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INSTALLATION/OPERATION
DEVIATION FROM THESE INSTRUCTIONS MAY LEAD TO IMPROPER OP-
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WARNING:
ERATION OF THE MACHINE WHICH COULD CAUSE PERSONAL INJURY
ERATION OF THE MACHINE WHICH COULD CAUSE PERSONAL INJURY
TO OPERATORS OR OTHER NEARBY PERSONNEL.
TO OPERATORS OR OTHER NEARBY PERSONNEL.
CAUTION:
1.0 DESCRIPTION
1.1
The Altronic DET-1600 Detonation Sensing Monitor is a 32-bit micropro-
cessor-based electronic instrument designed to detect and eliminate
detonation on natural gas-fueled engines before damage occurs.
Industry-standard low cost broadband piezoelectric vibration
sensors, mounted on the engine, are used to transform the vi-
brations caused by detonation into electrical signals which are
then evaluated by the DET-1600. The Detonation Sensing Monitor
uses the sensors to measure the combustion intensity of each
cylinder in a user-confi gured time window. The detonation
signals are fi ltered by programmable fi lters and then sent to
the microprocessor for further processing and evaluation.
This process is repeated for every cylinder on a cycle-by-
cycle basis. The resulting two reference numbers, one for
detonation intensity and the other for the lack of a com-
bustion process, or misfi re, are displayed on a LCD display.
These reference numbers are used to control two output
switches, typically one for load control and the other for
shutdown, and a 4-20mA current loop or Modbus RTU out-
put used to retard ignition timing.
The 2 x 16 backlit LCD is used to display the detonation and
misfi re reference level numbers, engine cylinder labels, control and
output switch status, the cause of shutdown log, as well as diagnos-
tic messages. The reference numbers are compared to adjustable
setpoint values. These setpoint values are user adjustable and when
exceeded by the reference numbers signal the output switches to trip.
The switches can be used to control load, ignition timing, and ⁄ o r to
shut down the engine. The 4-20mA current loop output is fully confi g-
urable and can be used to adjust ignition timing or engine load. The
RS485 Modbus RTU output can be used for timing adjustment.
DEVIATION FROM THIS INSTALLATION/OPERATING MANUAL
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MAY LEAD TO IMPROPER OPERATION OF THE MONITORED
MACHINE WHICH COULD CAUSE PERSONAL INJURY TO
OPERATORS OR OTHER NEARBY PERSONNEL.
THE DET-1600 DETONATION SENSING MONITOR IS CERTIFIED
FOR USE IN CLASS I, GROUPS C & D, DIVISION 2 HAZARDOUS
LOCATIONS WHEN INSTALLED IN ACCORDANCE WITH THESE
INSTRUCTIONS.
THE SENSOR INPUT LEADS CONNECTED TO THIS DEVICE
OPERATE AT A LOW VOLTAGE AND POWER LEVEL AND MUST
NOT CONTACT ANY EXTERNAL VOLTAGE SOURCE. DAMAGE TO
THE SYSTEM WILL RESULT FROM CONNECTION BETWEEN THE
INPUT SENSOR LEADS AND THE IGNITION SYSTEM OR ANY AC
OR DC POWER SOURCE ABOVE 36 VDC.
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DET-1600 DETONATION
SENSING MONITOR
FORM DET-1600 IOM 11-09
www.altronicinc.com
1
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Summary of Contents for Altronic DET-1600
- Page 1 INPUT SENSOR LEADS AND THE IGNITION SYSTEM OR ANY AC OR DC POWER SOURCE ABOVE 36 VDC. 1.0 DESCRIPTION The Altronic DET-1600 Detonation Sensing Monitor is a 32-bit micropro- cessor-based electronic instrument designed to detect and eliminate detonation on natural gas-fueled engines before damage occurs.
- Page 2 Phoenix-type connectors. The If future transportation or DET-1600 can be set up for one sensor per cylinder, one per two cylin- storage of the monitor is ders, or one per bank.
- Page 3 3.1 DETONATION SENSING MONITOR (SEE FIGURE 1) Monitor with the LCD display Mount the DET-1600 inside a control panel or to a suitable fl at surface facing direct sunlight. The so that the display is at a convenient viewing height. A drilling tem- display temperature range plate is provided.
- Page 4 Connect a wire from the number ¹ cylinder ignition coil primary of a negative ground C.D. ignition sys- tem to the back of the DET-1600 monitor to the terminal marked #1 COIL INPUT. The ground connection will be made through the DC- terminal on the back of the monitor that is connected to panel ground which should be the same as engine ground.
- Page 5 Use a two conductor cable of 20-22AWG (Altronic 693134-x or equivalent) to wire the detonation sensor to the sensor input terminals on the back of the DET-1600. The sensor cables should be run in rigid conduit or Sealtite⁄Liquidtite to protect the wires from breakage.
- Page 6 4.6 OUTPUT SWITCH WIRING Exceeding a setpoint value will cause the user programmable output switch to turn ON/OFF with respect to its common. The DET-1600 con- tains two output switches. Switch 1 is typically used to initiate load control and switch 2 is typically used to initiate a shutdown sequence.
- Page 7 The DET-1600 Detonation Monitor is CSA certifi ed for CLASS I, DIVISION 2, GROUPS C & D areas. The DET-1600 is certifi ed as a component only and is required to be installed in a suitable enclosure where the suitability of the combination is subject to the local inspection authority having jurisdiction.
- Page 8 5.2 DETONATION AND MISFIRE The DET-1600 system can detect both detonation and misfi re. While detonation is a greater amplitude signal, misfi re is the absence of a normal combustion process. The same cylinder sensor is used for both misfi...
- Page 9 5.4 INPUT SIGNAL FILTERING Detonation, as well as the mechanical engine noises, occurs in the audible frequency range of 20Hz to 20kHz. The DET-1600 uses a con- fi gurable band-pass fi lter to separate the detonation vibrations from the normal engine vibrations. The theoretical detonation frequency is based on the cylinder bore diameter and the speed of sound at a typical combustion temperature and pressure.
- Page 10 DET-1600 DETONATION SENSING MONITOR The fi rst line of defense of the DET-1600 system is typically to control load. If either a misfi re or detonation occurs (the misfi re reference number goes below the misfi re setpoint value or the detonation refer- ence number goes above the detonation setpoint value) output switch #1 will activate.
- Page 11 Click on each tab to select the page to be confi gured. Following are the descriptions of each confi guration parameter. 6.3 TERMINAL PROGRAM, ESTABLISHING COMMUNICATIONS Connect the DET-1600 to the PC via the RS485 port marked RS485 MODBUS SLAVE through a RS485 to RS232 adapter (for wiring details SEE SECTION 4.8 FIGURE 12 (RS485 COMMUNICATIONS, PC HOOK-UP).
- Page 12 Use the COM Port Command Menu to confi gure the PC to “talk” to the Monitor: Com port “x” (x is the com port used on the PC), Baud Rate (set to the same as the DET-1600, 1000ms Timeout, Parity none, and 1 Stop Bit. 6.6 SLAVE ID Set the Slave ID to match the DET-1600 Node Number.
- Page 13 Enter 2 for a two-, or 4 for a four-stroke engine. 7.3 AUTOSCAN The time entered here in seconds will be used by the DET-1600 as the display time for each cylinder channel when automatically displaying the home screen channels. If zero is entered, the display will remain on the displayed channel until it is advanced using the keypad.
- Page 14 7.6 MAP SENSORS The MAP SENSOR table assigns a unique cylinder identifi cation label to each channel. The DET-1600 must be wired to match the fi ring order of the engine. The DET-1600 reads each sensor in the Firing Event order from 1 to max number of cylinders.
- Page 15 Normal Run Tim- ing Value. If set to User Value, the DET-1600 uses the normal run timing value entered by the user in the Normal Run Timing Value entry box. If the DET-1600 is confi...
- Page 16 The Misfi re Setpoint Value is a user-confi gurable low setpoint value. It is used to trigger the DET-1600 to take action if the misfi re level value measured from any sensor goes below the setpoint caused by a sus- tained misfi...
- Page 17 8.3 BAD SENSOR SETPOINT VALUE The Bad Sensor Setpoint Value is a user-confi gurable low setpoint value. It is used to trigger the DET-1600 to take action if the knock sensor or its wiring for any monitored cylinder goes open or shorted. A bad sensor will cause the input to go low.
- Page 18 Modbus or by cycling the power. When set to Nonlatch, the switch will stay tripped when the Monitor is at the Max Retard Timing Value Allowed but will automatically reset when the DET-1600 returns the engine timing to a no retard condition. FORM DET-1600 IOM 11-09...
- Page 19 8.6.1 CONTROL RPM VALUE When the engine is started and the rpm is below the Control RPM Value, the DET-1600 will not activate the outputs. It will act as a monitor only. This will allow the engine to start and become stable without the control outputs taking eff...
- Page 20 Monitor detects either misfi re or detonation. Enable the Current Loop Control by selecting the check box on the terminal program or from the menu in the DET-1600. Use the Loop LO and Loop HI confi guration parameters to set the range in degrees retard, essentially the two endpoints.
- Page 21 Display Module the Manual Retard value can only be changed by the Default Ignition Timing value in the DET-1600. When install- ing the DET-1600, and if Modbus Control is used to retard the igni- tion timing, set the Manual Retard value for the CPU-95 Enhanced Display Module in the Default Ignition Timing entry box.
- Page 22 The value is also shown on the DET-1600’s home screen. An example of the calculated value would be if the user entered 24°btdc for the Normal Run Timing Value and the DET-1600 is imposing 5° of retard, a value of 5° retard would be displayed.
- Page 23 INSTALLATION/OPERATION MANUAL grator time constant can be confi gured separately for each cylinder for detonation and misfi re. When confi guring each cylinder input for misfi re detection, these parameters are used to calibrate the cylin- der’s sensor for a low signal, or the absence of a normal combustion process.
- Page 24 The Window Parameters are Open Detonation/Misfi re Window and Duration of Detonation/Misfi re Window. These user confi gurable parameters allow the DET-1600 to detect detonation and misfi re only during the expect- ed time frame. The window parameters will be used at the confi gured time after top-dead-center for each cylinder.
- Page 25 9.10.2 DURATION OF MISFIRE WINDOW The Duration of Misfi re Window is the window open time, or du- ration, in absolute crank angle degrees that the DET-1600 will detect misfi re for each cylinder. The range is 1 to max window opening.
- Page 26 The Status Diagnostics are an indication of each parameter’s current condition. 10.3.1 ENGINE ROTATION The indicator will be on when the DET-1600 is above the indi- cation rpm. Minimum rpm is 200 rpm. 10.3.2 CONTROL RPM REACHED The indicator will be on when the engine rpm is above the confi...
- Page 27 10.3.5 SWITCH #2 ACTIVATED The indicator will be on when Switch #2 is activated. 10.3.6 SUPPLY VOLTAGE The supply voltage seen by the DET-1600 will be displayed in the text box. 10.3.7 ENGINE RPM The engine rpm calculated by the DET-1600 will be displayed in the text box.
- Page 28 Controlling knock intensity is further complicated by en- gine cycle to cycle variations. Because of the variations of the deto- nation signal for each engine rotation the DET-1600 must be set up for an average value from a large number of samples.
- Page 29 The best way to calibrate the DET-1600 det- and enabled prior to device onation signal processing parameters is if an actual signal for incipi- ent detonation can be safely produced.
- Page 30 13.0 KEYPAD DESCRIPTION 13.1 The DET-1600 Detonation Sensing Monitor contains an eight-key front key- pad which is used to view the reference data for each cylinder, view and change the setpoint values, view the diagnostic data, and to access the menu.
- Page 31 14.0 HOME SCREEN DESCRIPTION When the DET-1600 Detonation Monitor is in the home screen, it displays the global system status on the fi rst line along with switch ¹ and ²...
- Page 32 DET-1600 DETONATION SENSING MONITOR 14.0 HOME SCREEN DESCRIPTION (continued) Home Screen Global System Status REF. NUMBER VS. REF. NUMBER VS. Cylinder inder Number Number DET. SETPOINT MISFIRE SETPOINT Individual Cyl Status DETONATION SENSED The cylinder number descriptions are one or two digits and can be confi...
- Page 33 INSTALLATION/OPERATION MANUAL 14.1 SYSTEM STATUS The fi rst line of the display shows the global status of the DET-1600 system. The system status descriptions are: No RPM 01 D: 0 M: 0 No RPM is displayed on power-up of the DET-1600. No RPM indicates...
- Page 34 Ign Ret 10° sw1 05 D:815 M:650 D Ign Ret xx° is displayed if detonation continues to occur. The DET-1600 will send out a signal to retard the ignition timing (either by cur- rent loop or Modbus). xx represents the current amount of retard in- fl...
- Page 35 INSTALLATION/OPERATION MANUAL View Alrms sw1 2 ENTER 01 D: 0 M: 0 View Alrms = View Alarms – When switch #2 trips, which is typically used to shut down the engine, the View Alarms message will blink al- ternately with the system status message. Press the ENTER/ACK key to acknowledge the condition.
- Page 36 SETPTS The Maximum Retard Timing Value Allowed is the maximum amount of retard that the DET-1600 can infl ict on the engine via the ignition system in order to control detonation. For example, if the ignition system’s normal run timing value is 24°btdc and the Max Retard Timing Value Allowed is set at 10 degrees, the DET-1600 can retard the engine to a maximum of 14°btdc.
- Page 37 SETPTS MAX RETARDÇü 60s The DET-1600 upon reaching the max retard value will wait the Re- tard Step Time plus the confi gured Switch #2 Trip Time at Max Retard before shutting down the engine (if switch #2 is set up to shut the engine down).
- Page 38 16.1 GENERAL INFORMATION – Confi guration of the DET-1600 must be performed using the terminal program. The screen menus on the DET-1600 are used during operation of the system to view or modify the signifi cant operating parameters. AUTOSCAN SETUP Çü...
- Page 39 The Control Lockout Time is used to lock out (disable) the output switch- es, current loop, and Modbus control on start-up. Previous to tim- ing out, the DET-1600 will act as a monitor only and will not activate the outputs. This allows the engine to start and stabilize without the output switches or control interfering with engine start-up and loading.
- Page 40 DET-1600 DETONATION SENSING MONITOR 16.10 SECURITY The security feature allows for protection from data inadvertently being changed. There are several areas in the menu system that can be protected as well as two layers of protection. The menus that can be protected are the GENERAL SETTINGS, the SETPOINT VALUES, and the ability to make COMMUNICATIONS setting changes.
- Page 41 17.2 FAULT DIAGNOSTICS Fault Diagnostics are used as a troubleshooting aid. The following mes- sages can be viewed if the DET-1600 does not sense the required signal. 17.2.1 NO SD SIGNAL Displayed when the DET-1600 senses a lack of the shutdown lead volt- age.
- Page 42 18.0 RS-485 COMMUNICATIONS, MODBUS RTU 18.1 The DET-1600 is compliant to the Modicon Modbus RTU standard. Maxi- mum number of registers that can be read at one time is limited to 32. Maximum number of booleans that can be read at one time is limited to 256.
- Page 43 Location Label Default Notes Read/Write bits 00000’s Global Functions 00001 Reserved 00002 Ignition Timing Control Enabled Enable/Disable Detonation Control, Revert to default timing 00003 Protect Confi guration Protect general confi guration from being changed 00004 Protect Setpoints Protect setpoint confi guration from being changed 00005 Protect Comms Protect Communication confi...
- Page 44 Location Input # Individual Functions Default Notes 00033 Input is Enabled 00034 Input is Enabled 00035 Input is Enabled 00036 Input is Enabled 00037 Input is Enabled 00038 Input is Enabled 00039 Input is Enabled 00040 Input is Enabled 00041 Input is Enabled 00042 Input is Enabled...
- Page 45 Location Label Notes Read only bits 10000’s Global Functions 10001 Rotation Sensed no rotation rotation The DET has sensed the engine is rotating. Use for loss of rotation 10002 Timing Control engaged Ignition timing is being controlled by the DET 10003 Switch 1 Activated Output switch 1 activated by detonation or misfi...
- Page 46 Location Input # Individual Functions Notes 10027 Sensor Status Bad Sensor Sensor is detected and operating properly or is not detected 10028 Sensor Status Bad Sensor Sensor is detected and operating properly or is not detected 10029 Sensor Status Bad Sensor Sensor is detected and operating properly or is not detected 10030 Sensor Status...
- Page 47 Location Input # Individual Functions Notes 10058 Misfi re Detected Status misfi re detected Misfi re detected on this channel 10059 Misfi re Detected Status misfi re detected Misfi re detected on this channel 10060 Misfi re Detected Status misfi re detected Misfi...
- Page 48 Location Input # Individual Functions Notes 10089 Detonation Status @ ‘SW2’ detonation detected latched Detonation Status on this channel at “SW2 “ 10090 Detonation Status @ ‘SW2’ detonation detected latched Detonation Status on this channel at “SW2 “ 10091 Detonation Status @ ‘SW2’ detonation detected latched Detonation Status on this channel at “SW2 “...
- Page 49 Location Label Units Size(bits) Min Notes Read only bytes 30000’s Global Functions 30001 Same as 10001-10016 30002 Same as 10017-10032 Bad Sensor Status Flags 30003 Same as 10033-10048 Detonation Status Flags 30004 Same as 10049-10064 Misfi re Status Flags 30005 Same as 10065-10080 Alarms Bad Sensor Status Flags 30006...
- Page 50 Location Input # Individual Functions Units Size(bits) Min Notes 30025 Misfi re Level 1023 30026 Misfi re Level 1023 30027 Misfi re Level 1023 30028 Misfi re Level 1023 30029 Misfi re Level 1023 30030 Misfi re Level 1023 30031 Detonation Level 1023 30032...
- Page 51 Location Input # Individual Functions Units Size(bits) Min Notes 30053 Retard from default timing degrees Default timing is set by Ignition system 30054 Retard from default timing degrees Default timing is set by Ignition system 30055 Retard from default timing degrees Default timing is set by Ignition system 30056...
- Page 52 Location Label Units Size (bits) Default Notes Read/Write bytes 40000’s Global Functions 40001 Coils 001-016 65535 40002 Coils 017-032 65535 40003 Coils 033-048 65535 65535 Inputs Enabled 40004 Coils 049-064 65535 40005 Coils 065-080 65535 40006 Coils 081-096 65535 40007 Coils 097-112 65535 40008...
- Page 53 Location Label Units Size (bits) Default Notes 40024 Switch 1 Hysteresis time seconds 40025 DET Setpoint Value (SW1) 1023 40026 Switch 2 Time until Tripped seconds 40027 Control Initialization Time seconds “CD200 - 4mA = 16° retard, 20mA = 0° retard CPU95 - 4mA = 0°...
- Page 54 Location Input # Individual Functions Units Size (bits) Default Notes 40050 Factory 40051 misfi re gain (0-63) misfi re bandpass fi lter freq. 40052 (0-63) misfi re Integrator time 40053 constant (0-31) 40054 detonation gain (0-63) detonation bandpass freq. 40055 (0-63) detonation Integrator time 40056...
- Page 55 INSTALLATION/OPERATION MANUAL Firing Starting Event Location 40050 40070 40090 40110 40130 40150 40170 40190 40210 40230 40250 40270 40290 40310 40330 40350 FIRING EVENT 16 Firing Size Location Label Units Default Notes event # (bits) 40350 Factory 40351 misfi re gain (0-63) SEE GAIN CHART, PAGE 56 40352 misfi...
- Page 56 DET-1600 DETONATION SENSING MONITOR GAIN CHART BANDPASS CHART (Registers 40351 and 40354) (Registers 40352 and 40355) Register Value Gain Register Value Gain Register Value Bandpass Filter Freq. Register Value Bandpass Filter Freq. 2.000 0.258 1.220 kHz 8.020 kHz 1.882 0.250 1.260 kHz...
- Page 57 Engine fi ring order ..The engine cylinder fi ring sequence. normal run timing value ... The timing value in °btdc that the engine runs at with normal loads. This is the max advanced tim- ing value and the DET-1600 can only retard the engine timing from this value. www.altronicinc.com...
- Page 58 WIRING DIAGRAM – MODBUS CONTROL TO IGNITION SYSTEM WIRING DIAGRAM – CURRENT LOOP, CPU-95 WIRING DIAGRAM – CURRENT LOOP, CD200/DISN 10. WIRING DIAGRAM – ALTRONIC ANNUNCIATOR SYSTEMS 11. WIRING DIAGRAM – DC RELAYS 12. WIRING DIAGRAM – RS-485 COMMUNICATIONS, PC HOOK-UP...
- Page 59 INSTALLATION/OPERATION MANUAL FIGURE 1. MOUNTING DIMENSIONS AND SPECIFICATIONS www.altronicinc.com...
- Page 60 DET-1600 DETONATION SENSING MONITOR FIGURE 2. FLOWCHART FORM DET-1600 IOM 11-09...
- Page 61 INSTALLATION/OPERATION MANUAL FIGURE 3. HOME SCREENS www.altronicinc.com...
- Page 62 DET-1600 DETONATION SENSING MONITOR FIGURE 4. MOUNTING, DIMENSIONS, AND SPECS – KNOCK SENSORS FORM DET-1600 IOM 11-09...
- Page 63 INSTALLATION/OPERATION MANUAL FIGURE 5. WIRING DIAGRAM – DETONATION SENSORS www.altronicinc.com...
- Page 64 DET-1600 DETONATION SENSING MONITOR FIGURE 6. WIRING DIAGRAM – POWER, INPUTS, AND OUTPUTS FORM DET-1600 IOM 11-09...
- Page 65 INSTALLATION/OPERATION MANUAL FIGURE 7. WIRING DIAGRAM – MODBUS CONTROL TO IGNITION SYSTEM www.altronicinc.com...
- Page 66 DET-1600 DETONATION SENSING MONITOR FIGURE 8. WIRING DIAGRAM – CURRENT LOOP, CPU95 FORM DET-1600 IOM 11-09...
- Page 67 INSTALLATION/OPERATION MANUAL FIGURE 9. WIRING DIAGRAM – CURRENT LOOP, CD200/DISN B & D www.altronicinc.com...
- Page 68 DET-1600 DETONATION SENSING MONITOR FIGURE 10. WIRING DIAGRAM – ALTRONIC ANNUNCIATOR SYSTEMS FORM DET-1600 IOM 11-09...
- Page 69 INSTALLATION/OPERATION MANUAL FIGURE 11. WIRING DIAGRAM – DC RELAYS www.altronicinc.com...
- Page 70 DET-1600 DETONATION SENSING MONITOR FIGURE 12. WIRING DIAGRAM – RS-485 COMMUNICATIONS, PC HOOK-UP FORM DET-1600 IOM 11-09...
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