CHP Cogenerator — When the Control Electronics Fail
A CHP (Combined Heat and Power) cogenerator is an investment of €150,000–2,500,000. Running at 8,000 h/year, producing 150–2,500 kWh of electricity, the controller is the critical system — deciding on grid synchronisation safety, gas engine speed regulation, alternator AVR control, and protection management (overcurrent, phase loss, loss of synchronism). Controller failure = cogenerator shutdown and combined electricity and heat losses of €200–2,000/day.
A new Deif AGC-4 controller costs €2,800–5,400. ComAp InteliSys NT: €3,200–6,800. Lead time: 4–14 weeks. Our repair: 5–12 working days, €320–1,600.
We serve cogenerator operators, industrial plants with their own power stations, and service engineers from Poland, Germany, Austria, Czech Republic, Slovakia, Belgium, Netherlands, Denmark, Sweden, Finland, Romania, Hungary.
CHP and Genset Controllers We Repair
Deif A/S (Denmark)
- Deif AGC-4: Flagship genset/cogenerator controller with synchronisation, multi-unit parallel operation, busbar management. Interfaces: Modbus RTU/TCP, Profibus, CANopen, DNP3, IEC 61850. Failures: failed CPU card (NXP i.MX6), "CAN Bus Fault" — failed CAN transceiver (TI SN65HVD232), failed I/O expansion module, failed TFT display.
- Deif AGC-3 / AGC-2: Older generation. Failures: exploded electrolytics on 24VDC supply, corrupted firmware flash chip, sync error — failed frequency converter (VC TCXO).
- Deif CHP Controller: Dedicated gas cogenerator controller. Manages: ignition map, gas dosing, cooling, heat recovery, synchronisation. Failures: failed engine I/F card, "Speed Deviation" — failed PWM governor output, failed magnetic speed sensor.
- Deif PPM-3 (Power Plant Manager): Power plant management controller. Failures: failed Ethernet/Modbus TCP card, redundant power supply failure.
- Deif ASC-4 (Auto Synchronizer): Auto synchronisation module. Failures: "Sync Check Fail" — failed voltage and phase measurement channel.
ComAp (Czech Republic)
- ComAp InteliGen NT (IGEN-NT): Genset controller with synchronisation. Interfaces: Modbus, CANopen, Ethernet. Failures: failed CPU card (Samsung ARM), failed analogue input module (AI8), "Fail to sync" — failed voltage/frequency converter, exploded electrolytics on main board.
- ComAp InteliSys NT (ISYS-NT): Multi-genset controller. Failures: failed IL-NT communication card, failed CAN expander module, EEPROM corruption.
- ComAp InteliSys 9 (IS-9): Latest platform. Failures: failed 7" TFT touchscreen, "App Config Error" — erased firmware after surge.
- ComAp InteliLite NT (IL-NT): Small genset controller. Failures: failed AMF (Automatic Mains Failure) converter, "Low Fuel" with good sensor — failed analogue input.
Woodward (USA)
- Woodward easYgen-3000 Series (3100, 3200, 3300, 3400, 3500): Synchronised genset controller series. Interfaces: CAN J1939, Modbus RTU/TCP, PROFIBUS. Failures: failed CPU card (Freescale/NXP PowerPC), "Governor Fault" — failed speed governor PWM output, failed analogue card (4–20 mA), failed ModEx expansion connector.
- Woodward 723 / 723PLUS Digital Speed Control: Classic engine speed governor. Failures: failed actuator output amplifier (MOSFET BD140/TIP147), analogue channel zero drift, corrupted NVRAM with regulation parameters.
- Woodward ProAct Governor: Electro-hydraulic actuator speed governor. Failures: failed PWM actuator driver card, "Actuator Open Circuit" error.
Heinzmann (Germany)
- Heinzmann MICT: Gas engine and ignition system controller. Manages: ignition timing, mixture enrichment, NOx exhaust (lambda control). Failures: failed CPU card (Motorola 68332 or ARM Cortex-M), "Knock Sensor Fault" — failed piezo input, failed lambda measurement channel, failed ignition output card.
Motortech (Germany)
- Motortech MM4.10 / MM4.20: Gas engine ignition controller. Manages ignition timing, cylinder diagnostics, CAN J1939 comms. Failures: failed ignition coil outputs (IGBT per cylinder: IXGH32N60), "Misfiring Detection" — failed cylinder pressure transducer, failed CAN card.
- Motortech CITO: Combustion analyser and timing optimiser. Failures: failed pressure transducers (PCB piezo), failed DSP card.
AVR Alternator Regulators — Stamford, Leroy-Somer, Meccalte
- Stamford MX321 / MX341 / SX460: Analogue AVR for Stamford alternators. Failures: failed MOSFET or SCR thyristors, failed electrolytics, voltage trim potentiometer drift. Repair: €120–320.
- Leroy-Somer D350 / D400 / AREP: AVR for Leroy-Somer (Nidec) alternators. Failures: failed control thyristor, failed excitation rectifier diode, "Voltage Dip" under load. Repair: €140–380.
- Meccalte AVR60-5 / SR7 / SR8: Failures: burned voltage sensing resistor, failed suppressor capacitors, "Overvoltage Trip". Repair: €100–280.
- Basler AEX / DECS-100 / DECS-250: Digital AVR with CAN. Failures: failed CPU card, U/I transducer calibration error. Repair: €280–680.
Pricing
| Module | Manufacturer / Model | Repair Cost |
|---|---|---|
| Genset / CHP controller — CPU card | Deif AGC-4, ComAp InteliGen NT, Woodward easYgen-3000 | €480–1,200 |
| Controller I/O module | Deif, ComAp, Woodward | €220–580 |
| Communication card repair (Modbus/Profibus/CAN/Ethernet) | Deif AGC-4, ComAp InteliSys, Woodward easYgen | €180–480 |
| Gas engine ignition controller | Heinzmann MICT, Motortech MM4.10/MM4.20 | €380–980 |
| Speed governor (regulator) | Woodward 723/723PLUS, Heinzmann DGS | €280–720 |
| Analogue AVR repair | Stamford MX321/MX341, Leroy-Somer D350, Meccalte | €100–380 |
| Digital AVR repair | Basler DECS-100/250, Leroy-Somer D400 | €280–680 |
| Synchronisation module repair (ASC/MSC) | Deif ASC-4, Woodward easYgen sync module | €220–560 |
| Firmware reflash / config restore | All models | €120–380 |
| Full controller overhaul | All models | €580–1,600 |
| Diagnostic without repair | — | €80 |
DHL Express shipping Poland / Europe. Repair time: 5–12 working days. Warranty: 12 months. Service open Mon–Fri 08:00–16:00. No-fix no-fee.