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Incon: User Manual
Incon: User Manual
Incon: User Manual
INCON
Integrated Speed and Injection Controller
User manual
Warnings !!
The data in this manual only describes the product and is not warranty of performance or characteristic.
Note:
ComAp believes that all information provided in this manual is correct and reliable and reserves the right
to update at any time.
ComAp does not assume any responsibility for its use unless otherwise expressly undertaken.
General information
Application
The system has been developed to control the speed and power of a gas engine by varying timing and
duration of opening of gas injection valves for engines of up to 12 cylinders. The INCON-2 includes speed
governor function.
Description of operation
The overall system consists of:
• Unit INCON-2
• Speed pickup
• Camshaft pickup
• Crankshaft top dead center TDC pickup
• Gas Admission Valves on each cylinder
GEV
INCON Gas
El. mag. valve Exhaust
control system Air
Camshaft
pickup
Magnetic
pickup
Speed
pickup
INCON-2 controls the beginning and duration of gas admission into the suction port (before suction valve).
Varying the GAV opening duration controls engine speed and load. INCON-2 can individually control timing
of each GAV. This is used for equalizing of exhaust gas temperatures of individual cylinders.
The beginning and duration of opening are specified in crankshaft angular rotation degrees (see Engine
timing diagram).
! Warning !
Connectors must be downward oriented because of protection from dust.
! Warning !
Unit must be mounted on a secure, massive bracket on or near the engine using vibration damping mounts.
Avoid areas of excessive vibration and ambient temperature greater than 70 °C (158 °F).
INCON
Electronic Fuel Injection
Control Unit
K1 K2 K3 K4 K5 K6
A B C D E F G H I J K L
speed
engine engine pickup
6x electromagnetic valve 6x electromagnetic valve position position
pickup camshaft
pickup
1 1 2 1 1 1 1
6 4 3 6 6
K2
K1 4 3 K3 K4 K5 K6
12 8 6 12 12
1
F A
12 11 10
2
3
E B
4
9
5
D C
8
6
7
K2
1
4
SUPPLY 24VDC
2
+
3
K3
RPM
1
8
CRANK
7
CAM
6
+24V
+24V
5
K4
CAN L
1
CAN H No termination
6
3
4
K5
ANALOG INPUT
4 - 20mA OR
1
0 - 10V
12 11 10
DROOP RATED
4
SPEED UP BO COMMON
8
SHUTDOWN WARNING
+Bat (-Bat)
7
K6
L G
12 11 10
2
3
K H
4
9
J I
8
6
7
Connector K3 – Pickups
PIN Description
1,8 RPM pickup
2 CAM - Camshaft reset pickup, input
7 CAM - Camshaft reset pickup, 0V
3 TDC pickup, input
6 TDC pickup, 0V
4 +24V supply for active pickups
5 Shielding
Connector K6
PIN Description
1,2 Gas Valve G
3,4 Gas Valve H
5,6 Gas Valve I
7,8 Gas Valve J
9,10 Gas Valve K
11,12 Gas Valve L
RUN
1 POWER RS 232 9
CRANK
RPM
CAM
DROOP
RATE
RUN
2 8
OUT1
- OUT2
+
JP8
JP14
JP13
JP4
JP3
3 7
2
JP17
1
K1 K2 K3 K4 K5 K6
1 …. LED indication
JP …. Jumpers marking
RPM pickup
The RPM pickup senses the ring gear teeth or holes on the flywheel.
We recommend min 30 teeth (pulses) per revolution.
Active pickup
5 °
°-1
10
0,5 mm
TDC
A
Index "A" - 10°-25° before TDC
(Top Dead Center)
Camshaft
1:2
The number of pins and their spacing on the flywheel depends on the number of cylinders and the firing
sequence.
Examples:
For twelve-cylinder Vee engine with 60° between cylinder banks use six pins with angular spacing 60°.
For twelve-cylinder Vee engine with 45° between cylinder banks use six pins with angular spacing in 45°,
75°, 45° … series.
For six-cylinder in-line engine use three pins with angular spacing 120°.
For nine-cylinder in-line engine use nine pins with angular spacing 40°.
If NPN active pickup is used: close jumper JP13, set jumper JP8 to position 2 (no external resistor is
needed).
If PNP pickup is used: close jumper JP13, open jumper JP8 (no external resistor is needed).
If inductive (passive) pickup is used (not recommended): open jumper JP13 and set jumper JP8 to position
1.
!WARNING!
It is essential that the interior of all gas manifolds be absolutely clean prior to GAV installation and engine
start up. There must not be any dust or contaminations, weld slug, rust, and other solid particles present!
Contamination of GAV by dirt may cause erratic function of the valve!
Firing order
INCON outputs A … to L must be connected to engine cylinders according following table.
A B C D E F G H I J K L
1 2 3 4 5 6 7 8 9 10 11 12
Note: Measured GAV current does not correspond to real solenoid current because of measuring point is
near the ground and parallel resistor is placed to GAV coil.
Setting Valve control: Scope settings = [Std, RPM, A-L] changes the Scope (RS232 diagnostics data)
channels structure:
Following is an example of WinScope RPM pickup signals record (engine start). The CAM signal is
rectangular due to very low frequency on low RPM.
Hint:
GAV diagnostics activation and deactivation does not change the WinScope channels setting. Standard
channels description setting does not correspond to GAV diagnostics / see table above.
+24V 0V 0V +24V
COM COM
INCON INCON
RUN – K5:9
Input function depends on setting of Basic settings: Ext Fuel Control.
• Ext Fuel Control = 0 … INCON internal speed governor is used.
RUN input must be active (closed) to run the engine. Switching this input to OFF immediately closes all Gas
valves.
• Ext Fuel Control = 1 … external speed governor (e.g. ECON-2S) is used.
Closed RUN input activates automatic temperature corrections when Temperature compensation:
Automatic correction = 1. All INCON valves outputs are inactive (opened) when RUN input is opened.
Hint:
It is recommended to activate automatic temperature compensation in Bi-fuel engine operation only.
RATED – K5:3
If input RATED is active, Requested RPM = Nominal RPM, otherwise Requested RPM = Idle RPM.
DROOP – K5:10
This input switches governor to Droop mode. Status of DROOP input is important also for range of
Requested RPM.
Hint:
Set parameter Droop to 0 or switch input DROOP off for isochronous operation. Droop is active only on
Rated RPM when input DROOP is closed.
SPEED UP – K5:8
If active and SPEED DOWN is not active, the requested speed is increasing.
WARNING – K5:6
Output closes, if any internal warning is active. As soon as the internal warning is deactivated, the output
opens.
Possible warnings:
• RPM, CAM, TDC pickup fail: Pickup fail is activated when the difference between any of RPM, TDC and
CAM value is higher than 10 RPM. Pickup fail is not indicated on Binary output K5:6 –warning below 200
RPM. Pickup fail is not indicated by separate RPM, TDC, CAM flag below 50 RPM.
• Over speed: Indication is active when actual RPM is over Basic setting: Overspeed RPM.
• Temperature corrections limit: Indication is active when automatic correction reach Temperature
compensation: Corr limit.
Hint:
From INCON-3.1 is available a new RPM, TDC, CAM pickups diagnostic via INCON RS232 scope channels.
16 bit status word with RPM, TDC and CAM flag is available in “Operational menu – Status” screeen and on
the CAN bus.
Analog input
Dose request – K5:1
0-10V or 0-20mA – input for requested valve opening if the setpoint Basic settings: External Fuel Control
=1.
In this case the external governor is used for speed control and INCON works as gas dose actuator -
receiving requested valve opening via analog input K5:1, 12.
Close JP3 jumper for 0-20mA or JP4 jumper for 0-10V analog input range.
Nominal RPM + 8%
Nominal RPM
Nominal RPM - 8%
SpeedRampTime
START - S
As soon as Measured RPM reaches 10 RPM, INCON opens the gas valves to Init Start Dose. The start dose
can grow up in time form Init Start Dose to Max Start Dose. The start sequence ends as soon as Measured
RPM reaches Start RPM and since this moment begins normal speed regulation. If the Measured RPM
drops below 10 RPM during start, the start sequence starts again from the beginning.
Time
Speed
Idle RPM
Time
PID SET - P
Gain [%]
Gain of the speed PID loop.
Step: 0.1%
Range: 0 – 999.9 %
Integration [%]
Integration part of the speed PID loop.
Step: 0.1%
Range: 0 – 200.0 %
Derivation [%]
Derivative part of the speed PID loop.
Step: 0.1%
Range: 0 – 200.0 %
Droop [%]
Immediate droop is calculated from immediate fuel dose and setpoints Droop, No Load Dose and Full Load
Dose.
Step: 0.1%
Range: 0 – 15.0 %
If binary input DROOP is active and setpoint Droop is non-zero, the Requested RPM decays with the
governor fuel dose. Parameters Droop, No Load Dose and Full Load Dose are used for calculation of actual
Requested RPM, see the figure below.
Requested RPM
Nominal RPM
Fuel Dose
… to …
Injection Start
DOSE control
range
Maximum Dose
180
There are two different modes of control of the current passing through a coil of gas valve electromagnet:
- Opening period; full voltage of INCON's internal High voltage supply is connected to the coil to open
the valve as soon as possible
- Retaining period; current through the coil is controlled by PWM regulation
100%
GEV Current
Peak
current
Holding current
Time
a) Linear “fix” correction of opening period of gas valves in dependency on average fuel dose. For each
individual cylinder is possible to set correction that is added or deducted from the average fuel dose.
Correction is set for two values of engine load (fuel dose). Correction for different engine loads is linear
interpolation in between these two points.
b) Feedback corrections based on exhaust temperatures of individual cylinders. Exhaust gas temperatures
are measured by external device and send to INCON via CAN bus.
INCON compares temperature of each cylinder with average value and depends on temperature difference
modify corrections of all cylinders. Setpoint Temperature compensation: Corr Gain (it was constant Corr
Step in v 2.0) is temperature difference multiplying factor. Correction change depends on temperature
difference of this cylinder and Corr Gain.
Automatic correction starts (after activation) from fix setting of Cylx Corr Low and Cylx Corr High. Each
cylinder correction is limited by Corr Limit setpoint (can not be higher). Correction value is limited to Corr
Limit when Cylx Corr Low and Cylx Corr High setting is over this limit - after automatic correction is
activated.
Period between corrections and amplitude of corrections are settable. If the measured temperatures are
not valid, (e.g. because of sensor fail on some cylinder), INCON-2 automatically switches to compensation
method a).
Closed RUN input activates automatic corrections in Automatic mode when Basic settings: Ext Fuel Control
= 1, i.e. external speed governor (e.g. ECON-2S) is used.
Automatic corrections are activated after engine reach Rated RPM (after Binary input RATED is closed)
when Basic settings: Ext Fuel Control = 0, i.e. INCON internal speed governor is used. Aut.corrections are
switched off when Binary input RATED is opened.
Hint:
Always set setpoints for compensation method a), because they may be needed if there is any problem on
thermocouples, external analog modules or CAN bus.
u el
g eF -75
e ra
Av
uel
v e rage F on
A recti
+ cor
+50
Cyl1_Corr_L
Automatic Corr [ 0 / 1 / 2]
Parameter enables/disables automatic correction = exhaust temperatures compensation.
Automatic Corr = 0
Automatic exhaust temperature compensation is disabled and each cylinder actual dose correction is based
on fix (manual) setting - see setpoints Temperature compensation: Cylx Corr Low, Cylx Corr High.
Automatic Corr = 1
Automatic exhaust temperature compensation is enabled. Each cylinder temperature compensation starts
from fix (manual) setting - see setpoints Temperature compensation: Cylx Corr Low, Cylx Corr High after
compensation is activated.
Automatic Corr = 2
Automatic exhaust temperature compensation is enabled. Each cylinder temperature compensation starts
from 0 (fix) setting after compensation is activated. Starting value does not depend on Temperature
compensation setting.
Hint:
If automatic correction is enabled and no frames with exhaust temperatures are detected on CAN bus, BO
WARNING is closed and INCON uses fix corrections based on Cyl1 Corr Low, Cyl1 Corr High, …Cyl12 Corr
Low, Cyl12 Corr High.
Correction of one cylinder is switched to fix value if corresponding cylinder temperature sensor fails.
Note:
Bits 0 to 4 are mirror of binary inputs.
Bits 5 and 6 are mirror of binary outputs.
Bits 8, 9, 10 stays active until the next engine start.
MAIN MENU
Info I
Parameters P
Operation O
PARAMETERS:
[unit]
Basic settings B Setpoint description
(adjustment range)
Idle RPM [RPM] (100 ÷ 2000) Engine Idle speed
Rated RPM [RPM] (100 ÷ 2000) Engine Rated (Nominal) speed
Overspeed RPM [RPM] (100 ÷ 2000) Engine Over speed limit
Idle Ramp Time [ RPM/s] (1 – 999) Pass time between Idle and Rated RPM
Pass time between Min and Max Requested
Speed Ramp Time [ s ] (1 – 999)
Speed
Geer Teeth [ - ] (1 ÷ 500) Number of teeth on flywheel
Cylinders Number [ - ] (1 ÷ 24) Number of engine cylinders
Ext Fuel Control [ - ] (0, 1) 1 – internal governor not used
Valve test [ - ] (0, 1) 1 – test of valves
[unit]
Start S Setpoint description
(adjustment range)
Defines end of cranking and start of speed
Start RPM [RPM] (0 ÷ 400)
regulation
Init Start Dose [0.1°] (0 ÷ 180.0) Gas valve opening on crank start
Max Start Dose [0.1°] (0 ÷ 180.0) Maximum valve opening during cranking
Pass time from Initial Start Dose to Max Start
Fuel Ramp Time [ s ] (0 ÷ 999)
Dose during cranking
Start Ramp Time [ RPM/s ] (0 ÷ 999) Pass time from Start RPM to Idle RPM
[unit]
PID set P Setpoint description
(adjustment range)
[unit]
Valve config V Setpoint description
(adjustment range)
Defines firing order of cylinder connected to
Out A FirOrder [ - ] (0 ÷ 24)
INCON output A.
Defines firing order of cylinder connected to I
Out B FirOrder [ - ] (0 ÷ 24)
INCON output B.
Defines firing order of cylinder connected to
Out C FirOrder [ - ] (0 ÷ 24)
INCON output C.
Defines firing order of cylinder connected to I
Out D FirOrder [ - ] (0 ÷ 24)
INCON output D.
Defines firing order of cylinder connected to
Out E FirOrder [ - ] (0 ÷ 24)
INCON output E.
Defines firing order of cylinder connected to I
Out F FirOrder [ - ] (0 ÷ 24)
INCON output F.
Defines firing order of cylinder connected to
Out G FirOrder [ - ] (0 ÷ 24)
INCON output G.
Defines firing order of cylinder connected to I
Out H FirOrder [ - ] (0 ÷ 24)
INCON output H.
Defines firing order of cylinder connected to
Out I FirOrder [ - ] (0 ÷ 24)
INCON output I.
Defines firing order of cylinder connected to I
Out J FirOrder [ - ] (0 ÷ 24)
INCON output J.
Defines firing order of cylinder connected to
Out K FirOrder [ - ] (0 ÷ 24)
INCON output K.
Defines firing order of cylinder connected to I
Out L FirOrder [ - ] (0 ÷ 24)
INCON output L.
Injection Start [0.1°] (0 ÷ 180.0) Angle from TDC to start of gas injection
[unit]
Valve control R Setpoint description
(adjustment range)
Opening Delay [0.1ms] (0 ÷ 99.9) Opening delay of gas valves
Peak Current [0.1%] (0 ÷ 100.0) Peak valve current
Holding Current [0.1%] (0 ÷ 100.0) Holding valve current
Scope setting [ - ] (Std, RPM, A÷L) RS232 INCON scope settings
Temperature [unit]
(adjustment range) Setpoint description
compensation C
Cyl1 Corr Low [0.1°] (0 ÷ 180.0) Correction of cylinder no.1 on low load
Cyl1 Corr High [0.1°] (0 ÷ 180.0) Correction of cylinder no.1 on high load
Cyl2 Corr Low [0.1°] (0 ÷ 180.0) Correction of cylinder no.2 on low load
Cyl2 Corr High [0.1°] (0 ÷ 180.0) Correction of cylinder no.2 on high load
Cyl3 Corr Low [0.1°] (0 ÷ 180.0) Correction of cylinder no.3 on low load
InconDump-1.1
InconDump-1.1 - INCON/ECON setpoints editor functions:
• Load setpoints from binary “ins” file or directly from INCON
• Modify separate setpoints
• Save setpoints to binary “ins” or to text “txt” file
• Print setpoints list
• Download setpoints to INCON
Operating conditions
Operating temperature -20..+70oC
Storage temperature -30..+80oC
Protection front panel IP65
Humidity 85% without condensation
Standard conformity
Low Voltage Directive EN 61010-1:95 +A1:97
Electromagnetic Compatibility EN 50081-1:94, EN 50081-2:96
EN 50082-1:99, EN 50082-2:97