afr 03 002-e 01-08 kronos 20 · engine & turbine controls kronos 20 electronically controlled...

Heinzmann GmbH & Co. KG Engine & Turbine Controls Am Haselbach 1 D-79677 Schönau (Schwarzwald) Germany Phone +49 7673 8208-0 Fax +49 7673 8208-188 Email [email protected] www.heinzmann.com V.A.T. No: DE145551926

HEINZMANN® Engine & Turbine Controls

KRONOS 20

Electronically controlled Air Fuel Ratio Control System

for Gas Engines with open / closed Control Loop

Copyright 2007 by Heinzmann GmbH & Co. KG All rights reserved. This publication may not be reproduced by any means whatsoever or passed on to any third parties.

Manual AFR 03 002-e / 01-08

Read this entire manual and all other publications appertaining to the work to be performed before installing, operating or servicing your equipment.

Practice all plant and safety instructions and precautions.

Failure to follow instructions may result in personal injury and/or dam-age to property.

HEINZMANN will refuse all liability for injury or damage which re-sults from not following instructions

Please note before commissioning the installation: Before starting to install any equipment, the installation must have been switched dead!

Be sure to use cable shieldings and power supply connections meeting the requirements of the European Directive concerning EMI.

Check the functionality of the existing protection and monitoring sys-tems.

To prevent damages to the equipment and personal injuries, it is imperative that the following monitoring and protection systems have been installed: Overspeed protection acting independently of the speed governor

Overtemperature protection

HEINZMANN will refuse all liability for damage which results from missing or insufficiently working overspeed protection

Generator installation will in addition require: Overcurrent protection

Protection against faulty synchronization due to excessive frequency, voltage or phase differences

Reverse power protection

Overspeeding can be caused by:

Failure of the voltage supply

Failure of the actuator, the control unit or of any accessory device

Sluggish and blocking linkage

Warning

Danger

Danger

Danger!High

Voltage

Danger

The examples, data and any other information in this manual are in-tended exclusively as instruction aids and should not be used in any particular application without independent testing and verification by the person making the application.

Independent testing and verification are especially important in any ap-plication in which malfunction might result in personal injury or dam-age to property.

HEINZMANN make no warranties, express or implied, that the exam-ples, data, or other information in this volume are free of error, that they are consistent with industry standards, or that they will meet the requirements for any particular application.

HEINZMANN expressly disclaim the implied warranties of merchant-ability and of fitness for any particular purpose, even if HEINZMANN have been advised of a particular purpose and even if a particular pur-pose is indicated in the manual.

HEINZMANN also disclaim all liability for direct, indirect, incidental or consequential damages that result from any use of the examples, data, or other information contained in this manual.

HEINZMANN make no warranties for the conception and engineering of the technical installation as a whole. This is the responsibility of the user and of his planning staff and specialists. It is also their responsibil-ity to verify whether the performance features of our devices will meet the intended purposes. The user is also responsible for correct commis-sioning of the total installation.

Warning

Danger

Contents

KRONOS 20

Contents

Page

1 Safety Instructions and Related Symbols............................................................................ 1 1.1 Basic Safety Measures for Normal Operation................................................................. 2 1.2 Basic Safety Measures for Servicing and Maintenance .................................................. 2 1.3 Before Putting an Installation into Service after Maintenance and Repair Works.......... 3

2 General ................................................................................................................................... 4 2.1 System Characteristics..................................................................................................... 4 2.2 Applications..................................................................................................................... 4 2.3 System Components ........................................................................................................ 5 2.4 System Specifications...................................................................................................... 5 2.5 Operational Principle....................................................................................................... 6 2.6 General Application......................................................................................................... 7 2.7 Additional Functions ....................................................................................................... 8 2.8 Gas Train ......................................................................................................................... 9

3 Sensors.................................................................................................................................. 10 3.1 Overview Table ............................................................................................................. 10 3.2 Speed Pickup IA…........................................................................................................ 10

3.2.1 Technical Data ....................................................................................................... 10 3.2.2 Mounting Position.................................................................................................. 11 3.2.3 Tooth Shape ........................................................................................................... 11 3.2.4 Distance of the Speed Pickup ................................................................................ 11 3.2.5 Dimensional Drawing ............................................................................................ 12 3.2.6 ATEX Certification of Speed Pickups................................................................... 13

3.3 Double Sensor P/T-S-01 for Pressure and Temperature Measurement in Intake Manifold .............................................................................................................................. 13

3.3.1 Technical Data ....................................................................................................... 13 3.3.2 Dimensional Drawing ............................................................................................ 14 3.3.3 Mounting................................................................................................................ 14 3.3.4 ATEX Certification for Double Sensor P/T-S-01.................................................. 15

3.4 λ Sensor LSM 11 for Exhaust Gas Measurement (optional)......................................... 15 3.4.1 Technical Data ....................................................................................................... 15 3.4.2 Dimensional Drawing ............................................................................................ 17

4 Control Unit KRONOS 20.................................................................................................. 18 4.1 Technical Data............................................................................................................... 18

4.1.1 General................................................................................................................... 18 4.1.2 Inputs and Outputs ................................................................................................. 19

Contents

KRONOS 20

4.2 Dimensional Drawing.................................................................................................... 20 4.3 Mounting Position ......................................................................................................... 22

5 Gas Valves E-LES ............................................................................................................... 23 5.1 Structure and Operating Principle ................................................................................. 23 5.2 Technical Data............................................................................................................... 24

5.2.1 Specifications for all E-LES Gas Valves............................................................... 24 5.2.2 Additional Specifications for Gas Valve E-LES 30 .............................................. 25 5.2.3 Additional Specifications for Gas Valve E-LES 50 .............................................. 25 5.2.4 Additional Specifications for Gas Valve E-LES 80 .............................................. 25

5.3 Dimensional Drawings .................................................................................................. 26 5.4 Mounting ....................................................................................................................... 29 5.5 ATEX Certification of E-LES… Gas Valves................................................................ 29

6 Electric Connection ............................................................................................................. 31 6.1 Wiring Diagrams ........................................................................................................... 32

6.1.1 Wiring Diagram for KRONOS 20 with open Loop............................................... 32 6.1.2 Wiring Diagram for KRONOS 20 with closed Loop (power signal, CH4 signal).............................................................................................................................. 33 6.1.3 Wiring Diagram for KRONOS 20 with λ-Sensor Signal ...................................... 34

6.2 Cable Harness................................................................................................................ 35 6.3 Enclosed Cables............................................................................................................. 36

6.3.1 Cable W2 to Gas Valve E-LES.............................................................................. 36 6.3.2 Cable W3 to Pressure / Temperature Sensor P/T-S-01.......................................... 37 6.3.3 Cable W4 to Speed Pickup IA… ........................................................................... 38 6.3.4 Cable W5 to λ-Sensor LSM 11.............................................................................. 39

7 Parameter Settings for Control Unit KRONOS 20.......................................................... 40 7.1 Parametrization with the Hand Held Programmer 3 ..................................................... 40 7.2 Parametrization with the PC / Laptop ........................................................................... 40

8 General Mounting Instructions.......................................................................................... 41

9 Commissioning .................................................................................................................... 42 9.1 General Safety Information for Commissioning ........................................................... 42 9.2 General Information on the first Engine Start ............................................................... 42 9.3 Commissioning for OPEN LOOP (open control circuit) .............................................. 43 9.4 Further Commissioning for CLOSED LOOP (closed control circuit) with Output Power 45 9.5 Further commissioning for CLOSED LOOP with λ1 control (KRONOS 20 version with λ1 sensor) 47

Contents

KRONOS 20

10 Misfire Detection (optional).............................................................................................. 49 10.1 General ........................................................................................................................ 49 10.2 Putting into Operation ................................................................................................. 49

11 Operation ........................................................................................................................... 51

12 Maintenance and Service.................................................................................................. 52

13 Error Handling.................................................................................................................. 53 13.1 General ........................................................................................................................ 53 13.2 Categories of Errors und Emergency Operation after System Failure ........................ 53 13.3 Error Memories ........................................................................................................... 55 13.4 Bootloader ................................................................................................................... 56

13.4.1 Bootloader-Start Tests ......................................................................................... 56 13.4.2 Bootloader Communication................................................................................. 57

13.5 Error Parameter List .................................................................................................... 58

14 Parameter Description...................................................................................................... 65 14.1 Synoptical Table .......................................................................................................... 65 14.2 List 1: Parameters ........................................................................................................ 70 14.3 List 2: Measurements .................................................................................................. 77 14.4 List 3: Functions .......................................................................................................... 89 14.5 List 4: Characteristics and Maps ................................................................................. 92

15 Figure List.......................................................................................................................... 94

16 EC Declaration of Conformity ......................................................................................... 95

17 Order Form for KRONOS Systems ................................................................................ 96

18 Order Specifications for Manuals.................................................................................... 97

1 Safety Instructions and Related Symbols

KRONOS 20 1


This publication offers wherever necessary practical safety instructions to indicate inevitable residual risks when operating the engine. These residual risks imply dangers to

persons

product and engine

environment.

The symbols used in this publication are in the first place intended to direct your attention to the safety instructions!

This symbol is to indicate that there may exist dangers to the engine, to the material and to the environment.

This symbol is to indicate that there may exist dangers to persons. (Danger to life, personal injury)

This symbol is to indicate that there exist particular danger due to electri-cal high tension. (Mortal danger).

This symbol does not refer to any safety instructions but offers important notes for better understanding the functions that are being discussed. They should by all means be observed and practiced. The respective text is printed in italics.

The primary issue of these safety instructions is to prevent personal injuries! Whenever some safety instruction is preceded by a warning triangle labelled “Danger” this is to indicate that it is not possible to definitely exclude the presence of danger to persons, en-gine, material and/or environment.

If, however, some safety instruction is preceded by the warning triangle labelled “Caution” this will indicate that danger of life or personal injury is not involved.

The symbols used in the text do not supersede the safety instructions. So please do not skip the respective texts but read them thoroughly!

Note

Warning

Danger

Danger!High

Voltage


2 KRONOS 20

In this publication the Table of Contents is preceded by diverse instructions that among other things serve to ensure safety of operation. It is absolutely imperative that these hints be read and understood before commissioning or servicing the installation.

1.1 Basic Safety Measures for Normal Operation

• The installation may be operated only by authorized persons who have been duly trained and who are fully acquainted with the operating instructions so that they are capable of working in accordance with them.

• Before turning the installation on please verify and make sure that - only authorized persons are present within the working range of the engine; - nobody will be in danger of suffering injuries by starting the engine.

• Before starting the engine always check the installation for visible damages and make sure it is not put into operation unless it is in perfect condition. On detecting any faults please inform your superior immediately!

• Before starting the engine remove any unnecessary material and/or objects from the working range of the installation/engine.

• Before starting the engine check and make sure that all safety devices are working properly!

1.2 Basic Safety Measures for Servicing and Maintenance

• Before performing any maintenance or repair work make sure the working area of the engine has been closed to unauthorized persons. Put on a sign warning that mainte-nance or repair work is being done.

• Before performing any maintenance or repair work switch off the master switch of the power supply and secure it by a padlock! The key must be kept by the person perform-ing the maintenance and repair works.

• Before performing any maintenance and repair work make sure that all parts of engine to be touched have cooled down to ambient temperature and are dead!

• Refasten loose connections!

• Replace at once any damaged lines and/or cables!

• Keep the cabinet always closed. Access should be permitted only to authorized per-sons having a key or tools.


KRONOS 20 3

• Never use a water hose to clean cabinets or other casings of electric equipment!

1.3 Before Putting an Installation into Service after Maintenance and Repair Works

• Check on all slackened screw connections to have been tightened again!

• Make sure the control linkage has been reattached and all cables have been recon-nected.

• Make sure all safety devices of the installation are in perfect order and are working properly!

2 General

4 KRONOS 20

2 General

2.1 System Characteristics

• Affordable and trustworthy electronic Lambda control system

• Improved starting, idling, synchronizing and load behaviour

• Freely parametrizable, load and speed dependent mixing ratio map

• Cold start enrichment possible

• Easy adaptation to different engine and gas types, requiring only minor parameter modifications

• Only three sensors are required accordingly simple installation and reliable operation

• Simple and easy parameter setting and diagnosis with HEINZMANN DcDesk 2000 communications software Optional: - Communication with handheld programmer HEINZMANN HP-03 or the optional integrated programmer - CAN communication

• Extends application range of existing gas mixers mixing inserts therefore may be used for different gas qualities within a certain range

• The mixture control systems as a trimming system is largely self-regulating on basis of Bernoulli’s Law, thus avoiding constant movement of the regulating valve, to best ad-vantage of control stability.

• In case of error, the mixture control system can be operated by hand in the conventional way.

• The closed-loop version may be regulated via the power signal, an oxygen sensor or via a CH4 signal.

• Optional misfire detection is possible.

2.2 Applications

• Lean-burn engines

• Lambda 1 engines

• Stationary engines and vehicles

• Engines with fixed and variable speed

• Fuels: propane, natural gas, sewage gas, landfill gas, carburetted hydrogen vapour

• Fuels with changing gas quality

2 General

KRONOS 20 5

2.3 System Components

• Gas control valve E-LES 30 / E-LES 50 / E-LES 80

• Control unit KRONOS 20

• Intake manifold pressure sensor with integrated temperature sensor P/T-S-01

• Speed pickup IA…

• Cable harness cable to the digitally controlled main adjusting screw sensor cable for P-/T sensor speed pickup cable communication cable between control unit and PC

• Communications software DcDesk 2000

• Optional λ sensor

• Optional gas mixer from KRONOS 10

This system components may only be combined with gas mixers that meet the HEINZMANN specifications. If a different gas mixer shall be used con-sult HEINZMANN.

2.4 System Specifications

All ATEX certified components are suitable for zone 2.

Supply voltage 12 V DC or 24 V DC,

Min. supply voltage 10 V DC (E-LES 30/50) 18 V (E-LES 80)

Max. supply voltage 32 V DC

Residual ripple 10 % maximum at 100 Hz

Current consumption max. 2 A

Admissible voltage drop at max. max. 10 % current drawing

Fuse (external) 6 A

λ- range: 0.9..2.3

System is ready 10 s after energizing

Reaction time 100% deviation control in 0.3 s

Note

2 General

6 KRONOS 20

Resolution 1250 steps (E-LES 30) 2000 steps (E-LES 50) 3800 steps (E-LES 80)

λ map 100 points

Calorific value range 4..200 MJ/m³

Gas filter requirement max. mesh size 50 µm

Admissible concentration of (H2S) hydrogen sulphide max. 0.1 %

Fuels might not hold any corrosive constituents. If in doubt consult HEINZMANN

See below for detailed specifications of single components.

Performance Range:

E-LES 30-x: 80 kW (landfill gas) ... 250 kW (propane)



The indicated performance ranges are based on an assumed engine efficiency of 35%.

assumed calorific value (Hu): natural gas: 34 MJoule/nm³ landfill gas: 18 MJoule/nm³ propane: 90 Mjoule/nm³

The volume flow rate of the E-LES gas valve depends on the gas mixer and its design. The indicated performance range is valid only if the gas valve design is done by HEINZMANN. For applications combined with other gas mixers the volume flow rate can be 50% lower.

2.5 Operational Principle

The basic components of a conventional gas mixing system are:

• Gas mixer

• Main Adjusting Screw (MAS)

• Zero pressure regulator (ZPR)

Gas-air-fuel-ratio is determined essentially by the configuration of the gas mixer. On con-dition that the output pressure of the zero governor (ZPR) always corresponds to the air in-put pressure of the gas mixer, the air-fuel-ratio remains constant for different volume flow rates or engine loads. In practice, gas bores are chosen slightly greater than theoretically

2 General

KRONOS 20 7

necessary. This results in a greater influence of the main adjusting screw which is able to regulate the air-fuel-ratio within a limited range.

Theoretically it is possible fit gas bores on a Venturi tube in a way to cover the whole calo-rific value range for an application, e.g. from propane to landfill gas, as long as there is a possibility to compensate the differences relating to calorific value, air-fuel-ratio and gas density with the volume flow control.

This means that a MAS with a definite relation between valve position and opening cross-section may be placed in a way to obtain a desired air-fuel-ratio. But usually mixers for a specific gas quality are designed to give the gas control valve only limited adjusting au-thority.

A digitally controlled MAS like the HEINZMANN E-LES (digital lambda adjustment screw) that receives its inputs from a speed and load dependent map and reacts to gas pres-sure and mixture temperature variations, makes it possible to obtain an ideal gas-air mix-ture under all operating conditions.

Based on measured signals such as engine speed, inlet manifold pressure, mixture tempera-ture as well as on programmed parameters such as engine displacement and volumetric ef-ficiency the mixture flow may be calculated. The stored gas data and the mixer and gas valve characteristics allow to calculate current pressure conditions and gas flow. This al-lows a mixture control according to the physical model of a Venturi based system.

The valve cross-sectional area calculated by the control unit and the according valve posi-tion are adjusted accordingly by a stepping motor.

For engines of the same type no different parameter settings are required. In case of differ-ent gas quality only the gas bores must be adapted.

2.6 General Application

The gas valve E-LES may be used for the following applications:

• As conventional MAS In this application, the parameters relating to the desired valve position / gas valve cross-sectional opening area are set to the desired parameter value. Different settings may be implemented and reproduced simply by changing the parameter. Non mechani-cal adjustments are required. This mode of operation can be convenient when gas type changes frequently. The right to effect changes may be limited by assigning specific permissions. The settings may be changed via a remote connection.

• As Positioner The desired valve position / gas valve cross-sectional opening area are adjusted by the control unit according to a set value derived from an external control (current / voltage signal). This allows to include the system in an external lambda regulating system.

• As stand-alone Gas Mixture Control System

2 General

8 KRONOS 20

In connection with the gas mixer, the valve functions as an ideal lambda control system, with a freely programmable lambda map in dependence of speed and load. In an ex-tended closed-loop version it allows compensation for changes in gas quality and envi-ronmental factors. This makes it possible to use biogas with minimal emissions.

Figure 1: KRONOS 20 System

2.7 Additional Functions

• Engine Stop On activation of the digital input for engine stop, the gas valve will be completely closed in dependence of the parameter settings until the engine stops. But usually the engine will be stopped by closing the gas shut-off valve on the gas train.

• Overspeed Protection Overspeed may be set in a parameter. If this overspeed is exceeded the control unit emits an alarm and closes the gas valve.

• Operating Hours Counter Sums up the hours during which the engine runs (speed is recognized). In addition the number of engine starts is registered.

• Error Diagnosis and Error Messages

2 General

KRONOS 20 9

In case of sensor error, an alarm is given and, if necessary, the system goes in emer-gency operation or closes the valve, thereby stopping the engine. Internal errors are also recognized and are saved like all other errors. All errors can be extracted with an exter-nal handheld programmer or, if the communications software is installed and a cable available, read out to a PC / laptop computer.

• Communication Serial interface for the HEINZMANN communications programme DcDesk 2000 or for a handheld programmer (HEINZMANN communications cable required).

A CAN interface is available for communication with other HEINZMANN control units and, if adequately configured, allows communication with external devices such as SPS. In this way the system may be integrated flexibly in a comprehensive engine manage-ment solution.

• Optional Misfire Detection As an option, expanded software for misfire detection is available.

2.8 Gas Train

The components of the gas train such as magnetic valve, gas filter and, in particular, zero pressure regulator constitute a unity in an optimally working system of gas regulation. HEINZMANN is very experienced in this context and able to design and deliver according gas train with the according certificate.

In principle, a standard zero pressure regulator may be used. The starting pressure of the governor must be adjustable within a range from 0 to +25 mm water column (2.5 mbar). The ideal starting pressure is usually determined with start tests. A good starting value is 5 mm water column. The determined value must be entered in the list of parameters. The unit of the value to enter is Pa (25 mm H2O = 250 Pascal).

Most pressure regulators are subject to wear and sensitive against vibrations. Therefore HEINZMANN recommends to attach the governor not to the engine but to the frame. The pressure governor is not included in the standard scope of delivery of the KRONOS 20 system. On request, it can be delivered by HEINZMANN or a specific pressure regulator can be recommended by HEINZMANN.

3 Sensors

10 KRONOS 20

3 Sensors

3.1 Overview Table

Sensor Speed Intake Mani-fold Pressure

Intake Manifold Temperature

λ Sensor (optional)

HZM name IA .. P/T-S-01 LSM 11

Connection SV 6-IA-2K 2 pin Pressure sensor connector 4 pins

Measuring methods

inductive, active

piezo resistance, active NTC, passive electrochemical

Measuring range 50..9,000 Hz 0.2..3.0 bar abs. -40 to +130°C 1.00..2.00

Power supply range

4.5..5.5 V DC 12..13 V AC/DC

Output signal range 0..10 V AC 0.3..4.8 V 0..50 kOhm 0..900 mV

Operating tem-perature range -8 to +120°C -40 to + 130°C up to + 800°C

In order to allow sufficient flexibility and comparability of sensors, the min./max. values of pressure sensors and temperature sensors are programmable.

3.2 Speed Pickup IA…

3.2.1 Technical Data

Operating principle inductive sensor

Distance from measuring wheel 0.5 to 0.8 mm

Output 0 V to 12 V AC

Signal type sine (depending from tooth shape)

Resistance approx. 52 Ohm

Temperature range housing -8°C to +120°C cable -5°C to +80°C

Protection grade IP 55

Vibration < 10g, 10 to 100 Hz

Shock < 50g, 11 ms half sine

Connector used SV 6 - IA - 2K (EDV-No: 010-02-170-00)

3 Sensors

KRONOS 20 11

3.2.2 Mounting Position

The mounting position of the speed pickup must be such as to allow a frequency as high as possible. The HEINZMANN digital control of the KRONOS 20 series is normally designed for a frequency of max. 9,000 Hz. Frequency may be calculated as follows:

f (Hz) = n z( / min) *160

z = number of teeth on impulse wheel

Example:

n = 1,500

z = 160

f = 60

160*1500 = 4,000 Hz

In addition, attention should be paid that the sensor can pick up the speed without alteration, e.g. by being mounted on the starter gear of the flywheel.

The pickup wheel must be made of magnetic material (e.g. steel or cast iron).

3.2.3 Tooth Shape

Tooth shape is optional. The top width of the tooth should be 2.5 mm minimum, the width and depth of the gap at least 4 mm. For a perforated disk the same measurements apply.

A radial position of the speed pickup is preferable for tolerance reasons.

3.2.4 Distance of the Speed Pickup

Distance of the speed pickup to the top of the teeth should be approx. 0.5 to 0.8 mm. (the speed pickup can be screwed onto the top of the tooth and screwed back approx. half a revolution.)

Note

3 Sensors

12 KRONOS 20

mind.4mm

mind. 2.5mm

mind. 4mm

0.5-0.8mm

Figure 2: Distance of the Speed Pickup

3.2.5 Dimensional Drawing

G

L 35

19

Figure 3: Dimensions of the Speed Pickup

Unit

Type L(mm) G Notes

01 - 38 38 M 16 x 1.5

02 - 76 76 M 16 x 1.5 connector

03 - 102 102 M 16 x 1.5 used

11 - 38 38 5/8"-18UNF-2A SV6-IA-2K

12 - 76 76 5/8"-18UNF-2A (010-02-170-00)

13 - 102 102 5/8"-18UNF-2A

The according name for ordering is e.g., IA 02-76.

3 Sensors

KRONOS 20 13

3.2.6 ATEX Certification of Speed Pickups

All speed pickups described in the previous chapters are ATEX-certified according to EN 50021:1999 flame proof protection type "n". If the speed pickups are used in such an ambient and require an ATEX certificate, the wiring of the pickup must be done and delivered by HEINZMANN too. In this case, HEINZMANN will attach the following information sign to the wire close to the speed pickup plug:

HEINZMANN GmbH & Co. KG Germanywww.heinzmann.de Tel.: +49 7673 8208-0Type: z.B. IA 02-76, II3G Ex nA II T4

Tcable: -5°C to +80°C, Thousing: -8°C to +120°CTÜV 06 ATEX 552893

WARNING - EXPLOSION HAZARD - DO NOT DISCONNECT WHILE CIRCUIT

IS LIVE UNLESS AREA IS KNOWNTO BE NON-HAZARDOUS

Figure 4: Information Sign on Speed Pickup Cable, Front and Back

3.3 Double Sensor P/T-S-01 for Pressure and Temperature Measurement in Intake Manifold


Power supply 5±0.5 V

Current consumption 6..12.5 mA at 5 V

EMI 100 V/m

Operating temperature range -40°C to +130°C

Storage temperature -40°C to +130°C


Part-no.: 600-00-082-00

Used cable pressure sensor cable (part-no.: 600-81-045-..)

Pressure Sensor

Pressure range 0.2..3 bar abs.

Tolerance ±1,5 %

Signal voltage 0.3..4.8 V linear

Response time10/90 1 ms

3 Sensors

14 KRONOS 20

Temperature Sensor

Type NTC

Temperature measuring range -40°C to +130°C

Resistance at 20 °C (R20) 2.5 kOhm ±5 %

Max. measuring current 1 mA (5 V with 1 kOhm series resistor)

Temperature time constant t63 approx. 10 seconds (air; v = 6 m/s)


600-00-082-00HEINZMANN

2 134

27,8

19,6

46,5

9

12,05+/-0,08

60

14

12

48

6,7

20

9..1

2 2215

Figure 5: Dimensional Drawing of Double Sensor P/T-S-01

Sensor hole diameter 12.5±0.1 mm

Mounting screw thread M6

3.3.3 Mounting

The sensor is designed for mounting on an even surface of the intake manifold. The pressure joint and the temperature sensor reach into the manifold together and are sealed against atmosphere with an O-ring.

3 Sensors

KRONOS 20 15

Adequate mounting into the intake manifold (pressure taping point at the top of the manifold, joint bent downwards) must make sure that no condensate accumulates inside the pressure cell.

In addition, the sensor should neither be mounted too close to the throttle valve nor to the cylinder intakes.

3.3.4 ATEX Certification for Double Sensor P/T-S-01

The double sensor P/T-S-01 is ATEX-certified according to EN 60079-0:2004 (General requirements) and EN 60 079-15:2003 (type of protection "n"). If the sensor is used in such an ambient and require an ATEX certificate, the wiring of the sensor must be done by HEINZMANN too. In this case, HEINZMANN will attach the following sticker to the wire close to the sensor plug:

HEINZMANN GmbH & Co. KG Germanywww.heinzmann.de Tel.: +49 7673 8208-0

Type: P/T-S-01, II3G Ex nA II T4Tcable: -5°C to +80°C, Thousing: -40°C to +130°C

TÜV 07 ATEX 552892X

WARNING - EXPLOSION HAZARD - DO NOT DISCONNECT WHILE CIRCUIT

IS LIVE UNLESS AREA IS KNOWNTO BE NON-HAZARDOUS

Figure 6: Information Sign on Double Sensor Cable, Front and Back

3.4 λ Sensor LSM 11 for Exhaust Gas Measurement (optional)


Power supply for heating 12..13 V AC/DC

Current consumption 1.25 mA at 12 V

Signal output voltage 0..0.9 V DC

Permanent exhaust gas temperature +150°C to +600°C

Maximum exhaust gas temperature +800°C

Storage temperature -40°C to +100°C

Part-no.: Sensor 010-80-020-00 corresponding cable 600-81-054-00

3 Sensors

16 KRONOS 20

The sensor housing is connected to the negative pin of the sensor output. In unfavourable conditions, ground circuit loops may hap-pen that falsify the output signal considerably and thus disturb con-trol activity. This must be taken into account during commissioning. It may be necessary to optimize the wiring or to use a galvanic sepa-ration.

Warning

3 Sensors

KRONOS 20 17


12

22,6

M18x1,5

10,5

28,2

21,8

SW 22

66

2500

2300

73

Figure 7: Dimensional Drawing λ Sensor LSM 11

4 Control Unit KRONOS 20

18 KRONOS 20


4.1 Technical Data

4.1.1 General

Power supply 12 V DC or 24 V DC Min. voltage 10 V DC Max. voltage 32 V DC

Residual ripple max. 10 % maximum at 100 Hz

Current consumption max. 1 A

Admissible voltage drop at max. power consumption max. 10 % at control unit

Fuse 6 A

Storage temperature -40°C to +85°C Operating temperature -40°C to +80°C

Air humidity up to 98 % at 55 °C

Vibration max. 2 mm at 10..20 Hz max. 0.24 mm at 21..63 Hz max. 9 g at 64..2000 Hz

Shock 50 g, 11 ms, half sine


Isolation resistance > 1 MOhm at 48 V DC

Weight approx. 0.5 kg

EMC 89/336/EEC and 95/54/EEC


KRONOS 20 19

4.1.2 Inputs and Outputs

All inputs and outputs are reverse polarity protected and short-circuit-proof against bat-tery plus and minus.

Temperature input (terminal 4) for PT1000 / Ni1000 sensors Tolerances: < ±2°C at 0°C to 130°C, otherwise < ±4°C

Reference voltage for P-/T sensor Uref = 5 V ±1 %, Iref < 30 mA (terminal 6)

Closed loop input (terminal 7) U = 0..5 V, Re = 100 kΩ, fg = 15 Hz or I = 4..20 mA

Digital input (terminal 9) U0 < 2 V, U1 > 6.5 V, Rpd = 100 kΩ

Digital input engine stop U0 < 2 V, U1 > 6.0 V Rpd = 4.75 kΩ (terminal 11) or Rpu = 4.75 kΩ or Rpd = 150 kΩ

Speed input (terminal 13) for inductive sensors, with fi = 25 to 9000 Hz, Ui = 0.5 to 30 V AC

MAP pressure input (terminal 16) U = 0..5 V, Re = 100 kΩ, fg = 15 Hz

Control outputs for gas valve Isink < 0.3 A, Urest < 1.0 V, Ileak < 0.1 mA (terminals 1 and 2) Rpu = 4.75 kΩ or Rpu = ∞, low-side switching

Digital output error lamp Isink < 0.3 A, Urest < 1.0 V, Ileak < 0.1 mA (terminal 10) Rpu = 4.75 kΩ or Rpu = ∞, low-side switching

Serial interface ISO 9141, variable from 2.4 kbit/s to 57.6 kbit/s Standard 9.6 kbit/s

CAN bus (terminals H and L) HEINZMANN-CAN or customer specification


20 KRONOS 20

4.2 Dimensional Drawing

84,5

16 165

112

30

Am Haselbach 1D-79677 Schönau/GermanyPhone: +49 (7673) 8208-0Fax: +49 (7673) 8208-188

R

1918

T

1715

1413

1211

109

87

65

4H

L1

23

1620

21C

ANH

CAN

LP2

P10V

Tmp

0V+5V

SpA0V

SpDErr

Stp0V

Pu0V

FbCFbM

FbR0V

+Act--Batt+

GND

GND

GND

REF

GND

GND

MAP

GND

STOP/DI

+-

CANH

CANL

6A

Serial No.

Type-No.VPH2

PH1

MAT

CL-IN

45

118,5

5

40

KRO

NO

S 20-A

2221

2019

1716

1514

1312

1110

98

76

12

34

518

2324

closed loop version

Figure 8: Dimensional Drawing of Control Unit KRONOS 20 with Power Signal Input

The fastening element for top-hat-rail in the above drawing is available on re-quest.

Note


KRONOS 20 21

84,5

16 165

112

30

Am Haselbach 1D-79677 Schönau/GermanyPhone: +49 (7673) 8208-0Fax: +49 (7673) 8208-188

R

1918

T

1715

1413

1211

109

87

65

4H

L1

23

1620

21C

ANH

CAN

LP2

P10V

Tmp

0V+5V

SpA0V

SpDErr

Stp0V

Pu0V

FbCFbM

FbR0V

+Act--Batt+

GND

GND

GND

REF

GND

GND

MAP

GND

STOP/DI

+-

CANH

CANL

6A

Serial No.

Type-No.VPH2

PH1

MAT

CL-IN

45

118,5

5

40

KRO

NO

S 20-A

λ -sensorHeating 22

2120

1917

1615

1413

1211

109

87

61

23

45

1823

24

λ1 - closed loop version

Figure 9: Dimensional drawing of control unit KRONOS 20 with λ sensor input

The fastening element for top-hat rail in the above drawing is available on re-quest.

Note


22 KRONOS 20

4.3 Mounting Position

When the mounting position is chosen, attention should be paid to easy accessibility of the connection terminals and to the possibility of having to substitute the unit on site. Mount-ing position is optional. When the unit is mounted directly on the engine, it must be fas-tened to vibration dampeners.

The control unit is available with or without fastener for top-hat rail mounting.

5 Gas Valves E-LES

KRONOS 20 23

5 Gas Valves E-LES

5.1 Structure and Operating Principle

The stepping motor drives a spindle with external thread. The teflon-coated aluminium pis-ton with internal thread moves in line with the rotation of the spindle. The special thread-ing prevents play between spindle and piston threads. The piston moves within a coated bushing. This bushing features three exponentially shaped intake openings. This profile al-lows a gas flow change linear to the stepping motor position. Due to this design, only the forces of friction of the valve itself act on the piston. The shaft of the stepping motor is sealed against gas leakage.

The control electronics of the stepping motor is mounted directly onto the gas valve and is controlled by the KRONOS control unit with a special bit pattern via 2 digital outputs. This type of control in principle allows the use of different HEINZMANN control units for dif-ferent purposes.

Immediately after energizing the system or after a reset the stepping motor carries out a reference run towards stop to determine the zero position. This may take up to 8 seconds, depending on the system’s dimensions. The system is ready for operation only after the reference run is completed.

5 Gas Valves E-LES

24 KRONOS 20

5.2 Technical Data

All inputs and outputs are reverse polarity protected and short-circuit-proof against battery plus and minus.

5.2.1 Specifications for all E-LES Gas Valves

Power supply 12 V DC or 24 V DC Min. voltage 10 V DC Max. voltage 32 V DC

Residual ripple max. 10 % at 100 Hz

Current consumption max. 1.5 A

Admissible voltage drop max. 10 % at max. power consumption

Fuse 6 A

Stepping motor frequency 500 Hz

Storage temperature -40°C to +85°C Ambient temperature during operating -20°C to +80°C

Air humidity up to 98 % at 55°C

Admissible pressure of fuel supply max. 0.1 bar

Admissible concentration of

hydrogen sulphide (H2S) in fuel max. 0.1 %

Vibration max. 2 m/s at 10..20 Hz max. 0.24 m/s at 21..63 Hz max. 9 g at 64..2000 Hz

Shock 50 g, 11 ms, half sine


EMC 89/336/EEC and 95/54/EEC

Connection DIN 45321; 7 pin male

Gas valves E-LES might only be used as control valves! Never use as shut-off valve!

Warning

5 Gas Valves E-LES

KRONOS 20 25

5.2.2 Additional Specifications for Gas Valve E-LES 30

Valve resolution 1200 steps at 6 revolutions

Positioning time for 0..100% 2.5 seconds

Weight approx. 1 kg



Positioning time for 0..100% 4 seconds

Weight approx. 1.8 kg


Min. voltage 18 V DC


Positioning time for 0..100% 8 seconds

Weight approx. 12 kg

5 Gas Valves E-LES

26 KRONOS 20

5.3 Dimensional Drawings

60

1

2

34

5

6

7

GND

+UB

Ph1

Ph2

M5

M5 M5 M5

4832

138

48

48

94

324860

42,5

10

DO NOT DISCONNECT WHILE CIRCUIT IS LIVE UNLESS AREA IS KNOWN TO

BE NON-HAZARDOUS!

WARNING - EXPLOSION HAZARD

BEFORE REMOVING THE COVER, SWITCH OFF THE POWER SUPPLYAND WAIT AT MINIMUM 5 SECONDSTO DISCHARGE THE ENERGY OF

THE CAPACITIES!

Figure 10: Dimensional Drawing E-LES 30

5 Gas Valves E-LES

KRONOS 20 27

1

2

34

5

6

7

GND

138

114

71,5

46,5

75

62,5

32,5

80

85DIN 2999-R2

48,5

221

58,5 62,5

25

+UB

Ph1

Ph2

DIN

299

9-R

p2


5 Gas Valves E-LES

28 KRONOS 20

1

2

34

5

6

7

GND

+UB

Ph1

Ph2

80 200

336 10

5

125

130

76

226

Connection flange fitting to welding-neck flange accordingto DIN 2633 PN 16 DN 80


5 Gas Valves E-LES

KRONOS 20 29

5.4 Mounting

The gas fittings of E-LES 50 have 2" B.S.P. threads. The gas valve may therefore option-ally be screwed directly onto the gas mixer. The used standard pipe threads allow easy connection to all common gas pipes. To reduce vibration it is recommended to mount the gas valve at the end of the gas piping and to connect it to the gas mixer with a flexible tube. The passage between gas piping and gas mixer must always be flexible.

The axial connection of the valve is usually used as gas inlet, the radial connection as gas outlet.

The type E-LES 80 features connection flanges as shown in the above drawing. They cor-respond to standard flanges, as they are common for pipe diameters greater than 2".

The type E-LES 30 also has flange fastenings. They can be extended with threaded flanges.

To safeguard error-free and low-wear operation, a gas filter with maximum mesh of 50 µm must be installed in the gas piping.

All work on the valves must be carried out exclusively by trained per-sonnel and in conformity with current standards and requirements.

The mounting position must be chosen in a way to avoid vibration and pulsation as much as possible.

In addition, the valve’s mounting position must be chosen depending on the protection type.

In general, mounting position is optional. But it should be avoided to mount the valves up-side down with the step motor directed downward. If this mounting position should be necessary consult HEINZMANN.

The gas valve must be equipped with sufficient equipotential bonding. On the gas valve a screw with M6 thread is provided for the this kind of connection.

5.5 ATEX Certification of E-LES… Gas Valves

E-LES gas valves are ATEX certified according to EN 50021:1999, type of protection "n". If the gas valves are used in such a context and require an ATEX certificate, the wiring of the gas valve must be done and delivered by HEINZMANN too.

The inside of the gas-containing parts has not been taken into account for the ATEX valuation.

On the housing of the E-LES gas valves two stickers have been applied. An additional warning sign has been applied to the cover of the stepping motor control.

Warning

Note

5 Gas Valves E-LES

30 KRONOS 20

Sign 1 shows the general and ATEX-relevant information.

HEINZMANN GmbH & Co. KGGermany Tel.: +49 7673 8208-0

www.heinzmann.com

II3G EEx nA II T4Tamb: -20°C to +80°CTÜV 07 ATEX xxxxxx

Figure 13: Sign bearing general and ATEX-relevant Information

Sign 2 bears the exact type designation and serial number.

Type: z.B. E-LES 50Serial No: yy mm xxxx-zz

Figure 14: Sign with Type Designation and Serial Number

Sign 3 on the control cover contains warnings about disconnecting the plug and re-moving the cover.

DO NOT DISCONNECT WHILE CIRCUIT IS LIVE UNLESS AREA IS KNOWN TO

BE NON-HAZARDOUS!

WARNING - EXPLOSION HAZARD

BEFORE REMOVING THE COVER, SWITCH OFF THE POWER SUPPLYAND WAIT AT MINIMUM 5 SECONDS

TO DISCHARGE THE ENERGY OF THE CAPACITIES!

Figure 15: Warning Sign on E-LES Stepping Motor Control Cover

6 Electric Connection

KRONOS 20 31


All wiring must be carried out exclusively by trained personnel and in conformity with current norms and regulations.

The electric connection must be done in accordance with the wiring diagrams provided by HEINZMANN and by the plant builder. Only specified cable types may be used for wiring. All indicated cable cross-sections must be adhered to at all costs.

The control valve is controlled by a HEINZMANN control unit. In special cases the control valve may be connected to a third party control unit of the plant builder. In this case an express authorization by HEINZMANN is required. The specification provided by HEINZMANN must be adhered at all costs.

Warning

Warning


32 KRONOS 20

6.1 Wiring Diagrams

6.1.1 Wiring Diagram for KRONOS 20 with open Loop

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

12/24 V

21

56

KRONOS 20

E-LES

Electronicallycontrolled MAS

Battery

Fuse6 A

Governoron

Control Unit

Engine Stop

Common Alarm

34

73

2

41

Boost Pressure Sensor

Temperature Sensor

AB

Magnetic Pickup IA ..

542 3

T x DR x D

24V0V

Connection toProgrammer

or PC

1

SUB-D plug 9-pole

T

H L

Figure 16: Wiring Diagram for KRONOS 20 with open Loop


KRONOS 20 33

6.1.2 Wiring Diagram for KRONOS 20 with closed Loop (power signal, CH4 signal)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

12/24 V

21

56

KRONOS 20

E-LES


Battery

Fuse6 A

Governoron

Control Unit

Engine Stop

Common Alarm

34

73

2

41


Temperature Sensor

AB


Load Signalor CH4-Signal

542 3

T x DR x D

24V0V


or PC

1

SUB-D plug 9-pole

21

T

H L

Figure 17: Wiring Diagram for KRONOS 20 with closed Loop


34 KRONOS 20

6.1.3 Wiring Diagram for KRONOS 20 with λ-Sensor Signal

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

12/24 V

21

56

KRONOS 20

E-LES


Battery

Fuse6 A

Governoron

Control Unit

Engine Stop

Summenalarm

34

73

2

41


Temperature Sensor

AB


Lambda-Signal

542 3

T x DR x D

24V0V


or PC

1

SUB-D plug 9-pole

black +grey -

T

H L

whitewhite

Heater forLambda-Sensor

Figure 18: Wiring Diagram for KRONOS 20 with closed Loop and λ-Sensor Signal


KRONOS 20 35

6.2 Cable Harness

W1

Battery

E-LES

Temperature- / Pressure Sensor

Magnetic Pickup

Closed Loop Input

Digital Inputs

Error Indicators

Communication

W2

W3

W4

W6

W7

W10

+ -

M

Control Unit

KRONOS 20

W5

Figure 19: Cable designations

W 1 power supply max. length 15 m 2 x 1.50 mm²

W 2 gas valve control max. length 15 m 4 x 0.75 mm²

W 3 pressure / temperature sensor max. length 15 m 4 x 0.75 mm²

W 4 speed pickup 2 x 0.75 mm²

W 5 actual power signal or λ-sensor signal max. length 15 m 2/4 x 0.75 mm²

W 6 motor stop switch 1 x 0.75 mm² (the switch must be powered with +24V)

W 7 error message 1 x 0.75 mm² (the switch must be powered with +24V)

W 10 communication max. 20 m (at 9600 baud) 4 x 0.14 mm²


36 KRONOS 20

6.3 Enclosed Cables

The following cables will be provided by HEINZMANN in the required length.

6.3.1 Cable W2 to Gas Valve E-LES

1

2

34

5

6

7

GND

+UB

Ph1

Ph2Le

ngth

on

requ

est (

max

. 15

m)

Housing21

2120 1

245

Ground+UB

Phase 2Phase 1Screen

browngreenyellowwhite

Terminal Plug Pin Function ColourTerminal Assignment of Cable

Figure 20: Cable W2


KRONOS 20 37

6.3.2 Cable W3 to Pressure / Temperature Sensor P/T-S-01

Leng

th o

n re

ques

t (m

ax. 1

5 m

)

Housing1664

15 1234

GroundNTC Signal

+ 5VPressure Signal

Screen

brownwhitegreenyellow

Terminal Plug Pin Function ColourTerminal Assignment of Cable

Figure 21: Cable W3


38 KRONOS 20

6.3.3 Cable W4 to Speed Pickup IA…

Leng

th o

n re

ques

t (m

ax. 1

5 m

)

Housing1312 A

B SignalGround

Screen

12

Terminal Plug Pin Function No.Terminal Assignment of Cable

Figure 22: Cable W4


KRONOS 20 39

6.3.4 Cable W5 to λ-Sensor LSM 11

191887 Sensor +

Sensor -HeaterHeater

yellowgreenwhiteblack

Terminal Function ColourTerminal Assignment of Cable

yellow white brown

A

A

green

Leng

th o

n re

ques

t (m

ax. 1

5 m

)

150

60

Figure 23: Cable W5 for λ-Control

HEINZMANN®

Fehler! Verweisquelle konnte nicht gefunden werden. Fehler! Verweisquelle konnte nicht gefunden werden.

40 KRONOS 20

7 Parameter Settings for Control Unit KRONOS 20 The software for the HEINZMANN digital controllers conceived so that parametrizing can be done either by the engine manufacturer or by the final customer if the necessary instruments (communications tool) are available. Only a few basic parameters are pre-set in the HEINZMANN factory. This means that the digital governor usually gets its definitive set of data from a source external to HEINZMANN.

An exception is made for control units delivered in greater numbers. If HEINZMANN has been provided in advance with a definitive set of data, this data can be trasferred to the units in the factory.

As a principle, initial programming should always be conducted by experienced personnel and must be checked before first commissioning the engine.

How parameter are adjusted and what meaning they have is explained in detail in the manual "Basic information 2000".

The following sections describe the possibilities of parametrizing the control unit:

7.1 Parametrization with the Hand Held Programmer 3

All parametrization can be done by means of the hand held programmer ‘Programmer 3’. This handy device is particularly suited for development and series calibration as well as for servicing. This unit needs no external power supply.

7.2 Parametrization with the PC / Laptop

Parametrization can also be conducted using a PC and the comfortable HEINZMANN communication software DcDesk 2000. As compared with the hand held programmer, it offers the great advantage of having various curves graphically represented on the screen and being at the same time able to introduce changes as well as of having time diagrams displayed without an oscilloscope when commissioning the control unit on the engine. Fur-thermore, the PC offers a better overview as the PC programme has a menu structure and allows to have several parameters continuously displayed.

Besides, the PC programme permits to save and download the operational data to and from data mediums. Additional there is the following usefull application:

Once parameterization has been completed for a specific engine type and its application, the data set can be stored to disk. For future applications of similar type, the data sets can be downloaded and re-used with the new control units.

KRONOS 20 41

8 General Mounting Instructions All components must be mounted in a vibration-free manner.

All screws must be tightened.

All components must be connected to equipotential bonding.

All components must be installed only in the allowed areas.

All components must be installed in a way to protect their connectors from impact damage.

The inside of the components (gas containing parts) is not part of the ATEX speci-fication.

Note

9 Commissioning

42 KRONOS 20

9 Commissioning

9.1 General Safety Information for Commissioning

All commissioning tasks must be carried out exclusively by trained per-sonnel and in conformity with current standards and regulations.

The operator is also responsible for putting the technical installation as a whole into opera-tion correctly.

Before commissioning the installation, please note:

• Before starting to install any equipment, the installation must have been switched off!

• Check the function ability of the existing protection and monitoring systems.

The system may be put into operation only if the terminal box cover is mounted.

9.2 General Information on the first Engine Start

• Adjust speed pickup distance according to the instructions.

• Verify that the software is correct and the main parameters: engine data, number of teeth, mixer data, gas valve data, sensor data, gas data, lambda data etc.!

• If required, adjust sensors.

• Before the engine is started, test the electric connections and the basic functioning of the system in positioning mode (parameters 5705 and 5706)!

• It is recommended to begin by starting the engine first without connecting a control unit.

Ensure adequate overspeed protection!

• Start the engine after pre-setting according to the description below.

• Optimization of lambda map and correction values as described below.

Knock protection must be active or attention must be paid to audible knocking.

Warning

Warning

Danger

9 Commissioning

KRONOS 20 43

9.3 Commissioning for OPEN LOOP (open control circuit)

In order to obtain a satisfactory control behaviour of the AFR system in an open control circuit the set lambda values must not necessarily be equal to the actual measured values. The same holds true for other values, such as calculated gas flow and pressure in relation to the respective measured values. The control quality of the open loop system as a whole is not prejudiced by these differences. Example: If there is no measuring device for lambda measuring but a measuring device for the adjustment of NOx content in the exhaust gas is available instead, the commissioning personnel does not need to know the actual lambda value in order to carry out a satisfactory adjustment of the system.

Still in Open Loop too, it is advisable to carry out the correct adjustment of the AFR sys-tem if the required devices are available. The clear structures of the respectively relevant parameters allows an easy and understandable commissioning and fine-tuning and reduces errors.

For a correct diagnosis, state monitoring and for the operation with a closed loop a com-plete calibration is necessary. The actual measured values must correspond to the variables and set values of the mixture control. For this calibration the following devices are re-quired:

• A universal lambda sensor or an oxygen analyzer for exhaust gas in connection with a valid conversion table from O2 % to lambda.

• A gas flowmeter for the measurement of nm3/h (standardized measurement at 1013.25 mbar and 0° C). If gas quality and engine efficiency are known, the produced electric power may be used instead to approximately determine gas flow. Qgas [nm3/h] = (power [kW] x 3600)/(ηset x Hu[kJ/nm3]).

After the parameters have been determined and set, the engine may be started and load ap-plied gradually. In order to avoid misfiring, ingnition failures and knocking and to adjust the desired NOx value, continuous corrections of the set lambda value in dependence of load and speed are necessary.

Adequate adjustment of the zero pressure regulator is particularly important during start-up! Pressure offset should not normally be higher than + 2..3 mbar to ensure a safe engine start. Experience shows that this is where errors frequently happen.

After engine warm-up the AFR control must be verified in open loop (5400 ClosedOrO-penLoop=0) and with different load-points according to the following procedure:

9 Commissioning

44 KRONOS 20

A) The desired lambda value must correspond roughly to the measured lambda value (calibration of 1424 VenturiEfficiency)

Due to variations in the engine and the gas train the venturi suction pressure not always generates the same gas flow in relation to air flow. The measured lambda value therefore not always corresponds to the set lambda value, although the mixture in not too rich or too lean for the engine. The adjustment should be carried out with an upper load point.

If λmea (measured value) = λdes (3462 LambdaDesiredValue), (within ± 2 %), then continue with B) If λmea < λdes then: 1. Increase ηvent (1424 VenturiEfficiency) until λmea = λdes or until the engine misfires or

the engine power drops. 2. λmea increases (engine runs on leaner mixture). Example: was λmea =1.70 and now

changes to λmea =1.75 3. Change λset (7400-7599 LambdaMap) in the respective load/speed point. Example:

was λset = 1.75 and is now changed to λset = 1.70 4. Verify the lambda values 5. If λmea < λdes repeat steps 1 to 4 When λmea > λdes then: 1. Reduce ηvent (1424 VenturiEfficiency) until λmea = λdes or to the lower ignition limit.

Attention, danger of knocking! 2. λmea is reduced (engine runs on richer mixture). Example: was λmea=1.70 and now

changes to λmea=1.65 3. Change λset (7400-7599 LambdaMap) in the respective load/speed point. Example:

was λset =1.65 and now is changed to λset = 1.70 4. Verify the lambda values 5. If λmea > λdes repeat steps 1 to 4

B) Measured gas flow must correspond roughly to calculated gas flow (calibration of 9420 - 9483 VolEffMap or 1412 VolEfficiencyConst)

Depending on different engine settings and operational conditions, volumetric efficiency and therefore the calculated mixture flow may vary. This may lead to a difference between the effective and the calculated gas flow. There is a fixed relation between calculated mix-ture flow and calculated gas flow. This relation is based on the gas data and the desired lambda. The calibration is started with rated power and repeated at three other load points. It is advisable to calibrate the map.

9 Commissioning

KRONOS 20 45

If Qgasmea (measured value) = Qgascal (3453 GasFlowRateDesired), (within ± 2 %), then continue with C) If Qgasmea < Qgascal then: 1. Reduce ηvol (9420 - 9483 VolEffMap or 1412 VolEfficiencyConst) at the current load

and speed point of the map until Qgascal = Qgasmea. If Qgasmea < Qgascal then: 1. Increase ηvol (9420 - 9483 VolEffMap or 1412 VolEfficiencyConst) at the current load

and speed point of the map until Qgascal = Qgasmea

2. Repeat this calibration for the other three load points, e.g., 80 %, 60 % and 40 % load.

3. Interpolate the missing values in the volumetric efficiency map (9420 - 9483 VolEff-Map) at rated speed and verify and, if necessary, calibrate the values at other speeds.

By changing Venturi efficiency (A) or volumetric efficiency (B) the quantity and the mix-ing ratio of the gas mixture have been calibrated.

9.4 Further Commissioning for CLOSED LOOP (closed control circuit) with Output Power

In order to obtain a good regulation of the mixture control in a closed control circuit the desired lambda values (λdes (3462 LambdaDesiredValue)) must not necessarily correspond to the actual measured values (λcal (3463 LambdaActualValue)). Variations up to ± 20 % are acceptable. This is also true for other values, such as calculated gas flow rate (Qgascal (3453 GasFlowRateDesired)), calculated generator power (Pcal (3411 Calculated-Power)) and mechanical generator efficiency (ηset (9500-9583 MechEffMap or 1413 MechEfficiencyConst)) in relation to the respective measured values. The quality of the open loop and of the closed loop systems as a whole is not prejudiced by these differences. Example: If no measuring device is available for measuring the λ value, but measuring de-vices for the adjustment of NOx emissions and/or oxygen content ratio are available in-stead, a satisfactory adjustment of the system is possible without knowing the effective λ value.

The parameter values pre-set by HEINZMANN usually lead to a satisfactory control result both for open loop and for closed loop and constitute a good starting point for fine tuning.

C) Measured generator output power must correspond roughly to effective genera-tor output (calibration of 2914 MeasuredPower)

If Pmea (measured value) = Pact (2914 MeasuredPower), (within ± 2 %), then continue with D)

9 Commissioning

46 KRONOS 20

If the variation is greater: change the reference values (988 MeasPowerSensorLow and 989 MeasPowerSensorHigh) of the power sensor input signal at different loads so that Pmea = Pact

D) The calculated lambda value must correspond roughly to the desired lambda

value (calibration of 9500 - 9583 MechEffMap or 1413 MechEfficiencyConst)

If λcal (3463 LambdaActualValue) = λdes (3462 LambdaDesiredValue), (within ± 1 %), then continue with E) When λcal < λdes then: 1a. Increase ηset (9500 - 9583 MechEffMap or 1413 MechEfficiencyConst) at the according

load point in the generator efficiency table until λcal = λdes

When λcal > λdes then: 1b. Decrease ηset (9500 - 9583 MechEffMap or 1413 MechEfficiencyConst) at the accord-

ing load point in the efficiency table (engine with generator) until λcal = λdes

2. Repeat this calibration for the other three load points, e.g., 80 %, 60 % and 40 % load.

3. When “Closed Loop” is active, the system switches automatically to “Open Loop” as soon as output is inferior to e.g. 40 % (depending on 1400 ClosedLpPowerMinRate).

4. Increase load until rated output is reached. For all loadpoints λcal = λdes = λmea should hold true.

5. Measured exhaust gas values should correspond to desired exhaust gas values for all loads. Corrections must be made in the λ table.

6. If this is the case, the AFR control is now ready to be switched in Closed Loop opera-tion (5400 ClosedOrOpenLoop).

E) Verification of the closed control circuit

1. Verify the adjustment of I-parameter for Closed Loop Control (1401 ClosedLoop-Gov:I) and, if necessary, change the value to obtain the desired control characteristics and stability. Observe that the speed of the AFR control is approx. 25 times slower than the speed of the speed control circuit.

2. Switch on Closed Loop Mode (5400 ClosedOrOpenLoop = 1).

3. Mark the position of the adjustment spindle of the zero governor.

9 Commissioning

KRONOS 20 47

4. Count the number of counter-clockwise revolutions required to achieve gas output pressure drop. The mixture change resulting from this forced disturbance should lead to a leaner operation and the closed loop should then correct this effect.

5. Go back to the starting point.

6. Turn a few clockwise revolutions to repeat the test for a richer mixture.

7. Go back to the original position of the zero governor adjustment spindle.

8. A further disturbance can be brought about by opening the compensating line.

9. Working with a biogas plant or landfill gas plant, ask the plant operator to change gas composition in order to check the dimensioning of the fuel system (control reserve) and the control system (correction quality).

9.5 Further commissioning for CLOSED LOOP with λ1 control (KRONOS 20 version with λ1 sensor)

General:

Commissioning of λ1 control is carried out in two steps:

- adjustments for open loop

- adjustments for closed loop

Open loop operation is active when the engine starts, as long as the lambda sensor is not ready for operation yet, when the sensor has failed or if closed loop operation has not been activated yet (5400 ClosedOrOpenLoop). During calibration of the open loop, closed loop operation may not be active.

Correct calibration in open loop guarantees that closed loop operation achieves an ap-proximate λ1 ratio straight away and the corrections for closed loop remain small under all operating conditions. This allows a good starting behaviour and, due to the relatively small lambda trim values (3464 LambdaTrim Value), also a good dynamic behaviour in closed loop. In addition, the trim value range may be limited to a small range (1464 LambdaT-rimValueLimit). This avoids major variations in case the sensor fails.

In closed loop, fine tuning is done by a pre-setting a default control voltage for the λ sensor within the voltage jump range. For λ1 this value is usually set between 0.1 and 0.7 Volt. This procedure allows a very precise lambda control

Settings for open loop:

1. First, disable (5400 ClosedOrOpenLoop). Verify the load and speed dependent λ adjustment values (7400-7599 LambdaMap). To begin with, all map values should be set to 1 (this table serves only for later correction purposes here).

9 Commissioning

48 KRONOS 20

2. Verify other important parameter settings for engine, mixer and gas data before start-ing the engine.

3. Start the engine with the pre-set parameters in open loop mode.

4. Check the voltage signal of the lambda sensor after the start (2915 LamdaProbe). Voltage should have dropped below 1 Volt within 40 seconds (cold start test of sen-sor).

5. Calibration of Venturi efficiency (1424 VenturiEfficiency):

Run the engine in a range of 50 – 100 % load and increase or reduce Venturi effi-ciency until the voltage signal of the lambda sensor (2915 LambdaProbe) is in a range between 0.1 and 0.7 Volt (measured lambda is approx. 1).

6. Calibration of lambda map for other operating points:

Change load in several steps between 0 and 100 % and set the respective map values (for speed and intake manifold pressure) so that they result in a voltage signal of the lambda sensor (2915 LambdaProbe) between 0.1 and 0.7 V (measured lambda is approx. 1). Repeat these settings for low and high idle speed.

7. To achieve optimal starting behaviour, the respective map values for the motor start range (pressure is 1 bar at low speed) are corrected in order to have the engine starting correctly in all conditions. Please note that the neighbouring values must be adapted accordingly.

8. Now the effective lambda value at all loads is always approximately 1. Verify the set-ting for several operating points.

Settings for closed loop:

1. Check (1464 LambdaTrimValueLimit) to adjust the control range. Start with ±0.05.

2. Enable the closed loop with (5400 ClosedOrOpenLoop = 1).

3. Operate the engine with varying loads and observe the exhaust gas values. Set (1471 LambdaProbeSetPoint) for lambda fine tuning so as be within the required exhaust gas value range.

4. Check the measured value parameter (3664 LambdaTrimValue) over the complete load range. Note that this value is limited by (1464 LambdaTrimValueLimit). To achieve a sufficiently ample control range (1464 LambdaTrimValueLimit) must be set to a correspondingly high value. On the other hand, it should guaranteed that in case of sensor failure the engine still runs within a safe range.

5. To conclude, check the open loop settings once more.

10 Misfire Detection (optional)

KRONOS 20 49


10.1 General

Misfire detection is available as an optional function in KRONOS 20. It is based on the ob-servation of the speed variation caused by each ignition. Since only speed and power sig-nals are used, no additional sensor is required.

When (4050 SpeedVarDetectOn) is active, the control unit calculates a value for speed variance on the basis of (2000 Speed) and the sampling value (50 SpeedVarSampleSize) while the engine is running and indicates it as (2050 SpeedVariance). The value changes if single cylinders misfire. Since speed change is load-dependent even if the engine ignites correctly, for the error message both a warning and a shutdown characteristic are defined, both of which are load-dependent.

To determine the parameters for Misfire Monitoring, single cylinders must be switched off on the engine test stand and the sampling value (50 SpeedVarSampleSize) must be deter-mined in relation to (2050 SpeedVariance).

10.2 Putting into Operation

1. Let the engine run at rated speed and rated load under normal conditions. All cylinders must ignite correctly. The function (4050 SpeedVarDetectOn) must be active and the functions (4055 MisfireWarnCurveOn) and (4056 MisfireEcyCurveOn) must be dis-abled.

2. Raise parameter (50 SpeedVarSampleSize) step by step from 3 to max. 20. Record the value of (2050 SpeedVariance) for each step.

3. Switch off one cylinder, maintaining the load as far as possible.

4. Repeat step 2 for this load and this switched-off cylinder. In doing so, optimize the fil-ter constant (51 SpeedVarFilterConst) used for determining (2050 SpeedVariance). The value of (2050 SpeedVariance) must increase as much as possible in comparison to normal conditions to achieve maximum sensitivity.

5. Record the value of (50 SpeedVarSampleSize) for which the relative increase of (2050 SpeedVariance) is highest. The best sensibility is found when the relation between (2050 SpeedVariance) and misfiring and normal ignition is highest.

6. Now determine parameter (50 SpeedVarSampleSize) for the other switched-off cylin-ders and, if required, for different loads by repeating steps 2 to 5.

7. Choose the value of parameter (50 SpeedVarSampleSize) which yields the clearest relative variation in (2050 SpeedVariance) under all conditions and represents the best compromise for the measurements taken under different loads and with different inac-tive cylinders.


50 KRONOS 20

Filtering of speed signals for misfire monitoring must always be done over two crankshaft rotations.

To determine the thresholds for monitoring and error messages proceed as follows:

1. Using the identified value for (50 SpeedVarSampleSize), run the engine to several load points both under normal conditions and with selected cylinders switched-off. Two different load-dependent curves for (2050 SpeedVariance) result, one representing the "good" and the other the "bad" operating conditions. Pay attention that the curves dif-fer noticeably from each other at all chosen load points.

2. Record the load value in (6000 MisfireWarn:P(x)) and (6020 MisfireEcy:P(x)). Draw the warning characteristic and shutoff characteristic between the two limit characteris-tics and record the respective values in (6010 MisfireWarn:nVar(x)) and (6030 Mis-fireEcy:nVar(x)). Enable the functions (4055 MisfireWarnCurveOn) and/or (4056 Mis-fireEcyCurveOn).

3. Determine the delay times for (55 MisfireWarnDelay) and (56 MisfireEcyDelay). Only when the current value of (2050 SpeedVariance) has exceeded the warning and/or the shutoff characteristic for at least the respective time indicated the errors (3046 ErrMis-fireWarn) / (3047 ErrMisfireEcy) are triggered. When the value of (2050 SpeedVari-ance) falls below the load-dependent trigger level by relative 15 % the error (3046 ErrMisfireWarns) is cleared. The emergency shutoff signal (3047 ErrMisfireEcy) on the other hand can be cleared only by a reset or by an error clearing through a commu-nication module or switch function.

Note

11 Operation

KRONOS 20 51

11 Operation The system must be operated in a way to reliably exclude damage of any type.

In particular, the system may be operated only within the electrical and technical ranges indi-cated in the specification.

Correct operation, damages and wear of all components should be checked regularly.

Concentration of hydrogen sulphide (H2S) in fuel must not exceed 0.1 %!

The gas must be dry!

When using biogasis used as fuel, gas bearing components and sections of the system must be inspected twice a year!

To high residual concentration of hydrogen sulphide (H2S)or too much residual humidity may cause corrosive effects that might block mechani-cal componets. This might result in overspeed and serious damage to the engine!

Gas valves E-LES might only be used as control valves! Never use as shut-off valve!

Warning

12 Maintenance and Service

52 KRONOS 20

12 Maintenance and Service

Repairs of HEINZMANN devices must always be carried out at the manu-facturer’s factory.

Always switch off the power before cleaning the system.

The KRONOS 20 system is designed to require no maintenance and needs no specific upkeep actions. Still, the state of all components such as cables, connectors, sensors and gas valves must be checked regularly for damages, wear and correct functioning. In particular, for opera-tion under normal strain conditions it is recommended to check that the gas valve once a year at least. When using aggressive fuels valves should be checked more frequent. Check whether the valve runs smooth when turning the handwheel while the engine is still.

The state of pistons and cylinder face should additionally be checked with dismounted valve. If strain is heavier, for instance due to vibration or dirt, the test must be carried out corre-spondingly more often. If the valve is noticeably worn out, the complete gas valve must be replaced.

The control valve must be in perfect exterior condition. Its surface may not be impaired me-chanically or by chemical substances. The surface must be kept from getting dirty also in or-der to avoid heat accumulation.

Only cleaning procedures allowed for the respective protection type may be used.

The devices may in no case be opened by the customer.

Warning

Warning

Danger

13 Error Handling

KRONOS 20 53

13 Error Handling

13.1 General

The HEINZMANN Digital Controls of the KRONOS 20 series include an integrated error monitoring system by which errors caused by sensors, speed pickups, etc., may be detected and reported. By means of a permanently assigned digital output the error types can be output via some visual signal.

The different errors can be viewed by the parameters 3001..3094. A currently set error pa-rameter will read the value “1”, otherwise the value “0”.

Generally, the following errors types can be distinguished:

Errors in configuring the control and adjusting the parameters These errors are caused by erroneous input on the part of the user and cannot be in-tercepted by the HEINZMANN diagnosis tool. They do not occur with controls from series production.

Errors occuring during operation These errors are the most significant ones when using governors produced in series. Errors such as failure of the speed pickups, setpoint adjusters, pressure and tem-perature sensor or logical errors such out of tolerance conditions.

Internal computational errors of the control These errors may be due to defective components or other inadmissible operating conditions. Under normal circumstances, they are not likely to occur.

To cancel an error one should first establish and eliminate its cause before clearing any of the current errors. Some errors are cleared automatically as soon as the failure cause has been eliminated. Errors can be cleared by means of the PC, by the Hand Held Programmer or, if accordingly configured, by the digital input 2828 SwitchErrorReset. If the system does not stop reporting an error, the search for its cause must go on.

Principally, the control starts operating on the assumption that there is no error and will only then begin to check for possible occurrences of errors. This implies that the control can be put into an error free state by a Reset of Control Unit, but will immediately begin to report any errors that are currently active.

13.2 Categories of Errors und Emergency Operation after System Failure

There are two categories of errors. One category comprises errors that permit of maintain-ing engine operation though functionality will in some cases be restricted (e.g., warnings, sensor failures for pressure, temperature, output power). A parametrized substitute value for the failed sensor can be set and will influence the behaviour of the emergency opera-tion.

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54 KRONOS 20

The other category consists of what are called fatal errors that will cause a emergency shutdown of the engine (e.g., overspeeding, failure of both speed pickups) or a emergency operation. Has a fatal error occured the system tries to set the gas valve to a parametrized fixed position or to keep the actual valve position. In this case the emergency operation mode is equivalent to a mechanical system using a main adjusting screw

The parametrization of the system behaviour at the occurrence of fatal errors is made by:

319 StepperPosSubst Substitute value for valve position

4319 SubstOrLastStepprPos = 1 Substitute value will be used or

4319 SubstOrLastStepprPos = 0 last valve position will be kept

The emergency shutdown of the engine can be achieved by setting the substitute value for valve position to „0“ and using this position on occurrence of error.

These error categories are sigalled by the following tow parameters

3800 EmergencyAlarm Emergency alarm

3801 CommonAlarm Common alarm

The parameter 3801 CommonAlarm will be set on the occurrence of any error, 3800 Emer-gencyAlarm only for fatal errors Thus, 3800 EmergencyAlarm will never occur alone by it-self.

For the further external use or visualization of the failure status the value of the common alarm is permanently assigned to Pin 10 of the control unit.

As to the common alarm, there also exists the option to make the output blink at a fre-quency of 1 Hz for identifying warnings. For this purpose, the parameter

5101 CommAlarmWarnFlashOn = 1

is to be set. As soon as any true error (no warning) is coming in, he common alarm will be continuously active.

The common alarm output can also be configured such that the output is reset for 0.5 seconds on the occurrence of any new error. An SPS connected to the output will thus be able to detect the new error. For this configuration, the parameter

5102 CommonAlarmResetOn = 1

should be set and the above function disabled (5101 CommAlarmWarnFlashOn = 0).

13 Error Handling

KRONOS 20 55

13.3 Error Memories

When the control is powered down it will lose any existing information on actual errors. In order to be able to check upon which errors have occurred, a permanent error memory has been incorporated in the control. Any errors that have occurred at least once will be stored there, the order and the time of their occurrence, however, will be ignored.

For every error the extended error memory of the KRONOS 20 stores the number of occur-rence since last reset. Further the the date of the first and the last occurrence of the error is stored in the control unit. The date is related to the operating hour meter which represents the engine running time

3871 OperatingHourMeter hours of engine-hour indicator and

3872 OperatingSecondMeter seconds of engine-hour indicator

An error occuring from time to time and disappearing immediately will be recorded in the control unit only once per second. For that the engine must be running otherwise the sec-onds of the operating hour meter are not changing.

In addition to the time of occurring of a failure further values will be recorded as failure condition data. As a standard the following four measurements at the time of occurring the failure will be stored

2000 Speed Current speed value

2302 StepperPos Position of stepper motor

2912 ManifoldPressure Manifold pressure

2913 ManifoldTemp Manifold temperature

The failure condition data can be parametrised. Find further information in the documenta-tion of the Windows®-Programms DcDesk 2000.

The status of the permanent error counter can be seen from the parameter numbers 3101..3194. The corresponding error counter parameter to each failure is defined as failure parameter number +100. The related time stamp and failure condition data can be read out only by special commands of the diagnisis tool DcDesk 2000 or the hand programmer.

The permanent error memory can be cleared by means of the PC or the Hand Programmer only. After clearance, the control will revert to accumulating any occurring errors in the empty error memory.

When the parameter 5100 NoStoreSerrOn is set to “1” and the error memory is then cleared, no errors will be stored in the error memory before the next re-set of the control unit. This feature is to provide the possibility of shipping a control with customer specific data in an error-free state without having to stimulate the inputs with the correct values. The parameter 5100 itself cannot be stored.

Note

13 Error Handling

56 KRONOS 20

13.4 Bootloader

The HEINZMANN Digital Controls include what is called a bootloader. This programme section is stored at a specific location of the read-only memory (ROM) and is programmed once for all at the factory. The bootloader cannot be cleared except by means of special devices.

On starting the control programme by powering it up or by a reset, the bootloader pro-gramme is always executed first. This programme performs various relevant tests telling whether the actual control programme is or is not operable. Based on these tests the boot-loader decides whether further programme execution can be handed on to the control pro-gramme or whether execution must remain confined to the bootloader to preclude any risk of personal injury or damage to the engine.

As long as the programme is in bootloader mode, KRONOS 20 cannot start to work. The entire bootloader tests and the subsequent initialization of the main programme will take about 300 ms..

13.4.1 Bootloader-Start Tests

The following section describes which tests are performed by the bootloader and which measures may have to be taken. As long as these test are being conducted, there will be no communication with the device, especially when due to some fatal error the pro-gramme is caught in an infinite loop. For this reason, the current test mode is indicated using the error output. The output is toggled to get an indication about the current test.

Watchdog-Test This is to check whether the watchdog integrated into the processor is operable. This is to ensure that in case of an undefined programme execution the control will go into a safe state after a pre-defined time. If the outcome of the watchdog test is negative, the bootloader programme will remain in an endless loop, and the above indications will not change.

Bootloader Programme-Test The error output signal will be reset. By this test, a check-sum is calculated over the memory area containing the bootloader programme and compared with the check-sum pre-programmed at the factory. If the sums do not match, the bootloader pro-gramme will remain in an endless loop, and the above indications will be maintained.

RAM-Test Boot Loader Programme During this test, various binary patterns are written to the RAM used by boot loader and read out again. If at least one storage location does not contain the expected code, the bootloader programme enters into an endless loop, and the above indica-tions are maintained.

Note

13 Error Handling

KRONOS 20 57

RAM-Test Main Programme During this test, various binary patterns are written to the RAM used by boot loader and read out again. If at least one storage location does not contain the expected code, the bootloader programme will switch to a condition where a communication wth the HEINZMANN-diagnosis tool is possible. The cause of the error and the test status can be seen in the parameters

3078 ErrRamTest = 1 Error RAM-Test,

3800 TestStatus = 1 Test status,

3801 TestValue1 faulty address,

3802 TestValue2 faulty test value

3803 TestValue3 faulty read back content of the address

Main Programme-Test During this test, various binary patterns are written to the RAM used by the main programme and read out again. If at least one storage location does not contain the expected code, the bootloader programme will switch to a condition where a com-munication with the HEINZMANN-diagnosis tool is possible. The cause of the error and the test status can be seen in the parameters

3087 ErrMainCheckSum = 1 Error main programme-Test,

3800 TestStatus = 0 Test status

3801 TestValue1 expected check sum

3802 TestValue2 calculated check sum

In this operation status it is possible to load a new main programme.

13.4.2 Bootloader Communication

Serial communication with the bootloader can be entered into when the error output si-gnal is given out three times shortly with a long interval. Further the the bootloader communication status can be seen when only a few parameters, measuring and display values are visible. In this state, errors will be reported on the one hand; on the other hand, it serves as a starting point for downloading a new control programme (only with DcDesk 2000). By principle, this procedure will always have to be carried out by the bootloader.

If the system is entering the bootloader mode unforeseen, HEINZMANN should be informed. For further error diagnosis the values for parameters should be read out and redirected to HEINZMANN as an error description Note

13 Error Handling

58 KRONOS 20

13.5 Error Parameter List

The below error parameter list contains descriptions of the causes of each single error and of the control's response. Furthermore, it lists the appropriate actions to be taken to remove the respective error.

Starting from parameter number 3001(error memory) and 3101 (permanent error memory) the errors are sorted by ascending numbers with the parameter on the left indicating the ac-tual error as stored in the volatile memory and with the parameter on the right indicating the one stored as a sentinel in the permanent error memory.

13 Error Handling

KRONOS 20 59

3001 ErrPickUp 3101 SErrPickUp

Cause: - Speed pickup is at fault. - Distance between speed pickup and gear rim is too large. - Speed pickup is supplying faulty redundant pulses. - Interruption of cable from speed pickup. - Speed pickup wrongly mounted.

Response: - Error message: emergency alarm by a fatal error. - Emergency operation with substitute value for valve position.

Action: - Check distance between speed pickup and gear rim. - Check preferred direction of speed pickup. - Check cable to speed pickup. - Check speed pickup, replace if necessary.

3004 ErrOverSpeed 3104 SErrOverSpeed

Cause: - Engine speed was/is exceeding overspeed.

Response: - Error message: emergency alarm by a fatal error. - Emergency operation with substitute value for valve position.

Action: - Check overspeed parameter (21 SpeedOver). - Check speed sensor. - Check parameter 1 TeethPickUp for number of teeth.

3017 ErrManifoldPressure 3117 SErrManifoldPressure

Cause: - Short circuit or cable break at sensor input for manifold pressure.

Response: - Error message: Common alarm. - Emergency operation in Open-Loop mode. - Emergency operation with substitute value or last valid sensor value. depending on choosen response mode. - Error is cleared automatically when sensor values are within tolerances, depending on choosen response mode.

Action: - Check sensor cable for short circuit or cable break. - Check manifold pressure sensor and replace if required. - Check tolerance values for manifold pressure sensor.

3018 ErrManifoldTemp 3118 SErrManifoldTemp

Cause: - Short circuit or cable break at sensor input for manifold temperature.

Response: - Error message: Common alarm. - Emergency operation with substitute value or last valid sensor value. depending on choosen response mode. - Error is cleared automatically when sensor values are within tolerances, depending on choosen response mode.

Action: - Check sensor cable for short circuit or cable break.

13 Error Handling

60 KRONOS 20

- Check manifold temperature sensor and replace if required. - Check tolerance values for manifold temperature sensor.

3019 ErrMeasuredPower 3119 SErrMeasuredPower

Cause: - Short circuit or cable break at sensor input for measured power.

Response: - Error message: Common alarm. - Emergency operation with substitute value or last valid sensor value depending on choosen response mode. - Operation mode Open-Loop for emergency operation only if the substitute value. for measured power is lower than the switch level for Closed-Loop mode. - Error is cleared automatically when sensor values are within tolerances, depending on choosen response mode.

Action: - Check sensor cable for short circuit or cable break. - Check power sensor and replace if required. - Check tolerance values for power sensor.

3020 ErrLambda 3120 SErrLambda

Cause: - Short circuit or cable break at sensor input for lambda sensor.

Response: - Error message: Common alarm. - Emergency operation in Open-Loop mode. - Emergency operation with substitute value or last valid sensor value. depending on choosen response mode. - Error is cleared automatically when sensor values are within tolerances, depending on choosen response mode.

Action: - Check sensor cable for short circuit or cable break. - Check lambda sensor and replace if required. - Check tolerance values for lambda sensor.

3021 ErrCH4Content 3121 SErrCH4Content

Cause: - Short circuit or cable break at sensor input for CH4-content.

Response: - Error message: Common alarm. - Emergency operation with substitute value or last valid sensor value. depending on choosen response mode. - Error is cleared automatically when sensor values are within tolerances, depending on choosen response mode.

Action: - Check sensor cable for short circuit or cable break. - Check CH4-sensor and replace if required. - Check tolerance values for CH4-sensor.

3046 ErrMisfireWarn 3146 SErrMisfireWarn

Cause: - Speed variance has exceeded the power dependent warning curve for monitoring of misfiring.

13 Error Handling

KRONOS 20 61

Response: - Error message: Common alarm as warning. - Error is cleared automatically when speed variance are within warning curve.

Action: - Engine check, particulary the spark plugs. - Check parameters of warning curve for misfire monitoring.

3047 ErrMisfireEcy 3147 SErrMisfireEcy

Cause: - Speed variance has exceeded the power dependent emergency curve for monitoring of misfiring.

Response: - Error message: Common alarm. - Emergency operation in Open-Loop mode

Action: - Engine check, particulary the spark plugs. - Check parameters of emergency curve for misfire monitoring.

3048 ErrPowerSupplyWarn 3148 SErrPowerSupplyWarn

Cause: - Supply voltage is lower than the minimum voltage for stepper motor control of the E-LES.

Response: - Error message: Common alarm as warning. - No control of stepper motor and valve position because of possibility of stepping errors. - Error is cleared automatically when supply voltage is above minimum voltage.

Action: - Check supply voltage. - Check measured value 3600 PowerSupply of the supply voltage.

3061 ErrDigitalOutput1 3161 SErrDigitalOutput1

Cause: - Short circuit or cable break of the E-LES stepper motor wiring harness on digital output 1.

Response: - Error message: Emergency alarm by fatal error. - No control of stepper motor and valve position.

Action: - Check cable harness to E-LES stepper motor control for short circuit and cable break.

3062 ErrDigitalOutput2 3162 SErrDigitalOutput2

Cause: - Short circuit or cable break of the E-LES stepper motor wiring harness on digital output 2.

Response: - Error message: Emergency alarm by fatal error. - No control of stepper motor and valve position.

Action: - Check cable harness to E-LES stepper motor control for short circuit and cable break.

13 Error Handling

62 KRONOS 20

3076 ErrParamStore 3176 SErrParamStore

Cause: - Occurrence of an error on parameter programming of E2PROM.

Response: - Error message: Emergency alarm by fatal error. - Emergency operation possible with substitute value for valve position but not advisible.

Action: - Restart governor by a reset. - Notify HEINZMANN.

3077 ErrProgramTest 3177 SErrProgramTest

Cause: - Current monitoring of the programme memory reports an error.



3078 ErrRAMTest 3178 SErrRAMTest

Cause: - Current monitoring of the working memory reports an error.


Action: - Note down the values of the parameters 3895 RAMTestAddr and 3896 RAMTestPattern as an extended error description. - Restart governor by a reset. - Notify HEINZMANN.

3080 ErrDisplay 3180 SErrDisplay

Cause: - Error in display control.

Response: - Error message: Common alarm. - No communication with keyboard and disply on control unit.


Note: - Only at systems with keyboards and displays.

3081 Err5V_Ref 3181 SErr5V_Ref

Cause: - The internal reference voltage 5 V is not within the permissible range

Response: - Error message: Common alarm.


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KRONOS 20 63

3085 ErrVoltage 3185 SErrVoltage

Cause: - The supply voltage for the governor is not within the permissible range.

Response: - Error message: Common alarm.

Action: - Restart governor by a reset. - Notify HEINZMANN. - Check voltage supply.

3090 ErrData 3190 SErrData

Cause: - No data found or check sum over data is wrong oder read access E2PROM reports an error.

Response: - Error message: Emergency alarm by fatal error. - Governor is operating by default parameters. - Engine should not be started.

Action: - Note down the values of the parameter 3099 EEPROMErrorCode - Check data for correct setting, save parameters and restart control unit by a reset. - Notify HEINZMANN.

Note: - This error will occur only after restart by by switch on the supply voltage or when reseting.

3092 ErrConfiguration 3192 SErrConfiguration

Cause: - Configuration of the programmed parameters are not plausible.


Action: - Write down the values of the parameter 3000 ConfigurationError. - Check data for correct setting, save parameters and restart control unit by a reset. - Notify HEINZMANN.

Note: - This error will occur only after restart by by switch on the supply voltage or when reseting.

3093 ErrStack 3193 SErrStack

Cause: - Internal programming or computing error, “stack-overflow”.


Action: - Write down the values of parameters 3897 CstackTestFreeBytes and 3898 IstackTestFreeBytes. - Restart governor by a reset

13 Error Handling

64 KRONOS 20

- Notify HEINZMANN.

3094 ErrIntern 3194 SErrIntern

Cause: - Internal programming or computing error, so-called "EXCEPTION" error.


Action: - Write down the values of the parameters 3195 SExceptionNumber, 3196 SExceptionAddrLow, 3197 SExceptionAddrHigh and 3198 SExceptionFlag - Restart governor by a reset - Notify HEINZMANN.

14 Parameter Description

KRONOS 20 65


14.1 Synoptical Table

In the table below the different parameter groups are listed in adjacent colums. It is fol-lowed by another table itemizing all parameters by number and identifier and grouping them in accordance with the previous four lists. This will make it easier to understand the interrelations between the different parameters.

Parameters Measurements Functions Curves No. Designation No. Designation No. Designation No. Designation

1 Number of teeth / speed 2000 Speed Pickup / Speed 6000 Misfiring

50 Speed deviation / Misfiring



250 Start 2250 Start

300 Stepper Motor 2300 Stepper Motor 4300 Stepper Motor

800 Switch Functions 2800 Switch Functions / Digital Outputs

4800 Digital Inputs

900 Sensors 2900 Sensors

1000 Error Handling 3000 Current Errors 5000 Error Handling

1400 AFR 3400 AFR 5400 AFR 7400 AFR: Lambda-Map

1500 Analogue Inputs 3500 Analogue Outputs 5500 Analogue Inputs 7500 AFR: Lambda-Map

3600 Internal Inputs 5600 Internal Inputs 7600 AFR: Gas valve curve

1700 Positioner 5700 Positioner

1800 Status 3800 Status

7900 Temperature sensor

9400 AFR: Map Volumetric efficiency

9500 AFR: Map Mechanical efficiency

9600 AFR: Curve CH4-content


66 KRONOS 20

Parameters Measurements Functions Curves 2000 Speed 6000 MisfireWarn:P 1 TeethPickUp 2003 SpeedPickUpValue 6010 MisfireWarn:nVar 6020 MisfireEcy:P 21 SpeedOver 6030 MisfireEcy:nVar 50 SpeedVarSampleSize 2050 SpeedVariance 4050 SpeedVarDetectOn 51 SpeedVarFilterConst 55 MisfireWarnDelay 4055 MisfireWarnCurveOn 56 MisfireEcyDelay 4056 MisfireEcyCurveOn 2250 EngineStartCounter 255 StartSpeed1 256 StartSpeed2 2302 StepperPos 314 StepperPosSecureMin 315 StepperPosSecureMax 317 StepperPosOffset 318 StepperPosDeadBand 319 StepperPosSubst 4319 SubstOrLastStepprPos 2331 StepperPosAbsMax 2332 StepperPosSetpoint 2333 StepperPosSetpSelect 810 FunctEngineStop 2810 SwitchEngineStop 4810 StopImpulseOrSwitch 4811 StopOpenOrClose 828 FunctErrorReset 2828 SwitchErrorReset 2851 DigitalOut1 2852 DigitalOut2 912 AssignIn_MnfldPress 2912 ManifoldPressure 913 AssignIn_MnfldTemp 2913 ManifoldTemp 914 AssignIn_MeasPower 2914 MeasuredPower 915 AssignIn_Lambda 2915 Lambda 916 AssignIn_CH4Content 2916 CH4Content 986 MnfldPressSensorLow 987 MnfldPressSensorHigh 988 MeasPowerSensorLow 989 MeasPowerSensorHigh 990 LambdaSensorLow 991 LambdaSensorHigh 992 CH4ContentSensorLow 993 CH4ContentSensorHigh 3000 ConfigurationError 3001 ErrPickUp 3004 ErrOverSpeed 1012 SubstMnfldPressure 5012 SubstOrLastMnfldPres 1013 SubstManifoldTemp 5013 SubstOrLastMnfldTemp 1014 SubstMeasuredPower 5014 SubstOrLastMeasPower 1015 SubstLambda 5015 SubstOrLastLambda 1016 SubstCH4Content 5016 SubstOrLastCH4Cntent 3017 ErrManifoldPressure 3018 ErrManifoldTemp 3019 ErrMeasuredPower 3020 ErrLambda 3021 ErrCH4Content 3046 ErrMisfireWarn 3047 ErrMisfireEcy 3048 ErrPowerSupplyWarn


KRONOS 20 67

Parameters Measurements Functions Curves 5052 HoldOrResetMnfldPres 5053 HoldOrResetMnfldTemp 5054 HoldOrResetMeasPower 5055 HoldOrResetLambda 5056 HoldOrResetCH4Cntent 3061 ErrDigitalOutput1 3062 ErrDigitalOutput2 3076 ErrParamStore 3077 ErrProgramTest 3078 ErrRAMTest 3080 ErrDisplay 3081 Err5V_Ref 3085 ErrVoltage 3090 ErrData 3092 ErrConfiguration 3093 ErrStack 3094 ErrIntern 3099 EEPROMErrorCode 5100 NoStoreSErrOn 3101 SErrPickUp 5101 CommAlarmWarnFlashOn 5102 CommonAlarmResetOn 3104 SErrOverSpeed 3117 SErrManifoldPressure 3118 SErrManifoldTemp 3119 SErrMeasuredPower 3120 SErrLambda 3121 SErrCH4Content 3146 SErrMisfireWarn 3147 SErrMisfireEcy 3148 SErrPowerSupplyWarn 3161 SErrDigitalOutput1 3162 SErrDigitalOutput2 3176 SErrParamStore 3177 SErrProgramTest 3178 SErrRAMTest 3180 SErrDisplay 3181 SErr5V_Ref 3185 SErrVoltage 3190 SErrData 3192 SErrConfiguration 3193 SErrStack 3194 SErrIntern 3195 SExceptionNumber 3196 SExceptionAddrLow 3197 SExceptionAddrHigh 3198 SExceptionFlag 1400 ClosedLpPowerMinRate 3400 ClosedLpPowerActive 5400 ClosedOrOpenLoop 7400 LambdaMap:n 1401 ClosedLoopGov:I 3401 ClosedLpLambdaActive 3402 ClosedLpCH4Active 1410 EngineDisplacement 3410 MixtureFlowRate 1411 EngineRatedPower 3411 CalculatedPower 1412 VolEfficiencyConst 3412 VolumetricEfficiency 5412 VolEffMapOn 1413 MechEfficiencyConst 3413 MechanicalEfficiency 5413 MechEffMapOn 1420 ThroatArea 3420 ThroatVelocity 1421 GasMeteringHolesArea 3421 ThroatDeltaPressure 1422 RefMeteringHolesArea 3422 HolesDeltaPressure 1423 HolesCorrFactor


68 KRONOS 20

Parameters Measurements Functions Curves 1424 VenturiEfficiency 1430 GasValveCorrFactor 3430 GasTotalDeltaPress 5430 GasValveELES80Or50 3431 GasValveOpeningArea 1440 ZPRFullLoadDroop 3440 ZPRDroopPressure 1441 ZPROffsetPressure 1450 GasDensityConst 3450 GasDensity 7450 LambdaMap:p 1451 CalorificValueConst 3451 CalorificValue 1452 LambdaStoichConst 3452 LambdaStoichiometric 3453 GasFlowRateDesired 3454 GasFlowRateActual 1460 LambdaTempCorrFactor 3460 LambdaTempCorr 5460 ControlLambda-1On 1461 RefTemp 3461 LambdaMap 1462 RichLeanMixtureCorr 3462 LambdaDesiredValue 3463 LambdaActualValue 3464 LambdaTrimValue 1466 LambdaActValueFilter 7500 LambdaMap:Lambda 1530 AnalogIn3_RefLow 3530 AnalogIn3 5530 AnalogIn3_Type 1531 AnalogIn3_RefHigh 3531 AnalogIn3_Value 1532 AnalogIn3_ErrorLow 1533 AnalogIn3_ErrorHigh 1534 AnalogIn3_Filter 1540 AnalogIn4_RefLow 3540 AnalogIn4 5540 AnalogIn4_Type 1541 AnalogIn4_RefHigh 3541 AnalogIn4_Value 1542 AnalogIn4_ErrorLow 1543 AnalogIn4_ErrorHigh 1544 AnalogIn4_Filter 3550 TempIn 3551 TempIn_Value 1552 TempIn_ErrorLow 1553 TempIn_ErrorHigh 1554 TempIn_Filter 3600 PowerSupply 5600 CheckPowerSupplyOn 7600 GasValve:A 3603 5V_Ref 7650 GasValve:Pos 1705 StepPositionerSetp 5705 StepperPositionerOn 1706 StepPositionerAmpl 5706 StpperPositionerMode 1707 StepPositionerTime 1800 Level 3800 EmergencyAlarm 3801 CommonAlarm 3802 EngineStop 3803 EngineStopped 3804 EngineStarting 3805 EngineRunning 3806 EngineReleased 3830 Phase 3840 HardwareVersion 3841 AddHardwareVersion 3842 SoftwareVersion 3843 BootSoftwareVersion 3844 SerialDate 3845 SerialNumber 3850 Identifier 3851 LastIdentifier 3865 CalculationTime 3870 Timer 3871 OperatingHourMeter


KRONOS 20 69

Parameters Measurements Functions Curves 3872 OperatingSecondMeter 1876 ValueStep 3895 RAMTestAddr 3896 RAMTestPattern 3897 CStackTestFreeBytes 3898 IStackTestFreeBytes 7900 TempIn1:digit 7920 TempIn1:T 9400 VolEffMap:n 9410 VolEffMap:p 9420 VolEffMap:Eta 9500 MechEffMap:n 9510 MechEffMap:p 9520 MechEffMap:Eta 9600 CH4:Content 9620 CH4:GasDensity 9640 CH4:CalorificVal 9660 CH4:LambdaStoich


70 KRONOS 20

14.2 List 1: Parameters

No. Name Signification

1 TeethPickUp Level: 4

Range: 1..400 Page(s):

Number of teeth of the measuring wheel for speed pickup 1

21 SpeedOver Level: 4

Range: 0..4000 1/min Page(s):

Speed trip for emergency stop in case of overspeed

50 SpeedVarSampleSize Level: 4


Signal for detection of speed deviation

51 SpeedVarFilterConst Level: 4

Range: 0..100 s Page(s):

Filter constant for detection of speed deviation

55 MisfireWarnDelay Level: 4


Delay time for Warning due to Misfiring

56 MisfireEcyDelay Level: 4


Delay time for Emergency stop due to Misfiring

255 StartSpeed1 Level: 4


Minimum speed for detection of engine start. Gas valve will be activated

256 StartSpeed2 Level: 4


Minimum speed for detection of engine is running. Monitoring speed pick up

314 StepperPosSecureMin Level: 6

Range: 0..3650 steps Page(s):

Lowest allowable gas valve position. Prevents hit of the piston on lower end stop and resulting from that posi-tion errors. Range depends on actual gas valve

315 StepperPosSecureMax Level: 6


Highest allowable gas valve position. Prevents hit of the piston on upper end stop and resulting from that posi-tion errors.Range depends on actual gas valve

317 StepperPosOffset Level: 6


Calibration value for gas valve position to match the parametrized flow characteristics Range depends on actual gas valve


KRONOS 20 71


318 StepperPosDeadBand Level: 4


Dead band for gas valve positioning. Prevents continuous stepping

319 StepperPosSubst Level: 4


Substitute value for valve position at occurence of fatal errors. Range depends on actual gas valve

810 FunctEngineStop Level: 6

Range: -5..5 Page(s):

Switch assignment to function „Engine stop“. Gas valve will be closed

828 FunctErrorReset Level: 6

Range: -5..5 Page(s):

Switch assignment to function „Reset errors“

912 AssignIn_MnfldPress Level: 6


Assignment of input channel to manifold pressure

913 AssignIn_MnfldTemp Level: 6


Assignment of input channel to manifold temperature

914 AssignIn_MeasPower Level: 6


Assignment of input channel to output power feedback

915 AssignIn_Lambda Level: 6


Assignment of input channel to lambda signal feedback

916 AssignIn_CH4Content Level: 6


Assignment of input channel to CH4 content feedback

986 MnfldPressSensorLow Level: 4

Range: 0..5 bar Page(s):

Min. value of manifold pressure sensor

987 MnfldPressSensorHigh Level: 4


Max. value of manifold pressure sensor


72 KRONOS 20


988 MeasPowerSensorLow Level: 4

Range: 0..2500 kW Page(s):

Min. value of output power sensor

989 MeasPowerSensorHigh Level: 4


Max. value of output power sensor

990 LambdaSensorLow Level: 4

Range: 0..2,5 Page(s):

Min. value of lambda sensor

991 LambdaSensorHigh Level: 4


Max. value of lambda sensor

992 CH4ContentSensorLow Level: 4

Range: 0..100 % Page(s):

Min. value of CH4-sensor

993 CH4ContentSensorHigh Level: 4


Max. value of CH4-sensor

1012 SubstMnfldPressure Level: 4


Substitute value for manifold pressure in case of sensor failure

1013 SubstManifoldTemp Level: 4

Range: -100..1000 °C Page(s):

Substitute value for manifold temperature in case of sensor failure

1014 SubstMeasuredPower Level: 4


Substitute value for output power in case of sensor fail-ure

1015 SubstLambda Level: 4


Substitute value for measured lambda in case of sensor failure

1016 SubstCH4Content Level: 4


Substitute value for measured CH4 in case of sensor failure


KRONOS 20 73


1400 ClosedLpPowerMinRate Level: 4


Output power switch point for mode change from Open loop mode to Closed loop mode

1401 ClosedLoopGov:I Level: 4


Stability value for lambda control in Closed loop mode

1410 EngineDisplacement Level: 4

Range: 0..100 dm³ Page(s):

Engine Displacement

1411 EngineRatedPower Level: 4


Engine rated power

1412 VolEfficiencyConst Level: 4

Range: 0,5..1 Page(s):

Constant value for volumetric efficiency of the engine

1413 MechEfficiencyConst Level: 4

Range: 0,1..0,5 Page(s):

Constant value for mechanical efficiency of the engine

1420 ThroatArea Level: 4

Range: 300..30000 mm² Page(s):

Throat area of gas mixer insert

1421 GasMeteringHolesArea Level: 4


Overall area of gas holes in the gas mixer insert

1422 RefMeteringHolesArea Level: 4


Overall area of reference gas holes in the gas mixer insert. Normally the same as in 1421

1423 HolesCorrFactor Level: 4


Correction factor for geometry of gas holes (depends on actual gas mixer insert)

1424 VenturiEfficiency Level: 4


Correction factor for efficiency of gas mixer insert ho-les (depends on actual gas mixer insert)


74 KRONOS 20


1430 GasValveCorrFactor Level: 4


Correction factor for geometry of the gas valve

1440 ZPRFullLoadDroop Level: 2

Range: 0..10 mbar Page(s):

Assumed pressure drop of the Zero pressure regulator at rated Load

1441 ZPROffsetPressure Level: 2

Range: 0..30000 Pa Page(s):

Pressure offset of the Zero pressure regulator

1450 GasDensityConst Level: 2

Range: 0,5..3 kg/m³ Page(s):

Constant gas density. At changing gas quality the cali-bration value will be used

1451 CalorificValueConst Level: 2

Range: 5..100 MJ/m³ Page(s):

Constant calorific value (LHV). At changing gas quality the calibration value will be used

1452 LambdaStoichConst Level: 2

Range: 1..30 m³/m³ Page(s):

Constant lambda stoichiom. value. At changing gas quality the calibration value will be used

1460 LambdaTempCorrFactor Level: 2

Range: 0..25 1/k°C Page(s):

Correction factor for temperature dependant lambda correction

1461 RefTemp Level: 2

Range: -100..1000 °C Page(s):

Reference temperature for temperature dependant lambda correction

1462 RichLeanMixtureCorr Level: 2


Offset value for entire lambda map

1466 LambdaActValueFilter Level: 4


Filter value for lambda value received from output po-wer signal

1530 AnalogIn3_RefLow Level: 4

Range: 0..22,7 mA Page(s):

Low reference value of analogue input 3. Standard for feedback signal (output power, lambda sensor, CH4 content). Here set for 0..22,7 mA


KRONOS 20 75


1531 AnalogIn3_RefHigh Level: 4


High reference value of analogue input 3

1532 AnalogIn3_ErrorLow Level: 4


Low error limit of analogue input 3

1533 AnalogIn3_ErrorHigh Level: 4


High error limit of analogue input 3

1534 AnalogIn3_Filter Level: 4


Filter value of analogue input 3

1540 AnalogIn4_RefLow Level: 4

Range: 0..5 V Page(s):

Low reference value of analogue input 4. Standard for manifold pressure. Here set for 0..5 V

1541 AnalogIn4_RefHigh Level: 4


High reference value of analogue input 4

1542 AnalogIn4_ErrorLow Level: 4


Low error limit of analogue input 4

1543 AnalogIn4_ErrorHigh Level: 4


High error limit of analogue input 4

1544 AnalogIn4_Filter Level: 4


Filter value of analogue input 4

1552 TempIn_ErrorLow Level: 4


Low error limit of temperature input Standard manifold temperature

1553 TempIn_ErrorHigh Level: 4


High error limit of temperature input


76 KRONOS 20


1554 TempIn_Filter Level: 4


Filter value of temperature input

1705 StepPositionerSetp Level: 4


Setpoint for stepper position in positioner mode

1706 StepPositionerAmpl Level: 4


Amplitude for stepper position in positioner mode

1707 StepPositionerTime Level: 4


Cycle time in positioner mode

1800 Level Level: 1


User level

1876 ValueStep Level: 2


Step width of value changes for PG-02


KRONOS 20 77

14.3 List 2: Measurements


2000 Speed Level: 1

Range: 0..4000 1/min Page(s): 55

Current speed value

2003 SpeedPickUpValue Level: 4


Unfiltered speed signal from speed pickup

2050 SpeedVariance Level: 4


Actual value of speed variance

2250 EngineStartCounter Level: 1


Engine start counter

2302 StepperPos Level: 4


Actual stepper position

2331 StepperPosAbsMax Level: 4


Absolute max. position of stepper motor (depending on E-LES type)

2332 StepperPosSetpoint Level: 4


Calculated setpoint for stepper motor

2333 StepperPosSetpSelect Level: 4


Actual setpoint for stepper motor

2810 SwitchEngineStop Level: 1


Switch position "Engine stop"

2828 SwitchErrorReset Level: 1


Switch position "Reset errors "

2851 DigitalOut1 Level: 6


Condition of digital output 1 (stepper motor control)


78 KRONOS 20


2852 DigitalOut2 Level: 6


Condition of digital output 2 (stepper motor control)

2912 ManifoldPressure Level: 1


Actual value of manifold pressure

2913 ManifoldTemp Level: 1

Range: -100..1000 °C Page(s):

Actual value of manifold temperature

2914 MeasuredPower Level: 1


Actual value of measured power

2915 Lambda Level: 1


Actual value of lambda sensor

2916 CH4Content Level: 1


Actual value of CH4 content

3000 ConfigurationError Level: 1


Error code software configuration

3001 ErrPickUp Level: 1


Error indication of speed sensor

3004 ErrOverSpeed Level: 1


Error indication due to overspeed

3017 ErrManifoldPressure Level: 1


Error indication of manifold pressure sensor

3018 ErrManifoldTemp Level: 1


Error indication of manifold temperature sensor


KRONOS 20 79


3019 ErrMeasuredPower Level: 1


Error indication of power sensor

3020 ErrLambda Level: 1


Error indication of lambda sensor

3021 ErrCH4Content Level: 1


Error indication of CH4 sensor

3046 ErrMisfireWarn Level: 1


Warning indication due to misfiring

3047 ErrMisfireEcy Level: 1


Alarm indication due to misfiring

3048 ErrPowerSupplyWarn Level: 1


Error indication of low power supply voltage Anzeige der Unterspannungswarnung

3061 ErrDigitalOutput1 Level: 1


Error at channel DigiIO 1 (connection to E-LES is faul-ty)

3062 ErrDigitalOutput2 Level: 1


Error at channel DigiIO 2 (connection to E-LES is faul-ty)

3076 ErrParamStore Level: 1


Error reported on storing parameters

3077 ErrProgramTest Level: 1


Error reported on programming check sum

3078 ErrRAMTest Level: 1


Error reported during RAM Test


80 KRONOS 20


3080 ErrDisplay Level: 1


Error indication for control display

3081 Err5V_Ref Level: 1


Error indication for 5 V reference voltage

3085 ErrVoltage Level: 1


Error indication for power supply voltage

3090 ErrData Level: 1


Error reported during parameter loady from EE-PROM

3092 ErrConfiguration Level: 1


Error indication for software configuration

3093 ErrStack Level: 1


Error indication for stack overflow

3094 ErrIntern Level: 1


Error indication for internal software fault

3099 EEPROMErrorCode Level: 6

Range: 0000..FFFF Hex Page(s):

Error code during loading of parameters from EE-PROM

3101 SErrPickUp Level: 1


Sentinel for the occurrence of 3001 ErrPickUp

3104 SErrOverSpeed Level: 1


Sentinel for the occurrence of 3004 ErrOverSpeed

3117 SErrManifoldPressure Level: 1


Sentinel for the occurrence of 3017 ErrManifoldPressure


KRONOS 20 81


3118 SErrManifoldTemp Level: 1


Sentinel for the occurrence of 3018 ErrManifoldTemp

3119 SErrMeasuredPower Level: 1


Sentinel for the occurrence of 3019 ErrMeasurePower

3120 SErrLambda Level: 1


Sentinel for the occurrence of 3020 ErrLambda

3121 SErrCH4Content Level: 1


Sentinel for the occurrence of 3021 ErrCH4Content

3146 SErrMisfireWarn Level: 1


Sentinel for the occurrence of 3046 ErrMisfireWarn

3147 SErrMisfireEcy Level: 1


Sentinel for the occurrence of 3047 ErrMisfireEcy

3148 SErrPowerSupplyWarn Level: 1


Sentinel for the occurrence of 3048 ErrPowerSupplyWarn

3161 SErrDigitalOutput1 Level: 1


Sentinel for the occurrence of 3061 ErrDigitalOutput2

3162 SErrDigitalOutput2 Level: 1


Sentinel for the occurrence of 3062 ErrDigitalOutput2

3176 SErrParamStore Level: 1


Sentinel for the occurrence of 3076 ErrParamStore

3177 SErrProgramTest Level: 1


Sentinel for the occurrence of 3077 ErrProgramTest


82 KRONOS 20


3178 SErrRAMTest Level: 1


Sentinel for the occurrence of 3078 ErrRAMTest

3180 SErrDisplay Level: 1


Sentinel for the occurrence of 3080 ErrDisplay

3181 SErr5V_Ref Level: 1


Sentinel for the occurrence of 3081 Err5V_Ref

3185 SErrVoltage Level: 1


Sentinel for the occurrence of 3085 ErrVoltage

3190 SErrData Level: 1


Sentinel for the occurrence of 3090 ErrData

3192 SErrConfiguration Level: 1


Sentinel for the occurrence of 3092 ErrConfiguration

3193 SErrStack Level: 1


Sentinel for the occurrence of 3093 ErrStack

3194 SErrIntern Level: 1


Sentinel for the occurrence of 3094 ErrIntern

3195 SExceptionNumber Level: 1


Sentinel for the occurrence of exeption number

3196 SExceptionAddrLow Level: 1


Sentinel for the occurrence of Exeption Addr. Low

3197 SExceptionAddrHigh Level: 1


Sentinel for the occurrence of Exeption Addr. High


KRONOS 20 83


3198 SExceptionFlag Level: 1


Sentinel for the occurrence of Exeption error

3400 ClosedLpPowerActive Level: 1


Operation mode Closed Loop with power feedback active

3401 ClosedLpLambdaActive Level: 1


Operation mode Closed Loop with lambda sensor feed-back active

3402 ClosedLpCH4Active Level: 1


Operation mode Closed Loop with CH4 sensor feed-back active

3410 MixtureFlowRate Level: 1

Range: 0..25000 m³n/h Page(s):

Calculated mix flow

3411 CalculatedPower Level: 1


Calculated generator power

3412 VolumetricEfficiency Level: 1


Current value for volumetric Efficiency of the engine

3413 MechanicalEfficiency Level: 1

Range: 0,1..0,5 Page(s):

Current value for mechanical Efficiency of the engine

3420 ThroatVelocity Level: 1

Range: 0..200 m/s Page(s):

Calculated gas velocity in the gas mixer throat

3421 ThroatDeltaPressure Level: 1


Calculated pressure difference in the gas mixer throat

3422 HolesDeltaPressure Level: 1


Calculated pressure difference in the gas holes of the gas mixer


84 KRONOS 20


3430 GasTotalDeltaPress Level: 1


Calculated overall pressure difference

3431 GasValveOpeningArea Level: 1


Calculated opening area of the E-LES

3440 ZPRDroopPressure Level: 1


Calculated pressure droop of the zero pressure regulator

3450 GasDensity Level: 1

Range: 0,5..3 kg/m³ Page(s):

Current gas density (variation only at CH4 content feedback)

3451 CalorificValue Level: 1

Range: 5..100 MJ/m³ Page(s):

Current gas calorific value (variation only at CH4 con-tent feedback)

3452 LambdaStoichiometric Level: 1

Range: 1..30 m³/m³ Page(s):

Current gas lambda stoichiometric (variation only at CH4 content feedback)

3453 GasFlowRateDesired Level: 1


Calculated gasflow setpoint based on lambda setpoint (3462 LambdaDesiredValue)

3454 GasFlowRateActual Level: 1


Calculated gasflow rate based on output power feed-back (2914 MeasuredPower)

3460 LambdaTempCorr Level: 1

Range: -1,25..1,25 Page(s):

Current factor for temperature dependant lambda cor-rection

3461 LambdaMap Level: 1


Current value from lambda map

3462 LambdaDesiredValue Level: 1


Temperature corrected actual lambda setpoint from lambda map


KRONOS 20 85


3463 LambdaActualValue Level: 1


Calculated and filtered lambda-actual value based on actual gas flow rate (3454 GasFlowRateActual)

3464 LambdaTrimValue Level: 1

Range: -1,25..1,25 Page(s):

Actual lambda-trim value at I-governor output

3530 AnalogIn3 Level: 1


Normalized value of analogue input 3

3531 AnalogIn3_Value Level: 1


Unnormalized value of analogue input 3

3540 AnalogIn4 Level: 1


Normalized value of analogue input 4

3541 AnalogIn4_Value Level: 1


Unnormalized value of analogue input 4

3550 TempIn Level: 1

Range: -100..1000 °C Page(s):

Normalized value of temperature input

3551 TempIn_Value Level: 1


Unnormalized value of temperature input

3600 PowerSupply Level: 1


Current value of supply voltage

3603 5V_Ref Level: 1


Current value of 5 V-reference voltage

3800 EmergencyAlarm Level: 1

Range: 0..1 Page(s): 54

Indication of emergency shutdown alarm due to fatal error


86 KRONOS 20


3801 CommonAlarm Level: 1

Range: 0..1 Page(s): 54

Indication of common alarm

3802 EngineStop Level: 1


Indication when engine is stopped by internally or ex-ternally executed engine stop Stepper motor in substitute or zero position

3803 EngineStopped Level: 1


Indication when engine is stopped

3804 EngineStarting Level: 1


Indication when engine is started

3805 EngineRunning Level: 1


Indication when engine is running

3806 EngineReleased Level: 1


Indication when AFR control is released

3830 Phase Level: 1


Current phase of AFR control

3840 HardwareVersion Level: 1


Version number of control hardware

3841 AddHardwareVersion Level: 1


Additional version number of control hardware

3842 SoftwareVersion Level: 1


Version number of control software

3843 BootSoftwareVersion Level: 1


Version number of bootsoftware


KRONOS 20 87


3844 SerialDate Level: 1


Serial date of control hardware

3845 SerialNumber Level: 1


Serial number of control hardware

3850 Identifier Level: 1


Identifikationsnummer des PC-Programms bzw. Hand-programmers

3851 LastIdentifier Level: 1


Identification number of PC-programme / Hand Held Programmer

3865 CalculationTime Level: 1

Range: 0..16,384 ms Page(s):

Value of remaining calculation time for main processor

3870 Timer

Level: 1 Range: 0..65,535 s Page(s):

Internal clock

3871 OperatingHourMeter Level: 1

Range: 0..65535 h Page(s):

Metering of operation hours

3872 OperatingSecondMeter Level: 1


Metering of operation seconds

3895 RAMTestAddr Level: 6


Value of currently tested memory address

3896 RAMTestPattern Level: 6


Current test pattern for RAM test

3897 CStackTestFreeBytes Level: 6

Range: 0000..0200 Hex Page(s):

Indication of free bytes in C-stack


88 KRONOS 20


3898 IStackTestFreeBytes Level: 6

Range: 0000..0200 Hex Page(s):

Indication of free bytes in I-stack


KRONOS 20 89

14.4 List 3: Functions


4050 SpeedVarDetectOn Level: 4


Activation of speed variance detection

4055 MisfireWarnCurveOn Level: 4


Activation of warning curve for monitoring of misfiring

4056 MisfireEcyCurveOn Level: 4


Activation of emergency curve for monitoring of misfiring

4319 SubstOrLastStepprPos Level: 4


Selection of stepper motor substitute position in case of emergency alarm by fatal error 0 = last valid value 1 = substitute value (319 StepperPosSubst)

4810 StopImpulseOrSwitch Level: 6


Selection of type of engine stop switch 0 = Stop active only while stop command is applied 1 = Stop active by one single switch pulse until engine stops

4811 StopOpenOrClose Level: 6


Switch function „engine stop“ is active if switch is 0 = opened 1 = closed

5012 SubstOrLastMnfldPres Level: 4


Selection of a substitute value for manifold pressure in case of failure 0 = last valid value 1 = substitute value (1012 SubstMnfldPressure)

5013 SubstOrLastMnfldTemp Level: 4


Selection of a substitute value for manifold temperature in case of failure 0 = last valid value 1 = substitute value (1013 SubstManifoldTemp)

5014 SubstOrLastMeasPower Level: 4


Selection of a substitute value for measured power in case of failure 0 = last valid value 1 = substitute value (1014 SubstMeasuredPower)

5015 SubstOrLastLambda Level: 4


Selection of a substitute value for lambda sensor in case of failure 0 = last valid value 1 = substitute value (1015 SubstLambda)


90 KRONOS 20


5016 SubstOrLastCH4Cntent Level: 4


Selection of a substitute value for CH4 content in case of failure 0 = last valid value 1 = substitute value (1016 SubstCH4Content)

5052 HoldOrResetMnfldPres Level: 4


Selection whether the error at manifold pressure sensor is to be held or automatically reset (0 = to be automatically reset, 1 = error is to be held)

5053 HoldOrResetMnfldTemp Level: 4


Selection whether the error at manifold temperature sensor is to be held or automatically reset (0 = to be automatically reset, 1 = error is to be held)

5054 HoldOrResetMeasPower Level: 4


Selection whether the error at measured power sensor is to be held or automatically reset (0 = to be automatically reset, 1 = error is to be held)

5055 HoldOrResetLambda Level: 4


Selection whether the error at lambda sensor is to be held or automatically reset (0 = to be automatically reset, 1 = error is to be held)

5056 HoldOrResetCH4Cntent Level: 4


Selection whether the error at CH4 sensor is to be held or automatically reset (0 = to be automatically reset, 1 = error is to be held)

5100 NoStoreSErrOn Level: 6


Enable/Disable no saving of errors before next reset

5101 CommAlarmWarnFlashOn Level: 4


Selection of whether the common alarm indicator is to blink when only warnings are active

5102 CommonAlarmResetOn Level: 4


Selection of whether the common alarm indicator is to be reset briefly (edge change) if some new error has occurred

5400 ClosedOrOpenLoop Level: 4


Selection of operation mode 0 = Open-Loop 1 = Closed-Loop

5412 VolEffMapOn Level: 4


Activation of volumetric efficiency map


KRONOS 20 91


5413 MechEffMapOn Level: 4


Activation of mechanical efficiency map

5430 GasValveELES80Or50 Level: 6


Selection of valve size (E-LES) 0 = E-LES 50 1 = E-LES 80

5460 ControlLambda-1On Level: 4


Activation of lambda 1 control ((O2-sensor)

5530 AnalogIn3_Type Level: 6


Signal type of analogue input 3 1 = 0..5 V 2 = 0..22,7 mA

5540 AnalogIn4_Type Level: 6


Signal type of analogue input 4 0 = 0..65535 Digits 1 = 0..5 V

5600 CheckPowerSupplyOn Level: 6


Activation of supply voltage monitoring

5705 StepperPositionerOn Level: 4


Activation of positioner mode for stepper motor (for test purposes)

5706 StpperPositionerMode Level: 4


Selection of positioner mode 0 = direct position input 1 = triangle 2 = steps mode


92 KRONOS 20

14.5 List 4: Characteristics and Maps


6000 MisfireWarn:P(x) up to 6007

Level: 4 Range: 0..2500 kW Page(s):

Output power values for misfire warning characteristics

6010 MisfireWarn:nVar(x) up to 6017

Level: 4 Range: 0..65,535 Page(s):

Speed variance values for misfire warning characteris-tics

6020 MisfireEcy:P(x) up to 6027

Level: 4 Range: 0..2500 kW Page(s):

Output power values for misfire emergency characteris-tics

6030 MisfireEcy:nVar(x) up to 6037


Speed variance values for misfire emergency character-istics

7400 LambdaMap:n(x) up to 7409

Level: 4 Range: 0..4000 1/min Page(s):

Speed values for lambda map

7450 LambdaMap:p(x) up to 7459

Level: 4 Range: 0..5 bar Page(s):

Manifold pressure values for lambda map

7500 LambdaMap:Lambda(x) up to 7599


Lambda values for lambda map

7600 GasValve:A(x) up to 7624

Level: 6 Range: 0..65535 mm² Page(s):

Cross sectional area for the gas valve characteristics

7650 GasValve:Pos(x) up to 7674

Level: 6 Range: 0..0 steps Page(s):

Position stepper motor for the gas valve characteristic Range depends on gas valve size

7900 TempIn1:digit(x) up to 7914

Level: 6 Range: 0..65535 Page(s):

AD-converter values for temperature linearization char-acteristic

7920 TempIn1:T(x) up to 7934

Level: 6 Range: -100..1000 °C Page(s):

Temperature values for temperature linearization characteristic


KRONOS 20 93


9400 VolEffMap:n(x) up to 9407


Speed values for volumetric efficiency map

9410 VolEffMap:p(x) up to 9417


Manifold pressure values for volumetric efficiency map

9420 VolEffMap:Eta(x) up to 9483

Level: 4 Range: 0,5..1 Page(s):

Volumetric efficiency values for volumetric efficiency map

9500 MechEffMap:n(x) up to 9507


Speed values for mechanical efficiency map

9510 MechEffMap:p(x) up to 9517


Manifold pressure values for mechanical efficiency map

9520 MechEffMap:Eta(x) up to 9583

Level: 4 Range: 0,1..0,5 Page(s):

Mechanical efficiency values for mechanical efficiency map

9600 CH4:Content(x) up to 9609

Level: 4 Range: 0..100 % Page(s):

Methane content values for the following methane con-tent dependant characteristic

9620 CH4:GasDensity(x) up to 9629

Level: 4 Range: 0,5..3 kg/m³ Page(s):

Gas density values for methane content dependant char-acteristic

9640 CH4:CalorificVal(x) up to 9649

Level: 4 Range: 5..100 MJ/m³ Page(s):

Gas calorific values for methane content dependant characteristic

9660 CH4:LambdaStoich(x) up to 9669

Level: 4 Range: 1..30 m³/m³ Page(s):

Stoichiometric air fuel ratio values for methane content dependant characteristic

15 Figure List

94 KRONOS 20

15 Figure List

Figure 1: KRONOS 20 System .................................................................................................. 8

Figure 2: Distance of the Speed Pickup ................................................................................... 12

Figure 3: Dimensions of the Speed Pickup .............................................................................. 12

Figure 4: Information Sign on Speed Pickup Cable, Front and Back ...................................... 13

Figure 5: Dimensional Drawing of Double Sensor P/T-S-01 .................................................. 14

Figure 6: Information Sign on Double Sensor Cable, Front and Back .................................... 15

Figure 7: Dimensional Drawing λ Sensor LSM 11.................................................................. 17

Figure 8: Dimensional Drawing of Control Unit KRONOS 20 with Power Signal Input....... 20

Figure 9: Dimensional drawing of control unit KRONOS 20 with λ sensor input .................. 21

Figure 10: Dimensional Drawing E-LES 30 ............................................................................ 26



Figure 13: Sign bearing general and ATEX-relevant Information .......................................... 30

Figure 14: Sign with Type Designation and Serial Number .................................................... 30

Figure 15: Warning Sign on E-LES Stepping Motor Control Cover....................................... 30

Figure 16: Wiring Diagram for KRONOS 20 with open Loop................................................ 32

Figure 17: Wiring Diagram for KRONOS 20 with closed Loop ............................................. 33

Figure 18: Wiring Diagram for KRONOS 20 with closed Loop and λ-Sensor Signal ............ 34

Figure 19: Cable designations .................................................................................................. 35

Figure 20: Cable W2 ................................................................................................................ 36

Figure 21: Cable W3 ................................................................................................................ 37

Figure 22: Cable W4 ................................................................................................................ 38

Figure 23: Cable W5 for λ-Control .......................................................................................... 39

16 EC Declaration of Conformity

KRONOS 20 95

16 EC Declaration of Conformity pursuant to RL 94/9/EG (ATEX 100a)

The declaring manufacturer

HEINZMANN GmbH & Co.KG Am Haselbach 1 D-79677 Schönau (Schwarzwald) Germany Telephone (0 76 73) 82 08-0 Telefax (0 76 73) 82 08-188 e-mail VAT ID: DE145551926

declares, with reference to the following type test certificate, issued by the authority TÜV NORD CERT GmbH & CO. KG, TÜV CERT certification authority, identified under No. 0032 below,

in its sole responsibility, that all components of the KRONOS 20 series

the speed sensors (speed pickups) IA 01-38, IA 02-76, IA 03-102, IA 11-38, IA 12-76, IA 13-102

the double sensor for pressure and temperature measurement P/T-S-01,

the lambda sensor LSM 11,

the gas valves E-LES 30, E-LES 50, E-LES 80

pursuant to the EC type test certificates TÜV 06 ATEX 552893 and TÜV 07 ATEX 552892 X,

complies with the requirements

of Directive 94/9/EC of the European Parliament and Commission of March 23rd 1994 on the approximation of the laws of the Member States concerning equipment and protective systems intended for use in poten-tially Explosive Atmospheres, as well as its amendment of 10/10/1996 (Official Journal EC No. L257, page 44).

The products have been designed and manufactured in compliance with the harmonized European Standard for Electrical apparatus for potentially expolosive atmospheres:

EN 13 463-1:2001 Fundamental principles and general requirements EN 13 463-5:2003 Protection by construcitonal safety “c”

The products have been granted CE identification mark confirming that they satisfy all relevant provisions.

This declaration is no promise of characteristics in the sense of the German product liability law. Please refer to the safety instructions and the manuals!

(Anton Gromer) CEO Schönau, March 2007

17 Order Form for KRONOS Systems

96 KRONOS 20

17 Order Form for KRONOS Systems

18 Order Specifications for Manuals

KRONOS 20 97

18 Order Specifications for Manuals

There is no charge for our technical manuals ordered in reasonable quantities.

Order the necessary manuals on our speed governors from your nearest

HEINZMANN location.

(Please click on “HEINZMANN location” to see the list of our subsidiaries and agents in the world).

Please include the following information:

• your name,

• the name and address of your company (you can simply include your business card),

• the address where you want the manuals sent (if different from above),

• the number(s) (as on front page bottom right) and title(s) of the desired manual(s),

• or the technical data of your HEINZMANN equipment,

• the quantity you want.

You can directly use the following fax-form for ordering one or several manuals.

Most of the manuals are available as Acrobat PDF-files, too. On request they can be sent via e-mail.

We solicit comments about the content and the presentation of our publications. Please, send your comments to:

HEINZMANN GmbH & Co. KG

Marketing Abteilung

Am Haselbach 1

D-79677 Schönau

Germany

Fax Reply

Order for HEINZMANN technical manuals Fax-Hotline +49 7673 8208 194

Please send me the following manuals:

Quantity No. of the manual Title

Please send me your new sales documentation about

( ) the HEINZMANN Analogue Governors Application:....................................................

( ) the HEINZMANN Digital Governors Application:....................................................

( ) the HEINZMANN Gas Engine Equipment Application:....................................................

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