kronos 20_afr 03 002-e 01-08.pdf

Heinzmann GmbH & Co. KG Engine & Turbine Controls Am Haselbach 1 D-79677 Schnau (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 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 -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 -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 1 control (KRONOS 20 version with 1 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

1 Safety Instructions and Related Symbols 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 Bernoullis 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 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

- 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)

map 100 points

Calorific value range 4..200 MJ/m

Gas filter requirement max. mesh size 50 m

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/nm landfill gas: 18 MJoule/nm propane: 90 Mjoule/nm

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 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 +130C 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 +120C -40 to + 130C up to + 800C

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 -8C to +120C cable -5C to +80C

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) *1

60

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: -5C to +80C, Thousing: -8C to +120CTV 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 50.5 V Current consumption 6..12.5 mA at 5 V

EMI 100 V/m

Operating temperature range -40C to +130C

Storage temperature -40C to +130C


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 -40C to +130C

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 22

15

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

Sensor hole diameter 12.50.1 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: -5C to +80C, Thousing: -40C to +130C

TV 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 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 +150C to +600C

Maximum exhaust gas temperature +800C

Storage temperature -40C to +100C

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

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: < 2C at 0C to 130C, otherwise < 4C

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 k, fg = 15 Hz or I = 4..20 mA

Digital input (terminal 9) U0 < 2 V, U1 > 6.5 V, Rpd = 100 k Digital input engine stop U0 < 2 V, U1 > 6.0 V Rpd = 4.75 k (terminal 11) or Rpu = 4.75 k or Rpd = 150 k 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 k, 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 k 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 k 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 Schnau/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.

V

PH2

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 Schnau/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.

V

PH2

PH1

MAT

CL-IN

45

118,5

5

40

KRO

NO

S 20-A

-sensorHeating 22

2120

1917

1615

1413

1211

109

87

61

23

45

1823

24

1 - closed loop version

Figure 9: Dimensional drawing of control unit KRONOS 20 with 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 systems 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 -40C to +85C Ambient temperature during operating -20C to +80C

Air humidity up to 98 % at 55C

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 m 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 valves 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: -20C to +80CTV 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 -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 -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 mm

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

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

W 4 speed pickup 2 x 0.75 mm

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

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

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

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


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 -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 -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)/(set 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 mea (measured value) = des (3462 LambdaDesiredValue), (within 2 %), then continue with B) If mea < des then: 1. Increase vent (1424 VenturiEfficiency) until mea = des or until the engine misfires or

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

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

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

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

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

was set =1.65 and now is changed to set = 1.70 4. Verify the lambda values 5. If mea > des 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 vol (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 vol (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 (des (3462 LambdaDesiredValue)) must not necessarily correspond to the actual measured values (cal (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 (set (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 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 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 cal (3463 LambdaActualValue) = des (3462 LambdaDesiredValue), (within 1 %), then continue with E) When cal < des then: 1a. Increase set (9500 - 9583 MechEffMap or 1413 MechEfficiencyConst) at the according

load point in the generator efficiency table until cal = des

When cal > des then: 1b. Decrease set (9500 - 9583 MechEffMap or 1413 MechEfficiencyConst) at the accord-

ing load point in the efficiency table (engine with generator) until cal = des

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 cal = des = mea should hold true.

5. Measured exhaust gas values should correspond to desired exhaust gas values for all loads. Corrections must be made in the 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 1 control (KRONOS 20 version with 1 sensor)

General:

Commissioning of 1 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 1 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 sensor within the voltage jump range. For 1 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 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-facturers 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.

13 Error Handling

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

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