Controllable Power

Advanced Electronic Solutions for Engine Management

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High performance solutions madesimple

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Contents

Technical Expertise and Adding Value Page 4-5Generator Controls Page 6-7Industrial Controls Page 8Marine Controls Page 9Mains Protections Page 10Remote Control and Monitoring Page 11Engine Governor Systems Page 12-13Training Page 14-15 Bi-Fuel Page 16-19

The Engine Control division represents a wide range of electronic products and components for diesel and gas engines and their applications from power generation to industrial engines, off-highway vehicles, construction machinery and marine engines.

We have partnered world leading controls producers to bring you a market leading product portfolio which includes multi engine load sharing, power control solutions, generator controllers, mains protections and the latest in remote controls and monitoring.

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Whatever your application, and whatever your control requirements, the IPU Engine Controls team will work with you to engineer the very best solution to meet your precise specifi cation – from concept to completion.

Hardware Regardless of application, environmental considerations, or classifi cation and approval requirements, our experienced technical sales team will advise on the ideal controls package for you.

SoftwareOur controls experts can provide support on PLC integration and confi guration of controller inputs/outputs to provide you with endless control and command possibilities.

Communications The IPU remote communication specialists will guide you on the most effective methods of communicating with your equipment, to help you protect your investment.

Concept

Technical Expertise and Adding Value

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Installation Practical advice on installations to ensure your schedules are maintained and the projects proceed in accordance with your plans and specifications.

Commissioning Our trained and experienced engineers working with you on site to ensure that the control equipment functions according to your requirements.

Training Years of accumulated controls knowledge shared with you and your engineers at our in-house training facility.

Aftersales Free, out of hours, technical hotline support. Our engineers, available to you – when you need them.Completion

PRIME MOVER

ENTRY LEVEL BASICATS

Mains Monitoring Mains Monitoring

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Generator Controls

Our comprehensive range of gen-set controllers cover applications from simple, manual/remote start, non-parallel generators through to complex, multi-generator synchronizing and load sharing and CHP facilities. From InteliNanoNT, a cost effective unit that meets the needs of small applications, through to InteliSysNT, a sophisticated, expandable controller for diffi cult applications, our ComAp control units offer users excellent fl exibility, simplicity and usability. We have a controller for every application...

InteliATSNT InteliNanoNT MRS InteliLITENT MRS

Application overview of ATS and Gen-set Controllers

Featuring...• Communication via CAN J1939 or

Modbus to a wide variety of EFI engines

• Super fast processing speed

• Multi-language user interface support

• In depth event history logging

• Active SMS & emails

• User friendly remote control and monitoring

• Flexible and expandable inputs/outputs

• Common set up software across the range

STANDBY

ENTRY LEVEL BASIC SIMPLE HIGH-END

PREMIUM &

COGENERATION

Your benefi ts...• Simple to use

• Effortless installation

• Easily confi gured to your exact requirements

• Straightforward trouble shooting and diagnostics

• Total integration with your engine system

• Outstanding support

Numerous expansion options...A comprehensive family of expansion modules and control accessories suitable for the whole range of generator controllers – as well as marine and industrial control units, including:

Speed control modules, input/output expansion modules, load sharing interfaces, communication modules, internet bridges, RS232 & RS485 interfaces, etc.

A variety of display options...

InteliVision 5 InteliVision 8 InteliVision 17Touch

Mains Monitoring Synchronising

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InteliNanoNT AMF InteliLITENT AMF

InteliCompactNT

InteliGenNT

InteliSysNT

InteliVision 8InteliVision 8 InteliVision 17TouchInteliVision 8

Application overview of ATS and Gen-set Controllers

Engine size / A

pp

lication

A range of sophisticated fl exible, controllers for a variety of applications as diverse as pumps, compressors, drilling rigs, fi re pumps, construction equipment, even electric motor controls. These controls can be tailored to meet the specifi c control requirements of the application.As with all ComAp products, they come with outstanding control, monitoring and protection features and can communicate with standard and proprietary CAN J1939 protocols to a wide range of EFI engines.

InteliDrive Mobile is an innovative controller that has been designed to provide excellent control capability in harsh applications. It will excel in unforgiving mobile applications and will withstand extreme temperatures and its robust construction will endure typical industrial shock and vibrations loads. With an extremely fl exible input and output structure, ID-Mobile can be customised to meet individual day to day machine control requirements such as drive control, process control or platform level supervision as well as enhanced engine management.

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Industrial Controls

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Marine Controls

We supply an integrated range of control solutions for all onboard ship engines and generators using CAN based technology. Designed and built to tried and tested ComAp principles harnessing the latest technology to give highly fl exible, reliable controllers with outstanding control and monitoring features.

Our controllers record all important values – speed, temperature, pressures or currents in an internal memory log. This event and performance tool is invaluable for recording whenever the engine or generator changes its operational status or when values exceed their normal levels.

All ComAp marine controllers are easily integrated into the ship, or boats, control system via Modbus or Modbus/TCP protocols and feature a fl exible user confi gurable I/O structure to match your precise needs. We can even provide you with effective ‘plug and play’ functionality.

ComAp marine control units are type approved by all major marine classifi cation societies and as part of the new norm IEC 60255 have undertaken extensive testing.

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Mains Protections

ComAp Mains Protection products from IPU are the ideal for all power generation sources where you are connected to the grid.MainsPro

MainsPro is a protection unit for mains-parallel applications including generator sets, cogeneration, micro turbines or renewable energy sources such as solar power plants or wind turbines. It provides adjustable voltage, frequency and ‘loss of mains’ protections to safeguard both the power supplier and the generators.

Easy to install and intuitive to use, practical features such as automatic reset, remote information and reliable monitoring make the MainsPro the perfect choice for any G59, G59/2 & G83 application.

InteliPro

InteliPro is a highly fl exible interconnection/mains decoupling relay. It is applicable for G10, G59/2 and IEEE 1547 requirements, and with extensive protective functions, it meets the strictest utility interconnection requirements and can be used in wide ranges of distributed generation applications such as renewables, fuel cell, bio mass and combined heat and power.

Advanced communications, remote monitoring and data/event logging make InteliPro an ideal solution for your smart applications.

ComAp WebSupervisor is a web based system, designed for monitoring and controlling of ComAp controllers through the internet.

This system offers a number of benefits to help optimize revenue, as each piece of equipment can be individually monitored for all important operation values.

The system works by sending regular updates to a remote, secure server, which then safely stores the information ready to be seen by selected users.

Connection to the server is easily accessible to any registered user through an internet enabled device, such as a PC, net-book or smart-phone; enabling equipment monitoring at any time, in any location.

The system provides a high level of administration and security through notifications such as event generated emails, created and sent to specific users to give fast and efficient updates.

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Remote Control & Monitoring

All ComAp controllers offer a wide range of communications options. Via GPRS, Ethernet, RS485 and RS232 you can receive a constant stream of data enabling you to make important decisions about your remote equipment. You can receive alarm announcements as they happen, monitor a wide range of engine performance parameters, accurately assess failure modes and remotely control equipment without the need for personnel site visits.

• Wireless remote monitoring

• On-line alarm notifications

• Remote system monitoring provides fuel savings

• Cost saving from more efficient service planning

• Reduced service call outs

• Totally mobile solution

• Data and history gathering

• Automatic reporting

• Works across all GSM networks

• Reliable coverage - globally

• Modbus

AirGate technology allows ComAp controllers to connect to the internet using the existing network infrastructure, negotiating firewalls and VPN systems and removing the requirement for static IP addresses. Following a simple online registration process, the AirGate technology in a controller is activated, then, even if the IP address changes, you can keep track of the remote equipment. AirGate supplied completely free of charge to all ComAp controller customers.

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Engine Governing Systems

IPU supplies GAC engine governor products. A wide, technically advanced, range of electronic governing and fuel control systems, complete with accessories. These engine control systems range in cost and complexity from single speed isochronous governors to sophisticated multi-engine load sharing /power control systems. A variety of complementing governing and control system accessories are also available. GAC engine governor products are ideal for original equipment applications as well as conversions and retro-fitment.

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Engine Speed Control UnitsAccurately control engine speed by comparing the measured speed from the Magnetic Pickup to an internal reference and adjusting the current supplied to the Actuator accordingly. A comprehensive range of engine speed controllers to meet any application from basic isochronous operation through to multifunction controllers incorporating switchable isochronous/droop operation, low smoke startup and speed switch relay contacts, and advanced microprocessor based digital controllers.

Engine ActuatorsProportional electromagnetic actuators position the fuel control mechanism and incorporate highly reliable rotary and linear designs; they offer fast response and precise control. They require no maintenance and can accommodate virtually any linkage confi guration. The range includes actuators that are integral to the fuel pump (including Stanadyne, Delphi and Bosch) as well as remote actuators that connect via linkage to a throttle or stop lever.

Magnetic Speed SensorsSpeed sensors are available in various lengths in both imperial and metric threads. Wire leads, military connectors or automotive connectors are also available.

John Deere Case Study

Governor Upgrade for SDMO Gensets Fitted with John Deere engines.

John Deere 3, 4 and 6 cylinder industrial and generator driven engines are fi tted with mechanical governors as standard. IPU Group supply integral fuel pump actuators to upgrade these engines to electronic governing, with variants for both Bosch and Stanadyne fuel injection pumps:

These electronic governor packages are suitable for retro-fi tting to John Deere engines in any applications, but are particularly suited to fi tment in power generation appliances.

Benefi ts• IPU can provide complete kits for John Deere

engines fi tted with either Stanadyne DB4 or Bosch “P” Type pumps with RSV mechanical governor on the 6081

• Both industrial variable speed drive and fi xed speed systems can be supplied

• You select the controller for either Single or Parallel generator operation or variable speed industrial application

• 12 or 24 V systems

• Isochronous Operation only for Single Running Controllers (ESD 2244-12/24)

• Isochronous and switchable Droop operation for Parallel running (ESD 5120/5520E)

• High reliability and 2 year warranty

• Competitive and proven systems

• IPU full technical support

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Training

IPU Product test and training facility

The IPU training centre provides the ideal environment to learn more about ComAp and GAC generator control and management products. The courses are tailored to meet the need of each customer from familiarization training to more in-depth specialist training suitable for design, test, installation and commissioning engineers. Our training facility has proved to be very popular and is designed to allow engineers to have real time, hands on training, where they can synchronize with another generator set or the mains in a live safe situation, as well as gain a better understanding of the set-up and software confi guration of the controllers and the remote control and monitoring capabilities.

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Customer Testimonial

“The training has enabled us to establish the true capability of our units on the Eurofi ghter test and ensured we set-up the equipment to a higher standard in the future. The environment was very good and with the equipment wired up ready to go we were able to explore the full potential of the equipment in a way we wouldn’t be able to back at BAE Warton. There is no doubt that you get more out of this than reading the manual”.

Mike Alder - technical specialist at BAE SYSTEMS.

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Bi-Fuel

ComAp’s simple Bi-Fuel conversion modifi es your original diesel engine so that it uses gas as the main fuel – subsequently reducing operating costs.

Bi-Fuel conversion requires no engine modifi cation and brings double benefi ts in every application:

• Affordable diesel engines combined with inexpensive gas

• Economic solution for all engines

• Flexible use of fuel

• Guaranteed power output

• Effi cient and safe operation

• Longer engine life and reduced maintenance costs make it the perfect investment

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How does it work?

ComAp Bi-Fuel is a fully automatic, dynamic modulating, solution fi tted with a gas throttle actuator. The solution will increase and decrease the gas amount dynamically across the engine load range automatically without any manual or regular adjustment required from the operator in order to maximise the gas usage safely.

The Bi-Fuel solution has a fully independent and stand alone control system ensuring that 100% diesel operation is possible at any time.

In order to avoid engine knocking, the ComAp DENOX knock detector/controller is installed, thus enabling engine operation at the most effi cient gas/diesel ratio possible.

The integrated Bi-Fuel solution independently monitors the vital engine parameters automatically while operating in Bi-Fuel mode and does not interfere with operation of the original equipment manufacturers existing safety shutdown protections or control of the engine or generator.

The Bi-Fuel solution is mainly concerned with engine safety and the safe control and modulation of the gas quantity.

Elements of the complete Bi-Fuel system• Fully integrated Bi-Fuel control panel

• Comprehensive knock detection system

• Diesel monitoring system

• Approved gas train made to required local and site standards

• Gas actuator

• Complete gas feed and air manifold vacuum feed back hoses

• Gas/air blenders

• Wire harnesses and sensors

• All required bolts and fi ttings

• Standard kit documentation

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Bi-Fuel

• Substitute up to 70% of your diesel consumption with gas

• Reduce your operational costs substantially

Fuel consumption at normal output

Case study of CAT 3512B, 1500 kVA, 1500 RPM

Fuel costs per year

Bi-Fuel Case Study

Wartsila 12V32E for the Mining Industry in Australia

Recently at a mining site in Australia, a very prestigious bi-fuel conversion project was completed using ComAp Bi-Fuel Solutions.

The underground copper-gold mine is located in the State of Queensland in North Eastern Australia. The mine site has 5x Wartsila 12V32E powered, 3850kW generating sets that were operating solely on diesel fuel oil before the conversion; the diesel generators provided all power to the main site for their operations that have large varying load swings.

Then all 5 engines were converted to bi-fuel operation. By simply replacing large percentages of the engines diesel use with the available natural gas on site, the Queensland site now benefi ts from substantial fi nancial savings because of the lower cost of natural gas compared to diesel fuel.

Benefi ts

• This easily integrated solution is highly reliable and works with a modulating dynamic

• The ComAp engine controller causes no reduction in power or effi ciency and is fully automated

• No modifi cations of the internal engine components are required

• Extended run times without need for refuelling

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Signifi cant saving and reduction in operating costs

IPU GROUP Engine Control DivisionVisit our Group website www.ipu.co.ukIPU Group, Churchbridge, Oldbury, West Midlands, B69 2AS England T: +44 (0) 121 511 0400 F: +44 (0) 121 511 0401 E: ipu@ipu.co.uk

© IPU Group April 2012

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