Perkins 4000 TRS Gas Engine Presentation

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.


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

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


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 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


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


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

Timing disc

Timing disc housing

Running clearance

Pick-up sensor


Trigger magnets

Re-set magnet


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 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.


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

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

Perkins 4000 TRS Gas Engine Presentation

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Transcript of Perkins 4000 TRS Gas Engine Presentation