OptiBlend Advantages

Operation & Installation

Major Components

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Major Bi-Fuel System Components and Sub-Systems

Gas Train
The gas train consists of a manual gas ball valve, gas filter, gas lock off solenoid, zero pressure regulator, gas control valve, and mixer.

The gas filter protects the gas train and engine from particulate contaminants that may be present in the gas stream. The zero pressure regulator accepts 1-5 psig gas supply pressure. The gas lock-off valve is direct-operated with a 24V solenoid, controlled by the PLC. The gas solenoid valve is energized before the gas control valve is allowed to open so that gas is not suddenly added to the combustion chamber. The zero pressure regulator detects changes in air flow through the mixer to maintain a constant air/fuel ratio, determined by the gas control valve position. The smart gas control valve has internal software with fault detection and supplemental speed control functionality.

MIXER
The OptiBlend System uses a proprietary mixer designed for complete mixing with an extremely low pressure drop along the air flow path. The mixer also directly integrates the gas control valve(s) to simplify installation and optimize dual fuel system response. Several sizes are available to cover a wide range of engine applications. The mixer is constructed from lightweight aluminum for easy integration with the engine air intake system, and no maintenance is required in operation.

SMART GAS CONTROL VALVE
The OptiBlend gas control valve is a microprocessor-based actuator with built-in speed control and internal fault detection. Integrated with a rugged throttle body, The valve is designed for severe on-engine industrial and automotive environments.

POWER TRANSDUCER
The Power Transducer provides the generator load (kW) and frequency (Hz) as 4-20mA signals, which are used by the PLC, Knock Detection Unit, and gas control valve. The Power Transducer is compatible with single- and three-phase electrical systems, with current and voltage measuring inputs for all phases. The primary measured values are calculated and displayed on a two-line, 16 character LCD display.

KNOCK DETECTION KIT
The knock detection system is used to protect the engine from damage due to detonation (knocking). At high loads, if too much gas is delivered, in combination with a variety of other environmental conditions (high heat, low humidity, etc.), the engine can knock. The knock detection unit continuously sends a 4-20mA bias signal to the OptiBlend PLC, which indicates the current knock severity. The knock detection unit also has internal fault detection and a relay output to indicate fault status.

The OptiBlend system can utilize up to 16 piezoelectric vibration sensors, which are generally mounted to a head bolt on each engine cylinder. The knock detection unit also utilizes engine phase (cam), speed, and generator load signals to filter mechanical noise and provide high sensitivity to even inaudible knock levels.

ENGINE VIBRATION SENSOR
At lower loads, high levels of natural gas fumigation can cause misfire, governor instability and excessive engine vibration. The engine vibration sensor provides a 4-20mA signal to the OptiBlend PLC.

PROGRAMMABLE LOGIC CONTROLLER
The PLC is comprised of a main CPU, one analog I/O module, and one analog input module. The controller is designed for critical applications in demanding industrial environments. Hythane Company’s proprietary software and control strategies ensure optimized performance and fuel cost savings with complete engine protection.

CONTROL PANEL
The control panel houses the power transducer; knock detection kit, and the PLC. The control panel can be upgraded with a graphical user interface

Alarms are annunciated in English-language messages (other languages can be programmed), and the controller maintains an alarm log of the last 100 events.