Pandaros Digital Governor _ Special Instruction _ REHS2806 _ May 2006 _ PERKINS.pdf

REHS2806 15 May 2006

Special Instruction AnalogIn1_RefLow ............................................ 16 AnalogIn1_RefHigh ........................................... 16 AnalogIn1_ErrorLow ......................................... 16 AnalogIn1_ErrorHigh ......................................... 16 LoadControlFactor and LoadControlReference .................................... 17 Synchronizer Settings ....................................... 17 ADC 2_Type .................................................. 17 AnalogIn2_RefLow ........................................ 17 AnalogIn2_RefHigh ....................................... 17 AnalogIn2_ErrorLow ...................................... 18 AnalogIn2_ErrorHigh ..................................... 18 SynchronFactor and SynchronReference ..... 18 Additional Programmable Parameters .............. 18 Engine Configuration ......................................... 18 SpeedMin1 and SpeedMin2 .......................... 18 SpeedMax1 and SpeedMax2 ........................ 18 Engine Stop ....................................................... 18 Switch or Impulse .......................................... 18 Close or Open ............................................... 18 Common Alarm ................................................. 18 Adjustment of PID parameters .............................. 18 PID Maps .............................................................. 19 Speed Ramps ....................................................... 20 Fixed Speed Ramp ........................................... 21 Programming example .................................. 21 Activation ....................................................... 21 Sectional Speed Ramp ......................................... 21 Programming Example ...................................... 23 Activation ........................................................... 23 System Wiring ....................................................... 23 External Connections Perkins Supplied Cable for Diesel Engines ................................................ 25 External Connections and the Connector for the Control Box for Diesel Engines ....................... 26 External Connections for Diesel Engines .......... 27 Cable Sizes ....................................................... 27 Alternative Connections for Speed Setting Inputs ............................................................... 27 Single or Parallel Generator Variable Speed .. 27 Parallel Generator Heinzmann LSU/Sync ..... 28 Parallel Generator other LSU/Sync ............... 29 Wiring Diagram for the Digital Control Box in IP Enclosure ........................................................ 30 Diagram for the Wiring Harness for 4006 and 4008 Diesel Engines ................................................ 31 Diagram for the Wiring for 4012 and 4016 Diesel Engines ........................................................... 31 Diagram for the Wiring for 4006 and 4008 Gas Engines ........................................................... 33

i02435096

Pandaros Digital Governor Industrial Engine 4006 TRS Gas Engine 4008 TRS Gas Engine 4012-46A Diesel Engine 4016-61A Diesel Engine

Table of Contents Introduction ........................................................... System Overview .................................................. Description of System ........................................... Diagram of the Governor System ......................... Specification of Governor System ........................ Current consumption of the governor ................ EMC Directives ................................................. Setting for the Feedback ....................................... Setting the Feedback without the Service Tool ..... Configuration ........................................................ Speed ................................................................ Droop/Isochronous ............................................ External Input for Speed Control .......................... Single generator fixed speed ............................ Single generatorvariable speed ........................ Parallel generator Heinzmann LSU/Sync ............. Parallel generator LSU/Sync ............................. Changing the configuration of the governor .......... Single generator fixed speed ............................ Single generator variable speed ........................... Droop ................................................................ Droop ............................................................. DroopRefLo ................................................... DroopRefHi .................................................... DroopSpeedRef ............................................. ADC1 Type .................................................... AnalogIn1_RefLo ........................................... AnalogIn1_RefHi ........................................... AnalogIn1_ErrorLow ...................................... AnalogIn1_ErrorHigh ..................................... AnalogIn1_Filter ............................................ Parallel generator Heinzmann LSU/Sync ............. Parallel generator other LSU/Sync .................... Load Control Settings ........................................... ADC 1_Type ......................................................

2 3 4 5 5 5 5 6 10 10 10 11 11 11 11 11 11 11 12 13 13 13 13 13 13 14 14 14 14 14 14 15 15 16 16

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Finding Faults .................................................... 35 Test 1 ............................................................. 35 Test 2 ............................................................. 35 Test 3 ............................................................. 35 Test 4 ............................................................. 35 Test 5 ............................................................. 36 Test 6 ............................................................. 36 The governor lever moves when cranking the engine but the engine will not start (Diesel Engines only) ................................................... 36 Test 1 ............................................................. 36 Test 2 ............................................................. 36 Test 3 ............................................................. 37 Test 4 ............................................................. 39 Test 5 ............................................................. 39 Governor moves to maximum position when power supply is switched on. ..................................... 40 Test 1 ............................................................. 40 Test 2 ............................................................. 40 The engine goes to overspeed after starting ..... 40 Test 1 ............................................................. 40 Test 2 ............................................................. 40 Test 3 ............................................................. 41 Test 4 ............................................................. 41 Test 5 ............................................................. 41 The governor is not stable ................................. 41 Test 1 ............................................................. 41 Test 2 ............................................................. 41 Test 3 ............................................................. 42 Test 4 ............................................................. 42 Test 5 ............................................................. 42 Test 6 ............................................................. 42 Test 7 ............................................................. 42 Speed droops under load .................................. 43 Test 1 ............................................................. 43 Test 2 ............................................................. 43 Test 3 ............................................................. 43 Test 4 ............................................................. 43 The engine will not pull load .............................. 43 Error Codes ....................................................... 44 Error Memory .................................................... 47

The actuator is connected to the linkage of the fuel injector on diesel engines in order to control the amount of fuel. The actuator is connected to the throttle valve on gas engines in order to control the amount of fuel. The control unit is engine mounted within an IP55 enclosure.

Introduction The Heinzmann Pandaros digital speed governor is installed to a Perkins 4000 Series engine. This Special Instruction gives an overview of the governor system and details of customer interface requirements. The control system consists of the following components:

• Control unit • Actuator • Setpoint adjusters • Sensors • Connection cables

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System Overview

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Illustration 1 (1) Laptop computer (2) Control unit (3) Run status (4) CAN Communication (5) DC - Desk displays (6) Governor errors (7) Stop/Run (8) Synchronizing (9) Load sharing (10) Voltage matching (11) Reactive load share

(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)

Speed ramp Load ramp Soft load transfer Isochronous ramp Power factor set Mains parallel Island parallel Group synchronizing Digital power control Governor sensor Actuator

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Note: A protection device for the external overspeed must always be used with the internal overspeed.

NOTICE Adjustments to the control unit may only be made by an authorised Perkins representative equipped with the necessary programmer. There are no user adjustments inside the box.

Description of System The electronic control unit is the center of the system. There is a 16 bit microprocessor in the control unit. The processor operates the program which controls the system. The program which controls the system is stored in a FLASH-EPROM section of the memory . The control unit compares the actual engine speed that is measured by the magnetic pickup on the flywheel with the desired speed of the engine. The control unit helps to drive the actuator and the input of the fuel to the engine so that the actual engine speed matches the desired engine speed. Boost pressure for the engine is measured and used in order to control fueling for optimum performance and minimum smoke. Additional inputs are available for the measurement of the following data:

• Engine temperature • Fueling control against engine temperature • Connection of additional automatic load sharing • Synchronizing equipment A PC program with special interface cable is used for initial setting of the parameters for the governor and optimizing the system and for finding faults. A CAN bus is available for connecting to digital sharing of loads and synchronizing equipment and future monitoring of the system. If a sensor or the actuator is at fault, an alarm is issued and there will be an engine shutdown. Internal errors get detected also and the errors will be stored as all other failures. All failures can be red with an external PC. To optimize the dynamics for every operating point, the parameters for the PID are corrected. The parameters depend on the engine speed, the engine temperature and load on the engine via stability maps. Proportional gain values, Integral gain values and gain values for the Derivative can be modified from the service tool. An point for the overspeed is programmed into the governor. If this point is exceeded, the governor will issue an alarm and the actuator will fully pull to the stop position.

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Diagram of the Governor System

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Illustration 2 (1) Switch inputs (2) Analog setpoint adjuster (3) Analog synchronizer (4) Analog unit of measure for the load

(5) (6) (7) (8)

(9) Pressure sensor (10) Temperature sensor (11) Actuator that senses position (12) Actuator drive

Failure lamp Interface RS 232 24 V Power supply Speed sensor

Specification of Governor System

Current consumption of the governor

• Supply voltage (24 VDC)

• The steady state condition is approximately one amp.

• Minimum voltage (9 VDC)

• The change of load is approximately three amp

• Maximum voltage (33 VDC)

to four amp.

• Maximum ripple voltage of 10 % at 100 Hz

• Maximum current is approximately 4.5 amp.

• Maximum current consumption for the governor

• The current limitation is approximately 2.5 amp.

is eleven amp.

EMC Directives

• Permissible voltage dip at maximum current consumption is 10 % at the control unit.

89/33/EWG, 95/54/EWG

• The protection of the fuse for the governor is fifteen

ISO 11452-2: Frequency band F2, 60 V/m

amp.

Functional status B

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ISO 7637-2: Frequency band F2, 60 V/m Functional status B ISO 7637-3: Frequency band F2, 60 V/m Functional status B VDE 0879-3: Severity Level 4 CE: EN 50081-2, EN 50082-2 All inputs and outputs are protected against a reverse voltage and a short circuit to the battery. Analog inputs may be set to 0 to 5 volts, 4 to 20 mA or +/- 3 volts in the software. Digital input engine stop U0 < 2 V, U1 > 6.0 V Digital output to the failure lamp is Isink < 0.3 A.

Setting for the Feedback The governor will operate correctly when the control box identifies the parameters for the feedback. The parameters will correspond to 0% and 100% of the position for the actuator. Whenever an actuator has been replaced, it is necessary to carry out a procedure to calibrate the feedback. The DC Desk service tool software can automatically carry out a calibration procedure to establish these parameters. Note: To properly perform automatic calibration, the actuator must operate smoothly and the actuator must be able to easily move from 0% to 100% (left stop and right stop). It is therefore necessary for the actuator to be disconnected from the engine linkage. This procedure is not necessary with the combined actuator and the valve for the throttle that is installed to gas engines.

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Illustration 3 (1) PC

(2) Control box

1. Connect the PC to the control box. 2. Power up the governor. Connect the cable to the control box and the actuator. Apply 24 VDC to the plus cable and to the minus cable from the box for the governor. 3. Start the Pandaros Packager service tool. For information on using Pandaros Packager, refer to the appropriate manual. 4. Select Start communication. The service tool will then load the data from the governor.

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Illustration 4

5. From the Adjustment – Actuator/Power Supply screen, click on the Automatic adjust start button.

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Illustration 5

6. The system will operate the automatic calibration procedure. When the calibration is complete, a dialog box will appear. Refer to illustration 6. The dialog box will show details of the values. Click the OK button in order to accept the settings.

Illustration 7

Illustration 6

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8. A dialog box will appear to state that the parameters have been stored by the software. Click on OK. Turn off 24 volt power supply. Disconnect the PC cable.

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9. The actuator can now be installed to the engine and the linkage connected.

7. The user will then be asked if the parameter values should be stored in the control unit. The user should select the option that states yes.

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Setting the Feedback without the Service Tool When the actuator is replaced and the Service Tool is not available, the setting for the feedback can be calibrated. Follow steps 1 to 6.

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Illustration 8

1. Remove the lid of the IP55 box for the governor. Remove the lid of the Pandaros box.

6. Remove the 24 V supply. Replace the covers and install the actuator to the engine.

Note: The later version of the box have a small hole in the lid of the box which allows the push button to be operated without removing the lid.

Configuration The engine will be configured in accordance with the requirements of the customer. The requirements of the customer are determined from the Sales Order Process. The configurations that are set in the factory are shown below:

2. Connect the cable from the control box to the actuator and apply 24 volts to the governor. 3. Locate the push button (1) for the setting for the feedback. Refer to illustration 8.

Speed

4. Ensure that the actuator output shaft has been disconnected from the engine linkage. The actuator should be free to move from 0% to 100%.

• 1500 rev/min

5. Press the button (1). The system will automatically calibrate the feedback.

• 1500/1800 rev/min

• 1800 rev/min

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Changing the configuration of the governor

Droop/Isochronous The default configuration will be isochronous operation. If the engine has been required to run in droop, the desired percentage droop will also have been set.

In order to change the configuration of the engine governor, use the Perkins service tool and the special communication cable. The communication connector is accessible inside the box for the governor. A security dongle is supplied. The dongle must be plugged into the PC parallel port before the software can operate.

External Input for Speed Control Single generator fixed speed

The various parameter settings for the engine modes are detailed below.

The default configuration is for an engine in order to operate in single generator mode. Single generator mode means that the mode is not paralleled with any other generator. This mode has no provision for external speed control. The speed will be fixed at 1500 rev/min or 1800 rev/min.

Note: After the parameters are changed, it is necessary to store the parameters in governor. Then power down the governor. Power up the governor again before the changes take effect.

Single generatorvariable speed

Refer to illustration 9 in order to view the configuration screen for the service tool.

This mode allows the Load Sharer input to be used with an external 5K potentiometer for manual speed setting control. In this configuration, an external speed setting control must be connected in order to enable the engine to run. There are options for either the synchronizer or the droop operation.

Parallel generator Heinzmann LSU/Sync The Heinzmann LSU/Sync provides the connection to the standard Heinzmann sharing of the analog loads and the synchronizing units. The connections are designated A3, B3 and E3.

• A3 is the common connection. • B3 is the input for the synchronizer. • E3 is the load sharer input. In this configuration, the necessary load sharing or synchronizing inputs must be connected in order to allow the engine to run.

Parallel generator LSU/Sync This configuration will be determined from a discussion with the provider of the genset. The configuration is available on special order. Perkins must agree with the configuration. The inputs for the speed/load control are +/- 3 V or 4-20mA. Note: Any other changes to the configuration require the use of the Service Tool and the special communication cable. Refer to the Service Tool manual for information on other configurable parameters.

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Illustration 9

Single generator fixed speed

For single speed 1800 rev/min operation, the parameter number SpeedFix2 is used to set the engine speed.

Select the button for Single generator fixed speed on the Generator Mode. The engine will operate in isochronous mode at a fixed speed of 1500 rev/min or 1800 rev/min. The engine will be switchable between these speeds.

For 1500/1800 rev/min operation, the parameter SpeedFix1 is used to set 1500 rev/min and the parameter SpeedFix2 is used to set 1800 rev/min. If the box LockedSwitchOn is selected, the engine will be single speed. The speed is selected by the SpeedFix1Locked or SpeedFix2Locked buttons.

Note: For some engines, the selection of 1800 rpm running can only be done by the factory. NOTICE Engines supplied as 1500 rev/min units must not be switched to 1800 rev/min units without approval from the factory. Hardware changes may be required for the engine to run at 1800 rev/min. Failure to heed this notice can lead to premature failures, product damage, personal injury or death.

If the box LockedSwitchOn is not selected the engine is switchable speed from an external switch. When the engine speed of 1500 or 1800 is selected, various parameters such as overspeed settings are automatically adjusted in order to suit the selected speed of the engine. The current overspeed setting is displayed on the screen. The setting cannot be changed.

For single speed 1500 rev/min operation, the parameter SpeedFix1 is used to set the engine speed.

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Single generator variable speed Droop For manual parallel operation, droop mode is required with an engine speed that is capable of being varied for synchronizing and the sharing of the load. This mode is selected by setting the Generator Mode to Parallel generator variable speed with droop. When the engine operates in droop mode, the following parameters must be set: Droop Set the required percentage droop. There are separate droop adjustments for 1500 rev/min and 1800 rev/min engines. The 1800 rev/min settings are labelled Droop2. DroopRefLo To set the parameter, turn the governor to the ON position. Run the engine at no load. Read the parameter ActPos from the Speed Governor – Adjustment tab. Refer to illustration 10. Enter the value into the parameter DroopRefLo. DroopRefHi To set the parameter, the governor must be powered up with the engine at full load. Read the parameter ActPos and enter the value into the parameter DroopRefHi. Setting DroopRefLo and DroopRefHi in this way ensures that the percentage droop set is accurate. DroopSpeedRef Set this parameter to the nominal running speed of the engine (1500 or 1800 rev/min). The analog input which will be used for the external speed control must now be set up. To set up the analog input, select the Configuration – Load Control tab. A screen will be displayed. Refer to illustration 10.

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Illustration 10

ADC1 Type

AnalogIn1_RefHi

The parameter enables the selection of the correct type of analog input. The settings are shown below.

• 0 to 5 volt input

AnalogIn1_Refhi will set the highest value for the analog input as an input that is valid. For an external speed control for the potentiometer, this should be set to 5.

• 0 to 10 volt input

AnalogIn1_ErrorLow

• 4 to 20 mA input

AnalogIn1_ErrorLow sets the lowest input level when an error will occur.

For external speed control from a 5K potentiometer, select 0 to 5 volt.

AnalogIn1_ErrorHigh AnalogIn1_ErrorHigh sets the high input level when an error will occur.

Note: After selecting a different type of analog input, the governor must reset for the change in order to take effect.

AnalogIn1_Filter

The other available adjustments are detailed below. AnalogIn1_RefLo

AnalogIn1_Filter sets the filter level. It is not normally necessary to change this value.

The AnalogIn1_RefLo will set the lowest value for the analog input as an input which is valid. For an external speed control for the potentiometer, this should be set to 0.

The remainder of the settings on the screen determine the value in the event of an error on the speed input. Store the last valid value or use a substitute value.

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Parallel generator Heinzmann LSU/Sync When the Generator Mode - Parallel generator option is selected, the screen will change. The screen will allow the selection of Heinzmann LMG/Syg or Other options.

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Illustration 11

If Heinzmann LMG/Syg is selected, the Load Control and the inputs for the synchronizer are automatically set to the correct values and no other adjustments are required.

The Load Control tab allows the setting of the input parameters of the Analogue 1. The Synchronizer tab allows the setting of the input parameters of the Analogue 2.

Parallel generator other LSU/Sync

Note: The range of the external speed control may be limited by parameters SpeedMin and SpeedMax. The parameters can be changed.

There are many possible variations of load sharing and requirements for the input of the synchronizer unit. Some options may only require one input whereas other options may require two inputs. The section details the available inputs and the possible settings for the inputs.

The remainder of the settings on this screen determine the value in the event of an error on the speed input. Store the last valid value or use a substitute value. For use with the digital load sharing or synchronizing units, refer to the factory.

For this mode, the Generator Mode must be set to Parallel Operation and the LSU/Sync mode set to Other. The Load Control and the Synchroniser tabs will allow the two analog inputs to be set for the variable speed option.

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Load Control Settings

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Illustration 12

ADC 1_Type

AnalogIn1_ErrorLow

The parameter enables the selection of the type of input that is required to activate analog input 2. The settings are listed below.

AnalogIn1_ErrorLow sets the lowest value at which analogue 1 input signal will give as an error. If AnalogueIn1_RefLo was set at 0.5 volt, AnalogIn1_ErrorLo could be set at 0.3 volt. This enables detection of an open circuit or faulty input signal.

• 0 to 5 volt input • 0 to 10 volt input

AnalogIn1_ErrorHigh

• 4 to 20 mA input

AnalogIn1_ErrorHigh sets the highest value at which analogue 1 input signal will give as an error. If AnalogueIn1_RefHi was set at 4.5 volt, AnalogIn1_ErrorHi could be set at 4.7 volt. This enables detection of a faulty input signal.

AnalogIn1_RefLow AnalogIn1_Reflow will set the lowest value that analog input 1 will allow as an input.

AnalogIn1_RefHigh AnalogIn1_RefHigh will set the largest value that analog input 1 will accept as a valid input.

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LoadControlFactor and LoadControlReference If analogue input 1 is used, the two parameters set the range of the external speed control and the reference % for nominal speed. If 1500 rev/min is the nominal running speed and speed variation of +/- 5% speed variation is required, set LoadControlFactor at 10% and LoadControlReference at 50%.

Synchronizer Settings

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Illustration 13

ADC 2_Type

AnalogIn2_RefLow

The parameter enables the correct selection of input that is required by analog input 2. The settings are listed below.

AnalogIn2_RefLow will set the smallest value that analog input 2 will accept as a valid input. AnalogIn2_RefHigh

• 0 to 5 volt input

AnalogIn2_RefHigh sets the highest value the analog input will accept as a valid input.

• 0 to 10 volt input • 4 to 20 mA input

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AnalogIn2_ErrorLow

Common Alarm

AnalogIn2_ErrorLow sets the lowest value at which the analog 2 input signal will give an error. If AnalogueIn2_RefLo was set at 0.5 volt, AnalogIn2_ErrorLo could be set at 0.3 volt. This enables detection of an open circuit or faulty input signal.

Connect a 24 volt lamp to the output in order to indicate a fault with the governor.

Adjustment of PID parameters The engine is supplied with the governor PID (Proportional, Integral and Derivative) gain parameters. The PID will give a stable operation with the majority of engine and alternator combinations. When instability occurs with a particular combination of engines and alternators, it will be necessary to change the governor PID.

AnalogIn2_ErrorHigh AnalogIn2_ErrorHigh sets the highest value at which the analog 2 input signal will give an error. If AnalogueIn2_RefHi is set at 4.5 volt, AnalogIn2_ErrorHi could be set at 4.7 volt. This enables detection of a faulty input signal.

The PID parameters are available on the Adjustment – Speed Governor tab. Refer to illustration 14.

SynchronFactor and SynchronReference When analog input 2 is used, the two parameters set the range of the external speed control. The two parameters will set the reference % for nominal speed. If 1500 rev/min is the nominal running speed and speed variation of +/- 5% speed variation is required, set SynchronFactor at 10% and SynchronReference at 50%.

Additional Programmable Parameters The section will list other parameters that are available. The section will provide an explanation of the functions of the parameter and the calibration procedures. These parameters are available on the Configuration – Engine tab.

Engine Configuration SpeedMin1 and SpeedMin2 The SpeedMin1 & SpeedMin2 parameter will set the minimum speed for the engine operation. SpeedMax1 and SpeedMax2 SpeedMax1 and SpeedMax2 sets the maximum speed for the engine operation.

Engine Stop Switch or Impulse When the parameter is set to switch the engine stop is active when the stop command is in operation. When the parameter is set to Impulse, the engine stop is active by a single switching pulse until the engine stops. Close or Open If this is set to Open then opening the stop switch will stop the engine. If this is set to Close then closing the stop switch will stop the engine.

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Illustration 14

Set the parameter values. Interrupt the engine speed for a short period of time by operating the engine stop switch. Observe the transient response. Continue to modify the PID parameters until the transient response is satisfactory.

To set the parameters, the engine is started. The engine can be operated to the working point. The adjustment can be made at this point. Usually, this working point will be at rated speed and off-load. To optimize the PID parameters, use the following procedure.

PID Maps

• Increase the P-factor Gain until the engine tends to become unstable. Decrease the P-factor until the speed oscillations disappear or the speed oscillations are reduced to a moderate level.

The PID values which give optimum performance are different for the various load values. Gains may be greater with increasing load. The governor gains are plotted. Plot gain versus load. The maps are created during the process of engine development. The service tool can change the maps.

• Increase the I-factor Stability until the engine

operation alters to speed oscillations that have longer waves.

There are two sets of PID maps. One map is for speed. The speed is determined by the parameter SpeedFix1. The other map is for speed that is determined by the parameter SpeedFix2.

• Increase the D-factor Derivative until the speed

oscillations disappear. If the oscillations cannot be eliminated by the D-factor, the I-factor must be reduced.

Note: The D-factor must not be increased beyond 25%. This will cause the actuator to draw excess current.

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To adjust the maps, on the Adjustment – Speed governor screen, click the PID Map open button. Then select the edit button on the map screen. For engines that are a fixed speed, only the first column is used. If necessary, change the gain entry against the actuator position (Y axis) when the instability of the gain occurs. The values are percentages. For example, 100 represents 100%. This does not change the basic PID values.

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Illustration 15

Speed Ramps

To achieve a slow ramp in speed, the control provides ramps that retard the acceleration. The rate of delay of increasing or decreasing the set value can be adjusted separately in either direction. Furthermore, it is possible to decide on the type of speed ramp via the parameter.

Speed ramps are not normally used in generating set applications. For pump sets it is preferable to have a ramp in speed that is slow from idle speed to full speed.

• FixedRamp is Fixed speed ramp. • Sectional Ramp is Sectional speed ramp.

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The ramp functions are activated by selecting the SpeedRampOn box on the Configuration – Engine tab.

Fixed Speed Ramp To use the fixed speed ramp, select the Fixed Ramp button. The fixed speed ramp is the rate of delay for the setpoint. The fixed speed ramp is identical across the entire speed range. The ramp rates for ramping upward and downward can be separately set via the parameters under SpeedRamp1.

• SpeedRampUp is the ramp rate for the upward ramp.

• SpeedRampDown is the ramp rate for the downward ramp.

The unit of these parameters is speed increase resp. speed decrease per second (revolutions per minute per second = rpmps). When ramping is desired in one direction the maximum value of the parameter is (4000 rpmps). The maximum value of the parameter is entered for the other direction. The speed setpoint that is delayed by the ramp can be viewed by the parameter SpeedSetpRamp. The parameter SpeedSetpSelect represents the speed setpoint for the ramp. Programming example Speed should rise from 1000 rpm to 1500 rpm in the course of 20 seconds. This is equivalent to an increase of speed of 500 rpm within 20 seconds or of 25 rpm per second. Deceleration is to work without ramp. Table 1

Parameter

Value

Unit

SpeedRampUp

25

rpmps

SpeedRampDown

4000

rpmps

Activation

• SpeedRampOn is selected. • FixedRamp is selected.

Sectional Speed Ramp In certain applications it is preferable that the ramping rate is not same for the entire speed range. The control will offer the option in order to separate the speed range into three sections. Then set the ramping rate for each respective section. The ramping rate will depend on the current setpoint value SpeedSetp.

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Illustration 16

Note: The points that will result in the ramping rate changing are determined by the parameters that are listed below.

• SpeedRamp1 - SpeedRampDown.

• SpeedRamp2 - SpeedSwitchToRamp.

• SpeedRamp2 - SpeedRampUp.

Change of the rate from section 1 to section 2.

Ramp rate for ramping upward in section 2

• SpeedRamp3 - SpeedSwitchToRamp.

• SpeedRamp2 - SpeedRampDown.

Change of the rate from section 2 to section 3.

Ramp rate for ramping downward in section 2

The ramping ratesin which the setpoint is delayed are in the respective sections. The ramping ratesare set via the following parameters.

• SpeedRamp3 - SpeedRampUp.

• SpeedRamp1 - SpeedRampUp.

• SpeedRamp - SpeedRampDown.

Ramp rate for ramping upward in section 1

Ramp rate for ramping downward in section 3

Ramp rate for ramping downward in section 1

Ramp rate for ramping upward in section 3

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The unit of the parameters is given by an increase in speed or a decrease of speed per second. The ramps are enabled by selecting the SpeedRampOn box. Selection of the sectional speed ramp is made by selecting the Sectional Ramp button. Two ramp sections can be provided. The switch point 2 is represented by the parameter SpeedRamp3. Switch point 2 must be set to the maximum value of speed. The speed setpoint is delayed by the ramp. The speed setpoint can be viewed by the parameter SpeedSetpRamp. The parameter SpeedSetpSelect represents the speed setpoint that the ramp is supposed to arrive at.

Programming Example The upward ramping rate between the minimum speed and 800 rpm is 100 rpmps. The reduction of speed is operated in a short period of time. The speed range of upward ramping rate lies between 800 rpm and 1200 rpm is 50 rpmps. The downward ramping rate is 40 rpmps. Between 1200 rpm and the maximum speed the upward rates and the downward rates are 20 rpmps. Table 2

Parameter

Value

Unit

SpeedRamp1 - SpeedRampUp

100

rpmps

SpeedRamp1 - SpeedRampDown

4000

rpmps

SpeedRamp2 - SpeedRampUp

50

rpmps

SpeedRamp2 - SpeedRampDown

40

rpmps

SpeedRamp3 - SpeedRampUp

20

rpmps

SpeedRamp3 - SpeedRampDown

20

rpmps

SpeedRamp2 - SpeedSwitchToRamp

800

rpmps

SpeedRamp3 - SpeedSwitchToRamp

1200

rpmps

Activation • SpeedRampOn is selected. • Sectional Ramp is selected.

System Wiring The cables (4) between the system components are provided and installed by Perkins. A system diagram is shown in illustration 17. The cable (6) which is 4 meters is equipped with a connector. The connector is attached to the control box. The connector is available for external connections to the unit. This cable may also be supplied by the OEM.

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Illustration 17 Typical example (1) Control Box (2) Boost Pressure Sensor (if equipped)

(3) Actuator (5) Magnetic Pickup

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External Connections Perkins Supplied Cable for Diesel Engines

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Illustration 18

• B+

B3 is a input for the synchronizer. B3 may be used for a control signal for speed from an analog synchronizer. B3 can be used for other external speed control that can depend on the configuration. For engines that are fixed speed, no connection is required.

A positive 24 VDC supply to the governor from the battery A 15A fuse or a circuit breaker must be installed in the circuit for overcurrent or short circuit protection.

• E3

Note: When an overspeed fault occurs the supply from the battery to the actuator and the stop solenoid should be removed.

Load sharer input is for a connection to a Heinzmann analog load sharing unit. For engines of a fixed speed, no connection is required.

• B-

• 0V and 5V

A negative 24 VDC is supplied from the battery to the governor.

There is a 5V supply for an external speed setting potentiometer for the configuration of a generator with a single variable speed. For engines with a fixed speed, no connection is required.

• Run/Stop Switch The switch that is connected from the wire to + 24V will enable the engine to run if the switch is closed. The engine will stop when the switch is open. This is the preferred method of normal stop. If the method of normal stop is not required, connect the wire for the Run/Stop Switch to +24V.

• 1500/1800 The switch that is connected from the wire to +24V will enable the engine to be switched between 1500 Rev/Min and 1800 Rev/Min speeds when switchable 1500/1800 Rev/Min running is configured. For engines that have a single speed, no connection is required. The switchable engine speed of 1500/1800 rev/min will return to a engine speed of 1500 rev/min. The switch will occur when there is no electrical connection.

• A3 A3 is common for synchronizer/load sharer input.

• B3

• Alarm

25

The alarm is a digital output in order to indicate a fault on the governor system. Connect a lamp or a relay between this connection and +24V for an indication of the fault condition. It is necessary to use the service tool to establish the reason for the fault indication.

• SCR SCR is the screen of the cable which is connected to the metal work of the connector at the control box for EMC requirements.

• CAN+ and CANCAN bus connections for digital load sharing/synchronizing (if equipped)

External Connections and the Connector for the Control Box for Diesel Engines

g01237963

Illustration 19

26

External Connections for Diesel Engines

g01237972

Illustration 20 (1) 15A fuse (2) Run/Stop Switch (if equipped)

(3) Alarm lamp (4) 1500/1800 switch

Cable Sizes

(5) CAN bus connections (6) External analog controls

Alternative Connections for Speed Setting Inputs

The cables for the supply for the battery must be 1.5 square mm minimum. The cables may be up to a maximum length of 7 meters. All other cables may be 0.5 square mm minimum.

Single or Parallel Generator Variable Speed Connect 0V and 5V to the potentiometer and the slider of the potentiometer to B3.

27

Illustration 21

g01237997

Illustration 22

(1) 5k potentiometer

g01238000

(1) Synchronizer SYG02 (2) Load measuring unit LMG 03-S2

Parallel Generator Heinzmann LSU/Sync

For the equivalent connections on the analog theseus unit, refer to the Heinzmann manual.

Connect A3, B3 and E3 wires. Refer to illustration 22.

28

Parallel Generator other LSU/Sync

Illustration 23

g01238308

(1) The external speed setting can be a voltage or a current.

29

Wiring Diagram for the Digital Control Box in IP Enclosure

g01238312

Illustration 24 (1) CAN H (2) CAN L

(3) Temperature Sensor (4) Boost Sensor 0.5 - 4.5V

30

(5) Boost Sensor 4 - 20mA

Diagram for the Wiring Harness for 4006 and 4008 Diesel Engines

g01248438

Illustration 25 (1) (2) (3) (4)

Control Box Boost Pressure Sensor Actuator Magnetic Pickup

(5) Connector for the OEM (J1) Connector for the control box for the magnetic pickup (J2) Connector for the magnetic pickup

Diagram for the Wiring for 4012 and 4016 Diesel Engines

31

(J3) Connector for the control box (J4) Actuator connector (J5) Boost pressure sensor connector

g01248511

Illustration 26

32

(1) (2) (3) (4) (5)

Relay RL2 Relay RL1 3 pin Deutsch connector Start relay Control box

(6) Actuator (7) Boost pressure sensor (8) Magnetic pickup (9) Connector for the OEM (10) Stop solenoid

Note: If there is an overspeed fault or an emergency stop, the supply of the battery to the actuator and the supply of the battery to the FPS input must be stopped.

Diagram for the Wiring for 4006 and 4008 Gas Engines

33

g01248508

Illustration 27 Typical example of the wiring diagram for a 4008 gas engine

34

(1) Hall effect pickup (2) Magnets on the camshaft gear (3) Ignition unit

(4) Ignition coils (5) HT leads (6) Control box for the governor

(7) Actuator or throttle valve (8) Magnetic speed pickup (9) Connector for the OEM

Finding Faults

Result

Note: The faults relate to problems with the governor system. The faults are not mechanical problems with the engine.

If the result is OK, proceed to Test 3. If the result is not OK, the governor is supplied with 24 volts from the wiring for the OEM onto the 14 pin plug at the left of the control box. Check for any blown fuses in the supply line and for damaged wiring or broken wiring.

Test 1 The lever of the governor will not move to the run position when the engine is cranked.

Check for reversed battery polarity. A diode is installed inside the control unit in order to protect against wrong polarity. No voltage will be measured if the battery polarity is incorrect.

Ensure that the Shutdown switch is working. Ensure that the switch is in the Run position. 1. Remove the lid of the control box by removing the 4 screws.

If necessary, repair the components or replace the components.

2. Turn off the 24 volt supply. Select the function for ohms on the multimeter. Connect the multimeter to terminals 11 and 21 of the Pandaros DC 6 module.

Replace the lid of the control box. STOP

3. Operate the run/stop switch. The run/stop switch is part of the panel for the OEM so details will vary.

Test 3 Check the signal from magnetic pickup.

Note: The control box can be programmed for the Run/Stop switch to be open or closed for operation. The default setting is closed for operation.

1. Disconnect the 2 pin plug from the pickup at the control box.

Result

2. Connect a multimeter on the AC voltage range to the cable from the pickup.

The result is OK when the resistance that is measured is less than 1 ohm with the switch closed. There should be a high resistance with an open switch.

3. Crank the engine. Check the pickup voltage at the speed of the engine cranking. The voltage should be 1.5V AC at the A2/B2 plug.

Proceed to Test 2. If the result is not OK, there is a fault in the wiring or in the switch. Investigate the fault. If necessary, repair the component or replace the component.

Result The result of the test is OK when the output voltage from the magnetic pickup is a minimum of 1.5 volts. The voltage should be measured when the engine is cranked. Proceed to Test 5.

Replace the lid of the control box. STOP

If the result is not OK, proceed to Test 4.

Test 2

Test 4

No DC voltage at control unit.

Check the resistance at the control unit.

1. Remove the lid of the control box by removing the 4 screws.

Set the multimeter to the setting for the electrical resistance. Use the multimeter to check the resistance. The resistance is approximately 52 ohms at the A2/B2 plug.

2. Turn on the 24 volt supply. Set the function of the DC voltage on the multimeter. Connect a multimeter to terminals 20 (-) and 21 (+) of the Pandaros DC 6 module.

Result

The measurement should show at least 24 volts.

35

If the result is not OK, there may be a problem with the linkage. Correct the fault and retest the equipment. If the resistance of the actuator is incorrect, the actuator is faulty. Replace the actuator and retest the new actuator.

If the resistance is OK, it is possible that metal particles have collected on the magnetic pickup. The reduced output or the gap between the pickup and the teeth of the timing ring may be greater than 0.5 to 0.8 mm. Remove the magnetic pickup. Clean the magnetic pickup or replace the magnetic pickup. Refer to Operation and Maintenance Manual, “Engine Speed/Timing Sensor - Clean/Inspect”.

STOP

If the result is not OK, there is a wiring fault or the magnetic pickup is faulty. If necessary, repair the magnetic pickup or replace the magnetic pickup.

The governor lever moves when cranking the engine but the engine will not start (Diesel Engines only)

STOP

Test 1

Test 5

The stop solenoid is not energized (6 and 8 cylinder Diesel Engine only).

An error with the control box exists. The error lamp will be illuminated.

When the engine is started, take note of the stop solenoid. The solenoid should be energized. The solenoid should be pulled into the correct position.

Remove the 24 Volt supply to the governor. This will clear any errors. Retest the equipment.

Result

If the result is OK, the actuator now moves when the engine is cranking. The error has been cleared.

If the result is OK, there may be a mechanical problem. There could be a fault with the fuel system. The faults may prevent the engine starting. Refer to the manual for the OEM for further information.

STOP

If the result is not OK, proceed to Test 2.

If the result is not OK, use Pandaros Packager service tool to investigate the error. Otherwise proceed to Test 6.

Test 2

Test 6

1. Remove the rubber boot from the stop solenoid in order to reveal the connections.

Result

Check the voltage at the solenoid.

Check the actuator..

2. Select the DC voltage range on the multimeter. Check that there is 24 volts on the positive terminal of the solenoid and the negative terminal of the solenoid.

1. Examine the actuator for objects that block the movement of the actuator. Examine the linkage in order to determine whether the linkage is incorrectly adjusted.

Result

2. Turn off the 24 volts supply. Move the actuator lever by hand in order to check free movement.

If the wiring to the solenoid is OK, the solenoid coil may have burned out. Replace the solenoid. Take care to position the replacement solenoid correctly. When the solenoid is energized, the solenoid should not impede the movement of the rack. The solenoid will push the rack to the stop position when the solenoid is not energized.

3. Remove the connecting plug from the actuator and check resistance at terminals B/C. The resistance should be approximately 2 ohm. Result

STOP

Without the Pandaros Packager service tool, the above tests cannot distinguish between the possibility of a faulty actuator or faulty control box. If the result is OK, replace the actuator. If necessary, replace the control box. Retest the equipment.

If the result is not OK, there is a problem in the wiring or circuitry to the solenoid. The circuit is not supplied by Perkins. Investigate the fault. If necessary, repair the component or replace the component.

STOP

STOP

36

Test 3 The stop solenoid is not energized (12 and 16 cylinder Diesel Engines only). The solenoids that are installed to the engines have two windings. A pull-in winding is supplied with 60 amp at 24 volts. The winding is only rated for 30 seconds. The second winding is a hold-in winding. The second winding is supplied with around 1 amp. The second winding is continuously rated. There is a switch that is installed inside the solenoid which initially shorts out the hold-in winding. The switch will open when the switch is pulled in. This will put the pull-in winding and the hold-in winding in series. The engines are installed with two relays. The stop solenoids must be energized before the engine can crank. This operation ensures that the full voltage of the battery is available to move the solenoids into the correct position. A situation can occur if the solenoids are energized at the same time as the starting motor. The voltage drop that is caused due to the starting motor may result in the incorrect operation of the solenoids. In this condition, the pull-in winding in the solenoids will burn out in around 30 seconds. The circuitry is shown in illustration 28.

37

g01259965

Illustration 28 (1) RL2 (2) RL1

(3) 3 pin Deutsch connector (4) Start relay

(5) The solenoid for the fuel stop is energized in order to operate.

If the result is not OK, ensure that the 24 volt supply is on. Use a multimeter on the DC voltage range across the coil of relay RL2. The reading should read at least 24 volts.

To start the engine, a 24 volt supply is initially put onto pin B of connector J4. This will immediately energize relay RL2. Both solenoids will be energized. The first solenoid moves into position. The internal contact supplies a battery negative onto the coil of relay RL1 which energizes. This supplies a voltage to the start relay contact. The second solenoid moves into position. The contact of the second solenoid supplies a battery negative onto the coil of the start relay. The start button is pressed. This supplies a positive battery voltage through pin C of J4 onto the other side of the start relay which then puts power to the solenoid coil of the starting motor (SMC). Observe the stop solenoids when the engine is started. The solenoids should be energized. The solenoids should be in the correct position. Result If the result is OK, there may be a mechanical problem or a fuel problem that prevents the correct engine operation. Refer to the Operation and Maintenance Manual for more information.

38

g01260004

Illustration 29 Wiring for the relay (1) Coil terminals

(2) Contact terminals

(3) J4 Deutsch DT3 connector

Result

Result

If the result is OK, proceed to test 4.

If the result is OK, the relay RL2 is OK. Proceed to Test 5.

If the result is not OK, there is a problem with the supply to relay RL2. Trace the wiring fault back through connector J4 to the control panel. If necessary, repair the component or replace the component.

If the result is not OK, the relay has failed. Replace the relay and check that the solenoids are now energized. STOP

STOP

Test 5

Test 4

Check the solenoid 1.

Check the voltage on the relay contact..

1. Remove the rubber covers from the end of both solenoids.

Turn on the 24 volt supply. Select the DC voltage range on the multimeter. Use a multimeter to check the voltage between each contact terminals. The contact terminals are the large connections on the top of the relay. The wire numbers are 10 and 14. Test the voltage between the contacts and the battery negative. Both the terminals should be 24 volts to the battery negative.

2. Locate the solenoid which has wire numbers 14 and 15. Wires 14 and 15 are connected to the main terminals.

39

The internal power driver in the control box may have failed. Replace the control box and retest the equipment.

3. Turn on the 24 volt supply. Select the DC voltage range on the multimeter. Use a multimeter to check the voltage on the positive terminal and the negative terminal of the solenoid. The numbers for the wires of the terminal are 14 and 15. The voltage should read 24 volts.

STOP

4. The solenoid should be energized. The solenoid should be pulled in.

The engine goes to overspeed after starting

5. Check the voltage between the positive solenoid and Aux terminals. The Aux terminal is marked with a positive sign within a circle. The voltage should read 24 volts.

The engine may overspeed due to incorrect assembly or adjustment.

Result

Engine overspeed could result in personal injury, loss of life and/or property damage.

If the result is OK, proceed to test 6.

Be prepared to stop the engine by activating the engine shutdown system or closing the air inlet lines.

If the result is not OK, the solenoid is faulty. Replace the solenoid and retest the solenoid. STOP

Test 1

Governor moves to maximum position when power supply is switched on.

Check the signal from magnetic pickup.

Note: Do not attempt to start the engine.

1. Disconnect the 2 pin plug from the pickup at the control box.

The actuator should not move until the governor receives a signal from the magnetic pickup in order to indicate that the engine is rotating. In this fault condition, the engine is likely to go into overspeed.

2. Select the AC voltage range on the multimeter. Connect a multimeter to the cable from the pickup.

Test 1

3. Crank the engine and check pickup voltage at cranking speed. The voltage is approximately 1.5V AC at control unit A2/B2 plug.

Inspect the wiring harness.

Result

1. Carefully examine all wiring between the control box and the actuator. Examine the cable to the pickup. Check the continuity of the screen on the magnetic pickup cable since failure of the screen can allow electrical interference to enter the cable. Electrical interference can result in a false speed signal.

If the result is OK,the voltage output from the pickup is at least 1.5 volts. The test should be conducted when the engine is cranked. Proceed to test 3.

Result

Check the resistance at the control box.

If the result is OK proceed to test 2.

1. Select the function of the resistance on the multimeter. Use the multimeter to check the resistance at the control unit A2/B2 plug. The resistance should be approximately 52 ohm.

If the result is not OK, proceed to test 2. Test 2

If the result is not OK, repair the wiring harness. If necessary, replace the wiring harness and retest the wiring harness.

Result

STOP Test 2 Inspect the control box.

40

Result

If the resistance is OK, it is possible that metal particles have collected on the magnetic pickup. This reduces the output or the gap between the pickup and the teeth for the engine flywheel may be greater than 0.5 to 0.8 mm. Remove the pickup. Clean the pickup or replace the pickup. Reinstall the magnetic pickup. Refer to Operation and Maintenance Manual, “Engine Speed/Timing Sensor - Clean/Inspect”.

If the result is OK, the engine no longer goes to overspeed. If resetting the governor gain parameters cleared the fault, carry out the procedure for the governor PID tuning. STOP

If the result is not OK, there is a wiring fault or the magnetic pickup is faulty. If necessary, repair the components or replace the components.

If the result is not OK, proceed to test 5.

Test 3

Replace the governor components.

Feedback for the actuator is not calibrated to the control box.

Result

Test 5

If the result is OK, STOP.

1. Disconnect the actuator from the linkage and carry out the Feedback Setting procedure. Reinstall the actuator and retest the actuator.

If the result is not OK, it is likely that there is a jammed linkage or a damaged injector. If necessary, repair the components or replace the components.

Result

STOP

If the result is OK, STOP.

The governor is not stable

If the result is not OK, proceed to test 4.

Test 1

Test 4

Check the signal from the magnetic pickup.

Check the parameters of the governor..

1. Disconnect the 2 pin plug from the pickup at the control box.

1. The test can only be carried out if the Pandaros Packager service tool is available. Remove the lid from the control box. Connect the cable that is supplied with the service tool to the 9 pin connector on the DC 6 control module.

2. Connect a multimeter on the AC voltage range to the cable from the pickup. 3. Crank the engine. Check the pickup voltage at the speed of the crank of the engine at the A2/B2 plug. The voltage is approximately 1.5V AC.

2. Connect the other end of the cable to the serial port of the PC. Operate the Pandaros Packager. Ensure that the security dongle is connected to the PC.

Result

3. Check the parameters.

If the result is OK, the output from the pickup is at least 1.5 volts when the engine is cranking. Proceed to test 3.

a. The parameters are SpeedFix 1 or 2 on the configuration screen. The parameters depend on the 1500/1800 switch position. The default is 1500 or 1800 rpm.

If the result is not OK, proceed to test 2. Test 2

b. The default gain on the adjustment screen is 12%.

Check the resistance at the control unit.

c. The default stability on the adjustment screen is 50%.

Select the function for ohms on the multimeter. Use the multimeter to check the resistance at the control unit A2/B2 plug. The resistance is approximately 52 ohm.

d. The default derivative on the adjustment screen is 15%.

Result

4. If the governor gain parameters are much lower than the default values, enter the default values. Retest the equipment.

41

If the result is OK, STOP.

If the resistance is OK, it is possible that metal particles have collected on the magnetic pickup. This has reduced the output or the gap between the pickup and the teeth of the flywheel may be greater than 0.5 to 0.8 mm. Remove the pickup. Clean the pickup or replace the pickup. Reinstall the pickup. Refer to Operation and Maintenance Manual, “Engine Speed/Timing Sensor - Clean/Inspect”.

If the result is not OK, proceed to test 5. Test 5 Supply voltage. Connect a multimeter on the DC voltage range to the supply for the battery to the governor. The reading with the running of the engine should be a constant and at least 24 volts. The ripple voltage is an AC voltage that is superimposed onto the 24 volts DC from a power supply. An example is a battery charger. The ripple voltage must not exceed 10% of the DC voltage. An oscilloscope may be required to test the ripple voltage.

If the result is not OK, there is a wiring fault or the magnetic pickup is faulty. If necessary, repair the pickup or replace the pickup. Test 3 External speed setting control 1. If no external speed setting control is installed, proceed to test 4.

Result If the result is OK, proceed to test 6.

2. Use the Pandaros Packager service tool. Select Single Generator Fixed Speed on the Configuration screen.

If the result is not OK, the input voltage may be low. Investigate the wiring and investigate the power supply circuit. If excessive ripple voltage is suspected, turn off the battery charger. Run the engine. If the problem is corrected, repair the battery charger or replace the battery charger.

3. Carry out a reset of the governor by removing and then reconnecting the 24 volt supply. 4. Run the engine. Run the engine at the load conditions that cause the engine speed to become unstable.

STOP

Result

Test 6

If the result is OK, there is a problem with the external speed control and the engine is following variations in the input voltage. Investigate the fault. If necessary, repair the component or replace the component.

Check the load fluctuations.

Test 4

If the load is continuously varying, the engine speed governor may not be able to keep the speed constant. The condition is not a fault. The condition occurs in the gensets that are driven by engines. When possible, test the engine with a constant load. An example would be banks of loads that are resistant. The test will establish if the load creates the problem.

The governor gains are incorrectly set.

Result

1. By using Pandaros Packager service tool, check the parameters.

The engine will run on a steady load. The settings for the governor gain are correct. The settings were measured in test 4. The load changes are too great for the engine capacity. Nothing can be done to the engine in order to improve this condition.

If the result is not OK, return the engine configuration to the previous setting and reset the governor.

a. The default gain on the adjustment screen is 12%.

If the result is not OK, proceed to test 7.

b. The default stability on the adjustment screen is 50%.

Test 7

c. The default derivative on the adjustment screen is 15%.

Play or friction in linkage (Diesel Engines only).

2. If the governor gain parameters are much lower than the default values, enter the default values and retest the equipment.

Examine the linkage between the actuator and injectors for any stiffness or excess play. If necessary, repair the linkage or replace the linkage.

Result

STOP

42

Speed droops under load

Replace the control box. Ensure that the settings in the new box are correct and retest the engine.

Test 1

STOP

The governor is set up for droop operation..

The engine will not pull load

Use the Pandaros Packager service tool to check the mode of the generator on the configuration screen. If the mode that is selected is not within the droop mode, the engine speed will decrease by the droop percentage as load is increased.

By using Pandaros Packager service tool, check for an indication of an error with the boost pressure and check the boost pressure reading on the Display screen with the engine on load.

Result

Result

If the result is OK, droop mode is not selected. Proceed to test 2. If the result is not OK, either select one of the non-droop operating modes or set the percentage droop to zero.

If the result is OK, the boost pressure sensor is operating correctly. The term Boost Pressure Limit Active will display 0 on the display screen. There is a mechanical problem with the engine. The engine is prevented from producing a full load. Investigate the fault. If necessary, repair the component.

STOP

STOP

Test 2

If the result is not OK, check the wiring to the boost pressure sensor. If necessary, replace the sensor.

The engine is being overloaded..

STOP

1. Check if the actuator is at the maximum stop for the fuel. If the actuator is at the maximum stop for the fuel, the engine is being overloaded or there is an engine problem which is preventing the engine from producing full power.

The Service Tool can be used to assist in the finding of faults. The display screens allow parameters such as speed, the actuator position and the boost pressure. The display screens and the facility that produces graphs in real time can be used to get a visual impression of the changes of the parameter during transients. If necessary, the data may be stored to a file. This function is available under the main menu Graphic – Curve Versus Time. Refer to illustration 30.

2. Use Pandaros Packager service tool to look at the display screen. Inspect the display in order to find out if there are active fuel limits. Result If the result is OK, proceed to test 3. If the result is not OK, investigate the cause of the overload or the lack of engine power. If the limit of the boost pressure is active, proceed to the symptom that describes the engine without full load. STOP Test 3 The governor stability is incorrectly set. Carry out the procedure to adjust the PID parameters. Result If the result is OK, STOP. If the result is not OK, proceed to test 4. Test 4 The control unit is faulty..

43

g01260016

Illustration 30

Error Codes The control box continuously monitors the system. If a fault is detected, the control box registers the fault. The control box will turn on the lamp for the alarm (if equipped). If the fault is serious the control box will stop the engine. Table 3

Name

Code

Value

Description

3000

ConfigurationError

0

An error with the configuration file

3001

ErrPickUp

0

An error with the speed sensor

3004

ErrOverSpeed

0

Engine overspeed

3007

ErrLoadInput

0

Load sharer input error

3008

ErrSyncInput

0

Synchronizer input error

3009

ErrBoostPressure

0

Boost pressure sensor error

3012

ErrCoolantTemp

0

Not used

3032

ErrCoolantTempWarn

0

Not used

3050

ErrFeedback

0

Actuator feedback signal error (continued)

44

(Table 3, contd)

3053

ErrActuatorDiff

0

The difference between the set value of the actuator and the actual value of the actuator is too big.

3056

ErrFeedbackRef

0

Error on reference value of the feedback of the actuator

3059

ErrFeedbackAdjust

0

Error during auto calibration of actuator

3076

ErrParamStore

0

Error on storing parameters

3077

ErrProgramTest

0

Error on programming checksum

3078

ErrRAMTest

0

Error during RAM test

3080

ErrDisplay

0

Not used

3081

Err5V_Ref

0

Error on 5 volt reference

3085

ErrVoltage

0

Error on voltage supply

3090

ErrData

0

Error on data block

3092

ErrConfiguration

0

Configuration error

3093

ErrStack

0

Error of internal management of the parameter

3094

ErrIntern

0

Internal software fault

3101

SErrPickUp

0

Sentinel for an error on the speed sensor

3104

SErrOverSpeed

0

Sentinel for Engine overspeed

3107

SErrLoadInput

0

Sentinel for Load sharer input error.

3108

SErrSyncInput

0

Sentinel for an error with the input of the synchronizer

3109

SErrBoostPressure

0

Sentinel for an error with the boost pressure sensor

3112

SErrCoolantTemp

0

Not used

3132

SErrCoolantTempWarn

0

Not used

3150

SErrFeedback

1

Sentinel for the error for the actuator feedback signal

3153

SErrActuatorDiff

0

Sentinel for the difference between the set value of the actuator and the actual value of the actuator is too big.

3156

SErrFeedbackRef

0

Sentinel for the error on reference value of feedback for the actuator

3159

SErrFeedbackAdjust

0

Sentinel for Error during auto calibration of actuator

3176

SErrParamStore

0

Sentinel for the error on storing parameters

3177

SErrProgramTest

0

Sentinel for the error on programming checksum

3178

SErrRAMTest

0

Error during RAM test

3180

SErrDisplay

0

Not used (continued)

45

(Table 3, contd)

3181

SErr5V_Ref

0

Sentinel for the error on 5 volt reference

3185

SErrVoltage

0

Sentinel for the error on voltage supply

3190

SErrData

0

Sentinel for the error on the data block

3192

SErrConfiguration

0

Sentinel for the error on the configuration

3193

SErrStack

0

Sentinel for the error of the management of the internal parameters

3194

SErrIntern

0

Sentinel for the internal software fault

3195

SExceptionNumber

0

Sentinel for the exception number

3196

SExceptionAddrLow

0000Hex

Sentinel for the software fault

3197

SExceptionAddrHigh

0000Hex

Sentinel for the software fault

3198

SExceptionFlag

0000Hex

Sentinel for the software fault

The current errors are displayed by selecting Error – Current Errors from the top menu of Pandaros Packager. Refer to illustration 31.

g01238737

Illustration 31

The current error screen is then displayed. Refer to illustration 32.

46

g01260308

Illustration 32

Provided that the current errors have been cleared, the current error screen can be cleared. Use the Clear Errors button to clear the errors. To clear the Time Stamp screen, click the Reset Time Stamp button.

Error Memory Although the current errors can be cleared, a history of errors is stored in the Error Memory. The history of errors can be displayed. The history of errors cannot be cleared.

47

Illustration 33

Copyright © 2006 Perkins Engines Company Limited All Rights Reserved

g01238433

Printed in U.K.