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Perkins Logic Control Governor

INSTALLATION MANUAL

Installation, programming and diagnostics

Publication TPD 1470E, Issue 4.


© Proprietary information of Perkins Engines Company Limited, all rights reserved.
The information is correct at the time of print.
Published in August 2002 by Technical Publications,
Perkins Engines Company Limited, Peterborough PE1 5NA England

i
This publication is written in
Perkins Approved Clear English

This publication is divided into six chapters:

1 General information

2 System and description

3 Installation

4 Software programming

5 Diagnostics

6 Control specifications

The following pages contain a detailed table of contents

ii
Various Engine Types

Contents

1 General information
Introduction . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 1
Functions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 1
Service Tool Software . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 2
Hardware ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 2

2 System and application


System Operation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 3
Hardware Configuration .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 4
Logic and support functions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 6

3 Installation
Setting instructions for both on and off-load conditions .. ... ... ... ... ... ... ... ... ... ... ... ... .. 7
How to set the frequency where full load can be applied ... ... ... ... ... ... ... ... ... ... ... ... .. 8
How to set the frequency where no load is available .. ... ... ... ... ... ... ... ... ... ... ... ... ... .. 9
To fit the Perkins LC governor ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 10
Electrical installation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 12

4 Software programming
Software installation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 17
Speed governor applications .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 22
Viewing and Resetting Fault Codes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 23

Installation Manual, TPD 1470E, issue 4 iii


Various Engine Types

5 Diagnostics
Problems / causes / tests ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 25

6 Control specifications
Specifications and characteristics ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 27

iv Installation Manual, TPD 1470E, issue 4


Various Engine Types

1
General information 1

Introduction
The purpose of this manual is to provide Perkins’ distributors and OEMs with the necessary information for the
application of the Perkins Logic Control (LC) governor control for diesel engines.
The Perkins LC governor is an electronic speed control governor which contains both a rotary actuator and a
controller circuit board in the same housing. The unit can provide a number of pre-set speeds, bias speeds,
control, diagnostic, and datalink functions.
Topics covered include installation, software programming, and diagnostics.
The functionality and characteristics of the control can be tailored using a computer loaded with the Service
Tool software.
The terms “left side” and “right side” apply when the engine is viewed from the flywheel end.
Danger is indicated in the text by two methods:
Warning! This indicates that there is a possible danger to the person.
Caution: This indicates that there is a possible danger to the engine.
Note: Is used where the information is important, but there is not a danger.

Functions
Speed setting functions include:
l 50/60 Hz select: selects between two speed set points based on voltage input when power is first applied
to the governor
l Raise / lower adjust: ramps engine speed up or down based on voltage inputs while the engine is being run
Speed bias functions include:
l Isochronous: does not bias the current speed set point in any way.
Speed sensing functions include:
l MPU speed sensing: Converts flywheel speed or gear speed pulses into engine speed, in rev/min.
Control functions include:
l Speed control coefficients: reset, compensation and gain.
Logic and support functions include:
l Overspeed error: Detects when the actual engine speed exceeds a threshold
l Underspeed error: Detects when the actual engine speed falls below a threshold
l Failsafe error: Detects a loss of the speed signal input
l Configuration error: Detects when a configuration has not been downloaded into the control
l Relay control: Controls the relay output driver during error conditions
l Fault storage: Stores a fault code in EEPROM whenever an error condition has occurred
l Governor state: Tracks the state of the engine (off, crank, start, run, or error) based on error detection
functions and actual engine speed.

Installation Manual, TPD 1470E, issue 4 1


1 Various Engine Types
Service Tool Software
Because the governor is a digital control system with no externally accessible adjustments, a companion
software tool is available to help the distributor or the OEM with each phase of application development,
manufacture, and field service. The LC Governor software is a Microsoft Windows based GUI (graphic user
interface). The LC Governor software is compatible with Windows 95/98/2000/NT and gives the distributor and
the OEM the ability to:
l Download configuration files during the manufacture
l Extract and view fault codes for field diagnosis
l Update control dynamics during field service.
The software service tool is available, please contact your Perkins service distributor. Detailed descriptions of
software installation are available in Chapter 4.

Hardware
Hardware is available in the form of kits which are tailored to meet the requirements for the application.
Kit number 1 2 3 4 6
After-market
U5MK0650 U5MK0651 U5MK0652 U5MK0653 U5MK0654
Part number
Option kit
(ZZ00788) (ZZ00789) (ZZ00790) (ZZ00791) (ZZ00793)
Part number
LC governor, 12-pin plug, Plug,
3.152
‘O’ ring, Socket, ‘O’ ring,
Heatshield, Magnetic pickup,
Contents Allen screws, Wedge, Screw,
Nuts, and adaptor
Setscrew, Connector pins, Nut,
Washers
Sealing washer Blanking plugs Washer

Note: The following two kits are re-usable throughout the range of engines which have the option to fit the
LC Governor.
Kit number 5 7
After-market
2880A016 500F001
Part number
Option kit
(ZZ00792) (ZZ00794)
Part number
Programming
Contents CD for programming
harness

2 Installation Manual, TPD 1470E, issue 4


Various Engine Types

2
System and application 2

System Operation
The LC governor is ready for operation immediately (within 0.25 second) when the power supply is connected.
Power may be connected to the governor at the same time that the engine starter motor is engaged. Once the
engine has started, the engine will immediately go to the speed value selected. The governor will drive the fuel
linkage between the minimum and maximum fuel delivery points to maintain steady state speed control.
At an engine shutdown command, the engine shutdown solenoid, or solenoid valve in the diesel fuel supply,
should be de-activated and the power supply disconnected from the speed control. The signal to this solenoid
should be sent directly from the engine control panel and should be independent of the governor. When not
powered, the governor cannot drive the actuator to minimum fuel.
Warning! If the engine shut down solenoid or the fuel solenoid valve has been de-activated, the LC governor
cannot be used to shut down the engine.

Installation Manual, TPD 1470E, issue 4 3


2 Various Engine Types
Hardware Configuration
The LC governor has a 12 pin Deutsch DT connector (reference DT04-12PA) integrally moulded into its
housing. Pins are assigned to specific functions and cannot be changed.
The table below shows the assignments for each auxiliary-based function in the control.
Function Aux 1 Aux 2 Aux 3 Aux 4
Isochronus load sharing X
50/60 Hz select X
Lower speed X
Raise speed X

Warning! If the engine shut down solenoid or the fuel solenoid valve has been de-activated, the LC governor
cannot be used to shut down the engine.
50 / 60 Hz select
This feature allows the speed set point to be switched between a primary and a secondary engine rated speed.
A discrete input is used to toggle between the two set speeds. This input comes into AUX4. When the engine
is started with the input at the low state (ground), the controller adjusts the engine speed to the 50Hz speed
setting. When the engine is started with the pin in the high state (+12V dc), the controller will run at the 60Hz
speed setting. Any state changes on the AUX pin will be ignored once the engine is running. The state is
determined only when power is first applied to the governor.
Raise / lower adjust
This feature allows the user to change the speed set point with external voltage inputs. Speed will change at
the rate of 2 rev/min per second.
Note: This must not be used for ramping from 50 Hz to 60 Hz.
Lower
This AUX2 voltage input acts directly on the internal speed set point within the LC governor, and will
progressively decrease the speed set point down to a lower limit at a rate of 2 rev/min per second for as long
as the input is in a high state. When this input goes low, the speed reference will remain fixed at the last setting
reached the instant the input went low.
Raise
This AUX3 voltage input acts directly upon the internal speed set point within the LC governor, and will
progressively increase the speed reference up to an upper limit at a rate of 2 rev/min per second for as long
as the input is in a high state. When this input goes low, the speed reference will remain fixed at the last setting
reached the instant the input went low.
Speed biasing
Isochronus
This is the default speed biasing function and maintains the engine at one speed setting throughout operation
regardless of load.
Auxiliary biasing (isochronus load sharing)
This feature allows the user to alter the speed set point with an external signal. It is only available using the
appropriate file on the CD and a load sharing module. This input comes into AUX1, and is programmable as
±3V input. This function modifies the desired engine speed with the following formula:
speed reference * bias percentage * offset AUX1 input voltage
The bias percentage is a programmed value of ±7%. This analog input should be provided by a voltage
transmitter via twisted, shielded wire pairs.

4 Installation Manual, TPD 1470E, issue 4


Various Engine Types 2
Speed sensing
Magnetic pickup (MPU)
The MPU input has been designed for variable reluctance speed sensors and not Hall-effect devices. The
frequency range of the MPU input is: 100Hz to 12 000Hz (designed to accept at least 14 000Hz to provide a
margin of safety). The required minimum peak-to-peak voltage is 2V dc @ 100Hz and 25V dc @ 12 000Hz.
This function expects engine speed pulses present on pins 11 (MPU +ve) and 3 (MPU –ve). The number of
flywheel or gear teeth that pass the magnetic pickup for one crankshaft revolution is programmed into the
configuration file. Perkins’ configuration files are pre-programmed with 126 teeth per revolution.
For correct setting of the Perkins MPU, rotate the crankshaft 360° and position the highest point of the
flywheel / ring gear against the MPU aperture by use of a dial test indicator (DTI). Screw in the MPU until its
face lightly contacts a starter ring gear tooth and not the gap between two teeth, then unscrew by ½ to one
turn to give a gap of 0,5 / 1,0 mm (0.0197 / 0.0394 in). Tighten the locknut. Rotate the crankshaft again to
ensure there is no contact with the starter ring gear.
Related configuration file parameters: mpu, flywheel teeth.
Control functions
Speed control
This is the function of the governor. It calculates the difference between the desired speed and the actual
measured engine speed, and adjusts the desired actuator position as a result. Speed setting functions and
dynamics functions are responsible for selecting the active speed set point and set of dynamics for this
function.
Dynamics functions
A variety of dynamics or gains are available for tuning the engine and actuator response. The response of the
movement of the actuator is controlled by PID (proportional, integral, and derivative) control terms. The speed
control of the engine is controlled by reset, gain, and compensation terms, and the user has access to these
terms only.
Dual dynamics
This feature allows for toggling between two sets of user-defined dynamics or gains - it is not enabled on
Perkins’ configuration files.
Cold start timer
In demanding GenSet applications that require ‘G3’ performance but are also intolerant of cold start instability,
the LC governor offers a cold start timer function that sets the gain of the controller to a lower-than-normal
value until a pre-programmed, non adjustable, amount of time expires. This gives an engine time to warm up
before switching to a normal gain value.
Automatic gain trim
To correct for engine power variation and its effect on governor performance, the LC governor contains an
automatic gain adjustment function that trims the gain of the controller based on steady-state and transient
engine speed performance measurements. Based on performance criteria programmed into the LC governor
and the stability or load transient performance of the engine, the function will increase or decrease the currently
active gain setting. This function can be used to combat the effects of engine running-in, engine-to-engine
variance, altitude, temperature, and fuel quality. This function is not intended to mask serious engine faults,
like large vacuum leaks, or other such failures.
This function continuously monitors the speed of the engine relative to the currently active speed reference. If
this function observes a steady-state speed band that exceeds a programmable set point, then the currently
active gain parameter is decreased until the programmable minimum gain setting is reached. If this function
detects a transient offspeed that exceeds a programmable set point, then the currently active gain parameter
is increased until the programmable maximum gain setting is reached. This feature is pre-programmed and
non-adjustable.

Installation Manual, TPD 1470E, issue 4 5


2 Various Engine Types
Logic and support functions
Overspeed error
The LC governor control has an overspeed function that is set to shut down the engine at 2080 rev/min - a
speed that is typically 110% of maximum rated speed. When the control senses this speed, it will drive the
actuator to minimum fuel, turn on the relay contact output, and the software will store a fault bit in EEPROM.
Cycling power to the LC governor will restore normal operation, but the fault bit will remain in non-volatile
memory until reset.
Caution: The LC governor control is not used as the primary overspeed protection device.
Related configuration file parameters: overspeed, EE fault storage, relay control, overspeed threshold.
Underspeed error
The LC governor control has a programmable underspeed function that is set to shut down the engine at 480
rev/min. When the control senses this speed, it will drive the actuator to minimum position, turn on the relay
contact output, and the software will store a fault bit in EEPROM.
Failsafe error
To protect the engine against overspeed upon loss of the speed input signal, the control will drive the actuator
to minimum position anytime the control senses a lost speed input for a programmable amount of time not to
exceed 0.5 second. The relay contact output will also be turned on and the software will store a fault bit in
EEPROM. Cycling power to the LC governor will restore normal operation, but the fault bit will remain in non-
volatile memory until reset.
Related configuration file parameters: Failsafe, Failsafe timeout period, EE fault storage, relay control.
Configuration error
The Configuration Error function is permanently enabled to check for the presence or absence of a
configuration file in the control during power-up. If a configuration error is detected, software sets the
configuration error flag, activating the relay output and rendering the control inoperable until the power is
cycled.
Relay control
This switchable, discrete output is a closure to ground capable of sinking 250mA with an output voltage rise of
less than 1.5V, and is available to power external relays for devices such as fuel shutoff solenoids. It has an
internal protection diode, so it is not necessary to provide one externally. This output is normally floating with
a very weak resistor to an internal +ve 5V, but when an error condition occurs (overspeed, configuration,
failsafe), this output sinks up to 250mA to ground.
There are two conditions that will prevent this output from operating. The first is if battery positive is accidentally
connected to it, and the second is if it is shorted to ground. If this output is intended to drive a fault light, these
conditions will not be obvious.
Fault storage
When the governor state transitions to ‘error,’ the source of the error (configuration, overspeed, or failsafe) is
stored as a set bit in the control fault register of the LC governor’s EEPROM.

6 Installation Manual, TPD 1470E, issue 4


Various Engine Types

3
Installation 3
This chapter covers the installation of the governor to the fuel pump and the associated electrical system.

Setting instructions for both on and off-load conditions


Warning! Ensure that the engine cannot be started.
1 Clean the upper surface of the pump to remove all dirt and other debris.
2 Release the locknut (A1) and remove the allen screw (A2) together with the locknut. Fit the
setscrew (B1) together with the sealing washer supplied with the governor. Tighten the setscrew to 5,1 Nm
(45 lbf in) 0,52 kgf m.
Caution: Only adjust the droop screw at this stage if it is suspected as being out of adjustment.
3 Release the locknut (C1) and adjust the governor droop allen screw (C2) clockwise until it contacts the fuel
metering valve lightly and can be turned no further.
Caution: If the governor droop allen screw is over-tightened, damage to the metering valve will be caused.
4 Adjust the screw (C2) in a counter-clockwise direction the number of turns specified, see page 8. Tighten
the locknut (C1) to 4,5 Nm (40 lbf in) 0,46 kgf m. Do not exceed this torque.
Note: If an electronic overspeed device is fitted to the generator adjust it to operate at 65Hz or above. Please
refer to the generator set instruction manual.

1
A Gen 1031 B Gen 1038

1
2

C XV1002

Installation Manual, TPD 1470E, issue 4 7


3 Various Engine Types
How to set the frequency where full load can be applied
1 Start the engine and, while the engine runs with no load applied, release the throttle lever locknut (A1) and
the pivot locknut (B1). Finger tighten only the pivot locknut and slowly adjust the throttle lever screw (C1) to
set the frequency to the limits specified in table 1 - setting values (flight speed of the engine).
E.g.1 - 1006TG2A 50 Hz : No-load frequency is 54 ± 0.4 Hz (1608 - 1632 engine rev/min), e.g.2 - 1006TG2A
60 Hz : No-load frequency is 63.2 ± 0.1 Hz (1893 - 1899 engine rev/min). Tighten the adjustment screw locknut
(A1) and the pivot locknut (B1) to 5,7 Nm (50 lbf in) 0,58 kgf m.
2 To set for full load / speed, while the engine / genset runs at full load as specified in the genset manual,
unlock the droop screw as described in items 3 and 4 see page 7, and adjust the droop screw until the full load
frequency is within the limits defined in table 1 - setting values. E.g.1 - 1006TG2A 50 Hz : Full load frequency
50 ± 0.4 Hz (1488 - 1512 engine rev/min), e.g.2 - 1006TG2A 60 Hz : Full load frequency 60 ± 0.2 Hz
(1794 - 1806 engine rev/min). All examples will be the same.
Note: To raise the engine speed from 1500 rev/min to 1950 rev/min (65Hz - 67Hz) will be approximately nine
turns clockwise on the throttle lever screw (C1).

Table 1: Setting values


Frequency / flight speed (throttle) settings
Engine type Rating 50 Hz 60 Hz Governor droop screw
curve Full load No-load Full load No-load adjustment (counter
(Hz) (Hz) (Hz) (Hz) clockwise from fully in)
3.1524 CM T2318 TBA TBA TBA TBA 1 turn
1004G, AA & AG T2320 50 ± 0.4 52.3 ± 0.6 60 ± 0.2 61.8 ± 0.5 1.25 turn
1004TG1 AH T2324 TBA TBA TBA TBA 0.75 turn
1004TG2, AB & AH T2326 50 ± 0.4 52.5 ±0.6 60 ± 0.2 62.5 ± 0.4 0.75 turn
1006TG2A YB T2330 50 ± 0.4 54 ± 0.4 60 ± 0.2 63.2 ± 0.1 1 turn

Continued

1
2

A XV1003 B XV1004

1
C XV1005

8 Installation Manual, TPD 1470E, issue 4


Various Engine Types 3
How to set the frequency where no load is available
1 Start the engine and while the engine runs, release the throttle lever locknut (A1) and the pivot locknut (B1).
Finger tighten only the pivot locknut and slowly adjust the throttle lever screw (C1) to set the frequency to the
limits specified in table 1 - setting values (flight speed of the engine). E.g. - 1006TG2A 50 Hz : No load
frequency 54 ± 0.4 Hz (1608 - 1632 engine rev/min). Tighten the adjustment screw locknut (A1) and the pivot
locknut (B1) to 5,7 Nm (50 lbf in) 0,58 kgf m.
2 Unlock the droop screw as described in item 3, and observe the Caution. Adjust the droop screw as
described in item 4, the number of turns as defined in table 1. Lock the droop screw.
3 This setting should be adequate, but if full load cannot be achieved, then adjust the droop screw counter
clockwise by one flat of the screw and re-tighten as described in items 3 and 4 see page 7.
4 If the performance is unstable, then adjust the droop screw clockwise by one flat of the screw and retighten
as described in items 3 and 4 see page 7. If instability is still present, then repeat this step. Check that full load
can be achieved.
The mechanical governor must now be set to the overspeed position
5 Release the throttle lever locknut (A1) and the pivot locknut (B1). Finger tighten only the pivot locknut and
slowly adjust the throttle lever screw (C1) to set the frequency to 65.9 ± 0.9 Hz (1950 - 2000 engine rev/min).
Tighten the adjustment screw locknut (A1) and the pivot locknut (B1) to 5,7 Nm (50 lbf in) 0,58 kgf m.
6 The LC governor can now be fitted.

1
2

A XV1003 B XV1004

1
C XV1005

Installation Manual, TPD 1470E, issue 4 9


3 Various Engine Types
To fit the Perkins LC governor
1 Ensure that the engine is stopped and cannot be started. Remove the protector unit (if fitted) from the
governor mounting holes and ensure the threaded holes are free from dirt, oil and other debris.
Caution: Ensure that the fuel is turned off.
2 Ensure that the area around the governor blanking plug (A2) is clean and free from dirt and other debris.
Use a suitable tool to remove the threaded governor blanking plug, ensure that the plug seal remains attached
to the plug and retain the plug and seal. Ensure that the threads in the pump body are not damaged.
Caution: Ensure no dirt or debris enters the pump.
3 Lubricate the LC governor ‘O’ ring (B3) with clean diesel fuel, rotate the actuator lever (B2) fully clockwise,
and insert the governor (B4) into the pump top cover, aligned as shown in (C). Ensure that the actuator lever
(B2) is to the right of the fuel control linkage (B1) see inset.
Warning! Diesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain
persons. Protect your hands with gloves or a special solution to protect the skin.
Caution: Ensure that the governor is aligned correctly into the pump body. Incorrect alignment may cause
serious damage to the generator if there is no over-speed protection.
4 Press the governor (C1) fully into position and secure with the four setscrews (C3). Tighten the setscrews
to 4,0 Nm (35.4 lbf in) 0,41 kgf m.
Note: The governor should fit easily into the pump. If it does not fit easily, do not use force, remove the
governor and check that the actuator lever (B2) is correctly aligned to the fuel control linkage.
5 Connect the electrical connector (C2).
6 The LC governor may now be programmed using the software, please see Chapter 4.
Continued

4
1
3

1
2

A XV1003 B Gen 1039

C Gen 1040

10 Installation Manual, TPD 1470E, issue 4


Various Engine Types 3
7 For 3.1524 series engines only, fit the heat shield (A2) over the nuts and washers to the lift bracket stud (A1)
and to the coolant elbow stud (A3). Secure with nuts and washers supplied. Tighten the lift bracket nut (A1) to
37 Nm (29 lbf ft) 3,7 kgf m, and the coolant elbow nut (A3) to 27 Nm (20 lbf ft) 2,8 kgf m.
Caution: If the pump has to be removed from the engine for test purposes or warranty reasons, the LC
governor should not be removed from the pump. This will prevent the ingress of dirt or any other debris into
the pump.

A Gen 1041

Installation Manual, TPD 1470E, issue 4 11


3 Various Engine Types
Electrical installation
Guidelines
A pinout of the LC governor, as viewed into the control connector, is shown below. Typical connections to
external devices are also shown.
Typical LC governor application wiring

1. 12V
12 1 2. GND
11 2 3. MPU -ve
4. AUX3 (Raise speed)
10 3 5. AUX1 -ve (GND) (Load sharing)
9 4 6. AUX4 (60Hz select)
7. NOT USED
8 5 8. AUX1 +ve (Load sharing)
6 9. ERROR RELAY
7
10. AUX2 (Lower speed)
11. MPU +ve
12. NOT USED

Note: If any features are not required in the application, the related wiring may be omitted.
The LC governor has an operation voltage range of 8 to 16V dc with a nominal voltage of 13.5V dc. The power
supply is load dump and reverse polarity protected, and consumes 64W maximum power at a peak current of
4A (16V dc) assuming 4 ohm stator resistance at 25 °C. The control system should be protected with a 6A fuse
in the voltage supply lines. The application should be configured to turn on power to the governor when the
engine is first switched to start. Power should be removed just before the engine is shut off so that the actuator
loses torque.
The LC governor senses speed from a variable reluctance magnetic pickup (MPU).
Continued

12 Installation Manual, TPD 1470E, issue 4


Various Engine Types 3
Typical wiring diagram

2
3
+12
12 1 +12V

MPU+ GND
11 2

TX AUX2 MPU-
10 3

RELAY AUX3
9 4

AUX1+ AUX1-(GND)
8 5

+5V OUT AUX4


7 6
4

1 2 3 4 5

6 7 8 9

DTR
GND
CTS
RTS
DSR

A XV1001-2

Note: The wiring shown in bold is the minimum necessary for the governor to operate.

Key Description
1 Speed sensor
2 12-pin connector
On / Off switch in
3
programming harness
4 Computer connector

Continued

Installation Manual, TPD 1470E, issue 4 13


3 Various Engine Types
To set the correct gap between the magnetic pickup (MPU) and the flywheel or gear teeth see page 5.
Voltage threshold curve

25 Vpp

20 Vpp

15 Vpp

10 Vpp

5 Vpp

2 kHz 4 kHz 6 kHz 8 kHz 10 kHz 12 kHz

MPU input voltage (peak to peak) requirement vs. input frequency


The relay output driver is activated any time the LC governor detects an error condition (overspeed,
underspeed, failsafe, or configuration error). The driver sinks up to 250mA of current through an external
device powered from +ve 12V. This driver is internally protected against inductive flyback.
The LC governor has three dedicated digital inputs (AUX2, AUX3, and AUX4) used to activate various features
of the control. Shorting an input pin to +ve 12V activates it. Removal of +ve 12V dc from an input pin or shorting
the pin to ground deactivates the input. At least 4 volts must be present on an input pin in order to change its
state from inactive to active. All discrete inputs will be the same voltage as the system power supply and will
be active only while the input is in a high state. Greater than 4 V dc is considered high, and less than 1V dc is
considered low.
All connector pins are short-circuit protected to ground and power except pins 2, 3, and 5, which are not
protected against shorts to battery positive. Installation of a fuse on the power ground wire to pin 2 would
provide protection to these pins but does not mean one is not needed in the power connection. Pin one (B +ve)
still needs protection against a short to ground.
AUX1 is configured as a ±3V dc analogue input. The LC governor may be interfaced to other load shared
equipment through the AUX1 +ve and AUX1 –ve inputs.
Continued

14 Installation Manual, TPD 1470E, issue 4


Various Engine Types 3
The following Deutsch connector components are recommended for harness designs:
Recommended Optional
Mating connector DT06-12SA-P012 DT06-12SA
Secondary lock W12S-P012 N/A
Sockets 0462-201-16141 0462-201-16141

Use 1 – 1,5 mm² (16 to 18 AWG) stranded copper wire with insulation that meets temperature requirements
in the harness design. In the event a wire is not used for each of the 12 pins on the control, a Deutsch 114017
blanking plug should be used in place of each missing wire to environmentally seal the connector from the
elements. A wiring harness stress relief within 400 mm (16 in) of the control’s connector is recommended. The
maximum recommended harness length is 6,1 m (20 feet). Dress the harness with wire loom to contain it in a
single bundle. Use grommets when the harness is passed through metal panels. Ground the MPU signal wire
shield at the control, but do not ground the MPU signal wire shield at the MPU.
Also use twisted pair, shielded wires for the AUX1 input when Isochronus Load Sharing is used. Ground this
shield on the engine near the control.

Installation Manual, TPD 1470E, issue 4 15


This page is intentionally blank
Various Engine Types

4
Software programming 4

This chapter covers the process to tune, configure, and service the LC governor via the Software Suite.
The hardware listed below is required to work with the LC governor, regardless of whether an application is
being developed by engineering, a configuration file is being downloaded in production, or the application is
being serviced in the field:
l PC-compatible laptop or desktop computer with at least one available serial communications port, and
Windows 95/98/2000/NT as the operating system
l Programming / datalink harness.
Note: The engine / generator set should not be run with the programming harness connected to the computer.

Software installation
The software is available on CD or the Perkins secure internet site.
Locate the executable file and double click using the left mouse button to install.
Follow the instructions on the screen.

Continued

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4 Various Engine Types
Once the software setup is complete you will need to re-boot your machine to update the registry settings.

Continued

18 Installation Manual, TPD 1470E, issue 4


Various Engine Types 4
Using the LC governor software.
Select the LC governor control program from the menu.

The screen below will appear for a short time and then disappear.

Continued

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4 Various Engine Types
This is the first screen that appears when the graphic user interface (GUI) is initialised. To use the GUI flash
tool, the user must have either an LC governor with a supported firmware revision or the user must have
access to a valid configuration file.

The GUI supports firmware revisions. The dialog box in the centre of the screen will indicate that a
“LC SPD/TOPPING” configuration format will be used. If your system shows up as another configuration
format, contact Perkins Technical Support Centre, www.help_technical@perkins.com.
IDENTITY CONTROL - Identifies which version of firmware an LC governor has. This requires that an LC
governor be connected to your computer with a programming harness.
IMPORT CONFIG FILE - Opens an existing configuration file. Select the desired file using the browser
(configuration files use a *.lcs extension).
Note: In working with the LC governor, the power must be cycled from time to time. The user will be prompted
to turn power on or off. If the power is not cycled in 10 seconds, a message will appear which allows a retry or
the cancellation of the current activity.
Continued

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Various Engine Types 4
Once a valid file or valid LC governor has been identified, the screen below is displayed. The box in the centre
of the screen identifies which version of LC governor is being used.

CONFIGURATION MENU - The configuration menu, shown below, allows you to download alternative
configuration files to the LC governor.

If you select the ‘Write Configuration File To LCS’ button you will be able to select a file from a location of your
choice, displayed below.

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4 Various Engine Types
Speed governor applications
Caution: Know in advance how to safely shut off the engine during normal and emergency stop conditions.
When power to the governor is shut off, this does not guarantee a shutdown; it depends on the final application.
Safety needs to be the primary thought during this procedure.

Speed governor applications require that the speed control loop be tuned for load transients and steady-state
stability. Use this procedure to derive the values of the speed control coefficients (reset, gain, and
compensation) for a fixed engine speed. The speed control coefficients are described below:

GAIN determines how fast the control responds to an error in speed when the speed reference is changed or
a load disturbance occurs. A value too high will result in sustained, fast oscillations in speed. A value too small
will result in poor control performance and possibly slower oscillations.

RESET prevents there being a slow surge at steady state and controls restrictions when speed error returns
to zero after a speed alteration. A value too high will result in large, low frequency variations in engine speed.
The actuator will tend to “bang” from stop-to-stop. A value slightly too high is indicated by an over-restricted
condition, or the speed error returning too slowly to zero. A value slightly too low is indicated by an under-
restricted condition, or the speed value may overshoot the reference and then reset, possibly with several
restricted oscillations. A value too low will result in a slow, low amplitude surge of speed about the speed
reference.

COMPENSATION term compensates for actuator lag. It adjusts the rate of change in actuator output when a
load alteration occurs. A value too low will result in slow and under-damped control. A value too high will result
in excessive high frequency actuator movement.

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Various Engine Types 4
Viewing and Resetting Fault Codes
To view the contents of a control’s fault register, press the View Fault Codes button located in the Fault Code
Menu. The program will display which of the error bits are set within the register (configuration error, overspeed
error, or failsafe error). A configuration error is the result of not downloading a configuration file into a new
control. Overspeed and failsafe errors all relate to issues with the MPU or connection to an ignition system.

Reset Fault Codes


To clear the contents of the control fault register, press the Reset Fault Codes button. The program will reset
the state of all error bits.

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4 Various Engine Types
Messages
In working with the LC governor, the power must be cycled from time to time. The user will be prompted to turn
power on or off. If the power is not cycled in 10 seconds, a message will appear which allows a retry or the
cancellation of the current activity.

If a fault is generated, the appropriate window in the fault code menu which normally shows a black sector
containing the words ‘NOT SET’ will change to a red sector containing the word ‘SET’.

24 Installation Manual, TPD 1470E, issue 4


Various Engine Types

5
Diagnostics 5

Problems / causes / tests


This chapter presents several broad categories of application failures typically experienced in the field,
possible causes, and some tests used to verify the causes. For more detailed information about governor
system failure modes and effects, contact your Perkins local supplier or dealer.
The problems / causes / tests listed below require the end user to have a digital multimeter at his disposal for
testing voltages and checking continuity, and that the application has been engineered and tested thoroughly.
Problem Possible Cause Suggested Test
Engine does not start Stuck linkage / seized shaft Assess smoothness and friction.
Remove and reinstall MPU per OEM’s
instructions.
MPU gap too large
Rotate engine manually to check for
interference.
Disconnect harness from governor.
MPU signal connection open Activate application. Test for 2V rms
between MPU +ve pin and MPU –ve pin.
Wrong configuration file
Remove and reinstall MPU per OEM’s
Engine starts, but shuts down on instructions.
MPU gap too large
error Rotate engine manually to check for
interference.
Disconnect harness from governor.
Continuously check resistance between
MPU signal intermittent
MPU+ pin and MPU– pin while inspecting
harness and connectors.
Wrong configuration file
Power not applied etc.,
Engine starts but runs at overspeed
Linkage slipped on shaft etc.
Disconnect starter motor solenoid.
Disconnect harness from governor.
Activate application. Check for correct
Incorrect mode of operation AUX inputs shorted or open
voltage level between AUX pin(s) under
question and ground pin for known
application modes.
Move linkage by hand.
Sticky linkage Assess smoothness, friction, and return
spring force.
Unable to develop full power Wrong configuration file
Seized shaft
Disconnect harness from governor. Attach
programming harness. View status of fault
Fault code set
codes. Take appropriate action for active
faults.
Engine runs but speed gradually Programming harness still Reload configuration file and disconnect
increases or decreases connected to the computer computer
Voltage still being applied to pin 4 or
Reset speed
pin 10
Remove voltage supply to pin 4 or pin 10

Installation Manual, TPD 1470, issue 4 25


5 Various Engine Types
Problem Possible Cause Suggested Test
If overspeed occurs on transient, raise
Overspeed Error Gains not set properly for transients
common gain to reduce overshoot.
Wrong configuration file
Follow instructions for MPU intermittent
Speed sensing error
under Failsafe Error.
Disconnect harness from governor.
Continuously check continuity between IGN
Failsafe Error MPU signal intermittent
pin and ignition coil primary while inspecting
harness and connectors during cranking.
Engine running at extremely low
Increase failsafe timeout period.
speed
Disconnect harness from governor.
No configuration file written to Attach programming harness to governor.
Configuration Error
controller. Write appropriate configuration file to
controller using the software tools.

Programming diagnostics
Problem Possible Cause Suggested Test/Correction
Error message: Configuration file has OEM security
Obtain correct configuration file.
Missing ACCESS.KEY file key written to it
Error message:
The configuration data is the wrong
Configuration file not same version
format. Try converting the data to Obtain correct configuration file.
as actuator
the current LC governor
Firmware Rev
Error message:
No power to actuator Check connections and retry.
Timed Out!
Error message:
Unable to establish link. Exit real No power to actuator Check connections and retry.
time tuner?

26 Installation Manual, TPD 1470, issue 4


Various Engine Types

6
Control specifications 6

Specifications and characteristics

Specifications
Power supply 12V systems (8 - 16V dc) with reverse polarity protection
Power consumption 64 W maximum
Torque 0,34 Nm (0.25 lbf ft)
Mass / weight 425 g (15 ounces)

Control characteristics
Speed input and range Magnetic pickup, 126 teeth per revolution
Engine type 4-cycle diesel fuel
Target speed To be able to be set - 50Hz / 60Hz
Actuator torque High efficiency torque motor delivers 0,34 Nm (0.25 lbf ft)
(standard model) over 60° travel range to operate fuel or air control
Function options Isochronus speed (50 or 60 Hz)

Environment
Ambient Operating temperature –40 to +85 °C (–40 to +185 °F)
Ambient Storage temperature –40 to +125 °C (–40 to +257 °F)
EMI /RFI EN50081-1 (emissions)
EN50082-2 (immunity)
Humidity US MIL-STD 810E, Method 507.3, Procedure III
Salt Spray US MIL-STD 810E, Method 509.3, Procedure I
Shock US MIL-STD 810E, Method 516.4, Procedure I
Random Vibration US MIL-STD 202F, Procedure 214A, Test Condition ID
Drop SAE J1211, Paragraph 4.8.3 (modified)
Thermal Shock SAE J1455, Paragraph 4.1.3.2
Dust SAE J1455, Paragraph 4.7
Pressure Wash A modified SAE J1455, Paragraph 4.5
Fluid Resistance A modified SAE J1455, Paragraph 4.4
Electrical Load Power Connection
Electrical Transient 2 J per SAE J1455, Paragraph 4.11.2.2.1

Compliance
UL/cUL Listed (UL requires a Class 2 power source)
CE Compliant
Y2K Compliant
Other 89/392/EEC Machinery Directive

Reliability and quality goals


The LC governor control system has a reliability target of 17 500 hours MTBF. It also has a quality goal of less than 25
PPM when measuring out-of-the-box defects. This quality goal is a target based on continuous improvement.

Installation Manual, TPD 1470E, issue 4 27


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