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

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

System Overview

g01216812

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

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.

Diagram of the Governor System

g01216814

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

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.

g01216887

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.

g01216892

Illustration 4

5. From the Adjustment Actuator/Power Supply

screen, click on the Automatic adjust start button.

g01216909

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

g01216949

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.

g01216921

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.

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.

g01216965

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

10

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.

11

g01217756

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.

12

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.

13

g01217988

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.

14

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.

g01217991

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.

15

Load Control Settings

g01217994

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.

16

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

g01220859

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

17

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.

18

g01220944

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.

19

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.

g01220950

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.

20

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.

21

g01221147

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

22

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.

23

g01237886

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

(3) Actuator
(5) Magnetic Pickup

24

External Connections Perkins Supplied

Cable for Diesel Engines

g01237943

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

An error with the configuration file

3001

ErrPickUp

An error with the speed sensor

3004

ErrOverSpeed

Engine overspeed

3007

ErrLoadInput

Load sharer input error

3008

ErrSyncInput

Synchronizer input error

3009

ErrBoostPressure

Boost pressure sensor error

3012

ErrCoolantTemp

Not used

3032

ErrCoolantTempWarn

Not used

3050

ErrFeedback

Actuator feedback signal error

(continued)

44

(Table 3, contd)

3053

ErrActuatorDiff

The difference between the set

value of the actuator and the
actual value of the actuator is too
big.

3056

ErrFeedbackRef

Error on reference value of the

feedback of the actuator

3059

ErrFeedbackAdjust

Error during auto calibration of

actuator

3076

ErrParamStore

Error on storing parameters

3077

ErrProgramTest

Error on programming checksum

3078

ErrRAMTest

Error during RAM test

3080

ErrDisplay

Not used

3081

Err5V_Ref

Error on 5 volt reference

3085

ErrVoltage

Error on voltage supply

3090

ErrData

Error on data block

3092

ErrConfiguration

Configuration error

3093

ErrStack

Error of internal management of

the parameter

3094

ErrIntern

Internal software fault

3101

SErrPickUp

Sentinel for an error on the speed

sensor

3104

SErrOverSpeed

Sentinel for Engine overspeed

3107

SErrLoadInput

Sentinel for Load sharer input

error.

3108

SErrSyncInput

Sentinel for an error with the input

of the synchronizer

3109

SErrBoostPressure

Sentinel for an error with the boost

pressure sensor

3112

SErrCoolantTemp

Not used

3132

SErrCoolantTempWarn

Not used

3150

SErrFeedback

Sentinel for the error for the

actuator feedback signal

3153

SErrActuatorDiff

Sentinel for the difference between

the set value of the actuator and
the actual value of the actuator is
too big.

3156

SErrFeedbackRef

Sentinel for the error on reference

value of feedback for the actuator

3159

SErrFeedbackAdjust

Sentinel for Error during auto

calibration of actuator

3176

SErrParamStore

Sentinel for the error on storing

parameters

3177

SErrProgramTest

Sentinel for the error on

programming checksum

3178

SErrRAMTest

Error during RAM test

3180

SErrDisplay

Not used
(continued)

45

(Table 3, contd)

3181

SErr5V_Ref

Sentinel for the error on 5 volt

reference

3185

SErrVoltage

Sentinel for the error on voltage

supply

3190

SErrData

Sentinel for the error on the data

block

3192

SErrConfiguration

Sentinel for the error on the

configuration

3193

SErrStack

Sentinel for the error of the

management of the internal
parameters

3194

SErrIntern

Sentinel for the internal software

fault

3195

SExceptionNumber

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.