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Heinzmann HELENOS V DC 2040DP.2-01 Manual

Digital electronic speed governors basic systems
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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
7011
HEINZMANN
Digital Electronic Speed Governors
Basic Systems
HELENOS V
DC 2005DP.2-01
DC 2040DP.2-01
Heinzmann GmbH & Co. KG
Engine & Turbine Controls
Am Haselbach 1
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
Druckschrift DG 97 014-e / 04-06

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  • Page 1 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...
  • Page 3 Helenos V for engines from approx. 80 kW up to approx. 2000 kW Basic System DG 2005DP.2 - 01 Basic System DG 2040DP.2 - 01 Control Unit DC 2005DP.2 - 01 Control Unit DC 2040DP.2 - 01 Actuator StG 2005DP Actuator StG 2040 DP Setpoint Pot.
  • Page 4 Practice all plant and safety instructions and precautions. Warning 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 Danger Please note before commissioning the installation:...
  • Page 5 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.

  • Page 6: Table Of Contents

    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 ...........................
  • 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 ..................
  • Page 8 Contents 17 Order Specifications for Manuals ..................57 HELENOS V...

  • Page 9: Safety Instructions And Related Symbols

    1 Safety Instructions and Related Symbols 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...

  • Page 10: Basic Safety Measures For Normal Operation

    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.

  • Page 11: Before Putting An Installation Into Service After Maintenance And Repair Works

    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! •...

  • Page 12: General

    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.

  • Page 13: Functions

    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.
  • Page 14 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.
  • Page 15 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.

  • Page 16: Mode Of Operation

    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.

  • Page 17: Further Information

    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.

  • Page 18: Block Diagram Of The Digital Governor Helenos

    6 Block Diagram of the Digital Governor HELENOS 6 Block Diagram of the Digital Governor HELENOS Feedback Drive Figure 1: Blockdiagram DG 16.1 - 03 up to DG 40.1 - 03 HELENOS V...

  • Page 19: Sensors

    7 Sensors 7 Sensors 7.1 Overview Coolant Sensor Speed Oil Pressure Boost Pressure Temperature HZM Designation IA .. TS 01-28-PT1000 DSO 01-6 DSL/G 0..-2 DSO 01-10 DSL/G 0..-5 DSO 01-16 DSL/G 0..-10 Connection SV 6-IA-2K SV 6-IA-2K DIN 43650 A DIN 43650 A 2 pole 2 pole...

  • Page 20: Magnetic Pickup Ia

    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...

  • Page 21: Tooth Profile

    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.

  • Page 22: Mounting Measurements

    7 Sensors 7.2.6 Mounting Measurements Figure 3: Magnetic Pickup Measures Thread Length Thread Size Remarks L (mm) Type 01 - 38 M 16 x 1,5 02 - 76 M 16 x 1,5 03 - 102 M 16 x 1,5 11 - 38 5/8"-18UNF-2A appropriate 12 - 76...

  • Page 23: Cooling Medium Temperature Sensor Ts 01 - 28 - Pt 1000

    7 Sensors 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 Maximum operating current 3 mA Recommended operating current approx 1mA Time constant in fluids approx.

  • Page 24: Pressure Sensors

    7 Sensors 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...

  • Page 25: Boost Pressure Sensors

    7 Sensors 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...

  • Page 26: Boost Pressure Sensor With Housing And Terminal Strip

    7 Sensors 7.4.2.2 Boost Pressure Sensor with Housing and Terminal Strip 29,5 SW 24 H EINZM AN N GmbH + Co. Am Haselbach 1 D-79677 SchÎnau/Schw. Germany Phone: (07673) 8208-0 Telefax: (07673) 8208-88 27,5 Figure 7: Boost Pressure Sensor with Housing Max.

  • Page 27: Speed Setpoint Adjusters

    8 Speed Setpoint Adjusters 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...

  • Page 28: Setpoint Value Adjustment By Current Signal

    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.

  • Page 29: 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 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)

  • Page 30: Inputs And Outputs

    PWM with 2000 Hz, I < 6,4 A Serial Interface ISO 9141, Heinzmann Communication 9.2 Mounting When selecting the location, care should be taken for easy access in order to facilitate read- out of the failure indication and replacement of the device under field conditions. Any mounting position is admissible.

  • Page 31: Measurements

    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...
  • Page 32 9 Control Unit DC 2005DP.2 - 01 up to DC 2040DP.2 - 01 Control Unit with terminal strip (DC ... 2 - 01 - 55) 43,5 Figure 11: Control Unit DC 2005DP.2 - 01 up to DC 2040DP.2 - 01 HELENOS V...

  • Page 33: Actuators

    10 Actuators 10 Actuators 10.1 Design and Mode Operation Feedback System Stop Lever Injection Pump (no delivery item) Lace up Adapter Plate Working Coil Control Rod Travel (adjustable from 14 to 21 mm) 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.

  • Page 34: Installation

    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.

  • Page 35: Specification

    10 Actuators 10.3 Specification StG 2005 DP StG 2040 DP Maximum control rod travel 21 mm 21 mm Spring power of back spring in stop position approx. 9 N approx. 30 N Spring power of back spring in full position 14 N 50 N Maximum positioning force...

  • Page 36: Measurements

    10 Actuators 10.4 Measurements 27,5 Figure 13: Actuator StG 2005 DP HELENOS V...
  • Page 37 10 Actuators 131,5 Figure 14: Actuator StG 2040 DP Measurements HELENOS V...

  • Page 38: Electric Connection

    11 Electric Connection 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.

  • Page 39: Connection Of Power Supply

    11 Electric Connection In case of a plug connection the shielding is jamed in the strain relief of the plug. sensor plug shielding shrink sleeve strain relief 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.
  • Page 40 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.

  • Page 41: Example Of Connection For Generator Set With Digital Accessories

    11 Electric Connection 11.3 Example of Connection for Generator Set with digital Accessories (Island parallel- and mains operation) Control Unit DC … 2 - 01 - 55 Plug 1 Plug 2 Plug 3 SUB-D Plug Actuator 5 4 2 3 T x D Connection R x D...
  • Page 42 11 Electric Connection Control Unit DC …2 - 01 - 00 11 12 19 21 20 32 31 30 35 34 36 37 SUB-D Pug Actuator 48 49 43 44 45 46 71 74 73 5 4 2 3 T x D R x D Connection Programmer 2...

  • Page 43: Example Of Connection For Generator Set With Analogue Accessories

    11 Electric Connection 11.4 Example of Connection for Generator Set with analogue Accessories (Island parallel- and mains operation) Control Unit DC …2 - 01 - 00 11 12 19 21 20 36 37 SUB-D Plug Actuator 48 49 43 44 45 46 71 74 73 5 4 2 3...
  • Page 44 11 Electric Connection Control Unit DC …2 - 01 - 00 11 12 19 21 20 36 37 SUB-D Plug Actuator 43 44 71 74 73 48 49 45 46 5 4 2 3 T x D R x D Connection Programmer 2 Diagnostics...

  • Page 45: Example Of Connection For Vehicle Operation

    11 Electric Connection 11.5 Example of Connection for Vehicle Operation Control Unit DC …2 - 01 - 55 Plug 1 Plug 2 Plug 3 SUB-D Plug Actuator T x D R x D Connection Programmer 2 Diagnostics Motor Stop green Fixed Speed 1 StG 2005 DP Display...
  • Page 46 11 Electric Connection Control Unit DC …2 - 01 - 00 19 21 20 11 12 18 16 32 31 30 35 34 36 37 SUB-D Plug Actuator 48 49 43 44 45 46 53 55 71 74 73 5 4 2 3 T x D R x D Connection...

  • Page 47: Example Of Connection For Locomotive Operation With 16 Notches

    11 Electric Connection 11.6 Example of Connection for Locomotive Operation with 16 Notches Control Unit DC …2 - 01 - 55 Plug 1 Plug 2 Plug 3 SUB-D Plug Actuator 5 4 2 T x D R x D Connection Programmer 2 Diagnostics Motor Stop...
  • Page 48 11 Electric Connection Control Unit DC …2 - 01 - 00 11 12 19 21 20 18 16 32 31 30 36 37 SUB-D Plug Actuator 48 49 43 44 45 46 53 55 71 74 73 T x D Connection R x D Programmer 2...

  • Page 49: Example Of Connection For Locomotive Operation With Speed Setpoint Via Current Signal

    11 Electric Connection 11.7 Example of Connection for Locomotive Operation with Speed Setpoint via Current Signal Control Unit DC …2 - 01 - 55 Plug 1 Plug 2 Plug 3 SUB-D Plug Actuator 5 4 2 3 T x D Connection R x D Programmer 2...
  • Page 50 11 Electric Connection Control Unit DC …2 - 01 - 00 11 12 19 21 20 18 16 36 37 SUB-D Plug Actuator 48 49 43 44 45 46 53 55 71 74 73 T x D R x D Connection Programmer 2 Diagnostics...

  • Page 51: Example Of Connection For Marine Operation With Master/Slave

    11 Electric Connection 11.8 Example of Connection for Marine Operation with Master/Slave (Twin operation: 2 engines on one shaft) Control Unit DC …2 - 01 - 55 Plug 1 Plug 2 Plug 3 SUB-D Plug Actuator 5 4 2 T x D R x D Connection Programmer 2...
  • Page 52 11 Electric Connection Control Unit DC …2 - 01 - 00 11 12 19 21 20 18 16 32 31 30 36 37 SUB-D Plug Actuator 48 49 43 44 45 46 53 55 71 74 73 5 4 2 T x D R x D Connection...

  • Page 53: Example Of Connection For Marine Operation In Single Operation

    11 Electric Connection 11.9 Example of Connection for Marine Operation in single Operation Control Unit DC …2 - 01 - 55 Plug 1 Plug 2 Plug 3 SUB-D Plug Actuator 5 4 2 T x D R x D Connection Programmer 2 Diagnostics Motor Stop...
  • Page 54 11 Electric Connection Control Unit DC …2 - 01 - 00 11 12 19 21 20 18 16 31 30 36 37 SUB-D Plug Actuator 48 49 43 44 45 46 53 55 71 74 73 5 4 2 T x D R x D Connection Programmer 2...

  • Page 55: Harness

    12 Harness 12 Harness 12.1 Cable Lenghts Control Unit DC 2005DP.2 - 01 - 55 or DC 2040.2 - 01 - 55 Digital Inputs Actuator StG 2005 DP/ StG 2040 DP Power Output Pickups Frequency Inputs Sensors Inputs Overspeed Communication Protection Status Battery...

  • Page 56: Plug Designations

    12 Harness 12.2 Plug Designations Control Unit DC ... 2 - 01 - 55 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) Magnetic Pickup IA ...

  • Page 57: Programming Possibilities

    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.

  • Page 58: Assembly Line End Programming

    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. HELENOS V...

  • Page 59: Starting The Engine - Brief Instructions

    14 Starting the Engine - Brief Instructions 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: Gain to 50 Stability...

  • Page 60: Ordering Specifications

    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.
  • 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 .....
  • Page 62 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 .....

  • Page 63: Figure List

    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 ....................
  • Page 64 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 ...................
  • Page 65 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, •...
  • Page 66 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 ..........

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