InteliBifuel

DENOX
Knocking detector device

HW & SW versions 1.0.0

Copyright © 2014 ComAp a.s.

Written by Jan Kovacka
Prague, Czech Republic
ComAp, a.s. Kundratka 2359/17
180 00 Praha 8, Czech Republic
Tel: +420 246 012 111, Fax: +420 266 316 647
E-mail: info@comap.cz, www.comap.cz
Reference guide
Table of Contents
Table of Contents -2-
Safety notice -3-
General guidelines -4-
What is described in this manual? -4-
Text -4-
Conformity declaration -4-
General description -5-
Function description -5-
Dimensions -7-
Terminals -8-
Harness recommendation -9-
IBF-Denox box LEDs - 11 -
IBF-Denox Installation - 12 -
Inputs and Outputs structure - 13 -
Binary Inputs - 14 -
Binary Outputs - 14 -
Thermocouple analog inputs (TC1-TC16) - 14 -
Synchronization – Timing – Camshaft sensor inputs - 15 -
Sync input DIP switches - 15 -
CAM Mechanical Position (pick-up) sensor - 16 -
Knocking sensor - 17 -
Knocking Sensor Installation - 17 -
Analog output - 19 -
Communication links - 19 -
DenEditBF - 20 -
Main screen - 20 -
Password levels - 22 -
Main Menu - 23 -
Process monitoring - 25 -
Actual knocking values - 25 -
Knocking history - 25 -
Actual misfiring values - 25 -
Diagnose output LEDs - 25 -
Parameters - 26 -
Sound recording - 26 -
Diagnose mode - 27 -
Knocking params - 28 -
Knocking gains - 29 -
Firing sequence - 30 -
Output options - 30 -
Misfiring params - 31 -
Misfiring gains - 31 -
CAN params - 32 -
Status line - 32 -
Configuration procedure - 33 -
TDC Synchronization - 33 -
Technical data - 34 -
IBF Denox - 34 -
Knock sensor (recommended) - 35 -
Active Sensor (recommended) - 35 -
CAN bus interface - 35 -
Appendix A. Configuration example - 36 -
Configuration procedure - 38 -
Cylinder Numbers transformation for IBF-Denox - 38 -

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Safety notice

Important safety information

Study the concrete and approved Technical Documentation (drawings,
operating manuals etc.) to see the final solution for the specific project.
Applied products and parts might be different with each engine and
project.

Important safety information

All restrictions and recommendations on assembly drawing or other
approved technical documentation have higher priority than data in this
manual!

Important safety information

Before working on the system, please read carefully all warnings
hereunder as well as in all other publications. Observe all safety
rules and recommended procedures. Avoid any activities which
could result in personal injuries or damage to the machine and
equipment.

If certain instructions are difficult to understand or doubts arise, as

to how to perform an operation, call immediately the ComAp, a. s.
technical support.

A wrong and incomplete procedure or incorrect setting may cause

an accident and destruction of mechanical as well as other parts of
the internal combustion engine. An incorrect operation of the gas
equipment may lead to an explosion and consequently, to fire. Any
unauthorized and unprofessional intervention may result in personal
injury or death.

Warning!
Keep on mind a knocking is very inadvisable and
dangerous.
Manage the knocking test effectively and avoid engine
knocking for longer time.

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General guidelines
What is described in this manual?
This manual describes knocking monitoring system and its software utility DenEditBF.
Special attention is paid to various upgraded versions of knocking component system.
This manual is intended for everybody who is concerned in general information, in installation, operation and
maintenance of the Knocking detector device.

Text
PAGE (Capital letters in the frame) buttons on the front panel
Break Return (Italic) set points
Generator protections (Bold) Set point group
REMOTE START/STOP (Capital letters) binary inputs and outputs

Conformity declaration

Following described machine complies with the appropriate basic safety and health
requirement of the EC Low Voltage Directive No: 73/23 / EEC and EC
Electromagnetic Compatibility Directive 89/336 / EEC based on its design and type,
as brought into circulation by us.

Note:
ComAp believes that all information provided herein is correct and reliable and reserves the right to update at any
time. ComAp does not assume any responsibility for its use unless otherwise expressly undertaken.

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General description
Function description
IBF-Denox was designed for BiFuel engines without ignition system normally used on gas engines. From this
reason some interface signals have different function – e.g. gas (i.e. engine power) reduction compare to ignition
timing change etc.

During detonating combustion vibrations are generated. Their frequency is typical for specific engine type. Knocking
sensor measures vibration energy in narrow frequency band, where knocking is expected. This energy corresponds
to knocking level. Measurement is executed only during specific section of working cycle, where detonating
combustion is possible. This increases sensitivity and improves immunity against random noise.

IBF-Denox is able to analyze two stroke and four stroke engines with up to 20 cylinders and with maximal ignition
frequency 1 kHz. The knocking detector device can work in three basic modes.
• Measuring mode
• Interface diagnostic mode
• Knocking, misfiring detection mode

Measuring mode
The time mark of camshaft is sent to PC-DenEditBF software via USB communication channel. The signal from
selected knocking sensor is visible in DenEditBF or can be recorded into file. Actually measured knocking sensor
is selected on PC.

Interface diagnostic mode

Values adjusted in Diagnose window are copied to analog and binary outputs of knocking detector device.
Evaluation of knocking is not processed.
List of basic SW functional blocks in Knocking detection mode
• Timing – synchronization of detection process
• Knocking sensor signal processing. It is possible to process up to two sensors currently
• Generating of analog and binary outputs to modify engine gas / load
• Bad sensor detection, broken wire detection
• Controlling of LED indicators of knocking sensors and timing impulses
• Communication with PC
• Communication with controller via CAN bus

IBF-Denox contains:
- 20 channels marked from A to T for knocking and misfiring detection unit and
- two 8 channels Analog inputs for 16 J-K-L thermocouples – temperature or other values measuring

Hint: those modules are functionally equal to InteliAIN8TC modules.

Above three modules are located in single IP67/IP69K box and are accessible over CAN bus as three separate
modules.

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 20 knocking
channels 2 Analog outputs
A-T OUT U / OUT I
DENOX
3 Binary outputs
ISU / IMP BOUT1-3

8 inputs AIN8TC
TC1- TC8 TCL
8 inputs
TC9- TC16 AIN8TC
TCH

CAN 1 CAN 1

IBF Denox - Internal Block Diagram

Hint: configure following three modules in DriveConfig: IBF-Denox, Analog inputs module AIN1 and AIN2. Please
note the default addresses of AIN modules are 1 and 2 and it is possible to modify them in case the default
addresses are engaged ... see PCB layout. For more detail see manual „IBF-Mobile Reference Guide 1.0. or
higher“

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Dimensions

78,5 (3.09")
63,6 (2.5") DETAIL A
A
12,8
117 (4.6") 40,1 (1.58")

6
11
6,5

4 x bracket
Screw Type M6 DIN912
257,6 (10.14")

240 (9.45")

Hexagonal socket head

206,4 (8.13")
242 (9.53")

The IBF-Denox chassis is assembled with two parts (controller case and controller cover). Both parts are connected
together with 19 bolts (2,9 x 16mm).
NOTE:
The unit is completed with two screws for the delivery. The rest of screws are attached so the unit can be completed
before applying. The main reason is to setup the terminator resistors 120 Ohm at CAN 1939 communication line
easily applicable.
Enclosure Type rating: Type 1.
Suitable conductor protection shall be provided in accordance with NFPA 70, Article 240.
Communication circuits shall be connected to communication circuits of Listed Equipment.

Disassembling:
• Screw out 19 bolts from the bottom side of the controller case.
• Gently divide controller cover and case.
• The silicone sealing is lubricated some lube could be present in the joint.

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Assembling:

• Settle the silicone sealing and be sure the sealing is undamaged

• Fit the controller case and cover so that both parts are matching
properly in joint shells.
• Firstly screw up all bolts but do not finalize. Finalize all bolts with
the sequence as shown below. The maximum torque is 1 Nm

Bottom side of box

Terminals

Pins (numbering) location (four rows per 12 pins each, power pins are in bold)
Left side male connector BROWN Right side male connector BLACK
1 2 3 4 5 6 7 8 9 10 11 12 1 49 50 51 52 53 54 55 56 57 58 89 60
13 14 15 16 17 18 19 20 21 22 23 24 2 61 62 63 64 65 66 67 68 69 70 71 72
25 26 27 28 29 30 31 32 33 34 35 36 3 73 74 75 76 77 78 79 80 81 82 83 84
37 38 39 40 41 42 43 44 45 46 47 48 4 85 86 87 88 89 90 91 92 93 94 95 96
A B C D E F G H J K L M A B C D E F G H J K L M

Left side connector BROWN - Pins function

4 3 2 1
37 TC1+ 25 TC1- A 13 A-GND 1 A-IN
38 TC2+ 26 TC2- B 14 B-GND 2 B-IN
39 TC3+ 27 TC3- C 15 C-GND 3 C-IN
40 TC4+ 28 TC4- D 16 D-GND 4 D-IN
41 TC5+ 29 TC5- E 17 E-GND 5 E-IN
42 TC6+ 30 TC6- F 18 F-GND 6 F-IN
43 TC7+ 31 TC7- G 19 G-GND 7 G-IN
44 TC8+ 32 TC8- H 20 H-GND 8 H-IN
45 BOUT1 33 BOUT3 J 21 I-GND 9 I-IN
46 BOUT2 34 BOUT COM K 22 J-GND 10 J-IN
47 +BAT PWR 35 IMP- L 23 11
ISU BL ISU +23V
48 -BAT PWR 36 IMP+ M 24 12
ISU BR ISU GND

Right side connector BLACK - Pins function

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 4 3 2 1
85 TC9+ 73 TC9- A 61 K-GND 49 K-IN
86 TC10+ 74 TC10- B 62 L-GND 50 L-IN
87 TC11+ 75 TC11- C 63 M-GND 51 M-IN
88 TC12+ 76 TC12- D 64 N-GND 52 N-IN
89 TC13+ 77 TC13- E 65 O-GND 53 O-IN
90 TC14+ 78 TC14- F 66 P-GND 54 P-IN
91 TC15+ 79 TC15- G 67 Q-GND 55 Q-IN
92 TC16+ 80 TC16- H 68 R-GND 56 R-IN
93 CAN L 81 CAN H J 69 S-GND 57 S-IN
94 CAN L 82 CAN H K 70 T-GND 58 T-IN
95 +BAT PWR 83 CAN COM L 71 AOUT U+5V 59 AOUT I-

96 -BAT PWR 84 OUT U M 72 AOUT U 0V 60 AOUT I+

Harness recommendation
All 96 signals are connected via two MOLEX CMC 98993 (4x12) 48 pins connectors. Bold (power) items are
connected via MOLEX CMC stronger pins – recommended wires crosscut is 1,5 mm2.

IBF Denox

Connectors

ITEM COMAP ORDER CODE

Set of connectors TERM SET ID-MOBILE

Includes:
right and left connector (black, brown) accessories (pins, plugs)
NOTE: MOLEX connector: Series 64320

Insert the connector until it stops in the header Rotate the lever

Lock it on the cover cap until it clicks

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 Press on the latch Rotate the lever

For more details see:

http://www.molex.com/molex/products/family?key=cmc_connectors&channel=products&chanName=family&page
Title=Introduction

Customer adjustable
AIN1 module CAN Address TC1 – TC8 1 to 16; default 1
AIN1 module CAN Address TC9 – TC16 1 to 16; default 2
CAN bus terminator 120 Ω ON – OFF
ISU input switches DIP switches: 1 – 5 See schematic layout below
IMP input switches DIP switches: 7 – 8 See schematic layout below
Knocking sensors sensitivity

Indicators
CAN status LEDs
Denox Status 4-LEDs
ISU / IMP indication LEDs
BOUT1, ..2, ..3 indication LEDs
CAN data traffic indication
Power-Run-Alarm-Status Visible outside the box – table below
Input activity indication Visible inside on PCB only
BOUT state indication Visible inside on PCB only

Programming interface, diagnostic tools – for internal use.

USB config and test connector Just for internal use
DSP prg interface connector ISP/JTAG
DSP prg. ATlink
DSP boot Jumper
AIN1 prg. ATlink / BOOT jumper TC1 – TC8
AIN2 prg. ATlink / BOOT jumper TC9 – TC16
Hint: all programming interface is for ComAp internal use only. For any module reprogramming ask ComAp
service.

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 Schematic layout of switches on IBF-Denox

IBF-Denox box LEDs

There are four three-color (Green-Orange-Red) indication LEDs with three possible lighting states: OFF, Blink,
Steady.

See function description in table below.

Name on
sticker GREEN ORANGE RED
Steady Blink Blink Steady Blink OFF

PWR = OK; POWER = OK;

POWER No Power
CAN(DenoxData) CAN(DenoxData
= OK ) = Fail
Ignition pulse = No ignition
RUN
OK pulse detected
Bad
ALARM Knocking OK
Sensors
Load
STATUS Trip OK
reduction

IBF-Denox box LEDs

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IBF-Denox Installation
Standard component set is IBF-Mobile + IBF-Denox using the specific harness for system wiring.

Hint: IBF-Denox is currently not supported by other ComAp Inteli-… controllers like InteliGen, InteliSys,
InteliDrive.

Good knowledge of IBF-Denox functionality and configuration possibilities enables simplified wiring or correction
of wiring mistakes. See configuration example in Appendix A

Wire size: 12-26AWG

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Inputs and Outputs structure
Top

Left Right
Bottom

37 TC1+ 85
AIN: TC9+ AIN:
25 TC1- 73
±100mV TC9- ±100mV
38 TC2+ 86
TC10+
26 TC2- 74
TC10-
39 Configurable 87
TC3+ TC11+
27 through 75
TC3- TC11-
40 sensor list: 88
TC4+ TC12+
Thermocouples 28 Type J, K, L 76 Thermocouples
TC4- TC12-
41 TC5+ 89
TC13+
29 TC5- 77
TC13-
42 TC6+ 90
TC14+
30 TC6- 78
TC14-
43 TC7+ 91
TC15+
31 TC7- 79
TC15-
44 TC8+ 92
TC16+
32 TC8- 80
TC16-

1 A-IN K-IN 49
13 A-GND K-GND 61
2 B-IN L-IN 50
14 B-GND L-GND 62
3 C-IN M-IN 51
15 C-GND M-GND 63
4 D-IN N-IN 52
Knocking 16 64 Knocking
sensors D-GND N-GND sensors
5 E-IN O-IN 53
17 E-GND O-GND 65
6 F-IN P-IN 54
18 F-GND P-GND 66
7 G-IN Q-IN 55
19 G-GND Q-GND 67
8 H-IN R-IN 56
20 H-GND R-GND 68
9 I-IN S-IN 57
21 I-GND S-GND 69
10 J-IN T-IN 58
22 J-GND T-GND 70

45 BOUT1 OUTU 84 Analog voltage output

46 BOUT2 OUTU +5V 71 5V power supply
Status bits 33 72
BOUT3 OUTU 0V
34 BOUT COM OUTI - 59 Analog current output
OUTI + 60 + Power supply
Timing input 35 IMP-
IMP 36 IMP+ CAN H 81
CAN L 93
11 ISU +23V 82 CAN1 line*
Timing input 23 CAN H
ISU BL CAN L 94
ISU 24 ISU BR 83
12 CAN COM
ISU GND
47 USB
POWER PLUS
48 POWER MINUS
95 POWER PLUS
96 POWER MINUS

* 2 pairs are prepared to keep correct line arrangement

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Binary Inputs
no Binary input is available on IBF-Denox.

Binary Outputs
three bipolar SSR (Solid State Relay) BOUTs
Active when
ENGINE KNOCKING Analog output
BOUT1 ENGINE KNOCKING Gas reduction (Normalized Analog
Output)> 5%
Trip (knocking OR misfiring)
BOUT2 Trip
See Immediate stop limit
BOUT3 Gas Reduction Analog output Gas reduction
(Normalized Analog Output)=100%

Hint: BOUT Trip has selectable polarity NO/NC by parameter - Output options: Trip Contact Inactive
Binary output wiring example

IBF-Denox
BOUT COM 34

BOUT1 45

BOUT2 46

BOUT3 33
+ BAT PWR
- BAT PWR

48, 96 47, 95

Note:
Rectangle with gray filling represents
internal connection

Thermocouple analog inputs (TC1-TC16)

Up to 16 thermocouples are ready to sense the temperature. The inputs are configured by PC SW DriveConfig
through the main controller like IBF-Mobile. The measured data are transmitted via CAN 1939 communication
line.

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Synchronization – Timing – Camshaft sensor inputs
The reading of TDC of cylinder No.1 is used in the function of timing input. The passive inductive sensor or an
active sensor is used. The sensor is usually installed on camshaft.
Inputs Parameters:
• ISU input – symmetric input, input resistance is by internal DIP switch on PCB. Active sensor interface – it
is possible to connect PNP or NPN sensors.
There are recommended active inductive proximity switching sensors produced by Siemens type BERO
3RG4. Detailed information is available on
http://www.siemens.cz/siemjetstorage/files/9332_Katalog$BERO$3RG4$kompl$01$02$cz$V1.pdf
• IMP input – it is possible to connect passive magnetic sensor, input resistance is by internal DIP switch on
PCB.

IBF-Denox IBF-Denox
ISU +BAT 11 11

+
ISUBL 23 IN PNP 23

IMP+ 36

+
NPN
ISUBR 24 24 IN

35
IMP-
-
ISU GND 12 12

IMP
ISU
Recommended connection of timing sensor - Passive Recommended connection of timing sensor –
magnetic sensor Active inductive proximity switch (PNP/NPN)

Sync input DIP switches

Are located on PCB and enable to adapt inputs resistance for any type of camshaft sensor

Function On = Off =

1 IMP + freq.filter Filter ON Filter OFF

(for higher input noise resistance)
2 IMP DC/AC coupling DC coupling AC coupling

3 IMP Pull Up 1000 Ω Pull Up ON No Pull Up

IMP Rin LOW/HIGH
4 4-On, 5-Off: 8300Ω
between 23-ISUBL and 24-ISUBR
4-0ff, 5-On: 8300Ω 4-Off, 5-Off: 10000 Ω
IMP Rin LOW/HIGH
5 4-On, 5-On: 4500Ω
between 23-ISUBL and 24-ISUBR
6 N/A
ISU Rin between
7 220 Ω 1000 Ω
23-ISUBL and 24-ISUBR
ISU Rin LOW/HIGH
8 220 Ω 1000 Ω
23-ISUBL and 24-ISUBR

Hint: switch 7 and 8 must be switched ON or OFF together – i.e. acceptable state is both On or both Off.

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CAM Mechanical Position (pick-up) sensor
Camshaft sensor answers the purpose of synchronization of acoustic engine signals to work cycle of the first
cylinder. The sensor identifies the dead-point of 1st cylinder, which is followed by fuel combustion period. The
pulse corresponds to the passage of the pin.
The front edge of the pulse must to precede the Detonation evaluation window, i.e. Detonation window delay
must be more than 0 (see Knocking params card). However the front edge may occur after finishing of the
Detonation evaluation window assigned to the cylinder combusting as the last in previous working cycle only.
There is implemented Sync input diagnostics: The SPURIOUS PULSE indication LED is activated when sensor
(including wiring) gives more or less pulses than expected in actual state.

Description and Function: Top Dead Center (TDC) of combustion cycle sensing for Denox unit.

Location: Camshaft cover or any location suitable for specification of TDC of combustion
cycle (CAM front cover, CAM side cover, Drive with same RPM equivalent to
camshaft RPM)

Installation: Camshaft Position sensor (Active pick-up) must be place at TDC (the tolerance is
from 5° up to 15° before TDC) of the 1st cylinder - combustion cycle (NOT exhaust
cycle). Principal schematic drawing of the position see picture 5.0a

CAM Sensor and Pin Example of Installation CAM pin schematic drawing

Warning!
Any incorrect installation of the CAM pin will cause the knocking
detection system functionless and the engine will be not protected
against dangerous detonation.

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 Rules and Restrictions
Have in mind the following:
• Verify rotation direction of the Camshaft.
• Set the distance in between the pin and position sensor properly
• Crank the engine drive slowly first to be sure all position points are
correct and no any collisions in between the pin and sensor
(eventually pin and other engine parts) are arising.

Knocking sensor
The recommended sensor type is piezoelectric acceleration transducer Bosch; O 261 231 006

There are 20 inputs organized in two odd-even channels. Internal switch on PCB enables switch sensitivity in two
steps - Lo/Hi.
Up to 20 analog inputs are ready to sense acoustic signals of cylinders to recognize and evaluate the respective
knocking.
Parameters:
• AC coupled
• Signal amplification switchable in two levels. Respective jumper plug is not available to user.
• Input resistance at least 1 M

Sensor fails are transmitted over CAN to IBF-Mobile to be visible in IMON (or on connected InteliVision display)
and reported in history).
In case of IBF-Denox fail can be sensor easily configured on other physical input (in case there are free ones).
Hint: Version IBF-Denox-1.0 does not support using one knocking sensor for two cylinders.

Knocking Sensor Installation

Description and Function: Sensing of combustion noise for knocking detection system (DENOX)

Location: As closest to the combustion chamber as possible. Most commonly on cylinder

head or engine block on each cylinder.

Installation: The Knocking Sensor is mechanically installed on a suitable place with bolt or stud
bolt. The sensors must rest directly on their metal surfaces. Use must not be made
of packing plates, spring or toothed lock washers for support. The contact surface
of the mounting hole must be of high quality to ensure low-resonance coupling of
the sensors to the measurement location. The sensor cable is to be laid such that
no resonance vibration can occur. The sensor must not be allowed to have contact
with liquids for lengthy periods.

Rules and Restrictions:

• The sensor must be installed without any washer.
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 • The sensing surface must completely seat on the straight surface.
• Have in mind the sensor must be easily removable if the engine is
maintained.
Caution:
The knocking sensor must be installed without any washer or any additional equipment which could change the
correct sensing.
Note:
A heat shield for knocking sensor is highly recommended. Knocking sensor operating temperature 130°C max.

Knocking sensor installation example

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Analog output
Analog outputs: GAS REDUCTION is transferred over CAN bus to IBF-Mobile. Vice more there are two hw
analog outputs 5V/10mA or 4-20mA working from GAS REDUCTION signal source. GAS REDUCTION value is
visible in DenEditBF on gauge Normalized analog outputs.
Measured knocking energy in every working cycle is compared against adjustable “Gas Reduction Limit”. If the
intensity of the knocking is higher than limit then analogue output GAS REDUCTION increases. When knocking
energy falls under the limit then the value of analogue output decreases. Decreasing rate depends on “Decrease
ramp” setpoint.
If the “Gas Reduction Limit” is over crossed and the Analog output Gas reduction (Normalized analog output) is
higher than 5% then the binary output ENGINE KNOCKING is activated. The minimal duration of ENGINE
KNOCKING output is 0,5sec.
If full scale of analog output GAS REDUCTION is reached and engine is still knocking the GAS REDUCTION binary
output is activated. It should be connected to controller and used as command for engine gas reduction.
When the engine stops knocking, output LOAD REDUCTION is deactivated, but analog outputs remain at full scale
for another period which can be set by Delay after gas reduction setpoint and begin decrease after this period
elapses. The decrease period should be longer than time engine require reaching full load again.
The last binary output TRIP is activated when knocking energy is greater than immediate stop limit. It should be
used as emergency stop signal.

IMMEDIATE
STOP LIMIT

GAS REDUCTION
KNOCKING LEVEL LIMIT

GAS REDUCTION
(BINARY OUTPUT)

TRIP
(BINARY OUTPUT) MAX LEVEL
OF ANALOG
OUTPUT
DECREASE
RAMP
NORMALIZED ANALOG
OUTPUT
DELAY AFTER
(ANALOG OUTPUT) GAS REDUCTION
GAS REDUCTION
GAIN

Communication links
CAN Open, galvanic separation, 1 CAN connector
USB – minimal required speed 90 kB/s (44.1 kHz, 16 bit), type of connector B.
This connector is used for transfer of acoustic signals and for control/set of Knocking detector device.

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DenEditBF
DenEditBF is compatible with following Denox types:
Denox-2; Version: 1.0 to 1.3 (incompatible with higher)
Denox-20; Version: 1.0 to 2.5 (incompatible with higher)

DenEdit BF is PC tool for IBF-Denox setting and monitoring. Parameters setting can be provided in both Off-line
and On-line mode.

Main screen

1 – Main menu
2 – Toolbar
3 – Graphic displays of analog output and knocking intensity
4 – Status and fault LEDs
5 – Cards for process monitoring(The picture visualizes a 20-sensor version of device in OFF-line mode)
6 – Cards of settings and parameters
7 – Status bar

There are three parts (fields) in the main DenEditBF window where the folders visibility depends on password
level - see below.
• Indicators: General values gauges, Status LEDs, Error LEDs
• Bar graphs and indication for all cylinders actual states - folders
• Parameter folders

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Indicators
Indicators operate On-line mode. Those values are visible using InteliMonitor connected to IBF-Mobile controller
communicating with IBF-Denox over CAN1 as well.
Indicates actual analog value GAS REDUCTION transformed
Normalized analog on analog outputs AOUT-U (0-5VDC) or AOUT-I (4 - 20mA)
0,0% - 100,0%
output where 100% means 5V or 20mA
Output is transmitted over CAN to IBF-Mobile controller.
Adjustable in Mode
Display Minimal or Maximal value from all or one selected
Minimal, cylinder.
Maximal, If single cylinder is selected then the knocking intensity of this
Knocking intensity Single cylinder channel is displayed.
Independently on the selection in Display menu the cylinder
with actually maximal knocking intensity is visualized in the
upper right corner. Appropriate number of the cylinder is
displayed too.
KNOCKING Indicates active engine knocking at least on one cylinder
TRIP Indicates active binary output TRIP
Status LED's
REDUCTION Indicates active GAS REDUCTION function
MISFIRING Indicates detected Misfiring at least on one cylinder
LOW RPM Indicates zero and low RPM.
NO ISU PULSES No impulses are detected in SYNC INPUT ISU or IMP.
The engine is stopped or sensor and/or cable are damaged.
Impulses in SYNS INPUT ISU or IMP are erratic, irregular.
SPURIOUS PULSES Possible reason: Timing sensor does wrong, low sensitivity of
Errors LED's the Timing sensor or electric disturbance and noise. Wrong
selection of SYNC method.
EEPROM FAULT Wrong checksum after power up.
Faulty sensor number is possible to identify on the card
BAD SENSOR Actual knocking values. Bad sensor’s identification number is
marked by red color on the card Actual knocking values.

Hint: There is change in the meaning of Cylinder number for IBF-Denox in DenEditBF !
In previous versions of Denox device Cylinder number represents firing order. For new IBF-Denox Cylinder
number represents engine cylinder number. This change is thanks to Configuration table and possibility to assign
different Cylinder number to appropriate Denox channel.

Bar graphs for on-line process monitoring

Displaying of individual cylinder status using the identification color:
• Active sensor – green
• Passive (not used) sensor – grey
Actual knocking
0,0% - 100,0% • Bad (faulty) sensor – red
values Graphical displaying of actual knocking intensity of individual
cylinders. The grey, yellow and red areas mean the knocking intensity
limits. Boundaries g-y-r are defined by Ignition reduction limit and
Immediate stop limit in Output options card
One minute (fix time) report of knocking intensity of all active
Knocking history 0,0% - 100,0% channels.
Hint: Diagnostic tool for optimal parameters setting.
Indicator of actual difference between each cylinder noise and
Actual misfiring values ±100% average value. Yellow line = Wrn misfiring limit; Red lines = Misfiring
limit – for Misfiring counter activation.
Diagnose output LED On/Off Indication of both Knocking and Misfiring for all cylinders.

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Password levels
There are three access levels in On-line mode: locked, Operator and Administrator as highest level.

Off-line Enables editing of all parameters and saving to file.

Locked
Operator Invisible: Diagnose LEDs
On-line I – level Engine configuration: ReadOnly
Administrator The highest level. All values and parameters are visible and
II – level possible to edit.

Cylinder configuration Y n.a. ReadOnly Y

Value folders:
Actual Knocking values n.a. Y Y Y
Knocking history n.a. Y Y Y
Actual misfiring values n.a. n.a. Y Y
Diagnose output LEDs n.a. n.a. n.a. Y
Parameter folders:
Mode Y ReadOnly Y Y
Knocking params Y n.a. n.a. Y
Knocking gains Y n.a. n.a. Y
Firing sequence Y n.a. n.a. Y
Output options Y n.a. n.a. Y
Misfiring params Y n.a. n.a. Y
Misfiring gains Y n.a. n.a. Y
CAN params Y Y Y Y
Sound frecording n.a. n.a. Y Y

Hint: changed parameters are written to IBF-Denox one by one after Enter key hit in On-Line mode. Engine
configuration is written to IBF-Denox after the OK button is pressed.

Locked

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 Operator view

Administrator view

Main Menu

Connection
Connect USB On-line connection is necessary for Parameters setting and IBF-Denox
monitoring.
Disconnect Close connection.

Open Get all parameters setting from file.

parameters
Save as Save actual parameters settings and cylinder configuration to „*.dep” file – in
directory Parameters.
Hint: archive valid IBF-Denox settings for future engine service.
Exit Exit DenEditBF.

Controller
Enter password Three protection levels are available Locked, Operator and
Administrator.
Deactivate password Lock most of parameters change and values monitoring.
Change password Max. 5 numeric characters
Get encrypted In case you forgot the password ComAp can encrypt password from
password this code (like password decode in Inteli controllers).
Device type Denox2 Compatibility with different Denox types. Selected Device type stays for
Denox20 next DenEditBF start-up.
IBFDenox
Device SW ver.1.0 Software version info related to connected Denox.
Reset peak value Reset Knocking intensity max/min gauge.

Engine – Engine settings

Engine type specification and relation between Cylinder number, Denox channel and Firing order – see more
detail in configuration Example.

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Hint: Cylinder number assignment in Cylinder configuration is valid for all parameters and values in DenEditBF.

Example: Knocking intensity, gains, misfiring status and other items visible under cylinder number 7 are applied
to Denox channel G which fire 7th in the order.

Help – About

Hint: Report DenEditBF and IBF-Denox version when asking for ComAp technical support.

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IBF-Denox-1.0.0-Reference Guide.pdf
Process monitoring
Actual knocking values
Intensity scale:
• Displaying of minimal, maximal and average knocking intensity from all cylinders
• Displaying of peak value of knocking (yellow triangle)

Hint: Bar graphs numbers correspond to engine cylinder numbering – compare to previous version (Denox2/20)
where it was firing order.

Knocking history
• Knocking history from active sensors in last 1 minute
• Displaying of maximal knocking value (yellow dashed line)
• Possibility to set sensor channel as active via click on legend (same as on Mode card)

Actual misfiring values

• Displaying average noise of whole engine in right upper corner
• Displaying actual misfiring deviation

Diagnose output LEDs

• Visualization knocking and misfiring status – useful for function LED Latch

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Parameters
Most of parameters are protected by password against modification. There are two levels – see chapter above.

The setpoints are not written into Knocking detector device immediately. After the setpoint is
edited the setpoint value is marked by blue color. The setpoint is written to Knocking detector
device after ENTER key is pressed only. Mode
Selection of cylinders for knocking analysis.
Analyzed cylinders
Hint: One or more cylinders can be switched off for system diagnostics.
Sound recording See details below …
Min Selection value displayed on knocking gauge in the middle of upper field:
Minimal knocking value from all cylinders
Display Max
Maximal knocking value from all cylinders
Single Knocking value of just one selected cylinder
Enable knock LED On/Off The any cylinder knocking indicator stays active even after “single knock”
latch detection when Enabled. Operates for Diagnose output LEDs as well as for
STATUS- ENGINE KNOCKING.
Knocking Diagnose and Status LED are automatically switched off after
Switch OFF/ON to
knocking disappears when Knock LED latch is disabled.
reset
Knocking detector device diagnostics
It is possible to set binary output signals by setting in appropriate
Diagnose checkboxes.
It is possible to change value of regulation output in Reg. Output box
It is possible to set IBF-Denox status LEDs

Sound recording
Options:
All cylinders record (cycle)
Selected cylinders record (cycle)
Single cylinder record
Selected sens. (cylinders) = ALL
Set Record time length in range 1 to 60s
Press Start button and confirm file name. Each cylinder is
automatically recorded one by one in separate files while the
Recording sound file window appears. File names are created
automatically. Recording cycle can be stopped any time pressing the
Stop button.
Selected sens. (cylinders) = SEL
Set Record time length in range 1 to 60s
Press Start button and confirm file name. Only cylinders marked as
Analyzed in Mode folder are recorded in separate files. File names are
created automatically to easy identify content. Recording cycle can be
stopped any time by pressing the Stop button.
Select sensor (cylinder) in range from A to T (i.e. IBF-Denox knocking
input) with cylinder number in brackets (that corresponds to cylinder
configuration).
Press Run button, confirm or modify file name and target directory.
The Recording sound file window appears. The record runs until Stop
button is closed.

Automatic file name - example:

IBF_2015-11-18_15-44-48_Ch-A_Fir-1_Cyl-1.au … where
IBF Connected device type: IBF-Denox
2015-11-18 Date: 18. November 2015
15-44-48 File Save Time: 15hour, 44minutes, 48 seconds
Ch-A_Fir-1_Cyl-1 Info: Denox channel-A, FiringOrder-1,Cylinder-1

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 Warning!
Knocking protection is deactivated during samples
recording!
Mind a knocking is very inadvisable and dangerous.

Diagnose mode
Enables simulation of
- all three Binary outputs BOUT1-Knocking, BOUT2- GasReduction, BOUT3 – TRIP to check functionality of
IBF-Denox interface.
- Analog output Gas reduction in full range 0,0 to 100,0%
- IBF-Denox Status three-color LEDs located on IBF-Denox box. Activation both RED and GREEN color
simulates ORANGE color.

Warning!
Standard IBF Denox function is blocked when Diagnose
is active!
Mind a knocking is very inadvisable and dangerous.

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Knocking params
st
Deton.window Delay of the beginning of 1 cylinder detonation measuring interval
0,0° -180,0° after camshaft synchronization impuls. The front edge of
delay (*)
synchronization impuls is considered. The parameter represents the
angle as a relative part of working cycle (4-stroke engine … 720°)
Knock filter 305 – 15070 Hz Characteristic frequency of knocking
frequency
Attenuation 0,000 – 1,000 Attenuation ratio with selection between KNOCKing or REFerence
noise channels.
Deton. Window Angle interval of knocking evaluation during bi-fuel combustion. The
0,0° -60,0°
with (*) parameter represents the angle as a relative part of working cycle (4-
stroke engine … 720°)
Ref.filter frequency 305 – 15070 Hz Characteristic frequency of background noise independent on the
knocking.
Hint: Parameters marked (*) are available (is possible to modify/adjust) from InteliMonitor or DriveConfig.

Cycle /
cylinder count x nr.cylinder

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Knocking gains

The gain of each input signal is possible to set in the range 0 – 300. The pushbutton Default causes the setting of
all input signal gains to 100.
Recommended procedure of Input gains tuning:
o Record acoustic signals from all channels using DenEditBF.
o Check envelopes of records. Signals peaks must not be limited by the maximal amplitude of knocking
detecting device input amplifier. Take in account maximum engine load and eventual knocking amplitude.
o If signal peaks are limited in any channel then remove both jumpers defining the amplification. Jumpers
are covered inside of a knocking detecting device.
o Adjust function as follows:
o Set the initiate values of Input gains setpoints to 100.
o Set the ref. Filter frequency to 10120Hz.
o Set Knock filter frequency to value corresponding to background noise.
o Set Attenuation to 1,000
o Tune Input gains to balance knocking-like signals columns. Examples see below – cylinder number 6.

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Firing sequence
Table appears in case an Irregular engine type is configured in Engine setings
Output options
(*)
Ignition reduction limit
(*)
Immediate stop limit
(*)
Decrease ramp
(*)
Gas reduction gain
Maximum output value
Delay after gas reduction (*)
Reverse analog output
Enable max.out setting
Enable knock LED latch
switch on/off to reset
Enable bad sensor detect
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Maximal acceptable level of knocking detection signals from
0,0% –
all selected cylinders. While exceeded, the knocking state is
100,0%
reported.
0,0% – For binary output TRIP activation.
100,0%
If the knocking state is not detected (see the setpoint Ignition
0,0%/s – reduction limit above) then analog output (value) GAS
100,0%/s REDUCTION decreases with the speed defined by Decrease
ramp setpoint.
If the knocking is detected (see the setpoint Ignition reduction
limit above), the analog output GAS REDUCTION signal is
0,0% –
increasing. The speed of the rise is given by the setpoint
100,0%
Timing reduction gain. The speed of increasing is equal to
arithmetic multiplication of gain value and knocking value.
Max. value of analog output GAS REDUCTION limit. The
0,0% –
setting is enabled if the setpoint Enable max. output setting is
100,0%
set to ON only. … ???
The delay of the GAS REDUCTION decreasing starts after
0,0s – 25,4s
the knocking state is over (disappears).
If checked then the maximal value of analog output GAS
Y –N
REDUCTION means no knocking and vice versa.
If checked then it is possible to set the maximal level of
Y–N analog output GAS REDUCTION. (see the setpoint Maximum
output value above).
Corresponding cylinder Diagnose indicator stays active when
knocking was detected till this Enable tick on/off reset ... as
Y–N well as the STATUS ENGINE KNOCKING LED. Indicators
disappear automatically when no knocking and this option is
disabled.
Related to ERRORS BAD SENSOR LED
If checked then detected failure of sensor is latched and
signalized on relevant knocking/misfiring sensor’s LED.
Y–N Sensor failure blocks both knocking and misfiring detection
on relevant cylinder (is not counted to average), but sensor
value is indicated as Actual knocking and Misfiring value.
- 30 -
 CLOSE NO – NC output logic selection
Trip contact inactive
OPEN
The name identifying the parameter set. The length may be
Max 15 up to 15 characters. The parameter is visualized on upper
Name of controller ASCII side of frame of program window.
characters.

Hint: Parameters marked (*) are available (is possible to modify/adjust) from InteliMonitor or DriveConfig.

Misfiring params

Background noise limit (average from all cylinders) for

misfiring detection activation. No misfiring detection
Firing limit (*) 0,0% – 100,0%
below this limit (to avoid wrong misfiring detection e.g.
during the engine idle – low noise state).
Max difference between average value and each single
Misfiring limit (*) 0% – 100% cylinder. The cylinder misfiring is detected when
difference is higher than limit.
Wrn Misfiring (*) 0% – 100% Serves just for indication and diagnostics.
Number of misfiring occurrences (each single case
when cylinder is below Misfiring limit compare to
average) counted for each cylinder separately. The
Misfiring count 0 - 100 Binary output TRIP is activated when count reaches the
limit and Misfiring trip is enabled.
TRIP is deactivated after first correct working cycle.
Analog output is not activated by Misfiring function.
The binary output TRIP can be activated by misfiring as
Misfiring trip enabled Y-N
well when misfiring count is reached.
Corresponding cylinder Diagnose indicator stays active
when misfiring was detected till this Enable tick on/off
Enable misfiring LED latch reset ... as well as the STATUS MISFIRING
Y–N
switch on/off to reset LED.Indicators disappear automatically when no
misfiring and this option is disabled.

Hint: Parameters marked (*) are available (is possible to modify/adjust) from InteliMonitor or DriveConfig.

Misfiring gains

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Gains serve for balancing of separate channel signals due to different sensor sensitivity, wiring or location on the
engine. Can be used for diagnostics of single channels or sensors: switching one signal off to check if this one
could cause existing problems or not.

The gain of each input signal is possible to set in the range 0 – 300. The pushbutton Default causes the setting of
all input signal gains to 100.

CAN params

CANOpen mode For third party controllers.

Communication mode
Inteli-controller
Address 79 is dedicated for Comap’s intelli-controller
CAN address 1 – 127
communication
Adjustable just for CAN open mode
Bus speed 50 – 1000 kb/s
Constant 250 kb/s for Intelli-controller

Status line

The status line on the window frame displays

• Brief help concerning icon pointed by the cursor
• Communication status
• Software version of knocking detector device
• Type of knocking detection device (D-2, D-20, IBF, …)

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Configuration procedure
Configuration can be provided in both On-line or Off-line mode without IBF-Denox.
Is fully recommended knock sensors assigning into the IBF Denox channels according of cylinders firing order
even DenEdit BF can manage various cases.
1st cylinder in combustion order – channel A
2nd cylinder in combustion order – channel B
…
Xth cylinder in combustion order – channel T
Based on engine type and installation go through following steps:
Step 1. Set or check correct Device type: see Menu Controller-Device type.
Step 2. Engine – Engine settings – Cylinder configuration´

1. Select Engine type: cylinder count, 2/4 strokes, V-type and angle. if any.
Hint: Some other tables and bargraphs are reduced according the Cylinder count.
2. Fill table Denox channel A .. N and Cylinder number according existing sensor wiring.
3. Select Sync input and method.
4. Use Check cylinder configuration to avoid come prohibited setting and duplicities.
Sharing sensors – not applicable in version 1.0.

TDC Synchronization
There are two physical inputs for process synchronization ISU and IMP.
ISU Active sensor with open collector output
IMP Passive magnetic pickup
Sync method – see pictograms in Cylinder configuration.

One gap / pulse for 1-st TDC. For 1-st TDC

Missing gap / pulse for 1-st TDC.
Double gap / pulse for 1-st TDC.
Double for 1-st and single for other cylinders.

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Technical data
IBF Denox
Parameter Specification
Timing input ISU Active pickup with PNP or NPN output or ISU
Type of sensor Input resistance 220/1000Ω
Max. input voltage
• LOAD RESISTANCE 220Ω … 24V
• 1kΩ … 36V
Max. frequency 1kHz
Timing input IMP M
Type of sensor agnetic pick-up
Minimum input voltage 3 Vpk-pk (from 4 Hz to 4 kHz)
Maximum input voltage 50 Veff
Minimum measured frequency 4 Hz
Maximum measured frequency 10 kHz (min. input voltage 6Vpk-pk)
Knocking sensors inputs Input resistance >1M Ω
Binary outputs All three outputs have one common terminal,
max. voltage is 36V, max. load current is 150mA
Analog outputs 1) 0 to 5V, load current max. 2mA
Voltage accuracy ± 0.5% + ± 50mV
Note: auxiliary power source 5VDC is needed
2) current loop 4-20mA passive, max. voltage 30V
Current accuracy ± 2% + ± 200uA

Operating conditions Surrounding air temperature rating 80°C

Suitable for pollution degree 3
Low voltage circuits (35 volts or less) shall be supplied
from the engine starting battery or an isolated
secondary circuit
Operating Temperature range -40 ÷ +80°C
Storage Temperature range -40  +80oC
Humidity 97% without condensation
Power supply 8  36 V DC
Consumption 150mA/24V, 4W max.
USB USB 1.1, 1MB/s, connector type “B”
CAN Galvanic isolated, 250kBd
Degree of protection IP 69k
Dimension – electronic unit 240x260x78 mm
Weight 1,2 kg
Standard conformity EN 61010-1:95 +A1:97
Low Voltage Directive EN 61000-6-2, October 2001
Electromagnetic Compatibility EN60068-2
Vibration N 61000-2-6
N 61000-2-27
Environmental EN 61000-2-1
N 61000-2-2
EN 61000-2-30

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Knock sensor (recommended)
Parameter Specification
Sensor principle Piezoelectric acceleration transducer
Sensor type Bosch O 261 231 006
Frequency range 0,3 kHz – 20 kHz
Resonance frequency > 20 kHz
Temperature range -40  +130°C
Dimension – sensor 45 x 20 x 21 mm
Sensor mounting M8 x 25 (cast iron)
M8 x 30 (aluminium)

Active Sensor (recommended)

Parameter Specification
Sensor principle Active inductive proximity switching sensor
Sensor type Siemens 3RG40 22 active pick-up (NPN/PNP)
Power supply 15  34VDC
Temperature range -25  +85°C
Dimension M12 x 65mm
Weight ≤ 0.1 kg
Sensor mounting Female screw M12 x 1

CAN bus interface

Maximal CAN bus length
Basic setting: CAN bus mode 200m
Speed 250kBd
Nominal impedance 120
Cable type twisted pair (shielded)

Following dynamic cable parameters are important especially for maximal 200 meters CAN bus length and 32 ID-
COM units connected:
Nominal Velocity of Propagation min. 75% (max. 4,4 ns/m)
Wire crosscut min.0,25 mm2
Maximal attenuation (at 1 MHz) 2 dB / 100m

Recommended Industrial Automation & Process Control Cables:

BELDEN (see http://www.belden.com):
• 3086A DeviceBus for Honeywell SDS
LAPP CABLE (see http://www.lappcable.com)
• Unitronic BUS DeviceNet Trunk Cable
• Unitronic BUS DeviceNet Drop Cable
• Unitronic BUS CAN
• Unitronic-FD BUS P CAN UL/CSA

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IBF-Denox-1.0.0-Reference Guide.pdf
Appendix A. Configuration example

Important safety information

IBF-Denox installation and configuration is very specific and

sophisticated procedure that must be provided by trained and
authorized person only. Wrong installation and settings can cause
engine damage in case it does not indicate knocking properly.

Below configuration examples are just simple and standard ones.

There is much more an option due to IBF-Denox system flexibility and
it is not possible to describe all of them. Specific installation cases
please consult with ComAp technical support.

First of all you need detail engine data. Suppose to install IBF-Denox on engine type KTA50 – see specification
on Figure 1 below.

There are following parts of installation procedure:

- Install synchronization mark as sensor.
- Configure IBF-Denox using DenEditBF.
- Install and wire knocking sensors according configuration.
- Setup all parameters.
- Check the function – simulating knocking and/or misfiring.
- Archive configuration for future service.

The first example suppose installation of passive inductive sensor installed on timing reference wheel on
camshaft against single “screw” mark located slightly before 1-st cylinder TDC.

The second example suppose the same engine but single TDC mark installed on 6-th cylinder (e.g. due to
mistake or mechanical problems – impossibility to put mark on the 1-st cylinder). The knocking sensors wiring
can stay without changes, just IBF-Denox Cylinder configuration change is needed.

The third example comes from 2-nd example but suppose IBF-Denox has destroyed one knocking sensor input
– e.g. Channel B (it means wrong input, wrong connector or cutted wire in harness ... possible but difficult to
repair).

Knocking sensors in all examples are installed one sensor per each cylinder.

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 Figure 1 - KTA50 Engine specification

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Configuration procedure
Example 1.
Open DenEditBF and select menu item Engine - Engine settings and open
Configuration – Cylinder configuration window

Figure 2 - Cylinder configuration - default

According Engine Specification set following parameters:

V-type
V-angle = 60°
4-stroke
Cylinder count = 16
Sync input = ISU (passive inductive sensor)
Sync method = single positive mark (pin on timing reference wheel on camshaft)

Figure 3 - Cylinder configuration 1-st step

Cylinder Numbers transformation for IBF-Denox

Engine specification uses the same cylinder numbering 1 to 8 for both Left and Right bank – but DenEditBF
configuration window uses numbering in range 1 to 16.
Based on this numbering we can transform firing order from specification:
Table 1 - Firing order

Denox Channel A B C D E F G H I J K L M N O P
Firing 1R 1L 3R 3L 2R 2L 5R 4L 8R 8L 6R 6L 7R 7L 4R 5L
sequence
Cylinder No. 1 9 3 11 2 10 5 12 8 16 6 14 7 15 4 13

Fill Table 1 into DenEditBF - Cylinder configuration window

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Figure 4 - Cylinder configuration after 2-nd step

Hint: Red color Cylinder number during configuration procedure indicates numbers duplicity (i.e. this cylinder is
twice in table). The Check Cylinder conf. button does the same.

The relation between Cylinder no. and Denox channel in table – Figure 4 specify the knocking sensors wiring.

Example 2.
The same engine and sensor wiring but single TDC mark is installed on 6R-th (i.e. 6-th) cylinder.

When we go back to Table 2 – Firing order we can easily transform

Table 2 - SYNC on 6-th cylinder

Firing Order
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
(Denox)
Denox Channel A B C D E F G H I J K L M N O P
Cylinder No. 1 9 3 11 2 10 5 12 8 16 6 14 7 15 4 13
Table 2 - after Synchronization pin was installed to 6R- 6th cylinder.
Denox Channel K L M N O P A B C D E F G H I J
Cylinder No. 6 14 7 15 4 13 1 9 3 11 2 10 5 12 8 16

To keep existing knocking sensor wiring from Example 1 without changes – the configuration looks as below.

Figure 5 – Synchronization mark is before 6th cylinder (6R)

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Example 3
comes from 2-nd example but suppose IBF-Denox has destroyed input – e.g. Channel B.
Compare to Figure 5 there is on position Firing order 8 (odd – black) Denox channel = R instead (wrong) channel
B. – just simple one change.

Hint: There are only two free „even“ IBF-Denox channels R or T for this case. „Odd“channels S and U are
blocked as replacement of „even“ B but can be used as replacement of e.g. C or other odd channels.

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