Heinzmann GmbH & Co.

KG
Engine & Turbine Controls
Am Haselbach 1
D-79677 Schnau (Schwarzwald)
Germany
Phone +49 7673 8208-0
Fax +49 7673 8208-188
E-mail [email protected]
www.heinzmann.com
V.A.T. No.: DE145551926






HEINZMANN

Digital Electronic Speed Governors


Basic Systems

HELENOS IV

DG EDC.2-01








Copyright 2007 by Heinzmann GmbH & Co. KG. All rights reserved. This document may not be reproduced or handed on to third parties.
Manual DG 96 003-e / 01-97Druckschrift

HEINZMANN Speed Governors
HELENOS IV







Helenos IV
for engines from approx. 200kW up to approx. 1500kW
Basic System DG EDC 2 - 01
D : Digital
DG : Digital Governor (Basic System)
DC : Digital Control Unit
StG : Actuator (Stellgert)
SW : Setpoint Potentiometer (Sollwertpot.)
IA : Pickup (Impulsaufnehmer)
Control Unit DC EDC 2 - 01
Actuator Bosch EDC
Setpoint Pot. SW ...
Pickup IA ...




HEINZMANN Speed
Governors
HELENOS IV

WARNING

Read this entire manual and all other publications appertaining
to the work to be performed before installing, operating or
servicing this equipment.
Practice all plant and safety instructions and precautions. Failure
to follow instructions correctly may result in personal injury
and/or damage to property.








WARNING

The engine, turbine or any other type of power plant must be
equipped with separate overspeed-, overtemperature- resp.
overpressure shutdown devices operating independently of the
electronic speed governor. Such devices are absolutely
indispensable in order to protect operating personnel against
injuries and the engine against damages that may occur in case
of a runaway or of a failure of the electronic speed control.








We retain the right to introduce technical changes!
Contents
HELENOS IV



Co n t e n t s
P a g e
1. General Remarks.......................................................................................... 1
2. Functions ...................................................................................................... 2
3. Mode of Operation........................................................................................ 5
4. Block Diagram of the Digital Governor DG EDC 2 - 01 ............................ 6
5. Pickup IA ... ................................................................................................... 7
5.1. Specification............................................................................................ 7
5.2. Installation............................................................................................... 7
5.3. Tooth profile............................................................................................ 8
Due to tolerances, a radial arrangement of the magnetic pickup is
preferable.5.4. Clearance of Magnetic Pickup................................................ 8
5.4. Clearance of Magnetic Pickup................................................................. 9
5.5. Mounting Measurements....................................................................... 10
5.6. Redundant Speed Signal ...................................................................... 10
6. Setpoint Potentiometers and Sensors...................................................... 11
6.1. Setpoint Potentiometer SW 01 - 1 - o (one turn)................................... 11
6.2. Setpoint Potentiometer SW 02 - 10 - o (10 turns) ................................. 11
6.3. Setpoint Value Adjustment by Current Signal ....................................... 12
6.4. Digital Presetting of Setpoint Values..................................................... 12
6.5. Setpoint Value Adjustment by Pedal ..................................................... 12
6.6. Pressure Sensors.................................................................................. 12
6.7. Temperature Sensors ........................................................................... 13
7. Control Unit DC EDC 2 - 01........................................................................ 14
7.1. Specification.......................................................................................... 14
Remark ........................................................................................................ 15
7.2. Measurements ...................................................................................... 16
Contents
HELENOS IV
8. Actuators..................................................................................................... 18
8.1. Design and Mode of Operation............................................................. 18
8.2. Specification.......................................................................................... 19
9. Electric Connection.................................................................................... 20
9.1. Connection of Shielding........................................................................ 20
9.2. Example of Connection for Generator Set..................................... 22
(Parallel- and mains operation with digital accessories)............................... 22
9.3. Example of Connection for Generator Set..................................... 26
9.4. Example of Connection for Vehicle Operation....................................... 30
9.5. Example of Connection for Locomotive Operation........................ 33
9.6. Example of Connection for Locomotive Operation........................ 37
9.7. Example of Connection for Marine Operation................................ 41
9.8. Example of Connection for Marine Operation................................ 45
9.9. I/O- Configuration according to Customers Demand............................. 50
10. Programming Possibilities ...................................................................... 51
10.1. Programming by the Manufacturer...................................................... 51
10.2. Programming with the Hand- Held Programmer 2.............................. 51
10.3. Programming by PC............................................................................ 51
10.4. Programming with User Masks ........................................................... 52
10.5. Transferring Data Sets........................................................................ 52
10.6. Assembly Line End Programming....................................................... 52
11.Starting the Engine - Brief Instructions................................................... 53
12. Plug Connections ..................................................................................... 55
13. Ordering Specifications ........................................................................... 56
13.1. General Informations........................................................................... 56
13.2. Cable Harness .................................................................................... 57
13.3. Cable Lengths..................................................................................... 58
a) L1 =Control unit - battery................................................................... 58
b) L2 =Control unit - actuator................................................................. 58
c) L3 =Control unit - setpoint adjusting unit............................................ 58
d) L4 =Control unit - pickup.................................................................... 59
e) L5 =Control unit - sensor inputs......................................................... 59
f) L6 =Control unit - digital inputs ........................................................... 59
g) L7 =Control unit - overspeed protection............................................. 59
h) L8 =Control unit - controlled current output........................................ 59
Contents
HELENOS IV
i) L9 =Control unit - status indicator ....................................................... 59
j) L10 =Control unit - analogue outputs.................................................. 60
k) L11 =Control unit - frequency input.................................................... 60
l) L12 =Control unit - PWM input............................................................ 60
m) L13 =Communication......................................................................... 60
14. Order Specifications for Brochures........................................................ 61
1. General Remarks
HELENOS IV 1
1. General Remarks
Robert Bosch Company delivers size P in-line injection pumps where the all
electric actuator is directly mounted on the pump.

According to an agreement between HEINZMANN and Bosch the delivery of
the controller as well as the customer service, e.g. training, application service,
technical service, will in certain cases be done by HEINZMANN.

This agreement covers the following business parts:

Stationary applications, such as gensets, total energy plants
Heavy duty machines, such as crawlers
Agriculture machines, such as tractors, harvestors
Locomotive applications
Marine applications
Special vehicles, such as mobile cranes

This agreement does not cover any truck applications.

In order to cover the various functions HEINZMANN offers 3 different lines of
governor systems:

PRIAMOS IV - DG EDC 1 - 03
Systems with complex functions

HELENOS IV - DG EC 2 - 01
Systems with medium number of functions

ALEXANDROS IV - DG EDC 3 - 00
Systems with low number of functions

This brochure describes the Helenos IV system

System PRIAMOS IV please refer to brochure DG 96 004-e
System ALEXANDROS IV please refer to brochure DG 96 ...-e
2. Functions
2 HELENOS IV
2. Functions
The HEINZMANN digital governor with the control unit DC EDC 2 - 01
constitutes a speed governor offering a medium range of functions.

In addition to speed regulation, the following functions are available:

a) Starting Fuel Flow Adjustment

When setting starting fuel flow, starting minimum fuel flow or starting
maximum fuel flow are available as alternatives. Furthermore, variable
starting fuel flow can be provided, by which starting fuel flow is increased
automatically during start-up.

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) 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.

d) 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.

e) 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.
1. General Remarks
HELENOS IV 3
f) 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.

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.

h) Velocity Limitation

For vehicles velocity limitations may be provided.

i) Velocity Regulation

For vehicles velocity regulation can be provided, by which the vehicle is
made to maintain some preset velocity.

j) 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.

k) Load Regulation System

For diesel-electric locomotive operation, a load regulation system can be
provided, by which generator output is regulated in dependence on speed
resp. load.

l) Anti Stick Slip Device

For locomotive operation, an anti stick slip device can be provided.

2. Functions
4 HELENOS IV
m) Accessories

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).

n) Output Signals

For speed and actuator travel, proportional signals are available in the
range of
420 mA. They can be used for purposes of display or for further
processing (e.g., switches).
Furthermore, if errors occur at the sensors or within the control system, an
alarm is given.

o) Operating Data Storage

On request, operating data storage can be provided, by which in cases of
disturbances and failures the causes may be traced back even at some
later time.


When selecting and determining the functions, it has to be ascertained whether
the hardware equipment suffices with respect to the total range of functions.
3. Mode of Operation
HELENOS IV 5
3. 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.
4. Blockdiagram
6 HELENOS IV
4. Block Diagram of the Digital Governor DG EDC 2 - 01
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Feedback
Drive

figure 1: blockdiagram DG EDC 2 - 01
5. Pickup
HELENOS IV 7
5. Pickup IA ...
The pick-up integrated inside the Bosch actuator is normally not used because
its resolution is not high enough (half engine speed, low number of teeth)


5.1. Specification
IA 02 - 76 to IA 12 - 102
Temperatur Range -55 C to +120 C
Output Voltage 0,5 to 10 Volt ~(AC)
Resistance approx. 52 Ohm
Distance from Pickup Wheel 0,5 to 0,8 mm
Protection grade IP 55


5.2. 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 governors are
designed for a maximum frequency of 12000 Hz. Frequency (by Hz) is
calculated according to the formula

f
(Hz)
=
n z ( / min) * 1
60



z = number of teeth on the pickup wheel

Example:

n = 1.500
z = 160

f =
1500*160
60
= 4.000 Hz
5. Pickup
8 HELENOS IV
NB: 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).


5.3. 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 pickup is
preferable.
5. Pickup
HELENOS IV 9
5.4. Clearance of Magnetic Pickup
The distance between the magnetic pulse pickup and the tooth top should
range from 0.5 and 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.)



4mm(at least)
2.5mm(at least)
4mm(at least)
0.5 - 0.8mm


figure 2: clerance of pickup
5. Pickup
10 HELENOS IV
5.5. Mounting Measurements


G
L 35
19


figure 3: measurements of pickup


Measures L G Remarks
Type (mm)
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 SV6-IA-2K
12 - 76 76 5/8"-18UNF-2A
13 - 102 102 5/8"-18UNF-2A


Ordering specification, e.g. IA 02-76



5.6. Redundant Speed Signal
If precautions are to be taken with regard to failures of 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.
6. Setpoint Potentiometers and Sensors
HELENOS IV 11
6. Setpoint Potentiometers and Sensors
Dependent on particular applications, a series of setpoint potentiometers are
available for the HEINZMANN Digital Controls.

6.1. Setpoint Potentiometer SW 01 - 1 - o (one turn)
Displacement Angle approx. 312
Resistance 5 kOhm
Temperature Range -55 C to +120 C
Protection IP 00

9,5
3/8" - 32 NEF - 2A

2
9
2
3
14

figure 4: potentiometer SW 01 - 1


6.2. Setpoint Potentiometer SW 02 - 10 - o (10 turns)
Displacement Angle 10 turns
Resistance 5 kOhm
Temperature Range -55 C to +105 C
Protection IP 00

8,8
3/8" - 32 NEF - 2A

2
2
1
6
20

figure 5: potentiometer SW 02 - 10
6. Setpoint Potentiometers and Sensors
12 HELENOS IV
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.

Equally, instead of the knob a clamping fixture can be installed. Ordering
specification is to changed to SW ..-..-k.


6.3. Setpoint Value Adjustment by Current Signal
For the speed setpoint value a current signal of 420 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.


6.4. Digital Presetting of Setpoint Values
A 4 bit binary coded digital input for 16 speed levels from n
min
to n
max
can
be directly connected to the control unit.


6.5. 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.


6.6. Pressure Sensors
For pneumatic setpoint adjustment are pressure sensors available as follows:

pressure range up to 10 bar DSG 01
up to 5 bar DSG 02

As boost pressure sensor for a range up to 2 bar the pressure sensor DSG
03 is available.
6. Setpoint Potentiometers and Sensors
HELENOS IV 13
6.7. Temperature Sensors
As temperature sensors NTC - resistors or Ni 1000 - resistors are to be
utilized.
7. Control Unit DC EDC 2 01
14 HELENOS IV
7. Control Unit DC EDC 2 - 01
7.1. Specification
Operating 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

Permissible Voltage Dip at
Maximum Voltage of Actuator maximum 10 % in control
device

Fuse Protection of Governor
Electronic 3 A
Power stage 16 A

Current Consumption approx. 200 mA + current of
actuator

Storing Temperature - 55 C to+85 C

Operating Ambient Temperature - 40 C to +70 C

Humidity up to 100 %

Control Frequency 200 to 12.000 Hz

Steady State Variation 0.25 %

Speed Variation due to Temperature for
Frequency greater than 500 Hz
between -40 C and +70C 1 %

Protection grade
DC EDC 2 - 01 - 00 IP 00
DC EDC 2 - 01 - 55 IP 55
7. Control Unit DC EDC 2 - 01
HELENOS IV 15
Weight
DC EDC 2 - 01 - 00 approx. 1.2kg
DC EDC 2 - 01 - 55 approx. 3kg


Remark
The control unit is available with terminal strip (DC EDC 2 - 01 - 00) or
with plug-in connectors (DC EDC 2 - 01 - 55) alternatively. At delivery of
the control unit the exact governor type together with identification of
housing, software version and serial number is printed on the type
plate.

Example: DC EDC 2 - 01 - 55 - 12700
7. Control Unit DC EDC 2 01
16 HELENOS IV
7.2. Measurements
Control Unit with plug-in connectors (DC EDC 2 - 01 - 55)

2
0
5
2
6
0
2
4
0
25 110
160
6,5
9
2
4
2
2
0
5
5
1
3
0
H E I N Z M A N N S e r i a l N o . :
f o r B a s i c S y s t e m E
R a n g e V o l t a g e
G m b H + C o .
A m H a s e l b a c h 1
D - 7 9 6 7 7 S c h n a u ( S c h w a r z w a l d )
G e r m a n y
P h o n e : ( 0 7 6 7 3 ) 8 2 0 8 - 0
T e l e f a x : ( 0 7 6 7 3 ) 8 2 0 8 - 8 8


figure 6: housing of DC EDC 2 - 01 - 55
7. Control Unit DC EDC 2 - 01
HELENOS IV 17
Control Unit with terminal strip (DC EDC 2 - 01 - 00)



1
2
2
,
5
2,5
43,5
2
1
3
4
5
6
7
8
9
1
0
1
1
1
2
1
3
1
4
1
5
1
6
1
7
1
8
1
9
2
0
2
1
2
2
2
3
2
4
2
5
2
6
2
7
2
8
2
9
3
0
3
1
3
2
3
3
3
4
3
5
3
6
3
7
3
8
3
9
4
0
4
1
4
2
4
3
4
4
4
5
4
6
4
7
4
8
4
9
5
0
5
1
5
2
5
3
5
4
5
5
5
6
5
7
5
8
5
9
6
0
6
1
6
2
6
3
6
4
6
5
6
6
6
7
6
8
6
9
7
0
7
1
7
2
7
3
7
4
2
4
0
2
6
0
1
0
6,5
15 110
148
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:
(
0
7
6
7
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2
0
8
- 0
T
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le
fa
x
:
(
0
7
6
7
3
) 8
2
0
8
- 8
8



figure 7: housing of DC EDC 2 - 01 - 00
8. Actuators
18 HELENOS IV
8. Actuators
8.1. Design and Mode of Operation

EDC - actuator
injection pump


figure 8: sectional drawing of actuator

The Bosch - EDC - actuator (RE...) is directly mounted on the in-line pump so
that there is no linkage necessary.

The spring loaded control rack is moved by a magnet, where the spring
power moves the control rack to stop position and the magnet power to max.
fuel.

The position of the control rack is monitored by a no-touch feedback system
and transferred to the control unit.
8.
Actuators
HELENOS IV 19
8.2. Specification
(For information only! Refer to appropriate Bosch- documents)


Bosch - EDC
Max. actuator trevel 21mm
Spring power of back spring
in stop position

approx. 10 N
Spring power of back spring
in full position

approx. 50 N
Max. magnetic power approx. 75 N
Max. current consomption approx. 11 A
Current consamption in operation approx. 4-6 A
Coil resistance of governing magnet R
20
approx. 0,6 Ohm
Storage temperature -55C to +90C
Ambient temperature in operation -40C to +80C
Ambient temperature with
reduced governor functions

-40C to 0C
Protection graed IP 55
9. Electric Connection
20 HELENOS IV
9. Electric Connection
9.1. 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.


H E I N Z M A N N S e r i a l N o . :
f o r B a s i c S y s t e m E
R a n g e V o l t a g e
G m b H + C o .
A m H a s e l b a c h 1
D - 7 9 6 7 7 S c h n a u ( S c h w a r z w a l d )
G e r m a n y
P h o n e : ( 0 7 6 7 3 ) 8 2 0 8 - 0
T e l e f a x : ( 0 7 6 7 3 ) 8 2 0 8 - 8 8
sensor
control unit
seperate wire

figure 9: 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.


potentiometer
shielding
shrink sleeve


figure 10: shield connection without plug
9. Electric Connection
HELENOS IV 21
In case of a plug connection the shielding is jamed in the strain relief of the
plug.


sensor plug
strain relief
shielding
shrink sleeve


figure 11: shield connection in the plug


9. Electric Connection

HELENOS IV 22
9.2. Example of Connection for Generator Set
(Parallel- and mains operation with digital accessories)
5 4 2 3
7
2
5
1
6
A
B
A
B
Bosch EDC
Actuator
16 A slow
Governor on
T x D
R x D
24V
0V
DC EDC 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
Governor
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 0,75mm
2


9. Electric
Connection
HELENOS IV 23
figure 12: connections with plugs (IP 55) for genset with digital accessories
9. Electric Connection

HELENOS IV 24


5 4 2 3
7
2
5
1
6
A
B
A
B
Bosch EDC
Actuator
16 A slow
Governor on
red green
T x D
R x D
24V
0V
DC EDC 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
Governor
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 0,75mm
2


9. Electric
Connection
HELENOS IV 25
figure 13: connections with terminal strip (IP 00) for genset with digital accessories
9. Electric Connection

HELENOS IV 26
9.3. Example of Connection for Generator Set
(Parallel- and mains operation with analogue accessories)

5 4 2 3
7
2
5
1
6
A
B
A
B
Bosch EDC
Motor Stop
T x D
R x D
24V
0V
DC EDC 2 - 01 - 55
Control Unit
+
24V
ll
Droop
Fixed Speed
1
2
A
B
A
B
A
B
-
1 B
1
C
1
G
1
H
1
N
1
F
1
A
1
V
1
Z
1
U
1
Y
1
D
1
L
1
K
1
A
2
M
2
L
2
N
2
K
2
B
2
R
2
P
2
C
2
E
2
D
2
P
3
B
3
R
3
M
3
A
3
U
3
N
3
L
3
l
Load
Measuring
Unit
LMG 03
1516 14
16A
17
SyG 02
20 kOhm
Synchronizer
R
1
X
1
J
2
T
2
16 A slow
Governor on
S
2
F
2
0 - 5V
4 - 20mA
0 - 5V
4 - 20mA
T x D
R x D
24V
0V
max.
min.
5 kOhm Manual Setpoint
470 Ohm
470 Ohm
M
1
T
1
W
1
S
1
U
2
G
2
C
3
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
Governor
Overspeed
Display fuel
Display fuel
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 0,75mm
2

9. Electric
Connection
HELENOS IV 27
figure 14: connections with plugs (IP 55) for genset with analogue accessories
9. Electric Connection

HELENOS IV 28


5 4 2 3
7
2
5
1
6
A
B
A
B
Bosch EDC
Motor Stop
T x D
R x D
24V
0V
DC EDC 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
Governor
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 0,75mm
2

9. Electric
Connection
HELENOS IV 29
figure 15: connections with terminal strip (IP 00) for genset with analogue accessories
9. Electric Connection

HELENOS IV 30
9.4. Example of Connection for Vehicle Operation
5 4 2 3
7
2
5
1
6
A
B
A
B
Bosch EDC
Motor Stop
T x D
R x D
24V
0V
DC EDC 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
H
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
Governor
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 0,75mm
2


figure 16: connections with plugs (IP 55) for vehicle operation
9. Electric
Connection
HELENOS IV 31


5 4 2 3
7
2
5
1
6
A
B
A
B
Bosch EDC
T x D
R x D
24V
0V
DC EDC 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
Governor
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 0,75mm
2


9. Electric Connection

HELENOS IV 32
figure 17: connections with terminal strip (IP 00) for vehicle operation
9. Electric
Connection
HELENOS IV 33
9.5. Example of Connection for Locomotive Operation
(16 speed levels)

5 4 2 3
7
2
5
1
6
A
B
A
B
Bosch EDC
Motor Stop
T x D
R x D
24V
0V
DC EDC 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 Sensor
Manual Setpoint
red green
Display
Overall Alarm
Governor
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 0,75mm
2

9. Electric Connection

HELENOS IV 34

figure 18: connections with plugs (IP 55) for locomotive with speed steps
9. Electric
Connection
HELENOS IV 35


5 4 2 3
7
2
5
1
6
A
B
A
B
Bosch EDC
T x D
R xD
24V
0V
DC EDC 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 xD
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
Governor
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 0,75mm
2


9. Electric Connection

HELENOS IV 36
figure 19: connections with terminal strip (IP 00) for locomotive with speed steps
9. Electric
Connection
HELENOS IV 37
9.6. Example of Connection for Locomotive Operation
(Speed adjustment by current signal)

5 4 2 3
7
2
5
1
6
A
B
A
B
Bosch EDC
Motor Stop
T x D
R x D
24V
0V
DC EDC 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
Governor
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 0,75mm
2


9. Electric Connection

HELENOS IV 38
figure 20: connections with plugs (IP 55) for locomotive with current input
9. Electric
Connection
HELENOS IV 39


5 4 2 3
7
2
5
1
6
A
B
A
B
Bosch EDC
T x D
R x D
24V
0V
DC EDC 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 4546 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
Governor
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 0,75mm
2


9. Electric Connection

HELENOS IV 40
figure 21: connections with terminal strip (IP 00) for locomotive with current input
9. Electric
Connection
HELENOS IV 41
9.7. Example of Connection for Marine Operation
(Twin operation: 2 engines with 1 propeller)

5 4 2 3
7
2
5
1
6
A
B
A
B
Bosch EDC
T x D
R x D
24V
0V
DC EDC 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
Governor
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 0,75mm
2

9. Electric Connection

HELENOS IV 42

figure 22: connections with plugs (IP 55) for marine twin operation
9. Electric
Connection
HELENOS IV 43


5 4 2 3
7
2
5
1
6
A
B
A
B
Bosch EDC
T x D
R x D
24V
0V
DC EDC 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
Governor
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 0,75mm
2


9. Electric Connection

HELENOS IV 44
figure 23: connections with terminal strip (IP 00) for marine twin operation
9. Electric
Connection
HELENOS IV 45
9.8. Example of Connection for Marine Operation
(Single engines)

5 4 2 3
7
2
5
1
6
A
B
A
B
Bosch EDC
T x D
R x D
24V
0V
DC EDC 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
Governor
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 0,75mm
2

9. Electric Connection

HELENOS IV 46

figure 24: connections with plugs (IP 55) for marine single operation
9. Electric
Connection
HELENOS IV 47


5 4 2 3
7
2
5
1
6
A
B
A
B
Bosch EDC
T x D
R x D
24V
0V
DC EDC 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
Governor
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 0,75mm
2


9. Electric Connection

HELENOS IV 48
figure 25: connections with terminal strip (IP 00) for marine single operation
9. Electric Connection
50 HELENOS IV
9.9. I/O- Configuration according to Customers Demand
For different modes of usage HEINZMANN suggests the input/output-
configuration as shown in the following table:

10. Programming Possibilities
HELENOS IV 51
10. Programming Possibilities
Programming the Heinzmann Digital Governor can be performed according to
the possibilities described below:


10.1. 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.


10.2. 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.


10.3. 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.


10. Programming Possibilities
52 HELENOS IV
10.4. 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.


10.5. 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.


10.6. 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.



For more details consult the special brochure DG 94 104 - e.
11. Starting the Engine - Brief Instruction
HELENOS IV 53
11. Starting the Engine - Brief Instructions
11.1 Adjust clearance of magnetic pulse pickup.

11.2 Check program with respect to relevant parameters: number of teeth,
speed, etc.

11.3 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.


Attention: Overspeed protection must be guaranteed!

11.4 Start engine and run it up to nominal speed using the set point
potentiometer.

11.5 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.

11.6 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.

11. Starting the Engine - Brief Instruction
54 HELENOS IV
11.7 Gain-correction (P-correction) for gas engines resp. for variable speed
governors with larger speed ranges; adjust map if necessary.

11.8 Checking the remaining program items, e.g., starting fuel injection,
ramp time, etc.

The adjustment procedures as required for items 11.2 bis 11.8 and any
further
options of adjustemnt are in detail described in brochure DG 95110 - e.
12. Plug Connections
HELENOS IV 55
12. Plug Connections

Pickup IA ...
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)
Control Unit
DC EDC 2 - 01
I II III
Injection Pump with
EDC-Actuator
SV EDC-7 K (010-02-335-00)


figure 26: plugs with desination
13. Ordering Specifications
56 HELENOS IV
13. Ordering Specifications
13.1. General Informations
Every data as

supply voltage and kind of usage
parameters, such as speeds and number of teeth on the flywheel
sensors, such as speed probes, pressure and temperature sensors
limitation curves
additional functions
monitoring funktions
input / output configuration

are noted in the brochure Order Information Digital Speed Governors
Nr. DG 96012-e and shoud be transferred to HEINZMANN.

13. Ordering Specifications
HELENOS IV 57
13.2. Cable Harness

Control Unit
DC EDC 2 - 01
L4
L5
L7
L1
L3 L10
L8
L11
L12
L13
Pickups
Sensors
Overspeed
Protection
Battery
Setpoint
Adjuster
Analogue
Outputs
Status
Indicator
Communikation
PWM - Inputs
Frequency
Inputs
Power Outputs
L9
I II III
L2
Injection Pump with
EDC-Actuator
L6
Digital Inputs


figure 27: harness with cable numbers


13. Ordering Specifications
58 HELENOS IV
13.3. Cable Lengths
It is of advantage to obtain the harness together with the governor.

The necessary cable lengths and versions of units have to be registered here
and transfered to HEINZMANN.

Please note: 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 - battery
L 1 Control unit - battery ....... cm
Cable size up to 15 m 2 x 2.50 mm
over 15 - 30 m 2 x 4.00 mm


b) L2 = Control unit - actuator
L 2.1 Control unit - actuator (feedback) ....... cm 3 x 0.75 mmshielded
L 2.2 Control unit - actuator (power) ....... cm
Cable size up to 10 m 2 x 2.50 mm
over 10 - 20 m 2 x 4.00 mm
over 20 - 40 m 2 x 6.00 mm


c) L3 = Control unit - setpoint adjusting unit
L 3.1 Control unit - setpoint poti 1 ....... cm 3 x 0.75 mmshielded
L 3.2 Control unit - setpoint poti 2 ....... cm 3 x 0.75 mmshielded
13. Ordering Specifications
HELENOS IV 59
L 3.3 Control unit - 4-20 mA input ....... cm 2 x 0.75 mm
L 3.4 Control unit - synchronizer ....... cm 2 x 0.75 mmshielded
L 3.5 Control unit - load measuring unit ....... cm 2 x 0.75 mmshielded


d) L4 = Control unit - pickup
L 4.1 Control unit - pickup 1 ....... cm 2 x 0.75 mmshielded
L 4.2 Control unit - pickup 2 ....... cm 2 x 0.75 mmshielded


e) L5 = Control unit - sensor inputs
L 5.1 Control unit - temperature 1 ....... cm 2 x 0.75 mm
L 5.2 Control unit - cooling water temperature.... cm 2 x 0.75 mm
L 5.3 Control unit - boost pressure ....... cm 3 x 0.75 mm
L 5.4 Control unit - oil pressure ....... cm 3 x 0.75 mm


f) L6 = Control unit - digital inputs
L 6.1 Control unit - switch 1 - 4 ....... cm 5 x 0.75 mm
L 6.2 Control unit - switch 5 - 8 ....... cm 5 x 0.75 mm


g) L7 = Control unit - overspeed protection
L 7 Control unit - overspeed protection ....... cm 2 x 1.50 mm


h) L8 = Control unit - controlled current output
L 8 Control unit - contr. current output ....... cm 2 x 1.50 mm


i) L9 = Control unit - status indicator
L 9.1 Control unit - "Overall alarm" ind. ....... cm 2 x 0.75 mm
L 9.2 Control unit - "Overspeed" ind. ....... cm 2 x 0.75 mm
13. Ordering Specifications
60 HELENOS IV
j) L10 = Control unit - analogue outputs
L 10.1 Control unit - display fuel (V) ....... cm 2 x 0.75 mm
L 10.2 Control unit - display fuel (A) ....... cm 2 x 0.75 mm
L 10.3 Control unit - display speed (V) ....... cm 2 x 0.75 mm
L 10.4 Control unit - display speed (A) ....... cm 2 x 0.75 mm
L 10.5 Control unit - load sharing ....... cm 2 x 0.75 mm
L 10.6 Control unit - controll pitch propeller ....... cm 2 x 0.75 mm


k) L11 = Control unit - frequency input
L 11 Control unit - tacho ....... cm 2 x 0.75 mm


l) L12 = Control unit - PWM input
L 12 Control unit - PWM-in ....... cm 2 x 0.75 mm


m) L13 = Communication
L 13.1 Control unit - CAN - Bus ....... cm 2 x 0.14 mmshielded
L 13.2 Control unit - PC ....... cm 4 x 0.14 mmshielded
14. Order Specifications for Brochures
HELENOS IV 61
14. Order Specifications for Brochures
Our technical brochures can be ordered without any charges.

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 join your business
card),
the address where you want the brochures to be sent (if different from the
above),
the number and title of the desired brochure,
or technical data of your HEINZMANN equipment,
the quantity you want.

You can directly use the following fax-document for ordering one or several
brochures.

Most of the manuals are available as Acrobat PDF-files, too. On request they
can be send via e-mail.

We request your comments about the content and the presentation of our
brochures. Please send your comments to:


HEINZMANN GmbH & Co. KG
Service Department
Am Haselbach 1
D-79677 Schnau
Germany


Fax Reply

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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: ....................................................


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