Det-1600 Iom 11-09

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INSTALLATION/OPERATION
WARNING:
DEVIATION FROM THIS INSTALLATION/OPERATING MANUAL DEVIATION FROM THESE INSTRUCTIONS MAY LEAD TO IMPROPER OPMAY LEAD TO IMPROPER OPERATION OF THE MONITORED ERATION OF THE MACHINE WHICH COULD CAUSE PERSONAL INJURY MACHINE WHICH COULDPERSONNEL. CAUSE PERSONAL INJURY TO TO OPERATORS OR OTHER NEARBY OPERATORS OR OTHER NEARBY PERSONNEL.
DET-1600 DETONATION SENSING MONITOR

FORM DET-1600 IOM 11-09
CAUTION:
THE DET-1600 DETONATION SENSING MONITOR IS CERTIFIED FOR USE IN CLASS I, GROUPS C & D, DIVISION 2 HAzARDOUS LOCATIONS WHEN INSTALLED IN ACCORDANCE WITH THESE INSTRUCTIONS. THE SENSOR INPUT LEADS CONNECTED TO THIS DEVICE OPERATE AT A LOW VOLTAGE AND POWER LEVEL AND MUST NOT CONTACT ANY ExTERNAL VOLTAGE SOURCE. DAMAGE TO THE SYSTEM WILL RESULT FROM CONNECTION BETWEEN THE INPUT SENSOR LEADS AND THE IGNITION SYSTEM OR ANY AC OR DC POWER SOURCE ABOVE 36 VDC.
1.0 DESCRIPTION 1.1 The Altronic DET-1600 Detonation Sensing Monitor is a 32-bit microprocessor-based electronic instrument designed to detect and eliminate detonation on natural gas-fueled engines before damage occurs. Industry-standard low cost broadband piezoelectric vibration sensors, mounted on the engine, are used to transform the vibrations caused by detonation into electrical signals which are then evaluated by the DET-1600. The Detonation Sensing Monitor uses the sensors to measure the combustion intensity of each cylinder in a user-configured time window. The detonation signals are filtered by programmable filters and then sent to the microprocessor for further processing and evaluation. This process is repeated for every cylinder on a cycle-bycycle basis. The resulting two reference numbers, one for detonation intensity and the other for the lack of a combustion process, or misfire, are displayed on a LCD display. These reference numbers are used to control two output switches, typically one for load control and the other for shutdown, and a 4-20mA current loop or Modbus RTU output used to retard ignition timing.
The 2 x 16 backlit LCD is used to display the detonation and misfire reference level numbers, engine cylinder labels, control and output switch status, the cause of shutdown log, as well as diagnostic messages. The reference numbers are compared to adjustable setpoint values. These setpoint values are user adjustable and when exceeded by the reference numbers signal the output switches to trip. The switches can be used to control load, ignition timing, and/or to shut down the engine. The 4-20mA current loop output is fully configurable and can be used to adjust ignition timing or engine load. The RS485 Modbus RTU output can be used for timing adjustment.
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1.2 The DET-1600 is housed in a 6.5" x 6.5" rugged powder-coated aluminum case. The user interface is an 8-key membrane keypad along with a 2 x 16 backlit LCD. The monitor accepts up to 16 detonation sensors that are wired to pluggable Phoenix-type connectors. The DET-1600 can be set up for one sensor per cylinder, one per two cylinders, or one per bank.
1.3 POWER REQUIREMENT
The power requirement is 10 to 32Vdc, 0.30Amp max. cation using the TERMINAL PROGRAM on a PC or laptop computer. For similar setups, configurations can be saved to the PC and recalled at a later time. A library of applications can be created saving time and effort for similar applications.
PRIOR TO USE ON AN ENGINE. REFER TO WARNING: CONFIGURED SECTION 6.0, CONFIGURING THE DET-1600. THE DET-1600 Detonation Sensing Monitor MUST BE
NOTE: If possible, keep the original shipping container. If future transportation or storage of the monitor is necessary, this container will provide the optimum protection.
1.4 The DET-1600 is configured (user customized) for each engine appli-
2.0 DETONATION/vIbRATION SENSORS 2.1 The detonation (or knock) sensors convert the engine vibrations to
an electrical signal that is proportional to acceleration. These signals are then used by the DET-1600 to measure the amplitude and frequency of the detonation. The sensors are of the low cost automotive broadband piezoelectric type. In order to use these signals properly, the sensors must be securely bolted to the engine block at their optimum locations (see mounting section below and FIGURES 3, 4, AND 5 for further sensor application information). The detonation/vibration sensor suggested for use with the DET-1600 Detonation Sensing Monitor is the Bosch P/N 0 261 231 148. Equivalent models from other manufacturers may also be used. The Bosch sensor is available from Altronic as P/N 615107. The cable assembly is P/N 693134-x. Description Vibration Sensor Cable Assembly, 10 Cable Assembly, 20 Cable Assembly, 30 Cable Assembly, 40 Cable Assembly, 50 Cable Assembly, 100 Part Number 615107 693134-1 693134-2 693134-3 693134-4 693134-5 693134-6
2 FORM DET-1600 IOM 11-09
INSTALLATION/OPERATION MANUAL
NOTE: Avoid mounting the Monitor with the LCD display facing direct sunlight. The display temperature range is -22F to +175F (-30C to +80C).
3.0 MOUNTING 3.1 DETONATION SENSING MONITOR (SEE FIGURE 1)

Mount the DET-1600 inside a control panel or to a suitable flat surface so that the display is at a convenient viewing height. A drilling template is provided. The number, location, and mounting procedure of the detonation sensors are dependent on the engine type and number of sensors used for the system. One sensor per cylinder is required for misfire detection. 3.2.1 LOCATION The sensors should be as symmetrically distributed between the cylinders as possible and positioned in the center of each cylinder on the engine crankcase just below the cylinder heads. If possible, refrain from mounting sensors to the cylinder head as valve gear noise may interfere with the sensor signal. The mechanical noise level may prevent proper operation of misfire detection if sensors are mounted on the head bolts. The sensors should be mounted at locations where exposure to liquids such as gasoline, antifreeze, oil, brake fluid, etc is minimal. Angular mounting position is arbitrary. 3.2.2 MOUNTING PROCEDURE Mount the detonation sensors to a smooth surface on the engine crankcase. A surface that is not smooth will give erratic readings. Drill and tap the block perpendicular to the surface, counterbore if necessary, and take care not to penetrate the water jacket. Use a bolt of M8x25, grade 8.8. Make sure the bolt does not bottom-out in the tapped hole. Torque the bolt to 20 5Nm (15 1FtLb). Do not over-tighten, damage may occur to the sensor. No washer of any kind is permissible. Only the metallic part of the sensor ( 22mm) may make contact with the engine.
3.2 DETONATION SENSORS (SEE FIGURE 4)
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4.0 WIRING (SEE WIRING DIAGRAMS) 4.1 GENERAL
The DET-1600 is designed to work with negative ground C.D. ignition systems with a nominal primary voltage of 100 to 250 volts peak. The DET-1600 uses the Ignition Systems shutdown lead as well as the #1 cylinders primary lead as input signals. Each cylinder firing must be available for proper operation. In addition the following guidelines must be adhered to: 1. The engine ignition system must be a negative ground C.D. ignition system with a nominal primary voltage of 100 to 250 volts peak. 2. The ignition shutdown lead signal must provide one firing for each cylinder. Consult factory for applications with dual capacitor ignition systems with only half of the cylinder signals available on the shutdown lead. 3. For the minority of engines with non-repeating odd firing patterns or engines that fire two cylinders at a time, consult the factory for installation procedures. Take care not to damage the insulation and take precautions against damage from vibration, abrasion or liquids in conduits. Also never run sensor, low voltage power, current loop, communications, or output switch wires in the same conduit as the ignition wiring or other high energy wiring such as AC line power, etc. Keep wires at least 12 inches away from all high voltage wiring. Keep secondary wires to spark plugs and other high voltage wiring at least 8 inches (200mm) away from detonation sensors and their wiring.
NOTE: Altronic HIGHLY RECOMMENDS the use of resistor spark plugs and/or spark plug leads with all digital instrumentation as a means of reducing the impact of RFI (radio frequency interference) on operation.
4.2 POWER WIRING
Connect the power input wires to terminals (DC+) and (DC-); power requirement is 10 to 32Vdc, 0.30Amp max. Connect the minus terminal (DC-) to panel ground, which must be the same as engine ground. DO NOT CONNECT THE MINUS TERMINAL DIRECTLY TO THE IGNITION SYSTEM COMMON COIL GROUND ON THE ENGINE. The shutdown lead of an ignition system is used to sense rotation and for determining the timing degree window position. Connect a wire from the shutdown lead of a negative ground C.D. ignition system to the back of the DET-1600 monitor to the terminal marked SD LEAD. The ground connection will be made through the DC- terminal on the back of the monitor that is connected to panel ground which should be the same as engine ground.
4.3 SHUTDOWN LEAD INPUT
NOTE: The ignition shutdown lead must provide one firing for each cylinder.
4.4 NUMbER 1 CYLINDER IGNITION COIL PRIMARY OF A C.D. IGNITION SYSTEM
The number 1 cylinder signal is used to sense rotation, calculate rpm and for an angular reference point. Connect a wire from the number 1 cylinder ignition coil primary of a negative ground C.D. ignition system to the back of the DET-1600 monitor to the terminal marked #1 COIL INPUT. The ground connection will be made through the DC- terminal on the back of the monitor that is connected to panel ground which should be the same as engine ground.
4.5 DETONATION SENSOR WIRING
The detonation sensors generate low voltage bipolar signals of approximately 26mV/g. Mount the sensors as described above. Each detonation sensor requires two wires. Use a two conductor cable of 20-22AWG (Altronic 693134-x or equivalent) to wire the detonation sensor to the sensor input terminals on the back of the DET-1600. The sensor cables should be run in rigid conduit or Sealtite/Liquidtite to protect the wires from breakage. Wire the detonation sensors in the firing order of the engine. Use the sensor wiring chart FIGURE 5 as a wiring aid. Wiring examples of sensors: Example 1 One sensor per cylinder on 6 cylinder inline engine Firing order: 1-5-3-6-2-4 Sensor configuration: Sensor #1 for cylinder #1 Sensor #5 for cylinder #5 Sensor #3 for cylinder #3 Sensor #6 for cylinder #6 Sensor #2 for cylinder #2 Sensor #4 for cylinder #4
Terminal # on back of DET-1600 Cylinder # (as marked on engine) Sensor #
1 1 1
2 5 5
3 3 3
4 6 6
5 2 2
6 4 4
Example 2 One sensor per cylinder on a 12 cylinder V engine. Firing order: 1R-6L-5R-2L-3R-4L-6R-1L-2R-5L-4R-3L Sensor configuration: Sensor #1 for cylinder 1R Sensor #12 for cylinder 6L Sensor #5 for cylinder 5R Sensor #9 for cylinder 3L
Terminal # on back of DET-1600 Cylinder # (as marked on engine) Sensor #
1 1R 1 2 6L 12 3 5R 5 4 2L 8 5 3R 3 6 4L 10 7 6R 6 8 1L 7 9 2R 2 10 5L 11 11 4R 4 12 3L 9
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4.6 OUTPUT SWITCH WIRING
Exceeding a setpoint value will cause the user programmable output switch to turn ON/OFF with respect to its common. The DET-1600 contains two output switches. Switch 1 is typically used to initiate load control and switch 2 is typically used to initiate a shutdown sequence. Output switch 1 will trip when an input value exceeds either the misfire setpoint value (a low setpoint) or the detonation setpoint value (a high setpoint). Output switch 2 will trip when the max retard value has been reached and the switch 2 timer has expired. These switches are solid state, form C (N/O and N/C) break-before-make contacts and are isolated from the power supply. Switch 1 is closed with the absence of power and switch 2 is open with the absence of power. The switches are rated at 200V, 200mA and the N/O switch has a unique internal overload current protection circuit. If an overload occurs, the internal circuitry limits current to safe levels. When the overload is removed, the relay resumes its normal ON characteristics. These switches can be wired to engine management systems, an Altronic annunciator system or to pilot duty relays as shown by the wiring diagrams.
4.7 OUTPUT CURRENT LOOP WIRING
The DET-1600 has a 4-20mA current loop output available. This output can be used to retard ignition timing, control loads, or adjust system valves, actuators, and other devices commonly used in process control. The current loop output is labeled 4-20mA OUT and is internally limited to 25mA. The output is protected against open and short circuits. A 250 ohm receiving resistor can be used over the entire supply voltage range from 10 to 32Vdc. The maximum load resistance that can be tolerated in the loop is determined by the supply voltage. When using the maximum rated loop resistor of 500 ohms with a desired full scale loop output of 20mA, the supply voltage must be between 15 and 32Vdc. At 12Vdc supply voltage, the maximum load resistor for 20 mA loop output current is 350 ohms. REFER TO THE WIRING DIAGRAMS for typical hook-up. The DET-1600 has two RS485 Modbus RTU communications links, one is a master the other a slave. The Modbus slave port is used to transfer data to and from a PC or laptop to configure and monitor the DET-1600. The Modbus master port is used to transfer timing data instructions to an ignition system to perform ignition timing control. Wire the Modbus slave terminals to a PC or laptop computer to configure and monitor the DET-1600. If the installation requires ignition control via Modbus, wire the Modbus master to a Modbus RTU-enabled ignition system. Use a two-conductor shielded cable of fine gauge stranded wire and connect the wires to the terminals marked RS485 A and RS485 B. Make the following connections to the other communication device A to A(-) and B to B(+). If required, connect the shield wire to the master device only.
4.8 RS-485 COMMUNICATIONS WIRING
4.9 HAZARDOUS AREA OPERATION
The DET-1600 Detonation Monitor is CSA certified for CLASS I, DIVISION 2, GROUPS C & D areas. The DET-1600 is certified as a component only and is required to be installed in a suitable enclosure where the suitability of the combination is subject to the local inspection authority having jurisdiction. The power connections to the DET-1600 must be in accordance with the National Electrical Code and in Canada, the Canadian Electrical Code. In addition, the following requirements must be met: 1. 2. 3. Run the sensor wires leaving the panel in a separate conduit from all other wiring and keep them separate throughout the installation. Power, input, and output wiring must have a grade of insulation capable of withstanding an AC voltage of 500 volts RMS. In general, run wires in separate conduits and junction boxes from high voltage wires such as ignition, fuel valve, and other high voltage wiring.
WARNING ExPLOSION HAzARD:
DO NOT DISCONNECT EQUIPMENT IN DIV. 2 ENVIRONMENT UNLESS POWER IS SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAzARDOUS.
4.10 TESTING SENSOR LEADS
If it becomes necessary to check sensor to terminal wiring with an ohmmeter or other testing device, first disconnect the sensor wires from the monitor. This will prevent possible damage to the devices sensitive low voltage detection circuitry.
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5.0 THEORY OF OPERATION 5.1 DETONATION, AN OvERvIEW
A normal combustion process starts with the spark from the spark plug that occurs sometime before top dead center. This spark ignites the air fuel mixture. It burns in a steady controlled fashion across the chamber in a three dimensional fashion burning all of the fuel in the chamber for a complete burn. This causes a peak pressure to build up in the cylinder which acts upon the piston forcing it down. Peak pressure usually occurs around 16 degrees after-top-dead-center. This is the ideal or normal combustion process. When an engine is pushed to its limits by overload, over-boost, low fuel btu, mis-tuning, and/or inadequate cooling a pinging or knocking is heard, this is called detonation. Detonation is the spontaneous combustion or the disruption of the normal controlled flame path in the combustion chamber caused by the autoignition of the end gasses in the cylinder. Detonation typically occurs after the normal combustion is initiated by the spark plug and occurs somewhere between 5atdc to 30atdc. The end gas in the combustion chamber lacks sufficient fuel rating to withstand the pressure and heat developed and causes the remaining fuel mixture to spontaneously combust. Detonation causes a pressure spike in the combustion chamber of a short duration that causes the engine to ring, or resonate like it was hit by a hammer. A small detonation is called incipient knock because it is barely audible. If the detonation is large enough, it can be heard. If detonation is allowed to continue, it can damage the engine. The DET-1600 Detonation Monitor is designed to guard spark-ignited gas engines from damage due to detonation.
5.2 DETONATION AND MISFIRE
The DET-1600 system can detect both detonation and misfire. While detonation is a greater amplitude signal, misfire is the absence of a normal combustion process. The same cylinder sensor is used for both misfire and detonation detection. However, once the sensor signal enters the DET-1600, the signal takes separate paths, one for misfire another for detonation. The result of these processing actions is a separate misfire and detonation reference number. Both numbers are simultaneously displayed on the LCD. Separate user configuration parameters are available for misfire and detonation. The parameters are: the band-pass frequency, gain, integrator time, sampling windows, setpoint values, and display lag filter values. These parameters will typically be configured differently for misfire and detonation.
5.3 WINDOWING
The DET-1600 uses a technique called WINDOWING, a user-configurable parameter which allows the device to detect detonation and misfire only during the expected time frame. Windowing is used to suppress the unwanted noises in the engine such as valves opening and closing, pistons changing direction, and also electrical noise generated each time the spark plug fires. All of these create vibrations in the same frequency range as knock. Therefore, the time for measuring knock detection has to be during expected knock periods of the engine cycle. This is called knock windowing and reduces the risk of misdetection. The window opens and closes for each individual cylinder firing. As mentioned above, detonation, when it occurs, typically occurs between 5atdc to 30atdc. In the DET-1600, a separate window opening and duration can be configured for detonation and misfire.
5.4 INPUT SIGNAL FILTERING
Detonation, as well as the mechanical engine noises, occurs in the audible frequency range of 20Hz to 20kHz. The DET-1600 uses a configurable band-pass filter to separate the detonation vibrations from the normal engine vibrations. The theoretical detonation frequency is based on the cylinder bore diameter and the speed of sound at a typical combustion temperature and pressure. In reality, other factors also come into play such as engine mass, sensor mounting position, and the sensor design itself. Generally, a larger bore will have a lower frequency. The configurable gain is used to amplify the signal to a level that can be readily used by the system. The configurable integrator time is the resolution of the signal seen for a given time period. A shorter integrator time value will result in a larger output value because it will more closely approximate the signal. Longer integration times allow more averaging and thus will result in a smaller output value.
5.5 SEQUENCE OF OPERATION, SETPOINTS AND OUTPUTS
When the engine is running, a detonation and misfire reference level for each cylinder will be displayed on the LCD display one channel at a time. The reference numbers are a representation of the vibration intensity from the sensors. The range is 0 to 999. The outputs on the DET-1600 (two switch outputs, a 4-20mA current loop output, and/or a Modbus RTU RS-485 output) will be enabled after the engine has reached the Control RPM Value and the Control Lockout Time has expired. Both of these parameters are configurable and allow the engine to idle, ramp up in rpm, and become stable without the outputs taking affect. Once the engine is at run speed and loaded, the reference levels from the sensors will continuously be compared against the Misfire and Detonation setpoint values.
NOTE: The reference numbers are related to the amplitude of the vibration signal from the sensor. On an operating engine, some variation is to be expected, especially as load, speed or ambient temperature changes.
Although the outputs of this system can be used in several different ways, the control and safety philosophy of the DET-1600 is as follows:
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The first line of defense of the DET-1600 system is typically to control load. If either a misfire or detonation occurs (the misfire reference number goes below the misfire setpoint value or the detonation reference number goes above the detonation setpoint value) output switch #1 will activate. Switch #1 is intended to be connected to a load control management system and to initiate load reduction of the engine. If the load reduction solves the problem (the reference numbers return to normal) no further steps are necessary, switch #1 will deactivate. The load controller can then return the engine back to full load. If however, despite the load reduction, detonation continues for longer than the ignition Retard Step Timer time, the DET-1600 system will initiate its second line of defense and take steps to retard the ignition timing. Either the 4-20mA loop or the Modbus is assumed to be tied to an external device performing timing control, which can be the ignition system itself. The timing will be retarded in the step size set by the Retard Step Value programmed by the user. The Ignition Retard Step Timer will commence. When the Retard Step Timer expires and if detonation is still occurring, the ignition will retard the same step size amount. This process is repeated until the initiated output action solves the problem (reference numbers return to a value below the setpoint value). With the lack of detonation, the ignition timing will remain stable for the time configured in the Time Between Advance Steps. Once detonation is under control, the DET-1600 will begin removing the inserted ignition retard (advance the timing) in the amount configured in the Advance Step Value parameter. If detonation does not recur, the ignition timing will continue towards zero added retard in the amount configured for the Advance Step Value. This process will continue until the ignition timing has returned to its normal run timing value. If detonation has still not reoccurred, output switch #1 will deactivate so that the load control system can increase the load again and the engine can resume its normal operation. If detonation continues, and the DET-1600 reaches the Max Retard Timing Value Allowed, the third line of defense will occur, switch #2 will activate. Up until now, load has been reduced and ignition timing has been retarded to the maximum configured value. Currently, there is only one thing left to do and that is to shut down the engine to protect it from damage. Switch #2 (if wired to do so) will KILL the ignition system shutting down the engine. The display will flash View Alarms. The shutdown status will be recorded in the status log. The status log can be viewed for the cause of the shutdown.
10 FORM DET-1600 IOM 11-09
6.0 CONFIGURING THE DET-1600
DET-1600 Detonation Sensing Monitor MUST BE WARNING: THE CONFIGURED PRIOR TO USE ON AN ENGINE.
6.1 OvERvIEW
As conditions differ per engine and application (sensor mounting, different engine types, etc.) the DET-1600 Detonation Monitor is customized for each engine application using the TERMINAL PROGRAM on a PC or laptop computer. Each parameter is described below. The configuration parameter values must be carefully chosen and entered by a technician to assure proper operation of the system. The TERMINAL PROGRAM is included on the CDROM supplied with each DET-1600 Monitor. Once loaded on the PC, the connection parameters set, the DET-1600 powered and RS485 communication output wired to the Monitor, the current configuration can be viewed. Make the required changes to each configuration parameter; the new value will be written to the Monitor as each parameter is entered. The same terminal program is used to fine tune the parameters when on a live engine. Once the setup is complete, the parameters can be saved to a file on the PC and later recalled for similar applications.
6.2 TERMINAL PROGRAM STRUCTURE
The terminal program is designed with command menus and several folder tabs at the top of the page. Each tab is labeled with the general heading of the configuration parameters for each page. Click on each tab to select the page to be configured. Following are the descriptions of each configuration parameter. Connect the DET-1600 to the PC via the RS485 port marked RS485 MODBUS SLAVE through a RS485 to RS232 adapter (for wiring details SEE SECTION 4.8 and FIGURE 12 (RS485 COMMUNICATIONS, PC HOOK-UP). Power the DET-1600. Load and run the terminal program. Set the Com Port settings to: Com port x (x is the com port used on the PC), 19200 Baud, 1000ms Timeout, Parity none, and 1 Stop Bit. Set the Slave ID to 1.
6.3 TERMINAL PROGRAM, ESTAbLISHING COMMUNICATIONS
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6.4 FILE
6.4.1 LOAD FROM A FILE The LOAD feature allows the user to load a previously saved detonation configuration file (.dcf) to the terminal program. To load a file, disconnect from the DET-1600 using the Disconnect command; select FILE, then LOAD. In the list that opens, select the drive, folder, and desired file. The data will be loaded into the terminal program but not into the unit. Connect to the DET-1600 to upload the configuration parameters to the DET-1600 Monitor. 6.4.2 SAVE TO A FILE The SAVE feature allows the user to save the setup to a file for later use in the same or another DET-1600. Once the setup is complete, use the SAVE button to save the parameters to a file on the PC. The file extension preferred for the file is .dcf. So that the file format is similar use: # of cylinders_cycles_engine type and numeric number. An example would be: 12_4_Wauk01.dcf
6.5 COM PORT
Use the COM Port Command Menu to configure the PC to talk to the Monitor: Com port x (x is the com port used on the PC), Baud Rate (set to the same as the DET-1600, 1000ms Timeout, Parity none, and 1 Stop Bit.
6.6 SLAvE ID
Set the Slave ID to match the DET-1600 Node Number. SEE SECTION 16.9. Use this Command Menu to begin communications with the DET-1600, Connect, or to end communications, Disconnect. Use the Reset COM Stats Command Menu to zero out any past communication errors to the DET-1600. ROI mimics the DET-1600 LCD and keypad on the PC screen. The ROI unit shows the LCD screens on the PC the same as the DET-1600 monitors LCD screens. The ROI virtual keypad keys can be used to navigate the menus the same as pressing the keypad keys on the DET-1600. This is especially useful during the live calibration on the engine. Both the terminal program and the ROI monitor can be seen together on the PCs screen. Click on the ROI Command Menu to bring up the ROI.
6.7 CONNECT/DISCONNECT
6.8 RESET COM STATS
6.9 ROI (REMOTE OPERATOR INTERFACE)
12 FORM DET-1600 IOM 11-09
7.0 CONFIGURATION PARAMETERS GENERAL SETUP
7.1 # OF CYLINDERS
Enter the number of engine cylinders from 1 to 16. The # of cylinders and cycles is used in conjunction with the ignition shutdown lead to calculate engine rpm and windows. Enter 2 for a two-, or 4 for a four-stroke engine.
7.2 CYCLES
7.3 AUTOSCAN
The time entered here in seconds will be used by the DET-1600 as the display time for each cylinder channel when automatically displaying the home screen channels. If zero is entered, the display will remain on the displayed channel until it is advanced using the keypad. The range is 0 to 30 seconds.
7.4 LAG FILTER
The lag filter is used to stabilize the display reading of the detonation and misfire numbers displayed on the LCD from a changing sensor input signal. The output reaction time is directly tied to the lag filter. Misfire and detonation have separate lag filters allowing for customization of each. The rate of change is less for large values. The filter value range is from 1 to 255, 1 being no filter value and 255 being maximum filter value. A typical filter value might be 240. When Display values by ten is enabled the detonation and misfire reference numbers on the lcd will display in tens (the far right digit will always be 0).
7.5 DISPLAY vALUES bY TEN
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7.6 MAP SENSORS
The MAP SENSOR table assigns a unique cylinder identification label to each channel. The DET-1600 must be wired to match the firing order of the engine. The DET-1600 reads each sensor in the Firing Event order from 1 to max number of cylinders. The fire event is the order of the ignition shutdown lead pulses.
The Fire Event is from 1 to x in numerical order, x being max.

number of engine cylinders.
The Cyl lbl is a unique programmable engine cylinder identi-
fier. The cylinder label is displayed on the LCD to describe each cylinder channel in the home screens. The cylinder label can be up to any two alphanumeric characters to describe the cylinder number. Examples are 1, 5, etc. or 1R, 6L etc. or A, B, etc. listen for detonation and misfire for the particular cylinder or fire event. The sensor number should be the same as the firing event number except in special applications.
The Sensor # is the sensor that will be used by the DET-1600 to
Examples of applications: Example 1 One sensor per cylinder on 6 cylinder inline engine Firing order: 1-5-3-6-2-4 Sensor configuration: Sensor #1 for cylinder #1 Sensor #5 for cylinder #5 Sensor #3 for cylinder #3 Sensor #6 for cylinder #6 Sensor #2 for cylinder #2 Sensor #4 for cylinder #4
Fire Event (also terminal # on back of DET-1600) Cyl lbl (identifier shown on LCD) Sensor #
1 1 1
2 5 2
3 3 3
4 6 4
5 2 5
6 4 6
Example 2 One sensor per cylinder on a 12 cylinder V engine. Firing order: 1R-6L-5R-2L-3R-4L-6R-1L-2R-5L-4R-3L Sensor configuration: Sensor #1 for cylinder 1R Sensor #12 for cylinder 6L Sensor #5 for cylinder 5R Sensor #9 for cylinder 3L
Fire Event (also terminal # on back of DET-1600) Cyl lbl (identifier shown on LCD) Sensor #
1 1R 1 2 6L 2 3 5R 3 4 2L 4 5 3R 5 6 4L 6 7 6R 7 8 1L 8 9 2R 9 10 5L 10 11 4R 11 12 3L 12
14 FORM DET-1600 IOM 11-09
7.7 SECURITY SEE SECTION 16.10 FOR ExPLANATION. 7.8 TIMING DATA INPUT
The Timing Data Input selection is used to specify the source of ignition timing information. In order to calculate and display the correct engine retard value on the LCD, the DET-1600 must know the timing value of where the engine runs at normal load, or the Normal Run Timing Value. If set to User Value, the DET-1600 uses the normal run timing value entered by the user in the Normal Run Timing Value entry box. If the DET-1600 is configured to receive its timing information from the ignition system via the RS485 Master Modbus port, From Ignition System should be selected. Select this option when configuring the DET-1600 to retard ignition timing using the ignition systems 4-20mA input.
7.9 USER ENTERED vALUE
7.9.1 NORMAL RUN TIMING VALUE The Normal Run Timing Value is the timing value in btdc (degrees before-top-dead-center) that the engine runs at with normal loads. The DET-1600 will use this number as the maximum advanced timing value and can only retard the engine timing from this value. IMPORTANT: In order for the DET-1600 to calculate and display the correct retard timing value the Normal Run Timing Value must match the engine timing. Ignition timing must be verified on the engine with a timing light.
7.10 FROM IGNITION SYSTEM
Select this option to configure the DET-1600 to receive and send ignition timing via modbus from the ignition system.
7.10.1 IGNITION TIMING MODBUS REGISTER The Ignition Timing Modbus Register is the Modbus register location number in the ignition system that will be used by the DET-1600 to read the ignition timing. IGNITION SYSTEM CD200 CPU-95 ENHANCED DISPLAY MODULE REGISTER# 30006 30130
7.10.2 IGNITION NODE ID Enter the ignition system node ID. Must match ignition systems node ID. Must be different from DET-1600 s node ID number. 7.10.3 IGNITION BAUD RATE Select the baud rate that matches the ignition system baud rate. 7.10.4 TIMING READ FROM IGNITION The actual timing read from the ignition system at the ignition register number entered in the Ignition Timing Modbus Register.
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8.0 CONFIGURATION PARAMETERS SETPOINTS/OUTPUTS
8.1 DETONATION SETPOINT vALUE
The Detonation Setpoint Value is a user-configurable high setpoint. It is used to trigger the DET-1600 to take action if the detonation level value measured from any sensor goes above the setpoint caused by a sustained detonation in the corresponding cylinder. Output switch #1, Ignition retard, and output switch #2 (when these are configured to do so) will take action when detonation is sensed. If detonation is detected, a D will be displayed on the home screen in the lower right corner of the affected cylinder channel. The value entered should be noticeably above the normal engine reference level. A typical value entered for a detonation number might be 800; assuming the DET-1600 detonation parameters are adjusted to display a nominal reference level of 500. The range is from 0 to 999. The value should be fine tuned when on a live engine. The Misfire Setpoint Value is a user-configurable low setpoint value. It is used to trigger the DET-1600 to take action if the misfire level value measured from any sensor goes below the setpoint caused by a sustained misfire in the corresponding cylinder. Output switch #1 (when enabled) will activate when misfire is sensed. If misfire is detected, an M will be displayed on the home screen in the lower right corner of the affected cylinder channel. The value entered should be noticeably below the normal engine reference level and above the Bad Sensor Setpoint Level. A typical value entered for a misfire number might be 200; assuming the DET-1600 detonation parameters are adjusted to display a nominal reference level of 500. The range is from 0 to 999. The value entered should be fine-tuned when on a live engine.
8.2 MISFIRE SETPOINT vALUE
16 FORM DET-1600 IOM 11-09
8.3 bAD SENSOR SETPOINT vALUE
The Bad Sensor Setpoint Value is a user-configurable low setpoint value. It is used to trigger the DET-1600 to take action if the knock sensor or its wiring for any monitored cylinder goes open or shorted. A bad sensor will cause the input to go low. When the reference number for any input goes below the bad sensor setpoint value set, the monitor will register a bad sensor. A bad sensor indicator can be triggered by either the misfire reference level or the detonation reference level measured; however misfire has priority. If a bad sensor is detected, an S will be displayed on the home screen in the lower right corner of the affected cylinder channel. The Bad Sensor Setpoint Value is a low setpoint. Output switch #1 can be configured to take action by selecting Trip On Fault Diagnostic. The value entered should be below the misfire setpoint value but above zero. Please note that the input does not go to zero with an open sensor during operation, the input is affected by the electrical noise impressed on the input. The range of the bad sensor setpoint level is 0 to 999, the default value for a bad sensor is 50. The value entered should be fine-tuned when on a live engine.
8.4 OUTPUT SWITCH #1
Output switch #1 is designed to be used as a load control output. The switch is activated when either a Misfire Setpoint Value or a Detonation Setpoint Value is violated for any of the monitored cylinders. Please note that switch #1 (as well as timing control) is locked out by the Control RPM Value and the Control Lockout Time timing control parameters during start-up. In simple systems (without load control and analog timing control) switch #1 can be used as a one-step timing adjust contact. Connect the switch contact to the ignition system one-step timing control input. 8.4.1 DISABLE If Disable is selected, output switch #1 will not activate. 8.4.2 NONLATCH OR LATCH Switch #1 can be configured for latching or nonlatching. When set to Latch the switch will stay tripped continuously until it is either reset manually (using the RESET key on the keypad), a reset is sent via Modbus or by cycling the power. When set to Nonlatch the switch will stay tripped if any channels reference number is below the misfire setpoint or above the detonation setpoint. It will automatically reset when the detonation or misfire values have returned to within the limits plus the hysteresis time set. 8.4.3 HYSTERESIS TIME A Hysteresis Time can be used when the output switch is configured as nonlatching to prevent it from oscillating or turning on and off around the setpoint. When, after having been outside the setpoint value limits, the detonation or misfire reference level returns to within the setpoint value limits, the hysteresis timer starts and the switch stays tripped for the configured hysteresis time. If during the hysteresis time the setpoint is violated again, the hysteresis timer starts over. The hysteresis timer value is for switch #1 and is common for both the detonation and misfire setpoints. The hysteresis value can be set from 0 to 999 seconds.
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8.4.4 SHELF OR FAILSAFE STATE Switch #1 is a closed switch when in the shelf state (with the absence of power). The switch can be configured for either failsafe or shelf state. When set to Shelf state, the output switch will be closed when no setpoint values are violated. When set to Failsafe, the output switch will be open when no setpoint values are violated. If set to Failsafe and the power is lost to the Monitor, the output switch will change states (it will close). 8.4.5 TRIP ON FAULT DIAGNOSTIC The DET-1600 monitors several diagnostic conditions and can alarm the user when these conditions occur. Along with the Fault Diagnostic menu on the DET-1600 which shows these conditions, output switch #1 can be selected to open or close (depending on if it is set for SHELF or FAILSAFE.) Bad Sensor, Misfire, and Detonation, along with the diagnostics listed in SECTION 10.0, when faulted or diagnosed, will display VIEW ALARMS alternating with the current condition on the LCD. Press the view alarms key to view and acknowledge the cause of the condition. The ENTER/ACK key when pressed will acknowledge the condition.
8.5 OUTPUT SWITCH #2
Output Switch #2 is designed to be used as an engine shutdown output. The switch is activated after switch #1 has tripped, the Max Retard Timing Value is reached, and the Time Before Tripping Switch #2 has elapsed. The switch can be connected to an Altronic Annunciator System, an ignition low voltage shutdown input, or to pilot-duty relays. 8.5.1 DISABLE If Disable is selected, output switch #2 will not activate. 8.5.2 SHELF or FAILSAFE STATE Switch #2 is an open switch when in the shelf state (with the absence of power). The switch can be configured for either Failsafe or Shelf state. When set to Shelf state, the output switch will be open for normal run conditions. When set to Failsafe, the output switch will be closed for normal run conditions. If set to Failsafe and the power is lost to the Monitor, the output switch will change states (it will open). 8.5.3 NONLATCH or LATCH Switch #2 can be configured for latching or nonlatching. When set to Latch the switch will stay tripped continuously until it is either reset manually (using the RESET key on the keypad), a reset is sent via Modbus or by cycling the power. When set to Nonlatch, the switch will stay tripped when the Monitor is at the Max Retard Timing Value Allowed but will automatically reset when the DET-1600 returns the engine timing to a no retard condition.
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8.6 TIMING CONTROL PARAMETERS
These parameters control when and how the DET-1600 controls engine timing to protect the engine from detonation. 8.6.1 CONTROL RPM VALUE When the engine is started and the rpm is below the Control RPM Value, the DET-1600 will not activate the outputs. It will act as a monitor only. This will allow the engine to start and become stable without the control outputs taking effect. Once the Control RPM Value has been reached and the Control Lockout Time has elapsed, the outputs will be enabled and can take action. The range is 200 to 3000 rpm. 8.6.2 CONTROL LOCKOUT TIME The Control Lockout Time starts when the DET-1600 has started and reached the Control RPM Value. The output switches, current loop, and Modbus control are disabled during this start-up time. This allows the engine to stabilize without any of the outputs (switches or control) interfering with engine start-up and loading. If at any time the engine rpm goes below the Control RPM Value the timer resets and starts again. During this time the LCD shows Not Armed. If a misfire, detonation or bad sensor occurs, the associated designator (M, D, or S) will be displayed on the home screen on the affected cylinder channel. Enter a time from 1 to 999 seconds. After the timer has expired the outputs will be enabled. 8.6.3 MAx RETARD TIMING VALUE ALLOWED The Max Retard Timing Value Allowed is the maximum amount of retard that the DET-1600 can impose on the engine via the ignition system in order to control detonation. For example, if the ignition systems normal run timing value is 24btdc, the Normal Run Timing Value would be set to 24btdc, and if the Max Retard Timing Value Allowed is set to 10 degrees, the maximum retard imposed by the DET-1600 would be a maximum of 24 10 = 14btdc. When the Max Retard Timing Value Allowed is reached and the Retard Step Time elapses, there is nothing more that the DET-1600 can do to control detonation, switch #2 will trip. Switch #2 should be wired to shut down the engine to prevent damage. 8.6.4 RETARD STEP VALUE The Retard Step Value is the amount of retard in degrees that the control output will change for each step when taking timing retard action to control detonation. The range is 0 to 10 degrees. For example, if the Max Retard Value is 12 degrees and the Retard Step Value is 2 degrees, the DET-1600 will retard the ignition timing 2, wait the Time Between Retard Steps, retard another 2 etc. 8.6.5 RETARD STEP TIME The Retard Step Time is the amount of time in seconds that the control output will wait between retard steps when taking retard action to control detonation. The range is 0 to 999 seconds.
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8.6.6 SWITCH #2 TRIP TIME AT MAx RETARD When the Max Retard Value Allowed is reached, the DET-1600 will wait the configured Retard Step Time. If this time has expired and detonation is still detected, it will wait the Switch #2 Trip Time before tripping output switch #2 and shutting down the engine (if switch #2 is set up to shut the engine down). The range is 0 to 999 seconds. 8.6.7 ADVANCE STEP VALUE The Advance Step Value is the amount of advance degrees that the control output will change for each step when returning to the normal run ignition timing value when no detonation is detected. The range is 0 to 10 degrees. 8.6.8 ADVANCE STEP TIME The Advance Step Time is the amount of time in seconds that the control output will wait between Advance steps when returning to the normal run ignition timing value when no detonation is detected. The range is 0 to 999 seconds. 8.6.9 DISABLE IGNITION TIMING CONTROL Use this selection to disable both the current loop control and the Modbus control outputs. This has no effect on the output switches. Please note that the logic is not disabled, only the outputs are disabled. Switch 2 will still trip if and when it is configured to do so. This feature is accessible from either the Terminal Program or the DET-1600 setup menu. 8.6.10 CURRENT LOOP CONTROL The Current Loop Control is an output from the DET-1600 designed to connect to the ignition system current loop input to retard the ignition timing when the Monitor detects either misfire or detonation. Enable the Current Loop Control by selecting the check box on the terminal program or from the menu in the DET-1600. Use the Loop LO and Loop HI configuration parameters to set the range in degrees retard, essentially the two endpoints. The output can be configured for forward or reverse acting. For forward acting, or increasing retard with increasing current, set the 4mA point for zero retard and the 20mA point to a max retard value in engine degrees. For reverse acting, or decreasing retard with decreasing current, set the 4mA point for max retard and the 20mA point to zero retard. As an example; to increase ignition retard with increasing current from 0 degrees retard to 24 degrees retard, enter the Loop LO point at 0 degrees and the Loop HI point at 24 degrees retard. When configuring the Current Loop Control, confirm and match the ignition system current loop input parameters so that each system works together as desired. The Current Loop Control works in conjunction with the Max Retard Value Allowed, Retard and Advance Step Values, and the Time Between Advance and Retard Step parameters.
NOTE: Typically, the use of either the Current Loop Control or the Modbus Control outputs from the DET-1600 will be used to control the ignition timing, not both.
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8.6.11 MODBUS CONTROL The Modbus Control is an output from the DET-1600 designed to connect to the ignition systems RS485 communications port to retard the ignition timing when the Monitor detects detonation. Enable the Modbus Control by selecting the check box on the terminal program or from the menu in the DET-1600. Select From Ignition System located on the General Setup tab and set the parameters associated with it for modbus control. SEE SECTION 7.9. The Modbus Control works in conjunction with the Max Retard Value Allowed, Retard and Advance Step Values, and the Time Between Advance and Retard Step parameters. 8.6.12 TIMING RETARD REGISTER (IGNITION) This is the register number in the ignition system that the DET-1600 will use to retard the timing when detonation is sensed. IGNITION SYSTEM CD200 CPU-95 ENHANCED DISPLAY MODULE REGISTER# 40007 40001
8.6.13 DEFAULT IGNITION TIMING (RETARD) The Default Ignition Timing is the timing value in btdc (degrees beforetop-dead-center) at which the engine runs under normal loads. It is a user-entered value. On the CPU-95 Enhanced Display Module the DET-1600 uses the Manual Retard value to retard ignition timing. When the DET-1600 is talking to the CPU-95 Enhanced Display Module the Manual Retard value can only be changed by the Default Ignition Timing value in the DET-1600. When installing the DET-1600, and if Modbus Control is used to retard the ignition timing, set the Manual Retard value for the CPU-95 Enhanced Display Module in the Default Ignition Timing entry box. On the CD-200 Ignition System the DET-1600 uses the Insertion Retard value to retard ignition timing. When the DET-1600 is talking to the CD-200 Ignition System, the Insertion Retard value can only be changed by the Default Ignition Timing value in the DET-1600. When installing the DET-1600, and if Modbus Control is used to retard the ignition timing, set the Insertion Retard value for the CD-200 Ignition System in the Default Ignition Timing entry box. IMPORTANT: In order for the DET-1600 to calculate and display the correct retard timing value the Default Ignition Timing value must match the engine timing. Ignition timing must be verified on the engine with a timing light.
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9.0 DETONATION/MISFIRE
9.1 DETONATION/MISFIRE LEvEL, LINEAR GAUGES
The linear gauges on the detonation and misfire tabs (on the terminal program) are used to show the detonation and misfire levels for each cylinder. Each gauge is arranged above the signal processing parameters for the corresponding cylinder so that the levels can easily be assessed when calibrating the DET-1600 on a live engine. The range is from 0 to 999 and the ON level is shown as filled. The reference number for each cylinder is shown at the top of each gauge. The cylinder label for each gauge is shown below the gauge. The average detonation and misfire level for all of the configured and enabled cylinders is calculated and displayed in the Detonation AVG. text box for detonation and the Misfire AVG. for misfire. The average detonation and misfire levels can be used when calibrating the DET-1600 to achieve a nominal reference level. The Global Retard is the amount of retard imposed on the ignition system by the DET-1600 when detonation is detected. The amount is determined from the user entered Retard Step Value. This is a read-only value. The value is also shown on the DET-1600s home screen. An example of the calculated value would be if the user entered 24btdc for the Normal Run Timing Value and the DET-1600 is imposing 5 of retard, a value of 5 retard would be displayed. The signal processing parameters are band-pass frequency, gain, and integrator time constant. The DET-1600 allows each cylinder to be individually tuned to allow for the variance of the signal it receives from the configured knock sensor. Gain, band-pass frequency, and inte-
9.2 AvERAGE DETONATION/MISFIRE LEvEL
9.3 GLObAL RETARD
9.4 SIGNAL PROCESSING PARAMETERS
22 FORM DET-1600 IOM 11-09
grator time constant can be configured separately for each cylinder for detonation and misfire. When configuring each cylinder input for misfire detection, these parameters are used to calibrate the cylinders sensor for a low signal, or the absence of a normal combustion process. When configuring each cylinder input for detonation detection, these parameters are used to calibrate the cylinders sensor for a high signal, or extra noise signal (detonation) at a determined center or band-pass frequency. Use the selection boxes in the terminal program to configure the signal processing parameters for each cylinder for both detonation and misfire. Generally each parameter should be configured in the order of band-pass, gain, and then integrator. It is imperative to equalize each cylinders reference number because of the common detonation, misfire and bad sensor setpoints. 9.4.1 BAND-PASS FREQUENCY The band-pass filter is used to pass the knock induced vibrations (frequencies) within a certain range and reject (attenuate) the unwanted normal occurring mechanical engine vibration frequencies that occur in normal engine operation (frequencies that are outside that range). The desired frequencies may be different depending on if we are detecting misfire or detonation, the engine type, engine speed, the characteristics of the particular engine, and the sensor type and location. A starting point for the band-pass frequency can be calculated by using the formula: frequency in Hz = (25,140/bore (inches)) x 3. For a 9.5" bore, the calculation equals 7939Hz. The closest frequency that can be chosen from the menu is 8.020kHz. The final band-pass frequency value should be fine-tuned during a live calibration on the engine. The center frequency of the band-pass range can be selected from 1.22kHz to 19.98kHz in 64 steps. Note that on smaller bore engines a multiplication factor of x2 may be a better starting point. 9.4.2 GAIN The gain adjustment is used to amplify the signal from the knock sensor. It is used to compensate for different levels of signals from the sensors due to different loads, rpms and distances from the source. The gain is used to equalize the output from each sensor to achieve a similar reference number for each cylinder. A starting gain value might be 1. The final gain value should be fine tuned during a live calibration on the engine. 64 different gain settings can be selected from .111 (a small gain value) to 2 (a large gain value). 9.4.3 INTEGRATOR TIME The integrator time value is the amount of input signal of the filtered sensor signal realized by the reference number. It is the resolution of the signal seen for a given time period. A shorter integrator time value will result in a larger output value. Longer integration times will result in a smaller output value. A starting integrator value might be 200. The final integrator value should be fine tuned during a live calibration on the engine. It should be chosen to equalize the reference numbers for each cylinder. The integrator time constant can be configured from 40us to 600us in 32 steps.
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9.5 NORMALIZED OFFSET
The Normalized Offset value is an addition or subtraction from the reference number. It allows for further equalization of each individual cylinders reference number to the others. It is typically set to zero unless the cylinders reference numbers cannot be equalized with the signal processing parameters. It can also be used to adjust a cylinders reference number when a bad sensor was replaced to equalize it to the others to avoid changing the signal processing parameters. The maximum offset value is 500. Enabled is used to enable/disable each cylinder individually from its ability to affect the output switches, ignition retard control and average detonation and misfire levels. When disabled, the LCD will show a dash (-) in the lower right corner of the LCD for that cylinder. REFER TO SECTIONS 8.1 AND 8.2. These values are displayed on the detonation and misfire screens in the terminal program for convenience during live engine calibration. These values can be changed from this screen. Copy Setup copies the signal processing parameters from cylinder #1 and pastes them to the other configured cylinders. The copy command is separate for detonation and misfire. For ease of setup, this allows the user to place only cylinder #1 in detonation and then calibrate the signal processing parameters for cylinder #1. Once the parameters have been calibrated for cylinder #1, they can be applied to the other cylinders. Each cylinder can be individually adjusted from the copied parameters if further adjustment is needed. Normalize can be used to automatically equalize the configured channels to the average of all of the cylinders. Given that there is one common setpoint for all of the cylinders, the reference numbers during normal run (when no detonation or misfire is occurring) should be similar. The Normalize feature automatically adds or subtracts an offset value to each cylinders reference number. The offset number is displayed for each cylinder in the Normalized Offset box. Click the Normalize button and a pop-up box with the calculated average of the configured and enabled cylinders will appear, either press Enter to accept or type in a preferred number and press Enter. The Window Parameters are Open Detonation/Misfire Window and Duration of Detonation/Misfire Window. These user configurable parameters allow the DET-1600 to detect detonation and misfire only during the expected time frame. The window parameters will be used at the configured time after top-dead-center for each cylinder. REFER TO SECTION 5.4 for further description on windowing.
9.6 ENAbLED
9.7 DETONATION/MISFIRE SETPOINT vALUE
9.8 COPY SETUP
9.9 NORMALIZE
9.10 WINDOW PARAMETERS
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NOTE: The window opening for each cylinder must not overlap into the next odd cylinder for the odd cylinder numbers, or even cylinder for the even cylinder numbers. The closing of a cylinders window must occur at least 1 degree before the opening of the next odd or even cylinders window opening. This is determined by the number of cylinders and the firing angle for each engine.
When an engine detonates it occurs after top-dead-center, typically between 5atdc and 30atdc, depending on the engine. The optimum window start and stop time depends on engine speed, engine timing, and load. The window Open and Duration parameters can independently be adjusted for misfire and detonation. Use the following formula to calculate the maximum allowable window opening: ((360* Cycle/2) /#cyls)*2 Ex: 16 cyl, 4 cycle ((360*2)/16)*2 = 90 degrees max window opening. The Normal Run Timing value + Open Window value + Duration of Window value must be less than the maximum allowable window size. 9.10.1 OPEN MISFIRE WINDOW The Open Misfire Window parameter is the position in crankshaft degrees after-top-dead-center (atdc) that the DET-1600 will start to detect misfire for each cylinder. The range is 0atdc to max window opening -1. 9.10.2 DURATION OF MISFIRE WINDOW The Duration of Misfire Window is the window open time, or duration, in absolute crank angle degrees that the DET-1600 will detect misfire for each cylinder. The range is 1 to max window opening. 9.10.3 OPEN DETONATION WINDOW The Open Detonation Window parameter is the position in crankshaft degrees after-top-dead-center (atdc) that the DET-1600 will start to detect detonation for each cylinder. The range is 1atdc to max window opening -2. 9.10.4 DURATION OF DETONATION WINDOW The Duration of Detonation Window is the window open time, or duration, in absolute crank angle degrees that the DET-1600 will detect detonation for each cylinder. The range is 1 to max window opening.
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10.0 DIAGNOSTICS
10.1 The diagnostics tab can be used to get an overall view of the status
for both the current condition of the system as well as the faulted condition. The Cylinder/Sensor Status, Status Diagnostics, and Fault Diagnostics are the current condition of the Monitor, while the Shutdown Cylinder/Sensor Status is the history of the sensor status of the Monitor.
10.2 CYLINDER/SENSOR STATUS The Cylinder/Sensor Status is used

to show collectively the current live status of each input. The status will change with each condition change. Each configured input will show OK, D, M, S, or . OK The reference number is between the misfire and detonation levels and is working properly D The reference number is above the detonation setpoint value M The reference number is below the misfire setpoint value S The reference number is below the bad sensor setpoint value The input is disabled The Status Diagnostics are an indication of each parameters current condition.
10.3 STATUS DIAGNOSTICS
10.3.1 ENGINE ROTATION The indicator will be on when the DET-1600 is above the indication rpm. Minimum rpm is 200 rpm. 10.3.2 CONTROL RPM REACHED The indicator will be on when the engine rpm is above the configured control rpm. 10.3.3 TIMING CONTROL ENGAGED The indicator will be on when the ignition timing control is engaged.
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10.3.4 SWITCH #1 ACTIVATED The indicator will be on when Switch #1 is activated. 10.3.5 SWITCH #2 ACTIVATED The indicator will be on when Switch #2 is activated. 10.3.6 SUPPLY VOLTAGE The supply voltage seen by the DET-1600 will be displayed in the text box. 10.3.7 ENGINE RPM The engine rpm calculated by the DET-1600 will be displayed in the text box.
10.4 SHUTDOWN CYLINDER/SENSOR STATUS
The Shutdown Cylinder/Sensor Status is used to show collectively the status of each input at shutdown. A snapshot of the condition of the cylinder sensors is taken when switch #2 (the shutdown switch) trips. Each configured input will show OK, D, M, S, or and will remain until reset is performed either by the keypad or Modbus communications. These conditions will remain with the interruption of power. OK The reference number is between the misfire and detonation levels and is working properly D The reference number is above the detonation setpoint value M The reference number is below the misfire setpoint value S The reference number is below the bad sensor setpoint value The input is disabled The Fault Diagnostics are an indication of each parameters condition. These can be used if the DET-1600 is not operating properly.
10.5 FAULT DIAGNOSTICS
10.5.1 SHUTDOWN LEAD SIGNAL The indicator will be on when the DET-1600 senses voltage on the shutdown lead. Minimum voltage is 75 volts peak. 10.5.2 #1 CYLINDER SIGNAL The indicator will be on when the DET-1600 senses voltage from the #1 coil primary. Minimum voltage is 75 volts peak. 10.5.3 CURRENT LOOP FAULT The indicator will be on if the current loop is activated and the loop wiring becomes disconnected, open or shorted. 10.5.4 COMMUNICATION TO IGNITION The indicator will be on when the DET-1600 is configured to talk to an ignition system and communications is established on the RS485 Modbus Master port. 10.5.5 WATCHDOG The DET-1600 Detonation Sensing Monitor contains an internal watchdog monitor. If the Monitor gets interrupted by either an undervoltage condition or unusual EMI spike, etc., the internal watchdog will automatically set the Monitor back on track without interruption. No action is required by the user.
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ADJUSTMENT OF THE ENGINE OPERATING PARAMETERS, INCLUDING ENGINE LOAD, SHOULD BE UNDERTAKEN ONLY BY QUALIFIED PERSONNEL WHO ARE FAMILIAR WITH THE ENGINE BEING SET-UP. HEAVY OR UNACCEPTABLE LEVELS OF DETONATION, AS DETERMINED BY SAID PERSONNEL, MUST BE AVOIDED AT ALL TIMES AND SHOULD SERVE AS A SIGNAL TO STOP THE ENGINE IMMEDIATELY TO PREVENT POSSIBLE ENGINE DAMAGE AND PERSONAL INJURY. AT NO TIME SHOULD THE ENGINE BE OVERLOADED.
WARNING:
11.0 LIvE CALIbRATION AT ENGINE SITE
Detonation or Knock is a condition that limits how efficiently an engine can operate. Severe knock is harmful to the engine and must be avoided. Controlling knock intensity is further complicated by engine cycle to cycle variations. Because of the variations of the detonation signal for each engine rotation the DET-1600 must be set up for an average value from a large number of samples. The terminal program is used to calibrate or fine tune the DET-1600 on a live engine. Many of the parameters can be inserted using the terminal program on a bench but the monitor must be calibrated with the engine loaded.
11.1 EQUIPMENT NEEDED
Laptop computer with DET-1600 Terminal Program up and running. RS485 Adapter wired from the PC to the DET-1600 (SEE FIG. 12). An oscilloscope would be helpful but is not required.
11.2 GETTING STARTED
At this point, the DET-1600 system should be mounted and wired. Apply power to the system. The configuration parameters should have been entered either from a file that was saved from a previously configured similar application or from the default parameters suggested in this manual. Select Connect from the Command bar. Select from either the current configuration in the DET-1600 or the configuration in the terminal program. Assure that the pre-configured parameters are accurate. Start and load the engine. Adjust the Window Parameters for both misfire and detonation. REFER TO SECTION 9.10. Ideal peak pressure in the cylinder occurs around 16atdc, so the window should be open before, and last longer than, 16atdc. A suggested starting point is 5 to 10atdc with a duration of 20 degrees. Windows can also be calibrated with an oscilloscope. Connect channel 1 of the scope to trigger from the #1 coil firing, and channel 2 of the scope to the knock sensor for cyl #1. Both of these signals are available on the back of the DET-1600. For misfire setup, adjust the scope to display the normal cylinder firing signal coming from the sensor being observed on channel 2 of the scope. Use the signal observed and the scope settings to calculate the timing degrees. Adjust the window accordingly.
11.3 WINDOW SAMPLING PARAMETERS
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NOTE: A spreadsheet to aid in calculating crank angle timing is included on the CD enclosed with the DET-1600.
For detonation setup, create an incipient detonation condition. Adjust the scope to display the detonation peak signal coming from the sensor being observed on channel 2 of the scope. Use the signal and the scope settings to calculate the timing degrees. Detonation will typically occur between 5atdc and 30atdc. Adjust the window accordingly.
ASSURE THAT THE WINDOWS CAPTURE THE SENSOR SIGNAL FOR ALL CONDITIONS. IF THE DETONATION OR MISFIRE SIGNAL IS NOT CAPTURED IN THE WINDOW OR IT GOES OUTSIDE OF THE WINDOW, ERRATIC OPERATION OF THE DET-1600 SYSTEM WILL OCCUR.
CAUTION:
11.4 SIGNAL PROCESSING PARAMETERS

NOTE: The engine shutdown switch should be located and enabled prior to device setup.
Once the window parameters have been set, adjust the signal processing parameters (band-pass frequency, gain, and integrator time). Each of these parameters can be adjusted individually for each cylinder for both misfire and detonation. The best way to calibrate the DET-1600 detonation signal processing parameters is if an actual signal for incipient detonation can be safely produced. If it is not possible to run the engine with incipient detonation, then typical values for a given engine model may have to be used as a calibration starting point. Adjust the band-pass first, then gain, then the integrator.
OVERLOAD CONDITION CAN OCCUR QUICKLY WHEN AN CAUTION: AN ENGINE IS NOT FIRING ON ALL CYLINDERS. REDUCE ENGINE LOAD WHEN CREATING A MISFIRE CONDITION.
MISFIRE Create a misfire condition on one of the cylinders. DO NOT open or short any cylinders primary to cause a misfire. If cylinder #1s coil primary is shorted, a Fault diagnostic will occur, and the DET-1600 will go to NO RPM. With the engine area confirmed to be non-hazardous by the use of a combustible gas detector, the misfire can be created by opening or grounding the coil secondary lead (spark plug lead) for that cylinder. If a misfire condition cannot be created safely, then a starting value for misfire of 250 based upon a normal signal level adjusted to 500 is a good starting point. Adjust the signal processing parameters for the cylinder that is misfiring. Set cylinder #1s parameters to the calibrated values. Use the Copy Setup button in the terminal program to copy these settings to the other cylinder channels. SEE SECTION 9.8 for information regarding this feature.
HEAVY DETONATION IS HEARD AT ANY POINT DURING WARNING: IF THESE SETUP OPERATIONS, STOP ENGINE IMMEDIATELY.
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11.4 SIGNAL PROCESSING PARAMETERS (continued)
DETONATION SEE SECTION 5.1 Create an incipient detonation condition on one of the cylinders (in this example cylinder #1 is used). If using a CPU-95 Ignition System, advance the global timing to a point of incipient knock and then use the individual cylinder timing adjustment feature on the CPU-95 to force cylinder #1 into very light, incipient detonation (SEE DEFINITION AT RIGHT). Adjust the signal processing parameters for cylinder #1. Use the Copy Setup button in the terminal program to copy these settings to the other cylinder channels. SEE SECTION 9.8 for information regarding this feature. This should yield a good starting point for the signal processing parameters, particularly if each cylinder has its own sensor. Some further individual cylinder calibration may be required in order to attain the required similar reference number for all of the cylinders (the integrator may need to be tweaked). Please note that other schemes may need to be employed for one sensor for several cylinders. 11.4.1 BAND-PASS SEE SECTION 9.4.1 11.4.2 GAIN SEE SECTION 9.4.2 11.4.3 INTEGRATOR SEE SECTION 9.4.3
NOTE: Incipient Detonation is a very light, barely audible knocking sound similar to the pinging sometimes heard in an automobile engine as the car starts up a steep hill.
12.0 OPERATION 12.1 A 16-character x 2 line back-lit LCD display is used for a visual output of
the system. A sealed membrane keypad is used to navigate the LCD screens. The DET-1600 menu system allows the relevant operational parameters to be viewed and adjusted via the keypad when in use on the engine. A flowchart (FIG. 2) is included in this manual for reference. Configuration and calibration must be performed using the terminal program provided.
13.0 KEYPAD DESCRIPTION 13.1 The DET-1600 Detonation Sensing Monitor contains an eight-key front keypad which is used to view the reference data for each cylinder, view and change the setpoint values, view the diagnostic data, and to access the menu. The eight front panel keys are VIEW ALARMS, RESET, SETUP, ENTER/ACK, SETPTS, ESC, , and (up and down arrow keys).
13.2 vIEW ALARMS
The VIEW ALARMS key allows the user to view the alarms occurring when switch #2 trips and of any current fault diagnostic messages. The fault diagnostic messages will automatically clear when the fault diagnostic clears. Pressing VIEW ALARMS displays the alarms that occurred when switch #2 tripped. Each occurrence is displayed in the firing order. Additional key presses will show further occurrences. Each occurrence will appear once in the list. After displaying all of the captured occurrences, the display will ask CLEAR STATUS
30 FORM DET-1600 IOM 11-09
LOG?. Select YES and ENTER to clear the logs, NO to retain them. If no occurrences are logged, the display will show CYL STATUS LOG/NONE. Press ESC to return to the home screen.
13.3 RESET
The RESET key resets the loop to no retard, clears the output switch(es) and resets the control lockout timer. SEE SECTION 14.3 for more information on reset.
CAUTION:
13.4 SETUP
PRESSING RESET WILL CAUSE THE TIMING TO ABRUPTLY RETURN TO THE FULL ADVANCED VALUE AND WILL CLEAR THE OUTPUT SWITCHES TO THEIR NOT TRIPPED POSITION.
The SETUP key is used to scroll through the setup menu. The ENTER/ACK key is used to save new data or a new configuration in nonvolatile memory. The setup will remain even through powerdown. The ENTER/ACK key is also used to acknowledge alarms. The SETPTS (setpoints) key is used to view or change the setpoint values. REFER TO SECTION 15.0 for more information. NOTE: The setpoints cannot be changed if the protection is set to On. The ESC (escape) key can be used at any time during the setup, setpoint or view alarm modes to return to the home screen. When the ESC key is pressed in any configuration mode, any changed values are ignored (not stored in memory), the configuration returns to the previous values, and the display returns to the home screen. The ESC key is also used to toggle between the numerical and graphical home screens. The up and down arrow keys are used to increment or decrement the displayed cylinder channel number and corresponding reference number. Each press of the up arrow key increments the channel one at a time while the down arrow key decrements it. These keys also scroll through the selections in the setup menu and are used to increase or decrease values for setpoints and setup values.
13.5 ENTER/ACK
13.6 SETPTS
13.7 ESC
13.8
14.0 HOME SCREEN DESCRIPTION
When the DET-1600 Detonation Monitor is in the home screen, it displays the global system status on the first line along with switch 1 and 2 status. On the second line, the cylinder number (xx) and its corresponding reference numbers for detonation and misfire along with D, M, S, or for Detonation, Misfire, Bad Sensor, or Cylinder Channel Disabled Status are displayed.
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14.0 HOME SCREEN DESCRIPTION (continued)
Home Screen
Global System Status
Cylinder Number
REF. NUMBER VS. DET. SETPOINT
REF. NUMBER VS. MISFIRE SETPOINT Individual Cyl Status
DETONATION SENSED
The cylinder number descriptions are one or two digits and can be configured from the terminal program for up to two ASCII characters. They will be shown in the fire event order as configured in the terminal program. Typical configurations are 01, 05, etc. or 1R, 6L, etc. The detonation (D:) and misfire (M:) numbers represent the detonation/vibration amplitude level from each cylinder. The numbers are unitless reference numbers with a range from 0 to 999. Each configured cylinder has its own set of reference numbers. A larger number indicates a larger signal; a smaller number indicates a smaller signal. D, M, S, or for Detonation, Misfire, Bad Sensor, or Disabled (D, M, S, or ) will display in the lower right corner on the LCD of the affected cylinder number if the following conditions exist:
D = M= S = =
Detonation a cylinder is detonating Misfire a cylinder is misfiring Bad Sensor a cylinder has either a bad sensor, open or shorted wiring Disabled a cylinder channel has been disabled
D, M, S, or are mutually exclusive and have the following priority: 1. Disabled 2. Bad Sensor 3. Detonation 4. Misfire Use or to scroll through the cylinder channels.
NOTE: If a sensor or its wiring becomes open, shorted, or disconnected from the DET-1600, the display will show S (bad sensor) on the corresponding LCD cylinder screen. If configured to trip on fault diagnostic, output switch #1 will activate.
32 FORM DET-1600 IOM 11-09
14.1 SYSTEM STATUS
The first line of the display shows the global status of the DET-1600 system. The system status descriptions are:
No RPM 01 D: 0 M: 0
No RPM is displayed on power-up of the DET-1600. No RPM indicates that power is applied to the DET-1600 and the engine is not rotating (the DET-1600 is not receiving the shutdown and #1 coil signals from the ignition system). The D and M numbers will be zero. The monitor is ready for engine start-up. NOTE: The minimum run rpm is 200.
Not Armed 01 D:500 M:495

Not Armed is displayed upon engine startup indicating that the DET-1600 is operating in monitor mode and will not activate the outputs. This allows the engine to start and stabilize without either of the output switches or control interfering with engine start-up and loading. The individual cylinder status indicators will display in this mode. The Monitor will remain in this mode until the engine rpm is above the Control RPM Value and the Control Lockout Time has expired.
Normal Run 01 D:500 M:495

Normal Run indicates the DET-1600 is in normal operation mode. The Control Lockout Time has expired and engine rpm is above the Control RPM. The reference numbers from the sensors are being compared to the configured setpoints and the output switches and timing control will take effect upon a detonation or misfire condition.
Det Sensed sw1 05 D:725 M:650 D

Det Sensed is displayed if detonation is sensed on any input. A D will be shown in the lower right corner on each cylinder channel that is detonating. sw1 will appear on the first line indicating that switch #1 (the load control switch) is activated.
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33

14.1 SYSTEM STATUS (continued)
Mis Sensed sw1 03 D:325 M:235 M

Mis Sensed is displayed if misfire is occurring on any input. An M will be shown in the lower right corner on each cylinder channel that is misfiring. sw1 will appear on the first line indicating that switch #1 (the load control switch) is activated.
Ign Ret 10 sw1 05 D:815 M:650 D

Ign Ret xx is displayed if detonation continues to occur. The DET-1600 will send out a signal to retard the ignition timing (either by current loop or Modbus). xx represents the current amount of retard inflicted on the ignition system. Any one of the cylinder channels that are violating the detonation setpoint value will cause the DET-1600 to retard timing and display Ign Ret. The cylinder channel that is detonating will show a D in the lower right corner of the LCD.
Ign Ret 18 sw1 2 05 D:825 M:675 D

sw1 = Switch #1 is activated sw1 will trip and display when switch #1 is activated by either detonation or misfire. sw2 = Switch #2 is activated sw2 will trip and display if detonation is sensed, and continues, causing the ignition retard value to reach the Max Retard Timing Value Allowed and Switch #2 Trip Time at Max Retard to time out.
Bad Sensor 03 D:50 M:55 S
ENTER ACK
Bad Sensor is displayed if a sensor is determined to be open or shorted on a configured input. An S will be shown in the lower right corner on the respective cylinder channel. If Output switch #1 is configured to trip on fault diagnostic sw1 will appear on the first line indicating that switch #1 is activated. Press the ENTER/ACK key to acknowledge the condition and clear the global Bad Sensor status.
34 FORM DET-1600 IOM 11-09
View Alrms sw1 2 01 D: 0 M: 0 ENTER ACK
View Alrms = View Alarms When switch #2 trips, which is typically used to shut down the engine, the View Alarms message will blink alternately with the system status message. Press the ENTER/ACK key to acknowledge the condition. Press the VIEW ALARMS key to view the Alarms message to see what caused the shutdown. SEE SECTION 17.0 for further information on the View Alarms feature.
14.2 bARGRAPH
Det Sensed sw1 01 D:725 M:650 D Det Sensed sw1 D
ESC
A bargraph screen showing each configured cylinder channels reference level in graphic form and whether a detonation D, misfire M, bad sensor S, or if the channel has been disabled , is shown on the bottom row of the display. The top row remains the same. The bargraph screen is also considered a home screen. It can be used as a quick overview of each cylinder channels current condition. The graph is shown in the engines firing order. Each vertical bar is a cylinder channel. Only the configured channels are shown. To view the bargraph, press the ESC key from the numeric home screen. Press the ESC key again to return to the numeric home screen. There is no time-out for the bargraph screen; it will remain until ESC is pressed. The bargraph screen shown above is configured for 6 cylinders.
14.3 RESET
RESET
PERFORM RESET? NO
Reset can be initiated in one of two ways: by pressing the RESET key or, by sending a reset command via the RS-485 communications. Pressing RESET from the home screen resets the Control Lockout Timer, places the current loop and Modbus outputs to a no retard condition, and places the output switches in the non-tripped condition. When the reset key is pressed, the display will show PERFORM RESET?. The default is NO. Use the up or down arrow key to select YES and press ENTER.
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15.0 SETPOINTS 15.1 The setpoint menu allows adjustment of MISFIRE, DETONATION, MAx
RETARD VALUE, SWITCH 2 TRIP TIME AT MAx RETARD, and BAD SENSOR setpoints. From the home screen, press the SETPTS key to access the setpoint menu. Press the or (up/down arrow keys) to adjust the setpoint value. Press ENTER to save the value. The LCD will show SAVED and return to the current screen. Press ESC to return to the home screen.
15.2 MISFIRE SETPTS
MISFIRE 200
NOTE: When in the setpoints mode, the previous setpoint values are monitored, and the new value is monitored only after the ENTER key is pressed. If no key is pressed for 30 seconds, the display will return to the home screen and the previous value.
The misfire setpoint is a low setpoint. If the misfire reference number goes below the misfire setpoint, switch #1 will activate. The misfire setpoint can be set anywhere within the range of the scanner.
15.3 DETONATION SETPTS
DETONATION 800
The detonation setpoint is a high setpoint. If the detonation reference number goes above the detonation setpoint, switch #1 will activate and the timing will be adjusted. The detonation setpoint can be set anywhere within the range of the scanner.
15.4 MAX RETARD vALUE SETPTS
MAX RETARD VALUE 10
The Maximum Retard Timing Value Allowed is the maximum amount of retard that the DET-1600 can inflict on the engine via the ignition system in order to control detonation. For example, if the ignition systems normal run timing value is 24btdc and the Max Retard Timing Value Allowed is set at 10 degrees, the DET-1600 can retard the engine to a maximum of 14btdc. The max range is 0 to 90 degrees. The Maximum Retard Timing Value Allowed is also used as an indication to trip switch #2. When this point is reached, there is nothing more that the DET-1600 can do to eliminate detonation. Switch #2 should be wired to shut down the engine to prevent damage. When the maximum retard timing value is reached, the SWITCH 2 TRIP TIME AT MAx RETARD timer begins. When the timer lapses, switch #2 will activate.
36 FORM DET-1600 IOM 11-09
15.5 SW2 TRIP TIME @ MAX RETARD SETPTS
SW2 TRIP TIME @ MAX RETARD 60s
The DET-1600 upon reaching the max retard value will wait the Retard Step Time plus the configured Switch #2 Trip Time at Max Retard before shutting down the engine (if switch #2 is set up to shut the engine down). The range is 0 to 999 seconds.
15.6 bAD SENSOR SETPTS
BAD SENSOR 80
The bad sensor setpoint is a low setpoint. If either the misfire reference number or the detonation reference number goes below the bad sensor setpoint, switch #1 will activate (Switch #1 must be configured in the terminal program; Trip On Fault Diagnostic check box must be checked). The bad sensor setpoint can be set anywhere within the range of the scanner.
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37

16.0 SCREEN MENUS 16.1 GENERAL INFORMATION Configuration of the DET-1600 must
be performed using the terminal program. The screen menus on the DET-1600 are used during operation of the system to view or modify the significant operating parameters.
SETUP
AUTOSCAN 3s
Press the SETUP key to enter the menu from the home screen (FIGURE 2) for a flowchart that shows step-by-step progression through the monitors menu). Press the SETUP key to progress through the menu. Where arrows are shown, use the or arrow keys on the keypad to increase or decrease values or to scroll through the selections. After making a change, press the ENTER key to save the configuration to memory; the display will read SAVED. It is at this time that the new data is saved. The ESC (escape) key can be used at any time to abort the menu and return to the home screen. During configuration, the gauge allows 30 seconds between keystrokes to change or save a new configuration. If the time lapses without a keystroke, the monitor will automatically return to the home screen without making any changes.
16.2 AUTOSCAN
AUTOSCAN0-30s configures the display to scroll automatically between the configured cylinder channels. Autoscan can be set from 1 to 30 seconds or OFF (O). With AUTOSCAN turned on, when in the numeric home screen, the gauge will display each channel for the selected time period before automatically switching to the next channel. The arrow key can be used to quickly advance to the next channel. With AUTOSCAN turned OFF, the scanner continually displays one channel at a time. Press the arrow key to display the next channel. Press the arrow key to display the previous channel. The display filter can be used to slow down the amount of change to the misfire and detonation reference numbers that can occur from the constantly changing sensor input signal. Changing the filter value has a direct affect on output switch #1s reaction time. The rate of change is less for larger values. The filter value is read-out in a number from 1 to 255, 1 being no filter value and 255 being maximum filter value. Misfire and detonation have their own separate filter settings. To set the filter value, use the or arrow key to select either DET or MIS. Use the or arrow keys to increase or decrease the filter value and press ENTER to save.
NOTE: Autoscan is disabled while in the bargraph home screen.
16.3 FILTER
38 FORM DET-1600 IOM 11-09
16.4 TIMING CONTROL
Use this menu to turn either the current loop control and/or the Modbus control ON or OFF, depending on which one is being used. Timing control on or off has no effect on the output switches. When the engine rpm is below the Control RPM Value, the DET-1600 will act as a monitor only and will not activate the outputs. The range is 200 to 3000 rpm.
16.5 CONTROL RPM vALUE
16.6 CONTROL LOCKOUT TIME
The Control Lockout Time is used to lock out (disable) the output switches, current loop, and Modbus control on start-up. Previous to timing out, the DET-1600 will act as a monitor only and will not activate the outputs. This allows the engine to start and stabilize without the output switches or control interfering with engine start-up and loading. The timer starts when the DET-1600 reaches the Control RPM Value. If the engine rpm goes below the Control RPM Value the timer resets. Enter a time from 0 to 999 seconds. The DET-1600 has two methods of controlling timing, current loop control and Modbus control. Select either LOOP or MODBUS and ON or OFF. The two output switches can be configured to ACTIVE, YES or NO, FAILSAFE or SHELF STATE, and LATCHING or NONLATCHING. For descriptions of these SEE SECTIONS 8.5 AND 8.6. The DET-1600 Detonation Monitor is part of a system that has been carefully designed to easily interface to popular computers, ignition systems, PLCs, and instruments. The serial communications are compliant to the Modicon Modbus RTU standard and uses RS-485 for its hardware communication format. Two communication ports are available in the DET-1600, a master and a slave. Use the master port when the DET-1600 is used to initiate the transactions, the slave when the DET-1600 is used to respond to the requested data from a master. The Modbus master will be wired to the ignition system when the DET-1600 is used to retard ignition timing. The Modbus slave will be wired to the PC or laptop when configuring and monitoring the DET-1600. To view or adjust the communication parameters, select COMMUNICATIONS from the menu and press ENTER. Select the node number from 01 to 99. Select the baud rate. The following baud rates are available: 9600, 19200, 38400, 57600, and 115200.
16.7 CONTROL METHOD
16.8 OUTPUT SWITCHES
16.9 COMMUNICATIONS
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16.10 SECURITY
The security feature allows for protection from data inadvertently being changed. There are several areas in the menu system that can be protected as well as two layers of protection. The menus that can be protected are the GENERAL SETTINGS, the SETPOINT VALUES, and the ability to make COMMUNICATIONS setting changes. When protection is ON, the user is able to view the values in the menu but not able to change them. If an attempt is made to change the values the display will read PASSWORD PROTECTED!. The user must enter the proper password in the security menu to be able to make changes. If the correct password is entered, and protection is set to OFF, the requested values can be changed. To enter, set, or change a password, select SECURITY from the menu and press ENTER. Each of the areas (GENERAL, SETPOINT, and COMMUNICATIONS) can individually be turned on or off by using the or arrow keys. When an area is protected, the display will read ON, not protected will show as OFF. To enter a password, when in the security menu, press SETUP, ENTER PASSWORD will be displayed. Use the or arrow keys to increase or decrease each of the 3-digit password numbers and press ENTER. Any number from 000 to 999 can be used.
NOTE: Autoscan, filter values, and reset cannot be locked out by security protection.
16.10.1 GENERAL When set to ON, prevents the user from changing TIMING CONTROL, CONTROL LOCKOUT TIME, CONTROL RPM, CONTROL METHOD, and OUTPUT SWITCHES. 16.10.2 SETPOINT VALUES When set to ON, prevents the user from changing the setpoint values. All setpoint values can be read but not changed. 16.10.3 COMMUNICATIONS When set to ON prevents the user from changing the Modbus register data via the Modbus serial communications. The user can read data but not write data when communications protection is on. If the user attempts to perform a Modbus write, the error message INVALID FUNCTION CODE will be sent. 16.10.4 PASSWORD A numerical password is the second level of protection. When Set Security Password is selected, the user will be prompted to enter a 3-digit password. To enter a password, use the or arrow key to increase or decrease the underlined digit from 0 to 9 and press ENTER. The next digit will be underlined, use the same procedure to continue to enter a 3-digit password and press ENTER to save. Any number from 000 to 999 can be used. When the password is set to 000, no password will be required to make changes to the security screen. With a password set, if an attempt is made to turn off any of the security bits in the security menu, the message PASSWORD PROTECTED! will appear. To allow changes, from the security menu press SETUP to access the password screen. If the proper password is entered, the user can turn off the security bits. Changes will now be allowed. If the incorrect password is entered, the display will show PASSWORD INVALID and continue to deny access to the protected menus.
40 FORM DET-1600 IOM 11-09
17.0 vIEW ALARMS MENUS
The VIEW ALARMS menu allows the user to view the cause of shutdown and of any current fault diagnostic messages.
VIEW ALARMS
~STATUS LOG FAULT DIAGS
Pressing VIEW ALARMS brings up a STATUS LOG and FAULT DIAGS screen.
17.1 STATUS LOG

VIEW ALARMS
CYL STATUS LOG CYL 05 D
Selecting STATUS LOG displays the alarms that were occurring when switch #2 (the shutdown switch) tripped. The screen shows the cylinder number that caused the shutdown and D, M, or S for detonation, misfire, and bad sensor. Pressing the down arrow key will show the occurrences in the firing order. Each occurrence will appear once. After displaying all of the registered occurrences, the display will show CLR LOG?. Choose YES to clear the log or NO to retain the log. The display will revert back to the home screen. The logs are held in RAM only (volatile memory). If power is lost all past logs will be cleared. If no occurrences are logged, the display will show CYL STATUS LOG/NONE, press ESC to return to the home screen. Each time switch #2 trips a new set of status logs will be saved; the previous log messages will be overwritten with the new set.
17.2 FAULT DIAGNOSTICS
Fault Diagnostics are used as a troubleshooting aid. The following messages can be viewed if the DET-1600 does not sense the required signal. 17.2.1 NO SD SIGNAL Displayed when the DET-1600 senses a lack of the shutdown lead voltage. Minimum voltage is 75 volts peak. 17.2.2 NO CYL #1 Displayed when the DET-1600 senses a lack of the #1 coil primary voltage. Minimum voltage is 75 volts peak.
17.2.3 LOOP FAULT Displayed if the current loop is activated and the loop wiring becomes disconnected, open or shorted. 17.2.4 COM TO IGN Displayed if the DET-1600 is configured to talk to an ignition system and communications is broken between the RS485 Modbus Master port and the ignition system. 17.2.5 INTRNL FAILURE Displayed if an internal failure occurs. Cycle the power to clear. The fault diagnostic messages will automatically clear when the fault clears.
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17.3 RESET STATUS LOG
To clear the alarm log, press the VIEW ALARMS key and select the CYLINDER STATUS LOG. Press the down arrow key until the display shows CLR LOG?, select YES and press ENTER. The logs will be cleared. The RESET key does not clear the alarms. It does however reset the loop and clears the output switch(es) when set to latching mode.
18.0 RS-485 COMMUNICATIONS, MODbUS RTU 18.1 The DET-1600 is compliant to the Modicon Modbus RTU standard. Maximum number of registers that can be read at one time is limited to 32. Maximum number of booleans that can be read at one time is limited to 256. The default configuration is 19200 baud, 8 Data bits, No Parity, 1 Stop bit ( 19200 8N1 ). The MODBUS address list is on the following pages.
42 FORM DET-1600 IOM 11-09
Location
Label
Default Notes
Read/Write bits
00000s No Off Off Off Off shelf non-latch Off Off shelf non-latch User value Disabled Disabled Disabled Enabled 0 Enabled 0 Displays reference numbers by tens Enabled 0 External 0 latch 0 switch 2 setup failsafe 0 switch 2 setup On 0 switch 2 On 0 latch 0 switch 1 setup Allow switch 1 to activate if a fault diagnostic is flagged failsafe 0 switch 1 setup On 0 On 0 On 0 Protect setpoint configuration from being changed Protect Communication configuration from being changed On 0 Protect general configuration from being changed Yes 0 Enable/Disable Detonation Control, Revert to default timing
Global Functions
00001
Reserved
00002
Ignition Timing Control Enabled
00003
Protect Configuration
00004
Protect Setpoints
00005
Protect Comms
00006
Switch 1 Enabled (1=on)
00007
Reserved
00008
Switch 1 state (0=shelf 1=FS)
00009
Switch 1 type (1=Latched)
00010
Switch 1 Trip on Diagnostics
00011
Switch 2 Enabled (1=on)
00012
Reserved
00013
Switch 2 state (0=shelf 1=FS)
00014
Switch 2 type (1=Latched)
00015
Reserved
00016
External Ign timing Enabled
00017
Current Loop Ignition Control Enabled
00018
Modbus Ignition Control Enabled
00019
Display by tens mode
00020
Reserved
00021
Reserved
00023
Reserved
00024
Reserved
00025
Reserved
00026
Reserved
00027
Reserved
00028
Reserved
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00029
Reserved
00030
Reserved
00031
Reserved
43
00032
Reserved
Location Input is Enabled Input is Enabled Input is Enabled Input is Enabled Input is Enabled Input is Enabled Input is Enabled Input is Enabled Input is Enabled Input is Enabled Input is Enabled Input is Enabled Input is Enabled Input is Enabled Input is Enabled Input is Enabled No Yes 1 No Yes 1 No Yes 1 No Yes 1 No Yes 1 No Yes 1 No Yes 1 No Yes 1 No Yes 1 No Yes 1 No Yes 1 No Yes 1 No Yes 1 No Yes 1 No Yes 1 No Yes 1
Input # Individual Functions
Default Notes
00033
00034
00035
00036
00037
00038
44 FORM DET-1600 IOM 11-09
00039
00040
00041
00042
10
00043
11
00044
12
00045
13
00046
14
00047
15
00048
16
Location
Label
Notes
Read only bits
10000s 10001 10002 10003 10004 10005 10006 10007 10008 10009 10010 10011 10012 no rotation No No No below No No No Read only No No No outputs active no alarms OK outputs inactive alarms Window invalid Controls are locked out during the Control Initialization time The Alarms Status registers contain valid (most recent Data) The Window open or close parameters are out of range rotation Yes Yes Yes above Yes Yes Yes Write Yes Yes Yes Controls Locked Out
Global Functions Rotation Sensed Timing Control engaged Switch 1 Activated Switch 2 Activated Control RPM Achieved G Lead Signal Present #1 cyl Signal Present Ignition Communication Present Factory Calibration R/W Watchdog Reset Flag Current Loop fault
The DET has sensed the engine is rotating. Use for loss of rotation Ignition timing is being controlled by the DET Output switch 1 activated by detonation or misfire Output switch 2 activated by detonation Engine is below or above control RPM DET Diagnostics DET Diagnostics DET Diagnostics Factory Calibration Read/Write Self-Reliant Reset Function
10013
10014 10015 10016 OK OK OK OK OK OK OK OK OK OK Bad Sensor Bad Sensor Bad Sensor Bad Sensor Bad Sensor Bad Sensor Bad Sensor Bad Sensor Bad Sensor Bad Sensor
10017 10018 10019 Sensor Status Sensor Status Sensor Status Sensor Status Sensor Status Sensor Status Sensor Status
Alarms Present Invalid Window Parameter Reserved Input # Individual Functions 1 Sensor Status 2 Sensor Status 3 Sensor Status
Sensor is detected and operating properly or is not detected Sensor is detected and operating properly or is not detected Sensor is detected and operating properly or is not detected Sensor is detected and operating properly or is not detected Sensor is detected and operating properly or is not detected Sensor is detected and operating properly or is not detected Sensor is detected and operating properly or is not detected Sensor is detected and operating properly or is not detected Sensor is detected and operating properly or is not detected Sensor is detected and operating properly or is not detected
10020 10021 10022
4 5 6
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10023 10024 10025 10026
7 8 9 10
45
46 FORM DET-1600 IOM 11-09
Location 10027 10028 10029 10030 10031 10032 10033 10034 10035 10036 10037 10038 10039 10040 10041 10042 10043 10044 10045 10046 10047 10048 10049 10050 10051 10052 10053 10054 10055 10056 10057
Input # 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9
Individual Functions Sensor Status Sensor Status Sensor Status Sensor Status Sensor Status Sensor Status Detonation Detected Status Detonation Detected Status Detonation Detected Status Detonation Detected Status Detonation Detected Status Detonation Detected Status Detonation Detected Status Detonation Detected Status Detonation Detected Status Detonation Detected Status Detonation Detected Status Detonation Detected Status Detonation Detected Status Detonation Detected Status Detonation Detected Status Detonation Detected Status Misfire Detected Status Misfire Detected Status Misfire Detected Status Misfire Detected Status Misfire Detected Status Misfire Detected Status Misfire Detected Status Misfire Detected Status Misfire Detected Status
0 OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK
1 Bad Sensor Bad Sensor Bad Sensor Bad Sensor Bad Sensor Bad Sensor detonation detected detonation detected detonation detected detonation detected detonation detected detonation detected detonation detected detonation detected detonation detected detonation detected detonation detected detonation detected detonation detected detonation detected detonation detected detonation detected misfire detected misfire detected misfire detected misfire detected misfire detected misfire detected misfire detected misfire detected misfire detected
Notes Sensor is detected and operating properly or is not detected Sensor is detected and operating properly or is not detected Sensor is detected and operating properly or is not detected Sensor is detected and operating properly or is not detected Sensor is detected and operating properly or is not detected Sensor is detected and operating properly or is not detected Detonation detected on this channel Detonation detected on this channel Detonation detected on this channel Detonation detected on this channel Detonation detected on this channel Detonation detected on this channel Detonation detected on this channel Detonation detected on this channel Detonation detected on this channel Detonation detected on this channel Detonation detected on this channel Detonation detected on this channel Detonation detected on this channel Detonation detected on this channel Detonation detected on this channel Detonation detected on this channel Misfire detected on this channel Misfire detected on this channel Misfire detected on this channel Misfire detected on this channel Misfire detected on this channel Misfire detected on this channel Misfire detected on this channel Misfire detected on this channel Misfire detected on this channel
Location 10058 10059 10060 10061 10062 10063 10064 10065 10066 10067 10068 10069 10070 10071 10072 10073 10074 10075 10076 Sensor Status @ SW2 Sensor Status @ SW2 Sensor Status @ SW2 Sensor Status @ SW2 Detonation Status @ SW2 Detonation Status @ SW2 Detonation Status @ SW2 Detonation Status @ SW2 Detonation Status @ SW2 Detonation Status @ SW2 Detonation Status @ SW2 Detonation Status @ SW2 OK OK OK OK OK OK OK OK OK OK OK OK Bad Sensor Bad Sensor Bad Sensor Bad Sensor detonation detected detonation detected detonation detected detonation detected detonation detected detonation detected detonation detected detonation detected Sensor Status at SW 2 trip Sensor Status at SW 2 trip Sensor Status at SW 2 trip Sensor Status at SW 2 trip latched Detonation Status on this channel at SW2 latched Detonation Status on this channel at SW2 latched Detonation Status on this channel at SW2 latched Detonation Status on this channel at SW2 latched Detonation Status on this channel at SW2 latched Detonation Status on this channel at SW2 latched Detonation Status on this channel at SW2 latched Detonation Status on this channel at SW2
Input # 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12
Individual Functions Misfire Detected Status Misfire Detected Status Misfire Detected Status Misfire Detected Status Misfire Detected Status Misfire Detected Status Misfire Detected Status Sensor Status @ SW2 Sensor Status @ SW2 Sensor Status @ SW2 Sensor Status @ SW2 Sensor Status @ SW2 Sensor Status @ SW2 Sensor Status @ SW2 Sensor Status @ SW2 Sensor Status @ SW2 Sensor Status @ SW2 Sensor Status @ SW2 Sensor Status @ SW2
0 OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK
1 misfire detected misfire detected misfire detected misfire detected misfire detected misfire detected misfire detected Bad Sensor Bad Sensor Bad Sensor Bad Sensor Bad Sensor Bad Sensor Bad Sensor Bad Sensor Bad Sensor Bad Sensor Bad Sensor Bad Sensor
Notes Misfire detected on this channel Misfire detected on this channel Misfire detected on this channel Misfire detected on this channel Misfire detected on this channel Misfire detected on this channel Misfire detected on this channel Sensor Status at SW 2 trip Sensor Status at SW 2 trip Sensor Status at SW 2 trip Sensor Status at SW 2 trip Sensor Status at SW 2 trip Sensor Status at SW 2 trip Sensor Status at SW 2 trip Sensor Status at SW 2 trip Sensor Status at SW 2 trip Sensor Status at SW 2 trip Sensor Status at SW 2 trip Sensor Status at SW 2 trip
10077 10078
13 14
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10079 10080 10081 10082 10083 10084 10085 10086 10087 10088
15 16 1 2 3 4 5 6 7 8
47
48 FORM DET-1600 IOM 11-09
Location 10089 10090 10091 10092 10093 10094 10095 10096 10097 10098 10099 10100 10101 10102 10103 10104 10105 10106 10107 10108 10109 10110 10111 10112
Input # 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Individual Functions Detonation Status @ SW2 Detonation Status @ SW2 Detonation Status @ SW2 Detonation Status @ SW2 Detonation Status @ SW2 Detonation Status @ SW2 Detonation Status @ SW2 Detonation Status @ SW2 Misfire status @ SW2 Misfire status @ SW2 Misfire status @ SW2 Misfire status @ SW2 Misfire status @ SW2 Misfire status @ SW2 Misfire status @ SW2 Misfire status @ SW2 Misfire status @ SW2 Misfire status @ SW2 Misfire status @ SW2 Misfire status @ SW2 Misfire status @ SW2 Misfire status @ SW2 Misfire status @ SW2 Misfire status @ SW2
0 OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK
1 detonation detected detonation detected detonation detected detonation detected detonation detected detonation detected detonation detected detonation detected misfire detected misfire detected misfire detected misfire detected misfire detected misfire detected misfire detected misfire detected misfire detected misfire detected misfire detected misfire detected misfire detected misfire detected misfire detected misfire detected
Notes latched Detonation Status on this channel at SW2 latched Detonation Status on this channel at SW2 latched Detonation Status on this channel at SW2 latched Detonation Status on this channel at SW2 latched Detonation Status on this channel at SW2 latched Detonation Status on this channel at SW2 latched Detonation Status on this channel at SW2 latched Detonation Status on this channel at SW2 latched Misfire status on this channel at SW2 latched Misfire status on this channel at SW2 latched Misfire status on this channel at SW2 latched Misfire status on this channel at SW2 latched Misfire status on this channel at SW2 latched Misfire status on this channel at SW2 latched Misfire status on this channel at SW2 latched Misfire status on this channel at SW2 latched Misfire status on this channel at SW2 latched Misfire status on this channel at SW2 latched Misfire status on this channel at SW2 latched Misfire status on this channel at SW2 latched Misfire status on this channel at SW2 latched Misfire status on this channel at SW2 latched Misfire status on this channel at SW2 latched Misfire status on this channel at SW2
Location
Label
Units
Size(bits) Min
Max
Notes
Read only bytes
Bad Sensor Status Flags Detonation Status Flags Misfire Status Flags Alarms Bad Sensor Status Flags Alarms Detonation Status Flags Alarms Misfire Status Flags degrees volts RPM --16 16 16 16 16 0 0 0 0 0 90 The Spark timing value from the Ignition System -Voltage measured at supply terminals 3600 1023 1023
30000s 30001 30002 30003 30004 30005 30006 30007 30008 30009 30010 30011 30012 30013 30014
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30015 30016 30017 30018 30019 30020 30021 30022 30023 30024
Global Functions Same as 10001-10016 Same as 10017-10032 Same as 10033-10048 Same as 10049-10064 Same as 10065-10080 Same as 10081-10096 Same as 10097-10112 Same as 10113-10128 Default timing from Ignition System Suppply Voltage (1234=12.34 V) Calculated Engine RPM Average Misfire Level Average Detonation Level Reserved Input # Individual Functions 1 Misfire Level 2 Misfire Level 3 Misfire Level 4 Misfire Level 5 Misfire Level 6 Misfire Level 7 Misfire Level 8 Misfire Level 9 Misfire Level 10 Misfire Level ----------16 16 16 16 16 16 16 16 16 16 0 0 0 0 0 0 0 0 0 0 1023 1023 1023 1023 1023 1023 1023 1023 1023 1023
49
Location 30025 30026 30027 30028 30029 30030 30031 30032 30033 30034 30035 30036 30037 30038 30039 30040 30041 30042 30043 30044 30045 30046 30047 30048 30049 30050 30051 30052 Default timing is set by Ignition system Default timing is set by Ignition system Default timing is set by Ignition system Default timing is set by Ignition system Default timing is set by Ignition system Default timing is set by Ignition system
Input # 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6
Individual Functions Misfire Level Misfire Level Misfire Level Misfire Level Misfire Level Misfire Level Detonation Level Detonation Level Detonation Level Detonation Level Detonation Level Detonation Level Detonation Level Detonation Level Detonation Level Detonation Level Detonation Level Detonation Level Detonation Level Detonation Level Detonation Level Detonation Level Retard from default timing Retard from default timing Retard from default timing Retard from default timing Retard from default timing Retard from default timing
Units Size(bits) Min -16 0 -16 0 -16 0 -16 0 -16 0 -16 0 -16 0 -16 0 -16 0 -16 0 -16 0 -16 0 -16 0 -16 0 -16 0 -16 0 -16 0 -16 0 -16 0 -16 0 -16 0 -16 0 degrees 16 0 degrees 16 0 degrees 16 0 degrees 16 0 degrees 16 0 degrees 16 0
Max 1023 1023 1023 1023 1023 1023 1023 1023 1023 1023 1023 1023 1023 1023 1023 1023 1023 1023 1023 1023 1023 1023 90 90 90 90 90 90
Notes
50 FORM DET-1600 IOM 11-09
Location 30053 30054 30055 30056 30057 30058 30059 30060 30061 30062 30063
Input # 7 8 9 10 11 12 13 14 15 16
Individual Functions Retard from default timing Retard from default timing Retard from default timing Retard from default timing Retard from default timing Retard from default timing Retard from default timing Retard from default timing Retard from default timing Retard from default timing Direct Hi Trip Setpoint Flags
Units Size(bits) Min Max degrees 16 0 90 degrees 16 0 90 degrees 16 0 90 degrees 16 0 90 degrees 16 0 90 degrees 16 0 90 degrees 16 0 90 degrees 16 0 90 degrees 16 0 90 degrees 16 0 90 binary 16 0 65535
Notes Default timing is set by Ignition system Default timing is set by Ignition system Default timing is set by Ignition system Default timing is set by Ignition system Default timing is set by Ignition system Default timing is set by Ignition system Default timing is set by Ignition system Default timing is set by Ignition system Default timing is set by Ignition system Default timing is set by Ignition system Cylinders 1 to 16
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51
Location
Label
Units
Size (bits)
Min
Max
Default
Notes
Read/Write bytes
40000s --------seconds -bits/sec 16 -----RPM degrees degrees degrees degrees -Units Size bits) 16 0 Min 16 1 16 1 90 90 1023 Max 16 1 90 16 1 90 16 200 3000 900 20 10 20 10 300 Default Notes 16 1 16 6 RPM value where DET is able to adjust timing In degrees from firing. In degrees from opening of misfire window In degrees from firing. In degrees from opening of detonation window 16 1 255 240 16 2 4 4 16 1 16 6 16 1 255 240 000 999 000 16 19.2K 16 1 99 1 0=9.6K, 1=19.2K, 2=38.4K, 3=57.6K, 4=115.2K 16 0 30 0 0=off, 1-30 sec. 16 0 65535 0 16 0 65535 0 16 0 65535 0 16 0 65535 0 16 0 65535 0 16 0 65535 65535 Inputs Enabled 16 0 65535 0 16 0 65535 0
Global Functions
40001
Coils 001-016
40002
Coils 017-032
40003
Coils 033-048
52 FORM DET-1600 IOM 11-09
40004
Coils 049-064
40005
Coils 065-080
40006
Coils 081-096
40007
Coils 097-112
40008
Coils 113-128
40009
Auto Scan (1 to 30 sec.)
40010
Node Number (1-99)
40011
Baud Rate (0=9.6K, 1=19.2K,)
40012
Security Password (000 - 999)
40013
Det Lag Filter Gain Value (1-255)
40014
Number of Cylinders (1-16)
40015
2 or 4 cycle
40016
Misfire Lag Filter Gain Value (1-255)
40017
Number of sensors used (1-16)
40018
Control RPM value (200-3000)
40019
Open Misfire Window
40020
Duration of Misfire Window
40021
Open Detonation Window
40022
Duration of Detonation Window
40023
Misfire Setpoint Value (SW1)
Location
Label
Location seconds -seconds seconds degrees Retard 16 0 90 24 degrees Retard 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 1 0 0 40001 1 1023 40999 900 99 4 30001 30999 500 1024 1024 30006 50 40007 0 2 0 0=9.6K, 1=19.2K, 2=38.4K, 3=57.6K, 4=115.2K 0 999 10 0 999 2 0 10 1 0 10 1 0 90 24 step value to retard when detecting detonation step value to advance when previously retarded and no detonation is present Detonation must exceed set level for this long before taking action The absence of detonation must exceed set level for this long before taking action Bypasses ignition retard, 1024 = Off External Ignitions Modbus register location for engine timing MF or DET levels below this setpoint will indicate a bad/missing sensor 0 90 32 0 65535 10923 In degrees before TDC. Ignored if external ignition timing flag set. 0 65535 54613 0 90 0 Counts Counts degrees degrees degrees degrees seconds seconds ------------CD200 - 4mA = 16 retard, 20mA = 0 retard CPU95 - 4mA = 0 retard, 20mA = 48 retard (A code) CPU95 - 4mA = 0 retard, 20mA = 36 retard (B code) CPU95 - 4mA = 0 retard, 20mA = 24 retard (C code) DISN800 - 4mA = 8 retard, 20mA = 0 retard 16 1 999 1 16 0 999 3 16 0 1023 800 16 0 999 3
Label
Units
Size (bits)
Min
Max
Default
Notes
40024
Switch 1 Hysteresis time
40025
DET Setpoint Value (SW1)
40026
Switch 2 Time until Tripped
40027
Control Initialization Time
40028
Current Loop Hi (20mA)
40029
Current Loop Lo (4mA)
40030
Current Loop Cal 20mA (AD Counts)
40031
Current Loop Cal 4mA (AD Counts)
40032
Ignition Timing BTDC (user input value)
40033
Max Retard timing value allowed
40034
Retard step value (1-10)
40035
Advance step value (1-10)
40036
Time (sec.) Between Retard Steps
40037
Time (sec.) Between Advance Steps
40038
Direct Hi Trip Setpoint
40039
External Ignition Modbus Timing Location
40040
Bad Sensor Setpoint
40041
Timing Retard Register (Ignition)
40042
Default Ignition Timing (Retard)
40043
Ignition Node ID
40044
Ignition Baud Rate
40045
Reserved
40046
Reserved
40047
Reserved
40048
Reserved
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40049
Reserved
53
Location -------16 16 --16 16 --16 16 16 16 -16 16 0 65535 0 Used for special commands, momentary 16 1 16 firing event 16 0 65355 xx Two ASCII characters 16 -500 500 0 16 -500 500 0 Offset Value to Normalize the Misfire Level Offset Value to Normalize the Detonation Level 16 16 0 31 26 16 0 63 35 16 0 63 14 16 0 31 26 16 0 63 35 16 0 63 14
Input #
Individual Functions
Units
Size (bits)
Min
Max
Default
Notes
40050
Factory
40051
misfire gain (0-63)
40052
misfire bandpass filter freq. (0-63)
40053
misfire Integrator time constant (0-31)
54 FORM DET-1600 IOM 11-09

Momentary Momentary
40054
detonation gain (0-63)
40055
detonation bandpass freq. (0-63)
40056
detonation Integrator time constant (0-31)
40057
Reserved
40058
Reserved
40059
Reserved
40060
Misfire Normalization Offset
40061
Detonation Normalization Offset
40062
Reserved
40063
Reserved
40064
Cylinder Label (xx)
40065
Sensor Number (1-16)
40066
Reserved
40067
Reserved
40068
Reserved
40069
Reserved
40370
Key Command Register
40371
Reserved
KEY COMMANDS
Value
Function
64260
Clears the Alarms Present Flag
64515
Perform a control reset
Firing Event 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Starting Location 40050 40070 40090 40110 40130 40150 40170 40190 40210 40230 40250 40270 40290 40310 40330 40350
FIRING EVENT 16 Location 40350 40351 40352 40353 40354 40355 40356 40357 40358 40359 40360 40361 40362 40363 40364 40365 40366 40367 40368 40369 Firing event # 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 Label Factory misfire gain (0-63) misfire bandpass filter freq. (0-63) misfire Integrator time constant (0-31) detonation gain (0-63) detonation bandpass freq. (0-63) detonation Integrator time constant (0-31) Reserved Reserved Reserved Misfire Normalization Offset Detonation Normalization Offset Reserved Reserved Cylinder Label (XX) Sensor Number (1-16) Reserved Reserved Reserved Reserved -------0 0 --0 0 --0 0 0 0 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 0 0 0 0 0 0 0 0 0 -500 -500 0 0 0 1 0 0 0 0 63 63 31 63 63 31 0 0 0 500 500 0 0 65355 16 0 0 0 0 14 35 26 14 35 26 0 0 0 0 0 0 0 XX 16 0 0 0 0 SEE GAIN chART, PAGE 56 SEE bANDPASS chART, PAGE 56 SEE INTEGRATOR chART, PAGE 57 SEE GAIN chART, PAGE 56 SEE bANDPASS chART, PAGE 56 SEE INTEGRATOR chART, PAGE 57 MF or DET levels below this setpoint will indicate a bad/missing sensor 0 0 Offset Value to Normalize the Misfire Level Offset Value to Normalize the Detonation Level 0 0 Two AScII characters 0 0 0 0 0 Size Units (bits) Min Max Default Notes
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55

GAIN chART (Registers 40351 and 40354)
Register Value 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 Gain 2.000 1.882 1.778 1.684 1.600 1.523 1.455 1.391 1.333 1.280 1.231 1.185 1.143 1.063 1.000 0.944 0.895 0.850 0.810 0.773 0.739 0.708 0.680 0.654 0.630 0.607 0.586 0.567 0.548 0.500 0.471 0.444 0.421 0.400 0.381 0.364 0.348 0.333 0.320 0.308 0.296 0.286 0.276 0.267 Register Value 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 Gain 0.258 0.250 0.236 0.222 0.211 0.200 0.190 0.182 0.174 0.167 0.160 0.154 0.148 0.143 0.138 0.133 0.129 0.125 0.118 0.111
bANDPASS chART (Registers 40352 and 40355)

Register Value 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 Bandpass Filter Freq. 1.220 khz 1.260 khz 1.310 khz 1.350 khz 1.400 khz 1.450 khz 1.510 khz 1.570 khz 1.630 khz 1.710 khz 1.780 khz 1.870 khz 1.960 khz 2.070 khz 2.180 khz 2.310 khz 2.460 khz 2.540 khz 2.620 khz 2.710 khz 2.810 khz 2.920 khz 3.030 khz 3.150 khz 3.280 khz 3.430 khz 3.590 khz 3.760 khz 3.950 khz 4.160 khz 4.390 khz 4.660 khz 4.950 khz 5.120 khz 5.290 khz 5.480 khz 5.680 khz 5.900 khz 6.120 khz 6.370 khz 6.640 khz 6.940 khz 7.270 khz 7.630 khz Register Value 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 Bandpass Filter Freq. 8.020 khz 8.460 khz 8.950 khz 9.500 khz 10.120 khz 10.460 khz 10.830 khz 11.220 khz 11.650 khz 12.100 khz 12.600 khz 13.140 khz 13.720 khz 14.360 khz 15.070 khz 15.840 khz 16.710 khz 17.670 khz 18.760 khz 19.980 khz
56 FORM DET-1600 IOM 11-09
INTEGRATOR chART (Registers 40353 and 40356)
Register Value 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Integrator Time const 40 45 50 55 60 65 70 75 80 90 100 110 120 130 140 150 160 180 200 220 240 260 280 300 320 360 400 440 480 520 560 600
GLOSSARY:
TDc Top Dead Center - The highest piston position, where the piston turns and moves back down btdc Engine degrees Before Top Dead Center atdc Engine degrees After Top Dead Center Fire Event From 1 to x in numerical order of the engine firing order Engine firing order The engine cylinder firing sequence. normal run timing value The timing value in btdc that the engine runs at with normal loads This is the max advanced timing value and the DET-1600 can only retard the engine timing from this value
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57

FIGURES SECTION: 1. 2. 3. 4. 5. 6. 7. 8. 9. MOUNTING DIMENSIONS AND SPECIFICATIONS FLOWCHART HOME SCREENS MOUNTING, DIMENSIONS, AND SPECS KNOCK SENSORS WIRING DIAGRAM DETONATION SENSORS WIRING DIAGRAM POWER, INPUTS, AND OUTPUTS WIRING DIAGRAM MODbUS CONTROL TO IGNITION SYSTEM WIRING DIAGRAM CURRENT LOOP, CPU-95 WIRING DIAGRAM CURRENT LOOP, CD200/DISN
10. WIRING DIAGRAM ALTRONIC ANNUNCIATOR SYSTEMS 11. WIRING DIAGRAM DC RELAYS 12. WIRING DIAGRAM RS-485 COMMUNICATIONS, PC HOOK-UP
58 FORM DET-1600 IOM 11-09
FIGURE 1. MOUNTING DIMENSIONS AND SPECIFICATIONS
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59

FIGURE 2. FLOWCHART
60 FORM DET-1600 IOM 11-09
FIGURE 3. HOME SCREENS
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61

FIGURE 4. MOUNTING, DIMENSIONS, AND SPECS KNOCK SENSORS
62 FORM DET-1600 IOM 11-09
FIGURE 5. WIRING DIAGRAM DETONATION SENSORS
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63

FIGURE 6. WIRING DIAGRAM POWER, INPUTS, AND OUTPUTS
64 FORM DET-1600 IOM 11-09
FIGURE 7. WIRING DIAGRAM MODbUS CONTROL TO IGNITION SYSTEM
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65

FIGURE 8. WIRING DIAGRAM CURRENT LOOP, CPU95
66 FORM DET-1600 IOM 11-09
FIGURE 9. WIRING DIAGRAM CURRENT LOOP, CD200/DISN
B&D
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67

FIGURE 10. WIRING DIAGRAM ALTRONIC ANNUNCIATOR SYSTEMS
68 FORM DET-1600 IOM 11-09
FIGURE 11. WIRING DIAGRAM DC RELAYS
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69

FIGURE 12. WIRING DIAGRAM RS-485 COMMUNICATIONS, PC HOOK-UP
70 FORM DET-1600 IOM 11-09

Det-1600 Iom 11-09

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DET-1600 DETONATION SENSING MONITOR

DET-1600 DETONATION SENSING MONITOR

1.3 POWER REQUIREMENT

2 FORM DET-1600 IOM 11-09

3.0 MOUNTING 3.1 DETONATION SENSING MONITOR (SEE FIGURE 1)

3.2 DETONATION SENSORS (SEE FIGURE 4)

DET-1600 DETONATION SENSING MONITOR

4.2 POWER WIRING

4.3 SHUTDOWN LEAD INPUT

4.4 NUMbER 1 CYLINDER IGNITION COIL PRIMARY OF A C.D. IGNITION SYSTEM

4 FORM DET-1600 IOM 11-09

Terminal # on back of DET-1600 Cylinder # (as marked on engine) Sensor #

DET-1600 DETONATION SENSING MONITOR

4.7 OUTPUT CURRENT LOOP WIRING

4.8 RS-485 COMMUNICATIONS WIRING

6 FORM DET-1600 IOM 11-09

WARNING ExPLOSION HAzARD:

4.10 TESTING SENSOR LEADS

DET-1600 DETONATION SENSING MONITOR

5.2 DETONATION AND MISFIRE

8 FORM DET-1600 IOM 11-09

5.4 INPUT SIGNAL FILTERING

5.5 SEQUENCE OF OPERATION, SETPOINTS AND OUTPUTS

DET-1600 DETONATION SENSING MONITOR

10 FORM DET-1600 IOM 11-09

6.2 TERMINAL PROGRAM STRUCTURE

6.3 TERMINAL PROGRAM, ESTAbLISHING COMMUNICATIONS

DET-1600 DETONATION SENSING MONITOR

6.5 COM PORT

6.8 RESET COM STATS

6.9 ROI (REMOTE OPERATOR INTERFACE)

12 FORM DET-1600 IOM 11-09

7.4 LAG FILTER

7.5 DISPLAY vALUES bY TEN

DET-1600 DETONATION SENSING MONITOR

The Fire Event is from 1 to x in numerical order, x being max.

The Cyl lbl is a unique programmable engine cylinder identi-

The Sensor # is the sensor that will be used by the DET-1600 to

14 FORM DET-1600 IOM 11-09

7.9 USER ENTERED vALUE

7.10 FROM IGNITION SYSTEM

DET-1600 DETONATION SENSING MONITOR

8.1 DETONATION SETPOINT vALUE

8.2 MISFIRE SETPOINT vALUE

16 FORM DET-1600 IOM 11-09

8.4 OUTPUT SWITCH #1

DET-1600 DETONATION SENSING MONITOR

8.5 OUTPUT SWITCH #2

18 FORM DET-1600 IOM 11-09

DET-1600 DETONATION SENSING MONITOR

20 FORM DET-1600 IOM 11-09

DET-1600 DETONATION SENSING MONITOR

9.1 DETONATION/MISFIRE LEvEL, LINEAR GAUGES

9.2 AvERAGE DETONATION/MISFIRE LEvEL

9.3 GLObAL RETARD

9.4 SIGNAL PROCESSING PARAMETERS

22 FORM DET-1600 IOM 11-09