Summary of Contents for Heinzmann HELENOS V DC 2040DP.2-01
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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...
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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.
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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:...
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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.
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 ...........................
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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 ..................
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Contents 17 Order Specifications for Manuals ..................57 HELENOS V...
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...
1 Safety Instructions and Related Symbols In this publication the Table of Contents is preceded by diverse instructions that among other things serve to ensure safety of operation. It is absolutely imperative that these hints be read and understood before commissioning or servicing the installation.
1 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! •...
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.
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.
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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.
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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.
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.
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.
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...
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...
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.
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.
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...
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...
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...
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.
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)
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.
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...
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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...
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.
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.
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...
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.
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.
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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.
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...
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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...
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...
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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...
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...
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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...
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...
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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...
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...
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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...
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...
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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...
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...
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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...
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...
13.4 Programming with User Masks Principally, programming may be performed with the help of user masks that have been provided by HEINZMANN or may conveniently be created by the user himself. Within a user mask, only those parameters are accessible that are actually needed.
13 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...
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...
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.
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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 .....
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15 Ordering Specifications j) L10 = Control Unit - Analogue Outputs L 10.1 Control unit - display voltage 1 ..... cm 2 x 0,75 mm² L 10.2 Control unit - display current 1 ..... cm 2 x 0,75 mm² L 10.3 Control unit - display voltage 2 .....
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 ....................
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16 Figure List Figure 29: Connection with Plugs (IP 55) for Marine Operation in single Operation ..... 45 Figure 30: Connection with Terminal Strip (IP 00) for Marine Operation in single Operation ..............................46 Figure 31: Harness with Cable Numbers ................. 47 Figure 32: Plugs with Designation ...................
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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, •...
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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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