Perkins 4000 TRS Gas Engine Presentation

Gas TRS EXPERT

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Mechanical Overview  Utilising proven 4016-E61TRS combustion technology  Cylinder head, Piston, Liner

 Extruded oil rail  Improved closed circuit breather filtration.  Dry exhaust manifold

Mechanical Overview - Head

TESi

TRS

Mechanical Overview - Piston

TESi Low Compression

TRS

Mechanical Overview – CCB Option

TESi CCB = Closed Circuit Breather

TRS

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.

4006-23TRS1 / TRS2 6 cyl. water cooled lean burn Gas Engine TRS1 = 322 kWm TRS2 = 393 kWm



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 gas Biogas Landfill Gas Digester Gas

4008-30TRS1 / TRS2 8 cyl. water cooled lean burn Gas Engine TRS1 = 447 kWm TRS2 = 526 kWm



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 gas Biogas Landfill Gas Digester Gas

New TRS Gas Product ZPR (zero pressure regulator)

Pandaros Governor Altronic Ignition Unit

CAC (charge air cooler) Oil Cooler Gas inlet

Gas Start-up panel

Control panel

Gas Solenoid valve

New TRS Gas Product

Ignition coil

CCB (closed circuit breather)

Ignition Mpu Ignition Timing

Auxiliaries panel

Control System Overview 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

Gas Solenoid Controls

Power supply

Pressure switches

4000 Series Knock Detection Valve

Valve seat Pitot tube

Flow

Diaphragms Compensation line connection

Adjuster under cap

Spring

ZPR OPERATION  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.

Induction System

Crankcase Breather

(MAS) Mixture or Main Adjusting Screw

Zero Pressure Regulator

Balance Line

Gas Start-up panel components

Kilowatt Transducer Kronos AFR Control unit

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 RS232 interface

12V or 24V DC supply

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 NOx response 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. 2. 3.

4. 5.

Connect Heinzmann DCDesk software to Kronos controller (RS232) Save current data file to PC Select Number 1462 RichLeanMixtureCorr

Adjusting this Number up increases NOx reading and lowering reduces the NOx reading 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.

Kilowatt Transducer Set-up 4006/8 1. 2. 3. 4. 4. 5. 6. 7. 8. 9. 10. 11.

Connect Heinzmann DCDesk software to Kronos / Electra service point Save current data file to PC Enable open loop mode (see line 10 below) With engine running at 0 load, in measurements window read number 3531 AnalogIn3_value / 3511 AnalogIn1_value On Kw sensor Adjust pot kW I O/P zero or 4mA until number 3531 / 3511 reads close to or 4mA In the Parameters window feed this figure into number 1530 AnalogIn3_RefLow / 1510 AnalogIn1_RefLow 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_value On Kw sensor adjust pot kWI O/P 1mA or 20mA until number 3531 / 3511 reads close to or 20mA In the parameter window feed this figure plus 0.50 mA into number 1531 AnalogIn3_RefHigh / 1511 AnalogIn1_RefHigh Enable closed loop mode Save parameter file to control box In operation to enable and disable the AFR open and closed loop operation function 5400 / 5340 Can 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

kWI O/P 1mA or 20mA pot kWI O/P zero or 4mA pot

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

Standard USB connection

Det-Con

Knock Detection system

 Measures vibration levels per cylinder

Failed piston due to detonation

 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

4000 Series Knock Detection (Detcon20)

Detcon 20 Knock Detection Password

4000 Detcon Settings and Monitoring Cards Connection

Timing reduction

Den-Edit used with Det-Con unit

Level of Knock

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 the Diagnose 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 The base program has the BAD sensor detect enabled As standard. If one of the on engine sensors fail The Knocking Values screen will Show that sensor highlighted in red.

05

NB: The sensor are wired in engine Firing 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

Altronic DISN Ignition Unit Running clearance Timing disc housing

Timing disc

Pick-up sensor

Altronic DISN Ignition Unit

Re-set magnet Trigger magnets

4000 TRS Gas Engine

Pandaros Digital Governor

Pandaros – overview in-line

Heinzmann Governor Ignition Unit

Pandaros – overview

GOVERNOR STATUS RUN STATUS CAN COMMUNICATION DCPANDAROS - DESK DISPLAYS PACKAGER DISPLAYS GOVERNOR ERRORS

ACCESSORIES Stop / run •

Laptop computer

Actuator

•

Synchronising

•

Load sharing

•

Voltage matching

•

Reactive load share

•

Speed ramp

•

Load ramp

•

Soft load transfer

•

Isochronous ramp

•

Power factor set

•

Mains parallel

•

Island parallel

•

Group synchronising

•

Digital power control

Magnetic pick-up

0,50 to 0,80mm

Pandaros – Connecting to a PC

Changing the governor configuration

Perkins cable and dongle 1. 2.

Coms lead Part no:680/192 USB dongle Part no:680/219

Using DcDesk – Connecting to a PC

4000 TRS Gas Engine

Using Pandaros – Connecting to a PC

Feedback Setting

Feedback Setting

Feedback Setting

Feedback Setting

Feedback Setting without service tool

Feedback Setting without service tool

Perkins Service Tool Configuration Screen

Generator Mode - Single generator fixed speed selected

Perkins Service Tool Configuration Screen

Changing the governor configuration

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

Load Control

Synchroniser Settings

Droop Setting

Engine Stop

Common Alarm

Adjustment of PID parameters

PID maps

Speed Ramps

Governor errors

Governor errors .

Active error

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 MIC500 Ignition controller. If an over speed is recorded for any reason Switch of the power to the MIC500 To clear the fault.

Elektra AFR Control System

TRS Software Programs 2

DcDesk 2000 used with Pandaros and Kronos

Den-Edit used with Det-Con unit

TRS Software Programs 2

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 included In 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 Applications Or Service department and is enclosed with the Den-Edit software on Perkins CD TPCD1539 (MIC 500 Controller)

DcDesk Software basics Connection: 1. 2. 3.

4. 5. 6.

2 Connect communication lead between Pandaros or Kronos socket Insert Heinzmann Dongle into laptop On tool bar select start communication or press F5 key

Once connection is achieved the program will run through a Screen to upload the controller parameters 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

DcDesk Software basics 2 Saving and loading a programs 1. 2.

On tool bar select FILE Select Save all parameter values and left click

3.

The STORE file screen will appear

2

4.

Select an appropriate folder and click the save button

You Must save the current file before attempting any changes to the controller

Loading a Parameter file to the controller 2

1. 2.

On tool bar select FILE Select load parameter values and left click

3.

The load parameters screen will appear (next slide)

2

4. 5.

Select file to be uploaded and click the OPEN tab 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 has2 been used as an example)

2.

In the bottom left hand corner the parameter number, name & current setting will appear Number

3. 3. 4.

Name

Setting

Highlight or click in the current setting window and change the figure to requirement Press the F6 key to save change to control unit, if this is not done The unit will operate at the setting but once power has been removed from the controller the unit will return to the original setting

Using and Recording Data For engine set up or factory diagnostic assistance. It may be neccesary to view or record engine Performance data 2

1. 2. 3.

On DcDesk tool bar select GRAPHIC Select CURVE Versus TIME The graph window will appear

4.

5.

To load parameters to the graph select the corresponding number from the desired window 2

Type the number into the left hand grey box and press enter the parameter corresponding to the number will then be loaded onto the graph

Adding further recording slots It may be necessary to add further parameters on the record graph To do this follow the below procedure 1. 2.

Open the curve versus time graph Select the OTHER tab

3. 4.

The Options screen will then appear this has 3 tabs, select the CURVE PARAMETERS tab In the NUMBER of CURVES box select the number of parameter boxes to use

5. These will be available to set once back in the graph screen

6. 7. 8. 9.

To view a running engine click the START button and click the STOP tab to stop To record a graph screen. In the top right hand corner click the START2 REC tab to record the parameters you have set. 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 following C\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.

Parameter recordings To aid in diagnostics issue’s the following parameter recording are required as a minimum from the stated control units

Pandaros minimum record sets: 1. 2. 3.

2000 Speed 2300 Actpos 2330ActPoSetpoint

Elektra Air Fuel Ratio minimum record sets:

Kronos Air Fuel Ratio minimum record sets:

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

1. 2. 3. 4. 5. 6. 7.

2000 Speed 2300 Actpos 2910GasTemp 2914 GasPressure 2915 GasDeltaPressure 2916 Vent1DeltaPressure 2917 Vent2DeltaPressure 3301 EngineThermalPower 3346 ClosedLooplambdaTrim 3300 MeasElectricPower

2000 Speed 2302 Stepper Pos 2912 ManifoldPressure 2913 ManifoldTemp 2914 MeasuredPower 3411 CalculatedPower 3511 AnalogIn3 Value

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