AFR control system

GAS ENGINE MANAGEMENT SOLUTION

Description:
Air Fuel Ratio (AFR) control system from ComAp Systems is a comprehensive solution for generating sets driven by lean burn gas engines. The system consists of several specic control and interface modules: InteliSysNT AFR Highly congurable, expandable gen-set controller with built-in PLC functions ECON-3, ECON-4 digital speed governor with possible misring detection (in ECON-4 only) I-Step interface to stepper motor actuator controlling variable gas/air mixer DENOX-20 anti-knocking system with 20 channels, (marketed as DetCon20 by MOTORTECH) I/O modules inputs and outputs for various analog and binary signals. Optimal set of modules depends on engine size and number of cylinders. Control modules are fully integrated via CAN bus. The key parameters from all modules are accessible via the main display on InteliSys. All key algorithms are eld proven on many installations: AFR algorithm keeps air to fuel ratio on the optimal level, ensuring the right exhaust gas emissions with minimum of AFR readjusting Knocking and misring detections protect engine from severe damage when the gas quality exceeds the expected limits or when some engine defect makes combustion unreliable

Benets:
Fully integrated system all parts and parameters are monitored and accessible from a single point. Simple and robust AFR algorithm does not require lambda sensor. Gen-set performance log stored in InteliSysNT AFR is an invaluable tool for troubleshooting. Solution for various types of gases natural gas, landll gas, biogas, with possible utilization of the CH4 content of the gas. Built-in PLC functions and high congurability of InteliSysNT AFR enables to build the system exactly satisfying the customer needs.

Excellent remote monitoring features backed by sophisticated PC programs are respecially suited to eet owners helping plan maintenance and trace production of heat and energy for each genset from the eet.

Elements of the system

USB 2.0 interface Dimensions 284x180 mm (front panel) Sealed to IP65 16 BI, 16 BO, 4 AI, 1 AO on the IS-NT unit Number of total inputs/outputs can be easily extended via expansion modules, connected to CAN line.

Integrated xed and congurable protections:

3 phase integrated generator protections (U + f) IDMT overcurrent, Shortcurrent protection IDMT Overload protection Reverse power protection Earth fault protection 3 phase integrated Mains protection Vector shift protection All Binary, Analogue inputs free congurable for various types of protections Additional 160 programmable protections for any measured value in the controller to create customer specic protection

InteliSysNT AFR
Description:
InteliSysNT AFR provides comprehensive AFR control system for lean burn applications for single or multiple gas gen-sets. The system offers a solution for either a single gen-set or up to 32 gen-sets in parallel. Powerful graphical display, with possibility of color display version with user friendly control allows even new users to nd quickly the required information.

Communication:
2RS232/RS485 interface with Modbus RTU protocol support Analogue / GSM / ISDN / CDMA modem communication support SMS messages / emails based on engine protection activation Ethernet / Internet interface via IG-IB module

Benets:
Field proven AFR solution ensures the right exhaust gas emissions with minimum of AFR readjusting, minimizing the operator interference with the system Solution for various types of gases natural gas, landll gas, biogas, with possible utilization of the CH4 content of the gas No Lambda sensor required Excellent congurability enables the user to achieve the required behaviour for their application One solution for both gen-set applications and large CHP applications Wide range of communication possibilities means you can monitor and supervise the system remotely, from ofce or home Built-in PLC with user friendly PLC

Editor removes the necessity of external PLC usage Gen-set performance log for an regular overview (kW per month, etc) and easy problem checking

PC software:
GenCong free conguration tool for controller adjustment InteliMonitor free PC SCADA software for supervision of single or multiple controllers, for multiple sites congurable site structure. Direct / Modem / Internet connection

Features:
Automatic synchronizing and power control (via speed governor) Voltage and PF control Generator measurement: U, I, Hz, kW, kVAr, kVA, PF Mains/Bus measurement: U, I, Hz, kW, kVAr, PF Manual and Automatic operational mode Event-based history (up to 1000 records) with customer selectable list of stored values, RTC, static values Interface to remote display units (3xIS-Display)

Upgrade kits:
IGS-NT-AFR-PCM: enables the functionality of the AFR control system IGS-NT-AFR-LSM+PMS: enables the functionality of the AFR control system and enables the PMS system for multiple operation (via CAN bus)

Elements of the system

ECON-3
Speed governor for control of various types of actuators (Heinzmann, GAC, Woodward) Capable of controlling 2 actuators from one unit Integration with InteliSysNT AFR controller via CAN line Parameters for adjustment accessible via main unit 3 PID loops for adjustment Actuator response Speed control Load control

ECON-4
Digital speed governor as an alternative to ECON-3 governor, capable to control 1 actuator Additional feature against ECON-3 is possible misring detection, signalized in the main controller

I-Step tep p
Stepper motor driver Capable of controlling up to 2 stepper motors from 1 unit Integration with InteliSysNT AFR controller via CAN line Parameters for adjustment accessible via main unit Adjustable start speed and start steps, maximum speed Adjustable stepper maximum allowable current 3 operational modes: Calibration to 1 end-point Calibration to 2 end-points Position feedback information

DENOX-20 OX-20 2
Anti knocking device Field proven solution of knocking detection Integration with InteliSysNT AFR controller via CAN line Parameters for adjustment accessible via main unit Up to 20 monitoring channels One channel can be congured for 1 cylinder monitoring, or for monitoring of 2 neighbouring cylinders

Schematic diagram
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ECON-4 can be used as an alternative to ECON-3 on systems where just one actuator is tted. Ignition module communication (displaying Ignition data) is not supported by default. In case of specic requirements the Ignition module support can be implemented (via RS485, CAN, etc.).

ATOR GENER GAS E NGINE

You can get more information about air fuel ratio on

www.comapsystems.com/solutions/afr-solutions

References

Complex CHP
United Kingdom, London
A Jenbacher 6 series engine, 1945 kW, fuelled by natural gas was converted from Jenbacher Dia. Ne solution to ComAp Systems AFR solution. The system was supplied and commissioned by ComAp Systems UK. The complexity of the system and high number of sensing signals led to solution with InteliSysNT AFR for engine control and InteliSysNT for auxiliaries control. The engine is demanded to run automatically at predened times throughout the day exporting electrical power of 1945 kW into the grid and supplying the customers greenhouses with heating water of dened temperature. The ComAp Systems solution also provides essential signals to the customers PLC for exhaust gas treatment to obtain CO2 for further utilization within the greenhouses.

Agrogen
Germany, Merkendorf
Agrogen, located in Merkendorf Germany, is one of the leading suppliers of cogen sets into the biogas industry. Its gensets are controlled by ComAps InteliSysNT controller line using the AFR (air fuel ratio control) software allowing efcient control of the plant and its heat circuits as well as emissions under variable load. As the system is fully integrated using CAN bus based extensions modules, it allows full remote control and adjustment over GSM/GPRS modem and via Internet.

Mini AFR solutions

InteliGenNT miniAFR is the InteliGenNT based variant of the AFR lean burn control system for generating sets up to 75kW. Ideal prize/performance ratio solution for micro and mini CHP installations, utilizing the similar AFR algorithm from InteliSysNT AFR.

Upgrade kits: IGS-NT-miniAFR-PCM: enables the functionality of the lean burn AFR control system IGS-NT-miniAFR-LSM+PMS: enables the Power management functionality in the miniAFR software

For more information about our products and solutions visit

www.comapsystems.com
MANUFACTURER: LOCAL DISTRIBUTOR / PARTNER:

ComAp Systems
division of ComAp Phone: + 420 246 012 111 Fax: + 420 266 316 647 E-mail: ofce@comapsystems.com Internet: www.comapsystems.com

Features and specication are subject to change without prior notice.

2010-04/CSLEAFR