ComAp ECON-4 Technical Data Manual
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ComAp ECON-4 Technical Data Manual

ComAp ECON-4 Technical Data Manual

Digital speed governor
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ECON-4
SW version 1.4.0
1 Document information
2 System overview
3 Applications overview
4 Installation and wiring
5 ECON-4 setup
6 Communication
7 Technical data
8 Appendix
Copyright © 2017 ComAp a.s.
Written by Jiří Schiller
Prague, Czech Republic
ComAp a.s., U Uranie 1612/14a,
170 00 Prague 7, Czech Republic
Tel: +420 246 012 111
E-mail: info@comap.cz, www.comap-control.com
Digital Speed Governor
4
7
8
9
22
40
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43
Global Guide

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Summary of Contents for ComAp ECON-4

  • Page 1 3 Applications overview 4 Installation and wiring 5 ECON-4 setup 6 Communication 7 Technical data 8 Appendix Copyright © 2017 ComAp a.s. Written by Jiří Schiller Prague, Czech Republic ComAp a.s., U Uranie 1612/14a, 170 00 Prague 7, Czech Republic Global Guide Tel: +420 246 012 111 E-mail: info@comap.cz, www.comap-control.com...

  • Page 2: Table Of Contents

    5.1 Quick start - how to set ECON4 and controller 5.1.1 Breakers feedback handling (CB request modes) 5.1.2 Speed control handling (Speed request modes) 5.2 Entering password 5.2.1 Modify password from WinScope 5.2.2 Modify password from GenConfig 5.3 Data 5.3.1 Data Binary inputs ECON-4 1.4.0 Global Guide...
  • Page 3 5.3.3 Data Analog inputs 5.3.4 Data Analog outputs 5.3.5 ECON adjustement for various types of actuators 5.4 ECON-4 configuration and PC tools 5.4.1 Setpoints adjustements in WinScope SW: 5.4.2 Econ-4 firmware update 5.5 ECON adjustement for various types of actuators 5.5.1 Adjustment for LINEAR actuator type (typically Woodward...

  • Page 4: Document Information

    Official version of the ComAp’s End User's Guide/Manual is the version published in English. ComAp reserves the right to update this End User's Guide/Manual at any time. ComAp does not assume any responsibility for its use outside of the scope of the Terms or the Conditions and the License Agreement.
  • Page 5 For more details relating to the Ownership, Extent of Permitted Reproductions Term of Use of the Documentation and to the Confidentiality rules please review and comply with the ComAp’s License Agreement, Terms and Conditions available on www.comap-control.com.

  • Page 6: Symbols In This Manual

    Battery Mains Breaker Pick - up Connector - Resistor female Connector - Resistor male adjustable Controller RS 232 simplified female ECON-4 simplified Starter Fuel Voltage solenoid measureme Fuse Fuse switch Generator Generator schematic Grounding Jumper Load Mains ECON-4 1.4.0 Global Guide...

  • Page 7: System Overview

    Analog Output in case of actuator with 0-20mA(4-20mA) usage. This actuator can control a fuel rack for diesel engines or a mixture throttle valve for gas engines. ECON-4 ADV is advanced version, it is dedicated specially to control of engine in island operations where load steps are expected.

  • Page 8: Applications Overview

    3 Applications overview 3.1 Wiring overview 6 back to Table of contents ECON-4 1.4.0 Global Guide...

  • Page 9: Installation And Wiring

    4 Installation and wiring 4.1 Package content 4.2 Module installation 4.3 Jumper position 4.4 Recommended wiring 6 back to Table of contents 4.1 Package content The package contains: ECON-4 module Terminal blocks ECON-4 1.4.0 Global Guide...

  • Page 10: Module Installation

    4.2 Module installation 4.2.1 Dimensions and mounting Image 4.1 Dimensions, terminals and mounting Note: ECON-4 unit is mounted on DIN rail 35 mm. ECON-4 1.4.0 Global Guide...

  • Page 11: Jumper Position

    4.3 Jumper position Jumper Meaning AOUT switch between current and voltage analogue output Current: link the 2 pins from right side Voltage: link the 2 pins from left side 120 Ohm resistor for CAN line termination Boot Reset ECON-4 1.4.0 Global Guide...

  • Page 12: Recommended Wiring

    The “-“terminal of the battery has to be properly grounded. Cables for binary inputs and analogue inputs must not be placed along power cables. Analogue inputs should use shielded cables, especially when length >3m. Always use shielded cable for Magnetic pick-up. ECON-4 1.4.0 Global Guide...

  • Page 13: Grounding

    Maximum continuous DC Power supplyvoltage is 36 V DC. Maximum short term allowable power supply voltage is 39 V DC. The ECON-4’s power supply terminals are protected against large pulse power disturbances. When there is a potential risk of the controller being subjected to conditions outside its capabilities, an outside protection device should be used.
  • Page 14 Speed gain, Speed int w, Speed der w Load gain, Load int, Load der Load control according Speed/Fuel Line Note: There is more Load gain and Load der values in ECON-4 ADV. Which set will be used depends on actuall power. GCB fdb (S4.2)

  • Page 15: Analog Inputs

    Speed gain, Speed int w, Speed der w Load gain, Load int, Load der Load control according Speed/Fuel Line Note: There is more Load gain and Load der values in ECON-4 ADV. Which set will be used depends on actuall power. NOMINAL (S4.3) The Required speed is set to Nominal RPM if the Nominal input is closed, otherwise is the Request set to Idle RPM.
  • Page 16 Slave. If feedback from slave is connected to analog input on S3.2 setpoint LoadAnticipation has to be =0. Othervise wrong value will be used for load anticip resulting unstability and unpredictive control Principle of connection Master Slave is shown on next picture. ECON-4 1.4.0 Global Guide...

  • Page 17: Analog Output

    4.4.6 Analog output ECON-4 has one analog output configurable to 0-10V or 0-20mA range by jumper setting – see in table below. If configured to 0-20mA range, output works as an active current source. The analog output function is fix (copy of the value sent to ACT output - GAS DOSE).

  • Page 18: Interface To Actuators

    P6 adjusted to voltage option. 4.4.7 Interface to actuators ECON-4 has one interface to actuator. The interface has a bipolar PWM output in bridge configuration and position feedback input. It is recommended to connect PWM output by a twisted cable and connect feedback input by a shielded cable.
  • Page 19 This type of actuator has always position feedback. For this actuator choose option ActTypex: Wiring: BRIDGE. For Heinzmann actuators, Jumper P21 – supply of the position feedback must be set to option 0-10V. For Woodward and GAC actuators this jumper must be set to position 0- ECON-4 1.4.0 Global Guide...

  • Page 20: Speed Pick-Up

    4.4.8 Speed Pick-up Always use a shielded cable, connect shielding to a grounding screw. ECON-4 supports both active (powered) and passive (magnetic) pickups. Pick-up Recommended wiring Jumpers Link 1 and 2 Active NPN Link 4 and 5 Active PNP Link 1 and 2...
  • Page 21 120-ohm (internal or external) resistor terminated. Maximal CAN bus length is 200 meters. ECON-4 contains internal 120-ohm resistor, connected through a removable jumper P7. For CAN data cables details see chapter Technical data – Communication interface. CAN cable shielding connect to CAN COM terminal.

  • Page 22: Econ-4 Setup

    6 back to Table of contents 5.1 Quick start - how to set ECON4 and controller The following description should help you to quick adjust the ECON-4 speed governor. The ECON-4 can be found in different modes used for control of module and engine.

  • Page 23: Speed Control Handling (Speed Request Modes)

    In case of DATA control of breaker`s feedback, logical signals from breakers has to be linked to Binary outputs of ECON4 in Genconfig. Terminals S4.1 and S4.2. do not need to be wired. 5.1.2 Speed control handling (Speed request modes) Speed request set to ANA mode Image 5.3 Speed request - ANA mode ECON-4 1.4.0 Global Guide...
  • Page 24 In case of BINary control, the ECON-4 is fully controlled via binary inputs – terminals S4.3 – S4.8.(except CB control). The input S4.6 is the ON/OFF signal to ECON-4, in case it is not active, speed governor will not open the throttle.
  • Page 25 Go to GenConfig, card Modules – Extension modules – Others – ECON-4 > Insert b. Configuration of Binary outputs of IGS-NT All the ECON-4 inputs are in fact IGS-NT outputs (IGS-NT controller sends the signals to ECON-4 unit). BO1 – this configuration of feedback is independent and is described in previous chapter Breaker`s feedback handling (CB request modes) BO2 –...
  • Page 26 AIN1 – Engine RPM The engine RPM can be sent from ECON-4 into the IS-NT via CAN line as well. Configure the AIN1 in the following way: Function – RPM pick-up Sensor –...
  • Page 27 IMPORTANT: Please, take in account, there are several setpoints of ECON-4, which are not accessible via IGS-NT control unit in case of DATA mode. These parameters are crucial for ECON-4 and used Actuator adjustment and so these are accessible via ECON-4 connection ONLY. Use ComAp PC sw WinScope to adjust these setpoints.

  • Page 28: Entering Password

    Global Guide. 5.3 Data Following data are communicated between IS-NT (specific sw branches only) and ECON-4 via CAN bus. Correct function depends on configuration by PC GenConfig software. 5.3.1 Data Binary inputs Following data from ECON-4 can be used for states indication or alarms activation.

  • Page 29: Data Binary Outputs

    Run/Stop   Droop The physical RUN/STOP – S5.6 binary input must be closed in any type of control to run ECON-4 i.e. in “DATA mode” together with data command BO4 Run/Stop to enable speed control function (unblock the actuator from 0% position).
  • Page 30 The maximum ECON-4 current is given by resistance of the actuator and power supply of ECON-4. ECON-4 is rated to maximum 8 Amps. In case the actuator has resistance 32 Ohms and power supply is 24V, then maximum ECON-4 current is: 24/32 = 0,75A = 750mA. This means 100% of ECON current is 750mA.
  • Page 31 This means 100% of ECON theoretical current is 9,6A. In case the maximum allowable actuator current is 5A, then this is 52% of maximum ECON-4 theoretical current. This value will be used for the maximum current limitation. So adjust ActType1: Act Max Cur = 52%, Act Max Cur Del = 5 sec and Act ReducedCur = e.g.

  • Page 32: Econ-4 Configuration And Pc Tools

    5.4 ECON-4 configuration and PC tools 5.4.1 Setpoints adjustements in WinScope SW: Connect RS232 port on your PC to RS232 port on ECON-4. Open connection and select Controller type EMCON5, ECON-3, INCON, RailCon, select your RS232 com port and press OK Image 5.5 Direct connection of WinScope SW to ECON-4...

  • Page 33: Econ-4 Firmware Update

    5.4.2 Econ-4 firmware update For ECON-4 firmware upgrade use ComAp FlashProgrammer – see below, choose card ECON-4 (common for ECON-4). Tick the button Program and choose the appropriate firmware using icon “Locate…” You can save your setpoints from an existing site and program them together with the new firmware. However the program change does not influence the setpoints, so you can keep them in ECON-4.

  • Page 34: Econ Adjustement For Various Types Of Actuators

    The maximum ECON-4 current is given by resistance of the actuator and power supply of ECON-4. ECON-4 is rated to maximum 8 Amps. In case the actuator has resistance 32 Ohms and power supply is 24V, then maximum ECON-4 current is: 24/32 = 0,75A = 750mA. This means 100% of ECON current is 750mA.

  • Page 35: Adjustment For Linear No Fdb Actuator Type (Typically Gac, Woodward)

    B. Choose one ActType x group, e.g. ActType 1 and adjust parameter Wiring to LINEAR NO FDB C. ECON-4 does not measure the current through actuator. The output signal is PWM, with frequency 6000 Hz. The maximum ECON-4 current is given by resistance of the actuator and power supply of ECON-4. ECON- 4 is rated to maximum 8 Amps.
  • Page 36 This means 100% of ECON theoretical current is 9,6A. In case the maximum allowable actuator current is 5A, then this is 52% of maximum ECON-4 theoretical current. This value will be used for the maximum current limitation. So adjust ActType1: Act Max Cur = 52%, Act Max Cur Del = 5 sec and Act ReducedCur = e.g.

  • Page 37: Detailed Fucntion

    Purpose of this behavior is to prevent the Overspeed situation by detecting the RPM increase and step change of the fuel (closing the fuel). As the RPM are dropping down subsequently towards the Nominal RPM the fuel is ECON-4 1.4.0 Global Guide...
  • Page 38 Speed governor function in Idle or local load mode ECON-4 compares the Reference and Actual speeds of the engine and calculates the Regulation error. The Actual speed is measured from the period of the signal generated by the magnetic pickup sensing gears of the flywheel.
  • Page 39 Speed request offset oi zero and actual throttle position respects speed request and Speed/fuel line. Speed request offset is decreased according ramp, which is set in setpoint SGOoffsetRamp. Time in this setpoint is time needed to change Speed request offset from 10V to 0V. 6 back to ECON-4 setup ECON-4 1.4.0 Global Guide...

  • Page 40: Communication

    6.1 Connection to ECON-4 Connect RS232 cable and start WinScope software. Click on the Connection, Open Connection and choose Direct connection type, EmCon5, ECON-4, INCON Controller type, choose the right COM port and press O.K. button. 6 back to Table of contents...

  • Page 41: Technical Data

    Low voltage directive EN 61010-1:95 +A1:97 Electromagnetic EN 50081-1:94, EN 50081-2:96 EN 50082-1:99, EN 50082-2:97 compatibility Vibrations 5 - 25 Hz, ± 1,6mm 25 - 100 Hz, a = 4 g a = 200 m/s Shocks ECON-4 1.4.0 Global Guide...
  • Page 42 2 Vpk-pk (from 4 Hz to 4 kHz) Maximum input voltage 50 Veff Minimum measured 4 Hz frequency Maximum measured 10 kHz (min. input voltage 6Vpk-pk) frequency Frequency measurement 0,2 % tolerance 6 back to Table of contents ECON-4 1.4.0 Global Guide...

  • Page 43: Appendix

    8 Appendix 8.1 Setpoints 6 back to Table of contents ECON-4 1.4.0 Global Guide...

  • Page 44: Setpoints

    8.1.8 Act type 3 –predefined for Woodward F-series PWM 8.1.9 Act type 4 – predefined for Heinzmann STG 10 8.1.10 Group: Analog sensors 8.1.11 List of tested actuators by ComAp For full list of Setpoints go to the chapter List of setpoints (page 45).

  • Page 45: List Of Setpoints

    Speed der w Load anticip Load 1 Load 2 Load 3 Load 4 LAder+limit LAder-limit LAder+ LAder- LAder+recover LAder-recover Group of setpoints: Analog sensors LoReqSpeed Inp HiReqSpeed Inp AOUT 0 AOUT 100 FBD 0 pos FBD 100 pos ECON-4 1.4.0 Global Guide...

  • Page 46: Group: Engine Startgroup: Econ4-Engrpm

    Related applications Setpoint visibility Always Description Maximum acceptable speed of the engine. If the actual engine speed is higher, ECON-4 immediately closes the actuator. Normal function is restored after detection of zero engine speed. 6 back to List of setpoints...
  • Page 47 Idle-Nom ramp is directly time that the ramp needs to go from Idle RPM (page Nominal RPM (page 46) and vice versa. The ramping speed is the same for both up and down directions. 6 back to List of setpoints ECON-4 1.4.0 Global Guide...
  • Page 48 BI Speed ramp is actually time that the ramp needs to go from - 8% toNominal RPM (page 46) + 8% and vice versa. The ramping speed is the same for both up and down directions. 6 back to List of setpoints ECON-4 1.4.0 Global Guide...
  • Page 49 The setpoint defines source of the Speed reference of the engine. Speed Request value Speed reference source SPEED UP, SPEED DOWN SPEED REQUEST DATA CAN bus Speed request - BIN Speed request - ANA Speed request - DATA 6 back to List of setpoints ECON-4 1.4.0 Global Guide...
  • Page 50 Setpoint visibility WinScope only Description When actual RPM reaches this value Gas Dose (throttle position) is immediately set to Idle Fuel value or zero (closed position) according setting in setpoint PreOverSpReduct . 6 back to List of setpoints ECON-4 1.4.0 Global Guide...

  • Page 51: Group: Engine Startgroup: Econ4-Engstart

    Related FW 1.4.0 Range [units] Start RPM - Nominal RPM Default value Force value Step Comm object 7172 Related applications Setpoint visibility Always Description Initial position of the actuator during start 6 back to List of setpoints ECON-4 1.4.0 Global Guide...
  • Page 52 Step Comm object 7175 Related applications Setpoint visibility Always Description This setpoint defines speed of ramp from Starting RPM to Idle RPM. It is directly the time of ramp from. 6 back to List of setpoints ECON-4 1.4.0 Global Guide...

  • Page 53: Group: Main Pidgroup: Econ-4-Mainpid

    Note: ECON-4 can work only if Starting RPM < Idle RPM < Nominal RPM. If this condition is not met, ECON-4 activates bit Invalid setpoints in Transmit PDO 1, see description of CAN protocol. It is not possible to run the engine if the bit Invalid setpoint is signalized.
  • Page 54 Default value Force value Step 0.1 % Comm object 7178 Related applications Setpoint visibility Always Description Derivative part of the PID speed regulation loop. Note: Setpoint is active for unloaded engine. 6 back to List of setpoints ECON-4 1.4.0 Global Guide...
  • Page 55 Force value Step 0.1 % Comm object 12176 Related applications Setpoint visibility WinScope only Description Derivative part of the PID regulation loop in case the actual RPM differs from Requested RPM for more than RPM window.. ECON-4 1.4.0 Global Guide...
  • Page 56 There is 5 different setpoints Load der: Load der 1 Load der 2 Load der 3 Load der 4 Load 1 (page 59) For more information about Load der setting please see ECON-4 Global Guide. 6 back to List of setpoints ECON-4 1.4.0 Global Guide...
  • Page 57 There is 5 different setpoints Load Int: Load Int 1 Load Int 2 Load Int 3 Load Int 4 For more information about Load Int setting please see Load 1 (page 59) ECON-4 Global Guide. 6 back to List of setpoints ECON-4 1.4.0 Global Guide...
  • Page 58 Description Governor is equipped by load anticipation feedback, which helps to keep stable speed in case of fast load changes. In the case of load jump forces the ECON-4 governor output (Actuator lever) by jump according to Load anticip setting.
  • Page 59 There is 5 load bands defined via setpoints Load 1 to Load 5 and different Load gain, Load Int, Load der and Load anticip setpoints are active in each band. 6 back to List of setpoints ECON-4 1.4.0 Global Guide...
  • Page 60 There is 5 load bands defined via setpoints Load 1 to Load 5 and different Load gain, Load Int, Load der and Load anticip setpoints are active in each band. 6 back to List of setpoints ECON-4 1.4.0 Global Guide...
  • Page 61 There is 5 load bands defined via setpoints Load 1 to Load 5 and different Load gain, Load Int, Load der and Load anticip setpoints are active in each band. 6 back to List of setpoints ECON-4 1.4.0 Global Guide...
  • Page 62 Setpoint visibility Always Description Droop of speed governor. The governor lovers the speed reference by Droop percent of the Nominal RPM (page 46) over the range from zero to MaxFuel (page 63). 6 back to List of setpoints ECON-4 1.4.0 Global Guide...
  • Page 63 IdleFuel is base (together with MaxFuel) for Droop function calculation.. Note: Set this setpoint after engine is running on Nominal speed (no load) according to the real position of Actuator lever 6 back to List of setpoints ECON-4 1.4.0 Global Guide...
  • Page 64 ECON-4 must be in AUTO for normal operation. Mode MAN can be used during installation to check the function of the actuator and linkage. If ECON-4 is in MAN mode, it sets the actuator to position Act position. It can be switched to MAN mode only any time even engine is running. This allows measurement of transition curve to calculate PID parameters.
  • Page 65 Step 0.1 % Comm object 7191 Related applications Setpoint visibility Always Description Adjusts the actuator position in the Econ-4 Mode = MAN. 6 back to List of setpoints PWM rate 1.4.0 Setpoint group Main PID Related FW configured ECON-4 extension...
  • Page 66 This defines ramp according SGOoffset is removed after parallel. For details see chapter Speed governor function in network parallel mode see see Speed governor function in parallel mode on page 38 ECON- 4 Global Guide. Note: Setpoint is active for unloaded engine. 6 back to List of setpoints ECON-4 1.4.0 Global Guide...
  • Page 67 ECON-4 ADV extension module Range [units] 0 – 100.0 % Default value Force value Step Comm object 14403 Related applications Setpoint visibility WinScope only Description Amount of derivation when Load increases 6 back to List of setpoints ECON-4 1.4.0 Global Guide...
  • Page 68 Setpoint visibility WinScope only Description Derivation curve definition – drop from - value. Initial value is divided by this number repeatedly once per 0.1s. So higher value means faster drop to zero. 6 back to List of setpoints ECON-4 1.4.0 Global Guide...

  • Page 69: Act Type 1 - Predefined For Woodward Itb 0-200 Ma

    8.1.6 Act type 1 – predefined for Woodward ITB 0-200 mA There are 4 identical groups of setpoints in ECON-4. They are used to setup the output circuits for particular types of actuators and tune the actuator position PID loop.
  • Page 70 Range [units] 0.0 – 100.0 [%] Default value Force value Step 0.1 % Comm object 11114 Related applications Setpoint visibility WinScope only Description Reduced actuator current when overload protection was activated. 6 back to List of setpoints ECON-4 1.4.0 Global Guide...

  • Page 71: Act Type 2 - Predefined For Woodward Itb Pwm

    6 back to List of setpoints 8.1.7 Act type 2 – predefined for Woodward ITB PWM There are 4 identical groups of setpoints in ECON-4. They are used to setup the output circuits for particular types of actuators and tune the actuator position PID loop.

  • Page 72: Act Type 4 - Predefined For Heinzmann Stg

    6 back to List of setpoints 8.1.9 Act type 4 – predefined for Heinzmann STG 10 There are 4 identical groups of setpoints in ECON-4. They are used to setup the output circuits for particular types of actuators and tune the actuator position PID loop.
  • Page 73 Setpoint visibility WinScope only Description Feedback fully closed position voltage. Connect the position feedback to the ECON-4 terminals. Keep the actuator lever in fully closed position and measure a dc voltage between the terminals S2.1 and S2.3. This voltage put as this setpoint value.

  • Page 74: List Of Tested Actuators By Comap

    Setpoint visibility WinScope only Description Feedback fully opened position voltage. Connect the position feedback to the ECON-4 terminals. Keep the actuator lever in fully opened position (by hand) and measure a dc voltage between the terminals S2.1 and S2.3. This voltage put as this setpoint value.

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