@Perkins

DetCon20
Detonation Monitoring System
For Perkins 4000 TRS Series Engines

Contents
General guidelines .................................................................................................................. 3 Conformity declaration ....................................................................................................... 3 General description ................................................................................................................. 4 Terminals and Dimensions ................................................................................................. 4 Electronic unit................................................................................................................. 4 Terminal Layout.............................................................................................................. 5 Detonation sensor............................................................................................................ 6 Principle of Detonation Detection ...................................................................................... 7 Control Function: ............................................................................................................ 7 Description of function ........................................................................................................... 8 Inputs, Outputs and Indications .......................................................................................... 8 Inputs............................................................................................................................... 8 Timing input.................................................................................................................... 8 Outputs............................................................................................................................ 9 Indications..................................................................................................................... 10 Communication links .................................................................................................... 10 PC software supporting the Detcon20 (DenEdit) ................................................................. 11 First steps .......................................................................................................................... 11 Communication port setting.......................................................................................... 11 Main window of program ................................................................................................. 12 Menu icons in main window......................................................................................... 12 Regulation output and detonation intensity ...................................................................... 13 Indication LEDs............................................................................................................... 13 Typical Displays ............................................................................................................... 15 Actual detonation values................................................................................................... 16 Detonation history............................................................................................................. 16 Can parameters.................................................................................................................. 17 Status line.......................................................................................................................... 17 Settings.................................................................................................................................. 17 Technical data ....................................................................................................................... 18 Electronic unit................................................................................................................... 18 Detonation sensor.............................................................................................................. 19 ISU Ignition Sensor........................................................................................................... 19 Wiring 4006-23TRS........................................................................................................... 20 Wiring within ignition rail ................................................................................................ 20 External Connections Ignition Rail to Detcon ............................................................... 21 Wiring 4008-30TRS........................................................................................................... 22 Wiring within ignition rail ................................................................................................ 22 External Connections Ignition Rail to Detcon ............................................................... 23

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General guidelines
This manual describes the Detcon 20 detonation monitoring system and its software utility DenEdit. This manual is intended to give an overview of the system, operation and maintenance of the detonation system.

Conformity declaration
Following described machine complies with the appropriate basic safety and health requirement of the EC Low Voltage Directive No: 73/23 / EEC and EC Electromagnetic Compatibility Directive 89/336 / EEC based on its design and type, as brought into circulation by us.

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General description
Terminals and Dimensions
Electronic unit

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Terminal Layout

Caution: The wiring of the detonation sensors has to be in the firing order of the engine. For more wiring information, see the full engine wiring diagram.

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Detonation sensor

The max. Torque for the Sensor bolt is 30Nm.

Caution! The position of the detonation sensors at the engine directly influences the function of the complete detonation detection system. In order to achieve optimum function of the DetCon system it is strictly necessary to install the detonation sensors having a direct connection to the engine block. Installation with no direct connection to the engine (e.g. by gaskets) is not suitable. The detonation sensors are installed on the engine as shown below :

When wiring the detonation sensors make sure that the firing order is kept:

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Principle of Detonation Detection

During detonation, combustion vibrations are generated. Their frequency is typical for a specific engine type. The detonation detector measures vibration energy in a narrow frequency band, where detonation is expected. This energy corresponds to detonation level. Measurement is executed only during a specific section of the engine cycle, where detonating combustion is possible. This increases sensitivity and improves immunity against random noise.

Control Function:
Detonation detector device has three binary outputs: TRIP ENGINE KNOCKING LOAD REDUCTION and two analog outputs for TIMING REDUCTION: 0 5 V voltage output and 4 20 mA current loop Both analog outputs work concurrently. For the 4006-23TRS and 4008-30TRS engines, the 4-20mA output is used. Measured detonation energy in every working cycle is compared against an adjustable limit Ignition reduction limit. If the limit is reached, output ENGINE KNOCKING is activated. At the same time the analogue output increases its value. When detonation energy falls under the limit, then the value of the analogue output decreases. Decreasing rate is depended on Decrease ramp setpoint. If full scale of the analogue outputs is reached and engine is still detonating, LOAD REDUCTION output is activated. It may be connected to controller and used as command for power reduction. NOTE : Perkins recommend that Load Reduction is not used and that the LOAD REDUCTION output is used to shutdown the engine. When the engine stops detonation, the output LOAD REDUCTION is deactivated, but the analogue outputs remain at full scale for another period which is set by Delay after load reduction setpoint and begin to decrease after this period elapses. This period should be longer than the time the engine requires to reach full load again. The last binary output TRIP is activated when the detonation energy is greater than the Immediate stop limit. It should be used as an emergency stop signal.

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Description of function
The controller device is able to analyse two stroke and four stroke engines with up to 20 cylinders and with maximal ignition frequency 1 kHz. The detonation detector device can work in three basic modes. Measuring mode Interface diagnostic mode Detonation detection mode

Measuring mode The timing signal is sent to a PC via a USB communication channel. The signal from selected detonation is sent via USB too. The detonation sensor actually being measured is selected on the PC. Interface diagnostic mode Values adjusted in the Diagnose window are copied to the analog and binary outputs of the detonation detector device. Evaluation of detonation is not carried out. List of basic SW functional blocks in Detonation detection mode Timing synchronization of detection process Detonation sensor signal processing. It is possible to process up to two sensors currently Generating of analog outputs, binary outputs Detection of faulty detonation sensor Controlling of LED indicators of detonation sensors and time mark Communication with PC Communication via CAN bus

Inputs, Outputs and Indications

Inputs Timing input
The reading of TDC of cylinder No.1 is used in the function of timing input. The passive inductive sensor ISU is used. See the engine wiring diagram for details of the connections.

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Detonation sensors inputs 20 analog inputs are provided to sense the detonation signals of cylinders to recognize and evaluate the respective detonation.

Outputs
3 x Binary Output

Binary Outputs

Common Engine Knocking Potential Free Output

Trip Output

Load Reduction output

2 x Analog Output galvanic separation, 4 20 mA, 0 5V

Wiring for 4-20mA loop.

Terminal strip K4
1 2 3 4 5 6 7 8 9 10 11 12

+ 24V

To Ignition System 4-20mA

- 24V

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Indications
20 LEDs at individual inputs for detonation sensors - controlled by software LED indication of supply LED indication of synchronization pulses controlled by software 3x LED indicators of closed binary output 1x LED indicator of analog output level LED indicator of data transmission on CAN bus

Communication links
CAN Open, galvanic separation, 1 CAN connector USB minimal required speed 90 kB/s (44.1 kHz, 16 bit), type of connector B.

This connector is used for transfer of detonation signals and for control/set of detonation detector device.

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PC software supporting the Detcon20 (DenEdit)

The DenEdit software is intended to display the parameters of the detonation detector device, to display actual values and to maintain setpoint-files in off-line operation. DenEdit is applicable in Windows 2000/XP etc. operational systems.

First steps
Before a PC can communicate with the Detcon20, it is necessary to install the application (DenEdit) and a driver to enable communication via a USB port. The PC communicates with the detonation detector device logically via COM port but physically via a USB port. In order to do this it is necessary to install a Virtual COM Port (VCP) mapped to USB.. The simplest way to do this is to run the CDM_Setup.exe programme. This will automatically install the necessary drivers onto the PC. Having done this, it is necessary to establish the communications port which has been allocated by the PC for this application. To do this, open Settings, Control Panel, System, Hardware, Device Manager. Click on the Plus sign next to Ports (Com & LPT) and a list of com ports will appear and note which com port has been allocated to the USB/Serial adaptor. Now run the Denedit software and click on the Connection menu and select Setup.

Communication port setting

The correct communication port of PC as previously determined, should now be selected. The check-box Open connection after startup defines the requirement to connect the detonation detector on-line automatically immediately after startup of this supporting software. Next it is possible to select the page which will be activated in the main window by clicking on the required radiobutton.

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Main window of program

1

1 Main menu 2 Toolbar 3 Regulation and Detonation intensity graphic displays 4 Fault and status signalization LEDs 5 Cards for settings and monitoring of the process 6 Status bar

Menu icons in main window

Connection Connect USB Disconnect Open file device Save as Setup Exit

Connect detonation detector device to PC Disconnect detonation detector device from PC Open file1 of previously saved setpoints of detonation detector Save the setpoint archive which name is defined by user Setup of communication (see above) Program termination

The file is named *.den. Using this item you will open also setpoints imported by previous supporting software DetCon_Can16 (the archives filename is *.p16). The item Open file loads automatically the on-line connected detonation detector or (in off-line!) the supporting software maintains the saved file only.

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Controller Enter Password Enter password to enable changes of setpoints value Deactivate password Disable of setpoints value changes Change password Change of password Get encrypted password Support of forgotten password recognition1 Reset peak Reset of detected peak of detonation shown in the card Detonation history Help About Information about application and software version

Regulation output and detonation intensity

Detonation detector device Regulation Output Displays actual value of analogue output The value is expressed in % of output range. Detonation intensity Displays actual value of detonation in % of maximal value. The channel with the highest detonation intensity is selected automatically. Its detonation value and channel number are shown in the right upper corner It is possible to select which value is to be displayed on the card Mode: - Maximal value of detonation2 - Minimal value of detonation - Chosen measuring channel

Indication LEDs
STATUS The STATUS indication group mirrors detonation detector device binary outputs ENGINE KNOCKING Detonation indication. Actual value of detonation intensity of each cylinder is indicated on the card Actual detonation values. While the detonation level Ignition reduction limit is exceeded, the text ENGINE KNOCKING becomes blue. The click on the text evokes switching to the visualization of Actual detonation card.

LOAD REDUCTION Regulation analogue output reached Maximum output value

1

TRIP Alarm, shut down. Details about function see in chapter Outputs description

The encryption of forgotten password is done by a special program. The program is available at device manufacturer. 2 If maximal value of detonation is selected then values in the left and the right corners are identical.

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ERRORS

The ERRORS indication group displays results of devices internal diagnostics LOW RPM NO ISU PULSES SPURIOUS PULSE EEPROM FAULT BAD SENSOR No impulses are detected on the TIMING INPUT. The genset is stopped or sensor and/or cable is torn off Impulses on the TIMING INPUT are erratic. Perhaps the Timing sensor is faulty, sensitivity of the Timing sensor is not correct or electrical disturbance, noise Setpoints are damaged. Refer to the factory. The faulty sensor can be identified on the screen Actual detonation values. While the sensor is faulty, the text BAD SENSOR becomes blue. Clicking on the text evokes switching to the display of Actual detonation screen. The bad sensors identification number is marked by red color on the screen Actual detonation values.

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Typical Displays
Normal Operation

Engine Detonating

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Actual detonation values

Displaying of individual sensor status using the identification cylinder number color: Active sensor green Passive (not used) sensor grey Bad (faulty) sensor red Graphical displaying of actual detonation values of individual channels. The grey, yellow and red areas mean the detonation intensity. Boundaries g-y-r are defined by Ignition reduction limit and Immediate stop limit in Output options screen

The column along left side: Displaying of minimal, maximal and average detonation value from all channels Displaying of peak value of detonation (yellow triangle)

Detonation history
Detonation history from active sensors in last 1 minute Displaying of maximal detonation value (yellow dashed line) Possibility to set channel as active via click on legend (same as on Mode screen)

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Can parameters
_ Setpoints for communication via CAN bus.

Status line

The status line on the window frame displays Brief help concerning icon pointed by the cursor Communication status Software version of detonation detector device

Settings
The system is pre-programmed to suit the engine type and the settings are password protected. There are no user adjustments required.

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Technical data
Electronic unit

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Detonation sensor

ISU Ignition Sensor

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Wiring 4006-23TRS
The detonation sensor wiring is incorporated into the ignition wiring rail as shown below and terminates at a Deutsch 31 pin connector :
Cylinder 1

Knock sensor connector at rear Coil

KS6 KS5 KS4 KS3 KS2

208
KS1

Ignition and detonation sensing rail is mounted with coils horizontal as above

Top View

Connector to Knock Control Module Deutsch HDP26 24-31S Supplied with matching connector

To ignition unit 18S-1S

Wiring within ignition rail

Deutsch HDP20 24-31 Connector

1 2 3

22 23 24

19 20 21

13 14 15

10 11 12

16 17 18

25 26

J A E C

D G

To ignition trigger unit

+ + + + + +
6

Ignition Coil

HT Lead & Extension

2 1 KS1 2 1 KS2 2 1 KS3 2 1 KS4 2 1 KS5 2 1 KS6

Knock Sensor Wiring

Ignition Wiring

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Wiring 4006-23TRS Continued External Connections Ignition Rail to Detcon

Deutsch HDP20 24-31 Connector to Wiring Rail

3 2 1 24 23 22

21 20 19 15 14 13

12 11 10

18 17 16

25 26

4-20mA signal To Pin 'V' of Engine Harness Connector

Out Out Coil

Trigger Unit

Ignition

8 9

10 11 12 13 14 15

4 5

10 11 12

Terminal strip K1

Terminal strip K2

Detcon20 Detonation Sensing Module Terminal strip K4

1 2 3 4 5 6 7 8 9 10 11 12

Connections to OEM Panel

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Common Knock Alarm Knock S/D

+ 24V - 24V

Wiring 4008-30TRS
The detonation sensor wiring is incorporated into the ignition wiring rail as shown below and terminates at a Deutsch 31 pin connector :

Knock sensor connector at rear Coil

KS8 KS7 KS6 KS5 KS4 KS3 KS2 KS1

Top View

Connector to Knock Control Module Deutsch HDP26 24-31S Supplied with matching connector

To ignition unit 18S-1S

Wiring within ignition rail

Deutsch HDP20 24-31 Connector
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
E C D F B I H A

2 1 KS1

2 1 KS2

2 1 KS3

2 1 KS4

2 1 KS5

2 1 KS6

2 1 KS7

2 1 KS8

Ignition Wiring

Knock Sensor Wiring

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To ignition trigger unit

J G

Wiring 4008-30TRS Continued External Connections Ignition Rail to Detcon

Deutsch HDP20 24-31 Connector to Wiring Rail
3 2 1 6 5 4 9 8 7 12 11 10 15 14 13 18 17 16 21 20 19 24 23 22 25 26

4-20mA signal To Pin 'V' of Engine Harness Connector

Out Out Coil

Trigger Unit

Ignition

8 9

10 11 12 13 14 15

2 3

4 5

10 11 12

Terminal strip K1

Terminal strip K2

Detcon20 Detonation Sensing Module Terminal strip K4

1 2 3 4 5 6 7 8 9 10 11 12

Connections to OEM Panel

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Common Knock Alarm Knock S/D

+ 24V - 24V