Gas TRS

EXPERT
Domestics

Fire Exits

Breaks

Lunch

Toilets

Smoking

Mobile Phones
Mechanical Overview

 Utilising proven 4016-E61TRS combustion technology

 Cylinder head, Piston, Liner

 Extruded oil rail

 Improved closed circuit breather filtration.

 Dry exhaust manifold

Mechanical Overview - Head

TESi TRS
Mechanical Overview - Piston

TESi TRS
Low Compression
Mechanical Overview CCB Option

TESi TRS
CCB = Closed Circuit Breather
Mechanical Overview - Manifold

TESi TRS
Engine Specifications

TRS range of engines:

A) Cogen specification both for natural gas and biogases for Combined
Heat and Power application
This specification is offered to manufacturers of Combined Heat and Power
(CHP/Cogeneration) plants,

B) Gas Electro-unit specification both for natural gas and biogases for
Power Generation applications
This specification is offered to manufacturers of radiator cooled generator sets both for
continuous and standby applications.
4006-23TRS1 / TRS2

6 cyl. water cooled lean burn Gas Engine

TRS1 = 322 kWm
TRS2 = 393 kWm

 Arrangement Vertical, in-line

 Cycle 4 stroke
 Induction system Turbocharged,
mixture cooled
 Displacement 22.92 litres
 Bore and stroke 160 mm x 190 mm
 Compression ratio 12:1

 Fuel Natural gas

Biogas
Landfill Gas
Digester Gas
4008-30TRS1 / TRS2

8 cyl. water cooled lean burn Gas Engine

TRS1 = 447 kWm
TRS2 = 526 kWm

 Arrangement Vertical, in-line

 Cycle 4 stroke
 Induction system Turbocharged,
mixture cooled
 Displacement 30.56 litres
 Bore and stroke 160 mm x 190 mm
 Compression ratio 12:1

 Fuel Natural gas

Biogas
Landfill Gas
Digester Gas
 New TRS Gas Product

ZPR
(zero pressure regulator)

Pandaros Governor

Altronic Ignition Unit

CAC
(charge air cooler)

Oil Cooler
Gas inlet

Gas Start-up panel Control panel Gas Solenoid valve

New TRS Gas Product

Ignition coil CCB (closed circuit breather)

Ignition Mpu
Ignition Timing

Auxiliaries panel
Control System Overview

In - line engines
 Heinzmann Pandaros
 Kronos K20 AFR Control (ZPR)
 Detcon 20 Knock detection
 Altronic DISN 800C Ignition
 LKG01 Load sensor

Vee engines
 Heinzmann Pandaros X2
 Elektra AFR Control (no ZPR)
 Detcon 20 Knock detection
 Motortech MIC 500 Ignition Vee
 LKG01 Load sensor
ZPR = Zero Pressure Regulator
Gas Solenoid Controls

Power supply

Pressure switches
4000 Series Knock Detection

Valve Valve seat ZPR OPERATION

Pitot tube
 A sectioned ZPR is shown
Flow here.
 The adjuster should be wound
counter clockwise (CW.) until
the valve is fully closed.
 Turn the adjuster 17 full turns
clockwise (CCW).
 This should give sufficient gas
Diaphragms for initial starting.
Compensation Spring
line connection

Adjuster
under cap
Induction System

Crankcase Zero Pressure

Breather Regulator

(MAS) Mixture
or Main Balance Line
Adjusting Screw
Gas Start-up panel components

Kilowatt Transducer

Kronos AFR
Control unit

Detcon20
Detonation sensing
module
4006 & 4008TRS Kronos 20
Kronos 20 AFR Control System

Basic components for 4006-23TRS and 4008-30TRS

fuel system.
Kronos 20 AFR Control System

On the K20 System the Main Adjustment Screw is

electronically controlled to provide adjustability to
the gas flow.
4006 & 4008TRS Kronos 20

The Kronos 20 is an electronically controlled closed loop

AFR trim system that allows speed and or load
dependant Lambda values to be controlled within a
certain range. Control of the Lambda results in improved
engine load acceptance and efficiency over the
operating range. The closed loop version uses engine
output power to correct for changes in gas quality and
pressure. The system operates on low pressure gas
supplies in conjunction with the standard Perkins
supplied Zero Pressure Regulator.
4006 & 4008TRS Kronos 20

The system utilises a a std low pressure

gas system with ZPR where the Main
Adjusting Screw is replaced with an
electronic stepper motor. The valve is
available in 50 and 80mm diameter
versions for natural and landfill gas
capability.
4006 & 4008TRS Kronos 20

The closed loop system requires 3

sensors to operate:
Speed (Via MPU)
MAP and MAT (combined sensor)
Load (Kwe sensor customer supply)
4006 & 4008TRS Kronos 20

RS232 interface 12V or 24V DC supply

4006 & 4008TRS Kronos 20

Customer interface is via

Heinzmann DC Desk PC
software. Access to controller
settings is regulated by the
hardware dongle available
from Perkins. The software
will allow basic adjustment for
on site commissioning or
adjustment and graphical
output of system parameters.
4006 & 4008TRS Kronos 20

Perkins optimise
the Lambda map
of the engine to
give good
transient
capability below
50% load and a
linear NOx
response up to
100% load. These
maps are preset
and not
adjustable.
4006 & 4008TRS Kronos 20

Parameter 1462 Adjusts emissions levels default setting

is 100% moving value up increases emissions level decreasing
value lowers emissions level (make small adjustments only)

DcDesk 2000 used with Kronos

Kronos 20 AFR Control System
Kronos 20 AFR Control System
Kronos 20 AFR Control System
4006 & 4008TRS Kronos 20

Parameter 1462 Adjusts emissions levels default setting

is 100% moving value up increases emissions level decreasing
value lowers emissions level (make small adjustments only)
4006 & 4008TRS Kronos 20

Emissions Adjustment with Kronos 20

1. Connect Heinzmann DCDesk software to Kronos controller

(RS232)
2. Save current data file to PC
3. Select Number 1462 RichLeanMixtureCorr

4. Adjusting this Number up increases NOx reading and lowering reduces the NOx reading
5. Once adjustment is complete press enter then F6 to save the data to the Kronos controller

NB: Kronos 20 AFR direction.

On initial start up of the engine the controller closes fully then moves to a set start position
Turning the mixer counter clockwise closes the valve
Turning the mixer clockwise opens the valve
Kilowatt Transducer
Potentiometers
for load
reference set-up
Kilowatt Transducer Set-up 4006/8

Number 5400 Set value to 0 to enable set up of KW transducer

Set back to 1 when completed.
Check that Parameters 5412 and 5413 are set to 1
Kilowatt Transducer Set-up 4016

Parameter 5340 Set value to 0 to enable set up of KW transducer

Set back to 1 when completed.
 Kilowatt Transducer Set-up 4006/8
1. Connect Heinzmann DCDesk software to Kronos / Electra service point
2. Save current data file to PC
3. Enable open loop mode (see line 10 below)
4. With engine running at 0 load, in measurements window read number 3531 AnalogIn3_value / 3511 AnalogIn1_value
4. On Kw sensor Adjust pot kW I O/P zero or 4mA until number 3531 / 3511 reads close to or 4mA
5. In the Parameters window feed this figure into number 1530 AnalogIn3_RefLow / 1510 AnalogIn1_RefLow
6. Apply load to engine (NB Monitor emissions levels and adjust if required) when engine is at full
load read number 3531 AnalogIn3_value / 3511 AnalogIn1_value
7. On Kw sensor adjust pot kWI O/P 1mA or 20mA until number 3531 / 3511 reads close to or 20mA
8. In the parameter window feed this figure plus 0.50 mA into number 1531 AnalogIn3_RefHigh / 1511 AnalogIn1_RefHigh
9. Enable closed loop mode
10. Save parameter file to control box
11. In operation to enable and disable the AFR open and closed loop operation function 5400 / 5340
Can be changed

Note Font in blue corresponds to 4006 / 8 If any red LEDS are ON

Font in Red corresponds to 4016 reverse its corresponding CT connections

kWI O/P 1mA or 20mA pot

kWI O/P zero or 4mA pot

Kilowatt Transducer Set-up 4006/8
Kilowatt Transducer Set-up 4016
4000 TRS Gas Engine

Detcon 20 Knock Detection

 Knock Detection system

Objective
 Prevent piston failure due to:
 Detonation
 Plug / lead failure
 Air filter blockage
 Overload running
 Variable gas quality

 Reduces risk of total engine loss

 System will be factory set and tested on engine.
 Configuration will be set to trip on sensor defect or maximum retard reached
4000 Series Knock Detection (Detcon20)

Standard USB connection

Det-Con
Knock Detection system

Failed piston due to

detonation
 Measures vibration levels per cylinder
 Detects detonation
 Retards timing up to a max 8 degrees
 If retardation does not work sends signal to O.E.M panel to stop engine
 Once detonation levels have lowered to acceptable limits load / timing
adjusted back to optimum running conditions
4000 Series Knock Detection (Detcon20)
Detcon 20 Knock Detection Password
4000 Detcon Settings and Monitoring Cards

Connection

Timing Level
reduction of
Knock

Den-Edit used with Det-Con unit

4000 Series Knock Detection

Den-Edit Diagnostic Mode

The Den-Edit program has an internal diagnostic mode that allows the operator to test
Some of the knock unit features.

In the mode window select the diagnose button

Remember after carrying out test to unselect
the
Diagnose button if this is not done the knock
unit will not function
4000 Series Knock Detection
Detcon 20 Knock Detection
Detcon 20 Knock Detection

Detection of failed Knock Sensors

The base program has the

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

05 NB: The sensor are wired in engine

Firing order
4000 TRS Gas Engine

Altronic DISN Ignition Unit

Ignition System
Ignition System (Altronic DISN)

 Digital ignition system

 No moving parts
 Generic throughout Perkins range (except 4016E61TRS 4016-61TRS
Uses the MIC500 control unit)
 Analogue input from external potentiometer for timing control
 Manual timing (16 position switch)
 On board diagnostics
 Negative ground ignition coils
Altronic DISN Ignition Unit
Altronic DISN Ignition Unit
Altronic DISN Ignition Unit
Altronic DISN Ignition Unit
Altronic DISN Ignition Unit

Running clearance

Timing disc
housing

Timing disc

Pick-up sensor
Altronic DISN Ignition Unit

Re-set magnet

Trigger magnets
4000 TRS Gas Engine

Pandaros Digital Governor

 Pandaros overview in-line

Heinzmann Governor
Ignition Unit
Pandaros overview

GOVERNOR STATUS
RUN STATUS
CAN COMMUNICATION
DC-
PANDAROS
- DESK DISPLAYS
PACKAGER DISPLAYS
GOVERNOR ERRORS

ACCESSORIES
Stop / run
Synchronising
Load sharing
Voltage matching
Reactive load share
Speed ramp
Load ramp
Laptop computer Soft load transfer
Isochronous ramp
Power factor set
Mains parallel
Island parallel
Actuator
Group synchronising
Digital power control
Magnetic pick-up

0,50 to 0,80mm
Pandaros Connecting to a PC
Changing the governor configuration

Perkins cable and dongle

1. Coms lead Part no:680/192

2. USB dongle Part no:680/219
Using DcDesk Connecting to a PC

4000 TRS Gas Engine

Using Pandaros Connecting to a PC
Feedback Setting
Feedback Setting
Feedback Setting
Feedback Setting
Feedback Setting without service tool
Feedback Setting without service tool
Perkins Service Tool Configuration Screen

Generator Mode - Single generator fixed speed selected

Perkins Service Tool Configuration Screen
Changing the governor configuration

NOTE : After changing some parameters, it is necessary

to Store parameters in governor and then reset the
governor before the changes take effect. When this is
required, the following message will appear.
Changing the governor configuration
Changing the governor configuration
Changing the governor configuration
Changing the governor configuration
Changing the governor configuration
Changing the governor configuration
Load Control
Synchroniser Settings
Droop Setting
Engine Stop
Common Alarm
Adjustment of PID parameters
PID maps
Speed Ramps
Governor errors
Governor errors
.

Active
error
Governor errors
Pandaros Digital Governor Overview
Elektra AFR Control System
Motortech MIC530 Ignition Controller
Motortech MIC530 Ignition Controller

The IC.exe program connects automatically to the MIC500

Ignition controller.

If an over speed is recorded for any reason Switch of the power to the MIC500
To clear the fault.
Elektra AFR Control System
TRS Software Programs

DcDesk 2000 used with

Pandaros and Kronos

Den-Edit used with Det-Con unit

TRS Software Programs

Perkins Pandaros packager can be used

with Pandaros/Governor controller only

IC.exe used with MIC500

Where to find the software

DcDesk, Pandaros packager and Den-Edit are included

In Perkins CD Electronic Governor Software
EGS part number TPCD1539.

Alternatively the DcDesk & Pandaros software can be downloaded

From the Heinzmann web site: www.heinzmann.com

The IC.exe program is available by contacting Perkins Applications

Or Service department and is enclosed with the Den-Edit software on
Perkins CD TPCD1539 (MIC 500 Controller)
DcDesk Software basics

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

4. Once connection is achieved the program will run through a

5. Screen to upload the controller parameters
6. Check that the tab has turned GREEN in the bottom left hand corner
(IF a failure to connect window appears check power to control unit is on)

When making changes

Make sure the unit is
ONLINE
DcDesk Software basics
2
Saving and loading a programs

1. On tool bar select FILE

2. Select Save all parameter values and left click
3. The STORE file screen will appear

4. Select an appropriate folder and click the save button

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

1.
2
On tool bar select FILE
2. Select load parameter values and left click

3. The load parameters screen will appear (next slide)

 2

4. Select file to be uploaded and click the OPEN tab

5. The compare file screen will appear (next slide) on this screen you can
either click the file compare tab this will tell you the differences between
the saved file and the current controller file or click the LOAD parameters
tab this will upload the selected file into the controller
2
Making changes to the program

1. In one of the windows select the appropriate function to be altered

(Gain has2 been used as an example)

2. In the bottom left hand corner the parameter number, name

& current setting will appear

Number Name Setting

3. Highlight or click in the current setting window and change the

figure to requirement
3. Press the F6 key to save change to control unit, if this is not done
4. The unit will operate at the setting but once power has been removed
from the controller the unit will return to the original setting
Using and Recording Data

For engine set up or factory diagnostic assistance.

It may be neccesary to view or record engine
Performance data
2

1. On DcDesk tool bar select GRAPHIC

2. Select CURVE Versus TIME
3. The graph window will appear
4. To load parameters to the graph select the corresponding number from the
desired window
2

5. Type the number into the left hand grey box and press enter
the parameter corresponding to the number will then be loaded onto
the graph
Adding further recording slots

It may be necessary to add further parameters on the record graph

To do this follow the below procedure
1. Open the curve versus time graph
2. Select the OTHER tab

3. The Options screen will then appear this has 3 tabs,

select the CURVE PARAMETERS tab
4. In the NUMBER of CURVES box select the number of parameter
boxes to use

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

6. To view a running engine click the START button and
click the STOP tab to stop
7. To record a graph screen. In the top right hand corner click the
8. START2 REC tab to record the parameters you have set.
9. To stop recording click the STOP tab
Saving a recording

The record is automatically saved into the following file:

C\program files dcdesk 2000\record sets\recorder_t.rec
E-mailing a record or parameter file

1. Open the relevant folder in the case of the recording look in the following
C\program files dcdesk 2000\record sets\recorder_t.rec

For a Pandaros or Elektra program file save as described earlier

These files can then be copied and e-mailed as any standard file.
 Parameter recordings

To aid in diagnostics issues the following parameter recording

are required as a minimum from the stated control units

Pandaros minimum record sets:

1. 2000 Speed
2. 2300 Actpos
3. 2330ActPoSetpoint

Elektra Air Fuel Ratio minimum record sets: Kronos Air Fuel Ratio minimum record sets:

1. 2000 Speed 1. 2000 Speed

2. 2300 Actpos 2. 2302 Stepper Pos
3. 2910GasTemp 3. 2912 ManifoldPressure
4. 2914 GasPressure 4. 2913 ManifoldTemp
5. 2915 GasDeltaPressure 5. 2914 MeasuredPower
6. 2916 Vent1DeltaPressure 6. 3411 CalculatedPower
7. 2917 Vent2DeltaPressure 7. 3511 AnalogIn3 Value
8. 3301 EngineThermalPower
9. 3346 ClosedLooplambdaTrim
10. 3300 MeasElectricPower
Pre-support Request Check List

 Before making a request for product support,

with regard to a 4000 Series gas engine, please
ensure you have the following information
available where appropriate.
 This information is important for a rapid
diagnosis and will assist with the resolution of any
issues.
Pre-support Request Check List. Cont

 Before making a request for product support,

with regard to a 4000 Series gas engine, please
ensure you have the following information
available where appropriate.
 This information is important for a rapid
diagnosis and will assist with the resolution of any
issues.
Questions