Installation and Operations Manual

Knock Monitoring
System

DetCon2

All rights reserved. Subject to technical modifications.

Version 2.0, 14.12.2000
DetCon2-E.doc; 29.12.2003

MOTORTECH GmbH
Hogrevestr. 21-23 D-29223 Celle
Telefon: +49 5141 9399-0 Fax: +49 5141 9399-98 / -99
eMail: motortech@motortech.de Internet : www.motortech.de

Table Of Contents

Page

1 Features

2 Function Description

2.1 Principle Of Knock Detection

2.2 Control Functions
2.3 Analog Output
2.4 Binary Outputs
2.5 Alarm Features
2.6 Output Functions Control Unit

3 Installation
3.1 Hardware Configuration
3.2 Software Configuration

4
4
4
5
5
5
6
6
6

4 Technical Specifications

10

4.1 Knock Sensor

4.2 Control Unit
4.3 Ignition Sensor

10
10
10

5 Wiring
5.1 Wiring Diagram Control Unit
5.2 Circuit Board / Description of LEDs
5.3 Wiring Diagram Ignition Sensor

6 Dimensions / Mounting
6.1 Control Unit
6.2 Knock Sensor
6.3 Ignition Sensor

DetCon2 Installation And Operations Manual

Page 2/14

11
11
12
12
13
13
13
14

MOTORTECH GmbH Celle www.motortech.de

DetCon2-E.doc; 29.12.2003 11:18

1 Features

Knock monitoring

Designed for gas engines, operating with fuels of changing quality

Up to two knock sensors connectable

Analog output to ignition control unit for timing control

3 binary outputs for control signals to engine management system

Panel mounting

Warning!!!
Caution High Voltage!!! Danger to life!!!
When engine is running, ignition sensor should
not be touched, disconnected or removed.

ATTENTION!!!
The knock monitoring system detects engine
knocking as far as possible but not guaranteed.

ATTENTION!!!
With V-engines it is only possible to run the
system, when only single-firing ignition systems
are mounted, not double-firing systems.

ATTENTION!!!
High tension leads with integrated 5 k resistor
are required to run the knock monitoring
system.

DetCon2 Installation And Operations Manual

Page 3/14

MOTORTECH GmbH Celle www.motortech.de

DetCon2-E.doc; 29.12.2003 11:18

2 Function Description
2.1 Principle Of Knock Detection
During detonation combustion, a frequency is generated, which is typical for each engine type. detcon
measures the vibration energy in the narrow frequency band, where knocking can be expected. This
energy is equivalent to a knocking level. Measurements are executed during that specific section of
working cycle, where detonating is possible. This increases the sensitivity of the knock monitoring
system and improves immunity against random noise.

2.2 Control Functions

The control unit has one analog output:
IGNITION TIMING REGULATION
And three binary outputs:
ENGINE KNOCKING
LOAD REDUCTION
TRIP
Measured knock energy in every working cycle will be compared with adjustable limit, IGNITION
REDUCTION LIMIT . When this limit will be reached, the output ENGINE KNOCKING will be
activated. At the same time, the analog output increases its value from 0 to 5 V (or from 4 - 20 mA).
Increase rate is depending on knocking energy and parameter TIMING REDUCTION GAIN. This
analog output is designed for timing reduction and should be connected to the ignition controller.
When knocking energy falls under this limit, the value of analog output decreases. Decreasing rate is
depending on parameter DECREASE RAMP.

2.3 Analog Output

There are different features to choose for the analog output (depending on which kind of ignition
control unit is used):
Output 0 5 V
Output 4 20 mA
Output 20 4 mA
If 4 20 mA is used (see wiring of control unit, section 5.1, page 12) the user could set 4 20 mA or
20 4 mA (depending on which kind of ignition control unit is used).
The features can be set by items 1 3 in the software program, page 2 of parameter window.

DetCon2 Installation And Operations Manual

Page 4/14

MOTORTECH GmbH Celle www.motortech.de

DetCon2-E.doc; 29.12.2003 11:18

2.4 Binary Outputs

When full scale of analog output is reached and engine is still knocking, the binary output LOAD
REDUCTION will be activated. It should be connected to the control unit and should be used as a
command for power reduction.
When engine stops knocking, the output LOAD REDUCTION will be disabled, but analog output will
remain at full scale for another period, which can be set by parameter DELAY AFTER LOAD
REDUCTION. After this time, value of analog output will be reset. Please note that this period should
be longer than the time, the engine requires to reach full load again.
The third binary output TRIP will be enabled when the knocking energy is higher than parameter
IMMEDIATE STOP LIMIT. It should be used as an emergency stop signal.

2.5 Alarm Features

In case that there occur signal losses from the knock sensor or from the ignition sensor (e.g. cable
damage), the output signal TRIP for immediate shutdown of the engine will be activated and the
engine stops.
To choose this function please see items 4 6 of page 2 of parameter window.

Programming of ignition control unit:

The cylinder(s) where the knock sensor(s) is (are) mounted has to fire 2 before the
other cylinders fire.
2.6 Output Functions Control Unit

DetCon2 Installation And Operations Manual

Page 5/14

MOTORTECH GmbH Celle www.motortech.de

DetCon2-E.doc; 29.12.2003 11:18

3 Installation
Customer installation is possible only for those engine types, for which the knocking frequencies
already have been measured.
For wiring of the control units, please refer to sections 5.1 - 5.3 on pages 12 - 14.
Binary outputs can be connected in both polarity as they are galvanicly seperated.
For wiring of the ignition sensor, please refer to section 5.3 on page 14.
For installation of the knock sensor(s), please refer to section 6.2 on page 16.

3.1 Hardware Configuration

It is necessary to setup the requested mode of analog output (0 5 V or 5 0 V; 4 20 mA or 20 4
mA), which depends on your ignition control unit. To choose the mode, please refer to the wiring
diagrams of the control unit, section 5.1 on page 12.

3.2 Software Configuration

First install the software program (included in scope of supply) on your PC or Laptop. Minimum
system requirements are MS-DOS.

Copy all files out of the folder "detcon2" on your hard disc. A destination folder has to be created
before.

Now please connect your detcon control unit to your PC/Laptop. Therefore please take a "NullModem" cable and connect it from COM1 or COM2 of your PC/Laptop to the control unit. Cable is
included in scope of supply. When using a different kind of cable, both detcon control unit and
your PC/Laptop could be damaged.

To start the program from MS DOS box, please type "denox" (connection with COM 1) or "denox2"
(connection with COM 2).

Computers, connected to detcon, must be galvanicly speperated from grid potential and any other
potential of the genset. We recommend to use a notebook with internal batteries during detcon
configuration. During communication the detcon control unit must be powered up.

DetCon2 Installation And Operations Manual

Page 6/14

MOTORTECH GmbH Celle www.motortech.de

DetCon2-E.doc; 29.12.2003 11:18

After program is loaded, you will see "detcon DEBUGER/LOADER, Version x" on the screen.

The screen consists of two windows:

parameter window above

communication window below

To switch between both windows press [F5].

Parameter window shows all necessary values for correct function of detcon on your requested
engine. Blue parameters are not user configurable, black parameters can be set by user. Please see
table below for meaning of parameters.
Press [F4] to switch to page 2 of the paremeter window.
Press [F3] to load specific engine data.
To change parameter values please press [F2]. Choose required parameter by using the cursor keys
and . To change requested values please press keys or (to speed up changes please press
CTRL + or ).
Press [F7] to send parameters to detcon control unit.
Press [F8] to read parameters from detcon control unit.

DetCon2 Installation And Operations Manual

Page 7/14

MOTORTECH GmbH Celle www.motortech.de

DetCon2-E.doc; 29.12.2003 11:18

Communication window shows all user changeable values and also contents a program help file
(press [F1]).
Function of keys [F2], [F3], [F7] and [F8] see above.
When connection to control unit is established following message will appear:
COM 1 (COM 2) linked to: detcon (version x) OK.
In the last two lines you can see actually set values (please see table below for their meaning).
To leave the program press [ALT + X].

Parameter window, page 1

No.

Parameter

Range

Description

Function control

Not user changeable.

Reference filter frequency

Not user changeable.

Knock filter frequency

Not user changeable.

Balance control

Not user changeable.

Integrator time constant

Not user changeable.

Detonation window delay

Not user changeable.

Detonation window width

Not user changeable.

Background window delay

Not user changeable.

Number of measurements

Not user changeable.

10

Gain of input amplifier

Not user changeable.

11

TIMING REDUCTION GAIN

0 100%

12

DECREASE RAMP

0 31,5%
per sec.

13

IGNITION REDUCTION LIMIT

0 235

14

DELAY AFTER LOAD REDUCTION

0 255
0,1 sec.

15

IMMEDIATE STOP LIMIT

0 235

DetCon2 Installation And Operations Manual

Page 8/14

Determine increase rate of analog

output used for timing control when
engine is knocking.
Determine decrease rate of analog
output used for timing control when
engine is not knocking.
Determine limit for measured
knocking energy when output engine
knocking is activated and ignition
timing is reduced
Determine delay between
deactivation of load reduction output
and that moment when ignition timing
returns to normal state
Determine limit for measured
knocking energy when output TRIP
is enabled.

MOTORTECH GmbH Celle www.motortech.de

DetCon2-E.doc; 29.12.2003 11:18

Parameter window, page 2

No.

Parameter

Range

REVERSE ANALOG OUTPUT

Yes / No

ENABLE MAX. OUTPUT SETTING

Yes / No

MAXMUM OUTPUT VALUE

0 100%

TRIP CONTACT INACTIVE

Open /
Close

ENABLE BAD SENSOR DETECT

Yes / No

ENABLR SECOND SENSOR

Yes / No

Description
Changes 4 20 mA to 20 4 mA if
YES.
Enables point 1 if chosen YES.
Maximum analog output value (if
enabled), 100% = 20 mA.
Enables alarm features for signal
loss of ignition sensor:
Open = no alarm
Close = alarm if signal failure.
Enables alarm feature for signal loss
of knock sensor 1.
Enables alarm feature for signal loss
of knock sensor 2.

Table communication window

No.

Parameter

Range

KNOCKING INTENSITY

0 235

detcon REGULATION OUTPUT

0 100%

DetCon2 Installation And Operations Manual

Page 9/14

Description
Instantaneous measured value of
knocking energy.
Instantaneous value of detcon
regulation output
(analog output for ignition timing
control).

MOTORTECH GmbH Celle www.motortech.de

DetCon2-E.doc; 29.12.2003 11:18

4 Technical Specifications
4.1 Knock Sensor
Parameter
Knock sensor
Frequency range
Resonance frequency
Temperature range
Dimensions
Mounting

Specification
Piezoelectric acceleration transducer
1 20 kHz
> 20 kHz
-40 - +130C
45 x 20 x 21 mm
Screw M8 x 25 (Cylinder head cast iron)
Screw M8 x 30 (Cylinder head aluminium)

4.2 Control Unit

Parameter
Binary outputs

Specification
All three outputs have one common terminal, max.
voltage 33 V, max. load current 50 mA
1) 0 - 5 V (+0, 0,5 V), max. load current 2mA
2) current loop 4 20 mA, max. voltage 30 V
-25 - +70C
9 - 36 VDC
IP20
160 x 200 x 46 mm (incl. rail)
approx. 1,0 kg
Panel mounting

Analog ouput
Temperature range
Power supply
Protection class
Dimensions
Weight
Mounting

4.3 Ignition Sensor

Parameter
Ignition sensor
Temperature range
Dimensions
Weight
Mounting

DetCon2 Installation And Operations Manual

Page 10/14

Specification
Ignition coil current sensor
-25 - +70C
70 x 46 x 48 mm (incl. rail)
approx. 0,1 kg
Rail

MOTORTECH GmbH Celle www.motortech.de

DetCon2-E.doc; 29.12.2003 11:18

5 Wiring
5.1 Wiring Diagram Control Unit

DetCon2 Installation And Operations Manual

Page 11/14

MOTORTECH GmbH Celle www.motortech.de

DetCon2-E.doc; 29.12.2003 11:18

5.2 Circuit Board / Description of LEDs

DetCon

5.3 Wiring Diagram Ignition Sensor

DetCon Control Unit

DetCon2 Installation And Operations Manual

Page 12/14

MOTORTECH GmbH Celle www.motortech.de

DetCon2-E.doc; 29.12.2003 11:18

6 Dimensions / Mounting
6.1 Control Unit

6.2 Knock Sensor

DetCon2 Installation And Operations Manual

Page 13/14

MOTORTECH GmbH Celle www.motortech.de

DetCon2-E.doc; 29.12.2003 11:18

6.3 Ignition Sensor

DetCon2 Installation And Operations Manual

Page 14/14

MOTORTECH GmbH Celle www.motortech.de

DetCon2-E.doc; 29.12.2003 11:18