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Motortech DetCon series, Operating Manual

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Motortech DetCon series Operating Manual Download Page 2

Original instructions 

Copyright 

© Copyright 2019 MOTORTECH GmbH. All rights reserved. 

Distribution and reproduction of this publication or parts thereof, regardless of the specific 
purpose and form, are not permissible without express written approval by MOTORTECH. 
Information contained in this publication may be changed without prior notice. 

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of the MOTORTECH GmbH. All further trademarks and logos displayed or used in this publication 
are the property of the respective entitled person. 

Summary of Contents for DetCon series

Page 1: ...DetCon Detonation Controller Operating Manual P N 01 30 002 Rev 02 2019...

Page 2: ...orm are not permissible without express written approval by MOTORTECH Information contained in this publication may be changed without prior notice Trademarks MOTORTECH products and the MOTORTECH logo...

Page 3: ...8 4 Product Description 20 4 1 Technical Data 20 4 1 1 Certifications 20 4 1 2 Mechanical Data 28 4 1 3 Warning Notices on the Device 29 4 1 4 Product Identification Labels on the Device 30 4 1 5 Elec...

Page 4: ...Reduction 67 7 3 Engine Stop 67 8 DenEdit Settings 68 8 1 DenEdit System Requirements 68 8 2 Installation and First Steps in DenEdit 69 8 3 User Interface Overview 72 8 4 Menu Bar and Toolbar 73 8 5 D...

Page 5: ...Table of Contents Rev 02 2019 5 10 Disturbances 85 11 Maintenance 86 11 1 Spare Parts and Accessories 86 12 Index 87...

Page 6: ...level of technical knowledge with respect to the operation of gas engines and basic knowledge of electronic ignition systems are necessary Persons who are only authorized to operate the gas engine sh...

Page 7: ...ices networks Asynchronous serial connection system for networking control devices CE Conformit Europ enne Conformity with EU directives Mark based on EU legislation for certain products in conjunctio...

Page 8: ...2 2019 Abb Term Description Explanation LED Light Emitting Diode Light emitting electronic semi conductor MIC MOTORTECH Ignition Controller USB Universal Serial Bus Serial wiring system to connect a c...

Page 9: ...state of the art and therefore safe and reliable to operate Nevertheless the equipment can cause risks or damage can occur if the following instructions are not complied with The gas engine must only...

Page 10: ...ive equipment PPE e g safety shoes and gloves must be worn during all work on the engine Your behavior can reduce possible residual risks to a minimum Pay attention to a responsible handling of the ga...

Page 11: ...The ESD standard IEC 61340 5 1 2016 must be observed during installation No warranty is given for damage due to electrostatic discharge Operational safety The DetCon detonation controller requires hig...

Page 12: ...mode V engines can only use the DetCon detonation controller with single ignition and not in double ignition mode The DetCon uses two time windows per cylinder to detect engine knocking These time win...

Page 13: ...on This system does not detect so called early ignition The reason for this is an excessive increase in pressure and temperature of the as yet non combusted mixture due to the pressure and temperature...

Page 14: ...ustion process These have a frequency which is characteristic for the engine type The DetCon measures the vibratory energy within a narrow frequency range which is typical for the respective engine Th...

Page 15: ...CKING binary output Signal on the binary output indicating knocking LOAD REDUCTION binary output Signal on the binary output effecting load reduction TRIP binary output Signal on the binary output ind...

Page 16: ...ts and the engine is still knocking the binary output for load reduction LOAD REDUCTION is activated A master control e g ALL IN ONE can control load reduction via this output LOAD REDUCTION is deacti...

Page 17: ...ined via the signal on the ASO output No other sensor is required Ignition controllers without ASO output The ignition timing is determined using a signal from the ignition sensor unit ISU connected b...

Page 18: ...ATEX directive 2014 34 EU II Device group II Ex areas with the exception of mines at risk of firedamp 3G Equipment category 3 Ex hazard rare and short term Substance group G Gases Ex Explosion protec...

Page 19: ...ion The USB interface may only be used in a non hazardous atmosphere There is a danger of sparking Sealing of the enclosure to the enclosure cover The enclosure is sealed against the enclosure cover b...

Page 20: ...d switch cabinet P N Device Description 43 00 002 DetCon2 Detonation Controlle Two inputs CSA IP20 for mounting in a CSA certified control cabinet 43 00 102 DetCon2 Detonation Controller Two inputs IP...

Page 21: ...eneric standards Emission for residential commercial and light industrial environments EN 61000 6 4 2007 A1 2011 Electromagnetic compatibility EMC Part 6 4 Generic standards Emission for industrial en...

Page 22: ...llowing directive ATEX Directive 2014 34 EU EN 60079 0 2012 A11 2013 Potentially explosive atmospheres Part 0 Equipment General requirements EN 60079 7 2015 A1 2018 Potentially explosive atmospheres P...

Page 23: ...4 Product Description Rev 02 2019 23...

Page 24: ...4 Product Description 24 Rev 02 2019...

Page 25: ...4 Product Description Rev 02 2019 25...

Page 26: ...4 Product Description 26 Rev 02 2019...

Page 27: ...4 Product Description Rev 02 2019 27...

Page 28: ...wings on page 35 Mounting for the electric unit DIN rail mounting Weight DetCon2 0 59 kg 1 30 lbs DetCon20 0 74 kg 1 63 lbs Shape of device See chapter Overview Drawings on page 35 Mechanical Environm...

Page 29: ...nd the installation and operation manuals prior to installing or making any adjustments ATEX EXPLOSION HAZARD Do not open enclosure or disconnect while circuit is live unless area is known to be non h...

Page 30: ...s on the Device On the device you will find the necessary numbers for a clear product identification Example DetCon in ATEX certified enclosure Abbreviation Description P N Part number of the device S...

Page 31: ...tputs The inputs and outputs have the following electrical data Inputs and outputs Values Ignition pulse input Input resistance 220 1 k Max input voltage 24 V at a load resistance of 220 36 V at a loa...

Page 32: ...MOTORTECH detonation sensors DetCon detonation controller systems are parameterized for operation with MOTORTECH detonation sensors piezoelectric acceleration transducers The use of other sensors ent...

Page 33: ...th 8 8 Torque 15 Nm 5 Nm 11 lb ft 2 2 lb ft for the following fixing screws M6 strength 10 9 with sleeve for fixing to the cylinder head screw If necessary the material of the cylinder head screw on w...

Page 34: ...Sensor 75 5 mm x 44 25 mm x 49 mm 2 97 x 1 74 x 1 93 incl DIN rail see Mounting the Ignition Sensor Unit ISU on page 53 Sensor mount DIN rail mounting 4 1 9 Technical Data of the Camshaft Sensor The c...

Page 35: ...roduct Description Rev 02 2019 35 4 1 10 Requirements for External Equipment External equipment shall fulfill the input and output specifications of the DetCon 4 1 11 Overview Drawings DetCon2 Dimensi...

Page 36: ...duct Description 36 Rev 02 2019 DetCon2 Ports Connections and LEDs For the functions of the individual ports connections and LEDs please refer to the table following the drawings accompanying the DetC...

Page 37: ...4 Product Description Rev 02 2019 37 DetCon20 Dimensions...

Page 38: ...tCon2 Sensor 1 20 DetCon20 Connections of the detonation sensors A white B brown S shield see Wiring of the Detonation Sensors on page 57 Timing1 Timing2 Shield 0 V 24 V Connections for the ignition s...

Page 39: ...age is available BINARY OUTPUTS LEDs These LEDs light up if the respective binary output Engine Knocking Trip Load Reduction has been activated TIMING REDUCTION ANALOG OUTPUTS LED This LED lights up i...

Page 40: ...4 Product Description 40 Rev 02 2019 DetCon Model in Enclosure Dimensions CSA Certified DetCon variant in ATEX enclosure Dimensions...

Page 41: ...70 C 158 F are present are not permissible and result in the warranty being voided Danger of explosion In order to prevent the connection terminals from falling out or loosening brackets must be moun...

Page 42: ...flying sparks If you do not see this protection externally it is installed internally Risk of Destruction When mounting the device it must be ensured that no vibrations occur during operation and that...

Page 43: ...protective conductor connection is located on the outside of the DetCon20 detonation controller enclosure Requirements EN 60439 1 2014 06 15 3 to be observed The external protective conductor must al...

Page 44: ...of the ATEX enclosure are designed in M 8 Connection of external protective conductor The external protective conductor is connected with the enclosed stainless steel screws nuts washers and lock wash...

Page 45: ...sufficient contact pressure in conjunction with the enclosed spring washer The choice of materials for the protective conductor connection is such that electrochemical corrosion is not to be expected...

Page 46: ...The maximum number for each side of the enclosure is selected according to the following table so that the side walls are not weakened and the stability of the enclosure is not impaired Screw size Si...

Page 47: ...possible standard lead glands is reduced Mixed fitting of lead bushings is possible Areas for intrinsically safe circuits must be marked separately Unused openings for lead bushings must be closed wit...

Page 48: ...erforated diameter mm Brass Polyamide Brass Polyamide Brass Polyamide M 12x1 5 2 5 1 8 2 5 1 8 2 0 1 48 2 0 1 48 2 5 1 8 2 5 1 8 12 5 M 16x1 5 4 0 2 95 4 0 2 95 2 5 1 8 2 5 1 8 4 0 2 95 4 0 2 95 16 5...

Page 49: ...locking capacitor board ATEX Use MOTORTECH detonation sensors DetCon detonation controller systems are parameterized for operation with MOTORTECH detonation sensors piezoelectric acceleration transduc...

Page 50: ...mission Mounting In order to ensure the best functioning of the DetCon detonation controller it is mandatory to install the sensors as follows There must be a direct connection to the engine block Ins...

Page 51: ...leeve The torque for mounting in the case of mounting with M8 screws strength 8 8 is 20 Nm 5 Nm 14 8 lb ft 3 7 lb ft and with M6 screws strength 12 9 with sleeve 15 Nm 3 Nm 11 lb ft 2 2 lb ft Also lay...

Page 52: ...on cylinder head screws or bolts Drill an M6 hole with a maximum depth of 12 mm 0 47 in the cylinder head screw and fix the detonation sensor with a screw of type M 6x25 10 9 and an adapter sleeve to...

Page 53: ...then five blocking capacitor boards are required One blocking capacitor board is used for each of the four knock sensors required 1 Plug the required blocking capacitor boards into the connectors mar...

Page 54: ...ection Mounting the Camshaft Sensor on page 55 No ignition sensor unit is needed when using a MOTORTECH ignition sensor unit with ASO e g MIC6 output either You can find information in the section Wir...

Page 55: ...DetCon via the ASO output Overview of Use Ignition Sensor Unit and Load Resistance Jumper The following table provides an overview of the applications for which you must use the ignition sensor unit...

Page 56: ...Mounting possibilities allowing for the reception of the required signal differ according to the engine type It may be necessary for example to insert a screw or drill a hole into the camshaft or ins...

Page 57: ...inputs on the DetCon according to the resulting sequence If all cylinders are not fitted with detonation sensors the first detonation sensor is assigned to the first cylinder used in the firing order...

Page 58: ...utput from MOTORTECH e g MIC6 In this case the ignition pulse is transmitted to the DetCon via the auxiliary synchronization output ASO The jumper identified with Load Resistance must be removed Posit...

Page 59: ...tion Configuration of the ignition controller In the configuration software MICT for the MOTORTECH ignition controllers with ASO output the adjustments for the DetCon can be easily made using the butt...

Page 60: ...h the designation Load Resistance must not have been removed Position Load Resistance Jumper The jumper Load Resistance changes the input resistance of the ignition input Jumper set 220 Jumper removed...

Page 61: ...Con ignition input Timing1 black DetCon ignition input Timing2 brown Not used Primary side of ignition coil of first cylinder Ignition controller ignition output of the first cylinder Connections on t...

Page 62: ...ation Load Resistance must be removed Position Load Resistance Jumper The jumper Load Resistance changes the input resistance of the ignition input Jumper set 220 Jumper removed 1 k It is on the upper...

Page 63: ...6 Wiring of the Device Rev 02 2019 63 Connections on the DetCon The ignition sensor unit is connected to the DetCon via the connector Ignition Pulse NPN sensor connection PNP sensor connection...

Page 64: ...6 5 Wiring of the Binary Outputs Example Configuration K1 Relay Engine Knocking Knocking Warning K2 Relay Trip Engine Stop K3 Relay Load Reduction The following illustrations show examples of two alt...

Page 65: ...ller 4 20 mA signal Alternative Output connector on the DetCon Connection on the Ignition Controller 4 20 mA signal 0 5 V Output connector on the DetCon Connection on the Ignition Controller 0 5 V sig...

Page 66: ...see drawing The maximum wire length depends on the bit rate Bit rate Maximum wire length Maximum length of a stub Maximum length of all stubs 1 Mbit s 25 m 82 1 5 m 5 7 5 m 25 800 kbit s 50 m 164 2 5...

Page 67: ...limited using the analog outputs via the Maximum output value 7 2 Load Reduction If the ignition timing can no longer be corrected via the analog outputs and the engine is still knocking the binary o...

Page 68: ...transmitted to the outputs of the device Knocking analysis is not carried out Knock Detection Mode Knock detection mode is the operation mode of the detonation controller After synchronization the si...

Page 69: ...ontinue Set up the Virtual Communication Port The PC communicates logically with the DetCon via the communication port COM but physically via USB For this reason it may be necessary with some operatin...

Page 70: ...ow Setup via the menu entry Connection Setup 6 In the field USB serial converter COM port enter the number of the COM port set on the PC 7 If you activate the checkbox Open connection after startup th...

Page 71: ...ine via the menu entry Connection Open Parameters The file name indicates which file corresponds to which DetCon device type and to which engine See also the following example Name of the parameter fi...

Page 72: ...e Overview The user interface is divided into different areas No Area Menu bar Toolbar Display area of the analog output signal and the knocking intensity Error and status displays Tabs for process mo...

Page 73: ...word is 0 zero Controller Deactivate password If parameters secured by a password have been changed this function can be used to secure password protection for access to the software Controller Change...

Page 74: ...tensity Various knocking intensity values can be indicated on the right display The values are shown as a percentage of the maximum value The selection of the displayed value is made in the tab Mode R...

Page 75: ...RIOUS PULSE The pulses at the ignition input Timing are faulty This can have the following causes defective ignition sensor unit ISU incorrect sensitivity of the ignition sensor unit check jumper Load...

Page 76: ...imit the border between green and yellow Immediate stop limit the border between yellow and red The condition of the detonation sensor is also marked in color The colors of the sensor number indicate...

Page 77: ...eters The following tabs are available for the process settings Mode In this tab you can enter general display and diagnostics settings This is also where you can start sound recordings of knocking si...

Page 78: ...nsor 2 Then click on the button Record sound file An input window opens 3 Select a save location for the sound file au and enter a filename The sound recording starts and is shown graphically in a sep...

Page 79: ...etting Irregular allows you to define an individual firing sequence in the tab Firing sequence 2 4 stroke Select the operating mode of the engine 2 stroke or 4 stroke V angle Enter the firing angle fo...

Page 80: ...her to amplify the input signals of the individual detonation sensors or to attenuate them values 100 in order to suppress signals similar to knocking signals Values between 0 and 300 can be specified...

Page 81: ...the timing reduction signal analog outputs is disabled as soon as knocking decreases below the Ignition reduction limit Timing reduction gain Enter the value for the Timing reduction gain This value i...

Page 82: ...ve detonation sensors are indicated via the status display BAD SENSOR This function only detects sensors which provide faulty signals If a wire has ruptured or a sensor gives no signals for some other...

Page 83: ...e following settings for communication with the HMI module PowerView3 selectCANopen mode CAN address freely selectable set identical address in PowerView3 Bus speed 250 kBit s 8 9 Status Bar The statu...

Page 84: ...hecked before initial operation The enclosures must be properly installed The enclosures must not be damaged especially the gaskets There must be no foreign objects in the housing The terminal compart...

Page 85: ...etonation sensors are indicated via the status display BAD SENSOR This function only detects sensors which provide faulty signals If a wire has ruptured or a sensor gives no signals for some other rea...

Page 86: ...ce and repair must be carried out in accordance with EN 60079 17 During maintenance in particular the parts on which the protection class depends must be checked This includes in particular the seals...

Page 87: ...eduction Declaration 13 Setting 81 Device Connecting with PC 69 Disposal 12 Function 13 Dimensions Drawing 35 Overview 28 E Engine Calibrating 79 Engine knocking Declaration 13 Engine Stop Declaration...

Page 88: ...Mode 78 O Outputs Overview 31 Testing 78 P Parameter file Loading 69 Power consumption 31 R Regulations Overview 20 S Safety Instructions Device 11 General 9 Software Installation 69 Menu 73 Overview...

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