Speed governor – 12/24 valves output

Manual or automatic temperature compensation

INCON
Integrated Speed and Injection Controller

SW version 3.1, May 2006

User manual

ComAp, spol. s r.o.

Copyright © 2005 ComAp s.r.o. Světova 7, 180 00 Praha 8, Czech Republic
Written by Aleš Procházka Tel: +420 2 66316661, Fax: +420 2 66316647
Prague, Czech Republic E-mail: info@comap.cz, www.comap.cz
1. Table of Contents
1. Table of Contents.......................................................................................................................................2
2. Introduction ................................................................................................................................................4
Warnings !! .....................................................................................................................................................4
General information........................................................................................................................................4
Application .................................................................................................................................................4
Description of operation.............................................................................................................................4
3. Installation..................................................................................................................................................6
INCON-2 Unit .................................................................................................................................................6
Dimensions and mounting holes position ..................................................................................................6
Recommended wiring ................................................................................................................................7
Connector pin description ..........................................................................................................................9
Jumpers and LED’s location ....................................................................................................................10
Pickups.........................................................................................................................................................11
RPM pickup..............................................................................................................................................11
Camshaft (CAM) pickup...........................................................................................................................11
Crankshaft (TDC) pickup (Top Dead Center pickup)...............................................................................12
Pickups jumper configuration...................................................................................................................12
Gas Admission Valves GAV.........................................................................................................................12
Firing order...............................................................................................................................................12
GAV current diagnostics ..........................................................................................................................13
4. Inputs and outputs ...................................................................................................................................15
Binary inputs.................................................................................................................................................15
RUN – K5:9..............................................................................................................................................15
RATED – K5:3 .........................................................................................................................................15
DROOP – K5:10 ......................................................................................................................................15
SPEED UP – K5:8 ...................................................................................................................................15
SPEED DOWN – K5:4.............................................................................................................................15
Binary outputs ..............................................................................................................................................16
WARNING – K5:6 ....................................................................................................................................16
INCON FAIL – K5:7 .................................................................................................................................16
Analog input .................................................................................................................................................16
Dose request – K5:1 ................................................................................................................................16
5. Setpoints ..................................................................................................................................................17
BASIC SET - B ..........................................................................................................................................17
Idle RPM [ RPM ] ............................................................................................................................17
Rated RPM [ RPM ] ........................................................................................................................17
Overspeed RPM [ RPM ] ....................................................................................................................17
Idle Ramp Time [ RPM/s ] ..................................................................................................................17
Speed Ramp Time [ s ]........................................................................................................................17
Gear Teeth [ - ]................................................................................................................................18
Cylinders Number [ - ] ......................................................................................................................18
Ext Fuel Control [ 0 / 1 ]......................................................................................................................18
Valve Test [ 0 / 1 ] .............................................................................................................................18
START - S ..................................................................................................................................................18
Init Start Dose [ 0.1° ] .........................................................................................................................18
Max Start Dose [ 0.1° ] .......................................................................................................................18
Fuel Ramp Time [ s ] ..........................................................................................................................18
Start Ramp Time [ s ]..........................................................................................................................19
Start RPM [ RPM ] ............................................................................................................................19
PID SET - P................................................................................................................................................19
Gain [ % ].........................................................................................................................................19
Integration [ % ] .................................................................................................................................19
Derivation [ % ] .................................................................................................................................19
Maximum Dose [ 0.1°] ........................................................................................................................20
MaxStartUp dose [ 0.1°] .....................................................................................................................20
Droop [ % ] .....................................................................................................................................20

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 No Load Dose [ ° ] ..............................................................................................................................20
Full Load Dose [ ° ] .............................................................................................................................20
VALVE CONFIG - V ..................................................................................................................................21
Out A FirOrder [ - ]..............................................................................................................................21
Out B FirOrder [ - ]..............................................................................................................................21
Out L FirOrder [ - ] ..............................................................................................................................21
Injection Start [ 0.1°] ...........................................................................................................................21
VALVE CONTROL - R ..............................................................................................................................22
Opening Delay [ 0.1ms ] .....................................................................................................................22
Peak Current [ 0.1% ].........................................................................................................................22
Holding Current [ 0.1% ] .....................................................................................................................22
Scope setting [ Std, RPM, A to L ]......................................................................................................22
TEMPER COMP - C...................................................................................................................................23
Cyl 1 Corr Low [ 0.1° ] ........................................................................................................................23
Cyl 1 Corr High [ 0.1° ] .......................................................................................................................23
Cyl2 Corr Low, Cyl2 Corr High [ 0.1° ]..................................................................................................24
Cyl12 Corr Low, Cyl12 Corr High [ 0.1° ] .............................................................................................24
Automatic Corr [ 0 / 1 / 2] ...................................................................................................................24
Contr Addr [ 34 – 122 ] ...................................................................................................................24
Corr Period [ s ] ...............................................................................................................................24
Corr Gain [ 0.1°]...............................................................................................................................25
Corr Limit [ 0.1°]...............................................................................................................................25
List of possible warnings and shutdowns.....................................................................................................25
6. User interface – setpoint menu................................................................................................................26
WinScope and WinScopeQ..........................................................................................................................26
PARAMETERS: .......................................................................................................................................26
InconDump-1.1.............................................................................................................................................28
Operational menu.........................................................................................................................................29
7. Technical data..........................................................................................................................................30
Power supply................................................................................................................................................30
Operating conditions ....................................................................................................................................30
Dimensions and weight ................................................................................................................................30
Binary inputs and outputs.............................................................................................................................30
Binary inputs ............................................................................................................................................30
Contact relay outputs...............................................................................................................................30
RPM pickup input .........................................................................................................................................30
TDC pickup input..........................................................................................................................................30
Camshaft pickup input..................................................................................................................................31

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2. Introduction
The major intent of this manual is to provide the end user with the necessary information for proper
installation, operating and maintenance of the INCON gas injection unit.

Warnings !!
The data in this manual only describes the product and is not warranty of performance or characteristic.

!!! CAUTION !!!

Dangerous voltage
Never touch any terminals that are in connection with the Gas injectors!
Never touch anything inside the INCON, when the box is opened and power supply is connected!
If you need to perform any modification inside the INCON, always disconnect the power supply
and wait at least 1 minute, before starting carrying out any task.
Always connect grounding terminals!

Adjust set points

All parameters are pre adjusted to their typical values. But the set points in the Setpoint group “Basic
settings” !!must!! be adjusted before the first startup of the engine.
!!! WRONG ADJUSTMENT OF BASIC PARAMETERS
CAN DESTROY THE ENGINE !!!
The following instructions are for qualified personnel only. To avoid personal injury do
not perform any action not specified in this User guide !!!

Note:
ComAp believes that all information provided in this manual is correct and reliable and reserves the right
to update at any time.
ComAp does not assume any responsibility for its use unless otherwise expressly undertaken.

General information
Application
The system has been developed to control the speed and power of a gas engine by varying timing and
duration of opening of gas injection valves for engines of up to 12 cylinders. The INCON-2 includes speed
governor function.

Description of operation
The overall system consists of:
• Unit INCON-2
• Speed pickup
• Camshaft pickup
• Crankshaft top dead center TDC pickup
• Gas Admission Valves on each cylinder

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 Gas governor

GEV
INCON Gas
El. mag. valve Exhaust
control system Air

Camshaft
pickup

Magnetic
pickup

Speed
pickup

INCON-2 controls the beginning and duration of gas admission into the suction port (before suction valve).

Varying the GAV opening duration controls engine speed and load. INCON-2 can individually control timing
of each GAV. This is used for equalizing of exhaust gas temperatures of individual cylinders.
The beginning and duration of opening are specified in crankshaft angular rotation degrees (see Engine
timing diagram).

For proper function INCON-2 needs signals from 3 pickups:

• Speed pickup on flywheel – signal is used for measurement of engine speed
• TDC pickup on crankshaft – signal is used as a timestamp for timing of the valves
• Reset pickup on camshaft – signal is used for distinction of the suction stroke of the first cylinder

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3. Installation
INCON-2 Unit
The unit is inside a metal box with a removable cover fixed with four screws to the main housing. There are
eight connectors located on the bottom part of the box.

! Warning !
Connectors must be downward oriented because of protection from dust.

! Warning !

Unit must be mounted on a secure, massive bracket on or near the engine using vibration damping mounts.
Avoid areas of excessive vibration and ambient temperature greater than 70 °C (158 °F).

Dimensions and mounting holes position

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Recommended wiring

INCON
Electronic Fuel Injection
Control Unit

K1 K2 K3 K4 K5 K6

CAN BUS CONTROL

I/O
battery supply
24 VDC

A B C D E F G H I J K L
speed
engine engine pickup
6x electromagnetic valve 6x electromagnetic valve position position
pickup camshaft
pickup

1 1 2 1 1 1 1
6 4 3 6 6
K2
K1 4 3 K3 K4 K5 K6
12 8 6 12 12

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 K1

1
F A

12 11 10

2
3
E B

4
9

5
D C
8

6
7
K2

1
4

SUPPLY 24VDC
2

+
3
K3

RPM
1
8

CRANK
7

CAM
6

+24V
+24V
5

K4

CAN L
1

CAN H No termination
6

COM resistor inside !

5

3
4

K5

ANALOG INPUT
4 - 20mA OR
1

0 - 10V
12 11 10

BI COMMON +Bat (-Bat)

3

DROOP RATED
4

RUN SPEED DOWN -Bat (+Bat)

9

SPEED UP BO COMMON
8

SHUTDOWN WARNING
+Bat (-Bat)
7
K6

L G
12 11 10

2
3

K H
4
9

J I
8

6
7

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Connector pin description
Connector K1 – GAS VALVES
PIN Description
1,2 Gas Valve A
3,4 Gas Valve B
5,6 Gas Valve C
7,8 Gas Valve D
9,10 Gas Valve E
11,12 Gas Valve F

Connector K2 – Power Supply

PIN Description
1,4 Power supply 0V
2,3 Power supply 24V

Connector K3 – Pickups
PIN Description
1,8 RPM pickup
2 CAM - Camshaft reset pickup, input
7 CAM - Camshaft reset pickup, 0V
3 TDC pickup, input
6 TDC pickup, 0V
4 +24V supply for active pickups
5 Shielding

Connector K4 – CAN Bus, isolated

PIN Description
1,6 CAN L
2,5 CAN H
3,4 Shielding

Connector K5 – Control signals, all signals isolated

PIN Description
1 Analog input 0-10V/0-20mA – input for requested valve opening if External Fuel Control=1
12 Analog ground
11 Shielding – reserve
2 Common potential for BI
3 BI RATED
4 BI SPEED DOWN
8 BI SPEED UP
9 BI RUN
10 BI DROOP
5 Common potential for BO
6 BO WARNING
7 BO INCON FAIL

Connector K6
PIN Description
1,2 Gas Valve G
3,4 Gas Valve H
5,6 Gas Valve I
7,8 Gas Valve J
9,10 Gas Valve K
11,12 Gas Valve L

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Note:
a) Connector pins are crimped type, by DEUTSCH. The proper DEUTSCH tool for crimping is HDT-48-
00.
b) Usable wire size is AWG14 thru AWG18.
c) It is recommended to use double wires for power supply connection because of connector and wire
current rating. In some cases, the supply current could be up to 15A peak.
Be sure to make good shielding!
• Careful shielding avoids interference problems.
• Connect shielding at one end of wire only (INCON side).
• INCON case must be properly connected to PE line. Connection by case screws is not good enough.
• Pickups must be connected by shielded cables – any disturbance can cause improper INCON
function.
• We recommend connecting the speed analog input by shielded cable.
• We recommend connecting the gas valves by shielded cables.

Jumpers and LED’s location

JP1: EPROM write protect

4 5 6 10 11 12

RUN
1 POWER RS 232 9
CRANK
RPM
CAM

DROOP
RATE
RUN

2 8
OUT1
- OUT2
+
JP8
JP14

JP13

JP4
JP3

3 7
2

JP17
1

K1 K2 K3 K4 K5 K6

1 …. LED indication
JP …. Jumpers marking

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Pickups
Pickups should be mounted at a massive, vibration free position. Constant air gap has to be kept.

RPM pickup
The RPM pickup senses the ring gear teeth or holes on the flywheel.
We recommend min 30 teeth (pulses) per revolution.

Camshaft (CAM) pickup

The camshaft signal detects TDC of cylinder no 1.

Installation of the pin:

Set the flywheel to the position 10 – 25° before TDC of the cylinder no 1, exhaust stroke.
Mark the position of the pin.
Drill the hole and fix the pin.

Active pickup

5 °
°-1
10
0,5 mm
TDC
A
Index "A" - 10°-25° before TDC
(Top Dead Center)

Camshaft
1:2

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Crankshaft (TDC) pickup (Top Dead Center pickup)
Crankshaft pickup senses metallic pins located on the flywheel that provide pulses indicating top dead center
of cylinders. Inductive or active type pickup can be used.
TDC sensor signal quality strongly influences the engine behaviour.

The number of pins and their spacing on the flywheel depends on the number of cylinders and the firing
sequence.

Examples:
For twelve-cylinder Vee engine with 60° between cylinder banks use six pins with angular spacing 60°.
For twelve-cylinder Vee engine with 45° between cylinder banks use six pins with angular spacing in 45°,
75°, 45° … series.
For six-cylinder in-line engine use three pins with angular spacing 120°.
For nine-cylinder in-line engine use nine pins with angular spacing 40°.

Pickups jumper configuration

Pickup Pickup type
RPM Inductive (passive) No jumper settings
CAM NPN JP14 CLOSE
PNP JP14 OPEN
TDC NPN JP13 CLOSE; JP8 “2”
PNP JP13 CLOSE; JP8 OPEN

RPM pickup is always inductive type (passive) – no jumper setting is required.

CAM - camshaft pickup is always active type, preferably NPN type

If you use NPN active pickup, close jumper JP14 (no external resistor is needed).
If you use PNP pickup, open jumper JP14 (no external resistor is needed).
Power supply for active pickups is provided in pickup’s connector.

TDC - Crankshaft pickup: all three types of sensors can be used:

• Active NPN
• Active PNP
• Inductive (passive) – not recommended

If NPN active pickup is used: close jumper JP13, set jumper JP8 to position 2 (no external resistor is
needed).
If PNP pickup is used: close jumper JP13, open jumper JP8 (no external resistor is needed).
If inductive (passive) pickup is used (not recommended): open jumper JP13 and set jumper JP8 to position
1.

Gas Admission Valves GAV

Installation of Gas Admission Valves GAV depends on engine type and on arrangement of filling manifold
and cylinder heads.
GAV may be installed in any orientation.
GAV is being mounted to the cylinder head or air filling manifold using M 8 socket head screws.
The contact surface of the GAV is sealed by means of O-ring located in the groove.

!WARNING!
It is essential that the interior of all gas manifolds be absolutely clean prior to GAV installation and engine
start up. There must not be any dust or contaminations, weld slug, rust, and other solid particles present!
Contamination of GAV by dirt may cause erratic function of the valve!

Firing order
INCON outputs A … to L must be connected to engine cylinders according following table.

A B C D E F G H I J K L
1 2 3 4 5 6 7 8 9 10 11 12

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The gas valves opening order is defined by setpoints Valve control: Out A FirOrder to Out L FirOrder.

GAV current diagnostics

Gas valve current diagnostics is a new feature of INCON firmware version 3-0. It is possible to visualize one
selected channel current on PC WinScope screen - see setpoint Valve control: Scope settings.
Selected INCON channel current is periodically sampled during pulse duration. Data are transmitted to
INCON RS 232 port after pulse sampling is finished and new sample period starts. Not each pulse is
sampled by this method (app. one of 100).

SAMPLING DATA TRANSMITTING SAMPLING

Note: Measured GAV current does not correspond to real solenoid current because of measuring point is
near the ground and parallel resistor is placed to GAV coil.

Setting Valve control: Scope settings = [Std, RPM, A-L] changes the Scope (RS232 diagnostics data)
channels structure:

Std RPM A-L

Channel 1 RPM (actual) RPM (actual) RPM (actual)
Channel 2 RPM (request) TDC (actual) GAV A – L current
Channel 3 Dose CAM (actual) Actual fuel dose
Channel 4 Droop 0 (not used) “A” = selected GAV

Following is an example of WinScope RPM pickup signals record (engine start). The CAM signal is
rectangular due to very low frequency on low RPM.

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Following is an example of WinScope GAV current record.

Current (Channel 2) range: value 1000 corresponds to 5 amps current.

Recommended WinScope X axis scale is 5 sec. It corresponds app 20 ms per one screen.

Hint:
GAV diagnostics activation and deactivation does not change the WinScope channels setting. Standard
channels description setting does not correspond to GAV diagnostics / see table above.

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4. Inputs and outputs
Binary inputs
Hint:
Binary inputs can be connected with common plus or with common minus. Binary inputs are isolated from
power supply.

Inputs switching to Battery + Inputs switching to Battery -

+24V 0V 0V +24V

COM COM
INCON INCON

RUN – K5:9
Input function depends on setting of Basic settings: Ext Fuel Control.
• Ext Fuel Control = 0 … INCON internal speed governor is used.
RUN input must be active (closed) to run the engine. Switching this input to OFF immediately closes all Gas
valves.
• Ext Fuel Control = 1 … external speed governor (e.g. ECON-2S) is used.
Closed RUN input activates automatic temperature corrections when Temperature compensation:
Automatic correction = 1. All INCON valves outputs are inactive (opened) when RUN input is opened.
Hint:
It is recommended to activate automatic temperature compensation in Bi-fuel engine operation only.

RATED – K5:3
If input RATED is active, Requested RPM = Nominal RPM, otherwise Requested RPM = Idle RPM.

DROOP – K5:10
This input switches governor to Droop mode. Status of DROOP input is important also for range of
Requested RPM.
Hint:
Set parameter Droop to 0 or switch input DROOP off for isochronous operation. Droop is active only on
Rated RPM when input DROOP is closed.

SPEED UP – K5:8
If active and SPEED DOWN is not active, the requested speed is increasing.

SPEED DOWN – K5:4

If active and SPEED UP is not active, the requested speed is decreasing.
Hint:
The Requested RPM can be changed in the range ± 8% from Rated RPM by binary inputs SPEED UP and
SPEED DOWN after engine RPM reach Rated speed level only.
If both SPEED UP and SPEED DOWN binary inputs are active, requested speed is not changing its value.

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Binary outputs
Binary outputs are potential free relay outputs. The common potential for outputs is on connector K5, pin 5 =
K5:5

WARNING – K5:6
Output closes, if any internal warning is active. As soon as the internal warning is deactivated, the output
opens.
Possible warnings:
• RPM, CAM, TDC pickup fail: Pickup fail is activated when the difference between any of RPM, TDC and
CAM value is higher than 10 RPM. Pickup fail is not indicated on Binary output K5:6 –warning below 200
RPM. Pickup fail is not indicated by separate RPM, TDC, CAM flag below 50 RPM.
• Over speed: Indication is active when actual RPM is over Basic setting: Overspeed RPM.
• Temperature corrections limit: Indication is active when automatic correction reach Temperature
compensation: Corr limit.
Hint:
From INCON-3.1 is available a new RPM, TDC, CAM pickups diagnostic via INCON RS232 scope channels.
16 bit status word with RPM, TDC and CAM flag is available in “Operational menu – Status” screeen and on
the CAN bus.

INCON FAIL – K5:7

Output closes, if an internal setpoint checksum is wrong after power supply switch on. The INCON program
is blocked and in the Terminal window (on PC) is message: “Wrong parameters”

Analog input
Dose request – K5:1
0-10V or 0-20mA – input for requested valve opening if the setpoint Basic settings: External Fuel Control
=1.
In this case the external governor is used for speed control and INCON works as gas dose actuator -
receiving requested valve opening via analog input K5:1, 12.
Close JP3 jumper for 0-20mA or JP4 jumper for 0-10V analog input range.

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5. Setpoints
BASIC SET -B
Idle RPM [ RPM ]
Engine Idle speed.
Step: 1RPM
Range: 100 – 2000 RPM

Rated RPM [ RPM ]

Engine Rated (nominal) speed.
Step: 1RPM
Range: 100 – 2000 RPM

Overspeed RPM [ RPM ]

If the measured engine RPM is above this limit, all gas valves are immediately closed and remain closed till
RPM < Overspeed RPM. BI WARNING is closed if RPM > Overspeed RPM and opened if RPM <
Overspeed.
Step: 1RPM
Range: 100 – 2000 RPM

Idle Ramp Time [ RPM/s ]

Ramp speed between Idle RPM and Nominal RPM and vice versa.
Step: 1 s
Range: 1 – 999 s

Speed Ramp Time [s]

This setpoint defines reaction speed of SPEED UP and SPEED DOWN inputs. Speed Ramp Time is time
Requested RPM needs to change from (Nominal RPM – 8%) to (Nominal RPM + 8%).
Step: 1 s
Range: 1 – 999 s
Hint:
ReqSpeed can be set from (Nominal RPM – 8%) to (Nominal RPM + 8%) if engine RPM reach the Rated
RPM.

Requested Speed Ramp

Nominal RPM + 8%

Nominal RPM

Nominal RPM - 8%

SpeedRampTime

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Gear Teeth [-]
Number of teeth on engine flywheel that are sensed by RPM pick-up.
Step: 1
Range: 1 – 500

Cylinders Number [-]

Number of engine cylinders.
Step: 1
Range: 1 – 24

Ext Fuel Control [0/1]

If set to 1, external governor is used for speed control. In that case INCON works as actuator, receiving
requested valve opening via analog input.
Range: 0 – internal speed control is used
1 – external speed control is used
Hint:
Ext Fuel Control change can be activated only after the power switch on or after Valve test On/Off.

Valve Test [0/1]

If set to 0 INCON operates in standard mode.
If set to 1 (= TEST) INCON generates constant pulses corresponding to Number of Cylinders without respect
to speed and TDC sensor signal and without corrections.
Range: 0 – standard operation
1 – TEST mode
Hint:
Use Valve Test for INCON hardware and Valves wiring test. Firing order is still fix does not change depends
on Out X FirOrder setpoint.
Valve Test is blocked on running engine !!! Do not start engine during Valve test !!!

START - S
As soon as Measured RPM reaches 10 RPM, INCON opens the gas valves to Init Start Dose. The start dose
can grow up in time form Init Start Dose to Max Start Dose. The start sequence ends as soon as Measured
RPM reaches Start RPM and since this moment begins normal speed regulation. If the Measured RPM
drops below 10 RPM during start, the start sequence starts again from the beginning.

Init Start Dose [ 0.1° ]

Gas valve opening when the engine reaches 10 RPM during start.
Step: 0.1 o
Range: 0 to 180.0 o

Max Start Dose [ 0.1° ]

Max valve opening during engine start. Valve opening rises from Initial Start Dose to Max Start Dose during
cranking.
Step: 0.1 o
Range: 0 to 180.0 o

Fuel Ramp Time [s]

Time from Initial Start dose to Max Start dose. Fuel ramp is activated when RPM > 10.
Step: 1 s
Range: 1 – 999 s

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 Fuel

Max Start Dose

Init Start Dose

Fuel Ramp Time

Time

Start Ramp Time [s]

Ramp speed from Start RPM to Idle RPM.
Step: 1s
Range: 1 – 999 s

Start RPM [ RPM ]

If engine speed is higher than this limit, governor ends start sequence and begins the speed regulation.
Step: 1 RPM
Range: 1 – 400 RPM

Speed

Idle RPM

Start Ramp Time

Start RPM

Time

PID SET - P
Gain [%]
Gain of the speed PID loop.
Step: 0.1%
Range: 0 – 999.9 %

Integration [%]
Integration part of the speed PID loop.
Step: 0.1%
Range: 0 – 200.0 %

Derivation [%]
Derivative part of the speed PID loop.
Step: 0.1%
Range: 0 – 200.0 %

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Maximum Dose [ 0.1°]
Maximum average fuel dose for all cylinders is limited by setpoint Maximum dose. Actual dose for individual
cylinders can be higher due to temperature compensation. Maximum dose does not limit the Initial Start
Dose and Max Start Dose.
Step: 0.1 o
Range: 0 to 180.0 o

MaxStartUp dose [ 0.1°]

Dose limit between Idle RPM and Rated RPM during starting procedure. Dose limit changes to Maximum
dose after engine reach the Rated RPM.
Step: 0.1 o
Range: 0 to 180.0 o

Droop [%]
Immediate droop is calculated from immediate fuel dose and setpoints Droop, No Load Dose and Full Load
Dose.
Step: 0.1%
Range: 0 – 15.0 %

No Load Dose [°]

Fuel dose on no load and nominal speed, it is used for calculation of governor droop.
Step: 0.1 o
Range: 0 to 180.0 o

Full Load Dose [°]

Fuel dose on full load and nominal speed, it is used for calculation of governor droop.
Step: 0.1 o
Range: 0 to 180.0 o
Hint:
No Load Dose and Full Load Dose is used as Droop reference and reference for Low power and High power
temperature corrections.

If binary input DROOP is active and setpoint Droop is non-zero, the Requested RPM decays with the
governor fuel dose. Parameters Droop, No Load Dose and Full Load Dose are used for calculation of actual
Requested RPM, see the figure below.

Requested RPM

Nominal RPM

Nominal RPM - Droop

Fuel Dose

No Load Dose Maximum Dose

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VALVE CONFIG -V
Out A FirOrder [-]
Defines position of the Physical output terminal B in the engine firing order. Set to 0 when INCON output is
not used. Usually Physical output A is connected to the cylinder 1 and thus setpoint Out A FirOrder is
position of cylinder 1 in firing order of the engine.
Range: 0 – 24

Out B FirOrder [-]

Defines position of the Physical output terminal B of INCON in the cylinder firing order. Set to 0 when INCON
output is not used. Usually Physical output B is connected to the cylinder 2 and thus setpoint Out B FirOrder
is position of cylinder 2 in firing order of the engine.
Range: 0 – 24

… to …

Out L FirOrder [-]

Defines position of the Physical output terminal L of INCON in the cylinder firing order. Set to 0 when INCON
output is not used. Usually Physical output L is connected to the cylinder 12 and thus setpoint Out L FirOrder
is position of cylinder 12 in firing order of the engine.
Range: 0 – 24

Example of 8 cylinders configuration.

Wiring
INCON2 Engine Setpoints setting Cylinder fire order
output cylinder (example)
K1: 1, 2 - A 1 Out A FirOrder 1 1
K1: 3, 4 - B 2 Out B FirOrder 3 3
K1: 5, 6 - C 3 Out C FirOrder 5 5
K1: 7, 8 - D 4 Out D FirOrder 7 7
K1: 9,10 - E 5 Out E FirOrder 2 2
K1:11,12 - F 6 Out F FirOrder 4 4
K6: 1, 2 - G 7 Out G FirOrder 6 6
K6: 3, 4 - H 8 Out H FirOrder 8 8
K6: 5, 6 - I Not used Out I FirOrder 0 Not used
K6: 7, 8 - J Not used Out J FirOrder 0 Not used
K6: 9,10 - K Not used Out K FirOrder 0 Not used
K6:11,12 - L Not used Out L FirOrder 0 Not used

Injection Start [ 0.1°]

This parameter defines the point when the valves open, a crank angle from Top Dead Center to opening of
gas valves, see the figure below.
Step: 0,1o
Range: 0 to 180.0o
TDC = 0

Injection Start

DOSE control
range

Maximum Dose

180

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VALVE CONTROL -R
Opening Delay [ 0.1ms ]
There is a delay between the time when voltage is applied to the electromagnetic gas valves and time when
the valves really open. This delay is compensated by parameter Opening Delay. See documentation of gas
valves for recommended value.
Step: 0.1 ms
Range: 0 – 99.9 ms

There are two different modes of control of the current passing through a coil of gas valve electromagnet:
- Opening period; full voltage of INCON's internal High voltage supply is connected to the coil to open
the valve as soon as possible
- Retaining period; current through the coil is controlled by PWM regulation
100%
GEV Current

Peak
current
Holding current

Time

Peak Current [ 0.1% ]

See documentation of gas valve for recommended value.
Step: 0.1 %
Range: 0 – 100.0 %

Holding Current [ 0.1% ]

See documentation of gas valve for recommended value.
Step: 0.1 %
Range: 0 – 100.0 %
Hint:
Valves control is activated above 20 RPM during engine start and deactivated below 10 RPM during engine
stop. The valves are closed below 10 RPM. These limits are fix.

Scope setting [ Std, RPM, A to L ]

Setting Valve control: Scope settings = [Std, RPM, A-L] changes the Scope (RS232 diagnostics data)
channels structure:

Std RPM A-L

Channel 1 RPM (actual) RPM (actual) RPM (actual)
Channel 2 RPM (request) TDC (actual) GAV A – L current
Channel 3 Dose CAM (actual) Actual fuel dose
Channel 4 Droop 0 (not used) “A” = selected GAV

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TEMPER COMP - C
INCON-2 uses two methods of compensation of exhaust gas temperatures from individual cylinders:

a) Linear “fix” correction of opening period of gas valves in dependency on average fuel dose. For each
individual cylinder is possible to set correction that is added or deducted from the average fuel dose.
Correction is set for two values of engine load (fuel dose). Correction for different engine loads is linear
interpolation in between these two points.

b) Feedback corrections based on exhaust temperatures of individual cylinders. Exhaust gas temperatures
are measured by external device and send to INCON via CAN bus.
INCON compares temperature of each cylinder with average value and depends on temperature difference
modify corrections of all cylinders. Setpoint Temperature compensation: Corr Gain (it was constant Corr
Step in v 2.0) is temperature difference multiplying factor. Correction change depends on temperature
difference of this cylinder and Corr Gain.
Automatic correction starts (after activation) from fix setting of Cylx Corr Low and Cylx Corr High. Each
cylinder correction is limited by Corr Limit setpoint (can not be higher). Correction value is limited to Corr
Limit when Cylx Corr Low and Cylx Corr High setting is over this limit - after automatic correction is
activated.
Period between corrections and amplitude of corrections are settable. If the measured temperatures are
not valid, (e.g. because of sensor fail on some cylinder), INCON-2 automatically switches to compensation
method a).
Closed RUN input activates automatic corrections in Automatic mode when Basic settings: Ext Fuel Control
= 1, i.e. external speed governor (e.g. ECON-2S) is used.
Automatic corrections are activated after engine reach Rated RPM (after Binary input RATED is closed)
when Basic settings: Ext Fuel Control = 0, i.e. INCON internal speed governor is used. Aut.corrections are
switched off when Binary input RATED is opened.

Automatic correction activation:

Internal speed governor When RPM reaches Rated RPM, stays active until engine stop.
External speed governor When Bin input RUN is closed.

Hint:
Always set setpoints for compensation method a), because they may be needed if there is any problem on
thermocouples, external analog modules or CAN bus.

u el
g eF -75
e ra
Av
uel
v e rage F on
A recti
+ cor
+50
Cyl1_Corr_L

No Load Dose Full Load Dose

Cyl 1 Corr Low [ 0.1° ]

Defines the correction of cylinder no 1 on 0° dose.
Step: 0.1 o
Range: -99.9 to 99.9 o

Cyl 1 Corr High [ 0.1° ]

Defines the correction of cylinder no 1 on 180° dose.

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Step: 0.1 o
Range: -99.9 to 99.9 o

Cyl2 Corr Low, Cyl2 Corr High [ 0.1° ]

… to …

Cyl12 Corr Low, Cyl12 Corr High [ 0.1° ]

Hint:
The cylinder number means position in “Engine cylinder numbering”, not in firing order of the engine.

Automatic Corr [ 0 / 1 / 2]
Parameter enables/disables automatic correction = exhaust temperatures compensation.

Automatic Corr = 0
Automatic exhaust temperature compensation is disabled and each cylinder actual dose correction is based
on fix (manual) setting - see setpoints Temperature compensation: Cylx Corr Low, Cylx Corr High.

Automatic Corr = 1
Automatic exhaust temperature compensation is enabled. Each cylinder temperature compensation starts
from fix (manual) setting - see setpoints Temperature compensation: Cylx Corr Low, Cylx Corr High after
compensation is activated.

Automatic Corr = 2
Automatic exhaust temperature compensation is enabled. Each cylinder temperature compensation starts
from 0 (fix) setting after compensation is activated. Starting value does not depend on Temperature
compensation setting.

Automatic Corr Automatic temperature compensation Compensation starting point

0 DISABLED, each cylinder correction is fix based on Temperature compensation setting.
1 ENABLED Fix, based on Temperature compensation setting.
2 ENABLED Starts from zero correction.

When automatic correction is activated:

• Basic settings: Ext Fuel Control = 1, i.e. external speed governor (e.g. ECON-2S) is used.
Closed K5:9 binary input RUN activates automatic corrections when Automatic mode is activated (Automatic
Corr = 1 or 2).
• Basic settings: Ext Fuel Control = 0, i.e. INCON internal speed governor is used.
Automatic corrections are activated after engine speed request reach Basic setting: Rated RPM (after
Binary input RATED is closed). Automatic corrections are deactivated when Binary input RATED is opened.

Ext Fuel Control Aut.correction is activated when

0 Binary inputs RUN and RATED are closed.
Speed request reach Basic setting: Rated RPM
1 Binary input RUN (K5:9) is closed.

Hint:
If automatic correction is enabled and no frames with exhaust temperatures are detected on CAN bus, BO
WARNING is closed and INCON uses fix corrections based on Cyl1 Corr Low, Cyl1 Corr High, …Cyl12 Corr
Low, Cyl12 Corr High.
Correction of one cylinder is switched to fix value if corresponding cylinder temperature sensor fails.

Contr Addr [ 34 – 122 ]

Incon Address on the can BUS. Default settings for IS/BF controller is 77.
Step: 1
Range: 34 – 122

Corr Period [s]

Time between two correction calculations.
Step: 1 s

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Range: 1 – 600 s

Corr Gain [ 0.1°]

INCON compares temperature of each cylinder with average value and depends on temperature difference
modifies corrections of all cylinders. Corr Gain is cylinder temperature difference multiplying factor.
Example: 100% Corr Gain gain makes correction step 2,5° for temperature difference 1 °C.
Step: 1 %
Range: 0 – 100 %

Corr Limit [ 0.1°]

Maximum absolute value of correction. Automatic correction is reduced to this limit even if fix correction is
set higher by Cylx Corr High and Cylx Corr Low setpoints. If correction of any cylinder reaches this limit,
binary output WARNING is activated.
Step: 0.1°
Range: 0 – 99.9°
Hint:
Manual temperature correction can be set out of Corr Limit without WARNING when Automatic correction is
switched OFF.

List of possible warnings and shutdowns

16 bit status word is available on the CAN bus. Separate bits can be configured in Master (e.g. InteliDrive)
controller to be visible on the screen.
Bit Function Bit Function
0 BI state: Droop 8 RPM pickup fail (in relation between pickups)
1 BI state: Rated 9 TDC pickup fail (in relation between pickups)
2 BI state: Run 10 CAM pickup fail (in relation between pickups)
3 BI state: RPM increase 11 Over speed
4 BI state: RPM decrease 12 Warning temperature limit
5 BO state: Warning 13 RPM lost (for speed control)
6 BO state: INCON fail 14 Common fail RPM, TDC, CAM (deayed against
bits 8, 9, 10).
7 Invalid setpoints 15 Not used

Note:
Bits 0 to 4 are mirror of binary inputs.
Bits 5 and 6 are mirror of binary outputs.
Bits 8, 9, 10 stays active until the next engine start.

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6. User interface – setpoint menu
There are two PC tools for INCON setpoints modification: WinScope (or WinScopeQ) and InconDump.

WinScope and WinScopeQ

Use PC software WinScopeQ or WinScope for INCON setpoints modification.
Procedure:
Connect RS232 cable between INCON and PC
Start WinScope or WinScopeQ
Use Open connection command
Select Connection: Direct, Controller: ECON/INCON, PC COM port
Select command Terminal – Show
Main menu screens can be switched by Letters (see table below) and Up/Down keys.

MAIN MENU
Info I
Parameters P
Operation O

PARAMETERS:
[unit]
Basic settings B Setpoint description
(adjustment range)
Idle RPM [RPM] (100 ÷ 2000) Engine Idle speed
Rated RPM [RPM] (100 ÷ 2000) Engine Rated (Nominal) speed
Overspeed RPM [RPM] (100 ÷ 2000) Engine Over speed limit
Idle Ramp Time [ RPM/s] (1 – 999) Pass time between Idle and Rated RPM
Pass time between Min and Max Requested
Speed Ramp Time [ s ] (1 – 999)
Speed
Geer Teeth [ - ] (1 ÷ 500) Number of teeth on flywheel
Cylinders Number [ - ] (1 ÷ 24) Number of engine cylinders
Ext Fuel Control [ - ] (0, 1) 1 – internal governor not used
Valve test [ - ] (0, 1) 1 – test of valves

[unit]
Start S Setpoint description
(adjustment range)
Defines end of cranking and start of speed
Start RPM [RPM] (0 ÷ 400)
regulation
Init Start Dose [0.1°] (0 ÷ 180.0) Gas valve opening on crank start
Max Start Dose [0.1°] (0 ÷ 180.0) Maximum valve opening during cranking
Pass time from Initial Start Dose to Max Start
Fuel Ramp Time [ s ] (0 ÷ 999)
Dose during cranking
Start Ramp Time [ RPM/s ] (0 ÷ 999) Pass time from Start RPM to Idle RPM

[unit]
PID set P Setpoint description
(adjustment range)

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 Gain [0.1%] (0 ÷ 999.0) Governor gain
Integration [0.1%] (0 ÷ 200.0) Governor integration
Derivation [0.1%] (0 ÷ 200.0) Governor derivative
Maximum Dose [0.1°] (0 ÷ 180.0) Speed regulator output limit
Droop [0.1%] (0 ÷ 15.0) Governor droop
Valve opening on nominal speed
No Load Dose [0.1°] (0 ÷ 180.0)
and no load, Droop reference.
Full Load Dose [0.1°] (0 ÷ 180.0) Droop reference.

[unit]
Valve config V Setpoint description
(adjustment range)
Defines firing order of cylinder connected to
Out A FirOrder [ - ] (0 ÷ 24)
INCON output A.
Defines firing order of cylinder connected to I
Out B FirOrder [ - ] (0 ÷ 24)
INCON output B.
Defines firing order of cylinder connected to
Out C FirOrder [ - ] (0 ÷ 24)
INCON output C.
Defines firing order of cylinder connected to I
Out D FirOrder [ - ] (0 ÷ 24)
INCON output D.
Defines firing order of cylinder connected to
Out E FirOrder [ - ] (0 ÷ 24)
INCON output E.
Defines firing order of cylinder connected to I
Out F FirOrder [ - ] (0 ÷ 24)
INCON output F.
Defines firing order of cylinder connected to
Out G FirOrder [ - ] (0 ÷ 24)
INCON output G.
Defines firing order of cylinder connected to I
Out H FirOrder [ - ] (0 ÷ 24)
INCON output H.
Defines firing order of cylinder connected to
Out I FirOrder [ - ] (0 ÷ 24)
INCON output I.
Defines firing order of cylinder connected to I
Out J FirOrder [ - ] (0 ÷ 24)
INCON output J.
Defines firing order of cylinder connected to
Out K FirOrder [ - ] (0 ÷ 24)
INCON output K.
Defines firing order of cylinder connected to I
Out L FirOrder [ - ] (0 ÷ 24)
INCON output L.
Injection Start [0.1°] (0 ÷ 180.0) Angle from TDC to start of gas injection

[unit]
Valve control R Setpoint description
(adjustment range)
Opening Delay [0.1ms] (0 ÷ 99.9) Opening delay of gas valves
Peak Current [0.1%] (0 ÷ 100.0) Peak valve current
Holding Current [0.1%] (0 ÷ 100.0) Holding valve current
Scope setting [ - ] (Std, RPM, A÷L) RS232 INCON scope settings

Temperature [unit]
(adjustment range) Setpoint description
compensation C
Cyl1 Corr Low [0.1°] (0 ÷ 180.0) Correction of cylinder no.1 on low load
Cyl1 Corr High [0.1°] (0 ÷ 180.0) Correction of cylinder no.1 on high load
Cyl2 Corr Low [0.1°] (0 ÷ 180.0) Correction of cylinder no.2 on low load
Cyl2 Corr High [0.1°] (0 ÷ 180.0) Correction of cylinder no.2 on high load
Cyl3 Corr Low [0.1°] (0 ÷ 180.0) Correction of cylinder no.3 on low load

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 Cyl3 Corr High [0.1°] (0 ÷ 180.0) Correction of cylinder no.3 on high load
Cyl4 Corr Low [0.1°] (0 ÷ 180.0) Correction of cylinder no.4 on low load
Cyl4 Corr High [0.1°] (0 ÷ 180.0) Correction of cylinder no.4 on high load
Cyl5 Corr Low [0.1°] (0 ÷ 180.0) Correction of cylinder no.5 on low load
Cyl5 Corr High [0.1°] (0 ÷ 180.0) Correction of cylinder no.5 on high load
Cyl6 Corr Low [0.1°] (0 ÷ 180.0) Correction of cylinder no.6 on low load
Cyl6 Corr High [0.1°] (0 ÷ 180.0) Correction of cylinder no.6 on high load
Cyl7 Corr Low [0.1°] (0 ÷ 180.0) Correction of cylinder no.7 on low load
Cyl7 Corr High [0.1°] (0 ÷ 180.0) Correction of cylinder no.7 on high load
Cyl8 Corr Low [0.1°] (0 ÷ 180.0) Correction of cylinder no.8 on low load
Cyl8 Corr High [0.1°] (0 ÷ 180.0) Correction of cylinder no.8 on high load
Cyl9 Corr Low [0.1°] (0 ÷ 180.0) Correction of cylinder no.9 on low load
Cyl9 Corr High [0.1°] (0 ÷ 180.0) Correction of cylinder no.9 on high load
Cyl10 Corr Low [0.1°] (0 ÷ 180.0) Correction of cylinder no.10 on low load
Cyl10 Corr High [0.1°] (0 ÷ 180.0) Correction of cylinder no.10 on high load
Cyl11 Corr Low [0.1°] (0 ÷ 180.0) Correction of cylinder no.11 on low load
Cyl11 Corr High [0.1°] (0 ÷ 180.0) Correction of cylinder no.11 on high load
Cyl12 Corr Low [0.1°] (0 ÷ 180.0) Correction of cylinder no.12 on low load
Cyl12 Corr High [0.1°] (0 ÷ 180.0) Correction of cylinder no.12 on high load
Automatic Corr [ - ] (0, 1, 2) Switches ON / OFF automatic correction
Contr Addr [ - ] (34 ÷ 122) INCON address
Corr Period [ s ] (1 ÷ 999) Time between two corrections
Corr Step [0.1°] (0 ÷ 180.0) Constant one correction step
Corr Limit [0.1°] (0 ÷ 180.0) Maximum absolute value of correction

InconDump-1.1
InconDump-1.1 - INCON/ECON setpoints editor functions:
• Load setpoints from binary “ins” file or directly from INCON
• Modify separate setpoints
• Save setpoints to binary “ins” or to text “txt” file
• Print setpoints list
• Download setpoints to INCON

Refer to InconDump-1.1 pdf manual.

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Operational menu
Start WinScopeQ - Terminal – select O = OPERATION DATA
STATUS
RPM=OK Engine RPM Ovs=No Over speed status
TDC=OK Top dead center sensor UnS=No Under speed status
CAM=OK CAM shaft sensor TCo=No Temperature correction on limit status
TEMPERATURE (received via CAN bus)
A= 400 Temperature of cylinder connected to D= 400 Temperature of cylinder connected to
INCON output A INCON output D
B= 400 … dtto output B E= 400 … dtto output E
C= 400 … dtto output C F= 400 … dtto output F
TEMPERATURE
G= 400 … dtto output G J= 400 … dtto output J
H= 400 … dtto output H K= 400 … dtto output K
I= 400 … dtto output I L= 400 … dtto output L
DOSE CORRECTION
A= +0 Actual dose correction for output A D= +0 Actual dose correction for output D
B= +0 Actual dose correction for output B E= +0 Actual dose correction for output E
C= +0 Actual dose correction for output C F= +0 Actual dose correction for output F
DOSE CORRECTION
G= +0 Actual dose correction for output G J= +0 Actual dose correction for output J
H= +0 Actual dose correction for output H K= +0 Actual dose correction for output K
I= +0 Actual dose correction for output I L= +0 Actual dose correction for output L
OPERATION DATA

RPM= 0 Engine RPM

DOSE= 0 Fuel dose

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7. Technical data
Power supply
Voltage supply 18 – 36V DC
Consumption 2 – 12A

Operating conditions
Operating temperature -20..+70oC
Storage temperature -30..+80oC
Protection front panel IP65
Humidity 85% without condensation
Standard conformity
Low Voltage Directive EN 61010-1:95 +A1:97
Electromagnetic Compatibility EN 50081-1:94, EN 50081-2:96
EN 50082-1:99, EN 50082-2:97

Dimensions and weight

Dimensions 400x230x111mm
Weight 3,5 kg

Binary inputs and outputs

Binary inputs
Electrically separated
Number of inputs 5
Input resistance 4,7 kΩ
Input range 0-36 VDC
Switching voltage level for close contact indication 0-2 V
Max voltage level for open contact indication 8-36 V

Contact relay outputs

Electrically separated
Number of outputs 2
Electric life cycle min 100.000 switching cycles
Maximum current 1 A DC resistive load
Maximum switching voltage 36 VDC
Minimum load 24 V / 0,1 A
Insulation voltage 500 Veff

RPM pickup input

Type of sensor magnetic pick-up
Minimum input voltage 3 Vpk-pk (from 4 Hz to 4 kHz)
Maximum input voltage 50 Veff
Minimum measured frequency 4 Hz
Maximum measured frequency 10 kHz (min. input voltage 6Vpk-pk)
Frequency measurement tolerance 0,5 %

TDC pickup input

Type of sensor magnetic pick-up or active pickup with PNP or NPN output
Minimum input voltage 3 Vpk-pk
Maximum input voltage 50 Veff

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Camshaft pickup input
Type of sensor active pickup with PNP or NPN output
Minimum input voltage 3 Vpk-pk
Maximum input voltage 50 Veff

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