ComAp ECON-4 Instruction manual

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: [phone]
E-mail: [email protected], www.comap-control.com Global Guide
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

ECON-4 1.4.0 Global Guide 2
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 the governor system 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 and mounting 10
4.3 Jumper position 11
4.4 Recommended wiring 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 and controller 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

ECON-4 1.4.0 Global Guide 3
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 WinScope SW: 32
5.4.2 Econ-4 firmware 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 - speed governor 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 type 1 – predefined for Woodward ITB 0-200 mA 69
8.1.7 Act type 2 – predefined for Woodward ITB PWM 71
8.1.8 Act type 3 –predefined for Woodward F-series PWM 71
8.1.9 Act type 4 – predefined for Heinzmann STG 10 72
8.1.10 Group: Analog sensors 72
8.1.11 List of tested actuators by ComAp 74

ECON-4 1.4.0 Global Guide 4
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 usage of ECON-4 for control of engine. ECON-4 Global 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 Documentation is 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 and provision of Services” (Terms) and/or in the
“Standardní podmínky projektů komplexního řešení 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 and by 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 and applicable 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 the Terms or the Conditions and the License Agreement.
Licensed End User is 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 written consent 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

ECON-4 1.4.0 Global Guide 5
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.

1.4 Symbols in this manual
Battery
Breaker
Connector -
female
Connector -
male
Controller
simplified
ECON-4
simplified
Fuel
solenoid
Fuse
Fuse switch
Generator
Generator
schematic
Grounding
Jumper
Load
Mains
Mains
Pick - up
Resistor
Resistor
adjustable
RS232
female
Starter
Voltage
measureme
nt
ECON-4 1.4.0 Global Guide 6

ECON-4 1.4.0 Global Guide 7
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 some binary 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.
6back to Table of contents

ECON-4 1.4.0 Global Guide 8
3 Applications overview
3.1 Wiring overview
6back to Table of contents

ECON-4 1.4.0 Global Guide 9
4 Installation and wiring
4.1 Package content 9
4.2 Module installation 10
4.3 Jumper position 11
4.4 Recommended wiring 12
6back to Table of contents
4.1 Package content
The package contains:
ECON-4 module
Terminal blocks

ECON-4 1.4.0 Global Guide 10
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 11
4.3 Jumper position
Jumper Meaning
P6
AOUT switch between current and voltage analogue output
Current: link the 2 pins from right side
Voltage: link the 2 pins from left side
P7 120 Ohm resistor for CAN line termination
P9 Boot
P10 Reset

ECON-4 1.4.0 Global Guide 12
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)
6back 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.
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 13
4.4.2 Grounding
Use as short as possible cable to the grounding 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 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.
Power Supply Fusing
An eight-amp fuse should be connected in-line with the battery positive terminal to the controller and modules.
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

ECON-4 1.4.0 Global Guide 14
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 the setpoint Speed request.
Speed Request value CB Request value
Input BIN ANA DATA BIN DATA
MCB fdb (S4.1) (page 14) MCB fdb S4.1 Cmd.1
GCB fdb S4.2 Cmd.2
NOMINAL S4.3 S4.3 Cmd.2
SPEED UP S4.4 X X
SPEED DOWN S4.5 X X
RUN / STOP S4.6 S4.6 S4.6 &
Cmd.3
DROOP S4.7 S4.7 Cmd.4
RESERVE S4.8
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 and MCB fdb decide which setpoints are used in PID speed regulation loop and which type of
regulation is used (Iddle/Island/Parallel):
MCB
state
GCB
state lRPM - Requested RPMl > RPM window PID constants
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
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 and MCB fdb decide which setpoints are used in PID speed regulation loop and which type of
regulation is used (Iddle/Island/Parallel):
MCB
state
GCB
state lRPM - Requested RPMl > RPM window PID constants
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

ECON-4 1.4.0 Global Guide 15
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 – see in table below. The analog input function is fixed.

ECON-4 1.4.0 Global Guide 16
Range Recommended wiring Input Terminals Jumpers
0-20 mA
SPEED REQUEST S3.1 P22 – 20 mA
ACTIVE POWER S3.2 P23 – 20 mA
0-10 V
SPEED REQUEST S3.1 P22 – 10 V
ACTIVE POWER S3.2 P23 – 10 V
SPEED REQUEST (S3.1)
The input defines speed reference. 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 can be 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 master to 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 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 17
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). Analogue output range is fully programmable in range 0-10V or 0-
20mA – see setpoints: Analog settings: AOUT 0%and AOUT 100%.
Range Recommended wiring Output Terminals Jumpers
0-20
mA AOUT S6.1 S6.2 P6 - 20 mA
0-10 V AOUT S6.1
S6.2 P6 - 10 V
Gas Dose (S6.1)
Output signal corresponds to actuator requested position. The limits are fully scaleable in range 0-10V (0-
20mA).
E.g an actuator with input 4-20mA is used, the AOUT2 range setpoints should be adjusted in the following way:

ECON-4 1.4.0 Global Guide 18
Analog sensors: AOUT2 0% = 20% (20% from 20mA = 4mA)
Analog sensors: AOUT2 100% = 100%
and jumper 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%
and jumper 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 S1.3 -
Feedback
0 - 5 V
S2.2
S2.1
S2.3
P21
5V
Feedback
0 - 10 V
S2.2
S2.1
S2.3
P21
10V
Types of actuators supported by ECON-4
With current input 200mA
Example: Typical example is Woodward UG-A.
It is electro-hydraulic actuator – in principle a small electromagnetic actuator with hydraulic booster. It has
proportional characteristic – the bigger is the current, the bigger is the angle of the actuator, the polarity of the
current is not important. Actuator is usually without electrical position feedback. For this actuator choose option
ActType: Wiring: LINEAR NO FEEDBACK

ECON-4 1.4.0 Global Guide 19
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
long as the current flows through the actuator, actuator’s lever moves. Direction of movement of the actuator
lever depends on polarity of the current. 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-
5V.

ECON-4 1.4.0 Global Guide 20
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
Active NPN Link 1 and 2
Link 4 and 5
Active PNP Link 1 and 2
Passive Link 2 and 3
If the jumper is in position 2-3, terminals GND and SIG are separated 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.
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