DK 200 Operating Manual Rev 1 0 PDF
DK 200 Operating Manual Rev 1 0 PDF
DK 200 Operating Manual Rev 1 0 PDF
On-Line Surveillance
System
Operating Guide
Revision 1.0
January 2016
3 Raw Holdings
East Calder
West Lothian EH53 0HY, UK
T: +44 1506 885000
F: +44 1506 885501
W: www.iconresearch.co.uk
NOTICE
Information contained in this document is believed to
be accurate and reliable. However, due to ongoing
product developments and revisions, Icon Research
Ltd cannot guarantee the accuracy of this document
after the date published nor can it accept
responsibility for errors or omissions.
CHAPTER 2 – DIAGNOSTIC Mode
2.1 DK‐200 DIAGNOSTIC Mode .............................................................................. 2‐1
2.2 Test Crank Pickups ............................................................................................ 2‐2
2.3 Test Pressure Sensors ....................................................................................... 2‐2
2.4 Read Pmax ........................................................................................................ 2‐3
2.5 Taking Local Measurements ............................................................................. 2‐4
2.6 Defining Network Settings ................................................................................ 2‐5
2.7 Reset Default Settings ...................................................................................... 2‐6
2.8 System Information .......................................................................................... 2‐7
CHAPTER 3 – NORMAL Mode
3.1 DK‐200 NORMAL Mode .................................................................................... 3‐1
3.2 Graph View ....................................................................................................... 3‐2
3.3 Table View ........................................................................................................ 3‐2
3.4 Histogram View ................................................................................................ 3‐3
3.5 Viewing Engine parameters .............................................................................. 3‐3
Chapter 1 – Overview of the DK‐200
Chapter 1 – Overview of the DK‐200
1.1 Using This Manual
This manual describes the setup and operation of the DK‐200 on‐line
monitoring system. It assumes that all sensor and communication
connections have been made and that the unit has been powered up.
Note that the DK‐200 requires a safety earth as described in the installation
instructions. Ensure that the unit is correctly installed before proceeding.
Chapter 2 describes how to operate the DK‐200 in diagnostic mode which is
used for setup, installation and commissioning. In this mode the system,
including sensor and pickup connections, can be checked without having a
network connection to a host computer.
Chapter 3 describes operation in normal mode ie. when connected to a host
computer via a network.
1.2 DK‐200 Hardware Overview
Setting up and viewing of data is carried out entirely by use of the
touchscreen display. This is accessed by opening the door of the unit. The
door is sealed to prevent ingress of moisture. If it is required to power the
unit down locally, this can be done by operating the circuit‐breaker inside the
unit. Remove the plastic safety barrier to access this breaker.
The circuitry of the DK‐200 comprises two boards and a LCD display. The
display is full VGA size with a capacitive touchscreen. The display
incorporates an integral LED backlight to ensure long life. The main board
carries out data acquisition and processing tasks while the lower interface
board conditions the incoming signals for compatibility with the main board.
Both boards are powered from an internal 24Vdc supply
There are a number of indicator LED’s on the boards. Refer to the picture
below for an explanation of these.
1‐1
Chapter 1 – Overview of the DK‐200
NORM LED
Display/Touchscreen
FAULT LED
DIAG LED
SPD LED
Main Board
Ethernet Port
LINK LED
Interface Board
Isolator
Pressure Sensor Inputs
PWR LED TDC LED FLY LED REL 1 LED REL 2 LED
Crank Signal Inputs
1‐2
Chapter 1 – Overview of the DK‐200
Main Board LED Functions
LED COLOUR FUNCTION
FAULT Red A fault has occurred on the unit. Investigation is
required.
NORM Green The DK‐200 is operating in NORMAL display mode.
DIAG Green The DK‐200 is operating in DIAGNOSTIC setup mode.
LINK Green A suitable ethernet network has been detected. The
LED flashes off to indicate data communication.
SPD Orange Illuminates orange when network speed is 100Base‐T.
Remains off when operating at 10Base‐T.
PWR Green Power is applied to the main board.
TDC Green Flashes when TDC pulse is detected.
FLY Green Flashes when FLY pulse is detected. May appear solid
at high pulse rates.
REL 1 Green Relay 1 is set.
REL 2 Green Relay 2 is set.
Interface Board LED Functions
LED COLOUR FUNCTION
PWR Green Power is applied to the interface board.
1.3 Operating the DK‐200 with the Touchscreen
The touchscreen on the DK‐200 enables quick and easy navigation of its
features. All control of the unit is carried out via the touchscreen. The
touchscreen is a capacitive type with Xensation™ glass for extreme
ruggedness. The touchscreen should be operated without wearing gloves.
Note that any button that has red text indicates that it is valid for a key tap
and will take you to that screen or function. If the text on a button is grey,
the function is not available or not valid at that time. If a button has a yellow
background, this indicates that the button function is selected at this time.
1.4 DK‐200 Modes
The DK‐200 has two modes of operation namely NORMAL and DIAGNOSTIC.
1‐3
Chapter 1 – Overview of the DK‐200
In normal mode, the device is under the control of a host computer and is
typically acquiring measurement data and returning data to the host over the
ethernet network. Diagnostic mode is used for setting up the DK‐200 and
checking operation, including all connected sensors, without the unit having
to be connected to a host. Diagnostic mode is very useful when installing and
commissioning on an engine.
It is possible to move between normal and diagnostic mode while the system
and engine are running. However, the system must be in normal mode for
data to be transferred to the host. If the system is left in diagnostic mode, it
will revert back to normal mode after 10 minutes if a key is not pressed. The
NORM and DIAG LED’s at the bottom of the main board indicate which mode
is active.
The two modes of operation are detailed in the next two chapters.
1‐4
Chapter 2 – DIAGNOSTIC Mode
Chapter 2 – DIAGNOSTIC Mode
2.1 DK‐200 DIAGNOSTIC Mode
Diagnostic mode enables the DK‐200 to be run independently of a host
computer and is used for setup, during installation and commissioning, and
for debugging in the event of a problem.
When the DK‐200 is first turned on, the screen below will appear.
Note that the time is set automatically when the unit is connected to the
server on the host computer. When first turned on the screen will show Time
Not Set.
To enter Diagnostic Mode, tap DIAGS on the top right corner of the first
screen as shown above. The main diagnostic test selection screen will now
be displayed as shown below. If you wish to return to normal mode, tap the
HOME button.
When you are in any of the diagnostic tests, tapping the DIAGS button will
bring you back to the main diagnostic test selection screen. When there are
more channels than can be displayed on a particular screen, you can scroll
vertically through the channels using the up/down arrows labelled CHAN.
2‐1
Chapter 2 – DIAGNOSTIC Mode
When installing and commissioning a system, it is suggested that the checks
are carried out in the order of the buttons on the screen.
2.2 Test Crank Pickups
Tapping TEST CRANK PICKUPS takes you to the following screen.
The test checks the pulses coming in from the TDC and FLY pickups. Note
that the engine must be running to carry out this test. A report is given on
the screen, an example of which is shown above. The Variance figure is a
measure of the jitter on the sequence of pulses being detected.
If no pulses are detected, this is displayed on the screen and the START
button is enabled. Issues with the crank pickups and wiring should be
rectified and the START button tapped to restart the test.
2.3 Test Pressure Sensors
The pressure sensors connected to the DK‐200 can checked by tapping the
TEST PRESSURE SENSORS button. Sensors can be checked with the engine
running or stopped.
When the engine is running, tap the RUNNING button. The minimum
voltage, maximum voltage and Vpk‐pk from the sensor on each channel are
displayed, together with a value of Pmax based on a nominal sensitivity of
50uA/bar and a PScav of 2.0 bar. (The resulting voltage is based on a load
resistor of 250 ohms giving 12.5mV/bar). On channel 8 in the screen below,
for example, Vpk‐pk of 600mV gives 48.0 bar plus PScav of 2.0, resulting in
50.0 bar. Note that diagnostic mode assumes a PScav of 2.0 bar.
2‐2
Chapter 2 – DIAGNOSTIC Mode
The main purpose of this test is to ensure that the voltage range from each
sensor lies comfortably within the 0V to 5V input range of the DK‐200. On
any channel, if the minimum voltage is tending towards zero or the maximum
voltage is tending towards 5V, then this should be investigated.
If the engine is stopped, the bias voltage from the sensors can be viewed.
Only the bias voltage is available as there is no dynamic pressure signal
present. Tapping the STOPPED button will display the screen below.
The Bias is displayed as a voltage and a current, the relationship being based
on a load resistor of 250R as fitted to each channel on the DK‐200. The bias
voltage/current on each channel should be checked against the sensor
manufacturer’s data sheet to ensure that the bias (or sometimes called
quiescent voltage/current) is within the expected range.
2.4 Read Pmax
With the engine running, it is useful to measure the Pmax being returned
from the sensors. Tapping READ PMAX brings up the screen below.
2‐3
Chapter 2 – DIAGNOSTIC Mode
The test provides an analysis of the Pmax values returned from the sensors
during the test. The Pmax column shows the latest (or instantaneous) value
for each channel while the other three columns provide the minimum,
maximum and average values recorded during the test. To clear the values
and start another test, tap RESET.
Note that the values in bar are based on a nominal sensor sensitivity of
50uA/bar or 12.5mV/bar, and a PScav of 2.0 bar.
2.5 Taking Local Measurements
It is possible to measure and display real‐time traces from all cylinders in
diagnostic mode. Tapping RUN LOCAL brings up the screen below.
Note that there are three types of engine that can be measured, namely a
generic 2‐stroke, a generic 4‐stroke and My Engine where the engine
parameters have been loaded into the DK‐200. Tap the appropriate selection
for the way that the measurements are interpreted and displayed.
2‐4
Chapter 2 – DIAGNOSTIC Mode
Tapping 2‐STROKE selects a generic two‐stroke engine. Make this selection if
the DK‐200 is mounted on a two‐stroke engine and you have not yet
uploaded any engine details to the DK‐200. The display will show an angular
range of ‐180⁰ to +180⁰. Tapping 4‐STROKE will select a generic four‐stroke
engine with an angular range of ‐360⁰ to +360⁰. The generic engines assume
a sensitivity of 50uA/bar or 12.5mV/bar, and a PScav of 2.0 bar.
If you have already loaded an engine into the DK‐200 via the network, you
can select MY ENGINE which will apply the engine parameters. The test now
shows cylinders as it is known which cylinder is connected to which channel.
The red trace shows the cylinder currently selected – use the CYL up/down
arrows to select different cylinders.
2.6 Inserting Network Settings
The network settings for the DK‐200 are set by tapping the NETWORK
SETTINGS button. The screen below will be displayed.
The MAC address of the DK‐200 unit is displayed. The IP Address, Subnet
mask and Gateway for the ethernet network are changed by tapping the
appropriate EDIT button. An example of the IP Address edit screen is shown
below. Simply enter the desired IP address with the dot separator in the
correct places and tap DONE. If you enter an incorrect syntax, the DONE
button will be greyed out.
IMPORTANT: Note that, once editing is completed, the unit must be power‐
cycled for updated network settings to take effect.
2‐5
Chapter 2 – DIAGNOSTIC Mode
The same applies to the Subnet mask and Gateway entries.
IMPORTANT: Note that, once editing is completed, the unit must be power‐
cycled for updated network settings to take effect.
All units on leaving the factory have settings as in the table below. Note that
all units on a network must have a unique IP address. It is essential,
therefore, that appropriate IP addresses are set.
Factory Network Settings
IP Address 192.168.101.101
Subnet Mask 255.255.255.000
Gateway 192.168.101.1
2.7 Reset Default Settings
The default settings can be applied to the DK‐200 by tapping the RESET
DEFAULT SETTINGS button. This erases all engine details held by the DK‐200.
Note that this operation does NOT modify network settings. The screen is
shown below.
2‐6
Chapter 2 – DIAGNOSTIC Mode
Clicking OK brings up the countdown screen shown below. You have 10
seconds to abort the default setting process if you wish by tapping the centre
of the countdown counter.
2.8 System Information
Tapping the ABOUT button provides information about the DK‐200 unit,
including hardware and software versions and date of last calibration. The
size of the internal memory and free space is also shown. The screen is
shown below.
The lower display area on the ABOUT screen is used for testing the
touchscreen. Tapping on the touchscreen shows the X‐Y co‐ordinates in a
range of 640 x 480 of where the tap was detected.
2‐7
Chapter 2 – DIAGNOSTIC Mode
2‐8
Chapter 3 – NORMAL Mode
Chapter 3 – NORMAL Mode
3.1 DK‐200 NORMAL Mode
In normal mode, the DK‐200 operates under the control of a host computer
via an ethernet network. The DK‐200 receives commands from a server
running on a PC and responds to these. The usual sequence is the acquiring
of data, averaging the measurements and transferring the results over the
network.
The main view screen in normal mode is shown below. This can be displayed
by tapping the HOME button in the menu structure. If the system is left in
diagnostic mode, it will revert back to normal mode after 10 minutes if a key
is not pressed (as if the HOME button had been tapped).
The main view screen is shown below.
The screen gives a summary of the overall status of the system, namely
indicated power from the engine at the current RPM, status of the pressure
and crank sensors, and the operation currently being carried out. If the green
border around a parameter turns yellow or red, this means that the
corresponding function is out of limits and should be investigated using
diagnostic mode. A yellow border indicates that alert limits have been
reached as specified in the host application, and a red border indicates that
fail limits have been reached. The sensors are tested before every set of
cylinder measurements to ensure the integrity of the data.
Tapping the TRACES button brings up the screen below. Here the
measurements from the engine can be viewed as graphs, in a table or in
histogram format. The screen below will appear.
3‐1
Chapter 3 – NORMAL Mode
3.2 Graph View
When the TRACES button is tapped, graph view as above is shown first. You
can select the three different views (graph, table and histogram) by tapping
the corresponding button on the right panel. Tapping the CYL up/down
arrows in graph view scrolls through the cylinders. Pmax for the selected
cylinder and engine RPM are shown in the banner at the bottom of the
screen.
3.3 Table View
Tapping the TABLE button brings up table view as shown below.
Key parameters for each cylinder are shown together with, where
appropriate, the average value for all the cylinders. It is possible to see
cylinder values which are deviating from the average.
3‐2
Chapter 3 – NORMAL Mode
3.4 Histogram View
Histograms of Pmax and indicated power can be shown by tapping the HIST
button, as per the screens below. Tapping the Pmax and Power buttons
toggles between the histograms.
3.5 Viewing Engine Parameters
The parameters of the engine can be viewed by tapping on the engine name
at the top left side of the screen. An example screen is shown below. The
left/right arrows toggle through the Cylinder parameters.
3‐3
Chapter 3 – NORMAL Mode
3‐4