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ENGINE CONTROLS

IGNITION | AIR/FUEL RATIO CONTROL

INSTRUMENTS


About Gill Instruments With headquarters in Lymington, UK, Gill Instruments Ltd supply ignition and air/fuel ratio control systems for stationary and portable gas engines. We have over twenty years of experience in the industry, supplying aftermarket retrofit, gas engine packagers and OEMs worldwide. All of our engine control products have been developed using the very latest technology to provide the user with intelligent, efficient systems that will increase fuel economy, reduce emissions and engine wear. We offer a complete selection of ignition modules, coils, pick-ups, diesel to CNG/LNG conversion kits and air/fuel ratio control systems, as well as CSA® certified complete ignition and air/fuel systems. An overview of our product offering follows in this brochure, with full specifications located at the rear. Further details, images and datasheets are available on our website: www.gillusa.com

UK Headquarters

USA Office

Gill Instruments Ltd Saltmarsh Park 67 Gosport Street, Lymington Hampshire SO41 9EG

Gill Instruments Ltd 21 Marine Drive Mexico, MO 65265

ý www.gill.co.uk

ý www.gillusa.com

* ignition@gill.co.uk

* ignition@gill.co.uk

( +44 (0)1590 613500

( +1 573-581-9979

Contents Product Overview..............................................................................................................................................2 Introduction to Gill Inductive Ignition Technology...........................................................................................3 Ignition Modules................................................................................................................................................4 Inductive Ignition Coils/Pickups........................................................................................................................5 Advanced Spark Diagnostics.............................................................................................................................5 MaxiSpark Package............................................................................................................................................6 Introduction to Gill Air/Fuel Ratio Control Technology.....................................................................................7 AF120 Air/Fuel Ratio Control Module...............................................................................................................8 RICE NESHAP......................................................................................................................................................8 ZeroDrift Package...............................................................................................................................................9 EH12 Shielded Industrial System......................................................................................................................10 IDU10 Digital Display.........................................................................................................................................10 ULTIMATE Package.............................................................................................................................................11 Timing Systems..................................................................................................................................................12 Product Specifications.......................................................................................................................................13

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Product Overview The Gill Engine Control range is flexible enough to offer cost-effective solutions for almost any engine configuration from 1 to 12 cylinders. Our core product offering encompasses ignition and air/fuel control systems, as shown in the diagram below. DISPLAY

IGNITION CONTROL MODULES

INDUCTIVE IGNITION COILS

INDUCTIVE PICK-UPS

TRIM-FUEL BYPASS VALVE

AIR / FUEL RATIO CONTROL MODULE

DISPLAY

Class 1, Div. 2, Groups C and D

OXYGEN SENSOR

Selected products carry CSA速 Approval, just look for the CSA速 logo

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Introduction to MaxiSpark Ignition Technology Gill ignition systems use inductive technology to reliably ignite the air/fuel mixture. Inductive coils are more efficient than capacitor discharge coils as they provide longer spark duration, ensuring complete combustion, especially on lean burn and turbo charged engines. An inductive ignition coil provides only the required energy to ionize or 'jump' the spark plug gap; the remaining energy from the ignition coil is used to maintain the spark and does not reduce spark plug life. Capacitor discharge coils release almost all their energy instantaneously, therefore considerably reducing the amount of energy available to maintain the spark.

IGNITION SPARK DURATION

Advantages Of MaxiSpark  Longer spark duration, ensuring complete combustion

MaxiSpark

Typical CDI System 0

1000

2000

 Adjustable dwell time

 Optimized engine performance and efficiency 3000

 Reduce or eliminate misfires

A MaxiSpark inductive ignition system can produce a spark duration in excess of 2000µs, compared to a maximum of 600 µs in a capacitor discharge system. The dwell time in an inductive ignition system can be adjusted for each specific engine application to optimize combustion of lean mixtures. Increasing the dwell time will provide more energy into the primary coil. The high energy and long, programmable spark duration is a considerable advantage since they provide better ignition of lean or non-homogenous air/fuel mixtures. In many cases engines that are unable to meet emission standards with capacitor discharge systems can be brought into compliance with Gill inductive ignition systems.

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Ignition Modules Gill ignition modules are designed to control naturally aspirated, turbo-charged and lean-burn engines operating on LPG, natural gas and biogas. Both the GS and GT versions are designed with the latest inductive ignition technology to provide a powerful spark with long duration, enabling complete combustion of low calorific value fuels as well as lean air/fuel mixtures. They have been specifically designed for the stationary gas engine market, however the modules are also currently used in a wide variety of portable and industrial vehicle applications.

GT6: up to 6 cylinders

GS8/GT8: up to 8 cylinders

GS12/GT12: up to 12 cylinders

 Ignition modules for 1 - 12 cylinder engines

 Fully programmable with Windows® based software

 Set-up file - save, send, store all parameters

 2D and 3D mapping - speed , timing , load

 Logging - verify proper operation or easy troubleshooting

 Configurable for OEM engine timing disc patterns and sensors

 Fully adjustable Spark energy level and duration

- optimizes engine performance

 On-board LED status indicator

 Advanced spark diagnostics - Standard feature on all GS series modules

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Inductive Ignition Coils/Pickups Gill Ignition Coils are available in several electrical and mechanical configurations. The frame mount ignition coil (FM40), is designed for small gasoline and gas engine applications, surface mount ignition coils (SM60 and CY90) with a higher energy output designed for gas engines and integral coils (IC6 and IC12) designed for coil on plug applications. With extended spark duration far in excess of any produced by CDI ignition systems, Gill ignition coils provide superior performance.

Frame & Surface Mount Coils Class 1, Div. 2, Groups C and D

FM40

SM60 A & SM60 T

Integral Coils

IC6

IC12

C Y90 F

FLANGE MODEL

C Y90 T

3-STUD MODEL

The IC coils versions are used where existing integral coils have been applied or elimination of the secondary lead is desired. There is not a reduction in energy or duration, a condition that is common with capacitor discharge integral coils. The IC 6 and IC 12 coil are compatible with integral designed industrial spark plugs.

Advanced Spark Diagnostics Real-time Monitoring of HT Lead & Spark Plug Health through PC or IDU10 Display A standard feature with the GS8 and GS12 ignition modules, Advanced Spark Diagnostics allows the user to remotely monitor the condition of the high tension voltage supplied to the spark plugs.

Features

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C Y90 S

CSA® APPROVED

 Monitor health of HT leads and spark plugs  Error condition output when value falls outside set limits  Real-time engine condition data displayed graphically or in a table  Increase service intervals by only changing spark plugs as and when required.


MaxiSpark Package The Gill MaxiSpark Ignition System has been designed for naturally aspirated, turbo charged and lean-burn 1-12 cylinder engines operating on natural gas, LPG, propane, landfill and biogas. The ignition system allows complete control over the ignition spark characteristics with comprehensive real-time system diagnostics. The MaxiSpark ignition system includes a sophisticated ignition module with inductive ignition coils. This long spark duration ensures complete combustion of the air/fuel mixture, increasing engine efficiency, reducing emissions and optimizing overall engine performance.

System Overview

MaxiSpark Ignition System

Gill Instruments Ltd

IDU-10

Esc

1609-00-010

Ok

072805

Digital Display (Optional) Ignition Coils

Ignition Module

MaxiSpark IGNITION MODULE

GS12

1500-00-030 C123

Shielded Enclosure (Optional) Inductive Pickup & Timing Wheel

Featured Products

GS Series Ignition Module

Inductive Ignition Coil

Threaded Ignition Pickup

IDU10 Digital Display

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Introduction to ZeroDrift Air/Fuel Ratio Control The Gill ZeroDrift air/fuel ratio control system provides cost effective emissions control for gaseous fueled engines used in the most demanding industrial applications. The system is designed to accurately control the air/fuel ratio of stoichiometric engines equipped with a three way catalytic converter, and lean burn engines with or without a catalyst.

 Automatically controls optimum air/fuel ratio

 Reduces engine emissions

 Prolongs catalyst life

 Improves engine efficiency

 No need for constant manual engine tuning

The Gill ZeroDrift system uses a wide band oxygen sensor (UGEO) that provides a consistent linear output, in relation to percentage of oxygen in an engine’s exhaust. This provides accurate measurement from very fuel rich air/fuel mixtures up to Atmospheric concentration – see graph below. This sensor can be used in both stoichiometric (richburn) and lean burn configurations and allows the use of our dynamic , single setpoint technology systems.

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Typical Applications

 CHP Engines

 Generator Set Engines

 Compressor Engines

 Commercial Vehicle Engines

 Fork Lift Truck Engines


AF120 Air/Fuel Control Module The AF120 control module can be used within a variety of control systems. In the carburetor bypass configuration the Gill AF120 fuel valve can be utilized. Alternatively the module can be used to control fuel pressure regulator systems and systems requiring turbo waste gate control.

 One module can be used for rich-burn, lean-burn or 4-20 mA operation

 Fast start up due to heating of UEGO sensor.

 Programmable via easy to use Windows based software

 Controls Lambda value with dynamic, single setpoint technology

 Adjustable valve start-up position and warm-up time.

 Load mapping feature included

 The 4-20 mA output can drive pneumatic control valves on engines equipped with turbo waste gate.

AF120 Air/Fuel Valve The AF120 fuel valve has been specifically designed to operate with the AF120 control module where a fuel bypass ('trim fuel') system can be utilized. Using a stepper motor with over two hundred steps provides precise control with ZeroDrift - Exclusive at Gill.

AF120 Air/Fuel Valve

RICE NESHAP

Oxygen Sensor

Oxygen Sensor The wide band oxygen sensor is placed into the exhaust stream before the 3 way catalyst. This particular sensor is robust against gas poisoning ensuring extended sensor life cycle.

Reciprocating Internal Combustion Engines National Emissions Standards for Hazardous Air Pollutants or RICE NESHAP was introduced by the US Environmental Protection Agency (EPA) as part of the Clean Air Act. Gills emissions control products are ideal for integrating into your systems to aid compliance with the Federal Regulations. The specific requirements are based on several factors:

    

Fuel type Engine size Continuous or emergency use only Being classed a major or minor source Location - just to name a few.

Please visit www.gillusa.com for further information and links to EPA information.

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ZeroDrift Package

ZeroDrift Air/Fuel Control

System Overview

The Gill ZeroDrift Air/Fuel Ratio Control System provides cost-effective emissions control for stationary and portable industrial gas engines. The system automatically controls the optimum air/fuel ratio throughout the engine’s use, ensuring the engine remains continuously in compliance with emission standards.

Gill Instruments Ltd

IDU-10

Esc

Ok

1609-00-010

Air/Fuel Controller

072805

Digital Display (Optional)

ZeroDrift

Fuel Bypass Valve

AIR/FUEL MODULE

C123 AF120 1495-00-026

Oxygen Sensor

Shielded Enclosure (Optional)

The ZeroDrift air/fuel controller has been designed to control air/fuel ratio of both rich (stoichiometric) or lean burn industrial gas engines. The system improves engine efficiency and eliminates the requirement for constant manual engine adjustment often associated with other air/fuel ratio control technologies.

Featured Products

EH12 Shielded Enclosure

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AF120 Air/Fuel Control Module

Fuel Bypass Valve

IDU10 Digital Display


EH12 Shielded Industrial System The Gill EH12 is a CSA® approved shielded enclosure, housing the GS8 or GS12 ignition modules. This unit allows easy internal wiring termination negating the need for additional junction boxes. When used with our range of ignition modules and coils, this system provides highly accurate and extremely powerful inductive ignition, producing spark durations well in excess of any capacitor discharge ignition system. The EH12 Ignition System will control naturally aspirated or turbo-charged engines running on natural gas, biogas, LPG and CNG in either Rich burn (stoichiometric) or lean-burn air/ fuel ratios. The system offers increased flexibility and is proven to lower exhaust emissions, improve engine efficiency, reduce maintenance and decrease operational costs.

 CSA® Certified Class 1, DIV 2, Groups C & D  Compatible with GS8 & GS12 Ignition Modules Class 1, Div. 2, Groups C and D

 Header-type connectors for quick and simple installation  Controls up to 24 coils on up to 12 cylinder engines (two coils per cylinder)  Optional remote display  Optional pick-up interface unit (PIU) to replace existing 2 and 3 pickup systems used by other manufacturers  Advanced spark diagnostics to monitor real-time performance of spark plug voltage and spark duration are standard

IDU10 Display The IDU10 Display is designed for use with Gill ignition and air/fuel control systems (factory configured for the application type). The unit is available in both panelmount and surface-mount configurations, with a robust case sealed to IP65 and clear, intuitive menu structure.

Control Panel Mount Unit

Surface Mount Unit

The IDU10 Display is compatible with the GT 8, 12 modules, all GS series modules and the Gill AF120 Air/Fuel Control Module. The Display can be used as a remote unit with the EH12 shielded protective enclosure and offers users comprehensive display and control functions including:

Ignition Control

Air/Fuel Control

 Engine RPM and ignition angle  Real-Time monitoring of Ignition System status  Allows engine timing adjustment via PIN lockable keypad  Status flags

 Lambda (mA)  Lambda Heater Resistance (Ohms)  Valve Position (% open)  Allows Setpoint (mA) adjustment via PIN lockable keypad  Status Flags

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Ultimate Package The Gill ULTIMATE Engine Control System package combines the MaxiSpark Ignition System with the ZeroDrift Air/Fuel Ratio Control System, designed to increase efficiency and reduce emissions of industrial gas engines.

ULTIMATE Ignition System & Air/Fuel Control

MaxiSpark Ignition System

Ignition Module

Ignition Coils

Digital Display (Optional) Gill Instruments Ltd

MaxiSpark

IDU-10

IGNITION MODULE

GS12

1500-00-030 C123

Esc

1609-00-010

Ok

072805

ZeroDrift

Inductive Pickup & Timing Wheel

Air/Fuel Control

Oxygen Sensor

Air/Fuel Controller

Digital Display (Optional)

Fuel Bypass Valve

Gill Instruments Ltd

ZeroDrift

IDU-10

AIR/FUEL MODULE

C123 AF120 1495-00-026 Part No. 1495-00-026

Esc

1609-00-010

Ok

072805

All components within the ULTIMATE Engine Control System have been designed to work in harmony, ensuring the complete engine control system is as efficient as possible. It is usually possible for engines that are unable to meet modern emissions regulations (RICE NESHAP) to be brought into compliance with the Gill Ultimate engine control system.

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Timing Systems Gill has a wide range of ignition timing systems, sensors/pickups and timing wheels, with customized systems available for OEM installations. Our ignition conversion kits are designed to convert Altronic® III and Altronic® V systems to fully programmable, advanced Gill ignition systems.

A3 Conversion Kit

OEM Timing Disk & Pickup

We are compatible with several existing OEM disks.

A5 Conversion Kit Gill ignition systems are extremely flexible, so converting your existing timing system is simple. Our systems can be installed using a standard Gill timing setup or can be programmed to suit your existing timing requirements.

Distributor Conversion Kit example Gill can provide conversion systems for:

Accel Distributor Cap

 Conversion of Altronic® III Kit  Conversion of Altronic® V Kit  Conversion of Distributor Timing Kits  OEM Cam Timing

Location Collar Pickup Assembly

 Drill Flywheel Timing  2-Pickup Timing (primary & secondary disk)  2-3 Pickup Timing (most conventional systems)

Timing Disk Shaft

Support Block

Distributor Rotor Casing

These are examples of the systems Gill can convert. If your system is not listed please contact Gill to discuss your requirements.

Inductive Engine Pickup Examples Standard

Push-in

Threaded

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Product Specifications Advanced Features for ALL Maxi-Spark Models

MaxiSpark

Power

Ignition System

12 / 24 VDC, 5 amp (fuse size for installation)

Software

Windows® based -available in multi-level security versions - basic to advanced .

Programming

File set-up, save, send, store. Configuration file can be saved, or emailed.

Logging

Verification and troubleshooting - Files can be emailed for additional review by support staff

Communications

RS 232, DB 9 female connection

Environmental

-40°C to + 90°C Sealed to IP67

Maximum RPM

4,000 RPM

GS Series Number of Cylinders

GS8

GS12

1-8 (programmable)

1-12 (programmable)

Spark Energy / Duration

500 to 3,000 μSeconds

Timing

Global, individual cylinder, dual fuel

Timing Maps

2D - speed and timing or 3D - speed, timing and load . 10 user - adjustable maps

Trigger Methods

Single, dual or 3 pickup . All methods on listed on page 12

Features

Tach output signal, shutdown ground, on-board status lights, fuel valve and ignition sequencing

Spark Diagnostics

Included - real-time monitoring with computer or optional IDU 10 Display. Adjustable alarms

Application

All horsepower and engine sizes 1-10,000 HP, 1 or 2 coils per cylinder capability

Certifications

CSA Class 1 Div 2 Group C, D (when installed in EH 12 housing listed below)

GT Series GT6

GT8

GT12

Number of Cylinders

1 - 6 (programmable)

1 - 8 (programmable)

1 - 12 (programmable)

Spark Energy / Duration

500 to 1,500 μSeconds

500 to 3,000 μSeconds

Global, dual fuel

Global, individual cylinder, dual fuel

2D - speed and timing 2 maps

2D - speed and timing or 3D - speed, timing and load with 5 maps

Trigger Methods

Single - and methods on page 12

Single, dual or 3 pickup . All methods on listed on page 12

Features

Tach output, status light, dual fuel

Tach output signal, shutdown ground, on-board status lights, fuel valve

Application

Engines less than 800 in3 ( 13 L)

All horsepower and engine sizes 1 - 10,000 HP, 1 or 2 coils per cylinder

Timing Timing Maps

Coils FM 40T

SM60A

SM60T

CY 90T

CY 90F

CY 90S

IC 6

IC 12

Energy mJ

> 40

> 60

> 60

> 100

> 100

> 100

> 60

> 60

Inductance mH

2.5

3.5

3.5

5.0

5.0

5.0

3.5

3.5

CSA Certified Enclosure For use with Both GS series ignition modules and AF 120 series Module Inlet / Outlet Hubs Dimensions (L x W x D)

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Three1/2” NPT female and one 3/4 female inlets/outlets - Eliminates multiple junction boxes 10" x 12" x 5"/ 254mm x 304mm x 122mm


ZeroDrift Air/Fuel Control

AF120 Air/Fuel Ratio Control Module Power

12 / 24 VDC, 5 Amp (fuse size for installation)

Software

Windows® based - password protected

Programming

File set-up, save, send, store. Configuration file can be saved or emailed

Logging

Verification and troubleshooting-files can be emailed for additional review by support staff

Communications Application

RS 232, DB 9 female connection Rich-burn (Stoichiometric) or lean-burn engines. Turbo waste gate or other 4-20mA control, bypass configuration with Gill valve

Input

MAP, throttle position sensor or any 0-5VDC sensor linear to engine load

Control

Dynamic single setpoint

Outputs

Gill AF valves or 4-20 mA , 0-5 VDC power for sensor input

Certifications

CSA Class 1 Div 2 Group C,D (when installed in EH 12 housing)

Environmental

-40°C to + 90°C sealed to IP67

Air/Fuel Valve Motor

Low voltage stepper motor with 200+ steps for high resolution

Fuel Connection

3/8 NPT inlet (bottom) and 3/8 NPT outlet (side)

Material - Body

Premium grade aluminum

Material - Needle

High grade aluminum and stainless steel shaft

IDU10 Digital Display Panel Mount

Surface Mount

Power

9 - 30 VDC

Display

LCD 4 line dual backlight

Security

View all data - adjustments are password protected

Input / Adjustment

Easy 4-key toggle system, with monitor, clear and reset

Panel Dimensions

(LxWxD) inch 5.83 x 3.70 x 1.34, metric 148 x 94 x 34mm - narrow width housing for use in control panel

Surface Dimensions

(LxWxD) inch 5.83 x 3.70 X 2.25, metric 148 x 94 x 57mm - inlet is 1/2 NPT female threaded hub

Certifications

CSA Class 1 Div 2 Group C, D

Environmental

-40°C to +60°C sealed to IP67 Ignition

Air / Fuel

Main Screen

RPM and ignition timing

Setpoint value, lambda, valve position, oxygen sensor heater

Adjustments

Ignition timing, dwell (duration), update rate

Valve setpoint, update rate

All diagnostic points, clear and reset. Spark diagnostics on GS models

All diagnostic points, clear and reset

Alarms

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UK Headquarters Gill Instruments Ltd Saltmarsh Park 67 Gosport Street, Lymington Hampshire SO41 9EG ý www.gill.co.uk * ignition@gill.co.uk ( +44 (0)1590 613500

USA Office Gill Instruments Ltd 21 Marine Drive Mexico, MO 65265 ý www.gillusa.com * contact@gillusa.com ( +1 573-581-9979

www.gillusa.com

© Gill Instruments Ltd. Gill ® is a registered trademark of the Gill Group of Companies.


Engine Controls IGNITION | AIR/FUEL RATIO CONTROL

INSTRUMENTS


UK Headquarters Gill Instruments Ltd Saltmarsh Park 67 Gosport Street, Lymington Hampshire SO41 9EG ý www.gill.co.uk * ignition@gill.co.uk ( +44 (0)1590 613500

USA Office Gill Instruments Ltd 21 Marine Drive Mexico, MO 65265 ý www.gillusa.com * contact@gillusa.com ( +1 573-581-9979

www.gillusa.com

© Gill Instruments Ltd. Gill ® is a registered trademark of the Gill Group of Companies.


ENGINE CONTROLS

IGNITION | AIR/FUEL RATIO CONTROL

Engine Controls  

Brochure showcasing Gill Instruments range of Engine Control products

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