Heinzmann Speed Governors
Heinzmann Speed Governors
without SaCoS-system
with actuators
StG 90 and StG180
10.05.2007 Seite 1
Layout
speed pickups
speed signal
controlled
engine speed
actuator
feedback
fuel setpoint
calculated
Power
speed setpoint
supply
speed governor
Parameter 2902
Parameter 2331
Voltage
fixator
Pick up
Power amplifier
ADC3
Out 1 Out 2 Dig. Inputs
Parameters 1531,
Parameters Parameters 1532, 1533, 1534
1641, 1642 1646, 1647 1 3 4 5
38V DC
Parameters 2901, 3531
Speed setting remote
Voltage
Speed decrease
Speed increase
limiter
Engine stop
24V DC
43V DC
Voltage
converter
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Signal forms
actuator
0-8 V
PWM
Power supply
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Main components for both engine types
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Main components V-engine
Pin assignment
A
A Feedback Signal
F B B
C
D
C
E E Feedback +8V
D F Feedback Ground
Pin assignment
A Actuator -
G A
B Actuator +
B C
F D
H
C E
E F
D G Actuator -
H Actuator +
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Actuator StG180 V-engine
Pin assignment
A
A Feedback Signal
F B B
C
D
C
E E Feedback +8V
D F Feedback Ground
Pin assignment
A Actuator -
G A
B Actuator +
B C
F D
H
C E
E F
D G Actuator -
H Actuator +
Socket 1 2 3 4 5
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Power supply L- engine
Socket 1 2 3 4
Governor:
• L2 supply (+ 24V)
• J2 supply (- Digital inputs)
• N2 supply (- 24/40V)
• U2 supply (- 24/40V)
Actuator:
• A2 supply (+ 40V)
• M2 supply (+ 40V)
Governor:
A2 supply (+24V) Socket 1 2 3 4 5
L2 supply (+24V)
M2 supply (+ 24V)
J2 supply (-Digital inputs)
N2 supply (-24V)
U2 supply (- 24V)
Actuator:
A5 supply 40V
B5 supply 40V
C5 supply (-)
D5 supply (-)
10.05.2007 Seite 7
Speed sensing
DC90 DC180
Socket 1 2 3 4 Socket 1 2 3 4 5
P1 Pickup Ground
Q1 Pickup 1 signal
V1 shield of pickups
Z1 Pickup 2 signal
K1/ U1 Pickup 2 Ground
Analog inputs
DC90 DC180
Socket 1 2 3 4 Socket 1 2 3 4 5
ADC1 A3/B3
ADC2 U3/L3 0…5V potentiometer controlstand
ADC3 C3/D3 4…20 mA remote speed setpoint
ADC4 T1/Y1 4…20 mA ext. fuel / boost limiter
ADC5 R1/K1
ADC6 J1/P1
ADC7 L1/K1
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Calibration and alarm limit value
setting for analog inputs
750
REF_Low 11900 rpm
4 mA 450
9900 rpm
ERR_Low 0%
0 mA 0 rpm
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Analog outputs
DC90 DC180
Socket 1 2 3 4 Socket 1 2 3 4 5
4095 rpm 21 mA
20 mA
Analog_OUT_REF_HIGH=95%
(20mA=95% of 21 mA)
Analog_OUT_VAL_MAX=22%
(900 rpm=22% of 4095 rpm)
Speed at 20 mA 900 rpm
Analog_OUT_REF_LOW=19%
(4mA=19% of 21 mA)
4 mA
Analog_OUT_VAL_MIN=0%
(0 rpm=0% of 4095 rpm)
0 mA
Speed at 4 mA 0 rpm
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Parameters for analog outputs
Digital inputs
DC90 DC180
Socket 1 2 3 4 Socket 1 2 3 4 5
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Parameters for digital inputs
810 FUNCT_ENGINE_STOP = -1
811 FUNCT_SPEED_MIN = 0
812 FUNCT_DROOP = 6
813 FUNCT_TORQUE_LIMIT = 0
814 FUNCT_RANGE = 0
815 FUNCT_SPEED_FIX1 = 5
816 FUNCT_SPEED_FIX2 = 0
817 FUNCT_ACT_POS_MAX = 0
825 FUNCT_SPEED_INC = 4 Assignment of the digital function by
826 FUNCT_SPEED_DEC = 3 choosing the number of the digital input !
827 FUNCT_SETPOINT1 = 2
828 FUNCT_SETPOINT2 = -2 Using the „-“ sign means to invert the
833 FUNCT_START = 0 input signal
834 FUNCT_BUS = 8
835 FUNCT_MASTER = 0
836 FUNCT_CLUTCH = 0
837 FUNCT_LOAD_TRANSFER = 0
838 FUNCT_ERROR_RESET = 10
Digital outputs
DC90 DC180
Socket 1 2 3 4 Socket 1 2 3 4 5
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Parameters for digital outputs
Socket 1 2 3 4
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Actuator output and feedback V-engine
Socket 1 2 3 4 5
65535
10,0V
ERR_High
8,0V 54300 100%
51800
REF_High
REF_Low
6500
4000
1,0V 0%
ERR_Low
0,0V
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Parameters for actuator connection
To set the correct alarm limits increase the FEEDBACK_REF_HIGH value by 2000 bit
and decrease the FEEDBACK_REF_LOW value by 2000 bit.
10.05.2007 Seite 15
Procedure for calibration of
actuator connection
Automatic calibration
With automatic calibration the evaluation of the reference values is done by the governor
itself. The governor will energize the actuator for a certain time to ensure that it will
traverse to its minimum and maximum positions and will then evaluate the reference
values. The values thus obtained are entered under the respective parameters and - in
contrast to manual calibration - will be available immediately.
10.05.2007 Seite 16
Master-slave load sharing
Socket 1 2 3 4 Socket 1 2 3 4
Master: Slave:
• Y1 PWM (-) • E3 PWM input signal
• S1 PWM output (master- • U3 PWM input (-)
slave load sharing)
• V3 shield
• F1 shield
• R3 (-)
Slave: Master:
• E3 PWM input signal • Y1 PWM (-)
• U3 PWM input (-) • S1 PWM output (master-
• V3 shield slave load sharing)
• R3 (-) • F1 shield
NoLi © MAN Diesel SE 10.05.2007 < 33 >
Internal Display
10.05.2007 Seite 17
Internal Display
d Data block error: The control is not able to continue operation because it did not find a
valid data block. This error is equivalent to the errors 3062 ERR_DATA or 3064
ERR_LOGICAL.
E Fatal error: This error is reported whenever serious errors concerningthe inputs and/or
outputs have occurred (e.g., actuator notconnected, failure of both speed pickups. etc.)
such that the control cannot continue to operate. This error is equivalent to the errors
causing an emergency shutdown.
E. Exception error: Internal computing error. This error is equivalent to the error 3072
ERR_INTERN.
Internal LEDs
No. Parameter Meaning
1 - The auxiliariy processor (CPU) has detected an error
2 - The main processor is working
3 3820 LED_PICK_UP1 Pulses from speed pickup 1 are missing
4 3821 LED_PICK_UP2 Pulses from speed pickup 2 are missing
5 3822 LED_ACTUATOR The actuator is at fault. This LED will be illuminated if one of the
following errors occurs:
•3000 ERR_FEEDBACK_ADJUST
•3001 ERR_FEEDBACK
•3002 ERR_FEEDBACK2
1
•3003 ERR_FEEDBACK3
: •3004 ERR_ACTUATOR_DIFF
: Supply voltage for actuator 1/2/3 is low. This LED will be illuminated if
6 3823 LED_Voltage
one of the following errors occurs:
10
•3011 ERR_VOLTAGE
•3012 ERR_VOLTAGE2
•3013 ERR_VOLTAGE3
7 3824 LED_ERROR At least one error did occur. The LED is an equivalent of the general
alarm output
8 3825 LED_BOOST Actuator position is limited by Boost Pressure Dependent Fuel
Limitation. This is a warning but no error state.
9 3826 LED_MAX Actuator position is limited by some fuel limitation function. This is a
warning but not no error state
10 3827 LED_MIN Actuator position is limited by some fuel limitation function. This is a
warning but not no error state
10.05.2007 Seite 18
Start algorithm – normal start
s pe e d
p
am
dr
ee
sp
a rt
St
S ta rt
256 START2_SPEED = 130 1/min
s pe e d 1
tim e
257 START3_SPEED = 150 1/min
F ue l
a d m is s io n 260 START1_ACT_POS = 40 %
S ta rt
Pos. 2
P o s itio n e d a fte r a c tiv a tio n o f s p e e d
co n tro l lim ite d fu el ra c k p o s itio n
261 START2_ACT_POS = 45 %
F u el ra ck p o s itio n
S ta rt tim e 1
S ta rt tim e 2
PID - controller
}
• 100 GAIN (P) = 55,0 %
• 101 STABILITY (I) = 7,0 %
• 102 DERIVATIVE (D) = 25,0 %
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Charge air pressure limiter
90
80
70
60
50
40
30
20
10
0
0 0,5 1,0 1,5 2,0 2,5 3,0 ...
Charge air pressure / bar
Given values are just examples !!
NoLi © MAN Diesel SE 10.05.2007 < 39 >
Troubleshooting
10.05.2007 Seite 20
Troubleshooting
Replacement of a governor
1. Readout the parameters from the faulty governor. Use Handheld Programmer
and press key “2nd” and “get Data”.
2. Switch off the power supply.
3. Replace the governor and connect the plugs.
4. Switch on power.
5. Check the Software Version of the new governor. Use Handheld Programmer
and check value of parameter 3842. Compare with “old” Software Version.
Not equal !!! contact MAN
6. Send parameters from the “old” governor to the “new”. Use Handheld
Programmer and press “2nd” and “send Data”. After the data are transferred save
data to the governor. Therefore press “2nd” and “save Data”.
7. Reset the governor by switching of and on the power supply.
8. Calibrate the actuator connection as learned in this training.
9. Calibrate all analog in and outputs that are used on the plant.
10. Prepare engine for start and check emergency stop device for proper function.
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Replacement of an actuator
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Exercises
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