ComAp ECON-4 Technical Data Manual

ECON-4

Digital Speed Governor

SW version 1.4.0

1 Document information 4

2 System overview 7

3 Applications overview 8

4 Installation and wiring 9

5 ECON-4 setup 22

6 Communication 40

7 Technical data 41

8 Appendix 43

Copyright © 2017 ComAp a.s.
Written by Jiří Schiller
Prague, Czech Republic
ComAp a.s., U Uranie 1612/14a,
170 00 Prague 7, CzechRepublic
Tel: [phone]
E-mail: [e-mail], www.comap-control.com

Global Guide

Table of contents

1 Document information 4

1.1 Clarification of notation 4

1.2 About this guide 4

1.3 Legal notice 4

1.4 Symbols in this manual 6

2 System overview 7

2.1 Description of thegovernorsystem 7

2.1.1 Control by CAN-bus 7

3 Applications overview 8

3.1 Wiring overview 8

4 Installation and wiring 9

4.1 Package content 9

4.2 Module installation 10

4.2.1 Dimensions andmounting 10

4.3 Jumperposition 11

4.4 Recommendedwiring 12

4.4.1 General 12

4.4.2 Grounding 13

4.4.3 Power Supply 13

4.4.4 Binary inputs 13

4.4.5 Analog inputs 15

4.4.6 Analog output 17

4.4.7 Interface to actuators 18

4.4.8 Speed Pick-up 20

4.4.9 Communication wiring 20

5 ECON-4 setup 22

5.1 Quick start - how to set ECON4 andcontroller 22

5.1.1 Breakers feedback handling (CB request modes) 22

5.1.2 Speed control handling (Speed request modes) 23

5.2 Entering password 28

5.2.1 Modify password from WinScope 28

5.2.2 Modify password from GenConfig 28

5.3 Data 28

5.3.1 Data Binary inputs 28

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5.3.2 Data Binary outputs 29

5.3.3 Data Analog inputs 29

5.3.4 Data Analog outputs 29

5.3.5 ECON adjustement for various types of actuators 29

5.4 ECON-4 configuration and PC tools 32

5.4.1 Setpoints adjustements in WinScopeSW: 32

5.4.2 Econ-4firmware update 33

5.5 ECON adjustement for various types of actuators 34

5.5.1 Adjustment for LINEAR actuator type (typically Woodward 34

5.5.2 Adjustment for LINEAR NO FDB actuator type (typically GAC, Woodward) 35

5.5.3 Adjustment for BRIDGE actuator type (typically Heinzmann) 35

5.6 Detailed fucntion 37

5.6.1 Block schematics - speedgovernor 37

6 Communication 40

6.1 Connection to ECON-4 40

7 Technical data 41

8 Appendix 43

8.1 Setpoints 44

8.1.1 List of setpoint groups 44

8.1.2 List of setpoints 45

8.1.3 Group: Engine StartGroup: ECON4-EngRPM 46

8.1.4 Group: Engine StartGroup: ECON4-EngStart 51

8.1.5 Group: Main PIDGroup: ECON-4-MainPID 53

8.1.6 Act type1 – predefined for Woodward ITB 0-200 mA 69

8.1.7 Act type2 – predefined for Woodward ITB PWM 71

8.1.8 Act type3 –predefined for Woodward F-series PWM 71

8.1.9 Act type4 – predefined for Heinzmann STG 10 72

8.1.10 Group: Analog sensors 72

8.1.11 List of tested actuators by ComAp 74

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1 Document information

1.1 Clarification of notation 4

1.2 About this guide 4

1.3 Legal notice 4

1.4 Symbols in this manual 6

1.1 Clarification of notation

Note: This type of paragraph calls readers attention to a notice or related theme.

IMPORTANT: This type of paragraph highlights a procedure, adjustment etc., which can cause a

damage or improper function of the equipment if not performed correctly and may not be clear at

first sight.

Example: This type of paragraph contains information that is used to illustrate how a specific function

works.

1.2 About this guide

This guide describes usageof ECON-4 forcontrol of engine. ECON-4Global Guide provides basic information
how to install and operate ECON-4 Extension module.

1.3 Legal notice

This End User's Guide/Manual as part of the Documentationis an inseparable part of ComAp’s Product and

may be used exclusively according to the conditions defined in the “END USER or Distributor LICENSE
AGREEMENT CONDITIONS – COMAP CONTROL SYSTEMS SOFTWARE” (License Agreement) and/or in
the “ComAp a.s. Standard terms for sale of Products andprovision of Services” (Terms) and/or in the
“Standardní podmínky projektů komplexníhořešení ke smlouvě o dílo, Standard Conditions for Supply of
Complete Solutions” (Conditions) as applicable.

ComAp’s License Agreement is governed by the Czech Civil Code 89/2012 Col., by the Authorship Act
121/2000 Col., by international treaties andby other relevant legal documents regulating protection of the
intellectual properties (TRIPS).

The End User and/or ComAp’s Distributor shall only be permitted to use this End User's Guide/Manual with
ComAp Control System Registered Products. The Documentation is not intended andapplicable for any other
purpose.

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 theTerms or the Conditions and the License Agreement.

Licensed End Useris entitled to make only necessary number of copies of the End User's Guide/Manual. Any
translation of this End User's Guide/Manual without the prior written consent of ComAp is expressly prohibited!

Even if the prior writtenconsent from ComAp is acquired, ComAp does not take any responsibility for the
content, trustworthiness and quality of any such translation. ComAp will deem a translation equal to this End

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User's Guide/Manual only if it agrees to verify such translation. The terms and conditions of such verification
must be agreed in the written form and in advance.

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.

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1.4 Symbols in this manual

Battery

Breaker

Connector -

female

Connector -

male

Controller

simplified

ECON-4

simplified

Fuel

solenoid

Fuse

Mains

Pick - up

Resistor

Resistor

adjustable

RS232

female

Starter

Voltage

measureme

nt

Fuse switch

Generator

Generator
schematic

Grounding

Jumper

Load

Mains

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2 System overview

2.1 Description of the governor system

ECON-4 is a flexible speed governor capable to operate in various configurations. Possible configurations can
be:

a. Control via CAN – it reads the values of control bits and required analog values from the CAN bus line and

not from its terminals (expect from BIN S4.6 Run/Stop, this signal must be present in all 3 modes)

b. Control via Binary signals

c. Control via Analogue and binary inputs.

Speed and power of a single fuel engine is always controlled by the actuator connected to ACT terminals or
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.

2.1.1 Control by CAN-bus

ECON-4 can receive values of somebinary and analog control inputs via CAN-bus communication line from
engine controller, (see setpoints Speed request (page 49) or CB request (page 50) for more information). This
arrangement can significantly simplify the wiring on site.

Control of speed request by CAN-bus is active only if setpoint Speed request (page 49) has value DATA

Control of GCB and MCB feedback by CAN-bus is active only if setpoint CB request (page 50) has value DATA.

6 back to Table of contents

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3 Applications overview

3.1 Wiring overview

6 back to Table of contents

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4 Installation and wiring

4.1 Package content 9

4.2 Module installation 10

4.3 Jumperposition 11

4.4 Recommendedwiring 12

6 back to Table of contents

4.1 Package content

The package contains:

ECON-4 module

Terminal blocks

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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.

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4.3 Jumper position

Jumper

P6

P7

P9

P10

Meaning

AOUT switch between current and voltage analogue output

Current: link the 2 pins fromright side

Voltage: link the 2 pins from left side

120 Ohm resistor for CAN line termination

Boot

Reset

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4.4 Recommended wiring

Postion Terminal groups Link

Power supply Actuators Power Supply (page 13)

Actuator feedback Interface to actuators (page 18)

Analog inputs Analog inputs (page 15)

Binary inputs Binary inputs (page 13)

Magnetick Pick-up Speed Pick-up (page 20)

Analog outputs Analog output (page 17)

Communications Communication wiring (page 20)

6 back to Installation and wiring

4.4.1 General

Use grounding terminals.

The “-“terminal of the battery has to be properly grounded.

Cables for binary inputs and analogue inputs must not be placed along power cables.

Analogueinputs should use shielded cables, especially when length >3m.

Always use shielded cable for Magnetic pick-up.

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4.4.2 Grounding

Use as short as possible cable to thegrounding point on the switchboard.

Use cable min. 2,5 mm2.

The “-“terminal of the battery has to be properly grounded.

4.4.3 Power Supply

Use min. power supply cable of 4mm2.

Maximum continuous DC Power supplyvoltageis 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.

Power Supply Fusing

An eight-amp fuse should be connected in-line with the battery positive terminal to the controller andmodules.
ECON-4 should never be connected directly to the starting battery.

Recommended fuse is slow type– T8A.

4.4.4 Binary inputs

Binary inputs have internal load resistor 4.4 kΩ connected to the battery plus.

Image 4.2 Binary inputs wiring scheme

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Binary inputs are used to control the function of the ECON-4 digital governor.

Binary inputs can be read from:

the physical Binary inputs (terminals S4.x),

from the CAN-bus (byte Command in the Receive PDO),

in dependence on the value of thesetpoint Speed request.

Speed Request value CB Request value

Input

MCB fdb (S4.1) (page 14) MCB fd b

GCB fdb

NOMINAL

SPEED UP

SPEED DOWN

RUN / STOP

DROOP

RESERVE

BIN ANA DATA BIN DATA

S4.1 Cmd.1

S4.2 Cmd.2

S4.3 S4.3 Cmd.2

S4.4 X X

S4.5 X X

S4.6 S4.6

S4.7 S4.7 Cmd.4

S4.8

S4.6 &
Cmd.3

Note: Cmd.x is bit x in the byte Command of the Receive PDO, see description of CAN protocol. S4.x

isECON-4 terminal. Both the physical Binary input S4.6 and the corresponding bit Cmd.3 received via

CANbus must be active to activate Binary input RUN in DATA mode. In case of lost communication on

CANbus, all bits of the byte Command are set to 0 – it deactivates

MCB fdb (S4.1)

Inputs GCB andMCB fdb decide which setpoints are used in PID speed regulation loop and which type of
regulation is used (Iddle/Island/Parallel):

MCB

state

OFF OFF NO Speed gain, Speed int, Speed der

OFF OFF YES Speed gain, Speed int w, Speed der w

ON OFF NO Speed gain, Speed int, Speed der

ON OFF YES Speed gain, Speed int w, Speed der w

OFF ON - Load gain, Load int, Load der

ON ON - Load control according Speed/Fuel Line

GCB

state

lRPM - Requested RPMl > RPM window PID constants

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)

Inputs GCB andMCB fdb decide which setpoints are used in PID speed regulation loop and which type of
regulation is used (Iddle/Island/Parallel):

MCB

state

OFF OFF NO Speed gain, Speed int, Speed der

OFF OFF YES Speed gain, Speed int w, Speed der w

ON OFF NO Speed gain, Speed int, Speed der

GCB

state

lRPM - Requested RPMl > RPM window PID constants

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ON OFF YES Speed gain, Speed int w, Speed der w

OFF ON - Load gain, Load int, Load der

ON ON - 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.

SPEED UP (S4.4)

Inputs SPEED UP and SPEED DOWN are used for setting of the speed reference of the engine. The speed
reference can be changed in the range from Nominal RPM - PerChSpdNom% to Nominal RPM +
PerChSpdNom%. Setpoint: EngineRPM:PerChSpdNom [1-20%] defines the maximum Percentage change of
Speed from Nominal in case BIN or ANA mode of control is used.

Setpoint BI Speed ramp decides how fast the speed reference changes, if the inputs SPEED UP or SPEED
DOWN are active.

Note: Inputs SPEED UP and SPEED DOWN are active only if the setpoint Speed request has value BIN.

SPEED DOWN (S4.5)

Inputs SPEED UP and SPEED DOWN are used for setting of the speed reference of the engine. The speed
reference can be changed in the range from Nominal RPM - PerChSpdNom% to Nominal RPM +
PerChSpdNom%. Setpoint: EngineRPM:PerChSpdNom [1-20%] defines the maximum Percentage change of
Speed from Nominal in case BIN or ANA mode of control is used.

Setpoint BI Speed ramp decides how fast the speed reference changes, if the inputs SPEED UP or SPEED
DOWN are active.

Note: Inputs SPEED UP and SPEED DOWN are active only if the setpoint Speed request has value BIN.

RUN (S4.6)

If the input is not active, governor immediately set the actuator to stop position.

DROOP (S4.7)

The input activates droop function – see setpoint Droop (page 62).

BIN 8 (S4.8)

BIN 8 is reserved for next functions.

4.4.5 Analog inputs

There are 2 analog inputs available on the ECON-4. Each of them can be configured either as 0-20mA or 0-10V
range by jumper setting – seein table below. The analoginput function is fixed.

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Range Recommended wiring Input Terminals Jumpers

SPEED REQUEST S3.1 P22 – 20 mA

0-20 mA

ACTIVE POWER S3.2 P23 – 20 mA

SPEED REQUEST S3.1 P22 – 10 V

0-10 V

ACTIVE POWER S3.2 P23 – 10 V

SPEED REQUEST (S3.1)

The input defines speedreference. It can be set in the range from Nominal RPM - PerChSpdNom% to Nominal
RPM + PerChSpdNom%. Setpoint: EngineRPM:PerChSpdNom [1-20%] defines the maximum Percentage
change of Speed from Nominal in case BIN or ANA mode of control is used.

Example: Analog input SPEED REQUEST is set to range 0 – 10 V, Nominal RPM is 1500 RPM, Input
voltage is 6 V. Speed reference is then ReqSpeed = 1500 + (PerChSpdNom/100)*1500*(6-5)/5 = 1524 RPM.
PerChSpdNom = 8 in the previous calculation.

Note: Input SPEED REQUEST is active only if the setpoint Speed request has value ANA.

ACTIVE POWER (S3.2)

Input from the external transmitter of Active power. Value of the Active power is used to improve load step
response of the governor. Input ACTIVE POWER is active only, if the setpoint Speed request has not value
DATA. The input sensitivity can be adjusted by setpoint Load anticip.

Note: Input ACTIVE POWER is active only if the setpoint Speed request has value BIN or ANA and setpoint

Load anticip > 0.

Collaboration with ECON-4Slave

Physical analog input on terminal S3.2 canbe used also when ECON4-Slave is used. In this case feedback
from slave actuator is put on analogue output on slave and can be connected back to masterto see it in one
Winscope (connected to master) and in controller thru CAN as Misf Angle.

Original Misf Angle calculation is not used in latest version of ECON4 and in version 1.4 is used to show
feedback from Slave. If feedback from slave is connected to analog input on S3.2 setpoint LoadAnticipationhas
to be =0. Othervise wrong value will be used forload anticip resulting unstability and unpredictive control

Principle of connection Master Slave is shown on next picture.

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4.4.6 Analog output

ECON-4 has one analogoutput configurable to 0-10V or 0-20mA range by jumper setting – see in table below. If
configuredto 0-20mA range, output works as an active current source. The analogoutput function is fix (copy of
the value sent to ACT output - GAS DOSE). Analogueoutput range is fully programmable in range 0-10V or 0­20mA – see setpoints: Analog settings: AOUT 0%and AOUT 100%.

Range Recommended wiring Output Terminals Jumpers

0-20
mA

0-10 V AOUT

AOUT

S6.1
S6.2

S6.1
S6.2

P6 - 20 mA

P6 - 10 V

Gas Dose (S6.1)

Output signal corresponds to actuator requested position. The limits are fully scaleablein range 0-10V (0­20mA).

E.g an actuator with input 4-20mA is used, theAOUT2 range setpoints should be adjusted in the following way:

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Analog sensors: AOUT2 0% = 20% (20% from 20mA = 4mA)

Analog sensors: AOUT2 100% = 100%

andjumper P6 adjusted to current option.

In case an actuator with an input 0-5V is used, the AOUT2 setpoints should be adjusted in the following way:

Analog sensors: AOUT2 0% = 0%

Analog sensors: AOUT2 100% = 50%

andjumper 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.

Range Recommended wiring Terminals Jumpers

Ooutput
0 - 8 A

Feedback
0 - 5 V

Feedback
0 - 10 V

Types of actuators supported by ECON-4

With current input 200mA

Example: Typical example is Woodward UG-A.

S1.3 -

S2.2
S2.1
S2.3

S2.2
S2.1
S2.3

P21

P21
10V

5V

It is electro-hydraulic actuator – in principle a small electromagnetic actuator with hydraulic booster. It has
proportional characteristic – the bigger is the current, thebigger is the angle of the actuator, the polarity of the
current is not important. Actuatoris usually without electrical position feedback. For this actuator choose option
ActType: Wiring: LINEAR NO FEEDBACK

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With current input max. 10A

Example: Typical examples are actuators from GAC, Woodward Flowtech ITB.

It is electro-magnetic actuator with a strong return spring. This is in principle electromagnet with proportional
characteristic – the bigger is the current to the actuator, the bigger is the angle of the actuator. The polarity of the
current is not important. This type of actuator can be with or without position feedback. For this actuator choose
option ActType: Wiring: LINEAR or LINEAR NO FEEDBACK.

Motor driven actuators

Example: Typical examples are actuators from Heinzmann (STG 6, 10, 30, 2040.)

It is in principle a DC electromotor driving actuator lever. Since it is a motor, it has integrating characteristic – as
longas the current flows through the actuator, actuator’s lever moves. Direction of movement of the actuator
lever depends on polarity of the current. This typeof 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 0­5V.

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4.4.8 Speed Pick-up

Always use a shieldedcable, connect shieldingto a grounding screw. ECON-4 supports both active (powered)
andpassive (magnetic) pickups.

Pick-up Recommended wiring Jumpers

Active NPN

Active PNP Link 1 and 2

Passive Link 2 and 3

If the jumper is in position 2-3, terminals GND and SIG areseparated from all other terminals. This enables to
share one pick-up by two modules, for instance by a speed governor and by an ignition, without danger of
creating a ground loop.

Link 1 and 2
Link 4 and 5

4.4.9 Communication wiring

CAN bus connection

ECON-4 is equipped by CAN communication line. CAN bus terminals are electrically isolated from any other
terminals.

Note: Following ECON-4 CAN setting is necessary to communicate with InteliSys NT:

CAN mode (Object number 10338) = 1 sets ComAp protocol

CAN NODE-ID (Object number10306) = 88 (decimal) sets address of the module

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Connection rules

CAN bus line must be connected in series, from one unit to the next (no star, no cable stubs, and no branches)
both ends must be by the 120-ohm (internal or external) resistorterminated. 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 seechapter Technical data – Communication interface. CAN cable shielding
connect to CAN COM terminal.

6 back to Recommended wiring

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5 ECON-4 setup

5.1 Quick start - how to set ECON4 andcontroller 22

5.2 Entering password 28

5.3 Data 28

5.4 ECON-4 configuration and PC tools 32

5.5 ECON adjustement for various types of actuators 34

5.6 Detailed fucntion 37

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-4speed governor. The ECON-4 can be
found in different modes used for control of moduleand engine.

Basically any input signal of ECON4 can be suppliedeither using wired signal or using data from CAN1 line.

Input signals of ECON4 areseparated in to two groups each group can be controlled in different way.

Group Setpoint Signal

Breaker`s
feedback

Speed control

Block schema where data flow in different modes is shown is located in Setpoints section CB request (page 50)
andSpeed request (page 49)

There is separated description of setting for different modes for CB request and Speed request on following
pages.

CB
request

Speed
request

GCB feedback

MCB feedback

Speed request analogue signal

Actual power analogue signal

SpeedUp and SpeedDown binary
signal

Idle/Nominal binary signal

Droop binary signal

RUN binary signal

Possible control

mode

BIN/ANA/DATA

BIN/DATA

5.1.1 Breakers feedback handling (CB request modes)

CB request set to BIN mode

Image 5.1 CB request - BIN mode

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In case of binary control of breaker`s feedback, signals from breakers has to be wired to terminals S4.1 and
S4.2. You do not needto link any source to Binary outputs of ECON4 in Genconfig.

CB request set to DATA mode

Image 5.2 CB request - DATA mode

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

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