Gas TRS
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 - Head
Mechanical Overview - Piston
TESi
Mechanical Overview – CCB Option
TESi
TRS
Mechanical Overview - Manifold
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 gas
Biogas Landfill Gas
Digester Gas
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 30.56 litres
Bore and stroke 160 mm x 190 mm
Compression ratio 12:1
Fuel Natural gas
Biogas Landfill Gas
Digester Gas
8 cyl. water cooled lean burn Gas Engine
TRS1 = 447 kWm
TRS2 = 526 kWm
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)
New TRS Gas Product
Ignition coil
CCB
(closed circuit breather)
Ignition Timing
Ignition Mpu
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
4000 Series Knock Detection
ZPR OPERATION
Flow Adjuster under cap Spring Diaphragms Pitot tube Valve Valve seatCompensation 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
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
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 supply
RS232 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
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
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
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 PC
3. Select Number 1462 RichLeanMixtureCorr
4. Adjusting this Number up increases NOx reading and lowering reduces the NOx reading
5. 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
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.
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/ Electraservice 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/ 3511reads 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_value
7. On Kw sensor adjust pot kWI O/P 1mA or 20mA until number 3531/ 3511reads 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/ 5340
Can be changed
Note – Font in bluecorresponds to 4006 / 8 Font in Redcorresponds to 4016
If any red LEDS are ON
4000 TRS Gas Engine
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.
4000 Series Knock Detection (Detcon20)
2
Det-Con
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 Detcon Settings and Monitoring Cards
Level
of
Knock
Timing
reduction
Den-Edit used with Det-Con unit
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
Detcon 20 Knock Detection
Detection of failed Knock Sensors
05
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.
NB: The sensor are wired in engine Firing order
4000 TRS Gas Engine
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
Timing disc Timing disc
housing
Running clearance
Pick-up sensor
Trigger magnets
Re-set magnet
4000 TRS Gas Engine
Pandaros – overview in-line
Heinzmann Governor
Pandaros – overview
Actuator RUN STATUS RUN STATUS CAN COMMUNICATION CAN COMMUNICATIONDC-PANDAROS PACKAGER DISPLAYS-DESK DISPLAYS GOVERNOR ERRORS
GOVERNOR 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
Magnetic pick-up
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
Generator Mode - Single generator fixed speed selected
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.
.
Active
error
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.
2
TRS Software Programs
DcDesk 2000 used with
Pandaros and Kronos
2
TRS Software Programs
Perkins Pandaros packager can be used
with Pandaros/Governor controller only
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)
2
DcDesk Software basics
Connection:
1. Connect communication lead between Pandaros or Kronos socket
2. Insert Heinzmann Dongle into laptop
3. On tool bar select start communication or press F5 key
4. Once connection is achieved the program will run through a
5. Screen to upload the controller parameters
6. 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
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 changes to the controller
2
Loading a Parameter file to the controller
1.
On tool bar select FILE
2.
Select load parameter values and left click
2
4. Select file to be uploaded and click the OPEN tab
5. 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 Name Setting
3. Highlight or click in the current setting window and change the
figure to requirement
3. Press the F6 key to save change to control unit, if this is not done
4. The unit will operate at the setting but once power has been removed
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 GRAPHIC
2. Select CURVE Versus TIME
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 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. Open the curve versus time graph
2. 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 parameter
boxes to use
2
6. To view a running engine click the START button and
click the STOP tab to stop
7. To record a graph screen. In the top right hand corner click the 8. START REC tab to record the parameters you have set.
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.
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 recording are required as a minimum from the stated control units