Post on 11-Mar-2015
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Gas TRS
EXPERT
Domestics
� Fire Exits
� Breaks
� Lunch
� Toilets
� Smoking
� Mobile Phones
� Utilising proven 4016-E61TRS combustion technology
� Cylinder head, Piston, Liner
� Extruded oil rail
� Improved closed circuit breather filtration.
� Dry exhaust manifold
Mechanical Overview
Mechanical Overview - Head
TESi TRS
Mechanical Overview - Piston
TESi Low Compression
TRS
Mechanical Overview – CCB Option
TESi TRS
CCB = Closed Circuit Breather
Mechanical Overview - Manifold
TESi TRS
Engine Specifications
TRS range of engines:
A) Cogen specification both for natural gas and biogases for Combined Heat and Power application
This specification is offered to manufacturers of Combined Heat and Power
(CHP/Cogeneration) plants,
B) Gas Electro-unit specification both for natural gas and biogases for Power Generation applications
This specification is offered to manufacturers of radiator cooled generator sets both for
continuous and standby applications.
� Arrangement Vertical, in-line
� Cycle 4 stroke
� Induction system Turbocharged, mixture cooled
� Displacement 22.92 litres
� Bore and stroke 160 mm x 190 mm
� Compression ratio 12:1
� Fuel Natural gasBiogas
Landfill Gas
Digester Gas
6 cyl. water cooled lean burn Gas EngineTRS1 = 322 kWm
TRS2 = 393 kWm
4006-23TRS1 / TRS2
� Arrangement Vertical, in-line
� Cycle 4 stroke
� Induction system Turbocharged, mixture cooled
� Displacement 30.56 litres
� Bore and stroke 160 mm x 190 mm
� Compression ratio 12:1
� Fuel Natural gasBiogas
Landfill Gas
Digester Gas
8 cyl. water cooled lean burn Gas EngineTRS1 = 447 kWm
TRS2 = 526 kWm
4008-30TRS1 / TRS2
New TRS Gas Product
ZPR(zero pressure regulator)
Pandaros Governor
Altronic Ignition Unit
Gas Solenoid valve
Gas inlet
Gas Start-up panel Control panel
CAC(charge air cooler)
Oil Cooler
New TRS Gas Product
Ignition coil CCB (closed circuit breather)
Ignition TimingIgnition Mpu
Auxiliaries panel
In - line engines� Heinzmann Pandaros
� Kronos K20 AFR Control (ZPR)
� Detcon 20 Knock detection
� Altronic DISN 800C Ignition
� LKG01 Load sensor
Vee engines� Heinzmann Pandaros X2
� Elektra AFR Control – (no ZPR)
� Detcon 20 Knock detection
� Motortech MIC 500 Ignition – Vee
� LKG01 Load sensor
ZPR = Zero Pressure Regulator
Control System Overview
Gas Solenoid Controls
Power supply
Pressure switches
4000 Series Knock Detection
ZPR OPERATION
Flow
Adjuster
under cap
Spring
Diaphragms
Pitot tube
Valve Valve seat
Compensation
line connection
� A sectioned ZPR is shown
here.
� The adjuster should be wound
counter clockwise (CW.) until
the valve is fully closed.
� Turn the adjuster 17 full turns
clockwise (CCW).
� This should give sufficient gas
for initial starting.
Crankcase Breather
(MAS) Mixture or Main Adjusting Screw
Zero Pressure Regulator
Balance Line
Induction System
Gas Start-up panel components
Kronos AFR Control unit
Kilowatt Transducer
Detcon20 Detonation sensing module
4006 & 4008TRS Kronos 20
Kronos 20 AFR Control System
Basic components for 4006-23TRS and 4008-30TRS fuel system.
Kronos 20 AFR Control System
On the K20 System the Main Adjustment Screw is electronically controlled to provide adjustability to the gas flow.
4006 & 4008TRS Kronos 20
The Kronos 20 is an electronically controlled closed loop AFR trim system that allows speed and or load
dependant Lambda values to be controlled within a
certain range. Control of the Lambda results in improved engine load acceptance and efficiency over the
operating range. The closed loop version uses engine output power to correct for changes in gas quality and
pressure. The system operates on low pressure gas supplies in conjunction with the standard Perkins
supplied Zero Pressure Regulator.
4006 & 4008TRS Kronos 20
The system utilises a a std low pressure
gas system with ZPR where the Main Adjusting Screw is replaced with an
electronic stepper motor. The valve is
available in 50 and 80mm diameter versions for natural and landfill gas
capability.
4006 & 4008TRS Kronos 20
The closed loop system requires 3 sensors to operate:
•Speed (Via MPU)
•MAP and MAT (combined sensor)
•Load (Kwe sensor customer supply)
4006 & 4008TRS Kronos 20
12V or 24V DC supplyRS232 interface
4006 & 4008TRS Kronos 20
Customer interface is via Heinzmann DC Desk PC
software. Access to controller
settings is regulated by the hardware dongle available
from Perkins. The software will allow basic adjustment for
on site commissioning or adjustment and graphical
output of system parameters.
4006 & 4008TRS Kronos 20
Perkins optimise the Lambda map
of the engine to
give good transient
capability below 50% load and a
linear NOxresponse up to
100% load. These
maps are preset and not
adjustable.
4006 & 4008TRS Kronos 20
Parameter 1462 Adjusts emissions levels default setting
is 100% moving value up increases emissions level decreasing
value lowers emissions level (make small adjustments only)
DcDesk 2000 used with Kronos
Kronos 20 AFR Control System
Kronos 20 AFR Control System
Kronos 20 AFR Control System
4006 & 4008TRS Kronos 20
Parameter 1462 Adjusts emissions levels default setting
is 100% moving value up increases emissions level decreasing
value lowers emissions level (make small adjustments only)
4006 & 4008TRS Kronos 20
Emissions Adjustment with Kronos 20
1. Connect Heinzmann DCDesk software to Kronos controller (RS232)
2. Save current data file to PC3. Select Number 1462 RichLeanMixtureCorr
4. Adjusting this Number up increases NOx reading and lowering reduces the NOx reading5. Once adjustment is complete press enter then F6 to save the data to the Kronos controller
NB: Kronos 20 AFR direction.
On initial start up of the engine the controller closes fully then moves to a set start position
• Turning the mixer counter clockwise closes the valve
• Turning the mixer clockwise opens the valve
Kilowatt Transducer
Potentiometers for load reference set-up
Kilowatt Transducer Set-up 4006/8
Number 5400 Set value to 0 to enable set up of KW transducer
Set back to 1 when completed.
Check that Parameters 5412 and 5413 are set to 1
Kilowatt Transducer Set-up 4016
Parameter 5340 Set value to 0 to enable set up of KW transducer
Set back to 1 when completed.
kWI O/P zero or 4mA pot
kWI O/P 1mA or 20mA pot
Kilowatt Transducer Set-up 4006/8
1. Connect Heinzmann DCDesk software to Kronos / Electra service point
2. Save current data file to PC
3. Enable open loop mode (see line 10 below) 4. With engine running at 0 load, in measurements window read number 3531 AnalogIn3_value / 3511 AnalogIn1_value
4. On Kw sensor Adjust pot kW I O/P zero or 4mA until number 3531 / 3511 reads close to or 4mA
5. In the Parameters window feed this figure into number 1530 AnalogIn3_RefLow / 1510 AnalogIn1_RefLow
6. Apply load to engine (NB Monitor emissions levels and adjust if required) when engine is at full
load read number 3531 AnalogIn3_value / 3511 AnalogIn1_value7. On Kw sensor adjust pot kWI O/P 1mA or 20mA until number 3531 / 3511 reads close to or 20mA
8. In the parameter window feed this figure plus 0.50 mA into number 1531 AnalogIn3_RefHigh / 1511 AnalogIn1_RefHigh
9. Enable closed loop mode
10. Save parameter file to control box
11. In operation to enable and disable the AFR open and closed loop operation function 5400 / 5340Can be changed
Note – Font in blue corresponds to 4006 / 8
Font in Red corresponds to 4016
If any red LEDS are ON
reverse its corresponding CT connections
Kilowatt Transducer Set-up 4006/8
Kilowatt Transducer Set-up 4016
4000 TRS Gas Engine
Detcon 20 Knock Detection
Knock Detection system
Objective
� Prevent piston failure due to:
� Detonation
� Plug / lead failure
� Air filter blockage
� Overload running
� Variable gas quality
� Reduces risk of total engine loss
� System will be factory set and tested on engine.
� Configuration will be set to trip on sensor defect or maximum retard reached
4000 Series Knock Detection (Detcon20)
2
Det-Con
Standard USB connection
Knock Detection system
� Measures vibration levels per cylinder
� Detects detonation
� Retards timing up to a max 8 degrees
� If retardation does not work sends signal to O.E.M panel to stop engine
� Once detonation levels have lowered to acceptable limits load / timing
adjusted back to optimum running conditions
Failed piston due to detonation
4000 Series Knock Detection (Detcon20)
Detcon 20 Knock Detection Password
4000 Detcon Settings and Monitoring Cards
Level of
Knock
Timing reduction
Den-Edit used with Det-Con unit
Connection
4000 Series Knock Detection
Den-Edit Diagnostic Mode
The Den-Edit program has an internal diagnostic mode that allows the operator to test Some of the knock unit features.
In the mode window select the diagnose button Remember after carrying out test to unselect theDiagnose button if this is not done the knock unit will not function
4000 Series Knock Detection
Detcon 20 Knock Detection
Detcon 20 Knock Detection
Detection of failed Knock Sensors
05
The base program has the BAD sensor detect enabledAs standard.If one of the on engine sensors fail The Knocking Values screen willShow that sensor highlighted in red.
NB: The sensor are wired in engineFiring order
4000 TRS Gas Engine
Altronic DISN Ignition Unit
Ignition System
Ignition System (Altronic DISN)
� Digital ignition system
� No moving parts
� Generic throughout Perkins range (except 4016E61TRS 4016-61TRS
Uses the MIC500 control unit)
� Analogue input from external potentiometer for timing control
� Manual timing (16 position switch)
� On board diagnostics
� Negative ground ignition coils
Altronic DISN Ignition Unit
Altronic DISN Ignition Unit
Altronic DISN Ignition Unit
Altronic DISN Ignition Unit
Timing disc
Timing disc housing
Running clearance
Pick-up sensor
Altronic DISN Ignition Unit
Trigger magnets
Re-set magnet
Altronic DISN Ignition Unit
4000 TRS Gas Engine
Pandaros Digital Governor
Pandaros – overview in-line
Heinzmann GovernorIgnition Unit
Pandaros – overview
Actuator
RUN STATUSRUN STATUS
CAN COMMUNICATIONCAN COMMUNICATION
DC-- DESK DISPLAYSPANDAROS PACKAGER DISPLAYS
GOVERNOR ERRORSGOVERNOR ERRORS
Laptop computer
ACCESSORIES•• Stop / runStop / run
•• SynchronisingSynchronising
•• Load sharingLoad sharing
•• Voltage matchingVoltage matching
•• Reactive load shareReactive load share
•• Speed rampSpeed ramp
•• Load rampLoad ramp
•• Soft load transferSoft load transfer
•• Isochronous rampIsochronous ramp
•• Power factor setPower factor set
•• Mains parallelMains parallel
•• Island parallelIsland parallel
•• Group synchronisingGroup synchronising
•• Digital power controlDigital power control
GOVERNOR STATUS
Magnetic pick-up
0,50 to 0,80mm
Pandaros – Connecting to a PC
Changing the governor configuration
Perkins cable and dongle
1. Coms lead Part no:680/192
2. USB dongle Part no:680/219
4000 TRS Gas Engine
Using DcDesk – Connecting to a PC
Using Pandaros – Connecting to a PC
Feedback Setting
Feedback Setting
Feedback Setting
Feedback Setting
Feedback Setting without service tool
Feedback Setting without service tool
Generator Mode - Single generator fixed speed selected
Perkins Service Tool Configuration Screen
Perkins Service Tool Configuration Screen
NOTE : After changing some parameters, it is necessary to ‘ Store parameters in governor ’ and then reset the governor before the changes take effect. When this is required, the following message will appear.
Changing the governor configuration
Changing the governor configuration
Changing the governor configuration
Changing the governor configuration
Changing the governor configuration
Changing the governor configuration
Changing the governor configuration
Load Control
Synchroniser Settings
Droop Setting
Engine Stop
Common Alarm
Adjustment of PID parameters
PID maps
Speed Ramps
Governor errors
.
Active error
Governor errors
Governor errors
Pandaros Digital Governor – Overview
Elektra AFR Control System
Motortech MIC530 Ignition Controller
Motortech MIC530 Ignition Controller
The IC.exe program connects automatically to the MIC500Ignition controller.
If an over speed is recorded for any reason Switch of the power to the MIC500To clear the fault.
Elektra AFR Control System
2
TRS Software Programs
DcDesk 2000 used with
Pandaros and Kronos
Den-Edit used with Det-Con unit
2
TRS Software Programs
Perkins Pandaros packager can be used
with Pandaros/Governor controller only
IC.exe used with MIC500
Where to find the software
DcDesk, Pandaros packager and Den-Edit are includedIn Perkins CD Electronic Governor Software EGS part number TPCD1539.
Alternatively the DcDesk & Pandaros software can be downloaded From the Heinzmann web site: www.heinzmann.com
The IC.exe program is available by contacting Perkins ApplicationsOr Service department and is enclosed with the Den-Edit software onPerkins CD TPCD1539 (MIC 500 Controller)
2
DcDesk Software basics
Connection:
1. Connect communication lead between Pandaros or Kronos socket2. Insert Heinzmann Dongle into laptop3. On tool bar select start communication or press F5 key
4. Once connection is achieved the program will run through a5. Screen to upload the controller parameters6. Check that the tab has turned GREEN in the bottom left hand corner
(IF a failure to connect window appears check power to control unit is on)
When making changes
Make sure the unit is
ONLINE
2
Saving and loading a programs
1. On tool bar select FILE 2. Select Save all parameter values and left click
DcDesk Software basics
2
3. The STORE file screen will appear
4. Select an appropriate folder and click the save button
You Must save the current file before attempting any changesto the controller
2
Loading a Parameter file to the controller
1. On tool bar select FILE
2. Select load parameter values and left click
3. The load parameters screen will appear (next slide)
2
4. Select file to be uploaded and click the OPEN tab5. The compare file screen will appear (next slide) on this screen you can
either click the file compare tab this will tell you the differences between the saved file and the current controller file or click the LOAD parameters tab this will upload the selected file into the controller
2
2
Making changes to the program
1. In one of the windows select the appropriate function to be altered(Gain has been used as an example)
2. In the bottom left hand corner the parameter number, name & current setting will appear
Number SettingName
3. Highlight or click in the current setting window and change thefigure to requirement
3. Press the F6 key to save change to control unit, if this is not done4. The unit will operate at the setting but once power has been removed
from the controller the unit will return to the original setting
2
Using and Recording Data
For engine set up or factory diagnostic assistance.
It may be neccesary to view or record engine
Performance data
1. On DcDesk tool bar select GRAPHIC2. Select CURVE Versus TIME3. The graph window will appear
2
4. To load parameters to the graph select the corresponding number from the desired window
5. Type the number into the left hand grey box and press enterthe parameter corresponding to the number will then be loaded ontothe graph
Adding further recording slots
It may be necessary to add further parameters on the record graphTo do this follow the below procedure
1. Open the curve versus time graph2. Select the OTHER tab
3. The Options screen will then appear this has 3 tabs,select the CURVE PARAMETERS tab
4. In the NUMBER of CURVES box select the number of parameterboxes to use
5. These will be available to set once back in the graph screen
2
6. To view a running engine click the START button andclick the STOP tab to stop
7. To record a graph screen. In the top right hand corner click the8. START REC tab to record the parameters you have set.9. To stop recording click the STOP tab
Saving a recording
The record is automatically saved into the following file:C\program files dcdesk 2000\record sets\recorder_t.rec
E-mailing a record or parameter file
1. Open the relevant folder in the case of the recording look in the followingC\program files dcdesk 2000\record sets\recorder_t.rec
For a Pandaros or Elektra program file save as described earlier These files can then be copied and e-mailed as any standard file.
Pandaros minimum record sets:
1. 2000 Speed
2. 2300 Actpos
3. 2330ActPoSetpoint
Elektra Air Fuel Ratio minimum record sets:
1. 2000 Speed
2. 2300 Actpos
3. 2910GasTemp
4. 2914 GasPressure
5. 2915 GasDeltaPressure
6. 2916 Vent1DeltaPressure
7. 2917 Vent2DeltaPressure
8. 3301 EngineThermalPower
9. 3346 ClosedLooplambdaTrim
10. 3300 MeasElectricPower
To aid in diagnostics issue’s the following parameter recordingare required as a minimum from the stated control units
Kronos Air Fuel Ratio minimum record sets:
1. 2000 Speed
2. 2302 Stepper Pos
3. 2912 ManifoldPressure
4. 2913 ManifoldTemp
5. 2914 MeasuredPower
6. 3411 CalculatedPower
7. 3511 AnalogIn3 Value
Parameter recordings
Pre-support Request Check List
� Before making a request for product support, with regard to a 4000 Series gas engine, please ensure you have the following information available where appropriate.
� This information is important for a rapid diagnosis and will assist with the resolution of any issues.
Pre-support Request Check List. Cont…
� Before making a request for product support, with regard to a 4000 Series gas engine, please ensure you have the following information available where appropriate.
� This information is important for a rapid diagnosis and will assist with the resolution of any issues.
Questions