List of engines where the original control system was converted to ComAp solution

Draft, working version, rev.1., updated 11.8.2016

GE Jenbacher engines

 J208
 J312
 J316
 J320
 J616

Control system, which was converted:

 Main control system (completely replaced by ComAp control system)

o Dia.Ne Blue
o Dia.Ne XT
o ComAp solution - In both cases replaced by InteliSys controller (IS-NTC-BB, InteliSys
gas would fit better)

The Jenbacher solution is a PLC system, which controls completely the gen-set and related
circuits, technologies (CHP, intercoolers, etc.)

ComAp solution which can be used to replace the Dia.Ne control system:

o InteliSys Gas controller

o HMI based on customer preferences (InteliVision family)
o I/O modules – type and number of modules depends on the engine size and also on
the fact whether the application is a CHP or not. The modules are usually
combination of: I-AIN8, I-AIN8TC, I-IO8/8 and could be also I-AOUT8
o IG-AVRi
o IG-AVRi-Trans
o AFR functionality – AFC dongle:
 For single applications: IS-AFC-PCM
 For multiple applications: IS-AFC-LSM+PMS
o Speed governor: ECON-4
o Stepper motor driver: I-STEP

Control of the application (e.g. CHP) is done inside the InteliSys PLC interpreter. Similarly
control of other circuits like Intercooler circuit, engine Preheating is done in this internal PLC
interpreter.

 Speed governor (controlling mainly Heinzmann STG xx actuator). Actuator stays on engine
o Heinzmann
o Woodward integrated actuators
o ComAp solution - used ECON-4 instead of original electronics

 AFR control (stepper motor stays on engine)

o Saia Burges stepper motor with 4-20mA position feedback information
 o ComAp solution - Replace the driver of the mixer - New control by I-Step module.
The position feedback is connected to any analogue input of the system (not
connected to the I-Step) and can be used for better mixer control.

 Turbo By-pass (mechanical parts stay on engine, in case of Pierburg also amplifiers)
o Pierburg proportional solenoids (one or more connected mechanically in parallel).
There might be fitted converters from 4-20mA to 0-200mA, these shall stay on site,
or similar booster/amplifier needs to be used.
o Woodward FlowTech (actuator - flap) controlled usually by 4-20mA, 0-5V or PWM
signal
o ComAp solution - No dedicated module needed, Bypass is controlled through any
analogue output based on the Bypass valve/actuator input. So output on the main
unit or from some I/O card can be used.

 Ignition – stays on engine, usually no change

o WW IC line
 Not supported over communication so far
o Motortech MIC line
 Support in the ECU List GEMS
o ATTENTION – on some Jenbacher lines (especially line 4) there is fitted Jenbacher
SAFI Ignition (made by Hoerbigger/Altronic) for Jenbacher. This ignition has
communication interface to main control unit and likely cannot work without this
interface – the conversion has not been done so far, there might be an issue about
it!!! Shall you know more about it, please share it.

CAT (including MWM) engines

 MWM – TCG 2016, 2020 lines

 CAT lines – no known conversions done so far, but some probably exist…

Control system fitted on the engine:

 Main control system – fully replaced

o TEM
o TEM EVO
o In both cases replaced by InteliSys (IntelISys Gas would fit)

The MWM solution is PLC based engine controller. The TEM solution does not control
alternator side. TEM solution does cover the CHP control and control of all other necessary
circuits. For alternator control (synchronisation, load control) there is a separate module, e.g.
from Deif, WW.

ComAp solution which can be used to replace the TEM control system:

o InteliSys Gas controller

o HMI based on customer preferences (InteliVision family)
 o I/O modules – type and number of modules depends on the engine size and also on
the fact whether the application is a CHP or not. The modules are usually
combination of: I-AIN8, I-AIN8TC, I-IO8/8 and could be also I-AOUT8
o IG-AVRi
o IG-AVRi-Trans
o AFR functionality – AFC dongle:
 For single applications: IS-AFC-PCM
 For multiple applications: IS-AFC-LSM+PMS
o Speed governor: ECON-4
o Stepper motor driver: I-STEP
Control of the application (e.g. CHP) is done inside the InteliSys PLC interpreter. Similarly
control of other circuits like Intercooler circuit, engine Preheating is done in this internal PLC
interpreter.

 Speed governor (controlling mainly Heinzmann STGxx actuators). Actuator stays on the
engine
o Heinzmann
o Replaced by ECON-4

 AFR control – stepper stays on the engine

o RMG stepper motor with end-points (proximity switch) – 2 options, either 0%
position or 0% and 100% position. There is no position feedback on this mixer.
o Replaced by I-Step, which can handle the end positions detection.

 Waste gate control

o No electrical control

 Ignition – stays on the engine…

o Altronic CPU95
o Altronic CD200
o Available communication interface to these modules
 CD200 – available as a “module” in the GenConfig card, Others in InteliSys
Gas (1.1.0 and further)
 CPU95 – support over I-CB Modbus

In case of new MWM engines, where there is a TEM control system, we can provide to customers the
following solution:

Customer, usually a packager who is packaging the MWM engines, keeps the TEM system on the
engine. TEM system does engine control. It can also control the CHP, but the packager has to provide
to the MWM the detail specification and the solution is programmed by sw engineers of MWM.

Providing ComAp solution on top of the TEM solution means for the customer:

 Control of the alternator (synchronisation, load control) – this is needed anyway, as TEM
does not do it
 Control of the CHP is in Packager hands, as he can design the CHP control inside the ComAp
solution, which means he is able to react faster and do the changes even during
commissioning or based on customer’s actual wishes. The solution means:
o InteliSys Gas – control of the alternator and CHP
o I-CB/MWM TEME – communication interface to the TEM panel
o Display unit – based on the customer’s preferences and budget
o I/O modules – based on the size of the installation
o Communication interface modules (Ethernet connection is part of the InteliSys Gas)
o IG-AVRi + IG-AVRi Trans