Knocking detector device DENOX 2, DENOX 20

HW & SW versions, December 2006

User guide

Copyright 2006 ComAp s.r.o. Prague, Czech Republic

ComAp, spol. s r.o. Svtova 7, 180 00 Praha 8, Czech Republic Tel: +420 2 66316661, Fax: +420 2 66316647 E-mail: info@comap.cz, www.comap.cz

Table of Contents
Table of Contents General guidelines What is described in this manual? Text Conformity declaration General description Terminals and Dimensions 20-sensors electronic unit 2-sensors electronic unit Knocking sensor Camshaft sensor Principle of Knocking Detection 20-sensors electronic unit 2-sensors electronic unit Camshaft sensor installation Control Function: Description of function Inputs, Outputs and Signalization Inputs Outputs Signalization Communication links PC software supporting the knocking detector device (DenEdit) First steps Virtual COM Port driver (VCP) Controller name definition Communication port setting Main window of program Regulation output and knocking intensity Signalization LEDs Monitoring cards Actual knocking values Knocking history Settings cards Mode card (20-sensors unit) Mode card (2-sensors unit) Knocking setpoints card Outputs options Input gains Firing sequence Can params Status line Technical data Electronic unit Knock sensor (recommended) ISU Ignition Sensor (recommended) -2-3-3-3-3-4-4-4-6-8-8-8-8-8-9-9- 10 - 10 - 10 - 11 - 11 - 11 - 12 - 12 - 12 - 12 - 12 - 13 - 15 - 15 - 16 - 16 - 17 - 17 - 17 - 17 - 19 - 21 - 22 - 23 - 23 - 23 - 24 - 24 - 25 - 25 -

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General guidelines
What is described in this manual?
This manual describes knocks monitoring system and its software utility DenEdit. What is the purpose of this manual? This manual is intended for everybody who is concerned in general information, in installation, operation and maintenance of the Knocking detector device.

Text
PAGE Break Return Generator protections REMOTE START/STOP (Capital letters in the frame) buttons on the front panel (Italic) set points (Bold) Set point group (Capital letters) binary inputs and outputs

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.

Note: ComAp believes that all information provided herein 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.

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General description
Terminals and Dimensions
20-sensors electronic unit

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2-sensors electronic unit

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Knocking sensor
The recommended type is piezoelectric acceleration transducer Bosch; O 261 231 006

Camshaft sensor
There are recommended active inductive proximity switching sensors produced by Siemens type BERO 3RG4. Detailed information is available on http://www.siemens.cz/siemjetstorage/files/9332_Katalog$BERO$3RG4$kompl$01$02$cz$V1.pdf

Principle of Knocking Detection

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

20-sensors electronic unit

20-sensors type of electronic knocking detector is equipped by up to 20 knocking detection sensors. Each knocking sensor processes sounds from one cylinder only. On the other hand each engine cylinder is equipped by one associated sensor.

2-sensors electronic unit

2-sensors type of electronic knocking detector is equipped by one or two knocking detection sensors only. Each of one or two sensors is installed and assigned to one or more cylinders. For this reason an eventual knocking is monitored on selected cylinders only. Thus it is necessary to install knocking sensors to that cylinders, which most probably and/or first of all will begin to knock. Important note: The design of some engines is characteristic by fact that two cylinders are firing at once. In this case concurrently firing cylinders must be divided to A and B sensor. The exclusion of most cylinders from knocking detection process it is the main diversity of 2sensors knocking detection unit. DENOX 2, DENOX 20, HW&SW versions ComAp December 2006 Denox2_20-DenEdit-1.2.PDF -8-

Camshaft sensor installation

Camshaft sensor answers the purpose of synchronization of acoustic engine signals to work cycle of the first cylinder. The sensor identifies the dead-point of 1st cylinder, which is followed by fuel combustion period. The pulse corresponds to the passage of the pin. The front edge of the pulse must to precede the Detonation evaluation window, i.e. Detonation window delay must be more than 0 (see Knocking params card). However the front edge may occur after finishing of the Detonation evaluation window assigned to the cylinder combusting as the last in previous working cycle only.

Control Function:
Knocking detector device has three binary outputs: ENGINE KNOCKING TRIP 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. User should choose relevant output according to ignition unit input for timing reduction (please consult manufacturer of ignition unit). Measured knocking energy in every working cycle is compared against adjustable limit Ignition reduction limit. If the intensity of the knocking is higher than limit then analogue output TIMING REDUCTION value increases. When knocking energy falls under the limit then the value of analogue output decreases. Decreasing rate is depending on Decrease ramp setpoint. If the Ignition reduction limit is overcrossed and the Normalized analogue output is higher than 5% then the binary output ENGINE KNOCKING is activated. The duration of ENGINE KNOCKING activity is at least 0,5sec. If full scale of analogue outputs is reached and engine is still knocking, LOAD REDUCTION output is activated. It should be connected to controller and used as command for power reduction. When engine stops knocking, output LOAD REDUCTION is deactivated, but analogue outputs remain at full scale for another period which can be set by Delay after load reduction setpoint and begin decrease after this period elapses. This period should be longer than time engine require to reach full load again. The last binary output TRIP is activated when knocking energy is greater than Immediate stop limit. It should be used as emergency stop signal.

IMMEDIATE STOP LIMIT

KNOCKING LEVEL

IGNITION REDUCTION LIMIT

ENGINE KNOCKING (BINARY OUTPUT)

LOAD REDUCTION TRIP (BINARY

DECREASE RAMP DELAY AFTER LOAD REDUCTION

MAX LEVEL OF ANALOG OUTPUT

TIMING REDUCTION

TIMING REDUCTION GAIN

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Description of function
The both (2-sensors and 20-sensors) controller devices are able to analyse two stroke and four stroke engines with up to 20 cylinders and with maximal ignition frequency 1 kHz. The knocking detector device can work in three basic modes. Measuring mode Interface diagnostic mode Knocking detection mode Measuring mode The time mark of camshaft is sent to PC via USB communication channel. The signal from selected knocking sensor is sent via USB too. Actually measured knocking sensor is selected on PC. Interface diagnostic mode Values adjusted in Diagnose window are copied to analog and binary outputs of knocking detector device. Evaluation of knocking is not proceeded. List of basic SW functional blocks in Knocking detection mode Timing synchronization of detection process Knocking sensor signal processing. It is possible to process up to two sensors currently Generating of analog output, binary outputs Detection of torn off knocking sensor Controlling of LED indicators of knocking sensors and time mark Communication with PC Communication via CAN bus

Inputs, Outputs and Signalization

Inputs
Timing input The reading of TDC of cylinder No.1 is used in the function of timing input. The passive inductive sensor ISU or an active sensor is used. Parameters: ISU interface symetric input, input resistance is 220. Jumper plug marked Load resistance is inserted. Active sensor interface it is possible to connect PNP or NPN sensors, input load resistance is 1k. Jumper plug marked Load resistance is removed

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Recommended connection of timing sensor Knocking sensors inputs Either 20 or 2 analog inputs are ready to sense acoustic signals of cylinders to recognize and evaluate the respective knocking. Parameters: AC coupled Signal amplification switchable in two levels. Respective jumper plug is not available to user. Input resistance at least 1 M

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

Signalization
Either 20 or 2 LEDs at individual inputs for knocking sensors - controlled by SW LED signalization of supply LED signalization of synchronization pulses controlled by SW 3x signalization of closed binary output 1x signalization of analog output level LED signalization of data transmition on CAN

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 acoustic signals and for control/set of Knocking detector device.

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PC software supporting the knocking detector device (DenEdit1)

The DenEdit software is intended to parametrization of both types of knocking detector device, to visualize actual values and to maintain setpoints-files in off-line operation. DenEdit is applicable in Windows 2000/XP etc. operational systems.

First steps
Virtual COM Port driver (VCP)
As first it is necessary to install the application (DenEdit). The PC communicates with the knocking detector device logically via COM port but physically via USB port. That means it is necessary to install Virtual COM Port (VCP) mapped to USB.. If the knocking detector device is connected to PC by USB cable and powered and VCP driver is not installed then the user is automatically prompted to install the driver. It is recommended to use the VCP driver previously downloaded and unzipped from http://www.ftdichip.com/Drivers/VCP.htm. Another standard way is to install the driver off-line on request of the user.

Controller name definition

After installation of PC software supporting the knocking detector device the user has to define the knocking detector device name. Related window will be opened automatically after first start of the PC software.

Next, the communication port definition is needed.

Communication port setting

The program can be renamed. After first start of renamed program the same filename with extension ini is automatically created. Settings in new *.ini file are default. DENOX 2, DENOX 20, HW&SW versions ComAp December 2006 - 12 Denox2_20-DenEdit-1.2.PDF

The correct communication port of PC should be selected. The controller communicates through USB port with your PC (DenEdit). However the PCs communication port is mapped as COM port . You need to select the communication port number in menu Connection -> Setup. The check-box Open connection after startup defines the requirement to connect the knocking detector on-line automatically immediately after startup of this supporting SW.

Main window of program

1 Main menu 2 Toolbar 3 Regulation and Knocking intensity graphic displays 4 Fault and status signalization LEDs 5 Cards for process monitoring 6 Cards for settings of the process (The picture visualizes a 20-sensor version of device) 7 Status bar

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Menu icons in main window

Connection

o o o

Connect USB Disconnect Open parameters

Connection Knocking detector device to PC Disconnection of Knocking detector device from PC Open file1 of previously saved setpoints of knocking detector device. DenEdit checks the compatibility of opened file with connected device. If problem or incompatibility occurs then the command is canceled Save the setpoint archive which name is defined by user. Internal structure and the file-extension corresponds with the type of unit (2- or 20-sensors) Setup of communication (see above) Program termination

Save as

o o

Setup Exit

Controller

o o o o o o o

Enter Password Deactivate password Change password Get encrypted password Two sensors mode

Enter password to enable changes of setpoints value

Disable of setpoints value changes Change of password Support of forgotten password recognition2 Selection between 2- and 20-sensors device. The item is active in OFF-LINE mode only. Device SW ver 2.0 or higher Selection of actual SW version of knocking detector. SW version can be read on the device label Reset peak Reset of detected peak of knocking shown in the card Knocking history

The file is named *.den for 20-sensors unit and *.de2 for 2-sensors unit. Using this item you will open also setpoints imported by previous supporting SW Denox_Can16 (the archives filename is *.p16). The menu-item Open file loads the on-line connected knocking detector. In off-line the DenEdit SW maintans the saved files in *.den (20-sensors device) and *.de2 (2-sensors device) formats. 2 The encryption of forgotten password is proceeded by special program. The program is available at device manufacturer. DENOX 2, DENOX 20, HW&SW versions ComAp December 2006 - 14 Denox2_20-DenEdit-1.2.PDF

Help o

About

Information about application and SW version

Regulation output and knocking intensity

Normalized analog output o Displays actual value of analog output o The value is expressed in % of output range. Take in account that the physical output range might be limited by Outputs options - Maximum output value setpoint

Knocking intensity o It is possible to select which value we want to be displayed on a pointer-type instrument. Make the selection in the card Mode: - Maximal value of knocking1 - Minimal value of knocking - Selected cylinder The measuring instrument displays actual value of knocking in % of maximal value. o The maximum value of knocking intensity is continuously selected. The number of related channel and the value of knocking are visualized in the upper right corner.

Signalization LEDs

STATUS The STATUS signalization group mirrors Knocking detector device binary outputs o ENGINE KNOCKING Knocking signalization. Actual value of knocking intensity of each cylinder is visualized on the card Actual knocking values. o TRIP Alarm, shut down. Details about function see in chapter Outputs description o REDUCTION Regulation analogue output reached Maximum output value

If maximal value of knocking is selected then values in the pointer-type instrument and in the upper right corner field are identical. DENOX 2, DENOX 20, HW&SW versions ComAp December 2006 - 15 Denox2_20-DenEdit-1.2.PDF

ERRORS The ERRORS signalization group visualizes results of devices internal diagnostics o LOW RPM o o NO ISU PULSES SPURIOUS PULSE No impulses are detected in TIMING INPUT. The genset is stopped or sensor and/or cable is torn off Impulses in TIMING INPUT are erratic. Perhaps Timing sensor does wrong, sensitivity of the Timing sensor is not proper or electric disturbance, noise Setpoints are damaged. Try to set setpoints again. If no success ask for the reparation of knocking detector device. Faulty sensor is possible to identify on the card Actual knocking values. Bad sensors identification number is marked by red color on the card Actual knocking values.

o o

EEPROM FAULT BAD SENSOR

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

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

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Knocking history

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

Settings cards
Mode card (20-sensors unit)

In this example the knocking is evaluated by all sensors with exception of Nos. 7 and 9 of 16-sensors knocking detector device. That means the knocking detection is executed from cylinders firing as the 1st, 2nd, 3rd, 6th, 8th, 10th e.t.c. in the firing order.

Mode card (2-sensors unit)

In this example the knocking is evaluated by sensors A and B. The cylinders firing as the 1st and as 3rd in the firing order are assigned to sensor A. The cylinders firing as the 2nd and as 4th in the firing order are assigned to sensor B. That means the knocking detection is executed from cylinders firing as 1st, 2nd, 3rd and 4th in firing order.

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Analysed cylinders

Selected sensor Display Record sound file

Diagnose

20- sensors unit: Selection of cylinders for knocking analysis 2-sensors unit: Selection of cylinders for knocking analysis and allocation to sensors A and B Selection of active sensor for displaying and sound recording Selection of value displayed on knocking intensity graphical display Button for sound recording from selected sensor After file name input the sound recording in SndAudio (*.au) format will be started Recording is displayed graphically and will be stopped by Stop button Knocking detector device diagnostics It is possible to set binary output signals by setting in appropriate checkboxes It is possible to change value of regulation output in Reg. Output box

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Knocking setpoints card

Setpoints for settings of Knocking detector device like engine type, etc. Protected by password Engine type Organization of engine o In-line o V-type o Irregular5 available for Device SW 2.0 and higher only Principle of engine o 2-stroke o 4-stroke Cylinders count o Count of cylinders o (only for V-type organization) The angle of camshaft between cylinders firing as 1st and as 2nd in order Delay of the beginning of 1st cylinder detonation Detonation window delay measuring interval after camshaft synchronization impuls. The front edge of synchronization impuls is considered. Time interval of knocking evaluation during bi-fuel Detonation window width combustion Characteristic frequency of knocking Knock filter frequency Characteristic frequency of background independent Reference filter frequency on the knocking Attenuation Ratio of attenuator Position of attenuator o Knock signal branch o Reference signal branch

Irregular means irregular angle intervals between cylinder firing. Angles of combustion start are defined in Firing sequence card. If the Irregular engine organization is selected then the Firing sequence card is available. DENOX 2, DENOX 20, HW&SW versions ComAp December 2006 - 19 Denox2_20-DenEdit-1.2.PDF

NOTE:
The setpoints are not written into Knocking detector device immediately. After the setpoint is edited the setpoint value is marked by blue color. The setpoint is written to Knocking detector device after ENTER key is pressed only.

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Outputs options
Setpoints for knocking detection, output settings, etc Protected by password

Ignition reduction limit Immediate stop limit Decrease ramp

Timing reduction gain

Maximum output value

Delay after load reduction

Reverse analog output

Enable max. output setting

Enable knock LED latch (switch ON/OFF to reset) Enable bad sensor detect Trip contact inactive

Minimal level of knocking detection signal. While exceeded, the knocking is reported. While exceeded, binary output TRIP is active If the knocking is not detected (see the setpoint Ignition reduction limit above) then TIMING REDUCTION decreases with the speed defined by setpoint If the knocking is detected (see the setpoint Ignition reduction limit above), the analog output TIMING REDUCTION signal is increasing. The speed of the rise is given by the setpoint Timing reduction gain. The speed is equal to arithmetic product of setpoint value and knocking value Max. value of analog output TIMING REDUCTION. The setting is enabled if the setpoint Enable max. output setting is set to ON only. The delay of the TIMING REDUCTION decreasing after the knocking will fall-off. (see the setpoint Ignition reduction limit above) If checked then the maximal value of analog output TIMING REDUCTION means no knocking and vice versa. If checked then it is possible to set the maximal level of analog output TIMING REDUCTION. (see the setpoint Maximum output value above). If checked then detected knocking is latched and signalized on relevant knocking sensors LED If checked then detected failure of sensor is latched and signalized on relevant knocking sensors LED Selection of positive/negative logic of binary output signal TRIP6.

If the setpoint Trip contact inactive is set to CLOSE then the binary output TRIP is ON only while signal of Ignition pulse (camshaft turning) is detected and there is none reason to stop the engine. That means there is no failure of knocking sensors and the knocking value does not exceed the value of Immediate stop limit setpoint. DENOX 2, DENOX 20, HW&SW versions ComAp December 2006 - 21 Denox2_20-DenEdit-1.2.PDF

Input gains

Input gains card is available for knocking detector devices programmed by firmware version 2.0 and higher only The gain of each input signal is possible to set in the range 0 300. The pushbutton Default causes the setting of all input signal gains to 100. Input gains in knocking detector devices programmed by firmware older than 2.0 are set to 100 and it is not possible to change the value.

Recommended procedure of Input gains tuning: o Record acoustic signals from all channels using DenEdit. o Check7 envelopes of records. Signals peaks must not be limited by the maximal amplitude of knocking detecting device input amplifier. Take in account maximum engine load and eventual knocking amplitude. o If signal peaks are limited in any channel then remove both jumpers defining the amplification. Jumpers are covered inside of a knocking detecting device. o Adjust fuction as follows: o Set the initiate values of Input gains setpoints to 100. o Set the ref. Filter frequency to 10120Hz. o Set Knock filter frequency to value corresponding to background noise. o Set Attenuation to 1,000 o Tune Input gains to balance knocking-like signals columns. Example see bellow.

The Cool96 audio signal analyzer is used usually. DENOX 2, DENOX 20, HW&SW versions ComAp December 2006 Denox2_20-DenEdit-1.2.PDF

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Firing sequence

Firing sequence card is available for knocking detector devices programmed by firmware version 2.0 and higher and at same time Engine type cylinders organization is set to Irregular The dead point of each cylinder angle is set to Cylinder No.1. Hence the angle value of Cylinder No.1 is in principle equal to 0,0. The pushbutton Default causes cylinders angle setting In-line-like Engine type. Consider these values as initial values for consecutive definition of irregularities.

Can params
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 knocking detector device Name of knocking detection unit

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Technical data
Electronic unit
Parameter Timing input Specification Input resistance 220/1000 Max. input voltage LOAD RESISTANCE 270 24V 1k 36V Max. frequency 800Hz Knocking sensors inputs Binary outputs Analog outputs Input resistance >1M All three outputs have one common terminal, max. voltage is 33V, max. load current is 50mA 1) 0 to 5V, load current max. 2mA Voltage accuracy 2% Note: auxiliary power source 5VDC is needed 2) current loop 4-20mA passive, max. voltage 30V Current accuracy 2% Operating Temperature range Storage Temperature range Humidity Power supply Consumption -10 +60oC -40 +80oC 95% without condensation 9 36 V DC 0,1 A for 24V supply 0,1 A for 36V supply 0,3A for 9V supply USB CAN Degree of protection Dimension electronic unit USB 1.1, 1MB/s, connector type B Galvanic isolated, 250kBd IP 20 20-sensors electronic unit: 160 x 187 x 52 mm 2-sensors electronic unit: 160 x 147 x 52 mm (including DIN rail clamp) 20-sensors electronic unit: 1 kg 2-sensors electronic unit: 0,8kg DIN rail mounting

Weight Electronic unit mounting

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Knock sensor (recommended)

Parameter Sensor principle Sensor type Frequency range Resonance frequency Temperature range Dimension sensor Sensor mounting Specification Piezoelectric acceleration transducer Bosch O 261 231 006 1 kHz 20 kHz > 20 kHz -40 +130C 45 x 20 x 21 mm M8 x 25 (cast iron) M8 x 30 (aluminium)

ISU Ignition Sensor (recommended)

Parameter Sensor principle Sensor type Power supply Temperature range Dimension Weight Sensor mounting Specification Active inductive proximity switching sensor Siemens 3RG40 22 active pick-up 15 34VDC -25 +85C M12 x 65mm 0.1 kg Female screw M12 x 1

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