pdf iD-BF and HSC-ID conversion kit operating

manual 2 DriveConfig-2.5.pdf and higher PC configuration software 3 DriveMonitor-2.5.pdf and higher PC monitoring software 4 InteliCommunicationGuide.pdf Communication guide


Terminal and dimensions

ID-BF The iD-BF controller is based on iD-DCU hardware unit. The iD-CCU has to be modified by another SW firmware and the front panel is labeled by special iD-BF sticker. The front panel of the InteliDrive controller is intended for installation in an overall enclosure – rubber seal for IP 65 - see chapter Technical data.

Front panel LED Right RED Active alarm indication Blinks when new alarm is activated.

Steady lights after “Fault reset” confirmation - when alarm is still active. Disappears after “Fault reset” confirmation – when alarm is inactive.

Left GREEN Engine running indication Light when engine is running.


ID-DCU terminals

Grounding Terminal

BOOT JUMPER

BINARY INPUTSRPM

BINARY INPUTSANALOG INPUTS

BINARY OUTPUTS

POWER8 - 36 V DC

EXTE

NSIO

NM

ODUL

EID

-RPU

RS23

2

LB1

EXTE

NSIO

NM

ODUL

EID

-COM

+ -RPM

GND

RPM

IN

BI1

BI2

BI3

BI4

BI5

SHIE

LDCO

M

D+BO1

BO2

BO3

BO4

BO5

BO8

BO6

BO12

BO13

BO14

BO9

BO7

BO10

BO11

AIN1

AIN2

AIN3

AIN4

AIN6

+

AIN5

+

AIN8

+

AIN8

-

AIN6

-

AIN5

-

AIN7

+

AIN7

-

BI6

BI7

BI8

BI9

BI10

BI11

BI13

BI12

BI14

ID-DCU-Industrial

RPM Pulse measuring of diesel flow (diesel flowmeter) BI1 to BI14 Binary inputs, active when closed to minus power supply BO1 to BO14 Binary outputs; Low side switch; 0,5 Amps each; D+ D plus terminal AIN1 to AIN4 Analog inputs – group 1 AIN5+, AIN5- AIN6+, AIN6- AIN7+, AIN7- AIN8+, AIN8-

Analog inputs – group 2

ID-DCU xx -LT version with display preheating LT is an option for extending of operating temperature range from -20 to -40 °C. Heating foil is not part of standard ID-DCU and ID-MCU (without -LT extension).

Board temperature

+5 °C- 40 °C

Preh

eatin

g

3,5 W

The only one low temperature sensitive part is the controller display. ID-DCU-Industrial-LT version contains a preheating foil on the display activated below +5°C (measured on the PCB). Heating is switched off when controller power supply is below 10VDC (together with display backlight).


IG-DFM Terminals IG-DFM module is interface module for InteliDrive controller application. It is compatible with ID-BF firmware. Module is mounted directly to ID-DCU controller case. Module power supply: 8 to 36VDC.

CURRENT SENSE inputs CURRENT SENSE terminals are intended to measure electric current exciting a by proportionally controlled diesel actuator. The principle of measurement consists in measurement of DC or PWM electric current similarly to simple DC Ampermeter. There are available three input ranges. The proper mearuring range should be selected according to the real current range of used diesel actuator.

ACTUATOR and ACTUATOR POSITION The gas ACTUATOR is realized by proportionally controlled Gas throttle valve. The IG-DFM unit provides the servo control of the gas throttle valve. Terminals labeled ACTUATOR powers the valve coil. The coil is energized by PWM signal. Terminals ACTUATOR POSITION are intended to measure the actuator feedback. The feedback measuring circuits are energized by auxiliary power source 5VDC presented on the connector also.


ID-COM terminals Communication interface. ID-COM is mounted directly to ID-DCU box.

CAN1 Extension modules: EMS, IS-AIN8, IS-BIN16/8, IGS-PTM, IGL-RA15 CAN2 Intercontroller: I-RD-CAN, IG-MU, I-LB, I-LB+, IG-IB, others ID-

DCU

ID-DCU ID-COM

INTERFACE

INTERFACE

INTERFACE

CAN1J1939

J1587

CAN2PRO

CES

SOR

TTL

TTL

TTL

120 ohms

120 ohms

Hint: Put jumper to connect the internal 120 ohms terminating resistor for CAN2 interface. ID-COM module is not required when inter-controller CAN2 and J1587 lines are not used. In this case connect Extension modules CAN1 directly to Extension modules port ID-COM on ID-DCU (9-pin connector: 5=H, 9=L).


ID-DCU / IG-DFM / ID-COM dimensions ID-COM and IG-DFM are mounted directly to ID-DCU case. I-RD Industrial (Slave panel) has the same dimensions.

ID-SCM

ID-DCU

ID-COM

183 (7,2")

80(3,

1")

42,5

(1,7")

24 (0,9"

)47

(1,8")

~11

0(4,3

")

170 (8,87")

RS232

123(

4,8")

110

(4,4"

)

Cutoutfor InteliDrive

113 x 175 mm(4.4 x 6,9“)

ID-DCU box is fixed using four screw clips. Notice: iD-SCM in the picture read as iG-DFM


IS-BIN16/8 Extension module with 16 binary inputs and 8 binary outputs. All I/O can be configured to any logical function or protection - see chapter Binary inputs and Binary outputs. RPM1 and RPM2 inputs are not supported in InteliDrive.

IS-BIN16/8 module is connected on InteliDrive CAN1 bus. The corresponding module Address must be set on module and in controller configuration. Communication fail is indicated in controller Alarm list and by binary outputs Comm BIN fail, Comm BOUT fail. Use DriveConfig PC tool for controller configuration.

The Binary I/O specification see in chapter Technical data.

45 (1,8")146 (5,7")

160

(6,3

") 40 (1,6")

25 (1,0")

IN1

-

RPM

+

IN 2

IN1

+

RPM

-

IS-BIN 16/8

IS-BIN16/8 unit is DIN rail mount (35mm)


IS-AIN8 Extension module with 8 analog inputs. All inputs can be configured to any logical function or protection - see chapter Analog inputs. IS-AIN8 module is connected on InteliDrive CAN1 bus. The corresponding module Address must be set on module and in controller configuration. Communication fail is indicated in controller Alarm list and by binary output Comm AIN fail. Use DriveConfig PC tool for controller configuration. The analog inputs specification see in chapter Technical data.

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

+

iS-AIN8

IS-AIN8 unit is DIN rail mount (35mm)


IGS-PTM Extension module with 4 analog inputs, 8 Binary I/O. All I/O can be configured to any logical function or protection - see chapter Binary inputs, Binary outputs and Analog inputs.

IGS-PTM module is connected on InteliDrive CAN1 bus. The corresponding module Address (1 to 4) must be set on module and in controller configuration. Communication fail is indicated in controller Alarm list and by binary output CommBIN fail, CommBOUT fail, CommAIN fail. Use DriveConfig PC tool for controller configuration.

Any analog input can be configured for range: • 0 – 250 Ω (suitable for Pt100, Ni100), • 0 – 100 mV (suitable for thermocouples), • 0 – 20 mA.

Detail description see in IGS-PTM-1.0.pdf manual.

95 mm(3,7´´)

43 mm(1,7´´)

96 m

m (3

,8´´

)COMPENSATION

GND

POWER

8-36V DC

BINARY OUTPUTS

BINARY INPUTS ANALOG INPUTS

AI4

BI8

BI7

BI6

BI5

BI4

BI3

BI2

BI1

0-20 mA ANALOG OUT

BO8

BO1

BO2

BO3

BO4

BO5

BO6

BO7

CAN

RxTx

CAN

LH

COM

LB 4

AO-

AO+

iGS-PTM

IGS-PTM unit is DIN rail (35mm) mounted.


I-AOUT8 Extension module with 8 analog outputs. All outputs can be configured to any logical function - see chapter Analog outputs. I-AOUT8 module is connected on InteliDrive CAN1 bus. The corresponding module Address 1 to 4 (default 1) must be set on module and in controller configuration. Communication fail is indicated in controller Alarm list and by binary output Comm AOUT fail. Use DriveConfig PC tool for controller configuration. Each analog output can be switched by jumper for.

- 0 to 20mA - 0 to 10VDC (default) - PWM (Pulse With Modulation on 1,2kHz)

Module is 35 mm DIN rail mounted. CAN1 terminating 120 ohm resistor jumper is connected in default.

95 mm (3,7´)43 mm(1,7´)

Powersupply

I-AOUT8ComApHW:SW:

ANALOG OUTPUTS

ANALOG OUTPUTS

CAN

U - I - p U - I - p U - I - p U - I - p

p - I - U p - I - U p - I - U p - I - U

1 2 Pwr

120 ohm

Hint: Extension module communication fail can be configured in DriveConfig to No protection, Warning, Shutdown.


I-CB communication bridge I-CB (Communication bridge) is programmable CAN1 bus interface between InteliDrive and Engine Control Units (like MTU, CAT etc.) without standard J1939 communication protocol. Engine values from ECU (RPM, Oil pressure and other) are converted to standard InteliDrive I/O protocol.

Use ICBEdit software to configure I-CB.

I-CB unit is DIN rail (35mm) mounted.

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-RD-CAN (Remote Panel)

Hint: The ID-DCU-Industrial controller can be used as a I-RD-CAN remote display after uploading of the I-RD-CAN firmware

• Remote Display I-RD-CAN (Remote Panel) works as “a remote control panel” for the ID-DCU master

controller. • All panel buttons works the same way as corresponding buttons on master controller. All LEDs displays

the same state as corresponding LEDs on master controller. • Start, Stop buttons and setpoint changes are not active when master ID-DCU controller is in Local mode. • I-RD-CAN screen listing does not influence screen on master controller. • Interruption of the serial line between master device and I-RD-CAN will have no effect to the engine.

Master device will always be able to work without connected Remote display. • I-RD-CAN displays the same screens as it’s master controller and can be switched to the same

languages. The user interface is identical as the master controller. • I-RD-CAN is the same mechanical and electronic design (the same box but some electronic components

were removed). No inputs and outputs are available on I-RD-CAN only. • It is possible to connect I-RD-CAN to ID-DCU via RS232 (38,4kbps) or via CAN bus(50 or 250 kbps). • I-RD-CAN automatically downloads new configuration table from master controller if the CRC doesn’t

match the CRC of the stored configuration table. • I-RD-CAN uses separate mhx firmware different from controller firmware compatible with both ID-DCU-

Industrial and ID-VP-Industrial. • I-RD-CAN firmware can be reprogrammed via Boot load procedure only.

BL


• I-RD-CAN backlight can be switched to full intensity when middle power supply terminal (D+ in DCU) is closed to + power supply.

I-RD-CAN backlight-brightness intensity change (the same procedure for ID-DCU and I-RD-CAN) 1. Enter+Page buttons = switch to Info screen and then 2. Enter+Up/Down button increases/decreases the display backlight (it is stored - until the next change). 3. The setpoint Basic setting: LightTimeOff in I-RD works locally for I-RD (this is only exception) and it is not transferred to the central unit. Backlight is after this time switched off from current level. Any key touch activates the backlight. That means it is possible to set I-RD backlight level and LightTimeOff independent to ID-DCU. From I-RD firmware version 1.2 and hardware version 2.0 from s.n. xxxx0006 is possible to change Remote panel display backlight between adjustable and full level via external switch – see drawing below.

Opened switch = Backlight is adjustable by Enter-Up/Enter-Down panel keys from INFO screen (Enter-Page)

POWER8-36VDC

+ -

POWERSUPPLY

BACKLITESWITCH

REMOTE PANEL

Closed switch = full backlight like in ID-DCU

Hint: It is not possible to control I-RD backlight continuously via analog input like on ID-DCU.

I-RD-CAN wiring RS232 interface: three wire cable (2-3, 3-2, 5-5), max. cable length up 10 meters.

ID-CU I-RDRS232 RS232Contr.addr 1

CAN addr. 1

Contr.addr 1

Using converters to RS485 or RS422 increases distance up to 1000 meters. 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, baud rate 38400bps.

ID-CU I-RDRS232 RS232RS232 / RS422/485

RS232 / RS422/485

RS422/485Converter Converter

Contr.addr 1

CAN addr. 1

Contr.addr 1

CAN bus connection requires ID-COM module on ID-DCU. Use I-RD-CAN Central unit 9-pin connector (5=CAN H, 9=CAN L) to connect CAN bus. Put jumper to connect I-RD-CAN internal 120-ohm resistor for CAN bus line terminating.

ID-CU CAN2

ID-C

OM

I-RDContr.addr 1

CAN addr. 1

Contr.addr 15 - CAN H9 = CAN L

120

ohm

I-RD-CAN can monitor any ID-DCU controller on the CAN2 bus based on I-RD-CAN Contr. address setting.

BL


1.ID-CU CAN2ID

-CO

MI-RD

2.ID-CU

ID-C

OM

`

`

Contr.addr 1

Contr.addr 2

CAN addr. 1

Contr.addr 25 - CAN H9 = CAN L 12

0 oh

m

It is possible to connect up to two I-RD-CAN to common CAN2 bus. The I-RD-CAN address must be different in this case.

1.ID-CU CAN2

ID-C

OM

I-RD

2.ID-CU

ID-C

OM

I-RD

CAN addr. 1

CAN addr. 2

Contr.addr 1

Contr.addr 2

Contr.addr 1

Contr.addr 2

5 - CAN H9 = CAN L

120

ohm

120

ohm

Hint: There is no connection between ID-DCU and Remote panel during ID-DCU controller programming and in INIT state.

How to establish ID-DCU to I-RD-CAN connection Following screen appears after I-RD-CAN power supply is switched on and there is no connection to ID-DCU established. Screen rows Meaning / selection range I-RD front panel button to change I-RD-Industrial 1.x I-RD firmware branch and version ComAp 2004 Copyright SN: xxxxxxxx Controller serial number Contr. Addr: 1 Controller address: 1 to 32 Up, Down Connection: CAN addr.1 Connection: CAN addr.1, CAN addr.2,

RS232 Page

NO CONNECTION TRYING…. , PROGRAMMING I-RD status during Init state.

1. Connect selected communication line between ID-DCU controller and I-RD-CAN panel. 2. Switch ID-DCU and I-RD-CAN power supply on. 3. After I-RD-CAN Initialization screen appears: Use front panel Up/Down buttons to change Controller

address in the range 1 to 32. This I-RD-CAN Controller address must correspond to connected ID-DCU Basic setting: Controller address setpoint.

4. Use Page button to set I-RD-CAN connection: CAN addr.1, CAN addr.2 or RS232. 5. Then press Enter button to start data download. Message TRAYING … appears on the I-RD-CAN

screen. Unsuccessful attempt to read data is repeated each 15 sec. 6. The Programming bargraph appears on I-RD-CAN screen after connection is opened. 7. Standard ID-DCU screen appears after complete configuration is loaded to I-RD-CAN.

Hint: To switch to Init screen press Page button for more than 2 sec when CFG table error message appears on the I-RD-CAN screen.


I-LB, I-LB+ Modem interface unit for multiple engines with more separate internal channels for controller connection:

- Local connection 1 (I-LB local address 1) - Local connection 2 (I-LB local address 2) - Modem connection 1 (I-LB modem address 1) - Modem connection 2 (I-LB modem address 2)

It is necessary to select which connection type(s) a particular I-LB is using. In I-LB+ version, there is additional USB slave port, which can be used as a local connection only, together with RS232-modem connection. See more details in Inteli Communication Guide.

Jumper selection tree ComAp / ModBus – selects between ComAp PC tools (InteliMonitor, WinScope, ...) and third party PC SW for monitoring: - ComAp

o Direct / Modem – selects between direct connection (via RS232 or RS485) and modem connection type DIRECT

• RS232 / RS485 – selection of serial communication type • ADR1 / ADR2 – selection between two available local communication channels; if I-LB+ is

used, the USB communication automatically occupies the other channel MODEM

• HW / SW control – selection between modems with full interface • ADR1 / ADR2 – selection between two available modem communication channels; IG/IS-

NT controllers only, in ID the secondary modem channel not available • Setting RS232 / RS485 jumper to RS232 position is obligatory

- ModBus (not available at USB port of I-LB+, USB port always works in ComAp mode)

o Direct / Modem – selects between direct connection (via RS232 or RS485) and modem connection type

DIRECT • RS232 / RS485 – selection of serial communication type • ADR1 / ADR2 – selection between two available local communication channels; if I-

LB+ is used, the USB communication automatically occupies the other channel MODEM

• ADR1 / ADR2 – selection between two available modem communication channels; IG/IS-NT controllers only, in ID the secondary modem channel not available

• Setting HW / SW control has no influence; a modem with HW control is always expected in this mode

o ModBus Rate (9600 / 19200 / 38400 / 57600 bps) – selects the communication speed when ModBus protocol is selected, no matter if in Direct or Modem mode


IG-IB Internet bridge Internet interface unit for single or multiple engines.

95 mm(3,7´´)

43 mm(1,7´´)

96 m

m (3

,8´´

)

See Internet communication It is recommended to use IG-IB firmware version 2.0 IG-IB unit is DIN 35 mm rail mounted.

Rules for I-RD-CAN, I-LB and IG-IB – CAN2 address setting There are only 2 addresses on the CAN2 bus, that are shared between IG/ID, I-RD-CAN and I-LB, I-LB+ (IG-MU) - when used for direct cable connection. That means only two of these modules can be used at the same time on the same bus. The I-LB (IG-MU) can be connected as third device when is used for modem connection.

The following CAN addresses are used for modules connected to CAN2 (intercontroller CAN bus). There cannot be more modules using the same address connected at the same time.

Address can be changed using jumpers, configuration program or from the display - refer to the corresponding chapter or reference guide for detailed description.

Real

CAN2 Address IG-MU I-LB

I-LB (modem) I-LB+

IG-IB (IBConfig ≤ 1.5)

IG-IB (IBConfig ≥ 1.6) I-RD-CAN

122 addr. 2 123 addr. 2 addr. 2 addr. 1 addr. 1 addr. 2 addr. 2 124 addr. 1 addr.1 addr. 2 addr. 2 addr. 1 addr. 1 125 modem addr. 1

Hint: Please note that USB port is using its CAN address only if an external device is connected to the USB port of I-LB+. Make sure that other device (e.g. IG-IB) is not using the same CAN address as USB port of an I-LB+, because using USB port could interrupt CAN communication. Hint: Please note that addresses 1 and 2 (123, 124) are exchanged in versions IBConfig ≤ 1.5 and IBConfig ≥ 1.6 (see the table above). • IG-MU, I-LB address is set by Jumper • IG-IB address is set during configuration by IBConfig PC software. • InteliVision and I-RD-CAN address can be set from I-RD-CAN keyboard during initialization.


I-RB.. technical description Relay board contains 16 or 8 relays for ID-DCU binary (open collector) output separation. All relays are placed in sockets. Product options I-RB16 16 relays, load 24 VDC I-RB8 8 relays, load 24 VDC I-RB16-231 16 relays, load 231 VAC I-RB8-231 8 relays, load 231 VAC

Number relays: 16 or 8 in sockets Nominal voltage: 24 VDC Voltage range: 16,8 – 36 VDC Relay opens at: 10% of nominal voltage Electric / mechanic cycles: 100 000 / 10 000 000 Operating temperature range: - 40°C to 70°C Maximal load: 6 A resistive load at 24VDC 4 A inductive load at 24 VDC 2 A at 231VAC Contacts protection: varistor 14DK390

1K

2 3

1-2 n.o. 1-3 n.c.

Mechanical dimension I-RB16 is 35 mm DIN rail mounted. One unit contains two parts (separate PCB) 8 relays each on common plastic base. I-RB16, I-RB8 is 60mm high from DIN rail base.

16X17

11 1 11 1 11

1 +X18

11 1 11 1 11

RE1

RE2

RE3

ER4

RE5

RE6

RE7

RE8

RE9

RE10

RE11

ER12

RE13

RE14

RE15

RE16

X3 X1X2X6 X4X5X8 X7X11 X9X10X14 X12X13X16 X15

9 + 8

16 X18 9 +View B

X18

8 X17 1 +

View B

3 X1 1

X1 X2 X3 X4 X5 X6 X7 X8 X9 X10 X11 X12 X13 X14 X15 X16

View A

3 X2 1 3 X3 1 3 X4 1 3 X5 1 3 X6 1 3 X7 1 3 X8 1 3 X9 1 3 X10 1 3 X11 1 3 X12 1 3 X13 1 3 X14 1 3 X15 1 3 X16 1

View A300

95

X17

Hint: I-RB16 contains two separate boards, 8 relay each.


Recommended wiring

Wiring example

14

L H

H

-

A

B

12345678

HL

AB

CAN2

CAN1

ID-COM

+

L

CAN2

J158

7

J193

9

K17 K18I-RB16

9 9

1 2 3

16x

K1-K16

120 ohm

120

ohm

CAN2

59

HL

IS-BIN

LH

IS-AIN

LH

IGS-PTM

LH

120

ohm

+ -POWER

+ -POWER

+ -POWER

120 ohm

IG-IBIG-MU

+ -POWER

+ -POWER

L HL H

120

ohm


Electronic engine without redundancy line

14-

12345678

HL

AB

+

J193

9

K17 K18I-RB16

9 9

1 2 3

16x

K1-K16

CAN1

59

HL

120

ohm

IS-BIN

LH

IS-AIN

LH

IGS-PTM

LH

120

ohm

+ -POWER

+ -POWER

+ -POWER

120 ohm

Engine without ECU (mechanical engine)

14

K17 K18I-RB16

9 9

1 2 3

16x

K1-K16

CAN1

59

HL

120

ohm

IS-BIN

LH

IS-AIN

LH

IGS-PTM

LH

120

ohm

+ -POWER

+ -POWER

+ -POWER

120 ohm +-


Communication architecture

RS232 One of following possibilities is available:

PC software interface (DriveConfig, DriveMonitor). Modbus protocol option for SCADA systems. Analog or GSM Modem interface. IG-IB – internet interface.

RS232/MODBUS - CATERPILLAR connection and configuration iD-BF controller communicates with CATERPILLAR EMCP 3.x via connector of iD-BF labeled RS232. Standard RS232 cable is led to RS232/485 converter. Next the shielded cable RS 485 follows to CATERPILLAR EMCP 3.x MODBUS terminals.

The converter RS232/485 ADAM-4520 module produced by ADVANTECH is recommended.

The MODBUS communication parameters should be set in RS232/485 and EMCP 3.x units as follows:

Baud rate 19200 Bd Parity none Numer of stopbits 1 MODBUS password default value (0) Slave (EMCP 3.x) Address 1

CAN1 / J1939 / KWP2000 CAN1 is data line for controller Inputs/Outputs extension. It is possible to connect following extension modules:

ECU (Engine Control Unit), IGS-PTM (8 BI, 8BO, 4AI, 1AO), IS-AIN (8AI), IS-BIN (16BI, 8BO).

Full physical CAN interface on ID-DCU is available, no ID-COM interface needed. Maximal CAN bus length is up to 200m.

CAN2 Inter-controller CAN for multiple engines applications. ID-COM module is necessary. It is possible to connect

ID-DCU controllers and/or I-LB, I-LB+, IG-MU (Direct cable, analog modem or GSM modem interface) and/or IG-IB (Internet interface) and/or I-RD Industrial remote display (Slave panel).

There are some limits for number of modules connected to CAN2 – see Rules for I-RD, IG-MU and IG-IB CAN address setting. The data rate is selectable in two levels: 250 kbd for 200 meters line and 62 kbd for 900 meters line.

Redundancy line (e.g.J1708) There are 2 datalinks in the system, one CAN SAE J1939 datalink and one SAE J1708/J1587 datalink. The J1939 datalink is used for control and monitoring data. The J1708/J1587 datalink is used for redundancy control and monitoring. The ID-COM interface is necessary to use for synchronous J1708/1587 data line.

CAN bus Connection rules CAN bus line must be connected in series, from one unit to the next (no star, no cable stubs, no branches) both ends must by the 120-ohm (internal or external) resistor terminated. Maximal CAN2 bus length is up to 200 meters when Basic settings: CAN bus mode = 32C or up to 900 meters when Basic settings: CAN bus mode = 8C. For CAN data cables details see chapter Technical data – Communication interface. CAN cable shielding connect to ID-DCU case.


ID-DCU contains internal fix 120-ohm resistor on CAN1 bus. Use D SUB9 male connector: CAN H = 5, CAN L = 9, COMMON = 3 and 8. ID-DCU must be on the CAN bus end. IGS-PTM units contains internal jumper-removable 120 ohm resistor. To be sure check resistor presence by ohmmeter. Unit with internal resistor should be connected to the end of CAN2 line.

I-CB wiring and configuration

CAN H

CAN L

EngineControl Unit

120o

hm

Controller

CAN HCAN L

CA N L

CAN HC O M

CAN L

CAN HCO M

CAN H

CAN L

I-CB

CAN 1 CAN ECU

ECU

120o

hm

CAN

1C

AN 2

1. Configure I-CB using I-CBEdit software. Configured I-CB behaves like fictive IS-AIN and IS-BIN units. I-

CB configuration associates selected values (from ECU database) received from Engine Control Unit to selected CAN addressees (fictive IS-AIN, IS-BIN inputs and outputs).

2. Configure corresponding CONTROLLER CAN addresses in PC configuration tool. 3. Configure separate inputs and outputs in corresponding Analog, Binary inputs, outputs in PC

configuration tool. Hint: In case of CAT engines, there is RS232 connection between I-CB and CCM.


Getting started

How to install Hint: All components shall be used within marked electrical ratings – see chapter Technical data.

General To ensure proper function:

Use grounding terminals. Wiring for binary inputs and analog inputs must not be lead parallel with high voltage/current cables. Analog and binary inputs should be provided with shielded cables, especially when length >3m.

Power supply Use min. power supply cable of 1.5 mm2 to ensure proper function. Maximum continuous DC power supply voltage is 36VDC. Maximum allowable power supply voltage is 39VDC – see chapter Technical data. Hint: The InteliDrive controller should be grounded properly in order to protect against atmospheric discharges !! Install separate conductors for signal and power inputs. Allow for conductor voltage drop when determining conductor size. All power supplies must have common ground.

+

+

Battery

-

-controllerand load

HUGELOADS

STARTER

T2,5 A

Power supply fusing T2,5 Amp fuse (depends on load size) should be connected in-line with the battery positive terminal to the controller and modules. Controller and I/O modules should never be connected directly to the starting battery.

Fuse value and type depends on number of connected devices and wire length.

Recommended fuse (not fast) type - due to internal capacitors charging during power up.

Binary output protections Do not connect binary outputs directly to DC relays without protection diodes. Use protection diodes even if the relays are not connected directly to controller outputs. Use a fast recovery 3A / 50V diodes.


+-

K1 K1K2 K2

24VDC+-

controller

Fuse

Fuse

Battery

DC relays

Fuse

Example of controller protection

Grounding To ensure proper function:

The shortest possible piece of wire should be used when grounding the controller. Use cable min. 2,5mm2 . The “-“ terminal of the battery has to be properly grounded.

Magnetic pick-up To ensure proper function use a shielded cable.

+

Battery

-

GACSpeed Control Unit

ESD 5500

MAGNETICPICK-UP

CDSignal

Signal

+

+-

-PowerSupply

PowerSupply

GND

RPM-IN

controller

Be aware of interference signal from Speed governor when one speed pick-up is used.

ID-DCU Analog inputs hardware configuration Configure Analog inputs AI1-AI8 connection by jumpers on PCB (remove cover).

Jumpers setting


Grounding Terminal

BOOT JUMPER

BINARY INPUTSRPM

BINARY INPUTSANALOG INPUTS

BINARY OUTPUTS POWER8 - 36 V DC

EXTE

NSIO

NMO

DULE

ID-R

PU

RS23

2

LB1

EXTE

NSIO

NMO

DULE

ID-C

OM

+ -RPM

GND

RPM

IN

BI1

BI2

BI3

BI4

BI5

SHIE

LDCO

M

D+BO1

BO2

BO3

BO4

BO5

BO8

BO6

BO12

BO13

BO14

BO9

BO7

BO10

BO11

AIN1

AIN2

AIN3

AIN4

AIN6

+

AIN5

+

AIN8

+AI

N8-

AIN6

-

AIN5

-

AIN7

+AI

N7-

BI6

BI7

BI8

BI9

BI10

BI11

BI13

BI12

BI14

1234

AI1

AI2

AI3

AI4

1234 AI

5+

AI6+

AI7+

AI8+

1234

Current Measurement – jumper on pins 1-2.

1234

Voltage (thermocouples AI5-AI8) measurement – jumper on pins 2-3.

1234

Resistance measurement - jumper on pins 3-4.

Hint: Maximal voltage on controller Differential analog inputs AI5 to AI8 is in the range –2 to +5 VDC against minus power supply terminal !

Controller default jumper setting from production AI1 to AI4 Current sensor AI5 to AI8 Resistance sensor

Examples of ID-DCU analog inputs connection

ID-CU

CO

M-

PO

WE

R

AI4

AI3

AI2

AI1 AI6

-A

I6+

AI5

-A

I5+

AI8

-A

I8+

AI7

-A

I7+

A ll jumpers in position (3-4)

Standard connection of resistive sensors to ID-DCU analog inputs AI1 to AI8. The COM terminal must be always connected to the negative power terminal.

v

+

v+

-

CO

M-

PO

WE

R

AI1

(3-

4)

AI4

AI3

(2-

3)A

I2 (

1-2)

AI6

-A

I6+

AI5

-A

I5+

AI8

-A

I8+

AI7

-A

I7+

(3-4

)

(1-2

)

(1-2

)

(2-3

)

+

Different sensors connection to ID-DCU. AIx configuration jumpers must be in corresponding position and corresponding DriveConfig configuration according to used sensor. Analog input common terminal COM has to be connected to ID minus Power supply terminal. Mixed connection of ID-DCU analog inputs: AI2, AI7 – current sensor AI1, AI5 – resistive sensor AI3, AI8 – voltage input


AI6 – thermocouple (voltage) AI4 – Not used

ID-CUCO

M- P

OW

ER

AI4

AI3

AI2

AI1

AI6-

AI6+

AI5-

AI5+

AI8-

AI8+

AI7-

AI7+

All jumpers in position (3-4)

2x 4

70 o

hms

2x 4

70 o

hms

Mixed connection of ID-DCU analog inputs: AI1, AI2, AI5, AI6 – resistive sensor AI3, AI7 – binary input AI4, AI8 – three state input Analog input common terminal COM has to be connected to ID minus Power supply terminal.

To ensure a proper function use shielded cables, especially for length over 3m.

ID-DCU Analog inputs software configuration See table below

Protections:No protection

WarningSensor failColldownShutdownAlarm only

HistRecord only



HistRecord only



HistRecord only

Sensorcharacteristics

+

RI

Analog input



HistRecord only

Logical analoginput list

Analog output

Binary outputs

State machine

Hardwarejumper

ID-DCU

Valu

e

Bargraph

Hint: ID-DCU hardware jumper must correspond with software configuration.

Configuration See drawing above. Property Value Name Value name is displayed on the screens and in the Alarm list and History record.

Enter up to 14 ASCII characters. Name is automatically set to Function name if function is selected from the Logical function list – see Function item.

Dim Dimension is displayed on the screens. Select dimension from the list or add a new one.

Sensor Select sensor from the list or create a customer sensor characteristics in User sensor window. There must be corresponding analog input hardware jumper setting in InteliDrive controller. See Sensor availability table below.

Resolution Output value (reading) resolution. DriveConfig indicates when Resolution is out of the value range.

Sensor range Full output value (reading) range for 20 mA (current), 250 Ω, 2400 Ω (resistive), 1 V, 100 mV (voltage) sensor.

Protection type Select from the list. Configure two levels protection as standard or more levels (window) protection in Expert mode.

Active when Configure direction Over or Under limit when protection is activated. Block type Configure protection activity: All the time or Engine running with three different

20mA = 10,0 Bar


adjustable delays when protection is active after engine start (RPM > Starting RPM). Bargraph 100% Value for bargarph full scale. Function Select from the list if function is required or leave free if input is a protection only.

Sensors availability Sensors available on ID-DCU AI1 – AI4 Resolution Sensor range HW jumper Pt1000/°C, Ni1000/°C, Pt1000/°F, Ni1000/°F

Fix, not configurable Resistance: 3-4

4-20 mA active, ±20 mA active (measures + only)

For 20 mA input Current: 1-2

0-250 Ω, 0-2400 Ω

See Hint below

For 250 or 2400 Ω Input

Resistance: 3-4

Sensors available on ID-DCU AI5 – AI8 Resolution Sensor range HW jumper Pt100/°C, Pt1000/°C, Ni100/°C, Ni1000/°C, Pt100/°F, Pt1000/°F, Ni100/°F, Ni1000/°F Fix, not configurable Resistance: 3-4

Thermocpl J/°C, Th…. K/°C, Th…L/°C, Thermocpl J/°F, Th…. K/°F, Th…L/°F Fix, not configurable Voltage: 2-3

4-20 mA active, ±20 mA active For 20 mA input Current: 1-2 0-250 Ω, 0-2400 Ω For 250 or 2400 Ω

input Resistance: 3-4

±1 V, 0-100mV

See Hint below

For 1V or 100mV Voltage: 2-3 Hint: Out of range resolution (e.g. 100,000) is indicated in DriveConfig.


Configuration examples • Conversion from 4-20mA to 6,0 Bar Oil pressure sensor (Wrn+Sd protection and Oil pressure function)

• Conversion from ± 1V input to engine speed request 0 to 100% Step 1. Create new User sensor

Hint: HW configuration: CU 0-1V can be used for characteristics ± 1V, but this ± characteristics can be configured to AI5 to AI8 inputs only ! Sensor range (gray background) automatically follows the User sensor characteristics (zero value in drawing above is not important).


• Conversion from ± 20mA to ±100% request

Req

uest

[%]

-20

mA

20 m

A

+100%

mA0

mA

-100%

Sens

or fa

il

Sens

or fa

il

Bargraph

0% +100%

Sensor characteristics ± 20mA works in full ± range on ID-DCU AI5 to AI8 only. ID-DCU AI1 to AI4 measures 0 to 20 mA range only. Default sensor characteristics creates conversion to ±100%. Bargraph indicates only positive values 0 to +100%.


• Conversion from ± 20mA to +100% request with User sensor

-20

mA

20 m

A

+100%

mA0

mA

0%+50%R

eque

st [%

]

Sens

or fa

il

Sens

or fa

ilBargraph indication

0% 100%

Sensor characteristics ± 20mA works in full ± range on ID-DCU AI5 to AI8 only. ID-DCU AI1 to AI4 measures 0 to 20 mA range only. Step 1. Create User sensor like below. Step 2. Configure user sensor instead default ± 20mA sensor. Step 3. Configure Bargraph 100% to correspond User sensor. Bargraph indicates full 0 to 100% range in this case.

1. Step: Create User sensor like below.

2. Step: Configure user sensor instead default ± 20mA sensor.


User sensor examples Availability Configuration AI1 to AI4 AI5 to AI8 Analog input jumper = 1-2 (current)

0 - 20mA / 600

AI1 to AI4 AI5 to AI8

4 - 20mA / 100,0

AI5 to AI8 Analog input jumper = 2-3 (voltage)

0 – 1V / 10,000

AI5 to AI8

0 - 100mV / 100,00

AI1 to AI4 AI5 to AI8 Analog input jumper = 3-4 (resistance)

0 – 1200 ohm / 100

Hint: It is possible to set up to 30 points non-linear sensor characteristics. Connect external resistors (voltage divider) to extend input voltage range.


Analog inputs on IS-AIN8 IS-AIN8 analog inputs can be configured to

• Resistor two wire input • Resistor three wire input • Current input • Thermocouple input • Voltage input

Select sensor characteristic from the list or define user sensor characteristic in DriveConfig.

ABCD

Resistor sensor input – two wire connection. Range 0 to 2400 ohms. Pt100, Pt1000, Ni100, Ni1000 D terminal is shielding

ABCD

Resistor sensor input – three wire connection. Range 0 to 2400 ohms. Pt100, Pt1000, Ni100, Ni1000 – recommended. D terminal is shielding

ABCD

Passive current sensor (current source is in IS-AIN8) Range 0 to + 20 mA or 4 to + 20 mA D terminal is shielding

ABCD

+ +24 VDC

0 VDCSensor

mA

ABCD

+

+24 VDC

0 VDC

SensormA

Active current sensor (current source is in sensor) Range –20mA to +20 mA or 4 to + 20 mA D terminal is shielding

ABCD

+

Thermocouple J, K, L D terminal is shielding From IS-AIN8 hardware version 5.1 can be B thermocouple terminal connected to frame.

ABCD

+

Voltage input Range 0 to + 2500 mV. Voltage range is 0 to ± 1000 mV. D terminal is shielding


ABCD

+

R1

R2

For 10V input voltage range connect external resistors R1, R2 and select sensor characteristic 10V. R1=10 Kohm, R2=2,7 Kohm. D terminal is shielding

Hint Thermocouples connected to IS-AIN8 hardware versions below 5.0 must be galvanically separated from the frame. If the thermocouples are connected to IS-AIN8, appropriate jumpers must be removed (see rear sticker).

Analog as Binary input To use Analog input as binary configure following characteristics:

Primary Converted 0 0 1000 1

Analog as three state (tristate) binary input Open, close and failure (broken wire, short wire) states are detected. Threshold level is 750 Ω, failure is detected when circuit resistance is <10 Ω or > 2400 Ω.

Analog Sensor availability Table of supported sensors on various modules. Do not configure sensors, that are not supported on the input.

ID AI1-4 ID AI5-8 IGS-PTM IS-AIN8PT100/°C Y Y Y PT1000/°C Y Y Y NI100/°C Y Y Y NI1000/°C Y Y Y PT100/°F Y Y Y PT1000/°F Y Y Y NI100/°F Y Y Y NI1000/°F Y Y Y Thermo J/°C Y Y Thermo K/°C Y Y Thermo L/°C Y Y Thermo J/°F Y Y Thermo K/°F Y Y Thermo L/°F Y Y 4-20mA passive Y 4-20mA active Y Y Y Y 0-20mA passive Y +-20mA active Y Y Y Y 0-250ohm Y Y Y Y 0-2400ohm Y Y Y 0-4V Y 0-2.4V Y +-1V Y Y 0-10V Y 0-100mV Y Y Y Tristate Y Y

Hint: Fahrenheit sensors are supported from IS-AIN8 of sw version 2.2 only.


Binary inputs / outputs on ID-DCU Use wiring cables min. of 1.0 mm2 to ensure proper function.

+24V

DC

0 V

DC

BI 1

BI 2

BI 3

BI 4

BI 5

BI 6

BI 7

BI 8

BI 9 BI 1

0

BI 1

2

BI 1

3

BI 1

4

BI 1

1

+ -

BO 7

BO 8

BO 9

BO 1

0

BO 1

2

BO 1

3

BO 1

4

BO 1

1

ID-DCU

BO 1

BO 2

BO 3

BO 4

BO 5

BO 6

Hint: Incorrect polarity of the binary output connection may cause a damage of the binary outputs.

Binary inputs on IS-BIN16/8 There are two groups of eight Binary inputs BI1 to BI8 and BI9 to BI16. Each group has a separate Common terminal COM1 and COM2. The Common terminal can be connected to positive or negative pole – see following drawing. Binary inputs are galvanically separated from IS-BIN16/8 power supply. A Binary inputs Common terminal is connected to positive supply terminal, Binary inputs contacts are closed to negative supply terminals.

Binary inputs common terminal is connected to negative supply terminal, Binary inputs contacts are closed to positive supply terminals.

IS-B

IN 1

6/8

IS-B

IN 1

6/8

Input voltage range for opened contact is from 8 VDC to Power supply VDC. Input voltage range for closed contact is from 0 to 2 VDC. Voltage level is defined between Binary input and Binary input COM terminal and does not depend on “positive” or “negative” connection. Hint: It is recommended to separate inputs by diodes when two or more binary inputs are connected in parallel to avoid wrong input activation when one controller is switched off.

controllerBIBI

controller


Binary outputs on IS-BIN16/8 IS-BIN16/8 binary outputs are galvanically separated from IS-BIN16/8 power supply. It is necessary to connect plus 24 VDC (power supply ) to IS-BIN16/8 terminal according to following drawing. The maximum load values are 0.5 A / 36V for one output.

IS

-BIN

16/

8

Binary output separation In some special cases e.g. when Relays plus terminal is disconnected via EMERGENCY STOP contact, the binary outputs must be separated using diodes to avoid false Binary output LED indication. In the Example below when EMERGENCY STOP contact is opened, the BO3 LED should light (without separating diode SD3) even if the BO3 output is opened.

+

BO 3

BO 4

BO x

- POWER SUPPLY

EMERGENCYSTOP

+24VDC

0 VDC

iS-CUiS-BINiGS-PTMiG-IOM

SD3

SD4

IS-AIN8, IS-BIN8/16 address setting • Press Address button during IS-AIN8 power supply on to switch to addressing mode. • Then repeatedly press or keep pressed address button to adjust required address according to IS-CU

configuration. • After setting requested address, release the buttons and wait until the digits blink – it indicates write the

changed address to EEPROM memory. Hint: CAN address 0 disables corresponding CAN message (Group data are not send).

IS-AIN8, IS-BIN8/16 SW version check Let suppose IS-AIN8 of SW version 1.4. Shortly press address button. Following sequence appears on the display: number “1”, one second pause, number “4”, two second pause, number “1”, one second pause, number “4”, two second pause and finally IS-AIN8 actual address. Table of recommended CAN1 address setting on IS-AIN8 and IS-BIN16/8

CAN 1 Address CAN1 Address 1. iS-AIN8 1 Inputs Outputs 2. iS-AIN8 2 1. iS-BIN16/8 1 1 3. iS-AIN8 3 2. iS-BIN16/8 3 2 4. iS-AIN8 4 3. iS-BIN16/8 5 3 4. iS-BIN16/8 7 4


Table of corresponding address setting in DriveConfig – during ID-DCU configuration. Address Address 1. iS-AIN8 1 Inputs Outputs 2. iS-AIN8 2 1. iS-BIN16/8 1, 2 1 3. iS-AIN8 3 2. iS-BIN16/8 3. 4 2 4. iS-AIN8 4 3. iS-BIN16/8 5, 6 3 4. iS-BIN16/8 7, 8 4

Hint: IS-BIN16/8 module has separate CAN1 addresses for binary inputs Group 1, Group 2 and binary outputs Group (total three addresses). The CAN1 address for BI Group 1 and for BO Group can be adjusted on the iS-BIN16/8. The address for BI Group 2 is set automatically to the address following after BI Group 1. CAN bus line has to be terminated by 120 ohm resistors on the both ends. For longer distances is recommended to connect CAN COM terminals between all controllers and cable shielding to the ground in one point. External units can be connected on the CAN bus line in any order, but line arrangement (no tails no star) is necessary. Recommended CAN bus data cables see in Chapter Technical data. I-LB, I-LB+, IG-MU and IG-IB units are connected to CAN2 bus.

IGS-PTM and IGL-RA15 module connection It is possible to connect up to four IGS-PTM and one IGL-RA15 to one controller. IGS-PTM behaves like IS-AIN and IS-BIN modules in one unit. IGS-PTM and IGL-RA15units contain internal jumper removable 120-ohm resistor. Hint: Only IGS-PTM from hardware version 2.0 and software version 4.0 is compatible with InteliDrive.


Logical Binary Inputs List Any InteliDrive controller extension physical binary input can be configured as “function” or “protection”. Following chapter contains Logical binary inputs list that can be configured to any physical input. ID-DCU binary inputs Remote start, Remote stop, Rem start/stop are not active in LOC mode. Hint: Minimal input pulse duration is 120 ms to be detected as valid (binary inputs sampling rate is 100 ms). Adjustable delay can be configured to any binary input when is used as a protection: Standard = 0,5 sec or one of BinInp delay 1, 2, 3 that can be adjusted by corresponding Setpoint BinInp delay 1, 2, 3.

Input

BI delay configuration

Setpoint

Standard (0,5s) BinInp delay 1 BinInp delay 1 BinInp delay 2 BinInp delay 2

BinInp delay 3 BinInp delay 3 See setpoints BinInp delay 1 [s] etc…

Access Lock If the input is closed

- Panel buttons START, STOP are inactive - No setpoints can be adjusted from controller front panel - Controller mode (e.g. OFF-RUN) cannot be changed - Fault reset (screen sensitive), Horn reset buttons are still active - It is possible to list Values, Setpoints and History - Binary inputs function is without change

Active Access lock is indicated by “L” in the upper right corner of controller screen. Hint: Access lock does not protect Setpoints change, Mode change and START, STOP commands from Drive Monitor (direct or modem). To avoid unqualified changes of the selected setpoints or commands use password protection.

Remote Lock If the input is closed following commands via serial line (e.g. from DriveMonitor or from remote display) are inactive:

- Remote engine start, stop commands - Fault reset and horn reset - Setpoints change

Engine can be started, stopped via Binary inputs (e.g. Remote start) or via front panel buttons. InteliDrive local / remote commands blocking overview Y = available; N = blocked Device Command Access lock Remote lock Local mode ID-DCU panel START N Y Y STOP N Y Y FLT RES Y Y Y HORN RES Y Y Y Setpoint change N Y Y Mode change N Y Y ID-DCU Bin Inputs Remote start Y Y N Remote stop Y Y N Remote OFF Y Y N External modules Bin Inputs

...start/stop Y Y N

Remote OFF Y Y N


Remote HBR Y Y N I-RD-CAN START N N N (serial line) STOP N N N FLT RES N N N HORN RES N N N Setpoint change N N N Mode change N N DriveMonitor START Y N N (serial line) STOP Y N N FLT RES Y Y N HORN RES Y Y N Setpoint change Y N N Mode change Y N N

Low Brightness Active Binary input switches ID-DCU display backlight between two adjustable intensity levels. Alternative intensity of the backlight can be set independently by ID-DCU panel buttons:

1. Hold Enter and press Page to switch to ID Info screen (from any measure screen) 2. Hold Enter and pres Up/Down arrow key to increase/decrease display brightness

The adjusted intensity is stored in nonvolatile memory.

Hint:

Both backlight levels are default (from production) set to maximum.

Force Block Active input blocks protections that are configured as “Force Block”. Corresponding setpoint is ForceBlock del.

Fault Reset Binary input for Alarm acknowledge (level sensitive) has the same function as controller front panel button Fault reset.

Hint: There is separate acknowledge for ECU Alarms – see Binary input ECU FltReset.

Horn Reset Binary input Horn reset is level sensitive.

Remote OFF Controller is switched to OFF mode if input is closed and back to previous mode after is opened. Input is not active in LOC mode. Active binary input Remote OFF is indicated by “L” character in the right up corner on ID_DCU screen.

Hint: Remote OFF will switch controller to OFF mode even if the Access code or Remote lock is active or Controller mode is password protected.

ECUComFailBlck Active input enables to block indication of ECU communication fail e.g. in the case the ECU is switched off.

Emergency Stop Engine Shut down activation. It is recommended to configure Emergency stop as normally closed contact from safety reason (this configuration is in default aid archive).

Hint: The iD-BF controller controls the gas fuel only and is not related to diesel fuel control. Thus the “Emergency Stop” in this iD-BF application means immediate stop of bi-fuel operation. If the “Emergency Stop” is activated the genset may continue in the diesel mode operation.


Remote Start External “edge sensitive” request for Bi-fuel mode start. Binary input is inactive in Local mode.

Binary input REMOTE START signal is equivalent to ID-DCU (I-RD) front panel Start button.

Remote Stop Engine “edge sensitive” stop request. The first edge changes engine state from bi-fuel running to Slow close, the second edge stops engine (skip the rest of Slow close). Binary input is inactive in Local mode. REMOTE STOP signal is equivalent to ID-DCU (I-RD) front panel Stop button.

Hint: Binary inputs Remote start, Remote stop and Rem start/stop are edge (not level) sensitive. Minimal pulse duration to safely detect the edge is at least the 120 ms (binary input sampling rate is 100 ms).

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 operationactive not active Enabled active active Disabled

not active not active Disabled not active active Disabled

Dx Trip Knocking detector DENOX activates its output signal Dx Trip if Denox is receiving pulses from pick-up sensor on rotating camshaft. (Rotating camshaft identifies the genset as running)

In iD-BF the input DxTrip must be activated while the engine is running (The value GasRegulation:Diesel is not equal to zero) and vice versa. To span the eventual contradiction of signals Dx Trip and GasRegulation:Diesel during the starting and/or stopping processes of genset, the 60sec latency is adjusted before Shut Down protection activation.

If the binary input „Dx Trip“ is not configured then iD-BF supposes the DENOX device is not included in the control system so that the correspondence of Dx Trip and GasRegulation:Diesel is not checked.

Hint: The logical binary input (LBI) “Dx Trip” is intended to check the activity and availability of the knocking detector DENOX as mentioned above. However physical binary input has two functions. Beside the checking of the DENOX activity the dramatic value of the knocking (detected by DENOX) is also communicated.

It is recommended to assign both the LBI “Dx Trip” and standard Shut down protection (while the bi-fuel operation mode is running) to one physic binary input.

RegGas Press Input indicates Gas pressure downstream of regulator. The pressure is failed when activated. Gas shutdown is activated immediately. The latency period is started in the moment of shut-off gas valve opening (GasOK signal output) to span the transient time of gas pressure regulator. The latency period continues for Diesel protect:RegGasPrDel.

Manual Reg This feature is important in genset systems manual load sharing working in parallel with another gensets and/or mains.

If the input is configured then the genset active power is stabilized during bi-fuel starting and stopping ramps. The power is stabilized on the value registered in the moment of the opening/closing gas valve ramp begin.

The activating edge of the binary input abandons the generator power stabilization. The stabilization procedure is abandoned

either by activating edge of the binary input Manual Reg


or in the end of the gas valve ramp

whichever event comes as first.

CylDiffEvalBlk If the input CylDiffEvalBlk is activated then the differential exhaust temperature protection is blocked.

Sd Override Blocks all protections except Over-speed and Emergency stop (=Sprinkler).

• All alarms are detected • Alarms are recorded on the controller Alarm list screen • Alarm are recorded into History • Enabled Active calls remains active • Controller front panel engine RED LED blinks or lights • Does not influence electronic engine via J1939

Rem Start/Stop The input Rem Start/Stop is not active in LOC mode. The input Rem Start/Stop is active in MAN mode only.

The activating edge of Rem Start/Stop has the same function as the panel pushbutton START. The deactivating edge of Rem Start/Stop has the same function as the panel pushbutton STOP

Hint: This input can be configured to Binary output Timer active to enable engine automatic start/stop function – see Basic settings / Timer setpoints.

Hint: Engine stays running when Rem start/stop is opened prior to controller LOC mode disabling because the edge and not the level is important.

ModeL Button The input cycles backward through engine operation modes OFF <- RUN. The ‘ModeL Button‘ binary input is equivalent to ID-DCU (I-RD) front panel MODE→ button. ModeR Button The input cycles forward through engine operation modes OFF -> RUN. The ‘ModeR Button‘ binary input is equivalent to ID-DCU (I-RD) front panel ←MODE button. Page Button The input cycles through the display screens (MEASUREMENT->ADJUSTEMENT->HISTORY -> etc.). The ‘Page Button‘ binary input is equivalent to ID-DCU (I-RD) front panel PAGE button. Enter Button The input confirms set point value. The ‘Enter Button‘ binary input is equivalent to ID-DCU (I-RD) front panel ENTER button. Up Button The input selects the set point, select the screen or increase set point value. The ‘Up Button‘ binary input is equivalent to ID-DCU (I-RD) front panel ↑ button. Down Button The input selects the set point, select the screen or increase set point value. The ‘Down Button‘ binary input is equivalent to ID-DCU (I-RD) front panel ↓ button.


Binary inputs assigned to CAT EMCP3, ICB (CAT CCM) and J1939 (CAT) configurations There are no additional and/or special logical binary inputs characteristic for CAT EMCP3, ICB (CAT CCM) and J1939 (CAT) configurations.

Binary inputs protection


Property: Function line is free, no logical function is (ususally) selected.


Logical Binary outputs List Hint: Depends on Modules configuration there exist more groups of binary values that can be configured to any physical binary output.

Source – Log Bout

Horn Binary output for Horn, Buzzer alarm acoustic indication. Output is automatically switched off after Engine protection: Horn timeout. Horn is active unlimited time (until Fault reset) when Horn timeout = 0.

Alarm The output closes if any alarm is activated and opens after Fault reset even if the Alarm is still active.

Common Alarm The output closes if any Wrn, Sd, Fls, alarm is active and stays closed until all alarms disappear and FAULT RESET is pressed = output is opened when Alarm list is empty.

Common Wrn The output closes when any Warning alarm is active. Output opens when all Wrn alarms disappear and FAULT RESET is pressed (no Wrn alarm in Alarm list).

Common Sd The output closes when any Shut-down alarm is active. Output opens when all Sd alarms disappear and FAULT RESET is pressed (no Sd alarm in Alarm list).

Common Stp The output closes when any slow stop alarm appears. The output opens, if no slow stop alarm is active and FAULT RESET is pressed The output closes when any Cool-down alarm is active. Output opens when all Cd alarms disappear and FAULT RESET is pressed (no Cd alarm in Alarm list).

Common Fls The output closes when any Sensor fail alarm is active. Output opens when all Fls alarms disappear and FAULT RESET is pressed (no Fls alarm in Alarm list).


OFF Mode The output is closed in controller OFF mode.

MAN Mode The output is closed in controller MAN mode.

AUT Mode The output is closed in controller AUT mode.

Not used Configure this selection when output is not used.

Not in LOC The output is closed, if LOC mode is not selected.

In LOC The output is closed, if LOC mode is selected.

CPU ready CPU indication – output is closed when CPU is ready.

Knocking Output is closed and History record is activated when analog input assigned as Denox exceeds Diesel protect:DetonationLim. Another OK History record is activated when Denox output signal subsded.

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

Diesel OK Binary output DIESEL OK indicates all conditions for genset in bi-fuel operation. The signal is used to activate the light indicator „DIESEL OK“

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 Denox fault is detected i.e. if the information about stopped/running genset obtained from values GasRegulation:Diesel and Dx Trip is contradictory for mote than 60secs.

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. See also the binary input Manual Reg.

CtrlHeartBeat Indicates correctly running firmware when cycling on/off with 0,5 sec period.

Comm AIN fail Communication warning fail when any Analog input module address does not communicate (2s timeout).

Comm BIN fail Communication warning fail when any Binary input module address does not communicate (2s timeout).


Comm AOUT Fail Communication warning fail when any Analog output module address does not communicate (2s timeout).

Comm BOUT Fail Communication warning fail when any Binary output module address does not communicate (2s timeout).

Alarm Blink Function is based on Binary output COMMON ALARM - stays closed when any alarm is active (at least one item in Alarm list) and opens for 2 sec when any new Alarm is activated. The first activation is delayed 2 sec. No Fault reset influence when at least one alarm is active. Output opens when Alarm list is empty.

Logical 0 Constant value that can be configured to any output (e.g. CurrentGear in Volvo-PRP).

Logical 1 Constant value that can be configured to any output (e.g. CurrentGear in Volvo-PRP).

Timer Active Binary output Timer Active is closed and opened according to Timer setpoints setting. Engine starts and stops when this output is connected (configured) to Binary input Rem start/stop. Timer is active in all controller modes include OFF mode.

Alarm Blink Act Mirror of controller panel RED LED: Starts flashing with new Alarm, light simultaneously after confirmation (Fault reset).

Common SdO Indicates active Sd overwrite protection, i.e. when some active protection is blocked by Shut-down override function.

StartButtEcho The pulse as consequence of iD-BF panel START keystroke.

Stop ButtEcho The pulse as consequence of iD-BF panel STOP keystroke.

FltResButtEcho The pulse as consequence of iD-BF panel FAULT RESET keystroke.

CylOvrToDiesel Output closes when Cylinder temperature protection of 2nd level alarm appears. The output opens, if no Cylinder temperature protection of 2nd level alarm is active and FAULT RESET is pressed.

T cyl differ Output closes when engine cylinder temperature difference warning is active.

RemoteControl 1 ... RemoteControl 8 Logical binary outputs controlled by Remote Switches menu of Drive Monitor.


Source – Info

CAN16 1 ... CAN16 16, CAN32 1 ... CAN32 16 Corresponding output is closed when controller equipped by relevant communication address on the intercontroller bus (CAN2) is not available.

Source – Prg.states Programmable states (protections) list. Any item from the following list activates Alarm list indication.

ECU ECU communication failure

ECU MODBUS ECU MODBUS communication failure

Bad SCADA Pswrd The password of ECU SCADA differs fom expected “0000”

J1587 J1587 communication fail indication.

ECU Alarm List Output is closed when at least one item is in ECU Alarm list.

UnivState 1 … UnivState 7 Universal states 1 to Universal states 7 indication. See Universal states description.

EcuDiagBlocked Output is closed when Basic setting: ECU diag = DISABLED.

PLC Message 1 … PLC Message 4 Indication of programmable PLC state.

Emergency Stop Indication of Emergency stop input.

OthrCommEr Intercontroller communication error.

Battery Volt Indication when battery voltage (ID-DCU power supply) is out of Engine protect: Batt <V and Batt >V limits

WrnService Time Output is closed when Service time (count down) = 0. Hint: History record and Alarm list indication is activated as well.

Detonation Output is closed and History record is activated when analog input assigned as Denox exceeds Diesel protect:DetonationLim. Another OK History record is activated when Denox output signal subsided. Output opens when Detonation subsided and FAULT RESET is pressed


Engine power Output is closed when Engine power (LAI) measurement is faulty.

Sd Denox Fail Output is closed when Denox fault is detected i.e. if the information about stopped/running genset obtained from values GasRegulation:Diesel and Dx Trip is contradictory for mote than 60secs. Output opens when Sd Denox Fail is deactivated and FAULT RESET is pressed

Diesel Output is closed when Diesel (LAI) measurement is faulty.

SdRegGasPress Output is closed when SdRegGasPress protection is occured.

Fuel Rate Output is closed when Diesel (LAI) measurement is faulty.

Sd DFM Fail Output is closed when iG-DFM internal connection is faulty.

DifCylTmp1 … DifCylTmp16 Output closes when Cylinder Nr.N (N ... 1 to 16) temperature protection of 2nd level alarm appears. The output opens, if Cylinder Nr.N temperature protection of 2nd level alarm is not active and FAULT RESET was pressed.

Source – Ana protections List of Analog inputs protection indication is dynamic. Any protection configured e.g. on Analog input appears in Source: Ana protection Binary output list.


Source – Bin protections List of Binary inputs protection - indication is dynamic. Any protection configured on Binary input appears in Source: Bin protection.

Source – Binary Inputs CU Binary CU list contains all ID-DCU binary inputs that can be configured to Binary outputs. This source contains binary inputs physical states (no protection activity).

Source – Binary Inputs List (depend on modules configuration) contains all Extension modules binary inputs that can be configured to any Binary outputs. This source contains binary inputs physical states (no protection activity).

Binary outputs assigned to CAT EMCP3, ICB (CAT CCM) and J1939 (CAT) configurations There are no additional and/or special logical binary outputs characteristic for CAT EMCP3, ICB (CAT CCM) and J1939 (CAT) configurations.


Logical analog inputs list LCD Brightness Analog input for external LCD brightness setting (e.g. via potentiometer). Keyboard LCD brightness setting does not work when input is configured. Expected value is in the range 0 to 100%.

Filter Input Analog inputs intended to provide the additional functional block of digital filter. Filtering constant is equal to 1sec. The filter may be used to filter physical input(s), e.g. Gen Power. Corresponding output Specials:FilterOutput can be assigned to common LAI.

EnginePwrMeas Analog input intended to measure of active power. The current transmitter is used usually and thus the power for full 20mA is adjusted by range setpoint of assigned sensor.

Denox Analog input from external engine detonation unit DENOX signal. The current transmitter is used usually. 20mA corresponds to 100% output value “Detonation” in % that is readable. See chapter Gas regulation values.

Offset Analog input for simulation of Convert power table or to offset the curve of the Gas Valve requesed position. This input is mainly used for installation and testing.

FuelRate Analog inputs intended to provide the Fuel rate evaluation and vizualization. The Fuel rate is evaluated on the base of physical analog value (flowmeter or value read from ECU) assigned to Fuel rate input.

FLSRExhaust T1 … FLSRExhaust T2 Analog inputs intended to provide the FLSR of exhaust gas. The physical analog value(s) (exhaust tenperatures) assigned to FLSRExhaust T1, 2 is checked for FLSR protection.

Cyl Temp 1 … Cyl Temp 16 Analog inputs for engine Cylinder temperature measuring.

Analog inputs assigned to CAT EMCP3, ICB (CAT CCM) and J1939 (CAT) configurations Standard analog values may be configured for genset electronic control units (ECU). However the commissioning engineer has to take in account configurability also on the other end of communicatieon cable i.e. configurability of ECU data transmitions.

i-CB communication unit maps the received analogue values as values from AIN unit. The configuration set in iD-BF must certainly correspond to configuration i-CB. Do not forget to select analogue sensors type as “Electronic”!

Beside of values obtained by standard methods of configuration threre are present also two non configurable analog inputs:

Fuel Rate FuelCons (if available)

The additional values are available in values groups dedicated to electronic genset


Analog inputs from J1939 configuration

Analog inputs protection

How to configure three level protection ? Three level protection configuration

1. Switch to I-O , analog inputs, e.g. ID-AIN8 2. Switch to Expert mode


3. Configure standard two level protection 4.

Expert field is now empty. This field is visible in Expert mode only. Standard two level protection (ID-AIN8) example:


4. Above step configured protection are now visible in Expert field

… and corresponding limits as well 5. Add the third protection: “+” button, and edit Property (e.g. Wrn, Under, ….) Any protection limit/delay can be set to Constant (then value is fix, specified in line below) and cant be changed by customer (not included in setpoint list) … or …


In example above is Wrn limit type set to Const = 60. There is visible setpoint corresponding to Wrn , Over protection. It is possible to change limit name, value and limits.

Use “+” button to add new limit for the third (Wrn, Under) protection. Name “Limit3” can be changed. Limit and Delay type must be in this case set to “Setpoint”


Use “+” button to add Delay setpoint and set/change name value and limits.


How to indicate AIN 8 protection on BO ? 1. Select free universal state for selected protection

2. Configure this Univ state to some Binary output and modify Bin output Name.


Oil pressure and Water temperature on the first ID controller screen indication 1. Reading from ID-DCU analog inputs


2. Reading form J1939 J1939 value

logical function

Please note there can be configured Protection as well.

Protection types Warning Indication only (no gas stop) Shutdown Immediatelly closes the gas – immediate transition to the Diesel mode Stp Smoothly closes the gas (ramp) and transition to the Diesel mode Fail sensor Measured value is out of sensor characteristics. Warning + Fls Warning is activated in the case of sensor fail as well Shutdown + Fls Shut down is activated in the case of sensor fail as well Sd override This protection stays active in the case of Sd override is activated. Alarm only Only Alarm list indication, disappear without confirmation HistRecOnly History record only


Analog outputs Any of values from the Source list can be configured to any physical ot ECU/J1939 (virtual) Analog output. Analog outputs availability Module Number of outputs Note IGS-PTM 1 10V or 20mA I-AOUT8 8 10V or 20mA or pwm ECU (J1939) 4 (virtual) Format depends on ECU

Analog output configuration The two limits “Lo limit” and “Hi limit” can be modified in DriveConfig. “Lo limit” corresponds to low Analog output limit i.e. 0V or 0mA output and Hi limit corresponds to full range 10V or 20mA output. Lo limit and Hi limit transfer the full internal analog value range to Analog output range. Following is example of transfer characteristics 0 - 100% to 0 – 20mA.

10V or 20 mA

Lo limit Hi limit0 100

Analog valuein controller0V or 0 mA

Following is example of transfer characteristics 0 - 100% to 4 – 20mA.

4 mA

20 mA

Lo limit Hi limit-25 100

Hint: Adjust corresponding negative Lo limit to obtain 4 – 20mA output characteristics.


Physical Analog output configuration


InteliDrive – Engine ECU communication Example of standard J1939 engine List of possible J1939 analog data that can be configured to received in ID-DCU.

Name Engine speed RPM Actual torque % Demand torque % Colant temp °C EngineOil temp °C Boost Pressure bar Intake Manifold Temp °C Air Intake pressure bar Exhaust Gas Temp °C Accelator Padal position % Percent Load % Fuel Rate L/h EngOil Filter Diff.Press bar Battery Potential (Voltage) V Fuel Delivery Pressure bar Engine Oil level % Crankcase Pressure bar Coolant Pressure bar Coolant Level %

FAULT RESET = accepts (confirms) diagnostic message = removes inactive message form ECU Alarm list only when ECU Alarm list is visible. Hint: FAULT RESET button is “screen sensitive”. It is active only on selected actual controller screen.


Setpoints

Password There are three levels of password protection. 0. User level allows change of of non-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 a setpoint name (on controller screen) if the setpoint is password protected. The asterisk mark is removed only when the password is set from controllers front panel. The asterisk mark is still visible on controller screen even if the password is set from DriveMonitor. Even though one level may have been set from the front panel, the affected setpoints are not accessible from DriveMonitor (direct or Modem) until this level is set in DriveMonitor (direct or Modem). Setpoints opened from front panel are automatically closed 15 minutes after the last key has been depressed or when wrong value of setpoint is set. It is possible to protect remote Start, Stop commands from DriveMonitor as well. This three level command protection can be configured from DriveConfig.

EnterPassword Password is a four-digit number. Only setpoints associated with the entered password level can be modified. Use ↑ or ↓ to select the desired password and then hit enter.

ChangePassword 1

ChangePassword 2

ChangePassword 3 Hint: Any password can be changed once that level password or higher has been entered. To change password protection:

Open DriveConfig Select Setpoints window Set desired protection level: 0 or 1 or 2 or 3

Access code • Can be changed from DriveMonitor software only (Monitor – Change Access code). • Has to be set before remote modem or SMS connection is opened. • Can be up to 16 ASCII characters

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

Engine commands and Statistics protection Commands (Engine cmd) password protection protects Start, Stop, Horn reset, Fault reset commands from DriveMonitor direct, Modem or GSM modem or Remote Display connection. Selected Command password level 0, 1, 2, 3 is valid for all engine commands. Separately can be protected statistic commands: ClearStatistics, SetSucc starts, EngRun hours, SetUnsuc starts. a) Engine command: Start, Stop, Fault reset, Horn reset. "Engine Cmd" Password protection blocks: above commands from DriveMonitor, via Modbus, from I-RP via SMS.


"Engine Cmd" Password protection does not block: activation via Panel buttons and Binary inputs. b) The other four options protects statistics values modification from DriveMonitor. There is no other access to modify statistics - i.e. cant be changed from panel. Clear statistics is common protection for all three statistic values. Setting of statistic is possible protect separately - from Monitor only. To set commands protection from DriveConfig:

Open DriveConfig Select Commands window Set Password = 0 (no protection) or level 1 or 2 or 3

Hint: All setpoints below can be modified from Remote panel or DriveMonitor as well.

Basic settings

Engine Name User defined name, used for InteliDrive controller identification at remote phone or mobile connection. Engine name is max 14 characters long and have to be entered manually using DriveConfig software. Hint: Engine name is not changed when new archive is loaded. Check Engine name after firmware upgrade.

Mode ID [ OFF, MAN, AUT ] Equivalent to Controller mode changes by MODE→ or ←MODE buttons. Hint: Mode change can be separately password protected. Mode can be changed by binary input Remote OFF or Remote HRB .

Nomin power [ kW ] The nominal (or maximum) genset load. The setpoint is used as the upper limit of bargraphs of Engine Power, Gas Power and Diesel Power values (visualization on iD-BF LCD panel). Step: 1 kW Range: 0 – 3000 kW

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

DslFlowMax [ ltr/h ] The maximum diesel consumption (related to a maximal load) of the genset. However if the diesel-flow rate is measured only indirectly by the analog input CURRENT SENSE on iG-DFM unit as excitation of the diesel actuator then exact value of Diesel flow rate is not known. Set the value of DslFlowMax to zero.

Step: 0,1 ltr/h Range: 0,0 – 2000,0 ltr/h

DslConsCoeff [ i/ltr ] If the diesel-flow rate is measured by the flowmeter equipped with the impulse output then DslConsCoeff setpoint defines the number of impulses per one volume unit (usually liters). The active impulse transmitter measuring the diesel flow should be connected to iD-DCU terminals RPM.

If the diesel consumption per hour and total diesel consumption is to be read from ECU then set DslConsCoeff to zero.

Step: 0,1 i/ltr Range: 0,0 – 2000,0 i/ltr


Hint: The consumption is counted both in diesel and bi-fuel work.

Explanation of DslFlowMax and DslConsCoeff adjustment See flow diagram bellow as the instructions for settings of setpoint and the reading of values according to the used type of diesel flow sensor.


DslFlowMax = xx [ltr/h] … means maximum diesel consumption at nominal power Example: If the diesel-flow rate is measured by the flow meter equipped with the impulse output (engine with flow meter) then set the number of impulses per one volume unit [i/ltr] to DslConstCoeff. Maximal diesel consumption at nominal power [ltr/h] set to DslFlowMax. For detailed description of the corresponding setpoints see the Basic settings group.

YES

NO

Type of diesel flow sensor

Analogue Current/voltage

output Flow Meter

NO

YES

DslConsCoeff = 0 [i/ltr] DslFlowMax = xx [ltr/h] AI Fuel rate→LAI Fuel rate

START

Electronic engine control

ECU

Electric pulses Flow Meter

Electrically excited diesel

actuator

YES

YES

NO

Basic settings group setpoints

& Fuel rate cfg

DslConsCoeff = 0 [i/ltr] DslFlowMax = xx [ltr/h] Fuel ECU →LAI Fuel rate

DslConsCoeff = N [i/ltr] DslFlowMax = xx [ltr/h] Flow Meter→ LAI Fuel rate

DslConsCoeff = 0 [i/ltr] DslFlowMax = 0 [ltr/h]

Fuel rate read from ECU

Diesel % calculated from Fuel rate (coeff. DslFlowMax)

Fuel rate measured (coeff. DslConsCoeff)Diesel % calculated from Fuel rate (coeff. DslFlowMax)

Fuel rate unavailable

Diesel % measured by IG-DFM module

Diesel % calculated from Fuel rate (coeff. DslFlowMax)

Fuel rate read from linear analogue input

Values


The instantaneous Fuel rate is calculated from instant value of flow meter signal referred to scale DslConsCoeff.

The value Diesel [%] is calculated from instant value of diesel flow referred to scale DslFlowMax (how many percent of instantaneous diesel flow is based on the DslFlowMax).

DieslFlowLowLim [%] In some cases an inductive position sensor is used to detect the diesel actuator lever position. The sensor usually generates the current in the range 4-20mA. The setpoint DieslFlowLowLim is used to suppress the zero position (usually 4mA) to 0% of diesel percentage. Step: 0.1 % Range: 0.0 - 75.0 % Example: The position of diesel actuator arm is sensed by sensor generating the current in the range (4-20mA). The value corresponds with 20-100% of iG-DFM’s input measurement range. It is to suppress the functional zero of the sensor (4mA) to zero of the user range. That means it is to set the setpoint BasicSettings-DieslFlowLowLim = 20.0%. Transformed characteristics see in the picture bellow.

0102030405060708090

100

0 20 40 60 80 100

Input Diesel [% of input measuring range]

Tran

sfor

med

Inpu

t Die

sel

[% o

f usa

ge r

ange

]

GasValveLoLim [%] Effective gas throttle zone is narrower than the ACTUATOR output voltage range (0 to 100%) of iG-DFM unit. The setpoint Basic Settings:GasValveLoLim together with Basic Settings:GasValveHiLim provides the use of the full range (0 – 100%) of Convert Power:GasThrottle. Due to the feature the use of full mechanical range of throttle valve comes clear and effective.

Set the GasValveLoLim to the percentual value of output range corresponding with position of lower end of the gas throttle valve movement.


Step: 0.1 % Range: 0.0 - GasValveHiLim % Hint: Recommended adjusting procedure of GasValveLoLim and GasValveHiLim: Stop the genset and set GasValveLoLim to 0% and GasValveHiLim to 100,0%. Switch the operation mode to OFF and the Diesel protect:GasRegulOffset value set to VALVETEST. Turn the potentiometer Offset from zero to maximum and check when the gas throttle valve reaches positions: 1. throttle begins starts to move from closed position and read the first value Gas valve % 2. throttle reaches the opened mechanical limit and read the second value Gas valve % The first value of Gas valve % use to set the GasValveLoLim (the begin of opening) and the second value of Gas valve % use to set the GasValveHiLim (the end of opening).

GasValveHiLim [%] See explanations in the Basic Settings:GasValveLoLim. Step: 0.1 % Range: GasValveLoLim - 100.0 %

Service Time [h] Running hours down counter is decremented when engine is running. Service alarm is indicated in Alarm list and History record activated when counter reach zero. Service time setpoint is actual counter value. Step: 1 h Range: 0 – 65535 h Hint: Once the service time has elapsed the Service time will have to be adjusted to non-zero value to clear the alarm and begin a new countdown.

Controller Addr (1 .. 32) [-] Controller identification number. Each engine in the group has to have its own unique number. Default value is 1. Hint: The InteliDrive Contr. addr must correspond to DriveMonitor or DriveConfig communication setup setting when opening Direct or Modem connection.

RS232 Mode [ STANDARD / MODBUS ] Communication protocol selection. STANDARD: InteliDrive (DriveConfig, DriveMonitor, Remote panel) communication protocol. MODBUS: Modbus RTU protocol. Hint: Detail Modbus protocol description include some examples see in InteliGen Communication guide.

CAN Bus Mode [ 32C / 8C ] Inter-controller, I-RD-CAN, I-LB, I-LB+, IG-MU, IG-IB CAN2 bus speed selection. 32C: High speed CAN (250 kbps) applicable up to 32 controllers, CAN bus limited up to 200 meters. 8C: Low speed CAN (50 kbps) applicable up to 8 controllers, CAN bus limited up to 900 meters. Hint: Low speed CAN2 bus use for long distance connection only. Set all connected controllers to the same speed. Other units I-RD-CAN, I-LB, IG-IB detect CAN bus speed automatically.

CANAddrSwitch [ MODEM, OTHER ] Selection of communication mode CAN125.

MODEM: Modem communication OTHER: Communication object needed to be published as r-setpoint

Hint:

The modem may be connected to the i-LB and Access code is nort required


LightTimeOff [ min ] Timeout for ID display backlight automatic switch off. Zero setting disables display backlight switch off. Backlight is automatically switched on after any key press or Alarm activation. Step: 1 min Range: 0 – 250 min Hint: LightTimerOff setpoint influences the Remote panel not master controller when changed on Remote panel.

MODBUS [ 9600, 19200, 38400 ] Modbus interface baud rate speed setting.

Timer ON [hh:mm:ss]

Timer OFF [hh:mm:ss]

Timer Repeat [Never, Mon-Fri, Mon-Sat, Mon-Sun, Sat-Sun] Logical binary output Timer Active is closed when actual time is over the Time ON and opened when actual time is over Time OFF. The function depends on Timer repeat settings. The output is closed when controller is switched On and Timer settings corresponds to closed state. Hint: To use this function wire the Binary output Timer active to Binary input Rem start-stop.

Diesel protect

DieselLimMin [kW] When evaluated Diesel power is less than DieselLimMin the gas throttle valve (9) starts closing down (GasDecRamp) due to FLSR diesel limitation. The gas throttle valve closing speed is set by Diesel Gain. Step: 1 kW Range: 0 – Min Power kW

DieselLimCls [kW] The Gas (both outputs for gas safety valve (8) and throttle valve(9)) are deactivated when Diesel power (fuel) is less than DieselLimCls. Bi-fuel operation is again enabled after 10 seconds delay. Step: 1 kW Range: 0 – 3000 kW

Diesel Gain (Diesel increasing) [-] Setpoint controls the FLSR (Fast Low – Slow Recovery) Diesel limitation. Setpoint influences the gas throttle valve closing speed (and diesel increasing portion) when Diesel actuator current Id (fuel) is less than DieselLimMin. (Fast Low period) The throttle valve closing speed 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 controls the FLSR (Fast Low – Slow Recovery) Diesel limitation. Setpoint influences the gas throttle valve opening speed when Diesel actuator current (fuel) is higher than DieselLimMin. (Slow Recovery period) Step: 0,1 %/s Range: 0,0 – 200,0 %/s

Detonation Lim (Detonation limit) [%] The Knocking warning alarm is indicated when analog input from DENOX is over this limit. Step: 0,1 % Range: 0,0 – 100,0 %


DetonationFrom [ % ] Limit for analog input from DENOX. If the analog input is higher than DetonationFrom then the gas output is reduced. 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 required 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 is higher

this limit. Gas is closed when actual engine power is below limit 2

inDieselLimMMinPower +.

Step: 1 kW Range: DieselLimMin – 3000 kW

RegGasPrDel [s] In the moment of the gas shut-off activation starts a short period of ignorance of gas overpressure downstream of gas pressure regulator. The duration of the period is RegGasPrDel Step: 1 s Range: 0 – 60 s

Gas Dec Ramp (Gas decreasing ramp) [%/s] Gas throttle valve closing speed for normal SlowClose procedure. Step: 0,01 %/s Range: 0,00 – 10,00 %/s

Gas Ramp (Gas increasing ramp) [%/s] Speed of Gas throttle valve opening during start (first gas open). Step: 0,01 %/s Range: 0,00 – 10,00 %/s

Gas Ramp Start [%] Required initial gas throttle valve position in the moment of gas shut-off valve opening. Starting position of gas throttle valve during the transition to bi-fuel operation mode Step: 0,1 % Range: 0,0 – 100,0 %

Gas ramp

Gas Ramp Start

Conditions for gasthrottle valve opening

SlowCloseactive

GasRegulOffset [DISABLE/ENABLE/VALVETEST] Additional manual offset of Gas throttle valve is enabled od disabled. This function was designed mainly for testing of optimal valve characteristic setting. The value of the offset is defined by Physic analogue input which assigned to Logical function Offset

DISABLE: Analogue input Offset is ignored. ENABLE: Analogue input Offset is accepted. VALVETEST: Analogue input Offset is directly used to positioning of Gas throttle valve. The value is accepted only in OFF operational mode and stopped genset. 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 ] Starting limit of FLSR Exhaust temperature protection 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 throttle valve position reduction. Fast Limit Slow Rate function operates according to following formulas

Gas throttle valve position reduction formula:

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

Gas throttle valve position increasing formula:

FLSR = FLSR – ExhaustDecRmp

FLSR value is subtraced from the required Throttle valve position.

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

Active Power PI regulator Hint: The Active Power PI Regulator is useful in bi-fuel gensets not having automatic load sharing system and working in parallel mode with another genset(s) and/or mains. While the gas butterfly valve position is ramped then the actual generator power is stabilized by Active Power PI regulator. The regulation is abandoned by activation of MANUAL REG Logic binary input 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

Horn Timeout [s] The maximum amount of time the Binary output Horn is closed (horn, buzzer will sound). If it desired to have the horn sound until the alarm is cleared then set to zero. Step: 1s Range: 0 – 600 s

BFOnlyBlkDel1 [s] Delay for Engine bi-fuel operation Alarms activation – group 1 – see drawing below. (Look for RUNOnlyBlkDel in the picture) Step: 1s Range: 0 – 60 s

BFOnlyBlkDel2 [s] Delay for Engine bi-fuel operation Alarms activation – group 2. (Look for BFOnlyBlkDel in the picture) Step: 1s Range: 0 – 60 s

BFOnlyBlkDel3 [s] Delay for Engine bi-fuel operation Alarms activation – group 3. (Look for BFOnlyBlkDel in the picture) Step: 1s Range: 0 – 60 s


BINARY INPUT

BinInp delayphysical

BINARY INPUT

closed

Internal value

Engine running state

RunOnlyBlkDel

PROTECTION activeinactive

BINARY INPUT


BINARY INPUT

closed

Internal value


RunOnlyBlkDel

PROTECTION activeinactive Hint: Engine running state = RPM > Engine params: Starting RPM or Analog input Oil pressure > Engine params: Starting Poil or Active Binary input Run indication1 or Active Binary input Run indication2 or Active Binary input Run indication3.

BinInp Delay 1 [s] Binary input protection is activated when input is closed for longer time than BinInp delay 1. To use this filter Binary input must be configured in DriveConfig for Property – Delay = BinInp delay 1. Step: 1s Range: 0 – 60 s

BinInp Delay 2 [s] Binary input protection is activated when input is closed for longer time than BinInp delay 2. To use this filter Binary input must be configured in DriveConfig for Property – Delay = BinInp delay 2. Step: 1s Range: 0 – 60 s

BinInp Delay 3 [s] Binary input protection is activated when input is closed for longer time than BinInp delay 3. To use this filter Binary input must be configured in DriveConfig for Property – Delay = BinInp delay 3. Step: 1s Range: 0 – 60 s Hint: BinInp delay is active only for Binary inputs configured as protection and it is related to protection only. BinInp delay does not have any influence on an optionable logical function of an input.

DriveConfig: I/O, Property, Protection active = Closed

BINARY INPUT


BINARY INPUTInternal value

no change

BINARY INPUT


BINARY INPUT

closed

Internal value


BINARY INPUT



DriveConfig: I/O, Property, Protection active = Opened

opened

ForceBlock Del [s] Delay for Force block protection activation after Binary input Force block is opened. Protection deactivation is without delay. Protection is activated/deactivated independent on engine running or not running state. Step: 1s Range: 0 – 60 s

BINARY INPUTForceBlock delFORCE BLOCK

Protection

closed

BINARY INPUTProt, block type = Force block

closed

active activeinactive

Principle of differential temperature protection The principle of differential cylinder exhaust temperature from the average temperature is explained in the picture bellow. There is defined an double area round about average exhaust temperature of cylinders. Setpoints define the limits of both areas. If the temperature deviates from the area of the 1st level then Warning is activated. The deviation from the 2nd level activates the Diesel protection.

Gen-set power

Cyl

inde

r te

mpe

ratu

rede

viat

ion

from

ave

rage

Max+CylDifPmin

Max-CylDifPmin

Max+CylDifPnom

Nominal powerPminCylDifEval

Max-CylDifPnom

+

-

Average temperature

Drawing text translation Cylinder temperature deviation from average Cylinder temperature deviation from average Average temperature Average temperature Max+CylDifPmin Max+CylDifPmin Max-CylDifPmin Max-CylDifPmin PminCylDifEval PminCylDifEval Max+CylDifPnom Max+CylDifPnom Max-CylDifPnom Max-CylDifPnom Nominal power Nominal power Gen-set power Gen-set power

Max+CylDifPmin1 [ °C ] Maximum positive temperature deviation of any cylinder from the average at the PminCylDifEval load. If the temperature difference exceeds the allowed deviation then the Warning alarm is activated. Alarm will be activated depending on Block type - all the time or after some delay (BFOnlyBlkDelX) after transition to bi-fuel mode. Step: 1 °C Range: 0 ... 1000 °C


Max-CylDifPmin1 [ °C ] Maximum negative temperature deviation of any cylinder from the average at the PminCylDifEval load. If the temperature difference exceeds the allowed deviation then the Warning alarm is activated. Alarm will be activated depending on Block type – all the time or after some delay (BFOnlyBlkDelX) after transition to bi-fuel mode. Step: 1 °C Range: 0 ... 1000 °C

Max+CylDifPnom1 [ °C ] Maximum positive temperature deviation of any cylinder from the average at the Nomin power load. If the temperature difference exceeds the allowed deviation then the Warning alarm is activated. Alarm will be activated depending on Block type - all the time or after some delay (BFOnlyBlkDelX) after transition to bi-fuel mode. Step: 1 °C Range: 0 ... 1000 °C

Max-CylDifPnom1 [ °C ] Maximum negative temperature deviation of any cylinder from the average at the Nomin power load. If the temperature difference exceeds the allowed deviation then the Warning alarm is activated. Alarm will be activated depending on Block type – all the time or after some delay (BFOnlyBlkDelX) after transition to bi-fuel mode. Step: 1 °C Range: 0 ... 1000 °C

Max+CylDifPmin2 [ °C ] Maximum positive temperature deviation of any cylinder from the average at the PminCylDifEval load. If the temperature difference exceeds the allowed deviation then the Diesel protection is activated. Alarm will be activated depending on Block type - all the time or after some delay (BFOnlyBlkDelX) after transition to bi-fuel mode. Step: 1 °C Range: 0 ... 1000 °C

Max-CylDifPmin2 [ °C ] Maximum negative temperature deviation of any cylinder from the average at the PminCylDifEval load. If the temperature difference exceeds the allowed deviation then the Diesel protection is activated. Alarm will be activated depending on Block type – all the time or after some delay (BFOnlyBlkDelX) after transition to bi-fuel mode. Step: 1 °C Range: 0 ... 1000 °C

Max+CylDifPnom2 [ °C ] Maximum positive temperature deviation of any cylinder from the average at the Nomin power load. If the temperature difference exceeds the allowed deviation then the Diesel protection is activated. Alarm will be activated depending on Block type - all the time or after some delay (BFOnlyBlkDelX) after transition to bi-fuel mode. Step: 1 °C Range: 0 ... 1000 °C

Max-CylDifPnom2 [ °C ] Maximum negative temperature deviation of any cylinder from the average at the Nomin power load. If the temperature difference exceeds the allowed deviation then the Diesel protection is activated. Alarm will be activated depending on Block type – all the time or after some delay (BFOnlyBlkDelX) after transition to bi-fuel mode. Step: 1 °C Range: 0 ... 1000 °C


PminCylDifEval [ kW ] Minimum gen-set Power for Cylinder temperature Difference evaluation. The protection is not evaluated, if the gen-set power is lower than this limit. Step: 1 kW Range: 0,0 – kW Nominal power kW

CylDifEvalDel [ s ] Cylinder temperature Difference Evaluation Delay. Step: 1s Range: 0 – 600 s Hint: Do not mistake for EngineProtect:BFOnlyBlkDelx setpoint

CylEvalDualDel The delay of differential cylinder temperature protection after the transition to the bi-fuel operation mode.

The effect of the setpoint is the same like BFOnlyBlkDelx setpoint, but the CylEvalDualDel is assigned to the differential cylinder temperature protection only. Step: 1s Range: 0 – 600 s

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

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

Batt Volt Del [s] Delay for battery voltage alarms. Step: 1s Range: 0 – 600 s

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 15,5 % 3 300 30,0 % 4 400 40,0 % 5 500 50,5 % 6 600 57,0 % 7 700 60,0 % 8 800 50,0 % 9 900 36,0 % 10 1000 30,0 %

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


GasThrottle 1 … 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 [ % ]

Die

sel p

ower

[ kW

]

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

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

Analog Inputs

AIN1 Offset … AIN8 Offset [ ] Analog input channel offset constant Step: 1 Range: -32767 to 32767

Active call/SMS

Warning Call [DISABLED / ENABLED] Enables or disables active calls/SMS to selected phone or mobile numbers when a Warning alarm occurs.

Shut Down Call [DISABLED / ENABLED] Enables or disables active calls to selected phone or mobile numbers when a Shut down alarm occurs.

Slow Close Call [DISABLED / ENABLED] Enables or disables active calls/SMS to selected phone or mobile numbers when a Slow Close (Diesel) alarm occurs.

AcallCH1..3-Type Up to three separate channels are available for any one of the following types of messages: DISABLED: Channel is disabled. DATA: Standard analog, GSM or ISDN modem connection to DriveMonitor. 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. Each above message type has either a number or an e-mail address associated to it. For more details see DriveMonitor guide chapter IG-IB Internet communication. Hint: To receive active call run DriveMonitor – Type of connection = Active call. DriveMonitor Active call window contains list of received AIG or AIS files. Each list item contains Engine name, Date, Time, IS serial number.

Num Rings 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 immediately but after controller is switched on or when modem is connected to controller.

A.C.Multiplier [ - ] Setpoint specify the number of attempt to open the Active call connection when the phone line is engaged. Step: 1 Range: 1 to 250 Hint: Timeout for connection is 90 sec and after 120 sec controller starts the next attempt. Incoming calls are blocked during the time the controller is trying to send an active call type.

Date and time

Time [HHMMSS] Controller internal Real Time Clock adjustment.

Date [DDMMYY] Actual date adjustment

Time Stamp 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 Time stamp is recorded when TimeStamp Per = 0. RTC and Date is in each History record.

Protections Protection group contains all Analog inputs and Binary inputs protection limits and delays. List is dynamically created during configuration process.


PLC - programmable functions Following programmable functions are available in ID-DCU-Industrial-2.0 software. Use DriveConfig-2.0 or higher software to configure PLC functions. To enable PLC click on PLC modules used in DriveConfig and then go to PLC configuration window.

Available functions Config item Selection

Available Note

Log Func I. 32

AND, OR 2 to 8 inputs

Log Func II. 16

XOR, RS 2 inputs

Comp Hyst 8

Analog input Two limits Binary output

Comp Time 8

Analog input One limit + delay Binary output

Ana Switch 4

Two analog inputs Analog output Binary input as selector

Math Func 4

ADD, SUB, ABS, AVG, MAX, MIN

Mov Avg 2

Analog input Analog output

InterpolFunc 2

Linear interpolation

ForceHistory 4

Binary input causes history record when changes from 0 to 1

ForceProtect 4

Adjustable protection levels

PID Ana 2

PID control loop with analog output Function was replaced by PID Ana B with adjustable Bias value.


PID Bin 2

PID control loop with binary output

Counter 2

Edges counter One limit Binary output

Timer 2

Periodic signal generator Binary output Analog input

Delay 16

Adjustable rising and falling edge delay

RAMP 4

Ramp Analog input, analog output. Two setpoints for Ramp-up and down speed (in number of units per second). Enable-Up, Enable-Down: Ena/Disables the ramp.

PID Ana B PID control with Analog output and adjustable Bias 2

PID Analog output jumps to adjustable Bias value when Gate input is active (instead zero as before) and starts from Bias.

Math functions with expandable number of inputs up to 8. 4

Selectable: ADD, AVG, MAX, MIN Eight analog inputs, one analog output.

CMPW Window comparator 8

Comparator Analog input, two limits, analog output. Binary output is active when input is within limits.

Up/Down Request value generator Holding register 4

Analog output is changing within 2 limits (by defined rate of change) when Up/Down binary input is active.

Jump to … 8

Binary input Ena / Disables jump over the selected number of the next following PLC blocks. Jumps to the last one when number of blocks is higher than existing.

Increase / Decrease (Turn switch) 2

Analog output (internal register) can be Increased / Decreased by one with rising edge of binary input “Inc” / “Dec” in range from 0 to adjustable limit (max 65535). Register is Inc / Decreased over zero when "Cycle" option is ticked. Register stops on 0 even other Dec pulses come (or on Max for Inc pulses) when "Cycle" option is not ticked. Example of "Cycle" when Max = 5: 1-2-3-4-5-0-1-... or ...4-3-2-1-0-5-4- ...


Example of "No-Cycle" when Max = 5: 1-2-3-4-5-5-5-... or ...4-3-2-1-0-0-0- ... Binary input "Reset" switch the Analog output to adjustable “Default” value.

Conversion table 4

Table (conversion) can contain up to 30 items. Input can be connected to (above) Inc/Dec function.

Ana to Bin converter 4

Selected part of Analog input can be decomposed (decoded) to four binary outputs.

Ana formats converter 16

Converts any "Short" and "Long" analog value format to (signed) Integer format compatible with all PLC analog inputs. The invalid Analog output is indicated (####) when Analog input value is out of Integer range.

General specification • Each function output can be configured to - another function in PLC window - from another function input) - any physical terminal (e.g. to controller) - from I/O window • Each function limit (parameter) can be configured as - constant limit (fix): just write requested value into the field (-32000 to +32000) - setpoint limit (customer adjustable): click on field and select one from PLC setpoint list - any value (e.g. from Analog input): click on field and select one from controller or PLC values list • All PLC function analog inputs are signed type and that why the following analog values must not be

configured to any comparator and PID analog input: - Load sharing: ThrottlePos. - Info: ECU DiagSource, Timer val, PasswordDecode. - Statistics: NumSuccStarts, NumUnscStarts, Service time. • All function limits and analog outputs must follow input analog value format:

- e.g. input value is 0 to 10,0 bars, then setpoint limit is e.g. 3,2. • Any time and delay limit is in 0,1s step in the range 0,0 to 3276,7 sec. • PLC consistency check indicates incorrect PLC configuration.

PLC values Binary List contains 64 internal binary values (bits) PLC Bout 1.1 to PLC Bout 1.8 ..... PLC

Bout 8.1 to PLC Bout 8.8 that can be configured as any PLC function binary input or output. Anly used PLC Bout x.x can be configured to ID-DCU controller or external modules physical terminals. Used values are visible on controller screen.

Analog It is available 16 internal analog values PLC Aout1 to PLC Aout16 that can be configured as any PLC function input or output.

Any used PLC Aout x can be configured as physical analog output. Used values are visible on controller screen.

PLC resource Unsigned value that is automatically used for Counter, Timer and Inc/Dec functions. Values are visible in DriveMonitor only. Only four resources is available for 2x Counter, 2x Timer and 2x Inc/Dec.


PLC functions description

Log Func I. Logical functions: AND, OR. Two to eight inputs AND, OR functions are available. Maximal number of functions: 32 OR, AND logic

Input No.1 Input No.2 OR AND 0 0 0 0 0 1 1 0 1 0 1 0 1 1 1 1

I/O Note

Input No. 1 I1 Binary input 1 Input No. 2 I2 Binary input 2 ……..

Input No. 8 I8 Binary input 8 Output Function type “OR” or “AND”

To add/remove input click on + or – button. It is possible to invert any input or output. Maximum number of inputs is 8.

Log Func II. Logical functions XOR, RS Maximal number of functions: 16. XOR logic

Input No.1 Input No.2 XOR 0 0 0 0 1 1 1 0 1 1 1 0

R-S (Flip-Flop) logic Input No.1 (S) Input No.2 (R) RS

0 -> 1 0 0 -> 1 1 0 -> 1 1 -> 0

1 -> 0 1 0 0 1 -> 0 0 1 1 -> 0 0 -> 1

I/O Note Input 1 S input for RS Input 2 R input for RS Output Binary output Function Type “XOR” or “RS”

Comp Hyst Comparator with hysteresis. Maximal number of functions: 8

I/O Note Input 1 Analog input Input On ON limit Input Off OFF limit Output Binary output ON and OFF limit can be configured as - constant limit (fix): just write requested value into the field (-32000 to +32000) - setpoint limit (customer adjustable): click on field and select one from PLC setpoint list - any value (e.g. from Analog input): click on field and select one from controller or PLC values list Output signal depends on limits order.


Input ON < Input OFF

Input ON

Input OFF

Output

Comp Time Comparator with limit and delay. Maximal number of functions: 8.

I/O Note Input 1 Analog input Input 2 ON/OFF limit Delay Delay [0,1s] in the range: 0,0 to 3276,7 sec. Output Binary output

ON/OFF limit can be configured as - constant limit (fix): just write requested value into the field (-32000 to +32000) - setpoint limit (customer adjustable): click on field and select one from PLC setpoint list - any value (e.g. from Analog input): click on field and select one from controller or PLC values list

delay delay delay

Input 2

Inpu

t 1

Output

Window comparator Comparator indicating the value is within the two limits. Maximal number of functions: 8.

I/O Note Input 1 Analog input Input ON ON limit Input OFF OFF limit Output Binary output

ON/OFF limits can be configured as - constant limit (fix): just write requested value into the field (-32000 to +32000) - setpoint limit (customer adjustable): click on field and select one from PLC setpoint list - any value (e.g. from Analog input): click on field and select one from controller or PLC values list


Input ON < Input OFF

Input ON

Input OFF

WindowOutput

Ana Switch Analog switch. Binary input selects which analog input is connected to analog output. Maximal number of functions: 4

I/O Note Input 1 Analog input 1 Input 2 Analog input 2 Input Sw Input selection. Output = Input1 when Input sw is opened. Output Analog output

Input 1

Input 2Output

Switch

Math Func, Extended Math Mathematical functions from two up to eight analog inputs. Maximal number of functions: 4

I/O Note Input 1 Analog input 1 Input 2 Analog input 2 … Input 8

Function type ADD, SUB, ABS, AVG, MAX, MIN

Output Analog output The same input format is required for both analog inputs (e.g. 0,1).

Function description ADD Output = A + B SUB Output = A - B ABS Output = Absolute (A – B) AVG Output = (A + B) / 2 MAX Output = MAXIMUM (A; B) MIN Output = MINIMUM (A; B)

Input 1

Input 2Output

ADDSUBABSAVGMAXMIN


Mov Avg Moving average with adjustable weight and period. Maximal number of functions: 2

I/O Note Input Analog input Exp.weigh 1 to 5 Period 100 to 5000 ms Output Analog output

Output value format follows the input format.

InterpolFunc Linear interpolation based on two points line. Analog output corresponds to linear characteristic specified by two points. Max number of functions: 2

I/O Note X1 The first point X Y1 The first point Y X2 The second point X Y2 The second point Y Input Analog input Output Analog output

Analog output format follows analog input.

Output

InputX1

Y1

X2

Y2

ForceHistory History record is activated when binary input value is changed from 0 to 1. Maximal number of functions: 4

I/O Note Input Binary input

ForceProtect Force programmable state. Function activates selected programmable state. Max number of functions: 4

I/O Note Protection type Select type from the list.


Lvl1 Level 1 protection: Warning Lvl2 Level 2 protection: Shut down, Cool down Fls Sensor fail

Connect selected levels to binary input from the list. Selected protection level is activated when corresponding binary input is closed (active).

PID Ana Bias PID control loop with analog output. Maximal number of functions: 8

I/O Note Input Analog input Requested value Configure as constant, PLC setpoint or value. Input GAIN PID proportional factor Input INT PID integral factor Input DER PID derivative factor

Input BIAS When binary input GATE is active the BIAS value is forced to output.

Input GATE PID works when gate is not configured. Inactive binary input GATE sets PID output to adjustable Input Bias value and blocks PID calculation when configured.

Output Analog output. Range: -10000 to +10000 Period Period of PID calculation: 100 to 5000 msec.

PID analog input can be configured to any analog value (physical input) Requested value, Input Bias and PID setting can be configured as constant or setpoint or analog value (physical input) from the object list. Sensor fail on measured (or requested) value set PID output to Input bias and blocks PID calculation. There is configurable LoLimit (for 0V or 0mA output) and HiLimit (10VDC or 20mA) for analog output configuration.

PID Bin PID control loop with binary outputs. Maximal number of functions: 2

I/O Note Input Analog input Requested value Configure as constant, PLC setpoint or value. Input GAIN PID proportional factor Input INT PID integral factor Input DER PID derivative factor

Input GATE Active binary input GATE blocks PID calculation and set both outputs to zero.

Output Up Binary output UP. Output Down Binary output DOWN. Period Period of PID calculation: 100 to 5000 msec.

Actuator time Period between actuator’s lower and upper stop: 100 to 5000 msec.

PID analog input can be configured to any analog value (physical input) Requested value and PID setting can be configured as constant or setpoint or analog value (physical input) from the object list. Active binary input GATE blocks PID calculation - binary outputs are inactive. Sensor fail on measured (or requested) value blocks PID calculation.

Counter Impulse counter. Maximal number of functions: 2


I/O Note Input cnt Counter binary input. Input clr Counter clear (reset) binary input. Input lim Analog – limit level input (max 65535). Output Binary output – over limit indication.

Counter can counts rising or falling edge. The result is stored in volatile memory and it is lost when controller is switched off. Binary output is activated when counter is over limit. Output stays closed even if counter overflow over maximum 65535. Counter contains binary Reset input (level sensitive) that set counter to zero, resets binary output and blocks counting when active. Maximal counter value is 65535 (16 bites wide) and continues to zero. The minimal pulse period is 0,2 sec (max 5 Hz) - in this case the counter overflow after 218 minutes.

Timer Periodic signal generator. Maximal number of functions: 2

I/O Note Input reload val Analog value specifies period of Binary output change [ 0,1s]. Input reload Closed binary input Reload reloads timer period when closed. Input run Binary input must be closed to activate Timer. Output Binary output.

Binary output changes state with period given by analog Input reload val [ 0,1s ] when Binary input Run is closed and Binary input Reload is opened. Timer starts with low state period when selection Firs down is ticked. E.g. Output changes state each 10 sec when input value is 100. Timer reloads (accepts period change) in the end of period or when binary input Reload is closed. Reload function can be useful when very long time period is running.

Delay Delay module – adjustable delay for rising/falling edges. Maximal number of functions: 16

I/O Note Input Binary input. Input time up Delay of rising edge in 0,1s Input time down Delay of falling edge in 0,1s Input reset Binary input to reset output. Output Binary output.

IN

RESET

OUTTup

Tdown

Rising and Falling edge delay.

Hint: Use Tdown > Tup for propper functionality

IN

RESET

OUTTup

Tdown


IN

RESET

OUTTup

Tdown

Rising and Falling edge delay.

IN

RESET

OUTTup

Tdown

IN

RESET

OUTTup Tdown =0

0,1 s

Tdown

Tup

Tinup > 100 ms

IN

RESET

OUT

Noise filter – does not accept input signal shorter than 100 ms.

IN

RESET

OUT

T rstup > 100 ms

Tup

Reset signal function

Puls on edge Function depends on selection Puls on edge. Function generates pulse on rising edge when Input time up is configured or pulse on falling edge when Input time down is configured.

IN

RESET

OUT Tup Tdown

Two pulses when both Time up and Time down setpoints are configured and input pulse is longer than Time up.

IN

RESET

OUT Tup

Tdown

One common pulse when T up > T in (input)


IN

RESET

OUT

T

Tdown

Tupup

Reset signal function

IN

RESET

Ti

OUT Tup

OUT Tdown

Tdown =0

OUT

OUT

Tdown =0

< TiTup

Puls on edge

Tup > Ti

Tup > Ti Tdown >0

Single pulse when Tup<Ti and Tdown = 0. Max output pulse length is Ti when Tup>Ti and Tdown = 0. One long pulse “Ti+Tdown” when Tup>Ti and Tdown>0. Two separate pulses when Tup<Ti and Tdown>0.

RAMP The analog output changes state in constant speed adjustable to different values Up and Down. Maximal number of functions: 4

I/O Note Input AIN Analog input. Input time up AIN Ramp-up time in Units per second. Input time down AIN Ramp-down time in Units per second. Output AOUT Analog output.

Option: tick EnableUp and EnableDown in PLC RAMP configuration window. The output follows input when both corresponding Enable Up/Dn is not selected and input change is slower than the change given by ‘time-up’ and ‘time-down’ input setpoints.

Output

Input

Ramp Up

Up/Down The analog output is increasing or decreasing according to binary inputs Up and Down activation. Maximal number of functions: 4

I/O Note Limit1 AIN Up-limit for Analog output. Limit2 AIN Lo-limit for Analog output. Reset BIN Binary input to reset the output to Default output value. Speed up AIN Rising speed (setpoint, constant) - Units per second.


Speed down AIN Falling speed (setpoint, constant) - Units per second. Up BIN Binary input to activate Analog output increasing. Down BIN Binary input to activate Analog output decreasing.

Default output value AIN The Analog output switches to this value after start-up or reset or when both Up and Down inputs are activated.

Analog output AOUT Analog output. UP/Down block can be used as a Holding register. Required settings for holding register with analog input, binary input and one analog output:

I/O Note Reset Binary input. Default output value Analog input. Output Analog output.

Analog output follows analog input if Reset is active if it is not active analog output is frozen and stays at the last known value.

Jump I/O Note

Input BIN Jump activation. Jump over Const. Internal constant – possible to change during configuration only. Jump to Const. …. Option instead Jump over.


Jump to: PLC Item 5

Binary input

inactive

Jump to: PLC Item 5

Binary input

active

PLC Item 1

PLC Item 2

PLC Item 3

PLC Item 4

PLC Item 5

PLC Item 1

PLC Item 2

PLC Item 3

PLC Item 4

PLC Item 5

Inc/Dec I/O Note

Inc. BIN Binary input rising edge increase Analog output by one. Dec. BIN Binary input rising edge decrease Analog output by one. Reset BIN Binary input rising edge set Analog output to Default (see below). Max Const. Binary input to activate Analog output increasing. Default Const. Binary input to activate Analog output decreasing. Cycle tick Min-Max limit or cycle mode selection. Analog output AOUT Analog output.

Mux const. I/O Note

Analog input AIN Up-limit for Analog output.

Table Item (primary): fix numbers in the range from 0 to 30.

Analog: up to 30 items of Integer values in the range ±32000. Binary: Decoded Analog values.

Analog output AOUT Analog output.

Analog input Analog outUp to 30 points table of integer

Decomposer I/O Note


Analog input AIN Analog input. Selected bits selection One of four parts of input value selection. Test value test Test of bits structure above. Out 1 BIN Binary output of selected part of input - weight 1. Out 2 BIN Binary output of selected part of input - weight 2. Out 3 BIN Binary output of selected part of input - weight 4. Out 4 BIN Binary output of selected part of input - weight 8.

Analog input

Binary outputsOut 1Out 2Out 3Out 4

Convert I/O Note

Analog input AIN Analog input in any “Short” or “Long” format. Analog output AOUT Analog output = input converted to (signed) Integer16.

PLC configuration example Let suppose a diesel compressor. The engine speed is controlled via ID-SCM (IG-PCM) Speed governor analog output (no data communication). InteliDrive measures output pressure.

ID-DCU

ID-S

CM

Speedgovernor

ENGINE Compressor

PressureSensor

Speedgovernor

output

Required function Based on adjustable pressure limits ID controller switch the engine between RPM1 to RPM2. When Pressure drops below Pressure ON limit engine increases from RPM1 to RPM2 and after Pressure increases above Press OFF limit goes back to RPM1.


Pressure ON

Pressure OFF

RPM2

RPM1

RPM

Pres

sure

Function structure

CompHyst

Sensorcharacteristic

Pressure sensor

ID-DCU

Analog input

(IG-PCM)

Speedgovernoroutput

Pressure ON

Pressure OFF

AnaSwitch

RPM 1

RPM 2Analog output

ID-SCM

Configuration steps 1. Start DriveConfig-2.0 and open default DCU-Industrial-SS-2.0T2.aid (all speed archive). 2. Go to DriveConfig - Modules window: click “PLC Used” and “IG-PCM Used”.

Hint: Standard IG-PCM module can be used in ID-DCU-Industrial-2.0 for Speed governor output because ID-SCM module is not available now.


3. Pressure measuring: configure pressure sensor characteristic – suppose range 0 to 10,0 bars on ID-DCU Analog input 4. Wrn and Sd protection limits should be adjusted over Pressure OFF limit.

4. Go to PLC window and select (click on) PLC function Comp Hyst

5. Configure Comparator Input: click on button and select input value from the list.


6. Configure comparator limits Input ON, Input OFF as PLC setpoints.

7. Edit setpoint name in PLC setpoints list.

Result look like this

8. Select PLC function Ana Switch, configure Input 1 and Input 2 as PLC setpoints and edit the setpoint names to Pressure ON and Pressure OFF.


9. Configure binary Input SW: PLC values: PLC Bout 1.1.

10. Rename output to RPM out.

11. Go to I/O window and configure analog IG-PCM AOUT1 as RPM out. Then configure analog output Lo limit (value for –10.00V output) and Hi limit (value for –10.00V output).

Spee

dgo

vern

or o

utpu

t

-2000

2000

-10,00V

+10,00V

Speed governor output characteristics for Lo limit and Hi limit setting above.

Speed governor output voltage in this case (when RPM1= 500 and RPM2=1800) is 9V when pressure is low and 2,5V when pressure is high.


Function details notices

Protections



HistRecord only



HistRecord only



HistRecord only

Sensorcharacteristics

+

RI

Analog input



HistRecord only


Analog output

Binary outputs

State machine

Hardwarejumper

ID-DCU

Hint: There are visible only the first two bar graph marks for protection limits indication on ID-DCU screen !!!


Analog output

Binary output

State machine

J1939 analog


WarningWrn+ColldownWrn+Shutdown

Sensor failAlarm only

HistRecord only

ID-DCU


WarningColldownShutdownSensor fail

Warning+BWShutdown+BW

Alarm onlyHistRecord only

Logical binaryinput list

Binary output

Binary output

State machine

Binary input

(J1939 BI)

ID-DCU


How to configure analog input window protection 1. Switch DriveConfig to EXPERT mode.

2. Configure standard two level analog protection


3. Add another protections in EXPERT window. There can be set the same delay for all four limits.

Protection delay and blocking BINARY INPUT


BINARY INPUT

closed

Internal value

BINARY INPUT



DriveConfig: I/O, Property, Protection active = Opened

opened

BINARY INPUT


BINARY INPUT

closed

Internal value


RunOnlyBlkDel


BINARY INPUT


BINARY INPUT

closed

Internal value


RunOnlyBlkDel



Universal states State is a value joined to each Analog input or value. State indicates if any protection configured on corresponding analog input is active or not.. When is any state configured as protection the corresponding Binary output appears in Analog protection list and can be used for selective external indication of Alarm. State is reset (output is opened) when corresponding Alarm is not active and confirmed (Fault reset was pressed).

Protection limitAnalog value increasing Analog value decreasing

Fault reset button

Protection state There is seven universal (free) states available in ID-DCU-1.1 that are not joined to any value or input. They can be used mostly for some values that have not state (e.g. RPM or other that are not measured on Analog input). This way can be configured protection to any ID-DCU internal value or more levels external indication. Example of Universal state1 configuration to Engine speed (Warning for Engine speed > 1600RPM, 1s): This configuration is available in DriveConfig – Expert mode.


Alarm management Following alarms and protections are available:

Prefix Meaning No protection

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

Alarm only HisRecOnly

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

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

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

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

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

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

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

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

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


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

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

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

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

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

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

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

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

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

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

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

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

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


Gen-set power

Cyl

inde

r te

mpe

ratu

rede

viat

ion

from

ave

rage

Max+CylDifPmin

Max-CylDifPmin

Max+CylDifPnom

Nominal powerPminCylDifEval

Max-CylDifPnom

+

-

Average temperature

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

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

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

(e.g. 100 ) on InteliDrive screen when value is out of limits (binary input protection is active).

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


Bi-fuel conversion kit principles

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

BI-FUEL CONTROLSYSTEM

active

throttle bodygas filter

senzorpressure

Engine governor

flywheel

camshaft

safety-valvedouble

regulatorgas pressure

valvehand

pressuresenzor

senzortemperature

senzortemperature

2

3

4

5

6

7

89

10

1GENERATOR

SWITCHBOARD

Power transducer

InteliDrive

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

1. Generator active power measurement Active power is one of the main entries into the regulation. Actual power of the generator is evaluated from voltage and current measured by common three-phase transducer.

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

3. Boost Air Temperature


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

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

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

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

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

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

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

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

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

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


Principle of operation

Gas throttle valve control

FLSRDieselLimMinDiesel GainDieselDecRmp

PWM

4 - 20 mA Detonation signalfrom DENOX

Engine power

Diesel actuator current

Gas throttlevalve position

GasRegulOffset

-

-

Engine power [ kW ]Gas

Thro

ttle

1-10

0 [ %

]

FLSRExhaustTmpLimExhaustTmpGainExhaustDecRmp

Exhaust Temperature

Convert Power

DetonationFromDetonation Lim

Gas Request

Gas Regul

Gas Valve

DieselLimCls

EngineShut down

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

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

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

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

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

Default Shutdown and Slow stop of the gas 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 accomplished.

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

• Gas Pressure downstream the Gas Pressure Regulator; “Sensor 2” – binary signal used to protect the engine in case of failure of Gas Pressure Regulator. If too high pressure of gas is detected (and


contact is activated), immediate gas shutdown is accomplished. The period of gas shut-off opening (Gas OK output) is spanned for Diesel protect:RegGasPrDel.

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

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

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

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

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

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

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


Operator Interface

Pushbuttons and LEDs

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

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

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

3

9

10

11

12

2 1 4 5

6

7

8


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

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

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

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

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

Press PAGE to leave selected set points group.

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

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

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

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

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

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


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

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

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

Main screen indication

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

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

3 2 1 4 5

7

8 9

6


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

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

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

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

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

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

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

Alarm indication Possible Alarm list and History record prefixes

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

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

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


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

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

Customer’s DG

Controller name

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

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

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

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

type Information available on

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


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

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

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

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

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

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

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

Main screen


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

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

Request confirmation and exit

Enter active when Engine params: EnLocalSpeed = ENABLED

Exit without confirmation Page

Fast edit screen

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

Info screen exit Automatic after 10 sec to Main screen

Info screen

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

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


Operation instructions

Operational modes

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

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

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

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

Manual operation mode - MAN

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

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

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

If emergent situation press emergency GAS STOP pushbutton on panel.

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

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

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

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

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


Controller configuration and monitoring InteliDrive sw pack contains separate PC software tools: DriveConfig (DC) and DriveMonitor (DM). DriveConfig and DriveMonitor is based on Windows 95/98/NT/ME/2000/XP or higher platform and requires 5 Mbyte of hard disc free space.

Direct connection to the PC InteliDrive can be connected directly with PC via RS232 interface. Use the standard cable RS232 cable to connect PC with InteliDrive controller. Hint: Make sure the grounding system on controller and PC – COM port (negative of the PC DC supply) are identical – before the first direct connection. There must not be any voltage between these two points otherwise the internal PTC protection activates and interrupts RS232 communication. In such case disconnect RS232 line wait a minute for PTC recovery and try again. The simple solution is to assure, that the PC supply 240/20V is ground free (GND terminal is not connected).

5 - GND

2 - RxD3 - TxD

PC

5 - GND

2 - RxD3 - TxD

RS2

32

RS2

32

230 VAC

0 VD

C

CONTROLLER

+-Battery

Required the samevoltage potentialbetween GND‘s

RS 232

Default archive The ID-DCU controller can be programmed by various firmware. The firmware iD-BF-x.x.mhx is one of them. The iD-BF firmware is assembled with application BF-x.x.aid. Since there is only one application then the one is also considered as default one. configuration can be changed in the DriveConfig software.

DriveConfig There are two controller file types:

Firmware Application file (archive) ID-DCU-Industrial-2.5.mhx DCU-Industrial-SS-2.5.aid

DCU-Industrial-AS-2.0.aid5 Delivered controller contains firmware and default configuration. Any Application file can be modified by customer using DriveConfig PC software. It is possible to download Application file from the controller, modify it and download back. There must be corresponding version of Application file with firmware in controller. Hint: Any ECU Inputs/Outputs configuration procedure has to start from default AS or SS archive. The problems can occur when the finished ECU configuration is simply changed to another ECU (e.g. from Volvo to Scania) without ECU-1 module unselecting (unclicking). Configuration aid file does not contain the History record when had been read from the ID controller by DriveConfig. To load History file from InteliDrive use DriveMonitor software only.


Application file - archive There exists one binary type of configuration file only. Config file “*.aid” contains:

• Complete I/O configuration (include extension modules if any) • Setpoints setting • All available languages

Configuration file can be opened (Open file or Load from ID) modified and stored to the PC (Save, Save as) or downloaded to Controller (Store to ID).

DriveConfig functions Tool for ID-DCU controller and extension modules configuration

• Extension modules addressing • All I/O function or protection configuration • Setpoints adjusting • Sensor characteristics modification • History record modification • Password level protection modification (password value must be changed in DriveMonitor) • Controller firmware (mhx file) upgrade • Controller application file Up/Down load • Language translator enables (not available in version 1.0)

o Create Dictionary between two languages (Dictionary can be used repeatedly) o Translate current text in Controller (in any language) o Add new language (up to controller memory limit)

PC to ID-DCU controller connection • Uploading or downloading procedure only (no continuous on-line connection) • Direct RS232 connection • Modem and internet connection

Configuration steps Following configuration steps are available in DriveConfig software: • Configure addresses of Extension modules when more inputs and outputs are required • Configure J1939/J1587 interface when Electronic engine is connected • Configure Binary inputs as Protection or Function • Configure Binary outputs • Configure Analog inputs as Protection or Function • Define user sensors • Configure History record • Configure password protection • Add/Translate the language

Translator Enables to translate all or some texts to up 5 languages that are all available in controller. Controller language can be changed from panel buttons. It is possible to operate different languages on each ID-DCU, Remote panel and Drive Monitor. Hint: Check all screens if some texts are not shortened.

Not supported functions • No continuous system monitoring (measured values are not available) • No remote control (Start, Stop, …) via serial data line. • No History (log) monitoring, only History header. • No Modem, GSM and internet interface support.


Configuration lock protects any (sophisticated) aid configuration (e.g. with complex PLC functions) in controller against unwanted loading (and using) by the third person. Locked configuration is not possible to open with DriveConfig without Level 3 password setting. For service purposes can be aid file loaded by DriveMonitor but again without possibility to open in Off-line mode by DriveConfig without password.

Configuration lock is available from firmware versions ID-DCU-Industrial-2.5 and ID-DCU-Marine-1.6 (coming soon) can be Ena/Disabled in DriveConfig – Modules window.

Hint: On-line help is available in DriverConfig after function F1 key is pressed.

DriveMonitor

Functions • On-line direct, Modem or Internet connection to one engine • Active Modem or Internet call from engine to PC (activated by selected Alarm) • Continuous one engine monitoring in on-line connection • On-line or Off-line History record listing • Setpoints listing and adjusting (password protected) • Statistics value (e.g. Running hours) Set/Reset • Password and Access code change

Connection type

Direct connection via RS232 (up to 10m). For longer distance use RS232/RS485 converters (e.g. ADVANTECH – ADAM 4520).

Modem connection via Analog, ISDN or GSM modem.

Internet via IG-IB (InteliGen internet interface unit). IG-IB Internet - Ethernet or Dial-up connection is available.

Active call (via modem). Controller calls to the preselected telephone number and sends the AID file when active call is activated. To receive AID file the DriveMonitor must be in Active call waiting window.

Off line connection enables open and list Application AID file stored in PC.

Hint: More detail regarding different types of connection see in IG-IS Communication guide.

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

ID-RPU window … not available in Industrial version

Setpoints: listing and adjusting

Values: reading of all I/O include external modules

History list: complete history list.


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

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

Modbus communication See detail description in InteliCommunicationGuide-xxx.pdf. • Direct connection: RS232, RS422, RS485 • Modem connection • 9600, 19200 or 38400 bps, 8 data bits, 1 stop bit, no parity • Transfer mode RTU • Function 3 (Read Multiply Registers) • Function 6 (Write Single Register) • Function 16 (Write Multiply Registers) • The response to an incoming message is sent with minimum 4.096 ms delay after message reception Data block reading is available from ID-DCU-Industrial-2.4 and maximal block size is up to 65 registers. The complete description of Modbus communication protocol can be found in Modbus Protocol Reference Guide PI-MBUS-300 and Open Modbus Specification Release 1.0. Both documents are available from web site at http://www.modicon.com/openmbus/ .

Modbus Multipack message It is special communication object that contains all values that are used for History record (configurable) and can be read by one command. Hint: Detail Modbus command description and examples see in ComAp Communication guide and in DriveConfig On-line help.

Communication object vs. Register All the data intended for communication has its representation as communication objects in the controller. The communication object is represented by the n-byte array in the controller memory and identified by the unique 16-bit communication object number. The register, according to Modbus communication protocol, represents a two-byte data and in communication functions is referenced by 16-bit register address. Further in the description of communication functions the communication object number will always be used as

http://www.modicon.com/openmbus/


a register address and length of the communication object will be expressed by number of registers. Just one communication object can be read or written by one communication function. Hint: It is possible to download the Actual InteliDrive controller object description corresponding to actual configuration from on-line controller or from aid archive using DriveConfig software.


Technical data

ID-DCU

Power supply Nominal power supply 24 VDC Power supply range 8 – 36 VDC Current consumption (depends on supply voltage) 0,34A at 8VDC

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

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

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

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

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

Shocks a = 200 m/s2 Hint: The ID-DCU-Industrial controller can also fulfill requirements of the NFPA 20 standard by using of controller’s PLC functions.

Dimensions and weight Dimensions (183x123x47mm)

See chapter terminals and dimensions Weight 800g

Binary inputs Number of inputs 14 Input impedance 4,7 kΩ Input range 0-36 VDC Switching voltage level for close contact indication 0-2 V Voltage level for open contact indication 8-36 V Minimal input duration 110 ms

Binary open collector outputs Number of outputs 14 Maximum current - outputs BO1, BO2 1A Maximum current - outputs BO3 - BO14 0,5 A Maximum switching voltage 36 VDC


Speed pick-up input Type of sensor magnetic pick-up (connection by shielded cable is recommended) Input impedance 10 kΩ Minimum input voltage 2 Vpk-pk (from 4 Hz to 4 kHz) Maximum input voltage 50 Veff Minimum measured frequency 4 Hz Maximum measured frequency 10 kHz (min. input voltage 6Vpk-pk) Frequency measurement tolerance 1,5 %

D+ function Max. D+ output current 300 mA. Guaranteed level for signal Charging OK 90% of supply voltage.

Analog inputs Not electrically separated Group 1 AI1 – AI4 Number of inputs 4 unipolar Resolution 10 bits Jumper selectable range V, ohm, mA Maximal resistance range 2500 Ω Maximal voltage range 1,0 V Maximal current range 0 – 20 mA Input impedance 180 Ω for mA measuring Input impedance > 100 kΩ for V measuring Resistance measurement tolerance ± 2 % ± 2 Ω out of measured value Voltage measurement tolerance ± 1 % ± 1mV out of measured value Current measurement tolerance ± 1 % ± 0,5mA out of measured value Group 2 AI5 – AI8 Number of inputs 4 bipolar Resolution Up to 16 bits Jumper selectable range V, ohm, mA, thermo coupler Maximal resistance range 2500 Ω Maximal voltage range ± 1000 mV or 100mV The maximal input voltage offset is in the range from –2 to +5 VDC against controller minus power supply when AI5 to AI8 is used for differential voltage measuring. Maximal current range ± 0 - 20 mA active 0 - 20 mA passive Input impedance 50 Ω for mA measuring Input impedance > 100 kΩ for V measuring Resistance measurement tolerance ± 0,5 % ± 2 Ω out of measured value Voltage measurement tolerance ± 0,5 % ± 1mV out of measured value Current measurement tolerance ± 0,5 % ± 0,5mA out of measured value

RS232 interface Maximal distance 10m Speed 19.2kBd

I-RD-CAN Basic technical data are equal to ID-DCU. There are no binary and analog inputs and outputs. Communication interface CAN, RS232


IG-DFM Nominal power supply 24 VDC Power supply 8 – 36 V DC Mechanical dimensions: 108 x 108 x 25 mm, Interface to controller direct mounted (SUB25) Binary inputs and outputs no 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

CAN bus interface Maximal CAN bus length Basic setting: CAN bus mode = 32C 200m Basic setting: CAN bus mode = 8C 900m Speed (32C) 250kBd Speed ( 8C) 64kBd Nominal impedance 120Ω Cable type twisted pair (shielded) Following dynamic cable parameters are important especially for maximal 200 meters CAN bus length and 32 ID-COM units connected: Nominal Velocity of Propagation min. 75% (max. 4,4 ns/m) Wire crosscut min.0,25 mm2 Maximal attenuation (at 1 MHz) 2 dB / 100m Recommended Industrial Automation & Process Control Cables: BELDEN (see http://www.belden.com):

• 3082A DeviceBus for Allen-Bradley DeviceNet • 3083A DeviceBus for Allen-Bradley DeviceNet • 3086A DeviceBus for Honeywell SDS • 3087A DeviceBus for Honeywell SDS • 3084A DeviceBus for Allen-Bradley DeviceNet • 3085A DeviceBus for Allen-Bradley DeviceNet • 3105A Paired EIA Industrial RS485 cable

LAPP CABLE (see http://www.lappcable.com)

• Unitronic BUS DeviceNet Trunk Cable • Unitronic BUS DeviceNet Drop Cable • Unitronic BUS CAN • Unitronic-FD BUS P CAN UL/CSA

IS-BIN16/8, IS-AIN8 Nominal power supply 24 VDC Power supply range 8 – 36 VDC Consumption (depends on supply voltage and configuration) 100 – 300mA Mechanical dimensions: 150 x 160 x 50 mm ,

DIN rail (35 mm) mounted

http://www.belden.com/

http://www.lappcable.com/


Connection to IS-CU (galvanically separated) CAN1 Operating temperature -30..+70oC Storage temperature -40..+80oC 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

IS-BIN16/8 Binary inputs Galvanically separated two groups Number of inputs 8 + 8 Input resistance 3 kΩ Input voltage range 0-36 VDC Input voltage level for open contact 8 to Power supply VDC Input voltage level for close contact 0 to 2 VDC Voltage level is defined between Binary input and Binary input COM terminal.

Open collector outputs Number of outputs (galvanically separated) 8 Maximum current 0,5 A Maximum switching voltage 36 VDC

Frequency inputs Number of inputs 2 (RPM1, RPM2) RPM1 Type of sensor magnetic pick-up Minimum input voltage 2 Vpk-pk (from 4 Hz to 4 kHz) Maximum input voltage 50 Veff Maximum measured frequency 8 kHz (min. input voltage 6Vpk-pk), frequency mode RPM2 Type of sensor Contact or Active sensor Minimal pulse width 10 ms, integration mode Maximum measured frequency 60 Hz, integration mode Note: RPM1, RPM2 are available from IS SW version 2.6

IS-AIN8

Analog inputs Number of inputs 8 Not galvanic separated Resolution 16 bits Each analog input can be software configured to: Measuring range Accuracy From to Resistance 0 Ω 2400 Ω ± 0,5 % 0 Ω 250 Ω ± 1,0 % Current Passive 0 / 4 mA 20 mA ± 0,5 % Active 4 mA 20 mA ± 0,5 % Active 0 mA ± 20 mA ± 0,5 % Voltage Thermocouples J, K, L type ± 0,2 % 0 mV 100 mV ± 0,2 %


Measuring range Accuracy From to - 1000 mV + 1000 mV ± 0,5 % 0 mV 2500 mV ± 0,5 % Hint: Sensors must be isolated from the engine body (except for thermocouples (since HW version 5.0)). Follow rear sticker description and remove the appropriate jumpers in case of thermocouples not isolated from the engine body.

IGL-RA15

Power supply Nominal power supply 24 VDC Power supply range 8 – 36 VDC Consumption 0,35-0,1A (+1A max horn output) Depend on supply voltage

Operating conditions Operating temperature -20..+70oC Storage temperature -30..+80oC Protection front panel IP65

Dimensions and weight Dimensions 180x120x55mm Weight 950g

Horn output Maximum current 1 A Maximum switching voltage 36 VDC

IGS-PTM Nominal power supply 24 VDC Power supply range 8 – 36 VDC Consumption 0,1A depend on supply voltage Mechanical dimensions: 40 x 95 x 45 mm , DIN rail (35 mm) mounted Interface to controller CAN Operating temperature -30..+70oC Binary inputs Number of inputs 8 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

Binary open collector outputs Number of outputs 8 Maximum current 0,5 A Maximum switching voltage 36 VDC

Analog inputs Not electrically separated Number of inputs 4 Resolution 10 bits


Maximal resistance range 0 – 250 Ω Maximal voltage range 0 – 100 mV Maximal current range 0 – 20 mA Resistance measurement tolerance 1 % ± 2 Ω out of measured value Voltage measurement tolerance 1,5 % ± 1mV out of measured value Current measurement tolerance 2,5 % ±0,5mA out of measured value

Analog output Not electrically separated Number of inputs 1 Resolution 10 bits Output range 0 to 20 mA ± 0,33 mA

I-AOUT8 Nominal power supply 24 VDC Power supply range 8 – 36 VDC Consumption 0,1A depend on supply voltage Mechanical dimensions: 40 x 95 x 45 mm , 35 mm DIN rail mounted Interface to controller CAN Operating temperature -30..+70oC Number of analog outputs 8 (not electrically separated) Output range 0 to 10 VDC 0 to 20 mA

I-RBxx Number relays: 16 or 8 in sockets Nominal voltage: 24 VDC Voltage range: 16,8 – 36 VDC Relay opens at: 10% of nominal voltage Electric / mechanic cycles: 100 000 / 10 000 000 Operating temperature range: - 40°C to 70°C Maximal load: 6 A resistive load at 24VDC 4 A inductive load at 24 VDC (I-RBxx-231) 2 A at 231VAC Contacts protection: varistor 14DK390

I-LB Nominal power supply 24 VDC Power supply range 8 – 36 VDC Consumption 100 – 300mA Mechanical dimensions: 150 x 160 x 50 mm 35 mm DIN rail mounted Interface CAN / RS 422 / RS 485 to controller RS232 to Modem Operating temperature -30..+70oC Storage temperature -30..+70oC Front panel protection IP 20

IG-IB Nominal power supply 24 VDC Power supply range 8 – 36 VDC Consumption 100 – 300mA Mechanical dimensions 150 x 160 x 50 mm 35 mm DIN rail mounted Interface RS232 to controller


RS232 to Modem CAN bus Ethernet Operating temperature -30..+70oC Storage temperature -30..+70oC Front panel protection IP 20

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