DETCON -DETONATION CONTROLLER - OPERATING MANUAL - MOTORTECH
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DetCon –Detonation Controller
Operating Manual
P/N 01.30.002 | Rev. 02/2019
Original instructions Copyright © Copyright 2019 MOTORTECH GmbH. All rights reserved. Distribution and reproduction of this publication or parts thereof, regardless of the specific purpose and form, are not permissible without express written approval by MOTORTECH. Information contained in this publication may be changed without prior notice. Trademarks MOTORTECH products and the MOTORTECH logo are registered and/or common law trademarks of the MOTORTECH GmbH. All further trademarks and logos displayed or used in this publication are the property of the respective entitled person.
Table of Contents 1 General Information .................................................................................................... 6 1.1 What Is the Purpose of this Operating Manual? ......................................................... 6 1.2 Who Is this Operating Manual Targeted to? ............................................................... 6 1.3 Which Symbols Are Used in the Operating Manual? ................................................... 6 1.4 Which Abbreviations/Acronyms Are Used in the Operating Manual? ........................... 7 2 Safety Instructions ..................................................................................................... 9 2.1 General Safety Instructions ..................................................................................... 9 2.2 Electrostatic Discharge Hazards ............................................................................ 10 2.3 Special Safety Instructions for the Device ............................................................... 11 2.4 Proper Disposal .................................................................................................... 12 3 Intended Use ............................................................................................................. 13 3.1 Functional Description .......................................................................................... 13 3.2 Applications ......................................................................................................... 17 3.3 Application in hazardous areas ............................................................................. 17 3.3.1 USA, Canada ...................................................................................................... 17 3.3.2 European Union ................................................................................................. 18 4 Product Description ...................................................................................................20 4.1 Technical Data ...................................................................................................... 20 4.1.1 Certifications ..................................................................................................... 20 4.1.2 Mechanical Data ................................................................................................ 28 4.1.3 Warning Notices on the Device ............................................................................ 29 4.1.4 Product Identification - Labels on the Device ........................................................ 30 4.1.5 Electrical Data .................................................................................................... 31 4.1.6 Interfaces .......................................................................................................... 32 4.1.7 Technical Data of the Detonation Sensors ............................................................ 32 4.1.8 Technical Data of the Ignition Sensor Unit (ISU) ................................................... 34 4.1.9 Technical Data of the Camshaft Sensor ................................................................ 34 4.1.10 Requirements for External Equipment ................................................................ 35 4.1.11 Overview Drawings ........................................................................................... 35 5 Installation Instructions ............................................................................................. 41 5.1 Ground Connection / Protective Conductor Connection on ATEX Enclosure ................ 43 5.2 Lead bushings through the enclosure wall on the ATEX enclosure ............................ 45 5.3 Mounting the Detonation Sensors.......................................................................... 49 5.4 Mounting the Ignition Sensor Unit (ISU) ................................................................. 54 5.5 Mounting the Camshaft Sensor.............................................................................. 56 Rev. 02/2019 3
Table of Contents 6 Wiring of the Device ................................................................................................... 57 6.1 Wiring of the Detonation Sensors .......................................................................... 57 6.2 Wiring for Ignition Controller with ASO Output ....................................................... 58 6.3 Wiring of the Ignition Sensor Unit (ISU) .................................................................. 60 6.4 Wiring of the Camshaft Sensor (for Diesel and Pilot Injection Engines Only) ............. 62 6.5 Wiring of the Binary Outputs ................................................................................. 64 6.6 Wiring of the Analog Outputs for Ignition Timing Reduction ..................................... 65 6.7 Wiring CAN Bus .................................................................................................... 66 7 Functions ................................................................................................................... 67 7.1 Ignition Timing Reduction ...................................................................................... 67 7.2 Load Reduction .................................................................................................... 67 7.3 Engine Stop ......................................................................................................... 67 8 DenEdit Settings ....................................................................................................... 68 8.1 DenEdit System Requirements ............................................................................... 68 8.2 Installation and First Steps in DenEdit ................................................................... 69 8.3 User Interface Overview ........................................................................................ 72 8.4 Menu Bar and Toolbar .......................................................................................... 73 8.5 Display Area of the Analog Output Signal and the Knocking Intensity....................... 74 8.6 Error and Status Displays ..................................................................................... 74 8.7 Tabs for Process Monitoring .................................................................................. 76 8.7.1 Tab: Actual Knocking Values ............................................................................... 76 8.7.2 Tab: Knocking History ........................................................................................ 77 8.8 Tabs for the Process Parameters ........................................................................... 77 8.8.1 Tab: Mode ......................................................................................................... 78 8.8.2 Tab: Knocking Params ....................................................................................... 79 8.8.3 Tab: Input Gains ................................................................................................ 80 8.8.4 Tab: Firing Sequence ......................................................................................... 80 8.8.5 Tab: Output Options .......................................................................................... 81 8.8.6 Tab: CAN Params............................................................................................... 82 8.9 Status Bar ........................................................................................................... 83 9 Operation ................................................................................................................. 84 9.1 Start-up ............................................................................................................... 84 9.2 Shutdown ............................................................................................................ 84 4 Rev. 02/2019
Table of Contents 10 Disturbances ............................................................................................................85 11 Maintenance............................................................................................................ 86 11.1 Spare Parts and Accessories ................................................................................. 86 12 Index .......................................................................................................................87 Rev. 02/2019 5
1 General Information
Read through this operating manual carefully before use and become familiar with the product.
Installation and start-up should not be carried out before reading and understanding this
document. Keep this manual readily available so that you can reference it as needed.
1.1 What Is the Purpose of this Operating Manual?
This manual serves as an aid for the installation and operation of the product and supports the
technical staff with all operating and maintenance tasks to be performed. Furthermore, this
manual is aimed at preventing dangers to life and health of the user and third parties.
1.2 Who Is this Operating Manual Targeted to?
The operating manual provides a code of conduct for personnel tasked with the setup,
operation, maintenance, and repair of gas engines. A certain level of technical knowledge with
respect to the operation of gas engines and basic knowledge of electronic ignition systems are
necessary. Persons who are only authorized to operate the gas engine shall be trained by the
operating company and shall be expressly instructed concerning potential hazards.
1.3 Which Symbols Are Used in the Operating Manual?
The following symbols are used in this manual and must be observed:
Example
This symbol indicates examples, which point out necessary handling steps
and techniques. In addition, you receive additional information from the
examples, which will increase your knowledge.
Notice
This symbol indicates important notices for the user. Follow these. In
addition, this symbol is used for overviews that give you a summary of the
necessary work steps.
Warning
This symbol indicates warnings for possible risks of property damage or
risks to health. Read these warning notices carefully and take the
mentioned precautionary measures.
6 Rev. 02/2019
1 General Information
Danger
This symbol indicates warnings for danger to life, especially due to high
voltage. Read these warning notices carefully and take the mentioned
precautionary measures.
1.4 Which Abbreviations/Acronyms Are Used in the Operating Manual?
In the manual or the user interface, the following abbreviations / acronyms are used.
Abb. Term Description Explanation
ASO Auxiliary Output of the MOTORTECH
Synchroni- ignition controllers for
zation Output synchronization with the
DetCon
CAN Controller Area Bus for control Asynchronous serial
Bus Network Bus devices / networks connection system for
networking control devices
CE Conformité Conformity with EU Mark based on EU legislation
Européenne directives for certain products in
conjunction with product safety
CSA Canadian Standards Organization that defines
Association standards, inspects products
for safety compliance, and
issues pertinent certifications.
DC Direct Current
DetCon Detonation Serves to prevent major engine
Controller damage that can be caused by
knocking combustion.
EMI Electromagnetic
Interference
EMC Electromagnetic Compatibility of electrical or
Compatibility electronic equipment items
with their surroundings
HV High Voltage
ISU Ignition Sensor Unit
°KW Crankshaft angle in Unit for the rotation angle of
degrees the crankshaft
Rev. 02/2019 7
1 General Information
Abb. Term Description Explanation
LED Light Emitting Diode Light emitting electronic semi-
conductor
MIC MOTORTECH Ignition
Controller
USB Universal Serial Bus Serial wiring system to connect
a computer to external
equipment
8 Rev. 02/2019
2 Safety Instructions
2.1 General Safety Instructions
The following safety instructions must be followed in the area in which the device is operated:
High voltage! Danger to life!
While the engine is running, the area around the ignition system especially
holds the risk of danger due to high voltage. The following parts should
therefore not be touched or removed unless explicitly stated otherwise:
– Ignition coils and caps
– Wires of the high voltage circuit
– In- and output wiring of the ignition controller
– Pickups and their wiring
Danger to persons with pacemakers!
Electromagnetic impulses in the wiring of the ignition system may exceed
the permissible limits of pacemakers. Persons with pacemakers must
therefore not be present in the vicinity of the ignition system being
operated. Mark the operating location of the ignition system with the
corresponding standardized warning symbol.
MOTORTECH equipment is manufactured as state of the art and therefore safe and reliable to
operate. Nevertheless the equipment can cause risks or damage can occur, if the following
instructions are not complied with:
– The gas engine must only be operated by trained and authorized personnel.
– Operate the equipment only within the parameters specified in the technical data.
– Use the equipment correctly and for its intended use only.
– Never apply force.
– For all work such as installation, conversion, adaptation, maintenance, and repair, all
equipment must be disconnected from the mains and secured against unintentional
reactivation.
– Perform only such maintenance and repair work as is described in this operating manual,
and follow the instructions given while working.
– Only use spare parts supplied by MOTORTECH for the maintenance of the device.
– Further work must only be performed by personnel authorized by MOTORTECH. Non-
compliance with the instructions will void any warranties for the proper function of the
equipment as well as the responsibility for the validity of the certifications.
– Safety devices must not be dismounted or disabled.
9 Rev. 02/2019
2 Safety Instructions
– Avoid all activities that can impair the function of the equipment.
– Operate the equipment only while it is in proper condition.
– Investigate all changes detected while operating the gas engine or ignition system.
– Ensure compliance with all laws, directives and regulations applicable to the operation of
your system, including such not expressly stated herein.
– If the system is not entirely tight and sealed, gas may escape and result in explosion hazard.
The inhalation of gas can also lead to death or severe health damages. Therefore, upon
completion of all assembly works, always check the system's tightness.
– Always ensure adequate ventilation of the engine compartment.
– Ensure a safe position at the gas engine.
– There is a risk of burning on hot surfaces. Allow the engine to cool down before starting any
work.
– Personal protective equipment (PPE), e.g. safety shoes and gloves, must be worn during all
work on the engine.
– Your behavior can reduce possible residual risks to a minimum. Pay attention to a
responsible handling of the gas engine and the gas-carrying system.
2.2 Electrostatic Discharge Hazards
Electronic equipment is sensitive to static electricity. To protect these components from damage
caused by static electricity, special precautions must be taken to minimize or prevent
electrostatic discharge.
Observe these safety precautions while you work with the equipment or in its vicinity.
– Before performing maintenance or repair work, ensure that the static electricity inherent to
your body is discharged.
– Do not wear clothing made from synthetic materials to prevent static electricity from
building up. Your clothing should therefore be made of cotton or cotton mix materials.
– Keep plastics such as vinyl and Styrofoam materials as far away from the control system, the
modules, and the work environment as possible.
– Do not remove the circuit boards from the enclosure of the device.
10 Rev. 02/20192 Safety Instructions
2.3 Special Safety Instructions for the Device
High voltage! Danger to life!
There is danger to life while the engine is operating due to high voltage. The
following safety instructions must therefore be observed when the engine is
running:
– Do not touch the ignition sensor unit (ISU)
– Do not remove the ignition sensor unit (ISU)
– Do not loosen the wiring
Risk of destruction due to electrostatic discharge!
The DetCon detonation controller may only be installed in a switch cabinet
by qualified personnel trained in the handling of ESD-endangered
components, observing the ESD regulations. The ESD standard IEC 61340-5-
1:2016 must be observed during installation. No warranty is given for
damage due to electrostatic discharge.
Operational safety
The DetCon detonation controller requires high voltage ignition wires
with integrated 5 kΩ resistance, as otherwise interference in the detonation
sensor signals may be caused. Any other ignition wires must be replaced.
Risk of damage
The detonation sensor attachment screws must not be tightened too firmly,
as otherwise the sensors will be damaged and no longer function
properly.Observe the following information for sensor mounting:
– Torque: 20 Nm ± 5 Nm (14.8 ± 3.7 lb-ft) for mounting screws:
– made of cast iron: M8 x 25 mm (0.98"), Strength: 8.8
– made of aluminium: M8 x 30 mm (1.18"), strength: 8.8
– Torque: 15 Nm ± 5 Nm (11 lb-ft ±2.2 lb-ft) for M6 fixing screws, strength
10.9 with sleeve
Rev. 02/2019 112 Safety Instructions
Operational safety
Please note that the detonation sensors must be mounted according to the
firing order of the cylinders. Refer to the pertinent section Wiring of the
Detonation Sensors on page 57.
Detonation detection
The DetCon detonation controller detects knocking as far as possible, but
not bindingly.
DetCon only usable in single ignition mode
V-engines can only use the DetCon detonation controller with single
ignition and not in double ignition mode.
The DetCon uses two time windows per cylinder to detect engine knocking.
These time windows are opened in single ignition mode based on the
ignition pulse. In double ignition mode it is not possible to correctly assign
the time windows to all cylinders.
2.4 Proper Disposal
After the expiration of its service life, MOTORTECH equipment can be disposed of with other
commercial waste, or it may be returned to MOTORTECH. We will ensure its environmentally
friendly disposal.
12 Rev. 02/20193 Intended Use
3.1 Functional Description
Pos. Designation
Valve
Spark plug
Piston
Normal Combustion
The graphics show the desired type of
combustion of the gas/air mixture in the
combustion chamber. The ignition spark
ignites the gas/air mixture. The flame front
spreads out evenly in the combustion
chamber with the specific laminar flame
speed of the gas/air mixture. The cylinder
pressure increases slightly during
combustion.
Knocking Combustion
Knocking combustion arises if the gas/air
mixture self-ignites before the actual flame
front, but after the ignition . This system
does not detect so-called early ignition.
The reason for this is an excessive increase
in pressure and temperature of the as yet
non-combusted mixture due to the pressure
and temperature fronts preceding the normal
flame front. The pressure and temperature
fronts arising from the self-ignition, in turn,
make further self-ignitions possible. High-
frequency pressure waves arise in the
combustion chamber, which are introduced
into the engine structure via the walls of the
combustion chamber and released as air-
borne noise into the environment. The
knocking becomes audible in this way .
Compared to normal combustion,
significantly higher peak pressures arise,
which may lead to major engine damage in
addition to the higher thermal load.
13 Rev. 02/20193 Intended Use
Detonation Control System – Overview
Pos. no Description Pos. no Description
DetCon detonation controller Wiring rail (ignition)
Detonation sensor wiring PowerView3
Detonation sensor ALL-IN-ONE
Ignition controller Laptop
Detonation Controller
The task of the DetCon detonation controller is to avoid engine damage from knocking
combustion.
Vibration occurs in the engine compartment during the combustion process. These have a
frequency which is characteristic for the engine type. The DetCon measures the vibratory energy
within a narrow frequency range which is typical for the respective engine. The energy measured
is proportional to the knocking level.
Measurement is only carried out within operating cycles in which combustion is possible. This
increases the sensitivity of the measurement and minimizes its reaction to random noises. The
operating cycles are determined according to application and the ignition controller used via an
auxiliary synchronization output, an ignition sensor unit (ISU) or a camshaft sensor.
14 Rev. 02/20193 Intended Use
The following diagram and the explanations below it illustrate the basic control process of the
system:
Term used in diagram Description
Knocking Level Example of the progression of knocking energy
IMMEDIATE STOP LIMIT The maximum value at which the engine is stopped
IGNITION REDUCTION LIMIT The maximum value upon which an ignition timing reduction
is performed
ENGINE KNOCKING (binary Signal on the binary output indicating knocking.
output)
LOAD REDUCTION (binary Signal on the binary output effecting load reduction.
output)
TRIP (binary output) Signal on the binary output indicating that the IMMEDIATE
STOP LIMIT has been exceeded or that a faulty sensor has
been detected.
Timing Reduction (analog Curve of the analog signal for timing reduction
output)
MAX. LEVEL OF ANALOG Maximum value of the timing reduction
OUTPUT
Timing Reduction Gain Speed of the timing reduction
Decrease Ramp Speed of the timing reduction
Delay after load reduction Delay time following a load reduction
Rev. 02/2019 153 Intended Use
The measured knocking energy (Knocking Level curve) is compared in every cycle with a preset
maximum value (IGNITION REDUCTION LIMIT). If this maximum value is reached, the binary
output ENGINE KNOCKING is activated. At the same time, the analog outputs change their values
(Timing Reduction curve). The rate at which the value of the signal changes is specified by the
setting Timing Reduction Gain. The analog signals are transmitted to the ignition controller, thus
adjusting the ignition timing. If this causes the knocking energy to fall below the maximum
value, the values at the analog outputs are also reduced. The rate of this reduction is adjusted
according to the preset value Decrease Ramp.
If the ignition timing can no longer be corrected via the analog outputs and the engine is still
knocking, the binary output for load reduction (LOAD REDUCTION) is activated. A master control
(e.g. ALL-IN-ONE) can control load reduction via this output.
LOAD REDUCTION is deactivated again if the engine knocking stops. However, the analog
outputs remain active for a further period which is set via the function Delay after load reduction.
This period must be longer than required for reaching full load.
The third binary output, i.e. TRIP, is activated when the knocking exceeds the maximum value
IMMEDIATE STOP LIMIT. This can be used as an emergency stop signal to force the engine to stop.
Checkbox Enable bad sensor detect
Activate the checkbox so that faulty knock sensors are indicated by the BAD
SENSOR status display. This function only detects sensors that supply
faulty signals. If there is a cable break or a sensor does not supply a signal
at all for any other reason, this is not indicated. If a faulty sensor is
detected, the binary output TRIP is also switched..
16 Rev. 02/20193 Intended Use
3.2 Applications
The DetCon detonation controller can analyze two-stroke and four-stroke engines with up to 20
cylinders and up to a maximum 1 kHz ignition frequency. The device is available in two versions:
– DetCon2 for two detonation sensors
– DetCon20 for up to 20 detonation sensors
Both device types are available as a built-in device for a control cabinet or with a CSA certified
enclosure. The following manual applies to both device types. Any differences between the two
versions are clearly identified.
In order to define the time frame for potential knocking, the detonation controller must know the
ignition timing of the first cylinder in the firing sequence. Depending on the application and the
ignition controller used, this can be determined in different ways:
– Gas engines:
– MOTORTECH ignition controllers with auxiliary synchronization output ASO (e. g. MIC6)
The ignition timing is determined via the signal on the ASO output. No other sensor is
required.
– Ignition controllers without ASO output:
The ignition timing is determined using a signal from the ignition sensor unit (ISU)
connected between the ignition output and the ignition coil of the first cylinder
– Diesel and pilot injection engines:
– The fuel injection timing is determined using the signal from an inductive camshaft
sensor.
Any use other than the one described in the operating manual shall be considered improper use
and will result in the voiding of all warranties.
3.3 Application in hazardous areas
3.3.1 USA, Canada
The DetCon detonation controller is certified by the CSA for use in a Class I, Division 2, Groups C
and D, T4 hazardous area in the USA and Canada. It is essential that you observe the
instructions of the CSA certificate 1401608 (LR 211392) (see Certification section).
The DetCon detonation controller can be supplied in a CSA-certified housing (P/N 43.00.102, P/N
43.00.202, P/N 43.00.120, P/N 43.00.220) or installed in an appropriately certified switch
cabinet and thus complies with the guidelines mentioned in the Certification section.
Rev. 02/2019 173 Intended Use
3.3.2 European Union
The DetCon detonation controller in ATEX enclosure is certified according to ATEX directive
2014/34/EU for use in a potentially explosive atmosphere in the European Union:
II 3G Ex ec IIA T4
Labeling Description
Symbol for explosion protection, the product complies with ATEX
directive 2014/34/EU
II Device group
II = Ex-areas with the exception of mines at risk of firedamp
3G Equipment category
3 = Ex-hazard rare and short-term
Substance group
G = Gases
Ex Explosion protection according to EN 60079-xx, (-0, -7 )
ec Type of ignition protection
ec = Device protection through increased safety "e"
IIA Subdivision into explosion groups:
II = Gases
A = Gases such as propane
T4 Temperature class
T4 = max. surface temperature ≤ +135 °C (+275 °F)
X X = Special conditions must be observed when using the operating
resources
18 Rev. 02/20193 Intended Use
Instructions for handling the DetCon20 detonation controller in hazardous areas
Danger of explosion!
Only use the detonation sensor approved by MOTORTECH and the required
number of blocking capacitor boards for operation in hazardous areas.
P/N Description
43.20.001 Detonation sensor without sensor lead, two-pole
43.30.004-60 Detonation sensor lead, 18 m (59.06 ft)
43.20.029 Blocking capacitor board (ATEX)
Danger of explosion!
The USB interface may only be used in a non-hazardous atmosphere. There
is a danger of sparking.
Sealing of the enclosure to the enclosure cover
The enclosure is sealed against the enclosure cover by a foamed silicone
seal. The overlapping of the foam bead (start point/end point) of the seal
cannot be produced without any joints due to the material, but has no
influence on the specified IP protection class.
Use MOTORTECH detonation sensors
DetCon detonation controller systems are parameterized for operation with
MOTORTECH detonation sensors (piezoelectric acceleration transducers).
The use of other sensors entails a new calibration of the engine.
Rev. 02/2019 194 Product Description
4.1 Technical Data
4.1.1 Certifications
The detonation controller of the DetCon series are certified as per the following regulations:
CSA
The DetCon detonation controllers can be supplied in a CSA certified enclosure.
The applied requirements are:
– Class I, Div. 2, Group C,D; T4
– CSA Std. C22.2 No. 0-10
– CSA Std. C22.2 No. 142-M1987 (R 2004)
– CSA Std. C22.2 No. 213-M1987 (R 2004)
– ANSI/ISA 12.12.01, Ed. 1 (2007)
– UL Std. No. 916, Ed. 3 (1998)
The corresponding directives are also met if the DetCon detonation controller is installed in a
correspondingly certified switch cabinet.
P/N Device Description
43.00.002 DetCon2 Detonation Two inputs, CSA, IP20, for mounting in a CSA-
Controlle certified control cabinet
43.00.102 DetCon2 Detonation Two inputs, IP 20, built into a CSA-certified
Controller enclosure, including ISU ignition sensor unit P/N
43.20.002
43.00.202 DetCon2 Detonation Two inputs, IP 20, built into a CSA-certified
Controller enclosure
43.00.020 DetCon20 Detonation 20 inputs, CSA, IP20, for mounting in a CSA-certified
Controller control cabinet
43.00.120 DetCon20 Detonation 20 inputs, IP 20, built into a CSA-certified enclosure,
Controller including ISU Ignition sensor unit P/N 43.20.002
43.00.220 DetCon20 Detonation 20 inputs, IP 20, built into a CSA-certified enclosure
Controller
20 Rev. 02/20194 Product Description
CE
The DetCon detonation controllers P/N 43.00.002, P/N 43.00.020 and P/N 43.50.033 comply
with the following EU directives:
– EMC Directive 2014/30/EU
– EN 61000-6-1:2007
Electromagnetic compatibility (EMC) - Part 6-1: Generic standards –
Immunity to interference for residential, commercial and light-industrial environments
– EN 61000-6-2:2005 + AC:2005
Electromagnetic compatibility (EMC) – Part 6-2: Generic standards –
Immunity for industrial environments
– EN 61000-6-3:2007 + A1:2011 + AC:2012
Electromagnetic compatibility (EMC) – Part 6-3: Generic standards –
Emission for residential, commercial and light-industrial environments
– EN 61000-6-4:2007 + A1:2011
Electromagnetic compatibility (EMC) – Part 6-4: Generic standards –
Emission for industrial environments
– RoHS Directive 2011/65/EU
– Other standards applied:
– EN 61010-1:2010
Safety requirements for electrical equipment for measurement, control, and laboratory
use –
Part 1: General requirements
P/N Device Description
43.00.002 DetCon2 Detonation Two inputs, CSA, IP20, in use without control
Controller cabinet only in non-hazardous areas
43.00.020 DetCon20 Detonation 20 inputs, CSA, IP20, in use without control
Controller cabinet only in non-hazardous areas
43.50.003 DetCon20 Detonation 20 inputs, IP20, exclusively for use in non-
Controller hazardous areas
Rev. 02/2019 214 Product Description
The DetCon detonation controller can be supplied in an ATEX-certified enclosure (P/N 93.43.220)
and additionally complies with the following directive:
– ATEX Directive 2014/34/EU
– EN 60079-0:2012 + A11:2013
Potentially explosive atmospheres – Part 0: Equipment – General requirements
– EN 60079-7:2015 + A1:2018
Potentially explosive atmospheres – Part 7: Equipment protection by increased safety "e
P/N Device Description
93.43.220 DetCon20 Detonation 20 inputs, IP 20, built into an ATEX-certified
Controller enclosure
22 Rev. 02/20194 Product Description Rev. 02/2019 23
4 Product Description 24 Rev. 02/2019
4 Product Description Rev. 02/2019 25
4 Product Description 26 Rev. 02/2019
4 Product Description Rev. 02/2019 27
4 Product Description
4.1.2 Mechanical Data
The DetCon has the following mechanical characteristics:
Feature Value
Dimensions of the electric unit DetCon2
(incl. DIN rail clamps) 160 mm x 147 mm x 52 mm (6.3" x 7.36" x 2.05")
(length x width x height)
DetCon20
160 mm x 187 mm x 52 mm (6.3" x 5.78" x 2.05")
(length x width x height)
Device in certified enclosure (CSA, ATEX)
300 mm x 300 mm x 300 mm x 120 mm (11.81" x 11.81" x
4.92")
(length x width x height)
For details, see chapter Overview Drawings on page 35
Mounting for the electric unit DIN rail mounting
Weight DetCon2: 0.59 kg (1.30 lbs)
DetCon20: 0.74 kg (1.63 lbs)
Shape of device See chapter Overview Drawings on page 35
Mechanical Environmental Protection: IP 20
Conditions
Protection class in potentially hazardous areas ( enclosure
variants): IP 66
Climatic Environmental DetCon without enclosure
Conditions
Ambient temperature: –10 °C to +60 °C (+14 °F to +140 °F)
Storage temperature; –40 °C to +80 °C (–40 °F to +176 °F)
Device in certified enclosure (CSA, ATEX)
Ambient temperature: –10 °C to +60 °C (+14 °F to +140 °F)
Storage temperature (CSA): –20 °C to +80 °C (–4 °F to +176
°F)
Storage temperature (ATEX): –30 °C to +80 °C (–22 °F to
+176 °F)
max. 95% humidity without condensation
28 Rev. 02/20194 Product Description
4.1.3 Warning Notices on the Device
The safety instructions on the device or on the enclosure are valid for the DetCon and all
connected components.
Variant Information text
ATEX and CSA WARNING – EXPLOSION HAZARD – Substitution of components may
impair suitability for Class I, Division 2. Do not disconnect equipment
unless power has been switched off or the area is known to be non-
hazardous.
All WARNING! Read and understand the installation and operation manuals
prior to installing or making any adjustments.
ATEX EXPLOSION HAZARD – Do not open enclosure or disconnect while circuit
is live unless area is known to be non-hazardous. For wiring details
please refer to operation manual.
ATEX The device must be installed and operated only in an environment that
ensures a pollution degree 2 (or better) according to IEC/EN 60664-1.
All CAUTION – Do not pressure wash this ignition module. Damage to
electronic components may result.
CSA EXPLOSION HAZARD – Do not disconnect while circuit is live unless area
is known to be non-hazardous. For wiring details please refer to
operation manual
Rev. 02/2019 294 Product Description 4.1.4 Product Identification - Labels on the Device On the device you will find the necessary numbers for a clear product identification: Example: DetCon in ATEX-certified enclosure Abbreviation Description P/N Part number of the device S/N Serial number of the device 2019 Year of construction of the device 30 Rev. 02/2019
4 Product Description
4.1.5 Electrical Data
The DetCon has the following electrical characteristics:
Feature Value
Rated current 0.1 A to 0,3 A
Power consumption 0.1 A at 24 V
0.1 A at 36 V
0.3 A at 9 V
Supply voltag 9 V DC to 36 V DC
ATEX: Protective conductor cross- 4 mm2 to 35 mm2 ( observe EN 60079-0:2014-06, 15.3)
section
Electrical Data for Inputs and Outputs
The inputs and outputs have the following electrical data:
Inputs and outputs Values
Ignition pulse input Input resistance 220 /1 k
Max. input voltage:
24 V at a load resistance of 220
36 V at a load resistance of 1 k
Max. frequency 800 Hz
Detonation sensor input Input resistance > 1 M
4-20 mA output Max. voltage 30 V
Current accuracy ± 2%
0-5 V output Max. current 2 mA
Voltage accuracy ± 2%
Auxiliary power 5 V DC required
Binary outputs All three outputs share a single connection and are potential-
free (galvanically separated optocouplers).
Max. voltage 33 V
Max. current 50 mA
Rev. 02/2019 314 Product Description
4.1.6 Interfaces
USB Interface
– Compatible with USB 1.1
– Connector B version
– Transfer rate 1 MBit/s
Danger of explosion!
The USB interface may only be used in a non-hazardous atmosphere. There
is a danger of sparking.
CAN Bus Interface
– Galvanically isolated
– Baud rate 250 kBd
4.1.7 Technical Data of the Detonation Sensors
Use MOTORTECH detonation sensors
DetCon detonation controller systems are parameterized for operation with
MOTORTECH detonation sensors (piezoelectric acceleration transducers).
The use of other sensors entails a new calibration of the engine.
Danger of explosion!
Only use the detonation sensor approved by MOTORTECH and the required
number of blocking capacitor boards for operation in hazardous areas.
P/N Description
43.20.001 Detonation sensor without sensor lead, two-pole
43.30.004-60 Detonation sensor lead, 18 m (59.06 ft)
43.20.029 Blocking capacitor board (ATEX)
32 Rev. 02/20194 Product Description
The MOTORTECH detonation sensors have the following technical data:
Feature Value
Sensor principle Piezoelectric acceleration transducer
Sensor type MOTORTECH
Frequency range 1 kHz to 20 kHz
Resonance frequency > 20 kHz
Temperature range –40 °C to +130 °C (–40 °F to +266 °F)
Dimensions, Sensor 45 mm x 20 mm x 21 mm (1,77'' x 0,79'' x 0,83'')
(see Mounting the Knocking Sensors)
Sensor mount Torque: 20 Nm ± 5 Nm (14.8 lb-ft ± 3.7 lb-ft) for the following
fixing screws:
– Cast iron: M8 x 25 mm (0.98"), strength 8.8
– Aluminium: M8 x 30 mm (1.18") , Strength 8.8
Torque: 15 Nm ± 5 Nm (11 lb-ft ±2.2 lb-ft) for the following fixing
screws:
– M6, strength 10.9 with sleeve for fixing to the cylinder head
screw.
If necessary, the material of the cylinder head screw on which
the sensor is mounted should also be taken into account
Blocking capacitor board for use in potentially explosive atmospheres
The blocking capacitor board serves as a safety barrier between the DetCon20 and the
Knock sensors, which makes the use of knock sensors in potentially explosive areas
is made possible.
The blocking capacitor board has the following technical data:
Feature Value
Temperature range –10 °C to +60 °C (+14 °F to +140 °F)
Dimensions (mm) 40 mm x 47 mm x 12 mm (1.57" x 1.85" x 0.019 ")
Flammability class UL 94-V2
Article number P/N 43.20.029
Rev. 02/2019 334 Product Description
4.1.8 Technical Data of the Ignition Sensor Unit (ISU)
The ignition sensor unit has the following technical data:
Feature Value
Sensor principle Signal transducer
Sensor type MOTORTECH
Voltage 90 V DC to 300 V DC
supply
Temperature range –25 °C to +70 °C (–13 °F to +158 °F)
Dimensions, Sensor 75.5 mm x 44.25 mm x 49 mm (2.97" x 1.74" x 1.93") incl. DIN
rail
(see Mounting the Ignition Sensor Unit (ISU) on page 53)
Sensor mount DIN rail mounting
4.1.9 Technical Data of the Camshaft Sensor
The camshaft sensor has the following technical data:
Feature Value
Sensor principle active, inductive proximity switching sensor
Sensor type MOTORTECH
Voltage 15 to 34 V DC
supply
Temperature range –25 °C to +85 °C (–13 °F to +185 °F)
Dimensions, Sensor M12 x 1 thread; length 60 mm (2.36") or 100 mm (3.94")
Sensor mount Nut M12 x 1
34 Rev. 02/20194 Product Description 4.1.10 Requirements for External Equipment External equipment shall fulfill the input and output specifications of the DetCon. 4.1.11 Overview Drawings DetCon2 – Dimensions Rev. 02/2019 35
4 Product Description DetCon2 – Ports/Connections and LEDs For the functions of the individual ports/connections and LEDs, please refer to the table following the drawings accompanying the DetCon20. 36 Rev. 02/2019
4 Product Description DetCon20 – Dimensions Rev. 02/2019 37
4 Product Description
DetCon20 – Ports/Connections and LEDs
Labeling Function
LOAD RESISTANCE Jumper which must be removed if no ignition sensor unit (ISU) is
used (when using a camshaft sensor or MOTORTECH ignition
controllers with ASO output)
Sensor A-B (DetCon2) Connections of the detonation sensors (A=white, B=brown,
Sensor 1-20 S=shield) (see Wiring of the Detonation Sensors on page 57)
(DetCon20)
Timing1, Timing2, Connections for the ignition sensor unit (ISU) or the camshaft
Shield 0 V, +24 V sensor (see Wiring of the Ignition Sensor Unit (ISU) on page 59 or
Wiring of the Camshaft Sensor (for Diesel and Pilot Injection Engines
Only) on page 62)
IGNITION PULSE (LED) This LED flashes when an ignition pulse is transmitted to the
DetCon.
38 Rev. 02/20194 Product Description
Labeling Function
KNOCKING SENSORS The LEDs flash if knocking has been detected on the associated
(LEDs) cylinders. If the checkbox Enable knock LED latch (switch ON/OFF to
reset) is activated in the Output options tab, the LEDs light up
permanently as soon as a knock has occurred, instead of flashing.
In this case the LEDs must also be reset manually (see Tab: Output
Options on page 81 )
USB (LED) This LED flashes when data is being transferred via the USB
connection.
CAN TX and RX (LEDs) These LEDs flash when data is being transferred via the CAN bus
(RX=data is being received, TX=data is being transmitted).
POWER SUPPLY (LED) This LED lights up if the supply voltage is available.
BINARY OUTPUTS These LEDs light up if the respective binary output (Engine
(LEDs) Knocking, Trip, Load Reduction) has been activated.
TIMING REDUCTION This LED lights up if an ignition timing reduction has been executed
ANALOG OUTPUTS via one of the two analog outputs (0-5 V or 4-20 mA).
(LED)
USB Port for the data transmission to the PC.
CAN (H, COM, L) Port for communication via CAN bus with master control devices
(such as ALL-IN-ONE).
9-36 V DC (pos., neg., Connection for the voltage supply
ground)
Common Reference potential for the binary outputs (+ or –)
Engine Knocking, Trip, Connections of the binary outputs
Load Reduction
0 V DC, 0-5 V DC, Connections of the analog 0-5 V output (see Wiring of the Analog
+5 V DC Outputs for Ignition Timing Reduction on page 64)
4-20 mA-, 4-20 mA+ Connections of the analog 4-20 mA output (see Wiring of the Analog
Outputs for Ignition Timing Reduction on page 64)
Rev. 02/2019 394 Product Description DetCon Model in Enclosure – Dimensions (CSA Certified) DetCon variant in ATEX enclosure – Dimensions 40 Rev. 02/2019
5 Installation Instructions
Unpack the equipment, taking care not to damage it, and ensure that the operating manual is
always stored with the equipment and is easily accessible. Check the contents for completeness
and verify that the device type meets your application requirements.
Scope of Supply
The supply scope of the device consists of the following components:
– DetCon detonation controller
– CD-ROM with software for configuring the device
– USB interface lead for connecting the device to a PC/laptop
– Operating Manual
– additionally provided for the model with enclosure: screw set and screw joints
Installation locations where strong vibrations or ambient temperatures of below –40 °C (–40 °F)
or above +70 °C (+158 °F) are present are not permissible and result in the warranty being
voided.
Danger of explosion!
In order to prevent the connection terminals from falling out or loosening,
brackets must be mounted on the DetCon detonation controller in
potentially explosive areas which are screwed over the connection
terminals before commissioning and thus fix them in place. There is a
danger of sparking.
Danger of explosion!
The device may only be installed and operated in hazardous areas in an
environment that ensures pollution degree 2 (or better, danger of leakage
currents) according to IEC/EN 60664-1. There is a danger of sparking
Danger of explosion!
Do not disconnect connections as long as the circuit is active unless the
environment is classified as non-explosive. Refer to the operating
instructions for wiring instructions. There is a danger of sparking.
41 Rev. 02/20195 Installation Instructions
ATEX Protection!
Some versions of the ATEX-certified DetCon20 have an external ATEX
protection connected to the CAN bus and the inputs. This external ATEX
protection must not be removed in order to prevent possible flying sparks.
If you do not see this protection externally, it is installed internally.
Risk of Destruction!
When mounting the device, it must be ensured that no vibrations occur
during operation and that temperatures are not exceeded. Otherwise
electronic components can be destroyed. Please read the section
Mechanical data.
Use of wire end sleeves
When connecting the cables to the DetCon detonation controller, use wire
end sleeves to protect the stripped ends.
42 Rev. 02/20195 Installation Instructions
5.1 Ground Connection / Protective Conductor Connection on ATEX Enclosure
The external protective conductor connection is located on the outside of the DetCon20
detonation controller enclosure.
Requirements EN 60439-1:2014-06, 15.3 to be observed!
The external protective conductor must always be connected.
1. Connect the external protective conductor to the corresponding connection as shown in the
following figure.
Rev. 02/2019 435 Installation Instructions
Pos. no Description
Blind rivet nut for M8
Enclosure
Washer ISO 7092-8.4
External protective conductor: Minimum cross section is 4 mm2,
Observe EN 60079-0:2014-06, 15.3!
Ring lead lugs DIN 46234, nominal cross section > 2.5 mm2-35 mm2
Tubular lead lugs DIN 46235, nominal cross section 10 mm2 - 35 mm2
Spring washer DIN 127-B8
Hexagon nut ISO 4017-M8x20
Protective conductor connections of the ATEX enclosure
All protective conductor connections of the ATEX enclosure are designed in
M 8.
Connection of external protective conductor
The external protective conductor is connected with the enclosed stainless
steel screws, nuts, washers and lock washers. The external protective
conductor must be provided with a commercially available lead lug of
suitable cross-section and ring diameter. The lead lugs selected must
comply with one of the following standards:
– DIN 46234 for lead lug
– DIN 46235 for tubular lead lugs
The cross-section for the protective conductor must be dimensioned as follows:
Cross section of phase Minimum cross section of corresponding
conductor S [mm2] protective conductor Sp [mm2]
S 16 S
16 < S 35 16
S > 35 0.5 x S
44 Rev. 02/20195 Installation Instructions
Observe requirements EN 60439-0
– The protective conductor connection parts are designed for a minimum
cross-section of 4 mm2.
– When installing the external protective conductor connection, care
must be taken to ensure that the conductors are secured against
twisting and loosening. This is achieved by professionally and firmly
laying the protective conductors close to the enclosure body.
– Applying a torque of 10 Nm to the screw connection ensures sufficient
contact pressure in conjunction with the enclosed spring washer.
– The choice of materials for the protective conductor connection is such
that electrochemical corrosion is not to be expected. Protective
conductors must be adequately protected against mechanical,
electrodynamic and thermodynamic influences and forces.
– Mechanical connections of protective conductors must be accessible
for inspection and testing.
5.2 Lead bushings through the enclosure wall on the ATEX enclosure
In order to be able to connect the DetCon-detonation controller to other devices, the leads must
be conducted through openings in the enclosure wall. This is possible in the form of screw
connections.
Rev. 02/2019 455 Installation Instructions Maximum number of lead bushings The maximum number of lead bushings depends on their size. The maximum number for each side of the enclosure is selected according to the following table so that the side walls are not weakened and the stability of the enclosure is not impaired. Screw size Side A Side B Side C Side D M 12 33 31 33 33 M 16 19 17 29 29 M 20 16 14 16 16 M 25 13 11 13 13 M 32 4 2 9 9 M 40 3 1 3 3 M 50 2 1 2 2 46 Rev. 02/2019
5 Installation Instructions
Type examination certificate
All lead bushings and cable bushings must have a separate EC type
examination certificate.
Dummy plugs used require a separate EC type examination certificate.
Operational safety
All lead bushings must be mounted with a metal locknut.
When using lead bushings with strain relief and bending protection, the
number of possible standard lead glands is reduced.
Mixed fitting of lead bushings is possible. Areas for intrinsically safe
circuits must be marked separately.
Unused openings for lead bushings must be closed with blind plugs made
of cold impact resistant plastic or metal.
The lead bushings must be mounted in such a way that independent
loosening is prevented and permanent sealing of the lead and lead entry
points can be guaranteed. Lead ties are used for lead fixing.
The spacing of the lead bushings must be selected so that a torque wrench
can be used to tighten the lead bushings and cap nuts. .
Rev. 02/2019 475 Installation Instructions
Tightening torques
The tightening torques must be observed when installing the cable bushings. If no specific
information is available, the following values must be used.
Size Tightening torque Tightening torque of Tightening torque of Core-
of connecting piece cap nuts [Nm (lb-ft)] locknut [Nm (lb-ft)] perforated-
[Nm (lb-ft)] diameter
[mm]
Brass Polyamide Brass Polyamide Brass Polyamide
M 12x1.5 2.5 2.5 2.0 2.0 2.5 2.5 12.5
(1.8) (1.8) (1.48) (1.48) (1.8) (1.8)
M 16x1.5 4.0 4.0 2.5 2.5 4.0 4.0 16.5
(2.95) (2.95) (1.8) (1.8) (2.95) (2.95)
M 20x1.5 4.0 4.0 2.5 3.5 4.0 4.0 20.5
(2.95) (2.95) (1.8) (2.58) (2.95) (2.95)
M 25x1.5 7.5 7.5 12.0 5.0 7.5 7.5 25.5
(5.53) (5.53) (8.85) (3.69) (5.53) (5.53)
M 32x1.5 7.5 7.5 12.0 12.0 7.5 7.5 32.5
(5.53) (5.53) (8.85) (8.85) (5.53) (5.53)
M 40x1.5 7.5 7.5 12.0 12.0 7.5 7.5 40.5
(5.53) (5.53) (8.85) (8.85) (5.53) (5.53)
M 50x1.5 7.5 7.5 12.0 12.0 7.5 7.5 50.5
(5.53) (5.53) (8.85) (8.85) (5.53) (5.53)
48 Rev. 02/20195 Installation Instructions
5.3 Mounting the Detonation Sensors
Danger of explosion!
Only use the detonation sensor approved by MOTORTECH and the required
number of blocking capacitor boards for operation in hazardous areas.
P/N Description
43.20.001 Detonation sensor without sensor lead, two-pole
43.30.004-60 Detonation sensor lead, 18 m (59.06 ft)
43.20.029 Blocking capacitor board (ATEX)
Use MOTORTECH detonation sensors
DetCon detonation controller systems are parameterized for operation with
MOTORTECH detonation sensors (piezoelectric acceleration transducers).
The use of other sensors entails a new calibration of the engine.
Observe the instructions of the engine manufacturer
The following mounting instructions are for orientation only. In any case,
observe the instructions of the respective engine manufacturer for the
installation of detonation sensors and the installation of detonation
controllers.
Dimensions of the Sensor
Rev. 02/2019 495 Installation Instructions
Dimensions of the Required Bore
An M6 screw can also be used as an alternative to M8 screw for the mounting of the detonation
sensor. In this case, however, an adapter sleeve must be used in the sensor to close in the
resultant hollow space, thus ensuring optimal signal transmission.
Mounting
In order to ensure the best functioning of the DetCon detonation controller, it is mandatory to
install the sensors as follows:
– There must be a direct connection to the engine block.
– Installations without a direct connection to the engine block (e. g. with sealings) are
unsuitable.
– Only the metal surface of the sensor may rest on the engine.
– Do not use washers, spring washers, or toothed washers.
– The knocking sensors may not come into contact with liquids (e. g. oil, coolant, water) over a
longer period of time
50 Rev. 02/20195 Installation Instructions
Risk of Destruction!
The fastening screws of the knock sensors must not be tightened too much,
otherwise the sensors will be damaged and will no longer function properly.
Observe the following information for sensor mounting:
– Torque: 20 Nm ± 5 Nm (14.8 ± 3.7 lb-ft) for mounting screws:
– made of cast iron: M8 x 25 mm (0.98"), Strength: 8.8
– aluminium: M8 x 30 mm (1.18"), strength: 8.8
– Torque: 15 Nm ± 5 Nm (11 lb-ft ±2.2 lb-ft) for M6 fixing screws, strength
10.9 with sleeve .
The torque for mounting in the case of mounting with M8 screws (strength 8.8) is 20 Nm ±5 Nm
(14.8 lb-ft ±3.7 lb-ft) and with M6 screws (strength 12.9) with sleeve 15 Nm ±3 Nm (11 lb-ft ±
2,2 lb-ft).
Also, lay the sensor cables in such a way that no resonance vibrations can occur on the cable.
Otherwise, there is a risk of breakage.
The required mounting of the knocking sensors may vary depending on the engine type used.
The following locations are, in principle, possible for fitting the knocking sensors taking into
account the aforementioned specifications
– On the engine block
For mounting on the engine block use screws of the type M 8x30-8.8 (AL-engine block) or
M 8x25-8.8 (CI-engine block).
Rev. 02/2019 515 Installation Instructions
– On the cylinder head screws
Especially when it comes to engine conversions, it has proven to be worthwhile to attach the
knocking sensors on cylinder head screws or -bolts.
Drill an M6-hole with a maximum depth of 12 mm (0.47") in the cylinder head screw and fix
the detonation sensor with a screw of type M 6x25-10.9 and an adapter sleeve to fill the
hollow space
– On the nuts of the cylinder head studs
Contact the engine manufacturer if you are not sure whether the cylinder head screw is suitable
for the installation.
52 Rev. 02/20195 Installation Instructions
Mounting the blocking capacitor board for use in hazardous areas
A blocking capacitor board has four outputs. If all 20 possible knock sensor inputs are used with
a DetCon20, then five blocking capacitor boards are required.
One blocking capacitor board is used for each of the four knock sensors required.
1. Plug the required blocking capacitor boards into the connectors (marked red in the figure)
for the knock sensors on the DetCon20.
2. The wiring of the knock sensors has to be done as described above, with the difference that
you now use the connector plug on the blocking capacitor board.
Rev. 02/2019 535 Installation Instructions
5.4 Mounting the Ignition Sensor Unit (ISU)
The ignition sensor unit is mounted on a DIN rail on the engine in direct proximity to the ignition
coil of the first cylinder in the firing order, which is equipped with a detonation sensor or in the
vicinity of the ignition controller.
For information on wiring connections, please refer to section Wiring of the Ignition Sensor Unit
(ISU) on page 59.
For diesel and pilot injection engines, a camshaft sensor is used instead of an ignition sensor
unit (ISU). Refer to the section Mounting the Camshaft Sensor on page 55. No ignition sensor
unit is needed when using a MOTORTECH ignition sensor unit with ASO (e. g. MIC6) output
either. You can find information in the section Wiring for Ignition Controller with ASO Output on
page 58.
Mounting on the engine
The ignition sensor unit is fully sealed and therefore resistant to vibrations.
When mounting on the engine or in an environment in which vibrations
arise, only the connector must be secured e.g. by means of a cable tie.
Please note that the contacts of the connector are bare and must be
protected against moisture and contamination. If the engine should be in
such a location, the ignition sensor unit can be, for example, mounted in a
junction box or housed in a control cabinet.
54 Rev. 02/2019You can also read
