Heinzmann HELENOS III Parts list manual

Copyright 2009 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.
5228 Manual DG 09 008-e / 12-09
Heinzmann GmbH & Co. KG
Engine & Turbine Management
Am Haselbach 1
D-79677 Schönau
Germany
Phone [phone] - 0
Fax [phone] - 188
E-mail [email protected]
www.heinzmann.com
V.A.T. No.: DE145551926
HEINZMANN
Engine & Turbine Management
Digital Control System
HELENOS III
DG 162 - 02
DG 302 - 02
DG 402 - 02
Technical description

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 actuator
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
Warning
Danger
Danger
Danger
Danger!
High
Voltage

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.
Warning
Danger

Helenos III
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.
HEINZMANN retains the right to introduce technical changes!
NOTICE

Helenos III
Chart of system HELENOS III
HELENOS III
for engines from approx. 800 kW up to approx. 4000 kW
Basic System DG 162 - 02 Basic System DG 302 - 02 Basic System DG 402 - 02
Control Unit DC 162 - 02** Control Unit DC 302 - 02** Control Unit DC 402 - 02**
Actuator StG 16 - * Actuator StG 30 - * Actuator StG 40 - *
Setpoint Pot. SW … Setpoint Pot. SW … Setpoint Pot. SW …
Pick-up IA …
D : Digital
DG : Digital Governor (Basic
System)
DC : Digital Control Unit
StG : Actuator
SW : Setpoint Potentiometer
IA : Pick-up

Contents
Helenos III
Contents
Page
1. General Remarks ................................................................................................................. 1
2. Mode of Operation ............................................................................................................... 3
3. Block Diagram of the Digital Governor DG 162 - up to DG 402 -................................... 4
4. Pick-up IA ... ......................................................................................................................... 5
4.1. Specification ................................................................................................................... 5
4.2. Installation ...................................................................................................................... 5
4.3. Tooth profile................................................................................................................... 6
4.4. Clearance of Magnetic Pick-up ...................................................................................... 6
4.5. Mounting Measurements................................................................................................ 7
4.6. Redundant Speed Signal................................................................................................. 7
5. Speed Setpoint Adjusters and Sensors ............................................................................... 8
5.1.Speed Setpoint Potentiometer SW 01-1-B ...................................................................... 8
5.2.Speed Setpoint Potentiometer SW 02-10-B .................................................................... 8
5.3. Setpoint Value Adjustment by Current Signal ............................................................... 9
5.4. Setpoint Value Adjustment by Pedal.............................................................................. 9
5.5. Pressure Sensors ............................................................................................................. 9
5.6.Temperature Sensor TS - 2000 F for Measuring Fluid Temperatures .......................... 10
6. Control Unit DC 162 - 02, DC 302 - 02 and DC 402 - 02 ................................................ 11
6.1. Specification ................................................................................................................. 11
6.2. Measurements............................................................................................................... 12
7. Actuators ............................................................................................................................. 14
7.1. Design and Mode of Operation .................................................................................... 14
7.2. Installation .................................................................................................................... 15
7.3. Specification ................................................................................................................. 16
7.4. Measurements............................................................................................................... 17
8. Regulating Linkage ............................................................................................................ 18
8.1. Length of Regulating Rack........................................................................................... 18
8.2. Connecting Linkage...................................................................................................... 18
8.3. Linkage Adjustment for Diesel Engines....................................................................... 19
8.4. Linkage Adjustment for Carburettor Engines .............................................................. 20

Contents
Helenos III
9. Electric Connection............................................................................................................ 21
9.1. Connection of Shielding ............................................................................................... 21
9.2. Connection for Generator Set with digital Accessories ............................................... 23
9.3. Connection for Generator Set with analoque Accessories ........................................... 25
9.4. Connection for Vehicle Operation................................................................................ 27
9.5. Connection for Locomotive Operation, 16 Speed Levels ............................................ 29
9.6. Connection for Locomotive Operation with Current Signal ........................................ 31
9.7. Connection for Marine Operation, Twin Operation..................................................... 33
9.8. Connection for Marine Operation, Single Engine........................................................ 35
10. Programming Possibilities............................................................................................... 37
10.1. Programming by the Manufacturer ............................................................................ 37
10.2. Programming with the Hand- Held Programmer 2 .................................................... 37
10.3. Programming by PC ................................................................................................... 37
10.4. Programming with User Masks .................................................................................. 37
10.5. Transferring Data Sets................................................................................................ 38
11. Starting the Engine - Brief Instructions......................................................................... 39
12. Ordering Specifications ................................................................................................... 40
12.1. General Informations.................................................................................................. 40
12.2. Harness ....................................................................................................................... 41
12.3. Plug Connections........................................................................................................ 42
12.4. Cable lengths .............................................................................................................. 43
a) L1 = Control unit - battery.......................................................................................... 43
b) L2 = Control unit - actuator........................................................................................ 43
c) L3 = Control unit - setpoint adjusting unit ................................................................. 43
d) L4 = Control unit - pick-up ........................................................................................ 44
e) L5 = Control unit - sensor inputs................................................................................ 44
f) L6 = Control unit - digital inputs ................................................................................ 44
g) L7 = Control unit - overspeed protection ................................................................... 44
h) L8 = Control unit - controlled current output............................................................. 44
i) L9 = Control unit - status indicator ............................................................................. 44
j) L10 = Control unit - analogue outputs ........................................................................ 45
k) L11 = Control unit - frequency input ......................................................................... 45
l) L12 = Control unit - PWM input................................................................................. 45
m) L13 = Communication............................................................................................... 45
13. Download of Manuals ...................................................................................................... 46

1 General Remarks
HELENOS III 1
1. General Remarks
Heinzmann digital governors with control unit DC 162 - 02, DC 302 - 02 and
DC 402 - 02 constitute speed governors 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.
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.

1 General Remarks
HELENOS III
2
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.
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
4–20 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.

2 Mode of Operation
HELENOS III 3
2. Mode of Operation
The actual speed of the engine is read by a pulse pick-up 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.

3. Block Diagram of the Digital Governor
HELENOS III
4
3. Block Diagram of the Digital Governor DG 162 - up to DG 402 -
Fig. 1: Blockdiagram DG 162 - up to DG 402 -

4. Pick-up
HELENOS III 5
4. Pick-up IA ...
4.1. 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 Pick-up Wheel 0,5 to 0,8 mm
Protection grade IP 54
4.2. Installation
The installation of the pick-up has to be arranged in such a way as to obtain a frequency as
high as possible. Normally, the HEINZMANN governors DG 162 - 02, DG 302 - 02 and
DG 402 - 02 are designed for a maximum frequency of 12000 Hz. Frequency (by Hz) is
calculated according to the formula
f
(Hz) = nz(/min)*1
60
z = number of teeth on the pick-up wheel
Example:
n = 1.500
z = 160
f =
1500 *160
60 = 4.000 Hz
NB: It should be taken care that the speed can be measured by the pulse pick-up without
any bias. For best results therefore, the speed pick-up should take the engine speed
from the crankshaft. A suitable position for this is, e.g., the starter gear (but not the
injection pump wheel).
The pick-up gear must consist of magnetic material (e.g., steel, cast iron).

4. Pick-up
HELENOS III
6
4.3. Tooth profile
Any tooth profile is admissible. The top width of the tooth should be 2.5 mm minimum,
the gap and the depth of the gap at least 4 mm. For index plates the same dimensions are
valid.
Due to tolerances, a radial arrangement of the magnetic pick-up is preferable..
4.4. Clearance of Magnetic Pick-up
The distance between the magnetic pulse pick-up and the tooth top should range from 0.5
and 0.8 mm. (It is possible to screw in the magnetic pick-up till it touches the tooth and
then unscrew it for about half a turn.)
4mm(at least)
2.5mm(at least)
4mm(at least)
0.5 - 0.8mm
Fig. 2: Clerance of Pick-up

4. Pick-up
HELENOS III 7
4.5. Mounting Measurements
G
L35
19
Fig. 3: Measurements of Pick-up
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
4.6. Redundant Speed Signal
If precautions are to be taken with regard to failures of the pulse pick-up, a second pulse
pick-up 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 pick-up 1, the governor automatically switches over to the
redundant speed signal and gives an alarm.

5. Speed Setpoint Adjusters and Sensors
HELENOS III
8
5. Speed Setpoint Adjusters and Sensors
Dependent on particular applications, a series of setpoint adjusters are available for the
HEINZMANN Digital Controls.
5.1. Speed Setpoint Potentiometer SW 01-1-B
(1 turn with Limitation Resistors)
(EDV-No.: 600 00 041 01)
Displacement angle approx. 312°
Potentiometer resistance 5 kOhm
Limitation resistance 2 x 470 Ohm
Temperature range -55 °C to + 120 °C
Protection grade IP 00
9,5
3/8" - 32 NEF - 2A
Ø 27
23
26
Fig. 4: Potentiometer SW 01 - 1
5.2. Speed Setpoint Potentiometer SW 02-10-B
(10 turns with Limitation Resistors)
(EDV-No.: 600 00 042 01)
Displacement angle 10 turns
Potentiometer resistance 5 kOhm
Limitation resistance 2 x 470 Ohm
Temperature range -55 °C to + 105 °C
Protection grade IP 00
8,8
3/8" - 32 NEF - 2A
Ø 23
17
32
Fig. 5: Potentiometer SW 02 - 10

5. Speed Setpoint Adjusters and Sensors
HELENOS III 9
On request, the potentiometers, as specified under 5.1 and 5.2, 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.
5.3. 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 the speed to a programmable substitute
value.
5.4. 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 manual E 83 005 - e.
5.5. Pressure Sensors
For pneumatic setpoint adjustment are pressure sensors available as follows:
pressure range up to 10 bar DSG 01 (EDV- No.: 604 00 026 00)
up to 5 bar DSG 02 (EDV- No.: 604 00 026 01)
As boost pressure sensor for a range up to 2 bar the pressure sensor DSG 03
(EDV- No.: 604 00 024 02) is available.

5. Speed Setpoint Adjusters and Sensors
HELENOS III
10
5.6. Temperature Sensor TS - 2000 F for Measuring Fluid Temperatures
(EDV- No.: 600 00 034 00)
Measuring range -20°C to +130°C
Accuracy ± 1.5°C
Resistance at 25°C (R25) 2,000 Ohm ±0.5%
Maximum operating voltage 10 V
Maximum operating current 5 mA
Recommended operating current approx. 1 mA
Time constant in fluids approx. 13 s
Admissible socket temperature range -40°C to +105°C
Protection type IP 65
Vibration <10 g. 10 – 100 Hz
Shock <50 g. 11 ms half-sine wave
Tightening moment 100 Nm ±15 %
Corresponding connector SVM - TS - 2K (EDV- No.: 010 02 170 00)
B
A
Seal Ring DIN 7603-14x18 (Cu)
Pin Configuration:
B = -
20
SW
5/8"-24
M14x1,5
8h7
16
28
17,5
56,5
A = +
Fig. 6: Temperature Sensor TS - 2000 F
PT 1000- types can be used alternatively.
For measuring gas temperatures PT 1000- types must be used.

6. Control Unit
HELENOS III 11
6. Control Unit DC 162 - 02, DC 302 - 02 and DC 402 - 02
6.1. Specification
Operating Voltage 24 V DC (12 … 32 V DC)
Maximum Voltage 36 V DC absolute
Minimum Voltage 9 V DC absolute, short term
Maximum Ripple Voltage maximum 10 % with 100 Hz
Permissible Voltage Drop at
Maximum Voltage of Actuator maximum 10 % in control device
Fuse Protection of Governor 16 A, slow
Current Consumption approx. 0.2 A + current of actuator
at 24 V DC
Operating Ambient Temperature -40 °C to +70°C
Storing Temperature -55 °C to +85 °C
Humidity up to 100 %
Control Frequency 200 to 12.000 Hz
Steady State Variation ±0.25 % of rated speed
Protection grade
DC ... 2 - 02 - 00 IP 00
DC ... 2 - 02 - 55 IP 55
Weight
DC ... 2 - 02 - 00 approx. 1.2 kg
DC ... 2 - 02 - 55 approx. 3 kg
Remark
The control unit is available with terminal strip (DC ... 2 - 02 - 00) or with plug-in
connectors (DC ... 2 - 02 - 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. For example: DC 162 - 02 - 55 - 12700

6. Control Unit DC
HELENOS III
12
6.2. Measurements
Control Unit with plug-in connectors (DC ... 2 - 02 - 55)
205
260 240
25 110
160
6,5
92
42
20
55
130
HEINZMANN Serial No.:
for Basic System E
Range Voltage
GmbH + Co.
Am Haselbach 1
D - 79677 Schönau (Schwarzwald)
Germany
Phone: [phone] - 0
Telefax: (0 76 73) 82 08 - 88
Fig. 7: Housing of DC 162 - 02 - 55 up to DC 402 - 02 - 55