Heinzmann GmbH & Co. KG
Motor- & Turbinenmanagement
Am Haselbach 1
D-79677 Schönau
Telefon +49 (0)7673 8208-0
Telefax +49 (0)7673 8208-188
E-Mail info@heinzmann.com
www.heinzmann.com
USt-IdNr.: DE145551926
HEINZMANN
Digital Electronic Speed Governors
Digital Basic System
PANDAROS - II
DG 2010.6-01 up to -05
DG 2040.6-01 up to -05
DG 2080.6-01 up to -05
All rights reserved. This publication may not be reproduced by any means whatsoever or passed on to any third parties.
Manual DG 01 002-e / 12-17 8155
Copyright 2017 by Heinzmann GmbH & Co. KG.
The appropriate manuals must be thoroughly studied before installation, initial start-up and maintenance.
All instructions pertaining to the system and safety must be followed in
full. Non-observance of the instructions may lead to injury to persons
and/or material damage.
HEINZMANN shall not be held liable for any damage caused through
non-observance of instructions.
Independent tests and inspections are of particular importance for all
applications in which a malfunction could result in injury to persons or
material damage.
All examples and data, as well as all other information in this manual
are there solely for the purpose of instruction and they may not be used
for special application without the operator running independent tests
and inspections beforehand.
HEINZMANN does not guarantee, neither expressly nor tacitly, that
the examples, data or other information in this manual is free from error, complies with industrial standards or fulfils the requirements of any
special application.
To avoid any injury to persons and damage to systems, the following monitoring and protective systems must be provided:
Overspeed protection independent of the rpm controller
HEINZMANN shall not be held liable for any damage caused through
missing or insufficiently rated overspeed protection.
thermal overload protection
The following must also be provided for alternator systems:
Overcurrent protection
Protection against faulty synchronisation for excessively-large frequen-
cy, voltage or phase difference
Directional contactor
The reasons for overspeeding may be:
Failure of positioning device, control unit or its auxiliary devices
Linkage sluggishness and jamming
The following must be observed before an installation:
Always disconnect the electrical mains supply before any interventions
to the system.
Only use cable screening and mains supply connections that correspond
with the European Union EMC Directive
Check the function of all installed protection and monitoring systems
Digital Governor Basic System PANDAROS II
Please observe the following for electronically controlled injection
(MVC):
For common rail systems each injector line must be equipped with a
separate mechanical flow-rate limiter
For unit pump (PLD) and pump-injector unit (PDE) systems, the fuel
enable is first made possible by the solenoid valve’s control plunger
motion. This means that in the event of the control plunger sticking, the
fuel supply to the injection valve is stopped.
As soon as the positioning device receives power, it can actuate the
controller output shaft automatically at any given time. The range of the
controller shaft or control linkage must therefore be secured against unauthorised access.
HEINZMANN expressly rejects any implied guarantee pertaining to
any marketability or suitability for a special purpose, including in the
event that HEINZMANN was notified of such a special purpose or the
manual contains a reference to such a special purpose.
HEINZMANN shall not be held liable for any indirect and direct dam-
age nor for any incidental and consequential damage that results from
application of any of the examples, data or miscellaneous information
as given in this manual.
HEINZMANN shall not provide any guarantee for the design and planning
of the overall technical system. This is a matter of the operator its planners
and its specialist engineers. They are also responsible for checking whether
the performances of our devices match the intended purpose. The operator is
also responsible for a correct initial start-up of the overall system.
Digital Governor Basic System PANDAROS II
Contents
Contents
Page
1 Safety instructions and related symbols .............................................................................. 1
1.1 Basic safety measures for normal operation 2
1.2 Basic safety measures for servicing and maintenance 2
1.3 Before putting an installation into service after maintenance and repair works 2
2 General ................................................................................................................................... 3
3 Functions ................................................................................................................................ 4
3.1 General functions 4
3.2 Variation specific additional functions 6
3.2.1 Variation DC 6-01 (Standard Generator) ................................................................. 6
3.2.2 Variation DC 6-02 (Standard General) .................................................................... 6
3.2.3 Variation DC 6-03 (Extended Generator) ................................................................ 6
3.2.4 Variation DC 6-05 (Extended General, especially vehicle) .................................... 7
3.2.5 Variation DC 6-00 (ful flexibility) ........................................................................... 8
3.2.6 Variation DC 6-06 (positioner) ................................................................................ 9
4 Further information ............................................................................................................ 10
5 Block diagram ...................................................................................................................... 11
6 Sensors .................................................................................................................................. 12
6.1 Overview 12
6.2 Magnetic pick-up IA ... 13
6.2.1 Technical data ........................................................................................................ 13
6.2.2 Installation ............................................................................................................. 13
6.2.3 Tooth profile .......................................................................................................... 14
6.2.4 Clearance of magnetic pick-up .............................................................................. 14
6.2.5 Dimensions ............................................................................................................ 15
6.3 Coolant temperature sensor TS 01-28-PT1000 (EDV- No.: 600-00-053-00) 16
6.4 Pressure sensors 17
6.4.1 Oil pressure sensor ................................................................................................. 17
6.4.2 Boost pressure sensors ........................................................................................... 18
6.4.2.1 Boost pressure sensor with plug ..................................................................... 18
6.4.2.2 Boost pressure sensor with housing and terminal strip .................................. 19
Digital Governor Basic System PANDAROS II
Contents
7 Setpoint adjusters ................................................................................................................ 20
7.1 Setpoint potentiometer SW 01-1-b (1 turn) (EDV- No.: 600-00-041-01) 20
7.2 Setpoint potentiometer SW 02-10-b (10 turn) (EDV- No.: 600-00-042-01) 20
7.3 Setpoint value adjustment by current signal 21
7.4 Digital presetting of setpoint values 21
7.5 Setpoint value adjustment by pedal 21
7.6 Pneumatic setpoint adjuster 21
8 Control unit DC 6-00 ... 05 .................................................................................................. 22
8.1 Specification 22
8.1.1 General ................................................................................................................... 22
8.1.2 Inputs and outputs .................................................................................................. 23
8.2 Dimensions 24
8.3 Mounting 25
9 Actuators .............................................................................................................................. 26
9.1 Design and mode of operation 26
9.1 Variations 27
9.2 Installation 27
9.3 Specification 28
9.4 Dimensions 29
10 Regulating linkage ............................................................................................................. 32
10.1 Length of lever arm 32
10.2 Order specification for lever arm 32
10.3 Connecting linkage 32
10.3.1 Linkage adjustment for diesel engines ................................................................. 33
10.3.2 Linkage adjustment for carburetor engines ......................................................... 33
11 Electrical connection ......................................................................................................... 35
11.1 Connection table for variation DG 6-00 35
11.2 Optional assignment of inputs and outputs, variation DG 6-00 36
11.2.1 Digital Inputs ....................................................................................................... 36
11.2.2 Analogue and PWM Inputs .................................................................................. 37
11.2.3 Digital Outputs ..................................................................................................... 37
11.2.4 Analogue and PWM Outputs ............................................................................... 37
11.3 Connection for variation DG 6-01 (standard generator) 38
11.4 Connection for variation DG 6-02 (standard general) 39
11.5 Connection for variation DG 6-03 (extended generator) 40
11.5.1 Digital Inputs ....................................................................................................... 41
11.5.2 Analogue and PWM Inputs .................................................................................. 41
11.6 Connection for variation DG 6-05 (extended general) 42
11.7 Harness 43
Digital Governor Basic System PANDAROS II
Contents
12 Parametrization options ................................................................................................... 45
12.1 Parametrization at the factory 45
12.2 Parametrization with the Hand Held Programmer HP 03 45
12.3 Parametrierung mit dem PC / Laptop 45
12.4 Parametrization with user mask 46
12.5 Transferring data sets 46
12.6 Assembly line end programming 46
13 Starting the engine - brief instruction ............................................................................. 47
14 Ordering details ................................................................................................................. 48
15 Download of manuals ........................................................................................................ 49
Digital Governor Basic System PANDAROS II
1 Safety instructions and related symbols
DANGER indicates a hazardous situation the consequence of which could
be fatal or severe injuries if it is not prevented.
WARNING indicates a hazardous situation which could lead to fatal injury
or severe injuries if it is not prevented.
CAUTION indicates a hazardous situation which could lead to minor injuries if it is not prevented.
NOTICE indicates possible material damage.
Safety instructions are not only denoted by a signal word but also by hazard
warning triangles. Hazard warning triangles can contain different symbols
to illustrate the danger. However, the symbol used is no substitute for the
actual text of the safety instructions. The text must therefore always be read
in full!
This symbol does not refer to any safety instructions but offers important
notes for better understanding the functions that are being discussed. They
should by all means be observed and practiced.
1 Safety instructions and related symbols
This publication offers wherever necessary practical safety instructions to indicate inevitable
residual risks when operating the engine. These residual risks imply dangers to
- Personnel
- Product and machine
- The environment
The primary aim of the safety instructions is to prevent personal injury!
The signal words used in this publication are specifically designed to direct your attention to possible damage extent!
In this publication the Table of Contents is preceded by diverse instructions that among
other things serve to ensure safety of operation. It is absolutely imperative that these
hints be read and understood before commissioning or servicing the installation.
Digital Governor Basic System PANDAROS II 1
1 Safety instructions and related symbols
1.1 Basic safety measures for normal operation
The installation may be operated only by authorized persons who have been duly
trained and who are fully acquainted with the operating instructions so that they are capable of working in accordance with them.
Before turning the installation on please verify and make sure that
- only authorized persons are present within the working range of the engine;
- nobody will be in danger of suffering injuries by starting the engine.
Before starting the engine always check the installation for visible damages and make
sure it is not put into operation unless it is in perfect condition. On detecting any faults
please inform your superior immediately!
Before starting the engine remove any unnecessary material and/or objects from the
working range of the installation/engine.
Before starting the engine check and make sure that all safety devices are working
properly!
1.2 Basic safety measures for servicing and maintenance
Before performing any maintenance or repair work make sure the working area of the
engine has been closed to unauthorized persons. Put on a sign warning that maintenance
or repair work is being done.
Before performing any maintenance or repair work switch off the master switch of the
power supply and secure it by a padlock! The key must be kept by the person performing the maintenance and repair works.
Before performing any maintenance and repair work make sure that all parts of engine
to be touched have cooled down to ambient temperature and are dead!
Refasten loose connections!
Replace at once any damaged lines and/or cables!
Keep the cabinet always closed. Access should be permitted only to authorized persons
having a key or tools.
Never use a water hose to clean cabinets or other casings of electric equipment!
1.3 Before putting an installation into service after maintenance and repair works
Check on all slackened screw connections to have been tightened again!
Make sure the control linkage has been reattached and all cables have been reconnected.
Make sure all safety devices of the installation are in perfect order and are working
properly!
2 Digital Governor Basic System PANDAROS II
2 General
2 General
The HEINZMANN Digital Governors of the PANDAROS series have been designed as speed
governors for diesel and gas engines with low and medium power. In addition to their primary
purpose of controlling speed, these governors are capable of performing some other tasks and
functions.
The control system consists of the control unit, the actuator, the setpoint adjusters, the sensors, and the connection cables.
The control unit includes the control electronics. At the core of the control unit is a very fast
and powerful 16 bit microprocessor. The actual controller program on which the processor
operates, is permanently stored in a FLASH-EPROM.
The current engine speed is sensed by a magnetic pick-up on the flywheel or a measuring wheel.
One temperature sensor can measure the engine temperature and can cause changings of gov-
ernor parameters or alarm messages.
The speed setpoint, additional sensor inputs and the inputs for the analogue accessory are de-
pending on variations.
In the case of the DC 6-00 variant, which offers the largest functional scope and flexibility,
the user must configure all inputs and outputs themselves.
With regard to the other variants, no additional outputs are provided aside from the error mes-
sage output. In certain cases, the inputs are already specifically pre-configured and all parameters that are not required for the respective application are omitted so as to maintain a
clearer overview of the controller and to make start-up easier to perform.
With the serial interface ISO 9141 resp. RS 232 is communication to other devices possible.
Digital Governor Basic System PANDAROS II 3
3 Functions
3 Functions
The HEINZMANN digital controllers from the PANDAROS series are speed governors in
which, depending on the variant in question, further variant-specific functions are available in
addition to the speed control and the general functions.
3.1 General functions
a) Start fuel adjustment
For setting start fuel, minimum start quantity or maximum start quantity may alternatively be selected. If necessary either can be configured in dependence of temperature.
Furthermore, variable start quantity can be provided, by which start quantity is automatically increased during start-up.
b) Speed ramps
For applications where speed is not supposed to respond to changes of setpoint values
as fast as possible, a speed ramp is available. According to requirements, it may be parametrized separately for increasing or decreasing speed. In addition, a separate speed
ramp is provided for start-up which will make the engine ramp slowly to operating
speed after starting.
c) All speed governing with adjustable droop
Several applications e.g. generators in parallel without HEINZMANN load measuring
unit might require speed control with droop (proportional band). The droop can be adjusted as desired. With droop adjusted to 0, the governor operates in isochronous mode.
d) Setting the speed range
The minimum and maximum speed adjustable by the (external) setpoint, can be parametrized.
e) Engine stop
When the switch input for engine shutdown is activated, the governor will cause the actuator to fully pull to stop direction until the engine has stopped.
f) Overspeed protection
An overspeed point can be parametrized. If this point is overcome, the governor will issue an alarm and the actuator will fully pull to stop direction.
g) Gradient monitoring
The engine speed signal can be monitored for a permissible change speed (gradient).
4 Digital Governor Basic System PANDAROS II
3 Functions
h) Correction of PID parameters
To optimize the dynamics for every operating point, the PID parameters may be corrected in dependence of speed, temperature and load by means of freely programmable
stability maps.
i) Speed dependent fuel limitation
It is possible to program fuel limitation curves in dependence of speed so that for all
speeds there can be torque reduction as is admissible for the engine or desired by the user.
j) Temperature dependent idling speed and fuel limitation
At low temperatures, the engine can be run at some higher idling speed. With the engine
warming up, idling speed is reduced to its normal value. It is possible to program fuel
limitation curves in dependence of temperature so that for every temperature there will
be torque reduction available as is admissible for the engine or desired by the user.
k) Operating hour meter
The operating hours when the engine is turning (speed is detected) will be added.
l) Failure diagnosis and display
If a sensor or the actuator is at fault, an alarm is issued and there will be a change-over
to emergency operation if so provided or an engine shutdown. Internal errors get detected also and they will be stored as all other failures. All failures can be read out with an
external hand programmer or with a communication program on a PC or laptop with
communication cable.
m) Communication
An ISO 9141 interface is provided to enable communication with a Heinzmann communication tool.
Digital Governor Basic System PANDAROS II 5
3 Functions
3.2 Variation specific additional functions
3.2.1 Variation DC 6-01 (Standard Generator)
(refer to connection diagram DC 6-01)
The speed setpoint is realized with two push buttons: increase speed and decrease speed.
3.2.2 Variation DC 6-02 (Standard General)
(refer to connection diagram DC 6-02)
The speed setpoint is given by an analogue setpoint source (voltage source 0 … 5 V,
current 4 … 20 mA or potentiometer 5 k) and one switch input for fixed speed.
3.2.3 Variation DC 6-03 (Extended Generator)
(refer to connection diagram DC 6-03)
The assignment of the function and the calibration of the inputs must be performed by
the customer themselves in this context. The following functions are also available, although the limited number of inputs means that they cannot all be used simultaneously:
a) Free configurability of inputs
Five digital inputs are available in total, up to three of which can also optionally be
configured as analogue inputs featuring 0 … 5 V or 4 … 20 mA if required.
b) Speed offset selection
All analogue or digital control signals that are conventionally used on the market for
the purpose of generating a speed offset selection for a superordinate generator control may be applied. This naturally also includes signals from ComAp, Deapsea,
Deif, Kuhse, Stucke, etc. as well as analogue additional devices from Heinzmann.
c) Communication with Heinzmann generator management DGM-02
If the corresponding parameter settings have been made, the digital generator management from Heinzmann (THESEUS DGM-02) can be connected via CAN bus.
d) Idling speed
It is possible to switch to the idling speed for a warm-up or cool-down phase.
e) P-range changeover
It is possible to switch between two different P-ranges.
f) Speed range changeover
It is possible to switch between two different speed ranges.
6 Digital Governor Basic System PANDAROS II
3 Functions
g) Manual/automatic mode
It is possible to switch between manual and automatic mode.
h) Generator switch
In order to make quicker adjustments when opening the power generator switch, it is
possible to activate a special function that queries the status of the power generator
switch. This status can be assigned to a digital input.
i) Deleting errors
The current errors can be deleted by pressing an assigned button at a digital input.
j) Automatic calibration of the actuator
After replacing the control device or the actuator, the feedback of the actuator can be
recalibrated by pressing an assigned button (actuator and control device are adjusted
in line with one another).
3.2.4 Variation DC 6-05 (Extended General, especially vehicle)
(refer to connection diagram DC 6-05)
a) Speed setpoint
The speed setpoint is given by an analogue setpoint source (voltage source 0 … 5 V,
current 4 … 20 mA or potentiometer 5k) and a switch input for fixed speed.
b) Boost pressure sensor
An analogue input is already specified for use with a boost pressure sensor. The input
can be configured for a 0 … 5 V or 4 … 20 mA signal.
For turbocharged engines, fuelling can be reduced to achieve smokeless operation
whenever there is no boost pressure (e.g., during start-up or on load changes). The
respective limit curves can be programmed accordingly.
c) Oil pressure sensor
An analogue input is already specified for use with an oil pressure sensor. The input
can be configured for a 0 … 5 V or 4 … 20 mA signal.
For the purpose of oil pressure monitoring, speed/pressure dependent limit curves
can be provided. If oil pressure is low, an alarm is issued; if oil pressure continues to
drop, the engine is shut down.
d) Idle-/Maximum speed governor
The governor may also be adjusted as an idle/max speed governor.
Digital Governor Basic System PANDAROS II 7
3 Functions
3.2.5 Variation DC 6-00 (ful flexibility)
This variant is not pre-configured and contains all the previously described functions of
the different variants.
The only option that is not provided is that of communication with the digital generator
management THESEUS via CAN bus.
This variant continues to feature the following additional functions:
a) Second speed sensor
A digital input can be reconfigured in order to support the use of a second speed sensor (featuring a Hall design).
b) Second fixed speed
It is possible to assign a second fixed speed.
c) Setpoint selection via notches
For simple applications for locomotive operation, the speed setpoint selection can be
performed via notches. In this context, the bit combinations of up to four digital inputs can be assigned to corresponding speed setpoints.
d) Changeover between limiting curves
It is possible to switch between two different limiting curves.
e) Jet Assist
A Jet Assist function can also be activated in order to perform quick adjustments for
load compensation at low levels of boost pressure.
f) Analogue outputs
The multifunctional ports (terminals 1 and 2) can also be configured as analogue
outputs featuring 4 … 20 mA. In this way, every available analogue measured value
or calculated setpoint can be output.
g) PWM outputs
The multifunctional ports (terminals 1 and 2) can also be configured as PWM outputs. In this way, every available analogue measured value or calculated setpoint can
be output.
h) Digital outputs
The multifunctional ports (terminals 1 and 2) can also be configured as digital outputs. This makes it possible for every digital measured value to be output.
8 Digital Governor Basic System PANDAROS II
3 Functions
i) PWM inputs
The multifunctional ports (terminals 1 and 2) and digital input 3 can also be configured as PWM inputs. In this way, every available analogue measured value or calculated setpoint can be output.
j) PE module adjustment
Via CAN bus, it is possible to communicate with an additional PE module of type
DC 6. This can then control a second actuator and provide additional inputs and outputs that can be configured from the speed governor. The typical application in this
regard is the control of V-type engines with two actuators.
3.2.6 Variation DC 6-06 (positioner)
This variant does not feature an integrated speed governor. In this context, the corresponding actuator is controlled via an actuator setpoint position signal received from an
external source. This variant is described in a dedicated publication.
Digital Governor Basic System PANDAROS II 9
4 Further information
4 Further information
This publication describes in detail the technical data and connections of the control electronics, of the sensors, of the setpoint adjusters and of the actuators.
The functions of the different adjustment parameters and characteristics are described in detail
in the manual
Basic Information Control device for conventional injection Manual DG 07 001-e
The mode of operation of the communication program DcDesk 2000 is described in detail in
the manual
Operation Instructions of Communication Program DcDesk 2000,
Manual-No. DG 00 003-e
10 Digital Governor Basic System PANDAROS II
5 Block diagram
-
DC
24 V - Power Supply
Switch Inputs
Analogue Setpoint Adjuster
Interface RS 232
Pressure Sensors
Temperature Sensor
Micro Controler
Actuator
Drive
DC
EEPROM
ISO9141
Speed Sensor
Watch-
dog 1
Watch-
dog 2
Watch-
dog 3
DC 6 Board
5 V
Actuator Position
Sensing
M
Integrated Hand Programmer
Failure Lamp
Analogue
Synchronizer
Analogue
Load Measuring Unit
LCD-Display
WINDOW
FUNCTION
ESCAPE
ENTER
5 Block diagram
According to the different types, there are not all functions and inputs available!
Fig. 1: Block diagram
Digital Governor Basic System PANDAROS II 11
6 Sensors
Sensor
Speed
Coolant
Temperature
Oil Pressure
Boost Pressure
HZM - Designation
IA ..
TS 01-28-PT1000
DSO 01-6
DSO 01-10
DSL/G 0..-2
DSL/G 0..-5
DSL/G 0..-10
Connection
SV 6-IA-2K
2 pole
SV 6-IA-2K
2 pole
DIN 43650 A
2 line system
DIN 43650 A
2 line system
Measuring Procedure
inductive, active
PT1000, passive
active
active
Measuring Range
50 ... 9.000 Hz
-50 ... +150°C
0 ... 6 bar
0 ... 10 bar
0 ... 2 bar
0 ... 5 bar
0 ... 10 bar
Supply Voltage
Range
passiv
10 ... 34 V DC
12 ... 36 V DC
Output Signal Range
0 ... 10 V AC
ca. 700 ... 1500 Ohm
4 ... 20 mA
4 ... 20 mA
Operating Temperature Range
-55 ... +120°C
-50 ... +150°C
-25 ... +125°C
-40 ... +100°C
6 Sensors
6.1 Overview
In order to ensure maximum flexibility with regard to the sensors, the minimum/ maximum
current values and the measuring ranges of the pressure and temperature sensors have been
provided programmable.
12 Digital Governor Basic System PANDAROS II
6 Sensors
60
*min)/1( zn
60
160*1500
It should be taken care that the speed can be measured by the pulse pickup without any bias. For best results therefore, the speed pick-up should
take the engine speed from the crankshaft. A suitable position for this is,
e.g., the starter gear but not the injection pump wheel.
The pick-up gear must consist of magnetic material (e.g., steel, cast iron).
6.2 Magnetic pick-up IA ...
6.2.1 Technical data
Operating principle inductive sensor
Distance from sensing gear 0.5 ... 0.8 mm
Output 0 … 10 V AC
Signal form Sine (depending on tooth shape)
Resistance approx.. 52 Ohm
Temperature range -55°C … +125°C
Protection grade IP 55
Vibration < 10g, 10 ... 100 Hz
Shock < 50g, 11 ms half sine wave
Corresponding plug SV 6-IA-2K (EDV- No.: 010-02-170-00)
6.2.2 Installation
The installation of the pick-up has to be arranged in such a way as to obtain a frequency
as high as possible. Normally, the HEINZMANN governors of the series Pandaros are
designed for a maximum frequency of 9000 Hz. Frequency (by Hz) is calculated according to the formula
f
(Hz)
=
z = number of teeth on the pick-up wheel
Example:
n = 1.500
z = 160
f =
= 4.000 Hz
Digital Governor Basic System PANDAROS II 13
6 Sensors
6.2.3 Tooth profile
Any tooth profile is admissible. The top width of the tooth should be 2.5 mm minimum,
the gap and the depth of the gap at least 4 mm. For index plates the same dimensions are
valid.
Due to tolerances, a radial arrangement of the magnetic pick-up is preferable.
6.2.4 Clearance of magnetic pick-up
The distance between the magnetic pulse pick-up and the tooth top should range from
0.5 and 0.8 mm. (It is possible to screw in the magnetic pick-up till it touches the tooth
and then unscrew it for about half a turn)
Fig. 2: Clerance of pick-up
14 Digital Governor Basic System PANDAROS II
6.2.5 Dimensions
G
L
35
19
Measures
L
(mm)
G
Remarks
Type
01-38
38
M 16 x 1,5
02-76
76
M 16 x 1,5
appropriate
03-102
102
M 16 x 1,5
plug
11-38
38
5/8"-18UNF-2A
SV 6-IA-2K
12-76
76
5/8"-18UNF-2A
(010-02-170-00)
13-102
102
5/8"-18UNF-2A
6 Sensors
Fig. 3: Dimensions of pick-up
Ordering specification, e.g. IA 02-76
Digital Governor Basic System PANDAROS II 15
6 Sensors
B
A
seal ring DIN 7603-14x18 (Cu)
pin configuration:
B = -
19
SW
5/8"-24
M14x1,5
8
h7
16
28
17,5
56,5
A = +
6.3 Coolant temperature sensor TS 01-28-PT1000
(EDV- No.: 600-00-053-00)
Measuring range -50°C … +150°C
Precision 1.5°C
Resistance at 25 °C (R25) 1000 Ohm 0.5 %
Maximum operating voltage 5 V
Maximum operating current 3 mA
Recommended operating current approx. 1 mA
Time constant in fluids approx. 13 seconds
Admissible temp. range of connector -40°C … +105°C
Protection grade IP 65
Vibration < 20 g, 10 … 300 Hz
Shock < 50 g, 11 ms half-sine wave
Tightening torque 50 Nm 15 %
Appropriate connector SV 6-IA-2K (EDV- No.: 010-02-170-00)
Fig. 4: Temperature sensor TS 01-28-PT1000
16 Digital Governor Basic System PANDAROS II
6 Sensors
Pressure Sensor
EDV- No.
Max. Oper. Pressure (bar)
DSO 01-6
600-00-058-00
6
DSO 01-10
600-00-058-01
10
12
22
48,8 26
Ø 19
27
R1/4"
M5
SW 19
6.4 Pressure sensors
6.4.1 Oil pressure sensor
Measuring range 0 … 6 bar or 0 … 10 bar
Over pressure 15 bar resp. 20 bar
Supply voltage 10 … 34 V DC
Output signal 4 … 20 mA
Storage temperature -25°C … +85°C
Ambient temperature -25°C … +85°C
Oil temperature -25°C … +125°C
Protection grade IP 65
Vibration < 20 g, 10 … 300 Hz
Shock < 50 g, 11 ms half-sine wave
Tightening torque max. 25 Nm
Connection DIN 43650-A, 2-line system
Fig. 5: Oil pressure sensor
Digital Governor Basic System PANDAROS II 17
6 Sensors
Pressure Sensor
EDV- No.
Maximum Operating
Pressure (bar rel.)
DSL 01-2
600-00-057-00
2
DSL 01-5
600-00-057-01
5
DSL 01-10
600-00-057-02
10
92
12
2
R3/8"
Ø 30
128
30,5
Ø 19
PG9
SW 24
33,5
53
6.4.2 Boost pressure sensors
The boost pressure sensors are also available in an additional housing with terminal
strip.
Measuring range 0 … 2 bar, 0 … 5 bar or 0 … 10 bar
Over pressure 4 bar resp. 10 bar resp. 16 bar
Supply voltage 12 … 36 V DC
Output signal 4 … 20 mA
Storage temperature -55°C … +100°C
Ambient temperature -40°C … +100°C
Protection grade IP 65
Vibration < 2 g, 5 … 500 Hz
Shock < 50 g, 11 ms half-sine wave
Connection DIN 43650-A or terminal strip, 2-line system
6.4.2.1 Boost pressure sensor with plug
Fig. 6: Boost pressure sensor with plug
18 Digital Governor Basic System PANDAROS II
6 Sensors
Pressure Sensor
EDV- No.
Maximum Operating
Pressure (bar rel.)
DSG 04-2
600-00-056-00
2
DSG 04-5
600-00-056-01
5
DSG 04-10
600-00-056-02
10
Am Haselbach 1
D-79677 SchÎnau/Schw.
Germany
Phone: (07673) 8208-0
Telefax: (07673) 8208-88
GmbH + Co.
HEINZMANN
R
10
4,5
52
57
27,5
14
80
113
125
6
91
29,5
SW 24
R3/8"
R1/4"
15
30
30
6.4.2.2 Boost pressure sensor with housing and terminal strip
Fig. 7: Boost pressure sensor with housing
Digital Governor Basic System PANDAROS II 19
7 Setpoint adjusters
9,5
3/8" - 32 NEF - 2A
Ø 27
23
26
8,8
3/8" - 32 NEF - 2A
Ø 23
17
32
7 Setpoint adjusters
With regard to the variety of applications, various setpoint adjusters are available for the
HEINZMANN digital speed governors of series PANDAROS. The customer specifies the
setpoint selection type by means of parameter settings. As a result, it is not necessary for
HEINZMANN to adapt the hardware prior to delivering the controller.
7.1 Setpoint potentiometer SW 01-1-b (1 turn)
(EDV- No.: 600-00-041-01)
Displacement angle approx. 312°
Resistance 5 kOhm
Temperature range -55°C … +120°C
Protection grade IP 00
7.2 Setpoint potentiometer SW 02-10-b (10 turn)
(EDV- No.: 600-00-042-01)
Displacement angle 10 turns
Resistance 5 kOhm
Temperature range -55°C … +105°C
Protection grade IP 00
Fig. 8: Potentiometer SW 01-1-b
20 Digital Governor Basic System PANDAROS II
Fig. 9: Potentiometer SW 02-10-b
7 Setpoint adjusters
On request, the potentiometers, as specified under 6.1. and 6.2. can be supplied with
analogue adjustment knob with lock in place of the standard rotating knob. In this case,
ordering specification is SW..-..-m.
Likewise, a clamping fixture can be installed instead of the knob. The ordering
specification will then be SW ..-..-k.
7.3 Setpoint value adjustment by current signal
For the speed setpoint value a current signal of 4 … 20 mA can be directly connected to
the control unit. If the signal fails, the governor will adjust minimum speed according to
the 4 mA value or use a pre-programmed substitute value.
7.4 Digital presetting of setpoint values
With the corresponding configuration, a digital setpoint selection (e.g. digital
synchronization performed manually or via PLC) can be implemented directly via two
switch inputs (higher/lower speed).
7.5 Setpoint value adjustment by pedal
The electronical foot pedal EFP is basically an angular position transducer that translates
gas pedal positions into a proportional current or voltage for 0 … 45° rotational
displacement. The resulting output can be used for speed setting. For more information
refer to manual E 83 005 - e.
7.6 Pneumatic setpoint adjuster
If pneumatic setpoint adjustment is desired, the boost pressure sensors may be used to
supply the signals. For detailed specifications of these sensors refer to chapter 6.4.2.
Digital Governor Basic System PANDAROS II 21
8 Control unit DC 6-00 ... 05
8 Control unit DC 6-00 ... 05
8.1 Specification
8.1.1 General
Supply voltage 12 V DC or 24 V DC
Min. voltage 9 V DC or 18 V DC
Max. voltage 33 V DC
Max. ripple voltage max. 10 % at 100 Hz
Maximum power rating max. 7 A, and
max. 11 A for max. 60 seconds
Permissible voltage dip at
maximum current consumption max. 10 % at control unit
Fuse protection of governor 12 A
Storing temperature -40°C … +85°C
Operating temperature -40°C … +80°C
Humidity up to 98% at 55°C
Dynamic strength max. 2 mm at 10 … 20 Hz,
max. 0,24 m/s at 21 … 63 Hz
max. 7 g at 64 … 2000 Hz
Shock 50 g, 11 ms- half-sine wave
Protection grade IP 00
Insulation resistance > 1 MOhm at 48 V DC
Weight approx. 0.5 kg
EMC directives 2004/108/EG
2004/104/EG
according to EMC standards: ISO 11452-2
ISO 7637-2 / -3
DIN EN 61000-6
22 Digital Governor Basic System PANDAROS II
8 Control unit DC 6-00 ... 05
8.1.2 Inputs and outputs
All inputs and outputs are protected against reverse-voltage and short circuit to battery
plus and minus.
Speed input for inductive sensor, with
fi = 25 … 9000 Hz, Ui = 0.5 … 30 V AC
Temperature input for PT1000 / Ni1000 sensors
tolerance: < ±2°C at 0°C … 130°C,
rest < ±4°C
Reference voltage setpoint adjuster U
= 5 V ±1 %, I
ref
< 30 mA
ref
Analogue input 1 U = 0 ... 5 V, Ri > 100 k,
when for HZM SyG, Rpu > 100 k
or U = 0 … 10 V, Ri > 17 k,
or I = 4 … 20 mA, Ri > 250
Analogue input 2 U = 0 … 5 V, Ri > 100 k,
when for HZM LMG, Rpu > 10 k
or U = 0 … 10 V, Ri > 17 k,
or I = 4 … 20 mA, Ri > 250
Analogue input 3 U = 0 … 5 V, Ri > 100 k,
or I = 4 … 20 mA, Ri > 250
Digita inputs 1 to 5 U0 < 1.0 V, U1 > 3.5 V, Ri > 100 k
PWM inputs 1 to 3 U0 < 1.0 V, U1 > 3.5 V typical 5 V max. 24 V,
Ri > 100 k,
frequency = 50 … 500 Hz
Analogue outputs 1 and 2 I = 0 ... 22 mA, R
Digital outputs 1 and 2 I
PWM outputs 1 and 2 I
= 300 mA, low side switched
max
= 300 mA, low side switched
max
= 420 Ohm
Lmax
frequency = 50 … 500 Hz
Digital output failure lamp I
= 300 mA, low side switched
max
Actuator position sensing internal in actuator with reference feedback
analogue U = 1.4 … 3.0 V, U
= 8 V ±x %, I
ref
< 20 mA
ref
digital only with HEINZMANN-StG and Bosch EDC
Drive output I < 7 A, I < 11 A for T < 60 s, PWM
Serial interface ISO 9141, variable from 2.4 kbit/s …. 57.6 kbit/s
standard 9.6 kbit/s
Digital Governor Basic System PANDAROS II 23
8 Control unit DC 6-00 ... 05
8.2 Dimensions
Fig. 10: Housing of control unit DC 6-01 ... 05
24 Digital Governor Basic System PANDAROS II
8 Control unit DC 6-00 ... 05
8.3 Mounting
When selecting the location, care should be taken for easy access in order to facilitate readout of the failure indication and replacement of the device under field conditions. Any
mounting position is admissible. When fitting the device directly on the engine, it should
be mounted using vibration absorbers.
Digital Governor Basic System PANDAROS II 25
9 Actuators
Permanet Magnet
Armature
Feedback Cam
Governor Output Shaft
Feedback Probe
Return Spring
9 Actuators
9.1 Design and mode of operation
A multi-polar magnetised permanent magnet is mounted on the actuator shaft. Opposite the
permanent magnet an armature is fixed. When current is given to the armature, a torque in
one direction is obtained. Changing the polarity of the current results in direction changes.
The use of special materials and long-time lubricants assures maintenance-free operation
and long working life of the actuators.
A feedback cam is mounted on the governor output shaft which is scanned contactlessly by
a probe, thus transmitting the precise position of the output shaft to the control unit.
If the actuator strikes against a stop, as may occur, e.g., under parallel mains operation or
may be caused by engine overload or cylinder failure, the current limitation will take effect. This reduces the current via an e-function such that no damage can occur on the actuator.
Fig. 11: Sectional drawing of actuator
26 Digital Governor Basic System PANDAROS II
9 Actuators
Actuators with plug-in connections
Actuators with terminal strips
StG 2010.xx-SV
StG 2010.xx-KV
StG 2040.xx-SV
StG 2040.xx-KV
StG 2080.xx-SV
StG 2080.xx-KV
Altogether, this type of actuator provides the following advantages:
- High regulation power working in both directions.
- Extremely low current consumption during steady state and relatively low current consumption on change of load.
- Indifference to slow voltage changes of the supply; abrupt voltage changes cause governor disturbances.
- maintenance-free
9.1 Variations
The actuator can be equipped with either a terminal strip or a plug-in connector.
Currently the following basic variations are available:
The xx in the designations are representing additionally differences at the variations, for
exsample:
Operating angle (standard 36°, optional 68°)
Connection plug (standard 5 pole with thread, optional 6 pole or bayonet)
Feedback (standard analogue, optional additionally with temperature compensation)
Return spring (standard installed, optional without or reinforced)
The exact type designations are available on request.
9.2 Installation
The actuator must be mounted firmly on the engine by means of reinforced brackets. Unstable arrangements, as caused by weak bracket material or missing stiffenings, have to be
avoided by all means; they are bound to intensify vibrations, which will lead to premature
wear of the actuator and the connecting linkage!
Generally any mounting position is possible; however, the actuators should not be mounted
with the plug connection pointing straight upward.
Digital Governor Basic System PANDAROS II 27
9 Actuators
StG 2010.xx
StG 2040.xx
StG 2080.xx
Effective rotation at output shaft
36°
36°
36°
Max. torque at actuator output shaft
approx. 1.4 Nm
approx. 6.5 Nm
approx. 11 Nm
Torque in steady state condition
approx. 0.5 Nm
approx. 2.2 Nm
approx. 3.7 Nm
Response time 0-100 % without load
approx. 45 ms
approx. 50 ms
approx. 60 ms
Current consumption of whole
governor
maximum current
safe current in steady state
condition
approx. 4.5 A
approx. 1 A
Storage temperature
-55°C … +110°C
Ambiente temperature in operation
-25°C … +90°C
Ambiente temp., special application
-40°C … +90°C
Humidity
up to 100 %
Protection grade
housing
connectors
IP 65
IP 00 / IP 65
Weight
approx. 2.2 kg
approx. 3.9 kg
approx. 6.6 kg
9.3 Specification
28 Digital Governor Basic System PANDAROS II
9.4 Dimensions
HEI NZMANN
GmbH+Co.
Drehzahlregler
Am Haselbach 1
D-79677 SchÎnau
Germany
Tel:(07673)8208-0
Fax:(07673)8208-88
40 12,5
112
8
0
100
F
ü
l
l
u
n
g
F
u
e
l
C
o
m
b
u
s
t
i
b
l
e
68
92
108
122
M8
15
137
17
25 69
17
55
131
36°
X
view X with terminal strip
(shown without output shaft and pointer)
view X with plug-in connector
(shown without output shaft and pointer)
1
2
3
4
5
9 Actuators
Fig. 12: Actuators StG 2010.xx
Digital Governor Basic System PANDAROS II 29
9 Actuators
HEI NZMANN
GmbH+Co.
Drehzahlregler
Am Haselbach 1
D-79677 SchÎnau
Germany
Tel:(07673)8208-0
Fax:(07673)8208-88
0
100
F
ü
l
l
u
n
g
F
u
e
l
C
o
m
b
u
s
t
i
b
l
e
SAE Serration 3/8" - 36
11
60
97
19
146
20
28
86
110
128
144
157
M8
155
67
15
36°
1
2
3
4
5
X
view X with terminal strip
(shown without output shaft and pointer)
view X with plug-in connector
(shown without output shaft and pointer)
Fig. 13: Actuator StG 2040.xx
30 Digital Governor Basic System PANDAROS II
9 Actuators
0
Füllung Fuel
Combustible
Am Haselbach 1
D-79677 SchÎnau
Germany
Telefon: (07673) 8208-0
Telefax: (07673) 8208-88
HEINZMANN
GmbH + Co.
R
Serial No.
for BasicSystem E
Range Voltage
Patents pending
100
9010
16
25
123
173
16
SAE Serration 1/2" - 36
174
165
120
100
70
M8
15
78
170
36°
1
2
3
4
5
X
view X with terminal strip view X with plug-in connector
Fig. 14: Actuator StG 2080.xx
Digital Governor Basic System PANDAROS II 31
10 Regulating linkage
10 Regulating linkage
10.1 Length of lever arm
The length of the lever arm is determined in such a way that approx. 90 % of the governor
output shaft adjustment angle can be used. Based on this, the rack length L of governors
with 36° adjustment angle is calculated as L = 1.8 a, "a" being the travel distance of the injection pump or the carburetor.
10.2 Order specification for lever arm
Actuator 2010 Please order RH 2010-01
EDV- No.: 511 80 004 00
Actuator 2040 Please order RH 2040-01
EDV- No.: 502 80 017 00
Actuator 2080 Please order RH 2080-01
EDV- No.: 504 80 010 00
10.3 Connecting linkage
The connecting linkage from the governor to the injection pump or the carburettor should
be length-adjustable and have a (pressure or tension) elastic link. If the actuators torque is
less than 10 Nm, the elastic link is not needed. If possible, joint rod heads in accordance
with DIN 648 should be used as connecting links. The linkage must operate easily and
without clearance.
In case of friction or backlash in the linkage connecting actuator and injection pump resp.
throttle valve no optimal control is possible.
32 Digital Governor Basic System PANDAROS II
10 Regulating linkage
If carburettor or injection pump are to the right of the actuator as opposed
to their position on the drawings, then the direction of motion of the elastic
link must also be reversed.
0
Füllung Fuel
Combustible
Am Haselbach 1
D-79677 SchÎnau
Germany
Telefon: (07673) 8208-0
Telefax: (07673) 8208-88
HEINZMANN
GmbH + Co.
R
Serial No.
for BasicSystem E
Range Voltage
Patents pending
100
Stop
Displacement
Angle
Injection Pump
Actuator
0 - 2 Fuel Mark
Full Load Position
0
Füllung Fuel
Combustible
Am Haselbach 1
D-79677 SchÎnau
Germany
Telefon: (07673) 8208-0
Telefax: (07673) 8208-88
HEINZMANN
GmbH + Co.
R
Serial No.
for BasicSystem E
Range Voltage
Patents pending
100
Actuator
Displacement
Angle
Full Load Position
Idle Position
Throttle Valve
Stop Screw for Idle Speed
10.3.1 Linkage adjustment for diesel engines
The length of the connecting linkage is adjusted in such a way that with the governor in
stop position the injection pump is set to 0 - 2 fuel marks. (Travel of the injection pump
control rack is limited by the governor.)
Fig. 15: Linkage for diesel engines
10.3.2 Linkage adjustment for carburetor engines
For carburetor or gas engines, the length of the connecting linkage is adjusted in such a
way that with the governor in full load position the throttle valve is completely open. In
idling speed position, the elastic link must be slightly overcome. This allows adjustment
of the idle screw without changing the governor adjustment.
Digital Governor Basic System PANDAROS II 33
Fig. 16: Linkage for carburetor and gas engines
11 Electrical connection
Terminal
Function
H
CAN communication high-connection
L
CAN communication low-connection
1
Digital input 2 (switch to +24 V), or
Analogue input 2, 0 … 5 V or 0 … 10 V or 0 … 22 mA, or
PWM input 2, or
Digital output 2 (low side switched), or
Analogue output 2, 0 … 20 mA, or
PWM output 2
2
Digital input 1 (switch to +24 V), or
Analogue input 1, 0 … 5 V or 0 … 10 V or 0 … 22 mA, or
PWM input 1, or
Digital output 1 (low side switched), or
Analogue output 1, 0 … 20 mA, or
PWM output 1
3
GND for terminals 1 and 2
4
Temperature sensor signals
5
GND for temperature sensor
6
+5V reference supply voltage for setpoint potentiometer
7
Digital input 3 (switch to +24 V), or
Analogue input 3, 0 … 5 V or 0 … 22 mA, or
11 Electrical connection
The electrical connection possibilities are depending on the variation of the control unit.
As the pin connections for the DG 6-00 variant support highly flexible configuration, a termi-
nal connection diagram for this purpose would be too unclear. In the case of this variant, the
potential connection options and functions of the inputs and outputs are therefore identified
using a table.
Terminal connection diagrams are available for all other variants.
The parameter settings for the configurable terminals and the functions of the individual pa-
rameters are described in detail in the publication
Basic information on control units for conventional injection via actuators, publication no.
DG 07 001-d.
11.1 Connection table for variation DG 6-00
Digital Governor Basic System PANDAROS II 35
11 Electrical connection
Terminal
Function
8
GND
9
Digital input 4 (switch to +24 V)
10
Error output (low side switched)
11
Digital input 5 (switch to +24 V), or
PWM input 3, or
speed sensor 2 (Halls ensor)
12
Speed sensor GND
13
Speed sensor signal
14
GND
15
Actuator feedback GND, pin E at actuator plug
16
Actuator feedback signal 1.6 ... 2.8 V, pin A at actuator plug
17
Actuator feedback + 8 V reference, pin D at actuator plug
20
Power supply GND
21
Power supply +24 V
24
Actuator drive line minus, pin B at actuator plug
25
Actuator drive line plus, pin C at actuator plug
11.2 Optional assignment of inputs and outputs, variation DG 6-00
11.2.1 Digital Inputs
The following parameters are available for assignment of digital inputs:
810 FunctEngineStop
811 FunctIdleSpeed
812 FunctDroop2Or1
813 FunctForcedLimit
814 FunctSpeedRange2Or1
815 FunctSpeedFix1
816 FunctSpeedFix2
817 FunctSpeedLimit2Or1
819 FunctNotch3
820 FunctNotch2
821 FunctNotch1
822 FunctNotch0
825 FunctSpeedInc
36 Digital Governor Basic System PANDAROS II
11 Electrical connection
826 FunctSpeedDec
827 FunctSetpoint2Or1
828 FunctErrorReset
829 FunctFreezeSetp1
830 FunctFreezeSetp2
831 FunctIMOrAllSpeedGov
833 FunctForcedStart
834 FunctSyncEnable
835 FunctLoadEnable
836 FunctAutoOrManual
845 FunctAutoAdjust
846 FunctGenBreaker
11.2.2 Analogue and PWM Inputs
The following parameters are available for assignment of analogue or PWM inputs:
900 AssignIn_Setp1Ext
901 AssignIn_Setp2Ext
902 AssignIn_LoadCtrlInp
903 AssignIn_SyncInput
904 AssignIn_BoostPress
905 AssignIn_OilPress
907 AssignIn_CoolantTemp
908 AssignIn_ChAirTemp
909 AssignIn_OilTemp
910 AssignIn_FuelTemp
911 AssignIn_ExhaustTemp
918 AssignIn_MeasPower
923 AssignIn_FuelLimExt
11.2.3 Digital Outputs
All parameters that can only adopt a value of 0 or 1 can be assigned to digital outputs,
regardless of whether these are set parameters or measured value parameters.
11.2.4 Analogue and PWM Outputs
All parameters that feature an analogue value range can be assigned to analogue or
PWM outputs, regardless of whether these are set parameters or measured value parameters.
Digital Governor Basic System PANDAROS II 37
11 Electrical connection
11.3 Connection for variation DG 6-01 (standard generator)
Fig. 17: Connection diagram for variation DG 6-01
38 Digital Governor Basic System PANDAROS II
11 Electrical connection
11.4 Connection for variation DG 6-02 (standard general)
Fig. 18: Connection diagram for variation DG 6-02
Digital Governor Basic System PANDAROS II 39
11 Electrical connection
11.5 Connection for variation DG 6-03 (extended generator)
As a result of the numerous options for assigning analogue and digital inputs, the following
terminal connection diagram only indicates the types of the potential inputs. The functions
that can be assigned to these inputs are listed below.
Fig. 19: Connection diagram for variation DG 6-03
40 Digital Governor Basic System PANDAROS II
11 Electrical connection
11.5.1 Digital Inputs
The following parameters are available for assignment of digital inputs:
810 FunctEngineStop
811 FunctIdleSpeed
812 FunctDroop2Or1
814 FunctSpeedRange2Or1
815 FunctSpeedFix1
825 FunctSpeedInc
826 FunctSpeedDec
828 FunctErrorReset
834 FunctSyncEnable
835 FunctLoadEnable
836 FunctAutoOrManual
845 FunctAutoAdjust
846 FunctGenBreaker
11.5.2 Analogue and PWM Inputs
The following parameters are available for assignment of analogue or PWM inputs:
900 AssignIn_SetpExt
902 AssignIn_LoadCtrlInp
903 AssignIn_SyncInput
904 AssignIn_BoostPress
907 AssignIn_CoolantTemp
918 AssignIn_MeasPower
Digital Governor Basic System PANDAROS II 41
11 Electrical connection
11.6 Connection for variation DG 6-05 (extended general)
Fig. 20: Connection diagram for variation DG 6-05
42 Digital Governor Basic System PANDAROS II
11.7 Harness
It is not possible to use all offered signals at the same time, because some
inputs have to be assigned differently depending on the variation.
L1
Battery
Control Unit DC 6-01..05
Actuator
Setpoint Adjuster
Magnetic Pickup
Sensors
Switch Inputs
Error Messages
Communication
L2
L3
L4
L5
L6
L7
L10
+
-
Füllung Fuel Com bustible
0
50
100
10
20
30
40
50
60
70
80
90
100
0
Control unit DC 6-01…05
11 Electrical connection
Digital Governor Basic System PANDAROS II 43
Fig. 21: Cable designation
11 Electrical connection
The allowed length and necessary cross-sections of the cables to connect are as follows:
L 1 Power supply max. 15 m 2 x 2,50 mm²
L 2.1 Actuator feedback 3 x 0,75 mm² shielded
L 2.2 Actuator drive up to 10 m 2 x 2,50 mm²
over 10 … 20 m 2 x 4,00 mm²
L 3.1 Setpoint potentiometer 3 x 0,75 mm² shielded
L 3.2 4 ... 20 mA input 2 x 0,75 mm²
L 3.3 0 … 5 V input 2 x 0,75 mm² shielded
L 3.4 Synchronizer 2 x 0,75 mm² shielded
L 3.5 Load measuring unit 2 x 0,75 mm² shielded
L 4 Magnetic pick-up 2 x 0,75 mm² shielded
L 5.1 Temperature sensor 2 x 0,75 mm²
L 5.2 Boost pressure sensor 2 x 0,75 mm²
L 5.3 Oil pressure sensor 2 x 0,75 mm²
L 6.1 Engine stop 1 x 0,75 mm²
L 6.2 Increase speed 1 x 0,75 mm²
L 6.3 Decrease speed 1 x 0,75 mm²
L 6.4 other switch functions 1 x 0,75 mm²
(the switches have to be supplied with battery plus)
L 7 Error message 1 x 0,75 mm²
(the error lamp has to be supplied with battery plus, ground is switched)
L 13 CAN communication with DGM 02 2 x 0,14 mm² shielded
44 Digital Governor Basic System PANDAROS II
12 Parametrization options
12 Parametrization options
The software of the HEINZMANN digital controllers is designed in such a way that the parameter settings can be implemented both at the premises of the engine manufacturer and,
with the help of corresponding resources (communication tools), also at the premises of the
end customer. Upon leaving the HEINZMANN factory, only selected parameters are preset to
practical values. This means that the digital control device normally receives its final parameter setting from a source other than HEINZMANN.
Controllers featuring larger piece counts are an exception to this rule. If HEINZMANN is able
to provide a final parameter setting, this can be integrated ex works.
As a principle, first programming should always be conducted by experienced personnel and
must be checked before first commissioning the engine.
The publication 'Basic information 2000' provides a detailed description of the significance of
the parameters and how they are set.
The following sections describe the possibilities of parametrizing the control unit:
12.1 Parametrization at the factory
During final inspection at the factory, the functionability of the unit is checked by a test
programme. If the operational data for the control unit is available, the test programme is
carried out using this data. It is then only the dynamics data and if need be the fuel limitations and sensors that will have to be calibrated on the engine.
12.2 Parametrization with the Hand Held Programmer HP 03
All parametrization can also be done by means of the hand held programmer
‘Programmer 3’. This handy device is particularly suited for development and series
calibration as well as for servicing. The device does not require an external voltage supply.
12.3 Parametrierung mit dem PC / Laptop
Parametrization can also be conducted using a PC and the comfortable HEINZMANN
software DcDesk 2000. As compared with the hand held programmer, it offers the great
advantage of having various curves graphically represented on the screen and being at the
same time able to introduce changes as well as of having time diagrams displayed without
an oscilloscope when commissioning the control unit on the engine. Furthermore, the PC
offers a better overview as the PC programme has a menu structure and allows to have
several parameters continuously displayed.
Digital Governor Basic System PANDAROS II 45
12 Parametrization options
DcDesk 2000 also makes it possible for operating data to be saved to and loaded from data
carriers. This results in the following practical application:
Once the parameter settings for an engine design and its application have been specified,
the parameter setting can be saved. If there are other applications of the same type, the
setting can simply be transferred to new controllers.
12.4 Parametrization with user mask
Principally, parametrization may be performed with the help of user masks that have been
provided by HEINZMANN or may conveniently be created by the user himself. Within a
user mask, only those parameters are accessible which are actually needed.
12.5 Transferring data sets
Once parametrizing a particular engine model and its application has been completed, the
data set can be saved (in the hand held programmer or on a floppy disk). For other
applications of the same kind the data set can then be downloaded into the respective
control units.
12.6 Assembly line end programming
This type parametrizing is used by the engine manufacturer during the test bench run when
the control unit is programmed in accordance with the engine requirements as laid down in
the order.
46 Digital Governor Basic System PANDAROS II
13 Starting the engine - brief instruction
Additional overspeed protection independent of the speed con-
troller is compulsory!
13 Starting the engine - brief instruction
13.1 Adjust clearance of magnetic pulse pick-up.
13.2 Check program with respect to relevant parameters: number of teeth, speed, etc.
13.3 Calibrate sensors and setpoint adjusters, if necessary.
13.4 Make autoadjustment of actuator.Autoabgleich.
13.5 Set point potentiometer in mid-position
P - Gain to 10
I - Stability to 5
D- Derivative to 5
If the dynamic values have already been determined for an installation, they can be
programmed directly at this point.
13.6 Start engine and run it up to nominal speed using the set point potentiometeren.
13.7 Increase gain (P-fraction) up to instability and reduce until stability is attained.
Increase stability (I-fraction) up to instability and reduce until stability is attained.
Increase derivative (D-fraction) up to instability and reduce until stability is attained.
With these values set, engine speed is to be disturbed briefly (e.g., by shortly pressing
the stop switch), and the transient oscillations are to be observed.
13.8 Check over the entire speed range.
If for maximum and minimum speed other values than the programmed ones should
result, this will be due to tolerances of the set point potentiometer. If the speed derivation is not acceptable, it will be necessary to measure the setpoint source.
13.9 Gain-correction (P-correction) for gas engines resp. for variable speed governors with
larger speed ranges; adjust map if necessary.
13.10 Checking the remaining program items, e.g., starting fuel injection, ramp time, etc.
Digital Governor Basic System PANDAROS II 47
14 Ordering details
14 Ordering details
Control device:
Designation DC X .6-0Y
X = actuator type used 16, 30 or 40
Y = application variant 0 … 5 (see terminal connection diagrams)
The hardware and software of the control device are adapted prior to delivery in line with the
application variant, including the control device type. All other settings that are required, such
as the number of teeth, speed range, limiting curves, dynamic parameters and start procedure,
must be set by the customer themselves.
In the case of the variants Y = 0 or Y = 3, the customer must also configure the inputs and
outputs. This requires a Heinzmann communication tool with access to level 6 parameters
(access to all parameters).
Actuator:
One of the types listed in chapter 9.3 must be specified here.
Lever arm:
The type listed in chapter 10.2 must be specified here.
Speed pickup:
One of the types listed in chapter 6.2.5 must be specified here.
Additional sensors:
If additional sensors or a setpoint adjuster are required, the ordering details can be found in
the corresponding chapters.
Harness:
It is recommended to have the cable set produced at HEINZMANN. The necessary cable
lengths must be stated for the individual connections.
The cabling to the actuator and to the speed pickup must be performed by HEINZMANN in
all cases, as it is necessary in this context to use HEINZMANN plugs: the cables are soldered
onto the contacts of these plugs.
The order designations of the individual cables can be found in chapter 11.7.
48 Digital Governor Basic System PANDAROS II
15 Download of manuals
15 Download of manuals
Technical manuals can be downloaded in pdf-format from our homepage:
www.heinzmann.com
If the desired manual should not be available there, send an e-mail to:
info@heinzmann.de
or write to:
HEINZMANN GmbH & Co. KG
Technische Redaktion
Am Haselbach 1
D-79677 Schönau/Germany
Please include the following information:
your name
name and address of your company
e-mail or address where you want the manuals to be sent to (if different from above)
item code (as on front page, bottom right) and title of the desired manual
or alternatively the technical data of your HEINZMANN equipment.
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Digital Governor Basic System PANDAROS II 49
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