Page 1
Heinzmann GmbH & Co. KG
Engine & Turbine Controls
D-79677 Schönau (Schwarzwald)
Germany
Phone +49 7673 8208-0
Fax +49 7673 8208-188
E-mail info@heinzmann.com
www.heinzmann.com
V.A.T. No.: DE145551926
Am Haselbach 1
HEINZMANN
Digital Electronic Speed Governors
Basic Systems
HELENOS V
DC 2005DP.2-01
DC 2040DP.2-01
Copyright 2006 by Heinzmann GmbH & Co. KG. All rights reserved.
This publication may not be reproduced by any means whatsoever or passed on to any third parties
Druckschrift DG 97 014-e / 04-06
7011
Page 2
Page 3
Helenos V
for engines from approx. 80 kW up to approx. 2000 kW
Basic System DG 2005DP.2
- 01
Control Unit DC 2005DP.2
- 01
Actuator StG 2005DP
Setpoint Pot. SW ...
Pickup IA ...
Basic System DG 2040DP.2 - 01
Control Unit DC 2040DP.2 - 01
Actuator StG 2040 DP
Setpoint Pot. SW ...
Pickup IA ...
D : Digital
DG : Digital Governor (Basic System)
DC : Digital Control Unit
StG
:
Actuator (Stellgerät)
SW : Setpoint Potentiometer (Sollwertpot)
IA : Pickup (Impulsaufnehmer
HELENOS V
Page 4
Warning
Danger
Danger
Danger!
High
Voltage
Danger
Read this entire manual and all other publications appertaining to the
work to be performed before installing, operating or servicing your
equipment.
Practice all plant and safety instructions and precautions.
Failure to follow instructions may result in personal injury and/or
damage to property.
HEINZMANN will refuse all liability for injury or damage which
results from not following instructions
Please note before commissioning the installation:
Before starting to install any equipment, the installation must have been
switched dead!
Be sure to use cable shieldings and power supply connections meeting
the requirements of the European Directive concerning EMI.
Check the functionality of the existing protection and monitoring
systems.
To prevent damages to the equipment and personal injuries, it is
imperative that the following monitoring and protection systems
have been installed:
Overspeed protection acting independently of the speed governor
Overtemperature protection
HEINZMANN will refuse all liability for damage which results from
missing or insufficiently working overspeed protection
Generator installation will in addition require:
Overcurrent protection
Protection against faulty synchronization due to excessive frequency,
voltage or phase differences
Reverse power protection
Overspeeding can be caused by:
Failure of the voltage supply
Failure of the actuator, the control unit or of any accessory device
Sluggish and blocking linkage
Page 5
Warning
Warning
Danger
Electronically controlled injection (MVC) will in addition require
to observe the following:
With Common Rail systems a separate mechanical flow limiter must
be provided for each injector pipe.
With Pump-Pipe-Nozzle (PPN) and Pump Nozzle (PNE) systems fuel
release may be enabled only by the movement of control piston of the
solenoid valve. This is to inhibit fuel from being delivered to the
injection nozzle in case of seizure of the control piston.
The examples, data and any other information in this manual are
intended exclusively as instruction aids and should not be used in any
particular application without independent testing and verification by
the person making the application.
Independent testing and verification are especially important in any
application in which malfunction might result in personal injury or
damage to property.
HEINZMANN make no warranties, express or implied, that the
examples, data, or other information in this volume are free of error,
that they are consistent with industry standards, or that they will meet
the requirements for any particular application.
HEINZMANN expressly disclaim the implied warranties of
merchantability and of fitness for any particular purpose, even if
HEINZMANN have been advised of a particular purpose and even if a
particular purpose is indicated in the manual.
HEINZMANN also disclaim all liability for direct, indirect, incidental
or consequential damages that result from any use of the examples,
data, or other information contained in this manual.
HEINZMANN make no warranties for the conception and engineering
of the technical installation as a whole. This is the responsibility of the
user and of his planning staff and specialists. It is also their
responsibility to verify whether the performance features of our devices
will meet the intended purposes. The user is also responsible for correct
commissioning of the total installation.
Page 6
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 .......... 3
2 General ................................................................................................................................... 4
3 Functions ................................................................................................................................ 5
4 Mode of Operation ................................................................................................................ 8
5 Further information .............................................................................................................. 9
6 Block Diagram of the Digital Governor HELENOS ........................................................ 10
7 Sensors .................................................................................................................................. 11
7.1 Overview ....................................................................................................................... 11
7.2 Magnetic Pickup IA ... ................................................................................................... 12
7.2.1 Technical Datas ...................................................................................................... 12
7.2.2 Installation ............................................................................................................. 12
7.2.3 Tooth Profile .......................................................................................................... 13
7.2.4 Clearance for IA 02 - 76 up to IA 13 - 102 ............................................................ 13
7.2.5 Clearance for IA 22 - 76 and IA 23 - 102 .............................................................. 13
7.2.6 Mounting Measurements ....................................................................................... 14
7.2.7 Redundant Speed Signal ........................................................................................ 14
7.3 Cooling Medium Temperature Sensor TS 01 - 28 - PT 1000 ....................................... 15
7.4 Pressure Sensors ............................................................................................................ 16
7.4.1 Oil Pressure Sensor ................................................................................................ 16
7.4.2 Boost Pressure Sensors .......................................................................................... 17
7.4.2.1 Boost Pressure Sensor with Plug ................................................................... 17
7.4.2.2 Boost Pressure Sensor with Housing and Terminal Strip .............................. 18
8 Speed Setpoint Adjusters .................................................................................................... 19
8.1 Setpoint Potentiometer SW 01 - 1 - b (1 turn) ............................................................... 19
8.2 Setpoint Potentiometer SW 02 - 10 - b (10- turn) ......................................................... 19
8.3 Setpoint Value Adjustment by Current Signal .............................................................. 20
8.4 Digital Presetting of Setpoint Values ............................................................................ 20
8.5 Setpoint Value Adjustment by Pedal ............................................................................. 20
8.6 Pneumatic Setpoint Adjusters ........................................................................................ 20
HELENOS V
Page 7
Contents
9 Control Unit DC 2005DP.2 - 01 up to DC 2040DP.2 - 01 ................................................ 21
9.1 Specification .................................................................................................................. 21
9.1.1 General ................................................................................................................... 21
9.1.2 Inputs and Outputs ................................................................................................. 22
9.2 Mounting ....................................................................................................................... 22
9.3 Measurements ................................................................................................................ 23
10 Actuators ............................................................................................................................ 25
10.1 Design and Mode Operation ........................................................................................ 25
10.2 Installation ................................................................................................................... 26
10.3 Specification ................................................................................................................ 27
10.4 Measurements .............................................................................................................. 28
11 Electric Connection ........................................................................................................... 30
11.1 Connection of Shielding .............................................................................................. 30
11.2 Connection of Power Supply ....................................................................................... 31
11.3 Example of Connection for Generator Set with digital Accessories ........................... 33
11.4 Example of Connection for Generator Set with analogue Accessories ....................... 35
11.5 Example of Connection for Vehicle Operation ........................................................... 37
11.6 Example of Connection for Locomotive Operation with 16 Notches ......................... 39
11.7 Example of Connection for Locomotive Operation with Speed Setpoint via Current
Signal ................................................................................................................................... 41
11.8 Example of Connection for Marine Operation with Master/Slave .............................. 43
11.9 Example of Connection for Marine Operation in single Operation ............................ 45
12 Harness ............................................................................................................................... 47
12.1 Cable Lenghts .............................................................................................................. 47
12.2 Plug Designations ........................................................................................................ 48
13 Programming Possibilities ................................................................................................ 49
13.1 Programming by the Manufacturer.............................................................................. 49
13.2 Programming with the Hand- Held Programmer 2 ..................................................... 49
13.3 Programming by PC .................................................................................................... 49
13.4 Programming with User Masks ................................................................................... 49
13.5 Transferring Data Sets ................................................................................................. 49
13.6 Assembly Line End Programming .............................................................................. 50
14 Starting the Engine - Brief Instructions .......................................................................... 51
15 Ordering Specifications .................................................................................................... 52
15.1 General......................................................................................................................... 52
15.2 Cable Length ............................................................................................................... 52
16 Figure List .......................................................................................................................... 55
HELENOS V
Page 8
Contents
17 Order Specifications for Manuals .................................................................................... 57
HELENOS V
Page 9
1 Safety Instructions and Related Symbols
Warning
Danger
Danger!
High
Voltage
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
persons
product and engine
environment.
The symbols used in this publication are in the first place intended to direct your attention to
the safety instructions!
This symbol is to indicate that there may exist dangers to the engine, to the
material and to the environment.
This symbol is to indicate that there may exist dangers to persons. (Danger
to life, personal injury))
This symbol is to indicate that there exist particular danger due to
electrical high tension. (Mortal danger).
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. The respective text is printed in italics.
The primary issue of these safety instructions is to prevent personal injuries!
Whenever some safety instruction is preceded by a warning triangle labelled “Danger” this is
to indicate that it is not possible to definitely exclude the presence of danger to persons,
engine, material and/or environment.
If, however, some safety instruction is preceded by the warning triangle labelled “Caution”
this will indicate that danger of life or personal injury is not involved.
The symbols used in the text do not supersede the safety instructions. So please do not
skip the respective texts but read them thoroughly!
HELENOS V 1
Page 10
1 Safety Instructions and Related Symbols
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.
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.
2 HELENOS V
Page 11
1 Safety Instructions and Related Symbols
• 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!
HELENOS V 3
Page 12
2 General
4
2 General
The HEINZMANN Digitals Controls of the HELENOS series are designed as universal speed
controls for diesel engines, gas engines, and other prime movers. In addition to their primary
purpose of controlling speed, these governors are capable of performing a multitude of other
tasks and functions.
At the core of the control unit is a very fast and powerful microprocessor (CPU). The
controller programme itself based on which the microprocessor operates is permanently stored
in a so-called Flash-ROM.
In addition to the main processor, the HEINZMANN control unit is optional equipped with
an auxiliary processor (CPU2) performing two monitoring functions. On the one hand, the
auxiliary processor will monitor engine speed for overspeeding independently of the main
processor, on the other hand, it will supervise the operatability of the main processor itself. If
the auxiliary processor detects overspeed or if the main processor is at fault, the auxiliary
processor will execute an emergency engine shutdown.
Actual engine speed is measured by a magnetic pickup on the starter gear. For fail-safe
operation, either an additional speed pickup can be installed, or the control can use the
alternator signal from terminal W as a substitute for the speed signal. Thus, there will be no
interruption of operation if the first pickup should happen to fail.
Engine speed is set by one or more setpoint adjusters. These adjusters can be designed to be
analogue or digital ones. Further digital inputs permit to switch on functions or to change over
to other functions.
Furthermore, there are various sensors provided to feed the control all the data it needs to
adjust the engine's operating state. As an example, it is possible to have several temperature
and pressure signals transmitted from the engine.
The actuator regulating fuel supply to the engine is driven by a PWM signal.
The control generates analogue and digital signals which are used to indicate the engine's
operating conditions or serve other purposes and functions. Communication with other units
is established via a serial interface and a CAN bus.
HELENOS V
Page 13
3 Functions
3 Functions
HEINZMANN digital governors with control units of the series HELENOS V constitute
speed governors offering a midium range of functions.
In addition to speed regulation, the following functions are available:
a) Adjustment of Speed Range
The minimum and maximum speed which can be reached by setpoint value is adjustable by
parameter setting. Two different speed ranges are available.
b) Speed Ramp
For applications in which speed is not supposed to respond as fast as possible to changes of
setpoint values (e.g., locomotive operation), a speed ramp is available which according to
requirements may be programmed separately for increasing or decreasing speed.
c) Start Quantity Adjustment
For setting start quantity, 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.
d) Fixed Fuel Limitation
For the stop-position and the maximum fuelling position "electric catches" can be provided.
This will prevent the governor's thrust from affecting the terminal stops of the injection pump,
etc.
e) Speed Dependent Fuel Limitation
For variable speed governors, there is provided an option of programming speed dependent
limit curves. Thus, for any speed, torque can be reduced as is permissible for the engine or
desired by the user.
f) Boost Pressure Dependent Fuel Limitation
For turbocharged engines, fuelling can be reduced to achieve smokeless operation in case of
missing boost pressure (e.g., starting or load change). The respective limit curves can be
programmed accordingly.
HELENOS V 5
Page 14
3 Functions
g) Temperature Dependent Idling Speed
For 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. To protect the engine against
possible damages from high temperatures the full load characteristic can be decreased in
dependence of temperature.
h) Oil Pressure Monitoring
For the purpose of oil pressure monitoring, speed/pressure dependent limit curves can be
provided. If oil pressure is too low, an alarm is given; if oil pressure continues to drop, the
engine is shut down.
i) 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.
j) All Speed Governing with adjustable Droop
Some applications require speed governing with droop, e,g, generator parallel operation
without HEINZMANN-load measuring unit. The droop can be adjusted as desired. With
droop adjusted to 0, the governor operates in isochronuous mode.
k) Idling and Maximum Speed Control
For vehicle application, the governor can be made to operate as an idling and maximum speed
controller. In addition, one fixed intermediate speed is available, e.g., for an application
combining driving and stationary mode (e.g., generator at power take-off). If necessary, a
change-over switching of the droop can be provided, i.e., during stationary operation also
droop zero is possible.
l) 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.
m) Overspeed Protection
An overspeed point can be parametrised. If this point is overcome, the governor will issue an
alarm and the actuator will fully pull to stop direction.
6 HELENOS V
Page 15
3 Functions
n) Output Signals
The control unit has four analogue outputs available, two current outputs (4..20 mA) and two
voltage outputs (0..5 V).
o) Failure Diagnosis and Display
If a sensor or the actuator is at fault, an external alarm is issued and there will be 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
handprogrammer or, if a communication program with communication cable is existing with a
PC or laptop computer.
p) Velocity Limitation and Velocity Control
In vehicle operation the velocity of the vehicle can be limited or controlled (cruise control).
q) Locomotive Operation
In locomotive operation, setpoints can be defined by means of analogue setpoint or by using
up to 16 digital speed stage switches.
For Diesel-electric locomotives the excitation of generator can be controlled depending on
speed and load by an analogue signal.
An anti stick slip device can be provided.
r) Generator Operation
In generator operation the synchronisation and load sharing can be done either in manual
mode (analogue input / digital input) with droop or isochronous in automatic mode with
accessory units from HEINZMANN.
s) CAN-Bus
Accessories such as synchronizing units, load measuring units, disturbance variable
compensation units can be connected via a CAN-Bus within the control unit. The CAN-Bus
may also be used to implement load distribution by equal fuelling (e.g., two engines on one
gear).
When selecting and determining the functions, it has to be ascertained whether
the hardware equipment suffices with respect to the total range of functions.
HELENOS V 7
Page 16
4 Mode of Operation
4 Mode of Operation
The actual speed of the engine is read by a pulse pickup from a cog wheel, preferably from
the starter gear. The microprocessor (CPU) of the control unit compares the actual speed with
the preset value. If differences are stated, the new actuator signal is calculated by the CPU and
transmitted to the actuator via the output stage. Feedback from the actuator indicates the
current position of the output shaft thus allowing optimum signal adjustment by the CPU.
As the governor comprises an I-fraction and as for any load level the speed is permanently
compared with a fixed preset value, speed can be kept constant also in steady state, i.e., droop
is zero.
For applications requiring droop, the speed related to the respective fuelling is calculated by
the CPU and entered as correction of the setpoint value.
During standstill, a particular circuit ensures that only the current of the control unit is
received by the governor, but no current flows to the actuator motor.
8 HELENOS V
Page 17
5 Further information
5 Further information
This publication describes in detail the data and connections of the control electronics, of the
sensors, of the setpoint adjusters and of the actuators.
The function of the different adjustment parameters and characteristics are described in detail
in the manual
Basic Information 2000, Manual-No. DG 00 001-e
The mode of operation of the communication programme DcDesk 2000 is described in detail
in the manual
Operating Instructions Communication Program DcDesk 2000,
Manual-No. DG 00 003-e
The HEINZMANN governors series HELENOS are customized produced and preadjusted.
Therefore it is necessary to get the filled in manual
Order-Information Digital Speed Governors, Manual No. DG 96 012-e
from the customer.
HELENOS V 9
Page 18
6 Block Diagram of the Digital Governor HELENOS
Memory
Mikroprocessor
Power
CAN - Bus
Interface
Control Unit
DC ..2-01
Magnetic pickup
Redundant Engine Speed Signal
Setpoint Values
Temperature Sensor
Engine Stop
Oil Pressure Sensor
Digital Inputs
Actuator
Engine Speed
Actuator Travel
Alarm
Programming Attachment
Diagnostics
Digital Application Units
e.g. Synchronizer, Load
Measuring Unit
Converter
Converter
Converter
Boost Pressure
Sensor
Amplifier
Feedback
Drive
6 Block Diagram of the Digital Governor HELENOS
Figure 1: Blockdiagram DG 16.1 - 03 up to DG 40.1 - 03
10 HELENOS V
Page 19
7 Sensors
Connection
SV 6-IA-2K
SV 6-IA-2K
DIN 43650 A
DIN 43650 A
Measuring Procedure
inductive, active
PT1000, passive
active
active
Measuring Range
50...6.000 Hz
-50...+150°C
0...6 bar
0...2 bar
Supply Voltage
passive
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
-55...+120°C
-50...+150°C
-25...+125°C
-40...+100°C
7.1 Overview
7 Sensors
Sensor Speed
HZM Designation IA .. TS 01-28-PT1000 DSO 01-6
2 pole
Range
Temperature Range
Temperature
2 pole
Oil Pressure Boost Pressure
DSL/G 0..-2
DSO 01-10
DSO 01-16
2 Line System
0...10 bar
DSL/G 0..-5
DSL/G 0..-10
2 Line System
0...5 bar
0...10 bar
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.
Coolant
HELENOS V 11
Page 20
7 Sensors
60
*min)/1( zn
60
80
*500
7.2 Magnetic Pickup IA ...
7.2.1 Technical Datas
Operating principle inductive sensor
Distance from sensing gear standard 0.5 to 0.8 mm
with IA 22.. and IA 23.. 2.5 to 3 mm
Output 0 V .. 10 V AC
Signal form Sine (depending on tooth shape)
Resistance approx. 52 Ohm, with IA 22.. and IA 23..
approx. 130 Ohm
Temperature range -55°C up to +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)
7.2.2 Installation
The installation of the pickup has to be arranged in such a way as to obtain a frequency
as high as possible. Normally, the HEINZMANN digital governors DG 16.1 - 03 up to
DG 40.1 - 03 are designed for a maximum frequency of 6.000 Hz. The frequency (by
Hz) is calculated according to the formula:
f
(Hz)
=
z = number of teeth on the pickup wheel
Example:
n = 500
z = 80
f =
= 666.67 Hz
It should be taken care that the speed can be measured by the pulse pickup without any
bias. For best results therefore, the speed pickup 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 pickup gear must consist of magnetic material (e.g., steel, cast iron).
12 HELENOS V
Page 21
7 Sensors
7.2.3 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 (8 mm at IA 22 - 76 and IA 23 - 102).
For index plates the same dimensions are valid.
Due to tolerances, a radial arrangement of the magnetic pickup is preferable.
7.2.4 Clearance for IA 02 - 76 up to IA 13 - 102
The distance between the magnetic pulse pickup and the tooth top should range from
0.5 to 0.8 mm. (It is possible to screw in the magnetic pickup till it touches the tooth and
then unscrew it for about half a turn.)
7.2.5 Clearance for IA 22 - 76 and IA 23 - 102
The distance between the magnetic pulse pickup and the tooth top should range from
2.5 to 3 mm. (It is possible to screw in the magnetic pickup till it touches the tooth and
then unscrew it for about two turns.)
Figure 2: Clerance of Pickup
HELENOS V 13
Page 22
7 Sensors
G
L
35
19
7.2.6 Mounting Measurements
Figure 3: Magnetic Pickup
Measures
Type
Thread Length
L (mm)
01 - 38 38 M 16 x 1,5
02 - 76 76 M 16 x 1,5
03 - 102 102 M 16 x 1,5
11 - 38 38 5/8"-18UNF-2A appropriate
12 - 76 76 5/8"-18UNF-2A plug
13 - 102 102 5/8"-18UNF-2A SV6-IA-2K
22 - 76 76 M 24 x 1,5
23 - 102 102 M 24 x 1,5
Ordering specification, e.g. IA 02-76.
Thread Size
G
Remarks
7.2.7 Redundant Speed Signal
If precautions are to be taken with regard to failures od the pulse pickup, a second pulse
pickup can be connected to the control unit. In case that an electric generator with
terminal W is available, this signal may be used for emergency operation as well as any
other signal of a tachogenerator.
In case of a failure on puls pickup 1, the governor automatically switches over to the
redundant speed signal and gives an alarm.
14 HELENOS V
Page 23
7 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 = +
7.3 Cooling Medium Temperature Sensor TS 01 - 28 - PT 1000
Measuring range -50°C up to +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 1mA
Time constant in fluids approx. 13 seconds
Admissible temperature range
of connector socket -40°C up to +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 %
Connector SV 6 - IA - 2K (EDV- No.: 010 02 170 00)
EDV-No.: 600-00-053-00
Figure 4: Temperature Sensor TS 01 - 28 - PT 1000
HELENOS V 15
Page 24
7 Sensors
12
22
48,8 26
Ø 19
27
G1/4"
M5
SW 19
7.4 Pressure Sensors
7.4.1 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 up to +85°C
Ambient temperature -25°C up to +85°C
Oil temperature -25°C up to +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
Figure 5: Oil Pressure Sensor
Pressure Sensor EDV- No.
Max. Operating
Pressure (bar)
DSO 01 - 6 600-00-058-00 6
DSO 01 - 10 600-00-058-01 10
16 HELENOS V
Page 25
7 Sensors
89
12
2
G3/8"
Ø 30
124,7
30,5
Ø 19
PG9
SW 24
33,5
53
7.4.2 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 up to +100°C
Ambient temperature -40°C up to +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
7.4.2.1 Boost Pressure Sensor with Plug
Figure 6: Boost Pressure Sensor with Plug
Boost Pressure EDV- No.
DSL 01 - 2 600-00-057-00 2
Max. Operating
Pressure (bar rel.)
DSL 01 - 5 600-00-057-01 5
DSL 01 - 10 600-00-057-02 10
HELENOS V 17
Page 26
7 Sensors
Am Haselbach 1
D-79677 SchÎnau/ Schw.
Germany
Phone: (07673) 8208 -0
Telefax: (07673) 8208-88
GmbH + Co.
HEI NZMANN
R
10
4,5
52
57
27,5
14
80
113
125
6
91
29,5
SW 24
G3/8"
G1/4"
15
30
30
7.4.2.2 Boost Pressure Sensor with Housing and Terminal Strip
Figure 7: Boost Pressure Sensor with Housing
Pressure Sensor EDV- No.
Max. 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
18 HELENOS V
Page 27
8 Speed Setpoint Adjusters
9,5
3/8" - 32 NEF - 2A
Ø 27
23
26
8,8
3/8" - 32 NEF - 2A
Ø 23
17
32
8 Speed Setpoint Adjusters
Dependent on particular applications, a series of setpoint adjusters are available for the
HEINZMANN Digital Controls.
8.1 Setpoint Potentiometer SW 01 - 1 - b (1 turn)
Displacement angle approx. 312°
Resistance 5 kOhm
Temperature range -55°C to + 120°C
Protection grade IP 00
Figure 8: Potentiometer SW 01 - 1 - b
8.2 Setpoint Potentiometer SW 02 - 10 - b (10- turn)
Displacement angle 10 turns
Resistance 5 kOhm
Temperature range -55°C to + 120°C
Protection grade IP 00
HELENOS V 19
Figure 9: Potentiometer SW 02 - 10 - b
Page 28
8 Speed Setpoint Adjusters
On request, the potentiometers, as specified under 8.1 and 8.2, can be supplied with
analogue adjustment knob with lock in place of the standard rotating knob. In this case,
ordering specification is SW..-..-m.
Equally, instead of the knob a clamping fixture can be installed. Ordering specification is
to changed to SW ..-..-k.
8.3 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 set minimum speed according to the 4 mA
value or a programmable substitute value.
8.4 Digital Presetting of Setpoint Values
A 4 bit binary coded digital input for 16 speed levels from n
connected to the control unit.
min
to n
can be directly
max
8.5 Setpoint Value Adjustment by Pedal
This unit is basically an angular position transducer that translates a foot pedal into a
proportional current or voltage for 0 - 45° rotation. The resulting output can be used for
speed setting. For more information refer broschure E 83 005 - e.
8.6 Pneumatic Setpoint Adjusters
For pneumatic setpoint adjustment are the boost pressure sensors usable. For more
informations of the sensors refer to chapter 7.5.2.
20 HELENOS V
Page 29
9 Control Unit DC 2005DP.2 - 01 up to DC 2040DP.2 - 01
9 Control Unit DC 2005DP.2 - 01 up to DC 2040DP.2 - 01
9.1 Specification
9.1.1 General
Supply Voltage 24 V DC (12 V DC)
Maximum Voltage 35 V DC
Minimum Voltage 18 V DC (9 V DC)
Maximum Ripple Voltage maximum 10 % with 100 Hz
Current Consumption approx. 200 mA + current of actuator
Permissible voltage dip at
maximum current consumption max. 10 % in Control unit
Fuse protection of governor 16 A
Storing Temperature -55°C up to +85°C
Operating Temperature -40°C up to +70°C
Humidity up to 98% at 55°C,
Shock 50 g, 11 ms- half-sine wave
Protection grade
DC ...2 - 01 - 00 IP 00
DC ...2 - 01 - 55 IP 55
Weight
DC ...2 - 01 - 00 approx. 1.2 kg
DC ...2 - 01 - 55 approx. 3 kg
Insulation resistance > 1 MOhm at 48 V DC
HELENOS V 21
Page 30
9 Control Unit DC 2005DP.2 - 01 up to DC 2040DP.2 - 01
9.1.2 Inputs and Outputs
Supply voltage sensors Input voltage
Reference Voltage setpoint adjuster U
= 5 V DC, I
ref
= 20 mA (10 mA)
max
2 Speed inputs for Inductive sensor
1 Temperature input for PT 1000
1 Temperature input for NTC
4 Analogue inputs U = 0..5 V, fg = 16 Hz
or I = 4 .. 20 mA, fg = 16 Hz
4 Digital inputs Rpd = 2,2 kΩ, fg = 160 Hz
4 Digital /PWM- In- Outputs Rpu = 2,2 kΩ, I
2 Analogue Outputs Current I
2 Analogue Outputs Voltage U
1 PWM-Output I
= 0 .. 22,5 mA, R
out
= 0 .. 5 V, R
out
< 3 A
sink
2 Digital Outputs failure lamp High-Side-Switch, I
Actuator position sensing U
= 1,4 ..3,0 V, U
Reg.weg
< 0,1 A, fg = 160 Hz
sink
= 470 Ω (125 Ω)
max
= 250 Ω (500 Ω)
min
< 3 A
max
ref
= 8 V, I
< 20 mA
ref
Drive output PWM with 2000 Hz, I
< 6,4 A
eff
Serial Interface ISO 9141, Heinzmann Communication
9.2 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.
22 HELENOS V
Page 31
205
260
240
25
110
160
6,5
92
42
20
55
130
H EI NZ M AN N
Serial No.:
for Basic System E
Range Voltage
GmbH + Co.
Am Haselbach 1
D - 79677 Schönau (Schwarzwald)
Germany
Phone: (0 76 73) 82 08 - 0
Telefax: (0 76 73) 82 08 - 88
9 Control Unit DC 2005DP.2 - 01 up to DC 2040DP.2 - 01
9.3 Measurements
Control Unit with plug-in connectors (DC ... 2 - 01 - 55)
Figure 10: Control Unit DC 2005DP.2 - 01 up to DC 2040DP.2 - 01
HELENOS V 23
Page 32
9 Control Unit DC 2005DP.2 - 01 up to DC 2040DP.2 - 01
122,5
2,5
43,5
21
3 4 5 6
7 8 9 10 11
12 13 14 15
16 17 18 19 20
21 22 23 24 25
26 27 28 29
30 31 32 33 34
35 36 37
38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74
240
260
10
6,5
15
110
148
HEINZMANN
Serial No.:
for Basic System E
Range Voltage
GmbH + Co.
Am Haselb ach 1
D - 7967 7 Sch önau (Sc hwarzwal d)
Germany
Phone: (0 76 73) 82 08 - 0
Telefax: ( 0 76 73) 82 08 - 88
Control Unit with terminal strip (DC ... 2 - 01 - 55)
Figure 11: Control Unit DC 2005DP.2 - 01 up to DC 2040DP.2 - 01
24 HELENOS V
Page 33
10 Actuators
Stop Lever
Working Coil
Feedback System
Injection Pump
(no delivery item)
Control Rod Travel
(adjustable from 14 to 21 mm)
Lace up
Adapter Plate
10 Actuators
10.1 Design and Mode Operation
Figure 12: Sectional Drawing of Actuator
A multipole-magnetised permanent magnet is mounted on the internal actuator shaft.
Opposite the permanent magnet a coil shell with the working coils is fixed. On feeding
current through the coils, torque and rotary motion in one direction is produced. Reversing
current polarity will produce torque in the opposite direction.
The lever which is fixed to the internal shaft is connected to the control rod of the injection
pump by a special linkage system. By this, the rotary motion of the internal shaft is directly
transmitted as a linear motion to the control rod.
On the actuator shaft, also the governor feedback is firmly mounted which operates
contact-free and transmits the position of the governor output shaft accurately to the
control unit. By this, the control unit is able to rapidly calculate the linkage adjustment as
required by speed changes, and to accommodate current accordingly.
An additional external lever provides the possibility of executing an emergency shutdown.
However, in order to stop the engine by means of this stop lever it will be necessary to
overcome the electric positioning force working in the direction of 100%. Therefore,
before executing an emergency shutdown by the stop lever, the voltage supply should first
be switched off.
HELENOS V 25
Page 34
10 Actuators
Due to the closed assemblage, the control linkage is fully protected for maintenance-free
operation and long durability of the actuators.
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
after approx. 20 seconds; by this the current to the actuator is reduced to a value that
cannot harm the motor.
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 disturbance.
- Due to direct assemblage, the linkage is fully protected and maintenance-free, and there
is no need for complicated linkage adjustment.
10.2 Installation
For the different pump systems, a variety of assembly kits is provided consisting mainly of
the adapter plate and the customer-specific linkage connection.
The assembly kits come with detailed assembling instructions which will help the user to
do the mounting easily by himself.
26 HELENOS V
Page 35
10 Actuators
Spring power of back spring
Spring power of back spring
Maximum positioning force
approx. 20 N
approx. 110 N
Maximum current consumption
6 A
6 A
Current consumtion in operation
1.5 ... 3 A
1.5 ... 3 A
Coil resistance of governing magnet
1.4 Ohm
2 Ohm
Storage temperature
-55°C … 110°C
-55°C … 110°C
Ambient temperature in operation
-25°C … 90°C
-25°C … 90°C
Vibration level
± 1 mm at 1 ... 20 Hz
± 1 mm at 1 ... 20 Hz
Shock level
30 g, 11 ms, half sine
30 g, 11 ms, halb sine
Protection grade
IP 55
IP 55
Weight
approx. 2.4 kg
approx. 4.2 kg
10.3 Specification
StG 2005 DP StG 2040 DP
Maximum control rod travel 21 mm 21 mm
in stop position
in full position
approx. 9 N
14 N
max. 0.24 m/s at 21 ... 63 Hz
max. 9g at 64 ... 2000 Hz
approx. 30 N
50 N
max. 0.24 m/s at 21 ... 63 Hz
max. 5g at 64 ... 300 Hz
HELENOS V 27
Page 36
10 Actuators
68
27,5
102
3
32,5
167
147,5
140,5
88
100
105
10.4 Measurements
Figure 13: Actuator StG 2005 DP
28 HELENOS V
Page 37
10 Actuators
108
108
36
88
130
141
154
131,5
125
111
Figure 14: Actuator StG 2040 DP Measurements
HELENOS V 29
Page 38
11 Electric Connection
HEINZMANN
Seri al No. :
for Basic System E
Range Voltage
GmbH + Co.
Am Haselbach 1
D - 79677 Schönau (Schwarzwald)
Germany
Phone: (0 76 73) 82 08 - 0
Telefax: (0 76 73) 82 08 - 88
sensor
control unit
seperate wire
potentiometer
shielding
shrink sleeve
11 Electric Connection
11.1 Connection of Shielding
To avoid elektromagnetic influences it is necessary to connect cable shields at both ends.
This includes shielding from control housing to sensors, from control housing to
potentiometers, from control housing to actuator and from control housing to accessory
units. If there is a potential difference between the control housing and any of these other
componets, to avoid currents via the shielding it is necessary to run a separate wire from
the control housing to each of these components.
Figure 15: Connection of seperat Wire
At cable ends without plugs (e.g. terminal strip or pins) the shielding must be connected at
the housing near the contacts.
Figure 16: Shield Connection without Plug
30 HELENOS V
Page 39
11 Electric Connection
sensor plug
strain relief
shielding
shrink sleeve
In case of a plug connection the shielding is jamed in the strain relief of the plug.
Figure 17: Shield Connection in the Plug
11.2 Connection of Power Supply
Inappropriate choice of power supply or insufficient battery capacitance or incorrect
connection of the power supply line or too small cable sizes of the feed line and the motor
line of the actuator are bound have an adverse effect upon the performance of the speed
governor. In steady state operation, this will cause a heavy increase of current consumption
and unnecessary vibration of the actuator drive. The high current consumption will in its
turn lead to overheating of the actuator or the amplifier in the control unit, and the
vibration will result in premature wear of the gear and bearing parts or of the linkage.
In altogether, the lifetime of the control system is distinctly reduced by the
errors described above.
The following figure shows both a wrong and a correct cabling:
HELENOS V 31
Page 40
11 Electric Connection
(-)
(+)
E
F
-
+
+
-
The control unit has to
be connected via a fuse
and a switch directly to
the battery!
(-)
(+)
E
F
-
+
Cable to Power
Supply
L1
+
-
Battery
Engine
HEINZMANN
Actuator
StG ...
Actuator Cable L2
Switch Board
Gover nor
on/of f
Charger
HEINZMANN
Control Unit
KG/DC ...
Engine
...
Switch Board
The ripple voltage of the charger is fed
directly into the electronic governor!
This will demage the actuator!
correct
1) Coils (e.g. stopping solenoid, gas valve) have to be equipped with a protective circuit to eliminate high
indunctance votages. Diode type e.g. 1N4002
HEINZMANN
Control Unit
KG/DC ...
HEINZMANN
Actuator
StG ...
Fuse
Cable to Power
Supply L1
Actuator Cable
L2
wrong
Charger
Gover nor
on/of f
Battery
Freewheeling
Diode 1)
Warning
Warning
Figure 18: Correct Connection of Power Supply
If there are battery chargers with rapid charge mode installed in the
plant, the rapid charge mode should no be used during operation.
If there is no battery provided, it is absolutely necessary that a three phase power supply
or a stabilized one phase power supply with at least 24 V DC, 10 Amps output power be
used as a power source.
HEINZMANN offers for the control system PRIAMOS I the power supply NG 01 and if
an additional backup system is required, the power supply NG 01 + NSV 01 and NG 04.
For more informations, refer to the separate manuals E 88 002-e and E 97 002-e.
The cable sizes and cable lengths described in the wiring diagrams
must not be exceeded!
When power supply, battery and cabling have been correctly dimensioned, then on starting
the engine or with the actuator operating at maximum current consumption (approx. 6.4
Amps), a drop of the supply voltage directly at the control unit of approx. 2 Volts
maximum only will be admissible.
32 HELENOS V
Page 41
11 Electric Connection
5 4 2
3
C
B
A
D
E
A
B
A
B
StG 2005 DP
StG 2040 DP
Actuator
16 A slow
Governor on
T x D
R x D
24V
0V
DC … 2 - 01 - 55
Control Unit
+
24V
ll
Low
High
A
B
A
B
A
B
-
0 - 5V
4 - 20mA
0 - 5V
4 - 20mA
T x D
R x D
24V
0V
1
Y
1
Z 1 M
1
T
1
N
1
G
1
X
1
W
1
F
1
A
1
B
1
H
1
D
1
C
1
S
1
R
1
U
1
V
1
A
2
M
2
L
2
N
2
K
2
U
2
B
2
P
2
C
2
J
2
T
2
P
3
C
3
B
3
K
3
J
3
T
3
S
3
G
3
E
3
F
3
M
3
A
3
U
3
N
3
L
3
l
R
3
SUB-D Plug
Plug 3
Plug 2
Plug 1
Magnetic Pickup 1 IA ...
Magnetic Pickup 2 IA...
(or Terminal W )
Temperature Sensor
Overspeed Protection
Cooling Water Sensor
red
green
Display
Overall Alarm
Gover nor
Overspeed
Display fuel
Display fuel
Display speed
Display speed
Motor Stop
Droop
Manuel Set Point
Set Value +
Fixed Speed
1 2 Set Value -
Connection
Programmer 2
Diagnostics
CAN - Bus
Connection of
Digital Accessories
Connection
PC
Cable Size
I up to 10 m 2,5 mm
2
over 10 - 20 m 4,0 mm
2
over 20 - 40 m 6,0 mm
2
II up to 15 m 2,5
mm 2 over 15 - 30 m 4,0
mm
2
Rest 0,75
mm
2
11.3 Example of Connection for Generator Set with digital Accessories
(Island parallel- and mains operation)
Figure 19: Connections with Plug (IP 55) for Genset with digital Accessories
HELENOS V 33
Page 42
11 Electric Connection
5 4 2
3
C
B
A
D
E
A
B
A
B
StG 2005 DP
StG 2040 DP
Actuator
16 A slow
Governor on
red green
T x D
R x D
24V
0V
DC …2
- 01 - 00
Control Unit
+
24V
ll
Low
High
A
B
A
B
A
B
-
0 - 5V
4 - 20mA
0 - 5V
4 - 20mA
T x D
R x D
24V
0V
1
l
SUB-D Pug
48
49
47
43
44
45
46
50
51
52
61
60
56
58
63
71
74
73
2
1
11
12
10
7
9 13 14
15
24
23
19
21
20
22
32
31
30
26
28
35
34
36
37
67
27
Magnetic Pickup 1 IA ...
Magnetic Pickup 2 IA...
(or Terminal W)
Temperature Sensor
Overspeed Protection
Cooling Water Sensor
Display
Overall Alarm
Gover nor
Overspeed
Display fuel
Display fuel
Display speed
Display speed
Motor Stop
Droop
Manuel Set Point
Set Value +
Fixed Speed
1
2
Set Value -
Connection
Programmer 2
Diagnostics
CAN - Bus
Connection of
Digital Accessories
Connection
PC
Cable Size
I up to 10 m 2,5 mm
2
over 10 - 20 m 4,0 mm
2
over 20 - 40 m 6,0 mm
2
II up to 15 m 2,5
mm
2
over 15 - 30 m 4,0
mm
2
Rest 0,75
mm
2
Figure 20: Connections with Terminal Strip (IP 00) for Genset with digital Accessories
HELENOS V 34
Page 43
11 Electric Connection
5 4 2 3 C B A D E A B A B
StG 2005 DP
StG 2040 DP
Motor Stop
T x D
R x D
24V
0V
DC …2 - 01 - 00
Control Unit
+
24V
ll
Droop
Fixed Speed
1
2
A
B A B A B - 1
l
LMG 03
15
16
14
16A
17
SyG 02
20 kOhm
16 A slow
Governor on
0 - 5V
4 - 20mA
0 - 5V
4 - 20mA
T x D
R x D
24V
0V
max.
min.
5 kOhm
470 Ohm
470 Ohm
SUB-D Plug
48
49
47
43
44
45
46
50
51
52
61
60
56
58
63
71
74
73 2 1
11
12
10 7 9
13 6 15
24
23
19
21
20
22
26
28
36
37
27
14
45
16
18
55
53
54
17
Actuator
Magnetic Pickup 1 IA ...
Magnetic Pickup 2 IA...
(or Terminal W )
Temperature Sensor
Overspeed Protection
Cooling Water Sensor
Synchronizer
Manual Setpoint
red
green
Display
Overall Alarm
Gover nor
Overspeed
Display fuel
Display fuel
Display speed
Display speed
Load
Measuring
Unit
Connection
Programmer 2
Diagnostics
Connection
PC
Cable Size
I up to 10 m 2,5 mm
2
over 10 - 20 m 4,0 mm
2
over 20 - 40 m 6,0 mm
2
II up to 15 m 2,5
mm
2
over 15 - 30 m 4,0
mm 2 Rest 0,75
mm
2
11.4 Example of Connection for Generator Set with analogue Accessories
(Island parallel- and mains operation)
Figure 21: Connection with Plugs (IP 55) for Genset with analogue Accessories
HELENOS V 35
Page 44
11 Electric Connection
5 4 2 3 C B A D E A B A B
StG 2005 DP
StG 2040 DP
Motor Stop
T x D
R x D
24V
0V
DC …2 - 01 - 00
Control Unit
+
24V
ll
Droop
Fixed Speed
1
2
A
B A B A B - 1
l
LMG 03
15
16
14
16A
17
SyG 02
20 kOhm
16 A slow
Governor on
0 - 5V
4 - 20mA
0 - 5V
4 - 20mA
T x D
R x D
24V
0V
max.
min.
5 kOhm
470 Ohm
470 Ohm
SUB-D Plug
48
49
47
43
44
45
46
50
51
52
61
60
56
58
63
71
74
73 2 1
11
12
10 7 9
13 6 15
24
23
19
21
20
22
26
28
36
37
27
14
45
16
18
55
53
54
17
Actuator
Magnetic Pickup 1 IA ...
Magnetic Pickup 2 IA...
(or Terminal W )
Temperature Sensor
Overspeed Protection
Cooling Water Sensor
Synchronizer
Manual Setpoint
red
green
Display
Overall Alarm
Gover nor
Overspeed
Display fuel
Display fuel
Display speed
Display speed
Load
Measuring
Unit
Connection
Programmer 2
Diagnostics
Connection
PC
Cable Size
I up to 10 m 2,5 mm
2
over 10 - 20 m 4,0 mm
2
over 20 - 40 m 6,0 mm
2
II up to 15 m 2,5
mm
2
over 15 - 30 m 4,0
mm 2 Rest 0,75
mm
2
Figure 22: Connection with Terminal Strip (IP 00) for Genset with analogue Accessories
HELENOS V 36
Page 45
11 Electric Connection
5 4 2 3
C
B
A
D
E
A
B
A
B
StG 2005 DP
StG 2040 DP
Motor Stop
T x D
R x D
24V
0V
DC …2 - 01 - 55
Control Unit
+
24V
ll
Idle
Speed Range
Fixed Speed 2
Fixed Speed 1
A
B
A
B
A
B
-
Fuel Limitation
1
N
2
U
2
L
2
M
2
A
2
C
3
B
3
K
3
J
3
T
3
S
3
G
3
E
3
F
3
M
3
A
3
U
3
N
3
L
3
l
A
B
Boost Pressure Sensor
Oil Pressure Sensor
Torque
P
3
1
2
1
2
A
B
Velocity Sensor
R
3
D
3
16 A slow
Governor on
R
3
C
A
B
C
0 - 5V
4 - 20mA
0 - 5V
4 - 20mA
max. min.
5 kOhm
Manual Setpoint 1
470 Ohm
470 Ohm
max.
min.
5 kOhm
470 Ohm
470 Ohm
Low
High
T x D
R x D
24V
0V
Y
1
Z
1
M
1
T
1
N
1
G
1
X
1
W
1
F
1
A
1
B
1
H
1
D
1
C
1
S
1
R
1
U
1
V
1
J
1
P
1
Q
1
E
1
L
1
K
1
K
2
B
2
R
2
P
2
C
2
E
2
D
2
J
2
T
2
S
2
F
2
G
2
H
2
SUB-D Plug
Plug 3 Plug 2 Plug 1
Actuator
Magnetic Pickup 1 IA ...
Magnetic Pickup 2 IA...
(or Terminal W)
Temperature Sensor
Overspeed Protection
Cooling Water Sensor
red
green
Display
Overall Alarm
Gover nor
Overspeed
Display fuel
Display fuel
Display speed
Display speed
Manual Setpoint 2
Connection
Programmer 2
Diagnostics
CAN
- Bus
Connection of
Digital Accessories
Connection
PC
Cable Size
I up to 10 m 2,5 mm
2
over 10 - 20 m 4,0 mm
2
over 20 - 40 m 6,0 mm
2
II up to 15 m 2,5
mm
2
over 15 - 30 m 4,0
mm
2
Rest 0,75
mm
2
11.5 Example of Connection for Vehicle Operation
Figure 23: Connection with Plugs (IP 55) for Vehicle Operation
HELENOS V 37
Page 46
11 Electric Connection
5 4 2 3
C
B
A
D
E
A
B
A
B
StG 2005 DP
StG 2040 DP
T x D
R x D
24V
0V
DC …2 - 01 - 00
Control Unit
+
24V
ll
A
B
A
B
A
B
-
1
l
A
B
1
2
1
2
A
B
16 A slow
Governor on
C
A
B
C
0 - 5V
4 - 20mA
0 - 5V
4 - 20mA
max.
min.
5 kOhm
470 Ohm
470 Ohm
max.
min.
5 kOhm
470 Ohm
470 Ohm
Low
High
T x D
R x D
24V
0V
SUB-D Plug
48 49 47 43 44 45 46 50 51 52 61 60
56 58
63 71 74 73
2
1
11 12 10
7
9 13 14
15
24 23 19
21
20 22
32 31 30 26 28 35 34 36 37
67
27
9 3 4
41
5 6
18 16 17
53 55 54
29
33
Boost Pressure Sensor
Oil Pressure Sensor
Actuator
Magnetic Pickup 1 IA ...
Magnetic Pickup 2 IA...
(or Terminal W)
Temperature Sensor
Overspeed Protection
Cooling Water Sensor
Manual Setpoint 1
red
green
Display
Overall Alarm
Gover nor
Overspeed
Display fuel
Display fuel
Display speed
Display speed
Manual Setpoint 2
Motor Stop
Idle
Speed Range
Fixed Speed 2
Fixed Speed 1
Fuel Limitation
Torque
Velocity Sensor
Connection
Programmer 2
Diagnostics
CAN - Bus
Connection of
Digital Accessories
Connection
PC
Cable Size
I up to 10 m 2,5 mm
2
over 10 - 20 m 4,0 mm
2
over 20 - 40 m 6,0 mm
2
II up to 15 m 2,5
mm
2
over 15 - 30 m 4,0
mm
2
Rest 0,75
mm
2
Figure 24: Connection with Terminal Strip (IP 00) for Vehicle Operation
HELENOS V 38
Page 47
11 Electric Connection
5 4 2 3
C
B
A
D
E
A
B
A
B
StG 2005 DP
StG 2040 DP
Motor Stop
T x D
R x D
24V
0V
DC …2 - 01 - 55
Control Unit
+
24V
SUB-D Plug
Idle
Anti Stick Slip Device
Bit 0
Speed
A
B
A
B
A
B
-
Bit 1
1
M
3
A
3
U
3
N
3
L
3
l Bit 2
Bit 3
Manual
Remote
ll
16 A slow
Governor on
A
B
C
A
B
C
0 - 5V
4 - 20mA 0 - 5V
4 - 20mA
max.
min.
5 kOhm
470 Ohm
470 Ohm
T x D
R x D
24V
0V
Y
1
Z
1
M
1
T
1
N
1
G
1
X
1
W
1
F
1
A
1
B
1
H
1
D
1
C
1
S
1
R
1
U
1
V
1
J
1
P
1
Q
1
E
1
L
1
K
1
N
2
U
2
L
2
M
2
A
2
K
2
B
2
R
2
P
2
C
2
E
2
D
2
J
2
T
2
F
2
C
3
B
3
K
3
J
3
T
3
S
3
P
3
D
3
R
3
H
3
Plug 3 Plug 2 Plug 1
Boost Pressure Sensor
Oil Pressure Sensor
Actuator
Magnetic Pickup 1 IA ...
Magnetic Pickup 2 IA...
(or Terminal W)
Temperature Sensor
Overspeed Protection
Cooling Water Senso r
Manual Setpoint
red green
Display
Overall Alarm
Gover nor
Overspeed
Display fuel
Load Sharing
Display speed
Display speed
Connection
Programmer 2
Diagnostics
Connection
PC
Cable Size
I up to 10 m 2,5 mm
2
over 10
- 20 m 4,0 mm
2
over 20 - 40 m 6,0 mm
2
II up to 15 m 2,5
mm
2
over 15 - 30 m 4,0
mm
2
Rest 0,75
mm
2
11.6 Example of Connection for Locomotive Operation with 16 Notches
Figure 25: Connection with Plugs (IP 55) for Loco Operation with 16 Notches
HELENOS V 39
Page 48
11 Electric Connection
5 4 2 3
C
B
A
D
E
A
B
A
B
StG 2005 DP
StG 2040 DP
T x D
R x D
24V
0V
DC …2 - 01 - 00
Control Unit
+
24V
SUB-D Plug
Bit 0
A
B
A
B
A
B
-
Bit 1
1
l
Bit 2
Bit 3
ll
16 A slow
Governor on
A
B
C
A
B
C
0 - 5V
4 - 20mA
0 - 5V
4 - 20mA
max.
min.
5 kOhm
470 Ohm
470 Ohm
T x D
R x D
24V
0V
48 49 47 43 44 45 46 50 51 52 61 60 56 58 63 71 74 73
2
1
11 12 10 7 9 13 14
15
24 23
19 21 20 22
32 31 30 26 28 36
37 67 27 9 3 4 41 5 6
18 16
53 55
29 33
Boost Pressure Sensor
Oil Pressure Sensor
Actuator
Magnetic Pickup 1 IA ...
Magnetic Pickup 2 IA...
(or Terminal W)
Temperature Sensor
Overspeed Protection
Cooling Water Sensor
Manual Setpoint
red green
Display
Overall Alarm
Gover nor
Overspeed
Display fuel
Load Sharing
Display speed
Display speed
Motor Stop
Idle
Anti Stick Slip Device
Speed
Manual
Remote
Connection
Programmer 2
Diagnostics
Connection
PC
Cable Size
I up to 10 m 2,5 mm
2
over 10 - 20 m 4,0 mm
2
over 20 - 40 m 6,0 mm
2
II up to 15 m 2,5
mm
2
over 15 - 30 m 4,0
mm
2
Rest 0,75
mm
2
Figure 26: Connection with Terminal Strip (IP 00) for Loco Operation with 16 Notches
HELENOS V 40
Page 49
11 Electric Connection
5 4 2
3
C
B A D
E
A
B
A
B
StG 2005 DP
StG 2040 DP
Motor Stop
T x D
R x D 24V
0V
DC …2 - 01 - 55
Control Unit
+
24V
Idle
Anti Stick Slip Device
Speed
A
B
A
B
A
B
-
1
B 3 D 3 K 3 C
3
P 3 S 3 M 3 A
3
U
3 N 3 L 3
Manual
Remote
Fixed Speed
Remote Speed
4
- 20mA
R
3
l
ll
16 A slow
Governor on
Y 1 Z 1 M 1 T 1 N 1 G 1 X 1 W 1 F 1 A
1 B 1 H 1 D 1 C 1 S 1 R 1 U 1 V 1 J 1 P 1 Q 1
E
1
L
1
K
1
A
B
C
A
B
C
0 - 5V
4 - 20mA
0 - 5V
4 - 20mA
max.
min.
5 kOhm
470 Ohm
470 Ohm
N 2 U 2 L 2 M
2 A 2
K 2 B 2 R 2 P 2 C 2 E 2 D
2
J 2 T 2 F
2 S 2 G 2
T x D
R x D
24V
0V
SUB-D Plug
Plug 3 Plug 2 Plug 1 Boost Pressure Sensor
Oil Pressure Sensor
Actuator
Magnetic Pickup 1 IA ...
Magnetic Pickup 2 IA...
(or Terminal W )
Temperature Sensor
Overspeed Protection
Cooling Water Sensor
Manual Speed
red
green
Display
Overall Alarm
Gover nor
Overspeed
Display fuel
Load Sharing
Display speed
Display speed
Connection
Programmer 2
Diagnostics
Connection
PC
Cable Size
I up to 10 m 2,5 mm
2
over 10 - 20 m 4,0 mm
2
over 20 - 40 m 6,0 mm
2
II up to 15 m 2,5
mm 2 over 15 - 30 m 4,0
mm
2
Rest 0,75
mm
2
11.7 Example of Connection for Locomotive Operation with Speed Setpoint via Current Signal
Figure 27: Connection with Plugs (IP 55) for Loco Operation with Speed Setpoint via Current Signal
HELENOS V 41
Page 50
11 Electric Connection
5 4 2 3
C
B
A
D
E
A
B
A
B
StG 2005 DP
StG 2040 DP
T x D
R x D
24V
0V
DC …2 - 01 - 00
Control Unit
+
24V
A
B
A
B
A
B
-
1
4 - 20mA
l
ll
16 A slow
Governor on
A
B
C
A
B
C
0 - 5V
4 - 20mA
0 - 5V
4 - 20mA
max.
min.
5 kOhm
470 Ohm
470 Ohm
T x D
R x D
24V
0V
SUB-D Plug
48 49 47 43 44 45 46 50 51 52 61 60 56 58 63 71 74 73
2
1 11
12 10 7
9 13 14
15 24
23
19
21 20
22 30 26 28
36
37
67
27
9 3 4
41
5 6
18 16 17
53 55 54
29
Boost Pressure Sensor
Oil Pressure Sensor
Actuator
Magnetic Pickup 1 IA ...
Magnetic Pickup 2 IA...
(or Terminal W)
Temperature Sensor
Overspeed Protection
Cooling Water Sensor
Remote Speed
Manual Speed
red
green
Display
Overall Alarm
Gover nor
Overspeed
Display fuel
Load Sharing
Display speed
Display speed
Motor Stop
Idle
Anti Stick Slip Device
Speed
Manual
Remote
Fixed Speed
Connection
Programmer 2
Diagnostics
Connection
PC
Cable Size
I up to 10 m 2,5 mm
2
over 10 - 20 m 4,0 mm
2
over 20 - 40 m 6,0 mm
2
II up to 15 m 2,5
mm
2
over 15 - 30 m 4,0
mm
2
Rest 0,75
mm
2
Figure 28: Connection with Terminal Strip (IP 00) for Loco Operation with Speed Setpoint via Current Signal
HELENOS V 42
Page 51
11 Electric Connection
5 4 2 3
C
B
A
D
E
A
B
A
B
StG 2005
StG 2040
T x D
R x D
24V
0V
DC …2 - 01 - 55
Control Unit
+
24V
A
B
A
B
A
B
-
1
B
3
D
3
K
3
C
3
P
3
S
3
M
3
A
3
U
3
N
3
L
3
4 - 20mA
R
3
l
ll
16 A slow
Governor on
Y
1
Z
1
M
1
T
1
N
1
G
1
X
1
W
1
F
1
A
1
B
1
H
1
D
1
C
1
S
1
R
1
U
1
V
1
J
1
P
1
Q
1
E
1
L
1
K
1
A
B C
A
B
C
0 - 5V
4 - 20mA
0 - 5V
4 - 20mA
max.
min.
5 kOhm
470 Ohm
470 Ohm
N
2
U
2
L
2
M
2
A
2
K
2
B
2
R
2
P
2
C
2
E
2
D
2
J
2
T
2
F
2
S
2
G
2
T x D
R x D
24V
0V
SUB-D Plug
Plug 3 Plug 2 Plug 1
Motor Stop
Idle
Constrained Opening StG
Setpoint
Manual
Remote
Clutch
Fuel Limitation
Master/Slave Definition
Load Transfer
J
3
T
3
H
3
Boost Pressure Sensor
Oil Pressure Sensor
Actuator
Magnetic Pickup 1 IA ...
Magnetic Pickup 2 IA...
(or Terminal W)
Temperature Sensor
Overspeed Protection
Cooling Water Sensor
Remote Speed
Manual Speed
red green
Display
Overall Alarm
Gover nor
Overspeed
Display fuel
Control
Pitch Propeller
Display speed
Display speed
Connection
Programmer 2
Diagnostics
Connection
PC
Cable Size
I up to 10 m 2,5 mm
2
over 10 - 20 m 4,0 mm
2
over 20 - 40 m 6,0 mm
2
II up to 15 m 2,5
mm
2
over 15 - 30 m 4,0
mm
2
Rest 0,75
mm
2
11.8 Example of Connection for Marine Operation with Master/Slave
(Twin operation: 2 engines on one shaft)
Figure 29: Connection with Plugs (IP 55) for Marine Operation with Master/Slave
HELENOS V 43
Page 52
11 Electric Connection
5 4 2
3
C
B
A
D
E
A
B
A
B
StG 2005 DP
StG 2040 DP
T x D
R x D
24V
0V
DC …2 - 01 - 00
Control Unit
+
24V
A
B
A
B
A
B
-
1
4 - 20mA l
ll
16 A slow
Governor on
A
B
C
A
B
C
0 - 5V
4 - 20mA
0 - 5V
4 - 20mA
max.
min.
5 kOhm
470 Ohm
470 Ohm
T x D
R x D
24V
0V
SUB-D Plug
48 49 47 43 44 45 46 50
51
52 61 60 56 58
63
71 74 73
2
1 11
12 10 7
9 13 14
15 24
23
19
21 20
22
32
31 30 26 28
36
37
67
27
9 3 4
41
5 6
18 16 17
53 55 54
29
33
Boost Pressure Sensor
Oil Pressure Sensor
Actuator
Magnetic Pickup 1 IA ...
Magnetic Pickup 2 IA...
(or Terminal W)
Temperature Sensor
Overspeed Protection
Cooling Water Sensor
Remote Speed
Manual Speed
red green
Display
Overall Alarm
Gover nor
Overspeed
Display fuel
Control
Pitch Propeller
Display speed
Display speed
Motor Stop
Idle
Constrained Opening StG
Setpoint
Manual
Remote
Clutch
Fuel Limitation
Master/Slave Definition
Load Transfer
Connection
Programmer 2
Diagnostics
Connection
PC
Cable Size
I up to 10 m 2,5 mm
2
over 10 - 20 m 4,0 mm
2
over 20 - 40 m 6,0 mm
2
II up to 15 m 2,5
mm
2
over 15 - 30 m 4,0
mm
2
Rest 0,75
mm
2
Figure 30: Connection with Terminal Strip (IP 00) for Marine Operation with Master/Slave
HELENOS V 44
Page 53
11 Electric Connection
5 4 2 3
C
B
A
D
E
A
B
A
B
StG 2005 DP
StG 2040 DP
T x D
R x D
24V
0V DC …2 - 01 - 55
Control Unit
+
24V
A B
A
B
A
B
-
1
B
3
D
3
K
3
C
3
P
3
S
3
M
3
A
3
U
3
N
3
L
3
4 - 20mA
R
3
l
ll
16 A slow
Governor on
Y
1
Z
1
M
1
T
1
N
1
G
1
X
1
W
1
F
1
A
1
B
1
H
1
D
1
C
1
S
1
R
1
U
1
V
1
J
1
P
1
Q
1
E
1
L
1
K
1
A
B
C
A
B
C
0 - 5V
4 - 20mA
0 - 5V
4 - 20mA
max.
min.
5 kOhm
470 Ohm
470 Ohm
N
2
U
2
L
2
M
2
A
2
K
2
B
2
R
2
P
2
C
2
E
2
D
2
J
2
T
2
F
2
S
2
G
2
T x D
R x D
24V
0V
SUB-D Plug
Plug 3 Plug 2 Plug 1
Motor Stop
Idle
Constrained Opening StG
Setpoint
Manual
Remote
Clutch
Fuel Limitation
J
3
Boost Pressure Sensor
Oil Pressure Sensor
Actuator
Magnetic Pickup 1 IA ...
Magnetic Pickup 2 IA...
(or Terminal W)
Temperature Sensor
Overspeed Protection
Cooling Water Sensor
Remote Speed
Manual Speed
red green
Display
Overall Alarm
Gover nor
Overspeed
Display fuel
Control
Pitch Propeller
Display speed
Display speed
Connection
Programmer 2
Diagnostics
Connection
PC
Cable Size
I up to 10 m 2,5 mm
2
over 10 - 20 m 4,0 mm
2
over 20 - 40 m 6,0 mm
2
II up to 15 m 2,5
mm
2
over 15 - 30 m 4,0
mm
2
Rest 0,75
mm
2
11.9 Example of Connection for Marine Operation in single Operation
Figure 31: Connection with Plugs (IP 55) for Marine Operation in single Operation
HELENOS V 45
Page 54
11 Electric Connection
5 4 2
3
C
B
A
D
E
A
B
A
B
StG 2005 DP
StG 2040 DP
T x D
R x D
24V
0V
DC …2 - 01
- 00
Control Unit
+
24V
A
B
A
B
A
B
-
1
4 - 20mA
l
ll
16 A slow Governor on
A
B
C
A
B
C
0 - 5V
4 - 20mA
0 - 5V 4 - 20mA
max.
min.
5 kOhm
470 Ohm
470 Ohm
T x D
R x D
24V
0V
SUB-D Plug
48
49
47
43
44
45
46
50
51
52
61
60
56
58
63
71
74
73
2 1 11
12
10 7 9
13
14
15
24
23
19
21
20
22
31
30
26
28
36
37
67
27 9 3
4
41
5
6
18
16
17
53
55
54
29
Boost Pressure Sensor
Oil Pressure Sensor
Actuator
Magnetic Pickup 1 IA ...
Magnetic Pickup 2 IA...
(or Terminal W)
Temperature Sensor
Overspeed Protection
Cooling Water Sensor
Remote Speed
Manual Speed
red green
Display
Overall Alarm
Gover nor
Overspeed
Display fuel
Control
Pitch Propeller
Display speed
Display speed
Motor Stop
Idle
Constrained Opening StG
Setpoint
Manual
Remote
Clutch
Fuel Limitation
Connection
Programmer 2
Diagnostics
Connection
PC
Cable Size
I up to 10 m 2,5 mm
2
over 10 - 20 m 4,0 mm
2
over 20 - 40 m 6,0 mm
2
II up to 15 m 2,5
mm
2
over 15 - 30 m 4,0
mm
2
Rest 0,75
mm
2
Figure 32: Connection with Terminal Strip (IP 00) for Marine Operation in single Operation
HELENOS V 46
Page 55
12 Harness
Control Unit
DC 2005DP.2 - 01 - 55 or
DC 2040.2 - 01 - 55
L2
L4
L5
L7
L1
L3 L10
L8
L11
L12
L13
Pickups
Sensors
Overspeed
Protection
Battery
Setpoint
Adjuster
Analogue
Outputs
Status
Indicator
Communication
PWM
Inputs
Frequency
Inputs
Power
Output
L9
I
II
III
L6
Digital
Inputs
Actuator
StG 2005 DP/
StG 2040 DP
12.1 Cable Lenghts
12 Harness
HELENOS V 47
Figure 33: Harness with Cable Numbers
Page 56
12 Harness
Magnetic Pickup IA ...
Actuator
StG ...
SV 103-DC-19 SG (010-02-183-00)
SV 103-DC-19 PG (010-02-222-00)
SV 103-DC-24 SG (010-02-185-00)
SV 103-DC-24 PK (010-02-177-00)
SV 103-DC-19 SK (010-02-165-00)
SV 103-DC-19 PK (010-02-175-00)
SV 6-IA-2 K (010-02-170-00)
SV AMP-StG-7 KW (010-02-431-00)
Control Unit
DC ... 2 - 01 - 55
I II III
12.2 Plug Designations
48 HELENOS V
Figure 34: Plugs with Designation
Page 57
13 Programming Possibilities
13 Programming Possibilities
Programming the HEINZMANN Digital Governor can be performed according to the
possibilities described below:
13.1 Programming by the Manufacturer
During final inspection by the manufacturer, the functionability of the governor is checked
by means of a test program. If the operational data for the governor are available, the test
program is executed using those data. On the engine, only the dynamic values and, if
necessary, the actuator position limits and sensors have to be adjusted.
13.2 Programming with the Hand- Held Programmer 2
The entire programming can be performed using the Hand-Held Programmer 2. This handy
device may be conveniently used for development and for serial adjustment as well as for
service purposes.
13.3 Programming by PC
Programming can also be performed using the PC. In comparison with the hand-held
programmer, this method offers advantages with respect to the possibilities of having
characteristic curves readily displayed on the screen and easily varied; the same holds for
the time diagrams when putting the governor into operation on the engine. Furthermore,
the PC offers a better overview, as the PC program presents a menu structure and is able to
continuously display several parameters at a time.
The PC program also permits to save and load governor data to and from diskettes.
13.4 Programming with User Masks
Principally, programming 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 that are actually needed.
13.5 Transferring Data Sets
Once programming with respect to a specific engine type and its application has been
completed, the data set can be stored (in the hand-held programmer or on diskette). For
future cases of similar applications, the data set may be downloaded into the new
governors.
HELENOS V 49
Page 58
13 Programming Possibilities
13.6 Assembly Line End Programming
This method of programming is applied by the engine manufacturer during the final bench
tests of the engine. On this occasion, the governor is programmed with regard to operation
requirements and to ordering specifications.
50 HELENOS V
Page 59
14 Starting the Engine - Brief Instructions
Warning
14 Starting the Engine - Brief Instructions
14.1 Adjust clearance of magnetic pulse pickup.
14.2 Check program with respect to relevant parameters: number of teeth, speed, etc.
14.3 Set point potentiometer in mid-position:
P - Gain to 50
I - Stability to 0
D- Derivative to 0
If the dynamic values have already been determined for an installation, they can be
programmed directly at this point.
Overspeed protection must be guaranteed!
14.4 Start engine and run it up to nominal speed using the set point potentiometer.
14.5 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.
Increse 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.
14.6 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.
14.7 Gain-correction (P-correction) for gas engines resp. for variable speed governors with
larger speed ranges; adjust map if necessary.
14.8 Checking the remaining program items, e.g., starting fuel injection, ramp time, etc.
The adjustment procedures as required for items 14.2 up to 14.8 and any further
options of adjustemnt are in detail described in brochure DG 95110 - e.
HELENOS V 51
Page 60
15 Ordering Specifications
15 Ordering Specifications
15.1 General
To know which informations we need, we have made a special order information for
digital governors. It has the No. DG 96 012-d. This form has to be filled in and send to
HEINZMANN together with the order.
15.2 Cable Length
It is of advantage to obtain the harness together with the governor.
It is not possible to use all signals simultaneous because some inputs and
outputs of the governor have various options depending on the application.
Version of Control Unit:
with plugs (IP55) with terminal strip (IP00)
Version of Actuator:
with plug (IP55) with terminal strip (IP00)
a) L1 = Control Unit - Power Supply
L 1 Control unit - power supply ............. cm
Cable size up to 15 m 2 x 2.50 mm²
over 15 - 30 m 2 x 4.00 mm²
b) L2 = Control Unit - Actuator
L 2.1 Control unit - actuator (feedback) ............. cm 3 x 0,75 mm² shielded
L 2.2 Control unit - actuator (power) ............. cm
Cable size up to 10 m 2 x 2.50 mm²
over 10 - 20 m 2 x 4.00 mm²
over 20 - 30 m 2 x 6.00 mm²
52 HELENOS V
Page 61
15 Ordering Specifications
c) L3 = Control Unit - Setpoint Adjuster
L 3.1 Control unit - setpoint poti 1 ............. cm 3 x 0,75 mm² shielded
L 3.2 Control unit - setpoint poti 2 ............. cm 3 x 0,75 mm² shielded
L 3.3 Control unit - 4..20 mA input ............. cm 2 x 0,75 mm²
L 3.4 Control unit - synchronizer ............. cm 2 x 0,75 mm² shielded
L 3.5 Control unit - load measuring unit ............. cm 2 x 0,75 mm² shielded
d) L4 = Control Unit - Magnetic Pickup
L 4.1 Control unit - magnetic pickup 1 ............. cm 2 x 0,75 mm² shielded
L 4.2 Control unit - magnetic pickup 2 ............. cm 2 x 0,75 mm² shielded
e) L5 = Control Unit - Sensors
L 5.1 Control unit - temperature 1 sensor ............. cm 2 x 0,75 mm²
L 5.2 Control unit - coolant temp. sensor ............. cm 2 x 0,75 mm²
L 5.3 Control unit - boost pressure sensor ............. cm 3 x 0,75 mm²
L 5.4 Control unit - oil pressure sensor ............. cm 3 x 0,75 mm²
f) L6 = Control Unit - Digital Inputs
L 6.1 Control unit - switch 1 - 4 ............. cm 5 x 0,75 mm²
L 6.2 Control unit - switch 5 - 8 ............. cm 5 x 0,75 mm²
g) L7 = Control Unit - Overspeed Protection
L 7 Control unit - overspeed protection ............. cm 2 x 1.5 mm²
h) L8 = Control Unit – Controlled Current Output
L 7 Control unit – contr. current output ............. cm 2 x 1.5 mm²
i) L9 = Control Unit - Status Indicator
L 9.1 Control unit - common alarm ............. cm 2 x 0,75 mm²
L 9.2 Control unit - overspeed ............. cm 2 x 0,75 mm²
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15 Ordering Specifications
j) L10 = Control Unit - Analogue Outputs
L 10.1 Control unit - display voltage 1 ............. cm 2 x 0,75 mm²
L 10.2 Control unit - display current 1 ............. cm 2 x 0,75 mm²
L 10.3 Control unit - display voltage 2 ............. cm 2 x 0,75 mm²
L 10.4 Control unit - display current 2 ............. cm 2 x 0,75 mm²
L 10.5 Control unit - load sharing ............. cm 2 x 0,75 mm²
L 10.6 Control unit - pitch propeller control ............. cm 2 x 0,75 mm²
k) L11 = Control Unit - Frequency Input
L 11 Control unit - tacho ............. cm 2 x 0,75 mm²
l) L12 = Control Unit - PWM Input
L 12 Control unit - PWM input ............. cm 2 x 0,75 mm²
m) L13 = Communication
L 13.1 Control unit - CAN - Bus ............. cm 2 x 0.14 mm² shielded
L 13.2 Control unit - PC ............. cm 4 x 0.14 mm² shielded
54 HELENOS V
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16 Figure List
16 Figure List
Figure 1: Blockdiagram DG 16.1 - 03 up to DG 40.1 - 03 ...................................................... 10
Figure 2: Clerance of Pickup .................................................................................................... 13
Figure 3: Magnetic Pickup ....................................................................................................... 14
Figure 4: Temperature Sensor TS 01 - 28 - PT 1000 ............................................................... 15
Figure 5: Oil Pressure Sensor ................................................................................................... 16
Figure 6: Boost Pressure Sensor with Plug .............................................................................. 17
Figure 7: Boost Pressure Sensor with Housing ........................................................................ 18
Figure 8: Control Unit DC 2005DP.2 - 01 up to DC 2040DP.2 - 01 ....................................... 23
Figure 9: Control Unit DC 2005DP.2 - 01 up to DC 2040DP.2 - 01 ....................................... 24
Figure 10: Sectional Drawing of Actuator ............................................................................... 25
Figure 11: Actuator StG 2005 DP ............................................................................................ 28
Figure 12: Actuator StG 2040 DP Measurements .................................................................... 29
Figure 13: Connection of seperat Wire .................................................................................... 30
Figure 14: Shield Connection without Plug ............................................................................. 30
Figure 15: Shield Connection in the Plug ................................................................................ 31
Figure 16: Correct Connection of Power Supply ..................................................................... 32
Figure 17: Connections with Plug (IP 55) for Genset with digital Accessories ...................... 33
Figure 18: Connections with Terminal Strip (IP 00) for Genset with digital Accessories ...... 34
Figure 19: Connection with Plugs (IP 55) for Genset with analogue Accessories .................. 35
Figure 20: Connection with Terminal Strip (IP 00) for Genset with analogue Accessories .... 36
Figure 21: Connection with Plugs (IP 55) for Vehicle Operation ............................................ 37
Figure 22: Connection with Terminal Strip (IP 00) for Vehicle Operation ............................. 38
Figure 23: Connection with Plugs (IP 55) for Loco Operation with 16 Notches ..................... 39
Figure 24: Connection with Terminal Strip (IP 00) for Loco Operation with 16 Notches ...... 40
Figure 25: Connection with Plugs (IP 55) for Loco Operation with Speed Setpoint via Current
Signal ........................................................................................................................................ 41
Figure 26: Connection with Terminal Strip (IP 00) for Loco Operation with Speed Setpoint
via Current Signal ..................................................................................................................... 42
Figure 27: Connection with Plugs (IP 55) for Marine Operation with Master/Slave .............. 43
Figure 28: Connection with Terminal Strip (IP 00) for Marine Operation with Master/Slave 44
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16 Figure List
Figure 29: Connection with Plugs (IP 55) for Marine Operation in single Operation ............. 45
Figure 30: Connection with Terminal Strip (IP 00) for Marine Operation in single Operation
.................................................................................................................................................. 46
Figure 31: Harness with Cable Numbers ................................................................................. 47
Figure 32: Plugs with Designation ........................................................................................... 48
56 HELENOS V
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17 Order Specifications for Manuals
17 Order Specifications for Manuals
There is no charge for our technical manuals ordered in reasonable quantities.
Order the necessary manuals on our speed governors from your nearest
HEINZMANN location.
(Please click on “HEINZMANN location” to see the list of our subsidiaries and agents in the
world).
Please include the following information:
• your name,
• the name and address of your company (you can simply include your business card),
• the address where you want the manuals sent (if different from above),
• the number(s) (as on front page bottom right) and title(s) of the desired manual(s),
• or the technical data of your HEINZMANN equipment,
• the quantity you want.
You can directly use the following fax-form for ordering one or several manuals.
Most of the manuals are available as acrobat PDF-files, too. On request they can be send via
e-mail.
We solicit comments about the content and the presentation of our publications. Please, send
your comments to:
HEINZMANN GmbH & Co. KG
Service Department
Am Haselbach 1
D-79677 Schönau
Germany
HELENOS V 57
Page 66
Fax Reply
Order for HEINZMANN technical manuals
Fax-Hotline +49 7673 8208 194
Please send me the following manuals:
Quantity No. of the manual Title
Please send me your new sales documentation about
( ) the HEINZMANN Analogue Governors Application: ....................................................
( ) the HEINZMANN Digital Governors Application: ....................................................
( ) the HEINZMANN Gas Engine Equipment Application: ....................................................
Company ......................................................................................................................................
Contact Person ..............................................................................................................................
Department ...................................................................................................................................
Address ......................................................... Country/Code/Town ..............................................
Phone. ........................................................... Fax .........................................................................
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Activity .........................................................................................................................................
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