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Technical Instruction No.

1502-0065

Heinzmann Controller for StG 10 and StG 30 Actuators

1. Function:___________________________________________________________1
1.1
1.2

Use and general function:


Protection functions:

1
1

2. Assembly:__________________________________________________________2
2.1
2.2

Wiring:
Terminal strip allocation:

2
3

3. Settings: ___________________________________________________________4
3.1
3.2

Current range:
Position settings auto adjust:

5
5

4. Cumulative failure transmitting output:__________________________________7


4.1
4.2
4.3

General:
Controller warnings / self-resetting:
Controller emergency shutdowns:

7
7
7

5. Troubleshooting: ____________________________________________________8
5.1

Failure message - warning:

1. Function:
1.1

Use and general function:


The Heinzmann Pandaros controller is used in conjunction with the Heinzmann StG10 or StG30
actuator and controls the position of the throttle valve. The controllers control electronics include a
powerful 16-bit microprocessor. The actual actuator position (voltage signal: approx. 1.4 V = 0 %, approx.
3.0 V = 100 %) is compared to the engine control setpoint position (current signal: 0-20mA). The
actuating variable calculated from the setpoint value and actual value is transmitted to the power output
transformer in the control electronics. This output then controls the engine in the actuator. The actual
controller program that the microprocessor uses is permanently stored in a flash EPROM.

1.2

Protection functions:
The servo amplifier is equipped with protection functions both for the actuator (current limiter) and the
auto-protection functions (short-circuit protection, etc.).
Short-circuit protection:
If a short circuit occurs in the power output side of the actuator circuit, the amplifiers output transformer is
switched off automatically.
The controller is pole-error protected and short-circuit protected at all the digital and analogue inputs and
outputs of the control electronics against the positive and negative of the power supply.
Overvoltage / undervoltage protection:
If the supply voltage exceeds 32 V or falls below 9 V, the amplifier is switched off and the failure
transmitting output is activated.

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Technical Instruction No.:

1502-0065

Heinzmann Controller for StG 10 and StG 30 Actuators

Current limiter:
A peak current of 6.4 A (max. 20 sec.) and a constant current of 3.2 A are permitted in order to protect the
actuator from thermal overload. The controller guarantees these limiting conditions by reducing the
current to the constant current approx. 5 seconds after the permissible constant current is exceeded. The
power consumption of the actuator can be checked by measuring the current at the output side of the
actuator circuit.
The current limiter is only activated if the actuator is obstructed or overloaded. This is an
indication of the incorrect setting of a mechanical component (control rod assembly, throttle
valve) or a malfunction!

2. Assembly:
The controllers control electronics are contained in a metal housing (B x H x D = 165 x 105 x 65mm),
which is suitable for top-hat rail mounting. The connection is established via the terminal strip on the
circuit board.

2.1

Wiring:
Cable sets with prepared connectors (for actuators) are used to make the electrical connection with the
actuators.
TL 234658
StG 10
Type 2 and 3 engines
TL 234666
StG 30
Type 6 engines
The connection with the actuators is established by means of two cables.
L1: approx. 9 m 2-pole, 1.5 mm, shielded plastic-sheathed cable (engine connection)
L2: approx. 9 m 3-pole, 0.75 mm, shielded plastic-sheathed cable (signal connection)

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Technical Instruction No.:

1502-0065

Heinzmann Controller for StG 10 and StG 30 Actuators

Both cables are led to the connection on the actuator in a common connector (MIL). The cable shields
must be led to the terminal strip on the controllers circuit board. The shield for the signal cable L2 must
be connected to the corresponding terminal strip (14 | Shld). The shields for L1 and L2 must be earthed at
the entry to the module interface box.
2.2

Terminal strip allocation:


Connections to the controller are made on a consecutively numbered circuit board terminal strip. A short
description of the terminal clamps is printed on the housing cover.
Pandaros terminal strip

Pin
1
2
3
4
5
6
7
8
9
10
11

12
13
14
15
16
17
18
19
20
21
22
23
24
25

Function
Not in use!
Not in use!
Not in use!
Not in use!
Shield for mA signal
Not in use!
mA signal setpoint (+)
mA signal setpoint (-)
Dig. input for auto adjust
(bridge to Terminal No. 11)
Failure transmitting output
Dig. input for servomotor stop
(bridge to Terminal No. 9 for
actuator - auto adjust)
Not in use!
Not in use!
Shield for position signal
GND for StG position sensor
StG position signal
Power supply for StG position
sensor
Bridge to Terminal No. 22
Bridge to Terminal No. 23
0 V supply
+24 V supply
Bridge to Terminal No. 18
Bridge to Terminal No. 19
Engine 1
Engine 2

Description on
cover

Pin No. of
actuator

Cable conductors
for L1 and L2

SHIELD
FB-COM
FB-MEA
FB-REF

Connector housing
E
A
D

Shield for L2
3 L2
2 L2
1 L2

DRIVEDRIVE+
+
DRIVEDRIVE+
DRIVE- to Actuator
DRIVE+ to Actuator

B
C

1 L1
2 L1

SHIELD
AC symbol
GND
Closing contact
symbol (SpD)
Lamp symbol
STOP / DI (Stp)

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Technical Instruction No.:

1502-0065

Heinzmann Controller for StG 10 and StG 30 Actuators

Comparison of terminal strips for subsequent modifications:


Alge servo amplifier (TL No. 319169) and Heinzmanns Pandaros controller (TL No. 369160)

Function
Shield for position signal

Alge servo amplifier


Pin No. / Description
X9: 1 / Earth symbol

Power supply for StG position


sensor
StG position signal
GND for StG position sensor
mA signal setpoint (+)
mA signal setpoint (-)
Shield for mA signal
Opening contact signal relay
Base contact signal relay
Closing contact signal relay

X9: 2

+12 V

X9: 3
X9: 4
X9: 5
X9: 6
X9: 7
X9: 8
X9: 9
X9: 10

/
/
/
/
/
/
/
/

Pos.
GND
+mA
+mA
Earth symbol
Opening contact
Base
Closing contact

Function
+24 V supply
0 V supply
Shield for engine

Alge servo amplifier


Pin No. / Description
X10: 1 / +24 V
X10: 2
/
X10: 3 / Earth symbol

Engine 1
Engine 2
Shield

X10: 4
X10: 5
X10: 6

/
/
/

M1
M2
Earth symbol

Pandaros PIN No. of


PIN No.
actuator
14
Connector
housing
17
D

Cable L2
(3 x 0.75)
Shield

16
15
7
8
5

2
3

A
E

Pandaros PIN No. of


PIN No.
actuator
21
20
Connector
housing
24
B
25
C

Cable L1
(2 x 1.75)

Shield
1
2

3. Settings:
As supplied, the preset 0% and 100% position of the controller is only approximate. All other settings,
such as control circuit amplification, have already been adjusted to the optimum value for operating with
the StG 10 and StG 30. It is essential that the 0% and 100% position is set accurately before the engine
is operated for the first time. The setting is made by means of an auto adjust function, i.e. when a wire
jumper is connected to the Pandaros controller the actuator is adjusted automatically for the 0% and
100% position.
The auto adjust function must be carried out each time the controller or the actuator is replaced. An auto
adjust is also required when the Pandaros is retrofitted to a field system and mechanical changes are
made, e.g. adjustments to the control rod assembly!

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Technical Instruction No.:

1502-0065

Heinzmann Controller for StG 10 and StG 30 Actuators

3.1

Current range:
The Pandaros must be selected for the analogue position setpoint with a current signal in the range of 0
20 mA. The setpoint cannot be switched from 0 20 mA to 0 200 mA, as is the case with the Alge
servo amplifier (TL No. 319169).
When the Pandaros is retrofitted to EMS 2000 systems the 0 200 mA setpoint signal must be
adjusted to a 0 20 mA setpoint signal by means of an active measuring transducer with 3-way
galvanic separation (input / output / supply).
The measuring transducer is part number 399003.

3.2

Position settings auto adjust:


Because of manufacturing tolerances for the position feedback system and the throttle valve rod
assembly the end positions must be set on first use, after the rod assembly has been adjusted (see
maintenance instructions). This is done through an automatic adjustment of the StG10 or StG30 throttle
valve actuator with the Pandaros controller during engine standstill.
The throttle valve and the control rod assembly must be properly set by mechanical means in conjunction
with the actuator before the auto adjust can take place. The throttle valve and the control rod assembly
must not be obstructed or stiff.
Conditions for automatic adjustment of the 0% and 100% position:
To carry out the auto adjust, you need to have a wire jumper between terminals No. 9 and No. 11 of the
controller. Another requirement for the adjustment is that the engine should be at a standstill and the
controller powered by the power supply.
Triggering automatic adjustment for the 0% and 100% position:
Once the above conditions have been met, the auto adjust procedure can start. A wire connection must
be established for at least 10 seconds continuously between terminal No. 9 on the controller and terminal
No. 21, the positive pole of the + 24V DC power supply, without interruption. For operational safety
reasons, the wire must first be connected to terminal No. 9 before the connection is made to the power
supply. The auto adjust procedure is successfully completed after approx. 10 seconds. During this time
the actuator runs through the entire possible adjustment range from 0% to 100%. The actuator holds the
0% position for 5 seconds and then the 100% position, also for about 5 seconds. At the same time the
adjustment range is initialised and the 0% and 100% end position is stored by the microprocessor in the
control electronics. Once the adjustment has been completed within about 10 seconds, it is essential to
break the connection between terminal No. 9 and the +24V DC terminal No. 21. As a precautionary
measure, the connection must first be broken at the 24V DC terminal No. 21. If the connection between
terminal No. 9 and the +24V DC terminal is broken first, this means that the auto adjust procedure will
have to be repeated.
The wire jumper between terminals No. 9 and No. 11 is only needed so that the + 24V DC terminals are
simultaneously positioned at the digital inputs of terminals No. 9 and No. 11 during the auto adjust
procedure. As long as the + 24V DC potential is not present at terminals No. 9 or No. 11, the wire jumper
is not relevant to the operation of the actuator. Under the conditions described above, this connection
must not therefore be removed.

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Technical Instruction No.:

1502-0065

Heinzmann Controller for StG 10 and StG 30 Actuators

Operation of the digital input at terminal No. 11 Servomotor Stop:


A potential of +24V DC at terminal No. 11 switches the controllers motor output to stop, i.e. the actuator
remains at the 0% position, irrespective of the current setpoint position. This is the trigger for auto adjust.
Operation of the digital input at terminal No. 9:
A potential of +24V DC at terminal No. 9 triggers auto adjust for the 0% and 100% position. However, this
is conditional on the digital input Servomotor Stop (terminal No. 11) being switched to + 24V DC
beforehand or simultaneously.

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Technical Instruction No.:

1502-0065

Heinzmann Controller for StG 10 and StG 30 Actuators

4. Cumulative failure transmitting output:


4.1

General:
The controller has a cumulative failure transmitting outlet (warning and emergency shutdown), in the form
of a group alarm via a switching transistor output. When an internally monitored failure occurs, the
transistor switches over and internally connects the failure transmitting output (terminal 10) to the earth
for the power supply (0V | terminal 20). Pandaross internal diagnosis system can distinguish between
self-resetting error warnings and errors which will result in emergency shutdown of the servomotor.
This cumulative failure transmitting output (warning and emergency shutdown) is integrated by means of
a pull-up resistor directly into the dia.ne AMM as warning number 1192 with the text Actuator/Controller
Failure (closed-circuit principle). In general, controllers in new installations have been switched off during
engine standstill since the year 2000. This extends the service life of the device. As the controller is not
activated during engine standstill, the controllers cumulative failure transmitting output is only monitored
by the dia.ne AMM when the engine is running.

4.2

Controller warnings / self-resetting:


A warning is issued via the controllers failure transmitting output when:
- the deviation between the setpoint position and the actual position is more than one second greater
than 10% of the normal route.
- an error has occurred at the analogue setpoint for the actuator position. The setpoint is not in the
range 0 mA to 21mA.
- the power supply is not in the permissible range of 9 to 32V DC.
The failure transmitting output is automatically reset when the controller data are again within the
defined error limits. The current warning on the dia.ne AMM can then be reset.

4.3

Controller emergency shutdowns:


An emergency shutdown of the controller occurs in the cases of error as described and is indicated by the
failure transmitting output:
- Fault in the actuators feedback system (defective position feedback, cable break or actuator not
connected or plugged in).
- Fault in automatic adjustment procedure.
- Internal fault in controllers electronics.
In the event of an emergency shutdown the controller blocks the actuator at the 0% position. The fault
must first be rectified and the controllers active failure transmitting output reset so that the actuator can
be restarted. The controller is reset by resetting the power supply and released for operation. Resetting is
done by switching the controllers power supply off and on again and is only necessary in installations in
which the controller and the actuator can still be operated during engine standstill.
Since the year 2000, controllers in new installations have been switched off during engine standstill in
order to extend the service life of the controllers and actuators. It is not necessary to reset the power
supply, as described above, during engine standstill after rectifying a fault as the controller has already
been switched off while the fault was being rectified. On engine startup the controllers power supply is
automatically switched on again with the ignition request and the cumulative failure transmitting output is
reset at the same time. It is possible to operate the actuator again.

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Technical Instruction No.:

1502-0065

Heinzmann Controller for StG 10 and StG 30 Actuators

5. Troubleshooting:
5.1

Failure message - warning:


Message text and number Error
Solution
ACTUATOR/CONTROLLER
Emergency shutdown - controller:
FAILURE
1192
Fault in the actuators feedback
system, actuator not connected or
plugged in;

Inspect cabling from controller to


actuator and check connector; cable
break or short circuit;
Check the actuator for possible
defective position feedback
(electronics), i.e. voltage signal
outside set range (approx. 1.4 V =
0% and 3.0 V = 100%)
- Replace actuator

Fault in automatic adjustment

Inspect cabling; repeat automatic


adjustment in accordance with the
TI; actuator should not be
mechanically blocked, check
smooth operation;

Defective internal electronics

Check out above causes and if


no fault can be found and yet failure
cannot be rectified by resetting, i.e.
by switching the controllers power
supply off and on again replace
the device!

Controller warnings - selfresetting:


ACTUATOR/CONTROLLER Deviation setpoint / actual position Check control rods and check
that throttle valve is operating
>10% for longer than 1 second
FAILURE
smoothly and is securely seated;
1192
Excessive forces acting on the
throttle valve, nominal moment
being exceeded, resulting in
increased deviation between
setpoint / actual position;

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Technical Instruction No.:

1502-0065

Heinzmann Controller for StG 10 and StG 30 Actuators

Inspect cabling from controller to


actuator; cable break, short circuit or
actuator not connected;

Error in analogue setpoint, signal Error in analogue setpoint, signal


value outside 0 - 21 mA range
value outside 0 - 21 mA range

Overvoltage / undervoltage of 24V


DC power supply
Error in internal electronic power
supply (5V)

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Check 24V DC power supply and


cabling;
Check for blown fuse in interface
cabinet;
Check the internal release relay
(ignition) during engine standstill
the controller and the actuator are
switched off;

Date: 2003-12
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